2001-2005 Porsche 911 Turbo (996) Service & Repair Manual

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Table of Contents Information on handling of the GT2 scope......................................................................................................1 0 Technical data..................................................................................................................................................2 Engine ......................................................................................................................................................3 Engine design ...........................................................................................................................................4 Engine cooling .........................................................................................................................................5 Engine lubrication ....................................................................................................................................5 Engine control ..........................................................................................................................................5 Heating .....................................................................................................................................................6 Fuel system..............................................................................................................................................6 Electrical system ......................................................................................................................................6 Exhaust system........................................................................................................................................7 Emission control ......................................................................................................................................7 Transmission ............................................................................................................................................7 Clutch .......................................................................................................................................................7 Transmission ............................................................................................................................................8 Body designs ............................................................................................................................................9 Running gear ............................................................................................................................................9 Brakes....................................................................................................................................................10 Wheels and tyres ....................................................................................................................................11 Spare wheel ............................................................................................................................................11 Wheel alignment ....................................................................................................................................11 Dimensions............................................................................................................................................12 Weights according to DIN 700 20 .........................................................................................................12 Filling capacities ....................................................................................................................................13 Performance data...................................................................................................................................14 Climbing performance ...........................................................................................................................15 Specific power.......................................................................................................................................15 0 Entire vehicle General ................................................................................................................................16 Lifting the vehicle ..................................................................................................................................16 Power unit ..........................................................................................................................................................17 Engine M96/70......................................................................................................................................17 Engine ....................................................................................................................................................18 Engine design .........................................................................................................................................18 Engine cooling .......................................................................................................................................19 Engine lubrication ..................................................................................................................................19 Engine control ........................................................................................................................................20 0 Transmission..................................................................................................................................................21 6-speed manual transmission G 96.50 ..................................................................................................21 Front wheel drive Z 96.00 ......................................................................................................................22 0 Body .................................................................................................................................................................23 Body of high-strength steel 1 ................................................................................................................23 Body of high-strength steel 2 ................................................................................................................24 Water drainage plan Coupé 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Table of Contents 0 Body Refrigerant circuit ..................................................................................................................................26 Component arrangement, Airbag System B05 ......................................................................................26 0 Electrics ...........................................................................................................................................................28 Fuse assignments...................................................................................................................................28 0 Power supply..................................................................................................................................................31 Work instructions after disconnecting the battery .................................................................................31 Control module memories.....................................................................................................................31 Supply voltage fault entry ......................................................................................................................32 Test drive after connecting the battery ...................................................................................................32 2470 DME control module ....................................................................................................................32 3730 Tiptronic ........................................................................................................................................33 6452 Power windows .............................................................................................................................33 90 25 Instrument cluster .........................................................................................................................33 9030 Clock .............................................................................................................................................33 9023 Fuel level display ..........................................................................................................................34 9120 Radio .............................................................................................................................................34 9110 PCM ..............................................................................................................................................34 01 General maintenance: Test drive...............................................................................................................36 01 Diagnostic system: Read out fault memory and activate systems ...........................................................37 Activating systems .................................................................................................................................37 Read out fault memory ...........................................................................................................................37 Load Navigation .....................................................................................................................................38 01 Battery: checking the charge state.............................................................................................................39 Tools......................................................................................................................................................39 Checking charge state with battery tester ..............................................................................................39 01 Windscreen wiper/washer system, headlight washer ...............................................................................40 Mix ratio of fluids for windscreen washer system .................................................................................40 01 Checking the function of the vehicle's lights and the headlight setting ..................................................41 Checking the adjustment of the headlights ............................................................................................41 Adjusting the main headlights...............................................................................................................42 Adjusting the main headlights, USA version .........................................................................................43 Fog light adjustment ..............................................................................................................................43 01 Checking the function of electrical equipment, as well as the indicator and warning lights ................45 01 Alarm system: checking operation of indicators .......................................................................................46 01 Activating/deactivating the parking aid .....................................................................................................47 General ...................................................................................................................................................47 Activating the parking aid without PST 2.............................................................................................47 einordnung ii

Table of Contents 01 Activating/deactivating the parking aid Deactivating the parking aid without PST 2 ..........................................................................................48 Activating the parking aid with PST 2 ...................................................................................................48 Selecting door mirror to be lowered, left/right ......................................................................................49 Adjusting the lowering angle for the passenger door mirror .................................................................49 Deactivating the parking aid with PST 2 ...............................................................................................50 01 Removing transport lock (spring strut locking devices) Turbo and GT2 ...........................................51 General ...................................................................................................................................................51 Removing spring strut locking devices ..................................................................................................51 Technical Data GT2 .......................................................................................................................................53 Engine ....................................................................................................................................................54 Engine design .........................................................................................................................................54 Engine cooling .......................................................................................................................................55 Engine lubrication ..................................................................................................................................55 Engine control ........................................................................................................................................55 Fuel system............................................................................................................................................56 Electrical system ....................................................................................................................................56 Exhaust system......................................................................................................................................56 Emission control ....................................................................................................................................56 Technical data...................................................................................................................................................57 Engine ....................................................................................................................................................58 Engine design .........................................................................................................................................58 Engine cooling .......................................................................................................................................59 Engine lubrication ..................................................................................................................................59 Engine control ........................................................................................................................................59 Fuel system............................................................................................................................................60 Electrical system ....................................................................................................................................60 Exhaust system......................................................................................................................................60 Emission control ....................................................................................................................................60 Precautionary measures when working on fuel system .................................................................................61 03 Diagnostic system: reading out fault memory ...........................................................................................62 Reading out fault memory.....................................................................................................................62 03 General maintenance: test drive .................................................................................................................63 03 Removing and installing drive belt .............................................................................................................64 Removal overview of the drive belt (engine installed) ..........................................................................64 Installation overview of the drive belt (engine installed) ......................................................................65 94 56 19 Removing and installing bulb for direction indicator light...........................................................67 Removing bulb for direction indicator light ..........................................................................................67 Installing bulb for direction indicator light ............................................................................................67 einordnung iii

Table of Contents 03 Changing the engine oil and oil filter .........................................................................................................68 03 Changing the engine oil (without oil filter) ................................................................................................72 03 Replacing spark plugs ..................................................................................................................................74 Removing spark plugs...........................................................................................................................74 Installing spark plugs .............................................................................................................................75 03 Checking cooling system ..............................................................................................................................77 Coolant: checking level, antifreeze content and leaks ...........................................................................77 03 Replacing air cleaner element .....................................................................................................................79 Removing air cleaner .............................................................................................................................79 Installing air cleaner ...............................................................................................................................81 03 Replacing the fuel filter ...............................................................................................................................85 03 Clutch: checking the play and pedal end position....................................................................................89 Checking clutch free play ......................................................................................................................89 Checking the pedal end position (pedal return/return force) .................................................................89 03 Changing transmission oil ...........................................................................................................................90 Changing transmission oil.....................................................................................................................90 Tightening torques .................................................................................................................................90 03 Checking and topping up the ATF .............................................................................................................91 Tools......................................................................................................................................................91 Checking and topping up the ATF .........................................................................................................91 Tightening torques .................................................................................................................................93 03 Replacing ATF.............................................................................................................................................94 Tools......................................................................................................................................................94 Replacing ATF fluid ..............................................................................................................................94 Tightening torques .................................................................................................................................96 03 Removing and installing ATF filter ............................................................................................................97 Tools......................................................................................................................................................97 Removing ATF filter.............................................................................................................................97 Installing ATF filter ...............................................................................................................................98 Tightening torques .................................................................................................................................99 03 Replacing and checking transmission oil in final drive ..........................................................................100 Tools....................................................................................................................................................100 Changing transmission oil in final drive ..............................................................................................100 Tightening torques ...............................................................................................................................102 einordnung iv

Table of Contents 03 Changing transmission oil in front wheel drive ......................................................................................103 Changing transmission oil in front wheel drive ...................................................................................103 Tightening torques ...............................................................................................................................103 03 Changing transmission oil - GT2 .............................................................................................................105 Changing transmission oil - GT2 ........................................................................................................105 Topping up transmission oil - GT2 .....................................................................................................105 Tightening torques ...............................................................................................................................106 03 Steering gear: fluid level and bellows .......................................................................................................107 Power steering: checking the fluid level ..............................................................................................107 General ..........................................................................................................................................107 Power steering: checking the fluid level .......................................................................................107 Steering gear: visual inspection of the bellows ....................................................................................109 03 Axle joints/drive shafts ..............................................................................................................................110 Tie rod ends: checking the play and dust bellows ...............................................................................110 Axle joints: checking the play and dust bellows ..................................................................................110 Drive shafts: visual inspection of the boots .........................................................................................111 03 Running gear adjustment/storage of assemblies .....................................................................................112 Running gear adjustment (wheel alignment values) ............................................................................112 Storage of assemblies and running gear ...............................................................................................112 03 Tyres and spare wheel: checking condition and tyre pressure ..............................................................113 Checking condition ..............................................................................................................................113 Tyre pressure for cold tyres (approx. 20 °C) .......................................................................................113 911 Turbo ......................................................................................................................................113 911 GT2 (M002/M003) .................................................................................................................113 03 Checking and changing the brake fluid ...................................................................................................115 Checking the brake fluid level .............................................................................................................115 Changing the brake fluid ......................................................................................................................115 03 Parking brake: checking the free play of the parking brake lever.......................................................117 Parking brake: checking the free play of the parking brake lever .......................................................117 Adjusting the parking brake ..........................................................................................................117 03 Visual inspection: brake lines/brake pads/brake discs ...........................................................................119 Brake hoses and lines ...........................................................................................................................119 Brake system: visual inspection of the brake pads and brake discs for wear ......................................119 03 Checking the wheel mounting ...................................................................................................................121 03 Checking lid and doors ..............................................................................................................................122 Checking lid lock, front and rear .........................................................................................................122 Checking the catch bar ..................................................................................................................122 Checking safety hook, front lid ............................................................................................................122 einordnung v

Table of Contents 03 Checking lid and doors Function test, checking door lock ........................................................................................................122 Functional inspection of the tank cap lock..........................................................................................123 Checking door and lid tightening torques ............................................................................................123 Checking inner release of luggage compartment (Trunk Entrapment) ................................................123 Tightening torques ...............................................................................................................................124 03 Checking seat belts .....................................................................................................................................125 Functional inspection ...........................................................................................................................125 Condition inspection ............................................................................................................................125 03 Inspecting the airbag system .....................................................................................................................126 Visual inspection ..................................................................................................................................126 Checking airbag warning light .............................................................................................................126 Function test of the airbag system.......................................................................................................126 03 Passenger protection maintenance: checking roll-over protection system ..........................................128 03 Particle filter: replacing the filter element..............................................................................................129 Removing particle filter .......................................................................................................................129 Installing particle filter .........................................................................................................................129 03 Checking the function of the vehicle's lights...........................................................................................130 Adjusting the main headlights.............................................................................................................130 Setting ..................................................................................................................................................131 Adjusting the main headlights, USA version .......................................................................................132 Fog light adjustment ............................................................................................................................132 Removing main headlight ....................................................................................................................132 Installing main headlight.....................................................................................................................133 03 Windscreen wiper/washer system, headlight washer .............................................................................135 03 Checking the function of electrical equipment, as well as the indicator and warning lights ..............136 03 Additional maintenance - USA................................................................................................................137 Additional maintenance, replacing spark plugs ...................................................................................137 Additional maintenance every 60,000 mls/96,000 km........................................................................137 Additional maintenance every 90,000 mls/144,000 km......................................................................138 Maintenance every 2 years ...................................................................................................................138 Maintenance after 4, 8, 10 then every 2 years .....................................................................................138 03 Additional maintenance - as of MY 2004 ................................................................................................139 Additional maintenance, replacing spark plugs ...................................................................................139 Additional maintenance every 80,000 km/48,000 mls ........................................................................139 Additional maintenance every 160,000 km/96,000 mls ......................................................................139 Maintenance every 2 years ...................................................................................................................140 Maintenance after 4, 8, 10 then every 2 years .....................................................................................140 einordnung vi

Table of Contents 03 Additional maintenance - USA - as of MY 2004...................................................................................141 Additional maintenance, replacing spark plugs ...................................................................................141 Additional maintenance every 60,000 mls/96,000 km........................................................................141 Additional maintenance every 90,000 mls/144,000 km......................................................................142 Maintenance every 2 years ...................................................................................................................142 Maintenance after 4, 8, 10 then every 2 years .....................................................................................142 03 Additional maintenance .............................................................................................................................144 Additional maintenance, replacing spark plugs ...................................................................................144 Additional maintenance every 80,000 km/48,000 mls ........................................................................144 Additional maintenance every 160,000 km/96,000 mls ......................................................................144 Maintenance every 2 years ...................................................................................................................145 Maintenance after 4, 8, 10 then every 2 years .....................................................................................145 3 Technical data..............................................................................................................................................146 6-speed manual transmission G 96.50 ................................................................................................146 Manual transmission tightening torques ........................................................................................147 Front wheel drive Z 96.00 ....................................................................................................................147 Front-axle drive tightening torques ..............................................................................................148 3 Technical data..............................................................................................................................................149 5-speed Tiptronic transmission A 96.50-150 .....................................................................................149 Tightening torques for Tiptronic transmission ..............................................................................150 Front wheel drive Z 96.00 ....................................................................................................................151 Front-axle drive tightening torques ..............................................................................................151 4 Removing transport lock (spring strut locking devices) Turbo and GT2 ...........................................153 General .................................................................................................................................................153 Removing spring strut locking devices ................................................................................................153 4 Lifting the vehicle .........................................................................................................................................155 Lift the vehicle .....................................................................................................................................155 4 Tests/notes for all-wheel drive...................................................................................................................156 Balancing wheels on vehicle ................................................................................................................156 Power test .............................................................................................................................................156 Brake test .............................................................................................................................................156 Towing manual transmission vehicles .................................................................................................156 Towing Tiptronic vehicles ...................................................................................................................156 4 Switching off PSM ........................................................................................................................................157 Switching off PSM ...............................................................................................................................157 Switching PSM back on .......................................................................................................................157 Characteristic features of Tiptronic vehicles (slip upshift) ..................................................................158 5 Plug location plan .........................................................................................................................................159 Top of front end ...................................................................................................................................159 Bottom of front end ..............................................................................................................................160 einordnung vii

Table of Contents 5 Plug location plan Side of front end ...................................................................................................................................160 Bottom of lower side member and floor ..............................................................................................161 Top of lower side member and floor ....................................................................................................161 Bottom of rear end ...............................................................................................................................162 Top of rear end .....................................................................................................................................162 Side of rear end ....................................................................................................................................163 Seam seals ........................................................................................................................................................164 Accessories..........................................................................................................................................164 Front lid .........................................................................................................................................165 Door ...............................................................................................................................................165 Sliding roof panel ..........................................................................................................................166 5 Work sequence for accident repair ............................................................................................................167 5 Work sequence for determining scope of damaged vehicles involved in an accident...........................169 5 Corrosion protection measures during repairs .........................................................................................171 Measures for maintaining long-term body protection........................................................................171 Prerequisite for ensuring vailidity of the long-life guarantee .............................................................171 5 Vehicle identification number .....................................................................................................................172 Imprinting new vehicle identification number .....................................................................................172 Materials, tools .....................................................................................................................................173 5 Change identification data plate .................................................................................................................174 5 Undersealing .................................................................................................................................................176 Overview diagram, lower front of vehicle ...........................................................................................176 Overview diagram, bottom of lower side member and floor ...............................................................177 Overview diagram, lower rear end .......................................................................................................178 Tools and materials ..............................................................................................................................178 5 Water drainage plan Cabriolet...............................................................................................................179 5 Check dimensions for body repair - Cabriolet structure ........................................................................180 Structure dimensions for cabriolet .......................................................................................................180 5 Safety notes ...................................................................................................................................................183 Safety instructions for raising vehicles ................................................................................................183 Danger of injury when raising vehicles .........................................................................................183 Damage when raising vehicles ......................................................................................................183 Safety instructions for welding ............................................................................................................184 Dangers of injury when welding ...................................................................................................184 Safety instructions for flying sparks during grinding and welding work ......................................184 Safety instructions for fuel tank ....................................................................................................185 Safety instructions for air conditioning .........................................................................................185 einordnung viii

Table of Contents 5 Safety notes Safety instructions for sticking ............................................................................................................185 Safety instructions for Teromix-6700 two-component adhesive................................................185 Safety instructions for installation work ..............................................................................................186 Safety instructions for sharp-edged body and unit parts ..............................................................186 Safety instructions for airbag system............................................................................................186 Safety instructions for door ...........................................................................................................186 Safety instructions for corrosion protection .........................................................................................187 Safety instructions for plug location plan (body) ..........................................................................187 Safety instructions for water drains (body) ...................................................................................187 5 General information and quality notes ......................................................................................................188 Measures for maintaining long-term body protection........................................................................188 Prerequisite for maintaining the long-life guarantee ....................................................................188 Electronic control modules ..................................................................................................................188 Protection against overvoltage ......................................................................................................189 Replacing control modules ............................................................................................................189 5 Tools and metalworking tools for body repairs ........................................................................................190 Straightening systems ..........................................................................................................................190 Metalworking tools ..............................................................................................................................190 Electrical equipment ......................................................................................................................190 Mechanical equipment..................................................................................................................191 Compressed-air equipment ...........................................................................................................191 Welding equipment .......................................................................................................................192 5 Diagram - keys to symbols for welding work ...........................................................................................193 Resistance spot welding .......................................................................................................................193 Inert-gas arc welding (MAG procedure) .............................................................................................193 Gas welding.........................................................................................................................................193 5 Check dimensions for body repair.............................................................................................................195 Floorpan check dimensions ..................................................................................................................195 5 Water drainage plan ....................................................................................................................................198 5 Diagram - body gap dimensions................................................................................................................199 Gap dimensions, body front .................................................................................................................199 Gap dimensions, body centre ...............................................................................................................201 Gap dimensions, body rear..................................................................................................................202 Gap dimensions, body rear Carrera 4S .............................................................................................204 Diagram - Gap dimensions, Cabriolet................................................................................................206 Diagram - Centre gap dimensions, Cabriolet ...............................................................................206 Diagram - Gap dimensions, rear Cabriolet ...................................................................................208 Diagram, gap dimensions, Cabriolet rear - Carrera 4S................................................................209 Diagram - Gap dimensions, hardtop .............................................................................................210 einordnung ix

2001-2005 Porsche 911 Turbo (996) Service & Repair Manual

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