Porsche 911 Carrera (996) Service Repair Manual

Technical Manual 9..?? ~"'7~~ (996) T echnicallnformation Contents: Group 0 Entire vehicle -General WKD 483 721 www.WorkshopManuals.co.uk

911 Carrera (996) Foreword Foreword The workshop documentation for the 911 Carrera (996) model has the designation "911 Carrera (996)" Technical Manual and contains Technical Information as well as instructions on Repairs. Theintegration of the technical information published in the "911 Carrera (996)" Technical Manual with the instructions on repairs provides the userwitha complex reference work thatcombines into onebook associated or cross-referenced material of relevance to workshops andoriginating from various information media. The "911 Carrera (996)" Technical Manual consists of 15 folders, subdividedinto the following Groups 0 Entire vehicle -General 0 Diagnosis, part 1 (up to RepairGroup 45) *1 0 Diagnosis, part 2 (as of RepairGroup 61) *2 1 Engine,part 1 (up to RepairGroup 13) *3 1 Engine,part 2 (as of RepairGroup 15) *4 2 Fuel, exhaust,engine electronics 3 Transmission, manualtransmission 3 Transmission, automatictransmission 4 Running gear 5 Body 6 Body equipment, exterior 7 Body equipment, interior 8 / 9 Air conditioning / Electrics 9 Circuit diagrams, part 1 (up to and includingthe '99 model) *5 9 Circuit diagrams, part 2 (as of the '00 model) *6 *1 The two folders with Group 0 are to be regarded as one folder; i.e. file the "Technical Information" notices only in front of the repair descriptions in the folder "Group0 -Diagnosis, part I" (up to Repair Group 45). .2 The second folder "Group0 -Diagnosis, part 2" (as of Repair Group 61) includesthe further Repair Groupsbelongingto Group O. *3 The two folders with Group 1 are to be regarded as one folder; i.e. file the "Technical Information' notices only in front of the repair descriptionsin the folder "Group1 -Engine, part 1" (up to Repair Group 13). *4 The second folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe further Repair Groups belongingto Group 1. VORW.CHP Foreword Printed in Germany -35, October 1999 www.WorkshopManuals.co.uk

Foreword 911 Carrera (996) .5 The two folders with Group 9 are to be regarded as one folder; i.e. file the "Technical Information" notices only in front of the repair descriptions in the folder "Group9 -Circuit diagrams, part I" (up to and including the '99 model). *6 The second folder "Group9 -Circuit diagrams, part 2" (as of the '00 model) includesthe further circuit diagrams belongingto Group 9. The "911 Carrera (996)" TechnicalManual has the same structure in each folder, with the following breakdown for all Groups: Title page: "911 Carrera (996)" Technical Manual > Foreword Title page: "Technical Information" > Table of Contents,Technicalinformation > Technicalinformation Title page: "Repair" > RepairGroups: overview > Table of Contents,repairs > General/technical data > Instructions on repairs As can be seen from the breakdown, the published TechnicalInformationis in the front part of each folder -numbered according to the Groups.The Table of Contents assigned to each Group will be peri- odically updated. Following the Technical Information, separated by a title page, the instructions on repairs -assigned according to the Groups or broken down into RepairGroups -are included in the folders. Theinstructions on repairs will be extended andupdated by means of supplements. Note Sheets that already exist in the "911 Carrera (996)"TechnicalManualand are updated or revised and thereby exchanged by a supplement are designated "replacement sheet". Revisions or technical modificationson pages of these replacement sheets are identified for the user with a vertical bar at the margin. www.WorkshopManuals.co.uk

Record sheet for supplements to We ask that you file the supplement under the appropriateRepairGroups and enter them in the table below to provide an overview. Date filed Signature Supplement No. already filed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 www.WorkshopManuals.co.uk

Record sheet for to We ask that you file the supplementsunder the appropriate RepairGroups and enter them in the table below to provide an overview. I EINTRAG2.CHP www.WorkshopManuals.co.uk

911 Carrera (996) Structure of Technical Manual -Repair 911 Carrera (996) Technical Manual -Repair General The TechnicalManual-Repair -describes all essentialwork operationsrequiring special instructionsto ensure that repairs are performed properly. It should be in the hands of the workshop foremen and the workshop personnel,as careful compliance with the stated instructions is a preconditionfor maintaining the traffic and operating safety of the vehicle. In addition, of course, the generally customary basic safety rules for the repair of motor vehicles are unrestrictedly applicable. Structure Overview of repair groups Contents Technicaldata / general Description of repairs Breakdown of Repair Groups Tools, special tools and materials required for repair Exploded drawing andillustration of sequence Legend for exploded drawing and description of sequence Instructions for assembly and adjustment The TechnicalManualis regularlyexpanded by supplements, which must be incorporated immediately to preserve the usefulnessof the Manual. As verification of completeness, the record sheet should be com- pleted. 911 Carrera (996) Technical Manual- Repair Printed in Germany, 1997 www.WorkshopManuals.co.uk

Structure of exploded view C B A 911 Cm I996) En.n..Lubrication 'iEi 17 A 17 B c Enchl. -L.rieatlon 911 C 1996) H H Removing and installing oil pomp with coolant guide housing Coo~nt dr.;n ~ug MIO x I 2 Sea.ng r;ng Al8, 135 3 Hexagor;head bdt M6,70 4 HexagD"head bdt M6,70 5 Hexagrohead bolt M6,20 6 OJ PlXl1>wiUl coolant go hous;ng 7 Gasket Tight.,;"g "Xque 10 Nm 175 tUb I Always 'ePace; ;ns,,' or fit orty n coolant glide hous;ng hasbeen put onto the C"Mcase Always ,e..ace;;nsert or fil orjy n coolanlguKle hous;ng hasbeen put onto the cr'Mcase 8 Gasket 9 Dr"., 10 O-ring 11 ~ug wiu, guide pin 12 Piston 13 Sp,ing 14 Se.hng ring Always repiace 11ghtenmg tor,ue 25 (19fUbl 01 Replace F 112019 Removing and installing oil pump w~h coolant guide housmg E "'I'! G "'m".C.'m..,!"? D 8 G A B C D E F = - H J - Imprint, supplement number, year of printing Title of exploded view Item number of exploded view, in disassembly sequence Special instructionsto be followed during installationor removal K Repair Group, numbers RepairGroup, text Vehicletype Page number Internal Porsche number Work operation, consisting of "After-sales service number" and 'Title" = Structure of exploded view Printed in Germany, 1997 www.WorkshopManuals.co.uk

911 Carrera (996) Structure of Technical Manual -Repair Structure of sequence description A~ c B AS7 c B Door front, contrallock.., system - 911 Carrera (996) 911 Carrerai9961 Door front. central locking system H H Removing and installing door Observe die safety instructions for handling airba. vehicles before removing the door with sklo airba. 1 Remove the igrution ke, 2 Disconnect and cover the negative terminal of the batte" 3 Aft.. Ifiscorv1ecbng the bane", assemt;y wo'" or ou.." wo'" mvst be stoned on~ afte' a waiting time of 1 ml L Ino"",.ono Unscrew fastenmg screw from Remov;ng door J K No Procedure 1 Loosen fasten;ng screw 2 Loosen door brake Uoscrew hexa.OIl brake Disconnect pi"" COMootion loosen To" sc,ew rT25J,p,sh ,,'g 'p byappro.. 3 mm and then p," the who~ pwg co"'ection oLlt of theA,;IIac Ca""n LatchklCI'C5 In tile "ue can braa- off! P,II oLlt lockingel,ment at the bottom pa" ot u., ",g connection and disco",ect the ",g connection Unsc"w lock"g sc,ew I,om the doo, Nnc, and~ the doo' '4'wards old01the hinges loos,n T", sc'ewon latch sir." and,emo., latch st,." 4 Looson ',"h strike.. 57.3 D 57 51 19 Removm, .nd ;n,tallm, doo, F Prim,d;, ..,m..,'99' G 57 -2 D .96571 E G A B C D E F = - Imprint, supplement number, year of printing Title of sequencedescription Sequence number in order of sequence Procedurein the sequence Descriptionor explanationof the procedure H J K L - Repair Group, numbers Repair Group, text Vehicle type Page number Internal Porsche number Work operation, consisting of "After-sales service number" and 'Title" Structure of sequence description Printed in Germany, 1997 www.WorkshopManuals.co.uk

Group 0: Entire vehicle -General Sales check Maintenance 0 01 03 Group 0: Diagnosis On-board diagnosis DME diagnosis Tiptronic diagnosis ABS diagnosis 0 03 24 37 45 Group 0: 0 61 69 69 72 80 90 91 91 94 Diagnosis Convertible-top diagnosis Airbag diagnosis Roll-over protection system diagnosis Seat memory diagnosis Heating diagnosis Alarm system diagnosis PCM diagnosis ParkAssistent diagnosis HBA diagnosis Group 1: 1 10 13 Engine Engine-Crankcase, suspension Engine-Crankshaft, pistons Group 1: 1 15 17 19 Engine Engine -Cylinder head,valve drive Engine -Lubrication Engine -Cooling Group 2: 2 20 21 24 25 26 27 28 Fuel, exhaust, engine electronics Fuel supply, control Exhaust system, turbocharging Fuel system, electronic injection Fuel system, K-Jetronic Exhaust system Starter, powersupply, cruise control Ignition system Group 3: 3 30 34 35 39 Transmission, manual transmission Clutch, control Manual transmission-Actuation, housing Manual transmission-Gears, shafts, intogearsh Final drive, differential,differential lock Group 3: 3 32 37 38 39 Transmission, automatic transmission Torque converter Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differential lock Overview of repair groups Printed in Germany -35, October 1999 REPGRU.CHP www.WorkshopManuals.co.uk

Group 4: 4 40 42 44 45 46 47 48 Running gear Front wheel suspension, drive shafts Rear wheel suspension, drive shafts Wheels,tires, suspensionalignment Anti-LockBrake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering Group 5: 5 50 51 53 55 57 Body Body front Body center, roof,frame Body rear Lids, flaps Door front, central locking; system Group 6: 6 60 61 63 64 66 68 69 Body equipment, exterior Sliding roof Convertible top, hardtop Bumpers Glazing, window control Exterior equipment Interior equipment Passenger protection Group 7: Body equipment, interior Linings, insulation Seat frames Seatupholsteries, covers 7 70 72 74 Group 8: 8 80 85 87 88 Air conditioning Heating Ventilation Air conditioning Auxiliary air conditioningsystem Group 9 9 90 91 92 94 96 Electrics Instruments, alarm system Radio,telephone,on-board computerI navigation Windshield wiper and washer system lights, lamps, switches exterior lights, lamps, switchesinterior, theft protection Group 9: 9 97 Circuit diagrams Wiring (up to and including the '99 model) 9 97 Group 9: Circuit diagrams Wiring (from the '00 model) Overview of repair groups Printed in Germany -35, October 1999 REPGRU.CHP www.WorkshopManuals.co.uk

Porsche 911 Carrera (996) Service Repair Manual

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