2005 Porsche 997 Service & Repair Manual
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AfterSales Training
911 Turbo/GT2/GT3 Engine Repair P10T
®
Porsche AfterSales Training
Student Name: ________________________________________________
Training Center Location: ________________________________________________
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Date: ___________________
Important Notice:The contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-of-world
English speaking market. The electronic text and graphic files were then imported by Porsche Cars N.A, Inc. and edited for con-
tent. Some equipment and technical data listed in this publication may not be applicable for our market. Specifications are sub-
ject to change without notice.
We have attempted to render the text within this publication to American English as best as we could. We reserve the right to
make changes without notice.
© 2006 Porsche Cars North America, Inc. All Rights Reserved. Reproduction or translation in whole or in part is not permitted
without written authorization from publisher. AfterSales Training Publications
Dr. Ing. h.c. F. Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation
the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman
TM
, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and
the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile. The third
party trademarks contained herein are the properties of their respective owners. Porsche Cars North America, Inc., believes the
specifications to be correct at the time of printing. However, specifications, standard equipment and options are subject to
change without notice.
Part Number - PNA P10 T02 Edition - 9/06
Table of Contents
911 Turbo/GT2/GT3 Engine Repair
Description Section
Engine Type Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
911 Turbo (996) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
911 Turbo (997) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
911 GT2 (996) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
911 GT3 (996) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
911 GT3 (997) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
911 Turbo/GT2/GT3 Engine Repair
Engine Type Designations
911 Turbo/GT2/GT3 Engine Repair Page 1.1
911 and Boxster Engine Type Designations Since Model Year 1984
Model Engine Displ. Engine Power Installed In
Year Type Liters kW / HP
1984 930.20 3.2 170/231 911 Carrera - RoW
930.21 3.2 152/207 911 Carrera - USA/Canada/Japan
930.66 3.3 221/300 911 Turbo - Worldwide
1985 930.20 3.2 170/231 911 Carrera - RoW
930.21 3.2 152/207 FRG/USA/Canada/Japan (with catalytic converter)
930.26 3.2 170/231 Sweden /Switzerland /AustraIia
930.66 3.3 221/300 911 Turbo - Worldwide
1986 930.20 3.2 170/231 911 Carrera - RoW
930.21 3.2 152/207 911 Carrera USA/Canada/Japan
930.26 3.2 170/231 911 Carrera Sweden./Switzerland/Australia
930.66 3.3 221/300 R0W/Canada
930.68 3.3 208/282 911 Turbo - USA (with catalytic convverter)
1987 930.20 3.2 170/231 911 Carrera - RoW
930.25 3.2 160/217 USA / Japan
930.26 3.2 170/231 Sweden
930.66 3.3 221/300 RoW/Canada
930.68 3.3 210/282 USA (with catalytic converter)
1988 930.20 3.2 170/231 911 Carrera - RoW
930.25 3.2 160/217 USA/Japan/Canada/Australia/RoW (with catalytic conv.)
930.26 3.2 170/231 Sweden
930.66 3.3 221/300 Turbo RoW
930.68 3.3 210/282 Turbo USA/Canada
1989 930.20 3.2 170/231 911 Carrera - RoW
930.25 3.2 160/217 USA/Canada/Japan/Australia/RoW (with catalytic conv.)
930.66 3.3 221/300 911 Turbo - RoW
930.68 3.3 210/282 911 Turbo - USA
M 64.01 3.6 184/250 911 Carrera 4 (964) - Worldwide
1990 M 64.01 3.6 184/250 911 Carrera (964) 2/4 with manual transmission - Worldwide
M 64.02 3.6 184/250 911 Carrera (964) 2 with tiptronic transmission - Worldwide
Engine Number Identification
Digit: 123 45678
Example: 65V 00136
Engine Type: (6 = 6 Cyl. Engine)
Engine Version:
Model Year:
Serial Number:
Engine number is stamped on
the bottom of the crankcase.
Page 1.2 911 Turbo/GT2/GT3 Engine Repair
Engine Type Designations
Model Engine Displ. Engine Power Installed In
Year Type Liters kW / HP
1991 M64.01 3.6 184/250 911 Carrera (964) 2/4
M64.02 3.6 184/250 911 Carrera (964) 2
M30.69 3.3 235/320 911 Turbo (964)
1992 M64.01 3.6 184/250 911 Carrera (964) 2/4
M64.02 3.6 184/250 911 Carrera (964) 2
M64.03 3.6 191/260 911 Carrera (964) RS
M30.69 3.3 235/320 911 Turbo (964)
1993 M64.01 3.6 184/250 911 Carrera (964) 2/4
M64.02 3.6 184/250 911 Carrera (964) 2
M64.03 3.6 191/260 911 Carrera (964) RS
M64.50 3.6 265/360 911 Turbo (964)
1994 M64.01 3.6 184/250 911 Carrera (964) 2/4 USA
M64.02 3.6 184/250 911 Carrera (964) 2 USA
M64.05 3.6 200/272 911 Carrera (964) RoW
M64.06 3.6 200/272 911 Carrera (964) RoW & Taiwan with Tiptronic
M64.50 3.6 265/355 911 Turbo USA/CDN
1995 M64.05 3.6 200/272 911 Carrera (964) RoW
M64.06 3.6 200/272 911 Carrera (964) RoW
M64.20 3.7 220/300 911 Carrera (993) RS RoW
M64.07 3.6 200/272 911 Carrera (993) USA
M64.08 3.6 200/272 911 Carrera (993) USA
1996 M64.21 3.6 210/285 911 Carrera (993) /C4 /C4S RoW
M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic
M64.23 3.6 210/285 911 Carrera (993) /C4/C4S USA
M64.24 3.6 210/285 911 Carrera (993) USA Tiptronic
M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN
1997 M64.21 3.6 210/285 911 Carrera (993) /C4 /C4S RoW
M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic
M64.23 3.6 210/285 911 Carrera (993) /C4/C4S USA
M64.24 3.6 210/285 911 Carrera (993) USA Tiptronic
M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN
M96.20 2.5 150/204 Boxster
1998 M64.21 3.6 210/285 911 Carrera (993) /C4/C4S RoW
M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic
M64.23 3.6 210/285 911 Carrera (993) /C4 & C4S USA/CDN
M64.24 3.6 210/285 911 Carrera (993) USA/CDN Tiptronic
M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN
M96.20 2.5 150/204 Boxster
1999 M96.01 3.4 220/296 911 Carrera (996)
M96.20 2.5 150/204 Boxster
2000 M96.01 3.4 220/296 911 Carrera (996)
M96.02 3.4 220/296 911 Carrera (996) 4
M96.04 3.4 220/296 911 Carrera (996) 2/4
M96.22 2.7 162/217 Boxster
M96.21 3.2 185/250 Boxster S
Engine Type Designations
911 Turbo/GT2/GT3 Engine Repair Page 1.3
Model Engine Displ. Engine Power Installed In
Year Type Liters kW / HP
2001 M96.01 3.4 220/296 911 Carrera (996)
M96.02 3.4 220/296 911 Carrera (996) 4
M96.04 3.4 220/296 911 Carrera (996) 2/4
M96.22 2.7 162/217 Boxster
M96.21 3.2 185/250 Boxster S
M96.70 3.6 309/414 911 Turbo (996)
M96.70S 3.6 340/456 911 GT2 (996)
2002 M96.03 3.6 232/310 911 Carrera (996) 2/4/4S
M96.22 2.7 162/217 Boxster
M96.21 3.2 185/250 Boxster S
M96.70 3.6 309/414 911 Turbo (996)
M96.70S 3.6 340/456 911 GT2 (996)
2003 M96.03 3.6 235/315 911 Carrera (996) 2/4/4S
M96.23 2.7 168/225 Boxster
M96.24 3.2 191/256 Boxster S
M96.70 3.6 309/414 911 Turbo (996)
M96.70S 3.6 340/456 911 GT2 (996)
2004 M96.03 3.6 235/315 911 Carrera (996) 2/4/4S
M96.03S 3.6 254/340 911 Carrera (996) 2/4/4S (Special Model - 40 Year)
M96.23 2.7 168/225 Boxster
M96.24 3.2 191/256 Boxster S
M96.70 3.6 309/414 911 Turbo (996)
M96.70SL 3.6 355/476 911 GT2 (996)
M96.79 3.6 284/381 911 GT3 (996)
2005 M96.03 3.6 235/315 911 Carrera (996) 2/4/4S
M96.05 3.6 239/325 911 Carrera (997)
M97.01 3.8 261/355 911 Carrera S (997)
M96.25 2.7 176/240 Boxster (987)
M96.26 3.2 206/280 Boxster S (987)
M96.70 3.6 309/414 911 Turbo (996)
M96.70S 3.6 340/456 911 GT2 (996)
M96.79 3.6 280/381 911 GT3 (996)
2006 M96.05 3.6 239/325 911 Carrera 2/4 (997)
M97.01 3.8 261/355 911 Carrera 2/4 S (997)
M96.25 2.7 176/240 Boxster (987)
M96.26 3.2 206/280 Boxster S (987)
M97.21 3.4 217/295 Cayman S (987)
2007 M96.05 3.6 239/325 911 Carrera 2/4 (997)
M97.01 3.8 261/355 911 Carrera 2/4 S (997)
M97.20 2.7 180/245 Boxster (987)
M97.21 3.4 217/295 Boxster S (987)
M97.20 2.7 180/245 Cayman (987)
M97.21 3.4 217/295 Cayman S (987)
M97.70 3.6 353/480 911 Turbo (997)
M97.76 3.6 305/415 911 GT3 (997)
* The HP number over the years has been listed in SAE or DIN. (Kw to SAE HP factor is x 1.34, SAE HP to DIN HP factor is x 1.014)
Page 1.4 911 Turbo/GT2/GT3 Engine Repair
Engine Type Designations
Notes:
911 Turbo (996)
911 Turbo/GT2/GT3 Engine Repair Page 2.1
Subject Page
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Valve Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
VarioCam Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Page 2.2 911 Turbo/GT2/GT3 Engine Repair
911 Turbo (996)
Notes:
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This is the complete official full factory service repair manual for the Porsche 997 2005. It provides detailed information for general maintenance, periodic tune-ups, engine servicing, disassembly, reassembly, fuel and lubrication systems, electrical system, chassis, wiring diagrams, tools, and more. This manual is designed for both professional mechanics and DIY enthusiasts. It is available in a printable .PDF format, compatible with all PC-based Windows operating systems and Mac. The file can be saved to your hard drive and burned to a CD-ROM for easy access. No shipping is required. The language of the manual is English, and it is printable without any restrictions. Adobe Reader is required for viewing. Get your Porsche 997 2005 service manual now to access a wealth of information for maintaining and repairing your vehicle.
- Detailed substeps expand on repair procedure information.
- Notes, cautions, and warnings throughout each chapter pinpoint critical information.
- Numbered instructions guide you through every repair procedure step by step.
- Bold figure numbers help you quickly match illustrations with instructions.
- Detailed illustrations, drawings, and photos guide you through every procedure.
- Enlarged inset helps you identify and examine parts in detail.
- Numbered table of contents is easy to use so that you can find the information you need fast.
This comprehensive manual covers a wide range of topics including specifications, lube points, oil types, fuel and lubrication systems, electrical system, ignition, charging, starter, battery, switches, chassis, wheels, brakes, steering, suspension, axles, wiring diagrams, tools, tightening torques, service data, engine service, gearbox, exhaust system, fault finding, clutch removal and installation, bodywork, cooling system, transmission, electrics, brake servicing procedures, U-joint service procedures, CV joint service procedures, timing chain service, exhaust service, and more. It includes abundant illustrations, pictures, diagrams, and more. This is a full professional quality in-depth service and repair manual for the Porsche 997 2005.
