Porsche 997 (4 & 4s) 911, 911 Turbo, GT2, GT3 Engines Parts Manual & Complete Workshop Service Repair Manual

Table of Contents 20 15 IN Calibrating fuel-level sensor system - as of MY 2005...................................................................38 Warning notes for calibrating fuel-level sensor system .........................................................................38 Calibrating fuel-level sensor system, C2 .........................................................................................39 24 46 TW Technical data, intake system - as of MY 2005 ............................................................................42 Technical values ....................................................................................................................................42 Intake system ...................................................................................................................................42 Intake system tightening torques .....................................................................................................42 26 01 TW Technical data, exhaust system - as of MY 2005 .........................................................................45 Technical values ....................................................................................................................................45 Exhaust system and emission control ..............................................................................................45 Exhaust system tightening torques ..................................................................................................45 27 06 IN External power connection, jump lead starting - as of MY 2005 .................................................48 Preliminary work..................................................................................................................................48 Preliminary work for external power connection, jump lead starting .............................................48 General warning notes ..........................................................................................................................49 Warning notes for external power connection, jump lead starting ..................................................49 Information...........................................................................................................................................49 External power connection ..............................................................................................................49 Jump lead starting ............................................................................................................................50 Subsequent work ...................................................................................................................................51 Rework on external power connection, jump lead starting .............................................................51 27 06 IN Work instructions after disconnecting the battery - as of MY 2005 ............................................54 Disconnecting and connecting the battery ............................................................................................54 Disconnecting and connecting the battery .......................................................................................54 Effect of disconnection or total discharge of battery on electrical systems in the vehicle and the precautions to be taken .......................................................................................................55 Test drive after disconnecting battery .............................................................................................59 Effects of overvoltage on electrical and electronic systems during welding work and the precautions to be taken............................................................................................................59 27 06 IN Electrical emergency release for lid - as of MY 2005 ....................................................................62 Electrical emergency release, front lid ...................................................................................................62 34 35 TW Technical data, transmission - as of MY 2005 .............................................................................65 Technical values ....................................................................................................................................65 Technical data ..................................................................................................................................65 Transmission ratios ..........................................................................................................................65 Filling capacities ..............................................................................................................................65 34 35 TW Technical data, transmission - as of MY 2005 .............................................................................68 Technical values ....................................................................................................................................68 Technical data ..................................................................................................................................68 Transmission ratios ..........................................................................................................................68 Filling capacities ..............................................................................................................................68 Diagnostic system: reading out fault memory and activating systems ii

Table of Contents 37 35 TW Technical data, automatic transmission - as of MY 2005 ...........................................................71 Technical values ....................................................................................................................................71 Technical data ..................................................................................................................................71 Transmission ratios ..........................................................................................................................71 Filling capacities ..............................................................................................................................71 37 35 TW Technical data, automatic transmission - as of MY 2005 ...........................................................74 Technical values ....................................................................................................................................74 Technical data ..................................................................................................................................74 Transmission ratios ..........................................................................................................................74 Filling capacities ..............................................................................................................................74 39 88 TW Technical data on front final drive - as of MY 2006 ...................................................................77 Technical values ....................................................................................................................................77 Technical values ..............................................................................................................................77 Transmission ratio ...........................................................................................................................77 Filling capacities ..............................................................................................................................77 61 01 IN Convertible top service position - as of MY 2005 ..........................................................................80 Convertible top service position ...........................................................................................................80 Move convertible top to service position ........................................................................................80 Ending convertible top service position ..........................................................................................81 61 01 IN Overview of convertible-top components - as of MY 2005 ...........................................................85 Overview of convertible-top components ..............................................................................................85 61 01 IN Diagram of convertible top - as of MY 2005 ..................................................................................88 Diagram of convertible top ....................................................................................................................88 61 01 K2 Calibrating convertible top - as of MY 2005 .................................................................................91 Preliminary work..................................................................................................................................91 Preliminary work for calibration .....................................................................................................91 General warning notes ..........................................................................................................................91 Warning note on calibration ............................................................................................................91 Calibrating convertible top ..............................................................................................................92 61 02 IN Assembly instructions for hardtop assembly fixture - as of MY 2005 .........................................94 Tools......................................................................................................................................................94 Tools and materials ...............................................................................................................................94 Tools and materials.........................................................................................................................94 Assembly instructions for hardtop assembly fixture............................................................................95 Making support cheeks ....................................................................................................................96 Making swivel arm ..........................................................................................................................96 Fitting swivel and support cheeks on the basic plate ......................................................................97 Fitting mounting points for the hardtop locking lever on the plate .................................................98 Fitting horizontal banner arm and support on the base plate..........................................................99 Diagnostic system: reading out fault memory and activating systems iii

Table of Contents 61 28 IN Care and cleaning of the convertible top - as of MY 2005 ..........................................................102 Care and cleaning of the convertible top ............................................................................................102 General information......................................................................................................................102 Cleaning the convertible top ..........................................................................................................103 Care of convertible top ..................................................................................................................103 Care of convertible-top seals .........................................................................................................103 64 12 IN Processing of Porsche 2-component window bonding agents - as of MY 2005 .........................106 Pre-treatment of bonding surfaces ......................................................................................................106 Pre-treating adhesive flanges on vehicle windows ........................................................................106 Pre-treating adhesive flanges on vehicle body ..............................................................................107 Handling processing device ................................................................................................................107 Double cartridge press ...................................................................................................................107 69 68 K2 Calibrating AWS control unit - as of MY 2005 ...........................................................................113 Tools....................................................................................................................................................113 Calibrating AWS control unit .............................................................................................................113 Calibrating AWS control unit ........................................................................................................113 87 43 IN Laying compressor/condenser line - as of MY 2005 ....................................................................118 Laying compressor/condenser line.....................................................................................................118 87 45 IN Laying compressor/evaporator line - as of MY 2005 ..................................................................122 Laying compressor/evaporator line ......................................................................................................122 94 15 IN Converting headlights for left/right-hand driving - as of MY 2005 ...........................................126 Converting halogen headlights for left/right-hand driving ..................................................................126 Converting Bi-Xenon headlights for left/right-hand driving........................................................127 94 23 IN Bulb table and installation instructions - as of MY 2005 ............................................................130 Bulb table ............................................................................................................................................130 Bulb table......................................................................................................................................130 Installation instructions .......................................................................................................................131 Installation instructions for bulbs ..................................................................................................131 97 72 IN Optical waveguide (LWL) - MOST bus - as of MY 2005...........................................................134 Tools....................................................................................................................................................134 Optical waveguide (LWL) - MOST bus .............................................................................................134 Requirements when working with LWL .......................................................................................134 Storage, Packing, Transport ..........................................................................................................134 Installing the LWL in the vehicle ..................................................................................................135 Repair ............................................................................................................................................135 Push-on connector - dust boots.....................................................................................................135 Control unit plug connector (wiring harness side) ........................................................................136 Push-on connector - connection points.........................................................................................136 Optical fiber (LWL) - module .......................................................................................................136 Optical waveguide variants ...........................................................................................................137 Removing and installing optical contacts on connector side........................................................140 Diagnostic system: reading out fault memory and activating systems iv

Table of Contents 97 72 IN Optical waveguide (LWL) - MOST bus - as of MY 2005 Installing optical contacts on connector side .................................................................................141 Removing and installing optical contacts on socket side ..............................................................141 Installing optical contacts on socket side ......................................................................................142 97 97 IN Connector - General information - as of MY 2005 ......................................................................146 Tools....................................................................................................................................................146 Connector - General information..................................................................................................146 Procedure for releasing connectors that are difficult to move .......................................................149 01 01 00 Sales check - as of MY 2005 ...........................................................................................................153 Sales check ..........................................................................................................................................153 03 24 00 Minor maintenance - as of MY 2005 .............................................................................................157 Minor maintenance .............................................................................................................................157 03 26 00 Major maintenance - as of MY 2005 .............................................................................................161 Major maintenance ..............................................................................................................................161 03 35 00 On-board diagnosis (OBD) - as of MY 2005 .................................................................................165 Tools....................................................................................................................................................165 Reading out and erasing fault memory ...............................................................................................165 Reading out and erasing fault memory ..........................................................................................165 03 60 00 Additional maintenance of drive belt - as of MY 2005 ................................................................168 Additional maintenance of drive belt ..................................................................................................168 03 81 00 Additional maintenance of spark plugs - as of MY 2005............................................................171 Additional maintenance of spark plugs ...............................................................................................171 Additional maintenance for spark plugs ........................................................................................171 03 83 00 Additional maintenance every 90,000 km/60.000 mls or every 6 years - as of MY 2005.........174 Additional maintenance every 90,000 km/60.000 mls or every 6 years .............................................174 03 88 00 Additional maintenance every 180,000 km/120.000 mls or every 12 years - as of MY 2005...177 Additional maintenance every 180,000 km/120.000 mls or every 12 years .......................................177 Notes ..............................................................................................................................................177 Additional maintenance every 180,000 km/120,000 mls or every 12 years .................................177 Additional maintenance every 180,000 km/120,000 mls or every 12 years .................................177 03 88 00 Additional maintenance every 180,000 km/120.000 mls or every 12 years - as of MY 2005...180 Additional maintenance every 180,000 km/120.000 mls or every 12 years .......................................180 Notes ..............................................................................................................................................180 Additional maintenance every 180,000 km/120,000 mls or every 12 years .................................180 Additional maintenance every 180,000 km/120,000 mls or every 12 years .................................180 Additional maintenance every 180,000 km/120,000 mls or every 12 years .................................181 Diagnostic system: reading out fault memory and activating systems v

Table of Contents 10 01 19 Removing and installing engine - as of MY 2005 .........................................................................183 Tools....................................................................................................................................................183 Preliminary work for removing the engine .........................................................................................184 Preparations for removing the engine...........................................................................................185 Removing engine ................................................................................................................................186 Removing engine ...........................................................................................................................186 Installing engine ..................................................................................................................................201 Installing engine ............................................................................................................................201 Subsequent work for installation of engine........................................................................................208 Installing engine - subsequent work ..............................................................................................209 10 01 37 Disassembling and assembling engine - as of MY 2005 ...............................................................212 Tools....................................................................................................................................................212 Preliminary work for disassembling engine.......................................................................................214 Preliminary work for disassembling engine ..................................................................................214 Component overview - engine ............................................................................................................215 Component overview - engine......................................................................................................215 Disassembling engine - up to crankcase .............................................................................................217 Disassembling engine - up to crankcase ........................................................................................217 Assembling engine - from crankcase ..................................................................................................231 Assembling engine - from crankcase ............................................................................................231 Assembling engine, subsequent work .................................................................................................237 Assembling engine, touching up ...................................................................................................237 10 30 19 Removing and installing engine carrier - as of MY 2005 ............................................................240 Preliminary work................................................................................................................................240 Preliminary work ...........................................................................................................................240 Removing engine carrier .....................................................................................................................240 Removing engine carrier ...............................................................................................................240 Installing engine carrier ......................................................................................................................242 Installing engine carrier .................................................................................................................242 Subsequent work .................................................................................................................................242 Subsequent work ...........................................................................................................................242 10 55 19 Removing and installing oil separator - as of MY 2005..............................................................245 Tools....................................................................................................................................................245 Preliminary work................................................................................................................................245 Preliminary work for removing oil separator ................................................................................245 Removing oil separator .......................................................................................................................245 Removing oil separator.................................................................................................................245 Installing oil separator .........................................................................................................................249 Installing oil separator ...................................................................................................................249 Subsequent work .................................................................................................................................251 Subsequent work for installing oil separator .................................................................................251 13 10 20 Removing and installing pistons - as of MY 2005 ........................................................................254 Tools....................................................................................................................................................254 Removing pistons, preliminary work ..................................................................................................257 Diagnostic system: reading out fault memory and activating systems vi

Table of Contents 13 10 20 Removing and installing pistons - as of MY 2005 Removing pistons, preliminary work ............................................................................................257 Removing pistons...............................................................................................................................257 Removing pistons ..........................................................................................................................258 Disassembling pistons/connecting rods, cylinder 1-3 .........................................................................262 Disassembling pistons/connecting rods, cylinder 1-3 ...................................................................262 Assembling pistons/connecting rods, cylinder 1-3 .............................................................................263 Assembling pistons/connecting rods, cylinder 1-3 ........................................................................264 Piston markings ...................................................................................................................................266 Piston markings .............................................................................................................................266 Installing pistons .................................................................................................................................267 Installing pistons ............................................................................................................................267 Installing pistons, touching up ............................................................................................................280 Installing pistons, touching up .......................................................................................................280 13 48 19 Removing and installing crankshaft - as of MY 2005 ..................................................................283 Tools....................................................................................................................................................283 Removing crankshaft, preliminary work ............................................................................................284 Removing crankshaft, preliminary work .......................................................................................284 Removing crankshaft ..........................................................................................................................287 Removing crankshaft .....................................................................................................................287 Installing crankshaft ............................................................................................................................290 Installing crankshaft ......................................................................................................................290 Installing crankshaft, touching up .......................................................................................................294 Installing crankshaft, touching up .................................................................................................294 13 59 19 Removing and installing crankshaft sealing ring - Flywheel side - as of MY 2005..................299 Tools....................................................................................................................................................299 Preliminary work for crankshaft sealing ring on flywheel side ..........................................................300 Preliminary work for crankshaft sealing ring on flywheel side ....................................................300 Removing crankshaft sealing ring on flywheel side ...........................................................................301 Removing crankshaft sealing ring on flywheel side.....................................................................301 Installing crankshaft sealing ring on flywheel side .............................................................................303 Installing crankshaft sealing ring (PTFE) on flywheel side ..........................................................303 Subsequent work for crankshaft sealing ring on flywheel side ..........................................................307 Subsequent work for crankshaft sealing ring on flywheel side .....................................................307 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 ................................................310 Tools....................................................................................................................................................310 Preliminary work................................................................................................................................310 Preliminary work for double-mass flywheel .................................................................................310 Removing double-mass flywheel - 3.8 l .............................................................................................310 Removing double-mass flywheel - 3.8 l ........................................................................................310 Installing double-mass flywheel .........................................................................................................312 Installing double-mass flywheel ....................................................................................................312 Subsequent work .................................................................................................................................312 Subsequent work for double-mass flywheel.................................................................................312 Diagnostic system: reading out fault memory and activating systems vii

Table of Contents 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 ................................................315 Tools....................................................................................................................................................315 Preliminary work................................................................................................................................315 Preliminary work for double-mass flywheel .................................................................................315 Removing double-mass flywheel - 3.6 l .............................................................................................315 Removing double-mass flywheel - 3.6 l ........................................................................................315 Installing double-mass flywheel .........................................................................................................317 Installing double-mass flywheel ....................................................................................................317 Subsequent work .................................................................................................................................317 Subsequent work for double-mass flywheel.................................................................................317 13 63 19 Removing and installing drive plate for converter - as of MY 2005 ..........................................320 Tools....................................................................................................................................................320 Preliminary work for drive plate for converter ...................................................................................320 Preliminary work for drive plate for converter.............................................................................320 Removing drive plate for converter ....................................................................................................320 Removing drive plate for converter ...............................................................................................320 Installing drive plate for converter ......................................................................................................321 Installing drive plate for converter ................................................................................................321 Subsequent work for drive plate for converter...................................................................................322 Subsequent work for drive plate for converter ..............................................................................322 13 74 19 Removing and installing crankshaft sealing ring - belt pulley side - as of MY 2005 ................324 Tools....................................................................................................................................................324 Preliminary work for crankshaft sealing ring - belt pulley side ..........................................................324 Preliminary work for crankshaft sealing ring - belt pulley side ....................................................324 Removing crankshaft sealing ring - belt pulley side ...........................................................................324 Removing the crankshaft sealing ring - belt pulley side ...............................................................324 Installing crankshaft sealing ring - belt pulley side ............................................................................326 Installing crankshaft sealing ring - belt pulley side .......................................................................326 Subsequent work for crankshaft sealing ring - belt pulley side ..........................................................327 Subsequent work for crankshaft sealing ring - belt pulley side....................................................327 13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005 .....330 Tools....................................................................................................................................................330 Preliminary work - engine installed ....................................................................................................330 Preliminary work for removing belt pulley/vibration damper - engine installed ..........................330 Removing belt pulley/vibration damper - engine installed .................................................................331 Removing belt pulley (3.6 l) - engine installed .............................................................................331 Installing belt pulley/vibration damper - engine installed ..................................................................332 Installing belt pulley - 3.6 l engine installed .................................................................................332 Subsequent work for installing belt pulley - engine installed .............................................................332 Subsequent work for installing belt pulley - engine installed .......................................................332 13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005 .....335 Tools....................................................................................................................................................335 Preliminary work - engine installed ....................................................................................................335 Preliminary work for removing belt pulley/vibration damper - engine installed ..........................335 Diagnostic system: reading out fault memory and activating systems viii

Table of Contents 13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005 Removing belt pulley/vibration damper - engine installed .................................................................336 Removing vibration damper (3.8 l) - engine installed ...................................................................336 Installing belt pulley/vibration damper - engine installed ..................................................................337 Installing vibration damper - 3.8 l engine installed .......................................................................337 Subsequent work for installing belt pulley - engine installed .............................................................338 Subsequent work for installing belt pulley - engine installed .......................................................338 13 78 19 Removing and installing drive belt - as of MY 2005 ....................................................................341 Preliminary work................................................................................................................................341 Preliminary work for removing drive belt .....................................................................................341 removing .............................................................................................................................................341 Removing drive belt ......................................................................................................................341 Installing.............................................................................................................................................342 Installing drive belt ........................................................................................................................342 Reworking ...........................................................................................................................................343 Work subsequent to installing drive belt .......................................................................................343 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 ........345 Tools....................................................................................................................................................345 Camshaft designation M96/05 ............................................................................................................346 Camshaft designation M96/05 .......................................................................................................346 Allocation of inlet camshaft adjustment device ..................................................................................347 Allocation of inlet camshaft adjustment device ............................................................................347 Allocation of chain tensioners............................................................................................................348 Allocation of chain tensioners .......................................................................................................348 Preliminary work for removing camshafts.........................................................................................349 Preliminary work for removing camshafts ....................................................................................349 Removing camshaft - engine removed...............................................................................................351 Removing camshafts - engine removed ........................................................................................351 Installing camshaft - engine removed .................................................................................................354 Installing camshafts, adjusting timing - engine removed ..............................................................354 Subsequent work for installing camshafts ..........................................................................................363 Subsequent work for installing camshafts .....................................................................................363 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 ........367 Tools....................................................................................................................................................367 Allocation of inlet camshaft adjustment device ..................................................................................368 Allocation of inlet camshaft adjustment device ............................................................................368 Allocation of chain tensioners............................................................................................................369 Allocation of chain tensioners .......................................................................................................369 Preliminary work for removing camshafts.........................................................................................370 Preliminary work for removing camshafts ....................................................................................370 Removing camshaft - engine removed...............................................................................................372 Removing camshafts - engine removed ........................................................................................372 Installing camshaft - engine removed .................................................................................................375 Installing camshafts, adjusting timing - engine removed ..............................................................375 Subsequent work for installing camshafts ..........................................................................................384 Diagnostic system: reading out fault memory and activating systems ix

Table of Contents 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 Subsequent work for installing camshafts .....................................................................................384 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 ........388 Tools....................................................................................................................................................388 Camshaft designation M97/01 ............................................................................................................389 Camshaft designation M97/01 .......................................................................................................389 Allocation of inlet camshaft adjustment device ..................................................................................390 Allocation of inlet camshaft adjustment device ............................................................................390 Allocation of chain tensioners............................................................................................................391 Allocation of chain tensioners .......................................................................................................391 Preliminary work for removing camshafts.........................................................................................392 Preliminary work for removing camshafts ....................................................................................392 Removing camshaft - engine removed...............................................................................................394 Removing camshafts - engine removed ........................................................................................394 Installing camshaft - engine removed .................................................................................................397 Installing camshafts, adjusting timing - engine removed ..............................................................397 Subsequent work for installing camshafts ..........................................................................................406 Subsequent work for installing camshafts .....................................................................................406 15 21 19 Removing and installing bearing cover for intermediate shaft - as of MY 2005......................410 Tools....................................................................................................................................................410 Preliminary work for bearing cover for intermediate shaft................................................................411 Preliminary work for bearing cover for intermediate shaft ...........................................................411 Removing bearing cover for intermediate shaft ..................................................................................411 Removing bearing cover for intermediate shaft ............................................................................412 Installing bearing cover for intermediate shaft ...................................................................................415 Installing bearing cover for intermediate shaft ..............................................................................415 Subsequent work for bearing cover for intermediate shaft .................................................................417 Subsequent work for bearing cover for intermediate shaft ...........................................................417 15 21 19 Removing and installing bearing cover for intermediate shaft - M97/01 - as of MY 2005 ......420 Tools....................................................................................................................................................420 Preliminary work for bearing cover for intermediate shaft................................................................421 Preliminary work for bearing cover for intermediate shaft ...........................................................421 Removing bearing cover for intermediate shaft ..................................................................................422 Removing bearing cover for intermediate shaft - up to engine number 685 09 790 .....................422 Removing bearing cover for intermediate shaft - from engine number 685 09 791 .....................426 Installing bearing cover for intermediate shaft ...................................................................................431 Installing bearing cover for intermediate shaft - up to engine number 685 09 790 ......................432 Installing bearing cover for intermediate shaft - from engine number 685 09 791 .......................434 Subsequent work for bearing cover for intermediate shaft .................................................................437 Subsequent work for bearing cover for intermediate shaft ...........................................................437 15 21 19 Removing and installing bearing cover for intermediate shaft - M96/05 - as of MY 2005 ......440 Tools....................................................................................................................................................440 Removing bearing cover for intermediate shaft ..................................................................................441 Removing bearing cover for intermediate shaft - up to engine number 695 07 475 .....................441 Diagnostic system: reading out fault memory and activating systems x

Porsche 997 (4 & 4s) 911, 911 Turbo, GT2, GT3 Engines Parts Manual & Complete Workshop Service Repair Manual

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