Porsche 911 CARRERA - 1999 User manual

TechnicalManual
9.1'.1' ~7~ (996)
Technicallnformation
Contents:
Group9
Electrics
WKD483 721
www.WorkshopManuals.co.uk

911 Carrera (996) Foreword
Foreword
Theworkshopdocumentationfor the 911 Carrera(996)model hasthe designation
"911 Carrera (996)" Technical Manual
and containsTechnical Information as well as instructionsonRepairs.
Theintegrationof the technicalinformationpublishedin the"911 Carrera(996)"TechnicalManualwith
the instructionson repairs providesthe userwith a complexreferencework that combinesinto one book
associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various informa-
tion media.
The"911 Carrera (996)"TechnicalManualconsists of 15 folders,subdividedintothe followingGroups
0 Entirevehicle-General
0 Diagnosis,part 1 (upto RepairGroup45) .1
0 Diagnosis,part 2 (asof RepairGroup61) .2
1 Engine,part 1 (upto RepairGroup 13) .3
1 Engine,part 2 (asof RepairGroup 15) .4
2 Fuel,exhaust,engineelectronics
3 Transmission,manualtransmission
3 Transmission,automatictransmission
4 Runninggear
5 Body
6 Bodyequipment,exterior
7 Bodyequipment,interior
8 / 9 Air conditioning/ Electrics
9 Circuitdiagrams,part 1 (upto and includingthe '99 model).5
9 Circuitdiagrams,part 2 (as of the '00 model).6
*1 Thetwo folders with Group0 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group0 -Diagnosis, part I"
(up to Repair Group 45).
*2 Thesecond folder "Group0 -Diagnosis, part 2" (as of Repair Group 61) includesthe further
RepairGroupsbelongingto GroupO.
*3 Thetwo folderswith Group1 are to be regardedas one folder; i.e. file the "TechnicalInformation"
noticesonlyin front of the repair descriptionsinthe folder "Group1 -Engine, part 1"
(upto RepairGroup13).
*4 Thesecond folder "Group1 -Engine, part 2"(as of Repair Group 15) includesthe further Repair
Groupsbelongingto Group1.
VORW.CHP
Foreword
Printed in Germany -35, October 1999
www.WorkshopManuals.co.uk

*5 ThetwofolderswithGroup9 areto beregardedasonefolder;i.e.filethe"TechnicalInformation"
noticesonlyinfrontoftherepairdescriptionsinthefolder"Group9 -Circuit diagrams,partI" (upto
andincludingthe '99 model).
*6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuit diagramsbelongingto Group9.
The"911 Carrera(996)"TechnicalManualhasthe same structure in each folder,with the followingbreak-
downfor all Groups:
Title page: "911 Carrera (996)" Technical Manual
> Foreword
Title page: "Technical Information"
> Table of Contents,Technicalinformation
> Technicalinformation
Titje page: "Repair"
> RepairGroups:overview
> Table of Contents,repairs
> General/technical data
> Instructionson repairs
As can be seenfrom the breakdown,the publishedTechnicalInformationis in the front part of eachfol-
der -numbered accordingto the Groups.TheTable of Contentsassignedto eachGroupwill be peri-
odicallyupdated.
Followingthe TechnicalInformation,separatedby a title page,the instructionson repairs-assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedin the folders.
Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.
Note
Sheetsthat alreadyexist in the "911 Carrera(996)"TechnicalManualandare updatedor revised
and therebyexchangedby a supplementare designated"replacementsheet".Revisionsor technical
modificationson pagesof these replacementsheetsare identifiedfor the userwith a vertical bar at
themargin.
www.WorkshopManuals.co.uk

Overview of repair groups
911 Carrera (996)
0
01
03
Group 0: Entire vehicle -General
Salescheck
Maintenance
0
03
24
37
45
Group 0: Diagnosis
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
0
61
69
69
72
80
90
91
91
94
Group 0: Diagnosis
Convertible-topdiagnosis
Airbagdiagnosis
Roll-overprotectionsystemdiagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarmsystem diagnosis
PCMdiagnosis
ParkAssistentdiagnosis
HBAdiagnosis
1
10
13
Group 1: Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons 1
15
17
19
Group 1: Engine
Engine-Cylinder head,valvedrive
Engine-Lubrication
Engine-Cooling 2
20
21
24
25
26
27
28
Group 2: Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem,turbocharging
Fuelsystem,electronicinjection
Fuelsystem,K-Jetronic
Exhaustsystem
Starter, power supply,cruisecontrol
Ignitionsystem 3
30
34
35
39
Group 3: Transmission, manual transmission
Clutch, control
Manual transmission -Actuation, housing
Manual transmission -Gears, shafts, into gearsh,
Final drive, differential, differential lock
3
32
37
38
39
Group 3: Transmission, automatic transmission
Torqueconverter
Automatictransmission-Actuation, housing
Automatictransmission-Gears, control
Finaldrive, differential,differentiallock
Overview of repair groups
Printed in Germany -35, October 1999 REPGRU.CHP
www.WorkshopManuals.co.uk

Overview of repair groups 911 Carrera (996)
Group 4: 4
40
42
44
45
46
47
48
Running gear
Frontwheelsuspension,driveshafts
Rearwheel suspension,driveshafts
Wheels,tires, suspensionalignment
Ant~LockBrakeSystem(ABS)
Brakes-Brake mechanics
Brakes-Hydraulics, regulator,booster
Steering
Group 5: 5
50
51
53
55
57
Body
Bodyfront
Bodycenter,roof,frame
Bodyrear
Lids,flaps
Doorfront,centrallockingsystem
Group 6: 6
60
61
63
64
66
68
69
Body equipment, exterior
Slidingroof
Convertibletop,hardtop
Bumpers
Glazing,windowcontrol
Exteriorequipment
Interiorequipment
Passengerprotection 7
70
72
74
Group 7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
8
80
85
87
88
Group 8: Air conditioning
Heating
Ventilation
Air conditioning
Auxiliaryair conditioningsystem
9
90
91
92
94
96
Group 9 Electrics
Instruments,alarmsystem
Radio,telephone,on-boardcomputer,navigation
Windshieldwiper andwashersystem
Lights, lamps,switchesexterior
Lights, lamps,switchesinterior,theft protection
9
97
Group 9: Circuit diagrams
Wiring(upto and includingthe '99 model)
9
97
Group 9: Circuit diagrams
Wiring(fromthe '00 model)
Overview of repair groups
Printed in Germany -35, October 1999
REPGRU.CHP
www.WorkshopManuals.co.uk

8
911 Carrera (996) Contents
8Air
8
88
Air conditioning
Technicaldatafor the air-conditioningsystem 1
80
802319 80 -1
Heating
Removingandinstallingheatexchanger
85
851019
851519
851106
8530 19
85 78 19
85 10 19
85
85
85
85
85
85
Ventilation
Removing and installing mechanical heating / fresh air control. ..
Removing and installing heating / fresh air unit.Installing and adjusting bowden cables of the heating/fresh air control
Removing and installing heater/fresh-air blower motor.Removing and installing drive motor for fresh-air/recirculation valve.
Removing and installing bulb for rotary blower switch.
87
8703
8703 17
87
8783 19
87 55 19
8734 19
87 70 19
870119
87 50 19
87 27 19
8720 19
8720 19
87 59 19
8782 19
87 58 19
87 78 19
875319
8769 19
8702 19
87 34 19
87.
87-
87-
87.
87-
87-
87.
87-
87-
87-
87-
87.
87.
87-
87-
87.
87-
87.
87.
87-
Air conditioning
Safety regulations when handling refrigerant R 134aAssembly work on the air-conditioning system.Setpoints for pressures and temperatures.Removing and installing pressure switch for the air-conditioning system
Removing and installing fluid tank.Removing and installing the compressor.Removing and installing the expansion valve.Removing and installing the heatingjair-conditioning unit.Removing and installing the condenser.Removing and installing the magnetic coupling.Removing and installing drive motors of the heater/air-conditioning unit
Removing and installing drive motor for fresh-air/recirculation valve. .
Removing and installing outside temperature sensor.Removing and installing interior temperature sensor.Removing and installing footwell blower outlet sensor.Removing and installing blower driver.Removing and installing fan for condenser.Removing and installing ballast resistor for fan motor.Removing and installing the heatingjair-conditioning control.Removing and installing compressor -GT3
1
8 Air conditioning
Printed in Germany -25, 1999 996TOC
1
3
7,11
13
15
1
2
13
15
17
19
23
25
29
.31
33
35.37
39
41
.43
45
.47
.49
.51
www.WorkshopManuals.co.uk

911 Carrera (996) Air conditioning
8Technical data for the air-conditioning system
Compressor type 7 58 16
Refrigerantquantity 900 g refrigerant R 134a
195:t 15 cm3NO8
Refrigerantoil inthe compressor
Hexagon-head bolts on Thread Tightening torque in Nm (ftlb.)
Tightening torques:
Expansionvalve M6 9 (6.5ftlb.:
M5 6 (4.5 ftlb
Compressor M8 23 (17ftlb.
M8 23 (17ftlb.) Refrigerantline
M10 26...36(19...27ftlb.)
Oilfiller screw
Fluidtank M6 6 (4.5ftlb
M8 14(10.5ftlb.: Flangeconnections
ofthe refrigerantlines
Note
Wheninstallingthe refrigerantlines,the screwconnectionsandthe a-rings mustbe wetted
with refrigerantoil.
The refrigerant oil must be disposed of as special-category waste.
.8 -1
8 Technical data for the air-conditioning system
Printed in Germany -5, 1997 9968_1
www.WorkshopManuals.co.uk

Heating
Boxster
80 23 19 Removing and installing heat exchanger
Removal
1. Removethe covers overthe heating/air-con-
ditioningsystem, battery andfluidtank. Dis-
connectthe battery andcover the terminalor
battery.
6. Releaseheatexchangerandpullitupandout.
~)
~
l
/'I
t
2. Removethe entirewiper linkwith wiper motor
(seeRepairGroup92). ..0:::::;;
~;;." =_J {\
~ =I
3. Loosenrightdomestrutandbracketatthe
cowlframeandremove. 0-=I
~\~
;
\:"" \'\
""'
288 -96
I
\Installation
1. Sealcoveroverthe heatexchangerairtight
with butyladhesive.
-I , ~
~ \ 2. Replacecover ifdamaged.
3. The heatexchangeris connectedto the
enginecooling system,and coolantflows
through it whenthe engineis running.After re-
movingor installingthe heatexchanger,vent
the coolingsystem(seeRepairGroup19).
90.97
4. Clamp shutboth heater hosesin front of the
heatexchangerwith a commerciallyavailable
hoseclamp. Loosenheaterhoses at the heat
exchangerandpulloff.
5. Carefullyremovecover overthe heatex-
changer.
80 -1
80 23 19 Removing and installing heat exchanger
Printed in Germany, 1996 986801
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
85 10 19 Removingand installing mechanical heating and fresh-air control
Removal
1. Carefullyunclipbafflefromtheheatingand
fresh-aircontrol.
Installation
1. Clipin Bowdencablesandroute carefully
(do notbend).
2. Unscrewfastening screws(4 ea.)andpullcon-
trol moduleout ofthe dashboard. 2. Engageelectricalplug connections:do not
jam cables.
3. Pulloff electrical plug connections.
UnclipBowdencablesandpull outupwardsor
detachcables. LabelBowdencablesbefore
removal.
289 -98
85 10 19 Removing and installing mechanical heating and fresh-air control
Printed in Germany, 1997 996851
85 -1
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
85 15 19 Removingand installing heating and fresh-air control
Removal
1. Removethe covers overthe heating/fresh-air
system,batteryandfluidtank. Disconnectand
removethe battery.
4. Looseninstrumentpanelanduncliprightside
upwards.Disconnectthe electricalplug corr
nections.
2. Removesteeringwheelandloosensteering-
columnpanel.Complywith safetyregulations
whenhandlingairbag units(seeRepairGroup
69).
3. Undothe central screw (clamp)onthe stee-
ring columnswitchfrom belowandpull it
forwardsslightly. Removethe cover atthe top
and disconnectthe electricalplug connecti-
ons. Removethe steeringcolumnswitch.
92.97
5. Removesteering-columncover (4screws).
107 -96
46.97
85 15 19 Removing and installing heating and fresh-air control
Printed in Germany, 1997 996851
85 -3
www.WorkshopManuals.co.uk