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
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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.
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~
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/'I
t
2. Removethe entirewiper linkwith wiper motor
(seeRepairGroup92). ..0:::::;;
~;;." =_J {\
~ =I
3. Loosenrightdomestrutandbracketatthe
cowlframeandremove. 0-=I
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;
\:"" \'\
""'
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

6. Removeradio and heatingandfresh-aircon-
trol. Unclipthe switchpanelonthe left andon
the right. pisconnectthe electricalplugcon-
nections.Undothe retainingframe inthe
centerandremoveit.
11. Loosendashboardon the bottom, centre,
leftandright. Carefullyremovethe
dashboardanddetachthe loudspeakercable.
111-96
12. Loosencentretunnelsupport at the top of
supportingframe andloosenbottom tunnel
holder.
43- 97
7. Removeleft side nozzleand disconnect
electricalplugconnection.Unclipcover of sun
sensoran~defroster panelandremove.
8. Undotheinteriormonitoringsystemand
disconnecttheelectricalplugconnection.
D
~\a 0
f
9. Removethe air guide atthe bottomright.
Removethe passenger'sairbagunit.
Complywith safetyregulationswhenhandling
airbagunits(seeRepairGroup69). 10
CD
10. Removethe front cover of the center con-
sole. Undothe fuse holderand diagnosis
plug int~e left footwell. 1.1
112 -96
Removing and installing heating and fresh-air control
996851 Printed in Germany, 1997
85 15 19
85 -4
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
13. Removethe left airguide. Onlyloosenthe
defrost channel.Undoand removethe center
air distributorcasing.
18. Loosenholderof heatingandfresh-aircon-
trol on the upper right ofthe passengerside.
14. Disconnectelectricalplugconnectionfrom
heatingandfresh-aircontrol.
15. LQosenbattery positiveconnectionatthe
currentdistributor and currentdistributor at
the firewallcover. if--==-~
-
r
1/
/
114-96
d
...f 19. Carefullylowerheatingandfresh-aircontrol
intothe footwellandremove. Do notdamage
the electricalplug connectionsor cables.
"\~
~
113.96 Installation
1. Ensurethatthe air distributorcasingandair
guidesare correctlypositioned.Engagethe
electricalplugconnectionsand carefullylay
the electricalcables(do notpinch).
16. Clampshutbothheaterhosesin front of the
h~at exchanger with a commercially available
h se clamp. Disconnect the heating hoses
0 the heatexchangerandplugthe connec-
tions. 2. Complywith safetyregulationswhenhandling
airbag units(seeRepairGroup69).
17. Loosenheatingandfresh-aircontrol atthe
coverfirewall(3 nuts).
85 15 19 Removing and installing heating and fresh-air control
Printed in Germany, 1997 996851
85 -5
www.WorkshopManuals.co.uk

3. Setthe steeringcolumnswitch:
Measurewith a depth gaugebetweenend of
steering shaftand steering-columnswitch
cover plate (seefigure).
Adjustment dimension 55 :t 0.5 mm
0
~
---
55'
rt:
115.96
4. Replacegasketbetweencurrentdistributor
andfirewall if necessary.After the current
distributoris mountedon the firewall (tighten-
ingtorque 15 Nm(11 ftlb.))the batterycable
istightenedwith a new hexagonnutM8.
Tighteningtorque: 15 Nm(11 ftlb.)
5. The heatexchangeris connectedto the
enginecooling system,and coolantflows
through it whenthe engineis running.After
removingor installingthe heating/fresh-air
control,ventthe coolingsystem(seeRepair
Group19).
'0,5
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
85 IiI 06 Installing and adjusting bowden cables of the heating/fresh-air control
Note
Install,the heating/fresh-aircontrol with installed
bowdencables.Thesleevesofthe bowden
cablesare adjustedatthe fasteningpointson
the heating/fresh-airunit.
Adjusting temperature valve
1. Turntemperaturecontrolto left-handstop
(cold).Temperaturevalveclosed;no passage
to the heatexchanger.
lOt.
~
M
~
~B
0C '~::J
e
~~
00 534/1 .96
536 -96 2. Engagebowdencableinthe adjustinglever.
A-Bowden cable,temperaturevalve
B -Bowden cable,footwelVdefrostvalve
C-Bowden cable,centralvalve
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
Printed in Germany, 1997 996851
85 -7
www.WorkshopManuals.co.uk

Ventilation 911 Carrera (996)
3. Pushadjustinglever of the temperaturevalve
upto its stop and usethe retainingclip to
fastenthe sleeveofthe bowdencableonthe
fasteningpoint.
2. Engagebowdencableintheadjustinglever.
3. Pushadjustinglever of the footwell/defrost
valveupto its stop andusethe retainingclip
to fastenthe sleeveof the bowdencableto
the fasteningpoint.
~,
)
/
537 -96
538 -96
Adjustingfootwelljdefrost valve
1. Turn rotary knob for air distribution to the
symbolforthefootwell.Defrosteroutlet
closed;no passageto the windscreen.
Adjusting central valve
1. Turnrotary knobfor air distributionto the
symbolfor the footwell.Air outletto the
centreandside ventsclosed.
(SeeFigure534/2 -96).
2. Engagebowdencableinthe adjustinglever.
c ,~ ::J
534/2 -96
Installing and adjusting bowden cables of the heating/fresh-air control
996851 Printed in Germany, 1997
85 -8 85 11 06
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
3. Pushadjustinglever of the centralvalveup to
its stop and usethe retainingclip to fasten
the sleeveof the bowdencableonthe fasten-
ingpoint.
\
~-
\
539.96
Note
Performa function test after installingthe
bowdencables. Test limit positionof the rotary
knobsfor air distributionandadjustinglevers of
the valves.
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
Printed in Germany, 1997 996851
85 -9
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
85 30 19 Removing and installing heater/fresh-air blower motor
Remove and install heater/fresh-air blower
motor with installed heating/fresh-air unit.
Lr~
Removal
1. Removefootwell bulkheadand rightair guide.
Pulloff electrical plug connectionon the
blowermotor andremovewire from the
holder.
-~
0
0_0
~~
Thefigure showsthe heating/fresh-airunitwhen
removed.
531.96
~Note
Whenthe housinglid is removed,the blower
motor is simultaneouslydetachedfrom its
guide.Holdthe blowermotor and carefully
removeit in downwarddirection.
4( o@o
~/\o
d"
~
;t!{-§~
530 -96
2. Pulloffelectricalplugconnectiononthebal-
lastresistorandundobothfasteningscrews
onthehousinglid.
Theballastresistorandhousinglidare
a spare part.
532 -96
85 -11
8530 19 Removing and installing heater/fresh-air blower motor
Printed in Germany, 1997 996851
www.WorkshopManuals.co.uk

Ventilation 911 Carrera (996)
Installation
1.Installblowermotorandfastenhousinglid.
2. Tightenfasteningscrews carefully
(plastichpusing),
3. Engageelectrical plug connectionsand per-
form a functiontest.
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911 Carrera (996) Ventilation
85 78 19 Removingand installing drive motor for fresh-air/recirculation valve
Remove and install drive motor on installed
heating/fresh-air unit Note
Ifthe rotaryknobfor air distributionis setto
Defrost(windscreen)with the recirculation
buttonswitchedon, the recirculationbuttonis
automaticallyswitchedoff.
Removal
1. Th~recirculationbutton mustbe pressed
before removal(fresh-airsupplyblocked).The
drive motor of the installedheating/fresh-air
unitcan be removedin this position(recircula-
tion).
Installation
1. Theremovalor installationpositionofthe
drivemotor andfresh-air/recirculationvalve
cannotbe changed.
2. Removefootwell bulkheadand rightair guide.
Disconnectelectrical plug connectionof the
drive motor and undofasteningscrew. 2. Tightenfasteningscrew carefully
(plastichousing).
3. Engageelectricalplugconnectionandroute
wire carefully.
4. Performafunctiontestafterinstallation.
542.96
3. Swiveldownthe drive motor andremove it to
the side.
85 -13
85 78 19 Removing and installing drive motor for fresh-air/recirculation valve
Printed in Germany, 1997 996851
www.WorkshopManuals.co.uk

911 Carrera (996) Ventilation
85 10 19 Removing and installing bulb for rotary blower switch
Removal
1. Pulloff rotaryblowerswitch. Installation
1. Insertbulbwith connectinghose.Detach
connectinghose bytwisting it off the bulb.
2. Pullout bulb.Thebulbcanbe pulledout by
puslhinga connectinghose of a vacuumline
onto it (seediagram of hose connections,
RepairGroup24).
2. Checkfunctionof the bulb.
535 -96
85 -15
85 10 19 Removing and installing bulb for rotary blower switch
Printed in Germany, 1997 996851
www.WorkshopManuals.co.uk