Porsche 911 CARRERA - 2001 User manual

TechnicalManual
.9 ..1'..1'~"7~"I:::z: (996 )
TechnicalInformation
Contents:
Group1
Engine
Part 1 (up to Repair Group 13)
WKD483 721
TITEL.CHP
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911 Carrera (996) Foreword
Foreword
ThismanualcontainsTechnicalInformationaswell asinstructions
on repairsfor Porschevehicles.Itis intendedfor the soleuseof
workshopsbelongingto PorscheAG.
Thedescriptionsform the basisfor professionalandcorrect mainte-
nanceandrepairwork.Thecontentofthework procedures
describedis basedonthe levelof trainingof a fitter whohascom-
pletedvocationaltrainingand hasa soundknowledgeofthe prod-
uct. Thislevelof knowledgeis necessaryin orderto carry outthe
work described.
Warning notes
Thewarningnotesand safetyinstructionsareclassifiedbythe
respectivesignaIisingword (DangerI Warning,Caution)besidethe
warningsymbol.
To preventinjuryandrestrictedoperatingandtraffic safetyofthe
vehicle,or damageto thevehicleasthe resultof incorrectwork,
readtheseinstructionscarefullyandobservethem withoutfail.
Itis notpossiblefor PorscheAGto givea detailedevaluationofall
dangersituationsfor the personscarryingoutthe work. It is there-
fore imperativethatallpersonscarryingoutrepairandmaintenance
work on Porschevehiclesusetheir specialistknowledgeto ensure
thattheir ownsafetyis notatrisk andthe procedurechosenwill not
haveanynegativeeffectsonthevehicle-especiallywithregardto
safety.
Itis therefore expresslyspecifiedthatallwork involvedinthe work
proceduresdescribedshouldbecarriedoutonlyinaccordancewith
thevalidguidelinesandregulationsofthelocal authoritiesresponsi-
blewith respectto healthandaccidentpreventionandenvironmen-
-1 page 1
Foreword
Printed in Germany -44, 2001 vorwort
Warns against death or very serious injury which will cer-
tainly occur if the instructions are not observed.
Warns against death or very serious injury which may occur
if the instructions are not observed.
Warns against minor injury or damage to property if the
instructions are not observed.
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911 Carrera(996)
Foreword
tal protection, andincompliancewiththe legalrequirementsof
individualcountries.
Notes
Notescontainadvisoryinformationrelatedto theworkprocedure
whichmakesthefitter's work easier.Thefollowingpictogramindi-
catesthis information:
[IJ Note!
Containsadvisoryinformationwhichmakestheworkprocedureeas-
ier.
Dueto the continuousdevelopmentand improvementofour vehi-
cles,there maybe discrepanciesbetweenthe actualtechnicalsta-
tus ofthe vehiclesandthe work descriptions.Anyexisting
deviationsare correctedby meansof supplements,andthe scope
ofthe descriptionsis extendedwith supplements.
PorscheAGretainsthe rightto implementchangesat anytimeand
withoutprior notice.
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911 Carrera(996) Foreword
Table of Contents
1Foreword
Foreword
Foreword
Use . -1 page
-2 page
t
-
Table of Contents
Printedin Germany-44, 2001 masterVlt2
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911 Carrera (996) Foreword
Overview
Supple-
ment Edition Topic Article number
Basicedition
0
44 WKD483721
05/1997
OS/2000
11/2000 iForeword WKD483721.44
Supplement Overview
Printed in Germany -44, 2001 masterVlt2
www.WorkshopManuals.co.uk

911 Carrera (996) Foreword
Use
Theworkshopdocumentationfor the911 Carrera(996) modelhas
the designation
-"911 Carrera (996)" Technical Manual- and contains Techni-
callnformation aswell asinstructionsonrepairs.
Theintegrationofthetechnicalinformationpublishedinthe"911
Carrera(996)"TechnicalManualwiththeinstructionson repairspro-
videsthe userwith a complexreferencework thatcombinesinto
onebook associatedor cross-referencedmaterialof relevanceto
workshopsandoriginatingfrom variousinformationmedia.
The"911 Carrera(996)"TechnicalManualconsists of 15 folders,
subdividedintothe followingGroups
.0 Entirevehicle-General
.0 Diagnosis,1 Engine,part 1 (upto RepairGroup45)
.0 Diagnosis,1 Engine,part2 (upto RepairGroup69)
.1 Engine,part1 (upto RepairGroup13)
.1 Engine,part 2 (asof RepairGroup15)
.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,part1 (upto andincluding'99 model)
.9 Circuitdiagrams,part2 (asofandincluding'00 model)
Thetwo folders withGroup0 areto be regardedas onefolder;i.e.
file the "Technicallnformation"noticesonlyinthe folder "Group0
Diagnosis,part 1"-up to Repair Group 45-.
Thesecondfolder Group0 Diagnosis,part 2 -as of Repair Group
69- includesthefurther RepairGroupsbelongingto GroupO.
Thetwo folderswith Group1 areto beregardedas onefolder; i.e.
filethe "Technicallnformation"onlyinfront ofthe repairdescriptions
inthe folder Group1 -Engine, part1 -up to Repair Group 13-.
Thesecondfolder Group1 Diagnosis,part 2 -as of Repair Group
15- includesthefurther RepairGroupsbelongingto GroupO.
-2 page 1
Use
Printedin Germany-44, 2001 handhabung
www.WorkshopManuals.co.uk

911 Carrera (996)
Foreword
Thetwo folders withGroup9 areto be regardedas one folder;i.e.
filethe liTechnicallnformation"noticesonlyinthefolder Group9 Cir-
cuit diagrams,part1 -up to '99 model-.
Thesecondfolder Group9 Circuitdiagrams,part2 -as of '00
model- includesthe further RepairGroupsbelongingto Group9
The"Boxster(986)"TechnicalManualhasthe samestructurein
eachfolderIwiththe followingbreakdownfor allGroups:
Title page: "Boxster (986)" Technical Manual
> Foreword
Title page: "Technical information"
> Tableof contents,Technicalinformation>Technicalinformation
Title page: "Repair"
> RepairGroups:overview>Tableof contents,repairs>Genera!/
technicaldata> Instructionson repairs
Ascanbeseenfrom the breakdown,the publishedTechnicallnfor-
mationis inthe front part of eachfolder-numbered accordingto
the Groups.TheTableofContentsassignedto eachGroupwillbe
periodicallyupdated.
Followingthe TechnicalInformation,separatedbyatitlepage,the
instructionson repairs-assigned accordingto the Groupsor bro-
kendownintoRepairGroups-are includedinthefolders.
Theinstructionson repairswillbeextendedandupdatedbymeans
ofsupplements.
rn Note!
Sheetsthat alreadyexistinthe"911 Carrera(996)"TechnicalMan-
ualandare updatedor revisedand therebyexchangedbya supple-
mentaredesignatedin thefooter withthesupplementnumber
correspondingto thecurrentversion:e.g. "Printedin Germany-2,-
2000"
rn Note!
Dueto a systemmodificationintheTechnicalLiteratureproduction,
the followingprocedureshavechangedinmodelyear2000!
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911 Carrera(996) Foreword
1 -The previous record sheet in the folder "O-General" and
the supplement contents sheet -red sheet- have been
omitted. A supplement overview now appears sepa-
rately in each folder. The new supplement contents
sheet can be destroyed after the supplement is filed in
the folder.
[IJ Note!
Thesupplementoverviewsheetis replacedwiththerelevant
supplementinthecorrespondingfolderandmustnolongerbe
maintainedby hand.
2 -The page numbering in the new and the replaced chap-
ters are no longer continuous. Each new chapter is now
given an additional chapter number followed by the
page number e.g.-2 Page 11 ~ Rep. Gr. 0; General
3 -The old page numbering still applies to existing chap-
ters and those that are not replaced.
-2 page 3
Use
Printed in Germany -44,2001 handhabung
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911 Carrera (996) Overview of repair groups
Group 0: Entire vehicle -General
Salescheck
Maintenance
0
01
03
Group 0: Diagnosis
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
0
03
24
37
45
Group 0: 0
61
69
69
72
80
90
91
91
94
Diagnosis
Convertible-topdiagnosis
Airbagdiagnosis
Rol~overprotectionsystemdiagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarmsystem diagnosis
PCMdiagnosis
ParkAssistentdiagnosis
HBAdiagnosis
Group 1: 1
10
13
Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons
Group 1: 1
15
17
19
Engine
Engine-Cylinder head,valvedrive
Engine-Lubrication
Engine-Cooling
Group 2: 2
20
21
24
25
26
27
28
Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem,turbocharging
Fuelsystem,electronicinjection
Fuelsystem,K-Jetronic
Exhaustsystem
Starter,power supply,cruisecontrol
Ignitionsystem
Group 3: 3
30
34
35
39
Transmission, manual transmission
Clutch,control
Manualtransmission-Actuation, housing
Manualtransmission-Gears, shafts,intogearsh
Finaldrive, differential,differentiallock
Group 3: 3
32
37
38
39
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
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Overview of repair groups 911 Carrera (996)
Group 4: 4
40
42
44
45
46
47
48
Running gear
Frontwheel suspension,drive shafts
Rearwheel suspension,drive shafts
Wheels,tires, suspensionalignment
Anti-LockBrakeSystem(ABS)
Brakes-Brake mechanics
Brakes-Hydraulics, regulator, booster
Steering
Group5: 5
50
51
53
55
57
Body
Body front
Body center, roof, frame
Body rear
Lids, flaps
Door front, central locking system
Group 6: 6
60
61
63
64
66
68
69
Body equipment, exterior
Slidingroof
Convertibletop, hardtop
Bumpers
Glazing,windowcontrol
Exteriorequipment
Interiorequipment
Passengerprotection
Group 7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
7
70
72
74
Group 8: 8
80
85
87
88
Air conditioning
Heating
Ventilation
Air conditioning
Auxiliary air conditioning system
Group 9 9
90
91
92
94
96
Electrics
Instruments, alarm system
Radio, telephone, on-board computer, navigation
Windshield wiper and washer system
Lights, lamps, switches exterior
Lights, lamps, switches interior, theft protection
Group 9: 9
97
Circuit diagrams
Wiring(upto andincludingthe '99 model)
9
97
Group 9: Circuit diagrams
Wiring(fromthe'00 model)
8
Overview of repair groups
Printed in Germany. 35, October 1999
REPGRU.CHP
www.WorkshopManuals.co.uk

911 Carrera (996) Table of Contents
1Engine, pari 1 (up to Repair Group 13)
1Engine
Tighteningtorquesfor engineM96/01
3.4Iengineperformancekit/ X51.. 1
11
7
10
100119
100137
101037
100119
100137
101037
102021
10- 1
10- 9
10-51
10 -57
10-69
10 -201
10-225
Engine -Crankcase, suspension
Removing and installing engine (vehicle with Tiptronic transmission)
Disassembling and assembling engine.Disassembling and assembling crankcase halves.Removing and installing engine -GT3Disassembling and assembling engine -GT3Disassembling and assembling crankcase -GT3Removingcylinder-GT3
13
137819
137720
138219
137319
137337
134937
137419
135919
131019
137819
137337
134837
131019
132023
1326 23
13- 1
13- 5
13- 7
13- 9
13-19
13-23
13-33
13 -39
13-41
13-69
13 -79
13-201
13-209
13-213
13 -220
Engine -Crankshaft, pistons
Removing and installing drive belt.Removing and installing deflection rollers for drive belt.Removing and installing tensioning roller for drive belt.Removing and installing belt tensionerDisassembling and assembling belt tensioner. ,
Disassembling and assembling bearing housing with crankshaft. .
Removing and installing crankshaft sealing ring.Removing and installing crankshaft sealing ring -Engine installed
Removing and installing pistons.Removing and installing drive belt -GT3Disassembling and assembling belt tensioner -GT3Disassembling and assembling crankshaft -GT3Removing and installing pistons -GT3Installing pistons -GT3 '.""""""""."
Installing piston pin with piston-pin circlip -GT3 ""..'"
1 Engine, part 1 (up to Repair Group 13)
Printed in Germany -39, 2000 1
996TOC
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911 Carrera (996) Engine
1Tightening torques for engine M96/01
Crankshaft, bearing housing, crankcase
Screws, bearing housing
Initial tightening:
Final tightening:
M9 x 129 25 (19)
1 x 900 turn
Connecting-rod screws
Initial tightening:
Final tightening:
M9 x 1.25 20 (15)
1 x 900turn
Oilguideon
bearinghousing M6 (micro-encaps.) 10 (7.5)
Screwsforjoining
crankcasehalves M6 13(10.0)
M9 x 160
M9 x 95 22 (16) 22 (16)
Additionalbolts,
crankcase/bearing housing
Oilsuctionpipeto
crankcase M6 10 (7.5)
Air/oil separatorto
crankcase 10 (7.5)M6
Oilpanto
crankcase 10 (7.5)
M6
Oildrain plug
to oil pan MIa x 1.5 50 (37)
S80 x 3 25:t 1 (19:t 1)
Oilfilter to crankcase
Coolantguidehousing
to crankcase 45 (33)MID
MID x 1 10 + 5 (7.5 + 3.5)
Coolantdrainplug
Screwplugfor oil
reliefvalve M20x 1.5 25(19)
1 -1
1 Tightening torques for engine M96jOl
Printed in Germany -23, 1999 9961_1
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Intermediateshaftflange
to crankcase M6(micro-encaps. 10(7.5)
Lock nuton intermediate
shaftflange M8 xl 13 (10.0) or 11 (8.0) if
special tool 9110 is used
Screw plug for piston pin
assembly bore on cylinder
bank 4 -6 M27x 2 80 (59)
Engine carrier to engine MID 46 (34)
Boltfor guiderail M6 10 (7.5)
Pulleyto
crankshaft
Initialtightening:
Finaltightening:
M16 x 15 50 (37)
1 x 900turn
Double-massflywheelto
crankshaft
Initialtightening:
Finaltightening:
MI0 x 1 x 50 (12.9) 25 (19)
1 x 900turn
Thrustplateto double-mass
flywheel M8 23 (17)
Drive plate on crankshaft
(Tiptronic)
Initial tightening:
Final tightening:
MIa x 1 x 25 (12.9) 25 (19)
1 x 900 turn
Waterpumpto
crankcase M6 10(7.5)
Chain tensioner to
crankcase M27 x 2 80 (59)
Belttensionerroller on
leverfor tensioningelement MID 60 (44)
1 -2 1Tightening torques for engine M96jOl
Printed in Germany -23, 1999
9961_1
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911 Carrera (996) Engine
Location Thread Tightening torque
Nm (ftlb.)
Beltdeflectionroller 1
to crankcase MIa x 145 (10.9)
MIa x 145 (8.8) 65 (48)
46 (34)
Belt deflection roller 2
to bracket for hydraulic pump M8x 55 23 (17)
M16x 1.5Belt pulleyto generator 65:t 5 (48:t 3.5)
Beltpulleyto hydraulicpump M8 x 12 23 (17)
.8
1 -3
1 Tightening torques for engine M96jOl
Printed in Germany -13, 1998 9961_1
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Engine 911 Carrera (996)
Cylinder head
Cylinderheadto crankcase
Initial tightening or
tightening to flatten
1st step
2nd step:
MIOx 230
30 (22)
Cylinderheadscrewscompletelyundone
Final tightening
1st step
2nd step
3rd step
20 (
600
600
Flat-base tappet housing
to cylinder head 10 (7.5)M6
Camshaftbearingsaddles
to cylinderhead M6 10 (7.5)
Cylinder-headcover
to cylinderhead M6 13(10.0)
30 (22) + 3 (2.0) first fitting
25 (19)+ 5 (3.5) re-fitting
Sparkplugs M14x 1.25
Camshaft drive pinion and
drive plate to camshaft M6 x 15(10.9) 14(10.5)
M27x 2 80 (59)
Chaintensionerto cylinderhead
Intakepipeto cylinderhead M6(micro-encaps.) 9.7 (7.0)
Plug,oil-pressureduct
to cylinderhead MIDx 1 10 (7.5)
Oil return pump
to cylinder head 10 (7.5)
M6
Tightening torques for engine M96jOl
Printed in Germany -13, 1998
1
1 -4 9961_1
15)
turn
turn
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Accessories
sensors, sending units, switches and ancillaries
Oil~evelsenderto
crankcase M14 x .25 max. 20 (15)
Oxygensensorto
catalyticconverter MI8 55:t 5 (41:t 3.5)
Knocksensor M8 20:f: 2 (15 :f: 1.5)
Hallsender M6 (micro-encaps, 10:1:0.5(7.5:1:0.5)
Speedsender M6(micro-encaps 10:t 0.5 (7.5:t 0.5)
NTC I
coolahttemperature M14x 1.5 25 :t 5 (19:t 3.5)
Oil-pressureswitch M14x 1.5 25:t 5 (19:t 3.5)
Starter MID 45 (33)
MID
Generator 45 (33)
Igniti~ncoil to cylinder
head'cover M6 10 (7.5)
Power steering pump (hydraulic
pump) to bracket M8 23 (17)
Pressurepipe to power
steeringpump M16 24 (18)
M8 23 (17)
Oilreservoirto
power steeringpump
Checkvalvefor
auxiliaryair pump M22x 1.5 32 (24)
Coolantpumpto
crankcase M6 10 (7.5)
1 Tightening torques for engine M96jOl
Printed in Germany -23, 1999 1 -5
9961_1
www.WorkshopManuals.co.uk

911 Carrera (996) Engine
13.4 engine performance kit / X51 (not for USAvehicles)
Foreword
Thef~"OWingchapterdescribesa performancekitfor the911 Carrera(996). Acharacteristicofthe new
engin is its continuouspower development,particularlyathigherenginespeedsabove5,000 rpm. The
only hangesare modificationsto the engine.
Technical data
Engine 911 Carrera (996) X51
M96/01 M96/01 S
Engin~type
Numb~rof cylinders 66
Bore 96 96mm
78
Strok~ 78mm
cm3 3,387
Displ~cement 3,387
11.3 11.3 1Compressionratio
Max. ~ngine power kW(HP) 221 (300) 235 (320)
6,800 6,600
at en&inespeed rpm
Nm(ftlb.) 350 (259) 360 (266)Max.1orque
at en~inespeed 4,600 5,000
rpm
kW(HP;1) 63.8 (86.8) 66.4 (94.5)
Max.Ilitreoutput
Engin
tspeedlimitationby
fuel c toft at 7,300 7,400
rpm
700 800
Idlesweed rpm
280 287
Top speed km/h
1 -7
1 3.4 I engine performance kit / X51 (not for USAvehicles)
Printed in Germany -29, 1999 9961_7
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911 Carrera (996)
Engine
Differences
22_99
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911 Carrera (996) Engine
Differences
Item 1 Pistons
Item 2 Inlet camshafts and exhaust camshafts
Item ~ Valve discs, valve springs, valve guides, valve seats
Item 4 Valves, valve caps
Item 5 Dual-chamber suction pump at cylinder bank 4 -6
Item 6 Oil suction pipe
1 3.4 I engine performance kit / X51
Printed in Germany -21, 1999
1 -9
9961_7
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Engine 911 Carrera (996)
Differences
12
I~l
10
97
8
608_98
8
13.4 I engine performance kit / X51
Printed in Germany -21, 1999
1-10 9961_7
www.WorkshopManuals.co.uk