Porsche 911 CARRERA 4 - User manual

TechnicalManual
9ff Ca; :7~-a: (996)
TechnicalInformation
Contents:
WKD483 721
www.WorkshopManuals.co.uk

Foreword
Theworkshopdocumentationfor the 911 Carrera(996)modelhasthe designation
"911 Carrera (996)" Technical Manual
andcontainsTechnical Information aswell as instructionson Repairs.
The integrationof the technicalinformationpublishedin the"911 Carrera (996)"Tec~nicalManualwith
the instructionson repairsprovidesthe userwitha complexreferencework thatconPbinesinto onebook
associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrpmvarious 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 mod I) .5
9 Circuitdiagrams,part 2 (as of the '00 model).6
*1 Thetwo folderswith Group0 are to be regardedas one folder; i.e. file the "Tfchnicallnformation'
notices onlyin front of the repairdescriptionsin the folder "Group0 -Diagno~is, part 1"
(up to Repair Group 45). I
..2 Thesecond folder "Group0 -Diagnosis, part 2" (as of Repair Group 61) ircludesthe further
RepairGroupsbelongingto GroupO.
*3 ThetwofolderswithGroup1 areto beregardedasonefolder;i.e.filethe"Tfchnicallnformation"
noticesonlyinfrontoftherepairdescriptionsinthefolder"Group1 -Engine,lpart1"
(up to Repair Group 13). I
*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) incl~desthe further Repair
Groupsbelongingto Group1. I
VORW.CHP
Foreword
Printed in Germany -35, October 1999
www.WorkshopManuals.co.uk

.5 Thetwo folderswith Group9 are to be regardedas one folder;i.e. file the "Technifallnformation"
notices onlyin front of the repairdescriptionsin the folder "Group9 -Circuit diagr+ms,part I" (up to
and including the '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 samestructure in each folder,withthe following break-
downfor all Groups:
Title page: "911 Carrera (996)" Technical Manual
> Foreword
Title page: "Technical Information"
> Table of Contents,Technicalinformation
> Technicalinformation
TiUe page: "Repair"
> RepairGroups:overview
> Table of Contents,repairs
> General/technical data
> Instructionson repairs
Ascanbeseenfromthe breakdown,thepublishedTechnicalInformationis inthefrontpa~ ofeachfol-
der-numberedaccordingto theGroups.TheTableofContentsassignedto eachGroup~ill be peri-
odically updated. I
Followingthe TechnicalInformation,separatedby a title page,the instructionson repairsi assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedin thefolders. I
Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.
Note
Sheetsthat alreadyexistin the"911 Carrera(996)"TechnicalManualand are updatedor feVisedand therebyexchangedby a supplementare designated"replacementsheet".Revisionsor technical
modificationson pages of these replacementsheetsare identifiedfor the userwith a verti al bar at
themargin.
Foreword
Printed in Germany -35, October 1999
VORW.CHP
www.WorkshopManuals.co.uk

*5 Thetwo folderswith Group9 areto be regardedas one folder; i.e. file the "TechnicalInformation"
notices onlyin front of the repairdescriptionsin the folder "Group9 -Circuit diagrams,part 1" (up to
and includingthe '99 model).
.6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuitdiagramsbelongingto Group9.
The"911 Carrera(996)"TechnicalManualhasthe samestructure in each folder,with the followingbreak-
downfor all Groups:
Title page: "911 Carrera (996)" Technical Manual
> Foreword
Title page: "Technical Information"
> Tableof Contents,Technicalinformation
> Technicalinformation
Title 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 each fol-
der -numbered accordingto the Groups.TheTableof Contentsassignedto eachGroupwill be peri-
odicallyupdated.
Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedin the folders.
Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.
Note
Sheetsthat alreadyexist in the"911 Carrera (996)"TechnicalManualand are updatedor revised
and therebyexchangedbya supplementare designated"replacementsheet",Revisionsor technical
modificationson pages of these replacementsheetsare identifiedfor the userwith a vertical bar at
themargin.
www.WorkshopManuals.co.uk

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
Roll-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,powersupply,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
www.WorkshopManuals.co.uk

Overview of repair groups 911 Carrera (996)
Group 4: 4
40
42
44
45
46
47
48
Running gear
Front wheel suspension, drive shafts
Rear wheel suspension, drive shafts
Wheels, tires, suspension alignment
Anti-Lock Brake System (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
Door front, centrallockingsystem
Group 6: 6
60
61
63
64
66
68
69
Body equipment, exterior
Slidingroof
Convertibletop, hardtop
Bumpers
Glazing,windowcontrol
Exterior equipment
Interior equipment
Passengerprotection
Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
7
70
72
74
Group 7:
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 andincludingthe'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

911 Carrera (996) Table of Contents
4Running gear
4
4
4
4
4
4
4
4 -
4-
4-
4-
4-
4-
Running gear
Running gear -Overview: 911 Carrera (996)StabiliserallocationRemoving spring strut locking devices -Carrera and GT3
Running gear, general -GT3Notes on repair instructions -GT3Testsjnotes-GT3
40
40
40
40
40
40
40
40
40-
40-
40-
40-
40-
40-
40-
Front wheel suspension, drive shafts
Tightening torques for front axle.Removing and installing front spring strut.Removing and installing front spring strut -GT3 ...
Disassembling and assembling front spring strut. ..
Disassembling and assembling front spring strut -GT3
Removing and installing front wheel bearing.Installing caster eccentric.
42
42
427119
42
42
42 58 19
4209 19
425219
422119
422119
42- 1
42- 5
42- 7
42 -14a
42-15
42 -21
42-23
42-31
42 -37
Rear wheel suspension, drive shafts
Tightening torques for rear axle.Removing and installing rear spring strut.Disassembling and assembling rear spring strut.Disassembling and assembling rear spring strut -GT3Removing and installing rear wheel bearing.Removing and installing rear tie rod (toe control arm)Removing and installing rear wheel bearing housing (wheel carrier)
Removing and installing drive shaft (manual transmission)Removing and installing drive shaft (Tiptronic transmission)
44
44
44
44
44
44
44
44
Wheels, tires, suspension alignment
Wheels and tyres (tyre pressure/mounting wheel on vehicle)
Adjustment values for suspension alignment.Alignment cards for Carrera (996) and GT3Complete suspension alignment.Suspension alignment GT3General tyre mounting instructions.Checking rims ,
44-
44-
44-
44-
44-
44-
44-
1
4 Running gear
Printed in Germany -39, 2000 996TOC
1
5
7
9
11
13
85 19
85 19
5719
1923
1
5
6a
7
12a
13
19
1
3
6
9
16a
.17
.21
www.WorkshopManuals.co.uk

Table of Contents 911 Carrera (996)
44
44
44
Identifyingsizefor 18~nchTurbowheels(Technologiewheels)
Tyrefailure/lyre sealant-GT3Tyre mountingfor critical wheels/lyre pairs. 44 -23
44-25
44 -27
45
45
45
45
45
45
45
451119
451519
45
45
45
45
45
45
45
45
Anti-lock Brake System (ABS)
Important information on ABS 5.3 and ABS/TC 5.3 ..
ABS 5.3 system description.ABS/TC 5.3 system description.Component arrangement (ABS and ABS/TC).Function of individual components.ABS test with Porsche System Tester 2.Removing and installing front speed sensor.Removing and installing rear speed sensor.
46
46
46
46
46
46 36 20
46 38 20
461115
46
46 83 16
4650 19
4653 19
46 83 20
46 50 04
46 53 04
4605 19
..46 -1
..46 -3
..46 -4a
..46 -5
..46 -7
..46 -9
..46 -11
..46 -13
..46 -15
..46-17
..46 -19
..46 -21
..46 -23
..46 -25
..46 -29
Brakes -Brake mechanics
Tightening torques for brake mechanics. ...
Technical data (brake disc wear limit)Technical data (brake disc wear limit) -GT3 .
Measuring brake pad thickness.Removing and installing front disc brake pads.
Removing and installing rear disc brake pads.
Adjusting brake pushrodChecking brake~ight switch setting.Adjusting parking brake shoes.Removing and installing front brake disc. ..
Removing and installing rear brake disc. ...
Removing and installing parking brake shoes.
Measuring lateral run-out of front brake discs.
Measuring lateral run-out of rear brake discs.
Removing and installing brake pedal.
47
47
47
47
1
3
7
47
4701 07
4708 55
Brakes -Hydraulics, regulator, booster
Tighteningtorquesfor brakehydraulics. .
BleedingbrakesChangingbrakefluid.
4 Running gear
Printed in Germany -39, 2000
2996TOC
1
2
4
6
7
11
13
15
www.WorkshopManuals.co.uk

911 Carrera (996) Table of Contents
48.
48.
48-
48-
48-
48.
48-
48-
48-
48
48
48
48
48
48
48
48
48
48
Steering
Tightening torques for steering.Test and assembly work on power steering. .
Removing and installing steering wheel (airbag) .
Replacing steering system after accident damage
Removing and installing steering gear.Plug~n couplings for steering hydraulics. ...
Removing and installing lock barrel.Replacing steering lock.Removing and installing hydraulic pump. ...
.3
4 Running gear
Printed in Germany -39, 2000 996TOC
.1
.3 5
7
9.13
19
21
29
10
90
07
08
98
19
19
19
55
19
www.WorkshopManuals.co.uk

911 Carrera (996) Running gear
4Overview of 911 Carrera (996) running gear
Front axle / steering
McPhersonwheelsuspensionwith offset spring.Twin-tubegas-filledshock absorbersin standardor
sportsversion.
Inorder to obtaingreater stiffnesswith reducedintrinsicweight ascomparedwith steel,the following
componentshavebeenmadefrom aluminium:
Control arms,diagonalbrace,track rod, wheelcarrier andcross member/ side member.
Rack-and-pinionsteeringgear (i = 16.9 : 1) withhydraulicassistance.
Steering wheel longitudinally adjustable (40 mm).
Further improvement of steering precision and reduction in the turning circle (10.6 m) as com-
pared with the previous 911 Carrera (993).
\'...
~-~
386 -97
4 Overview of 911 Carrera (996) running gear
Printed in Germany, 1997 9964_1
4 -1
www.WorkshopManuals.co.uk