Porsche 911 CARRERA 4 - User manual

TechnicalManual
9.1'.1' ~7~ (996)
TechnicalInformation
Contents:
Group 3
Transmission,manualtransmission
WKD483 721

911 Carrera Transmission, manual transmission
Supplement Overview
Supple-
ment Edition Topic Article number
Basicedition
0
4
5
WKD483721
Generalsupplement WKD483721.04
05/1997
OS/2000
09/1997
12/1997
05/1998
06/1998
07/1998
08/1998
11/1998
02/1999
03/1999
04/1999
05/1999
06/1999
10/1999
11/2000
Generalsupplement WKD483721.05
9WKD483721.09
Generalsupplement
12
13 Generalsupplement WKD483721.12
Generalsupplement WKD483721.13
14
18
22
WKD483721.14
Generalsupplement
Generalsupplement WKD483721.18
WKD483721.22
Generalsupplement
25 Generalsupplement WKD483721.25
WKD483721.26
26
28
29
35
44
Generalsupplement WKD483721.28
Generalsupplement
Generalsupplement WKD483721.29
WKD483721.35Generalsupplement
Generalsupplement WKD483721.44
Supplement Overview
Printed in Germany -44,2001 master3s

Foreword
911 Carrera(996)
Table of Contents
1Foreword
Foreword
Foreword
Use.. 1
1
-1 page
-2 page
Table of Contents
Printed in Germany -44, 2001 masterVlt2

911 Carrera (996) Foreword
Foreword
ThismanualcontainsTechnicallnformationaswellasinstructions
on repairsfor Porschevehicles.Itis intendedfor the soleuseof
workshopsbelongingto PorscheAG.
Thedescriptionsformthe basisfor professionalandcorrect mainte-
nanceandrepairwork.Thecontentofthework procedures
describedis basedonthe leveloftrainingofafitter whohascom-
pletedvocationaltrainingandhasa soundknowledgeofthe prod-
uct. Thislevelof knowledgeis necessaryinorder to carry outthe
workdescribed.
Warning notes
Thewarningnotesand safetyinstructionsareclassifiedbythe
respectivesignalisingword (Danger,Warning,Caution)besidethe
warningsymbol.
To preventinjuryandrestrictedoperatingandtraffic safetyofthe
vehicle,or damageto thevehicleasthe resultof incorrectwork,
readthese instructionscarefullyandobservethem withoutfail.
Itis notpossiblefor PorscheAGto givea detailedevaluationofall
dangersituationsfor the personscarryingoutthework. Itis there-
fore imperativethatall personscarryingoutrepairandmaintenance
work onPorschevehiclesusetheir specialistknowledgeto ensure
thattheir own safetyis not atrisk andtheprocedurechosenwill not
haveanynegativeeffects onthevehicle-especiallywithregardto
safety.
Itistherefore expresslyspecifiedthatallwork involvedinthework
proceduresdescribedshouldbecarriedoutonlyinaccordancewith
the validguidelinesandregulationsofthe localauthoritiesresponsi-
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.

911 Carrera (996)
Foreword
tal protection, andin compliancewiththe legalrequirementsof
individualcountries.
Notes
Notescontainadvisoryinformationrelatedto theworkprocedure
whichmakesthe fitter's work easier.Thefollowingpictogramindi-
catesthis information:
rn Note!
Containsadvisoryinformationwhichmakestheworkprocedureeas-
ier.
Dueto the continuousdevelopmentand improvementofour vehi-
cles,there maybediscrepanciesbetweenthe actualtechnicalsta-
tus ofthe vehiclesandthe work descriptions.Anyexisting
deviationsare correctedby meansof supplements,andthe scope
ofthe descriptionsis extendedwith supplements.
PorscheAGretainsthe rightto implementchangesat anytime and
withoutprior notice.

911 Carrera (996) Foreword
Use
Theworkshopdocumentationfor the 911 Carrera(996)modelhas
the designation
-"911 Carrera (996)" Technical Manual- andcontainsTechni-
callnformation aswell asinstructionsonrepairs.
Theintegrationofthetechnicalinformationpublishedinthe"911
Carrera(996)"TechnicalManualwiththeinstructionson repairspro-
videsthe userwith a complexreferencework thatcombinesinto
onebookassociatedor 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,part 2(upto RepairGroup69)
.1 Engine,part 1 (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,part 2 (asof andincluding'00 model)
Thetwofolders withGroupa areto beregardedas one folder; i.e,
filethe "Technicallnformation"noticesonlyinthe folder "Groupa
Diagnosis,part I" -up to Repair Group 45-.
Thesecondfolder Group0 Diagnosis,part 2 -as of Repair Group
69- includesthe further RepairGroupsbelongingto GroupO.
Thetwofolders withGroup1 areto beregardedasonefolder;i.e.
filethe "Technicallnformation"onlyinfront ofthe repairdescriptions
inthe folder Group1 -Engine, part1 -up to Repair Group 13-.
Thesecondfolder Group1 Diagnosis,part2 -as of Repair Group
15- includesthefurther RepairGroupsbelongingto GroupO.
-2 page 1
handhabung
Use
Printed in Germany -44,2001

9.11Carrera(996)
Foreword
Thetwo folderswith Group9 areto be regardedas onefolder;i.e.
file the liTechnicallnformation"noticesonlyinthefolder Group9 Cir-
cuit diagrams,part1 -up to '99 model-.
Thesecondfolder Group9 Circuitdiagrams,part2 -as of '00
model- includesthefurther RepairGroupsbelongingto Group9,
The"Boxster(986)"TechnicalManualhasthe samestructurein
eachfolder,withthefollowingbreakdownfor allGroups:
Title page: "Boxster (986)" Technical Manual
> Foreword
Title page: "Technical information"
>
Tableof contents,Technicalinformation>Technicalinformation
Title page: "Repair"
> RepairGroups:overview>Tableof contents,repairs>General
technicaldata> Instructionson repairs
Ascanbe seenfrom the breakdown,the publishedTechnicallnfor.
mationis inthe frontpart ofeachfolder-numbered accordingto
the Groups.TheTableof Contentsassignedto eachGroupwillbe
periodicallyupdated.
Followingthe TechnicalInformation,separatedbya title page,the
instructionsonrepairs-assigned accordingto the Groupsor bro-
kendowninto RepairGroups-are includedinthefolders.
Theinstructionson repairswill beextendedandupdatedbymeans
ofsupplements.
rn Note!
Sheetsthat alreadyexistin the"911 Carrera(996)"TechnicalMan-
ualandare updatedor revisedandtherebyexchangedbya supple-
mentare designatedin thefooter withthe supplementnumber
correspondingto thecurrentversion:e.g. "Printedin Germany-2,-
2000"
rn Note!
Dueto a systemmodificationinthe TechnicalLiteratureproduction,
thefollowingprocedureshavechangedinmodelyear2000!

Foreword
911 Carrera(996)
1 -The previous record sheet in the folder "O-Genera!" 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.
rn Note!
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
handhabung
Use
Printedin Germany-44. 2001
Thesupplementoverviewsheetis replacedwiththerelevant
supplementinthecorrespondingfolderandmustnolongerbe
maintainedby hand.

911 Carrera (996) Overview of repair groups
Group 0: Entire vehicle -General
Salescheck
Maintenance
0
01
03
Group 0: 0
03
24
37
45
Diagnosis
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
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
3
30
34
35
39
Group 3: Transmission, manual transmission
Clutch,control
Manualtransmission-Actuation, housing
Manualtransmission-Gears, shafts,intogearsh.
Finaldrive, differential,differentiallock
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

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,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
Door front, centrallockingsystem
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
8
80
85
87
88
Group 8: Air conditioning
Heating
Ventilation
Air conditioning
Auxiliary air conditioning system
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

911 Carrera Transmission,manualtransmission
Table of Contents
3Transmission, manual transmission
3
1
1
3
4
4
3-1 page
3-1 page
3-1 page
3-1 page
3-1 page
Transmission
Technical data ,
6-speed manual transmission G96/30 ...,
-Manual transmission tightening torques
FrontwheeldriveZ96.00 ,
-Front-axle drive tightening torques. ...,
30
305019
305037
300107
303019
300519
30
304519
30-1
30-3
30-5
30-7
30-9
30-17
30-21
Clutch, control
Removing and installing clutchDisassembling and assembling clutch.Bleeding the clutch systemRemoving and installing clutch slave cylinder..Removing and installing the clutch pedalClutch boost springs: Allocation and grease specification.
Removing and installing release bearing -GT3
34
340155
343519
340819
341219
344919
34-1
34-3
34-7
34-11
34-19
Manual transmission -Actuation, ass. housing
Changing transmission oilRemoving and installing transmission G 96Removing and installing shift consoleRemoving and installing shift and selector cables.Removing and installing closure cap for selector force mechanism.
Manual transmission -Gears, shafts, into gearsh.
Removingandinstallingsealingringfor inputshaft.
35
355019 35-1
39
392019
392219 39-1
39-3
39-7
Final drive -Differential, differential lock
Removingandinstallingcoverfor finaldrive ,
Removingandinstallingsealingringfor halfshaftflangeof limited-slip
differential. ,
Removingandinstallingsealingringfor halfshaftflange of differential
master3s
Table of Contents
Printed in Germany -44, 2001

Transmission
911 Carrera
Technical data
6-speed manual transmission G96/30
Model year
Installed in
Code
letter Equipment
lype
1999
911 Carrera4 (996)
6-speed
G96/30
3-1 page1
c3xxxxxl
Technical data
Printedin Germany-44,2001

3Transmission 911 Carrera
Structure of the transmission number
Manual transmission

3Transmission
911 Carrera
Manualtransmission tightening torques
Screw plug, oil drainage and oil filling M22
Drive shaft on the transmission flange M1 0
Clutch slave cylinder on transmission M8
Guide tube for release bearing on trans- M8
miSSion
Ball journal for release lever on tranmis- M8 25
sion
Cover for final drive on transmission hous- M8 25
ing
Transmission on engine M 12 / M1 0 85 / 45
Reversing light switch on transmission M12 15
Holder for shift cables on transmission M1 0 45
Cardan flange on transmission M20 120a)
Drive shaft on transmission flange M1 0 45
a) Counter collar nut with 170 Nm (126 ftlb), loosen again and tighten to 120 Nm (89 Nm) ='>Rep. Gr. 3982 19; Install and remove sealing
ring for cardan flange.
3081
23
24
3-1 page3
c3xxxxxl
Technical data
Printed in Germany -44.2001

3911 Carrera
Transmission
Front wheel drive Z 96.00
Front-axle final drive Z 96.00
General data 31 : 9 = 3,44
ITransmissionratio, finaldrive (Z2: ZI = i)
Bevelgeardrivewithouthypoidoffset
Finaldrive
Fillingcapacity approx.l.51
Front-axledrive tightening torques
28
25
25
39
65
65
Screwplug, oil drainageandoil filling
Coveronfinaldrive
Long-necktube onfinal drive
Driveshaftonfinaldrive
Reartransmissionsupportto transmissionmount
Reartransmissionsupporton body

911 Carrera Transmission
65
20
65
39
100
M8
MIa
M8
MI2
23
7
M8 x 40
M6
Fronttransmissionsupportonfront-axlecross
member
Studsonfront-axlecrossmember
Frontcross memberto finaldrive
Driveshaftsonfront-axlefinaldrive
Diagonalbracesonbodyandfront-axlecross
member
Tankstrapon body
Pipeholderontransmissionsupport
3-1 page5
c3xxxxxl
Technical data
Printedin Germany-44,2001

911 Carrera (996) Transmission
3Technical data (manual transmission G96/00J
Key to transmission numbers
127_97
G9600
T1
T001014
Serial number
Transmission type Index for version
within transmission number
1 = normaldifferential
2 = limited-slipdifferential
3-3
3 Technical data (manual transmission G96jOO)
Printed in Germany -18, 1998 9963_1

911 Carrera (996) Transmission
Technical data (manual transmission G96/00J
Manual transmission G96jOO
.3 Technical data (manual transmission G96jOO)
Printed in Germany -18, 1998 9963_1
3-5

911 Carrera (996) Transmission
Technical data (manual transmission G96/00J
Tightening torques (transmission G96jOO)
Location Thread Tightening torque
Nm (ftlb.)
Screwplug, oil drainage
andoil filling M22 30 (22)
Drive shafton transmission
flange MID 81 (60)
Clutchslavecylinderon
transmission M8 23 (17)
Guidetube for release
bearingon transmission M8 24 (18)
Balljournalfor releaselever
ontransmission M8 25 (19)
Coverforfinaldrive
ontransmission M8 25 (19)
Halfshaftflangeon limited-
slipdifferential MID 44 (33)
Transmission
onengine MI2
MID 85 (63)
45 (33)
Reversinglightswitch
ontransmission M12 15 (11)
Bracketfor shiftcableson
transmission MID 45 (33)
3 Technical data (manual transmission G96jOO)
Printed in Germany -18, 1998 9963_1
3-7

911 Carrera (996) Clutch, actuation
30 50 19 Removing and installing clutch
Tools
165_98
Item Special tool
9102 Explanation
A
B
B1
Designation
Centringmandrel
Toothedsegment 9538/1
Fasteningscrewfor
toothed segment Hexagon-headbolt
M12 x 50
30 50 19 Removing and installing clutch
Printed in Germany -13, 1998
30-1
996301