Porsche 911 Carrera (996) User manual

TechnicalManual
9ff ~"7'~~ (996)
TechnicalInformation
Contents:
Group 1
Engine
Part 2 (as of Repair Group 15)
WKD483 721
TlTEL.CHP
www.WorkshopManuals.co.uk

911 Carrera (996) Engine, part 2 (as of Repair Group 15)
Supplement Overview
Supple-
ment Edition Topic Article number
Basicedition WKD483721
005/1997
OS/2000
12/1997
05/1998
05/1998
10/1998
01/1999
01/1999
02/1999
02/1999
03/1999
04/1999
05/1999
06/1999
07/1999
09/1999
09/1999
10/1999
12/1999
12/1999
OS/2000
11/2000
WKD483721.05
5
9Generalsupplement WKD483721.09
IGeneral supplement
Generalsupplement WKD483721.10 10
17
20 WKD483721.17
Generalsupplement WKD483721.20
Generalsupplement WKD483721.21
21 Generalsupplement WKD483721.22
22
23 Generalsupplement WKD483721.23
Generalsupplement WKD483721.25
25
26 Generalsupplement WKD483721.26
Generalsupplement WKD483721.28
28
29
31
32
33
35
37
38
Generalsupplement WKD483721.29
Generalsupplement WKD483721.31
Generalsupplement WKD483721.32
Generalsupplement WKD483721.33
Generalsupplement WKD483721.35
Generalsupplement WKD483721.37
IGeneral supplement WKD483721.38
Generalsupplement WKD483721.39
Generalsupplement
39 WKD483721.44
Generalsupplement
44
Supplement Overview
Printed in Germany -44, 2001 Masterlt2
www.WorkshopManuals.co.uk

911 Carrera (996) Foreword
Foreword
Theworkshopdocumentationfor the 911 Carrera(996)modelhasthe designation
"911 Carrera (996)" Technical Manual
and containsTechnical Information aswell as instructionson Repairs.
Theintegrationof the technicalinformationpublishedinthe"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 (asof the '00 model)*6
*1 Thetwo folderswith Group0 areto be regardedas one folder; i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group0 -Diagnosis, part 1"
(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 descriptionsin the folder "Group1 -Engine, part I"
(up to Repair Group 13).
*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 Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repairdescriptionsinthe folder "Group9 -Circuit diagrams,part 1" (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 same structure in each folder,with the following break-
downfor all Groups:
Title page: "911 Carrera (996)" Technical Manual
> Foreword
Title page: "Technical Information"
> Tableof Contents,Technicalinformation
> Technicalinformation
Title page: "Repair"
> RepairGroups:overview
> Tableof Contents,repairs
> General/technical data
> Instructionson repairs
As can be seenfrom the breakdown,the publishedTechnicalInformationis inthe front part of eachfol-
der -numbered accordingto the Groups.TheTable of 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 alreadyexistin the"911 Carrera(996)"TechnicalManualandare updatedor revised
and therebyexchangedbya supplementare designated"replacementsheet".Revisionsor technical
modificationson pages of these replacementsheetsare identifiedfor the userwith a vertical bar at
the margin.
Foreword
Printed in Germany -35, October 1999
VORW.CHP
www.WorkshopManuals.co.uk

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
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,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
www.WorkshopManuals.co.uk

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 7
70
72
74
Group7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
Group 8: 8
80
85
87
88
Air conditioning
Heating
Ventilation
Air conditioning
Auxiliaryair conditioningsystem
Group 9 9
90
91
92
94
96
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
Circuit diagrams
Wiring(fromthe'00 model)
Group 9:
Overview of repair groups
Printed in Germany -35, October 1999
REPGRU.CHP
www.WorkshopManuals.co.uk

911 Carrera (996) Engine, part 2 (as of Repair Group 15)
Table of Contents
1Engine, part 2 (as of Repair Group IS)
15
157037
156519
156319
157023
157037
150519
150522
150515
150515
155920
155922
155924
15-1
15-7
15-9
15-11
15-15
15-23
15-27
15-39
15-43
15-47
15-51
15-55
15-61
15-65
15-71
15-77
15-81
15-83
15-87
15-89
15-95
15-101
15-103
15-107
15-111
15-113
15-117
15-121
15-129
15-135
15-137
15-139
15-141
15-149
15-161
15-163
15-173
15-183
155924
150533
159151
155902
154619
154619
155920
155927
155924
150515
155922
155924
150515
151820
150502
152319
153719
157049
150319
150321
150323
157019
157021
157023
152037
Engine -Cylinder head, valve drive
Disassembling and assembling cylinder head -Inner parts.Removing and installing valve springsRemoving and installing valve stem sealInstalling cylinder headDisassembling and assembling cylinder head -Camshaft drive.Removing and installing camshafts ,
Installing camshafts ,
Adjusting timing -Cylinder bank 1- 3 ,
Adjusting timing-Cylinder bank 4-6Removing and installing valve tappets -Engine removedRemoving valve tappets of cylinder bank 1- 3Installing valve tappets -Cylinder bank 1- 3Removing valve tappets of cylinder bank 4-6Installing valve tappets -cylinder bank 4- 6Completing camshaftsSealing cover for camshaft housing (cylinder head cover)Checking guide for valve tappetsRemoving and installing oil protection tubes -Engine installed..Removing and installing oil protection tubes -Engine installed..Removing and installing valve tappets -engine installed...Removing valve tappets of the cylinder bank 1- 3 -Engine installedInstalling valve tappets of the cylinder bank 1- 3 -Engine installed..Adjusting timing of cylinder bank 1 -3 -Engine installed.Removing valve tappets of the cylinder bank 4 -6 -Engine installedInstalling valve tappets of the cylinder bank 4- 6 -Engine installed..Adjusting timing of cylinder bank 4 -6 -Engine installed.Removing and installing closure cap for camshaft bore -Engine installed. ...
Checking camshafts (timing) -Engine installedRemoving and installing sealing ring for intermediate shaft -Engine installed
Removing and installing solenoid hydraulic valveReworking cylinder headRemoving and installing camshaft housing -GT3Removing camshaft housing -GT3Installingcamshafthousing-GT3Removing and installing cylinder head -GT3Removing cylinder head -GT3Installing cylinder head-GT3Disassembling and assembling intermediate shaft -GT3
Table of Contents
Printed in Germany -44, 2001 Masterlt2
www.WorkshopManuals.co.uk

911 Carrera(996)
Engine,part2 (asofRepairGroup15)
17
175319
172019
171919
171919
174019
175019
171519
171921
171937
171923
175219
176719
176721
176723
170719
17-1
17-5
17-9
17-11
17-17
17-23
17-27
17-33
17-39
17-49
17-55
17-67
17-69
17-82
17-97
Engine-Lubrication
Removing and installing air/oil separatorRemoving and installing oil pump with coolant guide housing... ...,
Removing and installing oil extraction pumps -Engine removed. ..,
Removing and installing oil extraction pumps -Engine installed.. ..,
Removing and installing oil-water heat exchanger -engine installed
Removing and installing oil pan -engine installed ,
Removing and installing oil filler neck ,
Removing oil extraction pump-GT3Disassembling and assembling oil extraction pump -GT3Installing oil extraction pump-GT3Removing and installing oil container-GT3 ,
Removing and installing bracket for oil cooler -GT3 ,
Removing bracket for oil cooler-GT3Installing bracket for oil cooler-GT3 ,
Removing and installing oil temperature sensor -GT3
19
193817
195819
195019
191201
195021
195023
195819
195519
195521
195523
197819
190100
190101
196219
Engine-Cooling
Draining and topping up with coolantRemoving and installing coolant regulator.Removing and installing coolant pumpCoolant warning light in instrument cluster.Removing coolant pump (engine installed) -GT3Installing coolant pump (engine installed) -GT3Removing and installing coolant regulator -GT3Removing and installing housing for coolant guide -GT3Removing housing for coolant guide -GT3Removing housing for coolant guide -GT3Removing and installing temperature sensor for coolant -GT3
Oil/coolant mixing ,
Checking the cooling system for leaksRemoving and installing coolant hoses -GT3Removing coolant hosesInstalling coolant hoses ,Tightening torques ,
19-1
19-5
19-9
19-17
19-19
19-25
19-31
19-41
19-43
19-54
19-66
19-69
19-72
19-73 page 1
19-73 page 2
19-73 page 11
19-73 page 21
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
15 70 37 Disassembling and assembling cylinder head -Inner pans
Tools (commercially available)
216_96
Special tool Explanation
Item
A
Designation
Shaft(/320 x 450 mm) Art.
Art.
Art.
Art.
B
C
D
E
Aluminiumsupports(1 pair)
Leverarm
Jointwith screw
Magneticdisassemblyhead Art. No. 6024650
Art. No. 6000102
F
Art. No. 6006015
Assemblyhead1bfor
valvekeys
Pressurepiece6e (3ea.:
G
Padfor valvediscs (3 ea.)
HArt.-No.6025665
(ItemsAto H: refer to Workshop
EquipmentManual,Chapter2.4,
No. 54)
Commerciallyavailable,M6 x 40
Screwsfor aluminiumsupports
(4 ea.)
15-1
15 7037 Disassembling and assembling cylinder head -Inner parts
Printed in Germany -10, 1998 996151
No.6024515
No.6023620
No.6023530
No. 6024520
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
Tools
cE
691_97
Special tool
3364
Item
A
Explanation
VWspecialtool
Designation
Extractorfor valvestem
seal
Press-ontool for valve
stem seal 3365 VWspecialtool
B
9605
c
Cl 9605/1
9604
D
E
Pressurepiece,for fitting
the oil protectiontubes
Pressurepiece, for fitting
the oil protectiontubes
(engineinstalled)
Handpressurepiece 1 set=2 ea.
Tensioningscrewfor relieving
the tensioningelements
(VarioCam)
9632
15 -3
15 70 37 Disassembling and assembling cylinder head -Inner parts
Printed in Germany -10, 1998 996151
www.WorkshopManuals.co.uk

Disassembling and assembling cylinder head
Diagram shows cylinder head 4 -6
69~97
15 -4 15 7037 Disassembling and assembling cylinder head -Inner parts
996151 Printed in Germany -10, 1998
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
Disassembling and assembling cylinder head
Note:
Installation
No. Designation Qty. Removal
1Valve collet 12 Ensure correct seating
26
Spring seat
3 Valvespring 6
4Valvestem seal 6Pulloffwith VW
specialtool 3364 Alwaysreplace.
Oilvalvestem and
installvalve.Pushplastic
assemblysleeveover
the valvestem.Oil
sealinglip of the valve
stem sealandpushonto
the assemblysleeve
or valveguide byhand.
Carefullypressthe valve
stem seal asfar as it will
go intothe valveguide
usingthe press-ontool,
VWspecialtool 3365
56
6 3
Valvespring
supportdisc
Exhaustvalve Oilvalvestem
7Inletvalve 3 Oilvalvestem
8 Valveguide, inlet 6
9Valveguide,
exhaust
10 3 Valveseatring,
exhaust
3Valveseatring,
inlet
15 -515 70 37 Disassembling and assembling cylinder head -Inner parts
Printed in Germany -10. 1998 996151
www.WorkshopManuals.co.uk

Engine -Cylinder head, valve drive 911 Carrera (996)
Assembly instructions
Thecylinderheadsdiffer in the area of the chain
tensionersand are thereforemarkedon the
front with 1 -3 or 4 -6 to preventmix-ups.
Cylinder bank 1 -3
567_96
Cylinder bank 4 -6
568_96
.15 7037 Disassembling and assembling cylinder head -Inner parts
996151 Printed in Germany -10, 1998
15 -6
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
15 65 19 Removing and installing valve springs
Use special tool from the Sauer company
Removal
1. Putshimplatesunderthe valvediscs (3 ea.]
Note
Putthe screwclamps onlyon the aluminium
supports, underno circumstanceson
the sealingsurface.
2. Mountshaftwith aluminiumsupportson
the cylinderhead. Fastencylinderhead
to the workbenchwith screwclamps. 3. Fastenmagneticdisassemblyheadto lever
arm. Pressvalvespringtogether in cylinder
headandundovalvecolletsfrom valvestem,
1/1::
,j
to
J
~
I -
~~~-1J
~
I~
.~~ -.
217_96
219_96
15 -7
15 65 19 Removing and installing valve springs
Printed in Germany -10, 1998 996157
www.WorkshopManuals.co.uk

911 Carrera (996)
Engine -Cylinder head, valve drive
Installation
2. Insertvalvespring support disc,valvespring
andvalvespring seatinto cylinderheadand
presstogether withthe assemblyhead.With
slightpressure,allowvalvecolletsto engage.
Thevalvecolletsare then automatically
positionedin the right place.
1. Fastenassemblyheadto leverarm. Shift
slidingsleeveaccordinglyand laythe valve
colletsinthe assemblyhead. Lightlyoil valve
collets,valvestem endandvalvespringseat.
22O_96
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911 Carrera (996) Engine -Cylinder head, valve drive
15 63 19 Removing and installing valve stem seal
Removal
InsertVWspecialtool 3364 into rib of valve
stem sealand pullout. ~G~
~
~A'
0"1";" 0
~!
I
I.
~
223_96
448-97
Installation
Fitoriginalvalvespring supportdisc. Slide
plastic assemblysleeve(136 mm)ontovalve
stem. Oilsealinglip and seatingsurface of valve
stem seal, put on by handand,with assembly
mandrel(VWspecialtool 3365), gentlytap
as far as the stop on the valveguide.Remove
plastic sleeve.
~'-
~
<::> /r-,~~' a
~
224_96
15 -9
1563 19 Removing and installing valve stem seal
Printed in Germany -10, 1998 996159
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
15 70 23 Installing cylinder head
Tools
\\
0
598_97
Item Designation Special tool
ATorqueangle
Torquewrench
Explanation
Referto WorkshopEquipment
Manual,Chapter2.4, No. 88
BSocketwrenchinsert
TorxT50 9633
Commerciallyavailable
Socketwrenchinsert
Torx T55 As of enginenumber
M96/01 66XO3084
M96/0268XOIO44
(modifiedcylinderheadscrews)
15-11
15 70 23 Installing cylinder head
Printed in Germany -23, 1999 9961511
www.WorkshopManuals.co.uk

911 Carrera (996)
Engine -Cylinder head, valve drive
Installing cylinder head
Fitcylinderheadgaskets.
Note
The gasketsare identifiedby Zyl.1 -3 or
Zyl. 4 -6 withOBEN/TOPI plusthe
correspondingpart number.
Ensurecorrect seating of dowel sleeves
in crankcase.Puton gaskets.
'0
,0 0 0 0 0
0 nOBEN/TOPOwKz~i:J':J0
510.97
bi 0 0 0 0
, , 00...,..,.." 0
"""'-: ~ " OBEN/ TOP WI Iyl. 4-6
514_97
15 70 23 Installing cylinder head
Printed in Germany -23, 1999
15 -12 9961511
www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive
2. Fastencylinderheads.
Moistencylinder-headscrews thinly
with engineoil.
Tightening sequence of cylinder-head screws
Initial tightening or tightening to flatten
1st step: 30 Nm (23 ftlb.)
2nd step: Completely loosen cylinder head screws
Final tightening
1st step: 20 Nm (15 ftlb.]
Applicationtorque inprescribed tightening
2ndstep:
3rd step: 1 x 600 :t 20
1 x 600 :t 20
Torque-angletightening
Torque-angletightening
65~97
15 -13
15 70 23 Installing cylinder head
Printed in Germany -23, 1999 9961511
sequence
in samesequence
in samesequence
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Engine -Cylinder head, valve drive 911 Carrera (996)
273..97
3. After tighteningthe cylinder-headscrews,
additionallyfastenfour pan-headscrews
M6 x 35 (10.9) (withcaptive washers)
inthe area ofthe chainbox.
Tighteningtorque 13 Nm(10 ftlb.)
637..97
15 70 23 Installing cylinder head
Printed in Germany -23, 1999
15-14 9961511
www.WorkshopManuals.co.uk