Porsche 996 TT Operating instructions

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Table of Contents
Information on handling of the GT2 scope.......................................................................................................1
0 Technical data..................................................................................................................................................2
Engine......................................................................................................................................................3
Engine design...........................................................................................................................................4
Engine cooling.........................................................................................................................................5
Engine lubrication....................................................................................................................................5
Engine control..........................................................................................................................................5
Heating.....................................................................................................................................................6
Fuel system..............................................................................................................................................6
Electrical system......................................................................................................................................6
Exhaust system........................................................................................................................................7
Emission control......................................................................................................................................7
Transmission............................................................................................................................................7
Clutch.......................................................................................................................................................7
Transmission............................................................................................................................................8
Body designs............................................................................................................................................9
Running gear............................................................................................................................................9
Brakes....................................................................................................................................................10
Wheels and tyres....................................................................................................................................11
Spare wheel............................................................................................................................................11
Wheel alignment....................................................................................................................................11
Dimensions............................................................................................................................................12
Weights according to DIN 700 20.........................................................................................................12
Filling capacities....................................................................................................................................13
Performance data...................................................................................................................................14
Climbing performance...........................................................................................................................15
Specific power.......................................................................................................................................15
0 Entire vehicle  General................................................................................................................................16
Lifting the vehicle..................................................................................................................................16
Power unit..........................................................................................................................................................17
Engine M96/70......................................................................................................................................17
Engine....................................................................................................................................................18
Engine design.........................................................................................................................................18
Engine cooling.......................................................................................................................................19
Engine lubrication..................................................................................................................................19
Engine control........................................................................................................................................20
0 Transmission..................................................................................................................................................21
6−speed manual transmission G 96.50..................................................................................................21
Front wheel drive Z 96.00......................................................................................................................22
0 Body.................................................................................................................................................................23
Body of high−strength steel 1................................................................................................................23
Body of high−strength steel 2................................................................................................................24
Water drainage plan  Coupé................................................................................................................25
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Table of Contents
0 Body Refrigerant circuit..................................................................................................................................26
Component arrangement, Airbag System B05......................................................................................26
0 Electrics...........................................................................................................................................................28
Fuse assignments...................................................................................................................................28
0 Power supply..................................................................................................................................................31
Work instructions after disconnecting the battery.................................................................................31
Control module memories.....................................................................................................................31
Supply voltage fault entry......................................................................................................................32
Test drive after connecting the battery...................................................................................................32
2470 DME control module....................................................................................................................32
3730 Tiptronic........................................................................................................................................33
6452 Power windows.............................................................................................................................33
90 25 Instrument cluster.........................................................................................................................33
9030 Clock.............................................................................................................................................33
9023 Fuel level display..........................................................................................................................34
9120 Radio.............................................................................................................................................34
9110 PCM..............................................................................................................................................34
01 General maintenance: Test drive...............................................................................................................36
01 Diagnostic system: Read out fault memory and activate systems...........................................................37
Activating systems.................................................................................................................................37
Read out fault memory...........................................................................................................................37
Load Navigation.....................................................................................................................................38
01 Battery: checking the charge state.............................................................................................................39
Tools......................................................................................................................................................39
Checking charge state with battery tester..............................................................................................39
01 Windscreen wiper/washer system, headlight washer...............................................................................40
Mix ratio of fluids for windscreen washer system.................................................................................40
01 Checking the function of the vehicle's lights and the headlight setting..................................................41
Checking the adjustment of the headlights............................................................................................41
Adjusting the main headlights...............................................................................................................42
Adjusting the main headlights, USA version.........................................................................................43
Fog light adjustment..............................................................................................................................43
01 Checking the function of electrical equipment, as well as the indicator and warning lights................45
01 Alarm system: checking operation of indicators.......................................................................................46
01 Activating/deactivating the parking aid.....................................................................................................47
General...................................................................................................................................................47
Activating the parking aid without PST 2.............................................................................................47
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01 Activating/deactivating the parking aid
Deactivating the parking aid without PST 2..........................................................................................48
Activating the parking aid with PST 2...................................................................................................48
Selecting door mirror to be lowered, left/right......................................................................................49
Adjusting the lowering angle for the passenger door mirror.................................................................49
Deactivating the parking aid with PST 2...............................................................................................50
01 Removing transport lock (spring strut locking devices)  Turbo and GT2...........................................51
General...................................................................................................................................................51
Removing spring strut locking devices..................................................................................................51
Technical Data  GT2.......................................................................................................................................53
Engine....................................................................................................................................................54
Engine design.........................................................................................................................................54
Engine cooling.......................................................................................................................................55
Engine lubrication..................................................................................................................................55
Engine control........................................................................................................................................55
Fuel system............................................................................................................................................56
Electrical system....................................................................................................................................56
Exhaust system......................................................................................................................................56
Emission control....................................................................................................................................56
Technical data...................................................................................................................................................57
Engine....................................................................................................................................................58
Engine design.........................................................................................................................................58
Engine cooling.......................................................................................................................................59
Engine lubrication..................................................................................................................................59
Engine control........................................................................................................................................59
Fuel system............................................................................................................................................60
Electrical system....................................................................................................................................60
Exhaust system......................................................................................................................................60
Emission control....................................................................................................................................60
Precautionary measures when working on fuel system.................................................................................61
03 Diagnostic system: reading out fault memory...........................................................................................62
Reading out fault memory.....................................................................................................................62
03 General maintenance: test drive.................................................................................................................63
03 Removing and installing drive belt.............................................................................................................64
Removal overview of the drive belt (engine installed)..........................................................................64
Installation overview of the drive belt (engine installed)......................................................................65
94 56 19 Removing and installing bulb for direction indicator light...........................................................67
Removing bulb for direction indicator light..........................................................................................67
Installing bulb for direction indicator light............................................................................................67
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03 Changing the engine oil and oil filter.........................................................................................................68
03 Changing the engine oil (without oil filter)................................................................................................72
03 Replacing spark plugs..................................................................................................................................74
Removing spark plugs...........................................................................................................................74
Installing spark plugs.............................................................................................................................75
03 Checking cooling system..............................................................................................................................77
Coolant: checking level, antifreeze content and leaks...........................................................................77
03 Replacing air cleaner element.....................................................................................................................79
Removing air cleaner.............................................................................................................................79
Installing air cleaner...............................................................................................................................81
03 Replacing the fuel filter...............................................................................................................................85
03 Clutch: checking the play and pedal end position....................................................................................89
Checking clutch free play......................................................................................................................89
Checking the pedal end position (pedal return/return force).................................................................89
03 Changing transmission oil...........................................................................................................................90
Changing transmission oil.....................................................................................................................90
Tightening torques.................................................................................................................................90
03 Checking and topping up the ATF.............................................................................................................91
Tools......................................................................................................................................................91
Checking and topping up the ATF.........................................................................................................91
Tightening torques.................................................................................................................................93
03 Replacing ATF.............................................................................................................................................94
Tools......................................................................................................................................................94
Replacing ATF fluid..............................................................................................................................94
Tightening torques.................................................................................................................................96
03 Removing and installing ATF filter............................................................................................................97
Tools......................................................................................................................................................97
Removing ATF filter.............................................................................................................................97
Installing ATF filter...............................................................................................................................98
Tightening torques.................................................................................................................................99
03 Replacing and checking transmission oil in final drive..........................................................................100
Tools....................................................................................................................................................100
Changing transmission oil in final drive..............................................................................................100
Tightening torques...............................................................................................................................102
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03 Changing transmission oil in front wheel drive......................................................................................103
Changing transmission oil in front wheel drive...................................................................................103
Tightening torques...............................................................................................................................103
03 Changing transmission oil − GT2.............................................................................................................105
Changing transmission oil − GT2........................................................................................................105
Topping up transmission oil − GT2.....................................................................................................105
Tightening torques...............................................................................................................................106
03 Steering gear: fluid level and bellows.......................................................................................................107
Power steering: checking the fluid level..............................................................................................107
General..........................................................................................................................................107
Power steering: checking the fluid level.......................................................................................107
Steering gear: visual inspection of the bellows....................................................................................109
03 Axle joints/drive shafts..............................................................................................................................110
Tie rod ends: checking the play and dust bellows...............................................................................110
Axle joints: checking the play and dust bellows..................................................................................110
Drive shafts: visual inspection of the boots.........................................................................................111
03 Running gear adjustment/storage of assemblies.....................................................................................112
Running gear adjustment (wheel alignment values)............................................................................112
Storage of assemblies and running gear...............................................................................................112
03 Tyres and spare wheel: checking condition and tyre pressure..............................................................113
Checking condition..............................................................................................................................113
Tyre pressure for cold tyres (approx. 20 °C).......................................................................................113
911 Turbo......................................................................................................................................113
911 GT2 (M002/M003).................................................................................................................113
03 Checking and changing the brake fluid...................................................................................................115
Checking the brake fluid level.............................................................................................................115
Changing the brake fluid......................................................................................................................115
03 Parking brake: checking the free play of the parking brake lever.......................................................117
Parking brake: checking the free play of the parking brake lever.......................................................117
Adjusting the parking brake..........................................................................................................117
03 Visual inspection: brake lines/brake pads/brake discs...........................................................................119
Brake hoses and lines...........................................................................................................................119
Brake system: visual inspection of the brake pads and brake discs for wear......................................119
03 Checking the wheel mounting...................................................................................................................121
03 Checking lid and doors..............................................................................................................................122
Checking lid lock, front and rear.........................................................................................................122
Checking the catch bar..................................................................................................................122
Checking safety hook, front lid............................................................................................................122
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03 Checking lid and doors
Function test, checking door lock........................................................................................................122
Functional inspection of the tank cap lock..........................................................................................123
Checking door and lid tightening torques............................................................................................123
Checking inner release of luggage compartment (Trunk Entrapment)................................................123
Tightening torques...............................................................................................................................124
03 Checking seat belts.....................................................................................................................................125
Functional inspection...........................................................................................................................125
Condition inspection............................................................................................................................125
03 Inspecting the airbag system.....................................................................................................................126
Visual inspection..................................................................................................................................126
Checking airbag warning light.............................................................................................................126
Function test of the airbag system.......................................................................................................126
03 Passenger protection maintenance: checking roll−over protection system..........................................128
03 Particle filter: replacing the filter element..............................................................................................129
Removing particle filter.......................................................................................................................129
Installing particle filter.........................................................................................................................129
03 Checking the function of the vehicle's lights...........................................................................................130
Adjusting the main headlights.............................................................................................................130
Setting..................................................................................................................................................131
Adjusting the main headlights, USA version.......................................................................................132
Fog light adjustment............................................................................................................................132
Removing main headlight....................................................................................................................132
Installing main headlight.....................................................................................................................133
03 Windscreen wiper/washer system, headlight washer.............................................................................135
03 Checking the function of electrical equipment, as well as the indicator and warning lights..............136
03 Additional maintenance − USA................................................................................................................137
Additional maintenance, replacing spark plugs...................................................................................137
Additional maintenance every 60,000 mls/96,000 km........................................................................137
Additional maintenance every 90,000 mls/144,000 km......................................................................138
Maintenance every 2 years...................................................................................................................138
Maintenance after 4, 8, 10 then every 2 years.....................................................................................138
03 Additional maintenance − as of MY 2004................................................................................................139
Additional maintenance, replacing spark plugs...................................................................................139
Additional maintenance every 80,000 km/48,000 mls........................................................................139
Additional maintenance every 160,000 km/96,000 mls......................................................................139
Maintenance every 2 years...................................................................................................................140
Maintenance after 4, 8, 10 then every 2 years.....................................................................................140
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03 Additional maintenance − USA − as of MY 2004...................................................................................141
Additional maintenance, replacing spark plugs...................................................................................141
Additional maintenance every 60,000 mls/96,000 km........................................................................141
Additional maintenance every 90,000 mls/144,000 km......................................................................142
Maintenance every 2 years...................................................................................................................142
Maintenance after 4, 8, 10 then every 2 years.....................................................................................142
03 Additional maintenance.............................................................................................................................144
Additional maintenance, replacing spark plugs...................................................................................144
Additional maintenance every 80,000 km/48,000 mls........................................................................144
Additional maintenance every 160,000 km/96,000 mls......................................................................144
Maintenance every 2 years...................................................................................................................145
Maintenance after 4, 8, 10 then every 2 years.....................................................................................145
3 Technical data..............................................................................................................................................146
6−speed manual transmission G 96.50................................................................................................146
Manual transmission tightening torques........................................................................................147
Front wheel drive Z 96.00....................................................................................................................147
Front−axle drive tightening torques..............................................................................................148
3 Technical data..............................................................................................................................................149
5−speed Tiptronic transmission A 96.50−150.....................................................................................149
Tightening torques for Tiptronic transmission..............................................................................150
Front wheel drive Z 96.00....................................................................................................................151
Front−axle drive tightening torques..............................................................................................151
4 Removing transport lock (spring strut locking devices)  Turbo and GT2...........................................153
General.................................................................................................................................................153
Removing spring strut locking devices................................................................................................153
4 Lifting the vehicle.........................................................................................................................................155
Lift the vehicle.....................................................................................................................................155
4 Tests/notes for all−wheel drive...................................................................................................................156
Balancing wheels on vehicle................................................................................................................156
Power test.............................................................................................................................................156
Brake test.............................................................................................................................................156
Towing manual transmission vehicles.................................................................................................156
Towing Tiptronic vehicles...................................................................................................................156
4 Switching off PSM........................................................................................................................................157
Switching off PSM...............................................................................................................................157
Switching PSM back on.......................................................................................................................157
Characteristic features of Tiptronic vehicles (slip upshift)..................................................................158
5 Plug location plan.........................................................................................................................................159
Top of front end...................................................................................................................................159
Bottom of front end..............................................................................................................................160
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5 Plug location plan
Side of front end...................................................................................................................................160
Bottom of lower side member and floor..............................................................................................161
Top of lower side member and floor....................................................................................................161
Bottom of rear end...............................................................................................................................162
Top of rear end.....................................................................................................................................162
Side of rear end....................................................................................................................................163
Seam seals........................................................................................................................................................164
Accessories..........................................................................................................................................164
Front lid.........................................................................................................................................165
Door...............................................................................................................................................165
Sliding roof panel..........................................................................................................................166
5 Work sequence for accident repair............................................................................................................167
5 Work sequence for determining scope of damaged vehicles involved in an accident...........................169
5 Corrosion protection measures during repairs.........................................................................................171
Measures for maintaining long−term body protection........................................................................171
Prerequisite for ensuring vailidity of the long−life guarantee.............................................................171
5 Vehicle identification number.....................................................................................................................172
Imprinting new vehicle identification number.....................................................................................172
Materials, tools.....................................................................................................................................173
5 Change identification data plate.................................................................................................................174
5 Undersealing.................................................................................................................................................176
Overview diagram, lower front of vehicle...........................................................................................176
Overview diagram, bottom of lower side member and floor...............................................................177
Overview diagram, lower rear end.......................................................................................................178
Tools and materials..............................................................................................................................178
5 Water drainage plan  Cabriolet...............................................................................................................179
5 Check dimensions for body repair − Cabriolet structure........................................................................180
Structure dimensions for cabriolet.......................................................................................................180
5 Safety notes...................................................................................................................................................183
Safety instructions for raising vehicles................................................................................................183
Danger of injury when raising vehicles.........................................................................................183
Damage when raising vehicles......................................................................................................183
Safety instructions for welding............................................................................................................184
Dangers of injury when welding...................................................................................................184
Safety instructions for flying sparks during grinding and welding work......................................184
Safety instructions for fuel tank....................................................................................................185
Safety instructions for air conditioning.........................................................................................185
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5 Safety notes
Safety instructions for sticking............................................................................................................185
Safety instructions for Teromix−6700 two−component adhesive................................................185
Safety instructions for installation work..............................................................................................186
Safety instructions for sharp−edged body and unit parts..............................................................186
Safety instructions for airbag system............................................................................................186
Safety instructions for door...........................................................................................................186
Safety instructions for corrosion protection.........................................................................................187
Safety instructions for plug location plan (body)..........................................................................187
Safety instructions for water drains (body)...................................................................................187
5 General information and quality notes......................................................................................................188
Measures for maintaining long−term body protection........................................................................188
Prerequisite for maintaining the long−life guarantee....................................................................188
Electronic control modules..................................................................................................................188
Protection against overvoltage......................................................................................................189
Replacing control modules............................................................................................................189
5 Tools and metalworking tools for body repairs........................................................................................190
Straightening systems..........................................................................................................................190
Metalworking tools..............................................................................................................................190
Electrical equipment......................................................................................................................190
Mechanical equipment..................................................................................................................191
Compressed−air equipment...........................................................................................................191
Welding equipment.......................................................................................................................192
5 Diagram − keys to symbols for welding work...........................................................................................193
Resistance spot welding.......................................................................................................................193
Inert−gas arc welding (MAG procedure).............................................................................................193
Gas welding.........................................................................................................................................193
5 Check dimensions for body repair.............................................................................................................195
Floorpan check dimensions..................................................................................................................195
5 Water drainage plan....................................................................................................................................198
5 Diagram − body gap dimensions................................................................................................................199
Gap dimensions, body front.................................................................................................................199
Gap dimensions, body centre...............................................................................................................201
Gap dimensions, body rear..................................................................................................................202
Gap dimensions, body rear  Carrera 4S.............................................................................................204
Diagram − Gap dimensions, Cabriolet................................................................................................206
Diagram − Centre gap dimensions, Cabriolet...............................................................................206
Diagram − Gap dimensions, rear Cabriolet...................................................................................208
Diagram, gap dimensions, Cabriolet rear − Carrera 4S................................................................209
Diagram − Gap dimensions, hardtop.............................................................................................210
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5 Body parts of high−strength steel...............................................................................................................212
High−strength steel plates....................................................................................................................213
Tailored blanks.....................................................................................................................................214
Baked hardening..................................................................................................................................215
Straightening body parts......................................................................................................................215
Welding work.......................................................................................................................................216
Reshaping.............................................................................................................................................216
Separation points..................................................................................................................................216
Diagram − Body, model year 2002......................................................................................................217
Structural body parts (model care) for model year 2002...............................................................217
6 Safety notes...................................................................................................................................................219
Safety instructions for work on car windows......................................................................................219
Danger of injury when working on car windows..........................................................................219
Material damage when removing the glass from car windows.....................................................219
Material damage when inserting the glass into car windows........................................................219
Safety instructions for installation work..............................................................................................220
Safety instructions for airbag system............................................................................................220
Safety instructions for sliding roof................................................................................................220
Safety instructions for rear spoiler................................................................................................220
Safety instructions for the pump unit hydraulic system of the rear spoiler...................................221
6 General information on installing and removing car windows...............................................................222
Removing glass with cutting wire separator........................................................................................222
Cutting power when removing glass with cutting thread..............................................................229
6 Overview of exterior colours.......................................................................................................................231
Exterior paintwork  solid...................................................................................................................231
Exterior paintwork  metallic/pearl.....................................................................................................231
Special colours.....................................................................................................................................232
6 Processing of Porsche 2−component window bonding agents.................................................................234
Overview of tools and materials..........................................................................................................234
Preparing the adhesive surfaces...........................................................................................................235
Combined procedure (handling double cartridge press)......................................................................236
7 Special notes for the care of soft−look paint surfaces...............................................................................239
Light soiling (e.g. dust)........................................................................................................................239
Heavy soiling (e.g. oily, greasy dirt)....................................................................................................239
8 Air conditioning...........................................................................................................................................241
Technical data for the air−conditioning system...................................................................................241
9 Work instructions after disconnecting the battery...................................................................................242
Effect of disconnection or total discharge of the battery on electrical systems in the vehicle,
subsequent measures...........................................................................................................................242
Control module memories...................................................................................................................242
Supply voltage fault entry....................................................................................................................243
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9 Work instructions after disconnecting the battery
Test drive after connecting the battery.................................................................................................243
2470 DME control module..................................................................................................................243
6452 Power windows...........................................................................................................................244
90 25 Instrument cluster.......................................................................................................................244
9030 Clock...........................................................................................................................................244
9023 Fuel level display........................................................................................................................244
9120 Radio...........................................................................................................................................245
9110 PCM............................................................................................................................................245
30 Clutch: checking fluid levels.....................................................................................................................247
General.................................................................................................................................................247
Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage
compartment.......................................................................................................................................247
Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment..........................................248
Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment........................................249
40 Tightening torques for front axle.............................................................................................................251
Cross member/side member (1 component)........................................................................................251
Diagonal brace.....................................................................................................................................251
Control arm..........................................................................................................................................251
Spring strut/wheel carrier.....................................................................................................................252
Front−axle final drive/drive shaft (Turbo)...........................................................................................252
Stabilizer..............................................................................................................................................253
Steering................................................................................................................................................253
Wheel fastening...................................................................................................................................253
42 Tightening torques for rear axle...............................................................................................................255
Carrier side section/cross member.......................................................................................................255
Axle strut..............................................................................................................................................255
Wheel carrier........................................................................................................................................256
Spring strut...........................................................................................................................................256
Drive shaft/stabilizer............................................................................................................................257
Unit mount...........................................................................................................................................257
44 Conversion table for wheel alignment values..........................................................................................258
Minutes in decimal degrees.................................................................................................................258
Conversion from minutes to decimal degrees (examples)............................................................258
Conversion from decimal degrees to minutes (examples)............................................................258
44 Adjusting values for suspension alignment − Turbo and GT2..............................................................260
Vehicle height......................................................................................................................................260
Wheel alignment values.......................................................................................................................260
44 Alignment card − Turbo............................................................................................................................262
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44 Suspension alignment, complete...............................................................................................................264
Vehicle height/wheel load....................................................................................................................265
Wheel−alignment corrections..............................................................................................................265
Rear axle........................................................................................................................................265
Front axle.......................................................................................................................................266
General procedure for suspension alignment.......................................................................................266
Vehicle height (vehicle height check)..................................................................................................267
General..........................................................................................................................................267
Preliminary work...........................................................................................................................267
Front axle.......................................................................................................................................268
Rear axle........................................................................................................................................268
Wheel alignment............................................................................................................................268
Rear axle..............................................................................................................................................269
Adjusting camber..........................................................................................................................269
Adjusting toe.................................................................................................................................270
Front axle.............................................................................................................................................271
Adjusting camber..........................................................................................................................271
Adjusting caster.............................................................................................................................271
Adjusting toe.................................................................................................................................272
Toe−difference angle.....................................................................................................................274
44 Wheel rims and tires..................................................................................................................................275
Tire condition / tire pressure................................................................................................................275
Tire pressure of cold tires (approx. 20° C)..........................................................................................275
911 Turbo......................................................................................................................................275
911 GT2 (M002/M003).................................................................................................................275
Overview of tires and wheels (series)..................................................................................................276
Notes on mounting tires................................................................................................................276
44 Tyres............................................................................................................................................................277
Mounting instructions..........................................................................................................................277
General..........................................................................................................................................277
Uncontrolled matching..................................................................................................................278
Controlled matching......................................................................................................................278
Fitting............................................................................................................................................278
Balancing weights................................................................................................................................279
Navigation system................................................................................................................................279
Wheel storage.......................................................................................................................................279
Tyre age...............................................................................................................................................280
44 Checking disc wheels.................................................................................................................................281
Checking the radial and lateral runout.................................................................................................281
44 Tyre mounting............................................................................................................................................282
Tools....................................................................................................................................................282
Notes on removing/mounting tyres......................................................................................................283
Removal...............................................................................................................................................283
Fitting...................................................................................................................................................284
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44 Balancing/optimising wheels.....................................................................................................................287
General.................................................................................................................................................287
Balancing/optimising wheels...............................................................................................................287
Further to 1: Mounting the tyre on the rim....................................................................................288
Further to 2: Stationary balancing with optimisation of the rolling smoothness..........................288
Further to 3: Mounting the wheel on the vehicle..........................................................................289
Further to 4: Electronic fine balancing..........................................................................................289
Further to 4a: Fine balancing of the front wheels.........................................................................290
Further to 4b: Fine balancing of the rear wheels...........................................................................290
Balancing weights................................................................................................................................291
Affixing the adhesive weights.......................................................................................................291
45 ABS/PSM 5.7 check with Porsche System Tester 2................................................................................292
Test with Porsche System Tester 2......................................................................................................292
46 Checking brake light switch setting.........................................................................................................293
Brake light switch setting....................................................................................................................293
Checking brake light switch setting.....................................................................................................293
Adjusting switch if pedal travel is too small........................................................................................294
1st possibility:................................................................................................................................294
2nd possibility:..............................................................................................................................294
Adjusting switch if pedal travel is too large..................................................................................294
46 Tightening torques for mechanical brake................................................................................................295
46 Technical data/Brake wear limit − Turbo...............................................................................................296
Technical data − Turbo with cast iron brake discs..............................................................................296
Wear limit technical data − Turbo with cast iron brake discs.............................................................297
46 Checking the thickness of the disc brake pads − Turbo and GT2.........................................................298
46 Technical data/Brake wear limit − Turbo with PCCB...........................................................................300
Technical data − Turbo with ceramic brake discs (PCCB).................................................................300
Wear limit technical data − Turbo with ceramic brake discs (PCCB).................................................301
47 Tightening torques for brake hydraulics.................................................................................................302
48 Tightening torques for steering................................................................................................................303
48 Test and assembly work on power steering.............................................................................................304
General.................................................................................................................................................304
Checking hydraulic fluid of power steering and servo clutch.............................................................304
Bleeding the steering system...............................................................................................................305
48 Assessment of steering gear after accident damage................................................................................307
Fundamentals.......................................................................................................................................307
Assessment of the steering of a vehicle involved in an accident..................................................307
Exceptional regulation / order handling........................................................................................308
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69 Safety regulations for vehicles with airbag and belt tensioner..............................................................309
Assembly and adjustment work...........................................................................................................310
Handling airbag and belt tensioner......................................................................................................311
Dangers for persons and the environment.....................................................................................311
Protective measures and rules of behaviour..................................................................................311
Behaviour in cases of malfunction or danger................................................................................312
Materials........................................................................................................................................313
General information.............................................................................................................................313
Component exchange after airbag triggering................................................................................314
After triggering of the side airbag unit..........................................................................................314
After triggering of belt tensioner...................................................................................................314
87 Nominal values for pressures and temperatures.....................................................................................315
General test prerequisites.....................................................................................................................315
Centre vent temperature as a function of ambient temperature.....................................................315
High pressure in cold circuit as a function of ambient temperature..............................................316
Low pressure in cold circuit as a function of ambient temperature..............................................316
91 Retrofitting mobile communication systems...........................................................................................318
96 Additional alarm system M 536................................................................................................................320
Removing alarm siren and tilt sensor...................................................................................................320
97 Measurement of closed−circuit current...................................................................................................321
Tools....................................................................................................................................................321
Preparations on the vehicle..................................................................................................................321
Connecting measuring device.......................................................................................................321
Measurement........................................................................................................................................322
27 06 Battery....................................................................................................................................................324
Battery − handling notes......................................................................................................................324
Warning notes and safety regulations for hydrocyanic acid batteries...........................................325
Removing and installing battery..........................................................................................................325
Remove battery....................................................................................................................................326
Install battery.......................................................................................................................................327
Visual inspection..................................................................................................................................328
Check acid level...................................................................................................................................328
Checking gravity of electrolyte............................................................................................................329
Open−circuit voltage measurement.....................................................................................................330
Battery load test...................................................................................................................................331
Charging battery...................................................................................................................................332
27 06 Electrical emergency release, front cover...........................................................................................334
Emergency release, front cover............................................................................................................334
40 09 Front−axle cross member − permissible combinations.....................................................................336
New front−axle cross member − as of model '02................................................................................336
Allocating the front−axle cross member to the body...........................................................................336
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40 09 Front−axle cross member − permissible combinations
Impermissible combination...........................................................................................................337
Permissible combinations..............................................................................................................337
Impermissible combination...........................................................................................................338
40 Disassembling and assembling front spring strut...................................................................................339
Tools....................................................................................................................................................339
Disassembly and assembly instructions...............................................................................................341
Disassembly...................................................................................................................................341
Distinguishing feature of coil springs and dampers......................................................................342
Preliminary work and notes on assembly......................................................................................342
Assembly.......................................................................................................................................343
42 71 Disassembling and assembling rear spring strut − Turbo................................................................346
Tools....................................................................................................................................................346
Disassembling and assembling rear spring strut..................................................................................346
Disassembly and assembly instructions...............................................................................................348
Disassembly...................................................................................................................................348
Distinguishing feature of coil springs and dampers......................................................................350
Assembly.......................................................................................................................................350
44 27 Instructions for collapsible wheel/spare wheel − Turbo with PCCB...............................................353
Mounting collapsible spare wheel − Turbo with PCCB......................................................................353
Placing collapsible spare wheel in to the vehicle − Turbo with PCCB...............................................354
45 60 Steering angle sensor............................................................................................................................355
Calibrating steering angle sensor.........................................................................................................355
Steering angle sensor position.......................................................................................................355
The steering angle sensor must be calibrated after:......................................................................355
Calibrating steering angle sensor..................................................................................................356
Check the steering angle sensor actual value in the following cases:...........................................357
Checking the steering angle sensor actual value...........................................................................357
66 72 Assignment of spoiler drive, relays and instrument cluster..............................................................358
Variants of the spoiler drive.................................................................................................................358
69 59 Disposal of airbag and belt tensioner units.........................................................................................359
Safety measures when igniting airbag units.........................................................................................359
Tools....................................................................................................................................................360
Connecting ignition tool......................................................................................................................361
Driver's side...................................................................................................................................361
Passenger's side.............................................................................................................................361
Side airbag.....................................................................................................................................361
Belt tensioner.................................................................................................................................362
Ignition.................................................................................................................................................362
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Table of Contents
87 03 Safety regulations when handling refrigerant R134a........................................................................364
92 66 Non−adjustable spray nozzles..............................................................................................................365
94 23 Bulb table and installation instructions..............................................................................................366
Bulb table.............................................................................................................................................366
Installing bulbs.....................................................................................................................................366
96 22 Bulb table and installation instructions..............................................................................................367
Bulb table.............................................................................................................................................367
Installing bulbs.....................................................................................................................................367
97 68 Optical waveguide − MOST bus..........................................................................................................368
Specifications on handling the optical waveguide...............................................................................368
Storage, packaging, transport........................................................................................................368
Installing optical waveguides in the vehicle..................................................................................368
Repairs...........................................................................................................................................369
Plug connectors....................................................................................................................................369
Protective dust caps.......................................................................................................................369
Control module plug connector (wiring harness side)..................................................................370
Connectors.....................................................................................................................................370
Removing and installing optical contacts............................................................................................371
Removing optical contacts on plug side........................................................................................372
Installing optical contacts on plug side.........................................................................................373
Removing optical contacts on bushing side..................................................................................374
Installing optical contacts on bushing side....................................................................................374
Optical waveguide modules.................................................................................................................375
Tools....................................................................................................................................................376
01 Sales check..................................................................................................................................................377
03 24 00 Minor maintenance..........................................................................................................................379
03 26 00 Major maintenance..........................................................................................................................381
03 50 00 Annual maintenance........................................................................................................................383
10 01 00 Tightening torques for M 96/70 engine..........................................................................................385
Crankshaft/crankcase...........................................................................................................................385
Cylinder, cylinder head and camshaft housing....................................................................................385
10 10 37 Disassembling and assembling crankcase......................................................................................387
Tools....................................................................................................................................................387
Adapting engine holder........................................................................................................................390
Left crankcase half (cylinder bank 1  3)............................................................................................392
Right crankcase half (cylinder bank 4 − 6)..........................................................................................394
Disassembling the crankcase...............................................................................................................396
Assembling the crankcase....................................................................................................................399
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Table of Contents
13 10 19 Removing and installing pistons (includes removing and installing cylinders).........................411
Tools....................................................................................................................................................411
Removing pistons and cylinders..........................................................................................................412
Removing pistons................................................................................................................................414
Installing pistons and cylinders............................................................................................................415
13 19 21 Removing piston rings.....................................................................................................................423
Tools....................................................................................................................................................423
Removal...............................................................................................................................................423
13 19 23 Installing piston rings......................................................................................................................427
Tools....................................................................................................................................................427
Installation...........................................................................................................................................427
13 48 37 Disassembling and assembling crankshaft....................................................................................431
Tools....................................................................................................................................................431
Disassembling crankshaft....................................................................................................................433
Identifying the ring knurled screw................................................................................................434
Pressing ring knurled screw in and out................................................................................................435
Pressing ring knurled screw out....................................................................................................435
Pressing ring knurled screw in......................................................................................................436
Assembling crankshaft.........................................................................................................................436
13 73 37 Disassembling and assembling belt tensioner................................................................................440
Assembly note......................................................................................................................................442
13 78 19 Removing and installing drive belt (engine installed)..................................................................443
Removal overview of the drive belt (engine installed)........................................................................443
Remove drive belt................................................................................................................................444
Installation overview of the drive belt (engine installed)....................................................................446
Install drive belt...................................................................................................................................448
15 03 21 Removing camshaft housing  engine removed............................................................................450
Tools....................................................................................................................................................450
Component overview and tightening torques......................................................................................450
Removing the camshaft housing..........................................................................................................453
15 03 23 Installing camshaft housing............................................................................................................458
15 05 02 Checking camshafts (timing)  engine removed...........................................................................460
Tools....................................................................................................................................................460
Checking camshafts.............................................................................................................................461
15 05 16 Setting camshafts (timing)  engine removed...............................................................................467
Tools....................................................................................................................................................467
Setting the camshafts (timing).............................................................................................................468
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Table of Contents
15 05 19 Removing and installing camshafts  engine removed.................................................................474
Tools....................................................................................................................................................474
Component overview and tightening torques......................................................................................475
Removing camshafts............................................................................................................................477
Installing camshafts.............................................................................................................................481
15 20 37 Disassembling and assembling intermediate shaft........................................................................487
15 55 19 Removing and installing hydraulic valve.......................................................................................489
Removing the hydraulic valve.............................................................................................................489
Installing the hydraulic valve...............................................................................................................491
15 70 21 Removing cylinder head..................................................................................................................494
Removing cylinder head......................................................................................................................496
15 70 23 Installing cylinder head...................................................................................................................497
17 04 19 Removing and installing oil pressure sender.................................................................................499
Removal...............................................................................................................................................499
Installation...........................................................................................................................................500
17 07 19 Removing and installing oil temperature sensor...........................................................................502
Removal...............................................................................................................................................502
Installation...........................................................................................................................................503
17 28 19 Removing and installing check valve  engine installed..............................................................505
Removal...............................................................................................................................................506
Installation...........................................................................................................................................508
17 40 19 Removing and installing oil cooler  Engine removed.................................................................510
Removing oil cooler.............................................................................................................................510
Installing oil cooler..............................................................................................................................511
17 52 19 Removing and installing oil container............................................................................................514
Removing oil container − removal overview......................................................................................514
Installing oil container.........................................................................................................................517
19 38 17 Draining and filling in coolant........................................................................................................520
Draining coolant...................................................................................................................................521
Filling in coolant..................................................................................................................................521
Bleeding the cooling system................................................................................................................521
19 40 19 Removing and installing coolant expansion tank..........................................................................523
Removal...............................................................................................................................................523
Installation...........................................................................................................................................527
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Table of Contents
19 50 19 Removing and installing coolant pump (engine installed)...........................................................529
Tools....................................................................................................................................................529
Removal...............................................................................................................................................529
Installation...........................................................................................................................................534
19 62 19 Removing and installing coolant hose at front left (Y−type coolant distributor)......................538
Tools....................................................................................................................................................538
Removal...............................................................................................................................................538
Installation...........................................................................................................................................540
20 02 01 Checking fuel pressure....................................................................................................................543
20 10 19 Removing and installing fuel tank..................................................................................................546
Removing fuel tank..............................................................................................................................548
Installing fuel tank...............................................................................................................................553
Tightening torques for front axle and fuel tank.............................................................................557
20 15 01 Calibrating fuel level sensor system...............................................................................................559
20 39 19 Removing and installing fuel return line.......................................................................................560
Removal...............................................................................................................................................560
Installation...........................................................................................................................................561
20 60 55 Replacing fuel filter..........................................................................................................................563
Removing fuel filter.............................................................................................................................563
20 66 01 Checking quantity delivered by fuel pump...................................................................................568
20 68 19 Removing and installing fuel cooler...............................................................................................571
Removing fuel cooler...........................................................................................................................571
Installing fuel cooler............................................................................................................................572
21 10 19 Removing and installing air guide for charge air cooling............................................................573
Removing air guide for charge air cooling..........................................................................................573
Installing air guide for charge air cooling............................................................................................575
21 30 19 Removing and installing turbocharger..........................................................................................577
Removing turbocharger.......................................................................................................................577
Installing turbocharger.........................................................................................................................579
21 43 19 Removing and installing the charge air cooler..............................................................................583
Removing the charge air cooler...........................................................................................................583
Installing the charge air cooler.............................................................................................................584
21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger.............................585
Check and adjust (cylinder bank 1 − 3)...............................................................................................585
Test................................................................................................................................................585
Adjusting.......................................................................................................................................586
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