Porsche 911 CARRERA 4 - Manuel utilisateur

TechnicalManual

9ff Ca; :7~-a: (996)

TechnicalInformation

Contents:

WKD483 721

www.WorkshopManuals.co.uk

Foreword

Theworkshopdocumentationfor the 911 Carrera(996)modelhasthe designation

"911 Carrera (996)" Technical Manual

andcontainsTechnical Information aswell as instructionson Repairs.

The integrationof the technicalinformationpublishedin the"911 Carrera (996)"Tec~nicalManualwith

the instructionson repairsprovidesthe userwitha complexreferencework thatconPbinesinto onebook

associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrpmvarious informa-

tion media.

The"911 Carrera(996)"TechnicalManualconsists of 15 folders,subdividedintothe followingGroups

0 Entirevehicle-General

0 Diagnosis,part 1 (upto RepairGroup45) .1

0 Diagnosis,part 2 (asof RepairGroup61) .2

1 Engine,part 1 (upto RepairGroup 13) .3

1 Engine,part 2 (asof RepairGroup 15) .4

2 Fuel,exhaust,engineelectronics

3 Transmission,manualtransmission

3 Transmission,automatictransmission

4 Runninggear

5 Body

6 Bodyequipment,exterior

7 Bodyequipment,interior

8 / 9 Air conditioning/ Electrics

9 Circuitdiagrams,part 1 (upto and includingthe '99 mod I) .5

9 Circuitdiagrams,part 2 (as of the '00 model).6

*1 Thetwo folderswith Group0 are to be regardedas one folder; i.e. file the "Tfchnicallnformation'

notices onlyin front of the repairdescriptionsin the folder "Group0 -Diagno~is, part 1"

(up to Repair Group 45). I

..2 Thesecond folder "Group0 -Diagnosis, part 2" (as of Repair Group 61) ircludesthe further

RepairGroupsbelongingto GroupO.

*3 ThetwofolderswithGroup1 areto beregardedasonefolder;i.e.filethe"Tfchnicallnformation"

noticesonlyinfrontoftherepairdescriptionsinthefolder"Group1 -Engine,lpart1"

(up to Repair Group 13). I

*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) incl~desthe further Repair

Groupsbelongingto Group1. I

VORW.CHP

Foreword

Printed in Germany -35, October 1999

www.WorkshopManuals.co.uk

.5 Thetwo folderswith Group9 are to be regardedas one folder;i.e. file the "Technifallnformation"

notices onlyin front of the repairdescriptionsin the folder "Group9 -Circuit diagr+ms,part I" (up to

and including the '99 model). :

*6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further

circuit diagramsbelongingto Group9.

The"911 Carrera (996)"TechnicalManualhasthe samestructure in each folder,withthe following break-

downfor all Groups:

Title page: "911 Carrera (996)" Technical Manual

> Foreword

Title page: "Technical Information"

> Table of Contents,Technicalinformation

> Technicalinformation

TiUe page: "Repair"

> RepairGroups:overview

> Table of Contents,repairs

> General/technical data

> Instructionson repairs

Ascanbeseenfromthe breakdown,thepublishedTechnicalInformationis inthefrontpa~ ofeachfol-

der-numberedaccordingto theGroups.TheTableofContentsassignedto eachGroup~ill be peri-

odically updated. I

Followingthe TechnicalInformation,separatedby a title page,the instructionson repairsi assigned

accordingto the Groupsor brokendowninto RepairGroups-are includedin thefolders. I

Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.

Note

Sheetsthat alreadyexistin the"911 Carrera(996)"TechnicalManualand are updatedor feVisedand therebyexchangedby a supplementare designated"replacementsheet".Revisionsor technical

modificationson pages of these replacementsheetsare identifiedfor the userwith a verti al bar at

themargin.

Foreword

Printed in Germany -35, October 1999

VORW.CHP

www.WorkshopManuals.co.uk

*5 Thetwo folderswith Group9 areto be regardedas one folder; i.e. file the "TechnicalInformation"

notices onlyin front of the repairdescriptionsin the folder "Group9 -Circuit diagrams,part 1" (up to

and includingthe '99 model).

.6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further

circuitdiagramsbelongingto Group9.

The"911 Carrera(996)"TechnicalManualhasthe samestructure in each folder,with the followingbreak-

downfor all Groups:

Title page: "911 Carrera (996)" Technical Manual

> Foreword

Title page: "Technical Information"

> Tableof Contents,Technicalinformation

> Technicalinformation

Title page: "Repair"

> RepairGroups:overview

> Table of Contents,repairs

> General/technical data

> Instructionson repairs

As can be seenfrom the breakdown,the publishedTechnicalInformationis in the front part of each fol-

der -numbered accordingto the Groups.TheTableof Contentsassignedto eachGroupwill be peri-

odicallyupdated.

Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned

accordingto the Groupsor brokendowninto RepairGroups-are includedin the folders.

Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.

Note

Sheetsthat alreadyexist in the"911 Carrera (996)"TechnicalManualand are updatedor revised

and therebyexchangedbya supplementare designated"replacementsheet",Revisionsor technical

modificationson pages of these replacementsheetsare identifiedfor the userwith a vertical bar at

themargin.

www.WorkshopManuals.co.uk

911 Carrera (996) Overview of repair groups

Group 0: Entire vehicle -General

Salescheck

Maintenance

Group 0: Diagnosis

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: 0

Diagnosis

Convertible-topdiagnosis

Airbagdiagnosis

Roll-overprotectionsystemdiagnosis

Seatmemorydiagnosis

Heatingdiagnosis

Alarmsystem diagnosis

PCMdiagnosis

ParkAssistentdiagnosis

HBAdiagnosis

Group 1: 1

Engine

Engine-Crankcase, suspension

Engine-Crankshaft, pistons

Group 1: 1

Engine

Engine-Cylinder head,valvedrive

Engine-Lubrication

Engine-Cooling

Group 2: 2

Fuel, exhaust, engine electronics

Fuelsupply,control

Exhaustsystem,turbocharging

Fuelsystem,electronicinjection

Fuelsystem,K-Jetronic

Exhaustsystem

Starter,powersupply,cruisecontrol

Ignitionsystem

Group 3: 3

Transmission, manual transmission

Clutch,control

Manualtransmission-Actuation, housing

Manualtransmission-Gears, shafts,intogearsh.

Finaldrive, differential,differentiallock

Group 3: 3

Transmission, automatic transmission

Torqueconverter

Automatictransmission-Actuation, housing

Automatictransmission-Gears, control

Finaldrive,differential,differentiallock

Overview of repair groups

Printed in Germany -35, October 1999 REPGRU.CHP

www.WorkshopManuals.co.uk

Overview of repair groups 911 Carrera (996)

Group 4: 4

Running gear

Front wheel suspension, drive shafts

Rear wheel suspension, drive shafts

Wheels, tires, suspension alignment

Anti-Lock Brake System (ABS)

Brakes -Brake mechanics

Brakes -Hydraulics, regulator, booster

Steering

Group 5: 5

Body

Bodyfront

Bodycenter, roof, frame

Bodyrear

Lids,flaps

Door front, centrallockingsystem

Group 6: 6

Body equipment, exterior

Slidingroof

Convertibletop, hardtop

Bumpers

Glazing,windowcontrol

Exterior equipment

Interior equipment

Passengerprotection

Body equipment, interior

Linings,insulation

Seatframes

Seatupholsteries,covers

Group 7:

Group 8: Air conditioning

Heating

Ventilation

Air conditioning

Auxiliaryair conditioningsystem

Group 9 Electrics

Instruments,alarmsystem

Radio,telephone,on-boardcomputer,navigation

Windshieldwiper andwashersystem

Lights, lamps,switchesexterior

Lights, lamps,switchesinterior,theft protection

Group 9: Circuit diagrams

Wiring(upto andincludingthe'99 model)

Group 9: Circuit diagrams

Wiring(fromthe '00 model)

Overview of repair groups

Printed in Germany -35, October 1999

REPGRU.CHP

www.WorkshopManuals.co.uk

911 Carrera (996) Table of Contents

4Running gear

4 -

Running gear

Running gear -Overview: 911 Carrera (996)StabiliserallocationRemoving spring strut locking devices -Carrera and GT3

Running gear, general -GT3Notes on repair instructions -GT3Testsjnotes-GT3

40-

Front wheel suspension, drive shafts

Tightening torques for front axle.Removing and installing front spring strut.Removing and installing front spring strut -GT3 ...

Disassembling and assembling front spring strut. ..

Disassembling and assembling front spring strut -GT3

Removing and installing front wheel bearing.Installing caster eccentric.

427119

42 58 19

4209 19

425219

422119

42- 1

42- 5

42- 7

42 -14a

42-15

42 -21

42-23

42-31

42 -37

Rear wheel suspension, drive shafts

Tightening torques for rear axle.Removing and installing rear spring strut.Disassembling and assembling rear spring strut.Disassembling and assembling rear spring strut -GT3Removing and installing rear wheel bearing.Removing and installing rear tie rod (toe control arm)Removing and installing rear wheel bearing housing (wheel carrier)

Removing and installing drive shaft (manual transmission)Removing and installing drive shaft (Tiptronic transmission)

Wheels, tires, suspension alignment

Wheels and tyres (tyre pressure/mounting wheel on vehicle)

Adjustment values for suspension alignment.Alignment cards for Carrera (996) and GT3Complete suspension alignment.Suspension alignment GT3General tyre mounting instructions.Checking rims ,

44-

4 Running gear

Printed in Germany -39, 2000 996TOC

85 19

5719

1923

12a

16a

.17

.21

www.WorkshopManuals.co.uk

Table of Contents 911 Carrera (996)

Identifyingsizefor 18~nchTurbowheels(Technologiewheels)

Tyrefailure/lyre sealant-GT3Tyre mountingfor critical wheels/lyre pairs. 44 -23

44-25

44 -27

451119

451519

Anti-lock Brake System (ABS)

Important information on ABS 5.3 and ABS/TC 5.3 ..

ABS 5.3 system description.ABS/TC 5.3 system description.Component arrangement (ABS and ABS/TC).Function of individual components.ABS test with Porsche System Tester 2.Removing and installing front speed sensor.Removing and installing rear speed sensor.

46 36 20

46 38 20

461115

46 83 16

4650 19

4653 19

46 83 20

46 50 04

46 53 04

4605 19

..46 -1

..46 -3

..46 -4a

..46 -5

..46 -7

..46 -9

..46 -11

..46 -13

..46 -15

..46-17

..46 -19

..46 -21

..46 -23

..46 -25

..46 -29

Brakes -Brake mechanics

Tightening torques for brake mechanics. ...

Technical data (brake disc wear limit)Technical data (brake disc wear limit) -GT3 .

Measuring brake pad thickness.Removing and installing front disc brake pads.

Removing and installing rear disc brake pads.

Adjusting brake pushrodChecking brake~ight switch setting.Adjusting parking brake shoes.Removing and installing front brake disc. ..

Removing and installing rear brake disc. ...

Removing and installing parking brake shoes.

Measuring lateral run-out of front brake discs.

Measuring lateral run-out of rear brake discs.

Removing and installing brake pedal.

4701 07

4708 55

Brakes -Hydraulics, regulator, booster

Tighteningtorquesfor brakehydraulics. .

BleedingbrakesChangingbrakefluid.

4 Running gear

Printed in Germany -39, 2000

2996TOC

www.WorkshopManuals.co.uk

911 Carrera (996) Table of Contents

48.

48-

48.

48-

Steering

Tightening torques for steering.Test and assembly work on power steering. .

Removing and installing steering wheel (airbag) .

Replacing steering system after accident damage

Removing and installing steering gear.Plug~n couplings for steering hydraulics. ...

Removing and installing lock barrel.Replacing steering lock.Removing and installing hydraulic pump. ...

4 Running gear

Printed in Germany -39, 2000 996TOC

.3 5

9.13

www.WorkshopManuals.co.uk

911 Carrera (996) Running gear

4Overview of 911 Carrera (996) running gear

Front axle / steering

McPhersonwheelsuspensionwith offset spring.Twin-tubegas-filledshock absorbersin standardor

sportsversion.

Inorder to obtaingreater stiffnesswith reducedintrinsicweight ascomparedwith steel,the following

componentshavebeenmadefrom aluminium:

Control arms,diagonalbrace,track rod, wheelcarrier andcross member/ side member.

Rack-and-pinionsteeringgear (i = 16.9 : 1) withhydraulicassistance.

Steering wheel longitudinally adjustable (40 mm).

Further improvement of steering precision and reduction in the turning circle (10.6 m) as com-

pared with the previous 911 Carrera (993).

\'...

~-~

386 -97

4 Overview of 911 Carrera (996) running gear

Printed in Germany, 1997 9964_1

4 -1

www.WorkshopManuals.co.uk

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