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TechnicalManual .9 ..1'..1' ~"7~"I:::z:
(9 9 6 )
Technical Information
Contents: Group 1 Engine Part 1 (up to Repair Group 13)
WKD483 721
TITEL.CHP
www.WorkshopManuals.co.uk 911 Carrera
(996)
Group 0:
Overview of repair groups
Entire vehicle -General Salescheck Maintenance
Group 0:
0 03
Diagnosis On-boarddiagnosis DMEdiagnosis Tiptronicdiagnosis ABSdiagnosis
Group 0:
Group 1:
Group 1:
Group 2:
24 37 45
Diagnosis
0
Convertible-topdiagnosis Airbag diagnosis Rol~overprotection system diagnosis Seat memory diagnosis Heatingdiagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
61 69 69 72
1 10
in Germany
-35,
13
Engine
1
Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
15
Fuel, exhaust, engine electronics
2 20
manual transmission
17
19
21 24 25
26
27 28
3
Clutch,control Manualtransmission-Actuation, housing Manualtransmission-Gears, shafts, intogearsh Final drive, differential,differential lock
30 34 35
Transmission, automatic transmission
3
Torqueconverter
32
Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differential lock
37 38
Overview of repair groups Printed
90 91 91 94
Engine
Transmission,
Group 3:
80
Engine-Crankcase, suspension Engine-Crankshaft, pistons
Fuel supply, control Exhaustsystem, turbocharging Fuel system, electronic injection Fuel system, K-Jetronic Exhaustsystem Starter, power supply, cruise control Ignition system
Group 3:
0 01 03
October
1999
REPGRU.CHP
39
39
www.WorkshopManuals.co.uk Overview of repair groups
Group 4:
Group 5:
Group 6:
Group 7:
Group 8:
911 Carrera
Running gear
4
Front wheel suspension,drive shafts Rear wheel suspension,drive shafts Wheels, tires, suspensionalignment Anti-LockBrake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
40 42 44
45 46 47 48
Body
5
Body front Body center, roof, frame Body rear Lids, flaps Door front, central locking system
50 51 53 55 57
6
Body equipment, exterior Slidingroof Convertible top, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
60 61 63 64
66
68 69
7
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers Air
70 72
74
8
conditioning
80
Heating Ventilation Air conditioning Auxiliary air conditioning system
Group 9
Group 9: Group 9:
(996)
85 87
88
Electrics
9
Instruments, alarm system Radio, telephone, on-board computer, navigation Windshield wiper and washer system Lights, lamps, switches exterior Lights, lamps, switches interior, theft protection
90 91 92 94
96
Circuit diagrams
9
Wiring (up to and includingthe '99 model)
97
Circuit diagrams
9
Wiring(fromthe '00 model)
97
Overview of repair groups REPGRU.CHP
Printed in Germany. 35, October 1999
8
www.WorkshopManuals.co.uk 911 Carrera
(996)
Table of Contents
1
Engine, pari 1 (up to Repair Group 13)
1
Engine
Tighteningtorquesfor engineM96/01 3.4 I engineperformancekit / X51 ..
10
Engine
100119 100137 101037 100119 100137 101037 102021
13
132023 1326 23
and
Disassembling Removing Disassembling Disassembling Removingcylinder-GT3
and
installing
engine
installing and and
assembling assembling
(vehicle
engine
with
engine crankcase engine. crankcase -GT3
Tiptronic
-GT3
7
10- 1 10- 9 10-51
transmission)
halves. -GT3
10 -57
10-69 10 -201
10-225
-Crankshaft,
Removing Disassembling Removing
and and
Disassembling
pistons
installing installing and
assembling
and
Removing
tensioning deflection drive belt
tensioner belt.
assembling
and
installing installing
pistons and
installing installing and and
belt
rollers roller tensioner.
bearing
crankshaft
for for
drive drive
housing
sealing sealing
belt.belt.
with
ring ring.
,
crankshaft.
-Engine
.
installed
13- 1 13- 5 13- 7 13- 9 13-19 13-23 13-33 13 -39
Disassembling Removing Installing
-GT3
assembling
pistons. drive pistons '.""""""""."
belt
crankshaft belt -GT3 -GT3 tensioner
-GT3
13-41 13-69
-GT3
13 -79
13-201 13-209 13-213 Installing
piston
pin
with
piston-pin
circlip
-GT3
-39,
2000
""..'"
13 -220
1
Engine, part 1 (up to Repair Group 13)
Printed in Germany
1
1
suspension
Removing
Engine
137819 137720 138219 137319 137337 134937 137419 135919 131019 137819 137337 134837 131019
1
-Crankcase,
1
996TOC
www.WorkshopManuals.co.uk 911 Carrera (996)
1
Engine
Tightening torques for engine M96/01
Crankshaft, bearing housing, crankcase
Screws, bearing housing Initial tightening:
M9 x 129
25 (19)
Final tightening:
1 x 900 turn
M9 x 1.25
Connecting-rod screws
20 (15) 1 x 900 turn
Initial tightening: Final tightening:
Oil guideon bearinghousing
M6 (micro-encaps.)
10 (7.5)
crankcase halves
M6
13 (10.0)
Additionalbolts,
M9 x 160 M9 x 95
22 (16)
M6
10 (7.5)
crankcase
M6
10 (7.5)
Oil pan to crankcase
M6
10 (7.5)
to oil pan
MIa x 1.5
50 (37)
Oil filter to crankcase
S80 x 3
25:t 1 (19:t 1)
to crankcase
MID
45 (33)
Coolantdrain plug
MID x 1
10 + 5 (7.5 + 3.5)
Screw plug for oil relief valve
M20 x 1.5
25 (19)
Screwsfor joining
crankcase/bearing
housing
Oil suction pipe to crankcase
22 (16)
Air/oil separator to
Oil drain plug
Coolantguidehousing
1
Tightening
Printed
in Germany
1 -1
torques for engine M96jOl -23,
1999
9961_1
www.WorkshopManuals.co.uk
Intermediateshaftflange to crankcase
M6 (micro-encaps.
10 (7.5)
Lock nut on intermediate shaft flange
M8 xl
13 (10.0) or 11 (8.0) if
special tool 9110 is used Screw plug for piston pin assembly bore on cylinder bank 4 -6
M27x 2
80 (59)
Engine carrier to engine
MID
46 (34)
Bolt for guide rail
M6
10 (7.5)
Pulleyto
crankshaft
M16 x 15
Initial tightening: Finaltightening:
50 (37) 1 x 900 turn
Double-massflywheel to crankshaft
MI0 x 1 x 50 (12.9)
Initial tightening: Finaltightening:
25 (19) 1 x 900 turn
Thrust plate to double-mass flywheel
M8
23 (17)
Drive plate on crankshaft (Tiptronic) Initial tightening:
MIa x 1 x 25 (12.9) 25 (19)
Final tightening:
1 x 900 turn
Water pump to
crankcase
M6
10 (7.5)
crankcase
M27 x 2
80 (59)
Belt tensioner roller on lever for tensioning element
MID
60 (44)
Chain tensioner to
1
1 -2 9961_1
Tightening
torques for engine M96jOl Printed
in Germany
-23,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Location
Thread
Tightening torque Nm (ftlb.)
MIa x 145 (10.9) MIa x 145 (8.8)
65 (48)
to bracket for hydraulic pump
M8 x 55
23 (17)
Belt pulleyto generator
M16 x 1.5
65 :t 5 (48 :t 3.5)
Belt pulleyto hydraulicpump
M8 x 12
23 (17)
Belt deflection roller 1 to crankcase
46 (34)
Belt deflection roller 2
8
.
1
Tightening
Printed
in Germany
torques -13,
1 -3
for engine M96jOl
1998
9961_1
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Cylinder head
Cylinderhead to crankcase Initial tightening tightening
MIO x 230
or
to flatten
1 st step 2nd step:
30 (22)
Cylinderhead screws completelyundone
Final tightening 1 st step 2nd step 3rd step
20 ( 15)
600 turn 600 turn
Flat-base tappet housing to cylinder head
M6
10 (7.5)
Camshaftbearing saddles to cylinder head
M6
10 (7.5)
Cylinder-headcover to cylinder head
M6
13 (10.0)
Sparkplugs
M14 x 1.25
30 (22) + 3 (2.0) first fitting 25 (19) + 5 (3.5) re-fitting
drive plate to camshaft
M6 x 15 (10.9)
14 (10.5)
Chaintensionerto cylinderhead
M27x 2
80 (59)
Intake pipe to cylinder head
M6 (micro-encaps.)
9.7 (7.0)
Plug, oil-pressureduct to cylinder head
MID x 1
10 (7.5)
M6
10 (7.5)
Camshaft drive pinion and
Oil return pump to cylinder head
1
1 -4
9961_1
Tightening
torques for engine M96jOl Printed in Germany -13, 1998
www.WorkshopManuals.co.uk
Accessories sensors, sending units, switches and ancillaries
Oil~evelsender to crankcase
M14 x .25
max. 20 (15)
Oxygen sensor to catalytic converter
MI8
55 :t 5 (41 :t 3.5)
Knocksensor
M8
20:f: 2 (15 :f: 1.5)
Hall sender
M6 (micro-encaps,
10:1:0.5(7.5:1:0.5)
Speed sender
M6 (micro-encaps
10 :t 0.5 (7.5 :t 0.5)
coolaht temperature
M14 x 1.5
25 :t 5 (19 :t 3.5)
Oil-pressure switch
M14 x 1.5
25 :t 5 (19 :t 3.5)
Starter
MID
45 (33)
Generator
MID
45 (33)
Igniti~n coil to cylinder head'cover
M6
10 (7.5)
M8
23 (17)
M16
24 (18)
power steering pump
M8
23 (17)
Check valve for auxiliaryair pump
M22 x 1.5
32 (24)
M6
10 (7.5)
NTC
I
Power steering pump (hydraulic pump) to bracket
Pressure pipe to power steering pump Oil reservoir to
Coolantpump to
crankcase
1
Tightening torques for engine M96jOl
Printed in Germany -23,
1999
1 -5 9961_1
www.WorkshopManuals.co.uk 911 Carrera (996)
3.4
1
Engine
engine performance kit / X51 (not for USA vehicles)
Foreword The f~ "OWingchapter describes a performance kit for the 911 Carrera(996). A characteristic of the new engin is its continuouspower development,particularlyat higher engine speedsabove 5,000 rpm. The only hangesare modificationsto the engine. Technical data Engine
911 Carrera (996)
X51
Engin~type
M96/01
M 96/01 S
Numb~r of cylinders
6
6
Bore
mm
96
96
Strok~
mm
78
78
Displ~cement
cm3
3,387
3,387
11.3
11.3 1
Compressionratio Max. ~ngine power
kW (HP)
221 (300)
235 (320)
at en&inespeed
rpm
6,800
6,600
Max.1orque
Nm (ftlb.)
350 (259)
360 (266)
at en~ine speed
rpm
4,600
5,000
Max. Ilitre output
kW (HP;1)
63.8 (86.8)
66.4 (94.5)
Engint speed limitation by fuel c toft at
rpm
7,300
7,400
Idle sweed
rpm
700
800
Top speed
km/h
280
287
1
3.4 I engine performance kit / X51 (not for USA vehicles)
Printed in Germany -29,
1999
9961_7
1 -7
www.WorkshopManuals.co.uk Engine
911 Carrera (996)
Differences
22_99
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Differences Item 1
Pistons
Item 2
Inlet camshafts and exhaust camshafts
Item ~
Valve discs, valve springs,
Item 4
Valves, valve caps
Item 5
Dual-chamber
Item 6
Oil suction pipe
1
valve guides, valve seats
suction pump at cylinder
3.4 I engine performance kit / X51
Printed in Germany -21, 1999
bank 4 -6
1 -9 9961_7
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I~l
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Differences
12
10
9 7
8 608_98
8 1
1-10 9961_7
3.4 I engine performance kit / X51 Printed in Germany
-21,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Differences Item 7
Oil pan with partition box
Item 8
Gasket for exhaust manifolds
Item 9
Exhaust manifolds
Item 10
Suction line on A/C compressor
Item 11
Intake pipes
Item 12
Intake distributors
1
1-11
3.4 I engine performance kit / X51
Printed
in Germany
-21,
1999
9961_7
.
.. -.1 ~ 1..-
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Differences Item 1
Pistons The valve recesses were mechanicallyadjusted to provide clearancefor the exhaustvalves. (Arrows.)
@
603_98
Camshafts
further to Item 2
-~ ---u--~1:;:::JI::'!i~~~~
[
...'
The inlet camshafts and exhaustcamshafts possess a greater cam stroke. Camshafts
of cylinder
bank 1 -3
Identificationon the camshaft
lL i 996.00
Inletcamshaft: Exhaustcamshaft:
991.003,4
L/KIT IN 1-3
996.00 3,4 L/KIT IN 1-3
605_98
further to Item 2
Camshafts
of cylinder
bank 4 -6
Identification on the camshaft
Q2~~~!~~~~~~~ w
iI
Inletcamshaft: Exhaustcamshaft:
992.00 3,4 L/KITIN 4-6 997.00 3,4 L/KITIN 4-6
L ~
997.00,
606_98
1
1-12 9961_7
3.4 I engine performance kit / X51 Printed in Germany. 21, 1999
8
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine
Differences Item 3
Valve discs, valve springs The following parts distinguishthe higher-performance enginefrom the standard engine in the area of the cylinder head: 1. Valve keys (standard part) 2. Valvedisc at top 3. Valvespring on outside 4. Valvespring on inside 5. Valve seal (standardpart) 6. Valvedisc at bottom 7. Valveguides 8. Cylinderhead 9. Valveseats The valve seats are additionallyprovided with a seat surface of 60°, 21_99
further to Item 3
Valve guides The valve guides were shortened in the area of the inlet and outlet ducts.
2O_99
further to Item 3
Cylinder head The cylinder heads already have a reduced height. Subsequentmachiningof the sealing surface is therefore not permissible.
19_99
1
1-13
3.4 I engine performance kit / X51
Printed
in Germany
-21,
1999
9961_7
www.WorkshopManuals.co.uk 911 Carrera
Engine
(996)
Differences Item 4
Valves Dependingon the time of assembly,the engines of the X51 are equippedwith two different valveversions.
59o_98
further
Valves
to Item 4 [::]
[:]
Version 1:
Q
Inlet valve (standard)and exhaustvalve (standard)are additionallyequippedwith valve caps.
17_99
Valves
further to Item 4
Version 2: (Introducedin December '98) Inlet and exhaustvalves lengthenedby 1.5 mm. Valve caps were omitted after introduction of the valves (version 2). The valve caps will remain in stock as replacementparts for the shorter standard valves of the 911 Carrera(996). Identification of inlet valve: Yellow dot on the valve disc Identification of exhaust valve: Black dot on valve disc 18_99
1
1-14 9961_7
3.4 I engine performance kit / X51 Printed in Germany -21, 1999