2003 Porsche 911-996 Service Repair Manual

www.WorkshopManuals.co.uk

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

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

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

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

www.WorkshopManuals.co.uk 911 Carrera (996)

Engine

Differences Item 5

Dual-chamber suction pump A dual-chambersuction pump, which is sealed with two sealing rings, is fitted on the cylinder head of cylinder bank 4 -6.

The M6 x 30 fastening screws (4 ea.) are fitted with Loctite 242 or 243.

592_98

Item 6

Oil suction pipe

The oil suction pipe is fitted between the dual-chamber suction pump and the cylinder head cover.

The rear M6 x 40 fastening screw is fitted with Loctite 242 or 243.

597_98

further

Oil suction pipe

to Item 6

A take-upbore for the oil suction pipe was added on the cylinder head cover of cylinder bank 4 -6.

595_98

1

1-15

3.4 I engine performance kit / X51

Printed

in Germany

-21,

1999

9961_7

1

www.WorkshopManuals.co.uk 911 Carrera (996)

Engine

Differences fur1her to Item 6

Oil suction pipe Oil suction pipe on cylinder head.

596_98

Shield

Item 6

The shield was modified accordinglyin the area of the oil suction pipe.

604_98

Item 7

Oil pan with partition box The partition box was redesignedand consists of metal {aluminiumsheetmetal}.The standard parts consist of plastic.

601_98

1

1 -16 9961_7

3.4 I engine performance kit / X51 Printed

in Germany

-21,

1999