Porsche 911 Carrera (Type 996) Service Manual: 1999-2005 - Complete Index | Transmission (Mechanics) | Manual Transmission

INDEX

WARNING
Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual. Airbag system (SRS) 02-18, 69-4 components 69-4 control module 69-4, 69-6, 69-11 crash sensor 69-13 deployment 69-5 driver airbag 69-14 contact spring 69-15 front seat belt buckle 69-8 front seat belt reel 69-7 inspecting 03-38 passenger airbag 69-5 rear seat belt buckle 69-10 rear seat belt reel 69-9 repairs 69-11 replacement recommendations 69-6 seat occupancy sensor 69-4, 69-5 side impact (door) airbag 69-19 smart 69-5 warning light 69-6 Air flow flap 87-2, 87-8 Air flow sensor 24-12 Alarm 96-5, 96-8 see also Anti-theft system Alignment 44-2 specifictions 44-3 Alternator (generator) 27-12 charging system 27-12 removing and installing 27-12 troubleshooting 27-3, 27-12 Amplifier 91-5 Antenna 91-4 Anti-theft system alarm 96-5, 96-8 components 96-4 electronic immobilizer 96-7 electronic immobilizer codes 96-7 electronic immobilizer control module 96-11 electronic immobilizer signal converter 96-10 LED 96-9 passenger compartment monitor 96-9 vehicle key 96-6 vehicle security 96-4 Antifreeze (engine coolant) 03-23, 19-1

1

Antilock brakes (ABS) ABS 45-2, 45-3 ABS/TC 45-2, 45-4 control switch 45-8 component descriptions 45-6 hydraulic unit / control module 45-6, 45-10 identification 45-2 wheel speed sensors 45-8, 45-9 see also Brakes see also Porsche Stability Management (PSM) ATF (automatic transmission fluid) 03-27, 37-5, 37-9 Automatic transmission 37-1 applications 02-12, 37-2 electrical components 37-4 fluid 03-27 cooler 37-24, 37-25 fluid and filter change to 2001 37-5 from 2002 37-9 gear position switch 37-27 gear ratios 37-2 installing 10-15, 37-14, 37-21 removing 10-3, 37-14, 37-21 removing / installing 37-14, 37-21 separating and rejoining 10-20 service 37-5 shift knob 37-26 shift cable 37-26 tiptronic basics 37-1 torque converter 32-1 Axle joint 03-35, 40-19, 42-19

A
A-pillar trim 70-4 Abbreviations and acronyms EWD-6 ABS (antilock brakes) see Antilock brakes (ABS) see also Brakes see also Porsche Stability Management (PSM) A/C blower 87-9 resistor 87-10 capacities 87-3 compressor 87-11 components 87-2, 87-8 condenser 19-8, 87-8 control panel 87-1 evaporator 87-2, 87-7, 87-8 fault detection 87-7 housing 87-2 refrigerant 87-3 sensor default values 87-6 troubleshooting 87-6 vent flaps and motors 87-2, 87-8 see also Heater Accelerator linkage see Throttle cable Aerodynamic lift 02-17 Air-conditioning see A/C see also Heater Air-oil separator 17-13 Air filter replacing 03-29

B
Badges see Emblems B-pillar trim 70-5 Back-up light switch manual transmission 34-8 Battery 27-5 charging 27-6 disconnection notes 03-40, 27-2 hydrometer test 27-7 jump starting 03-3 load voltage test 27-8 maintenance 03-3, 03-39, 03-40, 27-6 open circuit-voltage test 27-8 removing / installing 27-5 service 03-39 testing 27-7 troubleshooting 27-3

2

INDEX
Bearing, wheel front 40-12 rear 42-15 Belt, drive 03-28, 13-1, 48-18 Blade, wiper 92-2 Blower see A/C Body 02-17, 03-40 dimensions 02-17 door check strap, lubricating 03-41 front lid safety hook, checking 03-42 maintenance 03-38 Brake fluid 03-24, 03-25, 47-3 Brake light switch 45-6, 94-8 Brake pressure sensor 45-6 Brakes 02-23 bleeding 47-3 booster 47-7 caliper 47-8 fluid 03-24, 03-25, 47-3 master cylinder 47-5 pads 03-33, 46-2 parking brake 03-43, 46-7, 46-8 rotor 03-33, 46-2, 46-4 troubleshooting 47-2 Antilock brakes (ABS) Porsche Stability Management (PSM) Bulb applications exterior 94-4 instrument 90-11 interior 96-1 Bumper front 63-2 front bumper components 63-2 front bumper cover 63-3 front bumper removing and installing 63-5 rear 63-7 rear bumper components 63-7 rear bumper cover 63-8 rear bumper removing and installing 63-9 Caliper, brake 47-8 Camber 44-3 Camshaft assembly 15-28, 15-52 installing and timing (3.6 liter engine) 15-61 removing (3.6 liter engine) 15-57 timing, adjusting (3.4 liter engine) 15-32 Camshaft adjuster VarioCam solenoid removing and installing 15-53 Camshaft chain 15-2 assembly 15-28, 15-52 troubleshooting 15-3 Camshaft sensor removing and installing 28-6 Camshaft timing chain see Camshaft chain Capacities, fluid A/C system 87-3 automatic transmission to 2001 37-5 from 2002 37-10 coolant 19-1 front differential 39-8 manual transmission 03-26 oil 03-21, 17-1 rear differential 39-14, 39-15 windsheidl washer 03-27 Carbon canister, activated 24-2, 24-5 Caster 44-3 Catalytic converter 02-11, 26-4 diagnostic monitor OBD-4 Cautions 00-2 CD changer 91-3 Center brake light 94-17 Center console 70-1 Center driveshaft 39-3 Central locking 96-7 button 96-8 Charging system 27-12 Check Engine Light see MIL (malfunction indication light) Climate control see A/C see also Heater Clock 90-7 Clock setting 90-7 Clutch 30-1 assembly 30-2, 30-8 bleeding 30-8 checking 03-41 fluid 30-7 hydraulics 30-7 interlock switch 30-6 master cylinder 30-9 mechanical 30-2 replacing 30-3 slave cylinder 30-9 throw-out bearing 30-2, 30-3, 30-6 troubleshooting 30-2 Codes, fault see Diagnostic trouble code (DTC) Coil 28-13 Coil spring see Front suspension see also Rear suspension Communication components 91-1 Component locations 97-4, 97-26 Compressor 87-11 Condenser 19-8, 87-8 Constant velocity (CV) joint 03-35, 40-19, 42-19 Control arm see Front suspension see Rear suspension

C
C-pillar trim 70-6 Cabin microfilter replacing 03-39

INDEX
WARNING
Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual. Cooling system 19-1, 19-14, 19-15 antifreeze 03-23, 19-1 automatic transmission fluid cooler 37-24, 37-25 bleeding 19-12, 19-13 coolant pump 19-15, 19-17 cooling fans 19-6, 19-21, 19-22 cooling hoses 03-31, 19-3, 19-4, 19-5 coolant warning light 90-7 draining 19-11 engine oil cooler 17-6 filling 19-12 flushing 19-14 leak test 19-9 pump 15-15, 19-17 radiator 19-6, 19-7, 19-23 radiator air inlet duct 03-31 reservoir 19-16 thermostat 19-19 testing concentration 19-9 troubleshooting 19-8 warning light 19-8 see also Heater see also Maintenance Coolant thermostat 19-19 Crankshaft pulley 13-1 removing and installing, 13-2 Crankshaft pulley seal removing and installing 13-3 Crankshaft sensor removing and installing 28-12 Crash sensor front 69-4, 69-6 side impact 69-4, 69-13 Cruise control switch 48-4 CV joint 03-35, 40-19, 42-19 Cylinder head 15-2 camshaft chains 15-2 components (3.4 liter engine) 15-4 components (3.6 liter engine) 15-39 intermediate shaft bearing 15-3 removing and installing (3.4 liter engine) 15-13 removing and installing (3.6 liter engine) 15-45 repairs (3.4 liter engine) 15-4 repairs (3.6 liter engine) 15-39 timing, adjusting 15-32 troubleshooting 15-3 Cylinder head cover installing (3.4 liter engine) 15-9 installing (3.6 liter engine) 15-43 removing (3.4 liter engine) 15-5 removing (3.6 liter engine) 15-40

3

D
Deck lid see Trunk lid Diagnosis system 03-20, OBD-1 Diagnostic monitors OBD-3 Diagnostic trouble code (DTC) OBD-6, OBD-7, OBD-16, OBD-28 Differential see also Front differential see also Rear differential DME (digital motor electronics) 02-8, 02-9, 02-10, 02-22, 28-1 adaptation 24-6 applications 02-8, 24-1, 24-2, 24-3 camshaft sensor 28-6 crankshaft sensor 28-12 engine control module (ECM) 24-25 engine coolant temperature (ECT) sensor 24-11, 24-20 evaporative control system 02-22, 24-5 fuel injectors 24-21 FIO (fuel injector / ignition coil / oxygen sensor heater) relay 24-7 intake air housing 24-12 intake manifold 24-26 main relay 20-1, 24-10 mass air flow sensor 24-12 MIL 03-20, OBD-2 oxygen sensor 26-4 secondary air injection 02-11, 24-3, 24-13, 24-14 secondary air pump 24-13 secondary air valve 24-14 system overview 02-11, 24-2 throttle housing 24-13 see also Engine control module (ECM) see also Fuel injector see also Fuel pressure see also Fuel pump see also Ignition system Dome light 96-2

Convertible top 02-19, 61-1, 61-3 components 61-2 emergency closing 61-5 hydraulic pump 61-11 hydraulic system, filling and bleeding 61-12 operation 61-4 opening and closing 61-4 rollover protection system 61-17 rollover protection system 61-17 bars, lowering after deploy bars, lowering after deployment 61-18 function test 61-19 service 61-10 service position 61-10 troubleshooting 61-14 see also Rollover protection system Coolant (antifreeze) 03-23, 19-1 hydrometer 19-9 Coolant pump 19-15, 19-17 Coolant service 19-10

4

INDEX
Door 57-1 adjusting 57-2 central locking button 57-9 check strap, lubricating 03-41 courtesy light bulb 96-2 handle 57-8 lock 57-10 lock cylinder 57-8 lock microswitch 57-9 panel 57-3 removing and installing 57-1 striker 57-7 window see Door window Door glass see Door window Door lock 57-10 Door sill trim 70-9 Door window adjusting 64-2, 64-6 components 64-2 controls 64-3 drop-down feature 64-3 electric window control 64-1 fuse 64-3 glass 64-5 motor 64-10 regulator 64-11 repairs 64-5, 64-10 standardization 64-10 switch 64-4 Double-mass flywheel 30-1 Drains 50-5, 50-6, 50-7 Drive axle see also Front drive axle see also Rear drive axle Drive belt 03-28, 13-1, 48-18 Drive cycle OBD-5 Driveshaft see Center driveshaft DTC (diagnostic trouble code) see Diagnostic trouble code (DTC) Electrical components 97-4 Electric cooling fan 19-6, 19-21 Electrical switches see Switches Electrical system abbreviations and acronyms EWD-6 battery disconnection notes 27-2 component location table 97-4 component photos 97-26 engine 27-1 safety precautions 90-1 terminal designations EWD-5 troubleshooting 97-36 wire color codes EWD-3 Electrical wiring diagrams EWD-9 Electronic immobilizer 96-7, 96-10, 96-11 Emblems 66-3 Emergencies 03-2, 03-9 Emergency brake see Parking brake Emergency flasher 94-7 Engine 02-3 air filter 03-29 ait-oil separator 17-13 applications 1-2, 15-2, 02-3 components 02-4 crankshaft pulley 13-1 removing and installing 13-2 crankshaft seal pulley seal 13-3 rear main seal 13-5 displacement 02-3 drive belt 03-28, 13-1, 48-18 engine coolant temperature (ECT) sensor 24-11, 24-20 grounds 1999-2000 97-16 2001-2005 97-21 identification 24-1 installing 10-15 management see DME (digital motor electronics) mount 10-14, 10-18 oil 03-21, 03-22, 17-1 oil cooler 17-6 oil pan 17-9 oil pump 15-8, 15-22, 17-4, 17-5, 1710 on-board diagnostics OBD-1 overview 1-1 pulley system 13-1 removing 10-3 speed sensor see Crankshaft sensor see also Cooling system see also DME (digital motor electronics) see also Engine control module (ECM) see also Exhaust system see also Ignition system see also Lubrication system spark plugs 03-32 throttle valve, checkng 03-30 troubleshooting 15-3 Engine compartment blower 19-21, 55-5 Engine control module (ECM) 24-25 Engine coolant temperature (ECT) sensor 24-11, 24-20 Engine cooling fan 19-21, 55-5

E
ECM see Engine control module (ECM) ECT see Engine coolant temperature (ECT) sensor

INDEX
WARNING
Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual. Fasteners 03-12 see also Tightening fasteners Fault code see also Diagnostic trouble code (DTC) Fault memory 03-20 Fender front 50-4, 50-5 Filters air 03-29 fuel 03-34, 20-3 oil 03-22 ventilation microfilter 03-39 Firing order 28-1 Floor jack 03-10 Fluids and lubricants 03-21 see also Capacities, fluid Flywheel, dual-mass see Double-mass flywheel Foglight 94-14 Front differential 39-2 center driveshaft 39-3 components 39-6 fluid 39-8 fluid level, checking 39-8 fluid, replacing 39-8 front drive axle flange seal 39-2 removing snd installing 39-6 viscous coupler 39-9, 39-10 Front drive axle removing and installing 40-17 Front lid see Hood Front oil seal 13-5 Front suspension 02-14, 40-1 checking 03-35 components 40-2 diagonal control arm 40-4 ride height 44-3 strut assembly 40-6, 40-7 strut, removing and installing 40-8 stabilizer bar 40-5 tightening torques 03-36 transverse control arm 40-3 wheel bearing 40-12 wheel carrier 40-12 Fuel delvery tests 20-5 Fuel filter 03-34, 20-3 Fule gauge 90-7 fuel level light 90-7 Fuel injection 24-1, 24-21, 02-9 see also DME (digital motor electronics) see also Fuel injector Fuel injector 02-9, 24-21 relay 24-7 Fuel level sender 20-2, 20-8, 20-12 see also Fuel pump Fuel pressure operating fuel pump for tests 20-5, 20-6 pressure test 20-6 regulator 20-2 relieving pressure 20-5 testing 20-6 volume 20-7 see also Fuel pump Fuel pump Carrera 2 1999 - 2001 20-2 Carrera 2 2002 - 2005 20-2 Carrera 4 20-3 fuse and relay 20-1 operating fuel pump for tests 20-5, 20-6 removing / installing 20-8 troubleshooting 20-5 Fuel sending unit calibrating 20-12 removing / installing 20-8 Fuel system 20-1 checking pressure 20-6 checking volume 20-7 diagnostic monitor OBD-4 fuel delivery tests 20-5 sending unit 20-8, 20-12 Fuel tank 20-8 draining 20-8 filler flap 50-2, 50-3

5

Engine hood 55-5 aligning 55-6 components 55-5 emergency engine hood release to 2000 03-6 from 2001 03-8 engine hood release, servicing 55-7 removing and installing 55-6 strut 55-6 Engine identification 24-1 Engine management 24-2, 28-1 see also DME (digital motor electronics) Evaporative control system 24-5 diagnostic monitor OBD-4 Evaporator 87-2, 87-7, 87-8 Exhaust manifold 26-5 Exhaust system 02-11, 26-1, 26-2 catalytic converter 02-11, 26-4 checking 03-38 diagram 26-5 manifold 26-5 muffler 26-2 oxygen sensor 26-4 Exterior lights see Lights

F
Fan A/C blower 87-9 engine compartment blower 19-21 engine cooling fans 19-21, 55-5

Fuel trim see DME (digital motor electronics), adaptation Fuses 97-10, 97-13, 97-14

6
G

INDEX
Ignition system 02-11 camshaft sensor 28-6 checking for spark 28-3 coil 28-13 components 28-2 crankshaft sensor 28-12 disabling 28-2 electrical switch 48-6 firing order 28-1 knock sensor 28-14 relay 24-7 spark plugs 03-32 Immobilizer, electronic 96-7, 96-10, 96-11 IMS bearing see Intermediate shaft (IMS) bearing Indicator lights 03-2 Injector see Fuel injector Instruments 02-21, 90-2, 90-3, 90-4 bulbs 90-11 operation 90-5 repairs 90-9 versions 90-2 warning lights 90-8 Interior seat belts, checking 03-44 see also Trim, Interior Intermediate shaft (IMS) bearing 15-3 removing and installing 15-71 Intake air housing removing and installing 24-12 Intake manifold removing and installing 24-26 Interior lights checking 03-43 see also Lights Intermittent wiper switch 92-4

K
Key 96-6 transmitter battery, replacing 57-12, 96-6 Keyless entry 57-11, 96-6 Knock sensor removing and installing 28-14

Gearshift knob automatic transmission 37-26 manual transmission 34-2 Generator see Alternator (generator) Glove compartment 02-24 Grounds 97-16, 97-20

L
Lateral acceleration sensor 45-7, 45-13 Level sender, fuel 20-8 License plate light 94-19 Lights bulb applications exterior 94-4 instrument 90-11 interior 96-1 controls 94-5 exterior lights, checking 03-43 fuses 94-9 interior 96-1 checking 03-43 repairs front 94-10 rear 94-16 Litronic 02-2, 02-23, 94-2 see also Headlight Locks central locking button 57-9 central locking 96-7 door lock 57-10 door lock cylinder 57-8 door lock microswitch 57-9 keyless entry 57-11 trunk lid release motor 55-3 Lubrication system 17-4 air-oil separator 17-13 oil cooler 17-6 oil 03-21, 03-22 oil filter 03-22 oil level display 17-2 oil level sensor 17-2 oil pan 17-9 oil pumps 15-8, 15-22, 17-4, 17-5, 17-10 Luggage compartment lid see Trunk lid

H
Hand brake see Parking brake Handle, door 57-8 Hazard warning switch 94-7 Headlight 02-21, 02-23, 94-1 adjusting 03-43, 94-10 assembly 94-11 bulb applications 94-4 bulb, repalcing 94-13 controls 94-5 exterior lights, checking 03-43 replacing bulb 94-13 removing and installing 94-11 switch 94-5 troubleshooting 94-3 Heater components 80-2 core 80-4 troubleshooting 80-2 see also A/C see also Cooling system Hood emergnency release 03-6, 03-8 front lid safety hook, checking 03-42 see Trunk lid Horn 90-13 alarm horn 96-5 Hoses see Cooling system

J
Jacking 03-10 Jump starting 03-3

I
Idler pulley 13-2 Ignition lock cylinder 48-8 Ignition electrical switch 48-6

INDEX
WARNING
Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual. tables 03-16 test drive 03-46 throttle valve, checkng 03-30 tires 03-45 under car maintenance 03-31, 03-38 wipers and washers 03-27 Malfunction indication light see MIL (malfunction indication light) Manifold, exhaust 26-5 Manual transmission applications 02-12 , 34-1 back-up light switch 34-8 fluid 03-26 gear ratios 34-2 input shaft seal 34-7 installing 10-15, 34-6 overview 34-1 pilot bearing 30-4 removing 10-3, 34-3 separating and rejoining 10-19 shift knob 34-2 Mass air flow (MAF) sensor 24-12 Master cylinder brake 47-5 clutch 30-9 MIL (malfunction indication light) OBD-2 Mirror, outside rear view 66-1 glass 66-2 heater 66-3 Misfire diagnostic monitor OBD-4 Model year news 02-22 M-option codes 02-29, EWD-7 MOST-bus 02-26, 91-2 MRS (multiple restraint system) see Airbag system (SRS) Muffler 26-2

7

O
OBD (on-board diagnostics) 03-20, OBD-1 Oil cooler 17-6 Oil level checking 03-21 display 17-2 sensor 17-2 Oil pan removing and installing 17-9 Oil pumps 15-8, 15-22, 17-4, 17-5, 17-10 Oil service 03-22, 17-1 On-board computer 90-2, 90-3, 90-4, 90-7, 91-9 On-board diagnostics (OBD II) 03-20, OBD-1 Option codes 02-29, EWD-7 Outside door handle 57-8 Outside mirror switch 66-1 Oxygen sensor 26-4 diagnostic monitor OBD-4 heater relay 24-7

M
Maintenance 03-16, 03-17, 03-18, 03-19 airbags, inspecting 03-38 alignment 44-2 antifreeze 03-23, 19-1 automatic transmission fluid 03-27, 37-5, 37-9 battery 03-3, 03-39, 03-40 body exterior 03-38, 03-40 brake fluid 03-24, 03-25, 47-3 brake pads / rotors 03-33, 46-2, 46-4 clutch, checking 03-41 coolant hoses 03-31, 19-3, 19-4, 19-5 coolant level 03-23 CV joint boot, inspecting 03-35 differential oil 03-27 door check straps, hinges, lubricating 03-41 door locks, checking 03-42 drive belt 03-28, 13-1, 48-18 exhaust system, checking 03-38 exterior lights, checking 03-43 filters air 03-29 fuel 03-34, 20-3 oil 03-22 ventilation microfilter 03-39 fluids and lubricants 03-21 see also Capacities, fluid front differential 39-8 front lid safety hook, checking 03-42 hoses see also Cooling system front lid safety hook, checking 03-42 headlights, adjusting 03-43 interior lights, checking 03-43 manual transmission fluid 03-26 oil 03-21, 03-22, 17-1 parking brake 03-43, 46-7 power steering fluid 03-25 radiator air inlet duct 03-31 rear differential 39-14, 39-16 seat belts, checking 03-44 spark plugs 03-32 suspension and steering components, checking 03-35, 03-36, 03-37

P
P-codes OBD-7 Pads, brake 03-33 46-2 Parking assistant 91-2 Parking brake 46-7 adjusting 03-43, 46-7 shoes, replacing 46-8 switch 45-6 Parking light bulb front 94-15 Parts 03-13 Passenger compartment monitor 96-9 PCM see Porsche Communications Management (PCM)

N
Navigation 91-10 navigation display unit (PCM) 91-11 Neutral safety switch see Automatic transmission, gear position switch

8

INDEX
Pilot bearing 30-4 Pollen microfilter replacing 03-39 Porsche Communications Management (PCM) 02-26, 91-1, 91-4, 91-10, 91-11 Porsche Stability Management (PSM) 02-16, 45-5 control switch 45-8 hydraulic unit / control module 45-6, 45-10 lateral acceleration sensor 45-7, 45-13 precharge pump 45-7, 45-12 rotational rate sensor 45-7 steering angle sensor 45-8, 45-14 wheel speed sensors 45-8 see also Antilock brakes (ABS) see also Brakes Power mirror 66-1 Power steering see Steering Power window see Door window Pre-charge pump 45-7, 45-12 PSM see Porsche Stability Management (PSM) Pulley system 13-1 Rear differential 39-12 fluid 39-14 fluid level, checking 39-14, 39-15 fluid, replacing 39-14, 39-16 rear drive axle flange seal 39-12 Rear drive axle removing and installing 42-18 Rear main seal 13-5 Rear spoiler 02-17, 02-25, 55-10, 5-11, 55-13 drive motor, removing and installing 55-13 manual spoiler control 55-10 removing and installing 55-11 Rear suspension checking 03-35 components 42-2 diagnonal control arm 42-7 ride height 44-4 strut assembly 42-3 strut, removing and installing 42-4 sway bar 42-5 transverse control arm 42-5 tightening torques 03-37 toe control arm 42-7 upper control arm 42-9 wheel bearing 42-15 wheel carrier 42-10 Rear window 02-24, 02-25, 61-3 Receiver-drier 87-11, 87-14 Recirculation switch 87-1 Rotor, brake checking 03-33 removing and installing 46-4

S
Safety 03-9 Scan tool OBD-3 Seal, crankshaft pulley removing and installing 13-3 Seal, rear main removing and installing 13-5 Seat 72-1, 72-3 Seat belt 02-18, 02-24, 69-4 checking 03-44 Seat occupancy sensor 69-4, 69-5 Secondary air injection 02-11, 24-3 secondary air pump 24-13 secondary air valve 24-14 Serpentine belt see Drive belt Service information 03-9, 03-15 Shift knob automatic transmission 37-26 manual transmission 34-2 Side impact (door) airbag 69-19 Side turn signal light 94-15 exterior lights, checking 03-43 Siren 96-4, 96-5 Slave cylinder 30-9 Sound system 02-26 91-3 Spark plug 03-32 well 15-11 Speakers 91-7 Special Edition 02-27 Speed sensor, wheel 45-8, 45-9

R
Radiator 03-31, 19-6, 19-7, 19-23 removing and installing 19-23 Radiator cooling fans 19-6, 19-21 removing and installing 19-22 Radio 91-3, 91-4 Radio code 91-4 Rain sensor 92-1 Raising car safely 03-10 Readiness codes OBD-5

Refrigerant 87-3 Relays 97-26, 97-29 Remote key see Key Reversing light switch see Back-up light switch Ride height 44-3, 44-4 Roll bar 02-20 Rollover protection system 20-20, 61-17 bars, lowering after deployment 61-18 function test 61-19 see also Convertible top Rotational rate sensor 45-7

INDEX
WARNING
Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual. Sunroof 60-2 components 60-2 emergency closing 60-3 panel, removing and installing 60-5 Suspension see Front suspension see also Rear suspension see also Maintenance Sway bar see Stabilizer bar Switches ABS/TC 45-8 A/C 87-1 back-up light manual transmission 34-8 brake light 45-6, 94-8 central locking 57-9, 96-8 clutch interlock 30-6 convertible top 61-2, 61-4 cruise control 48-4 hazard warning 94-7 high beam 48-4 ignition cylinder 48-8 electrical switch 48-6 light 94-5 outside mirror 66-1 pedal cluster 30-6, 94-8 PSM 45-8 steering column stalk 48-4 turn signal 48-4 window 64-4 wiper / washer 92-4 see also Back-up light switch Test drive 03-46 Thermostat 19-19 Throttle cable 10-10 Throttle housing removing and installing 24-13 Throttle valve checking 03-30 Throw-out bearing 30-2, 30-3, 30-6 Tie rod 48-9 Tightening fasteners 03-12 torques 03-12 Timing chain see Camshaft chain Tiptronic see also Automatic transmission Tires 44-1 flat tire, changing 03-4 service 03-45 Toe 44-2, 44-3 Tools 03-15 Torque converter removing and installing 32-1 seal 32-2 Towing 03-4 Traction control (TC) see Antilock brakes see also Porsche Stability Management (PSM) Transmission 02-3, 02-12, 34-1 mount 10-14, 34-5, 37-20, see also Automatic transmission see also Manual transmission Trim, interior A-pillar trim 70-4 B-pillar trim 70-5 C-pillar trim 70-6 Center console 70-1 Door panel 57-3 Door sill trim 70-9 Side panel trim 70-7 Steering column covers 48-4

9

Splash shields see Underbody splash shields Spoiler, rear see Rear spoiler Spring, coil see Front suspension see also Rear suspension SRS (supplemental restraint system) see Airbag system (SRS) Stabilizer bar see Front suspension see also Rear suspension Starter 27-9 interlock switch 27-9, 30-6 removing / installing 27-10 troubleshooting 27-3, 27-9 Steering bleeding 48-12 checking 03-35 column covers 48-4 column stalk switch 48-4 fluid 03-25, 48-12 fluid lines 48-17 ignition electrical switch 48-6 ignition lock cylinder 48-8 pump 48-13 rack 48-10 steering angle sensor 45-8, 45-14 steering system 48-1 steering wheel 48-2 tie rod 48-9 Steering angle sensor 45-8, 45-14 Stop light switch see Brake light switch Strut front 40-6, 40-7, 40-8 rear 42-3, 42-4

T
Taillights 94-16 exterior lights, checking 03-43 Targa top 60-9 components 60-9 control module 60-18 cowl panel cover 60-15 emergency closing 60-9 fabric lining guide 60-14 front fabric lining 60-10 glass panel, removing and installing 60-19 rear fabric lining 60-13 sun blind electric motor 60-18 wind deflector 60-17 TC (traction control) see Antilock brakes see also Porsche Stability management (PSM) Tensioner pulley 13-2

10

INDEX
Washer 92-11 fluid level sensor 92-15 nozzle 92-11 pump 92-14 reservoir 92-13 see also Wiper Washing 03-40 Water drains 50-5, 50-6, 50-7 Water pump 19-15, 19-17 Waxing 03-40 Wheel, steering 48-2 Working under car safely 03-9

Trunk lid emergency release 02-24, 55-2 aligning 55-4 components 55-2 release motor 55-3 removing and installing 55-3 safety hooks, checking 03-42 struts 55-2 trunk lid release, servicing 55-7 Trunk light bulb 96-3 Turn signal bulb front 94-15 side 94-15 Turn signal switch 48-4

X
X-connectors EWD-8

U
Under car maintenance 03-31, 03-38 Underbody splash shields 03-11

Wheel alignment 44-2 ride height 44-3, 44-4 Wheel bearing front 40-12 rear 42-15 Wheel carrier front 40-12 rear 42-10 Wheel housing liner, front 50-1 Wheel speed sensor 45-8, 45-9 Wheels 44-1 Window see Door window Wiper 92-2 arm 92-3 assembly 92-5 assembly, removing and installing 92-6 blade 92-2, 92-3 checking 03-24 fuse 92-4 fluid 03-27 intermittent wipe interval control 92-5 motor, removing and installing 92-9 relay 92-4 switch 92-4 see also Washer Wiring circuit and terminal descriptions EWD-5 color codes EWD-3 diagrams EWD-9 Porsche abbreviations and acronyms EWD-6 sample EWD-4

V
Vacuum booster 47-7 Valve lift adjuster VarioCam solenoid removing and installing 15-55 VarioCam 02-3, 02-4, 02-5, 02-6, 02-9, 15-4, 15-40, 15-53, 15-55 Vehicle identification number (VIN) 01-1, 03-13, 31-14 Vent flaps and motors 87-2, 87-8 Ventilation microfilter replacing 03-39 Viscous coupler components 39-10 function test 39-9 removing and installing 39-10 Voltage tests 97-36

W
Warning lights 03-2, 19-8, 90-8 Warnings 00-1

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Porsche 911 Carrera (Type 996): 1999-2005
Carrera, Carrera 4, Carrera 4S
Price: $219.95 Bentley Stock No: P905 Publication Date: 2012-10-01 ISBN: 978-0-8376-1710-7 Hardcover, 8 3/8 in. x 11in. Case quantity: 5 1,024pages 1,477 full color photos and illustrations

The full-color Porsche 911 Carrera (Type 996) Service Manual: 1999-2005 is a comprehensive source of service information and specifications for Porsche 911 (Type 996) Coupe, Targa and Convertible models from 1999 to 2005. The aim throughout this manual has been simplicity and clarity, with practical explanations, step-by-step procedures and useful specifications. Whether you’re a professional or a do-it-yourself Porsche owner, this manual will help you understand, care for and repair your Porsche.

Intermediate shaft (IMS) bearing replacement.
15 Cylinder Head

Technical highlights
• Full-color repair manual pages (black and white electrical section). • Maintenance procedures for everything from flushing front and rear differential fluids to replacing the interior ventilation microfilter. This manual tells you what to do and when to do it. • Step-by-step engine and cylinder head removal and installation. • Cooling system filling and bleeding, coolant pump replacement and engine cooling fan and radiator service. • Fuel injection and ignition system service, including explanation of different Bosch DME engine management systems. • Clutch, flywheel and rear main seal service. • Front and rear drive train service, including front (C4) and rear differential service. • Brakes, steering, suspension and ABS maintenance, troubleshooting and repair. • Heating and air-conditioning repair, including A/C component replacement. • Body adjustments and repairs. • Convertible top service, including convertible top hydraulic motor and microswitch replacement and a diagnsotic fault code table. • Electrical system service, with an easy-to-use illustrated component locator section. • Wiring schematics for selected models, with power distribution, grounds, convertible top and other hard to find circuits.
Diagnosis and repair information for the power rear spoiler.
55 Trunk Lid, Engine Hood

Step-by-step brake pad, pad sensor and rotor replacement.
46 Brakes– Mechanical

Engines covered:
1999-2001: 3.4 liter (M96.01, M96.02, M96.04) 2002-2005: 3.6 liter (M96.03)

Transmissions covered:
G96 (6-speed manual) A96 (5-speed automatic)

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublishers.com/contact-us
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