996 TT Repair Manual

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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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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 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 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
03 Replacing ATF.............................................................................................................................................94
Tools......................................................................................................................................................94
Replacing ATF fluid..............................................................................................................................94
03 Removing and installing ATF filter............................................................................................................97

Tools......................................................................................................................................................97
Removing ATF filter.............................................................................................................................97
Installing ATF filter...............................................................................................................................98
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
03 Changing transmission oil − GT2.............................................................................................................105

Changing transmission oil − GT2........................................................................................................105
Topping up transmission oil − GT2.....................................................................................................105
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
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 every 80,000 km/48,000 mls........................................................................139
Additional maintenance every 160,000 km/96,000 mls......................................................................139
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03 Additional maintenance − USA − as of MY 2004...................................................................................141
Additional maintenance every 60,000 mls/96,000 km........................................................................141
Additional maintenance every 90,000 mls/144,000 km......................................................................142
03 Additional maintenance.............................................................................................................................144
Additional maintenance every 80,000 km/48,000 mls........................................................................144
Additional maintenance every 160,000 km/96,000 mls......................................................................144
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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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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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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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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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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21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger
Check and adjust (cylinder bank 4 − 6)...............................................................................................586
21 67 19 Removing and installing bypass flap control box on the turbocharger − Engine installed......588
Removing bypass flap control box on the turbocharger......................................................................588
Installing bypass flap control box on the turbocharger........................................................................589
21 75 20 Removing and installing oil container for exhaust turbocharger − Engine installed................591
Removing oil container for exhaust turbocharger...............................................................................591
Installing oil container for exhaust turbocharger.................................................................................593
21 80 19 Removing and installing oil pump for turbocharger....................................................................595

Tools....................................................................................................................................................595
Removal...............................................................................................................................................595
Installation...........................................................................................................................................604
21 90 19 Removing and installing pressure sensor......................................................................................609

Removal...............................................................................................................................................609
Installation...........................................................................................................................................609
24 00 33 Completing the vacuum connections..............................................................................................610
24 25 19 Removing and installing air cleaner...............................................................................................613

Removing air cleaner...........................................................................................................................613
Installing air cleaner.............................................................................................................................615
24 42 19 Removing and installing throttle body − Engine installed...........................................................617

Removing throttle body.......................................................................................................................617
Installing throttle body.........................................................................................................................618
24 46 01 Testing the intake distributor (leak test).......................................................................................620

Tools....................................................................................................................................................620
Leak test...............................................................................................................................................620
24 46 20 Removing and installing intake distributor Engine removed..................................................622

Removing intake distributor................................................................................................................622
Installing intake distributor..................................................................................................................624
24 46 37 Disassembling and assembling intake distributor........................................................................627

Disassembling the intake distributor....................................................................................................627
Vacuum lines.......................................................................................................................................629
24 69 19 Precautionary measures when handling oxygen sensors.............................................................631
24 73 19 Removing and installing oxygen sensors behind catalytic converter..........................................632

Removing oxygen sensors behind the catalytic converter...................................................................632
Oxygen sensor, left side :..............................................................................................................633
Oxygen sensor, right side :............................................................................................................633
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24 73 19 Removing and installing oxygen sensors behind catalytic converter
Installing oxygen sensors behind the catalytic converter....................................................................634
26 01 05 Exhaust system leak test..................................................................................................................635

Tools....................................................................................................................................................635
Leak test...............................................................................................................................................636
26 33 19 Removing and installing rear mufflers..........................................................................................637

Removing rear mufflers.......................................................................................................................637
Installing rear mufflers.........................................................................................................................639
26 65 19 Removing and installing secondary air pump...............................................................................641

Removal...............................................................................................................................................641
Installation...........................................................................................................................................642
27 22 19 Removing and installing three−phase generator..........................................................................643

Removing the three−phase generator..................................................................................................643
Installing the three−phase generator....................................................................................................644
Undoing and tightening the belt pulley................................................................................................644
Tool for holding the free−wheel pulley...............................................................................................644
27 27 19 Removing and installing bracket for generator............................................................................646

Removing bracket for generator..........................................................................................................646
Removal.........................................................................................................................................646
Installing bracket for generator............................................................................................................649
27 60 19 Removing and installing starter (manual transmission)..............................................................652

Removing the starter............................................................................................................................652
Installing the starter..............................................................................................................................652
28 39 19 Removing and installing hall sender − Engine installed...............................................................653

Removing hall sender..........................................................................................................................653
Installing hall sender............................................................................................................................654
28 70 55 Replacing the spark plugs...............................................................................................................656

Removing spark plugs.........................................................................................................................656
Installing spark plugs...........................................................................................................................657
28 72 20 Removing and installing knock sensor Engine removed..........................................................659

Removing and installing knock sensor, cylinder bank 1−3.................................................................659
Removing knock sensor, cylinder bank 4 − 6......................................................................................660
Installing knock sensor, cylinder bank 4 − 6.......................................................................................661
30 01 01 Checking clutch booster circuit......................................................................................................663

1. Checking accumulator.....................................................................................................................663
2. Checking valve (pressure−regulating valve)...................................................................................663
2.1 Checking the valve (pressure−regulating valve) in the clutch save cylinder..........................664
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30 01 01 Checking clutch booster circuit
2.2 Checking the valve (pressure−regulating valve) in the upper part of the expansion tank......664
30 01 07 Bleeding clutch operation................................................................................................................666

Disposal of Pentosin............................................................................................................................667
30 27 19 Removing and installing clutch pressure hose − Engine installed...............................................668

Removing clutch pressure hose...........................................................................................................668
Installing clutch pressure hose.............................................................................................................669
30 30 19 Removing and installing clutch slave cylinder..............................................................................671

Removal...............................................................................................................................................671
Installation...........................................................................................................................................674
30 31 19 Removing and installing the accumulator.....................................................................................676

Removal...............................................................................................................................................676
Installation...........................................................................................................................................677
30 45 19 Removing and installing release bearing (clutch removed).........................................................679

Removing release bearing....................................................................................................................680
Installing release bearing.....................................................................................................................680
30 50 19 Removing and installing clutch.......................................................................................................682

Tools....................................................................................................................................................682
Removing clutch..................................................................................................................................682
Installing clutch....................................................................................................................................683
30 50 37 Disassembling and assembling clutch............................................................................................684
30 56 01 Checking clutch drive plate for wear.............................................................................................685
03 24 00 Minor maintenance − USA..............................................................................................................686
03 24 00 Minor maintenance − as of MY 2003.............................................................................................688
03 24 00 Minor maintenance − USA − as of MY 2003.................................................................................690
03 24 00 Minor maintenance − as of MY 2004.............................................................................................692
03 24 00 Minor maintenance − USA − as of MY 2004.................................................................................694
32 47 19 Removing and installing torque−converter sealing ring..............................................................696

Tools....................................................................................................................................................696
Removing the torque−converter sealing ring.......................................................................................696
Installing the torque−converter sealing ring........................................................................................697
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32 50 19 Removing and installing torque converter....................................................................................698
Tools....................................................................................................................................................698
Removing the torque converter............................................................................................................698
Installing the torque converter.............................................................................................................699
03 26 00 Major maintenance − USA..............................................................................................................700
03 26 00 Major maintenance − as of MY 2003.............................................................................................702
03 26 00 Major maintenance − USA − as of MY 2003.................................................................................704
03 26 00 Major maintenance − as of MY 2004.............................................................................................706
03 26 00 Major maintenance − USA − as of MY 2004.................................................................................708
34 01 55 Changing transmission oil...............................................................................................................710

Changing transmission oil...................................................................................................................710
34 08 19 Removing and installing shift console............................................................................................711

Tools....................................................................................................................................................711
Removing and installing shift console.................................................................................................711
Removing shift console.......................................................................................................................712
Installing shift console.........................................................................................................................713
34 12 19 Removing and installing shift and selector cables........................................................................715

Tools....................................................................................................................................................715
Removing and installing shift and selector cables...............................................................................715
Removing shift and selector cables...............................................................................................716
Installing shift and selector cables.................................................................................................718
34 35 27 Removing and refitting the transmission.......................................................................................720

Tools....................................................................................................................................................720
Removing transmission........................................................................................................................720
Refitting transmission..........................................................................................................................722
34 49 19 Removing and installing closure cap for selector force mechanism............................................724

Tools....................................................................................................................................................724
Removing and installing closure cap for selector force mechanism....................................................724
Removing closure cap for selector force mechanism....................................................................725
Installing closure cap for selector force mechanism.....................................................................726
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03 50 00 Annual maintenance − USA............................................................................................................727
03 50 00 Annual maintenance − as of MY 2004...........................................................................................729
03 50 00 Annual maintenance − USA − as of MY 2004...............................................................................730
37 02 35 Checking and topping up the ATF.................................................................................................731

Tools....................................................................................................................................................731
Checking and topping up the ATF.......................................................................................................731
37 02 55 Replacing ATF fluid........................................................................................................................734

Tools....................................................................................................................................................734
Replacing ATF fluid............................................................................................................................734
37 08 19 Removing and installing selector support......................................................................................737

Removing and installing selector support............................................................................................737
Removing selector support............................................................................................................737
Installing selector support.............................................................................................................738
37 15 19 Removing and installing selector lever cable.................................................................................740

Tools....................................................................................................................................................740
Removing and installing selector lever cable......................................................................................740
Removing selector support............................................................................................................740
Installing selector support.............................................................................................................743
37 35 27 Removing and refitting the transmission.......................................................................................746

Tools....................................................................................................................................................746
Removing transmission........................................................................................................................747
Refitting transmission..........................................................................................................................748
37 58 19 Removing and installing ATF filter................................................................................................750

Tools....................................................................................................................................................750
Removing ATF filter...........................................................................................................................750
Installing ATF filter.............................................................................................................................751
38 77 19 Removing and installing electrohydraulic control unit................................................................753

Tools....................................................................................................................................................753
Removing the electrohydraulic control unit........................................................................................753
Installing the electrohydraulic control unit..........................................................................................756
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38 77 37 Disassembling and assembling electrohydraulic control unit......................................................759
Tools....................................................................................................................................................759
Overview..............................................................................................................................................759
Disconnecting hydraulic and electrical control unit............................................................................761
Removing solenoid and control valve..................................................................................................761
Installing solenoid and control valve...................................................................................................761
Reassembling the hydraulic and electrical control unit.......................................................................761
40 41 19 Removing and installing the front drive shaft...............................................................................763

Tools....................................................................................................................................................763
Removal...............................................................................................................................................763
Installation...........................................................................................................................................765
40 85 19 Removing and installing front spring strut...................................................................................766

Removal...............................................................................................................................................766
Installation...........................................................................................................................................767
42 58 19 Removing and installing rear−wheel bearing................................................................................769

Tools....................................................................................................................................................769
Removing and installing rear−wheel bearing................................................................................769
Notes on removal and installation........................................................................................................770
Removal.........................................................................................................................................771
Installation.....................................................................................................................................772
42 71 19 Removing and installing rear spring strut.....................................................................................773

Removal...............................................................................................................................................773
Installation...........................................................................................................................................773
44 05 19 Removing and installing the wheel − Turbo and GT2..................................................................775

Wheel mounting − Turbo and GT2......................................................................................................775
Removing/installing the wheel on vehicle − Turbo and GT2..............................................................775
44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)......................................................778

General.................................................................................................................................................778
Notes on removal and installation........................................................................................................778
Removal...............................................................................................................................................779
Installation...........................................................................................................................................779
45 11 19 Removing and installing front speed sensors................................................................................781

Removal...............................................................................................................................................781
Installation...........................................................................................................................................781
45 15 19 Removing and installing rear speed sensors..................................................................................782

Removal...............................................................................................................................................782
Installation...........................................................................................................................................782
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45 30 19 Removing and installing hydraulic unit.........................................................................................784
Replacing the hydraulic unit................................................................................................................784
Removal...............................................................................................................................................785
Installation...........................................................................................................................................786
45 59 19 Removing and installing rate−of−turn sensor...............................................................................788

Removal...............................................................................................................................................789
Installation...........................................................................................................................................790
45 59 31 Conversion of rate−of−turn sensor................................................................................................791

Overview of rate−of−turn sensor conversion......................................................................................792
Removal...............................................................................................................................................794
Fitting...................................................................................................................................................796
45 60 19 Removing and installing steering angle sensor.............................................................................799

Notes on steering wheel position during removal and installation......................................................799
Removal...............................................................................................................................................799
Notes on replacing the steering angle sensor − vehicles prior to '03 model........................................801
Component overview....................................................................................................................802
Installation...........................................................................................................................................803
45 64 19 Remove and install booster pump for PSM...................................................................................807

Removal...............................................................................................................................................807
Installation...........................................................................................................................................808
46 11 15 Adjusting the brake pushrod..........................................................................................................809
46 36 20 Removing and installing the front disc brake pads......................................................................810

Removal...............................................................................................................................................810
Installation...........................................................................................................................................811
Bedding in the brake pads.............................................................................................................812
46 38 20 Removing and installing the rear disc brake pads........................................................................813

Removal...............................................................................................................................................813
Installation...........................................................................................................................................814
Bedding in the brake pads.............................................................................................................815
46 50 04 Measuring front brake discs...........................................................................................................816

Measuring the front brake disc lateral runout......................................................................................816
Measuring the brake disc thickness tolerance...............................................................................817
Removing and installing the front brake disc..............................................................................................818

Removal...............................................................................................................................................818
Installation...........................................................................................................................................818
46 53 04 Measuring rear brake discs.............................................................................................................820

Measuring the rear brake disc lateral runout........................................................................................820
Measuring the brake disc thickness tolerance...............................................................................821
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46 53 19 Removing and installing the rear brake disc.................................................................................822
Removal...............................................................................................................................................822
Installation...........................................................................................................................................822
46 83 16 Adjusting the parking brake shoes.................................................................................................824

Check the free play of the parking brake lever....................................................................................824
Adjusting the parking brake.................................................................................................................824
46 83 19 Removing and installing the parking brake shoes........................................................................826

Removal...............................................................................................................................................826
Installation...........................................................................................................................................826
47 01 07 Bleeding brakes (vehicle with PSM)...............................................................................................829

PSM.....................................................................................................................................................829
Procedure for bleeding.........................................................................................................................829
1st step: Bleed brakes as usual.............................................................................................................829
2nd step: Bleeding at front on right with running booster pump.........................................................830
47 08 55 Changing brake fluid.......................................................................................................................832

Procedure for changing brake fluid......................................................................................................832
47 15 19 Removing and installing brake master cylinder...........................................................................834

Removal...............................................................................................................................................834
Installation...........................................................................................................................................835
47 70 19 Removing and installing brake booster.........................................................................................837

Removal...............................................................................................................................................837
Installation...........................................................................................................................................839
48 10 19 Removing and installing steering wheel.........................................................................................844

Removal...............................................................................................................................................844
Installation...........................................................................................................................................845
48 90 19 Removing and installing steering gear...........................................................................................846

Removal...............................................................................................................................................846
Installation...........................................................................................................................................847
Notes for sliding piece and airbag contact unit.............................................................................848
50 55 19 Removing and installing the wing..................................................................................................850
50 56 19 Removing and installing wheel housing liners, front....................................................................854
53 69 19 Removing and installing wheel housing liners, rear.....................................................................856
55 10 37 Disassembling and assembling release for front lid......................................................................858

Disassembling release for front cover..................................................................................................858
Assembling release for front cover......................................................................................................860
Removing and installing support for cap release..........................................................................861
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55 10 37 Disassembling and assembling release for front lid
Removing and installing support for cap release.................................................................................861
55 17 19 Removing and installing front lower part of lid lock....................................................................863

Removing and installing bowden cable for lock actuation..................................................................865
55 22 19 Removing and installing front lid...................................................................................................868
55 22 37 Disassembling and assembling front lid.........................................................................................870
55 25 19 Removing and installing front lid hinge.........................................................................................873
55 37 19 Removing and installing filler flap.................................................................................................875
55 57 37 Disassembling and assembling release for rear lid.......................................................................878

Disassembling release for rear lid........................................................................................................878
Assembling release for rear lid............................................................................................................880
55 86 19 Removing and installing lower part of lid lock.............................................................................882
55 90 19 Removing and installing rear lid....................................................................................................885
55 90 37 Disassembling and assembling rear lid..........................................................................................887

Disassembling rear lid..........................................................................................................................887
Assembling rear lid..............................................................................................................................890
Replacing the model logo....................................................................................................................893
55 91 19 Removing and installing lid hinge..................................................................................................894
57 11 37 Disassembling and assembling door handle..................................................................................897
57 37 19 Removing and installing inner door release (bowden cable) for door lock................................900
57 45 19 Removing and installing door handle............................................................................................903

Removing and installing orientation lighting (LED light−emitting diodes)........................................905
Removing orientation lighting (LED light−emitting diodes)........................................................905
Installing orientation lighting (LED light−emitting diodes).........................................................906
60 14 15 Re−teaching the lifting/sliding roof drive......................................................................................908
60 14 19 Removing and installing lifting/sliding roof drive........................................................................909

Removing lifting/sliding roof drive.....................................................................................................909
Installing lifting/sliding roof drive.......................................................................................................910
Emergency operation on lifting/sliding roof drive...............................................................................911
60 28 19 Removing and installing frame for sliding roof............................................................................912

Removing frame for sliding roof.........................................................................................................912
Installing frame for sliding roof...........................................................................................................914
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60 28 19 Removing and installing frame for sliding roof
Tightening torques.........................................................................................................................916
60 28 37 Disassembling and assembling frame for sliding roof..................................................................917

Disassembling frame for sliding roof..................................................................................................917
Assembling frame for sliding roof.......................................................................................................919
60 40 19 Removing and installing sliding roof panel...................................................................................921

Additional instructions for removing the inner panels........................................................................924
Additional instructions for fitting the inner panels..............................................................................925
63 10 19 Removing and installing front bumper..........................................................................................927

Removing and installing front bumper................................................................................................927
63 15 19 Removing and installing front spoiler............................................................................................930

Removing front spoiler........................................................................................................................930
Installing front spoiler..........................................................................................................................932
63 15 37 Disassembling and assembling front spoiler..................................................................................934

Disassembling front spoiler.................................................................................................................935
Removing front spoiler..................................................................................................................936
Assembling front spoiler......................................................................................................................937
Installing front spoiler...................................................................................................................939
63 50 19 Removing and installing rear bumper...........................................................................................941

Removing rear bumper........................................................................................................................941
Installing rear bumper..........................................................................................................................943
Additional assembly instructions for installation of the bumper.........................................................945
Adjustment dimensions of the bumper..........................................................................................945
Correct assembly of the heat shields.............................................................................................946
Additional assembly instructions for installation of the bumper − Carrera 4S...................................947
Correct assembly of the heat shields.............................................................................................947
Removing and installing frame with heat shield...........................................................................948
63 55 19 Removing and installing rear spoiler.............................................................................................950

Removing rear spoiler..........................................................................................................................950
Install rear spoiler................................................................................................................................952
63 55 37 Disassembling and assembling rear spoiler...................................................................................954

Disassembling rear spoiler...................................................................................................................954
Assembling rear spoiler.......................................................................................................................956
Additional instructions for replacing the rear spoiler..........................................................................958
64 86 01 Checking function of heating for rear window.............................................................................960

Check with the temperature probe.......................................................................................................960
xxix
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64 86 19 Removing and installing rear window...........................................................................................961
Removing rear window........................................................................................................................961
Preparing the window section for installation.....................................................................................963
Installing rear window.........................................................................................................................964
Overview of tools and materials..........................................................................................................967
66 13 19 Removing and installing air inlet....................................................................................................969

Removing air inlet...............................................................................................................................969
Installing air inlet.................................................................................................................................970
66 36 19 Removing and installing roof joint strip........................................................................................973

Removing roof joint strip.....................................................................................................................973
Installing roof joint strip......................................................................................................................975
66 58 19 Removing and installing rear spoiler.............................................................................................977

Removing rear spoiler..........................................................................................................................977
Installing rear spoiler...........................................................................................................................979
66 78 01 Checking function of heating for mirror glass..............................................................................982

Check with the temperature probe.......................................................................................................982
66 89 19 Removing and installing rearview mirror.....................................................................................983

Removing the rearview mirror.............................................................................................................983
Installing the rearview mirror..............................................................................................................985
68 17 37 Disassembling and assembling centre console...............................................................................987

Disassembling and assembling cover for the oddments tray...............................................................989
68 23 19 Removing and installing sun visors................................................................................................991

Removing sun visors............................................................................................................................991
Installing sun visors.............................................................................................................................992
68 23 37 Disassembling and assembling sun visor.......................................................................................993

Disassembling sun visor......................................................................................................................993
Assembling sun visor...........................................................................................................................995
68 27 13 Bonding on the interior rearview mirror.......................................................................................997

Bonding the assembled interior mirror onto the windscreen...............................................................997
68 27 19 Removing and installing the interior rearview mirror...............................................................1000

Removing the interior rearview mirror..............................................................................................1000
Installing the interior rearview mirror................................................................................................1002
69 53 19 Removing and installing the triggering unit for the airbag.......................................................1004

Removing triggering unit for airbag..................................................................................................1004
Installing triggering unit for airbag....................................................................................................1005
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69 54 19 Removing and installing the contact unit....................................................................................1006
Installing contact unit.........................................................................................................................1006
Installing contact unit.........................................................................................................................1006
69 58 19 Removing and installing the driver's airbag unit.......................................................................1008

Removing driver's airbag unit............................................................................................................1008
Installing driver's airbag unit.............................................................................................................1008
69 59 19 Removing and installing the passenger's airbag unit.................................................................1010

Removing passenger's airbag unit......................................................................................................1010
Installing passenger s airbag unit.....................................................................................................1011
69 63 19 Removing and installing the side airbag unit..............................................................................1012

Removing side airbag unit.................................................................................................................1012
Installing side airbag unit...................................................................................................................1013
Removing sensor for side airbag unit..........................................................................................1013
70 18 19 Removing and installing the instrument panel and instrument panel bracket........................1015
Removing and installing the instrument panel..................................................................................1015
Removing and installing the instrument panel bracket......................................................................1017
Tightening torque...............................................................................................................................1019
Tools and materials............................................................................................................................1019
70 18 37 Disassembling and assembling the instrument panel.................................................................1021

Disassembling the instrument panel..................................................................................................1021
Removing the regulator for wiping interval................................................................................1026
Removing the cigarette lighter....................................................................................................1026
Assembling the instrument panel.......................................................................................................1027
Installing the regulator for wiping interval..................................................................................1032
Installing the cigarette lighter......................................................................................................1032
Additional assembly notes for the cover and center nozzle for the instrument panel as of
model year 2002................................................................................................................................1033
Removing cover and center nozzle for the instrument panel......................................................1033
Removing holder.........................................................................................................................1034
Installing holder...........................................................................................................................1034
Installing cover and center nozzle for the instrument panel........................................................1035
70 22 19 Removing and installing cowl panel cover...................................................................................1037

Removing and installing cowl panel cover........................................................................................1037
70 59 19 Removing and installing door trim panel....................................................................................1040

Removing door trim panel.................................................................................................................1040
Installing door trim panel...................................................................................................................1042
Installation note for door sealing film................................................................................................1044
Installation note on door sealing film for vehicles without side airbag......................................1044
Notes on the installation of partly detached door sealing films..................................................1044
Fitting sliding strip on the inner door panel.......................................................................................1045
Materials and tools.............................................................................................................................1046
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70 59 19 Removing and installing door trim panel
70 65 19 Removing and installing oddments compartment lid.................................................................1047

Removing and installing oddments compartment lid........................................................................1047
70 84 19 Removing and installing roof lining.............................................................................................1050

Removing roof lining.........................................................................................................................1050
Installing roof lining..........................................................................................................................1052
80 23 19 Removing and installing heat exchanger.....................................................................................1055

Removing heat exchanger..................................................................................................................1055
Installing heat exchanger...................................................................................................................1055
85 30 19 Removing and installing heater/fresh−air blower motor...........................................................1056

Removing heater/fresh−air blower motor..........................................................................................1056
Installing heater/fresh−air blower motor...........................................................................................1057
87 01 19 Removing and installing the heating/air−conditioning unit.......................................................1058

Removing heating/air−conditioning unit...........................................................................................1058
Installing heating/air−conditioning unit.............................................................................................1060
87 02 19 Removing and installing the heating/air−conditioning control.................................................1062

Removing heating/air−conditioning control......................................................................................1062
Performing system test.......................................................................................................................1062
Tests...................................................................................................................................................1063
87 03 17 Assembly work on the air−conditioning system..........................................................................1064

Service unit SECU 134......................................................................................................................1064
Assembly work involving the refrigerant system..............................................................................1066
General assembly sequence...............................................................................................................1066
Removing refrigerant by suction and cleaning..................................................................................1067
Cleaning the refrigerant.....................................................................................................................1068
Draining off old refrigerant oil..........................................................................................................1068
Evacuating..........................................................................................................................................1069
Topping up with new refrigerant oil..................................................................................................1070
Filling via the high−pressure side......................................................................................................1070
Refilling the air−conditioning system................................................................................................1071
Distribution of the oil quantity in the refrigerant circuit....................................................................1072
87 20 19 Removing and installing drive motors.........................................................................................1073

Removing drive motors.....................................................................................................................1073
Removing drive motor for temperature valve and central valve.................................................1073
Removing drive motor for footwell/defrost................................................................................1074
Removing drive motor for fresh−air/recirculation valve............................................................1074
Installing drive motors.......................................................................................................................1074
Installing drive motor for temperature valve, central valve and footwell/defrost.......................1074
Installing drive motor for fresh−air/recirculation valve..............................................................1075
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87 27 19 Removing and installing the magnetic coupling.........................................................................1076
Removing the magnetic coupling......................................................................................................1076
Installing the magnetic coupling........................................................................................................1076
Checking the air gap of the magnet coupling..............................................................................1077
87 34 19 Removing and installing the compressor.....................................................................................1078

Removing the compressor..................................................................................................................1078
Installing the compressor...................................................................................................................1079
Running−in regulations for new compressor..............................................................................1080
87 50 19 Removing and installing the condenser.......................................................................................1081

Removing the condenser....................................................................................................................1081
Installing the condenser.....................................................................................................................1081
87 53 19 Removing and installing fan for condenser.................................................................................1083

Removing fan for condenser..............................................................................................................1083
Installing fan for condenser...............................................................................................................1083
87 55 19 Removing and installing the fluid tank........................................................................................1084

Removing fluid tank..........................................................................................................................1084
Installing fluid tank............................................................................................................................1084
87 58 19 Removing and installing footwell blower outlet sensor..............................................................1085

Removing footwell blower outlet sensor...........................................................................................1085
Installing footwell blower outlet sensor.............................................................................................1085
87 59 19 Removing and installing outside temperature sensor.................................................................1086

Removing outside temperature sensor...............................................................................................1086
Installing outside temperature sensor.................................................................................................1086
87 70 19 Removing and installing the expansion valve..............................................................................1087

Removing expansion valve................................................................................................................1087
Installing expansion valve..................................................................................................................1087
87 78 19 Removing and installing blower driver........................................................................................1088

Removing blower driver....................................................................................................................1088
Installing blower driver......................................................................................................................1088
87 82 19 Removing and installing interior temperature sensor................................................................1089

Removing interior temperature sensor...............................................................................................1089
Installing interior temperature sensor................................................................................................1089
87 83 19 Removing and installing pressure switch for the air−conditioning system..............................1090

Removing pressure switch for the air−conditioning system..............................................................1090
Installing pressure switch for the air−conditioning system...............................................................1090
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90 12 15 Setting ahead the total mileage counter in the instrument cluster............................................1091
Setting ahead with the Porsche System Tester 2...............................................................................1091
90 25 37 Disassembling and assembling instrument cluster.....................................................................1092
90 50 19 Removing and installing horn.......................................................................................................1093

Removing horn..................................................................................................................................1093
Installing horn....................................................................................................................................1094
91 12 15 Adjusting (calibrating) PCM navigation unit.............................................................................1095

GPS receiver......................................................................................................................................1095
Distance sensor..................................................................................................................................1095
Gyroscope..........................................................................................................................................1096
Procedure after commissioning..........................................................................................................1096
Procedure after changing a tyre.........................................................................................................1096
Procedure after the power supply has been interrupted.....................................................................1096
91 12 19 Removing and installing navigation unit.....................................................................................1097

Removing navigation unit..................................................................................................................1097
Installing navigation unit...................................................................................................................1097
Device code input........................................................................................................................1097
91 13 19 Removing and installing GPS antenna........................................................................................1099

Removing GPS antenna.....................................................................................................................1099
Installing GPS antenna.......................................................................................................................1099
91 20 19 Removing and installing the car radio.........................................................................................1101

Removing the car radio......................................................................................................................1101
Installing the car radio.......................................................................................................................1101
Entering the code number..................................................................................................................1102
91 47 19 Removing and installing radio antenna.......................................................................................1103

Removing radio antenna....................................................................................................................1103
Installing radio antenna......................................................................................................................1103
91 57 15 Setting hands−free microphone to the telephone type................................................................1104

Setting................................................................................................................................................1104
91 57 19 Removing and installing hands−free microphone......................................................................1105

Removing hands−free microphone....................................................................................................1105
Installing hands−free microphone.....................................................................................................1106
91 75 19 Removing and installing sensor for ParkAssistent.....................................................................1107

Removing sensor for ParkAssistent...................................................................................................1107
Installing sensor for ParkAssistent.....................................................................................................1107
ParkAssistent control module............................................................................................................1108
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92 15 19 Removing and installing the wiper motor...................................................................................1109
Removing wiper motor......................................................................................................................1109
Installing wiper motor........................................................................................................................1109
92 19 19 Removing and installing the wiper link.......................................................................................1111

Removing wiper link.........................................................................................................................1111
Installing wiper link...........................................................................................................................1111
92 27 19 Removing and installing the wiper blades...................................................................................1113
92 30 19 Removing and installing rear window wiper system..................................................................1114

Removing rear window wiper system................................................................................................1114
Installing rear window wiper system.................................................................................................1114
92 56 19 Removing and installing pump for windscreen washer system.................................................1115

Removing pump for windscreen washer system...............................................................................1115
Installing pump for windscreen washer system.................................................................................1115
92 60 19 Removing and installing tank for windscreen washer system...................................................1116

Removing tank for windscreen washer system (7 litres)...................................................................1116
Removing tank for windscreen washer system (3 litres)...................................................................1116
Installing tank for windscreen washer system...................................................................................1117
92 67 19 Removing and installing fluid level indicator..............................................................................1118

Removing fluid level indicator..........................................................................................................1118
Installing fluid level indicator............................................................................................................1118
92 70 19 Removing and installing cover for spray nozzle.........................................................................1119

Removing cover for spray nozzle......................................................................................................1119
Installing cover for spray nozzle........................................................................................................1119
92 72 19 Removing and installing spray nozzle for headlight washing system.......................................1120

Removing spray nozzle for headlight washing system......................................................................1120
Installing spray nozzle for headlight washing system.......................................................................1120
92 78 19 Removing and installing pump for headlight washing system..................................................1121

Removing pump for headlight washing system.................................................................................1121
Installing pump for headlight washing system..................................................................................1121
94 05 19 Removing and installing main light switch..................................................................................1122

Removing main light switch..............................................................................................................1122
Installing main light switch................................................................................................................1123
94 15 01 Troubleshooting on the Xenon headlight.....................................................................................1124
94 15 05 Main headlights − basic adjustment in the body.........................................................................1125

Adjustment instructions.....................................................................................................................1125
Adjustment procedure........................................................................................................................1126
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94 15 15 Left / right traffic conversion for Xenon headlights...................................................................1127
Converting Xenon headlights............................................................................................................1127
Installation.........................................................................................................................................1127
94 15 19 Removing and installing the main headlights.............................................................................1129
94 23 19 Removing and installing gas discharge lamp (Xenon headlights).............................................1130

Removing gas discharge lamp (Xenon headlights)...........................................................................1130
Installing gas discharge lamp (Xenon headlights).............................................................................1130
94 27 19 Removing and installing bulb for parking light..........................................................................1132

Removing bulb for parking light.......................................................................................................1132
Installing bulb for parking light.........................................................................................................1132
94 29 19 Removing and installing bulb for number plate light................................................................1133

Removing bulb for number plate light...............................................................................................1133
Installing bulb for number plate light................................................................................................1133
94 33 19 Removing and installing bulb for tail light..................................................................................1134

Removing bulb for tail light...............................................................................................................1134
Installing bulb for tail light................................................................................................................1134
94 47 19 Removing and installing the hazard warning light switch.........................................................1135

Removing hazard warning light switch.............................................................................................1135
Installing hazard warning light switch...............................................................................................1135
94 53 19 Removing and installing bulb for side direction indicator light................................................1136

Removing bulb for side direction indicator light...............................................................................1136
Installing bulb for side direction indicator light................................................................................1136
94 57 19 Removing and installing control module for gas discharge lamp.............................................1137

Removing control module for gas discharge lamp............................................................................1137
Installing control module for gas discharge lamp..............................................................................1138
94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight).........................1139
Removing bulb for auxiliary headlight..............................................................................................1139
Installing bulb for auxiliary headlight................................................................................................1139
94 67 19 Removing and installing bulb for fog light..................................................................................1140

Removing bulb for fog light..............................................................................................................1140
Installing bulb for fog light................................................................................................................1140
94 70 19 Removing and installing bulb for additional brake light...........................................................1141

Removing bulb for additional brake light..........................................................................................1141
Installing bulb for additional brake light...........................................................................................1141
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94 78 19 Removing and installing front angle sensor for headlight beam adjustment...........................1142
Removing front angle sensor for headlight beam adjustment...........................................................1142
Installing front angle sensor for headlight beam adjustment.............................................................1142
94 79 19 Removing and installing rear angle sensor for headlight beam adjustment............................1144
Removing rear angle sensor for headlight beam adjustment.............................................................1144
Installing rear angle sensor for headlight beam adjustment...............................................................1144
94 94 19 Removing and installing drive motor for headlight beam adjustment.....................................1146

Removing drive motor for headlight beam adjustment.....................................................................1146
Installing drive motor for headlight beam adjustment.......................................................................1146
94 98 19 Removing and installing control module for headlight beam adjustment...............................1147

Removing control module for headlight beam adjustment................................................................1147
Installing control module for headlight beam adjustment.................................................................1147
96 16 19 Removing and installing bulb for door warning light................................................................1148

Removing bulb for door warning light..............................................................................................1148
Installing bulb for door warning light................................................................................................1148
96 22 19 Removing and installing bulb for interior light..........................................................................1149

Removing bulb for interior light........................................................................................................1149
Installing bulb for interior light.........................................................................................................1149
96 41 19 Removing and installing bulb for luggage compartment light..................................................1150

Removing bulb for luggage compartment light.................................................................................1150
Installing bulb for luggage compartment light...................................................................................1150
96 43 19 Removing and installing bulb for engine compartment light....................................................1151

Removing bulb for engine compartment light...................................................................................1151
Installing bulb for engine compartment light.....................................................................................1151
96 62 01 Radio remote control in hand−held transmitter does not function...........................................1152

Empty battery in hand−held transmitter............................................................................................1152
Radio transmitter outside lock−in range............................................................................................1152
Atmospheric interference or interfering transmitters.........................................................................1152
Energy−saving mode active...............................................................................................................1153
Fault in hand−held transmitter or vehicle..........................................................................................1153
96 62 37 Disassembling and assembling hand−held transmitter..............................................................1154

Removing key from the bottom part..................................................................................................1154
Installing key in the bottom part........................................................................................................1154
96 62 55 Teaching hand−held transmitter..................................................................................................1155

General...............................................................................................................................................1155
Work preparation...............................................................................................................................1155
Procedure...........................................................................................................................................1156
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96 72 19 Removing and installing signal converter/immobilizer..............................................................1158
Removing signal converter/immobilizer............................................................................................1158
Installing signal converter/immobilizer.............................................................................................1159
96 85 19 Removing and installing passenger compartment monitoring sensor......................................1160

Removing and installing passenger compartment monitoring sensor...............................................1160
Removing and installing passenger compartment monitoring sensor...............................................1160
97 09 41 Repair of main wiring harness......................................................................................................1162

Removing main wiring harness.........................................................................................................1162
Installing main wiring harness...........................................................................................................1163
97 25 41 Repair of rear wiring harness.......................................................................................................1165

Removing rear wiring harness...........................................................................................................1165
Installing rear wiring harness.............................................................................................................1166
10 01 19 Removing and installing engine....................................................................................................1168

Tools for removal...............................................................................................................................1168
Removing engine...............................................................................................................................1169
10 01 19 Removing and installing engine....................................................................................................1179

Installing engine.................................................................................................................................1179
Tightening torques: Removing and installing engine........................................................................1182
24 40 20 Removing and installing injection valves − Engine removed.....................................................1183

Removing injection valves of cylinder bank 1 3............................................................................1183
Installing injection valves of cylinder bank 1 3..............................................................................1184
Installing injection valves of cylinder bank 4 6..............................................................................1185
24 40 20 Removing and installing injection valves − Engine installed.....................................................1186

Preliminary work...............................................................................................................................1186
Installing injection valves..................................................................................................................1192
24 69 19 Removing and installing oxygen sensors in front of catalytic converter..................................1200

Tools..................................................................................................................................................1200
Removing oxygen sensors in front of catalytic converter.................................................................1200
Oxygen sensor, left side :............................................................................................................1201
Oxygen sensor, right side :..........................................................................................................1202
Installing oxygen sensors in front of catalytic converter...................................................................1202
24 70 19 Removing and installing DME control module...........................................................................1204

Obtaining read−out and saving vehicle data from DME control module..........................................1205
Removing DME control module........................................................................................................1205
Installing the DME control module...................................................................................................1206
Programming the new DME control module 911 Turbo (996).........................................................1207
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24 70 19 Removing and installing DME control module
Programming the new DME control module − GT2 and version X51..............................................1208
Programming the DME control module 911 Turbo (996).................................................................1209
Programming DME control module − GT2 and version X51...........................................................1210
Version (data records) 911 Turbo (996)............................................................................................1212
Version (data records) − GT2............................................................................................................1213
27 60 19 Removing and installing starter (automatic transmission)........................................................1214

Removing the starter..........................................................................................................................1214
Installing the starter............................................................................................................................1215
34 35 37 Partially disassembling transmission...........................................................................................1216

Tools..................................................................................................................................................1216
Removing transmission cover............................................................................................................1217
Disassembling front gear set..............................................................................................................1217
Overview.....................................................................................................................................1217
Disassembling gear set................................................................................................................1219
Removing gear housing.....................................................................................................................1220
Removing input and output shaft.......................................................................................................1221
Overview.....................................................................................................................................1221
Removing shafts..........................................................................................................................1222
Dismantling input shaft......................................................................................................................1223
Overview.....................................................................................................................................1223
Disassembling shaft.....................................................................................................................1225
34 35 37 Assembling transmission...............................................................................................................1226
Tools..................................................................................................................................................1226
Assembling input shaft......................................................................................................................1227
Assembling shafts........................................................................................................................1227
Tightening torques.......................................................................................................................1228
Installing input and output shaft........................................................................................................1228
Installing shafts............................................................................................................................1228
Fitting gear housing...........................................................................................................................1232
Fitting housing.............................................................................................................................1232
Assembling front gear set..................................................................................................................1232
Assembling gear set.....................................................................................................................1232
Fitting front transmission case cover.................................................................................................1235
Fitting cover................................................................................................................................1235
35 50 19 Removing and installing sealing ring for input shaft.................................................................1236

Tools..................................................................................................................................................1236
Removing sealing ring for input shaft...............................................................................................1236
Installing sealing ring for input shaft.................................................................................................1237
Tightening torques.............................................................................................................................1238
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37 04 19 Removing and installing selector knob........................................................................................1240
Removing selector knob....................................................................................................................1240
Installing selector knob......................................................................................................................1240
37 30 19 Removing and installing Tiptronic control module....................................................................1242

Removing the control module............................................................................................................1242
Installing the control module.............................................................................................................1244
Coding the Tiptronic control module.................................................................................................1245
Tools..................................................................................................................................................1246
39 02 19 Removing and installing cardan shaft..........................................................................................1248

Tools..................................................................................................................................................1248
Removing cardan shaft......................................................................................................................1248
Installing cardan shaft........................................................................................................................1249
39 02 19 Removing and installing cardan shaft..........................................................................................1251

Tools..................................................................................................................................................1251
Removing and installing cardan shaft................................................................................................1251
Removing cardan shaft................................................................................................................1251
Installing cardan shaft.................................................................................................................1252
39 22 19 Removing and installing sealing ring for halfshaft flange.........................................................1254

Tools..................................................................................................................................................1254
Removing sealing ring for halfshaft flange.......................................................................................1254
Installing sealing ring for halfshaft flange.........................................................................................1255
39 22 19 Removing and installing sealing ring for short flanged shaft....................................................1256

Tools..................................................................................................................................................1256
Removing and installing sealing ring for short flanged shaft............................................................1256
Removing sealing ring for short flanged shaft............................................................................1256
Installing sealing ring for short flanged shaft..............................................................................1258
39 25 19 Removing and installing long flanged shaft.................................................................................1259

Tools..................................................................................................................................................1259
Removing and installing long flanged shaft......................................................................................1259
Removing long flanged shaft......................................................................................................1259
Installing long flanged shaft........................................................................................................1260
39 58 19 Removing and installing lid for front wheel drive......................................................................1262

Tools..................................................................................................................................................1262
Removing the lid for front wheel drive..............................................................................................1262
Installing the lid for front wheel drive...............................................................................................1263
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39 58 19 Removing and installing lid for front wheel drive
39 58 19 Removing and installing lid for front wheel drive......................................................................1264

Tools..................................................................................................................................................1264
Removing the lid for front wheel drive..............................................................................................1264
Installing the lid for front wheel drive...............................................................................................1265
39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive).............................1266
Tools..................................................................................................................................................1266
Removing the sealing ring for the flanged shaft (front wheel drive).................................................1266
Installing the sealing ring for the flanged shaft (front wheel drive)..................................................1267
39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive).............................1269
Tools..................................................................................................................................................1269
Removing the sealing ring for the flanged shaft (front wheel drive).................................................1269
Installing the sealing ring for the flanged shaft (front wheel drive)..................................................1270
39 60 01 Checking function of installed viscous clutch..............................................................................1272

Test conditions...................................................................................................................................1272
Checking function of installed viscous clutch...................................................................................1272
39 60 01 Checking function of installed viscous clutch..............................................................................1275

Test conditions...................................................................................................................................1275
Checking function of installed viscous clutch...................................................................................1275
39 60 19 Removing and installing the viscous clutch.................................................................................1278

Tools..................................................................................................................................................1278
Removing the viscous clutch.............................................................................................................1279
Installing the viscous clutch...............................................................................................................1279
39 60 19 Removing and installing the viscous clutch.................................................................................1281

Tools..................................................................................................................................................1281
Removing the viscous clutch.............................................................................................................1282
Installing the viscous clutch...............................................................................................................1282
39 62 19 Removing and installing support for front wheel drive.............................................................1284

Removing the support for front wheel drive......................................................................................1284
Installing the support for front wheel drive.......................................................................................1284
39 62 19 Removing and installing support for front wheel drive.............................................................1286

Removing the support for front wheel drive......................................................................................1286
Installing the support for front wheel drive.......................................................................................1286
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39 82 19 Removing and installing sealing ring for cardan flange.............................................................1288
Tools..................................................................................................................................................1288
Removing sealing ring for cardan flange...........................................................................................1288
Installing sealing ring for cardan flange............................................................................................1289
39 82 19 Removing and installing sealing ring for cardan flange.............................................................1291

Tools..................................................................................................................................................1291
Removing and installing sealing ring for cardan flange....................................................................1291
Removing sealing ring for cardan flange....................................................................................1291
Installing sealing ring for cardan flange......................................................................................1292
39 88 19 Removing and installing front wheel drive..................................................................................1294

Remove front wheel drive..................................................................................................................1294
Installing the front wheel drive..........................................................................................................1295
39 88 19 Removing and installing front wheel drive..................................................................................1297

Removing front wheel drive..............................................................................................................1297
Installing the front wheel drive..........................................................................................................1298
39 90 55 Replacing and checking transmission oil in final drive..............................................................1300

Tools..................................................................................................................................................1300
Changing transmission oil in final drive............................................................................................1300
39 90 55 Changing transmission oil in front wheel drive..........................................................................1303

Changing transmission oil in front wheel drive.................................................................................1303
39 90 55 Changing transmission oil in front wheel drive..........................................................................1305

Changing transmission oil in front wheel drive.................................................................................1305
42 21 19 Removing and installing rear drive shaft (manual transmission).............................................1307

Tools..................................................................................................................................................1307
Removing the drive shaft (manual transmission)..............................................................................1307
Installing the drive shaft (manual transmission)................................................................................1310
42 21 19 Removing and installing rear drive shaft (Tiptronic transmission)..........................................1313

Tools..................................................................................................................................................1313
Removing the drive shaft (Tiptronic transmission)...........................................................................1313
Installing the drive shaft (Tiptronic transmission).............................................................................1316
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45 46 19 Removing and installing front ABS lead.....................................................................................1320
Removing front ABS lead..................................................................................................................1320
Installing front ABS lead...................................................................................................................1322
Tools..................................................................................................................................................1324
45 46 19 Removing and installing rear ABS lead (Turbo & GT2)...........................................................1325

Removing rear ABS lead...................................................................................................................1325
Installing rear ABS lead.....................................................................................................................1327
Tools..................................................................................................................................................1330
46 50 02 Checking front gray cast iron brake discs (wear assessment)...................................................1331

General...............................................................................................................................................1331
1. Visual inspection for cracks and evaluating cracks.......................................................................1331
Evaluating the cracks on the gray cast iron brake discs..............................................................1332
2. Checking brake discs for minimum thickness...............................................................................1333
Notes on bedding in the new brake pads...........................................................................................1334
46 50 02 Checking front PCCB brake discs (wear assessment)................................................................1335

General...............................................................................................................................................1335
1. Visual inspection of the surfaces of the brake disc friction surfaces.............................................1335
PCCB brake disc wear appearance..............................................................................................1336
3. Checking brake discs for edge damage..........................................................................................1337
Note concerning bores (perforations) in the brake disc friction surface............................................1338
Note on bedding in the new brake pads.............................................................................................1338
46 53 02 Checking rear gray cast iron brake discs (wear assessment)....................................................1339

General...............................................................................................................................................1339
1. Visual inspection for cracks and evaluating cracks.......................................................................1339
Evaluating the cracks on the gray cast iron brake discs..............................................................1340
Notes on bedding in the new brake pads...........................................................................................1342
46 53 02 Checking rear PCCB brake discs (wear assessment).................................................................1343

General...............................................................................................................................................1343
1. Visual inspection of the surfaces of the brake disc friction surfaces.............................................1343
PCCB brake disc wear appearance..............................................................................................1344
3. Checking brake discs for edge damage..........................................................................................1345
Note concerning bores (perforations) in the brake disc friction surface............................................1346
Note on bedding in the new brake pads.............................................................................................1346
50 10 55 Replacing closing panel.................................................................................................................1347

Cutting out closing panel and front floor panel.................................................................................1347
Preparing closing panel and front floor panel for installation and fitting..........................................1349
Welding in closing panel and front floor panel.................................................................................1351
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50 10 55 Replacing closing panel
50 14 55 Replacing front wall.......................................................................................................................1353

Cutting out front wall.........................................................................................................................1353
Preparing front wall for installation and fitting.................................................................................1355
Welding in front wall.........................................................................................................................1357
50 74 55 Replacing wheel housing...............................................................................................................1359

Removing wheel housing, lower shell and outer side member from the body..................................1359
Preparing wheel housing, lower shell and outer side member for installation and fitting.................1361
Welding wheel housing, lower shell and outer side members into the body.....................................1363
50 74 56 Replacing wheel housings and side members (sectional repair)................................................1365

Cutting out wheel housings and side members..................................................................................1365
Preparing wheel housings and side members for installation and fitting..........................................1367
Welding in wheel housings and side members..................................................................................1369
50 79 55 Replacing front inner side member..............................................................................................1372

Removing front inner side member...................................................................................................1372
Preparing and fitting the front inner side member for installation.....................................................1374
Welding in front inner side member..................................................................................................1376
Materials, tools...................................................................................................................................1377
50 93 30 Cleaning front water drains on Coupé and Cabriolet................................................................1379

Cleaning front water drains on Coupé and Cabriolet.........................................................................1379
51 03 55 Replacing roof................................................................................................................................1382
Removing roof...................................................................................................................................1382
Preparation of roof for installation and fitting...................................................................................1384
Welding in roof..................................................................................................................................1386
51 21 55 Replacing rear centre panel..........................................................................................................1389

Removing rear centre panel...............................................................................................................1389
Preparing the rear centre panel for installation and fitting................................................................1391
Welding in the rear centre panel........................................................................................................1392
51 45 55 Replacing lower side member.......................................................................................................1395

Cutting out lower side member..........................................................................................................1395
Preparation for installation of lower side member and fitting...........................................................1397
Welding in lower side member..........................................................................................................1399
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51 45 55 Replacing lower side member − Cabriolet...................................................................................1401
Cutting out lower side member..........................................................................................................1401
Preparation for installation of lower side member and fitting...........................................................1403
Welding in lower side member..........................................................................................................1405
51 63 19 Removing and installing deformation element............................................................................1407

Removing deformation element.........................................................................................................1407
Installing deformation element..........................................................................................................1408
51 87 55 Replacing seat cross member........................................................................................................1409

Cutting out seat cross member...........................................................................................................1409
Preparation of seat cross member for installation and fitting............................................................1411
Welding in seat cross member...........................................................................................................1413
51 90 19 Removing and installing underside panel....................................................................................1415

Removing and installing front cover..................................................................................................1415
Removing and installing middle cover..............................................................................................1417
Removing and installing rear trim.....................................................................................................1418
53 05 55 Replacing rear closing panel.........................................................................................................1419

Cutting out rear closing panel............................................................................................................1419
Preparing the rear closing panel for installation and fitting...............................................................1421
Welding in rear closing panel............................................................................................................1422
53 55 55 Replacing side section....................................................................................................................1425

Cutting through side section..............................................................................................................1425
Preparing side section for installation and fitting..............................................................................1428
Welding in the side section................................................................................................................1430
Flanging the wheel arch edges GT2...............................................................................................1433
53 93 30 Cleaning rear water drains on Coupe and Cabriolet.................................................................1435

Cleaning rear water drains on Coupe and Cabriolet..........................................................................1435
55 62 19 Removing and installing front emergency release − as of MY 2003.........................................1438

Checking inner release of luggage compartment (Trunk Entrapment)..............................................1440
55 84 19 Removing and installing engine cover release.............................................................................1441

Checking inner release of luggage compartment (Trunk Entrapment)..............................................1441
Removing engine cover release.........................................................................................................1441
Installing engine cover release...........................................................................................................1442
57 51 16 Setting the door..............................................................................................................................1444
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57 51 19 Removing and installing door.......................................................................................................1446
57 51 37 Disassembling and assembling door.............................................................................................1450

Disassembling door............................................................................................................................1450
Assembling door................................................................................................................................1456
57 51 37 Disassembling and assembling door.............................................................................................1462

Diagram: sheetmetal clips and grommets..........................................................................................1462
Basic setting of door lock..................................................................................................................1463
Basic setting of the door lock before installation........................................................................1464
Standardising the system...................................................................................................................1465
Standardising the power windows...............................................................................................1465
Blockage detection function........................................................................................................1465
Precondition for operation of the power windows......................................................................1465
Fitting the door window in the clamping jaws..................................................................................1465
Adjusting the door window angle in the vehicle's longitudinal direction..........................................1466
Adjusting the door window height.....................................................................................................1466
Adjustment procedure:................................................................................................................1467
Checking the adjustment.............................................................................................................1467
Adjustment of the door window pressing force on the door seal at the top and sides.......................1467
Adjustment procedure:................................................................................................................1468
Checking the adjustment:............................................................................................................1468
Adjusting the lower stop of the power window unit..........................................................................1468
64 12 19 Removing and installing windscreen............................................................................................1470

Removing windscreen........................................................................................................................1470
Preparing the window section for installation...................................................................................1472
Preparing the windscreen for installation..........................................................................................1473
Fitting windscreen..............................................................................................................................1475
Overview of tools and materials........................................................................................................1478
64 54 19 Removing and installing power window motor...........................................................................1481

Removing power window motor.......................................................................................................1481
Installing power window motor.........................................................................................................1481
Standardising the new power window motor.....................................................................................1482
64 71 19 Removing and installing rear power windows (Cabriolet)........................................................1483

Removing rear power windows (Cabriolet).......................................................................................1484
Installing rear power windows (Cabriolet)........................................................................................1485
Additional instructions for adjusting or replacing the rear power window.......................................1487
Test and adjusting values...................................................................................................................1488
64 75 19 Removing and installing side window..........................................................................................1489

Removing side window.....................................................................................................................1489
Installing side window.......................................................................................................................1491
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64 75 19 Removing and installing side window
64 75 19 Removing and installing rear side window (Cabriolet)..............................................................1493

Removing side window.....................................................................................................................1493
Installing side window.......................................................................................................................1493
64 76 19 Removing and installing side window seal...................................................................................1495

Removing side window seal..............................................................................................................1495
Removing the retaining strip.......................................................................................................1497
Installing side window seal................................................................................................................1497
Installing the retaining strip.........................................................................................................1499
64 76 19 Removing and installing rear side window seal (Cabriolet)......................................................1500

Removing side window seal..............................................................................................................1500
Installing side window seal................................................................................................................1500
64 86 19 Removing and installing rear glass window of Cabriolet...........................................................1501

Removing rear glass window of Cabriolet.........................................................................................1501
Installing rear glass window of Cabriolet..........................................................................................1503
Use of the circlip pliers...............................................................................................................1505
64 86 19 Removing and installing rear window (hardtop)........................................................................1507

Removing rear window (hardtop)......................................................................................................1508
Preparing the window section (hardtop) for installation....................................................................1510
Preparing the rear window (hardtop) for installation.........................................................................1512
Installing rear window (hardtop).......................................................................................................1513
Overview of tools and materials........................................................................................................1516
66 31 19 Removing and installing sill cover................................................................................................1519

Removing sill cover...........................................................................................................................1519
Installing sill cover.............................................................................................................................1521
66 72 37 Disassembling and assembling pump unit...................................................................................1523

Removing hydraulic cylinder.............................................................................................................1524
Filling the hydraulic cylinder.............................................................................................................1526
Installing hydraulic cylinder..............................................................................................................1526
Removing pump.................................................................................................................................1528
Filling the pump unit..........................................................................................................................1529
Installing pump..................................................................................................................................1529
Bleeding the pump unit......................................................................................................................1531
Removing and installing wiring harness............................................................................................1533
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66 72 37 Disassembling and assembling pump unit
Removing wiring harness............................................................................................................1533
Installing wiring harness.............................................................................................................1534
Removing and installing micro switches for rear spoiler............................................................1536
Removing micro switches...........................................................................................................1536
Installing micro switches.............................................................................................................1537
Troubleshooting.................................................................................................................................1537
66 85 19 Removing and installing micro switches for rear spoiler...........................................................1539

Remove micro switches.....................................................................................................................1539
Installing micro switches...................................................................................................................1540
Tools..................................................................................................................................................1540
66 89 37 Disassembling and assembling the rearview mirror...................................................................1541

Disassembling the rearview mirror....................................................................................................1541
Assembling the rearview mirror........................................................................................................1543
68 05 19 Removing and installing inner sill (driver's side).......................................................................1546

Removing inner sill............................................................................................................................1546
Installing inner sill.............................................................................................................................1548
68 05 19 Removing and installing inner sill (passenger's side).................................................................1550

Removing inner sill............................................................................................................................1550
Installing inner sill.............................................................................................................................1551
68 11 19 Removing and installing glove compartment lock......................................................................1553

Removing and installing glove compartment lock............................................................................1553
68 12 19 Removing and installing lid for glove compartment..................................................................1555

Removing lid for glove compartment................................................................................................1555
Installing lid for glove compartment..................................................................................................1556
Replacing microswitch and interior light...........................................................................................1557
Replacing pneumatic shock absorber.................................................................................................1558
68 15 19 Removing and installing glove compartment..............................................................................1560

Removing glove compartment...........................................................................................................1560
Installing glove compartment............................................................................................................1562
68 17 19 Removing and installing center console (front section)..............................................................1564
68 17 19 Removing and installing center console.......................................................................................1568
68 30 19 Removing and installing cup holder.............................................................................................1571

Removing cup holder.........................................................................................................................1571
Installing cup holder..........................................................................................................................1572
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69 11 19 Removing and installing front three−point belt..........................................................................1573
Removing front three−point belt........................................................................................................1573
Installing front three−point belt.........................................................................................................1575
69 11 19 Removing and installing front three−point belt − Cabriolet.....................................................1577

Removing front three−point belt........................................................................................................1577
Installing front three−point belt.........................................................................................................1579
69 11 01 Checking seat belts.........................................................................................................................1581

Checking belt strap............................................................................................................................1581
Checking automatic belt device (locking effect)...............................................................................1582
Belt buckle, visual inspection............................................................................................................1583
Belt buckle, function test...................................................................................................................1583
Checking sash guides.........................................................................................................................1584
Checking mounting elements and mounting points...........................................................................1584
69 12 19 Removing and installing rear three−point belt...........................................................................1585

Removing rear three−point belt.........................................................................................................1585
Installing rear three−point belt...........................................................................................................1587
69 12 19 Removing and installing rear three−point belt − Cabriolet.......................................................1589

Removing rear three−point belt.........................................................................................................1589
Installing rear three−point belt...........................................................................................................1591
69 13 19 Removing and installing belt tensioner − as of MY 2002...........................................................1593

Removing belt tensioner....................................................................................................................1593
Installing belt tensioner......................................................................................................................1594
69 36 19 Removing and installing adjustment fitting (seat belt height adjuster)....................................1596

Removing and installing adjustment fitting.......................................................................................1596
69 51 19 Removing and installing sensor for side airbag..........................................................................1598

Remove sensor for side airbag...........................................................................................................1598
Install sensor for side airbag..............................................................................................................1600
Tools..................................................................................................................................................1601
69 72 19 Removing and installing roll−over bar........................................................................................1602

Safety instructions for work on the roll−over protection system.......................................................1602
Mechanical emergency triggering of the roll−over protection system..............................................1603
Removing roll−over protection system..............................................................................................1604
Installing roll−over protection system...............................................................................................1605
69 74 19 Removing and installing control module for roll−over protection system...............................1608

Removing control module.................................................................................................................1608
Installing control module...................................................................................................................1608
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69 77 19 Removing and installing frame for roll−over protection system...............................................1610
Removing and installing frame for roll−over protection system.......................................................1610
70 05 19 Removing and installing front luggage compartment trim........................................................1613

Removing and installing trims units..................................................................................................1613
Removing and installing carpet lining...............................................................................................1615
70 18 19 Removing and installing the instrument panel and instrument panel bracket − as of
model year 2003............................................................................................................................................1617
Removing and installing the instrument panel..................................................................................1618
Removing and installing the instrument panel bracket......................................................................1619
70 41 19 Removing and installing floor covering.......................................................................................1624
70 57 19 Removing and installing trim of A, B and C−pillars..................................................................1627

Removing and installing trim of A, B and C−pillars.........................................................................1627
Installing trim of A, B and C−pillars.................................................................................................1629
70 57 19 Removing and installing A−pillar trim Cabriolet...................................................................1631

Removing A−pillar trim.....................................................................................................................1631
Installing A−pillar trim......................................................................................................................1632
70 75 19 Removing and installing side−panel lining..................................................................................1635

Removing side−panel lining..............................................................................................................1635
Installing side−panel lining................................................................................................................1637
70 75 19 Removing and installing side−panel lining Cabriolet.............................................................1639

Removing side−panel lining..............................................................................................................1639
Installing side−panel lining................................................................................................................1641
70 84 19 Removing and installing Cabriolet roof lining............................................................................1643

Removing roof lining, front...............................................................................................................1644
Installing front roof lining..................................................................................................................1647
Removing rear roof lining..................................................................................................................1649
Installing rear roof lining...................................................................................................................1650
Removing and installing side roof lining...........................................................................................1652
Removing side roof lining...........................................................................................................1652
Installing side roof lining............................................................................................................1653
72 01 19 Removing and installing front seat...............................................................................................1654

Removing front seat...........................................................................................................................1654
Installing front seat............................................................................................................................1656
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72 21 19 Removing and installing cushion carrier.....................................................................................1658
Removing front cushion carrier.........................................................................................................1658
Installing front cushion carrier...........................................................................................................1660
72 36 19 Removing and installing motor for the lumbar support............................................................1662

Removing lumbar adjustment device for the lumbar support............................................................1663
Removing motor for the lumbar support...........................................................................................1664
Removing electrical line for the lumbar............................................................................................1664
Removing lumbar support.................................................................................................................1664
Installling lumbar adjustment device for the lumbar support............................................................1665
Installing motor for the lumbar support.............................................................................................1666
Installing electrical line for the lumbar..............................................................................................1666
Installing lumbar support...................................................................................................................1666
Tools..................................................................................................................................................1667
Test plan for the lumbar adjustment device.......................................................................................1667
72 86 19 Removing and installing switch for seat adjustment..................................................................1668

Removing switch for seat adjustment................................................................................................1669
Installing switch for seat adjustment..................................................................................................1670
72 87 19 Removing and installing electric motor for the seat adjustment...............................................1672

Removing electric motor for seat adjustment....................................................................................1672
Installing electric motor for seat adjustment......................................................................................1674
Tools..................................................................................................................................................1675
Test plan for the seat adjustment.......................................................................................................1675
72 88 19 Removing and installing electric motor for the front seat height adjustment.........................1677
Removing electric motor for front seat height adjustment................................................................1677
Installing electric motor for front seat height adjustment..................................................................1679
Tools..................................................................................................................................................1680
Test plan for the front seat height adjustment....................................................................................1680
72 89 19 Removing and installing electric motor for the backrest adjustment.......................................1682

Removing and installing electric motor for the backrest adjustment................................................1683
Installing electric motor for backrest adjustment...............................................................................1684
Routing of wiring harness for the backrest adjustment.....................................................................1685
Tools..................................................................................................................................................1685
Test plan for the backrest adjustment device.....................................................................................1686
72 92 19 Removing and installing electric motor for the rear seat height adjustment...........................1687
Removing electric motor for rear seat height adjustment..................................................................1687
Installing electric motor for rear seat height adjustment...................................................................1689
Tools..................................................................................................................................................1690
Test plan for the rear seat height adjustment.....................................................................................1690
74 13 55 Replacing cover for front seat cushion.........................................................................................1692

Removing cover for the front seat.....................................................................................................1692
Installing cover for the seat cushion..................................................................................................1694
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74 13 55 Replacing cover for front seat cushion
74 19 19 Removing and installing centre backrest strip............................................................................1696

Removing the backrest centre strip....................................................................................................1696
Installing the backrest centre strip.....................................................................................................1698
74 19 55 Replacing covering for backrest centre strip..............................................................................1699

Removing covering for backrest centre strip.....................................................................................1699
Installing covering for backrest centre strip.......................................................................................1701
74 27 19 Removing and installing control module for seat heating..........................................................1703

Removing and installing control module for seat heating.................................................................1704
Seat heating line route........................................................................................................................1704
Central plug........................................................................................................................................1705
Removing and installing pin housing for seat heating and belt buckle.............................................1705
Tools..................................................................................................................................................1706
Test plan for the seat heating.............................................................................................................1706
90 25 19 Removing and installing instrument cluster................................................................................1708

Removing instrument cluster.............................................................................................................1708
Installing instrument cluster...............................................................................................................1709
Coding the instrument cluster............................................................................................................1709
91 10 19 Removing and installing display and operator control unit (PCM)..........................................1711

Removing display and operator control unit (PCM)..........................................................................1712
Installing display and operator control unit (PCM)...........................................................................1712
Connecting and switching on the Porsche System Tester 2........................................................1712
Device code input........................................................................................................................1713
91 10 19 Removing and installing display and operator control unit (PCM 2) − as of MY 2003..........1714
Removing display and operator control unit (PCM 2).......................................................................1714
Installing display and operator control unit (PCM 2)........................................................................1715
Teaching display and operator control unit (PCM 2)........................................................................1717
91 20 02 Checking complaints about car radio system..............................................................................1721

Malfunctions in radio system.............................................................................................................1721
Reduced sound quality in one or more loudspeakers.........................................................................1722
Remedying problems with the amplifier............................................................................................1723
Interference noises.............................................................................................................................1724
Interference noises, checking cable connections.........................................................................1725
Interference noises due to alternator...........................................................................................1726
Interference noises due to engine................................................................................................1726
Interference noise due to antenna................................................................................................1727
Interference noises due to power supply.....................................................................................1728
Interference noises due to all looudspeakers...............................................................................1730
Electromagnetic compatibility (EMC) − Troubleshooting................................................................1731
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91 20 02 Checking complaints about car radio system
Tools..................................................................................................................................................1732
91 24 19 Removing and installing the car radio − as of MY 2003............................................................1733

Tools..................................................................................................................................................1733
Removing the car radio......................................................................................................................1733
Installing the car radio.......................................................................................................................1735
Teaching the car radio........................................................................................................................1735
91 42 19 Removing and installing rear loudspeakers, Bose sound package............................................1738

Removing rear loudspeakers..............................................................................................................1738
Installing rear loudspeakers...............................................................................................................1739
91 44 19 Removing and installing the loudspeaker amplifier...................................................................1741

Removing the loudspeaker amplifier.................................................................................................1741
Installing the loudspeaker amplifier...................................................................................................1743
91 74 19 Removing and installing control module for parking assistant.................................................1745

Removing control module for parking assistant................................................................................1745
Installing control module for parking assistant..................................................................................1746
91 84 19 Removing and installing antenna amplifier − as of MY 2003....................................................1747

Removing antenna amplifier..............................................................................................................1748
Installing antenna amplifier...............................................................................................................1748
91 86 19 Removing and installing control module for antenna................................................................1749

Removing control module for antenna..............................................................................................1749
Installing control module for antenna................................................................................................1750
91 90 19 Removing and installing control module for telephone..............................................................1752

Removing control module for telephone...........................................................................................1752
Installing control module for telephone.............................................................................................1753
92 12 19 Removing and installing rain sensor............................................................................................1754

Removing rain sensor........................................................................................................................1754
Installing rain sensor..........................................................................................................................1757
Open circuit in the rain sensor connection (emergency interval operation)......................................1760
92 13 19 Removing and installing control module for rain sensor...........................................................1761

Removing control module for rain sensor.........................................................................................1762
Installing control module for rain sensor...........................................................................................1763
Safety function in the event of failure (engine blockage)..................................................................1764
96 64 32 Converting installation position for tilt sensor, additional alarm system M536......................1765
Tools..................................................................................................................................................1767
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96 87 19 Removing and installing control unit for alarm system.............................................................1768
Removing control unit for alarm system...........................................................................................1768
Installing control unit for alarm system.............................................................................................1770
Teaching control unit for the alarm system.......................................................................................1771
97 89 19 Removing and installing current distributor..............................................................................1773

Removing current distributor.............................................................................................................1773
Installing the current distributor.........................................................................................................1775
97 92 19 Removing and installing fusible element in the current distributor.........................................1778

Removing fusible element from the current distributor.....................................................................1778
Installing fusible element in the current distributor...........................................................................1779
911 Turbo (996) Technical Manual.............................................................................................................1780

General...............................................................................................................................................1780
Structure.............................................................................................................................................1780
Breakdown of Repair Groups............................................................................................................1780
Legend for structure of sequence description....................................................................................1780
Structure of exploded view................................................................................................................1782
Structure of sequence description......................................................................................................1783
97 Wiring diagram for 911 Turbo (996), 01 model....................................................................................1785
97 Wiring diagram for 911 Turbo (996), 02 model....................................................................................1787
97 Circuit diagram for 911 Turbo (996), '03 model...................................................................................1789
Preconditions for using workshop documentation for Porsche vehicles.................................................1795
01 Mobile roofs: checking function.............................................................................................................1797

Checking sliding roof.........................................................................................................................1797
Checking convertible top...................................................................................................................1797
Checking the hardtop.........................................................................................................................1797
01 Glazing: visual inspection for damage...................................................................................................1799
01 Checking lid and doors............................................................................................................................1800

Checking lid lock, front and rear.......................................................................................................1800
Checking safety hook, front lid..........................................................................................................1800
Function test, checking door lock......................................................................................................1800
Functional inspection of the tank cap lock........................................................................................1800
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01 Interior equipment: visual inspection for damage and soiling............................................................1801
01 Removing transport protection..............................................................................................................1802

1 Removing external transport protection..........................................................................................1802
1 Removing internal transport protection..........................................................................................1803
01 Installing air guides for PCCB brake discs − GT2...............................................................................1804

Installing front air guides...................................................................................................................1804
Installing rear air guides.....................................................................................................................1804
01 Fitting front lip GT2.............................................................................................................................1806
01 Fitting six−point seat belt GT2............................................................................................................1807
01 Checking the Vehicle Ident. No..............................................................................................................1809
01 Checking the exterior equipment and paint finish...............................................................................1810

Checking exterior equipment.............................................................................................................1810
Checking paint finish.........................................................................................................................1810
01 Completing vehicle and checking equipment for completeness..........................................................1811

Checking vehicle equipment for completeness..................................................................................1811
Tools............................................................................................................................................1811
Completing the vehicle......................................................................................................................1812
3 Technical Data − GT2................................................................................................................................1813

6−speed manual transmission G 96.88..............................................................................................1813
Manual transmission tightening torques......................................................................................1814
4 Running gear, general − GT2...................................................................................................................1815

General...............................................................................................................................................1815
4 Notes on repair instructions − GT2..........................................................................................................1817

General...............................................................................................................................................1817
Adjustment operations on the spring struts........................................................................................1817
Suspension alignment........................................................................................................................1818
Wheel removal/installation................................................................................................................1818
Brake − General.................................................................................................................................1819
Brake booster.....................................................................................................................................1819
4 Tests / notes GT2.....................................................................................................................................1820

Note....................................................................................................................................................1820
Lifting platform / test stands..............................................................................................................1820
Wheel alignment platform.................................................................................................................1820
Brake test...........................................................................................................................................1820
Power test...........................................................................................................................................1820
Front and rear stabilizer setting..........................................................................................................1821
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4 Tests / notes GT2
Spoiler setting....................................................................................................................................1821
Racing camber values........................................................................................................................1822
44 Alignment card − GT2.............................................................................................................................1823
Suspension alignment − GT2.......................................................................................................................1825

Suspension alignment, complete........................................................................................................1825
Driving onto measuring platform.......................................................................................................1825
Tools..................................................................................................................................................1825
Deviating points for GT2...................................................................................................................1826
Notes on height changes/wheel−load changes...................................................................................1827
Vehicle height GT2............................................................................................................................1828
Wheel alignment................................................................................................................................1829
Front−axle camber setting...........................................................................................................1830
Camber fine adjustment...............................................................................................................1830
Camber/toe, rear axle..................................................................................................................1831
Instructions for fitting diagonal control arm on control arm GT2..................................................1831
44 Tyre failure / tyre sealant GT2............................................................................................................1833

Repair procedure................................................................................................................................1833
46 Technical data/Brake wear limit − GT2................................................................................................1835

Technical Data − GT2........................................................................................................................1835
Wear limit technical Data − GT2.......................................................................................................1836
40 Disassembling and assembling front spring strut GT2.....................................................................1837

Notes about adjustment work on the spring struts.............................................................................1837
Disassembling and assembling front spring strut GT2...................................................................1838
Disassembly and assembly instructions.............................................................................................1839
Disassembly.................................................................................................................................1839
Preliminary work and notes on assembly....................................................................................1840
Assembly.....................................................................................................................................1840
42 Disassembling and assembling rear spring strut − GT2......................................................................1843

Notes about adjustment work on the spring struts.............................................................................1843
Disassembling and assembling rear spring strut − GT2....................................................................1844
Disassembly.................................................................................................................................1846
Preliminary work and notes on assembly....................................................................................1846
Assembly.....................................................................................................................................1847
30 01 07 Bleeding the clutch system − GT2................................................................................................1850

Filling/bleeding..................................................................................................................................1850
30 45 19 Removing and installing release bearing (clutch removed) − GT2...........................................1852

Removing release bearing..................................................................................................................1853
Installing release bearing...................................................................................................................1853
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30 50 19 Removing and installing clutch − GT2.........................................................................................1855
Tools..................................................................................................................................................1855
Removing clutch................................................................................................................................1855
Installing clutch..................................................................................................................................1856
30 50 37 Disassembling and assembling clutch − GT2..............................................................................1857
34 01 55 Changing transmission oil − GT2.................................................................................................1858

Changing transmission oil − GT2......................................................................................................1858
Topping up transmission oil − GT2...................................................................................................1858
34 35 27 Removing and refitting the transmission − GT2.........................................................................1860

Tools..................................................................................................................................................1860
Removing transmission......................................................................................................................1860
Refitting transmission........................................................................................................................1861
34 37 37 Disassembling and assembling transmission housing − GT2.....................................................1864

Tools..................................................................................................................................................1864
Overview............................................................................................................................................1865
Disassembly.................................................................................................................................1867
Assembly.....................................................................................................................................1867
34 52 37 Disassembling and assembling gear housing − GT2...................................................................1869

Tools..................................................................................................................................................1869
Overview............................................................................................................................................1870
Disassembling gear housing..............................................................................................................1871
Disassembling gearshift..............................................................................................................1871
Removing outer bearing race......................................................................................................1872
Removing ball sleeves.................................................................................................................1872
Removing screw plug..................................................................................................................1872
Assembling gear housing...................................................................................................................1872
Assembling gearshift...................................................................................................................1873
Installing outer bearing race........................................................................................................1873
Installing ball sleeves..................................................................................................................1873
Installing screw plug...................................................................................................................1873
34 55 37 Disassembling and assembling front transmission cover GT2...............................................1875

Tools..................................................................................................................................................1875
Overview............................................................................................................................................1876
Disassembling front transmission case cover....................................................................................1877
Disassembling reverse idler gear.................................................................................................1877
Dismantling cylinder−roller bearing...........................................................................................1877
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34 55 37 Disassembling and assembling front transmission cover GT2
Disassembling outer bearing race................................................................................................1878
Assembling front transmission case cover.........................................................................................1879
Fitting reverse idler gear..............................................................................................................1879
Fitting cylindrical−roller bearing................................................................................................1879
Fitting outer bearing race............................................................................................................1880
34 72 19 Removing and installing transmission oil pump − GT2.............................................................1881

Tools..................................................................................................................................................1881
Removing transmission oil pump......................................................................................................1881
Installing transmission oil pump........................................................................................................1882
34 74 19 Removing and installing transmission oil cooler − GT2.............................................................1883

Tools..................................................................................................................................................1883
Overview............................................................................................................................................1883
Removing transmission oil cooler.....................................................................................................1884
Installing transmission oil cooler.......................................................................................................1886
35 50 19 Removing and installing sealing ring for drive shaft − GT2......................................................1888

Tools..................................................................................................................................................1888
Removing sealing ring for drive shaft...............................................................................................1888
Installing sealing ring for drive shaft.................................................................................................1889
39 08 15 Adjusting drive set − GT2.............................................................................................................1892

Tools..................................................................................................................................................1892
Sequence of adjustment operations....................................................................................................1893
Determining disc thickness S4 and S5...............................................................................................1893
Determining disc thickness S3...........................................................................................................1895
Determining disc thickness S1 and S2...............................................................................................1897
Determining total disc thickness S1 + S2....................................................................................1897
Dividing the total disc thickness into S1 and S2.........................................................................1898
Checking the circumferential backlash and setting, if necessary................................................1898
39 22 19 Removing and installing sealing ring for halfshaft flange − GT2.............................................1901

Tools..................................................................................................................................................1901
Removing sealing ring for halfshaft flange.......................................................................................1901
Installing sealing ring for halfshaft flange.........................................................................................1902
39 40 19 Removing and installing differential and differential lock − GT2............................................1904

Tools..................................................................................................................................................1904
Overview............................................................................................................................................1904
Removing differential and differential lock.......................................................................................1906
Installing diffential and differential lock...........................................................................................1906
lviii
einordnung
Table of Contents
39 40 19 Removing and installing differential and differential lock − GT2.
39 40 37 Assembling and disassembling differential and differential lock − GT2..................................1907

Tools..................................................................................................................................................1907
Overview............................................................................................................................................1907
Disassembling GKN differential lock................................................................................................1909
Assembling GKN differential lock....................................................................................................1909
46 16 24 Installing air ducts for PCCB brake discs − GT2.......................................................................1912

Installing front air ducts.....................................................................................................................1912
Installing rear air ducts.......................................................................................................................1913
46 36 20 Removing and installing the front disc brake pads − GT2 / Turbo with PCCB......................1914
Removal.............................................................................................................................................1915
Installation.........................................................................................................................................1917
Bedding in the brake pads...........................................................................................................1918
46 38 20 Removing and installing the rear disc brake pads − GT2 / Turbo with PCCB.......................1919
Removal.............................................................................................................................................1920
Installation.........................................................................................................................................1921
Bedding in the brake pads...........................................................................................................1922
46 50 19 Removing and installing the front PCCB brake disc.................................................................1923

Removal.............................................................................................................................................1923
Explanation of 2−part brake disc.......................................................................................................1924
Installation.........................................................................................................................................1924
Note on bedding in the new brake pads......................................................................................1925
46 53 19 Removing and installing the rear PCCB brake disc...................................................................1926

Removal.............................................................................................................................................1926
Explanation of 2−part brake disc.......................................................................................................1927
Installation.........................................................................................................................................1927
Note on bedding in the new brake pads......................................................................................1928
47 01 07 Bleeding brake − GT2....................................................................................................................1929

General...............................................................................................................................................1929
Bleeding brakes..................................................................................................................................1929
34 35 37 Disassembling transmission − GT2..............................................................................................1931

Tools..................................................................................................................................................1931
Removing transmission cover............................................................................................................1932
Disassembling front gear set..............................................................................................................1932
Overview.....................................................................................................................................1932
Disassembling gear set................................................................................................................1934
Removing gear housing.....................................................................................................................1935
Removing input and output shaft.......................................................................................................1935
lix
einordnung
Table of Contents
34 35 37 Disassembling transmission − GT2
Overview.....................................................................................................................................1936
Removing shafts..........................................................................................................................1937
Disassembling output shaft................................................................................................................1938
Overview.....................................................................................................................................1938
Dismantling input shaft......................................................................................................................1939
Overview.....................................................................................................................................1939
34 35 37 Assembling transmission − GT2...................................................................................................1942

Tools..................................................................................................................................................1942
Assembling shafts........................................................................................................................1943
Assembling shaft.........................................................................................................................1944
Installing input and output shaft........................................................................................................1944
Installing shafts............................................................................................................................1944
Fitting gear housing...........................................................................................................................1948
Fitting housing.............................................................................................................................1948
Assembling front gear set..................................................................................................................1948
Assembling gear set.....................................................................................................................1948
Fitting front transmission case cover.................................................................................................1951
Fitting cover................................................................................................................................1951
45 46 19 Removing and installing front ABS lead (GT2)..........................................................................1952

Removing front ABS lead..................................................................................................................1952
Installing front ABS lead...................................................................................................................1954
Tools..................................................................................................................................................1955
50 30 19 Removing and installing air guide GT2....................................................................................1956

Removing and installing air guide.....................................................................................................1956
55 90 19 Removing and installing rear lid − GT2......................................................................................1958

Removing and installing rear lid........................................................................................................1958
55 90 37 Disassembling and assembling rear lid GT2............................................................................1961

Disassembling rear lid........................................................................................................................1961
Assembling rear lid............................................................................................................................1964
Replace model logo.....................................................................................................................1966
Removing and installing rear−lid wiring harness.......................................................................1966
lx
einordnung
Table of Contents
63 15 19 Removing and installing front spoiler GT2..............................................................................1969
Removing front spoiler......................................................................................................................1969
Installing front spoiler........................................................................................................................1971
63 15 37 Disassembling and assembling front spoiler GT2...................................................................1973

Disassembling front spoiler...............................................................................................................1973
Removing front spoiler................................................................................................................1975
Installing front spoiler........................................................................................................................1976
Installing front spoiler.................................................................................................................1977
66 58 19 Removing and installing rear spoiler GT2...............................................................................1979

Removing rear spoiler........................................................................................................................1979
Installing rear spoiler.........................................................................................................................1981
Replacing rear spoiler fork..........................................................................................................1982
69 72 19 Removing and installing roll−over bar − GT2............................................................................1984

Removing roll−over bar.....................................................................................................................1984
Installing the roll−over bar................................................................................................................1987
Adjusting the roll−over bar................................................................................................................1991
Assembly instructions for the rear trim, the floor covering and the closure caps.............................1991
72 01 19 Removing and installing bucket seat GT2 − as of MY 2001...................................................1993

Removing bucket seat GT2................................................................................................................1993
Installing bucket seat GT2.................................................................................................................1995
Fitting six−point seat belt GT2................................................................................................1996
96 61 19 Removing and installing relay for main switch − GT2 − as of MY 2001..................................1998

Installing the main battery relay........................................................................................................1999
Installing inner EMERGENCY STOP switch...................................................................................2000
Removing the main battery relay.......................................................................................................2001
Removing the inner EMERGENCY STOP switch............................................................................2002
Operating the main battery switch.....................................................................................................2003
Status − A − Road . Status − B − Racing track...........................................................................2003
Actuating inner EMERGENCY STOP switch............................................................................2004
Moving the EMERGENCY STOP switch to its starting position...............................................2005
53 05 55 Replacing rear closing panel − Carrera 4S..................................................................................2006

Cutting out rear closing panel............................................................................................................2006
Inserting rear closing panel................................................................................................................2008
53 69 19 Removing and installing rear wheel housing liners − Carrera 4S.............................................2012
55 90 19 Removing and installing rear lid − Carrera 4S...........................................................................2014
55 90 37 Disassembling and assembling rear lid Carrera 4S................................................................2016

Disassembling rear lid........................................................................................................................2017
Assembling rear lid............................................................................................................................2019
lxi
einordnung
Table of Contents
55 90 37 Disassembling and assembling rear lid Carrera 4S
Removing and installing additional brake light.................................................................................2022
Installing rubber covering − Cabriolet...............................................................................................2023
Removing and installing reflector cover............................................................................................2024
Removing and installing wiring harness............................................................................................2024
Replacing the model logo..................................................................................................................2025
Test and adjustment values................................................................................................................2025
55 91 19 Removing and installing rear lid hinges − Carrera 4S...............................................................2027
19 58 19 Removing and installing coolant regulator..................................................................................2030

Removal overview of the coolant regulator.......................................................................................2030
Installation overview of the coolant regulator...................................................................................2033
lxii
Information on handling of the GT2 scope.
This supplement represents the basic edition for the vehicle 911 GT2.
The GT2 is recorded with the 911 Turbo in one file and is separated with a cardboard cover sheet. This
supplement should be filed behind the 911 Turbo material in the file Group 3 "Transmission, manual
transmission" and should be updated there with a separate Table of Contents.
996840, 996841
Information on handling of the GT2 scope. 1

0 Technical data
Engine
Engine design
Engine cooling
Engine lubrication
Engine control
Heating
Fuel system
Electrical system
Exhaust system
Emission control
Transmission
Clutch
Transmission
Body designs
Running gear
Brakes
Wheels and tyres
Spare wheel
Wheel alignment
Dimensions
Weights according to DIN 700 20
Filling capacities
Performance data
Climbing performance
Specific power
0 Technical data 2
einordnung
top of page
Engine
Engine
Engine type M96/70
No. of cylinders 6
Bore 100 (3.94) mm (in.)
Stroke 76.4 (3.01) mm (in.)
Cubic capacity 3600 (219.7) cm3 (cu.in.)
Compression ratio 9.4 : 1
Max. engine power 309 (420) kW (HP)
as per 80/1269/EEC
Net power as per SAE J1349 415 HP
Engine 3
einordnung
at engine speed 6000 rpm

Max. torque 560 (57.08) Nm (ftlb.)
as per 80/1269/EEC
Net torque as per SAE J1349 415 ftlb.
at engine speed 2700 to 4600 rpm
Max. litre output 85.8 (116.6) kW/l (HP/l)
HP/l (115.3)
Engine speed limitation
by fuel cutoff at
6750 rpm
Idle speed 740 ± 40 rpm
Automatic transmission 740 ± 40 rpm
Engine weight as per Manual transmission Automatic transmission
DIN 70020 A, kg 260* (572.7) 253 (557.27)
* including ZMS (double−mass flywheel)
top of page
Engine design
Engine design
Type 6−cylinder aluminium opposed−cylinder engine,
water cooled, bi−Turbo
Crankcase Vertically divided crankcase made from cast light
alloy, separate cylinder housing
Cylinder housing Cast light alloy with wet light alloy bushings
inserted, Nikasil coating
Crankshaft Forged, supported by 8 bearings
Crankshaft bearings Plain bearings
Connecting rods Forged
Con−rod bearings Plain bearings
Piston Pressed light alloy
Cylinder Nikasil cylinder lining
Cylinder head Light alloy
Camshaft housing Aluminium alloy
Valve guide Pressed in
Valve arrangement 2 inlet valves suspended in parallel V arrangement
2 exhaust valves suspended in parallel V
arrangement
Valve control Via flat−base tappets
Camshaft From the crankshaft via a gear wheel to the
intermediate shaft, and from there to the exhaust and
inlet camshafts via one double chain each.
Engine design 4
einordnung
Camshaft adjustment Porsche VarioCam Plus with 30° adjustment

Valve clearance Hydraulic valve clearance compensation
Valve timing
with 1 mm valve travel and zero clearance Inlet opens at 10° before TDC
(kinetic clearance of the operating plunger taken Inlet closes at 20° after BDC
into account, basic inlet camshaft setting early) Outlet opens at 41° before BDC
Outlet closes at 9° before TDC
Intake system Tuned−intake system (plastic)
top of page
Engine cooling
Engine cooling
Water cooling; 3 radiators ahead of the front wheels.
(Additional radiator for Tiptronic vehicles)
Two electric fans, controlled in three stages
top of page
Engine lubrication
Engine lubrication
Type Dry sump lubrication with separate canister
Oil cooling Via oil−water heat exchanger
Oil filter On pressure side behind oil pump
Oil pressure
at n = 5000 rpm Approx. 6.5 bar at 90° C
Oil pressure indicator Oil pressure indicator light plus instrument
Oil consumption Max. 1.0l/1000km
top of page
Engine control
Engine control
Engine control module Bosch ME 7.8
Ignition DME, individual spark coils, knock control
Firing order 1−6−2−4−3−5
Engine cooling 5
einordnung
Ignition timing control Via DME (ECM)

Spark plugs Bosch FR 5 LOC
Beru 14−FR 5 LDU
Electrode gap
mm (in) 1.6 ± 0.2 (0.06 ± 0.008)
E−gas Electronic throttle actuator control via DME ME 7.8
USA version On−Board Diagnosis II
Boost pressure control Absolutely pressure−guided turbocharger control
top of page
Heating
Heating
Via water heat exchanger, closed loop−controlled on air side
top of page
Fuel system
Fuel system
Injection ME 7.8 (Digitale−Motor−Electronic engine control module ECM)
Injection valves controlled sequentially
Fuel supply 1 electrical internal gear pump with 2 additional sucking jet pumps
Fuel quality (RON) 98 unleaded
top of page
Electrical system
Electrical system
Radio interference suppression ECE−R 10 and 95/54/EC
Rated voltage 12 V
Battery capacity 80/380 Ah/A
Starter 1.7 kW
Rated generator output 1680 (three−phase generator) W
top of page
Engine control 6
einordnung
Exhaust system
Exhaust system
2−pipe, 3−way catalytic converter exhaust system, rear mufflers
top of page
Emission control
Emission control
EURO III Stereo oxygen sensor closed−loop control and 3−way catalytic converter system,
each with a 2−stage catalytic converter on left+right, secondary air system,
Europe OBD
USA LEV Stereo oxygen sensor closed−loop control and 3−way catalytic converter system,
each with a 2−stage catalytic converter on left+right, secondary air system, OBD
II + ORVR
top of page
Transmission
Transmission
Engine and transmission bolted together to form a power unit. Rear axle drive via double−jointed
drive shafts, front axle drive via cardan shaft, front axle transmission and double−jointed drive shafts.
top of page
Clutch
Clutch
Manual transmission Single−plate dry clutch, hydraulic actuation with hydraulic
support, double−mass flywheel
Contact plate GGG 60
Clutch plate 240
Automatic transmission
Converter 270 (10.64) mm (in)
Moving−off ratio 1.92
Stall speed 2600 rpm
Exhaust system 7
einordnung
top of page
Transmission
Transmission
Manual Tiptronic Z front axle
transmission TOP transmission
TOP A 96.50 TOP
G 96.50 Z 96/00
Number of gears,
forward/reverse 6/1 5/2
Internal designation,
transmission ratios (i)
1st gear 3.82 3.59
2ndgear 2.05 2.19
3rd gear 1.41 1.41
4th gear 1.12 1.00
5th gear 0.92 0.83
6th gear 0.75
Reverse gear −2.86 −1.93/−3.16
Final drive Bevel gear
wheel
Final drive ration
rear axle (i) 3.44 2.889
front axle 2.883 3.44
Transmission weight
(dry) 68.6 116.5 (256.82)
kg (lbs) as−delivered condition dry
Transmission weight
wet and ready for
installation 72 125.2 (272.47) with converter, with oil,
kg (lbs) with cooler (as−delivered condition)
Front axle
transmission weight
with long−neck pipe 23.0
(wet)
kg (lbs)
top of page
Clutch 8
einordnung
Body designs
Body designs
Lightweight, galvanised all−steel integral body−frame, partially
HSLA, full−size airbag for driver and passenger, side airbag.
No. of seats = 2+2
top of page
Running gear
Running gear
Front axle Spring strut axle Wheels individually suspended by control arms with
trailing arms and spring struts (McPherson design,
optimised by Porsche)
Springs One truncated cone spring per wheel, with vibration
damper inside spring
Spring constant 33 N/mm
Spring wire diameter 12.6 to 14.0 mm (in)
Coil diameter 113.2 to 186.5 (3.6 to mm (in)
7.35)
No. of turns 4.05
Stabilizer diameter 23.6 x 3.5 mm (in) tube−type stabilizer
Vibration damper Double−acting hydraulic twin−tube gas−filled vibration damper
Rear axle Multi−link axle
Wheel suspension Wheels individually guided by 5 control arms
Springs Cylindrical coil spring per wheel, with coaxial vibration damper inside spring
Spring constant 60 N/mm
Spring wire diameter 13.21/13.35 mm (in)
Coil diameter 115.0 mm (in)
No. of turns 6.75/7.0
Stabilizer diameter 21.7 x 3.0 mm (in) tube−type stabilizer
Vibration damper Double−acting hydraulic single−tube gas−filled vibration damper
Steering
Steering wheel 380 (14.77) mm (in)
diameter
Steering ratio 16.9 :1 Left−hand drive
16.9 : 1 Right−hand drive
Turning circle 10.6 (34.8) m (ft)
diameter
Body designs 9
einordnung
Track circle diameter 10.2 (33.5) m (ft)

Steering wheel 2.98 Left−hand drive
revolutions
from lock to lock
2.98 Right−hand drive
Power steering pump Driven via poly V−belt
Ratio i = 1 : 0.95
top of page
Brakes
Brakes
Operating brake Foot operated, hydraulic−mechanical boost,
dual−circuit brake system, 4−piston Al monobloc
brake calipers at FA and RA, distributed per axle,
internally ventilated brake discs at front and rear axles.
Vacuum brake booster
(boost factor) 3.85
Brake master cylinder 25.4 (1.00) mm (in)
Brake master cylinder stroke 18/18 (0.71/0.71) mm (in)
Brake discs front 330 (13.00) mm (in)
rear 330 (13.00)
Effective brake disc front 134 (5.28) mm (in)
rear 136 (5.36)
Brake disc thickness front 34 (1.34) mm (in)
rear 28 (1.10)
Effective total brake pad area per wheel front 157 (24.34) cm2 (sq.in)
rear 127 (19.69)
Piston in brake caliper front 36 (1.42) and 44 (1.73) mm (in)
rear 28 (1.10) and 30 (1.18)
Parking brake Drum−type parking brake
Brake drum 180 (7.092) mm (in)
Brake shoe width 25 (0.985) mm (in)
Lining area per wheel 85 (13.08) cm2 (sq.in)
Running gear control systems Standard Porsche Stability Management (PSM) with
ABS, Traction Control (TC), ABD, MSR (engine drag
torque control), FZR (vehicle regulator) and EBV
(electronic brake distributor). Passive switching
possibility for TC, FZR and MSR.
top of page
Running gear 10
einordnung
Wheels and tyres
Wheels and tyres

Summer tyres RO (mm)
Tyre size, front on wheel 225/40 ZR 18 −8 J x 18 50*
Tyre size, rear on wheel 295/30 ZR 18 − 11 J x 18 45*
Winter tyres ** RO (mm)
Tyre size, front on wheel 225/40 R 18 88H M + S − 8 J x 18 50
Tyre size, rear on wheel 265/35 R 18 93H M + S − 10 J x 18 47**
* only if specified make is fitted

** M + S tyres with higher load rating and/or higher speed symbols can also be mounted optionally (rear =
max. 210 km/h or front = max. 240 km/h).
*** Snow chains approved if special chains are used.
top of page
Spare wheel
Spare wheel
Collapsible wheel 165/70 * −R16 92P Vredestein Space Master
Wheel 5.5 J x 16 rim offset 10
Tyre pressure summer winter
front 2.5 2.5 bar
rear 3.0 3.0 bar
Collapsible wheel 2.5 bar
top of page
Wheel alignment
Wheel alignment
Front axle
at DIN empty weight
Toe−in (total) + 5 min. ± 5 min.
(max. difference left to right: 5 min.)
Camber
USA 0 degrees ± 15 min.
RoW − 30 min. ± 15 min.
Wheels and tyres 11

einordnung
Caster 8 degrees ± 30 min.

Toe−difference angle at 20 degrees lock RoW − 2 degrees 20 min. ± 30 min.
USA − 1 degree 20 min. ± 30 min.
Rear axle
at DIN empty weight
Toe−in (per wheel) + 10 min. ± 5 min.
Camber − 1 degree 25 min. ± 15 min.
top of page
Dimensions
Dimensions
Length 4435 (174.74) mm (in)
Width 1830 (72.0) mm (in)
Height 1295 (51.02) at DIN empty weight mm (in)
Wheel base 2350 (92.59) mm (in)
Track widths 18 inch mm (in)
front 1465 (57.72) mm (in)
rear 1522 (59.97) mm (in)
Ground clearance 90* (3.55) mm (in)
for USA 110* (4.33)
at permissible total weight 55 (2.17)
Ramp angle 12.5* degrees
for USA 14.0* degrees
Overhang angle, front 10.0* degrees
Overhang angle, rear 13.0* degrees
* Design position according to Porsche definition in acc. with PN 230
top of page
Wheel alignment 12
einordnung
Coupé manual transmission Coupé Tiptronic

Empty weights according to equipment kg (lbs)
front 605 (1333.7) 605 (1333.7)
rear 935 (2061.2) 980 (2160.4)
entire Coupé* 1540 (3394.9) 1585 (2494.1)
* for EU homologation plus 75 kg driver's share (35 kg at front axle, 40 kg at rear axle)
Permissible axle load
Coupé, front 825 (1818.71) 825 (1708.49)
rear 1180 (2601.3) 1180 (2601.3)
Max. gross weight 1885 (4155.48) 1930 (4254.69)
Max. trailer load
Braked none none
Unbraked none none
Permissible towed weight none none
Permissible drawbar load none none
Permissible roof load, kg (lbs.)
with Original Porsche Roof Transport System 75 (165) 75 (165)
top of page
Filling capacities
Note
• Measurement of the engine oil level by instrument or oil dipstick!
• The Driver's Manual is definitive!
Filling capacities
Engine specification Approved:
Europe: According to ACEA Specification
A4−96 and special Porsche requirements
(refer to Techn. Info. notice about engine
oils)
USA, RoW: According to API SG und SHn
Specification and special Porsche
requirements (refer to Techn. Info. notice
about engine oils)
Engine oil quantity Approx. 12.5 (2.71) l (Imp. gal.)
change quantity 8.5
(1.84)
with filter change 8.75
(1.90)
Weights according to DIN 700 20 13

einordnung
Manual transmission with 3.8 (0.82) l (Imp. gal.)

differential
Automatic transmission with torque Approx. 9,0 (1,95) l (Imp. gal.)
converter
Differential 1.2 (0.26) l (Imp. gal.)
Specification for transmission oil Manual transmission Tiptronic
(first filling)
SAE 75 W90 Shell ATF 3403−M115
Mobilube PTX
Specification for differential SAE 85 W 90 or
transmission oil, Tiptronic (first BP Olex GO 4927
filling)
Fuel tank Reserve 12 (2.6) l (Imp. gal.)
RoW − refill volume Approx. 64 (13.87) l (Imp. gal.)
(nominal volume)
USA − refill volume Approx. 63 (13.65) l (Imp. gal.)
(nominal volume)
Coolant 28 (6.07) l (Imp. gal.) 29 (6.28) l (Imp. gal.)
Brake fluid reservoir Approx. 0.63 (0.136) l (Imp. gal.)
Tank for windscreen washer and Approx. 2.5/6.5 l (Imp. gal.)
headlight cleaning system (0.54/1.41)
Power steering 2.14 Pentosin CHF 11S l
top of page
Performance data
Performance data
Manual transmission Tiptronic
Top speed 305 298 km/h
(189.4) (185.1) mph
Acceleration 4.2 s 4.9 s 0 − 100 km/h
Kilometre from standing start 22.4 s 23.9 s
1/4 mile from standing start
Elasticity
80 − 120 km/h 5.0 s 5th gear
100 − 200 km/h 11.9 s 5th gear
top of page
Filling capacities 14
einordnung
1st gear 89.3 79.3 %
2nd gear 89.5 70.4 %
3rd gear 50.9 38.1 %
4th gear 37.4 24.3 %
5th gear 29.0 17.9 %
6th gear 21.9 − %
top of page
Specific power
Specific power
4.98 5.12 kg/kW
3.66 3.77 kg/HP
3.71 3.81 kg/HP
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Climbing performance 15
0 Entire vehicle General
Lifting the vehicle
top of page
Lifting the vehicle
CAUTION
Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the
lifting platform!
• Lift the vehicle only at the take−up points shown in the figure!
• Make sure the screw connections for the diagonal braces are accessible!
• When driving onto a platform lift, make sure that there is sufficient distance between the platform lift
and the vehicle!
• In order to avoid damage to the side members and side member panels, the mounting plates of the
platform lift must be raised!
front
rear
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
0 Entire vehicle General 16

Power unit
Engine M96/70
Engine
Engine design
Engine cooling
Engine lubrication
Engine control
top of page
Engine M96/70
top of page
Power unit 17
einordnung
Engine
Engine
Engine type M96/70
No. of cylinders 6
Bore 100 (3.94) mm (in.)
Stroke 76.4 (3.01) mm (in.)
Cubic capacity 3600 (219.7) cm3 (cu.in.)
Compression ratio 9.4 : 1
Max. engine power 309 (420) kW (HP)
as per 80/1269/EEC
Net power as per SAE J1349 415 HP
at engine speed 6000 rpm
Max. torque 560 (57.08) Nm (ftlb.)
as per 80/1269/EEC
Net torque as per SAE J1349 415 ftlb.
at engine speed 2700 to 4600 rpm
Max. litre output 85.8 (116.6) kW/l (HP/l)
HP/l (115.3)
Engine speed limitation
by fuel cutoff at
6750 rpm
Idle speed 740 ± 40 rpm
Automatic transmission 740 ± 40 rpm
Engine weight as per Manual transmission Automatic transmission
DIN 70020 A, kg 260* (572.7) 253 (557.27)
* including ZMS (double−mass flywheel)
top of page
Engine design
Engine design
Type 6−cylinder aluminium opposed−cylinder engine,
water cooled, bi−Turbo
Crankcase Vertically divided crankcase made from cast light
alloy, separate cylinder housing
Cylinder housing Cast light alloy with wet light alloy bushings
inserted, Nikasil coating
Engine 18
einordnung

Piston Pressed light alloy
Camshaft housing Non−metallic
2 exhaust valves suspended in parallel V
arrangement
Camshaft From the crankshaft via a gear wheel to the
intermediate shaft, and from there to the exhaust and
inlet camshafts via one double chain each.
Camshaft adjustment Porsche VarioCam Plus with 30° adjustment
Valve clearance Hydraulic valve clearance compensation
Valve timing
with 1 mm valve travel and zero clearance Inlet opens at 10° before TDC
(kinetic clearance of the operating plunger taken Inlet closes at 20° after BDC
into account, basic inlet camshaft setting early) Outlet opens at 41° before BDC
Outlet closes at 9° before TDC
Intake system Tuned−intake system (plastic)
top of page
Engine cooling
Engine cooling
Water cooling; 3 radiators ahead of the front wheels.
(Additional radiator for Tiptronic vehicles)
Two electric fans, controlled in three stages
top of page
Engine lubrication
Engine lubrication
Type Dry sump lubrication with separate canister
Oil cooling Via oil−water heat exchanger
Oil filter On pressure side behind oil pump
Engine design 19
einordnung
Oil pressure
at n = 5000 rpm Approx. 6.5 bar at 90° C
Oil pressure indicator Oil pressure indicator light plus instrument
Oil consumption Max. 1.0l/1000km
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Engine control
Engine control
Ignition timing control Via DME (ECM)
Beru 14−FR 5 LDU
Electrode gap
mm (in) 1.6 ± 0.2 (0.06 ± 0.008)
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Engine lubrication 20
0 Transmission
6−speed manual transmission G 96.50
Front wheel drive Z 96.00
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Type Code letter Equipment Installed in Model year

G 96.50 − 6−speed 911 Turbo (996) 2001
General data Manual transmission G 96.50

Transmission ratios Z1 : Z2 = Z2 : Z1
1st gear 11 : 42 = 3.82
2nd gear 21 : 43 = 2.05
3rd gear 27 : 38 = 1.41
4th gear 34 : 38 = 1.12
5th gear 37 : 34 = 0.92
6th gear 40 : 30 = 0.75
Reverse gear 14 : 40 = 2.86
Final drive Hypoid bevel gear drive with 10 mm offset
Transmission ratio, final drive 9 : 31 = 3.44
Filling capacity for new filling 3.8 l
Change quantity 3.0 l
0 Transmission 21
einordnung
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Z 96.00 − − 911 Turbo (996) world−wide 2001
General data Front−axle final drive Z 96.00

Transmission ratio, final drive (Z2 : Z1 = i) 31 : 9 = 3.44
Final drive Bevel gear drive without hypoid offset
Filling capacity approx. 1.5 l
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6−speed manual transmission G 96.50 22

0 Body
Body of high−strength steel 1
Water drainage plan Coupé
Refrigerant circuit
Component arrangement, Airbag System B05
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The indicated body parts are made by welding together plates of differing thicknesses and characteristics and
then deep−drawing these parts. In their crash behaviour, these body parts are characterised by their high
energy absorption.
0 Body 23
einordnung
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Note
• The use of high−strength steels for the body has an effect on body repairs. For this reason, only
Original Porsche parts must be used for repair work.
• Body repairs by means of reshaping are not possible if these body parts are correspondingly
deformed. Here, the repair must be carried out using new parts or by means of sectional repairs!
The indicated body parts attain their final strength only under the temperature effects of the production stage
of cathodic immersion painting and drying.
Body of high−strength steel 1 24

einordnung
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Water drainage plan Coupé
1 Water drainage: Rear of sliding roof

2 Water drainage: Front of sliding roof
3 Water drainage: Evaporator of heating and air−conditioning system
4 Water drainage: Tank tray
5 Water drainage: Radiator tank
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Body of high−strength steel 2 25

einordnung
Refrigerant circuit
1 Compressor
2 Condenser
3 Fluid tank
4 Expansion valve
5 Evaporator
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Component arrangement, Airbag System B05
Refrigerant circuit 26
einordnung
1 Triggering unit
2 Passenger's airbag unit
3 Warning light
4 Driver's airbag unit
5 Side airbag
6 Contact unit
7 Side−airbag sensor
8 Belt buckle, driver/passenger
9 Plug connection, child restraint system
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Component arrangement, Airbag System B05 27

0 Electrics
Fuse assignments
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Fuse assignments
A to E Fuses (rows A...E or 1...10)

F Switch for retractable spoiler
G Replacement fuses
H Gripper
No. Load Amperage

rating
Row A
1 High beam headlight, right 15
2 High beam headlight, left 15
3 Side lights, right 7.5
4 Side lights, left 7.5
5 Number plate light, instrument lighting 15
6 Seat heating 25
7 Fog lights, rear fog light 25
8 Number plate light for Canada 7.5
9 Dipped beam headlight, right 15
10 Dipped beam headlight, left 15
Row B
1 15
0 Electrics 28
einordnung
Instrument cluster, Tiptronic, PSM/ASR button, diagnosis, convertible−top

drive
2 Hazard warning light 15
3 Horn 25
4 Engine−compartment fan 15
5 Reversing lights, convertible−top drive control module, mirror and mirror 7.5
memory
6 Direction indicator light, power window touch−control enabling 15
7 Brake lights, cruise control 15
8 Control modules for central locking system, alarm system, DME, Tiptronic 15
9 Control module for ABS/ASR/PSM, Traction Control 15
10 Instrument cluster, diagnosis, headlight beam adjustment 15
Row C
1 DME relay 25
2 Ignition relay, oxygen sensors 30
3 Control module for central locking system, alarm system, power windows 15
4 Fuel pump relay 25
5 Engine−compartment fan (optional) 5
6 Windshield wipers 25
7 Terminal X, control wiring 5
8 Radiator fan 2 40
9 Headlight washer 25
10 Radiator fan 1 40
Note
• If the power windows should fail, check fuse C3 (15 A) in addition to fuse D1 (30 A).
No. Load Amperage

rating
Row D
1 Power windows 30
2 Door mirror, rear window heater 30
3 Convertible−top drive, sliding roof 30
4 Rear power windows, cabriolet 30
5 Cigarette lighter 15
6 Heating relay 30
7 Retractable spoiler 15
8 Radio 15
9 Sound package 15
10 Slot for additional equipment − Caution − max. 5A! 7,5
Fuse assignments 29
einordnung
Row E
1 Terminal 86 S, instrument cluster, radio, daytime driving light, control modules 7,5
for central locking, alarm system, information system, roll−over sensor
2 Control module for seat memory 7,5
3 Control module memory for seat adjustment, left 30
4 Control module memory for seat adjustment, right 30
5 Information system 7,5
6 Terminal 30, telephone, navigation control module 7,5
7 Air conditioning 7,5
8 Terminal 15, telephone, information system 7,5
9 PSM 25
10 PSM 15
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Fuse assignments 30
0 Power supply
Work instructions after disconnecting the battery
Control module memories
Supply voltage fault entry
Test drive after connecting the battery
2470 DME control module
3730 Tiptronic
6452 Power windows
90 25 Instrument cluster
9030 Clock
9023 Fuel level display
9120 Radio
9110 PCM
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Work instructions after disconnecting the battery
Note
• In order to avoid triggering the alarm siren (installed on right next to the battery) of vehicles with M
536, the battery must be disconnected with the ignition on!
• All loads must be switched off beforehand!
• Never disconnect battery with engine running!

• Never start engine without securely connected battery!
• Do not use a boost charger to start the engine!
• Whenever possible, use jump leads with overvoltage protection!
• Always disconnect both battery terminals before carrying out welding work on the vehicle!
• Wiring harness plugs of control modules or other electronic components must be connected or
disconnected with the ignition off. Exception: vehicles with the additional equipment M 536 (alarm
siren with tilt sensor)!
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Problem Remedy
Values and faults stored in the control modules can be If possible, all fault memories should
deleted if the battery is disconnected or completely be checked and, if necessary, printed
discharged. out before the battery is disconnected.
0 Power supply 31
einordnung
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Problem Remedy
The entry "supply voltage" could be stored in various control Delete the "supply voltage"
modules if the battery has been completely discharged. entry from the control modules
in question.
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Note
• The fault memories of all vehicle control modules should be read out again after the test drive!
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Note
• With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!
Problem Remedy
After the battery is connected.
• After disconnection of the power supply, the idle speed might With the DME ME 7.2, it is
change or fluctuate briefly until the idle speed positioner (M necessary to carry out a learning
5.2) or the throttle adjusting unit (ME 7.2) is readapted. and adaptation routine as
• The mixture adaptation is also lost. described below:
1. Switch the ignition on for 1
minute without starting the
engine. Do not actuate
accelerator pedal.
2. Switch off ignition for at
least 10 seconds.
This completes the adaptation
of the throttle adjusting unit.
Control module memories 32

einordnung
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3730 Tiptronic
Problem Remedy
The stored pressure adaptation values are lost if the power Carry out a test drive and drive the
supply to terminal 30 is interrupted. This can result in poor vehicle with different loads and at
shifting quality and rough shift operations during the different speeds so that all shift
adaptation phase. functions (manual and automatic
programme) are executed at least once.
This readapts the shifting pressures of the
system and thereby re−establishes smooth
shifting.
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6452 Power windows
Problem Remedy
The limit positions of the power windows are deleted from Manually close each power window as
the control module when the battery is disconnected and far as it will go, then press the rocker
connected. switch for closing the window again.
The limit position of the respective power
window is now stored in the control
module again.
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The trip counter is set to 0 when the power supply is disconnected.
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9030 Clock
Note
• In the case of vehicles with PCM, the date and time are deleted when the battery is disconnected!
Problem Remedy
2470 DME control module 33

einordnung
Depending on the software version, the clock is set to 12:00 a.m. or 1:00 a.m. Enter the
when the power supply is disconnected. current time
again.
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Problem Remedy
Refill at least 19 l of fuel; then the
• If the power supply is interrupted by a discharged or fuel level sensor is in operating
disconnected battery with the tank containing less than range and its display precision is
19 l, the calculated value for the range on remaining guaranteed.
fuel in the instrument cluster will be incorrect or
deleted.
• If the tank contains less than 10 l, it is possible that the
fuel level warning light is no longer activated.
• If the power supply is restored with the fuel level at
less than 19 l, it is possible that the fuel level display
may subsequently display too much.
This may lead to the vehicle breaking down.
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9120 Radio
Problem Remedy
The radio reverts to the Code function when the battery 1. Input the radio code.
is disconnected and is thus no longer ready for operation. 2. If the code card is unavailable, the radio
code can also be read from the DME
control module (under "Vehicle data").
3. This code is also available from the
Porsche IPAS.
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9110 PCM
Problem Remedy
1.
9030 Clock 34
einordnung
• The PCM reverts to the Code input Input the PCM code. If the code card is unavailable,
function when the battery is the PCM code can also be read from the DME
disconnected and is thus no longer control module (under "Vehicle data").
ready for operation. 2. This code is also available from the Porsche IPAS.
• When the power supply is
3. Switch on the PCM with a free panoramic
disconnected, the built−in GPS
view for approx. 20 minutes (to load GPS
receiver loses the so−called almanac
almanac).
containing the satellite orbital paths.
• The date and time are deleted when 4. The date and time are also adopted once the GPS
the battery is disconnected. almanac has been loaded; it may be necessary to
• Radio stations stored by the customer change over to summer time (daylight−saving time).
are no longer displayed. This time is transferred to the instrument cluster. If the
• If the telephone card was inserted time is then manually changed by means of the
and the telephone was ready for instrument cluster, this time is adopted by the PCM and
operation, the telephone is synchronised with GPS time.
subsequently disabled. 5. The stored stations are displayed again when
station buttons 1 to 6 are pressed.
6. The telephone is enabled again when the
telephone PIN code is entered with the SIM
telephone card inserted.
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9110 PCM 35
01 General maintenance: Test drive
Note
Note
• The following test items are included in the test drive.
Checking footbrake operation and actuation travel.

Actuating clutch, checking operation.
Actuating steering, checking operation.
Shifting gear, checking operation.
Parking assistant: Selecting reverse gear and checking operation.
Activating the automatic cruise control during the test drive and checking
operation.
Checking operation of heating adjustment when engine is warm.
Checking operation of air−conditioning system when the engine is
running.
Checking operation of the instruments.
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01 General maintenance: Test drive 36

01 Diagnostic system: Read out fault memory and
activate systems
Activating systems
Read out fault memory
Load Navigation
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Activating systems
Note
• The work procedure is menu−prompted, the Tester instructions have highest priority, further actuation
is specified using the arrow symbols e.g., >> .
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press
>> to continue.
2. Select Special functions menu using the cursor keys.
3. Change to Sports car analysis and start. After analysis was carried out, print out analysis log and
assign to vehicle procedure.
4. ’| Select vehicle type. Change to Sports car hand
over .
5. Observe Tester instructions and code >> using F8 .
6. Enter the required chassis number >> .
7. Pay attention to the instructions from the Tester All functions carried out and PCM/CDR was activated .
>> . Continue with => Read out fault memory.
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Read out fault memory
• Porsche System Tester connected to vehicle and System Tester started. Ignition switched on.
1. Select vehicle type. >>
Note
01 Diagnostic system: Read out fault memory and activate systems 37

einordnung
• All control modules are read out automatically one after the other.
2. Control modules showing an error have an asterisk in front of their designation >>
*DME.
3. Select these control modules, select Read out fault memory menu.
4. The fault memory can now be erased in the Erase fault memory menu. When PCM is installed,
continue with => Load Navigation.
• After the test drive, the fault memory must be read out again or erased. If the same faults are still
present, proceed in accordance with ’ 0, 20 − 97 Diagnosis Manual .
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Load Navigation
Note
• Only vehicles with PCM.
1. Insert Navigation CD in PCM and switch on PCM.

2. Navigation CD will be loaded.
3. Disconnect Tester on vehicle.
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Read out fault memory 38

01 Battery: checking the charge state
Tools
Checking charge state with battery tester
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Tools
Item Designation Source Remarks

Battery rapid−start charger see Workshop Equipment Manual, Chapter 3
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Checking charge state with battery tester
Note
• Follow the instructions for the Tester, topic: charge state/functional state.
• The tester must be connected directly to the battery.
1. Remove battery cover.

2. Connect the battery tester to the vehicle battery and check the charge state according to the operating
instructions for the tester.
Evaluation of test results and further procedures:
Open−circuit voltage Charge state Evaluation and procedure

12.7 − 12.5 V 100 − 80 % Charge state OK
12.5 − 12.2 V 80 − 50 % Charge state reduced, recharge battery and observe inactive
period of 2 h after charging. ’ 2, 2706 Battery
12.2 − 11.6 V 50 − 10 % Battery flat, recharge battery and observe inactive period of 2
h after charging. ’ 2, 2706 Battery
Below 11.6 V Below 10% Battery totally discharged, replace battery
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01 Battery: checking the charge state 39

01 Windscreen wiper/washer system, headlight
washer
Caution
Mix ratio of fluids for windscreen washer system
CAUTION
Danger of material damage if headlights are cleaned incorrectly!
• Use only soapy water to clean the exterior lights and the plastic headlight lenses!
• Never use chemical cleaning agents!
• To avoid scratches, do not rub with dry or only damp cloths, paper towels or insect−removal sponges!
Note
• The headlight washer nozzles are pre−set!
• It is not necessary to adjust them!
Check the function, fluid levels and nozzle

settings.
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Mix ratio of fluids for windscreen washer system
Fluid: Mix ratio:

Water Undiluted
1:1
Water/isopropanol 2:1
3:1
1:1
Water/ethanol 2:1
3:1
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01 Windscreen wiper/washer system, headlight washer 40

01 Checking the function of the vehicle's lights and
the headlight setting
Checking the adjustment of the headlights
Adjusting the main headlights
Adjusting the main headlights, USA version
Fog light adjustment
Vehicle lights:
• Switch on the ignition, and switch through all exterior and interior light functions in turn. Check the
function of the exterior lighting with the help of a second person.
Horn:
• Switch on ignition, press actuation for horn on steering wheel and check the sound of the horn.
Clock
• Check current time, set if necessary. In the instrument cluster, turn the right set−up button with the
Clock symbol to the left/right. This sets the hours. When this set−up button is pressed, the minute
display blinks. Now the minutes can be set by turning to the left/right. Compare the time in the
instrument cluster with time in PCM (if present) and if necessary, set the time in the PCM as well.
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Checking the adjustment of the headlights
Note
• Set the headlight adjustment unit to 10 cm/10 m (1%)!
• With this alignment, preference must be given to the central zone around the salient point of the
light/dark limit!
First, make the vertical adjustment of the dipped beam headlights.

1. To do this, line up the light/dark borderline running upwards at an angle on the right−hand side with the
dotted 15° line of the adjustment unit.
Next, perform the horizontal adjustment of the dipped beam headlights.
01 Checking the function of the vehicle's lights and the headlight setting 41
einordnung
2. To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the
dotted horizontal line of the adjustment unit.
Note
• The distance between the headlights and the adjustment unit should be as small as possible!
• It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the
formation of the light/dark limit in the adjustment unit clearly!
3. Secure the plugs after making the adjustment.

4. In the case of Xenon headlights, the ignition must be switched off and on after the adjustment has been
made with the lights switched on.
5. After this, the adjustment must be checked again.
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1. Open the luggage compartment lid.
2. Remove the luggage compartment mat on the wheel housing wall.
3. Open the cover for the headlight adjustment screws.

4. Clean the cover lens and switch on the dipped beam headlights.
Note
• The vehicle must be on a horizontal surface!
• Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)!
• Use a standard 5 mm ball−head screwdriver to make the headlight adjustment (free blade length 150
mm)!
Checking the adjustment of the headlights 42

einordnung
• Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower
screws must be turned in the same direction and for the same number of rotations!
5. Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a
person or 75 kg, the tyre pressure must correspond to the stipulated values) using a headlight
adjustment unit.
A Lateral adjustment
B Height and lateral adjustment
C Fog light adjustment
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Note
• A new adjustment may only be made in the case of accident repairs or replacement of the main
headlights!
Vertical and horizontal adjustment must be carried out with a headlight adjustment
unit.
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Note
Adjusting the main headlights 43

einordnung
Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a
adjustment unit.
Note
• Switched−on headlights must not be covered by a front apron or film!
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Fog light adjustment 44

01 Checking the function of electrical equipment, as
well as the indicator and warning lights
Turn ignition key and check function of warning and indicator lights (visual inspection).
Actuate power windows and check operation.
Check that rear window heater is in working order.
Adjust heater blower and fans to high and low and check the air vents for air throughput.
Check operation of front seats.
Check operation of radio.
Check operation of door mirror, check adjustment options.
Check operation of orientation lights.
Actuate central locking and check operation.
Operate cigarette lighter and check that it is in working order.
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01 Checking the function of electrical equipment, as well as the indicator and warning lights 45
01 Alarm system: checking operation of indicators
• Vehicle must be unlocked and the sales check step − Diagnostic system: systems activated and fault
memory read out − must be carried out.
1. Lock vehicle with the remote control. Shortly after locking, the alarm system horn should not issue
a warning tone. If a warning tone is issued, check all doors, as well as the convertible top, cover
for the glove compartment, and the cover for the centre console. Open and close these items again
in turn.
2. As soon as the vehicle is locked, the LED in the middle of the dashboard should show a double
flashing signal, and after 10 seconds have passed, a single flashing signal.
3. If a flashing signal is not shown, or if the double flashing signal continues, connect the System
Tester and read out the fault memory. ’ 0, 96 Alarm system diagnosis manual
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01 Alarm system: checking operation of indicators 46

01 Activating/deactivating the parking aid
Note
General
Activating the parking aid without PST 2
Deactivating the parking aid without PST 2
Activating the parking aid with PST 2
Selecting door mirror to be lowered, left/right
Adjusting the lowering angle for the passenger door mirror
Deactivating the parking aid with PST 2
Note
• This function is only available in vehicles with seat memory!
• Activation/deactivation can take place with/without PST 2!
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General
The automatic lowering of the passenger door mirror aids the driver during parking manoeuvres. After a time
delay which can be set, the door mirror is lowered by the set value as soon as reverse gear is engaged. If
reverse gear is disengaged again or the mirror adjustment switch touched with reverse gear still engaged, the
door mirror returns to its stored position.
The following settings can be selected from the menu and encoded using the PST 2:
• Parking aid (activated or deactivated)

• Parking aid with door mirror (right or left)
• Lowering
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Activating the parking aid without PST 2
1. Switch ignition on.
2. Engage reverse gear.
3. Adjust both door mirrors to desired
positions.
4. Adjust seat to desired position.
5. Save seat position.
Press M and corresponding seat memory position ( 1 , 2 or 3 ) simultaneously.
Note
01 Activating/deactivating the parking aid 47

einordnung
• The parking aid is activated for the respective seat position saved!
• Activation of the parking aid must be carried out individually for every seat position!
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Deactivating the parking aid without PST 2
2. Disengage reverse gear if
necessary.
3. Adjust both door mirrors to desired
positions.
4. Adjust seat to desired position.
5. Save seat position.
Press M and corresponding seat memory position ( 1 , 2 or 3 ) simultaneously.
Note
• The parking aid is now deactivated for the respective seat position!
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Activating the parking aid with PST 2
1. Connect the PST2 with the ignition off, then switch the ignition on.
2. Switch on the PST2 and wait for the start−up screen.
3. Press the >> key to go to the next level.
4. Select the vehicle type 911 (996) Turbo in the left−hand window using the v
key.
5. Press the −−> key to activate the right−hand window.
6. With the v key, select the Seat memory control module and press the >> key to go to the next level.
7. With the v key, select Modify coding and press the >> key to go to the next level.
8. With the v / ^ key, select the menu item Parking aid for position 1 or Parking aid for position 2 or
Parking aid for position 3 .
9. Press the >> key to alter the coding.
10. Select the menu item −activated− using the v / ^ key.
11. Press key F8 (coding)
Note
• The parking aid is now activated for the respective seat position!
Activating the parking aid without PST 2 48

einordnung
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Selecting door mirror to be lowered, left/right
Note
• The door mirror (left/right) can be adjusted with the PST 2 only!
4. Select the vehicle type 911Turbo (996) in the left−hand window using the v key.
6. With the v / ^ key, select the Seat memory control module and press the >> key to go to the next level.
7. Select the menu item Parking aid on door mirror using the ^ / ^ key.
9. Select the desired door mirror right or left using the v / ^ key.
Note
• The selected door mirror is now activated!
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Adjusting the lowering angle for the passenger door mirror
Note
• The lowering angle of the passenger door mirror can be adjusted with the PST 2 only!
8. Select the menu item −Lowering− using the v / ^ key.
10. Adjust the lowering angle using the v / ^ key.
Note
Activating the parking aid with PST 2 49

einordnung
• The lowering angle is now set!
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Deactivating the parking aid with PST 2
8. With the v / ^ key, select the menu item Parking aid for position 1 or Parking aid for position 2 or
Parking aid for position 3 .
10. Select the menu item −Deactivated− using the v / ^ key.
Note
• The parking aid is now deactivated for the respective seat position!
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Adjusting the lowering angle for the passenger door mirror 50

01 Removing transport lock (spring strut locking
devices) Turbo and GT2
General
Removing spring strut locking devices
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General
Spring strut locking devices are installed on the front axle of the following new vehicles in order to protect the
vehicle during transport (e.g. driving on and off when transported by lorry):
• Turbo RoW (new vehicles)

• Turbo USA (new vehicles)
• 911 GT2 (new vehicles)
This increases the ground clearance of the vehicle.

Tests have demonstrated that spring strut locking devices are not necessary at the rear axle.
WARNING
Danger of injury and damage to property if spring strut locking devices are installed when commencing
journey!
• If the spring strut locking devices are not removed, this will seriously impair the handling behaviour
and thus the driving safety!
• The spring strut locking devices must be removed before a test drive and before the vehicle is handed
over to the customer!
Note
• Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg!
• Include the spring strut locking devices with the normal warranty goods consignment!
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Note
• The wheels need not be removed!
1. Lift the vehicle (wheels at the front axle must be free).

2. Remove spring strut locking devices from all spring struts. To do this, pull spring strut locking
devices off the springs.
01 Removing transport lock (spring strut locking devices) Turbo and GT2 51
einordnung
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Removing spring strut locking devices 52

Technical Data GT2
Engine
Engine design
Engine cooling
Engine lubrication
Engine control
Fuel system
Electrical system
Exhaust system
Emission control
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Technical Data GT2 53

einordnung
Engine
Engine
Engine type M96/70 S
Bore mm (in.) 100 (3.94)
Stroke mm (in.) 76.4 (3.01)
Cubic capacity cm³ (cu. in.) 3600 (219.7)
Compression ratio 9.4:1
Max. engine power as per 80/1269/EEC kW 340
at engine speed rpm 5700
Max. torque Nm (ftlb.) 620 (63.20)
at engine speed rpm 3500 − 4500
Max. litre output kW/l, HP/l 94.44
Engine speed limitation by fuel cutoff at rpm 6750
Idle speed rpm 740 ± 40
Engine weight as per DIN 70020 A kg 260
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Engine design
Type 6−cylinder aluminium opposed−cylinder engine, water cooled, bi−Turbo

Crankcase Vertically divided crankcase made from cast light alloy, separate cylinder
housing
Cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating
2 exhaust valves suspended in parallel V arrangement
Camshaft From the crankshaft via a gear wheel to the intermediate shaft, and from there
to the exhaust and inlet camshafts via one double chain each.
Inlet opens 10° before TDC
Engine 54
einordnung
Timing with 1 mm
valve travel
Inlet closes 20° after BDC
Outlet opens 41° before BDC
Outlet closes 9° before TDC
Intake system Tuned−intake system
top of page
Engine cooling
Engine Water cooling; 3 radiators ahead of the front wheels. Two electric fans, controlled in
cooling three stages
top of page
Engine lubrication
Type Dry sump lubrication with separate oil container

Oil cooling Via oil−water heat exchanger on pressure side behind oil pump
Oil pressure at n=5000 rpm, T=90°C Approx. 6.5 bar
Oil pressure indicator Oil pressure indicator lamp plus instrument
Oil consumption Approx. 1.0 l/1000 km
top of page
Engine control

Beru 14−FR 5 LDU
Electrode gap 1.6±0.2 mm (0.06±0.008 in)
World−wide On−Board Diagnosis
Engine design 55
einordnung
top of page
Fuel system
Injection ME 7.8 (Digitale−Motor−Electronic) Injection valves controlled sequentially

Fuel required RON 98 unleaded
top of page
Electrical system

Rated voltage 12 V
Battery capacity 80 Ah (380 A)
Starter 1.7 kW
Generator output 1680 W
top of page
Exhaust system
Exhaust system 2−pipe, 3−way catalytic converter exhaust system, rear mufflers
top of page
Emission control
Europe/RoW Stereo oxygen sensor closed−loop control and 3−way catalytic converter system, each
with a 2−stage catalytic converter on left+right, secondary air system, Europe OBD
emission control: EU3/D4
USA Stereo oxygen sensor closed−loop control and 3−way catalytic converter system, each
with a 2−stage catalytic converter on left+right, secondary air system, OBD II + ORVR
emission control: LEV
996840, 996841
Engine control 56
Technical data
Engine
Engine design
Engine cooling
Engine lubrication
Engine control
Fuel system
Electrical system
Exhaust system
Emission control
top of page
Technical data 57
einordnung
Engine
Engine
Engine type M96/70
Bore mm (in.) 100 (3.94)
Stroke mm (in.) 76.4 (3.01)
Cubic capacity cm³ (cu. in.) 3600 (219.7)
Compression ratio 9.4:1
Max. engine power as per 80/1269/EEC kW 309
at engine speed rpm 6000
Max. torque Nm (ftlb.) 560 (57.08)
at engine speed rpm 2700−4600
Max. litre output kW/l 85.8
Engine speed limitation by fuel cutoff at rpm 6750
Idle speed rpm 740 ± 40
Engine weight as per DIN 70020 A kg
top of page
Engine design
Type 6−cylinder aluminium opposed−cylinder engine, water cooled, Bi−Turbo

Crankcase Vertically divided crankcase made from cast light alloy, separate cylinder
housing
Cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating
2 exhaust valves suspended in parallel V arrangement
Camshaft From the crankshaft via a gear wheel to the intermediate shaft, and from there
to the exhaust and inlet camshafts via one double chain each.
Inlet opens 10° before TDC
Engine 58
einordnung
Timing with 1 mm
valve travel
Inlet closes 20° after BDC
Outlet opens 41° before BDC
Outlet closes 9° before TDC
Intake system Tuned−intake system
top of page
Engine cooling
Engine Water cooling; 3 radiators in front of the front wheels. Two electric fans, controlled in
cooling three stages
top of page
Engine lubrication
Type Dry sump lubrication with separate oil canister

Oil cooling Via oil−water heat exchanger on pressure side behind oil pump
Oil pressure at n=5000 rpm, T=90°C Approx. 6.5 bar
Oil pressure indicator Oil pressure indicator lamp plus instrument
Oil consumption Approx. 1.0 l/1000 km
top of page
Engine control

Beru 14 − FR 6 LDU
Electrode gap 1.6±0.2 mm (0.06±0.008 in)
Boost pressure control Absolute pressure−guided turbocharger control
Engine design 59
einordnung
top of page
Fuel system
Injection ME 7.8 (Digitale−Motor−Electronic − engine control module ECM) Injection valves

controlled sequentially
Fuel ROZ 98
required
top of page
Electrical system

Rated voltage 12 V
Battery capacity 80 Ah (380 A)
Starter 1.7 kW
Generator output 1680 W
top of page
Exhaust system
Exhaust system 2−pipe, 3−way catalytic converter exhaust system, rear mufflers
top of page
Emission control
EURO Stereo oxygen sensor closed−loop control and 3−way catalytic converter system, each with a
II 2−stage catalytic converter on left+right, Secondary air system, Europe OBD
USA Stereo oxygen sensor closed−loop control and 3−way catalytic converter system, each with a
LEV 2−stage catalytic converter on left+right. Secondary air system, OBD II + ORVR
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Engine control 60
Precautionary measures when working on fuel
system
Caution
CAUTION
Danger of fire and injury!
• Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge.
• Danger of fire due to naked flame and flying sparks, e.g. during welding or sanding work
• Secure the vehicle, e.g. with a warning sign −illustration below− .
• Wear protective gloves that are fuel−resistant.
• Wear a breathing mask with activated carbon filter; do not breathe in any fuel fumes.
• Ensure that there is adequate ventilation or extract all fuel fumes.
• Before opening the fuel lines or fuel hoses, reduce the fuel pressure.
• Collect emerging fuel, absorb it if necessary with a suitable binding material and dispose of fuel
properly.
• Pay attention to cleanliness when working on the fuel system.
Secure vehicle with warning sign
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Precautionary measures when working on fuel system 61

03 Diagnostic system: reading out fault memory
Reading out fault memory
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Reading out fault memory
The method of reading out the fault memory is described in the operating instructions for the Porsche System
Tester 2. The operating instructions are supplied with each Tester. The Porsche System Tester 2 is connected
to the vehicle via a 16−pin diagnosis socket. The diagnosis socket is located inside the vehicle below the
instrument panel near the driver (left−hand drive vehicles) or the passenger (right−hand drive vehicles)
−Arrow− .
1. Start Porsche System Tester (PST) and follow the instructions on the Tester.
2. Select vehicle type, click >> and perform the automatic control module search.
3. If a star appears in front of the relevant control module, read out the fault memory. Follow the PST
instructions.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 Diagnostic system: reading out fault memory 62

03 General maintenance: test drive
Note
Note
• The following test items are included in the test drive.
Actuating the remote control of the central locking and checking operation.
Front seats: Checking adjustment possibilities for operation.
Checking footbrake operation and actuation travel.
Starting engine, checking operation.
Actuating clutch, checking operation.
Actuating steering, checking operation.
Shifting gear, checking operation.
Parking assistant: Selecting reverse gear and checking operation.
Activating the automatic cruise control during the test drive and checking
operation.
Actuating PSM switch during the test drive and checking operation.
Checking operation of heating adjustment when engine is warm.
Checking operation of air−conditioning system when the engine is
running.
Checking operation of the instruments.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 General maintenance: test drive 63

03 Removing and installing drive belt
Removal overview of the drive belt (engine installed)
Installation overview of the drive belt (engine installed)
To check the drive belt, it must be removed and installed. Procecedure is described below.
top of page
1 Removing air cleaner assembly

2 Loosening servo pump wheel
03 Removing and installing drive belt 64

einordnung
3 Relieving drive belt

4 Removing servo pump wheel
5 Removing drive belt
Check the drive belt for any cracks, flaws, and other damage. Replace if necessary.
Note
• The drive belt must be replaced at 60,000 miles for USA vehicles, and at 80,000 km or 48,000 miles
for RoW vehicles, according to the maintenance plan.
top of page
Note
• When inserting the drive belt, it is essential to observe the correct contact surface on the drive belt!
Removal overview of the drive belt (engine installed) 65

einordnung
1 Fitting the drive belt

2 Positioning servo pump wheel
3 Tensioning the drive belt
4 Tightening the fastening screws on servo pump
5 Installing the air cleaner assembly
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation overview of the drive belt (engine installed) 66

94 56 19 Removing and installing bulb for direction
indicator light
Removing bulb for direction indicator light
Installing bulb for direction indicator light
top of page
Removing bulb for direction indicator light
1. Switch off light. Remove main headlight.
2. Turn bulb socket counter−clockwise and remove from the headlight housing.
3. Take defective bulb out of the bulb socket (bayonet lock).
top of page
Installing bulb for direction indicator light
1. Install new bulb and ensure that it is correctly seated (bayonet lock).
2. Rotate bulb socket clockwise and engage.
3. Install main headlight and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 56 19 Removing and installing bulb for direction indicator light 67

03 Changing the engine oil and oil filter
Caution
WARNING
Danger of scalding from draining oil!
• Wear protective equipment specified.
1. Undo the oil drain plug on the crankcase and drain off the engine oil.
2. Undo the oil drain plug on the oil container and drain off the oil. An open−ended wrench must be
used to counter it in order to avoid damage to the oil container.
3. Drain engine oil from the turbochargers. To do this, unscrew the oil drain plugs on the oil
collection containers and drain the oil.
03 Changing the engine oil and oil filter 68

einordnung
4. Loosen the oil filter with special tool release key

9204 .
5. Change the oil filter element. To do this, pull the oil filter element out and replace the filter element
and the two O−rings.
1 Oil filter cover

2 O−ring 71.5 x 3.5
3 O−ring 10 x 2
4 Oil filter element
5 Oil filter housing

einordnung
Remove the remaining quantity of oil from the oil filter housing by suction.
6. Clean oil drain plugs. Always replace the sealing rings. Make sure that the sealing ring on the oil
container is 2 mm thick. Tighten the drain plug on the crankcase to 70 Nm (52 ftlb.) those on the oil
container to 60 Nm (44 ftlb.), and the drain plugs on the turbocharger to 30 Nm (22 ftlb.). Counter with a
wrench when tightening the drain plug on the oil tank.
7. Tighten oil filter. To do this, use the special tool release key 9204 and tighten the oil filter cover to 25 Nm
(19 ftlb.).
Slowly pour 7.8 litres of engine oil into the oil container.
Note
• Fill in engine oil slowly in order to allow the oil sufficient time to flow from the oil container into the
crankcase.
8. Check the oil level. Check oil level on the instrument cluster and correct. Seven segments must be
displayed in the instrument cluster.
Note
• This cannot be checked with the oil dipstick
• The vehicle must stand horizontally
• The engine must be idling during the check.

einordnung
• The vehicle must not be moved during the check
Location Thread Tightening torque Nm (ftlb.)

Oil drain plug on crankcase M20 x 1.5 70 (52)
Oil drain plug for oil container M20 x 1.5 60 (44)
Oil drain plug for turbocharger M18 x 1.5 30 (22)
Oil filter cover 25 (19)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing the engine oil (without oil filter)
Caution
WARNING
Danger of scalding from draining oil
• Wear protective clothing specified!
1. Undo the oil drain plug on the crankcase −arrow− and drain off the engine oil. Then equip the drain plug
with a new sealing ring and tighten to a torque of 70 Nm (52 ftlb.).
2. Undo the oil drain plug on the oil container and drain off the oil. It is absolutely necessary to counter with
a wrench when undoing or tightening the oil drain plug in order to prevent damage to the oil container.
Then equip the oil drain plug with a new sealing ring and tighten to a torque of 60 Nm (44 ftlb.).
3. Drain engine oil from the turbochargers. To do this, unscrew the drain plugs and drain the oil from
the collection containers. Subsequently equip the drain plugs with new seals and fit them.
Tightening torque: 30 Nm (22 ftlb.).
Note
• Always replace sealing rings!
4. Fill in engine oil. Slowly fill 7.8 litres of engine oil into the oil tank. Then start the engine, check the
engine oil pressure and allow the engine to warm up until the engine oil reaches a temperature of approx.
80 °C.
03 Changing the engine oil (without oil filter) 72

einordnung
5. Check engine oil level. Check engine oil level on the instrument cluster. Top up engine oil until the 7th
segment of the on−board computer display lights up. The following conditions must be maintained for the
measurement.
• Vehicle horizontal
• Engine at operating temperature
• Engine idling
• Vehicle stationary
WARNING
The engine oil level must not exceed the seventh segment on the instrument cluster display.
Note
• The oil change quantity (without oil filter change) is approx. 7.8 litres after a dripping time of 20
minutes!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
03 Changing the engine oil (without oil filter) 73

03 Replacing spark plugs
Removing spark plugs
Installing spark plugs
top of page
CAUTION
lifting platform!
• When driving onto a platform lift, ensure that there is sufficient distance between the platform lift and
the vehicle!
Item Special tool designation Remarks

A Spark plug socket wrench S 9706 KA Refer to Workshop Equipment Manual, Chapter
2.4, Nos. 14 and 15
Note
• Only this spark plug wrench was tested and approved!
1. Remove rear spoiler and centre heat shield ’ 63 55 19 Removing and installing rear spoiler .
2. Lift the vehicle.
3. Remove charge air cooler.
03 Replacing spark plugs 74

einordnung
4. Remove heat shield. Remove the heat shields located above the exhaust system.
5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagon head bolts for this
purpose.
6. Undo hexagon socket head bolts −arrows− of the ignition coils.
7. Pull off the ignition coils and hang them to the side with connected
cables.
8. Unscrew spark plugs with commercially available tool spark plug socket wrench No.14 , as stated
above.
top of page
1. Put on spark plugs by hand.
2.
Removing spark plugs 75

einordnung
Tighten spark plugs with commercially available tool spark plug socket wrench
No.14 .
3. Push on the ignition coils again.

4. Tighten hexagon socket heat bolts −arrows− for the ignition coils to 10 Nm (7.5 ftlb.).
5. Fit shields. Reinstall the shields above the ignition coils and tighten the screws to 10 Nm (7.5 ftlb.).
6. Reinstall the heat shields above the exhaust system.

7. Reinstall charge air cooler.
8. Fit rear spoiler ’ 63 55 19 Removing and installing rear
spoiler .
9. Lower the vehicle.

Screws for ignition coils M6 10 (7.5)
Screws for shield M6 10 (7.5)
New spark plug 30 + 3 (22 + 2)
Old spark plug 25 + 3 (19 + 2)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing spark plugs 76

03 Checking cooling system
Coolant: checking level, antifreeze content and leaks
top of page
Coolant: checking level, antifreeze content and leaks
Note
• The coolant filled in at the factory is intended for lifetime cooling and, thus, need not be changed. The
coolant must not be mixed with other coolants.
• Only original Porsche antifreeze should be used when changing or topping up the coolant.
1. Check antifreeze content: Open the lid on the coolant expansion tank and check the antifreeze content
with a frost protection testing device. If it is lower than −35 °C, it should be corrected accordingly.
2. Checking the cooling system for leaks: connect the cooling system test device with the adapter to the
coolant expansion tank and allow a test pressure of approx. 1 bar to build up. During the leak test on all
hose connections, check the tightness of the hose clamps and the condition of the coolant hoses.
3. Check cooling openings for external contamination: the cooling openings must not be excessively dirty. If
needed, clean these with a vacuum cleaner and a crevice nozzle made by the Kärcher company see
03 Checking cooling system 77

einordnung
Workshop Equipment Manual, Chapter 2.4, No. 160
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Coolant: checking level, antifreeze content and leaks 78

03 Replacing air cleaner element
Removing air cleaner
Installing air cleaner
top of page
1. Pull off hot film mass air flow sensor.

Push the plug downwards and press the grooved surface at the sides. Pull the plug up and off at the
same time.
2. Pull off the connecting hose between the left turbocharger and the intake pipe.
Unclip the retaining clips using a screwdriver and pull out the
hose.
03 Replacing air cleaner element 79

einordnung
Refit the retaining clips

immediately.
3. Undo hose clamp.

Undo the hose clamp −arrow− between the air cleaner housing and the intake
pipe.
4. Remove air
cleaner
housing.
Unscrew the fastening screw M6 x 34 at the rear of the air cleaner
housing.
5. Tilt air cleaner housing outwards.

Tilt the housing upwards and to the right by 90° and then turn the housing to the left by approx. 90°.
6. Unclip the hot film mass air flow meter cable.
a. Open the omega clip on the left side of the air cleaner housing and take out the
cable.
b. Take the air cleaner housing out of the engine
compartment.
Removing air cleaner 80

einordnung
7. Open air
cleaner
housing.
To do this, open the screws −arrows− and pull the two housing halves
apart.
8. Take out the
cleaner
element.
c. Take out the air cleaner
element.
d. Wipe out the two housing halves with a
cloth.
top of page
Installing air cleaner 81

einordnung
1. Insert filter element.

a. Insert the filter element into the cleaned air cleaner
housing.
b. Retighten the two air cleaner housing halves with the screws −arrow−
.
2. Clip in hot film mass air flow sensor cable.
Insert the cable into the omega clip on the left air cleaner housing side and then close
the clip.

einordnung
3. Place the air cleaner housing in the engine compartment as shown and move into installation position.
c. Turn the housing to the right by approx. 90° and push the rubber hose over the
flange.
d. Swivel the housing
downwards by 90°.
4. Tighten the fastening screw M6 x 34.

Tightening torque: 10 Nm (7.5 ftlb.)
5. Tighten the hose clamp

on the connecting hose.
Reconnect the plug on the hot film mass air flow
sensor.
Note
• The plug must engage audibly!

einordnung
6. Attach the connecting hose between the left turbocharger and the intake distributor.
Note
• The hose must engage audibly!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Replacing the fuel filter
1. Disconnect plug on the hot film mass air flow meter. To do this, push the plug downwards and press
on the grooved surface at the sides. Pull the plug up and off at the same time.
2. Pull off the connecting hose between the left turbocharger and the intake pipe. To do this, unclip
the retaining clip using a screwdriver and pull out the hose. Refit the retaining clips immediately.
3. Unscrew the fastening screw M6 x 34 at the rear of the air cleaner housing.
4. Undo hose clamp. Undo the hose clamp −arrow− between the air cleaner housing and the intake pipe.
5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards on the right by 90° and then turn the
housing to the left by approx. 90°.
6. Unclip the hot film mass air flow meter cable. Open the omega clip on the left side of the air cleaner
housing and take out the cable. Take the air cleaner housing out of the engine compartment.
03 Replacing the fuel filter 85

einordnung
7. Pull off the ground cable from the fuel filter.
8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel.
9. Disconnect the plug connection and collect the residual fuel. Protect open lines against dirt.
10. Remove fuel filter with holder. To to this, bend the retaining clip upward as shown −arrow− and
simultaneously remove the filter with holder.
11. Remove fuel filter. To do this, fully open the restraining strap and take the fuel filter out.

einordnung
12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way
that the mark −arrows− on the filter is aligned with the outer edge of the holder in installation
position.
13. Position the fuel filter with holder on the coolant expansion tank again and press it down at rear. The
holder must engage audibly.
14. Connect plug connector of the fuel supply line. The connector must engage audibly. Pull slightly to
ensure that the connection is properly locked.
15. Tighten fuel pressure line. Make sure to counter with a wrench when doing this.
16. Connect the ground cable to the filter.

17.

einordnung
Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left
air cleaner housing side and then close the clip.
18. Place the air cleaner housing in the engine compartment as shown and move into installation
position. To do this, first turn the housing to the right by approx. 90° and push the rubber hose
over the flange. Then swivel downwards by 90°.
19. Tighten the fastening screw M6x34 to 10 Nm (7.5 ftlb.).
20. Tighten the hose clamp on the connecting hose. Reconnect the plug on the hot film mass air flow
sensor. The connector must engage audibly.
21. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must
engage audibly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Clutch: checking the play and pedal end position
Checking clutch free play
Checking the pedal end position (pedal return/return force)
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Checking clutch free play
The clutch master cylinder has an inner stop. The push rod and the clutch pedal are always pressed against this
stop by the boost spring. Due to the automatic hydraulic adjustment of the clutch, it is not possible to
determine the clutch play by checking at the clutch pedal.
top of page
Checking the pedal end position (pedal return/return force)
Check that the pedal is in end position by pulling at the pedal (without the use of force) towards the
driver's seat.
Note
• The pedal must not give way during the process.
• If it gives way, the fault is in the boost spring or in the pedals.
The clutch push rod and the boost spring are not adjustable. The boost spring has 2 functions, namely to
provide pedal force assistance and to return the pedal. The following are some of the points which are
requirements for perfect clutch operation:
• Correct bleeding of the clutch hydraulics.

• No leaks in the hydraulic system.
• Pedal return to the starting position.
• Installation position of the pedals in accordance with the series condition.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 Clutch: checking the play and pedal end position 89

03 Changing transmission oil
Changing transmission oil
Tightening torques
top of page
Note
• Top up only with transmission oil approved by Porsche. See Parts Catalogue!
Filling capacity: 3.8 litres

Change quantity: 3.0 litres
1. Place oil collection pan under the transmission.
2. Unscrew the oil filler screw and drain plug and drain the oil with the vehicle
horizontal.
3. Clean the drain plug and filler plug.
4. Replace sealing ring for drain plug and tighten to 30 Nm (22
ftlb.).
5. Fill with oil up to the bottom edge of the oil filler opening.
6. Tighten filler plug to 30 Nm (22 ftlb.).
top of page
Tightening torques

Filler plug for transmission oil M22 30 (22)
Drain plug for transmission oil M22 30 (22)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
03 Changing transmission oil 90

03 Checking and topping up the ATF
Tools
Checking and topping up the ATF
Tightening torques
top of page
Tools

Connection hose 9507/1
top of page
Note
• Top up only with ATF approved by Porsche. See Parts Catalogue!
03 Checking and topping up the ATF 91

einordnung
Note
• The stipulated fluid level is extremely important for perfect functioning of the automatic transmission.
It is correct if there is a slight amount of ATF escaping at the control screw bore −B− at temperatures
between 30 °C and 40 °C.
Testing conditions:
• The transmission must not be in the reduced driving program.

• The ATF temperature must be between 30 °C and 40 °C. An ATF inspection at an insufficient ATF
temperature causes over−filling and an inspection at an excessive ATF temperature causes insufficient
filling.
• Selector lever in position "P" and engine idling.
• The air−conditioning system and the heater must be switched off.
• The vehicle must stand horizontally.

2. Connect the Porsche System Tester 2 and call up the ATF temperature.
Note
• The ATF temperature must not be higher than 40 °C at the start of the test.
3. Move selector lever to position "P" and allow engine to idle.
WARNING
Danger of injury from emerging ATF fluid!
ATF fluid can cause burns and chemical burns to the eyes!
• Wear protective goggles
4. Unscrew control screw −B− . If ATF escapes from the control bore and if the ATF temperature is
30 °C to 40 °C, the ATF level is Ok. If there is enough ATF fluid in the transmission, then continue
Checking and topping up the ATF 92

einordnung
with step 10.
Note
• The control screw must be closed no later than when an ATF temperature of 45 °C is reached.
5. If no ATF escapes from the control bore even though approx. 40 °C has been reached, the ATF must be
topped up.
Note
• To undo and tighten the cap nut for the charging valve, counter with an open−ended wrench.
6. Screw off cap nut for the charging

valve.
7. Screw special tool 9507/1 −A− onto the charging valve and top up ATF via the charging valve until
excess ATF emerges at the control bore.
8. Replace sealing ring for cap nut.
9. Screw on cap nut for charging valve.
Tightening torque: 40 Nm (30 ftlb.)
10. Screw in ATF control screw with a new sealing ring.
top of page
Tightening torques

Control screw to ATF pan M10 22 (16)
Cap nut to charging valve M14 x 1.5 40 (30)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Tightening torques 93
03 Replacing ATF
Tools
Replacing ATF fluid
Tightening torques
top of page
Tools

top of page
Replacing ATF fluid
Note
Filling capacity: approx. 9.0 litres

Change quantity: approx. 4.5 litres
03 Replacing ATF 94
einordnung
2. Unscrew drain screw −A− and drain ATF.
Note
• Without ATF, the engine must not be started and the vehicle must not be towed.
3. Replace sealing ring for drain plug and screw in plug.

4. Unscrew control screw −B− .
Note

valve.
6. Screw connection hose 9507/1 −A− onto charging valve. Top up with ATF via the charging valve until
surplus ATF runs out at the control screw bore.
Note
• All instructions and test conditions for "Checking and topping up ATF fluid" must be observed for
further work steps (see Serv. No. 370235).
Replacing ATF fluid 95

einordnung
9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control
screw −B− .
10. With the brake pedal pressed, change through all selector lever positions, remaining in each position for
approx. 10 s.
Note
11. Check the ATF level again and top up if necessary. => Checking and topping up the ATF
12. Replace sealing ring for cap nut and screw cap nut onto the charging valve.
13. Screw in the ATF control screw with a new sealing ring and tighten it to 20 Nm (15 ftlb.).
top of page
Tightening torques

Drain plug to ATF pan M10 22 (16)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
03 Removing and installing ATF filter
Tools
Removing ATF filter
Installing ATF filter
Tightening torques
top of page
Tools

top of page
Removing ATF filter
1. Remove underbody panels, rear and centre.
2. Remove cross member.
03 Removing and installing ATF filter 97

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3. Disengage cable on the retaining clips of the ATF

pan.
5. Unscrew drain screw −A− and drain ATF.
Note
6. Remove ATF pan (loosen screws crosswise).
7. Remove ATF filter.
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1. Thinly coat gasket on the suction collar of the new ATF filter with Vaseline and install
filter.
2. Clean ATF pan.
3. Fit ATF pan with new seal. Tighten the screws crosswise in several stages.
4. Replace sealing ring for ATF drain plug and tighten screw.
5. Fill in ATF. => Checking and topping up the ATF
6. Engage cable on the retaining clips of the ATF
pan.
7. Install cross member.
8. Install rear underside
panel.
Removing ATF filter 98

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Tightening torques

Drain plug to ATF pan M 10 22 (16)
ATF pan to transmission M6 8 (6)
Transmission cross member to body M 10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing ATF filter 99

03 Replacing and checking transmission oil in final
drive
Tools
Changing transmission oil in final drive
Tightening torques
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Tools

Filling system V.A.G 1924
top of page
Note
• Use only oils approved by Porsche. See Parts Catalogue!
03 Replacing and checking transmission oil in final drive 100

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1. Unscrew oil filler plug

−A− .
2. Unscrew oil drain plug −arrow− . Drain oil with vehicle standing horizontally.
4. Replace sealing rings for the drain plug and filler plug.
Note
• Attach the special tool as high as possible on the vehicle.
5. Fill in oil with special tool V.A.G 1924 up to the lower edge of the oil filler
opening.
6. To check the oil level, insert a suitable object (such as a bent wire) into the filler opening and use it to
read the oil level.
7. Screw in and tighten the filler plug and drain
plug.
Filler plug tightening torque: 22 Nm (16 ftlb.)
Drain plug tightening torque: 25 Nm (19 ftlb.)
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Changing transmission oil in final drive 101

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Tightening torques

Oil drain plug M21 x 1.5 25 (19)
Oil filler plug M18 x 1.5 22 (16)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing transmission oil in front wheel drive
Changing transmission oil in front wheel drive
Tightening torques
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Note

1. Remove underbody cover (front).

−A− .
3. Unscrew the oil drain plug −B− and drain the oil with the vehicle horizontal.
6. Tighten the drain plug and filler plug.
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Tightening torques

Screw plug, oil drainage and oil filling M18 28 (21)
03 Changing transmission oil in front wheel drive 103

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996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing transmission oil − GT2
Changing transmission oil − GT2
Topping up transmission oil − GT2
Tightening torques
Total capacity: 3.7 + 0.1 litres
Oil change quantity: 3.2 + 0.1 litres
Note
• Use only oils approved for this type by Porsche. See Parts Catalogue.
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1. Remove rear, centre and left underbody trim.

−1− .
3. Unscrew oil drain plug −2− and let oil drain off into a suitable
container.
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2. Screw in oil drain plug again and top up oil to the bottom edge of the oil filler
opening.
3. Screw in oil filler plug.
4. Fit underbody trim parts.
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03 Changing transmission oil − GT2 105

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Tightening torques

996840, 996841

03 Steering gear: fluid level and bellows
Power steering: checking the fluid level
Steering gear: visual inspection of the bellows
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General
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can
cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the
hydraulic circuit.
Grunt−like noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a
shortage of oil and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be
eliminated on the suction side. Alternatively, the defective part on the pressure side should be replaced.
For the Turbo, not only the power steering is supplied from the collective supply tank −A− located in the
engine compartment, but also the hydraulic clutch boost. The supply tank for GT2 has a different form. It is
located in the engine compartment.
Only Pentosin CHF 11 S may be used in the reservoir. Pentosin CHF 11 S can be ordered with the following
part number: Quantity supplied 1 litre = 000.043.203.33.
Note
• There is a second tank for clutch operation for the Turbo. This container is located in the luggage
compartment (under a cover).
03 Steering gear: fluid level and bellows 107

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• There are two marks on the dipstick located on the reservoir cap. One side bears the mark Cold for a
cold engine (approximately 20° C) and the other Hot for a hot engine (approximately 80° C).
• Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 °C).
CAUTION
Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the
coolant hoses when topping up or filling in.
• Observe the following specifications in order to avoid overfilling and thus overflowing.
• Multiple steering operations (manoeuvring) or/and actuating the clutch with the engine switched off
change the fluid level in the reservoir (actuating the clutch is not valid for the GT2). Fluid level rises.
In this case, the engine must be run for approx. 20 seconds immediately prior to the fluid level check.
• If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
• Replace visibly swollen coolant hoses.
1. Start engine and run it at idle speed for approx. 20 seconds. Switch off engine.
2. Open the engine cover.
3. Open reservoir cap.

4. Wipe off the dipstick. Close and then reopen the cap. The fluid level should lie in the hatched area beneath
the "Cold" mark (mark = maximum level at 20° C). Top up with Pentosin if necessary. *The upper "Hot"
mark is intended for a fluid temperature of 80° C.
• Do not add too much Pentosin! The respective marks are for the maximum fluid level at the "COLD"
or "HOT" temperature.
• If assembly work was performed previously, check the fluid level with the engine idling and without
operating the steering.
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Power steering: checking the fluid level 108

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Steering gear: visual inspection of the bellows
Note
• The bellows on the steering gear can be damaged by outside influences for example, by stone damage
or during assembly work.
• The steering gear can become leaky if dirt or moisture enter a leaky bellows.
Visually inspect the bellows for damage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Steering gear: visual inspection of the bellows 109

03 Axle joints/drive shafts
Tie rod ends: checking the play and dust bellows
Axle joints: checking the play and dust bellows
Drive shafts: visual inspection of the boots
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Tie rod ends: checking the play and dust bellows
Note
• The rubber dust bellows and bellows on the steering gear and on the tie rods can be damaged by
external influences, e.g. stone impact, or during assembly work.
• If a rubber dust bellow leaks, the joint or the tie rod must be replaced, because any dirt or moisture
that seeps in will destroy the joint.
1. Check the play and dust bellows.

2. Check that the dust bellows, bellows and joints are in working order and ensure that they are free of leaks.
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Axle joints: checking the play and dust bellows
1. Check
play.
2. Visually inspect the dust bellows for damage.
Note
• When doing so, the rubber dust bellows should be pressed down with the fingers in order to reveal
hidden cracks.
• If a rubber dust bellow leaks, the corresponding joint or control arm must be replaced, because any
dirt or moisture that seeps in will destroy the joint.
CAUTION
lifting platform.
• Lift the vehicle only at the take−up points provided.

• Make sure the screw connections for the diagonal braces are accessible.
• When driving onto a platform lift, ensure that there is sufficient distance between the platform lift and
the vehicle.
03 Axle joints/drive shafts 110

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3. Inspect the dust bellows of the axle joints (ball joints) on the suspension (front and rear) as follows:
• Put the vehicle onto a lifting platform with the steering lock disengaged.
• Perform a visual inspection after cleaning.
Note
• In the vicinity of the brake cover panels, no visual inspection is possible in a small area.
• Check this area by touch.
The procedure for the front axle is as follows:
• Turn the front wheels as far as they will go.

• Perform a visual inspection of the visible surfaces on the left and on the right.
• After turning the front wheels to the other steering stop, check the other half of each rubber dust
bellows.
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Drive shafts: visual inspection of the boots
Perform a visual inspection of the boots for leaks and
damage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Axle joints: checking the play and dust bellows 111

03 Running gear adjustment/storage of assemblies
Running gear adjustment (wheel alignment values)
Storage of assemblies and running gear
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Running gear adjustment (wheel alignment values)
Check that the screw connections of the running gear adjustment facility (wheel alignment values) at the
front and rear are secure.
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Storage of assemblies and running gear
Visual inspection of all rubber mounts for damage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 Running gear adjustment/storage of assemblies 112

03 Tyres and spare wheel: checking condition and
tyre pressure
Checking condition
Tyre pressure for cold tyres (approx. 20 °C)
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Checking condition
Tyres are a safety element that fulfil the demands placed on them only if they have the correct air pressure and
a sufficient tread depth.
WARNING
Danger of injury and damage to property as a result of modified handling behaviour if the pressure in the tyres
falls below the minimum values.
Danger of injury and damage to property as a result of modified handling behaviour in the case of insufficient
tread depth, foreign bodies, pricks, cracks and bulges in the sidewall (ply breakage).
• The air pressure must never be lower than the values specified (these are minimum pressures).
• A visual inspection of the tyres must be carried out.
1. Check condition and tyre pressure.

Valve caps protect the valve from dust and dirt and therefore from damage.
2. Always screw on valve caps tightly and replace missing valve caps.
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Tyre pressure for cold tyres (approx. 20 °C)
911 Turbo
18−inch wheels, summer and winter tires

Front 2.5 bar overpressure
Rear 3.0 bar overpressure
Collapsible wheel front/rear 2.5 bar overpressure
for 16 inch
2.8 bar overpressure
for 17 inch
911 GT2 (M002/M003)
Note
03 Tyres and spare wheel: checking condition and tyre pressure 113
einordnung
• 911 GT2 M002 = road version
• 911 GT2 M003 = Club Sport version

Front 2.2 bar overpressure
Rear 2.7 bar overpressure
Collapsible wheel not present
• Spare wheel/collapsible wheel not available! However there is a tyre repair kit in the luggage
compartment which can be used to repair the damaged tyre in the event of damage.
• For repairs in the event of damage, observe without fail the safety and operating instructions.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
911 GT2 (M002/M003) 114

03 Checking and changing the brake fluid
Checking the brake fluid level
Changing the brake fluid
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Checking the brake fluid level
1. Visually inspect brake fluid level.
Note
• The brake fluid level must be between min. and max..
• Observe brake fluid quality. Use only new DOT 4 brake fluid.
• This brake fluid is available under the following part numbers: quantity supplied 1 litres =
000.043.203.66 container volume. 30 litres = 000.043.203.67.
• The information applies to vehicles with PSM (Turbo) and without PSM (GT2).
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Changing the brake fluid
Note
• Observe brake fluid quality. Use only new DOT 4 brake fluid.
• The brake−fluid change interval using Super DOT4 brake fluid is two years.
• This brake fluid is available under the following part numbers: quantity supplied 1 litres =
000.043.203.66 container volume. 30 litres = 000.043.203.67.
1. Fill reservoir to its top edge with new brake fluid.

2. Connect a bleeding device to the brake fluid reservoir.
03 Checking and changing the brake fluid 115

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3. Switch on the bleeding device. Bleeding pressure is approximately 2.0 bar.
Note
• Drain brake fluid on every brake caliper on both bleeder valves.
• Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for
cleanliness, lack of air bubbles and to determine the brake fluid used.
4. Continue brake fluid change at the brake calipers (no special

sequence).
5. Open every bleeder valve until clear, bubble−free brake fluid emerges and until the corresponding change
quantity per brake calliper is reached (approx. 250 cm3 ).
6. Switch off and disconnect the bleeding device. Correct the brake fluid level if
necessary.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Changing the brake fluid 116

03 Parking brake: checking the free play of the
parking brake lever
Parking brake: checking the free play of the parking brake lever
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Parking brake: checking the free play of the parking brake lever
Checking the free play of the handbrake lever.
The parking brake has asbestos−free brake linings.
Note
• The handbrake with asbestos−free brake linings must never be adjusted in such a way that the lining
must grind down during operation.
• The handbrake must be adjusted if the handbrake lever can be pulled up by more than 4 teeth with
medium force application (without a braking effect).
Adjusting the parking brake
1. Remove the rear wheels.

2. Undo the parking brake lever and push back the disc brake pads of the rear axle until the brake disc can
rotate freely.
Note
• To make the turnbuckle accessible, open the cover of the tray behind the parking brake lever and
remove the rubber inlay and also the insert.
3. Undo the adjustment nuts −arrow− on the turnbuckle until the cables are without pretension.
4. With a screwdriver −Figure− , turn the adjustment device through a wheel bolt threaded hole so that the
brake disc can no longer be moved.
5. Turn back the adjustment fixture through 5 notches again (release approx. 3 notches until the brake disc
can be moved freely, then release another 2 notches).
03 Parking brake: checking the free play of the parking brake lever 117
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6. Repeat the procedure on the other wheel.

7. Pull up the parking brake lever by 2 teeth and adjust the adjustment nut of the turnbuckle until both
wheels can be turned manually with difficulty.
8. Release the parking brake lever and check whether both wheels can be turned
freely.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Adjusting the parking brake 118

03 Visual inspection: brake lines/brake pads/brake
discs
Brake hoses and lines
Brake system: visual inspection of the brake pads and brake discs for wear
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Brake hoses and lines
Carry out visual inspection for leaks, damage, routing and
corrosion.
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Brake system: visual inspection of the brake pads and brake
discs for wear
WARNING
Braking effect impaired if the brake pads are replaced too late.
Braking effect impaired if the brake discs are replaced too late.
Danger of injury and damage to vehicle if braking effect is impaired.
• The brake pads must be replaced when the brake pad warning indicator lights up, but no later than
when there is a residual pad thickness of 2 mm.
Note
• If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced.
• Replacing the warning contact can be avoided by replacing the brake pads no later than when the pad
thickness is 2.5 mm.
• Warning contacts must be replaced if the core of the wire is worn.
• However, if only the plastic part of the warning contact is worn, there is no need to replace it.
1. To check the brake pads, remove the wheels.
03 Visual inspection: brake lines/brake pads/brake discs 119

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2. Visually inspect the brake pads for wear (wear limit 2 mm).
3. Carry out visual inspection of the brake discs for wear.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Brake system: visual inspection of the brake pads and brakediscs for wear 120
03 Checking the wheel mounting
• Use suitable commercially available tools (wrench size 19 mm) together with a tested torque wrench ,
covering the range of 130 Nm (96 ftlb.). Never use an impact bolter.
• Do not loosen the wheel bolts to check the tightness. Tighten the wheel bolts or check for tightness
(tightening torque 130 Nm (96 ftlb.)).
1. Tighten the wheel bolts to 130 Nm (96 ftlb.) or check for tightness.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 Checking the wheel mounting 121

Checking lid lock, front and rear
Checking safety hook, front lid
Function test, checking door lock
Functional inspection of the tank cap lock
Checking door and lid tightening torques
Checking inner release of luggage compartment (Trunk Entrapment)
Tightening torques
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Check that the lid locks engage by insertion of the lock upper parts when the lids (front and rear) are
closed and that they disengage again when the lid releases are pulled.
Checking the catch bar
Check the catch bar for

wear.
• When the wear limit is reached, the catch bar must be replaced.
Dimension for new part Wear limit

7 mm 4 mm
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1. Check that the front lid is held down by the lower part of the lock of the safety hook after the lid lock is
opened.
2. Check whether the return spring on the lower part of the lock pulls back the safety hook as far as the stop.
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Check that the door lock engages in two stages through the locking wedge when the doors are closed and
that it disengages again when the door handle is operated (inside and outside).
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03 Checking lid and doors 122

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Lock
vehicle.
Check that the tank cap lock locks the tank cap in the closed position.
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Checking door and lid tightening torques
Check the tightening torque of the fastening screws of the door lock, the latch striker, the lower part
of the lid lock and the upper part of the lid lock.
Fastening screws of upper part of the lid lock on front cover. => Tightening torques
Fastening screws of lower part of the lid lock on front closing panel. => Tightening torques
=> Tightening torques
Fastening screws of latch striker on side section. => Tightening torques
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Checking inner release of luggage compartment (Trunk
Entrapment)
DANGER
• Danger of accident. If a person trapped in the front luggage compartment unlocks the front lid when
the vehicle is in motion, the lid will open completely after 30 seconds. The luggage compartment will
impact in front of the windscreen and can tear off.
• Stop the vehicle immediately when the warning lights light up.
Check whether the upper part of the lock automatically disengages from the lower part of the lock.
1. Engage the upper part of the lock No. 996 551 051 02 = tool (Porsche spare part) in the lower part of the
lock −direction of arrow− .
2. Unlock unlocking lever in the luggage compartment. Check whether the upper part of the lid lock
disengages automatically.
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Functional inspection of the tank cap lock 123

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Tightening torques
Tightening torque
Location Illustration Thread [Nm] (ftlb.)
Fastening screws of upper part of the lid lock on front M6 10 (7.5) Nm
cover (ftlb.)
Fastening screws of lower part of the lid lock on front M6 10 (7.5) Nm
closing panel (ftlb.)
Fastening screws on door lock on the doors M8 20 +2 (15 + Nm
1.5) (ftlb.)
Fastening screws of latch striker on side section M8 23 (17) Nm
(ftlb.)
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651,
996630, 996631

03 Checking seat belts
Functional inspection
Condition inspection
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Functional inspection
• It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by
pulling evenly, and the tongue of the seat belt must engage audibly in the buckle
• An abrupt pull on the belt strap must lock the belt retractor
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Condition inspection
• The belt strap must undergo a visual inspection for damage
• If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be
replaced
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651,
996630, 996631
03 Checking seat belts 125

03 Inspecting the airbag system
Visual inspection
Checking airbag warning light
Function test of the airbag system
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Visual inspection
1. Check airbag units visually:
a. Check that a trim or stickers are not attached to the airbag units (driver's, passenger's, side airbag).
b. Visual inspection of the components for damage and
deformation.
c. The system check must be acknowledged in the stamp spaces provided in the Guarantee and
Maintenance booklet.
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Checking airbag warning light
1. Function test of airbag
warning light in instrument
cluster:
a. Switch on
ignition.
Note
• The airbag warning light must light up for approx. 3 seconds. If the warning light does not light up,
check the light unit and power supply.
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Function test of the airbag system
1. Function test of the airbag system:
CAUTION
Danger of injury and damage to property as a result of incorrect handling of airbag units!
Always observe the safety regulations for handling airbag units ’ 6, 69 Safety regulations for handling airbag
and belt tensioner units .
Connect and switch on the Porsche System
Tester.
Switch on
ignition.
Establish communication with the airbag
03 Inspecting the airbag system 126

einordnung
control module.
Read out fault memory: No
fault stored.
Pull off fuse according to the circuit
diagram.
Fault present after approx. 30 seconds >> Airbag warning
light<<.
Insert E1 fuse
again.
Clear fault
memory.
Read out fault memory again after approx. 30 seconds: No fault
stored.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Function test of the airbag system 127

03 Passenger protection maintenance: checking
roll−over protection system
Caution
WARNING
Risk of injury if the roll−over bar is triggered!
> All persons must remain out of the operating range of the roll−over bar during diagnosis.
> Always keep the operating range of the roll−over bar free (do not leave tools there).
> Install, remove and transport the roll−over bar only when it is extended (triggered).
> Repairs to the roll−over bar and actuators are not permitted.
Note
• The roll−over bar must be triggered every two years at the latest, using the Porsche System Tester.
• Perform the function test on the roll−over protection system only with >> the hardtop and covering
cap removed << and the convertible top open.
1. Connect the Porsche System Tester to the diagnostic socket (data link connector) on the vehicle.
2. Switch on ignition.
3. Select menu item −Roll−over protection− .
4. Select the function −drive links− in the command line which appears.
5. Press the key combination described in the Tester; the roll−over protection system is triggered.
6. Pressing in the roll−over bar: press locking levers outward and press in the roll−over bar until it can be felt
to engage.
7. Fit cover caps on the left and right.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651,
996630, 996631
03 Passenger protection maintenance: checking roll−over protection system 128

03 Particle filter: replacing the filter element
Removing particle filter
Installing particle filter
Replacing filter element (with and without
carbon).
Note
• The particle filter is installed on the right in front of the heating/air−conditioning system!
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Removing particle filter
1. Remove the cover for the heating and air−conditioning system.
2. In conjunction with telephone preparation, loosen the antenna at the two top fastening screws and
unscrew the two bottom fastening screws. Remove antenna part.
3. Remove the particle filter upwards out of the housing guide −(arrow)− .
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Installing particle filter
1. Insert a new particle filter into the housing guide.
2. Check that the filter is correctly fitted and in the correct installation
position.
3. Insert antenna part at the top, screw in both top and bottom fastening screws. Tightening torque 6 Nm (4.5
ftlb.).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 Particle filter: replacing the filter element 129

03 Checking the function of the vehicle's lights
Setting
Removing main headlight
Installing main headlight
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1. Open the luggage compartment lid.
2. Remove the luggage compartment mat on the wheel housing wall.
3. Open the cover for the headlight adjustment screws.

4. Clean the cover lens and switch on the dipped beam headlights.
Note
• Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)!
• Use a standard 5 mm ball−head screwdriver to make the headlight adjustment (free blade length 150
mm)!
• Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower
screws must be turned in the same direction and for the same number of rotations!
03 Checking the function of the vehicle's lights 130

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5. Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a
adjustment unit.
A Lateral adjustment
B Height and lateral adjustment
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Setting
Note
• Set the headlight adjustment unit to 10 cm/10 m (1%)!
• With this alignment, preference must be given to the central zone around the salient point of the
light/dark limit!
First, make the vertical adjustment of the dipped beam headlights.

1. To do this, line up the light/dark borderline running upwards at an angle on the right−hand side with the
dotted 15° line of the adjustment unit.
Next, perform the horizontal adjustment of the dipped beam headlights.
2. To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the
dotted horizontal line of the adjustment unit.
Note
• The distance between the headlights and the adjustment unit should be as small as possible!
• It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the
formation of the light/dark limit in the adjustment unit clearly!
3. Secure the plugs after making the adjustment.

4. In the case of Xenon headlights, the ignition must be switched off and on after the adjustment has been
made with the lights switched on.
5. After this, the adjustment must be checked again.
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Adjusting the main headlights 131

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Note
headlights!
Vertical and horizontal adjustment must be carried out with a headlight adjustment
unit.
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Note
Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a
adjustment unit.
Note
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Removing main headlight
Note
• Risk of damage to headlights due to chafing and excessive temperatures.
• Headlights must not be covered when they are switched on, e.g. wing protection or film.
Adjusting the main headlights, USA version 132

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1. Release the side carpet by unscrewing plastic nut −A− −arrow− .
2. Pull rubber stopper −B− off the release opening.
3. Place the socket wrench from the tool kit on the release axle.
4. The toggle of the socket wrench should point horizontally to the rear.
5. Turn the socket wrench through approx. 180º −arrow A− and leave it in position.
6. The headlight is now unlocked and can be pulled forwards out of the wing.
7. Turn the socket wrench back until it points vertically −arrow B− downwards.
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Installing main headlight
Note
• Do not attach any covers (e.g. stone shields or films) in the area of the headlights.
Removing main headlight 133

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1. Insert the headlight into the guide rails and push it fully into the wing
−arrow− .
2. Press the headlight to the rear, turning the socket wrench at the same time until the wrench points
horizontally to the rear −arrow C− . In the process, the headlight lock must engage with an audible
and perceptible click.
3. Check the correct seating of the headlight, e.g. by pulling gently in the area of the fog light.
4. Insert rubber stopper in the release opening.

5. Screw the side carpet tight with the plastic screw −A− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing main headlight 134

03 Windscreen wiper/washer system, headlight
washer
Caution
CAUTION
Danger of material damage if headlights are cleaned incorrectly!
• Use only soapy water to clean the exterior lights and the plastic headlight lenses!
• Never use chemical cleaning agents!
• To avoid scratches, do not rub with dry or only damp cloths, paper towels or insect−removal sponges!
Note
• The headlight washer nozzles are pre−set!
• It is not necessary to adjust them!
Check the function, fluid levels and nozzle

settings.
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03 Windscreen wiper/washer system, headlight washer 135

03 Checking the function of electrical equipment, as
well as the indicator and warning lights
Turn ignition key and check function of warning and indicator lights (visual inspection).
Actuate power windows and check operation.
Check that rear window heater is in working order.
Adjust heater blower and fans to high and low and check the air vents for air throughput.
Check operation of front seats.
Check operation of radio.
Check operation of door mirror, check adjustment options.
Check operation of orientation lights.
Actuate central locking and check operation.
Operate cigarette lighter and check that it is in working order.
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03 Checking the function of electrical equipment, as well as the indicator and warning lights 136
03 Additional maintenance − USA
Caution
Additional maintenance, replacing spark plugs
Additional maintenance every 60,000 mls/96,000 km
Maintenance every 2 years
Maintenance after 4, 8, 10 then every 2 years
WARNING
Damage is possible if the wrong maintenance schedules are used for reimported vehicles!
• These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported
from the USA
• Vehicles reimported from the USA must be maintained according to the maintenance schedules for
RoW vehicles
The maintenance schedules for the US market have been added to the Technical Manual for the sake of
completeness.
top of page
Additional maintenance, replacing spark plugs => Replacing spark plugs OK

911 Turbo/ GT2 every 30,000mls/48,000km
top of page
Note
• It is recommended to replace the fuel filter every 60,000 mls (96,000 km).
Additional maintenance every 60,000 mls/96,000 km OK

Replace Polyrib belt => Removing and installing drive belt
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03 Additional maintenance − USA 137

einordnung

Manual transmission: change oil => Changing transmission oil or => Changing transmission oil −
GT2
Automatic transmission: change ATF and ATF filter => Replacing ATF and => Removing and
installing ATF filter
Automatic transmission: change oil in final drive => Replacing and checking transmission oil in
final drive
Final drive, front: change oil => Changing transmission oil in front wheel drive
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Maintenance every 2 years OK

Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake
fluid
Condition report preparing long−life guarantee
Form WKD 444 010 02 German
Form WKD 444 020 02 English
Form WKD 444 021 02 US English
Form WKD 444 030 02 French
Form WKD 444 031 02 French−Canadian
Form WKD 444 040 02 Italian
Form WKD 444 050 02 Spanish
Form WKD 444 091 02 Dutch
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Maintenance after 4, 8, 10 then every 2 years OK

Inspect airbag system => Inspecting the airbag system
Mount assemblies and running gear: visual inspection of all rubber mounts for damage
=> Running gear adjustment/storage of assemblies
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Additional maintenance every 90,000 mls/144,000 km 138

03 Additional maintenance − as of MY 2004
Note
Additional maintenance every 80,000 km/48,000 mls
Note
• Not valid for USA.
• The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are
operated in countries where the fuel has a high sulphur content (country coding M 150 in the control
module).
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911 Turbo/ GT2 every 40,000 km/24,000 mls
top of page
Additional maintenance every 80,000 km/48,000 mls OK

Replace the fuel filter => Replacing the fuel filter
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GT2
03 Additional maintenance − as of MY 2004 139

einordnung
final drive
top of page

fluid
Check roll−over protection system (only 911 Turbo Cabrio) => Passenger protection
maintenance&colon; checking roll−over protection system
top of page

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Additional maintenance every 160,000 km/96,000 mls 140

03 Additional maintenance − USA − as of MY 2004
Caution
WARNING
from the USA
RoW vehicles
completeness.
top of page

911 Turbo/ GT2 every 30,000mls/48,000km
top of page
Note
• It is recommended to replace the fuel filter every 60,000 mls (96,000 km).

top of page
03 Additional maintenance − USA − as of MY 2004 141

einordnung

GT2
final drive
top of page

fluid
Check roll−over protection system (only 911 Turbo Cabrio) => Passenger protection
maintenance&colon; checking roll−over protection system
top of page

Additional maintenance every 90,000 mls/144,000 km 142

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Maintenance after 4, 8, 10 then every 2 years 143

03 Additional maintenance
Note
Note
module).
top of page

911 Turbo/ GT2 every 40,000 km/24,000 mls
top of page

Replace the fuel filter => Replacing the fuel filter
top of page

GT2
03 Additional maintenance 144

einordnung
final drive
top of page

fluid
top of page

996420, 996421, 996450, 996451, 996840, 996841
Additional maintenance every 160,000 km/96,000 mls 145

3 Technical data
top of page

G 96.50 − 6−speed 911 Turbo (996) 2001

1st gear 11 : 42 = 3.82
2nd gear 21 : 43 = 2.05
3rd gear 27 : 38 = 1.41
4th gear 34 : 38 = 1.12
5th gear 37 : 34 = 0.92
6th gear 40 : 30 = 0.75
Filling capacity for new filling 3.8 l
Change quantity 3.0 l
3 Technical data 146

einordnung
Manual transmission tightening torques

Transmission on engine M10 45 (33)
Air flanges on transmission M6 10 (7.5)
Slave cylinder on transmission M10 x 35 45 (33)
Bracket for slave cylinder on transmission M8 x 20 23 (17)
Bracket for clutch control shaft on transmission M6 x 16 10 (7.5)
Guide tube for release bearing on transmission housing M6x14 10 (7.5)
Drive shaft on transmission flange M10 45 (33)
Transmission support to transmission mount M10 65 (48)
Transmission support to body M10 65 (48)
Collar nut/halfshaft flange M20 x 1.5 120 (89)
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Manual transmission tightening torques 147

einordnung

Front−axle drive tightening torques

Cover on final drive M8 25 (19)
Long−neck tube on final drive M8 x 36 25 (19)
Drive shaft on final drive M8 39 (29)
Rear transmission support to transmission mount M10 x 90 65 (48)
Rear transmission support on body M10 65 (48)
Front transmission support on front−axle cross member M10 65 (48)
Studs on front−axle cross member M8 20 (15)
Front cross member to final drive M10 65 (48)
Drive shafts on front−axle final drive M8 39 (29)
Diagonal braces on body and front−axle cross member M12 100 (74)
Tank strap on body M8 x 40 23 (17)
Pipe holder on transmission support M6 7 (5.0)
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Front wheel drive Z 96.00 148

3 Technical data
5−speed Tiptronic transmission A 96.50−150
top of page
5−speed Tiptronic transmission A 96.50−150

A 96.50−150 − 5−speed 911 Turbo (996) 2001
Note
• In order to protect the converter components from excessive centrifugal forces with the vehicle
stationary, this car has been equipped with torque converter centrifugal force protection . This
protection ensures that the engine speed is limited to 4000 rpm in the selector lever positions P and N.
General data Transmission A 96.50−150

Type Fully automatic 5−speed planetary gear set
(Tiptronic)
Ratio
Spur gear 0.76
1st gear 3.59
2nd gear 2.19
3rd gear 1.41
3 Technical data 149

einordnung
4th gear 1.00

5th gear 0.83
Reverse gear 1.93/3.16
Final drive Bevel gear drive
Final drive ratio (without spur gear) 9 : 34 = 3.77
Filling capacity, rear−axle final drive 1.2 l
Automatic section: new filling (with torque approx. 9.0 l
converter)
Change quantity approx. 4.5 l
Tightening torques for Tiptronic transmission
Tightening torque Nm
Location Thread (ftlb.)
ATF check screw to ATF pan M10 22 (16)
ATF drain plug on ATF pan M10 22 (16)
ATF pan to transmission housing M6 8 (6)
Cap nut to ATF charging valve M14 x 1.5 40 (30)
ATF charging valve to transmission housing M14 x 1.5 40 (30)
Filler plug for rear−axle oil M18 x 1.5 29 (21)
Drain plug for rear−axle oil M24 x 1.5 25 (19)
Hydraulic control unit on transmission housing M6 8 (6)
Short flanged shaft to differential M10 x 55 46 (34)
Cover for final drive on transmission housing M8 23 (17)
Mounting saddle for long flanged shaft to transmission M8 23 (17)
housing
Transmission support to transmission mount M10 65 (48)
Drive shaft to flanged shaft M10 81 (60)
Converter to drive plate M8 x 20 39 (29)
Crash support to intermediate case M8x60 23 (17)
Transmission to intermediate case M8x35 23 (17)
Collar nut 24 x 1.5 160 (118)
Water hose holder to transmission M6 10 (7.5)
Plug connection to socket M4 2.5 (2.0)
Holder to mounting saddle M6 10 (7.5)
top of page
5−speed Tiptronic transmission A 96.50−150 150

einordnung


Front−axle drive tightening torques

Cover to final drive M8 25 (19)
Long−neck tube to final drive M8 25 (19)
Drive shaft to final drive M8 39 (29)
Rear transmission support to transmission mount M10 x 90 65 (48)
Rear transmission support to body M10 65 (48)
Front transmission support to front−axle cross member M10 65 (48)
Studs on front−axle cross member M8 20 (15)
Front cross member to final drive M10 65 (48)
Front wheel drive Z 96.00 151

einordnung
Diagonal braces to body and front−axle cross member M12 100 (74)
Tank strap to body M8 x 40 23 (17)
Pipe holder to transmission support M6 7 (5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Front−axle drive tightening torques 152

4 Removing transport lock (spring strut locking
devices) Turbo and GT2
General
top of page
General
Spring strut locking devices are installed on the front axle of the following new vehicles in order to protect the
vehicle during transport (e.g. driving on and off during lorry transport):
• Turbo RoW (new vehicles)

• Turbo USA (new vehicles)
• 911 GT2 (new vehicles)
This increases the ground clearance of the vehicle.

Tests have demonstrated that spring strut locking devices are not necessary at the rear axle.
With the 911 GT2, the spoiler lip is also removed from the front spoiler. Fitting the enclosed front lip ’ 0
Entire vehicle − General, 01 Fitting front lip − GT2.
WARNING
Danger of injury and damage to property if spring strut locking devices are installed when commencing
journey!
• If the spring strut locking devices are not removed, this will seriously impair the handling behaviour
and thus the driving safety!
• The spring strut locking devices must be removed before a test drive and before the vehicle is handed
over to the customer!
Note
• Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg!
• Include the spring strut locking devices with the normal warranty goods consignment!
top of page
Note
• The wheels need not be removed!
1. Lift the vehicle (wheels at the front axle must be free).
4 Removing transport lock (spring strut locking devices) Turbo and GT2 153
einordnung
2. Remove spring strut locking devices from all spring struts. To do this, pull spring strut locking
devices off the springs.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing spring strut locking devices 154

4 Lifting the vehicle
Lift the vehicle
top of page
Lift the vehicle
CAUTION
lifting platform!
• Make sure the screw connections for the diagonal braces are accessible!
and the vehicle!
front
rear
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4 Lifting the vehicle 155

4 Tests/notes for all−wheel drive
Balancing wheels on vehicle
Power test
Brake test
Towing manual transmission vehicles
Towing Tiptronic vehicles
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Balancing wheels on vehicle
When fine balancing wheels on the vehicle, all four wheels must be raised and must be able to turn freely. If a
fault occurs in PSM (Porsche Stability Management), read out fault memory before fine balancing. After fine
balancing, the fault memory of the PSM control unit must be erased.
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Power test
Power tests can only be carried out on 4−roller type test stands!
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Brake test
Brake tests can only be carried out on roller−type test stands or plate test stands. If no all−wheel drive test
stand (roller−type test stand) is available, the following limit values must not be exceeded for conventional
roller−type test stands: Test speed max. 7.5 km/h Test duration max. 20 seconds.
top of page
Towing manual transmission vehicles
If vehicle is towed with raised front or rear axle, the wheels of the raised axle must be able to turn freely. The
ignition must be switched off and the shift lever must be in neutral.
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Towing Tiptronic vehicles
With engine not running, sufficient lubrication of the transmission is not ensured.
• Select position N. Switch off ignition.

• Do not exceed top speed of 50 km/h.
• Maximum towing distance 50 km.
• For longer towing distances the vehicle must be raised at the rear axle or transported on a trailer.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
4 Tests/notes for all−wheel drive 156

4 Switching off PSM
Note
Switching off PSM
Switching PSM back on
Characteristic features of Tiptronic vehicles (slip upshift)
Note
• The PSM (Porsche Stability Management) is automatically operational/switched on after each engine
start!
top of page
Switching off PSM
Press the PSM OFF logo of the rocker switch. The PSM switches off after a short delay.
When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the rocker
switch are lit.
• When braking, the vehicle is also stabilised when the PSM is switched off!
• One−sided wheel spin is also prevented when the PSM is switched off!
• On Tiptronic vehicles, the function slip upshift is switched off when PSM is switched off! =>
The PSM should always be switched on for normal driving.

In exceptional cases, it can be advantageous to switch off the PSM temporarily:
on a loose surface and in deep
snow
when rocking the vehicle free
when using snow chains.
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Switching PSM back on
Press the indicator light in the rocker switch. The PSM switches on after a short delay.
top of page
4 Switching off PSM 157

einordnung
Characteristic features of Tiptronic vehicles (slip upshift)

• When a maximum permissible speed difference between front and rear axle is exceeded, an integrated
slip monitoring shifts into the next highest gear. This increases the driving stability on slippery roads.
• When PSM is switched off, the slip monitoring (slip upshift function) is also switched off. In this
way, the Tiptronic enables an active sporty driving style also when the friction coefficent is low as is
the case with manual transmission vehicles.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Characteristic features of Tiptronic vehicles (slip upshift) 158

5 Plug location plan
Caution
Top of front end
Bottom of front end
Side of front end
Bottom of lower side member and floor
Top of lower side member and floor
Bottom of rear end
Top of rear end
Side of rear end
CAUTION
Danger of material damage (corrosion) due to entry of water when removing plugs!
• The body apertures are sealed with plugs in the factory, and must be sealed with the plugs provided
once more following disassembly or repair work!
top of page
Top of front end
A Rubber grommet hole Ø 20 mm

B Rubber grommet hole Ø 30 mm
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5 Plug location plan 159

einordnung
Bottom of front end
Plug hole Ø 20
F
mm
top of page
Side of front end

top of page
Bottom of front end 160

einordnung
Bottom of lower side member and floor

C Plug hole Ø 10 mm
D Plug hole Ø 10 mm
E Plug hole Ø 15 mm
top of page
Top of lower side member and floor

K Plug hole Ø 30 mm
Bottom of lower side member and floor 161

einordnung
top of page
Bottom of rear end

E Plug hole Ø 15 mm
F Plug hole Ø 20 mm
top of page
Top of rear end
Top of lower side member and floor 162

einordnung

L Plug hole Ø 55 mm
top of page
Side of rear end

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Top of rear end 163

Seam seals
Accessories
top of page
Accessories
Note
• Due to modifications to the spare part range, in the case of repair work accessories must be sealed
before assembly (painting) according to the following illustrations.
• The sealing material 000 043 204 38 can be applied directly to the accessories coated with KTL paint
(cathodic dipbath coating).
Seam seals 164

einordnung
• The seam seal can be painted over when it has reached approx. 70 % hardness (approx. 4 − 5 h at
20 °C, 50 % relative air humidity). (Higher air humidity or dampening with water accelerates the
hardening process).
• The hardening can be checked with a nail test. Press a finger nail gently into the hardened sealing
mass; if this causes no damage to the sealing mass surface, the seam seal can be painted.
Front lid
Door
Accessories 165
einordnung
Sliding roof panel
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Sliding roof panel 166

5 Work sequence for accident repair
Work sequence for accident repair
Determine scope of damage
“
Expose the area to be repaired
“
Make an economic or technical decision.
Should parts be repaired or replaced?
“
Determine the scope of replacement parts and have the parts obtained
’
−Repair− −Replacement−
Determine the scope of replacement Determine the scope of replacement parts and have the parts
parts and have the parts obtained obtained
“ “
Cover undamaged areas of the vehicle Cover undamaged areas of the vehicle so that they are
“ protected against fire
“
Pre−paint new parts from the inside
“
Reshape damaged areas Reshaped damaged area by straightening so that adjacent
“ contours or gap dimensions correspond to the series condition
“
Roughly cut out damaged areas
“
If necessary, apply filler or body Cut out remaining pieces
solder on reshaped areas “
“ Fit new parts in, then check the gap dimensions with the
accesories fitted
“
Protect spot−welded flanges against corrosion
“
Apply fine filler on repair areas Disconnect battery and observe safety and quality instructions
“ for welding.
“
Weld in new parts
“
Grind visible weld seams flat; if necessary apply body solder
or filler
“
If necessary, primer and seal the seam areas
“
If necessary, renew the stone impact protection
“
5 Work sequence for accident repair 167

einordnung
Paint the repaired area

“
If necessary, touch up the undersealing
“
Seal cavities
“
Fit accessories
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5 Work sequence for accident repair 168

5 Work sequence for determining scope of damaged
vehicles involved in an accident
Note
Note
• A body is constructed so that it has deformable zones in the front and rear area. These deformable
zones enable absorption of impact energy due to their special construction. The bearing structure in
these areas is adapted by a specific cross section reduction to provide optimum energy reduction in
the event of an impact.
• Due to the vehicle dimensions in the side area of the body, deformable zones can not be provided for
absorbing energy. The impact energy can only be absorbed to a small extent here through the
deformation of doors and columns. This is also the case for the roof area where only the roof seal can
absorb impact energy to a very small extent. In these areas, passenger protection is guaranteed by a
rigid construction of the passenger compartment.
• The aim of this design is to absorb the impact energy in defined areas to keep the passenger
compartment as free of damage as possible in the event of an accident. If the passenger compartment
has been deformed in the event of an accident, extremely large reshaping forces can be expected.
Repair work is often only possible in this case by replacing the body parts.
• In general, an impact occurs diagonally or offset to the vehicle axle so that mixed forms are usually
the result of a front and side impact or a rear and side impact. The deformation is not always in the
impact area. Due to bearing forces of loads such as running gear, drive line, occupants of the vehicle
and load or the body itself, deformation can also occur in the opposite areas.
• The following work sequence should provide assistance to correctly determine the scope of damage of
vehicles damaged in an accident.
Work sequence for determining scope of damaged vehicles involved in an accident

Identify impact points on the outer shell or the wheels
“
Remove accessories which limit view of the impact area
“
Check unit holders, running gear parts and steering parts for deformation and cracks
“
Determine scope of damage on the body
’
−Identifiable deformations on the body structure− −No identifiable deformations on the
body structure−
Visual inspection of the structural parts for creasing Check seam joining line on the
and bending from the impact starting from the central accessories’ 5 Diagram − Body gap
point of vehicle dimensions
“ “
5 Work sequence for determining scope of damaged vehicles involved in an accident 169
einordnung
Visual inspection of the structural parts on the Check accessories for paint abrasion
connection points for gaping plate connections (e.g. (accessories which have been in contact
entry area on the side member under the rubber seal of during the impact)
the door) “
“
Drive vehicle onto a lifting platform and raise. Measure Drive vehicle onto a lifting platform and
the measuring points or reference points specified in raise. Measure the measuring points or
the repair check dimensions table diagonally, reference points specified in the repair
horizontally and vertically using a compass or an check dimensions table diagonally,
electronic measuring system and compare with the horizontally and vertically using a
specified values. compass or an electronic measuring
’ 5 Repair check dimensions system and compare with the specified
“ values.
’ 5 Repair check dimensions
“
Decide whether vehicle is technically repairable Determine scope of any existing damage
“ to vehicle parts
’4
If necessary, measure running gear
electronically
’ 44 Suspension alignment
“
Decide whether vehicle is economically repairable Decide whether vehicle has to be
“ repaired
“
If necessary, repair vehicle
’ 5 Work sequence for accident repairs
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5 Work sequence for determining scope of damaged vehicles involved in an accident 170
5 Corrosion protection measures during repairs
Measures for maintaining long−term body protection
Prerequisite for ensuring vailidity of the long−life guarantee
top of page
Note
• After repair work, the standard corrosion−inhibiting coating should only be restored with the
corrosion−inhibiting agents approved by the manufacturer. The following points must be observed for
body repairs.
• Always apply welding primer to both sides of the welding flange when resistance spot welding.
• Prime repair areas from outside. Prime on both sides in the accessible areas.
• Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
• Only apply body sealant to primed sheetmetal parts.
• Apply single−coat top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint
build−up": Paint Manual
• Build up paint on bright sheetmetal panels according to the painting methods described in the Paint
manual .
• Repair or create standard undersealing by applying long−life undersealing material.
• Preserve cavities in the repair area with cavity preservation after applying a single−coat top coat.
• Check that the standard water drains (plugs) are functioning correctly or clean them after the cavity
preservation material has dried.
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Prerequisite for ensuring vailidity of the long−life guarantee
Porsche long−life guarantee conditions
• All body repair work must be carried out correctly and according to the specific Porsche instructions
for sheetmetal, paint and corrosion protection/preservation work.
• To prevent jeopardising the long−life guarantee, a Paint Condition Report is made out 2 years after
delivery of the vehicle. This condition report must be drafted annually be every Official Porsche
Centre.
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5 Corrosion protection measures during repairs 171

5 Vehicle identification number
Imprinting new vehicle identification number
Materials, tools
After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the
original vehicle identification number must be reimprinted onto the new body or the new sheet metal part.
The documentation of the imprinted vehicle identification number in the vehicle supplementary document or
legally permissible treatment can be obtained from the importer of the respective country.
An incorrectly imprinted (stamped) vehicle identification number should be permanently crossed through with
a X so that it remains legible. The vehicle identification number to be newly imprinted should be imprinted
above the crossed through identification number.
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Imprinting new vehicle identification number
1. Spacer for replacing the

vehicle identification
number
The spacer for applying the vehicle identification number is in the front, right firewall. Two sections are
intended for use.
Section 1 −A− is the
standard spacer.
Section 2 −B− is the spare spacer for a corrected vehicle identification
number.
2. Imprinting new vehicle identification number
=> Materials,
tools
Note
• Only imprint vehicle identification number in a KTL (cathodic−dip coated) sheetmetal part. 1)
• The area should be countered when imprinting the vehicle identification number.
5 Vehicle identification number 172

einordnung
a. Stamp the vehicle identification number to be replaced into the spacer with an 8 mm number
embossing tool and the Porsche star.
b. Mask imprinted vehicle
identification number.
c. Apply exterior
paintwork.
d. Remove the vehicle identification number
mark.
e. Paint repair area with clear
lacquer.
1) Cathodic−dip coating is the primer applied to the sheetmetal parts at the factory
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Materials, tools
Item Designation of the special tool Remarks

1 Number embossing tool 8 mm DIN Gr. 2.4; Workshop Equipment Manual
1451, closely spaced lettering
Nr.128−1
2 Porsche star Sonderwerkzeug 9693 Gr. 2.2; Workshop Equipment Manual
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Imprinting new vehicle identification number 173

5 Change identification data plate
After exchanging sheetmetal parts, side section, or doors, a new indentification data plate must be attached.
The identification data plate must be ordered from the importer of the respective country.
When ordering the indentification data plate, the item number −1− and vehicle identification number −2−
must be specified.
1. Installation location of identification data plate on the vehicle

A Right side section RoW
B Left doors USA/Canada
3. Identification data
plate RoW
a. Item
number
b. Vehicle identification
number
4. Identification data plate USA

a. Item
number
number
5 Change identification data plate 174

einordnung
5. Identification data plate Canada

a. Item
number
number
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5 Change identification data plate 175

5 Undersealing
Note
Overview diagram, lower front of vehicle
Overview diagram, bottom of lower side member and floor
Overview diagram, lower rear end
Tools and materials
Note
• In the case of repairs, before painting or the installation of ancillaries, the standard stone
shield/undersealing of the body structure must be must be recreated as shown in the following
illustrations.
• The undersealing must only be applied on primed sheetmetal panels.
top of page
Overview diagram, lower front of vehicle
5 Undersealing 176
einordnung
A 0.6 mm to 0.8 mm
B 0.4 mm to 0.6 mm
C 1 mm to 1.3 mm
top of page
Overview diagram, bottom of lower side member and floor
A 0.6 mm to 0.8 mm
B 0.4 mm to 0.6 mm
C 1 mm to 1.3 mm
top of page
Overview diagram, lower front of vehicle 177

einordnung
Overview diagram, lower rear end
A 0.6 mm to 0.8 mm
B 0.4 mm to 0.6 mm
C 1 mm to 1.3 mm
top of page
Tools and materials

−1− Recommendation Terostat multi−functional sealant 9320 Sprayable Manufacturer: Henkel
seam and compartment sealant Teroson GmbH
Postfach 10 56 20
69046 Heidelberg
www.teroson.com
−2− Recommendation Multi−press telescopic spray gun For working with Manufacturer: Henkel
Terostat 9320 Teroson GmbH
Postfach 10 56 20
69046 Heidelberg
www.teroson.com
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Overview diagram, lower rear end 178

5 Water drainage plan Cabriolet
1 Water drainage: Drainage panel

2 Water drainage: Drip tray
3 Water drainage: Drainage tube
4 Water drainage: Water channel, side section
5 Water drainage: Evaporator for heating and air−conditioning system
8 Water drainage: Inner panel of convertible top compartment lid
996630, 996631, 996620, 996621, 996650, 996651
5 Water drainage plan Cabriolet 179

5 Check dimensions for body repair − Cabriolet
structure
Structure dimensions for cabriolet
top of page
Structure dimensions for cabriolet
5 Check dimensions for body repair − Cabriolet structure 180

einordnung
Note
• All dimensions are measured on the body shell (with units removed) middle hole or middle screw
connection point. The dimensions are measured directly and, therefore, are oblique dimensions. Refer
to the relevant vehicle views for the positions of the measuring points. The measuring points are
identified for the right or left side in relation to the direction of travel (viewed from above).
Dimensions which are only specified for the left side of the vehicle also apply to the mirrorred image
on the right side of the vehicle.
Note
• The specified dimensions are used only for an approximate estimation of possible structural damage.
Repairs to the vehicle must be done using an alignment system.
Structure dimensions for cabriolet 181

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Measuring point Designation

−P1L− Convertible−top positioning screwed point (thread M6)
−P1R− Convertible−top positioning screwed point (thread M6)
−P2L− Locking screwed point (thread M6)
−P2R− Locking screwed point (thread M6)
−P3L− Convertible−top support/B−pillar
Screwed point (thread M8)
−P3R− Convertible−top support/B−pillar
−P4L− Convertible−top support/inner front side section
−P4R− Convertible−top support/inner front side section
−P5L− Convertible−top support/inner rear side section
−P5R− Convertible−top support/inner rear side section
−P6R− Auxiliary frame (roll−over bar) screwed points
(M8 thread)
−P6L− Auxiliary frame (roll−over bar) screwed points
(M8 thread)
Measured path Designation Dimension

P1 − P3 Oblique dimension, convertible−top support, B−pillar −A− 743.4 mm
P1 − P5 Oblique dimension, convertible−top support, front side −B− 1033.1 mm
section
P1 − P4 Oblique dimension, convertible−top support, rear side −C− 1092.8 mm
section
996630, 996631, 996620, 996621, 996650, 996651
Structure dimensions for cabriolet 182

5 Safety notes
Safety instructions for raising vehicles
Safety instructions for welding
Safety instructions for sticking
Safety instructions for installation work
Safety instructions for corrosion protection
top of page
Safety instructions for raising vehicles
Danger of injury when raising vehicles
DANGER
Risk of fatal injury due to vehicles slipping or tilting off lifting platforms!
• Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or mounting plates, and by raising, supporting or removing
units on raised vehicles!
• Align the vehicle evenly between the lifting platform columns.

• Lift the vehicle only at the take−up points provided.
• Check the correct seating of the mounting plates by raising the vehicle slightly and conducting a
visual inspection.
• In order to guarantee that the vehicle is not lifted off the mounting plates during assembly work, the
vehicle must be secured on the lifting platform when removing or supporting units or the shift in the
centre of gravity must be compensated with corresponding loads in the vehicle.
• In addition, the guidelines of the lifting platform manufacturers and the legal accident prevention
regulations and those of the mutual indemnity association (VGB 14) must be observed.
Damage when raising vehicles
CAUTION
Danger of material damage if the vehicle is raised incorrectly!
• Lifting or supporting the vehicle at unsuitable take−up points can lead to material damage on the
vehicle!
• Lift the vehicle only at the approved take−up points!

• Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area!
5 Safety notes 183

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top of page
Safety instructions for welding
Dangers of injury when welding
DANGER
Risk of fatal injury from high voltage during electric welding.
Danger of explosion and fire when welding in the area of highly inflammable materials.
Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanized steel!
Danger of injury from weld spatters and UV light when welding!
Danger of injury from false releases of pyrotechnical safety components!
• Do not perform welding work in a humid environment or on a wet background; there is a risk of fatal
injury from the voltage being conducted through the human body. Persons with heart pacemakers
should not perform welding work. Use insulating underlays.
• Remove highly flammable materials from the work area; if necessary, remove units with
fuel−carrying parts and protect work areas in the vehicle that are at risk of catching fire using
fire−proof covers.
• Ventilate the work area well.
• Remove smoke gases with a suitable extraction system (refer to Workshop Equipment Manual).
• Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if
necessary, a protective mask.
• For welding work, always disconnect both terminals on the battery. In the case of welding work in the
immediate vicinity of the control modules for pyrotechnical safety systems, remove the control
modules before beginning work.
• In addition, the guidelines of the welding equipment manufacturers and the legal accident prevention
regulations and those of the mutual indemnity association (BGV D1) must be observed.
Safety instructions for flying sparks during grinding and welding work
CAUTION
Danger of explosion and fire from flying sparks during grinding and welding work!
Danger of damage to vehicle parts and other vehicles due to flying sparks!
• Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts
with fire−proof covers and, if necessary, remove batteries and fuel−carrying components.
• No other vehicles may be left unprotected in areas used for body repair!
Damage when raising vehicles 184

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Safety instructions for fuel tank
CAUTION
Danger of fire due to fuel tank or fuel−carrying parts heating up during grinding and welding work!
• When carrying out grinding and welding work near the fuel tank or fuel−carrying parts, make sure
that these parts do not heat up!
• It is recommended to remove endangered parts!
• Cover the welding area comprehensively with fire−proof covers!
Safety instructions for air conditioning
CAUTION
Danger of injury due to the filled air−conditioning system bursting during welding and soldering work!
• In the case of extreme heating of filled air−conditioning systems, a very strong overpressure may be
caused in the system which may lead to an explosion.
• No welding, soldering or hot−air heating may take place on parts of the filled air−conditioning
system!
• While drying after painting work, the temperature burden on the vehicle must not exceed two hours at
a maximum temperature of 80 °C!
• Make sure that parts of the air−conditioning system do not heat up during welding or soldering work
on the vehicle!
top of page
Safety instructions for sticking
Safety instructions for Teromix−6700 two−component adhesive
CAUTION
Danger of damage to side section if binding time of adhesive is not observed!
• The new part must be welded in within 30 minutes!
top of page
Safety instructions for fuel tank 185

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Safety instructions for sharp−edged body and unit parts
CAUTION
Danger of injury from sharp edges on body and unit parts!
• Wear protective gloves when working in the area of sharp−edged body and unit parts!
Safety instructions for airbag system
CAUTION
Danger of injury if airbag units are triggered while ignition key is not removed!
• Always remove ignition key during body work, and do not commence adjustment work until a
waiting period of at least 1 minute has elapsed!
• The ground strap of the battery must be disconnected during work on the airbag system and alignment
bench work within the framework of body repair!
Safety instructions for door
CAUTION
Danger of material damage if the door lock is installed incorrectly!
Malfunctions in the alarm system!
• The door lock should be installed only when the actuating lever is in basic position!
CAUTION
Damage to plug connection lugs during door removal!
Damage to lugs when pulling the plug connection out of the A−pillar!
• The locking element at the bottom part of the plug connection must be pulled out before the plug
connection is disconnected!
CAUTION
Damage to the bowden cable when removing door trim panel!
Damage by bending the bowden cable at the hook!
• Pull the hook out of the end piece only after installation in the inner door release!
Safety instructions for installation work 186

einordnung
CAUTION
There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is
triggered: lower and raise door window!
• When carrying out assembly work in the area of the connection piece, the door handle and the door
lock, the fuse No. 1 in row D must be removed!
top of page
Safety instructions for corrosion protection
Safety instructions for plug location plan (body)
CAUTION
Danger of corrosion and of uncontrolled water penetration when removing plugs!
• The body apertures are sealed with plugs in the factory, and must be sealed with the plugs provided
once more following disassembly or repair work!
Safety instructions for water drains (body)
CAUTION
Water drainage hoses can be pushed out or pressed in by blowing them out of the body during cleaning!
• When cleaning, only blow the water drainage hoses out with light compressed−air pressure!
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Safety instructions for door 187

5 General information and quality notes
Electronic control modules
top of page
Note
• After repair work, the standard corrosion−inhibiting coating should only be restored with the
corrosion−inhibiting agents approved by the manufacturer. The following points must be observed for
body repairs.
• Always apply welding primer to both sides of the welding flange when resistance spot welding.
• Prime repair areas from outside. Prime on both sides in the accessible areas.
• Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
• When replacing structurally bonded body parts, proceed according to the information in the respective
repair instructions.
• Only apply body sealant to primed sheetmetal parts.
• Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build−up":
Paint Manual
• Build up paint on bright sheetmetal panels according to the painting methods described in the Paint
manual .
• Repair or create standard undersealing by applying long−life undersealing material.
• Preserve cavities in the repair area with cavity preservative after applying a top coat paint.
• Check that the standard water drains (plugs) function correctly or clean them after the cavity
preservation material has dried.
Prerequisite for maintaining the long−life guarantee
All body repair work must be carried out correctly and according to the specific Porsche instructions for
sheetmetal, paint and corrosion protection/preservation work. To prevent jeopardising the long−life guarantee,
a Paint Condition Report is made out 2 years after delivery of the vehicle. This condition report must be
updated annually by every Official Porsche Centre.
top of page
Electronic control modules
Note
• If electronic components, e.g. ABS control unit, have been removed for repair work and are then
reused, they must be given a functional check after fitting in accordance with existing specifications.
5 General information and quality notes 188

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Protection against overvoltage
To protect electronic control units from overvoltage during electric arc welding, the following work
regulations must be observed:
• When welding work is extensive, the electronic control units must be removed. Ensure that there are
no electrically insulated parts between the ground connection and the welding point.
• Remove clamp from negative terminal of battery and cover negative terminal of battery.
• Connect the ground connection of the electric arc welding equipment as near as possible to the
welding point on the part to be welded.
• Do not touch electronic control units or electric cables with the ground connection or the welding
electrode.
Replacing control modules
The replacement of electronic control modules after an accident is necessary if at least one of the following
conditions is met:
• The housing is noticeably deformed or damaged.

• The supporting surface or bracket is deformed (the unit shows no external damage).
• The plug connection is damaged or corroded by moisture.
• Functional checks or self−diagnosis of the unit reveals the fault "Control module faulty".
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
Protection against overvoltage 189

5 Tools and metalworking tools for body repairs
Note
Straightening systems
Metalworking tools
Note
• Detailed and additional information about tools and equipment can be found in the "Workshop
Equipment" manual.
top of page
Straightening systems
Shown on Celette type
top of page
Metalworking tools
Electrical equipment
5 Tools and metalworking tools for body repairs 190

einordnung
1. Drill
2. Angle grinder, large
3. Angle grinder, small
4. Sander
5. Hot−air gun
Mechanical equipment
6 Hole punch
7 Edge setter
Compressed−air equipment
Electrical equipment 191

einordnung
9 Air chisel
10 Body saw
11 Spotweld cutter
Welding equipment
12 Multispot spot welder

13 MIG welder
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Compressed−air equipment 192

5 Diagram − keys to symbols for welding work
Resistance spot welding
Inert−gas arc welding (MAG procedure)
Gas welding
top of page
Resistance spot welding
A Spot seam, single row

B Spot seam, double row
C Spot seam, double row offset
top of page
Inert−gas arc welding (MAG procedure)
A Plug weld
B Stitch weld
C Full weld
D Intermittent full weld
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Gas welding
5 Diagram − keys to symbols for welding work 193

einordnung
A Hard soldering
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Gas welding 194

5 Check dimensions for body repair
Floorpan check dimensions
top of page
Floorpan check dimensions
Note
• All dimensions are measured to the middle of the hole or screwed point. The dimensions are
measured directly and, therefore, are oblique dimensions. Dimensions in brackets are measured
horizontally.
5 Check dimensions for body repair 195

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Dimension Measuring points Designation Dimension in mm

P1 P1 P1 Impact absorber / pipe front 800±2
P2 P2 P2 Bearer side spare−wheel well 712±2
P3 P3 P3 Front axle front, front, low 610±1
P4 P4 P4 Front axle front, rear, high 731,2±1
P5 P5 P5 Rational location hole, side member front 800±1
P6 P6 P6 Spring strut bracket, front 985±2
P7 P7 P7 Front axle front, rear 773±1
P8 P8 P8 Front jacking point for hoist or car jack 1330±2
P9 P9 P9 Transmission support, front 256±2
P10 P10 P10 Transmission support, centre 270±2
P11 P11 P11 Transmission support, rear 400±2
P12 P12 P12 Rear jacking point for hoist or car jack 1370±2
P13 P13 P13 Rear diagonal brace 824±3
P14 P14 P14 Rear axle, front 836±2
P15 P15 P15 Rear axle, centre 821±2
P16 P16 P16 Spring strut bracket, rear 915±2
P17 P17 P17 Rear axle, rear 792±2
P18 P18 P18 Rational location hole, side member rear 945±1
P19 P19 P19 Engine mount location hole outside 889,2
P20 P20 P20 Engine mount 780±2
P21 P21 P21 Impact absorber / pipe rear 960±2
A P4 P7 In vehicle's longitudinal direction 507±2
B P5 P18 In vehicle's longitudinal direction 2795±1
C P8 P2 Vehicle diagonal dimension 1525±2
D P8 P3 Vehicle diagonal dimension 1279±2
E P8 P4 Vehicle diagonal dimension 1279±2 (1283±2)
F P8 P7 Vehicle diagonal dimension 1084±2
G P8 P12 Vehicle diagonal dimension 1929±2
H P8 P12 In vehicle's longitudinal direction 1350±2
I P13 P11 Vehicle diagonal dimension 875±3 (863±3)
J P13 P14 Vehicle diagonal dimension 1087±3 (1085±3)
K P13 P15 Vehicle diagonal dimension 1159±3 (1125±3)
L P13 P17 Vehicle diagonal dimension 1237±3 (1209±3)
M P13 P18 Vehicle diagonal dimension 1349±3 (1323±3)
N P13 P19 Vehicle diagonal dimension 1629±3
Measuring point Designation

P1 Screwed point
(M8 thread)
P2
Floorpan check dimensions 196

einordnung
Bearer side spare−wheel well screwed point

(M8 thread)
P3 FA, front screwed point low
(thread M12 x 1.5)
P4 FA, front screwed point high
(thread M14 x 1.5)
P5 Rational location hole, side member front
P6 Spring strut bracket, front
P7 FA, rear screwed point
(thread M14 x 1.5)
P8 Hoist/car jack front location hole
P9 Transmission support, front screwed point
(thread M10)
P10 Transmission support, centre screwed point
(thread M10)
P11 Transmission support, rear screwed point
(thread M 12 x 1.5)
P12 Hoist/car jack rear location hole
P13 Diagonal brace front screwed point
(thread M10)
P14 RA front screwed point
(thread M12 x 1.5)
P15 RA centre screwed point
(thread M12 x 1.5)
P16 Spring strut bracket, rear
P17 RA rear screwed point
(thread M12 x 1.5)
P18 Rational location hole, side member rear
P19 Engine mount location hole outside
P20 Engine mount screwed point
P21 Impact absorber / pipe rear screwed point
(thread M8)
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Floorpan check dimensions 197

5 Water drainage plan
A water drainage facility −1−2− is available on both sides of the vehicle.
1 Water drainage: Rear of sliding roof

2 Water drainage: Front of sliding roof
3 Water drainage: Evaporator of heating and air−conditioning system
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
5 Water drainage plan 198

5 Diagram − body gap dimensions
Note
Gap dimensions, body front
Gap dimensions, body centre
Gap dimensions, body rear
Gap dimensions, body rear Carrera 4S
Diagram − Gap dimensions, Cabriolet
Note
• Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap
specifications.
• Given a clearance in the openings that is too great or too small, the movable body parts or the
accessories must be centred accordingly.
• Ensure that the gaps do not run in a wedge−shaped fashion or do not narrow at local points.
• The given values are guidelines which should be observed as far as possible.
• The guidelines apply to repair and assembly work.
• Use star gauges to measure the gap dimensions,No.: 127−1, Workshop Equipment Manual, Chapter
2.4
top of page
Gap dimensions, body front
5 Diagram − body gap dimensions 199

einordnung
Designation Dimension Note

Front cover to front trim −A− 4+2 mm Cover only lowered (max. 1 mm)
Front cover to modular headlight −B− 4.5 mm Determine gap left to right
Modular headlight to front trim −C− 4.5 mm
Modular headlight to wing −D− 3.5 ±0.8 mm
−E− 2 −1.5 mm
Wing to front trim −F− 3 ±0.5 mm Gap is evident
Front wing to outer side section −G− 4+1 −0.5 mm
−H− 1.2 mm
Wing to front cover −J− 4 ±0.5 mm
Windscreen to A−pillar −K− 7.5+2.5 −1 mm Determine gap left to right
Windscreen to outer roof panel −L− 8.5+1 −2 mm
Filler flap to wing −M− 3.5 ±1 mm All the way round
Gap dimensions, body front 200

einordnung
top of page
Gap dimensions, body centre

Door to front wing −A− 4+2.5 mm Door only lowered (max. 1 mm)
Door to outer side −B− 4+1 −0.5 mm
section −C− 1.5 mm Doors only lowered
−D− 3.5+1 mm
−0.5
−E− 2 mm Doors only lowered
−F− +1
4 −0.5 mm Doors only raised
Gap dimensions, body centre 201

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−G− 4+1 −0.5 mm Door only raised (max. 1 mm)

Air inlet to outer side −H− 1.6 mm Determine regularly all the way round
section
Door window to rear −J− 7 ±1 mm
side window
Side section to outer roof −K− 25.3 mm
panel ±1
Roof joint strip to outer −L− 3.2 ±1 mm
roof panel
Sliding roof panel to −M− 5.5 mm All the way round, sliding roof panel only lowered
outer roof panel ±0.5 at front, only raised at rear (max. 1 mm)
top of page
Gap dimensions, body rear
Gap dimensions, body rear 202

einordnung

Side member cover to outer −A− 1.4 +0.5 mm
side section −B− 2 mm
Rear trim to outer side section −C− 3 ±0.5 mm Gap is evident
Tail light to outer side section −D− 3 ±0.5 mm
−E− 2 −1 mm Tail light only lowered
Rear trim to tail light −F− 5 ±2 mm
−G− 2+1 −2 mm Tail light only lowered
Rear lid to rear trim −H− 5 ±2 mm
−J− 2.2+0.5 mm Rear lid only lowered
−1.5
−K− 5 ±2 mm
−L− 1.8+0.5 mm Rear lid only lowered
Gap dimensions, body rear 203

einordnung
−1.5
Rear lid to tail light −M− 4.5 ±1 mm Tail light only lowered (max. 1 mm)
Rear lid to outer side section −N− 4.5 ±1 mm Rear lid only lowered (max. 1 mm).
determine left to right
Rear centre panel to outer side −O− 4.5 ±1 mm
section
Rear centre panel to rear lid −P− 6+1 −2 mm Rear lid only lowered (max. 1 mm)
Rear window to outer roof −Q− +1
7.3 −2 mm
panel
Rear window to rear centre −R− 8.5+1 −2 mm
panel −S− 8.9 mm Dimension is evident
Rear window to outer side −T− 7 mm
section −U− 6 mm Determine left to right
top of page
Gap dimensions, body rear Carrera 4S
Gap dimensions, body rear Carrera 4S 204

einordnung

Rear trim to outer side section −A− 3 ±0.5 mm Gap is evident
Tail light to outer side section −B− 3 ±0.5 mm
−C− 2 −1 mm Tail light only lowered
Tail light to middle side section −D− 3 ±0.5 mm
−E− 2 ±1 mm Tail light only lowered
Rear trim to tail light −F− 5 +1 −1 mm
−M− 2 +1 −2 Tail light only lowered
Rear lid to side section −G− 4.5 ±1 mm Determine gap left to right
Rear lid to rear spoiler −H− 5 ±2 mm Rear lid only lowered
Rear lid to spoiler top section −I− 4.5 ±1 mm Rear lid only lowered (max. 1 mm)
Rear centre panel to spoiler top −J− 6 ±1 mm Rear lid only lowered (max. 1 mm)
section
Gap dimensions, body rear Carrera 4S 205

einordnung
Rear lid to spoiler top section −K− 4.5 ±1 mm Rear lid only lowered (max. 1 mm).
determine seam
Rear window to outer roof panel −L− 7.3+1 −2 mm
Rear window to outer side −N− 6 mm
section −O− 7 mm Determine left to right
Outer side part to rear centre part −P− 4.3 ±1 mm
−Q− 1.2 mm Adhesive seam
Rear centre part to rear lid −R− 5.2 ±1 Only lowered
top of page
Diagram − Gap dimensions, Cabriolet
Diagram − Centre gap dimensions, Cabriolet
Diagram − Gap dimensions, Cabriolet 206

einordnung

Cowl panel frame to fender −A− 3.5 to 7.0 mm Continuous transition
±1
Windscreen to cowl panel frame −B− 8.5 +2.5 −1 mm
Door window to rear window −C− 9 ±1 mm
Rear side section flap to side trim panel −D− 4 +2.5 −1 mm Rear side section flap
raised (max. 0.5 mm),
lowered (max. 1.5 mm)
−E− 4 +2 mm Rear side section flap
raised (max. 1 mm)
Rear side section flap to frame trim panel −F− 3 +2 −0.5 mm Rear side section flap
for roll−over protection system raised (max. 0.3 mm)
Cowl panel frame to roof frame 1 −G− 7 ±1 mm Roof frame only lowered
Diagram − Centre gap dimensions, Cabriolet 207

einordnung
Diagram − Gap dimensions, rear Cabriolet

Side part to convertible−top compartment lid −A− 5 +1 mm Continuous seam
−0.5
−B− to joining line
−C− +1
5 −0.5 mm
Convertible−top compartment lid to rear lid −D− 6.4+1 −0.5 mm
Convertible−top compartment lid to rear lid −E− 6 +1 −0.5 mm
Diagram − Gap dimensions, rear Cabriolet 208

einordnung
Diagram, gap dimensions, Cabriolet rear − Carrera 4S

Side part to convertible−top compartment lid −A− +1
5 −0.5 mm Continuous seam joining
−B− to line
−C− +1
5 −0.5 mm
Convertible−top compartment lid to rear lid −D− 6.4 +1 mm
−0.5
Convertible−top compartment lid to spoiler top −E− 6 +1 mm
section
Diagram, gap dimensions, Cabriolet rear − Carrera 4S 209

einordnung
Diagram − Gap dimensions, hardtop

Windscreen frame to convertible top −A− 5.5 ±0.5 mm
−B− 4 +1 −2 mm Convertible top only lowered
Rear window to rear roof frame (Hardtop) −C− 10.4 mm
−D− 3 ±1.5 mm
Hardtop to convertible−top compartment lid −E− 5.5+2 mm
Hardtop to convertible−top compartment lid −F− 6.5+2 mm
−G− 7.8 ±4 mm Tail light only lowered
Roof joint strip to hardtop −H− 0.8 ±1 mm Only lowered
Hardtop to side section −I− 3+2 mm
Diagram − Gap dimensions, hardtop 210

einordnung
996420, 996421, 996450, 996451, 996630, 996631, 996430, 996431, 996620, 996621, 996650, 996651
Diagram − Gap dimensions, hardtop 211

5 Body parts of high−strength steel
High−strength steel plates
Tailored blanks
Baked hardening
Straightening body parts
Welding work
Reshaping
Separation points
Diagram − Body, model year 2002
The following body parts are made of high−strength steel (HS).
1 Bearer side at spare−wheel well, left and right

2 Connection bracket inner to side member front inner left and right
3 Side member front inner, left and right
5 Body parts of high−strength steel 212

einordnung
4 Web plate outer side member front outer left and right
5 Side member front outer, left and right
6 Cowl panel frame top, inner
7 Cowl panel frame bottom, outer
8 Cowl panel frame bottom, inner
9 A−pillar reinforcement, left and right
10 Side member floor front bottom, left and right
11 Bearer floor front top, left and right
12 Front crash support
13 Closing part front crash support
14 Tunnel reinforcement
15 Seat support, left and right
16 Hinge pillar, left and right
17 Cross member firewall, inner
18 Firewall
19 A−pillar reinforcement
20 Side member rear outer, left and right
21 Impact absorber mount
22 Side member rear inner, left and right
23 Web plate
A Reinforcement cross member firewall, front
B Reinforcement cross member firewall inner left
C Reinforcement cross member firewall inner right
Note
• Body parts −18− and −22− are welded together from plates of different material thicknesses and
characteristics and are then deep drawn!
• Body parts −A− , −B− and −C− possess extremely high tensile strength and are therefore not hot−dip
galvanized!
• Body parts −1 to 23− attain their final strength only after the production stage of cathodic immersion
painting and drying!
• The special material properties have effects on body repair. For this reason, only "Original Porsche
parts" must be used for repair work!
top of page
High−strength steel plates
Body parts of high−strength steel contribute to better protection of the passenger compartment and thus
increase protection of the passengers. In addition to improved crash safety, these parts also have a positive
influence on fatigue strength. In terms of crash behaviour, body parts made from high−strength sheet steel are
High−strength steel plates 213

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characterised by their higher energy absorption. But this also means that higher reshaping force must be
applied in reshaping work.
Note
• Only "Original Porsche parts" must be used for repair work!
top of page
Tailored blanks
The indicated body parts are made by welding together plates of differing thicknesses and characteristics and
then deep−drawing these parts. In their crash behaviour, these body parts are characterised by their high
energy absorption.
top of page
Tailored blanks 214

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Baked hardening
The indicated body parts attain their final strength only under the temperature effects of the production stage
of cathodic immersion painting and drying.
top of page
Straightening body parts
Note
• Only "Original Porsche parts" or sections of "Original Porsche parts" may be used!
The body and floor assembly are produced in series from deep−drawn panels. For this reason, accident
damage must be reshaped in the same way. Body repairs by reshaping are not possible if these body parts are
correspondingly deformed. Here, the repair must be carried out using new parts or by means of sectional
Baked hardening 215

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repairs. The separation of damaged body parts after reshaping against the accident direction should not take
place until after connection pieces have been straightened.
top of page
Welding work
Note
• The use of the oxyacetylene welding process is not permissible for body parts made of high−strength
steel!
• Test welding must be carried out in the case of resistance spotwelding (RP) of different panel
strengths!
The body parts made from high−strength steel can be welded using the RP resistance spot−welding or MIG
welding processes that are customary in workshops.
top of page
Reshaping
Note
• Only "Original Porsche parts" or sections of "Original Porsche parts" may be used for repair work!
• The separation of damaged body parts should not take place until after reshaping against the accident
direction has taken place and connection pieces have been straightened!
Body repairs by reshaping are not possible if these body parts are correspondingly deformed. Here, the repair
must be carried out using new parts or by means of sectional repairs.
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Separation points
Note
• Separation points which influence the strength of the body, and thus also the operating and traffic
safety of the vehicle, must be carried out according to the specifications of the relevant Technical
Manual Body repair!
• Body reinforcements can be separated or joined together only if this is specified in the method
descriptions. Otherwise, a damaged reinforcement must always be replaced with a new one!
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Straightening body parts 216

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Diagram − Body, model year 2002

In the model year 2001 (model care), the following structural body parts have been used in the body for
passive safety. As of model year 2002, all vehicles will be constructed with the structural parts shown in the
following diagram.
Structural body parts (model care) for model year 2002
Diagram − Body, model year 2002 217

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1. Front side members (cross member double connection)

2. Interior door reinforcement (diagonal)
3. Inner lower side member
4. Inner side part
5. Sliding roof reinforcement frame
6. Seat well cross tube
7. Gusset plate and
reinforcement plate of belt
height adjuster
8. Roof frame reinforcement pipe
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Structural body parts (model care) for model year 2002 218
6 Safety notes
Safety instructions for work on car windows
top of page
Safety instructions for work on car windows
Danger of injury when working on car windows
WARNING
Danger of cut injuries when removing and installing car windows!
• Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass
splinters and may cause cut injuries due to the knife of the cutter.
• Always wear protective gloves when working on car windows.

• Wear protective goggles when cutting out car windows.
• Only replace the cutting knife with the power supply disconnected in order to ensure that the cutter
cannot be switched on accidentally.
Material damage when removing the glass from car windows
CAUTION
Danger of paint damage and damage to surrounding section and to the label with the vehicle identification
number if windscreen is removed incorrectly!
• When cutting out the windscreen, ensure that the surrounding section and the label with the vehicle
identification number are not damaged!
• Cover painted areas adjacent to the window aperture with adhesive tape.
• Guide the cutting knife as closely as possible along the edge of the window.
Material damage when inserting the glass into car windows
CAUTION
Danger of material damage if specified curing time of adhesive is not observed!
• The vehicle must not be used until the curing time has elapsed.
6 Safety notes 219

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In order to ensure that the bonded joint is sufficiently strong, the following boundary conditions must be
adhered to:
• Curing time: 3 hours

• Temperature: at least 10°C
• Fixing time: approx. 1 hour
top of page
Safety instructions for airbag system
CAUTION
Danger of injury due to unintentional activation of airbag units!
bench jobs when the body is being repaired!
• After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar
tools may not be started until after a waiting period of 1 minute!
Safety instructions for sliding roof
CAUTION
Damage to water drainage channel and sliding roof mechanism when sliding roof panel is removed!
The rear water drainage channel or the sliding roof mechanism is damaged if the sliding/tilting roof trim is
moved incorrectly!
• The sliding roof mechanism must not be moved to the "Open" position when the sliding roof panel
has been removed!
• In order to avoid damage to the guides of the sliding roof, the sliding/tilting roof trim (Item 4) must be
moved without the use of force!
Safety instructions for rear spoiler
WARNING
Danger of injury and danger of damage to the vehicle if handling is modified when adjusting the additional
wing!
• The additional wing must be moved to the lowest position for use in public traffic!
Material damage when inserting the glass into car windows 220
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Safety instructions for the pump unit hydraulic system of the rear spoiler
DANGER
Danger of injury/damage during assembly work on the hydraulic system!
• The hydraulic system is under approx. 30 bar pressure when extended

• Do not smoke during work, avoid open flames. Danger of fire!
• Do not swallow hydraulic oil, avoid contact with skin/eyes.
• Rinse with water in the event of contact with skin/eyes.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Safety instructions for the pump unit hydraulic system of the rear spoiler 221
6 General information on installing and removing car
windows
Removing glass with cutting wire separator
top of page
Removing glass with cutting wire separator
Note
• The following instructions describe the general procedure for removing car windows with the glass
separating tool VAG 1474 B.
• Information on procedures relating to specific vehicles can be obtained from the instructions in the
corresponding chapters in the Technical Manual.

−A− Glass separating tool VAG See Workshop Equipment Contains component set
1474 B Manual, Chapter 3.5 A1−A9 and protective film for
dashboard
−B− Cutting thread See Parts Catalogue in Main
Group 8
Item Designation Item Designation

−A1− Guide rails −A6− Filler
−A2− Cutting tool (wire holder) −A7− Steering roller with arm bracket
6 General information on installing and removing car windows 222

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−A3− Spooling device −A8− Handle

−A4− Awl −A9− Square cutting wire
−A5− Guide rails
Note
• It is generally possible to remove the windscreen with the cutting wire and the optional cutting thread
contained in the tool set.
• In contrast to cutting threads, however, the cutting wire has the following disadvantages:
• Danger of injury when tearing off the cutting wire.
• Danger of damage to materials on paint surfaces and interior equipment parts.
• For the reasons outlined above we recommend using the cutting thread.
WARNING

CAUTION
Danger of paint damage and damage to surrounding section and to the label with the vehicle identification
number if windscreen is removed incorrectly!
• When cutting out the windscreen, ensure that the surrounding section and the label with the vehicle
identification number are not damaged!
• Cover painted areas adjacent to the window aperture with adhesive tape.
1. Cleaning glass
on the inside
Note
• In order to guarantee an optimum fastening intake grip, it is advisable to clean the inside of the glass
before removal.
Removing glass with cutting wire separator 223

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2. Applying protective film to the dashboard

a. Select the appropriate film −1− and insert between windscreen and damping
mat.
Note
• The film −1− protects the damping mat against damage when removing the glass.
3. Inserting cutting thread into the passenger compartment
Note
• In order to prevent damage, make sure that the vehicle identification number −C− is completely
covered by the protective film when pushing through the adhesive bead.
b. Push through adhesive bead on the glass on the edge of the vehicle identification number −C− with the
awl −A4− from the inside to the outside.
c. Pass cutting thread −B− through the eyelet on the awl
−A4− .
d. Draw cutting thread −B− into the passenger
compartment.
e. Pull cutting thread −B− out of the awl −A4−
.
f. Draw cutting thread −B− approx. 1 metre into the passenger
compartment.

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4. Inserting cutting thread into the gap in the glass

g. Pull cutting thread −B− in the direction of the arrow through the gap between the glass and the
body. Use filler −A6− if necessary.
Note
• The cutting thread should be positioned under the rim as far as possible. The sealing lip must be
raised slightly in the upper part of the glass in order to pull the cutting thread through.
5. Attaching cutting thread to the body

h. Attach the loose end of the cutting thread −B− firmly at a suitable point on the body with the fastening
screw −2− of a component (e.g. wiper motor fastening). To do this, unscrew the fastening screw, wind
the cutting thread −B− around the screw and tighten the fastening screw again.
6. Attaching cutting
thread to the spooling
device
i. Undo clamping screw
−3− .
j. Insert cutting thread −B− into the bore on the spooling device −A3−
.

einordnung
k. Attach cutting thread −B− firmly with the clamping screw −3−
.
7. Installing spooling device and deflection rollers on the glass

l. Position spooling device −A3− diagonally in the centre of
the glass.
m. Press spooling device −A3− with the fastening intakes firmly against the glass.
n. Fix fastening intake onto the glass by moving the actuating
lever.
8. Separating glass as far as P1

o. Separate glass by spooling the cutting thread on the spooling device as far as point −P1− .
9. Repositioning
spooling device
p. Release spooling
device.
q. Release the lower fastening intake on the spooling
device.
r. Pull cutting thread through onto the other side of the fastening
intake.
s. Fix fastening intake onto the glass by moving the actuating
lever.

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t. Position deflection roller in the lower right
corner.
u. Press deflection roller with fastening intake firmly against
the glass.
v. Fix fastening intake onto the glass by moving the actuating
lever.
w. Pass cutting thread over the deflection roller onto the spooling
device.
x. Separate glass by spooling the cutting thread on the spooling device as far as point −P2− .
Note
• The fastening force can be increased by moistening the fastening intake.

y. Release spooling
device.
z. Position deflection roller in the upper right
corner.
aa. Press deflection roller with fastening intake firmly against
the glass.
ab. Fix fastening intake onto the glass by moving the actuating lever.
ac. Pass cutting thread over the deflection roller onto the spooling
device.
ad. Separate glass by spooling the cutting thread on the spooling device as far as point −P3− .
Note

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12. Repositioning spooling device

ae. Release
spooling device.
af. Release the upper fastening intake on the spooling
device.
ag. Pull cutting thread through onto the other side of the fastening intake.
ah. Fix fastening intake onto the glass by moving the actuating lever.

ai. Position deflection roller in the upper
left corner.
aj. Press deflection roller with fastening intake firmly against
the glass.
ak. Fix fastening intake onto the glass by moving the actuating lever.
al. Pass cutting thread over the deflection roller onto the spooling
device.
am. Separate glass by spooling the cutting thread on the spooling device as far as point −P4− using
guide rail −A1− .
Note

einordnung

an. Release
spooling device.
ao. Position deflection roller in the lower left
corner.
ap. Press deflection roller with fastening intake firmly against the
glass.
aq. Fix fastening intake onto the glass by moving the actuating lever.
ar. Pass cutting thread over the deflection roller onto the spooling
device.
as. Separate glass by spooling the cutting thread on the spooling device as far as point −P5− .
Note
15. Removing glass

16. Pulling off surrounding section
at. Carefully detach the surrounding section from the
windscreen.
Note
• If the surrounding section is removed from the windscreen undamaged, it can be re−used.
Cutting power when removing glass with cutting thread
Note
• The power for separating the glass is weaker when the cutting thread is deflected to its maximum
point. An angle greater than 90° should be avoided.
Cutting power when removing glass with cutting thread 229

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High cutting power
Unfavourable angle (strong traction required)
Average cutting power
Favourable angle (average traction required)
Low cutting power
Optimum angle (minimum traction required)
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Cutting power when removing glass with cutting thread 230

6 Overview of exterior colours
Note
Exterior paintwork solid
Exterior paintwork metallic/pearl
Special colours
Note
• As from model year '02, the same colour code will be used for water−based paints and for
conventional paints.
top of page
Exterior paintwork solid
Model year
Colour designation Colour code
01 02 03 04 05 06 07 08 09 10
9A2 1) X
Biarritz white
9A3 1) X
Carrara white B9A 1) 2) X X X
741 1) X
Black
747 2) X
Black 041 1) 2) X X X
84A 1) X X X X
Guards red
80K 2) X X X X
12H 1) X X X X
Speed yellow
12G 2) X X X X
1) Water−based
2) Conventional
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Exterior paintwork metallic/pearl
Model year
01 02 03 04 05 06 07 08 09 10
744 1) X
Black metallic
746 2) X
Basalt black metallic C9Z 1) 2) X X X
6 Overview of exterior colours 231

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92U 1) X X X X
Arctic silver metallic
92T 2) X X X X
3A8 1) X X X X
Lapis blue metallic
3A9 2) X X X X
2A1 1) X X
Rainforest green metallic
2A2 2) X X
8A3 1) X X X
Orient red metallic
8A4 2) X X X
Carmona red metallic M3W 1) 2) X
1A8 1) X X
Zanzibar red pearl effect
1A9 2) X X
6A6 1) X X X X
Meridian metallic
6A7 2) X X X X
6B4 1) X X X X
Seal grey metallic
6B5 2) X X X X
Atlas grey metallic M7X 1) 2) X
39C 1) X X
Midnight blue metallic
37W 2) X X
Lagoon green metallic M6W 1) 2) X X
1) Water−based
2) Conventional
top of page
Special colours
Model year
01 02 03 04 05 06 07 08 09 10
3C7 1) X
Dark blue
347 2) X
Fayence yellow 1C1 1) 2) X
2B6 1) X
Wimbledon green metallic
23L 2) X
2B4 1) X X X X
Pine green metallic
22E 2) X X X X
3AE 1) X
Violet metallic
39G 2) X
3C8 1) X X X X
Cobalt blue metallic
37U 2) X X X X
92M 1) X X X X
Polar silver metallic
92E 2) X X X X
Exterior paintwork metallic/pearl 232

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GT silver metallic M7Z 1) 2) X

23F 1) X X X X
Slate metallic
22D 2) X X X X
39C 1) X X
Midnight blue metallic
37W 2) X X
1A8 1) X
Zanzibar red pearl effect
1A9 2) X
1) Water−based
2) Conventional
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Special colours 233

6 Processing of Porsche 2−component window
bonding agents
Overview of tools and materials
Preparing the adhesive surfaces
Combined procedure (handling double cartridge press)
top of page

−A− Double cartridge gun VAS 5237 See Workshop Equipment Manual,
Chapter 3.5
−B− Pipette VAG 1344 See Workshop Equipment Manual,
Chapter 3.5
6 Processing of Porsche 2−component window bonding agents 234

einordnung
−C− Special electric cutter (fine) VAG 1561 See Workshop Equipment Manual,
A Chapter 3.5
−D− Flashing knife, U−type 639.031.130.22
−H− 2−component window bonding agent Contains set
000.043.300.94 components
H1−H8

−H1− Cleaning solution −H5− Cartridge, component A
−H2− Primer −H6− Cartridge, component B
−H3− Activator −H7− Mixing nozzle
−H4− Swab −H8− Processing nozzle
top of page
Preparing the adhesive surfaces
Note
• The table below shows how to use cleaners, primers and activators when preparing the adhesive
surface.
Preparing the body glass for installation

Old glass New glass
Without preliminary With preliminary coat
coat
Cut back adhesive bead −Cleaner−
“ “
Clean rim (ceramic layer) Clean preliminary layer
“ “
−Activator− −Primer− −Activator−
“ “ “
Activate adhesive bead Prime rim (ceramic layer) Activate preliminary
(only necessary if car is idle for a long period) “ layer
“ “
Apply adhesive
Install glass
Prepare the window flange for installation

Old flange New flange
(old paint job) (new paint job)
Overview of tools and materials 235

einordnung
Cut back adhesive bead −Cleaner−

“ “
Clean flange surface
“
−Activator− −Primer−
“ “
Activate adhesive bead Prime rim (ceramic layer)
(only necessary if car is idle for a long period) “
“
Apply adhesive
Install glass
top of page
Combined procedure (handling double cartridge press)
CAUTION
• Observe the safety instructions of the individual adhesive set components.
Note
• In addition to this manual, observe the relevant job descriptions for installing car windows (Group 64)
in the Technical Manual!
1. Preparing cartridge components A and B −H5, H6−

a. Pierce the membrane in the nozzle connection of components A and B (aluminium cartridge) −H5−
with a screwdriver and extend the opening. Remove flanged cover on end of cartridge.
Preparing the adhesive surfaces 236

einordnung
2. Screwing on processing nozzle −H8−

b. Screw processing nozzle −H8− onto the mixing nozzle −H7−
.
3. Screwing on mixing nozzle −H7−

c. Screw both cartridges onto the mixing
nozzle.
4. Placing mixing cartridge in the double cartridge gun

d. Move pressure piston back
fully.
e. Place double cartridge −H5, H6− in the bonding gun −A−
.
5. Mixing adhesive components

f. By activating the valve −arrow− allow the pressure piston to move out slowly until the adhesive is
visible in the processing pipe.
Combined procedure (handling double cartridge press) 237

einordnung
6. Affixing car window
Note
• The bonding material has an open time of −15 min− , which means that the bonding material must be
applied and the car window must be assembled within this period of time.
• In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh
adhesive to a piece of cardboard before processing.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Combined procedure (handling double cartridge press) 238

7 Special notes for the care of soft−look paint
surfaces
Caution
Light soiling (e.g. dust)
Heavy soiling (e.g. oily, greasy dirt)
CAUTION
Damage to the soft−look paint coat if the cleaning agents or solvents available as accessories for cleaning the
vehicle interior are used. This also applies to the use of plastic polish 999.901.021.41 from the Porsche care
set.
The contents of these agents etch the paint coat (paint swells, rubber−like texture). Consequently, the paint
coat can fall off the substratum when a mechanical load is applied.
Furthermore, the surface may shine brightly after using the cleaning agents.
• The following procedure is recommended for the care or cleaning of soft−look paint surfaces on the
basis of laboratory tests.
top of page
Light soiling (e.g. dust)
It is possible to clean light soiling by selecting an option from the following cleaning tools and cleaning
fluids:
Cleaning tools Cleaning fluid Cleaning procedure

Soft household Clear water
sponge
Water with small amount of commercially available Gentle wiping
washing−up liquid added movements, do not
Soft, lint−free cloth Interior window cleaner (from Porsche care set) apply pressure
Note
Observe cleaning instructions, wipe down with clear
water if necessary
top of page
Heavy soiling (e.g. oily, greasy dirt)
It is possible to clean heavy soiling by selecting an option from the following cleaning tools and cleaning
fluids:
Cleaning tools Cleaning fluid Cleaning procedure

Soft household Water with small amount of commercially available
sponge washing−up liquid added
Gentle wiping
7 Special notes for the care of soft−look paint surfaces 239
movements, do not
apply pressure
einordnung
Interior window cleaner (from Porsche care set)

Note
Observe cleaning instructions, wipe down with clear
water if necessary
Soft, lint−free cloth
Solvent naphtha
Note:
Use solvent naphtha only, other solvents are not
permissible!
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Heavy soiling (e.g. oily, greasy dirt) 240

8 Air conditioning
Technical data for the air−conditioning system
top of page
Technical data for the air−conditioning system
Note
• When installing the refrigerant lines, the screw connections and the O−rings must be wetted with
refrigerant oil!
• The refrigerant oil must be disposed of as special−category waste!
Compressor type 7 SB 16
Refrigerant quantity 900 g Refrigerant R 134a
Refrigerant oil in the compressor 195 ± 15 cm3 ND 8
Hexagon−head bolts on: Thread Tightening torque in Nm (ftlb.)

Expansion valve M6 9 (6.5)
M5 6 (4.5)
Compressor M8 23 (17)
Refrigerant line M8 23 (17)
Oil filler plug M10 26 to 36 (19 to 27)
Fluid tank M6 6
Flange connections of the refrigerant lines
M8 14 (10.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
8 Air conditioning 241

9 Work instructions after disconnecting the battery
Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent
measures
6452 Power windows
9030 Clock
9120 Radio
9110 PCM
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Effect of disconnection or total discharge of the battery on
electrical systems in the vehicle, subsequent measures
Note
• All loads must be switched off beforehand!

• Do not use a boost charger to start the engine!
• Whenever possible, use jump leads with overvoltage protection!
• Always disconnect both battery terminals before carrying out welding work on the vehicle!
• Wiring harness plugs of control modules or other electronic components must be connected or
disconnected with the ignition off. Exception: vehicles with the additional equipment M 536 (alarm
siren with tilt sensor)!
top of page
Problem Remedy
Values and faults stored in the control modules can be If possible, all fault memories should
deleted if the battery is disconnected or completely be checked and, if necessary, printed
9 Work instructions after disconnecting the battery 242

einordnung
discharged. out before the battery is disconnected.
top of page
Problem Remedy
The entry "supply voltage" could be stored in various control Delete the "supply voltage"
modules if the battery has been completely discharged. entry from the control modules
in question.
top of page
Note
• The fault memories of all vehicle control modules should be read out again after the test drive!
top of page
Note
• With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!
Problem Remedy
After the battery is connected.
• After disconnection of the power supply, the idle speed With the DME ME 7.8, it is
might change or fluctuate briefly until the throttle necessary to carry out a learning and
adjusting unit (ME 7.8) is readapted. adaptation routine as described
• The mixture adaptation is also lost. below:
1. Switch the ignition on for 1
minute without starting the
engine. Do not actuate
accelerator pedal.
2. Switch off ignition for at least
10 seconds.
Control module memories 243

einordnung
This completes the adaptation of the

throttle adjusting unit.
top of page
6452 Power windows
Problem Remedy
The limit positions of the power windows are deleted from Manually close each power window as
the control module when the battery is disconnected and far as it will go, then press the rocker
connected. switch for closing the window again.
The limit position of the respective power
window is now stored in the control
module again.
top of page
The trip counter is set to 0 when the power supply is disconnected.
top of page
9030 Clock
Note
• In the case of vehicles with PCM, the date and time are deleted when the battery is disconnected!
Problem Remedy
The time is deleted when the power supply is disconnected. Enter the current time again.
top of page
Problem Remedy
Fill the tank; then the
• If the power supply is interrupted by a discharged or fuel level sensor is in
disconnected battery with the tank containing less than 19 l, the operating range and its
calculated value for the range on remaining fuel in the display precision is
2470 DME control module 244

einordnung
instrument cluster will be incorrect or deleted. guaranteed.

• If the tank contains less than 19 l, it is possible that the fuel level
warning light is no longer activated.
• If the power supply is restored with the fuel level at less than 19
l, it is possible that the fuel level display may subsequently
display an incorrect value.
This may lead to the vehicle breaking down.
top of page
9120 Radio
Problem Remedy
The radio reverts to the Code function when the battery 1. Input the radio code.
is disconnected and is thus no longer ready for operation. 2. If the code card is unavailable, the radio
code can also be read from the DME
control module (under "Vehicle data").
3. It is also possible to gain this code from
the Porsche IPAS.
top of page
9110 PCM
Problem Remedy
1. Input the PCM code. If the code card is unavailable,
• The PCM reverts to the Code input the PCM code can also be read from the DME
function when the battery is control module (under "Vehicle data").
disconnected and is thus no longer 2. It is also possible to gain this code from the Porsche
ready for operation. IPAS.
• When the power supply is
3. Switch on the PCM with a free panoramic
disconnected, the built−in GPS
view for approx. 20 minutes (to load GPS
receiver loses the so−called almanac
almanac).
containing the satellite orbital paths.
• The date and time are deleted when 4. The date and time are also adopted once the GPS
the battery is disconnected. almanac has been loaded; it may be necessary to
• Radio stations stored by the customer change over to summer time (daylight−saving time).
are no longer displayed. This time is transferred to the instrument cluster. If the
• If the telephone card was inserted time is then manually changed by means of the
and the telephone was ready for instrument cluster, this time is adopted by the PCM and
operation, the telephone is synchronised with GPS time.
subsequently disabled. 5. The stored stations are displayed again when
station buttons 1 to 6 are pressed.
9023 Fuel level display 245

einordnung
6. The telephone is enabled again when the

telephone PIN code is entered with the SIM
telephone card inserted.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
9110 PCM 246

30 Clutch: checking fluid levels
General
Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment
Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment
Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment
top of page
General
CAUTION
Danger of material damage if the wrong fluid is used!
• Fill Pentosin CHF 11 S only into both supply tanks!
Pentosin CHF 11 S can be ordered with the following part number:

Quantity supplied 6 litre = 000.043.203.33. Container volume: 1 litre cans (6 ea.).
Power steering and clutch actuation are supported by hydraulic auxiliary forces. A tandem servo pump is
available instead of the servo pump for the steering (996 naturally aspirated engine) for this purpose. Both
systems share one supply tank (expansion tank). This tank −A− is located in the engine compartment.
In addition, a second supply tank for the clutch actuating circuit is available in the luggage compartment under
the cover −A− .
top of page
Checking Pentosin CHF 11 S hydraulic fluid in the engine
compartment and luggage compartment
Note
30 Clutch: checking fluid levels 247

einordnung
• The supply tank for the power steering and the clutch booster circuit is located in the engine
compartment!
• The second supply tank for the clutch actuating circuit is secured under a cover in the luggage
compartment!
top of page
Checking Pentosin CHF 11 S hydraulic fluid in the engine
compartment
Note
• The dipstick located on the reservoir cap has the "Cold marking" (approx. 20 °C engine temperature)
on one side and the "Hot max" symbol on the other side.
Pentosin tank in the engine compartment
Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 °C).
CAUTION
coolant hoses when topping up or filling in!
• Observe the following specifications in order to avoid overfilling and thus overflowing!
• Multiple steering operations (manoeuvring) and/or actuating the clutch with the engine switched off
change the fluid level in the reservoir! Fluid level rises. In this case, the engine must be run for
approx. 20 seconds immediately prior to the fluid level check!
• If coolant hoses come into contact with Pentosin, thoroughly clean them with water
IMMEDIATELY!
• Replace visibly swollen coolant hoses!
4. Wipe off the dipstick. Close and then reopen the cap. The fluid level should be in the designated "Cold
range" (min./max. level at 20 °C). Top up with Pentosin if necessary. Do not add too much Pentosin! In
warmed−up condition, the fluid level must not exceed the "Hot max" mark!
Checking Pentosin CHF 11 S hydraulic fluid in the enginecompartment and luggage compartment
248
einordnung
top of page
Checking Pentosin CHF 11 S hydraulic fluid in the luggage
compartment
WARNING
Danger of damage and injury if the wrong fluid is filled in after the caps have been changed!
• If fluid is being filled into several tanks in the luggage compartment (brake fluid / water / Pentosin),
carry out these filling procedures in sequence (always screw off just one cap) so that the caps of the 3
tanks are not interchanged! This prevents any chance of another person filling in the wrong fluids at a
later stage!
Note
• On right−hand drive vehicles, the supply tank is located in the area of the brake fluid reservoir/control
module for automatic headlight beam adjustment (ALWR)!
• The fluid level on the transparent supply tank should always lie between the Min. and Max. marking!
• Hold the supply tank by hand (counter) to undo and tighten the cap.
• Pentosin CHF 11 S hydraulic fluid should not be topped up until the fluid level is at the lower
marking!
This tank −2− supplies the clutch actuating circuit with Pentosin.
1. Remove cover −A− .
Checking Pentosin CHF 11 S hydraulic fluid in the enginecompartment 249

einordnung
Front tank
1 Brake fluid reservoir / black cap with yellow marking.

2 Pentosin reservoir for clutch actuation / green cap
3 Washer fluid container / blue cap.
2. If the fluid level in the transparent container −2− does not lie between the Min. and Max. marking, screw
off the cap. Counter the container when doing this. Fill in Pentosin CHF 11 S hydraulic fluid up to the
Max. marking.
3. Screw cap (green) −2− closed. Counter the container when doing
this.
4. Install cover −A− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Checking Pentosin CHF 11 S hydraulic fluid in the luggagecompartment 250

40 Tightening torques for front axle
Cross member/side member (1 component)
Diagonal brace
Control arm
Spring strut/wheel carrier
Front−axle final drive/drive shaft (Turbo)
Stabilizer
Steering
Wheel fastening
top of page
Cross member/side member (1 component)

Cross member/side member
on body (front and rear) M14 x 1.5 160 (118)
Corner plate on side member M10 x 1.5 65 (48)
Corner plate on body M12 x 1.5 100 (74)
Corner plate on body M14 x 1.5 160 (118)
(with diagonal arm and side member)
top of page
Diagonal brace

Diagonal brace on body and side member M12 x 1.5 100 (74)
top of page
Control arm

Control arm on side member M12 x 1.5 120 (89)
Control arm on diagonal arm M14 x 1.5 160 (118)
Control arm on wheel carrier
(Ball joint) M12 x 1.5 75 (56)
40 Tightening torques for front axle 251

einordnung
911 GT2
Bssic camber setting on 2−part control arm M8 27 (20)
top of page
Spring strut/wheel carrier

Spring strut to wheel carrier
(shock−absorber tube clamp)
Turbo M12 x 1.5 100 (74)
911 GT2 M12 x 1.5 85 (63)
Spring seat clamp (Turbo) M6 10 (7.5)
Spring−strut mount to body
Turbo M8 33 (24)
911 GT2 M10 35 (26)
Spring−strut mount to piston rod
(Turbo and 911 GT2) M14 x 1.5 80 (59)
911 GT2
Stabilizer mating bearing to spring strut (lock nut) M52 x 1.5 50 (37)
911 GT2
Height adjustment on spring strut (lock nut) M52 x 1.5 50 (37)
Brake cover plate to wheel carrier M6 10 (7.5)

Brake disc on wheel hub M6 10 (7.5)
Brake caliper to wheel carrier * M12 x 1.5 85 (63) * 1)
Speed sensor on wheel carrier M6 10 (7.5)
Combination coupling to wheel carrier M6 10 (7.5)
Retainer plate for wheel bearing to wheel carrier M8 37 (27)
Wheel hub to wheel carrier M22 x 1.5 460 (340)
1) * Replace screws at front and rear axle whenever they have been removed.
top of page
Front−axle final drive/drive shaft (Turbo)
Front−axle drive shaft to final drive M8 39 (29)
Front−axle drive shaft on wheel hub M22 x 1.5 460 (340)
Rear front−axle transmission support to transmission bearing M10 65 (48)
Control arm 252

einordnung
Rear front−axle transmission support to body M10 65

Front front−axle transmission support to front−axle cross M10 65 (48)
member
Stud to front−axle cross member M8 20 (15)
Front−axle transmission support at front to final drive M10 65 (48)
Tank strap to body M8 23 (17)
top of page
Stabilizer

Stabilizer to side member M10 x 1.5 65 (48)
Stabilizer mount to stabilizer M10 46 (34)
Stabilizer mount to spring strut
(Turbo and 911 GT2) M10 46 (34)
911 GT2
top of page
Steering

(Unlisted values in Repair Group 48!)
Track rod (ball joint pin) on steering arm M12 x 1.5 75 (56)
Universal joint (steering shaft) at steering gear ** M8 23 (17) ** 1)
Steering gear on cross member *** M10 x 1.5 65 (48)*** 2)
1) ** Replace fit bolt whenever it has been removed.

2) *** Replace fastening screws whenever they have been removed.
top of page
Wheel fastening

Wheel to wheel hub **** M14 x 1.5 130 (96)**** 1)
1) ****
Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring)
of the wheel bolts with Optimoly TA (aluminium paste). Do not grease bearing surface of the spherical cap
Front−axle final drive/drive shaft (Turbo) 253

einordnung
facing the wheel. If heavily contaminated, clean bolts first with a lint−free cloth.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Wheel fastening 254

42 Tightening torques for rear axle
Carrier side section/cross member
Axle strut
Wheel carrier
Spring strut
Drive shaft/stabilizer
Unit mount
top of page
Carrier side section/cross member

Carrier side section to body 12 x 1.5 110 (81)
Studs for carrier side section to body only screw−in torque
M12 x 1.5 46 (34)
Cross member at rear to carrier side section M12 x 1.5 110 (81)
Cross member at front to carrier side section M10 x 1.5 65 (48)
Brake hose holder to carrier side section M6 10 (7.5)
Diagonal brace
to body M10 x 1.5 65 (48)
to cross member M12 x 1.5 110 (81)
to carrier side section (collar nut) M10 x 1.5 23 (17)
top of page
Axle strut

Control arm 2 (toe control arm)
to wheel carrier M12 x 1.5 75 (56)
to cross member (toe eccentric) M12 x 1.5 100 (74)
Control arm (lower control arm)
to carrier side section (camber eccentric) M12 x 1.5 100 (74)
Diagonal brace
to cross arm M14 x 1.5 160 (118)
on carrier side section M14 x 1.5 180 (133)
Control arm 3 and control arm 4 (upper control arms)
to carrier side section M12 x 1.5 110 (81)
42 Tightening torques for rear axle 255

einordnung
top of page
Wheel carrier

Wheel bearing to wheel carrier (lid) M8 37 (29)
Speed sensor to wheel carrier M6 10 (7.5)
Brake cover plate to wheel carrier M6 10 (7.5)
Brake disc to wheel hub M6 10 (7.5)
Brake caliper to wheel carrier * M12 x 1.5 85 (63)* 1)
Holder for combination wire to wheel carrier M6 10 (7.5)
Wheel to wheel hub ** M14 x 1.5 130 (96)** 2)
1) *Replace screws at front and rear axle whenever they have been removed.
2) **Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring)
top of page
Spring strut

Spring strut to body
Turbo M10 46 (34)
911 GT2 M10 / 10. 46 (34)*** 1)
Spring strut to wheel carrier M12 x 1.5 110 (81)
Shock absorber to mount (piston rod)
Turbo M12 x 1.5 58 (43)
911 GT2 M12 x 1.5 60 (44)
911 GT2
911 GT2
Height adjustment on spring strut (lock nut) M52 x 1.5 50 (37)
1) ***
GT2 with roll−over bar: Carry out a test drive after performing assembly work on the roll−over
bar/spring support on the body and then retighten the M10 fastening nuts (three per side) to the same torque!
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Axle strut 256

einordnung
Drive shaft/stabilizer

Drive shaft
to transmission M10 81 (60)
to wheel hub M22 x 1.5 460 (340)
Stabilizer to carrier side section M8 23 (17)

Stabilizer mount to stabilizer and spring strut
Turbo M10 46 (34)
911 GT2 M10 / 10. 65 (48)
911 GT2
top of page
Unit mount

Engine mount to body M8 23 (17)
Engine carrier to engine M10 65 (48)
Engine mount to engine carrier M12 x 1.5 85 (63)
Transmission carrier to intermediate carrier M10 65 (48)
Intermediate carrier to body M10 65 (48)
Longitudinal support to transmission carrier M10 65 (48)
Longitudinal support to body M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Drive shaft/stabilizer 257

44 Conversion table for wheel alignment values
Minutes in decimal degrees
top of page
Minutes in decimal degrees
• The wheel alignment values are specified in degrees and minutes in the Technical Manual (division in
60 units)!
• In countries in which the decimal degree is widely used, the electronic wheel alignment testers can be
converted from degrees/minutes (division in 60 units) to decimal degrees (division in 100 units) by
presseing a key (special function)! This function is standard for the electronic wheel alignment testers
approved by Porsche.
• Using the conversion table, minutes (') can be converted into decimal degrees and decimal degrees
into minutes (')! To do this, read out the required values with the help of the coordinates!
min (') 0 1 2 3 4 5 6 7 8 9
degrees (°)
0 0.017 0.033 0.050 0.067 0.083 0.100 0.117 0.133 0.150
10 0.167 0.183 0.200 0.217 0.233 0.250 0.267 0.283 0.300 0.317
20 0.333 0.350 0.367 0.383 0.400 0.417 0.433 0.450 0.467 0.483
30 0.500 0.517 0.533 0.550 0.567 0.583 0.600 0.617 0.633 0.650
40 0.667 0.683 0.700 0.717 0.733 0.750 0.767 0.783 0.800 0.817
50 0.833 0.850 0.867 0.883 0.900 0.917 0.933 0.950 0.967 0.983
60 1.000
Conversion from minutes to decimal degrees (examples)
• Example 1: Toe 17 min (17') = 0.283 decimal degrees according to table. Procedure for this: The
imaginary line starting at the top of the 7 mins column moving downwards and the line starting on the
left in the 10 mins row moving right meet at point/column 0.283.
• Example 2: Camber 1° 25' (1 degree and 25 min) = 1.417 decimal degrees. This is the result from the
table (1 degree or 60 mins) = 1.000 + 0.417 (25 min).
Conversion from decimal degrees to minutes (examples)
• Example 1: Toe 0.350 decimal degree = 21 min (21'). The decimal value (0.350) is searched for in the
table. The coordinates are subsequently formed from this point/value. Line to the left = 20' and line
upwards = 1' (amounts to 20' + 1').
• Example 2: Camber 1.683 decimal degrees = 1° 41' (1 degree and 41 min). This is attained as follows:
Divide the value in 1,000 = 1 degree (1°) and search for the remaining value 0.683 in the table. Then
44 Conversion table for wheel alignment values 258

einordnung
form the coordinates again. Line to the left = 40' and line upwards = 1' (amounts to 40' + 1').
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Conversion from decimal degrees to minutes (examples) 259

44 Adjusting values for suspension alignment −
Turbo and GT2
Vehicle height
Wheel alignment values
top of page
Vehicle height
Note
• The following values relate to the empty weight, i.e., full fuel tank, vehicle with spare
wheel/collapsible wheel (not GT2) and tools, but without driver and without additional weight.
• Turbo and GT2 (M002 and M003) up until model year 2004 are delivered with just one running gear
tuning. As of model year 2004, running gear X73 (20 mm tiefer) is also available as an option.
Vehicle height Turbo USA Turbo RoW Turbo X73 GT2

(20 mm lower)
Front−axle height
with 18−inch wheels [mm] 158 ± 10 138 ± 10 128 ± 10 118 + 5
(118 to 123)
From road contact surface to lower edge of hexagon−head bolt (a/f 18) of the tension−strut screw
connection to the body.
Rear−axle height
with 18−inch wheels [mm] 163 ± 10 153 ± 10 133 ± 10 133 + 5
(133 to 138)
From wheel contact surface to the locating bore in the rear−axle side section (between toe and camber
eccentrics).
top of page
Wheel alignment values
WARNING
Warning only applies to vehicles with PSM (only 911 Turbo)!
Danger of injury and damage to property due to malfunctions in the PSM control range if the steering angle
sensor is not calibrated or is calibrated incorrectly!
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester
2!
44 Adjusting values for suspension alignment − Turbo and GT2 260

einordnung
• The steering angle sensor actual value must be checked after a suspension alignment where no
changes were made to the wheel alignment values!
Note
• The following values relate to the empty weight, i.e., full fuel tank, vehicle with spare
wheel/collapsible wheel (not GT2) and tools, but without driver and without additional weight.
• A caster adjustment is normally not necessary and is therefore not present.
• The toe−difference angle value is also influenced by the vehicle height! For this reason the measured
result must be evaluated accordingly! No action is necessary in the case of small deviations from the
toe−difference angle required value, as long as the value to the right and the left is almost the same!
Wheel alignment values Turbo USA Turbo RoW Turbo X73 GT2
(20 mm
lower)
Front axle
Toe unpressed (total) + 5' ± 5' + 5' ± 5' + 5' ± 5' + 8' ± 2'
Toe difference angle at 20° lock − 1° 20' ± 30' − 1° 50' ± 30' − 1° 50' ± 30' − 1° 50' ±
30'
Camber (with wheels in straight−ahead 0° ± 15' − 30' ± 15' − 45' ± 15' − 1° ± 5'
position)
max. difference, left to right 20' 20' 20' 10'
Caster 8° ± 30' 8° ± 30' 8° ± 30' 8° ± 30'

Rear axle
Toe per wheel + 10' ± 5' + 10' ± 5' + 10' ± 5' + 13' ± 2'
Camber − 1° 25' ± 15' − 1° 25' ± 15' − 1° 40' ± 15' − 1° 50' ± 5'

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Wheel alignment values 261

44 Alignment card − Turbo
Porsche measurement of running gear
Customer: Rep. Order No.:
Street: Vehicle Ident No.:
Place: Licence number:
Telephone: Date of first registration:
Odometer reading: km/miles
Measurement made by: Date / signature:
Vehicle: 911 Turbo (996) Model:
Measurement prerequisite (vehicle weight): Empty weight as in DIN 70020.
This includes: full fuel tank, vehicle with spare wheel and tools.
Reason for measurement:
Make of tires: Size/model at front: Rear:
front left front right rear left rear right
Tire pressure of cold tires (bar)
Tire/wheel (any damage)
Tires − tread depth (mm)
Incoming measurement Nominal values/ Outgoing measurement

(max. Difference,
left/right ’)
Vehicle height:
Front (mm) left/right
Rear (mm) left/right
Rear axle:
Camber left/right
Toe left/right + 10' ± 5' / (max.10'
’)
total + 20' ± 10'
Drive−axle angle 0° 00' ± 10'
Front axle:
Caster left/right 8° ± 30' / (max.40'
’)
Toe−difference angle left
right
Camber left/right
Toe left/right + 3' ± 3'
total + 5' ± 5'
Since mainly electronic wheel−alignment testers in conjunction with printers are used, a specimen alignment
card is rarely required nowadays. In order for measured results to be documented in individual cases,
however, a copy of the alignment card shown above can be used.
44 Alignment card − Turbo 262

einordnung
Note
• In practice this means that alignment cards cannot be ordered!
• The alignment cards can be used for all 911 Turbo (996), USA and RoW!
1. Prepare copies of the corresponding alignment card shown.

2. Before measurement, enter the general data, vehicle model and the missing nominal values into the
copied alignment card.
Note
• Actual values that are identical in all versions have already been entered!
3. Enter the appropriate version, e.g. USA or RoW, in the Model column.
4. Carry out incoming measurement (actual status) and enter the values in the alignment card.
5. After adjustments (if these were necessary), enter the actual values in the column Outgoing
measurement.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
44 Alignment card − Turbo 263

44 Suspension alignment, complete
Vehicle height/wheel load
Wheel−alignment corrections
General procedure for suspension alignment
Vehicle height (vehicle height check)
Rear axle
Front axle
There are few differences between suspension alignment on the new 911 Turbo (996) and suspension
alignment procedures on the 911 Carrera (996). This involves the vehicle height adjustment, the wheel−load
difference from left to right, special tools and corrections to wheel alignment.
Modified quick−clamping holders are required for the 911 Turbo (996) (to fasten the measured−value pickups
on the wheels). The quick−clamping holders present can be retrofitted by replacing the clamping units on the
left and right. Supplier: Messrs. Beissbarth. These converted quick−clamping holders can also be used
retroactively for the other Porsche models. The order number for the new clamping units will be included in
the Workshop Equipment Manual.
Note
• Observe the changed tightening torque when using the insert (tool −A− )!
Designation
of the
special
Item tool Explanation
A Insert for Used to tighten the lock nut(s) at the front track bar(s) to the specified tightening
torque torque. It can also be used for loosening. The prescribed lock nut tightening torque of
wrench 50 Nm (37 ftlb.) corresponds to a setting on the torque wrench of approx. 35 Nm (26
9625 ftlb.).
44 Suspension alignment, complete 264

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B Insert for Used to tighten the lock nuts of the camber and toe eccentrics at the rear axle to the
torque specified tightening torque. It can also be used for loosening.
wrench
9626
C Torque Commercially available; use in combination with tools A and B.
wrench
covering
the range
between 35
Nm (26
ftlb.) and
85 Nm (63
ftlb.)
top of page
Vehicle height/wheel load
Note
• There are few differences between suspension alignment on the new 911 Turbo and suspension
alignment procedures on the 911 Carrera (996)!
• As with the 911 Carrera (996) models, there is no adjustment facility for changing the vehicle height!
• This applies to both the front and the rear axles!
• Since the vehicle height cannot be adjusted, it is not possible to adjust (fine adjustment) the
wheel−load difference between left and right at the rear and front axles!
The varying strength of pads between coil springs and spring seats on the right and left spring struts on the
front and rear axles is not intended for changing the vehicle height but for compensating for differences in
coil−spring load groups.
Because of the different equipment versions (additional equipment), a greater wheel−load difference between
the left and right is permissible than previously was the case in Porsche suspension alignment for the 911
Carrera (996) (over 20 kg is possible). This is partly the result of heavier components compared with standard
equipment and partly results from additional components that are asymmetrically arranged.
top of page
Wheel−alignment corrections
Rear axle
WARNING
Vehicle height/wheel load 265

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2!
• The steering angle sensor actual value must be checked after a suspension alignment which resulted in
no changes being made to the wheel alignment values!
Note
• Similar to the 911 Carrera models (996), the kinematic toe−in is not adjustable!
• Camber and toe can be adjusted via eccentrics!
Front axle
WARNING
2!
Note
• The caster is not adjustable!
• After adjusting the toe, the lock nuts on the track rods must be tightened to the prescribed tightening
torque of 50 Nm (37 ftlb.)!
• The steering angle sensor must be calibrated if the previous wheel alignment values (on rear and/or
front axle) were changed! => Steering angle sensor
top of page
General procedure for suspension alignment
Note
• Carry out suspension alignment with an optical or electronic wheel alignment tester!
• The measurement procedures should be taken from the operating instructions for the wheel alignment
tester involved!
In order to exclude erroneous measurements, the following preconditions must be met before alignment and
Rear axle 266

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the following points should be given special attention:
• Empty weight of vehicle in accordance with DIN 70020, i.e. car ready for the road, with full fuel tank,
spare wheel (collapsible wheel) and tools.
• Ball−joint and wheel−bearing play in order (wheel−bearing play cannot be adjusted).
• Tyre pressure in accordance with regulations, fairly uniform tyre tread.
• Quick−clamping holder for the 911 Turbo with adapter (for the measured−value pickups) correctly
secured to the wheels.
• Receiving surfaces for the quick−clamping holder on the wheels and the adapter surfaces must be
clean and flat. Always check the levelling surface on the wheels precisely in particular before fitting
the quick−clamping holders.
• Strictly comply with maintenance intervals for measuring equipment and measuring platform. If the
levelling of the measuring platform or of the measuring area is done in−house, levelling equipment is
required. A hose level is inadequate!
• Skilled handling of measuring equipment and measuring platform.
• Sliding plates with transverse motion (rotary motion) at the rear axle are advisable.
• Observe the Technical Literature of PAG, the manufacturer of the measuring equipment and the
manufacturer of the measuring platform.
• Do not treat measured values as a whole, but very critically in regard to driving dynamics, high−speed
strength of the tyres, tyre wear and cost/benefit effects (time required for correction of insubstantial
deviations). The toe values are of decisive significance for driving dynamics and tyre wear.
• If the vehicle is measured front and rear, check and adjust the wheel alignment values at the rear axle
first. Camber values at the front axle apply for the straight−ahead position of the wheels. Steering
wheel and steering gear in centre position when toe is being adjusted.
• Before wheel alignment values are adjusted at front and rear axles, it is recommended that the vehicle
height be checked at the DIN empty weight. Conclusions can then be drawn about wheel alignment
values in the event of any suspension alignment that becomes necessary later.
top of page
Vehicle height (vehicle height check)
General
Note
• The vehicle height at front and rear axle is not adjustable!
Preliminary work
1. For the height check, place the vehicle on a level surface or on the measuring platform (ready to
drive, with a full tank, spare wheel and tools).
2. Compress vehicle at front and rear by approximately 25 mm 2−3 times and allow it to spring back
freely.
General procedure for suspension alignment 267

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Front axle
Measure from road contact surface to the lower edge of the hexagon−head bolt of the tension−strut screw
connection on the body!
Rear axle
Measure from wheel contact surface to the locating bore in the rear−axle side section (between toe and
camber eccentrics)!
Wheel alignment
WARNING
2!
Note
• Only check or adjust wheel−alignment values when prescribed preconditions are met!
Front axle 268

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• If the vehicle is measured front and rear, check and adjust the rear axle first!
• After adjustment, tighten the appropriate screwed connections with the prescribed tightening torque!
top of page
Rear axle
1. Prepare vehicle for checking and/or adjustment of wheel alignment values.
2. Place front wheels on rotary table and rear wheels on rotary / sliding
plates.
3. Compress vehicle at front and rear by approximately 25 mm 2−3 times and allow it to spring back
freely.
Adjusting camber
WARNING
2!
Note
• Use insert for torque wrench 9626 in combination with a torque wrench to loosen and tighten the lock
nuts of the toe and camber eccentrics.
• Prescribed tightening torque of the lock nut(s) = 100 Nm (74 ftlb.)! Adjusting value on the torque
wrench (in contrast to earlier specifications) is also 100 Nm (74 ftlb.)!
Wheel alignment 269

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After loosening the lock nut, turn eccentric −B−

appropriately.
Adjusting toe
WARNING
2!
Note
• Use insert for torque wrench 9626 in combination with a torque wrench to loosen and tighten the lock
nuts of the toe and camber eccentrics.
• Prescribed tightening torque of the lock nut(s) = 100 Nm (74 ftlb.)! Adjusting value on the torque
wrench (in contrast to earlier specifications) is also 100 Nm (74 ftlb.)!
Adjusting camber 270

einordnung
After loosening the lock nut, turn eccentric −A−

appropriately.
top of page
Front axle
Adjusting camber
WARNING
2!
The camber is adjusted by moving the spring strut transversely.
For this purpose, loosen the −three outer fastening nuts− on the spring−strut mount and, to move
the spring strut, remove the covering cap on the piston rod.
Adjusting caster
The caster is not adjustable.
Adjusting toe 271

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Adjusting toe
WARNING
2!
Note
Preliminary work:
1. Check whether the steering wheel is displaced with respect to the steering gear.
2. To do this, centre the steering gear as described below.
3. Turn wheels to the straight−ahead
position.
4. Then readjust the front wheel alignment, if necessary, until pin No. −2− in driver No. −1− and the lug on
the steering gear housing No. −4− line up.
No. −3− is the desired breaking point for pins in new steering gears. The (new) pin No. 2 is inserted into
driver No. 1 and lies with its underside within the recess of lug No. 4. This locks the steering gear in the
centre position. After installation of a new steering gear, the lower part of the pin is sheared off (at the desired
breaking point No. −3− ) by turning the steering wheel. The upper part of the pin remains in the driver.
If necessary, reposition the steering wheel. When doing this, seek the best position.
WARNING
A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag components
cannot be ruled out! In the case of such a malfunction, an unsuitable steering wheel holder could cause injury
or damage!
• Use only steering wheel holders which do not project into the area of the airbag unit!
• Observe safety regulations when working with airbag vehicles!’ 69 Passenger protection
5. Clamp steering wheel in centre position with steering wheel holder.
Note
Adjusting toe 272

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• Use only steering wheel holders which do not project into the area of the airbag unit!
6. If necessary, shorten the guide rod −A− at top −(arrow)− .
7. Then adjust toe at hexagon −2− of the track rod(s) after loosening the lock nut(s) −1− . The
steering angle sensor must subsequently be calibrated by PSM!
WARNING
2!
Note
• In order to tighten the tie rod lock nut(s) to the prescribed tightening torque, use an insert for torque
wrench 9625 in conjunction with a torque wrench!
• The prescribed lock nut tightening torque of 50 Nm (37 ftlb.) corresponds to a setting on the torque
wrench of approx. 35 Nm (26 ftlb.)!
Adjusting toe 273

einordnung
Toe−difference angle
The toe−difference angle is not adjustable.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Toe−difference angle 274

44 Wheel rims and tires
Tire condition / tire pressure
Tire pressure of cold tires (approx. 20° C)
Overview of tires and wheels (series)
top of page
Tire condition / tire pressure
WARNING
Danger of injury and damage to property as a result of modified handling behavior if tires are used which do
not correspond to Porsche−specific requirements!
• The stated air pressures are minimum pressures and must never be fallen below, since in addition to
the unfavorable driving performance, this would bring about a risk of serious tire damage!
• Besides a check on air pressure, a visual check must be made for sufficient tread depth, foreign
bodies, punctures, cuts, cracks and bulges in the sidewall (ply breakage)!
Note
• Valve caps protect the valve from dust and dirt and therefore from leaks! Always screw caps tight and
replace any missing caps!
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Tire pressure of cold tires (approx. 20° C)
911 Turbo

front 2.5 bar overpressure
rear 3.0 bar overpressure
Collapsible wheel front/rear 2.5 bar overpressure
for 16 inch
2.8 bar overpressure
for 17 inch
911 GT2 (M002/M003)
Note
44 Wheel rims and tires 275

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• 911 GT2 M002 = road version
• 911 GT2 M003 = Club Sport version

front 2.2 bar overpressure
rear 2.7 bar overpressure
Collapsible wheel not present
• Spare wheel/collapsible wheel not available! However there is a tire repair kit in the luggage
compartment which can be used to repair the damaged tire in the event of damage!
• For repairs in the event of damage, observe without fail the safety and operating instructions
=> Repair procedure!
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Overview of tires and wheels (series)
Front axle Rear axle
Turbo 225/40 ZR 18 295/30 ZR 18
on 8J x 18 ET 50 on 11J x 18 ET 45
GT2 235/40 ZR 18 315/30 ZR 18
on 8.5J x 18 ET 40 on 12J x 18 ET 45
• The chart of tires and wheels for summer and winter should be taken from Technical Information (TI)
Group 4!
• When replacing summer tires, pay close attention to the tire specification number! The specification
characters N1, N2, N3 or N0 distinguish the summer tires specially authorised by Porsche from other
models of the same tire type and size!
Note
• When mounting the wheel on the vehicle, observe the mounting specifications of the wheel bolts
=> Removing and installing the wheel − Turbo and GT2!
Notes on mounting tires
• When fitting tires, the direction of rotation and the inner and outer sides should be noted!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
911 GT2 (M002/M003) 276

44 Tyres
Mounting instructions
Balancing weights
Navigation system
Wheel storage
Tyre age
top of page
Mounting instructions
General
Note
• Always use new valves when changing tyres! Steel valves (part no. 993.361.073.00) −1− are used for
18−inch Turbo II wheels and rubber valves −2− for 18−inch Turbo−Look II wheels. Steel valve
assembly ’ 443519 Removing and installing valve (steel valve).
• When fitting tyres, the direction of rotation and the inner and outer sides should be noted!
• Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix as the mounting paste!
When mounting tubeless tyres, check the sealing surface of the tyre and the disc wheel for cleanliness and any
signs of damage. Bear in mind here that the bead base performs the sealing function on tubeless tyres. If the
bead edge has to perform the sealing function, air can escape when the vehicle is driven aggressively.
When mounting the tyre beads, use only the prescribed tyre mounting pastes. The following can occur if an
unsuitable mounting paste is used:
• twisting of the tyre on the rim,

• fracture of the bead core during mounting,
• damage to the rim surface by aggressive substances.
If Contifix is used, apply sparingly to the tyre beads (due to risk of the tyre turning on the wheel). If possible,
the vehicle should not be driven for 24 hours after tyre mounting or matching.
Note
44 Tyres 277
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• Customers should be informed that the full performance of new or newly mounted tyres is achieved
only after a distance of 100 to 200 km (60 to 120 miles) has been driven. Extreme driving manoeuvres
(acceleration, braking) should be avoided.
• The absolute limit on how far the tyre can turn on the wheel must be regarded as 20 mm. An optimum
balancing result will be worsened in this case.
• Mark the relative positions of the tyre and wheel for reference.
In order to optimise smoothness of rolling, it is expedient − and necessary in individual cases − to mount the
tyre in a favourable position with respect to the wheel (matching).
Uncontrolled matching
Turning the tyre on the wheel by 90° or 180° if necessary in order to achieve an acceptable value with regard
to rolling smoothness (true running, imbalance and distribution of balance weights).
Controlled matching
With a balancing machine with matching program. In most cases, this produces an even better result with
regard to the rolling smoothness (true running, imbalance and distribution of the balance weights) than can be
achieved with uncontrolled matching.
Fitting
Maximum permissible radial runout and lateral runout of the light alloy wheels = 0.7 mm. Maximum
permissible radial runout and lateral runout of the wheel with tyre = 1.25 mm. Values less than 1.0 mm
better around 0.5 mm are desirable.
After mounting the tubeless tyres, inflate them without valve insert to approximately 4.0 bar gauge
pressure in order to ensure that they are seated properly on the wheel. At the latest when the
pressure reaches 4.0 bar, the tyre beads must pop out of the deep bed and over the hump of the
wheel shoulder in order to avoid fractures of the bead core. If necessary, interrupt the process and
coat all necessary surfaces with lubricant (tyre mounting paste) again. Then repeat the process.
Screw in the valve insert and set the prescribed tyre pressure.
If new tyres are to be mounted or the tyres of one axle are to be replaced, tyres of the same make and with the
same specification code must always be used on each of the two axles. If tyres are replaced on one axle only,
the different tread depth than on the other axle can cause a noticeable change in the familiar handling. This is
especially the case if new tyres are mounted on the rear axle. This effect decreases with increasing tyre
mileage.
Note
• If a tyre is damaged and it cannot be determined with absolute certainty that there is no ply damage
with all of its consequences or if the tyre was thermally or mechanically overloaded due to a loss of
pressure or other prior damage, we recommend replacement of the tyre in question for safety reasons!
General 278
einordnung
• When replacing a tyre on an axle, make sure that the tread depth of the new tyre does not differ from
that of the other tyre by more than 30 %!
• Repairs on ZR tyres are impermissible, as is the use of inner tubes in tubeless tyres!
• When replacing summer tyres, pay close attention to the tyre specification number!
The overview of summer and winter tyres is included in Technical Information (TI), Group 4. The
specification code N1, N2, N3 or N0 distinguishes summer tyres expressly approved by Porsche from other
versions of the same tyre type and size.
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Balancing weights
Type of balancing weights: Adhesive weights as used previously (no special version necessary). Also refer to
the spare parts catalogue.
Affix both weights on the inner side (arrows).
Note
• Observe program selection and operating instructions of the balancing machine.
top of page
Navigation system
After a wheel change, the full locating accuracy is attained only after a journey of approx. 50 km (if possible
on the motorway and at a speed > 60km/h). Additionally, high slip of the wheels (e.g. wheel spin) can result
in temporary incorrect positioning.
top of page
Wheel storage
• Tyres must be stored in a cool, dry and dark room with adequate ventilation. They must never come
into contact with fuel, oil, grease or chemicals. Complete wheels can be stacked for storage. It is
advisable to increase the tyre pressure by 0.4 bar.
• If the tyres are not mounted on wheels, store them in vertical position. Tyres stored in vertical
position should be turned every two weeks in order to prevent excessive flattening. If the tyres are
stacked in horizontal position, they will become severely deformed and cannot be seated in the rim
flange easily when they are mounted.
Fitting 279
einordnung
Optimum conditions for proper storage of the complete wheels are provided by the Original Porsche storage
stand (trolley), part number 000.044.000.38.
Tyres age due to physical and chemical processes, which can impair their function. If they are stored for an
extended period, they will harden and become brittle faster than do tyres that are in continual use. Hairline
ageing cracks can occur on older tyres. If tyres are in use, the kneading action activates the plasticizer in the
rubber and thereby prevents hardening and cracking.
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Tyre age
Note
• Tyres should not be older than 6 years! Not even the spare wheel!
The age of the tyre can be determined via the manufacturer's code, which is listed behind the DOT code on the
tyre sidewall. The date of manufacture (the last four digits) is located at the end of the code.
Example
DOT DM CP 05 Y 2200 22 = production
week
00 = production
year 2000
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Wheel storage 280

44 Checking disc wheels
Checking the radial and lateral runout
top of page
Checking the radial and lateral runout
Note
• Straightening and welding work on light alloy wheels is not permissible!
Maximum permissible radial runout and lateral runout of the light alloy wheels = 0.7 mm.
Maximum permissible radial runout and lateral runout of the wheel with tyre = 1.25 mm. Values less than 1.0
mm better around 0.5 mm are desirable. For this purpose, match the tyre (turn the tyre on the rim) if
necessary.
Note
• Use a tyre measuring gauge e.g. V.A.G. 1435 to measure wheels without tyres and wheels with
tyres.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
44 Checking disc wheels 281

44 Tyre mounting
Note
Tools
Notes on removing/mounting tyres
Removal
Fitting
Note
• The mounting machine described here is particularly suitable for the tyre combinations used on the
911 Turbo (996).
• All parts in contact with the wheel and the tyres are made of plastic.
• No large point load for wheel and tyres.
top of page
Tools
Item Designation of the special tool Explanation

A Holding−down device, commercially To hold down the tyre bead
available
B Assembly aid Commercially available; refer to Workshop
Equipment Manual, Chapter 2.5
C Adhesive weight remover Commercially available
44 Tyre mounting 282

einordnung
D Mounting lever commercially available
top of page
Notes on removing/mounting tyres
Note
• When fitting tyres, the direction of rotation and the inner and outer sides should be noted!
• Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix as the mounting paste.
• Ensure that no damage (scoring, soiling) is caused to the assembly head of the fitting machine during
fitting. Such damage may result in paint damage and pressure marks on the rim flange.
Avoid slipping on to the rim flange. Use rim flange protection (assembly aid)
−B− .
Adhesive tape can be used to protect the rim flange in individual cases, in order to prevent any paint
damage during fitting. The mounting lever can also be covered with adhesive tape in order to avoid
damaging the area around the spokes during removal.
The valve must always be replaced when changing a tyre. Steel valves −1− are used for 18−inch
Turbo II wheels and rubber valves −2− for 18−inch Turbo−Look II wheels.
Check the wheel for damage.
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Removal
1. Clamp
wheel.
Tools 283
einordnung
2. When pushing off the tyre, ensure that the bead press−off tool is set to the exact inch graduation. If this is
not the case, the rim flange may be damaged by the press−off rollers.
3. The wheel must be turned anti−clockwise when pressing the tyre off the rim. Otherwise, excessive forces
occur on the fastening bolts of the machine which can lead to bolt breakage. The tyre beads can be pressed
off at the same time or individually.
4. Before removing the tyre, coat the tyre beads with mounting paste to facilitate removal.
Note
• The mounting lever must be kept at a safe distance from the rim. This prevents damage (scratches,
pressure marks) to the rim spokes.
5. Put the assembly head on the rim flange. Position the assembly aid. The mounting lever is pushed into the
deep bed underneath the first tyre bead, and then guided over the assembly shoe and pushed down.
6. Lift the tyre bead out of the rim bed by turning the wheel to the right.
7. Position the assembly aid for the second tyre bead. Pull the tyre upwards and push it into the rim
bed underneath the second tyre bead using the mounting lever. Make sure that the mounting lever is
guided correctly (see Point 5). Turn the wheel to the right and remove the tyre.
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Fitting
Note
Removal 284
einordnung
• Do not use commercially available steel valves!
• The Porsche valves (part No. 993.361.073.00) are shorter; dimension −X− . Dimension −X− is 43 mm
for the Porsche version!
1. Free the wheel from the abraded rubber particles and check for damage.
2. A new valve must always be fitted. Steel valves −1− are used for 18−inch Turbo II wheels and
rubber valves −2− for 18−inch Turbo−Look II wheels.
3. Coat the wheel and tyre with tyre mounting paste − TIP TOP Universal, order No. 593 0601 − or
Contifix.
4. Place the tyre in the correct position on the wheel. Push in mounting arm and position on top of the
rim flange.
5. Guide the tyre bead through the assembly head. Fit the tyre bead in the deep bed by turning the wheel
to the right.
6. At the start of the mounting process of the second tyre bead, the mounting arm should be positioned
opposite to the valve. This prevents damage to the valve.
7. Press the second tyre bead onto the wheel as flat as possible and guide through the assembly
head.
8. Insert first holding−down device and position the second holding−down device offset by 90° to
120°. Fit tyre bead in deep bed by turning to the right.
9. Fill tyre with compressed air. At approx. 4.0 bar, the beads should pop over the hump. Coat the tyre
beads with mounting paste again if necessary so that they can pop over easily and gently.
Fitting 285
einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Fitting 286
44 Balancing/optimising wheels
General
Balancing/optimising wheels
Balancing weights
top of page
General
Excessive wheel imbalance not only produces vibrations and causes the steering wheel to shake, but also
results in increased wear on various parts of the running gear.
Even if the wheels are correctly balanced, excessive geometry errors (radial and axial runout) and misshapen
tyres, e.g. accumulations of material at one point of the tyre structure (spring action of tyre changes as the tyre
rolls), can cause rolling and steering imbalance.
Note
• Achieving a good result requires utmost care, observance of the instructions and procedure, and
attempting to eliminate even the very last gram of imbalance.
Recommendations / prerequisites
• Wheel suspension elements must be in good technical order.

• The wheels must be clean and without foreign objects in the tyre.
• Use a tyre measuring gauge, e.g. V.A.G 1435, to check axial and lateral runout values on wheels
without flat spots. Values less than 1.0 mm better around 0.5 mm are desirable.
• In order to achieve low radial runout errors or to optimise smoothness of rolling, it is expedient and
necessary in individual cases to match the tyre (i.e. to mount it in a favourable position with respect
to the wheel). Tips and mounting instructions, also about tyre mounting paste under => Tyres.
• If the rims (wheels without tyres) are true but the complete wheels have large axial and radial runout
values (due to ply breakage or other damage), tyre replacement may be necessary.
• Balance used wheels only after they have been warmed up by driving, otherwise flat spots will
simulate imbalance. Never perform matching in the case of flat spots.
• Correct tyre pressure is an important prerequisite.
• Place the balancing weights at the prescribed position. Refer to => Balancing weights for information
about putting on the balancing weights.
top of page
Balancing/optimising wheels
The entire process is subdivided into four operations.
1. Mounting the tyre on the
rim.
2. Stationary balancing of the wheel (eliminating the static and dynamic imbalance) with optimisation of the
rolling smoothness.
3.
44 Balancing/optimising wheels 287

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Mounting the wheel on the

vehicle.
4. Electronic fine balancing (static balancing) of the wheel on the vehicle after stationary balancing.
Required only in exceptional cases.
Further to 1: Mounting the tyre on the rim
Remove rubber residues and dried−on tyre paste from the rim, especially from the rim bead and the hump.
Examine rim for damage; remove old balancing weights.
Use the prescribed tyre mounting paste (only TIP TOP Universal, order No. 593 0601, 3.5 kg bucket, or
Contifix) so that the tyre does not turn on the rim the first time the car is driven, thereby destroying all of
the careful work. If the tyre turns by as little as 20 mm with respect to the rim, this can worsen an
optimum balancing result.
Mount tyre on the rim. When doing so, it is expedient and necessary in individual cases to mount the
tyre in a favourable position with respect to the wheel (matching). Controlled or uncontrolled matching.
Uncontrolled matching: Turning the tyre on the wheel by 90° or 180° if necessary in order to
achieve an acceptable value with regard to rolling smoothness (true running, imbalance and
distribution of balance weights).
Controlled matching: With a balancing machine with matching program. In most cases, this produces an
even better result with regard to the rolling smoothness (true running, imbalance and distribution of the
balance weights) than can be achieved with uncontrolled matching.
Fill tyres to a pressure of approx 4.0 bar. At the latest when the pressure reaches 4.0 bar, the beads must
pop up out of the deep bed and over the hump of the wheel shoulder in order to avoid fractures of the bead
core. If necessary, interrupt the process and generously coat all necessary surfaces with lubricant (tyre
mounting paste). Then repeat the process.
Check the fit of the tyre on the rim by means of the bead centring
line.
Set the prescribed tyre pressure => Wheel rims and tires.
Further to 2: Stationary balancing with optimisation of the rolling

smoothness
Clamp wheel on stationary balancing machine.

Observe the operating instructions of the balancing machine; occasionally adjust the machine if necessary.
The support surfaces of the wheel on the balancing flange (levelling surface) and the centring surface
must be clean.
Centre (clamp) the wheel from the inside with centring clamping device refer to Workshop
Equipment Manual, Chapter 3. This centring clamping device fits on all wheel balancing machines
approved by Porsche.
Check radial and axial runout during the 1st measuring run. Values less than 1.0 mm better around 0.5 mm
are desirable.
Consider the size of the measured balancing weights and their distribution on the inner and outer planes (inner
and outer rim flanges) critically.
A uniform distribution with low values (e.g. 25/30 g) means that the tyre was mounted correctly and the
quality of the tyre and rim is good.
Balancing/optimising wheels 288

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A value of 80/80 g should not be exceeded. A greatly different distribution, e.g. 30/70 g is very unfavourable;
this usually indicates incorrect mounting. Problem wheels of this kind often have pronounced radial and axial
runout values.
This can be remedied by matching (use correct mounting paste). Improvement is possible with uncontrolled
matching (manual); significant improvement is possible in almost all cases with rolling smoothness
optimisation program (controlled matching).
The tyre pressure must not be less than 1.5 bar overpressure during balancing.
Permissible residual imbalance less than 3 g, or max. 3 g per plane.
Further to 3: Mounting the wheel on the vehicle
Note
• Never use an impact bolter!
• Observe grease specification and information on the two−piece wheel bolt! This is described in the
section describing wheel removal and installation (mounting wheel on the vehicle) => Removing and
installing the wheel − Turbo and GT2!
Mount wheel with suitable commercially available tools.

If necessary, mark the position of the wheel on the wheel hub before removing the wheel. Use a piece of
adhesive tape to mark the wheel and the wheel hub. This will preserve any optimum balancing result
previously achieved by means of fine balancing (finish balancers), even after the wheel is re−mounted.
Screw in wheel bolts by hand and then tighten evenly. Start at the top when tightening. Always
observe the specified tightening torque of 130 Nm (96 ftlb.).
Prescribed tyre
pressure.
Further to 4: Electronic fine balancing
For electronic fine balancing of the wheels on the vehicle, refer to the operating instructions from the
equipment manufacturer for information about handling the equipment.
When performing fine balancing on all wheels, start with the front axle (4a).
Due to the all−wheel drive, all four wheels must be raised and must be able to turn freely.
• Fine balancing of the front wheels to correct torsional vibrations of the steering wheel at approx. 120
km/h.
• Fine balancing of the rear wheels to correct vibration at 180 km/h and speeds greater than 230 km/h.
The following applies to both the front axle and rear axle:
• the measured−value pickups must always stand on a firm surface,

• the measuring stand support must be located as close to the wheel as possible,
• doors and lids must be closed and the vehicle must not be touched during the measuring operation,
• ensure that the lifting equipment used (jack, platform lift) does not touch the vehicle.
Further to 2: Stationary balancing with optimisation of the rollingsmoothness 289

einordnung
Affix balancing weights on the outer plane (uniform procedure / could also be distributed or affixed on the
inner plane). Under no circumstance remove the weights affixed during stationary balancing. Mark the
balancing weight required by electronic fine balancing using a prick punch in order to distinguish it.
Read out and erase the PSM fault memory after fine balancing.
Further to 4a: Fine balancing of the front wheels
Note
• Due to the all−wheel drive, all four wheels must be raised and must be able to turn freely.
• Ensure that the take−up fork of the measuring support does not damage any parts!
Position measuring support at the front axle on the right and left. Before the first measuring run,
re−check to ensure that slipping from the measuring support is not possible!
Centre the sensitivity control. Carry out a measuring run.
Affix balancing weight if necessary. Then perform a check run. If the result is unacceptable
(precondition: the work was performed properly), calibrate the finish balancer. This means that the
sensitivity control must be adapted to the actual situation.
If the balancing result is still not quite right even after calibration (for example, 5 g), change the
balancing weight according to the balance correction table (balance correction schematic) and
thereby eliminate the residual imbalance.
Further to 4b: Fine balancing of the rear wheels
Note
• Due to the all−wheel drive, all four wheels must be raised and must be able to turn freely.
• Do not damage any parts with the take−up fork of the measuring support!
Position measuring support at the rear axle on the right and left. Before the first measuring run, re−check
to ensure that slipping from the measuring support is not possible!
Set the sensitivity control to 3...3.5 (depending on the equipment version). This corresponds to approx. 1/3
of the max. sensitivity.
Perform measuring run at a speed of 130 km/h or 1,150 to 1,200 rpm (wheel revolutions) in the highest
gear. Affix the corresponding balancing weight.
Perform a check run. Calibrate the finish balancer if the balancing result is unsatisfactory. This means that
the sensitivity control must be adapted to the actual conditions.
Then (in the case of a good balancing result) slowly increase the speed to 190 km/h and carefully observe
at what speed vibration can be felt at the steering wheel and/or seat again (mainly at 175 +/− 5 km/h).
Maintain this speed and re−balance the wheels in the same way as at 130 km/h. Do not affix any
new weights; instead, improve the wheel running smoothess by changing the existing weights
according to the balance correction schematic.
Further to 4: Electronic fine balancing 290

einordnung
The imbalance values shown here in this speed range are not real values. They are actually max. 1/4 to 1/3 of
the indicated values.
The subjective impression in the vehicle is the decisive criterion here. The balancing process is complete only
when no more vibrations caused by imbalance are perceptible!
top of page
Balancing weights
Balancing weights: Adhesive weights as used previously (no special version necessary). Also refer to the
spare parts catalogue.
Affix both weights on the inner side.
Note
• Observe program selection and operating instructions of the balancing machine.
Affixing the adhesive weights
Note
• Remove the protective film only immediately prior to sticking on the weight, as prolonged exposure
to the air will reduce the bonding strength!
• Pay attention to cleanliness!
Determine exact position of the balancing weights (if necessary, provisionally stick on the balancing
weights with a strip of adhesive tape until the correct position is determined).
Prepare bonding surface on the rim. The bonding surface must be perfectly clean and free of grease.
Remove protective paper from the bonding surface of the weight and press the weight firmly into
place.
The adhesive weight must be in contact uniformly over the entire surface.
Check to ensure that the balancing weight is seated firmly. It must not be possible to detach the weight
that was just stuck onto the rim by the application of a shear load at right angles to the longitudinal axis of
the weight.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Further to 4b: Fine balancing of the rear wheels 291

45 ABS/PSM 5.7 check with Porsche System Tester 2
Test with Porsche System Tester 2
top of page
Test with Porsche System Tester 2
Note
• If work has been done on the hydraulic unit, the speed sensors and the cable harness or if the
hydraulic unit is replaced, a system check (functional check) must be performed with the Porsche
System Tester 2! This is the case, for example, after accident repairs! This prevents any confusion of
electrical or hydraulic lines and ensures faultless operation of the system!
• If certain brake lines are replaced, e.g. at the intermediate piece in the front−left wheel housing, a
system check or a swap test (swap test menu) must also be performed! Unintentional bending of the
brake lines could lead to incorrect hydraulic allocation, despite the different thread sizes used (M12 x
1 and M 10 x 1)!
• If there is a fault indication during operation (when no assembly work was carried out beforehand),
diagnosis and troubleshooting are also carried out with the Porsche System Tester 2! To do this, select
the PSM system and read out the fault memory there! The fault can then be localized using the
appropriate menus (Drive links/Actual values)!
• The Porsche System Tester 2 is connected to the diagnositic socket in the front left footwell in the
same way as for the 911 Carrera (996)! Entry takes place through the ABS system (automatic status
change after PSM)!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
45 ABS/PSM 5.7 check with Porsche System Tester 2 292

46 Checking brake light switch setting
Brake light switch setting
Checking brake light switch setting
Adjusting switch if pedal travel is too small
top of page
Brake light switch setting
The switch travel of the brake light switch is designed so that the brake light lights up before braking pressure
builds up.
The switches are self−adjusting and are mounted in a bayonet lock in the pedal block by turning them through
90°. By way of its self−adjustment function, the switch compensates for the tolerances in the pedals during
initial assembly. Observe following note!
Note
• However, if the switch is "overpressed" during work on the pedals or on the brake unit, the switch
travel or pedal travel up to the switching point is lost!
The consequence:
• The brake lights are always on or flicker when travelling over bumps.
• In vehicles with cruise control, the cruise control can be deactivated as a result of vehicle vibrations
under certain circumstances.
• The switch must be readjusted after any work in which the brake pedal is moved out of its "normal"
position (for example, work on the pedals or on the brake unit)!
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Checking brake light switch setting
• The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up
(stop light switch −1− ).
• Check (make sure) that the brake light lights up before the pedal meets perceptible resistance or
before brake pressure builds up.
46 Checking brake light switch setting 293

einordnung
top of page
Adjusting switch if pedal travel is too small
There are two possibilities to adjust the switch if the pedal travel to the switching point is too small.
1st possibility:
1. Press the brake pedal and pull out the switch plunger.
2. Release the pedal.
3. Check
adjustment.
2nd possibility:
Note
• A play−free fit of the switch is no longer ensured after it has been installed and removed several
times. The switch must be replaced by a new switch as soon as it perceptibly "wobbles" in its
receiver.
• When installing the switch for the first time, it is essential to press it vertically against the bearing
surface. It will otherwise not be possible to lock the switch (90° turn), even if great force is exerted.
1. Release switch by turning it 90° and pull it out of the installation

opening.
2. Pull operating plunger out of the switch as far as it will go.
3. Reinstall the switch.
Adjusting switch if pedal travel is too large
1. Press pedal and press plunger into the switch by one notch (audible click).
The pedal travel to the switching point then decreases by approx. 3 − 4 mm.
2. Check adjustment again.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Checking brake light switch setting 294

46 Tightening torques for mechanical brake
Brake caliper * to front and rear axles M12 x 1.5 85 (63)* 1)
Brake disc to wheel hub (front and rear axles) M6 10 (7.5)
Brake cover plate to front and rear axles M6 10 (7.5)
Speed sensor to front and rear axles M6 10 (7.5)
Brake unit on body (aluminium interm. part) M8 23 (17)
Brake unit support on body M8 23 (17)
Parking brake console to body M8 23 (17)
Bracket for hydraulic unit on body M6 10 (7.5)
Hydraulic unit on holder M8 12 (9)
Booster pump for PSM on holder M6 7 (5)
Booster pump for PSM on body at front M6 4 (3)
Wheel to wheel hub ** M14 x 1.5 130** 2)
1) *Replace the brake caliper fastening screws on the front and rear axles every time they are removed.
2) **Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
46 Tightening torques for mechanical brake 295

46 Technical data/Brake wear limit − Turbo
Technical data − Turbo with cast iron brake discs
Wear limit technical data − Turbo with cast iron brake discs
top of page
Technical data − Turbo with cast iron brake discs
Designation Notes, dimensions Wear limit

Operating brake (foot brake) Hydraulic dual−circuit brake system with
with cast iron brake discs (standard brake) front−axle / rear−axle brake circuit division.
Vacuum brake booster, internally ventilated and
perforated cast iron brake discs with four−piston
monobloc fixed caliper at front and rear axles.
The brake calipers are painted red for visual
differentiation.
PSM* 1) (Porsche Stability Management)
standard.
Brake booster 10 inch

(vacuum)
Boost ratio 3.85
Brake master cylinder front 25.4 mm
rear 25.4 mm
Stroke 18/18 mm
Brake proportioning control ** EBV ** 2)
Brake discs front 330 mm

rear 330 mm
Effective brake discs front 267.8 mm
rear 271.2 mm
Piston in brake caliper front 2 x 44 + 2 x 36 mm

rear 2 x 30 + 2 x 28 mm
Brake pad area front 314 cm2

rear 254 cm2
Total brake pad area 568 cm2
1) *
Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine
drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching
46 Technical data/Brake wear limit − Turbo 296

einordnung
2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screw−in brake
proportioning valves are required!
top of page
Wear limit technical data − Turbo with cast iron brake discs
Depending on the wear of cast iron brake discs, two condition criteria can make replacement necessary:
1. Cracking in the holed (perforated) brake disc friction plates is in an advanced state.
2. Brake disc minimum thickness is not attained due to wear (material erosion due to friction).
Designation Note, dimensions Wear limit

Pad thickness front approx. 12.0 mm 2 mm
rear approx. 12.0 mm 2 mm
Brake disc thickness, new front 34 mm

rear 28 mm
Minimum brake disc thickness front 32.6 mm* 1)

after machining* 1) rear 26.6 mm* 1)
Brake disc wear limit front 32.0 mm

rear 26.0 mm
Peak−to−valley surface roughness 0.006 mm

of the brake disc after machining, max.
Thickness tolerance of the brake discs, max. 0.02 mm
Lateral runout of the brake disc, max. 0.03 mm
Lateral runout of the wheel hub, max. 0.03 mm
Lateral runout of the brake disc when installed, max. 0.06 mm
Pushrod play (measured at the brake pedal plate) approx. 1 mm
Parking brake Drum brake acting mechanically on

(handbrake) both rear wheels
Parking brake drum 180 mm 181 mm
Brake shoe width 25 mm
Brake pad thickness 4.5 mm 2 mm
1) * The brake disc must only be reworked symmetrically, i.e. from both sides evenly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Technical data − Turbo with cast iron brake discs 297

46 Checking the thickness of the disc brake pads −
Turbo and GT2
Caution
WARNING
Braking effect impaired if the brake pads are exchanged too late!
Braking effect impaired if the brake discs are exchanged too late!
Danger of injury and damage to vehicle if braking effect is impaired!
• The brake pads must be replaced when the brake pad warning indicator lights up, but no later than
when there is a residual pad thickness of 2 mm!
Note
• If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced!
• Replacing the warning contact can be avoided by replacing the brake pads no later than when the pad
thickness is 2.5 mm −arrows− !
• Warning contacts must be replaced if the core of the wire is worn!
• However, if only the plastic part of the warning contact is worn, there is no need to replace it!
CAUTION
Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel
removal/installation (danger of damage to brake discs)!
• Use assembly aids (assembly pins) in order to exclude any possibility of heavy contact of the wheel
with the brake disc! The assembly aids (2 assembly pins) are located in the luggage compartment!
46 Checking the thickness of the disc brake pads − Turbo and GT2 298
einordnung
1. To check the brake pads, remove the wheels. Screw the 2 assembly aids (assembly pins), instead of 2
wheel bolts, into the wheel hub before wheel removal/installation. During removal, first remove the 3
remaining wheel bolts and remove the wheel carefully, without touching the brake discs.
2. Visually inspect the brake pads for wear.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
46 Checking the thickness of the disc brake pads − Turbo and GT2 299
46 Technical data/Brake wear limit − Turbo with
PCCB
Technical data − Turbo with ceramic brake discs (PCCB)
Wear limit technical data − Turbo with ceramic brake discs (PCCB)
top of page
Technical data − Turbo with ceramic brake discs (PCCB)

Operating brake (foot brake)
with ceramic brake discs (special request) Hydraulic dual−circuit brake system with
front−axle / rear−axle brake−circuit
distribution. Vacuum brake booster, internally
ventilated and perforated ceramic brake discs
with six−piston monobloc fixed caliper on the
front axle and four−piston on the rear axle.
The brake calipers are painted yellow for
visual differentiation.
PSM* 1) (Porsche Stability Management)
standard.
(vacuum)
Boost ratio 3,85
rear 25.4 mm
Stroke 18/18 mm
Brake proportioning control ** EBV ** 2)
Brake discs front 350 mm (PCCB)
rear 350 mm (PCCB)
Effective brake discs front 284 mm
rear 291 mm
Piston in brake caliper front 2 x 38 mm
6−piston 2 x 32 mm
2 x 28 mm
rear
4−piston 2 x 30 + 2 x 28 mm
rear 248 cm2
1) *
Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine
drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching
46 Technical data/Brake wear limit − Turbo with PCCB 300

einordnung
2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screw−in brake
proportioning valves are required!
top of page
Wear limit technical data − Turbo with ceramic brake discs
(PCCB)

rear 28 mm
Brake discs minimum thickness front 33.5 mm
rear 27.5 mm

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Technical data − Turbo with ceramic brake discs (PCCB) 301

47 Tightening torques for brake hydraulics
Tightening
torque Nm
Brake pressure line to brake master cylinder, brake hose, distributor,

brake caliper and hydraulic unit M10 x 1 12−14 (9−10)
M12 x 1 20 (15)
Hydraulic unit on holder M8 12 (9)
Hydraulic unit to body M6 10 (7.5)
Booster pump for PSM
Booster pump on holder M6 7 (5)
Booster pump on body at front M6 4 (3)
Brake caliper
Connecting line to brake caliper M10 x 1 12 (9)
Bleeder screw to brake caliper M10 x 1 8 − 12 (6 − 9)
Brake pressure line to brake caliper M10 x 1 12 − 14 (9 −
10)
Brake unit
Brake unit on body M8 23 (17)
Brake unit support on body M8 23 (17)
Brake master cylinder on brake booster M14 49 (36)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
47 Tightening torques for brake hydraulics 302

48 Tightening torques for steering
Location Thread Tightening torque [Nm] (ftlb.)
Steering gear to cross member* M10/10.9 65 (48.8)* 1)
Tie rod (ball joint) to steering arm M12 x 1.5/10 75 (56.3)
Universal joint (steering shaft) to steering gear** M8 23 (17.3)** 2)
Tie rod to ball joint (lock nut) M14 x 1.5 50 (37.5)
Tie rod to steering rack M16 x 1.5 80 (60)
Steering wheel to steering shaft M16 x 1.5 45 (33.8)
Airbag module to steering wheel M6 10 (7.5)
Steering outer tube to pedal bearing block, top M10 x 1.5 46 (34.5)
Steering outer tube to pedal bearing block, bottom M14 20 (15)
Steering lock to steering outer tube M6 13 (9.8)
Transverse support to steering outer tube M8 23 (17.3)
Transverse support to support frame M8 23 (17.3)
Pressure and return pipes to steering gear M10 x 1.5 20 (15)
Plug−in couplings for steering hydraulic system a/f 15 *** 3) 30 (22.5)
a/f 19 *** 3) 40 (30)
1) * Replace screws whenever removed.

2) ** Replace fit bolt whenever it has been removed.
3) *** a/f = width across flats or wrench size (a/f 15 pressure line / a/f 19 return line).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
48 Tightening torques for steering 303

48 Test and assembly work on power steering
General
Checking hydraulic fluid of power steering and servo clutch
Bleeding the steering system
top of page
General
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can
cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the
hydraulic circuit.
Grunt−like noises when the steering is locked or foam formation in the reservoir indicates a shortage of oil
and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be eliminated on
the suction side. Alternatively, the defective part on the pressure side should be replaced.
Power steering and clutch operation are supported by hydraulic auxiliary forces. The common reservoir −A−
is located in the engine compartment.
Only Pentosin CHF 11 S may be filled into the reservoir. Pentosin CHF 11 S can be ordered with the
following part number: Quantity supplied 1 litre = 000.043.203.33.
Note
• There is a second tank in the luggage compartment for clutch operation. This container is located
under a cover!
• Rack−and−pinion steering gear and servo pump must not be repaired or dismantled!
top of page
Checking hydraulic fluid of power steering and servo clutch
Note
• Power steering and clutch operation are supported by hydraulic auxiliary forces!
• The reservoir is located in the engine compartment!
• The dipstick located on the reservoir cap has the "Cold marking" (approx. 20 °C engine temperature)
48 Test and assembly work on power steering 304

einordnung
on one side and the "Hot max" symbol on the other side.
Pentosin reservoir
Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 °C).
CAUTION
• Observe the following specifications in order to avoid overfilling and thus overflowing!
change the fluid level in the reservoir! Fluid level rises. In this case, the engine must be run for
approx. 20 seconds immediately prior to the fluid level check!
IMMEDIATELY!
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Bleeding the steering system
1. To fill the whole system after the installation of new steering components or lines or after a
substantial loss of hydraulic fluid, briefly start the engine a few times and, when it fires, switch it
off again immediately. This procedure causes the fluid level in the reservoir to fall rapidly, so
constantly add Pentosin CHF 11 S. The reservoir must not be sucked dry.
2. If the fluid level in the reservoir does not fall any further when the engine is briefly turned over, start the
engine and let it run at idling speed.
3. Rapidly turn the steering wheel from stop to stop several times so that the air can escape from the
cylinders. At the end positions of the piston, do not pull the steering wheel with more force than is
necessary in order to turn the steering (to prevent unnecessary build−up of pressure initially).
4. Observe fluid level during this procedure. If it continues to fall, add fluid until the level in the
reservoir remains constant and no more air bubbles rise in the reservoir when the steering wheel is
Checking hydraulic fluid of power steering and servo clutch 305

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turned.
5. Switch off engine.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Bleeding the steering system 306

48 Assessment of steering gear after accident
damage
Fundamentals
top of page
Fundamentals
Various kinds of damage can be caused to the steering gear in the event of accidents or driving conditions
resembling accidents. In cases where the steering gear shows no external damage it can be difficult and costly
to detect damage. Nevertheless, this damage represents an unacceptable risk for the vehicle, since it could lead
to failure of the steering system.
Since a comprehensive check on all individual parts of the steering gear is not feasible, as a rule, and is not
possible using the ordinary means of a workshop, instead the condition of other components that are easier to
check should be considered.
The following guidelines serve for a decision on whether the steering gear of a vehicle involved in an accident
should be replaced or may continue to be used.
Assessment of the steering of a vehicle involved in an accident
The steering gear can remain in the vehicle if all the following conditions are met:
• No visible damage to such front−axle parts as wheel rims, spring struts, wheel carriers, control arms,
steering arms, track rods, front−axle cross member, front−axle side members, the steering shaft or to
the points on the body where wheel suspension parts are bolted on.
• No impermissible rise in torque and no jamming or catching when the steering gear is turned from
stop to stop. When the steering is turned, the front wheels must be free (front axle raised) and, in
addition, the engine must be switched off (pump of power steering undriven).
• The permissible tolerances for wheel alignment must not be exceeded.
The steering gear must be repaired or replaced if one of the following points applies:
• Visible or detectable damage to the steering gear.

• Fire damage (e.g. steering bellows burnt).
Permanent deformation or breakage of:
• Steering−gear mounts
• Track rods
• Steering arms
• Spring struts
• Wheel carriers
• Control arms
• Front−axle side members
• Front−axle cross member
If the listed criteria are insufficient for a decision, we recommend that the steering gear be repaired or
48 Assessment of steering gear after accident damage 307

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replaced.
Exceptional regulation / order handling
If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an
expert or if this is impossible abroad, the importer should be called in at the cost of the refusing party. If
the decision contradicts the guideline, we recommend that a memorandum be drawn up on the point and that it
be countersigned by the expert.
Externally undamaged power−steering gears that have to be exchanged are available as an exchange part.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Assessment of the steering of a vehicle involved in an accident 308

69 Safety regulations for vehicles with airbag and belt
tensioner
Note
Assembly and adjustment work
Handling airbag and belt tensioner
General information
Note
• As from model year 2002, the front three−point belt will be fitted with a belt tensioner as standard.
WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 1)
Please observe the following points:
• The airbag units are pyrotechnical items in hazard class T 1!

• Handling, transport and storage of these units must conform to the explosives legislation!
• The listed statutory requirements refer to the Federal Republic of Germany!
• The relevant valid regulations must be observed in all other countries!
• The commencement of work with pyrotechnical items must be reported 14 days in advance to the
Trade Supervisory Office (responsible authority)!
• Airbag units may only be dispatched in transport packaging officially approved for that purpose!
• Airbag units may not be transported with other hazardous goods!
• Internally, they must always be transported in the luggage compartment or cargo hold of a vehicle
using the above−mentioned transport packaging!
• They must not be transported in the passenger's compartment!
• Airbag units must be stored in accordance with the second ordinance of the explosives legislation!
• This ordinance stipulates that small quantities of materials and objects may be stored at certain
locations without special storage approval!
• According to the Explosives Storage Directive of August 1997, these quantities are max. 10 kg (net)
in a work room and max. 100 kg (net) in a storage room in the case of Class T 1 pyrotechnical items!
WARNING
• Airbag units must be kept in a locked place!

• When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by
inflation of the airbag units in the event of accidental ignition)!
• Airbag units must be stored in a dry place and must not be stored together with other hazardous goods
(varnishes, etc.)!
• Loose airbag units, referred to as airbag modules below, or airbag modules installed in a loose
steering wheel must never become the actual (physical) property of the customer!
• The possession of loose airbag modules not installed in the vehicle is not permissible in the private
sector!
• Airbag modules may become the property of the customer only when installed in the vehicle!
69 Safety regulations for vehicles with airbag and belt tensioner 309
einordnung
top of page
Assembly and adjustment work
DANGER
Danger of injury through malfunction of airbag system.
• Never drive with an unlocked triggering unit − airbag.

• As long as the airbag triggering unit is not locked, the warning light lights up continuously.
The triggering unit is locked with the Porsche System Tester.
WARNING
Please observe the following point:
• Inspection and assembly work may only be carried out by specialist staff
Before working on the airbag system and also when working on neighbouring parts where there is a risk
because live parts are close to the airbag system, always implement the following safety measures:
1. Remove ignition key.
2. Disconnect and cover the negative terminal of the battery.
WARNING
• Inspection and assembly work may only be carried out by specialist staff!
• After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar
tools may not be started until after a waiting period of 1 minute! This is necessary in order to interrupt
the power supply to the airbag system and to ensure it is not triggered accidentally!
• This is necessary in order to interrupt the power supply to the airbag system and to ensure it is not
triggered accidentally!
• Airbag units must be fitted immediately after being removed from their storage location!
• On no account may airbag units be left lying around unsupervised!
• If work is interrupted, airbag units must immediately be locked away again!
• Airbag units must not come into contact with grease, oil, cleaning agents or similar substances!
• Airbag units may not be exposed to temperatures above 90 °C!
• Airbag units and control units which have fallen from a low height may no longer be installed!
• No additional linings, stickers or similar may be attached to the steering wheel in the vicinity of the
passenger's airbag and side airbag!
• No changes may be made to the wiring and to the components of the airbag system!
• The battery must always be disconnected before starting straightening and welding work with an
electrical welding unit!
• Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials
• Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. ’ 0, 6901 Airbag diagnosis .
Assembly and adjustment work 310

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WARNING
• The control module must be removed in advance if you have to perform welding in the immediate
vicinity of the control module!
• Airbag components may not be repaired!
• Airbag components must always be replaced!
• Wash your hands after touching triggered airbag units!
top of page
Handling airbag and belt tensioner
Dangers for persons and the environment
Note
• Injury caused by incorrect triggering of the installed unit.
• Injury caused by spinning away e.g. of the entire unit.
• Burns caused by touching the hot surfaces of a triggered unit.
• Damage to hearing due to the explosion when gas is released.
• Irritation caused by breathing in explosive dust, especially in older models.
• Irritation due to skin and eye contact with slag produced by the explosion, especially in older models.
• Airbag/belt tensioner components should neither be opened or repaired; always use only new parts.
• Injury caused by incorrect triggering due to manipulation of the short circuit bridge.
Protective measures and rules of behaviour
Note
• Assembly work only by trained staff.
• Carry out tests only with the Porsche System Tester diagnostic module; do not use test lamps,
voltmeters or ohmmeters.
Handling airbag and belt tensioner 311

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• Do not bring into contact with grease, solvents or cleaning agents.
• Do not expose to temperatures above 100°C.
• Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel.
When carrying, hold the airbag with the blow−out direction facing away from the body. Store the unit
with the airbag facing upwards.
• Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials
• Do not remove the short−circuit spring of the plug contacts.
• Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. ’ 0, 6901 Airbag diagnosis .
• During installation/removal or work on the vehicle involving shocks: switch off ignition, disconnect
and cover the negative terminal of the battery, wait 1 minute and only then disconnect the plug
connection.
• Transport: in transport packaging. Forbidden in passenger compartment!
• Storage in the workshop: max. 10 kg (=> 100 driver's or 50 passenger's airbags); security against
theft!
• The installation of the airbag/belt tensioner unit must be carried out immediately after removal from
the transport container.
• If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again.
• Leaving the belt tensioner unit unsupervised is not permitted.
Behaviour in cases of malfunction or danger
Note
• Protect against flames and heat.
• In case of fire, inform the fire brigade on arrival about the units present.
• Do not install mechanically damaged units or units that have fallen from a low height.
• Always replace units that are mechanically damaged (bulges, cracks).
• Because of the irritating combustion residues, only handle triggered airbags with protective gloves
and goggles.
• In the case of contact with combustion residues, wash the affected skin with soap and water.
Protective measures and rules of behaviour 312

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• In the case of eye contact, wash the eyes with water.
Materials

Porsche work clothing Gr. 2.6; Workshop Equipment Manual
top of page
General information
The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled by
a warning light. The warning light for the airbag system lights up in the event of a fault. The airbag warning
light lights for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in
the fault memory. If it lights up again, this indicates a fault in the system. The fault can be read out with the
Porsche System Tester 2.
Note
• A period of 10 seconds is required to enable the triggering unit to identify all faults in the system!
• In order to guarantee that every possible fault source is checked during the vehicle test, the ignition
must be switched on for at least 10 seconds!
• The fault memory must be cleared following a fault in the airbag system and after it has been
remedied!
• The replacement of a component must be noted in the Guarantee and Maintenance booklet!
• To do this, attach the documentation number in a free panel intended for that purpose!
• The documentation number is attached to the replacement part as a tear−off sticker!
• Exchanged airbag units or airbag modules must be taken into possession by the Porsche Centre or by
a dealer authorised by Porsche and must not be handed over to the customer (customer has no right to
possess them). They must be destroyed, disposed of or returned to the manufacturer in accordance
with the explosives ordinance and the hazardous materials ordinance!
• When the steering wheel is exchanged, e.g. to install a steering wheel from the Tequipment product
range, the airbag unit of the replaced steering wheel must be removed and destroyed, disposed of or
returned to the manufacturer before the steering wheel is handed over to the customer!
Behaviour in cases of malfunction or danger 313

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Component exchange after airbag triggering
The following components must be removed and replaced after the airbag system is triggered:
After triggering of the airbag unit on the driver's side:
• Contact unit
• Airbag unit, driver's side
After triggering of the airbag unit on the passenger's side:
• Airbag unit, passenger's side

• Triggering unit after the third time the airbag is triggered
After triggering of the side airbag unit
• Side airbag unit

• Sensor for the side airbag unit after the third time the side airbag is triggered
After triggering of belt tensioner
After triggering of a belt tensioner, driver's and/or passenger's unit.

After triggering one or more air bag units (driver's, passenger's and/or side airbag).
• All belt tensioner units
Note
• Because it is difficult to visually determine if one or both belt tensioners has been triggered, check the
following points.
• Read out the airbag fault memory with the Porsche System Tester.
• Check plug connection on the belt tensioner for damage.
• Pull out the belt strap as far as possible and check for wear.
• Perform a function test on the automatic belt device.
996420, 996421, 996450, 996451, 996840, 996841
Component exchange after airbag triggering 314

87 Nominal values for pressures and temperatures
Note
General test prerequisites
Note
• The temperature of the air from the centre dashboard vents must lie within the prescribed tolerance
range within 5 minutes, depending on the ambient temperature!
top of page
General test prerequisites
Close doors, windows and sliding
roof.
Insert temperature probe into centre vent.
Measure ambient
temperature.
Open all dashboard vents.
Switch ignition
on.
Press circulation
button.
Set temperature control to maximum cooling.
Switch fresh−air blower to stage 4.
Start
engine.
Operate air condition while idling.
Set engine speed to 2000 rpm (start of time measurement).
Note
• If the prescribed nominal values are not reached, the cooling system must be checked for leaks and
repaired!
Centre vent temperature as a function of ambient temperature
87 Nominal values for pressures and temperatures 315

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High pressure in cold circuit as a function of ambient temperature
Low pressure in cold circuit as a function of ambient temperature
Centre vent temperature as a function of ambient temperature 316

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996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Low pressure in cold circuit as a function of ambient temperature 317

91 Retrofitting mobile communication systems
Note
Note
• Observe the installation specifications and recommendations listed in the operating instructions!
• When mobile phones and two−way radios are correctly installed, they are not influenced by important
vehicle systems such as e.g. ABS, airbag and Motronic!
• The installation and wiring of vehicle systems must not be altered!
• A wiring arrangement parallel to these systems and their wiring harnesses (especially sensor wires) is
not permitted!
In general, it is necessary to get approval for the installation of mobile communication systems (car telephone,
mobile phone, two−way radios, etc.) in a vehicle that received its type approval after 1st January, 1996.
Mobile two−way radios (telephones) that are retrofitted must have a type approval for this vehicle and be
identified with an 'e'. In the Driver's Manual of its vehicles, Porsche has approved mobile telephones and
two−way radios with a maximum transmission power of 10 W. Porsche permits the installation and operation
of two−way radios over 10 W for the radio services listed below under the following preconditions:
• The transmission powers in the given frequency range may not exceed the respective Pmax values at
the antenna base.
• The installation must be carried out correctly and a non−reflecting adapted external antenna must be
used.
• Always observe the operating and installation instructions of the manufacturer for mobile phones,
two−way radios and antennas.
Volume Pmax /Watt Permitted location of antenna

Short wave up to 54 MHz 50 (PEP) on vehicle outside
4m band 20 (eff.) on vehicle outside
2m band 50 (eff.) on vehicle outside
70 cm 50 (eff.) on vehicle outside
23 cm 20 (eff.) on vehicle outside
C−net 25 (eff.) on vehicle outside
D−net 20 (PEP) on vehicle outside
E−net 10 (PEP) on vehicle outside
Note
• If a mobile phone or two−way radio is retrofitted which does not conform to Porsche installation
conditions, the general certification of the vehicle can be rendered null and void (EU EMV Vehicle
regulation 95/54)!
91 Retrofitting mobile communication systems 318

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• In this case it is necessary to have EMV experts inspect the Porsche in order to observe the protective
goals!
• The optimum range of the two−way radios can only be reached with an external antenna!
• Excessive electro−magnetic fields can occur in the vehicle from the operation of mobile phones and
two−way radios without an external antenna or with an external antenna that is incorrectly installed
(or defective)! In this case, malfunctions of the electronic vehicle systems and damage to health
cannot be entirely ruled out!
• In general, a suitably chosen antenna location and a reduction of transmission power if necessary
ensure adherence to the limit values of the DIN VDE 0848 Part 2 (Protection of persons in a
frequency range of 30 kHz to 300 Ghz)!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
91 Retrofitting mobile communication systems 319

96 Additional alarm system M 536
Note
Removing alarm siren and tilt sensor
Note
• Vehicles for Great Britain and Belgium are equipped with an alarm siren and tilt sensor in addition to
the standard alarm system!
• M 590 (lid release locks) is also standard equipment in these vehicles!
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Removing alarm siren and tilt sensor
1. Remove cover for fluid reservoir (air conditioning).
2. Pull off connector on the alarm siren.
3. Pull off connector on the tilt sensor.
4. Undo
nut.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 Additional alarm system M 536 320

97 Measurement of closed−circuit current
Tools
Preparations on the vehicle
Measurement
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Tools
Closed−circuit current should be measured using an analog ammeter or a digital multimeter with a long
integration time (to filter out voltage peaks).

−1− Multimeter 155 Gr. 2.5; Workshop Equipment Manual
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Preparations on the vehicle
Note
• Before measuring the closed−circuit current, determine the vehicle equipment (M−numbers) and
establish the expected closed−circuit current with the aid of the attached table. => Measurement
1. Open the front luggage compartment.

2. Close the lower part of the lock of the luggage−compartment lid with a suitable tool − e.g.
upper part of the lock with a suitable grip − with the luggage−compartment lid open.
3. Remove the ignition key and lock the vehicle with the key (alarm system is
activated).
Connecting measuring device
1. Set the measuring device to the highest possible current measuring

device.
2. With two alligator clips, connect the measuring instrument to the battery ground and to the second body
97 Measurement of closed−circuit current 321

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ground which is always available for RHD or LHD versions.

3. Remove ground strap from the body and secure against contact with the body. The on−board current now
flows via the ammeter.
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Measurement
• Select a measuring range which ensures that the pointer of the instrument is in the upper third of the
scale, as far as possible. Switch over measuring range without interruption. Read off the measured
values only after the waiting period specified in the table.
• Do not switch on any electrical consumers during the measurement (open central locking system,
etc.).
Note
• If the value of the closed−circuit current is higher than the value determined in the table, the cause
must be established.
• The recommended procedure for troubleshooting: With the measuring device connected, pull off the
fuses of terminal 30 and the relays successively. When disconnecting, observe the display values of
the measuring device to detect a reduction in current.
• After troubleshooting, screw the ground strap back on to the body in the proper manner.
• The measured values may deviate by approx. 20%.
• The values listed in the table depend on the condition of the battery, the ambient temperature and the
engine temperature.
Reading off the measuring range:
• Read off the measuring range only when at least 61 minutes have passed since the vehicle was locked.
From To mA
0 min. 5 min. Up to approx. 950
61 min. Until battery empty Up to approx. 30
Closed−circuit current in
Control module Equipment mA
Generator Standard 0.5
DME Standard 0.3
Instrument cluster Standard 1.4
Immobilizer/central locking Standard 13
Connecting measuring device 322

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Passenger compartment monitoring/tilt sensor M No. 534 6.6

Power windows, front Standard 1.1
Tiptronic* M No. 249 0.4
ABS Standard 0.1
PSM 0.1
Radio 1.0
CD changer M No. 692 0.8
Amplifiers, audio M No. 490 0.3
Navigation information system M No. 662 1.2
Navigation computer 0.7
PCM2 as from MY '03 2.8
Telephone as from MY '03 0.2
Both seat memeories M No. 537 1.6
Climatronic M No. 573 0.03
Standard production vehicle Total Approx. 19

Additional equipment Total Approx. 12
Maximum equipment Total Approx. 31
Note
• * After prior disconnection of the battery, terminal 15 must have been connected to the control
module at least once.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Measurement 323
27 06 Battery
Note
Battery − handling notes
Removing and installing battery
Remove battery
Install battery
Visual inspection
Check acid level
Checking gravity of electrolyte
Open−circuit voltage measurement
Battery load test
Charging battery
Note
• To prevent contact corrosion, only approved screws, nuts, discs etc. should be used. These elements
have a special surface coating and must be stored separately.
The battery is one of the most important electrical components in the vehicle. Fault−free functioning of the
battery contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery must
be checked and maintained according the versions in this chapter.
Besides the start function, the battery also has the tasks of buffer and supplier of electrical energy for the
entire vehicle electrical system.
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Battery − handling notes
Note
• Battery terminals should not be greased.
• The battery terminal clamps should only be attached without force to prevent damage to the battery
housing.
• The tightening torque for the battery clamps is 5 Nm (4 ftlb.).
• If the battery is to be reconnected, proceed according to ’ 9 work instructions after disconnecting the
battery .
• To guarantee that the battery does not leak, it is necessary that the original plug accompanying the
battery is screwed into the battery openings.
• In the case of loss or damage, only original plugs of the same design should be used.
• The plugs must be fitted with an o−ring seal.
27 06 Battery 324
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Warning notes and safety regulations for hydrocyanic acid batteries
1. −1− Fire, sparks, naked flames and smoking are forbidden:

Avoid sparking when using cables and electrical devices
Avoid short
circuits.
In batteries with central venting, there is an increased detonating gas concentration. The vent hose should
not be bent or blocked by dirt.
2. −2− Wear eye protection
3. −3− Keep children away from acids and
batteries.
4. −4− Danger of causticization:
Battery acid is highly caustic, therefore wear protective
gloves.
Do not tip battery, acid can emerge from the venting opening.
Note
• First aid: Rinse acid splashes to the eyes immediately with clear water for a few minutes. Consult a
doctor immediately. Neutralise acid splashes to the skin or clothing immediately with soap suds and
rinse again with plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
5. −5− Observe information on the battery, in the Technical Manual and in the Driver's
Manual.
6. −6− Danger of explosion:
A highly explosive detonating gas mixture occurs when charging batteries.
7. −7−
Disposal:
Hand in old batteries at a collection point.
8. −8− Never dispose of old batteries in the domestic rubbish!
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Removing and installing battery
Note
Warning notes and safety regulations for hydrocyanic acid batteries 325
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• The battery is located in the radiator tank.
• All loads must be switched off beforehand! Remove ignition key!
• The battery terminal clamps should only be attached without force to prevent damage to the battery
housing.
• Battery terminals should not be greased.
• Check that the battery is seated correctly after installation. Other dangers exist with a loose battery
such as: − Reduced service life due to vibration damage. − Damage to the grid plates of the battery. −
Damage to the battery housing through the retaining bracket (possible acid leak, high subsequent
costs). − Inadequate crash safety.
Functioning of central venting
Note
• Batteries of the latest state of the art are fitted with central venting.
• The gas occuring during the charging, emerges centrally through an opening on the upper cover side.
The backfire protection is integrated into the same position which prevents the ignition of the
combustible gas present in the battery.
• In batteries with hose/pipe for the central venting, ensure that the hose is not disconnected. Only then
can the battery be freely vented.
• In batteries without a hose/pipe for the central venting, ensure that the opening is not blocked on the
upper cover side of the battery.
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Remove battery
1. Switch ignition off and remove ignition key.
Removing and installing battery 326

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2. Open turn−lock fasteners −A− .

4. First disconnect the ground strap of the battery on the negative battery terminal. Unscrew hexagon
nut and remove terminal.
5. Undo hexagon nut on the positive battery terminal and remove terminal.
6. Pull off vent hose −A− and fix in a suitable position with insulating
tape.
7. Unscrew fastening screw −B− .
8. Remove
battery.
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Install battery
Note
• => Removing and installing battery
1. Insert
battery.
2. Screw in fastening screw −B− , position battery and tighten the fastening screw. Tightening torque:
Remove battery 327

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23 Nm (17 ftlb.)
3. Push on vent hose −A− .
4. First connect the positive cable then the negative − otherwise there is a danger of a short−circuit!
Tightening torque: 5 Nm (3.5 ftlb.).
5. Put on the battery cover and lock with the turn−lock fasteners.
6. ’ 9 Carry out work instructions after disconnecting the battery.
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Visual inspection
Before measurements such as open−circuit voltage, gravity of electrolyte or the battery load test are carried
out, a visual inspection of the battery must be performed.
Through this check, it can be determined:
• Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
• Whether the battery terminal (battery line connections) is damaged. Contact of the line connections
cannot be guaranteed if the battery terminal is damaged. This can cause a line fire and malfunctions in
the electrical system.
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Check acid level
CAUTION
The accident prevention regulations must be observed when handling battery acids.
Wear suitable protective clothing and protective glasses.
Only illuminate the inside of the battery with a torch.
Never illuminate the inside of the battery with a naked flame.
Do not handle a naked flame or lit cigarettes near batteries.
Observe the disposal regulations for batteries when disposing of batteries and sulphuric acids.
Note
• Use a commercially available battery filling bottle.
• The correct acid level of the battery is an important factor for long and efficient operation of the
battery.
• When the acid level is too low, a capacity loss (performance loss) of the battery occurs which is
caused by the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid),
it will lead to corrosion of the lead plates, the plate bridges and the cell connectors. The result of the
corrosion is that battery functioning cannot be guaranteed. The battery will become useless.
• If the acid level is too high, damage can occur by the battery acid leaking out (sulphuric acid water
mixture) outside the battery.
Install battery 328

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3. Unscrew battery plugs.
4. Shine a torch into the battery. The electolyte level of the battery must be at the protruding lug .
If the acid level is too low, refill distilled water using the battery filling bottle.
5. Screw in plug of the battery again and ensure that it is seated correctly.
6. Remount battery cover.
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Checking gravity of electrolyte
CAUTION
The accident prevention regulations must be observed when handling battery acids.
Wear suitable protective clothing.
Observe the disposal regulations for batteries when disposing of batteries and sulphuric acids.
Note
• Use commercially available battery acid tester. Gr. 3.0.6; Workshop Equipment Manual
• The electrolyte gravity test provides information about the state of the battery in connection with the
battery load test
• The temperature of the battery acid must be at least 10°C .
The gravity of electrolyte must be checked in all battery cells as follows.

2. Unscrew all battery plugs (plugs of the battery cell).
3. Dip the acid siphon or the pipette into the battery cell and take up the battery
acid.
4. Read off the gravity of electrolyte in kg/dm³ on the scale of the battery acid tester and compare with
the following table.
Battery charging condition in Spec.
normal climatic zones gravity in
kg/dm³
discharged 1.12
half charged 1.20
well charged 1.28
Check acid level 329

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Battery charging condition in Spec. gravity

tropical climatic zone (hot in kg/dm³
countries)
discharged 1.08
half charged 1.16
well charged 1.23
The gravity of electrolyte must be at least 1.24 kg/dm³.

If the gravity of electrolyte is too low, charge battery.
After charging the battery, repeat the electrolyte gravity
test.
The measuring values for the gravity of electrolyte of the individual battery cells should not deviate by more
than 0.03 kg/dm ³ from eachother.
Examples of non−permissible specific gravity of electrolyte deviations:

Battery cell: 1 2 3 4 5 6
Gravity of electrolyte per cell in kg/dm³
Example 1: 1.24 1.25 1.25 1.10 1.24 1.25
Example 2: 1.26 1.26 1.25 1.14 1.18 1.24
Example 1: The gravity of electrolyte in cell 4 is too low.

Example 2: The gravity of electrolyte in cells 4 and 5 is too low. The specific gravity of electrolyte deviations
between the battery cells is larger than 0.03 kg/dm³.
If the nominal values are not achieved, replace battery.
If the nominal values are achieved, screw in the original plug again.
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Open−circuit voltage measurement
Note
• Use a hand−held multimeter to measure the battery voltage. Gr. 2.5; Workshop Equipment Manual

2. Disconnect ground strap on the battery.
Note
• After charging and a waiting time of at least 2 hours during which the battery should neither be loaded
or charged.
3. Measure the battery voltage with a hand−held

multimeter.
The battery open−circuit voltage should not fall below 12.5V.
If the hand−held multimeter shows 12.5V or over, the battery voltage is
OK.
Checking gravity of electrolyte 330

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If the hand−held multimeter shows a battery voltage below 12.5V: Charge battery.
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Battery load test
Note
• The electrolyte gravity test provides information about the state of the battery in connection with the
battery load test.
• A battery test device is required for the load test. Gr. 3.9.1; Battery test charge device, Workshop
Equipment Manual.
• The battery must not be removed or disconnected.
• The battery must be charged before the load test is performed.
Carry out battery load test:

2. Observe the information in the operating instructions of the battery test
device.
3. Connect the pliers of the test lines to the battery terminal as described in the operating instructions
of the test device.
As the load current varies, the current must be set depending on the battery capacity (operating
instructions of test device).
The load test currents can also be referred to in the following tables.
4. Carry out the battery load test according to the operating instructions and compare to the test result of the
following tables.
A minimum voltage is determined by the battery load test depending on the specified battery voltage.
Table:
Battery capacity: 80Ah
Cooling test current 380A
Load current 300A
Minimum voltage (limit value) 9.5V
5. If the minimum voltage is not attained, replace battery.

Remarks on battery load test:
• The battery voltage sinks during this test due to the severe load on the battery.
• If the battery is in order, the voltage value only reduces to the minimum voltage.
• If the battery is faulty, the battery voltage will sink very quickly below the specified minimum
voltage.
• After the test has taken place, the low voltage value remains over a long period of time, the voltage
increases again slowly.
Open−circuit voltage measurement 331

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Charging battery
WARNING
The battery plugs must always be screwed in correctly when charging and during the voltage measurement
and the load measurement.
Rooms in which batteries are being charged, should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
Note
• A battery charging device is required. Gr. 3.9.1; Battery test charge device, Workshop Equipment
Manual.
• Observe charging device operating instructions.
• The battery must have a minimum temperature of 10°C.
• Do not charge batteries too quickly if possible as they can be damaged in this way.
• If totally discharged batteries are charged quickly, they will not take up a charge current or they will
be indicated too early as being full by the so−called surface charge .
1. Switch off battery charging device.

3. First disconnect the ground strap of the battery, then the positive battery
terminal.
4. Connect positive line of the battery charging device to the positive terminal of the
battery.
5. Connect negative line of the battery charging device to the negative terminal of the
battery.
6. Set the charge current on the battery of the charge device according to the battery capacity.
7. Switch on battery charging device.
Procedure for loading totally discharged batteries:
• Batteries which are not in operation for a long period of time, discharge.
• A battery is totally discharged if the open−circuit voltage has sunk below 11.6V. => Open−circuit
voltage measurement
• In totally discharged batteries, the battery acid (sulphuric acid water mixture) consists of virtually
only water, as the sulphuric acid proportion is considerably reduced.
• Totally discharged batteries sulphatise, i.e. the entire plate surface of the batteries harden.
• If totally discharged batteries are immediately recharged after an exhaustive discharge, the
sulphatisation recedes again.
• If these batteries are not recharged, the plates continue to harden and charge take−up ability is limited.
A reduction in the battery performance is the result.
• Totally discharged batteries must be charged with a low charge current as follows:
Battery load test 332

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Set charge current at maximum 5% of the battery capacity, ie. with a 80 Ah battery the charge
current is a max. 4 A.
8. Charge
battery.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Charging battery 333

27 06 Electrical emergency release, front cover
Note
Emergency release, front cover
Note
• In the event of a flat battery, the release engines of both covers can be supplied with electricity, via a
battery jump lead.
• A red marked emergency power unit is located on the fuse box in the driver's footwell.
• This emergency power contact can be pulled approx. 3 cm out of the fuse box, on which the plus side
of the auxiliary lead is connected.
• The transferring of the electricity supply to the release motors is carried out by a change−over relay
(mini relay), located on the rearside of the fuse box.
• Should the door be locked (alarm protected), an alarm would sound if somebody attempted to connect
the auxiliary lead.
• Turn off alarm system by locking and then unlocking the door.
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Emergency release, front cover
1. Unlock the vehicle at the door with the key.
2. Remove cover on the fuse box and pull emergency power contact out of the fuse box.
3. Connect red auxiliary wire (positive) onto this

contact.
27 06 Electrical emergency release, front cover 334

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4. Connect second auxiliary wire (negative) onto the vehicle ground (e.g. onto the lock bar of the B−pillar).
5. Connect auxiliary wire to an appropriate electricity source (e.g. separate vehicle battery).
6. Actuate the cover switch on the side member panel and open the
cover.
7. Disconnect auxiliary wire and push the emergency power contact back in.
8. Clip cover back onto the fuse box.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Emergency release, front cover 335

40 09 Front−axle cross member − permissible
combinations
New front−axle cross member − as of model '02
Allocating the front−axle cross member to the body
top of page
New front−axle cross member − as of model '02
• As of model '02, the front−axle cross member is attached to the body at the rear fastening with two
screws −arrows− . Up to this point (up to the end of model '01), only one screw was used for
fastening.
• The tightening torque has not been changed.
• The previous front−axle cross member −F1− , with one fastening screw securing it to the body (per
side) is still available as a spare part.
• Only certain combinations of front−axle cross member attachment −F1 or F2− to the body are
permitted!
F2 2 fastening points (as of model '02)

F1 1 fastening point
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Allocating the front−axle cross member to the body
CAUTION
Material damage will result in the area of the axle mount/axle fastening due to reduced strength, if correct
allocation is not observed!
• Only install permissible combinations of front−axle cross member to the body (standard
construction)!
• Do not install front−axle cross members with one fastening screw (F1) in vehicles with two body
mounting points (K2)!
40 09 Front−axle cross member − permissible combinations 336

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Impermissible combination
Front−axle cross member with one fastening bore −F1− and body with two fastening points −K2− .
• Attention: Impermissible combination!
Permissible combinations
Front−axle cross member with one fastening bore −F1− and body with one fastening point −K1− .
• Standard construction up to end model '01.
Front−axle cross member with two fastening bores −F2− and body with two fastening points −K2− .
• Standard construction as of model '02.
Impermissible combination 337

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Impermissible combination
The combination − front−axle cross member with two fastening bores and (F2) and body with one fastening
point (K1) − is not possible!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Impermissible combination 338

40 Disassembling and assembling front spring strut
Tools
Disassembly and assembly instructions
top of page
Tools
Item Designation of Explanation

the special tool
Spring clamp Commercially available in accordance with Technical Equipment Manual,
Chapter 2.4, No. 12. Clamping range of spring holder up to 165 mm spring
diameter on one side and 195 mm spring diameter on the other side.
40 Disassembling and assembling front spring strut 339

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No. Designation Qty. Removal Installation

1 Fastening nut 1 Before loosening the fastening nut, Use new fastening nut. Tighten
M 14 x 1 tension coil spring with the spring to 80 Nm (59 ftlb.).
clamp. Counter at the piston rod
when loosening the nut.
2 Stop plate 1 Mount in correct position (No. 2
and No. 7 are identical parts).
3 Spring strut mount 1 The "RI" or "LE" code for the
right or left side respectively is
stamped on the top of the spring
strut.
4 Back−up ring 1
4A Mount 1 Remove the mount from back−up Make sure it is seated properly
ring No. 4 only when replacing the in the back−up ring No 4.
mount (Lever out mount with a
small screwdriver).
Tools 340
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5 Spring plate 1 Observe allocation as per Spare

(compensation Parts Catalogue.
part)
6 Coil spring 1 Observe allocation as per Spare
Parts Catalogue.
7 Stop plate 1 Mount in correct position (No. 7
and No. 2 are identical parts).
8 Cup washer 1 Mount in correct position.
9 Additional spring 1 Mount on protective bellows
(No. 10)
10 Protective bellows 1
11 Nut 1 Tighten to 10 Nm (7.5 ftlb.).
12 Screw 1 The screw must be fitted in the
direction of travel.
13 Spring seat 1 Loosen spring seat from the Right and left side are different
vibration damper only when (the cast number is stamped on
replacing it. the bottom of the spring seat.) A
cast lug is located on the left
spring seat. The spring seat must
be centred on the vibration
damper.
14 Washer 1 The washer is inserted in the
spring seat.
15 Vibration damper 1 Observe allocation as per Spare
Parts Catalogue.
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Disassembly
CAUTION
Danger of injury due to spring tensioning!
• Never use an impact bolter to loosen or tighten the fastening nut!

• Use commercially available changeover ratchet!
Note
• When installing new parts, observe the allocation according to the Spare Parts Catalogue!
• To undo the connection − piston rod to spring strut mount − counter at the piston rod with countering
tool 9630 or a 7−mm Allen key.
Disassembly and assembly instructions 341

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1. Tension the coil spring with the spring clamp until the piston rod is
relieved.
2. Remove all parts from the piston rod.
Note
• Disassemble back−up ring −4− and mount −4A− only in the case of replacement.
3. Lever out the mount with a small screwdriver.
Distinguishing feature of coil springs and dampers
A Identification of the running gear version (spring constant/spring length) by two different coloured lines
(for example, 1 x blue and 1 x white). Refer to the Parts Catalogue for the allocation.
B Identification of the coil spring tolerance group (load group) for determination of the compensation part
(spring plate) thickness.
1 white line = 3.0 mm thick compensation part
1 green line = 6.5 mm thick compensation part
C Colour dot (colour label) to differentiate the damper identifier.
Preliminary work and notes on assembly
Note
• Observe the correct allocation (running gear version) when installing new springs and/or dampers!
• It is recommended to replace the coil springs only in pairs!
Disassembly 342
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• If the coil springs are exchanged, it might be necessary to use a different spring plate than before!
1. Replace nut for fastening the piston rod on the spring strut mount.
The following spring plates (compensation parts) are available:
1 white line = 3.0 mm thick compensation part
1 green line = 6.5 mm thick compensation part
2. Complete mount −4A− , back−up ring −4− and spring plate −5− (compensation part).
3. Fit protective bellows on additional spring.
4. Tension coil spring with spring clamp.
Assembly
CAUTION

If the vibration damper has been replaced or the spring seat loosened, align the appropriate spring
seat in the centre before tightening. The spring seat fastening screw must be installed in the
direction of travel when doing this.
Note
• Space constraints and the position of the stabilizer mount are decisive factors. The stabilizer mount
must be free of tension at complete right and left stops (ball heads still movable)!
• After the spring strut is installed, the position of the spring seat must be checked again and may need
minor adjustment!
Preliminary work and notes on assembly 343

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• Spring seats for the right and left sides are different! The distinguishing feature of the spring seat is a
cast lug on the left spring seat! Also, a different cast number is stamped on the bottom of the spring
seat!
Example:
996 343 508 02 even number for right side.
996 343 507 02 odd number for left side.
1. Slide the protective tube/additional spring assembly onto the piston rod.
2. Slide the cup washer −8− and stop plate −7− as far as they will go into the correct position on the piston
rod.
Vibration damper
3. Place pre−tensioned coil spring on the vibration damper.

4. Place the mount/back−up ring/spring plate assembly on the coil spring.
Note
• The "RI" or "LE" code and a positioning arrow for installation in the correct position in the vehicle
are stamped on the top of the spring strut mount −arrow− !
5. Place the left or right spring strut mount on the left or right section accordingly.
6. Place stop plate in the correct position on the spring strut mount and screw a new fastening nut onto the
piston rod.
Assembly 344
einordnung
Note
• Use a socket wrench insert open on one side to tighten the fastening nut on the spring strut mount! In
this way the specified tightening torque can be adhered to exactly! It is also possible to counter at the
piston rod with countering tool 9630 at the same time!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Assembly 345
42 71 Disassembling and assembling rear spring
strut − Turbo
Tools
Disassembling and assembling rear spring strut
top of page
Tools
Item Designation of the tool Remarks

Spring clamp (e.g. from Klann) Commercially available, clamping range of spring holder up
with spring holder to 165 mm spring diameter
top of page
Disassembling and assembling rear spring strut
42 71 Disassembling and assembling rear spring strut − Turbo 346

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1 Fastening nut 1 Before loosening the fastening nut, Use new fastening nut. Tighten to 58
M 12 x 1.5 tension coil spring with the spring Nm (43 ftlb.). First position
clamp. spring−strut mount 3.
Support at the piston rod with an
open−ended wrench (7 mm) when
loosening the nut.
2 Stop plate 1 Mount in correct position.
No. 2 and No. 6 are identical parts.
3 Spring strut 1 Remove complete assembly (mount The mounts for the right and left
mount with intermediate part No. 9 and sides are identical parts.
spring plate No. 10). Position the mount before tightening
the fastening nut No. 1.
4 Intermediate part 1 Observe allocation.
(compensation Join in correct position with spring
Disassembling and assembling rear spring strut 347

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part) plate No. 5.

5 Spring plate 1
6 Stop plate 1 Mount in correct position (No. 2 and
No. 6 are identical parts).
7 Washer 1
8 Additional 1 Mount on protective bellows (No. 9)
spring
9 Protective 1
bellows
10 Coil spring 1 Observe allocation as per Spare
Parts Catalogue.
11 Vibration 1 Observe allocation as per Spare
damper Parts Catalogue.
The vibration dampers for the right
and left sides are identical parts.
12 Spring plate, 1 Fit in correct position (groove facing
bottom snap ring).
13 Snap ring 1 Ensure perfect seating.
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Disassembly
CAUTION

Note
• Observe the correct allocation (running gear version) when installing new springs and/or dampers!
• It is recommended to replace the coil springs only in pairs!
• If the coil springs are exchanged, it might be necessary to use a different spring plate than before!

einordnung
1. Tension the coil spring with the spring clamp until the piston rod is
relieved.
2. To undo the connection (piston rod to spring strut mount) counter at the piston rod with a 7mm
open−ended wrench.
4. Replace nut for fastening the piston rod on the spring strut mount.
Preliminary work and notes on assembly:
The following spring plates (compensation parts) are available:
Allocation of the spring plate according to the coil spring tolerance group.
1 green line = 4.0 mm thick compensation part (coloured black)
1 white line = 0.5 mm thick compensation part (natural colour)
5. Press intermediate part (compensation part −4− ) into the spring plate −5− in the correct position (not
twisted) and complete with the mount −3− . Observe following note!
Note
• In the correct position means: None of the 7 cutouts −A− must be free on the spring plate −5− !
Disassembly 349
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6. Fit protective bellows on additional spring.
Distinguishing feature of coil springs and dampers
A Identification of the running gear version (spring constant/spring length) by two different coloured lines
(for example, 1 x gold and 1 x red). Refer to the Parts Catalogue for the allocation.
B Identification of the coil spring tolerance group (load group) for determination of the compensation part
(spring plate) thickness. Coil spring with:
1 green line = 4.0 mm thick compensation part (black)
1 white line = 0.5 mm thick compensation part (natural colour)
C Colour dot (colour label) to differentiate the vibration damper. For the Turbo, there is a variant for the
USA and a variant for the RoW. Vibration damper with:
Golden colour dot = RoW running gear
Red colour dot = USA running gear
1. Tension coil spring with spring clamp.
2. Clamp eye of vibration damper in the vice (use jaw liners).
Assembly
CAUTION

1. Place pre−tensioned coil spring on the vibration damper.

2. Slide the protective tube/additional spring assembly onto the piston rod.
Distinguishing feature of coil springs and dampers 350

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3. Slide the washer −7− and stop plate −6− (No. 6 in correct position) as far as they will go onto the
piston rod.
4. Place the spring strut mount (assembly of spring strut mount / intermediate part / spring plate) onto
the piston rod so that the end of the coil spring lies against the stop of the spring plate.
5. Place stop plate in the correct position on the spring strut mount.
6. Screw new fastening nut onto the piston rod until approx. 1 to 2 threads are visible above the
fastening nut.
Note
• The mounts for the right and left sides are identical parts!
Assembly 351
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• The mount is positioned correctly if one of the 3 fastening pins is aligned with the holder on the
damper tube!
7. Position the spring strut mount for installation (correctly position spring strut mount with respect to
the damper).
8. Tighten the fastening nut once the mount has been correctly positioned and the coil spring lies properly
against the stop. Tightening torque 58 Nm (43 ftlb.).
• Never use an impact bolter to tighten the fastening nut!
9. When tightening the fastening nut, hold at the piston rod using a special tool 9630 countering tool
or a 7 mm open−ended wrench.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Assembly 352
44 27 Instructions for collapsible wheel/spare wheel −
Turbo with PCCB
Mounting collapsible spare wheel − Turbo with PCCB
Placing collapsible spare wheel in to the vehicle − Turbo with PCCB
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Mounting collapsible spare wheel − Turbo with PCCB
Note
• The collapsible wheel is mounted at the front or rear axle wheels using the standard wheel bolts −A−
M14 x 1.5 (length 45 mm) dimension −X− !
WARNING
Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of injury and material damage through
impaired brake function exists if brake discs are damaged during the mounting/removal of wheels.
• Use assembly pins in order to exclude any possibility of heavy contact of the wheel with the brake
disc.
Screw the two enclosed assembly pins, instead of two wheel bolts, into the wheel hub before
wheel removal/mounting. During removal, first remove the three remaining wheel bolts and
remove the wheel carefully, without touching the brake discs.
Note
• The assembly pins can be ordered separately as a spare part! Part Nos.: 999 571 074 30.
44 27 Instructions for collapsible wheel/spare wheel − Turbo with PCCB 353

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top of page
Placing collapsible spare wheel in to the vehicle − Turbo with
PCCB
1. After using the collapsible spare wheel, release the air by unscrewing the valve
case.
Note
• It takes several hours for the tyre to resume its original form! It can only be stowed in the spare wheel
recess in the luggage compartment after it has resumed its initial form!
2. After releasing the air, fasten the tension straps lying opposite. To this purpose, pull the straps through the
rim and place around the tyre. Position the straps in such a way that the strap fastenings are on the inner
side of the rim.
3. Close the strap fastenings −arrow− . Retighten straps when necessary.

4. Stow the collapsible spare wheel in the spare wheel recess so that the tension straps lie to the front and to
the rear.
Note
• The collapsible spare wheel may only be repaired by the manufacturer.
• In the case of vehicles with PCCB, the spare wheel cannot be stowed in the spare wheel recess
without securing it with the tension straps!
• The loops on the tension straps simplify the removal of the collapsible spare wheel or its placement in
the vehicle.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Mounting collapsible spare wheel − Turbo with PCCB 354

45 60 Steering angle sensor
Calibrating steering angle sensor
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WARNING
Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated
incorrectly!
• Calibrate the steering angle sensor with the wheels in straight−ahead position!
Note
• A steering angle sensor is attached to the steering column/steering shaft for the PSM (Porsche
Stability Management)! PSM is standard in the 911 Turbo (996)!
• The steering angle sensor supplies information about the slip angle of the front wheels to the PSM
control module (intention of driver in relation to direction of travel)!
Steering angle sensor position
The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction
of travel must be programmed. This is done by calibrating with the Porsche System Tester 2 with the wheels
in straight−ahead position.
The steering angle sensor must be calibrated after:
1. A new steering angle sensor has been

installed,
2. The PSM control device has been
exchanged,
3.
45 60 Steering angle sensor 355

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The steering gear and / or components which change the zero position of the steering angle sensor
have been exchanged,
4. Accident
repairs,
5. Suspension alignment procedures during which the previous wheel alignment values were changed.
WARNING
Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated
incorrectly!
• Calibrate the steering angle sensor with the wheels in straight−ahead position!
Note
• Check the steering angle sensor actual value with wheels in straight−ahead position before calibrating
the steering angle sensor! Only recalibrate the steering angle sensor on the measuring platform if the
steering angle actual value lies outside the tolerance or is doubtful!
1. Drive vehicle onto measuring platform. Affix measured−value pickups to all wheels.
2. Check wheel alignment values and adjust if necessary. If the wheel alignment values on the front and rear
axles are correct, calibrate the steering angle sensor with the front wheels in straight−ahead position.
Calibration description in following text.
3. Select the "Calibrate steering angle sensor" menu with the Porsche System Tester 2 in the PSM
system. Entry to the PSM system takes place through the ABS system (automatic status change after
PSM).
4. Confirm calibration start. The procedure can also be interrupted.
5. Vehicle wheels in straight−ahead position.
Note
• This safety code must be extracted in the Actual Values menu, Safety Code sub−menu! The safety
code changes automatically each time provided that PSM is called up again!
• The calibration procedure will be interrupted if an incorrect safety code is entered! This
time−consuming procedure ensures that the steering angle sensor is not calibrated unintentionally!
• The steering angle sensor can be calibrated several times! The value (the zero position) is stored in the
steering angle sensor itself!
6. The PST 2 now requests the 4−digit safety code shown in the display.
7. Input the 4−digit safety code with the cursor keys (4 centre keys on right). Then continue with the (>>)
key.
Note
The steering angle sensor must be calibrated after: 356

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• The final possibility to interrupt the calibration is not to confirm the safety code input! To do this,
press the appropriate function key for no!
8. Confirm safety code input. Display in the Tester display after the safety code input has been confirmed:
Steering−angle sensor being calibrated.
For safety reasons, read out the current steering angle sensor actual value after calibration. To do this:
9. Leave the PSM system. Then call up PSM again and select the steering angle sensor in the Actual
values menu. Required display in the Tester display: 0° ± 3° when the wheels are in straight−ahead
position.
10. Repeat the calibration if the value is not correct.
Check the steering angle sensor actual value in the following cases:
1. Suspension alignment when no change has been made to the wheel alignment values.
2. As a check after steering angle sensor calibration.
Checking the steering angle sensor actual value
1. Connect the Porsche System Tester 2 to the diagnostic socket.

2. Select vehicle type and then enter PSM system. Entry takes place through the ABS system
(automatic status change after PSM).
3. Select steering angle sensor in the Actual values
menu.
4. Required display in the Tester display with wheels in straight−ahead position 0° ± 3° .
5. If the steering angle sensor actual value deviates or is doubtful, recalibrate the steering angle sensor on the
measuring platform.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Calibrating steering angle sensor 357

66 72 Assignment of spoiler drive, relays and
instrument cluster
Note
Variants of the spoiler drive
Note
• In the case of the 911 Turbo (996), it is essential when replacing the spoiler drive, the relay no. 9 or
the instrument cluster to note that only the variants listed in the table below can be installed together.
• Relay no. 9 is located on relay carrier 2.
• Variant 1 concerns the series launch vehicles up to production date 02.05.2000. This variant can no
longer be installed. If the drive module is defective, a variant 2 module must be installed.
• Variant 2 concerns the vehicles as from production date 02.05.2000 up to the model change 2002.
Instrument clusters with the index 01 can be installed as replacements for instrument clusters with
index 00. Instrument clusters with index 02 are not suitable for replacing instrument clusters with
index 01.
• Variant 3 as from model '02.
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Variants of the spoiler drive
Version Current no. of Rear spoiler Relay No. 9, Instrument cluster

the rear spoiler drive module extend spoiler
drive module
1 00253 to 00750 996.512.241.00 996.615.102.00 996.641.213.00 FFF to
(not spare part) 996.641.218.00 FFF
2 From 00751 to 996.512.241.01 996.615.122.00 996.641.213.00 FFF to
model '02 996.641.218.00 FFF
996.641.213.01 FFF to
996.641.218.01 FFF
3 As from '02 996.512.241.01 996.615.102.00 996.641.213.02 FFF to
model 996.641.218.02 FFF (instrument
cluster with integrated shut−down
delay for rear spoiler)
996420, 996421, 996450, 996451
66 72 Assignment of spoiler drive, relays and instrument cluster 358

69 59 Disposal of airbag and belt tensioner units
Note
Safety measures when igniting airbag units
Tools
Connecting ignition tool
Ignition
Note
• Country−specific statutory regulations and legislation based on them which go beyond these
instructions must always be observed and take precedence over these instructions!
• As from model year 2002, the front three−point belt will be fitted with a belt tensioner as standard.
WARNING
• Before disposal, the airbag units must be rendered harmless by electrical ignition and while observing
all precautionary measures, thereby preventing them being used incorrectly!
Note
• Airbag units are pyrotechnical items and can pose an environmental hazard!
• For this reason, non−ignited airbag units or entire vehicles must not be disposed of as normal scrap,
refuse or in other final storage facilities.
• If the vehicle had suffered fire damage which caused one or several airbags or the belt tensioner to be
ignited, additional ignition with the ignition device 9257 must be carried out in order to ensure that
only parts without pyrotechnical contents are scrapped!
• In the case of airbag units which cannot be ignited or if the conditions for safe ignition are
insufficient, always return the airbag units to Porsche or the respective importer in their original
packaging!
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Safety measures when igniting airbag units
WARNING
69 59 Disposal of airbag and belt tensioner units 359

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• Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible
person!
• Other normal accident prevention regulations must also be observed!
• Ignite airbag units only in their securely installed, original condition!
• Carry out ignition only in suitable, free areas!
• Use only the ignition tool intended for that purpose!
• All loose objects must first be removed from the expansion area of the airbag!
• Persons possibly affected must be informed of the resulting noise beforehand!
• Use ear protectors!
• Maintain a safety distance by utilising the entire cable length of the ignition tool!
• Do not connect the voltage source until all other preparations are complete!
• Choose a place in front of the vehicle. This also applies to persons not involved!
• Perform ignition with the doors closed and the side windows open!
• Do not approach the vehicle until after a waiting period (approx. 3 minutes) if ignition fails!
• Allow airbag units to cool down under observation following ignition!
• Avoid skin contact with ignited airbag units!
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Tools
Ignition cable for belt tensioner
Item Designation Special tool Remarks

A Ignition device 9257*
Safety measures when igniting airbag units 360

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B Ignition cable 9567 For driver's airbag

C Ignition cable 9566 For passenger's airbag
D Ignition cable 9257/2 For side airbag
E Ignition cable 9257/3 For belt tensioner
* Order if required
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Connecting ignition tool
Driver's side
Connect the ignition device 9257 with the adapter cable 9567 directly to the 2−pin plug of the driver's airbag
contact unit (under the steering column).
Passenger's side
Connect the ignition device 9257 with the adapter cable 9566 to the passenger's airbag plug connection. Place
the ignition device in front of the vehicle through the door gap.
Side airbag
Tools 361
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Connect the ignition device 9257 with the adapter cable 9257/2 to the side airbag plug connection. Place the
ignition device in front of the vehicle through the door gap.
Belt tensioner
Connect the ignition device 9257 with the adapter cable 9257/3 to the belt tensioner. Place the ignition device
in front of the vehicle through the door gap.
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Ignition
Side airbag 362

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Note
• The driver's and passenger's airbags and side airbags and the belt tensioner must be ignited separately!
Attach the ignition device to a vehicle battery and press the button.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Ignition 363
87 03 Safety regulations when handling refrigerant
R134a
The refrigerant R 134a which is used is known as a safety refrigerant. This means that this refrigerant is
non−flammable, non−explosive, non−toxic, non−irritating, odorless and tasteless. Despite this, you should
still follow the points below:
WARNING
Danger of injury as a result of contact with liquid or gaseous refrigerants!
• Wear rubber gloves to protect your hands!

• Treat affected skin in the same way as in the case of freezing. Rinse immediately with cold water and
then consult a physician!
• Wear safety goggles to protect your eyes!
• If refrigerant still gets in your eyes, consult a physician immediately!
CAUTION
Danger of fire due to the air−conditioning system heating up from sunlight shining into the vehicle or during
welding and soldering work!
• When carrying out repairs on the air−conditioning system, the system must be emptied by suction and
the refrigerant must be purified. Chlorine−free refrigerants must also not be allowed to escape into the
atmosphere and must be disposed of correctly!
• Due to their chemical composition, different refrigerants must not be mixed with each other! This also
applies for smaller quantities!
• No welding, soldering or hot−air heating may take place on parts of the filled air−conditioning system
or in its immediate vicinity!
• Make sure that parts of the air−conditioning system do not heat up during welding or soldering work
on the vehicle!
• While drying after painting work, the temperature burden on the vehicle must not exceed two hours at
a maximum temperature of 80°C!
• Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure
which can cause damage to the system or even lead to an explosion!
• R 134a is completely non−toxic at normal temperatures, but it decomposes upon contact with a flame
or at high temperatures!
• Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or other heat
sources for an extended period when full!
• The maximum permissible temperature of a filled refrigerant bottle must not exceed 45 °C!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
87 03 Safety regulations when handling refrigerant R134a 364

92 66 Non−adjustable spray nozzles
Note
Note
• The new spray nozzles for the windscreen washer system are not adjustable!
• Sharp objects (needles) must not be inserted in the nozzle holes!
• Do not install old and new spray nozzles together!
A Old version (adjustable)

B New version (non−adjustable)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 66 Non−adjustable spray nozzles 365

94 23 Bulb table and installation instructions
Bulb table
Installing bulbs
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Bulb table
Lamp Shape, Output

High beam headlight, dipped beam headlight D2S, 35 W
Auxiliary high beam headlight H 11, 55 W
Fog light H 3, 55 W
Direction indicator light PY, 21 W
Rear fog light P, 21 W
Reversing light P, 21 W
Brake light/parking light P, 21 W
Tail light P, 5 W
Parking light, front H, 6 W
Side direction indicator light W, 5 W
Additional brake light W, 3 W
Number plate light C, 5 W
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Installing bulbs
CAUTION
Danger of damage to property if bulbs are used or handled incorrectly!
• Only bulbs specified in the bulb table may be used!

• Bulbs with a higher wattage may cause damage to the bulb housing!
• To prevent short circuits, the load in question must be switched off while bulbs are changed!
• New bulbs must be clean and free of grease. Therefore, never touch bulbs with your bare hands!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 23 Bulb table and installation instructions 366

96 22 Bulb table and installation instructions
Bulb table
Installing bulbs
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Bulb table
Shape, Output
Interior light, door warning light W5W
Luggage compartment light K 10 W
Bulbs 1.5 W
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Installing bulbs
Note
• Only bulbs specified in the bulb table may be used!
• Bulbs with a higher wattage may cause damage to the bulb housing!
• To prevent short circuits, the load in question must be switched off while bulbs are changed!
• New bulbs must be clean and free of grease!
• Never touch bulbs with your bare hands!
• Use a cloth or soft paper for changing bulbs!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 22 Bulb table and installation instructions 367

97 68 Optical waveguide − MOST bus
Note
Specifications on handling the optical waveguide
Plug connectors
Removing and installing optical contacts
Optical waveguide modules
Tools
Note
• The optical waveguide will be used as from model year 2003.
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Specifications on handling the optical waveguide
• The plug connections must not be connected or disconnected with tools.
• The optical waveguide and the plug copnnections must not be brought into contact with liquids such
as water, leakage fluids, preservers, anti−freeze fluids or cleaning agents. This may impair the
function of the MOST system or even complete system failures. Even plug connectors with connected
protective caps must not be brought into contact with the listed liquids.
• If the optical contacts, plug connectors or bushings are not connected or the connectors are not
equipped with protective caps, all contact with dust and other materials (lubricants) must be avoided.
• The optical contacts, plug connectors or bushings must not be cleaned.
Storage, packaging, transport
• The optical waveguides must not be stored in the open air.

• The optical waveguides must be protected from direct sunlight when stored.
• The optical waveguides must not be exposed to high levels of air humidity when stored.
Recommended storage conditions: Temperature − between −20°C and +40°C, air humidity − between
40% and 60%.
• The optical waveguides must be stored in cardboard boxes or plastic bags.
• No forces may be exerted on the stored optical waveguides which could deform or damage them.
• The optical waveguides may only be stored with connected dust protective caps.
• During storage, the bending radius of 30 mm must always be maintained.
• Optical waveguides with damaged surfaces must be replaced.
Installing optical waveguides in the vehicle
The limit values listed below must not be exceeded when installing an optical waveguide in the vehicle:
97 68 Optical waveguide − MOST bus 368

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• Maximum permissible tensile load: 60 N
• Minimum bending radius after and during installation in vehicle: 25 mm
• Maximum number of torsions: 10 torsions per m
The following points must be observed when installing optical waveguides and wiring harnesses containing
optical waveguides:
• Damaged optical waveguides must not be installed.

• Before installing the optical waveguide or the wiring harness with optical waveguide into the vehicle,
you must check whether the protective dust caps have been attached properly. If this is not the case,
the optical waveguide set must not be installed.
• After and during installation of the optical waveguide into the vehicle, the minimum bending radius of
25 mm must be maintained.
• During installation of the optical waveguide into the vehicle, the optical guide must not be pulled to
set the length of the wiring harness (max. tensile load 60 N) and the optical guide must not be twisted
or coiled up.
• After installation of the optical waveguide into the vehicle, twisted optical guides must be
straightened.
• Lateral forces on the optical waveguides must always be avoided during installation of the optical
waveguide into the vehicle.
Repairs
Defective optical guides must be replaced. Repairs for optical waveguides are not planned.
When replacing optical waveguides, the optical contacts must be removed form the plug connectors.
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Plug connectors
Protective dust caps
Protective dust cap for optical contacts:
• If an optical waveguide is stored, transported or installed in a vehicle, the protective dust cap most
only be removed immediately before use in the plug.
• The protective dust cap must be replaced after every test of an optical waveguide.
The protective dust caps can be removed without actuating a lock.
• During or after removal of the protective dust cap, do not touch the exposed contact surfaces, because
otherwise the optical contacts may be damaged or soiled.
Protective dust cap for plug (wiring harness side):

If a ready−made wiring harness is installed, protective dust caps are already present on the plug for the optical
waveguide.
Installing optical waveguides in the vehicle 369

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By actuating the lock −arrow− , the protective dust cap can be pulled off.
• The protective dust cap must be replaced after every test of an optical waveguide.
• During or after removal of the protective dust cap, do not touch the exposed contact surfaces, because
otherwise the optical contacts may be damaged or soiled.
Control module plug connector (wiring harness side)
The optical waveguide is delivered with plastic contacts affixed. In case of repairs, these contacts are engaged
in the connector housing. Grey and black contacts with identical mechanical dimensions are used.
Grey contacts are used for the transfer wiring harness >> control module (optical input).
Black contacts are used for the transfer control module >> wiring harness.
Connectors
Structure of an optical waveguide connector:
−1− Optical contact, black

−2− Optical contact, grey
−3− Connector, plug side
−4− Connector, bushing side
−5− Bushing side optical waveguide module
−6− Optical contact, grey
−7− Optical contact, black
−8−
Springs
−9− Spring
cap
Protective dust caps 370

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Removing and installing optical contacts
Disconnecting plug connector at PCM:
• Remove PCM ’ 9, 911019 Removing and installing control unit (PCM2) .
Disconnecting plug connector at amplifier:
• Remove cover for brake booster.
Disconnecting connector in front luggage compartment:
Connectors 371
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Disconnecting plug connector at CD changer:
• Remove CD changer.
Disconnecting plug connector of control module for telephone:
• Remove passenger's seat ’ 7, 720119 Removing and installing front seat .

• Remove holder for control module for telephone ’ 9, 919019 Removing and installing control module
for telephone .
Removing optical contacts on plug side
1. Open the secondary lock with the press−out tool. Insert the tool in the appropriate opening and raise
the lock. The lock then engages in the upper setting => Tools.
Removing and installing optical contacts 372

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2. Position tool at the primary lock and raise the lock.

−A− Optical contact,
grey
−B− Optical contact, black
3. Pull carefully on the optical waveguide, e.g. −B− in the −direction of the arrow− . If it is not possible to
pull out the optical waveguide, check again whether the secondary lock has been completely unlocked and
whether the primary lock has been raised far enough.
• Conduct a visual check of the locks, the connector housing and the contacts for any possible damage
and, if necessary, replace the damaged parts.
Installing optical contacts on plug side
• Remove the protective dust cap immediately before the connection procedure.
• Check that the contact is in proper condition.
1. Push optical contact −B− into the plug until it engages audibly.
grey
Removing optical contacts on plug side 373

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2. Close the secondary lock −arrow− and check for proper seating of the optical contacts.
Removing optical contacts on bushing side
1. Unlock and remove the spring cap on both sides using the press−out tool
=> Tools.
2. Remove the optical waveguide module from the plug.
3. Position the unlocking tool at the contact lock of the optical waveguide module and raise the lock.
grey
4. Pull carefully on the optical waveguide, e.g. −B− in the −direction of the arrow− . If it is not
possible to pull out the optical waveguide, check again whether the lock has been completely
unlocked.
• Conduct a visual check of the locks, the connector housing and the contacts for any possible damage
and, if necessary, replace the damaged parts.
Installing optical contacts on bushing side
• Remove the protective dust cap immediately before the connection procedure.
• Check that the contact is in proper condition.
• Given a force of 10 N, the springs installed at the connector are pressed together. This leads to an
increase in the absorption, which may lead to system impairments or even system failures. Therefore
it is only permissible to pull the optical waveguide out of the connectors with a maximum force of 10
N.
Installing optical contacts on plug side 374

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1. Push the optical contacts −B− and −A− into the module until they engage perceptibly. Check for
proper seating of the optical contacts.
2. Connect the module to the connector on the bushing side.

3. Push the spring cap on to the connector until it engages perceptibly −arrow− .
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Optical waveguide modules
At least one transmitter diode and one receiver diode is installed in all MOST control modules. A transmitter
diode of an MOST device is connected to the respeective receiver diode of a second MOST device. A circuit
is created, in which the light signal in every control module is refreshed (the light signal is converted to an
electrical signal in every control module).
The graphic below shows the wiring of the individual MOST control modules which varies according to the
particular equipment.
Installing optical contacts on bushing side 375

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1 MOST control modules:

−A− Radio/PCM, lead −1− in connection with amplifier or CD changer without
telephone.
−A− Radio/PCM, lead −2− in connection with telephone without amplifier and CD
changer.
−A− Radio/PCM, lead −3− in connection with telephone and amplifier or CD changer.
−B− Amplifier, lead −4− without CD changer.
−B− Amplifier, lead −5− with CD changer.
−C− CD changer, without amplifier lead −6− .
−D− Telephone, lead −2− and in connection with amplifier, CD changer lead
−3− .
−E− Optical waveguide connector, located above the brake booster.
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Tools
Press−out tool:

1 Press−out tool 155/ 88069 Gr. 2.4; Workshop Equipment Manual
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Optical waveguide modules 376

01 Sales check
Working position 01 01 00 00
Working instruction to order no.
Workshop no.
Vehicle Ident. No.
OK Not
1) OK 2)
Check conformity of vehicle Ident. No. on vehicle, data bank, vehicle registration
documents and on−board literature => Checking the Vehicle Ident. No.
Remove transport locks, transport protection => Removing transport lock (spring strut
locking devices) – Turbo and GT2
Battery: check battery charge state (take transport and idle period into account)
=> Battery&colon; checking the charge state
Diagnostic system: read out or erase fault memory, activate systems => Diagnostic
system&colon; Read out fault memory and activate systems
Windscreen washer/headlight cleaning system: check operation, fluid level and nozzle
settings, pay attention to antifreeze protection in the winter months => Windscreen
wiper/washer system, headlight washer
Vehicle lights: check operation. All headlights: check adjustment. Horn and clock: check
operation => Checking the function of the vehicle's lights and the headlight setting
Electrical equipment, warning and indicator lights: check operation => Checking the
function of electrical equipment, as well as the indicator and warning lights
Mobile roofs: check operation => Mobile roofs&colon; checking function
Check engine oil level
Check tyre pressure => Tyres and spare wheel&colon; checking condition and tyre
pressure
Wheels, tyres: visual inspection for damage => Tyres and spare wheel&colon; checking
condition and tyre pressure
Check wheel mounting => Checking the wheel mounting
Brake hoses and lines: visual inspection for damage in the wheel area => Visual
inspection&colon; brake lines/brake pads/brake discsCheck brake fluid level
=> Checking and changing the brake fluid
Visual inspection for leaks: oils, fluids
Exterior equipment and paint finish, visual inspection for damage => Checking the
exterior equipment and paint finish
Glazing: visual inspection for damage => Glazing&colon; visual inspection for damage
Interior equipment: visual inspection for damage and soiling => Interior
equipment&colon; visual inspection for damage and soiling
Door and lid locks: check operation => Checking lid and doors
Alarm system: checking operation of indicators => Alarm system&colon; checking
operation of indicators
01 Sales check 377

einordnung
Complete vehicle and check equipment for completeness

=> Completing vehicle and checking equipment for completeness
=> Fitting front lip – GT2
Test drive OK Not

1) OK 2)
Foot and parking brakes, clutch, steering, automatic speed control, ParkAssist, heating,
air−conditioning system and instruments: check operation => General
maintenance&colon; Test drive
Transmission: check operation
Check vehicle for unusual handling behaviour, vibration and noise
Diagnostic system: read out or erase fault memory => Diagnostic system&colon; Read
out fault memory and activate systems
1) OK = functioning correctly
2) Not OK = not functioning correctly
Stamp of Official Porsche Centre
996430, 996431, 996420, 996421, 996450, 996451, 996840, 996841
01 Sales check 378

03 24 00 Minor maintenance
Note
Note
module).
• On vehicles with annual mileages of less than 15,000 km (9,000 mls), an annual maintenance must be
carried out once a year.
• Maintenance with oil filter change must be carried out at least every 2 years according to the mileage,
if the mileage for a major maintenance has not already been reached.
• For an annual mileage of more than 15,000 km (9,000 mls) we recommend carrying out the next
maintenance straight away.
• The term 'checking' includes all necessary subsequent work such as adjusting, readjusting, correcting
and topping up, but does not include repairing, replacing and reconditioning parts or assemblies.
Minor maintenance after: OK

20,000, 60,000, 100,000, 140,000 km etc./
12,000, 36,000, 60,000, 84,000 mls etc.
Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory
Change engine oil => Changing the engine oil and oil filter
Vehicle underside and engine compartment: visual inspection for leaks (oils and fluids) and
abrasion (lines and hoses)
Underbody panels: visual inspection for completeness, installation and damage
Power steering: check fluid level => Steering gear&colon; fluid level and bellows
Coolant hoses: check condition
Radiators and air inlets at front: visual inspection for external contamination and blockage
Coolant: check the level and antifreeze protection => Checking cooling system
Particle filter: replace filter element => Particle filter&colon; replacing the filter element
Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual
inspection&colon; brake lines/brake pads/brake discs. Check brake fluid level
Drive shafts: visual inspection of the boots for leaks and damage => Axle joints/drive shafts
Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare
wheel&colon; checking condition and tyre pressure
Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and
functioning properly => Checking lid and doors
03 24 00 Minor maintenance 379

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Vehicle lighting: check function; all headlights: check adjustment; horn: check operation
=> Checking the function of the vehicle's lights
Windscreen washer, headlight washer: check fluid level and nozzle settings, pay attention to
antifreeze protection in the winter months => Windscreen wiper/washer system, headlight
washer
All other electrical equipment as well as warning and indicator lights: check operation
=> Checking the function of electrical equipment, as well as the indicator and warning lights
Test drive:
Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch,
steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, air−conditioning
system and instruments: check operation => General maintenance&colon; test drive
Oils, fluids: visual inspection for leaks
996420, 996421, 996450, 996451, 996840, 996841
03 24 00 Minor maintenance 380

03 26 00 Major maintenance
Note
Note
• Not valid for USA!
module).
• The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with
the Tester < omitted as of model year 2002.
Major maintenance after OK

40,000, 80,000, 120,000, 160,000 km etc./
24,000, 48,000, 72,000, 96,000 mls, etc.
Polyrib belt: check condition => Removing and installing drive belt
Change engine oil and oil filter => Changing the engine oil and oil filter
Replace the spark plugs => Replacing spark plugs
Air cleaner: replace filter element => Replacing air cleaner element
Fuel system: visual inspection for damage, routing and secure fit of line connections
Parking brake: checking the free play of the parking brake lever => Parking brake&colon;
checking the free play of the parking brake lever
Brake system: visual inspection of the brake pads and brake discs for wear => Visual
inspection&colon; brake lines/brake pads/brake discs
Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal
end position
Throttle actuation: check smooth operation, check the full throttle position with the Tester
03 26 00 Major maintenance 381

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Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and
bellows
Checking the tie rod end play and dust bellows => Axle joints/drive shafts
Axle joints: check play, visual inspection of dust bellows for damage => Axle joints/drive
shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit
Exhaust system: visual inspection for leaks and damage, check suspension
Check the door, lid locks and safety hooks of the front lid to ensure that they are secure and
Seat belts: check operation and condition => Checking seat belts
washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841
03 26 00 Major maintenance 382

03 50 00 Annual maintenance
Note
Note
module).
Annual maintenance OK
=> Checking cooling system
Engine: check oil level => Changing the engine oil and oil filter
bellows
Tie rod ends: checking the play and dust bellows => Axle joints/drive shafts
Axle joints: check the play and visually inspect the dust bellows for damage => Axle
joints/drive shafts
03 50 00 Annual maintenance 383

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Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 50 00 Annual maintenance 384

10 01 00 Tightening torques for M 96/70 engine
Crankshaft/crankcase
Cylinder, cylinder head and camshaft housing
top of page
Crankshaft/crankcase
Note
• The fastening screw of the belt pulley must always be replaced.
Tightening
torque Nm
Initial tightening of connecting−rod screws M9 x 1.25 30 Nm [22 ftlb.]
± 10 %
Final tightening of connecting−rod screws M9 x 1.25 90° ± 2°
Oil pump on crankcase half M8 25 (19)
Crankcase bolts (through bolts) M10 x 1.25 50 (37)
Hexagon nuts or hexagon−head bolts on crankcase M8 23 (17)
Belt pulley on crankshaft M14 x 1.5 170 (126)
Flywheel on crankshaft M10 85 (63)
Drive plate on crankshaft (Tiptronic) M10 x 1.25 90 (67)
Drive plate on converter (Tiptronic) M8 39 (29)
Plugs of pressure relief valve on crankcase M18 x 1.5 50 (37)
Oil drain plug on crankcase M20 x 1.5 70 (52)
Screwed socket in crankcase M22 x 1.5 70 (52)
Plug on crankcase half at upper right (former oil pressure sensor M18 x 1.5 30 (22)
mounting location)
Driver of exhaust turbocharger oil extraction pump on intermediate 25 (19)
shaft
top of page
Cylinder, cylinder head and camshaft housing
Note
• The axial camshaft adjuster central screws (inlet camshaft) and sprocket wheel (exhaust camshaft)
must always be replaced.
10 01 00 Tightening torques for M 96/70 engine 385

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Cylinder head nut (coat thread and sealing M10 30 Nm (22 ftlb.), then unscrew; 20 Nm (15
surface of the nuts with engine oil) ftlb.) (joining torque); then retighten all
screws to 20 Nm (15 ftlb.); final tightening
with 120° turn
Camshaft housing (thread and sealing surface M8 (10.9) 23 Nm (17 ftlb.) initial tightening
of screw head are lightly oiled) 28 Nm (21 ftlb.) final tightening
Camshaft bearing cap on camshaft housing M6 (10.9) 13 (9.5)
Oil guide housing (screws microencapsulated − M5 (8.8) 7 (5)
replace)
Guide rail between the camshaft wheels M6 (10.9) 13 (9.5)
Central screw for axial camshaft adjuster on the M12 x 30 Nm [22 ftlb.] initial tightening
inlet camshaft; before tightening, the adjuster 1.5 x 120 170° torque angle (replace screw)
must be positioned to the left−hand stop
Sprocket wheel central screw on the exhaust M12 x 30 Nm [22 ftlb.] initial tightening
camshaft (internal serration) 1.5 90° torque angle (replace screw)
Guide/tensioning rail on crankcase 31 (23)
Camshaft housing cover on camshaft housing, M6 (8.8) 10 (7.5)
left /right
Oil extraction pump on camshaft housing M6 10 (7.5)
Control valve for axial camshaft adjuster M27 x 25 (19)
1.5
Holder for valve lift adjustment control valve M6 10 (7.5)
Water pump bracket and engine carrier on M10 65 (48)
crankcase (10.9)
Screw plug for exhaust turbocharger extraction M6 4 (3)
pumps
Screwed socket for exhaust turbocharger return M16 x 30 (22)
line 1.5
Oil drain plug on oil container − exhaust M18 x 30 (22)
turbocharger 1.5
Engine oil return line on neck/oil tank M30 x 60 (44)
1.5
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Cylinder, cylinder head and camshaft housing 386

10 10 37 Disassembling and assembling crankcase
Tools
Adapting engine holder
Left crankcase half (cylinder bank 1 3)
Right crankcase half (cylinder bank 4 − 6)
Disassembling the crankcase
Assembling the crankcase.
top of page
Tools
Item Designation Special tool Explanation

A Engine holder Holder P 201 Fasten to the right half of the crankcase (cyl. 4 −
6), only mount in connection with an adapter
9967 (order quantity, 2 ea.)
B Toothed segment and Toothed segment and
mounting elements mounting elements P
201 b
10 10 37 Disassembling and assembling crankcase 387

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Note
• If the special tool is to be screwed into position for the first time with the engine holder P 201, two
threaded bores must be provided in addition.

Engine holder (adapter) Engine holder 9667 Additional fastening of the crankcase via
four studs.

A Holding wrench for belt pulley Holding wrench
9548
Tools 388
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B Retaining device Retaining device For bracing the tension rod bolts
9662 when tightening
C Surface seal Drei Bond Silicon Type
1209
D Retainer plate Retainer plate P Screw the crankshaft to the
209a retainer plate with internal
serration screws Part No.
928.102.151 01. (order 3 pieces)
E Restraining straps (connecting rod) Restraining straps P
221
F Nut with internal serrations, wrench
size 14 for tension rod threaded part
G Assembly fixture for flywheel Retaining device P
238 b
H Snap ring pliers Commercially available
I Special grease for connecting−rod Optimol Optipit 000.043.204.17
bearings
J Holder for cylinder Set of retaining nuts For stabilising the retaining
P 140 device 9662 when bracing the
tension rod bolts

A Insertion device for sealing ring Press−in device P216 d
B Assembly sleeves for tension rod bolt seal Assembly sleeve 9511
C Assembly aid Fastening plate 9517/1
E Pressure piece for sealing ring Insert device 9517
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Tools 389
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Adapting engine holder
Note
• The threaded bores must only be provided if the adapter ring is used for the first time.
No. Procedure Instructions

1 Centring adapter on engine holder
2 Centring engine holder
3 Reworking engine holder
4 Fastening adapter on engine holder
5 Engine holder with adapter half
Adapting engine holder 390

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6 Mounting adapter half on crankcase
1. Centring adapter on engine holder. Fasten the adapter half with the already made bores −arrows−
with two auxiliary screws M10 x 60 onto the engine holder. Spot−drill or countersink the engine
holder slightly through the bores in the adapter ring using a drill bit Ø 6.5. The adapter ring serves
as the drilling template.
2. Rework engine holder. Drill a pilot hole for an M6 thread on the countersunk points. To do this, first drill
with a drill bit Ø 3mm, then with a drill bit Ø 5mm.
3. Drill pilot hole and cut thread.
4. Fasten adapter on engine holder. Fasten adapter with the supplied cylinder screws onto engine holder with
hexagon socket (M6 x 35).
Adapting engine holder 391

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5. Mount engine holder with adapter half. Screw engine holder with screwed in adapter half onto the
crankcase half of the cylinder bank 4 − 6.
6. Mount the second adapter half on crankcase. Screw the screw sleeves onto the studs and tighten by hand.
Screw in connecting screws of the adapter half and tighten with 10 Nm (7.5 ftlb.). Subsequently tighten
the assembly sleeves.
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Left crankcase half (cylinder bank 1 3)
Left crankcase half (cylinder bank 1 3) 392

einordnung
Note:
1 Hexagon−head bolt M8 x 1
50
2 Holder 1
2a Fastening nut M8
25
35
5 Sensor holder 1
6 Plug 1 Tightening torque 70 Nm (52 ftlb.)
7 Sealing ring A22 x 27 1 Always replace
8 Threaded insert M20 x 1.5 1
Left crankcase half (cylinder bank 1 3) 393

einordnung
9 Screw−in flanges (oil 1 Tightening torque 70 Nm (52 ftlb.)

return)
11 Screw plug for oil pressure 1 Tightening torque 50 Nm (37 ftlb.)
relief valve M18 x 24
13 Compression spring 1
14 Piston for excess pressure 1 Examine the piston and bore in the housing for traces
valve of scoring, if necessary replace the piston, then oil
15 Stud BM10 x 105 2 Projection length 106 mm
16 Stud 24 Projection length 150 mm
18 Stud M10 x 60 1 Projection length 169 mm
19 Dowel sleeve 1
20 Hexagon nut M10 x 1.25 1 Tightening torque 50 Nm (37 ftlb.)
21 Washer A10.5 1 Replace
22 Fastening nut 1 Replace
23 Washer 1
25 Washer 18
26 Multiple−tooth nut 11 Tightening torque 50 Nm (37 ftlb.), tighten with
double hexagon wrench insert while bracing with
retaining device, special tool 9662.
27 Washer 11
28 O−ring 8 x 2 11
29 Straight pin A8.0 x 2 11
30 Straight pin 1
31 Oversize plug 8.5 x 8.0 1
32 Oversize plug 14.00 x 8.5 1
33 Oversize plug 20.0 x 13 1
34 Crankcase half of cylinder 1 Apply surface seal to sealing surface
bank 1 − 3
35 Dowel sleeve 1
36 Oil spray jet for piston 3
cooling
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Right crankcase half (cylinder bank 4 − 6)
Right crankcase half (cylinder bank 4 − 6) 394

einordnung
Note:
1 Screw plug 1 Tightening torque 50 Nm (37 ftlb.)
2 Piston 1 Oil
4 Guide sleeve 1
5 Spacer ring 1
6 Sealing ring A18 x 24 1 Replace
7 omitted
8 omitted
9 omitted
10 Fastening nut M8 1
11 Washer 8.4 1
Right crankcase half (cylinder bank 4 − 6) 395

einordnung
12 Hexagon−head bolt M8 x 45 1
13 Fastening nut M8 1 Replace
15 Washer 1
18 Crash support 1
19 Tension rod bolts 11
20 Washer 11
21 O−ring 8 x 2 11 Replace, oiled lightly
22 O−ring 8.3 x 2.4 4 Replace
23 Tension rod bolts 2
24 Screw plug M18 x 1.5 1 Tightening torque 30 Nm (22 ftlb.)
26 Screw plug M16 x 1.5 1
34 Stud BM8 x 52 1
35 Stud BM8 x 28 1
36 Stud BM8 x 32 1
37 Stud BM10 x 140 1
38 Dowel sleeve 2
39 Stud BM10 x 60 1 Projection length 69.5
40 Pan−head screw M10 x 18 1 Tightening torque 45 Nm (33 ftlb.).
top of page
Disassembling the crankcase
Note
• The thrust plate, drive plate and the flywheel must be removed before fastening the engine onto the
engine holder or assembly support.
Disassembling the crankcase 396

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1. Position the toothed segment special tool P201b on the stud and undo the pan−head screws of the
clutch pressure plate in several stages and in diametrically opposite sequence, to avoid deforming
the thrust plate.
2. Fasten mounting device P238b with holder P140 onto the studs. Loosen flywheel screws and remove
the flywheel. Make sure that the pulse sender is not damaged.
Note
• If the engine holder special tool (adapter ring) 9667 is used for the first time, 2 threaded bores must be
made in addition.
3. Mount engine holder. See also sub−section "Adapting engine holder". => Adapting engine holder
Note
• The pulse sender should not be detached!
• Shear bolts were installed in the first vehicles.
Shear bolts on pulse sender
4. The shear bolts are replaced by micro−encapsulated hexagon head bolts

einordnung
M6 x 20.
Hexagon head bolts on pulse sender
5. Loosen belt pulley. To do this, a second person should counter with the holding wrench 9548 at the same
time. Do not continue to use the hexagon−head bolt.
6. Loosen the 18 hexagon nuts (M8) of the housing screw connections.
7. Loosen the hexagon nuts (wrench size 17) in the left crankcase half (cylinder bank 1 − 3).
8. Loosen tension rod bolts from the outside to the inside.
Note
• The tension rod bolts in thrust blocks 2, 3, 4 and 5 −arrows− can only be removed after removing the
crankcase half (cylinder bank 1 − 3).

einordnung
Removing tension rod bolts.
9. Crankcase half (cylinder bank 1 − 3).
10. Remove O−rings and tension rod bolts of thrust blocks 2, 3, 4 and 5.
top of page
Assembling the crankcase.
1. Fasten engine holder P201 to the right crankcase half (cylinder bank 4 − 6).
2. Check the matching number of the crankcase halves. The number is located on the top of the head lug.
Note
• There are tolerance groups 0 and 1
3. Allocation of the crankshaft gearwheel and the intermediate shaft to the crankcase. The tolerance group
number is imprinted on the crankcase −arrow− and must match the number on the intermediate shaft
gearwheel and the crankshaft gearwheel.
Assembling the crankcase. 399

einordnung
Pairing number on crankcase
Pairing number on crankshaft gearwheel −arrow−
Pairing number on the intermediate shaft gearwheel −arrow−
4. Clean crankcase halves thoroughly. Check whether there are any foreign objects (e.g. residual
sealant) in the receiving bores of the tension rod bolts.
5. Fit the mounting of the intermediate shaft. Insert new bearing shell halves in the crankcase half of
the cylinder bank 4 − 6.

einordnung
6. Oil the bearing surfaces. Insert intermediate shaft and check for true
running.
7. Insert new crankshaft bearing shell halves into the crankcase. Oil the bearing surfaces.
8. Check that the dowel sleeves are present and seated properly.
9. Insert crankshaft (excluding mount 8) into the crankcase half of the cylinder bank 4
− 6.
Note
• If the wear dimension has been attained, replace the intermediate shaft and the paired drive wheel
10. Check the circumferential backlash of the intermediate shaft. To do this, fasten a gauge holder e.g. VW
387 to the crankcase parting surface. The sealing surface must not be damaged during this procedure.
Align the dial guage on a tooth profile and determine play. Subsequently turn the intermediate shaft by
180 ° and repeat the measurement.
Circumferential backlash:
New dimension 0.035 − 0.084 mm
Wear dimension 0.10 mm
11. Remove intermediate shaft again.

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12. Let a second person lift the crankshaft slightly and push bearing no. 8 onto the crankshaft journal.
13. Lower the crankshaft slowly and insert crankshaft bearing no. 8 into the dowel pin.
14. Check installation position. If the mounting is correct, the centre of the bearing notch should be on the
same level as the sealing surface.
Note
• Oil sealing lip
Insert crankshaft sealing ring in the crankcase.
15. Grease sealing ring (19.5 x 26) on both sides and insert it into the crankcase half 4 − 6 in the area of the
oil pump mount.

einordnung
16. Insert the complete unit, oil pump with dumb−bell shaft and intermediate shaft with both timing chains
into the crankcase half.
17. Fasten new collar nuts (3 pieces). Tightening torque 23 Nm (17 ftlb.).
18. Check dumb−bell shaft. The dumb−bell shaft must be easily movable in axial direction. If
necessary, re−loosen the oil pump with the intermediate shaft and shift the dumb−bell shaft.
Note
• Additional O−rings are inserted on 4 tension rod bolts of the thrust block fastening, thrust blocks 2, 3,
4 and 5.
• The 4 tension rod bolts must be mounted before joining the crankcase halves.
19. Prepare the tension rod bolts for installation. The diagram shows the already mounted tension rod bolts in
the designated thrust blocks.
Note
• Do not oil sealing rings until shortly before fitting.
• Do not store oiled sealing rings.

einordnung
Prepare four tension rod bolts. Push sealing washers on to tension rod bolts. Feed lightly oiled
O−rings with conical sleeve from special tool 9511 over the threaded area and push them on to the
tapered section towards the head of the bolt.
Observe the A side and B side on the assembly sleeve 9511.
Insert the prepared tension rod bolts into the right crankcase half from below as far as they will go and
retain in this position.
Place conical sleeve on end of the thread. Push O−ring (dry) over the conical sleeve. Remove conical
sleeve and push the O−ring with the cylinder sleeve as far as the chamfer in the thrust block. Remove
cylinder sleeve.

einordnung
Cylinder sleeve application
20. Lift connecting rod of cylinder 4, 5 and 6 with restraining straps, special tool P221. Lift timing chain with
tension strap.
21. Coat both sides of sealing rings on the oil pump (2 pieces) and the sealing ring on the crankcase half with
vaseline and insert.
22. Prepare crankcase halves of the cylinder bank 1 − 3. To do this, insert the bearing shells of the crankshaft
and the intermediate shaft.
Degrease the sealing surface of the crankcase halves. Apply a uniform bead of silicone (Drei Bond Typ
1209) approximately 1.5 mm wide to the sealing surface of the crankcase half of cylinder bank 1 − 3.

einordnung
Check the relief groove in the area of the main bearing no. 7 for foreign objects, e.g. silicone residue
and clean if necessary.
Insert the crankcase half carefully over the preassembled tension rod bolts of thrust blocks 2, 3, 4 and 5, at
the same time having a second person pull the chain upwards through the chain space.
23. Remove restraining straps again.
Note
• Always replace fastening nuts
24. Join crankcase halves and secure with approx. 6 new fastening nuts with washers. Distribute the fastening
nuts evenly on the periphery and tighten by hand.

einordnung
25. Insert the prepared tension rod bolts of the crankcase half 4 − 6 and hold.
26. Push the conical sleeve of special tool 9511 with an oiled O−ring to the end of the thread.
27. Push the O−ring carefully away from the conical sleeve with the A−side (thin wall) of the cylinder sleeve.
View of the conical sleeve
28. Remove conical sleeve and carefully push round seal to its end position with the B−side (thick wall) of
the cylinder sleeve, while bracing the bolt head.
29. Mount sealing washers (dry) and press downwards slightly with B−side of cylinder sleeve.
30. Screw on outer multiple−tooth nuts (thread oiled) by hand.
31. Proceed in the same way with both studs of the crankcase half 4 − 6 (area of bearing 1) on the flywheel
side.
Note

einordnung
• Cover the chain space briefly when fitting so that parts do not fall into the crankcase.
32. Mount hexagon nut M10 x 1.25 and washer A10.5 on stud, with rounded side pointing towards the
hexagon nut.
33. Mount retaining device, special tool 9662, on corresponding tension rod bolts and position with holder,
special tool P140.
Note
• When tightening the tension rod bolts without a retaining device 9662, it is essential that a second
person braces the bolts.
• The O−ring is damaged when the tension rod bolts are turned.
• Use a 14 mm multiple−tooth socket from Snap−on to counter.
Retaining device 9662
34. Tighten tension rod bolts or studs with 50 Nm (37 ftlb.). When doing so, observe the tightening sequence.

einordnung
35. Tighten tension rod bolts onto the flywheel side to 50 Nm (37 ftlb.).
36. Fit new self−locking hexagon nut with washers and tighten to 50 Nm (37 ftlb.).
Note
• The self−locking nuts must always be replaced.
37. Fit remaining crankcase screw connections. Tighten the hexagon nuts to 23 Nm (17 ftlb.).
38. Fit belt pulley. Check the cylindrical pin (5 x 18) for deformation before fitting and replace if
necessary.

einordnung
39. Mount new cylindrical pin so that it is flush.
CAUTION
Danger of injury
• The holding wrench must be in contact with the belt pulley when tightening.
40. Always replace fastening screw of the belt pulley. When tightening the belt pulley, a second person
must counter with the special tool 9548. The belt pulley is tightened to 170 Nm (126 ftlb.).
41. Fit flywheel.
42. Check distance −Dimension X− between toothed ring and pulse sender and adjust if necessary.
Dimension X 1.0 ± 0.2 mm
43. Turn belt pulley or the crankshaft to TDC, cylinder 1 or 4.
44. Subsequently fit piston or cylinder (see Serv. No.: 13 10 19)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

13 10 19 Removing and installing pistons (includes
removing and installing cylinders)
Tools
Removing pistons and cylinders
Removing pistons
Installing pistons and cylinders
top of page
Tools
13 10 19 Removing and installing pistons (includes removing and installing cylinders) 411
einordnung

A Assembly aid Assembly aid 9657 For positioning the restraining
strap over the piston rings
B Restraining strap Restraining strap 9659 For mounting the pistons of
cylinders 2 and 5. (Scope of
delivery, 3 pieces)
C Piston ring restraining strap Refer to Workshop Equipment
Manual, Chapter 2.4, No. 57
D Pushing device Pushing device 9660 For mounting the bushings in the
cylinder housing
E Spacer Spacing pieces 9651
F Holder for cylinder Set of retaining nuts P
140
G Assembly aid Assembly aid 9500/6 For pre−assembly of piston
circlips in 9500/7
H Plunger Plunger 9500/4
I Assembly aid for piston pin Assembly sleeve For assembly of piston−pin
circlips. 9500/7 circlip
J Assembly aid for piston pin Assembly aid 9500/3 For pre−assembly of the circlip
circlips. in 9500/5
K Grease for O−rings on the cylinder Part No.: 999.917.788.00
mount bushings
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Removing pistons and cylinders
Tools 412
einordnung
Note:
1 Cylinder 1 Identify, e.g. with cyl. 1 −3 or 4 − 6
2 Bushings 3 Identify with cyl. 1, 2, 3, 4, 5 or 6; assign to Oil running surfaces
the corresponding piston
3 O−ring 3 Replace on principle, mount
104.00x2.00 with special grease, do not
twist
4 O−ring 6 Replace on principle, mount
110.00x2.50 with special grease, do not
twist
5 Piston pin 6 Lever out Replace on principle, ensure
circlip correct seating
6 Piston pin 3 Assign to the corresponding piston
Removing pistons and cylinders 413

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7 Piston 3 Identify with cyl. 1, 2, 3, 4, 5 or 6, assign to Oil piston shank

the corresponding bushing, do not mark or
clean piston with a sharp object.
8 Piston rings 9
9 Straight pins 1
A8, 0x14
10 Cylinder base 1 Replace on principle, note
seal installation position, "Top"
faces the front
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Removing pistons
Note
• Mark the cylinder bank accordingly before removing the cylinder.
1. Carefully lift the cylinder with the 3 bushings up and off the
pistons.
Note
• Mark the pistons using a pen, e.g. 1, 2 or 3.
2. Lever off piston pin circlips with a suitable screwdriver and dispose of.
Note
• The bushings should be marked accordingly
3. Knock bushing out of the cylinder. To do this, insert the pressure piece of the pushing device 9660 at
the foot of the bushing and knock the bushing out with a plastic hammer.
4.
Removing pistons 414

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Remove O−rings of cylinder and O−rings of the bushings and dispose of. Assign bushings to the
corresponding piston.
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Installing pistons and cylinders
Note
• Observe installation sequence
• The central pistons of cylinders 2 and 5 are mounted onto the connecting rod without bushing.
• The pistons of the outer cylinder 1 −3 and 4 − 6 are preassembled in the cylinder.
View of the central piston
View of the outer pistons
1. Mount individual pistons. Align the gaps of the piston rings offset by
120°.
CAUTION
Risk of damage!
• Pay close attention to the oil scraper rings when tightening the restraining strap.
Installing pistons and cylinders 415

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2. Oil piston liberally. Mount commercially available restraining strap. Position special tool 9659/9
on top of the piston (piston junk).
3. Align restraining strap. The restraining strap lock should be aligned between the inlet valve recesses.
Note
• The assembly sleeve is used to position the restraining strap.
• Work quickly when positioning to ensure that the piston rings are not damaged.
4. Insert the piston inverted into the assembly sleeve special tool 9657. Quickly press the piston
downwards and press the restraining strap downwards at the same time with the other hand.
5. Turn belt pulley or crankshaft clockwise until the connecting rods of cyl. 2 and 5 are at top dead centre.

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6. Mount the piston on the connecting rod. Push in oiled piston pin as far as it will go.
Note
• A second person's help is recommended for pushing the circlip into the piston.
• Cover the opening in the crankcase below the piston so that the snap ring can not fall into the
crankcase.
• After assembly, check that the snap ring is seated correctly via a visual inspection.
7. Push on the assembly sleeve 9500/7 with the already premounted piston pin circlip onto the piston
pin eye. Insert plunger into the conical assembly sleeve. When doing so, the smaller diameter of the
plunger serves as a guide into the piston pin. Push the snap ring into the piston pin retaining groove
in the piston using the plunger. The circlip must audibly engage.
Position of the snap ring
8. Prepare the cylinders, outer bushings and piston for installation.
Insert new O−rings into the cylinders. Grease O−ring areas liberally.

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Mount new O−rings onto the bushings. Grease O−ring area liberally.
Mount outer bushings in the cylinders. Align the bushings in the cylinder. The flattened areas must face
towards the other bushings in longitudinal direction.
The recesses on the bushing must align with the bores of the
studs.
Mount the outer bushings with pushing device special tool 9660.

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View of the mounting tool
The outer bushings can also be pushed in with an hydraulic press if necessary.
Oil piston shank. Mount commercially available piston restraining strap. Push piston into the
bushing. Push the piston restraining strap downwards at the same time during this procedure.
Check the position of the pistons. The large inlet valve recesses on the cylinders must face upwards.
If necessary turn the pistons in the bushing. Pull the pistons far enough out so that the piston pins can
just be inserted.

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9. Mount the piston pins into the associated pistons from the inner side. The piston pin should only be
inserted so far that the connecting rod can still be mounted.
10. Check pistons for correct installation position. The large valve recesses must face upwards in the
installation position.
11. Mount cylinder base seal above the studs.
12. Place spacer special tool 9651 on the outer stud.
13. Push premounted cylinder onto the studs.
Note

einordnung
• Check that the piston pin circlips are seated correctly!
14. Mount the piston pin and the piston pin circlip of the outer pistons from the inside (through the central
cylinder opening).
15. After fitting the piston pin circlip, push the cylinder up to the spacers 9651. Secure the cylinder with the
special tool, holder P 140.
16. Prepare central bushing. Fit new O−ring and grease liberally.
17. Position the bushing on the studs.
18. Fit pushing device 9660 on stud. Lay a plastic washer on the bushing and press the bushing into place on
the piston by turning the handwheel.

einordnung
View of the special tool
19. Slowly turn belt pulley or the crankshaft clockwise until the central piston can no longer be seen in
the gap between the cylinder and the crankcase. Then press the bushing into place with the pushing
device until the restraining strap detaches from the piston shank.
20. Open the restaining strap lock using two screwdrivers and guide the restraining strap out between
the crankcase and the bushing.
21. Subsequently press in the central bushing as far as it will go using the handwheel.
22. Remove holder P 140 from the studs.
23. Remove the spacer 9561 again between the crankcase and cylinder.
24. Subsequently push the cylinder in the direction of the crankcase and move to its installation position.
25. To avoid the cylinder bank being pushed out when the horizontal cylinder bank is fitted or when the
crankshaft is turned, secure cylinder bank with holder P 140.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

13 19 21 Removing piston rings
Tools
Removal
top of page
Tools

Piston ring pliers Gr. Commercially available; refer to Workshop For the removing and fixing
1 No. 58 Equipment Manual, Chapter 2.4, No.: 58 of the piston rings.
top of page
Removal
Note
• Combustion deposits on the piston crown are not to be removed mechanically!
13 19 21 Removing piston rings 423

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1 Prepare piston
2 Remove pistons with piston ring pliers.
3 Remove piston rings from piston ring pliers.
4 Look for the gap of the oil scraper ring.
5 Pull apart the oil scraper spring ring.
6 Remove oil scraper spring ring.
Removal 424
einordnung
1. Place the removed pistons on a clean surface and look for the gap of the piston
rings.
2. Remove the piston rings starting from the piston crown. In order to do this, place the middle point of
the piston ring pliers into the gap of the relevant ring. The holding arms of the piston ring pliers
should clasp the piston ring from above. Only open the piston ring as much as is needed to remove
the piston ring from the groove.
3. Remove piston ring from the pliers. Relieve the piston ring pliers and remove the piston ring from the
pliers.
4. Look for the gap of the oil scraper spring. In the ring groove of the oil scraper ring is another oil scraper
spring. Look for the gap here. This is exactly opposite the tighter winding.
Removal 425
einordnung
5. Pull apart the oil scraper spring at the gap.
6. Remove the oil scraper spring from the third ring groove.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removal 426
13 19 23 Installing piston rings
Tools
Installation
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Tools

Piston ring pliers Gr. 1 Commercially available; refer to Workshop For the removing
No. 58 Equipment Manual, Chapter 2.4, No.: 58 and installing of
piston rings
top of page
Installation
13 19 23 Installing piston rings 427

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1 Open oil scraper spring.

2 Push together oil scraper spring.
3 Align the gap of the oil scraper spring.
4 Insert piston ring into the piston ring pliers.
5 Install piston rings.
6 Check that the piston ring is correctly seated and positioned.
1.
Installation 428
einordnung
Open oil scraper spring. In order to do this, pull apart the oil scraper spring at the gap. The gap can be
recognised by the tighter winding of the spring.
2. Insert oil scraper spring. Insert the oil scraper spring into the lowest ring groove and then push together.
3. Align the gap of the oil scraper spring. The gap of the oil scraper spring must be installed offset by
approx. 60° into the twist lock of the second ring groove.
4. Insert piston ring into the piston ring pliers. Make sure that, when installed, the designation of the
piston rings is pointing in the direction of the piston crown.
5. Install piston rings. This will start the oil scraper ring. Place the gap of the oil scraper ring into the
middle point of the piston ring pliers. Carefully stretch the piston ring with the help of the pliers to a
point where this can be placed over the pistons into ring groove 3. The gap of the oil scraper ring
must be installed offset by exactly 180° into the gap of the oil scraper spring (or offset by 120° into
the twist lock of the second ring groove). Make sure that the oil scraper spring is in the oil scraper
ring. Then install the stepped taper faced ring (indicated by the lower recess on the outer edge).
With the help of the piston ring pliers, insert the stepped taper faced ring into the second ring
groove in such a way that the designation TOP is pointing towards the piston crown. The twist lock
Installation 429
einordnung
of the second ring groove must be between the gap of the stepped taper faced ring. Insert the taper
faced ring into the ring groove in such a way that the designation TOP is pointing toward the piston
crown.
6. Check that the piston ring is correctly seated and positioned. Make sure that the oil scraper spring is inside
the oil scraper ring. In terms of the piston ring in the ring groove 2, the twist lock must be on the inside of
the gap and the designation TOP must be pointing towards the piston crown. The highest piston ring must
be installed in such a way that the designation TOP is pointing towards the piston crown. The gaps of the
individual piston rings must always be offset by 120°.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 430
13 48 37 Disassembling and assembling crankshaft
Tools
Disassembling crankshaft
Pressing ring knurled screw in and out
Assembling crankshaft
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Tools

A Retainer plate P209 a
A1 Pan−head screws SP No. 928.102.151.01 (3 ea.)
B Snap ring pliers Commercially available
13 48 37 Disassembling and assembling crankshaft 431

einordnung

1 Radial sealing ring 1 Replace
2 Bearing sleeve, 1 Replace
bearing 8
3 Round seal 1 Replace, do not fit twisted
4 Radial sealing ring 1 Replace
5 Snap ring 1 Carry out insertion test
6 Spacer ring 1 Warm on heating plate, push on up to stop
7 Timing gear 1 Check toothing Note reference number, paired with intermediate
for wear, remove shaft, only install together, warm on heating plate,
if necessary push on up to stop. The collar of the timing gear
must point to bearing 7
8 Woodruff key 1 Lift out with side Replace
cutters and
remove
Tools 432
einordnung
9 Connecting rod nut 12 Replace, tightening torque:

M9 x 1.25 Initial tightening: 30 Nm (22 ftlb.)
Final tightening: 1 x 90° turn
10 Connecting rod 6 Note installation position and weight. Note
classification or matching number to
connecting−rod bearing cap
11 Connecting rod 6 Replace
bearing shell half
12 Connecting−rod 6 Note matching number to connecting rod
bearing cap
13 Connecting rod 6 Replace
bearing shell half
14 Con−rod bolts 12 Check
15 Main bearing shells 12 Replace
of bearings 2 to 7
16 Main thrust bearing 2 Replace
shells
17 Crankshaft 1 Check for wear,
carry out
sounding test
18 Roll pin 6.0 x 16 1 Check for presence and correct seat
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Disassembling crankshaft
1. Remove tensioning sleeve (6 x 16) with a vice−grip wrench.
2. Clamp retaining plate P 209 a in the
vice.
3. Fasten the crankshaft to the retaining plate with 3 −pan−head screws− LO No. 928 102 151 01.
4. Loosen connecting rods with socket wrench insert M14 and remove.
Disassembling crankshaft 433

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5. Remove snap ring with snap ring

pliers.
6. Remove spacer ring and timing gear with a conventional puller.
7. Raise Woodruff key with side cutters and remove.
8. Remove crankshaft from retaining plate.
9. Check crankshaft for shocks, cracks and wear.
10. Carry out sounding test.
Note
• Before assembling the connecting rods, check without fail the elongation of the ring knurled screws.
If the dimension X (38.3 mm) is exceeded, the connecting−rod bolts must be replaced.
11. Check the connecting rods. Determine the length of the connecting−rod bolts.
Note
• In the case of the connecting−rod version with a 3−ring knurled screw, no replacement is possible. In
this case, the entire connecting rod must be replaced. The 4−ring knurled screw is available as a spare
part.
Identifying the ring knurled screw
Identifying the ring knurled screw 434

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Note
• The visual difference between the 3−ring knurled screw and the 4−ring knurled screw can only be
detected when the screw is pressed out.
1. Identify the ring knurled screw. With the screw pressed in, measure the groove diameter.
Object Measured value Screw type
Diameter groove 1 > 7.9 mm 3−ring
knurled
screw
Diameter groove 1 < 7.9 mm 4−ring
knurled
screw
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Pressing ring knurled screw in and out
Pressing ring knurled screw out
CAUTION
In order to protect the con−rod cover, always insert alumininum sheet strips at the sides into the vice.
Pressing ring knurled screw in and out 435

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1. Clamp the con−rod cover into a machine vice. Press both 4−ring knurled screws out at the same time.
Pressing ring knurled screw in
CAUTION
In order to avoid damage to the joint face, always use an aluminium sleeve, e.g. from the special tool set P140
(retainer sleeves for cylinders).
1. Guide the new 4−ring knurled screw by hand into the previous (old) toothing and then press it in up to the
rest.
2. Re−allocate the con−rod cover and the connecting rod and lay to one side.
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Assembling crankshaft
1. Clean crankshaft thoroughly.
2. Rinse out oil bores with a hand pump and solvent naphtha several times.
3. With a visual inspection, check whether the oil ducts are blocked at the bearing surfaces and on the front
face (aluminium stoppers).
4. Clamp
crankshaft.
Pressing ring knurled screw out 436

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5. Lubricate the con−rod journals with grease (Optimal Optipit) and mount the connecting rods on the
crankshaft.
Note
• The matching numbers of the con−rods and the con−rod bearing caps must all point to the same side.
6. Tighten con−rod nuts.
7. After the tightening procedure, check the con−rod bolt for twisting.
8. Insert and align new Woodruff key for timing gear.
Note
• The collar of the timing gear must point to bearing 7!
Assembling crankshaft 437

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• As an assembly aid, remove the timing gear from the heat source e.g. with a piston restraining strap
and quickly mount or push it into place on the journal.
9. Warm the timing gear to approx. 150 − 200°C in an oil bath or on a heating plate and push it on to the
crankshaft journal up to the stop.
10. Heat up the spacer ring in the same way and push it on up to the stop.
11. Mount snap ring.
Note
• The snap ring must be inserted without play!
The following snap rings are available:
Part number Thickness (mm) Identification

901.102.148.00 2.4 blank
901.102.148.01 2.3 tempered blue*
901.102.148.02 2.2 tempered yellow/brown
901.102.148.03 2.1 black, gun−metal finish
* most frequently used snap ring for first assembly
12. Select the corresponding snap ring using an insertion test.

13. The opening of the snap ring should lie opposite the Woodruff key groove.
14. Knock the snap ring into the retaining groove with a blunt chisel.

Connecting rod nut M9 x 1.25 Initial tightening: 30 Nm (22 ftlb.); final tightening: 1 x 90 ° torque
angle

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

13 73 37 Disassembling and assembling belt
tensioner
Assembly note

1 Hexagon−head bolt M10 x 4 Insert the front right
60 hexagon−head bolt (direction of
travel) with Loctite 574.
Tightening torque: 65 Nm (48
ftlb.)
55
13 73 37 Disassembling and assembling belt tensioner 440

einordnung
25
4 Hexagon−head bolt M8 x 1 Tightening torque 23 Nm (17
55 ftlb.)
5 Cover plate 1
6 Deflection roller 1 Check for smooth running or
roughness before undoing
7 Spacer 1
8 O−ring 1 Check, replace if necessary
9 Hexagon−head bolt M8 x 1 Tightening torque: 23 Nm (17
55 ftlb.)
10 Cover plate 1
11 Deflection roller 1 Check for smooth running or
roughness before undoing
12 Spacer 1
13 O−ring 1 Check, replace if necessary
14 Hexagon−head bolt 1 Replace
(micro−encapsulated) M10
x 30
15 Tensioning roller 1 Undo at the hexagon (wrench Tightening torque:
size 24) and simultaneously 60 Nm (44 ftlb.)
counter at the hexagon−head Counter at the hexagon−head
bolt bolt when tightening (wrench
size 15)
16 Spacer ring 1
17 Threaded sleeve with 1
hexagon (wrench size 24)
18 Cover plate 1
19 Transmission lever with 1 Thread on to tensioning lever
hexagon (wrench size (No. 21). See Assembly note
15mm)
20 Pan−head screw M6 x 16 1 Tightening torque: 9.7 Nm (7
ftlb.)
21 Tensioning lever 1 Drive out of the tensioning Fit in correct position; grease in
element with a drift (ø 5) area of bearing
22 Dust cap 1
23 Pan−head screw M8 x 16 2 Tightening torque: 23 Nm (17
ftlb.)
24 Tensioning element 1
25 Dust cap 1
26 Bearing sleeve 1 Grease with Optimol Optipit
grease
27 Bearing sleeve 1 Grease with Optimol Optipit
grease
28 Dowel sleeve M6 x 10 2
29 Bracket 1
13 73 37 Disassembling and assembling belt tensioner 441

einordnung
top of page
Assembly note
1. Thread transmission lever on to tensioning lever.

2. Insert the front right hexagon−head bolt on the bracket with Loctite 574.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Assembly note 442

13 78 19 Removing and installing drive belt (engine
installed)
Remove drive belt
Install drive belt
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13 78 19 Removing and installing drive belt (engine installed) 443

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1 Remove air cleaner assembly

2 Loosen servo pump wheel
3 Relieve drive belt
4 Remove servo pump wheel
5 Remove drive belt
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Remove drive belt
Removal overview of the drive belt (engine installed) 444

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1. Remove air cleaner assembly

Remove the complete air cleaner assembly.
a. Undo hexagon−head bolt M6 x
34.
b. Undo the hose clamp on the throttle
body.
c. Pull off plug from hot film mass air flow sensor and remove air cleaner assembly.
2. Loosen servo pump wheel

d. Mark belt travel direction with a coloured
pen.
e. Undo the three −hexagon−head bolts− on the servo pump by approx. one half
turn.
3. Relieve drive belt

Relieve drive belt. To do this, turn the tensioning roller clockwise and simultaneously remove the belt
from the drive pulleys.
Remove drive belt 445

einordnung
4. Remove servo pump wheel
Note
• Only remove the servo pump wheel when the drive belt is completely relieved!
f. Remove servo pump wheel with drive belt to the

rear.
g. Remove the belt from all drive wheels and lift up to
remove.
top of page

einordnung
1 Fit drive belt

2 Position servo pump wheel
3 Tension drive belt
4 Tighten fastening screws on servo pump
5 Install air cleaner assembly
top of page

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Install drive belt
1. Fit drive belt

Fit the belt onto the drive
wheels.
2. Position servo pump wheel

a. Put on the servo pump wheel together with the drive
belt.
b. Slightly tighten the three fastening screws on the servo
pump wheel.
3. Tension drive belt
Note
• It is absolutely necessary to check that the drive belt is correctly seated on all belt pulleys!
c. To tension the drive belt, turn the tensioning roller −7− in clockwise direction and
simultaneously fit the drive belt on the deflection roller −8− .
d. Then slowly relieve. To do this, turn the tensioning roller slowly
anti−clockwise.
Install drive belt 448

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4. Tighten fastening
screws on servo
pump
Tighten the fastening screws of the servo pump drive
wheel.
5. Install air cleaner assembly

Install air cleaner assembly completely.
e. Attach connector onto mass air flow
meter.
f. Tighten the hose clamp on the throttle
body.
g. Tighten the M6 x 34 hexagon−head bolt to 10 Nm (7.5
ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Install drive belt 449

15 03 21 Removing camshaft housing engine
removed
Tools
Component overview and tightening torques
Removing the camshaft housing
top of page
Tools

−A− Special tool holding wrench 9653/1 For countering the exhaust camshaft Gr. 2.2.2 ;
Workshop Equipment Manual
−B− Special tool holding wrench 9653 For countering the inlet camshaft Gr. 2.2.2 ;
−C− Commerically available multiple−tooth Gr. 2.4; Workshop Equipment Manual, No. 31
socket wrench insert M12
−D− Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88
716/20
top of page
15 03 21 Removing camshaft housing engine removed 450

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1 Closure cap, green 2 Replace; insert dry
2 Cover with 3 1 Replace O−ring; tightening
hexagon−head bolts M6 x torque 10 Nm (7.5 ftlb.)
20 and O−ring
3 Oil pump with 3 1 Replace O−ring; tightening
hexagon−head bolts M6 x torque 10 Nm (7.5 ftlb.)
35 and O−ring
4 Hexagon−head bolt M 6 x 2 10 Nm (7.5 ftlb.)
25
5 Holder for hydraulic valve 1
6 Hydraulic valve for valve 1 Pull out carefully, use special Special tool Gr. 2.2.2; Workshop
lift adjustment tool relay puller 9235 if Equipment Manual
necessary
Component overview and tightening torques 451

einordnung
6a O−ring for hydraulic valve 1 Replace O−ring, oil lightly if

necessary (engine oil)
7 Hexagon−head bolt M6 x 1 10 Nm (7.5 ftlb.)
70
8 Hexagon−head bolt M 6 x 14 (Pages 4 − 6 only 12 M6 x 35) 10 Nm (7.5 ftlb.)
35
− Hexagon−head bolt M 6 x 2 Fastening holder for oil 10 Nm (7.5 ftlb.)
40 (only pages 4 − 6) container onto camshaft
housing cover
9 Camshaft housing lid 1 Clean sealing surface; sealant:
Drei Bond or Loctite 5900
10 Chain tensioner 1 2 hexagon−head bolts M6 Observe identification! 10 Nm
(7.5 ftlb.)
11 Guide rail with 3 1 10 Nm (7.5 ftlb.)
hexagon−head bolts M6 x
25
12 Pan−head screw, drive 1 Internal serration screw M12 x Replace screw; contact surfaces
plate and plate for sprocket 1.5, counter with special tool must be completely free of
wheel of exhaust camshaft holding wrench 9653/1 ; do grease and oil. Counter with
not interchange drive plate: special tool 9653/1; tightening
height, left/right is different torque 30 Nm (22 ftlb.) and 1 x
90° torque angle
13 Hexagon−head bolt M12 x 1 Counter with special tool Replace screw; counter with
1.5 x 120 with washer for holding wrench 9653 special tool 9653; tightening
actuating element of inlet torque 30 Nm (22 ftlb.) and 170°
camshaft torque angle
14 Chain sprocket of exhaust 1 Observe left and right side Contact surfaces must be
camshaft (coating) completely free of grease and oil.
15 Actuating element for inlet 1 Left stop for setting timing
camshaft
16 Screw M5 x 10 3 Screws can fall into the Replace screws, tightening
microencapsulated crankcase! Use solenoid torque 7 Nm (5.0 ftlb.)
(hexagon socket) socket wrench insert if
necessary
17 Oil guide housing 1 Do not confuse left and right Observe height!
part
18 Hexagon−head bolts M6 x 12 Unscrew screws from the Tighten in specified sequence
30 (10.9) inside (description); 13 Nm (9.5 ftlb.)
19 Camshaft bearing cap 6 Unscrew carefully! Grease lightly; observe matching
number!
20 Hexagon−head bolts M6 x 4 13 Nm (9.5 ftlb.)
30 (10.9)
21 Thrust bearing cover 2 Unscrew carefully! Grease lightly; observe matching
number!
22 Exhaust camshaft 1 Observe identification on the
rotor! (cylinder bank allocation)
23 Inlet camshaft 1

einordnung
Observe identification on the

rotor! (cylinder bank allocation)
24 Flat−base tappets of 6 Do not exchange Oil lightly, pay attention to
exhaust camshaft cleanliness!
25 Operating plunger of inlet 6 Do not exchange Oil lightly, pay attention to
camshaft cleanliness!
26 Camshaft housing with 18 1 If hexagon−head bolts of Tightening torques: Initial
hexagon−head bolts M8 x strength class 8.8 were tightening 23 Nm (17 ftlb.); final
50 (10.9) installed, exchange these for tightening 28 Nm (21 ftlb.)
bolts of strength class 10.9.
top of page
Removing the camshaft housing
The following prelimiminary work must be carried out:
• Remove engine ’ 100119 Removing and installing engine .

• Remove rear muffler.
• Remove the oil container ’ 175219 Removing and installing oil container .
• Remove generator ’ 272219 Removing and installing three−phase generator .
• Remove coolant guide housing.
1. Cylinder bank 1 − 3: Undo fuel collection pipe with injection valves and remove holder for
turbochargers.
2. Cylinder bank 4 − 6: Undo holder for turbochargers and remove bypass flap control box on turbocharger.
3. Remove ignition coil. Remove electrical plug of the ignition coils, unscrew 2 cylinder screws (hexagon
socket) M6 x 25 of each and pull ignition coils out of spark−plug recess.
4. Remove 2 closure caps (green, plastic) between camshaft housing cover and cylinder head (clutch side).
To do so, puncture the closure cap in the middle and lever out using a small slotted screwdriver.
5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a
wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening
screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off
the two components.
6. Remove solenoid hydraulic valve for valve lift adjustment. To do so, remove plug, unscrew both
hexagon−head bolts M6 x 25 and remove with the holder. Subsequently remove the valve.
Removing the camshaft housing 453

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7. Remove camshaft housing cover. Unscrew the 15 hexagon−head bolts M6 and remove the camshaft
housing cover. If this is stuck, it can be loosened by gently tapping with a plastic hammer.
8. Check engine position. The cylinder side which is to be worked on must be positioned to
overlapping TDC so that the camshaft can be removed without tension. For cylinder bank 1 − 3, this
means: the cams of the exhaust and inlet shaft of cylinder 1 point towards each other −Figure 8.1− ,
for cylinder bank 4 − 6: the cams of the exhaust and inlet camshaft of cylinder 4 point away from
eachother (each points towards the cylinder head outer wall) −Figure 8.2− .
Figure 8.1: Overlapping TDC of cylinder 1
• − 1 − Exhaust camshaft
• − 2 − Inlet camshaft

einordnung
9. Remove chain tensioner. To do this, unscrew the two fastening screws of the chain tensioner cover and
remove the cover. Then remove the chain tensioner.
10. Remove guide rail for timing chain. Remove the three fastening screws on the short guide rail
between the camshaft sprockets and remove the guide rail.
Note
11. Remove camshaft sprockets. The timing chain must not be loaded when the screw connection of the
camshaft sprockets is loosened. To remove the sprocket wheels, the actuating element of the inlet
camshaft must be countered using special tool holding wrench 9653 , and the sprocket wheel of the
exhaust camshaft must be countered using speical tool holding wrench 9653/1 .
Note
• Only remove oil guide housing from the camshaft if the camshaft has to be replaced!
• The pan−head screws of the oil guide housing can fall into the crankcase when unscewing, the use of
a magnetic socket wrench insert is therefore recommended.

einordnung
• The oil guide housing of cylinder 1 − 3 and 4 − 6 differ in height.
12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hot−air gun,
unscrew and remove the housing. The fastening screws are microencapsulated and therefore
must be replaced.
13. Remove camshaft bearing cap. To do so, uniformly unscrew the hexagon−head bolts of the relevant
bearing covers from the inside. Remove the bearing covers in the specified order.
14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be
confused.

einordnung
15. Remove thrust bearing cover. Unscrew the hexagon−head bolts and remove the thrust bearing
cover up and off.
16. Lift camshafts up and out.
WARNING
Do not confuse the flat−base tappets.
The flat−base tappets have been run in in their housing. Therefore, they must not be interchanged or soiled.
17. Remove the flat−based tappets. Pull the flat−based tappets upwards out of the camshaft housing. In
order to avoid confusing the individual flat−based tappets, they should be placed on a prepared
sheet of paper as shown in the diagram.
18. Remove the camshaft housing. Unscrew and remove the 18 hexagon−head bolts in the order specified.
Then remove the camshaft housing.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

15 03 23 Installing camshaft housing
Refer to tools and tightening torques in Chapter "Removing camshaft housing"!
1. Replace seals. Replace the seals between the chain box/camshaft housing and the cylinder
head/camshaft housing seal. The embossed recesses in the seal must face the cylinder head.
2. Place the camshaft housing in position. Carefully put the camshaft housing on in a staight line. When
doing so, make sure that the flat−based tappet guides are not damaged.
Note
• If screws of strength class 8.8 have been installed, these must be replaced by screws of strength class
10.9.
3. Mount the 18 hexagon−head bolts. The bolts are tightened in two stages in the order specified.
• Initial tightening: 23 Nm (17 ftlb.)

• Final tightening: 28 Nm (21 ftlb.)
4. Insert flat−based tappets. Spread a thin coat of clean engine oil on the flat−base tappets. Do not
interchange the flat−base tappets. In the case of the flat−base tappets for the inlet camshaft, make sure that
the feather keys are positioned in the grooves in the flat−base tappet housing.
5.
15 03 23 Installing camshaft housing 458

einordnung
Subsequently install the camshafts => Removing and installing camshafts – engine
removed.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
15 03 23 Installing camshaft housing 459

15 05 02 Checking camshafts (timing) engine
removed
Tools
Checking camshafts
top of page
Tools

716/20
15 05 02 Checking camshafts (timing) engine removed 460

einordnung

A Auxiliary chain tensioner 9401 For removing play from the timing drive
mechanism
B Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the
correct position
top of page
Checking camshafts

turbochargers.
3. Remove ignition coils. Remove electrical plug of the ignition coils, unscrew 2 cylinder screws (hexagon
4. Remove 6 spark plugs ’ 032000 Removing spark
plugs .
Tools 461
einordnung
the two components.
8. Fit auxiliary chain tensioner for both cylinder banks. Unscrew two hexagon−head bolts M6 on each chain
tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary
chain tensioners and then apply pretension using the hexagon−head bolt until the first ring on the piston
just disappears from view.
9. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 − 3 using the universal dial
gauge holder. Extend the probe of the dial gauge until it is certain that measurement on the piston crown is
possible.
Checking camshafts 462

einordnung
10. To set the timing, the respective cylinder side must be positioned to overlapping TDC. For this purpose,
turn the engine at the belt pulley of the crankshaft (in operating direction) until the maximum defection
(reversing point) is attained on the dial gauge. The cams of the 1st cylinder point towards each other
−Figure 10.1− , the cams of the 4th cylinder point away from eachother (each points towards cylinder
head outer wall) −Figure 10.2− .
• 1 − Exhaust camshaft
• 2 − Inlet camshaft
Note
• Camshaft adjusting element must be positioned to the left−hand stop! Use special tool holding wrench
9653 !

einordnung
11. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding
wrench 9653 to turn the actuating element of the inlet camshaft counter−clockwise until it
meets the stop.
Note
• Tighten the screws for the adjustment device only slightly. It must be possible to move the frame
easily by hand.
12. Fit adjustment devices. Use two screws to fasten the frame of both staking tools at the end of the cylinder
bank (clutch side) on the sealing surface for the valve cover. Tighten screws by hand only.
13. Insert holding keys. Insert the holding keys 9661/1 into the frame according to their identification
and then fasten them with two fastening screws to prevent them from dropping.
Adjustment device of cylinder bank 4 − 6
Note
• If the timing setting is correct, it must be possible to insert the appropriate holding key 9661/1 into the
slot of the camshaft without using much force.
• Set the timing if incorrect => Setting camshafts (timing) – engine removed

einordnung
Correctly set camshafts
14. Turn the engine on the belt pulley of the crankshaft by 360° clockwise so that the second cylinder side
can be checked. (Observe maximum defection of dial gauge indicator or TDC position!).
Note
9653 !
15. Position the holding keys 9661/1 of the corresponding cylinder bank. The holding keys must slide easily
into the camshaft slot.
16. Remove the adjustment devices and the dial gauge.
17. Remove the auxiliary chain tensioner. To do this, relieve the auxiliary chain tensioner and loosen the two
fastening screws.
18. Reinstall chain tensioner. Insert the chain tensioner into the chain housing in accordance with its
identification, then fit the chain tensioner cover with a new seal. Tighten the hexagon−head bolts M6 to
10 Nm (7.5 ftlb.).
19. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm −Figure− (drying time of
sealant approx. 5 min). Put on the camshaft housing cover and tighten the 15 fastening screws from the
inside with tightening torque.
Tightening torque of the hexagon−head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
20. Install solenoid hydraulic valve for valve lift adjustment. Put on holder with both hexagon−head bolts M6
x 25 and tighten the screws with tightening torque.
21. Fit the closure cap and the oil extraction pump with new O−rings. Tighten the hexagon−head bolts: 3 M6
x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque.
22. Fit four new closure caps (green) for camshaft housing cover in dry state.
23. Install spark plugs ’ 032000 Installing spark plugs .

einordnung
Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.)
24. Install ignition coils. Insert ignition coils in spark−plug recess. Position 2 pan−head screws (hexagon
socket) M6 x 25 and tighten with tightening torque. Connect cable plug.
Tightening torque of pan−head screw M6 10 Nm (7.5 ftlb.)
Note
• Replace fastening nuts for holder of turbocharger!
25. Cylinder bank 1 − 3: Install fuel collection pipe with injection valves and holder for turbochargers.
26. Cylinder bank 4 − 6: Fit holder for turbochargers and install bypass flap control box on turbocharger.
Tightening torque of fastening nut M8 25 Nm (19 ftlb.)
27. Install coolant guide housing.
28. Install generator ’ 272219 Removing and installing three−phase generator .
29. Install the oil container ’ 175219 Removing and installing oil container .
Note
• Replace fastening nuts for flange of turbocharger rear mufflers!
30. Install rear mufflers.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

15 05 16 Setting camshafts (timing) engine removed
Tools
Setting the camshafts (timing)
top of page
Tools

716/20
15 05 16 Setting camshafts (timing) engine removed 467

einordnung

A Auxiliary chain tensioner 9401 For removing play from the timing drive
mechanism
B Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the
correct position
top of page
Setting the camshafts (timing)
Preliminary work:
• Camshafts installed => Removing and installing camshafts – engine removed.
• Spark plugs removed ’ 032000 Removing spark plugs .
1. Unscrew camshaft sprockets. To undo the screw connection, the camshaft adjusting elements (inlet shaft)
must be countered using special tool holding wrench 9653 and the sprocket wheels (exhaust shaft) must
be countered using special tool holding wrench 9653/1 .
Tools 468
einordnung
2. Fit auxiliary chain tensioner for both cylinder banks. Unscrew two hexagon−head bolts M6 on each chain
tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary
chain tensioners and then apply pretension using the hexagon−head bolt until the first ring on the piston
just disappears from view.
3. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 − 3 using the universal dial
gauge holder. Extend the probe of the dial gauge until it is certain that measurement on the piston crown is
possible.
4. To set the timing, the respective cylinder side must be positioned to overlapping TDC. For this purpose,
turn the engine at the belt pulley of the crankshaft (in operating direction) until the maximum defection
(reversing point) is attained on the dial gauge. The cams of the 1st cylinder point towards each other
−Figure 4.1− , the cams of the 4th cylinder point away from each other (each points towards cylinder
head outer wall) −Figure 4.2− .
Figure 4.1: Position of the camshafts on overlapping of cylinder 1
Setting the camshafts (timing) 469

einordnung
Note
9653 !
5. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench
9653 to turn the actuating element of the inlet camshaft counter−clockwise until it meets the stop.
Note
• Tighten the screws for the adjustment device only slightly. It must be possible to move the frame
easily by hand.
6. Fit adjustment devices. Use two screws to fasten the frame of both staking tools at the end of the
cylinder bank (clutch side) on the sealing surface for the valve cover. Tighten screws by hand only.
7. Insert holding keys. Insert the holding keys 9661/1 into the frame according to their identification
and then fasten them with two fastening screws to prevent them from dropping.

einordnung
8. Set camshafts on cylinder side 1 − 3 (cams of both camshafts point towards each other on cylinder 1). To
do this, use a suitable open−ended wrench (a/f 30) to turn the hexagon on the camshafts until the holding
key of the staking tool easily enters the slot of the camshaft. Fix holding keys with both hexagon−head
bolts.
Correctly set camshafts
Note
9653 !
9. Tighten sprocket wheels. Check whether the actuating element of the inlet camshaft is still on the
left stop. Subsequently tighten the sprockets of the inlet and exhaust camshafts with initial
tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special
tools holding wrench 9653 or holding wrench 9653/1 . Subsequently remove the holding keys
9661/1 and tighten the exhaust camshaft with a 90° torque angle and the inlet camshaft with a 170°
torque angle. Counter camshafts with the appropriate special tools.
10.

einordnung
Turn the engine on the belt pulley of the crankshaft by 360° clockwise so that the second cylinder side
can be set. (Observe maximum defection of dial gauge indicator or TDC position!).
11. Set cylinder side 4 − 6 in the same way as side 1 − 3 (cams of both camshafts on cylinder 4 point
away from each other).
Note
9653 !
12. Tighten sprocket wheels. Check whether the actuating element of the inlet camshaft is still on the
left stop. Subsequently tighten the sprockets of the inlet and exhaust camshafts with initial
tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special
tools holding wrench 9653 or holding wrench 9653/1 . Subsequently remove the holding keys
9661/1 and tighten the exhaust camshaft with a 90° torque angle and the inlet camshaft with a
170° torque angle. Counter camshafts with the appropriate special tools.
13. Check the timing. Turn engine on belt pulley of crankshaft clockwise by 720°.
14. Refit the holding keys and check the timing on both cylinder sides.
15. Remove the adjustment devices and the dial gauge if timing is set correctly, otherwise repeat the setting.
16. Remove the auxiliary chain tensioner. To do this, relieve the auxiliary chain tensioner and loosen the two
fastening screws.
10 Nm (7.5 ftlb.).
18. Clean sealing surface for the camshaft housing cover.
19. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm −Figure− (drying time of
sealant approx. 5 min). Put on the camshaft housing cover and tighten the 15 fastening screws from the
inside with tightening torque.
Tightening torque of hexagaon−head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
Tightening torque of hexagon−head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
Tightening torque of hexagon−head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
23. Install spark plugs ’ 032000 Installing spark plugs .
Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.)
24.

einordnung
Install ignition coils. Insert ignition coils in spark−plug recess. Position 2 pan−head screws (hexagon
socket) M6 x 25 and tighten with tightening torque. Connect cable plug.
Tightening torque of pan−head screw M6 10 Nm (7.5 ftlb.)
Note
• Replace fastening nuts for holder of turbocharger!
25. Cylinder bank 1 − 3: Install fuel collection pipe with injection valves and holder for turbochargers.
26. Cylinder bank 4 − 6: Fit holder for turbochargers and install bypass flap control box on turbocharger.
27. Install coolant guide housing.
28. Install generator ’ 272219 Removing and installing three−phase generator .
29. Install the oil container ’ 175219 Removing and installing oil container .
Note
• Replace fastening nuts for flange of turbocharger rear mufflers!
30. Install rear mufflers.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

15 05 19 Removing and installing camshafts engine
removed
Tools
Removing camshafts
Installing camshafts
top of page
Tools

15 05 19 Removing and installing camshafts engine removed 474

einordnung
716/20
top of page

1 Closure cap, green 2 Replace; insert dry
2 Cover with 3 hexagon−head 1 Replace O−ring;
bolts M6 x 20 and O−ring tightening torque 10
Nm (7.5 ftlb.)
3 Oil pump with 3 1 Replace O−ring;
Tools 475
einordnung
hexagon−head bolts M6 x 35 tightening torque 10

and O−ring Nm (7.5 ftlb.)
4 Hexagon−head bolt M 6 x 25 2 10 Nm (7.5 ftlb.)
5 Holder for hydraulic valve 1
6 Hydraulic valve for valve lift 1 Pull out carefully, use special tool Special tool Gr.
adjustment relay puller 9235 if necessary 2.2.2; Workshop
Equipment Manual
6a O−ring for hydraulic valve 1 Replace O−ring, oil
lightly if necessary
(engine oil)
7 Hexagon−head bolt M6 x 70 1 10 Nm (7.5 ftlb.)
8 Hexagon−head bolt M 6 x 35 14 (Pages 4 − 6 only 12 M6 x 35) 10 Nm (7.5 ftlb.)
− Hexagon−head bolt M 6 x 40 2 Fastening holder for oil container 10 Nm (7.5 ftlb.)
(only pages 4 − 6) onto camshaft housing cover
9 Camshaft housing lid 1 Clean sealing surface
; sealant : Drei Bond
or Loctite 5900
10 Chain tensioner 1 2 hexagon−head bolts M6 Observe
identification! 10
Nm (7.5 ftlb.)
11 Guide rail with 3 1 10 Nm (7.5 ftlb.)
hexagon−head bolts M6 x 25
12 Pan−head screw, drive plate 1 Internal serration screw M12 x Replace screw;
and plate for sprocket wheel 1.5, counter with special tool contact surfaces
of exhaust camshaft holding wrench 9653/1 ; do not must be completely
interchange drive plate: Height, free of grease and
left/right is different oil. Counter with
special tool 9653/1;
tightening torque 30
Nm (22 ftlb.) and 1 x
90° torque angle
13 Hexagon−head bolt M12 x 1.5 1 Counter with special tool holding Replace screw;
x 120 with washer for wrench 9653 counter with special
actuating element of inlet tool 9653; tightening
camshaft torque 30 Nm (22
ftlb.) and 170°
torque angle
14 Chain sprocket of exhaust 1 Observe left and right side Contact surfaces
camshaft (coating) must be completely
free of grease and
oil.
15 Actuating element for inlet 1 Left stop for setting
camshaft timing
16 Screw M5 x 10 3 Screws can fall into the Replace screws,
microencapsulated (hexagon crankcase! Use magnetic socket tightening torque 7
socket) wrench insert if necessary Nm (5.0 ftlb.)
17 Oil guide housing 1 Do not confuse left and right part Observe height!

einordnung
18 Hexagon−head bolts M6 x 30 12 Unscrew screws from the inside Tighten in specified

(10.9) sequence
(description); 13 Nm
(9.5 ftlb.)
19 Camshaft bearing cap 6 Unscrew carefully! Grease lightly;
observe matching
number!
20 Hexagon−head bolts M6 x 30 4 13 Nm (9.5 ftlb.)
(10.9)
21 Thrust bearing cover 2 Unscrew carefully! Grease lightly;
observe matching
number!
22 Exhaust camshaft 1 Observe
identification on the
rotor! (Cylinder bank
allocation)
23 Inlet camshaft 1 Observe
identification on the
rotor! (Cylinder bank
allocation)
24 Camshaft housing 1
top of page
Removing camshafts

turbochargers.
3. Remove ignition coil. Remove cable plug of the ignition coils, unscrew 2 cylinder screws (hexagon
4. Remove 2 closure caps (green, plastic) between camshaft housing cover and cylinder head (clutch side).
To do so, puncture the closure cap in the middle and lever out using a small slotted screwdriver.
Removing camshafts 477

einordnung
the two components.
8. Check engine position. The cylinder side which is to be worked on must be positioned to
overlapping TDC so that the camshaft can be removed without tension. For cylinder bank 1 − 3, this
means: the cams of the exhaust and inlet shaft of cylinder 1 point towards each other −Figure 8.1− ,
for cylinder bank 4 − 6: the cams of the exhaust and inlet camshaft of cylinder 4 point away from
eachother (each points towards the cylinder head outer wall) −Figure 8.2− .

einordnung
9. Remove chain tensioner. To do this, unscrew the two fastening screws of the chain tensioner cover and
remove the cover. Then remove the chain tensioner.
10. Remove guide rail for timing chain. Remove the three fastening screws on the short guide rail
between the camshaft sprockets and remove the guide rail.
Note

einordnung
11. Remove camshaft sprockets. The timing chain must not be loaded when the screw connection of the
camshaft sprockets is loosened. To remove the sprocket wheels, the actuating element of the inlet
camshaft must be countered using special tool holding wrench 9653 , and the sprocket wheel of the
exhaust camshaft must be countered using speical tool holding wrench 9653/1 .
Note
• Only remove oil guide housing from the camshaft if the camshaft has to be replaced!
• The pan−head screws of the oil guide housing can fall into the crankcase when unscewing, the use of
a solenoid socket wrench insert is therefore recommended.
• The oil guide housing of cylinder 1 − 3 and 4 − 6 differ in height.
12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hot−air gun,
unscrew and remove the housing. The fastening screws are microencapsulated and therefore
must be replaced.
13. Remove camshaft bearing cap. To do so, uniformly unscrew the hexagon−head bolts of the relevant
bearing covers from the inside. Remove the bearing covers in the specified order.

einordnung
14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be
confused.
15. Remove thrust bearing cover. Unscrew the hexagon−head bolts and remove the thrust bearing
cover up and off.
16. Lift camshafts up and out.
top of page
Installing camshafts
Note
• The oil guide housing of cylinder banks 1 − 3 and 4 − 6 differ in height.
Comparative view of oil guide housing of cylinder banks 1 −3 and 4 − 6
The following assembly is only required if the oil guide housing has been disconnected from the camshaft
when removing!
Installing camshafts 481

einordnung
1. Mount the oil guide housing. Fit the oil guide housing above the three sealing rings of the inlet camshaft.
The oil guide housing should be lightly oiled for this purpose. Press the sealing rings together by hand and
push the oil guide housing over them.
Prefitted oil guide housing
2. Move engine to TDC. Turn engine on the belt pulley of the crankshaft clockwise until the TDC
mark on the belt pulley (crankshaft side of belt pulley) is aligned with the cast lug on the crankshaft
housing.
Note
• The camshafts are allocated via the identification on the rotor cover. The last three digits indicate the
cylinder bank in which the respective camshaft is installed.
Position of camshaft designation
WARNING
Risk of damage!
• The bearing locations must not be oiled. Only grease is permissible.

einordnung
3. Insert camshafts. The bearing locations of the camshafts must be lightly greased before installation. Place
the timing chain over the camshafts when inserting the camshafts.
4. Position camshafts. It must be ensured that the camshafts are correctly positioned in the bearing
locations. The camshafts must be turned such that the cams of the first cylinder of the bank are
located at overlapping TDC. This means that the cams of the inlet and exhaust shaft of the first
cylinder point towards each other −Figure 4.1− , the cams of the fourth cylinder point away from
each other −Figure 4.2− .
5. Fit bearing cover. Fit the six small bearing covers so that the bearing location numbers on the camshaft
housing and on the bearing location face each other. Make sure that the matching numbers on the bearing
covers and on the camshaft housing are identical. Position the hexagon−head bolts M6 x 30.
6. Fit thrust bearing cover. Place the large thrust bearing cover onto both camshafts and tighten the
hexagon−head bolts M6 x 30 slightly.

einordnung
7. Tighten bearing cover. Tighten the hexagon−head bolts M6 x 30 of the bearing cover uniformly to
tightening torque in the specified sequence.
Tightening torque of the bearing cover screws (10.9) 13 Nm (10 ftlb.)
8. Tighten oil guide housing. Replace the three pan−head screws M5 x 10 (microencapsulated) and tighten to
tightening torque.
Tightening torque of M5 pan−head screws (8.8) 7 Nm (5 ftlb.)
9. Tighten the hexagon−head bolts M6 x 30 for the thrust bearing cover to tightening torque.
Tightening torque of the thrust bearing screws M6 (10.9) 13 Nm (10 ftlb.)
Note
• The camshaft adjusting elements must be positioned to the left−hand stop! Use special tool holding
wrench 9653 !
• The hexagon−head bolts M12 for the actuating element of the inlet camshaft is to be replaced!
10. Place camshaft adjusting element onto inlet camshaft. Lay the timing chain onto the chain
sprocket of the camshaft adjusting element and place the adjusting element onto the inlet
camshaft. Tighten the new hexagon−head screw M12 x 120 by hand. Turn the camshaft adjusting
element to the left stop using special tool holding wrench 9653 .
New chain sprockets for the exhaust camshafts (left and right part) have been in use as of May 2001. The
identical chain sprocket remains an original Porsche part − observe part numbers!
Identification of the sprocket wheels

einordnung
• Left wheel with coating and part number (identification "left" on rear side)
• Right wheel with part number and identification "right" (coating on rear side)
Note
• The contact surfaces of the sprocket wheels and camshaft flange (exhaust side) must be completely
free of oil and grease!
• The coated surface points towards the camshaft flange!
• The drive plates for the oil extraction pumps differ in height. The drive plate on cylinder bank 1 − 3 is
higher!
• The internal serration screw M12 must be replaced!
11. Fit exhaust camshaft wheel. Clean mounting surface of the sprocket and of the exhaust camshaft and
remove all oil and grease. The inscription left must be visible for cylinder bank 1−3, and right must be
visible for cylinder bank 4−6. Push on the sprocket. Push on the drive plate for the oil extraction pump
and tighten the new internal−serration screw by hand. Observe height of drive plates of cylinder banks 1
− 3 and 4 − 6!
12. Mount the guide rail between the sprocket wheels. Tighten the three M6 x 25 hexagon−head bolts with
the correct tightening torque.
Tightening torque of the hexagon−head bolts M6 (10.9) 13 Nm (10 ftlb.)
13. Set the timing. => Setting camshafts (timing) – engine removed .
Note
• The following work can be carried out only after the timing has been adjusted!

einordnung
10 Nm (7.5 ftlb.).
15. Clean sealing surface for the camshaft housing cover.
16. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm −Figure− (drying time
of sealant approx. 5 min). Put on the camshaft housing cover and tighten the 15 fastening screws
from the inside to tightening torque.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

15 20 37 Disassembling and assembling intermediate
shaft

1 Thrust bearing shell half 1 Replace, insert in crankcase half of
cylinder bank 1 − 3
2 Bearing shell half 1 Replace, insert in crankcase half of
cylinder bank 1 − 3
3 Dumb−bell shaft 1 Check for true running without any
problems; it must be possible to shift shaft
slightly
4 Snap ring 13 x 1.75 1 Check, replace if Ensure secure seating
necessary
5 1 Ensure secure seating
15 20 37 Disassembling and assembling intermediate shaft 487

einordnung
Snap ring Check, replace if

13 x 1.75 necessary
6 Bearing shell half 1 Replace and insert into crankcase half of
cylinder bank 4−6
7 Thrust bearing shell half 1 Replace and insert into crankcase half of
cylinder bank 4−6
8 Snap ring The opening of the snap ring should lie
36 x 1.75 opposite the Woodruff key groove.
9 Sprocket wheel 1 Check toothing for Warm on heating plate, push on up to stop.
wear, press off if Collar points towards intermediate shaft
necessary gearwheel
10 Woodruff key 1
6.0 x 7.5
11 Snap ring 1 The opening of the snap ring should lie
36 x 1.75 opposite the Woodruff key groove.
12 Sprocket wheel 1 Check toothing for Warm on heating plate, push on up to stop.
wear, press off if Collar points towards intermediate shaft
necessary gearwheel
13 Woodruff key 1
14 Thread plug to drive 1 dispose of Use Torx E10 tool,
exhaust oil extraction replace screw,
pump M18x1.5 tightening torque 25 Nm (19 ftlb.).
15 Intermediate shaft 1 Paired with timing gear of the crankshaft,
only install together, take note of the
identification on the crankcase
16 Timing gear 1 Check teeth for wear Note reference number, paired with
intermediate shaft, only install together
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
15 20 37 Disassembling and assembling intermediate shaft 488

15 55 19 Removing and installing hydraulic valve
Removing the hydraulic valve
Installing the hydraulic valve
top of page
Removing the hydraulic valve
Preliminary work: The rear spoiler and the heat shields must be removed’ 63 Removing and installing rear
spoiler.
1. Remove the side heat shields on the relevant side of the vehicle.
2. Disconnect the connecting hose between the air cleaner and the charge air cooler. To do so, lever out the
retaining clip on the top of the charge air cooler and pull the hose out.
3.
15 55 19 Removing and installing hydraulic valve 489

einordnung
Pull the lower connecting hose off the charge air cooler. To do so, lever the retaining clip out and pull the
hose downwards.
4. Undo the front fastening. Unscrew the fastening nut and the two fastening
screws.
5. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield.
Then press the heat shield out of the studs.
6. Undo the rear fastening. Unscrew the fastening nut and the fastening
screw.
8. Remove heat shield. To do so, unscrew the two upper fastening nuts.
9. Remove the cover panel. Unscrew the cover panel located above the plug coils.
10. Remove the adjacent plug coils. Unscrew the two hexagon socket head bolts for this purpose. Pull out the
plug coils and hang them to one side.
11.
Removing the hydraulic valve 490

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Remove the fastening plate of the switch−over valve. To do so, unscrew the two hexagon−head bolts and
remove the plate.
12. Remove the switch−over valve. To do so, disconnect the electric plug. Press the sheetmetal braces of the
plug and pull the plug out at the same time. Then pull the switch−over valve out of the cylinder head.
WARNING
Take care of the coil spring!
During removal and installation, make sure that the coil spring is present and does not remain in the camshaft
housing.
View of the valve
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Installing the hydraulic valve
1. Replace O−ring. Replace the O−ring on the hydraulic valve.
Installing the hydraulic valve 491

einordnung
2. Press the hydraulic valve into place. Insert the hydraulic valve into the camshaft housing and press it
firmly into place. Place the retaining cover in place. Pay attention to the cut−out on the fastening
arm.
Note
• In order to make it easier to position the hydraulic valve, a socket with an extension of wrench size 20
may be used.
3. Position the two fastening screws and screw them in evenly. Tighten screws to 10 Nm (7.5 ftlb.)
4. Install the plug coils. Place the adjacent plug coils on the spark plugs again. Tighten the two fastening
screws to 10 Nm (7.5 ftlb.).
5. Install heat shield. Tighten the two fastening screws to 10 Nm (7.5 ftlb.).
6.

einordnung
Reinstall the shield of the exhaust system. Tighten the two fastening nuts on the side member for this
purpose.
7. Install charge air cooler. To do so, place the charge air cooler back in the vehicle.
8. Tighten the front two fastening nuts and the fastening screw in the wheel well, all to 23 Nm (17 ftlb.).
9. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.). Supply the two hose
connections on the charge air cooler with new O−rings and fit them in place. The connections must
audibly engage.
10. Tighten the two sheetmetal nuts on the heat shield.

Fit rear spoiler again ’ 63 Removing and installing rear spoiler.

Heat shield on camshaft cover M6 10 (7.5)
Plug coils M6 x 25 10 (7.5)
Fastening screws on the switch−over valve M6 x 25 10 (7.5)
Fastening screws on the charge air cooler M8 23 (17)
Fastening nuts on the charge air cooler M8 23 (17)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

15 70 21 Removing cylinder head
Removing cylinder head
15 70 21 Removing cylinder head 494

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1 Fastening nut 12
2 Washer 12
3 Cylinder−head gasket 1 Replace, observe marking
4 Valve keys 12
5 Upper spring retainer of the exhaust spring 6
6 Outer valve spring − exhaust valve 6
7 Inner valve spring − exhaust valve 6
8 Valve stem seal 6 Replace
9 Lower valve retainer − exhaust valve 6
10 Spacer − exhaust valve 6
11 Valve guide − exhaust valve 6
12 Exhaust valve seat ring 6
13 Exhaust valve 6
15 70 21 Removing cylinder head 495

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14 Valve keys 6
15 Upper spring retainer − inlet valve 12
16 Outer valve spring − inlet valve 6
17 Inner valve spring − inlet valve 6
18 Valve stem seal − inlet valve 6 Replace
19 Lower valve retainer 6
20 Spacer − inlet valve 6
21 Inlet valve 6
22 Inlet valve seat ring 6
23 Valve guide − inlet valve 6
24 Cylinder head 1
25 Dowel sleeve 1
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Removing cylinder head
• Preliminary work: Removing the camshaft housing
1. Remove the seal between the camshaft housing and the cylinder head. Do not use the seal
again.
2. Unscrew cylinder head. Unscrew the twelve internal−serration screws in ½−turn steps in the order
specified. Work according to the order specified in order to avoid distorting the cylinder head.
3. Remove cylinder head. Lift cylinder head straight
upward
WARNING
Risk of damage!
• Under no circumstances may carbon deposits on the cylinders be removed by mechanical means
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing cylinder head 496

15 70 23 Installing cylinder head
1. Replace cylinder head gasket. Replace the gasket between the cylinders and the cylinder head. The
designation "TOP" must face upwards.
2. Place cylinder head in position. Uniformly push the cylinder head over the studs from above.
When doing so, make sure that the sealing surface is not damaged. Hand−tighten the
multiple−tooth nuts.
3. Tighten cylinder head. The cylinder head screws are tightened in four steps. Important: all four steps
must be carried out in the order shown.
15 70 23 Installing cylinder head 497

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• Initial tightening to 30 Nm (22 ftlb.).

• Loosen all screws again in reverse order.
• Tighten screws to 20 Nm (15.0 ftlb.)
• Retighten screws to 20 Nm (15.0 ftlb.)
• Retighten screws with torque angle of 1 x 90°.

Cylinder−head 30 Nm (22 ftlb.), then loosen; 20 Nm (15.0 ftlb.); then retighten all screws
nuts again to 20 Nm (15.0 ftlb.) +90° torque angle
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
15 70 23 Installing cylinder head 498

17 04 19 Removing and installing oil pressure sender
Removal
Installation
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Removal
1. Undo fastening screw M6x34 on the air cleaner housing.

2. Undo hose clamp between the air cleaner housing and intake
manifold.
3. Tilt the complete air cleaner housing 90° upward and remove to the rear.
4. Pull off the connecting hoses between the charge air coolers and the pressure pipe. To do this,
unclip the locking clips with a screwdriver. Then return the locking clips to installation position.
Additionally undo a fastening screw on the right−hand pressure pipe side.
17 04 19 Removing and installing oil pressure sender 499

einordnung
5. Undo pressure pipe −middle− by removing the spring clip −5− , hose clamp −3− , hexagon−head bolts −1
& 2− and electrical plug −4− .
6. Pull off the electrical plug. Undo the fastening screws and remove the throttle
body.
7. Remove oil temperature sensor.
8. Remove plug (wrench size 19). Undo oil pressure sender. Important: always counter with a second wrench
(wrench size 22) when doing so. Pull off the electrical plug and unscrew the sender.
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Installation
1. Fasten sender with new sealing ring. Counter with a second wrench when doing this. Push on the
electrical plug.
Sender tightening torque: 30 Nm (22 ftlb.)
Removal 500
einordnung
2. Install oil temperature sensor with new sealing ring.

3. Check throttle sealing ring and replace it if necessary. Fasten throttle body. Push on the electrical plug.
4. Install pressure pipe. Wet the connecting hoses between the charge air coolers and pressure pipe
with water at the connecting points and fit the hoses. The hoses must audibly engage. Then recheck
whether they are positioned properly by tilting and pulling on them.

Oil pressure sender 30 (22)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 501
17 07 19 Removing and installing oil temperature
sensor
Removal
Installation
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Removal
1. Undo fastening screw M6x34 on the air cleaner housing (A/f 13).
2. Undo hose clamp between the air cleaner housing and intake
manifold.
3. Pull off electrical wire connector of the hot film mass air flow
meter:
• To do this, push the plug downwards and press on the grooved surface at the sides.
• Then pull the connector up and off.
• Open the omega clip on the left side of the air cleaner housing and take out the electrical wire of the
hot film mass air flow meter.
• Re−close the omega clip for the removal (risk of breakage)
4. Tilt the complete air cleaner housing 90° upwards and remove
rearwards.
17 07 19 Removing and installing oil temperature sensor 502

einordnung
5. Pull off the connecting hoses between the charge air coolers and the pressure pipe. To do this,
unclip the locking clips with a screwdriver. Then return the locking clips to installation position.
Additionally undo a fastening screw on the right−hand pressure pipe side.
6. Undo pressure pipe −middle− by removing the spring clip −5− , hose clamp −3− , hexagon−head
bolts −1 & 2− and electrical plug −4− . Pull off vacuum hose to the control valve.
7. Pull off electrical plug. Undo the fastening screws and remove the throttle
body.
8. Pull off plug, unscrew oil temperature sensor by using a straight ring wrench, A/f 22.
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Installation
1. Fasten oil temperature sensor with new sealing ring.
2. Check throttle sealing ring and replace it if necessary. Fasten throttle body. Push on electrical plug.
Removal 503
einordnung
3. Install pressure pipe. Wet the connecting hoses between the charge air coolers and pressure pipe with
water at the connecting points and fit the hoses. The hoses must audibly engage. Then re−check whether
they are positioned properly by tilting and pulling on them.
4. Install air cleaner assembly ’ 24 25 19 install and remove air cleaner .
Location Thread Tightening torque Nm (ftlbs.)

Oil temperature sensor 30 (22)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 504
17 28 19 Removing and installing check valve
engine installed
Removal
Installation
View of the check valve
17 28 19 Removing and installing check valve engine installed 505

einordnung

1 Oil drain plug 1 Hold Hold; tightening torque 60 Nm (44 ftlb.)
2 Copper sealing ring 20 x 1 Replace
24
35
4 Hexagon nut with washer 1
M8
5 Hexagon−head bolt M6 x 2 Tightening torque 10 Nm (7.5 ftlb.)
16
30
7 Check valve 1 Check for smoothness of operation; it must not
stick in any position. Replace if necessary.
8 Sealing ring 21.89 x 2.62 2 Replace; coat with Vaseline
9 Sealing ring 30 x 2.5 1 Replace; coat with Vaseline
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Removal
1. Raise the vehicle at the jacking points.
CAUTION
lifting platform!
and the vehicle!
Removal 506
einordnung
2. Remove oll filler cap.
3. Undo the oil drain plug (a/f 19) on the oil container. Make sure to counter with a wrench (a/f 27)
when doing this. Unscrew the loosened plug and drain the oil.
CAUTION
• Take suitable protective measures to avoid scalding by hot oil
4. Equip oil drain plug with new sealing ring and tighten. Make sure to counter with a wrench when
tightening. Tightening torque 60 Nm (44 ftlb.).
5. Undo oil drain plug on the crankcase. Unscrew the oil drain plug (a/f 15) and drain the oil. Then equip the
plug with a new sealing ring and tighten. Tightening torque 70 Nm (52 ftlb.).
CAUTION
• Take suitable protective measures to avoid scalding by hot oil
Removal 507
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6. Undo the lower right−hand fastening point of the oil tank.
7. Loosen and remove two hexagon−head bolts (M6 x 16) on the flexible flange of the oil tank.
8. Carefully press the flexible flange off the check valve with a plastic spatula; a second person should
press the oil tank to the right at the same time. Insert a suitable piece of wood between the crankcase
and oil container.
DANGER
Risk of damage!
• Do not twist the flange.
9. Undo the fastening screw (M8 x 30) and pull the check valve off the crankcase. Push the oil container
aside at the same time.
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Installation
1. Coat the new sealing rings of the check valve with Vaseline and fit them. Push the oil container aside
at the same time.
2. Equip the flexible flange with a new sealing ring, put the flange on the check valve without using
excessive force and fasten it in place.
3. Screw down the oil tank fastening point on the lower right side.
Installation 508
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4. Fill in engine oil.
Note
• The oil change quantity (without oil filter change) is approx. 7.8 litres after a dripping time of 20
minutes!
5. Warm the engine up to operating temperature and carry out a leak test.
6. Check the oil level.
7. Check engine oil level. Check engine oil level on the instrument cluster. Top up engine oil until the 7th
segment of the on−board computer display lights up. The following conditions must be maintained for the
measurement.
• Vehicle horizontal
• Engine at operating temperature
• Engine idling
• Vehicle stationary
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 509
17 40 19 Removing and installing oil cooler Engine
removed
Removing oil cooler
Installing oil cooler
• Remove and install oil container => Removing and installing oil container.
• Remove intake distributor ’ 244619 Removing and installing intake distributor .
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Removing oil cooler
1. Remove crankcase ventilation tube. Unscrew the two M6 screws −arrows− for this
purpose.
2. Undo the union nut −arrow− and remove the crankcase ventilation tube.
3. Undo the holder behind the oil cooler. Unscrew the M6 screw −arrow− for this purpose.
17 40 19 Removing and installing oil cooler Engine removed 510

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4. Pull coolant hose −2− off the oil cooler −1− . To do so, unscrew the screw−type hose clamp from
the coolant hose −2− and pull off the coolant hose.
5. Unscrew the four M6 screws −arrows− on the oil cooler and remove the oil cooler.
6. Suck out remaining oil.
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Installing oil cooler
Note
• Always replace the O−rings for the oil cooler!
1. Replace seals. Replace the four O−rings −arrows− between the bracket and oil cooler. Coat the O−rings
with a small amount of universal grease and insert.
2. Place oil cooler in position with the four M6 screws and tighten.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)
Removing oil cooler 511

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3. Fasten coolant hose −2− on the oil cooler −1− . To do so, place the coolant hose −2− in position and
tighten the screw−type hose clamp.
4. Install the crankcase ventilation tube. For this purpose, place the crankcase ventilation tube with the union
nut −arrow− in position, but do not tighten yet.
Note
• Always replace the flange seal for the crankcase ventilation tube!
5. Replace the flange seal; then place the two M6 screws −arrows− in position and tighten.
Tightening torque for hexagon−head bolts 10 Nm (7.5 ftlb.)
6. Tighten the union nut on the crankcase ventilation tube −arrow− with the correct tightening
torque.
Tightening torque for union nut 30 Nm (22 ftlb.)
Installing oil cooler 512

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7. Install intake distributor ’ 244619 Removing and installing intake distributor .

8. Install oil container => Removing and installing oil container.
9. Check oil level and top up if necessary ’ 032000 Changing engine oil and filter .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing oil cooler 513

17 52 19 Removing and installing oil container
Removing oil container − removal overview
Installing oil container
Preliminary work: ’ 100119 Removing and installing engine
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Removing oil container − removal overview
17 52 19 Removing and installing oil container 514

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1. Detaching oil return line and vent line

a. Detach return line on the oil container. Make sure to counter with a wrench at the oil
container.
b. Loosen the −hose clamp− at the vent line and pull off the vent hose.
Removing oil container − removal overview 515

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2. Pulling plug off oil level

sender and detaching oil
line
c. Pull −plug− off the oil level sender and set it
aside.
d. Detach the return line from the cylinder head. Make sure to counter with a wrench when doing
this in order to prevent damage to the oil container.
3. Detaching positive crankcase ventilation and oil container fastening

e. Loosen the −hose clamp− on the positive crankcase ventilation hose on the engine and pull off
the vent hose.
f. Loosen the oil container fastening
screw.
4. Detaching inlet line

Detach inlet line between the oil container and the engine. Unscrew the two hexagon socket head bolts
for this purpose.
5. Undo fastening screws

Undo the two oil container −fastening screws− at the
sides.
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Removing oil container − removal overview 516

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Installing oil container
1. Tightening fastening screws

Tighten the two oil container −fastening screws− at the
side holders.
Installing oil container 517

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2. Tightening inlet line

a. Fit a new O−ring on the inlet line between the oil container and engine and insert the line.
b. Tighten the two hexagon socket head
bolts.
Tightening torque: 9.7 Nm (7 ftlb.)
3. Tightening positive crankcase

ventilation and oil container
fastening
c. Push on the positive crankcase ventilation hose again and tighten the −hose clamp−
.
d. Position and tighten the oil container −fastening screw−
.
4. Pushing on oil level sender plug and tightening the oil line
e. Push on the oil level sender connecting cable
again.
f. Tighten the oil return line of the cylinder head. Make sure to counter with a wrench at the oil container
when doing this.

einordnung
5. Tightening oil
return line and vent
line
g. Tighten oil return line on the oil container. Make sure to counter with a wrench at the oil container
when doing this.
h. Push on vent hose again and fit the −spring band
clamp− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

19 38 17 Draining and filling in coolant
Caution
Draining coolant
Filling in coolant
Bleeding the cooling system
CAUTION
Risk of damage!
The drain cocks of the front radiator and side radiators must be opened only manually . Never open them with
tools.
Manually open drain cocks and drain/collect the coolant.
View of the drain cock
CAUTION
Risk of damage!
Never use tools to close the drain cocks.
1. Close drain cocks manually .
2. Check position of the locking springs on the drain cocks. The bows of the locking springs must always
point up.
19 38 17 Draining and filling in coolant 520

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CAUTION
Severe damage can occur if the installation position is incorrect (twisted out of position).
3. Vent the cooling system in connection with the System Tester 2 . Use menu item "Special functions" for
this purpose.
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Draining coolant
1. Unscrew cap on coolant expansion tank.
2. Undo coolant drain plugs on right and left and drain the coolant. Equip drain plugs with new seals.
Tightening torque 10 Nm (7.5 ftlb.) to 15 Nm (11.0 ftlb.).
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Filling in coolant
Note
• The engine cooling system is factory−filled with a lifetime engine coolant. This engine coolant must
not be mixed or replaced with other coolants. Use only original Porsche coolant when changing or
topping up the engine coolant.
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Bleeding the cooling system
Note
• The cooling system is bled in connection with the Porsche System Tester 2
1. Connect the Porsche System Tester 2 and switch on the ignition.

2. Select menu item "Special function" in the "Vehicle type" menu.
3. Press the ’ key to change to the "Control units" menu.
4. Select menu item "Cooling system" in the "Control units" menu and press the >> key.
Note
Draining coolant 521

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• The following message appears on the screen: Start function with [F8]
5. Press the F8 key and follow the further instructions of the Porsche System Tester 2 .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Bleeding the cooling system 522

19 40 19 Removing and installing coolant expansion
tank
Removal
Installation
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Removal
1. Unscrew the fastening screw M6 x 34 (a/f 13) on the rear side of the air cleaner
housing.
2. Disconnect the hot film mass air flow meter line of the air cleaner housing:
• Pull off electrical wire connector of the hot film mass air flow meter.
• Open omega clip.
• Remove electrical wire.
19 40 19 Removing and installing coolant expansion tank 523

einordnung
3. Tilt the air cleaner housing upwards to the right by 90° and then turn the air cleaner housing and remove
from the engine compartment.
4. Unscrew the hose clamp (a/f 7) between the air cleaner housing and the
cowl.
Note
• In order to avoid any damage when removing the intake pipes, pull off the connector.
5. Pull off the electrical connector on the solenoid hydraulic valve of the cylinder bank
1−3.
6. Undo pressure pipe −middle− by removing the spring clip −5− , hose clamp −3− , hexagon−head bolts −1
& 2− and electrical plug −4− .
7. Pull off vacuum hose to the control valve.
8. Unscrew fuel return line −1− and fuel supply line −2− . It is important to counter when performing this
step.
9. Remove fuel filter.
Removal 524
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10. Completely remove fuel filter with holder. To to this, bend the retaining clip upward as shown −arrow−
and at the same time remove the filter with holder.
11. Remove holder for fuel return line on the intake pipe (hexagon−head bolt M 6).
12. Undo three fastening screws on the front intake distributor separation point.
13. Remove hose clamp and pull off ventilation hose from the intake pipe.
14.
Removal 525
einordnung
Unscrew upper hexagon−head bolt, lift intake pipe out of the shaft bolt and remove rearwards. Remove
and dispose of seal.
15. Disconnect coolant hose with commercially available hose clip.
16. Unscrew spring band clamp or hose clamp on the coolant expansion tank.
17. Prepare auxiliary hose (internal diameter ) and a length of approx. 1 metre.
18. Pull off disconnected coolant hose, push auxiliary hose onto the supports and collect coolant in a
container.
19. Disconnect electrical plug connection from the sensor for the coolant−level indicator.
20. Undo the hexagon nut.
21. Pull coolant expansion tank out of the guide rails and remove rearwards.
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Removal 526
einordnung
Installation
1. Push coolant expansion tank into the guide rails and

fasten.
2. Attach connector from the sensor for the coolant−level
indicator.
3. Fasten the coolant hose with a new hose clamp 999.512.552.00 . Observe the installation position of the
screw−type hose clamp. The screw must be installed pointing vertically downwards.
4. Install intake
pipe:
• Fix new seal onto the separation point/intake distributor.

• Place suction line on the shaft bolts, at the same time push the hose of the recirculating air valves onto
the suction line.
• Fasten the hexagon−head bolt.
• Fasten ventilation line from the oil tank onto the intake distributor.
Installation 527
einordnung
• Fasten separation point.
5. Position the fuel filter with holder on the coolant expansion tank and press it down at the rear. The holder
must engage audibly.
6. Install fuel hoses.
7. Install rear pressure pipe.
8. Fit air cleaner assembly.
9. Remove hose clamp.
10. Fill in coolant.
11. Warm engine up to operating temperature. Perform tightness test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 528
19 50 19 Removing and installing coolant pump
(engine installed)
Tools
Removal
Installation
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Tools

A Retaining device 9624/1
B Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, Nos.
72 and 73
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Removal
1. Raise the vehicle at the prescribed jacking points.
2. Open engine compartment lid.
3. Disconnect
battery.
4. Remove rear spoiler ’ 635519 Removing and installing rear
spoiler .
5. Remove bumper with shield.
19 50 19 Removing and installing coolant pump (engine installed) 529

einordnung
6. Remove lateral shields.
7. Loosen fastening nuts.
8. Loosen fastening nuts on the turbocharger. Remove the shield.
9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two
−hexagon socket screws− for this purpose.
CAUTION
Falling rear muffler!
The rear muffler is loose after the restraining straps are removed. The rear muffler should be held by a second
person or supported with a transmission jack.
10. Push restraining straps out of the holder. Push the restraining strap into the recesses of the engine carrier
with a screwdriver and move outward.
11. Remove rear mufflers. Two persons can now remove the rear muffler.
Removal 530
einordnung
12. Undo fastening screw M 6 x 34 on the air cleaner housing.

13. Undo hose clamp between the air cleaner housing and intake manifold.
14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment.
15. Pull off the connecting hoses between the charge air coolers and the pressure pipe:
• Unclip the locking clips using a screwdriver and pull off the hose.
• Then clip the locking clips in again.
• Undo the right fastening screw on the refrigerant line.
16. Remove pressure pipe:
• Disconnect connector on the temperature pressure sensor −arrow 4− .

• In order to do this, undo 2 spring band clamps and 1 screw−type hose clamp A/f 7 (−arrow 5− and
−arrow 3− , 1 hose clamp not illustrated) and 3 hexagon−head bolts A/f 10 (−arrow 1− and −arrow
Removal 531
einordnung
2− ).
• Pull off vacuum hose to the control valve.
17. Disconnect oxygen sensor plug on the rear closing panel.
18. Disconnect oxygen sensor plug.

19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.
20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously
remove the drive belt from the generator.
21. In order to reduce the pressure in the cooling system, carefully open the coolant expansion tank. Undo
coolant drain plugs on left and right and collect coolant in a suitable container, so that it can be re−used.
22. Equip drain plugs with new sealing rings and then fasten.
Tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.).
Note
Removal 532
einordnung
• When swiveling, make sure not to damage the bellows on the lower joint!
23. Undo stabilizer of the cross member and swivel downwards or disengage.
24. Support the engine−transmission unit:
• In order to do this, fasten special tool (retaining device) 9624/1 on the take−up points of the stabilizer
mounts.
• Adjust the pressure screw, until the mounting point is touching the crankcase or the crash support.
25. Separate engine carrier from the engine mounts right and left (a/f 18)
26. Separate engine carrier from the coolant guide housing.
WARNING
Damage to the console and the oil lines can occur.
• After the engine carrier has been separated the bracket is only held by the oil lines and the O−rings.
• The auxiliary screws can only be removed once the coolant pump has been fastened.
Removal 533
einordnung
27. Immediately secure the bracket with a shorter auxiliary screw (M10 x 55).
28. Loosen and remove belt guard on the coolant pump.

29. Loosen hose clamp and pull coolant filler hose off the coolant pump.
30. Undo fastening screws of the coolant pump.
31. Remove coolant pump and dispose of seal.
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Installation
1. Clean sealing surfaces.
2. Install a new seal onto the coolant pump.
3. Install belt guard.

4. Fasten coolant filler hose onto the coolant pump.
Installation 534
einordnung
5. Remove auxiliary screw again.
6. Fasten engine carrier onto the bracket.

7. Fasten engine carrier onto the engine mounts (a/f 18).
8. Remove special tool (retaining device) 9624/1 .

9. Fasten
stabilizer.
10. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler
must be replaced. Move the rear muffler into installation position and push the two tensioning straps over
the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.
Installation 535
einordnung
11. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts.
12. Tighten restraining straps on the rear muffler.
13. Fit heat shields, bumper and rear spoiler.
14. Install drive belt ’ 13 78 19 removing and installing drive belt .

15. Check that the installation position of the drive belt on all drive wheels is correct. Check the installation
position on the belt pulley from underneath (use light source).
16. Install pressure pipe:
• Push on vacuum hose to the control valve.

• Fix connector onto the temperature pressure sensor.
• Fasten pressure pipe with 2 spring band clamps, 1 screw−type hose clamp and 3 hexagon−head bolts
(a/f 10, 10 Nm (7.5 ftlb.)).
17. Attach new O rings onto both pressure hoses and coat the O−rings and take−up bores on the pressure pipe
with plenty of water.
Installation 536
einordnung
18. Push the right and left pressure hoses into the pressure pipe, until they audibly engage.
19. Make sure that the pressure hoses have been fitted correctly, by tipping and pulling on the pressure hoses.
20. Install air cleaner housing.

21. Fasten hot film mass air flow meter line:
• Open omega clip on the left−hand side of the air cleaner housing,
• Insert electrical line of the hot film mass air flow meter,
• Close omega clip.
22. Connect battery.

23. Enter radio code.
Note
• The cooling system is bled in connection with the Porsche System Tester 2.
• Select special functions. Menu point.
24. Bleed the cooling system => Draining and filling in coolant.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 537
19 62 19 Removing and installing coolant hose at
front left (Y−type coolant distributor)
Tools
Removal
Installation
top of page
Tools

Spring−band Commercially available; refer to Workshop For opening and closing
clamp pliers Equipment Manual, Chapter 2.4, No. 72 or 73 spring−band clamps
top of page
Removal
1. Unscrew wheel bolts of the front left wheel.
2. Raise the vehicle at the prescribed support points.
3. Remove left front wheel. To do this, remove the wheel bolts and take the wheel off.
4. Remove front underbody cover.
5. Remove the front part of the left wheel housing liner ’ 50 56 19 Removing and installing front wheel
housing liner.
6. Undo and remove the left diagonal brace between the body and the side member. To do this, unscrew the
two fastening screws M 12 x 25 −(arrow)− .
Note
• Pull off the complete flange on the radiator. Do not loosen the hose clamp.
19 62 19 Removing and installing coolant hose at front left (Y−type coolant distributor) 538
einordnung
7. Drain coolant. To do this, unclip the −locking spring− on the flange for the coolant hose and pull the
coolant hose off. Approx. 5 litres of coolant will pour out. Collect the coolant.
8. Pull the pipe holder off the support after first lifting the holding straps somewhat with a small screwdriver.
Then pull the coolant line with the holder off the support.
9. Push the right hose clamp down. Loosen the hose clamp at the connection between the coolant pipe
of the left radiator and the Y−type distributor, then remove the complete coolant line between the
radiator and the Y−type distributor.
WARNING
Risk of damage to the coolant pipe when the coolant hose is cut open
• Do not cut too deeply when cutting open the coolant hose.
10. Loosen hose clamp at the inner coolant pipe (to the middle radiator) and at the Y−type distributor.
In order to facilitate work when pulling off the hose connection, cut the hose open vertically with
respect to its end face over a length of approx. 4 cm. The coolant pipe must not be damaged during
this procedure.
11. Loosen the lower hose clamp. Loosen the hose clamp at the connection point between the Y−pipe
and the coolant pipe.
12. Pull off the Y−type coolant distributor. To do this, pull the Y−type distributor off its three connection
points and take it out of the installation area.
Removal 539
einordnung
top of page
Installation
1. Put the two hose clamps back onto the connections which lead to the radiators. Fit the hose clamp
above the lower flange.
Note
• In order to facilitate fitting, wet the inside of the coolant hose with water in the fitting area and push
the hose onto the coolant pipes.
2. Return the Y−type distributor to installation position and push on the three connections.
3. Refit the rear hose clamp on the connection point of the Y−type distributor and on the coolant pipe of the
middle radiator.
4. Re−position the hose clamp between the Y−type distributor and the left radiator. Tighten the hose clamp.
5. Re−position the lower hose clamp on the Y−type distributor and

tighten it.
6. Push the −locking clip− back onto the radiator flanges. Make sure that the locking clip has been properly
inserted when doing this.
7. Position the coolant line in relation to the left radiator and clip the holder in again.
8. Replace the O−ring on the coolant hose flange.
Installation 540
einordnung
9. Wet the O−ring with plenty of water in order to facilitate fitting the coolant hose. Push on the
coolant hose. Press the coolant hose firmly onto the connection neck. The locking clip of the hose
fitting must audibly engage. Then re−check the correct fitting by tilting and pulling on the coolant
hose.
WARNING
Coolant hose can pop off
• Check whether the coolant hose fitting is securely seated.

• Never treat hose connections with a lubricant such as Vaseline or spray oil.
10. Check whether the locking spring at the radiator flange is properly seated. The locking spring must be
positioned between the two integral guides.
11. After fitting the Y−type coolant distributor, additionally check the position of the locking springs and
whether the coolant drain cocks are correctly engaged. The bows of the locking springs must always point
up.
12. In order to check proper engagement, manually turn the flange of the drain cocks
counterclockwise and clockwise. There must be approx. 1 mm play in both directions.
Installation 541
einordnung
Turn drain cock counterclockwise
Turn drain cock clockwise
13. Fit and fasten the left diagonal brace.

Tightening torque 100 Nm (74 ftlb.).
14. Fit front part of the wheel housing liner and the underbody cover ’ 50 56 19 Removing and
installing front wheel housing liner.
15. Mount front wheel. Tighten the wheel bolts.
16. Fill in coolant and bleed the cooling system in connection with the Porsche System Tester 2. To do
this, select menu item Special function , => Draining and filling in coolant.
17. Then check the cooling system for leaks.

Left diagonal brace M12 x 25 x 1.5 100 (74)
Front wheel 130 (96)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 542
20 02 01 Checking fuel pressure
Caution
WARNING
Observe the general safety instructions when working on the fuel system and when handling petrol and other
fuels => Precautionary measures when working on fuel system !
Attach or mount a warning notice on the vehicle in a clearly visible position −see Figure− !
Ensure good ventilation in the work area (e.g., open window, switch on exhauster)!
Secure vehicle with warning sign!

−A− Connecting lead see workshop equipment In connection with pressure gauge for
9559 manual chapter 2.2.2 connecting to the flange of the fuel
pressure line
−B− Pressure gauge P see workshop equipment
378a manual chapter 2.2.1
Note
20 02 01 Checking fuel pressure 543

einordnung
• The battery voltage may not fall below 12 volts during the fuel pressure check!
1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The
battery voltage must not fall below 12 volts during the check.
Note
• Use the brass closure cap on the test connection of the fuel pressure line only once as the sealing ring
cannot be replaced. To avoid possible leaks, the cap must be replaced after removal!
2. Release the metal cap on the test connection of the pressure pipe from the fuel filter to the fuel collection
pipe and screw it off by hand (a/f 13 mm).
3. Connect connecting lead 9559 with special tool pressure gauge P 378a (a/f 17 union nut) and manually
attach the line to the test connection of the fuel supply line −arrow− .
Procedure when the engine is standing still:
4. Connect the Porsche Tester PST 2 in the vehicle, switch on the ignition and switch off all loads,
such as the radio and air conditioning.
5. Activate fuel pump relay using Porsche System Tester. To do this, select the line drive links in the
DME control unit individual search and then select fuel pump relay −see figure− . Activate by
pressing the F8 key.
6. Read value on pressure gauge.

Target test values when engine not running: 3.8 ± 0.2 bar.
7. Switch off the fuel pump relay on the System Tester by pressing F8 .

einordnung
8. Switch off ignition, pull off System Tester connecting lead in the vehicle and switch off System Tester.
Checking while engine is idling:
9. To check the engine while it is idling, connect the pressure gauge as described above and start the engine.
Switch off the engine after reading the fuel pressure.
Target test values when engine is idling: 3.3 ± 0.2 bar.
10. Loosen the union nuts of the connecting cable 9559 for the special tool pressure gauge P 378a on the test
connection and remove special tool. Collect emerging fuel, e.g. with a cloth.
11. Position new closure cap on test connection and tighten (a/f 13 mm).
Tightening torque of new brass closure cap: 2.5 ± 0.5 Nm ( 0.5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 10 19 Removing and installing fuel tank
Caution
Removing fuel tank
Installing fuel tank
WARNING
CAUTION
Coolant is hazardous to the health and irritates the skin!
Danger of scalding when the engine is hot. Do not begin working until the engine has cooled down!
• When handling coolant, wear protective gloves and goggles!

• In case of contact with the skin or eyes, wash immediately with plenty of water!
20 10 19 Removing and installing fuel tank 546

einordnung

1 Union nut 1 VW / Audi socket Replace and secure with a spot of hot−melt
wrench 3217 adhesive; tightening torque 70 Nm (52 ftlb.)
2 Fuel level sensor 1
3 Sealing ring 1 Replace
4 Tank closure 1 Grease sealing ring with Vaseline
5 Hexagon−head bolt 2 Tightening torque 10 Nm (7.5 ftlb.)
M6 x 12
6 Fuel evaporative valve 1
7 Vent hose 1
8 Filler neck 1 Protect wing from Apply a thin coat of silicone spray in the
damage fitting area
9 Supporting ring 1
10 Seal 1 Replace
20 10 19 Removing and installing fuel tank 547

einordnung
11 Combination screw 2 Tightening torque: 23 Nm (17 ftlb.)

M8 x 40
12 Restraining strap 2 Loosen before Engage in front subframe
(right and left) removal of front−axle
13 Combination screw 2 Tightening torque: 23 Nm (17 ftlb.)
M8 x 40
14 Restraining strap 1
(transverse)
15 Bottom guard 1
16 Fuel tank 1 Do not pinch fuel level sensor
top of page
Removing fuel tank
Note
• To lock the steering wheel, use only the steering wheel holder −A− approved for airbags to prevent
damage or injury should an airbag be released!
1. Move steering wheel to centre position (front wheels straight−ahead) and lock it with the steering wheel
holder −arrow− .
Note
• Before disconnecting the battery, observe the work instructions ’ 9 Work instructions after
disconnecting the battery !
2. Disconnect battery. Disconnect negative terminal and cover the terminal or battery.
3. Remove the front wheels, using the prescribed special tool socket wrench insert P 300 to avoid
damage to the wheels.
4. Remove front wheel housing liner ’ 50 56 19 Removing and installing front wheel housing liner .
Note
• It is impermissible to suck out the fuel through the filler neck, as this can damage the inner flap on the
filler neck. Always suck out the fuel through the hole for the fuel level sensor.
Removing fuel tank 548

einordnung
• Remove fuel level sensor.
5. Empty the fuel tank. The fuel must be sucked out through the hole for the fuel level sensor. To do
this, remove the closure cap in the luggage compartment (unscrew four hexagon nuts a/f 10) and
disconnect all cable plugs and fuel lines from the fuel level sensor. Undo union nut with special
tool socket wrench 3217 , carefully remove the fuel level sensor and place in a clean container, e.g.
a bucket. Remove the fuel using a suitable fuel extractor. Cover hole for the fuel level sensor with a
cloth or similar.
Note
• To remove and install the front wheel drive the help of a second person is necessary
6. Remove the front−wheel drive complete with cardan shaft. Get a second person to help. See also ’
39 88 19 Removing and installing front wheel drive and ’ 39 02 19 Removing and installing cardan
shaft .
7. Drain coolant. To do this, clamp shut the coolant hoses between the cardan tunnel and the engine
(including the black vent line over the left coolant pipe) with hose clamps. Drain coolant at the radiator
drain plug ’ 19 38 17 Draining and filling in coolant . Collect coolant in a clean container for re−use.
8. Re−tighten drain plugs. Undo the coolant pipes and vent line at the cardan tunnel. To do so, slide off the
spring−band clamps at the rear using spring−band clamp pliers, unclip from the plastic holders, and
unscrew the two hexagon−head bolts M6 −Item 1− and the two hexagon nuts M6 −Item 3− at the front
pipe holder. Place a coolant collecting container ready, secure the pipes with wire and then pull from the
rear coolant hoses. Collect the draining coolant and allow pipes to drain.
9. Detach tank filler neck. To do so, remove closure cap and unscrew the hexagon bolt M6 x 12 −arrow− .

einordnung
10. Unclip seal of the filler neck in the right front wheel well −1− . Disconnect plug connections for
the vent lines at the filler neck −2− . Press release buttons and simultaneously pull the lines apart.
Disconnect ground strap −4− on the plug. Disconnect vent line to fuel tank −3− behind the spring
strut.
Note
• To avoid damage to the wing when removing and installing the filler neck, suitable protective covers
must be placed.
11. Turn the filler neck clockwise by approx. 45° and pull out carefully. The open surge flap must not be
damaged when pulling out the filler neck. Close the opening in the fuel tank (e.g.with the cap of a spray
can).
12. Loosen universal joint (steering shaft) −arrow− at steering gear. Take out the fit bolt M8 x 35 and
slide the universal joint upwards. If necessary, carefully force apart the clamping piece with a
screwdriver and spray with rust solvent. Replace fit bolt.
Note
• The suspension subframe must be lowered. To do this, undo the two screws fastening the steering
gear to the suspension subframe.
13. Detach steering gear from the suspension subframe. To do this, unscrew the two hexagon−head bolts

einordnung
M10 x 1.5 a/f 15 (on the underside of the suspension subframe) −5− and press off the steering gear ’ 48
90 19 Removing and installing steering gear .
14. Support suspension subframe with a transmission jack. Pull off the cable plug on the sensor of the
headlight beam adjustment −right arrow− . Detach stabilizer from the mount. To do this, remove the
hexagon nut M10 from each joint −left arrow in the Figure− , countering with an open−ended wrench at
the joint hexagon.
15. Detach suspension subframe. Undo the six hexagon−head bolts at the front and rear −Items 2, 6 and 7−
and lower complete suspension subframe by approx. 15 cm.
16. Disconnect all coolant lines. To do this, undo the four spring−band clamps −Item 4, upper part of
Figure− on the coolant hoses at the front and pull off the coolant pipes.
17. Undo a spring−band clamp for the vent line on the distributor hose in the left front wheel well −1− .
Remove coolant pipe.
18. Pull off vent line from distributor hose in the left front wheel well −Item 2, previous Figure− and unclip
from the two holders under the fuel tank −arrow− . Remove line on the coolant hose in the right front

einordnung
wheel well by undoing the spring−band clamps. If necessary, collect the draining coolant. Pull off vent
line to the side.
Note
• Observe the installation position of both connector tubes to the radiators in relation to the plastic
holders.
19. Disconnect both connector tubes to the radiators under the fuel tank and remove. To do this, undo hose
clamps on the coolant hoses.
20. Remove both plastic holders complete with coolant pipes from the body. To do this, pull back the
tab on each holder −2− , press the entire holder forwards and up −3− and remove the pipe package
together with both holders to the rear. Remove pipes from the plastic holders in the wheel wells.
Observe installation position of the coolant pipes!
21. Detach fuel tank restraining strap (transverse) from the body by unscrewing the two hexagon−head bolts
M8 x 40 −arrow− .
22. Lift the fuel tank from the support lugs −arrows− and, with the help of a second person, carefully
remove in a downward direction (avoiding damage to the hole for the fuel level sensor).
top of page

einordnung
Installing fuel tank
Note
• Fix connecting cable and fuel lines, using adhesive tape if necessary, to the body aperture for the fuel
level sensor
• Observe line routing between fuel tank and body (e.g. chafing, pinching)
1. Lift the fuel tank with the help of a second person and carefully insert from below (avoiding damage
to the hole for the fuel level sensor). Engage fuel tank on the support lugs on the floor of the body
−arrows− .
2. Install fuel tank restraining strap (transverse). Position hexagon bolts M8 x 40 at the sides of the body and
tighten −arrow− .
3. Insert fuel level sensor with new seal into fuel tank. Position and tighten new union nut. Fit lines and
plugs. After assembly, secure union nut with a spot of hot−melt adhesive. Fit closure cap in the luggage
compartment (screw tight the four hexagon nuts a/f 10) ’ 20 66 19 911 Carrera 4 (996) Removing and
installing fuel pump .
Tightening torque for union nut 70 Nm (52 ftlb.)
4. Pre−position connector tubes to the radiators together with pre−mounted holders (replace if necessary) in
installation position under the fuel tank. Clip holders to the body. To do this, hook the holders at the front
and engage the tab at the rear. Push the left and right pipes into coolant hoses and tighten screw−type hose
clamps.
Installing fuel tank 553

einordnung
5. Insert vent line into distributor hose in the left front wheel well −2− and into coolant hose in the
right front wheel well and fit the spring−band clamps.
6. Clip vent line into the two holders−arrows− on the coolant pipes.
7. Fasten coolant pipes at front. To do this, insert two aluminium pipes and a vent line in the network
into the corresponding coolant hoses and fit the five spring−band clamps (1 clamp for vent line on
the distributor hose in the left front wheel well −Item 2− and four clamps for coolant pipes −Item
4 in next figure− ).
8. Mount four pipe holders using two M6 hexagon−head bolts and two M6 hexagon nuts −Items 1
and 3 in next Figure− and fix coolant pipes on the vehicle underbody in the holders. Push coolant
pipes into the coolant hoses to the engine, tighten the spring−band clamps and remove the hose
clamps again.
Tightening torque of the hexagon−head bolts M6: 10 Nm (7.5 ftlb.)
Note
• When lifting the suspension subframe, protect servo lines of the steering from damage

einordnung
9. Carefully lift suspension subframe and fix with the six hexagon−head bolts −Items 2, 6 and 7− .
Screw suspension subframe into place to the prescribed tightening torque.
Tightening torque M14 x 1.5 : 160 Nm (118 ftlb.) (−Item 2− )
Tightening torque of corner plate to side member M10 x 1.5 : 65 Nm (48 ftlb.) (−Item 6− )
Tightening torque of corner plate to body M12 x 1.5 : 100 Nm (74 ftlb.) (−Item 7− )
10. Fit stabilizer to mount −left arrow− . To do this, screw two M10 hexagon nuts on the joint heads,
simultaneously countering at the joint hexagon with an open−ended wrench. Connect cable plug to sensor
of the headlight beam adjustment −right arrow− .
Tightening torque of M10 hexagon nut: 46 Nm (34 ftlb.)
Note
• Replace hexagon−head bolts for fastening the steering gear to the suspension subframe and the fit bolt
for the universal joint whenever they have been removed. Screw threads must be clean and free of
grease.
11. Position the steering gear with the centring sleeves in the through−holes on the suspension subframe and
screw into place with two new hexagon−head bolts a/f 15 M10 x 1.5 to the underside of the suspension
frame −5− ’ 48 90 19 Removing and installing steering gear .

einordnung
Note
• The lug on the toothed steering gear pin must engage in the clamping slot of the universal joint
−arrows− .
12. Push universal joint of the steering shaft onto the toothed steering gear pin. The lug must engage in the
clamping slot of the universal joint. Insert new fit bolt M8 x 35 into the retaining groove −arrow− and
tighten with the prescribed torque.
13. Install the front wheel drive with the help of a second person ’ 39 88 19 Removing and Installing front
wheel drive .
Note
• To facilitate installation, apply a thin coat of silicone spray to the filler neck in the fitting area.
14. Fit filler neck. Remove protective cap on fuel tank. Carefully push the filler neck with rotary movements
into the flange on the fuel tank (protect wing and wheel well from damage). Fit vent lines and ground
cable −Items 2, 3 and 4 in the next figure− by connecting to the filler neck.
15. Fit seal in correct position −1− . Ensure that the locking tabs are seated correctly.

einordnung
16. Tighten hexagon−head bolt M6 x 12 of the filler neck −arrow− . Coat seat of the cap seal with Vaseline.
Tightening torque 10 Nm (7.5 ftlb.)
17. Fill and bleed cooling system ’ 19 38 17 Filling and bleeding the cooling system .
18. Refill fuel tank.
19. Calibrate fuel level sensor system => Calibrating fuel level sensor system.
20. Install front wheel housing liners ’ 50 56 19 Removing and installing front wheel housing liner .
Note
• Observe specification for greasing wheel bolts ’ 44 05 19 Removing and installing wheel .
21. Fit the front wheels, using the prescribed special tool socket wrench insert P 300 to avoid damage to
the wheels.
Tightening torque of the wheel bolts : 130 Nm (96 ftlb.).
22. Connect the battery ’ 9 Work instructions after disconnecting the battery .
23. Remove steering wheel holder.
24. Check wheel arch values. In the case of deviations, perform a suspension alignment if necesary and
adjust ’ 44 Wheels, tires, suspension alignment .
Tightening torques for front axle and fuel tank
Cross member/side member on body (front and rear) M14 x 1.5 160
Corner plate on body M12 x 1.5 100
Diagonal brace on body and side member M12 x 1.5 100
Front−axle drive shaft to final drive M8 39
Rear front−axle transmission support to body M10 65
Front front−axle transmission support to front−axle cross M10 65
member
Stud to front−axle cross member M8 20
Tank strap to body M8 23
Stabilizer mount to stabilizer M10 46
Universal joint (steering shaft) to steering gear M8 23
Steering gear to cross member M10 x 1.5 65
Tightening torques for front axle and fuel tank 557

einordnung
Wheel to wheel hub M14 x 1.5 130
996410, 996411, 996420, 996421, 996450, 996451, 996430, 996431, 996610, 996611
Tightening torques for front axle and fuel tank 558

20 15 01 Calibrating fuel level sensor system
Caution
WARNING
Danger of fire and injury!
Observe general safety regulations on the fuel system!
Wear protective gloves!
Note
• Calibration is necessary after replacement of the fuel tank, fuel level sensor or instrument cluster.
• The fuel level sensor system need not be calibrated if the battery was disconnected or a plug
connection on the instrument cluster or fuel level sensor was removed. The values remain stored in
the instrument cluster.
• A range on remaining fuel of less than 15 km is not displayed in the instrument cluster.
1. Disconnect the battery and cover terminal or battery.

2. Remove cap over the fuel level sensor system.
3. Remove fuel level sensor. ’ Rep. Gr. 20 66 19; Removing and installing fuel pump.
4. Using a fuel extractor, completely drain the fuel tank through the fuel level sensor opening. Fuel extractor:
Refer to the Workshop Equipment Manual, Chapter 3 "Workshop Equipment".
5. −Make sure that the two recesses on the left and right−hand sides of the tank are emptied
completely.−
6. Reinstall the fuel level sensor and, with "ignition off", fill the tank with −28 litres− of fuel.
7. Perform tank calibration with the Porsche System Tester 2:
• Select vehicle type (911 Carrera)

• Select control modules
• Select instrument cluster
• Select menu item "Tank calibration"
• Confirm calibration
8. The fuel level sensor system has now been calibrated.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
20 15 01 Calibrating fuel level sensor system 559

20 39 19 Removing and installing fuel return line
Removal
Installation
top of page
Removal
1. Remove engine−transmission unit ’ 10, 10 removing and installing engine
2. Remove coolant expansion tank.
• Undo the hexagon nut.
• Disconnect electrical plug connection from the sensor for coolant−level indicator.
• Pull coolant expansion tank out of the guide rails and remove.
20 39 19 Removing and installing fuel return line 560

einordnung
3. Open line holder.
4. Disconnect line plug connection on the vehicle floor. In order to do this, press button and at the
same pull the wires apart. Collect residual fuel. Protect the open lines against dirt.
5. Guide the fuel return line out of the line holder and
remove.
top of page
Installation
1. Guide the fuel return line into the line holder and
insert.
2. Connect the lines onto the plug connections. The plug must engage audibly. Correct engagement of
the plug connection must be checked with a gentle pull.
Removal 561
einordnung
3. Close line holders.

4. Push coolant expansion tank into the guide rails and
fasten.
5. Attach connector from the sensor for the coolant−level

indicator.
6. Install engine again ’ 10 removing and installing engine.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 562
20 60 55 Replacing fuel filter
Removing fuel filter
top of page
Removing fuel filter
the grooved surface at the sides. Pull the plug up and off at the same time.
20 60 55 Replacing fuel filter 563

einordnung
the retaining clip using a screwdriver and pull out the hose. Refit the retaining clips immediately.
5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards on the right by 90° and then turn the
housing to the left by approx. 90°.
Removing fuel filter 564

einordnung
7. Pull off the ground cable from the fuel filter.
8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel.
9. Disconnect the plug connection and collect the residual fuel. Protect open lines against dirt.
10. Remove fuel filter with holder. To to this, bend the retaining clip upward as shown −arrow− and
simultaneously remove the filter with holder.
11. Remove fuel filter. To do this, fully open the restraining strap and take the fuel filter out.

einordnung
12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way
that the mark −arrows− on the filter is aligned with the outer edge of the holder in installation
position.
13. Position the fuel filter with holder on the coolant expansion tank again and press it down at rear. The
holder must engage audibly.
14. Connect plug connector of the fuel supply line. The plug must engage audibly. Pull slightly to
ensure that the connection is properly locked.
15. Tighten fuel pressure line. Make sure to counter with a wrench when doing this.
16. Connect the ground cable to the filter.

17.

einordnung
Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left
air cleaner housing side and then close the clip.
position. To do this, first turn the housing to the right by approx. 90° and push the rubber hose
over the flange. Then swivel downwards by 90°.
20. Tighten the hose clamp on the connecting hose. Reconnect the plug on the hot film mass air flow sensor.
The plug must engage audibly!
21. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must
engage audibly!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 66 01 Checking quantity delivered by fuel pump
Caution
WARNING
Only carry out checking when engine is standing still!
Ensure good ventilation in the work area (e.g., open window, switch on exhauster)!

−A− Connection hose see workshop equipment manual chapter Insert receptacle in open end
9507 2.2.2 of the hose
−B− Receptacle Original Porsche spare parts; part number To connect to the
996.106.255.00 rapid−action coupling of the
fuel return line
Note
20 66 01 Checking quantity delivered by fuel pump 568

einordnung
• The battery voltage may not fall below 12 volts during the fuel pressure check!
1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The
battery voltage must not fall below 12 volts during the check.
2. Connect the Porsche Tester PST 2 in the vehicle, switch on the ignition and switch off all loads,
such as the radio and air conditioning.
3. Remove the rear and middle underside panels. To remove the rear panel, the left side panel must also be
loosened, see ’ 911 Carrera (996), 51 90 19 Removing and installing underside panels , position 4, 5 and
9.
4. Loosen the rapid−action coupling on the fuel return line −arrow− ; to do this, press in the locking
lug and pull off the coupling. Collect emerging residual fuel with a cloth, for example.
5. Insert receptacle into the open end of the hose for the special tool connection hose 9507 and connect with
the rapid−action coupling of the fuel return line. Be sure that the coupling is fitted correctly (must engage
audibly) by pulling the line apart!
6. Put the open end of the hose in a petrol−resistant canister. Keep a stopwatch at hand for the following
measurement.
7. Activate the fuel pump relay using the Porsche System Tester PST 2. To do this, select the line drive
links in the DME control unit individual search and then select fuel pump relay. Activate by pressing
F8 −see figure− . After 30 seconds, deactivate the relay again by pressing F8 .
8. Transfer the collected fuel into a suitable measuring cup.
Target value for supplied fuel quantity:
− in 30 seconds, at least 1.25 litres
9.

einordnung
Remove the receptacle with hose and insert the rapid−action coupling onto the fuel return line. Be sure
that the coupling is fitted correctly (must engage audibly) by pulling the line apart!
10. Install underside panels ’ 911 Carrera (996), 51 90 19 Removing and installing underside panels.
11. Switch off ignition, switch off Porsche System Tester and disconnect.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 68 19 Removing and installing fuel cooler
Removing fuel cooler
Installing fuel cooler
top of page
Removing fuel cooler
Note
• It is necessary to remove the refrigerant by suction before removing the fuel cooler.
• The safety regulations must be observed during all work on the refrigerant system! (See: 87−1 Safety
regulations when handling refrigerant R134a)
1. Suck refrigerant out of the charging valves in the luggage

compartment.
2. Open the engine compartment lid and disconnect the refrigerant lines from the fuel cooler.
Immediately seal the openings with suitable plugs.
3. Disconnect the negative terminal of the battery.
WARNING
Danger of fire and injury! Observe general safety regulations on the fuel system! Wear protective gloves that
are fuel−resistant! Ensure that there is adequate ventilation.
CAUTION
Always counter at the fuel lines when undoing them.
20 68 19 Removing and installing fuel cooler 571

einordnung
4. Undoing fuel lines. Counter union nut with a/f 17 and with a/f 14.
5. Collect residual fuel. Undo holding clamp and remove fuel cooler.
top of page
Installing fuel cooler
1. Fit new seals on to refrigerant lines and fasten on to fuel cooler.
2. Fasten holding clamp of the fuel cooler.
CAUTION
Always counter at the fuel lines when fastening them.
3. Fastening fuel lines.
4. Drain and fill the refrigerant unit.
5. Warm the engine up to operating temperature and carry out a leak test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing fuel cooler 572

21 10 19 Removing and installing air guide for charge
air cooling
Removing air guide for charge air cooling
Installing air guide for charge air cooling
top of page
Removing air guide for charge air cooling
Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield
and bumper) ’ 635519 Removing and installing rear spoiler .
1. Remove wheel housing liner. (Serv. No.: 5369)
2. Pull the two connecting hoses off the charge air cooler. To do this, disconnect the connecting hose
between the engine and charge air cooler at the separation point beneath the tail light. Unclip the safety
bracket and pull out the hose.
21 10 19 Removing and installing air guide for charge air cooling 573
einordnung
Open hose clamp at bottom of charge air cooler and pull off the flange.
3. Remove charge air cooler. To do this, disconnect both hose connections on the charge air cooler.
Then unscrew the seven fastening screws on the charge air cooler (two at rear)
two at heat shield
and three in wheel housing. Remove charge air cooler.
4. Unscrew cover panel.

5. Unclip intake pipe. Unclip the pipe at the bottom and lift out.
6. Unscrew the four fastening nuts.
7. Pull air guide at the back end downwards and then take out of the body towards the rear.
top of page
Removing air guide for charge air cooling 574

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Installing air guide for charge air cooling
1. Reinstall air guide. Replace all seals on the air guide. Insert the front end of the air guide into the body.
Press the back end upwards into the wing.
2. Retighten air guide. Replace the four fastening clips of the intake pipe and tighten the air duct with the
−four fastening screws− .
3. Reinstall intake pipe −(catches)− . First insert the pipe into the duct and then press evenly into the body.
4. Reinstall cover panel. Insert the cover panel in the wheel well and tighten the seven −fastening
screws− to 10 Nm (7.5 ftlb.).
5. Install charge air cooler. Move the charge air cooler back into installation position. Tighten the two rear
−fastening screws− to 10 Nm (7.5 ftlb.).
Tighten the three front −fastening screws− to 10 Nm (7.5 ftlb.).
Then fasten the heat shield with two sheetmetal nuts.
Installing air guide for charge air cooling 575

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996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing air guide for charge air cooling 576

21 30 19 Removing and installing turbocharger
Removing turbocharger
Installing turbocharger
top of page
Removing turbocharger
Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield
and bumper) ’ 635519 Removing and installing rear spoiler .
CAUTION
Danger of burns! Parts of the exhaust system can be extremely hot. Do not begin work until the exhaust
system has cooled down.
1. Remove charge air cooler. To do this, disconnect both hose connections on the charge air cooler.
2. Then unscrew the two fastening screws and the hexagon nuts on the air charge cooler.
3. Unscrew the rear hexagon nut and the fastening screw.
4. Undo the two fastening nuts on the heat shield.

5. Take the charge air cooler out of the vehicle.
21 30 19 Removing and installing turbocharger 577

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6. Remove heat shield. Unscrew the heat shield covering the catalytic converter and the turbocharger.
Undo the two fastening nuts on the vehicle for this purpose.
WARNING
Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be
replaced.
7. Undo oil pipe and turbocharger support. Open and unscrew the upper oil pipe of the turbocharger at the
uppermost screw connection. Make sure to counter with an open ring wrench when doing this. Then open
the support of the turbocharger.
8. Pull off vacuum line. Pull off the vacuum line on the control box. Push a small screwdriver between
connection nipple and vacuum hose. Widen vacuum hose a little and spray in silicone spray at the
same time. Remove vacuum hose with angled pliers.
CAUTION
Damage to the control box. Never lever off the hose with a screwdriver.
9. Screw off oil pipes. Open the two oil pipes on the oil container. Collect draining
oil.
Removing turbocharger 578

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10. Undo pressure pipe from turbocharger. Undo the hose clamp and remove the pressure hose from
the exhaust turbocharger for this purpose.
11. Unscrew the four fastening nuts on the turbocharger flange to the catalytic converter.
12. Unscrew exhaust manifold. Unscrew the nine fastening screws for this purpose. Remove turbocharger
with exhaust manifold.
13. Open separation point between turbocharger and exhaust manifold.
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Installing turbocharger
1. Fit turbocharger. Insert a new seal between the turbocharger and the exhaust manifold and tighten
the three fastening screws to 30 Nm (22 ftlb.).
Installing turbocharger 579

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2. Tighten exhaust manifold on the cylinder head. Position exhaust manifold with new seals (cylinder head
and on the catalytic converter) on the cylinder head and insert in the exhaust catalytic converter at the
same time. Position the nine fastening screws on the cylinder head by hand and tighten in two stages. First
stage 25 Nm (18 ftlb.). Second stage 33 Nm (24 ftlb.).
Tightening occurs in two stages (first 25 Nm (18 ftlb.), then 33 Nm (24 ftlb.)) according to the sequence
shown.
3. Replace the four fastening nuts to the exhaust catalytic converter and tighten to 30 Nm (22
ftlb.).
4. Tighten the two oil pipes to 30 Nm (22 ftlb.)

each.

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5. Screw on the turbocharger support. Do not forget the washer beneath the new hexagon nut when doing
this. Tighten the hexagon nut to 23 Nm (17 ftlb.). Then position the hexagon nut of the vent line by hand
and tighten to 20 Nm (15 ftlb.).
6. Install heat shield. Move heat shield into installation position again and tighten the two sheetmetal
nuts.
7. Push the pressure pipe back onto the turbocharger and tighten the hose clamp.
8. Install charge air cooler. Insert the charge air cooler in the studs on the body. Tighten the rear fastening
nut and the two fastening screws to 23 Nm (17 ftlb.).
9. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.).

einordnung

11. Reconnect the two hose connections. Make sure that the clips are properly inserted when doing this. Press
in the hose support until it is heard to engage.
12. Carry out oil level and tightness test.
Note
• Conclude by carrying out oil level and tightness test.

Turbocharger on the exhaust manifold M8 23 (17 ftlb.)
Exhaust manifold on the cylinder head
1. 25 (19 ftlb.)
stage 33 (24.5 ftlb.)
2.
stage
Turbocharger on the exhaust catalytic converter M8 30 (22 ftlb.)
Oil inlet line M16 x 1.5 30 (22 ftlb.)
Oil return line M16 x 1.5 30 (22 ftlb.)
Turbocharger support M8 23 (17 ftlb.)
Oil inlet line on the turbocharger 20 (15.0 ftlb.)
Fastening screws on charge air cooler M8 23 (17 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

21 43 19 Removing and installing the charge air
cooler
Removing the charge air cooler.
Installing the charge air cooler
top of page
Removing the charge air cooler.
Preliminary work: The accesories rear end bumper (Serv. No.: 635519) and the wheel housing liner
(Serv.:536919) must be removed.
1. Disconnect the connecting hose between the air cleaner and the charge air cooler. To do so, lever out the
retaining clip on the top of the charge air cooler and pull the hose out.
2. Pull the lower connecting hose off the charge air cooler. To do so, lever the retaining clip out and pull the
hose downwards.
3. Undo the front fastening. Unscrew the fastening nut and the two fastening
screws.
4. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield.
Then press the heat shield out of the studs.
5. Undo the rear fastening. Unscrew the fastening nut and the fastening
screw.
21 43 19 Removing and installing the charge air cooler 583

einordnung
top of page
Installing the charge air cooler
1. Re−install the shield of the exhaust system. Tighten the two fastening nuts on the side member for
this purpose.
2. Install charge air cooler. To do so, place the charge air cooler back in the vehicle.
3. Tighten the front two fastening nuts and the fastening screw in the wheel well, all to 23 Nm (17 ftlb.).
4. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.). Supply the two hose
connections on the charge air cooler with new O−rings and fit them in place. The connections must
audibly engage.

Re−install the rear spoiler.

Fastening screws and nuts of the charge air cooler M8 23 Nm (17 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing the charge air cooler. 584

21 67 05 Checking and adjusting the bypass flap
control boxes on the turbocharger
Check and adjust (cylinder bank 1 − 3)

A Dial gauge holder VW 387
B Tester 9160/1
C Pressure gauge 9103/2 Use boost pressure gauge from 944 Turbo
top of page
Test
2.
21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger 585
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Fasten special tooldial gauge holder VW 387 onto the underneath of the camshaft housing (cylinder bank
1−3). Flanges with thread M 8 have been provided or this procedure.
3. Align tracer pin with push rod, set the dial gauge with pre−tension
to 0.
4. Connect special tool pressure gauge 9103/2 . Connect hand pump and pressure gauge together with
branch pieces. Hang pressure gauge on stabilizer.
5. Remove vacuum hoses from the control box:
• Push a small screwdriver between connection nipple and vacuum hose.

• Widen vacuum hose a little and spray in e.g. silicone spray at the same time.
• Pull off vacuum hose.
6. Connect connecting piece (shop−made) and Tecalan line (shop−made) onto the control box and connect
with the pressure gauge.
7. Produce overpressure of 0.5 bar with special tool tester 9160/1 . Read off pressure on special tool pressure
gauge 9103/2 . Have a second person read off the stroke of the push rod on the dial gauge at the same
time.
Prescribed stroke: 4 ± 0.5 mm.
Adjusting
1. Remove safety bracket.

2. Twist adjusting nut
accordingly.
Turning clockwise − stroke smaller.
Turning counter−clockwise − stroke larger.
3. Fit safety bracket again.
top of page
Test 586
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1. Fasten special tool dial gauge holder VW 387 onto the underneath of the right camshaft housing.
2. Make tracer pin (shop−made). The tracer pin must be bent accordingly in the area of the deflector plate.
3. Carry out checking and adjusting, using the same method used on cylinder bank 1−3.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Check and adjust (cylinder bank 4 − 6) 587

21 67 19 Removing and installing bypass flap control
box on the turbocharger − Engine installed
Removing bypass flap control box on the turbocharger
Installing bypass flap control box on the turbocharger
top of page
Removing bypass flap control box on the turbocharger
CAUTION
• Danger of burns! Parts of the exhaust system can be extremely hot.

• Do not begin work until the exhaust system has cooled down or wear suitable protective gloves!
1. Remove safety bracket on the push rod. To do so, carefully pull off the safety bracket with a screwdriver.
2. Loosen and then unscrew the nut on the push rod, and pull the push rod out of the release.
3. Remove vacuum hose from the control box. Push a small screwdriver between connection nipple and
vacuum hose. Widen vacuum hose a little and spray in silicone spray at the same time. Pull off vacuum
hose.
21 67 19 Removing and installing bypass flap control box on the turbocharger − Engine installed 588
einordnung
4. Undo and unscrew the two holder screws of the control box.
5. Remove control box.
top of page
Installing bypass flap control box on the turbocharger
1. Push the push rod of the control box into the bypass flap
release.
2. Secure the control box by screwing in and tightening the two holder screws.
3. Screw the nut on the push

rod.
4. Adjust the control box => Checking and adjusting the bypass flap control boxes on the turbocharger.
5. Push the vacuum hose on to the control box.
Removing bypass flap control box on the turbocharger 589

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6. Fit the safety bracket again, and check for correct seating.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing bypass flap control box on the turbocharger 590

21 75 20 Removing and installing oil container for
exhaust turbocharger − Engine installed
Removing oil container for exhaust turbocharger
Installing oil container for exhaust turbocharger
top of page
Removing oil container for exhaust turbocharger
WARNING
• Danger of scalding from draining oil!

WARNING
replaced.
Requirement:
• Remove rear spoiler ’ 635519 Removing and installing rear spoiler .
1. Remove heat shield ’ 635019 Removing and installing rear bumper .
2. Unscrew the oil drain plug −arrow− of the oil container and collect any emerging
oil.
21 75 20 Removing and installing oil container for exhaust turbocharger − Engine installed 591
einordnung
3. Unscrew the M6 screw on the heat shield −arrow− .
4. Undo both union nuts of the oil lines −arrows− a/f 17 and pull the lines out of the oil container by
removing the M6 screw −arrow− from the oil line holder.
Oil line holder
5. Unscrew both fastening screws (hexagon socket a/f 6) −arrows− .

6. Remove oil container.
Removing oil container for exhaust turbocharger 592

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Note
• Always replace the oil sealing ring −arrow− and the sealing ring for the oil drain plug!
top of page
Installing oil container for exhaust turbocharger
1. Place the lower union nut of the oil line −lower arrow− in position on the oil container.
2. Fasten the oil container using the two hexagon socket head bolts (a/f 6) −arrows− .
3. Place the upper oil line in position and tighten both union nuts.
Tightening torque 30 Nm (22 ftlb.)
Installing oil container for exhaust turbocharger 593

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4. Tighten the M6 screw −arrow− of the line holder.

5. Fit the heat shield using the M6 screw −arrow− .

6. Insert the drain plug −arrow− and the sealing ring.

7. Installing heat shield ’ 635019 Removing and installing rear

bumper .
8. Check oil level and top up if necessary ’ 032000 Changing engine oil and filter .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing oil container for exhaust turbocharger 594

21 80 19 Removing and installing oil pump for
turbocharger
Tools
Removal
Installation
top of page
Tools

A Retaining device 9624/1
B Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, Nos.
72 and 73
top of page
Removal
21 80 19 Removing and installing oil pump for turbocharger 595

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1 Pan−head screw M6 4 When tightening, simultaneously check operating
x 16 smoothness of the oil pump.
2 Oil−pump cover 1 Check for signs of scoring
3 O−ring 68 x 2 1 Replace; ensure correct position
4 Oil pump gear 1 Grease with Optipit
5 Oil pump gear 2 Grease with Optipit
6 O−ring Replace; apply a thin coat of Vaseline
7 Bracket
8 O−ring 28.0 x 4.5 4 Replace; coat with coolant
9 Connection fitting 2
10 Dust protection ring 2 Check, replace if necessary

2. Disconnect
battery.
4. Remove rear spoiler. Serv. No.: 63 55
19
5. Remove bumper with shield.
Removal 596
einordnung
6. Remove lateral shields.
7. Loosen fastening nuts.
8. Loosen fastening nuts on the turbocharger. Remove the shield.
9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two
CAUTION
The rear muffler is loose after the restraining straps are removed. The rear muffler should be held by a second
person or supported with a transmission jack.
10. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier
using a screwdriver and move outwards.−View from engine side−
11. Remove rear muffler. Two persons can now remove the rear muffler.
12. Undo fastening screw M 6 x 34 on the air cleaner housing.
Removal 597
einordnung
13. Undo hose clamp between the air cleaner housing and intake manifold.
14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment.
15. Pull of the connecting hoses between the charge air coolers and the pressure pipe. Unclip the locking clips
using a screwdriver and pull off the hose. Then clip the locking clips in again.
16. In order to remove the pressure pipe, loosen the hose clamps and hexagon−head bolts. Pull off the
electrical plug.
17. Disconnect oxygen sensor plug on the rear closing panel.
18. Disconnect oxygen sensor plug.

19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.
Removal 598
einordnung
20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the
drive belt.
21. Remove pulley from the hydraulic pump.
22. Remove generator.

23. Disconnect the hydraulic lines with plug−in coupling on the expansion tank.
Note
• Wear protective gloves!
• Collect emerging Pentosin!
• Protect the line against dirt and scratches with a cap!
• If hoses come into contact with Pentosin, clean them thoroughly without delay!
24. Insert tool between lines and the red unlocking ring and unlock by pulling black line to the right
and simultaneously pressing the tool against the red unlocking ring.
25. Unscrew two fastening screws (M8 x 25) with hexagon socket head bolts on the tank.
Removal 599
einordnung
26. Unscrew three M8 screws and one M6 screw between the hydraulic pump and the console. Pull the
expansion tank with hydraulic pump out of the bracket and suspend on the side.
27. Detach the air conditioning compressor and remove the bracket. To do this, disconnect the
electrical plug connection, remove the compressor and set it down with the hoses connected.
28. Disconnect the fuel lines on the fuel cooler. Make sure to counter with a wrench when doing this.
29. Loosen hose clamps on the intake distributor and pivot the throttle body upward. Undo the fastening
screws and remove the throttle body.
30. Unscrew closure cap of coolant expansion tank. Undo coolant drain plugs on right and left and drain
the coolant.
31. Equip drain plugs with new sealing rings.
Tightening torque: 10 to 15 Nm (7.5 to 11.0 ftlb.).
Removal 600
einordnung
32. Pull off the right and left coolant hoses. Lever off the locking clip for this purpose.
33. Refit the locking clip on the coolant neck.
34. Remove bracket for generator. Undo hexagon−head bolts.
35. Loosen coolant neck.
36. Undo coolant hoses over the coolant pump.
Removal 601
einordnung
Note
• Tip for easier assembly!
• The coolant hoses are easier to remove when the complete bracket is removed later.
37. Loosen the stabilizer at top and swivel it downward.
Note
• When swivelling, make sure not to damage the bellows on the lower joint!
38. Support the engine−transmission unit. Fasten special tool (retaining device) 9624/1 on the
take−up points of the stabilizer mounts. The pressure disc must rest on the crankcase or crash
support.
39. Separate engine carrier from the engine mounts (wrench size 18).
40. Loosen engine carrier on the bracket.
Removal 602
einordnung
41. Secure the bracket with a shorter auxiliary screw (M10 x 55).
42. Detach the oil supply line from the bracket (right−hand side).
43. Detach the oil supply lines from the bracket (left−hand side).
44. Remove auxiliary screw again.

45. Remove complete bracket. Simultaneously pull off coolant hoses.
46. Undo oil pump fastening screws and remove the cover.
Removal 603
einordnung
47. Check oil pump cover and contact surface of the oil pump gears in the bracket for signs of seizing or
excessive wear. The entire bracket must be replaced if necessary. The bracket, oil pump gear and oil
pump cover are matched.
top of page
Installation
1. Grease oil pump gears and contact surfaces with Optipitt assembly grease. Make sure that grease does not
enter the receiving bores for the dowel pins.
2. Insert oil pump gears in the housing. The all−round groove of the outer oil pump gears must face the oil
pump cover.
3. Fasten oil pump cover. When tightening, simultaneously check the operating smoothness of the
oil pump. Tighten the screws crosswise to 10 Nm (7.5 ftlb.).
Tightening torque 10 Nm (7.5 ftlb.).
4. Prepare bracket for installation. Unscrew plug (Torx T30).

5. Fit new O−ring on the oil pump cover and new O−rings on the lower coolant connection flanges. Apply a
thin coat of Vaseline on the O−rings.
Installation 604
einordnung
6. Position bracket on the crankcase and simultaneously use a screwdriver to connect the oil pump
drive shaft and the intermediate shaft. Do not use excessive force; gently press in place by hand.
7. Provisionally fasten the bracket using an auxiliary screw. The auxiliary screw can be removed again once
the oil lines and coolant hoses have been fastened.
Note
• Otherwise, the bracket is held only by the O−rings.
8. Apply Loctite 574 on the thread of the plug and fasten the plug.
9. Fit oil lines for the right−hand side. Use new O−rings.
Installation 605
einordnung
10. Fit oil lines for the left−hand side. Use new O−rings.
11. Fit coolant lines over the coolant pump. Use water or coolant to facilitate fitting.
Note
• If incorrectly positioned, the generator bracket would make contact and cause leaks.
12. Remove auxiliary screw.
13. Fasten engine carrier.

14. Fasten engine carrier on the engine mounts (wrench size 18).
Installation 606
einordnung
15. Remove special tool (retaining device) 9624/1 .

16. Fasten stabilizer.
17. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler
must be replaced. Move the rear muffler into installation position and push the two tensioning straps over
the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.
18. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts.
19. Tighten restraining straps on the rear muffler.
20. Fit heat shields, bumper and rear spoiler.
21. Install bracket for the generator. Replace the four O−rings on the two connecting flanges between
the two coolant outlet necks of cylinder bank 1−3. Then screw in the four fastening screws.
Important: The front right screw must be inserted with Loctite 574 (as shown in the illustration).
Installation 607
einordnung
22. Check whether locking clips are properly seated.

23. Fit coolant hoses. Always replace O−rings on the coolant hoses. Wet O−rings with plenty of water.
Note
• Never fit dry; only use water.
24. Push on coolant hose. Align the flange of the coolant hose as shown in the illustration (lug/groove). Press
the coolant hose firmly against the connection neck. The coolant hose must engage audibly. Then recheck
whether it is fitted properly by tilting and pulling on it.
25. Fit air−conditioning compressor. Do not forget the spacer sleeve.
26. Install throttle body.
27. Install generator.
28. Install hydraulic pump.
29. Fit drive belt (service No.: 13 78 19).
30. Install air cleaner assembly.
31. Bleed the cooling system. Use the Porsche System Tester 2 for this purpose. Select the "Special
functions" menu
32. Bleed the steering system. (Group 48)
33. Bring the engine to operating temperature and check it for leaks.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 608
21 90 19 Removing and installing pressure sensor
Removal
Installation
top of page
Removal
1. Undo hexagon−head bolt and pull pressure sensor out of the pressure pipe.
2. Press the button on the plug and pull off the plug at the same
time.
top of page
Installation
1. Fasten pressure sensor with a new hexagon−head bolt (M6 x 16) and tighten to 10 Nm (7.5 ftlb).
2. Fit plug. The plug should engage audibly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
21 90 19 Removing and installing pressure sensor 609

24 00 33 Completing the vacuum connections
24 00 33 Completing the vacuum connections 610

einordnung
1 Recirculating air valves

2 T−piece
3 Recirculating air valve hose
4 Air hose
6 Pipe 5 x 1 x 250
7 Curved hose
8 Pipe 5 x 1 x 245
9 Four−way branch piece
10 Pipe 5 x 1 x 250
11 Three−way branch piece
12 Pipe 4 x 1
13 Distributor pipe
14 Vacuum accumulator
15 Combination valve for secondary air

einordnung
16 Fuel pressure regulator

17 Electric switch−over valve for secondary air
18 Pipe 4 x 1 x 350
19 Pipe 4 x 1 x 500
20 Pipe 4 x 1 x 500
21 Curved protective hose
22 Check valve
Note
• When fitting the hosing, it is prohibited to use spray oil. Soap suds may be used to make fitting easier.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 25 19 Removing and installing air cleaner
top of page
the grooved surface at the sides. Pull the plug up and off at the same time.
the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately.
24 25 19 Removing and installing air cleaner 613

einordnung
5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards and to the right by 90° and then turn
the housing to the left by approx. 90°.
7. Open air cleaner housing. To do this, open the new captive screws and pull the two housing halves
apart.
8. Take out the cleaner element. Take out the air cleaner element. Wipe out the two housing halves with a
cloth.
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Removing air cleaner 614

einordnung
1. Insert filter element. Insert the filter element into the cleaned air cleaner housing. Retighten the two
air cleaner housing halves with the new captive screws.
2. Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left air
cleaner housing side and then close the clip.
position. To do this, first turn the housing to the right by approx. 90° and push the rubber hose over
the flange. Then swivel downwards by 90°.

einordnung
5. Tighten the hose clamp on the connecting hose. Reconnect the plug on the hot film mass air flow sensor.
The plug must engage audibly!
6. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must engage
audibly!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 42 19 Removing and installing throttle body −
Engine installed
Removing throttle body
Installing throttle body
top of page
Removing throttle body
1. Remove air cleaner housing => Removing and installing air cleaner.
2. Pull off the pressure hoses between the charge air coolers and the Y−shaped pressure pipe. To do
this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips
immediately.
3. Detach the holder over the air−conditioning compressor. Unscrew the M6 screw on the holder for this
purpose.
4. Undo the hose of the Y−shaped pressure pipe. To do so, undo the spring band clamp −arrow− and pull
the hose off the Y−shaped pressure pipe.
5. Remove the Y−shaped pressure pipe. To do so, undo the spring band clamp −3− and the hexagon−head
bolts −1 and 2− . Disconnect pressure sensor plug −4− .
6. Undo the rubber air cowl between the pressure pipe and the throttle body. To do so, open the
screw−type hose clamp on the throttle body side and remove the rubber air cowl.
24 42 19 Removing and installing throttle body − Engine installed 617

einordnung
7. Disconnect the connector at the throttle potentiometer −top arrow− and unscrew the four M6 screws
−arrows− .
8. Remove the throttle body.
top of page
Installing throttle body
Note
• Always replace the seal between the intake distributor and the throttle body!
1. Insert seal into the intake distributor.
2. Position the throttle body on the intake distributor and position and tighten the four M6 screws
−arrows− .
3. Position the Y−shaped pressure pipe with the rubber air cowl on the throttle body, connect the vacuum
hose −3− and fasten the spring band clamp. Connect the connector of the pressure sensor −4− and position
and tighten the M6 screws −1 and 2− .
4. Install the holder over the air−conditioning compressor. Position and tighten the M6 screw in the
holder for this purpose.
Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)
Removing throttle body 618

einordnung
5. Connect hose to the Y−shaped pipe and fasten with the spring band clamp −arrow− .
6. Install the pressure hoses between the charge air coolers and the Y−shaped pressure pipe; the
pressure hoses must engage audibly.
7. Install air cleaner housing => Removing and installing air cleaner.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing throttle body 619

24 46 01 Testing the intake distributor (leak test)
Tools
Leak test
top of page
Tools
Item Designation of the special Explanation

tool
Plug 9264/6 Rubber sleeve belongs to the scope of delivery of special tool
9264/6
top of page
Leak test
1. Undo fastening screw M6 x 34 on the air cleaner housing.
24 46 01 Testing the intake distributor (leak test) 620

einordnung
2. Undo rear hose clamp between the air cleaner housing and intake
manifold.
3. Tilt the complete air cleaner housing 90 ° to the left and remove to the
rear.
4. Push rubber sleeve of special tool 9264/6 onto the plug.
5. Insert plug with rubber sleeve into the sealing bellows and fasten with the original hose
clamp.
6. Generate a pressure of approx. 0.5 bar. Larger leaks are very easy to hear once the pressure has
built up; smaller leaks can be made visible with a leak−locating spray.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Leak test 621

24 46 20 Removing and installing intake distributor
Engine removed
Note
Removing intake distributor
Installing intake distributor
Note
• Pay attention to the routing of the vacuum hoses! => Completing the vacuum connections
• Pay attention to the storage of the individual parts! => Disassembling and assembling intake
distributor
top of page
Removing intake distributor
1. Remove the secondary air pump => Removing and installing secondary air
pump.
2. Undo the throttle body connections => Removing and installing throttle body − Engine installed.
3. Undo the 2 spring band clamps and the screw−type hose clamp −arrows− and pull off the hoses.
4. Unclip the vacuum line −arrow− on the strain relief strut.
24 46 20 Removing and installing intake distributor Engine removed 622

einordnung
5. Pull the three vacuum hoses −arrows− off the intake distributor.
6. Undo the holder of the fuel return line. Unscrew the M6 screw −arrow− for this
purpose.
7. Connect the connector of the overrun air valve −arrow− and pull off the two vacuum hoses −arrow− .
8. Remove the overrun air valve module.
9.
Removing intake distributor 623

einordnung
Remove the activated carbon filter lead. To do so, disconnect the plug connection on the bleeder valve
−arrow− and disconnect the coupling on the pressure pipe.
10. Undo the six upper screw−type hose clamps on the rubber sleeves of the intake distributors.
11. Disconnect all vacuum leads at the four−way branch piece.
Note
• All rubber sleeves must be sealed (foreign objects)!
12. Pull the intake distributor out of the rubber sleeves and lay to one side.
top of page
Installing intake distributor
Note
• Check rubber sleeves and replace, if necessary!
1. Coat the inside of the rubber sleeves slightly with Vaseline. Place intake distributor into rubber
sleeves and press into place evenly as far as the stops without tilting.
2. Connect all the vacuum leads at the four−way branch

piece.
3. Tighten the six upper screw−type hose clamps on the rubber
sleeves.
Installing intake distributor 624

einordnung
4. Install the activated carbon filter lead. To do so, connect the plug connection on the bleeder valve
−arrow− and the coupling on the pressure pipe.
5. Install the overrun air valve module.
6. Connect the connector of the overrun air valve module −top arrow− and push on the two vacuum hoses
−bottom arrow− .
7. Fasten the holder of the fuel return line. Position and tighten the M6 screw −arrow− for this purpose.

einordnung
8. Connect the three vacuum hoses −arrows− on the intake

distributor.
9. Clip the vacuum line −arrow− on to the strain relief strut.
10. Connect the three hoses to the upper box of the distributor pipe and fasten the hose clamps −arrows− .
11. Fasten the throttle body connections => Removing and installing throttle body − Engine installed.
12. Install secondary air pump => Removing and installing secondary air pump.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 46 37 Disassembling and assembling intake
distributor
Disassembling the intake distributor
Vacuum lines
top of page
Disassembling the intake distributor
24 46 37 Disassembling and assembling intake distributor 627

einordnung
1 Left intake distributor

2 Right intake distributor
3 Closure cap with strut
4 Hose clamp 70 to 90
5 Rubber sleeve Ø 80 with two hose clamps 80 to 100
6 Throttle with E−gas actuator
7 Fastening screws M6 x 50
9 Hexagon−head bolts M6 x 12
10 Hexagon−head bolts M6 x 18
11 Holder for intake air distributor pipe
12 Strain relief strut
13 Distributor pipe
1. Unscrew screws no. 8 and no. 10 and remove the strain relief.
Disassembling the intake distributor 628

einordnung
2. In each case, undo the two hose clamps on the left and right of the distributor pipe and push the
rubber sleeves as far as possible on to the distributor pipe. Then remove the distributor pipe.
3. Open the two hose clamps on the closure caps with strut and remove the
strut.
4. Disconnect the vacuum lines.
top of page
Vacuum lines
1 Recirculating air valves

2 T−piece
4 Air hose
Vacuum lines 629

einordnung
6 Pipe 5 x 1 x 250
7 Curved hose
8 Pipe 5 x 1 x 245
9 Four−way branch piece
10 Pipe 5 x 1 x 250
11 Three−way branch piece
12 Pipe 4 x 1
13 Distributor pipe
14 Vacuum accumulator
15 Combination valve for secondary air
16 Fuel pressure regulator
17 Electric switch−over valve for secondary air
18 Pipe 4 x 1 x 350
19 Pipe 4 x 1 x 500
20 Pipe 4 x 1 x 500
21 Curved protective hose
22 Check valve
Note
• When fitting the hosing, it is prohibited to use spray oil. Soap suds may be used to make fitting easier.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Vacuum lines 630

24 69 19 Precautionary measures when handling
oxygen sensors
Caution
CAUTION
Oxygen sensor can be damaged if handled improperly.
• Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread
grease must under no circumstances come into contact with the connector.
• Protect sensors before and after fitting against mechanical shocks.
• Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic
insulator.
• The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable
and connector.
• Cleanliness in the housing of the plug connections is of utmost importance for the function of the
oxygen sensor. Particles of dirt can impair the function of the oxygen sensor. Therefore, the connector
must be protected against any and all types of soiling.
• Sensors with soiled or damaged connector must no longer be used.
• Protect the cables and plugs when transporting the exhaust system with the sensors already fitted.
• High−pressure cleaning equipment must not be used in the area of the sensors and plug connections.
• Contact and corrosion agents, e.g. Stabilant, must not be applied on the plug contacts of the oxygen
sensors.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
24 69 19 Precautionary measures when handling oxygen sensors 631

24 73 19 Removing and installing oxygen sensors
behind catalytic converter
Removing oxygen sensors behind the catalytic converter
Installing oxygen sensors behind the catalytic converter
For tools, refer to Service No. 24 69 19 : Removing and installing oxygen sensors in front of the catalytic
converter.
Illustration shows oxygen sensors on the right side
• −1− Oxygen sensor in front of catalytic converter on the right side

• −2− Oxygen sensor behind catalytic converter on the right side
Oxgen sensor plug
• −1− Plug for sensor in front of catalytic converter with plastic clip (rectangular)
• −2− Plug for sensor behind catalytic converter (oval)
Note
• Observe precautionary measures when using oxygen sensors !
top of page
Removing oxygen sensors behind the catalytic converter
24 73 19 Removing and installing oxygen sensors behind catalytic converter 632

einordnung
Oxygen sensor, left side :
1. Remove air cleaner housing => Removing and installing air cleaner
2. Separate the oval plug connection for the oxygen sensor behind the catalytic converter in the left
engine compartment −2− .
3. Unclip the oxygen sensor wire behind the catalytic converter from the wire retainer and the
sheetmetal clips.
Note
• Always expose oxygen sensor wire so that the wire can turn when unscrewing the sensor.
4. Undo and unscrew oxygen sensor with a spanner or an open ring wrench (a/f 22).
Oxygen sensor, right side :
2. Separate the rectangular plug connection for the oxygen sensor behind the catalytic converter −2− .
3. Unclip the oxygen sensor wire behind the catalytic converter from the wire retainer and the
sheetmetal clips.
Note
top of page
Oxygen sensor, left side : 633

einordnung
Installing oxygen sensors behind the catalytic converter

Install the oxygen sensors in reverse order.
Note
• Always expose oxygen sensor wire so that the wire can turn when screwing in the sensor.
1. Position the oxygen sensor by hand and screw in as far as

possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681−1 and torque wrench.
Tightening torque: 55 ± 5 Nm (41 ± 4.0 ftlb.)
3. Lay oxygen sensor wire and fix in the sheetmetal clips and wire retainers on the left and right.
4. Close the oval plug connection.
5. Install the air cleaner housing again => Removing and installing air cleaner.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing oxygen sensors behind the catalytic converter 634

26 01 05 Exhaust system leak test
Caution
Tools
Leak test
CAUTION
• The permissible maximum pressure for performing the leak test is 1 bar !
Note
• The leak test must not be performed on a hot exhaust system as the rubber seals are only functional at
temperatures below 200 ° C !
top of page
Tools
Item 1 Plugs for the exhaust system leak test
Clamp setting : Rubber seal compressed
Item Special tool Remarks

designation
1
26 01 05 Exhaust system leak test 635

einordnung
Plug 9710/1 for 911 Gr. 2.2; Workshop Equipment Manual ; order replacement seals from the
Turbo (996) manufacturer (specification on the bottom of the plug)
Leak detection spray e.g. test spray TPS674, Messrs. TEGA, Würzburg
top of page
Leak test
1. Fit plugs in exhaust tailpipes on the rear muffler −see Figure− . Insert plugs into tailpipe outlets. To adapt
the diameter (seating surface of rubber seal), turn each handle clockwise or counter−clockwise until the
tailpipe outlets are air−tight by throwing the adapter handle through 90°.
Note
• Do not exceed the permissible pressure of 1 bar !
2. Connect pressure gauge to a valve and pressurize the exhaust system to 1 bar overpressure −see Figure− .
3. Wet individual disconnection points of the exhaust system (e.g. manifold flange, clamping sleeves) with
test spray to make any leaks visible. Repeat test procedure if necessary.
4. Remove pressure gauge and both
plugs.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Tools 636
26 33 19 Removing and installing rear mufflers
Removing rear mufflers
Installing rear mufflers
top of page
Removing rear mufflers
Preliminary work: Remove rear spoiler, rear bumper and centre heat shield (Serv. No.: 635519).
26 33 19 Removing and installing rear mufflers 637

einordnung
1. Unscrew rear muffler from the turbocharger. Unscrew the −four fastening nuts− on the left and
right for this purpose.
2. Disconnect oxygen sensors. Disconnect and disengage the four plugs at the rear of the closing panel
for this purpose.
3. Detach restraining straps. Undo the two restraining straps on the rear muffler. Unscrew the two
CAUTION
The rear muffler is loose after the restraining straps are removed. A second person should hold it up.
4. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier
using a screwdriver and move outwards.−View from engine side−
5. Remove rear muffler. Two persons can now remove the rear
muffler.
Removing rear mufflers 638

einordnung
top of page
Installing rear mufflers
1. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear
muffler must be replaced. Move the rear muffler into installation position and push the two
tensioning straps over the holder on the engine carrier. Then slightly tighten the two hexagon
socket head bolts.
2. Screw down the rear muffler on the exhaust catalytic converters. To do this, replace the four
fastening nuts on the turbocharger flange on the left and right of the vehicle and tighten to 30 Nm
(22 ftlb.).
3. Tighten tensioning straps. Centre the rear muffler and align free of tension. Tighten the two hexagon
socket screws to 15 Nm (11 ftlb.).
4. Connect oxygen sensors. Reconnect the four oxygen sensor cables and clip
them in.
To conclude: Install bumpers, centre heat shield and rear spoiler ’ 635519 Removing and installing rear
spoiler
.
Check exhaust system for leaks.

Screw connection on turbocharger flange M8 30 (22)
Restraining strap on rear muffler M6 15 (11)
Installing rear mufflers 639

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing rear mufflers 640

26 65 19 Removing and installing secondary air pump
Removal
Installation
top of page
Removal
1. Pull off right connecting hose between charge air cooler and pressure pipe:
• Unclip the locking clips using a screwdriver and pull off the hose.
• Then re−clip the locking clips onto the pressure pipe.
• Ensure correct seating.
2. Remove switch−over valve on the secondary air pump:
• In order to do this, press the locking tabs of the holding clip with a screwdriver in the direction of the
secondary air pump
• and at the same time push the switch−over valve to the right and remove.
• Undo upper fastening screw M6 x 10.
26 65 19 Removing and installing secondary air pump 641

einordnung
3. Undo lower fastening screw M6 x 10.

4. Disconnect the electrical plug connection. Undo air hose and pull off.
5. Lift the secondary air pump out of the engine compartment.
top of page
Installation
1. Install secondary air pump. Install plug connection and air hose.
2. Fasten secondary air pump housing with two hexagon−head bolts M6 x 10.
3. Clip switch−over valve onto the secondary air pump
housing.
4. Fix a new O−ring onto the right pressure hose and coat the O−ring and take−up bore with plenty of
water.
5. Push the pressure hose into the pressure pipe. The pressure hose must engage with an audible click.
6. Check that the pressure hose has been fitted correctly by tipping and pulling on the pressure
hose.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removal 642
27 22 19 Removing and installing three−phase
generator
Note
Removing the three−phase generator
Installing the three−phase generator
Undoing and tightening the belt pulley
Tool for holding the free−wheel pulley
Note
• When the engine is being cleaned with high−pressure cleaning equipment, make sure that the high
pressure blast is not directed directly onto the three−phase generator (risk of bearing damage).
top of page
Removing the three−phase generator
2. Remove the complete air cleaner assembly. Undo the fastening screw for the air cleaner housing and
the hose clamp on the air flow sensor.
3. Undo the hose on the charge air cooler at the left and right on the pressure pipe.
4. Disconnect the electrical plug connection on the air flow sensor and remove the complete air cleaner
assembly.
5. Remove the pressure pipe to the throttle body.
6. Relieve the drive belt at the tensioning pulley and remove the belt.
7. Remove the deflection roller under the three−phase generator.
8. Disconnect the cable lug of the B+ lead to the three−phase generator at the B+ disconnection point.
9. Undo left fastening screw (in direction of travel) and remove.

10. Undo right fastening screw by three turns.
11. A gentle tap on the fastening screw loosens the threaded bushing in the three−phase generator arm (use
aluminum mandrel). Unscrew fastening screw.
12. Remove three−phase generator and carefully pull a little to the rear.
13. Press the plug connection towards the three−phase generator housing, release and pull off.
14. Remove the three−phase generator towards the rear and disconnect the B+ lead.
27 22 19 Removing and installing three−phase generator 643

einordnung
top of page
Installing the three−phase generator
1. Fasten B+ lead and install three−phase generator.
2. The B+ lead must be fastened onto the long wiring arrangement −(arrow)− of the three−phase
generator (see Figure).
3. Install deflection roller and fit drive
belt.
Tightening torque of the hexagon nut M16 x 1.5: 65± 5 Nm (48 ± 3.5 ftlb)
Tightening torque of the hexagon−head bolts M10: 46 Nm (34 ftlb.)
Tightening torque of the M8 hexagon nut: 15 Nm (11 ftlb.)
Tightening torque of the deflection roller M10: 46 Nm (34 ftlb.)
4. Install air flow sensor with air cleaner assembly and connect
battery.
5. Perform a function test.
top of page
Undoing and tightening the belt pulley
Note
• The belt pulley can be undone or tightened using a standard commercially available tool.
• Double offset ring wrench a/f 24

• Screwdriver insert for internal serration screw a/f 10
• Cross handle and torque wrench
1. The hexagon nut a/f 24 must be countered with the ring wrench during
tightening.
2. The shaft is tightened to the prescribed tightening torque of 65 ± 5 Nm ( 48 ± 3.5 ftlb.) using the
screwdriver insert and the torque wrench.
top of page
Tool for holding the free−wheel pulley
Note
Removing the three−phase generator 644

einordnung
• Only for vehicles with manual transmission!
1. Use an a/f 17 multiple−tooth adapter to hold the free−wheel pulley.
2. A/f 17 multiple−tooth adapter: see Workshop Equipment Manual, chapter on commercially

available tools, No. 32−1.
3. Counter with a double ring wrench when tightening with the a/f 17 multiple−tooth
adapter.
4. The shaft is tightened to the prescribed tightening torque of 80 ± 5 Nm (59 ± 3.5 ftlb.) using the
screwdriver insert (a/f 10 internal serration screw) and torque wrench.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Tool for holding the free−wheel pulley 645

27 27 19 Removing and installing bracket for
generator
Removing bracket for generator
Installing bracket for generator
top of page
Removing bracket for generator
Removal
CAUTION
27 27 19 Removing and installing bracket for generator 646

einordnung
Risk of short circuit with battery connected
• The battery must be disconnected before any work is carried out on the engine.
1. Drain coolant. Open cap of coolant expansion tank. Unscrew coolant drain plugs on left and right and
drain the coolant. After draining the coolant, fit new sealing rings on the drain plugs.
Drain plug tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.)
2. Remove air cleaner housing. Undo hexagon−head bolt M6 x 34. Undo the hose clamp on the throttle
body. Remove connector from hot film mass air flow meter.
3. Removing drive belt ’ 137819 Removing and installing drive belt (engine
installed) .
4. Unclip the cable from the hot film air flow meter on the expansion tank of the hydraulic pump and lay it
aside. Detach the holder from the oil filler neck.
5. Undo fastening screws on the expansion tank −upper arrows− (two M8 screws) and the four screws
−lower arrows− (three M8 screws and one M6 screw) on the hydraulic pump. Pull the expansion tank
with hydraulic lines and with connected lines up out of the fastening bracket and lay aside to the
right−hand side.
6. Remove holder for oil filter bracket. Unscrew the M6 screw and undo the M8 screw for this purpose. Lift
the holder out.
Removal 647
einordnung
7. Separate the B+ disconnection point −arrow− under the cover for this purpose. Unscrew the left fastening
screw. Unscrew the right fastening screw by approx. 1 cm. Then drive it in with gentle taps of a hammer
until the screw head makes contact with the generator again. Now unscrew fastening screw completely.
Lift the generator upwards out of the engine compartment.
8. Remove air conditioning compressor from the bracket for the generator. Unscrew the three screws
−arrows− for this purpose. The throttle body can be swung upward for better accessibility to the
front screw. To do this, the two hose clamps must be removed.
Note
• Do not open air conditioning system!
9. Remove the compressor. Disconnect the electrical connection on the compressor. Unplug compressor. Lift
the compressor out of the engine compartment and lay it aside with the leads still connected. Protect the
body from damage with a cover.
10. Unclip coolant hose. To do this, unclip the safety bracket on the coolant neck with a screwdriver and pull
the coolant hose up and out.
11. Detach the coolant outlet neck of cylinder bank 4 to 6. Undo the two hexagon−head bolts on the coolant
outlet neck for this purpose.
12. Detach bracket for generator. Unscrew the four fastening screws −arrows− on the bracket for the
generator.
Removal 648
einordnung
13. Pull off the hose clamp −arrow− on the coolant connecting hose. Take bracket for the generator
out of the engine compartment upward and to the right.
14. Separate bracket for the generator. The bracket can be disassembled in the event of leaks. Unscrew the
three screws −arrows− for this purpose. Pull the two parts apart. Make sure that the two dowel sleeves
are not lost. Use a new O−ring with Vaseline when assembling the bracket for the generator.
Tightening torque of the three screws: 23 Nm (17 ftlb.)
top of page
Installing bracket for generator
1. Install bracket for the generator. Replace the four O−rings on the connecting sleeves between the two
coolant outlet necks and the bracket for the generator. Insert the bracket into the coolant outlet neck of
cylinder bank 1 to 3 from the right−hand side. Then screw in the four fastening screws.
Note
• Insert the front right screw −inset− with Loctite 574.
Installing bracket for generator 649

einordnung
2. Push on the coolant connecting hose between the oil/coolant heat exchanger and the bracket again and
tighten the hose clamp −arrow− .
3. Fit coolant outlet neck of cylinder bank 4 to 6. Insert the neck with the connecting sleeve into the bracket
for the generator for this purpose. Tighten the two fastening screws on the coolant outlet neck.
4. Insert retaining clip. Insert the retaining clip −arrow− into the groove provided as shown. Replace
the O−ring on the coolant hose.
5. Push on coolant hose. Align the connection neck of the coolant hose as shown in the illustration.
−lug/groove arrow− Press the coolant hose firmly against the connection neck. The clip must audibly
engage. Pull the hose slightly to check for secure seating.
6. Fit air−conditioning compressor. To do this, move the compressor into installation position.
Tighten the three fastening screws −arrows− of the air conditioning compressor.

7.

einordnung
Install generator. Return the generator to its mounting position. Connect plug connection and connect the
B+ line.
Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.)
Tightening torque for M10 hexagon−head bolt: 46 Nm (34 ftlb.)

8. Install holder for oil filter bracket. To do this, push in the holder in downward
direction.
9. Install hydraulic pump. Return the hydraulic pump with connected lines to its installation position
and tighten the fastening screws −arrows− .
Tightening torque for M8 fastening screws: 23 Nm (17 ftlb.)
Tightening torque for M6 fastening screw: 10 Nm (7.5 ftlb.)
Tightening torque for M8 fastening screw on the expansion tank: 23 Nm (17 ftlb.)
10. Refit oil filler neck and clip the cable from the hot film mass air flow meter into the holder on the
hydraulic expansion tank.
11. Install drive belt ’ 137819 Removing and installing drive belt.
12. Install air cleaner housing. Refit air cleaner housing into the mounts in the body. Tighten hexagon−head
bolt. Tighten the hose clamp on the throttle body and push the plug onto the hot film mass air flow meter.
Tightening torque for hexagon−head bolt M6 x 34: 10 Nm (7.5 ftlb.)

13. Connect battery. Reconnect the battery ground cable.
14. Fill in coolant. Fill in coolant through the expansion tank. Carefully bleed the vehicle ’ 193817 Draining
and topping up with coolant.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

27 60 19 Removing and installing starter (manual
transmission)
Removing the starter
Installing the starter
top of page
2. Pull back protective cap on the solenoid switch and undo terminal 30 lead (M8 nut) and terminal 50 (M6
nut).
3. Undo the upper fastening screw. To do this, use the 3/8 inch tool. Tools:
• Hexagon socket wrench insert a/f 15

• Universal joint
• Two short extensions
• Cross handle or ratchet
4. Undo the lower fastening screw.

5. Remove the starter from the holder and turn so that the solenoid switch is facing in the direction of the
halfshaft.
6. Remove starter in a downward direction.
top of page
1. Install and fasten starter. Fasten B+ lead from the battery and B+ lead from the engine to the B+
disconnection point to terminal 30 (M8 nut) on the solenoid switch.
2. Fasten terminal 50 lead (M6 nut) to the solenoid switch.
Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.), M6 screw: 6.5 Nm (5 ftlb.)
Tightening torque of the hexagon−head bolt M10: 46 Nm (34 ftlb.)
3. Push protective cap over the solenoid switch and engage in the B+ lead.
4. Connect the battery and perform a function
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
27 60 19 Removing and installing starter (manual transmission) 652

28 39 19 Removing and installing hall sender −
Engine installed
Caution
Removing hall sender
Installing hall sender
Tightening torques
WARNING

• Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must
be replaced!
Note
• The work procedures apply to both sides of the vehicle.
top of page
Removing hall sender
Preliminary work:
Remove rear spoiler. ’ 635519 Removing and installing rear spoiler
1. Remove charge air cooler. => Removing and installing the charge air cooler
WARNING
replaced!
2. Remove side heat shield by undoing the bolts on the heat shield. Undo the two sheetmetal nuts on
the lower end of the heat shield. Then, press the heat shield out of the studs. See partial description
in chapter ’ 635019 Removing and installing rear bumper.
28 39 19 Removing and installing hall sender − Engine installed 653

einordnung
Sheetmetal nuts on heat shield
3. Remove the shields above the plug coils. Unscrew the two hexagon−head bolts for this purpose.
4. Disconnect plug connection on hall sender by pressing the cable connector up using a long screwdriver, if
necessary.
5. Unscrew hexagon socket head bolt on hall sender.

6. Remove the hall sender.
top of page
Installing hall sender
Note
• The hexagon socket head bolt is micro−encapsulated and so must always be replaced!
• Replace sealing ring on hall sender.
1. Place new sealing ring over the hall sender, position hall sender, then screw in and tighten the new
hexagon socket head bolt.
Removing hall sender 654

einordnung
2. Clip in cable plug for hall sender using both

hands.
3. Fit the shields above the plug coils. Screw in the two hexagon−head bolts for this purpose.
WARNING
replaced!
4. Install heat shield. See partial description in chapter ’ 635019 Removing and installing rear bumper.
Sheetmetal nuts on heat shield
5. Install charge air cooler. => Removing and installing the charge air cooler
6. Install rear spoiler. ’ 635519 Removing and installing rear
spoiler
top of page
Tightening torques

Hall sender bolts M6 Replace; 10 (7.5)
Heat shield ignition coils M6 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing hall sender 655

28 70 55 Replacing the spark plugs
top of page

A Spark plug Workshop Equipment Manual, Chapter 2.4, No. 1 and extension
wrench no. 15
Note
• Only this spark plug wrench has been tested and approved.
1. Remove rear spoiler and centre heat shield ’ 635519 Removing and installing rear spoiler .
28 70 55 Replacing the spark plugs 656

einordnung
4. Remove shields. Remove the shields located above the exhaust

system.
5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagon−head bolts for this
purpose.
6. Undo hexagon socket head bolts −arrows− .
7. Pull off the plug coils and detach them to the side with connected
cables.
8. Screw out spark plugs with commercially available tool S9706 .
top of page
1. Put on spark plugs by hand.
2. Tighten spark plugs with commercially available tool S9706 .
Removing spark plugs 657

einordnung
3. Push on the plug coils again.

4. Tighten hexagon socket heat bolts −arrows− to 10 Nm (7.5 ftlb.).
5. Fit shields. Reinstall the shields above the plug coils and tighten to 10 Nm (7.5
ftlb.).
6. Reinstall the shields above the exhaust

system.
7. Reinstall charge air cooler.
8. Fit rear spoiler ’ 635519 Removing and installing rear
spoiler.
9. Lower
vehicle.

Plug coils M6 10 (7.5)
Shield M6 10 (7.5)
New spark plug 30 + 3 (22 + 2)
Old spark plug 25 + 3 (18 + 2)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing spark plugs 658

28 72 20 Removing and installing knock sensor
Engine removed
Removing and installing knock sensor, cylinder bank 1−3
Removing knock sensor, cylinder bank 4 − 6
Installing knock sensor, cylinder bank 4 − 6
top of page
Removing and installing knock sensor, cylinder bank 1−3
Removal
1. Disconnect plug −lower arrow− of the knock sensor and set it aside. Unscrew M8 hexagon−head bolt
−upper arrow− and remove the knock sensor.
Installation
2. Clean contact surface for the sensor on the engine
block.
Note
• In order to guarantee the proper function of the knock sensor, always use the correct tightening
torque!
3. In order to guarantee the proper function of the knock sensor, screw in the M8 hexagon−head bolt
−upper arrow− and tighten with the correct tightening torque, then connect the plug again.
top of page
28 72 20 Removing and installing knock sensor Engine removed 659

einordnung
Removing knock sensor, cylinder bank 4 − 6

1. Remove the oil container ’ 175219 Removing and installing oil container
2. Undo the crankcase ventilation tube. Unscrew the union nut −arrow− for this
purpose.
3. Remove crankcase ventilation tube. Unscrew the two M6 screws −arrows− for this
purpose.
4. Disconnect plug −lower arrow− of the knock sensor and set it

aside.
5. Unscrew screw −upper arrow− of the knock sensor and remove the knock sensor.
top of page
Removing knock sensor, cylinder bank 4 − 6 660

einordnung
Installing knock sensor, cylinder bank 4 − 6

1. Clean contact surface for the sensor on the engine
block.
Note
• In order to guarantee the proper function of the knock sensor, always use the correct tightening
torque!
2. Position the knock sensor, then screw in and tighten the M8 hexagon−head bolt −upper arrow− with the
correct tightening torque.
3. Insert plug −lower arrow− of the knock
sensor.
4. Install the crankcase ventilation tube. For this purpose, place the crankcase ventilation tube with the union
nut −arrow− in position, but do not tighten yet.
Note
• Always replace the flange seal of the crankcase ventilation tube!
Installing knock sensor, cylinder bank 4 − 6 661

einordnung
5. Replace the flange seal; then place the two M6 screws −arrows− in position and tighten.
Tightening torque for hexagon−head bolts 10 Nm (7.5 ftlb.)
6. Tighten the union nut −arrow− with the correct tightening torque.
7. Install the oil container ’ 175219 Removing and installing oil
container .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing knock sensor, cylinder bank 4 − 6 662

30 01 01 Checking clutch booster circuit
Caution
1. Checking accumulator
2. Checking valve (pressure−regulating valve)
CAUTION
Danger of material damage if the wrong fluid is used for the clutch hydraulic system!
Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with
the coolant hoses when topping up or filling in!
• Fill Pentosin CHF 11 S only into the supply tanks!

• To prevent overfilling and, therefore, overflowing, check the specifications in the clutch, fluid levels
description and observe them without fail!
change the fluid level in the engine−compartment reservoir! Fluid level rises. In this case, the engine
must be run for approx. 20 seconds immediately prior to the fluid level check!
IMMEDIATELY!
top of page
1. Checking accumulator
1. Cold start engine (accumulator temperature approx. 20°C) and let run for approx. 20 seconds
(accumulator is full).
2. With the engine switched off, depress the clutch pedal repeatedly until an abrupt rise in pedal resistance
against your foot can be felt (accumulator is empty). While doing this, count the number of depressions
carried out up to the point of the rise in pedal pressure!
3. If the number of times the pedal was depressed is over 35, the accumulator is −arrow− faulty and must be
replaced! => Removing and installing the accumulator
top of page
2. Checking valve (pressure−regulating valve)
Note
30 01 01 Checking clutch booster circuit 663

einordnung
• Checking the valve in the clutch save cylinder (2.1) is a direct measurement, while the valve in the
upper part of expansion tank cannot be directly tested (2.2)!
• If there is no hydraulic clutch boost after a hold time of 24 hours, at least one of the two valves is
definately damaged!
• Prior to the following check, ensure that the system is visually leak tight (externally)!
2.1 Checking the valve (pressure−regulating valve) in the clutch save cylinder
1. Warm engine up to operating temperature (approx. 80°C).
Note
• Take care when handling Pentosin! Wear protective glasses, gloves and protective clothing!
IMMEDIATELY!
2. With the engine switched off and the accumulator filled (before switching off the engine, the engine must
have been run for approx. 20 seconds without depressing the clutch pedal), remove the plastic return line
−arrow− from the expansion tank. To this purpose, push the red thrust ring in an axial direction, without
tilting, towards the tank and remove the line.
3. Collect the fluid which runs out in suitable measuring equipment (suitable container) and determine
the volume of fluid collected!
4. If more than 4 cm3 is collected after a measurement period of one hour, the valve in the clutch save
cylinder is faulty and and the save cylinder must be replaced. Removing and installing clutch slave
cylinder => Removing and installing clutch slave cylinder.
2.2 Checking the valve (pressure−regulating valve) in the upper part of the
expansion tank
This valve can only be checked indirectly.

A fault exists if the hydraulic clutch boost function does not last for an entire 24 hours, but where the valve in
the clutch save cylinder is functioning correctly (Test 2.1).
2. Checking valve (pressure−regulating valve) 664

einordnung
If the valve in the clutch save cylinder is functioning correctly according to the test in 2.1, the upper part of
the tank −A− must be replaced.
Note
• Before removing the upper part of the tank, slowly remove the Pentosin through the filler neck by
suction! When replacing the part, ensure thorough cleanliness!
• Loosen all lines on the upper part of the tank. Collect Pentosin which runs out of these!
• Replace upper part of tank, reconnect the lines and fill with Pentosin!
• Bleed clutch high−pressure hydraulic system. To this purpose, depress the clutch pedal approx. 10
times!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
2.2 Checking the valve (pressure−regulating valve) in the upper part of theexpansion tank 665
30 01 07 Bleeding clutch operation
Disposal of Pentosin
The actuating hydraulic system is bled via pumps on the pedal.
Note
• On right−hand drive vehicles, the supply tank is located in the area of the brake fluid reservoir/control
module for automatic headlight beam adjustment (ALWR)!
1. Fill supply tank.
2. Open bleeder valve on the servo unit −(arrow)− .
Note
• Make sure that the reservoir is not sucked dry. Top up during the procedure if necessary!
3. Pump with the clutch pedal until Pentosin emerges without air bubbles at the bleeder valve of the servo
unit (use collecting bottle).
Note
30 01 07 Bleeding clutch operation 666

einordnung
• If a bleeding device filled with Pentosin is available, clutch bleeding can proceed in the same manner
as for previous systems!
• To do this, the bleeding device is connected to the clutch reservoir at the front!
• The clutch high−pressure hydraulic system does not need to be bled in a special manner!
• It is sufficient to actuate the clutch pedal approx. 10 times with the engine running!
• The steering hydraulic system is bled in the usual manner!
top of page
Disposal of Pentosin
Pentosin can be disposed of together with waste oil.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Disposal of Pentosin 667

30 27 19 Removing and installing clutch pressure
hose − Engine installed
Caution
Removing clutch pressure hose
Installing clutch pressure hose
WARNING
Danger of injury if the clutch pressure hose is undone or disconnected without pressure reduction beforehand!
Reduce the pressure in the clutch system by actuating the clutch pedal at least 25 times!
Note
• Protect any coolant hoses present near to the removal work from all emerging Pentosin using suitable
means!
• If coolant hoses come into contact with Pentosin, thoroughly clean them with water immediately!
top of page
Removing clutch pressure hose
Requirements:
• Raise vehicle on lifting platform.

• Actuate the clutch pedal at least 25 times with the engine switched off so that the system is
depressurised.
1. Unclip the plug−in coupling for the hydraulic clutch operation system at the body (green line) and
unscrew using two open−ended wrenches a/f 15 −arrows A and B− .
2. Collect and dispose of emerging Pentosin by suitable means. Seal the green line with suitable rubber
or plastic plugs.
30 27 19 Removing and installing clutch pressure hose − Engine installed 668

einordnung
3. Disconnect the clutch pressure hose −1− from the slave cylinder with an open ring or open−ended
wrench a/f 14 and remove the hose.
Note
• Dispose of the old hose complete with the union nut and the holder!
top of page
Installing clutch pressure hose
Note
• Make sure that the pressure hose is routed above the parking brake cable!
1. Position the clutch pressure hose −1− by hand on the slave cylinder and screw the hose tight with an open
ring or open−ended wrench a/f 14.
2. Remove the rubber or plastic plugs from the green pressure line on the underbody and screw in a new
plug−in coupling (complete with union nut, holder and assembly mandrel) by hand and then screw tight
with two open−ended wrenches a/f 15 −arrows A and B− .
Removing clutch pressure hose 669

einordnung
3. Then pull out the assembly mandrel and press the connecting piece of the pressure hose into the plug−in
coupling.
Note
• If the pressure hose has been replaced, use a new holder and a new plug−in coupling!
• Instructions for the plug−in coupling are enclosed in the packaging!
4. Clip pressure hose back into the plastic

holder.
5. Bleeding clutch operation => Bleeding clutch operation.
6. Clean residual Pentosin off the vehicle using suitable means (e.g. water).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing clutch pressure hose 670

30 30 19 Removing and installing clutch slave
cylinder
Removal
Tightening torques
Installation
top of page
Removal
1. Raise vehicle on lifting platform. Disconnect
battery.
2. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised.
30 30 19 Removing and installing clutch slave cylinder 671

einordnung
3. Undo the screws −arrows− and remove the front cross member.
4. Remove clips from the coolant lines.
5. Remove bracket for the coolant lines.
6. Remove the ventilation connection piece from the clutch housing (3 screws).
Note
• This makes the area from the pressure line to the clutch slave cylinder more accessible!
7. Push the protection on to the left drive shaft and release the drive shaft at the transmission
flange.
Note
IMMEDIATELY!
8. Remove the pressure reservoir −arrow− . Use an open−ended wrench to undo the pressure reservoir.
Then turn the pressure reservoir further (remove) with an oil filter strap.
9. Disconnect (unscrew) the plug connector for the clutch hydraulic system at the body (green lead)
−arrow− .
Removal 672
einordnung
10. Remove the bracket for the slave cylinder (on transmission −arrow− and disconnect the slave
cylinder). Only undo the slave cylinder fastening screws (2 screws) −arrows− slightly (do not yet
unscrew completely).
11. Disconnect (unscrew) lead −1− on slave cylinder. Pull off return line −2− . To do so, press on the
red ring evenly (never on one side) −2a− and pull the lead out evenly while pressing (unlock). To
unlock, use a commercially available removal tool. In the process, observe Workshop Equipment
Manual, Chapter 2.4, No. 21 and the following note. Unscrew the pressure line −3− . Due to the
restricted space, it is sensible to use a commercially available open socket wrench + adapter.
Observe Workshop Equipment Manual, Chapter 2.4, No. 98−1.
Note
• The tool for unlocking the return line is the tool already familiar from the 986/996. It was used there
for unlocking the steering return line on the servo pump, among other elements.
12. Undo the slave cylinder fastening screws (2 screws). Carefully remove the slave cylinder.
top of page
Tightening torques
Tightening
Location Thread torque Nm (ftlb.)
Pressure line to slave cylinder M 12 x 1 20 (15)
Hose to slave cylinder M 14 x 1 30 (22)
Plug−in coupling for clutch hydraulic system (lead to a/f 15 30 (22)
body) a/f=wrench size (across flats)
Bracket to slave cylinder and transmission M8 23 (17)
Pressure reservoir to slave cylinder M14 x 1.5 30 (22)

einordnung
Cross member at front to side section M10 x 1.5 65 (48)

Drive shaft to transmission M10 81 (60)
top of page
Installation
Note
• Before installing the slave cylinder, it is sensible to remove the starter! This guarantees a better test
and the unequivocal centring of the tappet push rod of the slave cylinder in the release lever! The
slave cylinder can also be held in its installation position from this side!
• Observe the precise position of the slave cylinder before installation! The precise installation position
is attained by turning in the vehicle!
• The loosely attached transmission slave cylinder bracket ensures the correct installation height for
positioning the slave cylinder screws!
1. Remove the starter ’ 276019 Removing and installing

starter .
2. Remove the top cover (rubber cap) on the clutch housing in the area of the release lever.
3. Insert the clutch slave cylinder into the vehicle with the pushrod facing towards the transmission
and turn it into its installation position.
4. Fasten the transmission−slave cylinder bracket loosely to the slave cylinder with a screw. It is very
difficult to attach the screw later.
5. Install the clutch slave cylinder to the transmission housing/release lever. Pay attention to the
correct position of the pushrod! Do not tighten the fastening screws yet. This ensures better access
to the pressure line.
6. Place pressure line in position.
7. Tighten the pressure line and screw the slave cylinder
tight.
8. Insert the return line.
9. Install the hose of the master cylinder line on the slave cylinder.
10. Screw the master cylinder line together −arrow− and insert it into the guide on the body.
11. Install the pressure reservoir.
12. Position the input shaft on the transmission flange and tighten with 81 Nm (60 ftlb.).
13. Install the bracket for the water hoses and clip the hoses into place. Align the hoses.
Installation 674
einordnung
14. Install the starter ’ 276019 Removing and installing starter.

15. Install the front cross member.
16. Connect the battery and carry out the necessary subsequent work ’ 0 Entire Vehicle − General, 0
Power supply (work instructions after connecting the battery).
CAUTION
Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with
the coolant hoses when topping up or filling in!
• Fill Pentosin CHF 11 S only into both supply tanks!

• To prevent overfilling and so overflowing, check the specifications in the clutch, fluid levels
IMMEDIATELY!
17. Top up hydraulic fluid Pentosin CHF 11 S in the front expansion tank (luggage compartment) and in the
engine compartment. Observe the prescribed procedure without fail ’ 30 Clutch: checking fluid levels.
Front Pentosin tank
18. Bleed the clutch operation (clutch hydraulic system) ’ 30, 300107 Bleeding clutch operation.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 675
30 31 19 Removing and installing the accumulator
Removal
Installation
top of page
Removal
1. Raise vehicle on lifting platform.
2. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised.
30 31 19 Removing and installing the accumulator 676

einordnung
3. Undo the screws −arrows− and remove the front cross member.
4. Remove clips from the coolant lines.
5. Remove bracket for the coolant lines.
Note
IMMEDIATELY!
6. Remove the accumulator −arrow− . Use an open−ended wrench to undo the accumulator. Then turn the
accumulator further (remove) with an oil filter strap.
top of page
Installation
1. Set the accumulator in place and twist the accumulator into position using an oil filter strap. Use an
open−ended wrench to tighten the accumulator (tightening torque 30 Nm/22.2 ftlbs.).
2. Install the bracket for the water hoses and clip the hoses into place. Align the hoses.
3. Install the front cross member. Tightening torque of the fastening screws: 65 Nm (48.1 ftlb.).
CAUTION
• Fill Pentosin CHF 11 S only into the supply tanks!

• To prevent overfilling and, therefore, overflowing, check the specifications in the clutch, fluid levels
Removal 677
einordnung
IMMEDIATELY!
4. Top up hydraulic fluid Pentosin CHF 11 S in the expansion tank in the engine compartment.
5. Bleed clutch high−pressure hydraulic system. To this purpose, depress the clutch pedal approx. 10 times.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 678
30 45 19 Removing and installing release bearing
(clutch removed)
Removing release bearing
Installing release bearing

1 Snap ring 1 Remove using pointed−nose pliers, Ensure correct seating
simultaneously push down pressure plate
using a press.
2 Thrust plate 1 Engage lug (twist lock) in the
opening of a diaphragm spring
tongue
3 1 Check, do not wash out, just dry wipe Do not grease sliding surface
30 45 19 Removing and installing release bearing (clutch removed) 679

einordnung
Release
bearing
4 Spring 1 Mount in correct position
washer
5 Spacer 2 Fit 2 spacer washers
washer
6 Thrust plate 1 Check for wear, replace if
necessary
top of page
1. The release bearing is removed under a shop press. For this purpose, lay the release bearing down on
the bottom and press down on the pressure plate from above with a pressure piece (e.g. hardwood
block) until the snap ring can move freely.
2. Remove snap ring and take out release bearing.
top of page
Note
• Do not grease the sliding surfaces of the release bearing and the guide tube.
Removing release bearing 680

einordnung
Note
• The guide sleeve of the release bearing is slotted. The slot is irregular.
1. Fit spacer washers and spring washers on the new release bearing. When doing so, ensure that the parts
are fitted in the correct order and the spring washer is seated properly.
2. Insert release bearing in diaphragm spring plate. Engage lug on release bearing (twist lock) in the opening
between two tongues of the diaphragm spring.
3. Fit snap ring under the press. Ensure that the snap ring is seated
correctly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing release bearing 681

30 50 19 Removing and installing clutch
Tools
Removing clutch
Installing clutch
Tightening torques
top of page
Tools

A Toothed segment P201b
B Centring mandrel 9102
top of page
Removing clutch
1. Remove transmission ’ 34 35 27 Removing and refitting the
transmission.
30 50 19 Removing and installing clutch 682

einordnung
2. Position the toothed segment P201b −A− on the stud and undo the pan−head screws in several
stages and in diametrically opposite sequence, to avoid deforming the thrust plate.
top of page
Installing clutch
1. Fit drive plate with centring mandrel, special tools centring mandrel 9102 in the guide bearing
(needle bush).
2. Fit thrust plate. To do so, position the special tool toothed segment P201b −A− on the stud and
tighten the pan−head screws in several stages and in diametrically opposite sequence.
3. Remove the special tool centring mandrel 9102 .
4. Remove the special tool toothed segment P201b .
5. Refit transmission ’ 34 35 27 Removing and refitting the
transmission.
top of page
Tightening torques

Pan−head screws thrust plate − ZMS M8 23 (17)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing clutch 683

30 50 37 Disassembling and assembling clutch
No. Designation Qty. Removal Fitting

1 Pan−head 9 In order to avoid deformation of the In order to avoid deformation of the
screw M8 thrust plate housing, loosen screws in thrust plate housing, loosen screws in
several stages and in diametrically several stages and in diametrically
opposite sequence. opposite sequence.
2 Release 1 Do not wash out the bearing; replace
bearing loud bearings; do not grease the
sliding surface.
3 Thrust plate 1
4 Drive plate 1 Centre with centring mandrel 9102 .
5 Double−mass 1 Ensure the centring pins are seated
flywheel firmly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
30 50 37 Disassembling and assembling clutch 684

30 56 01 Checking clutch drive plate for wear
1. Remove clutch ’ 30 50 19 Removing and installing
clutch.
2. With a depth gauge, measure the distance between the lining surface and the rivet head (dimension x).
Note
• Only measure on the flanged side of the rivet head.
The wear dimension x measures 0.3 mm. If a smaller value is measured, the clutch drive plate must be
replaced. With a new clutch drive plate, this dimension measures approx. 1.7 mm.
Note
• It should be noted that the lining wear does not progress in linear fashion during the service life of the
clutch. Due to the settling behaviour of the clutch lining, the wear will appear to be greater at the
outset. However, the wear will become less as the mileage increases.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
30 56 01 Checking clutch drive plate for wear 685

03 24 00 Minor maintenance − USA
Caution
WARNING
from the USA
RoW vehicles => Minor maintenance
completeness.
Note
• It is extremely important to check the air cleaner (and replace it if necessary) each time minor
maintenance is carried out.
• On vehicles with annual mileages of less than 9,000 mls (15,000 km), an annual maintenance must be
• For an annual mileage of more than 9,000 mls (15,000 km) we recommend carrying out the next

15,000, 45,000, 75,000, 105,000 mls etc.
24,000, 72,000, 120,000, 168,000 km etc.
03 24 00 Minor maintenance − USA 686

einordnung

washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841
03 24 00 Minor maintenance − USA 687

03 24 00 Minor maintenance − as of MY 2003
Note
Note
module).
• The test item >Checking inner unlocking of luggage compartment (Trunk Entrapment) < has been
added to the countries specification C02 (for USA) and C36 (for Canada) as of model year 2003.

20,000, 60,000, 100,000, 140,000 km etc./
12,000, 36,000, 60,000, 84,000 mls etc.
03 24 00 Minor maintenance − as of MY 2003 688

einordnung
washer
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 24 00 Minor maintenance − USA − as of MY 2003
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note
• It is urgently recommended to check the air cleaner (and replace it if necessary) each time minor
maintenace is carried out.

15,000, 45,000, 75,000, 105,000 mls etc.
24,000, 72,000, 120,000, 168,000 km etc.
03 24 00 Minor maintenance − USA − as of MY 2003 690

einordnung
Tyres and spare wheel: check condition and tyre pressure => Tyres and spare wheel&colon;
checking condition and tyre pressure
functioning properly
=> Checking lid and doors
washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841

03 24 00 Minor maintenance − as of MY 2004
Note
Note
module).
• There is no annual maintenance for vehicles as of model year 2004.
• If the mileage for a regular service is not reached, minor maintenance must be carried out after 2, 6,
10..... years.

20,000, 60,000, 100,000, 140,000 km etc./
12,000, 36,000, 60,000, 84,000 mls etc.

einordnung
washer
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 24 00 Minor maintenance − USA − as of MY 2004
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note
• It is urgently recommended to check the air cleaner (and replace it if necessary) each time minor
maintenace is carried out.
• If the mileage for a regular service is not reached, minor maintenance must be carried out after 2, 6,
10..... years.

15,000, 45,000, 75,000, 105,000 mls etc.
24,000, 72,000, 120,000, 168,000 km etc.

einordnung
washer
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

32 47 19 Removing and installing torque−converter
sealing ring
Tools
Removing the torque−converter sealing ring
Installing the torque−converter sealing ring
top of page
Tools

A Lever VW 681
B Pressure piece 9670
top of page
Removing the torque−converter sealing ring
Removing converter ’ 32 Removing and installing torque converter .
32 47 19 Removing and installing torque−converter sealing ring 696

einordnung
1. Lever out the sealing ring using the lever VW 681 .
top of page
Installing the torque−converter sealing ring
1. Thinly coat sealing lip of sealing ring with Vaseline and drive sealing ring home as far as the mounting
face with pressure piece 9670 .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing the torque−converter sealing ring 697

32 50 19 Removing and installing torque converter
Tools
Removing the torque converter
Installing the torque converter
top of page
Tools

Locating pin 9595/1 long
top of page
Removing the torque converter
1. Remove engine−transmission unit (’ 100119 ) and remove the transmission ( => Removing and refitting
the transmission).
2. With transmission in horizontal position, remove the converter. Use two M8 x 120 screws for this
purpose.
32 50 19 Removing and installing torque converter 698

einordnung
top of page
Installing the torque converter
Note
• Check converter hub for traces of scoring. In the event of damage or faults, the converter must be
replaced.
1. Carefully push converter onto transmission shaft as far as the first stop. Then press converter by hand into
the converter bell housing and turn it until the recess in the converter hub engages in the driver of the
impeller and the converter perceptibly slides inward.
2. Check installation depth of the converter.

Installation depth: approx. 15 mm
WARNING
If the installed position of the converter is incorrect, the ATF pump can be destroyed when the transmission is
flange−mounted to the engine.
3. Fix converter in installation position with special tool (locating pin) 9595/1 .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing the torque converter 699

03 26 00 Major maintenance − USA
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note

30,000, 60,000, 90,000, 120,000 mls etc.
48,000, 96,000, 144,000, 192,000 km etc.
Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking
the free play of the parking brake lever
03 26 00 Major maintenance − USA 700

einordnung
end position
bellows
Tie rod ends: checking the play and dust bellows => Axle joints/drive shafts
washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841
03 26 00 Major maintenance − USA 701

03 26 00 Major maintenance − as of MY 2003
Note
Note
module).

40,000, 80,000, 120,000, 160,000 km etc./
24,000, 48,000, 72,000, 96,000 mls, etc.
03 26 00 Major maintenance − as of MY 2003 702

einordnung
end position
bellows
Checking the tie rod end play and dust bellows => Axle joints/drive shafts
washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance − USA − as of MY 2003
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note

30,000, 60,000, 90,000, 120,000 mls etc.
48,000, 96,000, 144,000, 192,000 km etc.
03 26 00 Major maintenance − USA − as of MY 2003 704

einordnung
end position
bellows
Tie rod ends: check the play and dust bellows => Axle joints/drive shafts
washer
Test drive:
996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance − as of MY 2004
Note
Note
module).
• If the mileage for a regular service is not reached, major maintenance must be carried out after 4, 8,
12..... years.

40,000, 80,000, 120,000, 160,000 km etc./
24,000, 48,000, 72,000, 96,000 mls, etc.

einordnung
end position
bellows
washer
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 26 00 Major maintenance − USA − as of MY 2004
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note
• If the mileage for a regular service is not reached, major maintenance must be carried out after 4, 8,
12..... years.

30,000, 60,000, 90,000, 120,000 mls etc.
48,000, 96,000, 144,000, 192,000 km etc.

einordnung
end position
bellows
washer
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

34 01 55 Changing transmission oil
Tightening torques
top of page
Note
• Top up only with transmission oil approved by Porsche. See Parts Catalogue!

Change quantity: 3.0 litres
2. Unscrew the oil filler screw and drain plug and drain the oil with the vehicle
horizontal.
3. Clean the drain plug and filler screw.
4. Replace sealing ring for drain plug and tighten to 30 Nm (22
ftlb.).
6. Tighten filler plug to 30 Nm (22 ftlb.).
top of page
Tightening torques

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
34 01 55 Changing transmission oil 710

34 08 19 Removing and installing shift console
Tools
Removing and installing shift console
Removing shift console
Installing shift console
Tightening torques
top of page
Tools

1 Locking bridge 9619
top of page
Removing and installing shift console
34 08 19 Removing and installing shift console 711

einordnung
A Shift console
B Selector cable (blue)
C Shift cable (black)
D Shift console cover
top of page
Removing shift console
1. Remove centre console.’ 68 17 19 Removing and installing centre
console.
2. Move shift lever to neutral position and fix with special tool (locking bridge)
9619 .
3. Remove shift console cover.
Removing and installing shift console 712

einordnung
4. Disengage selector cable −A− and shift cable −B− on shift console. To do this, slide the locking sleeve
−F− forward as far as it will go and turn it clockwise to removal position.
A Selector cable (blue)
B Shift cable (black)
C Adjuster open
D Adjuster closed
E Support bracket sleeve
F Locking sleeve
5. Carefully disengage support bracket sleeves −E− upward out of the shift console. Unlock the support
bracket sleeves by pressing in both plastic clips.
6. Unscrew fastening nuts for the shift console and remove the shift console.
top of page
Installing shift console
Note
• The shifting element is designed so that installation and adjustment are a single work step.
Precondition:
• Special tool (locking bridge) 9619 must be fitted to fix the shift lever.
• The transmission must be in neutral.
1. Insert the shift console and tighten the fastening nuts.

Removing shift console 713

einordnung
2. Insert the support brackets −E− in the correct position in the shift console. It must be possible to hear and
feel the support brackets engage.
C Adjuster open
D Adjuster closed
3. Engage the shift cable −B− and selector cable −A− in the open adjusters −C− and close the
adjusters (see magnified view). The locking sleeves on the adjuster must move to the end position
automatically.
4. Remove special tool (locking bridge) 9619 and shift through all gears as a
test.
5. Clip in shift console cover.
6. Install centre console ’ 68 17 19 Removing and installing centre
console.
top of page
Tightening torques

Shift console fastening screws M6 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing shift console 714

34 12 19 Removing and installing shift and selector
cables
Tools
Removing and installing shift and selector cables
Tightening torques
top of page
Tools

tool
A Removal tool Commercially available (refer to Workshop Equipment Manual,
Chapter 2.4, No. 21)
B Locking bridge 9619
top of page
Removing and installing shift and selector cables
34 12 19 Removing and installing shift and selector cables 715

einordnung

C Rubber sleeve
Removing shift and selector cables
Note
• The shift and selector cables have a common rubber sleeve and can only be replaced together. The
shift and selector cables must not be excessively bent.
1. Remove centre console.’ 68 17 19 Removing and installing centre

console.
2. Move shift lever to neutral position and fix with special tool (locking bridge)
9619 .
3. Remove shift console cover.
Removing and installing shift and selector cables 716

einordnung
Overview of shift console

C Adjuster open
E Adjuster closed
F Locking sleeve
4. Disengage selector cable −A− and shift cable −B− on shift console. To do this, slide the locking sleeve
−F− forward as far as it will go and turn it clockwise to removal position.
5. Carefully disengage support bracket sleeves −E− upward out of the shift console. Unlock the support
bracket sleeves by pressing in both plastic clips.
6. Remove parking brake console.
7. Remove underbody panels (middle and
rear).
8. Use a commercially available removal tool to lever off the shift cable end pieces −B− on the
transmission lever.
9. Detach the support bracket sleeves −A− at the support bracket. To do this, unclip the support bracket
sleeve (see enlarged view) and pull it out of the support bracket.
10. Remove transmission support.
11. Bend up the tabs −A− in the vehicle interior at the body opening and press the rubber sleeve outward
Removing shift and selector cables 717

einordnung
through the body opening.

12. Press the shift and selector cables downward through the body opening. To do this, carefully press
the support bracket sleeves through the body opening and pull the B+ wire out of the slotted rubber
sleeve.
Installing shift and selector cables
Note
• Each time the shift cables are removed from the transmission lever, the retaining clips of the shift
cable end pieces must be replaced.
1. Apply a generous coating of lubricant (e.g. Contifix tyre mounting paste) on the rubber sleeve and B+
wire in the area of the body opening.
2. Push shift and selector cables −C− through the body opening from
behind.
3. Insert B+ wire −A− into the slot of the rubber sleeve −B− and press sleeve into the body
opening.
4. Clip support bracket sleeves into the support bracket.
5. Fasten shift cable end pieces on the shift
lever.
6. Install transmission
support.
7. Fit underbody panels (middle and rear).
8. Bend tabs in the vehicle interior downward so that the rubber sleeve can no longer slip out of
place.
9. Install parking brake console.
10. Check function of parking brake and adjust it if necessary.’ 46 83 16 Adjusting parking brake shoes.
Note
• The shift and selector cables are routed underneath the console.
Installing shift and selector cables 718

einordnung
11. Insert the support brackets −E− in the shift console. It must be possible to hear and feel the support
brackets engage.
C Adjuster open
E Adjuster closed
12. Engage the shift cable −B− and selector cable −A− in the open adjusters −C− and close the
adjusters (see enlarged view). The locking sleeves on the adjuster must move to the end position
automatically.
13. Remove special tool (locking bridge) 9619 and shift through all gears as a test.
14. Clip in shift console cover.
15. Install centre console.’ 68 17 19 Removing and installing centre console.
top of page
Tightening torques

Parking brake console M8 23 (17)
Transmission support M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

34 35 27 Removing and refitting the transmission
Tools
Removing transmission
Refitting transmission
Tightening torques
top of page
Tools

tool
Gripper Commercially available ’ Workshop Equipment Manual Chapter
2.4, No. 50
top of page
1. Remove engine−transmission unit ’ 100119 .
2. Disengage starter cable on the right air
flange.
34 35 27 Removing and refitting the transmission 720

einordnung
3. Undo pressure pipe from slave cylinder.
4. Unscrew fastening screws for slave cylinder.

5. Hang slave cylinder on the engine without tension.
6. Remove left air flange and unscrew hexagon−head bolt for support.
7. Remove bearing cover with commercially available pliers (’ Workshop Equipment Manual
Chapter 2.4, No. 50 ).
8. Screw a screw (M6) into the clutch control shaft and pull out shaft.
9. Unscrew the fastening nuts for engine/transmission and separate the transmission from the engine.
top of page
Removing transmission 721

einordnung
Refitting occurs in reverse order, observing the following points:
Note
• Grease teeth of the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against
corrosion).
1. Insert release lever into the release bearing and fix in installation position with suitable adhesive tape.
2. Insert closure cap for the pulse sender opening in the correct position in the transmission housing
and mount transmission on the engine.
3. Ensure that the closure cap −A− is properly seated and positioned.
4. Fit release lever shaft with sealing rings.
Refitting transmission 722

einordnung
1 Hexagon−head bolt
2 Holder
3 Bearing cover
4 Needle−roller bearing with assembly bore
5 Sealing ring
6 Clutch control shaft
7 Release lever
5. Remove adhesive tape through the assembly opening in the release
fork.
6. Fit needle−roller bearing, bearing cover and support for clutch control shaft.
top of page
Tightening torques

Transmission on engine M10 45 (33)
Air flanges on transmission M6 10 (7.5)
Bracket for slave cylinder on transmission M8 x 20 23 (17)
Bracket for clutch control shaft on transmission M6 x 16 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

34 49 19 Removing and installing closure cap for
selector force mechanism
Tools
Removing and installing closure cap for selector force mechanism
Tightening torques
top of page
Tools

1 Press−out mandrel P 375
top of page
Removing and installing closure cap for selector force
mechanism
34 49 19 Removing and installing closure cap for selector force mechanism 724
einordnung
A Closure cap
Removing closure cap for selector force mechanism
1. Remove engine−transmission unit.’ 10 01 19 Removing and installing engine.
2. Shift transmission to neutral, unscrew fastening screw −A− and remove snap ring −B− .
A Fastening screw
B Snap ring
C Closure cap
3. Bore a 3.5 mm hole into the centre of the closure cap (coat drill with viscous grease to prevent
drilling chips from falling into the transmission). Screw in a sheetmetal screw (4.8 x 25) with a
large washer and lever out the closure cap using two screwdrivers.
Removing and installing closure cap for selector forcemechanism 725

einordnung
Installing closure cap for selector force mechanism
1. Insert closure cap and snap ring into the housing bore.
2. Use special tool (press−out mandrel) P 375 to push the snap ring and closure cap down until the snap ring
engages in its groove.
Note
• Ensure perfect seating of the snap ring.
3. Tighten fastening screw for gear housing.

4. Install engine−transmission unit. ’ 10 01 19 Removing and installing engine.
top of page
Tightening torques

Gear housing on transmission housing M8 25 (19)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing closure cap for selector force mechanism 726

03 50 00 Annual maintenance − USA
Caution
WARNING
from the USA
RoW vehicles
completeness.
Note
• Regular servicing with oil filter change must be carried out at least every 2 years according to the
mileage, if the mileage for a major maintenance has not already been reached.
regular servicing straight away.
Annual maintenance OK
=> Checking cooling system
Engine: check oil level => Changing the engine oil and oil filter
bellows
Axle joints: check the play and visually inspect the dust bellows for damage => Axle
joints/drive shafts
03 50 00 Annual maintenance − USA 727

einordnung
Test drive:
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 50 00 Annual maintenance − USA 728

03 50 00 Annual maintenance − as of MY 2004
Note
Note
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 50 00 Annual maintenance − as of MY 2004 729

03 50 00 Annual maintenance − USA − as of MY 2004
completeness.
Note
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
03 50 00 Annual maintenance − USA − as of MY 2004 730

37 02 35 Checking and topping up the ATF
Tools
Tightening torques
top of page
Tools

top of page
Note
37 02 35 Checking and topping up the ATF 731

einordnung
Note
• The stipulated fluid level is extremely important for perfect functioning of the automatic transmission.
It is correct if there is a slight amount of ATF escaping at the control screw bore −B− at temperatures
between 30 °C and 40 °C.
Testing conditions:
• The transmission must not be in the reduced driving program.

• The ATF temperature must be between 30 °C and 40 °C. An ATF inspection at an insufficient ATF
temperature causes over−filling and an inspection at an excessive ATF temperature causes insufficient
filling.
• Selector lever in position "P" and engine idling.
• The air−conditioning system and the heater must be switched off.
• The vehicle must stand horizontally.

Note
WARNING
Danger of injury from emerging ATF fluid!
ATF fluid can cause burns and chemical burns to the eyes!
• Wear protective goggles
4. Unscrew control screw −B− . If ATF escapes from the control bore and if the ATF temperature is
30 °C to 40 °C, the ATF level is in order. If there is enough ATF fluid in the transmission, then
Checking and topping up the ATF 732

einordnung
continue with step 10.
Note
• The control screw must be closed no later than when an ATF temperature of 45 °C is reached.
5. If no ATF escapes from the control bore even though approx. 40 °C has been reached, the ATF must be
topped up.
Note

valve.
7. Screw special tool 9507/1 −A− onto the charging valve and top up ATF via the charging valve until
excess ATF emerges at the control bore.
8. Replace sealing ring for cap nut.
9. Screw on cap nut for charging valve.
10. Screw in ATF control screw with a new sealing ring.
top of page
Tightening torques

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

37 02 55 Replacing ATF fluid
Tools
Replacing ATF fluid
Tightening torques
top of page
Tools

top of page
Replacing ATF fluid
Note

Change quantity: approx. 4.5 litres
37 02 55 Replacing ATF fluid 734

einordnung
2. Unscrew drain plug −A− and drain ATF.
Note
3. Replace sealing ring for drain plug and screw in plug.

4. Unscrew control screw −B− .
Note

valve.
6. Screw connection hose 9507/1 −A− onto charging valve. Top up with ATF via the charging valve until
surplus ATF runs out at the control screw bore.
Note
• All instructions and test conditions for "Checking and topping up ATF fluid" must be observed for
further work steps (see Serv. No. 370235).
Replacing ATF fluid 735

einordnung
9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control
screw −B− .
10. With the brake pedal pressed, change through all selector lever positions, remaining in each position for
approx. 10 s.
Note
11. Check the ATF level again and top up if necessary.

12. Replace sealing ring for cap nut and screw cap nut onto the charging valve.
13. Screw in the ATF control screw with a new sealing ring and tighten it to 20 Nm (15 ftlb.).
top of page
Tightening torques

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

37 08 19 Removing and installing selector support
Removing and installing selector support
Tightening torques
top of page
Removing and installing selector support
Removing selector support
1. Remove selector knob ’ 37 04 19 Removing and installing selector

knob.
2. Remove centre console ’ 68 17 19 Removing and installing centre
console.
3. Press together the retaining clip on the keylock cable −A− and lift adjuster −B− up out of the support
bracket (see enlarged view 1).
4. Disengage cable nipple −C− .

5. Disengage selector lever cable −D− on the selector support. To do this, slide the locking sleeve −E−
forward as far as it will go and turn it clockwise to removal position (see enlarged view 2).
6. Carefully disengage support bracket sleeve −F− upward out of the selector support. Unlock the support
bracket sleeves by pressing in both plastic clips (see enlarged view 3).
7. Unscrew fastening nuts −G− for selector support.
37 08 19 Removing and installing selector support 737

einordnung
8. Disconnect electrical plug connections −A− and remove the selector

support.
Installing selector support
Note
• Install in reverse order to removal.
1. Insert selector support and connect electrical plug connections.

2. Tighten fastening nuts.
3. Insert support bracket sleeve on the selector lever cable in the support bracket on the selector support.
Make sure the two plastic clips engage properly. (See enlarged view).
4. Push selector lever cable all the way back (see enlarged view); this shifts the transmission into park.
5. Move selector lever to position P.
Removing selector support 738

einordnung
6. Engage the selector lever cable into the open adjuster and close the adjuster (see enlarged view).
The locking sleeve on the adjuster must move to the end position automatically.
7. Engage cable nipple in the keylock lever.
8. Insert adjuster on the keylock cable into the support bracket. Make sure the two retaining clips engage
properly.
9. Install centre console ’ 68 17 19 Removing and installing centre
console.
10. Install selector knob ’ 37 04 19 Removing and installing selector knob.
top of page
Tightening torques

Shift console fastening screws M6 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing selector support 739

37 15 19 Removing and installing selector lever cable
Tools
Removing and installing selector lever cable
Tightening torques
top of page
Tools

tool
top of page
Removing and installing selector lever cable
Removing selector support
1. Remove selector knob’ 37 04 19 Removing and installing selector

knob.
2. Remove centre console’ 68 17 19 Removing and installing centre console.
37 15 19 Removing and installing selector lever cable 740

einordnung
3. Disengage selector lever cable −A− on the selector support. To do this, slide the locking sleeve −B−
forward as far as it will go and turn it clockwise to removal position (see enlarged view 1).
4. Carefully disengage support bracket sleeve −C− upward out of the selector support. Unlock the support
bracket sleeves by pressing in both plastic clips (see enlarged view 2).
5. Remove parking brake console.
6. Remove underbody panels (middle and
rear).
8. Remove plastic cover −A− around pinion

shaft.

einordnung
9. Remove transmission lever −A− from the transmission housing. To do this remove retaining clamp
−D− from the pivot point. Undo the transmission lever holder screws −C− and remove the
transmission lever holder −B− .
10. Remove support bracket sleeve −A− on selector lever cable from support bracket −B− . To do this, press
retaining clip −C− together and pull the support bracket sleeve out of the support bracket.
11. Lever the end piece of the selector lever cable off the transmission lever with a commercially available
removal tool. The selector lever cable can be pulled down somewhat with the transmission lever to allow
better access to the separation point.
Note
• When separating the selector lever cable and the transmission lever, make sure not to bend the
transmission lever or kink the selector lever cable too much.

einordnung
12. Bend up the tabs −A− in the vehicle interior at the body opening and press the rubber sleeve outward
through the body opening.
13. Pull B+ cable out of the slotted sleeve and pull the selector lever cable out through the body opening.
Installing selector support
Note
• Install in reverse order to removal.
1. Apply a generous coating of lubricant (e.g. Contifix tyre mounting paste) on the rubber sleeve and B+
wire in the area of the body opening.
2. Push selector cable −C− through the body opening from behind.
3. Insert B+ wire −A− into the slot of the rubber sleeve −B− and press sleeve into the body
opening.
4. Press end piece of the selector lever cable onto the ball head on the transmission
lever.
5. Insert support bracket sleeve on the selector lever cable into the support bracket. Ensure correct seating of
retaining clip in the support bracket.
6. Fit transmission lever and transmission lever holder. Ensure that the retaining clamp is seated
correctly.
Tightening torque for holder screws: 23 Nm (17 ftlb.)

7. Fit plastic cover around pinion shaft.
8. Install transmission
support.
9. Install underbody panels (middle and rear).
10. Install parking brake console.
Installing selector support 743

einordnung
11. Check function of parking brake and adjust if necessary.’ 46 83 16 Adjusting parking brake shoes.
12. Insert support bracket sleeve on the selector lever cable in the support bracket on the selector
support. Make sure the two plastic clips engage properly. (See enlarged view)
13. Push selector lever cable all the way back (see enlarged view); this shifts the transmission into park.
14. Move selector lever to position P.
15. Engage the selector lever cable into the open adjuster and close the adjuster (see enlarged view).
The locking sleeve on the adjuster must move to the end position automatically.
16. Install centre console.’ 68 17 19 Removing and installing centre console.
17. Install selector knob.’ 37 04 19 Removing and installing selector knob.
top of page
Tightening torques

Parking brake console M8 23 (17)
Transmission support M10 65 (48)
Transmission holder M8 23 (17)

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

37 35 27 Removing and refitting the transmission
Note
Tools
Tightening torques
Note
• When installing a new or replacement transmission, the adaptation values must be reset with the PST
2. The shifting quality may deteriorate slightly during the adaptation phase of the transmission control
module.
top of page
Tools

A Holder 9674
B Locating pin 9595/1 long
top of page
37 35 27 Removing and refitting the transmission 746

einordnung
2. Remove starter ’ 276019 .
3. Disengage B+ wire on bracket.
4. Pull off vacuum line for flat−seat valve on branch piece.
5. Disconnect coolant supply hose on pipe.
6. Disengage coolant hoses.

7. Remove drive belt ’ 137819 .
8. Rotate engine to TDC mark.
9. Unscrew two of the six converter fastening screws through the starter opening in the converter
housing.
Note

einordnung
• Turn the crankshaft 120° further in each case for the remaining four fastening screws.
10. Unscrew the remaining four fastening screws.
11. Remove crash support.
12. Unscrew the two upper fastening screws of the converter bell housing and suspend the
transmission from the workshop crane with special tool holder 9674 .
13. Unscrew the remaining four fastening screws and pull the transmission only far enough away from
the engine to allow insertion of special tool locating pin 9595/1 for holding the converter.
14. Remove transmission with converter.
top of page
Refitting occurs in reverse order, observing the following points:
1. Push special tool additional support 9111/6 all the way into the engine retainer plate.

einordnung
2. Check installation dimension of the converter.

Installation dimension approx. 15 mm
3. Hold converter in installation position with special tool locating pin 9595/1 and push transmission
in until the toothed ring on the flywheel touches the centering pin.
4. Remove special tool locating pin 9595/1 , push the transmission all the way in and bolt it to the
intermediate case.
5. Insert a wooden support of special tool spacer 9111/4 between the transmission housing and
transverse strut of special tool additional support 9111/6 .
top of page
Tightening torques

Torque converter to driver plate M8x20 39 (29)
Crash support to intermediate case M8x60 23 (17)
Transmission to intermediate case M8x35 23 (17)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

37 58 19 Removing and installing ATF filter
Tools
Removing ATF filter
Tightening torques
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Tools

top of page
Removing ATF filter
1. Remove underbody panels, rear and centre.
37 58 19 Removing and installing ATF filter 750

einordnung
3. Disengage cable at the retaining clips of the ATF pan.

Note
top of page
1. Thinly coat gasket on the suction collar of the new ATF filter with Vaseline and install
filter.
2. Clean ATF pan.
3. Fit ATF pan with new seal. Tighten the screws crosswise in several stages.
4. Replace sealing ring for ATF drain plug and tighten screw.
6. Engage cable on the retaining clips of the ATF
pan.
7. Install cross member.
8. Install rear underside
panel.
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Removing ATF filter 751

einordnung
Tightening torques

Drain plug to ATF pan M 10 22 (16)
Transmission cross member to body M 10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

38 77 19 Removing and installing electrohydraulic
control unit
Tools
Removing the electrohydraulic control unit
Installing the electrohydraulic control unit
Tightening torques
top of page
Tools

A Assembly aid 9663
B Ratchet 1/4 inch Commercially available
C Extension 1/4 inch Commercially available
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Removing the electrohydraulic control unit
38 77 19 Removing and installing electrohydraulic control unit 753

einordnung
Note
• Do not let engine run with the ATF pan removed or without ATF filling.
1. Remove rear underside

panel.
3. Disengage the coolant lines at the fastening points.

4. Disengage cable at the retaining clips of the ATF pan.
Removing the electrohydraulic control unit 754

einordnung
5. Disengage the coolant hoses in the area of the flanged shaft.

6. Pull vacuum pipe off the switch−over
valve.
7. Undo the left drive flange on the transmission side.
8. Remove the holders for the coolant

hoses.
9. Unlock the plug connection by turning it to the left and pull out the plug.
10. Unscrew the fastening screw for the pilot bushing using special tool assembly aid 9663 and pull out the
bushing.
Removing the electrohydraulic control unit 755

einordnung

15. Place selector lever in position − P − and unscrew the fastening screws for the control unit.
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Installing the electrohydraulic control unit
Install in reverse order, observing the following points:
1. Place selector lever in position − P − and place the control unit carefully in position. The selector
valve must engage in the driver of the notched plate.
2. First tighten screws for the control unit hand tight. Then
tighten.
Installing the electrohydraulic control unit 756

einordnung
3. Replace gasket for ATF pan.
4. Insert the plug connection with new sealing rings in the correct position and tighten the fastening screw.
Tightening torque: 2.5 Nm (2 ftlb.).
5. Screw in ATF drain plug.
6. Push the plug into the plug connection and lock by turning it to the right.
7. Install the holder for water hoses. It is essential that the centring pin engages in the holder bore. Tighten
the fastening screw.
8. Install the coolant hoses with hose holders in the correct position.
9. Push vacuum pipe onto switch−over
valve.
Installing the electrohydraulic control unit 757

einordnung
top of page
Tightening torques

Cross member to carrier side section M10 65 (48)
Plug connection to socket M4 2.5 (2.0)
Control unit to transmission M6 8 (6)
Water hose holder to transmission M6 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

38 77 37 Disassembling and assembling
electrohydraulic control unit
Tools
Overview
Disconnecting hydraulic and electrical control unit
Removing solenoid and control valve
Installing solenoid and control valve
Reassembling the hydraulic and electrical control unit
top of page
Tools
Item Special tool Remarks

designation
− Gripper Commercially available (refer to Workshop Equipment Manual, Chapter
2.4, No. 50)
top of page
Overview
38 77 37 Disassembling and assembling electrohydraulic control unit 759

einordnung

1 Cover 1
2 Cover 1
3 Screw (6x80) 2 Tighten to 8 Nm (6 ftlb.)
4 Screw (6x55) 1 Tighten to 8 Nm (6 ftlb.)
5 Leaf spring 3 Mount in correct position
6 Solenoid valve, 2−3 gearshift 1 Pull out with gripper
7 Control solenoid valve, converter jumper 1 As No. 6
8 Solenoid valve, 1−2 and 4−5 1 As No. 6
9 Solenoid valve, 3−4 gearshift 1 As No. 6
10 Control solenoid valve, shifting pressure 1 As No. 6
11 Control solenoid valve, modulating pressure 1 As No. 6
12 Electrical control unit 1
Overview 760
einordnung
13 Hydraulic control unit 1
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Disconnecting hydraulic and electrical control unit
1. Remove electrical control unit − 12 in overview −. To do so, bend back the retaining lug at the
strengthening rib on the oil temperature sensor.
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Removing solenoid and control valve
1. Pull off plastic cover − 1 or 2 in
overview.
2. Unscrew screw − 3 in overview −, remove leaf spring − 5 in overview − and pull out solenoid or control
valve − 6 to 11 in overview − if necessary with a pair of pliers.
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Installing solenoid and control valve
1. Press in new magnet or control valve − 6 to 11 in overview −. Ensure correct
seating.
2. Fit leaf spring − 5 in overview − and screw in screw − 3 in overview
−.
3. Fit plastic cover − 1 or 2 in overview −.
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Reassembling the hydraulic and electrical control unit
Disconnecting hydraulic and electrical control unit 761

einordnung
1. Place the control unit carefully in position. The guide pin must engage in the guide bore of the
hydraulic control unit.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Reassembling the hydraulic and electrical control unit 762

40 41 19 Removing and installing the front drive shaft
Tools
Removal
Installation
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Tools

A Torx screwdriver 9546 To counter the ball joints (track rod and
joint mount) during assembly and
disassembly.
B Ball joint extractor (track rod extractor), commercially
available; refer to Workshop Equipment Manual,
Chapter 2.4, No. 113
C Press−out tool (ball joint extractor) 9560 To press out the ball joint on the wheel
carrier.
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Removal
Note
• Before raising the vehicle, undo the drive shaft fastening at the wheel side! Actuate the brake while
doing this!
40 41 19 Removing and installing the front drive shaft 763

einordnung
• Remove diagonal brace to facilitate assembly (2 M12 screws)!
1. Remove front wheel and underside panel.

2. Undo the pan−head screws of the drive shaft on the transmission
flange.
Note
• The CV joint can come apart if the dust bellows holder −arrow− is removed or damaged. The joint
must therefore be secured against falling apart during removal, installation and transport with 8 mm
screws + nuts (2 ea.)!
• When loosening the fastening nuts, counter with special tool 9546 (Torx screwdriver)!
3. Disengage air guide on control arm.

4. Loosen stabilizer mount at stabilizer (counter with open−ended wrench).
5. Undo track rod and control arm on wheel carrier.
6. Press ball joint off control arm −1− with press−out tool 9560 and ball joint off track rod −2− using
a commercially available track rod extractor.
Note
• To prevent damage to the rubber sleeves of the ball joints, coat the rubber sleeves and the extractors
in this area with tyre mounting paste!
• Since the drive shaft can be moved in the wheel hub toothing only with great use of force, undo the
drive shaft using a copper mandrel (driving mandrel)! For unfavourable tolerances, the drive shaft
must be pressed out of the wheel hub toothing using a suitable wheel hub extractor!
7. Push protective tube (shop−made) onto the drive shaft (profile shaft).
8. Swivel (pull) spring strut outwards without using excess force and extend drive shaft.
Removal 764
einordnung
9. Do not damage the boots of the ball joints. Push a transport protective cap onto the joint if necessary.
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Installation
Install in reverse order.
Note
• Before installing, give the parts a visual check!
• Replace fastening nuts!
• Use correct tightening torques!
• Grease the toothing of the drive shaft with Optimoly HT! Additionally, only on the front axle, grease
the thread with Optimoly HT!
• Taper of ball joints and wheel carrier must be free of grease!
• When tightening the fastening nuts, counter with Torx screwdriver 9546 !
1. Grease the toothing and the thread of the drive shaft with Optimoly HT.
2. Swivel spring strut outwards and insert drive shaft into the vehicle.
3. Insert pan−head screws with shim plates into the halfshaft flange.
4. Insert drive shaft and fit pan−head screws. Fit new fastening nut M22 x 1.5.
5. Fit ball joints on wheel
carrier.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 765
40 85 19 Removing and installing front spring strut
Removal
Installation

A Torx screwdriver 9546 To counter the ball joints (track rod and joint mount) during
assembly and disassembly.
B Ball joint extractor (track rod Commercially available; refer to Workshop Equipment Manual,
extractor) Chapter 2.4, No. 113.
C Press−out tool (ball joint To press out the ball joint on the wheel carrier.
extractor) 9560
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Removal
1. Open front lid and remove the respective cover (right or
left).
2. Undo nut from drive shaft, raise vehicle and unbolt wheel.
3. Disengage air guide on control arm.
5. Undo track rod and control arm on wheel carrier.
40 85 19 Removing and installing front spring strut 766

einordnung
Note
• Use press−out tool 9560 −C− to press off the control arm −1− !
• Use a commercially available track rod extractor to press off the track rod −2− !
• When loosening the fastening nut, counter with Torx screwdriver!
6. Open plug connection on wheel carrier. Pull out the plugs and disconnect the plug connections on
the spring strut.
7. Loosen holder for brake lines/brake hose at wheel carrier.
8. Loosen brake caliper from wheel carrier and attach in wheel arch.
9. Mark the position of the collar nuts on the spring strut mount and undo.
Note
• Cover the drive shaft for protection before removing the spring strut! Drive shaft remains fitted on
front−axle final drive!
10. Loosen clamped connection between spring strut and wheel carrier and pull out spring strut from wheel
carrier.
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Installation
Install in reverse order to removal.
Note
• Do not grease screwed connections in Dacromet finish aluminium colour!
1. Replace brake caliper fastening screws and self−locking nuts.

2. Insert the drive shaft into the toothing of the wheel hub.
Removal 767
einordnung
Note
• The installation side "RE" (right) or "LI" (left) −arrow− is stamped on the spring strut mount!
• Note the installed position of the spring strut mount!
• The arrow markings must point in the direction of travel!
3. Insert wheel carrier with spring strut into the vehicle.

4. Check and adjust wheel alignment values at the front axle.
Note
• If assembly work was performed or parts replaced that affect the vehicle height, a complete wheel
alignment is necessary!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 768
42 58 19 Removing and installing rear−wheel bearing
Tools
Notes on removal and installation
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Tools
Designation
of the special
Item tool Explanation
A Press−out For pressing out the rear−wheel hub
mandrel P
297 a
B Separator Commercially available, see Workshop Equipment Manual, Chapter 2.4, No. 111.
(12−115 mm As a support when pressing out the rear−wheel hub and the wheel bearing inner
Ø) race of the wheel hub
C Tubular piece For pressing the wheel bearing out and in
VW 415A
D Pressure Use in combination with tubular piece−C− to press in the wheel bearing
piece 9247
Removing and installing rear−wheel bearing
42 58 19 Removing and installing rear−wheel bearing 769

einordnung

1 Wheel hub 1 Press out with pressure piece P Press in under a hydraulic press. To do
297 a under a hydraulic press. For this, place the wheel hub on the wheel
this purpose, use the separator and centring device and press it on the
corresponding shims for support. wheel bearing inner race using pressure
piece VW 415 A.
2 Hexagon−head 4 Tighten to 37 Nm (27 ftlb.)
bolt (10.9)
3 Lid 1 Fit in correct position (groove down).
4 Wheel bearing 1 Heat wheel bearing housing to Insert new wheel bearing in correct
approx. 100 °C (max. 120 °C). position (inscription facing the wheel
Press out wheel bearing with hub), and then press again slightly using
tubular piece VW 415 A (tool C). pressure piece 9247/3 (tool D) and
tubular piece VW 415 A (tool C).
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Note
• The wheel bearing is removed and installed with the wheel bearing housing removed.
Removing and installing rear−wheel bearing 770

einordnung
Removal
1. Remove brake disc, parking brake shoes, brake disc cover and speed sensor.
2. Press the rear−wheel hub out using press−out mandrel P 297 a . Use the separator as a support. If there is
not enough space for the wheel hub between the press, appropriate shims will additionally be necessary.
3. Remove retainer plate (lid) (four screws).
4. Heat wheel bearing housing to approx. 100 °C (max. 120 °C). Press out wheel bearing with tubular piece
VW 415A (tool −C− ).
Note
• Pull the inner bearing race several millimetres off the wheel hub so that the separator can be put into
place.
• For this purpose, use a two−claw puller in combination with a suitable pressure piece (e.g. VW 433).
Removal 771
einordnung
5. Press inner wheel bearing race off the wheel hub. Use the press−out mandrel P 297 a in connection with
the separator.
Installation
1. Before installation, clean the bore in the wheel bearing housing and remove any surface irregularities with
a polishing cloth.
2. Heat wheel bearing housing to approx. 100 °C (max. 120 °C). Insert new wheel bearing, and then press
again slightly using pressure piece 9247/3 −D− and tubular piece VW 415 A −C− .
3. Fit retainer plate (lid). Unless there is a water drain on both sides, fit the water drain (−arrow− ) in
the correct position i.e. facing downward. Observe tightening torque: 37 Nm (27 ftlb.)
4. Press in wheel hub. To do this, place the wheel hub on the wheel centring device and press it on the wheel
bearing inner race using pressure piece VW 415 A (tool C).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 772
42 71 19 Removing and installing rear spring strut
Removal
Installation
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Removal
2. Remove the rear wheel.
3. Mark the installed position of the spring strut mount (position of the three collar nuts, −arrows− ).
4. Loosen fastening nuts M10 from the spring strut mount in the vehicle
interior.
6. Loosen screw connection between spring strut/wheel carrier −arrow− .

7. Pull out (remove) spring
strut.
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Installation
Install in reverse order.
Note
• Replace fastening nuts!
• Do not grease screwed connections in Dacromet finish aluminium colour!
42 71 19 Removing and installing rear spring strut 773

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• When new parts are installed that affect vehicle height, suspension alignment must be carried out!
• Before tightening the fastening nuts, adjust spring strut mount in accordance with the applied marking
(position of the three fastening nuts)!
Insert spring strut into vehicle. Tightening torque 46 Nm (34 ftlb.).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 774
44 05 19 Removing and installing the wheel − Turbo
and GT2
Wheel mounting − Turbo and GT2
Removing/installing the wheel on vehicle − Turbo and GT2
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Wheel mounting − Turbo and GT2
• The wheels of the Turbo and GT2 are mounted with series wheel bolts −A− M14 x 1.5 (length 45
mm) dimension −X− !
• The intially planned procedure of using GT3 wheel bolts −B− M14 x 1.5 (length 50 mm) dimension
−X− is not applicable! Previous written publications should be altered accordingly!
Wheel bolts
A Series wheel bolt (Turbo and GT2) dimension X approx. 45

mm
B GT3 wheel bolt dimension X approx. 50 mm. Designation with GT or red color (arrow).
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Removing/installing the wheel on vehicle − Turbo and GT2
Note
• Use suitable commercially available tools (wrench size 19 mm)! Never use an impact bolter to tighten
the wheel bolts!
• Before the wheel is placed on the wheel hub, regrease the centering surface of the wheel hub (if
required) as necessary with a very thin coat of Optimoly TA (aluminium paste)!
• The wheel bolt consists of two parts that are permanently joined together! Other wheel bolts must not
be used!
CAUTION
44 05 19 Removing and installing the wheel − Turbo and GT2 775

einordnung
Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel
removal/installation (danger of damage to brake discs)!
1. In the case of vehicles with PCCB (Porsche Ceramic Composite Brake), screw the 2 assembly aids
(assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation. During
removal, first remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the
brake discs.
Note
• The assembly pins can be ordered separately as a spare part! Part No.: 999 571 074 30.
2. Fasten the wheels with series wheel bolts (Turbo and GT2) −A− M14 x 1.5 (length 45 mm)
dimension −X− .
3. In the case of heavy soiling, clean the wheel bolts and the concavities in the wheel with a lint−free
cloth.
4. Always apply a thin coat of Optimoly TA (aluminium paste) on the thread of the wheel bolts, on the shank
and between the bolt head bearing surface and spherical cap ring (under the head) −arrows− . Do not
grease the spherical cap bearing surface −X− of the wheel bolts that faces the wheel.
Removing/installing the wheel on vehicle − Turbo and GT2 776

einordnung
A Spherical cap ring (permanently connected with the wheel bolt)

X Spherical cap bearing surface facing the wheel (do not grease)
Note
• Rework on wheel bolts is impermissible!
5. Always replace damaged wheel

bolts.
This damage includes mechanical damage to the thread, the spherical cap and damage resulting from seizure
of the bolt head bearing surface and spherical cap ring. It must be possible to rotate the spherical cap ring on
the bolt shank and to move it in the axial direction.
Note
• Always observe the specified tightening torque of 130 Nm (96 ftlb.)!
6. Screw in wheel bolts by hand and then tighten evenly. Start at the top when
tightening.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing/installing the wheel on vehicle − Turbo and GT2 777

44 35 19 Removing and installing valve (steel valve)
(Turbo ll wheel)
General
Removal
Installation
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General
The steel valve must always be replaced when changing a tyre!
CAUTION
Loss of tyre pressure if the installation position of the components is not observed and the original Porsche SP
parts are not used when installing the steel valve.
• Fix disc into the correct position using the O−ring and the fastening nut!
• Only use the original valve cap!
top of page
• Do not use commercially available steel valves. The Porsche valves (part nos. 993.361.073.00) are
shorter (dimension X). −Dimension X− is approx. 43 mm for the Porsche version!
• The complete valve only is available as a spare part. See Spare Parts catalogue!
• The valve insert is commercially available!
44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel) 778

einordnung
• The valve cap −1− is provided with a seal (air−tight seal). Do not confuse with a commercially
available valve cap! The shaft of the fastening nut −2− must point towards the valve foot, because
otherwise the valve will not be secure!
• Position of the disc must be observed −3− −arrow− . If the disc is fitted incorrectly, the O−ring will
be damaged −4− . Serious damage is possible as a result!
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Removal
1. Unscrew valve cap.
2. Undo fastening nut −2− . When undoing the fastening nut −2− , counter with a screwdriver in the valve
foot. There is a slit in the valve foot to aid countering. Remove disc −3− and O−ring −4− . Pull out valve
−5− .
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Installation
1. Insert valve −5− with the fitted foot seal −(6)− into the wheel. The foot seal −6− is always fitted with new
valves!
Notes on removal and installation 779

einordnung
2. Place O−ring −4− carefully on to the valve from the outside. Mount disc −3− in the correct position
−arrow− . The O−ring then lies in the disc depression.
3. Install the fastening nut −2− with the shaft facing towards the valve foot. Tighten the fastening nut
−2− with a torque wrench to 3.5 (2.5 ftlbs.) ± 0.5 Nm (0.5 ftlb.). When tightening, counter with a
screwdriver on the slot of the valve foot.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 780
45 11 19 Removing and installing front speed sensors
Removal
Installation
top of page
Removal
1. With ignition switched off, open the combination plug connection at the spring strut and pull out
the plug for the speed sensor.
2. Loosen fastening screw (hexagon socket head bolt) and remove the speed sensor.
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Installation
Note
• Before installation, ensure that there are no metal chips at the magnetic edge of the speed sensor!
• The gap between speed sensor and pulse wheel is determined by the design and cannot be adjusted!
• There is no O−ring between speed sensor and wheel carrier!
• The speed sensors at front and rear axles are the same!
1. Coat speed sensor and the bore in the wheel carrier with Molykote Longterm 2.
2. Without using excessive force, insert speed sensor into wheel carrier and tighten the hexagon socket head
bolt to 10 Nm (7.5 ftlb.).
3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because
of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the
Actual Values menu, Speed submenu.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
45 11 19 Removing and installing front speed sensors 781

45 15 19 Removing and installing rear speed sensors
Removal
Installation
top of page
Removal
1. With ignition switched off, open the combination plug connection at the spring strut and pull out
the plug for the speed sensor.
2. Loosen fastening screw (hexagon socket head bolt) and remove the speed sensor.
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Installation
Note
• Before installation, ensure that there are no metal chips at the magnetic edge of the speed sensor!
• The gap between speed sensor and pulse wheel is determined by the design and cannot be adjusted!
• There is no O−ring between speed sensor and wheel carrier!
• The speed sensors at front and rear axles are the same!
1. Coat speed sensor and the bore in the wheel carrier with Molykote Longterm 2.
2. Without using excessive force, insert speed sensor into wheel carrier and tighten the hexagon socket head
bolt to 10 Nm (7.5 ftlb.).
3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because
of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the
Actual Values menu, Speed submenu.
45 15 19 Removing and installing rear speed sensors 782

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 783
45 30 19 Removing and installing hydraulic unit
Replacing the hydraulic unit
Removal
Installation
top of page
Replacing the hydraulic unit
When replacing the hydraulic unit −D− , observe the following points!
• 3 hydraulic unit variants have been installed in the 911 Turbo (996) since the production launch. First
version 996.355.955.51, modified version 996.355.955.57 and new/current version 996.355.955.58.
• The first version 996.355.955.51 is no longer available since existing supplies have been used up.
Instead of the first version 996.355.955.51, the new/current version with part number 996.355.955.58
should be installed.
• At the first installation of the new/current hydraulic unit 996.355.955.58 instead of the first version
996.355.955.51, ensure that the combination hydraulic unit/rate−of−turn sensor is correct! This
means: the hydraulic unit 996.355.955.58 can only be combined with the new/current rate−of−turn
sensor (part number 996.606.145.00). Replace the rate−of−turn sensor if necessary.
• For the conversion of the first−version rate−of−turn sensor (part number 996.606.147.00) to the
new/current version (part number 996.606.145.00), see ’ 455931 Conversion of rate−of−turn sensor.
First version: Rate−of−turn sensor with part No. 996.606.147.00
45 30 19 Removing and installing hydraulic unit 784

einordnung
New/current version: Rate−of−turn sensor with part No. 996.606.145.00.
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Removal
Note
• For the removal and installation of the hydraulic unit −D− , the booster pump −A− of the brake
master cylinder −B− and the brake booster −C− remains fitted (installed).
1. Switch off ignition. Remove cover −A− from the hydraulic unit/brake
unit.
2. Hold down brake pedal with pedal holder , so that the brake fluid does not run out of the expansion tank
completely.
Replacing the hydraulic unit 785

einordnung
3. To remove the hydraulic unit −D− , carry out the following removal
procedure:
Undo the brake lines on the hydraulic unit.
Remove the lines between the brake master cylinder intermediate piston circuit and the hydraulic
unit.
Close the brake lines and the brake line connections with suitable plugs.
Pull off pressure sensor plug.
Unlock/disconnect the control module plug on the hydraulic unit. Cover the plug connector and the plug!
Note
• In the case of assembly work on the hydraulic connections, the electrical plug connections on the
hydraulic unit must always be connected!
• This prevents the plug connections on the hydraulic unit or in the plugs inside from being splashed
with brake fluid or water!
• Any damp plug must be wiped dry before being disconnected from the plug on the hydraulic unit!
• Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in
the system!
Undo and guide out the hydraulic unit. In the case of unfavourable tolerances, remove the hydraulic unit
without the bracket for the hydraulic unit.
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Installation
1. Install in reverse order.
Note
• First connect the electrical plug connections on the hydraulic unit, so that the plug connections inside
or on the hydraulic unit can not be splashed with brake fluid or water!
• After bleeding, check the assignment of the brake lines/solenoid valves to the correct brake calipers!
To do so, call up the PSM system with the PST 2 and carry out a swap test!
2. Bleed the brakes => Bleeding brakes (vehicle with PSM).
Note
Removal 786
einordnung
• First bleed brakes as usual!
• Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been
done (after conventional bleeding) as otherwise damage to the booster pump can occur!
• To bleed at front on right with running booster pump, the bleeding device should remain connected
(switched on)! Bleeding pressure approximately 2.0 bar!
3. When replacing the hydraulic unit, code the control module (manual
transmission/Tiptronic).
4. Carry out the following tests:
Check the system (brake lines and connections) for leaks.
Read out and erase the fault memory of the PSM control module with the Porsche System Tester 2
(PST 2). Additionally perform the static test in the PSM system.
Check electrical and hydraulic lines (brake lines) for incorrect assignment using the PST 2.
Then start the engine. The PSM−related lights in the instrument cluster must go out when the engine is
running.
Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS
control operation, taking the road conditions into consideration. Read out the PSM fault memory again.
There must not be any stored faults.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 787
45 59 19 Removing and installing rate−of−turn sensor
Removal
Installation
Two versions of the rate−of−turn sensor have been installed for the PSM (Porsche Stability Management)
system in the 911 Turbo (996) since series intoduction of this vehicle. The first version −A− with part number
996.606.147.00 and the new/current version −B− with part number 996.606.145.00.
Note
• The transverse acceleration sensor is integrated in the rate−of−turn sensor.
45 59 19 Removing and installing rate−of−turn sensor 788

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• First version of the rate−of−turn sensor with part number 996.606.147.00. will no longer be available
after existing supplies are used up.
• The new/current rate−of−turn sensor 996.606.145.00 (introduction shortly before the end of model
year 2000) can be retrofitted instead of the first version 996.606.147.00. In case of first−time
installation, various parts must be replaced in the surrounding area and some parts are omitted. The
conversion to the new/current version is described in Repair Group 45, in the chapter "Conversion of
rate−of−turn sensor" => Conversion of rate−of−turn sensor.
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Removal
CAUTION
The rate−of−turn sensor is a micro−mechanical component and is very sensitive to impacts!
Note
• Perform removal and installation with the ignition switched off!
1. Move the front seats into the rear seat position.
Removal 789
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2. Remove side−panel lining in front of the centre console on the left −A− and right.
3. Remove fastening nuts of the rate−of−turn sensor on the right −arrow− and left.
4. Pull out the rate−of−turn sensor and unlock and pull off the plug with the ignition switched off.
Note
• Pull at the plug housing only! Never pull the electrical connections!
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Installation
2. After installing the rate−of−turn sensor, read out the PSM fault memory with the Porsche System
Tester 2 and erase. Carry out a static test. Then start the engine. The PSM−related lights in the
instrument cluster must go out when the engine is running. Read out the PSM fault memory again.
There must not be any stored faults.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 790
45 59 31 Conversion of rate−of−turn sensor
Overview of rate−of−turn sensor conversion
Removal
Fitting
Two versions of the rate−of−turn sensor have been installed for the PSM (Porsche Stability Management)
system in the 911 Turbo (996) since the production launch of this vehicle. The first version −A− with part
number 996.606.147.00 and the new/current version −B− with part number 996.606.145.00.
Note
• The transverse acceleration sensor is integrated in the rate−of−turn sensor.
45 59 31 Conversion of rate−of−turn sensor 791

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First version: Rate−of−turn sensor with part No. 996.606.147.00
After supplies of the old sensor have been used up, install the new rate−of−turn sensor with part number
996.606.145.00!
New/current version: Rate−of−turn sensor with part No. 996.606.145.00.
Introduced in production shortly prior to the end of model year 2000. The new/current rate−of−turn sensor can
be retrofitted. The following instructions describe the conversion.
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Overview of rate−of−turn sensor conversion
In case of first−time installation of the new/current rate−of−turn sensor, the front centre console support −1−
and the holder −2− must be replaced. The following parts are omitted: The bow −4− over the rate−of−turn
sensor −3− and the cable guide −5− . The adapter plug −X− must be installed between the plug −6− and the
rate−of−turn sensor −3− .
Overview of rate−of−turn sensor conversion 792

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1 Front centre console support

2 Holder
3 Rate−of−turn sensor
4 Bow over rate−of−turn sensor
5 Cable guide
6 Plug (Item X = adapter plug that is installed between the new rate−of−turn sensor and the existing
plug).
The table below for the 911 Turbo (996) provides an overview of the part allocation for replacement of a
rate−of−turn sensor 996.606.147.00 (first version).
Component SP No. / explanation
PSM control 996.618.149.01
module (Installed as standard)
Hydraulic unit 996.355.955.51
(Installed as standard)
Rate−of−turn 996.606.145.00
sensor (Item 3)
Adapter plug 996.622.901.00
(Item X) The adapter plug (adapter lead)
is installed between the new
rate−of−turn sensor and the
existing plug
Holder (Item 2) 996.552.309.08
Front centre 996.552.267.05
console support
(Item 3)
Bow over the 996.606.143.00
rate−of−turn Omitted
sensor (Item 4)
Cable guide (Item 996.610.224.00
5) Omitted
Overview of rate−of−turn sensor conversion 793

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Note
• The adapter plug is necessary because the plug and the connector assignment have changed as well!
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Removal
CAUTION
Danger of damage!
• The negative terminal of the battery must be disconnected before the airbag control unit is removed!
• Never use a boost charger to start the engine!
• Never pull off or push on the wiring harness plugs of the control modules or other electronic
components when the ignition is switched on!
1. Move the front seats into the rear seat position.

2. Disconnect the ground wire of the battery and cover the terminal or
battery.
3. Remove side−panel lining in front of the centre console on the left −A− and right.
4. Remove centre console front part −B− ’ 681719 Removing and installing centre console (front part). Then
remove centre console −C− ’ 681719 Removing and installing centre console.
Removal 794
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5. Remove cable guide for the rate−of−turn sensor and remove the front centre console support −arrows− .
6. On Tiptronic vehicles, disengage (loosen) the keylock cable −5− on the selector lever: To do
this
Press the retaining clip −4− together and carefully pull the adjuster −3− upward out of the support
bracket.
Disengage cable nipple −1− on the keylock lever −2− .
7. Unlock plug of the rate−of−turn sensor with the ignition switched off −arrow on the plug− and pull it
off. Undo fastening nuts −arrows− and remove the rate−of−turn sensor with bow.
Note
• Pull at the plug housing only! Never pull the electrical connections!
8. Remove the airbag control module ’ 695319 Removing and installing triggering unit for the airbag.
Removal 795
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Note
• Socket wrench insert 9259 is required for removal and installation of the airbag triggering unit.
9. Undo the fastening screws −arrows− on both sides and remove the holder −2− . To do this, guide
the electrical wiring and, if necessary, the keylock cable through the holder opening.
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Fitting
CAUTION
The rate−of−turn sensor is a micro−mechanical component and is very sensitive to impacts!
1. Install new/current holder −B− dimension X = approx. 60 mm (6 fastening screws). Dimension X of the
holder for the first version −A− is approx. 110 mm. To do this, guide the electrical wiring and, if
necessary, the keylock cable through the holder opening. Fit the plastic clips and the clips from the old
holder on the new holder.
2. Install airbag control unit. Use new shear−off nuts.
Tightening torque of the M6 hexagon nut: 10 Nm (7.5 ftlb.)
Fitting 796
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3. On Tiptronic vehicles, engage (fasten) the keylock cable on the selector lever. To do this, engage the cable
nipple −1− on the keylock lever −2− . Press housing for adjuster −3− into the support bracket until the
retaining clip −4− engages.
Note
• The new rate−of−turn sensor has a different plug and a different connector assignment. For this
reason, it is necessary to fit an adapter plug (adapter lead with plugs) between the new rate−of−turn
sensor and the existing plug!
4. Install the adapter plug (adapter lead with plugs) and the rate−of−turn sensor. To do this:
Connect the plug on the adapter lead −X− to the existing plug −6− . Then secure this plug
connection firmly to the red lead −A− with a tie−wrap −B− so that it can not slip.
Fit rate−of−turn sensor (new/current version) −3− part no. 999.606.145.00. First, feed (route) the adapter
lead −X− under the rate−of−turn sensor −3− . Then connect the plug −arrow− on the adapter lead −X− to
the rate−of−turn sensor −3− .
Note
• There is no bow over the new rate−of−turn sensor!
Fitting 797
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5. Prepare new/current support −B− (with dimension X = approx. 8 mm) for installation. Distinguishing
characteristics: Dimension X and diameter of the hole −arrows− . Dimension X of the holder for the first
version −A− approx. 12 mm.
6. Install new/current support −B− .
7. Install centre console −C− ’ 681719 Removing and installing centre console. Then install centre console
front part −B− ’ 681719 Removing and installing centre console (front part).
8. Install side panel linings in front of the centre console.
9. Connect battery ground cable.
10. Code the radio and PCM.
Read out and erase the fault memories of the airbag, PCM and PSM control modules with the
Porsche System Tester 2. Additionally perform the static test in the PSM system.
running.
Read out the PSM fault memory again. There must not be any stored
faults.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Fitting 798
45 60 19 Removing and installing steering angle
sensor
Notes on steering wheel position during removal and installation
Removal
Notes on replacing the steering angle sensor − vehicles prior to '03 model
Installation
• A steering angle sensor −C− is attached to the steering column/steering shaft for PSM (Porsche
Stability Management) in the 911 Turbo.
• Cover −D− remains fitted during removal and installation of the steering angle sensor.
• Removal of cover −D− is generally not permitted.
A Universal joint of steering shaft

C Steering angle sensor. Modified versions as of 2003 model => Notes on replacing the steering angle
sensor − vehicles prior to '03 model
D Cover
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Notes on steering wheel position during removal and
installation
• Lock the steering wheel and the front wheels in a straight−ahead position. Make sure that this position
is retained for reinstallation. Refit in the same position during installation.
• If this is not done, the airbag contact unit (spiral spring) can be damaged. Also, the steering wheel can
be crooked when the front wheels are in a straight−ahead position after the steering angle sensor has
been installed.
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Removal
1. Remove driver's seat.
2. Switch ignition off.
45 60 19 Removing and installing steering angle sensor 799

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3. Remove air duct.

4. Turn front wheels to a straight−ahead position. Fix the front wheels and the steering wheel in this position.
5. Undo hexagon−head bolt on universal joint −A− . Detach universal joint −A− from the upper steering
shaft and push into the lower steering shaft (−direction arrow− ). Disengage cable guide −B− in the
direction of travel.
A Universal joint of steering shaft
B Cable guide
C Steering angle sensor
D Cover
Note
• Pull at the plug housing only. Never pull the electrical connections.
6. Pull off steering angle sensor plug. The plug can be pulled off to the side −direction arrow− or to the
front (depending on the design of the steering angle sensor). Disengage steering angle sensor −C− to the
front. To do this, press carefully on the sensor (−direction arrow− ) through the opening in cover −D− .
Removal 800
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Notes on replacing the steering angle sensor − vehicles prior to
'03 model
A new steering angle sensor −C2− is installed as of the 2003 model (3−programme). This internally modified
steering angle sensor, −C2− , differs (externally) from the previous steering angle sensor, −C1− , in having a
larger plug connection that is also located in a different position. New steering angle sensor −C2− : axial plug
connection (below steering shaft)/previous steering angle sensor −C1− : radial (lateral) plug connection.
• When a replacement is required, new steering angle sensor −C2− can be retrofitted in place of the
previous version, −C1− .
• When new steering angle sensor −C2− is installed in vehicles prior to the 2003 model, new cable
guide −B2− (instead of the previous cable guide) and adapter lead −E− must be installed because of
the modified plug connection (larger plug, position of plug and modified plug assignment).
Notes on replacing the steering angle sensor − vehicles prior to '03 model 801
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• The main difference between the old cable guide, −B1− , and the new cable guide, −B2− ,
(implemented as standard as of the 2003 model) is the cable deflector at the end of the cable. There
are interruptions (openings) in the cable slot (ribs) of new cable guide −B2− for routing the lead (there
is no open circuit in the ribs in the old cable guide −B1− ).
• Adapter lead −E− is inserted (fitted) between new steering angle sensor −C2− and the existing
(previous) lead, −X− . The leads that are joined together, −X and E− , are then inserted with the plug
connection into the cable slot of new cable guide −B2− and secured with a tie−wrap −arrow− .
Note
• Before inserting leads −E and X− into the cable slot, fold them so that the leads lie directly above one
another and are correctly positioned.
Component overview
Component overview 802

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Designation New Replaced

component component
Steering 996.606.119.00 996.606.109.02
angle sensor
(C2 = new
sensor)
Cable guide 996.610.123.01 996.610.123.00
(B2 = new
cable guide)
Adapter lead 996.622.906.00 Additional lead
−E− (connection between
the old lead and the
new steering angle
sensor)
Pin assignment of adapter lead −E−

−Large plug− −Small plug−
(connection to the (connection to the
new steering plug from the old
angle sensor) steering angle
sensor)
Pin 1 Ground Pin 4
Pin 2 + 12 V Pin 3
(vehicle
voltage)
Pin 3 CAN H Pin 2
Pin 4 CAN L Pin 1
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Installation
CAUTION
The airbag will not function if the spiral spring in the airbag contact unit is damaged. Observe mounting
specifications.
• Avoid uncontrolled twisting of steering wheel in the wheel position (by turning the steering wheel
when the universal joint is being removed on the steering shaft). This means that if the steering wheel
is turned to fit the steering angle sensor, the same steering wheel position, and thereby the position of
the spiral spring in the airbag contact unit, must be re−established before fitting the universal joint.
• The front wheels, steering wheel and airbag contact unit must be positioned correctly in relation to
one another before the universal joint is fitted on the upper steering shaft, i.e. they must be in the same
positions that they were in before the removal (the steering wheel and spiral spring are positioned
centrally and the wheels are in a straight−ahead position).
Note
Installation 803
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• The steering angle sensor and its hub adapter must engage audibly.
• Use a new fastening screw on the universal joint. Observe the tightening torque of the screw.
• When replacing the steering angle sensor in pre−2003 vehicles, ensure that the components in the
surrounding areas are correctly assigned (this is determined by the steering angle sensor version that
is used).
• The steering angle sensor has no defined zero position when new. The position for "straight ahead"
direction of travel must be programmed. This is done by calibrating with the Porsche System Tester,
when the wheels are in a straight−ahead position, on the measuring station.
1. Secure the steering angle sensor to the steering column (steering shaft) in 2 stages . Stage 1: Secure
(engage) adapter −1− to the steering shaft. Stage 2: Fit steering angle sensor to adapter −1− (detailed
instructions on how to do this will follow).
1 Hub adapter
2 Driver for steering angle sensor
3 Internal locking tab (for securing to the upper steering shaft)
4 External locking tab
5 Engagement (cutout) on the driver
• Detailed instructions:
First, disengage hub adapter−1− from driver −2− of the steering angle sensor −engagement 5− and pull it
out.
Push hub adapter −1− onto the steering shaft. Locking tabs −3 and 4− must be facing the steering
wheel. Internal locking tab −3− must engage completely in the cutout in drive shaft −6− . Check
that it is fitting securely: hub adapter −1− must not be able to twist on the steering shaft. In order for
the cutout in steering shaft −6− to be visible in the opening of cover −D− , twist the steering wheel
out of its original position beforehand. Then return the steering wheel to its original position.
Installation 804
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Push steering angle sensor −C− across the hub adapter that has already been fitted. The driver of steering
angle sensor −2− is facing the steering column. External locking tab −4− in the hub adapter must engage
completely in the driver engagement. In order for locking tab −4− to be visible in the opening of cover
−D− , twist the steering wheel out of its original position beforehand. Then return the steering wheel to its
original position.
Note
• If the steering wheel was not secured before the steering wheel sensor was removed or if the steering
wheel was twisted when the steering angle sensor was fitted on the steering shaft, the contact unit
(spiral spring) may no longer be in the correct position. If this is the case, remove steering wheel and
move contact unit to centre position.
2. Secure steering shaft (universal joint) −A− in correct position − the same position that it was in before the
removal (wheels are in a straight−ahead position, steering wheel and spiral spring are in a central position)
− to the upper steering shaft.
3. Push plug onto steering angle sensor (plug in cable) and engage cable guide −B− . Install the new
cable guide with the adapter lead only when modified steering angle sensor version C2 is used for
the first time in vehicles prior to the 2003 model (see following text).
Conversion − new steering angle sensor in vehicles prior to the 2003 model
Installation 805
einordnung
When converting from the old to the new steering angle sensor design, −C2− , new cable guide −B2− and
new adapter lead −E− (large plug on steering angle sensor) must be installed instead of the old cable guide
and previous lead (small plug on steering angle sensor). To do this:
Fit new cable guide −B2− (engage on the steering column) and insert adapter lead −E− .
Plug in (engage) the large plug on adapter lead −E− to new steering angle sensor
−C2− .
Join together the plug from existing lead −X− and the plug from adapter lead
−E− .
Insert existing lead −X− and adapter lead −E− , together with the plug connection, into the cable
slot and secure with a thin tie−wrap −arrow− . Before inserting the leads into the cable slot, fold
them so that the leads lie directly above one another and are correctly positioned.
4. Install air duct.
CAUTION
Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly.
• The steering angle sensor has no defined zero position when new. The position for "straight ahead"
direction of travel must be programmed.
• Calibrate steering angle sensor using the Porsche System Tester with the wheels in a straight−ahead
position on the measuring station.
5. Calibrating steering angle sensor => Steering angle sensor.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 806
45 64 19 Remove and install booster pump for PSM
Removal
Installation
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Removal
Note
• The booster pump −1− is removed with the holder −1a− .
1. Switch off ignition.
2. Remove cover −A− from the hydraulic unit.
3. For the removal of the booster pump, carry out the following removal
steps:
Remove suction line −2− for booster pump. Undo pressure pipe on the booster pump −3− . Close the lines
and the pump connections with suitable plugs.
Release plug −4− −arrows− and disconnect. Remove connector housing rearwards from out of the
bracket −moving arrow− .
Undo the three plastic fastening nuts −5− and remove the booster pump −1− with the holder −1a− .
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45 64 19 Remove and install booster pump for PSM 807

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Installation
2. Bleed the brakes ’ 47 01 07 .
Note
• To bleed at front on right with running booster pump, the bleeding device should remain connected

Read out and erase the fault memory of the PSM control module with the Porsche System Tester 2.
Carry out a static test.
running.
Read out the PSM fault memory again. There must not be any stored
faults.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 808
46 11 15 Adjusting the brake pushrod
The brake pedal has no stop. Since, when the brake pushrod is correctly set, the brake pedal has no support
possibility in its original position, the permanently set free play in the brake unit is guaranteed. As a result a
pushrod play of approx. 1 mm is noticeable by manual actuation on the pedal plate of the brake pedal.
Adjusting the pushrod length changes the position of the brake pedal.
Note
• Check adjustment of the brake light switch if brake pushrod is adjusted.
Undo the lock nut and turn the pushrod accordingly at the hexagon −arrow− .
Brake pushrod
The brake pushrod is correctly set if −dimension X = 45 + 5 mm.− Perform measurement between the centre
of the brake pedal plate and the accelerator.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
46 11 15 Adjusting the brake pushrod 809

46 36 20 Removing and installing the front disc brake
pads
Caution
Removal
Installation
WARNING
Danger of accident if brake pads with the wrong brake pad quality are installed!
• Use only the type−specific brake pads in the Porsche Spare Parts Catalogue!
The pad backing plates (rear side of the brake pads) must not be greased!
Replace vibration dampers each time the pads are changed!
The vibration dampers have an adhesive protective film! The protective film must be pulled off before
installation!
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Removal
1. Remove the retainer (safety bracket) −arrow− and extract the retainer pin inwards.
2. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the
brake pad plates.
46 36 20 Removing and installing the front disc brake pads 810

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brake pad plates.
Note
• Replace warning contacts if the core of the wire is worn or worn through!
• The warning contact can continue to be used if there are only scrape marks on the plastic part of the
warning contact!
• If necessary, remove some brake fluid by suction from the brake fluid reservoir (brake fluid may
escape over the rim of the container!)!
4. Remove brake pads with a brake pad puller. Always observe the following important
points!
• Set back the brake pads as far as possible with the piston resetting fixture (press back)!
• Pull out brake pads together with the vibration dampers! If this is not possible (depending on wear of
the brake pads), use a spatula to detach the vibration dampers from the brake pad backing plate before
removing the pads!
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Installation
WARNING
Danger of accident if old parts are fitted on brake caliper!
• Fit new expanding spring, new retaining pin and new retainer (safety bracket) on the brake caliper!
Note
• Ensure correct brake pad quality! Use brake pads as per Spare Parts Catalogue!
• The pad backing plates (rear side of the brake pads) must not be greased!
1. Before installation of the brake pads, check the wear of the brake discs. For minimum thickness of
the brake discs, see Technical data/Brake wear limit in Repair Group 46.
2. If necessary, turn back the piston to its original position using the resetting fixture.
3. Fit new vibration dampers in the pistons. Remove protective film from the vibration dampers before
installation.
4. Insert the brake pads.
Removal 811
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5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) −arrow− . These parts are
available as a repair set and must be renewed each time the pads are changed.
6. Insert the warning contact wire and warning
contacts.
7. Firmly press the brake pedal several times to position the brake pads on the brake discs.
8. Check and, if necessary, correct the brake fluid
level.
Bedding in the brake pads
New brake pads require a bedding−in period of approx. 200 km! Not until then do they achieve their best
friction and wear coefficient. During this period, the brakes should be subjected to full stress when travelling
at high speed only in emergencies.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 812
46 38 20 Removing and installing the rear disc brake
pads
Caution
Removal
Installation
WARNING
The pad backing plates (rear side of the brake pads) must not be greased.
Replace vibration dampers each time the pads are changed.
The damper plates have an adhesive protective film. The protective film must be pulled off before installation.
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Removal
brake pad plates.
brake pad plates.
46 38 20 Removing and installing the rear disc brake pads 813

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Note
• Replace warning contacts if the core of the wire is worn or worn through.
warning contact.
4. Remove brake pads with a brake pad puller. Always observe the following important
points!
Note
• If necessary, remove some brake fluid by suction from the brake fluid reservoir beforehand (brake
fluid may escape over the rim of the container!).
• Set back the brake pads as far as possible with the piston resetting fixture (press back).
• Pull out brake pads together with the damper plates. If this is not possible (depending on wear of the
brake pads), use a spatula to detach the damper plates from the brake pad backing plate before
removing the pads.
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Installation
DANGER
Note
• Ensure correct brake pad quality. Use brake pads as per Spare Parts Catalogue.
• The pad backing plates (rear side of the brake pads) must not be greased.
1. Before installation of the brake pads, check the wear of the brake discs. For minimum thickness of
the brake discs, see Technical data/Brake wear limit in Repair Group 46.
2. If necessary, turn back the piston to its original position using the resetting fixture.
3. Fit new damper plates in the pistons. Remove protective film from the damper plates before
installation.
Removal 814
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5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) −arrow− . These parts are
available as a repair set and must be renewed each time the pads are changed.
contacts.
8. Next, check and if necessary correct the brake fluid level.
New brake pads require a bedding−in period of approx. 200 km! Not until then do they achieve their best
friction and wear coefficient. During this period, the brakes should be subjected to full stress when travelling
at high speed only in emergencies.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 815
46 50 04 Measuring front brake discs
Measuring the front brake disc lateral runout
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Measuring the front brake disc lateral runout
Includes: Measuring the brake disc thickness tolerance
• Measuring prerequisite: No tilt play at the wheel.
Note
• If necessary, provide the dial gauge holder with the Ate conversion set, order No. 03.9314 −
5510.3/01 (longer clamping wing screw and, possibly, also a bracket for the dial gauge).
• Do not damage the expanding spring when fitting the dial gauge holder.
1. Mount the adapter plate 9510/1 on the wheel hub. Tightening torque of the wheel bolts (fastening screws):
130 Nm (96 ftlb.).
2. Insert dial gauge holder, e.g. Ate order No. 03.9314−5500.3/01, into the brake caliper, align it
and secure it by tightening the clamping wing screw. If the brake disc cannot be turned freely,
set the brake pads back a little.
3. Secure the dial gauge with some preload. Put the measuring tip against the largest diameter of the brake
surface.
4. Turn the brake disc and, when doing so, read off the lateral runout at the dial
gauge.
Note
46 50 04 Measuring front brake discs 816

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• Lateral runout of the removed brake disc: max. 0.03 mm!
• Wheel hub lateral runout: max. 0.03 mm!
• The permissible lateral runout of the installed brake disc is max. 0.06 mm!
• Do not damage the brake hoses or brake lines during removal/installation of the brake caliper!
5. If the brake disc lateral runout exceeds 0,06 mm, mark the position in relation to the wheel hub and
remove the brake disc. Check the wheel hub lateral runout.
6. Check the wheel hub lateral runout as described below: Measure 1 x outside −arrow− and 1 x
inside −arrow− of the wheel bolt area (5−point measuring procedure) on the front face of the
wheel hub. Fasten the dial gauge using a commercially available universal dial gauge holder (refer
to Workshop Equipment Manual, Chapter 2.4, No. 147−1).
Wheel hub lateral runout is too large:
Replace the wheel hub.
Wheel hub lateral runout OK:
Clean the levelling and centring surfaces on the brake disc and wheel hub. Next, apply a thin coat
of Optimoly TA to the centring surface on the wheel hub. Fasten brake disc on the wheel hub in a
different position than before radially offset with respect to the wheel hub. Repeat the
measurement with adapter plate 9510/1 fitted. If the lateral runout is still greater than 0.06 mm,
replace the brake disc.
Measuring the brake disc thickness tolerance
Measure the brake disc thickness deviation within the brake surface at approx. 8 points by using the
micrometer. Thickness tolerance of the brake disc max. 0.02 mm (new condition: max. 0.01 mm).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Measuring the front brake disc lateral runout 817

Removing and installing the front brake disc
Removal
Installation
top of page
Removal
Note
• In order to gain better access for assembly work, it is beneficial to turn the wheels fully either to the
right or the left!
1. Remove front wheel. Press the electrical lead for the speed sensor/wear indicator out of the holder.
2. Undo the plug coupling for the speed sensor/wear indicator on the wheel carrier.
3. Loosen holder for brake line at wheel
carrier.
4. Disengage the electrical lead for the wear indicator from the
clips.
5. Set the brake pads back slightly with the piston resetting fixture .
6. Undo the brake caliper on the wheel carrier and hang it in a suitable place in the wheel well (do not open
the brake hydraulics!).
7. Take off the brake disc after removing the countersunk screws.
top of page
Installation
Note
• Do not confuse right and left brake discs during assembly! Distinguishing characteristic: involute
shape and spare part number (SP No.).
• The flat surface of the brake discs is marked with R = right or L = left.
• Spare part on left−hand side − third group number is odd. Spare part on right−hand side − third group
number is even. For example: SP No. Left brake disc: 996.351.409.02 SP No. Right brake disc:
996.351.410.02.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
Removing and installing the front brake disc 818

einordnung
4. Fit the brake disc.

L Left brake disc
5. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Tightening
torque of the fastening screws = 85 Nm (63 ftlb.).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 819
46 53 04 Measuring rear brake discs
Measuring the rear brake disc lateral runout
top of page
Measuring the rear brake disc lateral runout
Includes: Measuring the brake disc thickness tolerance
• Measuring prerequisite: No tilt play at the wheel.
Note
• If necessary, provide the dial gauge holder with the Ate conversion set, order No. 03.9314 −
5510.3/01 (longer clamping wing screw and, possibly, also a bracket for the dial gauge).
• Do not damage the expanding spring when fitting the dial gauge holder.
1. Mount the adapter plate 9510/1 on the wheel hub. Tightening torque of the wheel bolts (fastening screws):
130 Nm (96 ftlb.).
2. Insert dial gauge holder, e.g. Ate order No. 03.9314−5500.3/01, into the brake caliper, align it
and secure it by tightening the clamping wing screw. If the brake disc cannot be turned freely,
set the brake pads back a little.
3. Secure the dial gauge with some preload. Put the measuring tip against the largest diameter of the brake
surface.
4. Turn the brake disc and, when doing so, read off the lateral runout at the dial
gauge.
Note
46 53 04 Measuring rear brake discs 820

einordnung
• Lateral runout of the removed brake disc: max. 0.03 mm!
• Wheel hub lateral runout: max. 0.03 mm!
• The permissible lateral runout of the installed brake disc is max. 0.06 mm!
• Do not damage the brake hoses or brake lines during removal/installation of the brake caliper!
5. If the brake disc lateral runout exceeds 0,06 mm, mark the position in relation to the wheel hub and
remove the brake disc. Check the wheel hub lateral runout.
6. Check the wheel hub lateral runout as described below: Measure 1 x outside −arrow− and 1 x
inside −arrow− of the wheel bolt area (5−point measuring procedure) on the front face of the
wheel hub. Fasten the dial gauge using a commercially available universal dial gauge holder (refer
to Workshop Equipment Manual, Chapter 2.4, No. 147−1).
Wheel hub lateral runout is too large:
Replace the wheel hub.
Wheel hub lateral runout OK:
Clean the levelling and centring surfaces on the brake disc and wheel hub. Next, apply a thin coat
of Optimoly TA to the centring surface on the wheel hub. Fasten brake disc on the wheel hub in a
different position than before radially offset with respect to the wheel hub. Repeat the
measurement with adapter plate 9510/1 fitted. If the lateral runout is still greater than 0.06 mm,
replace the brake disc.
Measuring the brake disc thickness tolerance
Measure the brake disc thickness deviation within the brake surface at approx. 8 points by using the
micrometer. Thickness tolerance of the brake disc max. 0.02 mm (new condition: max. 0.01 mm).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Measuring the rear brake disc lateral runout 821

46 53 19 Removing and installing the rear brake disc
Removal
Installation
top of page
Removal
1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake
pad wear indicator.
2. With a screwdriver, turn the adjustment device towards "release" through a wheel bolt threaded hole.
3. Remove the brake caliper from the wheel carrier and suspend it in the wheel arch (do not open brake
hydraulics). First, pull out the electrical wires on the brake caliper holder and the brake pad wear wire on
the wheel carrier holder.
4. Take off the brake disc after removing the countersunk screws (arrows). If a stuck brake disc cannot be
removed by gentle tapping with a plastic hammer, evenly screw hexagon−head bolts into the two M8
threads of the brake disc, thereby pressing off the disc.
top of page
Installation
1. Clean the levelling and centering surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centering surface on the wheel hub.
Note
• Do not confuse right and left brake discs during assembly.
• Distinguishing characteristic: involute shape and spare part number (SP No.). The flat surface of the
brake discs is marked with R = right or L = left.
• Spare part on left−hand side − third group number is odd (SP No. Left brake disc: 996.352.405.00).
46 53 19 Removing and installing the rear brake disc 822

einordnung
• Spare part on right−hand side − third group number is even (SP No. Right brake disc:
996.352.406.00).
3. Adjust the parking brake shoes and parking brake cables.

4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Tightening
torque of the fastening screws = 85 Nm (63 ftlb.).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 823
46 83 16 Adjusting the parking brake shoes
Note
Check the free play of the parking brake lever
Note
• Includes: Adjust the parking brake shoes and parking brake cables.
top of page
Check the free play of the parking brake lever
The parkiing brake must be adjusted if the parking brake lever can be pulled up by more than 4 teeth with
medium force application without a braking effect being apparent.
Note
• The parking brake has asbestos−free brake linings.
• The parking brake with asbestos−free brake linings must never be adjusted in such a way that the
lining must "grind down" during operation.
top of page
1. Remove the rear wheels.
2. Undo the parking brake lever and push back the disc brake pads of the rear axle until the brake disc can
rotate freely.
Note
• To make the turnbuckle accessible, open the cover of the tray behind the parking brake lever and
remove the rubber inlay and also the insert.
46 83 16 Adjusting the parking brake shoes 824

einordnung
3. Undo the adjustment nuts −arrow− on the turnbuckle until the cables are without pretension.
4. With a screwdriver −Figure− , turn the adjustment device through a wheel bolt threaded hole so that the
brake disc can no longer be moved.
5. Turn back the adjustment fixture through 5 notches again (release approx. 3 notches until the brake disc
can be moved freely, then release another 2 notches).
6. Repeat the procedure on the other wheel.
7. Pull up the parking brake lever by 2 teeth and adjust the adjustment nut of the turnbuckle until both
wheels can be turned manually with difficulty.
8. Release the parking brake lever and check whether both wheels can be turned
freely.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Adjusting the parking brake 825

46 83 19 Removing and installing the parking brake
shoes
Removal
Installation
top of page
Removal
1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake
pad wear indicator.
4. Take off the brake disc after removing the countersunk screws. If a stuck brake disc cannot be removed by
gentle tapping with a plastic hammer, evenly screw hexagon−head bolts into the two M8 threads of the
brake disc, thereby pressing off the disc.
5. Remove compression springs, adjustment fixture and return springs. Remove parking brake shoes.
top of page
Installation
1. Lightly grease the adjustment device No. −2− , pins No. −8− /No. −9− on the actuating lever (spreading
lever) and the sliding surfaces of the parking brake shoes.
46 83 19 Removing and installing the parking brake shoes 826

einordnung
2. Install the actuating lever (spreading lever) No. −12− , brake shoes, return springs, compression springs
and adjustment device. The spreading lever (No 12.) is a 1−part assembly that cannot be disassembled.
This assembly consists of parts No. −6− , No. −7− and No. −8− .
Note
• The hook (the curved end of the spring) of compression spring No. −10− must point upward on the
upper brake shoe and downward on the lower brake shoe.
3. Again check to ensure that the parking brake shoes, adjustment device, return springs, compression
springs and spreading lever are positioned correctly, and adjust if necessary.
Note
• Ensure that the hooks of the compression springs No. −10− correctly clasp the wheel carrier −A− (if
necessary, check with the aid of a mirror).
4. Clean the levelling and centering surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centering surface on the wheel hub.
Note
• Do not confuse right and left brake discs during assembly.
• Distinguishing characteristic: involute shape and spare part number (SP No.). The flat surface of the
brake discs is marked with R = right or L = left.
• Spare part on left−hand side − third group number is odd (SP No. Left brake disc: 996.352.405.00).
Installation 827
einordnung
• Spare part on right−hand side − third group number is even (SP No. Right brake disc:
996.352.406.00).
6. Adjust the parking brake shoes and parking brake cables. Fit the brake caliper. Tightening torque of the
fastening screws: 85 Nm (63 ftlb.). Ensure that the brake hose and brake line are in perfect position.
Note
• Replace the brake caliper fastening screws after each removal.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 828
47 01 07 Bleeding brakes (vehicle with PSM)
PSM
Procedure for bleeding
1st step: Bleed brakes as usual
2nd step: Bleeding at front on right with running booster pump
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PSM
PSM (Porsche Stability Management) is standard in the 911 Turbo (996).
Note
• Observe brake−fluid quality! Use only new DOT4 brake fluid!
• The brake−fluid change interval using Super DOT4 brake fluid is two years!
• This brake fluid is available under the following part numbers: Quantity supplied 1 litre =
000.043.203.66! Quantity supplied 30 litre = 000.043.203.67!
top of page
Procedure for bleeding
1. Bleed brakes as usual.
2. Then bleed at front on right with running booster
pump.
top of page
1st step: Bleed brakes as usual
CAUTION
For vehicles with extremely high mileage or for very old vehicles, damage to the brake master cylinder can
occur and the primary boots can be damaged!
• Double the number of pumping cycles and use only half of the master brake cylinder stroke!
47 01 07 Bleeding brakes (vehicle with PSM) 829

einordnung
2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding
pressure approximately 2.0 bar.
Note
• Bleed the outer bleeder valve first!
3. Continue bleeding at the brake calipers in the sequence: Sequence: Rear right / rear left / front left / front
right.
4. Open each bleeder valve until clear, bubble−free brake fluid
emerges.
5. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness,
lack of air bubbles and to determine the brake fluid used.
After installing a new brake master cylinder and/or a new hydraulic unit, do the following while bleeding:
• Open the right rear bleeder valves, then fully depress the brake pedal several times.
• Hold for 2 − 3 seconds after each depression, then release slowly.
• Repeat this procedure in the sequence rear left / front right / front left. This will remove all air bubbles
(from the primary circuit).
Note
• Also carry out this procedure if the brake hydraulics was largely empty or if after bleeding residual air
can be detected by excessive brake−pedal travel!
6. Continue bleeding at front on right with running booster pump (Step 2).
top of page
2nd step: Bleeding at front on right with running booster pump
CAUTION
Note
• Bleed brakes as usual!
1st step: Bleed brakes as usual 830

einordnung
• To bleed at front on right with running booster pump the bleeding device remains connected
1. Connect the Porsche System Tester 2 to the diagnostic socket.

2. Switch ignition on. Select the "Bleed" menu in the PSM system. Entry takes place through the ABS
system (automatic status change after PSM).
3. Open the front right bleeder valve (use hose and collecting bottle).
Note
• After a certain period of time has elapsed, the Tester switches off automatically (leaves the menu)! If
necessary, continue the procedure after a certain waiting time (select Bleed menu again)!
4. Press the Start button on the System Tester. In this way the booster pump is activated.
5. Bleed until clear, bubble−free brake fluid emerges.
6. In addition (throughout bleeding operation) fully depress (pump) brake pedal as far as the stop at
least ten times.
7. Close the right front bleeder valve. Then immediately press the Stop button on the System Tester. In this
way pump operation is ended.
8. Switch ignition off and disconnect System Tester.
necessary.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
2nd step: Bleeding at front on right with running booster pump 831
47 08 55 Changing brake fluid
Note
Procedure for changing brake fluid
Note
000.043.203.66! Quantity supplied 30 litre = 000.043.203.67!
top of page
Procedure for changing brake fluid
2. Connect a bleeding device to the brake fluid reservoir.

3. Switch on the bleeding device. Bleeding pressure approximately
2.0 bar.
Note
• Drain brake fluid on every brake caliper on both bleeder valves!
4. Continue brake fluid change at the brake calipers (no special

sequence).
5. Open every bleeder valve until clear, bubble−free brake fluid emerges and until the corresponding change
quantity per brake calliper is reached (approximately 250 cm3 ).
47 08 55 Changing brake fluid 832

einordnung
necessary.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Procedure for changing brake fluid 833

47 15 19 Removing and installing brake master
cylinder
Removal
Installation
top of page
Removal
Note
• The booster pump −1− remains fitted (installed) during removal and installation of the brake master
cylinder.
1. Remove cover −A− from the hydraulic unit/brake

unit.
2. Remove brake fluid from reservoir using
suction.
3. Disconnect the electrical line (plug) on the reservoir.
4. Remove suction line of booster pump −2− .

5.
47 15 19 Removing and installing brake master cylinder 834

einordnung
Undo the brake lines on the brake master cylinder. Close the brake lines and the brake line connections
with suitable plugs.
Note
• −A− = Brake master cylinder fastening nuts
• −B− = Brake booster fastening screws (Torx)
6. Undo the fastening nuts −A− of the brake master cylinder. Pull out brake master
cylinder.
top of page
Installation
2. Bleed the brakes. => Bleeding brakes (vehicle with PSM)
Note
• To bleed at front on right with running booster pump the bleeding device remains connected
3. Carry out a function check of the brakes.
Removal 835
einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 836
47 70 19 Removing and installing brake booster
Removal
Installation
top of page
Removal
Note
• To remove and install brake booster −C− , the brake master cylinder−B− , the hydraulic unit −D− and
the booster pump −A− in vehicles with PSM (GT2 without PSM) must be removed.
• The assembly of the brake master cylinder −B− with the brake booster −C− must not be disconnected
for removal and installation if both parts should continue to be used!
1. Switch off ignition. Remove cover −A and B− .

2. Drain brake fluid explansion tank. To do so, suck brake fluid out of the expansion tank or pump out
the brake fluid using the brake pedal via a front and a rear brake caliper (use collecting bottle).
3. Disconnect the electrical line (plug) on the reservoir.
4. Undo the brake lines on the brake master cylinder. Close the brake lines and the brake line
connections with suitable plugs. Undo the fastening nuts −A− of the brake master cylinder. Pull out
47 70 19 Removing and installing brake booster 837

einordnung
brake master cylinder.
• The brake master cylinder must be disconnected from the brake booster if both parts should continue
to be used!
• −A− = Brake master cylinder fastening nuts
• −B− = Brake booster fastening screws (Torx)
5. In vehicles with PSM, remove the booster pump −1− with the holder−1a− . For the removal of the
booster pump, carry out the following removal steps:
Remove suction line −2− for booster pump. Undo pressure pipe on the booster pump −3− . Close the lines
and the pump connections with suitable plugs.
Release plug −4− −arrows− and disconnect. Remove connector housing rearwards from out of the
holder −moving arrow− .
Undo the three plastic fastening nuts −5− and remove the booster pump −1− with the holder −1a− .
Note
• In the case of assembly work on the hydraulic connections, the electrical plug connections on the
hydraulic unit must always be connected!
• This prevents the plug connections on the hydraulic unit or in the plugs inside from being splashed
with brake fluid or water!
• Any damp plug must be wiped dry before being disconnected from the plug on the hydraulic unit!
• Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in
the system!
6. Remove hydraulic unit. To remove the hydraulic unit, carry out the following removal
procedure:
Undo the brake lines on the hydraulic unit.
Close the brake lines and the brake line connections with suitable plugs.
Pull the plug off the pressure sensor if present (vehicles with PSM 5.7).
Unlock/disconnect the control module connector on the hydraulic unit. Cover the plug connection and the
plug!
Undo and guide out the hydraulic unit.
7. Remove holder of hydraulic unit (if still installed).
Removal 838
einordnung
8. Separate the 2 push rods from each other (loosen). For this purpose, remove the fastening nut (fastening
nut, standard as of April 2001)−arrow− . To make the retainer or the fastening nut accessible, adjust the
bellows positioned above the body.
9. Disengage the vacuum line on the brake booster. Undo the fastening screws −arrows− of the brake
booster (Torx T 45). Pull out brake booster.
top of page
Installation
• When replacing the brake booster, observe the correct allocation according to the Spare Parts
catalogue! Different transmission ratio (boost ratio) of the 911 Turbo (996) compared to the 911 GT2.
• Boost ratio 911 GT2 = 3.15 : 1. Boost ratio 911 Turbo (996) = 3.85 : 1.
1. Install new pushrod (push rod with fastening nut) −12.1− (if not already present) in place of −12− (push
rod with retainer). When doing so, observe installation dimension X (138 mm).
Installation 839
einordnung
Basic setting of the push rod −dimension X− is 138 mm (set in new brake boosters)! If necessary, correct
during the relevant work!
2. Insert brake booster with bellows −B− and tightened clamps

−6− .
Note
• Do not trap wiring harness!
3. Tighten fastening screws (Torx T 45) −arrow− to 23 Nm (17

ftlb.).
4. Connect the 2 push rods. To do so, mount the fastening nuts

−arrow−
Note
Installation 840
einordnung
• Adjusting the brake pushrod length changes the position of the brake pedal.
• Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given!
• After the brake pushrod is adjusted, check the brake light switch adjustment!
5. Check the postition of the brake pedal −Dimension X = 45 + 5 mm− . Perform measurement between the
centre of the brake pedal plate and the accelerator pedal. Perform a fine adjustment of the brake pushrod if
the correct position of the brake pedal is not given.
Fine adjustment of brake pushrods: Undo the lock nut for this purpose and the turn the push rod
accordingly at the hexagon −arrow− until −dimension X = 45 + 5 mm− has been achieved.
Subsequently re−tighten the the lock nut.
6. Fit the bellows onto the body and fasten with the
clamps.
7. Check the setting of the brake light switch −1− .

The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up. At the
same time, check (make sure) that the brake light lights up before the pedal meets perceptible resistance or
before brake pressure builds up. If necessary, set/re−adjust’ 46 Check brake−light setting.
8. Fit the vacuum hose for the brake booster.
9. Install hydraulic unit, boost pump (in vehicles with PSM) and brake master cylinder. Fit all brake
lines.
Note
Installation 841
einordnung
• Ensure that the reservoir is engaged correctly on the brake master cylinder.
10. Bleed the brakes Serv. No. 47 01 07 (vehicles with PSM) or bleed the brakes − GT2 (without PSM) Serv.
No. 41 01 07.
Note
• Only afterwards (after the conventional bleeding) should the booster pump control be performed
(continue bleeding) with the Porsche System Tester 2 in vehicles with PSM! If this is not observed,
damage can occur to the booster pump!
• To bleed at front on right with running booster pump (PSM), the bleeding device should remain
connected (switched on)! Bleeding pressure approximately 2.0 bar!
11. When replacing the hydraulic unit in vehicles with PSM (4−channel system), code the control
module (manual transmission or Tiptronic).
Check the system (brake lines and connections) for leaks.
Read out and erase the fault memory of the ABS or PSM control module with the Porsche System
Tester 2 (PST 2). Additionally, perform the static test in the system.
Check electrical and hydraulic lines (brake lines) for incorrect assignment using the PST 2.
Note
• The exchange test checks that the brake lines/solenoid valves are assigned to the correct brake
calipers (wheels)!
Then start the engine. The ABS and if necessary also the PSM−related lights in the instrument
cluster must go out when the engine is running.
Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS
control operation, taking the road conditions into consideration. Read out the ABS or PSM fault memory
again. There must not be any stored faults.
Installation 842
einordnung
13. Install covers −A / B− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 843
48 10 19 Removing and installing steering wheel
Removal
Installation
top of page
Removal
Note
• Replace fastening screws of the airbag unit whenever they have been loosened! The airbag unit must
always be set down so that the cushioned side faces upwards! If removed for an extended period, the
airbag unit must be kept in a locked place! Observe the safety regulations!
• To prevent unintended rotation of the contact unit (KE) when the steering wheel has been removed,
the contact unit locks itself when the steering wheel is pulled back! Likewise, the contact unit unlocks
automatically when the steering wheel is refitted!
2. Remove driver's airbag unit. For this purpose, loosen the two fastening screws −arrow− with a
screwdriver for TORX screwdriver insert T 30 V.A.G 1952 . Disconnect plug connection at airbag unit
and at steering wheel (for horn).
3. Loosen hexagon nut −arrow− and remove together with spring

washer.
4. Turn wheels to straight−ahead position. Then mark the position of the steering wheel with respect to the
steering shaft (for refitting). Remove steering wheel (in straight−ahead position).
top of page
48 10 19 Removing and installing steering wheel 844

einordnung
Installation
WARNING
Malfunctions of the driver's airbag unit possible! Do not trap the cable of the contact unit. Ensure correct
routing!
1. Refit the steering wheel with the wheels in the straight−ahead position or after disassembly with the
marking so that the upper spokes of the steering wheel are horizontal.
2. Fit hexagon nut −arrow− with spring washer and tighten to 45 Nm (33
ftlb).
3. Install driver's airbag unit. Use new fastening screws. Tightening torque: 10 Nm (7.5
ftlb.).
4. Check horn for operation.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 845
48 90 19 Removing and installing steering gear
Removal
Installation
top of page
Removal
1. Remove underside panel.
Note
• Fix the steering wheel with the wheels in straight−ahead position or remove the steering wheel with
the wheels in straight−ahead position! If this is not done, the airbag contact unit will have to be put in
centre position after installation of the stearing gear!
2. Loosen universal joint (steering shaft) −arrow− at steering

gear.
• Take out the clamping screw and slide the joint upwards.
3. Press out track−rod ball joint from steering arm. Use special tool press−out tool 9560 −C− . When
loosening the fastening nut, counter with Torx screwdriver 9546 −A− .
4. Repeat procedure on the other side.
5. Loosen feed and return lines at the steering gear.
48 90 19 Removing and installing steering gear 846

einordnung
• For this purpose, loosen the hexagon socket head bolt −(arrow)− and remove the retainer plate.
• Plug lines or use collecting container. Cover lines if necessary (danger of soiling).
6. Loosen the two steering−gear fastening screws (on the underside of the cross
member).
Note
• Ensure that no damage (scoring) is caused to the steering rack! To loosen and tighten the track rods,
secure the steering gear on a suitable plate!
7. Pull out steering gear to the left (to the right for right−hand drive vehicles).
8. If necessary, loosen and remove right and left track rods at steering gear.
Track rod on steering gear
top of page
Installation
Install in reverse order. It is essential to observe the following points while doing so:
• Replace steering−gear fastening screws and the fit bolt of the steering shaft whenever they have been
removed. Screw threads must be clean and free of grease.
• Ensure that no damage (scoring) is caused to the steering rack.
• Mount the track rods on the steering gear. Then secure the respective bellows with new clamping
rings.
• Push on universal joint (steering shaft) with the steering gear and steering wheel or airbag contact unit
(spiral spring) in centre position. For ease of assembly, put steering−gear fastening screws just in
place.
• Observe notes for sliding piece and airbag contact unit!
Removal 847
einordnung
• Observe note on steering−gear centre position in the section describing front track adjustment in
Repair Group 44!
Note
• When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant
hoses! Observe the specifications in order to avoid overfilling and thus overflowing!
IMMEDIATELY!
• After fitting the pressure lines, fill steering hydraulics with Pentosin CHF 11 S and bleed steering
system.
• Tighten all screw connections with the prescribed tightening torque values.
• Check and/or adjust track.
Notes for sliding piece and airbag contact unit
1. If sliding piece No. −1− was pulled off steering shaft No. −4− , notch No. −2− must point to the
tooth gap No. −3− on assembly.
WARNING
Malfunctions of the driver's airbag unit possible!
Do not trap the cable of the contact unit! Ensure correct routing!
2. If the steering wheel was not fixed before the steering gear was removed, the position of the contact
unit (spiral spring) may no longer be correct. In this event, remove steering wheel and move contact
unit to centre position!
Centre position:
3. First move contact unit against the end stop.
Installation 848
einordnung
4. Turn contact unit two revolutions back from the end stop and then continue turning as far as the centre
position mark. The exact centre position is indicated by the two No. −1− arrows.
1. Center position mark arrows No. −1−

2. Drivers that engage in the steering wheel
3. Locking (securing against turning), which becomes effective after removal of the steering wheel
5. Turn front wheels to straight−ahead position before fitting the steering wheel (steering shaft mounted on
steering gear).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Notes for sliding piece and airbag contact unit 849

50 55 19 Removing and installing the wing
50 55 19 Removing and installing the wing 850

einordnung
Note
• Before removing the wing, the following parts must be removed:
• ’ 440519 Removing and installing wheel
• => Removing and installing wheel housing liners, front
• => Removing and installing filler flap
• ’ 941419 Removing and installing headlight mount
• ’ 941519 Removing and installing headlights
• For the right wing, ’ 202519 Removing and installing carbon canister
• For the left wing, ’ 926019 Removing and installing tank for windscreen washer system

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1 Plastic 1 Press out pin in the centre
body−bound rivet of the rivet head.
5.0 x 11.5
2 Rubber sleeve 1 Pull off. Press in.
3 Guide ring 1 Press lug −A− and
disengage.
4 Tank lock 1
5 Sleeve 1 Press lugs of the sleeve
−B− and disengage.
6 Collar nut 1 Tightening torque: −10 Nm (7.5 ftlb.)−
M6 x 20
7 Angle piece 1
8 Plastic clip 1 Press apart lugs −C− and
pull off.
9 Collar screw 2 Undo two turns.
M6 x 20
10 Collar nut 2
M6
11 Wing brace 1
12 Torx sheetmetal
screw
T 20
13 Protective film 1 Replace
14 Sheetmetal screw 4
St 6.3 x 12
15 Sheetmetal nut 11
16 Wing 1 Pull out downwards at the Insert the wing under the lid hinge at the
A−pillar and remove to the front, fit the sheetmetal screws. Adjust
front. contours and joining dimensions
(see: Serv. No. 5 Diagram, Body joining
plan)
to the door and covers, tighten sheetmetal
screws −14, 12− .
17 Sheetmetal nut 2
−17−
18 Retaining strip 1 Undo the collar nuts−10− Fix retaining strip on the wing upward to the
out of the restraining strip. stop and fasten with the collar nuts −10− .
Tightening torque:−10 Nm (7.5 ftlb.)−
19 Transparent 1 Pull off. Replace.
protective film
20 Electrical plug 1 Press lug and separate.
connection −20−
21 Emergency cable 1

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22 Sheetmetal screw 2
B 4.2 x 18
23 Servo motor 1
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

50 56 19 Removing and installing wheel housing
liners, front
50 56 19 Removing and installing wheel housing liners, front 854

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1 Front left wheel housing liner, front 1
2 Front left wheel housing liner, rear 1
3 Sheetmetal nut Adjust to centre of hole.
B4.8 12
4 Expanding rivet St 6.3 1 Check, replace if necessary.
5 Combination screw
B4.8 x 16
6 Plastic nut T5 Check, replace if necessary.
22 x 10
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
50 56 19 Removing and installing wheel housing liners, front 855

53 69 19 Removing and installing wheel housing
liners, rear
53 69 19 Removing and installing wheel housing liners, rear 856

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1 Rear left wheel housing liner, front 1 Pull out downwards.
2 Rear left wheel housing liner, rear 1 Pull out downwards.
3 Sheetmetal screw −3− 7 Undo
4 Plastic nut T5. 5 Undo. Inspect and replace if necessary.
5 Sheetmetal nut 2
996420, 996421, 996450, 996451, 996840, 996841
53 69 19 Removing and installing wheel housing liners, rear 857

55 10 37 Disassembling and assembling release for
front lid
Disassembling release for front cover
Assembling release for front cover
Removing and installing support for cap release
top of page
Disassembling release for front cover
55 10 37 Disassembling and assembling release for front lid 858

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1 Releasing hexagon socket head Remove plastic plugs −3− and undo the hexagon socket head
bolts −2− bolts −2− from the sill by approx. 4 − 5 threads.
2 Removing sill −1− Lift sill −1− upwards out of the bottom support with a plastic
spatula and press out. Check fastening clips −4− , replace if
necessary.
3 Pulling off plug connections −5, Pull off plug connections −5, 6− on the actuating switches of the
6− of the actuating switches lids.
4 Removing actuating switches for Press the fastening ribs of the sill −arrows− outward with a
front lid −7, 8− screwdriver and unclip the actuating switch of the front lid −7− .
top of page
Disassembling release for front cover 859

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Assembling release for front cover

1 Installing actuating switch for Clip locking tabs of the actuating switch for the front lid −7−
front lid −7− into the fastening ribs of the sill.
2 Joining plug connections −5, 6− Push plug connections −5, 6− onto the actuating switches of the
of the actuating switches lids.
3 Attaching sill −1− Clip in new fastening clips −4− if necessary. Insert sill −1−
downward into the lower support and engage.
4 Tightening hexagon socket head Screw in hexagon socket head bolts −2− of the sill by approx. 4
bolts −2− − 5 threads. Seal holes of the sill with plastic plugs −3− .
Assembling release for front cover 860

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Shown on the Boxster
Note
• In order to remove the support for the cap release, the front seat must be removed.’ 720119 Removing
and installing front seat

1 Fastening screw 2 Unscrew. Screw in.
2 Support for cap 1 Preassembled dowel pin −3− is pressed in with the
release support −2− into the body.
3 Locating pin 1 Pull out the Press in the pin.
pin.
4 Felt support 1 Pull off. Check, if necessary, replace.
5 Plastic nut 1
top of page

1 Removal tool for Nr. 131 removing retaining Commercially available tools Gr. 2.4;
clips Workshop Equipment Manual
Removing and installing support for cap release 861

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996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing and installing support for cap release 862

55 17 19 Removing and installing front lower part of
lid lock
Removing and installing bowden cable for lock actuation
55 17 19 Removing and installing front lower part of lid lock 863

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1 Electrical plug 1 Turn in −direction of arrow A− and Position electrical plug
connection extend. connection on the lock
lock side panel and turn in
−direction of arrow B−
.
2 Electrical plug 1 At −arrow C− , press and disconnect. Plug in the electrical
connection plug connection.
3 Hexagon−head bolt 2 Undo. Screw in.
Tightening torque: −10
Nm (7.5 ftlb.)−
4 Cover panel 1 Separate from lower part of lid lock. Position on lower part of
lid lock.
5 Lower part of lid lock 1 Undo. Position on closing
panel.
55 17 19 Removing and installing front lower part of lid lock 864

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6 Bowden cable 1 Disengage nipple of the bowden cable Press in bowden cable
−6− and press the cover out of the cover −6− and engage
lower part of the lock. the nipple in the lower
part of the lock.
7 Bowden cable 1 Press bowden cable −7− ouf of the Press bowden cable −7−
emergency release lower part of the lid lock. into the lower part of the
lid lock.
8 Bowden cable 1 Turn bowden cable −8− in the => Installing engine
emergency release −direction of the arrow− and remove cover release
USA and Canada from the servo motor −9− .
vehicles only
9 Servo motor 1 => Removing engine cover release => Installing engine
emergency release cover release
USA and Canada
vehicles only
top of page
Removing and installing bowden cable for lock actuation
Removing and installing bowden cable for lock actuation 865

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1 Hexagon−head 2 Back off by 2 turns. Tightening torque:−10 Nm (7.5
bolt ftlb.)−
2 Cover panel 1 Lift out of the lower part of the lid Position on lower part of lid lock.
lock.
3 Electrical plug 1 Disconnect. Connect.
connection
4 Guide for bowden 1 Pull off. Push on.
cable
5−1 Bowden cable 1 Disengage nipple of bowden cable Pull the rubber sleeve
−5−1− and press the cover out of the −arrow A− in through the opening
lower part of the lid lock. of the closing panel.
Pull the rubber sleeve Press in bowden cable cover −5−1−
−arrow A− out of the closing panel. and engage the nipple into the
lower part of the lid lock.

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6 Servo motor for 1 Extend bowden cable −5−2− out of Insert bowden cable −5−2− into the
lid opener the stamp of the servo motor. stamp of the servo motor.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 22 19 Removing and installing front lid
55 22 19 Removing and installing front lid 868

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1 Combination 4 Tightening torque: −10 Nm (7.5 ftlb.)−
screw
M6 x 14
2 Lid 1 Undo combination screws −1− Position lid −2− on the left and right hinges
from the hinge and remove lid and adjust according to the lid contour to the
−2− . left side section.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
55 22 19 Removing and installing front lid 869

55 22 37 Disassembling and assembling front lid
55 22 37 Disassembling and assembling front lid 870

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1 Lid 1 Adjust lid −1− to the hinges in accordance
with the contours of the wings and the
front spoiler.
2 Rubber buffer 2 Unscrew rubber pads Screw in rubber pads −2− .
−2− .
3 Self−adhesive 1
label
tyre pressure
screw
M6 x 12
5 Upper part of lock Take upper part of lock Fasten upper part of lock −5− to the lid
−5− off lid −1− . −1− with the combination screws −4− and
adjust to the lower part of lock.
6 Tapping nut 2 Replace.

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Unscrew tapping nut

−6− of lid badge.
7 Badge on lid Remove base −8− of lid Insert base −8− and lid badge −7− into the
badge −7− . lid and fasten with tapping nut −6− .
8 Base 1
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 25 19 Removing and installing front lid hinge
55 25 19 Removing and installing front lid hinge 873

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1 Clip 4 Press out with a narrow Press in.
screwdriver.
2 Pneumatic spring 4
3 Combination 4 Undo fastening screws −3− Position hinge −4− on the body and
screw from the hinge −4− . screw in place with the fastening
M6 x 14 screws −3− .
Tightening torque: −10 Nm (7.5
ftlb.)−
4 Hinge 1
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
55 25 19 Removing and installing front lid hinge 874

55 37 19 Removing and installing filler flap
55 37 19 Removing and installing filler flap 875

einordnung

1 Filler flap 1 Insert a narrow screwdriver from above in front of Position filler flap
the clip −arrow− , press the fastening lug backwards on the wing
and hold, and carefully pull off the filler flap cut−out and press
upwards. in until the
fastening lugs
engage.
2 Plastic hinge 1 Insert the disassembly tool at the locking lugs on the Position the
left and right and lift via the locking lugs, push the plastic hinge at
plastic hinge against the disassembly tool and detach the filler flap and
from the filler flap. push on until it
engages
perceptibly.

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996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 57 37 Disassembling and assembling release for
rear lid
Disassembling release for rear lid
Assembling release for rear lid
top of page
Disassembling release for rear lid
55 57 37 Disassembling and assembling release for rear lid 878

einordnung

1 Undoing hexagon socket head Remove plastic plugs −3− and undo the hexagon socket head
bolts −2− bolts −2− from the sill by approx. 4 − 5 threads.
2 Removing sill −1− Lift sill −1− upwards out of the bottom support with a plastic
spatula and press out. Check fastening clips −4− , replace if
necessary.
3 Pulling off plug connections −5, Pull off plug connections −5, 6− on the actuating switches of the
6− of the actuating switches lids.
4 Removing actuating switches for Press the fastening ribs of the sill −arrows− outward with a
rear lid −7, 8− screwdriver and unclip the actuating switch of the rear lid −7− .
top of page
Disassembling release for rear lid 879

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Assembling release for rear lid

1 Installing actuating switch for Clip locking tabs of the actuating switch for the rear lid −7−
rear lid −7− into the fastening ribs of the sill.
2 Joining plug connections −5, 6− Push plug connections −5, 6− onto the actuating switches of the
of the actuating switches lids.
3 Putting on sill cover −1− Clip in new fastening clips −4− if necessary. Insert sill −1−
downward into the lower support and engage.
bolts −2− − 5 threads. Seal holes of the sill with plastic plugs −3− .
Assembling release for rear lid 880

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996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Assembling release for rear lid 881

55 86 19 Removing and installing lower part of lid
lock
55 86 19 Removing and installing lower part of lid lock 882

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1 Undo fastening 2 Tightening
screws −1− torque:
−10 Nm (7.5
ftlb.)−
2 Lower part of lid 1 Undo fastening screws −1− from the servo motor
lock unit −3− .
3 Servo motor unit 1
4 Retaining clip 1 Press out. Press in.
5 Emergency release 1
cable
6 Electrical plug 1 Interior lighting plug connection. Press lug
connection −arrow− and separate.
7 Electrical plug 1 Servo motor unit electrical plug connection. Press Connect
connection lugs −arrow− of the plug −7− and separate. coded plug

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−7− .
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 90 19 Removing and installing rear lid
55 90 19 Removing and installing rear lid 885

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1 Electrical plug 1 Press the lug of the electrical Connect electrical plug connection −1− .
connection plug connection −1− and
separate.
2 Hexagon−head 4 Undo. Tightening torque: −10 Nm (7.5 ftlb.)−
bolt
M6 x 16
3 Rear lid 1 Adjust lid −3− to the hinges in
accordance with the contours of the wings
and the front spoiler.
996420, 996421, 996450, 996451
55 90 19 Removing and installing rear lid 886

55 90 37 Disassembling and assembling rear lid
Disassembling rear lid
Assembling rear lid
Replacing the model logo
top of page
55 90 37 Disassembling and assembling rear lid 887

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DANGER
Danger of injury/damage during assembly work on the hydraulic system!
• The hydraulic system is under approx. 30 bar pressure when extended

• Do not smoke during work, avoid open flames. Danger of fire!
• Do not swallow hydraulic oil, avoid contact with skin/eyes.
• Rinse with water in the case of contact with skin/eyes.
• Open banjo bolts very slowly, otherwise oil which spills out may spray!
Note
• ’ 667237 Disassembling and assembling pump unit
Disassembling rear lid 888

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1 Remove spoiler ’ 665819 Removing and installing rear spoiler
Remove rear lid => Removing and installing rear lid
2 Remove additional brake Disengage cover −A− at the sides, unlock lock −B− . Remove brake
light −3− light and disconnect plug connection −C− .
3 Pull off rubber cover
−4−
4 Remove adjusting Unscrew rubber pad −5− and disengage collar −6− .
element
5 Remove upper part of Unscrew fastening screws −7− and remove upper part of lock −8− .
lock −8−

6 Remove air guide −9− Unscrew fastening screws −8− and remove air guide −9− .

einordnung
7 Remove fan with fan housing Disconnect plug connections for fan and engine compartment
−11− lighting on the fan housing. Unscrew fastening screws −10−
and remove fan with fan housing −11− .
8 Undo mount −13− Unscrew fastening screws −12− .
9 Remove pump unit −17− Pull mount −13− gently forwards and unscrew the fastening
with extension elements screws −16− of the pump unit −17− . Remove mount −13− .
−15l− and −15r− Unscrew the fastening screws −14− of the extension elements
−15l− and −15r− . Remove pump unit with extension elements.
Note:
Do not kink hydraulic lines!
10 Remove additional brake Unscrew fastening screws −18− . Take off additional brake
light holder −19− light holder −19− .
Pull off model logo
top of page
Assembling rear lid
Assembling rear lid 890

einordnung

1 Install additional Insert additional brake light holder −19− . Screw in fastening screws −18−
brake light holder and tighten to −10 Nm (7.5 ftlb.)− . Insert plug connection of the brake light
−19− under the additional brake light holder −19− .
2 Install pump unit Put on pump unit with extension elements.
−17− with Note: Extension element with microswitch must be located on the right−hand
extension elements side. Hose connections must both point in the direction of the centre and the
−15l− and −15r− rear edge of the lid −arrows− . Screw in fastening screws −14− of the
extension elements −15l− and −15r− and tighten −hand−tight− . Fit mount
−13− and fasten pump unit −17− with fastening screws −16− and tighten to
−10 Nm (7.5 ftlb.)− .
3 Fasten mount −13− Tighten fastening screws −12− to −10 Nm (7.5 ftlb.)− .
4 Install fan with fan Position fan with fan housing −11− , fasten with fastening screws −10− and
housing −11− tighten to −10 Nm (7.5 ftlb.)− . Connect plugs for fan and engine
compartment lighting on the fan housing.

einordnung
5 Remove air guide Unscrew fastening screws −8− and remove air guide −9− .
−9−

6 Install upper part of lock −8− Position upper part of lock −8− and fasten with
fastening screws −7− .
7 Install adjusting element Engage collar −6− . Screw in rubber pads −5− .
8 Install rubber cover −4−
9 Install additional brake light −3− Push on plug −C− . Insert brake light. Lock the lock
−B− . Engage cover −A− .
Install rear lid => Removing and installing rear lid
10 Install spoiler ’ 665819 Removing and installing rear spoiler
11 Check installation position of the The spoiler must be installed free of tension. If
extension elements and tighten the necessary, correct the installation position by shifting

einordnung
fastening screws. the extension elements. Tighten fastening screws

−arrows− to −10 Nm (7.5 ftlb.)− .
Stick on model logo => Replacing the model logo
top of page
1. Position logo with the dimensions −X = 332 mm− and −Y = 20 mm− on the rear lid and affix.
996420, 996421, 996450, 996451
Replacing the model logo 893

55 91 19 Removing and installing lid hinge
55 91 19 Removing and installing lid hinge 894

einordnung

1 Pneumatic spring 1 Press in lugs at the sides. Press together until the lugs engage at the
right cable sides.
sleeve
2 Fuse 4 Press out with a narrow Press in.
screwdriver.
3 Pneumatic spring 2
left/right
4 Stop clip 2
left/right
screw
M6 x 16
6 Lid hinge, right 1 Undo combination screws Adjust to the right side section in accordance
−5− . with lid contour.

einordnung
7 Lid hinge, left 1 Undo combination screws Adjust to the left side section in accordance
−5− . with lid contour.
996420, 996421, 996450, 996451, 996840, 996841

57 11 37 Disassembling and assembling door handle
57 11 37 Disassembling and assembling door handle 897

einordnung
CAUTION
There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is
triggered: lower and raise door window!
• When carrying out assembly work in the area of the connection piece, the bottom part of the door
handle and the door lock, the fuse No. 1 in row D must be removed!

1 M 6 collar nut 2 Undo.
2 Connection 1 Shift sliding piece of the
piece connection piece and unclip
actuating shaft −8− .
3 Handle liner 1 Pull out handle liner downward
at an angle.

einordnung
4 Base 1 Unclip. Clip in.

5 Microswitch 1 Unclip. Clip in.
6 Circlip 1 Press out. Press in.
7 Pin 1
8 Actuating shaft 1 Pull pin −7− out of the handle Position actuating shaft on the handle −No.
−13− and remove actuating 13− . Insert pin −7− and secure pin with the
shaft. circlip −6− .
9 S retainer 1
10 Pin rod 1 Replace.
11 Eccentric 1
12 Return spring 1
13 Handle 1 Pull pin rod −10− out of the Position return spring −12− , eccentric
handle liner −3− and separate −11− and handle on the handle liner −3− ,
handle from the handle liner. insert the pin rod −10− and secure retainer
−9− .
14 Buffer 2 Pull off. Replace.
15 Door handle 1
bottom part
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 37 19 Removing and installing inner door release
(bowden cable) for door lock
57 37 19 Removing and installing inner door release (bowden cable) for door lock 900
einordnung
CAUTION

1 Door trim 1 ’ 705919 Removing and installing door
panel trim panel
2 Bowden 1 Door handle side: Door handle side:
cable Press the lugs of the plastic clip −A− Engage bowden cable in the door
and extend to the rear. Push bowden handle −2− .
cable back into the end piece of the Pull the hook out of the end piece of
sleeve −B− . the sleeve only after installation in the
door handle. Plastic clip into the door
einordnung
Lock side: handle −2− .

−Inset X− Unclip bowden cable from
the door lock −C− . Swivel bowden Lock side:
cable by 90° −A− and pull it out of the −Inset Y− Insert the bowden cable in
actuating lever −B− . the actuating lever
−B− and rotate by 90° −A− . Clip
bowden cable into the door lock −C− .
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
57 45 19 Removing and installing door handle
Removing and installing orientation lighting (LED light−emitting
diodes)
57 45 19 Removing and installing door handle 903

einordnung

1 Door trim ’ 705919 Removing and installing
panel door trim panel
2 Return spring 1 Unclip from the door handle −5− and Clip into the door handle −5− and the
−2− the door trim panel −1− . door trim panel −1− .
3 Sleeve 1 Pull off from the return spring −2− . Put onto the return spring −2− .
4 Oval−head 4
screw
4.2 x 13
5 Door handle 1 Undo oval−head screws −4− and pull Insert door handle −5− into the door
−5− the door handle out of the door trim trim panel −1− from the rear and
panel −1− . position it.
Screw tight with the oval−head
screws −4− .
57 45 19 Removing and installing door handle 904

einordnung
top of page
Removing and installing orientation lighting (LED light−emitting
diodes)
Removing orientation lighting (LED light−emitting diodes)

1 Remove light−emitting Pull light−emitting diode housing −2− to the rear out of the locks on
diode housing −2− the cover −3− . Pull cover at front out of the door handle.
2 Remove light−emitting Raise the lug −arrow− of the light−emitting diode housing −1− and
diode housing −1− pull it out in a downward direction.
Removing and installing orientation lighting (LED light−emitting diodes) 905

einordnung
3 Pull LED unit out into the Pull LED unit out of the door handle to the rear.
door handle
Installing orientation lighting (LED light−emitting diodes)

1 Insert LED unit into the Insert LED unit into the door handle from the rear.
door handle
2 Install light−emitting Insert the light−emitting diode housing −1− into the guide of the door
diode housing −1− handle until the lug −arrow− engages.
3 Install light−emitting Position the light−emitting diode housing −2− into the door handle.
diode housing −2− The cable −arrow A− must point downwards. Push cover −3− into the
Removing orientation lighting (LED light−emitting diodes) 906

einordnung
door handle from the front until there is no more play on the lock of the
light−emitting diode housing.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing orientation lighting (LED light−emitting diodes) 907

60 14 15 Re−teaching the lifting/sliding roof drive
It is necessary to re−teach the lifting/sliding roof in the event of emergency operation or replacement of parts
on the lifting/sliding roof (seals, sliding−roof drive) or if the entire system is replaced. The data of limit
positions and characteristics are stored and are retained even if the battery is disconnected.
Teaching lifting/sliding roof drive
1. With the ignition switched on, press the lift button and move the lifting/sliding roof drive to the "raised"
limit position.
2. Press lift button again and keep depressed. After around 10 seconds, a complete cycle takes place from
the raised limit position to the positions "lower open close". Teaching of the characteristics has been
completed after this process.
Note
• The lift button must not be released during the entire process. In the event of a restart, the
lifting/sliding roof must always be moved to the limit position first.
3. If the lifting/sliding roof drive should move back in Item 1, then the closing force limitation function has
responded (lifting/sliding force drive was taught). The open button must be re−taught in this case.
Teaching lifting/sliding roof drive
1 Press the open button until the sliding roof stops. Then release the button. Press the open button
again until the lifting/sliding roof drive stops again. Then release the button.
2 Press the open button again and keep depressed. The entire process takes place after approx. 10 seconds:
"close − lift − lower − open − close".
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
60 14 15 Re−teaching the lifting/sliding roof drive 908

60 14 19 Removing and installing lifting/sliding roof
drive
Removing lifting/sliding roof drive
Installing lifting/sliding roof drive
Emergency operation on lifting/sliding roof drive
top of page
Removing lifting/sliding roof drive
1. Using a small screwdriver, carefully unclip both cover lenses at the openings provided. Undo fastening
screws with a crosshead screwdriver −arrow A− .
2. Unclip cover at the rear left and right −arrow B− , push forward towards the windscreen and
remove.
3. Unscrew both fastening screws −arrows− Torx T25 and take lifting/sliding roof drive down and off the
teeth.
4. Push lifting/sliding roof drive in the roof member trim to the side and take out to the bottom. Disconnect
the electrical plug connection.
top of page
60 14 19 Removing and installing lifting/sliding roof drive 909

einordnung
Installing lifting/sliding roof drive
Note
• Do not press on or touch the transmission/reception diodes with your fingers!
• The cover lenses must not be soiled or smudged with grease.
1. Engage electrical plug connection and carefully lay the wire (do not pinch).
Note
• Always replace the fastening screws of the lifting/sliding roof drive after they have been loosened
(microencapsulated).
2. Position lifting/sliding roof drive in the teeth of the frame for the sliding roof and fasten with the Torx
fastening screws −arrows− . Tightening torque: −6 Nm (4.5 ftlb.)−
3. Engage cover on the windscreen frame at front and push rearward. Unclip locking tabs −arrows B− of the
cover on the left and right. Tighten fastening screws with a crosshead screwdriver −A− .
4. Fit cover lenses.
top of page
Installing lifting/sliding roof drive 910

einordnung
Emergency operation on lifting/sliding roof drive

The lifting/sliding roof drive can also be operated manually if the electric drive should fail. Check fuse D 3
before emergency operation.
An angle screwdriver (a/f 4 hexagon socket) is clipped in behind the cover. The drive axle can be turned
with the angle screwdriver −see figure− . The lifting/sliding roof drive must not be operated again after
emergency operation.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Emergency operation on lifting/sliding roof drive 911

60 28 19 Removing and installing frame for sliding
roof
Removing frame for sliding roof
Installing frame for sliding roof
top of page
Removing frame for sliding roof
60 28 19 Removing and installing frame for sliding roof 912

einordnung
Note
• Due to additional body structure reinforcements in the roof, the connection points for the sliding roof
frame have changed in vehicles produced as from production date 01.01.2001. In these vehicles, the
holders at the side of the sliding roof frame have been omitted. The new sliding roof frame can also be
used in vehicles with a production date before 01.01.2001, if the separately available holders are
prefitted at the side of the frame.
CAUTION
Danger of damage to the seats during the removal of the sliding roof frame!
• During removal of the sliding roof frame, move both seats to the rear and tilt the backrests to the rear.
Removing frame for sliding roof 913

einordnung

Removing sliding roof panel => Removing and installing sliding roof panel
Removing roof lining ’ 708419 Removing and installing roof lining
1 Pull off water drain hoses Disconnect water drain hoses at the front and rear from the
water drain brackets of the frame for the sliding roof.
2 Disconnect the electrical plug Press in the locking tabs −arrows− on both sides and pull off
connection the electrical plug connection.
3 Unscrew the front fastening Unscrew the fastening screws at the front of the sliding roof
screws −A− frame.
4a Unscrew the fastening screws Unscrew the fastening screw from the sliding roof frame at the
−B, C− at the side side and the fastening screws from the retaining bracket on the
(vehicles without roof frame roof frame at the side.
reinforcement in the body
structure)
4b Unscrew the fastening screws Undo the fastening screws from the frame for the sliding roof at
−B− at the side the sides.
(vehicles with roof frame
structure)
Remove the sliding roof frame Remove the sliding roof frame with an assistant and pull it out
from the vehicle of the passenger compartment through the door aperture.
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Installing frame for sliding roof
Installing frame for sliding roof 914

einordnung

Prefit side holder −1− on Position side holder for sliding roof frame and fasten with fastening
the sliding roof frame screws −D− . Only tighten screws slightly, so that the holder can still
(only vehicles without be shifted.
roof frame reinforcement
in the body structure)
Insert frame for sliding Insert sliding roof frame with an assistant into the passenger
roof into the vehicle compartment through the door aperture and position at the
screw−mounting points.
1a Screw in the fastening Position the fastening screw of the sliding roof frame at the side and the
screws −B− at the side fastening screws of the retaining bracket on the roof frame at the side
(vehicles without roof and tighten by hand.
frame reinforcement in
the body structure)
1b
Installing frame for sliding roof 915

einordnung
Screw in the fastening Position the fastening screw of the sliding roof frame at the side and
screws −B− at the side tighten by hand.
(vehicles with roof frame
structure)
2 Screw in the front Position the fastening screws on the sliding roof frame at the front and
fastening screws −A− tighten by hand.
2a Screw in the fastening Position the fastening screws of the retaining brackets −C− . Align the
screws of the holder −C− retaining bracket laterally with the sliding roof frame and the roof
at the side frame −arrows− . Tighten the fastening screws of the retaining
(vehicles without roof brackets −D− with the correct tightening torque according to the
frame reinforcement in following table.
the body structure)
Tighten the fastening Tighten all fastening screws according to the following table.
screws with the correct
tightening torque
3 Connecting electrical plug Plug in the electrical plug connection. The locking tabs −arrow E−
connection must engage on both sides when the connection is made.
4 Push on water drain hoses Push the water drain hoses at the front and rear onto the water drain
brackets of the frame for the sliding roof.
Installing sliding roof => Removing and installing sliding roof panel
panel
Installing roof lining ’ 708419 Removing and installing roof lining
Tightening torques
Location Illustration Thread (ftlb.)
Fastening screw, sliding roof frame to roof frame −A− M6 7.5 (5.5)
reinforcement
Fastening screw, sliding roof holder to roof frame, at −B, C− M6 7,5 (5.5)
side
Fastening screw, sliding roof frame holder to sliding −D− M6 7.5 (5.5)
roof frame
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

60 28 37 Disassembling and assembling frame for
sliding roof
Disassembling frame for sliding roof
Assembling frame for sliding roof
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Disassembling frame for sliding roof
60 28 37 Disassembling and assembling frame for sliding roof 917

einordnung
The following accessories must be removed for the work operation "Disassembling and assembling frame for
sliding roof"! ’ 708419 Removing and installing roof lining ’ 602819 Removing and installing frame for
sliding roof
Note
• The following parts must be transferred from the sliding roof frame to be replaced to the new sliding
roof frame: Lifting/sliding roof drive, draught deflector, frame clips

1 Removing draught Fold the draught deflector up, press it inwards and out of the guides at
deflector the left and right sides and pull it out.
2 Removing frame clips Press in the left and right tabs of the frame clip −A− .
3 Removing lifting/sliding Unscrew both Torx T25 fastening screws and take lifting/sliding roof
roof drive drive down and off the teeth of the sliding roof frame.
Disassembling frame for sliding roof 918

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’ 601419 Removing and installing lifting/sliding roof drive
top of page
Assembling frame for sliding roof

1 Fitting frame clips Press the frame clips −A− in until the left and right tabs engage.
2 Fitting lifting/sliding Position lifting/sliding roof drive into the teeth of the frame. Screw in
roof drive with the Torx T25 fastening screws and tighten.
’ 601419 Removing and installing lifting/sliding roof drive ’ 601415
Re−teaching the lifting/sliding drive
Assembling frame for sliding roof 919

einordnung
3 Fitting draught Press the draught deflector in on the left and right and insert it into the
deflector guides at the sides. Fold up the draught deflector.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Assembling frame for sliding roof 920

60 40 19 Removing and installing sliding roof panel
Additional instructions for removing the inner panels
Additional instructions for fitting the inner panels
60 40 19 Removing and installing sliding roof panel 921

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CAUTION
Damage to rear water drainage channel or to the sliding roof mechanism when the sliding roof panel is
removed and when moving the trim of the sliding/tilting roof (Item 4)
• The sliding roof frame must not be moved to the "Open" position when the sliding roof panel has
been removed. The trim of the sliding/tilting roof (Item 4) must be shifted without the use of force.

1 Open sliding roof panel Open the sliding roof panel approx. 80 mm.
2 Disengage sliding/tilting roof Disengage (press) trim of sliding/tilting roof out of the left and
trim right−hand front catches towards the rear and out of the
drivers, and push back by approx. 30 mm.
3 Move sliding roof panel to Close the sliding roof panel and move to tilting position.
tilting position

einordnung
4 Sliding/tilting roof trim Push trim of sliding/tilting roof back evenly on the left and
right as far as it will go.
5 Close sliding roof panel Move the sliding roof panel to zero position (closed).
6 Remove sliding roof panel Unscrew fastening screws T25 from the sliding roof panel and
remove the panel from the sliding roof frame.
Note
• The sliding roof panel may be installed in the sliding roof frame only in zero position!

1 Insert sliding roof Push gate (inset) back on the left and right. Insert the sliding roof panel in
panel the sliding roof frame and screw in fastening screws T25 slightly.

einordnung
2 Adjust sliding roof Adjust the sliding roof panel in line with the roof contour: lower at the
panel front −dimension A− by up to −1.0 mm and higher at the rear −dimension
B− by up to +1.0 mm. Tighten fastening screws Torx T25.
Tightening torque −6 Nm (4.5 ftlb.)−
3 Move sliding roof Move sliding roof panel to tilting position. Carefully pull trim of the
panel to tilting sliding/tilting roof forwards evenly on the left and right until it is approx.
position, check inner 40 mm in front of the roof edge cut−out. Check whether the left and
panels right−hand inner side panels −Figure C− have engaged.
If inner panels are damaged or have become detached from the groove of
the sliding roof frame, take off the trim of the sliding/tilting roof with the
sliding roof panel removed and replace the inner panels if necessary.
See: Additional instructions for fitting the inner panels
4 Close sliding roof Move the sliding roof panel to zero position (closed).
panel
5 Engage sliding/tilting Push sliding/tilting roof trim forward as far as the roof edge cut−out. While
roof trim doing so, take care not to push trim of sliding/tilting roof upwards. This
could detach or damage the inner panels.
6 Open sliding roof Open sliding roof panel approx. 80 mm. Pull trim of sliding/tilting roof
panel forward until the left and right−hand drivers engage. Close sliding roof
panel.
Function test:
The trim of the sliding/tilting roof lies against the rear of the sliding roof
panel in tilting position. Close sliding roof panel. The trim of the
sliding/tilting roof must lie against the clamping frame of the roof lining on
the front, right and left with a slight degree of pre−tension. The trim of the
sliding/tilting roof must not lie against the rear cross bar of the roof lining.
A gap of approx. −0.5 mm− (cheque card thickness) must be left. There is
no gap at the rear cross member and the roof lining in vehicles with a fully
coated (flocked) clamping frame.
top of page
Additional instructions for removing the inner panels
Note
• When the inner panels are being removed or replaced, the sliding roof panel and sliding/tilting roof
trim should be removed and the gate of the roof frame should be extended (tilting position).
Removing inner panels
Additional instructions for removing the inner panels 924

einordnung
Position the sliding/tilting roof trim −dimension A− approx. 80 mm in front of the roof edge cut−out.
Disengage left and right inner side panels. Pull out the connector springs −B− on the gate and pull
the sliding/tilting roof trim upwards.
Push the sides of the inner panels out of the sliding roof frame inwards (centre of the
vehicle).
top of page
Additional instructions for fitting the inner panels
Installing inner panels
Press the sides of the inner panel into the sliding roof frame. Check function by sliding longitudinally.
Pull out the connector springs −B− on the gate and push in sliding/tilting roof trim. Push inner
panels under the sheetmetal panel of the sliding/tilting roof trim.
Additional instructions for fitting the inner panels 925

einordnung
Position the sliding/tilting roof trim −dimension A− approx. 80 mm in front of the roof edge cut−out.
Engage the left and right−hand inner side panels in the sliding/tilting roof trim. Repeat the
procedure for installing the sliding roof panel.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Additional instructions for fitting the inner panels 926

63 10 19 Removing and installing front bumper
Removing and installing front bumper
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Removing and installing front bumper
63 10 19 Removing and installing front bumper 927

einordnung
Note:
1 Collar nut 9
2 Retaining strip, 1 Undo collar nut −1− and Fix retaining strip on the transverse lock
centre remove centre retaining panel and fasten with the collar nuts −1− .
strip Tightening torque:−10 Nm (7.5 ftlb.)−
3 Left and right 1 Undo the collar nut −1− Position retaining strip on the wing upward
retaining strip and sheetmetal screw −4− so that the clearance rib rests against the side
out of the retaining strip section without gaps, and tighten with the
collar nuts −1− and the sheetmetal screw
−4− .
4 Sheetmetal screw 2 Tightening torque:−3 Nm (2 ftlb.)−
St 4.8 x 19
Removing and installing front bumper 928

einordnung
5 Spacer sleeve 2
5.2 x 14
6 Sheetmetal nut St 4 Inspect and replace if necessary.
4.8
7 Protective foil left, 2 Inspect and replace if necessary.
transparent foil on
right
8 Hexagon−head bolt 2 Tightening torque:−85 Nm (63 ftlb.)−
M12 x 1.5 x 100
9 Bumper mount 1 Undo hexagon−head bolt Attach the bumper mount to the impact
−8− from the bumper pipes −11, 11A− and fix it in position.
mount and remove. Fasten it with the hexagon−head bolt −8− .
10 Combination screw 4 Undo Tightening torque:−23 Nm (17 ftlb.)−
M8 x 30
11 Impact pipe 2 Undo combination screw Fix the impact pipe to the body with the seal
−10− and remove impact and fasten with the combination screw −10−
pipe and seal. .
11A USA version, 2 Undo combination screw Fix the impact absorber to the body with the
impact absorber −10− and remove impact seal and fasten with the combination screw
absorber and seal. −10− .
12 Seal, impact pipe 2 Inspect and replace if necessary.
12A USA version, 2 Inspect and replace if necessary.
impact absorber
seal
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing and installing front bumper 929

63 15 19 Removing and installing front spoiler
Removing front spoiler
Installing front spoiler
top of page
63 15 19 Removing and installing front spoiler 930

einordnung
Note
• Before removing the front spoiler the ’ 505619 Removing and installing wheel housing liner must be
removed!

1 Remove cover. Turn hexagon cap nut −2− by 45° and remove.
Undo sheetmetal screws −4− from the front part −1− .
2 Remove direction Press in spring clip of direction indicator light −arrow A− at the sides with
indicator light. a screwdriver and take out the direction indicator light −5− , disconnect
electrical connection.
3 Undo front spoiler at On the front spoiler, undo the sheetmetal screws −6− and spacer sleeve
the sides. −7− from the retaining strips on the left and right.
Removing front spoiler 931

einordnung
4 Press out temperature Press temperature sensor −9− out of the inlet grille.
sensor.
5 Undo front spoiler on Undo fastening screws −10− of the front spoiler on the underbody.
the underbody. Remove front spoiler −1− to the front.
top of page

1 Fit front spoiler −1− . Lift the front spoiler −1− near the headlights above the radiators on the
right and left.
−Note:− When inserting over the radiators, make sure that the covers
are not pressed out of the front spoiler!
Installing front spoiler 932

einordnung
2 Fit front spoiler on the Position front spoiler on the underbody and screw in place with the
underbody. fastening screws −10− .
3 Fit front spoiler at the Affix front spoiler to the retaining strip and fasten it with the sheetmetal
sides. screw −6− and spacer sleeve −7− .
4 Fit cover. Fasten the front end −1− with the sheetmetal screws −4− .
Affix cover −3− , turn hexagon cap nuts −2− by 45°.
5 Fit direction indicator Connect electrical plug connection of the direction indicator light −5− .
light. Insert lug −arrow− of the direction indicator light into the front end
−1− and clip into the sheetmetal clip.
6 Press in temperature Press temperature sensor into the inlet grille.
sensor
996420, 996421, 996450, 996451, 996430, 996431

63 15 37 Disassembling and assembling front spoiler
Disassembling front spoiler
Assembling front spoiler
63 15 37 Disassembling and assembling front spoiler 934

einordnung
top of page

1 Remove covering cap −2− . Gently press out covering cap −2− with a screwdriver.
Cut through the securing cord of the covering cap −2− and the
front end −1− .
Pull off protective film −3− .
2 Remove covering frame −4− . Press in the lugs of the covering frame −4− and lift it up and
off carefully.
3 Remove frame centre −5− . Carefully disengage the lugs of the frame centre −5− on all
sides using a screwdriver.
4 Grille frame −7− left, right Press retaining clip −6− out at the sides with a screwdriver
and remove. Carefully disengage the lug of the grille frame
Disassembling front spoiler 935

einordnung
−7− on all sides using a screwdriver.

5 Install USA version grille frame Carefully disengage the lugs of the grille frame −7A− on all
−7A− and impact horn −12A− on sides using a screwdriver.
the left and right. Remove hexagon−head bolt −10A− and the hexagon socket
head bolts −8A− from the spacer−9A− , remove impact horn
−12A− .
Note:
the retaining bracket −11A− must be destroyed in order to
remove it. The holding pegs in the front end must be cut off.
Note

einordnung
• The spoiler trim can be removed without removing the front spoiler!

1 Undo fastening screws Undo fastening screws −3− from the front spoiler −1− at the sides.
−3− .
2 Remove sheetmetal Pull sheetmetal frame −2− out of the lower rib of the front spoiler −1− .
frame −2−
3 Remove front spoiler Press in the lugs with a screwdriver, at the same time pull off the front
−1− . spoiler −1− outwards.
.
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Assembling front spoiler
Assembling front spoiler 937

einordnung

1 Install USA version grille Position the retaining bracket −11A− on the front end −1− . Melt the
frame −7A− and impact horn holding pegs in the front end with a soldering iron.
−12A− Fasten the impact horn −12A− to the retaining bracket −11A− with
the hexagon−head bolt −10A− .
Position spacer −9A− on the inside of the front end. With the
hexagon socket head bolts −8A− , screw the impact horn −12A−
through the retaining bracket −11A− .
Lock grille frame −7A− on all sides
2 Install grille frame −7− Lock grille frame −7− on all sides in the front end−1−
Press retaining clip −6− onto the front end −1− and the grille frame.
3 Install frame centre −5− Lock frame centre −5− on all sides in the front end −1− .
4 Install covering frame −4− Lock covering frame −4− into the front end −1− .
5 Install covering cap Pull securing cord into the eyelet of the covering cap −2− and front
end −1− .
Assembling front spoiler 938

einordnung
Position protective film −3− in the extension of the grille rib

running vertically on the inside and affix.

1 Fit front spoiler −1− . Insert the front spoiler −1− into the groove of the front end.
Make sure that all lugs are engaged.
2 Tighten front spoiler Use the fastening screws −3− and spacer sleeve −4− to tighten the front
−1− spoiler at the sides.
3 Fit sheetmetal frame Push the sheetmetal frame −2− into the lower rib of the front spoiler.
−2− .

einordnung
996420, 996421, 996450, 996451

63 50 19 Removing and installing rear bumper
Removing rear bumper
Installing rear bumper
Additional assembly instructions for installation of the bumper
Additional assembly instructions for installation of the bumper − Carrera 4S
Tightening torques
top of page
Removing rear bumper
63 50 19 Removing and installing rear bumper 941

einordnung

Removing rear spoiler => Removing rear spoiler
1 Remove retaining strip The instructions, => Removing and installing frame with heat shield must
at the sides −2− be used for the 996 Carrera 4S.
Remove collar nuts −1− and the retaining strips at the sides −2− . Pull off
anti−chafing film −3− . Pull off sheetmetal nut −4− .
2 Removing centre Screw off collar nuts −6− and remove centre retaining strip −5− . Check
retaining strip −5− sheetmetal nuts −7− , replace if necessary.
3 Remove and Unscrew sheetmetal screws −11− and fastening screws −10− , remove
disassemble rear rear bumper −8, (8A)− with fitted heat shield −9− . Unscrew fastening
bumper −8,− or −(8A)− screws −12− , remove heat shield at the bottom centre −9− and rear
(USA version) support −14− . If necessary, disassemble the rear support by unscrewing
the fastening screws −13− .
4 Removing centre heat Screw off collar nuts −17− and remove centre heat shield on top−18− .
shield on top −18−
Removing rear bumper 942

einordnung
5 Remove impact pipe Unscrew fastening screws −21− , remove impact pipe −19− or impact
−19− or impact absorber −19 A− with seal −20− or −20 A− .
absorber (USA version)
−19 A−
6 Remove heat shield at Unscrew collar nuts −22− and remove the heat shield at the sides −23− .
the sides −23− Note:
In order to remove the heat shield at the sides −23− , the charge air cooler
or the exhaust system must be removed.
’ 214319 Removing and installing the air charge cooler
’ 260119 Removing and installing the exhaust system
The exhaust system must be removed in type 996 Carrera 4S. See: 996
Carrera 4S Technical Manual ’ 260119 Removing and installing the
exhaust system
top of page
Installing rear bumper
Installing rear bumper 943

einordnung
CAUTION
Damage will result if deformed heat shields are fitted!
• Damaged or distorted heat shields must be straightened or replaced.

• Check heat shields for deformation, bonding (detachment of the aluminium layers), tears and missing
or damaged sealing strips.
• After assembling the bumper, check the heat shields for leaks.

1 Install centre heat shield on top −18− Screw on centre heat shield on top −18− with collar nuts
−17− .
2 Install heat shield at the sides −23− Position heat shield at the sides −23− from below and
screw on with collar nuts −22− .
Installing rear bumper 944

einordnung
3 Install impact pipe −19− or impact Position impact pipe −19− or impact absorber −19 A−
absorber (USA version) −19 A− with seal −20− or −20 A− and screw on with fastening
screws −21− . => Tightening torques
4 Install rear bumper −8,− or −(8A)− Position the heat shield−9− together with the rear support
(USA version) −14− and screw on using fastening screws −12− .
Position connecting angle −15− and screw on using
Position the rear bumper −8, (8A)− with the mounted
heat shield −9− and screw on with fastening screws −10−
. => Tightening torquesScrew in sheetmetal screws −11−
.
Check the adjustment dimensions of the => Additional assembly instructions for installation of
rear bumper and the assembly of the the bumper
heat shield and correct if necessary
5 Installing centre retaining strip −5− Position centre retaining strip −5− with sheetmetal nuts
attached −7− and screw on with collar nuts −6− .
Note:
observe adjsuting dimension! => Additional assembly
instructions for installation of the bumper => Additional
assembly instructions for installation of the bumper −
Carrera 4S
6 Put on anti−chafing film −3− Put on sheetmetal nut −4− and align. Stick on
anti−chafing film −3− with clearance −U = 8 mm− .
Note:
make sure that the anti−chafing film seals off the recess
of the sheetmetal nut completely.
7 Install retaining strip at the sides −2− Put on retaining strip at the sides −2− so that the
clearance rib −arrow− of the retaining strip rests against
the side section without gaps and screw on with the collar
nuts −1− .
Use the instructions => Removing and installing frame
with heat shield for type Carrera 4S.
Installing rear spoiler => Install rear spoiler
top of page
Additional assembly instructions for installation of the bumper
Adjustment dimensions of the bumper
Additional assembly instructions for installation of the bumper 945

einordnung
Note
• In order to reduce adjustment work to a minimum when assembling the rear spoiler, the rear bumper
or centre retaining strip must be aligned with the lower edge of the rear lid according to the
dimensions shown above.
• However, the precondition for precise positioning of the components is that the rear lid is optimally
adjusted and correctly locked in the lock in accordance with the joining plan, before the rear bumper
or centre retaining strip are assembled.
Note
• All measurements refer to the position −V = ±260 mm− .
1. Adjust the rear lid according to the joining

plan.
2. Adjust the rear bumper −8, 8A− on both sides to dimension −Y = 140 mm− . The measurements
can be changed by undoing or moving the impact pipes or impact absorbers (USA version).
3. Adjust the centre retaining strip −5− according to dimension −X = 147 mm− .
Correct assembly of the heat shields
Adjustment dimensions of the bumper 946

einordnung
CAUTION
Damage will result if heat shields are fitted incorrectly!
Observe the following points during assembly!
• Make sure the heat shields overlap correctly.

• There should not be any continuous gaps along the entire length of the heat shields.
• A gap of up to 2 mm wide and 30 mm long is permissible locally.
• At least more than 80 % of the total sealing area must be sealed off without gaps.
• The following minimum gap dimensions must be observed.
Note
• Measuring axis for dimension W in the extension of the lower retaining strip.
1. After assembly of the rear spoiler, check that there is a gap dimension −W >. 50 mm− between the shield
of the exhaust system −24− and the lower retaining strip −25− . Check heat shield projection −Z = 0 − 4
mm− .
top of page
Additional assembly instructions for installation of the bumper −
Carrera 4S
Correct assembly of the heat shields
Correct assembly of the heat shields 947

einordnung
CAUTION
Damage will result if heat shields are fitted incorrectly!
Observe the following points during assembly!
• Make sure the heat shields overlap correctly.

• There should not be any continuous gaps along the entire length of the heat shields.
• A gap of up to 2 mm wide and 30 mm long is permissible locally.
• At least more than 80 % of the total sealing area must be sealed off without gaps.
• The following minimum gap dimensions must be observed.
Note
• Measuring axis for dimension W in the extension of the lower retaining strip.
1. After assembly of the rear spoiler, check that there is a gap dimension of −W = min. 70 mm−
between the shield of the exhaust system −24− and the lower retaining strip −25− . The dimension is
measured diagonally upwards.
Removing and installing frame with heat shield
Correct assembly of the heat shields 948

einordnung
Removing the heat shield

Unscrew collar nuts −1− and fastening screw −11− , remove the frame with heat shield
−27− .
Installing the heat shield
Position the frame with the heat shield −27− so that the clearance rib −arrow− rests against the
retaining strip without gaps. Tighten the collar nuts −1− and fastening screw −11− .
top of page
Tightening torques
Location Illustration Thread Tightening torque

Fastening screws of impact pipe on body −21− M8 23 Nm (17 ftlb.)
Fastening screws of rear supports on rear bumper −12− M6 10 Nm (7.5 ftlb.)
Fastening screws of bumper on impact pipes −10− 85 Nm (63 ftlb.)
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Removing and installing frame with heat shield 949

63 55 19 Removing and installing rear spoiler
Removing rear spoiler
Install rear spoiler
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63 55 19 Removing and installing rear spoiler 950

einordnung

Remove tail light ’ 943319 Removing and installing bulb for rear light
1 Remove impact horns (only USA Unclip closure cap −1A− , undo fastening screws −3A−
version) −2A− and remove impact horn −2A− .
Note:
the fastening screws −3A− can remain on the bumper with
the washers −2A− .
2 Remove cover moulding −6− and Unscrew sheetmetal screws −5− and sheetmetal screws
sheetmetal screws −7− −7− . Remove cover moulding −6− .
3 Unscrew sheetmetal screws −8− Unscrew sheetmetal screws −8− .
4 Disconnect plug connection −9−
Remove rear spoiler
Removing rear spoiler 951

einordnung
top of page
Install rear spoiler
CAUTION
Damage will result if deformed heat shields are fitted!
• Damaged or distorted heat shields must be straightened or replaced.

• Check heat shields for deformation, bonding (detachment of the aluminium layers), tears and missing
or damaged sealing strips.
• After assembling the rear spoiler, check the heat shields for leaks.
Install rear spoiler 952

einordnung
Check the heat shields on the vehicle Observe safety instructions!

before fitting the rear spoiler Replace heat shields if necessary.
Check that the heat shields are properly fitted and correct if
necessary. => Removing and installing rear bumper
1 Check anti−chafing film −10− Check anti−chafing film −10− for leaks and damage,
replace anti−chafing film if necessary. => Installing rear
bumper
Check adjustment dimensions of => Additional assembly instructions for installation of the
bumper and rear end support, correct bumper
if necessary
2 Join plug connection −9−
Position rear spoiler on the vehicle Make sure that it is fitted free on tension.
Adjust the joining line of the rear spoiler as shown in the
joining plan.
3 Fit cover moulding −6− Put on cover moulding −6− and fasten rear spoiler with
sheetmetal screws −5− and sheetmetal screws −7− .
4 Screw in sheetmetal screws −8− Fasten rear spoiler with sheetmetal screws −8− .
5 Fit impact horns (only USA version) Put on impact horn −2A− , align at the sides and tighten
−2A− fastening screws −4A− to −23 Nm (17 ftlb.)− . Unclip
closure cap −1A− .
Note:
when putting on the impact horns, make sure the washers
−3A− are placed between the screw head and the bearing
surface of the impact horn.
Install rear light ’ 943319 Removing and installing bulb for rear light
Check the heat shields on the vehicle Observe safety instructions!
after fitting the rear spoiler Check that the heat shields are properly fitted and correct if
necessary. => Removing and installing rear bumper
6 Check gap dimensions −Y− , −Z− of Projection from rear spoiler: −Y = 11.5 − 16.5 mm−
the tailpipes, or adjust tailpipes Distance from rear spoiler: −Z > 20 mm−
Centre distance at the sides evenly to the left and right.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Install rear spoiler 953

63 55 37 Disassembling and assembling rear spoiler
Disassembling rear spoiler
Assembling rear spoiler
Additional instructions for replacing the rear spoiler
top of page
Disassembling rear spoiler
63 55 37 Disassembling and assembling rear spoiler 954

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Note
• When removing the air outlet grille −17− , do not undo the retaining clips by using the screwdriver
between the retaining clip and the rear end ribs!
• Use new retaining clips −18− for installation!

Removing rear spoiler => Removing rear spoiler
1 Remove shield cover Press off clamping washers −4− with a suitable tool, remove shield −3−
−1− and shield cover −1− with rivet bolt −2− .
2 Remove lower Bore out rivets −6− and lower retaining strip −5− .
retaining strip −5−
Disassembling rear spoiler 955

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3 Remove cover −11−

for towing lug
(not USA version!)
4 Remove ParkAssistent Disengage ParkAssistent sensor −7− and remove with isolating ring −8− .
sensor −7− Disengage installation housing −9− .
(only version with The retainer plate −10− remains on the rear spoiler.
ParkAssistent!) ’ 917519 Removing and installing sensor for ParkAssistent
5 Remove licence plate Unscrew fastening screws −12− , remove cover −13− and housing −14− .
light Remove licence plate light with wiring harness −15− . Unclip body−bound
rivets for licence plate holder −16− .
6 Remove air outlet Move retaining clips −18− as far as possible to one side and open up
grille −17− retaining clip with a screwdriver. Remove retaining clips −18− . Remove
the air outlet grille −17− .
Do not undo the retaining clips by using the screwdriver between the
retaining clip and the rear end ribs! Do not damage the fastening ribs of
the rear spoiler!
Use new retaining clips for installation!
top of page
Assembling rear spoiler
Assembling rear spoiler 956

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1 Install air outlet Put on air outlet grille −17− , align and fasten by pressing new retaining clips
grille −17− −18− onto the rear end ribs.
2 Install licence Clean the bearing surfaces of the wiring harness retainer on the inside of the
plate light rear spoiler. Affix new wiring harness retainer −19− . (Press on firmly and
briefly when affixing.) Put on licence plate light with wiring harness −15− ,
housing −14− and cover −13− and fasten licence plate light by screwing in the
fastening screws −12− . Clip in body−bound rivets for licence plate holder
−16− . Make sure the rubber sleeve of the licence plate light is installed
correctly.
3 Clip in cover Pull in new securing cord and secure.
−11− for towing
lug
(not USA
version!)
Assembling rear spoiler 957

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4 Install Engage installation housing −9− . Engage ParkAssistent sensor −7− with
ParkAssistent isolating ring −8− .
sensor −7− ’ 917519 Removing and installing sensor for ParkAssistent
(only version with
ParkAssistent!)
5 Install lower Push up lower retaining strip −5− and fasten with rivets −6− .
retaining strip −5−
6 Install shield Insert shield −3− and shield cover −2− with rivet bolts −1− . Press on new
cover −2− clamping washers −3− .
Note:
make sure that the system is free of gaps.
Install rear spoiler => Install rear spoiler
top of page
Additional instructions for replacing the rear spoiler
Note
• Additional cut−outs must be made for the impact horns (USA version) in the rear spoiler before the
new component is painted.
• For the ParkAssistent equipment version, no additional bore must be made on the new component. A
special spare part is available for this version which contains the bores and retainer plates to hold the
ParkAssistent.
1. Drill hole −C− in accordance with the markings inside the rear spoiler.
2. Saw out cut−outs −B− in accordance with the markings inside the rear spoiler.
3. Slant the upper and lower cut edges of the cut−outs −B− at an angle of −40°− (see cut −A−A− ).
Additional instructions for replacing the rear spoiler 958

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996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Additional instructions for replacing the rear spoiler 959

64 86 01 Checking function of heating for rear
window
Check with the temperature probe
top of page
Note
• The function of the heating for the rear window can be checked with a temperature probe with digital
display (see Workshop Equipment Manual).
• The indicator light in the rocker switch also lights up if a fault is present and the heating wires in the
rear window do not warm up!
The tip of the sensor is used to measure from the outside on the centre of the rear window.
Note
• The heating wire on the rear window must run exactly under the tip of the sensor for this
measurement procedure!
• After switching on at room temperature and a period of 2 minutes, the temperature must increase by
approx. 2 degrees!
• If no temperature increase is shown, the fault must be detected on the basis of the wiring diagram!
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
64 86 01 Checking function of heating for rear window 960

64 86 19 Removing and installing rear window
Removing rear window
Preparing the window section for installation
Installing rear window
top of page
Removing rear window
WARNING
64 86 19 Removing and installing rear window 961

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1. Removing the left and right−hand C−pillar trim

’ 705719 Removing and installing trim of A, B and C−pillars
2. Removing rear wall lining
3. Removing rear window wiper
Fold up the cap, unscrew the fastening nut, lift and detach the spring washer and
wiper arm.
4. Disconnecting the plug connection of the rear window heater
Pull off the plug for the rear window heater on the rear
window.
5. Opening door windows
Lower the door
windows.
Note
• The door windows must not be closed until after the curing time has elapsed.
6. Pulling off cover section

Detach the cover section −1− from the surrounding section of the rear window and pull off.
Note
• If the cover section is removed from the surrounding section undamaged, it can be re−used.
Removing rear window 962

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7. Removing rear window

Remove windscreen with the cutting wire separator. Use pull handle −A8− when
cutting.
The procedure for removing car windows is described in => Removing glass with cutting wire separator.
8. Taking off rear window
9. Pulling off surrounding section
a. Carefully detach the surrounding section from the rear
window.
Note
• If the surrounding section is removed from the rear window undamaged, it can be re−used.
top of page
1. Removing
adhesive from the
body
When removing remaining adhesive −2− with the cutting tool −C− and the flashing knife −D−
on the body, ensure that a surface coating of adhesive remains −3− .
Note
• The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free
of grease and do not clean with cleaning solution.
Preparing the window section for installation 963

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2. Cleaning and priming paint damage or

newly built−up paint areas in the
window aperture of the body
Clean new paint areas or damage to the top coat paint in the non−visible area of the glass section in the
body with cleaning solution −H1− and patch with primer −H2− .
Note
• A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section
and the application of the primer! No cleaning solution residues may remain on the body.
top of page
Installing rear window
CAUTION
adhered to:

Note
• The removed rear window can be reinstalled if there was no prior damage to the rear window and the
rear window was removed without damage.
Installing rear window 964

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1. Fitting surrounding section and cover section

Place surrounding section −4− on the rear window and press cover section −1− into the
groove of the surrounding section −4− .
Note
• If the surrounding section and cover section were removed from the rear window undamaged, they
can be re−used.
2. Preparing 2−component bonding material for processing

=> Processing of Porsche 2−component window
bonding agents
Note

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3. Applying adhesive to the rear window

Apply 2−component bonding material with the adhesive gun −A− to the rear window along the cover
section as a triangular bead measuring −X = approx. 15 mm− .
Note
• When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30
mm at the beginning and at the end.
4. Inserting rear window into the body
Note
• Two persons are needed to insert and adjust the rear window.
Apply suction cups −B− to the rear window and insert the rear window into the window aperture.
5. Aligning rear window

Align the rear window in the Z and Y
directions.
6. Cleaning fields of vision
Adhesive which has oozed out must be removed immediately and the affected fields of vision
must be cleaned using cleaning agent −H1− .
7. Plugging in rear window heater
Plug in the rear window
heater.
8. Installing rear window wiper
Put on the spring washer and wiper arm. Screw wiper arm on with the fastening nut. Close the cap.
9. Installing rear
wall lining
10. Installing left and right−hand C−pillar trim

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11. Closing door windows
Note
top of page
The following tools and materials are required for removal and installation of the rear window with
2−component adhesive:

Chapter 3.5

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Chapter 3.5
A Chapter 3.5
H1−H8


−A− Glass separating tool VAG 1474 See Workshop Equipment Manual, Contains set
B Chapter 3.5 components
A1−A9
−B− Cutting thread See Parts Catalogue in Main Group 8
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

66 13 19 Removing and installing air inlet
Removing air inlet
Installing air inlet
top of page
Removing air inlet
66 13 19 Removing and installing air inlet 969

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1 Remove air inlet Lift up air inlet −1− at the front edge evenly using an assembly wedge,
−1− disengage and pull forwards out of the air duct.
2 Remove retaining Unscrew sheetmetal screws −2− and pull off retaining clips −3− . If necessary,
clips −3− the tabs on the clips must be bent upwards using a screwdriver beforehand.
The retaining clips must be replaced for installation.
3 Pull off seal −4− Pull off seal −4− . Pull off spring clips −5− .
top of page
Installing air inlet
Removing air inlet 970

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1 Push on seal −4− Check seal −4− and spring clips −5− , replace if
necessary.
Attach spring clips −5− to the air inlet. Push seal −4−
onto the air inlet.
2 Install retaining clips −3− Put new retaining clips −3− onto the tabs of the side
section and align evenly in the lug bores.
Screw in sheetmetal screws −2− .
3 Install air inlet −1− Check lugs −arrows− on the air inlet −1− for damage,
replace air inlet if necessary.
Insert air inlet −1− in the air duct and engage evenly
into the retaining clips.
4 Check air inlet system on the side section ’ 5 Diagram − body gap dimensions
and check the gap dimension The air inlet system or the gap dimension can be
corrected by undoing and shifting the spring clips.
Installing air inlet 971

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996420, 996421, 996450, 996451, 996840, 996841
Installing air inlet 972

66 36 19 Removing and installing roof joint strip
Removing roof joint strip
Installing roof joint strip
top of page
Removing roof joint strip
66 36 19 Removing and installing roof joint strip 973

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1 Unclip roof joint strip Lift at both ends using a plastic spatula −1− and unclip all the way along.
2 Pull off roof joint seal Pull the roof joint seal out of the groove of the roof joint strip −2− .
3 Disengage roof joint On the outside of the roof joint clip −3− and roof joint strip, insert a
clips −3− narrow screwdriver in the centre and press the screwdriver outward until
the roof joint clip disengages.
4 Unclip fold−out element Insert a screwdriver beneath both ends of the fold−out element −4− , and
−4− lever out.
5 Detach spreader −5− Insert a plastic spatula into the wedge piece of the spreader −5− and
push. Remove the spreader.
6 Remove inner linings Lift up the clothes hook bracket −6− at the bottom with a plastic spatula
−7, 8− and pull off. Pull away the A and C−pillar trim towards the inside and
remove.
7 Detach the roof liner Unclip the metal strut −9− of the roof liner from the plastic clips.
Removing roof joint strip 974

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8 Detach base plate of Unscrew hexagon socket head bushing a/f 8 (micro−encapsulated) −12−
Roof Transport System . Remove the base plate −11− from the roof channel.
−11− .
top of page
Installing roof joint strip

1 Fit base plate of Roof The contact surface of the base plate must be free from dirt
Transport System −11− and grease. Position the base plate of the Roof Transport
System in the roof channel parallel to the roof channel.
Tighten hexagon socket head bushing a/f 8 −12−
(micro−encapsulated).
Installing roof joint strip 975

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2 Attach roof liner Push the metal strut −9− of the roof liner into the plastic clips.
3 Fit inner lining −7, 8− Position and clip in A and P−pillar trim. Fit the clothes hook
bracket −6− . The clothes hook bracket must be inserted into
the aluminium bracket without the use of force, otherwise the
aluminium bracket is deformed.
4 Fit spreaders −5− Position spreaders −5− (5 per roof channel) in the recesses,
beginning at the front. Press the spreader right down into the
roof channel, and push the wedge piece into the spreader until
the latter is braced in the roof channel.
5 Fit roof joint seal Push the roof joint seal onto the roof joint strip −2− all the
way round.
6 Clip in fold−out elements Position the fold−out element −4− in the cut−out of the roof
−4− joint strip, and press in the lugs at the ends until they lock into
place.
7 Engage roof joint clips −3− Insert the roof joint clips −3− narrow side first and press in
until the lug in the center locks into place.
8 Fit roof joint strip −13− Position the roof joint strip −13− over the roof channel, and
align the roof joint clips in the roof joint strip with the
spreaders so that they lie directly above one another. Push on
the roof joint strip.
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing roof joint strip 976

66 58 19 Removing and installing rear spoiler
Installing rear spoiler
top of page
66 58 19 Removing and installing rear spoiler 977

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Note
• The spoiler can only be removed from the rear lid when the extension elements are extended. After
retracting or extending three times with an obstacle, the control module detects the obstacle and
switches off. The control module is reset by switching the ignition off and on. In order to remove the
spoiler in the case of malfunctions in the drive module, lift the spoiler manually and support with
support pads.
CAUTION
Damage will result if emergency release of the drive module is carried out incorrectly!
• Always make sure to observe the exact sequence for emergency release of the drive module!
• During emergency release, the extension element retracts suddenly!
• Wear gloves during emergency release.
• Before release, cover off the painted areas of the lid near the extension elements with adhesive tape in

einordnung
order to avoid paint damage.
• During emergency release, the spoiler must be held tightly by an assistant.

1 Extend spoiler −1− Extend spoiler manually using the rocker switch with the ignition
(with drive module switched on.
intact)
2 Lift up spoiler −1− (if Pull spoiler upwards and push in two support pads −2− approx. 60 mm
drive module is faulty) high on the right and left between the rear lid and the spoiler. Note:
use suitable packaging material (e.g. styropore pad, cardboard) as a
support pad. The support pads should only be pushed in to the positions
shown in the figure.
3 Position outer tubes of Align the bore on the outer tube of the extension element −arrow− with
the extension elements the bore of the closure peg −4− by turning the outer tube −3− .
The outer tube should be turned in an anti−clockwise direction only.

4 Unlock right extension Insert hook wrench ’ No. 80/1, 2.4 Workshop Manual into the bores and
element turn clockwise by 90°.
5 Unlock left extension Insert hook wrench ’ No. 80/1, 2.4 Workshop Manual into the bores and
element turn clockwise by 90°.
Remove spoiler −1− Lift the spoiler up and off.
top of page
Installing rear spoiler 979

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1 Put on spoiler −1− Put spoiler −1− on both extension elements.
2 Lock spoiler −1− Insert hook wrench ’ No. 80/1, 2.4 Workshop Manual into the bores
and turn anti−clockwise until the closure peg engages in the lock of the
spoiler, then turn anti−clockwise by a further 90° until the lock locks.
Lock spoiler on both sides.
3 Cover bore of Cover off bore of closure peg −4− by gently turning the outer tube −3−
closure peg .
Note:
the outer tube −3− should be turned in an anti−clockwise direction
only! The visible bores should lie in front in the direction of travel.
The outer tube may need to be turned by a further 180°.
Retract spoiler −1− Retract spoiler manually using the rocker switch with the ignition
switched on.

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996420, 996421, 996450, 996451

66 78 01 Checking function of heating for mirror glass
Note
Note
• The function of the heating for the mirror glass can be checked with a temperature probe with digital
display (see Workshop Equipment Manual)!
• The indicator light in the rocker switch also lights up if a fault is present and the heating wires in the
mirror glass do not warm up!
top of page
The tip of the sensor is used to measure from the outside on the centre of the mirror glass.
Note
• After switching on at room temperature and a period of 1 minute, the temperature must increase by
approx. 2 degrees!
• If no temperature increase is shown, the fault must be detected on the basis of the wiring diagram!
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
66 78 01 Checking function of heating for mirror glass 982

66 89 19 Removing and installing rearview mirror
Removing the rearview mirror
Installing the rearview mirror
top of page
Removing the rearview mirror
66 89 19 Removing and installing rearview mirror 983

einordnung

1 Remove cover −1− Disengage cover −1− on the underside −arrow A− and unhook it
upwards out of the door triangle −arrow B− .
2 Disconnect the plug Press the safety catches −arrows− of the plug connection −2− and pull
connection of the the plug out.
adjustment button −2−
3 Disconnect the plug Disconnect the plug connection of the mirror housing −5− .
connection of the mirror
housing −5−
4 Remove mirror housing Pull off seal −4− . Unscrew fastening screws −6− and remove mirror
−8− housing −8− . Press off sealing strip −9− and pull filler piece −7−
upwards and out. Check fastening clips −10− , replace if necessary.
top of page
Removing the rearview mirror 984

einordnung
Installing the rearview mirror

1 Install mirror housing −7− Press the sealing strip −9− off and insert the bracket of the
filler piece −7− downwards. Position the filler piece −7− in the
mirror triangle. Position mirror housing −8− and fasten with
2 Connect the plug connection Stick on seal −4− . Check sealing grommet −11− and replace if
of the mirror housing −4− necessary; connect the plug connection of the mirror housing
−5− . Position the sealing grommet −11− in the mirror triangle.
3 Connect the plug connection Connect plug connection −2− . Check the proper engagement
of the adjustment button −2− of the plug connection.
4 Install cover −1− Hook cover −1− into the door triangle from above −arrow A−
and press into the fastening clips on the underside −arrow B− .
Installing the rearview mirror 985

einordnung
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing the rearview mirror 986

68 17 37 Disassembling and assembling centre
console
Disassembling and assembling cover for the oddments tray
68 17 37 Disassembling and assembling centre console 987

einordnung

1 Cover, front 1 Unclip. Clip in.
left
2 Clip 28 Check, replace if necessary
3 Cover, centre 1 Unclip. Clip in.
left
4 Fastening 3
screws
5 Lock support 1
6 Lock barrel 1 Press in the locking tabs in −inset C− and Press the lock barrel −6− in to the
guide the lock barrel −6− upwards out of lock support −5− until the latter
the lock support −5− . engages in the locking tabs.
7 Plastic nut 7
8 Microswitch 1 From the bracket −9− (see: −inset A− ), Clip into the bracket −9− .
raise the locking tab with a screwdriver
68 17 37 Disassembling and assembling centre console 988

einordnung
and unclip.
9 Bracket 1 Press the locking tabs of the bracket −9− Position bracket −9− on the lock
together with pointed−nose pliers −inset support −5− and clip into place.
B− and guide out of the lock support −5− . Ensure that the locking tabs
engage properly.
10 Cover, rear 1 Unclip. Clip in.
left
11 Cover, rear 1 Unclip. Clip in.
top
12 Fastening 4
screws
13 Extension 1 Unscrew fastening screws −12− from the Position the extension bracket
bracket extension bracket −13− and guide out of −13− on the centre console and
the centre console towards the rear. secure with the fastening
screws−12− .
top of page
Disassembling and assembling cover for the oddments tray

1 Fastening screws 8
2 Cover, oddments 1
tray
4 Retaining bracket 1 Undo the fastening screws −3− . Insert the retaining bracket −4− in to
−Note:− the limiting band −8− .
the retaining bracket is under Position together on the centre
tension due to the spring −7− . console and secure with the
Disassembling and assembling cover for the oddments tray 989

einordnung
Guide the retaining bracket −4− out fastening screws −3− .

of the limiting band −8− .
5 Hinge pin 1 Press the hinge pin −5− out and Position the spring −7− and the
remove the spring −7− or the lower lower section of the oddments tray
section of the oddments tray cover cover −6− together on the centre
−6− . console.
Press the hinge pin −5− into place.
6 Lower section of 1
oddments tray
cover
7 Spring 1
8 Limiting band 1 Unclip the limiting band −8− from Clip the retaining pin together with
the centre console together with the the limiting band −8− into the centre
retaining pin. console.
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Disassembling and assembling cover for the oddments tray 990

68 23 19 Removing and installing sun visors
Removing sun visors
Installing sun visors
top of page
Removing sun visors
68 23 19 Removing and installing sun visors 991

einordnung
1. Detach sun visor

Detach the sun visor from the thrust bearing and pull out of the mounting saddle towards the centre of
the car.
top of page
Installing sun visors
2. Fit sun visor

Insert the sun visor in the mounting saddle and push into the thrust
bearing.
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Removing sun visors 992

68 23 37 Disassembling and assembling sun visor
Disassembling sun visor
Assembling sun visor
top of page
Disassembling sun visor
68 23 37 Disassembling and assembling sun visor 993

einordnung

1 Unclip mirror insert −3− Insert a narrow screwdriver between the mirror insert −3− and the
mirror housing −2− at the bottom centre, and unclip the mirror insert.
2 Remove mirror insert Pull the mirror insert −3− upwards and remove from the mirror housing
−3− −2− .
3 Remove bulb −5− and Remove the Sofitte 12V/3W bulb −5− from the contact clip −4− . Take
contact clips −4− the contact clips upwards out of the holder.
4 Unclip mirror housing Insert a narrow plastic spatula between the mirror housing −2− and the
−2− sun visor −1− on the left and right and unclip the mirror housing.
5 Remove mirror housing Take the electric lead out of the mirror housing −2− and detach the
−2− mirror housing from the sun visor.
top of page
Disassembling sun visor 994

einordnung
Assembling sun visor

1 Insert mirror housing −2− Insert electric lead into the mirror housing −2− . Position the
mirror housing in the sun visor.
2 Press in mirror housing −2− Press the mirror housing −2− at all four corners until it locks
into place.
3 Insert contact clips −4− and Position the contact clips −4− in the mirror housing and fit
bulb −5− under the lug. Insert Sofitte 12V/3W bulb −5− .
4 Position mirror insert −3− Position the lugs on the left and right of the mirror insert −3−
into the mirror housing −2− .
5 Clip in mirror insert −3− Clip the mirror insert −3− into the mirror housing −2− on the
left, right and in the centre.
Assembling sun visor 995

einordnung
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Assembling sun visor 996

68 27 13 Bonding on the interior rearview mirror
Bonding the assembled interior mirror onto the windscreen
The following materials are required to bond on the complete interior mirror:
A Cleaning solution (000.043.157.00)*

B Primer (000.043.158.00)*
C Cover film (000.043.177.01)*
D Activator (000.043.052.00)*
E Adhesive (000.043.051.00)*
* = Porsche part number
top of page
Bonding the assembled interior mirror onto the windscreen
68 27 13 Bonding on the interior rearview mirror 997

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Note
• When using the primer, the drying time of 15 − 20 minutes must be observed!
• When using the activator, the drying time of 2 minutes must be observed!
• During adhesion, observe the press−on duration of 40 − 50 seconds!
• The bonding strength is 60% after one hour. 100% bonding strength is reached after 24 hours of
curing time!

1 Mark the position of the Mark the position of the bonding plate on the outside of the windscreen.
interior mirror Dimension −A− = 633 mm,
Bonding the assembled interior mirror onto the windscreen 998

einordnung
dimension −B− = 100 mm

Remove adhesive Remove adhesive residues from the windscreen mechanically using a
residues scraper. Remove adhesive residues on the bonding plate of the interior
mirror mechanically using a scraper.
2 Sand the bonding plate Sand the bonding plate of the interior mirror flat mechanically using 100
of the interior mirror flat grain sandpaper.
Clean the bonding plate Clean the bonding plate of the interior mirror with cleaning solution (A).
of the interior mirror
Clean the bonding area Clean the bonding area on the windscreen with cleaning solution (A).
on the windscreen
3 Mask the bonding area Mask the bonding area on the windscreen with primer template (cover
on the windscreen film C). The marking for the position of the interior mirror must be
visible in the center of the primer template.
4 Prime the bonding area Treat the masked bonding area on the windscreen thinly and evenly
on the windscreen using primer (B).
5 Activate the bonding Spray activator (D) onto the bonding area of the windscreen.
area on the windscreen
Remove the primer
template
6 Apply adhesive to the Apply a drop of adhesive (E) to the bonding plate of the interior mirror.
bonding plate
7 Stick on the interior Press the interior mirror with the bonding plate onto the primed and
mirror activated area of the windscreen.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Bonding the assembled interior mirror onto the windscreen 999

68 27 19 Removing and installing the interior rearview
mirror
Removing the interior rearview mirror
Installing the interior rearview mirror
top of page
Removing the interior rearview mirror
68 27 19 Removing and installing the interior rearview mirror 1000

einordnung

1 Secure the pliers and Set the pliers with the projecting plastic parts to the windscreen to the
detach the mirror diameter of the mirror base and secure to the mirror base.
Turn the rearview mirror through 90° at the mirror base using the pliers
9578 ’ No. 9578, 2.2 Workshop Manual . Release the pliers from the
mirror base.
2 Remove the mirror Unclip the base of the interior rearview mirror from the retainer plate on
the windscreen.
top of page
Removing the interior rearview mirror 1001

einordnung
Installing the interior rearview mirror
Note
• The small aluminium chip in the locking area must be removed after the interior rearview mirror has
been removed from its base, as it otherwise cannot be ensured that the mirror will be seated securely
when fitted.
• If the mirror is being fitted for the second or third time, inspect locking area of the mirror base for
signs of wear and replace the mirror if necessary.
Installing the interior rearview mirror 1002

einordnung

1 Check Check locking area for signs of wear, remove aluminium chip if necessary.
locking area
2 Insert the Clip the base of the interior rearview mirror, rotated through 90°, into the retainer
mirror plate on the windscreen.
3 Secure the Secure the pliers 9578 ’ No. 9578, 2.2 Workshop Manual with the projecting plastic
mirror parts to the windscreen on the mirror base. Turn the mirror base through 90° while
simultaneously pressing against the retainer plate with the pliers. The mirror must
not be turned past the locking point. Release the pliers from the mirror base.
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing the interior rearview mirror 1003

69 53 19 Removing and installing the triggering unit
for the airbag
Removing triggering unit for airbag
Installing triggering unit for airbag
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Removing triggering unit for airbag
WARNING
• The airbag ignition unit must not be removed with the plug plugged in!
• Waiting time following ignition off (battery disconnection) and detachment of the plug connection
during work on the airbag system at least 1 minute!
The ignition unit is located above the centre console.

3. Unclip front cover of the centre console on the left and right.
Fold up the safety bracket from the driver's side.
4. Disconnect the plug connection from the ignition unit.
5. Undo the shear−off nut with a socket wrench insert

9259 .
6. From the passenger's side, undo the shear−off nuts and M6 hexagon nut and remove the ignition unit.
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69 53 19 Removing and installing the triggering unit for the airbag 1004
einordnung
Installing triggering unit for airbag
Note
• The fastening points on the body must be metallically bright!
• Use a 1/4 inch Allen key to tighten the shear−off nuts!
• A new triggering unit must be locked after it has been installed!
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing triggering unit for airbag 1005

69 54 19 Removing and installing the contact unit
Installing contact unit
top of page
1. Remove the airbag steering wheel.’ 481019 Removing and installing airbag steering
wheel
2. Undo and remove the panel.
3. Undo the −fastening screws− of the contact unit.

4. Pull forward and disconnect the electrical plug connections.
5. Remove the contact unit.
Note
• To prevent unintended rotation of the contact unit (KE) when the steering wheel has been removed,
the contact unit locks itself when the steering wheel is pulled back!
• Likewise, the contact unit unlocks automatically when the steering wheel is refitted!
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1. Front wheels still unchanged in straight−ahead
position.
69 54 19 Removing and installing the contact unit 1006

einordnung
2. Ensure that the exact centre position −(arrows)− of the contact unit is maintained.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing contact unit 1007

69 58 19 Removing and installing the driver's airbag
unit
Removing driver's airbag unit
Installing driver's airbag unit
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Removing driver's airbag unit
3. Undo the −fastening screws− (2 ea.) with a socket wrench insert for inside Torx T 30 (at least 50 mm
long).
Note
• The self−locking screws must be replaced every time they are undone!
• To do this, undo the retaining bracket of the airbag unit (3 screws) in the steering wheel!
4. Disconnect the electrical plug connection.
WARNING
• The airbag unit must always be deposited so that the airbag opening faces upwards!
• If removed for an extended period, the airbag unit must be kept in a locked place!
• Observe the safety regulations!
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Installing driver's airbag unit
Tightening torque for fastening screws (2 screws M6 x 16): 10 Nm (7.5 ftlb.)
2. Tightening torque for retaining bracket (3 screws M5 x 20): 5 Nm (3.5 ftlb.)
69 58 19 Removing and installing the driver's airbag unit 1008

einordnung
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing driver's airbag unit 1009

69 59 19 Removing and installing the passenger's
airbag unit
Removing passenger's airbag unit
Installing passenger s airbag unit
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Removing passenger's airbag unit
WARNING
• If removed for an extended period, the airbag unit must be kept in a locked place!

3. Remove the air guide at the bottom right.
4. Undo the airbag unit from below and remove it rearward to the passenger's seat.
6. Pull out the hinge pin on the airbag unit and remove the panel.
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69 59 19 Removing and installing the passenger's airbag unit 1010

einordnung
Installing passenger s airbag unit

Tightening torque for fastening screws (2 screws M8 x 95): 20 Nm (15 ftlb.)
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing passenger s airbag unit 1011

69 63 19 Removing and installing the side airbag unit
Removing side airbag unit
Installing side airbag unit
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Removing side airbag unit
WARNING
• The airbag unit should be placed in a package or packed in film and, if removed for an extended
period, stored under dry conditions in a locked room!

3. Remove door trim panel. ’ 705937 Disassembling and assembling door trim
panel
Note
• Behind the "Airbag" inscription lies a screw M5 x 10 that is fastened on the fastening clip of the side
airbag unit!
• The fastening screws must always be replaced after removal!
4. Remove cover with "Airbag" inscription and unscrew the

screw.
5. Disconnect electrical plug connection and undo fastening screws.
6. Carefully remove side airbag unit from the door.
69 63 19 Removing and installing the side airbag unit 1012

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7. Deposit airbag unit correctly.
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Installing side airbag unit
Installation of left/right identification of the side airbag unit:
• Inscription R = Right door

• Inscription L = Left door
• Locking pin −A− must always point to the rear
• The wire connection point −B− must always face the front
• Fastening clip M5 −C− always to the rear
Note
• The cover film behind the side airbag unit must not be damaged (protects against water leaking in)!
1. Install airbag unit with the inscription "R" in the right−hand door and fasten.
2. Engage electrical plug connection.
Tightening torque for fastening screws (4 screws M6 x 16): 10 Nm (7.5 ftlb.), (1 screw M5 x 10): 6 Nm (4.5
ftlb.)
3. Reinstall the door trim panel.
Removing sensor for side airbag unit
WARNING
Removing side airbag unit 1013

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• After an accident, the sensor of the triggered side airbag unit must be examined for damage!
• The sensor must be replaced after the side airbag has been triggered for the third time!
Note
• Sensors for triggering the side airbag unit are fastened on the inner lower side member on the left and
right−hand sides in the vehicle!
The cover strip and the support on the lower side member must be
removed.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing sensor for side airbag unit 1014

70 18 19 Removing and installing the instrument
panel and instrument panel bracket
Removing and installing the instrument panel
Removing and installing the instrument panel bracket
Tightening torque
Tools and materials
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70 18 19 Removing and installing the instrument panel and instrument panel bracket 1015
einordnung
Note
• Before removing the instrument panel, it must be disassembled. => Disassembling the instrument
panel

1 Fastening screws 3 Unscrew fastening screws Screw the instrument panel −4− to the
−1− from the instrument instrument panel bracket with the
panel −4− . fastening screws −1− .
2 Fastening screws 13 Undo fastening screws −2− Screw the instrument panel −4− to the
from the instrument panel instrument panel bracket with the
−4− . fastening screws −2− .
3 On−Board Diagnosis 1 Unscrew the fastening screws Tighten the fastening screws −2− .
(OBD) socket −2− .
Removing and installing the instrument panel 1016

einordnung
4 Instrument panel 1 See: Position −1 and 2− See: Position −1 and 2−

5 Sheetmetal nut 2 Unscrew the fastening screws Inspect and replace if necessary.
−2− .
6 Instrument panel 1
bracket with knee
protector strip
7 Sheetmetal nut 11 Unscrew fastening screws −1 Inspect and replace if necessary.
and 2− from the instrument
panel −4− .
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Removing and installing the instrument panel bracket 1017

einordnung
Note
• Before removing the instrument panel bracket, the instrument panel must be disassembled.
=> Removing and installing the instrument panel bracket

8 Fastening screws 4 => Tightening torque
9 Threaded plate 4 It is screwed into position with the
compensating element −10− and the
fastening screw −8− .
10 Compensating 4 The compensating element −10− By screwing in the fastening screws
element is released by undoing the −8− , the compensating element −10−
fastening screw −18− . can be fixed and secured.
12 Instrument panel 1 Undo the fastening screws −8− Insert instrument panel bracket −12−
bracket in the compensating elements into the body. Fix compensating
−10− and guide the instrument elements −10− to the instrument panel
panel bracket −12− out of the bracket and screw down with the
body. fastening screws −8 and 11− .
13A Closure cap 2 Pull out. Press in.
13B Plug 2 Only installed on 911 coupé
versions.
14 Sheetmetal clip 4 Check, if necessary, replace.
16 USA version, 1 Unscrew fastening screw −15− Secure the knee protector strip −16− on
knee protector from the knee protector strip the instrument panel bracket −12− and
strip −16− . Remove the knee tighten the fastening screw −15− .
protector strip.
17 Cowl panel seal 1 Is destroyed when removed. Tighten protective film.
18 Adhesive pad 1 Is destroyed when removed.
• Attach the adhesive pad for
left−hand drives on the right
holder and on the left holder for
right−hand drives.
The bonding area must be free of dust

and grease.
Tighten protective film and position it.
=> Tools and materials
19 Clip 4
21 Shear−off nut 2 Undo the shear−off nut with
special tool 9259.

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23 Airbag control 1 See: ’ 695319 Removing and See: ’ 695319 Removing and installing
module installing the triggering unit for the triggering unit for the airbag.
the airbag.
24 Cover panel 4 Fix the cover panel in the body and the
instrument panel bracket −12− and
screw down with the fastening screws
−20− .
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Tightening torque
Tightening
torque [Nm]
A−pillar fastening screws on the instrument panel bracket −8− M8 23 (17) Nm
(ftlb.)
Cowl panel fastening screws on the instrument panel bracket −11− M6 10 (7.5) Nm
(ftlb.)
Knee protector strip fastening nuts on the instrument panel −14− M6 10 (7.5) Nm
bracket (ftlb.)
Knee protector fastening screws on the instrument panel −15− M8 6 (4.5) Nm
bracket (ftlb.)
Cover panel fastening screws on the instrument panel bracket −20− M6 10 (7.5) Nm
(tunnel) (ftlb.)
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Tools and materials
Cutting with adhesive pad
X 50 mm
Y 40 mm
Z 25 mm
Tightening torque 1019

einordnung
Punch out the crack −Z− at a diameter of 7 mm

1 Socket wrench insert 9259 Gr. 2.2; Workshop
Equipment Manual
2 Adhesive pad, commercially available Teflon adhesive tape ’ Cutting with adhesive pad
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Tools and materials 1020

70 18 37 Disassembling and assembling the
instrument panel
Disassembling the instrument panel
Assembling the instrument panel
Additional assembly notes for the cover and center nozzle for the instrument panel as of model year 2002
Note
• The following components; screen, center nozzle and holder have changed on the instrument panel for
model year 2002 (model care). The instrument panel has a glove compartment and a cupholder. The
procedures described in the following are to be carried out for repair work on the components (model
year 2002).
• ’ 681519 Removing and installing glove compartment
• ’ 683019 Removing and installing cup holder
• => Additional assembly notes for the cover and center nozzle for the instrument panel – as of
model year 2002
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Disassembling the instrument panel
70 18 37 Disassembling and assembling the instrument panel 1021

einordnung

Removing the A−pillar ’ 705719 Removing and installing A−pillar trim
trim
Removing the driver's ’ 695819 Removing and installing the driver's airbag
airbag
Removing passenger's ’ 695919 Removing and installing the passenger's airbag
airbag
1 Removing the alarm Lift the alarm readiness cover −3− and unclip it upwards out of the
readiness cover and clip −4− . The lens cover −2− can be unclipped for replacement
the defroster cover purposes.
Lift the defroster covers left and right −5, 6− with a plastic spatula
and unclip out of the clips −4− .
2 Removing the alarm Undo the fastening screws −7− , lift the alarm readiness unit −8− and
readiness unit disconnect the electrical connection.
Disassembling the instrument panel 1022

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3 Removing the Undo the fastening screws −9− , raise the outside of the loudspeaker
loudspeaker −10− and guide it out. At the plug connection −11− , press the locking
tab −arrow− and disconnect.
4 Removing the To remove the hazard warning light switch: switch on the switch
instrument mount −12− (button comes out). There are small openings on the sides which
now project over the instrument cowl. Insert two narrow screwdrivers
into the openings −arrow A− and pull off the button towards the
front. The hazard warning light switch −13− is held in the instrument
bridge −17− by two locking hooks −arrow B− . Press the right
locking hook towards the switch, grip the button holder with a pair of
pliers and pull out the switch towards the front. Press the collar −14−
out from the rear. Pull off the cover −15− on the left side and undo the
fastening screws −16− . Lift the instrument mount −17− on the left
and right and unclip from the clips −4− .
5 Disconnecting the Disconnect the electrical connection −18− on the rear side of the
electrical plug instrument mount. To do so, press the locking tab of the plug
connection connection and unlock the locking lever in the −direction of the
arrow− .

einordnung

6 Removing the side Pull off the covering caps −20, 20A− . Undo the fastening screws −21− on
nozzles and the the side, remove the side nozzle −22− towards the front.
temperature sensor Unclip the temperature sensor −24− out of the instrument panel towards
the rear.
Disconnect the electrical plug connection −23− .
7 Removing left side Pull forward the control button −25− of the light switch −31− as far as it
nozzles and main light will go −direction of the arrow− towards the front. Press in the locking
switch device at the lower side using a small screwdriver and remove the control
button towards the front.
Undo the fastening screws −21− at the side, remove the side nozzle
towards the front. Disconnect the plug connection −30− of the main light
switch −31− .
In order to disassemble the side nozzle, the covering cap −28− , the
fastening nut −26− and the inner race −27− of the main light switch −31−
can be removed. Remove light switch −31− from the side nozzle by

einordnung
turning it slightly in clockwise direction.

8 Removing the steering Undo the fastening screws −32− on the lower steering column switch
column switch cover cover −36− and remove both steering column covers −33, 36 or 35− .
9 Removing the steering Undo the fastening screw −37− in the cover −38− and the steering column
column switch switch −42− and remove. Disconnect the electrical plug connection.
In order to disassemble the steering column switch −42− , the slip ring
−41− can be disconnected by undoing the fastening screws −39, 40− .
See: ’ 695419 Removing and installing the contact unit.
10 Removing the steering Undo the fastening screw −43− in the steering column cover −44− and
column cover unclip the cover upwards.

11 Removing the switch cover Unclip the switch cover on the left and right −45, 46− towards
the front.
Disconnect the electrical plug connections of the tip switches.

einordnung
12 Removing the electrical See: ’ 870219 Removing and installing

air−conditioning and heating heating/air−conditioning control.
regulator variant −47− and the car See: ’ 912019 Removing and installing the car radio.
radio −48, 49−
13 Removing display and operator Press in and hold both spring clips −arrow A− . Pull out the
control unit display and operator control unit −50− . Disconnect the
(PCM)−50− electrical plug connections −51− on the rear side of the display
and operator control unit.
See: ’ 911019 Removing and installing display and operator
control unit (PCM).
14 Removing the PCM retaining Raise the retaining clip −arrow B− of the retaining bracket
bracket −52− and guide it out of the cut−out of the center nozzle −55−
.
Pull off the ground cable −53− .
15 Removing the center nozzle Undo the fastening screws −54− and guide the center nozzle
−55− out of the instrument panel −1− .
Undo the fastening screws −56− from the inside of the
retaining bracket −57− .
=> Additional assembly notes for the cover and center nozzle
for the instrument panel – as of model year 2002
=> Removing cover and center nozzle for the instrument panel
Removing the regulator for wiping interval
1. Disconnect the
electrical plug
connection.
2. Press the locking tabs of the regulator for the wipe interval −arrows A− outwards and guide the regulator
out of the front cover towards the front.
Removing the cigarette lighter
Removing the regulator for wiping interval 1026

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1. Disengage the cover −arrow A− upwards.

2. Press the lights bracket −arrow B−
out to the side with a narrow
screwdriver.
3. Disengage the cigarette lighter in the direction of −arrow C− out of the front cover.
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Assembling the instrument panel
Removing the cigarette lighter 1027

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Installing the regulator for wipe => Installing the regulator for wiping interval
interval
Installing the cigarette lighter => Installing the cigarette lighter
1 Installing the inside retaining bracket Position the inside retaining bracket −57− in the instrument
and the center nozzle panel −1− and secure with the fastening screws −56− .
Position the center nozzle −55− in the instrument panel and
secure with the fastening screws −54− .
=> Additional assembly notes for the cover and center
nozzle for the instrument panel – as of model year
2002 => Installing cover and center nozzle for the
instrument panel
2 Installing the PCM retaining bracket Insert the retaining bracket −52− in the cut−out of the
center nozzles. Plug the ground cable −53− into the
retaining bracket.
Assembling the instrument panel 1028

einordnung
3 Installing the PCM −50− Connect the electrical plug connection −51− on the rear
side of the PCM.
See: ’ 911019 Removing and installing display and
operator control unit (PCM).
4 Installing the electrical See: ’ 870219 Removing and installing the
air−conditioning and heating regulator heating/air−conditioning regulator.
variant −47− and audio See: ’ 912019 Removing and installing the car radio.
communication system −48−
5 Installing the switch covers Plug in the electrical plug connections. (Observe the color
designation of the wiring harness switches).
Check the clips −4− and replace if necessary. Clip in the
switch covers −45 and 46− into the center nozzle.

6

einordnung
Installing the steering Position the steering column cover −44− on the instrument panel and
column cover secure with the fastening screws −43− .
7 Installing the steering Connect the electrical plug connection of the steering column switch
column switch −42− and position on the steering column.
If necessary, install the contact unit −41− .
See: ’ 695419 Removing and installing the contact unit.
Position the cover −38− on the steering column switch and tighten with
8 Installing the steering Position the top and bottom steering column switch cover or laterally
column switch cover −33, 36, 35− .
Using the fastening screws −32− , screw the steering column switch
cover at the bottom −36− together with the steering column switch cover
at the top −33− .
9 Installing left side Connect the electrical plug connection −30− of the main light switch
nozzles and main light −31− .
switch Position the inner race −27− in the side nozzle −29− and engage the main
light switch in the inner race −27− by turning it slightly
counter−clockwise. Screw it down with the fastening nut −26− .
Tightening torque:−3.5 Nm (2.5 ftlb.)− Insert the side nozzle into the
instrument panel. Secure the side nozzle with the fastening screws −21− .
Place the control button −25− on the main light switch. Press the
covering cap −28− in.
10 Installing the right side Engage the temperature sensor −24− from the rear into the instrument
nozzles and the panel −1− .
temperature sensor Insert the side nozzle −22− into the instrument panel −1− . Secure the
side nozzle with the fastening screws −21− .
Press in the covering caps −20, 20A− .

einordnung

11 Connecting instrument Plug in the electrical plug connection of the instrument mount. After
cluster electrical plug inserting the plug connection −18− into the instrument mount, lock it in
connection the −direction of the arrow− .
12 Installing instrument Install the hazard warning light switch −13− and the collar −14− . Plug
mount in the hazard warning light switch electrical plug connection. Insert
instrument mount in the clip −4− . Secure with the fastening screws
−16− .
Place button −12− in position. If the vehicle is equipped with a
"handsfree telephone", connect the microphone plug connection instead
of the cover −17− and engage the microphone in the cut−out of the
instrument mount.
13 Installing the loudspeaker Connect electrical plug connection −11− . Insert the loudspeaker in the
instrument panel and secure with the fastening screws −9− .
14 Installing the alarm Connect the plug connection. Secure the alarm readiness unit −8− with
readiness unit the fastening screws −7− .

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15 Installing the alarm Clip the defroster covers on the left and right −5, 6− into the clips −4− .
readiness cover and the Clip the alarm readiness cover −3− above the alarm readiness unit −8−
defroster cover into the clips −4− .
Installing the regulator for wiping interval
1. Insert the regulator for the wiping

interval into the front cover from the
front. Ensure that the locking tabs −A−
have engaged.
2. Plug in the electrical plug connection.
Installing the cigarette lighter
1. Press the illumination ring with the

cigarette lighter −C− into the front
cover from the front.
2. Clip the lights bracket −B− into
place. Ensure that the locking tabs
have engaged.
3. Clip in the cover −A− .
Ensure that the locking tabs
have engaged.
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Installing the regulator for wiping interval 1032

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Additional assembly notes for the cover and center nozzle for
the instrument panel as of model year 2002
Removing cover and center nozzle for the instrument panel
1. Removing cover and center nozzle

a. Insert a plastic spatula into the side of the cover −1− and press
out.
b. Insert the second plate of the center nozzle into the metal clip −3− using a small screwdriver −2− .
Press and hold screwdriver upwards in the direction of arrow and simultaneously pull out the center
nozzle −2− with the cover −1− .
2. Removing
frame
Unscrew fastening screws −3− from the frame −4− .
Additional assembly notes for the cover and center nozzle for the instrument panel as of model
1033
year 2002
einordnung
3. Unclipping the cover

from the center nozzle
Push in locking tab on the cover −1− using a screwdriver. Pull out center nozzle −2− .
Removing holder
1. Removing
holder
Unscrew fastening screws −1− from the holder −A or B− .
Installing holder
Removing cover and center nozzle for the instrument panel 1034
einordnung
1. Installing
holder
Position the holder −A− on the instrument panel and secure with the fastening screws −1− .
Installing cover and center nozzle for the instrument panel
CAUTION
Danger of material damage to finished covers!
• The control switches must be correctly mounted before the cover is fitted.
• Particular care is required when clipping in finished covers.
• The finished covers of the Exclusive / or Tequipment range (carbon−fibre composite, light/dark
wood) could be damaged as a result.
1. Clipping in the center nozzle

Connect the cover −1− with the center nozzle −2− . Ensure that the locking tab is engaged on the
left and right side.
Installing holder 1035

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2. Installing
frame
a. Position the frame −5− on the instrument panel and secure with the fastening screws −3− .
3. Installing cover and center nozzle

b. Push the cover −1− with the center nozzle −2− into the instrument panel, ensuring that the clips are
engaged at the top and the locking tabs at the side.
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing cover and center nozzle for the instrument panel 1036
70 22 19 Removing and installing cowl panel cover
Removing and installing cowl panel cover
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Removing and installing cowl panel cover
70 22 19 Removing and installing cowl panel cover 1037

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1 Twist lock 2
2 Battery cover 1
3 Torx screw T25 2
M5 x 30
4 Radiator tank 1
cover, right
5 Radiator tank 1
cover, left
6 Dummy press−in 2
nut
7 Cam 2 Unclip Clip in
8 Cap 2 Position and press in With a small screwdriver
9 T5 plastic nut 2 Check, replace if necessary
Removing and installing cowl panel cover 1038

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10 Torx screw 3
T20 x 20
11 Cover 1
12 Nut 2 Undo Tightening torque: −17 Nm (13
ftlb.)−
13 Left wiper arm 1
14 Right wiper arm 1
15 Cowl panel cover 1
16 Sheetmetal nut 3 Adjust to centre of hole.
B4.8
17 Electrical plug 2 Press locking tabs together and Connect electrical plug
connection separate electrical plug connection. connection.
19 Spray nozzle 2 Use a screwdriver to lift the spray Push on water hose and press
nozzle at the front edge. Pull off water spray nozzle into the cowl panel
hose. cover.
19 T−piece 1 Twist and pull off. Remove filter Clean filter element if necessary.
(filter element) element.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing and installing cowl panel cover 1039

70 59 19 Removing and installing door trim panel
Removing door trim panel
Installing door trim panel
Installation note for door sealing film
Fitting sliding strip on the inner door panel
Materials and tools
Tightening torque
top of page
Removing door trim panel
70 59 19 Removing and installing door trim panel 1040

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WARNING
Airbag could inflate. Danger of injury or damage during fitting!
• 1. Remove ignition key.

• 2. Disconnect and cover the negative terminal of the battery.
• 3. After the battery is disconnected, assembly work or work on the vehicle may be started after a
waiting period of 1 minute.
CAUTION
Damage by bending the bowden cable at the hook.
• The hook of the bowden cable is pressed into the end piece of the cover for protection during
transport and assembly. Pull the hook out of the end piece only after installation in the inner door
release.
Removing door trim panel 1041

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1 Removing −1− cover Use a plastic spatula to release the clipped connection out of the door
handle on all sides.
Unscrew the fastening screws −2, 3, 4− .
2 Removing plastic cover Press the cover out with a narrow screwdriver −5− . Unscrew the
(airbag) fastening screw seated below it. Press light −7− out of the door trim
panel using a plastic spatula −10− .
Disconnect (pull off) electrical plug connection.
3 Disconnect bowden cable Disconnect electrical plug connection from the microswitch for the
and electrical plug door handle −9− and orientation lighting −10− .
connection Press lugs of the plastic clip −arrow A− and pull out towards the rear.
Push bowden cable −8− back into the end piece of the sleeve −arrow
B− .
4 Removing door trim panel Unscrew expanding nut from the door trim panel. Unclip door trim
panel out of the door on all sides and lift up and off.
Clips −13, 14− must be replaced for assembly.
5 Removing airbag Disconnect electrical plug connection −15− .
Unscrew fastening screws −16− out of the side airbag −17− and
remove.
6 Removing frame Unscrew fastening screws −18− from the mount −19− .
7 Removing door sealing Pull off carefully on all sides.
film
8 Removing sound box Disconnect electrical plug connection from the sound box −21− .
Unscrew fastening screws −22− from the sound box −23− .
top of page
Installing door trim panel
Installing door trim panel 1042

einordnung
CAUTION
Water may enter at the door film!
• Door films which have become completely detached or are torn must always be replaced.
• In the case of door films which have become partly detached at the top and side, the detached films
must be reattached using a butyl sealing cord.

1 Installing sound box Position sound box −23− in the door. Screw on the sound box with the
Connect electrical connection −21− .
2 Affixing door sealing Peel off protective film −A− on the door sealing film and position on the
film. door. Using a roller −B− , press on the door film on all sides −20− .
Attach the old door sealing film:
Installing door trim panel 1043

einordnung
=> Notes on the installation of partly detached door sealing films

3 Installing frame Position the frame −19− on the sound box. Make sure that the door sealing
film cut−out is positioned correctly on the sound box.
Screw in fastening screws −18− and tighten.
4 Installing side airbag Position side airbag −17− on the door and tighten fastening screws −16− .
The fastening screws −16− must be replaced each time they are undone.
5 Engaging bowden Engage bowden cable −7− in the door handle. Pull the hook out of the end
cable. piece of the sleeve only after installation in the door handle. Clip plastic
Connecting electrical clip into the door handle.
plug connection. Connect electrical plug connections −8, 9− .
6 Installing door trim The clips −13, 14− must be replaced every time the door trim panel is
panel removed.
Position the door trim panel on the door and clip it in.
7 Installing the airbag Position fastening screws −5− in the door trim panel and tighten.
plastic cover => Tightening torque
Press in plastic cover. Make sure the logo reads correctly.
8 Installing cover Screw in the fastening screws −2, 3, 4− and tighten. Clip in the cover −1−
on the door handle.
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Installation note for door sealing film
Installation note on door sealing film for vehicles without side airbag
The spare door sealing film comes with 4 holes for fastening the side airbag. For vehicles without airbag, the
holes in the door sealing film −2− must be covered with commercially available adhesive tape −1−
Notes on the installation of partly detached door sealing films
Door sealing films which have become completely detached or are torn must always be replaced.
Installation note for door sealing film 1044

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In the case of door sealing films which have become partly detached at the top and side, the detached films
must be reattached using a butyl sealing cord.
Beside the original point of attachment, attach a butyl cord −2− to the area where the door sealing film
−1− is detached, and firmly affix.
=> Materials and tools
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Fitting sliding strip on the inner door panel
A sliding strip must be stuck onto the front and rear sides of the inner door panel in order to prevent creaking
noises from the door area.
1. Sticking sliding strip onto the front of the inner door panel
Remove backing film from the sliding strip and stick the strip onto the front of the inner door
panel −arrow− . Start at the top (top edge of inner door panel) and follow the curvature.
Notes on the installation of partly detached door sealing films 1045

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1. Sticking sliding strip onto the rear of the inner door panel
Remove backing film from the sliding strip and stick the strip onto the rear of the inner door
panel −arrow− . Start at the top (top edge of inner door panel) and follow the curvature.
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Materials and tools

1 Butyl sealing cord to reaffix the Spare parts Gr. 8 −07/10; Parts Catalogue
door film
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Tightening torque
Tightening
Location Illustration Thread torque
Fastening screws on door trim panel on the doors Procedure 7, Item −5− M6 5.9 (4.4) Nm
(ftlb.)
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Fitting sliding strip on the inner door panel 1046

70 65 19 Removing and installing oddments
compartment lid
Removing and installing oddments compartment lid
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Removing and installing oddments compartment lid
70 65 19 Removing and installing oddments compartment lid 1047

einordnung

1 Door trim panel
2 Snap ring 1 Remove the snap ring −2− Put the snap ring onto the shaft with a snap
11 x 1 with a snap ring pliers. ring pliers −3− .
3 Shaft 1 Pull the shaft −3− out of the Position lid −4− in the door panel −1− and
guide mechanism −6− and guide mechanism −6− , and push in shaft
the lid −4− . −3− until it engages at the groove.
4 Lid for oddments 1 To remove lid for oddments
compartment compartment −4− , see: (Item
3)
5 Oval−head screw 2
4.2 x 14
6 Guide mechanism 1 Undo sheetmetal screws −5− Position the guide mechanism −6− on the
B 4.2 x 14 on the rear side of rear side of the door panel and tighten with
the door trim panel. the sheetmetal screws −5−
Removing and installing oddments compartment lid 1048

einordnung
B 4.2 x 14.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing and installing oddments compartment lid 1049

70 84 19 Removing and installing roof lining
Removing roof lining
Installing roof lining
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Removing roof lining
70 84 19 Removing and installing roof lining 1050

einordnung
Note
• Before removing the roof lining, the => Removing and installing trim of A, B and C−pillars and ’
6040 Removing and installing sliding roof panel must be removed!

1 Remove interior Using a small screwdriver, carefully unclip both cover lenses at the
light cover openings provided. Undo fastening screws M5 with a crosshead
screwdriver −arrow A− . Unclip cover at the rear left and right −arrow
B− , push forward towards the windshield and remove. Disconnect the
electrical plug connection of the sliding roof rocker switch and the
interior light
2 Remove sun visors ’ 6823 Removing and installing sun visors
and brackets Insert a small screwdriver into the slot in the cover of the sun visor
Removing roof lining 1051

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console and press out. Undo the cross−recess screw seated below it and
remove.
3 Unclip front plastic Undo the Torx screws −M6 x 25− in the plastic lining at the front and
lining unclip the lining out of the cowl panel frame in a downward direction at
the left and right.
4 Detach roof liner at Unclip the metal strut of the roof liner from the plastic clips at the right
sides and left.
5 Disengage rear Pull the rear plastic lining towards the rear out of the roof frame evenly
plastic lining on the left and right and disengage.
6 Disengage the Pull the metal brace contained in the fabric pocket down in the centre so
metal strut that it bends. Pull the metal strut out of the bracket on the left and right.
7 Disengage frame Pull the frame of the sliding roof cut−out backwards and downwards in
the centre at the front, so that the frame overlap at the corners is reduced
and it is possible to pull it out in a downward direction. Then pull out the
roof frame diagonally via the sliding roof cut−out inwards into the
passenger compartment.
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Installing roof lining
Installing roof lining 1052

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1 Check roof lining Note:
Before installing the roof lining, carry out a visual inspection of the rear
plastic lining to check that the Styrofoam cover and the self−adhesive
fabric parts on the locking peg are completely seated.
2 Fit frame Insert the roof frame diagonally from the inside via the sliding roof
cut−out of the passenger compartment. At the same time, pull the frame
backwards in the centre at the front of the sliding roof cut−out, so that
the frame overlap at the corners is reduced and it is possible to insert the
frame into the sliding roof cut−out.
3 Disengage the Pull the metal brace contained in the fabric pocket down in the centre so
metal strut that it bends. Pull the metal strut out of the bracket on the left and right.
4 Engage rear plastic Engage the rear plastic lining towards the rear into the roof frame evenly
lining on the left and right.
5

einordnung
Engage roof liner at Engage the metal strut of the roof liner into the plastic clips at the left
sides and right.
6 Clip in plastic Position the front plastic lining at the left and right on the cowl panel
lining at front frame and clip in. Tighten the Torx screws M6 x 25.
7 Install brackets and Position the bracket on the cowl panel frame, screw in cross−recess
sun visors screw. Press in the cover of the bracket until it engages. ’ 6823
Removing and installing sun visors
8 Remove interior Connect the electrical plug connection of the sliding roof rocker switch
light cover and the interior light. Position the cover at the front on the windscreen,
push backwards and clip in at the left and right −arrow B− . Position
cross−recess screws M5 −arrow A− and tighten. Carefully clip both
cover lenses into the openings provided.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

80 23 19 Removing and installing heat exchanger
Removing heat exchanger
Installing heat exchanger
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Removing heat exchanger
1. Remove the covers over the heating/air−conditioning system, battery and fluid tank.
3. Remove the entire wiper link with wiper motor. ’ 921519 Removing and installing wiper motor.
4. Loosen right dome strut and bracket at the cowl frame and remove −(arrows)− .
5. Clamp shut both heater hoses in front of the heat exchanger with a commercially available hose clamp.
Loosen heater hoses on the heat exchanger and pull off −(arrows)− .
6. Carefully remove cover over the heat exchanger.
7. Release heat exchanger −(arrows)− and pull it up and out.
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Installing heat exchanger
1. Seal cover over the heat exchanger airtight with butyl
adhesive.
2. Replace cover if damaged.
3. The heat exchanger is connected to the engine cooling system, and coolant flows through it when the
engine is running. After removing or installing the heat exchanger, vent the cooling system. ’ 193817
Draining and filling in coolant
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
80 23 19 Removing and installing heat exchanger 1055

85 30 19 Removing and installing heater/fresh−air
blower motor
Removing heater/fresh−air blower motor
Installing heater/fresh−air blower motor
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Removing heater/fresh−air blower motor
Note
• Remove and install heater/fresh−air blower motor with installed heating/fresh−air unit!
1. Remove footwell bulkhead and right air guide.

2. Pull off electrical plug connection on the blower motor −(arrows)− and remove wire from the holder.
3. Pull off electrical plug connection on the ballast resistor and undo both fastening screws on the housing lid
−(arrows)− . The ballast resistor and housing lid are one spare part.
Note
• When the housing lid is removed, the blower motor is simultaneously detached from its guide!
85 30 19 Removing and installing heater/fresh−air blower motor 1056

einordnung
4. Hold the blower motor and carefully remove it in downward

direction.
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Installing heater/fresh−air blower motor
1. Install blower motor and fasten housing lid.
2. Tighten fastening screws carefully (plastic housing).
3. Engage electrical plug connections and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing heater/fresh−air blower motor 1057

87 01 19 Removing and installing the
heating/air−conditioning unit
Removing heating/air−conditioning unit
Installing heating/air−conditioning unit
top of page
Removing heating/air−conditioning unit
2. Disconnect and remove the battery.
3. Remove the refrigerant by suction using the service unit.
4. Detach the air−conditioning lines at the expansion valve. Immediately close connections and
lines with plugs so that they are air−tight.
WARNING
• Always remove ignition key during body work, and do not commence work until a waiting period of
at least 1 minute has elapsed!
5. Remove steering wheel and loosen steering−column panel.
6. Undo the −central screw (clamp)− on the steering column switch from below and pull it forwards
slightly. Remove the cover at the top and disconnect the electrical plug connections. Remove the
steering column switch.
7. Loosen instrument panel and unclip right side upwards.

8. Disconnect the electrical plug connections.
87 01 19 Removing and installing the heating/air−conditioning unit 1058

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9. Remove steering−column cover (4 screws).
10. Remove the radio and heating/air−conditioning controller. Unclip the switch panel on the left and on the
right. Disconnect the electrical plug connections. Undo the retaining frame in the centre and remove.
11. Remove left side nozzle and disconnect electrical plug connection.
12. Unclip cover of sun sensor and defroster panel and remove.
13. Undo the passenger compartment monitoring and disconnect the electrical plug connection.
WARNING
14. Remove the air guide at the bottom right.

15. Remove the passenger's airbag unit.
16. Remove the front cover of the centre console.
17. Undo the fuse holder and data link connector in the left footwell.
18. Loosen dashboard on the bottom, centre, left and right.

19. Carefully remove the dashboard and detach the loudspeaker cable.
20. Loosen centre tunnel support at the top of supporting frame and loosen bottom tunnel holder.
21. Remove the left air guide. Only loosen the defrost channel. Undo and remove the centre air distributor
casing.
Removing heating/air−conditioning unit 1059

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22. Disconnect the central plug connections (2 ea.) from the heater/air−conditioning unit.
23. Loosen battery positive connection at the current distributor and current distributor −arrows− at the
firewall cover.
24. Clamp shut both heater hoses in front of the heat exchanger with a commercially available hose clamp.
Disconnect the heating hoses on the heat exchanger and plug the connections.
25. Undo heater/air−conditioning unit on the firewall cover (3 nuts). Pull off the water drainage hose from the
heater/air−conditioning unit.
26. Undo holder of the heater/air−conditioning unit from the passenger's side at the top right −arrow− .
27. Carefully lower the heater/air−conditioning unit downwards into the footwell and remove. Do
not damage the electrical plug connections or cables.
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Installing heating/air−conditioning unit
WARNING
1. Ensure that the air distributor casing and air guides are correctly positioned. Engage the electrical plug
connections and carefully lay the electrical cables (do not pinch).
Installing heating/air−conditioning unit 1060

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2. Set the steering column switch: Measure with a depth gauge between end of steering shaft and
steering−column switch cover plate.
Adjustment dimension: 55 ± 0.5 mm
3. Replace gasket between current distributor and firewall if
necessary.
4. After the current distributor is mounted on the firewall, the battery cable is tightened with a new hexagon
nut M8.
Note
• If the heating/air−conditioning unit is replaced, the refrigerant oil in the evaporator must be topped
up!
• Refrigerant oil removed from a previously run air−conditioning system may no longer be used
(special−category waste)!
5. Replace the rings for the refrigerant lines at the expansion valve and wet the new rings with
refrigerant oil.
6. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume removed
by suction + 20 cm3 ).
7. The heat exchanger is connected to the engine cooling system, and coolant flows through it
when the engine is running. After removing or installing the heater/air−conditioning unit,
bleed the cooling system ’ 193817 Draining and filling in coolant.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing heating/air−conditioning unit 1061

87 02 19 Removing and installing the
heating/air−conditioning control
Removing heating/air−conditioning control
Performing system test
Tests
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Removing heating/air−conditioning control
Note
• Basic adaptation to the system must be performed with a new heating/air−conditioning control!
• This is indicated by flashing of the displays for approx. 5 to 10 seconds each time the ignition is
switched on!
• Basic adaptation is performed during the system test!
1. Unclip
cover.
2. Unscrew −fastening screws− (2 ea.) and pull the heating/air−conditioning control out of the dashboard.
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Performing system test
1. Connect and switch on the Porsche System Tester 2.
2. Select air conditioning and menu item "System test"
The following conditions must be observed for the system test:
• Vehicle speed < 10 km/h

• Engine start detected and 10 seconds elapsed since engine start
• Terminal 15 supply voltage OK
• 5−volt supply voltage OK
• Engine temperature < 110 °C
• Outside temperature > 3 °C
87 02 19 Removing and installing the heating/air−conditioning control 1062

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Tests
• Display of all segments in the control module.
• The drive motors are traversed across the entire range once.
• The measured positioning travel is subjected to a plausibility test and stored as a fault if necessary.
• Two different voltage values are set on the fresh−air blower and tested.
• The A/C circuit is tested via the DME.
• All fault paths are tested, and any faults are stored.
• Basic adaptation is carried out after the system test has been completed.
• The display must no longer flash.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Performing system test 1063

87 03 17 Assembly work on the air−conditioning
system
Service unit SECU 134
Assembly work involving the refrigerant system
General assembly sequence
Removing refrigerant by suction and cleaning
Cleaning the refrigerant
Draining off old refrigerant oil
Evacuating
Topping up with new refrigerant oil
Filling via the high−pressure side
Refilling the air−conditioning system
Distribution of the oil quantity in the refrigerant circuit
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Service unit SECU 134
Note
• The manufacturer's operating and repair instructions must be observed when carrying out all work on
the service unit!
87 03 17 Assembly work on the air−conditioning system 1064

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1 Low−pressure pressure gauge

2 High−pressure pressure gauge
3 Torr meter
4 Low−pressure shut−off valve (blue)
5 High−pressure shut−off valve (red)
6 Torr meter shut−off valve (black)
7 Vacuum pump shut−off valve (yellow)
8 Low−pressure flange
9 High−pressure flange
10 Refrigerant inlet shut−off valve
11 Refrigerant outlet shut−off valve
12 Refrigerant oil inlet shut−off valve
13 Refrigerant oil vent valve
14 Moisture indicator
Service unit SECU 134 1065

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15 Oil tank vacuum flange

16 Hourmeter
17 SUCTION/END indicator light
18 SUCTION/CLEAN pressure switch
19 ON/OFF main switch
20 HEATING pressure switch
21 MALFUNCTION indicator light
22 VACUUM PUMP pressure switch
23 Filling cylinder with weight scale
24 Filling cylinder shut−off valve
25 Filling cylinder high−pressure gauge
26 Refrigerant oil suction nozzle
27 Refrigerant oil reservoir inspection glass
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Assembly work involving the refrigerant system
Note
• The safety regulations must be observed during all work on the refrigerant system! => Safety
regulations when handling refrigerant R134a
• During all work on the air−conditioning system which necessitates opening the refrigerant system, the
system contents must first be disposed of correctly!
• Dirt and moisture must be kept out of the air−conditioning system's pipe system!
• Thorough cleanliness must be ensured during all work!
• System components must never be cleaned on the inside with hot steam!
• Use only nitrogen for cleaning purposes!
• When replacing a component, all openings must be closed off with suitable plugs!
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General assembly sequence
Note
• Pay attention to sealing rings when disconnecting or connecting the hose connections!
• The charging valves are located in the area of the front right spring strut.
Assembly work involving the refrigerant system 1066

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−A− = high pressure −B− = low pressure
1. Remove refrigerant by suction.

2. Remove faulty part.
3. Evacuate.
4. Check the system for
leaks.
5. Rinse with refrigerant.
6. Empty the system by suction again.
7. Evacuate.
8. Fill.
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Removing refrigerant by suction and cleaning
Note
• Close all valves before carrying out each work step!
General assembly sequence 1067

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A Close B Open
Suction removal, start End
1 ON/OFF 3 SUCTION/END
2 SUCTION/CLEAN 4 ON/OFF
* Pressure too high/filling cylinder full.

Drain off refrigerant from the filling cylinder into a refrigerant bottle (approx.
50%).
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Cleaning the refrigerant
A Close B Open
Cleaning, start End
1 ON/OFF 3 CLEAN/END
2 SUCTION/CLEAN 4 ON/OFF
−*− Pressure too high/filling cylinder full.

−**− One revolution OPEN. After approx. 15 minutes CLOSED.
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Draining off old refrigerant oil
Removing refrigerant by suction and cleaning 1068

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A Close B Open
1 ON/OFF
Instructions:
−*1− open to −*2− OFF, then −*1− CLOSED and −*3− OPEN.
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Evacuating
A Close B Open
1 ON/OFF
Draining off old refrigerant oil 1069

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2 VACUUM PUMP
Evacuation time at least 15 minutes.
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Topping up with new refrigerant oil
A Close B Open
1 ON/OFF
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Filling via the high−pressure side
Evacuating 1070
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A Close B Open
1 ON/OFF
2 HEATING
−*− Pressure 8 ... 10 bar.

−**− If pressure is less than 8 bar.
Note
• Before carrying out internal suction removal of the SECU, the hand valves on both suction lines must
be closed!
After using the SECU, perform internal suction removal.
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Refilling the air−conditioning system
Note
• In the event of insufficient refrigeration performance, remove the refrigerant by suction, top up with
the stipulated quantity and check the system for leaks!
1. Remove the refrigerant by suction using the service unit

2. Determine the refrigerant oil quantity after the refrigerant has been removed by
suction.
3. Fill up with new refrigerant oil.
4. Evacuate.
5. Fill with the stipulated amount of refrigerant.
6. Check the system for
leaks.
Filling via the high−pressure side 1071

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Distribution of the oil quantity in the refrigerant circuit
Note
• Oil removed by suction must be returned to the system!
• After the refrigerant has been removed by suction and a component has been replaced, the oil quantity
must be determined and topped up by the quantity remaining in the removed component!
Oil quantity
Total oil quantity 195 ± 15 cm3
After suction removal from the system, the following quantities remain in the:
Condenser (2 x 20 cm3 ) approx. 40 cm3
Evaporator approx. 30 cm3
Fluid tank with lines approx. 30 cm3
Compressor approx. 50 cm3
Circulating oil quantity in the refrigerant circuit approx. 60 cm3
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Refilling the air−conditioning system 1072

87 20 19 Removing and installing drive motors
Note
Removing drive motors
Installing drive motors
Note
• Removal or installation is performed with the heating/air−conditioning unit installed!
top of page
Removing drive motors
Removing drive motor for temperature valve and central valve
Drive motor for temperature valve
Drive motor for central valve
1. Remove footwell bulkhead and air guides. Unclip centre console cover at the front and remove the
footwell vent −(3 screws)− .
2. Press pivot pin on the adjusting lever together and disengage the deflection
lever.
3. Unscrew drive motor of the heating/air−conditioning unit and disconnect the electrical plug connection.
87 20 19 Removing and installing drive motors 1073

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Removing drive motor for footwell/defrost
1. Unscrew drive motor with bracket from the heating/air−conditioning unit −(2 screws)− .
2. Swivel drive motor to the side and disengage the deflection
lever.
3. Disconnect electrical plug connection and detach bracket from the drive motor.
Removing drive motor for fresh−air/recirculation valve
1. In order to block the fresh−air supply, the Recirculation button must be pressed before removal.
The drive motor can be removed from the installed heating/air−conditioning unit in this position
(recirculation).
3. Disconnect electrical plug connection of the drive motor and undo fastening screw.
4. Disengage pivot pin on the adjusting lever with a screwdriver.

5. Swivel down the drive motor and remove it to the side.
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Installing drive motors
Installing drive motor for temperature valve, central valve and

footwell/defrost
1. Ensure that the deflection levers are seated correctly.

2. Tighten fastening screws carefully (plastic housing).
3. Engage electrical plug connections and route wire carefully.
Removing drive motor for footwell/defrost 1074

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4. Perform function test after installation of the drive motors.
Installing drive motor for fresh−air/recirculation valve
Note
• The removal or installation position of the drive motor and fresh−air/recirculation valve cannot be
changed!
• Ensure that the deflection lever of the outside−air valve is seated correctly!
1. Tighten fastening screw carefully (plastic housing).

2. Engage electrical plug connection and route wire carefully.
3. Perform a function test after installation.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing drive motor for temperature valve, central valve andfootwell/defrost 1075
87 27 19 Removing and installing the magnetic
coupling
Removing the magnetic coupling
Installing the magnetic coupling
top of page
Removing the magnetic coupling
1. Use a standard strap wrench to securely hold the pressure plate, and undo the fastening
screw.
2. Screw a screw M8 into the thread of the pressure plate until the pressure plate can be removed
manually.
3. Remove the spacer washers.
4. Use standard Seeger circlip ring pliers to remove the Seeger circlip ring. Manually remove the belt pulley.
5. Unscrew the cable of the magnetic coil from the compressor housing.
6. Remove the Seeger circlip ring.
7. Remove the magnetic coil from the compressor
housing.
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Installing the magnetic coupling
1. Place the magnetic coil on the compressor housing (the locking pin must engage in the locking hole).
87 27 19 Removing and installing the magnetic coupling 1076

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2. Install the Seeger circlip ring. The −slanted surface− of the Seeger circlip ring faces upwards (to the
fastening screw).
3. Tighten the pressure plate fastening screw.
Checking the air gap of the magnet coupling
1. Check the air gap between the pressure plate and belt pulley with a depth
gauge.
2. Place a rule on the outer edge of the belt pulley and use a depth gauge to measure up to the pressure plate.
Note
• Always measure at at least three points on the pressure plate in order to obtain a mean value!
• Distance: 0.5 mm ± 0.15 mm
3. Apply battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure
plate.
4. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing the magnetic coupling 1077

87 34 19 Removing and installing the compressor
Removing the compressor
Installing the compressor
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Removing the compressor
1. Remove the cover above the heating/air−conditioning system.
3. Disconnect the battery and cover terminal or battery. Remove the complete air cleaner assembly. Undo the
fastening screw for the air cleaner housing and the hose clamp on the air flow sensor.
4. Undo the hose on the charge air cooler at the left and right on the pressure pipe.
5. Disconnect the electrical plug connection on the air flow sensor and remove the complete air cleaner
assembly.
6. Remove the pressure pipe to the throttle body and disengage frequency valve on the
holder.
7. Just loosen belt pulley for hydraulic pump. Relieve the drive belt at the tensioning pulley and remove the
belt.
8. Remove belt pulley for hydraulic
pump.
9. Undo fastening screws on the expansion tank (2 M8 screws) and the hydraulic pump (3 M8 screws and
one M6). Leave aside expansion tank with hydraulic pump and connected lines.
10. Undo the fuel supply lines on the fuel cooler. Make sure to counter when doing this.
11. Remove throttle body.

12. Disconnect electrical plug connection for compressor.
13. Undo the compressor from the console (3 screws).

14. Lift the compressor with fastening screws out of the bracket and carefully remove to the rear.
87 34 19 Removing and installing the compressor 1078

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Note
• The hydraulic pump with expansion tank must be lifted slightly upwards when doing this!
15. Undo the refrigerant lines at the compressor. Immediately close connections and lines with plugs so that
they are air−tight.
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Installing the compressor
Note
• New compressors are pressurised and are filled with the required amount of oil for the refrigerant
circuit!
• The remaining oil quantity in the individual components must therefore be taken into account!
• Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run
air−conditioning system may no longer be used (special−category waste)!
1. First, open the cap on the high−pressure side and relieve the pressure from the compressor −A− .
2. Open the oil filler screw −B− on the compressor.

3. Empty approx. 80 cm3 of refrigerant oil out of the compressor and into a measuring glass. The
remaining quantity of oil (approx. 120 cm3 ) remains in the compressor.
4. Always replace the sealing ring.
Tightening torque for oil filler plug M10 x 1: 26 to 36 Nm (19 to 27 ftlb.)
5. Use fastening screws from the new compressor. Replace O−rings and wet the new rings with refrigerant
oil.
Tightening torque for refrigerant line, screws M8 x 32: 23 Nm (17 ftlb.)
6. Do not remove the plugs for the lines and compressor connection until shortly before
installation.
7. Install compressor with lines.
8. Engage electrical connection and install compressor with fastening screws.
9. Install expansion tank with hydraulic pump.
Tightening torque for the compressor fastening screws on the console, M8 screws: 23 Nm (17 ftlb.)
Tightening torques of the fastening screws for the belt pulley and hydraulic pump expansion tank: M8 screws:
23 Nm (17 ftlb.)
M6 screw: 10 Nm (7.5 ftlb.)
Removing the compressor 1079

einordnung
10. Mount belt pulley for hydraulic pump and fit drive belt.
11. Install throttle body and engage frequency valve.
12. Fasten the fuel supply lines on the fuel cooler. Make sure to counter when doing this.
13. Install the pressure pipe to the throttle body and air cleaner assembly.
14. Secure the hose on the left and right on the pressure pipe.
15. Connect the battery.
16. Fill the heating/air−conditioning system with refrigerant.
Running−in regulations for new compressor
Note
• Fill the air−conditioning system (fluid) via the high−pressure side from the refrigerant circuit with the
engine OFF.
1. If possible, all air outlet nozzles OPEN, circulating air CLOSED.

2. Start the engine and allow idle speed to stabilise (approx. 5
seconds).
3. Set the fan to max. output.
4. Switch on the air−conditioning system AC switch and allow it to run uninterrupted for at least 2 minutes
at 1500 rpm.
5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the air−conditioning
system is completed and the compressor can be run up to the max. engine speed.
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Installing the compressor 1080

87 50 19 Removing and installing the condenser
Removing the condenser
Installing the condenser
top of page
Removing the condenser
3. Completely remove the front spoiler. Remove the air guide to the condenser and pull off the electrical
plug connection on the temperature sensor.
4. Undo the refrigerant line on the condenser. Immediately close connections and lines with plugs so
that they are air−tight.
5. Undo the −fastening screws− from the condenser and pull the condenser to the side out of the holder.
top of page
Installing the condenser
Note
1. Do not remove the plugs for the lines and condenser connection until shortly before
installation.
2. Replace O−rings and wet the new rings with refrigerant oil.
Note
• When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21 mm
open−ended wrench!
Tightening torque for M8 refrigerant lines: 14 Nm (10.5 ftlb.)

Tightening torque for condenser: 4.0 ± 0.5 Nm (3.0 ± 0.5 ftlb.)
Tigthening torque for air guide: 4.0 ± 0.5 Nm (3.0 ± 0.5 ftlb.)
by suction + 20 cm3 )
87 50 19 Removing and installing the condenser 1081

einordnung
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Installing the condenser 1082

87 53 19 Removing and installing fan for condenser
Removing fan for condenser
Installing fan for condenser
top of page
Removing fan for condenser
1. Remove front wheel, front wheel housing liner and front spoiler.
2. Detach cooler bracket from the body −(1 nut, 2 M8 screws and 1 sheetmetal screw)− .
3. Undo −retaining clips− from the radiator and pull off the radiator bracket downwards.
4. Disconnect the electrical plug connection and undo 2 sheetmetal screws from the fan housing.
5. Pull the fan housing with fan motor out of the
holder.
6. Detach −fan motor and ballast resistor− from the fan housing and remove.
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Installing fan for condenser
1. After installation, check whether the fan can rotate freely.
2. Tighten front wheel.
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87 53 19 Removing and installing fan for condenser 1083

87 55 19 Removing and installing the fluid tank
Removing fluid tank
Installing fluid tank
top of page
Removing fluid tank
1. Remove the cover above the heating/air−conditioning system and fluid tank.
3. Undo the −hose clamp− on the fluid tank. Undo −both hexagon−head bolts− on the fluid tank and
remove the fluid tank upwards. Immediately close lines with plugs so that they are air−tight.
top of page
Installing fluid tank
Note
• The fluid tank must be replaced if the system suffers from operational faults (e.g. accident damage or
air−conditioning system depressurised)!
• Used refrigerant oil extracted from a previously run A/C unit must not be re−used!
1. Do not remove plugs until shortly before installation. Replace the O−ring on the branch piece and
on the refrigerant line, and wet the new O−rings with refrigerant oil.
2. Tighten both hexagon−head bolts on the fluid tank.
by suction +30 cm3 ).
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87 55 19 Removing and installing the fluid tank 1084

87 58 19 Removing and installing footwell blower
outlet sensor
Removing footwell blower outlet sensor
Installing footwell blower outlet sensor
top of page
Removing footwell blower outlet sensor
1. Remove footwell
bulkhead.
2. Unclip centre console cover at the front and remove the footwell vent (3
screws).
3. Turn blower outlet sensor by −90°− and pull it out.

4. Pull electrical plug connection off blower outlet sensor.
top of page
Installing footwell blower outlet sensor
1. Position temperature sensor on the heating/air−conditioning unit housing and turn by 90° (tighten).
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87 58 19 Removing and installing footwell blower outlet sensor 1085

87 59 19 Removing and installing outside temperature
sensor
Removing outside temperature sensor
Installing outside temperature sensor
top of page
Removing outside temperature sensor
Note
• Removing and installing outside temperature sensor on the installed heating/air−conditioning unit!

2. Remove drive motor for
fresh−air/recirculation valve.
3. Pull off electrical plug connection on the outside temperature sensor.
4. Turn temperature sensor by −90°− and pull it out.
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Installing outside temperature sensor
1. Place temperature sensor on the intake duct and turn by 90° (tighten).
3. Install drive motor for fresh−air/recirculation valve and perform a
function test.
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87 59 19 Removing and installing outside temperature sensor 1086

87 70 19 Removing and installing the expansion valve
Removing expansion valve
Installing expansion valve
top of page
Removing expansion valve
3. Detach the air−conditioning lines at the expansion valve. Immediately close connections and
lines with plugs so that they are air−tight.
4. Undo the expansion valve −arrow− and remove. Immediately close the lines to the evaporator with plugs
so that they are air−tight.
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Installing expansion valve
Note
Do not remove plugs until shortly before installation. Replace O−rings and wet the new rings with
refrigerant oil.
Tightening torques: M5 screw: 6 Nm (4.5 ftlb.), M6 screw: 9 Nm (6.5 ftlb.)
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87 70 19 Removing and installing the expansion valve 1087

87 78 19 Removing and installing blower driver
Removing blower driver
Installing blower driver
top of page
Removing blower driver
2. Unscrew fastening screw and detach the blower driver from the heating/air−conditioning unit housing
from below.
3. Pull blower driver out of the upper bracket and remove in downward direction.
4. Pull off electrical plug connection.
top of page
Installing blower driver
1. Engage the electrical plug connection and slide the blower driver into the upper bracket.
2. Tighten fastening screw carefully (plastic housing).
3. Install the air guide and footwell bulkhead.
4. Perform function test on heater/fresh−air blower motor.
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87 78 19 Removing and installing blower driver 1088

87 82 19 Removing and installing interior temperature
sensor
Removing interior temperature sensor
Installing interior temperature sensor
top of page
Removing interior temperature sensor
1. Pull off cover for temperature
sensor.
2. Undo three Torx screws of the right side vent and carefully pull the side vent out of the dashboard.
One Torx screw is located behind the cover.
3. Press locking tabs together slightly and remove temperature sensor from the dashboard.
top of page
Installing interior temperature sensor
1. Engage electrical plug connection, ensuring that the temperature sensor is seated properly in the
dashboard.
2. The cover simultaneously serves as the intake grille for the fan and must not be closed off.
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87 82 19 Removing and installing interior temperature sensor 1089

87 83 19 Removing and installing pressure switch for
the air−conditioning system
Removing pressure switch for the air−conditioning system
Installing pressure switch for the air−conditioning system
top of page
Removing pressure switch for the air−conditioning system
3. Pull off the cable plug −arrow− on the pressure switch.

4. Undo and unscrew the pressure switch.
top of page
Installing pressure switch for the air−conditioning system
Note
Replace the O−ring on the pressure switch and wet it with refrigerant oil.
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87 83 19 Removing and installing pressure switch for the air−conditioning system 1090
90 12 15 Setting ahead the total mileage counter in
the instrument cluster
Setting ahead with the Porsche System Tester 2
top of page
Setting ahead with the Porsche System Tester 2
Note
• The kilometre reading must be set ahead after replacement of the instrument cluster!
1. Select vehicle type 911 Turbo (996)

2. Select control modules
3. Select instrument cluster
4. Select total mileage
5. Input Vehicle Identification
Number
6. Confirm with F7
key
7. Input kilometre reading
8. Code with F8 key
The total mileage is adopted in the new instrument cluster after coding.
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90 12 15 Setting ahead the total mileage counter in the instrument cluster 1091
90 25 37 Disassembling and assembling instrument
cluster
Note
Note
• The instrument cluster should not be disassembled!
• The bulbs have been replaced with LEDs!
• The instrument cluster can be replaced as a complete unit only!
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90 25 37 Disassembling and assembling instrument cluster 1092

90 50 19 Removing and installing horn
Note
Removing horn
Installing horn
Note
• Both horns are fastened on a bracket on the right front side between the body and condenser!
Horn
A Horn − high−pitch
B Horn − low−pitch
top of page
Removing horn
Note
• The high−pitch horn can be removed from below through the sound outlet opening!
• The entire front spoiler must be removed in order to remove the low−pitch horn!
1. Pull off electrical plug connection and observe installation position of the
horn.
90 50 19 Removing and installing horn 1093

einordnung
2. Unscrew the M6 hexagon nut from the bracket and remove the high−pitch horn through the sound
outlet opening.
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Installing horn
1. Observe installation position of the horns!
• The horn must not touch the body or a bracket.

• A toothed washer must be fitted between the horn and bracket.
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Removing horn 1094

91 12 15 Adjusting (calibrating) PCM navigation unit
Note
GPS receiver
Distance sensor
Gyroscope
Procedure after commissioning
Procedure after changing a tyre
Procedure after the power supply has been interrupted
Note
• The PCM navigation unit must be calibrated after maintenance work or commissioning!
• Calibration is the prerequisite for exact route guidance!
The following components of the PCM navigation unit must be calibrated or initialised:
top of page
GPS receiver
Note
• When the power supply is disconnected (terminal 30), the built−in GPS receiver loses the so−called
almanac!
The almanac stores the satellite orbits and ensures fast location of the individual satellites when the system is
started.
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Distance sensor
Note
• The distance sensor must be calibrated after commissioning of the PCM navigation unit or after
changing a tyre!
• If a system that has already been calibrated is disconnected from the power supply (terminal 30), the
calibration of the distance sensor is retained!
• The distance signal changes if the circumference of the tyre changes (e.g. tyre change)!
• This modification must be calibrated by the PCM navigation unit afterwards!
The distance sensor transmits the distance travelled to the PCM navigation unit.
top of page
91 12 15 Adjusting (calibrating) PCM navigation unit 1095

einordnung
Gyroscope
Note
• The gyroscope detects changes in the direction of travel and must be calibrated after commissioning!
• The gyroscope must be calibrated after commissioning only!
• If a system that has already been calibrated is disconnected from the power supply (terminal 30), the
calibration of the gyroscope is retained!
The gyroscope shows temperature−dependency. This temperature−dependency is compensated by the system

if the "cold" (not calibrated) system is switched on and left to stand for approx. one hour.
top of page
Procedure after commissioning
1. Switch on the PCM with a free panoramic view for approx. 20 minutes (to load GPS
almanac).
2. Drive on a motorway if possible at a speed greater than 60 km/h for a distance of approx. 50 km
(calibration of the distance measurement).
3. Drive approx. 10 km in an urban area and take frequent turn−offs.
4. Stop for approx. 10 seconds occasionally (calibration of the
gyroscope).
5. Switch on the PCM navigation unit for approx. one hour with the vehicle horizontal.
Calibration is necessary after the following maintenance work:
• After changing a tyre.

• After the power supply has been interrupted.
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Procedure after changing a tyre
Drive on a motorway if possible at a speed greater than 60 km/h for a distance of approx. 50 km (calibration
of the distance measurement).
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Procedure after the power supply has been interrupted
Procedure after the power supply has been interrupted: Switch on the PCM with a free panoramic view for
approx. 20 minutes (to load GPS almanac).
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Gyroscope 1096
91 12 19 Removing and installing navigation unit
Note
Removing navigation unit
Installing navigation unit
Note
• Special tool V 160 must be used to remove the navigation unit!
top of page
Removing navigation unit
1. Unclip the cover on the left and right of the navigation unit.
2. Insert special tool V 160 into the recesses of the navigation unit and
engage.
3. Carefully push out the navigation unit rearward and disconnect plug connections.
top of page
Installing navigation unit
1. Engage the electrical plug connections and carefully lay the electrical leads (do not pinch).
2. Clip in cover on the left and right and perform a function test.
Device code input
Note
• The navigation unit is protected against theft by a device code!
91 12 19 Removing and installing navigation unit 1097

einordnung
Only the navigation code has to be input again if the navigation unit is
exchanged.
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Device code input 1098

91 13 19 Removing and installing GPS antenna
Note
Removing GPS antenna
Installing GPS antenna
Note
• The GPS antenna is located under a cover in the centre of the dashboard!
• A light−emitting diode for the alarm system and the sun sensor are accommodated in this housing!
• The GPS is fastened underneath with a magnet!
• The GPS antenna must not be covered by metallic or moist objects!
top of page
Removing GPS antenna
1. Unclip cover from behind and take out.
2. Undo both Torx T20 fastening screws with an angled screwdriver.

3. Remove housing with GPS antenna, disconnect electrical plug connection on the bottom, and remove GPS
antenna (magnet).
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Installing GPS antenna
2. Install housing with GPS antenna and clip in
cover.
91 13 19 Removing and installing GPS antenna 1099

einordnung
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Installing GPS antenna 1100

91 20 19 Removing and installing the car radio
Removing the car radio
Installing the car radio
Entering the code number
top of page
1. Remove the car radio with special tool 9570/1 (see Workshop Equipment Manual Chapter
2.2).
2. Engage the special tool to the right and left in the slits provided in the car
radio.
3. Carefully pull the car radio out of the holder using the special tools and disconnect the electrical plug
connections.
top of page
1. Remove the heating/air−conditioning control. ’ Rep. Gr. 870219; Removing and installing the
heating/air−conditioning control.
2. Engage the electrical plug connections on the car radio.
3. Pull the special tool out of the car radio by pressing gently on the retaining spring
−arrow− .
4. Carefully push the car radio into place.
5. Through the opening on the heating/air−conditioning control, it is possible to check the position of leads
in the support frame better and to prevent leads from becoming trapped.
91 20 19 Removing and installing the car radio 1101

einordnung
6. Install the heating/air−conditioning control.
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Entering the code number
1. If the car radio is disconnected from the power supply, it will be protected against theft the next
time it is connected.
2. After being switched on with the −ON− key, the term −CODE− is displayed followed by 4
asterisks.
3. The four−figure code number must be entered using the multi−function keys 1...0.
4. Example: code number 1530 (the code number can be found in the enclosed −CODE CARD− ). Enter the
code number with the multi−function keys.
5. The first asterisk disappears after the first number is entered. The second asterisk disappears after
the second number is entered, etc.
6. If the fourth number has been entered and all the other numbers were correct, the device switches itself on
automatically.
Note
• The −CODE CARD− must always be stored without fail outside the vehicle in a safe place. In this
way, improper use can be excluded. The enclosed window stickers should be adhered to the inside of
the vehicle windows!
7. If an incorrect code number has been entered, the term −CODE− will be displayed with the four asterisks
once more.
8. If an incorrect code is entered three times, the term −WAIT− is displayed and the device is blocked
for approx. 60 minutes.
9. Another three incorrect inputs block the device for an additional 60 minutes.
10. −Important:− the waiting time only counts down when the device is switched on.
Note
• The new code number should be entered in the Motronic, test step vehicle data, using the Porsche
System Tester 2!
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Installing the car radio 1102

91 47 19 Removing and installing radio antenna
Removing radio antenna
Installing radio antenna
top of page
Removing radio antenna
1. Remove the cover over the heating/air−conditioning system, battery and fluid tank.
2. Disconnect the antenna lead at the separation point. Just loosen the holder on the radio antenna (2
M5 x 12 screws).
3. Undo the wiper arm on the left and right and remove the cowl panel cover upwards over the wiper link.
4. Undo the radio antenna under the cowl panel cover and unclip
it.
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Installing radio antenna
1. Clip in the radio antenna and fasten it with 2
screws.
2. Install cowl panel cover and wiper arms. Engage antenna lead and fasten holder on the radio
antenna.
3. Install the covers over the heating/air−conditioning system, battery and fluid tank, and carry out a function
test.
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91 47 19 Removing and installing radio antenna 1103

91 57 15 Setting hands−free microphone to the
telephone type
Note
Setting
Note
• There is an adjustment possibility on the hands−free microphone for adapting it to the telephone
system installed in the vehicle!
The following positions must be set:
• Position 1: Not used

• Position 2: Passive operation
• Position 3: Active operation
top of page
Setting
Note
• The setting as delivered in new cars is position 3!
1. Carefully unclip hands−free microphone from the dashboard insert and pull
out.
2. Use a small screwdriver to set the position of the installed telephone system (e.g. Position 3 PCM).
3. Carefully clip the hands−free microphone into the dashboard insert again.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
91 57 15 Setting hands−free microphone to the telephone type 1104

91 57 19 Removing and installing hands−free
microphone
Removing hands−free microphone
Installing hands−free microphone
top of page
Removing hands−free microphone
2. Switch on the hazard warning light switch (button comes out).
On the sides of the button, there are small openings that project beyond the dashboard insert.
3. Insert two small screwdrivers into the openings and pull off the button −A− toward the
front.
4. Unclip the collar from the dashboard insert.
The hazard warning light switch −B− is held in the dashboard insert by two locking hooks.
5. Press the right locking hook toward the switch, grip the button holder with a pair of pliers and pull out the
switch.
6. Undo 5.0 x 30 Torx screw on the dashboard insert.
7. Pull out hands−free microphone on the left side and undo the 5.0 x 30 Torx
screw.
8. Unclip the dashboard insert and disconnect the electrical plug connection from the hands−free
microphone.
9. Pull hands−free microphone out of the dashboard
insert.
top of page
91 57 19 Removing and installing hands−free microphone 1105

einordnung
Installing hands−free microphone

1. Engage electrical plug connection of the hands−free microphone and fasten the dashboard insert onto the
dashboard.
2. Install hazard warning light switch.
3. Press button −A− onto the hazard warning light switch −B− until the button is heard to
engage.
4. Clip in hands−free microphone, connect the battery and perform a function
test.
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Installing hands−free microphone 1106

91 75 19 Removing and installing sensor for
ParkAssistent
Note
Removing sensor for ParkAssistent
Installing sensor for ParkAssistent
ParkAssistent control module
Note
• Four sensors for the ParkAssistent are installed in the rear spoiler!
• The rear spoiler must be taken off in order to remove a defective sensor!
• When painting, make sure that not only the membrane but also the cylindrical membrane edge (2 mm)
is coated with paint!
Layer thickness: max. 120 µm
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Removing sensor for ParkAssistent
1. Take off rear spoiler.
3. Slightly bend up the holding peg on the sensor housing and push out the sensor.
4. Remove isolating ring from the sensor.
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Installing sensor for ParkAssistent
Note
• Always fit the isolating ring before installing the sensor!
• The electrical plug connection in the vehicle must always point to the centre of the vehicle!
• Plug connection with marking (white adhesive tape) on the wiring harness always connected to outer
right sensor!
91 75 19 Removing and installing sensor for ParkAssistent 1107

einordnung
1. Fit isolating ring and push sensor into the sensor housing and engage.
2. Engage electrical plug connection and fit rear spoiler.
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ParkAssistent control module
Note
• The control module is fastened next to the alarm system/central locking system control module under
the driver's seat!
When removing, remove the seat and detach the retaining plate (two hexagon−head screws M6 x 16).
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Installing sensor for ParkAssistent 1108

92 15 19 Removing and installing the wiper motor
Removing wiper motor
Installing wiper motor
top of page
Removing wiper motor
1. Remove the covers above the battery and fluid
tank.
3. Undo the fastening nut of the link. When doing so, hold in position using an open−ended wrench
(width across flats 21 mm).
4. Remove the link.
5. Undo the −fastening screws− on the wiper motor (3 M6 screws) and the lower fastening screw on
the body.
6. Carefully raise the wiper link and remove the wiper motor downwards.
7. Disconnect the electrical plug connection on the wiper motor.
top of page
Installing wiper motor
1. Wiper motor in parking position.
2. Fit the link.
The installation position is identified by a 0 marking (parking position) on the console −(arrow)− .
4. Switch on the wiper motor and check the wiper position.
Tightening torque: Fastening screw, motor M6: 8 Nm (6 ftlb.)
Tightening torque: Fastening nut, link M8: 17 Nm (12.5 ftlb.)
92 15 19 Removing and installing the wiper motor 1109

einordnung
Tightening torque: Hexagon−head bolt M6: 10 Nm (7.5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing wiper motor 1110

92 19 19 Removing and installing the wiper link
Removing wiper link
Installing wiper link
top of page
Removing wiper link
3. Undo the wiper arm on the left and right and remove the cowl panel over the wiper
link.
4. Remove the left dome strut.
5. Undo the wiper link on the body −(3 M6 screws)− and disconnect the electrical plug connection on the
wiper motor.
6. Carefully remove the wiper link with wiper motor to the front.
top of page
Installing wiper link
Note
• Before installing the dome strut, the vehicle must be on its wheels!
1. Observe the installation sequence for the fastening screws −1 to

3− .
Tightening torques: Wiper arm nut M8: 17 Nm (12.5 ftlb.)
Tightening torques: Hexagon−head bolts M6: 10 Nm (7.5 ftlb.)
92 19 19 Removing and installing the wiper link 1111

einordnung
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Installing wiper link 1112

92 27 19 Removing and installing the wiper blades
Note
Note
• The wiper blades for the driver's and passenger's side are different!
• The wiper blade on the driver's side is straight!
• On the passenger's side it is curved −A− !
• This arrangement applies to left−hand drive and right−hand drive vehicles!
A Passenger's side
B Driver's side
Note
• The spoiler edge on the wiper blade on the driver's side must face downwards!
• The clip installation position must be observed when installing the wiper blades for left−hand drive
and right−hand drive vehicles!
A Clip for left−hand drive vehicles

B Clip for right−hand drive vehicles
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 27 19 Removing and installing the wiper blades 1113

92 30 19 Removing and installing rear window wiper
system
Removing rear window wiper system
Installing rear window wiper system
top of page
Removing rear window wiper system
Note
• The rubber seal of the rear wiper arm remains in the rear centre panel; do not remove!
• The relay can be unclipped and removed with the wiper motor installed!
1. Remove cover over rear−window wiper arm.

2. Undo the hexagon nut and pull off the rear−window wiper arm.
3. Remove the rear panel cover in front of the rear−window wiper motor.
4. Undo the retaining frame with rear−window wiper motor at the rear centre panel −(2 nuts, 1 screw)− and
pull out to the front.
top of page
Installing rear window wiper system
Note
• The spoiler edge on the rear−window wiper blade must face outwards!
Tightening torque: Hexagon nuts M6: 8 Nm (6 ftlb.)

Tightening torque: Hexagon−head bolt M6: 8 Nm (6 ftlb.)
Tightening torque: Wiper arm − nut M8: 17 Nm (12.5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
92 30 19 Removing and installing rear window wiper system 1114

92 56 19 Removing and installing pump for
windscreen washer system
Removing pump for windscreen washer system
Installing pump for windscreen washer system
top of page
Removing pump for windscreen washer system
Note
• A stuck hose can be pulled off more easily if it is heated with a hot−air gun!
1. Remove tank for windscreen washer system. => Removing and installing tank for windscreen
washer system
2. Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear.
3. Lift pump upwards out of the rubber sleeve.

4. Pull hose off the pump.
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Installing pump for windscreen washer system
1. Check rubber sleeve for pump, replace if necessary.
2. Install pump and tank, fill in water and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 56 19 Removing and installing pump for windscreen washer system 1115

92 60 19 Removing and installing tank for windscreen
washer system
Removing tank for windscreen washer system (7 litres)
Installing tank for windscreen washer system
top of page
1. Remove left front wheel and remove the wheel housing liner.
2. Extract water from the tank if necessary and release and pull out the filler neck.
3. Disconnect the hose for the headlight cleaner nozzle at the headlight
holder.
4. Carefully pull off the hose for the windscreen washer system.
5. Undo fastening screws and swing the holder inward.

6. Pull tank forward out of the holder and swivel it down at the rear.
7. Disconnect electrical plug connections of pumps and fluid level indicator and remove the tank in a
downward direction.
top of page
1. The 3 l tank is not equipped with a headlight cleaning
system.
2. The tank is fastened only by one M8 x 35 hexagon−head bolt.

92 60 19 Removing and installing tank for windscreen washer system 1116

einordnung
top of page
Installing tank for windscreen washer system
1. First push 7 l tank under the wing at front, then engage electrical plug connections of the pumps.
2. Push tank rearward into the holder and engage the electrical plug connection for the fluid level indicator.
3. Swivel the holder back (7 l tank) and fasten the
tank.
Tightening torque of the hexagon−head bolts M6 x 20: 10 Nm (7.5 ftlb.)
Tightening torque of the hexagon−head bolts M8 x 35: 20 Nm (15 ftlb.)
4. Engage hose for the headlight cleaning system and carefully push on the hose for the windscreen washer
system.
5. Engage filler neck and fill in water.
7. Install wheel housing liner and mount the left front wheel.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing tank for windscreen washer system (3 litres) 1117

92 67 19 Removing and installing fluid level indicator
Removing fluid level indicator
Installing fluid level indicator
top of page
Removing fluid level indicator
washer system
2. Pull sensor for fluid level indicator out of the tank to the
side.
top of page
Installing fluid level indicator
1. Check rubber sleeve for sensor, replace if necessary.
2. Install sensor and tank, fill in water and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 67 19 Removing and installing fluid level indicator 1118

92 70 19 Removing and installing cover for spray
nozzle
Removing cover for spray nozzle
Installing cover for spray nozzle
top of page
Removing cover for spray nozzle
Note
• The cover for the spray nozzle can no longer be disengaged or removed. Cover and spray nozzle head
are now a single spare part.
1. Actuate headlight washing system and hold nozzle head.
2. Use a screwdriver to unclip and remove the spray nozzle head −(arrow)− .
top of page
Installing cover for spray nozzle
1. Insert cover with spray nozzle head into the spray nozzle and press down firmly until it comes into
contact with the headlight lens.
2. The cover with spray nozzle head must audibly
engage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 70 19 Removing and installing cover for spray nozzle 1119

92 72 19 Removing and installing spray nozzle for
headlight washing system
Removing spray nozzle for headlight washing system
Installing spray nozzle for headlight washing system
top of page
Removing spray nozzle for headlight washing system
1. Remove and install cover for spray nozzle => Removing and installing cover for spray nozzle
2. Remove main headlight.
3. Undo the upper fastening screw (Torx T 20) on the retaining bracket.
4. Unclip lower fastening and remove retaining bracket.
5. Hold the rubber seal in the headlight housing and pull the spray nozzle out of the headlight
housing.
top of page
Installing spray nozzle for headlight washing system
1. Install the spray nozzle in the headlight housing.
2. Make sure that the rubber seal is correctly seated on the spray nozzle and in the headlight housing.
3. Clip in retaining bracket and tighten.
4. Install main headlight.
5. Insert cover with spray nozzle head into the spray nozzle and press down firmly until it comes into
contact with the headlight lens.
6. The cover with spray nozzle head must audibly
engage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
92 72 19 Removing and installing spray nozzle for headlight washing system 1120
92 78 19 Removing and installing pump for headlight
washing system
Removing pump for headlight washing system
Installing pump for headlight washing system
top of page
Removing pump for headlight washing system
Note
• A stuck hose can be pulled off more easily if it is heated with a hot−air gun!
washer system
2. Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear.
3. Remove spacer between the pumps and lift pump upwards out of the rubber sleeve.
4. Pull hose off the pump.
top of page
Installing pump for headlight washing system
1. Check rubber sleeve for pump, replace if necessary.
2. Install pump and tank, fill in water and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
92 78 19 Removing and installing pump for headlight washing system 1121

94 05 19 Removing and installing main light switch
Removing main light switch
Installing main light switch
top of page
Removing main light switch
2. Remove button of the light switch. Pull out the button as far as it will go and press in the locking element
on the lower side with a small screwdriver.
3. Undo three 4.0 x 18 Torx screws of the left side vent and carefully pull the side vent out of the dashboard.
One Torx screw is located in the light switch on the right.

5. Undo M16 x 1 hexagon nut of the light switch.
6. Pull the lighting unit switch out of the side vent to the front by approx. 5 mm.
7. Remove light switch from the side vent by turning it slightly in clockwise
direction.
top of page
94 05 19 Removing and installing main light switch 1122

einordnung
Installing main light switch

1. Engage light switch by turning it slightly in counter−clockwise direction.
Tightening torque of the hexagon nut M16 x 1: 3.5 Nm (2.5 ftlb.)
2. Engage electrical plug connections and install side
vent.
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing main light switch 1123

94 15 01 Troubleshooting on the Xenon headlight
Caution
WARNING
Danger of injury from high voltage!
• The light should always be switched off when the components (control module, gas discharge lamp,
drive motor) are removed and installed!
• The gas discharge lamp (D2S lamp) should only be operated when installed in the reflector and in the
installed headlight!
• A removed headlight does not have a high voltage!
Note
• For a faulty dipped beam or high beam headlight, the individual components (gas discharge lamp,
control module) can be replaced from the second headlight!
• Only the battery voltage can be checked with the headlight removed on the plug connection, to Pin 5
= 56a, Pin 11 = 56b and Pin 12 = 31, according to the wiring diagram in the wing!
• The gas discharge lamp should only be operated when installed in the reflector and in the installed
headlight!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 15 01 Troubleshooting on the Xenon headlight 1124

94 15 05 Main headlights − basic adjustment in the
body
Note
Adjustment instructions
Adjustment procedure
Note
• The main headlights have been fitted into the body at the factory!
headlights!
top of page
Adjustment instructions
Note
• The headlight cover plate should lie approximately 2 mm below the body edge!
The transition from the headlight housing to the body is in the same plane (level).
94 15 05 Main headlights − basic adjustment in the body 1125

einordnung
Factory fitting of the adjusting component fastening nuts
Fitting of the fastening nuts in the case of accident repairs or replacement of the main headlights
top of page
Adjustment procedure
1. Adjust fastening nuts to the same height as the old version and tighten slightly by hand.
Mounting plate removed
2. Press headlight housing firmly into the body and

lock.
3. After adjustment, tighten the fastening nuts.
Tightening torque: 8 ± 2 Nm ( 6 ± 1.5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Adjustment instructions 1126

94 15 15 Left / right traffic conversion for Xenon
headlights
Caution
Converting Xenon headlights
Installation
WARNING
Warning signs (yellow triangle with black high−voltage arrow) indicate high voltage (risk of fatal injury)!
The light should always be switched off when the components (control module, gas discharge lamp, drive
motor) are removed and installed. A removed headlight does not have a high voltage.
The gas discharge lamp (D2S lamp) should only be operated when installed in the reflector and in the installed
headlight.
Note
• The masking film for left/right−hand traffic should not be removed from Xenon headlights!
• In the headlight there is a changeover lever for driving in countries with left− or right−hand traffic!
• The changeover lever is located on the left and right of the housing beside the gas discharge lamp!
top of page
Converting Xenon headlights
2. Unscrew fastening screws (2 ea.) and open rear closure cap.
3. Put changeover lever into position T (tourist setting) using an 8 mm socket wrench insert.
top of page
Installation
1. Close cap and secure with fastening screws.
3. Repeat conversion for other headlight.
94 15 15 Left / right traffic conversion for Xenon headlights 1127

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installation 1128
94 15 19 Removing and installing the main headlights
Note
Note
A Open
B Close
The tool kit contains a wrench for opening and closing the headlights.
1. When installing, press headlights firmly into the wing.
2. Secure the plugs after installation.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 15 19 Removing and installing the main headlights 1129

94 23 19 Removing and installing gas discharge lamp
(Xenon headlights)
Caution
Removing gas discharge lamp (Xenon headlights)
Installing gas discharge lamp (Xenon headlights)
WARNING
• Gloves must be worn when changing the lamp!
• Do not touch the glass bulb!
top of page
Removing gas discharge lamp (Xenon headlights)

3. Undo electrical plug connection on the gas discharge lamp (bayonet lock).
4. Turn lamp fastener counter−clockwise (bayonet lock) and remove with the gas discharge lamp.
top of page
Installing gas discharge lamp (Xenon headlights)
1. Install new gas discharge lamp. Position lamp fastener −(lower arrow)− and turn to the right.
94 23 19 Removing and installing gas discharge lamp (Xenon headlights) 1130

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing gas discharge lamp (Xenon headlights) 1131

94 27 19 Removing and installing bulb for parking
light
Removing bulb for parking light
Installing bulb for parking light
top of page
Removing bulb for parking light
2. Open side cover and turn the parking light bulb socket out of the headlight reflector (do not pull on
the wires).
3. Unscrew defective bulb from the parking light bulb socket (bayonet lock).
top of page
Installing bulb for parking light
1. Install new bulb and engage parking light bulb socket in the
reflector.
2. Close cover and install main headlight.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 27 19 Removing and installing bulb for parking light 1132

94 29 19 Removing and installing bulb for number
plate light
Removing bulb for number plate light
Installing bulb for number plate light
top of page
Removing bulb for number plate light
1. Loosen both fastening screws and remove the number plate light.
2. Push back the rubber cover and remove defective bulb from between the contact springs.
top of page
Installing bulb for number plate light
1. Insert new bulb in the holes of the contact springs.
2. Push the rubber cover (protects against water leaking in) carefully over the number plate light and
fasten.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 29 19 Removing and installing bulb for number plate light 1133

94 33 19 Removing and installing bulb for tail light
Removing bulb for tail light
Installing bulb for tail light
top of page
Removing bulb for tail light
2. Unscrew fastening screws and pull out the tail light towards the
rear.
A Rear fog light
B Tail light
C Tail light/brake light
D Reversing light
E Direction indicator light
3. Turn bulb socket counter−clockwise and remove from the tail light.
4. Take defective bulb out of the bulb socket (bayonet lock).
top of page
Installing bulb for tail light
1. Install new bulb and ensure that it is correctly seated (bayonet lock).
2. Rotate bulb socket clockwise and engage.
3. Install the tail light, making sure the retaining lugs are seated properly.
4. Perform a function test of all bulbs.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 33 19 Removing and installing bulb for tail light 1134

94 47 19 Removing and installing the hazard warning
light switch
Removing hazard warning light switch
Installing hazard warning light switch
top of page
Removing hazard warning light switch
2. Insert two small screwdrivers into the openings and pull off the button −A− toward the
front.
4. Press the right locking hook toward the switch, grip the button holder with a pair of pliers and pull out the
switch toward the front.
top of page
Installing hazard warning light switch
engage.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 47 19 Removing and installing the hazard warning light switch 1135

94 53 19 Removing and installing bulb for side
direction indicator light
Removing bulb for side direction indicator light
Installing bulb for side direction indicator light
top of page
Removing bulb for side direction indicator light
1. Insert a screwdriver in the upper slot between the wheel housing liner and the direction indicator light
housing.
2. Unclip the retaining spring of the direction indicator light housing by pressing with the screwdriver.
3. Release and pull off electrical plug connection.
4. Turn bulb socket counter−clockwise and remove (bayonet lock).
5. Remove defective bulb.
top of page
Installing bulb for side direction indicator light
1. Insert new bulb in the bulb socket and install (bayonet lock).
2. Engage electrical plug connection and install direction indicator light.
3. Insert tabs of direction indicator light −arrow A− forwards into the
wing.
4. Engage retaining spring −arrow B− in the

wing.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 53 19 Removing and installing bulb for side direction indicator light 1136
94 57 19 Removing and installing control module for
gas discharge lamp
Caution
Removing control module for gas discharge lamp
Installing control module for gas discharge lamp
WARNING
top of page
Removing control module for gas discharge lamp
1. Switch off light.
2. Remove main headlight.

3. Detach the holder from the control module and
remove.
4. Release and pull off electrical plug connection from the control module.

6. Undo electrical plug connection on the gas discharge lamp (bayonet lock).
7.
94 57 19 Removing and installing control module for gas discharge lamp 1137
einordnung
Unclip the wiring arrangement from the closure cap and remove the control module with the
closure cap wire.
top of page
Installing control module for gas discharge lamp
2. Clip in wiring arrangement and check for correct seating.
3. Fasten holder with control module.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing control module for gas discharge lamp 1138

94 66 19 Removing and installing bulb for auxiliary
headlight (high beam headlight)
Removing bulb for auxiliary headlight
Installing bulb for auxiliary headlight
top of page
Removing bulb for auxiliary headlight
Note
• The bulb for auxiliary headlights (high beam headlight/headlight flasher) is located beneath the gas
discharge lamp for dipped beam/high beam headlight!

2. Unscrew fastening screws (2 ea.) and open rear closure cap. Unscrew bulb for the auxiliary headlight
(bayonet lock).
3. Release and disconnect electrical connection of the defective bulb.
top of page
Installing bulb for auxiliary headlight
1. Engage electrical plug connection. Install new bulb and ensure that it is correctly seated.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight) 1139
94 67 19 Removing and installing bulb for fog light
Removing bulb for fog light
Installing bulb for fog light
top of page
Removing bulb for fog light
2. Rotate the round cover in the headlight housing counter−clockwise and remove.
3. Disconnect electrical plug connection −(arrow)− from the defective bulb.

4. Press down retaining bracket −(arrow)− and swivel to the left.
5. Remove defective bulb.
top of page
Installing bulb for fog light
1. Install new bulb and ensure that it is correctly
seated.
2. Attach retaining bracket and engage electrical plug connection.
3. Close cover and install main headlight.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 67 19 Removing and installing bulb for fog light 1140

94 70 19 Removing and installing bulb for additional
brake light
Removing bulb for additional brake light
Installing bulb for additional brake light
top of page
Removing bulb for additional brake light
1. Carefully lever out the right−hand corner segment of the light lens with the screwdriver blade.
2. Pull corner segment out of the lock.
3. Turn lock of the additional brake light approx. 90° counter−clockwise and remove.
4. Disconnect electrical plug connection and disengage all fastening tabs of the bulb holder.
5. Remove bulb holder and take out defective bulb.
top of page
Installing bulb for additional brake light
1. Insert new bulb in the bulb holder.
2. Engage fastening tabs and connect electrical plug connection.
3. Insert additional brake light and turn lock approx. 90° clockwise.
4. Push corner segment into the lock and clip it in.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 70 19 Removing and installing bulb for additional brake light 1141

94 78 19 Removing and installing front angle sensor
for headlight beam adjustment
Removing front angle sensor for headlight beam adjustment
Installing front angle sensor for headlight beam adjustment
top of page
Removing front angle sensor for headlight beam adjustment
1. Remove front underside panel.
2. Hold intermediate link on rotary lever with second open−ended wrench and
release.
3. Push back the rubber cover over the electrical plug connection and remove electrical plug connection from
the angle sensor.
4. Detach retaining bracket for angle sensor from the side member underneath.
5. Detach the angle sensor from the retaining bracket and
remove it.
top of page
Installing front angle sensor for headlight beam adjustment
Note
• Once the angle sensor has been installed, the control module must be recalibrated with the Porsche
System Tester 2!
• After this, the main headlights must be readjusted with a commercially available 5 mm ball−head
screwdriver (free blade length 150 mm)!
94 78 19 Removing and installing front angle sensor for headlight beam adjustment 1142
einordnung
1. Fasten angle sensor on the retaining bracket and

install.
2. Engage electrical plug connection and pull rubber cover carefully over the plug connection (protects
against water leaking in).
3. Secure the linkage to the rotary lever and install underside panel.
Adjust the main headlights: ’ 0 Entire vehicle General
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing front angle sensor for headlight beam adjustment 1143

94 79 19 Removing and installing rear angle sensor
for headlight beam adjustment
Removing rear angle sensor for headlight beam adjustment
Installing rear angle sensor for headlight beam adjustment
top of page
Removing rear angle sensor for headlight beam adjustment
1. Hold intermediate link on rotary lever with second open−ended wrench and
release.
2. Push back the rubber cover over the electrical plug connection and remove electrical plug connection from
the angle sensor.
3. Detach retaining bracket for angle sensor, combination wire and brake line on the
body.
4. Detach the angle sensor from the retaining bracket and
remove it.
top of page
Installing rear angle sensor for headlight beam adjustment
Note
• Once the angle sensor has been installed, the control module must be recalibrated with the Porsche
System Tester 2!
1. Fasten angle sensor on the retaining bracket and

install.
2. Engage electrical plug connection and pull rubber cover carefully over the plug connection (protects
against water leaking in).
3. Secure the linkage to the rotary lever.
94 79 19 Removing and installing rear angle sensor for headlight beam adjustment 1144
einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing rear angle sensor for headlight beam adjustment 1145

94 94 19 Removing and installing drive motor for
headlight beam adjustment
Caution
Removing drive motor for headlight beam adjustment
Installing drive motor for headlight beam adjustment
WARNING
top of page
Removing drive motor for headlight beam adjustment
3. Disconnect the electrical plug connection from the drive motor and undo the fastening screws (2 screws).
4. Swivel drive motor to the side and remove towards the rear.
top of page
Installing drive motor for headlight beam adjustment
1. Install new drive motor. Install the ball head into the ball socket from the side and secure the drive motor.
2. Engage the electrical plug connection on the drive motor.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 94 19 Removing and installing drive motor for headlight beam adjustment 1146
headlight beam adjustment
Note
Removing control module for headlight beam adjustment
Installing control module for headlight beam adjustment
Note
• The control module is fastened on the right side of the dashboard beneath the passenger airbag unit!
top of page
Removing control module for headlight beam adjustment
2. Undo control module from below (2 sheetmetal screws).
3. Unlock the electrical plug connection and take out control module.
top of page
Installing control module for headlight beam adjustment
Note
• Once installed, the control module must be coded and calibrated with the Porsche System Tester 2!
1. Lock the electrical plug connection and fasten the control module to the bracket.
2. Install the right air guide and footwell
bulkhead.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
94 98 19 Removing and installing control module for headlight beam adjustment 1147
96 16 19 Removing and installing bulb for door
warning light
Removing bulb for door warning light
Installing bulb for door warning light
top of page
Removing bulb for door warning light
1. Press out −door warning light− carefully using a screwdriver.

2. Remove bulb socket from the door warning light and remove defective bulb.
top of page
Installing bulb for door warning light
1. Insert new bulb in the bulb socket and install.
2. Install door warning light in the door trim panel and perform a function test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
96 16 19 Removing and installing bulb for door warning light 1148

96 22 19 Removing and installing bulb for interior
light
Removing bulb for interior light
Installing bulb for interior light
top of page
Removing bulb for interior light
1. Pull the −interior light− out of the trim panel carefully from the
front.
2. Remove bulb for reading light. Disengage the bulb socket (bayonet lock) and remove defective bulb.
3. Remove interior light. Carefully unclip the light lens on the switch side −arrow− and remove.
4. Remove defective bulb from between the contact springs.
top of page
Installing bulb for interior light
1. Insert new bulb for the reading light in the bulb socket and install (bayonet lock).
2. Insert the new bulb for the interior light into the holes of the contact springs and clip in the light lens.
3. Install interior light. First insert into the trim panel at the rear, then press upwards at the front and engage.
4. Carry out a function test for the reading light and interior light.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 22 19 Removing and installing bulb for interior light 1149

96 41 19 Removing and installing bulb for luggage
compartment light
Removing bulb for luggage compartment light
Installing bulb for luggage compartment light
top of page
Removing bulb for luggage compartment light
1. Press −luggage compartment light− carefully out of the trim panel using a screwdriver.
top of page
Installing bulb for luggage compartment light
2. Install luggage compartment light in the trim panel and perform a function
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 41 19 Removing and installing bulb for luggage compartment light 1150

96 43 19 Removing and installing bulb for engine
compartment light
Removing bulb for engine compartment light
Installing bulb for engine compartment light
top of page
Removing bulb for engine compartment light
1. Press −engine compartment light− carefully out of the fan cover using a screwdriver.
top of page
Installing bulb for engine compartment light
2. Install engine compartment light into the fan cover and perform a function
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 43 19 Removing and installing bulb for engine compartment light 1151

96 62 01 Radio remote control in hand−held
transmitter does not function
Empty battery in hand−held transmitter
Radio transmitter outside lock−in range
Atmospheric interference or interfering transmitters
Energy−saving mode active
Fault in hand−held transmitter or vehicle
The radio remote control function is unavailable under the following five circumstances:
top of page
Empty battery in hand−held transmitter
• Battery replacement restores the full functionality without additional measures.
• The same applies in the case of an empty vehicle battery.
top of page
Radio transmitter outside lock−in range
Note
• If the transmitter is operated more than 256 times without reaching the associated receiver − e.g.
vehicle outside range or vehicle battery disconnected − the vehicle will not recognise the radio
transmitter the next time it is operated!
• If the number of operations is less than 1024, it is possible to perform re−synchronisation!
Re−synchronisation is carried out according to the following procedure:
• Switch on ignition with key and valid transponder.

• Switch off ignition.
• Remove ignition key from steering lock.
• Operate transmitter within 6 seconds after the key has been removed.
The lock−in range has now been reset to zero (as is the case with every recognised transmitter operation).
top of page
Atmospheric interference or interfering transmitters
The possibility of temporary interference by interference sources, and thus lack of function, cannot be ruled
out due to the many small users operating on the radio frequencies permissible for the automotive application.
The 996 model can be unlocked with the vehicle key via the door lock in the event of interference. Unlike
with the 993, this does not affect the immobilizer. Deactivation of the immobilizer is performed via the
transponder in the key head as soon as the key is turned in the steering lock.
96 62 01 Radio remote control in hand−held transmitter does not function 1152

einordnung
top of page
Energy−saving mode active
In order to keep "breakdowns" resulting from an empty battery to a minimum, the radio receiver, which draws
a high closed−circuit current, is switched off in the alarm system control module after a certain time in
addition to switch−off of the other loads.
• The radio receiver is switched off if the ignition is not switched on again within five days (120 h OFF
time).
• The radio receiver is switched off independently of the locking condition of the vehicle.
• A locked vehicle can be unlocked with the vehicle key. (This does not reactivate the radio receiver).
• In order to avoid triggering the alarm, the vehicle key with valid transponder must be turned in the
steering lock within the vehicle−entering delay of 10 seconds (due to the "passive arming" function −
automatic arming of the alarm system 30 seconds after the vehicle is left with the ignition key
removed; the central locking system is not activated in this case).
• This also applies for the Belgian market, if the vehicle was parked unlocked for longer than five days.
• If the radio receiver has been deactivated, it can be reactivated only by switching on the ignition
again.
• The switch−off time is reset if the ignition is switched on within five days, i.e. the system does not
enter energy−saving mode.
• If a valid radio command is recognised within the idle period (terminal 15 off), the switch−off time is
not reset.
top of page
Fault in hand−held transmitter or vehicle
• If the LED on the hand−held transmitter stays dark when the transmitter is operated, this is an
indication of either an empty battery or a faulty hand−held transmitter.
• Radio transmission is OK if the LED on the transmitter flashes when the transmitter is operated and
the alarm readiness lamp on the dashboard flashes rapidly.
Note
• If the alarm readiness light stays dark and chapters 1 to 4 can be excluded, the problem is a system
fault of the vehicle!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Atmospheric interference or interfering transmitters 1153

96 62 37 Disassembling and assembling hand−held
transmitter
Note
Removing key from the bottom part
Installing key in the bottom part
Note
• The top part of the hand−held transmitter is carefully lifted off with the fingernail or a small
screwdriver!
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Removing key from the bottom part
1. In order to remove the key from the bottom part, the compression spring in the sliding latch is compressed
and held with a small screwdriver.
2. Lift out the cap and relieve the compression

spring.
3. Push the sliding latch back and pull the key out of the bottom part.
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Installing key in the bottom part
1. Insert replacement key into the bottom part.
2. Install sliding latch and compression spring. Compress and hold compression spring using a small
screwdriver.
3. Insert the cap from above and relieve the compression spring.
4. Press the top and bottom parts of the hand−held transmitter together firmly.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
96 62 37 Disassembling and assembling hand−held transmitter 1154

96 62 55 Teaching hand−held transmitter
General
Work preparation
Procedure
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General
Up to four hand−held transmitters can be adapted to the control module. The hand−held transmitter can be
used to activate the central locking and the convertible top (for 996 Cabrio, country−specific version).
Another function is the immobilizer by means of the integrated transponder coil.
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Work preparation
Note
• If the key is stolen or the hand−held transmitter is faulty, all keys still in the customer's possession
will be required!
The following information is required to teach the hand−held transmitter:
• Key learning code from IPAS

• 24−digit Code No. (see barcode label on key grip)
Note
• During maintenance work, please bear in mind that the transmission frequency of the hand−held
transmitter is different according to the country of use!
• The corresponding reception frequency is printed on the alarm system control module!
This reception frequency is either:
• 433 Mhz with M−number M534
or
• 315 Mhz with M−number M535
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96 62 55 Teaching hand−held transmitter 1155

einordnung
Procedure
1. Connect the vehicle keys and the new hand−held transmitter and insert in the ignition.
2. Connect PST 2 and switch on ignition.
3. Select Alarm system in the menu and press the double arrow key >>
.
4. Select Learning function in the menu and press the double arrow key >>
5. Select menu item Transponder key and press the double arrow key >> .
The following message appears on the screen: "Input key learning code".
6. With the arrow keys, input the key learning code and press the double arrow key >> .
The following message appears on the screen: "Please confirm input".
7. Check the input and press the F7 key to confirm the input.
8. Distinguish between loss and fault and additional hand−held transmitter for the transponder.
a) Teaching an additional hand−held transmitter:
With the arrow key, select a free position (1, 2, 3 or 4) and press the F8 key.
Now the transponder code is saved in the selected position. Note the position of the new transponder code.
b) Teaching in the case of a lost or faulty hand−held transmitter:
Note
• Risk of theft due to the lost hand−held transmitter!
• It is essential to identify and delete the transponder code of the lost hand−held transmitter as
described in step 8 b)!
• It is essential to identify and delete the radio code of the lost hand−held transmitter as described in
step 12 b)!
• In this case, it is first necessary to identify and delete the stored transponder code of the lost
hand−held transmitter.
The remaining vehicle keys are required for this purpose:

One after the other, insert the keys into the ignition lock, switch the ignition on and establish
communication with the control module.
Current transponder shows the transponder code of the vehicle key that is presently inserted in the ignition
lock
Compare this transponder code with the transponder codes at positions 1
to 4.
This comparison allows the position of the lost hand−held transmitter (transponder code) to be identified, as
one transponder code is ultimately left over at positions 1 to 4.
Insert the vehicle key equipped with the new hand−held transmitter into the ignition lock and switch on
the ignition.
Establish communication between the PST2 and the control
module.
Select the identified position using the arrow keys and delete the transponder code with the F3 key.
Then press the F8 key.
9.
Procedure 1156
einordnung
Press the double arrow key << , select the menu item Remote control and press the double arrow key
>> .
"Input key learning code" appears on the screen
10. With the arrow keys, input the key learning code and press the double arrow key >> .
11. Check the input and press the F7 key to confirm the input.
12. Distinguish between loss and fault and additional hand−held transmitter for the radio code.
a) Teaching an additional hand−held transmitter:
Select the same position (1 to 4) as for the transponder key and press the [F8]
key.
b) Teaching in the case of a lost or faulty hand−held transmitter:
13. In this case, it is first necessary to identify and delete the stored "radio code" of the lost hand−held
transmitter.
The remaining hand−held transmitters are required for this purpose.
Press the locking button on the hand−held transmitter and then insert the vehicle key into the
ignition lock, switch on the ignition and re−establish communication with the control module.
Current radio key shows the "radio code" of the vehicle key that is presently inserted in the ignition lock.
Compare this radio code with the radio codes at positions 1 to 4.
This comparison allows the position of the lost hand−held transmitter (radio code) to be identified, as one
"radio code" is ultimately left over at positions 1 to 4.
Insert the vehicle key equipped with the new hand−held transmitter into the ignition lock and switch on
the ignition.
Establish communication with the control
module.
Select the identified position using the arrow keys and delete the radio code with the F3
key.
Then press the F8 key.
14. Carefully input the 24 digit code number with the arrow keys and press the double arrow key >> .
15. Check the input and press the F7 key.
Now the handheld transmitter is taught.
16. Go back to the menu item Learning function, remove the key and switch on the ignition again.
Once the key has been removed again, the hand−held transmitter is ready for use.
17. Check handheld transmitter for operation.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Procedure 1157
96 72 19 Removing and installing signal
converter/immobilizer
Removing signal converter/immobilizer
Installing signal converter/immobilizer
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Removing signal converter/immobilizer
Note
• The signal converter on the ignition steering lock housing can be removed through the opening in the
dashboard!

2. Remove left side nozzle. => Removing and installing main light switch
3. Open the locking button with a (short) cross−head screwdriver (1/4 turn counter−clockwise).
4. Pull the signal converter housing out of the holder to the rear.
5. Unlock the electrical plug connection from above and
disconnect.
6. Remove signal converter housing out of the side vent opening.
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96 72 19 Removing and installing signal converter/immobilizer 1158

einordnung
Installing signal converter/immobilizer

1. Close locking button of the signal converter housing (1/4 turn clockwise).
2. Engage electrical plug connections and install side
vent.
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing signal converter/immobilizer 1159

96 85 19 Removing and installing passenger
compartment monitoring sensor
Removing and installing passenger compartment monitoring sensor
Removing and installing passenger compartment monitoring sensor
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Removing and installing passenger compartment monitoring
sensor
1. Using a small screwdriver, carefully unclip both cover lenses at the openings provided.
2. Undo fastening screws M 5 with a cross−head screwdriver −A− .

3. Unclip sensor holder at the rear left and right −B− , push forward towards the windshield and
remove.
5. Unclip passenger compartment monitoring sensor at the side and remove from the sensor
holder.
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Removing and installing passenger compartment monitoring
sensor
Note
• Do not press on or touch the transmission/reception diodes with your fingers!
• The cover lenses must not be soiled or smudged with grease!
1. Engage the electrical plug connections and carefully lay the electrical cables (do not
pinch).
2. Clip in cover lenses again.
96 85 19 Removing and installing passenger compartment monitoring sensor 1160

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing and installing passenger compartment monitoringsensor 1161

97 09 41 Repair of main wiring harness
Note
Removing main wiring harness
Installing main wiring harness
Note
• The combination wires for ABS and BVA are integrated in the wiring harness. In the event of
damage, the integrated wires can be disconnected and replaced by repair wires. The disconnection
points are located at the front left and front right above the radiator tank. After repair, the following
function tests must be performed:
• ABS: Test with the Porsche System Tester 2.
• BVA: The indicator light must go out with the engine running and the brake linings intact.
• Disconnection point, front left: Join wires between the −arrows− with crimp connectors.
• Disconnection point, front right: Join wires between the −arrows− with crimp connectors.
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Removing main wiring harness
1. Take off cover of battery and radiator tank.
3.
97 09 41 Repair of main wiring harness 1162

einordnung
Remove front wheel housing liner. Undo cable ties in the area of the wheel housing, and remove
combination wire.
4. Carefully remove insulating tape from the combination wire in the area of the disconnection point and cut
the old combination wire before the exit to the wheel housing (do not damage any other wires).
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Installing main wiring harness
1. Install repair wire in the wheel housing. Join wires as specified in the table using a crimp connector
and crimping tool (see Workshop Equipment Manual No. 155 − 1).
2. Colour coding of left and right hand sides of wires:
• Wire 1 − br/gn
• Wire 2 − br/bk
• Wire 3 − br
• Wire 4 − br/bu
• Wire 5 − br/wt
• br − brown
• bk − black
• bu − blue
• wt − white
• gn − green
3. Cut wires to the correct length in the area of the disconnection point.
• Combination wire, colour/length (mm):

• br/bk − 20
• br/gn − 40
• br/wt − 60
• br/bu − 80
• br − 100
• Front−end wire, colour/length (mm):
• br/bk − 100
• br/gn − 80
• br/wt − 60
• br/bu − 40
• br − 20
4. Exercise caution when stripping insulation from wiring. Other wires must not be
damaged.
5. Push on the supplied heat−shrinking tubes.
6. Push the large heat−shrinking tube over all wires.
7. Strip 10 mm of insulation off the
wires.
8. Join wires using crimp connector.
9. Shrink shrink−fit hoses with a hot−air gun.
10. It is essential that all wires are watertight.
Removing main wiring harness 1163

einordnung
11. Wrap commercially available PVC tape all around the area of the connection points.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing main wiring harness 1164

97 25 41 Repair of rear wiring harness
Note
Removing rear wiring harness
Installing rear wiring harness
Note
• The combination wires for ABS and BVA are integrated in the wiring harness. In the event of
damage, the integrated wires can be removed and replaced by repair wires. The disconnection point is
the plug connection X 2/4 passenger compartment/rear end (white) or connection points. The plug
connection is situated behind the driver s seat on the left beneath the belt reel.
• After repair, the following function tests must be performed:
• ABS: Test with the Porsche System Tester 2.
• BVA: The indicator light must go out with the engine running and the brake linings intact.
• Plug connection X 2/4, −(Pfeil)− passenger compartment/rear end: Install preassembled contacts or
join wires at connection points.
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Removing rear wiring harness
2. Undo combination wire in the area of the rear wheel housing.
3. Remove trim of seat well and cover of rear side member.
4. Undo rubber grommet, unclip combination wire on inside and open wiring duct.
5. Uncover combination wire in the interior as far as plug connection X 2/4 and disconnect plug
connection (do not damage any other wires).
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97 25 41 Repair of rear wiring harness 1165

einordnung
Installing rear wiring harness

1. Install repair wire in wheel housing and route in the wiring duct as far as plug connection X 2/4.
2. Join wires at the connection points using a crimp connector and crimping tool (see Workshop
Equipment Manual No. 155 − 1). Install preassembled contacts in plug connection X 2/4.
3. Colour coding of left and right hand sides of wires:
• Wire 1 − br/gn
• Wire 2 − br/bk
• Wire 3 − br
• Wire 4 − br/bu
• Wire 5 − br/wt
• br − brown
• bk − black
• bu − blue
• wt − white
• gn − green
4. −Unlocking tool− to unlock the old contacts in the plug connection (see Workshop Equipment
Manual, No. 155).
5. Unlock the old contacts of the combination wire with the unlocking tool, and remove. Install new contacts
of the repair wire in the same location.
6. −Plug connection X 2/4− (white).

7. Combination wire,
rear left:
• Combination wire ABS and BVA in plug connection x 2/4 (white)

• br/wt in pin 16 (ABS)
• br/gr in pin 20 (BVA)
Installing rear wiring harness 1166

einordnung
8. Combination wire, rear right:

• br/bu in pin 19 (ABS)
9. The ground leads of the combination wires (brown) are the same on both right and left. Connection
point No. 48 as shown in circuit diagram.
10. Strip 10 mm of insulation off the wires.
11. Push on heat−shrinking tube.
12. Using a crimp connector, join brown wire of combination wire to brown wire of rear−end wiring harness
13. Shrink heat−shrinking tube with a hot−air gun so that wires are watertight.
14. BVA wire of combination wire (brown/green) at ?connection point No. 47 as shown in circuit diagram.
15. Strip 10 mm of wire.
17. Using a crimp connector, join brown/green wire of combination wire to brown/green wire of rear−end
wiring harness.
19. The BVA wires of the combination wires (brown/black) are the same on both right and left.
Connection point No. 46 as shown in circuit diagram.
20. Strip 10 mm of wire.
22. Using a crimp connector, join brown/black wire of combination wire to brown/black wire of rear−end
wiring harness.
24. Wind commercially available PVC tape around wires.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing rear wiring harness 1167

10 01 19 Removing and installing engine
Tools for removal
Removing engine
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Tools for removal
Item Designation of the Explanation

special tool
1 Engine retainer plate
9111/3
2 Adapter 9111/1
3 Spacer 9111/5 To compensate for the engine retainer plate in the necessary horizontal
position
4 Support plate with Separate the wooden supports and only fasten one half in each case on
wooden supports the support plate
9111/4
5 Additional support Required only for removal or installation with Tiptronic transmission.
9111/6 The additional support prevents the engine−transmission unit from
tilting off the engine plate
10 01 19 Removing and installing engine 1168

einordnung

tool
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Removing engine
1. Read out the fault memory with the Porsche System Tester 2 and print it out if necessary.
3. Install protective supports.
CAUTION
Danger of material damage if the vehicle is raised incorrectly!
• Raise the vehicle at the prescribed jacking points!

• Raise the vehicle by means of a workshop jack on the engine and move the mounting plate of the
lifting platform into the highest position!
Note
• Make sure the outer screw connections for the diagonal braces are accessible!
WARNING
Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand!
• Reduce pressure in the clutch system!

• Actuate clutch pedal at least 25 times for this purpose!
Tools for removal 1169

einordnung
5. Pull off the right and left pressure hoses; to do so, lever off the retaining clips.
6. Undo hexagon−head bolt M6 x 34.
7. Remove the complete air cleaner assembly.
8. In order to remove the pressure pipe, loosen the hexagon−head bolts, the hose clamp and the plug.
9. Disconnect vacuum hose from the switchover valve and remove the switchover valve from the holder.
After removing the presure hose, refit the retaining clip.
Removing engine 1170

einordnung
10. Detach the holder over the air−conditioning compressor.
11. Undo the fuel supply line on the fuel cooler. It is very important to counter when performing this
step.
Union nut a/f 17, counter with a/f 14.
12. Unscrew the hexagon−head bolts M8 x 12 on the belt pulley by approx. half a revolution.
13. Relieve drive belt and remove from the belt pulley of the hydraulic pump.
14. Remove belt pulley.
15. Disconnect the hydraulic lines with plug−in coupling on the expansion tank.
Note
• Wear protective gloves!
• Collect emerging Pentosin!
• Protect the line against dirt and scratches with a cap!
• If hoses come into contact with Pentosin, clean them thoroughly without delay!
Insert tool between line and the red unlocking ring and unlock by pulling black line to the right
and simultaneously pressing the tool against the red unlocking ring.
16. Unscrew the 2 fastening screws (M8 x 25 with hexagon socket head bolts) on the tank.

einordnung
17. Unscrew 3 screws (M8) and 1 screw (M6) between the hydraulic pump and the bracket.
18. Pull the expansion tank with hydraulic pump out of the bracket and lay to the side.
19. Remove throttle body.

20. Remove the compressor.
Note
• Always use the protective support!
Disconnect the electrical plug connection.

Lift out compressor and set it down with the hoses connected.
21. Undo engine wiring harnesses (2 round connectors with bayonet lock) on the right side in the engine
compartment.
22. To do this, turn round plugs counterclockwise and pull them off.
23. Disconnect oxygen sensor plug connections using a screwdriver.

einordnung
24. Disconnect oxygen sensor plug connections on the rear closing panel.
25. Unscrew the stabilizer.

26. Remove the front cross member and both diagonal braces.
27. Remove the rear cross member. To do this, only loosen the two upper hexagon−head bolts (M12 x 83)
(there are slots in the cross member).
Note
• Remove hexagon−head bolts in order to avoid damage to the reference mark sender cable or the oil
tank when the engine−transmission unit is subsequently lowered.
28. Unscrew and remove the halfshafts.
Note
• Always use the protective support!
29. Pull off plug for reversing light on the transmission.

einordnung
30. Detach and remove the transmission support.
31. Detach cardan shaft on transmission flange.
Note
• A second person should counter the cardan shaft when it is being removed!
32. Pull cardan shaft out of the front−axle final drive and set it aside.
33. Disengage shift cables with removal tool (Workshop Equipment Manual, Chapter 2.4, No. 21).
34. Remove starter.
Pull off protective cap.
Detach terminals 30 and 50.
Undo upper fastening screw with 3/8 inch tool, two short extensions, universal joint, hexagon
wrench insert a/f 15.
Undo the lower fastening screw.
Remove
starter.
35. Loosen both intake pipes on the exhaust turbocharger.

Also disconnect the plug for the boost pressure check on the left hand side.
Remove intake
pipes.

einordnung
36. Undo ground strap between engine and right side member (in area above cylinder 6).
37. Disconnect the clutch pressure line.
WARNING
Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand!
• Reduce pressure in the clutch system!

• Actuate clutch pedal at least 25 times!
Note
• The joint is located on the rear left side member (inside)!
• When undoing the screw coupling at the screw connection −A− , counter simultaneously at screw
connection −B− !
Disengage lead out of the holder.

Plug
lines.
38. Screw closure cap off coolant expansion tank.
39. Undo coolant drain plug on right and left and drain the coolant.
40. Equip drain plugs with new sealing rings.
Tightening torque: 10 + 5 Nm (7.5 + 3.5 ftlb.)

einordnung
41. Remove coolant hoses.

42. Place workshop jack and preassembled engine retainer plate underneath with slight load.
Spacer 9111/5 fitted
Engage support lever in horizontal

position.
43. Undo transmission support.
44. Separate engine carrier from the engine mounts (wrench size 18).
45. Carefully and in steps, lower the engine−transmission unit by approx. 10 cm.
46. The following parts must be undone or removed from this position:
Disconnect plug connection of tank vent.
Press unlocking buttons and simultaneously pull off the line.
47. Disconnect vacuum line for the brake booster

einordnung
Remove snap ring of vacuum line for the brake

booster.
Push the inner sleeve −(arrow 1)− against the outer sleeve −(arrow 2)− and pull off both sleeves together
in the direction of the arrow.
Undo the fuel supply line (1) and fuel return line (2) in the engine compartment (left).
Disengage fuel
filter.
Note
• Always counter when undoing the fuel supply line and fuel return line!
48. The intake air distributor is detached from the engine and remains in the engine compartment.
49. Undo the hose clamp and remove from the intake air distributor.

einordnung
50. Undo the hexagon−head bolt and lift the complete intake air distributor up and out of the support pins.
51. Suspend intake air distributor in the engine compartment.
Note
• While lowering, have a second person observe the engine−transmission clearance, especially in the
area of the oil container and the detached intake air distributor!
• If the vehicle is placed on its wheels or moved in the workshop, the rear cross member should be
refitted under all circumstances to maintain the structural strength!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

10 01 19 Removing and installing engine
Installing engine
Tightening torques: Removing and installing engine
top of page
Installing engine
Note
• The engine−transmission unit is installed in the reverse order. The following points must be given
special attention!
1. Lift the engine−transmission unit carefully and in steps.
Note
• Have a second person observe the engine−transmission clearance during lifting!
• Pay particular attention to the clearance between rear axle cross member, intake air distributor and oil
container!
2. The following assembly work must be carried out before the final installation position is reached:
Fasten lower coolant hose to expansion tank.
Position the intake air distributor on the support pins and simultaneously fit the line of the
switch−over valves. Fasten the hexagon−head bolt.
3. Fasten vent line on the intake air distributor.
10 01 19 Removing and installing engine 1179

einordnung
Fasten fuel filter, fuel supply line (1) and fuel return (2). Tighten the fuel supply line to 30 to 35 Nm (22
to 26 ftlb.) and the fuel return line to 25 Nm (19 ftlb.).
After the screw union of the fuel return line has been retightened, there must be a minimum distance
of A = 20 mm between the holders of the spring band clamps and the fuel line. If necessary, set this
distance with a spacer during the tightening process.
Push on vacuum line for the brake booster and fit plastic snap ring.
4. Fit engine wiring harness.
The round plugs are colour−coded on the inside:
upper round plug − black
lower round plug − grey
Line up marking of the round connector with marking on the

housing.
Installing engine 1180

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Turn round connector clockwise by approx. 90° (bayonet lock).
5. Insert spacer sleeve.

6. Fit air−conditioning compressor.
7. Fit drive belt.
Note
• Observe sequence when fitting the belt!
8. Fit coolant hoses with new O−rings and plenty of

water.
9. Attach the safety brackets onto the coolant supports before engaging the coolant hoses.
10. Move coolant hoses into installation position.
Note
• The coolant hoses must audibly engage when pushed into the flanges!
11. Fit pressure hoses between the charge air cooler and throttle body with new O−rings and wet with
plenty of water.
12. Attach the safety brackets (locking springs) onto the pressure pipe before engaging the pressure hoses.
Note
• The pressure hoses must audibly engage!
13. Check correct seating by pulling gently.
Installing engine 1181

einordnung
14. Fit crash support again. Coat the fastening screws with Loctite 574 and fasten. Tightening torque 23 Nm
(17 ftlb.).
15. Bleed steering system.
16. Bleed cooling system with the System Tester 2, under menu item "Special functions"
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Tightening torques: Removing and installing engine

Engine mount to engine carrier M12 85 (63)
Wheel to wheel hub M14 130 (96)
Rear−axle member to carrier side section M12 110 (81)
Cross member at front to carrier side section M10 65 (48)
Diagonal brace to body M10 65 (48)
Diagonal brace to cross member M12 110 (81)
Diagonal brace to carrier side section (collar nut) M10 23 (17)
Stabilizer to stabilizer mount M10 46 (34)
Ground strap to body M8 23 (17)
Fuel return line M14 25 ± 5 (19 ± 3.5)
Fuel supply line M16 30 + 5 (22 + 3.5)
Coolant drain plug M10 10 + 5 (7.5 + 3.5)
Cardan shaft on transmission flange M10 46 (34)
Clutch pressure line 30 (22)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Tightening torques: Removing and installing engine 1182

24 40 20 Removing and installing injection valves −
Engine removed
Caution
Removing injection valves of cylinder bank 1 3
Installing injection valves of cylinder bank 1 3
WARNING
fuels! => Precautionary measures when working on fuel system
Note
• Observe installation position of peripheral equipment! => Removing and installing injection valves −
Engine installed.
• As fuel may emerge from the fuel collection pipe, a cloth or similar should be placed around the
injection valves.
top of page
1. Remove connectors of the injection valves.
2. Remove the cable duct from the fuel collection pipe.
3. Unscrew the 2 M6 hexagon−head bolts from the fuel collection pipe.
4. Carefully pull the fuel collection pipe upwards until the injection valves are free.
5. Pull out the tab washers −A− of the injection valves.
6. Carefully pull out the injection valves −B− .
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24 40 20 Removing and installing injection valves − Engine removed 1183

einordnung

Requirement:
Remove the secondary air pump => Removing and installing secondary air pump.
2. Remove the cable duct from the fuel collection pipe.
3. Unscrew the 2 M6 hexagon−head bolts from the fuel collection pipe.
4. Carefully pull the fuel collection pipe upwards until the injection valves are free.
5. Pull out the tab washers of the injection valves
−A− .
6. Carefully pull out the injection valves −B− .
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Note
• If the injection valves are not replaced, the sealing rings of the injection valves must be checked and
replaced, if necessary!
1. Coat the sealing rings of the injection valves slightly with

Vaseline.
2. Press the injection valves carefully into the cylinder head.
3. Press the fuel collection pipe ont to the injection valves −A− .
4. Install the tab washers −B− of the injection valves. Ensure correct
seating.
5. Fasten the fuel collection pipe. To do so, screw in and tighten the two M6 screws.
6. Clip the cable duct to the fuel collection pipe.
Removing injection valves of cylinder bank 4 6 1184

einordnung
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Note
• If the injection valves are not replaced, the sealing rings of the injection valves must be checked and
replaced, if necessary!

Vaseline.
2. Press the injection valves carefully into the cylinder head.
3. Press the fuel collection pipe ont to the injection valves −A− .
4. Install the tab washers −B− of the injection valves. Ensure correct
seating.
5. Fasten the fuel collection pipe. To do so, screw in and tighten the two M6 hexagon−head
bolts.
6. Clip the cable duct to the fuel collection pipe.
7. Install secondary air pump => Removing and installing secondary air pump.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing injection valves of cylinder bank 1 3 1185

24 40 20 Removing and installing injection valves −
Engine installed
Caution
Preliminary work
Installing injection valves
WARNING
fuels! => Precautionary measures when working on fuel system
WARNING
The battery must be disconnected when working on electrical components.
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Preliminary work
1. Read out the fault memory with the Porsche System Tester.
2. Find out the radio code.
4. Remove rear spoiler ’ 63 55 19 Removing rear
spoiler .
5. Remove air cleaner housing => Removing and installing air cleaner.
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1. Pull off the connecting hoses between the charge air coolers and the Y−shaped pressure pipe. To
do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips
immediately.
purpose.
3. Undo the hose of the Y−shaped pressure pipe. To do so, undo the hose clamp −arrow− and pull the
hose off the Y−shaped pressure pipe.
24 40 20 Removing and installing injection valves − Engine installed 1186

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4. Remove the Y−shaped pressure pipe. To do so, undo the hose clamps −3 and 5− and the
hexagon−head bolts −1 and 2− . Pull off pressure sensor plug −4− .
5. Remove the three−phase generator => Removing and installing three−phase generator.
6. Remove box for connector. Unscrew the two M6 screws and lay the box to one
side.
CAUTION
• Do not lower engine too far!

• To avoid damage to the hoses, leads and engine, the engine must only be lowered by approx. 30 mm
− 40 mm!
7. Lower engine. Secure the engine against falling down with a workshop jack. Undo the two hexagon
nuts on the right and left of the engine mount. Lower engine by max. 30 mm − 40 mm.
8. Undo the hose −arrow− on the left pressure pipe. To do so, undo the hose clamp and pull the hose
−arrow− off the pressure pipe.

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9. Disconnect the connector of the overrun air valve module −arrow− and pull off the two vacuum hoses
−arrow− .
10. Undo the hose clamp on the left pressure pipe and remove the entire overrun air valve module
−Figure− .
11. Pull the vent line off the coolant expansion tank.
12. Remove fuel filter => Replacing fuel filter.
13. Loosen and unscrew the three fastening screws −arrows− at the front intake pipe connector.
14. Remove hose clamp and pull off ventilation hose from the intake pipe.

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15. Undo the upper fastening screw −right arrow− . Lift the intake pipe out of the shaft bolt −left arrow−
and remove towards the rear of the vehicle. Remove the seal.
16. Disconnect the activated carbon filter lead. To do so, disconnect the coupling −arrow− .
17. Pull off the connector −1− of the camshaft adjustment valve.
Note
• With all fuel lines, always counter with a second open−ended wrench!
18. Disconnect the fuel return line −2− (a/f 14 and 17). Unscrew the M6 screw in the holder −3− .
19. Disconnect the fuel supply line −4− (a/f 17 and 19).
20. Disconnect the fuel line −5− (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 − 6.
21. Unclip the cable duct on the fuel collection pipe and lay it as far as possible to the side.

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22. Undo the fuel collection pipe. Unscrew the two M6 screws −arrows− on the fuel collection pipe for this
purpose.
24. Carefully pull out the fuel collection pipe with the injection valves.
25. Pull off the tab washers of the injection valves −A− and pull the injection valve −B− out of the fuel
collection pipe.
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1. Remove rear right wheel housing liner.
2. Remove charge air cooler module.
3. Remove rear right heat insulation plate.
CAUTION
• Do not lower engine too far!

• To avoid damage to the hoses, leads and engine, the engine must only be lowered by approx. 30 mm
− 40 mm!
4. Lower engine. Secure the engine against falling down with a workshop jack. Undo the two hexagon
nuts on the right and left of the engine mount. Lower engine by max. 30 mm − 40 mm.
5. Disconnect the connectors of the ignition coils of cylinders 5
and 6.
6. Pull off the connectors for the valve lift adjustment valve and the hall
sender.
7. Remove the pressure hoses on the left and right of the Y−shaped pipe to the charge air cooler. To
do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips
immediately.

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purpose.
9. Remove the Y−shaped pressure pipe. To do so, undo the hose clamps −3 and 5− and the hexagon−head
bolts −1 and 2− . Disconnect pressure sensor plug −4− .
10. Disconnect the connectors of the main wiring harness −arrows− in the engine compartment on the
right and lay to one side.
11. Remove the secondary air pump => Removing and installing secondary air pump.
12. Pull off the vacuum hose on the fuel pressure regulator and lay it to one side.
13. Disconnect the fuel supply line −1− (a/f 19 and 22) and the fuel return line −2− (a/f 17 and 19).
14. Undo the cable duct at the fuel collection pipe.

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15. Undo the fuel collection pipe. Unscrew the two M6 screws −3− for this purpose.
Note
• When removing the fuel collection pipe, lever it up very carefully and pay attention to all leads in
order to avoid any damage!
16. First raise the fuel collection pipe carefully at cylinder 4, then at cylinder 6.
17. Raise the cable duct as far as possible, pull off the connectors of the injection valves and remove the
fuel collection pipe.
18. Remove the tab washers of the injection valves and pull the injection valves out of the fuel
collection pipe.
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Installing injection valves
1. Always fit new sealing rings on the injection valves.
Vaseline.
3. Press the injection valves into the fuel collection pipe −A− and then install the tab washers −B− . Align
the injection valves so that the lugs on the valves and the lugs on the fuel collection pipe lie directly above
one another. Ensure that the tab washers are seated correctly.
Installing injection valves 1192

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Note
• When installing the fuel collection pipe, make sure that the injection valves are not damaged or
soiled!
4. Place the fuel collection pipe with the injection valves of cylinder bank 4 − 6 in position on the right
intake distributor. Connect connectors of the injection valves. Carefully insert the injection valves
into the openings in the intake pipe.
5. Fasten the fuel collection pipe. Put on and tighten the two M6 screws −3− for this purpose.
Note
6. Position and tighten the fuel supply line −1− (a/f 19 and 22).
7. Connect the vacuum hose to the fuel pressure regulator.

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8. Position and tighten the fuel return line −2− (a/f 17 and 19).
9. Connect the cable duct to the fuel collection pipe. Ensure correct seating.
10. Connect hall sender connector.
11. Fit the connectors of the main wiring harness −arrows− in the engine compartment on the right.
12. Connect the connectors of the ingition coils of cylinder 5 and 6 and the connector of the valve lift
adjustment valve.
13. Place the fuel collection pipe with the injection valves of cylinder bank 1 − 3 in position on the left intake
distributor. Connect connectors of the injection valves. Carefully insert the injection valves into the
openings in the intake pipe.
14. Fasten the fuel collection pipe. Put on and tighten the two M6 screws −arrows− on the fuel collection
pipe for this purpose.
15. Connect the cable duct to the fuel collection pipe. Ensure correct seating.
Note

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16. Position and tighten the fuel line −5− (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 − 6.
17. Position and tighten the fuel supply line −4− (a/f 17 and 19).
18. Position and tighten the fuel return line −2− (a/f 14 and 17). Position the M6 screw in the holder −3−
, but do not tighten yet.
Tightening torque, return line 30 Nm (22 ftlb.)
19. Connect plug of camshaft adjuster −1− .
Note
• In order to check the fuel system for leaks, the following operations must be carried out!
20. Install fuel filter.

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21. Connect together the plug connection of the activated carbon filter lead. The plug must engage
audibly. Pull slightly to ensure that the connection is properly locked.
Note
• None of the electrical connections of the three−phase generator nor any of the other plug connections
may come into contact with the body or any other components!
22. Install the B+ lead and the plug connection on the three−phase generator. Lay the three−phase
generator aside. Make sure that the connections do not come into contact with the body or any
other components.
24. Connect the Porsche System Tester and switch on the ignition.
25. Then activate the fuel pump with the Porsche System Tester and allow the pump to run for approx. 2 − 3
min.
26. Disconnect battery.
27. Remove the three−phase generator. To do this, disconnect the B+ wire and the plug.
28. Remove fuel filter.
29. Install secondary air pump.
30. Install the rear right heat insulation plate.
31. Install charge air cooler module.
32. Install rear right wheel housing liner.
33. Insert new seal at the intake pipe connector.
34. Place the intake pipe in position on the shaft bolt −left arrow− .

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35. Connect the vent hose. Tighten hose clamp −arrow− .
36. Position and tighten the three screws at the front intake pipe connector.
37. Position and tighten the upper screw −right arrow− .

38. Tighten the M6 screw in the holder −3− .


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39. Tighten the hose −arrow− on the left pressure pipe. To do so, push the hose −arrow− on and
tighten the screw−type hose clamp.
40. Install the overrun air valve module −Figure− .
41. Connect the connector of the overrun air valve module −arrow− and push on the two vacuum hoses
−arrow− .
42. Install fuel filter ’ 20 60 55 Installing fuel filter .
43. Connect the vent line of the coolant expansion tank. Fasten hose clamp.
44. Fasten the engine to the engine mounts again. To do so, raise the lowered engine with the workshop
jack to its final position, position and the tighten both the collar nuts.
Tightening torque of collar nuts 85 Nm (63 ftlb.)
45. Install box for connector. Put on and tighten the two M6 screws −arrows− for this purpose.
46. Install three−phase generator ’ 27 22 19 Installing the three−phase generator .

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47. Press the Y−shaped pressure pipe into the air cowl of the throttle body, connect the hoses −3 and 5−
and fasten the hose clamps. Connect the connector of the pressure sensor −4− and position and
tighten the M6 screws −1 and 2− .
48. Install the holder over the air−conditioning compressor. Position and tighten the M6 screw in the holder
for this purpose.
49. Connect hose to the Y−shaped pipe and fasten with the hose clamp −arrow− .
50. Install the connecting hoses between the charge air coolers and the Y−shaped pressure pipe; the
connecting hoses must engage audibly.
51. Install air cleaner housing => Removing and installing air cleaner.
52. Install rear spoiler ’ 63 55 19 Installing rear spoiler .
55. Enter radio code.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 69 19 Removing and installing oxygen sensors in
front of catalytic converter
Tools
Removing oxygen sensors in front of catalytic converter
Installing oxygen sensors in front of catalytic converter
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Tools

Open ring wrench for oxygen sensor Hazet 4681−3 Gr. 2.4; No. 98 Workshop
Equipment Manual
Torque wrench 1/2 " Wille 730 R/12 or Torque wrench 1/2 Gr. 2.4; No. 90 Workshop
" Hazet 6291−1CT Equipment Manual
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Removing oxygen sensors in front of catalytic converter
24 69 19 Removing and installing oxygen sensors in front of catalytic converter 1200

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Illustration shows oxygen sensors on the right side
• −1− Oxygen sensor in front of catalytic converter on the right side

• −2− Oxygen sensor behind catalytic converter on the right side
Oxygen sensor plug
• −1− Plug for sensor in front of catalytic converter with plastic clip (rectangular)
• −2− Plug for sensor behind catalytic converter (oval)
Note
• Observe precautionary measures when using oxygen sensors !
Oxygen sensor, left side :
2. Separate the rectangular plug connection for the oxygen sensor in front of the catalytic converter in the
left engine compartment −1− . To do this, first open the plastic securing clip.
Removing oxygen sensors in front of catalytic converter 1201

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3. Unclip the oxygen sensor wire in front of the catalytic converter from the wire retainer and the sheetmetal
clips.
Note
Oxygen sensor, right side :
2. Separate the rectangular plug connection for the oxygen sensor in front of the catalytic converter
−1− . To do this, first open the plastic securing clip.
3. Unclip the oxygen sensor wire in front of the catalytic converter from the wire guide and the sheetmetal
clips.
Note
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Installing oxygen sensors in front of catalytic converter
The oxygen sensor is installed in reverse sequence.
Note
• Always expose oxygen sensor wire so that the wire can turn when screwing in the sensor.
1. Position the oxygen sensor by hand and screw in as far as

possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681−1 and torque wrench.
Oxygen sensor, left side : 1202

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Oxygen sensor in front of catalytic converter on left side
Oxygen sensor in front of catalytic converter on right side
Tightening torque: 55 ± 5 Nm (41 ± 4.0 ftlb.)

3. Lay oxygen sensor wire and fix in the sheetmetal clips and wire retainers on the left and right.
4. Close rectangular plug connections and secure with plastic clip.
5. Install the air cleaner housing again => Removing and installing air cleaner.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing oxygen sensors in front of catalytic converter 1203

24 70 19 Removing and installing DME control
module
Obtaining read−out and saving vehicle data from DME control
module
Removing DME control module
Installing the DME control module
Programming the new DME control module 911 Turbo (996)
Programming the new DME control module − GT2 and version
X51
Programming the DME control module 911 Turbo (996)
Programming DME control module − GT2 and version X51
Version (data records) 911 Turbo (996)
Version (data records) − GT2
24 70 19 Removing and installing DME control module 1204

einordnung
Note
• If the DME control module is replaced, it must be programmed using the Porsche System Tester.
Thus, the DME control module can be adapted to the vehicle, the national variant and the equipment.
The DME control module is located behind the right rear seat.
• If possible, before the DME control module is removed and replaced, a read−out of the vehicle data
should be obtained from the Porsche System Tester.
• Symbol for the TAB key = ’|
• Follow the instructions for the Porsche System Tester.
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Obtaining read−out and saving vehicle data from DME control
module
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. >> to
continue.
2. Select vehicle type using the cursor keys.
3. Using the ’| key, move from the vehicle type to the list of control units.
4. Select DME with the cursor keys and press the >> key.
5. Select "Control unit programming" with the cursor keys and press the >> key.
6. Select "Read−out control unit (vehicle data)" with the cursor keys and press the >>
key.
7. The message "Vehicle data read−out complete" will appear on the screen of the Porsche System Tester.
8. After replacement of the DME control module, the vehicle data is installed in the menu "Program
control unit" (see Section 6).
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Removing DME control module
Note
• Switch ignition off and remove ignition key.
1. Fold the backrests of the rear seats forward.

2. Lift the carpet lining up and remove.
Obtaining read−out and saving vehicle data from DME control module 1205
einordnung
3. Unscrew fastening screw −1− and loosen fixing nut −2− .

4. Turn over the control module holder −3− .
5. Push in connectors −A− −arrow− and pull out.

6. Push in locking element −arrow− of connectors −B− and actuate the latching lever −4− .
7. Unscrew 4 fastening screws on the control module holder −3− and remove the control module.
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Installing the DME control module
1. Fasten the control module on the control module holder with the four fastening screws. Tightening
torque: 10 Nm (7.5 ftlb.).
2. Push in connectors −B− on the DME control module and close the latching lever −4− until the lever
engages.
3. Press in plugs −A− on the control module, until they engage.
Removing DME control module 1206

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4. Turn over the control module holder −3− and push it in under the fastening nut −2− . Tighten both
fastening screws −1− and the fastening nut −2− . Tightening torque: 10 Nm (7.5 ftlb.).
5. Place carpet lining in position, paying attention to the fitted
shape.
6. Program the DME control module with the Porsche System Tester. => Programming the new DME
control module 911 Turbo (996) => Programming the new DME control module − GT2 and version X51
=> Programming the DME control module 911 Turbo (996) => Programming DME control module −
GT2 and version X51
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Programming the new DME control module 911 Turbo (996)
Note
• If a new DME control module is to be installed in a vehicle, the DME code specified in IPAS and the
immobilizer code must be entered in the DME control module.
• You can get the codes from IPAS or from your importer by specifying the vehicle identification
number.
• During DME programming, it is essential to guarantee the power supply for the Porsche System
Tester. In case of doubt, connect a charging unit to the vehicle battery.
• Symbol for the TAB key = ’| .
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on.
2. Select vehicle type using the cursor keys. In the 911 Turbo − 911 (996).
6. Select "Control unit programming with the cursor keys and press the >> key. Follow the
displayed programming instructions from the Porsche System Tester.
7. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7.
8. Enter the new DME (IPAS) programming code and confirm with the >> key.
9. Check the DME programming code again; if the code is correct, confirm with the F7 key.
10.
Installing the DME control module 1207

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Enter the new immobilizer code (IPAS), confirm with the >> key, check the code again and confirm
with the F7 key.
11. Select the required program map and confirm with the >> key. => Version (data records) 911 Turbo
(996)
12. The data and programming status is then loaded on to the DME control module. Do not interrupt
the programming sequence.
13. When the programming period has expired, follow the instructions from the Porsche System
Tester − CAN TIME OUT −.
14. Press the >> key. For the learning and adaptation routine of the throttle (E−gas), switch the
ignition on for 1 minute without starting the engine and without actuating the accelerator pedal.
Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle
adjusting unit and the programming sequence is complete.
15. Read out the fault memory and delete the fault − CAN TIME OUT − on every control unit that is
connected to the CAN.
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Programming the new DME control module − GT2 and version
X51
Note
• If a new DME control module is to be installed in a vehicle, the DME code specified in IPAS and the
immobilizer code must be entered in the DME control module.
number.
• In the case of the GT2, a Key 1 code is displayed in the Porsche System Tester (see Point 12); in
addition, a Key 2 code is required (see Point 15) in order to be able to transfer the data status required
for this vehicle type.
• Determine the Key 1 code by following the described procedure and finish with << . After receiving
the Key 2 code, begin again at Point 1.
• It is possible to program a GT2 DME control module as from Porsche System Tester Version 11.1.
2. Select vehicle type − GT2 − using the cursor keys.
3. Using the ’| key, move from the vehicle type to the list of control modules.
Programming the new DME control module 911 Turbo (996) 1208
einordnung
5. Select Control unit programming with the cursor keys and confirm with the >> key.
7. Enter the Veh. Ident. No. with the cursor keys and confirm.
8. Enter the new DME (IPAS) programming code and confirm with the >> key.
9. Check the DME programming code again; if the code is correct, confirm with the F7 key.
10. Enter the new immobilizer code (IPAS), check it again and confirm with F7.
11. Select the required program map and confirm with the >> key => Version (data records) − GT2
12. With the GT2, a Key 1 code is displayed in the Tester, which is automatically stored in the release
protocol.
13. With the ALT key (Hard copy), move into the Printer menu, select the release protocol and print it out.
14. The name and telephone number of the contact person must be noted on the release protocol. Fax the
protocol to Porsche AG, Dept. VAC1, fax no. 0049/711/911−8570.
15. A Key 2 code is then delivered to you by Dept. VAC1. Enter the Key 2 code with the cursor keys,
continue with the >> key and, after checking the Key 2 code, confirm it with the F7 key.
16. The data and programming status is then loaded on to the DME control module. Do not interrupt
the programming sequence.
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Programming the DME control module 911 Turbo (996)
Note
• If the DME control module from a different 911 Turbo (996) vehicle is being used, proceed as
follows. As a check, the DME code and the immobilizer code of the vehicle in which the control
module is being installed (NEW) and of the vehicle from which the control module has been removed
(OLD) are required.
• You can get the necessary codes from IPAS or from your importer by specifying the vehicle
• When programming maps, update the data records. Procedure is similar to − Control unit
programming −. Follow the instructions from the Porsche System Tester => Version (data records)
Programming the new DME control module − GT2 and versionX51 1209
einordnung
911 Turbo (996).
2. Select vehicle type using the cursor keys. In the 911 Turbo − 911 (996).
8. Enter the old DME (IPAS, vehicle − OLD) programming code with the cursor keys, continue with the
>> key and, after checking the code, confirm with F7.
9. Enter the new DME (IPAS, vehicle − NEW) programming code with the cursor keys, continue with the
>> key and, after checking, confirm with F7.
10. Enter the old immobilizer code (IPAS, vehicle − OLD), continue with the >> key, check the code again
and confirm with F7.
11. Enter the new immobilizer code (IPAS, vehicle − NEW), continue with the >> key, check the code
again and confirm with F7.
12. Select the required program map and confirm with the >> key. => Version (data records) 911 Turbo
(996)
13. The data status is loaded on to the DME control module. Do not interrupt the programming sequence.
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Programming DME control module − GT2 and version X51
Note
• X51 − increased performance.
• If the DME control module from a different GT2 vehicle is being used, proceed as follows. As a
check, the DME code and the immobilizer code of the vehicle in which the control module is being
installed (NEW) and of the vehicle from which the control module has been removed (OLD) are
required.
• You can get the necessary codes from IPAS or from your importer by specifying the vehicle
Programming the DME control module 911 Turbo (996) 1210

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• In the case of the GT2, a Key 1 code is displayed in the Porsche System Tester (see Point 13); in
addition, a Key 2 code is required (see Point 16) in order to be able to transfer the data status required
for this vehicle type.
• Determine the Key 1 code by following the described procedure and finish with << . After receiving
the Key 2 code, perform the following instruction.
• It is possible to program a GT2 DME control module as from Porsche System Tester Version 11.1.
• When programming maps, update the data records. Procedure is similar to − Control unit
programming −. Follow the instructions from the Porsche System Tester => Version (data records) −
GT2.
2. Select vehicle type GT2.
8. Enter the old DME (IPAS, vehicle − OLD) programming code with the cursor keys, continue with the
>> key and, after checking the code, confirm with F7.
9. Enter the new DME (IPAS, vehicle − NEW) programming code with the cursor keys, continue with the
>> key and, after checking, confirm with F7.
10. Enter the old immobilizer code (IPAS, vehicle − OLD), continue with the >> key, check the code again
and confirm with F7.
11. Enter the new immobilizer code (IPAS, vehicle − NEW), continue with the >> key, check the code
again and confirm with F7.
12. Select the required program map and confirm with the >> key. => Version (data records) − GT2
13. With the GT2, a Key 1 code is displayed in the Tester, which is automatically stored in the release
protocol.
14. With the ALT key (Hard copy), move into the Printer menu, select the release protocol and print it out.
15. The name and telephone number of the contact person must be noted on the release protocol. Fax the
protocol to Porsche AG, Dept. VAC1, fax no. 0049/711/911−8570.
16. A Key 2 code is then delivered to you by Dept. VAC1. Enter the Key 2 code with the cursor keys,
continue with the >> key and, after checking the Key 2 code, confirm it with the F7 key.
17. The data status is loaded on to the DME control module. Do not interrupt the programming sequence.
Programming DME control module − GT2 and version X51 1211

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Version (data records) 911 Turbo (996)
Note
• The table shown is included in the software status 11.0, Porsche System Tester 2.
• Later software versions may feature expanded contents.
• Under the heading − DME, Control unit programming, Control unit type − it is possible to check
whether the data record for this vehicle is up−to−date or not.
• In the case of − Not up−to−date − the data record can be updated with − Program map −. The
prerequisite is that a customer complaint has been submitted or that Porsche AG has arranged for this
to be done in the context of a campaign.
• In the case of − Up−to−date − the data record and the version are displayed.
Type/Diagnosis software Version Remarks

no.
M 150/2201 Manual Countries with leaded fuel
transmission
Tiptronic
EOBD/Japan/Australia Manual European On−Board Diagnosis. Rest of the world
transmission vehicles, including Europe (EU 3)
Tiptronic For Japan/Australia.
EOBD/2301 Manual European On−Board Diagnosis. Rest of the world
transmission vehicles, including Europe (EU 3) and Germany (EU
Tiptronic 3/D4).
OBD II/2101 LEV, manual Low Emission Vehicle, USA
transmission
LEV, Tiptronic
X51/M 150/5301 Manual Countries with leaded fuel
transmission
Tiptronic
X51/EOBD/Japan/Australia Manual European On−Board Diagnosis. Rest of the world
transmission vehicles, including Europe (EU 3)
Tiptronic For Japan/Australia.
X51/EOBD/5401 Manual European On−Board Diagnosis. Rest of the world
transmission vehicles, including Europe (EU 3) and Germany (EU
Version (data records) 911 Turbo (996) 1212

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Tiptronic 3/D4).
X51/OBD II/5201 Manual Low Emission Vehicle, USA
transmission
Tiptronic
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Version (data records) − GT2
Note
• The table shown is included in the software status 12.0, Porsche System Tester 2.
• Later software versions may feature expanded contents.
• Under the heading − DME, Control unit programming, Control unit type − it is possible to check
whether the data record for this vehicle is up−to−date or not.
• In the case of − Not up−to−date − the data record can be updated with − Program map −. The
prerequisite is that a customer complaint has been submitted or that Porsche AG has arranged for this
to be done in the context of a campaign.
• In the case of − Up−to−date − the data record and the version are displayed.
Type/Diagnosis software version Version Remarks

no.
GT2/5601 model '01 M 150 Countries with leaded fuel
5901 as from model '02
GT2 00/EOBD EU 3 Japan/Australia
5501 model '01
GT2/EOBD EU 3 Rest of the world vehicles, including Europe (EU
5501 model '01 3) and Germany (EU 3/D4)
GT2/OBD II LEV Low Emission Vehicle, USA
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Version (data records) − GT2 1213

27 60 19 Removing and installing starter (automatic
transmission)
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2. Disengage the parking brake cable from the left side behind the parking brake lever and push it back
into the guide.
3. Remove the cover under the automatic transmission.
4. Undo the cross member (2 screws M10) and pull the parking brake cable out of the
guide.
5. Disengage both the coolant lines for the heating under the automatic transmission (3 plastic holders).
6. Detach the sheetmetal holder from the transmission flange lid (1 screw
M6).
7. Disengage the sheetmetal holder and the plastic holder from the coolant
hoses.
8. Pull the coolant lines under the front transmission mount and allow them to hang
down.
9. Pull back protective cap on the solenoid switch and undo terminal 30 lead (M8 nut) and terminal 50 (M6
nut).
10. Pull protective cap off the B+ lead.
In order to undo the fastening screws, use a 3/8−inch tool.
11. Undo the upper M10 fastening screw. Tools:

• Short extension, approx. 130 mm long
• Universal joint
• 2 long extensions
12. Undo the lower M10 fastening screw. Tools:
27 60 19 Removing and installing starter (automatic transmission) 1214

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• Universal joint
• 2 long extensions
13. Press the coolant hoses to one side and carefully remove the starter downwards from the holder.
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1. Install and fasten starter. Fasten B+ lead from the battery and B+ lead from the engine B+ disconnection
point to terminal 30 (M8 nut) on the solenoid switch.
2. Fasten terminal 50 lead (M6 nut) to the solenoid switch.
Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.), M6 screw: 6.5 Nm (5 ftlb.)
Tightening torque of the hexagon−head bolt M10: 46 Nm (34 ftlb.)
3. Push protective cap over the solenoid switch and engage in the B+ lead.
4. Fasten the sheetmetal holder on the transmissioin flange lid and engage the plastic
holder.
5. Fasten the coolant lines under the automatic transmission and install the cross
member.
6. Install the parking brake cable and fasten the cover under the automatic
transmission.
test.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing the starter 1215

34 35 37 Partially disassembling transmission
Note
Tools
Removing transmission cover
Disassembling front gear set
Removing gear housing
Removing input and output shaft
Dismantling input shaft
Note
• If the transmission to be opened is still in the guarantee period (3 years), the letter −R− must be
imprinted after the transmission number.
Note
• Use the Damage Catalogue to diagnose the damage in the transmission.
top of page
Tools

A Socket wrench insert Special tool socket wrench insert 9105
B Socket wrench insert Commercially available; refer to Workshop Equipment
34 35 37 Partially disassembling transmission 1216

einordnung
C Retaining device Special tool retaining device 9253

D Socket wrench insert Special tool socket wrench insert 9282
E Pressure piece Special toolpressure piece 9656
F Two−armed extractor, span 250 Commercially available; refer to Workshop Equipment
G Separator 17 − 75 cm Commercially available; refer to Workshop Equipment
H Two−armed extractor, span 120 Commercially available; refer to Workshop Equipment
J Puller hook, 400 mm long Commercially available; refer to Workshop Equipment
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transmission.
2. Fasten the transmission on assembly support.
3. Drain transmission oil ’ 34 01 55 Changing transmission oil.
4. Fix the transmission with special tool retaining device 9253 and shift into a gear.
5. Unscrew the fastening nut for the cardan shaft flange with a commercially available socket wrench
insert Workshop Equipment Manual, Chapter 2.4, No. 64 .
6. If necessary force cardan shaft flange off with a rubber hammer.
7. Unscrew fastening screws for front transmission case cover and force transmission case cover off
with a rubber hammer if necessary.
top of page
Overview
Tools 1217
einordnung
No. Designation Qty.

1 Sleeve 1
2 Hexagon nut (self−locking) 1
3 Cylindrical−roller bearing 1
4 Thrust plate 1
5 Loose gearwheel, reverse gear 1
6 Synchronising ring 1
7 Needle−roller bearing 1
8 Bearing inner race 1
9 Shift collar 1
10 Washer 2
11 Hexagon−head bolt 2
12 Shift fork (reverse gear) 1
13 Spring 3
Overview 1218
einordnung
14 Ball 3
15 Driver dog 3
16 Guide sleeve with snap ring 1
17 Loose gearwheel, 5th gear 1
21 Shift collar 1
22 Driver dog 3
23 Ball 3
24 Spring 3
25 Guide sleeve 1
26 Shift fork (5th and 6th gears) 1
31 Thrust plate 1
34 Fixed gearwheel, reverse gear 1
35 Spacer sleeve 1
36 Fixed gear wheel, 5th gear 1
37 Spacer sleeve 1
38 Fixed gearwheel, 6th gear 1
39 Housing 1
Disassembling gear set
Note
• All needle−roller bearings which are not replaced must be designated in terms of the installation
position and allocation to the gear wheel.
1. Remove transmission cover.
Disassembling gear set 1219

einordnung
2. Remove nut −A− on input and output shaft.

3. Unscrew clamping screw from shift forks −B− .
4. Remove fixed gearwheel for reverse gear (no. 34 in overview) from the input shaft using the puller and
special tool pressure pieces 9656 . When doing so, pull off bearing inner race (no. 33 in overview).
5. Remove spacer sleeve (no. 35 in overview) from the input shaft.
6. Remove loose gearwheel for reverse gear (no. 5 in overview) with needle−roller bearing (no. 7 in
overview) from the output shaft using the puller. When doing so, also pull off the
cylindrical−roller bearing (no. 3 in overview) and thrust plate (no. 4 in overview).
7. Push complete gear set forwards onto output shaft using two mounting levers 1 − 2 cm.
8. Push gear set back behind the bearing inner race (no. 8 in overview) and remove bearing inner race
using the puller. If necessary, press the bearing inner race forwards again with the mounting lever.
9. Open up shift fork and remove complete
synchonization.
10. Remove fixed gear wheel, 5th gear (no. 36 in overview) and the spacer sleeve (no. 35 in overview).
11. Remove loose gearwheel, 5th gear (no. 17 in overview) with needle−roller bearing (no. 19 in overview).
12. Remove bearing inner race (no. 20 in overview) using the puller.
13. Open up shift fork and remove complete synchonization.
15. Press the bearing inner race (no. 30 in overview) forwards with the mounting lever and remove using the
puller.
16. Remove thrust plate (no. 31 in overview).
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2. Disassemble front gear set.
3. Unscrew fastening screws between the gear housing and the transmission.
4. Unscrew plug screw −A− and remove the spring with locking pins.
Removing gear housing 1220

einordnung
5. If necessary force gear housing off with a rubber hammer.
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Overview

2 Thrust plate 1
3 Loose gear wheel, 1st gear 1
4 Friction ring 1
Removing input and output shaft 1221

einordnung
5 Tapered ring 1
9 Shift collar 1
10 Guide sleeve 1
11 Driver dog 3
12 Ball 3
13 Spring 3
15 Tapered ring 1
16 Friction ring 1
17 Loose gear wheel, 2nd gear 1
20 Thrust plate 1
21 3rd gear fixed gear wheel 1
22 Locking element 2
23 Shift rod (1st/2nd gear) 1
24 Intermediate locking element 2
25 Shift rod (reverse gear) 1
26 Selector shaft 1
27 Shift rod (5th/6th gear) 1
28 Tensioning plate 1
29 Hexagon nut 7
30 Shift rod (3rd/4th gear) 1
32 Screw plug 4
33 Spring 4
34 Ball 4
35 Adjusting shim S3 X
36 Spacer sleeve 1
38 Transmission housing 1
Removing shafts
1. Unscrew screw plugs (no. 32 in overview) of the locking elements and remove springs (no. 33 in
overview) and ball (no. 34 in overview).
2. Pull out reverse gear shift rod (no. 25 in overview) and shift rods for 5th/6th gear (no. 27 in overview)
towards the front. Pay attention to the intermediate lock (no. 24 in overview) and locking elements (no. 22
Overview 1222
einordnung
in overview) during this procedure.

3. Remove differential lock ’ 39 40 19 Removing and installing differential and differential lock.
4. Remove cylindrical−roller bearing (no. 31 in overview) from input shaft using a
puller.
5. Pull loose gearwheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no.
2 in overview) and cylindrical−roller bearing (no. 1 in overview).
6. Pull off the fixed wheel for 3rd gear (no. 21 in overview) with synchronisation 1st/2nd gear (no.
16 to 4 in overview) and loose gearwheel for 2nd gear (no. 17 in overview).
7. Remove selector shaft (no. 26 in overview).
Note
• A specific disassembly of the synchronisation in assembled state may be recommendable as loss of

the small parts can then be avoided.
8. Unscrew nuts (no. 29 in overview) and remove tensioning plate (no. 28 in overview) with shafts and
remaining gear wheels.
9. Remove spacer sleeve (no. 36 in overview) and fixed wheel for 4th gear (no. 37 in overview) and take
output shaft out of the tensioning plate.
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Overview
Removing shafts 1223

einordnung

4 Four−point bearing 1
7 Shift rod / 3rd/4th gear shift fork 1
8 Locking element 1
9 Thrust plate 1
10 Loose gear wheel, 4th gear 1
Overview 1224
einordnung
14 Guide sleeve 1
15 Shift collar 1
16 Driver dog 3
17 Ball 3
18 Spring 3
20 Loose gear wheel, 3rd gear 1
22 Input shaft 1
Disassembling shaft
1. Clamp complete shaft into the vice with gear set and special tool socket wrench insert 9282 .
2. Remove fastening nut.
3. Press off loose gearwheel for 3rd gear (no. 20 in overview) with synchronisation (no. 11 to 19 in
overview), loose gearwheel for 4th gear (no. 10 in overview) and the remaining parts (nos. 2 to 9
in overview).
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Disassembling shaft 1225

34 35 37 Assembling transmission
Note
Tools
Assembling input shaft
Installing input and output shaft
Fitting gear housing
Assembling front gear set
Fitting front transmission case cover
Note
• If the transmission to be opened is still in the guarantee period (3 years), the letter −R− must be
imprinted after the transmission number.
Note
• Use the Damage Catalogue to diagnose the damage in the transmission.
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Tools

A Retaining device Special tool retaining device 9253
B Socket wrench insert Special tool socket wrench insert 9282
C Socket wrench insert Special tool socket wrench insert 9105
34 35 37 Assembling transmission 1226

einordnung
top of page
Assembling shafts
Note
• The overview diagram of the input shaft is provided in the chapter Disassembling transmission under
=> Overview.
1. Clamp shaft with special tool socket wrench insert 9282 in the vice.
2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the

overview. Pay attention to correct seating of the synchronising rings −A− and the driver dogs −B− . The
driver dogs with spring and ball must align with the dotting marks on the shift collar.
3. Check the synchronising rings for wear. To do this, push the synchronising rings onto the gear wheels and
measure the gap −A− with a feeler gauge.
Installation dimension (new): min. 0.9 mm
Wear dimension: 0.6.....0.7 mm
Note
• Gear wheels may only be replaced in pairs. Always employ used needle−roller bearings with the same
gear wheel and in the same running direction.
4. Push needle−roller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview)
and synchronisation onto input shaft.
Tools 1227
einordnung
5. Heat bearing inner race (no. 13 in overview) to 120°C and push onto input shaft.
6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto
input shaft. The large flat−ground side of the thrust plate faces towards the loose gearwheel (4th
gear).
8. Fit clamping plate with short lock (no. 5 and 8 in overview), four−point bearing (no. 4 in overview)
and shift fork (no. 7 in overview) onto input shaft.
10. Heat cylindrical−roller bearing (no. 2 in overview) to 120°C and push onto input shaft.
11. Screw new hexagon nut onto input shaft.
Tightening torques

Hexagon nut M30 x 1.5 250
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Installing shafts
Note
• An overview diagram of the installation is provided in the chapter Disassembling transmission under
=> Overview.
1. Insert output shaft −A− with adjusting shim S5 −B− and adusting shim S4 −C− into tensioning plate −F−
.
2. Push 4th gear fixed wheel −D− onto output shaft. The large collar faces the tensioning plate.
3. Push on the spacer sleeve −E− .
Assembling shafts 1228

einordnung
4. Affix adusting shim S3 −A− in the transmission case with viscous

grease.
5. Insert input and output shaft into the transmission case with tensioning plate and tighten nuts.
6. Push on 3rd gear fixed gear (no. 21 in overview) onto the output shaft. The large collar faces the
thrust plate (no. 20 in overview).
7. Push thrust plate onto the output
shaft.
8. Heat bearing inner race (no. 19 in overview) to 120°C and push onto output shaft.
9. Push needle−roller bearing (no. 18 in overview) onto bearing inner race.
10. Check synchronisation of 2nd gear. To do so, place the friction ring (no. 16 in overview), the tapered ring
(no. 15 in overview) and the synchronisation ring (no. 14 in overview) on the gear wheel (no. 17 in
overview). Measure the gap −A− with a feeler gauge. Perform the test again in the same way for 1st gear.
Installation dimension (new): 1.5 to 2.0 mm
Wear dimension: 1.2 mm
11. Push 2nd gear loose gearwheel (no. 17 in overview) onto needle−roller bearing.
12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronisation ring (no.
14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the
recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft.
14.
Installing shafts 1229

einordnung
Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 23 in overview). The turned groove
−A− in the shift collar must face the 2nd gear loose wheel.
Note
• The dotting marks on the shift collar must be centred with respect to the recesses in the guide sleeve.
15. When setting the shift collar in place, ensure that the dotting marks on the shift collar are centred
with respect to the recesses in the guide sleeve.
1 Shift collar
2 Ball
3 Driver dog
4 Spring
A Recognition groove
B Dotting mark
C 2nd gear − side
D 1st gear − side
16. Fit spring (no. 11 in overview), ball (no 12 in overview) and driver dog (no. 13 in overview). To do this,
push the shift collar in the direction of the 2nd gear loose gearwheel.
17. Fit the synchronising ring (no. 6 in overview), the tapered ring (no. 5 in overview) and the friction ring
(no. 4 in overview).
19. Push 1st gear loose gearwheel (no. 3 in overview) and thrust plate (no. 2 in overview) onto output
shaft.
20. Heat cylindrical−roller bearing (no. 1 in overview) to 120°C and push onto output shaft.

einordnung
22. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if
necessary. Ensure that that the rollers on the selector shaft are complete.
1 Shift rod for 3rd/4th gear
2 Locking element (short)
3 Shift rod for 5th/6th gear
4 Intermediate locking element
5 Locking element (long)
6 Reverse gear shift rod
7 Intermediate locking element
9 Shift rod for 1st/2nd gear
23. Fit locking elements (nos. 32, 33 and 34 in overview).

Note
• Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the
small locking elements and the balls of the lock can fall into the transmission.
Tightening torques

Tensioning plate on transmission case M 8 x 45 25 (19)
Screw plug locking element M 10 x 1 15 (11)
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einordnung
Fitting housing
1. Coat gear housing with Loctite 574 and put it on. To do this, insert shift rods into suitable bearing
locations and ensure correct engaging of the shift catch roller in the driver of the selector shaft.
2. Screw in fastening screws.
3. Fit locking pin, spring and screw plug.
Tightening torques

Fastening screws, gear housing M8 23 (17)
Screw plug M 18 x 1.5 25 (19)
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Note
• The overview diagram of the front gear set is provided in the chapter Disassembling transmission
under => Overview.
Assembling gear set
1. Place thrust plate (no. 31 in overview) onto output

shaft.
2. Heat bearing inner race (no. 30 in overview) to 120°C and place on output shaft.
3. Place fixed gear for 6th gear (no. 38 in overview) onto the input shaft. The large collar faces the spacer
sleeve (no. 37 in overview).
4. Place spacer sleeve (no. 37 in overview) onto input shaft.
Fitting gear housing 1232

einordnung
6. Place loose gearwheel for 6th gear (no. 28 in overview) with needle−roller bearing (no. 29 in overview)
onto output shaft.
7. Assemble synchronisation (nos. 27, 25 to 21 and 18 in overview).
Note
8. Place synchronisation with shift fork (no. 26 in overview) onto

output shaft.
onto output shaft.
11. Place fixed wheel for 5th gear (no. 36 in overview) onto the input shaft. The large collar faces the spacer
sleeve (no. 37 in overview).
13. Assemble synchronisation (nos. 16 to 13 and 9 in overview).
Note
Assembling gear set 1233

einordnung
14. Check the synchronising ring for wear. To do this, press synchronising ring onto the gear wheels and
15. Place synchronisation with shift fork (no. 12 in overview) onto output shaft.
17. Place loose gearwheel for reverse gear (no. 5 in overview) with needle−roller bearing (no. 7 in
overview) and synchronisation ring (no. 6 in overview) onto output shaft.
18. Place fixed gearwheel for reverse gear (no. 34 in overview) onto input shaft.
19. Heat bearing inner race (no. 33 in overview) to 120°C and place on input shaft.
20. Tighten new self−locking nuts (no. 32 in overview) on input shaft.
21. Place thrust plate (no. 4 in overview) onto output shaft.
22. Heat cylindrical−roller bearing (no. 3 in overview) to 120°C and place on output shaft.
23. Tighten new self−locking nuts (no. 2 in overview) on output shaft.
24. Adjust shift forks (nos. 26 and 12 in overview). The shift collar must have slight play in both directions in
idle position.
25. Secure shift forks with screws and washers (nos. 10 and 11 in overview).
26. Remove special tool retaining device 9253 .
27. Shift through all gears as a test.
Tightening torques

Nuts on output shaft M 30 x 1.25 300 (222)
Nuts on input shaft M 22 x 1.5 200 (148)
Shift fork screws M8 18 (13)
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einordnung
Fitting cover
1. Coat front transmission case cover with Loctite 574, put on and screw in fastening
screws.
2. Imprint the letter −R− after the transmission number (only on transmissions in guarantee period).
3. Fill with transmission oil ’ 34 01 55 Changing transmission oil.
4. Remove transmission from assembly support and fit onto the engine ’ 34 35 27 Removing and refitting the
transmission.
Tightening torques

Fastening screws, front transmission case cover M8 23 (17)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Fitting front transmission case cover 1235

35 50 19 Removing and installing sealing ring for
input shaft
Tools
Removing sealing ring for input shaft
Installing sealing ring for input shaft
Tightening torques
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Tools

1 Pressure piece 9256
2 Assembly sleeve 9255
3 Puller 9629
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Removing sealing ring for input shaft
1. Remove engine−transmission unit and remove the transmission => Removing and refitting the
transmission.
2. Remove guide tube for release bearing.
35 50 19 Removing and installing sealing ring for input shaft 1236

einordnung
3. Screw puller 9629 securely into the sealing

ring.
Note
• The coil spring must be pulled off the input shaft with a wire hook if the spring should jump down
when removing the sealing ring.
4. Pull out sealing ring by screwing in the hexagon−head screw.
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Installing sealing ring for input shaft
Removing sealing ring for input shaft 1237

einordnung
1. Push assembly sleeve 9255 onto the toothing of the input shaft.
2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g.
Liqui−Moly).
3. Drive in sealing ring with pressure piece 9256 as far as the mounting face.
4. Install guide tube and tighten the fastening screws.
Note
• The guide tube fastening screws are micro−encapsulated, therefore replace screws entirely.
5. Clean teeth of the input shaft and grease with a thin coat of Olista Longtime 3 EP (only as corrosion
protection).
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Tightening torques

Guide tube for release bearing on transmission housing M6x14 10
Installing sealing ring for input shaft 1238

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

37 04 19 Removing and installing selector knob
Removing selector knob
Installing selector knob
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Removing selector knob
1. Lever the locking button −A− off with a suitable tool or finger. The locking button must be pressed so that
the tool can be inserted between the selector lever −B− and locking button.
Note
• The ignition key must be in position 1 before the locking button can be pressed.
2. Remove compression spring −A− and pull spring clip −B− off toward the front.
3. Pull selector lever up and off.
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Installing selector knob
1. Assemble the selector knob with spring clip, compression spring and locking
button.
Note
• Fit conical compression spring with the small diameter facing the guide peg.
2.
37 04 19 Removing and installing selector knob 1240

einordnung
Press the complete selector knob onto the shift lever until it bottoms. The spring clip must fully engage in
the slot on the selector lever.
3. Check function of locking button.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing selector knob 1241

37 30 19 Removing and installing Tiptronic control
module
Note
Removing the control module
Installing the control module
Coding the Tiptronic control module
Tightening torques
Tools
Note
• The control module is located in the passenger compartment on the right on the B−pillar in front of
the rear seat well.
• The ignition key must be removed before starting the assembly work.
• If the Tiptronic control module is replaced, observe the points under coding the control module.
=> Coding the Tiptronic control module
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Removing the control module
• Remove front seat. ’ 7, 720119 Removing and installing front seat
• Remove the side lining at rear right ’ 707519 .
• Remove right sill ’ 680519
1. Unscrew lower fastening screw for the seat belt.

2. Disengage floor covering at the support and lay it in the vehicle
interior.
37 30 19 Removing and installing Tiptronic control module 1242

einordnung
3. Unlock locating peg −1− of the support using the commercially available removal tool. => Tightening
torques
4. Unscrew fastening screws −2− and nuts −3− and carefully pull the support up and out of the retaining
points.
5. Unlock and disconnect the electrical plug connection.
6. Detach holder −4− .

7. Pull control module out of the holder and pull it out downward at an
angle.
8. Press locking tabs −arrow− and disconnect plug connections from the control module.
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Removing the control module 1243

einordnung
Installing the control module
2. Insert control module into the holder and engage holder −4− .
4. Position the support and engage in lower side member.
Installing the control module 1244

einordnung
5. Push in the locating peg −1− of the support and check that it is sitting
correctly.
6. Tighten the fastening nuts −3− and the fastening screws −2− . Tightening torque −2− 7.2 Nm (5.5ftlbs.).
7. Lay the floor covering over the support and
engage.
• Using the Porsche System Tester, read out any faults present in the POSIP menu and erase. ’ 0, 69 01
Diagnosis/troubleshooting, airbag
• Insert sill. ’ 6, 680519 Removing and installing the sill
• Mount the side lining at rear. ’ 7, 707519 Removing and installing side panel lining
• Installing front seat. ’ 7, 720119 Removing and installing front seat
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Coding the Tiptronic control module
Note
• The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced.
• If a new control module is installed, the control module must adapt first. Poor shifting quality can be
expected therefore in the adaptation phase.
• After the test drive, let the engine run for 10 minutes at idle speed. This ensures that all adaptation
values are stored in the control module.
• The instructions of the Porsche System Tester have highest priority.
• The procedure listed has been structured generally, changes or additions can be made. The basis of
this is the Tester Software 13.1.
3. Using the >> key, move from the vehicle type to the list of control modules.
4. Select Tiptronic with the cursor keys and press the >> key.
5. Select "Coding" with the cursor keys and press the >> key.
6. Select vehicle version and code with the F8 key.
Coding the Tiptronic control module 1245

einordnung
RoW/ Japan P 80
Taiwan/ Korea P 83 / P 84
7. Tester confirmed: Coding has been modified .

8. Perform test drive and check fault memory with the System
Tester.
Resetting adaptation values:
Proceed as described under point 1 − 4.
Select menu item Reset adaptation values proceed with >> .
9. Confirm with F7 for Yes , F8 for No and proceed with >> .
10. Follow the instructions of the tester.
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Tightening torques

Seat belt on body 50
Fastening screw −2− Support 7,2
top of page
Tools

Removal tool Commercially available’
HandbuchWerkstattausrüstung Kapitel 2.4, Nr. 21

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Tools 1247
39 02 19 Removing and installing cardan shaft
Tools
Removing cardan shaft
Installing cardan shaft
Tightening torques
top of page
Tools

Assembly sleeve 9255
top of page
Note
• Observe max. joint angle of 20° when removing and fitting. Furthermore, the cardan joint must not be
loaded at max. deflection (stop).
1. Remove underbody covers (rear and centre).
39 02 19 Removing and installing cardan shaft 1248

einordnung
3. Detach cardan shaft at the transmission side and press it off the transmission flange with two mounting
levers.
4. Pull cardan shaft out of the splines of the central shaft and remove.
5. Remove bellows −arrow− from the central shaft.
top of page
1. Always replace bellows for cardan
shaft.
2. Slide special tool 9255 −A− over the shaft splines, lightly lubricate sleeve with Vaseline and push on
the bellows to the stop.
Removing cardan shaft 1249

einordnung
3. Grease bushing −A− with approx. 3 g of Olista Longtime 3EP .

4. Grease splines of the cardan shaft with Olista Longtime 3 EP . Slide shaft into the central shaft
splines and fit on the transmission side.
5. Push bellows −A− forward until it engages in the groove −C− of the central shaft. Check whether the
bellows is seated properly by pulling on it.
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Tightening torques

Transmission support to transmission bearing M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing cardan shaft 1250

39 02 19 Removing and installing cardan shaft
Tools
Removing and installing cardan shaft
Tightening torques
top of page
Tools

Assembly sleeve 9255
top of page
Removing and installing cardan shaft
Note
• Observe max. joint angle of 20° when removing and fitting. Furthermore, the cardan joint must not be
loaded at max. deflection (stop).
1. Remove underbody covers (rear and centre).
39 02 19 Removing and installing cardan shaft 1251

einordnung
3. Detach cardan shaft at the transmission side and press it off the transmission flange with two mounting
levers.
4. Pull cardan shaft out of the splines of the central shaft and remove.
5. Remove bellows −arrow− from the central shaft.

1. Always replace bellows for cardan
shaft.
2. Slide special tool 9255 −A− over the shaft splines, lightly lubricate sleeve with Vaseline and push on
the bellows to the stop.
Removing cardan shaft 1252

einordnung
3. Grease bushing −A− with approx. 3 g of Olista Longtime 3EP .

4. Grease splines of the cardan shaft with Olista Longtime 3 EP . Slide shaft into the central shaft
splines and fit on the transmission side.
5. Push bellows −A− forward until it engages in the groove −C− of the central shaft. Check whether the
bellows is seated properly by pulling on it.
top of page
Tightening torques

Transmission support to transmission bearing M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing cardan shaft 1253

halfshaft flange
Tools
Removing sealing ring for halfshaft flange
Installing sealing ring for halfshaft flange
Tightening torques
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Tools

1 Pressure piece Special tool pressure piece 9252
top of page
Note
• Protect drive shafts from damage. (Use 30 mm piece of hose)
1. Uncouple drive shaft on the transmission side.
39 22 19 Removing and installing sealing ring for halfshaft flange 1254

einordnung
2. Unscrew fastening screw for the halfshaft flange, unclip the B+ cable on the air flange and pull out the
halfshaft flange.
3. Lever out sealing ring using a suitable tool.
top of page
1. Fill the space between the dust and sealing lips with grease (e.g. Liqui−Moly) and drive in the sealing ring
up to the mounting face with special tool pressure piece 9252 .
2. Push in the halfshaft flange and tighten the fastening screw.
Tightening torque: 44 Nm (32 ftlbs.).
3. Clip the B+ cable onto the air flange and mount the drive shaft.
Tightening torque: 81 Nm (60 ftlbs.)
top of page
Tightening torques

Halfshaft flange fastening screw M10 44 (32 ftlbs.)
Halfshaft flange on drive shaft M10 81 (60 ftlbs.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing sealing ring for halfshaft flange 1255

short flanged shaft
Tools
Removing and installing sealing ring for short flanged shaft
Tightening torques
top of page
Tools

A Striker VW 771/1
B Extraction tool VW 771/37
C Pressure piece 9252
top of page
Removing and installing sealing ring for short flanged shaft
Removing sealing ring for short flanged shaft
Note
• The short flanged shaft can be removed only by partially undoing the wheel suspension.
39 22 19 Removing and installing sealing ring for short flanged shaft 1256
einordnung
1. Remove right rear wheel.

2. Uncouple drive shaft on the transmission side.
3. Undo right stabilizer mount.

Counter with an open−ended wrench when removing from the stabilizer fastening.
4. Undo the outer ends of both upper arms and remove the
screws.
5. Unscrew fastening screw for flanged shaft (Figure shows removed transmission).
6. Press wheel carrier downwards, remove spacer ring and pull out flanged shaft.
7. Remove sealing ring with special tools VW 771/1 and VW 771/37 (Figure shows removed transmission).
Removing sealing ring for short flanged shaft 1257

einordnung
Installing sealing ring for short flanged shaft
Note
• The sealing ring must fit in the housing at the same depth all round.
1. Thinly coat sealing lip and outer circumference of sealing ring with Vaseline and insert sealing ring with
special tool 9252 up to the stop (Figure shows removed transmission).
2. Fit drive shaft with spacer ring.
3. Check the transmission oil in the final drive and top up if necessary (see Serv. No.
399055).
top of page
Tightening torques

Wheel to wheel hub M14 x 1.5 130 (96)
Stabilizer to stabilizer mount M10 46 (34)
Control arm to carrier side section M12 x 1.5 110 (81)
Short flanged shaft to transmission M10 46 (34)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing sealing ring for short flanged shaft 1258

39 25 19 Removing and installing long flanged shaft
Tools
Removing and installing long flanged shaft
Tightening torques
top of page
Tools

Torx socket wrench 9330
top of page
Removing and installing long flanged shaft
Removing long flanged shaft
1. Remove left rear wheel.

2. Remove left drive shaft (refer to Serv. No. 422119).
3. Unscrew fastening screw for the water hose holder on the mounting saddle.
39 25 19 Removing and installing long flanged shaft 1259

einordnung
4. Unscrew fastening screws for the mounting saddle with a Torx socket wrench 9330 .
5. Carefully pull out flanged shaft.
Installing long flanged shaft
1. Check flanged shaft for burrs and sharp edges on the transmission end of the shaft −arrow− and deburr if
necessary.
Note
• While being inserted, the flanged shaft must be carefully guided with the hand in order to prevent
damage to the sealing ring in the transmission.
2. Carefully insert flanged shaft into the transmission.

3. Fit holder for water hoses and check for perfect seating of the
hoses.
top of page
Tightening torques

Mounting saddle for flanged shaft to transmission M6 23 (17)
Drive shaft on flanged shaft M10 81 (60)
Wheel to wheel hub M14 x 1.5 130 (96)
Holder to mounting saddle M6 10 (7.5)
Removing long flanged shaft 1260

einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

39 58 19 Removing and installing lid for front wheel
drive
Tools
Removing the lid for front wheel drive
Installing the lid for front wheel drive
Tightening torques
top of page
Tools

Centering pins 9321 M8
top of page
1. Remove the final drive => Removing and installing front wheel drive.
2. Drain
oil.
3. Press out flanged shaft with two mounting levers.
4. Unscrew fastening screws for the lid and remove the lid by tapping it with a plastic
hammer.
top of page
39 58 19 Removing and installing lid for front wheel drive 1262

einordnung

1. Fit sealing ring without twisting and coat it with
Vaseline.
2. Fit lid carefully and tighten screws uniformly in diagonally opposite sequence. Use centering pins
9321 as an assembly aid.
A Centering pins 9321
3. Always replace the snap ring for the halfshaft flange. To do this, clamp the flange in the vice with
protective jaws and press out the snap ring with the new snap ring .−A− .
A New snap ring
4. Grease the snap ring well and install the halfshaft flange with the special tools pull−in tool and
extractor P 254 and pressure pieces (4 items) 9247 .
5. Fill in ATF => Changing transmission oil in front wheel
drive.
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Tightening torques

Oil drain plug on final drive M18 x 1.5 28 (21)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the lid for front wheel drive 1263

39 58 19 Removing and installing lid for front wheel
drive
Tools
Tightening torques
top of page
Tools

Centering pins 9321 M8
top of page
2. Drain
oil.
4. Unscrew fastening screws for the lid and remove the lid by tapping it with a plastic
hammer.
top of page
39 58 19 Removing and installing lid for front wheel drive 1264

einordnung

1. Fit sealing ring without twisting and coat it with
Vaseline.
2. Fit lid carefully and tighten screws uniformly in diagonally opposite sequence. Use centering pins
9321 as an assembly aid.

A Centering pins 9321
protective jaws and press out the snap ring with the new snap ring −A− .
A New snap ring
4. Grease the snap ring well and install the halfshaft flange with the special tools pull−in tool and
extractor P 254 and pressure pieces (4 items) 9247 .
5. Fill in oil => Changing transmission oil in front wheel drive.
top of page
Tightening torques

Oil drain plug on final drive M18 x 1.5 28 (21)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the lid for front wheel drive 1265

flanged shaft (front wheel drive)
Tools
Removing the sealing ring for the flanged shaft (front wheel drive)
Installing the sealing ring for the flanged shaft (front wheel drive)
top of page
Tools

Pressure piece 9537
top of page
Removing the sealing ring for the flanged shaft (front wheel
drive)
1. Remove front drive shaft.’ 40 41 19 Removing and installing front drive
shaft
Note
• Do not damage the sealing ring seat!
39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive) 1266
einordnung
top of page
Installing the sealing ring for the flanged shaft (front wheel
drive)
1. Fill the space between the dust and sealing lips −arrow− on the new sealing ring with grease (e.g.
Liqui−Moly).
2. Drive in the sealing ring with the special tool pressure piece 9537 −arrow− up to the mounting face.
To do so, use a rubber hammer on the centre of the pressure piece.
protective jaws and press out the old snap ring with the new snap ring −A−
A New snap ring
Note
• Do not damage the drive shaft teeth when replacing them.
Removing the sealing ring for the flanged shaft (front wheeldrive) 1267
einordnung
4. Grease the snap ring thoroughly and drive in the halfshaft flange
−arrow− .
5. Check oil in front final drive. ’ 39 90 55 Changing oil for final drive
6. Install front drive shaft.’ 40 41 19 Removing and installing front drive shaft
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the sealing ring for the flanged shaft (front wheeldrive) 1268
flanged shaft (front wheel drive)
Tools
Removing the sealing ring for the flanged shaft (front wheel drive)
Installing the sealing ring for the flanged shaft (front wheel drive)
top of page
Tools

Pressure piece 9537
top of page
Removing the sealing ring for the flanged shaft (front wheel
drive)
1. Remove front drive shaft.’ 40 41 19 Removing and installing front drive
shaft
Note
• Do not damage the sealing ring seat!
39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive) 1269
einordnung
top of page
Installing the sealing ring for the flanged shaft (front wheel
drive)
1. Fill the space between the dust and sealing lips −arrow− on the new sealing ring with grease (e.g.
Liqui−Moly).
2. Drive in the sealing ring with the special tool pressure piece 9537 −arrow− up to the mounting face.
To do so, use a rubber hammer on the centre of the pressure piece.
protective jaws and press out the old snap ring with the new snap ring −A−
A New snap ring
Note
• Do not damage the drive shaft teeth when replacing them.
Removing the sealing ring for the flanged shaft (front wheeldrive) 1270
einordnung
4. Grease the snap ring thoroughly and drive in the halfshaft flange
−arrow− .
5. Check oil in front final drive. ’ 39 90 55 Changing oil for final drive
6. Install front drive shaft.’ 40 41 19 Removing and installing front drive shaft
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the sealing ring for the flanged shaft (front wheeldrive) 1271
39 60 01 Checking function of installed viscous
clutch
Test conditions
Checking function of installed viscous clutch
top of page
Test conditions
• Test only with viscous clutch at room temperature.
• Test speed of front wheels between 3 km/h and 5 km/h (wheels driven by rollers of roller brake
tester). Test duration 3 minutes; record the traction every 30 seconds.
• Repeat measurement after viscous clutch has cooled down for one hour.
top of page
1. Connect Porsche System Tester 2 and select −Actual values− menu (PSM
speed).
2. Drive front wheels of the vehicle onto the roller brake
tester.
3. Switch the engine off, set the hand brake and shift the transmission to
neutral.
4. When the brake−tester rollers have started, switch the ignition on and press the Continue key » of
the Porsche System Tester 2. The Tester then returns to the point at which diagnosis was
interrupted.
5. Drive front wheels by means of the brake tester rollers at a speed of 3 km/h, 4 km/h or 5 km/h.
6. Measure traction 6 times in three minutes. Measure the first traction value after 30 seconds operating time,
then carry out five more measurements every 30 seconds.
7. The viscous clutch functions properly if the traction of the front wheels lies within the limit curves in the
diagram, depending on the drive speed of the roller brake tester rollers.
Diagram for roller brake tester − speed 5 km/h:
39 60 01 Checking function of installed viscous clutch 1272

einordnung
A Relative measuring time in minutes

B Traction at the front wheels in Newtons (N)

Checking function of installed viscous clutch 1273

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

39 60 01 Checking function of installed viscous
clutch
Test conditions
top of page
Test conditions
• Test only with viscous clutch at room temperature.
• Test speed of front wheels between 3 km/h and 5 km/h (wheels driven by rollers of roller brake
tester). Test duration 3 minutes; record the traction every 30 seconds.
• Repeat measurement after viscous clutch has cooled down for one hour.
top of page
1. Connect Porsche System Tester 2 and select −Actual values− menu (PSM
speed).
2. Drive front wheels of the vehicle onto the roller brake
tester.
3. Switch the engine off, set the hand brake and shift the transmission to
neutral.
4. When the brake−tester rollers have started, switch the ignition on and press the Continue key » of
the Porsche System Tester 2. The Tester then returns to the point at which diagnosis was
interrupted.
5. Drive front wheels by means of the brake tester rollers at a speed of 3 km/h, 4 km/h or 5 km/h.
6. Measure traction 6 times in three minutes. Measure the first traction value after 30 seconds operating time,
then carry out five more measurements every 30 seconds.
7. The viscous clutch functions properly if the traction of the front wheels lies within the limit curves in the
diagram, depending on the drive speed of the roller brake tester rollers.
39 60 01 Checking function of installed viscous clutch 1275

einordnung



einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

39 60 19 Removing and installing the viscous clutch
Tools
Removing the viscous clutch
Installing the viscous clutch
Tightening torques
top of page
Tools

A Assembly aid 9638 2 parts
B Holding rails VW 457 Drill two 10.5 mm holes
39 60 19 Removing and installing the viscous clutch 1278

einordnung
1 Snap ring
2 Supporting ring
3 Viscous clutch
top of page
1. Remove the cardan shaft => Removing and installing cardan shaft.
2. Remove the final drive, front => Removing and installing front wheel drive.
3. Clamp final drive into the vice with special tool −A− holding rails VW 457 , drain oil and remove the
long−neck pipe.
A Special tool holding rails VW 457
4. Remove snap ring and take out viscous clutch with supporting ring.
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Tools 1279
einordnung
1. Insert supporting ring and fit snap ring −B− with special tool −A− assembly aid
9638 .
A Special tool assembly aid 9638
B Snap ring
2. Always replace O−ring for long−neck pipe and coat with Vaseline.
3. Uniformly tighten fastening screws for long−neck pipe in diagonally opposite sequence.
4. Fill in oil for final drive => Changing transmission oil in front wheel
drive.
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Tightening torques

Long−neck pipe on final drive M8 x 36 25 Nm (18 ftlb.)
Front transmission support on final drive M10 65 Nm (48 ftlb.)
Oil drain plug on final drive M18 x 1.5 28 Nm (21 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the viscous clutch 1280

39 60 19 Removing and installing the viscous clutch
Tools
Tightening torques
top of page
Tools

A Assembly aid 9638 2 parts
B Holding rails VW 457 Drill two 10.5 mm holes
39 60 19 Removing and installing the viscous clutch 1281

einordnung
1 Snap ring
2 Supporting ring
3 Viscous clutch
top of page
2. Remove the final drive, front => Removing and installing front wheel drive.
3. Clamp final drive into the vice with special tool holding rails VW 457 , drain oil and remove the
long−neck pipe.
A Special tool holding rails VW 457
4. Remove snap ring and take out viscous clutch with supporting ring.
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Tools 1282
einordnung
1. Insert supporting ring and fit snap ring with special tool assembly aid 9638 .
A Special tool assembly aid 9638
B Snap ring
2. Always replace O−ring for long−neck pipe and coat with Vaseline.
3. Uniformly tighten fastening screws for long−neck pipe in diagonally opposite sequence.
4. Fill in oil for final drive => Replacing and checking transmission oil in final
drive .
top of page
Tightening torques

Long−neck pipe on final drive M8 x 36 25 Nm (18 ftlb.)
Front transmission support on final drive M10 65 Nm (48 ftlb.)
Oil drain plug on final drive M18 x 1.5 28 Nm (21 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the viscous clutch 1283

39 62 19 Removing and installing support for front
wheel drive
Removing the support for front wheel drive
Installing the support for front wheel drive
Tightening torques
A Support for final drive

B Fastening screws
top of page
2. Unscrew fastening screws and remove support.
top of page
1. Mount support in correct position (angled side faces upwards)
39 62 19 Removing and installing support for front wheel drive 1284

einordnung
2. Tighten the fastening screws in two stages

1. Pre−tighten both screws to 5 Nm (3.5 ftlb.).
2. Tighten both screws to 65 Nm (48 ftlb.).
3. Install the final drive => Removing and installing front wheel drive.
top of page
Tightening torques

Transmission support on final drive M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the support for front wheel drive 1285

39 62 19 Removing and installing support for front
wheel drive
Tightening torques
A Support for final drive

B Fastening screws
top of page
2. Unscrew fastening screws and remove support.
top of page
1. Mount support in correct position (angled side faces upwards).
39 62 19 Removing and installing support for front wheel drive 1286

einordnung
2. Tighten the fastening screws in two stages.

1. Pre−tighten both screws to 5 Nm (3.5 ftlb.).
2. Tighten both screws to 65 Nm (48 ftlb.).
3. Install the final drive => Removing and installing front wheel drive.
top of page
Tightening torques

Transmission support on final drive M10 65 (48)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the support for front wheel drive 1287

cardan flange
Tools
Removing sealing ring for cardan flange
Installing sealing ring for cardan flange
Tightening torques
top of page
Tools

A Socket wrench insert commercially available (refer to Workshop Equipment
Manual, Chapter 2.4, No. 64)
C Three−arm puller Commercially available (refer to Technical Equipment
Manual, Chapter 2.4, No. 112−1)
D Hook VW 681
top of page
2. Place oil collection tray under the
transmission.
39 82 19 Removing and installing sealing ring for cardan flange 1288

einordnung
3. Engage a gear and firmly set the hand

brake.
4. Remove collar nut with a long a/f 30 socket wrench insert (refer to Workshop Equipment Manual, Chapter
2.4, No. 64).
5. Pull off the cardan flange with a three−arm puller (refer to Workshop Equipment Manual, Chapter 2.4,
No. 112−1).
6. Lever out the sealing ring on alternate sides with special tool hook VW 681 .
top of page
1. Degrease the pinion shaft journal (splines and thread), halfshaft flange splines and thread of the collar
nut with cleaning agent (e.g. Loctite quick cleaner).
2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. Liqui − Moly)
and drive in the sealing ring up to the mounting face using special tool pressure piece 9671 .
3. Coat halfshaft flange splines with screw locking lacquer (e.g. Loctite 243 or Omnifit 50 M) and fit the
flange.
4. Coat contact surface and thread of the collar nut with screw locking lacquer (as in step 4).
Removing sealing ring for cardan flange 1289

einordnung
5. Tighten the collar nut.

1 Halfshaft flange
2 Collar nut
A Screw locking lacquer (Loctite 243 or Omnifit 50 M)
6. Check transmission oil => Changing
transmission oil.
top of page
Tightening torques

Collar nut/halfshaft flange M20 x 1.5 120 (89)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing sealing ring for cardan flange 1290

cardan flange
Tools
Removing and installing sealing ring for cardan flange
Tightening torques
top of page
Tools

A Socket wrench 9669
C Three−arm puller Commercially available (refer to Technical Equipment
Manual, Chapter 2.4, No. 112−1)
D Hook VW 681
top of page
Removing and installing sealing ring for cardan flange
1. Remove cardan shaft (refer to Serv. No. 390219).

2.
39 82 19 Removing and installing sealing ring for cardan flange 1291

einordnung
Place oil collection tray under the

transmission.
3. Engage parking lock and firmly set the parking brake.
4. Remove collar nut with special tool

9669.
5. Pull off the cardan flange with a three−arm puller (refer to Workshop Equipment Manual, Chapter 2.4,
No. 112−1).
6. Lever off sealing ring with special tool VW

681.
1. Replace O−ring for cardan

flange.
2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. Liqui − Moly) and
drive in the sealing ring up to the mounting face using special tool 9668.
Removing sealing ring for cardan flange 1292

einordnung
3. Tighten collar nut and secure by pressing in the collar.

4. Install cardan shaft (refer to Serv. No. 390219).
top of page
Tightening torques

Collar nut 24 x 1.5 160 (118)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing sealing ring for cardan flange 1293

39 88 19 Removing and installing front wheel drive
Remove front wheel drive
Installing the front wheel drive
Tightening torques
1 Final drive front

2 Long−neck pipe with central pipe
3 Cardan shaft
4 Transmission support, rear
5 Transmission support, front
top of page
Remove front wheel drive
3. Remove diagonal brace −A− and cover −B− .

4. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of
hose with a diameter of 30 mm).
Note
39 88 19 Removing and installing front wheel drive 1294

einordnung
• To protect the coolant pipes against scratches when the final drive is removed or installed, it is
advisable to protect the pipes with adhesive tape in the area of the final drive.
5. Place transmission jack under the transmission and secure with fixing strap.
6. Remove pipe holder and unscrew fastening screws/nuts for the rear transmission
support.
A Pipe holder
B Transmission support
C Screw
Note
• Do not undo screw −C− !
7. Undo fastening nuts for front transmission support and unscrew the
studs.
A Transmission support
B Hexagon nut
C Stud
8. Carefully lower the transmission out. When doing so, avoid damaging the coolant
pipes.
top of page
Remove front wheel drive 1295

einordnung
1. Carefully lift in the transmission with a universal transmission jack. When doing so, do not damage
the coolant pipes.
2. Push studs through the front transmission mounts and screw into the front−axle cross
member.
Note
• If the hexagon−head bolt (M10 x 90) was undone on the rear transmission support/transmission
mount, it is essential to tighten the front transmission support first, then the rear transmission support
and the M10 x 90 screw on the rear transmission mount last.
3. Fasten transmission mounts on the front−axle cross member and on the

body.
top of page
Tightening torques

Studs on front−axle cross member M8 20 Nm (15 ftlb.)
Front transmission support on transmission M10 65 Nm (48 ftlb.)
Front transmission support on front−axle cross member M10 65 Nm (48 ftlb.)
Rear transmission support to body M10 65 Nm (48 ftlb.)
Rear transmission support to transmission bearing M10 x 90 65 Nm (48 ftlb.)
Drive shafts on front−axle final drive M8 39 Nm (29 ftlb.)
Diagonal brace on body and front−axle cross member M12 100 Nm (74 ftlb.)
Tank strap on body M8 x 40 23 Nm (17 ftlb.)
Pipe holder on transmission support M6 7 Nm (5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the front wheel drive 1296

39 88 19 Removing and installing front wheel drive
Removing front wheel drive
Tightening torques
1 Final drive front

2 Long−neck pipe with central pipe
3 Cardan shaft
4 Transmission support, rear
5 Transmission support, front
top of page
Removing front wheel drive
1. Remove the cardan shaft ’ 39 Removing and installing the cardan shaft .
3. Remove diagonal brace −A− and cover −B− .

4. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of
hose with a diameter of 30 mm).
Note
39 88 19 Removing and installing front wheel drive 1297

einordnung
• To protect the coolant pipes against scratches when the final drive is removed or installed, it is
advisable to protect the pipes with adhesive tape in the area of the final drive!
5. Place transmission jack under the transmission and secure with fixing strap.
6. Remove pipe holder and unscrew fastening screws/nuts for the rear transmission
support.
A Pipe holder
B Transmission support
C Screw
Note
• Do not undo screw −C− !
7. Undo fastening nuts for front transmission support and unscrew the
studs.
A Transmission support
B Hexagon nut
C Stud
8. Carefully lower the transmission out. When doing so, avoid damaging the coolant
pipes.
top of page
Removing front wheel drive 1298

einordnung
1. Carefully lift in the transmission with a universal transmission jack. When doing so, do not damage
the coolant pipes.
2. Push studs through the front transmission mounts and screw into the front−axle cross
member.
Note
• If the hexagon−head bolt (M10 x 90) was undone on the rear transmission support/transmission
mount, it is essential to tighten the front transmission support first, then the rear transmission support
and the M10 x 90 screw on the rear transmission mount last!
3. Fasten transmission mounts on the front−axle cross member and on the

body.
top of page
Tightening torques

Studs on front−axle cross member M8 20 Nm (15 ftlb.)
Front transmission support on transmission M10 65 Nm (48 ftlb.)
Front transmission support on front−axle cross member M10 65 Nm (48 ftlb.)
Rear transmission support on body M10 65 Nm (48 ftlb.)
Rear transmission support on transmission mount M10 x 90 65 Nm (48 ftlb.)
Drive shafts on front−axle final drive M8 39 Nm (29 ftlb.)
Diagonal braces on body and front−axle cross member M12 100 Nm (74 ftlb.)
Tank strap on body M8 x 40 23 Nm (17 ftlb.)
Pipe holder on transmission support M6 7 Nm (5 ftlb.)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing the front wheel drive 1299

39 90 55 Replacing and checking transmission oil in
final drive
Tools
Tightening torques
top of page
Tools

Filling system V.A.G 1924
top of page
Note
39 90 55 Replacing and checking transmission oil in final drive 1300

einordnung

−A− .
2. Unscrew oil drain plug −arrow− . Drain oil with vehicle standing horizontally.
4. Replace sealing rings for the drain plug and filler plug.
Note
• Attach the special tool as high as possible on the vehicle.
5. Fill in oil with special tool V.A.G 1924 up to the lower edge of the oil filler
opening.
6. To check the oil level, insert a suitable object (such as a bent wire) into the filler opening and use it to
read the oil level.
7. Screw in and tighten the filler plug and drain
plug.
Filler plug tightening torque: 22 Nm (16 ftlb.)
Drain plug tightening torque: 25 Nm (19 ftlb.)
top of page
Changing transmission oil in final drive 1301

einordnung
Tightening torques

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

39 90 55 Changing transmission oil in front wheel
drive
Tightening torques
top of page
Note


−A− .
top of page
Tightening torques
39 90 55 Changing transmission oil in front wheel drive 1303

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

39 90 55 Changing transmission oil in front wheel
drive
Tightening torques
top of page
Note


−A− .
top of page
Tightening torques
39 90 55 Changing transmission oil in front wheel drive 1305

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

42 21 19 Removing and installing rear drive shaft
(manual transmission)
Tools
Removing the drive shaft (manual transmission)
Installing the drive shaft (manual transmission)
top of page
Tools

A Torx screwdriver 9546 To counter the ball joints (track rod) during assembly and
disassembly.
B Press−out tool (ball joint extractor) To press out the ball joint on the wheel carrier.
9560
C Protective tube Protection of the drive shaft.
D Wheel−hub extractor To press the drive shaft out of the wheel hub.
top of page
Removing the drive shaft (manual transmission)
42 21 19 Removing and installing rear drive shaft (manual transmission) 1307

einordnung
Note
• Since the drive shaft can be moved only using great force, loosen the shaft inwards with taps on a
copper mandrel! For unfavourable tolerances, the drive shaft must be pressed out of the toothing using
a universal wheel−hub extractor! See step 9 also.
1. Lift the vehicle. Remove the wheel and undo axle nut −arrow− . Actuate the foot brake and parking
brake for this purpose.
2. Push the protection −arrow− over the drive shaft.
Removing the drive shaft (manual transmission) 1308

einordnung
3. Undo the drive shaft on the transmission flange.

4. Unscrew the lower linkage for the headlight height adjustment −arrow− (counter with open−ended
wrench). Only on left side!
5. Loosen stabilizer mount −arrow− at stabilizer (counter with open−ended wrench).
7. Remove the lower fastening screw of the spring strut −arrow− .

8. Undo the nut on the tie rod end (if necessary counter with Torx screwdriver 9546 ). Press the tie rod end
off with a press−out tool 9560 .
9. Disengage the parking brake cable at the
parking brake lever. To do this, remove the
floor of the oddments tray in the centre
console. Undo the 2 M8 nuts −1− . Remove
the tab washer −3− from the retaining lug
−4− with a screwdriver. Take the
corresponding parking brake cable out of the
guide.
10.
Removing the drive shaft (manual transmission) 1309

einordnung
Press the wear indicator/speed sensor wire out of the holder. Undo both upper axle struts and remove the
screws. Press the drive shaft out, if necessary (given unfavourable tolerances) with a wheel−hub
extractor.
11. Swivel the wheel carrier outwards until
there is enough space for the drive shaft
to be extended. A second fitter is
required!
top of page
Installing the drive shaft (manual transmission)
CAUTION
Danger of injury and material damage if the wheel carrier is raised incorrectly!
Installing the drive shaft (manual transmission) 1310

einordnung
• Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)!
When raising, use a suitable intermediate layer (hard rubber)!
• Do not damage the brake cover plate!
Note
• Carry out a visual inspection of all parts!
• Grease the drive shaft toothing with Optimoly HT!
• Replace self−locking nuts!
• The entire threaded parts of the axle must be tightened in vehicle position! Vehicle position means:
vehicle standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift!
Use an intermediate layer (hard rubber)! Do not damage the brake cover plate!
• It is not necessary to calibrate the sensor for headlight beam adjustment (only left vehicle side!)!
1. Swivel the wheel carrier outwards until there is enough space for the drive shaft to be inserted. 2. A
second fitter is required!
2. Fit both axle struts −arrows− on the wheel
carrier. Insert wear indicator/speed sensor
wire in the holder.
3. Engage the inside parking brake cable (reverse procedure to that described in Point 8 Removal).
Note
• When inserting the parking brake cable into the guide tube of the body, always make sure that the
sleeve of the parking brake cable is pushed fully onto the guide tube. Otherwise, correct adjustment of
the parking brake will not be possible.
4. Mount the tie rod

end on the wheel
carrier.
5. Insert the fastening screw of the lower spring strut −arrow− .

einordnung
7. Screw on the stabilizer mount −arrow− . Counter with an open−ended wrench when doing this.
8. Screw on the lower linkage for the headlight height adjustment −arrow− (counter with open−ended
9. Mount the drive shaft on the transmission flange.
10. Remove the drive shaft protection −arrow− .
11. Tighten axle nut −arrow− . Fasten the wheel.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

42 21 19 Removing and installing rear drive shaft
(Tiptronic transmission)
Tools
Removing the drive shaft (Tiptronic transmission)
Installing the drive shaft (Tiptronic transmission)
top of page
Tools

A Torx screwdriver 9546 To counter the ball joints (track rod) during assembly and
disassembly.
B Press−out tool (ball joint extractor) To press out the ball joint on the wheel carrier.
9560
C Protective tube Protection of the drive shaft.
D Wheel−hub extractor To press the drive shaft out of the wheel hub.
top of page
Removing the drive shaft (Tiptronic transmission)
42 21 19 Removing and installing rear drive shaft (Tiptronic transmission) 1313

einordnung
Note
• Since the drive shaft can be moved only using great force, loosen the shaft inwards with taps on a
copper mandrel! For unfavourable tolerances, the drive shaft must be pressed out of the toothing using
a universal wheel−hub extractor! See step 9 also.
1. Lift the vehicle. Remove the wheel and undo axle nut −arrow− . Actuate the foot brake and parking
brake for this purpose.
2. Push the protection −arrow− over the drive shaft.
Removing the drive shaft (Tiptronic transmission) 1314

einordnung
3. Undo the drive shaft with spacer ring on the transmission flange.
4. Unscrew the lower linkage for the headlight height adjustment −arrow− (left side only). Counter with
open−ended wrench.
5. Loosen stabilizer mount −arrow− at stabilizer (counter with open−ended wrench).
7. Remove the lower fastening screw of the spring strut −arrow− .

8. Undo the nut on the tie rod end (if necessary counter with Torx screwdriver 9546 ). Press the tie rod end
off with a press−out tool 9560 .
9. Disengage the parking brake cable at the
parking brake lever. To do this, remove the
floor of the oddments tray in the centre
console. Undo the 2 M8 nuts −1− . Remove
the tab washer −3− from the retaining lug
−4− with a screwdriver. Take the
corresponding parking brake cable out of the
guide.
10.
Removing the drive shaft (Tiptronic transmission) 1315

einordnung
Press the wear indicator/speed sensor wire out of the holder. Undo both upper axle struts and remove the
screws. Remove spacer ring from inner joint. Press the drive shaft out, if necessary (given unfavourable
tolerances) with a wheel−hub extractor.
to be extended. A second fitter is
required!
top of page
Installing the drive shaft (Tiptronic transmission)
CAUTION
Danger of injury and material damage if the wheel carrier is raised incorrectly!
Installing the drive shaft (Tiptronic transmission) 1316

einordnung
• Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)!
• When raising, use a suitable intermediate layer (hard rubber)!
• Do not damage the brake cover plate!
Note
• Carry out a visual inspection of all parts!
• Grease the drive shaft toothing with Optimoly HT!
• Replace self−locking nuts!
• A spacer ring is fitted between the drive shaft and transmission −arrow− ! The spacer ring is installed
in Tiptronic vehicles only!
• The entire threaded parts of the axle must be tightened in vehicle position! Vehicle position means:
vehicle standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift!
Use an intermediate layer (hard rubber)! Do not damage the brake cover plate!
• It is not necessary to calibrate the sensor for headlight beam adjustment (only left vehicle side!)!

to be retracted. A second fitter is
required!
2. Push spacer ring onto inner joint. Fit both
axle struts −arrows− on the wheel carrier.
Insert wear indicator/speed sensor wire in the

einordnung
holder.
3. Push sleeve −arrow− of the parking brake
cable −B− over the parking brake cable
guide tube −A− (push it onto the guide
tube as far as the stop). Engage the inside
parking brake (reverse procedure to that
described in Point 8 Removal).
Note
• Always make sure that the sleeve −arrow− of the parking brake cable −B− is pushed over the parking
brake cable guide tube −A− of the body! Otherwise, correct adjustment of the parking brake will not
be possible.
4. Mount the tie rod

end on the wheel
carrier.
5. Insert the fastening screw of the lower spring strut −arrow− .

einordnung
7. Screw on the stabilizer mount −arrow− . Counter with an open−ended wrench when doing this.
8. Screw on the lower linkage for the headlight height adjustment −arrow− (counter with open−ended
9. Mount the drive shaft with spacer ring on the transmission flange.
10. Remove the drive shaft protection −arrow− .
11. Tighten the axle nut. Fasten the wheel.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

45 46 19 Removing and installing front ABS lead
Removing front ABS lead
Installing front ABS lead
Tightening torques
Tools
top of page
• Remove front wheel. => Removing and installing the wheel − Turbo and GT2
• Remove front wheel housing liner. ’ 6, 505619 Removing and installing front wheel housing liner
• Remove cowl panel cover at centre and left. ’ 6, 664419 Removing and installing cowl panel cover
45 46 19 Removing and installing front ABS lead 1320

einordnung
1. Release lead lock for ABS lead plug −arrow A− and pull off both plugs −arrow B−
.
2. Unscrew the fastening nut −1− .
3. Take the lead out of the holders

−arrows− .
4. Open the clips −arrow A− .

5. Remove the fabric tape −B− and take out the lead −arrow
C− .
Note
• When cutting off the ABS lead, make sure that the length of lead in the interior is sufficient for
attaching the new lead.
6. Cut the lead in area −D− and remove it.
Removing front ABS lead 1321

einordnung
7. Cut through the fabric tape in the radiator tank, in the area −a− , and expose the remaining ABS lead.
top of page
1. Position the socket in installation position −arrow A− and secure with fastening nut
−1− .
2. Insert both plugs −arrow B− .
3. Fold back lead lock −arrow C− until it can be felt to engage on the
plugs.
4. Press the lead into the holders by pressing on the rubber sleeves
−arrow− .
Installing front ABS lead 1322

einordnung
5. Secure lead for headlight beam adjustment to the ABS lead using fabric tape
−A− .
6. Position the lead in installation position and close the clips −arrows
B− .
7. Push the lead through to the interior −arrow
C− .
Note
• Do not cut the ends of the lead too short so that the connection area can be moved from the original
installation position, if necessary, if there is insufficient space available.
• The individual leads in the wiring harness must be crimped and offset with respect to each other so
that the repair area does not become too thick.
8. Cut the ends of the lead to the required length and crimp it in area −a− with a crimp connector and
crimping tool. => Tools
• Cut off leads to different lengths (due to the shrink connection).

• Slide shrink−fit hose over the leads.
• Strip 10 mm of insulation off the leads.
• Connect leads with crimp connectors (do not confuse colours of the individual leads).
• Shrink shrink−fit hoses with a hot−air gun. It is essential that all leads are watertight.
• Wrap commercially available PVC tape all around the area of the connection points.
9. Secure the repair area to the adjacent wiring harnesses using tie−wraps −b− .
• Install cowl panel cover at centre and left. ’ 6, 664419 Removing and installing cowl panel cover
• Install front wheel housing liner. ’ 6, 505619 Removing and installing front wheel housing liner
• Fit front wheel. => Removing and installing the wheel − Turbo and GT2
top of page

einordnung
Tightening torques

Fastening nut −1− for securing ABS lead to spring strut M6 9.7 (7.2)
top of page
Tools
Item Designation of special tool Remarks

1 Repair set for wiring harness Workshop Equipment Manual, Gr. 2.4
155−1
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

45 46 19 Removing and installing rear ABS lead
(Turbo & GT2)
Removing rear ABS lead
Installing rear ABS lead
Tightening torques
Tools
top of page
Removing rear ABS lead
All models
• Remove rear wheel.
=> Removing and
45 46 19 Removing and installing rear ABS lead (Turbo & GT2) 1325
einordnung
installing the wheel

− Turbo and GT2
All models except for
GT2 and GT3 • Remove rear
backrest. ’ 7,
724719 Removing
and installing rear
backrest
• Remove emergency
seat cushion. ’ 7,
745719 Removing
and installing
emergency seat
cushion
• Release rear
three−point belt. ’
6, 691219
Removing and
installing rear
three−point belt
• Remove side−panel
lining. ’ 7, 707519
Removing and
installing
side−panel lining
1. Pull up carpet lining −arrow A− .

2. Fold carpeted floor forwards −arrow B− .
3. Release lead lock −arrow A− and pull off both plugs −arrow
B− .
4. Unscrew fastening nut −1− and remove the plug −arrow C− .
Removing rear ABS lead 1326

einordnung
5. Take the lead out of the holders

−arrows− .
Note
6. Cut off the lead in area −a− and press inwards using the rubber sleeve −b− (−arrow−
).
Note
• Only for vehicles with headlight beam adjustment (HBA)
7. Cut through the rubber sleeve at the side of the HBA lead −a− and remove the HBA lead −arrow− .
top of page
Installing rear ABS lead
Installing rear ABS lead 1327

einordnung
1. Position the socket in installation position −arrow A− and secure with fastening nut
−1− .
2. Insert both plugs −arrow B− .
3. Fold back lead lock −arrow C− until it can be felt to engage on the
plugs.
4. Press the lead into the holders by pressing on the rubber sleeves
−arrow− .
Note
• Choose the connection point at a position with sufficient room for connecting all the individual leads.
• The individual leads in the wiring harness must be crimped and offset with respect to each other so
that the repair area does not become too thick.
5. Push the lead through to the interior −arrow− .

einordnung
Note
• Only for vehicles with headlight beam adjustment (HBA)
6. Cut through the rubber sleeve −a− and position the HBA lead in the rubber sleeve −arrow A− .
7. Stick the rubber sleeve together and seal it at the cut edge −a− using a commercially available
PUR adhesive. Then press the rubber sleeve into the opening −arrow B− .
8. Crimp the lead in area −b− using a crimp connector and crimping tool.
=> Tools

All models
• Install rear wheel.
=> Removing and
installing the wheel −
Turbo and GT2
All models
except for GT2 • Install rear backrest. ’ 7,
and GT3 724719 Removing and
installing rear backrest
• Install emergency seat
cushion. ’ 7, 745719
Removing and installing
emergency seat cushion
• Secure rear three−point
belt. ’ 6, 691219
Removing and installing

einordnung
rear three−point belt

• Install side−panel lining. ’
7, 707519 Removing and
installing side−panel
lining
top of page
Tightening torques

Fastening nut −1− for securing ABS lead to spring strut M6 9.7 (7.2)
top of page
Tools

155−1
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

46 50 02 Checking front gray cast iron brake discs
(wear assessment)
General
1. Visual inspection for cracks and evaluating cracks
2. Checking brake discs for minimum thickness
Notes on bedding in the new brake pads
Includes:
1. Visual inspection for cracks and evaluating cracks => 1. Visual inspection for cracks and evaluating cracks
2. Checking brake discs for minimum thickness. => 2. Checking brake discs for minimum thickness
top of page
General
The condition of the parts can make replacement necessary under two criteria, depending on the wear of
perforated brake discs:
1. Cracking in the holed (perforated) friction plate is in an advanced state.
In practice, both forms of disc erosion occur.
Usually, it is necessary to replace the brake discs when they fall short of the brake disc minimum thickness.
Only in rare cases (for long−term race driving brake loads / very high temperature fluctuations in the friction
surfaces), the cracking and perforating can proceed so quickly that a premature disc change has to be
performed. Both criteria governing acceptable disc condition will be described separately in the following
sections.
top of page
Note
• Perforation starter cracks arise through material fatigue due to frequent and extreme heat elongation
fluctuations. These fluctuations in the disc temperature, which generally arise in racing, tear the
perforations in a radial direction due to material fatigue (changing heat elongation conditions). For
their part, these starter cracks allow a partial relaxation of the friction plate, so that the speed at which
the cracks develop is very slow.
• The maximum permissible perforation crack length is 5 mm.
• The growth of the perforation starter cracks or a tearing of the rim of the friction plate worsens the
smoothness of braking, decreases the disc strength and therefore makes a precautionary parts
replacement necessary.
46 50 02 Checking front gray cast iron brake discs (wear assessment) 1331
einordnung
Evaluating the cracks on the gray cast iron brake discs
• The brake discs must be replaced (as a precautionary measure), if the perforation crack length is over
5 mm (as there is no mileage reserve in the event of further extreme load) or / and the friction plate
rim is torn (lessens smoothness of braking and increases the liklihood that a disc will break)!
• In the evaluation of damage, the following drawings must be used!
A. Corresponds to a disc exposed to above−average load.
• Need not be taken out of the vehicle!
B. In parts, perforation starter cracks over 7 mm long. Conditions after shock braking 1,200 times (minimum
desired: shock braking 200 times).
• Brake disc can no longer be used!
C. Brake disc with torn friction plate rim −arrow− .
Evaluating the cracks on the gray cast iron brake discs 1332
einordnung
top of page
Note
• In the presence of high pressure forces, at the innermost and outermost hole−free friction plate track
−arrows− , the brake lining friction surface is the least worn, compared to the middle holed area. As a
result, in the case of weaker braking, a relatively higher surface pressure arises in these areas and
therefore greater wear of the friction plates. The natural balance between stronger and weaker braking
ensures that in almost all cases the typical wear profile of a perforated friction plate arises (inner and
outer smooth friction rim area is worn the most−arrows− .
• As opposed to smooth brake discs, by which the minimum thickness is measured in the middle of the
disc (effective friction radius), in the case of perforated brake discs, the minimum thickness must be
measured on the inner or outer friction surface track −arrows− , whichever is most worn.
• Brake disc thickness/wear limit: Max. 2.0 mm total wear permissible. Refer to the technical data for
the new dimension and other dimensions ’ 46 Technical data/wear limits − Turbo or GT2 with gray
cast iron brake discs .
Measure the smallest brake disc thickness with a suitable micrometer screw, at one of the two smooth
friction rim areas −arrows− (at the most worn friction rim area).
The following drawing shows the typical grooved wear profile −arrows− of a perforated gray cast iron brake
disc, which has been used to the wear limit, under tough conditions i.e. constant operation mode (test
2. Checking brake discs for minimum thickness 1333

einordnung
operation mode).
Arrows Zone where most wear occurs in brake disc friction surface
A Perforation friction zone (holed friction zone)
B smooth friction rim zone
top of page
In the case of the perforated (holed) friction plate, the contact pattern of newly installed brake pads adapts
more quickly to the wear profile of the previously operated brake disc than is the case with smooth brake
discs.
In general, the following applies: New brake pads must be broken in (bedding−in period), their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake
disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Notes on bedding in the new brake pads 1334

46 50 02 Checking front PCCB brake discs (wear
assessment)
General
1. Visual inspection of the surfaces of the brake disc friction surfaces
3. Checking brake discs for edge damage
Note concerning bores (perforations) in the brake disc friction surface
Note on bedding in the new brake pads
Includes:
1. Visual inspection for surface changes in the brake disc friction surfaces (wear assessment).
2. Check brake disc for minimum thickness (wear assessment/max. permissable total wear 0.5 mm) => 2.
Checking brake discs for minimum thickness.
3. Check brake discs for edge damage (damage due to improper use) => 3. Checking brake discs for edge
damage .
top of page
General
Two conditions of criteria can make replacement necessary depending on the wear of perforated brake discs:
1. Surface changes in the brake disc friction surfaces at advanced stage.
In practice, both forms of disc erosion usually occur.
Only in seldom cases (for long−term race driving brake loads / very high temperature fluctuations in the
friction surfaces), the surface changes can proceed so quickly that a premature disc change has to be
performed.
top of page
1. Visual inspection of the surfaces of the brake disc friction
surfaces
Note
• The friction surface changes occur due to material fatigue as a result of extremely high thermal load.
These disc temperatures which occur above all in racing operation cause a progressive material
fatigue.
• Effects on driving: The surface change worsens the smoothness of braking, decreases the disc strength
and increases the brake pad wear and therefore makes a precautionary parts replacement necessary.
The following illustrations (PCCB brake disc wear appearance) are to be used.
46 50 02 Checking front PCCB brake discs (wear assessment) 1335

einordnung
PCCB brake disc wear appearance
A. Friction area surface after normal brake load in street use operation.
• No replacement necessary!
B. Friction area surfaces after a long run and occasional higher load.
• Replacement not yet necessary!
C. End of service life of friction area surface or after highest load on a racing track.
• Replace brake discs in the case of connected friction surface damage > 1 cm2 .
top of page
PCCB brake disc wear appearance 1336

einordnung
Note
• For perforated brake discs, the minimum thickness must always be measured on the inner or outer
friction surface trace.
the new dimension and other dimensions ’ 46 Technical data/wear limits − GT2 or Turbo with PCCB
.
Measure the brake disc thickness dimension −X− , with a suitable micrometer screw or a brake disc
gauge in the area of the inner and outer friction surface traces −arrow− .
top of page
Note
• Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due to
edge damage!
• In this case, only one brake disc can be replaced if the friction area surface of the other PCCB brake
disc is in order.
The following criteria applies to edge damage assessment:
• Max. permissible width/depth = 2 mm!

• Max. permissible length = 10 mm!

einordnung
• Max. 3 damaged edge areas permissible!
top of page
Note concerning bores (perforations) in the brake disc friction
surface
CAUTION
PCCB (Porsche Ceramic Composite Brake): Danger of material damage (danger of damage to the brake discs)
if improper work is performed on the bores in the brake disc friction surface!
• Clean the bores on PCCB brake discs with high−pressure cleaning equipment (only if necessary). In
doing so, observe the environmental and safety regulations!
• Do not machine (boring or countersinking is not permissible)!
Use high−pressure cleaning equipment to clean or expose the bores in the brake disc friction surface.
top of page
New brake pads require a slightly longer bedding−in period for PCCB brake discs than cast iron brake discs.
disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
3. Checking brake discs for edge damage 1338

46 53 02 Checking rear gray cast iron brake discs
(wear assessment)
General
Includes:
1. Visual inspection for cracks and evaluating cracks => 1. Visual inspection for cracks and evaluating cracks
2. Checking brake discs for minimum thickness. => 2. Checking brake discs for minimum thickness
top of page
General
The condition of the parts can make replacement necessary under two criteria, depending on the wear of
perforated brake discs:
1. Cracking in the holed (perforated) friction plate is in an advanced state.
In practice, both forms of disc erosion occur.
Usually, it is necessary to replace the brake discs when they fall short of the brake disc minimum thickness.
Only in rare cases (for long−term race driving brake loads / very high temperature fluctuations in the friction
surfaces), the cracking and perforating can proceed so quickly that a premature disc change has to be
performed. Both criteria governing acceptable disc condition will be described separately in the following
sections.
top of page
Note
• Perforation starter cracks arise through material fatigue due to frequent and extreme heat elongation
fluctuations. These fluctuations in the disc temperature, which generally arise in racing conditions,
tear the perforations in a radial direction due to material fatigue (changing heat elongation
conditions). For their part, these starter cracks allow a partial relaxation of the friction plate, so that
the speed at which the cracks develop is very slow.
• The maximum permissible perforation crack length is 5 mm.
• The growth of the perforation starter cracks or a tearing of the rim of the friction plate worsens the
smoothness of braking, decreases the disc strength and therefore makes a precautionary parts
replacement necessary.
46 53 02 Checking rear gray cast iron brake discs (wear assessment) 1339
einordnung
Evaluating the cracks on the gray cast iron brake discs
• The brake discs must be replaced (as a precautionary measure), if the perforation crack length is over
5 mm (as there is no mileage reserve in the event of further extreme load) or / and the friction plate
rim is torn (less smooth braking and an increase in the liklihood that a disc will break)!
• In the evaluation of damage, the following drawings must be used!
A. Corresponds to a disc exposed to above−average load.
• Need not be taken out of the vehicle!
B. In parts, perforation starter cracks over 7 mm long. Conditions after shock braking 1,200 times (minimum
desired: shock braking 200 times).
C. Brake disc with torn friction plate rim −arrow− .
Evaluating the cracks on the gray cast iron brake discs 1340
einordnung
top of page
Note
• In the presence of high pressure forces, at the innermost and outermost hole−free friction plate track
−arrows− , the brake pad friction surface is the least worn, compared to the middle holed area. As a
result, in the case of weaker braking, a relatively higher surface pressure arises in these areas and
therefore greater wear of the friction plates. The natural balance between stronger and weaker braking
ensures that in almost all cases the typical wear profile of a perforated friction plate arises (inner and
outer smooth friction rim area is the most worn) −arrows− .
• As opposed to smooth brake discs, by which the minimum thickness is measured in the middle of the
disc (effective friction radius), in the case of perforated brake discs, the minimum thickness must be
measured on the inner or outer friction surface track, −arrows− whichever is most worn.
the new dimension and other dimensions ’ 46 Technical data/wear limits − Turbo or GT2 with gray
cast iron brake discs .
Measure the brake disc thinnest point with a suitable micrometer screw, at one of the two smooth friction
rim zones −arrows− (at the most worn friction rim area).
The following drawing shows the typical grooved wear profile −arrows− of a perforated gray cast iron brake
disc, which has been used to the wear limit, under tough conditions i.e. constant operation mode (test

einordnung
operation mode).
Arrows Zone where most wear occurs in brake disc friction surface
A Perforation friction zone (holed friction zone)
B smooth friction rim zone
top of page
In the case of the perforated (holed) friction plate, the contact pattern of newly installed brake pads adapts
more quickly to the wear profile of the previously operated brake disc than is the case with smooth brake
discs.
disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Notes on bedding in the new brake pads 1342

46 53 02 Checking rear PCCB brake discs (wear
assessment)
General
1. Visual inspection of the surfaces of the brake disc friction surfaces
Note concerning bores (perforations) in the brake disc friction surface
Includes:
1. Visual inspection for surface changes in the brake disc friction surfaces (wear assessment).
2. Check brake disc for minimum thickness (wear assessment/max. permissable total wear 0.5 mm) => 2.
Checking brake discs for minimum thickness.
3. Check brake discs for edge damage (damage due to improper use) => 3. Checking brake discs for edge
damage .
top of page
General
Two condition criteria can make replacement necessary depending on the wear of perforated brake discs:
1. Surface changes in the brake disc friction surfaces at advanced stage.
In practice, both forms of disc erosion usually occur.
Only in seldom cases (for long−term race driving brake loads / very high temperature fluctuations in the
friction surfaces), the surface changes can proceed so quickly that a premature disc change has to be
performed.
top of page
1. Visual inspection of the surfaces of the brake disc friction
surfaces
Note
• The friction surface changes occur due to material fatigue as a result of extremely high thermal load.
These disc temperatures which occur above all in racing operation cause a progressive material
fatigue.
• Effects on driving: The surface change worsens the smoothness of braking, decreases the disc strength
and increases the brake pad wear and therefore makes a precautionary parts replacement necessary.
The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.
46 53 02 Checking rear PCCB brake discs (wear assessment) 1343

einordnung
PCCB brake disc wear appearance
A. Friction area surface after normal brake load in street use operation.
• No replacement necessary!
B. Friction area surfaces after a long run and occasional higher load.
• Replacement not yet necessary!
C. End of service life of friction area surface or after highest load on a racing track.
• Replace brake discs in the case of connected friction surface damage > 1 cm2 .
top of page
PCCB brake disc wear appearance 1344

einordnung
Note
• For perforated brake discs, the minimum thickness must always be measured on the inner or outer
friction surface trace.
the new dimension and other dimensions ’ 46 Technical data/wear limits − GT2 or Turbo with PCCB
.
Measure the brake disc thickness dimension −X− , with a suitable micrometer screw or a brake disc
gauge in the area of the inner and outer friction surface traces −arrow− .
top of page
Note
• Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due to
edge damage!
• In this case, only one brake disc can be replaced if the friction area surface of the other PCCB brake
disc is in order!
The following criteria applies to edge damage assessment:
• Max. permissible width/depth = 2 mm!

• Max. permissible length = 10 mm!

einordnung
• Max. 3 damaged edge areas permissible!
top of page
Note concerning bores (perforations) in the brake disc friction
surface
CAUTION
PCCB (Porsche Ceramic Composite Brake): Damage of material damage (danger of damage to the brake
discs) if improper work is performed on the bores in the brake disc friction surface!
• Clean the bores on PCCB brake discs with high−pressure cleaning equipment (only if necessary). In
doing so, observe the environmental and safety regulations!
• Do not machine (boring or countersinking is not permissible)!
Use high−pressure cleaning equipment to clean or expose the bores in the brake disc friction surface.
top of page
braking effect is therefore not until after a few hundred kilometers. The slightly reduced braking effect must
be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
3. Checking brake discs for edge damage 1346

50 10 55 Replacing closing panel
Cutting out closing panel and front floor panel
Preparing closing panel and front floor panel for installation and fitting
Welding in closing panel and front floor panel
Tools and materials
Replacing closing panel and front floor panel
The following spare body parts are required for the sectional repair Replacing closing panel :
A = closing panel
B = front floor panel
top of page
Cutting out closing panel and front floor panel
50 10 55 Replacing closing panel 1347

einordnung
WARNING
During body repairs, the following safety instructions and the general information and quality instructions
must be followed. ’ 5 Safety notes
Note
• The accessories in the repair area should be removed, depending on the extent of the damage.
• All straightening work on the body in this area must have been completed before the damaged parts
are removed.

Place vehicle on the alignment Place the vehicle with the units installed at the rear onto the
bench set of straightening attachments and fasten in place.
Cutting out closing panel and front floor panel 1348

einordnung
1 Separating spot−welded joints Use the spotweld cutter to separate the spot−welded joints of
between the closing panel/side the closing panel to the side members −A, B− and the front
members and the front floor panel floor panel −C− from the outside.
2 Separating spot−welded joints Separate the spot−welded joints of the closing panel to the
between the closing panel/wheel wheel housings from the inside (luggage−compartment side)
housings −D− with the spotweld cutter.
3 Separating spot−welded joints Separate spot−welded joints of the front floor panel to the
between the front floor panel and bulkhead at the middle −F− from the inside
bulkhead at the middle. (luggage−compartment side) with the spotweld cutter.
4 Separating spot−welded joints Separate the spot−welded joints between the front floor panel
between the front floor panel and and bulkhead at the left and right sides −G− .
bulkhead at the sides
5 Separating spot−welded joints Separate spot−welded joints of the front floor panel to the
between the front floor panel/side side members on the left and right −E− from the outside with
members the spotweld cutter.
top of page
Preparing closing panel and front floor panel for installation and
fitting
Preparing closing panel and front floor panel for installation and fitting 1349
einordnung

1 Preparing spare parts Remove the factory−applied primer on the welding areas of the spare
parts −A, B, C, D, E, F, G− using the rotary brush.
Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart
for plug−welding with shielding gas.
=> Welding in closing panel and front floor panel
2 Cleaning the welding areas Remove underbody coating and paint layers, etc. from the welding
areas of the body with a hot−air gun or rotary brush.
3 Fitting the front floor panel Adjust the spare front floor panel to the side members and to the
in the body and fastening it bulkhead. Fasten the spare front floor panel to the straightening
on the straightening attachment for the front−axle mount and diagonal brace. Fasten the
attachments. side members to the straightening attachment for the impact pipes
(impact dampers).
4 Fitting in wings and front lid Fit the left and right wings and fit in the front lid.
=> Diagram − body gap dimensions
Preparing closing panel and front floor panel for installation and fitting 1350
einordnung
top of page
Welding in closing panel and front floor panel

1 Plug−welding front floor panel to the Plug−weld the front floor panel to the bulkhead at the
bulkhead at the middle under shielding gas middle −F− under shielding gas.
2 Plug−welding front floor panel to the Plug−weld radiator tank to the front floor panel −G−
bulkhead under shielding gas on the left and right under shielding gas.
3 Plug−welding the front floor panel to the Align the front floor panel with the side members on
side members under shielding gas the left and right −E− and plug−weld under shielding
gas.
Welding in closing panel and front floor panel 1351

einordnung
4 Spot−welding the closing panel Spot−weld the closing panel to the front floor panel
−C− and the side members on the left and right −A,
B− .
5 Spot−welding the closing panel to the Spot−weld the closing panels with the wheel housings
front floor panel on the left and right −D− .
top of page
Tools and materials

1 Basic straightening attachments for 911 Carrera (996) Nr. ’ 3 Workshop Equipment Manual
7250700
2 Additional straightening attachments for 996 Turbo Nr. ’ 3 Workshop Equipment Manual
7250710
3 Star gauges Nr. 127−1 ’ 2.4 Workshop Equipment
Manual
4 Shielding−gas welding device ’ 3 Workshop Equipment Manual
5 Multispot spotwelder ’ 3 Workshop Equipment Manual
6 Pneumatic body saw ’ 3 Workshop Equipment Manual
7 Angle grinder ’ 2.4 Workshop Equipment
Manual
8 Oscillating body saw (special electrical cutter) ’ 3 Workshop Equipment Manual
9 Multispot spotweld cutter ’ 3 Workshop Equipment Manual
10 Hole punch ’ 2.4 Workshop Equipment
Manual
11 Hot−air gun ’ 3 Workshop Equipment Manual
12 Rotary brush ’ 2.4 Workshop Equipment
Manual
13 Spotweld cutter 7 mm, No. 129 ’ 2.4 Workshop Equipment
Manual
996420, 996421, 996450, 996451, 996430, 996840, 996841

50 14 55 Replacing front wall
Cutting out front wall
Preparing front wall for installation and fitting
Welding in front wall
Tools and materials
The following spare body parts are required for the sectional repair Replacing front wall :
A = front wall
top of page
Cutting out front wall
50 14 55 Replacing front wall 1353

einordnung
WARNING
must be followed. ’ 5 Safety notes
Note
are removed.

=> Replacing closing panel
Cutting out front wall 1354

einordnung
Cutting out closing panel and

front floor panel
Place vehicle on the alignment Place the vehicle with the units installed at the rear onto the set
bench of straightening attachments and fasten in place.
1 Separating spot−welded joints Separate spot−welded joints of the front wall to the side
between front wall/side members −A− and the wheel housings −B− with the spotweld
members and wheel housings cutter.
2 Separating spot−welded joints Separate the spot−welded joints of the radiator tank to the front
between the radiator tank and wall from the inside (radiator−tank side) −C, D− with the
front wall spotweld cutter.
3 Separating spot−welded joints Separate spot welds of the front wall at the bottom to the side
and MIG seams between the member −E− with the spotweld cutter. Grind off the MIG seams
front wall and side members. joining the front wall at the sides to the side member −F, G−
with the parting grinder.
top of page
Preparing front wall for installation and fitting
Preparing front wall for installation and fitting 1355

einordnung

parts −A, B, C, D, E,− using the rotary brush.
Drill or punch (with a hole punch) 7 mm holes spaced 20 mm apart for
plug−welding with shielding gas
=> Welding in front wall
2 Cleaning the welding Remove underbody coating and paint layers, etc. from the welding areas
3 Inserting the front wall Adjust the spare front wall to the side members and the radiator tank.
into the body Fitting of the following parts => Replacing closing panel
top of page
Preparing front wall for installation and fitting 1356

einordnung
Welding in front wall

1 Plug−welding front wall/side Plug−weld front wall to the side members and wheel housing −A,
members and wheel housings B− under shielding gas.
2 Plug−welding radiator Plug−weld radiator tank to the front wall −C, D− on the left and
tank/front wall. right.
3 Welding the front wall/side Weld front wall at the bottom to the side member −E− and front
members under shielding gas wall at the sides to the side member −F, G− with a full weld
under shielding gas.
top of page
Welding in front wall 1357

einordnung
Tools and materials

1 Basic straightening attachments for 911 Carrera (996) ’ 3 Workshop Equipment Manual
7250700
2 Additional straightening attachments for 996 Turbo 7250710 ’ 3 Workshop Equipment Manual
3 Star gauges 127−1 ’ 2.4 Workshop Equipment
Manual
5 Multispot spotwelder ’ 3 Workshop Equipment Manual
7 Angle grinder ’ 3 Workshop Equipment Manual
Manual
12 Rotary brush ’ 3 Workshop Equipment Manual
13 Spotweld cutter 7 mm Nr. 129 ’ 2.4 Workshop Equipment
Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

50 74 55 Replacing wheel housing
Removing wheel housing, lower shell and outer side member from the body
Preparing wheel housing, lower shell and outer side member for installation and fitting
Welding wheel housing, lower shell and outer side members into the body
Tools and materials
Replacing wheel housing, bottom part and outer side member
The following spare body parts are required for the repair "Replacing wheel housings":
A = wheel housing
B = lower shell
C = outer side member
top of page
Removing wheel housing, lower shell and outer side member
from the body
50 74 55 Replacing wheel housing 1359

einordnung
WARNING
must be followed. ’ 5 Safety instructions
Note
are removed.

Placing vehicle on the alignment bench Place the vehicle with the units mounted at the rear onto
the set of straightening attachments and fasten it in
Removing wheel housing, lower shell and outer side memberfrom the body 1360
einordnung
position.
1 Separating the spot−welded joint Separate the spot−welded joints between the outer side
between the outer/inner side members member and inner side member −A, C, D− and the front
wall −B− with the spotweld cutter.
2 Separating welds between outer side Grind open the MIG seams between outer side member
member and front wall −E− and the front wall −F− and the support shell on the
floorpan −G− .
3 Separating the spot−welded joint Separate the spot−welded joint of the wheel housing to the
between the wheel housing and closing closing panel −H− using the spotweld cutter.
panel
4 Separating spot−welded joint between Separate spot−welded joint of the lower shell to the wheel
lower shell/wheel housing and hinge housing −J, E− and the hinge pillar −I− using the
pillar spotweld cutter.
5 Separating the spot−welded joint Separate the spot−welded joint (vehicle interior) of the
between the wheel housing/ A−pillar front wall −P− and hinge pillar −M− to the wheel housing
and transverse wall using the spotweld cutter.
Grind open the MIG seams −N, O− with the parting
grinder.
Separate the spot−welded joint of the wheel housing on
the outside to the front wall −L− using the spotweld
cutter.
top of page
Preparing wheel housing, lower shell and outer side member for
installation and fitting
Preparing wheel housing, lower shell and outer side member for installation and fitting 1361
einordnung

parts −A, B, C, D, E, F, G, H, I− using the rotary brush.
plug−welding with shielding gas. => Welding wheel housing, lower
shell and outer side members into the body
2 Cleaning the welding Remove underbody coating and paint layers, etc. from the welding
areas areas of the body with a hot−air gun or rotary brush.
3 Inserting outer side Straightening attachment −2− for front−axle mount or on the
member, wheel housing straightening attachment −1− for the impact pipes (impact absorbers)
into the body must fitted for the fitting work.
Fit wheel housing in the body and fasten on straightening attachment
−3− .
Insert spare outer side member on the inner side member.
4
Preparing wheel housing, lower shell and outer side member for installation and fitting 1362
einordnung
Fitting in wings and front Fit the left and right wings and fit in the front lid.
lid => Diagram − body gap dimensions
top of page
Welding wheel housing, lower shell and outer side members
into the body

1 Plug−welding wheel housing/hinge pillar, front Weld the spare wheel housing to the front
wall and cross member under shielding gas wall −N, O− with an interrupted full weld
Plug−weld the connection to the hinge pillar
−M− and the front wall −P, L− under
Welding wheel housing, lower shell and outer side members into the body 1363
einordnung
shielding gas.
2 Spot−welding the wheel housing Spot−weld the wheel housing to the outer
side member −K− .
3 Welding the lower shell under shielding gas Plug−weld the lower shell to the wheel
housing −J, E, I− under shielding gas.
4 Welding outer side member under shielding gas Spot−weld the outer side member to the
and with spot welds inner side member −A, D, C− .
Plug−weld the connection to the front wall
−B− under shielding gas.
5 Welding inner/outer side members and front Weld inner side member to outer side
wall under shielding gas member −E− and the front wall −F− with an
interrupted full weld under shielding gas.
6 Welding side member/support shell under Weld side members to the support shell −G−
shielding gas with a full weld under shielding gas.
top of page
Tools and materials

1 Basic straightening attachments for 911 Carrera (996) No. ’ 3 Workshop Equipment Manual
7250700
2 Additional straightening attachments for 996 Turbo No. ’ 3 Workshop Equipment Manual
7250710
3 Star gauges No. 127−1 ’ 2.4 Workshop Equipment
Manual
5 Multispot spot welder ’ 3 Workshop Equipment Manual
Manual
Manual
13 Spotweld cutter 7 mm, No. 129 ’ 2.4 Workshop Equipment
Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

50 74 56 Replacing wheel housings and side
members (sectional repair)
Cutting out wheel housings and side members
Preparing wheel housings and side members for installation and fitting
Welding in wheel housings and side members
Materials and tools
Partially replacing wheel housings and side members
The following spare body parts are required for the sectional repair Partially replacing wheel housings and
side members :
A Front outer side members

B Front inner side member
C Front wheel housing
top of page
Cutting out wheel housings and side members
50 74 56 Replacing wheel housings and side members (sectional repair) 1365

einordnung
WARNING
must be followed.
• => Safety instructions for raising vehicles

• => Safety instructions for welding
• => Safety instructions for sticking
• => Safety instructions for installation work
• => Safety instructions for corrosion protection
• => General information and quality notes
Note
are removed.
Cutting out wheel housings and side members 1366

einordnung

Remove accessories in the repair area according to the scope of damage existing on the vehicle.
Refit alignment bench with the basic straightening attachments according to the structural plans
included with the straightening attachments.
Position vehicle on alignment bench, align according to the control bores and firmly tighten with
the straightening attachment. Additionally fasten alignment bench to the bottom seam of the
vehicle with the side clamping claws.
Cover all accessories remaining in the vehicle and the neighbouring areas with fire−proof covers.
Reshape connection area of the sheetmetal parts to be replaced.
Expose welding areas Remove underbody coating and paint layers, etc. from the
welding areas of the body with the hot−air gun or rotary brush.
Closing panel and front floor => Replacing closing panel
panel already cut out
Front wall already cut out => Replacing front wall
1 Removing the wheel housings Remove the damaged sections of the wheel housings −B− with
the body saw.
Position the cut within the specified dimension −Y = 580 mm− .
2 Cutting off inner side member Note:
Do not cut through the inner reinforcements −arrow− when
cutting through the inner side members.
Remove the damaged sections of the inner/outer side members
−F− with the body saw.
Position the cut −Y− within the specified dimension −580 mm− .
3 Cutting off outer side members Do not cut through the inner reinforcements −arrow− when
and shortening to the offset to cutting through the outer side members.
the wheel housings Position the cut within the specified dimension −Y = 580 mm− .
Shorten the side members with the body saw and the spotweld
cutter, so that there is an offset of −dimension X = 50 mm−
between the inner/outer side members and the wheel housing.
top of page
Preparing wheel housings and side members for installation and
fitting
Preparing wheel housings and side members for installation and fitting 1367
einordnung

1 Preparing spare parts Transfer cut to the spare front wheel housings and then cut
to size.
Cut the spare side members to size with the body saw and
then fit so that there is an offset of −dimension X = 50
mm− between the inner and outer side members.
Remove the factory−applied primer on the welding areas
of the spare parts −A, B, C, D, E, F, G, H, I,− with the
rotary brush.
Drill or punch (with a hole punch) 7 mm holes spaced
20mm apart for plug−welding under shielding gas.
=> Welding in wheel housings and side members
2 Cleaning the welding areas Remove underbody coating and paint layers, etc. from the
welding areas of the body with a hot−air gun or rotary
brush.
Preparing wheel housings and side members for installation and fitting 1368
einordnung
3 Fitting the side members and wheel Fasten the spare innner side member on the straightening
housing in the body and fastening attachment for the front−axle mount or on the straightening
them on the straightening attachments. attachments for the impact pipes (impact absorbers) and fit
it in.
4 Fitting in front wall => Replacing front wall
5 Fitting the front floor panel in the => Replacing closing panel
body and fastening it on the
straightening attachment.
6 Fitting in wings and front lid Fit the left and right wings and fit in the front lid.
=> Gap dimensions, body front
top of page
Welding in wheel housings and side members
Welding in wheel housings and side members 1369

einordnung
Note
• When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit
width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

1 Welding in the inner side member. Weld the inner side member with a full butt weld −F−
2 Welding in wheel housings. Spot−weld wheel housings and inner side members −A−
. Weld the wheel housing from the outside with a full
butt weld −B− under shielding gas.
3 Welding in the outer side member. Spot−weld the outer side member to the inner side
member −H, I− . Weld the outer side member with a full
butt weld −F− under shielding gas.
4 Welding in front wall => Welding in front wall
5 Welding in closing panel and front => Welding in closing panel and front floor panel
floor panel
Removing vehicle from the Detach side clamping jaws and straightening
alignment bench attachments on the vehicle. Remove vehicle from the
alignment bench.
Cleaning spot−welded joints and Clean spot−welded joints and sheetmetal flanges with a
sheetmetal flanges with a wire brush wire brush. Grind shielding gas weld area visible after
installation, apply body solder to connectors to body and
align.
Prime flange areas with 2K primer.
Restore standard sealing with body sealant.
Paint exterior outer parts and neighbouring areas.
Restore standard undersealing protection with permanent undersealing protection agent.
Supplement cavity preservation.
Install removed accessories in the repair area.
top of page
Materials and tools

1 Basic straightening attachments for 911 Carrera (996) Nr. ’ 3 Workshop Equipment
7250700 Manual
2 Additional straightening attachments for 911 Turbo (996) Nr. ’ 3 Workshop Equipment
7250710 Manual
3 Star gauges Nr. 127−1 ’ 2.4 Workshop Equipment
Manual
Materials and tools 1370

einordnung
4 Shielding−gas welding device ’ 3 Workshop Equipment

Manual
5 Multispot spotwelder ’ 3 Workshop Equipment
Manual
6 Pneumatic body saw ’ 3 Workshop Equipment
Manual
7 Angle grinder ’ 2.4 Workshop Equipment
Manual
8 Oscillating body saw (special electrical cutter) ’ 3 Workshop Equipment
Manual
9 Multispot spotweld cutter ’ 3 Workshop Equipment
Manual
Manual
11 Hot−air gun ’ 3 Workshop Equipment
Manual
Manual
13 Spot−weld cutter 7 mm Nr. 129 ’ 2.4 Workshop Equipment
Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Materials and tools 1371

50 79 55 Replacing front inner side member
Removing front inner side member
Preparing and fitting the front inner side member for installation
Welding in front inner side member
Materials, tools
A Inner side member

B Web plate
top of page
Removing front inner side member
50 79 55 Replacing front inner side member 1372

einordnung
WARNING
must be followed.

Note
are removed.
Removing front inner side member 1373

einordnung

Remove accessories in the repair area according to the scope of damage existing on the
vehicle.
Refit alignment bench with the basic straightening attachments according to the structural
plans included with the straightening attachments.
Position vehicle on alignment bench, align according to the control bores and firmly tighten
with the straightening attachment. Additionally fasten alignment bench to the bottom seam of
the vehicle with the side clamping claws.
Cover all accessories remaining in the vehicle and the neighbouring areas with fire−proof
covers.
Replacing closing panel => Replacing closing panel
Replacing wheel housing => Replacing wheel housing
Replacing front wall => Replacing front wall
1 Disconnecting web plate Cut through the shielding gas weld −A− on the connection of the
web plate to the firewall.
2 Separating inner side Separate the spot−welded joints −B, C− using the spotweld cutter.
member Cut through the shielding gas weld −G− using the parting grinder.
3 Separating lower side Cut through the shielding gas weld −E, F− to the bottom floor of
member side member.
top of page
Preparing and fitting the front inner side member for installation
Preparing and fitting the front inner side member for installation 1374
einordnung

1 Cleaning the welding areas Remove the factory−applied primer on the welding areas of the
spare parts −A, B, C, D, E, F, G, X− using the rotary brush.
=> Welding in front inner side member
2 Cleaning welding and sealing Remove underbody coating and paint layers, etc. from the welding
areas areas of the body with the hot−air gun or rotary brush.
Coat single point flange areas All single point flange areas which will not receive a body adhesive
with zinc−rich varnish. application should be coated with a zinc−rich varnish −A, B, C, D,
E, F, G, X− .
3 Reinforcement spot welding Spot−weld the reinforcement −X− and the side member with six
spotwelds.
4 Inserting the side member Straightening attachment −arrow− for front−axle mount or on the
into the body impact pipe (impact absorber) −arrow− must be screwed on for the
Preparing and fitting the front inner side member for installation 1375
einordnung
fitting work.
5 Fitting web plate Fit the web plate on the inner side member.
6 Drilling through firewall Drill open the firewall from inside (passenger compartment) using
drill bit 7 mm.
top of page
Welding in front inner side member
Note
• When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit
width s = 1x sheet thickness to guarantee the required welding quality (welding through).
Welding in front inner side member 1376

einordnung

1 Spot−welding inner side Spot−weld web plate to side member −B, C− . Weld the
member/web plate connection to firewall −A− with an interrupted butt weld seam
2 Welding inner firewall/side Plug−weld the predrilled holes −D− from the firewall to inner
member under shielding gas side member.
3 Welding inner side member/ Weld the inner side member/base side member with a full butt
base side member under weld −F, E− under shielding gas.
shielding gas.
4 Inner side member/firewall Weld inner side member/firewall −G− with interrupted weld
seam under shielding gas.
Replacing front wall => Replacing front wall
Replacing wheel housing => Replacing wheel housing
Replacing closing panel => Replacing closing panel
Removing vehicle from the Detach side clamping jaws and straightening attachments on the
alignment bench vehicle. Remove vehicle from the alignment bench.
Cleaning spot−welded joints and Clean spot−welded joints and sheetmetal flanges with a wire
sheetmetal flanges with a wire brush. Grind shielding gas weld area visible after installation,
brush apply body solder to connectors to body and align.
top of page
Materials, tools

1 Straightening attachments 996 Gr. 3; Workshop Equipment Manual
Carrera
2 Additional straightening Gr. 3; Workshop Equipment Manual
attachments for 996 Turbo
2 Star gauges 127−1 Gr. 2.4; Workshop Equipment Manual
3 MIG welder Gr. 3; Workshop Equipment Manual
4 Multispot spotwelder Gr. 3; Workshop Equipment Manual
5 Pneumatic body saw Gr. 3; Workshop Equipment Manual
6 Angle grinder Gr. 3; Workshop Equipment Manual
7 Gr. 3; Workshop Equipment Manual
Materials, tools 1377

einordnung
Oscillating body saw (special

electrical cutter)
8 Multispot spotweld cutter Gr. 3; Workshop Equipment Manual
9 Hole punch Gr. 2.4; Workshop Equipment Manual
10 Hot−air gun Gr. 3; Workshop Equipment Manual
11 Rotary brush Gr. 3; Workshop Equipment Manual
12 Spotweld cutter 7 mm 129 Gr. 2.4; Workshop Equipment Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Materials, tools 1378

50 93 30 Cleaning front water drains on Coupé and
Cabriolet
Cleaning front water drains on Coupé and Cabriolet
top of page
Cleaning front water drains on Coupé and Cabriolet
50 93 30 Cleaning front water drains on Coupé and Cabriolet 1379

einordnung
CAUTION
Material damage due to water leakage!
• Water drainage hoses can be pushed out or pressed in when blown out of the body
• The water drains should be blown out carefully with compressed air.

Removing cowl panel ’ 702219 Removing and installing cowl panel cover
cover
1 Blow out water drains on Carefully blow out water drainage −1− from top −inset A− on
right side of front end right side of front of vehicle. Remove dirt particles from the
radiator tank −inset B− with the vacuum cleaner.
Cleaning front water drains on Coupé and Cabriolet 1380

einordnung
2 Blow out water drains on Carefully blow out water drainage −2− from top −inset A− on
right side of front end right side of front of vehicle. Remove dirt particles from the
radiator tank −inset B− with the vacuum cleaner.
3 Blow out water drainage on Put vehicle onto platform lift and carefully blow out the left water
left side of front end. drainage −3− −inset B− from the outside of the wheel arch.
Remove dirt particles from the radiator tank −inset B− with the
vacuum cleaner.
4 Blow out water drainage on Put vehicle onto platform lift and carefully blow out the left water
left side of front end. drainage −4− −inset A− from the outside of the wheel arch.
Remove dirt particles from the radiator tank −inset B− with the
vacuum cleaner.
Installing cowl panel cover ’ 702219 Removing and installing cowl panel cover
996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Cleaning front water drains on Coupé and Cabriolet 1381

51 03 55 Replacing roof
Removing roof
Preparation of roof for installation and fitting
Welding in roof
Tools and materials
The following spare body parts are required for the repair Replacing roof :
A Roof
top of page
Removing roof
51 03 55 Replacing roof 1382

einordnung
WARNING
must be followed.

Note
are removed.
Removing roof 1383

einordnung

Remove accessories in the repair area according to the scope of damage existing on the vehicle.
Refit alignment bench with the basic straightening attachments according to the structural plans
included with the straightening attachments.
Position vehicle on alignment bench, align according to the control bores and firmly tighten with
the straightening attachment. Additionally fasten alignment bench to the bottom seam of the
vehicle with the side clamping claws.
Cover all accessories remaining in the vehicle and the neighbouring areas with fire−proof covers.
1 Separating the spot−welded Separate the spot−welded joints between the outer roof panel and
joints between the outer roof the outer side section −C, D− and on the cowl panel frame −A−
panel/outer side section with the spotweld cutter.
2 Separating the spot−welded Separate the spot−welded joint between the outer roof panel and
joints between the outer roof the rear roof frame −B− with the spotweld cutter.
panel/rear roof frame
3 Separating the bonded joint Heat up the bonded joint between the outer roof panel and the
between the cowl panel frame cowl panel frame or the rear roof frame with the hot−air gun.
on the outer roof panel/rear roof Insert a metal spatula between the bonded joints and separate
frame them. Lift the outer roof panel upwards out of the body.
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Preparation of roof for installation and fitting
Preparation of roof for installation and fitting 1384

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1 Preparing spare part Remove the factory−applied primer on the welding areas of the spare part
−A, B, C, D− using the rotary brush.
2 Cleaning the Remove underbody coating and paint layers, etc. from the welding areas of
welding areas the body with a hot−air gun or rotary brush.
3 Fitting the outer Insert outer roof panel into the body.
roof panel Measure the dimension −X = 25.2 mm− on the left and right of the roof
channel.
It is necessary to measure dimension X between four corner points on the
outer roof panel and the outer side section.
4 Installing roof joint As a check, install the roof joint strips on the left and right.
strips ’ 663619 Removing and installing roof joint strip.
If necessary, recenter outer roof panel.
Preparation of roof for installation and fitting 1385

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top of page
Welding in roof
CAUTION
Observe the working time of the adhesive!
• The new part must be welded in within 30 minutes. Otherwise the adhesion of the adhesive is
impaired.

1 Applying adhesive => Tools and materials
Observe the working time of the adhesive:
Welding in roof 1386

einordnung
apply the adhesive evenly to the inside of the cowl panel

frame and the rear roof frame as a triangular bead
−dimension X = approx. 8 mm− .
2 Spot welding the outer roof Spot−weld the outer roof panel to the outer side section
panel/outer side section −C, D− .
Ensure that the spot−welding is carried out within the
corrugated cut−out of the inner roof frame −E− .
3 Spot welding the outer roof Spot−weld the outer roof panel to the rear roof frame
panel/rear roof frame −B− .
Removing vehicle from the Detach side clamping jaws and straightening
alignment bench attachments on the vehicle. Remove vehicle from the
alignment bench.
Cleaning spot−welded joints and Clean spot−welded joints and sheetmetal flanges with a
sheetmetal flanges with a wire brush wire brush. Grind shielding gas weld area visible after
installation, apply body solder to connectors to body and
align.
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Tools and materials

1 Teromix−6700 2−component adhesive Spare part Gr. 8; Parts Catalogue
2 Teromix processing nozzle Manufacturer: Henkel Teroson GmbH
Postfach 10 56 20
69046 Heidelberg
Hans−Bunte−Straße 4
Tel.: (066221) 7040
Fax: (066221) 704585
3 Basic straightening attachments for 911 Carrera (996) Gr. 3; Workshop Equipment Manual
10 Oscillating body saw (special electrical cutter) Gr. 3; Workshop Equipment Manual

einordnung

996420, 996430, 996431, 996840, 996841

51 21 55 Replacing rear centre panel
Removing rear centre panel
Preparing the rear centre panel for installation and fitting
Welding in the rear centre panel
Tools and materials
The following spare body parts are required for the repair Replacing rear centre panel :
A = Rear centre panel
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Removing rear centre panel
51 21 55 Replacing rear centre panel 1389

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WARNING
must be followed ’ 5 Safety instructions
Note
are removed.

1 Separate the spot−welded joint Separate the spot−welded joint between the outer rear centre
on the rear window aperture panel, the rear centre panel lock plate and the
Removing rear centre panel 1390

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convertible−top rest cross member −A, B− with the spotweld

cutter.
When loosening the connection −A− , both the body panels
(rear centre panel and rear centre panel lock plate) must be
cut open.
2 Separate rear centre panel from Cut through the brazed seam −C− on the connection to the
side section side section with the parting grinder.
3 Remove the rear centre panel At the factory, the rear centre panel is sealed to the
convertible−top rest cross member with an expanded sealant
on the left and right −arrows− . This seal is destroyed when
replacing the rear centre panel and must be replaced.
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Preparing the rear centre panel for installation and fitting
Preparing the rear centre panel for installation and fitting 1391
einordnung

1 Clean the Remove the factory−applied primer on the welding areas of the spare part −A,
welding areas B, C− using the rotary brush.
2 Prepare spare Remove underbody coating and paint layers, etc. from the welding areas of the
part body with a hot−air gun or rotary brush.
3 Set gap Set the gap between the side sections and the rear lid
=> Diagram − body gap dimensions
4 Insert seal On the inside of the new rear centre panel, a sealing foam −D− is applied. A
triangular bead −dimension "X" = approx. 15 mm− of body sealant must be
applied to the sealing foam.
Apply another triangular bead −dimension "X" = approx. 15 mm− of body
sealant into the impression on the underside of the convertible−top rest cross
member −E− .
5 Insert the rear Set the gap between the side sections and the rear lid
centre panel => Diagram − body gap dimensions
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Welding in the rear centre panel
Welding in the rear centre panel 1392

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1 Spot−weld the rear centre panel Spot−weld the connection between the rear centre panel and the
convertible−top rest cross member, top −A− or bottom −B− .
2 Weld the connection to the side Weld the overlap of the connection to the side section with a full
section under shielding gas. weld −C− of approx. 15 mm under shielding gas.
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Tools and materials
Item Tools Explanation

1 Star gauges Nr. 127−1 Gr. 2.4; Workshop Equipment Manual

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11 Spotweld cutter 7 mm Nr. 129 Gr. 2.4; Workshop Equipment Manual
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

51 45 55 Replacing lower side member
Cutting out lower side member
Preparation for installation of lower side member and fitting
Welding in lower side member
Tools and materials
The following spare body parts are required for the sectional repair Replacing lower side member :
A = lower side member
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51 45 55 Replacing lower side member 1395

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WARNING
must be followed. ’ 5 Safety instructions
Note
are removed.

1 Separating the spot−welded joint Separate the spot−welded joint between the outer lower side
between the outer/inner lower member and the inner lower side member −A− with the
Cutting out lower side member 1396

einordnung
side members spotweld cutter.

Cut through the connection to the A−pillar −B− with the body
saw. Position the cut so that the spare body part (outer lower
side member) overlaps A−pillar by approx. 60 mm.
Cut the connection to the side section −E− with the body saw.
Position the cut so that the spare body part (outer lower side
member) overlaps the side section by approx. 60 mm.
2 Sawing through the web plate Cut through the web plate at the top and bottom −F, G− with
the body saw.
3 Separating the spot−welded joint Separate the spot−welded joint between the outer lower side
between the outer/inner lower member and the inner lower side member −C− with the
side members spotweld cutter.
4 Separating the spot−welded joint Separate the spot−welded joint between the web plate and the
between the web plate/inner inner lower side member −D− with the spotweld cutter.
lower side member
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Preparation for installation of lower side member and fitting 1397

einordnung

1 Cleaning the welding Remove the factory−applied primer on the welding areas of the spare
areas part −A, B, C, D, E− using the rotary brush.
2 Preparing spare part Remove underbody coating and paint layers, etc. from the welding
3 Inserting outer lower side Insert outer lower side member into the body.
member Cut through the outer lower side member, overlapping at the separation
Fitting lower side member point, flush with the A−pillar −B− with the body saw.
separation point
4 Fitting lower side member Cut through the outer lower side member, overlapping at the separation
separation point point, flush with the side section −E− with the body saw.
5 Setting gap Set gap between door and outer lower side member. ’ 5 Body gap
dimensions

einordnung
top of page

1 Welding outer/inner lower side Plug−weld the outer lower side member to the inner lower side
members under shielding gas member −A− under shielding gas.
Weld the connection to the A−pillar −B− and the connection to
the side section −E− with a full weld under shielding gas.
2 Welding the web plate under Weld the web plate and the inner lower side member −D−
shielding gas together with an interrupted full weld under shielding gas.
3 Welding outer/inner lower side Plug−weld the outer lower side member and the inner lower
members under shielding gas side member −C− together under shielding gas.
Welding in lower side member 1399

einordnung
top of page
Tools and materials

1 Star gauges Nr. 127−1 ’ 2.4 Workshop Equipment Manual
2 MIG welder ’ 3 Workshop Equipment Manual
7 Hole punch ’ 2.4 Workshop Equipment Manual
10 Spotweld cutter 7 mm Nr. 129 ’ 2.4 Workshop Equipment Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

51 45 55 Replacing lower side member − Cabriolet
Tools and materials
The following spare body parts are required for the repair Replacing lower side member :
A = Lower side member
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51 45 55 Replacing lower side member − Cabriolet 1401

einordnung
WARNING
must be followed.

Note
are removed.
Cutting out lower side member 1402

einordnung

1 Separating the spot−welded Cut through the spot−welded joint between the outer lower side
joint between the outer/inner member and the inner lower side member −A− or between the
lower side members outer lower side member and the A−pillar −B− with the spotweld
cutter.
Cut through the connection to the side section −E− with the body
saw. Position the cut so that the spare body part (outer lower side
member) overlaps the side section by approx. 60 mm.
2 Sawing through the web plate Cut through the web plate at the top and bottom −F, G− with the
body saw.
3 Separating the spot−welded Separate the spot−welded joint between the outer lower side
joint between the outer/inner member and the inner lower side member −C− with the spotweld
lower side members cutter.
4 Separating the spot−welded Separate the spot−welded joint between the web plate and the
joint between the web inner lower side member −D− with the spotweld cutter.
plate/inner lower side member
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einordnung

1 Cleaning the welding Remove the factory−applied primer on the welding areas of the spare
areas part −A, B, C, D, E− using the rotary brush.
2 Preparing spare part Remove underbody coating and paint layers, etc. from the welding
3 Inserting outer lower side Insert outer lower side member into the body.
member
4 Fitting lower side member Cut through the outer lower side member, overlapping at the separation
separation point point, flush with the side section −E− with the body saw.
5 Setting gap Set gap between door and outer lower side member.
=> Gap dimensions, body centre
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einordnung

1 Welding outer/inner lower side Plug−weld the outer lower side member and the inner lower side
members under shielding gas member −A− as well as the connection to the A−pillar −B− with
shielding gas.
Weld the connection to the side section −E− with a continuous
full weld under shielding gas.
2 Welding the web plate under Weld the web plate and the inner lower side member −D−
shielding gas together with an intermittent full weld under shielding gas.
3 Welding outer/inner lower side Plug−weld the outer lower side member and the inner lower side
members under shielding gas member −C− together under shielding gas.
Welding in lower side member 1405

einordnung
top of page
Tools and materials

1 Star gauges no. 127−1 ’ 2.4 Workshop Equipment Manual
2 MIG welder ’ 3 Workshop Equipment Manual
3 Body saw ’ 3 Workshop Equipment Manual
7 Hole punch ’ 2.4 Workshop Equipment Manual
10 Spotweld cutter 7 mm no. 129 ’ 2.4 Workshop Equipment Manual
996630, 996631, 996620, 996621, 996650, 996651

51 63 19 Removing and installing deformation
element
Removing deformation element
Installing deformation element
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Removing deformation element
’ 705719 Removing the A−pillar trim
51 63 19 Removing and installing deformation element 1407

einordnung
1. Boring out deformation element

Drill out the pop rivets −1− using a 4 mm drill and remove the deformation
element −A− .
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Installing deformation element
WARNING
Danger of injury by damaged deformation elements after an accident!
• It is impermissible to perform repairs on the deformation elements.

• The deformation elements must be replaced in the event of visible damage or pressure marks.
1. Riveting on deformation element

Position deformation element −A− on inner cowl panel frame and rivet down using the pop
rivets −1− .
’ 705719 Installing A−pillar trim
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Removing deformation element 1408

51 87 55 Replacing seat cross member
Cutting out seat cross member
Preparation of seat cross member for installation and fitting
Welding in seat cross member
Tools and materials
The following spare body parts are required for the repair Replacing seat cross member :
A Seat cross member
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Cutting out seat cross member
51 87 55 Replacing seat cross member 1409

einordnung
WARNING
must be followed.

Note
are removed.
Cutting out seat cross member 1410

einordnung

Remove accessories in the repair area according to the scope of damage existing on the
vehicle.
Cover all accessories remaining in the vehicle and the neighbouring areas with fire−proof
covers.
Expose welding areas Remove underbody coating and paint layers, etc.
from the welding areas of the body with the
hot−air gun or rotary brush.
1 Separating spot−welded joints between the Separate the spot−weld joints between the seat
seat cross member and floorpan cross member and the floorpan −A, B− with the
spot−weld cutter.
2 Separating spot−welded joints between the Separate the spot−weld joints −C− between the
seat cross member and inner member seat cross member and inner member with the
spot−weld cutter.
3 Separating spot−welded joints between the Separate the spot−welded joints −D, E, F−
seat cross member and inner member between the seat cross member and inner lower
side member with the spot−weld cutter.
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Preparation of seat cross member for installation and fitting
Preparation of seat cross member for installation and fitting 1411

einordnung

1 Preparing spare Remove the factory−applied primer on the welding areas of the spare parts
parts −A, B,− using the rotary brush.
Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart for
plug−welding with shielding gas.
=> Welding in seat cross member
2 Cleaning the Remove underbody coating and paint layers, etc. from the welding areas of
welding areas the body with the hot−air gun or rotary brush.
3 Measuring seat Measure the seat cross member at the front screwed points (hole center)
cross member forward to the hole edge of the reinforcement in the floorpan
−dimension X = 405 mm−
−dimension Y = 453 mm−
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Preparation of seat cross member for installation and fitting 1412

einordnung
Welding in seat cross member

1 Plug−welding seat cross Plug−weld the seat cross member at the front and rear −A, B−
member under shielding gas under shielding gas.
2 Plug−welding seat cross Plug−weld the seat cross member at the sides −C− under
member under shielding gas shielding gas.
3 Plug−welding seat cross Plug−weld the seat cross member at the sides and middle −D, E,
member under shielding gas F− under shielding gas.
Cleaning spot−welded joints Clean spot−welded joints and sheetmetal flanges with a wire
and sheetmetal flanges with a brush. Grind shielding gas weld area visible after installation,
wire brush apply body solder to connectors to body and align.
Welding in seat cross member 1413

einordnung

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Tools and materials

5 Oscillating body saw (special Gr. 3; Workshop Equipment Manual
electrical cutter)
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

51 90 19 Removing and installing underside panel
Removing and installing front cover
Removing and installing middle cover
Removing and installing rear trim
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Removing and installing front cover
51 90 19 Removing and installing underside panel 1415

einordnung

1 Plastic nut 4 Check, if necessary, replace.
2 Clip 6 Insert a narrow screwdriver sideways into Check, if necessary, replace.
the clip and press out. The clip must lock with an
audible click.
3 Underside panel 1 Remove from underside panel middle. Insert in the middle of the
front underside panel.
4 Expanding rivet 6 Check, if necessary, replace.
5 Masking panel 1
left
6 Masking panel 1
right
Removing and installing front cover 1416

einordnung
top of page
Removing and installing middle cover

2 Side underside panel 1
3 Underside panel 1 Remove from underside panel front Insert in the underside panel front
middle and rear. and rear.
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Removing and installing middle cover 1417

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Removing and installing rear trim

2 Fastening screw 6
3 Underside panel 1 Remove from underside panel Insert in the middle of the underside
rear middle. panel.
996420, 996421, 996450, 996451, 996630, 996631, 996620, 996621, 996650, 996651, 996430, 996431
Removing and installing rear trim 1418

53 05 55 Replacing rear closing panel
Cutting out rear closing panel
Preparing the rear closing panel for installation and fitting
Welding in rear closing panel
Tools and materials
A = closing panel
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53 05 55 Replacing rear closing panel 1419

einordnung
WARNING
Note
are removed.

Place vehicle on the Place the vehicle with the units mounted at the front onto the set of
alignment bench straightening attachments and fasten it in position.
Cutting out rear closing panel 1420

einordnung
1 Separate the spot−welded Use a spotweld cutter to separate the connection between the inner
joint at the rear closing panel. side members and the rear closing panel −A− on the left and right.
2 Separate the spot−welded Use the spotweld cutter to separate the connection between the side
joint at the rear closing panel. section on the inside and the rear closing panel −B, C− .
3 Separate the spot−welded Separate the spot−welded joint between the engine mount at top
joint on the engine mount at −D− and the inner side member and the connection to the inner side
top section −F− with the spot−weld cutter.
4 Separate the spot−welded Use the spotweld cutter to separate the spot−welded joint between
joint on the engine mount at the engine mount at bottom −E− and the inner side member.
bottom
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Preparing the rear closing panel for installation and fitting
Preparing the rear closing panel for installation and fitting 1421
einordnung

1 Prepare spare parts Remove the factory−applied primer on the welding areas of the
spare parts −A, B, C, D, E− using the rotary brush.
Drill or punch (with a hole punch) 7 mm holes spaced 20 mm
apart for plug−welding with shielding gas
=> Welding in rear closing panel
2 Clean the welding areas Remove underbody coating and paint layers, etc. from the
welding areas of the body with a hot−air gun or rotary brush.
3 Insert the closing panel into Insert the closing panel spare part into the body and fasten it to
the body the straightening attachments.
If necessary, align it with the inner side sections and the side
members.
4 Fit add−on parts and check Fit the lid and set the gap dimensions
gap dimensions => Diagram − body gap dimensions => Removing and
installing rear lid
Fit the lower part of the lid lock at the rear => Removing and
installing lower part of lid lock and check whether the upper
part of the lock engages in the lower part of the lock.
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Welding in rear closing panel
Welding in rear closing panel 1422

einordnung

1 Plug−weld reinforcement/side member at Plug−weld the reinforcement between the side
bottom under shielding gas members at bottom −E− and the closing panel
2 Spot−weld the rear closing panel/side Spot−weld the connection between the inner
member on the inside side members −B, C− and the rear closing
panel on the left and right.
3 Plug−weld the engine mount/side member at Plug−weld the engine mounts at the left and
top under shielding gas right to the side member at top −D− under
shielding gas.
Plug−weld the connection −F− to the inner
side section with an approx.10 mm full weld.
4 Spot−weld the closing panel/side members Plug−weld the connection between the inner
on the inside side members −A− and the closing panel under
shielding gas.
Welding in rear closing panel 1423

einordnung
top of page
Tools and materials

2 Additional straightening attachments for 996 Turbo Gr. 3; Workshop Equipment Manual
996420, 996421, 996450, 996451, 996840, 996841

53 55 55 Replacing side section
Cutting through side section
Preparing side section for installation and fitting
Welding in the side section
Flanging the wheel arch edges GT2
Tools and materials
A = Side section
B = Seal
top of page
Cutting through side section
53 55 55 Replacing side section 1425

einordnung
WARNING
Note
are removed.

1 Separate the spot−welded Separate the spot−welded joint between the side section and the
joint on the B−pillar inner side section −A− with the spotweld cutter. Cut off the lower
Cutting through side section 1426

einordnung
side member −H− so that the spare body part (side section) overlaps
the lower side member by approx. 60 mm.
2 Separate the spot−welded Separate the spot−welded joint between the side section −C− and
joint on the lower side the lower side member −B− or wheel housing with the spotweld
member and the wheel cutter.
housing
3 Cut through centre of Trim the side section at the B−pillar centre with the body saw
B−pillar making a cut −G− so that the spare body part overlaps the centre of
the B−pillar by approx. 60 mm.
4 Cut through side section at Trim the side section at the C−pillar with the body saw making a cut
C−pillar −F− so that the spare body part overlaps the C−pillar by approx. 60
mm.
5 Separate the spot−welded Separate the spot−welded joint on the side window aperture of the
joint on the side window rear window −D− using the spotweld cutter.
aperture
Cutting through side section 1427

einordnung

6 Separate the spot−welded Separate the spot−welded joint between the side section of the rear
joint of the rear window window aperture and the inside of the side section −E− with the
aperture spotweld cutter.
7 Separate side section from Separate the spot−weld joint of the overlapping rear centre panel at the
rear centre panel top −2− using the spotweld cutter. Cut through the shielding gas weld
−1− on the connection to the lower side section with the parting
grinder.
8 Separate the spot−welded Separate the spot−welded joint between the light housing and the
joint on the light housing inside of the side section −3− and the rear transverse lock panel
connection −F− with the spotweld cutter.
9 Remove side section The side section is sealed from the light housing to the rear centre
panel connection in the factory using an expanded sealant. This seal
−4− is destroyed when replacing the side section and must be replaced.
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Preparing side section for installation and fitting
Preparing side section for installation and fitting 1428

einordnung

1 Clean welding Remove the factory−applied primer on the welding areas of the spare parts −A,
and sealing areas B, C, D, E, F, G, H, I− using the rotary brush.
plug−welding with shielding gas
=> Welding in the side section
2 Clean the welding Remove underbody coating and paint layers, etc. from the welding areas of the
areas body with the hot−air gun or rotary brush.
3 Adapt the side Fit the side section to the body. Insert door and rear lid to check the body
section to the contour. Adjust the gap dimensions between the door and rear lid and the body
body => Diagram − body gap dimensions
4 Fit side section Cut through both panels at the separation points where the side section overlaps
separation points the lower side member −I− , C−pillar −G− and B−pillar centre −H− using the
body saw.
5 Insert seal
Preparing side section for installation and fitting 1429

einordnung
Apply a triangular bead of body sealant −dimension "X" = approx. 12 mm−

high on all sides of the seal. Apply seal to the prepared holes on the inner side
section, position the pins at the seal and press into place.
CAUTION
Observe the working time of the adhesive (Items 5 and 6)!
• The new part must be welded in within 30 minutes. Otherwise the adhesion of the adhesive is
impaired.

6 Bond light housing with the Apply a triangular bead of adhesive (Teromix−6700)
inside of the side section −dimension "X" = approx. 10 mm high− on the
connection from the light housing to the inside of the side
section. The light housing must lie flush with the side
section.
7 Apply adhesive to the wheel Apply the adhesive as a triangular bead −dimension "X" =
arch up to the start of the side approx. 8 mm− on the inside of the side section, along the
member wheel arch up as far as the start of the side member.
8 Tack−weld side section under 1. On the inside of the side section, in the corner
shielding gas area, apply approx. 40 x 10 mm a triangular bead
of body sealant −dimension "X" = approx. 12
mm− .
2. Insert side section into the body. Check the
contours and gap dimensions. => Diagram −
body gap dimensions Tack−weld the side section
under shielding gas at the separation points.
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Welding in the side section
Welding in the side section 1430

einordnung

1 Weld the B−pillar under Plug−weld the B−pillar side section to the inside of the side
shielding gas section −A− under shielding gas. Weld the lower side member
connection on the side section to the lower side member −I−
with a continuous butt weld under shielding gas.
2 Weld B−pillar and C−pillar Weld B−pillar −H− and C−pillar −G− with a continuous butt
under shielding gas weld under shielding gas.
3 Spot−weld wheel arch and Plug−weld underside of lower side member −B− . Spot−weld
lower side member under wheel arch −C− .
shielding gas
4 Spot−weld side window Spot−weld the side window aperture to the inside of the side
aperture section −D− .

einordnung

5 Spot−weld rear Spot−weld the rear window aperture to the inside of the side section −E− .
window aperture
6 Spot−weld light Spot−weld light housing with the connecting angle and the connection to the
housing transverse lock panel −F− . On the inside of the side section (small figure),
make sure that the welding nuts are lined up with the hole pattern in the side
section. Screw in M6 hexagon−head bolts to position. Spot−weld the
connection with the side section −3− .
7 Weld the rear Plug−weld the top connection of the rear centre panel to the side section −2−
centre panel under shielding gas. Weld the lower connection with a continuous butt weld of
under shielding approx. 20 mm −1− under shielding gas.
gas
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einordnung
Flanging the wheel arch edges GT2

The Turbo Design wheels 12J x 18 ET 45 with 315/30 TR 18 tyres finish almost flush with the wing
apertures. Rework on the wheel−arch edges is only necessary with the above−mentioned wheel dimensions.
CAUTION
Paint damage can occur in the event of improper reworking of the wing seam!
• Only carry out reworking on painted wings when the wing seam is partially warmed.
• Partial painting is required if the conditions are unfavourable.
1. Reworking the wing seam

In the areas shown −A = approx. 50 mm− , −B = approx. 295 mm− , −C = approx. 25 mm− , the wing
seam and, if necessary, the rear spoiler must be reworked.
The wing seam must be flanged over a width of at least −D = 10 mm− and at least −E = 60°− ; never flange,
grind or cut off more than 65°.
2. Reworking rear spoiler

If the rear spoiler protrudes beyond the flanged side section, the protruding material of the rear spoiler
−arrow, inset X− must be ground or cut away.
top of page
Tools and materials

2 Additional straightening attachments for 996 Turbo Gr. 3; Workshop Equipment Manual
Flanging the wheel arch edges GT2 1433

einordnung

14 Teromix−6700 2−component adhesive Spare part Gr 8; Parts Catalogue;
Manufacturer: Henkel Teroson GmbH
Postfach 10 56 20
69046 Heidelberg
15 Teromix processing nozzle Spare part Gr 8; Parts Catalogue;
Manufacturer: Henkel Teroson GmbH
Postfach 10 56 20
69046 Heidelberg
996840, 996841, 996420, 996421, 996450, 996451, 996430, 996431

53 93 30 Cleaning rear water drains on Coupe and
Cabriolet
Cleaning rear water drains on Coupe and Cabriolet
Illustrated on the 911 Carrera Coupe and Cabriolet (996)
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Cleaning rear water drains on Coupe and Cabriolet
53 93 30 Cleaning rear water drains on Coupe and Cabriolet 1435

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CAUTION
Material damage due to water leakage!
• Water drainage hoses can be pushed out or pressed in when blown out of the body.
• The water drains should be blown out carefully with compressed air.
• The water hoses should only be blown out when the sliding/tilting roof is closed.

Removing side−panel lining ’ 707519
Removing rear wheel housing liners => Removing and installing wheel housing liners, rear
1
Cleaning rear water drains on Coupe and Cabriolet 1436

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Blowing out the water drain tube in Carefully blow out the water drain tube −A− in the water
the rear wheel housings on the left collection tray on the left and right. Remove any dirt
and right. particles from the water collection tray using the vacuum
cleaner −B− .
Installing side−panel lining ’ 707519
2 Blowing out the water drainage Water drainage hose:
hoses from the sliding/tilting roof at Carefully blow out the front water drainage hose in the
the front, rear, left and right. B−pillar −A− .
Rear water drainage hose:

Put vehicle onto lifting platform and carefully blow out the
water drain −A− on the left and right in the rear wheel
housing from the outside of the wheel arch.
Open sliding/tilting roof and remove dirt particles from the

sliding roof frame using the vacuum cleaner.
Installing wheel housing liner => Removing and installing wheel housing liners, rear
996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Cleaning rear water drains on Coupe and Cabriolet 1437

55 62 19 Removing and installing front emergency
release − as of MY 2003
Shown on 911 Carrera (996)
55 62 19 Removing and installing front emergency release − as of MY 2003 1438

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USA and Canada vehicles only

1 Luggage 1 Undo luggage compartment lining partly. Install luggage
compartment lining compartment
lining.
2 Emergency release 1 Unclip the gripper −2− from the luggage Clip the gripper
gripper compartment lining −1− . To do so, press in −2− into the
the locking tabs −arrows− . luggage
compartment lining
−1− .
3 Electrical plug 1 Disconnect electrical plug connection −3− . Plug in electrical
connection plug connection
−3− .
=> Checking inner
release of luggage
compartment
55 62 19 Removing and installing front emergency release − as of MY 2003 1439

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(Trunk
Entrapment)
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Entrapment)
DANGER
impact in front of the windshield and can tear off.
1. Engage the upper part of the lock 996 551 051 02 = tool (Porsche spare part) in the lower part of the lock
−direction of arrow− .
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Checking inner release of luggage compartment (Trunk Entrapment) 1440

55 84 19 Removing and installing engine cover
release
Removing engine cover release
Installing engine cover release
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Entrapment)
DANGER
impact in front of the windshield and can tear off.
1. Engage the upper part of lid lock, Part No. 996 551 051 02 = tool (Porsche spare part), in the lower part of
the lock −direction of arrow− .
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Removing engine cover release
• Remove front bumper ’ 6, 631019 Removing and installing front bumper .
55 84 19 Removing and installing engine cover release 1441

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1. Unscrew both fastening screws and remove the retaining strip.

3. Unscrew the fastening screws and disengage the
cable.
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Installing engine cover release
1. Engage the cable and position the motor at the holder.
2. Screw in the fastening screws. Tightening torque 1.5 Nm (1 ftlb.).
3. Position the holder with the motor on the retaining strip and screw tight with the fastening nuts.
Tightening torque 9.7 Nm (7 ftlb.).
Removing engine cover release 1442

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• Install front bumper ’ 6, 631019 Removing and installing front bumper .
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing engine cover release 1443

57 51 16 Setting the door
57 51 16 Setting the door 1444

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1 Setting the door Undo fastening screw −1− . Set the contour in relation to the wing and the side
at front member by shifting the angle pieces −3− in their vertical and horizontal positions.
’ 5 Body gap dimensions
The setting range can be extended by removing the centring sleeve −2− .
2 Setting the door Undo fastening screw −4− . Set the contour in relation to the rear wing and the
at rear side member by shifting the latch striker −5− in its vertical and horizontal
position. ’ 5 Body gap dimensions
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
57 51 16 Setting the door 1445

57 51 19 Removing and installing door
57 51 19 Removing and installing door 1446

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WARNING
Danger of injury if side airbag units in the door are triggered while ignition key is not removed
• Always remove ignition key during body work, and do not commence adjustment work until a
waiting period of at least 1 minute has elapsed!
• When working on the airbag system and during straightening work in the context of body repairs, the
ground strap must be disconnected!

1 Disconnecting the electrical Loosen Torx screw (T20), push plug up by approx. 3 mm and
plug connection then pull the whole plug connection out of the A−pillar.
Attention: locking tabs in the plug may break off!
Pull out locking element at the bottom part of the plug
connection and disconnect the plug connection.
2 Releasing door brake Unscrew Torx screw on the door brake.

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3 Undoing locking screw Insert special tool ’ No.9666, 2.4 (angle screwdriver) into the
as of model year 2001 upper door hinge and counter. Unscrew locking screw from the
lower door hinge and lift the door upwards out of the hinges.
4 Undoing locking screw Unscrew locking screw from the door hinge and lift the door
up to model year 2000 upwards out of the hinges.

1 Engaging the door Engage the door in the door hinge from above and screw in the locking screw.
up to model year Note: the locking screw is microencapsulated and must be replaced every time
2000 it is unscrewed.
Tightening torque −10 Nm (7.5 ftlb.)−
2 Engaging the door Engage door in door hinge from above, screw in locking screw and tighten
as of model year with −13 Nm (9.5 ftlb.)− .
2001 Note: the locking screw is microencapsulated and must be replaced every time
it is unscrewed.

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Use special tool ’ No. 9666, 2.4 (angle screwdriver) to counter.

3 Fitting door brake Screw the door brake to the body with the fastening screw.
Tightening torque: −23 Nm (17 ftlb.)−
4 Connecting Connect electrical plug connection.
electrical plug Attention: locking tabs in the plug can break off!
connection Press in the securing latch of the plug connection −B− . Push the whole plug
connection into the A−pillar. Press the plug down approx. 3 mm, so that the
locking tab −C− engages in the retaining bracket. Then screw the Torx
fastening screw (T20) tight.
Tightening torque: −2.5 Nm (2.0 ftlb.)−
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 51 37 Disassembling and assembling door
Disassembling door
Assembling door
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Disassembling door
WARNING
Danger of injury if side airbag units in the door are triggered while ignition key is not removed!
• Alway remove ignition key during body work, and do not commence adjustment work until a waiting
period of at least 1 minute has elapsed!
57 51 37 Disassembling and assembling door 1450

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CAUTION
CAUTION
Damage to plug connection lugs during door removal!
Damage to lugs when pulling the plug connection out of the A−pillar!
• The locking element at the bottom part of the plug connection must be pulled out before the plug
connection is disconnected!
CAUTION
Danger of material damage if the door lock is installed incorrectly!
Note
• The door trim parts must be removed before removing the parts inside the door!
• Follow the special instructions on installation and adjustment for assembly of the door: Serv. No. 70
39!
1. Remove
mount
Undo the M6 x16 hexagon−head bolt and remove the
mount.
Disassembling door 1451

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2. Unclip and disengage the bowden cable

a. Disengage support frame −arrow D−
upwards.
b. Unclip bowden cable −arrow B− from the
door lock.
c. Swivel bowden cable by 90° −arrow B− and pull it out of the actuating lever −arrow A− .
3. Disconnect connection piece

d. Move connection piece
−A− .
e. Press −C−
downwards.
f. Press the connection piece −B− upwards and separate from each
other.
4. Remove door handle and bottom part of door

g. Remove collar nuts
M6.
h. Separate bottom part of door handle from door handle and
remove.
i. Press electrical plug connection off microswitch −A− and
disconnect.
j. Unclip on the base of the electrical lead
−B− .

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5. Remove door lock

k. Undo micro−encapsulated Torx
screws T40 M8 x 14.
l. Disconnect the electrical plug connection. To do this, press the locking lug −A− on the plug
connection and separate in the direction of the arrow −B− .
m. Pull door lock with actuating motor unit out of the door.
6. Remove door window

n. Undo Torx screws T 30 on the clamping pieces of the power window unit.
o. Pull door window out of the door
channel.
7. Remove power window unit

p. Disconnect the electrical plug
connection.
q. Undo collar nuts M6 from the power window
unit.
r. Pull the power window unit downward out of the door
opening.

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8. Remove door brake

s. Unscrew Torx screw M8 −A− from the
A−pillar.
t. Remove collar nuts from the
door brake.
u. Pull out the door brake towards the
inside.
v. Remove the
seal.
9. Remove door seal on outside

w. Press out clip −A− with a plastic
spatula.
x. Pull off door seal on the
outside.
y. Carefully pull the seal out of the clips along the door
contour.
10. Remove window guide rail

z. Unscrew the B3.5 x 9.5 sheetmetal screw from the window guide
rail.
aa. Pull off the B 3.5 sheetmetal
nut.

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11. Remove door channel seal on inside

Pull the door channel seal on the inside off the bead of the door
channel.
12. Remove lid

Press out the 24 x 40 lid −A− and the 20 x 28 lid −B− with a plastic spatula.
13. Remove wiring harness

ab. Unclip the electrical wiring along the inner door
panel.
ac. Pull wiring harness out of the door in the −direction of the
arrow− .
14. Remove angle piece

Unscrew T 45 M8 x 33 Torx screw from the angle piece and the 12 x 8 x 7 centring sleeve.
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Assembling door
WARNING
Note
• Follow the special instructions on installation and adjustment for assembly of the door!
1. Stick in the insulation
Note
• In order to achieve better adhesion, heat the insulation using a hot−air gun!
Peel off the backing and stick the insulation into the door below the side−impact
bar.
2. Fit angle
piece
Position the angle piece with the 12 x 8 x 7 centring sleeve on the door and fasten with the T 45
M8 x 33 Torx screw.
Assembling door 1456

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3. Fit wiring harness

a. Insert wiring harness into the door in the −direction of the
arrow− .
b. Clip in the electrical wiring along the inner door
panel.
4. Fit
lid
Press in the 24 x 40 lid −A− and the 20 x 28 lid −B− .
5. Fit door
channel seal on
inside
Position the door channel seal on the inside −arrow− in the bead of the door channel and press
it on.
6. Fit window guide rail

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c. Push on the B 3.5 sheetmetal

nut.
d. Position the window guide rail and fasten it with the B3.5 x 9.5 sheetmetal screw.
7. Fit door seal

on outside
Position door seal on the outside at the top edge of the door and push
it on.
e. Clip in the seal along the door
contour.
f. Fasten the door seal on the inner door panel with the clip
−A− .
8. Fit door brake

g. Position the
seal.
h. Insert door brake from the inside and fasten it with the collar
nuts.
i. Screw Torx screw M8 −A− onto the
A−pillar.
9. Fit power window unit

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j. Insert power window unit into the door opening from

below.
k. Fasten the power window unit with the M6 collar
nuts.
See: Additional adjustment instructions for the power window.
l. Plug in the electrical plug
connection.
10. Fit door window

m. Insert door window into the door channel and position it in the front and rear clamping pieces of the
power window unit.
Note
• The bottom edge of the window must rest on the screw during adjustment!
• Observe additional instructions for adjusting the door window!
n. Tighten the T 30 Torx

screw.
Tightening torque: 8.5 ± 1.5 Nm (6.0 ± 1.0 ftlb.)
11. Fit door lock
Note
• The actuating lever must be locked in basic position before installation!
• Observe additional instructions for adjusting the door lock!
o. Insert door lock with actuating motor unit into the door and fasten with the micro−encapsulated T40
M8 x 14 Torx screw.
Tightening torque: 20 +2 Nm (15 + 1.5 ftlb.)

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p. Plug in the electrical plug

connection.
12. Fit connection piece

q. Clip in the electrical lead −B− on the
base.
r. Insert door handle and position the bottom part of the door handle on the door handle from
inside. Tighten with the collar nuts M 6.
s. Connect electrical plug connection
−A− .
13. Disconnect connection piece

t. Insert the connection piece into the actuating shaft −arrow A−
without play.
u. Push out the sliding piece −arrow B− until it can be heard to
engage.
v. Actuate the handle −arrow C− to ensure that the handle and door lock function without play.
14. Fit bowden cable

w. Insert bowden cable into the actuating lever −arrow D− and rotate by 90° −arrow C− .
x. Clip bowden cable into the door lock
−arrow B− .
y. Engage support frame −arrow A− on the
door lock.

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15. Fit mount

Position the mount in the door and fasten it with the M6 x 16
hexagon−head bolt.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 51 37 Disassembling and assembling door
Diagram: sheetmetal clips and grommets
Basic setting of door lock
Standardising the system
Fitting the door window in the clamping jaws
Adjusting the door window angle in the vehicle's longitudinal direction
Adjusting the door window height
Adjustment of the door window pressing force on the door seal at the top and
sides
Adjusting the lower stop of the power window unit
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Diagram: sheetmetal clips and grommets
57 51 37 Disassembling and assembling door 1462

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A Grommet
B M6 sheetmetal clip
C M5 sheetmetal clip
D Grommet
E Sheetmetal clip St 3.8
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Basic setting of door lock
WARNING
Diagram: sheetmetal clips and grommets 1463

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Basic setting of the door lock before installation
CAUTION
To prevent locking or unlocking actuation, or incorrect installation of the door lock!
1. Swivel out the actuating lever −A− in an upward

direction.
2. Lift the spring and simultaneously lower the spring hook of the actuating lever until it engages in
the locking spring −B− .
Note
• Greater force is necessary to actuate the door handle after installation of the door lock as the locking
spring audibly disengages.
Note
• Make sure that the lugs of the support frame are correctly locked when assembling the door lock to
protect againt theft −arrows: D− .
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Basic setting of door lock 1464

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Standardising the system
Standardising the power windows
The system must be re−standardised after an interruption in the power supply to the power window
electronics in the door. The position values for the short−stroke lowering function, position−controlled
lowering function in the case of convertible top actuation and enabling for "automatic start−up of window
closing" (one−touch function) are redefined. The standardisation process is initiated by continuous actuation
of the operating button Raise window .
Hold down the button Raise window until the window is closed and is switched off by the blockage
detection function of the power windows.
Blockage detection function
Note
• If the window drive encounters resistance during the door window movement, the motor is switched
off after a delay of 500 ms.
Precondition for operation of the power windows
• Ignition switched on.

• Ignition key should not be removed from the steering lock with the ignition switched off.
• The door is opened for the first time after switching off the ignition.
• Door opened.
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Fitting the door window in the clamping jaws
1. Insert the door window through the door channel into the clamping jaws of the front and rear drivers.
2. Position the door window corner flush with the driver at front.
Standardising the system 1465

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Note
• The bottom edge of the window must rest on the screw during adjustment.
3. Tighten the clamping jaws after completing the adjustment.

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Adjusting the door window angle in the vehicle's longitudinal
direction
Driver
1. Adjust to equalise the angle of the door window on the clamping jaws of the driver (upwards or
downwards).
Adjustment range 10 mm
2. Tighten the clamping jaw after completing the adjustment
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Adjusting the door window height
1. Adjust the upper limit stops of the drivers by screwing the Torx screw T30 in or out with socket E6
in or against the direction of travel.
Adjustment range approx. 15 mm
2. Adjust the drivers so that they meet the upper limit stops at the same time.
Note
Fitting the door window in the clamping jaws 1466

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• The adjusting screws of the drivers for the upper limit stops for the door window height are accessible
through 2 holes at the bottom of the door.
Adjustment procedure:
1. Open the
doors
2. Lock door lock with a
screwdriver.
3. Move the power window regulator into its upper position.
4. Adjust door window height at the drivers so that the door window evenly projects approx. 2 mm
above the roof strip.
Checking the adjustment
1. Close the doors.

2. Use a wax marker to mark the door window along the roof
strip.
3. Actuate the door handle until the window lowering function is activated.
Adjustment valve for window lowering function approx. 13 mm
Note
• The wax marking along the door window should be uniformly approx. 4 mm.
top of page
Adjustment of the door window pressing force on the door seal
at the top and sides
Adjusting the door window height 1467

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1. Move the power window unit rails by approx. 10 mm outwards or inwards.
Note
• The adjusting nuts of the power window unit rails for the pressing force of the door window upper
edge against the convertible top are accessible through two holes at the bottom of the door.
Adjustment procedure:
1. Open the
doors.
2. Move the power window regulator into its upper position and undo the combination nuts M 6 of the power
window rails.
3. Adjust the power window unit so that the upper edge of the door window is sufficiently pressed against
the door seal at the side
Checking the adjustment:
Clamp a sheet of paper between the door window and door

seal.
Note
• It must not be possible to pull out the sheet of paper.
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Adjusting the lower stop of the power window unit
Adjustment of the door window pressing force on the door sealat the top and sides 1468
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Note
• When replacing the power window unit, make sure that the correct position of the lower limit stop is
selected for the respective model.
• There are two bores lying one above the other with the screwed−on limit stops in the front power
window unit rail.
• The upper limit stop must be removed for the 911 Carrera (996) model.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Adjusting the lower stop of the power window unit 1469

64 12 19 Removing and installing windscreen
Removing windscreen
Preparing the windscreen for installation
Fitting windscreen
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Removing windscreen
WARNING
64 12 19 Removing and installing windscreen 1470

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1. Removing cowl panel cover

’ 702219 Removing and installing cowl panel cover
2. Removing inner A−pillar trim
3. Removing interior rearview mirror
’ 682719 Removing and installing interior rearview mirror
4. Opening door windows
Lower the door
windows.
Note

Undo and remove the cover section
−1− .
6. Removing defroster covers

Lift the alarm readiness light −2− and unclip it to the rear. Lift the defroster covers on the left and right
−3 and 4− and unclip them. Check fastening clips −5− , replace if necessary.
Removing windscreen 1471

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7. Disconnecting windscreen antenna plug connection

Release windscreen antenna plug connection −arrows− and pull it
off.
8. Removing spacer blocks

Insert a spatula under the spacer blocks −6− and remove the expanding rivets. Spacer blocks −6− must
be replaced.
9. Removing
windscreen
Remove windscreen with the cutting wire
separator.
Note
• The procedure for removing car windows is described in => Removing glass with cutting wire
separator.
top of page
Preparing the window section for installation 1472

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1. Removing
adhesive from the
body
When removing remaining adhesive −7− with the cutting tool −C− and the flashing knife −D−
on the body, ensure that a surface coating of adhesive remains −8− .
Note
2. Cleaning and priming paint damage or

newly built−up paint areas in the
window aperture of the body
body with cleaning solution −H1− and patch with primer −H2− .
Note
and the application of the primer! No cleaning solution residues may remain on the body.
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Preparing the windscreen for installation
Preparing the windscreen for installation 1473

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1. Removing adhesive from the windscreen
Note
• Only if the windscreen is re−installed!
Equip cutting device −C− with the flashing knife −D− and remove the remaining adhesive from the
windscreen, ensuring that a surface coating of adhesive remains.
Note
• The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and
do not clean with cleaning solution.
2. Fitting surrounding section and cover section

Place surrounding section −9− on the windscreen and press cover section −1− into the groove of the
surrounding section.
Note
• If the surrounding section and cover section were removed from the rear window undamaged, they
can be re−used.
Preparing the windscreen for installation 1474

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3. Marking the bonding area
Note
• Only if the windscreen is new and does not have a preliminary coat!
Before applying the adhesive material, mark the course of the adhesive bead in accordance
with the dimensions −E− = 160 mm, −F− = 30 mm on the left and right on the lower edge of
the windscreen.
4. Activating the bonding section of the windscreen
Note
• Only if the windscreen is re−installed!
During long idle periods apply activator −H3− to the remaining

adhesive.
Note
• Only with new windscreens!
a. Clean glass with cleaning solution

−H1− .
b. Apply primer −H2− to the glass flange in the area of the
marking.
Note
• A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the
application of the primer! No cleaning solution residues may remain on the body.
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Fitting windscreen
CAUTION
Fitting windscreen 1475

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adhered to:

Note
• The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the
windscreen was removed without damage.
1. Fitting spacer blocks

Clip in spacer blocks and press in body−bound
rivets.
2. Fitting defroster covers and the alarm readiness light

Check the fastening clips −5− , replace if necessary. Insert the defroster covers left and right −3 and
4− and clip in under the alarm readiness lug. Clip in alarm readiness light −2− .
bonding agents
Note

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4. Applying bonding material to the windscreen

Apply 2−component bonding material with the adhesive gun −A− to the windscreen along
the cover section as a triangular bead measuring −X = approx. 15 mm− .
Note
5. Inserting windscreen into the body
Note
• Two persons are needed to insert and adjust the windscreen.
Apply suction cups −B− to the windscreen and insert the windscreen into the window aperture.
Press the windscreen up as far as it will go. When doing so, press the lower edge of the glass
against the spacer blocks.
7. Attaching windscreen antenna

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Insert the plug of the windscreen antenna into the antenna

amplifier.
8. Installing inner A−pillar trim
9. Installing cowl panel cover
’ 702219 Removing and installing cowl panel cover
10. Bonding on interior rearview mirror
Note
• Only with new windscreens!
’ 682713 Bonding on interior rearview mirror

11. Installing interior rearview mirror
’ 682719 Removing and installing interior rearview mirror
Note
• The interior rearview mirror may only be installed after a curing time of three hours!
12. Closing door windows
Note
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The following tools and materials are required for removing and installing the windscreen with 2−component
adhesive:

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Chapter 3.5
Chapter 3.5
A Chapter 3.5
H1−H8


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−A− Glass separating tool VAG 1474 See Workshop Equipment Manual, Contains set
B Chapter 3.5 components
A1−A9
−B− Cutting thread See Parts Catalogue in Main Group 8

−A1− Guide rails −A6− Filler
−A2− Cutting tool (wire holder) −A7− Steering roller with arm bracket
−A3− Spooling device −A8− Handle
−A4− Awl −A9− Square cutting wire
−A5− Guide rails
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

64 54 19 Removing and installing power window
motor
Removing power window motor
Installing power window motor
Standardising the new power window motor
Tightening torques
top of page
Removing power window motor
1. Close door window.
WARNING
Airbag could inflate. Possible danger of injury or damage during fitting.
• 1. Remove ignition key.

• 2. Disconnect and cover the negative terminal of the battery.
• 3. After the battery is disconnected, work on the vehicle may only be started after a waiting period of
1 minute.
2. Remove door panel and loudspeaker unit. Carefully remove (do not crack) the front moulded foam part
from the inside of the door near the power window motor and the loudspeaker cut−out. See also:’ 705919
Removing and installing door trim panel.
3. Loosen the three fastening nuts −arrows− from the power window motor.
4. Press the power window unit out of the inner door panel until the fastening pins are free.
5. Unlock and remove the electrical plug connection −arrow− on both sides.
6. Unscrew fastening pins of power window motor. Remove power window unit from the toothing and take
out through the loudspeaker cut−out.
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Installing power window motor
1. Guide power window motor through the loudspeaker cut−out and insert in the toothing. Tighten fastening
pins of power window motor. => Tightening torques
3. Push power window unit onto fastening pins.
64 54 19 Removing and installing power window motor 1481

einordnung
4. Tighten the three fastening nuts on the power window motor. => Tightening torques
5. Carefully glue the moulded foam part onto the inside of the door (protects against water leaking
in).
6. Install loudspeaker unit and door panel.
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Standardising the new power window motor
1. Switch on ignition.
2. Open door window completely by continuously actuating the power window operating button,
and then close window. Press power window button until the window is closed and is switched off
by the blockage detection function of the power window motor. Standardisation is then
completed.
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Tightening torques
Location Illustration Thread Tightening torque [Nm] (ftlb.)

Fastening pins M6 M6 10 (7.5)
Fastening nut M6 M6 10 (7.5)
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996430, 996431, 996630, 996631
Installing power window motor 1482

64 71 19 Removing and installing rear power windows
(Cabriolet)
Removing rear power windows (Cabriolet)
Installing rear power windows (Cabriolet)
Additional instructions for adjusting or replacing the rear power window
Tools and materials
Tightening torques
Test and adjusting values
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64 71 19 Removing and installing rear power windows (Cabriolet) 1483

einordnung
Removing rear power windows (Cabriolet)

Convertible top in service ’ Removing and installing convertible top, 610119
position
Note: Removal and installation of the rear power window should be
carried out with a rear window pane. Otherwise adjustment work
is hindered during installation.
1 Removing side−panel Removing side−panel lining −1− . ’ 70 75 19
lining
2 Removing rear side Undo front and rear fastening screws −2− from the
window inner seal convertible−top support and the belt guide section, and pull rear
side window inner seal −3− up and out.
Removing rear power windows (Cabriolet) 1484

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3 Closing side window Press the micro−switch −4− in the windscreen frame and actuate
the rocker switch −5− at the same time.
4 Releasing power window Release adjusting elements with the adjustment tool −7− . To do
this, loosen and unscrew the nuts −6− from the adjusting element.
Adjustment tool for the rear power window. => Tools and
materials
CAUTION
Damage to or destruction of the convertible top when the convertible−top support is removed!
• The convertible top must no longer be electrically operated when the convertible−top support is
detached.

5 Detaching Undo fastening screws −2− and fastening nuts −8− from the convertible−top
convertible−top support −10− , pull the deflection fitting and belt guide section −9− up and
support out. Pull convertible−top support −10− inward and fix between B−pillar and
the convertible−top support with a spacing block −12− dimension −A = 30
mm− .
6 Removing power Push rear power window −11− upward, push both locking tabs of the
window electrical connection −13− outward and disconnect.
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Installing rear power windows (Cabriolet)
Installing rear power windows (Cabriolet) 1485

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1 Inserting power Connect electrical plug connections −13− , insert power window −11− into
window the window shaft from above and position in the mounts in the inner side
section.
2 Screwing down Remove spacing block −12− between B−pillar and convertible−top support
convertible−top −10− . Position fastening screws −2− and fastening nuts −8− in the
support convertible−top support −10− and tighten.
Insert the deflection fitting in the belt guide section −9− . Screw in and
tighten the fastening screws −2− .
3,4 Adjusting and By moving the power window −4− with respect to the longitudinal axis of the
screwing down vehicle, the power window can be adjusted by dimension −Y = ± 10 mm− .
power window The contact pressure of the side window upper edge on the convertible−top is
adjusted by screwing the adjusting element −A− in or out by dimension −X =
Installing rear power windows (Cabriolet) 1486

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± 10 mm− . The contact pressure on the rear window inner seal or the offset
from the door window is adjusted by screwing both of the upper adjusting
elements −B− in or out by dimension −X = ± 5 mm− .
Adjustment tool for the rear power window.
=> Tools and materials Step 1: −Figure 3−
Adjust the basic setting of the adjusting elements −B− from the top edge of
the rear side section to the side window.
−Dimension C− Front top edge of rear side section = 11 mm
−Dimension D− Rear top edge of rear side section = 14 mm
Step 2: −Figure 3−
Push the power window backward or forward to adjust the −gap E = 9 mm−
between the side window and door window.
Step 3: −Figure 4−
Adjust the contour or the offset from the door window on adjusting element
−A− . Screw down adjusting elements −A− and −B− .
4 Installing rear side Insert rear side window inner seal −3− into rear side section slot and position
window inner seal on the convertible−top support or belt guide section.
Screw in fastening screws −2− and tighten.
5 Installing ’ 70 75 19
side−panel lining
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Additional instructions for adjusting or replacing the rear power
window
1. The rear power windows can be operated if:
• the convertible−top is closed.

• the ignition is switched on.
• after the ignition is switched off, if the ignition key is not removed from the steering lock.
• after the ignition is switched off until a door is opened for the first time.
• the door is open, USA vehicles do not have this function.
1. Standardising the system

The system must be re−standardised after an interruption in the power supply to the power window
electronics. To do this the convertible top must be closed. The position−controlled lowering function in the
case of convertible top actuation, and enabling for "automatic start−up" of window closing and opening are
redefined. The standardisation process is initiated by continuous actuation of the operating button toward
"close window". To do this the convertible top must be closed and the hardtop must be fitted. The button must
be held until the window is closed and is switched off by the blockage detection function of the power
windows.
2. Blockage detection function
If the window drive encounters resistance when activated, the motor is switched off after a delay of 500 ms. If
the rocker switch is pressed again within 10 seconds, the side window closes the power window with all of its
closing force. The anti−crushing protection is deactivated.
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Additional instructions for adjusting or replacing the rear power window 1487
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Tools and materials

1 Adjustment tool 123−1 Gr. 2.4; Workshop Equipment Manual
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Tightening torques
Tightening torque
Fastening screws and fastening nuts in convertible−top −2.8− M8 23 (17)
support
Fastening screw for tightening the deflection fitting in M8 50 (37)
the belt guide section.
Adjusting elements of the door window −A, B− 23 (17)
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Adjust power windows −C− 11 mm Front top edge of rear side section
−D− 14 mm Rear top edge of rear side section
−E− 9 mm Gap between side window and door window
996630, 996631, 996620, 996621, 996650, 996651

64 75 19 Removing and installing side window
Removing side window
Installing side window
Tightening torques
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64 75 19 Removing and installing side window 1489

einordnung

Removing B and C pillars ’ 705719 Removing and installing trim of A, B and C
pillars.
1 Unscrew fastening nuts and screws. Unscrew the fastening screw−1− and remove the washer
−2− . Unscrew fastening nuts −3− .
2 Remove side window. Pull out side windows −4− downward in −in direction of
arrow− .
3 Pull off the rubber seal Pull off rubber seal−5− from the rim of the side window
section.
Removing the side window seal and => Removing side window seal
retaining strip, see:
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Removing side window 1490

einordnung
Note
• The removed side window can be reinstalled if:
• there is no prior damage to the side window.
• the side window was removed without being damaged.

1 Fitting the rubber seal Fit the rubber seal−5− on the rim of the side window section.
Installing side window 1491

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2 Remove side window. Affix suction cups to the side window. Insert side window −4−
at the top in the −direction of arrow− .
• ’1 Keep pressing the side window−4− upwards in

−direction of arrow B− and insert at the bottom.
• ’2 Pull the lip of the seal forward under the side
window −4− using a plastic spatula.
• ’3 Keep pressing the side window−4− upwards in
−direction of arrow B− and insert the spacer in the
retaining rail.
3 Adjusting gap dimension => Test and adjusting values
4 Unscrew fastening nuts and Screw down the fastening screw −1− and washer −2− . Screw
screws. down the fastening nuts −3− .
Tightening torque: => Tightening torques
Install B and C pillars ’ 705719 Install trim of A, B and C−pillars.
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Door window to side window −3− 7 ± 1mm Door window lowered, max. 1 mm
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Tightening torques
Location Illustration Thread Tightening torque

Fastening screw body to side window −1− M6 10 Nm (ftlb.)
Fastening nuts to side window adjusting element −2− M8 17 Nm (ftlb.)
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Test and adjusting values 1492

64 75 19 Removing and installing rear side window
(Cabriolet)
Tightening torques
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Release the side window from the clamping jaws of the rear power window with the side−panel lining and
rear side window inner seal removed and the side window extended. To do this press the micro−switch in the
windscreen frame and actuate the rocker switch at the same time until the side window is completely
extended. => Removing rear power windows (Cabriolet)
Lift the side window upward out of the rear side section slot.
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1. Installing the side window in the clamping jaws

The convertible top must be open to fit the side window. The power window must be in the upper position.
Insert the side window through the side section slot into the clamping jaws −arrows− of the front and rear
drivers.
2. Adjusting the side window angle in the vehicle's longitudinal direction

Moving the side window into the clamping jaws −inset− on the receiving rollers equalizes the angle of the
side window to the door window. The window bottom edge must lie against the receiving rollers in the
clamping jaws. Adjust the side window according to the contour of the door window and the −gap E = 9
mm− . Tighten the clamping jaws after completing the adjustment.
64 75 19 Removing and installing rear side window (Cabriolet) 1493

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Tightening torque: 8.5 (6.5) ± 1.5 Nm (1 ftlb.)
3. Adjusting the lower

stop of the power
window unit
It is possible to adjust the height of both lower stops −arrows− . However, this should only be adjusted
synchronously. The adjustment is only possible when the side window is lowered.
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Tightening torques
Tightening torque
Clamping jaws for installing the side windows 8.5 (6.5) ± 1.5 (1)
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Gap for adjusting the side −E− 9 Adjust the side window according to the contour of the
window mm door window and the gap.
996620, 996621, 996650, 996651, 996630, 996631
Installing side window 1494

64 76 19 Removing and installing side window seal
Removing side window seal
Installing side window seal
Materials and tools
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64 76 19 Removing and installing side window seal 1495

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Removing side => Removing side window
window
1 Removing side Bore out pop rivet from the integrated sheet metal strip of the side
window seal window seal −1− using a 4.1 mm drill bit. Pull out the side window seal
−1− in the −direction of the arrow− from the retaining strip−2− .
2 Boring out side Bore out the pop rivets−3− from the side window seal −1− using a 4.1
window seal mm drill bit.
Removing the => Removing the retaining strip
retaining strip
Removing side window seal 1496

einordnung
Removing the retaining strip
Removing the retaining strip

Using a 4.1 mm drill bit, bore out the pop rivets −3− from the retaining strip −2− .
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Removing the retaining strip 1497

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Installing the retaining strip => Installing the retaining strip
1 Riveting down the side Position the side window seal −1− on the centering hole−A− and
window seal to the body rivet it down using the pop rivet −3− . Then rivet down all pop
rivets.
2 Positioning the side window Coat the retaining strip −2− with soapy water. Insert the side
seal in the retaining strip window seal −1− in the retaining strip −2− .
3 Fitting the side window seal Starting from the rear, fit the side window seal −1− in the
in the retaining strip −direction of arrow− in the retaining strip −2− using the fitting
roller.
=> Materials and tools
4 Riveting down the side Position the integrated sheet metal strip of the side window seal
window seal −1− on the body and rivet it down using the pop rivet −3− .
Installing side window => Installing side window
Installing side window seal 1498

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Installing the retaining strip
Installing the retaining strip

Position the retaining strip −2− on the centering hole −C− and rivet the retaining strip down using the pop
rivet −3− . When riveting down the retaining strip, press toward the rear in the −direction of arrow− . Then
rivet down all pop rivets.
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Materials and tools

−1− Fitting roller 163−1 For fitting in the side Commercially available tool Gr. 2.4;
window seal Workshop Equipment Manual
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing the retaining strip 1499

64 76 19 Removing and installing rear side window
seal (Cabriolet)
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Remove the side window seal with the convertible top open and the side window extended. To do this press
the micro−switch in the windscreen frame and actuate the rocker switch at the same time until the side
window is completely extended. => Removing rear power windows (Cabriolet) Pull side window seal down
and out of the window profile.
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Remove adhesive residues from above and below the window profile if present. Pull the side window seal
from below into the window profile. Pull it in using soapy water as a lubricant. Clean the upper seal end (free
from grease and lubricant). Coat the upper surface of the seal −1− with Loctite 480 instant adhesive, and bond
with the profile of the side window.
996620, 996621, 996650, 996651, 996630, 996631
64 76 19 Removing and installing rear side window seal (Cabriolet) 1500

64 86 19 Removing and installing rear glass window
of Cabriolet
Removing rear glass window of Cabriolet
Installing rear glass window of Cabriolet
Tools and materials
Shown on 911 Carrera (996)
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Removing rear glass window of Cabriolet
64 86 19 Removing and installing rear glass window of Cabriolet 1501

einordnung
Note
• The rear glass window can be fitted into the vehicle when the convertible−top covering is installed or
removed.
• The rear glass window should always be installed first into the convertible−top covering when
replacing the convertible−top covering.

Removing roof lining at the ’ 708419 Removing and installing Cabriolet roof lining − as
front at rear of model year 2002
1 Disconnecting the electrical Disconnect electrical plug connection of the rear window
plug connection heater −1, 2, 3− on the left and right.
2
Removing rear glass window of Cabriolet 1502

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Detaching connection and Detach the connection to the convertible−top covering −6− .
tension strap Detach the tension belt −4− from the frame of the rear
window −5− .
3 Removing metal clips Insert a plastic spatula −direction of arrow A− underneath
the metal clip −7− and lift. Press out the metal clip using a
screwdriver −direction of arrow B− .
4 Taking off rear window Remove the rear window −5− from the convertible−top
covering −8− .
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Installing rear glass window of Cabriolet
CAUTION
Installing rear glass window of Cabriolet 1503

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Leak (entry of water) in rear glass window!
• The metal clips are designed to be fitted only once.

• Always replace the metal clips after removal −7− .
• Only fit the metal clips with the circlip pliers => Tools and materials.

1 Positioning rear window and Note:
aluminium frame on the Two persons are required for the work step.
convertible−top covering Position rear window −5− and aluminium frame −5a− on
convertible−top covering −8− . The aluminium frame and the rear
window are initially held on the convertible−top covering with
vice−grip wrenches on the left and right.
1. Ensure that the markings −C, D− correspond at the top and
bottom.
2. Check whether the edge frame −5c− of the convertible−top
covering is showing evenly all the way round and correct if
necessary.
2 Pushing the metal clips onto Push new metal clips −7− into all sides of the frame cutouts −F− of
the aluminium frame the rear window.
=> Use of the circlip pliers
3 Installing rear roof lining Push in the connection seal −10− of the roof lining −9− between
the rear window and the frame. Ensure that the clearance cuts of
the roof lining −E− on the left and right are positioned on the
electrical connection of the rear window.
4 Installing metal clips Knock the metal clips −7− with a plastic hammer. Make sure that
the metal clip −7− engages in the frame cutouts.
Only when replacing ’ Replacing convertible−top covering, 612855
convertible−top covering.
Installing convertible−top
covering
5 Attaching connection and Attach the tension strap −4− into the frame of the rear window.
tension strap Lay the connection under the convertible−top strips −X− and above
the corner bow −Y− .
Observe sequence illustrated.
6 Connecting electrical plug Plug in electrical plug connection −1, 2, 3− .
connection Check heating for rear windows.

Installing roof lining ’ 708419 Removing and installing Cabriolet roof lining − as of
model year 2002
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Installing rear glass window of Cabriolet 1504

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Tools and materials

1 Metal clips set for installing rear window Spare parts Gr. 8 − 11/10;
Parts Catalogue
2 Circlip pliers No. 9697 for installing metal clips Porsche special tool Gr. 2.2;
Workshop Equipment
Manual
3 Temperature probe No. 164 for checking heating of rear Commercially available tools
window Gr. 2.4; Workshop
Equipment Manual
4 Two universal vice−grip wrenches No. 127−2 for holding the Commercially available tools
rear window on the convertible−top covering Gr. 2.4; Workshop
Equipment Manual
Use of the circlip pliers
1. Inserting metal clips into the circlip pliers

a. Unscrew the knurled screw −11− with the circlip pliers in the −direction of the arrow− . Insert metal
clip −7− into the U−profile of the lower jaw −A− in −direction of arrow− . Insert the upper claw −X−
into the metal clip −7− in −direction of arrow− at the same time.
b. Insert into the upper adjusting claw −Y− in the metal clip −7− in −direction of arrow− . Tighten
knurled screw −11− .

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2. Pushing metal clips onto the aluminiuim frame. Removing circlip pliers from the metal clip
Pushing the metal clips onto the aluminium frame. => Installing rear glass window of
Cabriolet
c. Unscrew knurled screw −11− . Pull upper adjusting claw −Y− to the right in −direction of arrow− .
d. Push circlip pliers to the front −direction of arrow− and remove from the U−profile of the lower jaw
−A− .
e. Pull the circlip pliers to the left in −direction of arrow− and remove from the metal clip −7− with the
upper claw −X− .
996620, 996621, 996650, 996651, 996630, 996631
Use of the circlip pliers 1506

64 86 19 Removing and installing rear window
(hardtop)
Removing rear window (hardtop)
Preparing the window section (hardtop) for installation
Preparing the rear window (hardtop) for installation.
Installing rear window (hardtop)
Tightening torques
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64 86 19 Removing and installing rear window (hardtop) 1507

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Removing rear window (hardtop)
WARNING

• Only replace the cutting knife with the power supply disconnected, in order to avoid the cutter being
switched on accidentally.
1. Removing
hardtop
Unlock hardtop and take it off the
car.
2. Positioning the hardtop
Place outer side of the hardtop on the assembly
fixture.
3. Removing centring peg

Unscrew the fastening screw −1− from centring peg −2− on the left and right and remove centring peg
−2− .
4. Unclipping hardtop
locking element trim
Unclip hardtop locking element trim −3− on the left and
right.
Removing rear window (hardtop) 1508

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5. Unclipping interior trim parts

Unclip interior trim parts −4− at the side, front and rear from the hardtop body −5− .
6. Disengaging roof liner at rear

Pull the plastic rail −6− on the roof liner −7− to the rear and
detach it.
7. Disconnecting the plug connection of the rear window heater

Disconnect electrical plug connection −8− to the left and right on the rear
window.
Note
• To avoid damaging the electric cable when cutting out the rear window, affix the cable to the rear
window with adhesive tape.
Removing rear window (hardtop) 1509

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8. Turning
hardtop
Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.

Undo and remove the cover section
−9− .
Note
• If the cover section is removed undamaged, it can be re−used.
10. Removing rear window

Fit a U−type cutting knife −E− to the cutter −C− . Set the vibration frequency controller to 5. Cut
through the bond between the body and the rear window at the top, bottom and sides.
Note
• When cutting out the rear window, take care not to damage the rivet connections that are connecting
the hardtop body parts.
• When cutting out the rear window, make sure to cut close to the rear window.
11. Taking off rear window
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Preparing the window section (hardtop) for installation
Preparing the window section (hardtop) for installation 1510

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1. Removing adhesive on the hardtop body

When removing remaining adhesive −10− with the cutter −C− and the flashing knife −D− on the
hardtop body, ensure that a surface coating of adhesive remains −11− .
Note
• Remove remaining adhesive between the rivet connections as much as possible without damaging the
rivet connections.
2. Cleaning and priming paint damage or newly built−up paint areas in the window aperture of the hardtop
body
hardtop body with cleaning solution −H1− and patch with primer −H2− .
Note
and the application of the primer!
• No cleaning solution residues may remain on the body.
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Preparing the window section (hardtop) for installation 1511

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Preparing the rear window (hardtop) for installation.
1. Removing adhesive from the rear window
Note
• Only if the rear window is re−installed!
Equip cutter −C− with the flashing knife −D− and remove remaining adhesive from the rear window,
ensuring that a surface coating of adhesive remains.
Note
• The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and
do not clean with cleaning solution.
2. Applying activator to the bonding section of the rear window
Note
• Only if the rear window is re−installed!
During long idle periods apply activator −H3− to the remaining

adhesive.
Note
• Only with new rear windows!
a. Clean glass with cleaning solution

−H1− .
Preparing the rear window (hardtop) for installation. 1512

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b. Apply primer −H2− to the glass flange in the area of the

marking.
Note
• A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the
application of the primer! No cleaning solution residues may remain on the body.
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Installing rear window (hardtop)
CAUTION
adhered to:

Note
• The removed rear window can be reinstalled if there was no prior damage to the rear window and the
rear window was removed without damage.
1. Fitting cover section

Attach cover section −9− to the rear
window.
Note
• If the cover section is removed from the rear window undamaged, it can be re−used.
Installing rear window (hardtop) 1513

einordnung

bonding agents
Note
3. Applying adhesive to the rear window

Apply 2−component bonding material with the adhesive gun −A− to the rear window along the cover
section as a triangular bead measuring −X = approx. 15 mm− .
Note
4. Inserting rear window into the hardtop body

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Note
• Two persons are needed to insert and adjust the rear window.
a. Attach suction cups −B− to the rear

window.
b. Insert the rear window at the top of the window aperture and lay it down carefully into the aperture.
5. Fixing rear window

Press the rear window fully upwards, pressing on the lower edge of the glass while doing so.
Use adhesive tape to prevent the rear window from slipping at the side and the top.
7. Turning
hardtop
Place outer side of the hardtop on the assembly
fixture.
8. Plugging in rear window heater

Connect electrical plug connection −8− to the left and right of the rear
window.
9. Engaging roof liner to the rear

einordnung
Engage roof liner −7− to the rear using plastic rail −6−
.
10. Clipping in interior trim parts

Clip in interior trim parts −4− at the side, front and rear on the hardtop body −5− .
11. Clipping in hardtop locking element trim

Clip in hardtop locking element trim −3− on the left and
right.
12. Fitting centring pegs

Insert right and left centring pegs −2− , screw in fastening screw −1− and tighten to the specified
torque. => Tightening torques
13. Installing hardtop
Place hardtop on the car and lock
it.
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The following tools and materials are required for removal and installation of the rear window with
2−component adhesive:

einordnung

Chapter 3.5
Chapter 3.5
A Chapter 3.5
−E− Cutting knife, U−type 639.030.760.12
H1−H8

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Tightening torques
Location Illustration Thread Tightening torque [Nm] (ftlb.)

Centring peg fastening screw to hardtop body −1− M6 10 (7.5)

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996630, 996631, 996620, 996621, 996650, 996651

66 31 19 Removing and installing sill cover.
Removing sill cover
Installing sill cover
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Removing sill cover
66 31 19 Removing and installing sill cover. 1519

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1 Undoing front sill cover Unscrew fastening screw −2− from the wheel housing
liner −3− .
2 Undoing rear sill cover Unscrew fastening screw −2− from the rear wheel housing
liner −4− .
3 Undoing sill cover on the lower side Unscrew fastening screws −2− along the sill cover −1− .
member
4 Removing sill cover from the lower Remove sill cover from the lower side member in
side member −direction of arrow− .
Grommets −5− must always be replaced for installing the
sill cover −1− .
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Removing sill cover 1520

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Installing sill cover

1 Check U−clips and Check U−clips −6− and replace if necessary. The U−clips must be fixed
replace if necessary firmly on the rim of the lower side member.
2 Fitting grommets All grommets are to be replaced before installing the sill cover −1− . Spray
grommets with a lubricant, e.g. silicone spray for simplified mounting of
the sill pegs −5− .
3 Fitting sill cover Position sill cover −1− on the premounted grommets on the side member
and tighten with fastening screws −2− .
4 Screwing on rear sill Tighten rear sill cover and the rear wheel housing liner −3− using the
cover fastening screws −2− .
Installing sill cover 1521

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5 Screwing in front sill Tighten front sill cover and the front wheel housing liner −4− using the
cover fastening screws −2− .
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431
Installing sill cover 1522

66 72 37 Disassembling and assembling pump unit
Removing hydraulic cylinder
Filling the hydraulic cylinder
Installing hydraulic cylinder
Removing pump
Filling the pump unit
Installing pump
Bleeding the pump unit
Removing and installing wiring harness
Troubleshooting
Tools and materials
Note
• The hydraulic lines, banjo bolts and the sealing rings should always be replaced when replacing the
hydraulic cylinder or the pump drive.
66 72 37 Disassembling and assembling pump unit 1523

einordnung
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Removing hydraulic cylinder
Removing hydraulic cylinder 1524

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Removing pump unit ’ 559037 Disassembling and assembling rear lid
1 Pulling off cover caps Pull off cover caps −7− from the hydraulic cylinders −2− .
2 Moving pump motor to Before the pump unit can be disassembled, the pump motor must
initial position be moved to its lower initial position.
Move pump unit into lower initial position. To do this, connect
narrow contact to +12 V, wide contact ground (−) to the pump
motor according to the polarisation arrangement −A− .
The limit position is attained when the piston of the pump unit
moves onto the mechanical stop or the amperage rating is larger
than 10 A.
CAUTION
Removing hydraulic cylinder 1525

einordnung
The drive module is pressurised!
• => Safety instructions for the pump unit hydraulic system of the rear spoiler

3 Cutting tie wrap Cut tie wrap on the hydraulic line −5− using a pair of side cutters.
4 Disconnecting hydraulic Unscrew the short banjo bolts −1− from the hydraulic cylinders −2−
lines. of the hydraulic lines −4, 5− . To do this, counter with an
open−ended wrench −C− .
Disconnecting hydraulic => Removing pump
lines from the pump unit
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Filling the hydraulic cylinder
1. Filling the hydraulic cylinder

The hydraulic cylinder can only be filled in a retracted position.
a. Assemble hydraulic cylinder −2− vertically and fill with 5 ml Pentosin perhydraulic cylinder using a
syringe. => Tools and materials
Only Pentosin CHF 11 S may be filled into the hydraulic cylinder. Quantity supplied 1 litre container
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Installing hydraulic cylinder
Filling the hydraulic cylinder 1526

einordnung

Information: The lines, banjo bolts and sealing rings included in the scope of
replacement parts should always be replaced.
Installing hydraulic line on the Observe installation sequence of the hydraulic lines!
pump The hydraulic lines must be mounted first to the pump unit and
the pump motor must be extended and retracted.
=> Installing pump
1 Fitting short hydraulic line −4− . Fit short hydraulic line −4− with the sealing rings −6− . Screw
in short banjo bolt −1− .
2 Fitting long hydraulic line −5− . Fit long hydraulic line −5− with the sealing rings −6− . Screw
in short banjo bolt −1− .
3 Tightening short banjo bolt −1− Tighten short banjo bolt −1− , to do this, counter the hydraulic
with tightening torque. cylinder −2− with an open−ended wrench−C− .
Installing hydraulic cylinder 1527

einordnung
4 Fitting covering caps Push left and right covering cap −7− onto the hydraulic
cylinder −2− .
Bleeding the pump unit => Bleeding the pump unit
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Removing pump

Removing pump unit ’ 559037 Disassembling and assembling rear lid
Installing hydraulic => Installing hydraulic cylinder
cylinder
1 Disconnecting pump
Removing pump 1528

einordnung
Unscrew the long banjo bolts −3− from the hydraulic lines −4, 5− . To do
this, counter with an open−ended wrench −C− .
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Filling the pump unit
1. Filling the pump unit

a. Fill the pump vertically using a syringe with 20 ml Pentosin per pump chamber. => Tools and
materials
Only Pentosin CHF 11 S may be filled into the pump unit. Quantity supplied 1 litre container => Tools
and materials
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Installing pump
Filling the pump unit 1529

einordnung

Information: The lines, banjo bolts and sealing rings included in the scope of replacement
parts should always be replaced.
1 Fitting short Lay short hydraulic line −4− to the left leading from the pump unit −arrow A−
hydraulic line , position the sealing rings −6− . Screw in banjo bolt −3− and tighten slightly.
2 Fitting long Lay long hydraulic line −5− along the pump unit −arrow B− , position the
hydraulic line sealing rings −6− . Screw in banjo bolt −3− and tighten slightly.
3 Affixing cable Fasten long hydraulic line −5− to the pump unit with a cable tie −arrow− .
ties
4 Pulling out pump 1. Pull pump unit out so far that oil (Pentosin) emerges from both lines −4, 5−
unit .
2.
Installing pump 1530

einordnung
To do this, connect wide contact to +12 V, narrow contact ground

( ) to the pump motor according to the polarisation arrangement
−B− .
5 Inserting pump 3. Dip the hydraulic line ends completely in oil (Pentosin).
unit 4. Insert pump unit to the lower initial position. To do this, connect
wide contact ( ) to ground, narrow contact +12 V to the pump motor
according to the polarisation arrangement −A− .
5. To avoid oil leaking out, hold the hydraulic lines pointing vertically
upward after removing from the oil bath.
Installing => Installing hydraulic cylinder or => Filling the hydraulic cylinder
hydraulic cylinder
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Bleeding the pump unit
Bleeding the pump unit 1531

einordnung

1 Pulling out pump Pull hydraulic cylinder −2− out to the dimension −Y = 35 +2 mm− .
To do this, connect 12 V to the pump. Observe polarisation
arrangement −A− .
2 Bleeding short Slowly tighten short hydraulic line −4− until the hydraulic cylinder −2−
hydraulic line moves. If the hydraulic cylinder has reached the lower mechanical stop
−inset X− , push back onto the stop if necessary, hydraulic lines must
be laid parallel to eachother −inset Z− . Tighten banjo bolt −3− .
3 Bleeding long Slowly tighten long hydraulic line −5− until the hydraulic cylinder −2−
hydraulic line moves. If the hydraulic cylinder has reached the lower mechanical stop
−inset X− , push back onto the stop if necessary, hydraulic lines −inset
Z− must be laid parallel to eachother.
Tighten banjo bolt −3− .
Bleeding the pump unit 1532

einordnung
Installing pump unit ’ 559037 Disassembling and assembling rear lid
top of page
Removing wiring harness

1 Hydraulic cylinder, Loosen fastening screws on right hydraulic cylinder. Unscrew 2 fastening
right screws. 3. Screw can remain installed.
2 Unscrew 4 fastening screws −2− from the holder −1− .
Removing and installing wiring harness 1533

einordnung
Holder for micro

switch.
3 Remove additional Disengage cover −A− at the sides, unlock lock −B− . Pull off plug −C−
brake light −3− and remove additional brake light −3− .
4 Removing air guide Unscrew fastening screws −5− and remove air guide −4− .
−4−
5 Removing fan with fan Disconnect plug connections for fan and engine compartment lighting on
housing −6− the fan housing. Unscrew fastening screws −7− and remove fan with fan
housing −6− .
6 Disconnecting mount Unscrew fastening screws −9− . Remove mount −8− .
−8− Pull off plug connection on the pump unit.
7 Electrical plug Push in locking tab of the electrical plug connection −C− and pull apart.
connection Cut cable tie on the pneumatic spring.
Remove wiring harness.
Installing wiring harness
Removing wiring harness 1534

einordnung

1 Fastening holder −1− for micro Fasten holder −1− for both micro switches onto the hydraulic
switch cylinder with the fastening screws −2− .
Tightening torque: 0.5 Nm (0.5 ftlb.)
2 Fitting pump unit plug connection Insert electric plug on the pump unit.
and mount −8− . Screw in fastening screws −9− .
3 Installing fan with fan housing Put on fan with fan housing −6− and tighten with the three
−6− fastening screws −7− .
Push on plug for fan and plug for engine compartment lighting.
4 Installing air guide −4− Screw in both fastening screws −5− .
5 Installing additional brake light Push on plug −C− . Insert brake light. Lock the lock −B− .
−3− Engage cover −C− .
6 Fastening right hydraulic cylinder
Installing wiring harness 1535

einordnung
Screw the hydraulic cylinder to the spoiler with the fastening

screws.
7 Connecting the plug connection Press plug connection together in −direction of arrow− until it
engages.
Lay electric line on the pneumatic spring and fix with tie
wraps.
Removing and installing micro switches for rear spoiler
Note
• The rear spoiler is controlled via the instrument cluster.
• The micro switches can be checked with the Porsche System Tester.
• The micro switches are located on the right hydraulic cylinder.
• The operating principle of the micro switches differs (NO or NC contacts)
Removing micro switches
1. Unscrew fastening screws −2− for holder, micro switch −1− on the right hydraulic cylinder (4
screws) and remove holder.
2. Press the micro switch carefully out of the bracket using a screwdriver.
3.
Removing and installing micro switches for rear spoiler 1536

einordnung
Open the protective sleeve of the wiring harness by a few centimetres and cut wiring of micro
switch using a pair of side cutters.
Installing micro switches
1. Carefully push the new micro switch into the holder −1− . The micro switch with the blue lead at the
bottom and the micro switch with the grey lead at the top.
2. The operating principle of the micro switches differs (NO or NC contacts)
3. Join wires using crimp connector and crimping tool. => Tools and
materials
• Cut off lines to different lengths (due to the shrink connection).

• Strip 10 mm of insulation off the wires.
• Connect wires with crimp connectors (do not confuse colours of the individual wires).
• Shrink shrink−fit hoses with a hot−air gun. It is essential that all wires are watertight.
4. Position holder with micro switch −1− on the hydraulic cylinder. Fastening screws −2− Tightening
torque: 0.5 Nm.(0.5 ftlb.)
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Troubleshooting
Procedure Work instruction Cause

1 Possible causes of fault Diagnosis troubleshooting, spoiler
drive ’ Spoiler control, 9150
2 Drive motor for the pump does Connect battery voltage to the pump. ’ Pump faulty, replace
not turn. => Removing pump
3 Drive motor for the pump turns. ’ Pump faulty, replace
Hydraulic cylinders do not move. => Removing pump
4 One hydraulic cylinders does not Visual inspection: ’ Hydraulic cylinder
extend. −oil loss, visible fluid (Pentosin) on faulty, replace
hydraulic cylinder. => Removing hydraulic
cylinder
Removing micro switches 1537

einordnung
5 Hydraulic cylinders do not extend. Visual inspection: ’ Pump faulty, replace

−oil loss, visible fluid (Pentosin) on => Removing pump
the pump.
6 Hydraulic cylinders extend ’ Oil level too high.
automatically on parked vehicle. => Bleeding the pump
unit
top of page
Tools and materials

1 Pentosin CHF 11 S For filling the Spare part Gr 4; Parts Catalogue
pump unit and the hydraulic
cylinder
2 Syringe Commercial tool
3 Multimeter 155 Workshop Equipment Manual, Gr. 2.4
155−1
996420, 996421, 996450, 996451
Troubleshooting 1538
66 85 19 Removing and installing micro switches for
rear spoiler
Note
Remove micro switches
Tools
Note
• The rear spoiler is controlled via the instrument cluster.
• The micro switches can be checked with the Porsche System Tester 2.
• The micro switches are located on the right hydraulic cylinder.
• The operating principle of the micro switches differs (NO or NC contacts)
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Remove micro switches
1. Unscrew fastening screws −2− for holder, micro switch −1− on the right hydraulic cylinder (4
screws) and remove holder.
2. Press the micro switch carefully out of the bracket using a screwdriver.
3. Open the protective sleeve of the wiring harness by a few centimetres and cut wiring of micro
switch using a pair of side cutters.
66 85 19 Removing and installing micro switches for rear spoiler 1539

einordnung
top of page
1. Carefully push the new micro switch into the holder −1− . The micro switch with the blue lead at the
top and the micro switch with the grey lead at the bottom.
The operating principle of the micro switches differs (NO or NC
contacts)
2. Join wires using crimp connector and crimping tool. => Tools
• Cut off lines to different lengths (due to the shrink connection).

• Strip 10 mm of insulation off the wires.
• Connect wires with crimp connectors (do not confuse colours of the individual wires).
• Shrink shrink−fit hoses with a hot−air gun. It is essential that all wires are watertight.
3. Position holder with micro switch −1− on the hydraulic cylinder. Fastening screws −2− Tightening
torque: 0.5 Nm.(0.5 ftlb.)
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Tools

155−1
996420, 996421, 996450, 996451
Remove micro switches 1540

66 89 37 Disassembling and assembling the rearview
mirror
Disassembling the rearview mirror
Assembling the rearview mirror
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Disassembling the rearview mirror
66 89 37 Disassembling and assembling the rearview mirror 1541

einordnung

Removing rear−view
mirror
1 Folding in the rearview Fold in the rearview mirror in −direction of arrow− .
mirror
2 Removing rearview Carefully pull the rearview mirror glass −2− out of the metal clips.
mirror glass Disconnect electrical plug connection −3− .
3 Removing the rearview Unscrew fastening screws −4− from the rearview mirror shell −1− .
mirror shell
4 Removing the rearview Remove rearview mirror shell −1− upwards in the −direction of
mirror shell arrow− .
Remove foam strips.
Disassembling the rearview mirror 1542

einordnung

5 Removing the cover Press lugs −arrows− of the cover −9− and remove.
6 Removing the Unscrew fastening screw −6− from the positioning motor −7− .
positioning motor Disconnect electrical plug connection −8− .
7 Removing the metal clip Unscrew fastening screw −10− from the metal clip −11− and the
retaining bracket −12− .
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Assembling the rearview mirror
Assembling the rearview mirror 1543

einordnung

1 Installing metal clips Position metal clip −11− on the retaining bracket −12− and tighten with the
2 Installing positioning Plug in electrical plug connection −8− .
motor Position the positioning motor −7− on the retaining bracket and screw
down using the fastening screws −6− .
3 Installing cover Clip the cover −9− in the retaining bracket. Lug −arrows− must click into
place.

einordnung

4 Connecting the rearview Stick the foam strips in die recess of the rearview mirror shell.
mirror shell Position the rearview mirror shell−1− in −the direction of the
arrow− on the retaining bracket.
5 Tightening the rearview Secure the rearview mirror shell −1− with the fastening screws −4− .
mirror shell
6 Installing the rearview Plug in electrical plug connection −3− . Insert rearview mirror glass
mirror glass −2− into the metal clips.
7 Unfolding the rearview Fold up the rearview mirror in −direction of arrow− .
mirror
Installing the rearview
mirror
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

68 05 19 Removing and installing inner sill (driver's
side)
Removing inner sill
Installing inner sill
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Removing inner sill
68 05 19 Removing and installing inner sill (driver's side) 1546

einordnung

1 Undoing hexagon socket head bolts Remove plastic plugs −3− and undo the hexagon
−2− socket head bolts −2− from the sill by approx. 4 − 5
threads.
2 Removing the sill cover −1− Lift sill cover −1− upwards out of the bottom support
with a plastic spatula and press out. Check fastening
clips −4− , replace if necessary.
3 Pulling off plug connections −5, 6− Pull off plug connections −5, 6− on the actuating
of the actuating switches switches of the lids.
Remove actuating switch if necessary.
’ 5510 Dissassembling release for front lid
’ 5557 Disassembling release for rear lid
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Removing inner sill 1547

einordnung

1 Joining plug connections −5, 6− Install actuating switch if necessary.
of the actuating switches ’ 5510 Assembling release for front lid
’ 5557 Assembling release for rear lid
Push plug connections −5, 6− onto the actuating switches of the
lids.
2 Putting on sill cover −1− Clip in new fastening clips −4− if necessary. Insert sill cover
−1− downward into the lower support and engage.
bolts −2− − 5 threads. Seal holes of the sill cover with plastic plugs −3− .
Installing inner sill 1548

einordnung
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

68 05 19 Removing and installing inner sill
(passenger's side)
Removing inner sill
top of page
Removing inner sill
68 05 19 Removing and installing inner sill (passenger's side) 1550

einordnung

1 Undoing fastening Lift rubber mat −2− upward out of the odmments tray and unscrew the
screws −2− fastening screws −3− from the sill.
2 Removing sill −1− Lift sill −1− upwards out of the bottom support with a plastic spatula and
press out. Check fastening clips −4− , replace if necessary.
top of page
Removing inner sill 1551

einordnung

1 Putting on sill Clip in new fastening clips −4− if necessary. Insert sill −1− downward into the
−1− lower support and engage.
2 Fastening sill Screw in fastening screws −3− and lay rubber mat −2− into the oddments tray.
−2−
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

68 11 19 Removing and installing glove compartment
lock
Removing and installing glove compartment lock
top of page
Removing and installing glove compartment lock
68 11 19 Removing and installing glove compartment lock 1553

einordnung

1 Removing lid for 1 => Removing lid for glove => Installing lid for glove compartment
glove compartment compartment
2 Fastening screws 2 Unscrew the fastening Screw in fastening screws −2− .
screws −2− .
Note: The lock for the glove compartment can not be removed from the
handle.
3 Handle with lock 1 Remove lock for glove Position the lock for the glove
for glove compartment −3− from the compartment −3− in the glove
compartment glove compartment lid. compartment lid −1− and screw tight with
996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing and installing glove compartment lock 1554

68 12 19 Removing and installing lid for glove
compartment
Removing lid for glove compartment
Installing lid for glove compartment
Replacing microswitch and interior light
Replacing pneumatic shock absorber
• A = Lid for glove compartment
• B = Pneumatic shock absorber
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Removing lid for glove compartment
68 12 19 Removing and installing lid for glove compartment 1555

einordnung

1 Unscrewing the front fastening screws Unscrew front fastening screws −1− .
2 Unscrewing fastening screws at the side Unscrew fastening screws −1− at the side.
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Installing lid for glove compartment
Removing lid for glove compartment 1556

einordnung

Checking rubber stop Before installing the glove compartment lid, check the rubber
stop −2− to the left and right and replace, if necessary.
1 Screwing in the front fastening Screw in front fastening screws −1− .
screws
2 Screwing in fastening screws at Screw in fastening screws −1− at the side.
the side
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Replacing microswitch and interior light
Installing lid for glove compartment 1557

einordnung
1. Replacing microswitch and interior light
Note
• In the case of a defective microswitch, the complete wiring harness −4− must be replaced!
a. => Removing glove

compartment
b. On the retaining bracket −2− , press the locking tabs −A− apart. Guide out the microswitch −5− .
c. Insert a plastic spatula into the side of the interior light −1− and press out. Disconnect the electrical
plug connection.
2 − Installing microswitch and interior light
d. Plug in the electrical plug connection of the interior light −1− . Press the interior light −1− into the
cut−out of the glove compartment.
e. Press the microswitch −5− into the retaining bracket −2− . Note the coding of the microswitch.
f. To fit the glove compartment, engage the electrical lead −4− into the clip −3−
.
g. => Installing glove
compartment
top of page
Replacing pneumatic shock absorber
1. Removing the
Replacing microswitch and interior light 1558

einordnung
pneumatic shock
absorber
Press the pneumatic shock absorber −1− out of the fastening tab −arrow B− . Turn the pneumatic
shock absorber by 90° anti−clockwise in the direction of arrow −A− and guide it out of the glove
compartment.
2 − Installing the pneumatic shock absorber
Insert the pneumatic shock absorber −1− and turn it 90° clockwise in the direction of arrow −A− .
Insert the pneumatic shock absorber into the fastening tab towards the −direction of arrow B− .
996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Replacing pneumatic shock absorber 1559

68 15 19 Removing and installing glove compartment
Removing glove compartment
Installing glove compartment
top of page
Removing glove compartment
68 15 19 Removing and installing glove compartment 1560

einordnung

1 Unclipping plastic clips Unclip plastic clips −2− . Guide the insulation downwards out
of both corners −arrows− .
2 Unscrewing the rear fastening Unscrew fastening screws −3− from the glove compartment.
screws
3 Unscrewing the front fastening Unscrew fastening screws −4− from the glove compartment.
screws
4 Disconnecting the electrical plug Disconnect the electrical plug connection in the −direction of
connection the arrow− .
5 Removing the glove compartment Lift the glove compartment upwards −arrow− and guide it out
of the dashboard −1− .
top of page
Removing glove compartment 1561

einordnung
Installing glove compartment

1 Connecting electrical plug Connect the electrical plug connection in the −direction of
connection the arrow− .
2 Installing glove compartment Swivel the glove compartment into the dashboard in the
−direction of the arrow− .
Note the position of the locating peg −A− .
3 Screwing in the front fastening Screw in the fastening screws −4− in the glove compartment.
screws Tightening torque: 2.5 Nm (2 ftlb.)
4 Screwing in the rear fastening Screw in the fastening screws −3− in the glove compartment.
screws Tightening torque: 2.5 Nm (2 ftlb.)
5 Fitting the plastic clips
Installing glove compartment 1562

einordnung
Position the insulation, making sure that the corners are

inserted correctly under the dashboard. Press in plastic clips
−2− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996430, 996431, 996630, 996631
Installing glove compartment 1563

68 17 19 Removing and installing center console
(front section)
68 17 19 Removing and installing center console (front section) 1564

einordnung

1 Cover, front left 1 Unclip the front left cover −1− at the Position the front cover
sides. −1− on the front centre
console −15− and clip it
laterally into the clips
−3− .
2 Cover, front right 1 Unclip the front right cover −2− at the Position the front cover
sides. −2− on the front centre
console −15− and clip it
laterally into the clips
−3− .
3 Clip 10 Inspect clip −3− and
replace if necessary.
4 Cover cap 1
(telephone trim panel)
5 Fastening screw 9

einordnung
6 Telephone trim panel 1 Insert a wire into the hole of the cover Insert the locking tabs of
cap −4− and pull off the cover cap to the telephone trim panel
the rear. Undo the fastening screws into the front cover −8−
−5− and lift the telephone trim panel and screw it in place with
off the front cover −8− . the fastening screws −5− .
Tightening torque: −2.3
Nm (1.5 ftlb.)−
Press in cover cap −4− .
7 Installation frame for 1
(telephone handset)
8 Cover, front left 1 Unscrew fastening screws −5− , unclip Position cover at the
(telephone carrier) the cover from the centre console at the centre console at the
side and remove to the rear. front, clip in at the side
and fasten with the
fastening screws −5−
Nm (1.5 ftlb.)−
9 Adapter 1 Unscrew fastening screws −5− and Position the adapter at the
remove the adapter from the centre centre console at the front
console at front. −9− and fasten with the
Nm (1.5 ftlb.)−
10 Combi−single CD drive 1 See: ’ 911219 Removing and installing
for navigation navigation unit CD drive
11 Heating/air−conditioning 1 See: ’ 870219 Removing and installing
control the heating/air−conditioning control
12 Front trim 1 Unclip the front trim −12− towards the Connect the electrical
front and disconnect the plug connection, position the
connection of the rocker switch for the front trim −12− on the
seat heating. centre console −15− and
press into place.
13 Cover, left 1 Unclip the left cover −13− at the side Position the right cover
and pull out to the rear. −13− on the centre
console or on the cover
panel of the support
frame and clip the cover
into the clips −3− at the
side.
14 Cover, right 1 Unclip the right cover −14− at the side Position the right cover
and pull out to the rear. −14− on the centre
console or on the cover
panel of the support
frame at the front and clip
the cover into the clips
−3− at the side.
15 Centre console (front 1 Undo fastening screws −5− and lift the Position the front of the
section) front of the centre console −15− off. centre console −15− on
the holder −18− or on the

einordnung
dashboard frame and

secure with the fastening
screws −5− .
16 Plug−in nut 4 Inspect and replace if
necessary.
17 Collar nut 4 Tightening torque:
−10 Nm (7.5 ftlb.)−
18 Holder 1
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

68 17 19 Removing and installing center console
68 17 19 Removing and installing center console 1568

einordnung
Note
• Before removal, the centre console must be partly disassembled. For this purpose, remove both the
front covers and the front trim. => Removing and installing center console (front section)

1 Shift lever 1 Disengage from the clips −2− all Push on.
knob the way round. Pull the shift lever
knob −1− upwards and out.
2 Clip 4 Inspect and replace if necessary.
3 Fastening 3 Undo. Screw in.
screws
4 Ashtray insert 1 Lift out. Press in.
5 Expanding nut 2 Press out. Press in.

einordnung
6 Ashtray 1 Unclip the ashtray retaining bracket Connect the electrical plug connections,
retaining −6− upwards from the centre secure the ashtray retaining bracket −6−
bracket console and disconnect the in the centre console and fasten with the
electrical plug connections. fastening screws −3− .
7 Rubber insert 1
8 Floor 1 Undo fastening screw −3− from the Position the floor oddments tray −8− in
oddments tray floor oddments tray −8− . the centre console and fasten with the
9 Coin box 1 Unclip the coin box −9− and undo Tighten the fastening screw −3− and clip
the fastening screw −3− the coin box −9− into place.
underneath.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

68 30 19 Removing and installing cup holder
Removing cup holder
Installing cup holder
top of page
Removing cup holder
68 30 19 Removing and installing cup holder 1571

einordnung
1. Removing cup holder

’ 701837 Removing cover and centre nozzle for the instrument
panel
Press metal clip −1− −arrow− and hold. Pull the cup holder −2− out of the retaining bracket −3− .
top of page
Installing cup holder
1. Installing cup holder

Push cup holder −2− into the shaft of the retaining bracket −3− . Make sure that the metal clip
−1− engages.
’ 701837 Installing cover and centre nozzle for the instrument
panel
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996430, 996431, 996630, 996631
Removing cup holder 1572

69 11 19 Removing and installing front three−point
belt
Removing front three−point belt
Installing front three−point belt
top of page
69 11 19 Removing and installing front three−point belt 1573

einordnung

Removing side−panel ’ 707519 Removing and installing side−panel lining
lining
Removing B−pillar ’ 705719 Removing and installing trim of A, B and C−pillars
trim
1 Removing seat belt and Press out the covering cap −1− with a screwdriver. Unscrew fastening
fitting screw −2− . Remove the seat belt with fitting −4− and spacer sleeve −5− .
Removing belt => Removing belt tensioner
tensioner
Only on vehicles with
belt tensioner
2 Removing automatic Unscrew fastening screw −6− from the automatic belt device −7− .
belt device
3 Removing deflector Unscrew fastening screws −8− from the deflector −9− .
Removing front three−point belt 1574

einordnung
top of page

Only on vehicles with => Removing belt tensioner
belt tensioner
Installing belt
tensioner
1 Installing deflector Position the deflector and the seat belt on the inner side section and screw
tight with the fastening screws −8− .
2
Installing front three−point belt 1575

einordnung
Installing automatic Position the automatic belt device −7− . Make sure that the locking tab
belt device −arrow− of the automatic belt device is engaged correctly in the
sheetmetal bracket.
3 Removing seat belt Make sure that the belt strap can run properly!
and fitting Screw the fastening screw −2− , the seat belt with fitting −3− and the
spacer sleeve −5− tight on the inner lower side member.
trim
Removing side−panel ’ 707519 Removing and installing side−panel lining
lining
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

69 11 19 Removing and installing front three−point
belt − Cabriolet
top of page
69 11 19 Removing and installing front three−point belt − Cabriolet 1577

einordnung

1 Removing seat belt and Press out the covering cap −1− with a screwdriver. Unscrew fastening
fitting screw −2− . Remove the seat belt with fitting −4− and spacer sleeve −5− .
Removing side−panel ’ Removing side−panel lining, 707519
lining
2 Removing deflector Unscrew fastening screws −6− from the deflector −7− .
Removing belt => Removing belt tensioner
tensioner
belt tensioner
3 Removing automatic Unscrew fastening screw −6− from the automatic belt device −9− .
belt device
top of page
Removing front three−point belt 1578

einordnung

belt tensioner
Installing belt
tensioner
1 Installing automatic Position automatic belt device −9− . Make sure that the locking tab
belt device −arrow− of the automatic belt device is engaged correctly in the sheetmetal
bracket −8− .
2 Installing deflector Position the deflector −7− and the seat belt on the inner side section and
screw tight with the fastening screws −6− .

einordnung
Installing side−panel ’ Removing side−panel lining, 707519

lining
3 Installing seat belt Make sure that the belt strap can run properly!
and fitting Screw the fastening screw −2− , the seat belt with fitting −3− and the spacer
sleeve −5− tight on the inner lower side member and press in the covering
cap −1− .
996620, 996621, 996650, 996651, 996630, 996631

69 11 01 Checking seat belts
Caution
Checking belt strap
Checking automatic belt device (locking effect)
Belt buckle, visual inspection
Belt buckle, function test
Checking sash guides
Checking mounting elements and mounting points
CAUTION
• After any accident, the seat belt system must be checked systematically for proper function and
damage. If damage is found according to the test points, the entire seat belt system must be replaced.
Test points
=> Checking belt strap
=> Checking automatic belt device (locking effect)
=> Belt buckle, visual inspection
=> Belt buckle, function test
=> Checking sash guides
=> Checking mounting elements and mounting
points
Note
• In the case of damage which does not occur as the result of an accident, e.g. wear, only the damaged
part needs to be replaced.
top of page
Checking belt strap
Pull out the belt strap on the automatic belt device fully.
Check the belt strap for soiling; clean, if necessary, with mild soap suds. When drying, avoid direct
sunshine.
1. Damage type 1
69 11 01 Checking seat belts 1581

einordnung
If one of the damage types shown below −Figure 1 and 2− is found on an accident vehicle, the seat belt and
belt buckle must be replaced.
3. Damage type 2
If damage such as −Figure 1, 2, 3− is found on a vehicle not involved in an accident, it is sufficient to replace
the damaged seat belt.
4. Damage type 3
Burn marks from cigarettes, or similar.
5. Damage type 4
The belt tensioner must always be replaced if it has been triggered. The seat belt is damaged by the deflector
−Figure 4− .
top of page
Checking automatic belt device (locking effect)
The automatic belt device has two locking functions
• The first locking function is triggered by pulling the seat belt out quickly (belt extension acceleration).
Test
Pull the seat belt out of the automatic belt device with a strong pull.
• If no locking effect occurs, the entire seat belt and belt buckle must be replaced.
Checking belt strap 1582

einordnung
• In the case of faults in the extension or retraction of the seat belt, check whether the locking tab of the
automatic belt device is engaged correctly in the sheetmetal bracket on the body.
• The second locking function is triggered by a change in the sequence of vehicle movement
(vehicle−dependent locking function).
Test
CAUTION
For safety reasons, this driving test must be carried out on a traffic−free road, so that there is absolutely no
danger to other road users.
Fasten the seat belt.
Accelerate the vehicle to 20 km/h (12 mph) and then perform an emergency stop with the foot brake.
• If the belt is not locked by the blocking mechanism during the braking phase, the entire seat belt and
belt buckle must be replaced.
top of page
Belt buckle, visual inspection
Inspect the belt buckle for crack formation and flaking.
• In the case of damage, the entire seat belt and belt buckle must be replaced.
top of page
Belt buckle, function test
Checking belt buckle
Push the buckle into the belt buckle until it engages audibly. Check whether the lock mechanism has
engaged by pulling strongly on the belt strap.
• If the buckle fails to lock in the belt buckle even just once in at least 5 test procedures, the entire seat
belt and belt buckle must be replaced.
Checking belt buckle release

Release the seat belt by pressing with a finger on the button on the belt buckle.
• Carry out the test procedure at least 5 times. If the buckle fails to jump out even just once, the entire
seat belt and belt buckle must be replaced.
Note
• Lubricants must never be used to remedy noises or sluggishness of the buttons on the belt buckles.
Checking automatic belt device (locking effect) 1583

einordnung
top of page
Checking sash guides
Plastic−coated covers show fine, parallel scores after the belt system has been subjected to stress (seat belt
buckled during accident). On the other hand, wear caused by frequent use is indicated by a stripe−free,
smooth surface.
Inspect the sash guides for distortion, flaking and crack formation.
• In the case of scoring and/or damage, the entire seat belt and belt buckle must be replaced.
top of page
Checking mounting elements and mounting points
• Check the belt buckle strap for distortion.
• Check the function of the height adjuster.
• Check the mounting points (seat, B−pillar, C−pillar, vehicle floor) for distortion or thread damage.
• If damage is found on the parts, the entire seat belt and belt buckle must be replaced.
• Replace damaged or distorted mounting points.
996421, 996420, 996430, 996431, 996630, 996631, 996620, 996621, 996650, 996651, 996840, 996841
Belt buckle, function test 1584

69 12 19 Removing and installing rear three−point
belt
Removing rear three−point belt
Installing rear three−point belt
top of page
69 12 19 Removing and installing rear three−point belt 1585

einordnung

Removing ’ 707519 Removing and installing wheel trim
side−panel lining
Removing C−pillar ’ 705719 Removing and installing trim of A, B and C−pillars
1 Removing automatic Unscrew fastening screw −1− from the deflector −2− . Unscrew fastening
belt device screw −3− from the automatic belt device −4− .
2 Removing seat belt Press out the covering cap −5− with a screwdriver. Unscrew fastening screw
and fitting −6− . Remove the seat belt with fitting −7− and spacer sleeve −8− .
3 Removing seat Pull the seat cushion −9− upwards and out.
cushion
4 Removing the seat Press out the cover −10− with a plastic spatula.
belt Unscrew the fastening screw −11− from the metal clip −12− and the belt
buckle −13− .
Removing rear three−point belt 1586

einordnung
top of page

1 Removing the seat Position seat belt −13− with the metal clip −12− , seat well and the fastening
belt screw −11− .
2 Installing seat Position seat cushion −9− onto the Velcro fastening strip and press on.
cushion
3 Removing seat belt Make sure that the belt strap can run properly!
and fitting Screw the fastening screw −6− , washer −5− , seat belt with fitting −7− and
the spacer sleeve −8− tight on the inner lower side member.
4 Installing automatic Position the automatic belt device −7− , making sure that the locking tab
Installing rear three−point belt 1587

einordnung
bracket.
trim
Removing ’ 707519 Removing and installing wheel trim
side−panel lining
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

69 12 19 Removing and installing rear three−point
belt − Cabriolet
top of page
69 12 19 Removing and installing rear three−point belt − Cabriolet 1589

einordnung

Moving Cabriolet ’ 610119, Cabriolet Verdeck aus− und einbauen
convertible top to service
position
Removing rear wall lining => Removing roll−over protection system
and cover
1 Removing seat cushion Pull the seat cushion −1− upwards and out.
2 Removing belt buckle Press out the cover −2− with a plastic spatula.
Unscrew the fastening screw −3− from the metal clip −4− and the
belt buckle −5− .
3 Removing seat belt and Press out the covering cap −6− with a screwdriver. Unscrew
fitting fastening screw −7− . Remove the seat belt with fitting −8− and
spacer sleeve −9− .
4 Removing automatic belt Unscrew fastening screw −10− from the automatic belt device −11−
Removing rear three−point belt 1590

einordnung
device −A− . Remove automatic belt device −11− at the side −B− .
top of page

1 Installing automatic Position automatic belt device −1− −A− . Make sure that the locking tab
bracket and screw down with the fastening screw −2− −B− .
2 Installing seat belt Make sure that the belt strap can run properly!
and fitting Screw the fastening screw −5− , the seat belt with fitting −4− and the spacer
sleeve −3− tight on the inner lower side member and press in the cover −6− .

einordnung

3 Installing belt Screw the belt buckle −7− and the metal clip −8− tightly to the seat well with
buckle the fastening screw −9− and press in the cover −10− .
4 Installing seat Press the seat cushion −11− on to the Velcro fastenings.
cushion
Installing the rear => Installing roll−over protection system
wall lining and
cover
996310, 996311, 996610, 996611

69 13 19 Removing and installing belt tensioner − as
of MY 2002
Removing belt tensioner
Installing belt tensioner
top of page
Removing belt tensioner
Note
• As from model year 2002, the front three−point belts in the 911 Turbo (996) will contain belt
tensioners as standard. After the belt tensioners have been triggered, they must be replaced. The
triggering can be read out with the Porsche System Tester using the airbag control module (POSIP).
69 13 19 Removing and installing belt tensioner − as of MY 2002 1593

einordnung
Observe the direction of travel −arrow 3− .
=> Safety regulations for vehicles with airbag and belt tensioner => Disposal of airbag and belt tensioner units
=> Removing and installing front three−point belt
1. Pull belt −1− forwards.

2. Disable the fuse −2− for the electrical plug on the belt tensioner with a screwdriver in the −direction of
the arrow− .
3. Pull the plug −A− out of the belt tensioner −arrow− .

4. Unscrew the fastening screw −B− and remove the belt tensioner.
top of page
Installing belt tensioner
=> Safety regulations for vehicles with airbag and belt tensioner
1. Install belt tensioner. Observe the direction of travel −3− .

2. Screw fastening screw −B− , tightening torque 50 Nm (37 ftlb.).
3. Insert electrical plug −A− in the belt tensioner.
Removing belt tensioner 1594

einordnung
4. Push in fuse −2− with e.g. a screwdriver in the −direction of travel− until the fuse engages.
5. By gently pulling on the belt −arrow 1− , check the winding ability of the belt
strap.
=> Removing and installing front three−point belt
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431, 996630, 996631, 996620, 996621,
996650, 996651
Installing belt tensioner 1595

69 36 19 Removing and installing adjustment fitting
(seat belt height adjuster)
Removing and installing adjustment fitting
Illustrated on Targa (996)
top of page
Removing and installing adjustment fitting
69 36 19 Removing and installing adjustment fitting (seat belt height adjuster) 1596
einordnung
Note:
’ 705719 Removing and installing B−pillar
1 Fastening 1 Unscrew fastening screw −1− . Screw in fastening screw −1− and
screw tighten.
2 Adjustment 1 Guide the adjustment fitting −2− Insert the adjustment fitting −2−
fitting upwards out of the B−pillar in the downwards into the B−pillar in the
−direction of the arrow− . −direction of the arrow− .
Tighten fastening screw −1− .
996430, 996431, 996420, 996421, 996450, 996451
Removing and installing adjustment fitting 1597

69 51 19 Removing and installing sensor for side
airbag
Remove sensor for side airbag
Install sensor for side airbag
Tools
top of page
Remove sensor for side airbag
Note
• Sensors for triggering the side airbag unit are fastened on the inner lower side member on the left and
right−hand sides in the vehicle.
69 51 19 Removing and installing sensor for side airbag 1598

einordnung
• After an accident, the sensor of the triggered side airbag unit must be examined for damage and
replaced if necessary.
• The sensor must be replaced after the side airbag has been triggered for the third time
• Safety conditions must be observed when handling airbags. => Safety regulations for vehicles with
airbag and belt tensioner
• Remove front seat. ’ 7, 720119 Removing and installing front seat

• Remove the side lining at rear. ’ 7, 707519 Removing and installing side panel lining
• Remove sill. ’ 6, 680519 Removing and installing the sill
1. Disengage floor covering at the support and lay it in the vehicle

interior.
2. Unlock locating peg −1− of the support using the commercially available removal tool. => Tools
3. Unscrew fastening screws −2− and nuts −3− and carefully pull the support up and out of the retaining
points.
4. Loosen the electrical plug connection on the airbag sensor.
Remove sensor for side airbag 1599

einordnung
5. Remove both fastening screws and remove the sensor.
top of page
Install sensor for side airbag
1. Position sensor and secure with the fastening screws. Tightening torque 10 Nm (7.5 ftlb.).
2. Connect electrical plug connection.
3. Position the support and engage in lower side member.
Install sensor for side airbag 1600

einordnung
4. Push in the locating peg −1− of the support and check that it is sitting
correctly.
5. Tighten the fastening nuts −3− and the fastening screws −2− . Tightening torque −2− 7.2 Nm (5.5ftlbs.).
6. Lay the floor covering over the support and
engage.
• Using the Porsche System Tester, read out any faults present in the POSIP menu and erase. ’ 0, 69 01
Diagnosis/troubleshooting, airbag
• Insert sill. ’ 6, 680519 Removing and installing the sill
• Mount the side lining at rear. ’ 7, 707519 Removing and installing side panel lining
• Install front seat. ’ 7, 720119 Removing and installing front seat
top of page
Tools

Removal tool Commercially available’
HandbuchWerkstattausrüstung Kapitel 2.4, Nr. 21
996420, 996421, 996450, 996451
Tools 1601
69 72 19 Removing and installing roll−over bar
Safety instructions for work on the roll−over protection system
Mechanical emergency triggering of the roll−over protection system
Removing roll−over protection system
Installing roll−over protection system
Tightening torques
top of page
Safety instructions for work on the roll−over protection system
• It is impermissible to perform repairs on the roll−over bar modules.
• The roll−over bar modules must be replaced in the event of visible damage or pressure marks.
69 72 19 Removing and installing roll−over bar 1602

einordnung
WARNING
Danger of injury during work on the roll−over protection system!
• The movement range of the roll−over protection system must be kept clear.
• Work on the roll−over protection system must be performed only with the ignition key withdrawn.
• Please note: Do not begin assembly work until after a waiting time of 1 minute has elapsed.
• Tools or other objects must not be placed in the extension area of the roll−over protection system.
WARNING
Danger of injury during work on the roll−over protection system!
• Remove the roll−over bar modules only after the roll−over bar has been extended (triggered).
• After assembly work on the roll−over protection system but at least every 2 years the function of
the roll−over protection system must be tested by triggering it via the diagnostic interface of the
Porsche System Tester.
• Perform the function test on the roll−over protection system only with the hardtop and covering cap
removed and the convertible top open.
top of page
Mechanical emergency triggering of the roll−over protection
system
If the roll−over bar modules cannot be triggered via the diagnostic interface, mechanical emergency triggering
is possible.
WARNING
Danger of injury during mechanical emergency actuation!
• The movement range of the roll−over protection system must be kept clear.
Insert a screwdriver into the hole in the module and press it against the top edge of the pawl. Press the
screwdriver to the right −arrow A− and hold it while pressing up −arrow B− . The roll−over protection
system is released.
top of page
Safety instructions for work on the roll−over protection system 1603

einordnung
Removing roll−over protection system
WARNING
Danger of injury during assembly work! The roll−over bar module can be triggered.
• Remove the roll−over bar modules only after the roll−over bar has been extended (triggered).

1 Removing rear wall lining Remove fastening screws −1− from the rear wall lining −2−
on the left and right, and detach the auxiliary frame. Remove
rear wall lining.
2 Removing cover
Removing roll−over protection system 1604

einordnung
Unclip covering caps −3− . Unclip the cover −4− over the
roll−over protection −5− at the front, unscrew the fastening
screws −6− and lift the cover up and off.
3 Triggering roll−over Note:
protection system with the Actuate the roll−over protection system −5− only if:
Porsche System Tester 2
• the hardtop is removed
• the convertible top is open
• the caps are removed
Connect the Porsche System Tester to the diagnostic socket.

Switch on ignition. Select menu item "Roll−over protection".
Select menu item "Drive links" in the command line which
then appears. Press the key combination described in the
Tester; the roll−over protection system is triggered.
4 Undoing fastening screws Undo the fastening screws from the modules in the auxiliary
frame −8− and pull out in downward direction.
5 Disconnecting the electrical Press the electrical plug connection −9− −arrow A− and pull
plug connection apart.
top of page
Installing roll−over protection system
Installing roll−over protection system 1605

einordnung

1 Connecting electrical plug Plug in electrical plug connection −9− of the roll−over bar
connection modules.
2 Fitting roll−over bar modules Position the roll−over bar modules on the auxiliary frame −8−
and fasten them with the fastening screws −7− property class
10.9.
Tightening torque 33 Nm (24 ftlb) ± 3 Nm (2 ftlb).
3 Triggering roll−over Test the roll−over protection system −5− (function test). Select
protection system with the menu item "Roll−over protection". Select menu item "Drive
Porsche System Tester 2 links" in the command line which then appears. Press the key
combination described in the Tester; the roll−over protection
system is triggered.
Note:
Carry out the function test only with the cover caps removed.
4 Fitting cover
Installing roll−over protection system 1606

einordnung
Position cover −4− of the roll−over protection system over the

auxiliary frame and screw it down with the fastening
screws−6−
Press locking levers of the roll−over bar modules outward, and
press in the roll−over bar until it engages.
5 Press in the roll−over bar Press locking levers outward and press in the roll−over bar
until it can be felt to engage. Fit cover flaps −3− on the left and
right.
6 Fitting rear wall lining Position rear wall lining −2− on the auxiliary frame and fasten
it on the left and right using the −1− fastening screws.
top of page
Tightening torques
Tightening torque [Nm]

Attaching the roll−over bar modules to the −7− M8 33 (24)± 3 (2)
auxiliary frame
996630, 996631, 996420, 996421, 996450, 996451

roll−over protection system
Removing control module
Installing control module
Tools and materials
top of page
Removing control module
1. Remove ignition key
3. Only loosen the centre console and move it forwards a little. => Removing and installing center console
4. Remove the two rear belt buckles and take out the seat wells.
5. Undo the trim of the seat wells from the carpeting and lift up in the middle.
6. Using a support tool, support the trim and unscrew and remove the plastic screw from the control module
cover.
7. Disconnect the electrical plug connection. Undo the shear−off nuts with socket wrench insert => Tools
and materials, and remove the roll−over protection control module.
top of page
Installing control module
1. Install the roll−over protection control module in the centring holes with the fixing pins, and secure with
shear−off nuts.
2. Use a 1/4 inch Allen key to tighten the shear−off nuts.
3. Engage electrical plug connection and route wire carefully. Install control module cover, seat wells,
belt buckles and centre console.
69 74 19 Removing and installing control module for roll−over protection system 1608
einordnung
4. Following the installation of a new control module for the roll−over protection system, the transport lock
must be deactivated with the Porsche System Tester 2 (refer to Group 01, Entire vehicle General, Sales
check: Deactivating the transport lock in the roll−over protection system, 911 Cabriolet
top of page
Tools and materials

1 Socket wrench insert 9259 Gr. 2.2.2; Workshop Equipment Manual
996620, 996621, 996650, 996651, 996630, 996631
Installing control module 1609

69 77 19 Removing and installing frame for roll−over
protection system
Removing and installing frame for roll−over protection system
Tightening torques
top of page
Removing and installing frame for roll−over protection system
69 77 19 Removing and installing frame for roll−over protection system 1610

einordnung

1 Fastening screw 4 Unscrew. Tighten. => Tightening torques
2 Fastening nut 4 Unscrew. Tighten. => Tightening torques
3 Frame 1 Undo fastening screws Position frame in the vehicle.
−1− and fastening nuts −Dimension X: 491 ± 1 mm−
−2− , and lift frame −3− Measure centre of screwed point
out of the vehicle. (convertible−top support), side section on
inside, to frame cutout on right and left.
Tighten fastening screw −1− and fastening nut
−2− .
4 Fastening nut 2
5 Relay carriers 1
6 Wiring harness 1
7 Oval−head screw 10
Removing and installing frame for roll−over protection system 1611

einordnung
8 Convertible−top 1
control module
9 Fastening screw 4 => Tightening torques
10 Holder 2
12 Right bracket 1
13 Left bracket 1
16 Belt reel, left 1
17 Assembly key 1 Clip in.
19 Holder 1
20 DME + Tiptronic 1
control unit
21 Collar nuts 2 => Tightening torques
22 Z drive VDKD cpl. 1
23 Convertible top Z 1
drive
24 Fastening nut 4 => Tightening torques
top of page
Tightening torques
Tightening
torque [Nm]
Hexagon−head bolts for installing the roll−over bar −1− M10 65 (48)± 6 (4.5)
Collar nuts for installing the rear Z−supports −2− M10 48 (36)
Hexagon−head bolt for installing the holder −10− −9− M6 9.7 (7)
Hexagon−head bolt for installing the bracket on the right −11− M6 9.7 (7)
and left −12, 13−
Hexagon−head bolt −15− 50 (37)
Collar nuts for installing the DME + Tiptronic control unit −21− M6 7 (5)
on the holder
Collar nuts for installing the convertible top Z drive −24− M6 6 (4.5)
996620, 996621, 996650, 996651, 996630, 996631

70 05 19 Removing and installing front luggage
compartment trim
Removing and installing trims units
Removing and installing carpet lining
Tools and materials
top of page
Removing and installing trims units
70 05 19 Removing and installing front luggage compartment trim 1613

einordnung

1 Cam 2 Turn 90° and remove. Position and turn 90°.
2 Interior light 1 Press out. Press in.
3 Fastening screws 3 Unscrew. Screw in.
4 Trim units 1 Unscrew fastening screws −3− Screw in fastening screws −3− .
5 Holder 2
6 Holder 2
top of page
Removing and installing trims units 1614

einordnung
Removing and installing carpet lining

1 Plug 4 Removal tool: Press in.
2 Short plastic nuts 1 Unscrew. Screw in.
3 Cover cap 2
5 Panel 1
6 Front carpet lining 2
7 Rear carpet lining 2
8 Bottom carpet lining 1
Removing and installing carpet lining 1615

einordnung
9 Fastening nut 1
10 Holder 1
top of page
Tools and materials

1 Removal tool, universal no. 21 Gr. 2.4; Workshop Equipment Manual
996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

70 18 19 Removing and installing the instrument
panel and instrument panel bracket − as of model
year 2003
Tightening torque
Tools and materials
top of page
70 18 19 Removing and installing the instrument panel and instrument panel bracket − as of model
1617year 200
einordnung
Note
• Before removing the instrument panel, it must be disassembled. => Disassembling the instrument
panel

1 Fastening screws 3 Unscrew fastening screws Screw the instrument panel −4− to the
−1− from the instrument instrument panel bracket with the
panel −4− . fastening screws −1− .
Removing and installing the instrument panel 1618

einordnung
Undo fastening screws −2− Screw the instrument panel −4− to the
from the instrument panel instrument panel bracket with the
−4− . fastening screws −2− .
3 On−Board Diagnosis 1 Unscrew the fastening screws Tighten the fastening screws −2− .
(OBD) socket −2− .
4 Instrument panel 1 See: Position −1 and 2− See: Position −1 and 2−
5 Sheetmetal nut 2 Unscrew the fastening screws Inspect and replace if necessary.
−2− .
6 Instrument panel 1
bracket with knee
protector strip
7 Sheetmetal nut 11 Unscrew fastening screws −1 Inspect and replace if necessary.
and 2− from the instrument
panel −4− .
top of page

einordnung
Note
• Before removing the instrument panel bracket, the instrument panel must be disassembled.
=> Removing and installing the instrument panel bracket

7 Sheetmetal nut 4
9 Threaded plate 4 It is screwed into position with the
compensating element −10− and the
10 4

einordnung
Compensating The compensating element −10− By screwing in the fastening screws

element is released by undoing the −8− , the compensating element −10−
fastening screw −18− . can be fixed and secured.
12 Instrument panel 1 Undo the fastening screws −8− Insert instrument panel bracket −12−
bracket in the compensating elements into the body. Fix compensating
−10− and guide the instrument elements −10− to the instrument panel
panel bracket −12− out of the bracket and screw down with the
body. fastening screws −8 and 11− .
13A Closure cap 2 Pull out. Press in.
13B Plug 2 Only installed on 911 coupé
versions.
14 Sheetmetal clip 4 Check, if necessary, replace.
16A USA version, 1 Unscrew fastening screws −15− Secure the knee protector strip −16A−
knee protector from the knee protector strip on the instrument panel bracket −12−
strip −16A− . Remove the knee and tighten the fastening screw −15− .
protector strip.
16B USA version, 1 Unscrew fastening screws −15− Secure the knee protector strip −16B−
knee protector from the knee protector strip on the instrument panel bracket −12−
strip −16B− . Remove the knee and tighten the fastening screw −15− .
protector strip.
17 Cowl panel seal 1 Is destroyed when removed. Tighten protective film.
18 Adhesive pad 1 Is destroyed when removed.
• Attach the adhesive pad for
left−hand drives on the right
holder and on the left holder for
right−hand drives.
The bonding area must be free of dust

and grease.
Tighten protective film and position it.
19 Clip 4
21 Shear−off nut 2 Undo the shear−off nut with
special tool 9259.
23 Airbag control 1 See: ’ 695319 Removing and See: ’ 695319 Removing and installing
module installing the triggering unit for the triggering unit for the airbag.
the airbag.
24 Cover panel 4 Fix the cover panel in the body and the
instrument panel bracket −12− and
screw down with the fastening screws
−20− .

einordnung
26 Cover panel 1 Unscrew fastening screws −25− .

27 Strut 1 Unscrew fastening screws −2− Position strut −27− on the instrument
from the strut −27− on the left panel bracket −12− and tighten with the
and right. fastening screws −2− .
top of page
Tightening torque
Tightening
torque [Nm]
A−pillar fastening screws on the instrument panel bracket −8− M8 23 (17) Nm
(ftlb.)
Cowl panel fastening screws on the instrument panel bracket −11− M6 10 (7.5) Nm
(ftlb.)
Knee protector strip fastening nuts on the instrument panel −14− M6 10 (7.5) Nm
bracket (ftlb.)
Knee protector fastening screws on the instrument panel −15− M8 6 (4.5) Nm
bracket (ftlb.)
(tunnel) (ftlb.)
(ftlb.)
top of page
Tools and materials
Cutting with adhesive pad
X 50 mm
Y 40 mm
Z 25 mm
Punch out the crack −Z− at a diameter of 7 mm
Tightening torque 1622

einordnung

1 Socket wrench insert 9259 Gr. 2.2; Workshop
Equipment Manual
2 Adhesive pad, commercially available Teflon adhesive tape ’ Cutting with adhesive pad
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

70 41 19 Removing and installing floor covering
70 41 19 Removing and installing floor covering 1624

einordnung
• Before removing the floor covering −11− , the following components must be removed.
=> Removing and installing front seat

’ 681719 Removing and installing centre console
’ 681719 Removing and installing centre console − front section
’ 691119 Removing and installing front three−point belt

1 Plastic cover 1 Pull off plastic cover of the handle Attach plastic cover.
hole.
2 Plug−in terminal 1
4 Fuse box covering 1
frame
5 Fuse box 1

einordnung
6 Fastening screw 3
7 Foot rest cover 1 Unscrew fastening screws −6− and Install the foot rest cover −7−
remove foot rest cover −7− . after the floor covering is
fitted −11− .
8 Foot rest 1 Install the foot rest −8− before
the floor covering is fitted
−11− .
9 Grommet 1
10 Assembling release ’ 551037 Disassembling and ’ 551037 Disassembling and
for lid assembling release for lid assembling release for lid
’ 680519 Removing and installing ’ 680519 Removing and
inner sill installing inner sill
Insert floor covering −11− in
the cutout for the lid release
−10− or inner sill. See:
Section B − B
11 Floor covering 1 See: Section A − A Opening the See: Section A − A Closing
Velcro fastening −arrow− . the Velcro fastening −arrow−
.
12 Fastening screw 1
13 Holder, floor left 1 Install the holder left floor
−13− before the floor
covering is fitted −11− .
996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

70 57 19 Removing and installing trim of A, B and
C−pillars
Removing and installing trim of A, B and C−pillars
Installing trim of A, B and C−pillars
top of page
Removing and installing trim of A, B and C−pillars
70 57 19 Removing and installing trim of A, B and C−pillars 1627

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1 Unclipping clothes hook bracket Lift up the clothes hook bracket −1− at the bottom with
a plastic spatula and pull up and off.
2 Pressing out seat belt height adjuster Press seat belt height adjuster release −3− out of the
release hexagon−head bolt −4− using a screwdriver.
3 Removing B−pillar trim Undo hexagon−head bolt −4− of the sash guide mount
−5− .
Undo fastening screw −6− . Lift up B−pillar trim −7−
and remove.
4 Unclipping the C−pillar trim Pull C−pillar trim −10− inwards.
5 Unclip the A−pillar trim. Pull the A−pillar trim −11− inwards along the roof
frame and windscreen frame.
top of page
Removing and installing trim of A, B and C−pillars 1628

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Installing trim of A, B and C−pillars

1 Clipping in A−pillar Note:
trim before installation, check that the deformation element is seated properly
−A− .
Check sheetmetal clips −9− and replace if necessary.
Insert the A−pillar trim −11− at the side of the windscreen frame
(transition point to dashboard), clip in the A−pillar trim along the roof
frame.
2 Clipping in C−pillar Check sheetmetal clips −9− and replace if necessary.
trim Position and clip in the C−pillar trim −10− on the C−pillar.
3 Installing sash guide Push sleeve −8− onto the lug of the B−pillar trim −7− and insert in the
mount and B−pillar bottom of the B−pillar.
Installing trim of A, B and C−pillars 1629

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trim Press in the two clips −2− at the top and tighten B−pillar trim with the
Position sash guide mount −6− on the B−pillar and tighten with the
hexagon−head bolt −4− .
Tightening torque: −50 Nm (37 ftlb.)−
4 Pushing on seat belt Insert peg of the seat beat height adjuster release −3− into the
height adjuster release hexagon−head bolt bore −4− .
Note: The seat belt height adjuster release must not be separated. If the
cover of the retaining frame loosens when removing, the seat belt height
adjuster release −3− must always be replaced.1)
5 Fitting the clothes Insert the clothes hook bracket −1− carefully into the aluminium bracket at
hook bracket the top.
Note:
The clothes hook bracket −1− must be inserted into the aluminium bracket
without the use of force, otherwise the aluminium bracket is deformed.
Carefully press the clothes hook bracket into the sheetmetal clips at the
bottom −2− of the B −pillar trim −7− .
1) Inthe model year 2001, the seat belt height adjuster release −3− changed. The cover is now affixed on to the
retaining frame.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing trim of A, B and C−pillars 1630

70 57 19 Removing and installing A−pillar trim
Cabriolet
Removing A−pillar trim
Installing A−pillar trim
Tightening torques
top of page
Removing A−pillar trim
70 57 19 Removing and installing A−pillar trim Cabriolet 1631

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1 Removing convertible−top peg Unscrew fastening screw −1− from the convertible−top peg
housing housing −2− .
2 Unclipping the A−pillar trim Pull the A−pillar trim −3− inwards along the windscreen frame in
the −direction of arrow− .
3 Removing the A−pillar trim Remove the A−pillar trim −3− upwards −in the direction of the
arrow− .
top of page
Installing A−pillar trim
Removing A−pillar trim 1632

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1 Installing A−pillar Before installation, check that the deformation element is seated properly
trim −4− .
Check sheetmetal clips −5− and replace if necessary.
Insert the A−pillar trim −3− at the side of the windscreen frame (transition
point to instrument panel) in the −direction of the arrow− .
2 Clipping in A−pillar Clip in the A−pillar trim −3− along the roof frame in the −direction of
trim arrow− .
3 Installing In order to avoid rattling noises, each of the convertible−top peg housings
convertible−top peg on the left and right −2− must be facing outwards, in relation to the
housing centring pins fitted on the convertible top or hardtop, when tightening.
The convertible top must be closed or the hardtop must be fitted to check
the adjustment.
Tighten the fastening screws −1− .
Installing A−pillar trim 1633

einordnung
top of page
Tightening torques
Tightening torque [Nm]

Fastening screw for convertible−top peg housing to −1− M6 10 (7.5)
cowl panel frame
996630, 996631, 996620, 996621, 996650, 996651

70 75 19 Removing and installing side−panel lining
Removing side−panel lining
Installing side−panel lining
top of page
70 75 19 Removing and installing side−panel lining 1635

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Removing B−pillar => Removing and installing trim of A, B and C−pillars
1 Pulling off cover Pull cover −2− up and off −arrow− .
2 Undoing fastening screw Undo oval−head screw −3− from the side−panel lining.
3 Undoing side−panel lining Unscrew hexagon socket head bolt −5− , remove cover trim −6−
.
Pull out locking tabs of the side−panel lining −1− from the clips
in the rear side panel −arrow− .
Lift locking tabs of the side−panel on the lower side member and
pull out.
4 Disconnecting the electrical plug Press the lug −small arrow− of the electrical plug connection
connections for the loudspeaker −7− and separate.
top of page
Removing side−panel lining 1636

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1 Connecting the Connect the electrical plug connections for the loudspeaker −7− until the lug
electrical plug of the plug connection engages.
connections
2 Side−panel lining Position the side−panel lining −1− on the inside of the rear side section and
the inside of the lower side member and press the locking tabs into the clips.
Push on the cover −6− and tighten using the hexagon socket head bolt −5− .
3 Tightening fastening Position the oval−head screw −3− in the side−panel lining and tighten.
screw
4 Fitting cover Position the locking tabs of the cover −2− on the side−panel lining −arrow−
and press in.
Installing side−panel lining 1637

einordnung
5 Fitting seal Lift up the pillar seal along the side−panel lining using a plastic spatula
−arrow− .
Installing B−pillar => Installing trim of A, B and C−pillars
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

70 75 19 Removing and installing side−panel lining
Cabriolet
top of page
70 75 19 Removing and installing side−panel lining Cabriolet 1639

einordnung

Opening
convertible top
1 Folding over Unlock emergency seat backrest and fold over.
emergency seat
backrest
2 Removing holding Unscrew holding pegs −2− with Allen key St6. Remove cover −3− .
pegs and cover
3 Pulling off cover Pull cover −4− out of the clips to the front −5− . Unscrew fastening screw −6−
from the side−panel lining −1− . Press out collar −7− with a plastic spatula.
4 Removing Loosen the fastening screws −9− from the loudspeakers. Unscrew the
side−panel lining fastening screw −12− underneath from the sheetmetal bracket of the side
panels −1− . Press and disconnect the locking tab −11− of the electrical plug
connection for the loudspeaker.
Pull the side−panel lining −1− inwards until the clip −8− disengages.
Removing side−panel lining 1640

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Subsequently lift the trim at the bottom and remove towards the front.
top of page

1 Mounting the Insert pegs of the side−panel lining −1− on the inside of the rear side section and
side−panel lining on the frame of the roll−over protection. Press clip −8− into the inside rear side
section. Clip must engage audibly.
Position fastening screw −12− into the sheetmetal bracket in the cut−out for the
loudspeaker, and tighten. Plug in electrical plug connection −11− of
loudspeakers. Position the loudspeaker in the side−panel −1− and fasten with the
2 Fitting holding Position the cover trim −3− and the holding peg −2− in the cut−out of the
pegs and cover side−panel lining and screw in

einordnung
tightening torque 20 Nm (15.0 ftlb.)

3 Fitting cover Press in collar −7− , collar must engage audibly.
Check the clips −5− or replace. Fasten the side−panel lining with the fastening
screw −6− . Press the locking tabs of the cover −4− into the clips −5− .
4 Fitting seal Lift up the pillar seal along the side−panel lining using a plastic spatula
−arrow− .
Closing
convertible top
996630, 996631, 996620, 996621, 996650, 996651

70 84 19 Removing and installing Cabriolet roof lining
Removing roof lining, front
Installing front roof lining
Removing rear roof lining
Installing rear roof lining
Removing and installing side roof lining
Tightening torques
A = Front roof lining
B = Rear roof lining
C = Side roof lining
top of page
70 84 19 Removing and installing Cabriolet roof lining 1643

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Removing roof lining, front
CAUTION
Avoid damage to or destruction of the tension bow seal.
The following procedure Convertible top in service position must be observed!
• Move convertible top to the rear by means of the electric motor until the convertible−top
compartment lid has reached the rear end position. Move convertible top forward by means of the
electric motor until the convertible−top compartment lid moves forward, then interrupt closing
operation. Disengage left and right tension cables and fold up the tension bow. The convertible top
must no longer be electrically operated in this position.
Removing roof lining, front 1644

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Convertible top in Move convertible top to the rear by means of the electric motor until the
service position convertible−top compartment lid has reached the rear end position. Move
convertible top forward by means of the electric motor until the
convertible−top compartment lid moves forward, then interrupt closing
operation. Disengage left and right tension cables and fold up the tension
bow. The convertible top must no longer be electrically operated in this
position.
1 Removing Unscrew fastening screws −1− and remove convertible−top lock −2− .
convertible−top lock Disconnect electrical plug connection −3− .
2 Unscrewing fastening Unscrew the fastening screws −4− at the left and right.
screws
3 Pulling off front Pull off sewn−on clamping rail −5− of the roof lining on front roof frame 1
clamping rail on the left and right.
4 Pulling off the Pull off sewn−on clamping rail −6− of the roof lining on rear roof frame 1
clamping rail at the on the left and right.
rear
5 Removing roof lining Unscrew the expanding nuts −7− from the covering strip −8− and the rear
connection on front roof frame 1.
roof frame 1

einordnung

6 Removing clamping rail Unscrew fastening screws −9− on the left and right.
connection from the main bow Pull off connection of clamping rail −10− from the main bow in
−direction of arrow− .
Opening the Velcro fastening of Open the velcro fastenig on the side roof lining on the left and
the side roof lining right. See: => Removing and installing side roof lining
7 Opening the Velcro fastening Open the velcro fastening −13− of the roof lining on the corner
bow.
8 Removing bracing straps Unscrew fastening screw −14− from the bracing straps −X, Y− .
9 Removing roof lining connection Press the connection strip −15− of the roof lining out of the rear
at the corner bow groove of the corner bow using a plastic spatula.
Pull roof lining connection −16− out of the front groove of the
corner bow in −direction of arrow− .
top of page

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Installing front roof lining

1 Installing roof lining connection Insert and centre the roof lining connection −16− into the front
at the corner bow groove of the corner bow in −direction of arrow− .
Insert the connection strip −15− into the rear groove.
2 Pulling in bracing strap Pull bracing strap −X− into the plastic connection of the roof
lining −V− .
3 Fitting velcro fastening Press the velcro fastening −13− of the roof lining onto the corner
bow.
4 Installing bracing straps Position bracing strap −Y− underneath the bracing strap −X− .
Observe sequence as shown in the illustration.
Tighten the fastening screw −14− on main bow with the bracing
Installing front roof lining 1647

einordnung
straps.
Closing the Velcro fastening of Close the velcro fastening on the side roof lining on the left and
the side roof lining right. See: => Removing and installing side roof lining
5 Installing clamping rail Unscrew clamping rail connection −10− on the main bow in
connection from the main bow −direction of arrow−
Tighten the connection on the left and right with the fastening
screws −9− .

6 Installing roof lining Position cover strip −8− on roof frame 2. Press in expanding nuts −7−
connection on front roof .
frame 2
7 Pushing on the clamping Push sewn−on clamping rail −6− of the roof lining onto the left and
rail at the rear right of rear roof frame 1.
8
Installing front roof lining 1648

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Pushing on front clamping Push front sewn−on clamping rail −5− onto the front of roof frame 1
rail on the left and right.
9 Tightening front clamping Tighten the connection on the left and right with the fastening screws
rail −4− .
10 Installing convertible−top Plug in electrical plug connection −3− . Position convertible−top lock
lock −2− on roof frame 1. Coat the fastening screws −1− with
high−strength screw locking lacquer (Loctite 270) and tighten.
Ending service position
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Removing rear roof lining
Removing rear roof lining 1649

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Opening the side Velcro Open the velcro fastenig on the side roof lining on the left and right.
fastening See: => Removing side roof lining
1 Opening zip fastener. Disconnect the rear roof lining from the convertible−top cover by
opening the zip fastener −17− .
2 Disconnecting pushbutton Disconnect pushbutton −18−
3 Unscrewing the connection Unscrew fastening screw −19− from the bracing strap −Z− on the
left and right and from the rear roof lining −21− .
4 Removing tension hook of Bend brace −20− and remove from tension bow at the front in
side metal struts −direction of arrow− .
Remove brace from the textile case of the roof lining −21− .
5 Opening the Velcro fastening Open the velcro fastening −22− of the tension bow.
6 Undoing connection on Press connection −23− out of the groove on the tension bow.
tension bow
7 Pulling out connection on the Pull connection −24− carefully out of the groove on the rear
rear window window.
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Installing rear roof lining
Installing rear roof lining 1650

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1 Fitting roof lining Lift the metal clips using a plastic spatula −A− and insert a small
connection for the rear screwdriver under the metal clip −B− . Insert the connection seal
window −24− of the roof lining underneath the metal clips −C− . Ensure
that the clearance cuts of the roof lining −D− are positioned on the
electrical connection of the rear window.
Subsequently knock open the metal clips with a plastic hammer.
Make sure that the metal clips engage in the frame cutouts
2 Installing roof liner Press the roof lining connection −23− into the groove of the tension
connection to tension bow.
bow
3 Installing brace of side Insert brace −20− into the textile case of the roof lining. Insert brace
metal struts first at rear then bend and insert at front.
4 Tightening fastening Position the bracing strap −Z− underneath the roof lining −21− and
screws scew on to the main bow with the fastening screw −19− .
Installing rear roof lining 1651

einordnung
Observe sequence as shown in illlustration.

5 Closing the Velcro Close the velcro fastening −22− of the tension bow.
fastening.
6 Closing the pushbutton Close pushbutton −18−
7 Closing zip fastener Connect the rear roof lining to the main bow connection above the
corner bow using the zip fastener −17− .
Closing the Velcro Close the velcro fastening on the side roof lining on the left and
fastening of the side roof right. See: => Installing side roof lining
lining
top of page
Removing and installing side roof lining
Removing side roof lining
1. Opening the Velcro fastening

Disconnect the velcro fastening connection −11a− between the roof lining −11− at the side and the
corner bow −11b− in −direction of arrow− .
2. Removing roof lining at sides of roof frame 3

a. Drill out the fastening rivets −12a− . Remove the roof lining at the side −11− and the plastic insert
−12b− .
Removing and installing side roof lining 1652

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Installing side roof lining
1. Installing roof lining at sides of roof frame 3

a. Position the roof lining at the side −11− and the plastic insert −12b− on the main bow.
b. Rivet on to the holes provided on the main bow using the fastening rivets −12a− (included in scope of
replacement parts)
2. Closing the Velcro fastening.

Close the velcro fastening connection −11a− between the roof lining −11− at the side and the corner
bow −11b− in −direction of arrow− .
top of page
Tightening torques
Tightening
torque [Nm]
Fastening screws of convertible−top lock on roof frame 1 Item number −1− M6 8 (6) Nm
(ftlb.)
996630, 996631, 996620, 996621, 996650, 996651
Installing side roof lining 1653

72 01 19 Removing and installing front seat
Removing front seat
Installing front seat
top of page
Removing front seat
72 01 19 Removing and installing front seat 1654

einordnung

1 Remove seat rail cover Unscrew the sheetmetal screws out of the seat rail cover at the front
−2− . Pull seat rail cover on front end −2− out of the right and left seat
rails in forward direction
2 Undoing seat screws at Move seat to its rear limit position and undo the front M10 x 28 Torx
front screws −3− from the right and left seat rails using an E12 socket
wrench insert
3 Undoing seat screws at Move seat to its front limit position and undo the M10 x 28 Torx screws
rear −3− from the right and left seat rails using an E12 socket wrench insert
4 Disconnecting the Release plug connector locking device on the side −arrow− and
electrical plug connection separate the plug connection −4− .
top of page
Removing front seat 1655

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Installing front seat

1 Connecting electrical Join the plug connection −4− , press in plug connector locking device
plug connection on the side −arrow− .
2 Fitting seat screws at Position seat rails on the seat baseframe, screw the rear M10 x
rear 28 Torx screws −3− into the seat baseframe on the left and right
using the E12 socket wrench insert and tighten with tightening
torque: −65 Nm− (48 ftlb.).
3 Fitting seat screws at Move seat to its rear limit position, screw the front M10 x 28 Torx
front screws −3− into the seat baseframe on the left and right using the
E12 socket wrench insert and tighten with tightening torque: −65
Nm− (48 ftlb.).
Installing front seat 1656

einordnung
4 Fit seat rail cover Push seat rail cover −2− into front end of the left and right seat rails.
Tighten the seat rail cover with the sheetmetal screws.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing front seat 1657

72 21 19 Removing and installing cushion carrier
Removing front cushion carrier
Installing front cushion carrier
top of page
Removing front cushion carrier
72 21 19 Removing and installing cushion carrier 1658

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1 Removing control module Lift both holders of the cover −1− in −direction of arrow A− and
and cover remove to the front.
Unscrew the fastening screws −2− , position control module so
that the plastic clips −9− are exposed.
2 Removing switch for seat Unscrew fastening screw −4− from the switch for the seat
adjustment adjustment −5− . Pull the switch upwards and pull to the front
−arrow− . Subsequently remove through the opening of the
cushion carrier −direction of arrow− .
3 Disconnecting wiring Disconnect electrical plug connection of the seat heating, unclip
harness the lines from the metal clips −6− along the seat rail.
3a Removing wiring harness Remove wiring harness −7− from the cushion carrier; to do so,
press the locking tabs −arrow− and pull out of the cushion
carrier.
4
Removing front cushion carrier 1659

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Removing seat cushion Insert the retainer −8− of the plastic clip −9− at the sides using a
from seat frame. screwdriver and press out. Unclip the plastic clip −9− from the
seat frame. Remove cushion carrier from the seat frame.
top of page
Installing front cushion carrier

1 Installing wiring Plug in electrical plug connection of the seat heating −7− or insert the wiring
harness harness into the cushion carrier in the plastic clip in −direction of arrow− .
Clip in the line into the metal clips along the seat rails −6− .
2 Installing seat Position the seat cushion on to the seat frame and clip the plastic clip −9−
cushions on to seat into the seat frame. Push the retainer into the plastic clip −8− .
Installing front cushion carrier 1660

einordnung
frame
3 Installing switch for Pull switch for seat adjustment −5− out of the inner cushion carrier opening
seat adjustment and position. Secure the switch with the fastening screws −4− .
4 Installing control Position control module −3− and tighten with the fastening screws −2− .
module and cover Push on cover −1− in −direction of arrow A− .
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing front cushion carrier 1661

72 36 19 Removing and installing motor for the
lumbar support
Removing lumbar adjustment device for the lumbar support
Removing motor for the lumbar support
Removing electrical line for the lumbar
Removing lumbar support
Installling lumbar adjustment device for the lumbar support
Installing motor for the lumbar support
Installing electrical line for the lumbar
Installing lumbar support
Tools
Test plan for the lumbar adjustment device
72 36 19 Removing and installing motor for the lumbar support 1662

einordnung
top of page
Removing lumbar adjustment device for the lumbar support

Removing front seat => Removing front seat
Removing covering for front
backrest
1 Lumbar adjustment device Pull electrical plug connection −E− and −F− apart. Pull white air
without control module hose −A− off the lumbar with pressure switch −D− , air hose −B−
memory (red) and −C− (blue).
2 Lumbar adjustment device Unscrew fastening screw −arrow− and remove lumbar adjustment
−1− with control module device −1− .
memory
Removing lumbar adjustment device for the lumbar support 1663

einordnung
top of page
Removing motor for the lumbar support

3 Electrical plug connection −2− Pull off plug −2− on motor −3− for the lumbar support.
4 Motor −3− for the lumbar support Pull off air hose (white) and pull up and out from styrofoam.
top of page
Removing electrical line for the lumbar

5a Electrical plug connection −5− for Pull off plug −5− −arrow− on control module seat
lumbar memory −4− . Cut tie wrap on electric motor for the
seat height adjustment using a pair of side cutters.
5b Electrical plug connection −6− for Pull plug connection −6− apart below the seat.
lumbar without control module for seat
memory
6 Electrical line −7− Observe lead route −arrow− and remove line.
7 Electrical line Line runs parallel to the white air hose −A− .
Lumbar adjustment device. Disconnect tie wrap,
remove line. => Removing motor for the lumbar
support
top of page
Removing lumbar support

1 Air hose −B, Pull off red −B− and blue −C− air hose on the lumbar adjustment device.
C−
7 Lumbar support Pull off felt −arrow− and pull lumbar support −G− up and and out of the
backrest frame.
Removing motor for the lumbar support 1664

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top of page
Installling lumbar adjustment device for the lumbar support

1 Lumbar adjustment device −1− with Position lumbar adjustment device and secure on backrest
control module memory frame with the fastening screw −arrow− .
2 Lumbar adjustment device without Connect air hose −A− (white), −B− (red), −C− (blue),
control module memory electrical plug connection −E, F− on valve box.
Plug in pressure switch −D− .
top of page
Removing lumbar support 1665

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Installing motor for the lumbar support

3 Motor for the lumbar support −3− Plug in white air hose −A− on motor −3− and insert into
styrofoam.
4 Electrical plug connection −2− Join plug −2− with electrical lead of motor.
top of page
Installing electrical line for the lumbar

5a Electrical plug connection −5− with Fasten line to motor with tie wrap for the rear seat
control module for seat memory adjustment and insert plug −5− on the control module
−4− for the seat memory −arrow− .
5b Electrical plug connection −6− without Join plug connection −6− below the seat.
control module for seat memory
6 Electrical line −7− Lay line behind motor for along the lumbar support.
Observe routing under the lumbar support (airbag)
and along the seat frame −arrow− .
7 Electrical line Route the electrical line on the backrest frame parallel
to the air hose −A− and fix with tie wrap.
top of page
Installing lumbar support

7 Lumbar support Insert lumbar support −G− into the backrest frame from above and fix with felt
−G− strips −arrow− . Route red −B− and blue −C− air hose and fix loosely with tie
wraps.
1 Air hose −B, C− Connect air hose −B, C− on the valve box.
Install covering
for backrest.
Installing front => Removing front seat
seat
top of page
Installing motor for the lumbar support 1666

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Tools
Item Designation Special tool Explanation:

1 Multimeter Gr. 2.5; Workshop Equipment Manual
top of page
Test plan for the lumbar adjustment device
In the case of the complaint "lumbar support does not function", proceed according to the following work
instruction. As the seat functions vary, the test plan principally complies with the seat version with seat
memory adjustment. Work aids: Use wiring diagram and multimeter. => Tools
Incorrect
Work instruction Correct result result
1 Actuate switch positions on seat for lumbar support. ’ Step 2 ’ Step 4
Compressor for the lumbar is audible.
2 Actuate switch positions on seat for lumbar support. Valve ’ Step 3 ’ Step 4
block switches.
3 Take cover off backrest, check connections for air hose, Check pressure switch and hose
lumbar support and valve block. routing and replace if necessary.
’ End
4 Check fuse in the fuse box for the lumbar. ’ Step 5 Replace fuse
and perform
function test.
’ End
5 Measure the battery voltage on plug X 16/ X 17 without > 11V ’ Step 6 Check plug
memory or terminals 30 and 31 on the memory SG (see connection
wiring diagram) using a multimeter. and wiring.
’ End
6 When actuating the switch for the lumbar, clicking noises are Switch reacts. ’ Step ’ Step 8
audible from the control module for the seat memory. 7
7 Remove cover from backrest, check battery voltage of > 11V ’ Replace Check wiring
compressor plug connection using multimeter. compressor. and plug
’ End connection.
’ End
8 Control module for the seat memory. Replace
’ End
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Tools 1667
72 86 19 Removing and installing switch for seat
adjustment
Removing switch for seat adjustment
Installing switch for seat adjustment
72 86 19 Removing and installing switch for seat adjustment 1668

einordnung
top of page
Removing switch for seat adjustment

Removing front seat. => Removing front seat
1 Removing switch −2− from Unscrew fastening screws −1− .
seat. Pull switch −2− upward and remove to the front −arrow− .
2 Control module −4− in Undo fastening screws −3− . Detach control module −4− and fold it
connection with seat to the front. Pull out plugs −arrow− of control module together.
memory Unclip plugs, beginning on the right, natural, blue, black.
3 Plug connection −6, 7, 8− Pull plugs below seat −6− , seat height adjuster, −7− lumbar, −8−
without seat memory backrest apart and disconnect tie wrap for the line.
control module
Removing switch for seat adjustment 1669

einordnung
4 Lead route between seat −A− Seat cushion

cushion and seat frame. −B− Switch
−C− line
Pull out the plugs one after the other through this opening.
top of page
Installing switch for seat adjustment

1 Line −C− of seat adjustment Push the plugs of line −C− one after the other through the
switch −B− opening below the seat cushion −A− .
2 Line route −9− In connection with the seat memory control module, lay the line
−9− above the electric motors and along the seat memory control
Installing switch for seat adjustment 1670

einordnung
module −4− .
3 Plug connection −6, 7, 8− Plug connection without control module for seat memory. Join
plugs for −6− seat height adjustment, −7− lumbar, −8− backrest
and fix line with tie wrap.
4 Plug connection −arrow− on Clip plugs on to eachother starting on the right, natural, blue,
seat memory control module black and plug on to the control module −arrow− .
−4− . Insert control device −4− into the mount and screw in the
5 Installing switch −2− . Insert the switch −in direction of arrow− against the seat and
downward. Installing fastening screws −1− .
Installing front seat. => Removing front seat
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing switch for seat adjustment 1671

72 87 19 Removing and installing electric motor for
the seat adjustment
Removing electric motor for seat adjustment
Installing electric motor for seat adjustment
Tools
Test plan for the seat adjustment
A = Electric motor for seat adjustment.
top of page
Removing electric motor for seat adjustment
72 87 19 Removing and installing electric motor for the seat adjustment 1672
einordnung

1 Lock nut −1− Unscrew.
2 Fastening screws −2− Unscrew.
3 Electric motor −3− Unscrew.
4 Input shaft −4− Remove and check for damage.
5a Control module −6− in Unscrew fastening screws −5− and fold control module −6− to
connection with seat memory front −arrow− .
5b Plug connection −7− without Press plugs together in −direction of arrow− and pull apart.
seat memory control module. Press out the crimp sockets from plug using the unlocking tool.
=> Tools
6 Electric wire Cut the tie wrap using side cutters, follow cable routing and pull
off the plug −8− on the control module.
Removing electric motor for seat adjustment 1673

einordnung
top of page
Installing electric motor for seat adjustment

1 Input shaft −4− Insert the input shaft −4− into the gear mount by twisting
slightly.
2 Electric motor −3− Push motor −3− onto the shaft and ensure that the square fits
into the mount on the motor by twisting slightly.
3 Fastening screws −2− Position electric motor −3− with both fastening screws −2− and
tighten screws.
4 Lock nut
Installing electric motor for seat adjustment 1674

einordnung
Tighten.
5 Plug −8− in connection with seat Observe line routing and push in plug −8− on control module.
memory control module Fix line routing with a tie wrap.
6a Control module −6− Engage control module −6− and screw into place with the
6b Plug connection −7− without Push crimp sockets into the plug −7− until the sockets engage.
seat memory control module. Attach plug −7− , observe line routing and fasten with tie wrap.
Installing front seat => Removing front seat
top of page
Tools

1 Press−out tool for the crimp sockets No. 155 Gr. 2.4; Workshop Equipment Manual
top of page
Test plan for the seat adjustment
In the case of complaint "seat adjustment does not function", proceed according to test plan. As the seat
functions vary, the test plan principally complies with the seat version with seat memory adjustment. Work
aids: Use wiring diagram and multimeter. => Tools
Incorrect
1 Actuate switch on seat for seat adjustment, observe end Switch in control module ’ Step 2
position. is audible. ’ Step 3
2 Check fuse in the fuse box for the seat adjustment. ’ Step 3 Replace fuse
and perform
function test.
’ End
memory or terminals 30 and 31 on the memory SG (see If a function is not audible connection
wiring diagram) using a multimeter. under step 1, replace the and wiring.
control module memory. ’ End
4 Measure the voltage on the inserted plug for the seat > 4 V, when switching Replace
adjustment (on control module memory or below the seat from front − back, the switch.
− without memory) using a multimeter. Actuate the seat voltage switches from + to ’ End
adjuster switch with probe tip + on RE and with probe tip − ’ Step 5
− on BK.
5 Remove motor and check input shaft.
Tools 1675
einordnung
Remove faulty part.

’ End
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Test plan for the seat adjustment 1676

the front seat height adjustment
Removing electric motor for front seat height adjustment
Installing electric motor for front seat height adjustment
Tools
Test plan for the front seat height adjustment
A = Electric motor for the seat height adjustment.
top of page
Removing electric motor for front seat height adjustment
72 88 19 Removing and installing electric motor for the front seat height adjustment 1677
einordnung

2 Electric motor −2− Remove.
3 Input shaft −3− Remove and check for damage.
4a Control module −4− in Undo screws −5− . Detach control module −4− and fold it to the
connection with seat memory front. Pull out plugs of control module −arrow− .
4b Plug connection −6− without seat Press plugs −6− together and pull apart −arrow− . Press out the
memory control module. crimp sockets from plug using the unlocking tool => Tools
5 Electric line Cut tie wrap on motor with side cutters and remove unit.
top of page
Removing electric motor for front seat height adjustment 1678

einordnung
Installing electric motor for front seat height adjustment

1 Input shaft −3− Insert the input shaft −3− into the gear mount by twisting slightly.
2 Electric motor Push electric motor −2− onto the input shaft −3− and ensure that the square fits
−2− into the mount on the motor by twisting slightly.
3 Fastening Position electric motor −2− with both fastening screws −1− and tighten screws.
screws −1− Tightening torque: 7 Nm (5.0 ftlb.)
4 Electric line Observe line routing.
5a Control module Insert plug on control module −4− −arrow− . Secure routed line with tie wrap.
−4− Insert control module in the frame and screw in the fastening screws −5− .
5b
Installing electric motor for front seat height adjustment 1679

einordnung
Plug connection Push crimp sockets into the plug −6− until the sockets engage. Observe line
−6− routing and secure with tie wrap.
Installing front => Removing front seat
seat
top of page
Tools

top of page
Test plan for the front seat height adjustment
In the case of the complaint "seat height adjustment does not function", proceed according to test plan. As the
seat functions vary, the test plan complies with the seat version with seat memory adjustment. Work aids: Use
wiring diagram and multimeter => Tools
Incorrect
1 Actuate switch on seat for seat height adjustment, observe Switch in control module ’ Step 2
end position. is audible ’ Step 3
2 Check fuse in the fuse box for the seat height adjustment. ’ Step 3 Replace fuse
and perform
function test
’ End
3 Measure the battery voltage on plug X 16/X 17 without > 11V ’ Step 4 Check plug
memory or terminals 30 and 31 on the memory SG (see If a function is not connection
wiring diagram) using a multimeter. audible under step 1, and wiring
replace the control ’ End
module memory.
4 Measure the voltage on the inserted plug for the seat height > 4 V, when switching Replace
adjustment (on control module memory or below the seat − from front − back, the switch
without memory) using a multimeter. Actuate the seat voltage switches from + ’ End
height adjuster switch with probe tip + on RE and with to − ’ Step 5
probe tip − on BK.
5 Remove motor and check input shaft. Remove faulty part
’ End
Tools 1680
einordnung
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Test plan for the front seat height adjustment 1681

the backrest adjustment
Removing and installing electric motor for the backrest adjustment
Installing electric motor for backrest adjustment
Routing of wiring harness for the backrest adjustment
Tools
Test plan for the backrest adjustment device
top of page
72 89 19 Removing and installing electric motor for the backrest adjustment 1682
einordnung
Removing and installing electric motor for the backrest

adjustment

Removing covering for front
backrest
1 Clamping washer −1− Lever the clamping washer −1− off the input shaft −2− using a
screwdriver. Cover bearing surface for the screwdriver with a
strip of wood or plastic with a square cross section.
2 Undoing fastening screws Unscrew fastening screw −3− on backrest motor −4− .
−3− for backrest motor
3 Input shaft −2−
Removing and installing electric motor for the backrest adjustment 1683
einordnung
Push input shaft −2− on the left side through using a

screwdriver.
4 Input shaft −2− Pull out input shaft −2− on the right side until the backrest
motor can be removed.
5 Backrest motor −4− Remove backrest motor downward −direction of arrow− .
6 Electrical plug connection Push both locking tabs of the plug connection outwards using a
−5− screwdriver and pull the plug −5− downward.
top of page
Installing electric motor for backrest adjustment
Installing electric motor for backrest adjustment 1684

einordnung
1 Electrical plug Push plug −5− on to electric motor until it engages.

connection −5−
2 Backrest motor −4− Insert backrest motor −4− from below −direction of arrow− .
3 Input shaft −2− Insert input shaft from the right side as far as it will go −arrow− .
4 Fastening backrest Screw in fastening screw −3− . Ensure that the bushings −arrow− are seated
motor −4− correctly. Counter electric motor with your hand and tighten fastening screw
−3− .
5 Installing clamping Counter input shaft −2− on the right side and push clamping washer on to the
washer left side of the input shaft −2− using a 12 mm socket for example.
Installing covering
for backrest
top of page
Routing of wiring harness for the backrest adjustment
1. −A− Plug on the control module for the memory seat adjustment.
2. −B− Plug on the backrest adjustment
motor.
3. −X− Plug connection − without control module for the memory seat adjustment.
top of page
Tools

top of page
Routing of wiring harness for the backrest adjustment 1685

einordnung
Test plan for the backrest adjustment device

In the case of the complaint "backrest adjustment does not function", proceed according to test plan. As the
seat functions vary, the test plan principally complies with the seat version with seat memory adjustment.
Work aids: Use wiring diagram and multimeter. => Tools
Work instruction Correct result Incorrect result

1 Actuate switch positions on seat for backrest Switch in the control ’ Step 2
adjustment. module and electric
motor function are
audible. ’ Step 3
2 Check fuse in the fuse box for the backrest ’ Step 4 Replace fuse and
adjustment. perform function test.
’ End
3 Take cover partly of the backrest and check drive for Repair
backrest adjustment. ’ End
4 Measure the battery voltage on plug X 16/ X 17 > 11V, when switching If the battery voltage
without memory or terminals 30 and 31 on the from front − back, the is only displayed
memory SG (see wiring diagram) using a multimeter. voltage changes from briefly on the
+ to −. ’ Step 4 multimeter ’ Step 6.
If a function is not Replace at 0 V switch.
audible under step 1, ’ End
replace the control
module memory.
5 Measure the voltage on the inserted plug for the > 4 V, when switching Replace switch.
backrest adjustment (on control module memory or from front − back, the ’ End
below the seat − without memory) using a voltage changes from
multimeter. Actuate the backrest adjuster switch with + to −. ’ Step 6
probe tip + on GY/BK and with probe tip − on
GY/GN.
6 Partly remove backrest cover, check wiring harness > 11V Replace motor for the
and battery voltage on the electric motor. On inserted backrest adjustment
plug, probe tip + on BU − on BK. => Removing the ’ End
backrest centre strip
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Test plan for the backrest adjustment device 1686

the rear seat height adjustment
Removing electric motor for rear seat height adjustment
Installing electric motor for rear seat height adjustment
Tools
Test plan for the rear seat height adjustment
A = Electric motor for the seat height adjustment.
top of page
Removing electric motor for rear seat height adjustment
72 92 19 Removing and installing electric motor for the rear seat height adjustment 1687
einordnung

2 Electric motor −2− Remove in −direction of arrow− .
3 Input shaft −3− Pull out shaft −3− and check for damage.
4a Control module −5− in Unscrew both fastening screws −4− and fold control module
connection with seat memory −5− to the front. Pull plug −arrow 7− off the control module
4b Plug connection −6− without seat Press plugs −6− together in the −direction of arrow− and pull
memory control module. plug connection apart.
Press the crimp sockets out of the plug using the unlocking tool.
=> Tools
5 Electric wire Cut the tie wrap with side cutters, follow the cable routing and
remove completely.
Removing electric motor for rear seat height adjustment 1688

einordnung
top of page
Installing electric motor for rear seat height adjustment

1 Input shaft −3− Insert the input shaft −3− into the gear mount −arrow− by
twisting slightly.
2 Electric motor −2− Push motor −2− onto the shaft and ensure that the square fits
into the mount on the motor by twisting slightly.
3 Fastening screws −1− Position electric motor −2− with both fastening screws −1−
and tighten screws.
4 Line and plug connection −7− Observe line routing.
Installing electric motor for rear seat height adjustment 1689

einordnung
5a Seat memory control module −5− Insert plug −arrow 7− on control module −5− . Fix line route
with a tie wrap.
Engage control module and tighten with both fastening screws
−4− .
5b Plug connection −6− without seat Push crimp sockets into the plug −6− until the sockets engage.
memory control module. Observe line route and secure with tie wrap. => Tools
top of page
Tools

top of page
Test plan for the rear seat height adjustment
In the case of the complaint "seat height adjustment does not function", proceed according to test plan. As the
seat functions vary, the test plan principally complies with the seat version with seat memory adjustment.
Work aids: Use wiring diagram and multimeter. => Tools
Incorrect
1 Actuate switch on seat for seat height adjustment, observe Switch in control module ’ Step 2
end position. is audible. ’ Step 3
2 Check fuse in the fuse box for the seat height adjustment. ’ Step 3 Replace fuse
and perform
function test.
’ End
memory or terminals 30 and 31 on the memory SG (see If a function is not connection
wiring diagram) using a multimeter. audible under step 1, and wiring.
replace the control ’ End
module memory.
4 Measure the voltage on the inserted plug for the seat height > 4 V, when switching Replace
adjustment (on control module memory or below the seat − from front − back, the switch.
without memory) using a multimeter. Actuate the seat voltage changes from + to ’ End
height adjuster switch with probe tip + on RE and with −. ’ Step 5
probe tip − on BK.
5 Remove motor and check input shaft. Remove faulty part.
’ End
Tools 1690
einordnung
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Test plan for the rear seat height adjustment 1691

74 13 55 Replacing cover for front seat cushion
Removing cover for the front seat
Installing cover for the seat cushion.
Tools and materials
top of page
Removing cover for the front seat
74 13 55 Replacing cover for front seat cushion 1692

einordnung

Removing front => Removing front cushion carrier
cushion carrier
1 Removing seat cover Detach rear retaining rail −1− from the cushion carrier. Undo right and left
of cushion carrier side cushion clips −2− . Pull off the push−on bead −3− surrounding the seat
cover of the cushion carrier.
2 Destroying plastic Destroy plastic clips −4− with a screwdriver. Remove the seat cushion with
clips the cushion carrier foam part.
3 Cover for the seat Cut open the metal clips with side cutters −5− . Separate the cover for the
cushion. seat cushion from the foam part.
top of page
Removing cover for the front seat 1693

einordnung
Installing cover for the seat cushion.

1 Mounting the seat cover Position seat cover covering strips −C− with an integrated metal
on to the foam part (seat strut −A− on the centre, left and right seat centre strip and on the
cushion) provided cut−outs on the foam part −D− . Using the cushion clip
pliers and the cushion clips −E− , connect the integrated metal strut
of the foam part −B− to the metal strut for the seat cover −A−
covering strips.
2 Mounting the seat cover Note:
on to the cushion carrier The plastic clips −4− should always be replaced.
Insert plastic clips −4− onto the left and right covering strips −E−
and position on the provided cut−outs on the foam part and clip onto
Installing cover for the seat cushion. 1694

einordnung
the cushion carrier.

3 Fitting seat cover onto Fit the seat cover over the foam part so that it is free from wrinkles.
the cushion carrier Push the push−on bead −3− surrounding the seat cover onto the
cushion carrier.
Engage the rear retaining rail −1− in the cushion carrier.
Clip the seat cover at the right and left onto the cushion carrier −2− .
Installing cushion => Installing front cushion carrier
carrier
CAUTION
• Danger of material damage if excessive heat is applied!
• If creases form, only short partial warming with the hot−air gun is permissible. Always observe the
hot−air temperature of approx. 50 degrees Celsius (122 Fahrenheit).

Remedying creases in the backrest If creases form in the areas of the backrest cover, heat
cover them partially with the hot−air gun.
top of page
Tools and materials

1 Cushion clip pliers and cushion Gr. 2.4; Workshop Equipment Manual
clips Nr. 130
2 Cushion clips Spare part Gr 8; Parts Catalogue
3 Pneumatic staple gun Nr. 163 Gr. 2.4; Workshop Equipment Manual
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

74 19 19 Removing and installing centre backrest
strip
Removing the backrest centre strip
Installing the backrest centre strip
top of page
Removing the backrest centre strip
74 19 19 Removing and installing centre backrest strip 1696

einordnung

1 Detaching covering strip from the Press locking tabs of the backrest seat heating −A−
backrest shell and disconnect electrical and disconnect downward −B− . Unclip the
plug connection. electrical line −2− from the metal clips −3− along
the seat frame.
Pull backrest centre strip −1− downwards and out
of the backrest shell−4− .
2 Unclipping the backrest centre strip Insert your hand into the top of the backrest
covering and lift outward −arrow− .
Information: Do not lift the backrest covering too
firmly outwards as otherwise the plastic clips can
be destroyed.
Press the bead −6− out of the plastic clips −5−
using a screwdriver.
Removing the backrest centre strip 1697

einordnung
top of page
Installing the backrest centre strip

1 Clipping in the backrest centre Press the bead −6− into the plastic clips −5− .
strip at the top
2 Attaching the backrest centre strip Attach backrest centre strip −1− to the bottom of the backrest
at the bottom, inserting electrical shell −4− . Plug in backrest seat heating. Clip electrical line
plug connection −2− into the metal clips −3− along the seat frame.
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Installing the backrest centre strip 1698

74 19 55 Replacing covering for backrest centre strip
Removing covering for backrest centre strip
Installing covering for backrest centre strip
Tools and materials
top of page
Removing covering for backrest centre strip
74 19 55 Replacing covering for backrest centre strip 1699

einordnung

Removing backrest => Removing the backrest centre strip
centre strip
1 Pulling off fabric tape Pull of the felt strips −2− from the plastic frame −4− . Detach the
strips covering for the backrest centre strip −1− from all sides of the plastic
frame −4− .
2 Cutting through the Cut through the cushion clips −3− using side cutters. Detach the
cushion clips bead for the backrest centre strip −5− and the plastic frame −4− from
the centre strip foam part −6− .
top of page
Removing covering for backrest centre strip 1700

einordnung
Installing covering for backrest centre strip

1 Placing the cushion Position backrest centre strip −6− and plastic frame −4− onto the
clips centre strip foam part. Connect the covering strips −5− to the plastic
frame −4− using the cushion clip pliers −A− and the cushion clips −3−
.
2 Engaging the backrest Attach the covering for the backrest centre strip −1− to all sides of the
centre strip plastic frame −4− . At the connecting webs of the plastic frame −4− ,
affix a felt strip −2− , approx. 25mm wide, across the entire width of
the plastic frame.
Installing the backrest => Installing the backrest centre strip
Installing covering for backrest centre strip 1701

einordnung
centre strip
top of page
Tools and materials

1 Cushion clip pliers and cushion Gr. 2.4; Workshop Equipment Manual
clips Nr. 130
2 Cushion clips Spare part Gr 8; Parts Catalogue
3 Felt strips Spare part Gr 8; Parts Catalogue (Seat)
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

seat heating
Removing and installing control module for seat heating
Seat heating line route
Central plug
Removing and installing pin housing for seat heating and belt buckle
Tools
Test plan for the seat heating
top of page
74 27 19 Removing and installing control module for seat heating 1703

einordnung
Removing and installing control module for seat heating

The control module for the seat is located on the right side for the driver's seat and on the left side for the
passenger's seat.
−A− Backrest plug connection.
−B− Seat cushion plug connection.
−C− Plug connection for seat heating control module
−D− Expanding
rivet.
1. Removing control module for seat heating

=> Removing
front seat
a. Press the pin into the expanding rivet −D− with a thin screwdriver for example and remove the holder
together with the rivet and the control module.
b. Pull control module off the plug
−C− .
3. Installing control module for seat heating
a. Push control module onto the plug
−C− .
b. Fix the control module and holder with the expanding rivet −D− and press the pin in
the rivet.
top of page
Seat heating line route
−A− Plug connection for backrest heating element

−a− Press plug for backrest heating element together −arrow− and pull from the plug connection −A− .
−B− Plug connection for seat heating element
Removing and installing control module for seat heating 1704

einordnung
−b− Push plug for seat heating element onto −B− until the plug connection engages.
−C− Base for seat heating control module.
−D− Connection for seat heating wiring harness for the central
plug.
−E− Power supply, plug for central plug.
top of page
Central plug
−A− Coding pin: In the Boxster in opening 2, in the 911 Carrera and 911 Turbo in opening 5. Pin BR
opening 6, pin RE/VI opening 3.
−B− Slide in lock−in position.
1. Removing coding pin and pin

=> Removing
front seat
a. Pull slide −B− in −direction of arrow 1−
.
b. Lever out fuse −arrow 2− with a small screwdriver and remove
completely.
c. Pull out coding pin −A− with pliers. Press pin out of flat connector using press−out tool. => Tools
3. Removing coding pin and pin
a. Insert coding pin −A− and pin into the flat connector until it
engages.
b. Insert fuse −2− in −direction of arrow− until it
engages.
c. For seat installation: Insert counter plug into vehicle and push in slide −B−
.
top of page
Removing and installing pin housing for seat heating and belt
buckle
−C− Seat heating pin
housing
−D− Belt buckle pin
housing
Seat heating line route 1705

einordnung
1. Removing pin housing for seat heating and belt buckle

=> Removing
front seat
a. Cut tie wrap on rear side of central plug with side
cutters.
b. Push fuse −2− away from flat connector in −direction of
arrow 2− .
c. Pin housing: Push out the belt buckle −D− and seat heating −C− in −direction of
arrow 1− .
3. Installing pin housing for seat heating and belt buckle
a. First insert the seat heating pin housing −C− , then the belt buckle −D− into the flat connector.
b. Push fuse −2− onto the flat
connector.
c. Observe the line route and secure with tie wraps on the rear side of the flat
connector.
top of page
Tools

top of page
Test plan for the seat heating
In the case of the complaint "seat heating does not function", proceed according to the following work
instruction. Work aids: Use wiring diagram and multimeter. => Tools
Work instruction Correct result Incorrect result

1 Actuate seat heating switch, LED lights up in ’ Step 2 ’ Step 5
the switch
2 => Removing front seat > 11V ’ Step 3 Check plug connection and
Switch on ignition, measure battery voltage wiring.
on the plug bracket for the seat heating ’ End
Removing and installing pin housing for seat heating and beltbuckle 1706
einordnung
control module using a multimeter. Pin 5 and

pin 9.
3 Perform heat element resistance test for the Depending on Check resistance test on backrest
backrest and seat area using a multimeter. temperature, and seat area heating elements via
Pull the plug off the seat heating control approx 2 © ’ Step the respective connecting plug
module and check the resistance on the plug 4 (approx. 1 ©) and replace defect
bracket RE/WT pin 3 and BR pin 9. heating element
’. End
4 Seat heating control module ’ replace.
’ End
5 Check fuse in the fuse box for the seat ’ Step 6 Replace fuse and perform function
heating. test.
’ End
6 Check seat heating switch lines for continuity Replace switch for the seat heating.
using a multimeter. ’ End
996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841
Test plan for the seat heating 1707

90 25 19 Removing and installing instrument cluster
Removing instrument cluster
Installing instrument cluster
Coding the instrument cluster
top of page
Removing instrument cluster
Note
• If the vehicle is equipped with a handsfree telephone, disconnect the microphone plug connection
instead of the dummy plug!

3. Insert two small screwdrivers into the openings and pull off the button −A− towards the front.
5. Press the right locking hook towards the switch, grip the button holder with a pair of pliers and pull out
the switch towards the front.
6. Undo 5.0 x 30 Torx screw on the dashboard insert.
7. Pull off plug on the left side and undo the 5.0 x 30 Torx screw.
8. Unclip the dashboard insert and disconnect the electrical plug
connections.
9. Detach the instrument cluster from the dashboard insert and remove it.
top of page
90 25 19 Removing and installing instrument cluster 1708

einordnung
Installing instrument cluster

1. Engage electrical plug connections and fasten the dashboard insert on the
dashboard.
2. Install hazard warning light switch.
engage.
test.
• If a new instrument cluster has been installed, it must be coded.
top of page
Coding the instrument cluster
Note
• As of model year '01, the tolerance of the speed display has been restricted. This was achieved by
changing the software ("K−number") on the instrument cluster and PCM control module. The
"K−number" varies depending on vehicle type and country equipment.
• The reason is as follows: different displays of the total mileage and the fuel consumption/average
consumption in the instrument cluster and the PCM control module.
• Therefore, in the case of repairs, the K−number in the instrument cluster must be corrected with the
Porsche System Tester 2 (PST2) after the installation of a new instrument cluster in 911 Turbo
vehicles. > If this correction is not carried out, conflicting values for the total mileage and fuel
consumption/average consumption will be displayed on the instrument cluster and the PCM control
module when in driving mode.
PROCEDURE for coding the instrument cluster:

1. Connect the PST2 to the diagnostic socket; switch on the PST2 and the ignition.
2. In the menu "Control units", select Instrument
cluster
3. In the function selection, select Coding .
4. Select menu item Country coding .
5. Select the respective country and code with F8
key.
The other menu items are described in the Diagnosis Manual, folder ’ 0, 9025 Control module replacement,
instrument cluster .
Note
• In general, the K−number is adjusted when coding the instrument cluster. However, this point must be
checked again when coding is complete, as described under PROCEDURE for changing the
"K−number" in the instrument cluster (as of PST2 software 13.0):
Installing instrument cluster 1709

einordnung
PROCEDURE for changing the "K−number" in the instrument cluster (as of PST2 software 13.0):
6. In the function selection, select Synchronise K−number .
7. Start the function using the key
>> .
8. After the function has been successfully performed in the instrument cluster, the message K−number
synchronised or the message K−number updated appears in the Tester display. If the K−number is not
updated, a connection to the PCM is set up automatically. The message Connecting to PCM appears.
9. Then the message Function successfully completed
appears.
10. Return to the Start menu with the button "ESC", switch off the PST2 and disconnect from the
diagnostic socket.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Coding the instrument cluster 1710

91 10 19 Removing and installing display and
operator control unit (PCM)
Note
Removing display and operator control unit (PCM)
Installing display and operator control unit (PCM)
Note
• In the instrument cluster of the 911 Turbo, the tolerance of the speed display has been restricted. This
was achieved by changing the software ("K−number") on the instrument cluster and PCM control
module. The "K−number" varies depending on vehicle type and country equipment.
• The reason is as follows: different displays of the total mileage and the fuel consumption/average
consumption in the instrument cluster and the PCM control module.
• Therefore, in the case of repairs, the K−number in the PCM control module must be corrected with
the Porsche System Tester 2 (PST2) after the installation of a new PCM control module or a new
instrument cluster in vehicles as of model year '01. > If this correction is not carried out, conflicting
values for the total mileage and fuel consumption/average consumption will be displayed on the
instrument cluster and the PCM control module when in driving mode.
PROCEDURE for changing the "K−number" on PCM control module (as of PST2 Software 13.0):
1. Connect the PST2 to the diagnostic socket; switch on the PST2 and the ignition.
2. When the PST2 is ready, select vehicle type and start the automatic control module search with the key
>> .
3. In the menu "Control units", select Instrument
cluster
4. In the function selection, select Synchronise K−number .
5. Start the function using the key
>> .
6. After the function has been successfully performed in the instrument cluster, the message
K−number synchronised or the message K−number updated appears in the Tester display.
Subsequently, it is automatically connected to the PCM. The message Connecting to PCM appears.
7. After the function has been successfully performed in the PCM, the message K−number
synchronised or the message K−number updated appears in the Tester display. Subsequently, it is
automatically reconnected to the instrument cluster. The message Connecting to instrument cluster
appears.
8. Then the message Function successfully completed
appears.
9. Return to the Start menu with the button "ESC", switch off the PST2 and disconnect from the diagnostic
socket.
top of page
91 10 19 Removing and installing display and operator control unit (PCM) 1711
einordnung
Removing display and operator control unit (PCM)
1. Unclip the −switch covers− from below and let them dangle from the electric leads.
2. Press together both spring clamps on the display and operator control unit and carefully pull
out.
3. Disconnect electrical plug connections from the display and operator control unit.
top of page
Installing display and operator control unit (PCM)
Note
• After installation of a new display and operator control unit, the system must be activated with the
Porsche System Tester 2!
1. Engage the electrical plug connections and carefully lay the electrical leads (do not pinch).
Connecting and switching on the Porsche System Tester 2

2. Switch on PCM by pressing the volume control (display remains
dark).
Removing display and operator control unit (PCM) 1712

einordnung
3. Establish communication with the Porsche System Tester 2 and select

PCM.
4. Select Modify coding.
5. Select PCM active.
6. Confirm PCM active with the F8 key.
Device code input
The display and operator control unit is protected against theft by a device code. Furthermore, a code also
protects the navigation unit against unauthorised users.
Note
• Both codes must be input when the system is commissioned!
• Input the device code for the display and operator control unit first!
• Only the navigation code has to be input again if the navigation unit is exchanged!
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Connecting and switching on the Porsche System Tester 2 1713

91 10 19 Removing and installing display and
operator control unit (PCM 2) − as of MY 2003
Removing display and operator control unit (PCM 2)
Installing display and operator control unit (PCM 2)
Teaching display and operator control unit (PCM 2)
top of page
Removing display and operator control unit (PCM 2)
Note
• If the PCM is replaced by a new or a different PCM, read out the data with the Porsche System Tester
before removal. => Teaching display and operator control unit (PCM 2)
• The PCM has an optical waveguide (LWL). For information on the optical waveguide (LWL): ’ 97,
9768 Optical waveguide (LWL)
1. Unclip switch cover from below using a plastic spatula and disconnect electrical plug
connections.
2. Insert a hexagon−socket wrench sideways into the screw connection of the PCM detent
hooks.
3. Close the detents (2 each side) with the hexagon−socket wrench −A− and carefully pull out the PCM.
4. For re−installation, open the detents with the hexagon−socket
wrench −B− .
Note
91 10 19 Removing and installing display and operator control unit (PCM 2) − as of MY 2003 1714
einordnung
• The number of plug connections will vary, depending on the I No. (CD changer, Bose, amplifier).
• The variant without additional audio components (external Most control units) has a jumper (output to
input) connected to the optical waveguide plug.
5. Unlock and pull off antenna plugs −A, E, F− .

6. Unlock and disconnect the electrical plug connections in the order −C, B, D− .
top of page
Installing display and operator control unit (PCM 2)
Note
• If a new PCM is being installed, the navigation module must be removed from the old PCM and
installed in the new PCM.
• If the old PCM is being re−installed, then begin at Step 6.
1. Before the new PCM is installed, unlock and disconnect the protective plug −A− for the optical
waveguide.
2. Unclip the cover on the new and old PCM.
Removing display and operator control unit (PCM 2) 1715

einordnung
3. With the PCM removed, carefully lever out the navigation module using a screwdriver.
4. Insert the navigation module into the PCM to be installed.
5. Position the cover and press into place.
6. Push on the electrical plug connections for the display and operator control unit in the sequence −D, B,
A− and the antenna plugs −A, E and F− until they are felt to engage.
7. Check that the locking tabs on the PCM are out −arrow− , opening the lock with a
hexagon−socket wrench if necessary.
Note
• Before sliding the PCM into the installation slot, make sure that the electrical leads are not trapped by
the PCM or damaged.
8. Push the navigation unit into the installation slot until the locks engage on the PCM
housing.
Installing display and operator control unit (PCM 2) 1716

einordnung
9. Connect the electrical plug connections to the switch cover.

10. Position switch cover and press in until it is felt to engage.
Note
• After installation of a new display and operator control unit, the system must be activated with the
Porsche System Tester!
top of page
Teaching display and operator control unit (PCM 2)
Note
• If a new PCM is to be installed in a vehicle, the PCM2/CDR23 code specified in IPAS must be used.
number.
• During coding, the power supply for the Porsche System Tester should be guaranteed. Connect a
battery charging device to the vehicle battery.
• The Porsche System Tester instructions take precedence and in the event of a discrepancy these are
the instructions that must be followed. A discrepancy may arise with later software versions (from
20.0).
• The procedure described here has been structured generally; different text or additions may appear in
the Porsche System Tester.
>> to continue.
4. Select PCM2 with the cursor keys and press the >> key.
5. In the PCM2 menu, move to PCM2 MMI using the cursor keys and press the >>
key.
Teaching display and operator control unit (PCM 2) 1717

einordnung
6. Select Coding with the cursor keys and press the >> key.
7. If possible, select the coding, read it out and note it down if necessary.
8. Switch off ignition and replace the PCM2. => Removing display and operator control unit (PCM 2)
9. Switch on ignition. After replacement of the PCM2, go back to the PCM2 MMI menu using the >> key.
10. Select PCM2 code in the Coding menu and press >> to continue.
11. Enter the IPAS PCM2 code and code it with the F8 key.
12. Follow the instructions on the Tester.
Note
• In the case of a new PCM2, continue with Step 13.
In the PCM2 MMI menu:

13. Select Coding and press >> .
Note
• The following can be coded with software version 20.0 or higher.
14. Select K−number, standard and code with the F8 key.
K−number, standard:
Turbo RoW 3900
RoW 3967
Turbo USA 3984
USA 4010
15. Select K−number, real and code with the F8 key.

K−number, real:
Turbo RoW 3900
RoW 3967
Turbo USA 3984
USA 4010
16. Select Country coding , choose the relevant country and code with the F8 key.
17. Select Vehicle type vehicle coding and code with the F8 key.
Vehicle type vehicle coding

Not coded
911 (996)
Boxster
Cayenne
18. Select Vehicle version vehicle coding and code with the F8 key.
Vehicle version vehicle coding

einordnung
Not coded
Coupé
Cabrio
Targa
19. Select Air conditioning and code with the F8 key.

Air conditioning
Without air conditioning
With air conditioning
20. Select Units and code with the F8 key.
Units
RoW (°C, litre, km)
UK (°C, gallon, mph)
USA (°F, gallon, mph)
21. Select Time zone from 0 to −0.5 and code with the F8 key.
22. Select Right/left−hand drive vehicle coding and code with the F8 key.
Right/left−hand drive vehicle coding

Left−hand drive
Right−hand drive
23. Select Date , Time Summer/winter time , Display format , Timeout , Traffic broadcast loudspeaker boost ,
GAL and so on and code with the F8 key.
24. Switch to the MOST actual installed components list .
Note
• The installed components that are detected are displayed in the MOST actual installed components list
.
• Compare the installed components detected from the MOST actual installed components list with the
MOST required installed components list .
25. Switch to MOST required installed components list .

26. If the items in the actual list differ from those in the required list, update the MOST required
installed components list to the status of the MOST actual installed components list by coding.
27. Read out the fault memory and erase it if necessary.
28. Exit the PCM2 MMI menu by pressing << and switch to the PCM2 GW menu.
In the PCM2 GW menu:
29. Select the MOST switch in the Coding menu using the >> key and code with the F8 key. The MOST
switch is open if external control modules are installed (e.g. CD changer, amplifier). See Vehicle
equipment.

einordnung
MOST switch
Open (default)
Closed (internal ring)
30. Select Production mode and press >> .

31. Select Production mode Off and code with the F8 key.
32. Select Tuner parameters menu and code with the F8 key.
Tuner parameters
Europe
USA
South America
Australia
Asia
(South) Africa
Japan
33. Exit the PCM2 menu using the << key.

34. Read out the fault memory and erase it if necessary.
Note
• Switch on the PCM2. If the PCM2 cannot be switched on, or the PCM2 switches on but no music can
be heard, switch off the ignition, remove the ignition key, close the doors and lock the vehicle. Wait
until the alarm system LED flashes normally . Unlock the vehicle and switch on the PCM2 again.
• If the PCM2 still does not switch on after this procedure, proceed in accordance with the Technical
Manual. ’ 0, 9101 PCM/CDR23
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

91 20 02 Checking complaints about car radio system
Malfunctions in radio system
Reduced sound quality in one or more loudspeakers
Remedying problems with the amplifier
Interference noises
Electromagnetic compatibility (EMC) − Troubleshooting
Tools
top of page
Malfunctions in radio system
1. Check error and customer complaint.
3. Remove radio fuses (ignition and memory).
4. Wait approx. 3 minutes until all components are free of tension.
5. Insert fuses again.
6. Check error and customer complaint
again.
Work instruction Yes No

1 Check error and customer complaint Check battery charging condition and Does radio have a
again. battery cables for perfect contacts. CD player or a
Radio function OK? If the problem persists, contact radio magnetic−tape
manufacturer drive?
’ End Yes ’ Check
signal lead
No ’ Go to Step 2
2 Does radio have a display? If an audio signal can be heard, connect ’ Step 6
a functional radio
’ Step 3
If no audio signal can be heard ’ Step 5
3 Does the system now function Replace radio => Interference
perfectly? ’ End noises
’ End
4 7. Check all radio connections. Repair wiring harness or plug Connect
8. Check voltage at the connections connection functional radio
battery and ignition . ’ End ’ Step 3
9. Check ground connection of
radio.
Radio function OK?
5 10. Disconnect audio connections 13. Check connection between the Connect
from radio. radio and the amplifier with a functional radio
11. At maximum volume setting, multimeter. ’ Step 3
measure the alternating voltage at 14.
91 20 02 Checking complaints about car radio system 1721

einordnung
the outputs. Check the audio connections (+)

12. Is the voltage between 8.4 and (−) for short circuits or ground
and 11.0V? connections.
Radio function OK? 15. Check polarity of the entire wiring.
16. Repair any detected damage.
’ End
6 Is a short circuit present? Repair the cable connection and check ’ Step 4
the system
’ End
top of page
Reduced sound quality in one or more loudspeakers
Note
• Reduced sound quality may be accompanied by a humming noise.
1. Switch on the system and change the fader and balance setting on the
radio.
2. Check the fault status.
3. Find out on which channels the problem occurs.

1 Switch the radio between FM, Find out whether it is a question of If the problem only occurs in
AM, cassette and CD (depending an objective fault (’ go to Step 2) FM or AM radio reception,
on the available components). or a subjective perception (’ go to check the reception. If the
Does the problem occur in all Step 4) of the system behaviour. problem persists, replace the
program sources? radio or CD player
’ End
2 Is a humming noise audible on Check the polarity of the cable ’ Step 3
one channel? connection between the radio and
the Bose amplifier. Remedy any
possible problems. If the fault has
been remedied ’ End.
If the fault is still present ’ Step 3
3 Connect a functional radio/CD Replace radio/CD player Connect a functional
player. Problem remedied? ’ End amplifier
’ End
4 Carry out a comparative test with Involve the customer in the ’ Step 3
a functional system. comparative test.
System behaviour identical? Customer satisfied ’ End.
Customer not satisfied, consult
Porsche After Sales.
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Malfunctions in radio system 1722

einordnung
Remedying problems with the amplifier

1 Check amplifier connections Replace amplifier If the interference
for damage and then connect a ’ End noises only come from
functional amplifier. one loudspeaker, insert
Interference noises still a functional loudspeaker
present? ’ Step 2
2 Are the interference noises still Replace loudspeaker Lay the cable supply
present? ’ End lines again, making sure
that there is adequate
clearance to other
cables and electrical
components; if
necessary, reconnect the
loudspeaker connection.
Also, twist the
loudspeaker leads
together to minimise the
interference noises
’ Step 3
3 Are the interference noises still 1. Check the audio cables between the ’ End
present? radio and the amplifier for free
points, short circuits and high
resistance.
2. Check all cable connections for bent
or loose connections, corrosion or
other damage.
’ Step 4
4 Repair cable connections. Are 3. Localise the ground connection for No: ’ End
the interference noises still the amplifier.
present? 4. Disconnect the ground lead on the
amplifier side.
5. Re−connect the ground connection
at an appropriate point.
6. Measure the functionality of the
ground connection with a
multimeter beween the negative
terminal of the battery and the
relevant ground point (potential
difference).
’ Step 5
5 7. Localise the battery ’ End => Interference noises
connection (+) of the
Remedying problems with the amplifier 1723

einordnung
amplifier.
8. Disconnect the lead on the
amplifier side.
9. Insert an interference
filter.
10. The negative terminal of
the interference filter
should be installed facing
towards the amplifier.
Interference noises remedied?
top of page
Interference noises
Note
• This procedure is designed to help you find out how the interference noise has entered the system.
• In the following subchapters, the various interference noises are differentiated.
• The battery must be fully charged.

• No charging unit may be connected.

1 Does the interference noise Disconnect all electrical connections to ’ End
complained about by the retrofitted accessories, such as two−way radios,
customer really exist? mobile telephones, radar detectors, etc.
’ Step 2
2 Can the interference noise be Slowly pull the receiver component(s) out of => Interference
heard in all the loudspeakers? the holder and observe the noise. Does the noises, checking
interference noise change or disappear in the cable
process? connections
Yes ’ Step 4
No ’ Step 3
3 Disconnect the antenna from => Interference noise due to antenna => Interference
the radio and observe the noises due to all
interference noise. looudspeakers
Does the interference noise
change or disappear?
4 Does the interference noise => Interference noises due to alternator => Interference
change? => Interference noises due to engine noises due to all
=> Interference noises due to power supply looudspeakers
Interference noises 1724

einordnung
Interference noises, checking cable connections
Note
• Procedure for interference noises which enter the system via the audio connections.

1 1. As an experiment with the radio switched 3. Check the plug As an
off, exchange the loudspeaker cables of the contacts of the experiment, use
loudspeaker involved in the complaint with connecting cable on a new cable
those of a fully functional loudspeaker at the the amplifier and from the
amplifier output. the loudspeaker. amplifier to the
2. Switch the radio on. 4. Repair or clean any loudspeaker.
defective connections. Noise
Is the loudspeaker involved in the complaint now
disappeared:
free of interference noise?
insert new
Noise no longer present ’ End
audio cables
Noise still present ’ Step 2
and lay them
separately from
each other.
Noise no longer
present ’ End
Noise still
present ’ Step 4
2 5. With the radio switched off, exchange the 7. Check the plug contacts of Install a
cables between the radio and the amplifier. the cable on the amplifier functional
6. Switch the radio on. and the radio. amplifier
8. Repair or clean any ’ End
Is the loudspeaker involved in the complaint now
OK? defective connections.
Noise disappeared ’ End

Noise still present ’ Step 3
3 9. Check the audio wiring harness for a good As an experiment, insert new ’ End
ground connection. leads between the radio and
10. Measure with a multimeter at the negative the amplifier.
terminal of the battery. Repair the wiring Noise still present: install new
harness. amplifier and radio.
Noise remedied: install new
audio cables ’ End
Noise still present?
4 11. Check the plug contacts of the connecting As an experiment, install first ’ End
cable on the loudspeaker. a functional amplifier and then
12. Repair or clean any defective connections. a functional radio
’ End
Interference noises, checking cable connections 1725

einordnung
Interference noises due to alternator

1 Connect a plug connection 1. Check the connections of the battery. Make sure that ’
to the alternator. all connections are seated properly, are tightened and End
Start are not corroded.
engine. 2. Check the ground connection of the engine, the alternator
Minimise the volume at the and the battery's negative terminal and measure with a
radio. multimeter at the negative terminal of the battery and the
respective ground point (potential difference).
Switch on high loads and
change the engine speed 3. Make sure that all ground connections are fully tightened
with brief accelerations. and clean.
4. Check the connections of the alternator.
Are the interference noises still
present? If necessary: clean and repair the connections and, if necessary,
install a condenser ’ End
Interference noises due to engine
The following points should be checked first:
Note
• Make sure that the battery connections are seated properly and that the ground connection is
guaranteed.
• Check whether the ignition coils are loose or defective.
• Check the plug connections and supply lines for the ignition coils for damage.
• Check the ground connections on the engine.
• Check whether the correct spark plugs have been installed and that the electrode gap is OK.

1 Does the interference noise change Drive the vehicle in 1st or 2nd gear at a Does the
with the engine speed? speed of 3,000 rpm (with audible noise), interference
This work instruction must not be then suddenly remove the pressure from the noise only
carried out on public roads. accelerator. occur when the
Noise present: ’ car is driving?
1. ’ Step 2
Interference noises due to alternator 1726

einordnung
Check the lead connections to the Does the noise

injection nozzle. Check in particular for not occur
loose or corroded connections. when the car is
2. Check resistance of the injection driving?
nozzles. R = 12 Ohm +/− 0.6 Ohm. ’ Step 3
Noise no longer present ’ End

Noise present ’ Check the points listed
above under Note once more.
2 3. Check for faults caused by 5. Check the wiring of the Check the
vehicle components which have components for unfavourable radio reception
an influence on the speed. positioning and loose or corroded ’ End
4. Disconnect the component from connections.
the power supply and test again. 6. Lay the cables again or repair.
7. As an experiment, insert a functional
Noise still present? component and replace, if necessary.
’ End
3 8. Check the wiring of the As an experiment, insert a functional ’ End
components for unfavourable component and replace, if necessary
positioning and loose or corroded ’ End
connections.
9. Lay the leads again or repair.
Interference noise due to antenna
Note
• Follow this test routine if the interference noises come from the antenna.
• As an experiment, it is worth making a comparison by inserting a rod antenna.

1 1. Clean all connections. 5. Check all antenna mountings for good ’ End
2. Connect a ground strap to the ground connections with the negative
antenna plug. terminal of the battery.
3. Connect the other end of the ground 6. Check all hardware mountings for firm
strap to a suitable point on the car seating and clean ground connections.
body. Noise present ’ Step 2
4. Check the ground connection Noise not present ’ End
Interference noises due to engine 1727

einordnung
with a multimeter at the

negative terminal of the
battery.
Interference noise still present?
2 7. Cut the ground cable to the radio => Interference noises due to power supply Replace
approx. 30 cm from the device. ’ End defective
8. Make a ground connection directly components
to the radio housing. ’ End
9. Connect the 30−cm−long end
of the ground cable to the
radio housing.
10. Connect the new ground connection
to a suitable point on the car body.
11. Check the ground connection
with a multimeter at the
negative terminal of the
battery.
Interference noise still present?
Interference noises due to power supply
Note
• Use this test routine for interference noises which originate from the vehicle electrics.

1 1. Temporarily disconnect the The interference noise is triggered 4. Reconnect the
connections to terminals 30, 15 and via the radio original cable
ground on the radio. ’ Step 2 connections to
2. Connect terminals 30, 15 and ground the radio.
temporarily via a separate lead. 5. Temporarily
3. Connect the other end of this lead disconnect the
to the vehicle battery. connections to
terminals 30,
Interference noise still present? 15 and ground
on the
amplifier.
6. Connect
terminals 30,
15 and ground
temporarily
via a different
lead.
Interference noise due to antenna 1728

einordnung
7. Connect the
other end of
this lead to the
vehicle
battery.
If the noise is still

present, the
amplifier is the
cause of the fault ’
Step 2
Noise no longer
present ’ Step 3
2 Connect the other end of the improvised Lay terminals 30, 15 and the ’ Step 3
lead connection at the connection for ground lead differently or insert a
terminals 30, 15 to the fuse of the radio or new lead and lay the new lead at a
the amplifier. diastance from all other current
Interference noise still present? circuits.
Noise still present: ’ Step 3
Noise no longer present: ’ End
3 Check whether the noise occurs when a Localise the cause for the The noise occurs
switch or an accessory component is interference noise in the retrofitted when the engine is
switched on. accessories and remedy running
’ End ’ Step 4
The noise occurs
with the ignition
switched on and
the engine at
standstill
’ Step 5
4 Briefly disconnect the connections on the => Interference noises due to => Interference
alternator and start the engine. alternator noises due to
Noise still present? engine
5 8. Find out which circuit is causing the ’ Step 6 ’ End
interference noises by removing
individual fuses, relays and switches.
9. Insert all removed fuses, relays and
switches again.
10. Disconnect all components in turn
which are connected to the affected
circuit, until the interference noise
has disappeared.
11. Replace defective components.
6 12. Lay all wiring harnesses from ’ Step 7 ’ End
the defective component and
the connecting leads with
suitable clearance.
Interference noises due to power supply 1729

einordnung
13. Remove any audio cables which are

causing the problem from the wiring
harness.
7 14. If the suspected component uses the ’ Step 8 ’ End
same ground connection as a
component of the audio system,
establish a problem−free ground
connection.
15. If ground connections are running via
the same wiring harness, separate
them from each other.
16. Wrap the terminal 30 and 15 lead of
the suspected component with a film
or a metal tape and connect the lead
to a ground connection.
17. Check the ground connection
with an ohmmeter at the
negative terminal of the battery.
8 18. Find the positive cable of the ’ End ’ End
suspected component and cut the
cable at the component side.
19. Insert an interference filter between
the connecting cables.
Interference noises due to all looudspeakers
Note
• The loudspeaker leads are twisted together as standard.

1 Check all connections to the amplifier or the Repair the lead connection. ’ Step 2
radio. Take particular note of loose or bent pins, Noise still present? ’ Step 2.
corrosion or other damage. Noise remedied? ’ End
Damage present?
2 1. Localise the ground connection cable of the Disconnect all amplifiers but ’ End
amplifier. one from the power supply
2. Disconnect the ground connection cable on ’ Step 3
the amplifier side.
3. Lay the ground connection cable separately
Interference noises due to all looudspeakers 1730

einordnung
and connect.
4. Check the ground connection with an
ohmmeter at the negative terminal of the
battery.

3 5. Check all connections of the amplifier. ’ Step 4 Replace
6. As an experiment, insert a functional amplifier
amplifier in place of the suspected ’ End
defective one.

4 Disconnect the audio inputs from the amplifier, ’ Step 5 Repair the
whereby the connections for terminals 30, 15 and audio
ground must be maintained. connecting
Noise still present? cable, lay it
again or replace
’ End
5 If the amplifier is switched on via a relay, remove 7. Localise the battery Replace the
the relay and connect the amplifier directly to the connecting cable of the closing relay of
power supply. amplifier. the amplifier
Noise still present? 8. Cut this cable. ’ End
9. Install an
interference filter at
the cut point.
’ End
top of page
Electromagnetic compatibility (EMC) − Troubleshooting
Note
• Check the complaint to make sure that the symptoms really exist.

1 Is the vehicle equipped with retrofitted Remove the accessories / Collect information
accessories (radar detector, two−way radio, take them out of operation about the complaint:
mobile telephone)? ’ Step 2 Which reception
ranges are affected?
With engine
switched on or off?
Electromagnetic compatibility (EMC) − Troubleshooting 1731

einordnung
Constantly or
occasionally?
’ Step 3
2 Were the accessories installed according to the ’ Step 3 Correct installation
manufacturer's instructions? ’ End
3 Circle the EMC elements: ’ Step 4 ’ End
Trigger
Receiver
1. Check the suspected components.
2. Replace with functioning components.
Complaint still present?
4 Check the wiring between the trigger and the Consult Porsche After Repair lead connection
receiver: Sales ’ End
Ground ’ End
connection
Plug
connections
Positioning of wiring harness
Complaint still present?
top of page
Tools

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Tools 1732
91 24 19 Removing and installing the car radio − as of
MY 2003
Tools
Teaching the car radio
top of page
Tools
Removal tool

Removal tool 9570/1 See Workshop Equipment Manual, Chapter 2.2.2 Clips for removing radio
top of page
Note
• If the car radio is replaced by a new or a different car radio, read out the data with the Porsche System
Tester before removal. => Teaching the car radio
• The car radio has an optical waveguide (LWL). For information on the optical waveguide (LWL): ’
97, 9768 Optical waveguide (LWL)
91 24 19 Removing and installing the car radio − as of MY 2003 1733

einordnung
1. Insert removal tool into the openings provided on the radio until the tool is felt to engage.
2. Pull the radio completely out of the installation slot with the removal
tool.
3. Carefully place the radio on the centre console in front. It is advisable to place a cloth between the centre
console and the radio.
4. Unlock the plug connections by pressing the plug locking elements −a− and pull the plugs off the radio
−arrow− .
Note
• The number of plug connections will vary, depending on the I No. (CD changer, Bose, amplifier).
• The variant without additional audio components (external Most control units) has a jumper (output to
input) connected to the optical waveguide plug.
5. Press in the (coloured) detent hooks on the radio −arrow− and withdraw the removal tool at the same
time.
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Removing the car radio 1734

einordnung
1. Before the new radio is installed, unlock and disconnect the protective plug −A− for the optical
waveguide.
2. Press in electrical plug and optical waveguide plug on car radio until the plugs are felt to engage −a− .
Note
• Before sliding the car radio into the installation slot, make sure that the electrical leads are not trapped
by the car radio or damaged.
3. Push the car radio into the installation slot until the locks engage on the radio
housing.
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Teaching the car radio
Note
• If a new car radio is to be installed in a vehicle, the PCM2/CDR23 code specified in IPAS must be
used.
number.
• If possible, before the car radio is removed and replaced, a read−out of the vehicle data should be
obtained and noted down using the Porsche System Tester.
• During coding, the power supply for the Porsche System Tester should be guaranteed. Connect a
battery charging device to the vehicle battery.
Installing the car radio 1735

einordnung
• The Porsche System Tester instructions take precedence and in the event of a discrepancy these are
the instructions that must be followed. A discrepancy may arise with later software versions (from
20.0).
• The procedure described here has been structured generally; different text or additions may appear in
the Porsche System Tester.
>> to continue.
4. Select CDR23 with the cursor keys and press the >> key.
5. In the CDR23 menu, with the cursor keys on CDR23 press the >> key.
6. Select Coding with the cursor keys and press the >> key.
7. If possible, select the coding, read it out and note it down if necessary.
8. Switch off ignition and replace CDR23. => Removing the car radio
9. Switch on ignition. After replacing the CDR23, go back to the CDR23 menu using the >> key.
10. Select CDR23 code in the Coding menu and press >> to continue.
11. Enter the IPAS CDR23 code and code it with the F8 key.
12. Follow the instructions on the Tester.
Note
• In the case of a new car radio, continue with Step 13.
13. Select Traffic broadcast loudspeaker boost menu and code with the F8 key.
14. Select GAL (noise−dependent loudspeaker boost) menu and code with the F8 key.
15. Select Vehicle version vehicle coding and code with the F8 key.
Vehicle version vehicle coding
Not coded
Coupé
Cabrio
Targa
16. Select Air conditioning and code with the F8 key.

Air conditioning
Without air conditioning
With air conditioning
17. Select Right/left−hand drive vehicle coding and code with the F8 key.
Right/left−hand drive vehicle coding

Left−hand drive
Teaching the car radio 1736

einordnung
Right−hand drive
18. Select Production mode and press >> .

19. Select Production mode Off and code with the F8 key.
20. Select Tuner parameters menu and code with the F8 key.
Tuner parameters
Europe
USA
South America
Australia
Asia
(South) Africa
Japan
21. Exit the Coding menu and switch to MOST actual installed components list in the CDR23 menu.
Note
• The installed components that are detected are displayed in the MOST actual installed components list
.
• Compare the installed components detected from the MOST actual installed components list with the
MOST required installed components list .
22. In the menu CDR23 select MOST required installed components list .
23. If the items in the actual list differ from those in the required list, update the MOST required
installed components list to the status of the MOST actual installed components list by coding.
24. Exit the CDR23 menu using the << key, read out the fault memory and erase it if necessary.
25. Exit the CDR23 menu using the << key.
Note
• Switch on the car radio. If the car radio cannot be switched on, or the car radio switches on but no
music can be heard, switch off the ignition, remove the ignition key, close the doors and lock the
vehicle. Wait until the alarm system LED flashes normally . Unlock the vehicle and switch on the
radio again.
• If the radio still does not switch on after this procedure, proceed in accordance with the Technical
Manual. ’ 0, 9101 PCM/CDR23
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Teaching the car radio 1737

91 42 19 Removing and installing rear loudspeakers,
Bose sound package
Removing rear loudspeakers
Installing rear loudspeakers
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Removing rear loudspeakers
91 42 19 Removing and installing rear loudspeakers, Bose sound package 1738

einordnung

1 Removing cover trim Remove the cover trim −1− at the left and right towards the front.
2 Undoing fastening screw Unscrew the fastening screw −2− at the left and right.
3 Pulling out the sound Pull the sound package −3− in the −direction of the arrow− out of
package the bracket −4− and fold over.
4 Disconnecting the plug Press plugs −5− together and pull apart.
connection.
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Installing rear loudspeakers
Removing rear loudspeakers 1739

einordnung

1 Connecting plug connection Push in the plug connection −5− until the plug engages.
2 Positioning sound package Push the sound package −3− into the bracket −4− as far as the stop.
3 Fastening the sound package Screw in the fastening screws −2− at the left and right.
Tightening torque: 7.2 Nm (5.5 ftlb.)
4 Attaching the cover trim Position the cover trim −1− and press into place.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing rear loudspeakers 1740

91 44 19 Removing and installing the loudspeaker
amplifier
Removing the loudspeaker amplifier
Installing the loudspeaker amplifier
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Removing the loudspeaker amplifier
• Before removing the amplifier, take out the ignition key and switch off the audio system.
91 44 19 Removing and installing the loudspeaker amplifier 1741

einordnung
1. Open the luggage−compartment lid and if present, detach the additional amplifier on the clip −1− and
detach the additional amplifier (in the direction of travel) to the right.
2. Press connectors −arrow− together and pull apart. Remove additional amplifier.
3. Unscrew both fastening screws from the retaining bracket.
Bose amplifier:
4. Unplug both electrical connectors −arrow− .
Harman amplifier:
5. Remove the cover for the electrical connector.
Removing the loudspeaker amplifier 1742

einordnung
Harman amplifier:
6. Unplug both electrical connectors −arrow− .
7. Unscrew both fastening screws and pull the amplifier from the fastening clips.
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Installing the loudspeaker amplifier
1. Insert the amplifier in the retaining clip and secure with the two fastening
screws.
2. Insert both connectors until they perceptibly engage.
Bose amplifier:
Installing the loudspeaker amplifier 1743

einordnung
Harman amplifier:
3. Put on the cover on the Harman amplifier.
4. Screw on the retaining bracket with the amplifier and both fastening screws to the
body.
5. Plug in the connector of the additional amplifier and attach the additional amplifier on the retaining
bracket and secure using the clip −1− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installing the loudspeaker amplifier 1744

parking assistant
Note
Removing control module for parking assistant
Installing control module for parking assistant
Note
• The control module for the parling assistant is located under the left front seat.
• Before removing the control module, remove the ignition key.
• Removing front seat ’ 720119 Removing and installing front seat.
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Removing control module for parking assistant
1. Unscrew both fastening screws −arrow− from the cover.
2. Turn the cover over and disconnect both electrical plugs.

3. Unscrew the control module from the cover with the two fastening
screws.
91 74 19 Removing and installing control module for parking assistant 1745

einordnung
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Installing control module for parking assistant
1. Insert both plugs into the control module until they

engage.
2. Fit the control module onto the cover with both fastening screws.
3. Position the cover and screw tight with the fastening screws −arrow− .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing control module for parking assistant 1746

91 84 19 Removing and installing antenna amplifier −
as of MY 2003
Removing antenna amplifier
Installing antenna amplifier
Note
• The antenna amplifier is installed in connection with the PCM2.
• The antenna amplifiers are located on the A−pillars.
top of page
91 84 19 Removing and installing antenna amplifier − as of MY 2003 1747

einordnung
Removing antenna amplifier

• Remove the respective trim of the A−pillar ’ 7, 705719 Removing and installing A−pillar trim
1. Disconnect the antenna plugs for the windscreen −1− and −2− .
2. Disconnect the plug connections for the antenna control module −3, 4− left side, −3, 4, 5− right
side.
3. Unscrew the two fastening screws −6− .
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Installing antenna amplifier
1. Position the antenna amplifier on the A−pillar and screw the fastening screws −6− tight.
2. Connect the plug connections for the antenna control module −3, 4− left side, −3, 4, 5− right
side.
3. Connect the antenna plugs for the windscreen −1− and −2− .
• Install the respective trim of the A−pillar ’ 7, 705719 Removing and installing A−pillar trim
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Removing antenna amplifier 1748

antenna
Removing control module for antenna
Installing control module for antenna
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Removing control module for antenna
• Remove the right cover under the instrument panel ’ 7, 702219 Removing and installing cover under
instrument panel .
• Remove the ignition key and switch off the radio.
91 86 19 Removing and installing control module for antenna 1749

einordnung
1. Lever the control module on the left side out of the clip and pull it to the right out of the holder.
2. Swivel the control module in the direction of the arrow −A− and carefully pull it over the
passenger compartment carpet −B− − pay attention to the length of the lead.
3. Disconnect the electrical plugs

successively.
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Installing control module for antenna
1. Connect the electrical plugs successively.
Removing control module for antenna 1750

einordnung
2. Carefully push the control module over the passenger compartment carpet −B− and position the
module in the holder −A− .
3. Fasten the control module with the clip on the

holder.
Install the right cover under the instrument panel ’ 7, 702219 Removing and installing cover under instrument
panel .
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing control module for antenna 1751

telephone
Removing control module for telephone
Installing control module for telephone
• Remove right front seat. ’ 7, 720119 Removing and installing front seat
• Switch off ignition, remove key, switch off PCM or radio.
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Removing control module for telephone
1. Unscrew the 4 fastening screws from the holder.
2. Unscrew the 2 fastening screws from the holder and remove the control module from the holder.
top of page
91 90 19 Removing and installing control module for telephone 1752

einordnung
Installing control module for telephone
1. Connect the electrical plug connections on the control module.
2. Position the control module on the holder and screw the fastening screws tight. Tightening torque 10
Nm (7.5 ftlb.).
3. Lay the holder with the control module on the floorpan and fasten with the 4 fastening
screws.
• Install right front seat ’ 7, 720119 Removing and installing front seat
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Installing control module for telephone 1753

92 12 19 Removing and installing rain sensor
Removing rain sensor
Installing rain sensor
Open circuit in the rain sensor connection (emergency interval operation)
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Removing rain sensor
92 12 19 Removing and installing rain sensor 1754

einordnung
Limited functionality of the rain sensor when the following information points are not observed:
Note
• An adhesive pad must be used when reinstalling the rain sensor. See PET, main group 9, sub group
04.
• When assemblying the adhesive pad, air should not be trapped between the windscreen and the
adhesive pad or between the adhesive pad and the rain sensor.
• When installing the adhesive pad, a temperature of approx 20°C for the windscreen, the rain sensor
and the adhesive pad must be ensured. Carefully heat the windscreen with a hot−air gun for example.
• The sensor on the sticking surface must not be touched by fingers.
• If the sensor is new, remove the protection cap before the sensor is stuck onto the windscreen.
Removing rain sensor 1755

einordnung
• When sticking a new sensor, make sure that no air pockets are caught between the gel and the
windscreen. Air pockets could impair the function of the sensor.
• Sensor, orientation lights, wires and wiring ducts are spare parts.
If the old rain sensor is installed: begin with the instructions on Page 5.

1 Removing cover of infra−red Remove both covers and unscrew both screws −1− .
interior sensor
2 Line routing Disengage holder −2− for the line −arrow− and pull line
forward behind the headliner.
3 Disconnecting the plug connection Press plugs −3− and pull apart −arrow− .
Removing rain sensor 1756

einordnung
1 Removing cover of rain sensor Unclip the cover −1− of the rain sensor from above.
2 Removing orientation lights Remove orientation lights −2− .
3 Disconnecting the plug Carefully pull out the plug connection −3− out of and apart from
connection the holder.
4 Removing mirror Fold mirror −4− downwards and push down from the bracket.
5 Unclipping rain sensor holder Carefully unclip holder −5− of rain sensor at the top, bottom left
and right.
6 Undoing rain sensor from the Remove rain sensor −6− slowly from the windscreen.
windscreen
7 Pull of adhesive pad If the rain sensor is reinstalled, then slowly pull the adhesive pad
−7− off the rain sensor.
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Installing rain sensor
Installing rain sensor 1757

einordnung
Note
• Observe notes: => Removing rain sensor
• If the removed rain sensor is reinstalled, the surfaces must be free of adhesive residues. Do not use
harsh cleaning agents. Stick the adhesive pad onto the rain sensor at a temperature of approx. 20°C.

1 Sticking on rain sensor Push the rain sensor −6− onto the windscreen.
2 Clip in holder Push and press holder −5− onto the rain sensor until it engages.
3 Push on rearview mirror Push rearview mirror −4− onto the mirror holder from below.
4 Pushing on plug Join the plug connection −3− and insert into the mirror base.
5 Inserting orientation lights Inserting orientation lights −2− into the cover.

einordnung
6 Attaching cover of mirror Join both covers −1− , ensuring that the orientation light is correctly
base positioned.

1 Connecting the plug connection Press the plug connection −3− together.
2 Line routing Engage holder −2− for the line and push in line behind the
headliner.
3 Mounting cover of infra−red Tighten fastening screws −1− and clip in both infra−red
interior sensor interior sensor covers.
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einordnung
Open circuit in the rain sensor connection (emergency interval

operation)
Note
• The rain sensor control module independently detects a faulty rain sensor. Fixed intervals are
allocated to six sensitivity stages (wiping interval stages) as a remedial measure.
1. Ignition on and activate rain sensor.

2. If the windscreen wiper switches on intermittently, the rain sensor or the wiring must be checked
and replaced if necessary.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Open circuit in the rain sensor connection (emergency interval operation) 1760
rain sensor
Note
Removing control module for rain sensor
Installing control module for rain sensor
Safety function in the event of failure (engine blockage)
Note
• The control module for the rain sensor is located under the left cowl panel trim.
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92 13 19 Removing and installing control module for rain sensor 1761

einordnung
Removing control module for rain sensor
WARNING
When working in the area of the wiper link, the ignition key must be removed.

Remove the cover above the battery and fluid tank.
Turn on the windscreen wiper system and when the wiper reaches a vertical position on the
windscreen turn off the ignition.
1 Removal of cover for rain sensor Unscrew fastening screws for cover.
control module Switch on ignition and let wiper link run in end position.
2 Removing plug of rain sensor Remove cover with control module.
control module Open slide control of plug −A− and remove plug −B− .
Removing control module for rain sensor 1762

einordnung
3 Disconnect control module from the Pull the control module out of the cover on the side of the
cover electrical plug connection.
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Installing control module for rain sensor
WARNING
When working in the area of the wiper link, the ignition key must be removed.

1 Connect control Push the control module into the cover, ensuring a secure fit.
module with the cover
2
Installing control module for rain sensor 1763

einordnung
Postioning seal of Place the seal onto the cover and position correctly. If the seal is damaged,
cover replace for safety reasons.
3 Connecting battery Plug in electrical plug connection −B− and lock plug −A− .
4 Mount cover with Put on cover with control module. Switch ignition on and actuate
control module. windscreen wiper, windscreen wipers are vertical, switch off ignition.
Tighten fastening screws.
Ignition on, windscreen wiper runs in end position, ignition off. Tightening
fastening screw.
Install cover for battery and fluid container on the left (cowl panel).
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Safety function in the event of failure (engine blockage)
Note
• Two types of motor blockage can be distinguished in the rain sensor control module:
• 1. The front windscreen wiper does not leave the parking position when activated. If the windscreen
wiper does not move despite the appropriate power supply, actuation of the windscreen wiper motor is
interrupted after 3 seconds.
• 2. The front windscreen wiper locks after leaving the parking position.
• In both cases all operating modes are blocked after a motor block. The system can only be reactivated
after the steering column switch has returned to the >OFF< position.
• If one of these faults is present, replace the rain sensor control module.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651
Safety function in the event of failure (engine blockage) 1764

96 64 32 Converting installation position for tilt
sensor, additional alarm system M536
Note
Tools
Note
• As from model year 2002, the tilt sensor will be installed under the left front seat next to the alarm
control module.
• In vehicles up to model year 2001 inclusive, the tilt sensor is located in the radiator tank to the right of
the battery.
• If a new tilt sensor must be replaced in vehicles produced before model year 2002, the conversion
prcedure described below must be carried out.
• In connection with the the parking assistant control module, a new bracket (from model year 2002), a
new tilt sensor, a bracket for the tilt sensor and a wiring harness will be required for the conversion.
• Disconnect battery ’ 9 Work instructions after disconnecting the battery.
• Use the wiring diagram for the central locking alarm system, sheet 8 / 8A.
1. Remove the battery cover and the right cowl panel cover.
2. Pull off the plug on the tilt sensor.
3. Unscrew the fastening nut −arrow− .
4. Remove the tilt sensor and tie the electrical lead with insulating
tape.
5. Fit the battery cover and the right cowl panel
cover.
96 64 32 Converting installation position for tilt sensor, additional alarm system M536 1765
einordnung
6. Remove the left front seat ’ 720119 Removing and installing front seat, Group 7, Chapter 72−1 .
7. If a control module with parking assistant is installed, remove the bracket. To do so, unscrew the
two fastening screws −arrow− and disconnect both plugs. => Removing and installing control
module for parking assistant
8. Remove the alarm system control module. => Removing and installing control unit for alarm system
9. Disconnect the plug of the alarm control module, open the plug −A− and pull out the pin strip
−B− .
10. Remove pins 38 and 11 with the press−out tool 90207, insulate the lead and tie it to the wiring harness.
=> Tools
11. Push the pin of the grey lead from the service set into the plug for pin 38 until it engages and push
the pin of the grey/black lead into the plug for pin 11 until it, too, engages. => Tools
12. Push the pin strip −B− into the plug sleeve −A− and lock the plug.
96 64 32 Converting installation position for tilt sensor, additional alarm system M536 1766
einordnung
13. Lay the red/brown lead −C− from the service wiring harness to the plug (black) of the alarm system
control module, crimp the lead to the red/brown lead, pin B8 − wiring diagram, external loads, terminal
30 − and insulate the lead. The leads must be watertight. => Tools
14. Insert the plug for the alarm control module and fit the control module to the floorpan.
15. Engage the tilt sensor on the tilt sensor bracket.
16. Insert the service lead plug into the tilt sensor.
17. Fit the parking assistant control module to the new cover −1− with the fastening screws and insert
both plugs into the control module. Pay attention to the new installation position.
18. Insert the tilt sensor −3− into the cover −1− and screw the cover tight to the floorpan using the
fastening screws −arrow− .
19. Lay the lead under the cover, making sure that no electrical lead can be caught when the seat is operated.
20. Install the seat ’ 720119 Removing and installing front seat.
21. Make sure the system is functioning properly with the Porsche System Tester.
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Tools

155−1
2 Press−out tool 155 Workshop Equipment Manual, Gr. 2.4
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Tools 1767
96 87 19 Removing and installing control unit for
alarm system
Removing control unit for alarm system
Installing control unit for alarm system
Teaching control unit for the alarm system
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Removing control unit for alarm system
96 87 19 Removing and installing control unit for alarm system 1768

einordnung
Note
• Only remove the control unit with the battery disconnected => Work instructions after disconnecting
the battery
• Code numbers from IPAS are required.
• In order to prevent possible complications when teaching the transponder and radio codes, use the
spare key as well.
• The control unit for the alarm system can only be taught for one vehicle; a transfer to a different
vehicle is not possible.
Removing control unit for alarm system 1769

einordnung
Remove the left front seat ’ 720119 Removing and installing front seat, 72 − 1.
1 Opening lock Open the lock −1− by turning in the −direction of the arrow− . Take the
control unit out of the bracket and turn it around.
2 Disconnecting the Press connectors −2− together and pull apart.
connectors
3 Disconnecting the Press the locking −arrow− , fold back the lever and pull off the connector
connectors −3− .
Pull off the connector −4− .
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Installing control unit for alarm system
Note
Installing control unit for alarm system 1770

einordnung
• Only install the control unit with the battery disconnected => Work instructions after disconnecting
the battery

1 Inserting the connectors Insert the connector −2− until it engages.
2 Inserting the connectors Insert connector −4− .
Insert connector −3− and move the clip until it engages.
3 Screwing control unit Engage the control unit in the opening on the vehicle floor and close
tight the lock −1− in the −direction of the arrow− .
Installing left front seat ’ 720119 Removing and installing front seat, 72 − 1.
top of page
Teaching control unit for the alarm system
Note
• In order to prevent possible complications when teaching the transponder and radio codes, use the
spare key as well.
• The control unit for the alarm system can only be taught for one vehicle; a transfer to a different
vehicle is not possible. As soon as the immobilizer code has been entered and confirmed, it can no
longer be changed.
• The described teaching process was implemented with Tester version 12.0. Later software versions
may feature expanded contents.
• The instructions or prompts of the Porsche System Tester have highest priority.
• Code numbers from IPAS are required.
1. Switch on the ignition, connect the Porsche System Tester to the vehicle and start the System Tester.
2. Select the menu − Vehicle type −, − Alarm system −, then − Learning functions −.
3. Select the menu − Read out remote controls −, enter the key learning code and confirm with
F7.
4. The Tester confirms that the remote controls have been read.
5. Ignition off, disconnect the battery and remove the control unit.
6. Install the new control unit, connect the battery, switch on the ignition, Alarm system menu, >> ,
Learning functions menu.
7. Select the menu − Immobilizer −, enter the immobilizer code and confirm with F7.
8. Select the menu − Transfer remote controls −, enter the key learning code and confirm with F7.
9. Select the menu − Transponder key −, enter the key learning code and confirm with F7.
Note
Teaching control unit for the alarm system 1771

einordnung
• As the transponder coils must be taught individually, make sure that the allocation of the position is
taught as shown in the IPAS print−out.
10. The Porsche System Tester shows four positions. Under − Current key −, the transponder code of
the inserted key is shown. Check this code is in the same position as on the IPAS print−out and
confirm with F8.
11. Withdraw the key and repeat steps 9 to 10 for the remaining keys.
12. In the menu − Alarm system −, select − Coding −; in the menu Country coding, the respective country in
which the vehicle is used and the vehicle model (sliding roof, Cabrio) can be coded with F8.
13. In the menu − Version coding −, the locking of the doors can be adjusted ’ 9601 Control unit
function, Group 0 Diagnosis .
14. In vehicles with the M−number 536, an alarm siren/tilt sensor is also installed, which must be activated in
the menu − Alarm siren/tilt sensor −.
15. The teaching process has been completed; start the engine.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Teaching control unit for the alarm system 1772

97 89 19 Removing and installing current distributor
Removing current distributor
Installing the current distributor
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Removing current distributor
97 89 19 Removing and installing current distributor 1773

einordnung

Disconnecting Remove the battery cover and the cover of the right radiator tank ’ 702219
battery Removing and installing cowl panel cover.
’ 9 Work instructions after disconnecting the battery.
Disconnect and cover the ground terminal on the battery.
1 Current distributor Pull off the covering cap −1− . Unscrew the B+ connection −2− . Unscrew
fastening fastening nuts −3− .
2 Cover in passenger's Unscrew both plastic screws −4− and remove the cover −5− downwards.
footwell
3 Lowering the Disconnect the tie−wrap −7− from the water drainage −6− and pull off the
current distributor water drainage −6− . Press the current distributor −A− away from the
firewall −arrow− and lower downwards into the passenger's footwell.
4 Opening the current Disengage the lock −arrow− in the direction of the arrow and fold the cover
distributor open. Remove the service label −8− original −green− , after−sales service
−red− or −blue− .
Removing current distributor 1774

einordnung
5 Disconnecting the Mark the connection lines −C− to the relevant fusible element. Disconnect
connection lines connection lines −C− and positive lead B+ −B− . Disconnect tie−wrap −9− .
top of page
Installing the current distributor
Note
• The following spare parts must be installed again:
Hexagon nut M 6, 7 pieces

Hexagon nut M 8, 2 pieces
Service label, red
Depending on condition, flange seal current distributor/firewall
Tie−wraps
Installing the current distributor 1775

einordnung

1 Connecting the Connect the connection lines −C− and the positive lead B+ −B− to the current
connection lines distributor in the correct order. Fasten the lines to the current distributor with the
tie−wrap −9− .
Use the marking, the wiring diagram and new nuts.
M 6 tightening torque: 8 Nm (6 ftlb.)
M 8 tightening torque: 15 Nm (11 ftlb.)
2 Closing and Close the cover until both locking elements −arrow− engage. Affix the service
sealing the label −8− −red− .
current
distributor
3 Installing the Check the flange seal between the current distributor and the firewall for
current damage and replace, if necessary. Push the current distributor −A− into place
distributor between the heating/air−conditioning unit and the firewall. Move the current
distributor in the −direction of the arrow− until the studs of the current
distributor −A− fit into the firewall.

einordnung
Connect the water drainage −6− and fasten with a tie−wrap −7− .
4 Screwing the Tighten both hexagon nuts −3− . Connect the B+ lead −2− and screw into place
current with a new M 8 hexagon nut.
distributor tight M 8 tightening torque: 15 Nm (11 ftlb.)
Press cover cap −1− on.
5 Cover in Position the cover −5− from below and screw tight with the two fastening
passenger's screws −4− .
footwell
Connecting the ’ 9 Work instructions after disconnecting the battery.
battery
Installing the ’ 702219 Removing and installing cowl panel cover.
cowl panel cover
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

97 92 19 Removing and installing fusible element in
the current distributor
Removing fusible element from the current distributor
Installing fusible element in the current distributor
top of page
Removing fusible element from the current distributor
=> Removing current distributor
1. Remove cover for current distributor and remove the service

label.
2. Carefully lever off the cover −A− , e.g. with a screwdriver −arrow− . This will break the locking tabs and
the cover can be removed.
3. Remove the broken locking tabs from the current distributor.
97 92 19 Removing and installing fusible element in the current distributor 1778

einordnung
4. Unscrew the two hexagon nuts M 5 −3− from the blown fusible element −1− and remove with the
washers −2− .
top of page
Installing fusible element in the current distributor
Note
• The following spare parts must be replaced.
Hexagon nut M 8, 1 piece

Repair kit − replacement fusible element
1. Insert new fusible element −1− , using new washers −2− and new hexagon nuts −3− M 5.
2. Position and engage the blue after−sales service cover −A− .

3. Close the current distributor cover until it engages −arrow− .
4. Affix the blue service
label.
5. => Installing the current distributor
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Removing fusible element from the current distributor 1779

911 Turbo (996) Technical Manual
General
Structure
Breakdown of Repair Groups
Legend for structure of sequence description
Structure of exploded view
Structure of sequence description
top of page
General
The Technical Manual Repair describes all essential work operations requiring special instructions to
ensure that repairs are performed properly. It should be in the hands of the workshop foremen and the
workshop personnel, as careful compliance with the stated instructions is a precondition for maintaining the
traffic and operating safety of the vehicle. In addition, of course, the generally customary basic safety rules for
the repair of motor vehicles are unrestrictedly applicable.
top of page
Structure
• Overview of repair groups
• Table of Contents
• Technical data / general
• Description of repairs
top of page
Breakdown of Repair Groups
• Tools, special tools and materials required for repair
• Exploded drawings and illustration of sequence
• Legend for exploded drawing and description of sequence
• Instructions for assembly and adjustment
The Technical Manual is regularly expanded by supplements, which must be incorporated immediately to
preserve the usefulness of the Manual. As verification of completeness, the record sheet should be completed.
top of page
Legend for structure of sequence description
911 Turbo (996) Technical Manual 1780

einordnung
A Repair Group, number

B Repair Group, number
C Repair group, text
D Vehicle type
E Page number
F Internal Porsche number
G Work operation, consisting of ''After−sales service number'' and ''Title''
H Imprint, year of printing
I Title of legend for structure
J Structure of legend
N Structure of legend
top of page
Legend for structure of sequence description 1781

einordnung
Structure of exploded view

D Vehicle type
E Page number
I Title of exploded drawing
J No. of exploded drawing, in order of disassembly
K No. of exploded drawing, in order of disassembly
Structure of exploded view 1782

einordnung
M Description or explanation of procedure
top of page
Structure of sequence description

D Vehicle type
E Page number
Structure of sequence description 1783

einordnung

I Title of structure sequence description
J Sequence number, in order of sequence
K Sequence number, in order of sequence
L Procedure in the sequence
M Description or explanation of procedure
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Structure of sequence description 1784

97 Wiring diagram for 911 Turbo (996), 01 model
Contents
Sheet 1 Lights RoW
Sheet 1A Lights USA / Canada
Sheet 2 Instrument cluster / sensor
Sheet 2A Spoiler
Sheet 3 Wiper and washer system, headlight cleaning system, rear window wiper
Sheet 3A Wiper and washer system, headlight cleaning system, rain sensor
Sheet 3B Two−tone horns
Sheet 4A Climatronic
Sheet 5 Mirror adjustment, heated rear window
Sheet 5A Memory
Sheet 6 Sliding roof
Sheet 7 Power windows
Sheet 8 Central locking, alarm system (LHD)
Sheet 8A Central locking, alarm system (RHD)
Sheet 9 Airbag, POSIP (LHD)
Sheet 9A Airbag, POSIP (RHD)
Sheet 10 ABS − GT2
Sheet 10A PSM
Sheet 11 Tiptronic
Sheet 11A Seat
Sheet 11B Transmission cooling − GT2
Sheet 12 DME vehicle area
Sheet 12A DME engine area
Sheet 13 Radio for standard GT2
Sheet 13A Radio, sound package
Sheet 14 Parking assistant
Sheet 15 Info/ navigation system PCM
Sheet 15A Telephone, telephone preparation
Sheet 16 Power supply
Sheet 16A Power supply − GT2
Sheet 17 Ground points (LHD)
Sheet 17A Ground points (RHD)
Sheet 26 Relay carrier, assignment, jumper plugs
Sheet 27 Fuse assignments
The wiring diagram consists of individual wiring diagrams and overview sheets for ground points,
components, plug connections, connection points, relay carriers and fuses. The individual wiring diagrams are
subdivided into coordinate fields.
The ground points are identified with GP and their locations are shown in a vehicle diagram.
97 Wiring diagram for 911 Turbo (996), 01 model 1785

einordnung
The plug connections are identified with X and a number.
In the case of wires that branch off onto another sheet, the coordinates and, in some cases, the terminal
designations are specified.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

97 Wiring diagram for 911 Turbo (996), 02 model
Contents
Sheet 1 Lights RoW
Sheet 1A Lights USA / Canada
Sheet 2 Instrument cluster / sensor
Sheet 2A Spoiler
Sheet 3B Two−tone horns, cigarette lighter
Sheet 4 Heating
Sheet 5 Mirror adjustment (LHD)
Sheet 5A Memory (LHD)
Sheet 5B Mirror adjustment (RHD)
Sheet 5C Memory (RHD)
Sheet 5D Seat
Sheet 10A PSM
Sheet 11 Tiptronic
Sheet 11A Transmission cooling
Sheet 13 Radio for standard GT2, radio preparation
Sheet 13A Harman sound package − analog
Sheet 13B Bose sound package − analog
Sheet 14 Parking assistant
Sheet 15 Info/ navigation system PCM
Sheet 15A Telephone, mobile phone − analog

einordnung
Sheet 22 Components
Sheet 23 Plug connections, abbreviations
Sheet 24 Connection points / plug
Sheet 25 Overview of plugs
Sheet 28 Vehicle overview
The wiring diagram consists of individual wiring diagrams and overview sheets for ground points,
components, plug connections, connection points, relay carriers and fuses. The individual wiring diagrams are
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

97 Circuit diagram for 911 Turbo (996), '03 model
Contents
Sheet 1 Lights RoW
Sheet 1A Lights USA/Canada
Sheet 2 Instrument cluster/sensor
Sheet 2A Spoiler
Sheet 5D Seat
Sheet 10A PSM
Sheet 11 Tiptronic
Sheet 11A Transmission cooling − GT2
Sheet 13A Harman sound package − digital
Sheet 13B Bose sound package − digital
Sheet 13C CD changer
Sheet 14 ParkAssist
Sheet 15 Info/navigation system PCM2
Sheet 15A Telephone, mobile phone
Sheet 15B Telephone
97 Circuit diagram for 911 Turbo (996), '03 model 1789

einordnung

Sheet 22 Components
Sheet 24 Connection points/plug
Sheet 26 Optical wave guide, left−hand drive, sheet 1 of 2
Sheet 26 Optical wave guide, right−hand drive, sheet 2 of 2
Sheet 27 Antenna leads, left−hand drive, sheet 1 of 2
Sheet 27 Antenna leads, right−hand drive, sheet 2 of 2
The circuit diagram consists of individual circuit diagrams and overview sheets for ground points,
components, plug connections, connection points, relay carriers and fuses. The individual circuit diagrams are
The ground points are identified by GP and their locations are shown in a vehicle diagram.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Contents
Sheet 1 Lights RoW
Sheet 2A Spoiler
Sheet 3A Wiper and washer system, rain sensor
Sheet 5D Seat
Sheet 6A Cabriolet power−operated convertible top
Sheet 7A Power windows, Cabrio
Sheet 10 ABS 5.7 − GT2
Sheet 10A PSM
Sheet 11 Tiptronic
Sheet 14 ParkAssist
Sheet 15B Telephone

einordnung

Sheet 22 Components
Sheet 24 Connection points/plug
996420, 996421, 996450, 996451, 996840, 996841, 996620, 996621, 996650, 996651

Contents
Sheet 1 Lights RoW
Sheet 2A Spoiler
Sheet 3A Wiper and washer system, rain sensor
Sheet 5D Seat
Sheet 6A Cabriolet power−operated convertible top
Sheet 7A Power windows, Cabrio
Sheet 10 ABS 5.7 − GT2
Sheet 10A PSM
Sheet 11 Tiptronic
Sheet 14 ParkAssist
Sheet 15B Telephone

einordnung

Sheet 22 Components
Sheet 24 Connection points/plugs
In the case of lines that branch off onto another sheet, the coordinates and, in some cases, the terminal
996420, 996421, 996840, 996841, 996620, 996621

Preconditions for using workshop documentation for
Porsche vehicles
This data comprises technical information as well as instructions on repairs for Porsche vehicles and
documentation for training purposes. The descriptions are intended for the exclusive use by workshops and
their workshop staff.
Note
• The Dr. Ing. h.c. F. Porsche AG retains sole ownership of the copyright.
• It may not be transmitted to third parties.
• Graphics and text may not be duplicated or used in other electronic or printed publications without the
express consent of the Dr. Ing. h.c. F. Porsche AG.
General preconditions for repairing Porsche vehicles

The descriptions form the basis for professional and correct maintenance and repair work. The content of the
work procedures described is based on the level of training of a fitter with a sound knowledge of the product.
The fitter must have obtained knowledge of the product at training programs and courses offered by the Dr.
Ing. h.c.F. Porsche AG which are specific to the product and assembly before carrying out any of the work.
This level of knowledge is the precondition for carrying out the work described. The Dr. Ing. h.c. F. Porsche
AG will not be held liable if the described repair work is carried out without this knowledge.
Preconditions for body work on Porsche vehicles
The described repair work only applies to standard cases. Body repairs must only be carried out by skilled
persons who are specialised for such work. Given the overall picture of the damages, the workshop itself must
decide whether it is possible to return the vehicle to its proper condition. Repair works on Porsche vehicles
must be carried out with the tools and workshop equipment recommended and approved by the Dr. Ing. h.c. F.
Porsche AG. All body repair work must be carried out correctly and according to the Dr. Ing. h.c. F. Porsche
AG instructions for sheetmetal, paint and corrosion protection/preservation work.
Warning notes and safety instructions
The warning notes and safety instructions are classified by the respective signalising word (Danger, Warning,
Caution) beside the warning symbol.
DANGER
Warns against death or very serious injury which will certainly occur if the instructions are not observed.
WARNING
Warns against death or very serious injury which may occur if the instructions are not observed.
CAUTION
Warns against minor injury or damage to property if the instructions are not observed.
To prevent injury and restricted operating and traffic safety of the vehicle, or damage to the vehicle as the
result of incorrect work, read these warning notes and safety instructions carefully and observe them without
fail.
It is not possible for Dr. Ing. h.c. F. Porsche AG to give a detailed evaluation of all danger situations for the
persons carrying out the work. It is therefore imperative that all persons carrying out repair and maintenance
work on Porsche vehicles use their specialist knowledge to ensure that their own safety is not at risk and the
procedure chosen will not have any negative effects on the vehicle − especially with regard to safety.
It is therefore expressly specified that all work involved in the work procedures described should be carried
out only in accordance with the valid guidelines and regulations of the local authorities responsible with
Preconditions for using workshop documentation for Porsche vehicles 1795

einordnung
respect to health and accident prevention and environmental protection, and in compliance with the applicable
legal requirements and regulations.
Notes
Notes contain advisory information related to the work procedure which makes the fitter's work easier. The
following pictogram indicates this information:
Note
• Contains advisory information which makes the work procedure easier.
Due to the continuous development and improvement of our vehicles, there may be discrepancies between the
actual technical status of the vehicles and the work descriptions. Any existing deviations are corrected by
means of supplements, and the scope of the descriptions is extended with supplements.
The Dr. Ing. h.c. F. Porsche AG retains the right to implement changes at any time and without prior notice.
9paad1, 9paad7, 9paae1, 9paae7, 9paaf1
Preconditions for using workshop documentation for Porsche vehicles 1796

01 Mobile roofs: checking function
Checking sliding roof
Checking convertible top
Checking the hardtop
top of page
Checking sliding roof
1. Check sliding roof when opening and closing for function and noises.
top of page
Checking convertible top
1. Remove hardtop if
present.
2. This is done by pressing on the key with remote control (symbol button). Hold it in the unlocking position
until the convertible top has reached its final position or until the door windows are in the desired position.
Note
• Check that it is seated securely, which involves manually moving component against component.
3. Check the left and right front locating pegs on convertible top to ensure that they are secure and
functioning properly.
4. Check the convertible−top peg housing on cowl panel frame to ensure that it is secure and functioning
properly.
top of page
Checking the hardtop
Note
• Check that it is seated securely, which involves manually moving component against component.
1. Remove hardtop if
present.
2. Check the left and right front locating pegs on hardtop to ensure that they are secure and functioning
properly.
3. Check the front hardtop lock to ensure that it is secure and functioning
properly.
4. Check the rear hardtop lock on the left and right to ensure that it is secure and functioning properly.
5. Check the convertible−top peg housing on cowl panel frame to ensure that it is secure and functioning
properly.
01 Mobile roofs: checking function 1797

einordnung
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631
Checking the hardtop 1798

01 Glazing: visual inspection for damage
1. Visual inspection for film residue when removing the transport protection
2. Visual inspection for scratches and chips caused by flying
stones.
3. Visual inspection for damage to surrounding section or rubber profile of
glazing
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
01 Glazing: visual inspection for damage 1799

top of page
Check that the lid locks engage by insertion of the lock upper parts when the lids (front and rear) are
closed and that they disengage again when the lid releases are pulled.
top of page
1. Check that the front lid is held down by the lower part of the lock of the safety hook after the lid lock is
opened.
2. Check whether the return spring on the lower part of the lock pulls back the safety hook as far as the stop.
top of page
Check that the door lock engages in two stages through the locking wedge when the doors are closed and
that it disengages again when the door handle is operated (inside and outside).
top of page
Lock
vehicle.
Check that the tank cap lock locks the tank cap in the closed position.
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
01 Checking lid and doors 1800

01 Interior equipment: visual inspection for damage
and soiling
2. Visual inspection for scratches and
scoring
3. Visual inspection for soiling of interior equipment
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
01 Interior equipment: visual inspection for damage and soiling 1801

01 Removing transport protection
1 Removing external transport protection
1 Removing internal transport protection
top of page
1 Removing external transport protection
Installation Material 996 996 996 996
location Turbo GT2 C4S Turbo
Cabriolet
Front lid PP film, X XX X X
white
Rear lid PP film, X
white
Roof / PP film, X X X X
Hardtop white
Targa roof excluding
frame protection
Left and PP film, X X X X
right wing. white
Side panel PP film, X X X X
left and white
right.
Side PP film, X X X X
member white
Aerokit on
the driver's
side
Left and PP film, X X X X
right doors. white
Doors, PE profile X X X X
left/right strip
Styrodur
strip
Front Styropor X X X X
bumpers block
Rims 1) PVC EVA X X X X
film
Convertible non X
Top woven +
PEVA
Softtop X
cover
2)
01 Removing transport protection 1802

einordnung
1) Rim protection cover only in USA, Canada, Japan, Great Britain
2) Only overseas
top of page
1 Removing internal transport protection
Installation Material 996 Turbo,
location C4S, GT2,
Turbo
Cabriolet
Seats (front) PE film
X
covering
Inner sill IKS adhesive
X
tape, blue
Inner side Polypropylene
X
member film
Door trim panel TESA
at bottom transparent X
(loudspeaker) film, red
Footwell Cardboard
X
insert
Steering wheel Film covering X
Parking brake Cardboard
X
protection
PCM Film on the
X
display
Instrument cluster Cover X
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
1 Removing external transport protection 1803

01 Installing air guides for PCCB brake discs − GT2
Note
Installing front air guides
Installing rear air guides
Note
• The air guides (brake−air spoiler) on the front suspension of GT2 vehicles with PCCB brakes are
larger than those of a conventional brake system! Exclusively for PCCB brakes, air guides (brake−air
spoiler) are also mounted on the rear suspension!
• These air guides are not mounted during transport!
CAUTION
Damaged, worn or missing aerodynamic components such as spoilers or underside panels affect the driving
behaviour and therefore must be replaced immediately!
• Spoilers and undersides must therefore be regularly checked for damage!

• Please inform the customers concerned about this!
top of page
Installing front air guides
1. Mount the air guide (brake−air spoiler) on the front control arm (clip in similar to the standard air spoiler
on the Carrera 996 and Turbo 996). Then insert the expansion rivet (included in the scope of delivery) into
the bore present −arrow− . In vehicles with the model year 01, the bore −arrow− must also be drilled in
the wheel housing liner behind (drill 8mm through the existing bore).
2. Mount the air guide in the same manner on the other side of the vehicle.
top of page
Installing rear air guides
01 Installing air guides for PCCB brake discs − GT2 1804

einordnung
1. Push air guide (brake−air spoiler) onto the lower rear axle control arm from the front.
Subsequently fit the retaining clip −2− (included in the scope of delivery) from the rear. The
retaining clip −2− must be inserted into the slot of the air guide −arrow− at the top.
Connect the retaining clip −2− to the air guide −1− . To this purpose, push the three expansion rivets −3−
(included in the scope of delivery) into the bores drilled in the bracket and the air guide (two from above
and one from behind).
Note
• The illustration shows the rear of the air guide −1− (removed)!
• The left and right air guide −1− and retaining clip −2− differ from eachother!
2. Mount the air guide in the same manner on the other side of the vehicle.
996840, 996841
Installing rear air guides 1805

01 Fitting front lip GT2
The 911 GT2 is lowered by approx. 30 mm as standard to lower the centre of gravity of the vehicle. The front
lip is not fitted on the vehicle for protection when loading or unloading the vehicle. The front spoiler and
fastening screws included with the vehicle must be fitted.
Note
• Lift the vehicle on a lifting platform to fit the front spoiler.
1. Insert the front spoiler −1− into the groove on the front end. Ensure that all locking tabs have
engaged.
2. Place the sheetmetal nut −5− in position on the front end. Use the fastening screws −4− and spacer
sleeves −3− to tighten the front spoiler at the sides to the wheel housing liner −2− .
996840, 996841
01 Fitting front lip GT2 1806

01 Fitting six−point seat belt GT2
The six−point seat belt is not fitted on vehicle delivery for the Club Sport equipment.
1. Loop technique for fastening

the seat belt to the bucket seat
cross member
Loop the belt strap in the direction of the arrow −inset− around the front transverse strut on the bucket
seat into the adjustible slider. The projection −dimension = X− of the belt strap must be at least 100
mm.
2. Pulling six−point seat belt through the openings in the bucket seat
Pull six−point seat belt through the upper openings in the backrest from behind −arrow A− and
through the openings in the seat frame from the side −arrow B− .
3. Fitting belt fitting

Position foam part −4− and belt fitting −5− at the left and right on the seat frame. With the shim −3−
and the fastening screw −2− , screw the belt fitting −5− tight. Position the cover −1− on the fastening
screw −2− .
Use the foam part −4− for the Club Sport
version.
For the Cup racing version, mount the bushing −6− instead of the
foam part.
01 Fitting six−point seat belt GT2 1807

einordnung

cross member
a. Loop the belt strap in the direction of the arrow −inset− around the transverse strut on the roll cage
into the adjustible slider. The projection −dimension = X− of the belt strap must be at least 100 mm.
b. Roll up the projecting belt strap and bind it with a tie
wrap −1− .
996840, 996841
01 Fitting six−point seat belt GT2 1808

01 Checking the Vehicle Ident. No.
Check that the Vehicle Ident. No. is correct.
• Check the Vehicle Ident. No. on the lower left windscreen in direction of travel.
• Check the Vehicle Ident. No. in the front right luggage compartment.
• Check the Vehicle Ident. No. on the data bank self−adhesive label in front inner cover.
• Stick the lower data bank self−adhesive label on the front inner cover in the on−board literature
(Guarantee and Maintenance booklet).
• Check the Vehicle Ident. No. in the vehicle registration documents.
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
01 Checking the Vehicle Ident. No. 1809

01 Checking the exterior equipment and paint finish
Checking exterior equipment
Checking paint finish
top of page
Checking exterior equipment
Check for surface damages, dents, bulges or secure fitting of accessories such as front door mirrors,
and rear spoiler, door, front and rear cover.
top of page
Checking paint finish
Check for scoring, scratches, notches, scrapes, pores, bubbles, distinguishing marks in
paint.
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
01 Checking the exterior equipment and paint finish 1810

01 Completing vehicle and checking equipment for
completeness
Note
Checking vehicle equipment for completeness
Completing the vehicle
Note
• Country−specific equipment can be obtained from the relevant national importer!
top of page
Checking vehicle equipment for completeness
Allocation
Designation 911 (996)
911 C4S (996) Country−specific
Turbo GT2
Coupe Cabrio Coupe Cabrio Japan Europe Germany
Warning triangle X X X X X X
Emergency kit X X X X X X
Tool case X X X X
Tools => Tools
Socket for security wheel bolts X X X X X
Car jack X X X X
Vehicle key set X X X X X
Flare and flare holder X X X X X X
On−board information folder with
technical contents
=> Completing the vehicle
Driver's Manual, PCM/CDR,
Guarantee and Maintenance booklet
Windstop X X
Collapsible wheel X X X X
Compressor X X X X X
Sealant surface for tyres X
Tools
01 Completing vehicle and checking equipment for completeness 1811

einordnung
Allocation
Designation 911 (996)
911 C4S (996)
Turbo GT2
Coupe Cabrio Coupe Cabrio
Open−ended wrench X X X X X
Towing lug X X X X X
Screwdriver X X X X X
Plastic gloves X X X X X
Socket wrench for fitting main headlight X X X X X
Assembly aid for mounting wheels (aluminium bar with threads) X X X X X
Pipe socket wrench X X X X
Lever bar X X X X
Plastic bag X X X X
Two assembly aids for mounting wheels (aluminium bar with
X X X
threads) for vehicles with Ceramic Composite Brakes
Allen socket wrench for emergency unlocking under the trim
X X
operating buttons for sliding roof
Allen socket wrench for emergency unlocking behind the rear
X X
emergency seat trim
top of page
Completing the vehicle
On−board information folder with technical contents (Driver's Manual, Guarantee and
Maintenance booklet) are supplied by dealers or importers, except in German−speaking
countries.
PCM/CDR operating instructions and Navigation CD are supplied by dealers or importers, except in
German−speaking countries.
996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631,
996840, 996841
Tools 1812
3 Technical Data − GT2
top of page

G 96.88 − 6−speed GT2 (996) 2001

1. gear 11 : 42 = 3.82
2. gear 21 : 43 = 2.05
3. gear 27 : 38 = 1.41
4. gear 34 : 38 = 1.12
5. gear 37 : 34 = 0.92
6. gear 40 : 30 = 0.75
Filling capacity for new filling 3.7 l + 0.1 l
Change quantity 3.7 l + 0.1 l
3 Technical Data − GT2 1813

einordnung
Manual transmission tightening torques

Drain plug for transmission oil M22 x 1.5 30 (22 ftlb.)
Filler plug for transmission oil M22 x 1.5 30 (22 ftlb.)
Transmission on engine M10 45 (33 ftlb.)
Air flanges on transmission M6 10 (7.5 ftlb.)
Bracket for clutch control shaft on transmission M6 x 16 10 (7.5 ftlb.)
Guide tube for release bearing on transmission housing M6x14 10 (7.5 ftlb.)
Transmission support to transmission mount M10 65 (48 ftlb.)
Transmission support to body M10 65 (48 ftlb.)
Collar nut/halfshaft flange M20 x 1.5 120 (88.5 ftlb.)
996840, 996841
Manual transmission tightening torques 1814

4 Running gear, general − GT2
General
top of page
General
The 911 GT2 is available in the road version M002 and in a Club Sport version M003. The vehicle height of
both designs (M002 and M003) is approx. 20 mm less than the 911 Turbo (996).
The 911 GT2 differs from the 911 Turbo (996) through a newly shaped front end with enlarged air inlet
openings for the chilled−air supply of the radiators and of the front−wheel brakes.
Moreover, the 911 GT2 is equipped with a large, non−retractable rear spoiler. The rear spoiler has a manually
adjustable spoiler wing.
The Club Sport design (M 003) possesses a removable roll cage. The roll cage includes the spring strut
supports on the rear axle for stability. This further improves precise guidance of the rear wheels.
4 Running gear, general − GT2 1815

einordnung
The 911 GT2 is equipped as standard with the new Porsche Ceramic Composite Brake (PCCB). The brake
calipers, 6−piston on the front axle and 4−piston on the rear axle, are painted yellow.
The running gear of the 911 GT2 has been designed for an extremely sporty driving behaviour and superior
handling properties. Basically, the running gear of the 911 GT3 (996) has been taken over and adapted to the
specific new requirements (vehicle weight and driving performance).
Moreover, the GT2 is subject to special demands due to the possibility of its use for racing purposes.
These include:
• Lowering of the vehicle's centre of gravity with co−ordinated adjustment of the kinematics
• Adjustable stabilizers
• Extension of the adjustment range of the axle geometry for racing purposes and the related specific
requirements (e.g. camber)
• Reinforcement of relevant components (e.g. wheel carrier and front wheel bearing) for possible use of
racing tyres (on the racing track)
• Optimisation of wheel guides (especially rear axle).
Note
• The 911 GT2 is delivered with a running−gear setting co−ordinated with the tyres approved by
Porsche!
• If these setting values are changed in a manner only permissible for use on racing tracks, it is essential
that the standard settings are reset before the vehicle is driven on public roads!
• Attention: The adjustable spoiler (additional wing) is set to the lowest (horizontal) position for street
use!
• Changes to the setting to match the personal driving style are intended only for the racing track!
• The spoiler wing must be moved to the lowest position for use on public roads!
996840, 996841
General 1816
4 Notes on repair instructions − GT2
General
Tightening torques
Adjustment operations on the spring struts
Suspension alignment
Wheel removal/installation
Brake − General
Brake booster
top of page
General
The 911 Turbo (996), and also the 911 GT2, is the basic model covered by the repair, assembly and
adjustment operations in the "911 Carrera (996)" Technical Manual. Only the GT2−specific procedures which
deviate from this are additionally described in this Technical Manual.
top of page
Tightening torques
Tightening torques for the 911 Turbo (996) and 911 GT2 are almost the same. Tightening torques that deviate
or are additional are contained in the tables of the appropriate Repair Group for the 911 Turbo (996).
top of page
Adjustment operations on the spring struts
The front and rear axle spring strut has a thread and a height adjusting nut −2− for height adjustment. The
height adjusting nut −2− is secured against turning by the lock nut −1− . The stabilizer block (mounting
saddle for the stabilizer mount) −4− is also fitted on the thread. The stabilizer block can be vertically adjusted
and it is provided with a lock nut −3− . This adjustment possibility is only useful for racing. It can be used to
ensure that enough clearance is available for the stabilizer mount even for deviating vehicle heights (only for
racing) and also that the stabilizer mount can be fitted free of tension. The stabilizer block −4− does not need
to be adjusted for the vehicle height prescribed for street use. The stabilizer block is also adjusted for
replacement dampers.
Front axle
1. Lock nut
4 Notes on repair instructions − GT2 1817

einordnung
2. Height adjusting nut

3. Lock nut
4. Stabilizer block
Rear axle
1. Lock nut
2. Height adjusting nut
3. Lock nut
4. Stabilizer block
Note
• The special tool 9647 is required together with a torque wrench in order to adjust the vehicle height!
Description under 911 GT2 suspension alignment in Repair Group 44.
• The stabilizer block is also adjusted for replacement dampers!
top of page
Suspension alignment
The adjustment procedures and values on the front and rear axle differ in a number of respects from those of
the 911 Turbo (996).
Adjusting values in Repair Group 44.
The suspension alignment of the 911 GT2 is described after the suspension alignment of the 911 Turbo (996).
top of page
Wheel removal/installation
As the GT2 is equipped with PCCB (Porsche Ceramic Composite Brake), use assembly aids (assembly pins)
for wheel removal/installation, in order to exclude any possibility of heavy contact of the wheel with the brake
disc!
The assembly aids (2 assembly pins) are located in the luggage compartment!
Adjustment operations on the spring struts 1818

einordnung
Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub. During removal, first
remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the brake discs!
top of page
Brake − General
The brake fluid change is the same as with the 911 Turbo (996).
Bleeding of the GT2 is described in a new chapter.
The 911 GT2 is equipped as standard with the new Porsche Ceramic Composite Brake (PCCB). The brake
calipers, 6−piston on the front axle and 4−piston on the rear axle, are painted yellow.
The GT2 is equipped with 3−channel ABS (ABS 5.3) without PSM and without TC (Traction Control).
Because of the larger brake−disc diameter in the PCCB, the fastening screws of the front−axle and rear−axle
brake calipers are 85 mm long and gold−coloured to differentiate them.
top of page
Brake booster
When replacing the brake booster, observe the correct allocation according to the Spare Parts catalogue!
Altered transmission ratio (boost factor) compared to the 911 Turbo (996).
Boost factor 911 GT2 = 3.15 : 1. Boost factor 911 Turbo (996) = 3.85 : 1.
996840, 996841
Wheel removal/installation 1819

4 Tests / notes GT2
Note
Lifting platform / test stands
Wheel alignment platform
Brake test
Power test
Front and rear stabilizer setting
Spoiler setting
Racing camber values
top of page
Note
The tests and notes apply to the street version (base version) M002 and to the Club Sport version M003.
Suspension alignment 911 GT2 see Repair Group 44.
top of page
Lifting platform / test stands
Ensure clearance of the spoiler(s) and side members when driving onto lifting platforms and wheel alignment
platforms!
top of page
Wheel alignment platform
It is only possible to drive onto wheel alignment platforms if additional access ramps, for example 959 access
aids, are used!
A platform without a sloped position is unsuitable!
top of page
Brake test
Brake tests can only be carried out on roller−type test stands or plate test stands.
When driving onto the brake test stand, make sure to drive on as carefully as possible, especially during
compression. This helps to prevent the vehicle from bottoming out.
top of page
Power test
A power test is not permissible or possible!
top of page
4 Tests / notes GT2 1820

einordnung
Front and rear stabilizer setting
CAUTION
There will be alterations in the handling if the stabilizer standard setting is changed!
• The standard setting must not be changed for use on public roads!
• Attention: Changes to the setting to match the personal driving style are permissible only for the
racing track!
The front and rear stabilizers can be individually adjusted by means of 5 bores at the front and 4 bores at the
rear.
The front stabilizer with 26.8 x 4 mm diameter was adjusted (fitted) at the production launch to the center
position (position 3). This setting was modified in the current model year 2002. New/current adjustment:
Position 4 −arrow− . The new adjustment (Position 4) can also be used −arrow− for vehicles with a Stabi
center position (position 3)!
The rear stabilizer with 20.7 x 2.8 mm diameter is adjusted (fitted) to the second hardest position (third bore)
−arrow− .
This standard setting must not be changed for use on public roads! Attention: Changes to the setting to
match the personal driving style are permissible only for the racing track!
Adjustment/fitting of the GT2 road version: GT2 = 3rd bore −arrow− (GT3 = 2nd bore).
top of page
Spoiler setting
• The spoiler wing is set to the lowest (horizontal) position for street use!
• Changes to the setting are only intended for the racing track. The spoiler wing must be moved to the
lowest position for use on public roads!
top of page
Front and rear stabilizer setting 1821

einordnung
Racing camber values

• Front and rear racing camber values should only be adjusted for use on racing tracks!
• Only the values listed in Repair Group 44 are permitted for use on public roads!
996840, 996841
Racing camber values 1822

44 Alignment card − GT2
Porsche measurement of running gear
Customer: Rep. Order No.:
Street: Vehicle Ident No.:
Place: Licence number:
Telephone: Date of first registration:
Odometer reading: km/miles
Measurement made by: Date / signature:
Vehicle: 911 GT2 (996) M002 and M003 Model:
Measurement prerequisite (vehicle weight): Empty weight as in DIN 70020.
This includes: full fuel tank and vehicle with tools.
Reason for measurement:
Make of tires: Size/model at front: Rear:
front left front right rear left rear right
Tire pressure of cold tires (bar)
Tire/wheel (any damage)
Tires − tread depth (mm)
Incoming measurement Nominal values/ Outgoing measurement

(max. Difference,
left/right ’)
Vehicle height:
Front (mm) left/right
Rear (mm) left/right
Rear axle:
Camber left/right − 1° 50' ± 5' /
(max.10' ’)
Toe left/right + 13' ± 2' / (max. 5'
’)
total + 26' ± 4'
Drive−axle angle 0° 00' ± 5'
Front axle:
Caster left/right 8° ± 30' / (max.40'
’)
Toe−difference angle left − 1° 50' ± 30'
right − 1° 50' ± 30'
Camber left/right − 1° ± 5' / (max. 10'
’)
Toe left/right + 4' ± 1'
total + 8' ± 2'
44 Alignment card − GT2 1823

einordnung
Since mainly electronic wheel−alignment testers in conjunction with printers are used, a specimen alignment
card is rarely required nowadays. In order for measured results to be documented in individual cases,
however, a copy of the alignment card shown above can be used.
Note
• In practice this means that alignment cards cannot be ordered!
• The alignment cards can be used for all 911 GT2 (996), M002 = street vehicle and M003 = Club
Sport version!
1. Prepare copies of the corresponding alignment card shown.

2. Before measurement, enter the general data, vehicle model and the missing nominal values into the
copied alignment card.
Note
• Actual values that are identical in all versions have already been entered!
3. Enter the appropriate version, e.g. M002 or M003, in the Model column.
4. Carry out incoming measurement (actual state) and enter the values in the alignment card!
5. After adjustments (if these were necessary), enter the actual values in the column Outgoing
measurement.
996840, 996841
44 Alignment card − GT2 1824

Suspension alignment − GT2
Suspension alignment, complete
Driving onto measuring platform
Tools
Deviating points for GT2
Notes on height changes/wheel−load changes
Vehicle height GT2
Wheel alignment
Instructions for fitting diagonal control arm on control arm GT2
top of page
Suspension alignment, complete
Note
• The 911 GT2 suspension alignment contains only those procedures which deviate from those for the
911 Turbo (996) suspension alignment.
top of page
Driving onto measuring platform
Due to the reduced vehicle height, additional access ramps, for example 959 access aids, are required to drive
the vehicle onto the measuring platform. Otherwise the front spoiler would bottom on the platform. A
measuring platform without a sloped position is unsuitable.
top of page
Tools
The special tools for suspension alignment of the 911 Turbo (996) are also used for the 911 GT2.
Additionally, a hook wrench insert (special tool 9647) is required for the 911 GT2. The special tool 9647 is
required to change the vehicle height and to adjust the stabilizer mating bearing on the front and rear axle. The
special tool is used together with a torque wrench to tighten the lock nuts (slotted nuts) on the spring struts.
Tightening torques in Repair Group 40/42.
Suspension alignment − GT2 1825

einordnung
Special tool 9647
top of page
Deviating points for GT2
In the description of the 911 GT2 suspension alignment, only those points are listed which differ from the 911
Turbo (996).
These are:
• Changed adjustment values.

• Front−axle camber setting: Unlike the 911 Turbo (996), a basic camber adjustment is made by means
of intermediate plates on the 2−part control arm of the front axle for the 911 GT2. A 1 mm thick
adjustment plate is fitted as standard on the right and left in the 911 GT2 (M002 and M003)! Camber
adjustment (fine adjustment) is carried out at the spring−strut mount as for the 911 Turbo (996).
• For the measured−value pickups, electronic wheel alignment testers require spoiler adapters of 50 mm
and 100 mm in length, depending on the wheel alignment tester. This is the only means of enabling
data transfer from the right side to the left. The wheel alignment testers recommended by Porsche
which have a spoiler measuring program require 100 mm spoiler adapters on the rear axle. Observe
the operating instructions from manufacturer of the measuring instrument if necessary!
• In the case of the 911 GT2, the vehicle height can be adjusted on the front and rear axle using the
adjusting nut(s) at the corresponding spring strut(s). Max. wheel−load difference to right and left on
the front and rear axle is 15 kg.
• Check all wheels for clearance after adjustment and assembly work!
Note
• If a wheel removal is necessary, use assembly aids (assembly pins) in order to exclude any possibility
of heavy contact of the wheel with the brake disc! The assembly aids (2 assembly pins) are located in
the luggage compartment!
Tools 1826
einordnung
• Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel
removal/installation! During removal, first remove the 3 remaining wheel bolts and remove the wheel
carefully, without touching the brake discs!
top of page
Notes on height changes/wheel−load changes
When changing the height/wheel load, the following must be noted:
• A one−sided height change causes a wheel−load change at the same time. A wheel−load change on
one wheel also alters the wheel loads of the other wheels.
• A one−sided increase in the installed spring preload (raising vehicle) increases the wheel load.
• A one−sided decrease in the installed spring preload (lowering vehicle) decreases the wheel load.
• A change in the wheel−load is always transferred diagonally onto the other axle side. This means that
if the wheel load on one wheel is decreased or increased, the same occurs on the diagonally opposite
wheel.
• Maximum wheel−load difference from left to right on front and rear axle 15 kg.
• Example: Rear left spring preload C is increased. In this way the wheel load: rear left C and front
right B greater −−−−−−−−−− rear right D and front left A less. − − − − − − −
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Deviating points for GT2 1827

einordnung
Vehicle height GT2

The vehicle height on the front and rear axle of the 911 GT2 can be adjusted. Before wheel alignment values
are adjusted at front and rear axles, it is recommended or necessary that the height adjustment be checked at
the DIN empty weight. The height adjustment possibility allows the wheel−load difference from right to left
to be kept as small as possible, provided that wheel load weighing machines are available. The wheel−load
difference is adjusted by changing the vehicle height within the height tolerance. The priority is to achieve the
smallest possible wheel−load difference from left to right.
The height adjustment possibility allows:
• Differing wheel loads on left and right to be corrected. At the correct height the wheel−load
differences lie within a permissible range, provided that the coil springs have the same installation
position (installed spring preload) on each axle. Tolerance 1 mm. Wheel−load differences can be kept
as low as possible in conjunction with wheel−load weighing machines. Tolerance from right to left on
front and rear axle under 15 kg.
• Any impermissible height differences front axle to rear axle can be balanced out (only within the
permissible tolerance).
For the height check of the ready−to−drive vehicle (full tank and tools), place the vehicle on a level
surface or on the measuring platform.
Front axle: Measure from road contact surface to the lower edge of the hexagon−head bolt of the
tension−strut screw connection to the body. Measuring point as with 911 Turbo (996).
Front axle
Rear axle: Measure from wheel contact surface to the locating bore in the rear−axle side section (between toe
and camber eccentrics).
Rear axle
Note
Vehicle height GT2 1828

einordnung
• Required values for front and rear axle can be found in the table "Adjusting values for suspension
alignment"!
The vehicle height on the front and rear axle is adjusted by turning the adjusting nut −No. 2− . The lock nut
−No. 1− must first be loosened. Use a hook wrench or special tool 9647 (hook wrench insert) for this purpose.
Adjusting nut −No. 2− turn to the right = vehicle higher turn to the left = vehicle lower
After adjustment of the lock nut(s) −No. 1− on the front and rear axle, tighten with special tool 9647 in
conjunction with a torque wrench. Tightening torque −No. 1− = 50 Nm (37 ftlb.).
If the vehicle is measured front and rear, check and adjust the rear axle first. Nominal values in Repair Group
44. After adjustment, tighten the appropriate screwed connections with the prescribed tightening torque. See
tables in Rep. Gr. 40 and 42.
Front axle
1 Lock nut
2 Height adjusting nut
Rear axle
1 Lock nut
top of page
Wheel alignment
Note
• In the 911 GT2, ABS (without PSM) is used as a control system!
• After the wheel−alignment values are changed, the PSM−related work is therefore omitted in contrast
to the 911 Turbo (996)!
Wheel alignment 1829

einordnung
Front−axle camber setting
Note
• Front−axle camber setting: Unlike the 911 Turbo (996), a basic camber adjustment is made by means
of intermediate plates −arrow− on the 2−part control arm of the front axle for the 911 GT2.
• A 1 mm thick adjustment plate is fitted as standard on the right and left in the 911 GT2 (M002 and
M003)!
• Check all wheels for clearance after adjustment and assembly work!
Control arm GT2
− Basic camber setting through adjustment plates −arrow−

− series = one 1 mm−thick adjustment plate
By using thicker adjusting shims, the 2−part control arms permit a correspondingly increased camber value to
be obtained for circuit use.
In relation to this, observe also the note on the fitting of the diagonal control arm to the control arm GT2
=> Instructions for fitting diagonal control arm on control arm – GT2
Camber fine adjustment
The camber is adjusted by moving the spring strut transversely. For this purpose, loosen the three M8
fastening nuts −arrows− of the spring−strut mount. To shift the spring strut inwards or outwards
−arrows− , remove the cover cap over the piston rod!
Front−axle camber setting 1830

einordnung
Camber/toe, rear axle
As with the 911 Turbo (996), the wheel−alignment values on the rear axle are set at the toe eccentric −A−
and at the camber eccentric −B− .
top of page
Instructions for fitting diagonal control arm on control arm
GT2
Note
• In the case of the road version of the GT2 (M002 and M003), the diagonal control arm must be fitted
at the centre bore (No. 1) of the control arm.
Control arm, left
A Control arm, left

C Direction of travel
1 Centre bore for GT2 road model
2 Rear bore only for Cup vehicle (with racing circuit camber
values)
Camber/toe, rear axle 1831

einordnung
Control arm, right
B Control arm, right

C Direction of travel
1 Centre bore for GT2 road model
2 Rear bore only for Cup vehicle (with racing circuit camber values)
996840, 996841
Instructions for fitting diagonal control arm on control arm GT2 1832
44 Tyre failure / tyre sealant GT2
Note
Repair procedure
Note
• The 911 GT2 is delivered with a tyre repair kit! A spare wheel or emergency wheel is not available!
• The tyre repair kit (Tire Mobility System), a compressor and a pressure tester are located in the
luggage compartment!
• It is essential to observe the safety and operating instructions on the sealant bottle and on the
compressor!
• Sealing the tyre with the tyre repair kit is only an emergency repair!
• Even if the tyre is sealed, it may only be used for short journeys in the event of an emergency and
must be replaced by a professional workshop immediately!
• Avoid sharp acceleration and high speed on bends! The highest permissible speed is 80 km/h!
top of page
Repair procedure
1. Take out sealant bottle and compressor. Shake sealant bottle well.
2. Screw the accompanying filler hose onto the bottle. The foil on the closure cap is automatically punctured.
3. Remove the valve cap from the tyre valve and unscrew the valve insert with the accompanying valve
insert driver and set it aside on a clean surface.
4. Remove the sealing plug from the filler hose, push the hose onto the tyre valve.
5. Hold the bottle with its base upwards and empty the entire contents of the bottle into the tyre. Then
remove the hose and screw the valve insert tightly into the tyre valve again.
CAUTION
Damage to the compressor (danger of overheating) in the case of excessively long operation!
• Do not operate the compressor for longer than 6 minutes!
6. Screw the filler hose of the compressor onto the tyre valve, insert the plug into the cigarette lighter.
Pump tyre to 2.0 − 2.5 bar (read off pressure on pressure gauge).
7. If this air pressure cannot be reached, drive approx. 10 metres forward or backward with the vehicle,
so that the sealant can distribute itself in the tyre. Repeat pumping procedure.
Note
• If the required air pressure still cannot be reached, the tyre is too badly damaged!
44 Tyre failure / tyre sealant GT2 1833

einordnung
• In this case, Tirefit cannot provide the required sealing!
• If the tyre pressure has fallen to below 1.3 bar, do not travel any further! Danger of accident!
• If more than 1.3 bar is measured, adjust the air pressure to the correct value again if necessary (see
sticker in the filler flap) and continue the journey as far as the next workshop!
8. Affix the accompanying sticker in the driver's field of

view.
9. Continue the journey immediately with care at max. 80 km/h.
10. Check the tyre pressure after driving for 10 minutes (use service station or pressure gauge of the
compressor).
996840, 996841
Repair procedure 1834

46 Technical data/Brake wear limit − GT2
Technical Data − GT2
Wear limit technical Data − GT2
top of page
Technical Data − GT2
The first GT2 vehicles will start without PCCB. Instead of this a conventional braking system will be installed
with the following deviating specification:
• 6−piston front fixed caliper, 4−piston rear fixed caliper

• Front and rear fixed caliper painted yellow / front fixed caliper, identical part to PCCB
• Other front and rear brake pads (brake pad version) as for PCCB
• 350 mm cast iron front brake discs
• 330 mm cast iron rear brake discs

Operating brake (foot brake) Hydraulic dual−circuit brake system with
with ceramic brake discs front−axle / rear−axle brake−circuit distribution.
(production launch with cast iron brake discs) Vacuum brake booster, internally ventilated and
perforated brake discs with six−piston monobloc
fixed caliper on the front axle and four−piston
monobloc fixed caliper on the rear axle.
The brake calipers are painted yellow for visual
differentiation.
ABS 5.3 with CAN−Bus (3−channel ABS
without PSM and without TC (Traction
Control).
(vacuum)
Boost ratio 3.15
rear 25.4 mm
Stroke 18/18 mm
Brake proportioning control excluding
Brake discs front PCCB = 350 mm
steel = 350 mm
rear PCCB = 350 mm
steel = 330 mm
Effective brake discs front PCCB and steel
284 mm
rear PCCB 291 mm
steel 271.2 mm
46 Technical data/Brake wear limit − GT2 1835

einordnung
Piston in brake caliper front 2 x 38 mm

6−piston 2 x 32 mm
2 x 28 mm
rear
4−piston 2 x 30 + 2 x 28 mm
rear 248 cm2
top of page
Wear limit technical Data − GT2
Two condition criteria can make replacement necessary depending on the wear of PCCB brake discs:
1. Surface changes in the brake disc friction surfaces at an advanced stage.

rear 28 mm
Brake discs minimum thickness front PCCB = 33.5 mm
steel = 32.0 mm
rear PCCB = 27.5 mm
steel = 26.0 mm

996840, 996841
Technical Data − GT2 1836

40 Disassembling and assembling front spring strut
GT2
Notes about adjustment work on the spring struts
Disassembling and assembling front spring strut GT2
top of page
• The spring strut has a thread and a height adjusting nut −2− for height adjustment. The height
adjusting nut −2− is secured against turning by the lock nut −1− .
• The stabilizer block −4− (mounting saddle for the stabilizer mount) is also fitted on the thread. The
stabilizer block −4− can be vertically adjusted and it is provided with a lock nut −3− .
• This adustment possibility is only useful for racing. It can be used to ensure that enough clearance is
available for the stabilizer mount even for deviating vehicle heights (only for racing) and also that the
stabilizer mount can be fitted free of tension.
• The stabilizer block −4− does not need to be adjusted for the vehicle height prescribed for street use.
The stabilizer block −4− , dimension B is also set with replacement dampers.
1 Lock nut
3 Lock nut
4 Stabilizer block
A Pre−setting dimension for production (289 mm). The dimension may be different with the prescribed
vehicle height. If the damper is replaced, the actual dimension must be transferred to the new damper.
B Dimension = 198 mm (plus/minus 0.5 mm)
top of page
40 Disassembling and assembling front spring strut GT2 1837

einordnung
Disassembling and assembling front spring strut GT2

1 Fastening nut 1 If necessary, pre−tension with the spring clamp Use new fastening nut.
M 14 x 1 before loosening the fastening nut. This depends Grease thread of the piston
on the adjustment (pre−tension) of the coil rod with Optimoly HT
spring. Support at the piston rod with a (copper paste). Tighten to
countering tool Sonderwerkzeug 9630 or a 7 mm 80 Nm (59 ftlb.)
Allen key when loosening the nut.
2 Assembly of 1 Remove complete assembly (consisting of No. 8 The spring strut mounts for
spring strut / No. 9 / No. 10 / No. 11). the right and left sides are
mount identical parts.
3 Spring mount 1
Disassembling and assembling front spring strut GT2 1838

einordnung
4 Rubber 1 Replace if necessary

support
5 Bellows 1
6 Coil spring 1 Available as spare part only
in sets.
Mount in correct position
(tighter winding
downwards).
The coil spring is fitted
with a protective sheath on
one side.
7 Vibration 1 The vibration dampers for
damper the right and left sides are
identical parts
8 Spacer sleeve 1 Mount in correct position.
9 Retainer 1 Mount on protective
spring bellows (No. 10)
10 Protective 1
bellows
11 Spring strut 1 The spring strut mounts for
mount the right and left sides are
identical parts.
In the case of used mounts,
the bearing shell can be
regreased with Autol Top
2000.
Manufacturer:
Autol−Werke
Paradiesstr. 14
D−97080 Würzburg
top of page
Disassembly
CAUTION
• If necessary, tension the coil spring with the spring clamp until the piston rod is relieved!
1.

einordnung
If necessary, tension the coil spring with the spring clamp until the piston rod is relieved. To
undo the connection − piston rod to spring strut mount − counter at the piston rod with countering
tool Sonderwerkzeug 9630 or a 7−mm Allen key.
• If the vibration damper is to be replaced, set the height adjusting nut −2− to the same position as on
the old vibration damper (transfer the actual dimension A to the new vibration damper)! To do this, a
hook wrench insert Sonderwerkzeug 9647 is required.
• Tightening torque of the lock nuts −1+3− = 50 Nm (37 ftlb.)!
• The stabilizer mating bearing (mounting saddle) −4− need not be adjusted for street use!
• The hook wrench Sonderwerkzeug 9647 is required for changing the vehicle height (dimension A)
and for adjusting the stabilizer mating bearing (dimension B). The special tool is used together with a
torque wrench to tighten the lock nuts (slotted nuts) on the spring struts.
Assembly
Note
• When installing new parts, observe the allocation according to the Spare Parts Catalogue!
• The coil springs are only available in pairs!
Disassembly 1840
einordnung
1. Push coil spring −6− , spring plate −3− with rubber ring −4− and bellows −5− onto the vibration damper.
The tighter winding of the coil spring −6− must face down towards the damper tube −7− .
Note
• The coil spring is fitted with a protective sheath on one side!
2. Grease thread of the piston rod with Optimoly HT (copper grease/only at the front
axle).
3. Push the assembly of the spring strut mount −2− (consisting of Parts No. 8/ No. 9 / No. 10 / No. 11)
onto the piston rod.
Note
• The mounts for the right and left sides are identical parts!
• In the case of used mounts, the bearing shell can be regreased with Autol Top 2000! Manufacturer:
Autol−Werke, Paradiesstr. 14, D−97080 Würzburg.
• Replace nut for fastening the piston rod on the spring strut mount!
Assembly 1841
einordnung
4. Turn new fastening nut on the piston rod and tighten to 80 Nm (59 ftlb.). Use a −socket wrench insert−
(wrench size 22 mm) open on one side to tighten the fastening nut on the spring strut mount!
5. When tightening the fastening nut, hold at the piston rod using a countering tool Sonderwerkzeug 9630 or
a 7 mm Allen key.
996840, 996841
Assembly 1842
42 Disassembling and assembling rear spring strut −
GT2
Disassembling and assembling rear spring strut − GT2
top of page
• The spring strut has a thread and a height adjusting nut −1− for height adjustment. The height
adjusting nut −1− is secured against turning by the lock nut −2− .
• The stabilizer block −4− (mounting saddle for the stabilizer mount) is also fitted on the thread. The
stabilizer block −4− can be vertically adjusted and it is provided with a lock nut −3− . This adjustment
possibility is only useful for racing. It can be used to ensure that enough clearance is available for the
stabilizer mount even for deviating vehicle heights (only for racing) and also that the stabilizer mount
can be fitted free of tension.
• The stabilizer block −4− does not need to be adjusted for the vehicle height prescribed for street use!
A Pre−setting dimension for production (176 mm). The dimension may be different with the prescribed
vehicle height.
B Dimension B = 105 mm (plus/minus 1 mm)
C Dimension C = 90 degrees
• The mounting saddle is also set with replacement dampers (dimension B and dimension C)!
42 Disassembling and assembling rear spring strut − GT2 1843

einordnung
top of page
Disassembling and assembling rear spring strut − GT2

1 Fastening nut 1 If necessary, pre−tension the coil spring with the Use new fastening
M 12 x 1.5 spring clamp before loosening the fastening nut. nut. Tighten to 60
This depends on the pre−tension of the coil spring. Nm (44 ftlb.).
Support at the piston rod with a countering tool Position the spring
Sonderwerkzeug 9630 or an open−ended wrench strut mount No. 3
(7mm) when loosening the nut. first (see under
assembly
instructions).
Notes about adjustment work on the spring struts 1844

einordnung
2 Washer 1 Mount in correct

(stop plate) position. No. 2 and
No. 7 are identical
parts.
3 Spring strut 1 The mounts for the
mount right and left sides
are identical parts.
Position the mount
before tightening
the fastening nut
No.1 (see under
assembly
instructions).
4 Support ring 1 Standard as of model '02 (2) Renew if
(rubber washer) necessary.
Also fit on
vehicles, model
'01 (1).
5 Spring plate 1
6 Coil spring 1 Available as spare
part only in sets.
Mount in correct
position (tighter
winding
downwards).
The coil spring is
fitted as standard
with a protective
sheath at the top
and bottom as of
model '02 (2).
On vehicles of
model '01 (1),
mount (fit) the
protective sheath
at the top and
bottom in the area
of the contact
points of both
spring ends!
7 Washer 1 Mount in correct
(stop plate) position (No. 2
and No. 7 are
identical parts).
8 Washer 1
9 Additional 1
spring
10 Vibration 1 Observe allocation
damper as per Spare Parts
Disassembling and assembling rear spring strut − GT2 1845

einordnung
Catalogue. The
vibration dampers
for the right and
left sides are
identical parts.
top of page
Disassembly
CAUTION
• If necessary, tension the coil spring (depending on the spring preload) with the spring clamp until the
piston rod is relieved!
1. If necessary, tension the coil spring (depending on the spring preload) with the spring clamp until
the piston rod is relieved.
2. To undo the connection − piston rod to spring strut mount − counter at the piston rod with countering tool
Sonderwerkzeug 9630 or an open−ended wrench (7 mm).
• If the vibration damper is to be replaced, set the height adjusting nut −1− to the same position as on
the old vibration damper (transfer the actual dimension A to the new vibration damper). A hook
wrench insert, special tool 9647 is required for this purpose.
• Tightening torque of the lock nuts −2+3− = 50 Nm (37 ftlb.)!

einordnung
• The stabilizer mating bearing (mounting saddle) −4− need not be adjusted for street use.
• The hook wrench insert Sonderwerkzeug 9647 is required to change the vehicle height and to adjust
the stabilizer mating bearing on the front and rear axle. The special tool is used together with a torque
wrench to tighten the lock nuts (slotted nuts) on the spring struts.
Assembly
1. Slide the additional spring −9− , washer −8− and stop plate −7− (stop plate in correct position) as far as
they will go on the piston rod.
2. Place coil spring −6− in the correct position, tighter winding facing down, onto the vibration damper.
Note
Preliminary work and notes on assembly 1847

einordnung
• The coil spring −6− is fitted as standard with a protective sheath −arrows− at the top and bottom on
vehicles as of model '02 (2).
• On vehicles of model '01 (1), mount (fit) the protective sheath at the top and bottom −arrows− in the
area of the contact points of both spring ends.
3. Fit spring plate (spring retainer), support ring (rubber washer) and spring strut mount onto the coil spring.
Note
• If the support ring (rubber washer) is not yet available, fit the rubber washer on vehicles of model '01
(1)!
4. Place stop plate in the correct position on the spring strut mount.
Note
• Replace nut for fastening the piston rod on the spring strut mount!
5. Screw new fastening nut onto the piston rod until approx. 1 to 2 threads are visible above the
fastening nut.
Note
• The spring strut mount for the right and left sides are identical parts!
• The spring strut mount is positioned correctly if one of the 3 fastening pins is aligned with the
stabilizer mounting saddle!
6. Position the spring strut mount for installation (correctly position spring strut mount with respect to
the damper).
7. Once the mount has been positioned correctly, tighten the fastening nut. Tightening torque 60 Nm
(44 ftlb.).
Note
Assembly 1848
einordnung
8. When tightening the fastening nut, hold at the piston rod using a countering tool Sonderwerkzeug 9630 or
a 7 mm open−ended wrench.
996840, 996841
Assembly 1849
30 01 07 Bleeding the clutch system − GT2
Note
Filling/bleeding
Note
• The clutch hydraulics must always be filled or bled using a pressure filling and bleeding device.
Furthermore, the bleeder valve must be opened sufficiently and the gauge pressure must be approx.
2.0 bar.
• If there is no system pressure, before the system is filled or bled, the clutch pedal must be in the
"Pedal fully depressed" position. In order to avoid risk of injury or damage, the pedal must be guided
manually. Otherwise, the clutch pedal can move forward abruptly (as a result of servo kinematic
effects).
• If the system was open previously (e.g. for component replacement), the minimum filling or bleeding
time must be 30 seconds.
• Use only new Super DOT 4 brake fluid. This brake fluid is available under the following part
numbers: container volume 1 litre = 000.043.203.66, container volume 30 litres = 000.043.203.67.
top of page
Filling/bleeding
DANGER
Please note: danger of injury from depressing the clutch pedal, if there is no system pressure. The clutch pedal
will move forward abruptly as a result of servo kinematic effects.
• If the clutch pedal is fully depressed, the pedal must be guided manually.
1. If there is no or only lower system pressure, depress the clutch pedal fully. Guide the clutch pedal
manually.
2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is
approximately 2.0 bar.
3. The bleeder valve from the clutch slave cylinder (on the transmission) must be opened until clear,
bubble−free brake fluid emerges. Use a collecting bottle for precise examination of the emerging
30 01 07 Bleeding the clutch system − GT2 1850

einordnung
brake fluid for cleanliness and freedom from bubbles.
• If the system was open previously (e.g. for component replacement), the minimum filling or bleeding
time must be 30 seconds.
necessary.
996840, 996841
Filling/bleeding 1851
30 45 19 Removing and installing release bearing
(clutch removed) − GT2

1 Snap ring 1 Remove using pointed−nose pliers, Ensure correct seating
simultaneously push down pressure plate
using a press.
2 Thrust plate 1 Engage lug (twist lock) in the
opening of a diaphragm spring
tongue
3 1 Check, do not wash out, just dry wipe Do not grease sliding surface
30 45 19 Removing and installing release bearing (clutch removed) − GT2 1852

einordnung
Release
bearing
4 Spring 1 Mount in correct position
washer
5 Spacer 2 Fit 2 spacer washers
washer
6 Thrust plate 1 Check for wear, replace if
necessary
top of page
1. The release bearing is removed under a shop press. For this purpose, lay the release bearing down on
the bottom and press down on the pressure plate from above with a pressure piece (e.g. hardwood
block) until the snap ring can move freely.
2. Remove snap ring and take out release bearing.
top of page
Note
• Do not grease the sliding surfaces of the release bearing and the guide tube.
Removing release bearing 1853

einordnung
Note
• The guide sleeve of the release bearing is slotted. The slot is irregular.
1. Fit spacer washers and spring washers on the new release bearing. When doing so, ensure that the parts
are fitted in the correct order and the spring washer is seated properly.
2. Insert release bearing in diaphragm spring plate. Engage lug on release bearing (twist lock) in the opening
between two tongues of the diaphragm spring.
3. Fit snap ring under the press. Ensure that the snap ring is seated
correctly.
996840, 996841
Installing release bearing 1854

30 50 19 Removing and installing clutch − GT2
Tools
Removing clutch
Installing clutch
Tightening torques
top of page
Tools

A Toothed segment P201b
B Centring mandrel 9102
top of page
Removing clutch
transmission.
30 50 19 Removing and installing clutch − GT2 1855

einordnung
2. Position the toothed segment P201b −A− on the stud and undo the pan−head screws in several
stages and in diametrically opposite sequence, to avoid deforming the thrust plate.
top of page
Installing clutch
1. Fit drive plate with centring mandrel, special tool centring mandrel 9102 in the guide bearing (needle
bush).
2. Fit thrust plate. To do so, position the special tool toothed segment P201b −A− on the stud and
tighten the pan−head screws in several stages and in diametrically opposite sequence.
3. Remove the special tool centring mandrel 9102 .
4. Remove the special tool toothed segment P201b .
5. Refit transmission. ’ 34 35 27 Removing and refitting the transmission.
top of page
Tightening torques

Pan−head screws thrust plate − ZMS M8 23 (17 ftlb.)
996840, 996841
Removing clutch 1856

30 50 37 Disassembling and assembling clutch − GT2
No. Designation Qty. Removal Fitting

1 Pan−head 9 In order to avoid deformation of the In order to avoid deformation of the
screw M8 thrust plate housing, loosen screws in thrust plate housing, tighten screws in
several stages and in diametrically several stages and in diametrically
opposite sequence. opposite sequence.
2 Release 1 Do not wash out the bearing; replace
bearing loud bearings; do not grease the
sliding surface.
3 Thrust plate 1
4 Drive plate 1 Centre with centring mandrel 9102 .
5 Double−mass 1 Ensure the centring pins are seated
flywheel firmly.
996840, 996841
30 50 37 Disassembling and assembling clutch − GT2 1857

34 01 55 Changing transmission oil − GT2
Tightening torques
Total capacity: 3.7 + 0.1 Liter
Oil change quantity: 3.7 + 0.1 Liter
Note
• Use only oils approved for this type by Porsche. See Parts Catalogue.
top of page

−1− .
3. Unscrew oil drain plug −2− and let oil drain off into a suitable
container.
top of page
1. Clean the drain plug and filler screw.
2. Screw in oil drain plug again and top up oil up to the bottom edge of the oil filler
opening.
3. Screw in oil filler plug.
4. Fit underbody trim parts.
top of page
34 01 55 Changing transmission oil − GT2 1858

einordnung
Tightening torques

Oil filler plug M22 x 1.5 30 (22 ftlb.)
Oil drain plug M22 x 1.5 30 (22 ftlb.)
996840, 996841

34 35 27 Removing and refitting the transmission −
GT2
Tools
Tightening torques
top of page
Tools

tool
A Gripper Commercially available Rep. Gr. Workshop Equipment Manual
Chapter 2.4, No. 50
B Removal mandral Special tool 9287
top of page
2. Disengaging starter cable.
34 35 27 Removing and refitting the transmission − GT2 1860

einordnung
3. Pull of vacuum line from coolant valve −A− .
4. Remove right air flanges, unscrew hexagon−head bolt −A− seated below them for holder and
remove holder.
5. Remove bearing cover −B− with commercially available pliers’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 50 ) or lever off with screwdriver.
6. Screw a screw (M6) into the clutch control shaft and pull out shaft.
7. Unscrew the fastening nuts for engine/transmission and separate the transmission from the engine.
top of page
Note
• Grease teeth of the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against
corrosion).

einordnung
1. Insert release lever into the release bearing and fix in installation position with suitable adhesive tape.
2. Insert closure cap for the pulse sender opening in the correct position in the transmission housing
and mount transmission on the engine.
3. Ensure that the closure cap −A− is properly seated and positioned.
4. Fit release lever shaft with sealing rings.

1 Hexagon−head bolt
2 Holder
3 Bearing cover
4 Needle−roller bearing with assembly bore
5 Sealing ring
6 Clutch control shaft
7 Release lever

einordnung
5. Remove adhesive tape through the assembly opening in the release

fork.
6. Fit bearing cover with special tool removal mandrel 9287 .
7. Fit holder for clutch control shaft.
8. Refit transmission on motor and screw in screws.
9. Fit air flanges.
10. Engage starter cable and push vacuum line onto coolant valve.
11. Install engine−transmission unit. ’ 100119 .
top of page
Tightening torques

Transmission on engine M10 65 Nm (48 ftlb.)
Air flanges on transmission M6 10 (7.5 ftlb.)
Bracket for clutch control shaft on transmission M6 x 16 10 (7.5 ftlb.)
996840, 996841

34 37 37 Disassembling and assembling transmission
housing − GT2
Tools
Overview
Tightening torques
top of page
Tools

A Striker Special tool striker VW 771
B Protective sleeve Special tool protective sleeve 9649
C Pressure piece Special tool pressure piece 9648/2
D Threaded piece Special tool threaded piece VW 771/15
E Pressure piece Special tool pressure piece P 254 b
F Pressure piece Special tool pressure piece 3062
G Pressure piece Special tool pressure pieces 9247
H Pressure pieces Special tool pressure piece 9252
I Pressure piece Special tool pressure piece VW 513
J Pressure piece Special tool pressure piece 9649/1
K Socket wrench insert Special tool socket wrench insert 9658
L Pull−in tool and extractor Special tool pull−in tool and extractor P 254
M Mandrel Special tool mandrel 9515
34 37 37 Disassembling and assembling transmission housing − GT2 1864

einordnung
N Mandrel Special tool mandrel VW 295

O Drift Special tool drift P 264 b
P Pressure piece Special tool pressure piece 9648/1
Q Pressure piece Special tool pressure piece 9648
top of page
Overview

1 Screw plug 1 Clean, tighten to 30 Nm (22 ftlb.).
(with sealing Replace sealing ring.
ring)
Tools 1865
einordnung
2 Shaft seal 1 Install only after fitting the gear set.

3 Shaft seal 1 Drive in shaft seal with pressure piece
VW 513 as far as the mounting face. Fill
the space between the dust and sealing
lips with grease (e.g. Liqui Moly).
4 Ball sleeve 4 Remove with special tool striker Drive in with special tool pressure piece
VW 771 , special tool threaded 9648 . (Installation depth 0.6 mm).
part VW 771/15 and a suitable
internal puller.
5 Outer bearing 1 Drive out with aluminium or Drive in with special tool pressure piece
race copper mandrel, changing sides. 3062 and special tool mandrel VW 295
as far as the mounting face.
6 Outer bearing 1 Drive out from the inside with Drive in with special tool pressure pieces
race special tool pressure piece VW 9247 and special tool pull−in tool and
513 . extractor P 254 .
7 Outer bearing 1 Drive out from the inside with Drive in with special tool pressure piece
race special tool drift P 264 b . P 254 b and special tool pull−in tool and
extractor P 254 .
8 Circlip 1 Fit in correct position and make sure it is
seated properly.
9 Selector lever 1 Use special tool protective sleeve 9649 .
Insert in the correct position.
10 Rubber washer 1
11 Selector lever 1
12 Shaft seal 1 Drive in with special tool pressure piece
9649/1 . Fill the space between the dust
and sealing lips with grease (e.g. Liqui
Moly).
13 Bushing 2 Drive out with special tool Drive in with special tool pressure piece
pressure piece 9648/2 . 9648/1 .
14 Shift pinion 1 Axial play 0 to 0.15 mm. Setting with
shim (No.15).
15 Adjusting shim X Mark for refitting. Remeasure if necessary.
16 Snap ring 1 Push the snap ring and cap (no. 17)
down until the snap ring engages into the
groove.
17 Closure cap 1
18 Compression 1
spring
19 Bearing screw* 1 Remove with special tool socket Tighten to 50 Nm (37 ftlb.).
wrench insert 9658 .
• Unscrew it only if the

transmission has to be
disassembled!
20 Swivel arm 1
Overview 1866
einordnung
21 Transmission 1
housing
Note
• * Parts of the shifting mechanism will fall into the transmission if the bearing screw No. 23 is
unscrewed.
top of page
Disassembly
1. Remove closure cap. To do this, drill a 3.5 mm hole into the centre of the cap, screw in a
sheetmetal screw (4.8 x 25) with large washer, and lever the cap out using two screwdrivers.
Assembly
1. Fit selector lever and shift pinion in the correct position. (The driver cross is vertical and the selector lever
reaches the flat surface of the housing.)

einordnung
2. Fit the retainer in the correct position and make sure it is seated properly.
top of page
Tightening torques

Plug screw (no. 1 in overview) M22 x 1.5 30 (22)
Bearing screw − (no. 19 in overview) − 50 (37)
996840, 996841
Assembly 1868
34 52 37 Disassembling and assembling gear
housing − GT2
Tools
Overview
Disassembling gear housing
Assembling gear housing
Tightening torques
top of page
Tools

tool
A Striker Special tool Striker VW 771
B Pressure piece Special tool Pressure piece P 254 b
C Pressure piece Special tool Pressure piece P 254 a
D Mandrel Special toolPull−in tool and extractor P 254
E Threaded piece Special tool Threaded piece VW 771/15
F Internal puller 14 − 20 mm Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 108
G Pressure piece Special tool Pressure piece 9648/1
H Pressure piece Special tool Pressure piece 9648
J Pressure piece Special tool Pressure piece 9648/2
K Pressure piece Special tool Pressure piece 9649/1
34 52 37 Disassembling and assembling gear housing − GT2 1869

einordnung
top of page
Overview

1 Screw plug 1
2 Snap ring 1
3 Outer bearing race 1
4 Snap ring 1
5 Snap ring 1
7 Snap ring 1
8 Ball sleeve 1
Tools 1870
einordnung
9 Ball sleeve 1
10 Ball sleeve 1
11 Ball sleeve 1
12 Screw plug 1
14 Locking pin 1
15 Circlip 1
16 Shift lever 1
17 Shift catch 1
18 Roller 1
19 Shaft seal 1
20 Bearing sleeve 2
21 Rubber washer 1
22 Gear housing 1
top of page
Disassembling gear housing
2. Disassemble front gear set.
3. Remove gear housing.
Disassembling gearshift
1. Unscrew screw plug (no. 12 in overview) and remove compression spring and locking pin (no. 13
and 14 in overview).
2. Remove circlip (no. 15 in overview) with screwdriver.
3. Remove shift catch to the inside with roller (no. 17 and 18 in overview).
4. Pull shift lever outwards with rubber washer (no. 16 and 21 in overview).
5. Lever out shaft seal (no. 19 in overview) with screwdriver.
6. Drive out bearing sleeves (no. 20 in overview) with special tool pressure piece 9648 .
Overview 1871
einordnung
Removing outer bearing race
1. Remove snap ring (no. 2 or 5 in overview) with screwdriver.
2. Drive out outer bearing race (no. 3 or 6 in overview) with special tool pressure piece P 254 b or special
tool pressure piece P 254 a and special tool pull−in tool and extractor P 254 .
3. Remove snap ring (no. 4 or 7 in overview) from groove in outer bearing race.
Removing ball sleeves
1. Knock out ball sleeve (no. 8 to 11 in overview) outwards with internal puller 14 − 20 mm and special tool
striker VW 771 .
Removing screw plug
1. Unscrew screw plug (no. 1 in overview) with Allen key.
top of page
Assembling gear housing
1. Refit gear housing on transmission case and screw in screws.
2. Assemble front gear set.
3. Fit front transmission case cover.
Removing outer bearing race 1872

einordnung
Assembling gearshift
1. Drive in bearing sleeves (no. 20 in overview) with special tool pressure piece 9648/1 .
2. Drive in shaft seal (no. 19 in overview) with special tool pressure piece 9649/1 . Before doing this,
fill the space between the dust and sealing lips with grease (e.g. Liqui Moly).
3. Insert shift lever from outside with rubber washer (no. 16 and 20 in overview).
4. Push shift catch with roller (no. 17 and 18 in overview) onto shift lever from the inside.
5. Push on circlip (no. 15 in
overview).
6. Insert locking pin, compression spring and screw plug (no. 14, 13 and 12 in
overview)
Installing outer bearing race
1. Insert snap rings (no. 4 or 7 in overview) into the groove of the outer bearing race.
2. Drive in outer bearing race (no. 3 or 6 in overview) with special tool pressure piece P 254 b or special tool
pressure piece P 254 a and special tool pull−in tool and extractor P 254 from the outside.
3. Insert snap rings (no. 2 or 5 in overview).
Installing ball sleeves
1. Drive in ball sleeves (no. 9 and 10 in overview) with special tool pressure piece 9648 . Use short side
(installation depth 0.6 mm) of the special tool.
2. Drive in ball sleeves (no. 8 and 11 in overview) with special tool pressure piece 9648 . Use long side
(installation depth 1.4 mm) of the special tool.
Installing screw plug
1. Screw in plug screw (no. 1 in overview).

top of page
Tightening torques

Gear housing on transmission housing M8 23 (17 ftlb.)
Screw in plug screw (no. 12 in overview) M 20 (15 ftlb.)
Plug screw (no. 1 in overview) M 30 (22 ftlb.)
Assembling gearshift 1873

einordnung
996840, 996841

34 55 37 Disassembling and assembling front
transmission cover GT2
Tools
Overview
Disassembling front transmission case cover
Assembling front transmission case cover
Tightening torques
top of page
Tools

tool
A Internal puller 46 − 56 mm Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 108
B Counter support Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 106
C Internal puller 30 − 40 mm Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 108
D Counter support Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 107
E Pressure piece Special tool pressure pieces 9690
F Mandrel Special tool pull−in tool and extractor P 254
top of page
34 55 37 Disassembling and assembling front transmission cover GT2 1875

einordnung
Overview

2 Bearing segment 1
3 Reverse idler gear 1
5 Pin 1
6 Snap ring, large 1
8 Snap ring, small 1
10 Reversing light switch 1
Overview 1876
einordnung
11 Transmission cover 1
top of page
Disassembling front transmission case cover
1. Remove transmission. ’ 34 35 27 Removing and refitting the transmission −
GT2.
3. Drain transmission oil. ’ 34 01 55 Changing transmission oil − GT2.
4. Remove electric cable.
5. Remove hose −A− between oil cooler and transmission housing.

6. Remove oil cooler. To do this, undo screws −B− and lift oil cooler up and
off.
7. Unscrew fastening screws for front transmission case cover and remove transmission case cover.
Disassembling reverse idler gear
1. Unscrew the hexagon−head bolt (no. 1 in overview)

2. Remove toothed segment, reverse idler gear and needle−roller bearing.
Dismantling cylinder−roller bearing
Note
• The cylinder−roller bearing can be damaged during the dismantling.
1. Disassemble reverse idler gear.
Disassembling front transmission case cover 1877

einordnung
2. Clamp the transmission case cover in

the vice.
3. Remove snap ring with pliers
4. Affix internal puller 30 − 40 mm behind cylindrical−roller bearing. Ensure correct
seating.
5. Screw internal puller together with counter support and pull out cylindrical roller bearing by turning
the nut on the counter support.
Disassembling outer bearing race
1. Clamp the transmission case cover in

the vice.
2. Remove snap ring with pliers
Dismantling cylinder−roller bearing 1878

einordnung
3. Affix internal puller 46 − 56 mm behind outer bearing race. Ensure correct

seating.
4. Screw internal puller together with counter support and pull out cylindrical roller bearing by turning
the nut on the counter support.
top of page
Assembling front transmission case cover
1. Place front transmission case cover onto the transmission and screw in fastening screws.
2. Fit oil cooler.
3. Fit connecting hose between oil cooler and transmission.
4. Fit electric cable.
5. Fill with transmission oil. ’ 34 01 55 Changing transmission oil −
GT2.
6. Refitting transmission. ’ 34 35 27 Removing and refitting the transmission −
GT2.
Fitting reverse idler gear
1. Insert toothed segment, reverse idler gear and needle−roller bearing.

2. Screw in hexagon−head bolt (no. 1 in overview).
Fitting cylindrical−roller bearing
Note
• Always use new cylindrical−roller bearing.
1. Drive in cylindrical−roller bearing with special tool pressure piece 9690 .

2. Insert snap
ring.
3. Fit reverse idler gear.
Disassembling outer bearing race 1879

einordnung
Fitting outer bearing race
1. Drive in outer bearing race with special tool pressure pieces 9690 .
2. Insert snap
ring.
top of page
Tightening torques
Hexagon−head bolt (no. 1 in overview) M8 25 (18.5 ftlb.)
Transmission case cover fastening screws on transmission M8 23 (17 ftlb.)
housing
Oil cooler fastening screws on transmission M6 10 (7.5 ftlb.)
996840, 996841
Fitting outer bearing race 1880

34 72 19 Removing and installing transmission oil
pump − GT2
Tools
Removing transmission oil pump
Installing transmission oil pump
Tightening torques
top of page
Tools

A Removal tool Shop−made (flat steel 5 x 230)
top of page
Removing transmission oil pump
1. Remove the transmission oil cooler => Removing and installing transmission oil cooler −
GT2
34 72 19 Removing and installing transmission oil pump − GT2 1881

einordnung
2. Unscrew the fastening screws of the oil pump −A− .

3. Fasten the shop−made removal tool to the oil pump thread −B− with an M6 x 25 screw and drive
the oil pump out of the transmission housing with gentle taps with a hammer on the shop−made
removal tool.
top of page
Installing transmission oil pump
1. Grease the sealing rings of the transmission oil pump, e.g. with
Liqui−Moly .
2. Drive the transmission oil pump carefully into the transmission housing with a rubber
hammer.
3. Screw in the fastening screws between the transmission oil pump and the transmission
housing.
4. Fit the transmission oil cooler => Removing and installing transmission oil cooler −
GT2 .
top of page
Tightening torques
Fastening of transmission oil pump to transmission M 8 x 25 or M 8 x 23 (17)
housing 30
996840, 996841
Removing transmission oil pump 1882

34 74 19 Removing and installing transmission oil
cooler − GT2
Caution
Tools
Overview
Removing transmission oil cooler
Installing transmission oil cooler
Tightening torques
CAUTION
The described operation must not be performed on vehicles with an engine at operating temperature. Risk of
injury due to hot transmission oil or coolant.
top of page
Tools

A Hose clamp Special tool hose clamp VW3093
top of page
Overview
34 74 19 Removing and installing transmission oil cooler − GT2 1883

einordnung
A Transmission oil cooler
top of page
Removing transmission oil cooler
2. Drain transmission oil => Changing transmission oil − GT2.
3. Unscrew two hexagon−head bolts −A− and remove the transverse strut.
4. Disconnect the plug −B− and remove the electrical cable from the working
area.
5. Disengage the coolant line for the heating supply and return lines from the plastic clips −A− and pull
the line over the holders of the underbody trim −B− towards the rear.
Overview 1884
einordnung
6. Seal the coolant line by clamping it with special tool hose clamp VW3093
−A− .
7. Unscrew the transmission oil connecting line −A− between the oil cooler and the transmission on
the transmission oil cooler.
8. Seal the coolant line by clamping it with special tool hose clamp VW3093
−B− .
9. Place a suitable container under the vehicle to collect the coolant−oil mixture from the transmission
oil cooler.
WARNING
Coolant and transmission oil may emerge during the repair operations described below. With the engine at
operating temperature, there is a risk of scalding due to these liquids.
10. Undo the spring band clamp −A− and pull off the coolant hose.
11. Unscrew the holder screws −A− and the hexagon socket head bolt −B− and pull out the
transmission oil cooler with the bracket.
Removing transmission oil cooler 1885

einordnung
Note
• The cooler bracket can remain hanging on the fastened coolant hose while the transmission oil cooler
is replaced.
12. Unscrew the three fastening screws between the transmission oil cooler and the cooler bracket and
remove the transmission oil cooler.
top of page
Installing transmission oil cooler
1. Fit the oil cooler with new sealing rings on the cooler bracket and screw in the fastening
screws.
2. Position the cooler bracket with the transmission oil cooler on the oil
pump.
3. Screw in the hexagon socket head bolt between the cooler bracket and the oil pump.
4. Screw in the connecting screws between the holder and the transmission
housing.
5. Connect the coolant hose to the oil cooler and connect the spring band clamp.
6. Remove special tool hose clamp VW3093 from the coolant hoses.
7. Screw the transmission oil connecting line into place between the transmission oil cooler and the
transmission on the transmission oil cooler.
Note
• Grease the thread of the transmission oil connecting line, e.g. with Optimol optimoly paste .
8. Push the coolant lines for the heating supply and return lines over the holders of the underbody trim
towards the front and clip the lines into the plastic clips.
9. Lay the electrical cable and connect the plug.
10. Fit the transverse strut.
11. Fill with transmission oil => Changing transmission oil − GT2.
12. Fit underbody trims.
13. Bleed the engine cooling system ’ 19 01 07 Bleeding the cooling system .
top of page
Tightening torques
Location Thread
Installing transmission oil cooler 1886

einordnung
(ftlb.)
Fastening of oil cooler to cooler bracket M 6 x 20 10 (7.5)
Fastening of cooler bracket to oil pump M 6 x 55 10 (7.5)
Fastening of oil cooler holder to transmission housing M 8 x 20 23 (17)
Fastening of transmission oil line to transmission oil 34 (25)
cooler
Fastening of transverse strut M 10 x 1.25 65 (48)
996840, 996841

drive shaft − GT2
Tools
Removing sealing ring for drive shaft
Installing sealing ring for drive shaft
Tightening torques
top of page
Tools

1 Pressure piece Special tool Pressure piece 9256
2 Assembly sleeve Special tool Assembly sleeve 9255
3 Puller Special tool Puller 9629
top of page
Removing sealing ring for drive shaft
1. Remove engine−transmission unit and remove the transmission. => Removing and refitting the
transmission − GT2
2. Remove guide tube for release bearing.
35 50 19 Removing and installing sealing ring for drive shaft − GT2 1888
einordnung
3. Screw special tool puller 9629 securely into the sealing

ring.
Note
• The coil spring must be pulled off the drive shaft with a wire hook if the spiral tensioning spring
should jump down when removing the sealing ring.
4. Pull out sealing ring by screwing in the hexagon−head bolt.
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Installing sealing ring for drive shaft
Removing sealing ring for drive shaft 1889

einordnung
1. Push special tool assembly sleeve 9255 onto the toothing of the input
shaft.
2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g.
Liqui−Moly).
3. Drive in sealing ring with special tool pressure piece 9256 as far as the mounting face.
4. Install guide tube and tighten the fastening screws.
Note
• The guide tube fastening screws are micro−encapsulated, therefore replace screws entirely.
5. Clean teeth of the drive shaft and grease with a thin coat of Olista Longtime 3 EP (only as corrosion
protection).
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Tightening torques
Installing sealing ring for drive shaft 1890

einordnung
Guide tube for release bearing on transmission housing M6x14 10
996840, 996841

39 08 15 Adjusting drive set − GT2
Tools
Sequence of adjustment operations
Determining disc thickness S4 and S5
Determining disc thickness S3
top of page
Tools

tool
A Measuring mandrel Special tool measuring mandrel VW 385/1
B Centring discs Special tool centring sleeve 9109
C Universal master gauge Special tool universal master gauge VW 385/30
D Final dimension plate Special tool final dimension plate VW 385/17
E Dial gauge Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 136
F Gauge plunger Special tool gauge plunger VW 385/14
G Dial gauge extension (30 Special tool dial gauge extension VW 385/56
mm)
H Final dimension plate Special tool adjusting shim 9281
I Dial gauge holder Special tool dial gauge holder VW 387
J Clamping sleeve Special tool sleeve 9145
K Adjustment device Special tool adjustment device VW 521/4
39 08 15 Adjusting drive set − GT2 1892

einordnung
L Measuring lever Special tool measuring lever VW 388

M Gauge plunger Special tool gauge plunger VW 388
N Dial gauge extension (6 Special tool dial gauge extension VW 382/10
mm)
O Dial gauge extension (20 Special tool dial gauge extension 9150
mm)
P Clamping device Special tool retaining device 9562
Q Retaining device Special tool retaining device 9253
R Assembly sleeve Special tool assembly sleeve 9263
S Micrometer Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 135
T Drift Special tool drift P 264 b
top of page
Sequence of adjustment operations
If the pinion shaft and crown wheel have to be adjusted, it is best to follow the sequence below in the interest
of rational working:
1. Determine the total disc thickness S1 + S2.
2. Determine disc thickness S4 and S5.
3. Determine disc thickness S3.
4. Divide the total disc thickness into S1 and S2.
5. Check the circumferential backlash and set, if necessary.
Note
• The aim of the adjustment operations is to regain the position of maximum smooth running which was
determined in production on a testing machine.
top of page
1. Disassemble the transmission ’ 34 35 37 Disassembling and assembling
transmission.
Note
• The input shaft need not be disassembled for this setting.
Tools 1893
einordnung
2. Insert adjusting shim S3 −A− with a thickness of 1

mm.
3. If the tensioning plate has not been disassembled, install it with the input shaft.
4. Measure the play at the four−point bearing. To do so, fit the dial gauge with the special tool dial
gauge holder VW 387 . Press the outer bearing race forwards as far as possible and set the dial
gauge to 0.
5. Press the outer bearing race backwards as far as possible and read the play off the dial gauge.
Example: 1.00 mm
Note
• The measured play plus the specified bearing pretension of 0 to 0.07 mm indicate the thickness of disc
S4.
Example: 1.00 mm + 0.05 mm = 1.05 mm = S4

6. Experience shows that the thickness of disc S5 corresponds to the thickness of disc S4.
Example: S4 = S5 = 1.05 mm
.
9. Push on oil pump drive wheel −E− .
Determining disc thickness S4 and S5 1894

einordnung
10. Insert the preselected adjusting shim S3 into the transmission housing and install the tensioning plates
with the shafts.
top of page
Determining disc thickness S3
1. Push fixed wheel for 3rd gear on to the output shaft. The narrow collar faces the tensioning plate.
2. Shift into 4th gear.
3. Block the input shaft with special tool retaining device
9253 .
4. Push special tool assembly sleeve 9263 −A− and discs (Part No. 950.302.296.03) −B− on to the output
shaft.
5. Screw collar nut on to the output
shaft.
6. Set the setting collar on special tool measuring mandrel VW 385/1 to the dimension a ( approx. 65
mm ).
7. Complete the measuring mandrel as shown in the illustration.
Determining disc thickness S3 1895

einordnung
8. Read off the installation dimension E from the crown wheel.

1 Installation dimension E
2 Backlash F
3 Matching number
Example: E = 70.20 mm
9. Set the installation dimension E on special tool universal master gauge VW 385/30 and set the dial
gauge to 0 with 2 mm pretension.
10. Place special tool adjusting shim 9281 on the pinion head of the output shaft.
11. Insert the measuring mandrel as shown in the illustration.

12. Place the side transmission cover in position without an O−ring and pull downwards with 4 screws. Do
not knock.
13. Press tapered roller bearing with the centring screw over the spindle into the bearing shells. It should just
be possible to turn the measuring mandrel by hand.
14. Turn the measuring mandrel carefully back and forth until the reversing point on the dial gauge is
reached. At this point, the dial gauge extension is positioned exactly at right angles to the front face of the
pinion head.
15. Read off the deviation from the specified adjusting value E. If the deviation is greater than 0.04 mm, a
correction must be carried out.
Example: 0.10 mm
Note
• So in the example, the actual value of the adjusting dimension E would not be 70.20 but rather 70.30
mm.
16. In order to achieve the required adjusting dimension E, the adjusting shim S3 must be adjusted by the
measured value.
Example: new disc thickness S3 = 0.90 mm
17.
Determining disc thickness S3 1896

einordnung
In order to correct the altered disc S3, disc S4 must be altered in the opposite direction by the determined
value.
Example: S4 = 1.15 mm (increase by 0.10 mm)
18. As the thickness of disc S4 is identical to the thickness of disc S5, disc S5 must be altered by the same
value as disc S4.
Example: S5 = S4 = 1.15 mm
19. When the discs S3, S4 and S5 have been corrected appropriately and inserted, the adjusting dimension E
should be checked again.
top of page
Note
• The crown wheel must be adjusted again if the transmission housing, the side cover, the tapered roller
bearing for the differential, the differential housing or the drive set are replaced.
Determining total disc thickness S1 + S2
1. Remove the tensioning plate with the input and output shafts.
2. Insert 2 discs S1 and S2 with a thickness of 2.5 mm each into the differential and mount the tapered roller
bearing.
Note
• The chamfers of the adjusting shims point towards the housing.
3. Insert the differential into the housing and turn it several times.
4. Mount the side transmission cover without a shaft seal and screw in all
screws.
5. Fit special tool adjustment device VW 521/4 opposite the crown wheel side (S2 side) into the differential.
6. Place the special tool end plate VW 385/17 −B− on to the differential.
7. Fasten special tool dial gauge holder VW 387 on the housing with the dial gauge and the special tool
dial gauge extension VW 385/56 −A− .
8. Set dial gauge with 2 mm pretension to 0.
Determining disc thickness S1 and S2 1897

einordnung
9. Press the differential upwards as far as possible with special tool adjustment device VW
521/4 .
10. Read off the play on the dial gauge.
Example: 0.75 mm
Note
• The differential must not be turned during the measurement, as otherwise the measurement will be
falsified.
11. The total thickness of discs S1 and S2 is calculated from the total of the already inserted discs plus the
measured value plus the specified bearing pretension of the tapered roller bearing.
Example: 5.00 mm + 0.75 mm + 0.40 mm = 6.15 mm = S1 + S2
Note
• The pretension of the tapered roller bearing in this transmission is always 0.40 mm.
Dividing the total disc thickness into S1 and S2
Note
• In order to gain as precise a setting of the backlash as possible at this point, the adjusting shim S1
must be 1.4 mm thicker than adjusting shim S2.
Example: disc thickness S1 = 6.15 mm / 2 − 0.7 mm = 2.375 mm

Example: disc thickness S2 = 6.15 mm / 2 + 0.7 mm = 3.775 mm
Note
• As the adjusting shims are available in thicknesses from 1.5 to 2.8 mm in increments of 0.05 mm, the
calculated result must be rounded off. However, the total of the disc thicknesses S1 + S2 must not be
changed. To determine the thickness, measure the adjusting shims at several places with a
micrometer. The discs should also be checked for burrs and damage.
Example: disc thickness S1 = 2.375 mm; inserted adjusting shim = 2.35 mm

Example: disc thickness S2 = 3.775 mm; inserted adjusting shim = 3.80 mm
Example: total of both inserted discs = 2.35 + 3.80 = 6.15
1. Remove the differential and pull off both tapered roller bearings.
2. Insert the calculated adjusting shims S1 and S2.
Checking the circumferential backlash and setting, if necessary
Determining total disc thickness S1 + S2 1898

einordnung
1. Read off the backlash at the crown wheel.

1 Installation dimension E
2 Backlash F
3 Matching number
2. Mount the input and output shafts with tensioning plate and adjusting shims.
3. Mount the gear set and the gear housing. Then assemble front gear set ’ 34 35 37 Disassembling and
assembling transmission.
4. Screw collar nut on to the output
shaft.
5. Install the differential and mount the side transmission cover with all the
screws.
Note
• Always make sure a certain amount of backlash is present when tightening the screws. The drive
pinion must not jam under any circumstances.
Checking the circumferential backlash and setting, if necessary 1899

einordnung
6. Screw in special tool gauge plunger VW 388 with special tool adjustment device VW 521/4 and set
the lever length to 91 mm −a− .
7. Insert special tool adjustment device VW 521/4 into the differential with special tool bushing 9145 and
clamp tight.
8. Turn the differential several times in both directions so that the tapered roller bearings can
settle.
9. Mount the special tool dial gauge holder VW 387 with the dial gauge in such a way that a right angle is
formed between the dial gauge axis and the special tool gauge plunger VW 388 .
10. Install special tool retaining device 9562 .

11. Turn the crown wheel as far as it will go via the clamping screw of the special tool adjustment
device VW 521/4 and set the dial gauge to zero.
12. Turn the crown wheel back and read off the circumferential backlash.
13. This measurement should be performed a further three times. The crown wheel must be turned
90° before every measurement. The difference between the four measurements must not exceed
0.03 mm. Moreover, none of the measurements may deviate by more than 0.04 mm from the
circumferential backlash noted on the crown wheel. If any of the specified dimensions is not
observed, the adjusting shims S1 and S2 must be replaced again.
Note
• The total disc thickness S1 + S2 must not be changed.
996840, 996841
Checking the circumferential backlash and setting, if necessary 1900

halfshaft flange − GT2
Tools
Tightening torques
top of page
Tools

Pressure piece Special tool Pressure piece 9252
top of page
39 22 19 Removing and installing sealing ring for halfshaft flange − GT2 1901
einordnung
1. Unclip the B−plus cable from the holder −A− (only the right
side).
2. Uncouple drive shaft on the transmission side. Unscrew the hexagon socket head bolts
−B− .
3. Unscrew the fastening screw between the halfshaft flange and the transmission.
4. Unscrew the halfshaft flange out of the transmission past the drive
shaft.
top of page
1. Fill the space between the dust and sealing lips with grease (e.g. Liqui−Moly) and drive in the sealing ring
up to the mounting face with special tool pressure piece 9252 .
2. Push in the halfshaft flange and tighten the fastening screw. If necessary, hold the halfshaft flange with 2
screws.
Tightening torque: 44 Nm (32 ftlbs.).
3. Fitting the halfshaft flange on drive shaft
4. Clip in the B−plus cable in the holder (only the right side).
Removing sealing ring for halfshaft flange 1902

einordnung
top of page
Tightening torques

Halfshaft flange − fastening screw M10 44
Halfshaft flange on drive shaft M10 81
996840, 996841
Installing sealing ring for halfshaft flange 1903

39 40 19 Removing and installing differential and
differential lock − GT2.
Tools
Overview
Removing differential and differential lock
Installing diffential and differential lock
Tightening torques
top of page
Tools

A Pressure piece Special tool Pressure piece 9247/4
B Pressure piece Special tool Pressure piece 3062
C Pressure piece Special tool Pressure piece 9252
D Mandrel Special toolPull−in tool and extractor P254
E Mandrel Special tool mandral VW295
top of page
Overview
39 40 19 Removing and installing differential and differential lock − GT2. 1904

einordnung

2 Halfshaft flange 2
4 Cover for final drive 1
5 O−ring 1
6 Differential lock 1
7 Shaft seal 2
8 Bearing outer race 1
9 Bearing outer race 1
top of page
Overview 1905
einordnung
Removing differential and differential lock

1. Remove transmission. ’ 34 35 27 Removing and refitting the transmission −
GT2.
3. Pull out hexagon−head bolts (no. 1 in overview) and halfshaft flange (no. 2 in
overview).
4. Unscrew hexagon−head bolts (no. 3 in overview) and disassemble cover for final drive (no. 4 in
overview), possibly with a rubber hammer.
5. Remove
differential.
top of page
Installing diffential and differential lock
1. Insert
differential.
2. Insert cover with new, lightly oiled O−ring (no. 5 in overview) and screw in hexagon head bolts.
3. Push in halfshaft flange and screw in hexagon−head bolts.
Tightening torque: 44 Nm (32,5 ftlb.)
4. Refitting transmission. ’ 34 35 27 Removing and refitting the transmission −
GT2.
top of page
Tightening torques

Halfshaft flange fastening screws M8 44 (32,5 ftlb.)
Cover fastening screws M6 25 (18.5 ftlb.)
996840, 996841
Removing differential and differential lock 1906

39 40 37 Assembling and disassembling differential
and differential lock − GT2
Tools
Overview
Disassembling GKN differential lock
Assembling GKN differential lock
Tightening torques
top of page
Tools

A Connecting piece Shop−made (flat steel 6 x 18)
B Pressure piece Special tool pressure piece P263
C Pressure piece Special tool pressure piece P264b
D Clamping jaws Special tool clamping jaws 9646
top of page
Overview
39 40 37 Assembling and disassembling differential and differential lock − GT2 1907

einordnung

1 Large inner race of tapered roller bearing 1
2 Adjusting shim X
3 Small inner race of tapered roller bearing 1
4 Adjusting shim X
6 Crown wheel 1
7 Countersunk screw 3
8 Lids 1
9 Thrust plate 2
10 Cup spring 2
11 Outer discs 4
12 Inner disc 4
13 Thrust ring (outside) 1
Overview 1908
einordnung
14 Shaft bevel gear (with threaded washer) 2

15 Bevel pinion 4
16 Axle 2
17 Thrust ring (inside) 1
18 Housing 1
top of page
Disassembling GKN differential lock
1. Remove differential. ’ 39 40 19 Removing and installing differential and differential lock. − GT2
2. Clamp differential lock in the vice with special tool clamping jaws
9646 .
3. Remove tapered roller bearing −A− with
puller.
4. Undo hexagon−head bolts −B− and remove the crown wheel −C− .
5. Unscrew 3 cross−recess screws −A− and remove lid −B− .
Note
• The installation position of the lid in relation to the housing is marked for refitting.
6. Remove inner parts − see overview −.
top of page
Assembling GKN differential lock
Note
Disassembling GKN differential lock 1909

einordnung
• The complete disc pack should always be replaced in the case of repairs. Replacing individual discs is
not permissible. Oil discs, thrust rings and axles lightly with transmission oil before fitting.
1. Insert inner parts − see overview −. If necessary, affix thrust plates with viscous grease.
2. Put on cover and screw in cross recess screws.
3. Insert crown wheel and screw in hexagon−head bolts.
Note
• The hexagon−head bolts must always be replaced.
4. Press tapered roller bearing on with special tool drift P 264

b.
Note
• Depending on the type of repairs / replaced parts, the thickness of the adjusting shim (no. 2 in
overview) must be redetermined. ’ 39 08 15 Adusting drive set − GT2.
5. Now measure the basic locking torque by holding one of the halfshaft flanges in position and driving the
other. To do this, clamp one flange in the vice with two screws and position differential. Insert second
drive flange with shop−made connecting piece −A− and turn differential with a torque measuring tool. A
basic locking torque from 5 to 15 Nm (4 to 11 ftlb.) must be achieved.
6. Install differential. ’ 39 40 19 Removing and installing differential and differential lock −
GT2.
top of page
Tightening torques

Cross−recess screw for cover on housing M6 15 (11 ftlb.)
Hexagon−head bolts for crown wheel fastening M12 200 (148 ftlb.)
Assembling GKN differential lock 1910

einordnung
996840, 996841

46 16 24 Installing air ducts for PCCB brake discs −
GT2
Note
Installing front air ducts
Installing rear air ducts
Note
• The air ducts (brake−air spoiler) on the front suspension of GT2 vehicles with PCCB brakes are larger
than those of a conventional brake system! Exclusively for PCCB brakes, air ducts (brake−air spoiler)
are also mounted on the rear suspension!
• These air ducts are not mounted during transport!
CAUTION
Damaged, worn or missing aerodynamic components such as spoilers or underside panels affect the driving
behaviour and therefore must be replaced immediately!
• Spoilers and undersides must therefore be regularly checked for damage!

• Please inform the customers concerned about this!
top of page
Installing front air ducts
1. Mount the air duct (brake−air spoiler) on the front control arm (clip in similar to the standard air spoiler
on the Carrera 996 and Turbo 996). Then insert the expansion rivet (included in the scope of delivery) into
the bore present −arrow− . In vehicles with the model year 01, the bore −arrow− must also be drilled in
the wheel housing behind (8 mm, drill through from the existing bore).
2. Mount the air duct in the same manner on the other side of the vehicle.
top of page
46 16 24 Installing air ducts for PCCB brake discs − GT2 1912

einordnung
Installing rear air ducts
1. Push air duct (brake−air spoiler) onto the lower rear axle control arm from the
front.
Subsequently fit the retaining clip −2− (included in the scope of delivery) from the rear. The
retaining clip −2− must be inserted into the slot of the air duct −arrow− at the top.
Connect the retaining clip −2− to the air duct −1− . For this purpose, push the three expansion rivets −3−
(included in the scope of delivery) into the bores drilled in the bracket and the air duct (two from above
and one from behind).
Note
• The illustration shows the rear of the air duct −1− (removed)!
• The left and right air duct −1− and retaining clip −2− differ from eachother!
2. Mount the air duct in the same manner on the other side of the vehicle.
996840, 996841
Installing rear air ducts 1913

46 36 20 Removing and installing the front disc brake
pads − GT2 / Turbo with PCCB
Caution
Removal
Installation
WARNING
Note
• The GT2 is equipped with PCCB (Porsche Ceramic Composite Brake) as standard!
• In contrast to this, at the start of production, steel brake discs and brake pads are used at first!
• 2 vibration dampers −arrows− are fitted on each of the brake−pad supports!
• Vibration dampers are provided as additional damping measures!
• Replace vibration dampers each time the pads are changed!
• The damper plates have an adhesive protective film! The protective film must be pulled off before
installation!
46 36 20 Removing and installing the front disc brake pads − GT2 / Turbo with PCCB 1914
einordnung
• When fitting the vibration dampers on the small pistons, the cut−out on the vibration damper
−arrow− is to be positioned at the brake pads guide pins as otherwise the vibration damper will be
deformed!
top of page
Removal
CAUTION
PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/installation
(danger of damage to brake discs)!
1. Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel
removal/installation. During removal, first remove the three remaining wheel bolts and remove the wheel
carefully, without touching the brake discs.
Removal 1915
einordnung
2. Undo the screw on the retaining pin. Counter the retaining pin when doing
this.
3. Pull out the retaining pin towards the

inside.
brake pad plates.
Note
warning contact!
escape over the rim of the container)!
5. Set back the brake pads as far as possible with the piston resetting fixture (press back)!
6. Pull out brake pads together with the damper plates (remove). If this is not possible (depending on wear of
the brake pads), use a spatula to detach the damper plates from the brake pad backing plate before
removing the pads.
top of page
Removal 1916
einordnung
Installation
WARNING
• Fit new expanding spring and new retaining pin with a new screw on the brake caliper!
Note
• For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the wheel hub!
1. Before installation of the brake pads, check the wear of the brake discs => Checking front PCCB brake
discs (wear assessment).
2. If necessary, press back the piston to its original position using the resetting fixture.
3. Fit new damper plates in the pistons. As the vibration dampers are provided with a protective film, the
protective film must be removed before installation.
4. When fitting the vibration dampers on the small pistons, the cut−out on the vibration damper −arrow− is
to be positioned at the brake pads guide pins as otherwise the vibration damper will be deformed!
Installation 1917
einordnung
6. Fit new expanding spring and new retaining pin with a new screw on the brake caliper! These parts
are available as a repair set and must be renewed each time the pads are changed. When tightening
the screw, counter at the retaining pin! Tightening torque of the screw = 25 ± 3 Nm (2 ftlb.)
contacts.
level.
• New brake pads require a slightly longer bedding−in period for PCCB brake discs than cast iron brake
discs.
• In general, the following applies: New brake pads must be broken in (bedding−in period), their
optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly
reduced braking effect must be compensated for by increased pressure on the brake pedal. The same
also applies after a brake disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Bedding in the brake pads 1918

46 38 20 Removing and installing the rear disc brake
pads − GT2 / Turbo with PCCB
Caution
Removal
Installation
WARNING
Note
• The GT2 is equipped with PCCB (Porsche Ceramic Composite Brake) as standard!
• In contrast to this, at the start of production, steel brake discs and brake pads are used at first!
• 2 vibration dampers −arrows− are fitted on each of the brake−pad supports!
• Vibration dampers are provided as additional damping measures!
• Replace vibration dampers each time the pads are changed!
• The damper plates have an adhesive protective film! The protective film must be pulled off before
installation!
46 38 20 Removing and installing the rear disc brake pads − GT2 / Turbo with PCCB 1919
einordnung
top of page
Removal
CAUTION
brake pad plates.
Note
warning contact!
Removal 1920
einordnung
escape over the rim of the container)!
4. Set back the brake pads as far as possible with the piston resetting fixture (press back)!
5. Pull out brake pads together with the damper plates (remove). If this is not possible (depending on wear of
the brake pads), use a spatula to detach the damper plates from the brake pad backing plate before
removing the pads.
top of page
Installation
WARNING
Note
• For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the wheel hub!
1. Before installation of the brake pads, check the wear of the brake discs => Checking rear PCCB brake
discs (wear assessment) .
2. If necessary, press back the piston to its original position using the resetting fixture.
3. Fit new damper plates in the pistons. Remove protective film from the damper plates before
installation.
Installation 1921
einordnung
5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) −arrow− ! These
parts are available as a repair set and must be renewed each time the pads are changed!
contacts.
level.
• New brake pads require a slightly longer bedding−in period for PCCB brake discs than cast iron brake
discs.
• In general, the following applies: New brake pads must be worn in (bedding−in period), their
optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly
reduced braking effect must be compensated for by increased pressure on the brake pedal. The same
also applies after a brake disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Bedding in the brake pads 1922

46 50 19 Removing and installing the front PCCB
brake disc
Removal
Explanation of 2−part brake disc
Installation
top of page
Removal
CAUTION
2. Subsequently (after the wheel is disassembled) remove the 2 assembly aids (assembly pins)
again.
Note
• In order to gain better access for assembly work, it is beneficial to turn the wheels fully either to the
right or the left!
3. Press the electrical lead for the speed sensor/wear indicator out of the holder.
4. Undo the plug coupling for the speed sensor/wear indicator on the wheel carrier.
5. Loosen holder for brake line at wheel
carrier.
6. Disengage the electrical lead for the wear indicator from the
clips.
8.
46 50 19 Removing and installing the front PCCB brake disc 1923

einordnung
Undo the brake caliper on the wheel carrier and hang it in a suitable place in the wheel well (do not open
the brake hydraulics!).
9. Take off the brake disc after removing the countersunk screws.
top of page
• The PCCB brake discs consist of two parts on the front and rear axles. The brake disc −1− is screwed
to the brake−disc chamber −2− with 10 screws (M6) −3− .
• The complete brake disc only is available as a spare part (disc + brake−disc chamber)!
• Do not separate the brake−disc chamber −2− and brake disc −1− from each other. It is also not
permissible and not necessary to turn the screws −3− . The screws are safeguarded against turning by
compression in the bushing.
• It is essential that the tightening torque of the 10 screws is not changed (do not turn the screws) as this
will have a negative effect on the sound behaviour.
1 Brake disc
2 Brake−disc chamber
3 Screw (10 ea.)
top of page
Installation
Note
• Do not confuse right and left brake discs during assembly! Distinguishing characteristic: Involute
shape, identification and spare part number (SP No.)!
• The front PCCB brake discs of the Turbo and GT2 are different. Use the correct brake disc when
replacing!
• The front PCCB brake discs are marked with GT or Turbo, R = right or L = left and with an arrow for
the direction of rotation (additional diffence to right or left)!
• Spare part on left−hand side − third group number is odd. Example: SP No. Left brake disc =
996.351.031.92.
• Spare part on right−hand side − third group number is even. Example: SP No. Right brake disc=
996.351.032.92.
Removal 1924
einordnung
2. Clean the levelling and centring surfaces on the brake disc and wheel hub.
Note
• Replace the brake caliper fastening screws after each removal!
• The brake caliper fastening screws of the GT2 and Turbo with PCCB are 8 mm longer (85 mm) than
on the 911 Turbo with cast iron brake discs (77 mm)!
5. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ftlb.).
6. Mount wheel. For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the
wheel hub!
In general, the following applies: New brake pads must be worn in (bedding−in period), their optimum
disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 1925
46 53 19 Removing and installing the rear PCCB
brake disc
Removal
Installation
top of page
Removal
CAUTION
with the brake disc!
• The assembly aids (2 assembly pins) are located in the luggage compartment!
removal/installation. During removal, first remove the 3 remaining wheel bolts and remove the wheel
2. Subsequently (after the wheel is disassembled) remove the 2 assembly aids (assembly pins)
again.
5. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator.
46 53 19 Removing and installing the rear PCCB brake disc 1926

einordnung

7. Take off the brake disc after removing the countersunk screws. If a stuck brake disc cannot be removed,
evenly screw hexagon−head bolts into the two M8 threads of the brake disc, thereby pressing off the disc.
top of page
• The PCCB brake discs consist of two parts on the front and rear axles (illustration shows front brake
disc). The brake disc −1− is screwed to the brake−disc chamber −2− with 10 screws (M6) −3− .
• The complete brake disc only is available as a spare part (disc + brake−disc chamber)!
• Do not separate the brake−disc chamber −2− and brake disc −1− from each other. It is also not
permissible and not necessary to turn the screws −3− . The screws are safeguarded against turning by
the compression in the bushing.
• It is essential that the tightening torque of the 10 screws is not changed (do not turn the screws) as this
will have a negative effect on the sound behaviour.
1 Brake disc
2 Brake−disc chamber
3 Screw (10 ea.)
top of page
Installation
Note
• Do not confuse right and left brake discs during assembly! Distinguishing characteristic: Involute
shape, identification and spare part number (SP No.)!
• The brake discs are marked with R = right or L = left and with an arrow for the direction of rotation
(additional difference of right or left)!
• Spare part on left−hand side − third group number is odd. Example: SP No. Left brake disc =
996.352.031.02.
• Spare part on right−hand side − third group number is even. Example: SP No. Right brake disc=
996.352.032.02.
2. Clean the levelling and centring surfaces on the brake disc and wheel hub.
Removal 1927
einordnung
5. Adjust the parking brake shoes and parking brake cables.
Note
• Replace the brake caliper fastening screws after each removal!
• The brake caliper fastening screws for PCCB brake discs are 8 mm longer (85 mm) than on cast iron
brake discs (77 mm)!
6. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ftlb.).
7. Mount wheel. For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the
wheel hub.
In general, the following applies: New brake pads must be worn in (bedding−in period), their optimum
disc change.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Installation 1928
47 01 07 Bleeding brake − GT2
General
Bleeding brakes
top of page
General
The 911 GT2 is equipped with 3−channel ABS (ABS 5.3) without PSM (Porsche Stability Management) and
without TC (Traction Control).
Note
000.043.203.66! Container quantity 30 litres = 000.043.203.67!
top of page
Bleeding brakes
CAUTION
2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding
pressure approximately 2.0 bar.
Note
• Bleed the outer bleeder valve first!
47 01 07 Bleeding brake − GT2 1929

einordnung
3. Continue bleeding at the brake calipers in the sequence: Sequence: Rear right / rear left / front left / front
right.
4. Open each bleeder valve until clear, bubble−free brake fluid
emerges.
After installing a new brake master cylinder and/or a new hydraulic unit, do the following while bleeding:
• Open the right rear bleeder valves, then fully depress the brake pedal several times.
• Hold for 2 − 3 seconds after each depression, then release slowly.
• Repeat this procedure in the sequence rear left / front right / front left. This will remove all air bubbles
(from the primary circuit).
Note
• Also carry out this procedure if the brake hydraulics was largely empty or if after bleeding residual air
can be detected by excessive brake−pedal travel!
necessary.
996840, 996841
Bleeding brakes 1930

34 35 37 Disassembling transmission − GT2
Tools
Disassembling output shaft
top of page
Tools

tool
A Striker Special tool Striker VW 771
B Socket wrench insert Special tool Socket wrench insert 9105
C Retaining device Special tool Retaining device 9253
D Threaded piece Special tool Threaded piece VW 771/15
E Pressure pieces Special tool Pressure pieces 9656
F Two−armed extractor, span Commercially available ’ Handbuch Werkstattausrüstung Kapitel
250 2.4, Nr. 103
G Separator 17 − 75 cm Commercially available ’ Handbuch Werkstattausrüstung Kapitel
2.4, Nr. 109
H Two−armed extractor, span Commercially available ’ Handbuch Werkstattausrüstung Kapitel
120 2.4, Nr. 101
J Socket wrench insert Special tool Socket wrench insert 9282
34 35 37 Disassembling transmission − GT2 1931

einordnung
K Puller hook, 400 mm long Commercially available ’ Handbuch Werkstattausrüstung Kapitel

2.4, Nr. 105
top of page
1. Remove transmission. ’ 34 35 27 Removing and refitting the
transmission
3. Drain transmission oil. ’ 34 01 55 Change transmission oil.
4. Remove electric cable.
5. Remove hose −A− between oil cooler and transmission housing.

6. Remove oil cooler. To do this, undo screws −B− and lift oil cooler up and
off.
7. Remove the oil pump. To do this, remove screws. Screw in special tool threaded piece vw 771/15 in
thread −A− . Drive oil pump up and out with special tool striker vw 771 .
8. Unscrew fastening screws for front transmission case cover and force transmission case cover off
with a rubber hammer if necessary.
top of page
Overview
Tools 1932
einordnung

3 Thrust plate 1
4 Loose gearwheel, reverse gear 1
8 Shift collar 1
9 Washer 2
11 Shift fork (reverse gear) 1
12 Spring 3
13 Ball 3
Overview 1933
einordnung
14 Driver dog 3
15 Guide sleeve with snap ring 1
20 Shift collar 1
21 Driver dog 3
22 Ball 3
23 Spring 3
24 Guide sleeve 1
25 Shift fork (5th and 6th gears) 1
30 Thrust plate 1
33 Fixed gearwheel, reverse gear 1
34 Spacer sleeve 1
35 Fixed gear wheel, 5th gear 1
36 Spacer sleeve 1
38 Housing 1
Disassembling gear set

2. Fix the transmission with special tool retaining device 9253 and shift into a gear.
3. Remove nut −A− on input and output shaft.

4. Unscrew clamping screw from shift forks −B− .
5.
Disassembling gear set 1934

einordnung
Remove fixed gearwheel for reverse gear (no. 33 in overview) from the input shaft using the puller and
special tool pressure pieces 9656 . When doing so, pull off bearing inner race (no. 32 in overview).
6. Remove spacer sleeve (no. 34 in overview) from the input shaft.
7. Remove loose gearwheel for reverse gear (no. 4 in overview) with needle−roller bearing (no. 6 in
overview) from the output shaft using the puller and special tool pressure pieces 9656 . When
doing so, also pull off the cylindrical−roller bearing (no. 2 in overview) and thrust plates (no. 3
in overview).
8. Push complete gear set forwards onto output shaft using two mounting levers 1 − 2 cm.
9. Push gear set back behind the bearing inner race (no. 7 in overview) and remove bearing inner race using
the puller and special tool pressure pieces 9656 .
11. Remove fixed gear wheel, 5th gear (no. 35 in overview) and the spacer sleeve (no. 34 in overview).
13. Remove bearing inner race using puller and special tool pressure pieces 9656 .
16. Remove bearing inner race (no. 29 in overview) using puller and special tool pressure pieces 9656 .
17. Remove thrust plate (no. 30 in overview).
top of page
2. Disassembling front gear set.
3. Unscrew screw −A− and remove oil tube −B− .

4. Unscrew fastening screws between gear housing and transmission and remove
studs.
5. Unscrew plug screw −C− and remove the spring with locking pins.
6. If necessary force gear housing off with a rubber hammer.
top of page
Removing gear housing 1935

einordnung
Overview

2 Thrust plate 1
3 Loose gear wheel, 1st gear 1
4 Friction ring 1
5 Tapered ring 1
9 Shift collar 1
10 Guide sleeve 1
Overview 1936
einordnung
11 Driver dog 3
12 Ball 3
13 Spring 3
15 Tapered ring 1
16 Friction ring 1
17 Loose gear wheel, 2nd gear 1
20 Thrust plate 1
21 3rd gear fixed gear wheel 1
22 Oil tube 1
23 Locking element 2
24 Shift rod (1st/2nd gear) 1
25 Intermediate locking element 2
26 Shift rod (reverse gear) 1
27 Selector shaft 1
28 Shift rod (5th/6th gear) 1
30 Hexagon nut 7
31 Shift rod (3rd/4th gear) 1
33 Screw plug 4
34 Spring 4
35 Ball 4
38 Oil pump drive wheel 1
Removing shafts
1. Unscrew screw plugs (no. 33 in overview) of the locking elements and remove springs (no. 34 in
overview) and ball (no. 35 in overview).
2. Pull out reverse gear shift rod (no. 26 in overview) and shift rods for 5th/6th gear (no. 28 in overview)
towards the front. Pay attention to the intermediate lock (no. 25 in overview) and locking elements (no. 23
in overview) during this procedure.
3. Remove differential lock. ’ 39 40 19 Removing and installing differential and differential lock − GT2.
4. Remove oil tube (no. 22 in
overview).
5.
Removing shafts 1937

einordnung
Remove cylindrical−roller bearing (no. 32 in overview) from input shaft using a

puller.
6. Pull loose gearwheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no.
2 in overview) and cylindrical−roller bearing (no. 1 in overview).
7. Pull off the fixed wheel for 3rd gear (no. 21 in overview) with synchronisation 1st/2nd gear (no.
16 to 4 in overview) and loose gearwheel for 2nd gear (no. 17 in overview).
Note
• A specific disassembly of the synchronisation in assembled state may be recommendable as loss of

the small parts can then be avoided.
8. Unscrew nuts (no. 30 in overview) and remove tensioning plate (no. 29 in overview) with shafts and
remaining gear wheels.
9. Remove drive wheel of the oil pump (no. 38 in overview) and fixed wheel for 4th gear (no. 39 in
overview) and take output shaft out of the tensioning plate.
top of page
Disassembling output shaft
Overview

3 Bearing inner race 53.5 1
5 Bearing ring 56.0 mm 1
Disassembling output shaft 1938

einordnung
7 Output shaft 1
Disassembling shaft
1. Remove adjusting shim (no. 1 and 2 in overview) from shaft. Note the quantity and thickness for
reinstallation.
2. Press cylindrical−roller bearing (no. 6 in overview) off with bearing inner race (no. 5 and 3 in
overview) and four−point bearing (no. 4 in overview).
top of page
Overview
Overview 1939
einordnung

7 Shift rod / 3rd/4th gear shift fork 1
8 Locking element 1
9 Thrust plate 1
10 Loose gear wheel, 4th gear 1
Overview 1940
einordnung
14 Guide sleeve 1
15 Shift collar 1
16 Driver dog 3
17 Ball 3
18 Spring 3
20 Loose gear wheel, 3rd gear 1
22 Input shaft 1
Disassembling shaft
1. Clamp complete shaft into the vice with gear set and special tool socket wrench insert 9282 .
2. Remove fastening nut.
3. Press off loose gearwheel for 3rd gear (no. 20 in overview) with synchronisation (no. 11 to 19 in
overview), loose gearwheel for 4th gear (no. 10 in overview) and the remaining parts (in overview
2 to 9).
996840, 996841
Disassembling shaft 1941

34 35 37 Assembling transmission − GT2
Tools
top of page
Tools

A Retaining device Special tool Retaining device 9253
B Socket wrench insert Special tool Socket wrench insert 9282
C Socket wrench insert Special tool Socket wrench insert 9105
top of page
34 35 37 Assembling transmission − GT2 1942

einordnung
Assembling shafts
Note
• The overview diagram of the input shaft is provided in the chapter disassembling transmission under
Disassembling input shaft .
1. Clamp shaft with special tool socket wrench insert 9282 in the vice.
2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the

overview. Pay attention to correct seating of the steel synchronising rings −A− and the driver dogs −B− .
The driver dogs with spring and ball must align with the dotting marks on the shift collar. Make sure
furthermore that the rectangular indentations of the synchronising rings are positioned above the driver
dogs.
3. Check the synchronising rings for wear. check synchronising rings by pushin them onto the gear wheels
and measuring the gap −A− with a feeler gauge.
4. Push needle−roller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview)
and synchronisation onto input shaft.
6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input
shaft.
8. Fit clamping plate with short lock (no. 5 and 8 in overview), four−point bearing (no. 4 in overview)
and shift fork (no. 7 in overview) onto input shaft.
11. Screw new hexagon nut onto input shaft.
Assembling shafts 1943

einordnung
Tightening torques

Hexagon nut (no. 1 in overview) M30 x 1.5 250
top of page
Assembling shaft
Note
• The overview diagram of the output shaft is provided in the chapter disassembling transmission under
Disassembling output shaft .
1. Heat cylindrical−roller bearing (no. 6 in overview) to 120°C and push onto

output shaft.
3. Push on four−point bearing (no. 4 in overview) onto output shaft.
top of page
Installing shafts
Note
• An overview diagram of the installation is provided in the chapter 'disassembling transmission' under
Removing input and output shaft .

einordnung
.
3. Push on oil pump drive wheel −E− .
4. Affix adusting shim S3 −A− in the transmission case with viscous

grease.
5. Insert input and output shaft into the transmission case with tensioning plate and tighten nuts.
6. Push on 3rd gear fixed gear (no. 21 in overview) onto the output shaft. The large collar faces the thrust
plate.
7. Push thrust plate onto the output
shaft.
10. Check synchronisation of 1st/2nd gear. To do this, place the friction ring, the tapered ring and the
synchronising ring on the gear wheel. Measure the gap −A− with a feeler gauge. Perform test for
1st and 2nd gear.
Installation dimension (new): 1.5 to 2.0 mm
Wear dimension: 1.2 mm
11. Push 2nd gear loose gearwheel (no. 17 in overview) onto needle−roller bearing.

einordnung
12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronisation ring (no.
14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the
recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft.
14. Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 24 in overview). The turned groove
−A− in the shift collar must face the 2nd gear loose wheel.
Note
15. When setting the shift collar in place, ensure that the dotting marks on the shift collar are centred
with respect to the recesses in the guide sleeve.
1 Shift collar
2 Ball
3 Driver dog
4 Spring
A Recognition groove
B Dotting mark
C 2ndgear − side
E 1st gear − side
16. Fit spring (no. 11 in overview), ball (no 12 in overview) and driver dog (no. 13 in overview). To do this,
push the shift collar in the direction of the 2nd gear loose gearwheel.
17. Fit the synchronising ring (no. 6 in overview), the tapered ring (no. 5 in overview) and friction ring (no. 4
in overview).
19. Push 1st gear loose gearwheel (no. 3 in overview) and thrust plate (no. 2 in overview) onto output
shaft.

einordnung
20. Heat cylindrical−roller bearing (no. 1 in overview) to 120°C and push onto output shaft.
22. Fit oil tube (no. 22 in overview). Use new micro−encapsulated screw.
23. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if
necessary. Ensure that that the rollers on the selector shaft are complete.
1 Shift rod for 3rd/4th gear
3 Shift rod for 5th/6th gear
4 Intermediate lock
5 Locking element (long)
6 Reverse gear shift rod
7 Intermediate lock
9 Shift rod for 1st/2nd gear
24. Fit locking elements (no. 33, 34 and 35 in overview).
Note
• Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the
small locking elements and the balls of the lock can fall into the transmission.
Tightening torques

Tensioning plate on transmission case M8 25
Oil pipe on tensioning plate M5 6

einordnung
top of page
Fitting housing
1. Coat gear housing with Loctite 574 and put it on. To do this, insert shift rods into suitable bearing
locations and ensure correct engaging of the shift catch roller in the driver of the selector shaft.
2. Screw in fastening screws.
3. Fit locking pin, spring and plug screw.
Tightening torques

Gear housing fastening screws M8 23
Plug screw M 10 x 1 15
top of page
Note
• The overview diagram of the front gear set is provided in the chapter 'disassembling transmission'
under Disassembling front gear set .
Assembling gear set
1. Place thrust plate (no. 30 in overview) onto output

shaft.
3. Place fixed gear for 6th gear (no. 37 in overview) onto the input shaft.
Fitting gear housing 1948

einordnung
onto output shaft.
7. Assemble synchronisation (no. 26, 24 to 20 and 17 in overview). The rectangular recesses of the
synchonisation ring must be positioned above the driver dogs in the case of the steel
synchronisation ring (no. 26 in overview).
Note
8. Place synchronisation with shift fork (no. 25 in overview) onto

output shaft.
onto output shaft.
11. Place fixed gear for 5th gear (no. 35 in overview) onto the input shaft.
13. Assemble synchronisation (no. 15, 12 to 8 and in overview).
Note
Assembling gear set 1949

einordnung
14. Check the synchronising ring for wear. To do this, press synchronising ring onto the gear wheels and
15. Place synchronisation with shift fork (no. 8 in overview) onto output shaft.
17. Place loose gearwheel for reverse gear (no. 4 in overview) with needle−roller bearing (no. 6 in
overview) and synchronisation ring (no. 5 in overview) onto output shaft.
18. Place fixed gearwheel for reverse gear (no. 33 in overview) onto input shaft.
19. Heat bearing inner race (no. 32 in overview) to 120°C and place on input shaft.
20. Tighten new self−locking nuts (no. 31 in overview) on input shaft.
21. Place thrust plate (no. 3 in overview) onto output shaft.
22. Heat cylindrical−roller bearing (no. 2 in overview) to 120°C and place on output shaft.
23. Tighten new self−locking nuts (no. 1 in overview) on output shaft.
24. Adjust shift forks (no. 25 and 11 in overview). The shift collar must have slight play in both directions in
idle position.
25. Secure shift forks with screws and washers (no. 9 and 10 in overview).
26. Remove special tool (retaining device) 9253 .
27. Shift through all gears as a test.
Tightening torques

Nuts on output shaft M 30 x 1.25 300
Nuts on input shaft M 22 x 1.5 200
Shift fork screws M8 18
top of page

einordnung
Fitting cover
1. Coat front transmission case cover with Loctite 574, put on and screw in fastening
screws.
2. Fit the oil pump. To do this, drive in oil pump with a rubber hammer and screw in
screws.
3. Fit oil cooler. To do this, screw in hexagon socket head bolt −A− and two hexagon−head
bolts−B− .
Tightening torque for hexagon socket head bolt: 10 Nm (7.5 ftlb.)
Tightening torque for hexagon−head bolt: 23 Nm (17 ftlb.)
4. Fit connecting hose for oil cooler housing.
5. Fit electric cable.
6. Fill with transmission oil. ’ 34 01 55 Change transmission oil.
7. Remove transmission from assembly support and fit onto the engine. ’ 34 35 27 Removing and
refitting the transmission
Tightening torques

Fastening screws of front transmission case cover M8 23
Oil pump fastening screws M8 23
Hexagon socket head bolt of oil cooler M6 10
Hexagon−head bolt of oil cooler M8 23
996840, 996841
Fitting front transmission case cover 1951

45 46 19 Removing and installing front ABS lead
(GT2)
Tightening torques
Tools
top of page
• Remove front wheel. => Removing and installing the wheel − Turbo and GT2
• Remove front wheel housing liner. ’ 6, 505619 Removing and installing front wheel housing liner
• Remove cowl panel cover at centre and left. ’ 6, 664419 Removing and installing cowl panel cover
45 46 19 Removing and installing front ABS lead (GT2) 1952

einordnung
1. Release lead lock for the ABS plug connection −arrow A− and pull off both plugs −arrow B− .
2. Undo fastening screw −1− .
3. Take the lead out of the holders −arrows A− .

4. Open the clips −arrows B− and remove the lead −arrow C− .
5. Remove fabric tape −D− .
Note
6. Cut off the lead in area −E− and remove it.
7. Cut through the fabric tape in the radiator tank, in the area −a− , and expose the remaining ABS lead.
top of page
Removing front ABS lead 1953

einordnung
1. Position socket in installation position and secure using fastening screw

−1− .
2. Insert both plugs −arrow A− .
3. Fold back lead lock −arrow B− until it can be felt to engage on the
plugs.
4. Press the lead into the holders −arrow A− by inserting the rubber
sleeves.
5. Secure lead for headlight beam adjustment to the ABS lead using fabric tape −B− .
6. Position the lead in installation position −arrows C− and close the clips −arrows D− .
7. Push the lead through to the interior −arrow
E− .
Note
• Choose the connection point at a position with sufficient room for connecting all the individual leads.

einordnung
• Do not cut the ends of the lead too short so that the connection area can be moved from the original
installation position, if necessary, if there is insufficient space available.
8. Cut the ends of the lead in the radiator tank to the required length and crimp in area −a− with a crimp
connector and crimping tool. => Tools

9. Secure the repair area to the adjacent wiring harnesses using tie−wraps −c− .
• Install cowl panel cover at centre and left. ’ 6, 664419 Removing and installing cowl panel cover
• Install front wheel housing liner. ’ 6, 505619 Removing and installing front wheel housing liner
• Fit front wheel. => Removing and installing the wheel − Turbo and GT2
top of page
Tightening torques

Fastening screw −1− for securing ABS lead to spring strut M6 9.7 (7.2)
top of page
Tools

155−1
996840, 996841

50 30 19 Removing and installing air guide GT2
Removing and installing air guide
top of page
Removing and installing air guide
50 30 19 Removing and installing air guide GT2 1956

einordnung
Removing air guide

Pull air guide −1− out of the lines −A und B− .
Installing air guide
Push air guide −1− on to the lines −A und B− .
996840, 996841
Removing and installing air guide 1957

55 90 19 Removing and installing rear lid − GT2
Removing and installing rear lid
top of page
Removing and installing rear lid
55 90 19 Removing and installing rear lid − GT2 1958

einordnung
1 Electrical plug 1 Press the lug −arrow A− of Connect electrical plug connection −1− .
connection the electrical plug connection
−1− and separate.
2 Cable retainer 1 Press and open the lugs of the Insert the electrical wire into the cable
cable retainer −2− . Remove retainer −2− and close the cable retainer.
electrical wire. Ensure that the lugs have engaged correctly.
3 Fastening 4 Unscrew fastening screws. Tightening torque: −10 Nm (7.5 ftlb.)−
screws
4 Rear lid 1 Adjust lid −3− to the hinges in accordance
with the contours of the wings and the rear
spoiler => Diagram − body gap dimensions
Removing and installing rear lid 1959

einordnung
996840, 996841
Removing and installing rear lid 1960

GT2
Assembling rear lid
top of page
55 90 37 Disassembling and assembling rear lid GT2 1961

einordnung

Removing rear ’ 665819 Removing and installing rear spoiler − GT2
spoiler
1 Remove additional Disengage cover −A− at the sides, unlock lock −B− . Remove brake light
brake light −3− and disconnect plug connection −C− .
2 Remove rubber Pull rubber cover −4− out of the rear lid.
cover −4−
3 Remove adjusting Unscrew rubber pad −5− and disengage collar −6− .
element
4 Remove upper part Unscrew fastening screws −7− and remove upper part of lock −8− .
of lock −8−
5 Remove fan with fan Disconnect plug connections for fan and engine compartment lighting on the
housing −10− fan housing. Unscrew fastening screws −9− and remove fan with fan
housing −10− .

einordnung

6 Remove mount −12− Unscrew fastening screws −11− from the mount −12− .
7 Remove air guide Unscrew fastening screws −13− and remove air guide −14− .
−14−
8 Remove air guide Unscrew fastening screw −15− from the air guide −16− .
−16−
9 Remove bracket −19− Unscrew the fastening nuts −18− and the washers −17− from the bracket
−19− .
top of page

einordnung
Assembling rear lid

1 Install bracket Position the bracket −19− on the rear lid and screw in the fastening screws −18−
−19− and the lock washer −17− loosely.
• Position the brackets left and right −19− for the mounting point of the
rear spoiler fork −20− .
1. Place the rear spoiler on the rear lid. Ensure that the pegs −A− of the
rear spoiler fork −20− are guided into the bracket −19− . If necessary,
shift the bracket.
2. Tilt the rear spoiler und and down several times. Make sure that the rear
spoiler fork −20− is guided into the bracket −19− free of tension.

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3. Remove the rear spoiler.

4. Tighten the fastening screws −18− and the lock ring −17− .
2 Install air guide Insert air guide −16− and screw into place with the fastening screw −15− .
−16− Tightening torque: 10 Nm (7.5 ftlb.)
3 Install air guide Screw the air guide −13− into place on the inside of the lid with the fastening
−13− screws −14− . Make sure that the seal −14A− is fitted all around the air guide
−13− .
4 Install mount Position mount −12− . Tighten the fastening screws −11− .
−12− Tightening torque: 10 Nm (7.5 ftlb.)

5

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Install fan with Position the fan housing and fan −10− on the mount. Tighten with the fastening
fan housing −10− screws −9− . Connect plug connections for fan and engine compartment
lighting on the fan housing.
6 Install upper part Position upper part of lock −7− and fasten with fastening screws −8− .
of lock −8−
7 Install adjusting Engage collar −6− . Screw in rubber pads −5− . Apply plasticine to the rubber
element pad, close and open the lid. Determine the thickness of the plasticine and screw
the rubber pad in or out accordingly. => Diagram − body gap dimensions
8 Install rubber Press the rubber cover −4− into the rear lid −1− .
cover −4−
9 Install additional Push on electrical plug −C− . Insert the brake light into the rear lid. Lock the
brake light −3− lock −B− . Engage cover −A− .
Installing rear ’ 665819 Removing and installing rear spoiler − GT2
spoiler
Replace model logo
1. Position logo with the dimensions −X = 360 mm− and −Y = 20 mm− on the rear lid and affix.
Removing and installing rear−lid wiring harness
Replace model logo 1966

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1 Electrical plug 1 Press the lug of the electrical plug Plug in the electrical plug
connection connection −arrow− and separate. connection. Fasten the lead on
Cut through the tie wrap on the the shock absorber for the
gas−filled shock absorber (for the engine compartment lid with a
engine compartment lid) using side tie wrap.
cutters.
2 Additional 1 Disengage the cover at the side, Connect the plug and insert the
brake light unlock lock in −direction of arrow− brake light. Lock the lock in
. Remove brake light and disconnect opposite direction of −arrow− .
the plug connection. Clip in cover.
3 Wiring harness 1 −A− Pull out grommet with brake Lay the wiring harness and
light lead. Disconnect plug fasten lead into the mount with
connection −B− for fan on fan the fastening clips. Connect the
housing. −C− engine compartment plug −C− for the engine
Removing and installing rear−lid wiring harness 1967

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lighting, remove plug. −Arrow− compartment lighting and −B−

press fastening clips together and pull for the engine compartment fan.
out of the mount. Push the plug −A− with the
grommet through the opening
in the rear lid until the grommet
can be pushed into place.
996840, 996841
Removing and installing rear−lid wiring harness 1968

63 15 19 Removing and installing front spoiler GT2
top of page
63 15 19 Removing and installing front spoiler GT2 1969

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Remove wheel housing ’ 505619 Removing and installing wheel housing liner
liner
1 Remove cover. Turn hexagon cap nut −2− by 45° and remove.
Undo sheetmetal screws −4− from the front part −1− .
2 Remove direction Press in spring clip of direction indicator light −arrow A− at the
indicator light. sides with a screwdriver and take out the direction indicator light
−5− , disconnect electrical plug connection.
3 Undo front spoiler at the On the front spoiler, undo the fastening screws −6− and spacer
sides. sleeve −7− from the retaining strips on the left and right.
4 Undo front spoiler on the Undo fastening screws −8− of the front spoiler on the underbody.
underbody. Remove front spoiler −1− to the front.
top of page

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1 Fit front spoiler −1− . Lift the front spoiler −1− near the headlights above the radiators on the
right and left.
−Note:− When inserting over the radiators, make sure that the covers
are not pressed out of the front spoiler!
2 Fit front spoiler on the Position front spoiler on the underbody and screw in place with the
underbody. fastening screws −10− .
3 Fit front spoiler at the Affix front spoiler to the retaining strip and fasten it with the sheetmetal
sides. screw −6− and spacer sleeve −7− .
4 Fit cover. Fasten the front end −1− with the sheetmetal screws −4− .
Affix cover −3− , turn hexagon cap nuts −2− by 45°.

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5 Fit direction indicator Connect electrical plug connection of the direction indicator light −5− .
light. Insert lug −arrow− of the direction indicator light into the front end
−1− and clip into the sheetmetal clip.
Install wheel housing ’ 505619 Removing and installing wheel housing liner
liner
996840, 996841, 996430, 996431

63 15 37 Disassembling and assembling front spoiler
GT2
top of page
63 15 37 Disassembling and assembling front spoiler GT2 1973

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1 Remove covering cap Carefully press out covering cap −2− with a screwdriver.
−2− Cut through the securing cord−3− which links the front end −1− and
the covering cap.
2 Remove covering frame Press in the lugs of the covering frame −4− and lift it up and off
−4− carefully.
3 Remove air outlet frame Unscrew fastening screws −5− from the air outlet frame −6− .
−6−
4 Remove frame centre Carefully press the spring nut −8− out of the pegs of the front end
−9− −1− on the top side using a screwdriver. The spring nuts −8− are
destroyed during removal.
Guide the frame centre −9− out of the pegs of the front end towards
the rear.
5 Remove grille frame Carefully disengage the spring nuts −8− from the pegs of the front
−10− left, right end all the way round using a screwdriver. Guide the grille frame
Disassembling front spoiler 1974

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−10− out of the pegs towards the rear out of the front end −1− .

1 Undo fastening screws Undo fastening screws −4− from the front spoiler −1− and the wheel
−3− housing liner −2− at the sides.
2 Remove front spoiler Press in the lugs with a screwdriver, at the same time pull off the front
−1− spoiler −1− outwards.
top of page

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1 Install grille frame Position the grille frame −10− on all sides in the pegs of the front end −1− .
−10− Press the spring nut −8− on to the pegs of the front end −1− .
2 Install frame centre Position the grille frame −9− in the pegs of the front end −1− .
−9− Press the spring nut −8− on to the pegs of the front end −1− .
3 Install air outlet Check and, if necessary, replace sheetmetal nuts −7− .
frame −6− Position air outlet frame −6− on the front end −1− . Secure the air outlet
frame −6− with the fastening screws −5− .
4 Install covering Lock covering frame −4− into the front end −1− .
frame −4−
5 Install covering cap Pull the securing cord −3− through the eyelet in the covering cap −2− and

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−2− . the front end −1− .

1 Fit front spoiler Insert the front spoiler −1− into the groove of the front end.
−1− Make sure that all lugs are engaged.
2 Tighten front Place the sheetmetal nut −5− in position on the front end. Use the fastening
spoiler −1− screws −4− and spacer sleeves −3− to tighten the front spoiler at the sides with
the wheel housing liner −2− to the front end −1− .

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996840, 996841

66 58 19 Removing and installing rear spoiler GT2
top of page
66 58 19 Removing and installing rear spoiler GT2 1979

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CAUTION
Damage to paintwork when the rear spoiler is removed with the rear lid closed!
• Only remove the rear spoiler with the rear lid open.

1 Remove covering frame −2− Unscrew fastening screw −1− . Guide covering frame −2−
out.
2 Undo fastening screws −3− Unscrew fastening screws −3− by approx. 5 turns.
Open the rear lid Only remove the rear spoiler with the rear lid open.
3 Remove the rear spoiler −5− from Swivel the rear spoiler −5− upwards −arrow A− and
the rear lid guide it out in the direction of the arrow −arrow B− .

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top of page
CAUTION
Change in handling, the balance from the front to the rear axle is affected!
• The additional wing is set to the lowest (horizontal) position for street use. Changes to the setting (to
individually match the personal driving style) are only intended for the racing track. The wing tilt may
be adjusted from 1° to max. 6° for use on racing tracks.
• The additional wing must be moved to the lowest position for use in public traffic.

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Unscrew the To simplify the installation of the rear spoiler, the fastening screw −3− and
fastening screws the clamping piece −4− should be unscrewed fully.
−3− fully
Open the rear lid Only install the rear spoiler with the rear lid open.
1 Fit the rear spoiler 1. Place the rear spoiler −5− on to the rear lid. Ensure that the pegs −A− of
−5− on to the rear the rear spoiler fork are guided into the bracket −7− .
lid 2. Tilt the rear spoiler und and down several times. Make sure that the rear
spoiler fork −6− is guided into the bracket −7− free of tension. If
necessary, shift the bracket −7− ’ 55 Disassembling and assembling rear
lid
3. Tighten the fastening screws −3− and the clamping piece −4− .
Tightening torque: 23 (17)

2 Fit fastening screws Position the clamping piece −4− and tighten the clamping piece with the
−3− fastening screw −3− .
1 Install covering Guide covering frame −2− in. Screw in fastening screw −1− .
frame −2−
Replacing rear spoiler fork
1. Removing and installing rear spoiler fork

a. Unscrew the fastening screws −1− from the rear spoiler fork −2− and the rear
spoiler −3− .
b. Replace rear
spoiler fork
Note
• During installation, the fastening screws −1− must always be secured with Loctite 240 −inset− .
c. Position the rear spoiler fork −2− on the rear spoiler −3− . Secure the rear spoiler fork −2− with the
fastening screws −1− . Tightening torque: 10 Nm (7.5 ftlb.)
Replacing rear spoiler fork 1982

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996840, 996841
Replacing rear spoiler fork 1983

69 72 19 Removing and installing roll−over bar − GT2
Removing roll−over bar
Installing the roll−over bar
Adjusting the roll−over bar
Assembly instructions for the rear trim, the floor covering and the closure caps
top of page
Removing roll−over bar
69 72 19 Removing and installing roll−over bar − GT2 1984

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Before the removal of the base cage −C− , the bucket seats must be removed! ’ 707219 Removing and
installing bucket seats => Assembly instructions for the rear trim, the floor covering and the closure caps

1 Move right and left sections (A−pillar Undo the lock nut −1− of the adjusting element −2− in
support) −A, B− to each other to the direction of the arrow −X− .
relieve the tension and Relieve the tension on the right and left sections
disconnect the front transverse (A−pillar support) −A, B− by screwing in above the
connection adjusting element −2− in the direction of the arrow
−Y− into the left section (A−pillar support) −B− .
Unscrew the fastening screws −3− from the retainer
plate −4− and the right section (A−pillar support) −A−
.
2 Detach right section (A−pillar Unscrew the fastening screws −3− from the right
support) −A− section (A−pillar support) −A− and the base cage −C−
.
Removing roll−over bar 1985

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3 Detach right section −A− on the Unscrew the fastening nuts −5− and the washer −6−
underbody from the right section (A−pillar support) −A− .
Guide the section (A−pillar support) −A− out of the
passenger compartment to the right.
4 Detach left section −B− on the Unscrew fastening nuts −5− and washer −6− from the
underbody left section (A−pillar support) −B− .
5 Detach left section (A−pillar support) Unscrew the fastening screws −3− from the left
−B− section (A−pillar support) −B− and from the base cage
−C− .
Guide the section (A−pillar) −B− out of the passenger
compartment to the left.

6 Remove selector sleeves −9− Unscrew fastening nuts −5− from the fastening screws −8−
.
Removing roll−over bar 1986

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Push the selector sleeves −9− on to the spring dome

support sections −C, D− .
7 Remove base cage −C− on right side Unscrew the fastening nuts −5− and the washer −6− from
of underbody the base cage −C− .
8 Remove base cage −C− on left side of Unscrew the fastening nuts −5− and the washer −6− from
underbody the base cage −C− .
Guide the base cage −C− out of the passenger
compartment.
Note
• In order to unscrew the fastening nuts −7− from the spring strut mount, the vehicle must be standing
on its wheels.

9 Detach right spring Unscrew the fastening nuts −7− and guide the spring dome support section
dome support −D− out of the right spring strut mount.
section −D−
1) Carry out a test drive after performing assembly work on the roll−over
bar/spring strut mount threaded parts on the body and then re−tighten the
fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). The fastening
nut −7− must always be replaced.
10 Detach left spring Unscrew the fastening nuts −7− and guide the spring dome support section
dome support −E− out of the left spring strut mount.
section −E−
1) Carry out a test drive after performing assembly work on the roll−over
bar/spring strut mount threaded parts on the body and then re−tighten the
fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). The fastening
nut −7− must always be replaced.
1) Only when commissioning the vehicle without a roll−over bar
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Installing the roll−over bar
Installing the roll−over bar 1987

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DANGER
Re−tighten with correct tightening torque!
• Carry out a test drive after performing assembly work on the roll−over bar/spring strut mount
threaded parts on the body and then re−tighten the fastening nuts −7− with the correct tightening
torque!
Note
• Initially screw in and centre all the fastening screws and fastening nuts only in the sections −A, B, D,
E− and in the base cage −C− . Only then tighten the threaded parts with the prescribed tightening
torques. Adjust the adjusting element −2− last.

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1 Install right spring dome Position the spring dome support section −D− in the rear of the
support section −D− passenger compartment onto the spring strut mount on the right.
Tighten in place with the fastening nuts −7− .
The fastening nut −7− must always be replaced.
Carry out a test drive after performing assembly work on the
roll−over bar/spring strut mount threaded parts on the body and
then re−tighten the fastening nuts (three per side) to the torque: 46
Nm (34 ftlb.).
2 Install left spring dome Position the spring dome support section −E− in the rear of the
support section −E− passenger compartment onto the spring strut mount on the left.
Tighten in place with the fastening nuts −7− .
The fastening nut −7− must always be replaced.
Carry out a test drive after performing assembly work on the
roll−over bar/spring strut mount threaded parts on the body and
then re−tighten the fastening nuts (three per side) to the torque: 46
Nm (34 ftlb.).
3 Install base cage on right Position the base cage −C− on the fastening plate. Install the
of vehicle floor washers −6− and the fastening nuts −5− . Tightening torque: 23
Nm (17 ftlb.)
4 Install base cage −C− on Position the base cage −C− on the fastening plate. Install the
left of vehicle floor washers −6− and the fastening nuts −5− . Tightening torque: 23
Nm (17 ftlb.)
5 Install the base cage −C− Push selector sleeves −9− onto the spring dome support sections
and selector sleeves −9− on the left and right −D, E− . Position the base cage −C− onto the
sections of the spring dome support −A, B− . Push the selector
sleeves upwards over the connector tube of the base cage.
Screw the hole pattern of the selector sleeves on the hole pattern of
the base cage −C− and of the spring dome support sections −D, E−
. Install the fastening screws −8− and tighten with the fastening
nuts −5− . Tightening torque: 16 Nm (12 ftlb.)

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6 Install right section (A−pillar Guide the right section (A−pillar support) −A− inwards from the
support) −A− right door. Position on the fastening plate on the vehicle floor and
screw into place with the washers −6− and the fastening screws
−5− .
7 Install right section −A− on Screw into place on the screwed points of the base cage −C− with
the base cage −C− the fastening screws −3− .
8 Install left section (A−pillar Guide the left section (A−pillar support) −B− inwards from the left
support) −B− door.
Position on the fastening plate on the vehicle floor and screw into
place with the washers −6− and the fastening screws −5− .
9 Install left section −B− on the Screw into place on the screwed points of the base cage −C− with
base cage −C− the fastening screws −3− .

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10 Install the transverse Press the adjusting element −2− screwed into the transverse
connection of the sections connection into the groove −Z− of the section (A−pillar support)
(A−pillar support) −A, B− at −A− . At the same time, install the retainer plate −4− and screw
the front into place with the fastening screws −3− .
=> Adjusting the roll−over bar
top of page
Adjusting the roll−over bar
The foam coating of the A−pillar support sections must be pressed against the cowl panel frame trim.
1. Unscrew the adjusting element −2− in the direction of the arrow −Y− until the foam coating −3− of the
A−pillar support sections on the left and right −A, B− are pressed against the cowl panel frame trim.
2. Screw the lock nut −1− in the direction of the arrow −X− as far as it will go against the adjusting element
−2− and lock it against the adjusting element −2− .
top of page
Assembly instructions for the rear trim, the floor covering and
the closure caps
Adjusting the roll−over bar 1991

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1 Rear cover −1− 1 Lift the rear cover −1− up and out. Press the rear cover −1− in
between the side−panel
lining and the roll−over bar
−D, E− .2)
In vehicles where the

roll−over bar has been
removed, the rear cover may
be replaced if necessary (for
reasons of appearance).1)
2 Flaps in the floor 4 Pull out the flaps in the floor Press in the flaps in the floor
covering −2− covering −2− . covering −2− around the
roll−over bar −A, B, C− .
A Closure caps −3− 4 In order to install the roll−over bar, After the roll−over bar has
the closure caps −3− should be been removed, the flaps in
removed from the floor covering, the floor covering should be
inset −2− 2) closed with the closure caps
−3− .1)
1) Only after removal of the roll−over bar

2) Only during installation of the roll−over bar
996840, 996841
Assembly instructions for the rear trim, the floor covering andthe closure caps 1992
72 01 19 Removing and installing bucket seat GT2 −
as of MY 2001
Removing bucket seat GT2
Installing bucket seat GT2
top of page
Removing bucket seat GT2
72 01 19 Removing and installing bucket seat GT2 − as of MY 2001 1993

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1 Remove seat rail Insert a screwdriver under the locking tabs and press lightly upwards.
cover Caution!
Locking tabs can break.
Pull front seat rail cover −2− out of the right and left seat rails towards the
front.
2 Undoing seat Move seat to its rear limit position and undo the front M10 x 28 Torx screws
screws at front −3− from the right and left seat rails using an E 12 socket wrench insert.
3 Undoing seat Move seat to its front limit position and undo the M10 x 28 Torx screws −3−
screws at rear from the right and left seat rails using an E12 socket wrench insert.
top of page
Removing bucket seat GT2 1994

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Installing bucket seat GT2

1 Fitting seat screws Position seat rails on the seat baseframe, screw the rear M10 x 28 Torx
at rear screws −3− into the seat baseframe on the left and right using the E12
wrench socket and tighten with tightening torque: −65 Nm− (48 ftlb.).
2 Fitting seat screws Move seat to rear limit position and screw the front M10 x 28 Torx
at front screws −3− into the seat baseframe on the left and right using the E12
wrench socket and tighten with tightening torque: −65 Nm− (48 ftlb.).
3 Fit seat rail cover Push seat rail cover −2− into front end of the left and right seat rails until
−2− the locking tab audibly engages.
4 Fit six−point seat => Fitting six−point seat belt – GT2
belt
Installing bucket seat GT2 1995

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Fitting six−point seat belt GT2

cross member
Loop the belt strap in the direction of the arrow −inset− around the bucket seat transverse strut into the
adjustible slider. The projection −dimension = X− of the belt strap must be at least 100 mm.
2. Pulling six−point seat belt through the openings in the bucket seat
Pull six−point seat belt through the upper openings in the backrest from behind −arrow A− and
through the openings in the seat frame from the side −arrow B− .
3. Fitting belt fitting

Position foam part −4− and belt fitting −5− at the left and right on the seat frame. With the shim −3−
and the fastening screw −2− , screw the belt fitting −5− tight. Position the cover −1− on the fastening
screw −2− .
Use the foam part −4− for the Club Sport
version.
For the Cup racing version, mount the bushing −6− instead of the
foam part.
Fitting six−point seat belt GT2 1996

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cross member
a. Loop the belt strap in the direction of the arrow −inset− around the transverse strut on the roll cage
into the adjustible slider. The projection −dimension = X− of the belt strap must be at least 100 mm.
b. Roll up the projecting belt strap and bind it with a tie
wrap −1− .
996840, 996841
Fitting six−point seat belt GT2 1997

96 61 19 Removing and installing relay for main
switch − GT2 − as of MY 2001
Installing the main battery relay
Installing inner EMERGENCY STOP switch
Removing the main battery relay
Removing the inner EMERGENCY STOP switch
Operating the main battery switch
Note
• For GT2 vehicles in the Club Sport model, a main battery relay can be retrofitted with an
EMERGENCY STOP switch inside. The outer EMERGENCY STOP switch in the front left cowl
panel cover of the fluid tank and the necessary wiring are pre−fitted.
96 61 19 Removing and installing relay for main switch − GT2 − as of MY 2001 1998
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CAUTION
The vehicle must not be driven on public roads when in the Racing track status! When the inner or outer
EMERGENCY STOP switch is actuated, the entire electrical system is disconnected from the battery. This
means that all electrical consumers are switched off, including those required for driving on public roads. The
handling behaviour of the vehicle is changed due to the deactivated power supply for the control electronics.
top of page
Installing the main battery relay
Note
• After the installation of the main battery relay and switching off using the inner/outer EMERGENCY
STOP switch, the Work instructions after disconnecting the battery described in Chapter 9 must be
observed ’ 9−1 General . The battery may discharge if kept at a standstill for relatively long periods
in the Racing track status with the EMERGENCY STOP switches actuated.
The main battery relay is installed to the right of the battery (in conjunction with a battery of maximum 60
Ah). Fasten using the hexagon−head bolt M 8 x 16 enclosed in the delivery scope (tightening torque 23 Nm
(17 ftlb.)).
1. Remove the battery cover, the available ground cable − from the battery to the bulkhead − and the right
cowl panel cover ’ 702219 Removing and installing cowl panel cover .
2. In the case of a left−hand drive vehicle, lay the ground cable −1− pre−fitted on the main battery relay
from the relay (terminal 88) along behind the battery and connect it (tightening torque 6 Nm (4.5 ftlb.)).
3. In the case of a right−hand drive vehicle, replace the ground cable pre−fitted on the main battery relay
with the enclosed (shorter) cable and connect it to the ground terminal of the battery (tightening torque 6
Installing the main battery relay 1999

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Nm (4.5 ftlb.)).
4. Lay the ground cable from the relay (terminal 88a) to the right body/bulkhead ground point and
screw it in place (tightening torque 20 Nm (15 ftlb.)).
5. Lay the positive cable −2− from the main battery relay (pre−fitted) to the positive battery terminal
and screw it in place on the positive terminal with the hexagon−head bolt M 6 x 12 (tightening
torque 6 Nm (4.5 ftlb.).
6. The additional plug connection of the jumper plug and the wiring harness (secured with tie wrap) is
located under the right cowl panel cover in the area of the right dome strut. Cut the tie wrap with side
cutters. Disconnect the 6−pin additional plug connection from the jumper plug and the wiring harness.
7. Engage the plug connection in the 6−pin support on the main battery relay.
top of page
Installing inner EMERGENCY STOP switch
Note
• The necessary EMERGENCY STOP switch is delivered depending on the additional equipment
present:
EMERGENCY STOP switch in the centre console M 581.
Installing inner EMERGENCY STOP switch 2000

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EMERGENCY STOP switch − without centre console M 581 − in front of shift lever.
1. Carefully unclip the standard cover trims upwards with a suitable tool (e.g. screwdriver; plastic spatula).
2. The 3−pin plug connection required for the EMERGENCY STOP switch is located under the
cover in front of the shift lever and is marked with a white identification tape −A− . Connect the
3−pin plug to the plug connection of the EMERGENCY STOP switch and clip the relevant cover
back into place.
top of page
Removing the main battery relay
Note
• After the removal of the main battery relay and switching off using the inner/outer EMERGENCY
STOP switch, the Work instructions after disconnecting the battery ’ 9−1 General described in
Chapter 9 must be observed.
1. Remove the battery cover and the right cowl panel cover ’ 702219 Removing and installing cowl panel
cover.
2. Disconnect the ground terminal of the battery and lower away frfom the battery terminal.
3. Disconnect the 6−pin plug connection on the main battery relay by pressing on the locking lever and
Removing the main battery relay 2001

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pulling the plug connection apart.
4. Lay the 6−pin plug under the right cowl panel cover and connect the plug to the 6−pin plug located under
the right dome strut. Fasten the plug connection to the wiring harness with a tie wrap.
5. Unscrew the hexagon−head bolt M 6 x 12 on the positive cable −2− at the positive battery terminal.
6. Remove the ground cable −1− from the relay (terminal 88) (in left−hand drive vehicles laid next to the
battery). In right−hand drive vehicles, make sure that the battery is installed in the opposite manner from
that shown in the illustration.
7. Unscrew the ground cable from the relay (terminal 88a) to the bulkhead/body ground point and remove.
8. Screw the battery ground cable fitted upon delivery to the bulkhead/body (tightening torque 20 Nm (15
ftlb.)).
9. Unscrew the hexagon−head bolt M 8 x 16 designed for fastening the main battery relay holder and remove
the main battery relay including holder, wiring and hexagon−head bolt from the vehicle.
10. Connect the battery ground cable to the ground terminal of the battery and tighten the hexagon−head bolt
with a tightening torque of 6 Nm (4.5 ftlb.).
11. Fit the cowl panel cover and the battery cover.
top of page
Removing the inner EMERGENCY STOP switch
The necessary EMERGENCY STOP switch is installed depending on the additional equipment present:
Removing the inner EMERGENCY STOP switch 2002

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EMERGENCY STOP switch in the centre console M 581.
EMERGENCY STOP switch − without centre console M 581 − in front of shift lever.
1. Carefully unclip the cover trims with the EMERGENCY STOP switch upwards with a suitable
tool (e.g. screwdriver; plastic spatula).
2. Disconnect the 3−pin plug connection connected to the EMERGENCY STOP switch from the
wiring harness by pushing and pulling. Insert the wiring harness which is marked with a white
identification tape − A − into the shaft in the centre console. Clip the standard cover − without
EMERGENCY STOP switch − into place.
top of page
Operating the main battery switch
Status − A − Road . Status − B − Racing track
Operating the main battery switch 2003

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Note
• Turn the red actuation toggle (on the main battery relay) clockwise as far as the stop, status − A −
(bayonet). The main battery relay and the inner and outer EMERGENCY STOP switches are without
function.
Note
• Turn the red actuation toggle anti−clockwise and remove, status − B −.
• Outer EMERGENCY STOP switch − left cowl panel cover, standard − press forwards (switch
position On ). The EMERGENCY STOP switch is actuated with the red pull loop, which can be
disengaged and laid towards the outside under the rear edge of the luggage compartment lid.
Actuating inner EMERGENCY STOP switch
Push lever of the toggle switch forwards.

Fold the transparent cover of the emergency switch forwards and press the red switch. The switch position
Racing track is displayed with a warning lamp in the switch.
Status − A − Road . Status − B − Racing track 2004

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Moving the EMERGENCY STOP switch to its starting position
Press the red emergency switch once more and close the cover.
Note
• After the installation of the main battery relay and switching off using the inner/outer EMERGENCY
STOP switch, the Work instructions after disconnecting the battery ’ 9−1 General described in
Chapter 9 must be observed.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
Moving the EMERGENCY STOP switch to its starting position 2005

53 05 55 Replacing rear closing panel − Carrera 4S
Inserting rear closing panel
Tools and materials
A = closing panel
top of page
53 05 55 Replacing rear closing panel − Carrera 4S 2006

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WARNING
must be followed.

Note
Cutting out rear closing panel 2007

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are removed.

Placing vehicle on the Place the vehicle with the units mounted at the front onto the set of
alignment bench straightening attachments and fasten it in position.
1 Separating the spot−welded Use a spotweld cutter to separate the connection between the inner
joint at the rear closing panel. side members and the rear closing panel −A− on the left and right.
2 Separating the spot−welded Use the spotweld cutter to separate the connection between the side
joint at the rear closing panel. section on the inside and the rear closing panel −B, C− .
3 Separating the spot−welded Separate the spot−welded joint between the engine mount at top
joint on the engine mount at −D− and the inner side member and the connection to the inner
top side section −F− with the spot−weld cutter.
4 Separating the spot−welded Use the spotweld cutter to separate the spot−welded joint between
joint on the engine mount at the engine mount at bottom −E− and the inner side member.
bottom
top of page
Inserting rear closing panel
Inserting rear closing panel 2008

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1 Cleaning welding areas and Remove underbody coating and paint layers, etc. from the welding
preparing spare parts areas of the body with a hot−air gun or rotary brush.Remove the
factory−applied primer on the welding areas of the spare parts using
the rotary brush.
2 Inserting the closing panel Insert the closing panel spare part into the body and fasten it to the
into the body straightening attachments.
If necessary, align it with the inner side sections and the side
members. Fit the lid and set the gap dimensions
=> Gap dimensions, body rear => Removing and installing rear lid −
Carrera 4S
Fit lower lock part of the rear lid and check whether the upper lock
part engages in the lower lock part.
Inserting rear closing panel 2009

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3 Plug−welding the engine Plug−weld the engine mounts at the left and right to the side member
mount/side member at top at top −D− under shielding gas.
under shielding gas Plug−weld the connection −F− to the inner side section with an
approx.10 mm full weld.
4 Spot−welding the closing Plug−weld the connection between the inner side members −A− and
panel/side members on the the closing panel under shielding gas.
inside
top of page
Tools and materials
Item Tools Remarks
1 Basic straightening Gr. 3;
attachments for 911 Carrera Workshop
(996) Equipment
Manual
2 Additional straightening Gr. 3;
attachments for 996 Workshop
Equipment
Manual
3 Star gauges no. 127−1 Gr. 2.4;
Workshop
Equipment
Manual
4 MIG welder Gr. 3;
Workshop
Equipment
Manual
5 Multispot spotwelder Gr. 3;
Workshop
Equipment
Manual
6 Pneumatic body saw Gr. 3;
Workshop
Equipment
Manual
7 Angle grinder Gr. 3;
Workshop
Equipment
Manual
8 Oscillating body saw Gr. 3;
(special electrical cutter) Workshop
Equipment
Manual
9 Multispot spotweld cutter Gr. 3;
Workshop
Equipment

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Manual
10 Hole punch Gr. 2.4;
Workshop
Equipment
Manual
11 Hot−air gun Gr. 3;
Workshop
Equipment
Manual
12 Rotary brush Gr. 3;
Workshop
Equipment
Manual
13 Spotweld cutter 7 mm no. Gr. 2.4;
129 Workshop
Equipment
Manual
996430, 996431, 996630, 996631

53 69 19 Removing and installing rear wheel housing
liners − Carrera 4S
53 69 19 Removing and installing rear wheel housing liners − Carrera 4S 2012

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1 Wheel housing liner 1 Pull out downwards.
2 Sheetmetal screw 7 Unscrew.
3 Plastic nut T5 5 Unscrew. Inspect and replace if necessary.
4 Sheetmetal nut 2 Inspect and replace if necessary.
Removing and installing frame with heat shield, see: ’
635019 Additional assembly instructions for installation of
the bumper − Carrera 4S
996430, 996431
53 69 19 Removing and installing rear wheel housing liners − Carrera 4S 2013

55 90 19 Removing and installing rear lid − Carrera 4S
55 90 19 Removing and installing rear lid − Carrera 4S 2014

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1 Electrical plug 1 Press the lug of the electrical plug Plug in the electrical plug
connection connection −arrow− and separate. connection.
2 Fastening screws 4 Unscrew fastening screws. Tightening torque: −10 Nm
(7.5 ftlb.)−
3 Rear lid 1 Adjust lid to the hinges in
accordance with the contours
of the wings and the rear
spoiler.
=> Gap dimensions, body rear
– Carrera 4S
996430, 996431
55 90 19 Removing and installing rear lid − Carrera 4S 2015

Carrera 4S
Assembling rear lid
Removing and installing additional brake light
Installing rubber covering − Cabriolet
Removing and installing reflector cover
Test and adjustment values
Tightening torques
Materials and tools
55 90 37 Disassembling and assembling rear lid Carrera 4S 2016

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top of page

Extend spoiler manually.
1 Removing upper part of the Press out the plastic plugs −1− using a small screwdriver.
spoiler Unscrew the clamping screws −2− by turning 2 or 3 times.
Lift off upper part of the spoiler −3− .
2 Removing the folding wall 1. Press out the expanding rivets −4− .
from the upper part of the 2. Remove the rails −5− from the lower part of the spoiler
spoiler towards the rear.
3 3.

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Removing the folding wall Press out the clamping washer −7− with a screwdriver. The
from the cover clamping washers are destroyed by the action of removing
them.
4. Remove the fastening rail −8− and the folding wall −6− from
the cover towards the rear.
4 Removing the lower part of the 5. => Removing and installing additional brake light
spoiler 6. Unscrew the fastening nuts −9− from the upper part of the
spoiler and the hinge −11− . Remove the threaded plate −10−
.
7. Unscrew the fastening screws −12− from the lower part of the
spoiler and the actuating element. Remove the position spacer
−13− .
5 Removing hinge Unscrew fastening screws −14− from the hinge −11− .

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6 Removing the mount Unscrew fastening screws −15− and −16− from the actuating element
−17− .
7 Removing rubber covering Pull rubber cover −18− out of the rear cover.
8 Removing adjusting Unscrew rubber pad −19− and unclip collar −20− .
element
9 Removing upper part of Unscrew fastening screws −21− and remove upper part of lock −22− .
the lock
10 Removing fan with fan Disconnect plug connections for fan and engine compartment lighting
housing on the fan housing.
See: => Removing and installing wiring harness
Unscrew fastening screws −23− and remove fan with fan housing
−24− .
11 Removing air guide Pull off air guide −25− from the rear cover.
12 Removing model logo Pull off model logo −26− .
Removing reflector cover => Removing and installing reflector cover
top of page
Assembling rear lid

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1 Sticking on model logo => Replacing the model logo
2 Installing air guide Position the air guide −25− on the rear cover and insert.
3 Fitting fan with fan housing Position fan with fan housing −24− , screw down with fastening
screws −23− .
Connect plugs for fan and engine compartment lighting on the
fan housing.
See: => Removing and installing wiring harness
4 Fitting upper part of the Position upper part of the lock −22− and fasten with fastening
lock screws −21− .
5 Installing adjusting element Engage collar −20− . Screw in rubber pads −19− .
6 Fitting rubber covering Position the rubber covering −18− on the rear cover and push in.
=> Installing rubber covering − Cabriolet

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Installing wiring harness => Removing and installing wiring harness

7 Fitting mount Position the mount −17− on the rear cover and screw in using
the fastening screws −15− and −16− .

8 Fitting hinge Position hinge −11− and screw in using the fastening screws −14− .
9 Mounting the lower part of 1. Position the spacer −13− on the lower part of the spoiler. Tighten
the spoiler the fastening screws −12− .
2. Position the upper part of the spoiler on the hinge −11− . Using
the threaded plate −10− and the fastening nuts −9− securely
screw down the upper part of the spoiler.

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10 Mounting the folding wall 3. Position the fastening rail −8− on the folding wall −6− and the
on the cover rear cover.
4. Put new clamping washers −7− on the pegs of the fastening rail.
11 Mounting the the folding 5. Insert the rail −5− with the folding wall into the lower part
wall on the upper part of the of the spoiler in −direction of arrow− .
spoiler 6. Press in the expanding rivets −4− .
12 Mounting the upper part of 7. Adjust the clamping screws to dimension −X = 8
the spoiler mm− .
8. Place the upper part of the spoiler −3− on the lower part of the
spoiler. Ensure that the locking tabs −inset V− have engaged.
9. Screw down the clamping screws −2− .
Push in the plastic plugs −1− .
top of page
Removing and installing additional brake light
1. Removing additional brake light

a. Unclip cover −A− at the sides, unlock lock −B− . Remove brake light and disconnect plug connection
−C− .
Removing and installing additional brake light 2022

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1. Installing additional brake light

a. Push on plug −C− . Insert brake light. Lock the lock −B− . Clip in the cover −A− .
top of page
Installing rubber covering − Cabriolet
Fitting rubber covering
1. Clean bonding surface with cleaning agent. => Materials and
tools
2. Pull off protective film −A− on rubber covering

−18− .
3. Position rubber covering −18− on the dimension −X = 0.5 mm− and stick flush into the lid over the entire
length.
top of page
Installing rubber covering − Cabriolet 2023

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Removing and installing reflector cover
Removing reflector cover

Unscrew fastening screw −27− from the reflector cover −28− .
Install reflector cover
Secure the reflector cover −28− with the fastening screws −27− . => Tightening torques
=> Test and adjustment values
top of page
Removing wiring harness

1 Press the lug of the electrical plug connection, see inset −arrow− and separate.
2 Remove additional brake light. See: => Removing and installing additional brake light.
3 Pull out grommet −A− with brake light lead. Disconnect plug connection −B− for fan on fan housing.
Disconnect plug connection for engine compartment lighting −C− . Press the fastening clips −arrows−
together from the inner side of the mount and and remove.
Installing wiring harness
1 Lay the wiring harness and mount with the fastening clips from the inner side of the mount in the positions
specified −arrows− . Connect the plug −C− for the engine compartment lighting and −B− for the engine
compartment fan. Push the plug with the grommet −A− through the opening in the rear lid until the
grommet can be pushed into place.
2 Plug in the electrical plug connection.
3 Install additional brake light. See: => Removing and installing additional brake light.
Removing and installing reflector cover 2024

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top of page
1. Find the middle of the lid.

2. Position logo −Carrera− with the dimensions −A = 185 mm− and −B = 31 mm− on the rear lid and
affix.
3. Position logo −S− with the dimensions −C = 185 mm− and −B = 29 mm− on the rear lid and affix.
4. Insert logo −4− in the external cut opening −arrow− of the logo −S− .
top of page
Test and adjustment values
Note
• Illustration of the gap dimensions => Gap dimensions, body rear – Carrera 4S

Rear lid to rear trim −H− 5 ±2 mm
−J− 2.2+0.5 mm Rear lid only lowered
−1.5
−K− 5 ±2 mm
−L− 1.8+0.5 mm Rear lid only lowered
−1.5
Rear lid to tail light −M− 4.5 ±1 mm Tail light only lowered (max. 1 mm)
Rear lid to outer side −N− 4.5 ±1 mm Rear lid only lowered (max. 1 mm). determine
Removing and installing wiring harness 2025

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section left to right
top of page
Tightening torques
Tightening
torque [Nm]
Fastening screws of upper part of spoiler on lower part of −5− 10 (7.5) Nm (ftlb.)
spoiler
Fastening screws of spacer on mount −9− M6 10 (7.5) Nm (ftlb.)
Fastening screws of threaded plate on hinge −12− M6 10 (7.5) Nm (ftlb.)
Fastening screws of hinge on rear cover −14− M6 10 (7.5) Nm (ftlb.)
Fastening screws of mount on rear cover −15, 16− M6 10 (7.5) Nm (ftlb.)
Fastening screws of upper part of lock on rear cover −21− M6 10 (7.5) Nm (ftlb.)
Fastening screws fan with housing to rear cover −23− M6 10 (7.5) Nm (ftlb.)
Fastening screws of reflector cover on rear lid −27− M5 4 (3) Nm (ftlb.)
top of page
Materials and tools

Cleaning agent See Parts Catalogue in Main Group 8/03/05
996430, 996431, 996630, 996631
Test and adjustment values 2026

55 91 19 Removing and installing rear lid hinges −
Carrera 4S
55 91 19 Removing and installing rear lid hinges − Carrera 4S 2027

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1 Pneumatic 2
spring
left/right
2 Retainer 4 Press out with a narrow Press in.
screwdriver.
3 Stop clip 2
left/right
4 Collar nut 4 Tightening torque: −10 Nm (7.5 ftlb.)−
M6
5 Lid hinge, right 1 Loosen collar nut −4− . Adjust to the right side section in accordance
with lid contour.
6 Lid hinge, left 1 Loosen collar nut −4− . Adjust to the left side section in accordance
with lid contour.

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996430, 996431

19 58 19 Removing and installing coolant regulator
Removal overview of the coolant regulator
Installation overview of the coolant regulator

Assembly aid Refer to Workshop Equipment Manual, Chapter 2.2, No.: 9627
To change the coolant regulator
top of page
Removal overview of the coolant regulator
19 58 19 Removing and installing coolant regulator 2030

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1 Drain coolant
2 Remove closure cap
3 Remove coolant regulator housing
4 Remove coolant regulator
1. Drain
coolant
a.
Removal overview of the coolant regulator 2031

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Open lid on the expansion tank. Undo the drain plug on the two necks for coolant and collect the
coolant. After draining the coolant, fit new sealing rings on the drain plug −arrow− .
Tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.)
2. Remove closure cap

Remove the closure cap −arrow− on the cylinder head over the oil extraction pump of the cylinder
bank 1 to 3. To do this, remove the three hexagon−head bolts and remove the closure cap.
3. Remove coolant hose

Unclip the coolant hose on the housing of the coolant regulator with a screwdriver and pull the
coolant hose up and off.
4. Remove coolant
regulator housing
b. Undo the three fastening screws −arrow− of the coolant regulator
housing.
c. Remove the coolant regulator
housing.
Note
• Do not use the seal again!
Removal overview of the coolant regulator 2032

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5. Remove
coolant
regulator
d. Remove coolant regulator with assembly aid
9627 .
e. Insert assembly aid between the sheetmetal edges as shown. Push the assembly aid against the spring
force until the retaining bracket is released.
f. Turn coolant regulator by approx. 90° and take coolant regulator out of the
housing.
top of page
Installation overview of the coolant regulator
Installation overview of the coolant regulator 2033

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1 Install coolant regulator

2 Install coolant regulator housing
3 Push on coolant hose
4 Install closure cap
5 Bleed coolant circuit
1. Install coolant
regulator.

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a. Insert coolant regulator in the housing

as shown.
b. Push against the spring force using assembly aid 9627 and turn until both sheetmetal edges are
touching the housing.
2. Install coolant
regulator
housing
c. Clean sealing
surfaces.
d. Position coolant regulator housing with a new
seal.
e. Tighten the three fastening screws
−arrow− .
3. Push on coolant hose.

f. Insert retaining
clip.
g. Push the coolant hose with a new seal into the coolant regulator
housing.
h. Push hose downwards until the retaining clip is heard to
engage.
i. Pull the hose slightly to check for secure
seating.

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4. Install closure cap.

j. Reinstall the closure cap −arrow− beside the oil extraction pump on the cylinder
bank 1 to 3.
k. Lightly coat the O−ring with acid−free
grease.
l. Press in the closure cap −arrow− evenly by
hand.
m. Ensure that the fastening holes
overlap.
n. Tighten the three fastening
screws.
5. Bleed coolant circuit

Bleed the coolant circuit carefully. To do this, lift the bow on the closure
cap.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

996 TT Repair Manual

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996 TT Repair Manual

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0 Entire vehicle General................................................................................................................................16

01 General maintenance: Test drive...............................................................................................................36

01 Diagnostic system: Read out fault memory and activate systems...........................................................37

01 Battery: checking the charge state.............................................................................................................39

01 Windscreen wiper/washer system, headlight washer...............................................................................40

01 Alarm system: checking operation of indicators.......................................................................................46

01 Activating/deactivating the parking aid.....................................................................................................47

Technical Data GT2.......................................................................................................................................53

Precautionary measures when working on fuel system.................................................................................61

03 Diagnostic system: reading out fault memory...........................................................................................62

03 General maintenance: test drive.................................................................................................................63

03 Removing and installing drive belt.............................................................................................................64

94 56 19 Removing and installing bulb for direction indicator light...........................................................67

03 Changing the engine oil (without oil filter)................................................................................................72

03 Replacing spark plugs..................................................................................................................................74

03 Checking cooling system..............................................................................................................................77

03 Replacing air cleaner element.....................................................................................................................79

03 Replacing the fuel filter...............................................................................................................................85

03 Clutch: checking the play and pedal end position....................................................................................89

03 Changing transmission oil...........................................................................................................................90

03 Checking and topping up the ATF.............................................................................................................91

03 Removing and installing ATF filter............................................................................................................97

03 Replacing and checking transmission oil in final drive..........................................................................100

03 Changing transmission oil − GT2.............................................................................................................105

03 Steering gear: fluid level and bellows.......................................................................................................107

03 Axle joints/drive shafts..............................................................................................................................110

03 Running gear adjustment/storage of assemblies.....................................................................................112

03 Tyres and spare wheel: checking condition and tyre pressure..............................................................113

03 Checking and changing the brake fluid...................................................................................................115

03 Visual inspection: brake lines/brake pads/brake discs...........................................................................119

03 Checking the wheel mounting...................................................................................................................121

03 Checking lid and doors..............................................................................................................................122

03 Checking seat belts.....................................................................................................................................125

03 Inspecting the airbag system.....................................................................................................................126

03 Passenger protection maintenance: checking roll−over protection system..........................................128

03 Particle filter: replacing the filter element..............................................................................................129

03 Checking the function of the vehicle's lights...........................................................................................130

03 Windscreen wiper/washer system, headlight washer.............................................................................135

03 Additional maintenance − USA................................................................................................................137

03 Additional maintenance − as of MY 2004................................................................................................139

4 Lifting the vehicle.........................................................................................................................................155

4 Tests/notes for all−wheel drive...................................................................................................................156

4 Switching off PSM........................................................................................................................................157

5 Plug location plan.........................................................................................................................................159

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

5 Vehicle identification number.....................................................................................................................172

5 Change identification data plate.................................................................................................................174

5 Water drainage plan Cabriolet...............................................................................................................179

5 Check dimensions for body repair − Cabriolet structure........................................................................180

5 General information and quality notes......................................................................................................188

5 Tools and metalworking tools for body repairs........................................................................................190

5 Diagram − keys to symbols for welding work...........................................................................................193

5 Check dimensions for body repair.............................................................................................................195

5 Water drainage plan....................................................................................................................................198

5 Diagram − body gap dimensions................................................................................................................199

6 General information on installing and removing car windows...............................................................222

6 Overview of exterior colours.......................................................................................................................231

6 Processing of Porsche 2−component window bonding agents.................................................................234

7 Special notes for the care of soft−look paint surfaces...............................................................................239

9 Work instructions after disconnecting the battery...................................................................................242