Porsche 911 Carrera (996) Manual de usuario

TechnicalManual

9ff ~"7'~~ (996)

TechnicalInformation

Contents:

Group 1

Engine

Part 2 (as of Repair Group 15)

WKD483 721

TlTEL.CHP

www.WorkshopManuals.co.uk

911 Carrera (996) Engine, part 2 (as of Repair Group 15)

Supplement Overview

Supple-

ment Edition Topic Article number

Basicedition WKD483721

005/1997

OS/2000

12/1997

05/1998

10/1998

01/1999

02/1999

03/1999

04/1999

05/1999

06/1999

07/1999

09/1999

10/1999

12/1999

OS/2000

11/2000

WKD483721.05

9Generalsupplement WKD483721.09

IGeneral supplement

Generalsupplement WKD483721.10

20 WKD483721.17

Generalsupplement WKD483721.20

Generalsupplement WKD483721.21

21 Generalsupplement WKD483721.22

23 Generalsupplement WKD483721.23

Generalsupplement WKD483721.25

26 Generalsupplement WKD483721.26

Generalsupplement WKD483721.28

Generalsupplement WKD483721.29

Generalsupplement WKD483721.31

Generalsupplement WKD483721.32

Generalsupplement WKD483721.33

Generalsupplement WKD483721.35

Generalsupplement WKD483721.37

IGeneral supplement WKD483721.38

Generalsupplement WKD483721.39

Generalsupplement

39 WKD483721.44

Generalsupplement

Supplement Overview

Printed in Germany -44, 2001 Masterlt2

www.WorkshopManuals.co.uk

911 Carrera (996) Foreword

Foreword

Theworkshopdocumentationfor the 911 Carrera(996)modelhasthe designation

"911 Carrera (996)" Technical Manual

and containsTechnical Information aswell as instructionson Repairs.

Theintegrationof the technicalinformationpublishedinthe"911 Carrera(996)"TechnicalManualwith

the instructionson repairs providesthe userwith a complexreferencework that combinesinto one book

associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various informa-

tion media.

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

0 Entirevehicle-General

0 Diagnosis,part 1 (upto RepairGroup45) *1

0 Diagnosis,part 2 (asof RepairGroup61) *2

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

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

2 Fuel,exhaust,engineelectronics

3 Transmission,manualtransmission

3 Transmission,automatictransmission

4 Runninggear

5 Body

6 Bodyequipment,exterior

7 Bodyequipment,interior

8 / 9 Air conditioning/ Electrics

9 Circuitdiagrams,part 1 (upto and includingthe '99 model)*5

9 Circuitdiagrams,part 2 (asof the '00 model)*6

*1 Thetwo folderswith Group0 areto be regardedas one folder; i.e. file the "TechnicalInformation"

notices onlyin front of the repair descriptionsin the folder "Group0 -Diagnosis, part 1"

(up to Repair Group 45).

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

RepairGroupsbelongingto GroupO.

*3 Thetwo folderswith Group1 are to be regardedas one folder; i.e. file the "TechnicalInformation'

noticesonlyin front of the repair descriptionsin the folder "Group1 -Engine, part I"

(up to Repair Group 13).

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

Groupsbelongingto Group1.

VORW.CHP

Foreword

Printed in Germany -35, October 1999

www.WorkshopManuals.co.uk

*5 Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"

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

and including the '99 model).

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

circuit diagramsbelongingto Group9.

The"911 Carrera (996)"TechnicalManualhasthe same structure in each folder,with the following break-

downfor all Groups:

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

> Foreword

Title page: "Technical Information"

> Tableof Contents,Technicalinformation

> Technicalinformation

Title page: "Repair"

> RepairGroups:overview

> Tableof Contents,repairs

> General/technical data

> Instructionson repairs

As can be seenfrom the breakdown,the publishedTechnicalInformationis inthe front part of eachfol-

der -numbered accordingto the Groups.TheTable of Contentsassignedto eachGroupwill be peri-

odicallyupdated.

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

accordingto the Groupsor brokendowninto RepairGroups-are includedin the folders.

Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.

Note

Sheetsthat alreadyexistin the"911 Carrera(996)"TechnicalManualandare updatedor revised

and therebyexchangedbya supplementare designated"replacementsheet".Revisionsor technical

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

the margin.

Foreword

Printed in Germany -35, October 1999

VORW.CHP

www.WorkshopManuals.co.uk

911 Carrera (996) Overview of repair groups

Group 0: Entire vehicle -General

Salescheck

Maintenance

Group 0: 0

Diagnosis

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: 0

Diagnosis

Convertible-topdiagnosis

Airbagdiagnosis

Roll-overprotectionsystemdiagnosis

Seatmemorydiagnosis

Heatingdiagnosis

Alarmsystem diagnosis

PCMdiagnosis

ParkAssistentdiagnosis

HBAdiagnosis

Group 1: 1

Engine

Engine-Crankcase, suspension

Engine-Crankshaft, pistons

Group 1: Engine

Engine-Cylinder head,valvedrive

Engine-Lubrication

Engine-Cooling

Group 2: Fuel, exhaust, engine electronics

Fuelsupply,control

Exhaustsystem,turbocharging

Fuelsystem,electronicinjection

Fuelsystem,K-Jetronic

Exhaustsystem

Starter,powersupply,cruisecontrol

Ignitionsystem

Group 3: Transmission, manual transmission

Clutch,control

Manualtransmission-Actuation, housing

Manualtransmission-Gears, shafts,intogearsh.

Finaldrive,differential,differentiallock

Group 3: Transmission, automatic transmission

Torqueconverter

Automatictransmission-Actuation, housing

Automatictransmission-Gears, control

Finaldrive,differential,differentiallock

Overview of repair groups

Printed in Germany -35, October 1999 REPGRU.CHP

www.WorkshopManuals.co.uk

Group 4: 4

Running gear

Front wheel suspension, drive shafts

Rear wheel suspension, drive shafts

Wheels, tires, suspension alignment

Anti-Lock Brake System (ABS)

Brakes -Brake mechanics

Brakes -Hydraulics, regulator, booster

Steering

Group 5: 5

Body

Bodyfront

Bodycenter, roof,frame

Bodyrear

Lids,flaps

Door front, centrallockingsystem

Group 6: 6

Body equipment, exterior

Slidingroof

Convertibletop, hardtop

Bumpers

Glazing,windowcontrol

Exterior equipment

Interior equipment

Passengerprotection 7

Group7: Body equipment, interior

Linings,insulation

Seatframes

Seatupholsteries,covers

Group 8: 8

Air conditioning

Heating

Ventilation

Air conditioning

Auxiliaryair conditioningsystem

Group 9 9

Electrics

Instruments,alarmsystem

Radio,telephone,on-boardcomputer,navigation

Windshieldwiper andwashersystem

Lights, lamps,switchesexterior

Lights, lamps,switchesinterior,theft protection

Group 9: Circuit diagrams

Wiring(upto and includingthe '99 model)

Circuit diagrams

Wiring(fromthe'00 model)

Group 9:

Overview of repair groups

Printed in Germany -35, October 1999

REPGRU.CHP

www.WorkshopManuals.co.uk

911 Carrera (996) Engine, part 2 (as of Repair Group 15)

Table of Contents

1Engine, part 2 (as of Repair Group IS)

157037

156519

156319

157023

157037

150519

150522

150515

155920

155922

155924

15-1

15-7

15-9

15-11

15-15

15-23

15-27

15-39

15-43

15-47

15-51

15-55

15-61

15-65

15-71

15-77

15-81

15-83

15-87

15-89

15-95

15-101

15-103

15-107

15-111

15-113

15-117

15-121

15-129

15-135

15-137

15-139

15-141

15-149

15-161

15-163

15-173

15-183

155924

150533

159151

155902

154619

155920

155927

155924

150515

155922

155924

150515

151820

150502

152319

153719

157049

150319

150321

150323

157019

157021

157023

152037

Engine -Cylinder head, valve drive

Disassembling and assembling cylinder head -Inner parts.Removing and installing valve springsRemoving and installing valve stem sealInstalling cylinder headDisassembling and assembling cylinder head -Camshaft drive.Removing and installing camshafts ,

Installing camshafts ,

Adjusting timing -Cylinder bank 1- 3 ,

Adjusting timing-Cylinder bank 4-6Removing and installing valve tappets -Engine removedRemoving valve tappets of cylinder bank 1- 3Installing valve tappets -Cylinder bank 1- 3Removing valve tappets of cylinder bank 4-6Installing valve tappets -cylinder bank 4- 6Completing camshaftsSealing cover for camshaft housing (cylinder head cover)Checking guide for valve tappetsRemoving and installing oil protection tubes -Engine installed..Removing and installing oil protection tubes -Engine installed..Removing and installing valve tappets -engine installed...Removing valve tappets of the cylinder bank 1- 3 -Engine installedInstalling valve tappets of the cylinder bank 1- 3 -Engine installed..Adjusting timing of cylinder bank 1 -3 -Engine installed.Removing valve tappets of the cylinder bank 4 -6 -Engine installedInstalling valve tappets of the cylinder bank 4- 6 -Engine installed..Adjusting timing of cylinder bank 4 -6 -Engine installed.Removing and installing closure cap for camshaft bore -Engine installed. ...

Checking camshafts (timing) -Engine installedRemoving and installing sealing ring for intermediate shaft -Engine installed

Removing and installing solenoid hydraulic valveReworking cylinder headRemoving and installing camshaft housing -GT3Removing camshaft housing -GT3Installingcamshafthousing-GT3Removing and installing cylinder head -GT3Removing cylinder head -GT3Installing cylinder head-GT3Disassembling and assembling intermediate shaft -GT3

Table of Contents

Printed in Germany -44, 2001 Masterlt2

www.WorkshopManuals.co.uk

911 Carrera(996)

Engine,part2 (asofRepairGroup15)

175319

172019

171919

174019

175019

171519

171921

171937

171923

175219

176719

176721

176723

170719

17-1

17-5

17-9

17-11

17-17

17-23

17-27

17-33

17-39

17-49

17-55

17-67

17-69

17-82

17-97

Engine-Lubrication

Removing and installing air/oil separatorRemoving and installing oil pump with coolant guide housing... ...,

Removing and installing oil extraction pumps -Engine removed. ..,

Removing and installing oil extraction pumps -Engine installed.. ..,

Removing and installing oil-water heat exchanger -engine installed

Removing and installing oil pan -engine installed ,

Removing and installing oil filler neck ,

Removing oil extraction pump-GT3Disassembling and assembling oil extraction pump -GT3Installing oil extraction pump-GT3Removing and installing oil container-GT3 ,

Removing and installing bracket for oil cooler -GT3 ,

Removing bracket for oil cooler-GT3Installing bracket for oil cooler-GT3 ,

Removing and installing oil temperature sensor -GT3

193817

195819

195019

191201

195021

195023

195819

195519

195521

195523

197819

190100

190101

196219

Engine-Cooling

Draining and topping up with coolantRemoving and installing coolant regulator.Removing and installing coolant pumpCoolant warning light in instrument cluster.Removing coolant pump (engine installed) -GT3Installing coolant pump (engine installed) -GT3Removing and installing coolant regulator -GT3Removing and installing housing for coolant guide -GT3Removing housing for coolant guide -GT3Removing housing for coolant guide -GT3Removing and installing temperature sensor for coolant -GT3

Oil/coolant mixing ,

Checking the cooling system for leaksRemoving and installing coolant hoses -GT3Removing coolant hosesInstalling coolant hoses ,Tightening torques ,

19-1

19-5

19-9

19-17

19-19

19-25

19-31

19-41

19-43

19-54

19-66

19-69

19-72

19-73 page 1

19-73 page 2

19-73 page 11

19-73 page 21

www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive

15 70 37 Disassembling and assembling cylinder head -Inner pans

Tools (commercially available)

216_96

Special tool Explanation

Item

Designation

Shaft(/320 x 450 mm) Art.

Art.

Aluminiumsupports(1 pair)

Leverarm

Jointwith screw

Magneticdisassemblyhead Art. No. 6024650

Art. No. 6000102

Art. No. 6006015

Assemblyhead1bfor

valvekeys

Pressurepiece6e (3ea.:

Padfor valvediscs (3 ea.)

HArt.-No.6025665

(ItemsAto H: refer to Workshop

EquipmentManual,Chapter2.4,

No. 54)

Commerciallyavailable,M6 x 40

Screwsfor aluminiumsupports

(4 ea.)

15-1

15 7037 Disassembling and assembling cylinder head -Inner parts

Printed in Germany -10, 1998 996151

No.6024515

No.6023620

No.6023530

No. 6024520

www.WorkshopManuals.co.uk

911 Carrera (996) Engine -Cylinder head, valve drive

Tools

691_97

Special tool

3364

Item

Explanation

VWspecialtool

Designation

Extractorfor valvestem

seal

Press-ontool for valve

stem seal 3365 VWspecialtool

9605

Cl 9605/1

9604

Pressurepiece,for fitting

the oil protectiontubes

Pressurepiece, for fitting

the oil protectiontubes

(engineinstalled)

Handpressurepiece 1 set=2 ea.

Tensioningscrewfor relieving

the tensioningelements

(VarioCam)

9632

15 -3

15 70 37 Disassembling and assembling cylinder head -Inner parts

Printed in Germany -10, 1998 996151

www.WorkshopManuals.co.uk

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