Porsche 996 TT - User Manual

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Default Chapter2
- Table of Contents2
Information on Handling of the GT2 Scope64
Technical Data65
- Engine66
- Engine Design67
- Engine Cooling68
- Engine Lubrication68
- Engine Control68
- Heating69
- Fuel System69
- Electrical System69
- Exhaust System70
- Emission Control70
- Transmission70
- Clutch70
- Transmission71
- Body Designs72
- Running Gear72
- Brakes73
- Wheels and Tyres74
- Spare Wheel74
- Wheel Alignment74
- Dimensions75
- Weights According to DIN 700 2075
- Filling Capacities76
- Performance Data77
- Climbing Performance78
- Specific Power78
Entire Vehicle General79
- Lifting the Vehicle79
Power Unit80
- Engine M96/7080
- Engine81
- Engine Design81
- Engine Cooling82
- Engine Lubrication82
- Engine Control83
Transmission84
- 6−Speed Manual Transmission G 96.5084
- Front Wheel Drive Z 96.0085
Body86
- Body of High−Strength Steel 187
- Body of High−Strength Steel 287
- Water Drainage Plan Coupé88
0 Body89
- Refrigerant Circuit89
- Component Arrangement, Airbag System B0589
Electrics91
- Fuse Assignments91
Power Supply94
- Work Instructions after Disconnecting the Battery94
- Control Module Memories94
- Supply Voltage Fault Entry95
- Test Drive after Connecting the Battery95
- DME Control Module95
- Tiptronic96
- Power Windows96
- 25 Instrument Cluster96
- Clock96
- Fuel Level Display97
- Radio97
- Pcm97
General Maintenance: Test Drive99
Diagnostic System: Read out Fault Memory and Activate Systems100
- Activating Systems100
- Read out Fault Memory100
- Load Navigation101
Battery: Checking the Charge State102
- Tools102
- Checking Charge State with Battery Tester102
Windscreen Wiper/Washer System, Headlight Washer103
- MIX Ratio of Fluids for Windscreen Washer System103
Checking the Function of the Vehicle's Lights and the Headlight Setting104
- Checking the Adjustment of the Headlights104
- Adjusting the Main Headlights105
- Adjusting the Main Headlights, USA Version106
- Fog Light Adjustment106
Checking the Function of Electrical Equipment, as Well as the Indicator and Warning Lights108
Alarm System: Checking Operation of Indicators109
Activating/Deactivating the Parking Aid110
- General110
- Activating the Parking Aid Without PST 2110
- Deactivating the Parking Aid Without PST 2111
- Activating the Parking Aid with PST 2111
- Selecting Door Mirror to be Lowered, Left/Right112
- Adjusting the Lowering Angle for the Passenger Door Mirror112
- Deactivating the Parking Aid with PST 2113
Removing Transport Lock (Spring Strut Locking Devices) Turbo and GT2114
- General114
- Removing Spring Strut Locking Devices114
Technical Data GT2116
- Engine117
- Engine Design117
- Engine Cooling118
- Engine Lubrication118
- Engine Control118
- Fuel System119
- Electrical System119
- Exhaust System119
- Emission Control119
Technical Data120
- Engine121
- Engine Design121
- Engine Cooling122
- Engine Lubrication122
- Engine Control122
- Fuel System123
- Electrical System123
- Exhaust System123
- Emission Control123
Precautionary Measures When Working on Fuel System124
Diagnostic System: Reading out Fault Memory125
- Reading out Fault Memory125
General Maintenance: Test Drive126
Removing and Installing Drive Belt127
- Removal Overview of the Drive Belt (Engine Installed)127
- Installation Overview of the Drive Belt (Engine Installed)128
56 19 Removing and Installing Bulb for Direction Indicator Light130
- Removing Bulb for Direction Indicator Light130
- Installing Bulb for Direction Indicator Light130
Changing the Engine Oil and Oil Filter131
Changing the Engine Oil (Without Oil Filter)135
Replacing Spark Plugs137
- Removing Spark Plugs137
- Installing Spark Plugs138
Checking Cooling System140
- Coolant: Checking Level, Antifreeze Content and Leaks140
Replacing Air Cleaner Element142
- Removing Air Cleaner142
- Installing Air Cleaner144
Replacing the Fuel Filter148
Clutch: Checking the Play and Pedal End Position152
- Checking Clutch Free Play152
- Checking the Pedal End Position (Pedal Return/Return Force)152
Changing Transmission Oil153
- Tightening Torques153
Checking and Topping up the ATF154
- Tools154
- Tightening Torques156
Replacing ATF157
- Tools157
- Replacing ATF Fluid157
- Tightening Torques159
Removing and Installing ATF Filter160
- Tools160
- Removing ATF Filter160
- Installing ATF Filter161
- Tightening Torques162
Replacing and Checking Transmission Oil in Final Drive163
- Tools163
- Changing Transmission Oil in Final Drive163
- Tightening Torques165
Changing Transmission Oil in Front Wheel Drive166
- Tightening Torques166
Changing Transmission Oil − GT2168
- Topping up Transmission Oil − GT2168
- Tightening Torques169
Steering Gear: Fluid Level and Bellows170
- Power Steering: Checking the Fluid Level170
  - General170
- Steering Gear: Visual Inspection of the Bellows172
Axle Joints/Drive Shafts173
- Tie Rod Ends: Checking the Play and Dust Bellows173
- Axle Joints: Checking the Play and Dust Bellows173
- Drive Shafts: Visual Inspection of the Boots174
Running Gear Adjustment/Storage of Assemblies175
- Running Gear Adjustment (Wheel Alignment Values)175
- Storage of Assemblies and Running Gear175
Tyres and Spare Wheel: Checking Condition and Tyre Pressure176
- Checking Condition176
- Tyre Pressure for Cold Tyres (Approx. 20 °C)176
  - Turbo176
  - Gt2 (M002/M003)176
Checking and Changing the Brake Fluid178
- Checking the Brake Fluid Level178
- Changing the Brake Fluid178
Parking Brake: Checking the Free Play of the Parking Brake Lever180
- Adjusting the Parking Brake180
Visual Inspection: Brake Lines/Brake Pads/Brake Discs182
- Brake Hoses and Lines182
- Brake System: Visual Inspection of the Brake Pads and Brake Discs for Wear182
Checking the Wheel Mounting184
Checking Lid and Doors185
- Checking Lid Lock, Front and Rear185
  - Checking the Catch Bar185
- Checking Safety Hook, Front Lid185
- Function Test, Checking Door Lock185
- Functional Inspection of the Tank Cap Lock186
- Checking Door and Lid Tightening Torques186
- Checking Inner Release of Luggage Compartment (Trunk Entrapment)186
- Tightening Torques187
Checking Seat Belts188
- Functional Inspection188
- Condition Inspection188
Inspecting the Airbag System189
- Visual Inspection189
- Checking Airbag Warning Light189
- Function Test of the Airbag System189
Passenger Protection Maintenance: Checking Roll−Over Protection System191
Particle Filter: Replacing the Filter Element192
- Removing Particle Filter192
- Installing Particle Filter192
Checking the Function of the Vehicle's Lights193
- Adjusting the Main Headlights193
- Setting194
- Adjusting the Main Headlights, USA Version195
- Fog Light Adjustment195
- Removing Main Headlight195
- Installing Main Headlight196
Windscreen Wiper/Washer System, Headlight Washer198
Checking the Function of Electrical Equipment, as Well as the Indicator and Warning Lights199
Additional Maintenance − USA200
- Additional Maintenance, Replacing Spark Plugs200
- Additional Maintenance Every 60,000 Mls/96,000 Km200
- Additional Maintenance Every 90,000 Mls/144,000 Km201
- Maintenance Every 2 Years201
- Maintenance after 4, 8, 10 then Every 2 Years201
Additional Maintenance − as of MY 2004202
- Additional Maintenance, Replacing Spark Plugs202
- Additional Maintenance Every 80,000 Km/48,000 Mls202
- Additional Maintenance Every 160,000 Km/96,000 Mls202
- Maintenance Every 2 Years203
- Maintenance after 4, 8, 10 then Every 2 Years203
Additional Maintenance − USA − as of MY 2004204
- Additional Maintenance, Replacing Spark Plugs204
- Additional Maintenance Every 60,000 Mls/96,000 Km204
- Additional Maintenance Every 90,000 Mls/144,000 Km205
- Maintenance Every 2 Years205
- Maintenance after 4, 8, 10 then Every 2 Years205
Additional Maintenance207
- Additional Maintenance, Replacing Spark Plugs207
- Additional Maintenance Every 80,000 Km/48,000 Mls207
- Additional Maintenance Every 160,000 Km/96,000 Mls207
- Maintenance Every 2 Years208
- Maintenance after 4, 8, 10 then Every 2 Years208
Technical Data209
- 6−Speed Manual Transmission G 96.50209
  - Manual Transmission Tightening Torques210
- Front Wheel Drive Z 96.00210
  - Front−Axle Drive Tightening Torques211
Technical Data212
- 5−Speed Tiptronic Transmission a 96.50−150212
  - Tightening Torques for Tiptronic Transmission213
- Front Wheel Drive Z 96.00214
  - Front−Axle Drive Tightening Torques214
Removing Transport Lock (Spring Strut Locking Devices) Turbo and GT2216
- General216
- Removing Spring Strut Locking Devices216
Lifting the Vehicle218
- Lift the Vehicle218
Tests/Notes for All−Wheel Drive219
- Balancing Wheels on Vehicle219
- Power Test219
- Brake Test219
- Towing Manual Transmission Vehicles219
- Towing Tiptronic Vehicles219
Switching off PSM220
- Switching PSM Back on220
- Characteristic Features of Tiptronic Vehicles (Slip Upshift)221
Plug Location Plan222
- Top of Front End222
5 Plug Location Plan223
- Bottom of Front End223
- Side of Front End223
- Bottom of Lower Side Member and Floor224
- Top of Lower Side Member and Floor224
- Bottom of Rear End225
- Top of Rear End225
- Side of Rear End226
Seam Seals227
- Accessories227
Work Sequence for Accident Repair230
Work Sequence for Determining Scope of Damaged Vehicles Involved in an Accident232
Corrosion Protection Measures During Repairs234
- Measures for Maintaining Long−Term Body Protection234
- Prerequisite for Ensuring Vailidity of the Long−Life Guarantee234
Vehicle Identification Number235
- Imprinting New Vehicle Identification Number235
- Materials, Tools236
Change Identification Data Plate237
Undersealing239
- Overview Diagram, Lower Front of Vehicle239
- Overview Diagram, Bottom of Lower Side Member and Floor240
- Overview Diagram, Lower Rear End241
- Tools and Materials241
Water Drainage Plan Cabriolet242
Check Dimensions for Body Repair − Cabriolet Structure243
- Structure Dimensions for Cabriolet243
Safety Notes246
- Safety Instructions for Raising Vehicles246
  - Danger of Injury When Raising Vehicles246
  - Damage When Raising Vehicles246
- Safety Instructions for Welding247
5 Safety Notes248
- Safety Instructions for Sticking248
  - Safety Instructions for Teromix−6700 Two−Component Adhesive248
- Safety Instructions for Installation Work249
- Safety Instructions for Corrosion Protection250
  - Safety Instructions for Plug Location Plan (Body)250
  - Safety Instructions for Water Drains (Body)250
General Information and Quality Notes251
- Measures for Maintaining Long−Term Body Protection251
  - Prerequisite for Maintaining the Long−Life Guarantee251
- Electronic Control Modules251
  - Protection against Overvoltage252
  - Replacing Control Modules252
Tools and Metalworking Tools for Body Repairs253
- Straightening Systems253
- Metalworking Tools253
Diagram − Keys to Symbols for Welding Work256
- Resistance Spot Welding256
- Inert−Gas Arc Welding (MAG Procedure)256
- Gas Welding256
Check Dimensions for Body Repair258
- Floorpan Check Dimensions258
Water Drainage Plan261
Diagram − Body Gap Dimensions262
- Gap Dimensions, Body Front262
- Gap Dimensions, Body Centre264
- Gap Dimensions, Body Rear265
- Gap Dimensions, Body Rear Carrera 4S267
- Diagram − Gap Dimensions, Cabriolet269
Body Parts of High−Strength Steel275
- High−Strength Steel Plates276
- Tailored Blanks277
- Baked Hardening278
- Straightening Body Parts278
- Welding Work279
- Reshaping279
- Separation Points279
- Diagram − Body, Model Year 2002280
  - Structural Body Parts (Model Care) for Model Year 2002280
Safety Notes282
- Safety Instructions for Work on Car Windows282
- Safety Instructions for Installation Work283
General Information on Installing and Removing Car Windows285
- Removing Glass with Cutting Wire Separator285
  - Cutting Power When Removing Glass with Cutting Thread292
Overview of Exterior Colours294
- Exterior Paintwork Solid294
- Exterior Paintwork Metallic/Pearl294
- Special Colours295
Processing of Porsche 2−Component Window Bonding Agents297
- Overview of Tools and Materials297
- Preparing the Adhesive Surfaces298
- Combined Procedure (Handling Double Cartridge Press)299
Special Notes for the Care of Soft−Look Paint Surfaces302
- Light Soiling (E.g. Dust)302
- Heavy Soiling (E.g. Oily, Greasy Dirt)302
Air Conditioning304
- Technical Data for the Air−Conditioning System304
Work Instructions after Disconnecting the Battery305
- Effect of Disconnection or Total Discharge of the Battery on Electrical Systems in the Vehicle, Subsequent Measures305
- Control Module Memories305
9 Work Instructions after Disconnecting the Battery306
- Supply Voltage Fault Entry306
- Test Drive after Connecting the Battery306
- DME Control Module306
- Power Windows307
- 25 Instrument Cluster307
- Clock307
- Fuel Level Display307
- Radio308
- Pcm308
Clutch: Checking Fluid Levels310
- General310
- Checking Pentosin CHF 11 S Hydraulic Fluid in the Engine Compartment and Luggage Compartment310
- Checking Pentosin CHF 11 S Hydraulic Fluid in the Engine Compartment311
- Checking Pentosin CHF 11 S Hydraulic Fluid in the Luggage Compartment312
Tightening Torques for Front Axle314
- Cross Member/Side Member (1 Component)314
- Diagonal Brace314
- Control Arm314
- Spring Strut/Wheel Carrier315
- Front−Axle Final Drive/Drive Shaft (Turbo)315
- Stabilizer316
- Steering316
- Wheel Fastening316
Tightening Torques for Rear Axle318
- Carrier Side Section/Cross Member318
- Axle Strut318
- Wheel Carrier319
- Spring Strut319
- Drive Shaft/Stabilizer320
- Unit Mount320
Conversion Table for Wheel Alignment Values321
- Minutes in Decimal Degrees321
  - Conversion from Minutes to Decimal Degrees (Examples)321
  - Conversion from Decimal Degrees to Minutes (Examples)321
Adjusting Values for Suspension Alignment − Turbo and GT2323
- Vehicle Height323
- Wheel Alignment Values323
Alignment Card − Turbo325
Suspension Alignment, Complete327
- Vehicle Height/Wheel Load328
- Wheel−Alignment Corrections328
  - Rear Axle328
  - Front Axle329
- General Procedure for Suspension Alignment329
- Vehicle Height (Vehicle Height Check)330
- Rear Axle332
  - Adjusting Camber332
  - Adjusting Toe333
- Front Axle334
Wheel Rims and Tires338
- Tire Condition / Tire Pressure338
- Tire Pressure of Cold Tires (Approx. 20° C)338
  - Turbo338
  - Gt2 (M002/M003)338
- Overview of Tires and Wheels (Series)339
  - Notes on Mounting Tires339
Tyres340
- Mounting Instructions340
- Balancing Weights342
- Navigation System342
- Wheel Storage342
- Tyre Age343
Checking Disc Wheels344
- Checking the Radial and Lateral Runout344
Tyre Mounting345
- Tools345
- Notes on Removing/Mounting Tyres346
- Removal346
- Fitting347
Balancing/Optimising Wheels350
- General350
- Balancing Weights354
  - Affixing the Adhesive Weights354
ABS/PSM 5.7 Check with Porsche System Tester 2355
- Test with Porsche System Tester 2355
Checking Brake Light Switch Setting356
- Brake Light Switch Setting356
- Adjusting Switch if Pedal Travel Is too Small357
Tightening Torques for Mechanical Brake358
Technical Data/Brake Wear Limit − Turbo359
- Technical Data − Turbo with Cast Iron Brake Discs359
- Wear Limit Technical Data − Turbo with Cast Iron Brake Discs360
Checking the Thickness of the Disc Brake Pads − Turbo and GT2361
Technical Data/Brake Wear Limit − Turbo with PCCB363
- Technical Data − Turbo with Ceramic Brake Discs (PCCB)363
- Wear Limit Technical Data − Turbo with Ceramic Brake Discs (PCCB)364
Tightening Torques for Brake Hydraulics365
Tightening Torques for Steering366
Test and Assembly Work on Power Steering367
- General367
- Checking Hydraulic Fluid of Power Steering and Servo Clutch367
- Bleeding the Steering System368
Assessment of Steering Gear after Accident Damage370
- Fundamentals370
  - Assessment of the Steering of a Vehicle Involved in an Accident370
  - Exceptional Regulation / Order Handling371
Safety Regulations for Vehicles with Airbag and Belt Tensioner372
- Assembly and Adjustment Work373
- Handling Airbag and Belt Tensioner374
- General Information376
Nominal Values for Pressures and Temperatures378
- General Test Prerequisites378
Retrofitting Mobile Communication Systems381
Additional Alarm System M 536383
- Removing Alarm Siren and Tilt Sensor383
Measurement of Closed−Circuit Current384
- Tools384
- Preparations on the Vehicle384
  - Connecting Measuring Device384
- Measurement385
06 Battery387
- Battery − Handling Notes387
  - Warning Notes and Safety Regulations for Hydrocyanic Acid Batteries388
- Removing and Installing Battery388
- Remove Battery389
- Install Battery390
- Visual Inspection391
- Check Acid Level391
- Checking Gravity of Electrolyte392
- Open−Circuit Voltage Measurement393
- Battery Load Test394
- Charging Battery395
06 Electrical Emergency Release397
- Emergency Release, Front Cover397
09 Front−Axle Cross Member − Permissible Combinations399
- New Front−Axle Cross Member − as of Model '02399
- Allocating the Front−Axle Cross Member to the Body399
Disassembling and Assembling Front Spring Strut402
- Tools402
- Disassembly and Assembly Instructions404
71 Disassembling and Assembling Rear Spring Strut − Turbo409
- Tools409
- Disassembling and Assembling Rear Spring Strut409
- Disassembly and Assembly Instructions411
27 Instructions for Collapsible Wheel/Spare Wheel − Turbo with PCCB416
- Mounting Collapsible Spare Wheel − Turbo with PCCB416
- Placing Collapsible Spare Wheel in to the Vehicle − Turbo with PCCB417
60 Steering Angle Sensor418
- Calibrating Steering Angle Sensor418
72 Assignment of Spoiler Drive, Relays and Instrument Cluster421
- Variants of the Spoiler Drive421
59 Disposal of Airbag and Belt Tensioner Units422
- Safety Measures When Igniting Airbag Units422
- Tools423
- Connecting Ignition Tool424
- Ignition425
03 Safety Regulations When Handling Refrigerant R134A427
66 Non−Adjustable Spray Nozzles428
23 Bulb Table and Installation Instructions429
- Bulb Table429
- Installing Bulbs429
22 Bulb Table and Installation Instructions430
- Bulb Table430
- Installing Bulbs430
68 Optical Waveguide − most Bus431
- Specifications on Handling the Optical Waveguide431
- Plug Connectors432
- Removing and Installing Optical Contacts434
- Optical Waveguide Modules438
- Tools439
Sales Check440
24 00 Minor Maintenance442
26 00 Major Maintenance444
50 00 Annual Maintenance446
01 00 Tightening Torques for M 96/70 Engine448
- Crankshaft/Crankcase448
- Cylinder, Cylinder Head and Camshaft Housing448
10 37 Disassembling and Assembling Crankcase450
- Tools450
- Adapting Engine Holder453
- Left Crankcase Half (Cylinder Bank 1 3)455
- Right Crankcase Half (Cylinder Bank 4 − 6)457
- Disassembling the Crankcase459
- Assembling the Crankcase462
10 19 Removing and Installing Pistons (Includes Removing and Installing Cylinders)474
- Tools474
- Removing Pistons and Cylinders475
- Removing Pistons477
- Installing Pistons and Cylinders478
19 21 Removing Piston Rings486
- Tools486
- Removal486
19 23 Installing Piston Rings490
- Tools490
- Installation490
48 37 Disassembling and Assembling Crankshaft494
- Tools494
- Disassembling Crankshaft496
  - Identifying the Ring Knurled Screw497
- Pressing Ring Knurled Screw in and out498
  - Pressing Ring Knurled Screw out498
  - Pressing Ring Knurled Screw in499
- Assembling Crankshaft499
73 37 Disassembling and Assembling Belt Tensioner503
- Assembly Note505
78 19 Removing and Installing Drive Belt (Engine Installed)506
- Removal Overview of the Drive Belt (Engine Installed)506
- Remove Drive Belt507
- Installation Overview of the Drive Belt (Engine Installed)509
- Install Drive Belt511
03 21 Removing Camshaft Housing Engine Removed513
- Tools513
- Component Overview and Tightening Torques513
- Removing the Camshaft Housing516
03 23 Installing Camshaft Housing521
05 02 Checking Camshafts (Timing) Engine Removed523
- Tools523
- Checking Camshafts524
05 16 Setting Camshafts (Timing) Engine Removed530
- Tools530
- Setting the Camshafts (Timing)531
05 19 Removing and Installing Camshafts Engine Removed537
- Tools537
- Component Overview and Tightening Torques538
- Removing Camshafts540
- Installing Camshafts544
20 37 Disassembling and Assembling Intermediate Shaft550
55 19 Removing and Installing Hydraulic Valve552
- Removing the Hydraulic Valve552
- Installing the Hydraulic Valve554
70 21 Removing Cylinder Head557
- Removing Cylinder Head559
70 23 Installing Cylinder Head560
04 19 Removing and Installing Oil Pressure Sender562
- Removal562
- Installation563
07 19 Removing and Installing Oil Temperature Sensor565
- Removal565
- Installation566
28 19 Removing and Installing Check Valve Engine Installed568
- Removal569
- Installation571
40 19 Removing and Installing Oil Cooler Engine Removed573
- Removing Oil Cooler573
- Installing Oil Cooler574
52 19 Removing and Installing Oil Container577
- Removing Oil Container − Removal Overview577
- Installing Oil Container580
38 17 Draining and Filling in Coolant583
- Draining Coolant584
- Filling in Coolant584
- Bleeding the Cooling System584
40 19 Removing and Installing Coolant Expansion Tank586
- Removal586
- Installation590
50 19 Removing and Installing Coolant Pump (Engine Installed)592
- Tools592
- Removal592
- Installation597
62 19 Removing and Installing Coolant Hose at Front Left (Y−Type Coolant Distributor)601
- Tools601
- Removal601
- Installation603
02 01 Checking Fuel Pressure606
10 19 Removing and Installing Fuel Tank609
- Removing Fuel Tank611
- Installing Fuel Tank616
  - Tightening Torques for Front Axle and Fuel Tank620
15 01 Calibrating Fuel Level Sensor System622
39 19 Removing and Installing Fuel Return Line623
- Removal623
- Installation624
60 55 Replacing Fuel Filter626
- Removing Fuel Filter626
66 01 Checking Quantity Delivered by Fuel Pump631
68 19 Removing and Installing Fuel Cooler634
- Removing Fuel Cooler634
- Installing Fuel Cooler635
10 19 Removing and Installing Air Guide for Charge Air Cooling636
- Removing Air Guide for Charge Air Cooling636
- Installing Air Guide for Charge Air Cooling638
30 19 Removing and Installing Turbocharger640
- Removing Turbocharger640
- Installing Turbocharger642
43 19 Removing and Installing the Charge Air Cooler646
- Removing the Charge Air Cooler646
- Installing the Charge Air Cooler647
67 05 Checking and Adjusting the Bypass Flap Control Boxes on the Turbocharger648
- Check and Adjust (Cylinder Bank 1 − 3)648
  - Test648
  - Adjusting649
- Check and Adjust (Cylinder Bank 4 − 6)649
67 19 Removing and Installing Bypass Flap Control Box on the Turbocharger − Engine Installed651
- Removing Bypass Flap Control Box on the Turbocharger651
- Installing Bypass Flap Control Box on the Turbocharger652
75 20 Removing and Installing Oil Container for Exhaust Turbocharger − Engine Installed654
- Removing Oil Container for Exhaust Turbocharger654
- Installing Oil Container for Exhaust Turbocharger656
80 19 Removing and Installing Oil Pump for Turbocharger658
- Tools658
- Removal658
- Installation667
90 19 Removing and Installing Pressure Sensor672
- Removal672
- Installation672
00 33 Completing the Vacuum Connections673
25 19 Removing and Installing Air Cleaner676
- Removing Air Cleaner676
- Installing Air Cleaner678
42 19 Removing and Installing Throttle Body − Engine Installed680
- Removing Throttle Body680
- Installing Throttle Body681
46 01 Testing the Intake Distributor (Leak Test)683
- Tools683
- Leak Test683
46 20 Removing and Installing Intake Distributor Engine Removed685
- Removing Intake Distributor685
- Installing Intake Distributor687
46 37 Disassembling and Assembling Intake Distributor690
- Disassembling the Intake Distributor690
- Vacuum Lines692
69 19 Precautionary Measures When Handling Oxygen Sensors694
73 19 Removing and Installing Oxygen Sensors Behind Catalytic Converter695
- Removing Oxygen Sensors Behind the Catalytic Converter695
  - Oxygen Sensor, Left Side696
  - Oxygen Sensor, Right Side696
- Installing Oxygen Sensors Behind the Catalytic Converter697
01 05 Exhaust System Leak Test698
- Tools698
- Leak Test699
33 19 Removing and Installing Rear Mufflers700
- Removing Rear Mufflers700
- Installing Rear Mufflers702
65 19 Removing and Installing Secondary Air Pump704
- Removal704
- Installation705
22 19 Removing and Installing Three−Phase Generator706
- Removing the Three−Phase Generator706
- Installing the Three−Phase Generator707
- Undoing and Tightening the Belt Pulley707
- Tool for Holding the Free−Wheel Pulley707
27 19 Removing and Installing Bracket for Generator709
- Removing Bracket for Generator709
  - Removal709
- Installing Bracket for Generator712
60 19 Removing and Installing Starter (Manual Transmission)715
- Removing the Starter715
- Installing the Starter715
39 19 Removing and Installing Hall Sender − Engine Installed716
- Removing Hall Sender716
- Installing Hall Sender717
- Tightening Torques718
70 55 Replacing the Spark Plugs719
- Removing Spark Plugs719
- Installing Spark Plugs720
72 20 Removing and Installing Knock Sensor Engine Removed722
- Removing and Installing Knock Sensor, Cylinder Bank 1−3722
- Removing Knock Sensor, Cylinder Bank 4 − 6723
- Installing Knock Sensor, Cylinder Bank 4 − 6724
01 01 Checking Clutch Booster Circuit726
- Checking Accumulator726
- Checking Valve (Pressure−Regulating Valve)726
  - Checking the Valve (Pressure−Regulating Valve) in the Clutch Save Cylinder727
  - Checking the Valve (Pressure−Regulating Valve) in the Upper Part of the Expansion Tank727
01 07 Bleeding Clutch Operation729
- Disposal of Pentosin730
27 19 Removing and Installing Clutch Pressure Hose − Engine Installed731
- Removing Clutch Pressure Hose731
- Installing Clutch Pressure Hose732
30 19 Removing and Installing Clutch Slave Cylinder734
- Removal734
- Tightening Torques736
- Installation737
31 19 Removing and Installing the Accumulator739
- Removal739
- Installation740
45 19 Removing and Installing Release Bearing (Clutch Removed)742
- Removing Release Bearing743
- Installing Release Bearing743
50 19 Removing and Installing Clutch745
- Tools745
- Removing Clutch745
- Installing Clutch746
- Tightening Torques746
50 37 Disassembling and Assembling Clutch747
56 01 Checking Clutch Drive Plate for Wear748
24 00 Minor Maintenance − USA749
24 00 Minor Maintenance − as of MY 2003751
24 00 Minor Maintenance − USA − as of MY 2003753
24 00 Minor Maintenance − as of MY 2004755
24 00 Minor Maintenance − USA − as of MY 2004757
47 19 Removing and Installing Torque−Converter Sealing Ring759
- Tools759
- Removing the Torque−Converter Sealing Ring759
- Installing the Torque−Converter Sealing Ring760
50 19 Removing and Installing Torque Converter761
- Tools761
- Removing the Torque Converter761
- Installing the Torque Converter762
26 00 Major Maintenance − USA763
26 00 Major Maintenance − as of MY 2003765
26 00 Major Maintenance − USA − as of MY 2003767
26 00 Major Maintenance − as of MY 2004769
26 00 Major Maintenance − USA − as of MY 2004771
01 55 Changing Transmission Oil773
- Tightening Torques773
08 19 Removing and Installing Shift Console774
- Tools774
- Removing Shift Console775
- Installing Shift Console776
- Tightening Torques777
12 19 Removing and Installing Shift and Selector Cables778
- Tools778
  - Removing Shift and Selector Cables779
  - Installing Shift and Selector Cables781
- Tightening Torques782
35 27 Removing and Refitting the Transmission783
- Tools783
- Removing Transmission783
- Refitting Transmission785
- Tightening Torques786
49 19 Removing and Installing Closure Cap for Selector Force Mechanism787
- Tools787
  - Removing Closure Cap for Selector Force Mechanism788
  - Installing Closure Cap for Selector Force Mechanism789
- Tightening Torques789
50 00 Annual Maintenance − USA790
50 00 Annual Maintenance − as of MY 2004792
50 00 Annual Maintenance − USA − as of MY 2004793
02 35 Checking and Topping up the ATF794
- Tools794
- Tightening Torques796
02 55 Replacing ATF Fluid797
- Tools797
- Tightening Torques799
08 19 Removing and Installing Selector Support800
- Removing Selector Support800
- Installing Selector Support801
- Tightening Torques802
15 19 Removing and Installing Selector Lever Cable803
- Tools803
  - Removing Selector Support803
  - Installing Selector Support806
- Tightening Torques807
35 27 Removing and Refitting the Transmission809
- Tools809
- Removing Transmission810
- Refitting Transmission811
- Tightening Torques812
58 19 Removing and Installing ATF Filter813
- Tools813
- Removing ATF Filter813
- Installing ATF Filter814
- Tightening Torques815
77 19 Removing and Installing Electrohydraulic Control Unit816
- Tools816
- Removing the Electrohydraulic Control Unit816
- Installing the Electrohydraulic Control Unit819
- Tightening Torques821
77 37 Disassembling and Assembling Electrohydraulic Control Unit822
- Tools822
- Overview822
- Disconnecting Hydraulic and Electrical Control Unit824
- Removing Solenoid and Control Valve824
- Installing Solenoid and Control Valve824
- Reassembling the Hydraulic and Electrical Control Unit824
41 19 Removing and Installing the Front Drive Shaft826
- Tools826
- Removal826
- Installation828
85 19 Removing and Installing Front Spring Strut829
- Removal829
- Installation830
58 19 Removing and Installing Rear−Wheel Bearing832
- Tools832
- Notes on Removal and Installation833
  - Removal834
  - Installation835
71 19 Removing and Installing Rear Spring Strut836
- Removal836
- Installation836
05 19 Removing and Installing the Wheel − Turbo and GT2838
- Wheel Mounting − Turbo and GT2838
- Removing/Installing the Wheel on Vehicle − Turbo and GT2838
35 19 Removing and Installing Valve (Steel Valve) (Turbo Ll Wheel)841
- General841
- Notes on Removal and Installation841
- Removal842
- Installation842
11 19 Removing and Installing Front Speed Sensors844
- Removal844
- Installation844
15 19 Removing and Installing Rear Speed Sensors845
- Removal845
- Installation845
30 19 Removing and Installing Hydraulic Unit847
- Replacing the Hydraulic Unit847
- Removal848
- Installation849
59 19 Removing and Installing Rate−Of−Turn Sensor851
- Removal852
- Installation853
59 31 Conversion of Rate−Of−Turn Sensor854
- Overview of Rate−Of−Turn Sensor Conversion855
- Removal857
- Fitting859
60 19 Removing and Installing Steering Angle Sensor862
- Notes on Steering Wheel Position During Removal and Installation862
- Removal862
- Notes on Replacing the Steering Angle Sensor − Vehicles Prior to '03 Model864
  - Component Overview865
- Installation866
64 19 Remove and Install Booster Pump for PSM870
- Removal870
- Installation871
11 15 Adjusting the Brake Pushrod872
36 20 Removing and Installing the Front Disc Brake Pads873
- Removal873
- Installation874
  - Bedding in the Brake Pads875
38 20 Removing and Installing the Rear Disc Brake Pads876
- Removal876
- Installation877
  - Bedding in the Brake Pads878
50 04 Measuring Front Brake Discs879
- Measuring the Front Brake Disc Lateral Runout879
  - Measuring the Brake Disc Thickness Tolerance880
Removing and Installing the Front Brake Disc881
- Removal881
- Installation881
53 04 Measuring Rear Brake Discs883
- Measuring the Rear Brake Disc Lateral Runout883
  - Measuring the Brake Disc Thickness Tolerance884
53 19 Removing and Installing the Rear Brake Disc885
- Removal885
- Installation885
83 16 Adjusting the Parking Brake Shoes887
- Check the Free Play of the Parking Brake Lever887
- Adjusting the Parking Brake887
83 19 Removing and Installing the Parking Brake Shoes889
- Removal889
- Installation889
01 07 Bleeding Brakes (Vehicle with PSM)892
- Psm892
- Procedure for Bleeding892
- 1St Step: Bleed Brakes as Usual892
- 2Nd Step: Bleeding at Front on Right with Running Booster Pump893
08 55 Changing Brake Fluid895
- Procedure for Changing Brake Fluid895
15 19 Removing and Installing Brake Master Cylinder897
- Removal897
- Installation898
70 19 Removing and Installing Brake Booster900
- Removal900
- Installation902
10 19 Removing and Installing Steering Wheel907
- Removal907
- Installation908
90 19 Removing and Installing Steering Gear909
- Removal909
- Installation910
  - Notes for Sliding Piece and Airbag Contact Unit911
55 19 Removing and Installing the Wing913
56 19 Removing and Installing Wheel Housing Liners, Front917
69 19 Removing and Installing Wheel Housing Liners, Rear919
10 37 Disassembling and Assembling Release for Front Lid921
- Disassembling Release for921
- Assembling Release for Front Cover923
  - Removing and Installing Support for Cap Release924
10 37 Disassembling and Assembling Release for Front Lid Removing and Installing Support for Cap Release924
17 19 Removing and Installing Front Lower Part of Lid Lock926
- Removing and Installing Bowden Cable for Lock Actuation928
22 19 Removing and Installing Front Lid931
22 37 Disassembling and Assembling Front Lid933
25 19 Removing and Installing Front Lid Hinge936
37 19 Removing and Installing Filler Flap938
57 37 Disassembling and Assembling Release for Rear Lid941
- Disassembling Release for Rear Lid941
- Assembling Release for Rear Lid943
86 19 Removing and Installing Lower Part of Lid Lock945
90 19 Removing and Installing Rear Lid948
90 37 Disassembling and Assembling Rear Lid950
- Disassembling Rear Lid950
- Assembling Rear Lid953
- Replacing the Model Logo956
91 19 Removing and Installing Lid Hinge957
11 37 Disassembling and Assembling Door Handle960
37 19 Removing and Installing Inner Door Release (Bowden Cable) for Door Lock963
45 19 Removing and Installing Door Handle966
- Removing and Installing Orientation Lighting (LED Light−Emitting Diodes)968
  - Removing Orientation Lighting (LED Light−Emitting Diodes)968
  - Installing Orientation Lighting (LED Light−Emitting Diodes)969
14 15 Re−Teaching the Lifting/Sliding Roof Drive971
14 19 Removing and Installing Lifting/Sliding Roof Drive972
- Removing Lifting/Sliding Roof Drive972
- Installing Lifting/Sliding Roof Drive973
- Emergency Operation on Lifting/Sliding Roof Drive974
28 19 Removing and Installing Frame for Sliding Roof975
- Removing Frame for Sliding Roof975
- Installing Frame for Sliding Roof977
60 28 19 Removing and Installing Frame for Sliding Roof979
- Tightening Torques979
28 37 Disassembling and Assembling Frame for Sliding Roof980
- Disassembling Frame for Sliding Roof980
- Assembling Frame for Sliding Roof982
40 19 Removing and Installing Sliding Roof Panel984
- Additional Instructions for Removing the Inner Panels987
- Additional Instructions for Fitting the Inner Panels988
10 19 Removing and Installing Front Bumper990
15 19 Removing and Installing Front Spoiler993
- Removing Front Spoiler993
- Installing Front Spoiler995
15 37 Disassembling and Assembling Front Spoiler997
- Disassembling Front Spoiler998
  - Removing Front Spoiler999
- Assembling Front Spoiler1000
  - Installing Front Spoiler1002
50 19 Removing and Installing Rear Bumper1004
- Removing Rear Bumper1004
- Installing Rear Bumper1006
- Additional Assembly Instructions for Installation of the Bumper1008
  - Adjustment Dimensions of the Bumper1008
  - Correct Assembly of the Heat Shields1009
- Additional Assembly Instructions for Installation of the Bumper − Carrera 4S1010
  - Correct Assembly of the Heat Shields1010
  - Removing and Installing Frame with Heat Shield1011
- Tightening Torques1012
55 19 Removing and Installing Rear Spoiler1013
- Removing Rear Spoiler1013
- Install Rear Spoiler1015
55 37 Disassembling and Assembling Rear Spoiler1017
- Disassembling Rear Spoiler1017
- Assembling Rear Spoiler1019
- Additional Instructions for Replacing the Rear Spoiler1021
86 01 Checking Function of Heating for Rear Window1023
- Check with the Temperature Probe1023
86 19 Removing and Installing Rear Window1024
- Removing Rear Window1024
- Preparing the Window Section for Installation1026
- Installing Rear Window1027
- Overview of Tools and Materials1030
13 19 Removing and Installing Air Inlet1032
- Removing Air Inlet1032
- Installing Air Inlet1033
36 19 Removing and Installing Roof Joint Strip1036
- Removing Roof Joint Strip1036
- Installing Roof Joint Strip1038
58 19 Removing and Installing Rear Spoiler1040
- Removing Rear Spoiler1040
- Installing Rear Spoiler1042
78 01 Checking Function of Heating for Mirror Glass1045
- Check with the Temperature Probe1045
89 19 Removing and Installing Rearview Mirror1046
- Removing the Rearview Mirror1046
- Installing the Rearview Mirror1048
17 37 Disassembling and Assembling Centre Console1050
- Disassembling and Assembling Cover for the Oddments Tray1052
23 19 Removing and Installing Sun Visors1054
- Removing Sun Visors1054
- Installing Sun Visors1055
23 37 Disassembling and Assembling Sun Visor1056
- Disassembling Sun Visor1056
- Assembling Sun Visor1058
27 13 Bonding on the Interior Rearview Mirror1060
- Bonding the Assembled Interior Mirror Onto the Windscreen1060
27 19 Removing and Installing the Interior Rearview Mirror1063
- Removing the Interior Rearview Mirror1063
- Installing the Interior Rearview Mirror1065
53 19 Removing and Installing the Triggering Unit for the Airbag1067
- Removing Triggering Unit for Airbag1067
- Installing Triggering Unit for Airbag1068
54 19 Removing and Installing the Contact Unit1069
- Installing Contact Unit1069
58 19 Removing and Installing the Driver's Airbag Unit1071
- Removing Driver's Airbag Unit1071
- Installing Driver's Airbag Unit1071
59 19 Removing and Installing the Passenger's Airbag Unit1073
- Removing Passenger's Airbag Unit1073
- Installing Passenger S Airbag Unit1074
63 19 Removing and Installing the Side Airbag Unit1075
- Removing Side Airbag Unit1075
- Installing Side Airbag Unit1076
  - Removing Sensor for Side Airbag Unit1076
18 19 Removing and Installing the Instrument Panel and Instrument Panel Bracket1078
- Removing and Installing the Instrument Panel1078
- Removing and Installing the Instrument Panel Bracket1080
- Tightening Torque1082
- Tools and Materials1082
18 37 Disassembling and Assembling the Instrument Panel1084
- Disassembling the Instrument Panel1084
  - Removing the Regulator for Wiping Interval1089
  - Removing the Cigarette Lighter1089
- Assembling the Instrument Panel1090
  - Installing the Regulator for Wiping Interval1095
  - Installing the Cigarette Lighter1095
- Model Year 20021096
22 19 Removing and Installing Cowl Panel Cover1100
59 19 Removing and Installing Door Trim Panel1103
- Removing Door Trim Panel1103
- Installing Door Trim Panel1105
- Installation Note for Door Sealing Film1107
  - Installation Note on Door Sealing Film for Vehicles Without Side Airbag1107
  - Notes on the Installation of Partly Detached Door Sealing Films1107
- Fitting Sliding Strip on the Inner Door Panel1108
70 59 19 Removing and Installing Door Trim Panel1109
- Materials and Tools1109
- Tightening Torque1109
65 19 Removing and Installing Oddments Compartment Lid1110
84 19 Removing and Installing Roof Lining1113
- Removing Roof Lining1113
- Installing Roof Lining1115
23 19 Removing and Installing Heat Exchanger1118
- Removing Heat Exchanger1118
- Installing Heat Exchanger1118
30 19 Removing and Installing Heater/Fresh−Air Blower Motor1119
- Removing Heater/Fresh−Air Blower Motor1119
- Installing Heater/Fresh−Air Blower Motor1120
01 19 Removing and Installing the Heating/Air−Conditioning Unit1121
- Removing Heating/Air−Conditioning Unit1121
- Installing Heating/Air−Conditioning Unit1123
02 19 Removing and Installing the Heating/Air−Conditioning Control1125
- Removing Heating/Air−Conditioning Control1125
- Performing System Test1125
- Tests1126
03 17 Assembly Work on the Air−Conditioning System1127
- Service Unit SECU 1341127
- Assembly Work Involving the Refrigerant System1129
- General Assembly Sequence1129
- Removing Refrigerant by Suction and Cleaning1130
- Cleaning the Refrigerant1131
- Draining off Old Refrigerant Oil1131
- Evacuating1132
- Topping up with New Refrigerant Oil1133
- Filling Via the High−Pressure Side1133
- Refilling the Air−Conditioning System1134
- Distribution of the Oil Quantity in the Refrigerant Circuit1135
20 19 Removing and Installing Drive Motors1136
- Removing Drive Motors1136
- Installing Drive Motors1137
  - Installing Drive Motor for Temperature Valve, Central Valve and Footwell/Defrost1137
  - Installing Drive Motor for Fresh−Air/Recirculation Valve1138
27 19 Removing and Installing the Magnetic Coupling1139
- Removing the Magnetic Coupling1139
- Installing the Magnetic Coupling1139
  - Checking the Air Gap of the Magnet Coupling1140
34 19 Removing and Installing the Compressor1141
- Removing the Compressor1141
- Installing the Compressor1142
  - Running−In Regulations for New Compressor1143
50 19 Removing and Installing the Condenser1144
- Removing the Condenser1144
- Installing the Condenser1144
53 19 Removing and Installing Fan for Condenser1146
- Removing Fan for Condenser1146
- Installing Fan for Condenser1146
55 19 Removing and Installing the Fluid Tank1147
- Removing Fluid Tank1147
- Installing Fluid Tank1147
58 19 Removing and Installing Footwell Blower Outlet Sensor1148
- Removing Footwell Blower Outlet Sensor1148
- Installing Footwell Blower Outlet Sensor1148
59 19 Removing and Installing Outside Temperature Sensor1149
- Removing Outside Temperature Sensor1149
- Installing Outside Temperature Sensor1149
70 19 Removing and Installing the Expansion Valve1150
- Removing Expansion Valve1150
- Installing Expansion Valve1150
78 19 Removing and Installing Blower Driver1151
- Removing Blower Driver1151
- Installing Blower Driver1151
82 19 Removing and Installing Interior Temperature Sensor1152
- Removing Interior Temperature Sensor1152
- Installing Interior Temperature Sensor1152
83 19 Removing and Installing Pressure Switch for the Air−Conditioning System1153
- Removing Pressure Switch for the Air−Conditioning System1153
- Installing Pressure Switch for the Air−Conditioning System1153
12 15 Setting Ahead the Total Mileage Counter in the Instrument Cluster1154
- Setting Ahead with the Porsche System Tester 21154
25 37 Disassembling and Assembling Instrument Cluster1155
50 19 Removing and Installing Horn1156
- Removing Horn1156
- Installing Horn1157
12 15 Adjusting (Calibrating) PCM Navigation Unit1158
- GPS Receiver1158
- Distance Sensor1158
- Gyroscope1159
- Procedure after Commissioning1159
- Procedure after Changing a Tyre1159
- Procedure after the Power Supply Has Been Interrupted1159
12 19 Removing and Installing Navigation Unit1160
- Removing Navigation Unit1160
- Installing Navigation Unit1160
  - Device Code Input1160
13 19 Removing and Installing GPS Antenna1162
- Removing GPS Antenna1162
- Installing GPS Antenna1162
20 19 Removing and Installing the Car Radio1164
- Removing the Car Radio1164
- Installing the Car Radio1164
- Entering the Code Number1165
47 19 Removing and Installing Radio Antenna1166
- Removing Radio Antenna1166
- Installing Radio Antenna1166
57 15 Setting Hands−Free Microphone to the Telephone Type1167
- Setting1167
57 19 Removing and Installing Hands−Free Microphone1168
- Removing Hands−Free Microphone1168
- Installing Hands−Free Microphone1169
75 19 Removing and Installing Sensor for Parkassistent1170
- Removing Sensor for Parkassistent1170
- Installing Sensor for Parkassistent1170
- Parkassistent Control Module1171
15 19 Removing and Installing the Wiper Motor1172
- Removing Wiper Motor1172
- Installing Wiper Motor1172
19 19 Removing and Installing the Wiper Link1174
- Removing Wiper Link1174
- Installing Wiper Link1174
27 19 Removing and Installing the Wiper Blades1176
30 19 Removing and Installing Rear Window Wiper System1177
- Removing Rear Window Wiper System1177
- Installing Rear Window Wiper System1177
56 19 Removing and Installing Pump for Windscreen Washer System1178
- Removing Pump for Windscreen Washer System1178
- Installing Pump for Windscreen Washer System1178
60 19 Removing and Installing Tank for Windscreen Washer System1179
- Removing Tank for Windscreen Washer System (7 Litres)1179
- Removing Tank for Windscreen Washer System (3 Litres)1179
- Installing Tank for Windscreen Washer System1180
67 19 Removing and Installing Fluid Level Indicator1181
- Removing Fluid Level Indicator1181
- Installing Fluid Level Indicator1181
70 19 Removing and Installing Cover for Spray Nozzle1182
- Removing Cover for Spray Nozzle1182
- Installing Cover for Spray Nozzle1182
72 19 Removing and Installing Spray Nozzle for Headlight Washing System1183
- Removing Spray Nozzle for Headlight Washing System1183
- Installing Spray Nozzle for Headlight Washing System1183
78 19 Removing and Installing Pump for Headlight Washing System1184
- Removing Pump for Headlight Washing System1184
- Installing Pump for Headlight Washing System1184
05 19 Removing and Installing Main Light Switch1185
- Removing Main Light Switch1185
- Installing Main Light Switch1186
15 01 Troubleshooting on the Xenon Headlight1187
15 05 Main Headlights − Basic Adjustment in the Body1188
- Adjustment Instructions1188
- Adjustment Procedure1189
15 15 Left / Right Traffic Conversion for Xenon Headlights1190
- Converting Xenon Headlights1190
- Installation1190
15 19 Removing and Installing the Main Headlights1192
23 19 Removing and Installing Gas Discharge Lamp (Xenon Headlights)1193
- Removing Gas Discharge Lamp (Xenon Headlights)1193
- Installing Gas Discharge Lamp (Xenon Headlights)1193
27 19 Removing and Installing Bulb for Parking Light1195
- Removing Bulb for Parking Light1195
- Installing Bulb for Parking Light1195
29 19 Removing and Installing Bulb for Number Plate Light1196
- Removing Bulb for Number Plate Light1196
- Installing Bulb for Number Plate Light1196
33 19 Removing and Installing Bulb for Tail Light1197
- Removing Bulb for Tail Light1197
- Installing Bulb for Tail Light1197
47 19 Removing and Installing the Hazard Warning Light Switch1198
- Removing Hazard Warning Light Switch1198
- Installing Hazard Warning Light Switch1198
53 19 Removing and Installing Bulb for Side Direction Indicator Light1199
- Removing Bulb for Side Direction Indicator Light1199
- Installing Bulb for Side Direction Indicator Light1199
57 19 Removing and Installing Control Module for Gas Discharge Lamp1200
- Removing Control Module for Gas Discharge Lamp1200
- Installing Control Module for Gas Discharge Lamp1201
66 19 Removing and Installing Bulb for Auxiliary Headlight (High Beam Headlight)1202
- Removing Bulb for Auxiliary Headlight1202
- Installing Bulb for Auxiliary Headlight1202
67 19 Removing and Installing Bulb for Fog Light1203
- Removing Bulb for Fog Light1203
- Installing Bulb for Fog Light1203
70 19 Removing and Installing Bulb for Additional Brake Light1204
- Removing Bulb for Additional Brake Light1204
- Installing Bulb for Additional Brake Light1204
78 19 Removing and Installing Front Angle Sensor for Headlight Beam Adjustment1205
- Removing Front Angle Sensor for Headlight Beam Adjustment1205
- Installing Front Angle Sensor for Headlight Beam Adjustment1205
79 19 Removing and Installing Rear Angle Sensor for Headlight Beam Adjustment1207
- Removing Rear Angle Sensor for Headlight Beam Adjustment1207
- Installing Rear Angle Sensor for Headlight Beam Adjustment1207
94 19 Removing and Installing Drive Motor for Headlight Beam Adjustment1209
- Removing Drive Motor for Headlight Beam Adjustment1209
- Installing Drive Motor for Headlight Beam Adjustment1209
98 19 Removing and Installing Control Module for Headlight Beam Adjustment1210
- Removing Control Module for Headlight Beam Adjustment1210
- Installing Control Module for Headlight Beam Adjustment1210
16 19 Removing and Installing Bulb for Door Warning Light1211
- Removing Bulb for Door Warning Light1211
- Installing Bulb for Door Warning Light1211
22 19 Removing and Installing Bulb for Interior Light1212
- Removing Bulb for Interior Light1212
- Installing Bulb for Interior Light1212
41 19 Removing and Installing Bulb for Luggage Compartment Light1213
- Removing Bulb for Luggage Compartment Light1213
- Installing Bulb for Luggage Compartment Light1213
43 19 Removing and Installing Bulb for Engine Compartment Light1214
- Removing Bulb for Engine Compartment Light1214
- Installing Bulb for Engine Compartment Light1214
62 01 Radio Remote Control in Hand−Held Transmitter Does Not Function1215
- Empty Battery in Hand−Held Transmitter1215
- Radio Transmitter Outside Lock−In Range1215
- Atmospheric Interference or Interfering Transmitters1215
- Energy−Saving Mode Active1216
- Fault in Hand−Held Transmitter or Vehicle1216
62 37 Disassembling and Assembling Hand−Held Transmitter1217
- Removing Key from the Bottom Part1217
- Installing Key in the Bottom Part1217
62 55 Teaching Hand−Held Transmitter1218
- General1218
- Work Preparation1218
- Procedure1219
72 19 Removing and Installing Signal Converter/Immobilizer1221
- Removing Signal Converter/Immobilizer1221
- Installing Signal Converter/Immobilizer1222
85 19 Removing and Installing Passenger Compartment Monitoring Sensor1223
09 41 Repair of Main Wiring Harness1225
- Removing Main Wiring Harness1225
- Installing Main Wiring Harness1226
25 41 Repair of Rear Wiring Harness1228
- Removing Rear Wiring Harness1228
- Installing Rear Wiring Harness1229
01 19 Removing and Installing Engine1231
- Tools for Removal1231
- Removing Engine1232
01 19 Removing and Installing Engine1242
- Installing Engine1242
- Tightening Torques: Removing and Installing Engine1245
40 20 Removing and Installing Injection Valves − Engine Removed1246
- Removing Injection Valves of Cylinder Bank 11246
- Removing Injection Valves of Cylinder Bank 41247
- Installing Injection Valves of Cylinder Bank 11247
- Installing Injection Valves of Cylinder Bank 41248
40 20 Removing and Installing Injection Valves − Engine Installed1249
- Preliminary Work1249
- Removing Injection Valves of Cylinder Bank 11249
- Installing Injection Valves1255
69 19 Removing and Installing Oxygen Sensors in Front of Catalytic Converter1263
- Tools1263
- Removing Oxygen Sensors in Front of Catalytic Converter1263
  - Oxygen Sensor, Left Side1264
  - Oxygen Sensor, Right Side1265
- Installing Oxygen Sensors in Front of Catalytic Converter1265
70 19 Removing and Installing DME Control Module1267
- Obtaining Read−Out and Saving Vehicle Data from DME Control Module1268
- Removing DME Control Module1268
- Installing the DME Control Module1269
- Programming the New DME Control Module 911 Turbo (996)1270
24 70 19 Removing and Installing DME Control Module1271
- Programming the New DME Control Module − GT2 and Version X511271
- Programming the DME Control Module 911 Turbo (996)1272
- Programming DME Control Module − GT2 and Version X511273
- Version (Data Records) 911 Turbo (996)1275
- Version (Data Records) − GT21276
60 19 Removing and Installing Starter (Automatic Transmission)1277
- Removing the Starter1277
- Installing the Starter1278
35 37 Partially Disassembling Transmission1279
- Tools1279
- Removing Transmission Cover1280
- Disassembling Front Gear Set1280
  - Overview1280
  - Disassembling Gear Set1282
- Removing Gear Housing1283
- Removing Input and Output Shaft1284
  - Overview1284
  - Removing Shafts1285
- Dismantling Input Shaft1286
  - Overview1286
  - Disassembling Shaft1288
35 37 Assembling Transmission1289
- Tools1289
- Assembling Input Shaft1290
  - Assembling Shafts1290
  - Tightening Torques1291
- Installing Input and Output Shaft1291
  - Installing Shafts1291
  - Tightening Torques1294
- Fitting Gear Housing1295
  - Fitting Housing1295
  - Tightening Torques1295
- Assembling Front Gear Set1295
  - Assembling Gear Set1295
  - Tightening Torques1297
- Fitting Front Transmission Case Cover1298
  - Fitting Cover1298
  - Tightening Torques1298
50 19 Removing and Installing Sealing Ring for Input Shaft1299
- Tools1299
- Removing Sealing Ring for Input Shaft1299
- Installing Sealing Ring for Input Shaft1300
- Tightening Torques1301
04 19 Removing and Installing Selector Knob1303
- Removing Selector Knob1303
- Installing Selector Knob1303
30 19 Removing and Installing Tiptronic Control Module1305
- Removing the Control Module1305
- Installing the Control Module1307
- Coding the Tiptronic Control Module1308
- Tightening Torques1309
- Tools1309
02 19 Removing and Installing Cardan Shaft1311
- Tools1311
- Removing Cardan Shaft1311
- Installing Cardan Shaft1312
- Tightening Torques1313
02 19 Removing and Installing Cardan Shaft1314
- Tools1314
  - Removing Cardan Shaft1314
  - Installing Cardan Shaft1315
- Tightening Torques1316
22 19 Removing and Installing Sealing Ring for Halfshaft Flange1317
- Tools1317
- Removing Sealing Ring for Halfshaft Flange1317
- Installing Sealing Ring for Halfshaft Flange1318
- Tightening Torques1318
22 19 Removing and Installing Sealing Ring for Short Flanged Shaft1319
- Tools1319
  - Removing Sealing Ring for Short Flanged Shaft1319
  - Installing Sealing Ring for Short Flanged Shaft1321
- Tightening Torques1321
25 19 Removing and Installing Long Flanged Shaft1322
- Tools1322
  - Removing Long Flanged Shaft1322
  - Installing Long Flanged Shaft1323
- Tightening Torques1323
58 19 Removing and Installing Lid for Front Wheel Drive1325
- Tools1325
- Removing the Lid for Front Wheel Drive1325
- Installing the Lid for Front Wheel Drive1326
58 19 Removing and Installing Lid for Front Wheel Drive1326
- Tightening Torques1326
58 19 Removing and Installing Lid for Front Wheel Drive1327
- Tools1327
- Removing the Lid for Front Wheel Drive1327
- Installing the Lid for Front Wheel Drive1328
- Tightening Torques1328
59 19 Removing and Installing Sealing Ring for Flanged Shaft (Front Wheel Drive)1329
- Tools1329
- Removing the Sealing Ring for the Flanged Shaft (Front Wheel Drive)1329
- Installing the Sealing Ring for the Flanged Shaft (Front Wheel Drive)1330
59 19 Removing and Installing Sealing Ring for Flanged Shaft (Front Wheel Drive)1332
- Tools1332
- Removing the Sealing Ring for the Flanged Shaft (Front Wheel Drive)1332
- Installing the Sealing Ring for the Flanged Shaft (Front Wheel Drive)1333
60 01 Checking Function of Installed Viscous Clutch1335
- Test Conditions1335
60 01 Checking Function of Installed Viscous Clutch1338
- Test Conditions1338
60 19 Removing and Installing the Viscous Clutch1341
- Tools1341
- Removing the Viscous Clutch1342
- Installing the Viscous Clutch1342
- Tightening Torques1343
60 19 Removing and Installing the Viscous Clutch1344
- Tools1344
- Removing the Viscous Clutch1345
- Installing the Viscous Clutch1345
- Tightening Torques1346
62 19 Removing and Installing Support for Front Wheel Drive1347
- Removing the Support for Front Wheel Drive1347
- Installing the Support for Front Wheel Drive1347
- Tightening Torques1348
62 19 Removing and Installing Support for Front Wheel Drive1349
- Removing the Support for Front Wheel Drive1349
- Installing the Support for Front Wheel Drive1349
- Tightening Torques1350
82 19 Removing and Installing Sealing Ring for Cardan Flange1351
- Tools1351
- Removing Sealing Ring for Cardan Flange1351
- Installing Sealing Ring for Cardan Flange1352
- Tightening Torques1353
82 19 Removing and Installing Sealing Ring for Cardan Flange1354
- Tools1354
  - Removing Sealing Ring for Cardan Flange1354
  - Installing Sealing Ring for Cardan Flange1355
- Tightening Torques1356
88 19 Removing and Installing Front Wheel Drive1357
- Remove Front Wheel Drive1357
- Installing the Front Wheel Drive1358
- Tightening Torques1359
88 19 Removing and Installing Front Wheel Drive1360
- Removing Front Wheel Drive1360
- Installing the Front Wheel Drive1361
- Tightening Torques1362
90 55 Replacing and Checking Transmission Oil in Final Drive1363
- Tools1363
- Changing Transmission Oil in Final Drive1363
- Tightening Torques1365
90 55 Changing Transmission Oil in Front Wheel Drive1366
- Tightening Torques1366
90 55 Changing Transmission Oil in Front Wheel Drive1368
- Tightening Torques1368
21 19 Removing and Installing Rear Drive Shaft (Manual Transmission)1370
- Tools1370
- Removing the Drive Shaft (Manual Transmission)1370
- Installing the Drive Shaft (Manual Transmission)1373
21 19 Removing and Installing Rear Drive Shaft (Tiptronic Transmission)1376
- Tools1376
- Removing the Drive Shaft (Tiptronic Transmission)1376
- Installing the Drive Shaft (Tiptronic Transmission)1379
46 19 Removing and Installing Front ABS Lead1383
- Removing Front ABS Lead1383
- Installing Front ABS Lead1385
- Tightening Torques1387
- Tools1387
46 19 Removing and Installing Rear ABS Lead (Turbo & GT2)1388
- Removing Rear ABS Lead1388
- Installing Rear ABS Lead1390
- Tightening Torques1393
- Tools1393
50 02 Checking Front Gray Cast Iron Brake Discs (Wear Assessment)1394
- General1394
- Visual Inspection for Cracks and Evaluating Cracks1394
  - Evaluating the Cracks on the Gray Cast Iron Brake Discs1395
- Checking Brake Discs for Minimum Thickness1396
- Notes on Bedding in the New Brake Pads1397
50 02 Checking Front PCCB Brake Discs (Wear Assessment)1398
- General1398
- Visual Inspection of the Surfaces of the Brake Disc Friction Surfaces1398
  - PCCB Brake Disc Wear Appearance1399
- Checking Brake Discs for Minimum Thickness1400
- Checking Brake Discs for Edge Damage1400
- Note Concerning Bores (Perforations) in the Brake Disc Friction Surface1401
- Note on Bedding in the New Brake Pads1401
53 02 Checking Rear Gray Cast Iron Brake Discs (Wear Assessment)1402
- General1402
- Visual Inspection for Cracks and Evaluating Cracks1402
  - Evaluating the Cracks on the Gray Cast Iron Brake Discs1403
- Checking Brake Discs for Minimum Thickness1404
- Notes on Bedding in the New Brake Pads1405
53 02 Checking Rear PCCB Brake Discs (Wear Assessment)1406
- General1406
- Visual Inspection of the Surfaces of the Brake Disc Friction Surfaces1406
  - PCCB Brake Disc Wear Appearance1407
- Checking Brake Discs for Minimum Thickness1408
- Checking Brake Discs for Edge Damage1408
- Note Concerning Bores (Perforations) in the Brake Disc Friction Surface1409
- Note on Bedding in the New Brake Pads1409
10 55 Replacing Closing Panel1410
- Cutting out Closing Panel and Front Floor Panel1410
- Preparing Closing Panel and Front Floor Panel for Installation and Fitting1412
- Welding in Closing Panel and Front Floor Panel1414
50 10 55 Replacing Closing Panel1415
- Tools and Materials1415
14 55 Replacing Front Wall1416
- Cutting out Front Wall1416
- Preparing Front Wall for Installation and Fitting1418
- Welding in Front Wall1420
- Tools and Materials1421
74 55 Replacing Wheel Housing1422
- Removing Wheel Housing, Lower Shell and Outer Side Member from the Body1422
- Preparing Wheel Housing, Lower Shell and Outer Side Member for Installation and Fitting1424
- Welding Wheel Housing, Lower Shell and Outer Side Members into the Body1426
- Tools and Materials1427
74 56 Replacing Wheel Housings and Side Members (Sectional Repair)1428
- Cutting out Wheel Housings and Side Members1428
- Preparing Wheel Housings and Side Members for Installation and Fitting1430
- Welding in Wheel Housings and Side Members1432
- Materials and Tools1433
79 55 Replacing Front Inner Side Member1435
- Removing Front Inner Side Member1435
- Preparing and Fitting the Front Inner Side Member for Installation1437
- Welding in Front Inner Side Member1439
- Materials, Tools1440
93 30 Cleaning Front Water Drains on Coupé and Cabriolet1442
03 55 Replacing Roof1445
- Removing Roof1445
- Preparation of Roof for Installation and Fitting1447
- Welding in Roof1449
- Tools and Materials1450
21 55 Replacing Rear Centre Panel1452
- Removing Rear Centre Panel1452
- Preparing the Rear Centre Panel for Installation and Fitting1454
- Welding in the Rear Centre Panel1455
- Tools and Materials1456
45 55 Replacing Lower Side Member1458
- Cutting out Lower Side Member1458
- Preparation for Installation of Lower Side Member and Fitting1460
- Welding in Lower Side Member1462
- Tools and Materials1463
45 55 Replacing Lower Side Member − Cabriolet1464
- Cutting out Lower Side Member1464
- Preparation for Installation of Lower Side Member and Fitting1466
- Welding in Lower Side Member1468
- Tools and Materials1469
63 19 Removing and Installing Deformation Element1470
- Removing Deformation Element1470
- Installing Deformation Element1471
87 55 Replacing Seat Cross Member1472
- Cutting out Seat Cross Member1472
- Preparation of Seat Cross Member for Installation and Fitting1474
- Welding in Seat Cross Member1476
- Tools and Materials1477
90 19 Removing and Installing Underside Panel1478
- Removing and Installing Front Cover1478
- Removing and Installing Middle Cover1480
- Removing and Installing Rear Trim1481
05 55 Replacing Rear Closing Panel1482
- Cutting out Rear Closing Panel1482
- Preparing the Rear Closing Panel for Installation and Fitting1484
- Welding in Rear Closing Panel1485
- Tools and Materials1487
55 55 Replacing Side Section1488
- Cutting through Side Section1488
- Preparing Side Section for Installation and Fitting1491
- Welding in the Side Section1493
- Flanging the Wheel Arch Edges GT21496
- Tools and Materials1496
93 30 Cleaning Rear Water Drains on Coupe and Cabriolet1498
62 19 Removing and Installing Front Emergency Release − as of MY 20031501
- Checking Inner Release of Luggage Compartment (Trunk Entrapment)1503
84 19 Removing and Installing Engine Cover Release1504
- Checking Inner Release of Luggage Compartment (Trunk Entrapment)1504
- Removing Engine Cover Release1504
- Installing Engine Cover Release1505
51 16 Setting the Door1507
51 19 Removing and Installing Door1509
51 37 Disassembling and Assembling Door1513
- Disassembling Door1513
- Assembling Door1519
51 37 Disassembling and Assembling Door1525
- Diagram: Sheetmetal Clips and Grommets1525
- Basic Setting of Door Lock1526
  - Basic Setting of the Door Lock before Installation1527
- Standardising the System1528
- Fitting the Door Window in the Clamping Jaws1528
- Adjusting the Door Window Angle in the Vehicle's Longitudinal Direction1529
- Adjusting the Door Window Height1529
  - Adjustment Procedure1530
  - Checking the Adjustment1530
- Adjustment of the Door Window Pressing Force on the Door Seal at the Top and Sides1530
  - Adjustment Procedure1531
  - Checking the Adjustment1531
- Adjusting the Lower Stop of the Power Window Unit1531
12 19 Removing and Installing Windscreen1533
- Removing Windscreen1533
- Preparing the Window Section for Installation1535
- Preparing the Windscreen for Installation1536
- Fitting Windscreen1538
- Overview of Tools and Materials1541
54 19 Removing and Installing Power Window Motor1544
- Removing Power Window Motor1544
- Installing Power Window Motor1544
- Standardising the New Power Window Motor1545
- Tightening Torques1545
71 19 Removing and Installing Rear Power Windows (Cabriolet)1546
- Removing Rear Power Windows (Cabriolet)1547
- Installing Rear Power Windows (Cabriolet)1548
- Additional Instructions for Adjusting or Replacing the Rear Power Window1550
- Tools and Materials1551
- Tightening Torques1551
- Test and Adjusting Values1551
75 19 Removing and Installing Side Window1552
- Removing Side Window1552
- Installing Side Window1554
64 75 19 Removing and Installing Side Window1555
- Test and Adjusting Values1555
- Tightening Torques1555
75 19 Removing and Installing Rear Side Window (Cabriolet)1556
- Removing Side Window1556
- Installing Side Window1556
- Tightening Torques1557
- Test and Adjusting Values1557
76 19 Removing and Installing Side Window Seal1558
- Removing Side Window Seal1558
  - Removing the Retaining Strip1560
- Installing Side Window Seal1560
  - Installing the Retaining Strip1562
- Materials and Tools1562
76 19 Removing and Installing Rear Side Window Seal (Cabriolet)1563
- Removing Side Window Seal1563
- Installing Side Window Seal1563
86 19 Removing and Installing Rear Glass Window of Cabriolet1564
- Removing Rear Glass Window of Cabriolet1564
- Installing Rear Glass Window of Cabriolet1566
- Tools and Materials1568
  - Use of the Circlip Pliers1568
86 19 Removing and Installing Rear Window (Hardtop)1570
- Removing Rear Window (Hardtop)1571
- Preparing the Window Section (Hardtop) for Installation1573
- Preparing the Rear Window (Hardtop) for Installation1575
- Installing Rear Window (Hardtop)1576
- Overview of Tools and Materials1579
- Tightening Torques1580
31 19 Removing and Installing Sill Cover1582
- Removing Sill Cover1582
- Installing Sill Cover1584
72 37 Disassembling and Assembling Pump Unit1586
- Removing Hydraulic Cylinder1587
- Filling the Hydraulic Cylinder1589
- Installing Hydraulic Cylinder1589
- Removing Pump1591
- Filling the Pump Unit1592
- Installing Pump1592
- Bleeding the Pump Unit1594
66 72 37 Disassembling and Assembling Pump Unit1596
- Removing and Installing Wiring Harness1596
- Troubleshooting1600
- Tools and Materials1601
85 19 Removing and Installing Micro Switches for Rear Spoiler1602
- Remove Micro Switches1602
- Installing Micro Switches1603
- Tools1603
89 37 Disassembling and Assembling the Rearview Mirror1604
- Disassembling the Rearview Mirror1604
- Assembling the Rearview Mirror1606
05 19 Removing and Installing Inner Sill (Driver's Side)1609
- Removing Inner Sill1609
- Installing Inner Sill1611
05 19 Removing and Installing Inner Sill (Passenger's Side)1613
- Removing Inner Sill1613
- Installing Inner Sill1614
11 19 Removing and Installing Glove Compartment Lock1616
12 19 Removing and Installing Lid for Glove Compartment1618
- Removing Lid for Glove Compartment1618
- Installing Lid for Glove Compartment1619
- Replacing Microswitch and Interior Light1620
- Replacing Pneumatic Shock Absorber1621
15 19 Removing and Installing Glove Compartment1623
- Removing Glove Compartment1623
- Installing Glove Compartment1625
17 19 Removing and Installing Center Console (Front Section)1627
17 19 Removing and Installing Center Console1631
30 19 Removing and Installing Cup Holder1634
- Removing Cup Holder1634
- Installing Cup Holder1635
11 19 Removing and Installing Front Three−Point Belt1636
- Removing Front Three−Point Belt1636
- Installing Front Three−Point Belt1638
11 19 Removing and Installing Front Three−Point Belt − Cabriolet1640
- Removing Front Three−Point Belt1640
- Installing Front Three−Point Belt1642
11 01 Checking Seat Belts1644
- Checking Belt Strap1644
- Checking Automatic Belt Device (Locking Effect)1645
- Belt Buckle, Visual Inspection1646
- Belt Buckle, Function Test1646
- Checking Sash Guides1647
- Checking Mounting Elements and Mounting Points1647
12 19 Removing and Installing Rear Three−Point Belt1648
- Removing Rear Three−Point Belt1648
- Installing Rear Three−Point Belt1650
12 19 Removing and Installing Rear Three−Point Belt − Cabriolet1652
- Removing Rear Three−Point Belt1652
- Installing Rear Three−Point Belt1654
13 19 Removing and Installing Belt Tensioner − as of MY 20021656
- Removing Belt Tensioner1656
- Installing Belt Tensioner1657
36 19 Removing and Installing Adjustment Fitting (Seat Belt Height Adjuster)1659
- Removing and Installing Adjustment Fitting1659
51 19 Removing and Installing Sensor for Side Airbag1661
- Remove Sensor for Side Airbag1661
- Install Sensor for Side Airbag1663
- Tools1664
72 19 Removing and Installing Roll−Over Bar1665
- Safety Instructions for Work on the Roll−Over Protection System1665
- Mechanical Emergency Triggering of the Roll−Over Protection System1666
- Removing Roll−Over Protection System1667
- Installing Roll−Over Protection System1668
- Tightening Torques1670
74 19 Removing and Installing Control Module for Roll−Over Protection System1671
- Removing Control Module1671
- Installing Control Module1671
- Tools and Materials1672
77 19 Removing and Installing Frame for Roll−Over Protection System1673
- Tightening Torques1675
05 19 Removing and Installing Front Luggage Compartment Trim1676
- Removing and Installing Trims Units1676
- Removing and Installing Carpet Lining1678
- Tools and Materials1679
18 19 Removing and Installing the Instrument Panel and Instrument Panel Bracket − as of1680
Model Year 20031680
- Removing and Installing the Instrument Panel1681
- Removing and Installing the Instrument Panel Bracket1682
- Tightening Torque1685
- Tools and Materials1685
41 19 Removing and Installing Floor Covering1687
57 19 Removing and Installing Trim of A, B and C−Pillars1690
- Installing Trim of A, B and C−Pillars1692
57 19 Removing and Installing A−Pillar Trim Cabriolet1694
- Removing A−Pillar Trim1694
- Installing A−Pillar Trim1695
- Tightening Torques1697
75 19 Removing and Installing Side−Panel Lining1698
- Removing Side−Panel Lining1698
- Installing Side−Panel Lining1700
75 19 Removing and Installing Side−Panel Lining Cabriolet1702
- Removing Side−Panel Lining1702
- Installing Side−Panel Lining1704
84 19 Removing and Installing Cabriolet Roof Lining1706
- Removing Roof Lining, Front1707
- Installing Front Roof Lining1710
- Removing Rear Roof Lining1712
- Installing Rear Roof Lining1713
- Removing and Installing Side Roof Lining1715
  - Removing Side Roof Lining1715
  - Installing Side Roof Lining1716
- Tightening Torques1716
01 19 Removing and Installing Front Seat1717
- Removing Front Seat1717
- Installing Front Seat1719
21 19 Removing and Installing Cushion Carrier1721
- Removing Front Cushion Carrier1721
- Installing Front Cushion Carrier1723
36 19 Removing and Installing Motor for the Lumbar Support1725
- Removing Lumbar Adjustment Device for the Lumbar Support1726
- Removing Motor for the Lumbar Support1727
- Removing Electrical Line for the Lumbar1727
- Removing Lumbar Support1727
- Installling Lumbar Adjustment Device for the Lumbar Support1728
- Installing Motor for the Lumbar Support1729
- Installing Electrical Line for the Lumbar1729
- Installing Lumbar Support1729
- Tools1730
- Test Plan for the Lumbar Adjustment Device1730
86 19 Removing and Installing Switch for Seat Adjustment1731
- Removing Switch for Seat Adjustment1732
- Installing Switch for Seat Adjustment1733
87 19 Removing and Installing Electric Motor for the Seat Adjustment1735
- Removing Electric Motor for Seat Adjustment1735
- Installing Electric Motor for Seat Adjustment1737
- Tools1738
- Test Plan for the Seat Adjustment1738
88 19 Removing and Installing Electric Motor for the Front Seat Height Adjustment1740
- Removing Electric Motor for Front Seat Height Adjustment1740
- Installing Electric Motor for Front Seat Height Adjustment1742
- Tools1743
- Test Plan for the Front Seat Height Adjustment1743
89 19 Removing and Installing Electric Motor for the Backrest Adjustment1745
- Removing and Installing Electric Motor for the Backrest Adjustment1746
- Installing Electric Motor for Backrest Adjustment1747
- Routing of Wiring Harness for the Backrest Adjustment1748
- Tools1748
- Test Plan for the Backrest Adjustment Device1749
92 19 Removing and Installing Electric Motor for the Rear Seat Height Adjustment1750
- Removing Electric Motor for Rear Seat Height Adjustment1750
- Installing Electric Motor for Rear Seat Height Adjustment1752
- Tools1753
- Test Plan for the Rear Seat Height Adjustment1753
13 55 Replacing Cover for Front Seat Cushion1755
- Removing Cover for the Front Seat1755
- Installing Cover for the Seat Cushion1757
13 55 Replacing Cover for Front Seat Cushion Tools and Materials1758
19 19 Removing and Installing Centre Backrest Strip1759
- Removing the Backrest Centre Strip1759
- Installing the Backrest Centre Strip1761
19 55 Replacing Covering for Backrest Centre Strip1762
- Removing Covering for Backrest Centre Strip1762
- Installing Covering for Backrest Centre Strip1764
- Tools and Materials1765
27 19 Removing and Installing Control Module for Seat Heating1766
- Removing and Installing Control Module for Seat Heating1767
- Seat Heating Line Route1767
- Central Plug1768
- Removing and Installing Pin Housing for Seat Heating and Belt Buckle1768
- Tools1769
- Test Plan for the Seat Heating1769
25 19 Removing and Installing Instrument Cluster1771
- Removing Instrument Cluster1771
- Installing Instrument Cluster1772
- Coding the Instrument Cluster1772
10 19 Removing and Installing Display and Operator Control Unit (PCM)1774
- Removing Display and Operator Control Unit (PCM)1775
- Installing Display and Operator Control Unit (PCM)1775
  - Connecting and Switching on the Porsche System Tester 21775
  - Device Code Input1776
10 19 Removing and Installing Display and Operator Control Unit (PCM 2) − as of MY 20031777
- Removing Display and Operator Control Unit (PCM 2)1777
- Installing Display and Operator Control Unit (PCM 2)1778
- Teaching Display and Operator Control Unit (PCM 2)1780
20 02 Checking Complaints about Car Radio System1784
- Malfunctions in Radio System1784
- Reduced Sound Quality in One or more Loudspeakers1785
- Remedying Problems with the Amplifier1786
- Interference Noises1787
- Electromagnetic Compatibility (EMC) − Troubleshooting1794
20 02 Checking Complaints about Car Radio System Tools1795
24 19 Removing and Installing the Car Radio − as of MY 20031796
- Tools1796
- Removing the Car Radio1796
- Installing the Car Radio1798
- Teaching the Car Radio1798
42 19 Removing and Installing Rear Loudspeakers, Bose Sound Package1801
- Removing Rear Loudspeakers1801
- Installing Rear Loudspeakers1802
44 19 Removing and Installing the Loudspeaker Amplifier1804
- Removing the Loudspeaker Amplifier1804
- Installing the Loudspeaker Amplifier1806
74 19 Removing and Installing Control Module for Parking Assistant1808
- Removing Control Module for Parking Assistant1808
- Installing Control Module for Parking Assistant1809
84 19 Removing and Installing Antenna Amplifier − as of MY 20031810
- Removing Antenna Amplifier1811
- Installing Antenna Amplifier1811
86 19 Removing and Installing Control Module for Antenna1812
- Removing Control Module for Antenna1812
- Installing Control Module for Antenna1813
90 19 Removing and Installing Control Module for Telephone1815
- Removing Control Module for Telephone1815
- Installing Control Module for Telephone1816
12 19 Removing and Installing Rain Sensor1817
- Removing Rain Sensor1817
- Installing Rain Sensor1820
- Open Circuit in the Rain Sensor Connection (Emergency Interval Operation)1823
13 19 Removing and Installing Control Module for Rain Sensor1824
- Removing Control Module for Rain Sensor1825
- Installing Control Module for Rain Sensor1826
- Safety Function in the Event of Failure (Engine Blockage)1827
64 32 Converting Installation Position for Tilt Sensor, Additional Alarm System M5361828
- Tools1830
87 19 Removing and Installing Control Unit for Alarm System1831
- Removing Control Unit for Alarm System1831
- Installing Control Unit for Alarm System1833
- Teaching Control Unit for the Alarm System1834
89 19 Removing and Installing Current Distributor1836
- Removing Current Distributor1836
- Installing the Current Distributor1838
92 19 Removing and Installing Fusible Element in the Current Distributor1841
- Removing Fusible Element from the Current Distributor1841
- Installing Fusible Element in the Current Distributor1842
Turbo (996) Technical Manual1843
- General1843
- Structure1843
- Breakdown of Repair Groups1843
- Legend for Structure of Sequence Description1843
- Structure of Exploded View1845
- Structure of Sequence Description1846
Wiring Diagram for 911 Turbo (996), 01 Model1848
Wiring Diagram for 911 Turbo (996), 02 Model1850
Circuit Diagram for 911 Turbo (996), '03 Model1852
Circuit Diagram for 911 Turbo (996), '04 Model1854
Circuit Diagram for 911 Turbo (996), '05 Model1856
Preconditions for Using Workshop Documentation for Porsche Vehicles1858
Mobile Roofs: Checking Function1860
- Checking Sliding Roof1860
- Checking Convertible Top1860
- Checking the Hardtop1860
Glazing: Visual Inspection for Damage1862
Checking Lid and Doors1863
- Checking Lid Lock, Front and Rear1863
- Checking Safety Hook, Front Lid1863
- Function Test, Checking Door Lock1863
- Functional Inspection of the Tank Cap Lock1863
Interior Equipment: Visual Inspection for Damage and Soiling1864
Removing Transport Protection1865
- Removing External Transport Protection1865
- Removing Internal Transport Protection1866
Installing Air Guides for PCCB Brake Discs − GT21867
- Installing Front Air Guides1867
- Installing Rear Air Guides1867
Fitting Front Lip GT21869
Fitting Six−Point Seat Belt GT21870
Checking the Vehicle Ident. no1872
Checking the Exterior Equipment and Paint Finish1873
- Checking Exterior Equipment1873
- Checking Paint Finish1873
Completing Vehicle and Checking Equipment for Completeness1874
- Checking Vehicle Equipment for Completeness1874
  - Tools1874
- Completing the Vehicle1875
Technical Data − GT21876
- 6−Speed Manual Transmission G 96.881876
  - Manual Transmission Tightening Torques1877
Running Gear, General − GT21878
- General1878
Notes on Repair Instructions − GT21880
- General1880
- Tightening Torques1880
- Adjustment Operations on the Spring Struts1880
- Suspension Alignment1881
- Wheel Removal/Installation1881
- Brake − General1882
- Brake Booster1882
Tests / Notes GT21883
- Note1883
- Lifting Platform / Test Stands1883
- Wheel Alignment Platform1883
- Brake Test1883
- Power Test1883
4 Tests / Notes  GT21884
- Front and Rear Stabilizer Setting1884
- Spoiler Setting1884
- Racing Camber Values1885
Alignment Card − GT21886
Suspension Alignment − GT21888
- Suspension Alignment, Complete1888
- Driving Onto Measuring Platform1888
- Tools1888
- Deviating Points for GT21889
- Notes on Height Changes/Wheel−Load Changes1890
- Vehicle Height GT21891
- Wheel Alignment1892
- Instructions for Fitting Diagonal Control Arm on Control Arm GT21894
Tyre Failure / Tyre Sealant GT21896
- Repair Procedure1896
Technical Data/Brake Wear Limit − GT21898
- Technical Data − GT21898
- Wear Limit Technical Data − GT21899
Disassembling and Assembling Front Spring Strut GT21900
- Notes about Adjustment Work on the Spring Struts1900
- Disassembling and Assembling Front Spring Strut GT21901
- Disassembly and Assembly Instructions1902
Disassembling and Assembling Rear Spring Strut − GT21906
- Notes about Adjustment Work on the Spring Struts1906
- Disassembling and Assembling Rear Spring Strut − GT21907
- Disassembly and Assembly Instructions1909
01 07 Bleeding the Clutch System − GT21913
- Filling/Bleeding1913
45 19 Removing and Installing Release Bearing (Clutch Removed) − GT21915
- Removing Release Bearing1916
- Installing Release Bearing1916
50 19 Removing and Installing Clutch − GT21918
- Tools1918
- Removing Clutch1918
- Installing Clutch1919
- Tightening Torques1919
50 37 Disassembling and Assembling Clutch − GT21920
01 55 Changing Transmission Oil − GT21921
- Topping up Transmission Oil − GT21921
- Tightening Torques1922
35 27 Removing and Refitting the Transmission − GT21923
- Tools1923
- Removing Transmission1923
- Refitting Transmission1924
- Tightening Torques1926
37 37 Disassembling and Assembling Transmission Housing − GT21927
- Tools1927
- Overview1928
- Disassembly and Assembly Instructions1930
  - Disassembly1930
  - Assembly1930
- Tightening Torques1931
52 37 Disassembling and Assembling Gear Housing − GT21932
- Tools1932
- Overview1933
- Disassembling Gear Housing1934
- Assembling Gear Housing1935
- Tightening Torques1936
55 37 Disassembling and Assembling Front Transmission Cover GT21938
- Tools1938
- Overview1939
- Disassembling Front Transmission Case Cover1940
34 55 37 Disassembling and Assembling Front Transmission Cover  GT21941
- Assembling Front Transmission Case Cover1942
- Tightening Torques1943
72 19 Removing and Installing Transmission Oil Pump − GT21944
- Tools1944
- Removing Transmission Oil Pump1944
- Installing Transmission Oil Pump1945
- Tightening Torques1945
74 19 Removing and Installing Transmission Oil Cooler − GT21946
- Tools1946
- Overview1946
- Removing Transmission Oil Cooler1947
- Installing Transmission Oil Cooler1949
- Tightening Torques1949
50 19 Removing and Installing Sealing Ring for Drive Shaft − GT21951
- Tools1951
- Removing Sealing Ring for Drive Shaft1951
- Installing Sealing Ring for Drive Shaft1952
- Tightening Torques1953
08 15 Adjusting Drive Set − GT21955
- Tools1955
- Sequence of Adjustment Operations1956
- Determining Disc Thickness S4 and S51956
- Determining Disc Thickness S31958
- Determining Disc Thickness S1 and S21960
22 19 Removing and Installing Sealing Ring for Halfshaft Flange − GT21964
- Tools1964
- Removing Sealing Ring for Halfshaft Flange1964
- Installing Sealing Ring for Halfshaft Flange1965
- Tightening Torques1966
40 19 Removing and Installing Differential and Differential Lock − GT21967
- Tools1967
- Overview1967
39 40 19 Removing and Installing Differential and Differential Lock − GT2.1969
- Removing Differential and Differential Lock1969
- Installing Diffential and Differential Lock1969
- Tightening Torques1969
40 37 Assembling and Disassembling Differential and Differential Lock − GT21970
- Tools1970
- Overview1970
- Disassembling GKN Differential Lock1972
- Assembling GKN Differential Lock1972
- Tightening Torques1973
16 24 Installing Air Ducts for PCCB Brake Discs − GT21975
- Installing Front Air Ducts1975
- Installing Rear Air Ducts1976
36 20 Removing and Installing the Front Disc Brake Pads − GT2 / Turbo with PCCB1977
- Removal1978
- Installation1980
  - Bedding in the Brake Pads1981
38 20 Removing and Installing the Rear Disc Brake Pads − GT2 / Turbo with PCCB1982
- Removal1983
- Installation1984
  - Bedding in the Brake Pads1985
50 19 Removing and Installing the Front PCCB Brake Disc1986
- Removal1986
- Explanation of 2−Part Brake Disc1987
- Installation1987
  - Note on Bedding in the New Brake Pads1988
53 19 Removing and Installing the Rear PCCB Brake Disc1989
- Removal1989
- Explanation of 2−Part Brake Disc1990
- Installation1990
  - Note on Bedding in the New Brake Pads1991
01 07 Bleeding Brake − GT21992
- General1992
- Bleeding Brakes1992
35 37 Disassembling Transmission − GT21994
- Tools1994
- Removing Transmission Cover1995
- Disassembling Front Gear Set1995
  - Overview1995
  - Disassembling Gear Set1997
- Removing Gear Housing1998
- Removing Input and Output Shaft1998
  - Overview1999
  - Removing Shafts2000
34 35 37 Disassembling Transmission − GT21999
- Disassembling Output Shaft2001
  - Overview2001
  - Disassembling Shaft2002
- Dismantling Input Shaft2002
  - Overview2002
  - Disassembling Shaft2004
35 37 Assembling Transmission − GT22005
- Tools2005
- Assembling Input Shaft2005
  - Assembling Shafts2006
  - Tightening Torques2007
- Assembling Input Shaft2007
  - Assembling Shaft2007
- Installing Input and Output Shaft2007
  - Installing Shafts2007
  - Tightening Torques2010
- Fitting Gear Housing2011
  - Fitting Housing2011
  - Tightening Torques2011
- Assembling Front Gear Set2011
  - Assembling Gear Set2011
  - Tightening Torques2013
- Fitting Front Transmission Case Cover2014
  - Fitting Cover2014
  - Tightening Torques2014
46 19 Removing and Installing Front ABS Lead (GT2)2015
- Removing Front ABS Lead2015
- Installing Front ABS Lead2017
- Tightening Torques2018
- Tools2018
30 19 Removing and Installing Air Guide GT22019
- Removing and Installing Air Guide2019
90 19 Removing and Installing Rear Lid − GT22021
- Removing and Installing Rear Lid2021
90 37 Disassembling and Assembling Rear Lid GT22024
- Disassembling Rear Lid2024
- Assembling Rear Lid2027
  - Replace Model Logo2029
  - Removing and Installing Rear−Lid Wiring Harness2029
15 19 Removing and Installing Front Spoiler GT22032
- Removing Front Spoiler2032
- Installing Front Spoiler2034
15 37 Disassembling and Assembling Front Spoiler GT22036
- Disassembling Front Spoiler2036
  - Removing Front Spoiler2038
- Installing Front Spoiler2039
  - Installing Front Spoiler2040
58 19 Removing and Installing Rear Spoiler GT22042
- Removing Rear Spoiler2042
- Installing Rear Spoiler2044
  - Replacing Rear Spoiler Fork2045
72 19 Removing and Installing Roll−Over Bar − GT22047
- Removing Roll−Over Bar2047
- Installing the Roll−Over Bar2050
- Adjusting the Roll−Over Bar2054
- Assembly Instructions for the Rear Trim, the Floor Covering and the Closure Caps2054
01 19 Removing and Installing Bucket Seat GT2 − as of MY 20012056
- Removing Bucket Seat GT22056
- Installing Bucket Seat GT22058
  - Fitting Six−Point Seat Belt GT22059
61 19 Removing and Installing Relay for Main Switch − GT2 − as of MY 20012061
- Installing the Main Battery Relay2062
- Installing Inner EMERGENCY STOP Switch2063
- Removing the Main Battery Relay2064
- Removing the Inner EMERGENCY STOP Switch2065
- Operating the Main Battery Switch2066
05 55 Replacing Rear Closing Panel − Carrera 4S2069
- Cutting out Rear Closing Panel2069
- Inserting Rear Closing Panel2071
- Tools and Materials2073
69 19 Removing and Installing Rear Wheel Housing Liners − Carrera 4S2075
90 19 Removing and Installing Rear Lid − Carrera 4S2077
90 37 Disassembling and Assembling Rear Lid Carrera 4S2079
- Disassembling Rear Lid2080
- Assembling Rear Lid2082
55 90 37 Disassembling and Assembling Rear Lid  Carrera 4S2085
- Removing and Installing Additional Brake Light2085
- Installing Rubber Covering − Cabriolet2086
- Removing and Installing Reflector Cover2087
- Removing and Installing Wiring Harness2087
- Replacing the Model Logo2088
- Test and Adjustment Values2088
- Tightening Torques2089
- Materials and Tools2089
91 19 Removing and Installing Rear Lid Hinges − Carrera 4S2090
58 19 Removing and Installing Coolant Regulator2093
- Removal Overview of the Coolant Regulator2093
- Installation Overview of the Coolant Regulator2096

Brand	Porsche
Model	996 TT
Category	Automobile
Language	English

Porsche 996 TT - User Manual

Table of Contents

Porsche 996 TT Specifications

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