www.WorkshopManuals.co.uk
Technical Manual 9""" ~7~
(996)
Technical Information
Contents: Group 2
Fuel, exhaust, engine electronics
WKD483 721
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Foreword The workshop documentationfor the 911 Carrera (996) model has the designation "911 Carrera (996)" Technical Manual and contains Technical Information as well as instructions on Repairs. The integration of the technical informationpublishedin the "911 Carrera (996)" TechnicalManualwith the instructionson repairs provides the user with a complex reference work that combines into one book associated or cross-referencedmaterial of relevanceto workshops and originating from various information media. The "911 Carrera (996)" Technical Manualconsists of 15 folders, subdividedinto the following Groups 0 Entire vehicle -General 0 Diagnosis,part 1 (up to Repair Group 45) .1 0 Diagnosis,part 2 (as of Repair Group 61) .2 1 Engine,part 1 (up to Repair Group 13) .3 1 Engine,part 2 (as of RepairGroup 15) .4
*1
.2
2 3 3 4
Fuel, exhaust,engine electronics Transmission,manualtransmission Transmission,automatic transmission Runninggear
5
Body
6 7 8/ 9 9 9
Body equipment,exterior Body equipment,interior Air conditioning/ Electrics Circuit diagrams, part 1 (up to and includingthe '99 model) .5 Circuit diagrams, part 2 (as of the '00 model) .6
The two folders with Group 0 are to be regarded as one folder; i.e. file the "TechnicalInformation" notices only in front of the repair descriptions in the folder "Group0 -Diagnosis, part I" (up to Repair Group 45). The second 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 repairdescriptionsin the folder"Group1 -Engine, part 1" (up to Repair Group 13).
*4
The second folder "Group1 -Engine, part 2" (as of Repair Group 15) includes the further Repair Groups belongingto Group 1.
Foreword Printed
in Germany
-35,
October
1999
VORW.CHP
www.WorkshopManuals.co.uk Foreword
*5
911 Carrera (996)
The two folders with Group 9 are to be regarded as one folder; i.e. file the "TechnicalInformation" notices only in front of the repair descriptions in the folder "Group 9 -Circuit diagrams, part I" (up to
and including the '99 model). *6
The second folder "Group9 -Circuit diagrams, part 2" (as of the '00 model) includes the further circuit diagrams belongingto Group 9.
The "911 Carrera (996)" TechnicalManualhas the same structure in each folder, with the following breakdown for all Groups: Title page: "911 Carrera (996)" Technical Manual > Foreword Title page: "Technical
Information"
> Table of Contents,Technicalinformation > Technicalinformation Title page: "Repair"
> > > >
Repair Groups: overview Table of Contents,repairs General/technical data Instructions on repairs
As can be seen from the breakdown,the publishedTechnicalInformationis in the front part of each folder -numbered according to the Groups.The Table of Contents assigned to each Group will be periodically updated. Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned according to the Groups or broken down into RepairGroups -are included in the folders.
Theinstructionson repairswill be extendedandupdatedby meansof supplements.
Note Sheets that already exist in the "911 Carrera (996)" Technical Manualand are updated or revised and thereby exchanged by a supplementare designated "replacementsheet". Revisionsor technical modificationson pages of these replacementsheets are identified for the user with a vertical bar at
the margin.
Foreword VORW.CHP
Printed
in Germany
-35,
October
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Group 0:
Group 0:
Overview of repair groups
Entire vehicle -General Salescheck Maintenance
0 03
Diagnosis On-boarddiagnosis DMEdiagnosis Tiptronicdiagnosis ABSdiagnosis
Group 0:
Group 1:
24
37
45
Diagnosis
0
Convertible-topdiagnosis Airbag diagnosis Roll-overprotection system diagnosis Seat memory diagnosis Heatingdiagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
61 69
Group 3:
Group 3:
72 80 90 91 91 94 10 13
1
Engine Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
Group 2:
69
1
Engine Engine-Crankcase, suspension Engine-Crankshaft, pistons
Group 1:
0 01 03
15 17 19
Fuel, exhaust, engine electronics
2
Fuel supply, control Exhaustsystem, turbocharging Fuel system, electronic injection Fuel system, K-Jetronic Exhaustsystem Starter, power supply, cruise control Ignition system
20 21
Transmission, manual transmission
3 30
24
25 26 27
28
Clutch,control Manualtransmission-Actuation, housing Manualtransmission-Gears, shafts, intogearsh. Final drive, differential,differential lock
35 39
Transmission, automatic transmission
3
Torqueconverter
32 37 38 39
Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differentiallock
Overview of repair groups Printed in Germany -35, October 1999
REPGRU.CHP
34
www.WorkshopManuals.co.uk Overview of repair groups
Group 4:
Group 5:
Group 6:
Group 7:
Group 8:
Group 9
Group 9: Group 9:
911 Carrera (996)
Running gear
4
Front wheel suspension,drive shafts Rear wheel suspension,drive shafts Wheels, tires, suspensionalignment Anti-LockBrake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
40 42 44
45 46 47 48
Body
5
Body front Body center, roof, frame Body rear Lids, flaps Door front, central locking system
50
51 53
55 57
6
Body equipment, exterior Slidingroof Convertibletop, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
60 61 63 64 66
68 69
7
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers
70 72
74
8
Air conditioning Heating Ventilation Air conditioning Auxiliaryair conditioningsystem
80 85 87 88
Electrics
9
Instruments, alarmsystem Radio,telephone,on-boardcomputer,navigation Windshield wiperandwashersystem Lights, lamps,switchesexterior Lights,lamps,switchesinterior,theft protection
90 91 92 94 96
Circuit diagrams Wiring (up to and includingthe '99 model)
9 97
Circuit diagrams
9
Wiring(fromthe '00 model)
97
Overview of repair groups REPGRU.CHP
Printed
in Germany -35,
October
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
2
Fuel, exhaust, engine electronics
20
Fuel
2002 01 2066 01 20 66 19 20 1501 20 o~ 19 20 Ib 19 20 1501
2
Contents
supply,
Checking
control
fuel quantity pressure. delivered
Removing
and
Calibrating
installing
fuel
level
by
fuel
20. 1 20. .3 20- 5 20- 9 20- 11 20- 15
pump.
pump.
sensor
installing
fuel
...
system.
Removing
and
filler
neck.
Removing Calibrating
and fuel installing level sensor fuel
system tank.
.. ... -GT3
I
24
I
20 - 25
Fuel
I
system,
electronic
injection
I
24 3037 24 4637 24 70 24 4637 I
I I
26
Disassembling
and
Programming Disassembling
DME and
assembling
fuel intake ringdistributor. pipe.
24- 1
..
24 -5 assembling control module. intake
Exhaust
system
Installing Removing
exhaust and exhaust installing system system
distributor
24-11 24-15
-GT3
i
26 01 19 26 01 21 26 01 23 26 :73 20
catalytic exhaust -GT3 -GT3
system converters
-GT3
(engine
installed)
I
i
26 -7
I
26-13 Starter,
27:
26- 0 26- 1
power supply, cruise control
1
2716019 2722 19 2784 19 2760 19 2722 19 2727 19 I
Removing
and installing
three-phase starter.
Removing
and installing
cruise
Removing
and installing
three-phase starter -GT3 generator
Removing
and installing
2706
Work
28
Ignition
28 04 19 28 70 21 28 70 23
2
in Germany
bracket
after
control
for
disconnecting
...
actuator.
... -GT3
oil generator the
battery.
.
-GT3 ..
27- 1 27- 3 27- 5 27- 7 27- 9 27-11 27-21
system
Removing
and
installing
Removing Installing
spark spark
plugs plugs
ignition
switch
28 -1
28- 3
-GT3 -GT3
28-
Fuel, exhaust,
Printed
instructions
generator.
1
engine electronics
-38,
1999
5
996TOC
www.WorkshopManuals.co.uk 911 Carrera (996)
20 02 01
Fuel supply, control
Checking fuel pressure
Special tools
418g.96
Item
Designation
Special tool
A
Pressuregauge
P 378a
B
Connectionline
9559
20 02 01
20-1
Checking fuel pressure
Printed in Germany, 1997
Explanation
996201
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera (996)
Checking fuel pressure Test
1. Undo covering cap on test connection of fuel collection pipe and remove (width across flats 13 mm). 2. Connectpressure gauge (special tool P 378a) with connecting line (special tool 9559) and connectto test connection.
366.96
4. Nominal test values: Stationary engine 3.8 :t 0.2 bar Engine idling 3.3 :t 0.2 bar
Note
393.97
The seal or sealing ring in the brass closure cap is not exchangeable.It must therefore be used only once.
3. Actuate fuel pump, either with Porsche System Tester 2: The fuel pump can be actuated with the Porsche System Tester 2 or by bridging the
Tighteningtorque of the new brass closure cap 2.5 :f: 0,5 Nm. (2.0 :f: 0.5 ftlb.).
fuel-pumprelay. or via the fuel-pump
relay without Tester:
Disconnectfuel-pump relay from the central electrical board and bridge contacts 30 and 87 (identified as 3 and 5 on the central electrical board) with a fused shop-madecable. The fuel pump must now operate or deliver fuel.
20 02 01
20 -2 996201
Checking fuel pressure Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
20 66 01
Fuel supply, control
Checking quantity delivered by fuel pump
Requirement: Fuelfilter and electrical supply in order.
5. Connectfuel hose (shop-made,approx. 1.5 m long) to the connection piece and hold in a measuringdevice.
1. Relievepressure in fuel tank by openingtank
cap. 2. ConnectPorscheSystemTester2 3. Remove the complete air cleaner assembly.
4. Undo the fuel return line (width across flats 17 mm) in the engine compartment(left). It is essential to counter at the same time (width across flats 17 mm). Collect residual fuel. Observethe safety regulations.
1742.20
6. Actuate fuel pump with the Porsche System Tester 2 and allowfuel to flow for 30 seconds into a measuringcontainer. Quantity supplied
must be at least
850 cm3/30 s, i.e. after 30 seconds at least 850 cm3 fuel must be present in the measuringcontainer.
394 -96
20 66 01
Checking quantity delivered by fuel pump
Printed in Germany, 1997
996201
20-3
www.WorkshopManuals.co.uk 911 Carrera (996)
20 66 19
Fuel supply, control
Removing and installing fuel pump
~
,
, ~
/ /' ~
-
---
453g.96
20 66 19
Removing
Printed in Germany. 1997
and installing
fuel pump 996201
20 -5
~
www.WorkshopManuals.co.uk Fuel supply, control
Removing and installing fuel pump
911 Carrera (996)
--
Removal
I.~, ""..."
/
1. Undo battery terminals and battery holder. Lift battery out by holdingstrap.
"
2. Undo battery support cover (four hexagon nuts, wrench size 13). \
\
4. Disengagefuel line and disconnectelectrical plug connection.
446-96
5. Extract residualfuel.
II
Note Observethe safety regulations. 6. Lift fuel tank sending unit and disconnect electrical plug connection and fuel pipes.
~ ~
"
..-
445 -96
3. Undo union nut with VWspecial tool 3217.
"
447.96
6. Put on fuel-proofglove, hold the fuel pump fastened to tank floor, turn it to left (approx. 15°, bayonet lock) and remove fuel pump.
20 -6
20 66 19 996201
Removing and installing fuel pump Printed in Germany, 1997
"'"
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel supply, control
Installation 1. Position fuel pump; the edge of the fuel-pump housing faces the fuel tank sending unit
3. Insert fuel tank sending unit and turn until the marking on the sending unit matchesthe marking on the fuel tank.
installation-positionmarkings.
\
---
~
-
=II' g)
149-96
448 -96
4. Tighten union nut with special tool 3217. Tighteningtorque with new union nut and new sealing ring 70 Nm (52 ftlbJ.
2. Place fuel pump in this position on tank floor bayonetfixture and turn fuel pump to the right as far as the stop. Then check proper seating of fuel pump by pulling it up.
5. Attach fuel lines and electrical plug connection.The fuel lines must audiblyengage. Correct engagement must be checked with a gentle pull. The colour-codedplug (green) must be fitted to the connectionidentified with "V".
2066
19
Removing and installing fuel pump
Printed in Germany, 1997
996201
20 -7
> 3.
www.WorkshopManuals.co.uk 911 Carrera (996)
20 15 01
&
Fuel supply, control
Calibrating fuel level sensor system Warning! Danger of fire and injury!
Thefuel levelsensorsystemhas nowbeen calibrated.
> Observegeneral safety regulationson the fuel system.
Note
The fuel level sensor system need not be calibrated if the battery was disconnectedor a plug connectionon the instrumentcluster or fuel level sensor was removed. The values remain stored in the instrumentcluster.
Wear protective gloves,
Note
Calibrationis necessaryafter replacementof the fuel tank, fuel level sensor or instrumentcluster.
A range on remainingfuel of less than 15 km is not displayedin the instrumentcluster.
Removebattery and detach battery cover. 2. Removefuel level sensor; refer to ServoNo. 20 66 19 (Removingfuel pump). Using a fuel extractor, completelydrain the fuel tank through the fuel level sensor opening. Fuelextractor: Referto the Workshop EquipmentManual,Chapter 3 'Workshop Equipment". 4. Reinstallthe fuel level sensor and, with "ignition off', fill the tank with 12 litres of fuel. 5. Perform tank calibrationwith the Porsche SystemTester 2. Selectvehicle type (911 Carrera) Selectcontrol modules -Select instrumentcluster Select menu item Tank calibration -Confirm calibration
20 1501 Printed
Calibrating
in Germany
-29,
fuel level sensor system
1999
996209
20 -9
www.WorkshopManuals.co.uk 911 Carrera (996)
20 07 19
Fuel supply, control
Removing and installing filler neck
31_99
20 07 19 Printed
Removing and installing filler neck
in Germany
-21,
1999
9962011
20 -11
www.WorkshopManuals.co.uk
Removing and installing filler neck
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63_98
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~~'~"
20 07 19 9962011
Removing and installing
filler neck
Printed in Germany. 21, 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel supply, control
Removing filler neck Warning: Danger of fire and injury!
&
> Observe general safety regulationson the fuel system. > Wear protective gloves,
Removing filler neck
No.
Procedure
Instructions
Disconnectbattery
Detach negative terminal of battery (aff 10 mm) and cover the terminal or battery.
Removeright front wheel. Remove right front wheel housingliner.
1
Detachfiller neck
Removecap. Undo hexagon-headbolt. Unclip seal.
2
Detach fuel lines and
Press release buttons and simultaneouslypull the linesapart. Pull off the ground strap.
ground strap 3
Removefiller neck
20 07 19 Printed
Turn the filler neck clockwise by approx. 450 and pull out carefully. The open surge flap must not be damagedwhen pulling out the filler neck.
Removing and installing filler neck
in Germany
-21,
1999
9962011
20 -13
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera (996)
Installing filler neck
No.
Procedure
Instructions
4 + 5 Close the surge flap
Close the surge flap before fitting the filler neck, Engagesurge flap at the locking lug.
6
Filler neck
To facilitate installation,apply a thin coat of engine oil on the indicated area (arrow).
7
Fit filler neck
Carefullypush the filler neck into take-upflange on the fuel tank. Turn the filler neck anticlockwiseby approx. 45°. Fit fuel lines and ground strap Fit seal in correct position. Ensure that the locking tabs are seated correctly. Fasten the hexagon-headbolt. Coat seat of the cap seal with Vaseline.
20 -14
20 07 19 9962011
Removing and installing filler neck Printed in Germany -21, 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
20 10 19
Fuel supply, control
Removingand installing fuel tank
499_98
Item
Special tool
Designation
Explanation
A
Steering wheel holder
Part of the wheel alignmenttester
B
Assemblytool for
Refer to Workshop Equipment Manual,Chapter2.4, No. 72
spring-bandclamps
20 10 19 Printed
Removing
in Germany
-21,
and installing
1999
fuel tank 9962015
20 -15
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera (996)
Removing fuel tank
36_99
20 -16
20 10 19 9962015
Removing and installing Printed
in Germany
fuel tank -21,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel supply, control
47_99
20 10 19 Printed
Removing
in Germany
-21,
and installing
1999
fuel tank 9962015
20 -17
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera (996)
Removing fuel tank
&
Warning: Danger of fire and injury! > Observe general safety regulationson the fuel system, > Wear protective gloves.
Removing fuel tank
No.
Procedure
Instructions
Disconnectbattery
Detach negativeterminal of battery (aff 10 mm) and cover the terminal or battery. Emptythe fuel tank. The fuel must be sucked out through the hole for the fuel level sensor in the fuel tank. It is impermissibleto suck out the fuel through the filler neck, as this would damage the inner flap on the filler neck.
Opentank cap
Openthe rear lid. Removecap. Lift bow on bleeder valve.
2 + 3 Draincoolant
Undo drain plug on the coolant guide housing and drain the coolant. Additionallydetach the vent line and drain the coolant. Then fit drain plug with new sealing ring. Tightening torque: 10 + 5 Nm (7.5 + 3.5 ftlb.:
20 -18
201019 9962015
Removing and installing
fuel tank
Printed in Germany -21, 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Fuel supply, control
Procedure
Instructions
4
Detach coolant lines
Removefront wheels. Open spring band clamps on both sides and pull off the coolant lines. Remove underbody covers. Removeall coolantlines.
5
Detach restraining straps on the fuel tank
Removediagonal braces between body and side members Detach restraining straps. Removebottom guard of fuel tank and the restraining straps.
6 + 7 Detachfiller neck
Removecap. Undohexagorrhead bolt. Unclipseal.
8
Pressreleasebuttonsand simultaneously pullthe lines apart.Pulloff the groundstrap.
Detach fuel lines and ground strap
9
10
Removefiller neck
Turn the filler neck clockwise by approx. 450 and pull out carefully. The open surge flap must not be damagedwhen pulling out the filler neck. Close the opening in the fuel tank, e.g. with the cap of a spray can (/35 cm).
Removeconnectionson the fuel levelsensor
Disconnectfuel lines and electrical plug connection, To do this: press the release button on the fuel lines and pull off the fuel lines. press the release button on the electrical plug connection and disconnectthe plug connection.
11
Lockthe steeringwheel
12
Detach the universal joint
Move steering wheel to centre position and lock it with the steering wheel holder. Loosen universaljoint (steering shaft) at steering gear. Take out the clamping screw and push the universaljoint upwards.
20 10 19 Printed
Removing
in Germany
-21,
and installing fuel tank
1999
9962015
20 -19
www.WorkshopManuals.co.uk
No.
Procedure
Instructions
13
Support cross member
Detach steering gear from the cross member. Support cross member with a workshop jack.
14
Detach cross member (side member)
Undo hexagon-headbolts at the front and rearI and lower the cross member or the complete front axle by approx. 15 cm. Detach fuel tank restraining strap from the body. Disengagethe fuel tank and take it off in downwarddirection.
20 -20
20 10 19 9962015
Removing and installing Printed in Germany
fuel tank -21,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel supply, control
Installing fuel tank
48_99
20 10 19 Printed
Removing
in Germany
-21,
and installing fuel tank
1999
9962015
20 -21
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
Installing fuel tank No.
2
Procedure
Instructions
Fastenfuel tank
Lift the fuel tank and engage it on the support lugs on the floor of the body. Fastenthe restraining strap (transverse)on the floor of the body. Tighteningtorque: 25 Nm (19 ftlb.)
Fit coolant lines
Fit all coolant lines before lifting the front axle.
3 + 4 Fasten front axle
Lift front axle with the workshop jack and fasten. Tighteningtorques
5
Fastensteeringgear
6 + 7 Fituniversaljoint
Make sure the roll pin (13 x 14) is present and seated properly in the left fastening bore of the steering gear. Fastensteering gear with new MID x 1.5 x 45 hexagon-headbolts. Tighteningtorque: 65 Nm (48 ftlb.) Push universaljoint (steering shaft) onto the steering gear. The lug of the rotary plastic clip must engage in the clamping slot of the universaljoint. Fit new M8 x 35 fastening screw in the retaining groove. Tighteningtorque: 23 Nm (17 ftfb.)
8
Fastenfuel tank
Fit bottom guard and the restraining straps. The restraining straps are identified by "R"(right) and "L"(left).
9
Make connectionson the fuel level sensor
Fastenfuel linesandelectricalplugconnectoron the fuel levelsensor.
20 10 19 Printed
Removing and installing fuel tank
in Germany
-21,
1999
9962015
20 -23
www.WorkshopManuals.co.uk
No.
Procedure
Instructions
10
Fitfiller neck
To facilitate installation,apply a thin coat of engine oil on the indicated area (arrow). Removeprotective cap. Carefullypush the filler neck into take-upflange on the fuel tank. Turn the filler neck anticlockwiseby approx. 45°.
13
Fit seal
Fit seal in correct position. Ensure that the locking tabs are seated correctly. Fastenthe hexagon-headbolt. Coat seat of the cap seal with Vaseline.
14
Bleedcoolantsystem
Lift bow on bleeder valve,fill in coolant and bleed the system; refer to page 19 of Group 19, ServoNo. 1938 17.
Perform tightness test. Perform suspensionalignment.
20 -24
20 10 19 9962015
Removing and installing fuel tank Printed
in Germany
-21,
1999
3.
www.WorkshopManuals.co.uk 201501
&
Calibrating
fuel level sensor system -GT3
6. Performtank calibrationwith the Porsche SystemTester2.
Warning! Danger of fire and injury!
> Observegeneral safety regulationson the fuel system.
-Select vehicle type (911 Carrera) -Select control modules
> Wear protective gloves.
Selectinstrumentcluster Note
-Select menu item Tank calibration
Calibrationis necessaryafter replacementof the fuel tank, fuel level sensor or instrumentcluster. The fuel tank is the same part as for the 911 Carrera4.
-Confirm
The fuel level sensor system has now been calibrated.
Disconnectthe battery and cover terminal or battery. Removecap over the fuel level sensor
system. 2. Removefuel level sensor; refer to ServoNo. 2066 19 (Removingfuel pump). Using a fuel extractor, completelydrain the fuel tank through the fuel level sensor opening. Fuel extractor: Referto the Workshop EquipmentManual,Chapter 3 "Workshop
calibration
Note The fuel level sensor system need not be calibrated if the battery was disconnectedor a plug connectionon the instrumentcluster or fuel level sensor was removed.The values remain stored in the instrumentcluster. A range on remainingfuel of less than 15 km is not displayedin the instrumentcluster.
Equipment". 4. Make sure that the two recesses on the left and right-hand
sides of the tank are
emptied completely.
5. Reinstallthe fuel level sensor and, with "ignitionoff', fill the tank with 23 litres of fuel.
20 15 01
Calibrating
Printed in Germany
-29,
fuel level sensor system -GT3
1999
GT32025
20 -25
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel system -Electronic
injection
Disassembling and assembling fuel ring pipe Note:
No. Designation
Qty.
Removal
Installation
1
Protective sheath
2
Pipe 4 x 1 (420 mm long)
3
Clamp
1
4
Pressure regulator
1
5
a-ring
1
Replace
6
a-ring
1
Replace
7
Closure cap
1
Note The seal or sealing ring in the closure cap is not exchangeable.It must therefore be used only
1
Ensure correct seating
once. Tighteningtorque: 2.5 :to.5 Nm (2.0 :to.5 ftlb.) (Wrenchsize 13 mm) 8
Valve
1
9
Cable retainer
3
10
Hexagon-head bolt
4
11
Fuelring pipe
1
12
Clamp
6
13
Injectionvalve
6
14
a-ring
6
15
Hexagorrheadbolt
16
Fasteningclamp
24 30 37 Printed
Disassembling
in Germany
-28,
1999
and assembling
Unscrewusing a commerciallyavailable valve tool
Screw in using a commerciallyavailable valve tool
Ensure correct seating
Replace
fuel ring pipe 996241
24 -3
www.WorkshopManuals.co.uk Fuel system -Electronic
911 Carrera (996)
injection
Note:
No.
17
Designation Fuel supply line M16 x 1.5
Qty. 1
Removal
Installation
Ensure it is counteredwith a wrench while being
loosened
18
Fuel return line M14 x 1.5
1
Ensure it is counteredwith a wrench while being
loosened
Tighteningtorque: 30 + 5 Nm (22 + 3.5 ftlb.). (Wrenchsize 19 mm) Counterwith a wrench whiletightening, wrench size 19 mm. Tighteningtorque: 25 :t 5 Nm (19 :t 3.5 ftlb.). (Wrenchsize 19 mm) Counterwith a wrench whiletightening, wrench size 17 mm.
Note on No. 13 (injection valve) As of V-range (model year 2000) modified injection nozzles with improved injection spray. Identified by plug housing with different colour (colour: light green). Old injection valves (colour: blue) must no longer be installed in engines manufacturedfrom model year 2000 onwards. Mixed configurationis permissiblefor all engines manufacturedbefore model year 2000.
24 -4
24 30 37 996241
Disassembling
and assembling
fuel ring pipe
Printed
-28,
in Germany
1999
11 '-9 ~ ~
www.WorkshopManuals.co.uk
Disassembling and assembling intake distributor 29
~:::::::::::::~f=:::~~
~
35 34
36
37
~
~
38
---~
,,4443
at ~ f41
"'="-
~25
32
39
3738 ~-
26
~
27
~ I
8
42
...J
r-
~
~
~
...~ j-~ 2
47
I t>~
6
22 7
23 24
~-'b
3
~1
~
~-10 l!1-11
I 30 ~ ---
5 'I
~
12
~-1' ~-16 -15
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18
1-17
'1~Q~~-'9
24-6
24 46 37
242-98
Disassembling and assembling intake distributor 996245
Printed in Germany
-10,
1998
Istributor
www.WorkshopManuals.co.uk Fuel system, electronic injection
911 Carrera (996)
Disassembling and assembling intake distributor
Note:
No. Designation
Qty.
Removal
Installation
1
Hexagon-headbolt 6.0 x 16
4
2
Fasteningclamp
1
3
Throttle body
1
4
Hoseclamp
1
5
Fuel evaporativevalve
1
6
Hose clamp
1
7
Vent line
1
8
Sealingring
1
Check,replace if necessary
9
Temperature sensor
1
Checkfor correctseating Check for correct seating
for engine compartment
10
Grommet
1
11
Sheetmetal nut M6
1
12
Hose clamp
1
13
Hose clamp
1
14
Hexagon-head bolt 6 x 35
6
15
Intake di
1
on
cylinder bank 4 -6
16
Gasket
3
17
Hexagon-headbolt M6 x 35
4
18
Intake fitting on cylinder bank 4 -6
1
19
Gasket
1
20
Hexagon-headbolt
1
24 46 37 Printed
Replace
Replace
Disassembling and assembling intake distributor
in Germany
-10,
1998
996245
24 -7
www.WorkshopManuals.co.uk
21
Holder
22
Hexagon-headbolt 6.0 x 16
23
Closure cap
24
a-ring 11 x 2.5
1
25
Hoseclamp
1
26
Hose clamp
27
Adapter
1
28
Rubber sleeve
1
29
Hose clamp
1
30
Rubbersleeve
1
Check,replace if necessary
31
Hose clamp
32
Adapterwith tuningflap
1
Positionfacing intake distributor
33
Screw M5 x 16
2
34
Vacuum modulator
35
Hose
1
36
Pipe 4 x 1 (420 mm long)
1
37
Hoseclamp
2
38
Rubbersleeve
2
39
Hexagon-headbolt M6 x 35
6
40
Intake distributor on cylinder bank 1 -3
1
41
Gasket
1
42
Hexagon-headbolt 6.0 x 16
1
24 -8
2
24 46 37
Replace
Check,replace if necessary
Check,replace if necessary
Disassembling and assembling intake distributor 996245
Printed
in Germany
-10,
1998
www.WorkshopManuals.co.uk
No. Designation
Note:
Qty.
43
Adapter
1
44
a-ring
1
45
Hexagon-headbolt M6 x 35
4
46
Intake fitting on cylinder bank 1 -3
1
47
Gasket
1
24 46 37
Removal
Replace
Disassembling and assembling intake distributor
Printed in Germany -10, 1998
Installation
996245
24 -9
, ,~
www.WorkshopManuals.co.uk Fuel system, electronic
injection
911 Carrera (996)
Assembly instructions Position adapter (tuning part) to face the intake distributor. Turn the adapter accordingly until the arrow on the adapter is lined up with the arrow on the intake distributor.
=~-1j\
\r I"" 187_98
24 -10
24 46 37
Disassembling amj assembling intake distributor 996245
Printed in Gennany
-10,
1998
II
www.WorkshopManuals.co.uk 911 Carrera (996)
2470
Fuel system, electronic injection
Programming DME control module
General Whena DME control module is replaced,the new DMEcontrol module must be programmed. This sets the new DMEcontrol module to the catalytic converter version installed, among other things.
With the information about the VehicleIdent. Number and catalytic converter item number, the associated programme can be selected from the allocationtable. Figure 307_98 shows where the catalytic converter item number can be found on the vehicle.
Three catalytic converter versions are available in the ,PorscheSystem Tester 2: 1. OBD II control module
~
2. RoW control module
~
-
3. German control module (tri-metal catalytic converter)
~-
Note:
.-=. TheOBDII controlmoduleis installed onlyin USAvehicles.
I
/I
H~I_'-
~ r,;;;1
Work preparation
Catalytic converter item number
The following vehicle data must be provided before programming of the new DMEcontrol module can begin:
307_98
Programming
Vehicle Ident. No.
1. Connectand switch on the Porsche System Tester 2 and switch on the ignition.
Catalytic converter item No. corresponding to the catalytic converter version used
2. Select 911 (996) in the Vehicletype menu.
DME and immobilizer programming codes (from the Porsche IPAS system)
3. Select DME in the Control unit menu and press the double arrow key [»]. 4. Select Program control unit in the DME function selection menu and press the double arrow key [»].
24 70 Programming DME control module Printed in Germany -15, 1998
24 -11 9962411
www.WorkshopManuals.co.uk Fuel system, electronic injection
5. Select "Readcontrol units" and press the double arrow key [»].
911 Carrera (996)
15. Thefollowingmessageappearsonthe screen: "Inputnew immobilizer code" Input immobilizer code and press the double
6. Install new DME control module.
arrow key [»].
7. Select Program control unit in the Control unit programming menu and press the double arrow key [»].
16. The followingmessageappearson the screen: "Pleaseconfirm input" Confirm input with the [F7] key.
8. Ensure that all requirementsrequested on the screen are fulfilled and then press the double arrow key [»].
17. The followingmessageappearson the screen: "Selectdata record" Select data record according to the allocationtable and press the double arrow key [»].
9, The following message appears on the screen: "InputVehicle Ident,Number", InputVehicle IdentificationNumber and press the double arrow key [»], 10. The followingmessage appearson the screen: "Pleaseconfirm input" Confirm input with the [F7] key.
Thecontrolmodulewill nowbe programmed. Programming will takeapprox.5 minutes.
& ,
Warning:
> Neverinterruptthe programming process
11. The followingmessage appearson the screen: "Input old DMEprogramming code" Input DMEprogramming code and press the double arrow key [»].
18. The following messagewill appear after the programmingtime has elapsed: .Programmingwas completed successfully. Press the double arrow key [»], switch the ignition off and then on again.
12. The followingmessageappearson the screen: .Pleaseconfirm input" Confirm input with the [F7] key.
This completes programming of the DMEcontrol module.
13. The followingmessageappearson the screen: "Input new programming code" Input new DME programming code and press the double arrow key [»]. 14. The followingmessageappearson the screen: "Pleaseconfirm input" Confirm input with the [F7] key.
24 70 Programming DME control module
24 -12 9962411
Printed in Germany -15,1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel system, electronic injection
converter version
Vehicle Ident. Number
Catalytic converter item nump!!!r
OBDIIIcontrolmodule
WPOxx2xxxWxxxxxxx
996.113.021.53 996.113.022.53
RoWcontrol module
WPOZZZxxxWxxxxxxx
996.113.021.52 996.113.022.52
Germancontrol module
WPOZZZxxxWxxxxxxx
(tri-rnetalcatalytic converter)
1996.113.021.54 '996.113.022.54
WPOxx2xxxXxxxxxxx
OBD ill control module
996.113.022.53 RoW control
module
WPOZZZxxxXxxxxxxx
German control module
WPOZZZxxxXxxxxxxx
(tri-metal catalytic converter)
996.113.021.52 996.113.022.52 996.113.021.54 996.113.022.54
Allocationtable Note: The DME control module can also be reprogrammed using the Porsche System Tester 2. In this case, the old data record will be overwritten by a new record (e.g. RoW instead of Germany) Program map/data must be selected in Step 7 if reprogramming is necessary.
&
II1f~talytic !1996.113.021.53
Warning: Risk of damage if allocation is incorrect > Ensure correct allocation of the data record in the control module to the installed catalytic converter (refer to the allocation table)
24 70 Programming
24 -13
DME control module
Printed in Germany -12, 1998
9962411
www.WorkshopManuals.co.uk 911 Carrera (996)
24 46 37
Fuel system -Electronic
injection
Disassembling and assembling intake distributor -GT3
~
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,.-~
I(
~
275_99
24 46 37 Printed
Disassembling
in Germany
-28,
1999
and assembling
intake distributor 9962415
-GT3
24 -15
(..,11 ~ 8' '9 ../1
www.WorkshopManuals.co.uk
Disassembling and assembling intake distributor -GT3
3
4
A
7
5
1
t.!' ~ 9 "'-
-12
17
353_99
24 -16
24 46 37
Disassembling 9962415
and assembling
intake distributor Printed
in Germany
-28,
-GT3 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Fuel system, electronic injection
Disassembling and assembling intake distributor -GT3 Note:
No. Designation
Removal
Qty.
Installation
Intake distributor I left/right
2
2
Tuningpipe
1
3
Rubbersleeve
1
Check,replace if necessary
4
Rubbersleeve
3
Check,replace if necessary
5
Hose clamp 90 -150
8
6
Throttle body
7
Idle speed control housing
1
8
Adjusting screw
1
9
Hexagonnut M12
1
10
Combinationscrew M6 x 20
2
11
Hose clamp 70 -90
2
12
Rubbersleeve 0-48
6
13
Hose clamp 50 -70
12
14
Switch-over valveholder
1
15
Combinationscrew M6 x 12
2
16
Vacuumtank retaining bracket
1
17
Combinationscrew M6 x 35
2
18
Collar nut M6
2
19
Vacuumtank
1
20
Oval-headscrew 5 x 22
2
21
Screw plug M16 x 1.5
1
22
Sealingring 16 x 20
1
Check,replace if necessary
Replace
(aluminium)
24 46 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
intake distributor 9962415
-GT3
24 -17
1-1
www.WorkshopManuals.co.uk Fuel system, electronic
911 Carrera (996)
Note:
No. Designation
23
injection
Removai
Qty.
installation
1
Flangefor vacuum
Removing and installing intake pipe -GT3 1. Undo the two holders for the coolant lines 2. Undo the nine fastening screws and take off the intakepipe. For reinstallation,the seal betweenthe cylinder head and intake pipe must be replaced. The screws are tightened to 9.7 Nm (7.0 ftlb.).
/
/
-)
~~
:::...
'.-'1.7'«.
/'-
...
~ /
~ 214_99
24 -18
24 46 37
Disassembling 9962415
and assembling
intake distributor Printed in Germany
-29,
-GT3 1999
www.WorkshopManuals.co.uk 911 Carrera
(996)
Hose routing
Fuel system, electronic
injection
plan -GT3
421_99
24 46 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
intake distributor 9962415
-GT3
24 -19
www.WorkshopManuals.co.uk
No.
Designation
Removai
Qty.
1
12-22/9 hose clamp
2
Oil tank vent hose for partial load
3
T-piece
4
16-27/9 hose clamp
2
5
22x18.5 fastening clip
2
6
Oil tank vent hose for full load
1
24.8x22. retainingclip
2
8
16x20 seal
1
9
Neck
1
10
Vacuumhose
1
11
Neck
1
12
8-16/9 hose clamp
3
13
B 13.5 clip
1
14
Vent hose betweenoil cooler and expansiontank
1
15
Tank vent line
1
16
Tank vent line with valve
1
17
8-3/13 combinationclip
1
18
M 6x12 hexagon-headbolt
3
19
M 6 hexagon-headbolt
1
20
Combinationholder
1
21
8x15 hose holder
1
22
Vent pipe
1
Note:
installation
4
Replace
www.WorkshopManuals.co.uk
No. Designation
Qty.
23
Venthose
1
24
Oil tank vent hose for full partial load
1
25
19.2-21.8 single-lugclip
2
26
12-14single~ug clip
27
10-52/8-9 combinationclip
2
28
20.0/24.5 hose holder
1
Removai
Note:
installation
433_99
24 46 37
Disassembling
Printed in Germany
-29,
1999
and assembling
intake distributor 9962415
-GT3
24 -21
www.WorkshopManuals.co.uk 911 Carrera (996)
26 01 19
Engine, exhaust system
Removing and installing exhaust system -GT3
272_99
Includes: 2601
21 Removing exhaust system -GT3
26 01 23 Installing
2601
19
exhaust system -GT3
Removing and installing
Printed in Germany -29.
1999
exhaust system -GT3 9962600
26 -0
lO
www.WorkshopManuals.co.uk
26 01 21
Removing exhaust system -GT3
---
'1'
\\..
~
272_99
2601 Printed
21
Removing
in Germany
-28,
26 -1
exhaust system -GT3
1999
9962601
www.WorkshopManuals.co.uk
Removal overview of the exhaust system -GT3 ft
~
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~~
1111
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9962601
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260121
26 -2
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,
Removing
exhaust system -GT3
Printed
in Germany
-28,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine, exhaust system
Removal overview of the exhaust system -GT3 Preliminarywork: Disassemblethe accessories of the rear spoiler ServoNo. 6355 (contains: rear end, bottom centre heat shield and bumpers).
1
Undo fastening clamps
2
Removeend mufflers
3
Removecatalyticconverters
4
Removerear mufflerholders
5
Undo exhaustmanifolds
2601 21
Removing exhaust system -613
Printed in Germany.
28, 1999
26 -3 9962601
" ~
www.WorkshopManuals.co.uk
Removing exhaust system -GT3
No.
Instructions
Procedure
1
Undofastening clamps Undothe two exhaustclamps betweenthe catalytic converter and the rear muffler. Undo the fastening clamp on the support sheet and remove.
""
~ 350.»_99 Removeend mufflers
2
Removeboth end mufflers. Undothe three fastening screws on the left and right of each to do this.
Removecatalytic converters
3
Unclip oxygen sensor cable and unplug. Undothe three fastening screws on the exhaustmanifold. Carefullylift the catalytic converter up and off.
~ 350_c_99
26 -4
26 01 21 9962601
Removing
exhaust system -GT3
Printed
in Germany -28,
1999
'"
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Engine, exhaust system
Procedure
Instructions
4
Removerear muffler holder I
/
/0
To disassemblethe holder on the rear muffler, undo the four fastening screws on the left and right of the cylinder head respectively.
\
" ",
~::~:// 350_d_99
5
Removeexhaustmanifolds /
Undo the nine fastening screws of the exhaust manifolds on the left and right of the cylinder head respectively. Removeexhaustmanifolds.Do not use the seal between the cylinder head and the exhaustmanifoldsagain.
"
~
""'-""""
~~~/" 350_e_99
26 01 21
Removing
Printed in Germany
-28,
exhaust system -GT3
1999
26 -5 9962601
9962607
www.WorkshopManuals.co.uk 911 Carrera (996)
26 01 23
Engine, exhaust system
Installing
exhaust system -GT3
f"-
J.,
272_99
2601 Printed
23
Installing
in Germany
-28,
exhaust system -GT3 1999
26 -7
"" .,/' """ ~
www.WorkshopManuals.co.uk Engine, exhaust system
911 Carrera (996)
Installation overview of the exhaust system -GT3
1
//~~:==~~~
""'",
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;}I 351_99
26 01 23
26 -8 9962607
Installing
exhaust
Printed
system
in Germany -28,
-GT3 1999
9962607
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine, exhaust system
Installation overview of the exhaust system -GT3
1
Tightenexhaustmanifolds
2
Tighten rear muffler holder
3
Install catalytic converters
4
Install end mufflers
5
Tighten fastening clamps
26 01 23
Installing
Printed
in Germany
-28,
exhaust system -GT3 1999
26 -9
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Engine, exhaust system
Installing
No.
exhaust system -GT3 Instructions
Procedure
Tightenexhaustmanifolds
1
Position exhaustmanifold with new seal. Tighten the nine hexagon-headbolts on the cylinder head to 25 Nm (19 ftlb.).
Installholderfor rear muffler
2 ~~::~ii!!:'~"'"
~rQ
Position holder for rear muffler. Tighten the four fastening screws to 23 Nm (17 ftlb.),
~ 350_d_99
3
-~~~;;;?,I
Install catalytic converters Position catalytic converter on exhaustmanifold with new seal. Tightenthe three fastening screws on the exhaust manifoldto 30 Nm (22 ftlb.) Fit fastening clamp between catalytic converter and engine holder in horizontal position if possible and tighten.
26 01 23
26 -10 9962607
Installing
exhaust system -GT3
Printed
in Germany
-28,
1999
9962607
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Engine, exhaust system
Procedure
Instructions
4
Install rear mufflers Before assemblingthe rear mufflers, make sure that the two fastening clamps for each are fitted. Insert rear muffler into the catalytic converter. Screw rear muffler onto rear muffler holder. Tightenthe hexagon-headbolts to max. 23 Nm (17 ftlb.).
5
Tighten exhaustclamps Move the two exhaustclamps between each catalytic converter and rear muffler to horizontalposition if possible. Tighten exhaustclamps.
" Fit rear spoiler Fit the accessories of the rear spoiler ServoNo. 6355 (contains: rear end, centre heat shield and bumpers).
2601 Printed
23
Installing
in Germany
-28,
exhaust system -GT3 1999
26 -11
Iy
www.WorkshopManuals.co.uk 911 Carrera (996)
26 73 20
Exhaustsystem
Removing and installing catalytic converters -engine
installed
Tools
~\
~
'"
\\
"
2673000]
Item
Designation
Special tool
Explanation
Open ring wrench (angled)
Commerciallyavailable
Refer to Workshop Equipment Manual,Chapter2.4, No. 96-3
26 73 20
Removing
Printed in Germany
-38,
and installing
1999
catalytic
converters 9962613
-engine
installed
26 -13
>
www.WorkshopManuals.co.uk Exhaust system
991 Carrera (996)
Caution!
&
Oxygen sensor can be damaged
if handled improperly.
> Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must under no circumstancescome into contact with the plug. > Protect sensors -before and after fitting -against mechanicalshocks. Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator. > The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and plug. > Cleanlinessin the housing of the plug connectionsis of utmost importancefor the function of the oxygen sensor. Particles of dirt can impair the function of the oxygen sensor. Therefore,the plug must be protected against any and all types of soiling. Sensorswith soiled or damaged plug must no longer be used. Protect the cables and plugs when transporting the exhaustsystem with the sensors alreadyfitted. > High-pressurecleaning equipmentmust not be used in the area of the sensors and plug connections.
26 -14
26 73 20
Removing and installing 9962613
catalytic
converters
-engine
Printed in Germany
installed -38,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Exhaust system
Removing and installing catalytic converters Removal
Sequence when removing
1. Removeair cleanerassembly:
converters: Remove catalytic
.1 Undo hexagon-headbolt M6 x 34 (wrench size 13).
bank
converter
the catalytic
of cylinder
4 -6
1. In the enginecompartment, pull the oxygen sensor plug connectionfrom its holder, unlock and disconnect. Black connector -oxygen sensor in front of the catalytic converter Grey connector -oxygen sensor behindthe catalytic converter
261_97
1.2 Undo hose clamp on throttle body and pull plug off the mass air flow meter. Unclipwire on air cleaner housing and remove air cleaner assembly.
26730004
.,~
:q~I~'
2. Unclipcableon enginecarrier.
~,
~~.
""':~
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i(/
'- Before installing a new fuel pump, check the previous and the new fuel pumps to see the shape of the cut-outs for fastening the sucking jet pumps. Dependingon the cut-out, the previoussucking jet pumps can either continueto be used or must be replaced.
376_99
> Fuel pump/sucking jet pumps allocation: Previousfuel pump (cut-out not rounded): Old or new sucking jet pumps can be installed. New fuel pump (cut-outrounded): Onlyinstall new sucking jet pumps.
20 -110
20 66 19
Removing and installing fuel pump (911 Carrera 99620101
Printed
in Germany
-28,
4)
1999
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera 4 (996)
20 78 19
Removing and installing pedal encoder
Removal 1. Pull off the centre air duct (A)in the driver's footwell.
~\ i:::::::;;;;iiiii:i~;;;:J:\.~_\
382_98
3. Disengageelectrical plug connectionon the bracket. To do this, turn the plug connection counter-clockwisein the bracket and take it off. Disconnectplug connection.
2. Undo two hexagonnuts (a/t 10 mm) on the pedal encoder.
4. Pull pedal encoder out of the stud, disengage the cable from the cable disc and remove the pedal encoder in downwarddirection. Installation 1. Engagecable in the cable disc, insert the pedal encoder in the stud and fasten the pedal encoder with two hexagonnuts. Tighteningtorque 8 -9 Nm (6.0 -6.5 ftlb). 2. Positionelectrical plug connectionin the bracket and turn it clockwise until the plug connectionengages.
207819
Removing
Printed in Germany.
and installing
15, 1998
pedal encoder 99620111
20-111
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera 4 (996)
20 80 19
Removing and installing accelerator pedal
Removal 3. Disengageelectrical plug connectionon the bracket. To do this, turn the plug connection counter-clockwisein the bracket and take it off. Disconnectplug connection.
1. Pull off the centre air duct (A)in the driver's footwell.
4. Undotwo hexagonnuts (ajt 10 mm) on the pedalencoder.
383_98
2. Undo upper countersunk screw (M5 x 55) on the accelerator pedal and remove the accelerator pedal.
382_98
5. Pull pedal encoder out of the stud, disengage cable from the cable disc and remove the pedal encoder in downwarddirection. 6. Press both locking tabs of the cable guide together by hand and simultaneouslypull the cable out of the bracket. 380_98
208019 Printed
Removing
in Germany
and installing
-15, 1998
accelerator
pedal
99620113
20 -113
www.WorkshopManuals.co.uk Fuel supply, control
911 Carrera 4 (996)
Installation
4. Fitair duct.
1. Engagecable guide into the bracket. Then pull slightly to ensure that the connectionis properlylocked. 2. Fasten the accelerator pedal. Tightening torque of the countersunk screw (M5 x 55) 2.8 Nm :!: 10 % (2.0 ftlb. :!: 10 %)
3. Engage cable in the cable disc, insert the pedal encoder in the stud and fasten with two hexagon nuts. Tighteningtorque 8 -9 Nm (6.0 -6.5 ftlb).
383_98
382_98
20 -114
208019 99620113
Removing and installing accelerator pedal Printed in Germany -15,1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
20 15 01
Fuel supply, control
Calibrating fuel level sensor system 6. Perform tank calibrationwith the Porsche System Tester 2.
Warning! Danger of fire and injury!
&
> Observegeneral safety regulations on the fuel system,
-Select vehicle type (911 Carrera) -Select control modules
> Wear protective gloves.
-Select instrumentcluster Note
-Select menu item Tank calibration
Calibrationis necessaryafter replacementof the fuel tank, fuel level sensor or instrumentcluster. 1. Disconnectthe battery and cover terminal or battery. Removecap over the fuel level sensor
-Confirm calibration The fuel level sensor system has now been calibrated.
system. Note
2. Removefuel level sensor; refer to ServoNo. 2066 19 (Removingfuel pump),
The fuel level sensor system need not be calibrated if the battery was disconnectedor a plug connectionon the instrumentcluster or fuel level sensor was removed. The valuesremain stored in the instrumentcluster.
3. Using a fuel extractor, completelydrain the fuel tank through the fuel level sensor opening. Fuel extractor: Refer to the Workshop EquipmentManual,Chapter 3
A range on remainingfuel of less than 15 km is not displayedin the instrumentcluster.
"WorkshopEquipment'. 4. Make sure that the two recesses on the left and right-hand
sides of the tank are
emptied completely. 5. Reinstall the fuel level sensor and, with "ignition off', fill the tank with 28 litres of fuel. The indication
in the Porsche System
Tester 2 (old or new characteristic)
is the
decisive indication.
20 1501 Printed
Calibrating fuel level sensor system
in Germany
-39,
2000
99620115
20 -115
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
24 42 19
Fuel system, electronic injection
Removing and installing throttle body
Removal Removethe complete air cleaner assembly: 1.1 Unclip oil filler neck from upper part of the air cleaner. .2 Undo hexagon-head bolt M8 x 15.
The plug ;s shown turned to show the button more clearly.
186_98
2. Pull plug off the throttle body. Undo 4 hexagon-headbolts (M6 x 25) and remove the throttle body.
261_97
1.3 Pull plug off the hot film mass air flowmeter. To do this, pushthe button and simultaneously pull the plug off. Loosenhose clamp on the throttle body,unclipcable on the air cleanerhousingand removethe air cleaner
system.
359_98
3. Removesealing ring.
244219
Removing
Printed in Germany.
and installing
15, 1998
throttle
body 99624101
24 -101
www.WorkshopManuals.co.uk
Installation 1. Insert new sealing ring in the correct position.
378_98
2. Fit throttle body. Tighteningtorque for hexagon-head bolts 10 Nm (7.5 ftlb.) 3. Install air cleaner assembly. Note Before installation,make sure that the rubber sleeves (2 ea.) are present and properly seated in the transverse lock panel.
8
24 -102
244219 99624101
Removing
and installing
throttle
body
Printed in Germany -15,1998
