Porsche 996 GT2 - Supplementary Service Manual

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PORSCHE 996 GT2 - SUPPLEMENTARY SERVICE MANUAL

- English Supplementary Service Manual, for vehicles Porsche 996 GT2.

 
CONTENTS:

GROUP 0 GENERAL
0 TECHNICAL
- 0 Technical data
- 0 Entire vehicle   General
- 0 Power unit
- 0 Transmission
- 0 Body
- 0 Electrics
- 0 Power supply
01 SALES CHECK
- 01 Sales check
- 01 General maintenance: Test drive
- 01 Diagnostic system: Read out fault memory and activate systems
- 01 Battery: checking the charge state
- 01 Windscreen wiper/washer system, headlight washer
- 01 Checking the function of the vehicle's lights and the headlight setting
- 01 Checking the function of electrical equipment, as well as the indicator and warning lights
- 01 Alarm system: checking operation of indicators
- 01 Activating/deactivating the parking aid
- 01 Removing transport lock (spring strut locking devices)   Turbo and GT2
- 01 Mobile roofs: checking function
- 01 Glazing: visual inspection for damage
- 01 Checking lid and doors
- 01 Interior equipment: visual inspection for damage and soiling
- 01 Removing transport protection
- 01 Installing air guides for PCCB brake discs - GT2
- 01 Fitting front lip   GT2
- 01 Fitting six-point seat belt   GT2
- 01 Checking the Vehicle Ident. No.
- 01 Checking the exterior equipment and paint finish
- 01 Completing vehicle and checking equipment for completeness
03 MAINTENANCE
- 03 Diagnostic system: reading out fault memory
- 03 General maintenance: test drive
- 03 Removing and installing drive belt
- 03 Changing the engine oil and oil filter
- 03 Changing the engine oil (without oil filter)
- 03 Replacing spark plugs
- 03 Checking cooling system
- 03 Replacing air cleaner element
- 03 Replacing the fuel filter
- 03 Clutch: checking the play and pedal end position
- 03 Changing transmission oil
- 03 Changing transmission oil - GT2
- 03 Checking and topping up the ATF
- 03 Replacing ATF
- 03 Removing and installing ATF filter
- 03 Replacing and checking transmission oil in final drive
- 03 Changing transmission oil in front wheel drive
- 03 Steering gear: fluid level and bellows
- 03 Axle joints/drive shafts
- 03 Running gear adjustment/storage of assemblies
- 03 Tyres and spare wheel: checking condition and tyre pressure
- 03 Checking and changing the brake fluid
- 03 Parking brake: checking the free play of the parking brake lever
- 03 Visual inspection: brake lines/brake pads/brake discs
- 03 Checking the wheel mounting
- 03 Checking lid and doors
- 03 Checking seat belts
- 03 Inspecting the airbag system
- 03 Passenger protection maintenance: checking roll-over protection system
- 03 Particle filter: replacing the filter element
- 03 Checking the function of the vehicle's lights
- 03 Windscreen wiper/washer system, headlight washer
- 03 Checking the function of electrical equipment, as well as the indicator and warning lights
- 03 Additional maintenance - USA
- 03 Additional maintenance - as of MY 2004
- 03 Additional maintenance - USA - as of MY 2004
- 03 Additional maintenance
- 03 24 00 Minor maintenance
- 03 24 00 Minor maintenance - USA
- 03 24 00 Minor maintenance - as of MY 2003
- 03 24 00 Minor maintenance - USA - as of MY 2003
- 03 24 00 Minor maintenance - as of MY 2004
- 03 24 00 Minor maintenance - USA - as of MY 2004
- 03 26 00 Major maintenance
- 03 26 00 Major maintenance - USA
- 03 26 00 Major maintenance - as of MY 2003
- 03 26 00 Major maintenance - USA - as of MY 2003
- 03 26 00 Major maintenance - as of MY 2004
- 03 26 00 Major maintenance - USA - as of MY 2004
- 03 50 00 Annual maintenance
- 03 50 00 Annual maintenance - USA
- 03 50 00 Annual maintenance - as of MY 2004
- 03 50 00 Annual maintenance - USA - as of MY 2004

GROUP 1 ENGINE.
1 TECHNICAL DATA
- 1 Technical data
- 1 Technical Data GT2
10 CRANKCASE, SUSPENSION
- 10 01 00 Tightening torques for M 96/70 engine
- 10 01 19 Removing and installing engine-Removing
- 10 01 19 Removing and installing engine-Installing
- 10 10 37 Disassembling and assembling crankcase
13 CRANKSHAFT, PISTONS
- 13 10 19 Removing and installing pistons (includes removing and installing cylinders)
- 13 19 21 Removing piston rings
- 13 19 23 Installing piston rings
- 13 48 37 Disassembling and assembling crankshaft
- 13 73 37 Disassembling and assembling belt tensioner
- 13 78 19 Removing and installing drive belt (engine installed)
15 CYLINDER HEAD, VALVE DRIVE
- 15 03 21 Removing camshaft housing   engine removed
- 15 03 23 Installing camshaft housing
- 15 05 02 Checking camshafts (timing)   engine removed
- 15 05 16 Setting camshafts (timing)   engine removed
- 15 05 19 Removing and installing camshafts   engine removed
- 15 20 37 Disassembling and assembling intermediate shaft
- 15 55 19 Removing and installing hydraulic valve
- 15 70 21 Removing cylinder head
- 15 70 23 Installing cylinder head
17 LUBRICATION
- 17 04 19 Removing and installing oil pressure sender
- 17 07 19 Removing and installing oil temperature sensor
- 17 28 19 Removing and installing check valve   engine installed
- 17 40 19 Removing and installing oil cooler   Engine removed
- 17 52 19 Removing and installing oil container
COOLING
- 19 38 17 Draining and filling in coolant
- 19 40 19 Removing and installing coolant expansion tank
- 19 50 19 Removing and installing coolant pump (engine installed)
- 19 58 19 Removing and installing coolant regulator
- 19 62 19 Removing and installing coolant hose at front left (Y-type coolant distributor)

GROUP 2 FUEL, EXHAUST, POWER SUPPLY, DME
20 FUEL SUPPLY, CONTROL
- Precautionary measures when working on fuel system
- 20 02 01 Checking fuel pressure
- 20 10 19 Removing and installing fuel tank
- 20 15 01 Calibrating fuel level sensor system
- 20 39 19 Removing and installing fuel return line
- 20 60 55 Replacing fuel filter
- 20 66 01 Checking quantity delivered by fuel pump
- 20 68 19 Removing and installing fuel cooler
21 EXHAUST SYSTEM, TURBOCHARGING
- 21 10 19 Removing and installing air guide for charge air cooling
- 21 30 19 Removing and installing turbocharger
- 21 43 19 Removing and installing the charge air cooler
- 21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger
- 21 67 19 Removing and installing bypass flap control box on the turbocharger - Engine installed
- 21 75 20 Removing and installing oil container for exhaust turbocharger - Engine installed
- 21 80 19 Removing and installing oil pump for turbocharger
- 21 90 19 Removing and installing pressure sensor
24 FUEL SYSTEM, ELECTRONIC INJECTION
- 24 00 33 Completing the vacuum connections
- 24 25 19 Removing and installing air cleaner
- 24 40 20 Removing and installing injection valves - Engine removed
- 24 40 20 Removing and installing injection valves - Engine installed
- 24 42 19 Removing and installing throttle body - Engine installed
- 24 46 01 Testing the intake distributor (leak test)
- 24 46 20 Removing and installing intake distributor   Engine removed
- 24 46 37 Disassembling and assembling intake distributor
- 24 69 19 Precautionary measures when handling oxygen sensors
- 24 69 19 Removing and installing oxygen sensors in front of catalytic converter
- 24 70 19 Removing and installing DME control module
- 24 73 19 Removing and installing oxygen sensors behind catalytic converter
26 EXHAUST SYSTEM
- 26 01 05 Exhaust system leak test
- 26 33 19 Removing and installing rear mufflers
- 26 65 19 Removing and installing secondary air pump
27 STARTER, POWERSUPPLY, CRUISE CONTROL
- 27 06 Battery
- 27 06 Electrical emergency release, front cover
- 27 22 19 Removing and installing three-phase generator
- 27 27 19 Removing and installing bracket for generator
- 27 60 19 Removing and installing starter (manual transmission)
- 27 60 19 Removing and installing starter (automatic transmission)
28 IGNITION SYSTEM
- 28 39 19 Removing and installing hall sender - Engine installed
- 28 70 55 Replacing the spark plugs
- 28 72 20 Removing and installing knock sensor   Engine removed

GROUP 3 TRANSMISSION
3 TECHNICAL DATA
- 3 Technical data - Manual
- 3 Technical data - Tiptronic
- 3 Technical Data - GT2
MANUAL TRANSMISSION
- 30 CLUTCH, ACTUATION
- 34 ACTUATION, HOUSING
- 35 GEARS, SHAFTS
- 39 FINAL DRIVE, DIFFERENTIAL
AUTOMATIC TRANSMISSION
- 32 TORQUE CONVERTER
- 37 ACTUATION, HOUSING
- 38 GEARS, CONTROL
- 39 FINAL DRIVE, DIFFERENTIAL

GROUP 4 RUNNING GEAR
4 NOTES
- 4 Removing transport lock (spring strut locking devices)   Turbo and GT2
- 4 Lifting the vehicle
- 4 Tests/notes for all-wheel drive
- 4 Switching off PSM
- GT2 SPECIAL NOTES
40 FRONT SUSPENSION
- 40 Tightening torques for front axle
- 40 Disassembling and assembling front spring strut
- 40 Disassembling and assembling front spring strut   GT2
- 40 09 Front-axle cross member - permissible combinations
- 40 41 19 Removing and installing the front drive shaft
- 40 85 19 Removing and installing front spring strut
42 REAR SUSPENSION
- 42 Tightening torques for rear axle
- 42 Disassembling and assembling rear spring strut - GT2
- 42 21 19 Removing and installing rear drive shaft (manual transmission)
- 42 21 19 Removing and installing rear drive shaft (Tiptronic transmission)
- 42 58 19 Removing and installing rear-wheel bearing
- 42 71 Disassembling and assembling rear spring strut - Turbo
- 42 71 19 Removing and installing rear spring strut
44 WHEELS, TYRES, ALIGNMENT
- 44 Conversion table for wheel alignment values
- 44 Adjusting values for suspension alignment - Turbo and GT2
- 44 Alignment card - Turbo
- 44 Suspension alignment, complete
- 44 Wheel rims and tires
- 44 Tyres
- 44 Checking disc wheels
- 44 Tyre mounting
- 44 Balancing/optimising wheels
- 44 05 19 Removing and installing the wheel - Turbo and GT2
- 44 27 Instructions for collapsible wheel/spare wheel - Turbo with PCCB
- 44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)
- GT2 SPECIAL NOTES
45 ABS/PSM
- 45 ABS/PSM 5.7 check with Porsche System Tester 2
- 45 11 19 Removing and installing front speed sensors
- 45 15 19 Removing and installing rear speed sensors
- 45 30 19 Removing and installing hydraulic unit
- 45 46 19 Removing and installing front ABS lead
- 45 46 19 Removing and installing front ABS lead (GT2)
- 45 46 19 Removing and installing rear ABS lead (Turbo & GT2)
- 45 59 19 Removing and installing rate-of-turn sensor
- 45 59 31 Conversion of rate-of-turn sensor
- 45 60 Steering angle sensor
- 45 60 19 Removing and installing steering angle sensor
- 45 64 19 Remove and install booster pump for PSM
46 BRAKES MECHANICAL
- 46 Checking brake light switch setting
- 46 Tightening torques for mechanical brake
- 46 Technical data/Brake wear limit - Turbo
- 46 Checking the thickness of the disc brake pads - Turbo and GT2
- 46 Technical data/Brake wear limit - Turbo with PCCB
- 46 11 15 Adjusting the brake pushrod
- 46 36 20 Removing and installing the front disc brake pads
- 46 38 20 Removing and installing the rear disc brake pads
- 46 50 02 Checking front gray cast iron brake discs (wear assessment)
- 46 50 02 Checking front PCCB brake discs (wear assessment)
- 46 50 04 Measuring front brake discs
- 46 50 19Removing and installing the front brake disc
- 46 53 02 Checking rear gray cast iron brake discs (wear assessment)
- 46 53 02 Checking rear PCCB brake discs (wear assessment)
- 46 53 04 Measuring rear brake discs
- 46 53 19 Removing and installing the rear brake disc
- 46 83 16 Adjusting the parking brake shoes
- 46 83 19 Removing and installing the parking brake shoes
- GT2 SPECIAL SECTION
47 BRAKES HYDRAULIC
- 47 Tightening torques for brake hydraulics
- 47 01 07 Bleeding brakes (vehicle with PSM)
- 47 01 07 Bleeding brake - GT2
- 47 08 55 Changing brake fluid
- 47 15 19 Removing and installing brake master cylinder
- 47 70 19 Removing and installing brake booster
STEERING
- 48 Tightening torques for steering
- 48 Test and assembly work on power steering
- 48 Assessment of steering gear after accident damage
- 48 10 19 Removing and installing steering wheel
- 48 90 19 Removing and installing steering gear

GROUP 5 BODY
5 TECHNICAL NOTES
- Seam seals
- 5 Plug location plan
- 5 Work sequence for accident repair
- 5 Work sequence for determining scope of damaged vehicles involved in an accident
- 5 Corrosion protection measures during repairs
- 5 Vehicle identification number
- 5 Change identification data plate
- 5 Undersealing
- 5 Water drainage plan
- 5 Water drainage plan   Cabriolet
- 5 Check dimensions for body repair - Cabriolet structure
- 5 Safety notes
- 5 General information and quality notes
- 5 Tools and metalworking tools for body repairs
- 5 Diagram - keys to symbols for welding work
- 5 Check dimensions for body repair
- 5 Diagram - body gap dimensions
- 5 Body parts of high-strength steel
50 FRONT
- 50 10 55 Replacing closing panel
- 50 14 55 Replacing front wall
- 50 30 19 Removing and installing air guide   GT2
- 50 55 19 Removing and installing the wing
- 50 56 19 Removing and installing wheel housing liners, front
- 50 74 55 Replacing wheel housing
- 50 74 56 Replacing wheel housings and side members (sectional repair)
- 50 79 55 Replacing front inner side member
- 50 93 30 Cleaning front water drains on Coupé and Cabriolet
51 CENTRE, ROOF, FRAME
- 51 03 55 Replacing roof
- 51 21 55 Replacing rear centre panel
- 51 45 55 Replacing lower side member
- 51 45 55 Replacing lower side member - Cabriolet
- 51 63 19 Removing and installing deformation element
- 51 87 55 Replacing seat cross member
- 51 90 19 Removing and installing underside panel
53 REAR
- 53 05 55 Replacing rear closing panel
- 53 05 55 Replacing rear closing panel - Carrera 4S
- 53 55 55 Replacing side section
- 53 69 19 Removing and installing wheel housing liners, rear
- 53 69 19 Removing and installing rear wheel housing liners - Carrera 4S
- 55 90 19 Removing and installing rear lid - Carrera 4S
- 55 90 37 Disassembling and assembling rear lid   Carrera 4S
- 53 93 30 Cleaning rear water drains on Coupe and Cabriolet
55 LIDS
- 55 10 37 Disassembling and assembling release for front lid
- 55 17 19 Removing and installing front lower part of lid lock
- 55 22 19 Removing and installing front lid
- 55 22 37 Disassembling and assembling front lid
- 55 25 19 Removing and installing front lid hinge
- 55 37 19 Removing and installing filler flap
- 55 57 37 Disassembling and assembling release for rear lid
- 55 62 19 Removing and installing front emergency release - as of MY 2003
- 55 84 19 Removing and installing engine cover release
- 55 86 19 Removing and installing lower part of lid lock
- 55 90 19 Removing and installing rear lid
- 55 90 19 Removing and installing rear lid - GT2
- 55 90 37 Disassembling and assembling rear lid
- 55 90 37 Disassembling and assembling rear lid   GT2
- 55 91 19 Removing and installing lid hinge
- 55 91 19 Removing and installing rear lid hinges - Carrera 4S
57 DOORS,CENTRAL LOCKING
- 57 11 37 Disassembling and assembling door handle
- 57 37 19 Removing and installing inner door release (bowden cable) for door lock
- 57 45 19 Removing and installing door handle
- 57 51 16 Setting the door
- 57 51 19 Removing and installing door
- 57 51 37 Disassembling and assembling door
- 57 51 37 Disassembling and assembling door

GROUP 6 EXTERIOR EQUIPMENT
6 TECHNICAL NOTES
- 6 Safety notes
- 6 General information on installing and removing car windows
- 6 Overview of exterior colours
- 6 Processing of Porsche 2-component window bonding agents
60 SLIDING ROOF
- 60 14 15 Re-teaching the lifting/sliding roof drive
- 60 14 19 Removing and installing lifting/sliding roof drive
- 60 28 19 Removing and installing frame for sliding roof
- 60 28 37 Disassembling and assembling frame for sliding roof
- 60 40 19 Removing and installing sliding roof panel
61 CONVERTIBLE TOP, HARDTOP
63 BUMPERS
- 63 10 19 Removing and installing front bumper
- 63 15 19 Removing and installing front spoiler
- 63 15 19 Removing and installing front spoiler   GT2
- 63 15 37 Disassembling and assembling front spoiler
- 63 15 37 Disassembling and assembling front spoiler   GT2
- 63 50 19 Removing and installing rear bumper
- 63 55 19 Removing and installing rear spoiler
- 63 55 37 Disassembling and assembling rear spoiler
64 GLASS, WINDOW CONTROL
- 64 12 19 Removing and installing windscreen
- 64 54 19 Removing and installing power window motor
- 64 71 19 Removing and installing rear power windows (Cabriolet)
- 64 75 19 Removing and installing side window
- 64 75 19 Removing and installing rear side window (Cabriolet)
- 64 76 19 Removing and installing side window seal
- 64 76 19 Removing and installing rear side window seal (Cabriolet)
- 64 86 01 Checking function of heating for rear window
- 64 86 19 Removing and installing rear window
- 64 86 19 Removing and installing rear glass window of Cabriolet
- 64 86 19 Removing and installing rear window (hardtop)
66 EXTERIOR EQUIPMENT
- 66 13 19 Removing and installing air inlet
- 66 31 19 Removing and installing sill cover.
- 66 36 19 Removing and installing roof joint strip
- 66 58 19 Removing and installing rear spoiler
- 66 58 19 Removing and installing rear spoiler   GT2
- 66 72 Assignment of spoiler drive, relays and instrument cluster
- 66 72 37 Disassembling and assembling pump unit
- 66 78 01 Checking function of heating for mirror glass
- 66 85 19 Removing and installing micro switches for rear spoiler
- 66 89 19 Removing and installing rearview mirror
- 66 89 37 Disassembling and assembling the rearview mirror
68 INTERIOR EQUIPMENT
- 68 05 19 Removing and installing inner sill (driver's side)
- 68 05 19 Removing and installing inner sill (passenger's side)
- 68 11 19 Removing and installing glove compartment lock
- 68 12 19 Removing and installing lid for glove compartment
- 68 15 19 Removing and installing glove compartment
- 68 17 19 Removing and installing center console (front section)
- 68 17 19 Removing and installing center console
- 68 17 37 Disassembling and assembling centre console
- 68 23 19 Removing and installing sun visors
- 68 23 37 Disassembling and assembling sun visor
- 68 27 13 Bonding on the interior rearview mirror
- 68 27 19 Removing and installing the interior rearview mirror
- 68 30 19 Removing and installing cup holder
69 PASSENGER PROTECTION
- 69 Safety regulations for vehicles with airbag and belt tensioner
- 69 11 01 Checking seat belts
- 69 11 19 Removing and installing front three-point belt
- 69 11 19 Removing and installing front three-point belt - Cabriolet
- 69 12 19 Removing and installing rear three-point belt
- 69 12 19 Removing and installing rear three-point belt - Cabriolet
- 69 13 19 Removing and installing belt tensioner - as of MY 2002
- 69 36 19 Removing and installing adjustment fitting (seat belt height adjuster)
- 69 51 19 Removing and installing sensor for side airbag
- 69 53 19 Removing and installing the triggering unit for the airbag
- 69 54 19 Removing and installing the contact unit
- 69 58 19 Removing and installing the driver's airbag unit
- 69 59 Disposal of airbag and belt tensioner units
- 69 59 19 Removing and installing the passenger's airbag unit
- 69 63 19 Removing and installing the side airbag unit
- 69 72 19 Removing and installing roll-over bar
- 69 72 19 Removing and installing roll-over bar - GT2
- 69 74 19 Removing and installing control module for roll-over protection system
- 69 77 19 Removing and installing frame for roll-over protection system

GROUP 7 INTERIOR EQUIPMENT
7 TECHNICAL NOTES
- 7 Special notes for the care of soft-look paint surfaces
70 LININGS, INSULATION
- 70 05 19 Removing and installing front luggage compartment trim
- 70 18 19 Removing and installing the instrument panel and instrument panel bracket
- 70 18 19 Removing and installing the instrument panel and instrument panel bracket - as of model year 2003
- 70 18 37 Disassembling and assembling the instrument panel
- 70 22 19 Removing and installing cowl panel cover
- 70 41 19 Removing and installing floor covering
- 70 57 19 Removing and installing trim of A, B and C-pillars
- 70 57 19 Removing and installing A-pillar trim   Cabriolet
- 70 59 19 Removing and installing door trim panel
- 70 65 19 Removing and installing oddments compartment lid
- 70 75 19 Removing and installing side-panel lining
- 70 75 19 Removing and installing side-panel lining   Cabriolet
- 70 84 19 Removing and installing roof lining
- 70 84 19 Removing and installing Cabriolet roof lining
72 SEAT, FRAMES
- 72 01 19 Removing and installing front seat
- 72 01 19 Removing and installing bucket seat   GT2 - as of MY 2001
- 72 21 19 Removing and installing cushion carrier
- 72 36 19 Removing and installing motor for the lumbar support
- 72 86 19 Removing and installing switch for seat adjustment
- 72 87 19 Removing and installing electric motor for the seat adjustment
- 72 88 19 Removing and installing electric motor for the front seat height adjustment
- 72 89 19 Removing and installing electric motor for the backrest adjustment
- 72 92 19 Removing and installing electric motor for the rear seat height adjustment
74 SEAT UPHOLSTERIES, COVER
- 74 13 55 Replacing cover for front seat cushion
- 74 19 19 Removing and installing centre backrest strip
- 74 19 55 Replacing covering for backrest centre strip
- 74 27 19 Removing and installing control module for seat heating

GROUP 8 AIR CONDITIONING
8 TECHNICAL DATA
- 8 Air conditioning
80 HEATING
- 80 23 19 Removing and installing heat exchanger
85 VENTILATION
- 85 30 19 Removing and installing heater/fresh-air blower motor
87 AIR CONDITIONING
- 87 Nominal values for pressures and temperatures
- 87 01 19 Removing and installing the heating/air-conditioning unit
- 87 02 19 Removing and installing the heating/air-conditioning control
- 87 03 Safety regulations when handling refrigerant R134a

AND MORE....