Porsche 996 1997 to 2001 - Service Manual - Wiring Diagram - Parts Catalogue

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PORSCHE 996.1 (1997-2001) -  WORKSHOP MANUAL

- English Service Manual, Wiring Diagram and Spare Parts Catalogue to vehicles Porsche 996 1997 to 2001.

CONTENTS:

WORKSHOP MANUAL 1999 (3153 pages)

GROUP 0 GENERAL
996 WORKSHOP
Entire Vehicle - General
General
Technical Data
Lifting the vehicle
Power unit
Transmission
Running Gear
Body
Electrics
Power supply - general (work instructions after disconnecting the battery)
Technical data - GT3
Sales Check
Deactivating the transport lock
Activating the parking aid
Fitting front lip - GT3
Fitting roll-over bar (cage) - GT3
Fitting six-point seat belt - GT3
Removing transport lock (spring strut locking devices) - Carrera and GT3
Maintenance
Maintenance schedule
Maintenance
Maintenance - GT3
Diagnosis, Part 1 (up to Repair Group 45)
General
Installation location, diagnositc socket
Operating instructions, Porsche System Tester 2
DME
System M 11
Programming DME control module
Tiptronic
System G 50
Anti-lock brake system diagnosis
System PSM 5.3 and ABS/TC 5.3
PSM
System PSM 04
System PSM 05XX
Diagnosis, Part 2 (as of Repair Group 61)
Convertible-top diagnosis
System B 3.2
Airbag Diagnosis
System B 04
Airbag Diagnosis
System B 05
Roll-over protection system diagnosis
System UEB11
Seat memory diagnosis
System S 01
Heating diagnosis
System H 01
Alarm system diagnosis
System I 32
Instrument cluster diagnosis
System K 0X
PCM diagnosis
System N 01
ParkAssistent diagnosis
System P 01
Headlight beam adjustment diagnosis
System HBA 01
Engine, Part 1 (up to Repair Group 13)
Engine
Tightening torques for engines M96/01
3.4 l engine performance kit / X51
Engine - Crankcase, suspension
Removing and installing engine (vehicle with Tiptronic transmission)
Disassembling and assembling engine
Disassembling and assembling crankcase halves
Removing and installing engine - GT3
Disassembling and assembling engine - GT3
Disassembling and assembling crankcase - GT3
Removing cylinder - GT3
Engine - Crankshaft, pistons
Removing and installing drive belt
Removing and installing deflection rollers for drive belt
Removing and installing tensioning roller for drive belt
Removing and installing belt tensioner
Disassembling and assembling belt tensioner
Disassembling and assembling bearing housing with crankshaft
Removing and installing crankshaft sealing ring
Removing and installing crankshaft sealing ring - engine installed
Removing and installing pistons
Removing and installing drive belt - GT3
Disassembling and assembling belt tensioner - GT3
Disassembling and assembling crankshaft - GT3
Removing and installing pistons - GT3
Installing pistons - GT3
Installing piston pin with piston-pin circlip - GT3
Engine, Part 2 (as of Repair Group 15)
Engine - Cylinder head, valve drive
Diasassembling and assembling cylinder head - Inner parts
Removing and installing valve springs
Removing and installing valve stem seal
Installing cylinder head
Disassembling and assembling cylinder head - Camshaft drive
Removing and installing camshafts
Installing camshafts
Adjusting timing - cylinder bank 1 - 3
Adjusting timing - cylinder bank 4 - 6
Removing and installing valve tappets - engine removed
Removing valve tappets of cylinder bank 1 - 3
Installing valve tappets - Cylinder bank 1 - 3
Removing valve tappets of cylinder bank 4 - 6
Installing valve tappets - Cylinder bank 4 - 6
Completing camshafts
Sealing cover for camshaft housing (cylinder head cover)
Checking guide for valve tappets
Removing and installing oil protection tube (engine installed)
Removing and installing valve tappets (engine installed)
Removing valve tappets of the cylinder bank 1 - 3 (engine installed)
Installing valve tappets of the cylinder bank 1 - 3 (engine installed)
Adjusting timing of cylinder bank 1 - 3 (engine installed)
Removing valve tappets of the cylinder bank 4 - 6 (engine installed)
Installing valve tappets of the cylinder bank 4 - 6 (engine installed)
Adjusting timing of cylinder bank 4 - 6 (engine installed)
Removing and installing closure cap for camshaft bore (engine installed)
Checking camshaft (timing) (engine installed)
Removing and installing sealing ring for intermidiate shaft (engine installed)
Removing and installing solenoid hydraulic valve
Reworking cylinder head
Removing and installing camshaft housing - GT3
Removing camshaft housing - GT3
Installing camshaft housing - GT3
Removing and installing cylinder head - GT3
Removing cylinder head - GT3
Installing cylinder head - GT3
Disassembling and assembling intermediate shaft - GT3
Engine - Lubrication
Removing and installing air/oil separator
Removing and installing oil pump with coolant guide housing
Removing and installing oil extraction pumps
Removing and installing oil extraction pump (engine installed)
Removing and installing oil-water heat exhanger - Engine installed
Removing and installing oil pan (engine installed)
Removing and installing oil filler neck
Removing oil extraction pump - GT3
Disassembling and assembling oil extraction pump -GT3
Installing oil extraction pump - GT3
Removing and installing oil cooler - GT3
Removing and installing bracket for oil cooler - GT3
Removing bracket for oil cooler - GT3
Installing bracket for oil cooler - GT3
Removing and Installing oil temperature sensor - GT3
Engine - Cooling
Draining and topping up with coolant
Removing and installing coolant regulator
Removing and installing cooling pump
Coolant warning light in instrument cluster
Removing coolant pump (engine installed) - GT3
Installing coolant pump (engine installed) - GT3
Removing and installing coolant regulator - GT3
Removing and installing housing for coolant guide - GT3
Removing housing for coolant guide - GT3
Installing housing for coolant guide - GT3
Removing and installing temperature sensor for coolant - GT3
Oil/coolant mixing
Checking the cooling system for leaks
Removing and installing coolant hoses - GT3
Removing coolant hoses
Installing coolant hoses
Tightening torques
Fuel, exhaust, engine electronics
Fuel supply, control
Checking fuel pressure
Checking quantity delivered by fuel pump
Removing and installing fuel pump
Calibrating fuel level sensor system
Removing and installing fuel filler neck
Removing and installing fuel tank
Calibrating fuel level sensor system - GT3
Fuel system, electronic injection
Disassembling and assembling fuel ring pipe
Disassembling and assembling intake distributor
Programming DME control module
Disassembling and assembling intake distributor - GT3
Exhaust system
Removing and installing exhaust system - GT3
Removing exhaust system - GT3
Installing exhaust system - GT3
Removing and installing catalytic converters (engine installed)
Starter, power supply, cruise control
Removing and installing starter
Removing and installing three-phase generator
Removing and installing cruise control actuator
Removing and installing starter - GT3
Removing and installing three-phase generator - GT3
Removing and installing bracket for oil generator - GT3
Work instructions after disconnecting the battery
Ignition system
Removing and installing ignition switch
Removing spark plugs - GT3
Installing spark plugs - GT3
Transmission, manual transmission
911 Carrera (996)
Transmission
Technical data
6-Speed manual transmission G96/30
Manual transmission tightening torques
Front wheel drive Z96.00
Front-axle drive tightening torques
Clutch, control
Removing and installing clutch
Disassembling and assembling clutch
Bleeding the clutch system
Removing and installing clutch slave cylinder
Removing and installing clutch pedal
Clutch boost spring: allocation and grease specification
Removing and installing release bearing - GT3
Manual transmission - Actuation, ass. housing
Changing transmission oil
Removing and installing transmission G 96
Removing and installing the shift console
Removing and installing shift and selector cables
Removing and installing closure cap for selector force mechanism
Manual transmission - Gears, shafts, int. gearsh.
Removing and installing sealing ring for input shaft
Final drive - Differential, differential lock
Removing and installing cover for final drive
Removing and installing sealing ring for halfshaft flange of limited-slip differential
Removing and installing sealing ring for halfshaft flange of differential
911 Carrera 4 (996)
Power Transmission
Technical data
Final drive - Differential, differential lock
Removing and installing front final drive
Removing and installing cardan shaft
Removing and installing sealing ring for cardan flange
Removing and installing viscous clutch
Checking function of installed viscous clutch
Removing and installing sealing ring for flanged shaft
Removing and installing cover for final drive
Changing oil for final drive
Removing and installing support for final drive
Repair
911 Carrera 4 (996)
Power Transmission
Technical data
Final drive - Differential, differential lock
Removing and installing front final drive
Removing and installing cardan shaft
Removing and installing sealing ring for cardan flange
Removing and installing viscous clutch
Checking function of installed viscous clutch
Removing and installing sealing ring for flanged shaft
Removing and installing cover for final drive
Changing oil for final drive
Removing and installing support for final drive
911 Carrera (996) GT3
Power Transmsiion
Technical data (GT3)
Manual transmission - Actuation, hausing
Removing and installing the transmission
Removing and installing closure cap for selector force mechanism
Disassembling and assembling transmission
Disassembling and assembling front transmission cover
Disassembling and assembling gear housing
Disassembling and assembling transmission housing
Manual transmission - Gears, shafts, int. gearsh.
Removing and installing sealing ring for input shaft
Disassembling and assembling input shaft
Removing and installing pinion shaft
Removing pinion shaft bearing
Final drive - Differential, differential lock
Disassembling and assembling GKN differntial lock
Removing and installing differential lock
adjusting drive set
Transmission, automatic transmission
911 Carrera (996)
Transmission
Technical data
5-speed Tiptronic transmission A96/30
Tightening torques for Tiptronic transmission
Front wheel drive Z 96.00
Front-axle drive tightening torques
Automatic clutch - Torque converter
Removing and installing torque converter
Removing and installing torque-converter sealing ring
Automatic transmission - Auction, ass. housing
Removing and installing selector knob
Adjusting selector lever cable
Removing and installing selector support
Removing and installing selector lever cable
Removing and installing shiftlock solenoid
Checking and topping up ATF fluid
Replacing ATF fluid
Removing and installing ATF filter
Removing and installing inner oil tube
Removing and installing multi-function switch
Removing and installing sealing ring for selector shaft
Removing and installing tiptronic transmission A 96/00
Automatic transmission - Gears, control
Removing and installing hydraulic control unit
Removing and installing wiring harness
Removing and installing ATF cooler
Removing and installing sensor for transmission input speed
Removing and installing transmission speed sensor
Removing and installing pressure regulator
Final drive, differential, differential lock
Changing and checking transmission oil in final drive
Removing and installing differential
Removing and installing sealing ring for short flanged shaft
Removing and installing long flanged shaft
Removing and installing sealing ring for long flanged shaft
Removing and installing final drive/transmission housing double sealing ring
911 Carrera 4 (996)
Transmission
Technical data
Final drive - Differential, differential lock
Removing and installing sealing ring for cardan flange
Running gear
911 Carrera (996)
Running gear
Running gear - Overview: 911 Carrera (996)
Stabaliser allocation
Removing spring strut locking devices - Carrera and GT3
Running gear, general - GT3
Notes on repair instructions - GT3
Tests / notes - GT3
Front wheel suspension, drive shafts
Tightening torques for front axle
Removing and installing front spring strut
Removing and installing front spring strut - GT3
Disassembling and assembling front spring strut
Disassembling and assembling front spring strut - GT3
Removing and installing front wheel bearing
Installing caster eccentric
Rear wheel suspension, drive shafts
Tightening torques for rear axle
Removing and installing rear spring strut
Disassembling and assembling rear spring strut
Disassembling and assembling rear spring strut - GT3
Removing and installing rear wheel bearing
Removing and installing rear tie rod (toe control arm)
Removing and installing rear wheel bearing housing (wheel carrier)
Removing and installing drive shaft (manual transmission)
Removing and installing drive shaft (Tiptronic transmission)
Wheels, tires, suspension alignment
Wheels and tyres (tyre pressure / mounting wheel on vehicle)
Adjustment values for suspension alignment
Alignment cards for Carrera (996) and GT3
Complete suspension alignment
Suspension alignment GT3
General tyre mounting instructions
Checking rims
Identifying size for 18-inch Turbo wheels (Technologie wheels)
Tyre failure/tyre sealant - GT3
Tyre mounting for critical wheels/tyre pairs
Anti-Lock Brake System (ABS)
Important information on ABS 5.3 and ABS/TC 5.3
ABS 5.3 system description
ABS/TC 5.3 system description
Component arrangement (ABS and ABS/TC)
Function of individual components
ABS test with Porsche System Tester 2
Removing and installing front speed sensor
Removing and installing rear speed sensor
Brakes - Brake mechanics
Tightening torques for brake mechanics
Technical data (brake disc wear limit)
Technical data (brake disc wear limit) - GT3
measuring brake pad thickness
Removing and installing front disc brake pads
Removing and installing rear disc brake pads
Adjusting brake push rod
Checking brake-light switch setting
Adjusting parking brake shoes
Removing and installing front brake disc
Removing and installing rear brake disc
Removing and installing parking brake shoes
Measuring lateral runout of front brake discs
Measuring lateral runout of rear brake discs
Removing and installing brake pedal
Brakes - Hydraulics, regulator, booster
Tightening torques for brake hydraulics
Bleeding brakes
Changing brake fluid
Steering
Tightening torques for steering
Test and assembly work on power steering
Removing and installing steering wheel (airbag)
Replacing steering system after accident damage
Removing and installing steering gear
Plug couplings for steering hydraulics
Removing and installing lock barrel
Replacing steering lock
Removing and installing hydraulic pump
911 Carrera 4 (996)
Running gear
Overview of 911 Carrera 4 running gear
Notes on repair instructions
Tests/notes for all-wheel drive
Stabalizer allocation
Anti-Lock Brake System (ABS)
Overview of PSM references
Calibrating steering angle sensor
PSM component arrangement
Brakes - Brake mechanics
Technical data (brake disc wear dimension)
Brakes - Hydraulics, regulator, booster
Bleeding brakes (vehicle with PSM)
Changing brake fluid (vehicle with PSM)
Body
Body - general
Safety instructions for body repair
Safety instructions for disassembling components
Safety instructions for air conditioning
Safety instructions for fuel tank
Safety instructions for for paintwork, glass, upholstery, linings
Safety instructions for airbag system
Safety instructions for door
Safety instructions for sliding roof
Safety instructions for rear spoiler
Safety instructions for rear window
Safety instructions for windscreen
Safety instructions for heat shields
Safety instructions for cabriolet convertible top
Safety instructions for roll-over protection system
Safety instructions for plug location plan (body)
Safety instructions for water drains (body)
Safety instructions for welding
Safety instructions for Teromix-6700 two-component adhesive
Safety instructions for hydraulic system
Safety instructions for hardtop
Safety instructions for belt strap holder
General information and quality notes
Electronic control modules
- Protection against overvoltage
- Replacing control modules
Tools and metalworking tools for body repairs
Straightening systems

Metalworking tools
- Electrical equipment
- Mechanical equipment
- Compressed-air equipment
- Welding equipment
Check dimensions for body repair
Floor assembly control dimensions for the 996 Carrera model up to model year 2000
Floor assembly control dimensions for the the GT3 model
Floor assembly control dimensions for the 996 Carrera model from model year 2001
Body parts of high-strength steel
Water drainage plan
Water drainage plan - Cabriolet
Check dimensions for body repair - Cabriolet structure
Plug location plan
Diagram - body gap dimensions
Diagram - keys to symbols for welding work
Resistance spot welding
Inert-gas arc welding (MAG procedure)
Gas welding
Seam seals
Accessories
- Front lid
- Doors
- Sliding roof panel
- Rear lid
Work sequence for accident repair
Body front
Removing and installing wheel housing liner
Removing and installing the wing
Replacing closing panel
Cutting out closing panel and front floor panel
Preparing closing panel and front floor panel for installation and fitting
Welding in closing panel and front floor panel
Tools and materials
Replacing wheel housings and side members (sectional repair)
Cutting out wheel housings and side member
Preparing wheel housings and side members for installation and fitting
Welding in wheel housing and side members
Replacing wheel housings
Removing wheel housing, lower shell and outer side member from the body
Preparing wheel housing, lower shell and outer side member for installation and fitting
Welding wheel housing, lower shell and outer side members into the body
Tools and materials
Cleaning front water drains on Coupe and Cabriolet
Replacing front wall
Cutting out front wall
Preparing front wall for installation and fitting
Welding in front wall
Tools and materials
Replacing front wall - Carrera 4 / GT 3
Cutting out front wall
Preparing front wall for installation and fitting
Welding in front wall
Tools and materials
Body centre, roof, frame
Removing and installing underbody cover
Repalcing rear centre panel
Removing and installing deformation element
Replacing roof
Disconnecting roof
Preparation of roof for installation and fitting
Welding in roof
Tools and materials
Replacing lower side member
Cutting out lower side member
Preparation for installation of lower side member and fitting
Welding in lower side member
Tools and materials
Replacing lower side member - Cabriolet
Cutting out lower side member
Preparation for installation of lower side member and fitting
Welding lower side memeber
Tools and materials
Replacing seat cross member
Cutting out seat cross member
Preparation of seat cross member for installation and fitting
Welding in seat cross member
Tools and materials
Body rear
Removing and installing wheel housing liner
Cleaning rear water drains on Coupe and Cabriolet
Replacing side section
Replacing side section - Cabriolet
Replacing rear closing panel

AND  MORE....