Sie sind auf Seite 1von 13

I ndex

1

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

A

Abbreviations and acronyms

EWD-6

ABS (antilock brakes) see Antilock brakes (ABS) see also Brakes

A/C A/C and heater unit 80-10, 87-2 belt 03-27 blower 87-4 climate control panel 80-3, 87-1 resistor 87-10 capacities 87-4 compressor 87-5 components 87-4 condenser 87-7 condenser fan 87-9 condenser fan ballast resistor 87-10 control panel 87-1 evaporator 87-2, 87-12 expansion valve 87-12 fresh air flap electric motor 80-2 housing 87-2 receiver/drier 87-11 refrigerant and refrigerant oil 87-4 vent flaps 80-10, 87-2 see also Heater

Accelerator linkage see also Throttle cable

Air-conditioning see also A/C see also Heater

Air filter

replacing 03-32

Airbag system (SRS)

69-8

components 69-8 contact spring 69-10 control unit 69-8, 69-9

driver airbag 69-8, 69-9, 69-10 contact spring 69-8, 69-11 fault codes 69-8 inspecting 03-45 passenger airbag 69-8, 69-9, 69-12 warning light 90-2, 90-4

Air flow flap 80-10, 87-2

Air flow sensor

24-20

Alarm 96-5, 96-10 see also Anti-theft system

Alignment

44-2

front 44-2 front ride height 44-3 rear 44-4 specifications 44-5

Alternator (generator) 27-13, 27-14 alternator and regulator, checking

27-13

ATF (automatic transmission fluid) 03-25, 37-4, 37-5

ATF cooler

37-8

Automatic transmission

37-1

applications 02-7, 37-1

coding control unit 37-13 control unit diagnosis

1995

from 1996 OBD-50

OBD-38

control unit pinout

1995 OBD-37

from 1996 OBD-49 diagnostics 37-13 electrical components 37-3 fluid 03-24, 37-4, 37-5 cooler 37-8 fluid and filter change 37-5 gear position switch 37-10 gear ratios 37-3 installing 10a-17, 37-8 oil cooler assembly 37-8 removing 10a-2, 37-8 separating from engine 10a-20 service 03-24, 37-4 shift knob 37-12 shift lever cable 37-9, 37-10 tiptronic basics 37-2 torque converter 32-1 transverse acceleration sensor 37-3

Axle joint 03-41, 40-17, 42-15

B

Badges see also Emblems

Back-up light switch manual transmission 34-8, 97-35

Battery 27-2, 97-2, 97-8 charging 27-7 disconnection notes 03-47 grounding points 27-4 jump starting 03-3 load voltage test 27-6 maintenance 03-3, 03-46, 27-6 open circuit-voltage test 27-5 service 03-46 static current draw test 27-7 testing 27-5 troubleshooting 27-3

charging system 27-10 noisy alternator 27-14 replacing 27-14 troubleshooting 27-3, 27-12 see also Charging system
charging system 27-10
noisy alternator 27-14
replacing 27-14
troubleshooting 27-3, 27-12
see also Charging system

Anti-theft system alarm 96-5, 96-10 alarm LED 96-11 central locking 96-8 central locking switch 57-5, 96-10 components 96-5 door lock emergency operation 96-9 electronic immobilizer 96-8 control module 96-12 passenger compartment monitor

96-11

remote key 96-6 battery specifications 96-7 programming 96-7 replacing battery 96-7 vehicle security 96-5

Antilock brakes (ABS) ABS 45-2, 45-3 ABS 5 / ABD 45-4, 45-5, 45-8 control unit 45-10 component descriptions 45-6 hydraulic unit 45-9 system identification 45-3 wheel speed sensors 45-8 see also Brakes

Ash tray removing and installing 70-7

unit 45-9 system identification 45-3 wheel speed sensors 45-8 see also Brakes Ash tray removing and

2

I ndex

Bearing, wheel

front 40-14

rear 42-12

Belt, drive 03-26, 13a-1 A/C compressor 03-26 alternator 03-28, 27-13 engine cooling fan 03-30 power steering 48-13

Blade, wiper

92-2

Blower see also A/C

Body 02-12, 02-13, 02-14, 03-44 Cabriolet 002-13 Coupe 02-12 door check strap, lubricating 03-47 exterior 03-47 front lid safety hook, checking 03-48 maintenance 03-44 Targa 02-14 underbody, checking 03-40

Brake booster see Hydraulic brake booster see also Vacuum brake booster

Brake fluid 03-22, 03-23, 47-3, 47-4

Brake light switch 45-3, 45-4, 45-5, 94-4

Brake master cylinder with hydraulic booster 47-12 with vacuum booster 47-10

Brake pads checking 03-39 removing and installing 46-2

Brake rotor checking 03-39 removing and installing 46-4

Brakes

02-11

applications 02-11 bleeding with hydraulic booster 47-4 with vacuum booster 47-8 booster 47-4, 47-6, 47-13, 47-14 caliper 47-18 hydraulic brake booster circuit, depressurizing 47-6 hydraulic brake pressure accumulator

47-16

fluid 03-22, 03-23, 47-3 master cylinder 47-10, 47-12 pads 03-39, 46-2

parking brake 03-49, 46-6, 46-7 rotor 03-39, 46-2, 46-4 system description 47-1 troubleshooting 47-2 see also Antilock brakes (ABS)

Bulb applications

exterior 94-2

interior 96-2

Bumper bumper construction 63-1 front bumper 63-2 front bumper components Carrera 2 63-2 Carrera 4 63-4 front bumper cover 63-6 front bumper removing and installing

63-8

front bumper cover removing and installing 63-6 rear bumper 63-9 rear bumper components 63-9 rear bumper cover 63-10 rear bumper removing and installing

63-13

rear bumper cover removing and installing 63-10

Caster

44-2

Catalytic converter

26-6

diagnostic monitor OBD-5

Cautions

00-2

Center brake light

94-11

Center console

70-1

Center driveshaft

39-8

Central locking

96-8

switch 96-10

Charging system

27-10

alternator and regulator, checking

27-13

testing 27-13 troubleshooting 27-11 voltage regulator 27-18

Check strap

lubricating 03-47

Check Engine Light see MIL (malfunction indication light)

Climate control see also A/C see also Heater

Clock

90-4

setting 90-4

Clutch

30-1

assembly 30-2, 30-8 bleeding 30-8 checking 03-47 double-mass flywheel 30-1 fluid 30-7 hydraulic system 30-7 master cylinder 30-10, 30-11 mechanical 30-2 operation 30-3 pedal assembly 30-8 replacing 30-3 slave cylinder 30-9 throw-out bearing 30-3, 30-6 troubleshooting 30-2

Clutch master cylinder 30-10, 30-11

C
C

Cabin micro filter replacing 03-44

Caliper, brake

47-18

Camber

44-2

Camshaft adjusting timing 10b-22, 15b-10 installing 10b-21, 15b-8 removing 10b-5, 15b-1

Camshaft chain

15-10

Camshaft timing chain see Camshaft chain

Capacities, fluid A/C system 87-4 automatic transmission 37-7 front differential 39-2 manual transmission 03-24, 34-6 oil 03-17, 17-1 rear differential 39-13 windshield washer 03-25

Carbon canister, activated 24-2, 24-5

03-24, 34-6 oil 03-17, 17-1 rear differential 39-13 windshield washer 03-25 Carbon canister, activated 24-2, 24-5

I ndex

3

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Clutch slave cylinder

30-9

Coil

28-11

Coil spring see also Front suspension see also Rear suspension

Component locations 97-4, 97-10

Compressor

87-5

Condenser

87-7

Condenser fan

87-9

Constant velocity (CV) joint 03-41, 40-17, 42-15

Control arm see also Front suspension see also Rear suspension

Convertible top 02-13, 61-1, 61-2 components 61-2, 61-5, 61-6, 61-7,

61-8

convertible soft top 61-2 convertible top frame 61-2 drive cable, replacing 61-12 emergency closing 61-3 motor, removing and installing 61-9 service 61-9 transmission, removing and installing

61-10

troubleshooting 61-3

Camshafts adjusting timing 10b-22 installing 10b-21 removing 10b-5

Center console removing and installing 70-1

Central electric panel 97-8, 97-9, 97-10, 97-11

Crankcase assembling 10b-12 disassembling 10b-8

Crankshaft assembling 10b-11 assembly 13a-6 disassembling 10b-9 specifications 13a-7

Crankshaft pulley

13a-1

removing and installing 13a-2

Crankshaft pulley seal removing and installing 13a-3

Crankshaft sensor see Engine speed sensor

Cruise control

switch 48-3

Diagnosis system 03-16, OBD-1 reading fault memory 03-16

Diagnostic monitors

OBD-4

Diagnostic trouble code (DTC) 03-17, OBD-7

Differential see Front differential see also Rear differential

Distributor see Ignition distributor

DME (digital motor electronics) 02-6, 24-2, 24-3, 24-4, 24-5, 24-10, 24-11, 24-12, 24-13 applications 02-6, 24-2, 24-3 basic engine settings 24-5 crankshaft sensor see Engine speed sensor cylinder head temperature sensor

24-15

DME engine control module (ECM) 24-10, 24-11 accessing for tests 24-11 electrical connector (Bosch M 2.10)

electrical connector (Bosch M 5.2)

DME main / fuel pump relay 24-14,

24-20

DME M 2.10 55 pin diagnosis OBD-24 pinout OBD-22 DME system components Bosch M 2.10 24-4 Bosch M 5.2 24-5 emission controls 24-3 engine control module (ECM) 24-10, 24-11, 24-12, 24-13 replacing 24-22 engine managment overview 24-2 engine speed sensor 24-18 fuel injectors 24-25 ignition system 28-1 intake air housing 24-22 intake air temperature sensor 24-16 intake manifold 24-31 mass air flow sensor 24-23 MIL 03-17, OBD-3 oxygen sensor 24-18, 24-19, 24-20,

26-8

secondary air injection 24-6, 24-41,

24-42

secondary air pump 24-41 secondary air check valve 24-42 system overview 02-6, 24-2 throttle housing 24-38

CV joint 03-41, 40-17, 42-15 24-12 Cylinders installing 10b-18 24-11 removing 10b-7
CV joint
03-41, 40-17, 42-15
24-12
Cylinders
installing 10b-18
24-11
removing 10b-7

Cylinder head

15a-2

camshaft chains 10b-5, 10b-22, 15b-5, 15b-6, 15b-9, 15b-10 components 15a-2 installing 10b-19 removing 10b-6 service, 15a-2 timing, adjusting 15b-10 valve guide checking 15a-3 replacing 15a-5 valve seat, replacing 15a-5

Cylinder head cover

10b-5

Cylinder head temperature sensor testing 24-15

D

Dashboard dashboard cover, removing and installing 70-5

Deck lid see Trunk lid

head temperature sensor testing 24-15 D Dashboard dashboard cover, removing and installing 70-5 Deck lid see

4

I ndex

DME (digital motor electronics) (continued) throttle position sensor 24-17 see also Fuel injection see also Fuel injector see also Fuel pressure see also Fuel pump see also Ignition system

DME main / fuel pump relay

24-14

replacing 24-20

testing 20-13

Dome light see Interior light

Door

57-1

adjusting 57-2 central locking switch 57-5 check strap, lubricating 03-49 handle 57-4 lock 57-4, 57-5 lock cylinder 57-5 removing and installing 57-1 striker 57-4 trim panel 57-3 window see Door window

Door glass see Door window

Door hinge

lubricating 03-47

Door lock

57-5

Door window adjusting 64-5 motor 64-1 regulator 64-1 replacing glass 64-4

Double-mass flywheel

30-1

Drive axle see also Front drive axle see also Rear drive axle

Drive belt 03-26, 13a-1 A/C compressor 03-26 alternator 03-28, 27-13 engine cooling fan 03-30 power steering 48-13

Drive cycle

OBD-6

Driveshaft see Center driveshaft

DTC (diagnostic trouble code) see Diagnostic trouble code (DTC)

E

ECM see DME (digital motor electronics)

Electrical components 97-4, 97-29

Electric cooling fan see Oil cooling fan

Electrical switches

see Switches

Electrical system

97-1

abbreviations and acronyms EWD-6 battery disconnection notes 03-48

central electric panel 97-8, 97-9, 97-10, 97-11 circuit and terminal descriptions

EWD-5

component location table 97-4 component photos central electric panel 97-10 components underneath vehicle

troubleshooting 97-38 continuity, checking 97-40 measuring voltage 97-39 short circuits, testing 97-40 testing with ohmmeter 97-41 testing with voltmeter 97-41 voltage and voltage drop 97-38 voltage drop, testing 97-39 using wiring diagrams EWD-3 vehicle power supply 97-8 wiring color codes EWD-3 wiring diagram conventions EWD-4 X-connectors EWD-8

Electrical wiring diagrams

EWD-10

Electronic immobilizer 96-8, 96-12

Emblems

66-4

Emergencies

03-2

flat tire 03-4 indicator and warning lights 03-2 jump starting 03-3 towing 03-5

Emergency brake see Parking brake

Emergency flasher

94-4

Engine

02-3

air filter 03-31 applications 02-3, 1-2 assembling 10b-10 components 02-4 camshaft cases installing 10b-21 removing 10b-6 camshaft sprocket 10b-21 camshafts adjusting timing 10b-22, 15b-10 installing 10b-21, 15b-8 removing 10b-5, 15b-1 crankcase assembling 10b-12 disassembling 10b-8 crankshaft assembling 10b-11 assembly 13a-6 disassembling 10b-9 specifications 13a-7 crankshaft pulley 13a-1 removing and installing 13a-2 crankshaft seal pulley seal 13a-3 rear main seal 13a-4

97-16
97-16

diagnostic connection 97-19 engine compartment components 97-18, 97-19 engine compartment relay panel

97-12

ground points 97-20 trunk components 97-14, 97-15 trunk relay panel 97-13 electrical wiring diagrams EWD-10 engine 27-1 fuses central electric panel 97-9 engine compartment relay panel

97-10

trunk 97-10

ground applications

1995

(early) 97-23

1995

(late) 97-26

1996

97-30

1997-1998 97-34

ground points

1995 97-21

1996-1998 97-22 photos 97-20 relays central electric panel 97-11 engine compartment 97-12 trunk 97-13 terminal designations EWD-5

97-22 photos 97-20 relays central electric panel 97-11 engine compartment 97-12 trunk 97-13 terminal designations EWD-5

I ndex

5

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Engine (continued) cylinder heads installing 10b-19 removing 10b-6 service 15a-2 cylinders installing 10b-18 removing 10b-7 disassembling 10b-2 displacement 02-3 drive belt 03-26, 03-28, 03-30, 13a-1, 27-13, 48-13 grounds 1995 97-11 1996-1998 97-12 hydraulic lifter measuring 15b-13 replacing 15b-12 identification 1-2 installing 10a-17 lubrication system, flushing 17-7 lubrication warning system 17-5 management see DME (digital motor electronics) mount 10a-16 oil 03-17, 03-18 oil cooler 17-12 oil cooler thermostat 17-10 oil cooling fan 17-13 oil cooling fan ballast resistor 17-14 oil level sensor 17-6 oil pressure sensor, replacing 17-7 oil pressure, checking 17-4 oil pressure relief valve 17-10 oil pressure warning light 17-5, 90-3 oil pump 10b-9, 17-1, 17-4 oil return tube 17-16 oil tank, removing and installing 17-8 oil temperature sensor, replacing 17-7 on-board diagnostics OBD-1 overview 1-1 peripherals installing 10b-23 removing 10b-2

pistons checking wear 13b-4 components 13b-2 installing 10b-18 removing 10b-7 rings 13b-5 servicing 13b-5 weight 13b-4 pulley system 13a-1 removing 10a-2 rocker shaft and arm 10b-23, 15b-12 separating from engine automatic transmission 10a-20 manual transmission 10a-18 spark plugs 03-33 specifications 1-2 speed sensor 28-12 timing chains installing 10b-21 parallelism 10b-22 removing 10b-2 valve covers 15b-14 valve guide checking 15a-3 replacing 15a-4 valve seat, replacing 15a-5 valves 15a-6 spring height, setting 15a-7 stem seals, replacing 15a-7 see also DME (digital motor electronics) see also Engine control module (ECM) see also Exhaust system see also Ignition system see also Lubrication system

Engine compartment blower see Rear blower motor

Engine compartment relay panel see Relay panel

Engine control module (ECM) see DME (digital motor electronics)

Engine cooling fan 03-26, 03-30

Engine hood

55-6

aligning 55-8 components 55-6 hood release cable, replacing 55-10 removing and installing 55-7 strut 55-7

Engine identification

1-2

Engine management see DME (digital motor electronics)

Engine oil cooler

17-11

Evaporative control system diagnostic monitor OBD-5

Evaporator

87-12

Exhaust manifold

26-2, 26-7

Exhaust system 03-40, 26-1, 26-2, 26-3 catalytic converter 26-6 checking 03-40 components 26-2, 26-3 heat exchange components 26-10 heater control components 26-4 manifold 26-2, 26-7 muffler 26-3, 26-5 oxygen sensor 26-8

Expansion valve

87-12

Exterior lights

see Lights

F
F

Fan A/C blower 87-4 engine compartment blower see Rear blower motor engine cooling fan 03-26, 03-30

Fasteners

03-9

Fault code see Diagnostic trouble code (DTC)

Fault memory

03-16

Fender

50-1, 50-3

Filters air 03-31 cabin micro filter 03-44 fuel 03-32 oil 03-18

Firing order

28-3

Floor jack

03-7

Fluids and lubricants

03-17

see also Capacities, fluid

03-44 fuel 03-32 oil 03-18 Firing order 28-3 Floor jack 03-7 Fluids and lubricants 03-17 see

6

I ndex

Fluid lines fluid lines and hoses, checking 03-40

Flywheel, dual-mass see Double-mass flywheel

Foglight

94-8

Front differential

39-2

center driveshaft 39-3 components 39-2 fluid 03-25 fluid level, checking 39-2 fluid, replacing 39-3 front drive axle flange seal 39-4 removing and installing 39-5 viscous coupler 39-10

Front drive axle removing and installing 40-16

Front lid see Trunk lid

Front oil seal see Crankshaft pulley seal

Front suspension 02-9, 03-42, 40-1, 40-5 checking 03-41 components 40-2 control arm 40-5 control arm ball joint 40-6 drive axle (Carrera 4) 40-16 overview 40-3 ride height 44-3 strut assembly 40-8 strut, removing and installing 40-9 stabilizer bar 40-7 tightening torques 03-42 wheel bearing installing 40-16 removing 40-14 wheel carrier assembly 40-11 wheel carrier, removing and installing

40-11

Fuel delvery tests

20-8

fuel delivery volume, testing 20-10 see also Fuel pump see also Fuel system see also Fuel tank

Fuel filter

03-32

see also Fuel pump see also Fuel system see also Fuel tank

Fuel gauge

90-3

fuel level light 90-3 see also Fuel system see also Fuel tank

Fuel injection 24-1, 24-8, 24-20 cylinder head temperature sensor 24-15, 24-23 fuel pressure regulator 24-29 idle speed control valve 24-24 intake air housing 24-22 intake air temperature sensor 24-16 intake manifold 24-22 mass air flow sensor 24-23 oxygen sensor oxygen sensor system 24-18 heater circuit, testing 24-20 signal, testing 24-19 secondary air injection check valve 24-42 pump 24-41 throttle housing 24-38 vario-ram actuator 24-40 see also DME (digital motor electronics) see also Fuel injector

Fuel sending unit

20-6

replacing 20-7

Fuel system

20-3

checking pressure 20-8, 20-9 checking volume 20-10 diagnostic monitor OBD-5 fuel delivery tests 20-10 fuel pump delivery volume 20-10 sending unit 20-8, 20-7

Fuel tank

20-3

draining 20-3 filler flap 50-3 fuel level sending unit 20-6, 20-7 removing and installing 20-4 see also Fuel pump see also Fuel system

Fuse panel see Central electric panel

Fuses 97-8, 97-9, 97-10

G
G

Fuel injector 24-9, 24-25 relay 24-14, 24-20 replacing 24-25 resistance specification 24-9 testing 24-9

Fuel level sender 20-6, 20-7 see also Fuel pump

Fuel pressure operating fuel pump for tests 20-11 regulator 20-8, 20-9 relieving pressure 20-8 specifications 20-10 testing 20-8, 20-9 see also Fuel pump see also Fuel system

Fuel pump 20-11, 20-19 checking current draw 20-17 check valve, replacing 20-21 checking voltage 20-16 operating fuel pump for tests 20-11 relay see DME main / fuel pump relay replacing 20-19 troubleshooting 20-11 see also Fuel system

Fuel pump relay see DME main / fuel pump relay

Gearshift knob automatic transmission 37-12 manual transmission 34-2

Generator see Alternator (generator) see also Charging system

Glove compartment removing and installing 70-10

Grounds 97-21, 97-22, 97-23 97-26, 97-30,

97-34

H

Hand brake see Parking brake

Handle, door

57-4

Hazard warning switch

94-4

Headlight 03-50, 94-1, 94-5 adjusting aim 94-5 bulb applications 94-2 bulb, replacing 94-7 controls 94-3

switch 94-4 Headlight 03-50, 94-1, 94-5 adjusting aim 94-5 bulb applications 94-2 bulb, replacing 94-7 controls

I ndex

7

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Headlight (continued) exterior lights, checking 03-50 headlight design 94-1 light switch 94-3 Litronic system 94-1 replacing bulb 94-13 removing and installing 94-6 switch 94-3 troubleshooting 94-2

Heat exchange components replacing 26-10

I

Ignition coils

28-11, 97-37

Ignition distributor 28-10, 97-12 cap 28-10 ignition rotor 28-10

Ignition final stage

28-15

Ignition switch cylinder

48-14

Ignition switching unit

28-15

Ignition electrical switch

48-14

Ignition system

warning lights 90-2, 90-3, 90-4

Intake air housing removing and installing 24-22

Intake air temperature (IAT) sensor testing 24-16

Intake manifold removing and installing 24-31

Interior airbags, inspecting 03-45 ash tray 70-7 center console 70-1 dashboard cover 70-5 front seat 72-2 glove compartmenr 70-10 interior lights, checking 03-50 knee bar 70-8 rear seat 72-4 rear side panel 70-11 seat belt frame cover 72-4 seat belts, checking 03-51 sun visor 70-12 see also Interior light see also Trim, Interior

28-1

checking for spark 28-7 coil 28-11 components 28-1, 28-10 crankshaft sensor see Engine speed sensor disabling 28-4 distributor 28-13 distributor cap 28-10 electrical switch 48-14 final stage 28-15 firing order 28-3 ignition coils 28-11 ignition rotor 28-10 ignition system quick check 28-7 ignition system visual inspection 28-8 ignition timing 28-4 knock sensor 28-2, 28-14 maintenance 28-3 relay 24-18 spark plugs 03-34 spark plug wires 28-11 switching unit 28-15 troubleshooting 28-6, 28-7, 28-8 see also spark plugs

96-4
96-4

Interior light

Heater A/C and heater unit 80-10, 87-2 climate control panel 80-3, 87-1 components 80-2 flap and ducts 80-9 heat exchanger 80-2 rear blower motor ballast resistor 80-3 removing and installing 80-5 see also A/C see also Cooling system

Hood front lid safety hook, checking 03-48 see also Engine hood see also Trunk lid

Horn

90-6

alarm horn 96-5

Hoses fluid lines and hoses, checking 03-40

Hydraulic brake booster removing and installing 47-14

Hydraulic lifter measuring 15b-13 replacing 15b-12 rocker arm, removing 15b-12

checking 03-50 see also Lights

Intermittent wiper switch

92-4

J

Jacking

03-7

Jump starting

03-3

K

Key

Immobilizer, electronic 96-8, 96-12

Indicator lights

03-2

Injector see Fuel injector

Instruments 90-2, 90-3, 90-4 layout 90-2 removing and installing 90-5 repairs 90-9 replacing bulbs 90-5

96-6

programming remote key 96-7 transmitter battery, replacing 96-7

Keyless entry

96-8

Knock sensor

28-2

removing and installing 28-14 see also Ignition system

Knee bar removing and installing 70-8

96-8 Knock sensor 28-2 removing and installing 28-14 see also Ignition system Knee bar removing and

8

I ndex

L

Level sender, fuel

20-6

License plate light

94-11

Light switch

94-3

Lifter see Hydraulic lifter

Lights bulb applications exterior 94-2 interior 96-2 brake light switch 94-4 center brake light 94-10 checking 03-48 controls 94-3 engine compartment light 96-3 exterior lights, checking 03-48 front foglight 94-8 front turn signal 94-8 fuses 94-6 glove compartment light 96-4 hazard warning light switch 94-4 headlight adjusting aim 94-5 removing and installing 94-6 replacing bulb 94-7 interior light bulb 96-4 interior lights, checking 03-49 license plate light 94-11 light switch 94-3 repairs front 94-5 rear 94-10 taillights 94-10 trunk light 96-2 see also Headlight see also Litronic

Litronic

94-1

see also Headlight

Locks central locking 96-8 central locking switch 57-5, 96-10 checking 03-48 door lock 57-5 door lock cylinder 57-4 door lock emergency operation 96-9 front lid safety hook, checking 03-48 keyless entry 96-8

Lubrication system

17-1

oil 03-17, 03-18

oil cooler 17-12 oil cooler fan 17-13 oil filter 03-18 oil level checking 03-17 display 90-3 sensor 17-6 oil pressure display 90-3 oil pressure relief valve 17-7 oil pressure warning light 17-5, 90-3 oil pump 10b-9, 17-1, 17-4, 17-7 oil service 03-18, 17-1 oil temperature display 90-3

Luggage compartment lid see Trunk lid

M

Maintenance 03-1, 03-13, 03-17, 03-26, 03-33,

03-44

airbags, inspecting 03-44 alignment 44-2 automatic transmission fluid 03-24, 37-4, 37-5 battery 03-3, 03-46, 03-47 body exterior 03-47 brake fluid 03-22, 03-23, 47-3 brake pads / rotors 03-39, 46-2, 46-4 clutch, checking 03-47 CV joint boot, inspecting 03-41 differential oil 03-25 door check straps, hinges, lubricating

03-47

drive belt 03-26, 03-28, 03-30, 13a-1, 27-13, 48-13 exhaust system, checking 03-40 exterior lights, checking 03-48 filters air 03-31 cabin micro filter 03-44 fuel 03-32 oil 03-18 fluids and lubricants 03-17 see also Capacities, fluid front differential 03-25, 39-2, 39-3 front lid safety hook, checking 03-48 headlights, adjusting 03-49 interior lights, checking 03-49 manual transmission oil 03-24 oil 03-17, 03-18 parking brake 03-49, 46-6 power steering fluid 03-23 rear differential 03-25, 39-6, 39-12 seat belts, checking 03-49 spark plugs 03-33 suspension and steering components, checking 03-41, 03-42, 03-43

tables 03-13 test drive 03-50 tires 03-50 under car maintenance 03-33 wipers and washers 03-25

Malfunction indication light see MIL (malfunction indication light)

Manifold, exhaust

26-7

Manual transmission applications 02-7, 34-1 back-up light switch 34-8 fluid 03-24, 34-6 gear ratios 34-2 input shaft seal 34-7 installing 10a-17 overview 34-1 pilot bearing 30-5 removing 10a-2, 34-3 separating from engine 10a-18 shift knob 34-2 shift lever 34-4 shift linkage 34-3 transmission mount 34-5

24-23
24-23

Mass air flow (MAF) sensor

Master cylinder brake 47-10, 47-12 clutch 30-10, 34-11

Microfilter see Cabin micro filter

MIL (malfunction indication light)

OBD-3

Mirror, outside rear view

66-1

checking heater 66-3 components 66-2 replacing glass 66-1

Misfire diagnostic monitor OBD-5

Model year news

02-15

MRS (multiple restraint system) see Airbag system (SRS)

Muffler

26-5

N

Neutral safety switch see Automatic transmission, gear position switch

system) see Airbag system (SRS) Muffler 26-5 N Neutral safety switch see Automatic transmission, gear position

I ndex

9

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

O

OBD (on-board diagnostics) 03-16, OBD-1 diagnostic monitors OBD-4 diagnostic trouble codes (DTCs)

OBD-7

DME M 2.10 55 pin diagnosis OBD-22, OBD-24 pinout OBD-22 drive cycle OBD-5 freeze frame data OBD-4 malfunction indicator light (MIL)

OBD-3

readiness codes OBD-6 scan tool OBD-4 transmission control unit (1995) diagnosis OBD-38 pinout OBD-37 transmission control unit (from 1996) diagnosis OBD-50 pinout OBD-49

Odometer

90-4

Oil cooler

17-12

Oil cooler fan

17-13

Oil cooler thermostat

17-10

Oil cooling fan

17-13

Oil level

checking 03-17

gauge 90-3

sensor 17-6

Oil pressure gauge 90-3 relief valve 17-7 sensor 17-7

warning light 17-5, 90-3

Oil pumps 10b-9, 17-1, 17-4, 17-7

Oil return tube

17-16

Oil service

03-17, 17-1

Oil tank

17-8

Oil temperature

gauge 90-3

sensor 17-8

On-board computer

90-4

On-board diagnostics (OBD II) see OBD (on-board diagnostics)

Option codes

02-20

Outside door handle

57-4

removing 10b-7

rings 13b-5

servicing 13b-5

weight 13b-4

Pollen microfilter see Cabin micro filter

Power mirror

66-1

Power steering

see Steering

Power window see Door window

Pulley system

13a-1

R

Radio removing and installing 91-1

Radio security code

91-2

Raising car safely

Readiness codes

Rear blower motor

80-3

Rear differential

Oxygen sensor 24-18, 24-19, 24-20, 26-3, 26-8 diagnostic monitor OBD-5 testing heater circuit 24-20 testing
Oxygen sensor
24-18, 24-19, 24-20, 26-3, 26-8
diagnostic monitor OBD-5
testing heater circuit 24-20
testing signal 24-19
03-7
OBD-6

P

P-codes

OBD-7, OBD-8

Pads, brake

03-39, 46-2

Parking brake

46-6

adjusting 03-49, 46-6 shoes, replacing 46-7 switch 45-3, 45-4

Parking light bulb front 94-8

Parts

03-10, 03-11

Passenger compartment monitor

96-11

Pilot bearing

30-5

Pistons checking wear 13b-4 components 13b-2 installing 10b-18

39-11

components 39-11 fluid 03-25, 39-12 fluid level, checking 39-12 fluid, replacing 39-12 rear drive axle flange seal automatic, driver side 39-15 automatic, passenger side 39-13 manual 39-16

Rear drive axle removing and installing 42-14

Rear main seal

13a-4

Rear side panel removing and installing 70-11

Rear spoiler components 55-12 manual spoiler control 55-11

Rear suspension

42-2

checking 03-43

components 42-2

70-11 Rear spoiler components 55-12 manual spoiler control 55-11 Rear suspension 42-2 checking 03-43 components 42-2

10

I ndex

Rear suspension (continued) drive axle 42-14 lower control arm (A-arm) 42-8 multi-link axle assembly (LSA system)

42-6

overview 42-3 ride height 44-3 strut assembly 42-4 strut, removing and installing 42-4 stabilizer bar 42-3 tightening torques 03-43 toe control arm 42-7 upper control arm 42-6 wheel bearing 42-12 wheel carrier 42-9

Rear window

02-14

Receiver-drier

87-4, 87-11

Recirculation switch

87-1

Refrigerant

87-4

Relay panel engine compartment relay panel

97-12

trunk relay panel 97-13 see also Central electric panel

Relays 97-11, 97-12, 97-13

Release bearing

30-3

Remote key

see Key

Reversing light switch see Back-up light switch

Ride height

44-3

Rocker cover

66-5

Rotor, brake checking 03-39 removing and installing 46-4

S

Safety

03-6

working under car safely, 03-6

Scan tool

OBD-4

Seal, crankshaft pulley removing and installing 13-3

Seal, rear main removing and installing 13a-4

Seats front 72-2 drive cable, replacing 72-9 moving manually 72-7 general 72-1 rear (Cabriolet) 72-4 rear (Coupe and Targa) 72-4 seat belt frame cover 72-5

Seat belt 02-18, 02-24 checking 03-49 front seat belt components 69-3 removing and installing 69-4, 69-5 rear seat belt components 69-6 removing and installing 69-6, 69-7 seat belt frame cover 72-5

Seat belt frame cover

72-5

Speedometer

90-4

Splash shields see Underbody splash shields

Spoiler, rear see Rear spoiler

Spring, coil see Front suspension see Rear suspension

SRS (supplemental restraint system) see Airbag system (SRS)

Stabilizer bar see Front suspension see Rear suspension

Starter 27-2, 27-8 removing / installing 27-9 troubleshooting 27-8

Steering bleeding 48-9 checking 03-41 column stalk switch 48-3 fluid 03-23, 48-8, 48-9 fluid lines 48-8 ignition electrical switch 48-14 ignition lock cylinder 48-14 power steering belt 48-13 power steering pump 48-10 power steering system 48-1 rack 48-16 steering wheel 48-2 tie rod 48-9

Steering wheel

48-2

Stop light switch see Brake light switch

Strut front 40-8, 40-9 rear 42-4

Sunroof

60-2

cables 60-8 components 60-2 controls 60-3 emergency closing 60-4 guide rails 60-9 motor and drive unit 60-9 panel, adjusting height 60-5 panel, removing and installing 60-6 wind deflector 60-7

Sun visor removing and installing 70-12

Secondary air injection 24-3, 24-6, 24-41, 24-42 secondary air pump 24-41 secondary air valve 24-42
Secondary air injection
24-3, 24-6, 24-41, 24-42
secondary air pump 24-41
secondary air valve 24-42

Service information 03-6, 03-11, 03-12, 03-13 non-reusable fasteners 03-9 parts 03-10, 03-11 Porsche service 03-12 raising vehicle with floor jack 03-7 safety 03-6 tightening fasteners 03-9 tools 03-12 underbody splash shields 03-8 working under car safely, 03-6

Shift knob automatic transmission 37-12 manual transmission 34-2

Slave cylinder

30-9

Sound system

91-1

Spark plug

03-33

Spark plug wires

28-11

Speed sensor, wheel

45-8

transmission 34-2 Slave cylinder 30-9 Sound system 91-1 Spark plug 03-33 Spark plug wires 28-11 Speed

I ndex

11

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Porsche, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Suspension checking 03-41 tightening torques 03-42, 03-43 see also Front suspension see also Rear suspension see also Maintenance

Sway bar see Stabilizer bar

Switches back-up light manual transmission 34-8 brake light 45-3, 45-4, 45-5, 94-5 central locking 57-5, 96-10 cruise control 48-3 gear position switch automatic transmission 37-10 hazard warning 94-4 high beam 48-3 ignition cylinder 48-14 electrical switch 48-14 light 94-3 pedal cluster 30-6, 94-5 steering column stalk 48-3 turn signal 48-3 wiper / washer 92-4

T

Tachometer

90-3

Taillights

94-10

exterior lights, checking 03-48

Targa top 02-14, 60-10 components 60-12, 60-13 controls 60-13 drive motor basic adjustment 60-16 emergency closing 60-14

overview 60-10 sun blind motor, basic adjustment

60-16

TC (traction control) see also Antilock brakes (ABS)

Test drive

03-52

Thermostat see Oil cooler thermostat

Throttle cable

10a-16

Throttle housing

replacing 24-38

Throw-out bearing see Release bearing

Tie rod

48-9

Tightening fasteners

03-9

torques 03-10

Timing chain see Camshaft chain

door panel 57-3 glove compartment 70-10 knee bar 70-8 side panel trim 70-11

Trunk lid aligning 55-4 components 55-2 removing and installing 55-3 safety hooks, checking 03-49 struts 55-3 trunk lid release, servicing 55-8

Trunk light bulb

96-2

Trunk relay panel see Relay panel

Turn signal bulb front 94-8 rear 94-10

Turn signal switch

48-3

U

Under car maintenance 03-33, 03-40

Underbody

checking 03-40

Underbody splash shields

03-8

V

Vacuum brake booster

47-13

Valve covers removing and installing 15b-14

Valvetrain 02-4, 15a-3, 15a-6 valve guide checking 15a-3 replacing 15a-4 valve seat, replacing 15a-5 valves 15a-6 spring height, setting 15a-7 stem seals, replacing 15a-7

Vario-ram Intake System 02-4, 02-6 actuator 24-40

Vehicle identification number (VIN) 01-1, 03-11

Tiptronic see Automatic transmission Tires
Tiptronic
see Automatic transmission
Tires

44-1

flat tire, changing 03-4 service 03-51

Toe

44-5

Tools

03-12

Torque converter removing and installing 32-1 seal 32-2

Towing

03-5

Traction control (TC) see Antilock brakes

Transmission 02-7, 03-24, 34-1, 37-1 mount 10a-16, 34-5 see also Automatic transmission see also Manual transmission

Transmission control unit see OBD (on-board diagnostics)

Trim, interior ash tray 70-7 center console 70-1 dashboard cover 70-5

control unit see OBD (on-board diagnostics) Trim, interior ash tray 70-7 center console 70-1 dashboard cover

12

I ndex

Vent flaps and motors 80-10, 87-2

Ventilation microfilter see Cabin micro filter

Viscous coupler (C4) function test 39-10

Voltage tests 97-48, 97-39, 97-41 continuity 97-40 short circuits 97-40 testing with ohmmeter 97-41 testing with voltmeter 97-41 voltage 97-39 voltage and polarity 27-2 voltage drop 97-39

W

Warning lights 03-2, 19-8, 90-2, 90-3, 90-4

Warnings

00-1

Washer

92-11

headlight washer 92-11 fluid level sensor 92-11 pump 92-11 reservoir 92-11 see also Wiper

Washing

03-47

Waxing

03-47

Wheel alignment

44-2

front 44-2 front ride height 44-3 rear 44-4 specifications 44-5

Wheel bearing

front 40-14

rear 42-12

Wheel carrier

front 40-11

rear 42-9

Wheel housing liner, front

50-2

Wheel speed sensor wheel speed sensors 45-8

Wheel, steering

48-2

Wheels

44-1

Window see Door window

Wiper

92-2

arm 92-3 assembly, removing and installing

92-6

blade cleaning problems 92-2 replacing 92-2 checking 03-26 components 92-5 fuse 92-4 fluid 03-25 intermittent wipe interval control 92-4 motor, removing and installing 92-6 rear wiper 82-10 relay 92-4 switch 92-4 see also Washer

Wiring circuit and terminal descriptions

EWD-5 diagrams EWD-10 Porsche abbreviations and acronyms EWD-6
EWD-5
diagrams EWD-10
Porsche abbreviations and acronyms
EWD-6

option codes EWD-7 sample EWD-4 using wiring diagrams EWD-3 wiring color codes EWD-3 wiring diagram conventions EWD-4 wiring diagrams EWD-10 X-connectors EWD-8

Working under car safely

03-6

X

X-connectors

EWD-8

diagram conventions EWD-4 wiring diagrams EWD-10 X-connectors EWD-8 Working under car safely 03-6 X X-connectors EWD-8
established 19 50 Automotive Reference™ Full color repair procedures BentleyPublishers .com Porsche 911 (Type 993)

established 19 50 Automotive Reference™

Full color repair procedures
Full
color
repair
procedures
BentleyPublishers .com Porsche 911 (Type 993) Service Manual: 1995-1998 Carrera, Carrera S. Carrera 4, Carrera
BentleyPublishers
.com
Porsche 911 (Type 993)
Service Manual: 1995-1998
Carrera, Carrera S. Carrera 4, Carrera 4S
Bentley Stock No: P998
Publication Date: 2013-11-04
ISBN: 978-0-8376-1719-0
Hardcover, 8 3/8 in. x 11in.
Case quantity: 1
946 pages
1,523 full color photos and illustrations

The Porsche 911 Carrera (Type 993) Service Manual: 1995-1998 is a comprehensive source of service information and specifications for Porsche 911 (Type 993) Coupe, Cabriolet and Targa models from 1995 to 1998. The aim throughout this manual has been simplicity and clarity, with practical explanations, step-by-step procedures and useful specifications. Whether you’re a professional technician or a do-it- yourself Porsche owner, this manual will help you understand, care for and repair your Porsche.

Technical highlights

• Full-color repair manual pages (black and white electrical section).

• In-depth maintenance instructions for everything from changing the engine oil (and both oil filters) and Tiptronic transmission fluid to replacing the cabin microfilter. This manual tells you how and when to do it.

• Type 993 enthusiast guide with year-to-year model specifics, and a comprehensive listing of Porsche option codes.

• Step-by-step engine / transmission assembly removal and installation.

• Illustrated engine teardown and rebuild, with camshaft and timing chain replacement, detailing wear limits and nominal values.

• Fuel injection and ignition system service and component testing of different Bosch DME engine management systems, including the secondary air injection (SAI) system.

• Clutch, flywheel and rear main seal service.

• Front and rear drivetrain service, including front (C4) and rear differential service.

• Brakes, steering, suspension and ABS maintenance, troubleshooting and repair for both vacuum boost (C2) and hydraulic-boost (C4) brake systems.

• Heating and air-conditioning repair, including A/C component replacement.

• Body adjustments and repairs, including convertible top, sunroof and targa top service and adjustment.

• Electrical system service, with an easy-to-use illustrated component location section.

• Wiring schematics for selected models, with DME systems, power distribution, grounds, convertible top and other hard-to-find circuits.

grounds, convertible top and other hard-to-find circuits. Convertible top drive diagnosis and repair, including
grounds, convertible top and other hard-to-find circuits. Convertible top drive diagnosis and repair, including
grounds, convertible top and other hard-to-find circuits. Convertible top drive diagnosis and repair, including

Convertible top drive diagnosis and repair, including microswitch location and function.

61 Convertible Top

Full maintenance procedures, including drive belt replacement.

03 Service and Maintenance

Fuel pump testing and replacement.

20 Fuel Supply

Engines covered:

1995: 3.6 liter (M64.07 and M64.08) 1996-1998: 3.6 liter (OBD II M64.23 and M64.24)

Transmissions covered:

G50 (6-speed manual, RWD) G64 (6-speed manual, AWD) A50 (4-speed automatic)