www.WorkshopManuals.co.uk
TechnicalManual 911 Carrera (996)
Technicallnformation Repair
Contents Group 5 Body
WKD483 521 09
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Supplement Overview
Supplement
Edition
Article number
Topic
05/1997
Basic edition
2
08/1997
Generalsupplement
WKD483721.02
5
12/1997
Generalsupplement
WKD483721.05
7
02/1998
Cabrioletscope
WKD483721.07
9
05/1998
Folder separation 5/6
WKD483721.09
11
05/1998
Generalsupplement
WKD483721.11
13
06/1998
Generalsupplement
WKD483721.13
17
10/1998
Generalsupplement
WKD483721.17
18
11/1998
Generalsupplement
WKD483721.18
21
01/1999
Generalsupplement
WKD483721.21
22
02/1999
Folder separation6/7
WKD483721.22
23
02/1999
Generalsupplement
WKD483721.23
25
03/1999
GT3scope
WKD483721.25
26
10/1999
Folder separation0
WKD483721.26
28
05/1999
Generalsupplement
31
07/1999
Generalsupplement
WKD483721.28 WKD483721.31
33
08/1999
Generalsupplement
WKD483721.33
34
10/1999
Generalsupplement
WKD483721.34
35
10/1999
Folder separation9
WKD483721.35
42
08/2000
Generalsupplementand changesin modelyear
WKD483721.42
11/2000
Body repairs
44
Supplement
WKD483721
2001 WKD483721.44
Overview
Printed in Germany -44, 2001
master5
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Table of Contents
5
Foreword Foreword
Foreword Use
. .
Table of Contents Printed in Germany -42,
2000
mastereV
-1
page
-2
page
1 1
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Foreword This manualcontains Technicallnformation as well as instructions on repairsfor Porschevehicles. It is intendedfor the sole use of workshopsbelongingto PorscheAG. The descriptionsform the basis for professionaland correctmaintenanceand repair work. The content of the work procedures described is based on the level of training of a fitter who has completed vocationaltraining and has a sound knowledgeof the product. This level of knowledgeis necessaryin order to carry out the work described. Warning notes
The warning notes and safety instructionsare classified by the respectivesignalisingword (Danger,Warning,Caution)beside the warningsymbol.
Warns against death or very serious injury which will certainly occur if the instructions
are not observed.
Warns against death or very serious injury which may occur if the instructions
are not observed.
& Caution! Warns against minor injury or damage to property instructions
if the
are not observed.
To prevent injuryand restricted operating and traffic safety of the vehicle,or damageto the vehicle as the result of incorrect work, read these instructions carefullyand observethem without fail. It is not possiblefor PorscheAG to give a detailed evaluationof all danger situationsfor the persons carrying out the work. It is therefore imperativethat all persons carrying out repair and maintenance work on Porschevehicles use their specialistknowledgeto ensure that their own safety is not at risk and the procedurechosenwill not have anynegativeeffects on the vehicle -especially with regard to safety. It is therefore expresslyspecified that all work involvedin the work proceduresdescribed shouldbe carried out onlyin accordancewith the valid guidelinesand regulationsof the local authorities responsible with respect to health and accidentpreventionand environmen-
Foreword Printed in Germany -42,
-1 page 1 2000
vorwort
www.WorkshopManuals.co.uk Foreword
tal protection, and in compliancewith the legal requirementsof individualcountries. Notes Notes contain advisoryinformationrelated to the work procedure which makes the fitter's work easier. The following pictogram indicates this information:
rn Note! Containsadvisoryinformationwhichmakes the work procedure eas-
Ier. Dueto the continuous developmentand improvementof our vehicles, there may be discrepanciesbetweenthe actual technical status of the vehicles and the work descriptions.Any existing deviationsare corrected by means of supplements,and the scope of the descriptions is extendedwith supplements. PorscheAG retains the right to implementchangesat anytime and without prior notice.
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Use The workshopdocumentationfor the "911 Carrera (996)"model has the designation"911 Carrera (996) TechnicalManual"and contains Technicallnformation as well as instructionson Repairs. The integration of the technical informationpublishedin the "911 Carrera (996)" TechnicalManualwith the instructionson repairs provides the user with a complex referencework that combinesinto one book associated or cross-referencedmaterial of relevanceto workshops and originatingfrom various informationmedia.
The "911 Carrera (996)" TechnicalManualconsists of 15 folder$, subdividedinto the following Groups.
.a
Entire vehicle-General
.a
Diagnosis,part 1 (up to RepairGroup 45)
.a
Diagnosis,part 2 (as of RepairGroup 69)
.1
Engine,part 1 (up to RepairGroup 13)
.1
Engine,part 2 (as of RepairGroup 15)
.2
Fuel,exhaust,engine electronics
.3
Transmission,manualtransmission
.3
Transmission,automatictransmission
.4
Runninggear
.5
Body
.6
Body equipment, exterior
.7
Bodyequipment, interior
.8
/ 9 Air conditioning/ Electrics
.9
Circuit diagrams, part 1 (up to and including'99 model)
.9
Circuit diagrams,part 2 (as of and including'00 model)
The two folders with Group 0 are to be regarded as one folder; i.e. file the "Technicallnformation"notices only in the folder "Group0 Diagnosis,part 1" -up to Repair Group 45-. The second folder Group 0 Diagnosis,part 2 -as of Repair Group 69- includesthe further RepairGroupsbelongingto GroupO. The two folders with Group1 are to be regarded as one folder; i.e. file the "Technicallnformation"onlyin front of the repair descriptions in the folder Group 1 -Engine, part 1 -up to Repair Group 13-.
Use Printedin Germany- 42, 2000
-2 page 1 handhabung
www.WorkshopManuals.co.uk Foreword
The second folder Group1 Engine,part 2 -as of Repair Group 15- includesthe further RepairGroupsbelongingto Group 1. The two folders with Group9 are to be regarded as one folder; i,e. file the "Technicallnformation"notices only in the folder Group9 Circuit diagrams, part 1 -up to '99 model-. The second folder Group9 Circuit diagrams, part 2 -as of '00 model- includesthe further RepairGroups belongingto Group9. The"911 Carrera (996)"TechnicalManualhas the same structure in each folder, with the following breakdownfor all Groups:
Title page: "911 Carrera (996)" Technical
Manual
.Foreword Title page: "Technical information" .Table
of contents,TechnicalInformation
.T echnicallnformation Title page: "Repair"
.Overview of repair groups .T able of contents, repair .General/technical .Description
data
of repairs
As can be seen from the breakdown,the publishedTechnicallnformation is in the front part of each folder -numbered according to the Groups.The Table of Contentsassignedto each Groupwill be periodicallyupdated. Followingthe TechnicalInformation,separated by a title page, the instructions on repairs -assigned according to the Groupsor broken down into RepairGroups -are includedin the folders.
Theinstructionson repairswill be extendedandupdatedbymeans of supplements.
rn Note! Sheetsthat alreadyexist in the "911 Carrera (996)" TechnicalManual and are updated or revised and thereby exchangedby a supplement are designatedin the footer with the supplementnumber correspondingto the current version:e.g. "Printed in Germany-2,2000"
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
rn Note! Due to a systemmodificationin the TechnicalLiterature production, the followingprocedures have changedin model year 2000: 1 -The previous record sheet in the folder "O-Genera!" the supplement omitted.
contents
A supplement
and
sheet -red sheet- have been overview now appears sepa-
rately in each folder. The new supplement contents sheet can be destroyed after the supplement is filed in the folder.
Thesupplementoverviewsheet is replaced with the relevant supplementin the correspondingfolder and must no longer be maintainedby hand. 2 -The page numbering
in the new and the replaced
ters are no longer continuous.
Each new chapter
chapis now
given an additional chapter number followed by the page number e.g. -2 Page 11 => Rep. Gr. 0; General. 3 -The old page numbering
still applies to existing chap-
ters and those that are not replaced.
Use Printed in Germany -42,
-2 page 3 2000
handhabung
www.WorkshopManuals.co.uk
Group 0:
Entire vehicle -General Salescheck Maintenance
Group 0:
0 01 03
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 Heating diagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
61 69 69 72 80 90 91 91
1
Engine Engine -Crankcase, Engine -Crankshaft,
Group 1:
Group 2:
Group 3:
Group 3:
10
suspension pistons
13
Engine
1
Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
15 17 19
Fuel, exhaust, engine electronics Fuelsupply,control Exhaustsystem,turbocharging Fuelsystem,electronicinjection Fuelsystem,K-Jetronic Exhaustsystem Starter,powersupply,cruisecontrol Ignitionsystem
20 21 24 25 26 27
Transmission,
3
manual transmission
-35,
28
30
Transmission, automatic Torqueconverter
3
transmission
Overview of repair groups in Germany
2
Clutch, control Manualtransmission-Actuation, housing Manualtransmission-Gears, shafts, intogearsh Final drive, differential,differential lock
Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differential lock
Printed
94
October
1999
REPGRU.CHP
34
35 39
32 37 38
39
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 Ant~LockBrake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
40 42 44 45
46 47
48 5
Body
Bodyfront Bodycenter,roof,frame Bodyrear Lids,flaps Doorfront, centrallockingsystem
50 51 53 55 57
Body equipment, exterior Slidingroof Convertibletop, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
60 61 63 64 66 68 69
6
7
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers
70 72
74
8
Air conditioning Heating Ventilation Air conditioning Auxiliaryair conditioning system
80
85 87
88 9
Electrics Instruments, alarmsystem Radio,telephone,on-boardcomputer,navigation Windshield wiperandwashersystem Lights,lamps,switchesexterior Lights,lamps,switchesinterior,theft protection
90
Circuit diagrams
9
Wiring (up to and includingthe '99 model)
97
Circuit diagrams Wiring(fromthe 'DOmodel)
9 97
91
92
94
96
Overview of repair groups REPGRU.CHP
Printed
in Germany
-35,
October
1999
www.WorkshopManuals.co.uk
911 Carrera (996)
Body
Table of Contents
5
Body
5
Body -general
5
Safety
Safety Safety
instructions
Safety
5
5
General
Tools Check
instructions instructions instructions
for
instructions
for for
body
for for
windscreen water welding fuel disassembling air airbag door sliding rear roll-overprotection plug cabriolet paintwork, heat
instructions
for
hardtop
Safety
instructions
for
belt
-Electrical -Mechanical -Compressed-air -Welding Straightening Metalworkingtools Floor
information
and
dimensions assembly
control
metalworking
control
andmodules
equipment equipment systems equipment control for
drains system roof
convertible
hydraulic Teromix-6700
Safety
-Protectionagainstovervoltage -Replacing Electronic
conditioning repairtank spoiler window location shields
modules
equipmentbody
(body) plan
system
components...
upholstery, (body)
system
top.
linings
two-component
,
adhesive
'
,
strap
holder
quality
tools
glass,
,
notes
dimensions """"""""""'."""""."""""""""'" repair
for
'
body
for
repairs
the
996
Carrera
model
up
to
model
5 year Floor
Body
year
2000
parts
asembly assembly
2001
control
of
high-strength
control
dimensionsdimensions
for
for
the
the
GT3
996
model
steel
model
from
model
page
5-1
page
5-1
page
5-1
page
5-1
page
5-1
page
5-1
page
1 1 1 1 2 2 2
5-1
page
4
5-1
page
4
5-1
page
4
5-1
page
5
5-1
page
6
5-1
page
5-1
page
5-1
page
5-1
page
5-1
page
6 7 7 7 7
5-1
page
8
5-1
page
5-1
page
8 8
5-1
page
5-2
page
5-2
page
9 1 1
5-2
page
1
5-2
page
5-3
page
1 1
5-3
page
5-3
page
5-3
page
5-3
page
1 2 2 2
5-3
page
3
5-3
page
4
5-7
page
1
5-7
page
1
5-7
page
2
5-7
page
3
5-15
5
Table of Contents Printed in Germany -44,
Carrera
5-1
2001
master5
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
5 5 5 5 5
5
Water Water Check
drainage drainage dimensions
Plug
location
-Cabriolet
body
repair
-Cabriolet
5-21 5-23
structure
sequence seals welding
gap
-keyslid...
lid.
arc
roof
5-25 5-29
,
-body
-Sliding -Doors -Rear Accessories Inert-gas Resistance Gas -Front
for
plan
Diagram
Work Seam Diagram
plan
spot
welding to for
dimensions
panel
symbols welding accident
5-37 5-45 5-45 5-45 5-45 5-46 5-46 5-46 5-46 5-46 5-46 5-47
"'.".""""..""'..'
(MAG
for
repair.
procedure)welding
work.
5
5 50 505619 505519 501055
Body front Replacing Replacing Removing Replacing
Welding Welding Cutting Preparing Removing Preparing Tools
and
outwheel closing in and in
wheel closing wheel materials wheel closingwheel closing
installing
housings housing
panelhousings housing, housings housings panel panel panel
".".,."..",.",."""",.,.,..,..."., wheel the
and andand
and wing lower and and
and
housing front sidefront
front
sideside
side shell
members floorfloor
floormembers members members liner and
panel panel
panel
outer
(sectional
for for
side
installation installation
member
repair)
and and
from
fitting. fitting. ,.."
the
body
507455 Preparing
Welding and
Cleaning Replacing Replacing
501455
50-1 50-5
507456
509330 501455
page 1 page 1 page 1 page 1 page 1 page 2 page 2 page 3 page 3 page 4 page 1
Tools Welding Cutting Tools Cutting Preparing
wheel
fitting.
housing,
wheel
and
front out out front in front
lower
housing,
materials front materials front front front front
water
wall wall-
wall wall wall
shell
lower
wall wall
drainsCarrerafor for
installation installation
shell
on
4/
Coupe
and
and
GT
and 3
outer
outer
and
fitting fitting
side
member
side
Cabriolet
members
,
for
into
50-11
page
1
50-11
page
2
50-11
page
4
50-11
page
6
50-11
page
50-17
page
50-17
page
7 1 2
50-17
page
4
50-17
page
6
50-23
page
50-23
page
1 2
50-23
page
4
50-23
page
50-23
page
6 7
50-33
page
1
50-33
page
2
50-33
page
4
50-33
page
6
50-33
page
50-34
page
50-34
page
7 1 2
50-34
page
4
installation
the
body.
50-29
55
552237 559037 551037 Replacing
Replacing
536919 539330 535555 535555 530555 530555 Removing
53
Cleaning
Disconnecting
Preparation
Welding Tools Cutting Preparation
Welding Cutting Preparation
Welding Cutting
Welding
Removing
Replacing
Removing
Replacing Replacing Replacing
Replacing
519019 512155
Replacing
51
Replacing
Body centre, roof, frame
51-5
516319 510355 51-11
514555
514555
518755
Body rear
53-5
53-9
53-23
53-33
51-15 page
1
51-15 page
2
51-15 page
4
51-15 page
51-15 page
51-16 page
6 7 1
51-16 page
2
51-16 page
4
51-16 page
6
51-16 page
7
51-17 page
1
51-17 page
2
51-17 page
4
51-17 page
6
51-17 page
51-18 page
51-18 page
7 1 2
51-18 page
4
51-18 page
6
51-18 page 7
53-39
page
53-39
page
53-39
page
1 2 4
53-39
page
53-39
page
Disassembling
Printed in Germany-44, 2001
and
assembling
rear release front lid lid
for
front
lid
Table of Contents
master5
-up ,
fitting.
and
Cabriolet.
liner
installation
and
for
3
GT
housing
Coupe
panel
on
panel
panel
wheel
panel-
panel
closing
drains
closing
closing
rear
section section-Cabriolet
closing
closing
installing
water
rear
rear
materials
the
and
side
side
rear
rear in
out
rear
and
and
rear and roof
in
lower
out
in
roof
lower
of
installing
for
member-Cabriolet
and
fitting.
fitting.
fitting.
and
and
member member
installation
fitting
side
element
side
for
and
cover
,
lower lower
of of
member
installation
member
member
member
underbody
deformation
member
member
member
panel
cross
member
member
side side
side
side
cross
installation installation cross
roof roof seat
side side
cross
centre
installing
of
for
for
seat
lower
lower
seat
lower
materials
materials materials materials
in seat
in
lower
out out
and and and
and
Tools Tools
Tools
7
Preparation
6
page
Cutting
page
50-34
Preparing
50-34
Tools and materials
Welding
Weldingin front wall
Tools
911 Carrera (996)
www.WorkshopManuals.co.uk Body
to
51-1
model
53-1
year
2000
6 7
Lids
55-1 55-5 55-11
III
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
555737 559037 551037
Disassembling
and
assembling
release
for
Disassembling
and
assembling
rear release lid
-GT3 for front
Disassembling Assemblingreleaseforfrontlid Disassemblingreleaseforfrontlid and assembling
release
for
rear
rear
lid lid
lid
-up
to
-as
-as
model
of model
of model
year
2000
year
2001
year
... ..
2001
...
551037 Assemblingreleaseforrearlid Disassembling release
57
575119 575137
Door
Removing Disassembling Adjustment
front,
central
-Blockage -Precondition Assembling Adjusting -Checking Disassembling Diagram: -Basic Basicsettingofdoorlock Standardisingthe -Standardisingthepowerwindows Fitting -Adjustment Adjustment
the
andsetting the the instructions sheetmetal door
for
rear
locking
ofdoorthe detection installing and door door theprocedure: door forwindow ofadjustment assembling door system the window operation
lid
571137 575116 573719 574519
sides.
-Checking Adjusting -Removing -Installing -Adjustment Removing
the
and
door the
and
orientation theinstalling and orientation lower procedure: installing
adjustment: assembling
stop
55-30
page
1 2 4 1 2
55-30
page
4
57-1
page
57-5
page
1 1
57-5
page
57-5
page
57-6
page
57-6
page
57-6
page
57-6
page
2 7 1 1 1 2
57-6
page
2
57-6
page
2
57-6
page
57-6
page
57-6
page
3 3 3
57-6
page
4
57-6
page
4
57-6
page
4
57-6
page
5
57-6
page
57-6
page
57-6
page
57-6
page
5 5 5 6
57-21
page
57-25
page
57-26
page
57-27
page
1 1 1 1
57-27
page
4
57-27
page
4
page
6
55-29
page
55-29
page
55-29
page
55-30
page
system
clips fordoorfunction door window in
assembly the andangle height
lock ..,
door of clamping grommets pressing the
before in
the ofpower
the
vehicle's jaws installation. force
door windows.
on
longitudinalthe
door
seal
direction
at
the
575137
Disassembling Setting Removing
55-17 55-23
inner door
lighting orientation lighting of,
the handle door
door
(LED power
(LED release
handlelighting
light-emitting light-emitting window
(bowden
(LED
unit
light-emitting diodes) cable)
diodes)
for
door
diodes)
lock.
top
and
57-27
www.WorkshopManuals.co.uk 911 Carrera {996}
Body-general
Safety instructions for body repair Safety instructions for disassembling components
Change in centre of gravity
of vehicle when parts are
removed! Danger of injury and damage to vehicle if the vehicle falls from the lifting platform! If the centre of gravity of the vehicle is changed as a result of removed components, secured
the vehicle must be
on the lifting platform!
Safety instructions for air conditioning
Danger of fire due to the filled air-conditioning system heating up during welding and soldering work!
.No welding, soldering or hot-air heating may take place on parts of the filled air-conditioningsystem! .While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 80 °C! .Make sure that parts of the air-conditioning systemdo not heat up during welding or soldering work on the vehicle! Safety instructions for fuel tank
Danger of fire due to fuel tank or fuel-carrying
parts heating
up during grinding and welding work! When carrying
out grinding and welding work near the
fuel tank or fuel-carrying
parts, make sure that these
parts do not heat up! It is recommended .Adjacent
to remove endangered
parts must be covered!
parts!
www.WorkshopManuals.co.uk 5
Body -general
Safety instructions for paintwork, glass, upholstery, linings
Danger of fire and danger of damage to battery, paintwork and glass due to flying sparks during body repair! .No
other vehicles may be left unprotected
in areas used
for body repair!
Safety instructions for airbag system
Danger of injury if airbag units are triggered
while ignition
key is not removed! .Always
remove ignition
commence
adjustment
key during body work, and do not work until a waiting period of at
least 1 minute has elapsed! .The
ground strap of the battery must be disconnected
during work on the airbag system and alignment work within the framework
bench
of body repair!
Danger of injury if side airbag units in the door are triggered while ignition .Always
key is not removed!
remove ignition
commence
adjustment
key during body work, and do not work until a waiting period of at
least 1 minute has elapsed! .The
ground strap of the battery must be disconnected
during work on the airbag system and alignment work within the framework
bench
of body repair!
Safety instructions for door
Danger of material
damage if the door lock is installed incor-
rectly! Malfunctions
in the alarm system!
911 Carrera (996)
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Body -general
The door lock should be installed only when the actuating lever is in basic position!
Danger of injury if side airbag units in the door are triggered while ignition .Always
key is not removed!
remove ignition key during body work, and do not
commence
adjustment
work until a waiting period of at
least 1 minute has elapsed! The ground
strap of the battery must be disconnected
during work on the airbag system and alignment work within the framework
bench
of body repair!
There is a danger of injury if fingers or hands are trapped
by
the door window when the comfort function is triggered: lower and raise door window! When carrying
out assembly work in the area of the con-
nection piece (Item 3), the bottom part of the door handle (Item 4) and the door lock (Item 5), the fuse No.1
in row
D must be removed!
A
Caution!
Damage to plug connection lugs during door removal! Damage to lugs when pulling the plug connection
out of the
A-pillar! The locking element at the bottom part of the plug connection must be pulled out before the plug connection
is
disconnected!
Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook! Pull the hook out of the end piece only after installation
in
the inner door release!
5 Safety instructions Printed in Germany -42,
for body repair 2000
5-1 page 3 c5xxxxxl
www.WorkshopManuals.co.uk 5
Body-general
911 Carrera (996)
Safety instructions for sliding roof
Damage to water drainage
channel and sliding roof mecha-
nism when sliding roof panel is removed! The rear water drainage nism is damaged
channel or the sliding roof mecha.
if the sliding/tilting
roof trim is moved
incorrectly! .The
sliding roof panel must not be moved to the "Open"
position when the sliding roof panel has been removed! .In
order to avoid damage to the guides of the sliding roof, the sliding/tilting
roof panel (Item 4) must be moved with-
out the use of force!
Safety instructions for rear spoiler
Danger of injury and danger of damage to hydraulic if pressure
is discharged
The hydraulic
system
suddenly!
system is under 30 bar pressure when the rear
spoiler is extended! No work must be carried
out on the hydraulic
system
when the rear spoiler is extended!
Danger of injury and danger of damage to the vehicle if handling is modified whenadjusting the additional wing! .The
additional
wing must be moved to the lowest position
for use in public traffic!
Safety instructions for rear window
Damage to surrounding
section if rear window is removed
incorrectly! When cutting out the rear window, take care not to damage the surrounding
section!
8
www.WorkshopManuals.co.uk 911 Carrera (996)
Body-general
5
Damage to rear window if curing time of adhesive is not observed!
.The vehicle must not be used until the curing time has elapsed. In order to ensure that the bonded joint is sufficiently the following boundary conditions .Curing
strong,
must be adhered to:
time: 3 hours
.Temperature: .Fixing
at least 10 °C
time: approx. 1 hour
Wire strand can crack and melt off during heating if pressure frame is fitted incorrectly!
Rear window can be destroyed if pressure frame is fitted incorrectly! .The
pressure frame must be in contact on all sides!
Safety instructions for windscreen
Danger of injury and danger of damage to windscreen
if cur-
ing time of adhesive is not observed! .The
vehicle must not be used until the curing time has
elapsed.
In order to ensure that the bondedjoint is sufficiently strong, the following boundary conditions must be adhered to: .Curing
time: 3 hours
.Temperature: .Fixing
at least 10 °C
time: approx. 1 hour
Danger of damage to surrounding with the vehicle identification
section and to the label
number if rear window is
removed incorrectly!
5 Safety instructions
for body repair
Printedin Germany-42, 2000
5-1 page 5 c5xxxxxl
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body -general
.When
cutting out the rear window, ensure that the sur-
rounding section and the label with the vehicle identification number are not damaged!
Safety instructions for heat shields
Danger of heat accumulation
if deformed
heat shields are
assembled near the rear spoiler and rear bumper! .Damaged
or distorted heat shields must be straightened
or replaced!
Safety instructions for cabriolet convertible top
Damage to tension bow seal if convertible electrically .The
top is actuated
in service position!
convertible
top must no longer be electrically
moved
in service position!
Damage to convertible-top
frame if not running synchro-
nously during bleeding! .The
hydraulic
system can be bled only if the hydraulic
inders are removed from the convertible-top
cyl-
supports and
drive levers on both sides!
Short circuit and burns on convertible
top if wire strands are
crossed!
Wire strands must not be crossed!
Damage to or destruction electrical .The
of convertible
actuation when convertible
convertible
top is removed!
top must no longer be electrically
ated when the convertible-top
5-1 page 6
top in the case of
oper-
support is detached!
5 Safety instructions
c5xxxxxl
for body repair
Printed in Germany -42,
2000
.
www.WorkshopManuals.co.uk Safety instructions for roll-over protection system
Danger of injury if roll-over
bar is actuated
when roll-over
bar module is being removed! .Remove
the roll-over
bar modules only after the roll-over
bar has been extended (triggered)!
Safety instructions for plug location plan (body)
Danger of corrosion
and of unwanted water penetration
when
removing plugs! The body apertures
are sealed with plugs in the factory,
and must be resealed disassembly
with the plugs provided
following
or repair work!
Safety instructions for water drains (body)
Water drainage
hoses can be pushed out or pressed in by
blowing them out of the body during cleaning! The water drainage during cleaning
hoses must be blown out carefully
using compressed
air!
Safety instructions for welding
Irritation
to respiratory
tracts from toxic zinc oxide emitted
when welding galvanized .The .Smoke
steel!
work area must be well ventilated! gases must be removed with a suitable extraction
system! (Refer to Workshop Equipment
5 Safety instructions Printed in Germany -42,
Manual, Group 5).
for body repair 2000
5-1 page 7 c5xxxxxl
www.WorkshopManuals.co.uk Body -general
Safety instructions for Teromix-6700 two-component adhesive
Danger of damage to side section if binding time of adhesive is not observed! .The
new part must be welded in within 30 minutes!
Safety instructions for hydraulic system
Danger of damage to hydraulic bent, trapped .Do
system if hydraulic
lines are
or crushed during installation!
not bend, trap or crush hydraulic
lines during installa-
tion!
Safety instructions for hardtop
Danger of crushing and trapping of intervention
of components
in the case
in the hardtop mechanism!
The hardtop must be raised evenly on both sides!
Damage to the hardtop lining and windstopif the procedure is carried out incorrectly! .The
windstop must be removed before fitting the hardtop!
Damage to the rivet connections of the hardtop body if the rear windowis cut out incorrectly! .When
cutting out the rear window, make sure to cut close
to the rear window!
911 Carrera (996)
www.WorkshopManuals.co.uk Body-general
911 Carrera (996)
Safety instructions for belt strap holder
& Caution! Danger of impact
with the belt strap holders fitted on wheel!
.Pay attention to the two projecting belt strap holders when working on the vehicle!
Damage to the adhesive when entering or leaving the vehicle during the hot-melt process and the cooling time! Belt strap tension changes due to entering and leaving the vehicle! .Do
not enter or leave the vehicle during the hot-melt
process and the cooling time!
5
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Body -general
5
Electronic control modules
rn Note! If electronic components,e.g. ABScontrol module,have been removed for repair work and are then reused, they must be given a functionalcheck after installationin accordancewith the existing specifications! Protection against overvoltage To protect electronic control units from overvoltageduring electric arc welding, the following work regulationsmust be observed: .When welding work is extensive,the electronic control units must be removed. Ensurethat there are no electricallyinsulated parts betweenthe earth connectionand the weldingpoint. .Remove clamp from negativeterminal of battery and cover negative terminal of battery. .Connect the earth connection of the electric arc welding equipment as near as possibleto the welding point on the part to be welded. .Do not touch electronic c.ontrolunits or electric cableswith the earth connectionor the welding electrode. Replacing control modules The replacementof electronic control modulesafter an accidentis necessary if at least one of the following conditionsis met: The housingis noticeablydeformed or damaged. The supporting surface or bracket is deformed (the unit shows no external damage). .The
plug connection is damagedor corroded by moisture,
.Functional checks on or self-diagnosisof the unit revealsthe fault "Control module faulty",
5 General information Printed in Germany -42,
5-2 page 1
and quality notes 2000
c5xxxxx2
www.WorkshopManuals.co.uk 911 Carrera (996)
Body -general
Tools and
5
tools for body
rn Note! Detailedand additionalinformation abouttools and equipmentcan be found in the "WorkshopEquipment"manual.
Shownon Celette type
5 Tools and metalworking Printed in Germany -42,
2000
tools for body repairs
5-3 page1 c5xxxxx3
~
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body -general
Metalworking tools Electrical equipment
~r;"
c=:( 5
1 -Drill 2 -Angle grinder I large 3 -Angle grinder I small
4- Sander 5 -Hot-air gun
Mechanical equipment 6 -Hole punch 7 -Edge setter
5-3 page 2
5 Tools and metalworking c5xxxxx3
tools for body repairs
Printed in Germany -42,
2000
www.WorkshopManuals.co.uk 911 Carrera{996)
Body-general
5
Compressed-air equipment
10
11
9 -Air chisel 10 -Body saw 11 -Spotweld cutter
5 Tools and metalworking Printed in Germany-42. 2000
tools for body repairs
5-3 page 3 c5xxxxx3
www.WorkshopManuals.co.uk Body -general
Welding equipment
12 -Multispot spot-welder 13 -MIG weld~r
911 Carrera (996)
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
960:1:1.5
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body -general
rn Note! All dimensionsare measuredto the middle of the hole or screwed point. Thedimensionsare measured directly and, therefore,are oblique dimensions.Dimensionsin brackets are measured horizontally. Dimension
Measuring points
Designation
Dimension in mm
PI
PI-PI
Impactabsorber / pipe front
800:t2
P2
P2... P2
Bearer side spare-wheelwell
712:t2
P3
P3 -P3
Frontaxle front, front, low
610:t1
P4
P4 -P4
Frontaxle front, rear, high
731,2:t1
P5
P5 ~ P5
Rationallocation hole, side member front
800:t1
P6
P6 i P6
Spring strut bracket, front
985:t2
Frontaxle front, rear
773:t1
i
P7
P7 -+-P7 I
P8
P8 -P8
Frontjacking pointfor hoist or car jack
1330:t2
pg
pg T pg
Transmissionsupport, front
256:t2
i
PIG
PIG-PIG
Transmissionsupport, centre
270:t2
PIIA
PIIA-PIIA
GT3rear transmissionsupport (front screwed point)
472:t2
Pl18
Pll!B -PIIB
Reartransmissionsupport (rear screwed point) 490:t2 from model year 2001
PII
PIli -PII
Reartransmissionsupport up to model year
400:t2
2000 PI2
PI2 -PI2
Rearjacking pointfor hoist or car jack
PI3
PI3 -PI3
Rear diagonalbrace
PI4
PI~ -PI4
Rear axle, front
PI5
PI5 -PI5
Rear axle,centre
PIG
PI~ -PI6
Spring strut bracket, rear
PI?
PI ~ -PI?
Rear axle,rear
PI8
PIg -PIB
Rationallocation hole, side member rear
1370:t2824:t3836:t2821:t2915:t2792:t294
I
PI9
PI9-PI9
Engine mountlocation hole outside
PI9A
PI9A-PI9A
Validfor GT3 Outer engine mounttake-uphole
P20
P20 -P20
Centreengine mount
780:t2
P20A
P20A -P20A
Validfor GT3 Centre engine mount
847:t2
P21
P211-P21
Validfor GT3 Innerengine mount
717:t2
P22
P22 -P22
Impactabsorber / pipe rear
A
P4 -P7
In vehicle's longitudinaldirection
507:1:2
www.WorkshopManuals.co.uk 911 Carrera (996)
Dimension
Measuring
B
Body-general
Designation
Dimension
P5 -PI8
In vehicle's longitudinaldirection
2795:tl
C
P8 -P2
Vehiclediagonaldimension
1525:t2
D
P8 -P3
Vehiclediagonaldimension
1279:t2
E
P8 -P4
Vehiclediagonaldimension
1279:t2(1283:t2)
F
P8 -P7
Vehiclediagonaldimension
1084:t2
G
P8 -PI2
Vehiclediagonaldimension
1929:t2
H
P8 -PI2
In vehicle'slongitudinaldirection
1350:t2
PI3-PII
Vehiclediagonaldimension
875:t3 (863:t3)
a
PI3 -PIIA
Vehiclediagonaldimension
b
PI3-PIIB
Vehiclediagonaldimension
J
PI3 -PI4
Vehiclediagonaldimension
1087:t3{ 1085::!:3)
K
PI3 -PI5
Vehiclediagonaldimension
1159:t3{ 1125::!:3)
L
P13-P17
Vehiclediagonaldimension
1237:t3{ 1209::!:3)
M
PI3 -PI8
Vehiclediagonaldimension
1349:t3{ 1323::!:3)
N
PI3 -PI9
Vehiclediagonaldimension
1629:t3
Na
PI3 -PI9A
Vehiclediagonaldimension
Measuring
in mm
points
point
Designation
PI
Screwed point (M8 thread)
P2
Bearer side spare-wheelwell screwed point (M8 thread)
P3
FA,front screwed point low (thread M12 x 1.5)
P4
FA,front screwed point high (thread M14 x 1.5)
P5
Rationallocation hole, side member front
P6
Spring strut bracket, front
P7
FA,rear screwed point (thread M14 x 1.5)
P8
HoisVcar jack front location hole
pg
Transmissionsupport, front screwed point (thread MI0)
PIC
Transmissionsupport, centre screwed point (thread M1 0)
PII
Transmissionsupport, rear screwed point (thread M 12 x 1.5)
5 Check dimensions
for body repair
Printed in Germany -44,2001
5- 7 page 5 c5xxxxx4
89
www.WorkshopManuals.co.uk 911 Carrera (996)
Body-general
Measuring
point
Designation
P12
Hoist/car jack rear location hole
P13
Diagonalbrace front screwed point (thread MID)
P14
RAfront screwed point (thread M12 x 1.5)
P15
RAcentre screwed point (thread M12 x 1.5)
PI6
Spring strut bracket, rear
PI7
RArear screwed point (thread M12 x 1.5)
PI
Rationallocation hole, side member rear
PI
Screwed point (thread M8)for outer engine mounttake-uphole
PI 9A0
Screwed point (thread M8)for outer GT3engine mounttake-uphole
P2
Centre engine mount
P2'OA1
Screwed point (thread M8)for outer GT3engine mount
P2
Inner GT3engine mount, screwed point (thread M8)
P2.2
Impactabsorber / pipe rear screwed point (thread M8)
5 Check dimensions
5- 7 page 6 c5xxxxx4
for body repair
Printed in Germany -44.2001
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
5
Structure dimensions
69.97
5 -11
5 Repair check dimensions Printed in Germany, 1997
9965_11
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body
Structure dimensions
-
9"~+O96
p
N
CII
no
0
0 N Q.
N Q.
~+08L 't:j:£t8
,.. Do ~
~
I
~
~'-'Jj:
III/A.
~ ~1.+~t6
CD
,..
Q.
~
9'1.+~6l I
Q.
~+l'tI.6
Co
-
I
g'I.+~'1.~8
..
~
,..11.+9&8
II~I
~ Q.
~
...
... CO)
=1
.. N
Q.
~
/ I~Z;;OL~~I --.I ~- \-
;: / ~~9S~ " ;: 0-0 ."
-
1(t)I .
Q.
GI
Q.
"Cf
N ,..
Q.
-~,
tl
+1
I/)
I/)
~~ ,.. N
~
~1=O££" Q.
~
"-
In.
~ +1 ~
Do
0
In
U)
Q.
~+OOg 1.~'t"&I.L ,
In
~Q.
M Do
Q.
'-- I.~OI.9 't'+S'I.I.L
~
Q.
N
Do
.. Q.
... Do
-9'1.+008 ~+g86
13.97
5 Repair check dimensions
5 -12 9965_11
Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Structure dimensions Point L/R
Designation
Point L/R
Designation
1
Impact absorber / pipe front screwed point (thread M8)
13
Diagonalbrace front screwed point (thread MID)
2
Bearer side spare-wheelwell screwed point (thread M8)
14
RA front screwed point (thread M12 x 1.5)
3
FA, front screwed point low (thread M12 x 1.5)
15
RA centre screwed point
FA, front screwed point high (thread M14 x 1.5)
16
5
Rationallocation hole, side member front
17
RA rear screwed point (thread M12 x 1.5)
6
Spring strut bracket, front
18
Rationallocation hole, side member rear
7
FA,rear screwedpoint (threadM14x 1.5)
19
Engine mount location hole outside
8
Hoist/car jack front location hole
20
Engine mount screwed point
9
Transmission support, front screwed
21
Impact absorber / pipe rear
4
(thread M12 x 1.5)
rear
screwed point (thread M8)
point (thread M 10)
10
Transmissionsupport, centre screwed point (thread M 10)
11
Transmissionsupport, rear screwed point (thread M 12 x 1.5)
12
HoisVcar jack rear location hole
FA
=
Front axle
RA =
Rear axle
5 -13
5 Repair check dimensions Printed in Germany, 1997
Spring strut bracket
9965_11
www.WorkshopManuals.co.uk
5
Body parts of high-strength steel
Thefollowingbodyparts are madeof high-strength steel(HS). Bodyparts 18 and 22 are weldedtogetherfrom platesof differentmaterialthicknessesand characteristicsandare thendeepdrawn. Body parts A, Band C possess extremelyhigh tensile strength and are therefore not hot-dip galvanized. Body parts 1 to 23 attain their final strength only after the production stage of cathodic immersion painting and drying. This affects body repairs. For this reason, only "OriginalPorsche parts" must be used for repair work.
www.WorkshopManuals.co.uk
Body parts of high-strength steel
109.97
5 Body parts of high-strength steel
5 -16 9965_15
Printed
in Germany I 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Body parts of high-strength steel
No.
Designation
No.
Designation
1
Bearer side at spare-wheelwell left and right
15
Seat support left and right
16
Hinge pillar left and right
2
Connectionbracket inner to side member front inner left and right
17
Cross member firewall inner
18
Firewall
19
A-pillar reinforcement
20
Side member rear outer left and
3
Sidememberfrontinnerleft and right
4
Web plate outer side member front outer left and right
right
5
Side member front outer left and right
21
Impact absorber mount
6
Cowl panel frame top outer
22
Side member rear inner left and
7
Cowlpanelbottomouter
right
23 8
Cowl panel bottom inner
9
A-pillar reinforcementleft and right
10
Side member floor front bottom
Webplate
High-strength steel plates without galvanized surface
left and right
A
11
Bearer floor front top left and right
12
Front crash support
13
Closing part front crash support
14
Reinforcement cross member firewall front
B
=
Reinforcement crossmember firewallinnerleft
c
=
Reinforcementcross member firewall inner right
Tunnelreinforcement
5 Body parts of high-strength steel Printed in Germany, 1997
=
5 -17 9965_15
www.WorkshopManuals.co.uk
General remarks on the body parts of high-strength sheet steel Applicable
to 911 Carrera
(996) model
Body parts of high-strengthsteel contribute to better protection of the passenger compartmentand thus increase protection of the passengers.In additionto improved crash safety, these parts also have a positive influenceon fatigue strength. In terms of crash behaviour, body parts made from high-strengthsheet steel are distinguishedfor their higher energy absorption. But this also means that higher reshapingforce must be applied in reshaping
work.
Welding work Bodyparts of high-strength steelcan be weldedusingthe MIGweldingprocessesthat are customaryin workshops.Theuse of the oxyacetylene weldingprocessis not permissiblefor bodyparts madeof high-strength steel.
Repair note
Body repairs by reshaping are not possible if these body parts are correspondinglydeformed. Here, the repair must be made by the use of new parts or sectional repairs. For this purpose, only "Original Porsche parts" or sections of "Original Porsche parts" may be
used.
5 Body parts of high-strength steel
5 -18 9965_15
Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
5
Body parts of high-strength steel The indicated body parts are made by welding together plates of differing thickness and characteristics and then deep-drawingthese parts. In their crash behaviour,these body parts are distinguishedby their high energy absorption.
149- 97
5 -19 Printed in Germany, 1997
9965_19
www.WorkshopManuals.co.uk Body
911 Carrera (996)
Body parts of high-strength steel The indicated body parts attain their final strength only under the temperature effects of the production stage of cathodic immersion painting and drying.
148.97
Body repairs by reshaping are not possible if these body parts are correspondinglydeformed. Here,the repair must be made by the use of new parts or sectionalrepairs.
Theuse of high-strength steelsfor the bodyhasan effecton bodyrepairs.Forthis reason,only "Original
Porsche parts"
must be used for repair work.
5 -20 9965_19
Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
5
Body
Water drainage plan
287_99
1
Waterdrainage:slidingroof,rear
2
Waterdrainage:slidingroof, front
3
Water drainage: tank tray
4
Water drainage: evaporator of heatingand air-conditioningsystem
5
Waterdrainage:radiatortank
5 Water drainage Printed
in Germany
5- 21
plan -28,
1999
9965_21
~ \~
www.WorkshopManuals.co.uk 911 Carrera (996)
5
5
Body
Water drainage plan -Cabriolet --~
-..
T
~ ~
8
\."'.,
" '"d\
,,~1~~ ' The body apertures are sealed with plugs in the factory, and must be sealed with plugs once more following disassemblyor repair work.
Top of front end
::: """'-"~~ ~
A
/
/"
:/ \ I.
~ ~o"
B--
---\Y'~
181_98
A : Rubbergrommethole0 20 mm B : Rubber grommet hole f/J30 mm
5 -29
5 Plug location plan Printed in Germany -11, 1998
9965_29
www.WorkshopManuals.co.uk 5
Body
911 Carrera (996)
Bottom of front end
18O_98
F : Plughole0 20 mm
18
5 Plug location plan
5 -30 9965_29
Printed
in Gennany
-11,
1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Side of front end
179_98
A : Rubber grommet hole .0 20 mm B : Rubber grommet hole 0 30 mm
5 -31
5 Plug location plan Printed
in Germany
-11,
1998
9965_29
v~ ~
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body
Bottom of lower side member and floor
,
~\
9
~j
D 1/1
\
G
Q
""::§":
~
II Ij
ce /
J
,II
/
~ T
A
"-
A
.c
/
('
I
e~
/
",\
A/
b
E
E
17O_98
A : Rubber grommet hole .0 20 mm C : Plug hole .0 10 mm D : Plug hole 0' 10 mm
E : Plug hole 0 15 mm
5 Plug location
5 -32 9965_29
Printed
in Gennany
-11,
plan 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
5
Top of lower side member and floor
A
ell 0
O)J.
-
A
\\
A
11 I]
61
6 "-;:'\
6,
6
e
e
~~~;;;~~ "'K '~I
,!~~~;7~~~ j
I
169_98
A : Rubber grommet hole 0' 20 mm K : Plug hole eJ30 mm
5 -33
5 Plug location plan Printed in Germany.
11, 1998
9965_29
www.WorkshopManuals.co.uk 18 Bottom of rear end
/-
~ "./:"':'""', A
DL--.~
~~D
F
F r'--.,.1
~
\--'"I 1\
I -~
A
/
~ A
184_98
A : Rubber grommet hole 0 20 mm
D: Plug hole 0 10 mm E : Plug hole 0 15 mm F : Plug hole .0 20 mm
5-34
5 Plug location plan 9965_29
Printed in Gem1any -11, 1998
~
www.WorkshopManuals.co.uk 911 Carrera (996)
5
Body
8 Top of rear end
A
A
~
'\
A A ./
A L~~~ 182_98
A : Rubber grommet hole 0 20 mm B : Rubber grommet hole 0 30 mm
L : Closure cap hole .0 55 mm
5 -35
5 Plug location plan Printed
in Germany
-11,
1998
9965_29
~
www.WorkshopManuals.co.uk 5
911 Carrera (996)
Body
Side of rear end
~
-
~~
c~ :--,.
D D
-~ ~I
~:~::\~.
.9
D
-'/
n
0
1{1 D
~--J
183_98
A : Rubbergrommethole.0 20 mm 0 : Plug hole 0 10 mm
5 Plug location plan
5 -36 9965_29
Printed in Germany -11, 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
5
Body
Body gap dimensions
Body front
39o_98
A=6mm
B=3mm
C = 4.5 mm
D = 4.5 mm
E=4mm
F = 3.5 mm
Use star gauges to adjust or check the gap dimensions,see Workshop EquipmentTechnical Manual, Chapter 2.4 No. 127 -1
5 Body gap dimensions Printed in Germany -17, 1998
5 -37 9965_37
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Body gap dimensions Body centre
391_98
G=4mm
H=5mm
=4mm
Q=5mm
5 -39
5 Body gap dimensions Printed
in Germany
-17,
1998
9965_37
~
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Body gap dimensions
Body rear 392_98
J =3mm
K =3mm
L = 4.5 mm
M = 4.5 mm
N =5mm
O=6mm
P = 4.5 mm
R =9mm
v = 4.5 mm
5 -41
5 Body gap dimensions Printed
in Germany
-17,
1998
9965_37
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
5
Body gap dimensions Cabriolet body
--
393_98
J = 3 mm
K=3mm
L = 4.5 mm
M = 4.5 mm
N=5mm
O=6mm
P = 4.5 mm
R=9mm
S = 4.5 mm
T=6mm
v = 4.5 mm
5 -43
5 Body gap dimensions Printed
in Germany
-17,
1998
9965_37
. ~ ..
www.WorkshopManuals.co.uk 911 Carrera (996)
5
Body -general
Diagram -keys to symbols for welding work
Resistance spot welding A -Spot seam, single row
A
B -Spot seam, double row C -Spot seam, double row offset
Inert-gas
B
-...c ...
arc welding (MAG procedure)
A
A -Plug weld B -Stitch weld
cI>
B
-«««
c
«««
D
C -Full weld D -Intermittent full weld
...
Gas welding A -Hard soldering
~ ~
5 Diagram
-keys to symbols for welding work
Printed in Germany -42,
2000
A
5-45 page 1 c5xxxxll
www.WorkshopManuals.co.uk
~
www.WorkshopManuals.co.uk 5
Body-general
911 Carrera (996)
Accessories
rn Note! .Due to modificationsto the spare part range, in the case of repair work, accessories must be sealed before assembly(painting)according to the following illustrations. .The sealingmaterial 000 043 204 38 ca/1J be applied directly to the acessoriescoated with KTLpaint (cathodicdipbath coating). .The seam seal can be painted over when It has reached approx. 70 %hardness(approx.4 -5 h at 20 DC,50 %relative air humidity. Higher air humidityor dampeningwith water acceleratesthe hardeningprocess). .The hardeningcan be checked with a nailItest. Press a finger nail gently into the hardenedsealing mas$;if this causesno damage to the sealing mass surface, the seam seal can be
painted. Front lid
"
/
\,
\
"
~
5-46
'-
page 2
II
5 Seam seals
c5xxxx12
Printed in Germany -42,
2000
"""
www.WorkshopManuals.co.uk 911 Carrera(996)
Body-general
5
Doors
/
~
~
\
\
I
\.
0
JJ
Sliding roof panel
""
5 Seam seals Printed in Germany -42,
5-46 page 3 2000
c5xxxx12
~
www.WorkshopManuals.co.uk Body -general
Rear lid
911 Carrera (996)
www.WorkshopManuals.co.uk
911 Carrera (996)
Body-general
Wor~:sequence for accident repair Determinescope of damage J, Exposethe area to be repaired J, Make an economicor technicaldecision Shouldparts be repairedor replaced? J, Determinethe scope of replacementparts and have the parts obtained f-~
-Repair-
-Replacement-
Determinethe scope of replacementparts and havethe parts obtained
Determinethe scope of replacementparts and havethe parts obtained
,J..
Coverundamaged areasof the vehicle
Cover undamagedareas of the vehicle so that they are protected againstfire
J,
J,
Pre-paintnew parts from the inside J-
Reshapedamagedareas J,
Reshapedamaged area by straighteningso that adjacentcontoursor gap dimensionscorrespond to the series condition .1.
Roughlycut out damaged areas ,l.
Cutoutremainingpieces
If necessary,applyfiller or body solder on reshaped areas ,!.
.L
Fit new parts in, then check the gap dimensions with the accessoriesfitted J, Protect spot-weldedflanges againstcorrosion ,J,
Disconnect batteryandobservesafetyand quality instructionsfor welding.
Applyfine filler on repair areas ,!.
-l.
Weldin new parts ,l. Grindvisible weld seamsflat; if necessaryapply
bodysolderor filler ,\,
If necessary,primer and seal the seam areas
,l,
5 Work sequence for accident repair Printed in Germany -44,2001
5-47 page 1 c5xxxx13
www.WorkshopManuals.co.uk 5
Body -general
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
50 56 19
Body front
Removingand installing wheel housing liner
237-97
50 56 19 Removing and installing wheel housing liner Printed in Germany, 1997
996501
50 -1
www.WorkshopManuals.co.uk Body front
911 Carrera (996)
Removingand installing wheel housing liner
128. 96
50 -2
50 56 19 Removing and installing wheel housing liner 996501
Printed in Germany. 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Removingand installing wheel housing liner Note:
No. Designation
Qty.
1
Front left wheel housing liner
1
2
Front right wheel housing liner
1
3
Expandingrivet St6.3
8
Removal
Installation
Check,replaceif necessary
4
Combinationscrew
4
84.8 x 19
5
Plastic nut T5 22 x 10
12
necessary
6
Sheetmetal nut 84.8
6
7
Cover,left
1
8
Cover,right
1
5056
Check, replace if Adjust to center of hole.
19 Removing and installing wheel housing liner
Printed in Germany, 1997
996501
50 -3
www.WorkshopManuals.co.uk 911 Carrerea (996)
50 55 19
Body front
Removingand installing the wing
35- 97
50 -5
50 55 19 Removing and installing the wing Printed in Germany, 1997
966505
www.WorkshopManuals.co.uk Body front
911 Carrerea (996)
Removing and installing the wing
201a.96
50 55 19 Removing and installing the wing
50 -6 966505
Printed
in Germany,
1.9917
www.WorkshopManuals.co.uk 911 Carrerea (996)
Body front
Removing and installing the wil~g Before removing the wing, it is ne(:essary to remove the wheel, the wheel housing liner and the carbon canister.
Note:
No.
Designation
1
Rubber sleeve
2
Removal
Installation
1
Pulloff
Press in
Main headlight (combinationunit)
1
with a socket wrench (width across flats 5), disengage the main headlightand remove it to the front.
Insert the main headlight into the guides of the mountingplate and lock it with the socket wrench (width across flats 5)
3
Sliding piece
1
Pulloff downwards
Press in upwards
4
Plugconnection
iQty.
Removefrom the mounting plate by turning
5
Vent hose
1
Pull off
6
Fastening element
3
Undo
7
Mountingplate
1
Pull forwards and remove from the headlightrecess
Pushon
Insert the mountingplate into the holes provided for that purpose and press it back. Insertthe main headlightinto the mounting plate guides and lock in place with the socket wrench (width across flats 5). Adjustthe mounting plate with the headlightin accordance with the wing contours and tighten the fastening elements.
8
Collar nut M6
5
9
Strut
1
10
Headlightcleaningelement
1
5055
19 Removing and installing ithe wing
Printed in Germany, 1997
50 -7 966505
www.WorkshopManuals.co.uk
Note: No. Designation 11
Filler flap
Qty. 1
Removal
Installation
Insert a narrowscrewdriver from above in front of the clip, press the fastening lug backwardsand hold, and carefullypull off the filler
Pressin
flap upwards.
12
Protective tabs
1
Pull off
13
Rubber sleeve
1
Pulloff
14
Guidering
1
Unclip
Clipin
15
Sleeve
1
Unclip
Clipin
16
Hexagon-headbolt M6 x 20
1
Undo
Screwin
17
Emergencycable
1
Detach
Attach
18
Sheetmetal screw
2
Undo
Screw in
1
Disconnect the electrical plugconnection
Bolt the servo motor onto the sheetmetal bracket with the sheetmetal
84.2 x 18 19
Servomotor
screwsand connectthe electrical plug connection
20
Combinationscrew M6 x 14
2
Undo
21
Hinge
1
At the hinge,undo the combination screw by 2 -3
turns
22
SheetmetalnutSt6.3
11
23
Sheetmetalscrew St6.3 x 14
11
24
Wing
1
Pull out downwards at the Apillar and remove to the front
At the hinge, adjustthe contour of the wing to the lid
Insert the wing under the lid hinge and fit the sheetmetal screws. Adjustthe contours and gaps to the doors and lid. Tighten the sheetmetalscrews.
50 55 19 Removing and installing the wing
50-8 966505
Printed in Germany, 1997
I
www.WorkshopManuals.co.uk 911 Carrerea (996)
Body front
Note:
No. Designation
t~.
25
Rail
1
26
Spacer sleeve 4.8 x 19
4
27
SheetmetalnutSt4.8
2
28
Sheetmetalscrew4.8 x 19
1
29
Sliding piece
1
30
PVCseamseal
31
Adhesivetape
1
32
Sheetmetal screw
3
Removal
Installation
Undo
Fix and screw down
Whenreplacing the wing, put a PVCseam seal on the inside of the crimped seam of the wheel arch.
St6.3 x 12
33
1
Plastic hinge
Insert the standard mercially
com-
available
disassembly tool, e.g. Snap-on Order No.
Positionthe plastic hinge at the filler flap (Item 11) and push on until it perceptiblyengages.
A177A at the locking lugs on the left and right and lift over the locking lugs, push the plastic hinge against the disassembly tool and detach from the filler flap (Item 11).
50 55 19 Removing Printed in Germany, 1997
and installing
50 -9
the wing 966505
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Replacing closing panel Replacing closing panel and front floolr panel
The following spare body parts are requiredfor the repair "Replacingroof":
A = closing panel B = front floor panel
501055 Replacing closing panel Printed in Germany -44,2001
50-11 c5010551
page 1
www.WorkshopManuals.co.uk Body front
Cutting out closing panel and front flo()lr panel
911 Carrera(996)
www.WorkshopManuals.co.uk 911 Carrera (996)
&
Body front
Warning!
During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Rep. Gr. 5; ~;afety instructions
[IJ Note! .The .All
accessories in the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must havebeen completed before the damagedparts are removed.
No.
Procedure
Instructions
Placingvehicleon the alignmentbench
Placethe vehicle with the units installed at the rear onto the set of straighteningattachmentsand fasten in place.
1
Separatingspot-weldedjoints betweenthe closing panel/side members and the front floor panel
Usethe spotweld cutter to separatethe spot-weldedjoints of the closing panel to the side members-A, B- and the front floor panel -C- from the outside.
2
Separatingspot-weldedjoints betweenthe closing panel/wheel housings
Separatethe spot-weldedjoints of the closing panelto the whee!housingsfrom the inside (luggage-compartment side) -D- with the spotweldcutter.
3
Separatingspot-weldedjoints betweenthe front floor panel/side members
Separatespot-weldedjoints of the front floor panel to the side members on the left and right -E- from the outside with the spotweldcutter.
4
Separating spot welds betweenthe front floor panel and bulkhead.
Separatespot-weldedjoints of the front floor panelto the bulkheadat the middle -F- with the spotweldcutter.
50-11 page3
501055 Replacing closing panel Printed in Germany -44,2001
c5010551
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Removethe factory-appliedprimer on the welding areas of the spare parts -A, B, C, D, E, F- using the rotary brush. Drill or punch(with a hole punch).07 mm holes spaced 20 mm apart for plug-weldingwith shieldinggas. =} "Weldingin closing paneland front floor panel"in 50-11 page 6
2
Cleaningthe weldingareas
Removeunderbodycoating and paint layers, etc. from the welding areas of the body with a hot-air gun or rotary
brush.
3
Fittingthe front floor panel in the body and fastening it on the straighteningattachments.
Adjustthe spare front floor panelto the side members and to the bulkhead.Fastenthe spare front floor panel to the straighteningattachmentfor the front-axle mount and diagonal brace. Fastenthe side membersto the straightening attachmentfor the impact pipes (impact dampers).
4
Fittingin wingsandfrontlid
Fit the left and right wings and fit in the front lid. =} Rep. Gr. 552237; Disassemblingand assemblingfront lid =} Rep.Gr. 505519; Removingand installingthe wing
501055
Replacing
closing panel
Printed in Germany -44,2001
c5010551
50-11 page5
'"~I I""~, ./" '\. ~
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Welding in closing panel and front floor panel
~::::::::::~:::~,
\
~
/
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50-11 page6
/
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c
501055 Replacing closing panel
c5010551
Printed in Germany -44,
2001
www.WorkshopManuals.co.uk
911 Carrera (996)
Body front
Plug-weldingfront floor panelto the bulkhead under shieldinggas
Plug-weldthe front floor panelto the bulkhead-F- under shieldinggas.
2
Plug-weldingthe front floor panelto the side Align the front floor panelwith the side members on the members under shieldinggas left and right -E- and plug-weldunder shieldinggas.
3
Spot-weldingthe closing panel
Spot-weldthe closing panelto the front floor panel -C- and the side members on the left and right -A, B-.
4
Spot-weldingthe closing panelto the front floor panel
Spot-weldthe closing panelswith to wheel housingson the left and right -D-.
Tools and materials
Basic straighteningattachmentsfor 911 Carrera (996) Nr. 7250700
2
Star gauges Nr. 127-1
~ Rep. Gr. 3; WorkshopEquipment
Manual ~ Rep.Gr. 2.4; Workshop Equipment
Manual 3
~ Rep.Gr. 3; WorkshopEquipment
Shielding-gaswelding device
Manual 4
~ Rep. Gr. 3; Workshop Equipment
Multispot spotwelder
Manual
5
~ Rep.Gr. 3; Workshop Equipment
Pneumaticbody saw
Manual
6
Angle grinder
~ Rep. Gr. 2.4; Workshop Equipment Manual
7
Oscillatingbody saw (specialelectrical cutter)
~ Rep. Gr. 3; Workshop Equipment Manual
8
Multispotspotweld cutter
~ Rep. Gr. 3; Workshop Equipment Manual
9
Holepunch
~ Rep. Gr. 2.4; WorkshopEquipment
Manual 10
~ Rep.Gr. 3; WorkshopEquipment
Hot-airgun
Manual 11
~ Rep.Gr.2.4; Workshop Equipment
Rotary brush
Manual
12
501055
~ Rep.Gr. 2.4; Workshop Equipment Manual
Spotweldcutter (2)7mm, No. 129
Replacing
50-11 page 7
closing panel
Printed in Germany -44,2001
c5010551
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
(sectional repair) Partially replacing wheel housings and side members The following spare body parts are required for the sectionalrepair "Partiallyreplacing wheel housingsand side members":
c
8
A
A = front outer side member B = front inner side member C = front wheel housing
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
& Warning! During body repairs, the following safety instructions tions must be followed.
and the general information
and quality instruc-
=> Rep. Gr. 5; ~)afety instructions
rn Note! .The .All
accessories in the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must have been completedbefore the damagedparts are removed.
No.
Procedure
Instructions
Placingvehicle on the alignmentbench
Placethe vehiclewith the units mounted at the rear onto the set of straighteningattachmentsand fasten it in position.
Closing panel and front floor panel already cut out
=> 50-11 "Replacingclosing panel"
Frontwall alreadycut out
=> 50-33 "Replacingfront wall"
1
Removingthe wheel housings
Cut off the damaged areas of the wheel housings -8- with the body saw. Positionthe cut within the specified dimensionof -Y = 580 mm-.
2
Cutting off inner side member
Note: Do not cut through the inner reinforcements-arrow- when cutting through the inner side members. Removethe damaged areas of the outer/inner side members -F- with the body saw. Positionthe cut -Y-within the specified dimensionof -580 mm-.
3
Cutting off outer side members and shorten- Do not cut through the inner reinforcements-arrow- when ing to the offset to the wheel housings cutting through the outer side members. Positionthe cut within the specified dimension of -Y = 580 mm-. Use the body saw and spotweld cutter to shorten the side members until there is an offset of -dimension X = 50 mm- betweenthe inner/outer side membersand the wheel housing.
www.WorkshopManuals.co.uk Body front
Preparing wheel housings and side mernbers for installation and fitting
911 Carrera (996)
www.WorkshopManuals.co.uk
911 Carrera (996)
Body front
Transfercut to the spare front wheelhousingsand then cut to size. Cut spare side members to size with the body saw and fit in such a way that an offset of -dimension X = 50 mmresults betweenthe inner/outer side members. Removethe factory-appliedprimer on the welding areas of the spare parts -A, 8, C, D, E, F, G, H, 1-usingthe rotary
brush. Drill or punch(with a hole punch)07 mm holesspaced 20 mm apart for plug-weldingunder shieldinggas.~ "Welding in wheel housingsand side members"in 50-17 page 6
2
Cleaningthe welding areas
Removeunderbodycoating and paint layers,etc. from the welding areas of the body with a hot-airgun or rotary
brush. 3
Fitting the side membersand wheel housing Fastenthe spare innner side member on the straightening in the body and fasteningthem on the attachmentfor the front-axlemountor on the straightening straighteningattachments. attachmentsfor the impact pipes (impact absorbers)and fit it in.
4
Fitting in front wall
~ 50-33 "Replacingfront wall"
5
Fitting the front floor panel in the body and fastening it on the straightening attachment.
~ 50-11 "Replacingclosing panel"
6
Fitting in wings and front lid
Fit the left and right wings and fit in the front lid. => 5-37 "Diagram -body gap dimensions"
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Body front
Procedure
Instructions
Weldingin the innersidemember.
Weldthe inner side member with a full butt weld -F- under shieldinggas.
2
Weldingin wheelhousings.
Spot-weldwheel housingsand inner side members -A-. Weldthe wheel housingfrom the outside with a full butt weld -8- under shieldinggas.
3
Weldingin the outersidemember.
Spot-weldthe outer side member to the inner side member -H, I-. Weldthe outer side member with a full butt weld -F- under shieldinggas.
4
Weldingin front wall
=> chapter "Weldingin front wall"in 50-33
5
Weldingin closing panel and front floor
=> chapter "Weldingin closing panel and front floor panel"
panel
in 50-11
Item
2
Designation of the special tool
Explanation
Basic straighteningattachmentsfor 911 Carrera (996) Nr. 7250700
Manual
=>Rep.Gr. 3; Workshop Equipment =>Rep. Gr. 2.4; Workshop Equipment
Star gauges Nr. 127-1
Manual 3
Shielding-gas weldingdevice
=>Rep. Gr. 3; Workshop Equipment Manual
4
Multispotspotwelder
=> Rep.Gr. 3; Workshop Equipment Manual
5
Pneumaticbody saw
=> Rep. Gr. 3; Workshop Equipment Manual
6
Anglegrinder
=> Rep.Gr. 2.4; Workshop Equipment Manual
7
Oscillatingbody saw (specialelectrical cutter)
=> Rep.Gr. 3; Workshop Equipment
Manual 8
Multispotspotweld cutter
9
Holepunch
=> Rep.Gr. 3; Workshop Equipment Manual => Rep. Gr. 2.4; Workshop Equipment
Manual
10
Hot-airgun
=>Rep.Gr. 3; Workshop Equipment
Manual Rotarybrush
=>Rep. Gr. 2.4; Workshop Equipment
Manual
12
507456
=>Rep.Gr. 2.4; Workshop Equipment Manual
Spotweld cutter 07 mm Nr. 129
Replacing wheel housings and side members
Printed in Germany -44,2001
c5074561
(sectional
repair)
50-17
page 7
oVO ~
www.WorkshopManuals.co.uk Body front
911 Carrera (996)
Replacing wheel housing Replacing wheel housing,
bottom part and outer side member
The following spare body parts are requiredfor the repair "Replacingwheel housings'
~ 0 ./.,
A
XI
~ ~,
;/1
;-"
.
(5
p
.
~
c
B
A = wheel housing B = lower shell
C = outersidemember
507455
Replacing wheel housing
Printed in Germany-44.2001
50-23 c5074551
page 1
www.WorkshopManuals.co.uk Body front
Removing wheel housing, lower shell al1ldouter side member from the body
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
A Warning! During body repairs, the following safelY instructions and the general information tions must be followed. ~ Rep. Gr. 5; S:afety instructions
and quality instruc-
rn Note! .The .All
accessories in the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must have been completed before the damagedparts are removed.
No.
Procedure
Instructions
Placingvehicleon the alignmentbench
Placethe vehiclewith the units mounted at the rear onto the set of straightening attachmentsand fasten it in posi-
tion. Separatingthe spot-weldedjoint between the outer/inner side members
2
Separatethe spot-weldedjoints betweenthe outer side member and inner side member -A, C, D- and the front wall -B- with the spotweld cutter.
Separatingwelds betweenouter side mem- Grindopenthe MIGseamsbetweenouter side member -Eber and front wall and the front wall -F- and the support shell on the floorpan -G-.
3
Separatingthe spot-weldedjoint between the wheel housingand closing panel
4
Separatingspot-weldedjoint between lower Separatespot-weldedjoint of the lower shell to the wheel housing-J, E- and the hinge pillar -1-using the spotweld shell/wheel housingand hinge pillar cutter.
5
Separatingthe spot-weldedjoint between the wheel housing! A-pillarand transverse
wall
507455
Separatethe spot-weldedjoint of the wheel housingto the closing panel -H- using the spotweldcutter.
Separatethe spot-weldedjoint (vehicleinterior)of the front wall -P- and hinge pillar -M- to the wheel housingusing the spotweldcutter. Grindopen the MIGseams -N, 0- with the parting grinder. Separatethe spot-weldedjoint of the wheelhousingon the outside to the front wall -L- using the spotweldcutter.
Replacing wheel housing
Printed in Germany -44,2001
50-23 c5074551
page 3
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Preparingspare parts
Body front
Removethe factory-appliedprimer on the welding areas of the spare parts -A, B, C, D, E, F, G, H, 1-using the rotary
brush. Drill or punch(with a hole punch)07 mm holes spaced 20 mm apart for plug-weldingwith shieldinggas. ~ "Welding wheel housing,lower shell and outer side members into the body" in 50-23 page 6
2
Cleaningthe welding areas
Removeunderbodycoating and paint layers,etc. from the welding areas of the body with a hot-airgun or rotary
brush. 3
Insertingouter side member,wheel housing Straighteningattachment-2- for front-axlemountor on the into the body straighteningattachment-1- for the impact pipes (impact absorbers)must be screwed on for the fitting work. Fit wheel housingin the body and fasten on straightening attachment-3-. Insert spare outer side member on the inner side member.
4
Fitting in wings and front lid
Fit the left and right wings and fit in the front lid. ~ Rep. Gr. 505519; Removingand installingwings ~ Rep. Gr. 552237; Disassemblingand assembling front
lid
507455
Replacing wheel housing
Printed in Germany -44,2001
50-23 c5074551
page 5
www.WorkshopManuals.co.uk Body front
Welding wheel housing, lower shell and outer side members into the body
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
No.
Procedure
1
Plug-weldingwheel housing/hinge pillar, Weldthe spare wheel housingto the front wall -N, 0 -with front wall and cross member undershielding an interruptedfull weld under shieldinggas. gas Plug-weldthe connectionto the hinge pillar -M- and the front wall -P, L- under shieldinggas.
2
Spot-weldingthe wheel housing
Instructions
Spot-weldthe whee!housingto the outer side member
-K-. 3
Weldingthe lower shell under shielding gas
Plug-weldthe lower shell to the wheel housing -J, E, 1under shieldinggas.
4
Weldingouter side member under shielding Spot-weldthe outer side member to the inner side memgas and with spot welds ber -A, D, C-. Plug-weldthe connectionto the front wall -8- under shielding gas.
5
Weldinginner/outer side membersand front Weldinner side member to outer side member -R- and the wall under shieldinggas front wall -F- with an interruptedfull weld under shielding gas.
6
Weldingside member/support shell under shieldinggas
Weldside membersto the support shell -G- with a full weld under shieldinggas.
Tools and materials
Basic straighteningattachmentsfor 911 Carrera (996) Nr. 7250700
2
=>Rep.Gr.3; WorkshopEquipment Manual
=>Rep.Gr.2.4;WorkshopEquipment
Star gaugesNr. 127-1
Manual 4
Shielding-gas weldingdevice
5
Multispot spotwelder
=>Rep.Gr.3; WorkshopEquipment Manual =>Rep.Gr.3; WorkshopEquipment Manual
6
=>Rep.Gr.3; WorkshopEquipment
Pneumaticbody saw
Manual
7
=>Rep.Gr.3; WorkshopEquipment
Anglegrinder
Manual
8
Oscillatingbody saw (specialelectrical cutter)
9
Multispotspotweld cutter
=>Rep.Gr.3; WorkshopEquipment Manual =>Rep.Gr.3; WorkshopEquipment Manual
10
=>Rep.Gr. 2.4;WorkshopEquipment
Holepunch
Manual
11
=>Rep.Gr.3; WorkshopEquipment
Hot-airgun
Manual
507455
Replacing wheel housing
Printed in Germany -44,2001
50-23 c5074551
page 7
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Rotarybrush
~ Rep.Gr. 2.4; Workshop Equipment
Manual 13
Spotweldcutter 07 mm, No. 129
~ Rep. Gr. 2.4; Workshop Equipment
Manual
J, :"'... ~
www.WorkshopManuals.co.uk 911 Carrera (996)
50 93 30
Body
Cleaning front water drains on Coupe and Cabriolet
"'"
~
104_99
50 93 30 Cleaning
front water drains on Coupe and Cabriolet
Printed
1999
in Germany
-23,
9965029
50 -29
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Cleaning water drains on Coupe and Cabriolet
106_99
50 -30
50 93 30 Cleaning front water drains on Coupe and Cabriolet 9965029
Printed
in Germany
-23,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Cleaning water drains on Coupe and Cabriolet Removingcowl panel cover, see ServoNo. 7022.
&
Warning! Water drainage hoses can be pushed out or pressed in when blown out of the body! > The water drains of the Coupe and Cabrioletshould be blown out carefully with compressed air.
No.
Procedure
Instructions
1
Blowout Coupe, Cabriolet water drains on right side of front end.
Carefullyblowout water drain from top (inset A) on right side of front end. Removedirt particles from the radiator tank (inset B) with the vacuum cleaner.
2
Blowout Coupe, Cabriolet water drains on right side of front end.
Carefullyblowout water drain from top (inset A) on right side of front end. Removedirt particles from the radiator tank (inset B) with the vacuum cleaner.
3
Blowout Coupe, Cabriolet water drains on left side of
Put vehicle onto lifting platform and carefully blowout the left water drain (inset A) from the outside of the wheel arch. Removedirt particles from the radiator tank (inset B) with the vacuum cleaner.
front end.
4
Blowout Coupe, Cabriolet water drains on left side of front end.
Put vehicle onto lifting platform and carefully blowout the left water drain (inset A) from the outside of the wheel arch. Removedirt particles from the radiator tank (inset B) with the vacuum cleaner. Installingcowl panel cover, see ServoNo. 7022
50 93 30 Cleaning
front water drains on Coupe and Cabriolet
Printed
1999
in Germany
-23,
9965029
50 .31
www.WorkshopManuals.co.uk
911 Carrera (996)
Body front
The following spare body parts are requiredfor the repair "Replacingfront wall":
A = front wall
www.WorkshopManuals.co.uk Body front
Cutting out front wall
50-33
page 2
c501455
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Bodyfront
& Warning! During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Rep. Gr. 5; Safety instructions
rn Note! .The .All
accessoriesin the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must have been completed before the damagedparts are removed.
No.
Procedure
Instructions
Cutting out closing panel and front floor panel
=> 50-11 "Replacing closing panel"
Placingvehicle on the alignmentbench
Placethe vehiclewith the units installed at the rear onto the set of straightening attachmentsand fasten in place.
1
Separatingspot-weldedjoints betweenfront Separatespot-weldedjoints of the front wall to the side wall/side membersand wheel housings members -A, D- and the wheel housings-8- with the spotweld cutter.
2
Separatingspot-weldedjoints betweenthe radiator tank and front wall
501455
Separatethe spot-weldedjoints of the radiator tank to the front wall from the inside (radiator-tankside) -C- with the spotweldcutter.
Replacing front wall
Printedin Germany-44,2001
50-33 c5014551
page 3
www.WorkshopManuals.co.uk Preparing front wall for installation and fitting
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911 Carrera (996)
Body front
page 4
501455
c5014551
.t::1~
-/
Replacing
front wall
Printed in Germany -44,
2001
www.WorkshopManuals.co.uk
911 Carrera (996)
Body front
Removethe factory-appliedprimer on the weldingareas of the spare parts -A, B, C, D- using the rotary brush. Drill or punch(with a hole punch)07 mm holes spaced 20 mm apart for plug-weldingwith shieldinggas.~ "Welding in front wall"in 50-33 page 6
2
Cleaningthe weldingareas
Removeunderbodycoating and paint layers,etc. from the welding areas of the body with a hot-airgun or rotary
brush.
3
Insertingthe frontwallintothe body
Fitthe spare front wall on the side members and on the radiator tank. Fit in the subsequentparts ~ 50-11 "Replacingclosing panel"
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Welding in front wall
50-33
c5014551
page 6
501455
Replacing front wall
Printed in Germany -44,
2001
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
2
Body front
Procedure
Instructions
Plug-weldingfront wall/side members and wheel housings
Plug-weldthe front wall to the side members -A, D- and to the wheel housing -B- under shieldinggas.
Plug-weldingradiator tank/front wall.
Plug-weldradiator tank to the front wall -C- on the left and
right.
Tools and materials Item
Designation of the special tool
Explanation
Basic straighteningattachmentsfor 911 Carrera (996)
=} Rep.Gr. 3; Workshop Equipment Manual
7250700 2
Star gauges 127-1
=} Rep.Gr. 2.4; Workshop Equipment Manual
3
Shielding-gas weldingdevice
=} Rep.Gr. 3; Workshop Equipment Manual
4
Pneumaticbodysaw
=} Rep.Gr. 3; Workshop Equipment Manual
5
Anglegrinder
=} Rep.Gr. 3; Workshop Equipment Manual
6
Oscillating body saw (specialelectrical cutter)
=} Rep.Gr. 3; Workshop Equipment Manual
Multispot spotweld cutter
=} Rep. Gr. 3; Workshop Equipment Manual
8
Holepunch
=} Rep.Gr. 2.4; Workshop Equipment Manual
9
Hot-airgun
=} Rep.Gr. 3; Workshop Equipment Manual
10
Rotary brush
=} Rep.Gr. 3; Workshop Equipment Manual
11
Spotweld cutter 0: 7 mm Nr. 129
=} Rep. Gr. 2.4; Workshop Equipment Manual
501455
Replacing
front wall
Printed in Germany -44,2001
50-33 c5014551
page 7
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Replacing front wall -Carrera 4 / GT 3 The following spare body parts are required for the repair "Replacingfront wall":
A = front wall
www.WorkshopManuals.co.uk Cutting out front wall
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911 Carrera (996)
Bodyfront
501455 c5014552
Replacing
front wall -Carrera
4/
GT 3
Printed in Germany -44,2001
www.WorkshopManuals.co.uk
911 Carrera (996)
Body front
& Warning! During body repairs,
the following safety instructions
and the general information
and quality instruc-
tions must be followed. ~ Rep. Gr. 5; Safety instructions
[IJ Note! .The .All
accessories in the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must have been completed before the damagedparts are removed.
No.
Procedure
Instructions
Cutting out closing panel and front floor panel
=>50-11 "Replacingclosing panel"
Placingvehicle on the alignmentbench
Placethe vehiclewith the units installed at the rear onto the set of straightening attachmentsand fasten in place.
Separatingspot-weldedjoints betweenfront Separatespot-weldedjoints of the front wall to the side wall/side membersand wheel housings members -A- and the wheel housings-8- with the spotweld cutter.
2
Separatingspot-weldedjoints betweenthe radiator tank and front wall
3
Separatingspot-weldedjoints and MIG Separate spot welds of the front wall at the bottom to the seams betweenthe front wall and side mem- side member -E- with the spotweldcutter. Grind off the bers. MIGseamsjoining the front wall at the sides to the side member -F, G- with the parting grinder.
Separatethe spot-weldedjoints of the radiator tank to the front wall from the inside (radiator-tankside) -C, D- with the spotweld cutter.
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Removethe factory-appliedprimer on the welding areas of the spare parts -A, B, C, D, E- using the rotary brush. Drill or punch(with a hole punch)07 mm holes spaced 20 mm apart for plug-weldingwith shieldinggas.=> "Welding in front wall" in 50-34 page 6
2
Cleaningthe welding areas
Removeunderbodycoating and paint layers, etc. from the welding areas of the body with a hot-airgun or rotary
brush. 3
Insertingthe front wall into the body
Fitthe spare front wall on the side members and on the radiator tank. Fit in the subsequentparts => 50-11 "Replacingclosing
panel"
501455
Replacing
front wall -Carrera
Printed in Germany-44,2001
4/
GT 3 c5014552
50-34
page 5
www.WorkshopManuals.co.uk Body front
Welding in front wall
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Body front
Plug-weldingfront wall/side members and wheel housings
Plug-weldfront wall to the side members and wheel housing -A, B- under shieldinggas.
2
Plug-weldingradiator tank/front wall.
Plug-weldradiator tank to the front wall -C, D- on the left and right.
3
Weldingthe front wall/side members under shielding gas
Weld front wall at the bottom to the side member -E- and front wall at the sides to the side member -F, G- with a full weld under shieldinggas.
Tools and materials
Basic straightening attachments for 911 Carrera (996)
7250700
~ Rep. Gr. 3; Workshop Equipment Manual
Star gauges 127-1
~ Rep. Gr. 2.4; WorkshopEquipment Manual
3
Shielding-gas weldingdevice
~ Rep. Gr. 3; WorkshopEquipment Manual
4
Multispotspotwelder
~ Rep. Gr. 3; Workshop Equipment Manual
5
Pneumaticbody saw
~ Rep. Gr. 3; WorkshopEquipment Manual
6
Angle grinder
~ Rep. Gr. 3; WorkshopEquipment Manual
7
Oscillating body saw(specialelectrical cutter)
~ Rep. Gr. 3; WorkshopEquipment Manual
8
Multispotspotweld cutter
~ Rep.Gr. 3; Workshop Equipment Manual
9
Holepunch
~ Rep. Gr. 2.4; WorkshopEquipment Manual
10
Hot-airgun
~ Rep. Gr. 3; WorkshopEquipment Manual
11
Rotary brush
~ Rep. Gr. 3; Workshop Equipment Manual
12
Spotweld cutter (2j 7 mm Nr. 129
~ Rep. Gr. 2.4; Workshop Equipment Manual
501455
Replacing
front wall -Carrera
Printed in Germany -44,2001
4 / GT 3 c5014552
50-34
page 7
www.WorkshopManuals.co.uk 911 Carrera (996)
51 90 19
Body center, roof, frame
Removingand installing underbody cover
188 -97
51 90 19 Removing and installing underbody cover Printed in Germany, 1997
996511
51-1
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www.WorkshopManuals.co.uk
Removing and installing underbody cover
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Printed in Germany, 1997
,-
www.WorkshopManuals.co.uk 911 Carrera (996)
Body center, roof, frame
Removingand installing underbody cover Note:
No. Designation Undersidepanel front
2
Plastic nut
Qty. 1
Removal
Installation
Removefrom underside panel middle to the front
Insert to the rear into the underside panel middle
26
T5/22 x 10 3
Clip
Check,replace if
6
necessary
4
Undersidepanel middle
5
Undersidepanelrear
6
Expanding rivet D6
7
Masking panel left
8
Masking panel right
9
Cover
10
SheetmetalscrewB 4.8 x
1
Removefrom undersidepanel rear to the front.
6
Insert to the rear into the undersidepanel rear.
Check, replace if necessary.
1
16
20 11
Spacersleeve
10
12
Sheetmetal nut St 4.8
16
13
Side cover right
1
14
Side cover left
1
15
Rubber lip left
1
Pulloff
Pushon
16
Rubber lip right
1
Pull off
Pushon
17
Clip left
1
Check,replace if necessary.
18
Clip right
1
19
Sheetmetal bracket
1
20
Sheetmetal bracket
1
Check,replace if necessary.
51 90 19 Removing and installing: underbody cover Printed in Germany. 1997
996511
51
-3
www.WorkshopManuals.co.uk
911 Carrera (996)
51 21 55
Body centre, roof, frame
Replacing rear centre panel
489_98
51 21 55 Replacing rear centre panel Printed in Germany -18.
1998
51 996515
-5
~ /~--'"
www.WorkshopManuals.co.uk
Taking out rear centre panel
1
2
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51
51 21 55 Replacing
-6 996515
Printed
rear centre panel in Germany
-18,
1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Taking out rear centre panel Removethe following accessories: rear window(Serv. No. 6475), rear lid (Serv.No. 5590), rear-windowwiper system (Serv. No. 92 30), third brake light (Serv. No. 94 70), coolant expansiontank (Serv. No. 19 40).
No.
Procedure
Instructions
Separate the spot-welded joints on the rear window
Using a spotweld cutter, separate the spot-weldedjoint betweenthe outside of the rear centre panel,closing panel of rear centre panel to cross member of convertibletop rest.
aperture.
2
Separatejoints between rear centre panel and side panel.
Using an abrasivecutter, separate the shielding-gasweld seamsjoining the rear centre panel to the side panel.
3
Removerear centre panel.
The rear centre panel is factory-sealed at the joint to the convertibletop rest cross member with swollen sealant. The seal is destroyed when the rear centre panel is replaced,and must be renewed.
51
51 21 55 Replacing rear centre panel Printed in Germany.
18, 1998
996515
-7
www.WorkshopManuals.co.uk
Inserting rear centre panel
491_98
51
51 21 55 Replacing rear centre panel
-8
996515
Printed
in Germany
-18,
1998
1
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Inserting rear centre panel Warning: Welding galvanized steel sheets produces toxic zinc oxide
& No.
> The workplace must be well ventilated and the fumes must be extracted by a suitable extraction system. (e.g. refer to Workshop EquipmentManual,Group 5 Page 3.5 -35)
Procedure
Instructions
Cleanweld and sealingareas
Removeundersealing,paint, etc. from the welding areas on the body or sealing areas (convertibletop rest cross member)using a hot-air gun or rotary brush. Remove the factory-appliedprimer from the welding areas of the spare parts using a rotary brush.
2
Insert rear centre panel in the body
Insert rear centre panel in the body. Use the rear lid to check the bodycontour. Adjust the gap between the rear lid and the side panel to the body. See: ServoNo.5 Bodygap dimensions
3
Insertseal
Applya triangularbead dimension "X" = approx. 15 mm of body sealantto the inside of the rear centre panel seal. Applya triangularbead dimension "X" = approx. 15 mm of body sealantin the recess on the underside of the convertibletop rest cross member.
4
Insertrear centrepanel in the body
Insert rear centre panel in the body. Fix the rear centre panel in place using crimping pliers. Check contours
andgaps. 5
Spot-weldrear centre panel
51 21 55 Printed
Replacing
in Germany
-18,
Spot-weldthe rear centre panel to the rim of the window aperture and the joint at the bottom to the convertible top rest cross member.
rear centre panel 1998
51
996515
-9
www.WorkshopManuals.co.uk
No.
Procedure
Instructions
6
Weld joint to side panel
Weld the overlap to the side panelwith an interrupted full weld using shieldinggas.
using shieldinggas
51 21 55 Replacing rear centre panel
51 -10 996515
Printed in Gennany -18, 1998
www.WorkshopManuals.co.uk 51 63 19
Removing and installing deformation element
51630001
51 63 19 Removing Printed in Germany -34,
and installing 1999
deformation
element
9965111
51-II
www.WorkshopManuals.co.uk Body centre,
911 Carrera (996)
roof r frame
Removing deformation element
51630002
Installing deformation element
51630003
51-12
51 63 19 Removing and installing 9965111
deformation
Printed
in Germany
element -34,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Removing deformation element
The A-pillar trim must be removed for removal of the deformation element. Refer to Servo No. 70 57
Note: > From model year 2000 onwards,a deformation elementwill be fitted on the inner left and right sides of the windscreenframe.
Caution!
&
Danger of injury by damaged deformation elements after an accident. > It is impermissibleto perform repairs on the deformationelement. The deformation element must be replaced in the event of visible damage or pressure
marks.
No. Procedure
Instructions
Drill out the A 4.0 x 6.3 pop rivets (A) using a 4 mm .0 drill bit.
Drilling the pop rivet out
Installing deformation element
No.
Procedure
Instructions
Rivetingthe deformationelement.
Positionthe deformation element (A) with the A 4.0 x 6.3 pop rivets (8) at the existing holes in the windscreenframe and rivet it into place.
51 63 19 Removing Printed
in Germany
-34,
and installing 1999
deformation
element
9965111
51
-13
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Replacing roof The following spare body parts are requiredfor the repair "Replacingroof":
A = Roof
510355
Replacing
51-15 page1
roof
Printed in Germany -42,2000
c5103551
www.WorkshopManuals.co.uk 911 Carrera (996)
Bodycentre, roof, frame
Disconnecting roof
--
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rn Note! .The
accessoriesin the repair area should be removed,dependingon the extent of the damage.
.All straighteningwork on the body in this area must have been completedbefore the damagedparts are removed.
No.
Procedure
Instructions
Separatingthe spot-weldedjoint between the outer/inner lower side members
Separatethe spot-weldedjoint betweenthe outer lower side member and the inner lower side member -A- with the spotweldcutter. Cutthroughthe connectionto the A-pillar-8- with the body saw. Positionthe cut so that the spare body part (outer lower side member)overlapsA-pillarby approx. 60 mm. Cut the connectionto the side section -E- with the body saw. Positionthe cut so that the spare body part (outer lower side member)overlapsthe side section by approx. 60mm.
2
Sawingthrough the web plate
Cut through the web plate at the top and bottom -F, Gwith the body saw.
~
Separatingthe spot-weldedjoint between the outer/inner lower side members
Separatethe spot-weldedjoint betweenthe outer lower side memberand the inner lower side member -C- with the spotweldcutter.
4
Separatingthe spot-weldedjoint between the web plate/inner lower side member
Separatethe spot-weldedjoint betweenthe web plate and the inner lower side member -D- with the spotweldcutter.
~
514555 Replacing lower side member Printedin Germany-42. 2000
51-16 c5145551
page 3
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Body centre, roof, frame
Procedure
Instructions
Cleaningthe welding areas
Removethe factory-appliedprimer on the welding areas of the spare part -A, 8, C, D, E- using the rotary brush.
2
Preparingspare part
Removeunderbodycoating and paint layers, etc. from the welding areas of the body with a hot-airgun or rotary brush.
3
Insertingouter lower side member Fitting lower side member separation point
Insertthe outer lower side member into the body. Cutthrough the outer lower side member, overlapping at the separationpoint, flush with the A-pillar-8- using the body saw.
4
Fitting lower side member separation point
Cutthrough the outer lower side member,overlapping at the separationpoint, flush with the side section -E- with the body saw.
5
Setting gap
Set gap between door and outer lower side member. ~ 5-37 "Diagram-body gap dimensions"
514555
Replacing lower side member
Printed in Germany -42,
2000
51-16 page 5 c5145551
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Welding in lower side member
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www.WorkshopManuals.co.uk Body centre,roof, frame
911 Carrera (996)
Weldingouter/inner lower side members under shielding gas
Plug-weldthe outer lower side memberand the inner lower side member -A- with shieldinggas. Weldthe connectionto the A-pillar-B- and the connection to the side section -E- with a continuousfull weld under shieldinggas.
2
Weldingthe web plate under shieldinggas
Weldthe web plate and the inner lower side member -Dtogether with an intermittentfull weld under shieldinggas.
3
Weldingouter/inner lower side members under shielding gas
Plug-weldthe outer lower side memberand the inner lower side member .;C-together under shieldinggas.
Tools and materials
Star gauges Nr. 127-1
=> Rep. Gr. 2.4; WorkshopEquipment Manual
2
MIGwelder
=> Rep.Gr. 3; Workshop Equipment Manual
3
Body saw
=> Rep. Gr. 3; Workshop Equipment Manual
4
Angle grinder
~ Rep. Gr. 3; WorkshopEquipment
Manual
5
Oscillatingbody saw (specialelectrical cutter)
~ Rep. Gr. 3; WorkshopEquipment Manual
6
Multispotspotweld cutter
~ Rep. Gr. 3; WorkshopEquipment Manual
7
Hole punch
~ Rep. Gr. 2.4; Workshop Equipment Manual
8
Hot-airgun
~ Rep. Gr. 3; WorkshopEquipment Manual
9
Rotarybrush
=> Rep. Gr. 3; WorkshopEquipment Manual
10
Spotweldcutter 12'7 mm Nr. 129
=>Rep. Gr. 2.4; Workshop Equipment Manual
www.WorkshopManuals.co.uk Body centre, roof, frame
911 Carrera (996)
Replacing lower side member -Cabriolet The following spare body parts are requiredfor the sectional repair "Replacinglower side member"
A = Lower side member
514555
Replacing
lower side member
Printed in Germany -42,2000
-Cabriolet c5145552
51-17 page1
:/
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www.WorkshopManuals.co.uk Body centre, roof, frame
911 Carrera (996)
Cutting out lower side
-
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page 2
/
514555 c5145552
Replacing lower side member -Cabriolet Printed in Germany-42. 2000
www.WorkshopManuals.co.uk & Warning! During body repairs, the following safety instructions and the general information tions must be followed. ~ Rep. Gr. 5; Safety instructions
and quality instruc-
rn Note! .The
accessoriesin the repair area shouldbe removed,dependingon the extent of the damage.
.All straighteningwork on the body in this area must have been completed before the damagedparts are removed.
Separatingthe spot-weldedjoint between the outer/inner lower side members
Cutthrough the spot-weldedjoint betweenthe outer lower side member and the inner lower side member -A- or betweenthe outer lower side member and the A-pillar -8with the spotweldcutter. Cutthrough the connectionto the side section-E-with the body saw. Positionthe cut so that the spare body part (outer lower side member)overlapsthe side section by approx. 60 mm.
2
Sawingthrough the web plate
Cut through the web plate at the top and bottom -F, Gwith the body saw.
3
Separatingthe spot-weldedjoint between the outer/inner lower side members
Separatethe spot-weldedjoint betweenthe outer lower side member and the innerlower side member -C- with the spotweldcutter.
4
Separatingthe spot-weldedjoint between the web plate/inner lower side member
Separatethe spot-weldedjoint betweenthe web plate and the inner lower side member -D- with the spotweldcutter.
514555
Replacing lower side member
Printed in Germany -42,2000
-Cabriolet c5145552
51-17 page3
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
911 Carrera (996)
No.
2
Body centre, roof, frame
Procedure
Instructions
Cleaningthe welding areas
Removethe factory-appliedprimer on the weldingareas of the spare part -A, B, C, D, E- using the rotary brush.
Preparingsparepart
Removeunderbodycoating and paint layers,etc. from the welding areas of the body with a hot-airgun or rotary
brush. 3 4
Insertingouter lower side member
Insert outer lower side member into the body.
Fitting lower side member separation point
Cut through the outer lower side member,overlappingat the separationpoint, flush with the side section -E- with the body saw.
5
Setting gap
Set gap betweendoor and outer lower side member. => 5-37 "Diagram-body gap dimensions.
514555
Replacing lower side member
Printed in Germany -42,2000
-Cabriolet c5145552
51-17
page 5
" ", '" ,/( ;'" ~
www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Welding in lower side member
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www.WorkshopManuals.co.uk 911 Carrera (996)
Body centre, roof, frame
Weldingouter/inner lower side members under shielding gas
Plug-weldthe outer lower side member and the inner lower side member -A- as well as the connectionto the A-pillar -B- with shieldinggas. Weldthe connectionto the side section -E- with a continuous full weld under shieldinggas.
2
Weldingthe web plate under shieldinggas
Weldthe web plate and the inner lower side member -Dtogether with an intermittentfull weld under shieldinggas.
3
Weldingouter/inner lower side members under shielding gas
Plug-weldthe outer lower side member and the inner lower side member -C- together under shieldinggas.
Tools and materials Item
Designation of the special tool
Explanation
Star gaugesNr.127-1
~ Rep. Gr. 2.4; Workshop Equipment Manual
2
MIGwelder
~ Rep. Gr. 3; Workshop Equipment Manual
3
Body saw
~ Rep. Gr. 3; Workshop Equipment Manual
4
Angle grinder
~ Rep. Gr. 3; Workshop Equipment Manual
5
Oscillatingbody saw (specialelectrical cutter)
~ Rep. Gr. 3; Workshop Equipment Manual
6
Multispot spotweld cutter
~ Rep.Gr. 3; Workshop Equipment Manual
7
Hole punch
~ Rep. Gr. 2.4; WorkshopEquipment Manual
8
Hot-airgun
~ Rep. Gr. 3; Workshop Equipment Manual
9
Rotarybrush
~ Rep.Gr. 3; Workshop Equipment Manual
10
Spotweld cutter 0 7 mm Nr. 129
~ Rep. Gr. 2.4; Workshop Equipment Manual
www.WorkshopManuals.co.uk Body centre, roof, frame
911 Carrera (996)
Replacing seat cross member The following spare body parts are requiredfor the repair "Replacingseat cross member"
A = seat cross member
518755
Replacing
seat cross member
Printed in Germany-44,2001
51-18 page1 c5187551
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Body centre,roof, frame
911 Carrera (996)
& Warning! During body repairs, the following safety instructions and the general information and quality instructions must be followed. =} Rep. Gr. 5; Safety instructions
rn Note! .The .All
accessoriesin the repair area should be removed,dependingon the extent of the damage.
straighteningwork on the body in this area must have been completed before the damagedparts are removed.
Separatingspot-weldedjoints betweenthe seat cross member and floorpan
Separatethe spot-weldjoints betweenthe seat cross member and the floorpan -A, B- with the spot-weldcutter.
2
Separatingspot-weldedjoints betweenthe seat cross member and inner member
Separatethe spot-weldjoints -C- betweenthe seat cross member and inner member with the spot-weldcutter.
3
Separatingspot-weldedjoints betweenthe seat cross member and inner member
Separatethe spot-weldedjoints -D, E, F- betweenthe seat cross member and inner lower side member with the spotweld cutter.
"" ~ '" ~Ir ";::::::::~
www.WorkshopManuals.co.uk Body centre, roof, frame
911 Carrera (996)
Preparation of seat cross member for installation and fitting
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www.WorkshopManuals.co.uk
911 Carrera (996)
Body centre, roof, frame
Removethe factory-appliedprimer on the welding areas of the spare parts -A, B- using the rotary brush. Drill or punch(with a hole punch)07 mm holes spaced 20 mm apart for plug-weldingwith shieldinggas. ~ "Weldingin seat cross member"in 51-18 page 6
2
Cleaningthe weldingareas
Removeunderbodycoating and paint layers,etc. from the welding areas of the body with the hot-airgun or rotary brush.
3
Measuringseatcrossmember
Measurethe seat cross member at the front screwed points (hole center)forward to the hole edge of the reinforcement in the floorpan -dimension -dimension
518755
Replacing
seat cross member
Printed in Germany -44.2001
c5187551
X = 405 mmY = 453 mm-
51-18
page 5
www.WorkshopManuals.co.uk Body centre,roof, frame
Welding in seat cross member
911 Carrera (996)
www.WorkshopManuals.co.uk
No.
Procedure
Instructions
Plug-weldingseat cross member under $hieldinggas
Plug-weldthe seat cross member ~ t
2
Plug-weldingseat cross member under $hieldinggas
Plug-weldthe seat cross member t the sides -C- under shieldinggas.
3
If>lug-welding seat cross member under shieldinggas
Plug-weldthe seat cross member ~t the sides and middle -D, E, F- under shieldinggas.
Tools and materials
MIGwelder
~ Rep.Gr.3; WorkshopEquipment Manual
2
Angle grinder
=>Rep. Gr. 3; Workshop EquipmentManual
3
Multispotspotweld cutter
::} Rep.Gr. 3; Workshop EquipmentMan-
ual
4
Hoilepunch
~ Rep.Gr. 2.4; WorkshopEquipment
Manual
5
Hot-airgun
~ Rep.Gr. 3; Workshop EquipmentManual
6
Ro~ary brush
~ Rep. Gr. 3; Workshop EquipmentMan-
ual Spptweldcutter 07 mm Nr. 129
the front and rear -A,
B- under shielding gas.
~ Rep.Gr. 2.4;
WorkshopEquipment Manual
www.WorkshopManuals.co.uk 911 Carrera (996)
53 69 19
Body rear
Removingand in!.talling wheel housing liner
238 -97
53 69 19 Removing and installing wheel housing liner Printed in Germany, 1997
996531
53-1
www.WorkshopManuals.co.uk
Removingand installing wheel housing liners
323.97
53 -2
53 69 19 Removing and installing 996531
wheel housing liner Printed in Germany, 1997
www.WorkshopManuals.co.uk Body rear
911 Carrera (996)
Removingand installing wheel housing liners Note:
No.
Designation
1
Left wheel housing liner
1
Pulloutdownwards.
2
Rightwheel housing liner
1
Pulloutdownwards.
3
PlasticnutT5.
6
Unscrew.
Qty.
Removal
Installation
Inspect and replace if
necessary.
53 69 19 Removing and installing wheel housing liner Printed in Germany, 1997
996531
53 -3
www.WorkshopManuals.co.uk 911 Carrera (996)
53 93 30
Body
Cleaning rear water drains on Coupe and Cabriolet
105_99
53 93 30 Cleaning rear water drains on Coupe and Cabriolet Printed
in Germany
-23,
1999
996535
53 -5
~ if' ~ ~ 1
-~-~ ~ "" ~ "r{ ~\'>,'
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Cleaning rear water drains on Coupe and Cabriolet
~~"l]" -'\
4
~
--
-~
/\
\ ,
\
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/
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--
-107_99
53-6
53 93 30 Cleaning rear water drains on Coupe and Cabriolet 996535
Printed
in Germany
-23,
1999
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Body
Cleaning rear water drains on Coupe and Cabriolet Removingside-panellining,see ServoNo. 70 75; removing rear wheel housingliner, see ServoNo. 5369
&
Warning! Water drainage
hoses can be pushed out or pressed in when blown out of the body!
> The water drains of the Coupeand Cabrioletshould be blown out carefully with compressed air.
No.
Procedure
Instructions
1
Blowoutthe Cabrioletwater draintube in the rear wheel housingson the left and right.
Carefullyblowout the water drain tube (arrow A) in the water collection tray on the left and right. Removeany dirt particles from the water collection tray (arrow B) using the vacuum cleaner. Installing side-panellining,see ServoNo. 70 75
2
Blowout the water drainage hoses from the sliding/tilting roof at the front, rear I left and right.
Note: The water drainage hoses should only be blown out when the sliding/tilting roof is closed. Frontwater drainage hose: Carefullyblowout the front water drainage hose in the B-pillar (arrow A) on the left and right. Rearwater drainage hose: Putvehicle onto lifting platform and carefully blowout the water drain (arrow A) on the left and right in the rear wheel housingfrom the outside of the wheel arch Open sliding/tilting roof and remove dirt particles from the sliding roof frame using the vaclilumcleaner. Installingrear wheel housing liner, see ServoNo. 5369
53 93 30 Cleaning
rear water drains on Coupe and Cabriolet
Printed in Germany
1999
-23,
996535
53-7
www.WorkshopManuals.co.uk
,
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Separation points on side section
433_98
Lay separation points according to damage. Figure shows all separationpoints provided and also where part replacementis possible. Note:
t
A: C-pillar separation point
Do not damage inside qf side section
B: Lower side member separation point
Do not damage inner reinforcement
C: B-pillar centre separation point
Do not damage inside qf side section
D: Centre part replacement separation point
Do not damage outer wheel arch
53 55 55 Printed
Replacing
in Germany
-28,
53-11
side section
1999
996539
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Removing side section from the body
Removethe following accessories: side window ServoNo. 6475, rear window ServoNo. 6486, side-panellining ServoNo. 7057, Band C-pillarlining ServoNo. 7057, rear spoiler t erv. No. 63 55, roof j~int strip ServoNo. 66 36, release for rear lid ServNo. 55 57, taillight ServoNo.9 33, wheel housing liner ServoNo. 5369, coolant expansiontank ServoNo. 1940*, striker pin, front se t belt, door seal. = only when replacing the left side section
No.
Procedure
Instructions
1
Separate the spot-weldedjoint on the B-pillar
Separatethe spot-weldedjoint between the side section and the inside of the side section with the spotweldcutter. Cut off the lower side member with the body saw so that the spare body part (side section)ov~rlapsthe lower side member by approx. 60 mm. I
2
Separate the spot-weldedjoint on the lower side member and the wheel housing
Separatethe spot-weldedjoint betweenthe side section and the lower side member or wheel ~OUSing with the spotweld cutter. !
3
Cut through centre of B-pillar
Trim the side section at the B-pillarcentre with the body saw so that the spare body part overlapsthe centre of the B-pillarby approx. 60 mm.
4
Cut through side section at C-pillar
Trim the side section at the C-pillarwith the body saw so that the spare body part overlaps the C-pillarby approx. 60 mm.
Separate the spot-weldedjoint on the side window aperture
53 55 55 Printed
Separate the spot-welded joint on the Iside window aperture using the spotweld cutter.
Replacing side section
in Germany
-28,
1999
II
I
53 -13 996539
~
www.WorkshopManuals.co.uk
Removing side section from the body
6
L?
f\)
7
9
8
c 425_98
53 55 55
53 -14 996539
Replacing side section Printed
in Germany
-28,
1999
www.WorkshopManuals.co.uk Removing side section from the body
No.
Procedure
Instructions
6
Separate the spot-weldedjoint of the rear windowaperture.
Separatethe spot-weldedjoint betwee1 rear
window
aperture
and
the
inside
the
of the
side side
section section
with the spotweldcutter.
7
Separate side section from rear centre panel
Separatethe spot-weldjoint of the overlappingrear centre panel at the top using the spotweld cu er. Cut through the brazed seam on the connectionto he side section with the parting grinder.
8
Separate the spot-weldedjoint on the light housing
Separatethe spot-weldedjoint betweenthe light housing and the inside of the side section and the rear transverse lock panel connectionwith the spotweldJcutter.
9
Removeside section
r
The the
an
side rear
section centre
expanded
replacing
53 55 55
-28,
1999
sealed
sealant.
the
Replacing side section
Printed in Germany
panel is
side
section
connection
from
This
seal
and
the
is
must
lig the
in
destr
]
factory housing
yed
be
using
to
when
replaced.
53 -15 996539
www.WorkshopManuals.co.uk Body rear
9111 Carrera (996)
Inserting the side section into the body
426_98
53 55 55
53 -16 996539
Replacing side section Printed
in Gennany
-28,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Inserting the side section into the body
with
5
Group
Man
Equipment
Workshop
to
refer
(E.g.
system.
extraction
suitable
a
j
> The work area must be well ventilated and the smoke gases must be
ai,
&
removed
Warning: Toxic zinc oxide is emitted when welding galvanized steel
Page 3.5 -35)
No.
Procedure
Instructions
Cleanwelding and sealing areas
Removeunderbodycoating and paint~aYersfrom the welding areas on the body or sea ing areas (inside of side section)using a hot-air gun or ro ary brush. Remove the factory-appliedprimer from the welding areas of the spare part using the rotary brush.
2
Adapt the side section to the body
Fit the side section to the body. Insert door and rear lid to check the body contour. Adjust the g1 P dimensions betweenthe door and rear lid and th body. See: ServoNo.5 Body gap dimensions
3
Fit side section separation points
Cut through both panels at the separationpoints where the side section overlaps the lower sipe member, C-pillar and B-pillarcentre using the body sa~.
4
Insert seal
Apply a triangular bead of body seal~ t -dimension "X" = approx. 12 mm high -on all sid s of the side section seal. Positionthe seal on the Tucker olts on the inside of the side section and press on. I
5
Bond light housingwith the inside of the side section
Apply a triangular bead of adhesive(Teromix-6700) -dimension "X" = approx. 10 mm high -on the connectionfrom the light housingto the inside of the side section. The light housing mJst lie flush with the side section. I
53 55 55 Printed
Replacing side section
in Germany
-28,
1999
53 -17 996539
www.WorkshopManuals.co.uk
No.
www.WorkshopManuals.co.uk 911 Carrera (996)
Inserting
7
the side section into the body
Warning: Observe the working time of the adhesive (Item 6)
& 6
Body rear
> The new part must be welded in within 30 minutes. Otherwisethe adh1sionof the adhesive is impaired. i Procedure
Instructions
Apply adhesiveon the wheel arch up as far as the start of the side member and the water channel of the side section
Applythe adhesiveas a triangular bea 1
=
approx.
8
mm
-on
the
inside
of
-dimension
th
side
"X" section,
along the inner edge up as far as the s art of the side member and on the underside of the water channel. Referenceaddress: Teromix-6700 2-colmponent adhesiveand the Teromix processing nozzle Henkel Teroson GmbH I Postfach 10 56 20 69 0 46 Heidelberg Hans-Bunte-Str1aBe4 Telephone (06221) 7040 Fax (06221) 704585
Tack-weldside section under
Insert side section into the body. Checr
shielding gas
gap
dimensions.
Tack-weld
the
side
se
the tion
contours under
and shielding
gas at the separationpoints. 8
Spot-weldB-pillarand weld under shielding gas
9
10
Spot-weldwheel arch and weld under shielding gas Spot-weldside window aperture
53 55 55
Spot-weldthe B-pillarside section to the inside of the side section. Weld the lower side member connectionon the side section to the lower side member with a continuous butt weld under shieldinggas.
Plug-weld underside of lower side mem~er. Spot-weld wheel arch
Spot-weldthe side windowaperture to the inside of the side section. I
Replacing side section
Printed in Germany
-28,
1999
I
53 -19 996539
"< ;/ r ~ ,/ "'( ~
www.WorkshopManuals.co.uk 53
Body rear
911 Carrera (996)
Inserting the side section into the body
12 /
/:
1~ /
!
\ !~
/
14
/ /
111
" "
www.WorkshopManuals.co.uk 911 Carrera (996)
Inserting
Body rear
the side section -Cabriolet
into the body
Caution!
&
Observe the working time of the adhesive (Item 6)
t
The new part must be welded in within 30 minutes. Otherwisethe adh sion of the adhesive is impaired.
No.
Procedure
Instructions
6
Apply adhesiveon the inside of the water channeland on the wheel arch up as far as the start of the side member
Apply the adhesiveas a triangular bead (dimension "X" = approx. 8 mm) on the inside of the s de section, along the water channeland the wheel arch s far as the start of the side member. Referenceaddress: Teromix-6700 2-c mponentadhesive and the Teromix processing nozzle Henkel Teroson GmbH Postfach 10 56 20 69 0 46 Heidelberg Hans-Bunte-SttaBe 4 Telephone (06221) 7040 " Fax (06221) 704585 I
7
Tack-weldside section under
To do so, the vehicle must be standin on its wheels or positioned on the set of straightening ttachments. Insert side section into the body. Check the ontours and gap dimensions.Tack-weldthe side sectio under shielding gas at the separationpoint.
shielding gas
8
Weldthe B-pillarundershielding gas
9
10
Plug-weldundersideof lower side me
Spot-weldwheel arch and weld under shielding gas
wheel
Spot-weldwaterchannel
Spot-weldinside of side section with the water channel
53 55 55 Printed
Plug-weldthe B-pillarside section to the inside of the side section under shieldinggas. Weld the t ide section to the lower side member connectionwith a ontinuousbutt weld under shieldinggas.
1
Replacing side section -Cabriolet
in Germany
-33,
1999
ber.
Spot-weld
arch
9965323
53 -29
www.WorkshopManuals.co.uk Body rear
911 Carrera (996)
t?
J}
154_99
53 -30
53 55 55 9965323
Replacing
side section -Cabriolet Printed in Germany -33, 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
53
No.
Procedure
Instructions
11
Spot-weldlighthousing
Spot-weldlight housingwith the connecting angle and the connectionto the transverse lock pan~l. On the inside of the side section (small figure), make sure that the welding nuts are lined up with the hole pattern in the side section. Screw in M6 hexagol1l-head bolts to position. Spot-weldthe connectionwith the side section.
12
Weld cross member under
Weld the overlap of the cross member at the top with a stitch weld seam under shieldinggas. Weld the overlap on the lower side section connectionunder shieldinggas.
shielding gas
13
Mark bores for the insertion bushings
14
Fileoff insertionbushingsand insert
53 55 55 Printed
Replacing
in Germany
-33,
Cut the water channelas a template out of the removed side section as shown in Figure 13, Pliltit on the spare body part (side section)and mark the bores for the insertion bushings.Bore a 9.0 mm m, rk in the water channelusing a twist drill.
File off both bores to the hexagon of the insertion bushing using a needle-pointfile. I Insertthe insertion bushingusing the blind rivet nut manual device. Blind rivet nut manualdevice: refer to Workshop Equipment Manual,Chapter2.4, No. 125.
side section -Cabriolet
1999
53 -31 9965323
www.WorkshopManuals.co.uk 911 Carrera (996)
53 05 55
Body rear
Replacing rear closing panel
53050004
53 05 55 Printed
Replacing
in Germany
-34,
53 -33
rear closing panel
1999
9965333
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
53050005
53 05 55
53 -34 9965333
Replacing rear closing panel Printed
in Germany
-34,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Cutting out rear closing panel
Removethe accessories:rear spoiler(serv.No. 63 55), taillight (serv.No. 94 31), Il1>wer part of lid lock (serv.No. 55 86) and engine(serv.No. 10 01). Note: > All straighteningwork on the body in this area must have been compl~ed before the damaged parts are removed. I
No.
Procedure
Instructions
Placingvehicleon the alignment
Place the vehiclewith the units mount d at the front onto the set of straighteningattachments a d fasten it in
bench.
t
position.
1
Separatingthe spot-weldedjoint at the rear closing panel.
Use a spotweld cutter to separate the connectionbetween the inner side members and the rear dlosing panel on the left and right.
2
Separatingthe spot-weldedjoint at the rear closing panel.
Use the spotweld cutter to separate e connection betweenthe side section on the inside and the rear closing
:
panel. 3
Separatingthe spot-weldedjoint on the engine mount at top.
Use the spotweld cutter to separate thle spot-weldedjoint betweenthe engine mount at top and the inner side member.
4
Separating the spot-welded joint
Use the spotweld cutter to separate thle spot-weldedjoint betweenthe engine mount at bottom and the inner side member.
on the engine mount at bottom.
53 05 55 Printed
Replacing rear closing panel
in Germany
-34,
1999
53 -35 9965333
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk 911 Carrera (996)
Inserting
Body rear
rear closing panel
1
Cleaningthe welding areas
Removeunderbodycoating and paint layers from the welding areas using a hot-airgun or rotary brush. Remove the factory-appliedprimer from the w~lding areas of the spare parts using a rotary brush. I
2
Inserting the rear closing panel the engine mounVside
Insert the rear closing panel into the body and fit it on the inner side sections and the left and right side members. Fastenthe replacementrear closing 1 anel on the
member at bottom under
attachment
into the body and plug-weld
set.
Fit the lid and adjustthe gap widths. See: ServoNo.5 "Diagram of body g~p dimensions" Fit lower part of rear lid lock, see KD No. 55 86, and check whether the upper part of the li ck engages in the
shielding gas
lower part of the lock.
3
Plug-weldingthe engine mounVside member at top under shielding gas
Plug-weldthe engine mounts at the right and left to the side member under shieldinggas. Spot-weldthe connectionto the corne~panel and to the side section on the left and right. I
4
Spot-weldingthe rear closing panel/side member on the inside
Spot-weldthe connectionbetweenthe inner side members and the rear closing panel on the left and right.
53 05 55 Printed
Replacing rear closing panel
in Germany
-34,
1999
53 -37 9965333
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
GT3 Thefollowingsparebodypartsare requiredfor the repair"Replacing seatcross member"j
A = closing panel
530555
Replacing rear closing panel -GT 3
Printed in Germany -44, 2001
53-39 e5305552
page 1
"~
www.WorkshopManuals.co.uk 911 Carrera (996)
Bodyrear
Cutting out rear closing panel
L
'/
www.WorkshopManuals.co.uk Bodyrear
911 Carrera (996)
During body repairs, the following safety instructions and the general information and quality instructions must be followed. =>Rep. Gr. 5; Safety instructions
[IJ Note! .The accessories in the repair area should be removed,depending on the extent of the damage. .All straighteningwork on the body in this area must have been completed before the damagedparts are removed.
No.
Procedure
Instructions
Placingvehicle on the alignmentbench.
Placethe vehiclewith the units m unted at the front onto the set of straighteningattachme ts and fasten it in posi-
tion. Separatingthe spot-weldedjoint at the rear closing panel.
Use a spotweldcutter to separatethe connectionbetween the inner side members and the r ar closing panel -A- on the left and right.
2
Separatingthe spot-weldedjoint at the rear closing panel.
Use the spotweld cutter to separ te the connection betweenthe side section on the in ide and the rear closing panel -B, C-.
3
Separatingthe spot-weldedjoint on the engine mount at top.
Separatethe spot-weldedjoint be een the engine mount at top -D- and the inner side me ber and the connection to the inner side section -F- with he spot-weldcutter.
4
Separatingthe spot-weldedjoint on the engine mount at bottom.
Use the spotweld cutter to separ te the spot-weldedjoint betweenthe engine mount at bott m -E- and the inner side member.
530555
Replacing
rear closing panel -GT 3
Printed in Germany -44,2001
e5305552
53-39
page 3
, ""
www.WorkshopManuals.co.uk Body rear
Preparing the rear closing panel for installation and fitting
~~ ,
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Removethe factory-appliedprimer on the widing areas of the spare parts -A, 8, C, D, E- using the rotary brush. Drill or punch (with a hole punch)07 mm ho es spaced 20 mm apart for plug-weldingwith shieldinggas. ~ "Weldingin rear closing panel"in 53-39 age 6
2
Cleaningthe welding areas
Removeunderbodycoating and paint layers etc. from the welding areas of the body with a hot-airgun or rotar brush.
3
Inserting the closing panel into the
Insert spare closing panel into the body and fasten on the straighteningattachments. If necessary,adapt it to the inner side secti ns and side members.
body
4
Fitting add-onparts and check gap dimensions
Fit the lid and adjustthe gap widths. ~ Rep.Gr. 559037 ; Disassemblingand as embling rear lid Fit lower lock part of the rear lid and check hether the upper lock part engagesin the lower lock part.
"~8r ~
www.WorkshopManuals.co.uk 911 Carrera (996)
Body rear
Welding in rear closing panel
r
~15/. "'"
,';';--f
e
'"..,.
~
/
/
11
www.WorkshopManuals.co.uk 911 Carrera (996)
No.
Procedure
Body rear
Instructions
Plug-weldingreinforcement/sidemember at Plug-weldthe reinforcementbetw en the side members at bottom under shielding gas bottom -E- and the closing panel nder shieldinggas.
2
Spot-weldingthe rear closing panel/side member on the inside
Spot-weldthe connectionbetwee the inner side members -8, C- and the rear closing panel on the left and right.
3
Plug-weldingthe engine mount/side member at top under shielding gas
Plug-weldthe engine mounts at t e left and right to the side member at top -D- under shi Iding gas. Plug-weldthe connection -F- to t e inner side section with an approx.l 0 mm full weld.
4
Spot-welding the closingpanel/sidemembersonthe inside
Plug-weldthe connectionbetwee the inner side members -A- and the closing panel under s ielding gas.
Tools and materials
Item
Designationof the specialtool Basic straighteningattachmentsfor 911 Carrera (996)
=>Rep. Gr. 3;1WorkshopEquipment Manual I
2
Additionalstraightening attachments for 996 Turbo
=>Rep. Gr. 3; WorkshopEquipment Manual
3
StargaugesNr.127-1
=> Rep. Gr. 2.4; Workshop Equipment Manual
4
MIGwelder
=> Rep. Gr. 3; WorkshopEquipment Manual
5
Multispot spotwelder
=> Rep. Gr. 3; WorkshopEquipment Manual
6
Pneumaticbody saw
=> Rep. Gr. 3; WorkshopEquipment Manual
7
Anglegrinder
=> Rep.Gr. 3; Workshop Equipment Manual
8
Oscillatingbody saw (specialelectrical cutter)
=>Rep. Gr. 3; WorkshopEquipment Manual
9
Multispotspotweld cutter
=> Rep. Gr. 3; WorkshopEquipment Manual
10
Holepunch
=> Rep.Gr. 2 4; Workshop Equipment Manual
Hot-airgun
=> Rep. Gr. 3 Workshop Equipment Manual
Rotarybrush
=> Rep. Gr. 3 Workshop Equipment Manual
12
530555
Replacing rear closing panel -GT 3
Printed in Germany -44,2001
e5305552
53-39 page 7
www.WorkshopManuals.co.uk Body rear
Spot-weld cutter 07 mm Nr. 129
911 Carrera (996)
=>Rep.Gr.2.4; WorkshopEquipment Manual
www.WorkshopManuals.co.uk 911 Carrera
55 22 37
( 996 )
Lids, flaps
55
Disassemblingand assembling front lid
33.97
55 22 37 Disassembling and assembling front lid Printed in Germany, 1997
996551
55 -1
www.WorkshopManuals.co.uk Lids, flaps
911 Carrera ( 996 )
Disassemblingand assembling front lid
139-96
55-2
55 22 37 Disassembling and assembling front lid 996551
Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera ( 996 )
Lids, flaps
Disassembling and assembling front lid Note:
No. Designation
8
Qty.
1
Lid
1
2
Rubber buffer
2
3
Combinationscrew M6 x 12
2
4
Upper part of lock
1
5
Combinationscrew M6 x 14
6
Removal
Installation Adjust lid to the hingesin accordancewith the contours of the wings and the front spoiler.
Removerubber buffers by turning them.
Screw in rubber buffers.
Tighteningtorque: 10 Nm (7.5 ftlb.) Removeupper part of lock from lid.
Fasten upper part of lock to the lid with the combination screws and adjust to the lower part of lock.
10
Loosenfastening screws and remove lid from vehicle.
Lay lid on hingesand screwtight.
Hinge left
1
Loosen combinationscrews M6 x 14
Adjust to the left side section in accordance with lid contour.
7
Hinge right
1
Loosen combinationscrews M6 x 14
Adjust to the right side section in accordance with lid contour.
8
Plug connection
1
Disconnectcable-harness plug connection.
Connect cable-harness plug connection.
9
Bowden cable
1
Press Bowdencable out of holder.
Press Bowdencable into holder.
10
Lower part of lock
1
11
Combinationscrew M6 x 30
1
Fasten lower part of lock with combination screws and adjustto upper part of lock. Undo
55 22 37 Disassembling and assembling front lid Printed in Germany, 1997
996551
55 -3
www.WorkshopManuals.co.uk 911 Carrera
Lids, flaps
( 996 )
Note:
No. Designation
Qty.
Removal
Installatiolr1
12
Tapping nut
2
Unscrewfasteningnut of lid badge.
Replace
13
Badge on lid
1
Removebaseof lid badge.
Insertbaseandlid badge intothe lid andfasten withtappingnut.
14
Base
1
15
Emergency operation mechanism
1
16
Pneumaticspring
2
17
Catch
4
Presscatchout.
PresscatGhin.
18
Rubbersleeve
1
19
Plug
3 3
Back off hexagon socket head bolt by 4 -5 turns.
Screw hexagon socket head bolt into the bottom support by 2 -3 turns.
1
Removeplug 8.0 x 11 x 7.2 (Item 19), back off hexagon socket head bolt M6 x 25 by approx. 4 -5 turns. Lift kick plate upwards out of the bottom support with a plastic spatula and press out.
Positionkick plate on the support and push on. Screw down hexagon socket head bolts M6 x 25
8.0xllx7.2
20
Hexagon socket head bolt
M6 x 25
21
22
Kick plate with gripper
Plasticclip
6
See additional assembly instructions on Page 55-11
Check and replace if necessary.
55 -4
55 22 37 Disassembling and assembling front lid 996551
Printed in Germany, 1997
~
www.WorkshopManuals.co.uk 911 Carrera (996)
55 90 37
Lids, flaps
Disassembling and assembling rear lid
~~":-
~~~~ ""'"
"'" \~."""+'"~
\//
t
-
32O_97
55 90 37 Disassembling Printed
in Germany
-2,
1997
and assembling
rear lid 996555
55 -5
~~-I l~ L~ -'""" "" " /12 ~
www.WorkshopManuals.co.uk
Disassembling and assembling rear lid 3
11--.
12 -jJ 'v/
(
48
~
47
\
The additionalwing is set to the lowest (horizontal)position for streetIuse. Changes to the setting (to individuallymatch the personal driving style) are onl~ intendedfor the racing track. I The additionalwing must be moved to the lowest position for use in ~ublictraffic.
Note:
Nr.
Removal
Qty.
Designation
1
Countersunkscrew M6 x 16
2
2
Spoiler
1
3A
Left bearingangle
1
Installation Tightening torque: 10 Nm (7.5 ftlb.)
Turn rear spoiler approx. 450 upward and push
Inse ~
the
the
guide
poiler
fitting
into
the
forward.
of t e rear lid.
Remove
Inse~
in the
fittin
.Lowest
of
peg
adjustment position
see: inset Observe safety
instruction! 38
1
Right bearing angle
Remove
Inse~
in the
adjustment
fittin
.Lowest
position
see: inset
Observe safety instruction! 4
Spacerwasher
5
Countersunkscrew
4
10
Tightening torque: 2.8 Nm (2 ftlb.)
M4 x 8.0
6A
Left guide fitting
1
68
Right guide fitting
1
7A
Left adjusbnent fitting
1
78
Rightadjustment fitting
1
55 90 37 Disassembling Printed in Germany. 25, 1999
and assembling
rear lid -GT3 9965523
55 -25
www.WorkshopManuals.co.uk
Note: No.
Designation
8
Wiringharness
Qty. 1
Removal
Installation
Disconnectinterior light electrical plug connection
Connect~Iectricalplug connectiorl.
(inset A), (inset B) push air cleaner locking lug (arrow) outward, (inset C) push locking lug (arrow) on wiring harness disconnectionpoint and disconnect. Interior light
1
10
Hexagon socket head bolt M6 x 20
3
11
Fanwith fan housing
1
12
Air guide
1
13
Rubber cover
1
14
Rubber buffer
2
15
Adjusting element
2
16
Collar
2
9
Unclip andldisconnect electrical qlug connection.
Removefrom the inner side of the lid.
Pushin un1ilthe collar engages.
17
Combination screw
I
2
M6 x 12 18
Upper part of lock
1
Removeupperpart of lockfrom lid.
Fastenup er part of lock to the lid with the combinati n screws and adjustto the lower part of lock.
19
Logo GT3
1
Pulloff
Replace,p " off
protective aper and affix.
20
Spoilerlip
1
Pulloff
Glue on with a K-2 adhesive (Porsche plartno.
000.044.000.37).
55 -26
55 90 37 Disassembling 9965523
and assembling Printed
rear lid -GT3
in Germany
-25,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Lid
21
Cable retainer
1
22
Circlip
4
23
Pneumaticspring
24
Hexagon socket head bolt M6 x 16
8
25
Mount right
1
Press out
Pres~in
Loosen combination
Adju~tto the left side section in accordance with lid contour.
screwsM6 x 16.
26
1
Mount left
Loosen combination
screwsM6x 16. 27
Plasticstop
2
28
M5 nut
1
29
Washer
1
30
Inletfin
1
AdjU$tto the left side sectilonin accordance with lid contour.
Undo
Gluethe corner points arroW D into the lid with a K- adhesive(Porsche part o.
000. 44.000.37). Tigh en the inlet fin in the entre with the was er and the M5 nut.
31
1
Lid-plastic
AdjU f
in
ac
lid
ordance
to
the
hinges
with
the
cont urs of the wings and he front spoiler.
32
Combinationscrew M6 x 30
2
33
Lockingplate
1
Press locking plate out.
55 90 37 Disassembling and assembling rear lid -GT3 Printed in Germany
-25,
1999
9965523
Pres~lockingplatein.
55 -27
1 39
www.WorkshopManuals.co.uk 55
Lid
911 Carrera (996)
Note: No.
Designation
34
Lock
35
Holder
36
Plug connection
Qty.
Removal
1
1
37
Emergency operation mechanism
1
38
Bowden cable
1
Plug8.0 x 11 x 7.2
3
40
Hexagonsocketheadbolt M6 x 25
41
Kick plate with gripper
Installatio
1
Fastenlower part of lock with combination screws and adjus1to upper part of lock. I
Disconnectcable-harness plug connection.
plug conn~ction.
Press bowdencable out of holder.
Pressbo~dencable into holde~.
Back off hexagon socket head bolt by 4 -5 turns.
Screw he agon socket head bolt nto the bottom support b 2 -3 turns.
Removeplug 8.0 x 11 x 7.2 (Item 39), back off hexagon socket
Positionki k plate on the
supporta d pushon.
head bolt M6 x 25 by approx. 4 -5 turns. Lift kick plate upwards out of the bottom support with a plastic spatula and press out. 42
Plastic clip
Connectc~ble-harness
Screw do n hexagon socket he d bolts M6 x 25 Additional assembly instructions, see: Servo No. 55 10
r
1
Inspectan replaceif necessary
55 -28
55 90 37 Disassembling 9965523
and assembling Printed
rear lid -GT3
in Germany
-25,
1999
-
,~'" \\ 1 ~
www.WorkshopManuals.co.uk
55
Lids
911 Carrera (996)
Disassembling and assembling release for front lid -as of model year 2001
~
551037
Disassembling
Printed in Germany -42.2000
and assembling
release for front lid -as of model... c5510372
55-29
page 1
~
www.WorkshopManuals.co.uk 911 Carrera (996)
Lids
Disassembling release for front lid
"..., ,;
', ,
G)/
"'""
2
"""""..."
1 "
,.../,
"" " "
4
""""'~_/
"''"
www.WorkshopManuals.co.uk Lids
911 Carrera (996)
No.
55
Procedure
Instructions
Undoinghexagon socket head bolts -2-
Removeplastic plugs -3- and und the hexagon socket head bolts -2- from the sill by app ox. 4 -5 threads.
?
Removingsill-l-
Lift sill-l- upwards out of the bo om support with a plastic spatula and pressout. Check f stening clips -4-, replace if necessary.
3
Pulling off plug connections-5, 6- of the actuating switches
Pull off plug connections-5, 6- 0 the actuating switches of the lids.
4
Removingactuatingswitchesfor front lid -7 , 8-
Pressthe fasteningribs of the sill arrows- outwardwith a screwdriverand unclipthe actuati g switch of the front lid -7-.
551037
Disassembling
Printed in Germany -42,2000
and assembling
release for front lid -as of model... c5510372
55-29 page 3
'" "" ~ -3). ~
www.WorkshopManuals.co.uk Assembling release for front lid
0/ /
4
{
"""""""""
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'S!4~op 01 'uo!~~auuo~ 3nld le~!J~~al a4~~~aUUO~S!a'c 'v I x 8~ av 1 SMaJ~SXJO 1 pa~elnsd ~ua-oJ~!Wopun .I
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www.WorkshopManuals.co.uk I
1, ~
.. "
~
www.WorkshopManuals.co.uk 57
Doorfront, central locking system
4 -Remove
911 Carrera (996)
door handle and bottom part of door
1. Removecollar nuts M6. 2. Separatebottom part of door handlefrom door handle and remove.
~ A
3. Press electrical plug connection off microswitch -A- and disconnect.
0"1
4. Unclipon the base of the electrical lead -B-. ...[
B
...
.:t 5 -Remove door lock
...
1. Undomicro-encapsulatedTorx screws T40 M8 x 14. 2. Disconnectthe electrical plug connection.To do this, press the locking lug -A- on the plug connectionand separate in the direction of the arrow -B-. 3. Pull door lock with actuating motor unit out of the door.
"'-t A
6 -Remove
door window
...
1. Undo Torx screws T 30 on the clamping pieces of the power windowunit. fj
2. Pull door windowout of the door channel.
~ -
-~~:~~/ ...;,-
7"'"
~~
'=~~;:~3
fJ
..
www.WorkshopManuals.co.uk 911 Carrera (996)
7 -Remove
57
Doorfront, central locking system
...
power window unit
:
1. Disconnect the electricalplugconnection. 2. UndocollarnutsM6from the powerwindowunit. 3. Pullthe powerwindowunitdownwardout of the door opening.
8 -Remove
door brake
'1
1. UnscrewTorx screw M8 -A- from the A-pillar. :.;.
2. Removecollar nuts from the door brake. 3. Pull out the door brake towards the inside. 4. Removethe seal.
,
9 -Remove
!'
door seal on outside
1. Press out clip -A- with a plastic spatula. 2. Pull off door seal on the outside. 3. Carefullypull the seal out of the clips along the door contour.
r
575137
Disassembling
Printed in Germany -44,
"' ~ ~~::::::::::::~~::::::::;:::::::~ J'
and assembling
2001
door
57-5 c5751371
page 5
~ I.
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
10 -Remove
window guide rail
...
1. Unscrewthe B3.5x 9.5 sheetmetalscrewfromthe windowguiderail. 2. Pulloff the B 3.5 sheetmetalnut.
11 -Remove
door channel seal on inside
-Pull the door channelseal on the inside off the bead of the door channel.
'" 7
12 -Remove
lid
...
-Press out the 24 x 40 lid -A- and the 20 x 28 lid -8- with a plastic spatula.
'"A
60
~~
~
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
57
...
13 -Remove wiring harness 1. Unclipthe electrical wiring along the inner door panel.
"11('
2. Pullwiring harness out of the door in the -direction of the arrow-.
\
14 -Remove
angle piece
-Unscrew T 45 M8 x 33 Torx screw from the angle piece and the 12 x 8 x 7 centring sleeve.
Assembling door
Danger of injury if side airbag units in the door are triggered while ignition key is not removed! .Always
remove ignition
commence
adjustment
key during body work, and do not work until a waiting period of at
least 1 minute has elapsed! .The
ground strap of the battery must be disconnected
during work on the airbag system and alignment work within the framework
bench
of body repair!
[IJ Note! Followthe special instructionson installationand adjustmentfor assemblyof the door!
575137
Disassembling
and assembling
Printed in Germany-44, 2001
door
57-5 page 7 c5751371
~
www.WorkshopManuals.co.uk Doorfront, central locking system 1 -Stick
911 Carrera (996)
in the insulation
rn Note! ~/
In order to achievebetter adhesion,heat the insulationusing a hot-air gun! -Peel off the backing and stick the insulationinto the door belowthe side-impactbar.
~
"
I,' ...
~...
"
2 -Fit angle piece
-Position the angle piece with the 12x 8 x 7 centring sleeveon the door and fasten with the T 45 M8 x 33 Torx screw. Tightening
torque:
23 Nm (17 ftlb.)
...
3 -Fit wiring harness 1. Insert wiring harness into the door in the -direction
of
r/
the arrow-. 2. Clip in the electrical wiring along the inner door panel.
\
57-5 page 8
575137
c5751371
Disassembling
and assembling
door
Printed in Germany -44,2001
~
www.WorkshopManuals.co.uk
911 Carrera (996)
Doorfront, central locking system
4 -Fit lid
-Press in the 24 x 40 lid -A- and the 20 x 28 lid -B-.
'"A
60
~
~
5 -Fit door channel seal on inside -Position the door channelseal on the inside -arrow- in the bead of the door channeland press it on.
. '"' / °1
...
6 -Fit window guide rail
1. Pushon the 8 3.5 sheetmetalnut.
\\
2. Positionthe windowguide rail and fasten it with the 83.5 x 9.5 sheetmetalscrew. Tightening
torque:
1,4 Nm (1.0 ftlb.)
"
575137
Disassembling
Printed in Germany -44,
and assembling
2001
door
c5751371
57-5 page 9
c:;;
www.WorkshopManuals.co.uk Doorfront, central locking system
7 -Fit door seal on outside
911 Carrera (996)
...
-Position door seal on the outside at the top edge of the door and push it on. 1. Clip in the seal along the door contour. 2. Fastenthe door seal on the inner door panel with the clip -A-.
, 8 -Fitting
...
door brake
1. Positionthe seal. ,;.-
2. Insertdoor brake from the inside and fasten it with the collar nuts. Tightening
torque:
Tightening
torque:
23 Nm (17 ftlb.)
9 -Fit power window unit
1. Insert power window unit into the door openingfrom below. 2. Fastenthe power window unit with the M6 collar nuts. Tightening
torque:
10 Nm (7.5 ftlb.)
See: Additional adjustmentinstructionsfor the power window. 1. Plug in the electrical plug connection.
~
-
:
10 Nm (7.5 ftlb.)
1. Screw Torx screw M8 -A- onto the A-pillar.
'"
A
~ ,q",
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
10 -Fit door window
--
1. Insertdoor windowinto the door channeland position it in the front and rear clamping pieces of the power window
rI
unit.
.The
.-
.~~
bottom edge of the windowmust rest on the screw
during adjustment' .Observe dow!
1
//t
/ ,..z==
f~~:;;
,=~~,,~3
additionalinstructions for adjustingthe door win-
1. Tightenthe T 30 Torx screw. Tightening torque: 8.5:t 1.5 Nm (6.0:t 1.0 ftlb.)
...
11 -Fit door lock
rn
Note! J..I
.The actuatinglever must be locked in basic position before installation! .Observe
additionalinstructionsfor adjusting the door lock!
1. Insert door lock with actuatingmotor unit into the door and fasten with the micro-encapsulatedT40 M8 x 14 T orx
'i' 'f
.'"
screw. Tightening torque: 20 +2 Nm (15.0 + 3.5 ftlb.) 1. Plug in the electrical plug connection. 12 -Fit connection
piece
1. Clip in the electrical lead -8- on the base. 2. Insert door handleand position the bottom part of the door handleon the door handlefrom inside. Tightenwith the collar nuts M 6. Tightening
torque:
~
10 Nm (705 ftlbo)
1. Connectelectrical plug connection-A-.
575137
Disassembling
Printed in Germany-44,2001
and assemblil1g door
57-5 page 11 c5751371
www.WorkshopManuals.co.uk 13 -Disconnect
connection
piece
1. Insertthe connectionpiece into the actuating shaft -arrow A- withoutplay.
...
..;~
2. Push out the sliding piece -arrow B- until it can be heard to engage. 3. Actuate the handle -arrow C- to ensure that the handle and door lock function withoutplay.
14 -Fit bowden cable 1. Insertbowdencable into the actuating lever -arrow Dand rotate by 900 -arrow C-.
V6
2. Clip bowdencable into the door lock -arrow B-. 3. Engagesupport frame -arrow A- on the door lock.
B
15 -Fit
~ v~
911 Carrera (996)
Door front, central locking system
mount -Position
the mount in the door and fasten it with the M6 x
16 hexagon-head bolt. Tightening
torque:
10 Nm (7.5 ftlb.)
01
www.WorkshopManuals.co.uk Doorfront, central locking system
911 Carrera (996)
Adjustment instructions
57
for i~ssembly of the door
Diagram: sheetmetal clips and grommets
A -Grommet B -M6 sheetmetalclip C -M5 sheetmetalclip D -Grommet
E -Sheetmetalclip St 3.8 Basic setting of door lock
Danger of injury if side airbag units in the door are triggered while ignition key is not removed! .Always
remove ignition
commence
adjustment
key during ttody work, and do not work until a waiting period of at
least 1 minute has elapsed! .The
ground
strap of the battery mu~;t be disconnected
during work on the airbag system and alignment work within the framework
575137
Adjustment
of body repair!
instructions
Printed in Germany -44,2001
bench
for assembly of the door c5751372
57-6 page 1
.
www.WorkshopManuals.co.uk Doorfront, central locking system
911 Carrera (996)
~
Basic setting of the door lock before installation
D 0 -;1
~ if.
To prevent
locking or unlocking
installation
of the door lock!
Malfunctions
actuation,
or incorrect
in the alarm system!
The door lock should be installed only when the actuating lever is in basic position! 1. Swivel out the actuating lever -A- in an upward direction. 2. Lift the spring and simultaneouslylower the spring hook of the actuating lever until it engagesin the locking spring -B-.
[!J Note! Greaterforce is necessary to actuate the door handleafter installation of the door lock as the locking spring audiblydisengages.
rn Note! Makesure that the lugs of the support frame are correctly locked whenassemblingthe door lock to protect against theft-arrows: D-.
Standardising the system Standardising the power windows
The system must be re-standardisedafter an interruption in the power supplyto the power windowelectronics in the door. The position valuesfor the short-strokeloweringfunction,position-controlled loweringfunction in the case of convertibletop actuation and ena-
57-6 page 2
575137
Adjustment
c5751372
instructions
for assembly of the door Printed in Germany -44,
2001
~
www.WorkshopManuals.co.uk Doorfront, central locking system
57
911 Carrera (996)
bling for "automaticstart-up of windowclosing"(one-touchfunction) are redefined.The standardisationprocess is initiated by continuous actuation of the operating button [Raise window]. Hold down the button [Raise
window] until the window is
closed and is switched off by the blockage detection function of the power windows. Blockage detection function
If the windowdrive encountersresistanceduring the door window movement,the motor is switched off after a delay of 500 ms. Precondition for operation of the power 'windows .Ignition
switched on,
.Ignition key should not be removedfrom the steering lock with the ignition switchedoff. .The door is openedfor the first time after switching off the ignition. .Door
opened.
Fitting the door window in the clarnping jaws 1. Insertthe door windowthrough the door channelinto the
It
clampingjaws of the frontandreardrivers. 2. Positionthe door windowcornerflushwiththe driverat front.
.-
The bottom edge of the windowmust rest on the screw during adjustment.
3. Tightenthe clampingjawsaftercompletingthe adjustment. Tightening torque: 8,5 Nm (6.0 ftlb.]
575137
Adjustment
instructions
Printed in Germany -44,2001
for assembly of the door c5751372
57-6 page 3
-~
www.WorkshopManuals.co.uk Doorfront, central locking system
911 Carrera (996)
Adjusting the door window angle in the vehicle's longitudinal direction Driver
...
1. Adjustto equalisethe angle of the door windowon the clamping jaws of the driver (upwardsor downwards). Adjustment range 10 mm
2. Tightenthe clampingjawaftercompletingthe adjustment
Adjusting the door window height Adjustthe upper limit stops of the drivers by screwingthe Torx screw T30 in or out with socket E6 in or againstthe direction of travel. Adjustment range approx. 15 mm 2. Adjustthe drivers so that they meetthe upper limit stops at the same time.
rn Note! The adjustingscrews of the drivers for the upper limit stops for the door windowheight are accessiblethrough2 holes at the bottom of the door. Adjustment procedure: 1. Openthe doors 2. Lock door lock with a screwdriver. 3. Movethe power windowregulator into its upper position. 4. Adjust door window height at the drivers so that the door window evenlyprojects approx. 2 mm abovethe roof strip.
,
www.WorkshopManuals.co.uk Doorfront, central locking system
911 Carrera (996)
...
Checking the adjustment
1. Close the doors. 2. Use a wax marker to mark the door windowalong the roof
~
strip.
xf
3. Actuate the door handleuntil the windowloweringfunction is activated. Adjustment valve for window lowering Ifunction approx. 13
-f /
,~::::~=---I I
mm
~{-I-/\
The waxmarking along the door windowshould be uniformly approx. 4 mm.
Adjustment of the door window pressing force on the door seal at the top and sides
~
1. Movethe power window unit rails by approx. 10 mm outwards or inwards.
rn Note! The adjustingnuts of the power windowunit rails for the pressing force of the door windowupper edge against the convertibletop are accessible through two holes at the bottom of the door.
Adjustment procedure: 1. Openthe doors. 2. Movethe power windowregulator into its upper position and undo the combinationnuts M 6 of the power windowrails. 3. Adjustthe power window unit so that the upper edge of the door windowis sufficientlypressed againstthe door seal at the side Tightening torque: 10 Nm (7.5 ftlb. Checking the
Clampa sheet of paper betweenthe door windowand door seal.
rn Note! It must not be possible to pullout the sheet of paper.
575137
Adjustment
instructions
Printed in Germany -44,2001
for assembly of the door c5751372
57-6 page 5
!~ "-
www.WorkshopManuals.co.uk 911 Carrera (996)
Doorfront, central locking system
Adjusting the lower stop of the power window unit
'"
rn Note! ~
.When replacing the power window unit, make sure that the correct position of the lower limit stop is selected for the respective model. .There are two bores lying one above the other with the screwedon limit stops in the front power windowunit rail. .The upper limit stop must be removedfor the 911 Carrera (996) model.
57-6 page 6
575137
Adjustment
c5751372
instructions
for assembly of the door Printed inI Germany -44,2001
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
Additional assembly instructions for installation of the door lock
&
Warning: To prevent locking actuation:
The connectionpiece of th door handle (arrow C) must be instalIe in the actuating shaft of the door handleon y in its basic setting. Greater force is necessary 0 actuate the door handleafter installationof e door lock as the locking spring audiblyd sengages.
or unlocking
> The door lock must be installed only if the actuating lever is in basic position. Basic setting of the door lock before installation in the door
572_98
Basic setting is necessaryafter removal of the door lock with actuating motor unit. Swivel out the actuating lever (arrow A) in upward direction, lift the spring and simultaneouslylower the spring hook of the actuating lever until it engages in the locking spring (arrow B).
57 51 37 Disassembling and assembling door (adjustment instructions) Printed in Germany
-21,1999
9965717
57 -17
www.WorkshopManuals.co.uk
Additional instructions for adjusting the door window The power windows can be operated if:
Fitting the door window in the clamping jaws
-the ignition is switched on.
2
after the ignition is switched off I if the ignition key is not removed from the steering lock.
3,
after the ignition is switched off until a door is opened for the first time.
4. with a door open.
451_97
Standardising the system Installing the door window in t..
The system must be re-standardisedafter an interruption in the power supply to the power window electronics in the door. The position values for the short-stroke lowering function, position-controlledlowering function in the case of convertible top actuation and enablingfor "automatic start-up of window closing" (one-touchfunction) are redefined. The standardisationprocess is initiated by continuousactuation of the operating button toward "close window". The button must be held until the window is closed and is switched off by the blockage detection function of the power windows. Blockage
detection
door
Insertthe door windowthrough th~ door channel into the clamping jaws of the front and rear drivers. The bottom edge of the window must rest on the screw during adjustment.Position the door windowcorner flush with the driver at front. Tighten the clamping jaws after completing the adjustment. Tightening torque: 8.5 1.5 Nm (6.5 1.0 ftlb.)
function
If the window drive encountersresistance during the door windowmovement, the motor is switched off after a delay of 500 ms.
57 -18
57 51 37 Disassembling and assembling door (adjustment instructions) 9965717
Printed
in Germany
-21,
1999
J6
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front,
central locking system
Adjusting the door window angle in the vehicle's longitudinal direction
The upper limit stops of the drivers are adjusted in or againstthe direction of travel by screwing the Torx screw T30 in or out with socket E6 (adjusting range approx. 115mm). Adjustthe drivers so that they meet the upper limit stops at the same time. The adjusting screws of the drivers for the upper limit st~ps for the door window height are accessibl through 2 holes at the bottom of the door.
t
Adjustment
the
procedure:
door
lock
window height
at unitthe
evenly
projects
with
to drivers top
the
screwdniver.
position; so
approx.
f
that
2
door;
lock
Move
m
he djust
door
above
door
power
window window
the
roof
strip.
230_96
Checking the adjustment
Adjusting the clamping jaw at the driver upwards or downwards (adjusting range 10 mm) equalisesthe angle of the door window. Tighten the clamping jaw after completing the adjustment.
':: Adjusting
Open
a
---
the door window height
,/('
~
/,
489_97
Close the door and use a wa~ marker to mark the doorthe Actuate window door along handle the until r~the Ofstrip. window
231_96
lowering function (approx. 1 mm) is activated. The wax marking along the oor windowshould be uniformlyapprox. 4 mm~
57 51 37 Disassembling and assembling door (adjustment instructions) Printed in Germany -21, 1999
9965717
57 -19
~
www.WorkshopManuals.co.uk Door front, central locking system
Adjustment of the door window contact pressure on the door seal at the top and sides
911 Carrera (996)
Adjusting the lower stop of the power window unit
I
57O_1_97 232_96
Whenreplacingthe power window unit, make sure that the correct position of ~helower limit stop is selected for the respectiv~model.
The pressing force of the door window upper edge againstthe convertible top is adjusted by moving the power window unit rails outwards or inwards by approx. 10 mm.
There are two bores lying one ab ve the other with the screwed-onlimit stops in the front power window unit rail. The upper limit stop must be re ved for the 911 Carrera (996) model.
The adjusting nuts of the power window unit rails for the pressing force of the door window upper edge againstthe convertible top are accessible through two holes at the bottom of the door. Adjustment procedure: Openthe door, move the power window unit to top position and undo the M 6 combinationnuts of the power window unit rails. Adjust the power window unit so that the upper edge of the door window is sufficiently pressed againstthe door seal at the side. Tightening torque: 10 Nm (7.5 ftlb.) Checking the adjustment: Clamp a sheet of paper between the door window and door seal. It must not be possible to pull out the sheet of paper.
57 -20
57 51 37 Disassembling and assembling door (adjustment instructions) 9965717
Printed in Germany
-21,
1999
www.WorkshopManuals.co.uk Doorfront, centrallockingsystem
911 Carrera (996)
Disassembling and
571137
Disassembling
Printed in Germany -44,
and assembling
2001
door handle
door handle c5711371
57-21
page 1
www.WorkshopManuals.co.uk Door front, central locking system
911 Carrera (996)
www.WorkshopManuals.co.uk Doorfront, central locking system
911 Carrera (996)
There is a danger of injury if fingers or hands are trapped the door window when the comfort
57
by
function is triggered:
lower and raise door window! .When
carrying
out assembly work in the area of the con-
nection piece, the bottom part of the door handle and the door lock, the fuse No.1
No.
in row D must be removed!
Qty.
Designation
Removal
Installation
M6collarnut
Undo.
2
Connection piece
Shift sliding piece of the connection piece and unclip actuating shaft -8-.
3
Handleliner
1
Pull out handleliner downward at an angle.
4 5
Base
1
Unclip.
Clipi
Microswitch
1
Unclip.
Clipi .
6
Circlip
1
Pressout.
Press in,
7
Pin
1
8
Actuating shaft
1
Pull pin -7- out of the handle -13- and removeactuating shaft.
~ ' n actuating shaft on posit the h ndle -No. 13-. Insert pin -7 and secure pin with the ci clip -6-.
9
S retainer
1
10
Pinrod
1
11
Eccentric
1
12
Returnspring
1
13
Handle
1
j
'
Replafe.
Positi n returnspring-12-, Pull pin rod -10- out of the handleliner -3- and separate ecce tric -11- andhandleon handlefrom the handleliner. the h ndleliner-3-, insertthe pin ro -10- andsecure retain r -9-.
14 15
571137
Buffer
2
Doorhandlebottompart
1
Disassembling
and assembling
Printed in Germany -44, 2001
Pulloff.
door handle c5711371
Repl .
57-21 page 3
www.WorkshopManuals.co.uk
575116 Setting the door Printed in Germany -44,2001
57-25 c5751161
page 1
www.WorkshopManuals.co.uk Door front, central locking system
911 Carrera (996)
www.WorkshopManuals.co.uk
911 Carrera (996)
Doorfront,centrallockingsystem
Undofastening screw-1-. Setthe contour in relationto the wing and the side member by shi ing the angle pieces -3in their vertical and horizontalpostions. ==> Rep.Gr. 5; Body gap dimensions The setting range can be extende by removingthe centring sleeve -2-. Tighteningtorque: 23 Nm (17 ftlb )
2
575116
Setting the door at rear
Undofastening screw-4-. Setthe ontour in relationto the rear wing and the side member by shifting the latch striker -5- in its vertical and horizontalp sition. ==> Rep. Gr. 5; Bodygap dimensions Tighteningtorque: 23 Nm (17 ftlb )
Setting the door
Printed in Germany-44, 2001
c5751161
57-25
page 3
www.WorkshopManuals.co.uk 911 Carrera (996)
573719
Removing and installing
Printed in Germany-44,2001
Doorfront, central locking system
inner door release (bowden cable) for c5737191
'"
57-26
page 1
www.WorkshopManuals.co.uk Door front, central locking system
911 Carrera (996)
www.WorkshopManuals.co.uk Door front, central locking system
911 Carrera (996)
Damage to the bowden cable when relnoving
door trim
panel! Damage by bending the bowden cable at the hook! .Pull
the hook out of the end piece olnly after installation
in
the inner door release!
No.
Designation
1
Removal
Door trim panel
Qty. 1
2A
Doorhandle
1
=> 57-27 "Removingand installingdoor handle"
Parts of variant A can be only be in tailed together.
28
Doorhandle
1
=> 57-27 "Removingand installingdoor handle"
Parts of variantB can be only be in tailed together.
3A
1 Bowdencable Bowdencable variantA from VehicleIdentification
Door handleside: Pressthe lugs of the plastic clip -A- and extend to the rear. Pushbowdencable back into the end piece of the sleeve-8-.
Door handleside: Inser bowdencable in the door andle -2-. Pull t e hook out of the end piece of the sleeve only after instalation in the door handle.
Lock side: -Inset X- Unclip bowden cable from the door lock -C-, Swivelbowdencable by 900 -A- and pull it out of the actuating lever -8-.
Lock side: -ln5e Y -Insert the bowden cable in the actuating lever -8- a d rotate by 900 -A-. Clip owden cable into the door ock -C-.
Door handleside: Cuttie-wrap-4-, Lock side: -Inset X- Unclipthe bowden cable from the door lock -C-. Swivelbowdencable by 900 -A- and pull it out of the actuating lever -8-,
Door handleside: Inser bowdencable in the door andle -2A-. The bowden cable always must be set free f play. Ther are 3 possible positions t the door handle-X- in order to set the bowden cable free of play.
Numbers 99 ZXS60 0958 99 ZXS 64 0513 99 9XS 62 3890 99 1XS 65 2308
38
Bowdencable
RoW RoW USA USA
1
Installation
=> Rep.Gr. 705919; Removing and installingdoor trim panel
Lock side: -Ins~ Y -Insert in th
actuating
bowden
cable
lever
-B- a d rotate by 900 -A-. Clip owden cable into the door ock -C-.
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
57
Removing and installing door handle
574519
Removing and installing
Printed in Germany-44, 2001
door handle
57-27 page1 c5745191
www.WorkshopManuals.co.uk Door front, central locking system
57-27
page 2
574519
c5745191
911 Carrera (996)
Removing and installing door handle Printed in Germany-44,2001
www.WorkshopManuals.co.uk No.
Designation
Qty.
Door trim panel
Return spring -2-
1
3
Sleeve
1
Oval-headscrew
Installation
~ Rep.Gr. 705919; Removing and installingdoor trim panel
2
4
Removal
Unclipfrom the door handle -5- and the door trim panel -1-.
Clip irto the door handle -Sand ~hedoor trim panel-1-.
Pull off from the return spring Putdntothe returnspring -2-.
-2-.
Undooval-headscrews -4and pull the door handleout of the door trim panel -1-.
the
I
4
4.2 x 13 5
Door handle -5-
1
Insef
door oor
handle trim
panel
-5-1-
into from
the r ar and position it. Scre tight with the oval-head screws -4-.
www.WorkshopManuals.co.uk Removing and installing orientation lighting (LED light-emitting diodes) Removing orientation lighting (LED light-emitting
... ~ ,.!'""-"'" "./ ~ ,/
911 Carrera (996)
Doorfront, central locking system
diodes)
,...""
',
-
,:::::~
\
:;
2
" "",-~
/
/"
-
",,/
/
///
~~~ ;
~~===:===~=~~ I -'
/'"
~/
'"
...... /"
/'
/'"
/"
www.WorkshopManuals.co.uk 911 Carrera (996)
Door front, central locking system
57
www.WorkshopManuals.co.uk Door front, central locking system
Installing orientation lighting (LED light-emitting
57-27 page 6
911 Carrera (996)
diodes)
574519
c5745191
Removing and installing
door handle
Printed if) Germany -44,2001
www.WorkshopManuals.co.uk No.
Procedure
Instructions
InsertingLED unit into the door handle
Insert LED unit into the door handlefrom the rear.
2
Installinglight-emittingdiode housing -1-
Insertthe light-emittingdiode housing -1- into the guide of the door handleuntil the lug -arrow- engages.
3
Installinglight-emittingdiode housing -2-
Positionthe light-emittingdiode hQusing-2- into the door handle. The cable -arrow A- must point dbwnwards.Pushcover -3- into the door handlefrom the front until there is no more play on the lock of the light-emittingdiode housing.
