Porsche training p001 general repair and servicing sports cars

It was always ahead ofits time: While others were still using large-displacement 12-cylinder engines in their top models, the 911 Turbo managed toset new standards with a relatively smal

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AfterSales Training

Servicing & General Repair – Sports Cars

P001

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Student Name:

Training Center Location:

Instructor Name:

Date: _

Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its

rest-of-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject

to change without notice.

We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice

© 2014 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications

Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman®, Panamera®, Speedster®, Spyder®, 918 Spyder®, Tiptronic®, VarioCam®, PCM®, PDK®, 911®, 4S®, FOUR, UNCOMPROMISED.® and the model numbers and the distinctive shapes of the Porsche automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc believes the specifications to be correct at the time of printing Specifications, performance standards, standard equipment, options, and other elements shown are subject to change without notice Some options may be unavailable when a car is built Some vehicles may

be shown with non-U.S equipment The information contained herein is for internal use only by authorized Porsche dealers and authorized users and cannot be copied or distributed Porsche recommends seat belt usage and observance of traffic laws at all times.

Printed in the USA

Electrical Troubleshooting Logic

1 -Do you understand how the electrical consumer is expected to operate?

2 -Do you have the correct wiring diagram?

3 -If the circuit contains a fuse, is the fuse okay & of the correct amperage?

4 -Is there power provided to the circuit? Is the power source the correct voltage?

5 -Is the ground(s) for the circuit connected? Is the connection tight & free of resistance?

6 -Is the circuit being correctly activated by a switch, relay, sensor, microswitch, etc.?

7 -Are all electrical plugs connected securely with no tension, corrosion, or loose wires?

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“The best 911 ever.” With every new generation of the sports car classic comes the expectation that it is even better than itspredecessors Attempting to make the perfect sports car even better is both an honor and an obligation The new 911 onceagain succeeds in setting new benchmarks thanks to its sporty design, intelligent lightweight construction and new technolo-gies - and is even sportier and more suitable for day-to-day use than its predecessor.

The new 911 is the first to be completely redesigned in the last 15 years It has grown by 2.4˝ (6 cm) to 14.75’ (4.50 m) inlength One of the most noticeable changes, however, is the 3.9˝ (10 cm) longer wheelbase, which is clearly evident in theenhanced driving dynamics and the larger cabin Steel and aluminum have been combined in a perfectly coordinated hybriddesign that has made it possible to reduce the weight of 3042 lbs (1,380 kg) by 77 lbs (35 kg) despite the increased dimen-sions

The new 911 generation is available with two different engines The 3.4-liter flat-six engine of the Carrera delivers 350 hp andhas a top speed of 179 mph (289 km/h) A regenerative brake system, demand-controlled auxiliary units, a coasting function(rolling without engine power) and Auto Start Stop contribute to a reduced fuel consumption The new 7-speed transmissionhas been a significant contributing factor here The Carrera S reaches a top speed of 188 mph (302 km/h) with its 400-hp3.8-liter engine In addition to the higher engine speeds for both engine variants, the new roll stabilization system and thedynamic engine mountings, which are available with the Sport Chrono package, have played a major role in reducing the laptime on the Nordschleife with the Carrera S by 13 seconds to 7 minutes and 40 seconds

A high level of qualification throughout the entire AfterSales organization is essential to meet the high expectations of Porschecustomers, in spite of the ever increasing complexity of the technology used in the vehicles and the growing number ofdifferent variants The Information in this student guide describes the technical modifications that have been made to the new

911 (991) generation based on the vehicles from the 2nd generation 911 (997) model years 2008 to 2012

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Its presentation at the Paris Motor Show in 1974 marked the beginning of a unique success story for the 911 Turbo With theTurbo, a benchmark for the Sports Car was born A proverbial technology pioneer from the very beginning, each generation ofthe 911 Turbo represented the pinnacle of what is technologically possible in terms of performance It was always ahead ofits time: While others were still using large-displacement 12-cylinder engines in their top models, the 911 Turbo managed toset new standards with a relatively small, lightweight, but extremely powerful flat-six engine We have followed this traditionundeterred ever since Today, we use unique technologies, such as Variable Turbine Geometry (VTG), which significantlyincreases both the performance and efficiency of the turbo engine

Even with all the innovations that make up previous model history, the new generation of the 911 Turbo represents an

unusually large step forwards in terms of development: In essence, this is a completely new vehicle, with a longer wheelbase,wider track, larger wheels and intelligent lightweight construction The result is higher performance potential and greatercomfort

The new 911 Turbo S traditionally distinguishes itself with its particularly sporty brand positioning and outstanding drivingcharacteristics All the performance enhancing components offered as optional extras with the 911 Turbo are standard (e.g.the PDCC anti-roll stabilization system, the Sport Chrono package with dynamic engine mounts, PCCB ceramic brake systemand 20-inch Turbo S wheels with central lock) When it comes to performance, as a Sports Car that is fully suitable for

everyday operation, the 911 Turbo S comes very close to reaching two magic limits that previously seemed the exclusivepreserve of extreme Super Sports Cars: 0 to 62 mph (100 km/h) in 3.1 seconds and 0 to 124 mph (200 km/h) in 10.3seconds are unrivalled figures in the 911 Turbo segment To sum up: the 911 Turbo has been the benchmark since 1974

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Following the new 911 Carrera (991), is the new Boxster (981) Breathtaking styling, legendary driving dynamics combinedwith efficient performance and excellent day-to-day usability are the values that characterize the new Boxster The goal withthe third generation of the performance-oriented roadster was to confirm its top position in a very competitive environment inthe areas of driving dynamics as well as maximum performance with reasonable fuel consumption and low CO2emissions and

to further consolidate this position As with the new 911, the new Boxster also has a longer wheelbase and short overhangsfor a further improvement in driving dynamics

A completely redesigned, fully electrical convertible top provides for quieter driving and emphasizes the elongated side view

A significant reduction in weight through the use of aluminum and steel in the bodyshell has also reduced the fuel tion and emission values, as has downsizing the standard engine as well as using thermal management, vehicle electricalsystem recuperation and the Auto Start Stop function for all engine and transmission variants State-of-the-art audio andcommunication equipment with a top sound system as well as integration of driver assistance systems, such as the drivinglight assistant for increased comfort and safety, also ensure increased day-to-day usability

consump-A high level of qualification throughout the entire consump-AfterSales organization is essential to meet the high expectations of Porschecustomers, despite the ever increasing complexity of the technology used in the vehicles and the growing number of differentvariants The Information in this student guide describes the technical modifications that have been made to the new Boxstergeneration based on the vehicles from the 2nd generation 987 (model years 2008 to 2012)

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Description Section

Section 0 – General Information 0

Section 1 – Engine 1

Section 2 – Fuel, Exhaust and Engine Electrics 2

Section 3 – Transmission/Clutch 3

Section 4 – Chassis and Brakes 4

Section 5 – Body .5

Section 6 – Body Equipment, Exterior 6

Section 7 – Body Equipment, Interior 7

Section 8 – Heating and Air Conditioning 8

Section 9 – Electrical System 9

Conversion Charts 10

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Porsche Vehicle Identification Number (VIN) Structure

A81 = Boxster (981) (2013-on), Cayman (981) (2014-on) A87 = Boxster (987) (2010-12), Cayman (987) (2010-13) A91 = 911 (991) (2013-on)

A97 = 911 (997) (2010-12) A70 = Panamera (2010-on) (All models including Hybrid) APA = Cayenne (2010)

A2A = Cayenne (2011-on) (All models including Hybrid) A5B = Macan (2015)

types, such as; Coupe,

Cabriolet, Targa, SUV

(Cayenne), sedan

(Panamera), etc This

character can vary from

year to year.

Footnotes:

* Please check the specific VIN in the Model Information,

PPK Group 17, D2 series for exact vehicle specific

Model Type and Engine Type.

** See PPK Bulletin Group 16 D12 for complete list.

Model Years 1981–2009: Used VIN positions 7, 8 & 12 as Porsche model type

designation digits USA model years in ( ).

As of Model Year 2010: VIN position 7 was

changed to a “A”, leaving positions 8 & 12 as Porsche model type designation digits.

Position 5 uses alpha

char-acters A, B, C, etc to

indi-cate engine types, such as;

normally aspirated, turbo,

Hybrid, etc This character

can vary from year to year.

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Model Designations Used In Parts Catalogs and Workshop Manuals

911 911 (various 6 cylinder)911T 911 model (1968-73)911T 911 Turbo911S 911S (1975-77)911SC 911SC (1978-83)911C 911 Carrera (1984-89)911C2 911 Carrera 2911C4 911 Carrera 4911RS RS America (1993-94)912E 912E (1976)

914 914 (various models)

918 .918 Spyder (2015)

924 924 (various models)924T 924 Turbo924S 924S (1987-88)928 928 (various 8 cylinder)928S 928S

928 S4 928 S4 (1987-91)

928 GT 928 GT (1989-91)

928 GTS 928 (1993-95)

944 944 (various models)944T 944 Turbo944TS 944 Turbo S (1988)944S 944S (1987-88) (4 valve)

944 S2 944 S2 (1989-91) (4 valve)

951 944 Turbo964 911 (1989-94)

968 968970 Panamera (1st Generation) (2010-13)

970 Panamera (2nd Generation) (2014-on)

987 Cayman (2nd Generation) (2009-12)

991 911 (2012-on)993 911 (1995-98)996 911 (1999-05)

997 911 (1st Generation) (2005-08, Turbo 2007-09)997 911 (2nd Generation) (2009-12, Turbo 2010-13)9PA Cayenne (E1 - 1st Generation) (2003-06)9PA Cayenne (E1 - 2nd Generation) (2008-10)92A Cayenne (E2) (2011-on)95B Macan (2015)

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Sports Cars Engine Type Designations Since Model Year 1989

1990 M64.01 3.6 184/250 911 Carrera (964) 2/4 with manual transmission - Worldwide

M64.02 3.6 184/250 911 Carrera (964) 2 with tiptronic transmission - Worldwide

M64.24 3.6 210/285 911 Carrera (993) USA Tiptronic

M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN

Engine Number Identification

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Model Engine Displ Engine Power Installed In

1997 M64.21 3.6 210/285 911 Carrera (993) /C4 /C4S RoW

M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic M64.23 3.6 210/285 911 Carrera (993) /C4/C4S USAM64.24 3.6 210/285 911 Carrera (993) USA TiptronicM64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN

1998 M64.21 3.6 210/285 911 Carrera (993) /C4/C4S RoW

M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic M64.23 3.6 210/285 911 Carrera (993) /C4 & C4S USA/CDNM64.24 3.6 210/285 911 Carrera (993) USA/CDN TiptronicM64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN

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* The HP number over the years has been listed in SAE or DIN (Kw to SAE HP factor is x 1.34, SAE HP to DIN HP factor is x 1.014)

Sports Cars Engine Type Designations Since Model Year 1989 (cont’d)

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Sports Cars Transmission Type Designations Since Model Year 1989

G50.01 5-Speed M/T 911 Carrera - USA, Australia, JapanG50.02 5-Speed M/T 911 Carrera - Switzerland

G50.50 5-Speed M/T 911 Turbo - World-WideG64.00 5-Speed M/T 911 Carrera (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1990 A50.01 4-Speed A/T 911 Carrera 2 (964) - RoW, USA/Canada

G50.03 5-Speed M/T 911 Carrera 2 (964) - RoW, USA/CanadaG50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1991 A50.01 4-Speed A/T 911 Carrera 2 (964) - RoW, USA/Canada

G50.03 5-Speed M/T 911 Carrera 2 (964) - RoW, USA/CanadaG50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG50.52 5-Speed M/T 911 Turbo (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1992 A50.02 4-Speed A/T 911 Carrera 2 (964) - RoW

A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/CanadaG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG50.52 5-Speed M/T 911 Turbo (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - SwitzerlandG64.02 5-Speed M/T 911 Carrera 4 (964) - Taiwan

A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/Canada, TaiwanG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - Switzerland/TaiwanG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USAG64.01 5-Speed M/T 911 Carrera 4 (964) - SwitzerlandG64.02 5-Speed M/T 911 Carrera 4 (964) - Taiwan

Transmission Number Identification

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Model Transmission Technical Installed In

A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/Canada, TaiwanG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - Switzerland/TaiwanG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG50.52 5-Speed M/T 911 Turbo 3.6 (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USAG64.01 5-Speed M/T 911 Carrera 4 (964) - SwitzerlandG64.02 5-Speed M/T 911 Carrera 4 (964) - Taiwan

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera (993) - USA/Canada

G50.21 6-Speed M/T 911 Carrera (993) - RoW

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - USA/Canada

G50.21 6-Speed M/T 911 Carrera 2 (993) - RoWG64.20 6-Speed M/T 911 Carrera 4 (993) - USA/CanadaG64.21 6-Speed M/T 911 Carrera 4 (993) - RoW

G64.51 6-Speed M/T 911 Turbo (993) - World-Wide

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - RoW, USA/CanadaG64.20 6-Speed M/T 911 Carrera 4 (993) - RoW, USA/CanadaG64.51 6-Speed M/T 911 Turbo (993) - World-Wide

A86.00 5-Speed A/T Boxster (986)G86.00 5-Speed M/T Boxster (986)

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - RoW, USA/CanadaG64.20 6-Speed M/T 911 Carrera 4/4S (993) - RoW, USA/CanadaG64.42 6-Speed M/T 911 Turbo (993) - Taiwan

G64.51 6-Speed M/T 911 Turbo (993) - RoW, USA/CanadaA86.00 5-Speed A/T Boxster (986)

G86.00 5-Speed M/T Boxster (986)

G86.00 5-Speed M/T Boxster (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/Canada

Sports Cars Transmission Type Designations Since Model Year 1989 (cont’d)

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A86.20 5-Speed A/T Boxster S (986)G86.01 5-Speed M/T Boxster (986)G86.20 6-Speed M/T Boxster S (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.90 6-Speed M/T 911 GT3 (996) - RoW

A86.20 5-Speed A/T Boxster S (986)G86.01 5-Speed M/T Boxster (986)G86.20 6-Speed M/T Boxster S (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.50 6-Speed M/T 911 Turbo (996) - World-Wide

A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-WideG96.90 6-Speed M/T 911 GT3 (996) - RoW

A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-Wide

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A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-WideG96.96 6-Speed M/T 911 GT3 (996) - USA/Canada

A87.20 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.20 6-Speed M/T Boxster S (987)A96.10 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.35 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.01 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.31 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaA97.01 5-Speed A/T 911 Carrera/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera/S (997) - RoW, USA/CanadaG96.50 6-Speed M/T 911 Turbo (996) - World-Wide

A87.20 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.20 6-Speed M/T Boxster S (987)A87.21 5-Speed A/T Cayman S (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/Canada

A87.21 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.21 6-Speed M/T Boxster S (987)A87.02 5-Speed A/T Cayman (987)A87.21 5-Speed A/T Cayman S (987)G87.01 6-Speed M/T Cayman (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

A97.50 5-Speed A/T 911 Turbo (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - USA/Canada

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A87.21 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.21 6-Speed M/T Boxster S (987)A87.02 5-Speed A/T Cayman (987)A87.21 5-Speed A/T Cayman S (987)G87.01 6-Speed M/T Cayman (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S (987)CG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

A97.50 5-Speed A/T 911 Turbo (997) - World-WideG97.88 6-Speed M/T 911 GT2 (997) - World-Wide

CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S (987)CG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.55 6-Speed M/T 911 Turbo (997) - World-Wide

CG1.50 7-Speed PDK 911 Turbo (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - World-Wide

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CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.20 7-Speed PDK Boxster Spyder (987)G87.40 6-Speed M/T Boxster Spyder (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S (987)CG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.55 6-Speed M/T 911 Turbo (997) - World-Wide

CG1.50 7-Speed PDK 911 Turbo (997) - World-WideG97.88 6-Speed M/T 911 GT2 RS (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - World-WideG97.92 6-Speed M/T 911 GT3 RS (997) - World-Wide

CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.20 7-Speed PDK Boxster Spyder (987)G87.40 6-Speed M/T Boxster Spyder (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S/R (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S/R (987)C91.00 7-Speed PDK 911 Carrera (991) - RoW, USA/CanadaGG1.05 7-Speed M/T 911 Carrera S (991) - RoW, USA/CanadaCG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.55 6-Speed M/T 911 Turbo (997) - World-Wide

CG1.50 7-Speed PDK 911 Turbo (997) - World-WideG97.88 6-Speed M/T 911 GT2 RS (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - World-WideG97.92 6-Speed M/T 911 GT3 RS (997) - World-Wide

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2013 C91.00 7-Speed PDK 911 Carrera (991) - RoW, USA/Canada

GG1.05 7-Speed M/T 911 Carrera S (991) - RoW, USA/CanadaC91.30 7-Speed PDK 911 Carrera 4 (991) - RoW, USA/CanadaGG1.35 7-Speed M/T 911 Carrera 4S (991) - RoW, USA/CanadaCG2.05 7-Speed PDK Boxster (981)

CG2.25 7-Speed PDK Boxster S (981)G81.00 6-Speed M/T Boxster (981)G81.20 6-Speed M/T Boxster S (981)G97.55 6-Speed M/T 911 Turbo (997) - World-WideCG1.50 7-Speed PDK 911 Turbo/S (997) - World-Wide

2014 C91.00 7-Speed PDK 911 Carrera (991) - RoW, USA/Canada

GG1.05 7-Speed M/T 911 Carrera S (991) - RoW, USA/CanadaC91.30 7-Speed PDK 911 Carrera 4 (991) - RoW, USA/CanadaGG1.35 7-Speed M/T 911 Carrera 4S (991) - RoW, USA/CanadaCG1.90 7-Speed PDK 911 GT3 (991) - World-Wide

C91.55 7-Speed PDK 911 Turbo (991) - World-WideCG2.05 7-Speed PDK Boxster (981)

CG2.25 7-Speed PDK Boxster S (981)G81.00 6-Speed M/T Boxster (981)G81.20 6-Speed M/T Boxster S (981)CG2.05 7-Speed PDK Cayman (981)CG2.25 7-Speed PDK Cayman S (981)G81.00 6-Speed M/T Cayman (981)G81.20 6-Speed M/T Cayman S (981)

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Maintenance Checklist– 911 Carrera/S/4/4S/Turbo (991) (2014)Required Maintenance and Lubrication Service

After 40,000, 80,000, 120,000, 160,000 miles etc / 60,000, 120,000, 180,000, 240,000 km etc

Note: If the mileage for scheduled maintenance is not reached, maintenance must be performed no later than after

4, 8, 12 years.

The terms ‘check’ and ‘inspection’ include all necessary subsequent work such as adjusting, readjusting, correcting and topping off, but do not include repairing, replacing and reconditioning parts or assemblies.

Electrics

JDiagnosis system: Read out fault memory; reset maintenance interval

JWindshield wiper/washer system, headlight washer: Check function and nozzle adjustment

JHorn: Check operation

JTires: Check tire pressure (TPM)

JBatteries and ventilation hoses: Check condition

JElectrical equipment as well as indicator and warning lights: Check operation

Inside of Vehicle

JPollen filter: Replace filter element

JSeat belts: check function and condition

JDoor locks: check function

Front Luggage Compartment

JPollen filter: Replace pre-filter element

JCheck front lid lock and safety hook of the front lid for secure seating and function properly

JWindshield wiper/washer system, headlight washer: Check fluid level and antifreeze protection level

JCheck firewall body drains for debris

Outside of Vehicle

JCheck wiper blades

JVehicle lighting: Check operation

JAll headlights: Check adjustment

JRadiators and air intakes: Visual inspection for exterior debris and blockage

Under the Vehicle

JDrain engine oil

JVehicle underside and engine compartment: Visual inspection for leaks (oils and fluids) and abrasion (lines and hoses); Underbody panels: visual inspection for completeness, secure installation and damage

JTires: Check condition

JBrake system: Visual inspection of the brake pads & brake discs for wear (w/o removing wheels) (Except PCCB)

JVehicles with PCCB: As of MY 2014, PCCB Brake discs must be checked for wear during every service and whenever brakes pads are replaced using special tool VAS 6813 Please refer to workshop manual for work procedure.

JBrake hoses and lines: Visual inspection for damage, correct routing and corrosion Check brake fluid level

JSteering gear: Visual inspection of the dust boots for damage Tie rod ends: Check play and dust boots

JAxle shafts/Drive shafts: Visual inspection of the dust boots for leaks & signs of damage/wear

JExhaust system: Visual inspection for leaks and damage; check mounting and heat shields

Engine Compartment

JAir filter: Replace filter elements

JChange oil filter and fill engine oil (Every 10,000 miles/15,000 km, see separate Oil Change Sheet, PNA 000 162 LC)

JFuel lines and connections: Visual inspection for damage and leaks

JVisual inspection for leaks (oils and fluids)

JCoolant: Check level and antifreeze protection level

JPDCC: Check fluid level

JCheck firewall body drains for debris

JReplace spark plugs: every 40,000 miles / 60,000 km or 4 years (Except Turbo)

JReplace spark plugs: 911 Turbo every 30,000 miles / 45,000 km or 4 years

JCheck drive belt at 40,000 miles (60,000 km) or every 4 years

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Additional Maintenance – Convertible Top (Labor Operation 03 70 00 )

Service and maintain convertible top: every 20,000 miles / 30,000 km or 2 years

Replace PDCC reservoir

Replace drive belt

Change all-wheel drive controller oil (4-wheel drive models only)

Ancillary unit mounts and chassis: visual inspection of all rubber mountings and boots for damage

Manual transmission: change oil

PDK transmission: change oil

PDK transmission: change clutch oil

All-wheel final drive: change oil (4-wheel drive models only)

Change brake fluid (use only Original Porsche Brake Fluid)

Tire sealant (check expiration date and replace as necessary)

Inspection Performed - Technician Signature:

Road Test Check

Remote control, front seats, foot brake and electric parking brake (also operating travel), engine, clutch, steering,

transmission, ParkAssist, cruise control, PSM, PASM & Sport switches, sports exhaust system, door mirror fold-in

func-tion, heater, air-conditioning system and instruments: Check operation

Oils, fluids: Visual inspection for leaks

Road Test Performed - Technician Signature:

Customer Name: Date: / /

VIN: WPO _

Mileage (check one) Miles Kilometers: _

Dealer Name: Dealer Code:

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Oil Change Service Checklist– 911/S/4/4S/Turbo (991), Boxster/S & Cayman/S (981)

USA Models Only (2012-on)

Every 10,000 miles (15,000 km) or 1 year

Note: See appropriate Maintenance Checklists for complete maintenance requirements.

Oil Change Service Performed - Technician Signature:

Customer Name: Date: / /

VIN: WP _

Mileage (check one) Miles Kilometers: _

Dealer Name: Dealer Code:

Repair Order #: _

Technician Name:

Technician Signature:

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Subject Page

General Information – 911 Carrera (991) 2

General Information – Boxster/Cayman (981) 3

Belt Drive 4

Crankcase 4

Pistons 5

Engine Oil System 5

Oil Level Measurement 6

Engine Oil System 20

Dynamic Engine Mounts 22

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General Information

911 Carrera/S (991)

Two different engines are available for the 911 Carrera

(991) The standard models come with an engine where

the displacement has been reduced (to 3.4 liters from the

previous 3.6 liters) but the high torque of the previous

engine has been retained and the power increased further

This has been made possible by increasing the nominal

rpm from 6,500 rpm to 7,400 rpm

The S models still come with a 3.8-liter engine Here the

power has been increased by 15 hp to 400 hp (294 kW)

As with the 3.4-liter engine, the nominal rpm have been

increased to 7,400 rpm (+ 900 rpm) and the maximum

engine speed has been increased to 7,800 rpm (+ 300

rpm) The maximum torque is now 440 Nm (+ 20 Nm)

Full load curves for the 3.4-liter engine MA1.04

Technical Engine Specifications

Number of cylinders 6 Valves per cylinder 4 Displacement 3,436 cm 3

at engine speed 7,400 rpm Max torque 288 ft lb (390 Nm)

at engine speed 5,600 rpm Compression ratio 12.5 Intake-valve lift, small 3.6 mm Intake-valve lift, large 10.5 mm Exhaust valve lift 10.35 mm Governed speed 7,800 rpm (6,300 rpm cold) Engine weight, MT/PDK 432 lbs (196 kg)/423 lbs (192 kg) Cylinder firing order: 1-6-2-4-3-5

Number of cylinders 6 Valves per cylinder 4 Displacement 3,800 cm 3

at engine speed 5,600 rpm Compression ratio 12.5 Intake-valve lift, small 3.6 mm Intake-valve lift, large 11.0 mm Exhaust valve lift 11.0 mm Governed speed 7,800 rpm (6,300 rpm cold) Engine weight, MT/PDK 432 lbs (196 kg)/423 lbs (192 kg) Cylinder firing order: 1-6-2-4-3-5

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911 Carrera (991)/Boxster/Cayman (981)

Boxster/Cayman (981)

Two different engines are available for the Boxster/

Cayman (981) The standard models come with an engine

where the displacement has been reduced (to 2.7 liters

from the previous 2.9 liters) but the power has been

increased further (from 255 to 265 hp) This was made

possible by the use of direct fuel injection and an increase

in the nominal rpm from 6,400 rpm to 6,700 rpm

The displacement of 3.4 liters has been retained for the S

models, although here too the power has been increased

from 310 to 315 hp by increasing the nominal rpm

No of cylinders 6 Valves per cylinder 4 Displacement 2,706 cm 3

at engine speed 4,500 to 6,500 rpm Compression ratio 12.5

Intake-valve lift, small 3.6 mm Intake-valve lift, large 10.0 mm Exhaust-valve lift 9.7 mm Governed speed 7,800 rpm Engine weight MT/PDK 432 lbs (196 kg)/425 lbs (193 kg)

No of cylinders 6 Valves per cylinder 4 Displacement 3,436 cm 3

at engine speed 4,400 to 5,800 rpm Compression ratio 12.5

Intake-valve lift, small 3.6 mm Intake-valve lift, large 10.5 mm Exhaust-valve lift 10.35 mm Governed speed 7,800 rpm Engine weight MT/PDK 439 lbs (199 kg)/432 lbs (196 kg)

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Belt Drive

Since the 9x1 Sports Cars features electromechanical

steering, the servo pump on the engine is no longer

required If the vehicle is equipped with the optional PDCC

system, the hydraulic pump for this system is located at

• Attachment point for the engine strut

• Attachment point for the coolant pump

• Omission of the lifting eyebolt

The reason for these changes is the increased load at the attachment points.

Crankcase, Engine Suspension – Boxster (981)

The crankcase has been adopted from the predecessorengine with only minor changes in the following areas:

• Attachment point for the engine strut

• Omission of the lifting eyebolt

The engine suspension has been changed from a three-point mounting to a four-point mounting A special screw is used in order to remove the belt for maintenance work.

Notes:

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Precision milling is used on the piston in the groove for the

oil scraper ring as a way of effectively improving

emis-sions stability

Camshafts

Assembled camshafts are used on the 9x1 Sports Cars

An assembled camshaft is a camshaft on which the cams

are manufactured separately from the shaft body and are

subsequently attached permanently to the shaft body

Camshaft Adjuster

All engine versions are still equipped with VarioCam Plus,

the adjustment range is now 50° crank angle The vane

adjuster has an aluminum housing in order to optimize

Since only internal leaks can occur in the oil pump andthese do not cause any harm, it has been possible todispense with the following seals on the oil pumpcompared with the predecessor:

• Round seals on the oil extraction pumps

• O-ring on the pressure outlet

This has also allowed machining of the groove to bedispensed with

Additional changes are the asymmetric strainer and omission of the holder (see above illustrations).

Notes:

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Oil Level Measurement

The 9x1 series Sports Cars provide the option of

per-forming a dynamic oil level measurement when the vehicle

is moving and a static measurement without the engine

running when the vehicle is stationary If a display is shown

in the instrument cluster then it is valid in principle

The measuring options described below are possible due

to the integrated dry-sump lubrication of the engine and

the associated structure of the oil pan and sensor The

engine is filled with approx 10.6 qts (10 liters) of engine

oil, the change quantity is approx 7.9 qts (7.5 liters)

Important !

Engine oil must only be added when the engine is

switched off.

> When the rear lid is open, the engine-oil level in the

instrument cluster is only updated when the engine is

switched off

> When the rear lid is open and the engine is running, the

oil level is not updated, i.e the engine can be overfilled.

Oil Sensor

The sensor consists of an ultrasonic sensor with an

integrated evaluation unit and a temperature sensor for

detecting the engine oil temperature A measuring cup

with an inlet hole at the bottom and a vent hole at the top

is placed over the ultrasonic sensor A meander-shaped

element is used at the inlet hole to permit an accurate

measurement

Oil level OK, 100% Oil level OK, 75%

Oil level OK, 50% Oil level OK, 25%

Dynamic Measurement

Conditions for recalculation:

• Rear lid closed

on driving style

The measured values are only used for calculation if theconditions are met The result is then displayed in theinstrument cluster via CAN This value can also bedisplayed in the instrument cluster when the ignition is on

Static Measurement

Conditions for recalculation:

• Engine off

• Oil temperature at the sensor > 158° F (70° C.)

• Longitudinal and lateral acceleration < 1 m/s2, and tiltangle < 5.7°

• Wait max 60 seconds

When the ignition is switched on, the result is thentransmitted to the instrument cluster via CAN anddisplayed after 2.5 seconds

The following applies to both measurements:

If the conditions are not met when the measurement isperformed, the last valid value will be displayed A meanvalue calculated from the static measurement anddynamic measurement is displayed If there is no dynamicmeasurement, the static measurement value is alwaysdisplayed

Oil level measurement after opening the engine compartment lid:

When the engine compartment lid is opened for more than

45 seconds, all previously determined measured valuesare discarded because the DME control unit assumes thatoil was added

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The oil level is no longer displayed in the instrument

cluster and the message "Display only possible after short

time" appears A new static value is measured 60 seconds

after switching off the engine (engine oil temperature >

158° F./70° C.) even if the ignition is switched off

Minimum oil level reached

Oil level below minimum

Oil level below maximum

Notes:

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Cooling System

911 Carrera (991)

The coolant expansion tank is located in the service

opening under the engine compartment lid, on the left in

the direction of travel There are two caps on the tank,

both of which are black for reasons of appearance

The left-hand cap is for coolant, while the right-hand cap is

used as an oil filler opening The caps themselves are

identified with appropriate symbols The two threads are

different to avoid interchanging

The red ball indicates the current coolant level This ball

must be in the area between the min and max markings

when the engine is cold and the vehicle is level The

coolant quantity can vary between 30.3 and 32 qts (28.7

and 30.3 liters) depending on equipment

The coolant level indicator must be between the “MIN” and

“MAX” markings when the engine is cold and the vehicle ishorizontal The coolant quantity can vary between 6.1 and6.6 gal (23 and 25 liters) depending on equipment.Oil fill is on the right in direction of travel

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911 Turbo (991)

The engines in the new 911 Turbo and 911 Turbo S

models represent a systematic enhancement of the

well-proven and powerful engines used in the previous

• Turbocharging with variable turbine geometry (VTG)

• Direct fuel injection (DFI) with multi-hole injectors

• Cylinder heads with tumble intake ports

• Expansion intake manifold

• Integrated dry-sump lubrication

• Electronic demand-controlled oil pump

• 4-valve technology with hydraulic valve clearance

• On-board diagnosis (OBD II)

• 911 Turbo: Overboost function with higher maximum

torque (in combination with the optional Sport Chrono

package)

The development goals for the new 911 Turbo engines were as follows:

• Increase in power output and torque – 911 Turbo

• Increase in power output and torque (incl overboost) –

911 Turbo S

• Increase in maximum engine speed – 911 Turbo S

• High charge-air cooler efficiency

• Reduction of 15-16% in fuel consumption and CO2emissions

• Acoustics of the engine sound

• Adaptation of add-on parts due to wheelbase ing by 3.9 inches (100 mm)

lengthen-• Weight reduction

• New tailpipe system incl visual differentiation between

911 Turbo and

911 Turbo S

• Sports tailpipes option with additional differentiation

• Sound with SPORT button

These goals were achieved in particular thanks to the following new features and enhancements:

differen-• Optional sports tailpipes

• Geometric adaptation of add-on parts to the newspace available

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Full load curves 911 Turbo MA1.71

With the new engine developments and the vehicle-specific

changes aimed at reducing fuel consumption and CO2

emissions (e.g Auto Start Stop function, coasting, virtual

gears, …), the new 911 Turbo models achieve the

charac-teristic values shown below

Intake valve lift, small 3.6 mm

Intake valve lift, large 10.5 mm

Exhaust valve lift 10.32 mm

Governed speed 7,000 rpm

Engine weight 478.4 lbs (217 kg)

Full load curves 911 Turbo S MA1.71S

No of cylinders 6Valves per cylinder 4Displacement 3,800 cm3

At engine speed 6,500 – 6,750 rpm Max torque 516 ft lb (700 Nm)

At engine speed 2,100 – 4,250 rpm Compression ratio 9.8:1

Intake valve lift, small 3.6 mmIntake valve lift, large 10.5 mmExhaust valve lift 10.32 mmGoverned speed 7,200 rpm Engine weight 478.4 lbs (217 kg)

Notes:

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Belt Drive

Because the 911 Turbo and 911 Turbo S (991) feature

electromechanical steering, the servo pump on the engine

is no longer required If the vehicle is equipped with the

optional PDCC system, the hydraulic pump for this system

is mounted at this position

Belt drive with (lower) and without (upper) PDCC pump

Pistons and Connecting Rods

Similar to the previous model, forged aluminum pistonsare used to reliably achieve the high power values of thenew engine Many details of the piston rings were impro-ved to minimize frictional losses and a DLC coating wasalso applied to the first ring To reduce lateral forces andensure reliable transmission of the enormous gas forcesfrom the piston to the crankshaft, the connecting rod wasmodified compared with the previous model

A computer-optimized design of piston and connecting rod

in combination with a short compression height permitsthe components to be designed with an optimum power-to-weight ratio The low mass forces bring about a reduction

in the crank drive loads and enhance the smooth running

of the engine

To ensure the load capacity of the new 911 Turbo engines

as well as the higher power and torque values, the pistonswere strengthened and adapted This made it possible toincrease the maximum peak pressures by more than 10%and considerably improve internal efficiency As a result, itwas also possible to achieve the increases in power com-pared with the previous models at comparable boost pres-sures using new thermodynamic tuning (e.g valve timingand timing angle)

Note !

DLC Coating

The high-grade coating on the first piston ring is a DLCcoating

DLC (= Diamond-like Carbon) is a coating technology used

on high-performance cutting tools for machining metal It

is an amorphous carbon layer with outstanding anti-frictionand wear properties

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Piston Spray Cooling

In order to reduce the piston crown temperature, the 911

Turbo engines are provided with piston spray cooling The

spray nozzles are press-fitted in the crankcase To ensure

the necessary engine oil pressure at low rpm and high

engine oil temperatures, these spray nozzles only open at

a higher oil pressure

Crankshaft

The 911 Turbo features a gas-nitrided crankshaft to

transfer the high forces (see note at the left) The

crank-shaft is drop-forged, runs on eight bearings and has twelve

balancing weights The main bearing 4 is designed as a

thrust bearing Axial play is determined by two thrust

plates, which are inserted at the left and right of the

bearing The main bearings of journals 1/3/5/7/8 are

designed as plain bearings, while the main bearings of

journals 2/4/6 are designed as partially grooved bearings

The drive mechanism for the two drive chains for thecamshafts and demand-controlled oil pump is located onthe pulley side

Note !

Nitriding is a thermochemical heat treatment process that

is performed at temperatures between 662° F (350° C)and 1112° F (600° C) Positively charged ions from thefurnace wall (anode) strike the crankshaft, which serves asthe cathode, at a high collision speed This ion bombard-ment initially results in extremely intensive cleaning of thecrankshaft The surface is then enriched with nitrogen bysubsequent heating in a vacuum chamber This results ingreater surface hardness

Notes:

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Crank Drive

The two timing chains are controlled by guide and

tensioning rails Two hydraulic chain tensioners connected

to the engine oil circuit ensure the required tensioning of

both chains The guide rail for the oil pump drive is no

longer used on the new 911 Turbo engines

Crank drive and timing drive

Pulley

The pulley was adopted from the previous model

with the following design enhancements:

• Torsional vibration balancer

• Hub in forged aluminum

The pulley comprises a torsional vibration balancer with a

hub in forged aluminum and a steel flywheel This design

enhancement has allowed the improved smooth running

and acoustics of the engine to be retained for the new

911 Turbo

Cylinder Heads

Similar to the previous model, the camshafts are no longerlocated in separate camshaft housings, but are completelyintegrated in the cylinder heads This reduces the number

of components, sealing faces and threaded joints, ing in a more compact design and reduced overall weight

result-The improved cross-flow cooling enables good cooling ofthe cylinder head, in particular the areas subjected to highthermal loads around the exhaust valve seat rings Theintake ports have a special shape to support efficientmixing of the air and fuel The tumble port used here ischaracterized by narrowing of the intake ports upstream

of the valve seat This port shape accelerates the airflowing into the cylinder and sets it in a tumbling motion

As a result, the injected fuel is mixed even better with theair

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Assembled camshafts are used on the 911 Turbo (991)

An assembled camshaft is a camshaft on which the cams

are manufactured separately from the shaft body The

cams are subsequently joined permanently to the shaft

body

The separation of the camshaft into cams and shaft allows

a choice of material, production method and heat

treat-ment matched specifically to the functions and loads The

Presta technology used in an assembled camshaft offers

numerous advantages

The most important advantages are:

• Weight saving of 30–40% compared with a conventional

camshaft

• Transmission of high dynamic and static torques

• Combination of high-quality cam materials with

cost-effective, less highly stressed tube and end-piece

materials

• Reduced production costs for further machining and

final machining of the camshaft and therefore lower

investments and more favorable production costs

VarioCam Plus

The requirements imposed on engine design with regard

to customer requests for higher performance combinedwith improved driving comfort, compliance with emissionregulations and reduced fuel consumption create con-flicting design criteria The development of VarioCam Pluswas therefore based on the idea of producing a variableengine, which can be optimized for maximum performanceand also for regular driving in urban traffic or on countryroads This requires a control system for the intake cam-shaft to vary the opening and closing times in combinationwith a valve lift system

The camshaft control principle is based on the principle of

a vane adjuster, which is made completely of aluminum.The adjustment range is 50° crank angle The control unitdetermines the current position of the camshaft in relation

to the crankshaft (actual angle) on the basis of the speedsensor signal and the Hall sender signal The positioncontrol in the control unit receives the desired setpointangle via the programmed map values (engine speed,load, engine temperature) A controller in the Motronic unitactivates the 4-way proportional valve according to thedesired adjustment if there is a difference between thesetpoint angle and actual angle

Notes:

Trang 37

911 T

Engine Oil System

Variable Oil Pump

Similar to the previous model, the engine oil

pressure is supplied via a variable oil pump

This means that the correct oil quantity and

the correct oil pressure are always delivered

Since only internal leaks can occur in the oil

pump and these do not result in any

disadvan-tages, it has been possible to dispense with

the following seals on the oil pump compared

with the previous model:

• Sealing rings on the oil suction pumps (on

the back of the pump)

• O-ring on the pressure outlet (Figure 15,

16)

As a result, it was also possible to dispense

with machining of the corresponding grooves

Other modifications include the asymmetrical

strainer and omission of the holder

Engine oil circuit

Trang 38

To cope with the additional heat produced as a result of

the increased power, the radiators and radiator fans in the

front end have been redesigned Similar to the previous

models, the new 911 Turbo models also feature a center

radiator as standard equipment This is essentially new

and its air flow has been further improved, The side

radiators have a cooler surface with greater recooling

effi-ciency The output of the radiator fans was increased to

400 watts (997 Turbo/S II 280 watts)

To permit dissipation of the additional heat produced onthe new 911 Turbo S, additional air blades were fitted onthe sides of the front apron These allow a higher coolingair flow rate through the side radiators and ensure evenbetter radiator performance The additional air blades arealso used as standard on the 911 Turbo in extremely hotcountries

3 Engine oil heat exchanger

4 Heat exchanger for PDK gear wheel set

5 Heat exchanger for PDK clutches

6 Coolant expansion tank

7 Heating heat exchanger

8 Right radiator

9 Center radiator

10 Left radiator

11 Pump for front-axle final drive

12 Heat exchanger for front-axle final drive

13 Cooling system with thermostat open

14 Cooling system with thermostat closed

15 Check valve

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911 GT3 (991)

The engine in the new 911 GT3 has been completely

redesigned, adopting classic 911 GT3 components, such

as dry sump lubrication with a separate engine oil tank,

high engine speed concept, titanium connecting rods and

sports exhaust system, as well as including totally new

components, such as valve lever control for the valves

In addition, the new 911 GT3 engine also features direct

fuel injection (DFI), an electronic demand-controlled oil

pump and an enhanced high engine speed concept As a

result, the engine delivers a maximum power output of

475 hp (350 kW) and power output per liter of 125 hp/l

with a displacement of 3.8 liters

In addition to the mechanical and thermodynamic

enhance-ments, it was also possible to significantly reduce the

engine weight compared to the engine in the previous

model The weight reduction of approximately 55 lbs (25

kg) was primarily achieved by using a new lightweight

cylinder head, a new oil pan with integrated oil pump

module, a smaller engine oil tank, a plastic intake manifold

and aluminum camshaft controllers

Technical Data

No of cylinders 6Valves per cylinder 4Displacement 3,799 cm3

at engine speed 8,250 rpmMax torque 325 ft lb (440 Nm)

at engine speed 6,250 rpmCompression ratio 12.9 : 1Intake valve lift 12.7 mmOutlet valve lift 12.0 mmIntake valve diameter 42 mmExhaust valve diameter 36 mmIntake opens (1 mm) 24.8° after TDCIntake closes (1 mm) 84.9° after TDCExhaust opens (1 mm) 73.2° before TDCExhaust closes (1 mm) 18.5° before TDCGoverned speed 9,000 rpm

Crankshaft

The crankshaft in the 911 GT3 has been especiallyadapted to the GT3-specific pistons and connecting rods,but its basic design is the same as the crankshaft used inthe 911 Carrera (991)

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Belt Drive

The auxiliary units are driven in the same way as the

current 911 Carrera (991) model line The crankshaft

pulley on the GT3 does not have a torsional vibration

damper and its diameter is smaller This reduces the

weight and rotating mass The smaller diameter means

that the belt drive rotation speeds are adapted to the high

engine speeds

Belt pulley

Pistons and Connecting Rods

Like the previous models, the new 911 GT3 has forged

aluminum pistons and forged titanium connecting rods

The choice of material and forging technology makes

these highly stressed components especially lightweight

and sturdy

With these design features, these components meet thehigh thermal and mechanical requirements (includingmaximum engine speed of 9,000 rpm)

Valve Drive

The two timing chains on the GT3 are the same as theones used on the current 911 Carrera models (991) Theuse of valve lever control for the valves is new, combinedwith lightweight aluminum pistons, forged titanium con-necting rods and, hollow-drilled valves (intake andexhaust), allows for high engine rpm

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