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Porsche 911 Carrera 4 Carrera 2 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: 911 Carrera 4 / Carrera 2 Model Code: 996 Series (Carrera 2 and Carrera 4 variants) Common Nickname: 996 Carrera 👋 Introduction Market Position Positioning: The Porsche 911 Carrera 4 and Carrera 2 (996 generation) represented a significant evolution for the iconic 911, moving to a water-cooled engine and a more modern chassis. This manual targets owners and independent specialists looking for in-depth, authoritative repair information. Competitive Analysis Competitors: Competes with factory service manuals for contemporary performance vehicles like the Ferrari 360 Modena, Aston Martin DB7, and Chevrolet Corvette C5, offering a similar level of detail and technical specification. Key Features Features: Authentic Porsche factory data, detailed procedures, comprehensive wiring diagrams, torque specifications for all fasteners, troubleshooting guides, and parts information. 📋 Manual Details Coverage Areas Coverage: All mechanical and electrical systems, troubleshooting, diagnostics, repair, maintenance, and adjustments. Page Count Pages: Typically over 1000 pages for a complete factory service manual set, though specific product listings may vary. Manual Type Type: Factory Service Repair Manual Language Language: English (Standard for this model and market) Format Format: Likely a digital format (PDF) for easy searching and printing, or a printed manual. 📖 Manual Coverage Systems Covered Engine: Lubrication, cooling, fuel delivery, ignition, emissions control, engine mechanicals (disassembly, assembly, torque specs). Transmission: Manual (G96/00, G96/01, G96/10) and Tiptronic (G96.50) transmissions: disassembly, assembly, fluid capacities, torque specs, troubleshooting. Drivetrain: All-wheel drive (Carrera 4) system, front and rear axle assemblies, driveshafts, CV joints, differentials. Brakes: Hydraulic system, ABS, traction control (PSM), brake pad and rotor replacement, bleeding procedures, parking brake. Suspension Steering: Front and rear suspension components, shock absorbers, springs, control arms, alignment procedures, power steering system. Electrical: Wiring diagrams, battery, charging system, starter, lighting, ignition system, instrument cluster, comfort systems, body electronics. Body Chassis: Body panel removal and installation, doors, windows, convertible top (if applicable), chassis components, anti-corrosion measures. HVAC: Heating, ventilation, and air conditioning system components, refrigerant handling, troubleshooting. Diagnostics: OBD-II diagnostics, fault codes, diagnostic tools, troubleshooting flowcharts. Procedures Included Maintenance: Routine service, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection. Repair: Detailed step-by-step instructions for component replacement, engine rebuild, transmission repair, suspension overhaul, electrical component repair. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon issues. Installation Removal: Complete instructions for removing and reinstalling all major components and sub-assemblies. Adjustments: Alignment adjustments, throttle cable adjustments, clutch adjustments (if applicable). Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and component-level repair. 📊 Manual Specifications File Format Format Details: Likely PDF; should be searchable text, allowing for quick information retrieval. High-resolution scans or original digital files ensure clarity of diagrams and text. Print Quality Quality: If printed, expect clear text and high-quality reproduction of all diagrams, schematics, and photographs. Paper quality should be durable for workshop use. Binding Type Binding: If printed, likely spiral-bound or lay-flat binding to facilitate use during repairs. Paper Type Paper: If printed, durable, heavy-weight paper suitable for a workshop environment. ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated, Flat-Six (Boxer) Engine Codes: M96.01 (Carrera 2), M96.03 (Carrera 4, later Carrera 2) Displacement: 3.4 Liters (3387 cc) for early models, 3.6 Liters (3596 cc) for later models (2002 onwards). Performance Horsepower: Approx. 300 hp (3.4L), Approx. 320 hp (3.6L) Torque: Approx. 258 lb-ft (3.4L), Approx. 273 lb-ft (3.6L) Fuel System Fuel Injection: Sequential Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU: Bosch Motronic ME7.x Engine Mechanicals Bore Stroke: 93.0 mm x 82.7 mm (3.4L), 96.0 mm x 82.7 mm (3.6L) Compression Ratio: 11.5:1 Engine Block Material: Aluminum Alloy Cylinder Head Material: Aluminum Alloy Valvetrain: Dual Overhead Camshafts (DOHC), 4 valves per cylinder, VarioCam (variable valve timing on intake camshaft) 🔧 Transmission Standard Type: 6-Speed Manual (G96/00 for RWD, G96/01 for AWD) Optional Type: 5-Speed Tiptronic Automatic (G96.50) Features Clutch: Hydraulic, single dry plate Final Drive Ratio: Typically 3.44:1 (Manual RWD), 3.44:1 (Manual AWD), 3.15:1 (Tiptronic) Fluids Manual Transmission Fluid: Pentosin MTF LT-2 (or equivalent API GL-4, SAE 75W-90 synthetic) Tiptronic Transmission Fluid: Porsche ATF JWS 3309 (or equivalent) 📐 Dimensions Exterior Length: Approx. 4430 mm (174.4 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1305 mm (51.4 in) Wheelbase: Approx. 2350 mm (92.5 in) Weights Curb Weight: Approx. 1450-1550 kg (3197-3417 lbs) depending on configuration (Carrera 2 vs. Carrera 4, manual vs. Tiptronic) Gross Vehicle Weight Rating: Approx. 1900 kg (4189 lbs) Cargo Trunk Volume: Approx. 130 liters (4.6 cu ft) front trunk, plus rear 'frunk' space. 🛡️ Safety Features Ratings NHTSA Ratings: Specific NHTSA ratings for this generation are not readily available in a standardized format, but the chassis and safety features were considered robust for its time. Active Features Traction Control: Porsche...
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Porsche 911 Carrera 4 Carrera 2 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
911 Carrera 4 / Carrera 2
Model Code:
996 Series (Carrera 2 and Carrera 4 variants)
Common Nickname:
996 Carrera
👋 Introduction
Market Position
Positioning:
The Porsche 911 Carrera 4 and Carrera 2 (996 generation) represented a significant evolution for the iconic 911, moving to a water-cooled engine and a more modern chassis. This manual targets owners and independent specialists looking for in-depth, authoritative repair information.
Competitive Analysis
Competitors:
Competes with factory service manuals for contemporary performance vehicles like the Ferrari 360 Modena, Aston Martin DB7, and Chevrolet Corvette C5, offering a similar level of detail and technical specification.
Key Features
Features:
Authentic Porsche factory data, detailed procedures, comprehensive wiring diagrams, torque specifications for all fasteners, troubleshooting guides, and parts information.
📋 Manual Details
Coverage Areas
Coverage:
All mechanical and electrical systems, troubleshooting, diagnostics, repair, maintenance, and adjustments.
Page Count
Pages:
Typically over 1000 pages for a complete factory service manual set, though specific product listings may vary.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (Standard for this model and market)
Format
Format:
Likely a digital format (PDF) for easy searching and printing, or a printed manual.
📖 Manual Coverage
Systems Covered
Engine:
Lubrication, cooling, fuel delivery, ignition, emissions control, engine mechanicals (disassembly, assembly, torque specs).
Transmission:
Manual (G96/00, G96/01, G96/10) and Tiptronic (G96.50) transmissions: disassembly, assembly, fluid capacities, torque specs, troubleshooting.
Drivetrain:
All-wheel drive (Carrera 4) system, front and rear axle assemblies, driveshafts, CV joints, differentials.
Brakes:
Hydraulic system, ABS, traction control (PSM), brake pad and rotor replacement, bleeding procedures, parking brake.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, alignment procedures, power steering system.
Electrical:
Wiring diagrams, battery, charging system, starter, lighting, ignition system, instrument cluster, comfort systems, body electronics.
Body Chassis:
Body panel removal and installation, doors, windows, convertible top (if applicable), chassis components, anti-corrosion measures.
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant handling, troubleshooting.
Diagnostics:
OBD-II diagnostics, fault codes, diagnostic tools, troubleshooting flowcharts.
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection.
Repair:
Detailed step-by-step instructions for component replacement, engine rebuild, transmission repair, suspension overhaul, electrical component repair.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues.
Installation Removal:
Complete instructions for removing and reinstalling all major components and sub-assemblies.
Adjustments:
Alignment adjustments, throttle cable adjustments, clutch adjustments (if applicable).
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and component-level repair.
📊 Manual Specifications
File Format
Format Details:
Likely PDF; should be searchable text, allowing for quick information retrieval. High-resolution scans or original digital files ensure clarity of diagrams and text.
Print Quality
Quality:
If printed, expect clear text and high-quality reproduction of all diagrams, schematics, and photographs. Paper quality should be durable for workshop use.
Binding Type
Binding:
If printed, likely spiral-bound or lay-flat binding to facilitate use during repairs.
Paper Type
Paper:
If printed, durable, heavy-weight paper suitable for a workshop environment.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated, Flat-Six (Boxer)
Engine Codes:
M96.01 (Carrera 2), M96.03 (Carrera 4, later Carrera 2)
Displacement:
3.4 Liters (3387 cc) for early models, 3.6 Liters (3596 cc) for later models (2002 onwards).
Performance
Horsepower:
Approx. 300 hp (3.4L), Approx. 320 hp (3.6L)
Torque:
Approx. 258 lb-ft (3.4L), Approx. 273 lb-ft (3.6L)
Fuel System
Fuel Injection:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
ECU:
Bosch Motronic ME7.x
Engine Mechanicals
Bore Stroke:
93.0 mm x 82.7 mm (3.4L), 96.0 mm x 82.7 mm (3.6L)
Compression Ratio:
11.5:1
Engine Block Material:
Aluminum Alloy
Cylinder Head Material:
Aluminum Alloy
Valvetrain:
Dual Overhead Camshafts (DOHC), 4 valves per cylinder, VarioCam (variable valve timing on intake camshaft)
🔧 Transmission
Standard
Type:
6-Speed Manual (G96/00 for RWD, G96/01 for AWD)
Optional
Type:
5-Speed Tiptronic Automatic (G96.50)
Features
Clutch:
Hydraulic, single dry plate
Final Drive Ratio:
Typically 3.44:1 (Manual RWD), 3.44:1 (Manual AWD), 3.15:1 (Tiptronic)
Fluids
Manual Transmission Fluid:
Pentosin MTF LT-2 (or equivalent API GL-4, SAE 75W-90 synthetic)
Tiptronic Transmission Fluid:
Porsche ATF JWS 3309 (or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 4430 mm (174.4 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1305 mm (51.4 in)
Wheelbase:
Approx. 2350 mm (92.5 in)
Weights
Curb Weight:
Approx. 1450-1550 kg (3197-3417 lbs) depending on configuration (Carrera 2 vs. Carrera 4, manual vs. Tiptronic)
Gross Vehicle Weight Rating:
Approx. 1900 kg (4189 lbs)
Cargo
Trunk Volume:
Approx. 130 liters (4.6 cu ft) front trunk, plus rear 'frunk' space.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings for this generation are not readily available in a standardized format, but the chassis and safety features were considered robust for its time.
Active Features
Traction Control:
Porsche Stability Management (PSM) standard on most models.
ABS:
Standard Anti-lock Braking System.
Braking System:
Four-wheel disc brakes, typically ventilated with 4-piston calipers (larger optional PCCB ceramic brakes available).
Passive Features
Airbags:
Driver and passenger front airbags, side airbags.
Rollover Protection:
Integrated rollover protection structure.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners and belt force limiters.
💡 Technology Features
Infotainment
System:
PCM (Porsche Communication Management) system, typically with navigation, radio, CD player. Later models offered improved infotainment options.
Audio:
Optional Bose or High-End sound systems available.
Driver Assistance
Features:
Cruise control, parking assist sensors (rear), Bi-Xenon headlights (optional).
Connectivity
Connectivity Options:
Limited connectivity by modern standards. May include optional CD changer, telephone preparation.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000 miles or 12 months, whichever comes first. Check owner's manual for specific intervals.
Major Service:
Significant service intervals occur around 30,000 miles (e.g., spark plugs, filters, coolant) and 60,000 miles (e.g., drive belts, clutch inspection).
Fluid Specifications
Engine Oil:
Mobil 1 0W-40 synthetic is Porsche's recommended oil. Capacity approximately 8.5 liters (9 US quarts).
Coolant:
Porsche approved G48 or G40 coolant concentrate mixed 50/50 with distilled water. Capacity approximately 22 liters (5.8 US gallons).
Brake Fluid:
DOT 4 High Performance.
Known Issues
Common Issues:
IMS (Intermediate Shaft) bearing failure (especially on early models with specific bearing types), rear main seal leaks, cylinder scoring (less common with the 996 compared to the early M96 engine design), water pump leaks, AOS (Air/Oil Separator) failure.
Service Bulletins:
The manual will reference Technical Service Bulletins (TSBs) issued by Porsche for known issues and their fixes.
📚 Vehicle History
Brand Heritage
Heritage:
Porsche has a storied history with the 911, dating back to 1963, known for its rear-engine layout, performance, and motorsport pedigree.
Model Evolution
996 Generation:
The 996 generation (1997-2006) marked a significant departure from previous air-cooled 911s, introducing a water-cooled engine. This generation included the Carrera 2 (RWD) and Carrera 4 (AWD) variants, and later the Carrera 4S with wider bodywork and the 3.6L engine.
Production
Production Years:
1997-2006 (for the 996 generation). This manual specifically covers the Carrera 2 and Carrera 4 models within this range.
Manufacturing Location:
Stuttgart-Zuffenhausen, Germany.
🏆 Awards & Recognition
Recognitions
Awards:
While the 996 generation itself received mixed reviews initially due to the departure from air-cooling and its perceived design differences from older 911s, it has since gained appreciation as a capable and increasingly collectible modern classic. This manual helps maintain its performance and longevity, allowing owners to experience its intended driving dynamics.
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