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Table of ContentsInformation on handling of the GT2 scope.......................................................................................................1

0 Technical data..................................................................................................................................................2Engine......................................................................................................................................................3Engine design...........................................................................................................................................4Engine cooling.........................................................................................................................................5Engine lubrication....................................................................................................................................5Engine control..........................................................................................................................................5Heating.....................................................................................................................................................6Fuel system..............................................................................................................................................6Electrical system......................................................................................................................................6Exhaust system........................................................................................................................................7Emission control......................................................................................................................................7Transmission............................................................................................................................................7Clutch.......................................................................................................................................................7Transmission............................................................................................................................................8Body designs............................................................................................................................................9Running gear............................................................................................................................................9Brakes....................................................................................................................................................10Wheels and tyres....................................................................................................................................11Spare wheel............................................................................................................................................11Wheel alignment....................................................................................................................................11Dimensions............................................................................................................................................12Weights according to DIN 700 20.........................................................................................................12Filling capacities....................................................................................................................................13Performance data...................................................................................................................................14Climbing performance...........................................................................................................................15Specific power.......................................................................................................................................15

0 Entire vehicle General................................................................................................................................16Lifting the vehicle..................................................................................................................................16

Power unit..........................................................................................................................................................17Engine M96/70......................................................................................................................................17Engine....................................................................................................................................................18Engine design.........................................................................................................................................18Engine cooling.......................................................................................................................................19Engine lubrication..................................................................................................................................19Engine control........................................................................................................................................20

0 Transmission..................................................................................................................................................216speed manual transmission G 96.50..................................................................................................21Front wheel drive Z 96.00......................................................................................................................22

0 Body.................................................................................................................................................................23Body of highstrength steel 1................................................................................................................23Body of highstrength steel 2................................................................................................................24Water drainage plan Coup................................................................................................................25

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Table of Contents0 Body

Refrigerant circuit..................................................................................................................................26Component arrangement, Airbag System B05......................................................................................26

0 Electrics...........................................................................................................................................................28Fuse assignments...................................................................................................................................28

0 Power supply..................................................................................................................................................31Work instructions after disconnecting the battery.................................................................................31Control module memories.....................................................................................................................31Supply voltage fault entry......................................................................................................................32Test drive after connecting the battery...................................................................................................322470 DME control module....................................................................................................................323730 Tiptronic........................................................................................................................................336452 Power windows.............................................................................................................................3390 25 Instrument cluster.........................................................................................................................339030 Clock.............................................................................................................................................339023 Fuel level display..........................................................................................................................349120 Radio.............................................................................................................................................349110 PCM..............................................................................................................................................34

01 General maintenance: Test drive...............................................................................................................36

01 Diagnostic system: Read out fault memory and activate systems...........................................................37Activating systems.................................................................................................................................37Read out fault memory...........................................................................................................................37Load Navigation.....................................................................................................................................38

01 Battery: checking the charge state.............................................................................................................39Tools......................................................................................................................................................39Checking charge state with battery tester..............................................................................................39

01 Windscreen wiper/washer system, headlight washer...............................................................................40Mix ratio of fluids for windscreen washer system.................................................................................40

01 Checking the function of the vehicle's lights and the headlight setting..................................................41Checking the adjustment of the headlights............................................................................................41Adjusting the main headlights...............................................................................................................42Adjusting the main headlights, USA version.........................................................................................43Fog light adjustment..............................................................................................................................43

01 Checking the function of electrical equipment, as well as the indicator and warning lights................45

01 Alarm system: checking operation of indicators.......................................................................................46

01 Activating/deactivating the parking aid.....................................................................................................47General...................................................................................................................................................47Activating the parking aid without PST 2.............................................................................................47

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Table of Contents01 Activating/deactivating the parking aid

Deactivating the parking aid without PST 2..........................................................................................48Activating the parking aid with PST 2...................................................................................................48Selecting door mirror to be lowered, left/right......................................................................................49Adjusting the lowering angle for the passenger door mirror.................................................................49Deactivating the parking aid with PST 2...............................................................................................50

01 Removing transport lock (spring strut locking devices) Turbo and GT2...........................................51General...................................................................................................................................................51Removing spring strut locking devices..................................................................................................51

Technical Data GT2.......................................................................................................................................53Engine....................................................................................................................................................54Engine design.........................................................................................................................................54Engine cooling.......................................................................................................................................55Engine lubrication..................................................................................................................................55Engine control........................................................................................................................................55Fuel system............................................................................................................................................56Electrical system....................................................................................................................................56Exhaust system......................................................................................................................................56Emission control....................................................................................................................................56

Technical data...................................................................................................................................................57Engine....................................................................................................................................................58Engine design.........................................................................................................................................58Engine cooling.......................................................................................................................................59Engine lubrication..................................................................................................................................59Engine control........................................................................................................................................59Fuel system............................................................................................................................................60Electrical system....................................................................................................................................60Exhaust system......................................................................................................................................60Emission control....................................................................................................................................60

Precautionary measures when working on fuel system.................................................................................61

03 Diagnostic system: reading out fault memory...........................................................................................62Reading out fault memory.....................................................................................................................62

03 General maintenance: test drive.................................................................................................................63

03 Removing and installing drive belt.............................................................................................................64Removal overview of the drive belt (engine installed)..........................................................................64Installation overview of the drive belt (engine installed)......................................................................65

94 56 19 Removing and installing bulb for direction indicator light...........................................................67Removing bulb for direction indicator light..........................................................................................67Installing bulb for direction indicator light............................................................................................67

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Table of Contents03 Changing the engine oil and oil filter.........................................................................................................68

03 Changing the engine oil (without oil filter)................................................................................................72

03 Replacing spark plugs..................................................................................................................................74Removing spark plugs...........................................................................................................................74Installing spark plugs.............................................................................................................................75

03 Checking cooling system..............................................................................................................................77Coolant: checking level, antifreeze content and leaks...........................................................................77

03 Replacing air cleaner element.....................................................................................................................79Removing air cleaner.............................................................................................................................79Installing air cleaner...............................................................................................................................81

03 Replacing the fuel filter...............................................................................................................................85

03 Clutch: checking the play and pedal end position....................................................................................89Checking clutch free play......................................................................................................................89Checking the pedal end position (pedal return/return force).................................................................89

03 Changing transmission oil...........................................................................................................................90Changing transmission oil.....................................................................................................................90Tightening torques.................................................................................................................................90

03 Checking and topping up the ATF.............................................................................................................91Tools......................................................................................................................................................91Checking and topping up the ATF.........................................................................................................91Tightening torques.................................................................................................................................93

03 Replacing ATF.............................................................................................................................................94Tools......................................................................................................................................................94Replacing ATF fluid..............................................................................................................................94Tightening torques.................................................................................................................................96

03 Removing and installing ATF filter............................................................................................................97Tools......................................................................................................................................................97Removing ATF filter.............................................................................................................................97Installing ATF filter...............................................................................................................................98Tightening torques.................................................................................................................................99

03 Replacing and checking transmission oil in final drive..........................................................................100Tools....................................................................................................................................................100Changing transmission oil in final drive..............................................................................................100Tightening torques...............................................................................................................................102

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Table of Contents03 Changing transmission oil in front wheel drive......................................................................................103

Changing transmission oil in front wheel drive...................................................................................103Tightening torques...............................................................................................................................103

03 Changing transmission oil GT2.............................................................................................................105Changing transmission oil GT2........................................................................................................105Topping up transmission oil GT2.....................................................................................................105Tightening torques...............................................................................................................................106

03 Steering gear: fluid level and bellows.......................................................................................................107Power steering: checking the fluid level..............................................................................................107

General..........................................................................................................................................107Power steering: checking the fluid level.......................................................................................107

Steering gear: visual inspection of the bellows....................................................................................109

03 Axle joints/drive shafts..............................................................................................................................110Tie rod ends: checking the play and dust bellows...............................................................................110Axle joints: checking the play and dust bellows..................................................................................110Drive shafts: visual inspection of the boots.........................................................................................111

03 Running gear adjustment/storage of assemblies.....................................................................................112Running gear adjustment (wheel alignment values)............................................................................112Storage of assemblies and running gear...............................................................................................112

03 Tyres and spare wheel: checking condition and tyre pressure..............................................................113Checking condition..............................................................................................................................113Tyre pressure for cold tyres (approx. 20 C).......................................................................................113

911 Turbo......................................................................................................................................113911 GT2 (M002/M003).................................................................................................................113

03 Checking and changing the brake fluid...................................................................................................115Checking the brake fluid level.............................................................................................................115Changing the brake fluid......................................................................................................................115

03 Parking brake: checking the free play of the parking brake lever.......................................................117Parking brake: checking the free play of the parking brake lever.......................................................117

Adjusting the parking brake..........................................................................................................117

03 Visual inspection: brake lines/brake pads/brake discs...........................................................................119Brake hoses and lines...........................................................................................................................119Brake system: visual inspection of the brake pads and brake discs for wear......................................119

03 Checking the wheel mounting...................................................................................................................121

03 Checking lid and doors..............................................................................................................................122Checking lid lock, front and rear.........................................................................................................122

Checking the catch bar..................................................................................................................122Checking safety hook, front lid............................................................................................................122

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Table of Contents03 Checking lid and doors

Function test, checking door lock........................................................................................................122Functional inspection of the tank cap lock..........................................................................................123Checking door and lid tightening torques............................................................................................123Checking inner release of luggage compartment (Trunk Entrapment)................................................123Tightening torques...............................................................................................................................124

03 Checking seat belts.....................................................................................................................................125Functional inspection...........................................................................................................................125Condition inspection............................................................................................................................125

03 Inspecting the airbag system.....................................................................................................................126Visual inspection..................................................................................................................................126Checking airbag warning light.............................................................................................................126Function test of the airbag system.......................................................................................................126

03 Passenger protection maintenance: checking rollover protection system..........................................128

03 Particle filter: replacing the filter element..............................................................................................129Removing particle filter.......................................................................................................................129Installing particle filter.........................................................................................................................129

03 Checking the function of the vehicle's lights...........................................................................................130Adjusting the main headlights.............................................................................................................130Setting..................................................................................................................................................131Adjusting the main headlights, USA version.......................................................................................132Fog light adjustment............................................................................................................................132Removing main headlight....................................................................................................................132Installing main headlight.....................................................................................................................133

03 Windscreen wiper/washer system, headlight washer.............................................................................135

03 Checking the function of electrical equipment, as well as the indicator and warning lights..............136

03 Additional maintenance USA................................................................................................................137Additional maintenance, replacing spark plugs...................................................................................137Additional maintenance every 60,000 mls/96,000 km........................................................................137Additional maintenance every 90,000 mls/144,000 km......................................................................138Maintenance every 2 years...................................................................................................................138Maintenance after 4, 8, 10 then every 2 years.....................................................................................138

03 Additional maintenance as of MY 2004................................................................................................139Additional maintenance, replacing spark plugs...................................................................................139Additional maintenance every 80,000 km/48,000 mls........................................................................139Additional maintenance every 160,000 km/96,000 mls......................................................................139Maintenance every 2 years...................................................................................................................140Maintenance after 4, 8, 10 then every 2 years.....................................................................................140

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Table of Contents03 Additional maintenance USA as of MY 2004...................................................................................141

Additional maintenance, replacing spark plugs...................................................................................141Additional maintenance every 60,000 mls/96,000 km........................................................................141Additional maintenance every 90,000 mls/144,000 km......................................................................142Maintenance every 2 years...................................................................................................................142Maintenance after 4, 8, 10 then every 2 years.....................................................................................142

03 Additional maintenance.............................................................................................................................144Additional maintenance, replacing spark plugs...................................................................................144Additional maintenance every 80,000 km/48,000 mls........................................................................144Additional maintenance every 160,000 km/96,000 mls......................................................................144Maintenance every 2 years...................................................................................................................145Maintenance after 4, 8, 10 then every 2 years.....................................................................................145

3 Technical data..............................................................................................................................................1466speed manual transmission G 96.50................................................................................................146

Manual transmission tightening torques........................................................................................147Front wheel drive Z 96.00....................................................................................................................147

Frontaxle drive tightening torques..............................................................................................148

3 Technical data..............................................................................................................................................1495speed Tiptronic transmission A 96.50150.....................................................................................149

Tightening torques for Tiptronic transmission..............................................................................150Front wheel drive Z 96.00....................................................................................................................151

Frontaxle drive tightening torques..............................................................................................151

4 Removing transport lock (spring strut locking devices) Turbo and GT2...........................................153General.................................................................................................................................................153Removing spring strut locking devices................................................................................................153

4 Lifting the vehicle.........................................................................................................................................155Lift the vehicle.....................................................................................................................................155

4 Tests/notes for allwheel drive...................................................................................................................156Balancing wheels on vehicle................................................................................................................156Power test.............................................................................................................................................156Brake test.............................................................................................................................................156Towing manual transmission vehicles.................................................................................................156Towing Tiptronic vehicles...................................................................................................................156

4 Switching off PSM........................................................................................................................................157Switching off PSM...............................................................................................................................157Switching PSM back on.......................................................................................................................157Characteristic features of Tiptronic vehicles (slip upshift)..................................................................158

5 Plug location plan.........................................................................................................................................159Top of front end...................................................................................................................................159Bottom of front end..............................................................................................................................160

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Table of Contents5 Plug location plan

Side of front end...................................................................................................................................160Bottom of lower side member and floor..............................................................................................161Top of lower side member and floor....................................................................................................161Bottom of rear end...............................................................................................................................162Top of rear end.....................................................................................................................................162Side of rear end....................................................................................................................................163

Seam seals........................................................................................................................................................164Accessories..........................................................................................................................................164

Front lid.........................................................................................................................................165Door...............................................................................................................................................165Sliding roof panel..........................................................................................................................166

5 Work sequence for accident repair............................................................................................................167

5 Work sequence for determining scope of damaged vehicles involved in an accident...........................169

5 Corrosion protection measures during repairs.........................................................................................171Measures for maintaining longterm body protection........................................................................171Prerequisite for ensuring vailidity of the longlife guarantee.............................................................171

5 Vehicle identification number.....................................................................................................................172Imprinting new vehicle identification number.....................................................................................172Materials, tools.....................................................................................................................................173

5 Change identification data plate.................................................................................................................174

5 Undersealing.................................................................................................................................................176Overview diagram, lower front of vehicle...........................................................................................176Overview diagram, bottom of lower side member and floor...............................................................177Overview diagram, lower rear end.......................................................................................................178Tools and materials..............................................................................................................................178

5 Water drainage plan Cabriolet...............................................................................................................179

5 Check dimensions for body repair Cabriolet structure........................................................................180Structure dimensions for cabriolet.......................................................................................................180

5 Safety notes...................................................................................................................................................183Safety instructions for raising vehicles................................................................................................183

Danger of injury when raising vehicles.........................................................................................183Damage when raising vehicles......................................................................................................183

Safety instructions for welding............................................................................................................184Dangers of injury when welding...................................................................................................184Safety instructions for flying sparks during grinding and welding work......................................184Safety instructions for fuel tank....................................................................................................185Safety instructions for air conditioning.........................................................................................185

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Table of Contents5 Safety notes

Safety instructions for sticking............................................................................................................185Safety instructions for Teromix6700 twocomponent adhesive................................................185

Safety instructions for installation work..............................................................................................186Safety instructions for sharpedged body and unit parts..............................................................186Safety instructions for airbag system............................................................................................186Safety instructions for door...........................................................................................................186

Safety instructions for corrosion protection.........................................................................................187Safety instructions for plug location plan (body)..........................................................................187Safety instructions for water drains (body)...................................................................................187

5 General information and quality notes......................................................................................................188Measures for maintaining longterm body protection........................................................................188

Prerequisite for maintaining the longlife guarantee....................................................................188Electronic control modules..................................................................................................................188

Protection against overvoltage......................................................................................................189Replacing control modules............................................................................................................189

5 Tools and metalworking tools for body repairs........................................................................................190Straightening systems..........................................................................................................................190Metalworking tools..............................................................................................................................190

Electrical equipment......................................................................................................................190Mechanical equipment..................................................................................................................191Compressedair equipment...........................................................................................................191Welding equipment.......................................................................................................................192

5 Diagram keys to symbols for welding work...........................................................................................193Resistance spot welding.......................................................................................................................193Inertgas arc welding (MAG procedure).............................................................................................193Gas welding.........................................................................................................................................193

5 Check dimensions for body repair.............................................................................................................195Floorpan check dimensions..................................................................................................................195

5 Water drainage plan....................................................................................................................................198

5 Diagram body gap dimensions................................................................................................................199Gap dimensions, body front.................................................................................................................199Gap dimensions, body centre...............................................................................................................201Gap dimensions, body rear..................................................................................................................202Gap dimensions, body rear Carrera 4S.............................................................................................204Diagram Gap dimensions, Cabriolet................................................................................................206

Diagram Centre gap dimensions, Cabriolet...............................................................................206Diagram Gap dimensions, rear Cabriolet...................................................................................208Diagram, gap dimensions, Cabriolet rear Carrera 4S................................................................209Diagram Gap dimensions, hardtop.............................................................................................210

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Table of Contents5 Body parts of highstrength steel...............................................................................................................212

Highstrength steel plates....................................................................................................................213Tailored blanks.....................................................................................................................................214Baked hardening..................................................................................................................................215Straightening body parts......................................................................................................................215Welding work.......................................................................................................................................216Reshaping.............................................................................................................................................216Separation points..................................................................................................................................216Diagram Body, model year 2002......................................................................................................217

Structural body parts (model care) for model year 2002...............................................................217

6 Safety notes...................................................................................................................................................219Safety instructions for work on car windows......................................................................................219

Danger of injury when working on car windows..........................................................................219Material damage when removing the glass from car windows.....................................................219Material damage when inserting the glass into car windows........................................................219

Safety instructions for installation work..............................................................................................220Safety instructions for airbag system............................................................................................220Safety instructions for sliding roof................................................................................................220Safety instructions for rear spoiler................................................................................................220Safety instructions for the pump unit hydraulic system of the rear spoiler...................................221

6 General information on installing and removing car windows...............................................................222Removing glass with cutting wire separator........................................................................................222

Cutting power when removing glass with cutting thread..............................................................229

6 Overview of exterior colours.......................................................................................................................231Exterior paintwork solid...................................................................................................................231Exterior paintwork metallic/pearl.....................................................................................................231Special colours.....................................................................................................................................232

6 Processing of Porsche 2component window bonding agents.................................................................234Overview of tools and materials..........................................................................................................234Preparing the adhesive surfaces...........................................................................................................235Combined procedure (handling double cartridge press)......................................................................236

7 Special notes for the care of softlook paint surfaces...............................................................................239Light soiling (e.g. dust)........................................................................................................................239Heavy soiling (e.g. oily, greasy dirt)....................................................................................................239

8 Air conditioning...........................................................................................................................................241Technical data for the airconditioning system...................................................................................241

9 Work instructions after disconnecting the battery...................................................................................242Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures...........................................................................................................................242Control module memories...................................................................................................................242Supply voltage fault entry....................................................................................................................243

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Table of Contents9 Work instructions after disconnecting the battery

Test drive after connecting the battery.................................................................................................2432470 DME control module..................................................................................................................2436452 Power windows...........................................................................................................................24490 25 Instrument cluster.......................................................................................................................2449030 Clock...........................................................................................................................................2449023 Fuel level display........................................................................................................................2449120 Radio...........................................................................................................................................2459110 PCM............................................................................................................................................245

30 Clutch: checking fluid levels.....................................................................................................................247General.................................................................................................................................................247Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment.......................................................................................................................................247Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment..........................................248Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment........................................249

40 Tightening torques for front axle.............................................................................................................251Cross member/side member (1 component)........................................................................................251Diagonal brace.....................................................................................................................................251Control arm..........................................................................................................................................251Spring strut/wheel carrier.....................................................................................................................252Frontaxle final drive/drive shaft (Turbo)...........................................................................................252Stabilizer..............................................................................................................................................253Steering................................................................................................................................................253Wheel fastening...................................................................................................................................253

42 Tightening torques for rear axle...............................................................................................................255Carrier side section/cross member.......................................................................................................255Axle strut..............................................................................................................................................255Wheel carrier........................................................................................................................................256Spring strut...........................................................................................................................................256Drive shaft/stabilizer............................................................................................................................257Unit mount...........................................................................................................................................257

44 Conversion table for wheel alignment values..........................................................................................258Minutes in decimal degrees.................................................................................................................258

Conversion from minutes to decimal degrees (examples)............................................................258Conversion from decimal degrees to minutes (examples)............................................................258

44 Adjusting values for suspension alignment Turbo and GT2..............................................................260Vehicle height......................................................................................................................................260Wheel alignment values.......................................................................................................................260

44 Alignment card Turbo............................................................................................................................262

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Table of Contents44 Suspension alignment, complete...............................................................................................................264

Vehicle height/wheel load....................................................................................................................265Wheelalignment corrections..............................................................................................................265

Rear axle........................................................................................................................................265Front axle.......................................................................................................................................266

General procedure for suspension alignment.......................................................................................266Vehicle height (vehicle height check)..................................................................................................267

General..........................................................................................................................................267Preliminary work...........................................................................................................................267Front axle.......................................................................................................................................268Rear axle........................................................................................................................................268Wheel alignment............................................................................................................................268

Rear axle..............................................................................................................................................269Adjusting camber..........................................................................................................................269Adjusting toe.................................................................................................................................270

Front axle.............................................................................................................................................271Adjusting camber..........................................................................................................................271Adjusting caster.............................................................................................................................271Adjusting toe.................................................................................................................................272Toedifference angle.....................................................................................................................274

44 Wheel rims and tires..................................................................................................................................275Tire condition / tire pressure................................................................................................................275Tire pressure of cold tires (approx. 20 C)..........................................................................................275

911 Turbo......................................................................................................................................275911 GT2 (M002/M003).................................................................................................................275

Overview of tires and wheels (series)..................................................................................................276Notes on mounting tires................................................................................................................276

44 Tyres............................................................................................................................................................277Mounting instructions..........................................................................................................................277

General..........................................................................................................................................277Uncontrolled matching..................................................................................................................278Controlled matching......................................................................................................................278Fitting............................................................................................................................................278

Balancing weights................................................................................................................................279Navigation system................................................................................................................................279Wheel storage.......................................................................................................................................279Tyre age...............................................................................................................................................280

44 Checking disc wheels.................................................................................................................................281Checking the radial and lateral runout.................................................................................................281

44 Tyre mounting............................................................................................................................................282Tools....................................................................................................................................................282Notes on removing/mounting tyres......................................................................................................283Removal...............................................................................................................................................283Fitting...................................................................................................................................................284

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Table of Contents44 Balancing/optimising wheels.....................................................................................................................287

General.................................................................................................................................................287Balancing/optimising wheels...............................................................................................................287

Further to 1: Mounting the tyre on the rim....................................................................................288Further to 2: Stationary balancing with optimisation of the rolling smoothness..........................288Further to 3: Mounting the wheel on the vehicle..........................................................................289Further to 4: Electronic fine balancing..........................................................................................289Further to 4a: Fine balancing of the front wheels.........................................................................290Further to 4b: Fine balancing of the rear wheels...........................................................................290

Balancing weights................................................................................................................................291Affixing the adhesive weights.......................................................................................................291

45 ABS/PSM 5.7 check with Porsche System Tester 2................................................................................292Test with Porsche System Tester 2......................................................................................................292

46 Checking brake light switch setting.........................................................................................................293Brake light switch setting....................................................................................................................293Checking brake light switch setting.....................................................................................................293Adjusting switch if pedal travel is too small........................................................................................294

1st possibility:................................................................................................................................2942nd possibility:..............................................................................................................................294Adjusting switch if pedal travel is too large..................................................................................294

46 Tightening torques for mechanical brake................................................................................................295

46 Technical data/Brake wear limit Turbo...............................................................................................296Technical data Turbo with cast iron brake discs..............................................................................296Wear limit technical data Turbo with cast iron brake discs.............................................................297

46 Checking the thickness of the disc brake pads Turbo and GT2.........................................................298

46 Technical data/Brake wear limit Turbo with PCCB...........................................................................300Technical data Turbo with ceramic brake discs (PCCB).................................................................300Wear limit technical data Turbo with ceramic brake discs (PCCB).................................................301

47 Tightening torques for brake hydraulics.................................................................................................302

48 Tightening torques for steering................................................................................................................303

48 Test and assembly work on power steering.............................................................................................304General.................................................................................................................................................304Checking hydraulic fluid of power steering and servo clutch.............................................................304Bleeding the steering system...............................................................................................................305

48 Assessment of steering gear after accident damage................................................................................307Fundamentals.......................................................................................................................................307

Assessment of the steering of a vehicle involved in an accident..................................................307Exceptional regulation / order handling........................................................................................308

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Table of Contents69 Safety regulations for vehicles with airbag and belt tensioner..............................................................309

Assembly and adjustment work...........................................................................................................310Handling airbag and belt tensioner......................................................................................................311

Dangers for persons and the environment.....................................................................................311Protective measures and rules of behaviour..................................................................................311Behaviour in cases of malfunction or danger................................................................................312Materials........................................................................................................................................313

General information.............................................................................................................................313Component exchange after airbag triggering................................................................................314After triggering of the side airbag unit..........................................................................................314After triggering of belt tensioner...................................................................................................314

87 Nominal values for pressures and temperatures.....................................................................................315General test prerequisites.....................................................................................................................315

Centre vent temperature as a function of ambient temperature.....................................................315High pressure in cold circuit as a function of ambient temperature..............................................316Low pressure in cold circuit as a function of ambient temperature..............................................316

91 Retrofitting mobile communication systems...........................................................................................318

96 Additional alarm system M 536................................................................................................................320Removing alarm siren and tilt sensor...................................................................................................320

97 Measurement of closedcircuit current...................................................................................................321Tools....................................................................................................................................................321Preparations on the vehicle..................................................................................................................321

Connecting measuring device.......................................................................................................321Measurement........................................................................................................................................322

27 06 Battery....................................................................................................................................................324Battery handling notes......................................................................................................................324

Warning notes and safety regulations for hydrocyanic acid batteries...........................................325Removing and installing battery..........................................................................................................325Remove battery....................................................................................................................................326Install battery.......................................................................................................................................327Visual inspection..................................................................................................................................328Check acid level...................................................................................................................................328Checking gravity of electrolyte............................................................................................................329Opencircuit voltage measurement.....................................................................................................330Battery load test...................................................................................................................................331Charging battery...................................................................................................................................332

27 06 Electrical emergency release, front cover...........................................................................................334Emergency release, front cover............................................................................................................334

40 09 Frontaxle cross member permissible combinations.....................................................................336New frontaxle cross member as of model '02................................................................................336Allocating the frontaxle cross member to the body...........................................................................336

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Table of Contents40 09 Frontaxle cross member permissible combinations

Impermissible combination...........................................................................................................337Permissible combinations..............................................................................................................337Impermissible combination...........................................................................................................338

40 Disassembling and assembling front spring strut...................................................................................339Tools....................................................................................................................................................339Disassembly and assembly instructions...............................................................................................341

Disassembly...................................................................................................................................341Distinguishing feature of coil springs and dampers......................................................................342Preliminary work and notes on assembly......................................................................................342Assembly.......................................................................................................................................343

42 71 Disassembling and assembling rear spring strut Turbo................................................................346Tools....................................................................................................................................................346Disassembling and assembling rear spring strut..................................................................................346Disassembly and assembly instructions...............................................................................................348

Disassembly...................................................................................................................................348Distinguishing feature of coil springs and dampers......................................................................350Assembly.......................................................................................................................................350

44 27 Instructions for collapsible wheel/spare wheel Turbo with PCCB...............................................353Mounting collapsible spare wheel Turbo with PCCB......................................................................353Placing collapsible spare wheel in to the vehicle Turbo with PCCB...............................................354

45 60 Steering angle sensor............................................................................................................................355Calibrating steering angle sensor.........................................................................................................355

Steering angle sensor position.......................................................................................................355The steering angle sensor must be calibrated after:......................................................................355Calibrating steering angle sensor..................................................................................................356Check the steering angle sensor actual value in the following cases:...........................................357Checking the steering angle sensor actual value...........................................................................357

66 72 Assignment of spoiler drive, relays and instrument cluster..............................................................358Variants of the spoiler drive.................................................................................................................358

69 59 Disposal of airbag and belt tensioner units.........................................................................................359Safety measures when igniting airbag units.........................................................................................359Tools....................................................................................................................................................360Connecting ignition tool......................................................................................................................361

Driver's side...................................................................................................................................361Passenger's side.............................................................................................................................361Side airbag.....................................................................................................................................361Belt tensioner.................................................................................................................................362

Ignition.................................................................................................................................................362

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Table of Contents87 03 Safety regulations when handling refrigerant R134a........................................................................364

92 66 Nonadjustable spray nozzles..............................................................................................................365

94 23 Bulb table and installation instructions..............................................................................................366Bulb table.............................................................................................................................................366Installing bulbs.....................................................................................................................................366

96 22 Bulb table and installation instructions..............................................................................................367Bulb table.............................................................................................................................................367Installing bulbs.....................................................................................................................................367

97 68 Optical waveguide MOST bus..........................................................................................................368Specifications on handling the optical waveguide...............................................................................368

Storage, packaging, transport........................................................................................................368Installing optical waveguides in the vehicle..................................................................................368Repairs...........................................................................................................................................369

Plug connectors....................................................................................................................................369Protective dust caps.......................................................................................................................369Control module plug connector (wiring harness side)..................................................................370Connectors.....................................................................................................................................370

Removing and installing optical contacts............................................................................................371Removing optical contacts on plug side........................................................................................372Installing optical contacts on plug side.........................................................................................373Removing optical contacts on bushing side..................................................................................374Installing optical contacts on bushing side....................................................................................374

Optical waveguide modules.................................................................................................................375Tools....................................................................................................................................................376

01 Sales check..................................................................................................................................................377

03 24 00 Minor maintenance..........................................................................................................................379

03 26 00 Major maintenance..........................................................................................................................381

03 50 00 Annual maintenance........................................................................................................................383

10 01 00 Tightening torques for M 96/70 engine..........................................................................................385Crankshaft/crankcase...........................................................................................................................385Cylinder, cylinder head and camshaft housing....................................................................................385

10 10 37 Disassembling and assembling crankcase......................................................................................387Tools....................................................................................................................................................387Adapting engine holder........................................................................................................................390Left crankcase half (cylinder bank 1 3)............................................................................................392Right crankcase half (cylinder bank 4 6)..........................................................................................394Disassembling the crankcase...............................................................................................................396Assembling the crankcase....................................