ESP PORSCHE 911 CARRERA 2003 4.G Workshop Manual

Removingthewindstop
1.Foldbackuppersectionofwindstop.
2.MovebothredlockinghandlestopositionA
(open).
3.Pullwindstopoutoftheguidesoftheseat
belts.
A-Lockopen
B-Lockclosed
4.Foldthewindstoptogethersothatthesplit
windstoplowersectionisontheoutside.
5.Placewindstopintheprotectivebaginthe
luggagecompartmentandsealthevelcro
fasteningstriporzipperoftheprotective
bag.
Pleaseobservethechapter"Installingthe
windstop".
MobileRoofs
153

/!\Caution!
Dangerofdamageduetoinadvertentoper-
ationoftheconvertibletopwiththehard-
topfitted.

I>MakesurethatthefrontlockingleverGis
alwayscorrectlylocked.
Thisdisablestheconvertibletopdrive.
158MobileRoofs

10.
SwivelfrontlockingleverGtotherear.
ThelatchinghookHmustengageinthe
windshieldframe(arrow).
ThewhitemarkinglineJontheredlocking
buttonmustbecomevisiblewhenthehard-
topislockedproperly.

11.
InsertunlockinghandleDintooneofthe
rearhardtoplocks.
Turntheunlockinghandleinthedirectionof
thearrowasfarasthepressurepoint1,
thenturnforcefullyfurtherasfarasthe
stop2,untilthelockengagesperceptibly
andaudibly.
12.Repeatprocedureontheothersideofthe
hardtop.

ExerciseExtremeCautionwhen
WorkingonyourVehicle

/!\Warning!
Ignoring
the
followinginstructionsmay
causeseriouspersonalinjury.

[>
Theenginecompartmentofanymotorvehicle
isapotentiallyhazardousarea.Ifyouarenot
fullyfamiliarwithproperrepairprocedures,do
notattempttheadjustmentsdescribedonthe
followingpages.
Thiscautionappliestotheentirevehicle.
[>Onlyworkonyourvehicleoutdoorsorina
wellventilatedarea.
[>Ensurethattherearenoopenflamesinthe
areaofyourvehicleatanytimewhenfuel
fumesmightbepresent.Beespeciallycau-
tiousofsuchdevicessuchashotwater
heaterswhichigniteaflameintermittently.
[>Beforeworkingonanypartintheenginecom-
partment,turntheengineoffandletitcool
downsufficiently.Hotenginecompartment
componentscanburnskinoncontact.
[>Bealertandcautiousaroundengineatall
timeswhiletheengineisrunning.
Ifworkhastobeperformedwiththeengine
running,alwayssettheparkingbrake,and
makesuretheshiftleverisinneutralorthe
selectorleverisinposition"P"or"N".
168Maintenance,CarCare
[>
Inparticular,beverycarefultoensurethat
itemsofclothing(ties,shirt,sleevesetc.),
jewelry,longhair,handorfingerscannotget
caughtintheengine-compartmentblower,
fan,beltsorothermovingparts.
Theradiatorandradiatorfansareinthefront
ofthecar.
Theengine-compartmentblowerismounted
ontheenginecompartmentlid.
Thefanscanstartorcontinuerunningasa
functionoftemperature,evenwiththeengine
switchedoff.
Carryoutworkintheseareasonlywiththe
engineoffandexerciseextremecaution.
[>YourPorscheisequippedwithanelectronic
ignitionsystem.Whentheignitionison,high
voltageispresentinallwiresconnectedwith
theignitionsystem;therefore,exerciseex-
tremecautionwhenworkingonanypartof
theenginewhiletheignitionisonortheen-
gineisrunning.
[>Alwayssupportyourcarwithsafetystandsif
itisnecessarytoworkunderthecar.The
jacksuppliedwiththecarisnotadequatefor
thispurpose.
[>
Whenworkingunderthecarwithoutsafety
standsbutwiththewheelsontheground,
makesurethecarisonlevelground,the
wheelsareblocked,andthattheenginecan-
notbestarted.
Removetheignitionkey.
[>
Donotsmokeorallowanopenflamearound
thebatteryorfuel.
Keepafireextinguisherinclosereach.
[>Incompleteorimproperservicingmaycause
problemsintheoperationofthecar.Ifin
doubtaboutanyservicing,haveitdoneby
yourauthorizedPorschedealer.
Impropermaintenanceduringthewarranty
periodmayaffectyourPorschewarranty
coverage.
[>Suppliesoffluids,e.g.engineoil,brakefluid
orcoolant,arehazardoustoyourhealth.
Keepthesefluidsoutofchildren'sreachand
disposeoftheminaccordancewiththeap-
propriateregulations.
[>Somecountriesrequireadditionaltoolsand
specialsparepartstobecarried.
Pleasemakeenquiriesbeforedrivingabroad.
Powermeasurements
Powermeasurementsondynamometersarenot
approvedbyPorsche.

Coolant
level

Followtheinstructionsinthe"Cautions"chapter.
Thecoolingsystemisfilledatthefactorywitha
permanentcoolant.
Itprovidesyear-roundprotectionfromcorrosion
andfreezingdownto-31°Fj-35°C(Nordic
countries-40°Fj-40°C).
OnlyuseantifreezeauthorizedbyPorsche.
Checkingcoolantlevel
Theexpansiontankwithitsfillerorificeisinthe
enginecompartment.
~Checkthecoolantlevelregularlythroughthe
transparentexpansiontank.
Whentheengineiscoldandthecarislevelthe
fluidlevelmustliebetweenthe"Min."and"Max."
markings.

Toppingoffcoolant

A.Warning!
Dangerofseriouspersonalinjuryfrom
scalding.Coolantishazardoustoyour
health,andmaybefatalifswallowed.
~Donotopenthecapoftheexpansiontank
whiletheengineishot.
~Allowtheenginetocooldownbeforeopening
thecapandprotectyourhands,armsand
facefromanypossibleescapeofhotcoolant.
~Keepcoolantoutofchildren'sreach.
~Also,keepcoolantawayfromyourpets.
Theycanbeattractedtoitshouldtherebea
spill,ortousedcoolantleftinanopencon-
tainer.Coolantcanbedeadlytopetsifcon-
sumed.
1.Switchengineoffandletitcool.
Seethechapteronthe"Coolingsystem".
2.Covertheexpansiontankcapwithathick
rag.
Opencapslowlyandcarefullyandallowover-
pressuretoescape.
Thenunscrewcapcompletely.
3.Onlyaddamixtureofantifreezeandwaterin
equalparts,anddonotexceedthe"Max."
mark.
Antifreezeincoolant:
50%givesprotectiondownto-31°Fj-35°C
60%givesprotectiondownto-58°Fj-50°C
4.Screwcapfirmlyon.
Ifinanemergencypurewaterhasbeenadded,
themixratiomustbecorrectedatanauthorized
Porschedealer.
Markedlossofcoolantindicatesleakageinthe
coolingsystem.
Thecauseshouldimmediatelyberemediedat
anauthorizedPorschedealer.
~~~
Maintenance,CarCare
169

Engine-compartment
blower,

radiatorfan
Theradiatorandradiatorfansareinthefrontof
thecar.
Theengine-compartmentblowerismountedon
theenginecompartmentlid.
/?\.Warning!
Riskofinjury.
Aftertheengineisswitchedoff,theengine-
compartmentandcoolanttemperaturesare
monitoredforapprox.20minutes.
Duringthisperiod,anddependingontem-
perature,theengine-compartmentblower
andradiatorfansmaycontinuetorunor
starttorun.
I>Carryoutworkintheseareasonlywiththe
engineoffandexerciseextremecaution.
170Maintenance,CarCare
EngineOil
Engineoilconsumption
Itisnormalforyourenginetoconsumeoil.
Therateofoilconsumptiondependsonthe
qualityandviscosityofoil,thespeedatwhich
theengineisoperated,theclimate,roadcondi-
tionsaswellastheamountofdilutionandoxida-
tionofthelubricant.
Ifthevehicleisusedforrepeatedshorttrips,
andconsumesanormalamountofoil,theen-
gineoilmeasurementmaynotshowanydropin
theoillevelatall,evenafter600miles(1000
km)ormore.Thisisbecausetheoilisgradually
becomingdilutedwithfuelormoisture,makingit
appearthattheoillevelhasnotchanged.
Thedilutingingredientsevaporateoutwhenthe
vehicleisdrivenathighspeeds,asonanex-
pressway,makingitthenappearthatoilisex-
cessivelyconsumedafterdrivingathighspeeds.
Iftheconditionsyoudriveyourvehicleinare
dusty,humid,orhot,thefrequencyoftheoil
changeintervalsshouldbegreater.
Ifthevehicleisdrivenatahighrateofspeed,
climaticconditionsarewarm,andtheloadis
high,theoilshouldbecheckedmorefrequently,
asdrivingconditionswilldeterminetherateof
oilconsumption.
-Theengineinyourvehicledependsonoilto
lubricateandcoolallofitsmovingparts.
Therefore,theengineoilshouldbechecked
regularlyandkeptattherequiredlevel.
-Makeitahabittohavetheengineoillevel
checkedwitheveryfuelfilling.
-Theoilpressurewarninglightisnotanoil
levelindicator.
Theoilpressurewarninglightindicates
seriousenginedamagemaybeoccuring
whenlit,ifenginerpmisaboveidlespeed.

FuelEconomy
Fueleconomywillvarydependingon
where,whenandhowyoudrive,optional
equipmentinstalled,andthegeneralcondi-
tionofyourcar.
Acartunedtospecificationsandcorrectly
maintained,willhelpyoutoachieveoptimal
fueleconomy.
I>Haveyourvehicletunedtospecifications.
Aircleanershouldbedirtfreetoallowproper
engine"breathing".
Batteryshouldbefullycharged.
Wheelsshouldbeproperlyaligned.
Tiresshouldbeinflatedatcorrectpressure.
I>Alwaysmonitoryourfuelconsumption.
I>Drivesmoothly,avoidabruptchangesin
speedasmuchaspossible.
I>Avoidjackrabbitstartsandsuddenstops.
I>Donotdrivelongerthannecessaryinthe
lowergears.Shiftingintoahighergearearly
withoutluggingtheenginewillhelpsavefuel.
I>Prolonged"warmup"idlingwastesgas.Start
thevehiclejustbeforeyouarereadytodrive.
Accelerateslowlyandsmoothly.
I>Switchofftheengineifstationaryforlonger
periods.
I>Anyadditionalweightcarriedinthevehiclere-
ducesfueleconomy.Alwayskeepcargotoa
minimumandremoveallunnecessaryitems.
I>Organizeyourtripstotakeinseveralerrands
inonetrip.
I>Allelectricalaccessoriescontributetoin-
creasedfuelconsumption.
I>Onlyswitchontheairconditioningwhen
necessary.
I>DonotdrivewiththeRoofTransportSystem
mountedunlessyouneedit.
TheEPAestimatedm.p.g.istobeusedfor
comparisonpurposes,actualmileagemay
bedifferentfromtheestimatedm.p.g.,de-
pendingonyourdrivingspeed,weather
conditionsandtriplength.Youractual
highwaymileagewillprobablybelessthan
theestimatedm.p.g.
I>Pleaseobservealllocalandnationalspeed
limits.
OperatingYourPorscheinother
Countries
GovernmentregulationsintheUnitedStatesand
Canadarequirethatautomobilesmeetspecific
emissionregulationsandsafetystandards.
Therefore,carsbuiltfortheU.S.andCanada
differfromvehiclessoldinothercountries.
IfyouplantotakeyourPorscheoutsidethecon-
tinentallimitsoftheUnitedStatesorCanada,
thereisthepossibilitythat
-unleadedfuelmaynotbeavailable;
-unleadedfuelmayhaveaconsiderablylower
octanerating.Excessiveengineknockand
seriousdamagetobothengineandcatalytic
converterscouldresult;
-servicemaybeinadequateduetolackof
properservicefacilities,toolsordiagnostic
equipment;
-replacementpartsmaynotbeavailableor
verydifficulttoget.
Porsche
cannot
beresponsibleforthe
mechanicaldamagethatcouldresultbe-
causeofinadequatefuel,serviceorparts
availability.
IfyoupurchasedyourPorscheabroadandwant
tobringitbackhome,besuretofindoutabout
shippingandforwardingrequirements,aswell
ascurrentimportandcustomsregulations.
Maintenance,CarCare
175

Unleadedfuelsmaynotbeavailableoutsidethe
continentalU.S.andCanada.Therefore,werec-
ommendyoudonottakeyourcartoareasor
countrieswhereunleadedfuelmaynotbeavail-
able.

Octaneratings

Octaneratingindicatesafuel'sabilitytoresist
detonation.Therefore,buyingthecorrectoctane
gasisimportanttopreventengine"damage".
TheRONoctaneratingisbasedontheresearch
method.TheCLC(U.S.CostofLivingCouncil
octanerating)orAKI(antiknockindex)octane
ratingusuallydisplayedonU.S.fuelpumpsis
calculatedasresearchoctanenumberplus
motoroctanenumber,dividedby2,thatiswrit-
tenas:
RON+MON
2
orR+M
2
TheCLCorAKIoctaneratingisusuallylower
thantheRONrating:
Forexample:95RONequals90CLCorAKI
178Maintenance,CarCare
Fuels
containing
alcohol
andether

SomeareasoftheU.S.requireoxygenated
fuelsduringcertainportionsoftheyear.Oxyge-
natedfuelsarefuelswhichcontainalcohols
(suchasmethanolorethanol)orether(suchas
MTBE).
Undernormalconditions,theamountofthese
compoundsinthefuelwillnotaffectdriveability.
YoumayuseoxygenatedfuelsinyourPorsche,
providedtheoctanerequirementsforyourve-
hiclearemet.Werecommend,however,to
changetoadifferentfuelorstationifanyofthe
followingproblemsoccurwithyourvehicle:
-Deteriorationofdriveabilityandperformance.
-Substantiallyreducedfueleconomy.
-Vaporlockandnon-startproblems,especially
athighaltitudeorathightemperature.
-Enginemalfunctionorstalling.
Fuels
containing
MMT
SomeNorthAmericanfuelscontainanoctane
enhancingadditivecalledmethylcyclopentadienyl
manganesetricarbonyl(MMT).
Ifsuchfuelsareused,youremissioncontrol
systemperformancemaybenegativelyaffected.
Thecheckenginewarninglightonyourinstru-
mentpanelmayturnon.
Ifthisoccurs,Porscherecommendsyoustop
usingfuelscontainingMMT.
PortableFuelContainers

A
Danger!
Portablefuelcontainers,fullorpartially
empty,mayleakcausinganexplosion,or
resultinfireincaseofanaccident.

t>Nevercarryadditionalfuelinportablecon-
tainersinyourvehicle.

EmissionControl
System
Intheinterestofclean
air
Pollutionofourenvironmenthasbecomeaprob-
lemthatisofincreasingconcerntoallofus.We
urgeyoutojoinusinoureffortsforcleanerair
incontrollingthepollutantsemittedfromthe
automobile.
Porschehasdevelopedanemissioncontrolsys-
temthatcontrolsorreducesthosepartsofthe
emissionthatcanbeharmfultoourenviron-
ment.YourPorscheisequippedwithsuchasys-
tem.
PorschewarrantstheEmissionControlSystem
inyournewcarunderthetermsandconditions
setforthintheWarrantyBooklet.
You,astheownerofthevehicle,havethe
responsibilitytoprovideregularmaintenance
serviceforthevehicleandtokeeparecordof
allmaintenanceworkperformed.Tofacilitate
recordkeeping,havetheserviceperformedby
authorizedPorschedealers.TheyhavePorsche
trainedtechniciansandspecialtoolstoprovide
fastandefficientservice.

Toassure
efficientoperationofthe
EmissionControlSystem:
I>Haveyourvehiclemaintainedproperlyandin
accordancewiththerecommendationsde-
scribedinyourMaintenanceBooklet.
Lackofpropermaintenance,aswellasim-
properuseofthevehicle,willimpairthefunc-
tionoftheemissioncontrolsystemandcould
leadtodamage.
I>Donotalterorremoveanycomponentofthe
emissioncontrolsystem.
I>Donotalterorremoveanydevice,suchas
heatshields,switches,ignitionwires,valves,
etc.,whicharedesignedtoprotectyourvehi-
cle'semissioncontrolsystem.
Inadditiontoseriousenginedamage,thiscan
resultinafireifexcessrawfuelreachesthe
exhaustsystem.
I>Donotcontinuetooperateyourvehicleifyou
detectenginemisfireorotherunusualopera-
tingconditions.
Parking

/!\Warning!
Dangeroffire.

I>Donotparkoroperatethevehicleinareas
wherethehotexhaustsystemmaycomein
contactwithdrygrass,brush,fuelspillor
otherflammablematerial.
I>Ifyourcarcatchesonfireforanyreason,call
thefiredepartment.
Donotendangeryourlifebyattemptingto
putoutthefire.
Undercoating

/!\Warning!
Dangeroffireandseriouspersonalin-
juries.

I>Donotapplyadditionalundercoatingorrust-
proofingonorneartheexhaustmanifold,ex-
haustpipes,catalyticconvertersorheat
shields.Duringdrivingthesubstanceusedfor
undercoatingcouldoverheatandignite.
I>I>I>
Maintenance,CarCare
179

CarCareInstructions
Followtheinstructionsinthe"Cautions.
chapter.
Regularandcorrectcarehelpstomaintain
thevalueofyourcarandisalsoaprecon-
ditionfortheNewVehicleWarrantyandthe
AntiCorrosionWarranty.
YourauthorizedPorschedealerhasspe-
ciallydevelopedcar-careproductsfromthe
Porscheprogramavailableeithersinglyor
ascompletecar-caresets.Theywillbe
pleasedtohelpyouselectsuitablepro-
ducts.
WhetheryouusePorscheproductsorother
commerciallyavailablecleaningagentsfirst
makesureoftheircorrectapplication.
APorschethatiswell-caredforcanlooklike
newforyears.Italldependsontheamountof
caretheowneriswillingtogivethecar.
A.Warning!
Riskofseriouspersonalinjuryordamage
tothevehicleorproperty.
Cleaningagentsmaybehazardoustoyour
health.
Mostchemicalcleanersareconcentrates
whichrequiredilution.Highconcentrations
mightcauseproblemsrangingfromirrita-
tiontoseriousinjuryaswellasdamageto
yourvehicle.
I>Keepcleaningagentsoutofreachfromchild-
ren.
I>Observeallcautionlabels.
I>Alwaysreaddirectionsonthecontainerbe-
foreusinganyproduct.Thesedirectionsmay
containinformationnecessarytoavoidper-
sonalinjury.
I>Donotusefuel,kerosene,naphtha,nailpolish
removerorothervolatilecleaningfluids.They
maybetoxic,flammableorhazardousin
otherways.Onlyusespotremovingfluidsina
wellventedarea.
I>Donotcleantheundersideofchassis,fen-
ders,wheelcovers,etc.,withoutprotecting
yourhandsandarmsasyoumaycutyour-
selfonsharp-edgedmetalparts.
Moistureandroadsaltonbrakesmayaffect
brakingefficiency.
I>Testthebrakesaftereachvehiclewashing.
I>I>I>
Maintenance,CarCare
185

Washing
Thebestmethodofprotectingyourcarfrom
thedamagingeffectsoftheenvironmentisfre-
quentwashingandtheapplicationofapreserv-
ative.Theundersideofyourvehicleshouldalso
bewashedthoroughly,atthelatestwhensaltis
nolongerspreadontheroads.
Thelongersalt,roaddustandindustrialdust,
deadinsects,birddroppingsorsubstancesfrom
trees(resin,pollen)areallowedtoremainonthe
bodywork,themoreseriousistheirharmfulef-
fect.
Newcarsshouldbewashedcarefullywithplenty
ofclearwatertoprotectthenewpaintwork.
Darkpaintfinishesshowupthesmallestofsur-
facedamage(e.g.,scratches)morereadilythan
lightercolors.
Darkcolorsarealsomoresusceptibleto
scratchingbecauseofthecompositionoftheir
pigmentsandrequireparticularlycarefulpaint
care.
[>
Donotwashyourcarinbrightsunlightor
whilethebodyworkisstillhot.
[>Whenwashingbyhand,useabundantwater,
asoftspongeorwashbrush,andPorsche
carshampoo.
[>Beginbysprayingthebodythoroughlywith
watertorinseawayloosedirt.
186Maintenance,CarCare
[>
Afterwashing,rinsethecarwithplentyof
waterandthendrywithachamoisleather.
Donotusethesamechamoisleatherfor
dryingasyouuseforcleaningthewindshield
andwindows.
/!\.Warning!
Moisturewhichgetsontothebrakesduring
acarwashcanreducebrakingefficiencyor
makethebrakespullunevenlywhichcould
increasethedangerofanaccident,causing
seriouspersonalinjuriesordeath.
[>Alwaysapplythebrakesafewtimesafter
washingthecartotestbrakingefficiencyand
drythebrakediscs.
Whendoingthis,takecarenottohamper
otherroadusersbehindyou(trafficconditions
permitting).

Automatic
carwashes
Optionaladd-onpartsorpartswhichproject
beyondthecontoursofthevehiclemaybe
damagedbydesignfeatures(e.g.brushes)of
automaticcarwashes.
Thefollowing
parts
areparticularlysuscep-
tibletodamage:
-Windshieldwipers(alwaysswitchthemoffto
preventthemwipingunintentionallyinintermit-
tentorsensoroperation)
-Externaltelephoneantennas(alwaysunscrew)
-RoofTransportSystem(alwaysremovecom-
pletely)
-Fixedrearspoilerorextendedrearspoiler
-Wheels(thewidertherimandthelowerthe
tireheight,thegreatertheriskofdamage)
-High-glosswheels(topreventthesefromget-
tingscratched,donotcleanwiththewheel-
cleaningbrushesofthecarwash).
[>
Pleaseconsulttheoperatorbeforeusingauto-
maticcarwashes.
[>Washanddrybyhandallpointsnotreached
byacarwash,suchasdoorandlidseamsor
doorsills.
Note
Automaticcarwashesspraywateratodd
anglesandhighpressures,whicharenotseen
innormaldriving.Therefore,watercansome-
timesfinditswayintothepassengerscompart-
mentduringorshortlyafterthecarwash.