ignition PORSCHE 911 GT3 2004 5.G Service Manual

Gearshifting

The positions ofthe gears areshown onthe gear-
shift lever.

j!\
Warning!
Risk ofan accident.

~ Always checkthemovement ofthe clutch ped-
al before driving andmake surethatitis not
obstructed byafloor matorany other object.
~ Secure thefloor mattoprevent itfrom sliding
into positions thatcould interfere withthesafe
operation ofyour vehicle.
Your Porsche dealercanoffer youfloor mats
of the correct sizeincluding asecuring possi-
bility.

To avoid damage tothe clutch andtransmis-
sion:

~ Always depress theclutch pedalfullywhen
changing gears.
Make surethatthegearshift leveriscomplete-
ly engaged.
~ Only shiftintoreverse whenthecar has come
to acomplete stop.
~
Permitted enginespeed

~ Change intoahigher gearbefore theneedle
reaches thered mark onthe tachometer, or
ease offthe accelerator.
If the redzone isreached duringacceleration, fuel
feed isinterrupted.

j!\
Caution!
To avoid severe engine damage.

~ Always observe theengine rpmbefore down-
shifting toalower gear,soyou donot exceed
the maximum enginerpm.

Reverse

~ Depress theclutch pedalforseveral seconds
before shifting intoreverse.
Only then move thegearshift levertothe left,
overcoming thespring tension, andthen tothe
front.
Both back-up lightscome onwhen thetransmis-
sion isput into reverse (withignition on).
Controls,Instruments
109

Exercise ExtremeCautionwhen
Working onyour Vehicle

/!\
Warning!
Ignoring thefollowing instructions may
cause serious personal injury.

~ The engine compartment ofany motor vehicle
is apotentially hazardous area.Ifyou arenot
fully familiar withproper repairprocedures, do
not attempt theadjustments describedonthe
following pages.
This caution appliestothe entire vehicle.
~ Only work onyour vehicle outdoors orinawell
ventilated area.
~ Ensure thatthere arenoopen flames inthe
area ofyour vehicle atany time when fuel
fumes mightbepresent. Beespecially cau-
tious ofsuch devices suchashot water heat-
ers which igniteaflame intermittently.
~ Before working onany part inthe engine com-
partment, turntheengine offand letitcool
down sufficiently. Hotengine compartment
components canburn skinoncontact.
~ Bealert andcautious aroundengineatall
times whiletheengine isrunning.
If work hastobe performed withtheengine
running, alwayssetthe parking brake,and
make suretheshift lever isinneutral position.

1
Maintenance, CarCare ~
Inparticular, bevery careful toensure that
items ofclothing (ties,shirt, sleeves etc.),
jewelry, longhair,hand orfingers cannotget
caught inthe engine-compartment blower,fan,
belts orother moving parts.
The radiator andradiator fansareinthe front
of the car.
The engine-compartment blowerismounted
on the engine compartment lid.
The fans canstart orcontinue runningasa
function oftemperature, evenwiththeengine
switched off.
Carry outwork inthese areasonlywiththeen-
gine off,theignition switched off,and exercise
extreme caution.
~ Your Porsche isequipped withanelectronic ig-
nition system. Whentheignition ison, high
voltage ispresent inall wires connected with
the ignition system; therefore, exerciseex-
treme caution whenworking onany part ofthe
engine whiletheignition ison orthe engine is
running.
~ Always support yourcarwith safety stands ifit
is necessary towork under thecar.
~ When working underthecarwithout safety
stands butwith thewheels onthe ground,
make surethecarison level ground, the
wheels areblocked, andthat theengine
cannot bestarted.
Remove theignition key. ~
Donot smoke orallow anopen flame around
the battery orfuel.
Keep afire extinguisher inclose reach.
~ Incomplete orimproper servicingmaycause
problems inthe operation ofthe car. Ifin doubt
about anyservicing, haveitdone byyour
authorized Porschedealer.
Improper maintenance duringthewarranty
period mayaffect yourPorsche warranty cov-
erage.
~ Supplies offluids, e.g.engine oil,brake fluidor
coolant, arehazardous toyour health.
Keep these fluidsoutofchildren's reachand
dispose ofthem inaccordance withtheappro-
priate regulations.
~ Some countries requireadditional toolsand
special sparepartstobe carried.
Please makeenquiries beforedriving abroad.

Power measurements

Power measurements ondynamometers arenot
approved byPorsche.

Engine-compartment blower,
radiator fan

The radiator andradiator fansareinthe front of
the car.
The engine-compartment blowerismounted on
the engine compartment lid.

A
Warning!
Risk ofinjury.
After theengine isswitched off,theengine-
compartment andcoolant temperatures are
monitored forapprox. 20minutes.
During thisperiod, anddepending ontem-
perature, theengine-compartment blower
and radiator fansmaycontinue torun or
start torun.

t>
Carry outwork inthese areasonlywiththeen-
gine off,the ignition switched off,and exercise
extreme caution.

1
Maintenance, CarCare
Engine
Oil

Engine oilconsumption

It is normal foryour engine toconsume oil.
The rate ofoil consumption dependsonthe quality
and viscosity ofoil, the speed atwhich theengine
is operated, theclimate, roadconditions aswell
as the amount ofdilution andoxidation ofthe
lubricant.
If the vehicle isused forrepeated shorttrips, and
consumes anormal amount ofoil, the engine oil
measurement maynotshow anydrop inthe oil
level atall, even after600miles (1000 km)or
more. Thisisbecause theoilisgradually becom-
ing diluted withfuelormoisture, makingitappear
that theoillevel hasnotchanged.
The diluting ingredients evaporateoutwhen the
vehicle isdriven athigh speeds, ason anexpress-
way, making itthen appear thatoilisexcessively
consumed afterdriving athigh speeds.
If the conditions youdrive yourvehicle inare
dusty, humid, orhot, thefrequency ofthe oil
change intervals shouldbegreater. If
the vehicle isdriven atahigh rateofspeed,
climatic conditions arewarm, andtheload ishigh,
the oilshould bechecked morefrequently, as
driving conditions willdetermine therate ofoil
consumption.
- The engine inyour vehicle depends onoilto
lubricate andcool allofits moving parts.
Therefore, theengine oilshould bechecked
regularly andkept atthe required level.
- Make ita habit tohave theengine oillevel
checked withevery fuelfilling.
- The oilpressure warninglightisnot anoillevel
indicator.
The oilpressure warninglightindicates serious
engine damage maybeoccuring whenlit,ifen-
gine rpmisabove idlespeed.

1.
Important:
Stoptheengine andswitch offthe
FuelRecommendations

ignition.

Refuelling
Fuel tank capacity islisted under "Capacities".
Porsche doesnotrecommend theuse offuel ad-
ditives.

I>
Please observe thechapter "CAPACITIES" on
Page 185.
Maintenance, CarCare 2.
Slowly unscrew thetank cap.
Hang thetank caponthe plastic strapofthe
filler flap.
3. Insert fuel-hose nozzlefullyintothefiller neck
with thehandle ofthe fuel-hose nozzlefacing
down.
4. Donot add further fuelonce thecorrectly op-
erated automatic fuel-hosenozzlehas
switched off.
Fuel could sprayorcould runover inwarm
temperatures.
5. Replace thetank capimmediately after
refuelling andturn ituntil youhear itand feel it
engage.

If you lose thetank cap,youmust replace it
only with anoriginal parttoreduce the
possibility ofafire inthe event ofacollision.
Your
Porsche isequipped withcatalytic convert-
ers and must use
UNLEADED FUELONLY.

Your engine isdesigned toprovide optimum per-
formance andfuel economy usingunleaded premi-
um fuel with anoctane ratingof
98 RON
(93 CLC orAKI).
Porsche therefore recom-
mends theuse ofthese fuelsinyour vehicle.
Porsche alsorecognizes thatthese fuelsmaynot
always beavailable. Beassured thatyour vehicle
will operate properly onunleaded premiumfuels
with octane numbers ofatleast
95RON
(90 CLC orAKI),
sincetheengine's "Electronic
Oktane
™
knock control" willadapt theignition tim-
ing, ifnecessary.

The useofUNLEADED FUELONLY is
critically important tothe lifeofthe catalytic
converters. Depositsfromleaded fuelswill
ruin theconverters andmake itineffective as
an emission controldevice.

Cars withcatalytic converters haveasmaller fuel
tank opening, andgas station pumps havesmaller
nozzles. Thiswillprevent accidental pumpingof
leaded fuelintocars withcatalytic converters.

Emission ControlSystem

In the interest ofclean air
Pollution ofour environment hasbecome aprob-
lem that isof increasing concerntoall ofus. We
urge youtojoin us
in
our efforts forcleaner airin
controlling thepollutants emittedfromtheauto-
mobile.
Porsche hasdeveloped anemission controlsys-
tem that controls orreduces thosepartsofthe
emission thatcanbeharmful toour environment.
Your Porsche isequipped withsuch asystem.
Porsche warrants theEmission ControlSystem in
your newcarunder theterms andconditions set
forth inthe Warranty Booklet.
You, asthe owner ofthe vehicle, havethe
responsibility toprovide regularmaintenance ser-
vice forthe vehicle andtokeep arecord ofall
maintenance workperformed. Tofacilitate record
keeping, havetheservice performed byautho-
rized Porsche dealers.TheyhavePorsche trained
technicians andspecial toolstoprovide fastand
efficient service.
Maintenance, CarCare
To
assure efficient operation ofthe Emission
Control System:

~ Have yourvehicle maintained properlyandin
accordance withtherecommendations de-
scribed inyour Maintenance Booklet.
Lack ofproper maintenance, aswell asim-
proper useofthe vehicle, willimpair thefunc-
tion ofthe emission controlsystem andcould
lead todamage.
~ Donot alter orremove anycomponent ofthe
emission controlsystem.
~ Donot alter orremove anydevice, suchas
heat shields, switches, ignitionwires,valves,
etc., which aredesigned toprotect yourvehi-
cle's emission controlsystem.
In addition toserious enginedamage, thiscan
result inafire
if
excess rawfuel reaches the
exhaust system.
~ Donot continue tooperate yourvehicle ifyou
detect engine misfireorother unusual operat-
ing conditions. Parking

A
Warning!
Danger offire.

~ Donot park oroperate thevehicle inareas
where thehotexhaust systemmaycome in
contact withdrygrass, brush,fuelspill oroth-
er flammable material.

~ If
your carcatches onfire forany reason, call
the fire department.
Do not endanger yourlifebyattempting toput
out the fire.
Undercoating

A
Warning!
Danger offire and serious personal injuries.

~ Donot apply additional undercoating orrust-
proofing onornear theexhaust manifold,
exhaust pipes,catalytic converters orheat
shields. Duringdriving thesubstance usedfor
undercoating couldoverheat andignite.

HowEmission ControlWorks

When anautomobile engineisrunning, ituses en-
ergy generated throughthecombustion ofamix-
ture ofair and fuel. Depending onwhether acar is
driven fastorslowly orwhether theengine iscold
or hot, some ofthe fuel (hydrocarbons) maynot
be burned completely, butmay bedischarged into
the engine crankcase orexhaust system.Additon-
al hydrocarbons mayenter theatmosphere
through evaporation offuel from thefuel tank.
These hydrocarbons
(He),
when released intothe
air, contribute toundesirable pollution.
In addition, carbonmonoxide (CO)andoxides of
nitrogen (NOx)contribute toengine emissions.
They, too,areformed duringthecombustion pro-
cess anddischarged intotheexhaust system.
To reduce thesepollutants, yourPorsche is
equipped withaprecisely calibrated fuelinjection
system toassure afinely balanced air/fuelmixture
under alloperating conditions.
Oxygen
sensor

The oxygen sensor, installed inthe exhaust pipe
continuously sensestheoxygen content ofthe
exhaust andsignals theinformation toan electron-
ic control unit.Thecontrol unitcorrects theair/
fuel ratio, sothe engine always receives anaccu-
rately metered air/fuelmixture.

Crankcase ventilation

Through crankcase ventilation, undesirable emis-
sions fromtheengine crankcase arenotpermit-
ted toreach theoutside atmosphere. Theseemis-
sions arerecirculated fromthecrankcase tothe
air intake system. Fromheretheemissions mix
with theintake airand arelater burned inthe en-
gine.

Catalytic converters

The catalytic converters areefficient "clean-up"
devices builtintotheexhaust systemofthe vehi-
cle. The catalytic converters burntheundesirable
pollutants inthe exhaust gasbefore itis released
into theatmosphere.

The exclusive useofunleaded fueliscritical-
ly important forthe lifeofthe catalytic con-
verters. Therefore, onlyunleaded fuelmust
be used. The
catalytic converters willbedamaged by:

- push ortow starting thevehicle
- misfiring ofthe engine
- turning offthe ignition whilethevehicle ismov-
ing or
- driving untilthefuel tank iscompletely empty
- byother unusual operating conditions.

t>
Donot continue tooperate yourvehicle under
these conditions, sincerawfuelmight reach
the catalytic converters. Thiscould result in
overheating ofthe converters. Federallawpro-
hibits useofleaded fuelinthis car.
Maintenance, CarCare
125

A-
Passenger's side

B -
Driver's side

Wiper Blades

I>
When wiper performance deteriorates,replace
the wipers,

I>
Please observe thechapter "CARCARE IN-
STRUCTIONS" onPage 130.
A

Caution!
Risk ofdamage
if
the wiper armaCcidentally
falls back ontothe window.

I>
Always holdthewiper armsecurely whenre-
placing thewiper blade.

Risk ofdamage ifwiper blades thatarefro-
zen inplace areloosened improperly.

I>
Thaw thewiper blades beforeloosening them.
1.

Pull outignition key.
Fold wiper armaway fromthewindow.
2. Press together theplastic springofthe wiper
blade (rightarrow).
Pull wiper bladeoutofwiper arm.
3. Insert newwiper bladeandensure itengages.
Ensure thatthenew wiper bladegoesintothe
same position (direction ofspoiler) inthe wiper
arm andengages.
For wiper bladeAon the passenger's side,the
arch must facedown.
4. Carefully foldwiper armback ontothe win-
dow.
Maintenance, CarCare
129

Exercise ExtremeCautionwhen
Working onyour Vehicle

A
Warning!
Ignoring thefollowing instructions may
cause serious personal injury.

I>
The engine compartment ofany motor vehicle
is apotentially hazardous area.Ifyou arenot
fully familiar withproper repairprocedures, do
not attempt theadjustments describedonthe
following pages.
This caution appliestothe entire vehicle.

I>
Only work onyour vehicle outdoors orinawell
ventilated area.

I>
Ensure thatthere arenoopen flames inthe
area ofyour vehicle atany time when fuel
fumes mightbepresent. Beespecially cau-
tious ofsuch devices suchashot water heat-
ers which igniteaflame intermittently.

I>
Before working onany part inthe engine com-
partment, turntheengine offand letitcool
down sufficiently. Hotengine compartment
components canburn skinoncontact.

I>
Bealert andcautious aroundengineatall
times whiletheengine isrunning.
If work hastobe performed withtheengine
running, alwayssetthe parking brake,and
make suretheshift lever isin neutral position.

140
PracticalTips,Emergency Service
I>

Inparticular, bevery careful toensure that
items ofclothing (ties,shirt, sleeves etc.),jew-
elry, long hair,hand orfingers cannotget
caught inthe engine-compartment blower,fan,
belts orother moving parts.
The radiator andradiator fansareinthe front
of the car.
The fans canstart orcontinue runningasa
function oftemperature, evenwiththeengine
switched off.
Carry outwork inthese areasonlywith theen-
gine off,theignition switched off,and exercise
extreme caution.

I>
Your Porsche isequipped withanelectronic ig-
nition system. Whentheignition ison, high volt-
age ispresent inall wires connected withthe
ignition system; therefore, exerciseextreme
caution whenworking onany part ofthe engine
while theignition ison orthe engine isrunning.

I>
Always support yourcarwith safety stands ifit
is necessary towork under thecar.

I>
When working underthecarwithout safety
stands butwith thewheels onthe ground,
make surethecar ison level ground, the
wheels areblocked, andthat theengine
cannot bestarted.
Remove theignition key.
I>

Donot smoke orallow anopen flame around
the battery orfuel.
Keep afire extinguisher inclose reach.

I>
Incomplete orimproper servicingmaycause
problems inthe operation ofthe car. Ifin doubt
about anyservicing, haveitdone byyour au-
thorized Porschedealer.
Improper maintenance duringthewarranty pe-
riod may affect yourPorsche warranty cover·
age.

I>
Supplies offluids, e.g.engine oil,brake fluidor
coolant, arehazardous toyour health.
Keep these fluidsoutofchildren's reachand
dispose ofthem inaccordance withtheappro-
priate regulations.

I>
Some countries requireadditional toolsand
special sparepartstobe carried.
Please makeenquiries beforedriving abroad.

WheelBolts

/!\
Warning!
Risk ofwheel boltbreakage andwheel sepa-
ration, resulting insevere personal injuryor
death.

D>
Follow allinstructions concerningwheelbolts.

D>
Always cleanthewheel boltsbefore fitting.

D>
Apply athin coat of
Optimoly TA
(aluminium
pastel onthe thread andbetween thebolt head
and movable spherical capring
(arrows).
The bearing surfaceofthe spherical cap
facing thewheel mustnotbegreased.

Practical Tips,Emergency Service
D>

Replace damaged wheelbolts.
Only usetheOriginal Porsche wheelbolts
specially designed forthis vehicle type.

Tightening torque

Tightening torqueofwheel bolts:

130 Nmj96 ftlb.

Wheel Securing Bolts

The wrench socketforthe wheel securing boltsis
in the tool pocket.
To loosen ortighten thewheel boltwith anti-theft
protection, awrench socketwiththeappropriate
coding mustbeused between thewheel boltand
the wheel-bolt spanner.

D>
When positioning thewrench socket, ensure
that itengages fullyinthe teeth ofthe wheel
bolt.
If the wheels havetobe removed atthe workshop,
please donot forget tohand overthewrench
socket forthe wheel securing boltsalong withthe
car key.
Changing
awheel

A
Warning!
Risk ofinjury. Thecarmay slipoffthe jack.

D>
Make surethatnoone isinthe vehicle when
jacking upand changing awheel.

D>
Always placethecar onstable supports ifwork
has tobe carried outunder thecar.

Risk ofdamage tothe brake discsofthe
Porsche Ceramic Composite Brake(PCCB).

D>
Always screwinboth assembly aidswhen
changing awheel.
1. Fully apply thehand brake, engage 1st gear
and withdraw theignition key.
2. Secure thecaragainst rollingaway,e.g.by
means ofwedges underthewheels onthe op-
posite side.
This isparticularly importantonslopes.

Electrical System

In order toavoid damage andfaults inelectrical or
electronic systems,electrical accessories should
be installed atyour authorized Porschedealer.
~ Only useaccessories authorizedbyPorsche.

A
Warning!
Risk ofshort circuit andfire.
Replacing fusesorrelays withtheengine
running orthe ignition oncould cause elec-
trical shock.

~ Disconnected thebattery duringallwork on
the electrical system.
Please observe thechapter "BATTERY" on
Page 155.

Relays

Defective
relays
shouldbechanged onlybyan
authorized workshop.
Practical Tips,Emergency Service
Alann
system,
centrallocking

The status ofthe central locking andalarm system
is not changed bydisconnecting thebattery.
When thebattery isdisconnected, thealarm sys-
tem ceases tofunction.

Overload protection

If the central locking systemisoperated more
than tentimes within aminute, furtheroperation is
blocked for30seconds.
load
switch-off aftertwohours
or five days

If the ignition keyisremoved, loadswhich are
switched onorinstandby (e.g.power windows,
luggage compartment lighting,interiorlight,radio)
are automatically switchedoffafter approximately

2 hours.

If the vehicle isnot started orunlocked withthere-
mote control within
fivedays,
theremote control
standby function isswitched off(toprevent dis-
charging ofthe vehicle battery).
1. Inthis case, unlock thedriver's doorwiththe
key atthe door lock.
Leave thedoor closed inorder toprevent the
alarm system frombeing triggered.
2. Press button 1on the remote control.
The remote controlisnow activated again.