engine PORSCHE 911 GT3 2004 5.G Repair Manual

Power Steering
Power steering isassisted byhydraulic auxiliary
forces.
The hydraulic fluidreservoir islocated inthe en-
gine compartment.

Note

The flow noise heard atfull steering lockisdesign-
related anddoes notindicate adefect inthe steer-
ing syste m.
A

Warning!
Risk ofaccident.
When theengine isstopped
(e.g.
when on
tow) orthe hydraulic systemfails,there isno
assistance forsteering.
Therefore, substantially moreforce willhave
to be exerted inorder tosteer.

I>
Exercise greatcarewhen being towed.

t>
Have thefault remedied atyour nearest autho·
rized Porsche dealer.
Checking
hydraulicfluid

I>
Please observe thechapter "EXERCISE EX-
TREME CAUTION WHENWORKING ONYOUR
VEHICLE" onPage 112.

I>
Only usehydraulic fluidauthorized byPorsche.
Specification:
Please observe thechapter "CAPACITIES" on
Page 185.
Check thefluid level withtheengine stopped and

cold
(approximately 68°F
j20°C).

1. Start theengine andletitidle forapprox.
20 seconds.
Switch offthe engine.
2. Open theengine compartment lid.
3. Open thereservoir cap.
4. Wipe measuring rod.
Close lidand reopen. Thefluid level should lie
in the area ofthe "Cold" marking.
Add hydraulic fluidifnecessary.
5. Close capcarefully.
Close engine compartment lid.
Noticeable lossoffluid indicates leakageinthe
system.
The cause should beremedied immediately atan
authorized Porschedealer.
Maintenance, CarCare
J.27

AirFilter

A dirty airfilter notonly reduces engineperfor-
mance, butcan lead topremature enginewear.
Regular filterreplacement ispart ofthe routine
maintenance service.

[>
Industy conditions, checkthefilter element
more frequently andreplace ifnecessary.

Particle Filter

The fresh airpassing through theparticle filterinto
the passenger compartment isvirtually freeof
dust andpollen.

[>
Ifthe outside airispolluted byexhaust fumes,
press thecirculating-air button.
A dirty filter canbethe cause ofreduced airflow:

[>
Have filterreplaced byyour authorized
Porsche dealer.
Regular filterreplacement ispart ofthe routine
maintenance service.
Maintenance, CarCare
Manual
Transmission Oil

The transmission oilhas tobe checked and
changed atthe intervals listedinyour Maintenance
Schedule.

[>
Please observe thechapter "CAPACITIES" on
Page 185.
We recommend thatyouhave thetransmission oil
changed atyour Porsche dealer,whohasthere-
quired lubricants andthenecessary fillingequip-
ment.
If you suspect anoilleak inthe transmission, have
your authorized Porschedealercheckitout imme-
diately.

Engine compartment

The engine compartment andthesurface ofthe
engine aretreated withacorrosion-inhibitor atthe
factory.
If degreasing solventsareused toclean theen-
gine compartment orthe engine iswashed down,
the process almostinvariably removesthecorro-
sion-inhibiting coating.Itis then absolutely neces-
sary tohave adurable preservative appliedtoall
surfaces, bodyseams, jointsandassemblies in
the engine compartment. Thisalsoapplies when
corrosion-inhibitor partsarereplaced.

/!\
Caution!

Risk ofdamage tothe generator.

c>
Donot point thecleaning jetdirectly atthe al-
ternator, orcover thealternator.
Effective corrosion-proofing isparticularly impor-
tant during thecold weather season.Ifyour caris
driven frequently inareas where salthasbeen
spread onthe roads, thewhole engine compart-
ment should becleaned thoroughly afterthewin-
ter toprevent saltfrom causing anylasting dam-
age. Afull under-body washshould alsobeper-
formed atthe same time.
Windows

The road dustwhich settles onthe windshield and
windows containsparticles oftire rubber andoil
residue. Theinterior trimandupholstery release
particles, particularly instrong sunlight, whichcol-
lect onthe insides ofthe windows. Thesedeposits
are augmented byimpurities inthe airwhich en-
ters thecarthrough thefresh airvents.

c>
Clean allwindows regularly, insideandoutside,
with Porsche windowcleaner.

c>
Ifyou useachamois leatherforthe windows,
do not use itfor paintwork asitwill otherwise
pick upacertain amount ofpreservative orpol-
ish and could smear tilewindows andthus im-
pair vision.

c>
Remove deadinsects withthePorsche insect
remover.

Wiper blades

Wiper blades thatareinperfekt condition arevital
for aclear view.

c>
Replace thewiper blades twiceperyear (be-
fore andafter thecold season) orwhenever
wiper performance deteriorates.
C>

Periodically cleanthewiper blades with
Porsche windowcleaner, especially afterthe
vehicle hasbeen washed inacar wash.
If they arevery dirty (e.g. withinsect remains),
they canbecleaned withasponge orcloth.

Undercoating

As itis not possible toexclude therisk ofdamage
to this protective coatinginday today driving, it
is advisable tohave theunderside ofthe car in-
spected atcertain intervals -preferably beforethe
start ofwinter andagain inspring -and theunder-
coating restored asnecessary.
Your authorized Porschedealerisfamiliar withthe
bodyseal treatment procedures andhasthenec-
essary equipment forapplying factoryapproved
materials. Werecommend thatyouentrust them
with such work andinspections.
Unlike conventional sprayoils,undercoating and
rust-proofing compoundsbasedonbitumen or
wax donot attack thesound-proofing materialsap-
plied atthe factory.
Maintenance, CarCare
133

A
Warning!
Danger offire and serious personal injuries.

t>
Donot apply additional undercoating orrust-
proofing onornear theexhaust manifold, ex-
haust pipes, catalytic converters orheat
shields. Duringdriving thesubstance usedfor
undercoating couldoverheat andignite.

t>
Before applying freshunderseal, carefullyre-
move deposits ordirt and grease. Onceithas
dried, thenew undercoating compoundforms
a tough protective coatingwhichprovides effi-
cient rust-proofing ofthe floor panels andcom-
ponents.

t>
Always applyafresh coating ofsuitable preser-
vative tounprotected areasaftercleaning the
underside ofthe body, thetransmission, the
engine orcarrying outrepairs tounder-body,
engine ortransmission components.
Effective rust-proofing isparticularly important
during thecold weather season.
If
your carisdriv-
en frequently inareas where salthas been spread
on the roads, thewhole engine compartment
should becleaned thoroughly afterthewinter to
prevent saltfrom causing anylasting damage. A
full under-body washshould alsobeperformed at
the same time.

134
Maintenance, CarCare
Door,
roof,lidand window seals

t>
Wash dirt(e.g. abrasion, dust,roadsalts) from
all seals regularly usingwarm soapy water. Do
not use anychemical cleaningagentsorsol-
vents.
When thereisafrost hazard, theouter doorseals
and thefront andrear lidseals canbeprotected
against freezing intoplace byasuitable careprod-
uct.

In order toprevent damage tothe anti-
friction coating, theinner doorseals must
not betreated withcare products.
Headlights,
lights,interior andexterior

plastic parts

t>
Use
only
clean water andalittle dishwashing
detergent toclean lightlenses, plastichead-
light lenses, plasticpartsandsurfaces.
Do not clean whendry.
Use asoft sponge orasoft, lint-free cloth.Gen-
tly wipe thesurface withoutapplying toomuch
pressure.
The Porsche insidewindow cleanerisalso suit-
able forcleaning plasticsurfaces. Followthe
cleaning instructions onthe container.
Never useother chemical cleanersor
solvents.

£>
Rinse cleaned surfaces withclear water.

Storing yourPorsche

If you intend tostore yourPorsche foraprolonged
period, pleaseconsult yourauthorized Porsche
dealer. Thestaff willbeglad toadvise youonthe
most suitable andnecessary methods.
r> Clean yourvehicle thoroughly insideandout-
side.
Clean theengine compartment.
The under carriage andchassis components
should befree ofdirt and saltdeposits.
r> Fillupthe fuel tank.
r> Change theoiland oilfilter, andrunthe engine
for several minutes.
r>

Increase thetire pressure to58 psi (4bar).
It is not recommended tolift the vehicle, dueto
the possibility ofcorrosion onshock absorber
piston shafts.
The vehicle shouldbemoved slightly, approxi-
mately everyfourweeks, toprevent flatspot
on the tires.

Climate control

The airconditioning systemshouldbeingood
working condition andfully charged.

WindshieldjHeadlight washer

r> Check andcorrect antifreeze/cleaning solu-
tion level asnecessary.

Electrical system

r> Remove thebattery fromthevehicle andstore
it in acool dryplace, notonacement floor.

When thebattery isdisconnected, the
alarm system isdeactivated.

r> Recharge thebattery every3months. Ifthe
battery remains inthe vehicle withthecables
connected, itis necessary tocheck, remove
and recharge thebattery every2-3weeks.

Do not fast charge thebattery.

r> Please observe thechapter "SATTERY" on
Page 155.
Vehicle
interior

The interior mustbedry, especially inthe area of
the floor carpets. Theuseofdrying agents (Silica-
Gel) isrecommended invehicles withleather inte-
rior and inareas withhighhumidity. Therecom-
mended amountis3fabric bagsof1.1 Ibs.
(500 grams) eachplaced onthe floor carpets.
Windows, doorsandlidsmust beclosed. Theair
flaps should beopened.
Maintenance, CarCare

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.

A-Front
jacking point
Lifting theVehicle withaLifting
Platform orGarage Lift
The carmust beraised
only
atthe illustrated jack-
ing points.

t>
Please observe thechapter "CHANGING A
WHEEL" onPage 150.
Practical Tips,Emergency Service
B
-Rear jacking
point

A
Caution!
Serious injuryand/or serious damage tothe
engine orthe vehicle mayoccur, ifyou lift
the vehicle improperly.

t>
Never liftthe vehicle atany other place than
the jacking points.

t>
Never liftthe vehicle bythe engine, transmis-
sion oraxles.

t>
Donot damage anysensitive components in
the vicinity ofthe jacking points.
Platform
lift

Before thecarisdriven ontoalifting platform, it
must beensured thatthere isenough spacebe-
tween thelifting platform andthevehicle.

Garage lift

A garage liftmust beused
only
atthe illustrated
jacking points.

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.

A-Diagnostic socket

Replacing fuses

In order toprevent damage tocables andconsum-
ers inthe electrical systemduetoshort circuits
and overloads, theindividual circuitsareprotect-
ed byfuses.
The fuse boxisat lower leftinthe driver's footwell
and isprotected withaplastic cover.
A
-Plastic gripper

B -
Spare fuses

1. Before replacing afuse, switch offallelectrical
consumers andremove theignition key.
2. Toopen, pullthecover offatthe finger hole

(arrow).

The
fuse plan
and
instructions foremer-
gency unlocking ofthe luggage compart-
ment lidand engine compartment lid
can
be found onthe inside ofthe cover. 3.
Tocheck orreplace afuse, remove itfrom the
spring clipusing theplastic gripper
A.

A blown fuseindicates anoverload inthe cir-
cuit and canbeidentified bythe melted metal
strip.
4. Replace onlywithfuses ofthe same rating.
Spare fusesBare inthe lowest section ofthe
fuse box.

Important note

~ Ifafuse blows repeatedly, pleaseimmediately
consult anauthorized Porschedealer,sothat
the short circuit canbelocated andcorrected.
~ Never tryto"repair" fuses:youmay cause se-
rious damage toother partsofthe electrical
system.

~~~

Practical Tips,Emergency Service

Emergency unlockingofthe luggage
compartment lidand engine
compartment lid

Ifthe battery isdischarged, thelids can beopened
only withtheaidofadonor battery.
Unlocking lids
1. Use thekey tounlock thevehicle atthe door
lock.
Leave thekey inthe door lock.
2. Remove plasticcoveroverthefuse box.
3. Pullout positive terminal Ainthe fuse box.
4. Use ajumper cabletoconnect thepositive
terminal ofthe donor battery withpositive
terminal Ainthe fuse box.
Practical Tips,Emergency Service
Note

If
the vehicle waslocked, thealarm hornwillsound
when thenegative cableisconnected.
5. Use thesecond jumpercabletoconnect the
negative terminalofthe donor battery with
latch striker
B.

6. Switch thealarm system offbylocking andun-
locking atthe door lock.
7. Unlock theengine compartment lidorluggage
compartment lidwith theswitch. 8.
Disconnect thenegative cablefirst,thenthe
positive cable.
9. Push positive terminal Ainto thefuse boxand
push onthe plastic fuseboxcover.

Note

The engine cannot bestarted withthismethod.
Please observe thechapter "EMERGENCY START-
ING WITH JUMPER CABLES" onPage 160.