PORSCHE 911 TURBO 2004 4.G Information Manual

The new 911 TurboTh e new 911 Tu rb o
W VK 220 820 06 E/W W

· 6 ·
The new 911 Turbo 6
Drive 22
Chassis 50
Safety 64
Comfort 76
Environment 92
Personalisation 98
Factory collection 911 120
Service 122
Summary 124
Technical data 126
Index 128
The new 911 Turbo |Contents
Variable Turbine Geometry (VTG).
Electronic all-wheel drive.
Just when you thought it couldn’t get
any better…
The new 911 Turbo

· 13 ·The new 911 Turbo |
The new 911 TurboThe new 911 Turbo |The new 911 Turbo
In 1905, the Swiss engineer,
Dr. Alfred Büchi, filed the first ever
patent for a turbocharged piston
engine. The fundamental principle,
now a century old, remains
unchanged to this day: to use the
energy latent within the exhaust
flow from the engine to increase
overall performance.
The first turbocharged engine
was built in 1910 by the firm of
Murray-Willat. The concept was
embraced by the aviation industry,
which required an effective means
of compensating for the loss of
power caused by reduced oxygen
levels during high-altitude flight.Porsche was among the first
to recognise other benefits of
the technology, including higher
performance potential from
relatively small displacement
engines. This would lead to
the development of powerful
new engines with very modest
dimensions and weight.
The basic principle of a
turbocharged engine is to use
the exhaust gas flow to drive a
radial turbine which in turn drives
a compressor in the air intake
tract. The rotation of the
compressor generates a higher
intake pressure, thereby delivering
a greater amount of oxygen to
the engine. With more oxygen
available, more fuel can be burnt,
and higher performance can be
achieved. The density of the
air can be further increased by
cooling it prior to combustion.
The first ‘intercooler’ device on
a production Porsche appeared
in 1977 on the 911 Turbo 3.3.
· 12 · · 11 ·
From a stroke of genius.
From strength to strength.
The new 911 Turbo.

· 14 ·· 15 ·The new 911 Turbo |
The new 911 Turbo
The second 911 Turbo, launched
in 1977, developed 300 bhp from
a 3.3-litre intercooled engine.
Brake performance was similarly
enhanced, combining four-piston
aluminium fixed calipers with
cross-drilled discs.
In 1993, Porsche launched the
final 911Turbo to feature dedicated
rear-wheel drive. Based on the
Type 964 platform, it used a
3.6-litre engine to achieve a major
boost in output to 360 bhp.
Its Type 993 successor, launched
in 1995, set a range of new
benchmarks in supercar perform-
ance. All-wheel drive provided
greater active safety as well as
better driving dynamics. The
system also had a rear-axle bias
that retained the familiar Porsche
handling characteristics. Twin
exhaust turbochargers offered
better response and a more
harmonious build-up of power. The
last 911 Turbo to have an air-
cooled engine, it offered maximum
output of 408 bhp from a
3.6-litre displacement.
The first water-cooled 911 Turbo,
the Type 996, made its debut
in the year 2000. Also equipped
with all-wheel drive, it used
VarioCam Plus to achieve a major
improvement in all-round fuel
economy. The engine capacity
remained at 3.6 litres, while
output rose to 420 bhp fo r a
maximum speed of 305 km / h
(190 mph). The Type 996 model
was the first 911 Turbo with the
option of Tiptronic S transmission.
The subsequent launch of the
Turbo S version saw a further
rise in output to 450 bhp.
Now, the evolution of this
remarkable car has reached a
new pinnacle of achievement.
Over the following pages, we
will explore every aspect of the
new 911 Turbo.The first Porsche racing car to
feature turbocharged power made
its debut in the early 1970s. The
12-cylinder engine in the legendary
917 used a twin turbo system to
achieve a colossal 1,000 bhp
.
In 1972, the 917/10 with 5-litre
turbo engine claimed the North
American CanAm
championship.
In the following season, the
917/30, developing 1,100 bhp
from a 5.4-litre unit, became the
most powerful racing Porsche of
all time.
This invaluable race experience
inevitably found its way into our
production
road car development.
Just one year later, in 1974,
the 911 Turbo was born. Preceded
as it was by the 1973 oil crisis, it
was considered a
bold undertakingby Porsche. As history would show,
it was the first of many surprises in
the evolution of this legendary car.
The original 911 Turbo featured
widened wheel arches as well as
specially developed front and rear
spoilers. These major aerodynamic
refinements were essential
requirements given the increased
engine performance. Developing260 bhp, the first 911 Turbo could
reach 100 km / h (62 mph) in as
little as 5.5 seconds. Maximum
torque output of 343 Nm was
unprecedented in a 3-litre engine.
This exceptional performance
necessitated a new gearbox
design featuring specially
reinforced gears. Thus began a
new type of Porsche that would
soon acquire mythical status.
911 Turbo 3.0 (1974), 911 Turbo (2006)

The primary objective for every
911 Turbo is to challenge the
limits of technical feasibility. Not
only in terms of performance
and dynamics, but also when it
comes to ride comfort. On this
latest evolution, we’ve completely
redesigned a number of systems
and components. The result builds
on the achievements of the
previous 911 Turbo – a car widely
acknowledged as the ultimate in
sportscar design.
As you would expect, the new 911 Turbo meets the highest
expectations in terms of engine
performance. The classic flat-six
unit develops 353 kW (480 bhp)
at 6,000 rpm from a 3.6-litre
displacement. Maximum torque
of 620 Nm is available between
1,950 and 5,000 rpm. To achieve
that capability, we’ve combined
VarioCam Plus with twin turbo-
charger units featuring Variable
Turbine Geometry (VTG) –
a totally new technology on apetrol-
engined car. With a standard
manual
gearbox, the new 911 Turbo
requires just 3.9 seconds to reach
100 km / h (62 mph). Equipped
with the latest optional Tiptronic S
transmission, the car is 0.2 seconds
quicker on the standard sprint.
Benchmark times to 200 km / h
(124 mph) are 12.8 and
12 . 2
seconds, respectively. Maximum
speed with either transmission is
310 km / h (193 mph).
One of the most important engine
technologies, appearing for the
first time on a Porsche, is Variable
Turbine Geometry (see page 32).
The main components on this
system are the adjustable guide
vanes which channel the exhaust
flow onto the turbines, enabling
higher turbine speeds at lower
engine rpm. The most difficult
challenge when developing this
technology was the high exhaust-
gas temperature of around
1,000 ºC, which is unique to a
petrol engine. This enormous
thermal load is considerably
greater than the 700 ºC typically
encountered on a diesel-powered
car. It was only possible to
bridge this gap using materials
developed for aerospace
applications. The primary benefitsof Variable Turbine Geometry
include faster response, higher
torque output from lower engine
speeds, and greater top-end
power. Maximum torque is also
available over a wider engine
speed range. By eliminating the
problem of ‘turbo lag’, the
traditional weakness of the
turbocharged engine is finally
a thing of the past.
· 16 ·· 17 ·The new 911 Turbo |
The new 911 Turbo
Pioneering technology, dependable results.
Engineering the new 911 Turbo.

To apply these benefits efficiently
to the road, we required another
innovation in sportscar design: all-
wheel drive with Porsche Traction
Management (PTM). Using an
electronically controlled multi-plate
clutch, this intelligent technology
provides variable drive to each
axle. The front/rear split is con-
tin
uously adjusted based on current
road conditions and driver inputs.
Although biased towards the rear,
the front receives more power
whenever the situation requires.
Porsche Traction Management
is specifically designed to
optimise driving dynamics. The
additional traction provided by
both the all-wheel drive system
and PTM represents a major
improvement in active safety,
especially in the wet or on snow.
Another benchmark technology
on the new 911 Turbo is the
standard braking system. The
front and rear discs have a
generous diameter of 350 mm.On the optional Porsche Ceramic
Composite Brake (PCCB), the
front diameter is increased to
380 mm.
Other standard features on the
new 911 Turbo include a new
evolution of Porsche Stability
Management (PSM) as well as
Porsche Active Suspension
Management (PASM) featuring
electronic damper control.
A
limited-slip differential is available
for the rear axle as an option.
For even greater performance, the
car can be equipped with the
optional Sport Chrono Package
Turbo. Key features include
an ‘overboost’ function which
provides as much as 60 Nm
of additional torque under
acceleration. When the throttle
is fully open, the boost pressure
is increased temporarily by
approximately 0.2 bar. The
electronic throttle map is
also adjusted to give a more
dynamic response to pedal
inputs.
Other modifications when ‘Sport’
mode is selected include a major
rise in the trigger threshold used
by Porsche Stability Management
(PSM). The all-wheel drive system
featuring PTM provides a similar
increase in driver involvement
by sending a greater proportion
of drive torque directly to the
rear wheels. PASM provides a
stiffer suspension setup enabling
faster turn-in and better road
contact.
Another major development
on the new 911 Turbo is the
car’s lightweight design and
construction. The doors and front
lid are made from aluminium
which offers a range of benefits
in terms of both performance
and economy. Every gram of
weight on every component
is there for a specific reason.
As a result, the standard model (with six-speed manual gearbox)
weighs just 1,585 kg. Even more
impressive are the power-to-
weight ratio of 302.8 bhp per
tonne and surprisingly low fuel
consumption.This powerful potential is, of
course, matched by exemplary
ride quality on every type of
road. This rare combination of
performance and comfort is one of the distinguishing features
of the 911 Turbo.
· 18 ·· 19 ·The new 911 Turbo |
The new 911 Turbo

· 22 ·
provide effective protection
against stone chips.
Elegantly matched to the exterior
of the car is the all-new wheel
design. The 19-inch forged alloys
have a standard two-tone finish
as well as wide, low-profile tyres.
The standard tyre dimensions
are 235/35 ZR 19 (front) and
305/30 ZR 19 (rear).
The interior of the car is equally
compelling and entirely designed
around the driver. The high-quality
surfaces include a full leather
finish on the standard electric
seats as well as the dashboard,
doors and rear side panels. Two
sports seat options are also
available, one featuring adaptive
adjustment. The standard
equipment package includes a
new gear-knob design – created
exclusively for the 911 Turbo –
· 21 ·The new 911 Turbo |
The new 911 Turbo
The extreme capability of the new
911 Turbo is elegantly enclosed in
a highly distinctive exterior. While
signalling the unique athleticism of
the car, it remains unmistakably 911.
The aerodynamics are exceptionally
well balanced, with positive
downforce at the rear. The drag
coefficient is remarkably low
at just 0.31. With its streamlined
shape and lightweight build,
the new 911 Turbo offers excellent
fuel economy as well as super-
lative performance.The standard Bi-Xenon headlights
with integral cleaning system
are compact, stylish and elegantly
incorporated within the new
front-end design. The front apron
moulding is an entirely new
development, featuring high-
performance LED indicators in
the outer air intake ducts. The
compact front foglights are
neatly positioned on the outer
edges of the front apron.
The side air intakes, to the rear
of the doors, provide optimum air
delivery to the twin intercoolerunits. Equally efficient are the
cooling air ducts to the front and
rear brake assemblies. This
enhanced cooling action is an
important factor in the excellent
performance of the standard
braking system.
The body of the car is much wider
across the rear than the front. A
generous wheel track is combined
with wider tyres to achieve
enormous lateral grip. The engine
lid is another totally new design
and features an integral bi-plane
rear spoiler. The
upper wing
element is automatically
raised at
approximately 120 km / h (75 mph)
and lowered at around 60 km / h
(37 mph).
The rear apron moulding has also
been redesigned to blend with
the rest of the car. The side air
outlets and fully enclosed twin
tailpipes are a further indication of
the power within. Black plastic
sills along the sides of the body
· 20 ·
Some say power is all about muscle.
For us, it starts with the mind.
Drive
Poised for action, yet always relaxed.
Designing the new 911 Turbo.
Rear wing retracted
Rear wing deployed
and a three-spoke sports steering
wheel featuring 40 mm of height
and reach adjustment.
The overall design of the
new 911 Turbo marks another
new phase in the ongoing
evolution of this remarkable car.
Wholly integral to the fundamental
vehicle concept, every detail
is a direct expression of power,
composure and comfort.

· 26 ·The new 911 Turbo |
Drive
· 25 · · 24 · · 23 ·
7. Exhaust-gas turbocharger
with Variable Turbine
Geometry (VTG)
8. Intercoolers
9. Pressure pipe
10. Throttle valve
(electronically actuated)
11. Exhaust system
12. Oil filter
13. Engine oil reservoir
(dry-sump lubrication)
1. Radiator module (left)
2. Radiator module (centre)
3. Radiator module (right)
4. Coolant pipe
5. Coolant expansion tank
6. Air filter
14. Generator
15. PASM damper
16. Tandem brake booster
17. 6-speed manual gearbox
18. Front differential
19. Fuel tank1. Oil scavenge pump
2. Oil-pressure pump (obscured)
3. Engine oil reservoir
(dry-sump lubrication)
4. Camshaft adjuster (VarioCam Plus)
5. Intake camshaft
6. Tappets (with hydraulic valve
clearance adjustment)
7. Valve springs
8. Intake valves
9. Nikasil-coated cylinder bore
10. Forged aluminium piston
11. Forged connecting rod
12. Crankshaft
13. Camshaft drive chain
14. Camshaft drive chain tensioner
with guide rail
15. Single-spark ignition coil
16. Spark plug
17. Exhaust-gas turbocharger with
Variable Turbine Geometry (VTG)
18. Exhaust system
19. Catalytic converter
20. Pressure pipe
21. Throttle valve (electronically actuated)
22. Plenum chamber
23. Ancillary drive belt
24. Fluid reservoir for
power-steering system
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