light PORSCHE 911 TURBO 2004 4.G Information Manual

· 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.

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.

Lightweight design.
The six-cylinder boxer engine is
a highly compact unit offering
excellent cylinder charging and
torque characteristics as well
as optimum balance and minimal
vibration. With the cylinders
arranged horizontally on either
side of the crankshaft, the
layout is key to the car’s low
centre of gravity.
The alloy crankcase consists
of two main sections, each
containing one bank of cylinders.
The crankshaft runs in eight main
bearings and is driven by forged
connecting rods. For optimum
durability, we’ve used forged
aluminium pistons running in
Nikasil-coated aluminium liners
and featuring individual oil-spray
cooling. Key benefits include lower
frictional resistance and longer
service life.
The cylinder heads are made
from a lightweight alloy which
is extremely resistant to high
temperature. Each bank of
cylinders has two overhead
camshafts driving a set of four
valves – two inlet and two exhaust
– on each individual cylinder.
The valves are arranged in a ‘V’
configuration and feature a highly
efficient dual-spring design.
Engine performance is further
enhanced with the aid of bothVariable Turbine Geometry (VTG –
see page 32) and VarioCam Plus
(variable valve timing and lift
on inlet side – see page 38). The
benefits are not only greater
power and torque, but also better
fuel economy and lower emissions.
Dry-sump lubrication.
This classic dry-sump system
with separate oil reservoir
ensures consistent oil pressures
throughout the engine. In doing
so, it compensates for even the
most extreme and prolonged
gravitational loads.
After passing through the engine,
every drop of oil is returned
directly to the external reservoir.
The flow is driven by two pairs of
scavenge pumps in the cylinder
heads and a further two pumps in
the crankcase. Gas is removed
from the returning oil by means of
a defoaming device in the
reservoir. As a result, the oil
level in the reservoir remains
virtually constant at all times.
The oil is returned to the
lubrication points in the engine
by means of a dedicated
oil-feed pump. With a further
scavenge pump in each of the
twin turbocharger units, the
new 911 Turbo has a total of nineseparate pumps to drive the
lubrication system.
The oil level can be checked from
inside the car via the standard
on-board computer. This solution
is not only cleaner and more
convenient than a conventional
dipstick, it is also significantly
more accurate.
· 30 ·· 31 ·The new 911 Turbo |
Drive
Main rotating assembly and valve gear

The rear axle assembly is a race-
proven design featuring multi-link
LSA (Lightweight, Stable, Agile)
subframe-based suspension. Its
lightened construction provides
exceptional dynamic properties.
The axle kinematics improve
stability under acceleration by
reducing excessive compression.
The lightweight strut has an
aluminium damper instead of
conventional steel to help improve
handling and agility.
Combined, the suspension enables
smooth high-speed manoeuvres
in all road and track scenarios.
Pitch and roll are reduced to a
· 53 ·The new 911 Turbo |
Chassis
To transmit power with optimum
efficiency, the front and rear
suspension must be a s stable,
and as light, as possible.
Reducing weight, particularly on
the unsprung masses, brings
major benefits in terms of driving
dynamics.The new 911 Turbo is equipped
with an electronic damping
system as standard. For more
information on Porsche Active
Suspension Management (PASM),
see page 56.The independent front suspension
combines McPherson-type struts
with longitudinal and transverse
links. Each front wheel is preciselylocated, ensuring excellent
handling and directiona l stability.
Brake spoiler elements provide
efficient cooling for each of the
front brake units.
· 52 ·Front axle 911 TurboRear axle 911 Turbo
Suspension.
Precision, strength and lightweight design.
minimum, as are tyre noise and
vibration. Overall, the car offers
a level of stability that is equal to
the car’s performance potential.

The power-assisted steering is
not only sensitive and direct,
it also offers accurate feedback
from the road. Minimal driver
effort is required when parking,
while the turning circle is small
at just 10.9 metres – despite
the generous tyre width.
One of the key features of
the new steering system is thevariable-ratio gearing. Around the
straight-ahead position, the ratio
is less direct, enabling smoother
manoeuvres on the motorway. It
also reduces the risk of excessive
steering inputs which could
destabilise the car at high speed.
Turn the wheel harder and
the ratio becomes more direct,
enabling better manageability
through low-speed corners as well
as easier parking manoeuvres.
In all scenarios, the system
provides excellent feedback
while complementing the car’s
natural agility.
In short: all the precision of a
race-proven system, yet perfect
for everyday road use.
· 54 ·· 55 ·The new 911 Turbo |
Chassis
Wheels.
The final elements in the drivetrain
system are, of course, the
wheels and tyres. On the new
911 Turbo, we’ve used 19-inch
forged alloys as standard. The
front wheel dimensions are
8.5J x 19 with
235/35 ZR 19
tyres. Rear wheel size is 11J x 19
with 305/30 ZR 19 tyres. The
new wheel design features a
special two-tone look for even
greater visual impact. The sides
of each spoke have a titanium
paint finish, while the entire front
surface, including the flange, has
a polished finish.
Tyre Pressure Monitoring (TPM),
included as standard equipment,
provides early warning of
tyre pressure loss. The driver is
i
nformed via the on-board
computer display as well as a
separate indicator light.A range of optional 18 and 19-inch
winter wheels (all snow chain-
compatible) are available from
Porsche Tequipment. Vehicles
equipped with the optional
Porsche Ceramic Composite
Brake (PCCB) may only be fitted
with 19-inch winter wheels.
19-inch Turbo wheel
Steering.
Accuracy, comfort and excellent road contact.

This latest evolution of Porsche
Stability Management (PSM)
provides automatic assistance in
critical road scenarios. A powerful
driver aid, it uses a range of
sensors to monitor the direction,
speed, yaw velocity (speed of
rotation around the vertical axis)
and lateral acceleration of the car.
With this information, it can
then calculate the actual direction
of travel. If the car begins to
oversteer or understeer, PSM
applies selective braking onindividual wheels to bring it safely
back into line. Whenever PSM is
required to intervene, an indicator
light in the cockpit is illuminated.
Another scenario in which PSM is
invaluable is when applying the
throttle on wet or other low-grip
surfaces. Here, PSM uses the ABD
(automatic brake differential) and
ASR (anti-slip regulation) functions
in PTM to maintain traction and
stability.Standard equipment on the
911 Turbo, PSM assists with high-
precision inputs that enhance the
athleticism and agility of the car.
When ‘Sport’ mode is selected
on the optional Sport Chrono
Package Turbo (see page 60),
the PSM threshold is raised
higher still enabling greater driver
involvement – particularly
at speeds of up to 70 km / h
(44 mph).
The integral ABS ensures shorter
braking distances in critical road
scenarios. System inputs are
smooth and precise fo r greater
driver comfort. Active safety is
further enhanced with the aid of
two additional brake functions:
electronic brake prefill and brake
assist.
The prefill function is automatically
enabled whenever the throttle
pedal is suddenly released. The
pressure in the brake lines is
marginally increased, bringingeach of the pads into light contact
with the corresponding disc. If
the driver then decides to use the
brakes, the system can apply
the maximum force with virtually
no delay.
The brake assist function is
specifically designed for use in
emergency stops. When the
pressure on the brake pedal
exceeds a predefined threshold,the brake assist function uses
the PSM hydraulics to apply the
pressure required for maximum
deceleration. The result: shorter
braking distances.
For a more natural drive, PSM can
be manually disabled leaving only
the automatic brake differential
(ABD) in place. Although essentially
inactive, PSM remains present in
the background and can intervene
immediately under heavy braking
where at least one front wheel
requires ABS assistance. In ‘Sport’
mode, PSM will only respond
when ABS is active on both front
wheels.
In short, PSM provides the ideal
balance between electronically
assisted active safety and
freedom to enjoy the car’s
potential.
· 58 ·· 59 ·
Oversteer without PSM Oversteer with PSM
Car steers off line
Car steers off line PSM corrects
steering and
stabilises car
PSM corrects
steering and
stabilises car
Understeer without PSM Understeer with PSM
The new 911 Turbo |Chassis
Porsche Stability Management (PSM).
Enhanced stability control for the new 911 Turbo.

For maximum manoeuvrability,
PSM can be partially disabled
while the car is still in ‘Sport’
mode. PSM simply monitors the
forces acting on the car and
will only intervene in the most
critical of situations, e.g., when
ABS assistance is required on
both front wheels.
To help you quantify this
increased performance, the
Sport Chrono Package Turbo
includes a swivel-mounted timer
on the dashboard. Functions
are accessed via the control
stalk for the on-board computer.
Analogue dials measure hours,
minutes and seconds, while aseparate digital field displays
whole seconds, tenths and one
hundredths of a second. The
digital field runs in parallel with
a second display which is
conveniently located in the
instrument cluster.
Individual lap times can be
viewed, stored and analysed using
a special ‘performance display’
added to Porsche Communication
Management (see page 86).
Available information includes the
time and distance travelled on
the current lap, as well as the
number of laps completed and
the respective times. The system
can also display the current
fastest lap and remaining range
till empty. Driving times can be
recorded for any stretch of road
and benchmark times can be
defined. Other useful features
include a memory function
accessible via PCM. This can beused to store a range of personal
preferences, such as daytime
driving lights, ‘Welcome Home’
light function, air conditioning,
rain sensor activation and door-
lock mode.
· 62 ·· 63 ·The new 911 Turbo |
Chassis

The horizontal indicators in the
outer front air intakes feature high-
performance light-emitting diodes
(LEDs) for optimum visibility.
The standard front foglights on
the front apron moulding are
another distinctive design feature
on the new 911 Turbo.
At the rear of the car, the High-
Level third brake light is also
equipped with fast-response LEDs.
A pair of additional lights on the
inside of each door offer greater
convenience and safety at night.
The kerb light (white) provides
greater visibility when exiting the
car. The safety light (red) warns
traffic approaching from the rear
that the door is currently open.
The standard lighting system on
the new 911 Turbo features the
latest Bi-Xenon gas-discharge
technology offering a light quality
similar to daylight. The compact
main headlights provide a broad
swathe of light, ensuring greater
active safety in all road scenarios.Each headlight unit contains a gas-
discharge lamp featuring dynamic
range control. This automatic
adjustment of the light-beam angle
prevents hazardous dazzling of
oncoming vehicles due to small
undulations in the surface of the
road or heavy rear-end loads.The brightness of the lights is
approximately twice as great as
that of a halogen lamp. Other
standard features integral to the
system include a headlight cleaning
function.
· 66 ·· 67 ·The new 911 Turbo |
Safety
High-Level third brake lightBi-Xenon headlight
Active safety: lighting system.
Bright ideas for the darkest night.

The 911 Turbo easily complies
with all statutory requirements in
all markets worldwide in respect
of frontal, side, diagonal and rear
impact protection.
The reinforced bodyshell contains
a highly resilient passenger
cell offering exceptional crash
protection. At the front of the
car, the cell is protected by apatented system of longitudinal
and transverse members (1). In
the event of an accident, energy
is absorbed by three separate
load paths, one above the other,
which disperse the force of
impact and minimise deformation
of the passenger cell.The upper section of each door
features additional reinforcements
(4) which enhance the rigidity of
the car. An additional load path
(5) is used to channel energy
through the upper part of the shell
and protect the passenger cell.
In 1985, Porsche began using
super high-strength steel elements
in its door design to provide
greater occupant protection. On
the new 911 Turbo, this integral
reinforcement is made from
robust yet lightweight aluminium.
By increasing the proportion ofaluminium alloys and high-strength
steel, we’ve also increased the
car’s power-to-weight ratio. No less
than 20 % of the new 911 Turbo
is made from aluminium.
As you would expect, the entire
bodyshell structure receives
a highly effective anti-corrosion
treatment. Thirty years ago,
Porsche became the first manu-
facturer in the world to use
a hot-dip galvanised steel shell.
This exacting proces s is
absolutely fundamental to the
legendary durability of our cars.It also
ensures a consistently
high standard of crash protection,
even after many years on the
road. To underline our confidence
in this exceptional build quality,
the 911 Turbo comes with a
ten-year anti-corrosion warranty,
three-year paint warranty and
two-year warranty on the car as
a whole.
· 72 ·· 73 ·The new 911 Turbo |
Safety
1
1
1
5
4
3
3
12
Sheet steel
Tailored blanks
High-strength steel
Super high-strength steel
Aluminium Passive safety: bodyshell structure.
Adding strength, reducing weight.
Additional features include an
ultra-rigid bulkhead cross-member
(2) made from super high-strength
steel. This element is designed
to absorb impact forces from the
longitudinal members and thus
protect the front footwells. In a
minor collision, a system of easily
replaceable impact absorbers
(3) prevents costly damage to the
underlying bodyshell structure.