Ignition System (997) — Porsche 911 Carrera 997 (2004-2009)

Designation	997	997 S
Ignition	DME, individual spark coils, knock control
Firing order	1 - 6 - 2 - 4 - 3 - 5
Spark plugs	Bosch FRG 5KQEO
Electrode gap	1.6 ± 0.05 mm

Ignition system tightening torques

Designation	997	997 S
Spark plug	> Tightening torque: 22 ftlb +2 ftlb
Spark plug	> Tightening torque: 19 ftlb +2 ftlb
Ignition coil	> Tightening torque: 7.5 ftlb

Tools

Designation Type Number Explanation wrench VW-tool T10152

Removing ignition switch

Installation Location

Scheme 1

Scheme 1: Removing ignition switch

Scheme 2

1. Carefully lift up rubber sleeve on the ignition switch using a plastic spatula, for example, and remove it.

Scheme 3

2. Turn union nut using a narrow plastic spatula, for example, or using the special wrench T10152 tool and unscrew the ring from the ignition switch.

3. Press ignition switch inwards and remove towards the bottom.

Scheme 4

4. Release electric plug -a- and pull it off the ignition switch. (Scheme 4)

Scheme 5

Scheme 5: Installing ignition switch

1. Connect plug on ignition switch until it clicks into place.

Scheme 6

2. Position ignition switch in the instrument panel from below. Position union nut, re-adjust switch and tighten union nut using wrench T10152 . --> Tightening torque: 1.1 ftlb.

3. Place cover in position and slide it over the ignition switch, paying attention to the fitted shape.

Emergency operation of the ignition key lock

Note. In the event of insufficient or non-existent battery positive voltage, the ignition key can be removed using the emergency operation.

1. Lever out the small cover, at the top right next to the ignition key, at the ignition switch using a screwdriver.

2. Then, push a pen, for example, into the opening next to the key, turn the ignition key to position 0 and pull it out.

Designation Type Number Explanation spark plug socket wrench special tool NR.14 3/8" extension, 16° moveable special tool NR.15 socket wrench insert special tool P 300

Scheme 7

Scheme 7: Tools

Scheme 8

Preliminary work

Note. To remove and install the wheel bolts use the prescribed special tool socket wrench insert P 300 .

1. Remove rear wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

Scheme 9

Scheme 9: Removing spark plugs

1. Remove the 2 M6 x 20 fastening screws -arrows- for the shields on both cylinder heads and remove the plates.

2. Unplug cable plug for the ignition coils. To do this, slide the rubber grommets upward first. Press locking tabs on the respective ignition coil and pull off the individual plugs. In the interest of better accessibility, unplug the cable plugs for the solenoid hydraulic valves.

Scheme 10

3. Loosen two M6 x 25 fastening screws -arrows- each per ignition coil and remove the 6 ignition coils individually.

CAUTION

Incorrect tool for changing the spark plugs! Ceramic body breaks!

> Only use the approved tool spark plug socket wrench NR.14 and 3/8" extension, 16° moveable NR.15 .

4. Unscrew the spark plugs using the tool spark plug socket wrench NR.14 with 3/8" extension, 16° movable NR.15 .

Installing spark plugs

CAUTION

Incorrect tool for changing the spark plugs! Ceramic body breaks!

> Only use the approved tool spark plug socket wrench NR.14 and 3/8" extension, 16° moveable NR.15 .

1. Install spark plug with spark plug socket wrench NR.14 and 3/8" extension, 16° movable NR.15 . --> Tightening torque: 22 ftlb. If the spark plugs will be removed and installed again for another activity, the tightening torque is reduced. --> Tightening torque: 19 ftlb.

2. Insert ignition coils in the spark-plug recesses and tighten using two M6 x 25 fastening screws each. --> Tightening torque: 7.5 ftlb. . Then connect the cable plug and position the rubber grommet on the coils.

3. Insert the shield again and fit using two fastening screws. --> Tightening torque: 7.5 ftlb. .

Reworking

Note. To remove and install the wheel bolts use the prescribed special tool socket wrench insert P 300 .

1. Mount rear wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

Preliminary work for removing knock sensor

Note. Removing and installing oil separator information for the Carrera 2, Cabrio 2 and Cabrio 4 is not available from the manufacturer.

1. On cylinder bank 1-3, the three-phase generator must be removed. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. On cylinder bank 4-6, the oil separator must be removed without loosening the connection lines. For details refer to 10 55 19 Removing and installing oil separator - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

Scheme 11

Scheme 11: Removing knock sensor, cylinder bank 1-3

1. Mark and note the installation position of the knock sensor. Remove cable plug from knock sensor -1-.. Unscrew fastening screw and remove knock sensor. (Scheme 9)

Scheme 12

Scheme 12: Removing knock sensor, cylinder bank 4-6

1. Mark and note the installation position of the knock sensor. Remove cable plug from knock sensor -1-. Unscrew fastening screw -2- and remove knock sensor. (Scheme 10)

Installing knock sensor, cylinder bank 1 -3

Note. The precise tightening torque for the knock-sensor screw must be observed, otherwise the knock sensor might not function properly.

1. Clean contact surface on crankcase and move knock sensor to the installation position, according to removal position. Position and tighten fastening screw -1-. --> Tightening torque: 17 ftlb. (Scheme 11)

2. Push on cable plug.

Installing knock sensor, cylinder bank 4 -6