Porsche 911 TURBO User manual

GENERAL

Technical Date

Page 0.1

REPAIR GROUP

10

13

15

17

19

20

21

25

26

27

28

ENGINE

Engine-crankcase

Engine-Crankshaft, and moving parts

Engine-Cylinder Head, Valve drive

Engine-Lubrication

Engine -Cooling

Fuel Supply system

Turbocharger

Fuel system

Exhaust System

Starter, Power Supply

Ignition System

30

34

35

39

Clutch, Control

Mech. gear-shift system -actuat., hous.

Mech.gear-shift system -Gears, Shafts

Differential

TRAN S MISSION

40

4":>'

44

47

48

CHASSIS

Front Wheel Suspension

Rear Wheel Suspension

Wheels, Tires, measuring vehicle

Brakes, -Hydraulic -system

Steering

50

51

53

55

57

60

63

64

66

68

BODY

Body-Front Section

Body-Center Section

Body-Rear Section

Lids

Doors

Sliding Roof

Bumpers

Glasses

Exterior equipment

Interior equipment

HEATING. VENTILATION.

AIR CONDITIONING

Heater

Air Conditioaer

80

87

90

92

94

96

97

Instruments, Radio

Windshield Wipers and Washer

Exterior Lights

Interior Lights

Wiring

ELECTRICS

911 turbo

Alphabetical Index

Volume II

Page

Body, front section

..50-4

..50-1

..50-3

..50-5

..50-7

..50-7a

Body platform, front -type 911-turbo Body platform and front section gauge P 863 Dimensions for body platform. Repair control dimensions 911-turbo Repair control dimensions 911-turbo, Model 78 onwards

Straightening attachments for type 911-turbo -ENS 77.303

Body, rear section

Transverse rear axle tube 911-turbo

53-1

Hood

Engine hood, removing and installing from Model 78 onward

55-1

Exterior equipment

66-3

66-1

Fitting stoneguard foil to rear turbo fender

Fitting turbo emblem.

Interior equipment

Central console, removing and installing

68-1

Heating

Automatic heating control, removing and installing

Automatic heating control, checking.

00-1

00-5

Fittings, instruments, radio

9()-3

9()-4

9()~1

Electronic tachometer, checking. Electronic tachometer, removing and installing generator

Position of relays in the vehicle.

Alphabetical Index

Printed in Germany -VII, 1989

1

Volume II

Alphabetical Index

911 turbo

Page

97-1

97-13

97-19

97-17

97-29

97-25

97-23

97-7

97-31

97-11

97-9

97-27

97-5

97-61

97-79

97-115

97-153

97-197

Wiring

Current-flow diagram -911 turbo, Model 76 Current-flow diagram -911 turbo, Model 77 Current-flow diagram -911 turbo, Model 78 Additional current-flow diagram -exhaust temperature monitoring -type 911 turbo

Additional current-flow diagram -automatic heating control. Additional current-flow diagram -electric windows. Additional current-flow diagram -rear window wiper. Additional current-flow diagram -refrigerant system with front condenser. ...

Additional current-flow diagram -air-conditioning system. Additional current-flow diagram -engine compartment light. Additional current-flow diagram -fog lamp. Additional current-flow diagram -headlight cleaning system. Additional current-flow diagram -intermittent wiper c!rcuit, Model 76 Additional circuit diagram -alarm system, Model 85 Circuit diagram, Model 86 Circuitdiagram,ModeI87 Circuitdiagram,ModeI88 Circuitdiagram,ModeI89

Alphabetical Index

Printed in Germany -VII, 1989

2

Body -Front Section

FLOOR/FRAME CHECKPOINTS AND FRONT BODY SECnON GAUGES P 863 AND 863a

As already announced in the 1975 model information, checkpoints are welded to the floor/frame

assembly from 1975 models. The extent of damage is quickly diagnosed with the help of these

checkpoints and front body section gauge P 683 a (consisting of former gauge P 863 + additional

adaptor) .

The carrier pin of Type 930 Turbo is 21 mm higher. When measuring with front body section

gauge P 863,the distance between the upper edge of the gauge and the collar on the carrier pin

is 21 mm or, with the adaptor installed on the carrier pin, 13 rom.

The gauge can also be used to repair light front section damage (upsets up to 10 mm). Cars with

damage of this type no longer need to be installed on a straightening bench.

Installation of the gauge requires that the wheels, the guard, the carrier and the control arms be

removed. The gauge is then bolted to the front axle take-up points and front floor/frame checkpoints,

as illustrated above.

The distance from the rear floor/frame checkpoints and rear axle take-up points for the transmission

to the engine suspension is checked with a measuring staff.

This gauge is for checking only. It must be removed for straightening and welding operations

to prevent it from becoming bent through body distortions.

Note:

Printed in Germany

50-1

Floor/Frame and Front Body Section Gauge

50

Body

FLOOR/FRAME ASSEMBLY DRAWING

Printed in Germany

Floor/F'rame Assembly Drawing

50-2

Body

Dim.

Designation

mm

+

565.5 -2

A

Control arm take-up, front, inner

!

1

Carrier take-up

726

! 2

Front floor plate checkpoints

c

1200

! 2

D

Rear floor plate checkpoints

850

! 3

E

Engine suspension

752

!. 3

F Front floor/inner control arm checkpoint

1327

!. 3

Rear floor/ carrier checkpoint

1868

G

+

1528.5- 3

H Axle tube transmission/front. floor checkpoint

1346 "!. 3

1374

Axle tube transmission/inner engine suspension

from 1978 models

1557 :!: 3

1582

Rear floor/inner engine suspension checkpointK

from 1978 models

"to 3

1041

L

Front floor/inner control arm checkpoint

+

1215 -2

Front floor/rear floor checkpoints

M

1355 ! 3

13~4_-

Rear floor/inner engine suspension checkpoints

N

U91ILlll8models

0 Axle tube transmission/inner engine suspension 1245 :: 3

1273

All distances are measured from center of hole and horizontal.

Note

Distances to engine suspension bolts are measured direct (at an angle).

Note

Lengths measured on the left and right may not exceed the specified tolerances in difference

to each other.

Body -Front

FLOOR/FRAME ASSEMBLY TYPE 930 TURBO

In comparison to the Type 911, the carrier pin <i the Type 930 Turbo is 21 mm higher. This has

caused changes to the floor/frame assembly in the area marked in white.

The border on the wheelhouse and floor plate is cut out about 70'mm higher than the control arm

to allow accessibility.

Note

If new wheel housings are required for repairs. make these openings in the borders on both sides and

weld the seams to the floor plate.

Front Floor Assembly for Type 930 Turbo

50-4

Printed in Germany

Body

')"'

REPAIR REFERENCE POINTS FOR 930-turbo

Repair Reference Points for 930 Turbo 50-5

Printed in Germany III, 1978

Repair Reference Dimensions 930 Turbo

From 1978 Models

Body

STRAIGHTENING BENCH ATTACHMENT SET ENS 77.303 FOR TYPE 930 TURBO

The illustrated take-up points differ from the attachment set for Type 911 and are applicable to Turbo

cars.

The auxiliary carrier pin is installed 21 mm (0.827') higher.

The brackets on the rear axle cross tube are inclined upwards.

~""'

The take-up pin for the transmission suspension is located 25 mm (0.984') further forward.

The engine mount for Type 3.0 Turbo up to 1977 model conforms with Type 911.

The engine mount for Type 3.3 Turbo from 1978 model is moved further back by 30 mm (1.181 ").

REAR AXLE CROSS TUBE OF 930 TURBO

A new rear axle cross tube. Part No. 930 331 010 00,

-Fig. A -is installed in the Type 930 Turbo.

This cross tube differs from the version for the

Type 911 -Fig. B -as follows.

1. New, larger holders fgr rear axle trailing

arms at an angle of 2 30' upwards.

Reference point: 6 mm above the horizontal

as measured at the rear inner support plate

of the holder's lower edge.

2. New transmission suspension take-up pin

(offset 25 mm toward front).

Notes

1. The seat wells have dents on both sides of

the center t,'Jnnel above the holders for the

Type 930 Turbo (see figure).

2. Large seat belt reinforcement plates are

installed in all cars for Australia and France.

and in fact on the transmission tunnel. These

reinforcements are welded to the holders at

the rear axle cross tube to increase the

strength.

Rear Axle Cross Tube for 930 Turbo

53-1

Printed in Germany

Hoods and Lids

REMOVING AND INSTALLING ENGINE HOOD FROM 1978 MODELS, TURBO 3.3

Removing

1. Detach hose straps and ground wire at hinge..~.

Caution

Refrigerant hoses must not be detached from con-

denser, since otherwise-the high pressure refrigerant

would escape and the air conditioner would have

to be recharged.

Also make sure than fins of condenser are not bent.

Large area fin damage will impair the efficiency

of the ..ir conditioner.

4. Remove windshield wipex arms. Unscrew winds-

hield wiper holders and lift off connecting link-

age.

2. Mark and disconnect wires leading to rear

window wiper and engine compartment lamp.

Remove engine compartment lamp for this

purpose.

5. Detach engine hood at hinges and remove.

3. If car has air conditioning. loosen condenser

screw from hood (see arrow). Lay down conden-

ser in engine compartment carefully.

Printed in Germany -III, 1978

Removing and Installing Engine Hood

55 -1

Hoods and Lids

Disassembling

Notes on Installing

1. Unscrew rear spoiler carrier from hood and re-

move with reinforcement rail, see arrow.

When installing the windshield wiper shaft, it is

essential to insert spacer in hood. Wiper arm

should be installed that, when switched off, wiper

blade will be parallel to side window weatherstrip

(distance approx. 40 mm).

Note

When painting car, cover riveted weatherstrip

with tape.

2. Detach spoiler (polyurethane section) from

carrier, see arrow.

Printed in Germany

Removing and Installing Engine Hood

55 -2

Exterior Fittings

INSTALLING TURBO SIGN

There are nine 'Turbo" decals on each vehicle.

They are placed as follows: one on each door;

one on each front fender; two on each rear fender;

one for the rear lid.

Work Sequence:

Observe the following to make sure that the

decals adhere well to the painted body.

1. Wash and dry car. Remove wax and polish

in areas of decal.

2. Do not apply decal outdoors, if cold or moist.

The car and ambient temperature should be

0 0

about 20 C (68 F) for best results.

1. install the door decal, Part No. 930.559.303/

304 00/01 so that the paper edges (top front/

rear front) rest on the door waistline strip.

Make sure the opening around the door handle

is equidistant. Pull paper half off adhesive

surface. Place decal on door handle and press

on lightly. While pulling paper off, pull decal

forward and press on (smooth by hand from

rear to front).

Smooth decal toward the outside with a

plastic squeegee Pull off top protective paper

parallel to decal. Fold overlapping edges of

decal.

3. The thick beige paper covers the adhesive

surface.

4. Always start with the door decal and then

align the adjacent decal with this one.

5. Decals not pressed on firmly by rubbing

smooth can be pulled off again for alignment.

Puncture air bubbles with a needle and press

smooth.

6. Remove exterior mirror on doors.

Installing Turbo Sign

66 -1

Printed in Germany -1, 1976

Exterior Fittings

4. Install turbo sign decal -Part no. 930.559.307/

308 00/01 -below masking tape border parallel

to taillights. Make sure that the edges of the

front and rear decals are parallel. Fold ends of

decal at water drain molding.

2. Install front fender decal -Part no. 930.559.

301/302 00/01 -after the door decal has been

installed. Start at the door edge. Make sure

the point begins on the fender (not the head-

light rim). Align the top paper edge of the

front decal with the center of the headlight.

Press over fuel tank cover and after the

protective paper has been pulled off, cut

through decal which overlaps fuel flap cover.

3. Install rear fender decal -Part no. 930.559.

305/306 00/01 -aligning it with the door

decal. To facilitate alignment of the front

fender with rear tubo decal, masking tape

can be used.

Note

When applying the turbo sign decal make sure

that the shaded areas are pressed on without folds;

folds between shaded areas cannot be avoided

completely.

5. Install rear lid decal -Part no.930.559.309 00/

01 -at same height as fender decals and fold

the ends.

66 -2

Installing Turbo Sign

Printed in Germany

Exterior Fittings

INSTALLING TURBO DECALS ON REAR FENDERS

1. Using squeege pull upper lip of rubber guard

away from connector plate as far as necessary.

2. Clean and dry surfaces for decals.

3. Draw a pencil line 30 mm (1 1/8 iIi.) parallel

to wheel openiIig.

4. Peel protective paper off decal and place

decal on surface so that it matches the drawn

line and its bottom is covered about 3 mm

(1/8 in.) by the rubber guard strip.

5. Smooth decal toward outside and rub out

bubbles with a squeegee If necessary puncture

bubbles with a pin and press smooth.

Installing Decal on Turbo Rear Fenders

66 -3

Printed in Germany -I. 1976

Interior Fittings

REMOVING AND INSTALLING CENTER CONSOLE

Removing

1. Unscrew cap.

Caution! The capillary tube must not be

bent sharply or separated. since

it would be destroyed.

2. Pull off air conditioner switch knobs and

remove round nuts. Unscrew left and right

metal screws (arrow). Press down and remove

holder.

4. Remove mounting screws at front and rear

of center tunnel.

5. Pull up rubber cover on gearshift lever,

3. Disconnect wire plugs at both switches. Re-

move blower switch. Remove insulation tape

on white capillary tube and pull harness out

of center console (disconnect battery).

6. Lift center console and swing over the re-

leased parking brake lever to one side.

Removing and Installing Center Console

68 -1

Printed in Germany -II, 1976

Interior Fittings

7. Open up the opening for the harness to about

40 x 60 mm, so that the temperature switch

can be removed. This means first cutting the

proper depth with a saw and then cutting out

the metal with a shears. Remove center con-

sole.

Note

Open up the harness opening of a new center

console to the specified size.

If only the temperature switch has to be replaced,

the capillary tube' s front end in the floor plate

must be pulled out of the vaporizer housing. The

capillary tube is fastened to the harness at several

points with an insulation tape. Cut through insula-

tion tape and then slide on a matching sleeve to

cover the entire length. Pullout temperature

switch and slide in the new capillary tube through

the sleeve.

Printed in Germany

68 -2

Removing and Installing Center Console

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Porsche 911 TURBO User manual

Porsche 911 TURBO User manual

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