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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