Porsche 911 TURBO - 1989 Workshop Manual

Category
Engine
Type
Workshop Manual

This manual is also suitable for

GENERAL
Technical Date
Page 0.1
REPAIR GROUP
10
13
15
17
19
20
21
25
26
27
28
ENGINE
i:)lgine-crankcase
i:)lgine-Crankshaft, and moving parts
i:)lgine-Cylinder Head, Valve drive
i:)lgine-Lubrication
i:)lgine-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
42
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
FXterior equipment
Interior equipment
80
87
HEATING. VENTILATION.
AIR CONDITIONING
Heater
Air Conditio;Ier
90
92
94
96
97
Instruments, Radio
Windshield Wipers and Washer
Exterior Lights
Interior Lights
Wiring
ELECTRICS
Page
General
10 -01
Adjustment values and limits
Adjustment values and limits from 1978 models
10 -02
Specifications, general
Specifications, general from 1978 models
Tightening torques for engine
0.1
0.7
10 -03
Engine. Crankcase
10
10 -7
10 -8
10 -9
Engine. removing and installing
Engine/transmission unit, detaching and attaching
Engine/transmission unit, detaching and attaching from 1978 models
Engine, removing and installing -hydraulic
clutch mechanism, 5-speed, Model 89 onwards
Engine/gearbox assembly, separating and joining, Model
10 -14
Engine, Crankshaft, Pistons
Crankshaft sizes from 1978 models
13 -4
13 -3
13 -
13 -6
13 -1
13 -7
13 -9
Flywheel, removing/installing or machining
Layout of oil pump from 1978 models
Order of cylinders and air guide plates from 1978 .models
Piston and cylinder sizes, installation notes
Piston and cylinder sizes, installation notes from 1978 models
Pistons and cylinders, measuring
Weight classes of pistons -911 Turbo from 1980 models
13 -9
Engine. Cylinder Head. Val yes
Chain tensioner. removing and installing
Timing. adjusting
15 -1
Valve clearance, adjusting
15 -1
15 -1
15 -1
15 -3
Valve spring sizes
Camshafts, timing
Alphabetical Index
Printed in Germany -VII, 1989
1
Page
Fuel Supply
Delivery rate of fuel pumps. checking
Fuel pump. removing and installing
Pressure test of pumps
20 -1
20 -5
25 -1
Turbocharger
21 -11
21 -4 a
21 -5
21 -20
21 -9
21 -19
21 -4
21 -12
21 -1
Air pressure safety switch. checking
Bypass valve, checking function
Bypass valve, removing and installing
Charge air cooler, removing and installing from 1978 models
Charge pressure. checking
Charge pressure gauge. checking
Turbocharger. checking
Turbocharger, oil supply
Turbocharger. removing and installing
Turbocharger. survey
Valve housing. disassembling and assembling
21 -3
21 -6
Fuel Mixture
25 -19
25 -18
25 -13
25 -13
Air cleaner, removing and installing from 1978 models
Auxiliary air valve, removing and installing
Control pressure "cold", checking
Control pressure "warm", checking
Control pressure "warm-full throttle enrichment", checking
from 1978 models
25 -14
Fuel delivery rate for control pressure circuit. checking
Fuel distributor of mixture control unit. removing and installing
25 -14 b
25 -6 b
25 -1
Fuel system
Idle, adjusting
25 -
Idle, adjusting from 1978 models
25 -10 a
Alphabetical Index
Printed in Germany -VII, 1989
2
911 turbo
Alphabetical Index
Volume
Page
25 -6 d
25 -6
25 -6 a
25 -6 c
Mixture control unit, disassembling and assembling
Mixture control unit, removing and installing
Off position of air flow sensor plate, checking and adjusting
Piston pressure regulator with poppet valve, replacing
Pressure gauges, connecting and bleeding
25 -12
25 -14 a
25 -15
25 -16
25 -17
25 -17
25 -10
25 -11
System pressure, checking
Testing and adjusting values for fuel injection
Testing and adjusting values for fuel injection from 1978 models
Thermo shift valve, checking
Thermo shift valve. removing and installing
Throttle bypass valve, removing and installing
Tools for fuel pressure test
Checking Lambda control function
25 -21
Checking Lambda probe
25 -22
Exhaust System
26 -23
26 -32
Air filter of air pump, removing and installing
Air injection, disassembling and assembling
Air injection, disassembling and assembling engine type 930/51
and 930/52
26 -lB
26 -25
26 .26.26.
Air injection lines and adapters, removing and installing
Air pump, removing and installing
Belt of air pump, checking and adjusting
Blow-off switching valve, removing and installing
Control valve, blow-off switching valve and check valve, checking
26 -26
26 -24
26 -28
26 -27
26 -27
Control valve, removing and installing
EGR valve, checking
EGR valve, removing and installing
Exhaust filter, removing and installing
Exhaust system, disassembling and assembling
Exhaust system, disassembling and assembling
Exhaust system, survey engine type 930/50
26 -2
26 -8
26 -1
Alphabetical Index
Printed in Germany -VII, 1989
3
.22.36
.24
911 turbo
Volume I Alphabetical Index
Page
26 -6Exhaust system, survey engine type 930/52
Exhaust system, survey engine type 930/51, 930/53 and 930/54
Exhaust temperature. control
26 -
26 -29
26 -30
26 -39
Exhaust temperature control, checking
Hose connection plan, California
26 -37
26 -38
26 -29
26 -11
26 -31
26 -40
Hose connection plan. Europe
Hose connection plan, USA + Japan
Reactor and muffler cover
Reactor, removing and installing
Temperature sensor for exhaust temperature control. removing
and installing
Thermo valve. operating and testing
Ignition System
28 -13
28 -5
28 -14
28 -1
28 -2 a
28 -2 b
28 -3
28 -4 a
28 -4 c
28 -6
Delayed ignition cut-out
Distributor, checking in car
Ignition system from 1978 models
Ignition timing, adjusting
Ignition timing, adjusting from 1977 models
Ignition timing, adjusting from 1978 models
Ignition timing control, checking
Ignition timing control, checking from 1977 models
Ignition timing control, checking from 1978 models
Troubleshooting electronic ignition system
Clutch. Controls
30 -7
30 -13
30 -8
30
30-11
Clutch, adjusting from 1977 models
Clutch, adjusting on cars with power assistance from 19'18 models
Clutch, disassembling and assembling
Clutch disc, removing and installing
Clutch spring, removing and installing from 1978 models
Specifications
30 -03
Page
30 -07
30 -03
30 -01
Specifications from 1978 models
Tightening torques for manual transmission
Transmission, type 930
Transmission type G SO/50
30 -02
Clutch mechanism, disassembling and
assembling, Model 89
30 -15
Manual Transmission, Controls, Case
Front transmission cover, disassembling and assembling
Shift base, disassembling and assembling
34-1
34 -15
34 -19
34-3
34-7
34 -14
Shift controls, adjusting
Timing case, disassembling and assembling
Transmission case. disassembling and assembling
Transmission case with power clutch
Transmission case with power clutch from 1978 models
34 -14 e
Manual Transmission, Gears and Shafts
35 -1
35 -15
35 -9
35 -19
35 -7
35 -26
Change box, disassembling and assembling
Drive pinion, disassembling and assembling
Drive shaft, disassembling and assembling
Seal for drive shaft, removing and installing
Selector forks, adjusting
Synchronization, checking
Synchronization, disassembling and assembling
35 -23
Differential. Final Drive
39-17
39 -19
39-5
39-1
39 -9
39 -21
Backlash. adjusting
Backlash of ring gear. adjusting
Differential. disassembling and assembling
Differential. removing and installing
Drive pinion and ring gear. adjusting
Locking differential. disassembling and assembling
Spacers for ring gear adjustment. determining thickness
39 -17
Alphabetical Index
Printed in Germany -VII, 1989
5
Volume I
Alphabetical Index
911 turbo
Page
Front Wheel Suspension
40 '
40 .
40.
40.
Front axle, disassembling and assembling
Front axle, removing and installing
Specifications
Tightening torques for front axle
42 -8
42 -3
42 -1
42 .13
42 -01
42 -03
42 -14
Rear Wheel Suspension
Coil spring compressor P 289, machining
Rear axle, disassembling and assembling
Rear axle, removing and installing
Rear wheel, bearings, adjusting
Specifications
Tightening torques for rear axle
Wheel bearing play, checking
Wheels, Tires, Axle Alignment
44 -1
Adjustment values for axle alignment
Axle alignment. checking
Specifications
44-2
44 -01
Notes on alignment
44 -4
Sample test card
Brakes -Mechanical Parts
46 -
46 -
46 -
46 -
46.
46.
46.
46.
Brake pads -remove and install
Brake pad thickness -check
Brake system -911 Carrera Turbo look
Front wheel brakes -changes for Turbo 3.3 ltr.
Front wheel brakes -disassemble and assemble
Rear wheel brakes -disassemble and assemble
Technical data
Tightening torque
Alphabetical Index
Printed in Germany -VII, 1989
6
.3.1.01
.02
2
1
04
4a
5
11
01
-03
911 turbo
Alphabetical Index
Volume
Page
Brakes -Hydraulic Parts
47-1
47-7
47-12
47 -01
Brake calipers -disassemble and assemble
Brake caliper sections -disassemble and assemble
Brake circuit failure indicator
Tightening torque
Steering
48 -01
48 -1
Specifications for steering
Steering. disassembling and assembling
Tightening torques for steering
48-02
7
Alphabetical Index
Printed in Germany -VII, 1989
930
TURBO REPAIR MANUAL
This repair manual describes all of the important operations for which special instructions are
required to assure proper completions. This manual is essential for the shop foremen and
mechanics, who need this information to keep the vehicles in a safe operating condition. The
basic safety rules, of course, also apply to repairs on vehicles without exception.
The 930 Turbo Repair Manual only describes repair operations which differ from those for 911
models. Refer to the 911 Repair Manual for all other information.
The information is grouped according to repair numbers, which are identical to the first two digits
of the repair time and warranty code.
The repair group index and register cards are quick guides to find information in the manual.
Discriptions of design and function can be found in service training course reference material.
This repair manual will be kept up to date with workshop bulletins; the information of these
bulletins will be made part of the manual from time to time. We recommend that the Workshop
Bulletins be filed in the special folder provided for this purpose.
REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL
930
-Turbo
Please file the supplements according repair groups and make appropriate entries in the table below
Signature
Supplement No.
Filing Date
I
II
III
IV
v
VI
VII
VIII
IX
x
XI
XII
XIII
XIV
General
TECHNICAL DATA
(Refer to appropriate repair group for adjusting and wear limit data.)
Note: USA values listed in brackets.
ENGINE
Internal engine code
930/50, since Nov. 75 930/52 (USA, 930/51)
from Aug. 1976 (USA 930/53) Japan 930/54
mm/inch 95/3.74
mm/inch 70.4/2.77
3
/ .3
cm m. 2993/182.64
6.5: 1
Bore
Stroke
Swept volume
KW/HP
KW/HP
KW/HP
Compression ratio
Max. engine output according to
DilT 70020
Net power, SAE J 245
Gross power, SAE J 245
Technical Data
0.1
Printed in Germany -11. 1976
General
Nm/kpm 343/35
Nm/ft. lbs 332/245
Nm/ft. lbs. 389/286
at engine speed
of 4000 rpm
Max. torque, DIN 70020
Net torque. SAE J 245
~
Gross torque, SAE r 245
64/87 (58/82)
Max. liter output. DIN 70020
KW/l HP/l
rpm
rpm
+
7000 -200
207/456 (217/478)
210/463
rpm
Max. speed
Max. cruising speed
Cutoff speed of speed control in
distributor (overrev governor)
Weight of engine with air cleaner (dry)
kg/lbs
930/52
Engine Design
Engine block
Diecast, light alloy,
two sections
Crankshaft
No. of crankshaft bearings
Conrods
Conrod bearings
Piston pin bearings
Intermediate shaft bearings
Pistons
Forged (tenifer treated)
Eight
Forged steel
3 half-shell plain bearings
Press-fit bronze bushing
2-way plain bearing
Forged light alloy.
slipper skirt
Piston pins
Piston rings
Cylinders
Floating installation, snap rings
2 compression rings, 1 oil
scraper ring
Light alloy, nikasil coated
cylinders
Cylinder head
Valve seat inserts
Valve guides
Location of valves per cylinder
Exhaust valve
Valve springs
Valve drive
Camshaft
Separate, light alloy heads
Shrink -fit, annealed
sintered steel
Press-fit, special bronze
1 intake and 1 exhaust valve
suspended in V
N atrium -filled, reinforced
insert ring
2 coil springs per valve
One each overhead camshaft
left and right
Cast, 4 bearings, runs directly in
camshaft housing
Chain
Camshaft drive
Cooling
Engine
Air cooled via axial
blower on alternator
6800
6000
General
Blower drive
Belt off of crankshaft
Crankshaft/blower ratio
ca. 1:1.67
1560 l/s at 6000 rpm of crankshaft
Air delivery rate
Engine Lubrication
Oil cooling
Thermostatic control, oil cooler on engine
block in blower air stream, cooler coils in front
right wheelhouse
Full flow
0
ca. 4.0 at 80 C
bar
Elektric
0
ca. 150 C
1/1000 km
930/50 -
ca. 1.0 to 2.0
Oil filter
Oil pressure at 5500 rpm
Oil pressure gauge
Max. oil temp.
Oil consumption
Exhaust System
930/52 -
(930/51 -
(930/53 and
930/54
Single pipe system with turbocharger,
bypass valve and muffler
as above. but with additional air pump
double-pipe system. 2 reactors. bypass valve.
turbocharger and muffler, additional air pump)
as 930/51. but with EGR)
Heating
Warm air heater with automatic temperature
control. Warm and cool air mixable.
Fuel System
Fuel supply
Fuel octane
2 elec. roller cell pumps connected in line
96. premium grades (91-96)
RON
Electrics
Degree of suppression
Battery voltage
Battery capacity
ECE Regulation No. 10
v
12
Ah
66
Ah
88 (not with air conditioner)
980
Battery capacity
(optional extra)
Alternator/output
w
Ignition
Transformer
CDI (w/o contacts)
Bosch
Firing order
1-6-2-4-3-5
Brakes
Foot brakes
Hydraulic, dual-circuit disc brakes with
pneumatic booster, LHD only
282.5 inboard
Front brake disc diameter
mm
290 inboard
Rear brake disc diameter
mm
228
mm
Effective front brake disc dia
Effective rear brake disc dia.
244mm
Printed in Germanv -II. 1977
Technical Data
0.3
General
Front brake disc thickness
20
mm
20
257
76
52.5
mm
cm2
2
cm
2
Rear brake disc thickness
Total effective braking surface
Pad surface per front wheel
Pad surface per rear wheel
cm
Front caliper piston dia.
mm
Rear caliper piston dia.
38
mm
Mechanical acting on both rear wheels
mm
25
mm
cm2
Parking brakes
Parking brake drum diameter
Brake shoe width
Effective braking surface per wheel
85
Teves, Type T 52/7 inch
Brake pressure booster
Pressure ratio
1.8
Pedal ratio (mechanical)
5.2
Dimensions (DIN -Curb Weight)
mm/inch 4291/168.94
mm/inch 1775/69.88
Length
Width
Height
Height
mm/inch
mm/inch
1320/51.97 (1340/52.76)
1304/51.34 with standard 50 tires -only
up to 1977 Models
2272/89.45mm/inch
Wheelbase
Front track
Rear track
mm/inch
mm/inch
Ground clearance
mm/inch
mm/inch
1438/56.61 (1431/56.34)
1511/59.49 (1501/59.09)
141/5.55 with series 50 tires 15 inch
157/6.18 (175/6.89)
Ground clearance -full load
mm/inch
mm/inch
mm/inch
Curved ground clearance
Front overhang angle limited
by spoiler
120/4.72 with series 50 tires 15 inch
127/5.00 (155/6.10)
51,5/2.03 (78/3.07)
15° (16°)
14° 30' with standard 50 tires 15 inch
Rear overhang angle limited
by apron
17°
(ISo)
16° with standard 50 tires 15 inch
(DIN 70020)
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
1140/2514 from Nov. 75 1195/2635
1470/3241 ..1525/3363(1400/3087)
600/1323 ..625/1378 (600/1323)
870/1918 ..900/1984 (840/1852)
Weights
Curb weight
Max. total weight
Max. front axle load
Max. rear axle load
330/728 (205/452)
35/77 without exceeding max. total weight
Payload
Max. roof load including roof
Printed in Germany
Technical Data
0.4
General
Capacities
Engine (as measured with oil dipstick
according to Owner's Manual)
Brand name heavy duty oils meeting API Classifi-
cation SD or SE with a viscosity of: SAE 30 for summer,
SAE 20 for winter, SAE 20 W 20for permanent
0 0
temperatures betw. -15 and a C or SAE 10 W for
0
permanent temperatures below -15 C (10 W 50/15W 50/
20 W 50 multi-grade oils upon approval)
1
1
Ca. 13
Ca-.10
Total oil volume of system with oil
cooler coils
Oil change volume
Transmission and differential
Refer to page
30-05
Fuel tank 1
80, 8 liters in reserve
3
Brake fluid Ca. 240 (227)cm
Windshield washer 1
Ca.
8.5
Performance
Top speed
kph/mph
Above 250/155 (245/152)
Acceleration from
0 -100 kph/62 mph
sec
5.5 (5,7) DIN curb weight +
1/2 payload
24.0 (25,0)
4.4 ; kg/kW 6,0 (4,88; kg/kW 6,63)
sec
kg/HP
Km from standing start
Weight per horse-power
Hill climbing ability in 10
4-speed transmission
1st gear over 100
2nd gear 47
3rd gear 27
4th gear 16
(28)
(16,5)
0.5
Printed in Germany -11. 1976
Technical Data
General
Max. torque
(Net torque)
Nm / kpm
Nm / ft Ibs
412/42 (395 / 40.3)
395 / 291
at engine speed
rpm 4000
Max. liter output
kW / 1 / HP
67 / 91
Max. pexmissible speed
Max. constant speed
6700
6000
rpm
rpm
+
7000 -200
Governor cut-off speed
in distributor
rpm
Engine weight (dry) with
muffler
kg fIbs
230 / 507 (240 / 529)
Engine Design
4 stroke internal combustion
Type
Cooling system
Crankcase
Air
Light alloy metal
Forged, 8 plain bearings
Plain bearings
Light alloy metal
Crankshaft bearings
Connecting rod bearings
Cylinders. single
Arrangement of valves per cylinder
Val ve timing
Camshaft drive
1 intake valve
1 exhaust valve
Vee suspension
One OHC left and right
Chain
Camshaft bearings
Blower drive
Plain bearings
Belt in unit with alternator
Crankshaft/blower ratio
Lubrication
Fuel supply
Mixture
Charging
Approx.1 : 1.67
Dry sump with separate oil tank,
thermostat controlled oil cooling
and full flow oil filter, cooling tube
coil in front right wheel house
2 series connected elec. pumps
Continuous fuel injection
KKK exhaust turbocharger
0.8
Printed in GermanySpecifications, General
General
Electric System
ECE Regulation No. 10
v
12
Ah
Ah
Shielding class
Battery voltage
Battery capacitance
Battery capacitance (M -item)
66
88 (not with air conditioner)
Alternator power
Ignition system
Firing order
w
980
CD! (breakerless)
1-6-2-4-3-5
Exhaust System, Heater
Single pipe system with turbocharger.
bypass valve and muffler. Secondary air
il"jectiol! by auxiliary air pump in exhaust
system after each exhaust valve.
(USA + Japan also with reactors)
Automatic temperature control for heater
(at DIN curbweight)
Dimensions
Wheelbase
mm/inch
mm/inch
mm/inch
mm/inch
2272/89.45
Front track width
Rear track width
1432/56.38
1501/59.09
4291/168.94
Length
Width
mm/inch
mm/inch
m/ft
1775
69.88
1310 / 51.57 (1328
52.28)
Height
Turning circle dia.
10.7/35.10
120/4.72
Ground clearance. full load
mm/inch
Weights
kg/]
kg/]
kg/I
kg/]
1300 2867 (1295
2855)
1680 I 3704 (1500.700
I 1543 (625 I
1050 I 2315 (900 J
/ 3307)1378),
1984)
Curbweight by DIN
Max. total weight (static)
Max. front axle load (static)
Max. rear axle load (static)
Printed in Germany -III. 1978
Specifications, General
0.9
lbs
lbs
lbs
lbs
General
Capacities
Engine
Total amount of oil for system with
extra cooling pipe coil
1
Approx. 13, exact amount determined
by reading on oil dipstick, measured
with engine running at idle speed and
having operating temperature
Approx. 10
1
Amount for oil change
Amount of oil between min. and
max. marks on dipstick
1 Approx. 2
Brand name heavy duty oils for internal combustion engines
acc. to API Classification Sf. Use following viscosity mul-
ti-grade oils for year around operations (oil change every
20,000 km): SAE 10 W/50, 15 W/50 or 20 W/50. Do not
.0
use latter 011 for constant temperatures below -15 C. On-
ly use brand name oils tested and approved by Porsche.
Brand name single grade oils of API Classification SE
should only be used when multi-grade oils are not available
and normal operating conditions prevail, but the use of
such oils will require observance of the additional change
intervals according to season of year to prevent any damage.
Use SAE 30 oil for summer and SAE 20 W for winter (pro-
0
tection only for temperatures below + 5 C!).
Transmission + differential
1
See page 30 -05
1
80, of which 8 Itr. in reserve
3
Fuel tank
Brake fluid tank
cm
Windshield washer 1
Approx. 240 (227)
Approx.8.5
Performance
Top speed
km/h / mph 260/162 (250 / 155)
Acceleration 0 -100 km/h
Km from standing start
5.4 (5.6)
24.0
DIN curbweight +
1/2 payload
s
s
Printed in Germany
0.10
Specifications, General
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Porsche 911 TURBO - 1989 Workshop Manual

Category
Engine
Type
Workshop Manual
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