Porsche 911 TURBO Workshop Manual

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 -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

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 -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

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, 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.

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.

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

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

+

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

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

Ground clearance

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

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

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

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

SPECIFICATIONS -FROM 1978 MODELS, TURBO 3.3

(Adjustment values and wear limits are provided in pertinent repair groups)

Note: USA values in brackets

Engine

Factory engine code

Bore

Stroke

930/60 (USA 930/61. Gal. 930/63). Japan 930/62

from mod. 79 (USA 930j94). Japan 930/65

mm/inch 97 / 3.82

mm/inch 74.4/2.93

3 3

cm / inch 3299 / 201.3

Total displacement

Compression ratio

kW / HP

Max. engine power

at engine speed

rpm 5500

7.0: 1

221/300

(USA + Japan 195 / 265)

(195/261)

kW / HP

(Net power)

0.7Printed in Germany -IV. 1981 Specifications, General

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

+

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

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

2272/89.45

Front track width

Rear track width

1432/56.38

1501/59.09

4291/168.94

Length

Width

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/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

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

Printed in Germany

0.10

Specifications, General

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