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Carrera 4
List of Repair Groups
Technical Data
Page 0.1
Group
03
10
13
15
17
19
20
24
26
27
28
General
Repair Groups
Volume 1
Engine,
Maintenance
Maintenance, Self-diagnosis
Engine, Crankcase, Suspension
Engine, Crankshaft, Pistons
Engine, Cylinder Head and Valve Drive
Engine, Lubrication
Engine, Cooling
Fuel Supply
Fuel System, Electronic Injection
Exhaust System/Emission Controls
Starter, Power Supply, Cruise Control
Ignition System
Diagnosis
30
32
34
35
39
Volume II
Transmission
(manual)
Clutch, Controls
Clutch
Manual Transmission, Controls, Case
Manual Transmission, Gears, Shafts
Differential, Transaxle System, All-Wheel Drive
Diagnosis
30
32
37
38
39
Volume III
Clutch, Controls
Torque Converter
Automatic Transmission, Controls, Case
Automatic Transmission, Gears, Shafts
Differential, Transaxle System
Diagnosis
Transmission
(automatic)
40
42
44
45
46
47
48
Volume IV
Chassis
Front Wheel Suspension
Rear Wheel Suspension, Axle Shaft
Wheels, Tires, Alignment
Antiblock System
Brakes. Mechanical
Brakes, Hydraulics. Regulator, Booster
Steering
Diagnosis
50
51
53
55
57
60
61
63
64
66
68
72
74
Volume VI
Body
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
Doors
Electric Sunroof
Hardtop
Bumpers
Glasses. Window Control
Exterior Equipment
Interior Equipment
Seats
Seat Covers
80
85
87
Volume VI
Heating, Ventilation,
Air Condition
Electrics
90
91
92
94
96
Heater
Ventilation
Air Conditioner
Diagnosis
Instruments, Fuel Gauge, Alarm System
Radio, Telephone, On-board-computer
Windshield Wipers and Washer
Exterior Lights, Lamps, Switches
I nterior Lights
Diagnosis
97
Wiring
Volume VII
Electrics
Wiring Diagrams
Interior Equipment
Safety Precautions for Working on Cars with Airbag Airbag Steering Wheel -Removing and Installing. Airbag Components -Removing and Installing. Center Console / Information About Axial and Lateral Acceleration Sensors.
Seat Belts -Inspecting. Diagnosis.
.68 -1
.68- 3
.68- 4
.68- 9
.68-11
.068- 1
2 List of Contents
Printed in Germany -III, 1989
The Carrera 4 Repair Manual also has the contents for the Carrera 2.
Descriptions of repairs in this manual are based on the Carrera 4.
"Carrera 4" appears in the top line of each page.
Deviating descriptions of repairs for the Carrera 2 are provided after those for the Carrera 4. A yellow
sheet separates the repair descriptions for both models. "Carrera 2" appears in the top line of all
pages after the separating sheet. Page numbers begin with 100 for additional identification.
Page
50 -01
50 -07
Body -General
Repair Control Dimensions. Special Tools and Sheet Metal Machines for Repairs
Body -Front Section
Front End of Car -Replacing Partially. .
Front End of Car -Replacing Completely
50 -1
50 -5
Bumpers
Front Spoiler and Bumper -Removing and Installing
63 -
1
64 -1
64 -2
64 -8
64 -12
Windows, Window Controls
Windows- Removing and Installing. Windshield -Removing and Installing. Rear Side Windows -Removing and Installing.
Rear Window -Removing and Installing.
Exterior Equipment
Body Paint Colors -1989 Models Onward
Body Paint Colors -1990 Models Onward
Rear Spoiler -Removing and Installing.
66 -01
66 -02
66- 1
1
List of Contents
Printed in Germany -III, 1989
Body, General
911 Carrera 4
Dimensions for floor
N Point 12 -Point 15
0
Point 18 -Point 15
1492 :t 3 (1482 :t 3)
1696 :t 3 (1653 :t 3)
914.5 (913)
Point 20 -Point 5
p
1245:!: 2
R
Point 17 -Point 18
s
Point 17 -Point 19
1328:!: 2
All dimensions are measured from or to center of hole
Note
The dimensions are measured directly and are therefore oblique dimensions. The measurements in
brackets are measured horizontally.
Important
The deviation between left and right must not exceed the specified tolerances for the
length dimensions.
50 -03
Repair control dimensions
General Information
911 Carrera 4
Sheet Metal Machines (Standard):
236 -50
8
5
238 .50
308-50
235 -50
911 Carrera 4
Dimensions for assembly
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Repair control dimensions
Printed in Germany -1988
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Body, General
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50-130
Description
Point
(left/right)
1
2
3
4
5
6
7
11
12
13
14
15
16
17
18
19
20
Center bumper/impact absorbing tube, front
Mounting hole -final front section
Mount -FA side member
Mount FA spring strut
Mount -outer cross member FA
Mount -inner cross member FA
Mounting hole -wheel house
Mounting hole -switchboard
Mount -transmission cross member
Mount -outer cross tube RA
Mount -RA spring strut RA
Mount -engine bearing
Center of bumper/impact absorbing tube, rear
Jacking point -lifting platform, jack, front
Jacking point -jack, rear
Jacking point -lifting platform, rear
Hole -front final section
FA = Front axle
RA = Rear axle
50.131
50 -05
911 Carrera 4
General Information
Special Tools and Sheet Metal Machines for Repairs
Special Tools:
gA~
307 .50
A = P 290 (special tool for removing and installing door hinge pins)
B = P 852 (gage for windshield)
c = P 853 (gage for rear window)
D = P 854 (gages for left and right rear side windows)
E = P 856 (gage for rear opening -Targa)
50 -07
Special Tools and Sheet Metal Machines for Repairs
Printed in Germany -111,1989
General Information
911 Carrera 4
Sheet Metal Machines (Standard):
13
(fi)
10. I
~ ~I1'--
w
237 -so
Accessories:
8 = Welding spot cutter (for drill)
Electric Tools:
1 = Drill
2 = Right angle grinder, large
3 = Right angle grinder, small
4 "7 Grinder
5 = Hot air blower
Pneumatic Tools:
9 = Chisel
10 = Body saw
11 = Welding spot cutter
Welding Tools:
12 = Spot welding tongs
13 = Inert gas welder
Mechanical Tools:
6 = Punch
7 = Shouldering pliers
911 Carrera 4
Body -Front Section
Partially replacing front section
The following chassis parts are required for partial repair of the front section
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B
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188-50
End panelA
B
Connection plate
c
Front wheel house
D
Front side member
50 -1
Body -Front Section
911 Carrera 4
Partially replacing front section
Replacing end panel and connection plate, partially replacing wheel house and side member.
No.
Instructions
Position vehicle. with units installed. on the rational
straightening brackets and secure.
Procedure
Position vehicle
on the alignment bench
Remove damaged
parts from the
chassis
Using chassis saw, weld-point miller and angled grinder,
separate the damaged parts from the chassis.
Remove underseal from welding areas with hot-air
blower or rotary brush.
1
Clean welding areas
Fasten end section to the
straightening bracket
2
Align spare-wheel well with end section, secure with
clamps and spot weld.
3 Weld end section onto
spare-wheel well
Weld in connection plate4
5
Weld in wheel house
Weld in side member
and grind butt-weld joint
smooth.
Align connection plate, fasten to spare-wheel well, end
section and wheel house with clamps and spot weld.
Cut and align wheel house and side member. Offset
wheel house to the outside and fasten to the chassis
with clamps. Spot weld the wheel house to the end
section. Using the saw, cut to fit the fender connection
areas and butt weld.
Align the side member with the wheel house in such a
way that the ends connecting with the end sections form
an offset to the seams of connection plate and wheel
house. Butt weld side member and end sections. Spot
weld side member, wheel house and end section. Grind
butt-weld seams on side member smooth.
6
50 -3
Body -Front Section911 Carrera 4
Replacing Complete Front End of Car
Cutting Off Front End of Car Body
2
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312
50 -5
Replacing Complete Front End of Car
Printed in Germany -111,1989
~
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Body -Front Section
911 Carrera 4
Replacing Complete Front End of Car
Cutting Off Front End of Car Body
Remove all assemblies and attachments in and on the front end body section!
No.
Procedure
Set up car on straightening
bench
Cut through A-pillars
Instructions
Set up and mount car, with the rear-mounted units, on
the rational straightening bracket set.
Cut through A-pillars with a body saw as close as poss-
ible to the front end body section.
2
Cut through entrance
cover
3
Drill off welding spots of
side member
Cut through outside of entrance cover up to the side
member with a body saw and remove in area of side
member to body and side member to front end body
section spot welding connections.
Drill off welding spots between side member and body
(inside ar1d outside) as well as side member and front
end body section with a welding spot cutter.
Dr!" off welding spots between body floor plate and
front end body section floor plate with a welding spot
cutter.
Drill off welding spots of
floor plate assembly
4
Drill off welding spots of
seat carrier
5
Drill off welding spots between body seat carrier and
extension (on front end body section floor plate) with a
welding spot cutter.
Grind off inert gas welding seam between seat carrier
and extension.
Drill off rivets and remove data plate.
6
Remove data plate
911 Carrera 4
Body -Front Section
Replacing Complete Front End of Car
The following body replacement parts and special tools are required for replacement of the complete
"front end body section",
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4
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0
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0,~
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~
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~/
c
313.50
A = Special Tool P 852 (gage for windshield opening in body)
B = Front end body section
C = Eentrance cover
50 -7
Replacing Complete Front End of Car
Printed in Germany -111,1989
--::.~-rr
Body -Front Section
911 Carrera 4
Replacing Complete Front End of Car
Fitting Front End Body Section on Body
,.
..1
Replacing Complete Front End of Car
Printed in Germany -111,1989
50 -8
Body -Front Section
911 Carrera 4
Replacing Complete Front End of Car
Printed in Germany -111,1989
/
