Porsche Carrera 4 911 1989 Workshop Manual

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

J

~

) \"f",

\ "

r::= =

c-v ~1'1"'"

I,!.;- I -

1

P2-

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-=.=.:- ~ ~~ ~ --I

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P3

~

' PS-

'~

~:' ~

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p~~

[==~=== ~ ; li~ 19 " 1245:t2 -P19

132B:t2

P6

10

P1B

3756,5.t4

1 722=2 --~

~P18\

P17

Repair control dimensions

Printed in Germany -1988

'---~'l_.

--=.

,

Body, General

P14 "'"

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1-- .:::;::::: :::::--1-r-= ~ fO

-,.

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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

D

c

.~

~-o. '

~:::;.,. 0I

--:::::::::::::::r~~:::::::::::,

~

0

~"/

~/0

10

A

I:::)

"-

~

I

'b

~

--

B

~

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

1\~h~, """,':::~~

I, ,

I l -0

1,,001 ) C C .c -.\r _000 \ .c '

: \

: 0\

u

..,

1

~

~\ f

~:~=::~

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0

\~

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~,

~' v:oi

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~/ ,

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QI

8

cC

c

.~

~

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~

.~

.10\7/

3 BV

~~

,.

T~~~

/11

/"'.'"~

2--

Co

\~

~o

/~

\(

:>~

~

312

50 -5

Replacing Complete Front End of Car

Printed in Germany -111,1989

~

--"'~~/\

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",

/,

4

//

/,

~~~~J-

'" ,-.:-.,

0

~

-,

/~/ V /

~

0,~

~~

~

\---

~/

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

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Porsche Carrera 4 911 1989 Workshop Manual

Porsche Carrera 4 911 1989 Workshop Manual

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