Assembly notes
Sealing the crankcase mating sections Loctite 574 hardens only when contact with metal is made and air ingress is prevented. After having applied the sealant, bolt up the crankcase sections within approx. 10 minutes since the sealant bead applied directly to the metal surface will otherwise start to cure. In case of repairs, the old sealant coat must not necessarily be removed. It is sufficient to de-grease the surface and apply the new coat of sealant after the solvent has evaporated. New...
Checking Pistons And Cylinders
D1 Measuring point for wear and ovality 30 mm below top edge of cylinder The cylinder is worn if this measurement is 0.08 mm more than the new size specifications. Ovality is checked by measuring in directions a and b. The difference between a and b may not be more than 0.04 mm. D2 Measuring point for piston ring end gap clearance Rings slid in to height of cylinder base gasket. D Measuring point for wear At height of lower edge of piston pin bore. Replace pistons and cylinders if clearance...
Auxiliary Air Conditioner
An auxiliary evaporator for increased refrigeration output is available as an option M 570 . The auxiliary evaporator with 3-stage blower is installed instead of the rear parcel shelf. 7.Remove mounting screws 6 screws . The tightening torque for the M 6 Allen-head bolt is 9 Nm 7ftlb . Renew 0-rings in the connections in the lines to the expansion valve. Removing and Installing Expansion Valve M 5 bolt 6 Nm 4 ftlb M 6 bolt 9 Nm 7 ftlb 1.Remove evaporator see page 87 -120 . 3.Disconnect plug-in...
Technical data of air conditioning system As of MY 93
Refrigerant charge Refrigerant R 134 a 860 g with auxiliary air conditioning 1050 g Refrigerant oil in compressor 160 20 c.c. ND 8 Safety valve The valve opens at a positive pressure of 41 to 43 bar and on fluid tank closes again as soon as the pressure drops below this value. When fitting the refrigerant lines, coat the fittings and O-rings with refrigerant oil. Dispose of the refrigerant oil as hazardous waste. Technical data of air conditioning system Pressure and temperature specifications...
Wiring Diagram Type 924 S Model 86 Sheet 7
WIPER INTERMITTENT ACTION CONTROL RELAY WIPER INTERMITTENT ACTION CONTROL RELAY ' i-r - rr it- rr-rr TT- IT FT- z.B. D6 PLUG CONNECTION Si.Zu. FUSE INLET Si. Ab. FUSE OUTLET Z.B. IDS CONNECTION WITH FIELD INDICATION 6 AIR CONDITION M573 CIGARE LIGHTER 25 A MOUNTED ON BRACKED FOR HEA TER-INSTRUMENT PANEL DRIVER SIDE CLIPT ON INSTRUMENT PANEL DRIVER SIDE WARNING TIME WITH GONG BUZZER RELAYP-U ARE CLIPT ON CENTRAL ELECTRIC SYSTEM
Bleeding Clutch
The use of a pressure bleeder is recommended. 1. Fill tank with brake fluid to upper edge. Remove restrictor sleeve. Connect bleeder. 2. Switch on bleeder and open bleeder screw on clutch slave cylinder until escaping fluid is without air bubbles. Operate clutch pedal several times during this step. 3. If necessary because of residual air release traver less than 15 mm , unscrew slave cylinder on clutch housing. Push rod against stop in slave cylinder and release again bleeder switched off,...
Vw387 1
6. Move pinion up and down without turning it several times and note dial gage reading. Readings would be wrong if pinion is turned. 7. Add 1.1 mm for installed shims, 0.15 mm for bearing preload and 0.10 mm for bearing settling to dial gage reading. This results in Dial gage reading Installed shim Bearing preload Bearing settling 8. Remove pinion. Take out installed shim 1.1. mm and install shims of total thickness 3.16 mm in example at small bearing. 9. Install pinion again and check...
Adjusting drive pinion Note
The setting value E is indicated on the ring 1. Install complete gear set without S3 shims and tighten all tensioning plate hexagon-head nuts to 23 Nm 17 ftlb. . 2. Fit gear housing and locate with three nuts. 3. Install and engage sixth gear. 4. Block input shaft with Special Tool 9253 and tighten drive pinion collar nut to 300 Nm 5. Set adjusting ring of measuring mandrel VW 385 1 to dimension a. 6. Assemble measuring mandrel with centering disks 9109, tapered roller bearing, plunger VW 385...
Undercoating
As it is not possible to exclude the risk of damage to this protective coating in day to day driving, it is advisable to have the underside of the car inspected at certain intervals - preferably before the start of winter and again in spring - and the un-dercoating restored as necessary. Your authorized Porsche dealer is familiar with the bodyseal treatment procedures and has the necessary equipment for applying factory approved materials. We recommend that you entrust them with such work and...
Adjusting the timing
4. Mount the auxiliary chain tensioner, Special Tool 9401. Illustration shows left-hand side of the auxiliary chain tensioner 1. Turn the crankshaft until the marking on the pulley is exactly aligned with the seam of the crankcase or with the locating mark on the blower housing. 4. Mount the auxiliary chain tensioner, Special Tool 9401. Illustration shows left-hand side of the auxiliary chain tensioner 2. Position both camshafts with the punched marking pointing upwards. If this mark has not...
Corvette C6r Psi Ffsa Gt 2007 Decals
A new name to TMMI this month with Francorchamps Mini Models. Catering for the Corvette C6R in 1 25 , scale which is available from Revell in plastic kit form, this decal sheet makes a nice change from the usual yellow works livery and gives you all needed to build the car raced in the 2007 FFSA GT series by PSI. The sheet is nicely printed and gives all the light blue and white elements of the colour scheme, needing the bodywork to be simply painted dark blueJW www.historexagenls.com SEAT BELT...
Adjusting Brake Pressure Rod 1
86 Models Onward without stop on brake-pedal arm It is only necessary to adjust the brake pressure rod if - the brake booster is replaced - brake pressure rod adapter has been removed. 1.Adjust length of brake pressure rod by turning adapter or pressure rod. Length a must be 158 2 mm measured from the bearing face of the brake booster on the body to the center of the adapter pivot pin. If the car has manual transmission and the brake pedal is more than 8 mm lower than the clutch pedal, correct...
Lubrizol Additive Packet 3216c
11 C 0001 . . . 9999 16 C 0001 5000 16 C 5001 9999 The number of a manual transmission, read from below, is stamped on a transverse reinforcement rib in the rear area of the transmission case. The number of an automatic transmission is stamped on the left side of the center transmission case above the ATF sump. The number stamped on the right side is used for manufacturing control. Timing 1 mm stroke, no play I ntake opens Intake closes Exhaust opens Exhaust closes Basic ignition timing w o...
Balancing Seat Heating
- Voltmeter with internal resistance equal to or greater than M i2 with max. 2 mm dia. test probes - Connecting lead made locally Balancing requires connection of the removed seat on battery voltage terminals 15 and 31, see wiring diagram . - The seat being balanced should be left in the workshop so long, until it has reached the ambient temperature. - Connect seat on battery voltage. Do not switch on seat heating I If heating is switched on by mistake, let the seat cool off again until its...
Disassembling And Assembling Brake Calipers
1. Clamp caliper in a vise with soft jaws and detach connecting line. 3. Drive off brake caliper halves from bridge by applying knocks from a plastic hammer alternately. 4. Countersunk screws of spring plate are locked in bridge with Loctite 270. To 2. Unscrew bolts holding halves of brake unscrew, heat screws to approx. 150 C. caliper. This is necessary to prevent stripping 1. After replacing or loosening, lock countersunk screws for spring plate with Loctite 270. Install spring plate with...
Interior Equipment
Removing and installing rear side trim panel 68-1 Safety regulations for handling airbag vehicles 68-3 Removing and installing the airbag steering wheel 68-5 Removing and installing airbag Checking the airbag system to ensure that long-term functioning is guaranteed 68-11 Checking the safety Correct disposal of airbag units 68-15 Diagnosis Troubleshooting Airbag D68 - 1 Removing and installing power Removing seat backrest Disassembling seat Disassembling left seat track and removing fore aft...
Replacing Front End Partially
1. Cut off end plate at body floor plate. 1. Cut off end plate at body floor plate. The best method of repairing a damaged front end, of which the side members are bent or distorted in area of front axle or engine mounts, would not be replacing up to the deformation border, but complete replacement of side members and wheel houses at original connection points of floor or firewall. These repairs can be best performed with help from the Celette straightening bench and pertinent attachment set...
Front control arm removing and installing
Loosen front wheel lug nuts. Raise front of car and support it securely. Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Remove cotter pin from ball joint lock plate. Remove slotted round nut from ball joint using Porsche special tool no. P 280 b. Working underneath front of car, remove stone guard mounting bolts arrow . Remove stone guard. Unbolt and remove A C...
Checking Fuel Pressure
1. Unscrew capped nut on distributor injection tube. specifications, clamp return hose slowly with a clamp at rear next to the fuel level transmitter. Be careful that sealing ball does not fall out when taking off the capped nut. Catch escaping fuel. 2. Connect pressure tester P 378 or VW 1318 and P 378 c. if pressure is less than 4 bar, check fuel filter or, if applicable, replace fuel pump. 5. If engine cannot be operated, pull off relay XX and bridge terminals 30 and 87. Fuel pump should...
Changing the brake fluid bleeding the brakes
Use only new DOT brake fluid. Observe change intervals and brake fluid grade. Total brake fluid quantity for fluid change approx. 1 liter. On vehicles up to MY '92, the brake fluid must be replaced every 2 years as a minimum. As of MY '93, the brake fluid change interval has been increased to 3 years - along with the use of special DOT 4 brake fluid. The 3-year change interval is valid as of MY '93, but only in conjunction with the use of the special Porsche brake fluid. The brake fluid is...
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Basic Adjustment Of Mixture Control Screw After Replacement Of Operating Lever
This test requires that the sensor plate be positioned correctly rest position . Never apply downward pressure to adjusting wrench during adjustments, since this could change the injection timing. 6. Run engine to o 3eratin temperature oil temperature 80 to 90 C and adjust idle speed and CO level to their final specified values. 2. Bleed fuel lines. Disconnect injectors and hold in a container. Move sensor plate by hand many times . 3. Use adjusting wrench P 377 to initially turn the mixture...
Short to B
1. Pull off plug II on the display and operator control unit. 2. Pull off plug I 18-pole on the amplifier. 3. Check lead from plug II pin 14 to plug I pin 17 for short to B . Fault, fault code Possible causes, elimination, notes Check lead from plug II pin 14 to plug I pin 17 Speedometer A, navigation unit Open circuit short to ground short to B Fault code 24 Open circuit short to ground short to B 1. Pull off plug on the navigation unit. 2. Pull off plug I on the instrument cluster. 3. Check...
Replacing ignition switch
Requirements for Keylock - vehicles - When removing and installing the ignition switch, the lock barrel must be fitted to the steering lock housing. - The Keylock bowden cable may remain fitted. 1. Pull connector off ignition switch. Uncllp connector housing from steering column housing. 2. Turn ignition key No. 3 to position 0 key can be pulled off . Turn out fastening screws No. 1 of ignition key No. 2 . Extend ignition key carefully. In case of Keylock vehicles, the steering lock housing...
Removing And Installing Usa Type Bumpers
Beginning with the 1973 models, all vehicles exported to the USA are equipped with bumpers with rubber bumper horns in front and rear, and reinforced bumper brackets. The bumper horns deform under heavy impact. Additional rubber supports are mounted on the rear bumper horn brackets to further support the bumper center section and upper part of bumper horns against the rear transverse member. 1. Detach bumper from fender sides detach electrical wires if additional lamps are installed. 2. Detach...
Removing And Installing Auxiliary Air Valve 1
Removing and Installing Auxiliary Air Valve REMOVING AND INSTALLING AIR CLEA Note When Installing, be careful that spring-loaded Allen key for idle adjustment on mixture control unit is not damaged. 1, Unscrew bolts and detach vent hose of air cleaner. 2, Loosen hose clamps and pull off hoses. 2, Loosen hose clamps and pull off hoses. - - - - - i l-V W -1 .- - - - - - i l-V W -1 .- 3. Loosen vent hose clamp on oil filler neck and pull off hose. 4. Unscrew nut slightly and remove air cleaner. 4....
Power supply and earthground
Pins occupied at control unit and sensor plug are the same as for the lateral acceleration sensor. 17 Longitudinal acceleration sensor Implausible signal Signals from longitudinal acceleration sensor to control unit are incorrect. Sensor has a mechanical fault, installed position is incorrect or connecting wires have been accidentally interchanged. 1. Check lateral and longitudinal acceleration sensor, Page 45 - 1 45 - 5. 2. Renew sensor if necessary. Repairs to the sensor are not permitted. 3....
Test point 14
transmission The sensor transmits the transmission speed. ECU compares it to the wheel speed. Tlptronic warning lamp comes on, transmission is in emergency mode. Possible faults Open circuit, short to ground, short to positive, loose connection Check with Tester 9288 actual values . Store fault as of engine speed 2800 rpm a Measure resistance between pin 2 and pin 38. Nominal value approx. 350 Ohms b Check that pin 2 und pin 38 are free from shorts to ground. - Check o.k. ECU faulty 2 Also...
Front Axle
Adjust camber by turning eccentric bolt arrow . Adjust caster by moving the rear of suspension control arm from side to side. Center steering gear with special tool 9116 and adjust toe at tie rods. Steering difference angle cannot be adjusted. It can only be affected by replacing steering arm. REAR AXLE upto 1978 Models Adjusting Camber Rear wheel toe can be adjusted by moving trailing arm within slots with respect to torsion plate. Adjust toe angle using special tool US 4437 A. When tightening...
Adjusting gearshift
1. Set manual shift lever No. 3 to idle position. The transverse selector shaft is now in the 3rd and 4th gear shift plane. With the gearshift mechanism adjusted correctly, the shift lever No. 3 is not Inclined in transverse direction. Undo lock nuts No. 1 and turn centerpiece of the joint rod No. 2 until no transverse inclination remains anymore at the shift lever No. 3 . 2. To adjust shift lever, move the shift lever support mount arrow to the front or rear until the inclination is 85'. The...
Rear suspension 1
The main rear suspension components are the trailing arms, torsions plates, torsion bars, and shock absorbers. Torsion plates connect the wheel bearing housings to the transversely mounted torsion bars. The torsion bars, housed within the rear suspension subframe, are adjustable by means of unequal-numbered inner and outer splines. The rear wheel bearings are housed in the trailing arms. They are sealed and require no lubrication or adjustment. Half axle shafts with one constant velocity CV...
Retrofitting of a CD changer
92 00 19 Removing and installing windshield wiper system 92 00 19 Removing and installing windshield wiper system 92 00 19 Removing and installing windshield washer Connector housing for heated spray nozzle Disengage wires with commercially available extracting tool 92 00 19 Removing and installing headlight washer system
Wipers And Washers
If you have wires attached to your lock, your car was fitted with the factory alarm option. Remote rear hatch release failure is a common problem. To trou-bleshoot the problem, first check both fuses on the relay board. If you hear the motor turning but the hatch does not release, you may have an alignment problem. Most commonly, the release arm will not push the upper hatch release far enough. The easiest solution is to place a small shim under the forward end of the upper lock, altering the...
Removing And Installing Brake Pressure Regulator
1. Remove intake hoses and air cleaner upper section. 2. Drain both chambers of brake fluid tank by pumping out brake fluid through bleeder valves of front and rear wheel brake calipers diagonal brake circuit division . 1. Check brake pressure regulator car application on page 47-18. 2. Install brake pressure regulators. The mounting plate has a retaining tab for each brake pressure regulator to guarantee correct installed position and prevention of turning when tightening bolts 3. Detach brake...
Installation 1
3. Introduce drive shaft and tighten pan-head screws to 42 Nm 31 ftlb M 8 or 80 Nm 59 ftlb M 10 , respectively. 4. Coat seating surface of new M 22 x 1.5 lock nut with Optimoly HT and tighten to 460 Nm 339 ftlb . 1. Coat teeth, thread and stem of drive shaft with Optimoly HT. 2. Put shims on pan head screws and coat threads lightly with Optimoly HT. Insert pan head screws with shims into drive shaft flange, making sure the flange cover is not greased inadvertently. Wheels and tires Tire...
Light buzzer
Actuate drive link with F8 key Off On Test Noise inspection warning signal emitted Actuate drive link with F8 key Off On Test Noise inspection warning signal emitted Actuate drive link with F8 key Off On Test Noise inspection warning signal emitted Actuate drive link with F8 key Off On Test Noise inspection warning signal emitted
Tightening torques for mechanical brake system
Brake calipers to front and rear axles Brake disk to wheel hub front and rear axle Brake cover plate to front and rear axles
Determining engine speed sender clearance Tiptronic vehicles
The following spare parts and tools are req. for the Determining engine speed sender clearance operation
Installing coolant pump
Install rear-wall lining, service cover and left-hand seat Undo hexagon-head bolts. The lower right hexagon-head bolt is difficult to reach. To undo it, use flexible-head socket wrench 4001-10 by Stahlwille. Cut old metal seal between coolant pump and water guide housing at the connecting webs. Cut new spare metal seal combination seal for coolant pump and water guide housing at the connecting webs. Fit new sea and coolant pump simultaneously and fasten. Tightening torque 10 Nm 7 ftlb. . Fit...
A 911 521 007 07
seat and backrest surface porsche lettering cloth sports seat leatherette centre part head rest sports seat leatherette centre part head rest
Fill In ATF fluid
With the engine stopped, start by adding ATF fluid via the quick-fill adapter up to mark 1 on the reservoir. A Quick-fill adapter B Filler hose C Filling mark With selector lever set to ,,P, start engine and let engine idle, observing ATF level at reservoir and topping up to mark 1 immediately if required.
Clutch release lever lubricating cable operated clutch
If the clutch pedal is sticking or not returning all the way, the problem may be in the clutch release lever or auxiliary spring bushings. Do not apply lubricant to the pedal bushings to alleviate stiff pedal operation. Most lubricants will cause the bushings to swell. Raise car and support in a safe manner. Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Working under...
Lr1 Lr2
grey-beige grey-beige-grey F gt gt 94DN4 56824 black grey black F 94DN4 56 82 5 gt gt brown beige brown F 94DN4 56 82 5 gt gt grey-beige grey-beige-grey F 94DN4 56 82 5 gt gt seat and backrest surface porsche lettering cloth seat and backrest surface porsche lettering cloth seat and backrest surface porsche lettering cloth
Removing And Installing Bumpers
The front and rear bumpers are bolted to the bumper brackets with 2 each M 10 x 60 hexagon head bolts, plain washers and lockwashers. Fog lights and turn signals can either be removed with the front bumper, or removed separately. Fit and mount bumper brackets parallel to the body contour. The rear bumper and bumper brackets are mounted in the same manner.
Sealing the rear window Insulating the gap between rear window and body
The following tools and materials are needed for insulating the gap between the rear window and the body. B cartridge of insulation material C application nozzle Insulating the gap between rear window and body
Insulating the gap between rear window and body
Loosen and remove cover strip of rear window. Clean gap between rear window Wash out the gap between rear window and body with Dry gap between rear window and Dry the gap between rear window and body using corn-body. pressed air all around the rear window. Apply masking tape around the rear window, making sure that the mounting section for the cover strip is Apply masking tape all round the body opening for the rear window up to the edge of the gap. 5 Apply insulating material. Screw...
Oxygen sensor replacing
The oxygen sensor monitors engine combustion efficiency by measuring the oxygen content of the exhaust gasses. The output signal from the sensor is used to precisely control fuel delivery. Any problems with the oxygen sensor will directly affect exhaust emissions and the way the engine runs. Replacement of the oxygen sensor at the specified interval ensures that the engine and emission control system will continue to operate as designed. To remove sensor arrow from catalyst Detach oxygen sensor...
Clutch crossshaft bearing update hydraulic operated clutch
On G50 transmission built before April 6,1989, the clutch cross-shaft should be converted to the updated cross-shaft and release fork assembly. The cross-shaft update should be made whenever transmission or clutch repairs are being performed. On transmissions built from April 6, 1989, this update was part of the factory production. Standard differential up to 950 01 1K 03381 Limited-slip differential up to 950 01 2K 01159 The cross-shaft update consists of cutting the bearing bores using a...
Technology wheel TurboLook Design wheel
Technology wheels are hollow-spoke wheels. A new process is used to produce these wheels. The wheel rim and disk are two separate components which are joined by fric- With this new Porsche process, the wheel The wheel disk of Turbo-Look Design wheels is not hollow. Technology and Turbo-Look Design wheels The Technology wheel No. 1 has a steel valve, diameter approx. 8 mm. The Turbo-Look Design wheel No. 2 has a rubber valve, diameter approx. 11.3 mm. For additional distinguishing features on...