Evaporative emission control system
The charcoal canister collects and stores fuel vapors from the tank when the engine is idling or stopped. During normal driving, the fuel vapors are drawn into the engine and burned. A faulty evaporative emission control system can cause hard warm starting, erratic idle, or poor acceleration if the fuel vapors are drawn into the engine at the wrong time. A restrictor prevents rapid purging of the charcoal canister. A faulty evaporative emission control system usually affects driveability only...
Alternator replacing
Disconnect negative - battery cable and cover battery terminal to keep cable from accidentally contacting terminal. Be sure to read the battery disconnection cautions given on page viii before disconnecting the battery. Remove A C drive belt as described in 870 Air Conditioner. Remove V-belt. Reinstall pulley and nut fingertight. Remove alien bolt A from cooling housing strap. Remove bolts B from engine cooling shroud. Remove spark plug wire supports C . Pull alternator and fan out toward rear...
Front strut cartridge removing and installing
Remove front suspension strut as described earlier. Remove dust cover and rubber bumper from strut piston rod. Clamp housing in vise or other strut holding device. Using strut nut wrench, remove strut cartridge cap. Pull cartridge out of strut housing. Empty out oil in strut housing. Reassembly is reverse of disassembly. Strut cartridge cap to strut housing 120 20 Nm 87 14 ft-lb
Wheel Alignment
Replacement and or removal of front or rear suspension components, such as front or rear torsion bars or rear torsion plates, disturbs the wheel alignment settings. Replacement or adjustment of the torsion bars, rear torsion plates or rear trailing arms can affect vehicle ride height, which directly influences vehicle stability, chassis balance and even braking at all wheels. Vehicle balance weight must be checked at all four wheels, and ride height must be reset. See Extended alignment later...
transmission components
Remove end cover mounting nuts and washers arrows . Slide cover off selector shaft. Lock transmission input shaft with special tool P 37 a. Push 5th - reverse operating sleeve in to engage 5th gear. NOTE With input shaft locking tool installed and transmission in 5th gear, both shafts should be locked in place. Remove roll pin from castle nut on input shaft. Remove nuts arrows from input and output shafts. Remove input shaft locking tool special tool P 37 a . Remove reverse light switch...
Manually bleeding brakes
Using clean syringe, remove old brake fluid from reservoir. Clean out reservoir with a lint-free cloth. Top off brake fluid and replace reservoir cap. Connect bleeder hose and waste bottle to right rear bleeder screw. Have helper pump brakes several times. Then hold pedal down firmly on last pump. Open right rear caliper bleeder screw and allow fluid to expel. Close bleeder screw. Repeat previous two steps at least 12 times, or until discharged brake fluid is clean and without air bubbles....
Power Distribution 19861987 2 of 3
FROM FUSE 1 p. DIAGRAM ,E gt 1 OF 3 ADDITIONAL CLEANING FLUID PUMP RELAY FROM IGNITION SWITCH te-. DIAGRAM 1 OF 3 PASSENGERS PASSENGERS PASSENGER'S 4-WAY -WAY 4-WAY SPEEDO- CONVERTIBLE CONVERTIBLE METER TOP TOP FROM ALTERNATOR ffc. DIAGRAM y 1 OF 3 FROM IGNITION SWITCH DIAGRAM 1 OF 3
Porsche special tools
Some of the repairs covered in this manual call for the use of Porsche special tools. Many of the special tools are simply the best thing to use to do the job correctly. In these cases, the tool is identified with a part number and an ordering number, where available. This, however, does not automatically mean that the job is too complicated or out of reach of the novice. For example an affordable and very useful special tool is a hose clamping tool. This tool is helpful to clamp off fluid...
Rear shock absorber to body M1025 Nm 18 ftlb
TRAILING ARMS, TORSION PLATES AND TORSION BARS Replacement and or removal of the trailing arm, torsion plate or torsion bar disturbs the rear wheel alignment settings. Replacement or adjustment of the torsion plate or torsion bar also affects vehicle ride height, which directly influences vehicle stability. If ride height is changed, it is strongly recommended that the vehicle balance weight be checked at all four wheels using suitable wheel-load floor scales. See 440 Wheels, Tires, Alignment...
Battery
Electrolyte contains sulfuric acid and can cause severe burns. -Wear goggles, rubber gloves, and a rubber apron when working with battery electrolyte. -If electrolyte is spilled on your skin or clothing, flush the area at once with large quantities of water. -If electrolyte gets into your eyes, bathe them with large quantities of clean water for several minutes and call a physician. Batteries generate explosive gasses. Keep sparks and open flame away. Do not smoke. Replace a battery if the...
ani
Right Camshaft Pressure-Fed Tensioners Right Camshaft Pressure-Fed Tensioners Overflow to Crankcase Left Camshaft Overflow to Crankcase Left Camshaft The main bearings, rod bearings and camshaft bearings are supplied with pressurized oil. In addition, the undersides of the pistons are cooled using oil spray jets. Oilways in the camshaft cases provide splash lubrication for the rocker shafts and valve stems. A thermostat in the main oil circuit regulates the flow of oil to the engine oil cooler....
Vacuum bleeding brakes
Using clean syringe, remove old brake fluid from reservoir. Clean out reservoir with a lint-free cloth. Top off brake fluid and replace reservoir cap. Connect vacuum pump to right rear brake bleeder screw. Route discharge hose into waste bottle. Vacuum bleeding requires an air-tight seal between the pump and the bleeder screw. Any leakage will result in faulty bleeding. Open bleeder screw and withdraw brake fluid until it is clean and without air bubbles. Fill the brake fluid reservoir level...
Clutch master cylinder replacing
Working inside car, remove driver's floor mat. Pull accelerator pedal back to release accelerator push rod. Remove accelerator pedal mounting screws A and remove pedal. Remove pedal cluster cover after removing fastener at bottom and unhooking from above arrows . Disconnect brake push rod from brake pedal. Disconnect return spring from brake pedal. Disconnect clutch master cylinder push rod from clutch pedal. Inspect contact surfaces of slave cylinder push rod and release bearing lever for...
Fuel Supply
GENERAL 201-1 Test equipment 201 -1 Warnings and cautions 201-2 FUEL TANK AND LINES 201-3 Fuel tank, draining 201-3 Fuel tank, removing and installing 201-4 Fuel level sending unit 201-5 removing and installing 201 -5 Fuel level sending unit, testing 201-6 FUEL PRESSURE CHECKS 201-7 Relieving fuel pressure and connecting fuel pressure gauge 201-7 System pressure, testing 201-7 Fuel delivery volume, testing 201-9 FUEL PUMP ELECTRICAL CHECKS . . .201-9 Fuel pump, troubleshooting 201-9 Operating...
Door panel removing and installing
Remove trim screw and trim piece right arrow at front door edge. Remove two screws behind trim piece. Pry off concealing plug at rear of trim panel and remove screw behind plug left arrow . Remove upper trim panel by lifting up and over door lock pin. Pry off cover from door lock knob arrow . Remove knob mounting screw and knob. Remove lock knob trim by turning counterclockwise Remove screws from map pocket perimeter arrows and remove carpeted map pocket. Remove two screws from pocket door...
Alarm system switch testing
Alarm switch in off position. Ignition switch in off position. Remove alarm switch as described later. Measure resistance between terminals arrows . Alarm switch on, key horizontal 2-3 KQ. Alarm switch off, key vertical 4-5.5 K I Replace switch if resistance not as specified. Alarm circuit, testing Alarm circuit is tested with battery connected. Use care when connecting and disconnecting plugs. DO NOT allow any wires to touch vehicle body. Remove fresh air plenum in luggage compartment to...
Operating fuel pump for tests
To operate fuel pump for testing purposes without having to run engine, main fuel pump relay, located under driver seat, can be bypassed to power pump directly. Working below driver's seat, disconnect harness connector from main fuel pump relay arrow . Connect socket for relay terminal 30 to the socket for relay terminal 87b with fused jumper wire. After completing tests, remove jumper wire. The main fuel pump relay has a 4 mrrf red wire at terminal 30 in the relay socket. Terminal 87b has a...
Alignment
Wheel alignment is the precise adjustment of the steering and suspension components to ensure that all wheels are oriented correctly, compared to the other wheels, the chassis, and the direction of travel. Small changes can have a big effect on how the car drives. Proper alignment provides the best compromise between responsiveness, stability, and tire wear. Alignment specifications differ from model to model. It is important to use the correct alignment specifications for the specific car....
Shifter housing removing and installing
Remove left and right side screws securing front cover to center console. Slide cover forward of center console. Remove three screws holding center console to floor. Screw on left shown A . Right side is similar. Pull back rug slightly to reveal screw in middle of rear B . Without disconnecting wiring harnesses, lift center console over shifter and lay to one side. '. Detach leather shifter boot from foam rubber cover arrow . Pull shifter boot up to expose rubber o-ring arrow securing boot to...
Brake pad wear warning system
The brake pad wear warning system warns the driver with a light on the instrument panel when the pads are worn. This warning system should not be ignored. Failure to replace the pads soon after the light comes on may cause caliper or rotor damage that will add to the cost of repairs. A brake pad warning sensor is used on the inner pad of each brake caliper. The pad wear sensors are plugged into the pad wear warning system. The plug for each front sensor is clipped to the side of the front...
Cylinder Heads
Special CYLINDER HEADS 150-2 Cylinder head service 150-3 Valve guide, checking 150-4 Valve guide, replacing 150-4 Valve seat, checking 150-5 Valve seat, replacing 150-5 Valve seat, cutting 150-6 Valve spring height, setting 150-6 a. Valve Guide Outside Diameters 150-4 b. Valve Seat c. Valve Seat Cutting Guide 150-6 d. Valve A 1020 source Baum Tools Unlimited Valve spring compressor B P 206 Valve guide go nogo gauge Porsche ordering 000 721 206 00 C 87a source Baum Tools Unlimited . Valve guide...
Disabling ignition system
The ignition system should be disabled when making certain tests such as compression test or starter current draw test. Detach electrical harness connector to DME main relay arrow located under driver seat to disable ignition system. See 971 Electrical Component Locations for more information. Do not touch or disconnect any of the high tension cables from the coil, distributor cap or spark plugs while the engine is running or being cranked by the starter motor. Fatal voltage are present....
Car will not start
If the engine turns over slowly or not at all, especially on cold mornings, the battery may not be sufficiently charged. Jump-starting the battery from another car may help. Push starting or bump starting a car is not recommended. Be sure to read the cautions under Jump starting car prior to boosting a low battery. Failure to follow the cautions may result in damage to the electronic components in the car. If the engine is turning over at normal speed with the starter motor, the battery and...
Fuel Delivery Tests
Checking fuel delivery is a fundamental part of troubleshooting and diagnosing the engine management system. Fuel pressure directly influences fuel delivery. An accurate fuel pressure gauge will be needed to make the tests. Three significant fuel delivery values can be measured System pressure is created by the fuel pump and maintained by the pressure regulator. Fuel delivery volume is created by the fuel pump and affected by restrictions, such as clogged fuel filter. Residual pressure is...
General Jbd
The targa top is secured to the roof bar by means of three pins, and to the windshield frame by two locks, facilitating easy removal and installation.
Targa top folding and unfolding
Once it is removed from the car, the targa top must be folded in order to be stored in the luggage compartment. To fold or unfold, support the rear edge of the roof on a soft surface. The toes of your shoes work well in this operation. Folding Apply pressure simultaneously to middle of both hinged bows. Finish folding by applying light pressure to sides. Unfolding Simultaneously push both hinged bows outward to locked position.
Firing order
To determine start of firing order, inspect lip of ignition distributor body for cylinder 1 scribe mark arrow . The ignition rotor turns in a clockwise direction. Spark plug wires must be installed so that the spark plugs fire in the correct order. Porsche 911 Cylinder 1 is at left rear when viewing engine from rear of engine compartment.
Towing
The cars covered by this manual should be towed with a tow truck using wheel lift or flat bed equipment. Do not tow the car on all four wheels except for very short distances to move it to a safe place. Tow hooks are located under the front bumper. When towing the car from the front with the rear wheels on the ground, a maximum distance of 20 miles is acceptable. If the car needs to be towed further, have the rear wheels placed on dollies. Do not tow with sling-type equipment. The front...
Brake Pads And Rotors
Brake pads can be replaced without disconnecting the brake fluid line from the caliper or having to bleed the brakes. Brake rotor removal and replacement requires that the caliper be disconnected from the brake line in order to avoid bending the metal line. The rear rotors can be replaced without dissembling the wheel hub and bearing, but front rotor replacement requires that the wheel bearing hub be removed with the rotor and disassembled on a work bench. Always machine or replace brake rotors...
Door check removing and installing
Disconnect battery negative - cable. Prior to disconnecting the battery, read the battery disconnection caution given at the front of this manual on page viii. Installation is reverse of removal. Remove interior door panel as described earlier. Drive out door check pivot pin arrow . Remove door check mounting bolts at door edge arrows . Withdraw door check from inside door.
Fuel injectors testing
The injectors are turned on and off by the DME engine control module ECM . The quantity of fuel delivered to the engine is determined by the amount of time the injectors remain open. Injectors tests include electrical checks for resistance, power and ground signal from the ECM. Injector flow tests require specialized equipment that opens each injector for a precise amount of time to measure fuel delivery. Most authorized Porsche dealers can perform an injector balance test to locate clogged or...
Oxygen sensor system
The oxygen sensor system provides the ECM with feedback information about combustion efficiency. The signal is used to continuously control the air-fuel mixture. One surface of the exhaust-mounted oxygen sensor is exposed to the exhaust gas, while the other surface is exposed to the atmosphere. The difference in oxygen content between the two surfaces causes a chemical reaction that generates a low voltage electrical signal 100 - 900 mV . The low voltage signal of the oxygen sensor is not...
Clutch release bearing replacing
Lay clutch pressure plate with release bearing facing down in a press. Lightly press down on pressure plate, using suitable spacers and a steel bar. Remove release bearing locking ring. Early pressure plate shown. Later models are similar. Remove from press and remove release bearing from pressure plate. Release bearings are filled with a special grease and consequently must not be washed. When reinstalling release bearing, place shims and spring washer on first. Clutch pressure plate and...
Front wheel toe adjusting
Check to see if steering rack is in its center position when steering wheel is centered Starting from center position, turn steering wheel in one direction to stop, counting turns. Turn to stop in opposite direction while counting turns. If necessary, remove and center steering wheel at half the number of turns from stop to stop. Loosen 22 mm inner and outer tie rod locking nuts arrows . Adjust tie rod by turning center tube to change length. To keep steering wheel centered, adjust both tie...
Front wheel bearing play adjusting
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. Carefully pry off grease cap in center of bearing hub. A Loosen 6 mm alien clamp screw in wheel bearing lock nut. Loosen bearing lock nut approximately 14 turn. While rotating brake disc and bearing hub, tighten lock nut slowly in small increments...
Braking system 1
Porsche 911 Carrera models are equipped with power-assisted four-wheel disc brakes. A brake booster power-assists a dual-circuit master cylinder. A vacuum boost system is used in all models. Dual-piston calipers act on vented front and rear rotors. A brake pad wear sensor for each wheel indicates when pads need replacement. The parking brake is mechanically operated via dual cables. The parking brake system is independent of the rear disc brake system. The drum-style parking brake shoes act on...
Front wheel bearings replacing
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. Press brake pedal down about 1 in. and hold in place with a pedal stop. Holding the brake pedal down will prevent brake fluid from dripping out of open brake lines while the work is being performed. Working in wheel housing, disconnect electrical...
Rear wheel camber and toe adjusting
While performing alignment procedures, 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. Changing camber at one rear wheel will cause a change in the load at that wheel and consequently at all other wheels. Be sure to check vehicle corner loads as a final check. Changing camber at one rear wheel will also affect the toe setting at that wheel. A change in the rear toe by...
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...
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...
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...
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...
Fresh air valve cable adjusting
Access fresh air blower as described earlier. Remove bowden cable retaining spring clip arrow . Working at dashboard ventilation controls, slide fresh air lever to extreme left. Reinstall retaining spring clip. Check that flap operates smoothly and correctly.
Starting system troubleshooting
The battery and its cables should be in good condition when troubleshooting the starter. If in doubt about the battery, test as described earlier. Starter efficiency is affected by engine oil viscosity. This is especially true in cold weather. Table e lists symptoms of trouble with the starting system, their probable causes, and suggested corrective actions, most described later in this group. See 970 Electrical Wiring Diagrams for a wiring schematic of the starter system that can be used as a...
Oxygen sensor checking
Basic checking of Oxygen sensor efficiency using a pinout test harness Porsche special tool 9543 or equivalent is described below. Exhaust system parts can be hot enough to cause serious burns. When working near hot pipes or mufflers, use heavy gloves and other appropriate protection. For the most accurate test results, the engine must be fully warmed up, the exhaust system must be free of leaks, and all electrical consumers must be off. Disconnect ECM harness connector and connect pinout test...
Fuel Injection
Test Warnings and cautions 240-2 DME engine management, general 240-3 Emission controls 240-3 Basic engine settings 240-4 Ignition Throttle plate basic adjustment 240-5 FUEL DELIVERY TESTS 240-5 connecting fuel pressure gauge 240-6 Operating fuel pump for tests 240-6 System pressure, testing 240-7 Fuel delivery volume, testing 240-8 Residual fuel pressure, testing 240-9 COMPONENT TESTING 240-10 Fuel injectors, testing 240-10 Engine control module ECM 240-12 accessing for tests 240-13 Main fuel...
Clutch cable replacing
Raise car and support in a safe manner. Working under rear of car, loosen clutch cable housing lock-nuts A . Detach cable from clutch release lever. Working inside car, remove driver's side floor mat. Pull accelerator pedal back and disconnect accelerator push rod from pedal. Remove accelerator pedal mounting screws A and remove pedal. Remove pedal cluster cover by removing fastener at bottom and unhooking from above arrows . 5. Clevis clevis pin locking clip 5. Clevis clevis pin locking clip...
Heater blower motor removing and installing
The heater blower motor is located on top of the engine on the left side. Disconnect electrical harness connector A from blower. Detach blower air intake duct B . Remove two bolts at front and rear C from output elbow and detach elbow. Remove blower motor mounting fasteners arrows . Remove blower motor. Installation is reverse of removal.