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...
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....
Removing And Installing Rear Axle
2. Detach brake line at caliper and rear axle trailing arm. First depress brake pedal somewhat with pedal strut to prevent the brake fluid from escaping out of the 3. Disconnect stabilizer at rear axle trailing arm. 4. Detach drive shaft at transmission flange. 4. Detach drive shaft at transmission flange. 7. Lift rear axle strut with special tool P 289. Detach shock absorber at rear axle trailing arm. 8. Remove special tool P 289. Pull out drive shaft with joint toward inside of car. 9. Remove...
Machining Strut Retractor P 289
Various modifications have been made on the rear axle of 911 911 Turbo cars since the beginning of production. Consequently the holder on P 289 must be adapted to the present state. If tool is not changed, the light alloy rear axle trailing arms could be damaged when clamping the tool between spring strut and trailing arm to tighten the mounting bolts.
Current flow diagram 930 Turbo USA Model 78
E1 - Headlight switch 6,8,9,11,15,20 E3 - Emergency flasher switch 24,25,28,31,34 E6 - Headlight flasher switch 4 E20 - Instrument panel illumination potentiometer 20 E26 - Switch for glove compartment light 41 F5 - Switch for luggage compartment light 42 F32 - Manifold pressure limiting switch 59 H - Key warning buzzer contact 43 J1 - Hazard turn signal flasher 33,34,35 J 16 - Relay boost switch air meter contact 59,60 J - Relayforfuel pump I 54,55 J 27 - Diode for seat belt warning system 46...
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At engine speed of 4000 rpm ignition advance must be 26 t 4 before TDC. Vacuum advance hose disconnected At engine speed of 4000 rpm ignition advance must be 31 t 4 before TDC. Vacuum advance hose disconnected, but retard hose can remain connected as long as the test is made without engine load. If specified values are not reached, remove distributor and check in a test bench. CENTRIFUGAL ADVANCE CURVE - TURBO ENGINE 19 78 - U S A C A LI F O RNIA BTDC CENTRIFUGAL ADVANCE CURVE - TURBO ENGINE 19...
Adjusting Ignition Timing 19 78 Model
USA 10 - 2 ATDC at 950 - 1050 rpm Vacuum hoses ON California 5-1 ATDC at 950 - 1050 rpm Vacuum hoses ON Adjustments are made when engine oil is at a temperature of approx. 80 C 176 F . Pertinent mark on pulley must align with notch in blower housing at specified engine speed. After adjustment of the ignition timing, check ignition timing advance see page 28-4 c .
Disassembling And Assembling Front Wheel Brakes 1
1. Check condition of all parts and replace, if necessary. Bridges of brake calipers have cast bosses since 1984 models and this has changed the brake guards. Only brake calipers or caliper bridges with cast bosses are available for replacements after depletion of stocks in older models. In this case the new brake guard must also be installed or the old guard changed accordingly cutoff . 2. Clean centering surface for brake disc on wheel hub and apply a very thin coat of Optimoly TA. 3....
Location Of Relays In Car
Six standard relays are located in the fuse box in the luggage compartment. 1 - Air conditioner relay front in driving 5 - Electric window winder relay 6 - Fuel pump relay I front 7 - Fuel pump relay II rear The standard relays for the rear window defogger, turn signal emergency flasher lights and seat belt warning system are located on left side of luggage compartment floor as seen in driving direction - same as for the Type 911. The relays are accessible from the luggage compartment or after...
Current flow diagram 930 Turbo USA Model 77
E' - Headlight switch 6,8,9,11,15,20 E3 - Emergency flasher switch 24, 25, 28, 31, 34 E5 - Headlight flasher switch 4 E2 - Instrument panel illumination potentiometer 20 E26 - Switch for glove compartment light 41 F5 - Switch for luggage compartment light 42 F 32 - Manifold pressure limiting switch 59 H6 - Key warning buzzer contact 43 J' - Hazard turn signal flasher 33,34,35 J 16 - Relay boost switch air meter contact 59,60 J 17 - Relay for fuel pump I 54,55 J 27 - Diode for seat belt warning...
Removing And Installing Air Injection Line And Adapter
1. Remove heat exchanger and reactors. 3, Loosen air injection line and connections at adapters. Loosen the oil line slightly at the front left adapter and move aside for clearance. Removing and Installing Air Injection Line and Adapter CHECKING CONTROL VALVE, DIVERTER VALVE AND CHECK VALVE In operation control valve, diverter valve and check valve are connected with each other. A defective control valve could also destroy diverter valve as well as check valve. Always check all three parts, if...
Heater Controls
Checking Heat Sensor in Heater Flap Housing 2 - Connect ohmmeter to 2-pole plug of 135 ohm with warm engine at 100 C. Replace heat sensor if resistance is way off see Checking Interior Sensor . An interruption in one of the sensors or in the wires to the control unit will fake a too low or, a short circuit, a too high inside temperature. This will result in an improper movement of the heater lever up or down. Checking Power Supply to Control Unit 1 - Remove right side cover of control unit. 3 -...
Centering Discs 9109
N 18 is the deviation r on face of drive pinion. 4. Install thrust washer and cylindrical roller bearing. 5. Mount gear housing and secure with two nuts. N 12 is the deviation r on face of drive pinion. r Deviation __Q_.1_2_mm_ 7. Place appropriate pin or reverse gear shaft in bore of transmission case and slide in reverse gear II. 8. Torque drive pinion nut to specifications. 13. Set master gauge VW 385 30 to pinion setting 82.41 mm in example and place on master mandrel. Set dial gauge 3 mm...
Adjusting Ring Gear
Determining total shim thickness St t Sq S2 . Ring gear must be readjusted after replacement of tapered roller bearing for differential, differential housing or pinion ring gear set Drive pinion must be removed to determine preload of tapered roller bearing for differential. 1. Make sure tapered roller bearing outer races fit tight in transmission case or side transmission cover. 2. Install pertinent differential with one each 2.5 mm thick spacer on the ring gear end and opposite end. 3. Insert...
Troubleshooting Automatic
2 - Using an ohmmeter with an appropriate testing range, check the resistance between both coaxial connections on the sensor use test points . The resistance is very dependent on the temperature and should be about 1.5 kOhm at room temperature. Replace the temperature sensor if the resistance is about oo ohm interuption in sensor or about O ohm short circuit in sensor .
Axle Alignment Specifications
The following specifications apply to a car at curb weight according to DIN 70020 car with full fuel tank, spare wheel and tools . In brackets Turbo Carrera USA, Turbo Canada, Japan until end of 1982 models only. Beginning with 1983 models same values as for R. o. W. models. Difference angle at 20 lock toward toe Camber, front wheel pointing straight ahead Cross tube center to rear wheel cen. Can only be adjusted by replacing steering levers
Adjusting Igniton Timing
1. Connect engine tester or tachometer. This requires separating a 2-pole plug connector near CDI control unit. The connection can be made again with jumper wires, with a connection to black violet wires. Tachometer or engine tester is connected to this wire, which in turn usually goes to terminal 1 of the distributor. Standard tachometers engine testers normally connected to standard coil-type ignition, can also be Depending on type of tester used, tachometer installed in car could return to...
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3. Press release lever forward with a suitable tool to disengage . 1. Slide release lever with spring on to lever Printed in Germany - V, 1984 Removing and Installing Clutch Release Spring 30 - 11 2. Press back release lever with a suitable tool until release spring passes the top dead center point lever snaps against stop on console . 3. Remove adjusting lever again and mount as close as possible to release lever. 4. Make basic clutch adjustment. 30-12 Removing and Installing Clutch Release...
Checking Function Of Manifold Pressure Limiting Switch
1. Remove manifold pressure limiting switch. 2. Clamp manifold pressure limiting switch carefully. 3. Connect ohmmeter between switch housing and connecting terminal. Check that ohmmeter reads 0 ohms. 4. Install tubeless tire valve without valve insert on threads of switch. 5. Connect air pressure hose to pressure gauge at valve . 6. Increase pressure carefully. Check that ohm meter goes to OO at about 1, 5 bar. 7, Drop pressure slowly until ohmmeter again goes to 0, Now read pressure which...
Removing And Installing Air Pump
2. Loosen clamps and remove hose between mixture control unit and valve housing. 4, Peel off toothed belt and remove air pump with mount. 1. Install air pump with air pump mount and install toothed belt. 2. Press air pump to the left slightly and tighten the bolt on air pump bracket. Under thumb pressure, the toothed belt should deflect at midpoint by 6 - 8 mm 1 4 to 5 16 in. .
Adjusting Idle
Engine must be in perfect mechanical condition and ignition timing set correctly. 1. Run engine to operating temperature about 80 C 176 F . 5. Connect CO tester and separate tachometer according to manufacturer's instructions. Separate 2-pole plug connector when connecting tachometer. Use jumper wires to bridge connectors and provide terminal for connecting black violet wire to tachometer or engine tester. Black violet wire normally goes to terminal 1 of the distributor. The tachometer or...
Checking And Adjusting Drive Belt Of Air Pump
Drive belt tightness is correct if belt gives under thumb pressure applied at point midway between sprockets by 6 to 8 mm. 2. Turn self-locking adjusting bolt until belt tightness is correct. Tighten bolt. 3 - Control pressure regulator 4 - Auxiliary air regulator 10 - Intake air intercooler OPERATING AND TESTING THERMO TI AND 930 6 3 Thermo time valve in vacuum line between distributor and throttle housing is closed on a cold engine. This eliminates vacuum retard control and the ignition...
Checking And Adjusting Air Flow Sensor Plate At Rest Position
1. Pall off plug for safety switch on mixture.control unit. Turn ignition on and off again after approx. 10 seconds. Upper edge of air flow sensor plate must be flush with beginning of cone or max. 0.5 mm higher try for lower position . 2. Air flow sensor plate must be level and centered in the venturi cone. The edges of the plate mus1 not touch the sides of the cone and restrict the free movement of the plate and lever. An excessively high air flow sensor plate setting can be corrected by...
Checking Boost Pressure Gauge
If boost pressure gauge in tachometer fails, check all wire connections on tachometer or boost pressure sender against wiring diagram. Pull off wire on boost pressure sender. Turn on ignition. Boost pressure gauge needle must deflect fully. Hold disconnected wire against ground. Needle must return to zero. If gauge is OK, trouble is in pressure sender. If gauge is defective, tachometer will have to be replaced. Resistance of boost pressure sender measured between connecting lug and housing must...
Info Uty
Air cleaner must be installed for all adjustments. 1. Detach air hose from air pump and install a suitable plug in open end of hose. 3. Adjust mixture. Insert special tool 9156 into spring.-loaded Allen key in mixture control unit. Press down special tool approx. 18 mm to engage spring-loaded Allen key in mixture control screw. Figure shows control screw without air cleaner ADJUSTING IDLE - US CARS SINCE 1986 MODEL Engine Type 930 68
Checking Pistons And Cylinders
D1 Measuring point for wear and ovality 30 mm below upper edge of cylinder The cylinder is worn if the measurement is 0.08 mm more than the size at installation. Measurements are made in directions a and b to check ovality. The amount of deviation between a and b should not exceed 0.04 mm. D2 Measuring point for piston ring end gap Rings slid in at height of cylinder base gasket. D Measuring point for wear At lower edge of piston pin bore. Replace piston and cylinder if clearance exceeds 0.15...
Delayed Ignition Cutoff
A time delay relay for ignition cutoff will be installed in 19 77 Turbo Carrera Model. An open circuit in diode could prevent energizing of alternator charge indicator light does not come on while turning on ignition . lt 4L lt . Le lt .f A break in diode in blocking direction will be noticed by extended engine run-on after turning it off. When stopping engine, only fuel pumps are turned off at first. After a time delay of 3 to 5 seconds power supply for GDI control unit is broken...
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Testing and Adjusting Data for CIS Fuel Injection TESTING AND ADJUSTING VALUES FOR K-JETRONIC SINCE 1986 MODEL Engine Type 930 68 Control pressure cold equal to outside temperature System pressure Test value Adjusting value Minimum pressure after 10 minutes after 20 minutes Control pressure circuit Delivery rate at least 1500 cc 30 sec. valid for both pumps together Diagram for warm-up regulator Part No. 930.606.105.06 Bosch No. 0 438 140 153 3.75 0.20 bar kp crri2 2.90 0.20 bar kp cm2 6.7 to...
Porsche 930 Warm Up Regulator
A pressure above 0.8 bar 11 psi could damage the diaphragm in the warm-up regulator. Control pressure will now drop and must reach the specified value with warm-up regulator out of action see page 25 - 16 . If necessary, replace regulator. 3. Connect tester VW 1274 with locally made adapter on disconnected hose to warm-up regulator . 25-14 Checking Warm Control Pressure Checking Control Pressure Warm - Full Throttle Enrichment
Checking Clutch Disc
1. Check teeth. The clutch disc must move easily in axial direction on drive shaft without radial play. 2. Check rivets. Replace clutch disc if in doubt. 3. Check clutch lining. If clutch lining has oil spots, is burnt, torn or worn at spots, install a new disc. 4. Check lining thickness. Thickness of disc with riveted lining no tension is 10.1 0.3 mm. Wear limit no tension is 8.5 mm for symmetrical wear. The MFZ clutch pressure plate from Fichtel and Sachs is not designed for reconditioning or...
Testing And Adjusting Data For Cis Fuel Injection
Control pressure cold' acc. to outside temp. Control pressure warm Engine Type 930 51, 930 53 min. pressure after 10 minutes 20 minutes Diagram for warm-up control Part No. 911.606.105.02 and 930.606.105.00 Bosch No. 0 438 140 016 and 0 438 140 022 2.6 -3.0 bar atm 6.0 - 6.7 bar atm Engine Type 930 51 1 to 3 930 53 2 to 4 Testing and Adjusting Data for CIS Fuel Injection TESTING AND ADJUSTING DATA FOR CIS FUEL INJECTION 1978 MODEL 25 - 16 Testing and Adjusting Data for CIS Fuel Injection 25 -...
Removing And Installing Auxiliary Air Valve
2. Loosen clamps and disconnect hoses. 3. Pull off electric plug connectors. 4. Loosen socket head screws and remove auxiliary air valve. Removing and Installing Auxiliary Air Valve
Correcting Co Adjustment On Mixture Control Unit Us Cars
1. Remove the lead-sealed wrench and replace it with a new wrench, Part No. 930 110 910 01, if the CO level is not within specifications. 2. Adjust CO and engine idle speed. 3. Apply one drop of Loctite No. 270 in the bore of the adjusting wrench and close the bore with a plug, Part No. 930 110 921 00, after finishing adjustments. 25 - 10 f Correcting CO Adjustment on Mixture Control Unit Printed in Germany
Checking Waste Gate Operation
1. Loosen and remove control line to waste gate. 2. Run engine at idle speed. There must be noticeable vacuum in control line. With increasing engine speed, vacuum changes to pressure charging pressure . 3. Insert a plug in disconnected control line, so that engine will not stall while checking waste gate operation. 4. Carefully blow compressed air in control line opening of waste gate. Listen for sound of waste gate opening. Doxi.0.t.use more than 1,5 bar 21 psi air pressure. In addition to...
Disassembling And Assembling Waste Gate
1. Join waste gate base to valve housing and tighten mounting nuts slightly. 2. Align base and valve housing with a mandrel or long shaft drill of 10 mm 5 16 in. diameter. Tighten mounting nuts evenly. Mount waste gate cover in press when assembling.
Removing And Installing Rear Fuel Pump
1. Disconnect ground cable at battery. 2. Remove hollow bolt for pressure fuel line. 3. Pull off rubber caps and remove nuts attaching wires. 4. Loosen intake fuel line and catch escaping fuel. 5. Remove nuts and take fuel pump off bracket. , Loosen fuel pump clamp and take fuel pump off holder.
Removing And Installing Engine
The engine and transmission assembly is lowered to remove. 2. Disconnect ground cable at battery. 4. Loosen engine block vent hose at engine, pull off and plug opening at vent cover. 5. - Cars with air conditioning only -Detach compressor at console and leave it connected to the hoses in the car. The air conditioner system must be discharged if the compressor hoses are disconnected. 6. Remove relay plate cover and disconnect engine wires at relay plate, at adapter plug, relay plate socket and...
Info Xtc
HEATING, VENTILATION, Heater 80 AIR CONDITIONING Air Conditioner 87 Windshield Wipers and Washer 92 ELECTRICS Exterior Lights 94 Air filter, removing installing 1978 model 25 - 19 Air flow sensor plate, rest position, checking 25- 6a Air injection, disassembling assembling 26-12 - 1978 model 26-24 Air injection lines adapters, removing installing 26 - 19 Air pump - drive belt, checking adjusting 26 - 28 Automatic heater control - removing installing 80 - 1 Auxiliary air valve, removing...
Technical Data 1978 Model
Refer to appropriate repair group for adjusting and wear limit data Total displacement Compression ratio 930 61, Cal. 930 63, from 1979 models 930 64 mm inch 97 3.82 mm inch 74.4 2.93 cm3 inch3 3299 201.3 7.0 1 Max. engine speed Max. engine cruising speed Governor cut-off speed in distributor Camshaft drive Camshaft bearings Cooling fan drive Crankshaft blower ratio Lubrication Nm ft lbs 395 291 at engine speed of 4000 rpm One each overhead camshaft OHC, left and right Plain, directly on...
G And Wear Limit Data
measured betvi valve and rocker arm Intake valve stroke in TDC overlap at 0.1 mm tappet clearance 0.65 - 0.80 mm Intake valve springs Exhaust valve springs Intake valve springs 0 gt 3mm Ignition Timing Adjustment engine oil temperature at least 80 C 29 - 2 BTDC on crankshaft at 4000 rpm vacuum hose disconnected 5-3 ATDC on crankshaft at 950 - 50 rpm vacuum hose connected 7-2 ATDC on crankshaft at 1000 - 50 rpm vacuum hose connected 15 - 2 ATDC on crankshaft at 1000 - 50 rpm vacuum hose...
Turbo Carrera 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 Turbo Carrera Repair Manual only describes repair operations which differ from those for 911 models. Refer to the 911 Repair Manual...