Breakdown of the repair groups

Notes on assembly application of special tools 6. Diagnosis for the repair groups The Workshop Manual will be updated regularly by means of supplements which must be filed immediately to maintain the usefulness of the manual. Appropriate entries must be made in the record sheet to prove that the manual is complete. The content of this Workshop Manual will be supplemented with Technical Information Bulletins, which will be integrated into the manual from time...

Possible Causes Elimination Remarks

Check by means of circuit input test with system tester 9288 or Tester9268 Select test step and operate accelerator pedal. 9288 display Idle speed contact closed Idle speed contact open. 9268 display 1332 (idle speed contact closed) 0000 (idle speed contact open). Disconnect plug from DME control unit. Connect ohmmeter between terminal 52 and terminal 24 using test leads. Throttle valve opening angle > 1 If the values of the idle speed contact are not reached in this test, the test should be...

Tire condition inflation pressure

Tires constitute a safety element and they can only fulfill the demands made on them if the inflation pressure is correct and there is adequate tread depth. The specified inflation pressures are minimum pressures under no circumstances should the tire pressure be allowed to sink below these levels as this will not only detrimentally affect the driving behavior, but also increases the risk of serious tire damage. Valve caps protect the valves from dust and dirt and therefore prevent leakage....

B Control signal test

Connect DME test lead (Bosch No. 1 684 463 093) between solenoid valve and plug connection. Connect and adjust engine test in accordance with manufacturer's instructions. Carrera 2 Addendum Fuel System Electronic Control Possible Causes, Elimination, Remarks Tank venting valve is not activated permanently. The test must be performed within 7 minutes after starting an engine at operating temperature. (After this, interrupt tank venting valve activation for approx. 75 s and then continue.) Start...

Battery

The battery must always be disconnected from the vehicle wiring before starting any work on the electric system, to prevent possible short circuits. The battery must not, however, be disconnected when the engine is running. 3. Undo the ground terminal and pull off. Note The system adaption in the DEE control unit is lost when the battery is disconnected. The system must therefore be adapted using the System Tester 9288 after the check has been completed. 1. Check the fluid level in each cell....

Carrera 4Engine Crankshaft Pistons

Tightening torque 50 Nm (37 ftlb), tighten with double hexagon head socket insert Hexagon head nut M 10 x 1.25 (at main bearing saddle VII) bonded in place with Loctite 639, peened at circumference to lock projection length 130.2 - 0.5, use Loctite 649 to secure bond in place with Loctite 649, projection length 116 + 0.5 mm

Check Engine Lamp Malfunction Indicator Light MIL

As from model year '91, Californian legislation prescribes a warning lamp which lights up if a part relevant to the exhaust gas fails. As a function check of the warning lamp, it lights up when the ignition is switched on and goes out once the engine is running when this is started without depressing the accelerator. The warning lamp has a flashing code to indicate a defective fault path. To trigger off the flashing code, fully depress the accelerator pedal with the engine off and the ignition...

Checking and adjusting the valve clearance

Always check or adjust the valve clearance with the engine cold (approx. 20 C). Check by inserting the feeler gauge between the end face of the stem and the cap of the valve adjusting screw. If the spark plugs are not removed when the valves are adjusted, the engine must only be rotated at the bottom pulley or at the internal multi-tooth end of the generator shaft. Check hex nut on alternator shaft for tight fit after the adjustment has been completed. Valve clearance with the engine cold The...

Checking andor adjusting alternator fan wheel and air conditioning compressor drive belts

Caution Make sure the ignition key is pulled off whenever measurements are made. Checking used drive belts (alternator and fan wheel) Use belt tension measuring instrument (Special Tool 9574) to check tension. A description of how to use the Special Tool is contained in Repair Group 13, page 13-30. Retensioning the belt is only required if the belt tension displayed at the measuring instrument is less than 15 scale increments when the engine is cold and less than 20 scale increments when the...

Checking idle speed adjusting CO Tools

Sun Electric, Bosch refer to the Workshop Handbook Ratchet 1 4 inch to adjust the CO value Checking idle speed CO -with catalytic converter It is no longer possible to adjust the idle speed and CO value for vehicles with catalytic converters. Do not disconnect the Lambda probe for the idle speed CO check. Engine in faultless mechanical condition. Consumers must be switched off during the checking work. Carry out checking operations as fast as possible to ensure that the...

Crankshaft Standard and Repair Dimensions

Main bearing Big end bearing Main bearing, dia. d 1 dia. d 2 dia. d 3 (bearing 8) 59.971 59.990 54.971 54.990 30.980 30.993 59.721 59.740 54.721 54.740 30.730 30.743 59.471 59.490 54.471 54.490 30.480 30.493 Flange Timing gear fit Support Guide bearing dia. d 4 dia. d 5 dia. d 6 with A 89.780 90.000 42.002 42.013 29.960 29.993 28.000 28.060 89.580 29.670

Determining parallelity of chain sprockets

The parallelity offset between the driving sprocket on the intermediate shaft and the driven sprocket on the camshaft must not exceed 0,25 mm max. Before measuring, move the intermediate shaft in axial direction towards the flywheel to make sure the support collar of the bearing is seated correctly. To adjust the sprockets, insert or remove shims, Part No. 901.105.561.00 (shim thickness 0.5 mm) as required. As a rule, three shims are required below the left-hand sprocket (cyl. bank No. 1 to 3),...

Dismantling and assembling chain housing with camshaft drive Cylinder bank

Before dismantling, set cylinder no. 1 of engine to firing TDC (corresponds to overlapping TDC of cylinder No. 4). Punch marks of both camshafts point up. 911 Carrera 4 Engine, Crankshaft, Pistons Oil feed bore points down in addition, the spring retainers are marked with top and ,,RH bottom When levering off, avoid damaging the guiding edges of the guide rail Check for correct seating in chain housing Check for correct seating in support bracket Apply a thin coat of Optimoly HT to threads,...

Dismantling and assembling crankcase sections Righthand crankcase section

Note Unless indicated otherwise, apply Loctite 270 to all stud threads when assembling the engine coat threads lightly with Loctite 270, tightening torque 90 Nm (66 ftlb) Plug for oil pressure pressure relief valve Tension sleeve 8x16 (blower mounting) oil lightly, always use a second wrench to lock. To install, use a double hex head socket insert (14 A F) use a double hex head socket insert (14 A F) Stud (for mounting of oil pump) M 8 x 22 Stud M 8 x 32 (for circumferential mounting)

Dismantling and assembling doublemass flywheel

Bolt double-mass flywheel to retaining plate P 209 a (special tool) with three M 8 x 100 mm hex bolts. Insert aluminum washers under the bolt heads. As a rule, the double-mass flywheel should only be checked if transmission rattle is present at idle or in overrunning load mode or if respective customer complaints are received. Direction of rotation of secondary flywheel To facilitate subsequent reassembly, mark relative position of parts with a color pen. 1. Take off the end caps. Do not drill...

Dismantling and assembling hydraulic pump drive power steering

911 Carrera 4 Engine, Cylinder Head and Valve Drive Install in correct position, fit with toothed belt mounted in place Coat threads with Optimoly HT. Tightening torque 120 Nm (88 ftlb). Use Special Tool 9236 to lock. Hexagon head bolt M 6 x 28 (self-locking) Replace and or use Loctite 270 to insert

Dismantling and assembling intermediate shaft

Chain sprockets available as spare parts heat on heater plate, press on to stop, observe installation position matched with crankshaft gear, fit both parts as a unit 911 Carrera 4 Engine, Crankshaft, Pistons Measuring and repairing the crankcase Tools Internal measuring device with measuring ring dia. 65.000 mm Measuring and repairing the crankcase General Whenever the crankcase is dismantled in the course of rebuilding the engine, measure the main bearing bores. 1....

Dismantling and assembling the oil pump Note

If possible, dismantle and assemble the oil pump only in case of bearing damage Use Loctite 270, tighten to 8 Nm (6 ftlb) If required, drive in flush and secure with bolt locking compound suitable for temperatures up to 160 deg. C If severe score marks are found, replace oil pump as a unit. Check, valve opening pressure must be 180 + 20 mbar, install with Loctite 574 sealant 1. Remove the hot-air blower on the left-hand side to the rear of the engine compartment. 2. Undo the fuel return line...

DMEDiagnosis Troubleshootlng

After exhaust gas adjustment, perform system adaption. In the case of vehicles without catalytic converter, it must be ensured that the adapter plug (911.612.422.8) Is plugged onto the oxygen sensor connecting lead in order to avoid interference (see wiring diagram). c) Idle speed CO of vehicles with catalytic converter In these vehicles, adaption of the idle speed CO content takes place as well as adaptation of the idle speed. Consequently, it is only necessary to check the actual condition in...

Dr Ing hc F Porsche Aktiengesellschaft

911 Carrera 4 Fuel System - Electronic Control fcC Test point Description Page Important vehicle Testing Effect of faults (cross reference DME control unit plug 1 Power 2 Idle speed 3 Full load 4 Engine temperature 5 Air flow 6 Idle speed control 7 Oxygen regulation 8 Oxygen 9 I ntake air temperature 10 Knock sensor 11 Knock sensor 12 Control unit 13 Hall 14 Control unit 15 DME 16 Tank ventilating 17 Resonance 18 Check Engine warning 19 Injection 20 Fuel 21 Intake system 22 Ground and plug 23...

E Activation of the highvoltage end if ignition sparks are not triggered

The ignition trigger signal can be simulated for rapid troubleshooting at the ignition end. For this purpose, connect the oscilloscope tester lead terminal 4 to the ignition lead from the ignition coil to the high-voltage distributor (terminal 4). Disconnect the DME control unit plug. Switch on ignition. If a battery voltage is now applied intermittently to terminal 1 of the control unit plug with a test lead (e.g. control unit plug terminal 18), a high-voltage peak must be displayed on the...

Emission control system

Check that catalytic converter, Lambda probe and restricted filler inlet are present, visual inspection of all electrical connections and line connections, check that the Lambda probe is in working order. The fault memory of the DEE control unit has been read out (Tester 9268 9288). No fault indicated in the fuel or ignition system. Lift the vehicle, check that catalytic converter and Lambda probe are present. Check that the restricted filler inlet is present. Check the vacuum line connections...

Engine Crankshaft Pistons

VW 387. 4. Check pulley for runout, straightening with a copper hammer if necessary. Max. permissible lateral runout 0.5 mm. The hammer must only knock in the inside shell, since otherwise the rubber cord of the vibration damper would be destroyed. 5. Recheck tightness (235 Nm 170 ft. lbs.) after straightening.

Exhaust system

Visual inspection for leaks and damage, check that screw connections are fitted securely and examine the mounting 1. Check that the exhaust flange is fitted securely and inspect the entire exhaust system for leaks. 2. Check that the mounting on the heat exchanger cylinder head flange is fitted securely. 3. Check that all flange connections in the exhaust system as well as the Lambda probe and emission test plug are fitted securely. 4. Check that all screws on the flange, primary muffler...

Exhaust test

Adjusting the CO without catalytic converter It is no longer possible to adjust the Idle speed. The adjustment to the throttle housing is therefore not applicable. Adjusting the idle speed CO Precondition The engine must be in faultless mechanical condition. Consumers must be switched off during the adjusting operations. Carry out adjustments as quickly as possible to ensure that the intake channels do not heat up and falsify the CO value. Ambient temperature 15 -35 C (59 - 95 F) 1. Warm the...

Fault Fault Code Possible Causes Elimination Remarks

Connect a 2-pin DME test lead (Bosch No. 1 684 463 093) between the speed control and plug. Connect and adjust engine tester in accordance with manufacturer's instructions. Ensure that the lead connections do not have any ground contact with the vehicle. (Danger of short-circuit) The following display must be visible when the engine is running If no audible pulse exists in spite of the voltage and signal being present, replace the idle speed control.

Hill climbing

Refer to Technical Information Handbook approx. 11.5 I (approx. 9 I for oil change) determined by measurements with the oil dipstick as per Owner's Manual approx. 77 I (approx. 10 I reserve) approx. 0.75 I approx. 7.4 I approx. 0.7 I approx. 1.0 l The vehicle must only be lifted using the illustrated jacking points. When driving onto a lifting platform, make sure that there is enough clearance between the platform and the vehicle. The recommended Service Intervals...

If there is no signal check

- Power supply to ignition output stages and ignition coils - Ground point for ignition output stages (ground point at rear left of engine compartment). - Plug connections to ignition output stages, ignition coils and high-voltage distributor. - The components responsible for high voltage (e.g. ignition coil, ignition leads, spark plug connectors ). - Lead continuity from the control unit plug to the ignition output stage terminal 5.

Ignition circuits 1 and

Measure the CO and HC values with the engine at operating temperature and both ignition circuits in operation. 2. Switch off the engine and disconnect the plug from the final stage of ignition circuit I. 3. Start the engine and measure the CO and HC values. 4. Switch off the engine, connect the plug for ignition circuit I and disconnect the plug from the final stage of ignition circuit II. 5. Start the engine and measure the CO and HC values. The CO and HC values must not deviate considerably...

Important vehicle information

Always turn off the ignition or disconnect the battery for resistance tests (if this is not done, the measuring device may be destroyed). Always disconnect the speed sensor plug for compression tests. (If this is not done, dangerous high voltages and insulation damage to the ignition coil, high-voltage distributor and ignition leads may result. In addition, the remaining spark plugs of the 2nd ignition circuit could ignite.) The specified ignition coil (refer to Order No.) must not be replaced...

Info

If the System Tester 9288 cannot enter the diagnosis, check the following Items Note If the DME relay is faulty, no diagnosis is possible (engine cannot run). Power is supplied to some control units of the diagnosable systems via the DME relay Check adapter cable 9288 1 for continuity Check K and L wires to adapter lead 9288 1 for continuity. Socket 3 (8-pin connector) to pin 7 (19-pin socket). Socket 7 (8-pin connector) to pin 8 (19-pin socket). Check ground and terminal 15 of adapter cable...

List of Repair Groups Carrera

Engine, Cylinder Head and Valve Drive Starter, Power Supply, Cruise Control Differential, Transaxle System, All-Wheel Drive Automatic Transmission, Controls, Case Automatic Transmission, Gears, Shafts Brakes, Hydraulics, Regulator, Booster Instruments, Fuel Gauge, Alarm System Survey of Information Published in Technical Manual beginning in 1985 - Oil Pump with Intake Plate and Filter Screen - Oil Pressure Swith Oil Pressure Warning Lamp Flickers - New Nuts and New Cylinder Head Tightening...

Mportant

Oxygen sensor signal Knock sensor II Shield, for knock sensors, Hall sensor and ground for knock sensors Positive to Hall sensor Consumption gauge ti signal, cyl. 5 ti signal, cyl. 4 ti signal, cyl. 2 Voltage from DME relay with ignition Version coding Air-conditioning compressor AC switch Intake air temperature NTC I Engine temperature NTC II Altitude potentiometer Speed reference mark positive Speed reference mark negative shield Idle signal - throttle valve Full load signal - throttle valve...

No fault

If the warning light did indicate a warning, i.e. there is a fault, there appears a flashing code, e.g. 112 4 Constant fault (2 with loose contact) DME LH control unit The flashing code is listed in the Diagnosing Troubleshooting plan on page D 24 28-7. The fault can also be read direct using System Tester 9288. After a repair the fault memory must be

Operating the measuring instrument

1 Prepare measuring Lower pointer into measuring instrument, instrument for testing 2 Pick up measuring instrument Grasp rubber strap between thumb and index finger. 3 Position measuring instrument Position measuring instrument in center between pul The lateral stop of the instrument must rest on the side of the V-belt. 4 Measure belt tension Press pushbutton to apply uniform pressure in perpen dicular direction on top of V-belt until the detent spring can be heard (or felt) to disengage. After...

Power supply

Connect the voltmeter to terminal 2 and ground of the disconnected plug of the idle speed control using test leads. Switch ignition on. Display Battery voltage If no display Check power supply in accordance with wiring diagram. Control signal test Using the system tester 9288, it is possible to read the pulse duty factor in percent directly in the Actual value menu. Function test Switch on loads during idle operation. The pulse duty factor must change, while the idling speed remains constant....

Preconditions for troubleshooting are that the person performing the tests

is familiar with the location of components and the functioning and technical relationships of the systems being tested (model information) can read and evaluate Porsche wiring diagrams knows the functions of circuits and relays is capable of using testers, such as oscilloscope, voltmeter, ohmmeter and ammeter, as well as of evaluating the results. A fault text on the display (fault list for flashing code) does not always indicate a fault in this component, but could also indicate a fault in...

Reassembly notes

Use Special Tool 9119 to press in sealing ring to stop. Following elimination of the retaining pin at the camshaft housing, the support console may be centered using the muffler retaining strut. Then tighten hexagon head bolts. Fit upper sprocket with the toothed belt fitted in place. Lettering must point to the front. Tighten lower sprocket with 120 Nm (88 ftlb). When tightening, lock with Special Tool 9236.

Removing and Installing Starter

Unscrew and disconnect drive shaft on flange of differential. 3. Remove holder for engine splash guard. 4. Unscrew and lay clutch slave cylinder aside with the connected hose (use a 1 4 inch ratchet). 5. Unscrew upper starter hexagon socket nut with a 3 8 inch ratchet and 10 mm INHEX 1. Unscrew and disconnect drive shaft on flange of differential. 2. Unscrew upper holder for engine splash guard. 4. Disconnect term. 30 and 50 leads. 5. Disconnect ground strap...

Removing and installing the starter

Remove engine-transmission underbody cladding 1. Undo the universal shaft at the flange of the differential and disconnect. 3. Disconnect selector lever cord pull. 4. Undo holder for selector lever cord pull and disconnect completely. 5. Unlock cable holder, remove plug-in connection and disconnect. Carrera 2 Addendum Starter, power supply, cruise control 7. Place a transmission jack under the transmission support and undo fixing screws (6 ea.). 8. Carefully...

Removing and Installing Valve Stem

Pull off valve stem seals with Special Tool Slide a plastic installing sleeve on the valve stem to avoid damaging new valve stem seals. Part number of plastic installing sleeve 00 043 084 00. Lubricate sealing lip of valve stem seal lightly with oil and push on to valve guide carefully and with feeling, using pressure pad of Special Tool 10-204.

Removing dismantling and assembling fuel tank

Removing, dismantling and assembling fuel tank Tighten with wrench socket 9277 (Special Tool). Tightening torque 30 Nm (22 ftlb) Always replace when reassembling coat lightly with acid-proof grease Clean, coat threads lightly with Optimoly TA, tightening torque 25 Nm (18 ftlb) Assembly notes Removing and installing fuel tank 1. The fuel contents may be drawn off via the fuel level sender hole. For this purpose, the fuel tank must not be filled by more than 3 4. Before locating in its final...

Removing from flange

Undo torque converter fixing screws (M 6 x 16) and unscrew. (8 each). 3. Hang holding device 9325 behind the starter gear ring. During removal and flange-mounting, the holding device prevents the torque converter from falling out. 4. Hook transmission holder 9324 in the mounting bores of the transmission case. Make sure that it is fitted correctly. 5. Suspend transmission holder from workshop crane and slightly pre-tension workshop crane. 6. Undo transmission ring screw connection and...

Replacing Brake Fluid Bleeding Brakes and Lock Control

Since brake master cylinder circuits, consisting of the push rod circuit (for front axle) and intermediate piston circuit (for rear axle) with the ABS hydraulic control unit, are completely independent of the booster circuit (brake booster and lock control), brake fluid replacing and bleeding procedures are divided into different jobs (see next page). Brake master cylinder circuits (exception 3) Booster circuit (brake booster and lock control) 1+2 To axial and lateral lock cylinders (Q and L)...

Replacing transmission oil Manual transmission and front final drive

Manual transmission approx. 3.8 I Front final drive approx. 1.2 I Transmission oil SAE 75 W 90 of API classification GL5 (or MIL-L-2105 B) 1. Remove the front underbody panel and engine guard. 2. Drain the oil with the vehicle level and transmission at operating temperature. 3. Clean filter plug and drain plug, replace seals and tighten with 30 Nm (22 ftlb). 4. With the vehicle level, fill with transmission oil until the filler plug overflows.

Seals for doors hoods and roof

Remove scuffed rubber, apply a suitable preservative to maintain seals Remove scuffed rubber and soiling with benzine. Maintain seals with glycerine, talcum or similar preservatives. Checking the lighting system Adjust headlights 1. Undo the fastening screw holding the trim ring. 2. Ease the trim ring back at the bottom with a hardwood spatula or similar. 3. Clean the lens and switch on dipped beam. 4. Using a headlight aiming device, adjust the headlights with the vehicle in running condition...

Technical Data 911 Carrera

(Adjusting values and wear limits are included in the respective repair groups) Note USA values in brackets (engine type M 64 01) Drive unit max. torque As per 80 1269 EWG Net torque, SAE J 1349 Crankcase Crankshaft Crankshaft bearings Connecting rods Conrod bearings Pistons Cylinders Cylinder head Valve guides Valve arrangement Valve timing Camshaft Camshaft drive Valve clearance Timing 6-cylinder, four-stroke internal combustion engine with 2 horizontally opposed cylinder banks (flat engine)...

Test point 23 Speedreference mark sensor

This test can only be performed with an oscilloscope. For this purpose, connect and adjust a workshop oscilloscope in accordance with the manufacturer's instructions. Connect the positive tester lead via a test lead to the control unit plug terminal 47 and the negative tester lead via a test lead to control unit plug 48. Crank the engine with the starter. Sinusoidal oscillations of at least 3 V (speed pulses) and an intermediate higher amplitude (reference mark) must be displayed on the screen....

Test point 7 Oxygen regulation stop

Test 1 Check CO level with running engine and connected CO tester (between 0.4 - 1.2 ) too lean Check intake system for leaks (Test point 21) too rich Test system pressure (test point 20) Test injection valves for leaks (test point 20) The oxygen regulator cannot operate in its control range owing to problems with mixture preparation, e.g. too lean because of additional air or too rich because of a sticking injection valve. The oxygen regulator then moves up to the stop position.

Test pressure 38 02 bar

Read off the pressure value on the pressure gauge (nominal 3.8 0.2 bar). - Max. permissible temperature drop with warm engine 0.5 bar in 30 min. - If the pressure drops below the specified value, proceed as described below Build up pressure again by switching on the fuel pump briefly. Remove the return pipe (fuel pump must not be switched on).

Testing and adjusting specifications

As from Model 89 engine type M 64 01 Fuel pressure (Engine stationary) Fuel pump relay bridged * Measured upstream of catalytic converter and Lambda probe connector not separated. No CO adjustment ** The Idle speed can be checked only. There is no idle speed adjustment. Testing and adjusting specifications

Throttle control

Check bowden cables, linkages, joints for smooth operation. Check the tuning flap and full-throttle position. Each time the ignition is switched on, the tuning flap is opened and closed once by a vacuum. The opening and closing noise can be heard in the engine compartment. Visual inspection for leakage, check final position of the pedal The clutch pedal has no stop. It is in its initial position when the master cylinder is in its initial posi-The push rod cannot be adjusted. The preload on the...

Tightening torques for the engine

15(11) 2 x 90 2 Angle of rotation Crankcase - screw connection (Tension rod union) Hexagon nuts or hexagon head screws on the crankcase Driving plate to crankshaft (Tiptonic) Screw plug - relief and safety valve Screw neck in the left crankcase half (oil return to the oil tank) Screw neck in the right crankcase half (oil feed to the oil pump)

Ref 1 Replacing Brake Fluid

Replacing brake fluid is divided into two steps. Step 1 Replace brake fluid for the brake master cylinder circuit and clutch hydraulic system (conventional). Step 2 Replace brake fluid for the booster circuit (brake booster and lock control). This requires activating the lock solenoids with a 9288 System Tester and removing the brake fluid from each lock cylinder. Use of an electric filling and bleeding machine is recommended to guarantee fast and practical replacement of the brake fluid. Pour...

Powerassisted steering

Visual inspection for leaks and checking the fluid level Insufficient oil in the hydraulic system causes damage to the power-assisted steering. As a result of the high oil pressure in hydraulic system, even small leaks can lead to a drain on the fluid and damage the servo pump. Grunting noises when locking the steering or foam in the reservoir indicate lack of oil and or aspirated air. Before filling the reservoir, however, any leaks on the intake side must be repaired and the faulty part...

Camshafts timing

Identification code on the face end of the camshaft Left Right Inlet valve stroke at overlapping TDC with 0.1 mm valve clearance M 64 01 964 105 247 07 964 105 246 09 964 247 07 964 246 09 1,26 0,1 I. open 4 bef TDC Ex. open 44' bef BDC Ex. close 4 aft. TDC 911 Carrera 4 Engine, Cylinder Head, Valve Train

DME control unit with diagnostic capability

A self-diagnosis function with fault memory is integrated in the DME control unit which permits certain faults in the injection, ignition and knock regulating systems to be detected and stored. The DME control unit has a permanent positive connection to prevent deletion of detected and stored faults when the ignition is turned off. Detected faults remain stored in the fault memory for at least 50 engine starts (exception idle speed switch interruption faults). If the DME control unit plug or...

Accident hazards on electronic ignition systems

Transmission Line Wire Pulling Accident

Increased demands on the ignition systems made by modern engines and the desire for maintenance-free components have led to electronic ignition systems being used in series vehicles for some time now. As a rule, the ignition performance of electronic systems is higher than that of conventional systems and further increases in the performance are forecast for the future. This means that electronic ignition systems are entering into an area where contact with current-carrying parts or terminals...

Operating instructions for System Tester 9288

9288 Bosch

The Systemtester 9288 BOSCH KTS 301 is a microprocessor-con-trolled self-diagnosis tester. All systems which have a diagnosis interface as per ISO Standard can be tested with this tester. The following tests are possible Reading out the fault memory Sensor and status checks, tire-pressure monitoring RDK The Systemtester 9288 is a high-quality piece of electronic equipment. In order to prevent damage to the equipment as a result of improper use, please read the information in the operating...

Removing and installing the engine Tiptronic vehicles Special tools

996 Tiptronic Torque Drain Fluid

911 Carrera 2 Engine, crankcase, suspension Removing and installing the engine Tiptronic vehicles The engine-transmission assembly is removed completely downwards. 1. Support the vehicle at the support points. Note Align the rear right supports so that the transmission underbody cladding can be removed later on. 2. Disconnect the battery ground cable. 3. Disconnect the connectors 6 each at the intake distributor and remove the cable clip The drawing shows the engine in 45410 5. Undo the...

Coding the DME control unit

928 607 421

Various characteristic maps are integrated in the DME control unit in order to cover the different country-specific legislation and different vehicle types. These characteristic maps can be read directly in the Actual value menu with the system tester 9288. In order to permit calling up of these characteristic maps, a 2-pin plug connection and a 3-pin plug connection are brought out of the DME wiring harness. These must be jumpered differently, depending on the country-specific version....

Removing and installing generator

Unscrew negative terminal from battery and cover terminal. Take off protective cap. Undo hexagon head nut 24 mm A F , using a multi-tooth wrench included in car tool kit to lock. Press fan wheel off generator, using puller VW 202 if required. Adjust both puller hooks as required. 2 Fit fan wheel for generator cooling Align cooling fan housing with crankcase Install generator. Make sure the connections for terminal B and terminal D are positioned opposite the TDC line mark located on the edge of...

Dismantling and assembling pistons and cylinders

Stepped Taper Faced Ring

Always replace with new parts, fit dry Always replace with new parts, check for correct seating, use Special Tool 9500 Must remain allocated to the corresponding piston. Do not mix with parts from another cylinder, even within the same engine. When dismantling and assembling the engine, observe this procedure and mark parts accordingly. Observe inside dia., use suitable thrust pin Always replace with new parts, check for corr. seating, use Sp. Tool 9500 Double-bevelled oil control ring, groove...

Adjusting the timing

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...

Disassembling and Assembling Crankcase Tools

Bolt crankshaft on holding plate with multiple-tooth socket bolts, Part No. 928 102 152 01. 911 Carrera 4 Engine, Crankshaft, Pistons Pressing tool for seal flywheel end Carrera 4 Table Of Contents Carrera 2 Addendum Main Menu 13 Engine, Crankshaft, Pistons 911 Carrera 4

Disassembling and Assembling Camshaft Housing Cylinder Head Tools

Porsche Tool P200a

Disassembling and Assembling Camshaft Housing, Cylinder Head Screwdriver socket for multi-tooth nuts Standard, Stahlwille 73 Nm V 3 and 49-5 Wrench socket for temperature sensor II in calinderhead cyl. 3 Pressure pad for pressing in valve stem seals Dis. and assembling cylinder head, camshaft housing

Carrera 4Engine Crankcase Suspension

Carrera Transmission Install

Primary muffler catalytic converter - intermediate muffler spherical clip Intermediate muffler -final muffler spherical clip Restraining strap to intermediate muffler Cap nut on the fuel distribution line Primary flywheel to secondary flywheel 911 Carrera 4 Enginge, Crankcase, Suspension The engine transmission assembly is removed 1. Raise the vehicle at the jacking points. Adjust the right-hand rear jacking point in such a way that the transmission guard can 2. Disconnect the battery ground...

Fuel system

1010 l sec at 6100 rpm of the crankshaft Dry sump lubrication with isolated oil reservoir Thermostatically controlled, front oil cooler in the front right-hand fender, 2-stage electric blower approx. 5.0 bar at 90 degrees oil temperature 0-5 bar electric and oil pressure warning lamp Up to 1.5 I 1000 km Single-branch system joined together outside the heat exchanger, 3-way catalytic converter with closed-loop Lambda control, intermediate and final mufflers, partial encapsulation of the engine...