Crankshaft sensors removing and installing

Reference Sensors 1979 Porsche 911

Pull out connector locking plate at sensor connectors in left side of engine compartment. Detach one or both black connectors. Remove reference or speed sensor mounting bolt using a 5 ' If the sensor is seized in the mounting bracket, remove bracket mounting bolts arrows . Remove bracket with both sensors to work bench and replace sensor s as needed. Once bracket has been removed, sensor clearance gap must be reset as described below. When installing sensor mounting bracket, position sensor...

Rear wheel bearing removing and installing

Remove Rotor Drive Shaft

Wheel bearing replacement can be performed by removing the rear trailing arm as described earlier and pressing the bearing out on the bench. The following procedure describes utilizing a special bearing removal and installation tool that eliminates the need to remove the trailing arm from the car. Apply parking brake and shift transmission into reverse. Remove wheel hub center cap. Loosen stub axle nut 32 mm socket wrench through opening in center of wheel. Loosen rear wheel lug nuts. Release...

Engine Disassembly and Assembly

911 Engine Diassembles

ENGINE, DISASSEMBLY 102-2 Engine peripherals, removing 102-4 and camshafts, removing 102-8 cylinder heads, removing 102-12 Pistons and cylinders, removing 102-13 Crankcase, disassembling 102-14 Crankshaft, disassembling 102-16 ENGINE, ASSEMBLY 102-17 Crankshaft, assembling 102-18 Crankcase, assembling 102-19 Pistons and cylinders, installing 102-25 Cylinder heads, installing 102-27 Camshaft cases, camshafts and camshaft timing chains, installing .102-28 Camshaft timing, adjusting 102-31 Engine...

Windshield Wipers and Washers

Wiper Arm Bushings 911

Wiper blades 920-1 Wiper blade symptoms and fixes 920-1 Wiper blades, replacing 920-2 Wiper blade inserts, replacing 920-2 Wiper arms, removing and installing 920-3 WINDSHIELD WIPER ASSEMBLY 920-3 Windshield wiper assembly, removing and installing 920-3 washer system 920-5 removing and installing 920-5 removing and installing 920-6 removing and installing 920-6 Windshield wiper washer switches 920-7 Intermittent wiper action switch, removing and installing 920-7 This repair group covers...

Door panel removing and installing

Remove Door Panel Porsche 911

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...

Electrical component locations

Porsche 911 Turbo 1989 Fuse Box

The fuses, relays and control modules are located in various locations throughout the vehicle. Refer to the component location photos and tables in this repair group for electrical component locations. Replace fuses with those of the same rating. Installing a fuse with higher rating can lead to circuit failure and may also start a fire. Relay fuse positions vary by model and equipment. Fuses no. 1 -21 and are mounted in the front fuse relay panel located in the luggage compartment. There are...

CV joint and boot removing and installing

Axles For Electric Car

On all but 1984 models only the inner CV joint is replaceable separately. The outer joint must be replaced with the axle shaft. Remove axle shaft assembly as described earlier and place in shop vice with soft jaws. Cut off small and large CV boot clamps. Drive off dust cover and boot flange with punch arrows . Slide flange and boot away from inner CV joint. 1. Small clamp 5. Concave washer install with 2. CV joint boot concave facing CV joint 3. Large clamp 6. CV joint Boot flange 7. Inner dust...

Engine Management General

Iat Sensor

GENERAL 200-1 DME engine management system 200-1 Principles of operation 200-3 Fuel supply and fuel delivery 200-3 Volume air flow sensor 200-4 Cylinder head temperature sensor 200-5 Reference and speed sensors 200-5 Throttle position switches 200-6 Altitude correction switch 200-7 Oxygen sensor 200-7 Idle speed control 200-7 DME main fuel pump relay 200-8 Ignition timing 200-9 Emission DRIVEABILITY TROUBLESHOOTING .200-10 Mechanical condition 200-11 Preventive maintenance 200-12 Valve Basic...

Rear torsion bar setting

Torsion Bar Trailing Arm

If torsion bars are replaced or reset, 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 for more information. The initial position of each rear torsion bar is set by measuring torsion plate inclination in its unloaded position. With car close to ground level, use floor jack under trailing arm to relieve suspension load on shock absorber. Brake backing plate shown removed for clarity....

Ignition components testing

Spark Plug Wire Resistance Ohms

Primary coil resistance is measured with an ohmmeter between terminals 1 and 15. Measurement of secondary resistance is between terminals 4 and 15. Replace a coil which does not meet specifications. Correct values are in Table b. Check resistance of each spark plug end connector as well as wire itself. To test connector, use ohmmeter probe on both ends. Test shielded ends of coil and spark plug wires at distributor cap and coil using same method. To avoid damaging the distributor cap, do not...

Charging system troubleshooting

1984 Porsche 911 Wiring Diagram

Charging system trouble is indicated by an illuminated alternator warning light on the instrument panel, or by an under-or overcharged battery. The alternator generates electrical current by electrical induction. That is, a magnetic field is placed in motion to induce a current in a stationary coil. When the engine is running and the alternator is spinning, part of the current it produces energizes its electromagnetic field. When starting, some other current must be provided to initially...

Starter removing and installing 1987 to 1989 models

Porsche 911 Transmission Ground Strap

Disconnect negative - battery cable and cover battery terminal to keep cable from accidentally contacting terminal. Raise vehicle to gain access to bottom of engine. 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 underneath car, push back rubber boot covering shift linkage. Loosen hex bolt arrow and pull shift rod out of shift coupler. Unbolt stabilizer bracket...

Idle speed control valve testing

Porsche 964 Idle Speed Control Valve

The idle speed control valve controls the amount of air allowed to bypass the throttle to increase or decrease idle speed. Whenever the idle position switch is closed, the valve is in operation. Listen and feel for valve vibration or humming. If valve is not operating, check that idle switch is operating correctly as described above. If valve is functioning but idle speed is erratic, check valve as described below. Remove two hoses A and electrical harness connector C from valve. Remove...

Fuel injectors testing

Porsche 911 Speed Switch 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...

Front brake rotor removing and installing

1975 Porsche 911 Front Disk

Use a micrometer to measure rotor thickness at eight to ten positions on rotor braking surface. Rotor runout should be measured using a dial indicator setup. If a low speed shimmy goes away when the brakes are released, excessive rotor runout is probably the cause of the shimmy. If the rotor's runout is within limits, and the shimmy still persists, check the front wheel bearings as described in 401 Front Suspension. Brake rotors can be resurfaced by most local automotive machine shops. Always...

Axle shaft assembly removing and installing

Gear Wheel M20

Apply parking brake and shift transmission into reverse. Remove wheel hub center cap. Loosen stub axle nut 32 mm socket wrench through opening in center of wheel. Loosen rear wheel lug nuts. Release parking brake and shift transmission into neutral. Raise rear 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 rear wheel. Remove stub...

Engine Removal and Installation

Saab Brake Line Flanged Ends

Special REMOVAL AND INSTALLATION 101-2 Engine transmission, removing 101-2 Engine transmission, installing 101-10 Engine transmission, separating and rejoining 101-15 ENGINE TRANSMISSION MOUNTS . . .101-16 Engine mount, removing and installing 101-16 915 Transmission mount, replacing G50 This repair group covers engine removal and installation. The complete engine transmission assembly is removed as a single unit through the bottom of the engine bay. Removal and installation of the engine...

Transmission reassembling 915 transmission

Before assembly clean and check all parts to be sure they are in good operating condition. Lay parts out in order of assembly on a work bench. Install shims arrow on differential housing studs. NOTE Unless the pinion bearing is being replaced or repairs have been made to the differential, install the same shims that were removed during disassembly. If the differential bearing is replaced or repairs have been made to the differential, special differential setup procedures must be carried out....

Distributor cap and ignition rotor removing and installing

Ignition Timing 911

It is recommended that the cap and rotor be replaced as a set during a major maintenance. To replace cap and rotor, use flat-tipped screwdriver to press down and turn cap hold down pins Va turn each. If replacing cap, temporarily leave spark plug wires in old cap. Mount new cap on distributor and lock both pins. Change over one spark plug wire at a time from old cap to new cap. To avoid damaging the distributor cap, do not wiggle the connectors when removing the spark plug wires. If necessary,...

Engine removal and installation 101

Porsche 911 Engine Crossmember Bolts

Loosen inner constant velocity CV joint bolts arrows from differential drive flanges left side shown . Suspend shafts from body with mechanic's wire. On 1984 and early 1985 models cover CV joints with a plastic bag and tape bag to CV joint shaft to keep dirt out of the joints. Remove left and right heater hoses from heat exchanger connector. Lower vehicle until weight of engine transmission assembly engine is supported by hydraulic support or equivalent. If using a floor jack, raise it as much...

Pedal cluster disassembling and reassembling hydraulic operated clutch

Brake Clutch Pedal Cluster Porsche 911

Remove and clean pedal cluster assembly before starting to disassemble. Support pedal cluster in soft jawed vise. Drive out shaft roll pins arrows . Support shaft to prevent deformation of pedal cluster housing. Use 4 mm pin punch Automotion special tool no. TL-4600 to drive out dowel pins. Remove clutch pedal and cross-shaft. Remove bearing tube from brake pedal base. Remove brake pedal and brake pedal return spring. 12. Clutch cross-shaft inner end 14. Clutch master cylinder bellcrank Pedal...

Suspension Brakes and Steering General

Torsion Bar Suspension

Isolating pulling symptoms 400-10 Braking system troubleshooting 400-12 Brake diagnostic checks 400-12 Brake Suspension Specifications 400-3 Steering Braking System Specifications 400-6 Rim and Tire Sizes 400-7 Alignment Brake System This section covers general information for front and rear suspension, the braking system, and the steering system. Diagnostic and troubleshooting information on these systems is at the end of the section. The Porsche 911 Carrera suspension and steering systems are...

Oxygen sensor checking

Lt1 Ecm Program Run One Sensor

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...

Fluid And Lubricant Specifications

Porsche 911 Oil Plug Torque Spec

Engine oil viscosity SAE grade vs. operating temperature range shown for the Porsche engine covered in this manual. The fluids and lubricants specified by Porsche are listed in Table e. The use of fluids that do not meet Porsche's specifications may impair performance and reliability, and may void warranty coverage. 3.0 L 3.2 US qt. 3.4 L 3.6 US qt. Synthetic manual transmission fluid is not approved by the manufacturer, but its use may result in improved transmission performance and wear...

Genuine Porsche parts

Genuine Porsche replacement parts from an authorized Porsche dealer are designed and manufactured to the same high standards as the original parts. They will be the correct material, manufactured to the same specifications, and guaranteed to fit and work as intended by the engineers who designed the car. Some genuine Porsche parts have a limited warranty. Porsche is constantly updating and improving their cars, often making improvements during a given model year. Porsche may recommend a newer,...

Information you need to know

Hydraulic Clutch Reservoir 911 Porsche

When ordering parts it is important that you know the correct model designation for your car. Models covered in this manual are 911 Carrera coupe, targa and cabriolet configurations. Model Year. This is not necessarily the same as date of manufacture or date of sale. A 1986 model may have been manufactured in late 1985, and perhaps not sold until early 1986. It is still a 1986 model. Model years covered by this manual are 1984 to 1989. Date of Manufacture. This information is helpful...

Electrical Wiring Diagrams

GENERAL 970-1 WIRING DIAGRAMS 970-2 Air Conditioning and Heating 970-45 970-56 Back-up Lights 970-67 Central locking 970-37 Charging 970-34 Convertible Top 970-38 Cruise Control 970-59 Defogger 970-53 Engine Oil Cooling Fan 970-32 Engine Management 970-26 Exterior Lights 970-63 Fog Lights 970-69 Ground Instrument Panel 970-75 Power Distribution 970- 2 Power Rear Wiper Washer 1986 - 1989 970-90 Sound Warning System 970-85 WiperAA asher and Headlight Washer 970-87 Relay, fuse and control module...

Cylinder head temperature sensor testing

Porsche Head Cylinder Temperature Sensor

The cylinder head temperature sensor arrow is installed in cylinder head 3. The cylinder head temperature sensor signal is the main temperature signal to the ECM. Table j. Cylinder Head Temperature Sensor Resistance Specifications 15 - 30 C 60 - 85 F 40 C 105 F 80 C 175 F 100 C 212 F 130 C 265 F 4.4 - 6.8 k 2 1.4- 3.6 k 2 1.0-1.3 k 2 250 - 390 2 160-210 2 90 2 Disconnect harness plug from white connector on left side of engine arrow . Connect ohmmeter across white connector terminals....

Oxygen sensor heater circuit testing

Wiring Harness 1984 720

Check oxygen sensor heater circuit at harness side of oxygen sensor connector inset . Attach digital multimeter set on volts to harness terminals 2 and 3. If voltage signal does not fluctuate or if there is no change when oil filler cap is removed, check for a faulty sensor wire in harness or connector arrow in engine compartment. If no wiring faults can be found, sensor is probably faulty and should be replaced. Oxygen sensor replacement is a maintenance procedure scheduled at a specified...

Input shaft disassembling and assembling

Pilot Bearing Removal Tool

Mount shaft in vise using special tool P 355 a. Follow steps in illustration on following page. 1. Collar nut removal Use special tool P 252 a 41 mm socket or equivalent. Installation Torque to 230 Nm 166 ft-lb . Lock by punching collar. See detail A. 2. Roller bearing removal Press off with special tools VW 401, VW 402, VW 412. When pressing, support under 2nd gear 17 . Installation Heat to approx. 120 C 250 F . Press on with special tools VW 401, VW 454 press 3. Ball bearing inner race...

Automatic heating system

1984 Porsche 911 Heating System Diagram

The automatic heating system controls the passenger compartment temperature based on the setting of the temperature control knob. By comparing the passenger compartment temperature to the setting at the temperature control knob, the control module servo motor automatically opens or closes the heater control box valves to maintain the desired temperature. Control module with servo motor Housing Printed circuit board Rivet Heat exchanger temperature sensor Passenger compartment temperature sensor...

Clutch crossshaft bearing update hydraulic operated clutch

Porsche 944 Clutch Fork Shaft

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...

Mechanical Troubleshooting

When troubleshooting an engine that fails to start or runs poorly, first check its mechanical condition particularly if the engine has high mileage. A cylinder compression test is given in 010 General. Also covered there is a brief description of a wet compression test and a cylinder leak down test. Table b lists the symptoms of common engine mechanical problems, their probable causes and the suggested corrective actions. The bold type indicates the repair groups where applicable test and...