Throttle position switches

The full throttle switch is used for full throttle enrichment. The switch signals the ECM when the throttle is fully opened. A separate idle switch is used for the closed throttle signal. The closed throttle signal is also used for idle speed control and deceleration fuel cutoff. Both throttle position switches are mounted on the throttle housing and can be tested with the throttle housing installed. Before testing full throttle or idle switch, check that each is receiving reference voltage...

Electrical Checks And Component Testing

Use a high impedance digital multimeter for all voltage and resistance tests. ' An LED test light should be used in place of an incandes-cent-type test lamp. Avoid damaging harness connectors or relay panel sockets. Jumper wires should be fabricated with flat-blade end connectors that are the same size as the connector or relay terminal being tested. Always switch the test meter to the appropriate function and range before making test connections. Connect and disconnect the test equipment only...

Electrical testing

Many electrical problems can be understood and solved with only a little fundamental knowledge of how electrical circuits function. Electric current only flows in a complete circuit. To operate, every electrical device in the car requires a complete circuit including a voltage source and a path to ground. The positive (+) side of the battery is the original voltage source, and ground is any return path to the negative (-) side of the battery, whether through the wiring harness or the car body....

Wheel Bearings

Rear wheel bearings are serviced by replacement only, as they are usually damaged when removed. The rear wheel bearings are permanently sealed and lubricated and do not require any routine maintenance. Removing and installing the bearing on the car requires a special puller. If the necessary tools are not available, this work is best left to an authorized Porsche dealer or other qualified repair shop. Check the wheel bearing with the wheel off the ground and the car properly supported. Spin the...

Brake pads inspecting

Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts. Visually inspect brake pads for thickness and compare to specifications. Replace as necessary. Wear limit A (front or back) 2 mm (0.08 in.)

Sunroof

SUNROOF ASSEMBLY 601-2 Sunroof panel, emergency closing 601-2 Sunroof panel, adjusting 601-3 Sunroof panel, removing and installing 601-5 Wind deflector, removing and installing 601 -6 Sunroof cables, replacing 601-7 removing and installing 601 -7 Sunroof guide rails, cleaning 601-7

Axle Shafts

In a car with independent rear suspension the drive axles must be able to move with the suspension while delivering power to the wheels. To accomplish this, a constant velocity (CV) joint is located at each end of each axle shaft. A CV joint is similar in function to the more familiar universal joint. The CV joint allows for the smooth flow of power to the drive wheels even though the final drive, axles and wheels are not lined up with each other. The advantage of the more complicated CV joint...

Warning

Brake friction materials such as brake linings or pads contain abrasive fibers which can lead to illnesses. Do not create dust by grinding, sanding, or cleaning the pads with compressed air. Avoid breathing any brake friction fibers or dust. Brake fluid is poisonous, highly corrosive and dangerous to the environment. Wear safety glasses and rubber gloves when working with brake fluid. Do not siphon brake fluid with your mouth. Immediately clean away any fluid spilled on painted surfaces and...

Brake lines

Only straight metal brakes lines are available as replacements. To replace a brake line, first remove the old line from the car and measure its length. Using a new straight line of the same length, bend it to match the pattern of the old line. Each bend radius should be no smaller than about 15 mm (9 16 in.). Check that the protective coating on the brake line is not damaged after bending. Make sure the new brake line has sufficient clearance from the body and suspension when installed, to...

General

This group covers component replacement and adjustment procedures for the ventilation system. Refer to the following groups for further information 800 Heating, Ventilation, Air Conditioning-General The air distribution levers use cables to control fresh air and heated air to the footwells and the defroster outlets. A fresh air blower is located in the luggage compartment below the windshield. The ventilation controls have no control over air distribution to the center dash vent or the side...

Continuity checking

The continuity test can be used to check a circuit or switch. Because most automotive circuits are designed to have little or no resistance, a circuit or part of a circuit can be easily checked for faults using an ohmmeter. An open circuit or a circuit with high resistance will not allow current to flow. A circuit with little or no resistance allows current to flow easily. Use only a high quality digital ohmmeter having high input impedance when checking electronic components. The internal...

Tightening fasteners

When tightening the bolts or nuts that attach a component, it is always good practice to tighten the bolts gradually and evenly to avoid misalignment or over stressing any one portion of the component. For components sealed with gaskets, this method helps to ensure that the gasket will seal properly and completely. Where there are several fasteners, tighten them in a sequence alternating between opposite sides of the component. Repeat the sequence in stages until all the bolts are evenly...

Output shaft disassembling and assembling

The output shaft is also referred to as the pinion shaft. All parts should be installed dry. Follow steps in illustration on facing page. Details are covered below. Speedometer gear at forward end of shaft (not illustrated) Installation Heat to approx. 120 C (250 F) and press on. A Check clearance between shift fork and operating sleeve. Shift fork to operating sleeve max 0.5 mm (0.02 in.) B Asymmetric teeth (A) and recess (B) of 1 st - 2nd gear operating sleeve must face 1st gear. C Raised...

Special tools

Most of the operations and repairs in this section require the use of special tools. If you lack the skills and tools, or a suitable workplace for servicing the transmission, we suggest you leave these repairs to an authorized Porsche dealer or other qualified shop. Completely reconditioned transmissions are available from qualified Porsche repair facilities. Difficult shifting may be caused by worn out synchronizer teeth, sometimes referred to as dog teeth.

Warnings and cautions

Please observe the following cautions and warnings when performing any service or repair on the engine. The fuel system is designed to retain pressure even when the ignition is off. When working with the fuel system, loosen the fuel lines very slowly to allow residual fuel pressure to dissipate gradually. Avoid spraying fuel. Fuel is highly flammable. When working around fuel, do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other fire...

Wheels and tires general information

Check for tire directional markings (arrow on sidewall) before mounting a tire. Always replace tire valves when mounting new tires. Replace stick-on valve stem supports if missing. Use only rubber lubricant on the tire beads when mounting tires. Do not use silicone. Clean lubricant from bead area before inflating the tire to reduce the possibility of the tire slipping on the wheel. Fast acceleration and hard braking should be avoided for the first 150 miles after mounting a new tire. Inflate...

Raising car safely using vehicle jack

Remove plastic plug from jack receptacle in rocker panel (arrow). Place jack fully into square receptacle in rocker panel. Make sure jack is resting on flat, solid ground. Use board or other support to provide a firm surface for jack, if necessary. Raise car slowly with jack while constantly checking position of jack and car. Once car is raised, block wheel on opposite side of vehicle, to prevent car from unexpectedly rolling. Do not rely on the transmission or...

Safety

Although an automobile presents many hazards, common sense and good equipment can help ensure safety. Many accidents happen because of carelessness. Pay attention and stick to these few important safety rules. Never run the engine in the work area unless it is well-venti-lated. The exhaust should be vented to the outside. Carbon monoxide (CO) in the exhaust kills. Remove all neckties, scarfs, loose clothing, or jewelry when working near running engines or power tools. Tuck in shirts. Tie long...

Braking system

All 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 rotors and rear rotors. A brake pad wear sensor for each wheel indicates when pads need replacement. The dual-drum parking brake is integrated with the rear brake rotors. In order to prevent rear wheel lock-up and loss of steering control during hard braking,...

Buying Parts

Many of the maintenance and repair tasks in this manual call for the installation of new parts, or the use of new gaskets and other materials when reinstalling parts. Most often, the parts that will be needed should be on hand before beginning the job. Read the introductory text and the complete procedure to determine which parts will be needed. For some bigger jobs, partial disassembly and inspection are required to determine a complete parts list. Read the procedure carefully and, if...

Flushing brake system

Do not rely on flushing alone to clean a system contaminated with dirt or corrosion. The flushing procedure may actually force dirt in the lines into the calipers. To do the job thoroughly, the system must be disassembled and the parts individually cleaned. Use only brake fluid to flush the lines. Alcohol must not be used since it will encourage the accumulation of water in the system. When preparing to bleed the brakes, be sure to read the following warnings and cautions. When working...

Nonreusable fasteners

Many fasteners used on the cars covered by this manual must be replaced with new ones once they are removed. These include but are not limited to bolts, nuts (self-locking, nylock, etc.), cotter pins, studs, roll pins, clips and washers. Genuine Porsche parts should be the only replacement parts used for this purpose. Some bolts are designed to stretch during assembly and are permanently altered rendering them unreliable once removed. These are known as torque-to-yield fasteners. Always replace...

Wheels tires and alignment

Tires greatly influence the handling, stability and cornering performance of a Porsche. In order to gain the best possible performance from a Porsche all four wheels must be aligned correctly. If the torsion bars or torsion bar components have been replaced, the vehicle's corner weights (weight at each wheel) must be checked before an alignment is performed. For stability and control, wheels and tires must be in good condition and properly aligned. Tire inflation pressures, tire wear and wheel...

Nonreturnable parts

Some parts cannot be returned for credit, even if they are the wrong parts for the car. The best example is electrical parts, which are almost universally considered non-returnable because they are so easily damaged internally. Buy electrical parts carefully, and be as sure as possible that a replacement is needed, especially for expensive parts such as electronic control modules. It may be wise to let an authorized Porsche dealer or other qualified shop confirm your diagnosis before replacing...

Targa and Cabriolet models

Both the Targa and Cabriolet models are all-season vehicles with a high level of functionality, excellent interior comfort, and acoustic refinement. Early versions of the Cabriolet model used a manually operated top, with the fully automatic convertible top being introduced in the beginning of the 1986 model year. All pillars and frame members are of thin wall sheet metal and have been deep-drawn for maximum strength. This allows for control cables, linkages and heater lines to be accommodated....

Short circuit testing with ohmmeter

Remove blown fuse from circuit and disconnect cables from battery. Disconnect harness connector from circuit's load or component. Using an ohmmeter, connect one test lead to load side of fuse terminal (terminal leading to circuit) and the other test lead to ground. If there is continuity to ground, there is a short to ground. If there is no continuity, work from wire harness nearest to fuse relay panel and move or wiggle wires while observing meter. Continue to move down harness until meter...

And installing cableoperated clutch

Clutch cross-shaft repairs and upgrades are recommended during a clutch replacement job. Remove engine transmission from car. Separate engine from transmission. See 101 Engine Removal and Installation. Check for wear or damage in clutch release fork. Look for cracks in casting at stress points (arrows). Drive dowel pin out of clutch fork. Pull cross-shaft out of transmission, disengaging from fork. If the clutch release lever is frozen to the clutch cross-shaft, remove them together by sliding...

968 Sellers And Buyers Of Glass Mail

This repair group covers door repair information, including removal and installation of the door and the interior door panel. For information on the power windows and door glass replacement, see 640 Windows. For information on the power door locking system, see 950 Central Locking.

Door window adjusting Coupe models

Whenever the window regulator is removed, window adjustment should be checked. The glass should contact the top of the window frame squarely and should seat against the window seal uniformly. If the window stop is not adjusted correctly the door may become hard to close or wind noise may be a problem. The window regulator has two adjustments, one is for in-out tilt and the other is for front rear height parallelism. Remove door trim panel. See 570 Doors. Loosen bolts securing rear regulator...

Engine lid hood 5501

GENERAL 550-1 FRONT HOOD ASSEMBLY 550-1 Front hood, removing and installing 550-2 Hood, aligning 550-2 Hood latch, adjusting 550-3 Hood cable, replacing and adjusting 550-3 Hood, emergency opening with broken cable. 550-4 Hood hinge, replacing 550-4 Hood support struts, replacing 550-5 ENGINE LID ASSEMBLY 550-6 Engine lid, removing and installing 550-6 Engine lid grill, removing and installing 550-7 Engine lid, aligning 550-7 Engine lid strut, removing and installing 550-8

Exterior Trim

Special tools 660-1 outside rear view mirrors 660-2 Outside mirror glass, replacing 660-2 removing and installing 660-3 Outside mirror housing, removing and installing 660-3 exterior trim 660-4 Rocker panel, removing and installing 660-4 Rear reflector panel, removing and installing. .660-4 Porsche emblem 660-4 a. Outside Mirror Drive Motor Wire Colors 660-3

Ignition lock removing and installing

Disconnect negative (-) battery cable. Working under dashboard, remove knee trim panel screw (arrow) located above luggage compartment lid release handle. Working from below, remove trim mounting nut and washer from left stud (A). Working just below heater controls in center of dashboard, remove trim mounting nut and washer from right stud (B). Loosen lock nut and alien bolt (A) holding ignition lock arm in column support. Working from rear of ignition lock, disconnect harness connector from...

Alternator and regulator checking

Attach digital voltmeter to negative (-) and positive (+) battery terminals. Make sure tester is connected to clean areas of terminals. Set voltmeter to DCV scale. Start engine and run it at about 1500 rpm with all electrical accessories turned off. Measure voltage at battery. A reading much higher than 14.2 volts most likely indicates a faulty voltage regulator. A reading below 13.5 volts means that the battery is not adequately charged. This may be due to To determine which component is...

Door window regulator removing and installing

Remove door trim panel. See 570 Doors. Remove regulator arm support bolts (arrows). Disconnect electrical plug from window motor. Remove bolt securing regulator to door (arrow). Slide both regulator guide wheels out of front window guide rail. The guide wheels will not come out through the rear of the window guide rail. Be sure tape holds well. If the window drops into the door unexpectedly, it will most likely shatter. Push window into closed position and...

Short circuits

A short circuit is exactly what the name implies. The circuit takes a shorter path than it was designed to take. The most common short that causes problems is a short to ground where the insulation on a positive (+) wire wears away and the metal wire is exposed. When the wire rubs against a metal part of the car or other ground source, the circuit is shorted to ground. If the exposed wire is live (positive battery voltage), a fuse will blow and the circuit may be damaged. Shorts to ground can...

Hood support struts replacing

When replacing both hood support struts, do only one strut at a time. Raise hood and support in up position. Remove locking clip and clevis pin from support strut upper mounting (upper arrow). Remove locking clip and clevis pin from support strut lower mounting (lower arrow). Place new strut in position and install lower pin and locking clip. While compressing strut slightly, install upper pin and locking clip.

Brake rotor checking

Check the brake rotors for wear any time the brakes are serviced. Rotors that are scored with sharp ridges, warped, worn irregularly or cracked should be replaced. Brake rotors should always be resurfaced in pairs, with an equal amount of material removed from both sides of each rotor. Table a lists the dimensions for resurfacing rotors. Rotors which fail to meet these requirements should be replaced. On original equipment rotors, the minimum thickness dimension can be found stamped into the...

Expansion valve replacing

Following manufacturer's instructions, connect an approved refrigerant recovery recycling recharging unit to A C system and remove refrigerant. Do not discharge charge the A C system without proper equipment and training. Damage to the vehicle and personal injury may result. Read warnings and cautions given earlier. Remove evaporator temperature sensor duct support from expansion valve and gently push duct away from valve. Remove insulating tape (A) from expansion valve. Disconnect refrigerant...

Hood emergency opening with broken cable

See 630 Bumpers. Locate and punch mark position 50 mm (2 in.) down from bottom of bumper trim panel and 25 mm (1 in.) to the left of body center line. Drill an 8 mm (5 16 in.) hole through front body panel. Using a piece of stiff steel wire (6 mm or 1 4 in.) approximately 40 cm (16 in.) long, make a 90 bend 15 mm (0.6 in.) from wire end. Insert tool upward through hole in panel to catch hood release. Turn tool to right to release lock. Plug drilled hole (use...

Xerior Lighting

1984 Porsche 911 Instrument Wiring

GENERAL 940-1 Test equipment 940-1 940-1 FRONT LIGHTING 940-2 Headlights, aiming 940-3 Headlight sealed beam, replacing 940-3 Headlight halogen H-4 bulb, replacing 940-4 Front fog light assembly, removing and installing 940-4 Front turn signal bulb, replacing 940-5 Front turn signal assembly, removing and installing 940-5 REAR LIGHTING 940-5 Taillight bulb, replacing 940-5 Taillight assembly, removing and installing . . .940-5 Center brake light bulb, replacing 940-6 License plate light,...

Basic engine settings

The DME system compensates automatically for changes in the engine due to age, minor wear or small vacuum leaks. As a result, idle speed and mixture do not need adjustment as part of routine maintenance. See Table a. Table a. Idle and Emissions Specifications Table a. Idle and Emissions Specifications Measured at test port on front of catalytic converter, oxygen sensor disconnected Poor initial driveability may be encountered when the battery is disconnected and reconnected. When the battery is...

Bngne Lubrication

Lubrication system 170-1 Oil pressure relief valves 170-3 Oil pressure, checking 170-4 Lubrication warning system 170-5 Oil pressure warning light, testing 170-5 Oil level sensor, testing 170-6 Lubrication system, flushing 170-7 Engine oil tank, removing and installing 170-8 Engine oil cooler, removing and installing . . . .170-9 Auxiliary oil cooler pressure relief valve, removing and installing 170-11 Auxiliary oil cooler, removing and installing. .170-12 Auxiliary oil cooling fan, replacing...

Residual fuel pressure testing

For quick restarts and to avoid vapor lock, the fuel system is designed to retain fuel pressure after the engine has been turned off. This residual pressure is primarily maintained by a check valve (arrow) at the fuel pump outlet and by the fuel pressure regulator. Relieve fuel pressure and connect pressure gauge to test port (arrow) as described earlier. Operate fuel pump for approximately one minute as described under Operating fuel pump for tests. With pump off, observe fuel pressure gauge...

Hood cable replacing and adjusting

Install new cable and thread end through latch release arm and into cable clamp (arrow). While holding cable tight using pliers, tighten cable clamping screw. Check for proper hood latch operation before closing hood. While a helper pulls hood release, check that latch releases smoothly and returns to the locked position. If necessary readjust cable.

Steering column removing and installing

Disconnect negative (-) battery cable. Working inside luggage compartment, detach upper steering column universal as described earlier. Working in passenger compartment, remove steering wheel and steering column switches as described earlier. Working under dashboard, remove knee trim panel screw (arrow) located above luggage compartment lid release handle. Remove left outer A C vent from dash. Remove screw (A) from trim panel on left side of dash. While pulling on A C vent, release locking...

Tie rod removing and installing

To replace a worn tie rod end, first measure and record the overall length of the tie rod. This will ensure that the alignment will be disturbed as little as possible because of removal and installation. Raise car and remove front wheel on side to be repaired. Remove cotter pin from inner tie rod end bolt. Remove bolt. Either tie rod end can now be replaced by clamping tie rod shaft in shop vise.

Tire storage

The rubber in tires is sensitive to environmental conditions and foreign substances. Ozone, fuels, greases and oil all can have a destructive effect on tires. Store tires indoors where the temperature is between 14 F and 68 F and the air is dry. Wash tires before storing them. Keep tires out of sunlight or fluorescent lighting. Store tires on wheels with full tire pressure. Do not hang tires on hooks or stack them on top of each other.

Air Conditioning

Porsche 911 System

With the A C on, the air is cooled and dehumidified by the evaporator to maintain the desired temperature. Cooling efficiency of the air conditioner system is dependent on the engine rpm. The greater the rpm the higher the output from the air conditioner. The air conditioner works only with the engine running. The rear lid must be closed for the A C system to operate properly. The schematic view shown below is a typical A C system. In the Porsche system there are two condensers in the vehicle,...

Front suspension

Each front wheel includes a strut-type shock absorber mounted on a permanently lubricated ball joint. A control arm on each side houses a longitudinal torsion bar and is attached to the suspension subframe. The torsion bars are adjustable. Suspension travel is limited by progressive rubber buffers (bump stops) installed on each strut piston. Cornering control is enhanced by a transversely mounted stabilizer bar connected to the control arms and the rear of the suspension subframe with rubber...

Oxygen sensor

The oxygen sensor is mounted in the inlet side of the catalytic converter. The oxygen sensor monitors the exhaust gas and provides feedback about combustion efficiency to the engine control module (ECM). The catalytic converter reduces emissions most efficiently when the percentage of oxygen in the exhaust falls within a narrow range. Oxygen sensor diagnosis is covered in 240 Fuel Injection. Oxygen sensor replacement is covered in 030 Maintenance. A quick-check for detecting exhaust leaks is to...

AC components

The A C system removes heat and moisture from the passenger compartment. It accomplishes this through the application of four physical principles materials absorb heat as they change from a liquid to a gas (evaporate) materials give off heat as they change from a gas to a liquid (condense) the boiling point of a liquid varies with its pressure and, heat always flows from hot to cold. For example, the first principle is demonstrated by wetting your hand and then blowing on it. As the water...

Control module housing removing and installing

Remove passenger seat to gain access to heater controls and parking brake handle assembly. Remove access panel from right side of heater control housing. Disconnect heater valve servo control rod (arrow) from lever. Remove heater control housing trim screws from floor. Remove rubber sleeve covering parking brake lever. Lift control module housing up and turn over. Lift rug behind and under housing. Disconnect electrical harness connectors (arrows). With all wiring harnesses disconnected remove...

Bleeding Brakes

Brake bleeding is usually done for one of two reasons either to replace old brake fluid as part of routine maintenance or to expel trapped air in the system that resulted from opening the brake hydraulic system during repairs. Brake system bleeding can be done with a pressure bleeder, a vacuum bleeder or manually. Pressure bleeding is recommended as the most efficient method. When bleeding the brakes, start at the wheel farthest from the master cylinder and progress in the following order

Gaskets and seals

Once a gasket has been used, it is no longer capable of making as good a seal as when new, and is much more likely to leak. For this reason, Always plan to use new gaskets for any reassembly. Some gaskets are directional. Make sure that these are installed correctly. This same logic applies to any part used for sealing, including rubber O-rings and copper sealing washers. In places where a shaft must pass through a housing, flexible lip seals are used to keep the...

Synchronizer checking

Measure across synchronizer ring with gear and synchronizer fully assembled. If diameter exceeds specifications, replace synchronizer teeth. Synchronizer Ring Diameter Specification 3rd, 4th, 5th gears 76.3 0.18 mm (3.004 0.007 in.) 1st, 2nd gears 86.37 0.17 mm (3.400 0.007 in.) Remove circlip. Synchronizer ring should remain coiled inside synchronizer teeth. If not, teeth are worn and should be replaced. Check synchronizer teeth on gear assembly for damage or wear. The synchronizer teeth can...

Of 3

FROM IGNITION SWITCH (DIAGRAM 1 OF 3) CONTROL UNIT H> (0IAGRAM 1 OF 3) HEATER LEVER CONTACT CONNECTOR (NOT USED) REAR WINDOW OEFOGGER 4 MIRROR HEATING SWITCH I LUGGAGE I COMPARTMENT I FUSE OOX 1 FROM IGNITION SWITCH (DIACRAM 1 OF 3) I POWER'TOP 5 TOP i FUSE (FUSE .HOLDER Si T2.5A AOOITIONAL WINDSHIELD INTERMITTENT POTENTIO- CLEAN1NG WIPER WIPER METER FLUID MOTOR CONTROL BUTTON RIGHT INSIDE HEATED TEMPERATURE

Sunroof panel adjusting height

1984 Porsche 911 Quarter Panel Left Side

The sunroof panel should be adjusted If the top of the closed sunroof becomes misaligned with the roof of the car If it does not close squarely if there are wind noises at speed If the sunroof has been removed. Open sunroof approximately 100 mm (4). Carefully pull down on front of trim panel to free securing clips. Slide headliner panel back into roof cavity. Remove plastic caps covering front guide screws on left and right sides. Left side is shown (arrow). To adjust front height of sunroof...

Front hood removing and installing

Hood Hinge Adjust

Disconnect harness connector for luggage compartment light. Unclip harness from hood hinge. Remove light switch retaining nut from switch. Precisely mark hinge location on hood panel. Loosen hood mounting bolts on left and right sides (arrows). With aid of a helper, support hood while removing mounting bolts. Remove hood, guiding harness through hinge. Installation is reverse of removal. Repair any paint damage and paint any exposed metal. Check hood alignment as described next.

Replacing brake fluid

Porsche recommends that the brake fluid be replaced at least once every two years. This is due to the fact that brake fluid readily absorbs moisture. Moisture in the brake fluid can adversely affect braking performance and may also damage the system, leading to costly repairs. Replace the brake fluid using one of the procedures described later to expel the old fluid. Remove the filter strainer from the brake fluid reservoir and clean it in new, unused brake fluid. Using new, unused brake fluid,...

AC compressor clutch testing

To quickly check the operation of the compressor clutch, turn the ignition on and turn the temperature regulating knob to its full cold position. Turn the A C switch on and listen for the compressor clutch to click on. If no click is heard, the compressor clutch may not be receiving voltage or the clutch itself may be faulty. Check for battery voltage at single-wire connector (arrow) leading out of compressor. If voltage is present, compressor clutch is faulty and should be replaced. If no...

Spare parts kit

Carrying a basic set of spare parts can prevent a minor breakdown from turning into a major annoyance. Many of the following items won't allow you to do major repair work on the car, but they will help in the event of the failure of something that can disable the car or compromise its safety. (relay is located under driver's seat.) Alternator and A C drive belts (V-belts) Engine oil (one or two quarts) Fuse assortment (5A, 8A, 16A, 25A) Spare Parts Kit - Additional Contents Exterior lighting...

Door removing and installing

Disconnect battery negative (-) cable. Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii. Remove door panel. See Door panel, removing and installing. Label and disconnect wiring from all switches. Arrange wiring so that it can be easily withdrawn through door once door is unbolted. Table a. Window switch wiring connections Table a. Window switch wiring connections While supporting door, remove upper and lower hinge bolts...

Ignition system quickcheck

911 Targa Coil Wiring

If the engine does not start, the most fundamental step in troubleshooting the ignition system is to determine whether or not the system is making a spark at the spark plug. If no spark is present, then more detailed testing of the ignition system is necessary. To check for spark, turn ignition off and remove connector from a spark plug. Connect to known good spark plug. Attach jumper wire with alligator ends to spark plug threads and a good engine compartment ground. Do not hold the spark plug...

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...

Door window removing and installing

Position window about halfway down in door. Remove door trim panel. See 570 Doors. Remove window frame from door. See 570 Doors. Be careful not to drop two bolts located at the top front of the door. If bolts do drop Into the channel, use a magnet to fish them out through the drain hole in the bottom of the door. When removing the door frame, the window glass stays in the door. Carefully pry outer window weather-strip from top of door at Carefully peel off inner weather strip. Carefully pry...

Fender removing and installing

1985 Porsche Hood Cable Bracket

See 630 Bumpers. Peel up rubber hood seal on side to be repaired. Remove screw securing headlight ring (arrow) and remove ring. Remove headlight assembly screws (arrows). Disconnect electrical plugs and remove headlight assembly. Remove wiring connectors from headlight harness plug. Withdraw wiring harness from headlight bucket. Working inside headlight bucket, remove fender mounting bolt (M8). Disconnect cable from lid release (A). Pry out retaining ring from fuel filler...

Brake Calipers

Brake calipers are self-adjusting units. When brake fluid pressure is applied to the caliper piston, the seal ring in the caliper wall deforms slightly, allowing the piston to move out and engage the brakes. When brake fluid pressure is reduced, the seal ring returns to its original shape, pulling the piston back and disengaging the brakes. As brake pads or rotors wear, the deformation of the seal ring reaches its limit and the piston actually slides out further before regaining a stable...

Ventilation

GENERAL 850-1 Fresh and heated air distribution 850-1 FRESH AIR BLOWER 850-2 Fresh air blower, removing and installing . 850-2 VENTILATION CONTROLS 850-3 Ventilation controls, removing and installing . . 850-3 Fresh air valve cable, adjusting 850-4 Fresh air distribution cable, adjusting 850-4 Heated air distribution cable 850-4 Fresh air and heating footwell defrost flap controls

Heat exchanger temperature sensor removing and installing

Lift temperature control module housing as described earlier. Disconnect harness connector C at front of module. Use special wire connector tool to push wire ends out of plastic connector. The plastic connector will not fit through the hole in the rear bulkhead and must first be removed from the harness. Remove heater hose from left heat exchanger valve housing. Loosen clamp bolt and remove heat sensor sleeve. Drill out rivets arrows and remove sensor from sleeve. Rivet new sensor to sensor...

Ignition timing

Ignition timing is electronically controlled and is not adjustable on DME systems. The initial baseline ignition point is determined by crankshaft position during starting. This is signalled by a crankshaft reference sensor. Once the engine is running, the ignition point is continually changed based on the various inputs to the control module. Engine speed is signalled by a crankshaft speed sensor. A DME ignition characteristic map illustrating all the possible ignition points is shown. A map...

Steering wheel centering

If the steering rack was disturbed while the steering wheel was removed, or if a new unmarked steering wheel is being installed, the steering rack will have to be centered prior to installing the wheel in a straight ahead position. To center the steering rack, temporarily position the steering wheel on the column and turn until the road wheels point straight ahead. Reposition steering wheel and install lock washer and nut. Back car up a short distance and drive forward a short distance to see...

Heat exchanger control cable replacing and adjusting

The heat exchanger valve on each side is held open by a spring. Closing of the valves is controlled by a cable attached to the temperature control module or control lever. 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. Working underneath car, disconnect cable ends arrow from heat exchanger valves. Left side shown. Right is...

AC blower resistor pack testing

The A C blower resistor pack, located in a compartment behind the passenger side footrest, is also referred to as the bimetallic switch. If the evaporator blower works at the maximum setting, but not in A C blower switch positions II and III, test resistor Detach harness connector at resistor pack. With ignition switch on and blower switch in position II, there should be battery voltage at harness connector red green wire. With ignition on and blower switch in position III there should be...

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...

Maintenance

GENERAL 030-2 MAINTENANCE TABLES 030-2 FLUID AND LUBRICANT SPECIFICATIONS 030-5 ENGINE OIL SERVICE 030-6 Engine oil and filter, changing 030-6 MAINTENANCE 030-7 Air filter element, replacing 030-7 Spark plugs, replacing 030-8 wires, replacing 030-8 Fuel filter, replacing 030-9 Valve clearance, adjusting 030-9 Battery maintenance 030-12 Throttle housing and linkage, lubricating . . .030-13 V-belts, checking and replacing 030-13 Oxygen sensor, replacing 030-14 Tires, checking inflation pressure...

Fresh and heated air distribution

The air distribution levers control fresh air and heated air to the footwells and the defroster outlets. The slider controls have no control over air distribution to the center dash vent or the side dash vents. This center vent is used for A C only. The left and right side vents are for A C or heated air and are turned on and off by the vertical knurled control knob. Top lever s Controls fresh air intake from outside the vehicle. When the lever s is in the extreme left position, air intake...

Outside mirror glass replacing

The mirror glass is held in place by a large locking ring. Turning the locking ring left or right locks and unlocks the glass. The mirror glass should be at or above room temperature before removal. Otherwise, small plastic parts or glass will break. Press mirror glass in at bottom. Insert small screwdriver through hole in bottom of mirror housing and locate locking ring slots. Turn locking ring counterclockwise to release mirror glass. NOTE Inset shows slots in bottom of locking ring....

Outside mirror housing removing and installing

Remove mirror glass and motor as described earlier. Use wiring connector removal tool to push wire terminals out of mirror motor harness connector. Remove alien mounting bolt arrow at base of mirror housing. Remove mirror while feeding wiring harness through mirror base. Installation is reverse of removal. Wiring colors are shown in Table a. Table a. Outside Mirror Drive Motor Wire Colors 2. Rear torsion bar end cover 6. 3. Rocker panel mounting 7. screws Rocker panel end cover Plastic spacer...

Ignition system visual inspection

Pitted And Corroded Distributor Rotor

The spark plug wires, ignition coil, distributor cap and ignition rotor are subject to wear and electrical breakdown which will impair their ability to deliver a crisply timed and powerful spark. Many of these conditions are most easily detected by a thorough visual inspection. Dirt and moisture on any of these components are also potential causes of poor spark at the spark plugs. To inspect cap and rotor, use flat-tipped screwdriver to press down and turn cap hold down pins turn each. Inspect...

Door window adjusting Targa and Cabriolet models

Porsche 928 Door Panel

Whenever the window regulator is removed, the window adjustment should be checked. The glass should contact the top of the window frame squarely and should seat against the window seal uniformly. If the window stop is not adjusted correctly the door may become hard to close or wind noise may be a problem. The window regulator used in the targa and convertible uses to stops for setting window travel. Remove door trim panel. See 570 Doors. Lower window until stop bracket is aligned with access...

Electrical System General

1984 Porsche 911 Under Dash Wiring

GENERAL 900-1 Special tools 900-1 Electrical system safety precautions 900-1 Voltage and polarity 900-2 Wiring, fuses and relays 900-3 Electrical test equipment 900-3 WIRING DIAGRAMS 900-3 Wiring codes and abbreviations 900-3 ELECTRICAL TROUBLESHOOTING . . 900-5 Voltage and voltage drop 900-5 Voltage, measuring 900-6 Voltage drop, testing 900-6 Continuity, checking 900-7 Short circuits 900-7 Short circuit, testing with ohmmeter 900-7 Short circuit, testing with voltmeter 900-8 a. Wire Color...

Brake noise

Occasional groaning or squealing sounds from the disc brakes are usually caused by vibration being transmitted through the brake pads. Brake friction materials that contain little or no asbestos may contribute to brake noise. These noises are normal and rarely indicate a problem. Although there is no good solution, proper maintenance and repair can help minimize brake noise. Disc brake caliper assemblies include anti-rattle springs to minimize vibration and noise. Brake pads and calipers should...

Brake Master Cylinder And Power Booster

Porsche 928 Brake Regulator

The master cylinder is mounted to the rear of the brake booster. The master cylinder, power booster and brake fluid reservoir are mounted in the luggage compartment. The brake pedal operates the master cylinder via a pedal pushrod that passes through the firewall and operates a reversing lever. The reversing lever in turn operates the master cylinder brake booster push rod. The master cylinder piston acts on the brake fluid to create pressure in the system. The master cylinder and brake booster...

AC condenser blower front removing and installing

Disconnect negative - battery cable. See 030 Maintenance Remove luggage compartment floor mat. Disconnect blower electrical harness connector A . Remove screws arrows securing blower to floor. Slide blower back and lift out. Installation is reverse of removal. The A C evaporator assembly includes the following Evaporator and evaporator blower Expansion valve attached to the outside of the evaporator housing A C temperature control switch in the center console, connected to the evaporator...

Note

Brake Rotors Removal Tool

Brake caliper rebuilding procedures are beyond the scope of this manual. Remanufactured calipers are available from the Porsche dealer parts department, as well as a variety of after-market sources. Set caliper piston cutout alignment using Porsche special tool P 84. Check brake rotor for wear as described later. Replace or reface if necessary. Inspect brake pad sensor for wear or damage. Replace if necessary. Install new brake pads in caliper. NOTE Apply thin coat of Optimoly HT or equivalent...

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...

Rear brake rotor removing and installing

1989 Rear Brake Drum Bleeder Screw

Always replace or machine brake rotors in pairs. Press brake pedal down about 1 in. and hold in place with a pedal stop. This will prevent brake fluid from dripping out of open brake lines while the work is being performed. Raise car and remove rear wheels. Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts. Working at trailing arm, disconnect electrical...

Camshafts and Camshaft Cases

Negative Camber Adjustment Porsche 911

Special Camshafts, removing and installing 151-1 Camshaft CAMSHAFT CASES 151-9 Oil spray tube, replacing 151-9 a. Camshaft and Valvetrain Clearances 151-8 A 9191 Cam sprocket counterholding wrench B P 212 Camshaft sprocket lockpin extractor Battery electrolyte Is a corrosive acid. Always wear eye protection when working on or near the battery. This section covers information and repairs to the camshaft cases, camshafts, rocker shafts and rocker arms. Engine disassembly, including camshaft and...

Engine control module ECM accessing for tests

Porsche 924 Center Console

The DME engine control module C is located under the driver seat. Disconnect negative - battery cable. Wait approximately 1 minute. Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vii. Remove driver's seat. See 720 Seats. Disconnect ECM harness connector and connect pinout test harness to ECM for electrical tests of DME components. Table f. DME Engine Control Module ECM Harness Electrical Tests Battery voltage approximately...

Cruise Control

1985 Porsche 911 Turn Signal Wiring

GENERAL 960-1 Test equipment 960-1 ELECTRICAL SWITCHES 960-2 Console mounted switches 960-2 Door contact switch, removing and installing . 960-2 Fog light switch, removing and installing 960-2 Headlight switch, removing and installing 960-3 Horn contact ring, removing and installing 960-4 Ignition switch, removing and installing 960-4 Luggage compartment light alarm switch, removing and installing 960-3 removing and installing 960-4 removing and installing 960-5 removing and installing 960-5...

Engine General

Main Vent Vacuum Valve

Full-power curves 100-2 Acceleration curve 100-3 Engine case crankcase 100-4 Connecting rods 100-5 Cylinder head and valvetrain 100-6 Lubrication system 100-7 Engine MECHANICAL TROUBLESHOOTING . . .100-9 a. Engine b. Engine Mechanical Troubleshooting 100-9 The 1984-1989 Porsche Carrera models are fitted with a 3.2 liter, air cooled, horizontally-opposed engine. General engine specifications are shown in Table a. Note that there were slight variations in the engine used in 1987 and later cars....

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...

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...

AC compressor clutch replacing

Kompressor Porsche

The compressor clutch can be replaced without disturbing the sealed refrigerant system. Disconnect compressor clutch electrical connection. Loosen V-belt adjuster, slide A C compressor to left, and remove V-belt. Hold A C compressor clutch driveplate stationary with strap tool or equivalent to allow removal of retaining nut. Remove drive plate and pulley to access clutch magnetic winding. Remove circlip and slide magnetic coil off support. If reassembling with old parts, test magnetic coil...

Clutch replacing

Porsche 911 Clutch Replacement

The engine and transmission must be removed as a unit and than separated in order to service the clutch. It is normally recommended that the pressure plate and release bearing be replaced when a new clutch disc is installed. The flywheel and the transmission pilot shaft bearing should be carefully inspected when replacing the clutch. Replacing the clutch disc without replacing other worn components may accelerate clutch disc wear. Remove engine transmission from car. Separate engine from...

Digital multimeter

Many of the electrical tests in this manual call for the measurement of resistance ohms or voltage values. For safe and accurate tests of ignition, fuel injection, and emission control systems, the multi-meter, should be digital, with high at least 10,000 ohms input impedance. Some meters have automotive functions such as dwell and pulse width that are useful for troubleshooting ignition and fuel injection problems. The Motronic DME fuel and ignition system, and other electronic systems, may be...

Hood latch adjusting

Porsche Latch Spring

Before adjusting hood latch, be sure the hood is aligned evenly to fenders and cowl panel. The latch must locate in the center of the lock to close properly. The height at the front of the hood can be altered by sliding the lock assembly up or down on its mounting bolts. Loosen latch plate bolts arrows . Tighten bolts finger tight. Lower, but do not latch, hood so that latch plate pin centers itself in latch. Do not let hood lock with latch plate bolts loose. Open hood without altering position...

Rear bumper removal and installation

1984 Porsche 911 Pictures Wiring Dash

Working from behind, remove nuts and washers securing bumper bellows to body left and right sides of bumper . Carefully pull bellows away from bumper and body. Remove license plate light assemblies from bumper buffers and disconnect wiring harnesses. Working from behind, remove 3 nuts securing bumper buffers to bumpers. Pull buffers off of bumper on left and right sides. Remove concealing cap arrow from bumper protective strip and remove screw behind cap. Remove bumper mounting nuts arrows at...

Basic alignment

Always start a four wheel alignment procedure by beginning at the rear wheels. Make sure the car is loaded with a normal load. See below. Each front seat 68 kg 150 lb. Center of rear seat 68 kg 150 lb. Luggage compartment 21 kg 46 lb. Fuel Toe difference angle inside wheel 20 lock Can be changed only by replacing steering arm

F

Cluster tachometer upshift indicator to fuel pump via fuse box luggage compartment fusebox1, fuse 3, 25 amp N0. 1 I I No. 2 H No. 3 I No. 4 I no. 5 from Fuel pump main relay terminal 87b Ground front left, fuse box carrier from main fuel pump relay terminal 87b Do not measure resistance at terminal 9