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...

Wheel Bearings

The front wheel bearings are a tapered-roller design. Periodic repacking and adjustment is part of the normal maintenance routine for the car. See 030 Maintenance. When replacing wheel bearings, press equipment should be used to install the bearing races into the bearing hub. 3. Clamping alien bolt tighten to 15 Nm (11 ft-lb) 6. Outer race, outer wheel bearing 10. Outer race, inner wheel bearing

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.

Wheels Tires Alignment

General 440-1 Special tools and equipment 440-1 Wheels, tires and alignment 440-1 Wheels and tires, general information 440-2 WHEELS 440-3 Tire wear 440-4 Winter tires 440-5 Tire storage 440-5 WHEEL ALIGNMENT 440-6 Basic Extended alignment 440-7 Wheel load, checking 440-8 Front ride height, setting 440-8 Rear ride height, setting 440-9

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.

Diagnostic inspection and testing suspension

Suspension problems can usually be isolated and at least partially diagnosed by careful observation of the symptoms and inspection of the components that are the most likely cause. Torsion bars support the weight of the car and allow the suspension to travel smoothly over bumps and other road irregularities. A torsion bar that is twisted (loaded) by a bump simply unloads in the other direction with nearly the same force that loaded it. The function of a shock absorber, or damper, is to moderate...

General

The electric sunroof is operated by a motor drive and drive cables. The sunroof panel can be adjusted with out removing it from the car. Replacement of the sunroof liner or components such as the cable assembly require that the sunroof panel be removed. The sun roof drive motor is protected from damage by a slip coupling fitted between the motor and the drive. Be sure to check the front and rear drains in the corners of the sunroof for blockage. If water is entering through the sunroof one of...

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,...

Tightening Torques

Steering rack shaft support to body (6 mm alien) 25 Nm (18 ft-lb) Steering rack to suspension subframe 47 Nm (35 ft-lb) Steering universal pinch bolt 20 Nm (15 ft-lb) M10 45 Nm (33 ft-lb) M8 25 Nm (18 ft-lb) Tie rod to steering arm 45 Nm (33 ft-lb) Wheel to wheel hub 130 Nm (96 ft-lb)

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...

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

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...

Ground Distribution

Rear window defogger & mirror heating switch additional cleaning fluid pump relay passenger's power window switch driver's) driver's POWER window switch (driver's) passengers power window switch (passenger's) Ground Distribution 1S88-1989 (3 of 3) LICENSE WINDOW DEFOGGER WIPER CONTROL MOUNTED STOPLIGHT BLOWER HEATER (COUPE S. TARGA) HEATER 1 1 LEVER I CONTACT I CONNECTOR I j (NOT USED) ENGINE COMPARTMENT ALTERNATOR BLOWER

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

Sunroof Left Guide

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...

Heater

Special Automatic heating system 801-1 AUTOMATIC HEATING SYSTEM COMPONENT REPLACEMENT 801-2 removing and installing 801-2 Passenger compartment temperature sensor, removing and installing 801-3 removing and installing 801-4 Footwell blower, removing and installing 801-5 Footwell blowers series resistor, removing and installing 801-6 removing and installing 801-6 Heat exchanger control cable, replacing and adjusting 801-7

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...

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...

Refrigerant charge checking

The refrigerant R-12 charge is quickly checked by looking at the sight glass on the receiver dryer arrow , located in the left front wheel housing. It may be necessary to loosen the receiver dryer mounting clamps in order to rotate the sight glass into view. Start engine and turn A C on to its maximum setting. With compressor running clutch cycled on view sight glass. There should be few or no bubbles visible in the glass. A constant foaming indicates that system charge is low. Streaks on...

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

Porsche 911 Carrera Idle Control 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...

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

Hood hinge replacing

Porsche 911 Bonnet Hinges

Raise hood and support in up position. Mark hinge location on hood. When replacing both hood hinges, do one hinge at a time. Remove hood mounting bolts arrows . Disconnect hood support strut from hinge. Remove upper hood strut pin locking clip and remove pin. Remove hinge mounting bolts arrows and remove hinge. Installation is reverse of removal. Repair any paint damage and paint any exposed metal. Check hood alignment as described earlier.

Windshield Wipers and Washers

How Remove Wiper Arms

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...

AC receiverdrier replacing

The A C receiver drier is mounted in the rear of the left front wheel housing. The receiver drier must be replaced when -There is dirt in the A C system -The compressor has seized or has been replaced for any reason -The condenser or evaporator are replaced for any reason -The A C system is leaking and there is no more refrigerant -The A C system was open for 24 hours or more. Following manufacturer's instructions, connect an approved refrigerant recovery recycling recharging unit to A C system...

Transmission Service

The transmission case, which contains the transmission and differential gears, is a lightweight alloy die casting. The 915 transmission uses constant-mesh type gears, with Porsche's own design synchronizing system. Each forward gear 1 st through 5th is a mating pair of gears, and constant-mesh simply means the mating gears are always meshing. This section covers disassembly of the 915 transmission used on 1984 through 1986 models. Disassembly of the G50 transmission is not covered here. For...

Clutch slave cylinder replacing

Picture Slave Clutch Cylinder 1984

Using a clean syringe, remove brake fluid until the level is below the feed hose connection arrow for the clutch master cylinder. An alternate technique is to pinch off the clutch master cylinder feed hose, as shown. Brake fluid is poisonous. Do not siphon brake fluid with your mouth. Wear safety glasses when working with brake fluid and rubber gloves to prevent brake fluid from entering the bloodstream through cuts or scratches. Always dispose of old fluid...

Central Locking Service

Door Lock Actuator Disassembly

Central locking control module Central locking control module, replacing The central locking control module 1 is mounted in the right rear of the luggage compartment, directly below the windshield post. Disconnect negative - battery cable. Remove nut securing module to inner fender panel. Remove module from its mounting stud and disconnect multiple pin connector. Installation is reverse of removal. Door lock cylinder microswitch, removing and installing The door lock microswitch is attached...

Manual Transmission Gears and Shafts

Shaft Collar

GENERAL 350-1 Special tools 350-1 INPUT AND OUTPUT SHAFTS 350-1 Input shaft, disassembling and assembling 350-1 Output shaft, disassembling and assembling . 350-5 Synchronizer, checking 350-7 Synchronizer ring, removing and installing . 350-7 Synchronizer dog teeth 350-9 A P 355 a Input shaft mounting tool B P 252 a Input shaft collar nut socket 41 mm alternate 9105 Porsche ordering 000 721 910 50 C VW 401 or VW 402 Press support plate D VW 407 Input shaft bearing drift E VW 412 Input shaft...

Caution

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vii. Unsnap luggage compartment floor carpet and lift off. Remove fresh air blower cover retaining fasteners arrows . Remove cover. Remove screws arrows holding fresh air vent trim in cowl. Remove vent trim and screen. Working inside luggage compartment, detach fresh air plenum and blower connections Remove screws B holding fresh air blower housing in place. Disconnect heater...

AC evaporator blower motor testing

Porsche 911 1984 Dash Board

To test evaporator blower, first remove luggage compartment floor mat. Open access door in floor behind fuel tank. Detach connector arrow for A C evaporator blower motor and turn ignition and A C blower switch on position IIII, maximum setting . Check for battery voltage at connector red white wire. If voltage is present and blower does not operate, blower motor is faulty and should be replaced. If voltage is not present, check for a faulty fuse luggage compartment fuse box 3, fuse 2 , damaged...

Throttle plate basic adjustment

The factory-set throttle adjusting screw is not used to adjust idle speed. Its only function is to provide a mechanical stop for the linkage to prevent the throttle plate from contacting the inside of the throttle housing and causing wear. It should be adjusted only if the factory setting has been tampered with. To correct faulty throttle adjustment Remove tamper proof cap from throttle lever stop screw. Turn screw arrow counterclockwise until plate contacts throttle housing. Then turn screw...

Short circuit testing with voltmeter

Disconnect harness connector from circuit's load or component. Most fuses power more than one component. Be sure alt components are disconnected when checking for a short circuit. Using a digital multimeter, connect test leads across fuse terminals. Make sure power is present in circuit. If necessary turn key on. If voltage is present at voltmeter, there is a short to ground. If voltage is not present, work from wire harness nearest to fuse relay panel and move...

Static current draw test

Images Draw 1984

If the battery discharges over time, there may be a constant drain or current draw on the battery. A small static drain on the battery is normal, but a large drain will cause the battery to quickly discharge. Make a static current draw test as the first step when experiencing battery discharge. Make sure ignition and all electrical accessories are switched off. Disconnect battery negative - cable. Prior to disconnecting the battery, read the battery disconnection cautions given at the front of...

Selector shaft seal replacing

Planetary Screw Protective Boots

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. On 1984-1986 models Pull up center floor mat behind front seats. Remove 4 screws arrows from access panel and remove panel. Push back shift coupling protective boot and remove selector shaft set screw. On 1987-1989 models working underneath rear of car, push back rubber boot covering...

Torque wrench

A torque wrench is used to precisely tighten threaded fasteners to a predetermined value. Some of the repair procedures in this manual include Porsche-specified torque values in Newton-meters Nm and the equivalent values in pound-feet, more commonly written as foot-pounds ft-lb . Several types of torque wrenches are available. They all do the same job, but offer different convenience features at different prices. The most convenient ones have a built-in ratchet, and can be preset to indicate...

Shift rod coupling adjusting 19841986 models

Shift Rod Coupler Porsche

Access shift rod coupling in rear part of center tunnel as described above. Loosen shift rod clamping nut A on coupling. Turn transmission selector shaft counterclockwise as facing rear of car arrow 1 . With shift lever in neutral, pull shift lever towards driver's seat so that shift lever contacts stop. This will preload the shift rod in a counterclockwise direction arrow 2 as facing rear of car. Temporarily tighten shift rod coupling clamp, then test for correct adjustment Shift transmission...

AC system pressure testing

Ocular Pressure Testing

Test system pressure at an engine speed of 2,000 rpm and an outside temperature of approximately 77 F 25 C . Keep engine lid closed. Low side 0.81 - 2.0 bar 12-30 psi High side 7.93 -14.13 bar 115 - 205 psi Wear eye protection when testing the system. A C refrigerant at normal atmospheric pressures can evaporate and freeze anything it contacts. Table b lists A C refrigerant system capacities. Refrigerant R12 Total system capacity A C lubricating oil Compressor Evaporator Condensers Receiver...

Clutch release distance checking and adjusting cable operated clutch

Clutch Cable Spring 1984 Porsche 911

Clutch release distance is limited by an adjustable stop on the floor cover above the pedal cluster. This adjustment should be checked only after adjusting the clutch cable as described earlier. See Clutch cable, adjusting. Raise car and support in a safe manner. Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Working under transmission, use vernier calipers to measure...

Volume air flow sensor checking

The amount of air entering the engine is electrically measured by the volume air flow VAF sensor arrow . When the engine is running, intake air is drawn past the sensor vane and opens the spring-tensioned vane. The vane is mechanically connected to a potentiometer inside the sensor housing. A reference voltage is sent through the air flow sensor potentiometer and converted into an air volume signal based on the position of the vane. The VAF sensor also contains an integral intake air...

Brake caliper removing and installing

This procedure is applicable to both front and rear brake calipers. It is recommended brake calipers be replaced in pairs. Raise car and remove 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. Depress brake pedal approximately 1 inch and hold in place with a pedal depressor. This will prevent brake fluid from dripping out of open brake lines while the...

Battery maintenance

The battery is located in the luggage compartment, on the left side. When servicing the battery, always disconnect the negative - cable first, and connect it last. Simple maintenance of the battery and its terminal connections will ensure maximum starting performance, especially in colder temperatures. For a more detailed discussion of the battery and charging system, see 270 Battery, Starter, Alternator. A secure battery hold-down is important in order to prevent vibrations and road shock...

Door latch removing and installing

Porsche 911sc Door Lock Latch

See Door panel, removing and installing. Remove window glass. See 640 Windows. Remove window frame. See Door window frame, removing and installing. Working inside door, disconnect release cable and power door lock control rod from latch assembly. Disconnect locking rod from locking swivel on door. Remove rod support from door arrows . Working at door exterior, remove latch bolts arrows and remove latch from inside door. Installation is reverse of removal. If necessary,...

Muffler replacing

Raise car and support in a safe manner. Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Remove three M8 bolts and nuts that secure muffler to catalytic converter flange. Lubricate threads of two M10 alien bolts in muffler straps. Loosen both muffler strap bolts and slide each strap off muffler support while supporting muffler. Installation is reverse of removal. Use...

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...

Emergencies Changing a tire

Stop the car on as flat a surface as possible, in a place where you can be easily seen by other drivers. Turn on the emergency flashers, and set out flares or emergency markers well behind the car. Chock the wheel diagonally opposite to the one being changed. Firmly set the parking brake. Passengers should get out of the car and stand away from the road. If a tire goes flat while driving, pull well off the road. Changing a tire on a busy street or highway is very dangerous. If necessary, drive...

Parking brake shoes replacing

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 wheel. 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. Parking brake cable attachment at rear wheel Parking brake cable attachment at rear wheel Working at...

Tires checking inflation pressure

Correct tire inflation pressures are important to handling and stability, fuel economy, and tire wear. Tire pressures change with temperature. Pressures should be checked often during seasonal temperature changes. Correct tire pressure information can be found on an information label arrow on the rear engine compartment apron and in the owner's manual. Do not inflate any tire to a higher pressure than the tire's maximum inflation pressure listed on the sidewall. Use care when adding air to...

Front stabilizer bar removing and installing

Raise car and support in a safe manner. Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Working underneath front of car, remove stone guard mounting fasteners arrow . Remove stone guard. Loosen stabilizer rear bracket bolt A on left and right sides. Pry stabilizer bracket off crossmember subframe. Pull stabilizer backward, first from one control arm, then the other, to...

Input shaft seal replacing

Remove transmission and separate from engine as described in 101 Engine Removal and Installation. Remove clutch release bearing guide tube screws arrows . Remove guide tube using a shop made tool and pry bar. A tool to remove the release bearing guide tube can be made using 3 16 piece of steel rod. Bend hooks on both ends of wire to engage holes in guide tube. Lever the guide tube off using a pry bar. For information on clutch cross-shaft repairs, see 301 Clutch. Press input shaft seal out...