Engine removal and installation 101

Tape Drive 1989

.001801

1984 Porsche 911 Mirror Wiring

0018776

^ 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 as possible to allow for maximum travel when it is lowered with the engine.

^ Disconnect ground strap (A) between transmission and body.

• While supporting engine/transmission assembly, carefully remove two transmission mount bolts (B). Right side shown.

Check often to make sure that the car remains stable and well-supported while the engine is being removed.

^ Remove 2 engine support crossmember bolts (arrow) (right side shown).

911 Engine Removal

BENTLEY

0018153

^ Carefully lift car (or lower engine/transmission assembly) while allowing engine to tilt backward as assembly is removed from rear of car.

If separating the engine from the transmission, see Engine/transmission, separating and rejoining.

Engine/transmission, installing

^ Place engine/transmission assembly under engine/transmission bay. Lower car or raise engine/transmission.

— On 1984 -1986 models: Tilt engine back and guide shift rod into center tunnel hole.

^ Raise engine/transmission assembly up to approximately 3 in. of mounting points in engine bay.

Be very careful not to pinch any wiring harnesses or hoses between the body and the engine as it is raised up into the engine bay.

— With engine 3 in. from its mounts connect heat exchanger hoses.

Connecting heater hoses after engine is bolted in may result in damaged hoses.

Damaged Porsche 911

0018016

0018027

On 1987 - 1989 models: Working above driver's side of transmission, install clutch slave cylinder and torque bolts (arrows).

Be sure to align slave cylinder pushrod with clutch fork.

Tightening Torque

• Clutch slave cylinder to bell housing 25 Nm (18 ft-lb)

— Carefully raise engine/transmission assembly up to its installed position.

Place washer between engine mount and crossmember with washer concave facing up (A).

• Insert engine mounting bolt with concave washer facing down (B). Press bolt down through engine mount and washer into crossmember.

• Start engine mounting bolts into crossmember but do not tighten them.

Install transmission mount bolts and washers (A). Arrange washers as per for engine mount (shown above).

— Reattach transmission to body ground strap (B).

— Tighten engine and transmission mounting bolts.

Tightening Torques

• Crossmember to transmission 25 Nm (18 ft-lb)

• Crossmember to crossmember mount.. 80 Nm (58 ft-lb)

Transmission Ground Straps

0018776

Clutch Cable Joint

^ On 1984 - 1986 models: Install clutch release levers and clutch cable on bottom of transmission.

See 301 Clutch for detailed instructions on clutch adjustments on 1984 - 1986 models.

Install right and left CV joints and tighten bolts (arrows).

Tightening Torque

• CV joint to final drive flange 42 Nm (30 ft-lb)

— Connect starter power feed cable.

Reinstall stabilizer bar and tighten bolts (arrows).

Tightening Torques

• Stabilizer to trailing arm link (M12) 90 Nm (66 ft-lb)

— Install new sealing rings on both oil drain plugs and install.

Tightening Torques

911 Shift Cable Linkage

1D0Ï801S

1984 911 Accellerator Cable

n'8026"

Clutch Linkage Couplers

Reconnect oil tank S-hose and return hose (arrows). Coun-terhold return hose fitting (A) while tightening.

^ On 1987 - 1989 models: Install shift rod bolt (arrow) and tighten.

Tightening Torque

— Connect throttle linkage to relay lever on side of transmission.

^ Working inside passenger compartment, reconnect speedometer harness connectors (arrows) through hole in center tunnel.

— On 1984 - 1986 models: Connect shift rod to coupler and tighten.

• Install access cover and floor mats.

Tightening Torque

0018009

^ Attach cruise control cable to diaphragm housing. Pull back on locking plastic clip until it snaps into metal retainer (arrow).

• Mount cruise control cable flange to diaphragm housing.

^ Reconnect left side engine electrical harness connectors:

• Cylinder head temperature sensor (1)

If the speed sensor and reference sensor harness connectors are reversed, the engine will not start.

— Reattach remaining electrical harness connectors:

• Idle control valve

• Throttle switches

• Multi-pin connector beside left rear shock tower

• Multi pin connector in left rear fuse/relay panel

• Ignition coil secondary wire

• Ground connection to intake runner 1.

— Install rear fuse/relay panel cover.

— Remainder of installation is reverse of removal.

• Reinstall A/C compressor and adjust drive belt.

• Reconnect battery ground terminal.

Tightening Torque

— Start engine with a helper checking for leaks or any other problems.

— With engine running and at normal operating temperature add 2.5 quarts of engine oil.

Remove Wiring Harnes From 1984 Caprice

0018749

Engine/transmission, separating and rejoining

^ Detach wiring harness connectors (arrows) from transmission.

On 1987-1989 models: Remove clutch cross-shaft.

• Remove bolt (arrow) from cross-shaft retaining bracket.

• Pull out cross-shaft by attaching slide hammer with 6 mm bolt into end of cross-shaft.

A Remove 4 nuts holding transmission to engine and slide transmission off engine.

— Installation is reverse of removal, noting following.

• Cable-operated clutch: As transmission slides onto engine studs, turn clutch cross-shaft so that clutch release fork hooks into release bearing.

• Hydraulically operated clutch: Prior to installing transmission, use duct tape or equivalent to hold clutch release fork on release bearing. See 301 Clutch. Clutch cross-shaft is installed after engine and transmission are joined.

Clutch Fork Cross Shafts

0018741

Cross Shaft Mounting Bolts

0018154

ENGINE/TRANSMISSION MOUNTS

The engine or transmission crossmember rubber mounts can be damaged or weakened due to age, oil contamination or accident. This damage can cause excessive noise or vibration in the passenger compartment.

Engine mount, removing and installing

Refer to illustrations for component locations.

Removal of the rear engine mounting crossmember and mount bracket is covered in 102 Engine Disassembly and Assembly.

Tightening Torques

• Crossmember to crossmember mount.. 80 Nm (58 ft-lb)

• Engine mount carrier to crankcase 40 Nm (30 ft-lb)

• Engine mount crossmember to carrier 40 Nm (30 ft-lb)

Engine mount assembly Carrera Cabriolet

Porsche 911 Engine Crossmember Bolts

2. Lockwasher

3. Hex bolt M8x35

4. Washer

5. Bearing

6. Washer

7. Washer

8. Hex bolt M 12x1.5x95

9. Engine mount carrier

10. Washer

11. Hex bolt M10

18171B

12. Crossmember

13. Hex bolt M 10x35

14. End plate

15. Torsion bearing

16. Locknut M10

17. Vibration damper

18. Washer

19. Hex bolt M 10x45

20. Spacer rings

21. Washer

22. Locknut M6

Porsche 911 Engine Crossmember Bolts

2. Lockwasher

3. Hex bolt M8x35

4. Washer

5. Bearing

6. Washer

7. Washer

8. Hex bolt M 12x1.5x95

9. Engine mount carrier

10. Hex bolt M10x18

11. Spring washer

12. Hex nut M10

13. Washer

14. Hex bolt M10

15. Crossmember

Engine mount assembly Carrera Cabriolet

Engine mount Carrera Coupe and Targa

18171A

2. Lockwasher

3. Hex bolt M8x35

4. Washer

5. Bearing

6. Washer

7. Washer

8. Hex bolt M 12x1.5x95

9. Engine mount carrier

10. Washer

11. Hex bolt M10

18171B

12. Crossmember

13. Hex bolt M 10x35

14. End plate

15. Torsion bearing

16. Locknut M10

17. Vibration damper

18. Washer

19. Hex bolt M 10x45

20. Spacer rings

21. Washer

22. Locknut M6

Transmission mount, replacing (915 transmission-1984-1986)

Rubber transmission crossmember mounts in 1984-1986 models can be replaced without removing crossmember from transmission.

— Raise vehicle on lift and support safely.

Be sure vehicle is stable and fully supported on the manufacturer's lift points. Loosening of the engine/transmission assembly will upset the balance of the vehicle. Use tall jack stands to support the vehicle at all four corners.

— Support transmission while removing transmission cross-member mount long bolts.

— Lower transmission just enough to reach over crossmember and remove bolts holding mount to crossmember.

— Installation is reverse of removal.

Tightening Torques

• Crossmember to crossmember mount.. 80 Nm (56 ft-lb)

Transmission mount, replacing (G50 transmission-1987-1989)

Rubber transmission crossmember mounts in 1987-1989 models cannot be replaced separately.

— Raise vehicle on lift and support safely.

Be sure vehicle is stable and fully supported on the manufacturer's lift points. Loosening of the engine/transmission assembly will upset the balance of the vehicle. Use tall jack stands to support the vehicle at all four corners.

— Support transmission while removing transmission cross-member mount bolts from suspension crossmember.

— Remove crossmember mounting nuts from transmission studs.

— Installation is reverse of removal.

Tightening Torques

• Crossmember to transmission 25 Nm (18ft-lb)

Transmission crossmember (1984-1986)

Washers Concave

0018959

6. Concave washer

7. Lockwasher

8. Lockwasher

10. Hex bolt

1. Hex bolt M8x16

2. Crossmember

3. Washer

4. Locknut

5. Mount

Transmission crossmember (1984-1986)

0018959

6. Concave washer

7. Lockwasher

8. Lockwasher

10. Hex bolt

1. Hex bolt M8x16

2. Crossmember

3. Washer

4. Locknut

5. Mount

Transmission crossmember (1987-1989)

Transmission crossmember (1987-1989)

1. Concave washer

2. Crossmember

3. Washer

4. Locknut

0018960

5. Hex bolt M12

6. Washer

7. Concave washer

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.

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