Instructions For Welding Galvanized Sheet Metal

The entire floor frame assembly of the body is made of steel sheet galvanized on both sides. The zinc thickness varies between 7.5 and 20 micromillimeters depending on the corrosion protection. Together with other protective measures, such as cavity spraying, undercoating and modern painting techniques, the body has adequate protection against corrosion. This means several changes for repairs on sheet metal parts. - The zinc coat should be ground down as little as possible or damaged in any...

Removing And Installing Automatic Antenna Mast

Feed in wire briefly until it is engaged by the drive. Guide in wire and antenna mast by hand. 1. Turn on radio to run out antenna mast as far as possible. Unscrew and remove threaded bushing with an open-end wrench. 2. Remove antenna mast and plastic wire by pulling firmly. 1. Straighten plastic wire ends and slide into antenna adapter until wire ends touch. Removing and Installing Automatic Antenna Mast 3. Push threaded bushing into antenna adapter and...

Removing And Installing Door Window Glass And Window Lifter

Turn down window lifter far enough that the front mounting screw on the window lifting rail can be loosened through the large hole in the inside door panel. 1. Lubricate ratchet, install and bolt window lifter. 2. Unscrew rear guide rail on inside door panel and detach it at the window lifter. 3. Detach window lifter at lifting rail guides. 2. Install window glass, guiding lower arm of window lifter into lifting rail. 3. Bolt mounting plate to lifting rail, tightening screws only slightly. 4....

Special Tools And Shop Materials For Body Repairs

Welding jig for lock carrier 9117 Hydraulic 10 ton straightener with accessories Hand grinder with attachments (grinding wheels and stones, Angle grinder with attachments (cutting wheel 180 mm Pneumatic guns, equipment and materials for permanent undercoating for cavity sealing for sealing jobs Hydraulic (10 ton) straightener with accessories. Straightening attachment set ENS-224. 300 for Celette straightening bench Straightening attachment set ENS 224. 300 plus ENS 224. 309 from 1978 models...

Set Of Rear Axle Attachments From 19 7 8 Model

A new rear axle was installed in all Type 924 cars as of the 1978 model year. Consequently the body bolt positions have been changed. All new rear axle attachments for the Celette alignment bench are part of set ENS 244. 309. The component illustrated below will be required for rear axle pick-up (without removal or rear axle). Two parts on each side, mounted on the rear cross member, are required to pick-up the body when the engine transmission assembly is removed.

Removing And Installing Instrument Panel

924 Turbo Relays

Detach side padding plates and sun visors. 4. Loosen instrument panel mounting underneath loudspeaker insert. 2. Remove screw in glove compartment. 3. Detach side padding plates and sun visors. 4. Loosen instrument panel mounting underneath loudspeaker insert. 6. Remove steering wheel. Loosen steering column switch mounting screw and remove switch. Remove instrument panel.

Removing And Installing Rear Window Wiper

Porsche 924 Wiper Switch

Remove cover for wiper motor on inside of rear lid and pull off wires. 2. Unscrew lock nut on wiper arm. Lift off wiper arm holder with suitable pliers. 3. Press off cap and unscrew mounting nut. 5. Unscrew nuts on wiper motor and pull bracket off of wiper motor. 1. After fastening bracket on the wiper motor, tighten the round flat nut against the bracket on the inside. rear window and pull guide pins out of rear lid frame. rear window and pull guide pins out of rear lid frame. 2. Insert...

Servicing Automatic Antenna Mast

Clean a fully run out antenna mast with a low viscosity, non-resinous oil or a cleaning spray, e.g. MS-2 spray. We recommend antenna cleaning cloths, which could also be used by customers without problems. Run antenna mast in and out several times, and wipe off any dirt each time. Replace the mast, if mast parts are deformed or antenna movement is still difficult after cleaning thoroughly. If the mast movement is still difficult, i. e. antenna mast does not run out or in fully, after handling...

Removing And Installing Windshield Wiper Motor

When installing, connect the plug and turn on the ignition before securing the linkage. Move wiper arms to off position and mount linkage. 4. Check function on a wet windshield. Correct wiped area if necessary. 2. Unscrew wiper linkage, disconnect plugs, unscrew motor, remove mounting screw on frame, lift frame slightly and take out motor. Removing and Installing Windshield Wiper Motor

Removing And Installing Wiper Arms

924 Starter Removal

Remove cap and unscrew hexagon nut. Note washer 2. Fold up wiper arm and take off of shaft by carefully moving back and forth. Do not pry off. 4. Check operation on wet windshield. The wiper blade should not contact the ornamental frame of the windshield on the driver's side. 3. Adjust wiper arms so that they rest on upper edge of dark strip in off position. Install wiper arm with spoiler on driver's side.

Removing And Installing Outside Door Handle

Loosen self-locking screws on door frame. 2. Slide outside door handle forward and detach at outside door panel. When the door lock is mounted and the door trim is installed, the operating lever can be engaged with the door lock by inserting a screwdriver, the tip of which is bent, through an opening in the outside door panel. 3. Detach operating lever with installed door lock . 1. Stick liners on outside door handle. 2. Install and bolt outside door handle with operating lever making sure...

Installing New Version Rear Side Panels On Cars Prior To 198 0 Models

How Install Patch Panels Cars

Only the new version rear side panels from 1980 models are available for replacements. Or, depending on extent of damage, weld in a new reinforcement. After using up stocks of old version parts in cars prior to 1980 models, the new version rear side panel will be applicable to all models. The following additional procedures will be necessary to install the new version parts in cars prior to the 1980 models. 1. The striker pin base has been made 4, 5 mm deeper so that the longer pin from the...

Door Lock New Version From 1980 Models

Porsche Door Latch

The door lock inner part, door lock outer part and striker of Type 928 are used in all models as from 1980 models. The only deviation from the 928 version is a modified connecting lever for the door lock inner part on the passenger's side. The connector for the door lock inner part is located on the door outside handle. The door lock outer part must be bolted to the door lock inner part in opened state, since otherwise the connecting lever would be damaged by the release pin of the door lock...

Service Installing Strap For Removable Roof Panel

The removable roof panel can be set up on the fasteners while driving, if a strap is installed from the roof panel to the body. This strap will prevent the roof panel from lifting at the rear when driving on rough roads. 3. Lift trim at rear and insert a reinforcement plate. Then mount strap with a black 3,9 x 16 mm sheet metal screw and cloth covered washer. 6. Install roof, lock and clip on the strap. 1. Remove roof panel and press plastic rivets out of the roof trim in the rear area. 4....

Location Of Electric Equipment In Engine Compartment

Location Porsche 924 Cold Start Valve

1 - Ignition control unit Ignition control unit with EIS 2 - Low pressure switch air conditioner 3 - Idle stabilizer connection point 5 - Air conditioner compressor 6 - Frequency valve oxygen sensor 7 - Mileage counter oxygen sensor 8 - Brake fluid level transmitter 9 - Control pressure regulator 11 - Alarm system contact switch Location of Electric Equipment in Engine Compartment 17 - Temperature switch warm start 21 - Temperature time switch for cold start valve 22 - Coolant temperature...

Removing And Installing Speedometer Drive Cable

Porsche 924 Speedometer Wire

Pull out and fold down instrument panel. Disconnect drive cable on speedometer. 1. Remove cover on left front wheel hub. Remove circlip on drive cable. 2. Pull out drive cable on inside of steering knuckle by hand. 5. Pull iower drive cable end into upper section of engine compartment. Remove rubber grommet and pull off of drive cable. 2. Pull out drive cable on inside of steering knuckle by hand. 5. Pull iower drive cable end into upper section of engine compartment. Remove rubber grommet...

Removing And Installing Bumpers

The front and rear bumpers are bolted to the bumper brackets with 2 each M 10 x 60 hexagon head bolts, plain washers and lockwashers. Fog lights and turn signals can either be removed with the front bumper, or removed separately. Fit and mount bumper brackets parallel to the body contour. The rear bumper and bumper brackets are mounted in the same manner.

Repairs With Set Ens 224300 Attachment

These attachments can be applied to simple repair jobs of bodies with medium front and rear end damage. Remove Front and rear bumpers with brackets Front apron All damaged body parts as required by repair work Torsion plate covers and outer rubber mounts. Also remove running gear and engine depending on type of damage. Preparing Celette stand Mount cross member for rear axle attachments and supports for longitudinal Bolt attachments to rear axle cross tube. Bolt attachments to rear axle cross...

Alarm System 924

924 Horns Position Body Car

The alarm system is turned off and on with a separate key. The alarm switch is located in the side panel behind the driver's door lock. The key has to be turned to vertical position to turn the system off. Spare keys are not available for the alarm switch. If the key is lost, the alarm switch must be replaced. The key must be turned to horizontal position to turn the system on. The alarm would be set off by opening the driver's or passenger's door, trunk lid, engine hood and After setting off...

Preparing Body For Application Of Basic Straightening Attachments

Porsche 924 Body Parts

Bumpers with brackets or front rear impact absorbers Front apron All damaged body parts as required for straightening work Also remove engine, if front end of car is seriously damaged Prepare Celette stand Mount all attachments of straightening set, except bumper attachments. Loosen mounting bolts on spring strut domes to place body on Celette stand. Note Check horizontal position of Celette stand with a water level. Install bumper attachments only after positioning body. Mounting point on...

Removing And Installing Window Guides

Pull out window guides in door recess and All window guides are cut to proper length, so that they must be fitted properly by stretching or pressing. 4. Install outer window recess rail, assuring a neat fit with the end of the ornamental frame. 3. Remove outside window recess seal with ornamental strip. 1. Press lower front and rear window guides into guide rails and check for a neat fit 2. Slide on ornamental frame for upper door frame. Bend down the metal tongue behind the opening. 3. Coat...