Service

Date 30.04.90

31.12.90

VKQPI

Table Of Contents

Main Menu

List of Repair Groups

Carrera 4

General

Technical Data

Page 0.1

Repair Groups

Group

Volume 1

Maintenance, Self-diagnosis

03

Engine, Crankcase, Suspension

10

Engine,

Engine, Crankshaft, Pistons

13

Maintenance

Engine, Cylinder Head and Valve Drive

15

Engine, Lubrication

17

Engine, Cooling

19

Fuel Supply

20

Fuel System, Electronic Injection

24

Exhaust System/Emission Controls

26

Starter, Power Supply, Cruise Control

27

Ignition System

28

Diagnosis

Volume II

Clutch, Controls

30

Clutch

32

Transmission

Manual Transmission, Controls, Case

34

(manual)

Manual Transmission, Gears, Shafts

35

Differential, Transaxle System, All-Wheel Drive

39

Diagnosis

Clutch, Controls

30

Volume III

Torque Converter

32

Automatic Transmission, Controls, Case

37

Transmission

Automatic Transmission, Gears, Shafts

38

(automatic)

Differential, Transaxle System

39

Diagnosis

Volume IV

Front Wheel Suspension

40

Rear Wheel Suspension, Axle Shaft

42

Chassis

Wheels, Tires, Alignment

44

Antiblock System

45

Brakes, Mechanical

46

Brakes, Hydraulics, Regulator, Booster

47

Steering

48

Diagnosis

Volume VI

Body-Front Section

50

Body-Center Section

51

Body

Body-Rear Section

53

Lids

55

Doors

57

Electric Sunroof

60

Hardtop

61

Bumpers

63

Glasses, Window Control

64

Exterior Equipment

66

Interior Equipment

68

Seats

72

Seat Covers

74

Volume VI

Heater

80

Ventilation

85

Heating, Ventilation,

Air Conditioner

87

Air Condition

Diagnosis

Electrics

Instruments, Fuel Gauge, Alarm System

90

Radio, Telephone, On-board-computer

91

Windshield Wipers and Washer

92

Exterior Lights, Lamps, Switches

94

Interior Lights

96

Diagnosis

Volume VII

Wiring

97

Electrics

Wiring Diagrams

The workshop manual of the Carrera 4 also includes that for the Carrera 2. The Carrera 4 acts as the basis for description of the repairs in the manual. "Carrera 4" also appears on every page in the header line.

Deviating descriptions for repairs on the Carrera 2 follow those of the Carrera 4. These repair descriptions for both models are separated by a yellow sheet.

"Carrera 2" appears on all pages in the header line after the separating sheet. The page number starts with 100 as an additional distinction.

Page

Air-conditioning system

Technical data 87-01

Removing and installing components of the heating/air-conditioning system 87 - 1

Dismantling and assembling the heating/air-conditioning unit 87 - 3

Flap adjustment on the heating/air-conditioning unit 87 - 9

Checking the refrigerating capacity 87 -11

Removing and installing heating fan motors with built-in heating/air-conditioning unit . . 87-13

Safety regulations for handling the refrigerant R 12 87-17

Installation work on the air-conditioning system 87-18

Modifying wiring loom of heater A/C unit 87-27

Technical data as of Model '93 87-29

Pressure and temperature specifications 87-31

Diagnosis / Troubleshooting D 80/87 -1

Instruments, fuel gauge, alarm system

Acceleration sensors for longitudinal and transverse locks 90 - 1

Checking fuel tank sender unit 90- 3

Radio, telephone, on-board computer

Telephone preparation kits M 612 and M 195 91 - 1

Retrofitting of a telephone set 91- 7

Retrofitting of a CD changer 91-13

Windshield wipers and washer

Removing and installing the wiper motor 92 - 1

Diagnosis

Diagnosis / troubleshooting alarm system D90 - 1

Technical Data for Air Conditioner

Refrigerant volume 930 grams of Frigen R 12

Refrigerant in compressor 100 ± 20 cc of Densoil

Tightening Torque for Refrigerant Pipes

Outside Thread Dia.

Pitch/Inch

Torque in Nm (Ft. Lbs.)

5/8"

18 UNF

17 + 3 (12 ± 2)

3/4"

16 UNF

24 ± 4 (17 ± 3)

7/8"

14 UNF

33 ± 4 (24 ± 3)

Hex. Head Bolts on

Threads

Torque in Nm (Ft. Lbs.)

Expansion valve

M 5

6 (4.3)

Expansion valve

M 6

9 (6.5)

Compressor

M 8

28 (20)

Removing and Installing Heater/Air Conditioner

1. Disconnect battery ground lead.

3. Remove upper cover of heater/air conditioner (two screws with washers).

4. Disconnect central electric.

Fresh Air Inlet Grill
240-87

6. Lay central electric aside on a fender (use fender guard).

7. Pull off electric lead plug on blower final stage.

8. Remove firewall.

9. Remove fresh air inlet grill.

10. Unscrew mounting bolts.

5. Remove wire harness cover.

Drain Hose Rear Porsche 996 Schematic

11. Disconnect plug T 34 (on heater/air conditioner at right top).

12. Pull off condensation and rain water drain hoses (cut off straps) and press out molded rubber grommets upward.

243-87

13. Discharge the air conditioner (draw off refrigerant with a recycling machine),

14. Unscrew refrigerant pipes on expansion valve.

15. Disconnect Frigen switch plug.

16. Unscrew holder for refrigerant pipes.

17. Pull off air guides to the side nozzles. Note

When installing, insert the right air guide prior to complete installation of the heater/air conditioner (better accessibility). The left air guide can be inserted with an installed heater/air conditioner after removal of the large instrument cluster dial.

18. Remove radio.

19. Remove heater/air conditioner controls.

20. Pull off left and right warm air guide necks.

21. Disconnect wire harness no. 180 (is fastened on the passenger compartment wire harness).

22. Disconnect plug T 5 (underneath dashboard).

23. Unscrew mounting screws and nuts.

243-87

Porsche 964 Head Removal

LI

■Js^

- -i

250-87

Disassembling and Assembling Heater/Air Conditioner

Disassembling and Assembling Heater/Air Conditioner

Porsche 964 Dashboard Diagram

Note When:

No.

Description

Qty.

Removing

Installing

1

Tension spring

32

2

Screw

11

3

Screw

9

4

Washer

6

5

Holder

1

6

Housing cover, left

1

-

Housing cover, right

1

7

Liner, left

1

-

Liner, right

1

8

Retainer

2

9

Lever

1

10

Evaporator temp, sensor

1

Integrated in wire harness

Integrated in wire

harness

11

Grommet

1

12

Cover

13

Hexagon socket head

2

screw M 5

14

Holding plate

1

15

Expansion valve

1

16

Gasket

1

Replace. Coat with refri

17

Gasket

1

gerating oil

18

Evaporator

1

Don't damage fins

Don't damage fins

19

Connecting rod

1

20

Gasket

1

21

Ball socket

2

22

Nut M 5

2

23

Dust cover

3

Note When:

No.

Description

Qty.

Removing

Installing

24

Linkage

2

25

Screw

7

26

Holder

2

27

Motor for temperature

2

Adjust-see page 87 - 9

mixing flaps

28

Nut M 5

2

29

Circlip

2

30

Lever

2

31

Screw

1

32

Joint

1

33

Screw

4

34

Motor for defrost or center

1

Adjust-see page 87 - 9

nozzle

35

Self-tapping nut

4

36

Linkage clip

5

37

Linkage

1

38

Holder

1

39

Motor for fresh air flap

1

40

Motor for footwell flaps

1

Adjust-see page 87-10

41

Linkage

1

42

Holder

1

43

Clamp

3

44

Sheet metal frame with

1

rubber cover

45

Self-tapping nut

2

46

Screw

2

47

Mixing chamber tempera

2

Integrated in wire harness

Integrated in wire

ture sensor

harness

48

Clamp

2

Note When:

No.

Description

Qty.

Removing

Installing

49

Gasket

1

50

Upper housing section

1

51

Blower, left Blower, right

1 1

White plastic Black plastic

52

Rubber mount

53

Sealing cord

1

54

Clampr

1

55

Linkage

1

56

Lever

1

57

Drive

2

58

Strap

2

59

Holder

2

60

Seal

2

61

Water drain pipe

1

62

Water drain pipe

1

63

Connector

1

64

Holder

2

65

Seal

2

66

Water drain pipe

1

67

Connector

1

68

Water drain pipe

1

69

Rubber mount

1

70

Gasket

1

71

Lower housing section

1

Removing and Installing Heater/Air Conditioner Regulator

Note

Special Tool V 160 (which is also the order number) is required for removal of the heater / air conditioner reagulator. Supplier: Matra Werke GmbH Dieselstr. 30-40 D-6000 Frankfurt 11

254-87

1. Slide special tool into the openings provided on the heater/air conditioner regulator until it engages.

2. Press out heater/air conditioner regulator toward rear by hand from underneath.

3. Disconnect 25-pin and 35-pin plugs.

911 Heater Flap

257-87

Adjusting Flaps on Heater/Air Conditioner

Adjusting Defrost/Center Nozzle Flap

1. Run motor to ' defrost nozzle closed" final position by supplying 12 volts to pin 4 (positive) and pin 5 (negative) via two electric leads until the motor is in final position.

2. Press temperature mixing flap to "max. cold" position. Linkage and lever must be in a straight line.

257-87

2. Press defrost/center nozzle flap to "defrost nozzle closed" position (upper outlet closed).

3. Connect drive of motor on joint of flap and secure.

Adjusting Right Temperature Mixing Flap

1. Run motor to "max. cold" final position by supplying 12 volts to pin 4 (negative) and pin 5 (positive) via two electric leads until the motor is in final position.

3. Correct deviation in length by turning the ball socket on the linkage.

Adjusting Left Temperature Mixing Flap

1. Run motor to "max. cold" final position by supplying 12 volts to pin 4 (positive) and pin 5 (negative) via two electric leads until the motor is in final position.

2. Press temperature mixing flap to "max. cold" position. Linkage and lever must be in a straight line.

3. Correct deviation in length by turning the ball socket on the linkage.

Adjusting Flaps on Heater/Air Conditioner

Printed in Germany - III, 1989

Adjusting Footwell Flaps

1. Run motor to "footwell flaps closed" final position by supplying 12 volts to pin 4 (negative) and pin 5 (positive) via two electric leads until the motor is in final position. Lever of drive faces in direction of fresh air inlet.

2. Move both footwell flaps into closed position. Engage linkage on the lever and secure with a clamp.

Condenser 1989 Porsche
258-87

Adjusting Flaps on Heater/Air Conditioner

Printed in Germany - III, 1989

Checking Refrigerating Capacity Testing Conditions

- Park car where it is not subjected to sunshine.

- Clean the condenser.

- Close sun roof, doors and windows.

- Turn temperature control switch to "max. cold" final position (blue dot on scale).

- Slide defrost lever and footwell lever against the right stops (opened).

- Switch on blower to speed 4.

- Open all dashboard air outlets.

- Measure ambient temperature (outside of car).

Connect service tester on the air conditioner.

Dashboard Porsche 964
239-87

1 - High pressure

2 - Low pressure

Testing

1. Insert a thermometer (as recommended in the workshop manual) in the center nozzle outlet.

2. Start and run engine at speed of 2,000 rpm.

3. Switch on air conditioner.

4. Read the values for temperature on the center nozzle as well as high and low pressure with the compressor running after two minutes.

Values must be located in the shaded area of the following diagrams (read values in the diagrams according to the ambient temperature).

4.1 Temperature on center nozzle

253-87

A - Center nozzle temperature B - Ambient temperature

252-87

2. The condenser fan must switch to second speed with a refrigerant high pressure of ap-prox. 19 bar (270 psi).

252-87

4.2 Low pressure

4.3 High pressure bar

251-87

251-87

Check the following if specified values are not reached.

1. The temperature mixing flaps must be completely closed (warm air necks or sills must not be warm). Adjust if necessary.

Removing and installing Heater Blower Motors of Installed Heater/Air Conditioner

Tools

Porsche 964 Condenser
264-87

No.

Description

Special Tool

Order Number

Remarks

Puller

9512

000.721.951.20

Three-piece

Removing and Installing Heater Blower Motors of Installed Heater/Air Conditioner 87-13

Printed in Germany - III, 1989

Removing and Installing Heater Blower Motors of Installed Heater/Air Condi tioner

1. Disconnect battery ground lead.

2. Remove cover of heater/air conditioner (2 screws with washers).

3. Disconnect central electrics.

Dibujo Garaje

240-87

5. Lay central eletrics aside on the fender (use a fender guard).

6. Pull off electric lead plug on blower final stage.

7. Remove firewall.

Right Blower

8. Disconnect plug T 34 and take plug out of holder.

9. Remove clamps of motor cover and take off cover from above.

10. Mount part A of Special Tool 9512 on the shaft and turn clockwise. Make sure that openings in blower wheel are aligned with openings in housing.

4. Remove wire harness cover.

Remove Heater Blower Porsche 964

240-87

4. Remove wire harness cover.

87-14 Removing and Installing Heater Blower Motors of Installed Heater/Air Conditioner

Printed in Germany - III, 1989

Note

Observe installation position of part A of Special Tool 9512. Bore of fan wheel shaft is off-center (2 mm).

11. Slide part B into openings.

1984 Porsche 911 Mirror Wiring
266-87

12. Tighten wing screw (part C) until the blower motor disengages.

13. Pull off connecting leads. Left Blower

14. Unscrew expansion tank on tank.

15. Unscrew refrigerating pipes in cars with an air conditioner.

16. Remaining procedures are the same as those described in points 9 through 13.

Note

When installing, make sure that the blower motor engages correctly and connecting leads are not pinched.

Check whether the blower wheel can be turned easily.

911 Carrera 4

Air Conditioner

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