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Porsche Mechanics Germany

Dr. Ing. h.c. F. Porsche Aktiengesellschaft

The workshop manual Is only for the internal use of the Porsche Dealer Organization.

© 1988 Dr. Ing. h.c. F. Porsche Aktiengesellschaft Technical Service Department D-7140 Ludwigsburg

All rights reserved - Printed in Germany

Tabig^fgprtftijijgir Groups Carrera 4

Main Menu

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

Printed in Germany, 1988

Table of contents

Main Menu volume VII

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

Wiring

Additional electrical equipment 97-01

Repairing wiring harness No. 2 and No. 3 97-03

Repairing wiring harness No. 173 (DME wiring harness) 97-07

Wiring diagram type 911 Carrera 4 model 89 97 - 1

Wiring diagram type 911 Carrera 2/4 model 90 97-33

Wiring diagram type 911 Carrera 2/4 model 91 97-71

Wiring diagram type 911 Carrera 2/4 model 92 97 -109

Wiring diagram type 911 Carrera 2/4 model 93 97 -149

Table of contents

Printed in Germany - XX), 1994

Additional electrical equipment Note

Additional electrical equipment must be connected only to the connection possibilities described below.

Terminal 30 not fused:

1. Screw terminals at feeder to central electrics

2. Connector A 11

Terminal X not fused: Connector A 14 Terminal 15 not fused: Connector A 22

Fusing possibilities Note

Additional electrical equipment must be fused if the above connection possibilities can be used.

Incoming connector D 11 Outgoing connector C 45

Incoming connectors C 35 and D 15 Outgoing connector D 23

Terminal 31

1. Connector A 23

2. Ground points VI

3. Ground point VII

3. Separate fuses

Additional electrical equipment

Printed in Germany - VI, 1990

Wiring

Main^^i

Repairing wiring harness No. 2 and No. 3 Note

As of MY '93, the combination wires for ABS and BVA (brake pad wear monitor) are incorporated into the wiring harness. When repairing damaged wiring, the integral wirings may be cut off and replaced with repair wires.

Wiring harness No. 2 (passenger compartment) is already provided with the left and right rear wires.

Wiring harness No. 3 (trunk floor panel) includes the left and right front wires.

Run the following functional checks after the repair:

- ABS: Check with ABS tester.

BVA (brake pad wear monitor): The warning lamp must go off when the engine is running and if the pads are o.k.

Connector joints

Rear

In the right-hand and left-hand seat well, before the wires branch off to the outside.

Front

In the right-hand and left-hand luggage compartment above the side member near the spring strut domes.

Note

Unscrew convertible top motors (4 screws) on

Cabriolet models.

5. Cut open insulating tube for wiring harness, starting at the rubber grommets and continuing for approx. 20 cm to the right.

6. Remove PVC insulating tape.

7. Remove shrink-fit caps from connector joints.

8. Cut off connectors.

9. Remove combination wires.

10. Fit repair wires, starting at wheel carriers and routing them towards the seat well.

11. Strip wire along a length of 10 mm.

12. Connect wires according to table using crimp connectors and standard crimping tool (A).

c

A

E

I

D

Rear

1. Disconnect battery.

2. Fold emergency seat backrests forward.

3. Remove rear wall trim.

4. Use adhesive tape to locate insulating padding out of the way.

Main Menu 911 Carrera 4

Combination wire Wiring harn. No. 2

Color

Length

Color

rear left

br/sw

30 mm

br/sw

br/gn

60 mm

br/gn

br/ws

90 mm

ws*

br/bl

120 mm

Screen

br

150 mm

br

rear right

br/sw

30 mm

br/sw

br/gn

60 mm

br/gn

br/ws

90 mm

ge*

br/bl

120 mm

Screen

br

150 mm

br

* screened wires br - brown sw - black ge - yellow bl -blue ws - white gn - green

13. Solder tips after crimping (B).

14. Fit shrink-fit caps and shrink them using a hot-air gun (C).

15. Wrap up entire connector joint area using commercially available PVC tape.

Front right

1. Disconnect battery.

2. Remove RH front wheel

3. Remove rear wheel housing liner.

4. Slacken tie-wrap in wheel housing area.

5. Slacken tie-wrap in luggage compartment.

Slacken Wiring

6. Cut open insulating tube along wiring harness.

7. Remove PVC insulating tape.

8. Remove shrink-fit caps from connector joints.

9. Cut off connectors.

10. Remove combination wiring.

11. Fit repair wiring.

12. Strip wires along a length of 10 mm.

13. Connect wires according to table using crimp connectors and standard crimping tool (A).

C

A

B

m

-

I

1316-97

Combination wire Wiring harn. No. 3

Color

Length

Color

front right

br/sw

30 mm

br/sw

br/gn

60 mm

br/gn

br/ws

90 mm

gn*

br/bl

120 mm

Screen

br

150 mm

br

16. Wrap up entire connector joint area using commercially available PVC tape.

Front left

1. Disconnect battery.

2. Remove LH front wheel

3. Remove rear wheel housing liner.

4. Slacken tie-wrap in wheel housing area.

5. Remove bracket for brake fluid reservoir.

Porsche 964 Fix

* screened wire br - brown sw - black bl - blue ws - white gn - green

14. Solder tips after crimping (B).

15. Fit shrink-fit caps and shrink them using a hot-air gun (C).

Main Menu 911 Carrera 4

6. Slacken tie-wrap in luggage compartment.

6. Slacken tie-wrap in luggage compartment.

911 964 Rear Black

Combination wire Wiring harn. No. 3

7. Cut open insulating tube along wiring harness.

8. Remove PVC insulating tape.

9. Remove shrink caps from connector joints.

10. Cut off connectors.

11. Remove combination wire.

12. Fit repair wiring.

13. Strip wires along a length of 10 mm.

14. Connect wires according to table, using crimp connectors and standard crimping tool (A).

Combination wire Wiring harn. No. 3

Color

Length

Color

front left

br/sw

30 mm

br/sw

br/gn

60 mm

br/gn

br/ws

90 mm

rt*

br/bl

120 mm

Screen

br

150 mm

br

* screened wire br - brown sw - black rt - red bl -blue ws - white gn - green

15. Solder tips after crimping (B).

16. Put shrink-fit caps into place and shrink them using a hot-air gun (C).

17. Wrap up entire connector joint area using commercially available PVC tape.

Wiring

Repairing wiring harness No. 173 (DME

Replacing air flow sensor connector

Situation: Rough engine running, e.g. poor throttle response, rough idling.

Note

Leave a gap of approx. 15 mm between the air flow sensor connector and the oil tank breather pipe. If the gap is too small or if the connector touches the breather pipe, check the breather pipe routing and correct it if required.

Porsche 964 Dme Connectors

Speedster 1786-97

wiring harness)

Earth Harness Wire Porsche 964

On the Speedster, the breather pipe bracket is located to the right of the air flow sensor wire while, on the 911 Carrera, it is located to the left.

1. Remove upper air filter section with filter element.

2. Release oil tank brather hose from rubber shroud.

911 Air Flow Harness Bulletin

3. Pull connector off the air flow sensor. The connector is accessible from the right-hand side across the air filter.

Repairing wiring harness No. 173 (DME wiring harness)

Printed in Germany - XXI, 1994

Wiring

911 Carrera 4

4. Pull out wiring harness complete with connector from between air flow sensor and idle speed positioner towards the rear.

5. Push back rubber sleeve. Note

If the vehicle is fitted with a rubber sleeve with straight wire exit, fit angled rubber sleeve (wire exits towards left) from the repair kit.

6. Cut off wires close to the connector housing.

7. Strip wires along a length of approx. 5 mm.

8. Crimp connector contacts from repair kit with a crimping tool, e.g. VAG 000.097.003 A.

9. Connect wires to connector housing according to wiring diagram or the below table.

3 - blue/green

4 - green/black

Porsche 964 Dme Plug Connector
1789-97

Repairing wiring harness No. 173 (DME wiring harness)

Printed in Germany - XXI, 1994

Wiring Diagram Type 911 Carrera 4

Model 89

The wiring diagram consists of 11 individual wiring diagrams, 1 sheet construction components and 1 sheet plug connections and ground points. These are divided into coordinate fields.

Each individual wiring diagram contains a part of the central-electrics box in a dashdotted frame.

This part of the central-electrics box shows all the lines and relays necessary for the individual wiring diagram.

The earth/ground points are identified by "MP" and their location is shown in a vehicle diagram.

The 10-pin connectors on the central-electrics box are clipped together out of 3 parts, the 20-pin connectors are clipped together out of 5 parts.

Part 1, with the moduled-on fastening lug, is the "starting element".

Parts 2,3 and 4 are "module elements".

The 10-pin connectors only contents one "module element".

Start- and module elements are identified by the numbers 1 5.

Part 5 ist a "coding element".

The designations of the plug connections in the wiring diagram refer to the "starting element" from, for example, B 11 15, and to the first module element from B 21 25.

Main R/1

Wiring

Wiring Diagram Type 911 Carrera 4

Model 89

Coordinates

Sheet 1 1-10 Sheet 2 11-20

Sheet

3

21 -

30

Sheet

4

31 -

40

Sheet

5

41 -

50

Sheet

6

51 -

60

Sheet

7

61 -

70

Sheet

8

71 -

80

Sheet

9

81 -

90

Sheet 10

91 -

100

Sheet 11

Lights

Alarm System, Central Locks, Mirror, Power Window Regulator

Heater, AC, Coolant Fan, Rear Window Defogger

ABS, Porsche Dynamic AWD Control

Motor, Ignition, Cruise Control

Instruments, Sender, Central Informer

Seats

Rear Spoiler, Two-Tone Horns, Wipe- and Wash Cleaners

Radio

Fog Light, Rear Fog Light Central Electric Construction Components Plug Connections and Ground Points

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