Dismantling and assembling tensioning plate

With the shift rods fitted, the springs (No. 3) are under load Install in correct position, use 8 mm dia. locating mandrel to locate relative to tensioning plate hole Free length 51.3 + 0.5 mm wire thickness 1.5 mm. Do not cnfuse with spring No. 14 Free length 72.6 + 0.5 mm wire thickness 1.1 mm. Do not confuse with spring No. 13 Press in with suitable drift until it is seated 35 40 19 Removing and installing input shaft 35 40 19 Removing and installing input shaft Cylindrical roller bearing...

Measuring lateral runout of

1984 Porsche 911 Gauge Wiring Pictures

Concerns Measuring thickness tolerance of brake discs 1. Measuring requirements No tilt play of the wheel. 2. Fit adapter plate (Special Tool 9510 1) to wheel hub. Tightening torque of wheel nuts (mounting nuts) is 130 Nm (96 ftlb.). If required, fit dial gauge holder with Ate conversion kit, Part No. 03.9314-5510.3 01 (longer wing screw and bracket for dial gauge if necessary). 4. Fit dial gauge with a slight preload. Place measuring pointer on largest diameter of brake surface outside of...

Repairing incipient cracks between rear center panel and rear side panels

In order to repair the incipient cracks between the rear center panel and rear side panels, the engine compartment lid, the convertible top, the rear wheel houses and the engine compartment insulation must be partially dismantled. Disconnect electrical cables from rear lid Unclip connector cap from wire harness, disconnect connector and pull cable holder off hinge. Unscrew fastening nut of ground connection cable. Unscrew mounting screws. Lift lid off vehicle and place Remove mounting screws...

Notes on repair descriptions

The 911 Carrera (rear-wheel drive 993) forms the basis of the description of repair, assembly and adjustment operations. This means that the 911 Carrera 4 Repair Manual (filed after the separation sheet) covers only operations that affect the 911 Carrera 4. Most tightening torques of the 911 Carrera and 911 Carrera 4 are identical. Differing or additional tightening torques are included in the tables in the corresponding repair groups of the 911 Carrera (rear-wheel drive 993). Notes on...

Retrofitting a CD changer

Remove front compartment carpet, spare tire, protective cover, fuel tank and battery Insert pop rivet nuts for attachment of the CD changer bracket into side member Drill 20 mm dia. hole for routing of connecting wire Scribe attachment points for CD changer bracket on left-hand front end of side member. Using a 9.5 mm dia. drill bit, drill holes into side member according to scribe marks. Insert M 6 pop rivet nuts into side member and rivet in place using a pop rivet nut gun, Scribe hole for...

Body parts of stronger sheet steel

Porsche 911 Floor Replacement

The following body parts are made from stronger sheet steel A Front wheel housing B Inner side member C Front floor section member General remarks on body parts of stronger sheet steel Applicable to the 911 Carrera (993) types Body parts of stronger sheet steel contribute to the strength of the passenger compartment and thus serve to protect the passengers. Furthermore, the fatigue strength is improved in addition to the crash safety. In terms of crash behaviour, body parts made from stronger...

Info

Dismantling and assembling differential Hexagon tie ad boJt (with nbb d seating surface) Musi always be replaced, Threads must be dry and iree from grease. Tighten to 200 Nm (143 ftlb.). Threaded holes for ring gear bolts must be dry and free from grease. Observe matching number. Readjust if required. Pull off with suitable pullar and P 263 Pull off with suitable puller and P 263 Always replace as .1 set (with shaft bevel gears) Always replace as a set (with bevel pinion)

Fuel exhaust system engine electrical system

Transmission Clutch, control 30 Manual transmission Manual transmission - Controls, case 34 Manual transmission - Gears, shafts, inner operation 35 Final drive, differential, differential lock 39 Volume III Transmission 3 Transmission Automatic transmission - Torque converter 32 Automatic Automatic transmission - Controls, case 37 transmission Automatic transmission - Gears, control 38 Final drive, differential, differential lock 39 Chassis Front wheel suspension, drive shaft 40 Rear wheel...

Removal and assembly notes

Remove engine guard and rear underside 4. Disengage shift rod coupling from inner shift rod. 5. Support transmission on general-purpose transmission jack and unbolt transmission support from body. 6. Lower engine-transmission assembly only so far that the assembly will not rest on the stabilizer bar. 7. Determine installation position of reverse shift fork for reinstallation, measuring dimension A with depth gauge. 1. Tighten hexagon head nuts of drive pinion and input shaft to specified torque...

Checking front brake discs wear assessment

Visual inspection for cracks and crack 2. Checking brake discs for mimimum Two criteria may dictate replacement of drilled (perforated) brake discs 1. Advanced stage of cracking in drilled (perforated) friction disc. 2. Disc thickness is below minimum due to wear (material abrasion caused by friction). Both types of disc wear usually occur in service. Normally, brake discs will have to be replaced if the brake disc thickness is below minimum. Only in rare cases (if brakes are subjected to...

Brake system

Visual inspection of brake pads and brake Note The brake pads must be replaced on both sides of one single axle as soon as the brake pad wear warning lamp lights up or, at the latest, when the pads have worn down to a thickness of 2 mm. If pad wear is indicated by the wear warning lamp, the warning contact (sensor complete with wire and connector) must be replaced. Replacement of the warning contact(s) can be avoided by replacing the brake pads at the latest when they are worn to a thickness of...

Refitting the transmission

Apply a very thin coat of Olista Longtime 3 EP to input shaft splines (for corrosion protection only). Engage release fork into release bearing and use a suitable length of adhesive tape to locate it provisionally in installation posi- 2. Refit transmission to engine. 3. Engage release lever shaft with seals into release fork. 4. Remove locating tape from release fork across assembly hole. 5. Install needle-roller bearing, mount cover and bracket and tighten down with M 6 x 16 hexagon head bolt...

Dismantling and assembling crankcase sections Lefthand crankcase section

Note Unless Indicated otherwise, apply Loctite 270 to all stud threads when reassembling the engine replace, coat both sides with Loot rte 574 bond in place with Loc-tite 270, lightening torque 70 Nm (52 ftlb) tightening torque 50 Nm (37 ftlb), tighten with double hexagon head socket insert Hexagon head nut M 10 x 1.25 (at main bearing saddle VII) bonded in place with Loctite 639, peened at circumference to lock projection length 130.2 - 0.5, use Loctite 649 to secure 10 01 37 Dismantling and...

Changing transmission oil in real wheel drive Tiptronic

Transmission oil SAE 75 W 90 to API GL5 or MIL-L 2105 B, or optionally SAE 90. 2. Drain oil with vehicle on a level surface and transmission at operating temperature. 3. Clean filling and drain plugs, replace seals and tighten bolts to 50 Nm (37 ftlb.). 4. Fill in transmission oil with the vehicle on a level surface until the oil overflows at the neck.

Dismantling and assembling notes Note

Since 1 October 1994, the fixed wheel of second gear (no. 22) has been firmly fixed to the drive pinion the needle cage (no. 19) runs directly on the polished shaft. The thrust washer (no. 21) and the inner ring (no. 20) are no longer fitted. 1. Mount retaining plate 9282 in vise, fit input shaft and undo hexagon-head nut with Special Tool 9105. 2. Use a suitable tool (e.g. Kukko 17 -1) to press all parts off the input shaft over the 2nd gear wheel. 1. To inspect synchronizing rings, press...

Air cleaner

Unhook clamps and lift off housing cover. 2. Take out filter element and clean filter housing with a lint-free cloth. Check hose connections of entire intake system for tight fit Particle filter Replacing filter element The particle filters are fitted on the left and right-hand sides in front of the heater air conditioning housing. 1. Remove cover for heating and air condition ing system. Screw out knurled nut and disengage retaining clamps from housing cover using a screwdriver. Lift off...

Disassembling and assembling handheld transmitter

Car keys with integrated hand-held transmitter for vehicles with immobilizer The car key has been designed as a folding Hold housing in your left hand and press A Press A button and fold key into the housing A - Button to fold the key in and out B - Key for remote control C-LED 1. Slacken screw in upper part of the housing 2. Carefully remove battery and printed-circuit 3. Fold out car key with A button from lower 4. Carefully open and pull out cap using a small, pointed screwdriver and working...

Removing and installing starter Tiptronic

Disconnect battery and uncover terminal or 2. Remove engine guard and rear underside panel. Disconnect hot air pipe to left and 3. Slacken transmission mount bolts only (6 bolts) and lower by approx. 10 mm. 4. Disconnect wire from solenoid terminals 30 and 50. Undo wire clamp of terminal 30 from body and tie-wrap from starter. Undo suction oil pipe from body side member. 5. Using 3 8 inch tools (8 mm INHEX insert), undo hexagon head socket bolts from starter and remove ground strap. 1. Use two...

B

85 30 19 Removing and installing heater fresh air blower motors Removing and installing heater fresh air blower motors with the heater A C unit 1. Take off battery ground cable. 2. Remove cover of heater A C unit (2 screws with washers). 3. Unbolt Central Electrical System. 5. Disconnect electrical connector from blower housing cover and place Central Electrical System on fender (use fender protectors). 6. Pull connector off the blower final stage. 8. Separate connector and wire from housing...

Removing and installing ATF cooler

The ATF cooler is installed in the wheel house in front of the right front wheel. It is mounted on the engine oil cooler and cooled by the two-stage electric fan of the engine oil 1. Remove right headlight, unclip wire retainer and unscrew hexagon head screw for 4. Unscrew horn mount from wheel house. 5. Remove console. To do so, unscrew three hexagon nuts (M 8) from wheel house and one (M 6) for tension strut. 7. Disconnect ATF lines from cooler. 2. Remove front wheel housing liner and lower...

Summary

Maintenance Number ranges Technical data 68 64 19 Removing and installing driver airbag unit 68-15 68 66 19 Removing and installing contact unit 68-16 68 63 19 Removing and installing airbag triggering unit .68-17 68 68 19 Removing and installing passenger airbag unit . . .68-18 68 Checking operational readiness of airbag system . .68-20 68 47 19 Removing and installing Cabriolet draft stop .68-21 68 27 13 Bonding interior rearview mirror in place 68- 27 68 27 19 Removing and installing inside...

Dismantling and assembling suspension

A Rear crossmember B C Upper or front crossmember mount To ensure clarity, the front crossmember (C area) and the upper crossmember (B area) are not marked. These components as well as the rear crossmember (A) do not have to be removed. Actuate the brakes when undoing the lock nut. Replace. Coat threads, nut support face and drive shaft splines with Optimoly HT. Tighten to 460 Nm (340 ftlb.) Use an open-ended wrench to lock at ball joint of stabilizer mount Replace. Tighten to 46 Nm ((34 ftlb.)...

Safety precautions for working on cars with airbag

Airbag units are pyrotechnical items of Danger Class T 1. Handling, transport and storage are subject to the legislation for ex- The below legal requirements refer to the Federal Republic of Germany. Be sure to observe the relevant legislation in your country at all times. When storing airbag units, make sure that the padded side faces up (danger of injury if an airbag unit is ejected in case of accidental Airbag units may not be stored together with other products classified as dangerous items...

Manufacturer

Install a new plug no. 1 (see fig. 2345-40 on p. 40-23). The thread of the mount must not contain any residuals (stemming from the microencapsulation). Furthermore, the thread must be fat-free. The plug must be tightened only with the spring strut installed. Lower the vehicle to place it onto its wheels only after tightening plug no. 1. To tighten the fastening nut on the spring strut mount, use an open-jawed socket key insert, e.g. by Hazet. Thus the required tightening torque of 80 Nm can be...

ABS 5 ABD 4channel system

(for schematic diagram, refer to page 45 - 3), Number of brake pipes at adapter (in left-hand upper area of spare wheel well) ABD warning lamp and ABD operation lamp (information lamp) on vehicles fitted with ABS 5 ABD. After the ignition is switched on (lamp check), these lamps On vehicles fitted with ABS 5, these lamps in the instrument cluster are not

Repair group survey911 Carrera 993

Body Body front section 50 Body center section, roof, frame 51 Front doors, Central Locking System 57 Interior equipment, passenger protection 68 Volume VI Air conditioning 8 Air conditioning Heater 80 Vehicle electrics Ventilation 85 Auxiliary air conditioning system 88 Radio, telephone, on-board computer 91 Windshield wipers and washer 92 Exterior lights, lamps, switches 94 Interior lights, lamps, switches 96 Volume VII Electrical system 9

Safety measures

Ignition and preparation for ignition must be performed by qualified personnel and must be supervised by a second person responsible for the ignition process. Observe all other accident-prevention regulations. Ignite airbag units only in installed, original Ignite airbags only in suitable, open localise only the ignition tools intended for this Remove all other loose items from the expansion area of the airbag. Advise all affected personnel in advance of Keep safety distance by using the full...

Dismantling and assembling hydraulic control unit

38 77 19 Dismantling and assembling hydraulic control unit 38-113 Short legs must force on the ATF pan Short legs must force on the ATF pan Replace. Make sure that position is correct Observe correct length, tighten to 8 Nm (6 ftlb) The straight surface on the harness socket must point towards the outside 38- 114 38 77 19 Dismantling and assembling transmission

Changing engine oil without filter

Precondition Engine at operating tempera 1. Remove engine guard and right-hand side member panel. Undo the drain plugs in the crankcase and thermostat housing and drain engine oil. 2. Clean drain plugs. Always replace the seals. Tightening torque of drain plugs is 50 Nm (37 ftlb.) at the crankcase 50 + 5 Nm (37 + 3.7) 3. Fill with approx. 6 liters of engine oil. Run engine at idle and top up with approx. 3 liters. The oil change capacity is approx. 9 liters. Use only approved engine oils. Refer...

Raising the vehicle

The vehicle may only be raised at the jacking points illustrated. When driving the vehicle onto a lifting platform, make sure that there is sufficient clearance between the platform and the vehicle. Diagnosis system read out fault memory Particle filter replace filter element V-belt or Polyrib belt check condition and tension Replace spart plugs (only on vehicles without catalytic converter) Visual check for leaks oils and fluids Crankcase ventilation check tightness of hose connections Fuel...

Installation

Apply Molykote Longterm to the speed sensor and the hole in the wheel carrier. Caution There is no O-ring between the speed sensor and the wheel carrier. In addition, the front and rear speed sensors must not be confused with each other. Otherwise, the blade of the speed sensor will be offset 90 degrees from the pulse edge. Distinguishing feature Spare part no. marked on the speed sensor lead and position of mounting hole in relation to blade.

Disposal of airbag units

Airbag units are pyrotechnical components and may constitute an environmental hazard due to their explosive nature as well as due to the materials they contain. Airbag units that have not been ignited or complete vehicles with such airbags must therefore never be disposed of via the standard scrapping or other disposal procedures. The airbag units must first be rendered harmless by igniting them electrically observing all safety measures, to ensure that they cannot be used for non-authorized...

Remov and installing the wiring harness for the transmission

Remove the transmission underbody cladding. 6. Mark the push-on sleeves for re-installation and pull off from the solenoid valves. A Bayonet lock B Hexagon nut (a f 30) 4. Unscrew the hexagon nut for the transmission socket with a suitable extension. 5. Remove hydraulic control unit with wire harness (see also page 38-113). 2. Remove multi-functional switch (see page 37-105). 3. Disconnect the connector from the transmission socket. To do this, turn the bayonet lock to the left and disconnect...

Connecting ignition tools

Directly to 2-pin connector of contact unit (below steering column). With ignition cable 9567 to gas generator. Using the ignition lead, connect to both gas generators. Route ignition device across door gap and place in front of vehicle. Connect ignition device to a car battery and actuate button. Ignite driver's and passenger's airbags separately.

Layout

The layout in the below items remains unchanged throughout the repair manual 4. Legends for the exploded views 5. Assembly notes use of special tools As a new feature, however, the former item 6 (Repair group diagnosis) is no longer filed in the volume corresponding to the respective repair group. The Diagnosis test plans diagnosis procedures have been combined in a separate Diagnosis volume broken down according to the main groups 0 to 9. Another new feature is that the contents of the Service...

Removing and installing multifunctional switch on transmission

Remove transmission undertray. 3. Remove rear underside panel. 4. Remove left rear hot air pipe. 5. Disconnect selector lever cable from A selector lever cable C hexagon nut ( M 8 x 1) with washer 8. Detach, unlock and disconnect connector. 9. Unscrew fastening screws for multifunctional switch completely and remove switch. For installation, proceed in reverse order. Tightening torques Multi-functional switch to transmission 10 Nm Actuating lever to selector...

Visual inspection for cracks and crack assessment

1996 Porsche 993 Starter Wiring Diagram

Perforation cracks are caused by material fatigue due to severe, repeatedly fluctuating heat expansion. Disc temperature fluctuations of this nature that occur especially under racing conditions produce radial cracks in the perforation holes of the friction disc due to material fatigue (alternating themal expansion). These cracks, on the other hand, will reduce tension of the friction disc to a certain extent, i.e. crack grwoth continues only The maximum admissible perforation hole Further...

Maintenance

Porsche 993 Ecu Scanner

Diagnosis system Reading out the fault memory The procedure for reading out the fault memory is described in the operating instructions for System Tester 9288. A copy of the operating instructions is supplied with each tester. The System Tester 9288 is connected to the vehicle via a 19-pin socket. The socket is located in the passenger footwell next to the Also refer to Repair Group 03, Diagnosis, for operating instructions, repair group D, volume 8 diagnosis. Starting with Model Year '95, the...

Removing and installing tail panels

Undo the wheel housing liners partially before removing the tail panels Undo the wheel housing liners partially before removing the tail panels Unclip from end cover and undo electrical connection Reconnect electrical connection and clip into end cover Undo threaded stud (13), screw out fillister head screws (7), take end cover off tail panel and disconnect electrical connection Reconnect electrical connection, insert end cover and adjust with item 11 at bottom and item 7 at top to line up with...

Replacing fuel filter

Take out housing cover and filter element. 2. Separate air cleaner housing from intake air rail and unhook from air flow sensor. Lift up air cleaner housing and take out housing. Be careful no to lose the O-ring in the air cleaner housing air flow sensor. 3. Undo fuel lines, using a second wrench to lock. Drain remaining fuel into a suitable 4. Undo clamp and remove fuel filter.

Removing and installing condenser

Use service unit to draw off refrigerant. 2. Unbolt and take off left front wheel. 3. Remove wheel housing liner and lower section of front spoiler. 4. Disconnect connector linking the ballast resistor to the condenser fan. Undo refrigerant pipes from condenser, using a suitable tool to lock. 5. Plug ports and pipes immediately with a suitable air-tight seal. 6. Pull off electrical connector from fan motor. Unclip headlight wire and vent hose. 7. Disconnect both headlight cleaner hoses from...

Checking ATF fluid level

The specified fluid level is of great importance for proper operation of the automatic transmission. Selector lever is set to P The ATF fluid level must be between the MIN and MAX marks at a temperature of 80'C. A Testing range at 30 C ATF temperature B Testing range at 80 C ATF temperature lf reJUfired'top UP with ATF fuid across the Drive shafts Visual inspection of cup seals for leaks Exhaust system Visual inspection for leaks and damage, check bolt connections for tight fit and 1. Check...

Nominal values Notes Nominal values

Switching points of the pressure warning switch Brake pressure warning lamp warning point Cut-out point of the pump at the latest at the earliest Cut-in point of the pump (after pressure reduction) up to approx. 115 bar max. up to 133 bar as from 105+2 -5 bar at approx. 180 bar at approx. 160 bar Freedom from leaks of the booster circuit Pressure drop, starting from the cut-out point of the pump (precondition nominal value is achieved) not below 140 bar in 30 minutes not below 100 bar in 3...

Removing and installing

Unlock the main headlight in the luggage compartment and remove main headlight. Unclip safely clip in mounting using a screwdriver and remove lock lever with rubber sleeve. 2. Only loosen headlight mounting through openings in inside of luggage compartment using a 5 mm Allen socket wrench. Pull mounting up slightly and remove it. 3. Remove lower part of front spoiler. Only loosen the M 6 hexagon head screws from below and take out the mounting. Unhook the electric connector. Loosen headlight...

Diagnosis Troubleshooting Tiptronic

Fault, fault code Possible causes, elimination, notes Test point 31 Torque converter clutch always open Torque converter Fault possibility mechanical hydraulic fault in transmission *au't 1) Check ATF level and correct if necessary (refer to 911 Fault code 70 Carrera (993) Workshop Manual, Page 37 - 101). 2) Erase fault memory and perform a test drive. The diagnostic test conditions are achieved if - the torque converter clutch is electrically closed - engine torque > 200 Nm (148 ftlb) -...

Lili

Air temperature at center nozzle vs. ambient temperature 87 01 19 Dismantling and assembling heater A C unit Particle filter LH Particle filter RH Replace. Apply a thin coat of refrigerant oil. Replace. Apply a thin coat of refrigerant oil. Modifications to heater A C unit from model year '95 Electrically controlled bypass air flaps A solenoid valve controls the vacuum capsule of the bypass air flaps. The solenoid valve is mounted on the right of the heater A C unit. As a spare part, the vacuum...

Brake fluid change procedure Important notes

Depressurize booster circuit before changing the brake fluid. Do not depressurize by actuating the brake pedal but rather at the bleeding valve of the pressure accumulator. This will allow part of the old brake fluid to be drained. Caution Start by filling the accumulator completely (with ignition key in position 1, actuate brake pedal until pump starts to run). After the pump has switched off, pull off electrical connector and release pressure completely from accumulator vent valve. Open...

Practical procedure when readjusting the drive set

If it becomes necessary to adjust drive pinion and ring gear, follow the below sequence to ensure an efficient working procedure 1. Determine the total shim thickness Stot (Si plus S2) for the specified preload on the taper roller bearings differential. 2. Determine the thickness of shim S3. 3. Split the total shim thickness Stot into Si and S2 so that the specified circumferential backlash Is present between ring gear and drive pinion. The aim of this adjustment is to restore the smoothest...

Removing and installing alternator

Operation Installing alternator No. Operation Fit alternator in cooling blower housing Fit fan wheel for alternator cooling Unscrew negative terminal clamp from battery and cover Remove protective cap. Undo hexagon-head nut (24 mm A F) and use a polygon wrench (from car tool kit) to lock. Press fan wheel off the alternator, using puller VW 202 if required. Adapt both puller hooks to fit. Fit alternator. Make sure terminal B+ and terminal D + are opposite the TDC line...

Checking components of injection system for leaks

Remove air cleaner cap and air cleaner 2. Remove hose clamp from mass air flow sensor using cross-head screw driver, e.g. Wiha type, order no. 153-1 (350 mm long). 4. Lever off snap ring and remove protective 5. Fix sealing plate 9264 1 to hot-film mass air flow sensor using M4x40 screws and 3. Due to the limited space available, the mass air flow sensor and-the air filter housing must be separated in the engine compartment. To do so, turn mass air flow sensor in direction of arrow (direction...

Vehicles without catalytic converter Engine type M 640506

No provision for idle speed adjustment is made anymore. Adjustment on the throttle body is therefore omitted. Idle CO adjustment Adjustment requirements Perfect mechanical condition of engine. Loads must be switched off during the checks. Run check as quickly as possible to keep the intake ducts from heating up and causing faulty CO level readings. Ambient temperature 15 35 deg. C. 1. Warm up engine to operating temperature (70 90 deg. C oil temperature). 3. The CO potentiometer is located...

Technical Data

Gear ratios spur gear 1 st gear 2nd gear 3rd gear 4th gear reverse final drive fully automatic 4-speed planetary transmission (Tiptronic) final drive ratio 9 33 3.667 9 32 3.556 approx. 0.9 I multi-grade transmission oil 75 W 90 API specification GL5 (MIL-L 2105 B), or SAE 90 oil volume for automatic transmission total volume approx. 9.5 I with torque converter oil change approx. 3.5 I ATF-Dexron II D oil volume for automatic transmission total volume approx. 9.5 I with torque converter oil...

Tuning model 94 remote

As a result of tolerances in the ignition lock, it is not possible to define precisely the position at which the buzzer contact is closed by the ignition key. Depending on the tolerances, the buzzer contact(S) in the ignition lock may be closed between positions 0 and I or between positions I and II (Fig. B). I terminal X (windshield wipers on) When the key is removed from the ignition lock, the buzzer contact is opened (switched off). This signal is required for tuning the remote control...

Tire fitting using conventional machines

In order to prevent any damage to the paintwork, the rim flange should be covered with masking tape following tire removal. For tire removal and installation, a retaining tool, special tool 9539, is required. In addition, the end of the tire lever should be flattened and then rounded (see arrow) Insert wheel in machine and apply tire lubricant to inside of wheel and both tire beads. Before a tire is installed, the rubber valve must always be replaced. It is not always necessary to replace steel...

Checking wheel rims

Radial and lateral runout must be measured at the points on the inside of the wheel rim shown on the following drawing (dimension a). For measurements on wheels with or without tires, use a tire runout gage, e.g. V.A.G 1435 The maximum allowable radial and lateral runout on light alloy wheels is 0.7 mm. The maximum allowable radial and lateral runout on wheels with tires is 1.25 mm. Values lower than 1.0 mm (preferably around 0.5 mm) should be aimed for. See also page 44-23. Caution Welding and...

Important information for suspen sion alignment operations

When checking adjusting the suspension alignment, observe the following items Changing the height on one side will simultaneously cause a change in wheel load. A wheel load change on one wheel will also change the wheel loads of the other The wheel load is increased by increasing the installed spring preload on one side (raising The wheel load is reduced by reducing the installed spring preload on one side (lowering Wheel load changes are always transmitted diagonally on the other side of the...

Re 2 Bleeding the ABD circuit

Preparation Bleed brakes in conventional manner (for master cylinder circuits, refer to p. 47-12 13). The bleeder device remains connected (switched on) when the ABD circuit is bled. In addition, the booster circuit must be depressurized. Bleeding pressure approx. 1.5 to 2.0 bar. Overflow hose (vent) is blocked with hose clamp at brake fluid reservoir. Connect System Tester 9288 to diagnostic socket. Switch on ignition. Select Bleed menu. Close rear right bleeder valve. Then press Stop button...

Manual transmission

The Repair Manual of the 911 Carrera (993) also includes the 911 Carrera 4 manual (993 four-wheel drive). The 911 Carrera (993) is the basic model covered by the repair operations described in this Manual. 911 Carrera (993) is also indicated in the header of each page. Descriptions of repair operations that deviate for the 911 Carrera 4 will be included after the respec tive 911 Carrera section. The repair descriptions of both models are separated by a cover page. All pages included after the...

Porsche 993 Rear Suspension Chassis Mount Points

The introduction of a service number in the technical literature is intended to facilitate standardization and positive identification to allow direct cross-referencing among the various documents This is of particular importance with regard to the use of electronic media. The Repair Manual of the 911 Carrera (993) also includes the 911 Carrera 4 manual (993 four-wheel drive). The 911 Carrera (993) is the basic model covered by the repair operations described in this Manual. 911 Carrera (993)...

R

Replacing the complete roof Cutting roof panel and side panels from body Remove assemblies and accessories as well as complete interior equipment including all body glass Body straightening operations must be completed before the roof is replaced Set up vehicle on straightening Separate spotwelds at Separate spotwelds between roof rail rear wheel housing Separate spotwelds between roof and rear shelf panel Lift roof complete with side walls the body Separate flange joint of A-post flange panel...

Replacing floorpan

Cutting outer side member, center side member, inner side member and floorpan partially out Remove all ancillaries and accessories, including interior trim, from the center body section as well as the front fender Place vehicle onto bench-type straightening equipment 1 Cut through outer side member Cut through gusset plate and separate spotwelds Cut through center side member and separate spotwelds Separate weld seams of floor bracing panel Cut through inner side member, floorpan and tunnel....

Assembly notes

Removing and Installing spray tube on cam' shaft housing In case of bearing damage and when rebuilding the engine, the spray tubes must always be removed and cleaned thoroughly. If bearings are damaged, the lateral oil ducts must also be cleaned (removed 6.7 mm dia. plug and opposite 6.3 mm dia. balls). The ball may be pushed out with a threaded bar (M5) from the opposite side. Balls that do not retain a press-fit should be replaced by a plug. 1. Pre-drill lateral plugs (8.15 mm dia.) and upper...

Installation position of components

Retrofitting is described taking the Motorola International 2000 as an example. Other telephone systems may differ in certain details. Do not modify routing of the wiring, however, since this may lead to malfunctions during vehicle operation. The transmitter receiver unit is fitted within the emergency spare wheel in the luggage compartment. The telephone console is bolted to the right-hand side of the center console in the footwell Fit seat stop for passenger seat to the left seat rail below...

Speed manual transmission type G 50313233 for 911 Carrera RS

(basic vehicle and Clubsport) Switzerland Apart from a few differences, the transmission of the Carrera RS has a similar design to Carrera transmissions G50 20 21 the repair procedures are also similar. The major differences are as follows - 2nd gear wheel splined to drive shaft steel molybdenum synchronizer ring (type G50 32 only) - limited-slip differential as standard equipment (locking values 40 under acceleration,

Pistons

Weight classes for heavy pistons Pistons weighed complete with fittings (piston pins, piston rings, snap ring) Piston weight, complete, g Weight class within a set For replacement parts max. diff. 8 g Weight classes for light pistons Weight classes for light pistons Piston weight, complete, g Weight class within a set For replacement parts max. diff. 8 g

V16

Replace, coat threads with Loctite 574 if required, tightening torque 23 Nm (17 ftlb.) Washer, attached perma-nenlly to cyiinder bolt for item No. 1) Hey agon head boil with permaneni washer (M6x 2S, self-locking) Identification Cap for valve lifter bore is punch-marked along its circumference Pull out with suitable pliers but do not reuse Pull out with suitable pliers but do not reuse Oil sliding surface, use hold-down tool to push against mating surfaces on both sides, then tighten cylinder...

Removing and installing rear window

Mount Rear Window Porsche 993

The following tools and materials are required for removal and installation of the rear window using 2-pack adhesive Contents of adhesive set H 1 Cartridge component A H 2 Cartridge component B Activator (Solvent Cleaner) Cleaning solution Activator (Solvent Cleaner) Cleaning solution 64 86 19 Removing and installing rear window

Distribution of oil quantity in refrige

After the system contents have been drawn off, the following oil quanitites remain in the system Condenser Evaporator Fluid reservoir including piping Compressor Oil quantity circulating in refrigeration circuit On new vehicles, the drawn-off oil quantity is On older vehicles, this oil quantity is higher. The oil quantity drawn off must be added to Refrigerant oil drawn off from an A C unit that has already been operated must not be reused. When replacing a component, the oil quantity must be...

Important information on ABS 5 and ABS 5 ABD

The Porsche 911 Carrera (993) is supplied as standard equipment with ABS 5 (5th generation) or optionally (M number) with ABS 5 ABD. ABD Automatic Brake Differential. The major differences between ABS 5 and ABS 5 ABD are as follows Brake power controller at hydraulic unit ABS 5 1 ea. Diagnostics and system check of both systems are carried out with System Tester 9288. The pulse wheels of the front axle (tensioning discs) and the pulse rings of the rear axle have 48 teeth. The versions used on...

Remove Cassette Storage From Porsche 993

- Remove cassette box and trim panel above parking brake lever. - Loosen and completely unscrew lock nut and adjustment nut (No. 1) from arm (No. 2). Remove safety clip (No. 3) from support pin (No. 4) of parking brake lever and - Remove parking brake lever (with arm) - Unhook tab washer (no. 5) for parking brake cables from retaining lug (No. 6) - at top and bottom. - Unhook appropriate parking brake cable and pull it out of the guide from 8. Remove control arm 2 (toe control arm). Caution...

Removing and installing rear speed sensor

With the ignition switched off, open the connector assembly on the wheel carrier and unplug the connector for the speed sensor. 2. Unscrew the mounting bolt (Allen bolt) and remove the speed sensor. 1. Apply Molykote Longterm to the speed sensor and the hole in the wheel carrier. Caution There is no O-ring between the speed sensor and the wheel carrier. In addition, the front and rear speed sensors must not be confused with each other. Otherwise, the blade of the speed sensor will be offset 90...

Routing the wiring

993 Turbo Girl

Always insert suitable rubber grommets when routing wires through drill holes in sheetmetal panels. The antenna cable is routed from the passenger footwell across the right-hand A-post along the roof panel towards the B-post and to the antenna exit. Make sure the antenna cable does not cause any clattering noise. The sun visor and courtesy light will have to be removed for fitting of the antenna cable. The wiring is routed from the transmitter receiver unit towards the front wiring harness. It...

Troubleshooting the cruise controls control unit

Checking the multiple plug of the cruise control's control unit When cruise control malfunctions occur, the first item to be checked is fuse no. 19 in the central electrical system. The brake light is protected by the same fuse. 2. With the ignition off, remove the multiple plug from the control unit. 3. Connect measuring instrument voltmeter to terminal 12 ground and terminal 1 plus of the multiple plug. Turn ignition on. 4. Connect measuring instrument to terminal Press AUS key OFF on control...

Tightening torques for front axle

Porsche Special Tool 9560

Caution Do not apply grease to Dacromet-type screws and bolts aluminum-color appearance . Central tube Front-axle final drive Front-axle dinal drive to central tube Transmission mount rubber-metal mount Replace bolts only on front axle whenever the screw connection has been undone Do not unscrew while vehicle is standing on its wheels. Use new cap after dismantling. Stabilizer mount to wheel carrier and stabilizer bar for values not indicated, refer to Repair Group 48 Tie rod ball joint to...

Position spring strut mount as follows

position spring strut mount correctly relative to shock absorber eye . The left and right spring strut mounts are identical. There are therefore two markings on the mounts, R Right and L Left . Before positioning, check whether you are positioning a left or right shock absorber. The right mount is correctly positioned if the marking R Right is in line with the center of the stabilizer mount ball joint bolt. The left mount is correctly positioned if the marking L Left is in line with the center...

Checking rear brake discs wear assessment

Visual inspection for cracks and crack 2. Checking brake discs for minimum Two criteria may dictate replacement of drilled perforated brake discs 1. Advanced stage of cracking in drilled 2. Disc thickness is below minimum due to wear material abrasion caused by friction . Two types of disc wear usually occur in service. Normally, brake discs will have to be replaced if the brake disc thickness is below minimum. Only in rare cases if brakes are subjected to racing-like loads for longer...

Tests Note

Operation of the pump is regulated by means of the ignition key for testing purposes. Position 1 Pump on until switched off - In ignition key position 0, plug the electrical plug onto the pump. Locate the pressure gauge in a position where it can be seen. - For the tests, it is expedient to observe the a. Pressure accumulator - Gas filling pressure b. Switching points for the brake pressure c. Cut-in and cut-out points of the pump Turn the ignition key to position 1 pump a. Gas filling pressure...

Removing and installing Carrera RS steering wheel Momo

Steering Wheel Restoration

Remove the upholstered trim from the steering wheel see following text . Caution Do not dismantle the lid with the Porsche emblem. First pull lift the top and bottom of the hori zontal spokes on the trim over the steering wheel spokes. Then pull the trim over the vertical lower spoke lift it over the steering wheel spoke . Unplug horn connector from upholstered trim. 2. Unscrew hexagonal nut arrow Fig. 2196-48 and remove it together with lock washer. 3. Turn wheels of vehicle to straight...

Tightening torques for steering

Tightening Torques For Screw

Replace screws after every removal job. Use only genuine spare parts microencapsulated screws . Since 1995, 12.9 screws have been used previously 10.9 screws . For replacement, only 12.9 screws must be installed on all 993 vehicles. The threads of the screws and the washers must be clean and fat-free. Remove microencapsulation residuals from the threaded bores required to fix the steering gear use Aceton for cleaning, then blow out bores with compressed air . Before tightening, screw down the...

Adjusting brake pushrod

Stop Light Switch Brake Pedal

The brake pedal does not have a stop. The fixed clearance In the brake booster is ensured by the fact that the brake pedal does not have any support in the neutral position when the brake pushrod is adjusted correctly. When the brake pedal is actuated manually, a pushrod clearance of approx. 8 mm can be felt at the pedal plate. When the pushrod is adjusted at the pivot 3 , the position of the brake pedal changes as well. In this case, the stop light switch adjustment should therefore be checked...

Power transmission

Modifications for the '95 model year 3-17 Elasto-kinematic toe correction 42 4- 12 Coil springs layout 42 4- 13 Suspension alignment 44 4- 17 Bleeding the brakes 47 4 -23 Operation of the ABD 45 4-30 Constructional dimensions 50 5-4 Aerodynamics and air ducting 50 5 -8 Color scheme as of 1995 model year 60 6-1

Notes on fourpiston fixed caliper

1989 Pace Arrow Inside Wiring Diagram

The brake caliper halves must not be separated from each other. Piston seals, dirt scraper rings and spring plates may be replaced on an assembled To remove the spring plates, heat the mounting screws to approx. 150 C 300 F with a hot air gun since the screws have been installed with locking cement. Use new screws These screws are attached to the repair kit. The screw type has been changed and Torx srews are now used instead of hexagon socket screws. When stocks of the old kits have been used...

Interior Body Equipment

72 81 19 Removing and installing seat lift units . . 72 1 74 28 01 Checking seat heater 74-1 74 27 15 Calibrating controllable seat holder .74- 3 The Repair Manual for the 911 Carrera 993 , Vol. 5, also includes the Repair Manual for the 911 Carrera 4 993 4WD and the 911 Targa 993 . The 911 Carrera 993 forms the basis for the description of repair work in the Manual an 911 Carrera 993 appears at the top of each page. Where different or additional repair procedures apply to the 911 Carrera 4,...

Removing and installing front brake disc

Disconnect brake pipe from brake hose at spring strut and remove brake caliper. Before dismantling the brakes, push down brake pedal with pedal holder to prevent brake fluid from escaping from reservoir. Cover and plug brake hose and brake pipe to prevent ingress of dirt . Remove retaining spring from brake hose. 3. After having undone the countersunk screw s , take off brake disc. If the brake disc is binding and cannot be released even by applying light plastic hammer blows, screw two...

Technical data Carrera 4S Turbo Look

Hydraulic dual-circuit brake system with front axle rear axle circuit division. Hydraulic brake booster, internally vented and drilled brake discs with four-piston fixed calipers on front and rear axles. ABS ABD fitted as standard. Proportioning valve 2 units Switchover pressure reducing factor 2 x 44 2 x 36 mm 2 x 30 2 x 28 mm ABD automatic brake differential ABD automatic brake differential The brake disc must only be machined symmetrically, i.e. by an identical amount on both sides.

Brake fluid change procedure

Depressurize booster circuit before changing the brake fluid. Do not depressurize by actuating the brake pedal but rather at the bleeding valve of the pressure accumulator. This will allow part of the old brake fluid to be drained. Caution Start by filling the accumulator completely with ignition key in position 1, actuate brake pedal until pump starts to run . After the pump has switched off, pull off electrical connector and release pressure completely from accumulator vent valve. Open...

Removing and installing input shaft

Input Shaft Bearing Removal Tool

35 40 19 Removing and installing input shaft Fit with the same gearwheel. Heat to appro . 120 C Fit with the same gearwheel. Tabs must engage into the cutouts in the loose gearwheel Check for wear. Fit with the same gearwheel. Drivers must engage In Ihe cutouts in the tape-red ring. Thre lugs face the driver dogs. Fit with the same gearwheel. Heat to approx. 120 C Fit with the same gearwheel. Tabs mus engage into the cutouts in the loo se gearwheel Fit with tne same gearwheel, Heat to acprox....

Dismantling and assembling intake distributor

993 Porsche Cup Air Filter

911 Carrera RS engine with Varioram induction system M 64 20 Degrease seal surface of throttle valve flange and apply Loctite 574 sealant with velour roller. 24 46 37 Dismantling and assembling intake distributor tightening lonque 9 Nm 7 2 ftlb - tighten screws working crosswse Decrease seal surface and apply Locate 574 seaian with vetour roller Oil bore slightly. Install in correct position with rounded central platform facing center of intake pipe. install with fiat side towards upper section...

Removing and installing rear brake disc

Remove brake caliper from wheel carrier and suspend caliper inside wheel housing do not open hydraulic brake system . 3. Engage a screwdriver into the hole in the brake disc and turn adjuster in slackening direction. Lift off brake disc after removing countersunk screw s . 1. Clean end face and centering surface of brake disc and wheel hub. Apply a thin coat of Optimoly TA to centering surface of wheel hub. 2. Fit brake disc right and left-hand brake discs are identical . 3. Adjust parking...

Exceptional regulations order processing

If the steering gear replacement proposal by the shop is refused by the customer or insurance company for financial reasons, an expert, or if this is not possible in foreign countries, the importer should be consulted to be charged to the refusing party . If a decision is made against the above guidelines, it is recommended to file a note to this effect and have it signed by the expert. Power steering gears with no visible outside damage that require replacement will be availabe on an exchange...

Tightening torques for rear axle

Hexagon Bolts Tightening Torque

Caution Do not apply grease to Dacromet-type bolt unions aluminium-color appearance Subframe side parts to body rubber-metal mount Crossmember upper 2 parts Bolt connection to side parts Center bolt connection of 2 sections Arm 2 toe link to wheel carrier to crossmember eccentric Arm 1 5 lower link to suspension subframe to suspension subframe to wheel carrier Arm 3 camber link to wheel carrier Arm 4 caster link to wheel carrier 42 Tightening torques for rear axle When stocks of 8.8 bolts have...

Note

If new coil springs are installed, it may be necessary to use a different intermediate section. Intermediate sections with the following thicknesses are available 3.0 mm, 5.5 mm and 8 mm. Select the intermediate section in accordance with the tolerance group of the coil spring color coding colored lines on spring . 1 line 8.0 mm intermediate section 2 lines 5.5 mm intermediate section 3 lines 3.0 mm intermediate section Press intermediate section 10 into the correct position in the spring...

Checking adjusting the height

Adjust the height on the front axle at the adjustment nuts on the lower spring retainer as on 964 . For height adjustment on the rear axle, the strut must be removed to allow other spacers to be inserted at the upper spring retainers. The max. admissible front-to-rear deviation of 10 mm from the specified height must not be exceeded, i.e. the height at the front axle must not be exceeded by 10 mm full positive tolerance if the height at the rear axle is 10 mm below the specification full...

Installing the windshield

20 Apply adhesive to the wind shield 21 Adjust windshield using templates Apply a trapezoidal bead of 2-pack adhesive to the bonding section of the windshield using the bonding gun. Dimension x approx. 16 mm When applying the adhesive, be sure to apply the ad hesive in an overlapping manner 2 persons are required to insert and to adjust the windshield Insert windshield into window aperture of body in such a manner that the gaps between the windshield and the A-posts are parallel and that the...

General Engine

Porsche 993 Engine Under

10 Engine, Crankcase, Engine Mounts 10 01 19 Removing and installing the engine 10-101 10 01 19 Removing and installing the engine 10 01 19 Removing and installing the engine Auxiliary support for Special Tool 9111 3, attach engine mounting plate The auxiliary support should be fabricated in the shop The engine and transmission assembly is removed as a unit from below. Raise vehicle at jacking points. Disconnect battery ground cable 3. Place a suitable protective cover or a piece of hose on...

Removing and installing differential Tools

Porsche 993 Repaire

39 09 19 Removing and installing differential 911 Carrera 993 Final Drive, Differential, Differential Lock Differential or limited-slip differential Pack space between dust and sealing lips with grease e.g. qui amoly Pu 53 . Use thrust piece 9252 to press in until it is seated against the stop Pull out with suitable internal puller e.g. Kukko 21 - 8 Pull out with suitable internal puller e.g. Kukko 21 - 9 The halfshaft flange and seal ring can also be removed and installed with the transmission...

Removing and installing pressure warning switch

Location Radio Booster Porsche 993

With the ignition switch in position 0, pull off both plugs at the pump assembly. 3. Remove press, warning switch No. 1 Drawing 607-47 with special tool 9524. Prevent the pump assembly from turning while loosening the switch. Warning first clean the area round the pressure warning switch and cover it with non-fluffy cleaning cloths to trap the small amount of residual brake fluid which emerges 1. Screw in the pressure warning switch and tighten to a torque of 26 Nm 19 ftlb . Renew the O-ring...

Porsche 993 Rear Shock Absorber Mount Flange Ebay

Porsche 993 Rear Strut Bearing Pictures

Start by turning tie rod forward arrow . Then angle off ball joint ball pin , observing drawing, and pull out in this position. 3. Press tie rod ball joint off the steering ir, e.q. Nexus 168-1 suitable puller, e.c 1 , in conjunction with 12 mm cap nut 2 from Special Tool VW 267 a . 4. Remove stabilizer mount from stabilizer bar. To facilitate assembly for added assembly space and better tie rod position , move steering rack fully into steering housing. 5. Undo lock nuts 4 ea. M 8 from spring...

Changing brake fluid Vacuum brake booster

Vacuum Hose Porsche 993 Diagram

Caution The description below is only applicable to vehicles with vacuum brake booster. Use only new DOT 4 brake fluid. Observe change intervals and specified brake fluid grade. Refer to Page 47 - 5 for further Total brake fluid change quantity approx. - Top up reservoir with fresh brake fluid to upper edge. Connect bleeding device to Clamp the overflow hose bleeding hose shut with a hose clamp. The overflow hose bleeding hose has been omitted as of October 1995 refer to Technical Information,...

Dimensions for Cabriolet

Fuse Box 1984 Porsche 911

Horizontal distance between the mountings for the right locating peg and the left locating peg B 1306 2 Horizontal distance between the outer bolt hole for the right convertible top mount and the outer bolt hole for the left convertible top mount C 1340 3 Diagonal distance between the mounting for the convertible top locating peg and the outer bolt hole, for the convertible top mount on the B-pillar. D 763 3 Inclined distance between the mounting for the convertible top locating peg and the...