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Porsche 911 TURBO - 1975 WORSHOP Manual

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Summary of Contents for Porsche 911 TURBO - 1975 WORSHOP

  • Page 2 GENERAL Technical Date Page 0.1 REPAIR GROUP Engine-crankcase Engine-Crankshaft, and moving parts Engine-Cylinder Head, Valve drive Engine-Lubrication Engine -Cooling ENGINE Fuel Supply system Turbocharger Fuel system Exhaust System Starter, Power Supply Ignition System Clutch, Control Mech. gear-shift system -actuat., hous. TRAN S MISSION Mech.gear-shift system -Gears, Shafts Differential...

  • Page 3: Exterior Equipment

    911 turbo Alphabetical Index Volume II Page Body, front section Repair Repair Dimensions Body Body platform, platform control control dimensions dimensions front body front -type platform. section 911-turbo, 911-turbo 911-turbo gauge Model onwards ..50-4 ..50-1 ..50-3 ..50-5 ..50-7 ..50-7a Straightening attachments type 911-turbo...

  • Page 4: Wiring

    Volume II Alphabetical Index 911 turbo Page Wiring 97-1 Additional Current-flow Current-flow Current-flow current-flow diagram diagram diagram -911 -911 -911 diagram turbo, turbo, turbo, -exhaust Model Model Model temperature monitoring -type turbo 97-13 97-19 97-17 97-29 Additional Additional Additional Additional current-flow current-flow current-flow...
  • Page 5 Body -Front Section FLOOR/FRAME CHECKPOINTS AND FRONT BODY SECnON GAUGES P 863 AND 863a As already announced in the 1975 model information, checkpoints are welded to the floor/frame assembly from 1975 models. The extent of damage is quickly diagnosed with the help of these checkpoints and front body section gauge P 683 a (consisting of former gauge P 863 + additional adaptor) .

  • Page 6: Assembly Drawing

    Body FLOOR/FRAME ASSEMBLY DRAWING Printed in Germany 50-2 Floor/F'rame Assembly Drawing...
  • Page 7 Body Dim. Designation Control arm take-up, front, inner 565.5 Carrier take-up Front floor plate checkpoints 1200 Rear floor plate checkpoints Engine suspension !. 3 Front floor/inner control arm checkpoint 1327 !. 3 Rear floor/ carrier checkpoint 1868 1528.5- 3 Axle tube transmission/front. floor checkpoint 1346 "!.
  • Page 8 Body -Front FLOOR/FRAME ASSEMBLY TYPE TURBO In comparison to the Type 911, the carrier pin <i the Type 930 Turbo is 21 mm higher. This has caused changes to the floor/frame assembly in the area marked in white. The border on the wheelhouse and floor plate is cut out about 70'mm higher than the control arm to allow accessibility.
  • Page 10 Body REPAIR REFERENCE POINTS 930-turbo 50-5 Repair Reference Points for 930 Turbo ') "'...
  • Page 11 Repair Reference Dimensions 930 Turbo III, 1978 Printed in Germany From 1978 Models...
  • Page 12 Body STRAIGHTENING BENCH ATTACHMENT 77.303 TYPE TURBO The illustrated take-up points differ from the attachment set for Type 911 and are applicable to Turbo cars. The auxiliary carrier pin is installed 21 mm (0.827') higher. The brackets on the rear axle cross tube are inclined upwards. ~""' The take-up pin for the transmission suspension is located 25 mm (0.984') further forward.
  • Page 13 REAR AXLE CROSS TUBE OF 930 TURBO A new rear axle cross tube. Part No. 930 331 010 00, -Fig. A -is installed in the Type 930 Turbo. This cross tube differs from the version for the Type 911 -Fig. B -as follows.

  • Page 14: Removing And Installing

    Hoods and Lids REMOVING INSTALLING ENGINE HOOD FROM 1978 MODELS, TURBO Removing 1. Detach hose straps and ground wire at hinge..~. Caution Refrigerant hoses must not be detached from con- denser, since otherwise-the high pressure refrigerant would escape and the air conditioner would have to be recharged.
  • Page 15 Hoods and Lids Notes on Installing Disassembling 1. Unscrew rear spoiler carrier from hood and re- When installing the windshield wiper shaft, it is move with reinforcement rail, see arrow. essential to insert spacer in hood. Wiper arm should be installed that, when switched off, wiper blade will be parallel to side window weatherstrip (distance approx.

  • Page 16: Doors

    Exterior Fittings INSTALLING TURBO SIGN There are nine 'Turbo" decals on each vehicle. They are placed as follows: one on each door; one on each front fender; two on each rear fender; Work Sequence: one for the rear lid. 1. install the door decal, Part No. 930.559.303/ Observe the following to make sure that the 304 00/01 so that the paper edges (top front/ decals adhere well to the painted body.
  • Page 17 Exterior Fittings 2. Install front fender decal -Part no. 930.559. 4. Install turbo sign decal -Part no. 930.559.307/ 301/302 00/01 -after the door decal has been 308 00/01 -below masking tape border parallel installed. Start at the door edge. Make sure to taillights.
  • Page 18 Exterior Fittings INSTALLING TURBO DECALS ON REAR FENDERS 1. Using squeege pull upper lip of rubber guard away from connector plate as far as necessary. 2. Clean and dry surfaces for decals. 3. Draw a pencil line 30 mm (1 1/8 iIi.) parallel to wheel openiIig.
  • Page 19 Interior Fittings REMOVING INSTALLING CENTER CONSOLE Removing 1. Unscrew cap. Caution! The capillary tube must not be bent sharply or separated. since it would be destroyed. 2. Pull off air conditioner switch knobs and 4. Remove mounting screws at front and rear of center tunnel.
  • Page 20 Interior Fittings 7. Open up the opening for the harness to about 40 x 60 mm, so that the temperature switch can be removed. This means first cutting the proper depth with a saw and then cutting out the metal with a shears. Remove center con- sole.

  • Page 21: Heater Controls

    Heater AUTOMATC HEATER CONTROLS Removing and Installing Control Unit 1 -Pry both side covers off of control unit. 2 -Detach connecting rod between motor and heater lever. Removing and Installing Interior Sensor 1 -Remove both Phillips screws and pull down sensor carefully. 3 -Remove the four hex head screws, lift control unit carefully and disconnect the three plugs at the control unit.
  • Page 22 Heater Removing and Installing Heat Sensor in Heater Flap Housing 1. Loosen control unit and pull off the front 2-pole male plug. 2. Loosen carpet along center tunnel and clear cable up to grommet in heel plate. Pull both wires out of male plug housing (be carefull that they don't grab hold) and press out the grommet.
  • Page 23 Heater Install adaptor. Make sure that the heater flaps are adjusted evenly on both sides. 8. Secure plug housing to cable. The black wire must be located on the side of the housing with a tab. Place cable inside of car, paste carpets. connect plug to control unit and secure control unit again.

  • Page 24: Troubleshooting

    Heater TROUBLESHOOTING AUTOMATIC HEATER CONTROLS Checking Interior Sensor Checking Heat Sensor in Heater Flap Housing 1 -Remove interior sensor. 1 -Remove control unit. 2 -Connect ohmmeter to 2-pole plug of 2 -Using an ohmmeter with an appropriate testing range, check the resistance bet- heat sensor.
  • Page 25 Checking Power Supply to Control Unit 1 -Remove right side cover of control unit. 2 -Disconnect 3-pole plug. 3 -Turn on ignition and parking lights. 4 -Connect test lamp between brown and red/white as well as brown and gray/blue cables. Test lamp must come on in both cases.
  • Page 26 Radio Instruments, LOCATION OF RELAYS Six standard relays are located in the fuse box As for the Type 911. the standard relay for the in the luggage compartment. rear window defogger. the flasher relay. the timer relay for the seat belt warning system and the control unit for.
  • Page 27 Instruments, Radio 1 -Fuse/relay plate 2 -Hot starting valve relay 3 -Warm-up governor relay 4 -Air control/charge pressure relay 5 -2-stage rear window defogger control relay 6 -Voltage stabilizer CD! control unit 8 -Radio suppression Printed in Germany Location of Relays in Car !IO -2...
  • Page 28 Instruments, Radio Fuse/Relay Plate from 1976 Models to S -Rear fusebox (fuses S 2 -Fuse/relay plate -Relay. air control/charging pressure 4 -Relay. two stage rear window defogger 5 -Condenser, CDI control unit 6 -Radio suppressor 7 -Voltage stabilizer CD! control unit Location of Relays 90 -2 Pr inted...
  • Page 29 Instruments, Radio Regulator Plate from 1977 Models 1 -Tail fuse box 2 -Regulator plate 3 -Air flow sensor/charging pressure relay 4 -Delayed ignition cut-off relay 5 -Two-stage rear window defogger relay (not applicable from 1978 Models) 6 -CDI control unit capacitor 7 -Radio shield 8 -Voltage...

  • Page 30: Differential

    Instruments, Radio ELECTRONIC SPEEDOMETER Checking Electronic Speedometer Sensor Remove tunnel cover in front of emergency seats. Disconnect the flat male plugs at the connector in the tunnel and connect a test buzzer to the wires leading back. Lift car at rear axle and turn right rear wheel by hand.
  • Page 31 Instruments, Radio Removing and Installing Electronic Speedometer Sensor 1 -Remove right rear wheel. 2 -Remove hex head screw and take holder off of sensor. 3 -Take sensor wires out of holders and pull sensor out of transmission case. 4 -Separate connector in tunnel and pull out sensor wire toward rear.

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