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911 turbo
Front Wheel, Suspension
Technical data
Wheel suspension
independent wheel suspension with
control arms and spring struts
Suspension
one round torsion bar per wheel, longitudinal
Torsion bar
" 18.8 mm
Height adjustment -
at DIN curb weight
Page
44 -1
Shock absorbers
double-action hydraulic
shock absorber struts
Manufacturer
Bilstein
-different
configuration
from Mod.
89
onwards
Anti-roll bar
0 18 mm -from Model 77 onward 0 20 mm
from Model 85 onward 0 22 mm
40 -01
Technical
data
Printed in Germany -VII,
1989
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Related Manuals for Porsche 911 TURBO - 1989
Summary of Contents for Porsche 911 TURBO - 1989
- Page 1 911 turbo Front Wheel, Suspension Technical data Wheel suspension independent wheel suspension with control arms and spring struts one round torsion bar per wheel, longitudinal Suspension " 18.8 mm Torsion bar Height adjustment - Page 44 -1 at DIN curb weight Shock absorbers double-action hydraulic shock absorber struts...
- Page 2 General TORQUE SPECIFICATIONS FOR FRONT AXLE Location Threads Designation Class Torque Support bearing to M 14 x 1.5 strut Support bearing to Capscrew M 10 body Carrier to body M 12 x 1.5 Bolt Carrier strut guard Bolt M 10 to body Stabilizer and suspension Bolt...
- Page 3 Front Wheel Suspension REMOVING INSTALLING FRONT AXLE Removing 1. Disconnect brake hose at brake line aft er 5. Place jack underneath carrier. first depressing brake pedal somewhat with pedal strut to prevent brake fluid from escaping. 6. Detach steering shaft at steering shaft holder and lift joint off of steering shaft.
- Page 4 Front Wheel Suspension 8. Lower complete front axle assembly. Note Do not turn the steering wheel quickly from lock to lock when the car is raised, to prevent tIle cup from popping off at the steeritlg gear or tie rod (air compensation). Installing 1.
- Page 5 Front Wheel Suspension T GalS Special Tool Description Remarks Torque wrench Commexcial item, up to 36 mkg (261 ftlbs) Tie rod remover Commercial item Wrench P 280 b Printed in Germany -II. 1976 Disassembling and Assembling Front Axle 40-3...
- Page 6 Front Wheel Suspension Printed in Germany 40-4 Disassembling and Assembling Front Axle...
- Page 7 Front Wheel Suspension Notes Amt. Designation Removing Installing Capscrew M 10 Torque to specifications Washer Replace, if necessary Hex nut, self- Torque to locking specifications Washer Guard Strut Hex hd screw Torque to specifications Washer Replace, necessary Caliper Spacer Torque to Capscrew specifications Clamping nut...
- Page 8 Front Wheel Suspension Notes Designation Installing Removing Washer Replace, if necessary Hex head screw Brake disc Check for wear and damage Radial seal Replace, if necessary. Press in until seal is flush with hub. Clean. check for Taper roller wear and lubricate. bearing Replace.
- Page 9 Notes Description Remarks Installing Removing Drive out Threaded pin Install with lubricant Position it correctly. Replace! Hex nut Torque to specifications Replace, tab faces Lockplate Support disc Strut Check, replace if necessary Guard Heat and install to Spacer stop Seal Torque to Hex hd screw M 10...
- Page 10 Front Wheel Suspension Notes Description Amt, Remarks Installing Removing Loosen with Torque to P 280 b specifications. Lubricate threads Ball joint Check, replacing if necessary Hex hd screw Torque to M 10 specifications Washer Replace, if necessary Hed hd screw Torque to specifications Washer...
- Page 11 911 turbo Rear Wheel, Suspension Technical data Wheel suspension independent wheel suspension with semi-trailing arms one round torsion bar per wheel, transverse Suspension Torsion rod 0 26 mm -up to the end of Mod. 88 0 27 mm -from Mod. 89 onward* Height adjustment - at DIN curb weight Page 44 -2...
- Page 12 General TORQUE SPECIFICATIONS FOR REAR AXLE Location Threads Class Torque Designation ft. Ibs Cover to body Bolt Trailing arm to cross tube M 14 x I, 5 Strut to trailing arm Excenter M 12 x I, 5 Bolt Strut to trailing arm M 12 x I, 5 10,9 Caliper to trailing arm...
- Page 13 REMOVING INSTALLING REAR AXLE Removing 1. Lift car. 6. Remove brake disc. Lift rear axle strut with special tool P 289. Detach brake line at caliper and rear axle Detach shock absorber at rear axle trailing arm. First depress brake pedal trailing arm.
- Page 14 Rear Wheel Suspension Installing Slide in drive shaft through rear wheel hub before securing the shock absorber. Install spacer and parking brake cable. 3. Torque axle nuts to specifications. 4. Check axial play of wheel bearings. Max. wheel bearing play is 5/100 mm. Adjust play if necessary.
- Page 15 TOOLS Description Special Tool Remarks Torque wrench Commercial item, up to 750 Nm (75 kpm) Extention Commercia! item Hexagon socket SW 30 Commercial item Strut retractor P 289 Check tool, see page 42 -8 Commercial item Dial gauge holder with magnetic column Dial gauge Commercial...
- Page 16 Rear Wheel Suspension ~~~ 8 H,---8 ~---'-\ '", 2 2~="'." "'." -;;: IW)~ -" " ~~---\ " 11 .-.c ~~r ."., -CO) " ,-ft Printed in Germany Disassembling and Assembling Rear Axle 42-4...
- Page 17 Notes Amt. Description Remarks Removing Installing Spacer Cotter pin Replace. if necessary Castle nut Thrque to specifications Washer Screw M 6 Torque to specifications Brake disc Check for wear Hex nut M 14 x 1.5 Torque to speci- self-locking fications Hex hd screw Washer Vibration damp.
- Page 18 Rear Whee Suspension Note When: Special Description Instructions Removing Installing Nut M 12 x 1.5 Torque: 120 Nm page 42 -11 Lockwasher page42-11 Washer Bolt page 42 -11 Nut M 12 x 1.5 Torque: 85 Nm page 42 -11/12 Lockwasher page 42 -11/12 Washer only with...
- Page 19 Rear Whee Suspension Note When: Special Description Instructions Removing Installing Bolt Torque: 25 Nm Lockwasher Replace if necessary Brake backplate Guard Taper roller Check, lubricate bearing, outer taper rollers with multiple purpose grease Shaft seal Press in to stop Install in correct Spacer position Shaft seal...
- Page 20 Rear Wheel Suspension MACHINING STRUT RETRACTOR P 289 Various modifications have been made on the rear axle of 911/911 Turbo cars since the beginning of production. Consequently the holder on P 289 must be adapted to the present state. If tool is not changed, the light alloy rear axle trailing arms could be damaged when clamping the tool between spring strut and trailing arm to tighten the mounting bolts.
- Page 21 DISMANTLING AND ASSEMBLING INSTRUCTIONS Disassembling Assembling 1. Drive out rear wheel hub with special 1. Heat trailing arm. Insert outer bearing tool P 297 a. races and drive in with an appropriate mandrel. 2. Install parking brake with anchor and guard on trailing arm.
- Page 22 Rear Wheel Suspension 9. Bolt rear axle trailing arm on body (refer to information note for point 11). Slide in propeller shaft with drive shaft. 10. Adjust rear wheel bearings. 11. Adjust parking brake. Bleed brakes. Torque all screws and bolts to specifications.
- Page 23 Rear Wheel Suspension Rear Axle Trai Spring Strut Self-locking nuts are used instead of hexagon nuts with lockwashers (Schnorr) on rear axle trailing arm/spring strut connections and toe excenters beginning with December of 1983. The tightening torque value was also increased. The new bolts and self-locking nuts can be installed retroactively.
- Page 24 Rear Whee Suspension Toe Excenter 2.1 Excenter 901.333.133.05 same Nut M 12 x 1.5 900.076.035.02 900.910.085.02 (hexagon nut) (self-locking nut) 999.523.109.02 none Lockwasher 60 Nm 85 Nm Tightening torque Camber Excenter Excenter 901.333.133.04 same 900.078.017.02 same Nut M 12 x 1.5 999.523.109.02 same Lockwasher...
- Page 25 ADJUSTING REAR WHEEL BEARINGS The spacer between both rear wheel bearings is de- 3. Continue turning nuts until an axial play of 4/100 signed to be shortened in length permanently when to 1/100 mm is reached (while turning the torque tightening the castle nut more than a certain tor- could rise up to 45 kpm/325 ft.
- Page 26 CHECKING WHEEL BEARING PLAY 1. Remove wheel and take off brake liners. 2. Secure dial gauge holder with dial gauge to rear axle trailing arm or strut. 3. Check axial play. Adjust play if it is more than 0.05 mm (see page 42 -13).
- Page 27 911 turbo General Technical Data (Model 75) Rims Tires Rims Forged aluminum Standard tires -front wheels 185/70 VR 15 on 7" aluminum rear wheels 215/60 VR 15 on 8" aluminum Cold tire inflation -front 2.0 bar 2.5 bar rear Special tires -front wheels 205/50 VR 15 on 7"...
- Page 28 General 911 turbo Technical Data (Model 76) Turbo Rims and Tires Turbo Carrera (USA) Rims Forged aluminum Forged aluminum Standard tires Front wheels 205/50 VR 15 on 7" rims 185/70 VA 15 on 7" rims Rear wheels 225/50 VR 15 on 8" rims 215/60 VA 15 on 8"...
- Page 29 911 turbo General Technical Data (Model 77) 44 -03...
- Page 30 General 911 turbo Technical data (Model 78 onward) Wheels and tires Wheels Forged alloy Tires: front axle 205/55 VR* 16 on 7 J x 16 rim Rear axle 225/50 VR* 16 on 8 J x 16 rim Model 86 onwards 245/45 VR* 16 on 9 J x 16 rim Spare wheel Folded tire 165/15 on 51/2 x 15 rim...
- Page 31 911 turbo General Technical data Winter tires* Observe tachometer assignment if 50 series summer tires, 15 inch version were fitted (Model 76 and Model 75 with special tires). Tires** Rims -possible and recommended sizes. Recommended sizes in bold print. 195/65 R 15 M +891 6 J x 15 H2 front and front and rear 7 J x 15 H2 rear...
- Page 32 Specifications for alignment The following values apply to a car at curb weight as per DIN 70020 (full fuel tank, with spare wheel and tools). (Values in brackets: for turbo Carrera USA, turbo Canada, Japan up to end of Model 82 only. The specifications are the same as those for rest of the world vehicles from Model 83 onward).
- Page 33 The following values apply to a car at curb weight as per DIN 70020 (with full fuel tank, spare wheel and tools). (Values in brackets: for turbo Carrera USA, turbo Canada, Japan up to end of Model 82 only. The specifications correspond to those of rest of world vehicles from Model 83 onward.
- Page 34 Sample test card Date: measured by MEASURING CHART Rims and tires (damage treads) 200 left turn-in measured right Toe-in (not pressed) Wheel load in kg' Max. difference between left and right: 20 kg (911 Turbo max. 10 kg) cosIer " 2 .] 3.20 Printed in Germany...
- Page 35 Wheels, Tires, Measuring vehicle 911 turbo Notes on alignment Because of the type of seal installed between steering gear and tire rods. the rubber boot becomes twisted when adjusting the toe and may be damaged. To prevent this, pull the rubber boot away from the recess in the tie rod. Always replace the rubber boot when adjustment has been completed.
- Page 36 Genera TECHNICAL DATA FOR TURBO 3.3 -SINCE 1978 MODELS * The internal ratio (boosting factor) in the brake booster has been changed: formerly 2.25, since 1985 models 3.0. Code since 1985 models: label showing 3.0 ratio. It is possible to install the modified brake booster in older models (beginning with 1978). Technical Data 46 -01 Printed in Germany -V,...
- Page 37 General * Brake disc must only be machined symmetrically, i. e. uniformly on both sides. Deburr vent holes after machining. Printed in Germany Technical Data 46 -02...
- Page 38 911 turbo General TORQUE SPECIFICATIONS FOR MECHANICAL BRAKE PARTS Location Threads Description Class Torque Nm (ft Ib) 10.9 Nut on steering Socket hd. screw 15 (11) knuckle Brake caliper Bolt. M 12x1.5 70 (51) Socket hd. screw steering knuckle Brake flange/brake Bolt 23 (17) disc to hub...
- Page 39 911 turbo Brakes/Mechanica Parts INFORMATION ON BRAKES OF 911 CARRERA TURBO-LOOK The 911 Carrera in Turbo-look has the brake system of the Turbo 3.3. However I the rear wheel brake circu it has a brake force regulator as in the 911 Carrera. The brake force regulator is located on the luggage compartment floor immediately behind the brake master cylinder.
- Page 40 CHECKING THICKNESS OF BRAKE PADS Cars without Brake 2. Visually inspect brake pads for wear. Wear Indicator Brake pads must be replaced when thickness of 2 mm is reached. Cars with Brake Wear Indicator (since 1984 Models) All brake pads of one axle must be replaced when the brake pad wear indicator lamp comes on and, however, not later than after reaching a thickness of 2 mm.
- Page 41 Brakes, Mechanical Parts REMOVING AND INSTAlliNG BRAKE PADS -TURBO 3.3, BEGINNING WITH 1978 MODELS 3. Pullout brake pads with a suitable tool, Removing e. g. Hazet 1966 -2 impact puller with If brake pads are supposed to be reused, mark 4 mm pin diameter.
- Page 42 Note Rear Axle To prevent brake fluid from spilling, draw off some of brake fluid from tank before pushing back piston. This requires a syringe used exclusively with brake fluids. Brake fluid is poisonous and therefore must not be drawn out through a hose by mouth. 2.
- Page 43 Parts Brakes, Mechanica 6. Lubricate engaging eyes of spreader spring in bridge with Optimoly HT or Plastilube. Install new spreader spring that its flat side faces brake disc. If installed incorrectly, proper fit of brake pads cannot be guaranteed. In addition, high spot at center of cross would scrape on brake disc.
- Page 44 Brakes, Mechanical Parts MODIFIED FRONT WHEEL BRAKES FOR 3.3 LITER TURBO The front wheel brake disc/hub connection is changed since the production of 1981 models. The flange and ring connection has been changed to a brake disc shell connection as on the 911/3.0 Itr. Turbo. By designing the new brake discs with a shell the total distance (brake disc -hub) is 21 mm longer.
- Page 45 Brakes, Mechanical Parts TOOLS Special Tool Remarks Description VW 771 Slide hammer 9165 Only required up to end of Puller 1980 models Disassembling and Assembling Front Wheel Brakes Printed in Germany -IV. 1981...
- Page 46 Brakes, Mechanical Parts "'C~ ro.. (W') -,'. C") 1)-- Note The front wheel brake applicable up to end of 1980 models is shown. From 1981 models the brake disci wheel hub connection is changed (see page 46 -4).
- Page 47 Parts Brakes, Mechanica Note When: Special Description Instructions Removing Installing Torque: 70 Nm Bolt Washer Replace, if necessary Between caliper Spacer and steering knuckle Brake cal iper Less width than Only version Spacer on rear axle up to end of 1980 models (21 mm) See text...
- Page 48 Parts Brakes, Mechanica Note When: Special Instructions Description Removing Installing Torque: 23 Nm Washer Replace, if necessary Bolt Brake flange Only version up to end of 1980 models Screw Torque: 10 Nm Washer Replace, if necessary Guard Machine or Page 46 -10 Point 1 replace, if necessary...
- Page 49 Brakes, Mechanical Parts DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES Disassembling Version 1. Unscrew and plug brake line to prevent brake fluid Grease caps with welded tapped adapters are install. from flowing out of reservoir. Unscrew brake ed since Chassis No. 93 Z BS 000094 caliper.
- Page 50 Brakes, Mechanical Parts DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES " Disassemb '- "," '-..~ > 6"" CO)) " 1. Check condition of all parts and replace, tR.."'" (9)'- if necessary. OJ \ "'" .OJ {- '" (" .\J -""" (Q) '.. "" CO) ~ \ (Q) ~ Note: Bridges of brake calipers have cast bosses '"...
- Page 51 Brakes, Mechanical Parts <0 ;;.--~-~ ,... Printed in Germany -III, 1978 Disassembling and Assembling Rear Wheel Brakes 46 -11...
- Page 52 Brakes, Mechanical Parts Note When: Special Description Oty. Instructions Removing Installing Screw Torque: 60 Nm Washer Replace, if necessary Brake cal iper Wider than on Spacer front axle (28mm) Screw Brake disc Set back brake Check for wear and damage Hooks must be in Spring holes provided in...
- Page 53 DISASSEMBLING AND ASSEMBLING REAR WHEEL BRAKES 5. Unscrew brake caliper and remove brake Disassembling disc. If a tight fitting brake disc cannot be removed even after applying light 1. Remove spacer. Do not use sharp edged knocks with a plastic hammer, screw tools.
- Page 54 Brakes, Mechanical Parts 2. Assemble spreader lever. 4. Press down lower parking brake shoes with a screwdriver. Install assembled adjuster. Mount lower spring. 3. Install front (long) return spring with parking brake shoes on brake backing plate. Install 5. Check parking brake shoes, adjuster, return rear return spring and upper spring.
- Page 55 Brakes, Mechanical Parts 8. Adjust parking brake. Bleed service brakes. 6. Clean brake disc centering surface on wheel hub and apply a very thin coat of Optimoly Assemble brake disc and brake caliper. Tighten bolts to specified torque. Do not mix up left and right side discs, since inboard vent passages have an evolute shape.
- Page 56 General TORQUE SPECIFICATIONS HYDRAULIC BRAKE PARTS Location 11ueads Description Class Torque mkg (ft Ib) Master cylinder to 2.5 (18) vacuum booster Stop light switch to Stop light switch 1.5+ 0.4 M lOxl master cylinder (11 + 2.9) Brake booster unit 2.5 (18) to base Brake fluid reservoir...
- Page 57 Notes Genera Printed in Germany 47-02 Technical Data...
- Page 58 10 11 9 1617 3610 fJ-- :> ~"'-.J'-' /r--- ~ --IJ 1819 2 15 12 1314 Note: Blow-up view shows brake caliper of rear axle with 30 mm diameter piston (front axle piston diameter: 38 mm) and retaining tab of cross spring facing up. On brake caliper of front axle retaining tab is down, i.
- Page 59 Down Torque: 60 Nm Screw (43 ft. Ibs.) Brake cali per half,rked with outer (ma Porsche) Bottom on front axle, Page 47 -5 Bridge top on rear axle without opening Page 47 -5 Bridge with opening New version (without Brake cal iper half, no.
- Page 60 Note When: Special Description Instructions Oty. Removing Installing Seal Omitted since Replace Dec. 1984 Screw Heat to approx. Install with Loctite 1500 C No. 270. Heat screws to Assemble with correct i Spring plate with Page 47 -5 retainer approx. 1500C. bridge. Lock screws with Loctite No.
- Page 61 Brakes, Hydraulic Parts DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS Disassembling 1. Clamp caliper in a vise with soft jaws and 3. Drive off brake caliper halves from bridge detach connecting line. by applying knocks from a plastic hammer alternately. 4. Countersunk screws of spring plate are locked in bridge with Loctite 270.
- Page 62 Brakes, Hydraulic Parts Assembling Version 1. After replacing or loosening, lock counter. sunk screws for spring plate with Loctite 270. Install spring plate with retaining tab on bridge without opening. Note Following changes have been made on spring plates since the beginning of standard production.
- Page 63 Brake, Hydraulic Parts 2. Assemble brake caliper. 3. Replace seals on hollow bolt and adapter. 4. Check piston position -see page 46 -3 5. When installing brake pads, check for correct play between pad and recess, correct position of cross spring and clearance of lockplate in case of initial version spring plates (see pages 46 -2 to 46 -4).
- Page 64 Brakes, Hydraulic Parts Note: The blow-up view shows the outer front axle brake caliper half. Piston diameter on front axle = 38 mm. Piston diameter on rear axle = 30 mm. Mount piston and bleeder valve in correct position, depending on installation of brake caliper half on right or left side (setback surface on face of piston faces brake disc inlet/bleeder valve faces up).
- Page 65 Brakes, Hydraulic Parts Note When: Special Instructions Description Removing Installing Piston Press out of brake Use brake cylinder caliper half with paste. Check compressed air. piston position Use wood base - (position danger of injury! machined piston face) already while pressing in - page 46 -3 Dirt scraping ring See page 47 -9...
- Page 66 DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS Disassembling 1. Place brake caliper section on a wooden board with the piston facing down and press out piston with compressed air. 4. Lift out seals with a plastic rod. 2. Clamp brake caliper section in a vise with the cylinder bores facing up.
- Page 67 Brakes, Hydraulic Parts Note: Note: Machining cylinder bores and pistons is not Mount dirt scraping ring in brake caliper approved. Replace pistons or complete brake section that the ring's printed part number caliper section, as applicable. faces in. The sealing lip then faces out (in contradic- tion to the normal position of a radial shaft 3.
- Page 68 c Parts Brakes, Hydrau 7. Check for leaks (high pressure test) with a pressure tester. High Pressure Test Produce a pressure of 50 to 100 bar in the braking system with a pedal prop. The produced pressure must not drop by more than 10 % during the testing time of 10 minutes with a constantly applied pedal force.
- Page 69 Brakes, Hydraulic Parts BRAKE CIRCUIT FAILURE INDICATOR (UNTIL END OF 1983 MODELS) Each of both brake circuits has a brake light The brake circuit failure indicator has to switch on the brake master cylinder, which be cancelled by disconnecting the battery also functions as a brake warning switch in after repairing the brake system.
- Page 70 SPECIFICATIONS Steering Rack-and-pinion Steering wheel 380 mm (14.961") dia., lattice steering wheel with impact pad Steering ratio in center steering wheel angle to wheel angle 17.78 : 1 Turning circle dia. 10.8 m (35.4 feet) Track circle dia. 10.35 m (33.9 feet) Non of steering wheel turns from lock to lock approx.
- Page 71 General TORQUE SPECIFICATIONS FOR STEERING Location Material Threads Designation Torque ft Ibs Steering gear Bolt. M 10 Tie rod to rack Ball socket M 16 x 1.51c35K Ball socket to Castle nut M 10 x steering arm Ball socket to M14x1.51o4 tie rod (lock nut)
- Page 72 "" &") It. '-co V '""--t:) " °0 48-1 Printed in Germany 1976 Dismantling and Assembling Steering -,..
- Page 73 Steering Notes Amt. Designation Remarks Installing Removing Torque to Capscrew specifications Lockwasher Replace, if necessary Cover Must fit on steering shaft bearings conectly Hex hd screw Torque to M 10 x 35 specifications Washer Replace. if necessary Cotter pin 2 x 25 Replace Castle nut Torque to...
- Page 74 Steering Notes Designation Remarks Removing Installing Hex hd screw Torque to M 8 x 42 specifications Lockplate Replace Stop Visual inspection, Steering coupling replacing if necessary Steering shaft Check frictional Steering gear torque, replacing or repairing if necessary DLSASSEMBLING ASSEMBLING INSTRUCTIONS Note Assembling...