Porsche 1972 911 Workshop Manual
  1. Manuals
  2. Brands
  3. Porsche Manuals
  4. Automobile
  5. 1972 911
  6. Workshop manual

Porsche 1972 911 Workshop Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
Table Of Contents
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Workshop manual
h.
DR. ING.
F. PORSCHE KG
c.
STUTTGART-ZU FFENHAUSEN

Advertisement

Table of Contents
loading

Related Manuals for Porsche 1972 911

Summary of Contents for Porsche 1972 911

  • Page 1 Workshop manual DR. ING. F. PORSCHE KG STUTTGART-ZU FFENHAUSEN...
  • Page 2 This publication contains the essential removal, installation and adjustment procedures for the Porsche 911 vehicles sold in the USA and Canada. Components and procedures described in this manual are identical for all types unless differences are pointed out in the text. It is assumed that the reader is familiar with basic automotive repair procedures.
  • Page 3 Motor und Kupplung Engine and Clutch Moteur et Accouplement...
  • Page 4 E N G I N E C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA D e s c r i p t i o n Engine changes 1972 model Oil tank changes 1972 model Oil cooler system and oil circuit schematic Oil cooler.schematic 1973 model Oil cooler schematic with cooling coil...
  • Page 5 E N G I N E 2 . 2 E x h a u s t s y s t e m a n d h e a t i n g Exhaust system and heater blower, removing and installing Exhaust system 1978 model E m i s s i o n c o n t r o l...
  • Page 6 C y l i n d e r h e a d Valve springs, installed length Adjusting timing CYLINDERS AND PISTONS C y l i n d e r s a n d p i s t o n s Piston changes 1972 model Piston and cylinder dimensions...
  • Page 8 E n g i n e D e s c r i p t i o n B E G I ENGINE C H A N G E S G W I T H 1 9 7 2 MODELS G e n e r a l I n f o r m a t i o n Beginning with 1972 models, Type engines have a cubic displacement of 2.4 liters cu.
  • Page 9 E n g i n e D e s c r i p t i o n Individual changes and changed service operations are described on the pages that follow. Summary of Changes: 1. Technical Data Crankcase Crankshaft 4. Connecting rods and bearings 5.
  • Page 10 OIL TANK CHANGES BEGINNING W I T H 1 9 7 2 MODELS G e n e r a l I n f o r m a t i o n Beginning with 1972 models, the oil tank is located in right rear wheelhousing in front of the rear axle. The oil filler neck is now accessible from the outside.
  • Page 11 OIL C O O L I N G S Y S T E M A N D OIL C I R C U I T S C H E M A T I C T Y P E 9 1 1 S V E H I C L E S (FROM 7 2 - M O D E L S ) Full-flow oil filter 1 Auxiliary oil cooler 2 Oil canler...
  • Page 12 O I L C O O L E R S C H E M A T I C T Y P E 9 1 1 s V E H I C L E S ( F R O M 1 9 7 3 - M O D E L O N ) 1.
  • Page 15 ENGINE CROSS - S E C T I O N Air filter housing Cross -shaft Intake stacks Fuel injection pump Heat exchanger Camshaft Spur belt O i l screen Crankshaft Oil pump O i l screen in crankcase Connecting rod Piston Cylinder Exhaust valve...
  • Page 16 9 1 1 D e s c r i p t i o n...
  • Page 17 E N G I N E S I D E - S E C T I O N Air filter housing Air inlet tube Fuel injection lines Oil pressure sensor Crankcase Oil pump Pressure side (to lubrication points) Suction side (to oil tank) Connecting shaft Oil screen O i l drain plug (magnetic)
  • Page 18 D e s c r i p t i o n S P E C I F I C A T I O N S FOR T H E 2 . 7 LITER ENGINE WHERE D I F F E R I N G FROM T H E 2 .
  • Page 19 D e s c r i p t i o n E N G I N E C H A N G E S B E G I N N I N G W I T H 1 9 7 4 M O D E L S 1.
  • Page 21 D e s c r i p t i o n...
  • Page 22 D e s c r i p t i o n...

  • Page 23: Throttle Housing

    L A Y O U T D R A W I N G O F E M I S S I O N C O N T R O L 9 1 1 S C ( 1 9 8 0 M o d e l ) 2 Fuel injector 3 Thermo t i m e switch Oil temperature switch...
  • Page 24 T E C H N I C A L D A T A T Y P E 9 1 1 V E H I C L E S B E G I N N I N G W I T H 1 9 7 2 MODELS ENGINE four-stroke gasoline engine with two opposing cylinder banks Number of cylinders...
  • Page 25 9 1 1 T e c h n i c a l D a t a...
  • Page 26 dry sump Lubrication dry sump dry sump oil cooler on crankcase in oil cooler on crankcase in Oil cooling f a n air stream fan air stream fan air stream; auxiliary cooler in front of vehicle full flow full flow full flow Oil filter Oil consumption...
  • Page 27 forged steel forged steel, surface- Connecting rods forged steel hardened (Tenifer) Connecting rod split inserts, 3-layer split inserts, 3-layer split inserts, 3-layer bearings bronze, pressed-in bronze, pressed -in Piston pin bushings bronze, pressed-in light alloy, die-cast light alloy, forged Pistons light alloy, die-cast floating, with circlips floating, with circlips...
  • Page 28 Spark plug threads 1 4 x 1, machined into 1 4 x 1,25, machined into cylinder heads cylinder heads cylinder heads Valves 1 intake, 1 exhaust valve 1 intake, 1 exhaust valve per cylinder per cylinder per cylinder Valve arrangement overhead in 'V"...
  • Page 29 Valve timing with 1 m m (0.040 in.) valve clearance inlet opens 30" ATC inlet closes exhaust opens exhaust closes Intake valve lift a t overlap T C with 0.1 m m 2 , 4 2,8 m m (0.004 in.) valve clearance capacitive discharge system capacitive discharge system capacitive discharge system...
  • Page 30 (DIN HP) Horsepower Output N e...
  • Page 31 T e c h n i c a l D a t a Full-power Performan Engine Speed n (rpm)
  • Page 32 Type 911 Full-power Performance 1 50 1 40 22 mkp at 5200 rpm Engine Speed n (rmp)
  • Page 33 T e c h n i c a l D a t a Full-power Performance Carrera Engine Speed n (rpm)
  • Page 34 Spark plugs (gap in mm) (0.55) BOSCH W 260 T 20 (0.7) (0.55) BERU (0.7) F u e l i n j e c t i o n p u m p BOSCH No. 0408 126 019 PORSCHE No. 911 110 254 00...
  • Page 35 T e c h n i c a l a T E C H N I C A L D A T A , T Y P E 9 1 1 T USA C O N T I N U O U S I N J E C T I O N S Y S T E M Internal designation Horsepower rating (DIN) in HP or K W crankshaft rpm...
  • Page 36 T e c h n i c a l D a t a Full-power Performance Ne max 140 PS (DIN1 at 5700 rpm Md max at 4000 rpm. 2000 3000 4000 5000 6000 7000 peed n (rprn)
  • Page 37 T E C H N I C A L DATA FOR TYPE VEHICLES BEGINNING W I T H MODELS 9 1 1 1 9 7 4 9 1 1 9 1 1 M O T O R four-stroke gasoline engine with two opposing cylinder banks Number of cylinders Cylinder arrangement horizontal,...
  • Page 38 M a x . t o r q u e : according to DIN 70020, kpm/Nm according to SAE J 245, net lb.ft./Nm 3800 4000 all at crankshaft rpm of S p e c i f i c p o w e r o u t p u t : 65/48 according to DIN 70020, HP/ltr or KW/ltr according t o SAE J 245, net HP/ltr or KW/ltr...
  • Page 40 T e c h n i c a l D a t a...
  • Page 41 ine Speed n (rpml...
  • Page 42 T e c h n i c a l D a t a T E C H N I C A L D A T A FOR 1 9 7 5 9 1 1 S AND CARRERA MODELS E N G I N E California No.
  • Page 43 9 1 1 T e c h n i c a l D a t a T I G H T E N I N G T O R Q U E S FOR E N G I N E Torque Location Threads...
  • Page 44 T e c h n i c a l D a t a...
  • Page 45 T e c h n i c a l D a t a T E C H N I C A L D A T A T Y P E 9 1 1 1 9 7 6 MODEL EN GIN E Bore Stroke Displacement...
  • Page 46 T e c h n i c a l D a t a Valve spring s i z e s Intake Exhaust Basic ignition timing (vacuum hose connected) 50 rpm Spark plugs, gap 0.55mm/O.O22 in. Beru 235/14/3P C o o l i n g F a n D r i v e Air delivery rate shaft speed of 6000 rpm...
  • Page 47 T e c h n i c a l D a t a T E C H N I C A L D A T A T Y P E 9 1 1 S , 1 9 7 7 MODEL E N G I N E Engine type Bore...
  • Page 48 T e c h n i c a l D a t a Identifying number on cam end face Left camshaft Right camshaft Bearing journals Valve springs: free length Intake valve Exhaust valve Ignition Timing USA Version (vacuum hose permanently plugged, vacuum advance at 950 50 rpm...
  • Page 49 T e c h n i c a l D a t a T E C H N I C A L D A T A , T Y P E 9 1 1 S C 1 9 7 8 MODELS ENGINE Engine type California...
  • Page 50 T e c h n i c a l D a t a Identification on camshaft face Left camshaft Right camshaft Number of bearings Length of installed valve springs Intake valve Exhaust valve CDI (breakerless) I g n i t i o n Basic ignition timing 900 t o 1000 rpm (vacuum hose attached)
  • Page 51 T e c h n i c a l D a t a T E C H N I C A L D A T A , T Y P E 9 1 1 S C f r o m 1 9 8 0 M o d e l 911 SC E n g i n e Engine type (internal code)
  • Page 52 Identification on camshaft face Left camshaft Right camshaft Number of bearings four Valve spring installed length Intake valve Exhaust valve I g n i t i o n Basic ignition timing idle speed, vacuum hose dis- connected, 90' C/195 F oil temperature Spark plugs electrode gap...
  • Page 53 T e c h n i c a l D a t a T E C H N I C A L D A T A , T Y P E 9 1 1 S C f r o m 1 9 8 1 M o d e l s E n g i n e Engine type (internal code) Bore...
  • Page 54 T e c h n i c a l D a t a Identification on camshaft face Left camshaft Right camshaft four Number of bearings Installed length of valve springs Intake valve Exhaust valve CDI (breakerless) I g n i t i o n Basic ignition setting (vacuum hoses detached, oil tempera- ture approx.
  • Page 55 C o o l i n g S y s t e m , E x h a u s t . E m i s s i o n C o n t r o l R E P L A C I N G A N D A D J U S T I N G F A N D R I V E B E L T Effective with the 1980 models a l l 911 SC engines Adjusting instructions for engine prior to 1980 have t h e larger fan from t h e 911 Turbo, New belt...
  • Page 56 C o o l i n g S y s t e m ,...
  • Page 58 C o o l i n g S y s t e m , E x h a u s t S y s t e m . E m i s s i o n C o n t r o l Notes Description Remarks...
  • Page 59 C o o l i n g S y s t e m , E x h a u s t S y s t e m , E m i s s i o n C o n t r o l Notes Description Remarks...
  • Page 60 C o o l i n g S y s t e m , E x h a u s t S y s t e m , E m i s s i o n C o n t r o l E X H A U S T S Y S T E M 1 9 7 8 M O D E L S ( E n g i n e T y p e 9 3 0 / 0 4 , 0 6 )
  • Page 61 C o o l i n g S y s t e m , E x h a u s t S y s t e m , E m i s s i o n C o n t r o l REMOVING A N D I N S T A L L I N G AIR I N J E C T I O N...
  • Page 62 C o o l i n g S y s t e m , E x h a u s t S y s t e m , E m i s s i o n C o n t r o l Notes Description Remarks...
  • Page 63 C o o l i n g S y s t e m , E x h a u s t S y s t e m , E m i s s i o n C o n t r o l Notes Description Remarks...
  • Page 64 C o o l i n g S y s t e m . E x h a u s t S y s t e m , E m i s s i o n C o n t r o l T E N S I O N I N G AIR PUMP BELT A d j u s t i n g Loosen bolt.
  • Page 65 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s R E M O V I N G A N D I N S T A L L I N G R -E A C T O R S A N D E G R E Q U I P M E N T...
  • Page 66 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s Note when Description Remarks...
  • Page 67 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s Note when Description Remarks...
  • Page 68 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s Note when Description Remarks...
  • Page 69 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s E X H A U S T GAS R E C I R C U L A T I O N S Y S T E M Component parts of the exhaust gas recirculation system are subject to a certain amount of wear and must therefore be inspected and/or replaced after operation for...
  • Page 70 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s C H E C K I N G R E A C T O R FOR LEAKS N o t e T h e reactor's operation need not be checked.
  • Page 71 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s C H E C K I N G E X H A U S T GAS R E C I R C U L A T I O N S Y S T E M 1.
  • Page 72 C o o l i n g , e x h a u s t a n d e m i s s i o n c o n t r o l s y s t e m s C H E C K I N G AIR I N J E C T I O N S Y S T E M Clean air filter of secondary air pump with compressed air.
  • Page 73 R E M O V I N G A N D I N S T A L L I N G OIL TA 1. Remove right rear wheel. 6. Loosen retaining strap. C a u t i o n Cover brake disc to prevent oil spillage during removal of tank.
  • Page 74 R E M O V I N G A N D I N S T A L L I N G OIL T A N K ( F R O M 1 9 7 3 MODEL O N ) G e n e r a l : Beginning with the 1973 models, the oil tank is located in the right rear wheelhouse behind the rear axle.
  • Page 75 R E M O V I N G A N D I N S T A L L I N G A U X I L I A R Y P R E S S U R E R E L I E F V A L V E Disconnect oil hoses.
  • Page 76 D I S A S S E M B L I N G A N D R E A S S E M B L I N G A U X I L I A R Y P R E S S U R E R E L I E F V A L V E Note when: Remarks Description...
  • Page 77 R E M O V I N G A N D I N S T A L L I N G OIL COOLER C O I L R e m o v i n g Remove right front wheel. Disconnect oil hoses. Caution Counter with a second open-end wrench.
  • Page 78 R E M O V I N G A N D I N S T A L L I N G OIL COOLER G e n e r a l : Beginning with the 1973 models, all six-cylinder engines are equipped with a two-piece air shroud which simplifies the removal and installation of the oil cooler.
  • Page 79 I n s t a l l i n g Install new sealing rings a t the oil cooler. NOTE: When positioning the oil cooler on crankcase, make sure that sealing rings are properly seated.
  • Page 80 O i l C i r c u i t REMOVING A N D I N S T A L L I N G OIL T A N K BEGINNING W I T H 1 9 7 4 MODELS R e m o v a l 1.
  • Page 81 O i l C i r c u i t Open the lock plate, remove nut, and pull out support tube through the bottom. Remove oil tank retaining nuts and washers. I n s t a l l a t i o n 1.
  • Page 82 R E M O V I N G A N D I N S T A L L I N G P R E S S U R E R E L I E F V A L V E O F C O O L I N G C O I L B E G I N N I N G W I T H 1 9 7 4 M O D E L S R e m o v a l 1.
  • Page 83 D I S A S S E M B L I N G A N D R E A S S E M B L I N G P R E S S U R E R E L I E F V A L V E B e g i n n i n g w i t h M o d e l s 1 9 7 4...
  • Page 84 REMOVING A N D I N S T A L L I N G O I L COOLER COIL B e g i n n i n g w i t h 1 9 7 4 m o d e l s R e m o v a l 1.
  • Page 85 S E R V I C E I N S T A L L A T I O N O F C O O L I N G C O I L OIL L I N E S B E G I N N I N G W I T H 1 9 7 4 MODELS 6.
  • Page 86 10. Slide rocker panel cover between spacer and washer. Tighten cover. 15. Check for leaks. This requires the engine oil temperature to b e at least 83 C (182 F), so t h a t the pressure relief valve will release the flow of oil t o the cooling coil.
  • Page 87 R E P L A C I N G OIL LINES T O F R O N T OIL COOLER OR T O C O O L I N G C O I L Installation of side turn signals from 1981 models on made necessary to change the oil lines to the front oil cooler or cooling coil in the front wheel well area.
  • Page 88 2, Remove rocker panel cover by -unscrewing end at front and rear, -pulling off rubber guard and removing cover for jack support, -removing metal screws at top and loosening metal screws at bottom. 6. Unscrew mounting bracket and clamps. Remove oil lines.
  • Page 89 O i l C i r c u i t N o t e Coat oil line connection threads with Optimoly HT or Molykote A prior to installing. Make sure cooling coil remains installed without stress. If necessary, change installed position so that wheel does not scrape on cooling coil when turned to full lock position.
  • Page 90 8. Finish installation of cover. Connect rubber guard on one end, bend back sharply and press on continuously. Lip must fit tightly on body at top. If necessary, realign. 9. Check system for leaks. This requires that engine oil temperature be at least 83' c/181° F so that the governor can release flow to the cooling coil or front oil cooler.
  • Page 91 R E M O V I N G A N D I N S T A L L I N G F R O N T O I L C O O L E R ( 1 9 8 0 M o d e l ) Loosen lower nuts and remove oil cooler upward.
  • Page 92 S P R I N G S FOR PRESSURE RELIEF A N D S A F E T Y V A L V E S O F E N G I N E O I L C I R C U I T Pressure Relief Valve Safety Description...
  • Page 93 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d REMOVING A N D I N S T A L L I N G I N J E C T I O N TUBE I N C A M S H A F T H O U S I N G R e m o v i n g 5 m m dia.
  • Page 94 C a m s h a f t H o u s i n g a n d C y l i m d e r H e a d Lubricate new plug and hole;, coat with a double component adhesive hind install plug. CAUTION Upset plug befoie installation if it does not fit tightly in housidg ,...
  • Page 95 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d O V E R H A U L I N G C H A I N T E N S I O N E R T O O L S Description Special Tool...
  • Page 96 901.01 with modified parts are available from parts. Only t h e new version chain tensioner: may b e re- paired. New Version Identification: a) Chamfer on upper part of housing b) Total height: 78. 2 0 . 2 m m and Porsche trade-...
  • Page 97 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d...
  • Page 98 Note When: Special Description Removing Installing Bleed screw Sealing ring Replace Clamp Clamp only with complete new par1 Snap ring Replace Spring retainer Spring Replace Piston (alum. O-ring Replace ring Replace Snap ring Replace Piston Replace 3-ring Replace aall, 5 m m Replace Spring Replace...
  • Page 99 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d D I S A S S E M B L I N G A N D A S S E M B L I N G C H A I N T E N S I O N E R A s s e m b l i n g D i s a s s e m b l i n g Clamp chain tensioner in a vise and remove...
  • Page 100 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d 5. Clean inner and outer grooves of aluminum I N S T R U C T I O N S FOR : [ N S T A L L A T I O N piston.
  • Page 101 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d S E A L I N G C Y L I N D E R H E A D / C A M S H A F T H O U S I N G M A T I N G S U R F A C E S N o t e Only Loctite No.
  • Page 102 9 1 1 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d C H E C K I N G I N S T A L L E D L E N G T H OF VALVE SPRINGS Check distance A with Special Tool P 10 C.
  • Page 103 C a m s h a f t 1-1,ousing a n d C y l i n d e r H e a d I N S T A L L E D D I M E N S I O N S FOR 2 . 7 AND 3. 0 L I T E R E N G I N E S Vehicle Engine Intake Valve...
  • Page 104 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d A D J U S T I N G T I M I N G (Camshafts with Hexagon Head Mounting Bolts for Sprocket) T O O L S Description...
  • Page 105 C a m s h a f t H o u s i n g a n d C y l i n d e r H , e a d A D J U S T I N G T I M I N G (Camshafts with Hexagon Head Mounting Bolts for Sprocket) B a s i c S e t t i n g 1 .
  • Page 106 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d 3. In the position described above on bore in the F i n e A d j u s t m e n t sprocket will be exactly aligned with a bore in the sprocket flange.
  • Page 107 C a m s h a f t H o u s i n g a n d C y l i n d e r H e a d L e f t C a m s h a f t A d j u s t m e n t ( C y l i n d e r N o .
  • Page 108 C y l i n d e r s a n d P i s t o n s P I S T O N C H A N G E S B E G I N N I N G W I T H 1 9 7 2 M O D E L S 1 .
  • Page 109 P I S T O N A N D C Y L I N D E R D I M E N S I O N S B e g i n n i n g w i t h 1 9 7 2 m o d e l s Cylinder Cylinder Piston...
  • Page 110 C y l i n d e r s a n d P i s t o n s Cylinder Cylinder Piston markings bore dia. diameter T y p e 9 1 1 T Tolerances Standard ( M A H L E ) 84.000-84.010 83.970 84.010-84.020...
  • Page 111 C y l i n d e r s a n d P i s t o n s C Y L I N D E R H E I G H T T O L E R A N C E G R O U P S 1 9 7 2 - m o d e l s , 2 .
  • Page 112 C y l i n d e r s a n d P i s t o n s P I S T O N A N D C Y L I N D E R D I M E N S I O N S B e g i n n i n g w i t h 1973 m o d e l s Cylinder Cylinder...
  • Page 113 C y l i n d e r s a n d P i s t o n s P I S T O N S A N D C Y L I N D E R D I M E N S I O N S B E G I N N I N G W I T H MODELS 1 9 7 4...
  • Page 114 C y l i n d e r s a n d P i s t o n s I N S T A L L A T I O N I N S T R U C T I O N S FOR "LS" CYLINDERS AND P I S T O N S The ALUSIL cylinder (eutectic aluminum-silicon alloy) and FERROCOAT piston combination is known as "LS"...
  • Page 115 C y l i n d e r s a n d P i s t o n s P I S T O N AND CYLINDER S I Z E S "LS" MAHLE P i s t o n T y p e 9 1 1 Cylinder Cylinder...
  • Page 116 C y l i n d e r s a n d P i s t o n s C H E C K I N G P I S T O N S A N D CYLINDERS C y l i n d e r Measuring point for wear and ovality 30 mm below top edge of cylinder The cylinder is worn if this measurement is 0.08 mm...
  • Page 117 C y l i n d e r s a n d P i s t o n s P I S T O N A N D C Y L I N D E R S I Z E S 9 1 1 S C ( f r o m 1 9 7 8 M o d e l ) M a h l e Cylinder...
  • Page 118 C v l i n d e r s a n d P i s t o n s P I S T O N W E I G H T G R O U P S f r o m 1 9 8 0 M o d e 1 Installation Instructions: 1 .
  • Page 119 C y l i n d e r s a n d P i s t o n s P I S T O N W E I G H T C L A S S E S 9 1 1 S C f r o m 1 9 8 1 M o d e l s Weight Classes MAHLE Pistons Pistons weighed with attachments (piston pins, piston rings, snap rings)
  • Page 120 C r a n k c a s e a n d F l y w h e e l MEASURING AND R E C O N D I T I O N I N G CRANKCASE G e n e r a l The main bearing bores must be measured whenever the crankcase is disassembled for repair.
  • Page 121 C r a n k c a s e a n d F l y w h e e l Pressure-cast crankcases can be cut in one step and without oil to 62.25 mm diameter. R e a m i n g Attach self-made tool (see sketch below) to 4 oil screen attaching studs and fasten in bench vise.
  • Page 122 C r a n k c a s e a n d F l y w h e e l Remove-end-bearing bushing from bearing bore # 8 and fullv ream...
  • Page 123 9 1 1 C r a n k c a s e a n d F l y w h e e l M O D I F I E D F L Y W H E E L I N S T A L L A T I O N M O D E L S Note When Description...
  • Page 124 F L Y W H E E L W I T H P I L O T B E A R I N G / B U S H I N G F O R I N P U T S H A F T f r o m 1 9 8 0 M o d e l Note When Special...
  • Page 125 C r a n k c a s e , C a m s h a f t R E M O V I N G A N D I N S T A L L I N G O I L F I L T E R S C R E E N A N D S U C T I O N P L A T E Note When Special Description...
  • Page 126 C r a n k c a s e , C r a n k s h a f t ASSEMBLY I N S T R U C T I O N S S E A L I N G C R A N K C A S E M A T I N G S U R F A C E S N o t e Only use Loctite No.
  • Page 127 C r a n k c a s e a n d C r a n k s h a f t C R A N K C A S E C H A N G E S B E G I N N I N G W I T H 1 9 7 2 M O D E L S Distributor mounting flange.
  • Page 128 C R A N K S H A F T D I M E N S I O N S S T A N D A R D A N D R E C O N D I T I O N E D Main bearing Crankshaft pulley seat...
  • Page 129 C r a n k c a s e a n d C r a n k s h a f t C O N N E C T I N G ROD C H A N G E S B E G I N N I N G W I T H 1 9 7 2 M O D E L S 127.8 0.05 m m...
  • Page 130 C r a n k c a s e a n d C r a n k s h a f t C O N N E C T I N G ROD W E I G H T GROUPS Connecting rods are assigned to weight groups.
  • Page 131 C r a n k c a s e , C r a n k s h a f t C O N N E C T I N G R O D W E I G H T G R O U P S f r o m 1 9 7 8 M o d e l Connecting rods are in different weight groups, T h e weight group is indicated by the final digit of t h e part number.
  • Page 132 C r a n k c a s e a n d C r a n k s h a f t P I S T O N S FOR K J E T R O N I C E N G I N E S Pistons for K Jetronic-equipped engines of Type cavity in the piston top.
  • Page 133 C r a n k c a s e a n d C r a n k s h a f t A S S E M B L Y I N S T R U C T I O N S F O R P I S T O N S O N 9 1 1 S C ( 1 9 8 1 M o d e l s ) Domed surface on piston must f a c e intake valve.
  • Page 134 C r a n k c a s e a n d C r a n k s h a f t M O D I F I E D C R A N K S H A F T DRIVE 1 9 7 8 MODELS T O O L S Special Tool...
  • Page 135 C r a n k c a s e a n d C r a n k s h a f t M O D I F I E D C R A N K S H A F T D R I V E 1 9 7 8 M O D E L S...
  • Page 136 C r a n k c a s e a n d C r a n k s h a f t Note When Special Instruction Description Removing Installing Replace Oil seal Lubricate Check for wear Thrust main bearing shells 1 Lubricate Main bearing shells Lubricate...
  • Page 137 C r a n k c a s e a n d C r a n k s h a f t I N S T A L L A T I O N I N S T R U C T I O N S FOR M O D I F I E D C R A N K S H A F T DRIVE 1 9 7 8 MODELS C l a m p i n g C r a n k s h a f t...
  • Page 138 For clockwise rotating rotating distributor distributor (with Porsche emblem) (with emblem) I n s t a l l i n g C i r c l i p o n C r a n k s h a f t...
  • Page 139 C R A N K S H A F T S t a n d a r d a n d U n d e r s i z e s ( 1 9 7 8 M o d e l s ) Connecting rod Oil seal journal Seat for timing...
  • Page 140 Surface finish Edge deburre Paint dot Grind crankshaft oil seal surfaces only when deeply Undersize color codes scored. Grind to dimensions of 2 9 , 5 m m and 89.5 m m respectively. Otherwise polish out to 3 microns. 1st undersize blue paint dot 2nd undersize green paint dot...
  • Page 141 9 1 1 C L U T C H C H A N G E S B E G I N N I N G W I T H 1 9 7 2 MODELS 1. Clutch operating system has been redesigned. The throw-out fork and clutch lever are mounted and secured with lock rings on a shaft which is splined on both ends and located in the transmission housing.
  • Page 142 A D J U S T I N G C L U T C H 1. Turn self-locking adjusting nut until clutch pedal free travel is 20 (0.8 1.0 in.). 2. When checking, pull pedal in direction of arrow.
  • Page 143 R E M O V I N G A N D I N S T A L L I N G T H R O W O U T B E A R I N G...
  • Page 144 C l u t c h Note when Description References removing installing Snap ring Remove with snap ring Check for proper 9.1-2/3 pliers while pushing seating. Thrust washer Groove must face the 9 .l- 2/3 snap ring. Should not be washed only wiped with dry rag.
  • Page 145 C l u t c h I N S T R U C T I O N S FOR REMOVAL AND I N S T A L L A T I O N R e m o v a l Lay the pressure plate onto the throwout Place spacer and spring washer on the bearing and push down by pressing...
  • Page 146 C L U T C H 1 9 7 5 MODELS 911 S and Carrera Pressure plate 225 KSph Pressure Spring No. 3027 056 000 Part No. Drive shell Part No.
  • Page 147 C L U T C H M O D I F I C A T I O N S 1 9 7 8 M O D E L S...
  • Page 148 C l u t c h Special Note When Description Instructions Removing Installing Socket head screw Lock washer Replace Pressure plate Starter gear ring Clutch disc Thrust washer Release bearing Check Washer Spring washer Install in correct position...
  • Page 149 Kraftstoffanlage Fuel System Sistema d'alimentazione...

  • Page 150: Auxiliary Air Valve

    F U E L S Y S T E M C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA - 0 . 1 D e s c r i p t i o n Fuel system changes 1972 model Fuel injection pump changes 1972 model...
  • Page 151 Vacuum hose layout 1979 model Fuel and vacuum lines layout model 1980 SERVICING S e r v i c i n g i n f o r m a r i o n Regulator housing, removing and installing Induction air preheating system, checking Fresh air flap, adjusting Fresh air flap lever, replacing Hose clamps for cold start enrichment, installing...
  • Page 152 F u e l t a n k Fuel tank plug with CIS filter, cleaning Fuel tank (80 l i t e r ) , removing and installing 1974 model F u e l p u m p Fuel pump, removing and installing 1976 model Replacing check valve O x y g e n s e n s o r...
  • Page 153 D e s c r i p t i o n FUEL I N J E C T I O N PUMP CHANGES BEGINNING W I T H 1 9 7 2 MODELS The 2 , 4 liter engines are equipped with changed injection pumps. The changes consist of a wider contoured cam and modified centrifugal weights and springs.
  • Page 154 D e s c r i p t i o n C H A N G E S IN T H R O T T L E VALVE H O U S I N G S A N D I N T A K E M A N I F O L D S Beginning with the 1972 models, throttle valve stops in the throttle valve housing are relocated to the lever side.
  • Page 155 D e s c r i p t i o n...
  • Page 156 I N D U C T I O N AIR PREHEATING B E G I N N I N G W I T H 1 9 7 2 MODELS G e n e r a l I n f o r m a t i o n Beginning with the 1972 models, all 2.4 liter fuel injection engines are equipped with an induction air preheating system.
  • Page 157 D e s c r i p t i o n The induction air preheating system consists of: D e s i g n 1. A r e g u l a t o r h o u s i n g which is attached to the left velocity stalck by three 6 mm bolts.
  • Page 158 D e s c r i p t i o n F u n c t i o n A thermostat-controlled hot air flap maintains induction air temperature at 4 5 ' ~ E n g i n e s t a r t e d , c o l d ( b e l o w 4 5 ' ~ ( 1 1 2 O F ) Throttle at idle position (fresh air flap closed) Hot air flap open, engine draws hot air from heat exchanger.
  • Page 159 D e s c r i p t i o n C O N T I N U O U S I N J E C T I O N S Y S T E M ( C I S ) Beginning with the January 1973 production, Type 911 T vehicles are equipped with the continuous injection system (CIS).
  • Page 160 E N G I N E CROSS S E C T I O N Air duct Control pressure regulator (throttle valve position) Throttle valve Start (enrichment) valve Control pressure regulator (warm running compensa- tion) Heat exchanger-. Crankshaft Oil pump Oil screen Connecting rod Piston Cylinder...
  • Page 161 D e s c r i p t i o n M i x t u r e C o n t r o l U n i t Air Flow Sensor and Fuel Distributor. The air flow sensor consists of a venturi and a sensor plate which is attached to a lever.
  • Page 162 D e s c r i p t i o n The hydraulic pressure F2 will remain constant in a warm engine although i t can b e lowered through the reduction of control pressure, such as during warm-up or due to the given position of the throttle valve.
  • Page 163 F u e l F l o w The fuel flows from the electric fuel pump through an accumulator and filter to the mixture control unit. A pressure regulator in the primary sjstem maintains constant pressure in the system. From the mixture control unit, injection lines carry the fuei to the injection valves. In addition, a separate line carries fuel to the start (enrichment) valve.
  • Page 165 D e s c r i p t i o n E l e c t r i c F u e l P u m p A roller-type fuel pump is utilized. F u e l P r e s s u r e A c c u m u l . a t o r The fuel pressure accumulator is located in t h e primary circuit directly after the fuel pump.
  • Page 166 D e s c r i p t i o n I n j e c t i o n V a l v e s Since the injection, process is longer in a continuous injection system, the injection valves had to b e designed for a smaller fuel transfer rate The injection valve permits fine atomization of fuel when small amounts are transfered.
  • Page 167 9 1 1 D e s c r i p t i o n C o n t r o l P r e s s u r e R e g u l a t o r (Throttle Valve Position) The control pressure regulator for throttle valve position is basically similar to the regulator for the throttle valve housing.
  • Page 168 D e s c r i p t i o n T h e r m o s w i t c h Beginning with 1974 models, engines equipped with the continuous injection system (K-Jetronic) are furnished with a thermoswitch which is connected to the cold start enrichment valve.
  • Page 170 C O N T I N U O U S I N J E C T I O N S Y S T E M ( C I S ) Beginning with 1974 models, Type 911 and 911 S, vehicles are equipped with the continuous injection system.
  • Page 171 91 1 D e s c r i p t i o n FUEL E V A P O R A T I V E C O N T R O L S Y S T E M G e n e r a l All vehicles are equipped with a sealed fuel tank venting system incorporating an activated charcoal filter.
  • Page 172 S y s t e m C h e c k o u t C O N T I N U O U S I N J E C T I O N S Y S T E M ( C I S ) GENERAL CHECKOUT PROCEDURE Prerequisite for the CIS checkout is a properly functioning ignition system and proper mechanical condi- tion of the engine.
  • Page 173 V I S U A L I N S P E C T I O N The CIS should b e visually inspected prior to the initiation of work. V i s u a l i n s p e c t i o n f o r l e a k s : C h e c k i n g f r e e m o v e m e n t o f l e v e r i n a i r f l o w s e n s o r Check all fuel line connections for leaks.
  • Page 174 I n s p e c t i o n o f t h e f l e x i b l e s e n s o r p l a t e s t o p i n t h e a i r f l o w ( s e n s o r p l a t e i n p o s i t i o n o f r e s t ) The fuel system must be depressurized when performing this check.
  • Page 175 S y s t e m C h e c k o u t I N I T I A L C H E C K S The following tests are component tests. Final evaluation of individual parts is possible only upon completion of pressure checks.
  • Page 176 C h e c k i n g C o n t r o l P r e s s u r e R e g u l a t o r ( W a r m R u n n i n g C o m p e n s a t i o n ) 1.
  • Page 177 PRESSURE T E S T S TOOLS Special Tool Remarks Pressure tester...
  • Page 178 S y s t e m C h e c k o u t G e n e r a l The tester should b e connected into the control pressure line at the mixture control unit. The control pressure now is transmitted from the mixture control unit, through the three-way selector valve, to the control pressure regulators for warm running compensation or throttle valve...
  • Page 179 S y s t e m C h e c k o u t Connect pressure lines of control pressure regulators for warm running compensation and throttle valve position to second connector using original banjo bolt and gaskets. Turn selector valve to position Allow pressure gauge to hang down (hose stretched) and switch the ignition on.
  • Page 180 S y s t e m C h e c k o u t C h e c k i n g " W a r m " C o n t r o l P r e s s u r e Refer to page 1.1 1/15 for engines with vacuum controlled control pressure regulator for warm...
  • Page 181 S y s t e m C h e c k o u t C h e c k i n g S y s t e m P r e s s u r e Turn selector valve to position switch the ignition on.
  • Page 182 S y s t e m C h e c k o u t To locate the problem, switch the ignition on until control pressure has built up, then switch the ignition off again. Detach return hose from the control pressure regulator for warm running compensation.
  • Page 183 S y s t e m C h e c k o u t C H E C K I N G A U X I L I A R Y AIR D'EVICE Check idle rpm with control pressure regulator for throttle valve position connected (engine warm).
  • Page 184 C I S T E S T I N G A N D A D J U S T I N G S P E C I F I C A T I O N S ( 1 9 7 4 / 1 9 7 5 M o d e l s ) Test Step Test Specification References...
  • Page 185 S y s t e m C h e c k o u : t Test Step Test Specification References Control pressure "warm" Page 1.1 Throttle position version Throttle valve position: 2.8 t o 3.0 bar Idle, test specification adjusting specification 2.85 to 2.95 bar Partial, throttle...
  • Page 186 S y s t e m C h e c k o u t C I S T E S T I N G A N D A D J U S T I N G S P E C I F I C A T I O N S ( 1 9 7 6 / 1 9 7 7 M o d e l s ) Test Step Test Specification References...
  • Page 187 S y s t e m C h e c k o u t Test Step Test Specification References 1 9 7 7 M o d e l Testing at atmospheric 2.7 t o 3.1 bar pressure (no vacuum) To perform vacuum test, connect vacuum pump to control pressure regulator, Test pressure 520...
  • Page 188 S y s t e m C h e c k o u t C I S T E S T I N G A N D A D J U S T I N G S P E C I F I C A T I O N S ( 1 9 7 8 / 1 9 7 9 M o d e l s ) Test Step Test Specification References...
  • Page 189 S y s t e m C h e c k o u t C I S T E S T I N G A N D A D J U S T I N G S P E C I F I C A T I O N S ( 1 9 8 0 M o d e l w i t h O x y g e n S e n s o r ) Test Step Test Specification...
  • Page 190 9 1 1 C h e c k i n g T E S T I N G AND A D J U S T I N G VALUES (1981 Models with Oxygen Sensor Control) Test Step Special Instruction Electric fuel pump Page 1.1 Delivery rate at least 1000 cc/30 sec.
  • Page 191 C h e c k i n g Test Step Idle setting USA and California imd Canada High Altitude States Manual transm. 1977 models Sportomatic 1977 models 1977 models Idle speed (rpm) 1000 models models 1980 9 0 0 2 5 0 models 1973 models...
  • Page 192 S y s t e m C h e c k o u t C H E C K I N G C O N T R O L PRESSURE OF V A C U U M - C O N T R O L L E D C O N T R O L PRESSURE R E G U L A T O R Connect and bleed pressure gauge.
  • Page 193 S y s t e m C h e c k o u t - - ' 5. Turn on ignition (fuel pump runs)., 6. The control pressure rises slowly and must stabilize at 2.9 0.20 bar. The regulating time span varies with the ambienr temperature, Replace control pressure regulator (for warm running compensation) if necessary.
  • Page 194 S y s t e m C h e c k o u t C H E C K I N G " C O L D " C O N T R O L PRESSURE ( v a c u u m c o n t r o l l e d ( w a r m - c o n t r o l p r e s s u r e r e g u l a t o r ) T O O L S Description...
  • Page 195 S y s t e m C h e c k o u t ; C H E C K I N G " C O L D " C O N T R O L P R E S S U R E ( v a c u u m c o n t r o l l e d ( w a r m - u p ) c o n t r o l p r e s s u r e r e g u l a t o r ) N o t e standard relay in trunk (rear relay looking...

  • Page 196: Auxiliary Air Regulator

    C h e c k i n g C H E C K I N G A U X I L I A R Y AIR REGULATOR 1. Remove auxiliary air regulator. Connect ohmmeter to both terminals of auxiliary air regulator and check. Specifications: approx 33 ohm Check power supply of auxiliary air regulator.
  • Page 197 C h e c k i n g C H E C K I N G O P E R A T I O N OF S A F E T Y S W I T C H 1. Disconnect rubber straps and remove air cleaner cover as well as-the air cleaner cartridge.

  • Page 198: Thermo Valve

    C h e c k i n g C H E C K I N G T H E R M O V A L V E Blow into detached vacuum hose (from warm- Detach vacuum hose at warm-up regulator. up regulator) by mouth.
  • Page 199 S y s t e m C h e c k o u t C I S PROBLEMS REMEDIES A N D A properly working ignition system and good mechanical condition of the engine are pre- requisites for a successful CIS problem diagnosis. P r o b l e m Engine does not start or is difficult to start when cold Engine does not start or is difficult to start when warm...
  • Page 200 Pneumatic valve leaking Function check Cold start enrichment valve does not open Visual inspection Cold start enrichment valve leaking Visual inspection Defective injection valve Visual inspection Air flow sensor plate or control plunger binding Function check Air flow sensor plate not resting properly at stop Visual inspection Throttle valve does not open fully Visual check (adjust) Basic adjustment (idle) too rich...
  • Page 201 9 1 1 C h e c k i n g T R O U B L E S H O O T I N G A U T O M A T I C C H O K E 1 9 7 6 MODEL P r o b l e m : Speed remains too high at high engine temperatures or no speed...
  • Page 202 V A C U U M S Y S T E M L A Y O U T ( 1 9 7 8 M o d e l s )
  • Page 203 Ignition distributor Throttle housing Diverter valve Auxiliary air valve Deceleration valve Auxiliary air regulator Vacuum source for auxiliary air valve and auxiliary air regulator Thermo valve Vacuum source for power brake (Warm-up) control pressure regulator...
  • Page 204 S y s t e m C h e c k o u t L A Y O U T O F F U E L A N D V A C U U M L I N E S 9 1 1 S C ( f r o m 1 9 8 0 M o d e l ) Fuel lines Vacuum lines...
  • Page 205 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G REGULATOR H O U S I N G R e m o v i n g 2.
  • Page 206 S e r v i c i n g If the hot air flap, which controlled by a 2. Warm up engine at about 2500 rpm. The hot thermostat, does not work,, replace the air flap must close after about minutes.
  • Page 207 S e r v i c i n g REPLACING FRESH AIR FLAP LEVER C a u t i o n Prevent nut from falling into regulator housing by holding nut of retaining bolt during removal. 1. Remove bolt and lever. N o t e : Hold lock nut with punch or scriber.
  • Page 208 9 1 1 S e r v i c i n g I N S T A L L I N G HOSE CLAMPS F O R COLD S T A R T ENRICHMENT Tighten hose clamps with VW special tool Nr.
  • Page 209 F U E L I N J E C T I O N T O O L S Special Tool Description Remarks Injection nozzle tester with Use Bosch or similar injection two pressure gauges nozzle tester. Pressure gauge /cm 2 (0-355 psi) range: 0-25 k Line with fittings Use Bosch EF 8040/30 or similar...
  • Page 210 s e r v i c i n g C H E C K I N G FUEL I N J E C T O R S G e n e r a l Instructions for checking the injectors apply to vehicles equipped with either the mec$anical or CIS fuel injection.
  • Page 211 Replace injector, if opening pressure is outside of these tolerances. C h e c k i n g I n j e c t o r s C a u t i o n N o t e T h e injectors of one engine can b e replaced se- When pressure gauge shut-off valve is open increase pressure slowly- to avoM damag.ing.the parately.
  • Page 212 S e r v i c i n g C o n t i n u o u s F u e l I n j e c t i o n 1. Close pressure gauge shut-off valve and flush injector by operating lever many times.
  • Page 213 S e r v i c i n g D I S A S S E M B L I N G A N D R E A S S E M B L I N G...
  • Page 214 S e r v i c i n g Note when Description removing installing References Rubber strap Intake horn Filter cartridge Replace if necessary Duct Hose clamp Hose clamp Banjo bolt Gasket Replace Stud Gasket Replace Plug Allen bolt Tighten lightly, then Page 2.2 loosen by 1 turn Spring...
  • Page 215 91 1 S e r v i c i n g Note when Description Reference removing installing Allen bolt Lock washer Replace Washer Control pressure regula- tor for throttle valve posit ion Page 2.2 Spring Bolt Lock washer Terminal block Allen bolt Washer Auxiliary air device...
  • Page 216 s e r v i c i n g Note when Description Reference removing installing Support Sheet metal screw Holder Hose clamp Flame trap cartridge Plug Gasket Replace Allen bolt Spring washer Control pressure regula tor for warm running Page 2.2 compensation Intake pipe Hose clamp...
  • Page 218 S e r v i c i n g Note when Designation References removing installing Injection line Supply line t o control pressure regulator for warm running compensa Page 2.2 1/15 Supply line t o control pressure regulator for Page 2.2 throttle valve position 1/15 Supply line from fuel...
  • Page 219 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G M I X T U R E C O N T R O L U N I T R e m o v a l Disconnect all fuel lines and hoses from the mixture control unit.
  • Page 220 s e r v i c i n g R E M O V I N G A N D I N S T A L L I N G T H R O T T L E V A L V E H O U S I N G A N D C O N T R O L PRESSURE R E G U L A T O R ( T H R O T T L E V A L V E P O S I T I O N ) R e m o v a l Disconnect fuel line, which connects mixture...
  • Page 221 91 1 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G C O N T R O L P R E S S U R E R E G U L A T O R ( W A R M R U N N I N G C O M P E N S A T I O N ) 1.
  • Page 222 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G S T A R T ( E N R I C H M E N T ) V A L V E R e m o v a l Disconnect ground strap from both batteries.
  • Page 223 s e r v i c i n g R E M O V I N G AND I N S T A L L I N G FUEL F I L T E R Disconnect ground strap from both batteries. 2.
  • Page 224 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G FUEL PRESSURE A C C U M U L A T O R 1.
  • Page 225 R E M O V I N G A N D I N S T A L L I N G I N J E C T I O N V A L V E S T O O L S Description Special Tool Remarks...
  • Page 226 S e r v i c i n g R e m o v a l Unscrew coupling nut from the injection line at the injection valve. 2. Install special tool P 384 and pull injection valve out. If rubber bushing remains in the support sleeve, take the bushing out with a screwdriver.
  • Page 227 S e r v i c i n g R E P L A C I N G P L A S T I C F U E L L I N E S T O O L S Special Tools Remarks Description Installer...
  • Page 228 s e r v i c i n g The mixture control unit, control pressure regula- tor for throttle valve position and control pressure regulator for warm running compensation replace- ments are furnished with plastic fuel lines attached. Defective plastic fuel lines can b e replaced indivi- dually.
  • Page 229 S e r v i c i n g BLEEDING FUEL LINE S Y S T E M T h e fuel injection system must b e bled (prior to starting) whenever a fuel line system component has been replaced. Remove intake horn with filter cartridge.
  • Page 230 R e p a i r s D I S M A N T L I N G A N D A S S E M B L I N G M I X T U R E C O N T R O L U N I T...
  • Page 231 Note during: Description removal remarks Plug Torque to Seal A 10 Replace Shim Spring Piston Use conical wood Replace fuel distribu- peg to drive out tor if damaged Seal Torque t o cmkp Fuel distributor Don't let control do not dismantle plunger fall out Seal Replace...
  • Page 232 R e p a i r s Note during: Description removal installation remarks Circlip First remove this Install with sharp edgc circlip facing outward Cover Seal Replace Spring Ball Coat with silicone grease Circlip First install this cir- clip with sharp edge facing outward Cover Seal...
  • Page 233 R e p a i r s I N S T R U C T I O N S FOR D I S M A N T L I N G A N D ASSEMBLING M I X T U R E C O N T R O L U N I T REMOVING A N D I N S T A L L I N G SENSOR PLATE R e m o v i n g Clamp mixture contrdl unit vertically in vise...
  • Page 234 CAUTION This test requires that the sensor plate be set at the correct height (rest position). The upper edge of the sensor plate must be flush with the lower edge of venturi. The height position can be corrected by bending the wire clip (refer to page 1.1 Clamp mixture control unit vertically in vise with plastic guards an jaws.
  • Page 235 L O C A T I N G OPERATING LEVER W I T H FOLLOWER I N AIR FLOW SENSOR H O U S I N G mounting screw and tighten m e w slightly. 2. Adjust operating lever in flow sensor hous- ing.
  • Page 236 R e p a i r i n g B A S I C A D J U S T M E N T OF M I X T U R E C O N T R O L S C R E W A F T E R R E P L A C E M E N T O F O P E R A T I N G LEVER C a u t i o n C a u t i o n...
  • Page 237 R e p a i r s REPLACING P I S T O N SEAL OF FUEL DISTRIBUTOR PRESSURE RELIEF VALVE 1. Clean fuel thoroughly. 2. Remove plug, being careful of shim in plug. Remove spring and piston (if necessary, use conical wood peg).
  • Page 238 R e p a i r i n g D I S A S S E M B L I N G A N D A S S E M B L I N G M I X T U R E C O N T R O L U N I T MODIFICATIONS from April, 1976...
  • Page 239 R e p a i r i n g Note when Description Remarks removing installing Plug Torque to 13-15 Nm kpm) Seal Replace Shim Quantity as 0.1 m m thick required 0.5 m m thick Spring Pull out with Check, replace entire tapered wood distributor if damaged dowel...
  • Page 240 R e p a i r i n g Note when Description Remarks removing installing Stop bracket Plastic insulator Adjusting screw Leaf spring Bolt Torque to 5.0-5.5 Nm (0.50-0.55 kpm) and apply liquid locking agent Spring washer Sensor plate Check, replace if necessary Circlip Sharp side faces out...
  • Page 241 R e p a i r i n g Note when Description removing installing Pivot pin Operating lever Check whether bearing Adjusting lever play is excessive or needle bearing is d a m - aged, replace if neces- sary Mixture control screw Lubricate bearing bores Air flow sensor housing with (Bosch Ft...
  • Page 242 R e p a i r s REMOVING A N D I N S T A L L I N G V A C U U M C O N T R O L L E D W A R M - U P REGULATOR R e m o v i n g 1.
  • Page 243 R e p a i r s I n s t a l l i n g Torque fuel return line hollow bolt to 1.1 mkp. N o t e The bottom of the warm-up regulator and the holding plate must b e clean to assure proper ventilation for the warm-up regulator.
  • Page 244 R e p a i r s R E M O V I N G A N D I N S T A L L I N G A U X I L I A R Y A I R R E G U L A T O R Pull wire plugs off of auxiliary air regulator.
  • Page 245 R e p a i r i n g R E M O V I N G A N D I N S T A L L I N G T H E R M O V A L V E R e m o v i n g 1.
  • Page 246 S e r v i c i n g REMOVING A N D I N S T A L L I N G DIVERTER VALVE 1. Loosen hose clamps and detach hose between diverter valve and check valve as well as hose between diverter valve and air pump.
  • Page 247 S e r v i c i n g C L E A N I N G FUEL T A N K PLUG W I T H B U I L T - I N C I S FILTER Fuel supply problems can b e traced, among other things, to a dirty filter in the fuel tank plug.
  • Page 248 R e p a i r i n g R E M O V I N G A N D I N S T A L L I N G FUEL T A N K ( 8 0 L i t e r S t e e l T a n k f r o m 1 9 7 4 M o d e l s ) R e m o v i n g 1.
  • Page 249 R e p a i r s R E M O V I N G A N D I N S T A L L I N G FUEL P U M P 1 9 7 6 MODEL R e m o v i n g Loosen intake fuel hose clamp and remove fuel pump.
  • Page 250 R e p a i r s Pull cover over wire connectors and position rubber ring for installation. N o t e To prevent corrosion, make sure that cover fits properly. 4. Slide intake fuel hose on pump nipple and secure with hose clamp.
  • Page 251 9 1 1 R e p a i r i n g LAYOUT DRAWING OF CHECK VALVES ON FUEL PUMPS Note When: Special Description Installing Instructions Removing Fuel pump (long neck version with integrated check valve) Fuel pump Check valve with seal Always replace seal;...
  • Page 252 R e p a i r i n g R E P L A C I N G C H E C K VALVE Important: Observe safety pre-cautions for wdrk on fuel systems! 1 . Remove bottom guard. 2. Pinch fuel feed hose with a shut-off device and remove pressure hose end by unscrewing cap nut on fuel pump.
  • Page 253 S e r v i c i n g R E M O V I N G A N D I N S T A L L I N G 0 X . Y GEN S E N S O R R e m o v i n g Disconnect plug for oxygen sensor on left side of engine compartment, Push wire grommet...
  • Page 254 S e r v i c i n g I n s t a l l i n g 1. Coat threads of oxygen sensor with Bosch paste VW 140 16 Ft. N o t e Never allow assembly paste to get into slot of sensor, Tighten sensor to specified torque Reference value: 50...
  • Page 255 S e r v i c i n g A counter is installed behind the fresh air blower Remove right seat after loosening front and to monitor the operation time. It will turn on the rear screws on seat rails. oxygen sensor indicator lamp after car has been driven 30,000 miles.
  • Page 256 S e r v i c i n g C H E C K I N G F R E Q U E N C Y V A L V E FOR R E M O V I N G A N D I N S T A L L I N G T H R O T T L E O X Y G E N S E N S O R V A L V E S W I T C H 1.
  • Page 257 S e r v i c i n g C H E C K I N G A N D A D J U S T I N G T H R O T T L E V A L V E S W I T C H T O O L S Description Special Tool...
  • Page 258 S e r v i c i n g C H E C K I N G AND A D J U S T I N G T H R O T T L E VALVE S W I T C H 1 .
  • Page 259 REMOVING AND I N S T A L L I N G M I C R O S W I T C H FOR A C C E L E R A T I O N Pull off plugs and unscrew bolts. C H E C K I N G AND A D J U S T I N G M I C R O S W I T C H FOR A C C E L E R A T I O N E N R I C H M E N T ( f r o m 1 9 8 1 M o d e l s ) 1 .
  • Page 260 9 1 1 R e p a i r i n g C O R R E C T I N G C O LEVEL S E T T I N G ON M I X T U R E C O N T R O L U N I T ( f r o m 1 9 8 1 M o d e l s ) W I T H S H E A R - O F F SCREW 1 .
  • Page 261 A D J U S T I N G FUEL I N J E C T I O N P U M P W I T H E M I S S I O N T E S T E R S p e c i a l T o o l s P 228 c Prptractors 1.
  • Page 262 A d j u s t m e n t I n s t r u c t i o n s A D J U S T I N G E N G I N E I D L E S p e c i a l T o o l s P 230 c Socket (9 mm) N o t e...
  • Page 263 A d j u s t m e n t I n s t r u c t i o n s Remove cap. emissions Europa Depress the spring-loaded idle adjusting Carrera 2 - 3 7 0 screw with special tool c until you can feel it engage with the slot of the centrifugal governor.
  • Page 264 A d j u s t m e n t I n s t r u c t i o n s A D J U S T I N G M I C R O S W I T C H B E G I N N I N G W I T H 1 9 7 2 M O D E L S Loosen lock nut and back off adjusting screw 3.
  • Page 265 A d j u s t m e n t I n s t r u c t i o n s I D L E A D J U S T M E N T T O O L S Remarks Description Special Tool...
  • Page 266 A d j u s t m e n t I n s t r u c t i o n s 1. Run engine to operating temperature (approx. Make sure that hand throttle :Lever is pushed down to stop. 3.
  • Page 267 d) The air pump of engines with air injection must be disconnected to adjust CO. Disconnect pressure hose at pump and plug hose. Take the wrench out. Accelerate engine briefly. Wait until the CO-tester has stabilized for idle speed reading. Se page 1.1 1/14 e for specifications.
  • Page 268 A d j u s t m e n t I n s t r u c t i o n s A D J U S T I N G M I C R O S W I T C H 1.
  • Page 269 A d j u s t m e n t I n s t r u c t i o n s C H E C K I N G A N D A D J U S T I N G C O N T R O L PRESSURE REGULATOR FOR T H R O T T L E VALVE P O S I T I O N Connect and bleed P pressure tester and...
  • Page 270 A d j u s t m e n t I n s t r u c t i o n s A D J U S T I N G H A N D T H R O T T L E 1.
  • Page 271 A d j u s t i n g I n s t r u c t i o n s A D J U S T I N G I D L E , 9 1 1 S C 1 9 7 8 M O D E L S T O O L S Special Tool...
  • Page 272 A d j u s t i n g I n s t r u c t i o n s A d j u s t i n g N o t e Before starting with the idle adjustments, make sure that oil tank cap fits properly and its seal is in good condition.
  • Page 273 5. Turn idle speed screw or bypass screw on Turning counterclockwise lean mixture throttle housing, until specified speed is reached. Test specifications, see page 1/14 Note N o t e a) Always adjust C O level from lean to rich. Use separate tachometer of tester or similar Example: When adjustment is too rich, first instrument.
  • Page 274 A d j u s t i n g I n s t r u c t i o n s 11. Wait until tester shows exhaust concentra- tion a t i d l e speed. Test specifications, see page 1/14 If necessary, repeat adjusting procedure.
  • Page 275 A d j u s t i n g I n s t r u c t i o n s A D J U S T I N G I D L E S P E E D 9 1 1 S C 1 9 8 0 m o d e l T O O L S Description...
  • Page 276 A d j u s t i n g I n s t r u c t i o n s A d j u s t i n g Disconnect plug for oxygen sensor in engine N o t e compartment on left side.
  • Page 277 A d j u s t i n g I n s t r u c t i o n s 6. Remove plug in mixture control unit, between fuel distributor and venturi. 1 1 . Wait until CO tester shows CO concentration at idle speed.
  • Page 278 A d j u s t i n g I n s t r u c t i o n s A D J U S T I N G IDLE 9 1 1 ( f r o m 1 9 8 1 M o d e l s ) A d j u s t i n g N o t e Disconnect oxygen sensor plug in engine...
  • Page 279 A d j u s t i n g I n s t r u c t i o n s 6. Check CO level. If CO level does not correspond 10. Accelerate engine briefly. with specified value, remove mixture control unit and remove threaded part of shear-off screw in access bore for mixture control screw (see page centration a t idle speed.
  • Page 280 Getriebe Transmission Cambio...
  • Page 281 9 1 1 TRANSAXLE C O N T E N T S INFORMATION., DESCRIPTION, TECHNICAL DATA I n f o r m a t i o n Transmission, and 5 Speeds Sportomatic D e s c r i p t i o n Transmission, 5 Speeds, Operation Transmission, 5 Speeds, Power Transfer Transmission with Oil Pump, Description...

  • Page 282: Transmission Front Cover 1

    General Specifications, sp$omatic (1974 model) Transmission Diagram, 3 $peed Sportomatic 925/10 (1975 model) General Specifications, 31Speed Sportomatic 925/10 (1975 model) General Specifications, 3;Speed Sportomatic 925/09, 012, 013 Transmission Diagram, 3 :Speed Sportomatic (1976 model) S p e c i a l T o o l s Special Tools, SportomatIc Transmission TRANSMISSION, 5-SPEED MAN~UAL T r a n s m i s s i o n , d i s a i s e m b ~ i n ~ a n d a s s e m b l i n g...
  • Page 283 9 1 1 M a n u a l T r a n s m i s s i o n FOUR AND FIVE SPEED TRANSMISSION ( T Y P E 9 1 5 ) Beginning-with 1972 models, all Type 911 vehicles are equipped with the new, reinforced 4-speed transmission.
  • Page 284 M a n u a l ~ r a n s m i s s i o n j F U N C T I O N The five forward speeds and reverse a i e arranged in a double shift pattern.
  • Page 285 M a n u a l T r a n s m i s s i o n...

  • Page 286: Table Of Contents

    M a n u a l T r a n s m i s s i o n Transmission housing Transmission front cover Breather Reverse, Gear I Seal 5th speed, Gear I, fixed Speedometer drive, Gear I Roller bearing Spider, 5th and reverse speeds 1st speed, Gear I, fixed Flange nut Gear housing...
  • Page 287 M a n u a l T r a n s m i s s i o n : POWER FLOW In all gears, power flow is from the input shaft to the pinion shaft through the respectively engaged gear pair. The engaging and s nchronizing parts for lst, 2nd, and 5th gears are on the pinion shaft, and those for the 3rd and 4th gear are on the inpllt shaft.
  • Page 288 9 1 1 T r a n s m i s s i o n T Y P E 9 1 5 T R A N S M I S S I O N W I T H OIL P U M P Carrera 2.7 vehicles are equipped with Type 915/08 and 915/18 transmissions.
  • Page 289 T r a n s m i s s i o n D E S C R I P T I O N OF T H E OIL PUMP L U B R I C A T I O N S Y S T E M When the car is started, the input shaft sets the oil pump in motion.
  • Page 290 GENERAL I N S T R U C T I O N S FOR DISASSEMBLING A N D REASSEMBLING OF T R A N S - M I S S I O N W I T H OIL PUMP 1. Disassembly and reassembly of a transmission with oil pump is the same as that of a unit without the pump because the pressure line connections are of the slip-on type.
  • Page 291 T r a n s m i s s i o n...
  • Page 292 T r a n s m i s s i o n Oil pump cover Bushing Oil pump gear I1 Oil pump gear I Plug for pressure relief valve Oil pump coupling pin Transmission front cover Gear housing Pressure l i n e Differential housing...
  • Page 293 T r a n s m i s s i o n T Y P E 9 1 5 T R A N S M I S S I O N ( 1 9 7 4 M O D E L ) The following transmission versions are installed from 1974 models on: 4-speed transmission, 915/16 5-speed transmission, 915/06...
  • Page 294 T r a n s m i s s i o n Manual transmission 915 (1975 Models) The following transmissions are installed. No. of Gears Application Transmission Type Carrera All transmission types are based on those of 1974 models and only differ slightly from d c h other. The 3rd and 4th or 4th and 5th gears as well as the rear axle ratios have been changed the types 1/15).
  • Page 295 M a n u a l T r a n s m i s s i o n M A N U A L T R A N S M I S S I O N 9 1 5 ( 1 9 7 6 MODEL) The following transmission is available for the 1976 Model.
  • Page 296 M a n u a l T r a n s m i s s i o n M A N U A L T R A N S M I S S I O N 9 1 5 ( 1 9 7 6 M O D E L ) The following transmission is available for the 1976 Model.
  • Page 297 S P O R T O M A T I C 9 2 5 Beginning with Sept. 24, 1971 production, the Sportomatic transmission for 911 vehicles have been modified. The modified transmission have the following designations: 911 T and 911 S Repair procedures for these transmission differ only slightly for those contained in the 911 Workshop Manual, Volume I which applied t o models thru 1971.

  • Page 299: Roller Bearing 1

    S p o r t o m a t i c Speedometer drive Clutch plate turbine Ahaft Oil seal Flange nut Torque converter housi'r~~ Gear reverse gear Torque converter Speedometer gear sha Input shaft Ball bearing race Four point ball bearin Clamping plate Gear I, 2nd gear Roller bearing...
  • Page 301 Needle bearing cage seal Axial needle bearing cage Expansion bolt O-ring Threaded stud Ring gear Tapered roller bearing Differential spider g e a Axle flange Differential side gear Temperature sending unit Roll pin Temperature switch Anchor piece Thrust washer Shaft Reverse idler gear...
  • Page 302 9 1 1 P o w e r T r a n s f e r Power transfer from the engine through the torque converter and mechanical clutch is same in all driving ranges. In ranges L and the power is transfered from the fixed gears on the input shaft, through the synchro- nization components and free-wheeling gears on the pinion shaft, t o the pinion shaft.
  • Page 303 T r a n s m i s s i o n T Y P E 9 2 5 S P O R T O M A T I C T R A N S M I S S I O N ( 1 9 7 4 M O D E L ) Beginning with 1974 mod.els, Type 911 and 911 S vehicles can optionally be equipped with the Type This transmission versiori differs from that used in 1973 models only in the aspect of changed torque...
  • Page 304 9 1 1 S P O R T O M A T I C 9 2 5 ( 1 9 7 5 M o d e l s ) All 1975 models are available with a 3-speed sportomatic transmission (type 925/10) as optional extra equipment.
  • Page 305 S p o r t o m a t i c...
  • Page 306 Speedometer drive gear Turbine shaft Front transmission cover Oil seal Flanged nut Torque converter housing Reverse gear Torque converter Main shaft Speedometer drive shaft Ball bearing Four-point ball bearing Intermediate plate Clamping plate 2nd gear (22:29 M) Roller bearing 3rd gear Inner shift lever Transmission case Roller bearing...
  • Page 307 9 1 1 S P O R T O M A T I C 9 2 5 ( 1 9 7 6 M O D E L ) From 1976 models all cars can be delivered with a 3-speed sportomatic transmission as optional extra equipment.
  • Page 308 S P O R T O N I A T I C T R A N S M I S S I O N 9 2 5 ( 1 9 7 6 M O D E L ) T h e following transmissions are available from 1976 Models. Transmission Speeds For Model...
  • Page 309 Transmission Diagram Ring Ratio...
  • Page 310 Transmission Diagram 4-speed-transmission Type 91 5 Transmission Pinion to Ring Ratio...
  • Page 311 T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G T R A N S M I S S I O N H O U S I N G T O O L S Description Special Tool...
  • Page 312 T e c h n i c a l D a t a T I G H T E N I N G T O R Q U E S Location Description Thread Grade ft Ibs Transmission Magnetic plug housing Tapered (Oil drain) Transmission...
  • Page 313 General Specifications Type 915 Transmission 911 T 911 E 911 S Gear Ratios 1st gear 2nd gear 3rd gear 4th gear Reverse 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse Climbing Ability (calculated) Vehicle Weight: empty according to DIN 1/2 load 1st gear 2nd gear...
  • Page 314 General Specifications Type 915 Transmission 911 T 911 S Carrera 2.7 Rear Axle Drive Final drive ratio 7/31 4.429 Power transfer double-joint drive shafts, to rear wheels Transaxle Weight 4-speed transmission 54 kg, ready with oil and starter 5-speed transmission 56 kg, ready with oil and starter Filling Capacities Transmission and differential...
  • Page 315 T e c h n i c a l D a t a T a b l e o f T o l e r a n c e s f o r T y p e 9 1 5 T r a n s m i s s i o n Installed Wear Measuring...
  • Page 316 T e c h n i c a l D a t a Installed Wear Measuring tolerances Limit point (new) mm Side-play between shift fork and shift sleeve: 5th and reverse gear 1st and 2nd gear 3rd and 4th gear 5.
  • Page 317 Transmission Diagram 4-speed-transmissi Pinion to Ring Ratio 7 Type 9l5/l6 Transmission Remarks: This diagram shows guiding values, based on a medium effective rolling radius. Slight deviations due to tire tolerance variations in the rolling radius, wear and skidding of the wheels have not been taken into account. Subject to change without notice...
  • Page 318 T e c h n i c a l D a t a...
  • Page 319 General Data Type 915 Transmission (1974 model) 9 11 9 1 1 C a r r e r a Gear Ratios Type 915/16 transmission: 1st gear 2nd gear 3rd gear 4th gear Reverse gear Type 915/06 transmission: 1st gear 2nd gear 3rd gear 4th gear 5th gear...
  • Page 320 General Data Type 915 Transmission (1974 model) 9 11 9 1 1 S C a r r e r a Rear axle drive spiral bevel gears, differential Final drive ratio Power transfer Transaxle Weight 4-speed transmission 54 kg (119 lb), ready with oil and starter 5 -speed transmission 55 kg (121 lb), ready with oil and starter Filling Capacities...
  • Page 321 T e c h n i c a l D a t a...
  • Page 322 Transmission Diagram 9 1 1 Type 9 i 5 i 4 0 Transmission Pinion to Ring Ratio 8 medium effective rolling radius. Slight deviations due- to tire tolerance variations in the rolling radius, wear and skidding ofthe wheels have not been taken into account. Subject to change without notice...
  • Page 323 T e c h n i c a l D a t a Manual Transmission 915 (1975 Models) 911 S, Carrera Ratios 1st gear 2nd gear 3rd gear 4th gear Reverse 1st gea 2nd gear 3rd gear 4th gear 5th gear Reverse Final drive Transmission and differential...
  • Page 324 9 1 1 T e c h n i c a l D a t a General data Manual transmission 915 1976, 1977, 1978 and 1979 models Ratios 2nd gear 3rd gear 4th gear 5th gear Reverse Final drive ratio Capacity approx.
  • Page 325 Transmission Diagram 5-speed-transmission Type 915 /44 Transmission Pinion to Rlng Ratio 8...
  • Page 326 Transmiss ion Diagram -speed-transmission Type 91 5/49 Transmission euidina values, based on Remarks: This diagr; a medium effective rolling radius. slight deviations due- to tire tolerance variations in the rolling radius, wear and skidding of the wheels have not been taken into account. l - .
  • Page 327 T e c h n i c a l D a t a...
  • Page 328 T e c h n i c a l D a t a General Data 1st gear 2nd gear 3rd gear 4th gear Reverse gear Torque converter ratio Final drive ratio Approx. 3.0 ltr (3.17 Filling Capacities SAE 90 transmission oil, speci- fication Mil-L 2105 or Mil-L 2105B approx.
  • Page 329 T e c h n i c a l a T I G H T E N I N G TORQUES S P O R T O M A T I C 9 2 5 Location Description Thread Grade Transmission housing (at stud for side and front co- ver, and fork piece) Mid grip nut...
  • Page 330 T e c h n i c a l D a t a Location Description Thread Intermediate plate Bolt (clamping plate) Bellcrank shaft Intermediate plate Cover plug (shift detent) Transmission front cover Bolt (speedometer drive retainer) Transmission front cover Cover plug (9 mm dia ball parking lock)
  • Page 331 T e c h n i c a l D a t a...
  • Page 332 T e c h n i c a l D a t a G e n e r a l D a t a S p o r t o m a t i c ( 1 9 7 4 m o d e l ) Climbing ability percent 1st gear...
  • Page 334 T e c h n i c a l D a t a General Data Sportomatic 925 (1975 Models) Ratios 1st gear 2nd gear 3rd gear Reverse Converter Final drive Capacities Approx. 2.5 liters (2.65 US gt.) of SAE 90 transmiss.ion oil meeting Specifications of MIL-L-2105 or 2105 final drive Towing speed in...
  • Page 335 T e c h n i c a l D a t a S p o r t o m a t i c General Data Sportomatic 925 1976 and 1977 Models Ratios 19 76 Mod. 1977 Mod. 1st speed 2nd speed 3rd speed Reverse...
  • Page 336 Transmission Diagram Type 925/09/ 12 /13 Transmission Pinion to Ring Ratio...
  • Page 337 S p e c i a l T o o l s SPECIAL T O O L S S P O R T O M A T I C Mandrel Mandrel Installer Centering mandrel Installer Assembly plate Input shafl holder Remover Support plate Mandrel...
  • Page 338 M a n u a l T r a n s m i s s i o n T R A N S M I S S I O N T O O L S Description Special Tool Remarks Sleeve P 382 Puller P 386...

  • Page 340: Gear Housing

    9 1 1 M a n u a l T r a n s m i s s i o n Special Note when instructions Description Removing Installing Self-locking nut Replace if necessary, torque to specification Washer Clutch cable bracket Replace if necessary, Self-locking nut torque to specification...
  • Page 341 M a n u a l T r a n s m i s s i o n Special Note when instructions Description Removing Installing Check for wear. Sliding gear, 5th and reverse gear Replace, oil lightly. O-ring Thrust washer Check for wear.
  • Page 342 9 1 1 M a n u a l T r a n s m i s s i o n Note when Special instructions Description Removing Installing Thrust washer Replace if necessary, Self -locking nut torque to specification. Washer Cover with guide fork Replace.
  • Page 343 M a n u a l T r a n s m i s s i o n Note when Special instructions Description Removing Installing Input shaft Remove together with pinion shaft, 1st and 2nd speed selector fork, and complete 3rd and 4th speed shift rod.
  • Page 344 Note when Special Description instructions Removing Installing Seal Replace. Spring Short detent Check for free move- ment. 1st and 2nd speed selector fork rod Shim Note thickness and Recompute if Transmission housing...
  • Page 345 M a n u a l T r a n s m i s s i o n DISASSEMBLING AND ASSEMBLING MANUAL T R A N S M I S S I O N D i s a s s e m b l i n g 4.
  • Page 346 M a n u a l T r a n s m i s s i o n 6. Remove shift detent plug (3rd and 4th gear). Take out spring and detent. Remove plug from shift detent (1st and Remove bolt from selector fork of 1st and 2nd gear) and take out spring and detent.
  • Page 347 M a n u a l T r a n s m i s s i o n A s s e m b l i n g N o t e To keep the selector fork from binding on the selector fork rod, slightly open the selector fork clamping piece with a screwdriver.
  • Page 348 M a n u a l T r a n s m i s s i o n 1 1 . Lightly tighten selector fork and fork piece 20. Install thrust washer for 5th speed free gear. bolts. 12. Insert shift detent and spring, torque plug to specification.
  • Page 349 M a n u a l T r a n s m i s s i o n 27. Block input shaft with special tool P 37a, and engage 5th gear. Tighten input shaft castellated nut and pinion shaft flange nut to correct torque.
  • Page 350 M a n u a l T r ? n r r n i n s i o n Effective with the listed transmission numbers, the input shaft oil seal can b e replaced without the need for disassembling the transmission. Transmission Type from transmission No.
  • Page 351 M a n u a l T r a n s m i s s i o n I n s t a l l a t i o n 3. Drive oil seal into its seat with the aid of driver P 381.

  • Page 352: Synchronizing Ring

    M a n u a l T r a n s m i s s i o n A D J U S T I N G SELECTOR FORKS N o t e 4. position the 1st and 2nd speed selector fork Tighten input shaft flange nut to correct torque so that the shift sleeve is exactly in the before adjusting selector forks.
  • Page 353 M a n u a l T r a n s m i a s i o n Adjusting 5th and Reverse Speed Selector Fork 1. Push the idler gear on shaft against fixed gear I of 5th speed. Ad just clearance bet- ween idler gear and sliding gear in neutral position.
  • Page 354 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G F R O N T C O V E R T O O L S Remarks Special Tool...
  • Page 355 M a n u a l T r a n i m i r s . i o n D i s a s s e m b l i n g a n d A s s e m b l i n g F r o n t C o v e r...
  • Page 356 M a n u a l T r a n s m i s s i o n Special Note when Description instructions Removing Installing Backup light switch Torque to specifics- tion. Actuating pin Position properly. Seal Press out with small Drive fully into seat screwdriver.
  • Page 357 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G Drive on seal for speedometer drive with D i s a s s e m b l i n g special tool P 374.
  • Page 358 T r a n s m i s s i o n D I S A S S E M B L I N G A N D REASSEMBLING OIL P U M P T O O L S Description Special Remarks Support...
  • Page 359 D i s a s s e m b l y a n d R e a s s e m b l y...
  • Page 360 T r a n s m i s s i o n Special Note when Description instructions see removing installing Torque to speci- Allen bolt fication. Replace. Lock washer Pickup tube Replace. Oil O-ring lightly. Ball and spring can Torque to speci- Plug for pressure fall out.
  • Page 361 I N S T R U C T I O N S FOR DISASSEMBLY A N D REASSEMBLY D i s a s s e m b l y R e a s s e m b l y Note the thickness and number of gaskets Drive bushings into oil pump cover with when removing the oil pump cover to special tool P 368, making sure that they are...
  • Page 362 T r a n s m i s s i o n 2. Drive bushings into transmission front cover Install oil pump cover and tighten self- with special tool P making sure that locking nuts cross-wise to specified torque. 368, they are properly positioned and fully in.
  • Page 363 T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G T R A N S M I S S I O N H O U S I N G T O O L S Description Special Tool...
  • Page 364 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g T r a n s m i s s i o n H o u s i n g...
  • Page 365 9 1 1 M a n u a l T r a n s m i s s i o n Note when Special instructions Description Removing Installing Drive out. Tension spring with 3.1-4/5 P 366 and drive in. Drive out with flat Replace if necessary.
  • Page 366 D I S A S S E M B L I N G A N D A S S E M B L I N G A s s e m b l i n g 1. Drive shift detent securing roll pins out. 1.
  • Page 367 M a n u a l T r a n s m i s s i o n Install spring and sleeve, tension both with Gear housing special tool P 366, and drive roll pin in. Half-round dowel pin 3rd and 4th speed selector fork(shift) rod Short detent Roll pin Sleeve...
  • Page 368 M a n u a l T r a n s m i s s i o n F I N A L D R I V E H O U S I N G T O O L S Description Special Tool Remarks...
  • Page 369 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g F i n a l D r i v e H o u s i n g...
  • Page 370 M a n u a l T r a n s m i s s i o n Note when Special Description instructions Removing Installing Input shaft oil seal Drive out in direc- Install with Sealing lip faces with an appropriate bell housing.
  • Page 371 M a n u a l T r a n s m i s s i o n Note when Special Description instructions Note proper seating. 3.1-5/6 Heat transmission Heat transmission housing to 120°c housing to 1 2 0 ~ ~ plate and drive out and drive in with with US 8050.
  • Page 372 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D ASSEMBLING F I N A L DRIVE H O U S I N G D i s a s s e m b l i n g 4.
  • Page 373 M a n u a l T r a n s m i s s i o n A s s e m b l i n g 3. Heat housing to approximately 1 2 0 ~ ~ outer races in with special tool US 8050. C a u t i o n When cleaning the final drive housing, do not use corrosive cleaning materials as they will...
  • Page 374 9 1 1 M a n u a l T r a n s m i s s i o n 6. Drive in bushings for lever shaft with Special 5. Install input shaft seal with P 360a. Sealing lip faces bell housing. Tool P 375 (see drawing) and coat with grease having a lithium or silicone base.
  • Page 375 M a n u a l T r a n s m i s s i o n The adjustment dimensions are: Modified Clutch Release Lever 1975 Models From top edge of the bell housing to the tip of the throwout fork The shape of the clutch release lever for trans- mission types 915/40/45 has been modified due to the location of the pipes of the new exhaust...
  • Page 376 T r a n s m i s s i o n 2. Remove retaining bolt of pressure line (spray nozzle for ring and pinion gears) from differen- tial housing and pull the pressure line out. N O T E Due to the simple attachment of the pressure lines, they can be replaced without removal of the gears.
  • Page 377 M a n u a l T r a n s m i s s i o n T R A N S M I S S I O N H O U S I N G W I T H G U I D E T U B E F O R T H R O W O U T B E A R I N G T O O L S Description Special Tool...
  • Page 378 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d R e a s s e m b l i n g D i f f e r e n t i a l H o u s i n g...
  • Page 379 M a n u a l T r a n s m i s s i o n Note when: Remarks Description removing installing Input shaft Drive out inward Drive into seat with with fitting pipe oil seal piece Replace if necessary Snap ring Mark lever posi- Readjust if necessary...
  • Page 380 M a n u a l T r a n s m i s s i o n Note when: Remarks removing installing Breather Position properly and torque to specification Snap ring Remove with small Make sure it is screwdriver properly seated Bearing outer Heat differential...
  • Page 381 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D REASSEMBLING D I F F E R E N T I A L H O U S I N G 4.
  • Page 382 M a n u a l T r a n s m i s s i o n Heat differential housing to approx. 120' C and drive both bearing outer races R e a s s e m b l y into place with the aid of 8050.
  • Page 383 M a n u a l T r a n s m i s s i o n Drive input shaft oil seal into place with 7. Install clutch controls. P 381. NOTE 6. Drive in bushings for lever shaft with Special Tool (see drawing) and coat with grease P 375...
  • Page 384 M a n u a l T r a n s m i s s i o n From top edge of the bell housing to the root Modified Clutch Release Lever 1975 Models of the claw in the throwout lever The shape of the clutch release lever for trans- mission types 915/40/45 has been modified due to the location of the pipes of the new exhaust...
  • Page 385 M a n u a l T r a n s m i s s i o n T R A N S M I S S I O N C A S E W I T H B O L T E D G U I D E T U B E F O R R E L E A S E B E A R I N G T O O L S Special Tool Remarks...
  • Page 386 M a n u a l T r a n s m i s s i o n...
  • Page 387 9 1 1 M a n u a l T r a n s m i s s i o n Note when Special Description Removing Installing instructions see Phillips ctsk. screw Torque to specifica- tions Guide tube Use hook to remove Install with MoS2 additive lubricant Seal, drive shaft Drive out with...
  • Page 388 M a n u a l T r a n s m i s s i o n Note when :instructions see Removing Installing Heat case to approx Heat care to approx Bearing outer race drive in with drive out with US 8050 8050 Heat case to approx Heat case to approx...
  • Page 389 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G I N S T R U C T I O N S On the 1976 model manual transmission 915 the clutch release lever can b e preassembled and adjusted.
  • Page 390 M a n u a l T r a n s m i s s i o n R E M O V I N G A N D I N S T A L L I N G D R I V E S H A F T SEAL 1 9 7 6 MODEL The drive shaft seal of 1976 model manual transmission 915 c a n b e replaced without having to disassemble the transmission.
  • Page 391 M a n u a l T r a n s m i s s i o n T R A N S M I S S I O N C A S E W I T H A U X I L I A R Y C L U T C H S P R I N G ( 1 9 7 7 M O D E L S )
  • Page 392 M a n u a l T r a n s m i s s i o n Note when Description Remarks removing installing Spring Circlip Replace, if necessary Adjusting lever Adjust Seal omitted from Round pin March, 1979 Clutch release lever Coat pin for spring with all -purpose lube containing MoS...
  • Page 393 9 1 1 M a n u a l T r a n s m i s s i o n Note when Description Remarks removing installing Release fork Seal Replace, if necessary Bushing Drive out with Drive in with P 375 P 375 until positioned correctly...
  • Page 394 M a n u a l T r a n s m i s s i o n A s s e m b l i n g 1. Drive in bushings for lever shaft with Special Tool P (see drawing) and coat with grease having a lithium or silicone base.
  • Page 395 9 1 1 M a n u a l T r a n s m i s s i o n R E L E A S E L E V E R 1 9 7 8 M O D E L S...
  • Page 396 M a n u a l T r a n s m i s s i o n Note W,hen Special Description N o . Qty. Instructions Removing Installing Replace, if necessary Circlip Washer Replace Cover Replace, if necessary Circlip Washer Auxiliary spring Replace...
  • Page 397 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G I N S T R U C T I O N S D i s a s s e m b l i n g A s s e m b l i n g 1.
  • Page 398 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G I N P U T S H A F T T O O L S Description Special Tool...
  • Page 399 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g I n p u t S h a f t...

  • Page 400: Roller Bearing

    M a n u a l T r a n s m i s s i o n Note when Special Description instructions Removing Installing Flange nut Remove with P 252a Torque to 3.1-6/6 center punch. Roller bearing Press off with VW Press in with VW 401, 401, V W 402, and VW 454, and V W...
  • Page 401 M a n u a l T r a n s m i s s i o n Special Note when instructions Description Removing Installing Make sure bearings Fasten to respective Needle bearing have not been inter- gear and race with mechanic's wire.

  • Page 402: Flange Nut

    M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G I N P U T S H A F T 3.
  • Page 403 M a n u a l T r a n s m i s s i o n 1.. Press roller bearing on with thrust disc C a u t i o n VW 412 and press thrust tube VW 416b. When reinstalling needle bearings and races, make sure they are not interchanged with those of another gear.

  • Page 404: Input Shaft

    Always check input shaft for runout when i t is fully assembled and the flange nut torqued to proper specification. 1. Remove the input shaft outer bearing races from the transmission and final drive housings and place them on the pinion shaft (substitute bearings can b e used).
  • Page 405 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G P I N I O N S H A F T T O O L S Special Tool Remarks...
  • Page 406 9 1 1 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g P i n i o n S h a f t...
  • Page 407 M a n u a l T r a n s m i s s i o n Note when Special Description Installing instructions see Roller bearing Press off pinionshaft Press on with W 407 and VW 415 a. Thrust washer 1st speed Check synchronization.
  • Page 408 T r a n s m i s s i o n Note when .instructions Description Removing Large, smoothly ground 4th speed surface faces four- point bearing. Replace only in pairs. Clamping plate Heat to approx. 1 2 0 ~ ~ Press off with VW Bearing inner race 401, VW 412, and...
  • Page 409 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G P I N I O N S H A F T D i s a s s e m b l i n g A s s e m b l i n g 1.
  • Page 410 M a n u a l T r a n r m i r s i o n Press small roller bearing on pinion shaft using thrust disc V W 412 and thrust sleeve 3. Heat speedometer drive gear I to 120°C M o d i f i c a t i o n s f r o m 1 9 7 7 M o d e l s The asymmetrical pointed teeth of lst/2nd gear operating sleeve must face toward 1st...
  • Page 411 9 1 1 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G S Y N C H R O N I Z E R S T O O L S Remarks Special Tool...
  • Page 412 M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g S y n c h r o n i z e r s Note when Special Description...
  • Page 413 M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G AND ASSEMBLING S Y N C H R O N I Z E R S D i s a s s e m b l i n g 2.
  • Page 414 M a n u a l T r a n s m i s s i o n 2. Maximum clearance between selector fork C h e c k i n g and shifting sleeve of 1st through 5th speed: Dimension a 0.5 mm (0.02 in.).
  • Page 415 M a n u a l T r a n s m i s s i o n M O D I F I C A T I O N S T h e synchronization for 1st and 2nd gears has 2.
  • Page 416 D I S A S S E M B L I N G A N D A S S E M B L I N G T O R Q U E C O N V E R T E R H O U S I N G T O O L S Special Description...
  • Page 417 D i s a s s e m b l i n g a n d A s s e m b l i n g T o r q u e C o n v e r t e r H o u s i n g...
  • Page 418 Note when Special Description instructions installing removing loosen evenly in Tighten evenly in Socket-head bolt criss-cross pattern criss-cross pattern to specified torque. Replace if necessary. Lock washer Pressure plate Check wear, vents, only dry wipe. Check wear, check free Clutch disc movement on splines between clutch plate and input shaft.
  • Page 419 Note when Special installing removing instructions Oil seal Oil torque con- driver verter seating sur- face, drive in with P 359. Temperature switch Tighten to correct torque. Oil seal Replace Temperature sender Tighten to cor- rect torque. Replace Oil seal Threaded coupling Tighten to cor- rect torque.
  • Page 420 9 1 1 DISASSEMBLING AND ASSEMBLING T R A N S M I S S I O N T O O L S Description Special Remarks Tool Assembly plate Holding plate P 260 Sleeve P 3 6 4 P 3 6 0 Thrust piece Press plate VW 4 0 1...
  • Page 421 S p o r t o m a t i c Disassembling and Assembling Transmission...
  • Page 422 9 1 1 Note wh Special Description removing installing instructions Cap screw Tighten t o correct torque. Oil seal Replace Spring Ball, 9 m m Replace if necessary. Tighten t o correct torque. Washer Lock nut Replace if necessary. Tighten to correct torque.
  • Page 423 Special Note when instructions removing installing Push detent pin in. Check wear. Shift fork for re- Remove with selector gear. Check wear. Small end faces Detent pin Spring Speedometer drive groove faces expansion bolt head. Check wear. Reverse idler gear assembly Check wear.
  • Page 424 9 1 1 Description Note wt Special installing instructions removing Gasket Note quantity Recalculate if neces- and thickness. Tighten to correct torque. Spring Ball, 9 mm Reverse gear shift rod Detent Tighten to correct torque Spring washer Replace. Shift fork, 1st Mark for reassemb- Check wear.
  • Page 425 9 1 1 Description Note when Special installing instructions removing Pinion shaft Press out of intermediate Input shaft plate with P 353a. Spacer Bearing inner race Press in with VW 401, 4 . 1 and 426. half Transmission hou- sing...
  • Page 426 D I S A S S E M B L I N G A N D ASSEMBLING T R A N S M I S S I O N D i s a s s e m b l i n g Lock input shaft with P holder.
  • Page 427 Remove splined bushing. A s s e m b l i n g Remove reverse idler gear assembly to- Insert input shaft spacer, slide pinion and input shafts into the bearings of the inter- thrust needle bearing cage. mediate plate and splines of Reverse Gear I respectively.
  • Page 428 Slide intermediate plate and gear assembly Install reverse selector gear and shift fork. Detent pin in shaft rod for reverse gear and into transmission housing. Then using four spa- parking lock must be pushed in. cer bushings on folur of the studs, tighten in- termediate plate in a criss-cross pattern.
  • Page 429 9 1 1 D I S A S S E M B L I N G A N D A S S E M B L I N G T R A N S M I S S I O N F R O N T C O V E R T O O L S Description Special...
  • Page 430 Disassembling and Assembling Transmission Front Cover...
  • Page 431 Special Description instruct ions removing installing Tighten to specified Speedometer drive retaining torque. bolt Washer Blind hole in guide Speedometer drive (complete) bushing lines up with hole in cover. Elbow adapter Replace if necessary. Guide bushing Oil lightly. Gear shaft Drive in with P 218.
  • Page 432 S p o r t o m a t i c D I S A S S E M B L I N G A N D ASSEMBLING Heat transmission cover to approx. ,120' C D i s a s s e m b l i n g out the gear shaft bushing, Remove speedometer drive retaining bolt, pull out elbow adapter and gear shaft.
  • Page 433 9 1 1 Install shift rod seal with special tool P 218.
  • Page 434 9 1 1 DISASSEMBLING AND ASSEMBLING I N T E R M E D I A T E PLATE T O O L S Description Special Remarks Tool Centering mandrel In 2 parts. Thrust piece Installation arbor P 262 Guide sleeve...
  • Page 435 S p o r t o m a t i c D i s a s s e m b l i n g a n d A s s e m b l i n g I n t e r m e d i a t e P l a t e...
  • Page 436 9 1 1 Note when Description Special removing installing instructions Bolt Tighten to specified torque. Washer Clamping plate Check helicoil inserts. Four-point ball Check wear. bearing Align center with 372, Support plate Position properly when installing. Snap ring Remove with small screwdriver.
  • Page 437 Special Note when instructions removing installing Drive in with Bushing P 262. Drive in with Bushing Drive in with Bushing plate...
  • Page 438 D I S A S S E M B L I N G A N D ASSEMBLING I N T E R M E D I A T E P L A T E D i s a s s e m b l i n g Using special tools P press P 255,...
  • Page 439 A s s e m b l i n g Using special tools VW 407 and P 255, Press dowel pins in. They rnust protrude press Gear I for reverse gear into grooved approx. 5 . 5 mm (0.22 in. on each side of ball bearing.
  • Page 440 9 1 1 Place intermediate plate on top, insert second bearing inner race, and center four-point bearing with P 372. Tighten bolts to correct torque.
  • Page 441 M A I N S H A F T T O O L S Description Special Tool Remarks Plate Holder P 376 Thrust tube VW 416 b Thrust disc Socket wrench P 252 Torque wrench Local purchase...
  • Page 442 9 1 1 D I S M A N T L I N G A N D A S S E M B L I N G...
  • Page 443 9 1 1 Notes Description Remarks Removal Installation Spacer (2.6 mm thick) Unlock and loosen Torque to specifi- with P 252 cations Lockplate Replace Roller bearing Press off V W 401 Install with V W 412, and VW 412 VW 416 b and VW Washer Install correctly, bevel faces roller...
  • Page 444 D I S M A N T L I N G A N D ASSEMBLING I N S T R U C T I O N S D i s m a n t l i n g A s s e m b l i n g 1.
  • Page 445 P I N I O N S H A F T T O O L S Description Special Tool Remarks Drive sleeve VW 244 Guide No. 9100 Consists of 2 pieces Thrust disc VW 412 Plate VW 401...
  • Page 446 D I S M A N T L I N G A N D A S S E M B L I N G...
  • Page 447 Notes Description Remarks Qty. Removal Installation Bearing inner race Install with correct adapter Spacer (1 m m thick) Roller bearing Remove frompinion Install with VW 412. and 9100 Thrust washer Flat side faces needle bearing 1st gear 16:34 DA Check synchronization; From 1977 Models replace in pairs only with asymmetrical...
  • Page 448 Notes Remarks Removal Installation Spacer Shim Note number and Recalculate if thickness for in- necessary stallation Remove from pinion Install with correcl: shaft with VW adapter 9100 Pinion shaft Check for wear; measure thickness of shims again if necessary...
  • Page 449 S p o r t o m a t i c D I S M A N T L I N G AND A S S E M B L I N G I N S T R U C T I O N S D i s m a n t l i n g Install roller bearing on pinion shaft with appropriate adapter.
  • Page 450 9 1 1 C H E C K I N G C L U T C H PLAY 1. Raise car. 2. Press accelerator linkage operating lever on transmission toward full throttle (bleeds servo). Use left hand to press clutch intermediate lever toward right rear wheel.
  • Page 451 C H E C K I N G C O N T R O L VALVE A D J U S T M E N T This requires that the throttle operating linkage Place a strip of 4 m m thick metal between and engine idle speed are adjusted correctly.
  • Page 452 C l o s e d t h r o t t l e p o s i t i o n (downshifting on deceleration) Remove strip of metal at idle limit screw. The idle play set at 1.5 mm at the beginning could The closed throttle position can be adjusted at change because of c a m movement, but there the self-locking control screw with a screwdriver,...
  • Page 453 F i n a l D r i v e M a n u a l T r a n s m i s s i o n R E M O V I N G A N D I N S T A L L I N G F I N A L D R I V E T O O L S Remarks Special Tool...
  • Page 454 F i n a l D r i v e M a n u a l T r a n s m i s s i o n R e m o v i n g a n d I n s t a l l i n g F i n a l D r i v e...
  • Page 455 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Note when Special Description Instructions Removing Installing Expansion bolt Tighten to correct 5 .l-1/4 torque.
  • Page 456 F i n a l D r i v e M a n u a l T r a n s m i s s i o n R E M O V I N G A N D I N S T A L L I N G 2.
  • Page 457 F i n a l D r i v e M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G D I F F E R E N T I A L T O O L S Special Tool Remarks...
  • Page 458 F i n a l D r i v e M a n u a l T r a n s m i s s i o n D i s a s s e m b l i n g a n d A s s e m b l i n g D i f f e r e n t i a l...
  • Page 459 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Special Note when instruc Description Removing Installing Drive out. Replace if necessary Roll pin Drive out.
  • Page 460 F i n a l D . i v e M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G AND ASSEMBLING D I F F E R E N T I A L C a u t i o n D i s a s s e m b l i n g Do not interchange spacer washexs and shims.
  • Page 461 F i n a l D r i v e M a n u a l T r a n s m i s s i o n 4. Insert threaded retainers with lock rings into the large differential pinions (side gears) and slide the anchor piece between the threaded retainers (see illustration).
  • Page 462 F i n a l D r i v e / M a n u a l T r a n s m i s s i o n N o-t e With the 1976 Model the tapered roller bearing When replacing the magnetic carrier disc the is pulled off through openings in the magnetic tapered roller bearing preload does not have...
  • Page 463 9 1 1 F i n a l D r i v e M a n u a l T r a n s m i s s i o n T O O L S ,Description Special Tool Remarks Pressure pad Puller Pressure pad...
  • Page 464 F i n a l D r i v e M a n u a l T r a n s m i s s i o n...
  • Page 465 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Note When: Special Description Installing Instructions Roll pin Shaft Small differential gear Coat with MoS paste.
  • Page 466 F i n a l D i i v e M a n u a l T r a n s m i s s i o n D I S A S S E M B L I N G A N D A S S E M B L I N G I N S T R U C T I O N S D i s a s s e m b l i n g 2.
  • Page 467 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Coat differential gears with MoS paste. 4. Insert large differential gears with press-fit threaded retainers through large opening in differential case and locate with joint flanges.
  • Page 469 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Spacer S1 Spacer S2 Adjusting value...
  • Page 470 F i n a l D r i v e M a n u a l T r a n s m i s s i o n A D J U S T I N G R I N G G E A R A N D P I N I O N T O O L S Remarks Description...
  • Page 471 F i n a l D r i v e M a n u a l T r a n s m i s s i o n A D J U S T I N G P I N I O N S H A F T C a u t i o n By adding the design dimension "R"...
  • Page 472 F i n a l D r i v e B y adding the mandrel and gauge block dimen- Rotate the mandrel carefully until the sensor sions the "actual adjusting dimension" is obtained. forms a right angle with the face of the pinion.
  • Page 473 F i n a l D r i v e M a n u a l T r ~ a n r m i s s i o n Should the dial indicator read clockwise, the deviation when added to the "actual adjusting dimension"...
  • Page 474 F i n a l D r i v e M a n u a l T r a n s m i s s i o n D E T E R M I N I N G T O T A L S P A C E R T H I C K N E S S F O R R I N G GEAR A D J U S T M E N T Make sure that side bearing outer races are 5.
  • Page 475 F i n a l D r i v e M a n u a l T r a n s m i s s i o n C A U T I O N C A U T I O N Do not interchange spacer washers after removal.
  • Page 476 F i n a l D r i v e M a n u a l T r a n s m i s s i o n Spacers are available in increments of 0.10 mm from 2.4 to 3.7 mm. shim, 0.25 mm thick, permits adjustments to the nearest 0.05 mm.
  • Page 477 . A D J U S T I N G RING GEAR B A C K L A S H 1. Install gear cluster with shims determined at 4. Block pinion shaft with holder P 259a. t i m e of pinion shaft adjustment. 5.
  • Page 478 F i n a l D r i v e M a n u a l T r a n s m i s s i o n 6. Move dial indicator holder back and forth. 8. Spacers S1 and S2 can b e replaced with Read backlash on dial indicator.
  • Page 479 T r a n s m i s s i o n a n d D i f f e r e n t i a l T O O L S Special Remarks Designation Tool Nr. Setting gage shaft Gage block VW 385/4 V W 385/14...
  • Page 480 T r a n s m i s s i o n a n d D i f f e r e n t i a l A D J U S T I N G P I N I O N S H A F T W I T H UNIVERSAL S E T T I N G GAGE V W - 3 8 5 Determine adjustment value E from known NOTE: design value R...
  • Page 481 T r a n s m i s s i o n a n d D i f f e r e n t i a l 4. Slide gage blocks VW 385/4 onto the setting 6. Place setting pad VW 385/17 on the pinion gage shaft and screw contact plunger VW face.
  • Page 482 T r a n s m i s s i o n a n d D i f f e r e n t i a l C a u t i o n : If the value indicated on the gage deviates clockwise from the set design value (R= 66 .'30 mm), Never use a hammer when installing the housing then the dimension is smaller than 66.30 mm,...
  • Page 483 T r a n s m i s s i o n a n d D i f f e r e n t i a l NOTE:. If the shims were selected in proper thickness, the d i a l indicator must show the value of devia- tion "r"...
  • Page 484 S p o r t o m a t i c D i f f e r e n t i a l A D J U S T I N G RING GEAR AND P I N I O N e n e r a 1 Adjustment of the ring gear and pinion is important for quiet operation of the rear axle assembly.
  • Page 485 A D J U S T I N G RING GEAR A N D P I N I O N T h e holder P 357a is needed for blocking the 1. T h e design dimension "R" and the basic pinion shaft when measuring gear backlash.
  • Page 486 Vorderachse Front Axle...
  • Page 487 F R O N T AXLE C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA I n f o r m a t i o n D e s c r i p t i o n Front Axle Changes, from 1972 Model Self-Leveling Hydropneumatic Suspension Strut, Operation General Outline...
  • Page 488 F r o n t A x l e D e s c r i p t i o n F R O N T AXLE C H A N G E S BEGINNING W I T H 1 9 7 2 MODELS 1.
  • Page 489 D e s c r i p t i o n o f F r o n t A x l e D E S C R I P T I O N OF T H E SELF LEVELING H Y D R O P N E U M A T I C S U S P E N S I O N S Y S T E M G e n e r a l Beginning with 1972 models, self-leveling hydropneumatic front suspension struts are optional equipment...
  • Page 490 D e s c r i p t i o n o f F r o n t A x l e P u m p A c t i o n U n d e r L o a d Irregularities in the road surface causei the piston rod to move in relation to the pump rod.
  • Page 491 D e s c r i p t i o n o f F r o n t A x l e S p r i n g i n g A c t i o n Pressure in the oil reservoir acts on the top surface of the piston and exerts a small downward force on the piston.
  • Page 492 C r o s s - S e c t i o n o f S e l f - L e v e l i n g H y d r o p n e u m a t i c K O N I S u s p e n s i o n S t r u t 1.
  • Page 493 T e c h n i c a l D a t a GENERAL S P E C I F I C A T I O N S T Y P E 9 1 1 V E H I C L E S B E G I N N I N G W I T H 1 9 7 2 MODELS Wheel suspension independent, with shockabsorber struts and...
  • Page 494 T e c h n i c a l D a t a T E C H N I C A L D A T A V e h i c l e T y p e Wheel suspension independent, with shock absorber struts and transverse control arms Springing 1 round longitudinal torsion bar per wheel (hydropneu-...
  • Page 495 T e c h n i c a l D a t a T E C H N I C A L D A T A 1 9 7 5 k o d e l s M o d e l C a r r e r a Wheel suspension Independent with.
  • Page 496 T e c h n i c a l D a t a T E C H N I C A L D A T A f r o m 1 9 7 6 M o d e l M o d e l s F r o m 1 9 7 8 9 1 1 S 9 1 1 S C...
  • Page 497 T e c h n i c a l D a t a T I G H T E N I N G TORQUES FOR FRONT AXLE AND STEERING Location Description Thread Grade ft. lbs. Shockabsorber strut to upper mounting plate Tie rod clamping sleeve Allen bolt...
  • Page 498 T e c h n i c a l D a t a Location Description Thread Grade Hollow bolt to brake caliper Hollow bolt Steering coupling to steering shaft Bolt Steering shaft to steering unit Bolt Steering support attachment Allen bolt U-joint to steering shaft Bolt Steering wheel attachment...
  • Page 499 This acts as a quick reference for evaluating the alignment data. SAMPLE WHEEL A L I G N M E N T D A T A C H A R T type Vehicle: Porsche from model 72 on Name Chassis NO r...
  • Page 500 F r o n t A x l e R E M O V I N G A N D I N S T A L L I N G F R O N T A X L E BALL J O I N T T O O L S Special Tool Remarks...
  • Page 501 R E M O V I N G A N D I N S T A L L I ~ G . F R O N T A X L E BALL J O I N T...
  • Page 502 F r o n t A x l e Note when Special Description instructions removing installing Torque to specification Drive out. Install with multipurpose grease, noting proper seating. Replace. Cotter pin Replace. Lock plate Replace if necessary. Ball joint Check, replace if worn. Check, replace if (suspension strut) necessary.
  • Page 503 F r o n t A x l e A s s e m b l i n g 1. Coat double-wedge bolt with multi@rpose grease before assembling. 2. Installed position of the double-wedge is so that the retaining nut points for warh in the direction of travel.
  • Page 504 F r o n t A x l e C H E C K I N G SELF- LEVELING H Y D R O P N E U M A T I C S U S P E N S I O N S T R U T S S p e c i a l T o o l s : P 301b Measuring Mandrel 1.
  • Page 505 9 1 1 F r o n t A x l e L I G H T - ALLOY A U X I L I A R Y CROSS MEMBER FOR CARRERA 2.7 G e n e r a l Tightening torques for the front axle remain unchanged.
  • Page 506 S T A B I L I Z E R 1 9 7 4 MODELS G e n e r a l Beginning with the 1974 models, all vehicles are equipped with a' new, one-piece front axle stabilizer. The stabilizer bar diameter is mm in 911 and 911 S vehicles 20 m m in Carrera vehicles The stabilizer is mounted in rubber bushings located in the transverse control arms and t h e auxiliary...
  • Page 507 D I S A S S E M B L Y A N D R E A S S E $ ~ B L Y...
  • Page 508 9 1 1 F r o n t A x l e Note during Description References removal installation Bolt M 8 Tighten to specified torque Lock washer Replace Washer Bolt M 8 Tighten. to specified torque Lock washer Replace Clamp Stabilizer Rubber bushing Check for wear...
  • Page 509 F r o n t A x l e I N S T R U C T I O N S FOR REMOVAL A N D I N S T A L L A T I O N R e m o v a l 1.
  • Page 510 F r o n t A x l e I N S T A L L A T I O N N O T E S F O R S H O C K A B S O R B E R / S P R I N G S T R U T S With t h e 1975 Models a different height adjust- ment was introduced.
  • Page 511 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n STEERING COLUMN ARRANGEMENT BEGINNING W I T H 1 9 7 4 MODELS G e n e r a l Beginning with 1974 models, the steering column attachment to the instrument panel has been changed.
  • Page 512 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n D I S A S S E M B L Y A N D R E A S S E M B L Y...
  • Page 513 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n Note when: Description Remarks removing installing Pull off steering wheel Press into place Torque to specification Nut, SW 27...
  • Page 514 S t e e r i n g W h e e l and1 S t e e r i n g C o l u m n Note when: Description Remarks removing installing Switch housing top Switch housing bottom Nut, M 8 Stud Shear bolt, M 8...
  • Page 515 9 1 1 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n Note when: Description Remarks removing installing Remove from instru- Steering shaft tube ment panel together...
  • Page 516 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n D i s a s s e m b l y 5.
  • Page 517 S t e e r i n g W h e e l a n d S t e e r i n g C o l u m n R e a s s e m b l y 1.
  • Page 518 Hinterachse Rear Axle...
  • Page 519 9 1 1 C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA G e n e r a l I n f o r m a t i o n 0 . 1 D e s c r i p t i o n Rear Axle Changes- Beginning with 1972 Models T e c h n i c a l D a t a General Specifications...
  • Page 520 9 1 1 R e a r A x l e D e s c r i p t i o n REAR AXLE CHANGES BEGINNING W I T H 1 9 7 2 MODELS 1. Beginning with 1972 models, rear axle shockabsorbers have been modified. The outside diameter and overall length of the shockabsorbers has been increased: Outer diameter new:...
  • Page 521 9 1 1 T e c h n i c a l D a t a GENERAL S P E C I F I C A T I O N S T Y P E 9 1 1 V E H I C L E S BEGINNING W I T H 1 9 7 2 MODELS independent, with longitudinal trailing arms Wheel suspension...
  • Page 522 T e c h n i c a l D a t a GENERAL S P E C I F I C A T I O N S BEGINNING W I T H 1 9 7 4 MODELS V e h i c l e T y p e C a r r e r a Wheel suspension independent, with triangulated control arms...
  • Page 523 T e c h n i c a l D a t a T E C H N I C A L D A T A ( 1 9 7 5 M O D E L S ) M o d e l 9 1 1 S C a r r e r a Independent with triangulated control arms...
  • Page 524 T e c h n i c a l D a t a T E C H N I C A L D A T A f r o m 1 9 7 6 M o d e l f r o m 1 9 7 8 Wheel suspension Independent on trailing arms Springs...
  • Page 525 T e c h n i c a l D a t a T I G H T E N I N G TORQUES Thread Grade Location Description Bolt M 1 0 33.9 Bearing cap to body Bolt M 14x1,5 1 0 K Rear radius arm to axle cross 65.1...
  • Page 526 R e a r W h e e l A l i g n m e n t MEASURING REAR AXLE G e n e r a l I n f o r m a t i o n Beginning with models, rear axle camber specifications have been changed.
  • Page 527 REAR AXLE C O N T R O L ARMS T O O L S Description Special Tool Remarks Trailing arm positioner Driver for removing rear wheel hub Installer, rear wheel hub into control Torque wrench, Rear axle control arm alignment gauge Adapter for control arms beginning 295 c Used with...
  • Page 528 R e a r A x l e D I S A S S E M B L Y A N D R E A S S E M B L Y...
  • Page 529 9 1 1 R e a r A x l e Note when: Description removing installing Remarks Brake line Torque to specifica- Brake line retaining clip Pull out towards Brake hose center of vehicle Bolt, M 12 x 1.5 Torque to specifica- Lock washer Replace if necessary Brake caliper...
  • Page 530 Note when: Description removing installing Remarks Bolt, M Torque to specilica- Lock washer Replace if necessary Reinforcing cover Cotter pin Replace Castellated nut M 6 Washer Expander Seat properly Spring Parking brake cable Pull out towards vehicle center Spacer tube Seat properly.
  • Page 531 R e a r A x l e Note when: Description removing installing Washer Bolt, M 1 2 Washer Nut (thin), M 1 2 Torque to specifica- t ion Toothed washer Eccentric bolt for toe-in adjustment Eccentric bolt for camber adjustment Self-locking nut, Replace, torque to M 1 4...
  • Page 532 R e a r A x l e D i s a s s e m b l y 1. Detach drive shaft from transmission flange. Use flat chisel the area of the flange gasket to separate shaft assembly from flange. CAUTION Do not damage the flange surfaces.
  • Page 533 of P 297a. Remove cotter pin and castellated nut from brake cable stub. Pull brake cable out towards vehicle center. 9. Press ball bearing out with an appropriate thrust piece (approx. 65 m m dia.). C h e c k i n g P a r t s in rear axle control 1.
  • Page 534 R e a r A x l e 3. Using P 295b and P 295c, check axle control arm for deformation. If the control arm is in alignment, it will b e possible to push the test mandrel in with the rubber mounts installed.
  • Page 535 R e a r A x l e Using P 2981, and the wheel shaft, press the wheel hub into the double-row ball bearing. N O T E : Do not drive the wheel hub into the bearing with a hammer since this will damage the bearing.
  • Page 536 A x l e D i v e h a t AXLE DRIVESHAFTS LIGHTER VERSION G e n e r a l Beginning with October 6, 1971 production, all 911 models have new and lighter axle driveshafts (approx 0.9 kp lbs.
  • Page 537 Brernsen, Rader, Reifen Brakes, Wheels, Tires Freins, Roues, Pneus Freni, Ruote, Gomme...
  • Page 538 B r a k e s , W h e e l s , T i r e s C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA I n f o r m a t i o n D e s c r i p t i o n T e c h n i c a l D a t a General Data...
  • Page 539 T e c h n i c a l D a t a G E N E R A L D A T A t h r o u g h 1 9 7 7 m o d e l D i m e n s i o n s a n d W e a r I t e m...
  • Page 540 T e c h n i c a l D a t a D i m e n s i o n s a n d I t e m A d j u s t m e n t V a l u e s P a r k i n g B r a .
  • Page 541 T e c h n i c a l D a t a G E N E R A L D A T A f r o m 1 9 7 8 M o d e l D e s c r i p t i o n S p e c i f i c a t i o n s W e a r L i m i t s Hydraulic dual circuit brake system, separate...
  • Page 542 T e c h n i c a l D a t a D e s c r i p t i o n P a r k i n g b r a k e Drum brake mechanical action on both rear (hand- operated) wheels Brake drum dia.
  • Page 543 9 1 1 T e c h n i c a l D a t a T I G H T E N I N G TORQUES FOR FRONT A N D REAR BRAKES Grade Designation Thread Location Tandem brake master cylinder to transverse wall Nut (flat) Attachment of piston rod...
  • Page 544 B r a k e s , W h e e l s , T i r e s R E M O V I N G A N D I N S T A L L I N G BRAKE B O O S T E R...
  • Page 545 B r a k e s , W h e e l s , T i r e s Note when Remarks Description removing installing Install in correct position Pull back brake pedal Lock pin to stop, Lock pin must now be installed with- out tension, adjust operating rod if...
  • Page 546 B r a k e s , W h e e l s , T i r e s REMOVING AND I N S T A L L I N G I N S T R U C T I O N S R e m o v i n g 5.
  • Page 547 B r a k e s , W h e e l s , T i r e s A D J U S T I N G BRAKE O P E R A T I N G ROD N o t e The operating rod must b e attached when the brake pedal is a t its rest position without any force applied to the operating lever.
  • Page 548 B r a k e s , W h e e l s , T i r e s D I S A S S E M B L I N G B R A K E B O O S T E R A N D B R A K E M A S T E R C Y L I N D E R ( P A R T I A L L Y )
  • Page 549 B r a k e s , W h e e l s , T i r e s Notes Designation Installation Bolt cap Filter screen Torque to specifi- Hex. head screw cations Replace, if necessary Lockwasher Washer Tank Plug Torque to specifica- Hexagon nut tions.
  • Page 550 B r a k e s , W h e e l s , T i r e s Notes Designation Removal Installation Hexagon nut Torque to specifica- tions. Not too tight If staybolts are stret- ched or broken, replac brake booster.
  • Page 551 9 1 1 B r a k e s , W h e e l s , T i r e s C h e c k i n g B r a k e B o o s t e r Depress and release brake pedal several times with the engine stopped to remove any vacuum out of the booster.
  • Page 552 B r a k e s . W h e e l s . T i r e s N o t e When a brake circuit fails or after repairs on the brake system, a brake warning light installed in the dashboard comes on.
  • Page 553 W h e e l s a n d T i r e s C H E C K I N G WHEEL RIMS Points for measuring radial and lateral runout on inside and outside shoulders of rim. Distance "a" = 8 mm. 1.25 -mm Max.
  • Page 554 Double hump rims 012) were used on a general basis in the 1975 model year. Original Porsche rims are identified by the Porsche part number in the wheel rim. ~ e a n h ~ of numbec xxx.
  • Page 555 7 " and 8 Porsche rims must be fitted with a valve stem support, Part No. 911. 361. 561.00 or 01. 1 5 diecast rims (ATS) sometimes have a special cast boss in area of the valve stem bore, so that safe support can be guaranteed without a holding plate.
  • Page 556 G e n e r a l Aluminum wheel rims may only be balanced with balance weights which are cemented The cemented type balance weights supplied by Porsche are available in steps of 10 g from 10 to 80 g.
  • Page 557 W h e e l s a n d T i r e s I n s t a l l a t i o n 1 . Determine exact position of balance weights (if applicable first hold balance weights with pieces of tape until correct position has been determined).
  • Page 558 W h e e l s a n d T i r e s COLLAPSIBLE SPARE TIRE A spare wheel with a collapsible tire is used in cars with a 85 liter fuel tank to save spaye. From 1974 models on a 80 liter steel tank and a collapsible tire/ wheel are standard in ai.1 models. Rim size 5 1/2 14, tire size 7.35/185 Rim size 5 1/2...
  • Page 559 W h e e l s a n d T i r e s SURVEY OF WHEEL R I M S A N D T I R E S f r o m 1 9 7 2 M o d e l s Standard Rim Tire Optional Equipment...
  • Page 560 W h e e l s a n d T i r e s SURVEY OF WHEEL RIMS A N D T I R E S f r o m 1 9 7 5 M o . d e l s Optional ~ A u i ] nent Tire...
  • Page 561 9 1 1 W h e e l s a n d T i r e s WHEELS A N D T I R E S f r o m 1 9 7 6 M o d e l Optional Standard Wheel Tire Wheels...
  • Page 562 WHEELS A N D T I R E S Optional Wheels Tires Standard Wheels Tires front 6 J x 16 911 SC front 6 J rear 7 J rear 7 J W i n t e r T I r e s W h e e l s T i r e s 6 J x 1 5 front/...
  • Page 563 Pedal System and Levers Pedalier et Leviers Pedaleria e Leve...
  • Page 564 C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA 0 . 0 I n f o r m a t i o n 0 . 1 D e s c r i p t i o n 0 .
  • Page 565 T e c h n i c a l D a t a T I G H T E N I N G T O R Q U E S FOR MANUAL A N D PEDAL C O N T R O L S Location Designation Thread...
  • Page 566 9 1 1 L e v e r s DISASSEMBLING A N D ASSEMBLING SHIFT LEVER ASSEMBLY TOOLS Description Special Tools Remarks Assembly lever Locally manufactured Installer...
  • Page 567 D I S A S S E M B L I N G A N D A S S E M B L I N G S H I F T L E V E R A S S E M B L Y...
  • Page 568 L e v e r s Note when Special Description instructions removing installing Shift knob Shift knob retaining Replace. ring Dust boot Bolt, Lock. washer Replace. Bolt, M6 Spring washer Ball socket Use multipurpose grease with molybdenum additive. Pin, 30 x Drive out with punch.
  • Page 569 Note when Special Description instructions removing installing Serrated washer Replace. Bolt, M8 Clamping bolt Tapered bolt Shift rod coupling Dust boot Shift rod Lubricate pivot point.
  • Page 570 L e v e r s DISASSEMBLING AND ASSEMBLING S H I F T LEVER ASSEMBLY D i s a s s e m b l i n g Clamp the shift lever into a vice equipped with soft jaws. Drive off shift knob using the self- made tool.
  • Page 571 To install the guide pin springs: a. Position the stop plate to the shift bracket of the guide pins. b. Insert the second guide pin with snap ring at an angle. Slip the spring over the pin. c. Carefully push one end of the spring into the cutout.
  • Page 572 GEAR S H I F T ASSEMBLY E F F E C T I V E W I T H 1 9 7 3 MODELS G e n e r a l Beginning with the 1973 models, a ne1 s pressure-cast shift lever housing is install ed in all Type 911 vehicles equipped with a 5 -speed transmission.
  • Page 573 D I S A S S E M B L Y A N D R E A S S E M B L Y...
  • Page 574 M a n u a l C o n t r o l s Note when: Remarks Description removing installing Shift knob Interference sleeve Allen bolt, M8xZO Replace Spring washer Allen bolt, M6x20 Replace Spring washer Nut, M 6 Lock washer Apply MoS2 multi- Lock pawl carrier plate purpose grease...
  • Page 575 M a n u a l C o n t r o l s Note when: Remarks removing installing Apply MoS2 multi- purpose grease to friction points Shift lever housing Apply MoS2 multi- purpose grease to the inner surfaces Support bracket Bearing bush Nut, M 8 Schnorr lock washer...
  • Page 576 M a n u a l C o n t r o l s I N S T R U C T I O N S FOR DISASSEMBLY A N D REASSEMBLY D i s a s s e m b l y 1.
  • Page 577 M a n u a l C o n t r o l s R e a s s e m b l y 1. Install gear shift lever, with forks and pin in place, into the shift lever housing. 2 .
  • Page 578 L e v e r s A D J U S T I N G GEARSHIFT LINKAGE 1. Loosen shift rod clamp. Turn shift rod for Lightly tighten the shift rod clamp. selector shaft to the right in neutral position (seen in direction of driving).
  • Page 579 C o n t r o l s D I S M A N T L I N G A N D ASSEMBLING HEATER A N D HAND T H R O T T L E C O N T R O L S ( f r o m 19'75 M o d e l s ) G e n e r a l N o t e s The hand throttle and heater controls are located on the parking brake holder.
  • Page 580 C o n t r o l s REMOVING AND I N S T A L L I N G HEATER A N D HAND T H R O T T L E C O N T R O L S R e m o v i n g 1.
  • Page 581 C o n t r o l s I n s t a l l i n g 1. Pull heater cables into heater control lever, The longer heater cabIe is connected to left heater control lever. 2. Slide heater flap cables into guide tubes, Lubricate cables at the same time with a multi-purpose grease.
  • Page 582 o n t r s Check hand throttle position (refer to page Connect heater cables t o rotary valves at' heater body. Install grommets on guide tubes. 9. Check heater flap settings (refer to page R e p l a c i n g h e a t e r a n d h a n d t h r o t t l e c o n t r o l k n o b s Drive knobs off heater and hand throttle control levers with a piece of wood, or similar.
  • Page 583 A D J U S T I N G HEATER CONTROLS Move both heater control levers to front stop, slide to "off" position and tighten left and right h e a t a cables to rotary valves underneath vehicle. Heater flap valves must be; fully open. Check function of heater fl;ap.
  • Page 584 C o n t r o l s A D J U S T I N G H A N D T H R O T T L E C O N T R O L Remove tunnel cover and parking brake base cuff.
  • Page 585 P e d a l C o n t r o l s PEDAL C O N T R O L S G e n e r a l The clutch and brake pedals are mounted on a common clutch pedal shaft which is attached to the support fixture, The support fixture is bolted to the floor and brake master cylinder attachment to the brake master cylinder is by two studs which extend through the transverse panel.
  • Page 586 P e d a l C o n t r o l s D I S A S S E M B L I N G A N D R E A S S E M B L I N G...
  • Page 587 P e d a l C o n t r o l s Note when Special Description instructions removing installing Bolt, M 6 Washer Throttle pedal Pull back to remove. Throttle pedal stop Ad just. Throttle pedal pressure Detach. Lubricate ball socket with multipurpose grease.
  • Page 588 P e d a l C o n t r o l s Note when Special Description instructions removing installing Master cylinder rod Assemble and install rod prior to the installation of the pedal assembly. Adjust free play between rod and piston in the brake master cylinder.
  • Page 589 9 1 1 P e d a l C o n t r o l s Note when Special Description instructions removing installing Use new spring washer. Spring washer Support tube Install with multipurpose grease. Bushing Check for wear. Press in. Rubber cushion C h e c k f o r w e a r o r Replace if necessary.
  • Page 590 9 1 1 P e d a l C o n t r o l s I N S T R U C T I O N S FOR REMOVAL A N D I N S T A L L A T I O N R e m o v i n g 1.
  • Page 591 P e d a l C o n t r o l s P E D A L C O N T R O L S G e n e r a l Beginning with the 1974 models, all Type 911 vehicles are furnished with a supplemental clutch pedal spring to reduke the necessary pedal force.
  • Page 592 P e d a l C o n t r o l s D I S A S S E M B L Y A N D R E A S S E M B L Y...
  • Page 593 P e d a l C o n t r o l s Note during Description References removal installation Bolt M 6 Tighten t o specified torque Washer Throttle pedal Pull off rearward Throttle pedal stop Adjust Throttle control link Detach Grease ball socket with multi-purpose grease...
  • Page 594 P e d a l C o n t r o l s Note during Description removal installation Actuating rod Assemble and insert the actuating rod prior to the installa. assembly. Ad just clearance between the actuating rod and piston in brake master cylinder Stoplight switch actuating washer...
  • Page 595 P e d a l C o n t r o l s Note during References removal installation Support tube Use multipurpose grease Bushing Check for wear Press in Rubber stop Check for wear and Replace if necessary damage Brake pedal Return spring Bushing Check for wear...
  • Page 596 P e d a l C o n t r o l s I N S T R U C T I O N S FOR D I S A S S E M B L Y A N D REASSEMBLY D i s a s s e m b l y R e a s s e m b l y 1.
  • Page 597 P e d a l C o n t r o l s A D J U S T I N G C L U T C H C h e c k i n g C l u t c h F r e e P l a y The clutch pedal free play is mm.
  • Page 598 P e d a l C o n t r o l s A d j u s t i n g C l u t c h P e d a l T r a v e l Detach floor mat and remove. Loosen both travel stop retaining screws.
  • Page 599 9 1 1 P e d a l s A D J U S T I N G C L U T C H O N M O D E L S W I T H A U X I L I A R Y C L U T C H S P R I N G B a s i c A d j u s t m e n t C h e c k i n g C l u t c h P l a y Because of the auxiliary clutch spring t h e clutch...
  • Page 600 N o t e If there is not enough room for adjustment at the clutch cable holder, adjustments must also be made up front at the pedal assembly. Adjust stop on floor plate until the release travejr at the release lever is 25 0.5 mm (Turbo 0.5 mm).
  • Page 601 Auf bau Body Carrosserie Carrozzeria...
  • Page 602 C O N T E N T S INFOKMATION. DESCRIP7'10NS. SPECIFICATIONS 0 . 1 D e s c r i p r i o n s Body modifications Body modiiicarions 1973 model Body modifications BUMPERS B u m p e r s Front spoiler Bumper, removing and installing - model...
  • Page 603 ROOF Folding roof .modifications 1974 model Folding roof lock pin, service insralling Hardtop roof Folding top to hardtop, switching INTERIOR FITTlNGS 9 . 1 l n t e r i o r f i t t i n g s Targa roof adjustments Top wind deflector strip modifications Three point belt with automatic retractor and warning system,...
  • Page 604 PAINTING 2 2 . 1 P a i n t s Paints 1912 model Paints 1914 model Paints - 1978 model Range of body paint colors 22.2 M e t a l l i c p a i n t s Metallic paint wet on wet method Targa roll bar cover, painting...
  • Page 605 BODY C H A N G E S FROM 1 9 7 2 MODEL Beginning with 1972 models. the following body and trim changes were made. B o d y T h e shape of the rear seat sheetmetal and upper rear wall has been changed. They are the same shape for both Coupe and Targa models.
  • Page 606 installed in doors of older version h y filing t h e boll holes slightly. S e a t s Oil tank under right rear fender repositioned rcarivard r e n d e r witholit filler neck lid Black front horn g i i l l . Front bumpers in T y p e 911 vehicles equipped wilh spoiler.
  • Page 607 Seats with integrated head restraints. 4. T a r g a with solid roof t o p (fiberglass). Folding roof (optional) with central anchorage in rear. 5. Rear panel with reflectors and PORSCHE lettering. G. Seat belts with automatic action.
  • Page 608 F R O N T S P O I L E R T Y P E 9 1 1 S Beginning with 1972 models. Type 911 S vehicles are furnished with a front spoiler-type bumper as standard equipment. This modification results in increased stability at high speed. Initially made of fiberglass, these spoiler-type bumpers are made of steel sheetmetal from chassis 911 230 0385...
  • Page 609 B u m p e r s R E M O V I N G A N D I N S T A L L I N G U S A T Y P E B U M P E R S G e n e r a l Beginning with t h e models, a l l vehicles exported to t h e USA are equipped with bumpers with...
  • Page 610 D i s a s s e m b l i n g B u m p e r 1. Unscrew bumper brackets ( M 8 nuts nd Allen bolts). Detach bumper horns 3. Remove bumper t r i m strip 4 .
  • Page 611 B u m p e r s R e m o v i n g R e a r B u m p e r Detach bumper outer sections from support pipe and bumper bracket sides. Detach bumper brackets from t h e longitudinal members and r e m o v e c o m p l e t e bumper assembly 3.
  • Page 612 B u m p e r s R e a s s e m b l i n g B u m p e r N O T E : When installing bumpers which were dis- assembled for painting, it is best to reassemble the parts off the vehicle and then mounting the entire bumper assembly in its place.
  • Page 613 B u m p e r s Attach bumper t o langiludinal members, securing it by t h e brackets. If t h e rear part of t h e bumper does not press against t h e weathcr seal in t h e fender, that distance must be rtduced by inserting spacers between t h e bracket and longitudinal members, a t t h e front bolt.
  • Page 614 B u m p e r s F R O N T B U M P E R S E F F E C T I V E W I T H 1 9 7 4 M O D E L S...
  • Page 615 Note when: Remarks removing installing Description Flanged studs of d e - Front bumper formation t u b e must fit into cutouts. Sealing strip must fit alround. Grommet Use self- locking nuts. Nut, M 8 Washer Sheetmetal nuts, Detach side and pull Press into grommets Bumper strip off.
  • Page 616 B u m p e r s Note when: Remarks Description removing installing Preassemble side Front skirt skirts. Sheetmetal nut, Sheetmetal m e w , 6 . 3 Place against lock Gasket transverse panel Side skirt Install neatly Insert, top Insert, bottom Install neatly Sheetmetal screw...
  • Page 617 B u m p e r s Note when: Description Remarks removing installing Hydraulic damper Check, replace if (optional) necessary. Align bumper, then attach. Remove water reservoir Clamp Rubber buffer Check. replace if necessary Insert with Check. replace if sleeve necessary Washer Insert...
  • Page 618 9 1 1 B u m p e r s R E A R B U M P E R E F F E C T I V E W I T H 1 9 7 4 M O D E L S...
  • Page 619 B u m p e r s Description N o , Rear bumper Remove bumper strips Align bumper. Flanged and license p l a t e lamps, studs of deformation pull wires out tubes must fit into oval holes Grommet Bumper guard Nut.
  • Page 620 B u m p e r s Note when: Remarks Description removing installing Attach boot to both Detach from bumper lower fender parts on right, and from lower fender on left. press out Self-tapping nut Fit against fender contour section Replace damaged par1 Insert Install neatly...
  • Page 621 B u m p e r s Note when: Description Remarks removing installing Nut, M 8 Use self- locking nuts Washer Insert for Glue t o deformation mounting p l a t e t u b e...
  • Page 622 I n s t a l l i n g N o s e S p o i l e r Remarks Description Removal Installation Bolt flush on sides Nose spoiler Replace if necessary with apron Match chamfer Spacer Washer Use at front Insulator Bolt 6...
  • Page 623 R E M O V I N G A N D I N S T A L L I N G F R O N T L I D L O C K R e m o v a l 2 .
  • Page 624 O p e n i n g L i d L o c k w h e n C o n t r o l C a b l e b r e a k s press the boots out; remove bumper fasteners from collision tubes).
  • Page 625 R e a r L i d w i t h S p o i l e r...
  • Page 626 R e a r L i d w i t h S p o i l e r Notes Remarks Description Removal Installation Rear lid Even gaps all around. Adjust height with washers a t hinges Loosen guard Align. Secure with Spoiler studs and lock nuts Washer 5.3 m m...
  • Page 627 R E M O V I N G A N D I N S T A L L I N G D O O R P A N E L E F F E C T I V E W I T H 1974 M O D E L S G e n e r a l Beginning with 1974 models, t h e doors h a v e new t y p e of door panel.
  • Page 628 I n s t a l l a t i o n 1. Attach threaded plate (see arrow) with countersunk screw. hook Install control lever with connecting rod, spring to door inner panel. 3. Tightly glue weatherfoil to door inner panel. door panel on door.
  • Page 629 R E M O V I N G A N D I N S T A L L I N G D O O R S T O P Beginning with models, a l l Type 911 vehicles a r e equipped with a modified door stop. T h e door 1974 stop link is attached t o the door hinge post with a rollpin.
  • Page 630 I N S T A L L I N G R I D G E FILLERS Beginning with models, all Coupe vehicles are furnished with rubber ridge fillers which are glued 1914 to the front and rear part of the window frame to reduce wind noise. Make sure that the ridge fillers are glued into place with waterproof glue.
  • Page 631 P R E P A R I N G D O O R S M E L L S F O R R E M O I ' E C O N T R O L O U ' I S I D E M I R R O R 3.
  • Page 632 6. 1f necessary for t h e harness opening, drill Cut opening (according t o specifications) for operating switch in inner door panel, top. h o l e in t h e front inner door panel. For electric window winder. For outside mirror.
  • Page 633 S E R V I C E I N S T A L L I N G N E W D O O R L O C K C O N T R O L S All 1 9 7 1 models will have doors with a n improved, anti-theft lock control. T h e lock button lowers into tary knob.
  • Page 634 I N S T A L L I N G D O O R W I N D O W L I F T C H A N N E L A s s e m b l i n g 1.
  • Page 635 D o o r s R E M O V I N G A N D I N S T A L L I N G C L C C l ' R I C \WINDOIL' R E G U L A T O R S G e n e r a l Beginning with t h e April 26, 1112 production, new electric motors with an integral transmission, as well as modified toggle switches with mounling framer a r e used.
  • Page 636 together with caps. If the wire looin leading from the door into the c a r ' s interior is t o be removed, it will be necessary t o rake the door off. New motor and transmission with c a b l e layout. I n s t a l l i n g door.
  • Page 637 Insert toggle switches, cover caps, and wire looms. C o n n e c t a l l wires according 10 t h e new supplemental wiring diagram in Group 9 , p a g e 0. 1 - 2/11. Fasten [he wire looms t o carrier place and inner s h e e r m e t a l "...
  • Page 638 D o o r s a seclioli in the toggle swilcb area. 1 0 . door release, door pocket, folding compart- ment, door l e d g e rail, and outside window base chrome snip. Connect toggle switches and install. 1 1 .
  • Page 639 E L E C T R I C C R O S S A R M W I N D O W C O N T R O L S f r o m l ' j 8 0 M o d e l Electric cross arm window conrrols a r e installed in a l l cars as of t h e 1080 model year.
  • Page 640 S E R V I C E I N S T A L L A T I O N E L E C T R I C C R O S S A R M W l N D O W C O N T R O L S G e n e r a l I n f o r m a t i o n Electric cross arm window controls are installed in all cars as of the 1980 model year.
  • Page 641 D o o r s The plastic part of Targa window lift channels will have to be coated with rain molding cement, e. g. National Special Cemenr at the groove. Find localion for holes on inside door panel and drill two dia.
  • Page 642 D o o r s N o t e 8. Check door window for easy movement. Close slot must be made according to given dimensions door and check entire periphery of glass and/or in door inside panel of Targa models. The stop bracket window frame for neat fit at door weatherstrip, for height control will be accessible through this correcting window frame adjustment if necessary.
  • Page 643 A D J U S T I N G D O O R W I N D O W T A R G A The methods of adjustment have been improved since introduction of electric cross-arm window regulators from 1980 models on. T h e Targa window regulators now have two adjustable stop brackets for height control. The adjusting screw has been omitted.
  • Page 644 F o l d i n g R o o f M O D I F I C A T I O N S I N T A R G A F O L D I N G R O O F 1 9 1 4 M O D E L S Beginning with 1974 models, new METALLASTIK supports a r e used in t h e rear part of the folding roof;...
  • Page 645 F o l d i n g R o o f N O T E : Installation of t h e additional locating pin may h e accomplished only in folding roofs which have t h e pressure-cast aluminum frame. T h e rear f r a m e section is of t h e triangular coniigora- R e m o v a l Remove and slacken roof.
  • Page 646 F o l d i n g R o o f 911 565 145 10. Measure and mark t h e center of t h e roll bar. = . - Center t h e supparling p l a t e and weld Align cover plate, Part 911 565 133 40.
  • Page 647 F o l d i n g R o o f 6. Bend t h e inner panel front part t a m a t c h t h e rubber mount. Glue t h e leatherette covering t o t h e roll bar and cut t h e access h o l e out.
  • Page 649 R e m o v a b l e H a r d t o p Notes Remarks Installation Removal Install with heat- resistant adhesive Adjust to tension of Check, replace if windshield necessary Masher Check, replace if necessary Check, replace if necessary If required, install on stop pad to ad-...
  • Page 650 R e m o v a b l e H a r d t o p Remarks Description Removal Installation Washer Glue end pieces pro- Roof f r a m e seal side. loosen glued front perly, using foam and rear ends, re- left and right rubber underneath if m o v e m e t a l screws...
  • Page 651 Targa models (from 1974) can b e equipped with either a folding or solid roof. Two escutcheoils have t o b e installed on the windshield frame for t h e roof locl<s ou models delivered with folding roofs. Adjust- ments are the s a m e ior both folding and solid roofs.
  • Page 652 S m a l l leaks can b e repaired by gluing pieces of rubber on t h e roof especially a t t h e curved sections. 6. Close doors and remove inner door t r i m if t h e window frames and door windows protrude or do not align with t h e side roof frames correctly.
  • Page 653 3 m o d e l s REMOVING AND INSTALLING CABRIOLET n c e 1 R e m o v i n g Remove screws on rear wall t r i m panel at bottom Remove mounting screws and push buttons on on left and right sides.
  • Page 654 I n s t a l l i n g 4. Remove mounting screws on tensioning bar and bracket. A d j u s t i n g mm thick shims (max. 4 mrn) can be used underneath the top hinges for correction of height.
  • Page 655 3. Close top, pull down on grip plate with one hand and lock lock simultaneously. Repeat this step on the other side. top canvas cover between the front and rear If the top i s closed, make sure that there is equal ingly.
  • Page 656 6 . To adjust the tension of the rear window, loosen the mounting screws and then adjust the rear window tension with the tensioning screws on left and right sides.
  • Page 657 REMOVING A N D INSTALLING TOP SEALS R e m o v i n g 1. Open t o p locks and unzip the zipper. Remove nuts and washers on the B pillars and lift o f f seals with profile section rails and t r i m forward. Lay back top, loosen screws of top frame seals.
  • Page 658 3. Remove rivets o f grip plates and mounting Loosen seal o n hoop carefully screws o f hoop t r i m . 4. Remove grip plates, unclip hoop t r i m and unscrew locating pins and screws.
  • Page 659 91 1 I n s t a l l i n g Installation in reverse sequence All bearing surfaces for seals must be cleaned t o remove sealing and adhesive compound A d j u s t i n g Seals have t o be adjusted after closing the top.
  • Page 660 REMOVING AND INSTALLING FRONT TOP CANVAS COVER R e m o v i n g 3. Unscrew rnountlng screws on rear top t r l m 1. Remove key boards. B pillar seals, top frame See "Removing Top and Top Seals". Remove snaps or Tenax bases, mounting screws.
  • Page 661 Disconnect cemented canvas cover on front Loosen tensioning screws of tooth rails and remove screws. hoop. Disconnect rubber strap on roof liner Disconnect cemented top canvas cover on pillars and main hoop. 9. Unscrew screws of tensioning springs on top frame.
  • Page 662 2. Guide tensioning cables into openings i n t o p 10. Unscrew tensioning springs on tensioning canvas cover from front end. cables. Pull tensioning cables out of top frame and take o f f t o p canvas cover. 11.
  • Page 663 Mount t o o t h rails. Guide mounting strips of t o p Install and align t o p canvas cover that marks canvas cover underneath t o o t h rails, cut t o size, are aligned. Canvas cover seam must run in groove apply coat o f cement, stretch, connect doubled o f hoop edge.
  • Page 664 Loosen tooth rails and fold back top canvas 9. Install snaps or Tenax bases and screws with ccver. Insert seals a~;d coat canvas cover with cloth orotection washers. cement. Mount tooth rails and cement canvas cover on the B oillars. 10.
  • Page 665 tensioning cables into t o p frame. Mount rear and front canvas cover on real- hoop Install rear top trlm with a suitable tool.
  • Page 666 Screw on tensioning springs w i t h tensioning cables. The bracket has two raised bosses, w i t h which the tensioning force of the tensioning cables can be adjusted. Mount tensioning springs with bracket on the top frame. See "Installing Top and Top Seals"...
  • Page 667 REMOVING AND INSTALLING REAR TOP CANVAS COVER WITH TENSIONING BAR AND MOUNTING R A I L R e m o v i n g I n s t a l l i n g 1. Remove the key boards, side wall trim panels. Installation is in reverse sequence rear wall t r i m panel.
  • Page 668 REMOVING AND INSTALLING REAR TOP CANVAS COVER WITHOUT TENSIONING BAR AND MOUNTING RAIL R e m o v i n g Remove key boards, side wall trim panels, rear 3. Unscrew snap heads and Tenax bases on ten wall trim panel, B pillar seals, front canvas cover sioning bar.
  • Page 669 Mark distance from rear window to cementing 5. Disconnect and remove cemented mounting rail. edge of mounting rail on top canvas cover; approx. I n s t a l l i n g Cement mounting rail on top canvas cover accord- ing to marks.
  • Page 670 Fit canvas cover on tensioning bar and cut t o size. Cement canvas cover on outside of tension. washers and nuts. ing bar from the center t o left and right sides. Seam of canvas cover must run slightly higher than lower edge of the tensioning bar.
  • Page 671 REPLACING ZIPPER SLIDE R e m o v i n g L i f t off end hook towards inside 1. Remove Tenax base and self-tapping screw w i t h cloth protection washer o n the side, where the end hook i s located (on rear end o f front canvas cover) and open up sewn seam.
  • Page 672 I n s t a l l i n g 1. Press new zipper slide into real- zipper section. outside. 2. Insert zipper slide in front zipper section. zipper slide.
  • Page 673 Install key board, Tenax base and self-tapping I f applicable, drill a hole i n the front of the key screw with cloth protection washer as well as board, where the snap base i s mounted with a front and rear canvas covers w i t h two seam self-tapping screw (see figure).
  • Page 674 91 1 REMOVING AND INSTALLING ZIPPER R e m o v i n g Cement canvas cover on zipper from above 1. After removal of the rear top canvas cover with- out tensioning bar and without mounting rail. cut out zipper from rear canvas cover. Cement tensioning section surfaces.
  • Page 675 RECOMMENDED CEMENTS OR ADHESIVES Terocal 2444 for cementing seals u r e r : Teroson Werke GmbH M a n u f a c 6900 Heidelberg Dekalin 3649 for installation of canvas on metal or plastic u r e r : Deutsche Klebestoffwerke GmbH M a n u f a c Rodiger &...
  • Page 676 I n t e r i o r E q u i p m e n t NOTE Remove screw &om mirror arm and take off mirror base. Do not use adhesive plates on which the backing was already partially removed or plates from which the backing cannot be fully removed.
  • Page 677 I n t e r i o r F i t t i n g s I N S T A L L I N G I N T E R I O R R E A R V I E W M I R R O R Repair kit, Part No.
  • Page 678 I n t e r i o r E q u i p m e n t T A R G A ROOF A D J U S T M E N T S FROM 1 9 7 0 MODELS G e n e r a l If wind noise or creaking should occur in a Targa roof due to changed position, the following adjustments Creaking Noises...
  • Page 679 Tensioning rail Roof l a c k pawl Windshield f r a m e weatherstrlp, new version...
  • Page 680 I n t e r i o r E q u i p m e n t M O U L D I N G C H A N G E S Beginning with chassis numbers 911 251 0143 9 1 1 9 1 1 221 0091 9 1 1 E 9 1 1 231 0059...
  • Page 681 9 1 1 I n t e r i o r e q u i p m e n t I N E R T I A REEL S A F E T Y B E L T W I T H A U T O M A T I C L O C K I N G R E T R A C T O R ( C O U P E ) Note when S p e c i a l installing...
  • Page 682 I n t e r i o r ~ q u i p m e n t I N E R T I A KEEL S A F E T Y B E L T W I T H A U T O M A T I C L O C K I N G R E T R A C T O R ( T A R G A ) Special N o t e when instruction!
  • Page 683 I n t e r i o r E q u i p m e n t R E M O V I N G A N D I N S T A L L I N G I N E R T I A REEL S A F E T Y B E L T W I T H A U T O M A T I C L O C K I N G R E T R A C T O R A N D E L E C T R I C W A R N I N G D E V I S E R e m o v a l ( C o u p e a n d T a r g a ) Remove and reinstall buckle.
  • Page 684 9 1 1 I n t e r i o r E q u i p m e n t a) Remove both countersunk screws from I n s t a l l a t i o n ( C o u p e ) the cover and separate both halves.
  • Page 685 I n t e r i o r E q u i p m e n t Install upholstery cover and rosette plate. 3. Install yoke on door lock post; s e e sketch for l o c a - 6.
  • Page 686 I n t e r i o r E q u i p m e n t 9 . Join belt buckle covers and secure with location countersunk screws. 1 0 . Put the belt on, adjust, and check operation. When t h e belt is moved rapidly, the locking retractor must lock, and must unreel easily when moved slowly.
  • Page 687 I n t e r i o r E q u i p m e n t I n s t a l l a t i o n I n s t r u c t i o n s f o r T a r g a V e h i c l e s 1.
  • Page 688 I n t e r i o r E q u i p m e n t Pull t h e belt out horizontally and check un- reeling and retraction. T h e belt should reel i n center of r e t r a c t o r if not, correct t h e 12' alignment of t h e retractor.
  • Page 689 I n t e r i o r E q u i p m e n t R E M O V I N G A N D I N S T A L L I N G E L E C T R I C W I N D O W R E G U L A T O R S G e n e r a l Beginning with t h e Apr- 26-72 production, new electric motors with a n integral transmission, as well as modified toggle switches with mounting frames a r e used.
  • Page 690 I n t e r i o r E q u i p m e n t from junction bar, and pull wire looms out together with caps. If t h e wire l o o m leading from t h e door into t h e c a r ' s interior is t o b e removed, it will b e necessary t o t a k e t h e door off.
  • Page 691 i n t e r i o r E q u i p m e n t Insert toggle switches, cover caps. and wire new supplemental wiring diagram in Group Fasten t h e wire laoms t o carrier p l a t e and inner sheetmetal panel.
  • Page 692 I n t e r i o r ~ q u i p m e n t Glue t h e sealing foil in leak- free. Cut out a section in t h e toggle switch a r e a . 1 0 .
  • Page 693 I n t e r i o r E q u i p m e n t S E A T S General Beginning with 1 9 7 3 models, a l l standard and sport t y p e seats h a v e new lo~lgitudinal seat adjuster lacks on both sides of t h e seat.
  • Page 694 I n t e r i o r ~ q u i p r n e n t Installing Seats 1. At first, tighten seat rails only lightly. Check sent adjustment positions throughout the entire position range t o ensure that the lock pawls engage and the seat moves easily on the o i l s .
  • Page 695 I n t e r i o r E q u i p m e n t R E M O V I N G A N D I N S T A L L l N G O I L F I L L E R L I D A N D C O N T R O L G e n e r a l Beginning with 1972 models, o i l tanks in a l l T y p e 911 vehicles a r e located under the right rear fender, adjacent t o side m e m b e r and wheel housing.
  • Page 696 E x t e r i o r T r i m R E M O V I N G AN13 I N S T A L L I N G R O C K E R PANEL C O V E R R e m o v a l 1.
  • Page 697 G e n e r a l Beginning with 1974 models, an end panel will1 reflectors and PORSCHE lettering is mounted at the rear cross panel. A sheetmetal shroud, serving as heat shield, is located below the panel; it is inserted R e m o v a l Remove rear bumper.
  • Page 698 E x t e r i o r T r i m As from 1978 models t h e tail p l a t e is attached t o the tail panel with 1 0 clips. Part No. '399 591 This facilitates installation, in that t h e bumper and heat guard d o not h a v e t o be removed.
  • Page 699 E x t e r i o r T r i m L E T T E R I N G FOR CARRERA V E H I C L E S The following points must be observed to ensure that the lettering adheres firmly to the paint: 1.
  • Page 700 Mark location of t h e lettering 25 mnl from from bottom of lid in t h e c e n t e r . Peel off backing foil and affix t h e lettering as Affixing "Carrera Lettering on ].id Spoiler 1 6 0 Peel off backing foil and Elue t h e lettering optically horizontal t o t h e right.
  • Page 701 E x t e r i o r F i t t i n g s D E F O G G E R A N D R E h f O T E C O N T R O L Special Note when Description...
  • Page 702 E x t e r i o r F i t t i n g s R e m o v i n g Note: If i t is necessary t o t a k e t h e harness out of Use putty knife t o mirror glass clips out t h e door, r e m o v e t h e inner door trim and carrier plate.
  • Page 703 E x t e r i o r F i t t i n g s I N S T A L L I N G Wrap foam t a p e around socket/plug and T h e following points a r e important. insert it through oval opening in mirror housing so that t h e mirror m o v e m e n t is not restricted.
  • Page 704 E x t e r i o r E q u i p m e n t S E R V I C E I N S T A L L I N G E X T E R I O R MIRROR ON P A S S E N G E R ' S DOOR N o t e 3.
  • Page 705 Insert wire gromnlcl into door recess. door and mount mirror base with panel and insert r u h l w r g r o m m e t . 8. Press plug together and hold with self- adhesive f o a m tape. Note colors of wires and wiring diagram.
  • Page 706 12. Remove d r i i e r ' s door, a n d insert a n d connecl new fxterior mirror \wire harness. 13. C u l hole it1 l r i n of instrument panel, luggage c o m p a r t m e n t floor p l a t e a n left and right sides.
  • Page 707 Check dimensions for bottom groups from model 72 on Cotes de contrde pour le groupe de fonde partir du modele 72 Printed in Germany 18.1-1/1...
  • Page 708 R e p a i r s C H E C K I N G REAR A X L E C R O S S T U B E The rear axle tube for Types 911 and 911 Turbo c a n b e inspected for deformation with a locally m a d e tool and a torsion bar.
  • Page 709 R e p a i r s I N S T R U C T I O N S F O R \ v ' E L D I N G G A L V A N I Z E D S H E E T M E T A L 1 9 7 6 M O D E L For t h e 1 Y i C model t h e entire body is m a d e of steel s h e ~ l galvanized an both sides.
  • Page 710 R e p a i r s Never m a k e spot welds on edges of sheet m e t a l (spatter formation). C l e a n and dress electrodes on their flanks and tip surface only if t h e r e is a heavy c o a t of deposits. T h e t i p surface of t h e electrodes becomes harder from spot welding;...
  • Page 711 R e p a i r s T h e most suitable welding wire is of soft quality. 0.8 m m (0.031 in.) in diameter and has 0.8 silicon and manganese additives. T h e gas shielding flow rate should be set at about 1 7 cu. ft. per hour. For large scale welding adequate ventilation must b e provided.
  • Page 712 T h e new color code on t h e vehicle paint d a t a p l a t e is identical with the order numbers in the color c a - talogue. Example. 131 9 2 131 9 2 light ivory Three- digit paint numhel Porsche company Place o f application 131 9 2 131 9 2 Paint rnanulacturer Standard colors from 1972 model 1 3 1...
  • Page 713 P a i n t F i n i s h Optional colors from 1972 model: gulf orange fraise signal orange ivory irish green bush green lind green light green 3 26 icing blue gulf blue 3 29 sea blue Lilac olive beige grey...
  • Page 714 P a i n t F i n i s h C O L O R S E L E C T I O N E F F E C T I V E W I T H 1 9 7 4 M O D E L S Standard colors beginning wit'n 1974 models: India red...
  • Page 715 P a i n t i n g P A I N T S M O D E L indian red Standard Colors: talbot yellorr orange light yellow speedway green arrow blue cockney brown black grand prix white Optional Colors: c a r m i n e red yellow green irish green...
  • Page 716 P a i n t P A I N T S 1 9 7 8 M O D E L S Standard india red talbot yellow continental orange fern green olive green royal blue chocolate brown cashmere beige black grand prix white Metallic oak green light green...
  • Page 717 P a i n t w o r k M O D E L S S r a n d a r d C o l o r s f r o m 1979 M o d e l s : india red olive green cockney brown...
  • Page 718 p a i n t i n g R A N G E OF BODY P A I N T C O L O R S 1 9 8 1 M O D E L S S p e c i a l C o l o r s : guards red metallic moss green alpine white...
  • Page 719 P a i n t F i n i s h Metallic Paint Wet-on-Wet Process Until now, two different types of clear enamel with synthetic resin base were used in the course of repairs: clear enamel 84 0503 Two-component acryllic clear enamel 09168 with catalyst 22004...
  • Page 720 P A I N T I N G T A R G A ROLL BAR C O V E R G e n e r a l I n f o r m a t i o n The Targa roll bar cover (rustproof steel) has a coat of flat black polyurethane textured paint. In addition to metal parts, polyurethane paint can be used on parts made of fiber glass (Targa removable roo0 and rigid expanded polyurethane.
  • Page 721 S H O P M A T E R I A L S FOR B O D Y R E P A l R S Hydraulic 10 ton straightener with accessories Celette straightening bench Set of attachments ENS 17.360 Universal anchor ENS 937.900 Front end gauge Inert gas welder...
  • Page 722 F l o o r P a n e l A s s e m b l y D i m e n s i o n s...
  • Page 723 F l o o r P a n e l A s s e m b l y D i m e n s i o n s Dimension Location inch 565.5 22 1 / 4 1/32 Control arm mounts Auxiliary support 28 1 / 2 1/32...
  • Page 724 F r o n t ~ o d y E n d F l o o r A s s e m b l y C h e c k p o i n t s a n d F r o n t B o d y G a u g e s P 8 6 3 a n d 8 6 3 a As already announced ill the 1975 Model Iniormation, checkpoints a r e welded t o t h e frame/floor assembly of 1975 models.
  • Page 725 B o d y F r o n t R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g Includes: Lock panel, front tank support and left or right tank support.
  • Page 726 o d y i i a n l R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g Includes: Lock panel, front tank support and left or right tank support.
  • Page 727 R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g /Operation Areas Material 1. S e p a r a t i n g Cutting disc Chiseling Pneumatic chisel...
  • Page 728 R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g D a m a g e Diagnosis When t h e extent of d a m a g e cannot b e defined exactly. Check floor p l a t e assembly.
  • Page 729 R e p l a c i n g P a r t o f l ' r o l l i Damaged parts c a n b e separated in any sequence in accordance k i t h Lhc operations illustrate? below.
  • Page 730 B o d y , F r o n t R e p l a c i n g P a r t o f F r o n t W l i e e l h o u s i n g Check a x l e take- up points, aligning if necessary.
  • Page 731 B o d y F r o n t R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g If t h e wheelliousing was weld t h e new part overlapping t h e dented section.
  • Page 732 B o d y F r o n t R e p l a c i n g P a r t o f F r o n t W h e e l h o u s i n g Align and spot weld front tank support.
  • Page 733 E C O N O M I C A L REPAIRS W I T H C E L E T T E S T R A I G H T E N I N G BENCH FOR T Y P E 9 1 1 , 9 1 2 A N D 9 3 0 T U R B O The attachment set ENS 11.360 was developed for body straightening work.
  • Page 734 B o d y F r o n t S e c t i o n P R E P A R I N G B O D Y FOR USE O F A T T A C H M E N T S E T E N S 3 6 0 Remove:...
  • Page 735 From 1977 models on (adjustable spring strut setting) the shoulder bolts of side rnember/rear axle cross tube For these cars the bores in the take-ups of the attachment set must be enlarged by this amount. For the previous models these enlarged holes must be adapted by using suitable washers. Attachment set ENS 11.360 corresponds with version from 1977 models on.
  • Page 736 A T T A C H M E N T S E T FOR T Y P E 9 3 0 T U R B O ENS 7 7 . 3 0 3 The illustrated take-up points differ from Type 9 1 1 attachment set and are used for Turbo models, The auxiliary carrier pin is installed mm higher.
  • Page 737 E X T R A A T T A C H M E N T FOR E C O N O M I C A L REPAIR OF F R O N T E N D D A M A G E With this set of straightening bench attachments it is not necessary to remove the engine, transmission and rear running gear pars.
  • Page 738 B o d y F r o n t S e c t i o n Note: Before lowering the body on the straightening bench the attachments must be secured on the shoulder bolts.
  • Page 739 After bolting down the set of attachments, check t h e central position of the transmission bolts with the control pins. N o t e : The horizontal position of a moving checked with a (bubble) level.
  • Page 740 E X T R A A T T A C H M E N T FOR E C O N O M I C A L R E P A I R S O F BODY REAR S E C T I O N D A M A G E With this attachment set i t is not necessary to remove the bottom guard and front axle.
  • Page 741 B o d y R e a r S e c t i o n Economical extra attachment is bolted on auxiliary carrier pin. Remove auxiliary carrier bolts and mount adapter with longer bolts supplied.
  • Page 742 B o d y R e a r S e c t i o n Lower body in horizontal position. Set attachment set to 0 on scale and tighten. N o t e The auxiliary carrier pin is installed mm higher on Turbo cars. This deviation must be compensated for when installing the adapter.
  • Page 743 R e a r s e c t i o n used for additional anchorage...
  • Page 744 Universal anchor mounted on floor flange. Llndercoating should be renioved in this area to provide greater holding forces.
  • Page 745 COBRA 3 S T R A I G H T E N E R W I T H A C C E S S O R I E S This straightener can be permanently anchored on the bench. The pulling direction can be adjusted by swinging the beam even when anchored.
  • Page 746 B o d y , R e a r B O D Y R E P A I R S R E A R...
  • Page 747 B o d y , R e a r R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Includes: Wheelhousing inner and outer rear cross members, left or right engine brackets end plate and rear fender.
  • Page 748 R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Areas Material Separating Cutting disc Re move m e t a l scraps Welding torch, hand grinder and oliers Undercoating and...
  • Page 749 B o d y , R e a r R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r D a m a g e Diagnosis Alignment Before the damaged parts c a n he removed by cutting,align t h e ented section with hydraulic alignment equipment as well as possible.
  • Page 750 R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Damaged parts can b e separated in any sequence in accordance with tile operaiions illustrated.
  • Page 751 R e p l a c i n g P a I t o f I n n e r S i d e M e m b e r Align and weld new parts. Install side member with about 2 c m inches) overlap.
  • Page 752 B o d y , R e a r R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Align wheelhousing panel, cut and weld with about 2 c m (4inches) overlap. Butt weld in area of lid recess.
  • Page 753 9 1 1 B o d y . R e a r R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Align and butt weld outer section of cross member at center cutting point.
  • Page 754 R e p l a c i n g P a r t o f I n n e r S i d e M e m b e r Align and cut rear fender. Cut along cutting line from lid opening t o vent window so that it overlaps. Crimp new part using crimping pliers.
  • Page 755 Elektrische Anlage Electrical System lmpianto elettrico...
  • Page 756 C O N T E N T S INFORMATION, DESCRIPTION, TECHNICAL DATA D e s c r i p t i o n Ignition distributor, current flow diagram Wiring diagram Current flow diagram Relays and fuses Lighting Alternator 1975 model Ignition system modifications 1978 model 0 .
  • Page 757 9 1 1 WINDSHIELD WlPER AND WASHER SYSTEM 4 . 1 D e s c r i p t i o n 4 . 2 D i s a s s e m b l i n g a n d a s s e m b l i n g Adjustment instruction Removing and installing 4 .
  • Page 758 E L E C T R I C A L S Y S T E M 6 . 5 A u t o m a t i c h e a t i n g c o n t r o l Removing and installing Troubleshooting Disassembling and assembling...
  • Page 759 9 1 1 I g n i t i o n D e s c r i p t i o n I G N I T I O N D I S T R I B U T O R FOR 2 . 4 L I T E R E N G I N E S B E G I N N I N G W I T H 1 9 7 2 M O D E L S G e n e r a l I n f o r m a t i o n Beginning with the 1972-model year, all Type 911 vehicles are equipped with either...
  • Page 760 I g n i t i o n D e s c r i p t i o n The vacuum control unit retards the ignition timing during idle and low speed ranges. T h e ignition then fires 5O ATDC. This results in cleaner combustion, reducing the emission of harmful exhaust pollutants.
  • Page 761 I g n i t i o n D e s c r i p t i o n I G N I T I O N D I S T R I B U T O R FOR 2 . 7 LITER E N G I N E S Beginning with 1974 models.
  • Page 762 D e s c r i p t i o n C u r r e n t F l o w D i a g r a m How t o r e a d c u r r e n t f l o w d i a g r a m s In previous wiring diagrams electrical components were shown in the approximate position as you would find them on the car.
  • Page 763 D e s c r i p t i o n C u r r e n t F l o w D i a g r a m Most connectors or terminals are numbered. These numbers correspond with the numbers that are right next to most connectors on electrical components, such as switches and relays.
  • Page 764 D e s c r i p t i o n C u r r e n t F l o w D i a g r a m E l e c t r i c a l S y m b o l s Antenna Dipole antenna Heating resistor (element)
  • Page 765 911 T, 911 E, 911 S, Electric wiring diagram (Part Type Model FUSES: 33 Emergency flasher switch 1 Battery (not applicable in Italy and France) 17 Headlights Fuse box 36 Door contact switch 18 Turn signal, parking and side marker iights compartment light (side marker lights U S A only)
  • Page 766 Type 911 Electric wiring diagram (Part Model FUSES: 43 Safety belt contact, driver side 1 Battery (USA only) 78 Fuse box l ( 1 0 terminal) Fuse 2 Starter 44 Safety belt contact, passenger side 80 Fuse ban 111 (3 terminal) 3 Alternator 81 Fan motor compartment light...
  • Page 767 Electric wiring diagram (Part I) Type 911 Carrera 2.7, Model 73 33 Emergency flasher swltch FUSES: (not a p p c a b l e 36 Door contact switch Turn s ~ g n a l . p a r k n g and s d e marker 37 S w ~ t c h for luggage compartment light...
  • Page 768 2.7, Electric wiring diagram (Part Type 911 911 E, 911 Carrera Model FUSES: 77 Cigarette lighter 43 Safety belt contact, driver side Battery (USA only) 78 Fuse box l ( l 0 terminal) Fuse box 2 Starter 80 Fuse box 111 (3 terminal) 44 Safety belt contact, passenger side Interior light, clock, luggage 3 Alternator...
  • Page 769 Additional wiring diagram front and rear fog lights, Type 6 ~ u l t i - c o n n e c t o r terminal1 1 Fuse b o x I Ground connection-body Fuse b o x l l Fog lights 9 Rear fog light Fog lights switch...
  • Page 770 Additional wiring diagram electric window opener, Type 91 1 6 Switch f o r passenger side, right 1 Fuse b o x I Motor, drivei side 7 Ground connection. left Ground connection, r g h t 3 Motor, passenger side Terminal s t i ~ p Switch f o r passenger side, left Switch for driver side...
  • Page 771 Type 911 T with CIS, Electric wiring diagram (Part FUSES: 33 Emergency flasher switch 1 Battery (not applicable in Italy and France) 17 Headlights Fuse box I: Door contact switch 18 Turn signal, parking and side marker 1 Interior light, clock, luggage 37 Switch far luggage compartment light compartment light lights...
  • Page 772 Electric wiring diagram (Part II) Type 911 T with CIS, Model 73 FUSES: 77 Cigarette lighter 43 Safety belt contact, driver side Battery Fuse box I: (USA only) 78 Fuse box 1 110 terminal) 2 Starter 1 Interior light, clock, luggage 44 Safety belt contact, passenger side 80 Fuse box 111 (3 terminal) 3 Alternator...
  • Page 773 S U P P L E M E N T T O E L E C T R I C WIRING DIAGRAM T Y P E 9 1 1 T W I T H C O N T I N U O U S I N J E C T I O N S Y S T E M ( C I S ) . 1 9 7 3 MODEL Wiring in the area of fuse box 111 shown on page 0.1 2/15 differs in Type 911 T vehicles equipped with the Continuous Injection System (CIS) due to the Utilization of differing components.
  • Page 774 turn, and auxiliaiy heaicr contact s t o p light switch relay indicator indicator fuel gauge Oil orenure Electric clocl, w i p e r 76 77 window e l e m e n t G e a r l e v e r contact SPM (double) Multi-connector (14...
  • Page 775 T Y P E 9 1 1 , 9 1 1 S , M O D E L U S A Door contact switch Alternator charge indicator light C a b l e belt warning light Oil pressure indicator light Door contact switch Oil pressure switch No 9 1 C a b l e...
  • Page 776 Current flow diagram. Type 911 USA. Model 74 Current track Description Headlight switch Emergency flasher swltch Dimmer switch Parking light s w t c h Instrument panel l i u m n a t l o n potentiometer Left door s w t c h Right door switch Switch for luggage compartment light Brake warning switch...
  • Page 777 USA, Current flow diagram, Type Model...
  • Page 778 Current flow diagram, Type USA, Model Current track Battery Starter Generator Voltage regulator starter switch Fresh a r blower s w t c h Rear wlndow defogger s w t c h Left seat belt s w t c h Right seat belt switch Left seat sensor switch Right Seat...
  • Page 779 Additional current flow diagram CIS-injection engine, Type 911, Model Description Current track Throttle valve switch Thermo-switch for cold start valve Relay forwarnl-up regulator Warm-up regulator Cold start d v e Cable connector, fourteenfold regulator panel, rear...
  • Page 780 Additional current flow diagram CIS-injection and Sportomatic, Type 911, Model 74 Description Current track Starter Generator to ignition starter switch Starter cutout switch (bypass switch) Selector lever contact Back-up light switch Oil temperature switch Throttle valve switch (micro switch) Relay for warm-up regulator Generator charge indicator light Oil temperature indicator light Left back-up light...
  • Page 781 Additional current flow diagram CIS-injection and Sportomatic, Type 911, Model 74...
  • Page 782 Additional current flow diagram automatic heating system, Type Description Current track to ignitionjstarter switch Control unit for automatic heating system Instrument panel illumination potentiometer Speedometer illumination light Interior temperature sensor Exterior temperature sensor Fuses in the fuse box Cable connector, single, on luggage compartment floor...
  • Page 783 USA, Current flow diagram, Type 911 Model...
  • Page 784 USA, Current flow diagram, Type Model Description Current track - Battery C - Starter - Generator regulator Ignition starter switch - Windshield wiper switch - Fresh air blower switch - Rear window defogger switch - Left seat belt switch - Right seat belt switch - Left seat sensor switch - Right seat sensor switch pressure swttch...
  • Page 785 Current flow diagram, Type USA, Model...
  • Page 786 Additional current flow diagram California, Type 911, Model Description Current track (EGR) Mileage counter switch Oil temperature indicator Generator charge indicator light EGR warning light Fuel gauge illumination light Oil temperature indicator illumination light Oil pressure indicator illumination light...
  • Page 787 Additional current flow diagram intermittent wiper operation, Type 911 Description Current track to ignitionlstatter switch Windshield wiper switch Potentiometer for intermittent wiper operation Relay for intermittent wiper Operation in the fuse box Cable connector, single, on luggage compartment floor Cable connector, sixfold. below instrument panel Windshield wiper motor...
  • Page 788 Additional current flow diagram headlight washers, Type 911 Description Current track to battery to ignitionlstarter switch Dimmer switch Headlight washer switch to headlight relay (from model 76 to fuse Headlight washer relay to fuse in the Cable connector, single, behind instrument panel Cable connector.
  • Page 789 Additional current flow diagram headlight washers, Type 911...
  • Page 790 Additional current flow diagram automatic heating system, Type Description Current track to ignitionjstarter switch Control unit for automatic heating system Instrument panel illumination potentiometer Speedometer illumination light Interior temperature sensor Exterior temperature sensor Fuses in the fuse box Cable connector, single, on luggage compartment floor...
  • Page 791 Additional current flow diagram electric sliding roof, Type Description Current track to ignitionlstarter switch Switch for sliding roof Fuse in the fuse box Cable connector, single. near sliding roof motor Sliding roof motor...
  • Page 792 C u r r e n t F l o w D i a g r a m s A D D I T I O N A L C U R R E N T F L O W D I A G R A M E L E C T R I C W I N D O W C O N T R O L S M o d i f i c a t i o n 1 9 1 7 M o d e l s...
  • Page 793 Additional current flow diagram power windows, Type 911 Description Current track to battery ignitionlstarter switch Power window switch, driver side Power window switch, passenger side Power window relay Fuses fuse box Cable connector, single, behind fuse box in door well, left in door well, right Power window motor, left Power window motor, right...
  • Page 794 Additional current flow diagram power windows, Type 911...
  • Page 795 Additional current flow diagram rear window wiper, Type Description Current track to generator to ignitionlstarter switch Rear wiper switch Diode for rear wiper Fuses in the fuse box Fuses in the rear fuse box Cable connector, single behind instrument panel in engine compartment, left Rear wiper motor...
  • Page 796 Additional current flow diagram windshield and rear window defoggers Type Description Current track to battery to generator to voltage regulator to ignitionlstarter switch Windshield and rear window defogger switch Diode for windshield defogger Windshield defogger relay Relay for hvo-stage rear window defogger Windshield and rear window defogger indicator light Fuses fuse box...
  • Page 797 flow Additional current diagram windshield and rear window defoggers Type...
  • Page 798 USA, Current flow diagram, Type 911 S, Model Current track Description windshield wiper switch Headlight switch Turn signal switch Emergency flasher switch Dimmer switch Headlight flasher switch Parking iight switch Switch for glove compartment iight Stop light switch Left door switch Right door switch Back-up light switch switch tor luggage compartlnent iight...
  • Page 799 S, USA, Current flow diagram, Type 911 Model...
  • Page 801 S, USA, Current flow diagram, Type Model...
  • Page 802 Additional current flow diagram automatic speed control, Type 911...
  • Page 803 Additional current flow diagram automatic speed control, Type 911 Description Current track Selector lever contact (Sportomatic) Speed control switch Control unit for speed control Stop light switch Clutch pedal switch to speedometer (terminal 31 b) to speedometer (ground) Diode for speed control to control valve Solencid valve for speed control Fuses...
  • Page 804 Additional current flow diagram intermittent wiper operation, Model...
  • Page 805 Additional current flow diagram intermittent wiper operation, Model Description Current track to ignitionlstarter switch Windshield wiper switch Potentiometer for intermittent wiper operation Relay for intermittent wiper operation Fuses in the fuse box Cable connector, single on luggage compartment floor behind fuse box Cable connector, sixfold.
  • Page 806 Additional current flow diagram air conditioner with front condenser...
  • Page 807 Additional current flow diagram air conditioner with front condenser Description Current track to battery to starter to ignitionlstarter switch, terminal 50 to ignitionlstarter switch, terminal 15 Blower switch Temperature switch Thermostat Power supply relay Relay for condenser fan Electromagnetic clutch Fuses fuse Cable connector, single...
  • Page 808 Additional current flow diagram fog lights...
  • Page 809 Additional current flow diagram fog lights Description Current track to battery to headlight switch Fog light switch Fog light relay Fog light indicator light to left headlight Left fog light Right fog light fuse Cable connector Cable connector, double in luggage compartment, right...
  • Page 810 Additional current flow diagram engine compartment light Description Current track to headlight switch Engine compartment light Fuse fuse box Cable connector, single. near regulator panel Cable connector, sixfold, in engine compartment, rear left...
  • Page 811 Additional current flow diagram remotely controlled outside mirrors, Type 911...
  • Page 812 Additional current flow diagram remotely controlled outside mirrors, Type 911 Description Current track window defogger switch rear Mirror control switch Change-over switch for mirror control to oil pressure indicator light Magnetic clutch far mirror control, driver side Magnetic clutch for mirror control, passenger side Fuse on fuse box Cable connector, sixfold in mirror housing, driver side...
  • Page 813 Current flow diagram, Type 911 S, USA, Model 77...
  • Page 814 Current Row diagram, Type 911 S, USA, Model 77 Current track Description Dimmerswitch Fresh air blowerswitch Rearwindow defaggerswltch Instrument panel iiiumination potentiometer Stop lightswitch Back-uplightswitch Horns Horn relay Diode foiseat beitwarning system High beamindicatarl~ght Parking lghtsindicatorlight Hazard flasher indicator light Sealed beam unit.left headliaht Clock illumination light Ashtray illumlnatian light...
  • Page 815 Current flow diagram, Type 911 USA, Model 77...
  • Page 816 Current flow diagram, Type S, USA, Model 77 Description Battery Starter Generator Voltage regulator Windshield wiperswitch Left Outside mirrorcontrol switch Oil pressure swi!ch Parking brakeswitch Fuel gauge Tachometer Fuel pump Oil temperatureindicator Oil pressure sender unit pressure indicator Speedometer Relay forheater blower Relay forfuel pump Relay forintermittentwiperoperation Seat beltwarnlng system relaywith integrated buzzer...
  • Page 817 Additional current flow diagram brake booster, Type 911 Description Current irack Stop light switch Parking brake switch to oil temperature (terminal 15) to seat belt warning system relay to oil pressure indicator light Parking brakelbrake warning light Seat belt warning light Right stop light Left stop light to left rear turn signal (ground)
  • Page 818 Additional current flow diagram speed limiter, Type 911 Description Current track to generator to ignitionlstarter switch Fuel pump Air meter contact to speedometer (terminal A) Relay for fuel pump Speed limiter relay to warm-up regulator to fuse 16 Cable connector, single. near regulator panel Cable connector, double.
  • Page 819 Current flow diagram, SC, USA, Model 78 Type 911...
  • Page 820 Current flow diagram, Type 911 SC, USA, Modd 78 Description Windshieldwiperswitch Headlightswitch Turn signalswitch Fresh atr blower switch Instrument panel potentiometer Stop ilghtswitch Horns Hazard 1 turn signal flasher Diode for seat beltwarning system High beamindicatarlight Parking lightsindicator light Hazard flasher indtcatar light Sealed beam unit.leftheadlight Sealed beam unit, rightheadlight Speedometer illumination light...
  • Page 821 Current flow diagram, Type 911 SC, USA, Model 78...
  • Page 822 Current flow diagram, Type 911 SC, USA, Model 78 Description Current track Battery Starter Generator Heater blowelswitch Parking brakeswitch Tachometer Fuel gauge Fuel pump Oil temperature indicator Oil pressure indlcatar Oil ieveigauge Speedometer Relay farheater blower Relay farfuel pump Seat b e t warning system relay with integrated buzzer Speed switch Oil preSSUreindicatorlight Parking brake1 brake warnng light...
  • Page 823 Additional current flow diagram power windows 911 from model 77 Type...
  • Page 824 Additional current flow diagram power windows 911 from model 77 Type Description Current track to battery to ignitionlstarter switch (terminal to ignitionlstarter switch (terminal 15) Power window switch, driver side, for passenger side Power window switch, driver side Power window switch, passenger side Power window relay Fuse Fuse...
  • Page 825 Additional Current Flow Diagram Air Conditioner Type 911 from model...
  • Page 826 Additional Current Flow Diagram Air Conditioner Type 911 from model 77 Description Current track to battery to starter (terminal 50) to ignitionlstarter switch (terminal 15) to ignitionlstarter switch (terminal 50) Switch for AC Temperature switch for AC Thermo-switch for AC (excess temperature) Relay for AC Resistor for evaporator blower Electromagnetic clutch...
  • Page 827 Additional Current Flow Diagram Type 911 SC USA, Model 80 Oxygen Sensor System...
  • Page 828 Additional Current Flow Diagram, Type 9 1 1 SC USA, Model 80 Oxygen Sensor System CONTROL UNIT...
  • Page 829 Current Flow Diagram Type 911 SC USA Model 81 PART I POWER SUPPLY, STARTER FUEL PUMP HEATER VENTILPTOR IGNITION PART II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER PART Ill REAR LIGHT, BRAKE LIGHT HORNS INTERIOR LIGHT REAR WINDOW DEFOGGER PART IV OUTSIDE MIRROR FRESH AIR BLOWER CIGARETTE LIGHTER...
  • Page 830 Current Flow Diagram Type 911 SC USA Model 81 WlRE CONNECTORS ONE POLE NO ACTUAL WIRE, BUT RED: 16A. BLUE: (YELLOW: 5A. WHITE: INTERNAL CONNECTION OR CONNECTION FUSE 11 1 6 A BETWEEN EQUIPMENT HOUSING WlRE CROSS SECTION AND GROUND TWO POLE (E.
  • Page 831 Current Flow Diagram Type 911 SC USA Model 81, Part I POWER SUPPLY, STARTER FUEL PUMP HEATER VENTILATOR IGNITION...
  • Page 832 GENERATOR SUPPLEMENTARY AIR VALVE ALARM SYSTEM FUEL PUMP HEATER VENTILATION IGNITION COIL...
  • Page 833 Current Flow Diagram Type 911 SC Model 81, Part II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER...
  • Page 834 Current Flow Diagram Type 911 SC USA, Model 81, Part II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER...
  • Page 835 Current Flow Diagram Type 911 SC USA Model 81, Part Ill REAR LIGHTS, BRAKE LIGHTS HORNS INTERIOR LIGHT REAR WINDOW DEFOGGER...
  • Page 836 Current Flow Diagram Type 911 SC USA, Model EAR LI G HT S , BRAKE LIGHTS+ H O RN S I N TERI O R L I G H T - + . SWITCH...
  • Page 837 Current Flow Diagram Type 911 SC USA Model 81, Part IV OUTSIDE MIRROR FRESH AIR BLOWER WINDSHIELD WIPER POWER WINDOWS...
  • Page 838 Current Flow Diagram Type 911 SC USA, Model 81, Part W FRESH AIR BLOWER...
  • Page 839 Current Flow Diagram Type 9 1 1 SC USA Model 81, Part V OXYGEN SENSOR SYSTEM INSTRUMENT, SENDER UNITS...
  • Page 841 Current Flow Diagram Type 911 SC USA Model 81, Part VI...
  • Page 843 Additional Current Flow Diagram Type 911 SC Cruise control (Tempostat) BRAKE LIGHT SWITCH RELAY TEMPOSTAT (CRUISE CONTROL), SWITCH...

  • Page 844: Fog Light

    Additional Current Flow Diaaram Type 911 SC Fog light LIGHT SWITCH ONLY CH, S, N FUSE 2...
  • Page 845 Additional Current Flow Diagram Type 911 SC REAR WINDOW DEFOGGER...
  • Page 846 Additional Current Flow Diagram Type 911 SC Air Condition AC FAN SWITCH . - . FAN MOTOR AC FUSE 1 1 FUSE...
  • Page 847 Current Flow Diagram Type 911 SC USA Model 82 PART I POWER SUPPLY, STARTER FUEL PUMP HEATER VENTlL4TOR IGNITION PART II HEADLIGHT, FRONT TURN SIGN AL, HAZARD FLASHER PART REAR LIGHT, BRAKE LIGHT HORNS INTERIOR LIGHT REAR WINDOW DEFOGGER PART IV OUTSIDE MIRROR FRESH AIR BLOWER CIGARETTE LIGHTER...
  • Page 848 Current Flow Diagram USA Model Type 911 SC CONTINUATION OF WlRE PART V WlRE CONNECTORS CURRENT TRACK 3) ONE POLE A - NEAR REGULATOR PANEL BEHIND HEADLIGHT LEFT C -BEHIND HEADLIGHT RIGHT NO ACTUAL WIRE, BUT INTERNAL CONNECTION RED: 16A. BLUE: 24A1 OR CONNECTION FUSE 11 1 6 A BETWEEN...
  • Page 849 Current Flow Diagram Type 911 SC USA Model 82, Part I POWER SUPPLY, STARTER FUEL PUMP HEATER VENTILATOR IGNITION...
  • Page 850 GENERATOR AND REGULATOR FOR COLD START VALVE AIR FLOW SENSOR FUEL PUMP HEATER VENTLATOR HEATER VENTIMTOR IGNITION COIL...
  • Page 851 Current Flow Diagram Type 911 SC USA Model 82, Part II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER...
  • Page 852 DIMMER HEADLIGHT FLASHER SWITCH FUSE 4 5 A PARKING LIGHT FUSE 3 5 A CONTACT FUSE LICENSE PLATE LIGHT ASHTRAY LIGHT...
  • Page 853 Current Flow Diagram Type 911 SC Model 82, Part Ill REAR LIGHTS, BRAKE LIGHTS INTERIOR LIGHT REAR WINDOW DEFOGGER...
  • Page 855 E l e c t r i c a l A c c e s s o r i e s When installing antenna make sure there is perfect ground contact between base of antenna and fender. Base ground to battery negative pole ohm.
  • Page 856 Current Row Diagram Type 911 SC USA, Model 82, Part IV FRESH AIR BLOWER...
  • Page 857 Current Flow Diagram Type 911 SC USA Model 82,Part V OXYGENSENSORSYSTEM INSTRUMENT. SENDER UNITS...
  • Page 858 Current Flow Diagram Type 911 SC USA, Model 82, Part V...
  • Page 859 Current Flow Diagram Type 911 SC Model Part VI OXYGEN SENSOR SYSTEM HEADLIGHT WASHER...
  • Page 860 Current Flow Diagram Type 911 SC USA, Model 82, Part VI OXS CONTROL UNIT HEADLIGHT WASHER SWITCH OXYGEN SENSOR...
  • Page 861 D e s c r i p t i o n o f R e l a y s a n d F u s e s L O C A T I O N OF RELAYS A N D F U S E S T H E V E H I C L E E F F E C T I V E W I T H 1 9 7 4 M O D E L S Beginning with 1974 models, the fuse box is...
  • Page 862 D e s c r i p t i o n o f R e l a y s a n d F u s e s Additional fuses and relays a r e located on the luggage compartment floor (left, as seen in direction of driving), as well as on the mounting plate in the engine compartment.
  • Page 863 T h e 1975 911 S and Carrera models have a modified relay plate. Relay plate Standard relay for 1-stage rear window defogger (deleted for 2-stage heater) Standard relay for heater blower Standard relay for warm-up regulator Control relay for 2-stage rear window defogger (deleted for 1-stage heater) Voltage regulator Capacitor discharge ignition control unit Radio (interference) suppressor...
  • Page 864 9 1 1 L O C A T I O N O F R E L A Y S A N 1 9 7 6 M O D E L Depending on the c a r ' s equipment, t h e relay carrier in t h e fuse box is fitted with up t o 5 relays.
  • Page 865 D e s c r i p t i o n L i g h t i n g S y s t e m H A Z A R D W A R N I N G F L A S H E R Beginning with 1 9 1 3 models, a l l T y p e 911 vehicles a r e equipped with a new hazard warning flasher.
  • Page 866 D e s c r i p t i o n o f A l t e r n a t o r A L T E R N A T O R 1 9 7 5 M O D E L S An 840 alternator ( s a m e s i z e as t h e 770 alternator used previously) is installed as o f t h e 1975 model...
  • Page 867 D e s c r i p t i o n I g n i t i o n I G N I T I O N S Y S T E M M O D I I : I ( I A l ' I O N S M O D E L S Distributor turns counterclockwise.
  • Page 868 D e s c r i p t i o n I g n i t i o n C h a n g e s is equipped with a disuibuLor havlng a double vacuum unir for ierard and advance ignition conrrol.
  • Page 869 S t a r t e r T e c h n i c a l D a t a S T A R T E R G e n e r a l I n f o r m a t i o n Beginning with 1972 models, starter power output is increased from 0 .
  • Page 870 D I S A S S E M B L I N G A N D A S S E M F L I N G S T A R T E R T O O L S Special T o o l Remarks Press black Press pipe...
  • Page 871 D i s a s s e m b l i n g a n d A s s e m b l i n g S t a r t e r...
  • Page 872 S t a r t e r Note when Special Description instructions removing installing Lock washer Retaining screw Position rubber block field frame Solenoid Pull pinion engage- Check solenoid current draw and free movement ward. of core. Seal, lubri- Seal. O-ring Replace if damaged.
  • Page 873 S t a r t e r Note when instructions Description removing installing Negative brush Check for cracks, Brushes must move dirt, and tight connection. place in sets only. Lift with wire Brush pressure ca. 800 hook. 900 grams (28-32 oz.). Check for proper sealing.
  • Page 874 I n s t r u c t i o n s f o r R e m o v a l a n d I n s t a l l a t i o n Beginning with 1974 models, Type 911 and 911 S vehicles are equipped with the 0.8 HP starter motor. The 1.5 HP starter, standard in the 2.7 liter Carrera vehicles, can be installed on special order.
  • Page 875 L i g h t i n g E q u i p m e n t S E A L E D B E A M I l E A D L I S l H ' l ' S R e p l a c i n g S e a l e d B e a m Unscrew retaining screw and remove l a m p rim.
  • Page 876 L i g h t i n g E q u i p m e n t F O G L A M P S A N D F O G T A I L L A M P S u b s e q u e n t I n s t a l l a t i o n Disconnect battery ground strap.
  • Page 877 L i g h t i n g E q u i p m e n t Install the outer and Inner fog lamp mounting plates. The plate with the larger bulge is mounted outside. together with the rubber gasket. Use two Allen-head, ivl 6 15 bolts with washers and lock washers on each lamp unit.
  • Page 878 L i g h t i n g E q u i p m e n t Vehicles manufactured t o U.S. specifications a r e furnished with t h e h o l e already made; it is covered with a plug. Remove plug from luggage compartment pan and install a grommet in its place, or else cut a h o l e in t h e plug.
  • Page 879 L i g h t i n g E q u i p m e n t The wires are connected to the switch as follows: grey wire to Terminal 58 A white/green wire is already installed in the vehicle; it is accessible through the loud- speaker cutout and can be found taped to the wire loom located ther-.
  • Page 880 L i g h t i n g E c l u i p m r n t Reconnect battery and check l a m p operation. lamps are switched on and t h e yellow control light glows with reduced brightness. When t h e knob is turned, t h e fog tail l a m p is switched on and t h e yellow control light glows with full intensity.
  • Page 881 W i n d s h i e l d W i p e r a n d W a s h e r S y s t e m A D J U S T M E N T I N S T R U C T I O N S Beginning with February 1972 and the below given chassis serial numbers, all type vehicles are equipped with madified windshield wiper arms:...
  • Page 882 W i n d s h i e l d W i p e r a n d w a s h e r S y s t e m P U M P W I N D S H I E L D WASHER R e m o v a l a n d I n s t a l l a t i o n The windshield washer pump in model vehicles...
  • Page 883 W i n d s h i e l d W i p e r a n d W a s h e r S y s t e m W A T E R RESERVOIR W I N D S H I E L D WASHER S Y S T E M R e m o v a l a n d I n s t a l l a t i o n T h e left front wheel must b e removed when removing the water reservoir.
  • Page 884 W i n d s h i e l d W i p e r s a n d W a s h e r I N T E R M I T T E N T W I N I I S H I E L D W I P E R S W I T C H R e m o v i n g a n d I n s t a l l i n g P o t e n t i o m e t e r R e m o v i n g a n d I n s t a l l i n g I n t e r m i t t e n t R e l a y...
  • Page 885 E m i s s i o n c o n t r o l s E x h a u s t g a s r e c i r c u l a t i o n c a n l r o l All 1975 models with California equipment have exhaust gas reciiculation (EGR) to reduce the pollution from exhaust gases.
  • Page 886 E m i s s i o n c o n t r o l s T h e EGK indicator l a m p comes o n when t h e igni- t i o n is turned a n and goes out when the e n g i n e !;tarts.
  • Page 887 REMOVING AND I N S T A L L I N G SPEEDOMETER CABLE N o t e The blower housing of California equipped cars has to be removed to be able to detach the speedometer cable at the EGR elapsed mileage odometer switch. Pull the speedometer out of the dashboard of all other models to detach the speedometer cable.
  • Page 888 S p e e d o m e t e r Remove cover a t hack of tunnel. Disconnect speedometer c a b l e beneath car a t transmission. of car. I n s t a l l i n g 1.
  • Page 889 E L E C T R O N I C S P E E D O M E T E R C h e c k i n g E l e c t r o n i c S p e e d o l n e t e r S e n s o r Remove tunnel cover in front o f emergency seats.
  • Page 890 I n s t r u m e n t s , C o n t r o l s R e m o v i n g a n d I n s t a l l i n g E l e c l r o n i c S p e e d o m e t e r S e n s o r 1.
  • Page 891 E l e c t r i c a l A c c e s s o r i e s S A F E T Y BELT WARNING S Y S T E M Beginning with January 1972, all USA export vehicles are equipped with the safety belt warning system required by law.
  • Page 892 E l e c t r i c a l ~ c c e s s o r i e s S E A T BELT WARNING S Y S T E M 1 9 7 4 MODELS The seat belt warning system has been changed effective with the models.
  • Page 893 An improved interlock relay for the seat belt warning system was introduced around the December 1973. With the introduction of this relay, the warning system only activated (engine running) if the seat belts are unfastened while the seats are occupied.
  • Page 894 E l e c t r i c A c c e s s o r i e s S E A T BELT W A R N I N G S Y S T E M F R O M FEBRUARY 14, 1975 All models have a modified seat belt warning system as of February 24, 1975.
  • Page 895 E l e c t r i c a l A c c e s s o r i e s C O N T R O L I L L U M I N A T I O N Beginning with t h e models t h e following controls a r e illuminated: Heater control lever on t h e center tunnel.
  • Page 896 E l e c t r i c a l E q u i p m e n t H E A D L I G H T WASHERS Deprersing the switch in the instrument panel operates the water pump, which bolted to the front hood lock panel.
  • Page 897 E l e c t r i c a l A c c e s s o r i e s S A F E T Y B E L T W A R N I N G S Y S T E M R e m o v i n g a n d I n s t a l l i n g S e a t (Also s e e Group A two- pole connector is located under the seat.
  • Page 898 E l e c t r i c a l A c c e s s o r i e s R e m o v i n g a n d I n s t a l l i n g S a f e t y B e l t B u c k l e (Also see Group 8) T h e front plastic cover of t h e buckle can b e re-...
  • Page 899 E l e c t r i c a l A c c e s s o r i e s When replacing the wedge-base bulb it is necessary to open the control lamp for access. When installing the lamp, make sure that the rubber gasket is properly seated.
  • Page 900 E l e c t r i c a l A c c e s s o r i e s R e m o v i n g a n d I n s t a l l i n g S e a t C o n - t a c t i n P a s s e n g e r S e a t Remove seat (see Group page...
  • Page 901 E l e c t r i c a l A c c e s s o r i e s R e m o v i n g a n d I n s t a l l i n g S a f e t y B e l t L o c k i n t h e S p o r t S e a t Remove both countersunk screws and take the plastic cover off.
  • Page 902 E l e c t r i c a l A c c e s s o r i e s S A F E T Y BELT W A R N I N G S Y S T E M 1 9 7 4 MODELS R e m o v i n g a n d I n s t a l l i n g L o g i c R e l a y S w i t c h The logic relay switch rests in a socket which is...
  • Page 903 9 1 1 E l e c t r i c a l E q u i p m e n t S E A T BELT I N T E R L O C K S Y S T E M R e m o v i n g a n d I n s t a l l i n g T i m e R e l a y R e m o v i n g a n d I n s t a l l i n g S e a t B e l t / B r a k e W a r n i n g S y s t e m I n d i c a t o r H o u s i n g...
  • Page 904 E l e c t r i c a l A c c e s s o r i e s S A F E T Y BELT WARNING S Y S T E M 1 9 7 4 MODELS T r o u b l e s h o o t i n g S a f e t y B e l t W a r n i n g S y s t e m If the starter does not work despite properly attached...
  • Page 905 9 1 1 E l e c t r i c a l A c c e s s o r i e s C O N T R O L I L L U M I N A T I O N L e v e r A square, illuminated plaque showing the function of the heater control lever is located...
  • Page 906 E l e c t r i c a l A c c e s s o r i e s The control l a m p located in the hazard warning switch is connected to the light switch through a 150 Ohm resistor.
  • Page 907 E l e c t r i c a l E q u i p m e n t H E A D L I G H T W A S H E R S R e m o v i n g a n d I n s t a l l i n g S p r a y J e t s Remove turn signal housing from bumper.
  • Page 908 E l e c t r i c a l E q u i p m e n t R e m o v i n g a n d I n s t a l l i n g S w i t c h Disconnect battery.
  • Page 909 H e a d l i g h t c l e a n e r A d j u s t i n g s p e z i f i c a t i o n s Use a locally manufactured tool t o aim spray jets.
  • Page 910 E l e c t r i c A c c e s s o r i e s S e r v i c e I n s t a l l a t i o n o f H e a d l i g h t W a s h e r s b e g i n n i n g w i t h 1 9 7 4 M o d e l s Mark and drill nozzle mounting holes in bumper.
  • Page 911 E l e c t r i c A c c e s s o r i e s 4. Remove present fluid container and install new container. 5. Drill two holes on e a c h side of water pump bracket and bolt or rivet holder to lock panel.
  • Page 912 E l e c t r i c A c c e s s o r i e s Install water feed hose on intake neck and molded hose pressure adaptor af pump with hose clamps.Use longer molded hose models with air conditioners and shorten water feed hose to length about...
  • Page 913 E l e c t r i c ~ c c e s s o r i e s 9. Secure nozzles and rubber grommets to bumper with spring locks, connect them to pressure control valves and install bumper. 10. Disconnect hose at center connection of adaptor and connect it to center connection of valve adaptor.
  • Page 914 Secure relay t o l a c k panel with sheet m e t a l screw. Disconnect battery ground cable. Connect wires t o relay and water pump. Connect brown wire l o body ground. Place Install a n extra 3-position fusebox so that t h e b ~ a s s rails on t h e back f a c e upward.
  • Page 915 A U T O M A T I C H E A T I N G C O N T R O I R e m o v i n g a n d I n s t a l l i n g C o n t r o l U n i t Pry both side covers off of control unit.
  • Page 916 E l e c t r i c a l E q u i p m e n t R e m o v i n g a n d I n s t a l l i n g H e a t S e n s o r i n H e a t e r F l a p M o u s i n g 2- pole m a l e plug.
  • Page 917 E l e c t r i c a l E q u i p m e n t Install adapter. Make sure thar the heater flaps are adjusted evenly on both sides. Secure plug housing to cable. The black wire must be located on the side of the housing with a tab.
  • Page 918 E l e c t r i c a l E q u i p m e n t D i s a s s e m b l i n g a n d A s s e m b l i n g C o n t r o l U n i t...
  • Page 919 E l e c t r i c a l A c c e s s o r i e s Special Note When Removing Screw Washer Ball socket see page 6 . 5 Push in complereiy Bulb holder Bulb...
  • Page 920 E l e c t r i c a l A c c e s s o r i e s c l a m p a t ball socket with a screwdriver. When replacing ball sockets adjusr t o 124...
  • Page 921 E l e c t r i c a l E q u i p m e n t T R O U B L E S H O O T I N G A U T O M A T I C H E A T I N G C O N T R O L S C h e c k i n g H e a t S e n s o r i n H e a t e r C h e c k i n g I n t e r i o r S e n s o r F l a p H o u s i n g...
  • Page 922 C h e c k i n g P o w e r S u p p l y t o C o n t r o l U n i t 1. Remove right side cover of control unit. 2 .
  • Page 923 A U T O M A T I C S P E E D C O N T R O L R e m o v i n g a n d I n s t a l l i n g R e g u l a t o r R e m o v i n g a n d I n s t a l l i n g E n g a g e m e n t S w i t c h Remove cover in luggage compartment.
  • Page 924 E l e c t r i c a l E q u i p m e n t R e m o v i n g a n d I n s t a l l i n g C l u t c h R e m o v i n g a n d I n s t a l l i n g S e r v o P e d a l S w i t c h 1.
  • Page 925 9 1 1 E l e c t r i c a l E q u i p m e n t 4. Unscrew holder on throttle lever. R e m o v i n g a n d I n s t a l l i n g C a b l e Detach cable at throttle.
  • Page 926 E l e c t r i c A c c e s s o r i e s T r o u b l e s h o o t i n g A u t o m a t i c S p e e d C o n t r o l 1.
  • Page 927 E l e c t r i c a l A c c e s s o r i e s R E M O V I N G A N D I N S T A L L I N G A U T O M A T I C A N T E N N A 1 .
  • Page 928 E l e c t r i c a l A c c e s s o r i e s When installing antenna make sure there is perfect ground contact between base of antenna and fender. Base ground t o battery negative pole ohm.
  • Page 929 9 1 1 E l e c t r i c a l A c c e s s o r i e s 9 1 1 ALARM S Y S T E M F u n c t i o n The alarm system is switched on and off with a The alarm will be set off by opening the driver's separate key.
  • Page 930 E l e c t r i c a l A c c e s s o r i e s R e m o v i n g a n d I n s t a l l i n g A l a r m S w i t c h R e m o v i n g a n d I n s t a l l i n g A l a r m C o n t r o l U n i t 1.
  • Page 931 E l e c t r i c a l A c c e s s o r i e s R e m o v i n g a n d I n s t a l l i n g A l a r m H o r n T r o u b l e s h o o t i n g A l a r m S y s t e m Unscrew bottom guard on front axle.
  • Page 932 E l e c t r i c a l A c c e s s o r i e s C h e c k i n g L i n e s a n d C o n n e c t i o n s Remove alarm control unit.
  • Page 933 9 1 1 E l e c t r i c a l A c c e s s o r i e s C h e c k i n g F u n c t i o n o f C o n t r o l U n i t trunk light contact switch by hand.
  • Page 934 E l e c t r i c a l A c c e s s o r i e s 3. Set off alarm by opening a door. Leave system turned on and close door again. The alarm must last about 30 seconds.
  • Page 935 B a t t e r y BATTERY 1 9 7 4 M O D E L S R e m o v a l a n d I n s t a l l a t i o n Beginning with 1974 models, all vehicles are furnished with only one battery.
  • Page 936 B a t t e r y Special Note When: Description Instructions Removing Installing Socket head bolt Washer A 8.4 Bracket Rubber washer 5.5 x To install battery place bolt head in angled driver and holder.
  • Page 937 I g n i t i o n s y s t e m SPARK PLUGS Beginning with the 1972 models, the following spark plugs can be used in the 2.4 liter engines: Vehicle Type Spark Plug Type Electrode Gap BOSCH 235 P 21 BERU 235/14/3 P...
  • Page 938 0.55 mm Coat spark plug threads with a molybdenum paste (MoS2), such as MOLYKOTE HTP WHITE, prior to installation. Torque spark plugs to 2.5 3.0 mkp (24.5 29.4 Nm). N O T E Use only spark plugs approved by PORSCHE.
  • Page 939 I g n i t i o n S P A R K P L U G S Spark plugs 1976 Model Spark Plug Electrode Gap 0.55 mm/0.022 in. 911 S Bosch 235 P 21 0.55 mm/0.022 in. Beru 295/14/3P Spark plugs Model Spark Plug...
  • Page 940 I g n i t i o n S y s t e m E q u i p m e n t T a b l e s 1 9 8 0 M o d e l Ignition Transformer Version Remarks 9 1 1 SC...
  • Page 941 I g n i t i o n S y s t e m Control Unit Version Remarks 9 1 1 SC 930.602.702.0 Capacitor discharge ignition Bosch No. (CDI), breakerless...
  • Page 942 I g n i t i o n S y s t e m I G N I T I O N L E A D S Beginning with 1972 models, ignition lead lengths are as follows: From distributor to: Cylinder 1 330 m m (13 in.) 390 m m (15-11/32 in.)
  • Page 943 9 1 1 I g n i t i o n S y s t e m A D J U S T I N G A N D C H E C K I N G D I S T R I B U T O R A d j u s t i n g I g n i t i o n B r e a k e r P o i n t s 1.
  • Page 944 I g n i t i o n S y s t e m C h a n g i n g B r e a k e r P o i n t s 1. Remove distributor cap. rotor, and dust Remove slotted screws and disconnect wire from Terminal 1.
  • Page 945 I g n i t i o n S y s t e m A d j u s t i n g I g n i t i o n ( A l l 2 . 4 a n d 2 . 1 l i t e r e n g i n e s , e x c e p t 2 .
  • Page 946 I g n i t i o n s y s t e m A d j u s t i n g I g n i t i o n ( 2 . 7 l i t e r e n g i n e s ) The dwell angle must be checked, and corrected if necessary, prior to adjusting the ignition timing.
  • Page 947 I g n i t i o n s y s t e m C h e c k i n g T i m i n g A d v a n c e C u r v e Remove vacuum hose and compare advance curve with chart below at 1000 1500...
  • Page 948 I g n i t i o n S y s t e m C h e c k i n g D i s t r i b u t o r A d v a n c e C u r v e o n T e s t S t a n d The advance curves may b e checked only on a test stand equipped with CDS hookup.
  • Page 949 9 1 1 I g n i t i o n S y s t e m N o t e C o n t a c t B o u n c e The vacuum hose must be disconnected and speed reduction avoided during this test.
  • Page 950 I g n i t i o n s y s t e m V a c u u m 1. Connect vacuum line of test stand to distributor vacuum chamber. 2. Set speed t o 300 rpm and do not change during the test.
  • Page 951 I g n i t i o n S y s t e m S p e e d L i m i t e r D w e l l A n g l e 1. Mount c a p on distributor and connect accord- 1.
  • Page 952 I g n i t i o n S y s t e m I g n i t i o n A d v a n c e C u r v e s f o r 2 . 7 L i t e r C a r r e r a E n g i n e Testing is accomplished in s a m e m a n n e r as t h a t for distributors in 2.
  • Page 953 I g n i t i o n S y s t e m The mechanical advance curve g a p h applies to a distributor mounted in the test stand. Degrees Advance (BTC) Distributor Shaft Speed 950 rpm 1140 1380 rpm 1350 1930 rpm...
  • Page 954 I g n i t i o n s y s t e m Testing of vacuum advance is accomplished on the distributor test stand. Vacuum Advance (ATC) Vacuum 65 Tort 78 Torr The advance point must b e between 4.3' when vacuum is Torr.
  • Page 955 I g n i t i o n s y s t e m A D J U S T I N G I G N I T I O N T I M I N G ( T y p e 9 1 1 C a l i f o r n i a V e r s i o n U S A V e r s i o n Adjust t o 0 - 2...
  • Page 956 I g n i t i o n S y s t e m V A C U U M A D V A N C E C U R V E T Y P E 9 1 1 F R O M M O D E L 7 7 ( C A L I F O R N I A...
  • Page 957 I g n i t i o n S y s t e m C E N T R I F U G A L A D V A N C E C U R V E T Y P E 9 1 1 S C M O D E L 7 8 1000 1500...
  • Page 958 I g n i t i o n S y s t e m A d j u s t i n g I g n i t i o n T i m i n g a s f r o m 1 9 7 8 M o d e l s A d j u s t i n g v a l u e : T o measure engine speed, use a tester with an inductive speed recorder (clips).
  • Page 959 A d j u s t i n g l g n i r i o n T i m i n g - l 1 I 8 0 M o d e l s engine t o operating temperature (oil 3.
  • Page 960 I g n i t i o n S y s t e m C h e c k i n g I g n i t i o n R e t a r d / A d v a n c e 1 9 8 0 ~ o d e l s C h e c k i n g V a c u u m A d v a n c e Ignition timing adjusted t o specifications.
  • Page 961 I g n i t i o n s y s t e m C E N T R I F U G A L A D V A N C E C U R V E T Y P E 9 1 1 S C M O D E L 1 9 8 0 V A C U U M A D V A N C E C U R V E T Y P E 9 1 1 S C M O D E L 1 9 8 0...
  • Page 962 I g n i t i o n A d j u s t i n g I g n i t i o n T i m i n g f r o m 1 9 8 1 . M o d e l s engine warm (oil temperature about 90 C).
  • Page 963 I g n i t i o n C h e c k i n g I g n i t i o n T i m i n g C o n t r o l f r o m 1 9 8 1 M o d e l s Requirements: Ignition timing adjusted to specifications.
  • Page 964 9 1 1 I g n i t i o n C E N T R I F U G A L A D V A N C E C U R V E T Y P E 9 1 1 SC f r o m 1 9 8 1 M o d e l s BTDC 1000...
  • Page 965 Wartungsarbeiten, Technische Daten Maintenance, Specifications Travaux d'entretien, Caracteristiques techniques Lavori di manutenzione, dati tecnici...
  • Page 966 9 1 1 C O N T E N T S INFORMATION I n f o r m a t i o n TECHNICAL DATA Specifications Engine Fuel System Electrical System Transmission and Final Drive Chassis Capacities Dimensions Weights Performance Data Specification Changes, from 1973 model Carrera Specifications...
  • Page 967 T Y P E 9 1 1 S P E C I T I C A T I O N S BEGINNING W I T H 1 9 7 2 MODELS MOTOR 911 T 911 S four-stroke gasoline engine with two opposing cylinder banks Number of cylinders horizontal, three cylinders per bank Cylinder arrangement...
  • Page 968 Cut off speed of ignition 6500 100 rpm distributor speed limiter 7100 100 rpm 7300 100 rprn Fuel coctane requirement Engine weight approx 183 kp (404 lbs) approx. 182 kp (402 lbs) approx 182 kp (402 lbs) Nominal fuel comsumption 9.0 ltr/100 km 26.1 mpg 10.2 ltr/100 km 23.0 mpg Cooling system...
  • Page 969 Oil consumption 2 ltr/100 km 1 / 2 2 US Crankcase two-piece pressure casting of two-piece pressure casting of two-piece pressure casting of Crankshaft forged, surface-hardened forged. surface-hardened forged, surface-hardened Crankshaft bearings eight, plain journal eight, plain journal eight, plain journal Main bearings 1-7 split shell, tri-metal inserts split shell, tri-metal inserts...
  • Page 970 individual, grey -cast iron with individual, grey-cast iron sleeve with individual, grey-cast iron sleeve with C y l i n d e r s integral cooling fins finned light alloy jacket finned light alloy jacket C y l i n d e r h e a d s light alloy, finned individual castings light alloy, finned individual castings light alloy (Y -alloy) finned individual...
  • Page 971 Valve timing with 1 mm (0.039 in.) valve clearance inlet opens inlet closes exhaust opens exhaust closes Intake valve lift at overlap TC with m m (0.004 in.) valve clearance 2.7 mm (0.091 0.106 in.) 3 . 1 mm (0.106 0.122 in.) 5.4 mm (0.197 Valve clearance, cold,...
  • Page 972 1 electric roll-cell pump 1 electric roll-cell pump 1 electric roll-cell pump rransfer rate 125 ltr/h (128 qts/h) 125 ltr/h (128 qtsjh) 125 ltr/h (128 qts/h) /cm 2 (14.2 psi) /cm 2 (14.2 psi) 1 kp/cm (14.2 psi) /cm 2 (28.4 psi) approx approx.
  • Page 973 Spark plugs BOSCH W 235 P 21 BOSCH W 265 P 21 BOSCH W 265 P 21 (either kind) or similar BERU 265/14/3 P or similar BERU 265/14/3 P or similar 0.6 mm Electrode gap 0.6 mm Starter BOSCH 12 V, 1.5 HP BOSCH 12 V, 1.5 HP BOSCH 12 V, 1.5 HP B u l b L i s t ( 1 2 V)
  • Page 974 B u l b L i s t 911 S Sealed beam headlamps Fog lamps Front turn signal/parking lamps Rear turn signal Backup lamp Sidemarker lamp Interior lamp, luggage compartment lamp, glove compartment lamp License plate lamp Instrument lamps, control lamps, ashtray lamp Control lamp for ventilator and auxiliary heater...
  • Page 975 Transmission forward speeds, one reverse, forward speeds, one reverse, with Porsche synchronization with Porsche synchronization with Porsche synchronization (5 speeds optional) (5 speeds optional) (5 speeds optional)
  • Page 976 Gear ratio, reverse speed 3.325 3.325 Gear shift system shift linkage with floor mounted shift linkage with floor mounted shift linkage with floor mounted gearshift lever gearshift lever gearshift lever Rear axle drive spiral bevel gears, differential unit spiral bevel gears, differential unit spiral bevel gears, differential unit Rear axle ratio 7/31, 4.429...
  • Page 977 Tow-start speed ,in 35 kmh (21 mph) 35 krnh (21 mph) 35 kmh mph) St allspeed approx. 2500 2700 rpm approx. 2500 2700 rpm approx. 2900 3100 rpm Clutch speed approx. 3000 rpm approx. 3000 rpm approx. 3000 rpm C H A S S I S Body characteristics welded assembly, sheet metal box welded assembly, sheet metal box...
  • Page 978 double-action hydraulic double-action hydraulic front double-action hydraulic Shockabsorbers shockabsorber strub shockabsorber strub shockabsorber strub rear double-action hydraulic double-action hydraulic double-action hydraulic shockabsorber shockabsorber shockabsorber transverse, 15 mm Stabilizers rack-steering ZF rack-steering ZF rack-steering ZF Steering Mean steering ratio Steering wheel turns, lock-to-lock approx.
  • Page 979 15, optional 6J x 1 5 Wheels steel, 5 1/2J steel, 6J 15 or optional light 1 5 light-alloy steel or light alloy alloy Tires Tire pressures (cold) front 2.0 atrn (29 psi) 2.0 atrn (29 psi) 2.0 atrn (29 psi) rear 2 .
  • Page 980 Door opening angle approx. 70' approx. 70° approx. 70' W i n d o w s Windshield one-piece, constant radius, convex one-piece, constant radius, convex one-piece, constant radius, convex contour, laminated safety glass contour, laminated safety glass contour, laminated safety glass Door windo'ws crankdown windows crankdown windows...
  • Page 981 Ventilation flap-controlled fresh air chamber, flap-controlled fresh air chamber, flap-controlled fresh air chamber, 3-speed fan, air distributor system, 3-speed fan, air distributor system, 3-speed fan, air distributor system, centralized control unit centralized control unit centralized control unit C A P A C I T I E S Engine approx.
  • Page 982 4163 mm (163.9 in.) 4163 mm (163.9 in.) 4163 mm (163.9 in.) Length, USA and Canada only 1610 mm (63.39 in.) 1610 mm (63.39 in.) 1610 mm (63.39 in.) Width 1320 mm (51.93 in.) 1320 mm (51.97 in.) 1320 mm (51.97 in.) Height (unladen) 150 mm (5.91 in.) 150 mm (5.91 in.)
  • Page 983 ANCE DATA 220 kmh 230 kmh Max. speed (with 4 or 5 208 kmh 137 mph speed transmission) 129 mph,, 143 mph with Sportomatic transmission ca. 5 kmh (3 mph) slower than shown above 1 km with standing start at DIN empty weight 28.5 sec 27.5 sec...
  • Page 985 S p e c i f i c a t i o n s CARRERA 2 . 7 S P E C I T I C A T I O N S Shown below are specifications which differ from Type 911 S/2.4 E N G I N E T O U R I N G S P O R T...
  • Page 986 S p e c i f i c a t i o n s T O U R I N G S P O R T E L E C T R I C A L S Y S T E M Operating voltage Battery capacity Ignition distributor...
  • Page 987 S p e c i f i c a t i o n s T O U R I N G S P O R T D I M E N S I O N S WHEN E M P T Y PER DIN Track, front Track, rear, with 7 mm...
  • Page 988 9 1 1 S p e c i f i c a t i o n s S P E C I F I C A T I O N S FOR 1 9 7 4 MODELS C a r r e r a FILLING C A P A C I T I E S approx 1 1 Itr...
  • Page 989 C a r r e r a same as 911 same as 911 Empty weight, per same as 911 same as 911 with Sportomatic transmission same as 911 Max. permissible weight same as 911 Permissible axle load, front same as 911 same as 911 same as 911 rear...
  • Page 990 T e c h n i c a l D a t a T E C H N I C A L D A T A 1 9 7 5 MODELS C a r r e r a C A P A C I T I E S Engine (initial filling) Approx.
  • Page 991 T e c h n i c a l D a t a C a r r e r a W E I G H T S same as 911 S Curb weight according to DIN 1160 kg (2552 lb) 1160 kg (2552 Ib) same as 911 S with sportomatic transmission...
  • Page 992 T e c h n i c a l D a t a T E C H N I C A L D A T A C a p a c i t i e s Engine (initial filling) approx. 13 ltr. (13. 75 US qt) of brand name HD oil per API Classifications (measured with oil dipstick per operating instructions)
  • Page 993 W e i g h t Curb woight per DIN Max. total weight kg /lb Max. axle load, front rear Max. roof load *(only coupe) P e r f o r m a n c e above 220/136.7 Max. speed (with 5 speed transm. With Sporiomatic Acceleration 0 100 k m / h a t...
  • Page 994 T e c h n i c a l D a t a T E C H N I C A L D A T A C a p a c i t i e s Engine (initial filling) approx. ' 1 3 Itr. /13.75 US qt of brand name HD per API Classification (measured with oil dipstick per operating SD or SE;...
  • Page 995 T e c h n i c a l D a t a W e i g h t Curb weight per DIN Max. total weight Max. axle load, front rear Max. roof load ?only coupe) P e r f o r m a n c e Max.
  • Page 996 9 1 1 T e c h n i c a l D a t a T E C H N I C A L D A T A 1 9 8 0 M o d e l s C a p a c i t i e s approx.
  • Page 997 T e c h n i c a l D a t a W e i g h t Curb weight per DIN Max. total weight Max. axle load, front rear Max. roof load*(only coupe) P e r f o r m a n c e Max.
  • Page 998 T e c h n i c a l D a t a T E C H N I C A L D A T A 1 9 8 1 M o d e l s C a p a c i t i e s Engine (new filling) approx.
  • Page 999 9 1 1 T e c h n i c a l D a t a W e i g h t Curbweight acc. DIN Max. total weight Max. axle load, front rear Max. roof load (only coupe) P e r f o r m a n c e Max.
  • Page 1000 Maintenance S e r v i c e S c h e d u l e , T y p e 9 1 1 T , 9 1 1 a n d 9 1 1 S ( b e g i n n i n g w i t h 1 9 7 2 m o d e l s ) then at and every Maintenance required...
  • Page 1001 L u b r i c a t i o n S c h e d u l e f o r T y p e 9 1 1 T , 9 1 1 a n d 9 1 1 S ( b e g i n n i n g w i t h 1 9 7 2 m o d e l s ) then at and every Service required 1000 miles...
  • Page 1002 I. Required Maintenance for the Emission Control System at 1,000 miles Maintenance service required and every 20,000 miles Valves (check rocker arm shafts for tightness *) Check-!- adjust Adjust V-belt Check Manifold mounting b d t s Change Engine oil Change Replace Oil filter...
  • Page 1003 Maintenance service required then at and every 10,000 miles at 1,000 miles Change Transmission oil Change Door and hood hinges and locks Lubricate Check+ adjust Front wheel bearing play Steering gear and tie rod-connections and rubber boots Check for tightness and leaks Clutch pedal free play Adjust Check...
  • Page 1004 Required Maintenance for the Emission Control System then at and every additional at and at 1,000 miles Maintenance service required 15 000 miles every 30 000 miles Change Engine oil Change Clean Magnetic drain plugs Clean Replace Engine oil filter Replace Adjust or replace check tension and condition...
  • Page 1005 then at and every at 1,000 miles Maintenance service required 15 000 miles ..Door hinges and locks Lubricate Accelerator linkage Lubricate Door and Targa top weatherstrips: Remove rubber residue from contacting areas and coat with talc Maintain or other suitable rubber lubricant Change...

This manual is also suitable for:

1975 9111973 9111977 9111978 9111976 9111979 911 ... Show all

Table of Contents