Download
Share
Print this page
Porsche 912E 76 Service Information
  1. Manuals
  2. Brands
  3. Porsche Manuals
  4. Automobile
  5. 912E 76
  6. Service information

Porsche 912E 76 Service Information

Hide thumbs

Advertisement

Quick Links

Download this manual

Advertisement

loading

Related Manuals for Porsche 912E 76

Summary of Contents for Porsche 912E 76

  • Page 3 Porsche 912 E is equipped with Itr., cylinder engine (similar to that in the Type This motor has been fitted with the electronically controlled AFC fuel injection thermal reactors and exhaust gas recirculation techn ica spec ifica ions as follows:...
  • Page 4 · . a 5 speed transmission (based on transmission type 915) with modified transmission ratio and a newly designed clutch operation mechanism. · .. a like the 911, a dual-circuit brake system, disks brakes without "inner ventilation" · bodywork similar to the 911 but with permanently fixed rear side windows well as other minor changes.
  • Page 5 ENGINE CRANK CASE, CYLINDERS, ENGINE MOUNTS crank case and cylinders are the same as in the engine type 914/2 .0 Itr. following is new engine mount. It consists of a swung steel bar which is secured to the motor in the same way as in the 914. mounting points the chassis were moved...
  • Page 6 CRANK SHAFT DRIVE/PISTONS All parts of the crank shaft drive are th same as in the basic motor. An additional fan-belt pulley is fitted to drive the secondary air pump secured to the front of the air intake housing by means of a three-armed block and is driven by means of a shaft from the center of the cooling fan COOLI...
  • Page 7 FUEL SUPPL V The 912 fitted with 80 Itr. (inc!. 8 Itr. reserve) fuel tank. The f uel pump mounted the front ax le aux iary mount. filter the same as in the CIS injection It is secured to the left-h wheel well in the engine compart...
  • Page 8 ELECTRONIC FUEL INJECTION - AFC Porsche equipped with a motor that has a air flow controlled electronic fuel injection Before we describe this unit detail, a few words about the accelerator cable. accel tor cable is in two parts. The connector (arrow) is located within the engine compart­...
  • Page 9 ELECTRONIC FUEL INJECTION - AFC Description Intake-Air Sensor The intake-air sensor is located in the engine compartment at the right-hand side between the air filter and the throttle housing (L) Construction Aluminum housing (A) with Bye-pass channel (5) and Adjustment screw (6) Air sensor flap (1) with Back pressure valve (8) and Damping vane (2)
  • Page 10 ELECTRONIC FUEL INJECTION - AFC Throttle Switch is switch provides the control unit with necessary information for mixture enrichment and full load cond itions. It is not necessary to adjust this switch Problem condition: engine power Troubleshooting: Disconnect the wires from the switch and connect an ohm meter between contacts 3 18.
  • Page 11 ELECTRONIC FUEL INJECTION - AFC Temperature Sensor I temperature sensor I is located the intake air sensor housing and permanentely installed. replaced separately. Its function is measure the temperature of intake air and provide the control unit with appropriate information. Troubleshooting: Simi the intake-air...
  • Page 12 ELECTRONIC FUEL INJECTION - AFC Contro Unit The control unit is located in the engine compartment within a cavity welded to the right-hand wheel well. The contro unit processes information concerning owing: Volume of intake air Temperat ure of intake air Motor rpm Motor temperatu...
  • Page 13 ELECTRONIC FUEL INJECTION - AFC Fuel Injector volume of injected fuel is determined by the length time the injector is open e. the time of the impulse from the control unit). injector connected via the resistor (R). (The contro signal from the control unit is...
  • Page 14 ELECTRONIC FUEL INJECTION - AFC Auxiliary Air Regulator The engine requires during the warm-up phase a richer mixture. The increased volume is determined by the control unit (signal from temperature sensor II). The additional volume of air required for this purpose is regulated by the auxiliary air regulator and detoured around the throttle valve into the intake air distributor.
  • Page 15 ELECTRONIC FUEL INJECTION - AFC Cold Starting Valve ld starting valve located in intake air distributor and is activated a thermo time switch which is located adjacent to the intake air distributor. Troubleshooting: Thermo switch: Engine temperature under 10°C/ 50°F. Remove the plug from cold start...
  • Page 16 CIRCUIT DIAGRAM FOR THE AFC INJECTION Multipole plug Ignition coil Throttle switch 4 Intake-air Sensor Temperature sensor II 6 Cold start valve 7 Thermo me switch Fuel pump 9 Ground connection (Gnd) 10 Double relay 11 Auxiliary air regulator 12 Series resistor 13 Battery 14 Fuel injector cyl.

  • Page 17: Exhaust System

    EXHAUST SYSTEM The 912 E engines are equipped with a secondary air injection, thermal reactors and EGR. The muffler and heat exchangers are also new. The secondary air injection and the thermal reactors are designed to reduce the CO and HC emission in the exhaust.
  • Page 18 EXHAUST SYSTEM Thermal Reactor The thermal reactor mainly consists of two cylinders, one inside the other, (1) and (2). Cylinder 2, which is the combustion chamber, provided with exactly defined holes (5). The outside wall is covered with an insulating material. -6­...
  • Page 19 EXHAUST SYSTEM Exhaust Gas Recirculation (EGR) Exhaust gas rec ircul at designed red uce nitri c oxide emission particul ar load range of the engine. Construct ion: dev ice co nsists diaphragm contro va lve (A), exhaust gas (8) with filte (C) and a vac...
  • Page 20 IGNITION SYSTEM E motor is fitted with a battery ignition system. Due to the installation of the secondary air injection pump, the observation hole for the timing marker no longer accessible. The TDC marker (previously on the fan wheel) is now located on the fan-belt pully (arrow).

  • Page 21: Technical Specifications

    TECHNICAL SPECIFICATIONS Engine Number of cylinders 94/3.70 Bore mm/in Stroke capacity (actual) mm/in 71/2.80 /cu .in 19711120.3 Compression ratio Maximum horse power rating 70020 according to DI N HP/kW 90/66 Net power SAE J HP/kW 86/64 developed at 4900 141137 imum torqu Kpm/Nm 70020...
  • Page 22 TRANSMISSION The 5 speed transmission 923/02 is a development of the transmission type 915/44 (5 speed trans­ mission the 911) and differs from it the following points Clutch operation 2. Main shaft sp lines Ring gear pinion ratio 4th. gear ratio...
  • Page 23 CLUTCH/CLUTCH OPERATION Clutch pressure plate and disk. pressed clutch is a single dry plate clutch of design. clutch disk has 24 splines, unlike the 911 which has (SAE arrangement) spli nes. M 215 Description pressure plate: 215GUD Descr iption clutch disk: 4903 ­...
  • Page 24 CLUTCH/CLUTCH OPERATION Clutch lever and cable In order to obtai n a reverse movement from the one on the 911 model, the lever was moved in direction of the transmission housing The clutch cable 2080 1.5 mm long and has diameter of 3.0 mm.
  • Page 25 CLUTCH/CLUTCH OPERATION Adjustment of the lever and fork The lever and the fork must be correctly located in order to assure correct operation dimensions are as follows From t he mating surface on the transmission housing the lever is 71 mm Without altering 71 mm...
  • Page 26 Cl.UTCH/CLUTCH OPERATION Throw out bearing and guide Throw out bearing The bearing is maintenance free and must not be dismantled. The guide sleeve for the throw out bearing is bolted to the transmission housing. The main shaft oil seal is held within the guide sleeve (for ease of replacement of The space between transmission housing and guide sleeve is sealed by an O-ring.
  • Page 27 SHIFT MECHANISM/HOUSING Transmission Mounts Attached the transmission mount is a dampening material to reduce engine and transmission vibrations noise. SHAFTS/GEARS Main Shaft The main shaft also provided with splines. Gear-pair for 4th and 5th gear As previously mentioned, the transmission ratio for the gear...
  • Page 28 SHAFTS/GEARS Ring gear and pinion The ratio of ring gear and pinion is also different in the 923/02 923/02 4.4285 915/44 3.8750 Speedometer Drive The Type 912 E vehicles are equipped with an electronically controlled speedometer. Impulses from a magnetic disk which is mounted on the differential housing activate a reed relay. From there the impulses are fed to the speedometer.

  • Page 29: Specifications

    Single dry disk clutch M 215 K Sph Pressure plate 4903 - 5492 (500 - 560) Pressure N (kp) Clutch disk 5 speed manual transmission Porsche - synchro-Iock transmission Transmission Type 923/02 Ratio: 1st gear 11/35 i=3.1818 18/33 i = 1.8333 2nd gear 23/29 i = 1.2609...
  • Page 30 SUSPENSION/BRAKES The suspension and brake system in the 912 E is the same as in the 911 models except for a few minor details. Front axle independently suspended wheels on A-arms and struts, one torsion bar for each wheel. Rack and pinion steering with safety column Safety steering wheel with padd :ng,...
  • Page 31 FRONT SUSPENSION REAR SUSPENSION Vehicle alignment specifications The following specifications are valid for empty weight according to DIN 70020 (i. e. Vehicle including full fuel tank, spare wheel and tool kit). Front axle Hight alignment Center of wheel to center line of torsion bar 99 mm ±...
  • Page 32 FRONT SUSPENSION REAR SUSPENSION As previously mentioned, the front and rear suspension is identical to the Type 911 Shock absorbers - rear Either one of two types of shock absorbers, 80ge or Woodhead are used in production. Shock absorber color code 80ge black, with yellow test band Woodhead...
  • Page 33 BRAKES Hydraulic system/Brake failure warning device/ Hand brak warning light the 911, the master brake cyl inder is fitted with a brake fai lure warn ing device In the event of failure one of the brake circuits a warning lamp "BRAKE" is illuminated the dash-board.
  • Page 34 BRAKES Brake disks and calipers The 912 E is fitted with brake disks without ventilation on both front and rear axles. (Refer to technical specifications for dimensions and minimum brake pad thicknesses). 76, a type Commencing with Mod brake caliper is installed on the front axle on all vehicles including 911 Brake pads Front...

  • Page 35: Technical Specifications

    TECHNICAL SPECIFICATIONS Front suspension - steering Wheel suspension Independently suspended wheels on A-arms and struts, one torsion bar for each wheel Torsion bar diameter 18.8 mm/0.74 in Stab i Iizer dia. 16 mm/0.63 in. Shock absorber Double acting hydraulic shock absorber Manufacturer Boge/color coded black with yellow test band...
  • Page 36 BRAKE SYSTEM TECHNICAL SPECIFICATIONS Foot brake Hydraulic, dual circuit disk brakes with brake failure warn ing light Tandem master cylinder Bore diameter 19.05 mm/0.75 Stroke 18113 mm/0.7110.51 in ·Ratio at footbrake peddal Free travel movement-rod/piston 1 mm/0.39 in. Front wheel brakes Brake disk O-dia.
  • Page 37 TECHNICAL SPECIFICATIONS Over-all dimensions Length mm/in. 4291/168.94 Width mm/in. 16101 63.39 Hight mm/in. 13401 52 .76 Wheel base mm/in. 2271/ 89.41 Track width front mm/in. 13601 53 .54 Track width rear mmlin. 13301 52.36 Road clearance mm/in. 1801 7.10 Weight (DIN 70020) Ibs.
  • Page 38 TECHNICAL SPECIFICATIONS 80 Itr. inc!. 8 Itr. reserve Fuel tank capacity Itr. approx. Brake fluid reservoir Itr. approx. Windshield washer tank Performances Top speed km/h (mph) 178 (110.6) Acceleration 0 ­ 100 km/h s 13.5 km for standing start 34 .0 IN empty weight plus 1/2 load Hill climbing ability...
  • Page 39 BODY/FITTINGS body on the 912 E is ident to that of the 911 Mode ls. ing are new on th 912 E • Mode ent ification rear • Rear-si de windows permanent installed • Ny velour carpet • Seats Center st ripe Scotch plaid, Tweed or braided material...
  • Page 40 BODY/FITTINGS differentiating mark is the number identification on the rear lid The rear-side windows are permanently installed. The former side windows are available as an option The single-stage heated rear-window is standardi equipment. he 9 E interior upholstery consists of a nylon velour carpet, synthetic seat upholstery.
  • Page 41 BODY/FITTINGS As for the Type 911 Model 76, a radio with two speakers, one in the right and one the left door, be installed The speakerperforation on the dash board was removed. Door locking push button The safety push button for locking the door has been changed from 8 mm to 6.5 mm thickness. This ensures easier opening with the key during variations in temperature.
  • Page 42 BODY/FITTINGS Rear cross-member - Engine compartment Various fittings and attachments mounted on the rear cross-member for air filter with intake-air sensor 2 for active carbon contai 3 for the deceleration valve 4 for the heating blower motor Motor mountlR ight-hand wheel well The motor mount left and right - is welded to main body members (arrow)

  • Page 43: Air Conditioning Unit

    AIR CONDITIONING UNIT Air conditioning unit The air conditioning unit fitted in the vehicle type 912 E is equipped only with one condenser which is secured to the engine lid Located on the receiver dryer a thermo switch (electrical switch) which disconnects the compressor clutch and the air conditioning unit when the freon temperature is too...
  • Page 44 I. Required Maintenance for Emission Control System 912 E Required Requ ired Requi every 5,000 miles at 1,000 miles every 15,000 miles Engi oil Chang Engine oil ilter Replace pl ace Repl Valve clearance (at 5,000 miles recommended Check adjust maximum ine life, but not necessary to keep the...
  • Page 45 Ing. h. F. Porsche Aktiengesellschaft 7000 Stuttgart 40 Postfach 400 640 Customer Service Edited by Service School Walter Muschweck Werner Hahn Hans Obinger Dieter Printed by Beck & Co., Stuttgart 40 Illustrations, descriptions and drawings are provided solely to clarify the text.