Page 2 Technical Date GENERAL Page 0.1 REPAIR GROUP i:)lgine-crankcase i:)lgine-Crankshaft, and moving parts i:)lgine-Cylinder Head, Valve drive i:)lgine-Lubrication i:)lgine-Cooling ENGINE Fuel Supply system Turbocharger Fuel system Exhaust System Starter, Power Supply Ignition System Clutch, Control Mech. gear-shift system -actuat., hous. TRAN S MISSION Mech.gear-shift system -Gears, Shafts Differential Front Wheel Suspension...
Page 3 Page General Adjustment values and limits 10 -01 Adjustment values and limits from 1978 models 10 -02 Specifications, general Specifications, general from 1978 models Tightening torques for engine 10 -03 Engine. Crankcase Engine. removing and installing Engine/transmission unit, detaching and attaching 10 -7 Engine/transmission unit, detaching and attaching...
Page 4 Page Fuel Supply Delivery rate of fuel pumps. checking 20 -1 Fuel pump. removing and installing Pressure test of pumps 25 -1 Turbocharger Air pressure safety switch. checking 21 -11 Bypass valve, checking function 21 -4 Bypass valve, removing and installing 21 -5 Charge air cooler, removing and installing from 1978 models 21 -20...
Page 5 911 turbo Alphabetical Index Volume Page Mixture control unit, disassembling and assembling 25 -6 d Mixture control unit, removing and installing 25 -6 Off position of air flow sensor plate, checking and adjusting 25 -6 a Piston pressure regulator with poppet valve, replacing 25 -6 Pressure gauges, connecting and bleeding 25 -12...
Page 6 911 turbo Alphabetical Index Volume I Page Exhaust system, survey engine type 930/52 26 -6 26 - Exhaust system, survey engine type 930/51, 930/53 and 930/54 Exhaust temperature. control 26 -29 Exhaust temperature control, checking 26 -30 Hose connection plan, California 26 -39 Hose connection plan.
Page 7 Page Specifications from 1978 models 30 -07 Tightening torques for manual transmission 30 -03 Transmission, type 930 30 -01 Transmission type G SO/50 30 -02 Clutch mechanism, disassembling 30 -15 assembling, Model 89 Manual Transmission, Controls, Case Front transmission cover, disassembling and assembling 34-1 Shift base, disassembling and assembling 34 -15...
Page 8 Volume Alphabetical Index 911 turbo Page Front Wheel Suspension Front axle, disassembling and assembling 40 ' Front axle, removing and installing 40 . Specifications Tightening torques for front axle Rear Wheel Suspension Coil spring compressor P 289, machining Rear axle, disassembling and assembling Rear axle, removing and installing 42 -1 Rear wheel, bearings, adjusting...
Page 9 911 turbo Alphabetical Index Volume Page Brakes -Hydraulic Parts Brake calipers -disassemble and assemble 47-1 Brake caliper sections -disassemble and assemble 47-7 Brake circuit failure indicator 47-12 Tightening torque 47 -01 Steering Specifications for steering 48 -01 Steering. disassembling and assembling 48 -1 Tightening torques for steering 48-02...
Page 10 TURBO REPAIR MANUAL This repair manual describes all of the important operations for which special instructions are required to assure proper completions. This manual is essential for the shop foremen and mechanics, who need this information to keep the vehicles in a safe operating condition. The basic safety rules, of course, also apply to repairs on vehicles without exception.
Page 11 REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL -Turbo Please file the supplements according repair groups and make appropriate entries in the table below Supplement No. Filing Date Signature VIII XIII...
Page 12: Technical Data
General TECHNICAL DATA (Refer to appropriate repair group for adjusting and wear limit data.) Note: USA values listed in brackets. ENGINE 930/50, since Nov. 75 930/52 (USA, 930/51) Internal engine code from Aug. 1976 (USA 930/53) Japan 930/54 mm/inch 95/3.74 Bore Stroke mm/inch...
Page 13 General Max. torque, DIN 70020 Nm/kpm 343/35 at engine speed Net torque. SAE J 245 Nm/ft. lbs 332/245 of 4000 rpm Gross torque, SAE r 245 Nm/ft. lbs. 389/286 Max. liter output. DIN 70020 KW/l HP/l 64/87 (58/82) Max. speed 6800 Max.
Page 14 General Blower drive Belt off of crankshaft Crankshaft/blower ratio ca. 1:1.67 Air delivery rate 1560 l/s at 6000 rpm of crankshaft Engine Lubrication Oil cooling Thermostatic control, oil cooler on engine block in blower air stream, cooler coils in front right wheelhouse Oil filter Full flow...
Page 15 General Front brake disc thickness Rear brake disc thickness Total effective braking surface Pad surface per front wheel Pad surface per rear wheel 52.5 Front caliper piston dia. Rear caliper piston dia. Parking brakes Mechanical acting on both rear wheels Parking brake drum diameter Brake shoe width Effective braking surface per wheel...
Page 16 General Capacities Engine (as measured with oil dipstick Brand name heavy duty oils meeting API Classifi- according to Owner's Manual) cation SD or SE with a viscosity of: SAE 30 for summer, SAE 20 for winter, SAE 20 W 20for permanent temperatures betw.
Page 17: Specifications, General
General SPECIFICATIONS -FROM 1978 MODELS, TURBO (Adjustment values and wear limits are provided in pertinent repair groups) Note: USA values in brackets Engine 930/60 (USA 930/61. Gal. 930/63). Japan 930/62 Factory engine code from mod. 79 (USA 930j94). Japan 930/65 mm/inch 97 / 3.82 Bore...
Page 18 General Max. torque Nm / kpm at engine speed 412/42 (395 / 40.3) (Net torque) Nm / ft Ibs 395 / 291 rpm 4000 Max. liter output kW / 1 / HP 67 / 91 Max. pexmissible speed 6700 Max. constant speed 6000 Governor cut-off speed 7000...
Page 19: Ignition System
General Electric System Shielding class ECE Regulation No. 10 Battery voltage Battery capacitance 88 (not with air conditioner) Battery capacitance (M -item) Alternator power CD! (breakerless) Ignition system Firing order 1-6-2-4-3-5 Exhaust System, Heater Single pipe system with turbocharger. bypass valve and muffler. Secondary air il"jectiol! by auxiliary air pump in exhaust system after each exhaust valve.
Page 20: Differential
20,000 km): SAE 10 W/50, 15 W/50 or 20 W/50. Do not use latter 011 for constant temperatures below -15 C. On- ly use brand name oils tested and approved by Porsche. Brand name single grade oils of API Classification SE should only be used when multi-grade oils are not available...
Page 21 General TECHNICAL DATA ADJUST-ING WEAR LIMIT DATA ENGINE VALVE DR.VE Tappet clearance (cold engine) Intake 0.10 mm (measured bet", valve and rocker arm) 0.10 mm Exhaust Timing at 1 mm tappet clearance Intake opens 3 ATDC Intake closes 37 ABDC Exhaust opens 27 BBDC 5 BTDC...
Page 22 Genera nformation Engine Type 930/51 (USA) 26 ::!: 30 on crankshaft before TOG at 4000 rpm (vacuum hose disconnected) 29 :t 30 on crankshaft before TOG at 4000 rpm Engine Type 930/53 (USA) (vacuum hose disconnected) 30 :t 30 on crankshaft before TOG at 4000 rpm Engine Type 930/54 (Japan) (vacuum hose disconnected)
Page 23 911 turbo General Tightening torques for the engine Hexagon nuts or hexagon head bolts - crankcase Flywheel to M 12 x 1.5 crankshaft M 10 x 1.25 Model 78 onward Sleeve with needle bearing to crankshaft M 18 x 1.5 Screw plug pressure relief and safety valve...
Page 24 Tightening torques for the engine 10 -04 Printed in Germany -VII, 1989...
Page 25 911 turbo General Tightening torques for the engine 10 -05 Printed in Germany -VII, 1989...
Page 26 General 911 turbo Location Thread Lambda probe to catalytic M 18 x 1.5 converter Screw plug in catalytic M8x1 15 (11) converter 10x 1 Air-injection valve to cylinder 15 (11) head (union nut) Line to air-injection valve M 14 x 1.5 22 (16) Gearwheel to air pump 9.7 (7)
Page 27 Engine, Crankcase TOOLS...
Page 28 Engine, Crankcase T GalS Special Tool Remarks Description 9111 Modified Engine take-up plate Local manufacture 9111/1 Support plate Printed in Germany Removing and Installing Engine 10 -2...
Page 29 REMOVING INSTALLING ENGINE The engine and transmission assembly is lowered to remove. Removing Jack up car. 2. Disconnect ground cable at battery. 3. Remove air cleaner. 4. Loosen engine block vent hose at engine. pull off and plug opening at vent cover. 5.
Page 30 Engine-crankcase 7. Unscrew fuel hoses at filter and return line, 8. Disconnect accelerator linkage. 14. Loosen heater hoses at heat exchangers. and pull off. 9. Loosen rear tunnel cover screws and remove cover. 15. Remove rear stabilizer, 10. Pull boot off of body and slide it forward over the selector rod.
Page 31 20. Loosen drive shaft flange socket head 23. Loosen engine carrier bolts, screws at transmission. 21. Place car jack with appropriate 24. Lower car jack with engine/transmission attachment underneath engine/trans- assembly carefully and back it out. mission assembly at center point of gra- vity and apply a little pressure.
Page 32 Engine-crankcase Installing Observe the following instructions when installing. 1. Caution! Don't clamp the heater hoses. If necessary, slide them on the heat exchangers just before the engine/ transmission assembly is in its final position. 2. Torque specifications: Engine and transmission carrier hex head screws: 9.0 mkg (65 ftlb) Drive shaft/flange fil-...
Page 33 Engine-crankcase D ET AC HIN G AN D A TT AC HIN G EN GINE AN D TRANSMISSION 4. Pull transmission off of engine. Detaching 1. Remove wires at starter and backup light switch. Attaching 2. Remove clutch release lever circlip and take off lever and rubber ring.
Page 34 Engine, Crankcase DETACHING ATTACHING ENGINE/TRANSMISSION UNIT (FROM 1978 MODELS, TURBO 3.3) 2. Place hub of release bearing upright and enga- Detaching ge release fork on hub when attaching. Check proper position through opening in transmission 1. Disconnect wires from starter and backup case.
Page 35 Engine, removing and installing From Model 89 onward hydraulically operated clutch Special tools 88/400 10- 9...
Page 36 Engine, removing and installing Hydraulic clutch mechanism Note The engine/gearbox assembly is lowered out Cover the opening into the turbocharger. of the car complete. 5. Disconnect the crankcase vent hose and the Removing hose from the oil separator. 1. Raise the car at the jacking points. 2.
Page 37 7. Disconnect fuel hoses: 9. Undo the Phillips screws in the tunnel cover and remove the cover. Separate the tacho- A -from the fuel filter generator plug connections in the tunnel and pull the rubber bushing with cable con- B -from the pressure accumulator nector outwards.
Page 38 12. Disconnect the earth strap from the chassis. 17. Disconnect the clutch operating cylinder and hang up with line connected. 13. Undo the heating hoses at the heat exchan- gers and pull off. Note The clutch must never be operated if the cylin- 14.
Page 39 Installing The following points must be observed when installing: 1. Make sure that the brake line is routed cor- rectly. 88/392 10 -259 2. Caution. Do not trap the heating hoses, sli- de onto the heat exchanger just before the engine/gearbox assembly is in the correct in- stallation position.
Page 40 911 turbo Engine, Crankcase, Suspension 3. Undo the 4 fastening nuts and separate the Engine/gearbox assembly, separating and joining gearbox from the engine. Undo the upper fastening nut on the starter motor with Separating: Special Tool P 119. 1. Disconnect cables from starter motor and Joining reversing light switch.
Page 42: Piston Installation
Engine-crankshaft and moving parts PISTON CYLINDER SIZES -930 TURBO Piston Dia. D Cylinder Cylinder Dia. in mm in mm Code Standard Size Stamped 95.000-95.010 94.933- 94.947 94.943- 95.010-95.020 94.957 95.020-95.030 94.953- 94.967 Clearance between cylinder and piston: 0.053-0.077 mm PISTON INSTALLATION NOTES Because the piston pin bore is offset, the piston...
Page 43: Pistons And Cylinders
Engine-crankshaft and moving parts CHECKING PISTONS CYLINDERS Cylinders Dl = Measuring point for wear and ovality 30 mm below upper edge of cylinder The cylinder is worn if the measurement is 0.08 mm more than the size at installation. Measurements are made in directions a and b to check ovality.
Page 44 Engine-crankshaft and moving parts REMOVING INSTALLING FL YW HEEL Removing Installing 1. Loosen flywheel mounting screws under 1. The bearing surfaces of crankshaft, application of special tool P 238 and flywheel and pulley must be without remove flywheel (take off inner stop grease.
Page 45 Engine, Crankshaft, Moving Parts 911 turbo Crankshaft -standard and machining dimensions (from Model 78 onward, Turbo 3.3) Crankshaft -standard and machining dimensions (from Model 78 onward, Turbo 3.3) Printed in Germany -VII, 1989...
Page 46 911 turbo Engine, Crankshaft, Moving Parts Only grind the bearing surfaces for rotary shaft seals to the dimensions of 29.8 and 89.8 0:.' ~... entered here if the scratches are too deep. "'Ii ..it Otherwise, repolish as necessary, Rt = 3. Hollow out oil holes with R 0.5 after grinding.
Page 47 Layout of Oil Purr;p from 1978 Models, Turbo :::.3 Order of Cylinders Guide Plates from 1978 Models, Turbo 3.3' Printed in Germany 13 -6...
Page 48 Piston and cylinder dimensions from Model 78 onward, Turbo 3.3 Nikasil F. Mahle Cylinder designation cylinders pistons " Standard size Stamped 96.960 97.000 -97.007 96.970 97.007 -97.014 96.967 96.977 97.014-97.021 96.974 96.984 97.021-97.028 96.981 96.991 Clearance: cylinder -piston 0.030 -0.047 13-7...
Page 49 Piston weight classes -911 Turbo from Model 80 onward Rules for installation 1. The pistons installed in an engine must al- 2. Piston pins must always be matched to the ways be made by the same manufacturer respective piston and must never be mixed and of the appropriate weight class.
Page 50 CHECKING INSTALLED LENGTH OF VALVE SPRINGS Checking Note Set tool P 10 c to "33.5". 1. Install special tool P 10 c with shim corres- ponding to valve, spring support washer, spring retainer and both valve keepers. 2. Read distance "A" on special tool P 10 c and, if necessary.
Page 51: Camshafts, Timing
Camshafts, timing Type Camshaft Camshaft Identification code Inlet valve stroke Timing Left SP No. Right SP No. on the face end at overlapping with 1 mm of the camshaft TOC with 0.1 mm valve clearance Left Right valve clearance 930/66 930 105 14301 930 105 14201 930 143 01...
Page 52 Fuel Supply TOOLS 20 -1 Printed in Germany -II. 1976...
Page 53 CHECKING FUEL PUMP DELIVERY Note Before checking fuel pump, check for: -clean fuel filter -electrical connections OK -at least 11.5 volts at both fuel pumps 1. Detach fuel return line (left side of engine compartment). 4. Switch on ignition for 30 seconds. Both pumps must deliver 140 liter/hour or 1170 cc in 30 seconds.
Page 54 Fuel Supply 2. Connect pressure gauge of P 378 between intake line and rear fuel pump in conjunction with Special Tool P 9114. 3. Turn ignition on (after first bridging relays or pulling off plug at air sensor contact). 4. Read pressure gauge. Pressure must be between 2 and 4 bar.
Page 55 Fuel Supply REMOVING INSTALLING FRONT FUEL PUMP Removing 1. Disconnect minus lead at battery. 2. Remove bottom guard. 3. Pinch suction hose with a standard clamp. Loosen hose clip and pull off suction hose. 4. Pull off caps and unscrew electric connecting wire.
Page 56 Fuel Supply REMOVING INSTALLING REAR FUEL PUMP Removing 1. Disconnect minus lead at battery. 2. Unscrew capped nut, counterholding the adap- ter. Remove pressure line. 3~ Pull off caps and unscrew electric connecting wire. Loosen suction line, counterholding the adapter and catching the escaping fuel. 5.
Page 57: Turbocharger. Removing And Installing
REMOVING INSTALLING EXHAUST TURBOCHARGER Removing 1. Disconnect hose line between charge 5. Loosen hose line between inlet line and pressure line and compressor housing compressor housing (turbocharger) and (turbocharger) and oil pressure line slide hose to left. (from engine). Disconnect oil return line at oil tank and loosen oil drain tube of oil tank at bottom of turbocharger.
Page 58 Turbocharger Installing 1. Make sure that hose connections are made properly between the charge pressure line and inlet line to compressor housing. 2. Lubricate exhaust gas turbocharger with 2 to 4cm3 of engine oil after installation. Note When installing a new turbocharger. the connections are located by turning the compressor housing to align it with the turbine housing.
Page 59 Turbocharger REMOVING INSTALLING EXHAUST TURBOCHARGER (USA and Japan only) Removing Disconnect hose (arrow) between turbo outlet and turbo outlet duct. Disconnect oil pressure line (arrow) from engine. 4. Loosen muffler clamp and remove muffler. 2. Loosen rear apron socket head screws and remove apron with seal.
Page 60 Turbocharger 6. Loosen turbocharger to exhaust pipe mounting bolts as well as mounting nuts on turbocharger Note holder. Remove turbocharger. When instaUing a new turbocharger, the connections are located by turning the turbocharger com- pressor side to align it with the turbine side. a) Loosen strap on turbocharger a little.
Page 61 Turbocharger TURBOCHARGER Outlet duct Compressor housing Bearing housing Turbine housing Shaft bearing Shaft Compressor wheel Turbine wheel...
Page 62 Turbocharger CHECKING TURBOCHARGER SHAFT PLAY 1. Place dial gauge in holder. Special tool P 207 can be used as a holder. 2. Set dial gauge on end of turbine wheel shaft. Press rotor shaft against dial gauge, read and note play. Press rotor shaft in opposite direction, read and note play.
Page 63 Turbocharger CHECKING WASTE GATE OPERATION 1. Loosen and remove control line to waste gate. 2. Run engine at idle speed. There must be noti- ceable vacuum in control line. With increasing engine speed, vacuum changes to pressure (charging pressure). 3. Insert a plug in disconnected control line, so that engine will not stall while checking waste gate operation.
Page 64: Pressure Control
REMOVING INSTALLING WASTE GATE (CHARGE PRESSURE CONTROL VALVE) Removing Engine Type 930/50 1. Detach vent line and control line. Unlock and remove thermag nuts. Remove waste gate, upper gasket, heat guard and lower gasket. Engine Type 930/51 Installing Use new gaskets, seals, thermag nuts and lockplates.
Page 65 Turbocharger Dismantling and Assembling Pop-off Valve Housing Printed in Germany 21 -6...
Page 66 Turbocharger Notes Amt. Designation Special Notes Installing Removing Warm gear clamp Rubber sleeve Install conectly Worm gear clamp Hose Install correctly Hex hd screw Washer Worm gear clamp Install correctly Rubber sleeve Hose clamp Hose Hex nut Washer Hex hd screw Washer Idle air control valve...
Page 67 Turbocharger Notes Amt. Special Notes No.1 Designation Installing Removing Replace. if 24 ~ Gasket necessary Caution - Lubricate 25 I Control piston under spring slightly. check move- pressure ment in valve housing Spring Guide Hex nut 29 I Washer Cover with control line conn.
Page 68 Turbocharger TOOLS Special Tool Remarks Designation 9103 Charge pressure tester Threaded adapter 9103/1 For Turbo 3.3 Checking Charge Pressure 21 -9 Printed in Germany -llI, 1978...
Page 69: Charge Pressure
Turbocharger MEASURING CHARGE PRESSURE 1. Disconnect and remove electric plug and 5. Connect test line to adapter. counterholding the adapter. charge pressure safety switch. From 1978 Models, Turbo 3.3, switch is located behind valve housing as seen looking forward. Turbo 3.0 2.
Page 70 Turbocharger CHECKING FUNCTION OF AIR PRESSURE SAFETY SWITCH Checking 1. Remove air pressure safety switch. 2. Clamp air pressure safety switch carefully. 3. Connect buzzer between switch housing and connecting terminal (buzzer buzzes). 4. Install tubeless :tire rubber valve (without valve insert) on threads of switch.
Page 71 Turbocharger 21- 12 Printed in Germany Turbocharger Oil Supply...
Page 72 Turbocharger Notes Amt. D esigna tion Special Notes Installing Removing Hollow bolt Seal Replace Oil pressure line to turbocharger Pressure sensor Seal Replace Adaptor Seal Replace Adaptor Clean Filter screen Seal Replace Thexmag nut Replace Washer Gasket Replace Clamp Oil tank Rubber grommet Hex nut Replace...
Page 73 Turbocharger Notes Amt. Designation Special Notes Removing Installing Oil line from pump to tank Adaptor Seal Replace Hex hd screw Washer Oil pump See page 21 -18 Gasket Replace II. 1976 - 21- 14 Printed in Germany Turbocharger Oil Supply...
Page 74 Turbocharger PRESSURE LINE CONNECTION FOR TURBOCHARGER WITH PRESSURE SWITCH Notes Qty. Remarks Description Installing Removing Oil pressure switch Adapter Seal Replace Oil line Seal Replace Adapter Seal Replace Ball Turbocharger -Oil Supply 21 -15 Printed in Germany -II. 1976...
Page 75 Turbocharger Note when Qty. Remarks Description Installing Removing Hollow bolt Seal Replace Adapter Seal Replace Washer Oil pump Install dowel pin of oil pump shaft between socket head screws of pulley (13) Washer Cover, flange Printed in Germany Turbocharger Oil Pump 21 -16...
Page 76 Turbocharger Note when Qty. Remarks Description Removing Installing Socket head screw Washer Pulley Tighten. must deflect Drive belt, 80 teeth by 6 to 8 mm at center under thump pressure Bolt Washer Flange Replace, install properly Oil seal with VW 433 Replace, coat both sides Gasket with sealing compound...
Page 77 Turbocharger REMOVING INS T ALLIN G T URBOC HARG ER OIL PUM P Removing 1. Detach guard at exhaust pipe. 2. Detach pressure and inlet lines at oil pump. 3. Loosen bolts and remove oil pump with gasket. Installing Observe the following when installing: Note Keys of left camshaft must be installed to protrude beyond face of camshaft by 8 mm.
Page 78 Turbocharger CHECKING CHARGING PRESSURE GAGE If the charging pressure gage in the tachometer fails, check all wire connections on the tacho- meter or charging pressure sensor against the wiring diagram. Pull off wire on charging pres- sure sensor. Turn on ignition. The cl1 pressure gage r 0 Hold the disconnected...
Page 79 Turbocharger REMOVING INSTALLING CHARGE COOLER FROM 1978 MODELS TURBO 3.3) Removing 1. Loosen hose clamps on charge air cooler's 3. Unscrew hexagon head bolts and remove char- right side and pull off hoses. ge air cooler. Loosen and remove hexagon head bolt. 4.
Page 80 Turbocharger 4. Turn pressure pipe to one side, that marks on charge air cooler and pressure pipe align or pressure pipe is installed without stress. Note When replacing rubber seal on charge air cooler, make sure that it is positioned correctly (arrows face in forward direction).
Page 81 Fuel system 25 25-1 Fuel system Printed in Germany...
Page 82 Fuel system Notes Amt. Designation Special Notes Installing Removing Clamp Vacuum hose Hollow bolt Seal Replace Fuel return line Hollow bolt Seal Replace Fuel feed line Adaptor Seal Replace Clamp Vacuum line Cap screw Washer Warm-up go\emor Vacuum hose Clamp Control line, bypass valve Vacuum hose,...
Page 83 Fuel system Notes Amt. Designation Special Notes Removing Installing Linkage Hollow bolt Seal Replace Fuelline Cap screw Washer Cold starting valve Seal Replace Flange Rubber/metal pad Clamp Hose Clamp Hose Injection valve Seal Replace Hex nut Washer Air volume hsg. Gasket Replace, install correctly...
Page 84 Fuel system Fuel system 25-4 Printed in Germany...
Page 85 Fuel system Notes Amt. Remarks Description Installing Removing Hollow bolt Seal Replace Banjo Fitting Injection lines Cylinders 4 -6 Injection lines Cylinders 1 -3 Hollow bolt Seal Replace Hollow bolt Seal Replace Fuel return line Plug Seal Replace Fuel feed line Adaptor Seal Replace...
Page 86: Installation
INSTALLATION NOTES -REMOVING INSTALLING MIXTURE CONTROL 1. Torque fillister head screws 1 through 4 cross- 2. Tighten other fillister head screws and hex head wise to 10 Nm (1.0 kpm). screws (5 mm longer) with spring and plain washers to block and loosen again 1 trun each. The 5th screw is a hex head screw due to the lack of adequate space.
Page 87: Off Position
CHECKING ADJUSTING POSITION OF AIR FLOW SENSOR PLATE Checking 1. Pull off plug for safety switch on mixture con- trol unit. Turn on ignition and off again after approx. 10 seconds. Upper edge of air flow sensor plate must be flush with beginning of cone (relief funnel, top) or max.
Page 88 Fuel Mixture REMOVING INSTALLING FUEL DISTRIBUTOR OF MIXTURE CONTROL UNIT Notes Qty. Remarks Description Installing Removing Torque to 3, 5 Nm Fillister head screw (0, 35 kpm ' Don' t disassem- Caution! Do not If control piston has Fuel distributor let control piston been removed, clean thoroughly with un-...
Page 89 REPLACING PISTON PRESSURE REGULATOR WITH POPPET VALVE Note when Special Qty. Description Instructions Installing Removing Adapter with poppet Torque 13 -15 Nm valve (assembled unit) (1.3 -1.5 kpm) Spring Check system Shim Install same shims removed (always 3) (0.1,0.15,0.3,0.4 pressure 0.5 mm thick is req.) Flat seal Replace...
Page 90: Mixture Control Unit
Fuel Supply DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL UNIT Printed in Germany Disassembling and Assembling Mixture Control Unit 2S-6d...
Page 91 Fuel Supply Note When Qty. Special Description Instructions Installing Removing Adapter with poppet Torque 13 -15 valve (assembled unit) (1.3-1.5 kpm) a-ring Replace Set of parts "« Spring Shim as required Install same as Check system (0.1, 0.15, 0.3, removed (always 3) pressure 0.4, 0.5 mm thick) Flat seal...
Page 92 Fuel Supply Note When ~pecial Qty. Description Instructions Removing Installing Gasket Check, replace if necessary Capscrew Lockwasher Stop Hex. head bolt Torque 5.0 -5.5 Nm (0.50 -0.55 kpm) Support disc Sensor plate Check, replace if necessary. Cut edge of sensor plate or stamped code (--) faces up First remove this...
Page 93 Note When Special Qty. Description Instructions Removing Installing Cylindrical pin Adjusting lever Check Pivot fork lever Spring Spacer Torque Capscrew 4.7 -5.3 (0.47 -0.53 kpm) Position correctly Counterweight Capscrew Locknut Turned approx. 15U! Plug toward venturi Position correctly Stop spring Insulator Air flow sensor Lubricate bearing...
Page 94 Fuel Supply DISASSEMBLING ASSEMBLING MIXTURE CONTROL UNIT 1. Preassemble adjusting lever, spring and pivot 3. Make sure that spring fits properly. fork lever prior to installation in air flow sen- sor housing. 2. Use an appropriate cylindrical pin for this pur- pose, e.g.
Page 95 Fuel Supply 5. C enter adjusting lever in air flow sensor hou- 6. Align angular clearance between air flow sen- sing and tighten mounting screws. sor plate and venturi. The angular clearance must be uniform. It can be checked with a 0.10 mm feeler gauge.
Page 96 TOOLS Adjusting Idle Printed in Germany...
Page 97 Fuel system ADJUSTING IDLE Note Test requirements: 5. Connect CO tester and separate tachometer Engine must be in perfect mechanical condition according to manufacturer's instructions. and ignition timing set correctly. Separate 2-pole plug connector when connec- ting tachometer. Use jumper wires to bridge connectors and provide terminal for connecting black/violet wire to tachometer or engine 1.
Page 98 Caution a) Always adjust CO from lean to rich. Example: if idle screw setting is too rich, first turn counterclockwise further than necessary and then clockwise to nominal setting. 6. Turn air correction screw on throttle valve b) Never apply pressure to adjusting wrench while housing until specified speed is reached.
Page 99: Air Valve
Fuel system 11. Wait until CO tester shows a concentration of exhaust gas at idle speed. See Page 25-15 for adjusting data. Repeat procedure. if necessary. 12. Install air cleaner again and recheck idle speed and CO content. Caution Adjustments must be completed as quickly as possible to prevent overheating the intake ports.
Page 100 upply alIen key Hexagc r:::: Printed in Germany ,78 Models, 19 Idle fr. Adjusl...
Page 101 Fuel Supply ADJUSTING IDLE, FROM 1978 MODELS, TURBO Note Air cleaner must be installed for all adjustments. 1. Detach air hose from air pump and install a 3. Adjust mixture. Insert special tool 9156 into suitable plug in open end of hose. spring-loaded alIen key in mixture control unit.
Page 102 System ADJUSTING IDLE -US CARS SINCE 1986 MODEL 930/68 Type Engine TOOLS Remarks Special Tool Description 9156 Adjusting wrench US 8040 Adapter US 4492 CO tester P 229 b or Special screwdriver P 229 c...
Page 103: Adjusting Idle
ADJUSTING IDLE Note 3. Insert a suitable plug in the air hose between the air pump and blowoff Requirements: Adjusting switching valve. Engine must be in perfect mechanical condi- tion. Electric equipment must be switched off during adjustments. Adjustments must be completed as quickly as possible, to avoid excessive heat in the intake ports and consequently wrong CO values.
Page 104 System 6. Check CO level. If the CO level is not within specifications, correct the adjust- ment on the mixture control unit. Insert Special Tool 9156 in the spring loaded wrench in the mixture control unit. Press special tool down about 18 mm to have the spring loaded wrench engage in the mixture control screw.
Page 105 CORRECTING CO ADJUSTMENT ON MIXTURE CONTROL UNIT -US CARS 1. Remove the lead-sealed wrench and replace it with a new wrench, Part No. 93011091001, if the CO level is not within specifications. 2. Adjust CO and engine idle speed, 3. Apply one drop of Loctite No. 270 in the bore of the adjusting wrench and close the bore with a plug, Part No.
Page 106 TOOLS Fuel Pressure Tool Printed in Germany 25 -11 1976...
Page 107 Fuel system CHECKING PRESSURE Note For better understanding we have numbered connections and lever positions of change-over valve in the following text. Connecting and Bleeding Pressure Gauge 1. Remove air cleaner. 3. Switch selector valve to position 2. Let pressure gauge hang down (by its hose), disconnect 2-pole plug at mixture control unit (arrow) and turn on ignition (fuel pump runs).
Page 108: Control Pressure
CHECKING "COLD" CONTROL PRESSURE CHECKING "WARM" CONTROL PRESSURE This test can only be made on a cold engine. This test is carried out on a cold or warmengine. This test is absolutely essential for start or warm- up problems. (Connect and bleed pressure gauge.) 1.
Page 109 Fuel System 5. Disconnect 2-pole plug at mixture control FROM 1978 MODELS, TURBO and turn on ignition (fuel pump runs). ALSO MEASURING CONTROL PRESSURE "WARM WITH FULL THROTTLE ENRICH- MENT" CHECKING CONTROL PRESSURE "WARM- FULL THROTTLE ENRICHMENT" 1. Check control pressure "warm" (fuel pumps must be running) .
Page 110: Checking System Pressure
4. Pump warm-up regulator to approx. 0.5 bar CHECKING SYSTEM PRESSURE (7 psi) pressure. Note '1~ Connect and bleed pressure gauge. A pressure above 0.8 bar (11 psi) could damage the diaphragm in the warm-up regulator. Move selector valve to position 3. Disconnect Control pressure will now drop and must reach 2-pole plug at mixture control unit and turn on the specified value with warm-up regulator out...
Page 111 Fuel Mixture CHECKING FUEL DELIVERY RATE FOR CONTROL PRESSURE CIRCUIT Requirements Fuel pumps in correct opera- tional condition. Checking 1. Connect and bleed pressure gauge. 4. Turn on ignition. 5. Move switching valve to position 2 and let electric fuel pumps run exactly 1 minute by pulling off two-pin plug on mixture control unit.
Page 112 Fuel Mixture TESTING ADJUSTING DATA CONTINUOUS FUEL INJECTION Test Testing and Adjusting Data Special Notes Electric fuel pump Delivery rate mm. 1170 cm / 30 s Page 20 -3 (valid for both pumps together) Control pressure "cold" Diagram for warm-up control Page 25 -13 (acc.
Page 113: Testing And Adjusting Values For Fuel Injection
Fuel Mixture TESTING ADJUSTING VALUES FOR FUEL INJECTION (FROM 1978 MODELS, TURBO 3.3) Test Phase Testing/Adjusting Value Special Note Electric fuel pump Delivery rate at least 1170 cc/30 sec. Page 20 -3 (for both pumps together) Diagram for warm-up regulator Control pressure "cold"...
Page 114 Fuel Mixture T esting/ Adjusting Value T est Phase Canada Idle adjustment California I Japan I. Sweden Engine Europe (oil temp. approx. Type C/195 1000! 1000- 50 1000- 50 950-50 930 all Idle speed rpm 950- 50 1000;' 1.5 to 2t04* 930/60 2.5*...
Page 115: Testing And Adjusting
System TESTING AND ADJUSTING VALUES FOR K-JETRONIC SINCE 1986 MODEL Type 930/68 Engine Testing and Adjusting Values for K-Jetronic 25-16c Printed in Germany -VI, 1985 -Since 1986 Model...
Page 116 Fuel System Air pump disconnected. * * Measured in front of catalytic converter and oxygen sensor plug disconnected. Testing and Adjusting Values for K-Jetronic 25-16d Printed in Germany...
Page 117 911 turbo Fuel system Test and adjustment specifications for K Jetronic 25 -16e Test and adjustment specifications for K Jetronic Printed in Germany -VII, 1989...
Page 118 Fuel Mixture REMOVING INSTALLING TEMPERATURE CONTROL SWITCH Removing Disconnect electric wires, loosen hose clamps and unscrew the hexagon head bolt. CHECKING TEMPERATURE CONTROL VALVE 1. Detach vacuum hoses. 2. Blow air into vacuum hose taken off of the t-adapter by mouth. 3.
Page 119 Fuel Mixture Note A 0,5 mm long piece of resistance wire is in- stalled in the plus lead running to the tempera- ture control valve and represents a resistance of 3 ohms. A 3 ohm resistor (about 10 watts) must always be connected when connecting the temperature control valve, e.g.
Page 120 REMOVING INS TALLIN G AIR CL EA NER (FROM 1978 MOD ELS, TURBO 3.3) Note When installing, be careful that spring-loaded alIen key for idle adjustment on mixture control unit is not damaged. 4. Unscrew hexagon nut slightly and remove air cleaner.
Page 121 911 turbo Fuel system Checking the Lambda control function Test conditions -Engine at operating temperature Correctly adjusted idle speed. 1. Run the engine at idle. 2. Connect a digital dwell angle meter between pin A of the diagnosis connector in the engine compartment and earth.
Page 122 Checking the Lambda probe Test conditions Voltage characteristic of the Lambda probe at 600°C operating temperature -Engine at operating temperature. Correctly adjusted idle speed 1. Separate the Lambda probe plug connec- tion on the left-hand side at the rear of the engine compartment.
Page 123 EXHAUST SYSTEM LAYOUT DRAWING -Engine Type 930/50 Heat exchanger Bypass valve (charge pressure control valve) Bypass line Exhaust gas turbocharger Muffler ~haust System Layout Printed in Germany 1976 26 -1...
Page 124 Exhaust system Printed in Germany Dismantling and Assembling Exhaust...
Page 125 Exhaust System Notes Amt. Designation Special Notes Installing Removing Hex nut Hex head screw Clamp Thermag nut Replace Cap screw Clamp Muffler Seal Replace Support Gasket Replace Hex head screw Thermag nut Replace Hex nut with holder Gasket Worm gear clamp Rubber sleeve Install correctly Intake line...
Page 126 Exhaust System Notes Amt. Disignation Special Notes Installing Removing Gasket Replace Turbocharger Thermag nut Replace Lockplate Replace Bypass line Gasket Replace Thermag nut Replace: Lockplate Replace Bypass valve (charge pressure control valve) Gasket Replace Guard Gasket Replace Thermag nut Replace Lockplate Replace Bypass valve housing...
Page 127 Exhaust System Notes Amt. Special Notes Designation Installing Removing Thermag nut Replace Hex head screw Gasket Replace Exhaust pipe Seal Replace Support Flange Thermag nut Replace Hex head screw Gasket Replace Exhaust pipe Hex nut Washer Hex head screw Holder, muffler Dismantling and Assembling Exhaust Printed in Germany...
Page 128 Exhaust System EJ.{HAUST LINE SURVEY -ENGINE TYPE 930/52 1 Heat exchanger 2 Bypass valve (charging pressure control valve) 3 Bypass line 4 Turbocharger 5 Exhaust muffler I, 1976 Exhaust Line Survey Printed in Germany 26 -6...
Page 129: Exhaust System Layout
Exhaust System EXHAUST SYSTEM LAYOUT -ENGINE TYPE 930/51.930/53.930/54 Heat exchanger Waste gate Bypass line Turbocharger Muffler Reactor Exhaust System Layout Printed in Germany -II, 1976...
Page 130 Exhaust System Printed in Germany 26 -8...
Page 131 Exhaust System 26 Note when Qty. Remarks Description Installing Removing Thermag nut Replace Bolt Clamp Thermag nut Replace Socket head screw Clamp Muffler Seal Replace Support ring Gasket Replace Thermag nut Replace Holder, thermag nut Replace Bolt Washer Installation Turbocharger notes on Page 21 -2 Carrier,...
Page 132 Exhaust System Note when Qty. Descriptions Remarks Installing Removing Thermag nut Replace Lockplate Replace Waste gate Installation notes on Page 26 -13 Gasket Replace Thermag nut Replace Bolt Gasket Replace Thermag nut Replace Bolt Gasket Replace Exhaust line Thermag nut Replace Bolt Gasket...
Page 133 REMOVING INSTALLING REACTOR TOOLS Special Tool Remarks Description Socket wrench 9110 INSTALLATION NOTES Tighten nuts evenly to 2,0 -2,3mkg (15-17 ftlb), Removing and Installing Reactor 26 -11 Printed in Germany -IV. 1981...
Page 134 Exhaust System I, 1976 -Printed in Germany 26 -18 Disassembling and Assembling Air Injection En(1ine Tvne 9~O/fi' and 9~O/fi?
Page 135 Exhaust System Note when Qty. Description Remarks Removing Installing Wing nut Cover Filter element Check, replace if necessary Filter housing Bolt Washer Washer Bolt Washer Bolt Washer Washer Idler assembly see Page 26 -21 (pulleys 2 + 3) Drive belt, 72 teeth Tighten, it must deflect by 6 to 8 mm (1/4 to (Engine Type 930/53...
Page 136 Exhaust System Note when I No. Qty. Description Remarks Removing Installing Washer Washer Bolt Washer Air pump Rubber bearing Check, replace if necessary Spacer Rubber bearing Check, replace if necessary Spacer Air pump mount Socket head screw Washer Pulley 4 Hollow bolt Seal Replace...
Page 137 Exhaust System Note when Qty. Description Remarks Installing Removing Socket head screw Washer Pulley 1 Drive belt, 80 teeth Tighten, it must deflect by 6 to 8 mm (1/4 to 5/16 in.) at center under thumb pressure Bolt Washer Flange Seal Replace, install correctly with VW 433...
Page 138 Exhaust System REMOVING INSTALLING PUMP Removing 1. Loosen bolts and hoses on diverter valve and 3. Loosen nut on bracket and bolts on air pump remove valve. mount. 4. Peel off toothed belt and remove air pump 2. Loosen clamps and remove hose between with mount.
Page 139 REMOVING INSTALLING FILTER OF AIR PUMP Note Removing 1. Loosen and remove air hose between air pump When installing make sure that the air filter and diverter valve. does not touch other parts. 2. Loosen clamp and remove air filter. Removing and Installing Air Pump Printed in Germany -It 1976...
Page 140 Exhaust System REMOVING INSTALLING CONTROL VALVE Removing 1. Loosen clamps and pull control line off. 2. Loosen bolts and remove control valve. Installing Connect control line hoses properly. Connect hose from diverter valve to control valve at connection I (green ring). REMOVING INSTALLING DIVERTER...
Page 141 REMOVING INSTALLING INJECTION LINE ADAPTER 4. Tighten adapters to 1.0 -1.2 mkg Remove heat exchanger and reactors. (7 -9 ft Ib). 2. Loosen and remove check valve. 3. Loosen air injection line and connections at adapters. Note Loosen the oil line slightly at the front left adapter and move aside for clearance.
Page 142 Exhaust System CHECKING CONTROL VALVE. BLOW-OFF CONTROL VALVE CHECK VALVE Note In function the control valve, blow-off control valve and the check valve are connected with each other. A defective control valve could also destroy the blow-off control valve as well as the check valve.
Page 143: Gas Filter
REMOVING INSTALLING EXHAUST FILTER Removing Unscrew couplings, while counterholding. REMOVING INSTALLING EGR VALVE Removing 1. Detach vacuum hoses. 2. Disconnect pipe at valve. 3. Unscrew mounting bolts. Installing 1. Use new gasket. 26 -27 Printed in Germany -II, 1976...
Page 144 Exhaust System 2. Connect vacuum hoses as follows. Step I -from upper diaphragm box to left throttle housing connection (in driving direction). Connections are marked with red rings. Step II -from lower diaphragm box to right throttle housing connection (in driving direction).
Page 145: Gas Temperature
REACTOR EXHAUST MANIFOLD GUARD From 1977 Models all cars for exportation to Japan will have a guard underneath the reactors and exhaust manifold to conform with Japanese legislation. It is used to shield the radiation of heat and thus prevent the ignition of waste paper and similar items, which might be under a parked car having hot reactors and mufflers.
Page 146 Exhaust System CHECKING EXHAUST TEMPERATURE CONTROL 1. The "EX" indicator lamp must come on when turning on the ignition and go out when star- ting the engine. If not. replace the bulb or check the electric connections against the wiring diagram. 2.
Page 147 Exhaust System REMOVING INSTALLING TEMPERATURE SENSOR EXHAUST TEMPERATURE CONTROL Removing Unscrew fillister head screws of rear panel and remove panel with weatherseal. 2. Disconnect 2-pole plug connection. 3. Unscrew hexagon head bolt on rear engine guard. 4. Unscrew coupling and remove sensor. 26 -31 Printed in Germany -II.
Page 148 Exhaust System DISASSEMBLING ASSEMBLING INJECTION Ill. 1978 - Printed in Germany Disassembling and Assembling Air Injection 26 -32...
Page 149 Note When Special Qty. Description Instructions Removing Installing Hexagon nut Spring washer Hose clamp Air cleaner housing lower section Hose clamp Hose Winged nut Cover Filter cartridge Check, replace if necessary Hex. head bolt Spring washer Washer Bracket Hex. head bolt Spring washer Washer Air pump...
Page 150 Exhaust System Note When Special No. , Description Qty. Instructions Removing Installing Rubber mount Check.replace if necessary Air pump holder Spacer Rubber mount Check, replace if necessary Hexagon nut Spring washer Washer Rubber mount Check, replace if necessary Spacer Rubber mount Check, replace if necessary Spacer...
Page 151 Exhaust System Note When Special Qty. Description Instructions Removing Installing Adapter Seal Replace Hexagon nut Spring washer Oil pump Install cyl. pin of oil pump shaft be- tween capscrews of air pump drive gear Hexagon nut Spring washex Interm. flange cover Socket capscrew Spring washer...
Page 152 CHECKING ADJUSTING TOOTHED BELT OF AIR PUMP Checking Toothed belt tightness is correct, if belt gives under thumb pressure applied at point midway between pullies by 6 to 8 mm. Adjusting 1. Loosen hexagon head bolt slightly (arrow). 2. Turn self-locking adjusting bolt until belt tightness is correct.
Page 156 Exhaust System OPERATING TESTING THERMO VALVE OF ENGINE TYPES 930/61,930/62 AND 930/63 Thermo valve in vacuum line between distributor and throttle housing is closed on a cold engine. This eliminates vacuum retard control and the ignition timing moves toward advance by approx. 15 .which provides a fast idle speed after a cold start.
Page 157 ADJUSTING IGNITION TIMING Specifications Europe: 29 + 2 BTDC at 4000 rpm USA: ATDC at 950 -50 rpm 1. Connect engine tester and tachometer. The two-pole plug connection must be separated near the CD! control unit, if the tester applied does not call for tapping the engine speed inductively by way of a pliers laid over the ignition cable of cylinder number 1.
Page 158 Ignition System Note With the engine running the black/violet wire delivers about 450 V against ground. When connecting test equipment be careful that the connecting terminal does not contact the car's ground. A short circuit of this type could cause damage on the ignition control unit.
Page 159 Ignition System ADJUSTING IGNITION TIMING FROM 1977MODELS Specifications: The 2-pole plug connection near the CDI control unit (see Page 28 -1) has been deleted 29 -2 BTDC at 4000 rpm from 1977 Models. The wires now lead over Europe: the 14-pole plug on the regulator plate. USA: 7 -2 ATDC at 1000 -50 rpm...
Page 160 Ignition System ADJUSTING IGNITION TIMING FROM 1978 MODELS Adjusting Values: 29 before TDC at 4000 rpm After adjustment of the ignition timing. check Europe. R.o.W. ignition timing control (see page 28 -4 c). USA: 10 -2 after TDC at 1000 -50 rpm California, 5 -1 after...
Page 161 CHECKING IGNITION TIMING CONTROL Requirements: Ignition timing is set correctly. Check timing angle as follows. Europe Version USA Version Igmtlon angle must at Idle speed Ignition angle must be 26 -3 BTDC at engine 950 -50 rpm (vacuum hose connected) speed of 4000 rpm (vacuum hose disconnected) If specifications are not met, remove distributor and check on test bench.
Page 162 Ignition System VACUUM ADVANCE CURVE TURBO ENGINE correctly adjusted ignition timing and idling speed) v.OT 20'= '" .:.: 10t!. > "0 -< -10; Torr vacuum vacuum n.OT mbar vacuum Checking Ignition Timing Control ~~ c ~ ~ l S "--...
Page 163 CHECKING IGNITION TIMING ADVANCE CONTROL FROM 1977 MODELS Requirement: Ignition timing adjusted correctly. Checking Ignition Angle: Japan: Europe: The ignition angle must be 0 ~ 40 at idle The ignition angle must be 30 ~ 30 BTDC at speed of 900 -50 rpm (vacuum hose connected).
Page 164 VACUUM RETARD CURVE TURBO ENGINE FROM MODEL ATDC ,-++ -.i- Torr vacuum mbar vacuum APAN t:tt Printed in Germany Checking Ignition Timing Advance Control 28 -4...
Page 165: Ignition System From 1978 Models
Ignition System CHECKING IGNITION TIMING CONTROL FROM 1978 MODELS Requirement: ignition timing correct. Checking Ignition Angle: Europe California. Japan: At idle speed of 1000 -50 rpm ignition angle must At eng~e weed of 4000 rpm ignition angle must be between 0 -2 be 310 -4 before TDC.
Page 166 Ignition System VACUUM RETARD CURVE TURBO ENGINE FROM MODEL. EUROPE BTDC CENTRIFUGAL ADVANCE CURVE TURBO ENGINE FROM MODEL 78.USA. CALIFORNIA. JAPAN Printed in Germany Checking Ignition Timing Control 28-4d...
Page 168 Ignition System CHECKING DISTRIBUTOR IN CAR Turning the distributor shaft will produce alternating Present day workshop equipment is not current in the built-in coil and feed it to the CDI sufficient to inspect distributors throughly. control unit via a wire. with the aid of this alter- nating current signal.
Page 169: Troubleshooting Electronic Ignition System
Ignition System TROUBLESHOOTING ELECTRONIC IGNITION SYSTEM BOSCH CDI) T est Requirements: Battery fully charged, fuel in tank, engine or ambient temperature between 0 and + 40 c. (Temperature has a heavy influence on the measured values.) Pay attention to the information on dangers for any type of work on the CD! system (see Repair Manual 911, Vol.
Page 170 Ignition System Resistance of distributor rotor: 5 kohms Spark from spark plug? ...Repair high voltage end 3. Check ignition timing. Timing correct? ~ Adjust timing 4. Check fuel system. 5. Check ignition transformer. Disconnect plug and high voltage wire at ignition transformer.
Page 171 Ignition transformer primary (term. A and B): 0.10 to 0.165 ohms Ignition transformer secondary (term. 4 and A): 390 to 630 ohms Resistance correct? -Replace ignition transformer 6. Check wires and plugs of ignition system (CDI control unit, ignition/starter switch, distribu- tor, ignition transformer, tachometer) for tightness and oxidation.
Page 172 Ignition System 7. For ignition failure: Disconnect tachometer. If ignition failure is gone, the tachometer has a defect. If not, the tachometer is good. Ignition failure eliminated? -Replace control unit Engine must start or there must be engine output. If not, there is a mechanical defect. 8.
Page 173 Ignition System Check voltage at disconnected control unit plug between terminals 6 and 8 with the igni- tion on. The voltage must equal the battery voltage. Voltage correct? Eliminate break in supply line. 9. Check sensor resistance including sensor line at disconnected control unit plug between terminals 3 and 7.
Page 174 Ignition System Resistance correct? Repeat test at two-pole plug in sensor line. 10. Check ground of sensor coil including sensor line at disconnected control unit plug be- tween terminal 3 and car's ground terminal 7 and car's ground. Test values correct: Repair or replace wires between plug and CD! control unit.
Page 175 Ignition System Resistance infinite? Repeat test at 2-pole plug in sensor line (see page 28 -11). 11. Check sensor system for mechanical damage. Visual inspection: Is there clearance between the rotor and stator? Sensor system good? --Replace distributor 12. Disconnect tachometer. If there's an ignition spark now, the tacho- meter is defective.
Page 176 DELAYED IGNITION CUT-OFF A relay for delayed ignition cut-off will be An interruption in the diode could mean that installed in all 1977 Turbo Models. there is no longer a guarantee for energization of the alternator (charge indicator lamp does not come on while switching on the ignition).
Page 177 Ignition System IGNITION SYSTEM FROM 1978 MODELS A left-turning distributor is installed on 3.3 liter Cars in California version are equipped with a distributor having a double action pressure box turbocharged engines. At idle speed the intake vacuum produces igni- tion control toward retard, which is eliminated again when the throttle is open just slightly.

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