Porsche Workshop Manual 911 1972 - PDFCOFFEE.COM (2024)

Workshop manual

DR. ING. h. c. F. PORSCHE KG STUTTGART-ZUFFENHAUSEN

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P O R S C H E WORKSHOP M A N U A L 9 1 1

- FROM MODEL 1 9 7 2 O N

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. Special tools required in performing certain service operations are identified in the manual and recommended for use. Use of tools or procedures other than those recommended in this repair manual may b e detrimental t o the vehicle's safe operation as well as the safety of the person servicing the vehicle.

The Workshop Manual 911 - from model 1972 on red in supplements to volume I and 11.

- is subdivided into 10 Assembly Groups,

delive-

Survey of t h e i n d i v i d u a l Assembly Groups:

Engine and Clutch

Code No. 1

Fuel System

Code No. 2

Transmission

Code No. 3

Front Axle

Code No. 4

Rear Axle

Code No. 5

Brakes, Wheels, Tires

Code No. 6

Pedal Controls and Manual Controls

Code No. 7

Maintenance Jobs, Technical Data

Code No.. 0

Body

Code No. 8

Electrical System

Code No. 9

For identification of the volumes, the back of the folders is provided with a transparent pocket at the top for insertion of the pertinent type. To find the individual repair steps quickly, each Assembly Group of this Workshop Manual is subdivided into "Main Groups", "Chapters" and "Sections" and provided with a very detailed list of contents; refer to example on next page.

Technical Information sheets should be filed at the beginning of their respective groups. The contents of the Technical Informations will be incorporated into the Workshop Manual at suitable intervals. The List of Contents will be edited whenever extensions and supplements are published.

- XXXII, 1974 USA /CAN

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Motor und Kupplung Engine and Clutch Moteur et Accouplement Motore e Frizione

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ENGINE CONTENTS

INFORMATION, DESCRIPTION, TECHNICAL DATA 0.1

Description 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

- 1974 model

Engine, front view cross section Engine, ' side view cross section Specifications for 2.7 liter- engine where differ 2.4 liter-engine Engine changes

- 1974 model

Cross section of engine with emission control equipment Layout of exhaust gas recirculation system Engine cross section with emission control Emission control layout 0.2

- 1978/1979

models

- 1980 model

Technical data General data Power performance curves Technical data, Type 9 1 1 T

Continuous Injection System (CIS)

Technical data, Type 911/S/Carrera Full-power performance

- 1974 model

Technical data, Type 9 1 1 S and Carrera

- 1975 model

Engine tightening data Technical data, Type 911 - 1976 model Technical data, Type 9 1 1 S

- 1977 model

Technical data, Type 9 1 1 SC

- 1978 model

Technical data, Type 9 1 1 SC

- 1980 model

Technical Data, Type 9 1 1 SC

- from 1981 Models

COOLING SYSTEM, EXHAUST SYSTEM, EMISSION CONTROL 2.1

Cooling system Fan drive belt, replacing/adjusting

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911

ENGINE 2.2

Exhaust system and h e a t i n g Exhaust system and heater blower, removing and installing Exhaust system

2.3

- 1978 model

Emission control Air injection components, removing and installing Air pump belt, tensioning Reactors and EGR equipment, removing and installing Exhaust gas recirculation system Reactor, checking for 1e:aks Exhaust gas recirculation system, checking Air injection system, checking

OIL CIRCULATION 3.1

O'il c i r c u l a t i o n Oil tank, removing and installing Oil tank, removing and installing

- 1973 model

Auxiliary pressure relief valve, removing and installing Auxiliary pressure relief valve, disassembling and assembling Oil cooler coil, removing and installing Oil cooler, removing and installing 3.2

Oil tank, removing and installing - 1974 model

3.3

Pressure relief valve cooling coil, removing and installing - 1974 model;

3.4

Pressure relief valve, disassembling and assembling - 1974 model

3.5

Oil cooler coil, removing and installing

- 1974 model

Cooling coil oil lines, service installing

- 1974 model

Replacing oil lines to front oil cooler or to cooling coil Oil cooler, removing/installing Auxiliary pressure relief/safety valves 5

- CAMSHAFT HOUSING AND CYLINDER HEAD j

5.1

Camshaft housing Injection tube in camshaft housing, removing and installing Chain tensioner, overhauling Sealing cylinder head/camshaft housing mating surfaces

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ENGINE

5.2

Cylinder head Valve springs, installed length Adjusting timing

CYLINDERS AND PISTONS 6.1

Cylinders and pistons Piston changes

- 1972 model

- 1972 model Piston and cylinder dimensions - 1973 model

Piston and cylinder dimensions

- 1974 model

"LS " cylinders and pistons, installation instructions Pistons and cylinders, measuring Piston and cylinder sizes, 911 SC Piston weight classes 7

- 1978 model

- 911 SC from 1981 models

CRANKCASE AND CRANKSHAFT 7.1

Crankcase and crankshaft Crankcase, measuring and reconditioning 'Modified flywheel installation Flywheel with pilot bearing

- 1978 model

- 1980 model

Oil filter screen and suction plate, removing/installing Crankshaft Crankshaft changes

- 1972 model

Crankshaft dimensions Connecting rod changes

- 1972 model

Connecting rod weight groups Connecting rod weight groups

- 1978 model

Pistons for injection engines Modified crankshaft drive

- 1978 model

Crankshaft specifications, standard and undersize

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- 1978 model

911

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Engine Description

ENGINE 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

General Information Beginning with 1972 models, Type 911 engines have a cubic displacement of 2.4 liters (2341 c/142.8 cu. in. )

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911

Engine Description

Individual changes and changed service operations are described on the pages that follow.

Summary of Changes: 1. Technical Data 2. Crankcase 3. Crankshaft

4. Connecting rods and bearings 5. Pistons

6. Location of oil tank and oil lines 7. Clutch pressure plate, throwout bearing, and clutch disc

8. Ignition

- see Group 9 (Electrical System)

9. Fuel system

- see Group 2

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OIL TANK CHANGES

BEGINNING W I T H 1 9 7 2 MODELS

General Information 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. It is located under a hinged lid in the right rear fender. The oil filter housing is separated from the tank and mounted on the right engine compartment wall. The auxiliary oil cooler under the right front fender continues to be standard equipment in Type 911s vehicles.

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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 )

1 Auxiliary oil cooler 6 Full-flow oil filter - 2 Oil canler (engine mounted! 7 Crankcase- breather- to oil tank 3 Oil pump a Pressure pump 8 Oil screen b Scavenging pump 9 Engine thermostat (opens to oil cooler a t 83Oc/182'~ 4 Oil tank 5 Housing with thermostat 10 Air cleaner (opens to auxiliary oil 11 Oil tank breather to air cleaner cooler a t 8 3 ° ~ / 1 8 2 0 ~

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OIL COOLER S C H E M A T I C T Y P E 9 1 1 s VEHICLES (FROM 1 9 7 3 - M O D E L ON)

1. 2. 3. 4. 5.

Oil tank Pressure relief valve Inlet pipe Return pipe Radiator coil

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ENGINE CROSS - S E C T I O N

Air filter housing Cross -shaft Intake stacks Fuel injection pump Heat exchanger Camshaft Spur belt

Oil screen Crankshaft Oil pump

Oil screen in crankcase Connecting rod Piston Cylinder Exhaust valve Valve guide Oil hose connector (oil tank to oil pump) Valve spring Rocker arm shaft Camshaft Rocker arm Intake valve Fuel injector Upper air shroud Throttle valve housing Fuel injection line Cold start enrichment nozzle Crankcase ventilation filter Air filter housing retaining clips

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Description

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911

ENGINE 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

Oil drain plug (magnetic) Crankshaft Connecting rod Sprocket gear Intermediate shaft Heat exchanger Exhaust muffler Distributor drive gear Belt pulley V-belt AC generator Upper air shroud

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Description

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 . 4 LITER ENGINE

Crankcase:

Cylinder base bore in crankcase increased from 92 mm dia to 97 mm dia.

Pistons:

90 mm dia instead 84 mm dia Piston pin offset by 0.4 mm instead 0.8 mm.

Cylinders:

Cylinder walls coated with NIKASIL compound. Cooling fins reduced from 1 5 to 11.

Ignition distributor:

Advance curve changed.

Ignition timing:

TDC a t 850

Spark plugs: ( g a p i n m m )

BOSCH W 265 P 21 BOSCH W 260 T 2 BERU 265/14/3P BERU 260/14/3

T h r o t t l e v a l v e housing:

Idle air ports enlarged from 3.3 m m dia to 4 mm dia.

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- 950

rpm

(0.55) (0.1) (0.55) (0.7)

Description

ENGINE CHANGES

BEGINNING W I T H 1 9 7 4 MODELS

1. Type 911, 911 S, and Carrera engines are equipped with NIKASIL light-alloy cylinders with a 90 m m bore.

2. Pistons: Piston heads in Type 911 S engines are marked "A 2". Rype 911 pistons, by comparison, have a deeper depression and a higher protrusion, without special markings.

3. Cylinder head: The mounting orifice for the injection valve is discontinued since the valve is

relocated to the intake stack.

4. Type 911 and 911 S engines received modified camshafts with changed valve timing.

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Description

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Description

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911

LAYOUT DRAWING OF EMISSION CONTROL 9 1 1 SC (1980 Model)

1 Oxygen sensor 2 Fuel injector 3 Thermo t i m e switch 4 Oil temperature switch 5 Intake housing 6 Cold start valve 7 Vacuum control 8 Ignition distributor 9 Auxiliary air valve 10 Throttle valve switch 11 Throttle housing 1 2 Sensor plate 1 3 Mixture control unit 1 4 ' 3- way catalytic converter 1 5 Muffler 16 Fuel injection l i n e

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TECHNICAL DATA

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

Type

Number of cylinders

horizontal, three cylinders per bank

Cylinder arrangement

(3.31in.)

84 mm

(3.31 in.)

84 mm

Stroke

70.4 m m (2.77 in.)

70.4 mm (2.77 in.)

Engine displacement

2341cc

Comprqsion ratio

7.5 : 1

8.0 : 1

8.5 : 1

Horsepower rating (DIN)

140

165

190

137

157

181

20 mkp

21 mkp

22 mkp

166 ft/lb

174 ft/lb

181 ft/lb

4000 rpm

4500 rpm

5200 rpm

(SAE Net) Maximum torque (DIN) (SA E) @ engine speed

(3.31 in.)

84mm

Bore

( 1 4 2 . 8 ~ ~in.) .

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( 1 4 2 . 8 ~ ~ 1in.) .

( 1 4 2 . 8 ~ ~in.) .

911

Technical Data

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Lubrication

dry sump

Oil cooling

.oil cooler on crankcase in f a n air stream

oil cooler on crankcase in fan air stream

oil cooler on crankcase in fan air stream; auxiliary cooler in front of vehicle

Oil filter

full flow

Crankcase

two-piece pressure casting of aluminum/magnesium alloy

two-piece pressure casting of alurninum/magnesium alloy

two-piece pressure casti~lg of aluminum/magnesium alloy

Crankshaft

forged, surfacehardened

Intermediate shaft bearings

two, plain-journal

two, plain- journal

Crankshaft bearings

eight, plain- journal

Main bearings 1-7

split inserts, 3-layer

Main bearing 1

thrust bearing

Main bearing 8

one-piece bushing, hard -lead lined

one-piece bushing, hard-lead lined

one-piece bushing hard-lead lined

Oil consumption

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Connecting rods

forged steel

forged steel, surfacehardened (Tenifer)

Connecting rod bearings

split inserts, 3-layer

Piston pin bushings

bronze, pressed-in

bronze, pressed -in

Pistons

light alloy, die-cast

light alloy, forged

Piston pins

floating, with circlips

Piston rings

two compression rings one oil scraper

Cylinders

individual, grey cast iron with integral cooling fins

individual, grey cast iron sleeve with finned light alloy jacket

Cylinder heads

light alloy, finned individual castings for each cylinder

light alloy (Y -alloy), finned individual castings for each cylinder

Valve seat inserts

shrunk-in, grey -cast iron

shr unk-in, grey-cast iron

shrunk-in, grey-cast iron

Valve guides

shrunk-in, special bronze

shmnk-in, special bronze

shrunk-in, special bronze

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M 1 4 x 1,25, machined into cylinder heads

M 1 4 x 1,25, machined into

cylinder heads Valves

1'intake, 1 exhaust valve per cylinder

1 intake, 1 exhaust valve per cylinder

Valve arrangement

overhead in 'V"

overhead in "V"

overhead in 'V"

Exhaust valves

sodium cooled, with reinforced seat

Valve springs

2 coil springs per valve

Valve timing

OHC, 1 camshaft per cylinder bank

Camshafts

cast steel, in three plain bearings in base metal of camshaft housing

Camshaft drive

by chain

Valve clearance, cold, intake and exhaust

0.10 mm (0.004 in.) measured between valve stem and rocker arm

0.10 m m (0.004 in.) measured between valve stem and rocker arm

Spark plug threads

M 1 4 x 1, 25, machined into

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cylinder heads

Valve timing with 1 m m (0.040 in.) valve clearance inlet opens inlet closes exhaust opens exhaust closes

16' BTC 30" ATC 42' BTC 4 O BTC

Intake valve lift a t overlap T C with 0.1 m m (0.004 in.) valve clearance

2,4

16' 30' 42' 4'

- 2,8

38' 50' 40' 20'

BTC ATC BTC BTC

BTC ATC BTC ATC

mm capacitive discharge system (CDS)

capacitive discharge system (CDS)

Ignition type

capacitive discharge system (CDS)

Firing order

1-6-2-4-3-5

Ignition transformer

BOSCH

Distributor (either kind)

MARELLI 50.10.974.1 BOSCH JFUDR6 0231169003

MARELLI 50.10.974.2 BOSCH JFUDRG 0231169004

MARELLI 50.10.974.3 BOSCH JFUDRG 0231169005

Spark advance

centrifugal and vacuum

Basic ignition timing

5' ATC

900 rpm

5' ATC @ 900 rpm

5' ATC @ 900 rprn

38';

BOSCH

MARELLI 40'

f 3'

Dwell angle

BOSCH

1-6-2-4-3-5

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38':

MARELLI 40'

2 3'

BOSCH

38':

MARELLI 40'

3O 3'

Horsepower Output N e (DIN HP) b --

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911

Technical Data

Full-power Performan

Engine Speed n (rpm) Downloaded from www.Manualslib.com manuals search engine

s C1L vJ

Type 911 S

Full-power Performance

180

160

1 50

1 40

I 130

z 6 120 z 110 V

6 100 CI

L Q)

3 e a

90 80

I 70

Md max = 22 mkp I

Engine Speed n (rmp) Downloaded from www.Manualslib.com manuals search engine

at 5200 rpm I

Technical Data

Full-power Performance

Engine Speed n (rpm) Downloaded from www.Manualslib.com manuals search engine

911

Carrera

+ aQ

Technical Data

T E C H N I C A L D A T A FOR CARRERA 2 . 7 FROM 1 9 7 3 MODEL

Engine 6 90 70.4 2687 2653 8.5 : 1 210/154 630 0 26/255 5100 78/57 91

Number of cylinders Bore, m m Stroke, mm Displacement, actual, c c Displacement, tax formula, c c Compression ratio Max. horsepower, DIN HP or KW at crankshaft rpm Max. torque, DIN kpm or Nm at crankshaft rpm Specific power output, DIN HP/1 or KW/1 Required fuel rating, min. RON Nominal fuel consumption, ltr/100 km Engine weight, kg or Ibs

lo. a

approx 182/402

CyIinders and Pistons Cylinder material

Light alloy with NIKASIL-coated cjlinder bore

Piston material

Forged, aluminum alloy

Ignition Ignition distributor

BOSCH Nr. 023 1 1 6 9011 MARELLI M. 610 1 5 155

Breaker point gap

0.35 BOSCH and MARELLI

Dwell angle

BOSCH 38 2 '3 MARELLI 37 '3

Basic ignition adjustment

TDC at 900

Spark plugs (gap in mm)

BOSCH W 265 P 2 1 BOSCH W 260 T 20 BERU 265/14/3P BERU 260/14/3

Fuel injection pump

BOSCH No. 0408 126 019 PORSCHE No. 911 110 254 00

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50 rpm (0.55) (0.7) (0.55) (0.7)

Technical a

TECHNICAL DATA, TYPE 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 911/91 with manual transmission 911/96 with Sportomatic Horsepower rating (DIN) in HP or KW @ crankshaft rpm

max

Torque (DIN) in kpm or Nm @ crankshaft rpm Specific power output (DIN) in HP/liter or KW/liter Compression ratio Required octane rating

- research

Nominal fuel consumption (DIN) in ltr/100 km Engine weight in kg or l b

approx .

Valve Timing Camshaft, left, part number Camshaft, right, part number Camshaft identification, left Camshaft identification, right Cam height and base circle radius, intake Cam height and base circle radius, exhaust Intake valve lift at TDC overlap, with 1 mm valve clearance intake valve exhaust valve Valve timing with 1 mm valve clearance, in degfees of crankshaft rotation exhaust opens exhaust closes intake opens intake closes

30' 10' 0' 32'

Ignition timing at idle speed (engine warm)

5' ATC 900 t 50 rpm

Spark plugs BOSCH BERU Electrode gap

W 235 P 21 235/14/3P 0.55 mm

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BBC BTC BTC ABC

911

Technical Data

Full-power Performance

Ne max = 140 PS (DIN1 at 5700 rpm at 4000 rpm. Md max = 20,5 mkp

2000

3000

4000

5000

6000

peed n (rprn) Downloaded from www.Manualslib.com manuals search engine

7000

80(

T E C H N I C A L DATA FOR TYPE 9 1 1 VEHICLES BEGINNING W I T H 1 9 7 4 MODELS

911

9 1 1 YCARRERA

MOTOR

Type

four-stroke gasoline engine with two opposing cylinder banks

Number of cylinders

horizontal, 3 cylinders per bank

Cylinder arrangement

horizontal, 3 cylinders per bank

Bore, mm (inch)

90 (3.54)

Stroke, mm (inch)

70.4 (2.77)

Displacement, actual, c c (CID)

2687 (163.97)

Compression ratio Horsepower r a t i n g , max

according to DIN 70020, HPIKW according to SAE J 245, net HPIKW all at crankshaft rpm of

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Max. torque: according to DIN 70020, kpm/Nm

24/235

according to SAE J 245, net lb.ft./Nm

168/228

all at crankshaft rpm of

3800

4000

according to DIN 70020, HP/ltr or KW/ltr

55.8/41

65/48

according t o SAE J 245, net HP/ltr or KW/ltr

53.2/39.8

62.2/46.5

Octane requirements, RON

Fuel consumption (UFG) under mixed traffic conditions, approx.

Engine weight, kg/lbs, approx.

182/402

Intake opens

ATC

Intake closes

35'

ABC

50'

ABC

Exhaust opens

29'

BBC

24'

BBC

Exhaust closes

BTC

Intake valve stroke at TDC-overlap with 0.1 mm valve clearance model 75

0.7 0,5

0.40

- 0.54

S p e c i f i c power output:

- 14

- 15

Valve timing with 1 mm valve clearance:

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- 0.9 - 0.7

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a a

911

Technical Data

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ine Speed n (rpml Downloaded from www.Manualslib.com manuals search engine

WV)

Technical Data 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

ENGINE

USA

California

6' 50' 24' 2'

6' after TDC 50' after BDC 24' before BDC 2' before TDC

Type No. of cylinders Bore in mm (in. ) Stroke in mm (in. ) 3 3 Displacement in cm (in. ) Compression ratio Max. output: DIN HP or kW SAE NET HP or kW at crankshaft rpm Max. torque: DIN in kpm or Nm SAE NET ft lbs. or Nm a t crankshaft rpm Max. output/liter: SAE NET in HP/liter or kW/liter RON fuel specification Fuel consumption (DIN) in liter/100 km Approx. engine weight in kg (lbs. )

Valve timing with 1 mm valve clearance (in crankshaft degrees): Intake opens Intake closes Exhaust opens Exhaust closes Intake valve lift at overlap TDC with 0.1 mm valve clearance (in mm) Valve lift a t 0.1 mm clearance: Intake valve in mm Exhaust valve in mm Camshaft, right Camshaft, left Identification on face of camshafts: Camshaft, right Camshaft, left Valve spring sizes: Intake valve in mm Exhaust valve in mm Exhaust, b e a t i n g

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after TDC after BDC before BDC before TDC

Single pipe system with new heat exchangers, heater blower, primary muffler and new exhaust muffler and air injection

Double pipe system with reactors and heat exchangers, heater blower and new exhaust muffler, exhaust gas recirculation and air injection

911

Technical Data

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

Connecting rod nuts Crankease bolts All bolts on crankcase and camshaft housing Hexagon nuts (oil filter screen cover) Flywheel bolts (from 1978 models) Pilot bearing to crankshaft Pulley to crankshaft (without air conditioner) Double-belt pulley to crankshaft (with air conditioner) Safety valve plug to crankcase Pressure relief valve plug to crankcase Adapter (oil pressure sender) to crankcase Adapter in crankcase (oil return line) Cylinder head nuts

M 10 socket head

Rocker arm shafts

M 6 socket head

Nut on camshaft Hex. head bolt on camshaft Cover to camshaft housing Adapter to cylinder head (air injection) Air line (coupling nut) to adapter Reactor to cylinder head Spark plugs

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Technical Data

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911

Technical Data

TECHNICAL DATA

T Y P E 9 1 1 S, 1 9 7 6 MODEL

EN GIN E Type Bore Stroke Displacement Compression ratio Horsepower SAE Net a t engine speed Torque SAE Net at engine speed Output per liter SAE Net J245 Max. engine speed Cutoff speed of speed limiter in distributor Engine weight, dry Valve Drive Valve clearance, cold engine measured betw. valve and adjusting screw: Intake Exhaust Valve timing at 1 mm clearance Intake opens Intake closes Exhaust opens Exhaust c loses Intake valve lift at TDC overlap with 0 .I mm valve clearance Identifying number on cam end face Camshaft, left Camshaft, right No. of bearings

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6O o 500 ABDC :2 BBDC 2 BTDC

911

Technical Data

Valve spring sizes Intake Exhaust Basic ignition timing (vacuum hose connected)

5' ATDC a t 900 - 50 rpm Bosch W 235 P 21 Beru 235/14/3P

Spark plugs, gap 0.55mm/O.O22 in. Cooling

Fan Drive

1 : 1.8 ltr/sec. 1265 at crankshaft speed of 6000 rpm

Crankshaft/fan ratio Air delivery rate Lubrication Oil pressure at 5000 rpm and 80' ~ / 1 7 6 O ~ Oil consumption

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. .

approx approx

5 atm/73, 5 psi ltr/600 mi. 1.5

- 2.0

Technical Data

TECHNICAL DATA

ENGINE Engine type Bore

mm/inch

stroke

mm/inch

Displacement

3 3 c m /inch

Compression ratio Power SAE Net at engine speed

kW/HP rpm

Torque SAE Net a t engine speed

Nm/lbft rpm

Output per liter

kW/HP

Max. engine speed

rpm

Cutoff speed of speed limiter in distributor

rpm

Engine weight (dry)

kg/lbs

Valve drive Valve clearance (on cold engine) measured betw. valve and adjusting screw: Intake Exhaust

mm mm

Valve timing with 1 mm valve clearance Intake opens Intake closes Exhaust opens Exhaust closes Intake valve lift at TDC with 0 , l mm valve clearance

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6' 50; 2:

ATDC ABDC BBDC BTDC

T Y P E 9 1 1 S , 1 9 7 7 MODEL

Technical Data

Identifying number on cam end face Left camshaft Right camshaft Bearing journals Valve springs: free length Intake valve Exhaust valve

mm mm

Ignition Timing USA Version (vacuum hose permanently plugged, vacuum advance inoperable)

* California Version

15' ATDC at 1000 - 50 rpm

(vaccuum hose connected) Spark plugs Electrode gap

Cooling

0' - Z1 mark + at 950 50 rpm

Bosch W 225 T 30 -0.7Beru 225/14/3A -0.7::@osch W 235 P 21 -0.6-) := Beru 235/14/3P -0.55-)

Fan Drive

Crankshaftjfan ratio Air delivery rate

1 : 1.8 1265/sec. at 6000 rpm crankshaft speed

ltr

Engine Lubrication Oil pressure at 5000 rpm and 80' ~ / 1 7 6 OF Oil consumption (per 600 miles)

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. .

approx

5 bar/73.5 psi

approx

1.5

- 2.0

ltr/qt

9fl

Technical Data

TECHNICAL DATA, TYPE 9 1 1 SC

1 9 7 8 MODELS

ENGINE

USA 930/04 California 930/06

Engine type

Bore Stroke Total Displacement Compression ratio Net Horse power, SAE at engine speed Torque, SAE Net at engine speed Output per liter, SAE Net Max. engine speed Cut-off speed (overrev protection)

Speed limited by cutting off fuel pump 6700 to 7000 approx. 200/441

Engine weight (dry) Valve drive Valve clearance (cold engine) measured between valve and rocker arm adjusting screw Valve timing with 1 mm valve clearance

Intake valve lift at TDC overlap with 0.1 mm valve clearance

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Intake Exhaust Intake opens Intake closes Exhaust opens Exhaust closes

mm' mm IO~BTDC

53 ABDC 43' BBDC 3' ATDC

Technical Data

Identification on camshaft face Left camshaft Right camshaft Number of bearings Length of installed valve springs Intake valve Exhaust valve Ignition

CDI (breakerless)

Basic ignition timing (vacuum hose attached)

5' BTDC at idle of 900 t o 1000 rpm 0 (oilotemp. 80 C/ 176 F')

Spark plugs/electrode gap

Bosch W 145 T 30/0.8 (0 ,,032 in.) Beru 145/14/3 /0.8 (0 "032 inc.)

Emission control

930/04 air pump and catalytic converter 930/05, 930/15 and 930/06 air pump, catalytic converter and EGR

Cooling

Fan drive

Crankshaft/fan ratio: Air delivery rate

approx

1 : 1.8 1380 l/s at 6000 rpm of crankshaft

bar/psi 1/1000 km (US qt/600 mi.)

approx. 4.5/66 approx. 1.5 to 2.0

Engine lubrication Oil pressure at 5000 rpm and oil temp. of 80' C (176' F) Oil consumption

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Technical Data TECHNICAL D A T A , TYPE 9 1 1 SC

from 1980 Model

911 SC

Engine Engine type (internal code)

930/07

Bore

mm/inch

95.0/3.74

Stroke

mm/inch 3 . 3 c m /inch

70.4/2,77

Total displacement Compression ratio

2994/182.7 9.3: 1

Max. output per DIN 70020 Net horsepower per SAE J 245 a t engine speed

kW/HP kW/HP

Max. torque per DIN 70020 Net torque per SAE J 245 a t engine speed

Nm/kpm Nm/ft Ibs rP m

245/25 237/175 4200

Max. output per liter DIN 70020 SAE J 245

kW/1, HP/l kW/1, HP/l

44/60 42/57

Max. engine speed

rpm

7000

*Pm kg/lbs

Speed limited by switching off fuel ump 6300 t o g700 190/419

rpm

Cut-off speed (engine speed limiter) Engine weight (dry), approx. Valve train Valve clearance (cold engine) measured between valve and rocker arm adjusting screw Intake Exhaust

mm mm

Valve timing with 1 m m valve clearance Intake opens before TDC Intake closes after BDC Exhaust opens before BDC Exhaust closes before TDC Intake valve lift at TDC with 0 . 1 mm valve clearance

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132/180 128/172 5500

911

Ttchnical Data

Identification on camshaft face Left camshaft Right camshaft four

Number of bearings Valve spring installed length Intake valve Exhaust valve

Ignition

CDI (breakerless)

Basic ignition timing

5' BTDC at 900 to 1000 rpm idle speed, vacuum hose dis0 connected, 90' C/195 F oil temperature

Spark plugs

- electrode gap -

Bosch W 5 D (W 225 T 30)

- 0.7

Beru 14/5 D (225/14/3 A) - 0,7 -

Oxygen sensor and 3-way catalytic converrer

Emission Control

Cooling

- fan drive

Crankshaft/fan ratio Air delivery rate

approx.

1: 1.68 1500 l/sec. at 6000 rpm crankshaft speed

bar/psi

approx. 4. 5/66

Engine lubrication Oil ressure at 5000 rpm and 90' C/ 8 195 F oil temperature Oil consumption

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1/1000 km approx. 1. 5 to 2. 0 (1 US qt. /600 mi. )

Technical Data T E C H N I C A L D A T A , TYPE 9 1 1 S C

from 1981 Models

Engine Engine type (internal code) Bore

mm/inch

Stroke

mm/inch cm 3/inch 3

Total displacement Compression ratio Max. output acc. DIN 70020 Net power acc. SAE J 245 a t engine speed

k W/HP k W/HP rPm

Max. torque acc. DIN 70020 Net torque acc. SAE J 245 a t engine speed

Nm/kpm Nm/ft lbs rpm

Max. liter output acc. DIN 70020 SAE J 245

kWA, HP/I

Max. engine speed

rPm

k w h , HPA

Cut- off speed engine speed limiter

Engine weight (dry)

Speed limited by switching off fuel Pump rpm

6500 f 200

kp/lbs

approx. 190/419

Valve train Valve clearance (cold engine): measured between valve and rocker arm Intake mm Exhaust mm Valve timing with 1 mm valve clearance Intake opens Intake closes Exhaust opens Exhaust closes Intake valve lift at TDC overlap with 0.1 mm valve clearance

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7' before TDC 47' after BDC 49' before BDC 3 before TDC mm

911

Technical Data

Identification on camshaft face Left camshaft Right camshaft four

Number of bearings Installed length of valve springs Intake valve Exhaust valve

mm mm

Ignition

CDI (breakerless)

Basic ignition setting (vacuum hoses detached, oil temperature approx. 9 0 ~ ~ / 1 9 5 ~ ~ )

5' before TDC at 950 rpm

Spark plugs

electrode gap

Bosch W 5 D (W 225 T 30 ) -0.7 Beru 14/5 D (225/14/3 A) 0.7

Oxygen sensor with 3-way catalytic converter

Emission control

Cooling

blower drive

Crankshaft/fan ratio

approx. 1: 1.68

Air delivery rate

1500 ltr. /sec. at 6000 rpm crankshaft speed

Engine lubrication Oil pressure at 5000 rpm and approx 90' ~ / 1 9 5 OF oil temperature Oil consumption

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bar/psi

approx. 4.0/58

ltr, /lo00 km ( 1 US qt/600 mi.)

approx. 1.5

Cooling System, Exhaust. Emission Control

911

R E P L A C I N G AND A D J U S T I N G FAN DRIVE BELT

Effective with the 1980 models a l l 911 SC engines have t h e larger fan from t h e 911 Turbo, New belt size: 9.5 x 710 mm.

Note Only the approved belt from Goodyear, Part No. 999.192.176. 50, may b e used for these engines. When installing t h e new belt for t h e first time, i t must b e much tighter Than was formerly t h e case. Approximate rule: Tighten belt as in t h e past (belt deflects by 1 0 to 1 5 m m a t point midway between two pulleys), Then remove 1 shim from t h e shims between the pulley sections (approx. 5 m m deflection).

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Adjusting instructions for engine prior to 1980 models with small fan: Check tightness by applying thumb pressure at point midway between both pulleys. Deflection: approx. 10 t o 1 5 mm.

Cooling S y s t e m , Exhaust System,

ZW ffi

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Emission Control

943 11

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Cooling System, Exhaust System.

Description

Emission Control

Notes Removal

Installation

Hose clamp Hose (heater air/blower)

Hose must not touch anything

Hose clamp Heater hose, left Clamp, adapter Adapter Screw Clamp Blower

Install correctly

Sheet metal screw Washer Bolt Washer Heater air adapter Hose clamp Heater hose, right Bolt Lock washer Washer Clamp Nut (self-locking)

Replace if necessary

Bolt Gasket Fillister head screw Clamp

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Replace

911 Remarks

911 No.

Cooling System, Exhaust System,

Description

Emission Control

Notes Removal

Installation

Muffler

Check for leaks and damage

Nut (self-locking)

Replace if necessary

Bolt Primary muffler Gasket

Replace

Gasket

Replace

Nut Bolt Clamp Flange Seal

Replace

Support disc Nut (self-locking)

Replace if necessary

Bolt Adapter Gasket

Replace

Hose clamp Flex hose Screw Washer Clamp Adapter Heat exchanger Cable strap

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Check for damage

Remarks

Cooling System,

EXHAUST SYSTEM

.1 2

Exhaust System,

Emission Control

1 9 7 8 MODELS ( E n g i n e T y p e 9 3 0 / 0 4 ,

06)

Heat exchanger

Catalytic converter

Exhaust pipe

Exhaust muffler

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911

Cooling System,

Exhaust System,

REMOVING A N D I N S T A L L I N G AIR I N J E C T I O N

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Emission Control

911

Cooling System, Exhaust System, Emission Control

Description

Notes Removal

Installation

Remarks

Bolt Washer

Replace if necessary

Plain washer V-belt

Check tension

Nut Washer

Replace if necessary

Bracket Rubber/metal pad

Check, replacing if necessary

Holder, air pump Hose clamp Hose

Check, replacing if necessary

Nut Washer

Replace if necessary

Plain washer Bolt Washer

Replace if necessary

Plain washer Rubber bushing

Install correctly, lubricate lightly

Spacer Air pump Winged nut Filter cover Filter cartridge Filter housing

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Replace if necessary

Refer to page 2.3f/4

Cooling System,

Description

Exhaust System,

Emission Control

Notes Removal

Remarks

Installation

Nut Lock washer Pulley Flat key Carrier, air pump Seal Check valve Seal

Replace

Air line Jet

Torque 1.0 1.2 mkp

Seal

Replace

Pulley, engine

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911

Cooling System.

Exhaust System, Emission Control

T E N S I O N I N G AIR PUMP BELT

Adjusting

1. Loosen bolt.

2. Move air pump to left.

3. Tighten bolt.

4. The belt tension is correct, if the belt can be

pressed together about 1 5 mm (5/8 in.) at its centerpoint with considerable thumb pressure.

Removing/ installing pulley (California version).

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Cooling, exhaust and emission control systems

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

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Cooling, exhaust and emission control systems

Description

Note when removing

installing

EGR filter

Replace every 30, 000 miles

Nut (copper pltd.)

Replace

Bolt

Replace, if necessar:

Socket head screw Clamp Muffler

Check for leaks and damage

Gasket

Replace

Nut (copper pltd.)

Replace

Bolt

Replace, if necessar:

Heat exchanger

Check for leaks and damage

Gasket

Replace

Nut (copper pltd.)

Replace, torque to 2.3 mkp

Washer Reactor

Allow it to cool down to room temperature. Remove heat exchanger and oil return line

Check for leaks

Seal

Replace, install with blue side facing toward cylinder head

Nut (copper pltd.)

Replace

Bolt Heat exchanger

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- Replace, if necessary

Check for leaks and damage

911 Remarks

Cooling,

exhaust and emission control systems

Description

Note when removing

installing

Gasket

Replace

Nut (copper pltd.)

Replace, torque to 2.3 mkp

Remarks

Washer Reactor

Allow it to cool down to room temperature. Remove heat exchanger

Seal

Check for leaks

2.3-3/1

Replace, install blue s i d e facing toward cylinder head

Nut Washer Bolt Vacuum hose for stage I

Connect to top vacuum chamber

Vacuum hose for stage I1

Connect to bottom vacuum chamber

EGR valve outlet pipe

Only detach at EGR valve

Nut Washer Bolt Bolt EGR valve

Check, replacing if necessary

Gasket

Replace, install one betw. holder and EGR line and the other betw. valve and h o l d e ~

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2.3-2/6 2.3-3/2

Cooling, exhaust and emission control systems

No.

Description

EGR line

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Note when removing

installing

The right engine cover must b e removed to replace EGR line

Check passage, cleaning if necessary

911 Remarks

Cooling, exhaust and emission control systems

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 30, 000 miles (also refer to Group 9).

REMOVING A N D I N S T A L L I N G EGR VALVE

Removing 1. Disconnect vacuum hoses. 2. Detach EGR valve outlet pipe at valve. 3. Remove mounting bolts.

Note: The replacement of gaskets requires detaching the EGR line at the EGR filter and clamp.

Installing 1. Replace gaskets.

Connect vacuum hoses as follows: Stage I

Upper chamber to left connection on throttle housing (as seen in driving direction).

Stage 11 - Lower chamber to right connection on throttle housing (as seen in driving direction).

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Cooling, exhaust and emission control systems

C H E C K I N G R E A C T O R FOR LEAKS

Note T h e reactor's operation need not be checked. It only needs to b e checked for leaks.

1. Let engine run at idle.

2. Insert appropriate plug in outlet pipe of

muffler and check reactors for leaks by listening. Replace a leaky reactor.

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911

Cooling, exhaust and emission control systems

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. Let cold engine run at slightly higher idle. This will heat the outlet pipe from EGR filter to EGR valve.

2. Increase engine speed to about 4,000 rpm. The

outlet pipe from the EGR valve to the intake housing must now be hot, too.

If the outlet pipe between the EGR valve and intake housing is not hot, the following conditions could be causing this: a) EGR valve defective b) EGR lines plugged c) Vacuum bores in throttle valve housing plugged d) Vacuum hoses plugged or leaking e) EGR filter between muffler and EGR valve clogged

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Cooling,

exhaust and emission control systems

C H E C K I N G AIR I N J E C T I O N S Y S T E M

1 Clean air filter of secondary air pump with compressed air. Replace if severely clogged.

2. Check air pump belt tension (max. deflection:

10-15 mm).

3. Loosen and disconnect air injection hose a t

air pump. Insert plug in hose.

4. Connect CO tester according to manufacturer's

instructions.

Note The CO should be checked immediately after a test drive as long as the engine is still at operating temperature.

5. Adjust CO to 1.5 900 ? 50 rpm.

- 2.0 70at idle speed of

6. Reconnect air injection hose to air pump.

70with the engine idling at 900 50 rpm. If the CO is still above 1.0 70, there is a defect in the air injection system. Of course, the engine must b e in perfect working condition in every other aspect. If necessary, install a new pump to determine cause.

7. The CO must now drop below 1.0

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Oil Circuit

R E M O V I N G A N D I N S T A L L I N G OIL TA NK

1. Remove right rear wheel.

6. Loosen retaining strap.

Caution Cover brake disc to prevent oil spillage during removal of tank. 2 . Drain oil from tank.

3 . Loosen hose clamps and retaining clamp of

return line. 7. Pull tank partially out of the wheelhousing

and remove oil line, breather hoses, and oil level gauge wires. Remove tank.

4. Detach return hose from oil tank.

5. In Type 911 S also detach the oil hose from bottom of tank.

Make sure during installation that plastic caps between tank and body, and retaining strap liner are correctly seated. Coat oil hose connections with Molykote or similar lubricant when assembling.

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911

Oil Circuit

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 )

General: Beginning with the 1973 models, the oil tank is located in the right rear wheelhouse behind the rear axle.

Removing

2. Drain oil.

5. Detach tubular support from bumper outer part and longitudinal support. Turn support to the side.

3. Detach oil hoses and pressure relief valve.

6 . Unscrew oil filter.

1. Remove right rear wheel.

7 . Disconnect oil breather hoses from oil tank. Remove oil tank retaining nuts (accessible from engine compartment). Remove oil tank. Remove oil filter base.

Installing Note the following during reassembly: 1. Properly position rubber seal fitting between

wheelhouse panel and oil tank. Glue seal to the oil tank. 2 . Make sure that O-ring is properly seated in the oil filter base.

4. Detach ground straps from batteries. Disconnect electrical wires from the oil level sensor.

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i c i t

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 PRESSURE RELIEF VALVE

1. Disconnect oil hoses.

2 . Remove pressure relief valve from oil tank. Remove support bracket.

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911

oil c i r c u i t

D I S A S S E M B L I N G A N D REASSEMBLING A U X I L I A R Y PRESSURE RELIEF VALVE

Nr .

Description

Plug

Seal ring

1 5

Spring Relief valve plunger Relief valve housing

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Note when: removing

installing

Replace

Remarks

Oil Circuit

911

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

Removing

1. Remove right front wheel.

2 . Disconnect oil hoses.

Caution : Counter with a second open-end wrench.

4. Remove oil cooler coil.

Installing

Apply counter-force a t the oil lines during installation to prevent damage. Coat oil hose connectors with Molybdenum disulfide grease during installat ion. 3. Remove Allen bolts and retaining screw from

the right bumper bracket.

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R E M O V I N G A N D I N S T A L L I N G OIL COOLER

General: 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.

Removing

1. Remove air filter top.

4. Remove oil cooler air duct.

2 . Remove front engine shroud.

5. Drain oil. 3. Remove right engine shroud.

6 . Detach oil hose from oil cooler and remove

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911

Oil Circuit

Installing

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.

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Oil Circuit

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

Removal

1. Remove right rear wheel.

2. Drain oil.

3. Detach oil hoses and remove bolt from support tube of lower fender section.

4. Remove screws from support tube and turn it to the side.

5. Detach wires from oil level sender.

6. Detach breather hoses and remove tank cover from tank.

7. Unscrew oil filter.

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Oil Circuit

8. Open the lock plate, remove nut, and pull out

support tube through the bottom.

9. Remove oil tank retaining nuts and washers.

Installation

1. Glue wheelhouse gasket to oil tank in proper position.

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Oil Circuit

R E M O V I N G A N D I N S T A L L I N G PRESSURE RELIEF VALVE O F C O O L I N G C O I L BEGINNING W I T H 1 9 7 4 MODELS

Removal

1. Drain oil from tank.

2. Detach oil lines.

Remove retaining clamp from upper oil lines.

4. Remove t h e valve.

Caution: Catch spilling oil.

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911

Oil Circuit

D I S A S S E M B L I N G A N D REASSEMBLING PRESSURE RELIEF V A L V E Beginning with 1974 Models

Description

Note when: removing

installing

Plug Gasket

Replace

Spring Plunger Plug Gasket Spring Plunger for pressure relief valve Valve housing

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Replace

Remarks

911

Oil Circuit

REMOVING A N D I N S T A L L I N G O I L COOLER COIL Beginning with 1 9 7 4 models

Removal

1. Remove right front wheel.

Disconnect oil hoses. Caution: Counterhold with a second open-end wrench. Catch spilling oil.

Remove retaining bolt and take cooler coil out.

4. Remove attaching bracket.

Installation

1. Apply counter force when connecting oil lines to prevent damage.

2. Coat oil hose connectors with MOLYKOTE-A during installation.

3. Mount cooler coil without stress.

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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

1. Raise car on hoist. Remove wheels on right side of car.

6. Grind down or saw present spacers (three plastic bushings) to a thickness of 5mm (3/16 in.)

2. Drain oil from oil tank.

7. Place rubber guards on oil lines.

3. Disconnect oil return hose from engine to oil tank.

Place both oil lines along rocker panel. The top line must rest on fender connector plate. Install spacers and mounting clips. Only tighten mounting screws slightly.

4. Remove rocker panel cover.

5. Remove plugs in oil line and cooling coil

mounting points on front wheelhousing.

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9. Connect pressure relief valve housing to oil lines.

Oil Circuit

10. Slide in rocker panel cover between spacer and washer. Tighten cover.

15. Check for leaks. This requires the engine 0 0 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. 11. Place oil hoses along rear wheelhousing and connect. If necessary, cut threads on stud.

12. Connect cooling coil t o oil lines.

13. Fasten cooling coil and lines to wheelhousing.

14. Tighten all oil line connections.

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Oil Circuit

911

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 it necessary to change the oil lines to the front oil cooler or cooling coil in the front wheel well area.

Only new version lines w i l l be available from Parts after using up the former version oil lines. Changes made necessary when installing new lines in cars with old oil lines (without side turn signals) are described in the following instructions.

Old oil lines

Removing

1. Lift car on platform hoist. Remove wheels on right side of car. Spray rust removing solution on oil line connections.

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New oil lines

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.

3. Disconnect wires of automatic antenna (optional

extra equipment) inside of car. Unplug antenna wire on radio; removing right floor plate for this purpose. Pull both wires out of holes in wheel well.

4. Disconnect oil lines on pressure relief valve housing. Catch escaping oil.

Installing 1. When installing new lines in'cars without side -turn signals proceed as follows with the mounting points in the wheel well, : Point A Point B+C

Point D

5. Disconnect oil lines on cooling coil or at oil hoses for cars with a front oil cooler. Counterhold with a second open-end wrench.

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Is still applicabbe. Not applicable; plug with 6 x 10 mm hex. head bolts used in conjunction with a body sealing compound. New (drill a 5 r n dia. hole 255 mm/lO in. from wheel house/floor plate joint and 75 mm/3 in. from fender joint plate).

Oil Circuit Note 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.

5. Mount oil lines on wheel well. Use 6.3 x 19 mm hex. head metal screw at new mounting point when installing new oil lines in a car without side turn signals.

2. Install hoses on oil lines for protection.

3. Route both oil lines along side member trim.

Upper line must be on fender joint plate. Install spacers and clamps. Tighten mounting bolts only finger tight.

6. Reconnect automatic antenna wires. Check

function of radio and antenna.

7. Push in rocker panel cover between spacer and washer.

4. Connect oil lines on pressure relief valve housing

and cooling coil or oil hoses for cars with a front oil cooler.

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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. Correct oil level.

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Oil Circuit

911

REMOVING AND I N S T A L L I N G FRONT OIL COOLER ( 1 9 8 0 M o d e l )

Removing

4, Loosen lower nuts and remove oil cooler upward.

1. Remove right front wheel.

Use a second wrench as a counterhold. Catch escapGg oil.

Installing

When installing counterhold a t t h e cooler connections t o prevent damage.

Coat connections with Optimoly HT. 3. Loosen outer nut on upper rubber mount. Check connections for leaks. This requires that the regulator for t h e front o i l cooler b e open to have oil flowing through the cooler 0 0 (engine oil temperature above 8 3 C/181 F).

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Oil Circuit

911

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

No.

Description

Piston pressure relief valve

Spring

old

Spring

new

Spring guide

Gasket

Plug

Part No.

70 mm long

- 86 mm long

- without groove Plug - new - with groove

Spring, safety valve

Plug - new

old

with groove

Installation Note The (86 mm long) spring for pressure relief valve may only be installed together with the spring guide.

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Pressure Relief Valve from 1978

Safety Valve

Camshaft Housing and Cylinder Head

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

Removing 1. Drill 9 mm deep hole in plug with a 4.8 to 5 m m dia. drill bit. Then cut M 6 threads with a bottoming tap. Pull out plug with an M 6 screw and spacer,

CAUTION Be careful not to damage sealing surface when removing plug.

2. Loosen centering screws and slide injection

tube out.

Installing 1. Install injection tube, making sure that locating bore for plug is positioned correctly.

CAUTION Separate bores must face upward toward intake valve covers. Double bores, not shown in illustration, face cam bearing surface.

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911

Camshaft Housing and Cylimder Head

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 ,

Plug is pressed in about 0.3 p m deeper than sealing surface.

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Camshaft Housing and Cylinder Head

911

OVERHAULING CHAIN TENSIONER

TOOLS

No.

Description

Adjusting ring

Clamp

Assembly lever

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Special Tool

Remarks

For chain lensioner 930 1 0 5 049 00

O V E R H A U L I N G NEW VERSION C H A I N T E N S I O N E R

General Information

Only the chain tensioner having Part No. 930.105. 049.00 or the repair kit having Part No. 911.105. 901.01 with modified parts are available from parts. Only t h e new version chain tensioner: may b e repaired.

New Version Identification: a) Chamfer on upper part of housing b) Total height: 78. 2

- 0 . 2 m m and Porsche trade-

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Camshaft Housing and C y l i n d e r Head

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911

Camshaft Housing and Cylinder Head

Note When: Installing

No.

Description

Bleed screw

Sealing ring

Clamp

Snap ring

Spring retainer

Spring

Piston (alum. )

O-ring

Replace

0- ring

Replace

Snap ring

Replace

Piston

[ntermediate piece

Replace

3-ring

Replace

aall, 5 m m

Replace

Spring

Replace

Zage

Replace

Spring

Spring guide

Zhain tensioner housing

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Removing

Special Inst~uctions

Replace Clamp only with complete new par1 Replace

Replace

Camshaft Housing and Cylinder Head

DISASSEMBLING AND ASSEMBLING C H A I N TENSIONER

Disassembling

Assembling

1, Clamp chain tensioner in a vise and remove

1 . Clean parts thoroughly, check for wear and replace if necessary. Inspect piston spring for wear and deformation (bent) , replacing if necessary.

upper circlip.

Note Spring retainer under pressure.

2. Remove spring retainer and spring.

2. Push chain tensioner piston with mounted alu-

minum piston, without O-rings, into chain tensioner housing. Both pistons must move easily. It is especially important that the chain tensioner piston moves easily i n t h e lower piston position. Remove any pressure spots on the pistons with emery cloth.

3. Remove bleed screw and sealing ring. 3. Install spring guide, spring. cage, spring,

4. Pull out aluminum piston carefully with a

ball, intermediate piece with O-ring as well as piston and secure with snap ring.

suitable tool.

Note 5, Push lower snap ring out of groove with a small screwdriver inserted through bleed screw bore.

6. Remove piston, intermediate piece with O-ring valve ball (5 mm) with spring, cage for ball, spring and spring guide.

Note The intermediate piece could b e stuck in the piston. If so, remove intermediate piece by lightly tapping piston against piece of wood.

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When installing intermediate piece in the piston make sure O-ring fits properly in groove. Give O-ring a light coat of oil.

4. Fill chain tensioner to upper edge with 1 5 W/50

engine oil and bleed. Bend the end of an approx. 1 m m dia. steel wire to make an inclined step and push it through the piston bore against the ball (see Workshop Manual 911, Volume 1, Page E 106). Move piston up and down slowly within t h e stroke range until no more air bubbles escape at the bores.

Camshaft Housing and Cylinder Head 5. Clean inner and outer grooves of aluminum piston. Install new, lubricated O-rings and make sure they are not twisted. Install aluminum piston until the O-ring seals with the housing, Now open the bleed screw slightly and push down with Special Tool P 214 c until the tool rests on the edge of the chain tensioner. Then tighten bleed screw again without delay,

Install spring, spring retainer and snap ring.

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I N S T R U C T I O N S FOR : [ N S T A L L A T I O N OF CHAIN TENSIONER

To prevent- damage on the chain tensioner housing, it is not permitted. to pre-load the timing chain with a screwdriver. Force from the screwdriver could deform the chain tensioner housing, which in turn would cause the the a1umin;m piston (7) to seize. Only use Special Tool 9182 for pre-loading.

Camshaft Housing and Cylinder Head

911

SEALING CYLINDER HEAD/CAMSHAFT HOUSING M A T I N G SURFACES

Note Only Loctite No. 573 (green color) should be used as a sealing compound. Loctite No. 573 hardens only in conjunction with metal and exclusion of air. Not more than 10 minutes should elapse between application of sealing compound coat and assembly of parts, otherwise the sealing compound on metal would start to harden.

Removing Old S e a l i n g Compound During repairs the old sealing compound does not have to be removed. Only grease has to be removed from the surface. A new coat of sealing compound should be applied immediately after the cleaning solution has dried. The new Loctite will dissolve the old compound remaining in the surface finish and become hard again after assembly. Should it be necessary to remove the old sealing compound, the use of a fine steel brush is recommended for this work.

Applying Sealing Compound

1. When applying the sealing compound by hand it is recommended to use a short-pile velour roller. In addition, a tray will be required for the sealing compound with a ribbed surface for scraping off the roller.

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2. Apply a very thin coat of sealing compound on the mating surface of the camshaft housing.

Camshaft Housing and Cylinder Head

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. If necessary, correct by adding or removing chims.

Note Make sure spring retainer has perfect fit in special tool, machining special tool if necessary. I N S T A L L E D D I M E N S I O N S FOR 2 . 4 LITER ENGINE

Vehicle

911 T

911 E

911 S

Type

911/51 911/61

911/52 911/62

911/53 911/63

-Intake Valve Exhaust Valve

35 0.3 mm + 35 - 0.3 mm

Type Engine

34 0.3 mm + 34 - 0.3 mm

35.5 34.5

+ +-- 0.3 0.3

NOTE The above values can also be applied to the 2.2 liter engines in the course of repair.

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mm mm

911

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 TYP~

Engine Type

Intake Valve Exhaust Valve

Note The tolerances for cylinder heads of Carrera 3.0 and 911 SC models have been limited for manufacturing reasons. The distance of 34.5 mm must not be exceeded; the lower tolerance value would be ideal.

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Camshaft Housing and Cylinder Head

91!

ADJUSTING TIMING (Camshafts with Hexagon Head Mounting Bolts for Sprocket)

TOOLS

No.

Description

Special Tool

Holding wrench for sprockets

9191

Puller

P 212

Dial gauge holder

P 207

Clamp for chain tensioner

P 214

Dial gauge with tip

Assembly lever

9182

Feeler gauge

P 213

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Remarks

Standard Tip length: approx. 40 mrn

911

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,ead

ADJUSTING TIMING (Camshafts with Hexagon Head Mounting Bolts for Sprocket)

Basic S e t t i n g 1. Turn crankshaft until mark Z 1 on pulley is aligned with joint of crankcase or stripe on fan housing.

2. Position both camshafts so that punch marks face up. Engine has its basic setting (cylinder no. 1 = TDC and cylinder no. 4 = overlap) by adjusting mark Z 1 on pulley to joint and punch marks on camshafts to face up.

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Camshaft Housing and Cylinder Head

3. In the position described above on bore in the sprocket will be exactly aligned with a bore in the sprocket flange. Insert a locating pin in these exactly aligned bores.

Fine Adjustment

1. Check valve clearance and, if necessary, adjust exactly to 0.10 mm with Special Tool P 213. Exact valve clearance for intake valves of cylinders no. 1 and 4 is sufficient for timing adjustments. '

4. Tighten hexagon bolts for sprockets finger tight

hold with Special Tool P 9191. 2. Pre-load timing chains. Note To avoid damage on chain tensioner housing, it is not permitted to pre-load timing chains with a screwdriver. Supporting the screwdriver on the chain tensioner housing could deform the latter and cause seizure of the aluminum piston. Only use Special Tool 9182 for pre-loading.

Note Should one of the camshafts be turned out of basic setting position, proceed as follows, Remove locating pin from camshaft in basic setting position so that i t cannot turn during rhe following adjustment. Turn mislocated camshaft to basic setting position (punch mark faces up) with Special Tool 9191. Then remove sprocket mounting bolt and locating pin, and turn crankshaft to mark Z 1 again.

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Camshaft Housing and Cylinder Head

Left Camshaft Adjustment (Cylinder No. 1 ) 3. Mount dial gauge on stud of camshaft housing with Special Tool P 207. Set dial gauge to zero

7. Install locating pin again and tighten bolt finger tight, while holding.

on spring retainer of intake valve for cyl. no. 1 with valve closed and approx. 10 mm pre-load. 0

8. Turn crankshaft clockwise two turns (720 ) and recheck setting. Indicated vaiue should be within tolerances.

9. Tighten bolt of left camshaft to final torque of

120 Nm (86 ft lb), having a 2nd person hold with Special Tool P 9191.

4. Now slowly turn crankshaft clockwise from Z 1

(TDC) by about 1 turn and observe dial gauge a t same time. Continue turning until the mean value of the adjusting tolerance, e. g. 0.10 mm valve lift (for 930/16 engine), is reached.

Adjusting Values Right Camshaft Adjustment (Cylinder No. 4 ) Engine 9 30/16 Ideal value

1.4-1.7 mm 1.55 mm

5. Unscrew and remove mounting bolt on left sprocket and pull out locating pin with Special Tool P 212.

6. Turn crankshaft accordingly until mark Z 1on pulley is exactly aligned with joint of crankcase or stripe on fan housing.

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1. Set cylinder no. 4 to TDC (cyl. no. 1overlaps).

2. Repeat adjusting procedures described in points 3 through 9 on cylinder no. 4.

Cylinders and Pistons

PISTON CHANGES

BEGINNING WITH 1 9 7 2 MODELS

1. New pistons with flatter piston tops to reduce compression ratio:

7.5: 1

911 E

911 S

8.5: 1

511 T

8.0: 1

Required fuel octane rating = 9 1

2, Changed piston ring.

3. New table of dimensions for pistons and cylinders beginning with 1972 models.

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PISTON AND CYLINDER DIMENSIONS Beginning with 1972 models

Cylinder markings

Cylinder bore dia.

Piston diameter D 1

T y p e 911 S Pistons Standard 0 1 2

Tolerances 40.005 m m 83.950 83.960 83.970

84.000-84.010 84.010-84.020 84.020-84.030

1st oversize 0 KD1 1KD1 2KD1 2nd oversize 0 KD 2 1 KD 2 2 KD2

Cylinder/piston clearance: 0.04.5 -0.065 Piston weight: 354 3 g

T y p e 911 E Pistons Standard 0 1 2

Tolerances $ 0.005 m m 83.970 83.980 83.990

1st oversize 0 KD1 1 KD 1 2 KD 1

84.220 84.230 84.240

2nd oversize 0 KD2 1 ICD 2 2 KD2

84.470 84.480 84.490

Cylinder/piston clearance: 0.025 -0.045 Piston weight: 371 -t' 3 g

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Cylinders and Pistons

Cylinder markings

Cylinder bore dia.

Piston diameter D1

Type 911 T Standard ( M A H L E ) 0 84.000-84.010 1 84.010-84.020 2 84.020-84.030

Tolerances T0.005 83.970 83.980 83.990

1 s t oversize 0 KD 1 1 KD 1 2 KD 1

84.250-84.260 84.260-84.270 84.270-84.280

84.220 84.230 84.240

2nd oversize 0 KD 2 1 KD 2 2 KD 2

84.500-84.510 84.510-84.520 84.520-84.530

84.470 84.480 84.490

Cylinder/piston clearance: 0.025 -0.045 Piston weight: 376 2 3g

Type 911 T Standard ( S C H M I D T ) 0

1 2

84.000-84.010 84.010-84.020 84.020-84.030

1st oversize 0 KD 1 1 KD 1 2 KD1

84.250-84.260 84.260-84.270 84.270-84.280

84.220 84.230 84.240

2nd oversize 0 KD 2 1 KD 2 2 KD 2

84.500-84.510 84.510-84.520 84.520-84.530

84.470 84.480 84.490

Cylinder/piston clearance: 0.023-0.048 Piston weight: 375 4g For piston and wear limits see p a g e 6 . 1

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4/1

Tolerances + 0.007 - 0.008 83.970 83.980 83.990

911

Cylinders and Pistons

CYLINDER HEIGHT TOLERANCE GROUPS 1972- models, 2.4 liters

Code mark

Standard Cylinder Height Cylinder Installation Height Reconditioned C y l i n d a Height

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Cylinders and Pistons

911

PISTON AND CYLINDER DIMENSIONS B e g i n n i n g w i t h 1973 m o d e l s Cylinder markings

Cylinder bore dia

Piston diameter D 1

T y p e C a r r e r a 2.7 P i s t o n s Standard stamped

Tolerances 2 0.005 89.950 89.960 89.970

90.OOO-90.010 90.010-90.020 90.020-90.030

Cylinder/piston clearance: 0.025 Piston weight:

- 0.045

392 i 3 kg

C Y L I N D E R H E I G H T T O L E R A N C E OF 2.7 L I T E R E N G I N E S

Code Cylinder Installation Height

Oversize pistons and cylinders are not provided.

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Standard Cylinder Height

911

Cylinders and Pistons

PISTONS AND CYLINDER DIMENSIONS

T y p e 9 1 1 and 9 1 1 S Pistons

B E G I N N I N G W I T H 1 9 7 4 MODELS

Cylinder makings

Cylinder bore dia.

Piston diameter D1

Standard stamped 0 1 2

Tolerances

? 0.0005 90.000-90.010 90.010-90.020 90.020-90.030

Cylinder/piston clearance:

0.025

89.970 89.980 89.990

- 0.045

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 "LS" V e r s i o n

T y p e 9 1 1 Pistons

Cylinder markings .

Cylinder bore diameter

Standard stamped

Permissible weight difference in pistons of one set: 6 g max. Downloaded from www.Manualslib.com manuals search engine

Cylinder/piston clearance: 0.035-0.060

Piston diameter D l

911

Cylinders and Pistons

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" Cylinders and Pistons. In this system the surface coating is applied to the piston.

The assembly of the cylinder and piston must be made with particular care to avoid breaking the piston rings; the rings are chrome-plated and are thus harder and more brittle. When resistance is met while tightening the piston ring compressor, it is an indication 'that the rings are not seating properly in the grooves. In such case remove the ring compressor, check the piston rings for location, and repeat the procedure, carefully pushing the cylinder onto the piston.

I n s t a l l i n g Piston Rings The piston rings can be installed in their grooves by hand and without the use of tools. When installing rings 1 and 2, make sure that the rings are placed in the sequence and position shown in the illustration. I n s t a l l i n g T h r e e - P a r t O i l Ring The oil ring is made up of three parts, with each part installed separately. Install the expander first, then follow with the upper and lower rails. After installation check visually if the expander ends meet. Note Install gaps of individual ring parts as follows: Offset expander to rails by at least 45O. Offset rails to each other by a t least 90'.

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Cylinders and Pistons

P I S T O N AND CYLINDER S I Z E S

Piston T y p e 9 1 1 S

911

"LS" MAHLE

Cylinder Code

Cylinder Diameter

Piston diameter

90.000-90.012

90.012-90.024

90.024-90.036

89.96089.972 89.97289.984 89.98489.996

Standard Size stamped

Cylinder/piston clearance: 0.028

GAP OF "LS" P I S T O N RINGS

Make

MAHLE + SCHMIDT

Piston Ring

Gap wear limits in mm 1.0

R ring

Top

0.2

N ring

Center

0.15

SS 50 ring Bottom (3-piece consisting of expander and 2 rails)

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Gap in mm

0.4

- 0.4

- 0.35 - 1.4

1.0 2.0

- 0.052

Cylinders and Pistons

C H E C K I N G P I S T O N S A N D CYLINDERS Cylinder Dl Measuring point for wear and ovality 30 mm below top edge of cylinder

The cylinder is worn if this measurement is 0.08 mm more than the new size specifications. Ovality is checked by measuring in directions a and b. The difference between a and b may not b e more than 0.04 mm.

D2 = Measuring point for piston ring end gap clearance Rings slid in to height of cylinder base gasket.

Piston D = Measuring point for wear At height of lower edge of piston pin bore.

Caution Replace pistons and cylinders if clearance exceeds 0.15 mm.

P I S T O N RING END GAP Piston Ring

End Gap mm (new size)

Compression ring, I and I1 Oil scraper ring, I11 Oil scraper ring, 111, 3-piece "LS" ring (see checkpoint "D 2")

0.1 - 0.2 0.15 0.3

End Gap mm (wear limit)

0.4

- 1.4

P I S T O N RING S I D E CLEARANCE Piston Ring

Compression ring, I Compression ring, I1 Oil scraper ring, I11

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SIDE Clearance in mm (new size)

SIDE Clearance in mm (wear limit)

91,

Cylinders and Pistons

PISTON AND CYLINDER S I Z E S Mahle

Cylinder marking

Cylinder bore diameter mm

9 1 1 SC ( f r o m 1 9 7 8 M o d e l )

Piston diameter D m m

Standard size stamped

Clearance between cylinder and piston: 0.025

- 0.042

P I S T O N AND CYLINDER S I Z E S - 9 1 1 SC ( f r o m 1 9 7 8 M o d e l ) KS

Cylinder marking

Cylinder bore diameter m m

Piston diameter D mm

Standard size stamped

Clearance between cylinder and piston: 0. 023 - 0. 044 mm

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911

Cvlinders and Pistons

- from 1980 Mode1

P I S T O N WEIGHT GROUPS

Installation Instructions:

1. Only pistons of one make and appropriate weight group may be used in one engine.

2. Piston pins must always remain with the corresponding pistons and should not b e mixed up within an engine set. Watch this when disassembling and assembling an engine, marking parts if necessary.

Weight groups

MAHLE Pistons

Pistons weighed with attachments (piston pins, piston rings, snap rings)

Engine type Standard production

Max. difference in. weight 4 g

For installation Max, difference in weight 8 g

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Total Piston Weight in g Weight group within a set

Marking

Cylinders and Pistons

P I S T O N WEIGHT CLASSES

Weight Classes

9 1 1 SC f r o m 1 9 8 1 M o d e l s

MAHLE Pistons

Pistons weighed with attachments (piston pins, piston rings, snap rings)

Total Piston Weight in g Weight Class Within a Set

Code

Engine type Standard production Max. difference in weight 4 g

For Service Sector Max. difference in weight 8 g

Weight Classes

KS Pistons

Pistons weighed with attachments (piston pins, piston rings, snap rings)

Total Piston Weight in g Weight Class Within a Set

Engine Type Standard Production Max. difference in weight 4 g

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Code

911

Crankcase and Flywheel

911

MEASURING AND R E C O N D I T I O N I N G CRANKCASE

General The main bearing bores must be measured whenever the crankcase is disassembled for repair. These instructions apply as well to all pre-1972 model engines.

Measuring Attach crankcase half to bepch mount and assemble'both halves without the intermediate shafl. Lightly tighten all crankcase studs and two M8 retaining nuts at Bearing 1.

Measure all 8 main bearing bores with the inside micrometer. If the bores are too tight, they should be reamed with the main bearing reamer to standard diameter of 62.000 mm.

Align both crankcase halves with the aid of a plastic mallet. The joint in Bearing 8 must not be offset in relation to each half.

Bore diameter for main bearings 1 r 8 is 62.000 to 62.019 mm.

Using the inside micrometer, cross-check bore of Bearing 8. Realign bore if necessary.

If the bores are too large, they should be reamed to B-bearing oversize of 62.25 mm diameter. Control dimension for the B-bearing is 62.25 mm to 62.269 mm diameter.

Reconditioning General This procedure requires special tools and should only be performed by qualified personnel. Light-alloy (SILUMIN) crankcases must be reamed in two steps when reaming to the B-bearing size. Lubricate reamer with cutting oil during this procer dure. 4.

Tighten all crankcase studs and both M8 nuts to proper tor q ue.

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1. 2.

Step 1 = 62.15 mm diameter Step 2 = 62.25 mm diameter (B-bearing installation dimension)

911

Crankcase and Flywheel

Pressure-cast crankcases can be cut in one step and without oil to 62.25 mm diameter.

Reaming 1.

Attach self-made tool (see sketch below) to 4 oil screen attaching studs and fasten in bench vise.

S k e t c h for S e l f - M a d e T o o l T-bar 40 x 80 x 7 mm All edges beveled Insert rod (35 x 1200 mm) with main bearing reamer and ream Bearing, P until Bearing 2 is guided (reamer centers automatically in bore of Bearing 1).

Insert end bearing bushing EL35 in bore of Bearing 8.

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Insert end bearing bushing EL35 in bore of Bearing 1.

Ream all bearing bores until reamer reaches end bearing bushing of Bearing 8.

Crankcase and Flywheel

Remove-end-bearing bushing from bearing bore # 8 and fullv ream bear in^ 8.

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911

Crankcase and Flywheel

M O D I F I E D FLYWHEEL I N S T A L L A T I O N

No.

Description

Socket head

Flywheel

Bushing

Crankshaft

Qty

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911

1 9 7 8 MODELS

Note When Removing

Installing Torque 9 mkg

Special Instructions

FLYWHEEL W I T H P I L O T B E A R I N G / B U S H I N G FOR I N P U T S H A F T

from 1980 Model

No.

Description

Note When Removing Installing

Screw M 6x12

Tighten to specified torque, lock with Loct i t e 270

Bushing with needle bering

First secure flywheel, then bushing

Bolt

Tighten t o specified torque

Flywheel Crankshaft

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Special Instructions

Crankcase,

911

Camshaft

REMOVING AND I N S T A L L I N G OIL FILTER SCREEN A N D S U C T I O N P L A T E

No.

Description

Removing

Note When Installing

Oil drain plug

Seal

Replace

Nut

Tighten to about 1 0 Nrr 7 ft lb

Washer

Zover for oil filter scree

Replace 3 1 filter screen with iuction plate

Check for deformation, replacing if necessary. Watch installed position oil drain plug must face in recess of suction plate

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Replace

Special Instructions

Crankcase, Crankshaft

ASSEMBLY I N S T R U C T I O N S SEALING CRANKCASE M A T I N G SURFACES

Note Only use Loctite No. 573 (green color) as a sealing compound. Loctite No. 573 hardens only in conjunction with metal and exclusion of air. Never wait longer than about 1 0 minutes between applying coat of sealing compound and assembling parts, since the sealing compound applied directly on the metal would begin to harden.

Removing Old Sealing Compound During repairs the old compound need not be removed. It is only necessary to remove grease from the surface and to apply a coat of new sealing compound after the grease removing solution has dried. The new Loctite w i l l dissolve the old compound in the surface finish and harden again after assembly. Should it be absolutely necessary to remove the old sealing compound, a fine steel brush is recommended for this work.

Applying Sealing Compound

1. When applying sealing compound by hand use a short-pile velour roller. In addition, a tray with a ribbed surface for scraping off the roller will be required for the sealing compound.

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2. Apply a very thin coat of sealing compound with the velour roller.

Crankcase and Crankshaft

CRANKCASE CHANGES

BEGINNING W I T H 1 9 7 2 MODELS

Distributor mounting flange.

CHANGED CRANKSHAFT

Stroke Crankpin diameter Crankpin width Beginning with 1972

BEGINNING W I T H 1 9 7 2 MODELS

= 70.4 m m = 51.990

- 51.911

= 24 m m

models, all crankshafts have counterweights.

S e e next page for crankshaft dimensions.

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91,

CRANKSHAFT DIMENSIONS

Step

Crankshaft diameter Bearings 1- 8

Standard

Standard 62.00062.019 mm (2 .44O92.4417 in.) Oversize 62.26962.250 mm (2.45152.4508 in.)

-0.25 mm (-0 .OO98) -0.50 mm (-0.0197) -0.75 mm (-0.02%)

STANDARD AND RECONDITIONED

All main bearings d1

Connecting rod bearings d2

Main bearing diameter d 3 on crankshaft Bearing 8

Shoulder diameter d4

Timing gear seat diameter d5

mm in.

56.990-56.971 (2.2437-2.2429)

51.990-51.971 (2.0468-2.0461)

30.993-30.980 (1.2202-1.2197)

65.000-64.981 (2.5591-2.5583)

42.013-42.002 (1.6541-1.6536)

mm in.

56.740-56.721 (2.2339-2.2331)

51.740-51.721 (2.0382-2.0363)

30.743-30.730 (1.2104-1.2098)

mm in.

56.490-56.471 (2.2240-2.2233)

51.490-51.471 (2 .O272-2.0264)

30,493-30.480 (1.2005-1.2000)

mm in.

56.240-56.221 (2.2142-2.2134)

51.240-51.221 (2.0173-2.0166)

30.243-30.230 (1.1907-1.1902)

Crankshaft pulley seat diameter d6 29.993-29.960

Thrust bearing Width A 28.000-

64.500-64.310 (2.5394-2.5319)

Grind crankshaft oil seal s u r f x s only w h s deeply scorede Grind to dimensions of 29.5 mm (1.161 in.) and 64.5 mm (2.539 in.) Otherwise polish out. Polishing roughness = 2 5 microns

N o t e : After grinding, Tenifer-harden the crankshaft, then polish all bearing journals and thrust surface A. Magnaflux to check f o r c r a c k s . Maximum vertical runout = 0 .O4 mm (0.002 in.), measured at Bearing 4 and 8, with Bearing 1 and 7 on V-blocks. Maximum crankshaft unbalance = 10 cmg. Journal 3 and 5 must not b e straightened after the Tenifer treatment.

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Crankcase and Crankshaft

C O N N E C T I N G ROD C H A N G E S

BEGINNING W I T H 1 9 7 2 MODELS

A Distance between centers

127.8 (5.03)

b Width of piston pin bushing

26.0 (1.02)

c Big end width

23.8 (0.9370)

D Big end diameter (without bearing insert)

56.019 (2.2055)

E Small end diameter f

Piston pin bushing dia. (before installation) (Press-fit interference in rod)

G Inside diameter of installed piston pin bushing (finished) Piston pin clearance in bushing Wear limit Downloaded from www.Manualslib.com manuals search engine

0.05 m m (0.002 in.) 0.2 mm (0.008 in.) 0.1 mm (0.004 in.)

- 56.000 m m - (2.2047 in.) 25.021 - 25,000 m m (0.9851) - (0.9843 in.) 25.035 (0.9856) 0.014 (0 .OOO6) 22,033 (0.8674) 0.020 (0.0008) 0.055 (.0022)

- 25.055 m m - (0.9864 in.) - 0.055 m m - (0.0022 in.) - 22.020 m m - (0.8669 in.) -

0.039 m m

- (0.0015 in.)

911

Crankcase and Crankshaft

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. The pertinent weight group can be identified in spare part end numbers. The end number is stamped into connecting rods furnished as spare parts.

Weight up to more than grams grams --

Weight group for KD

KD connecting rod spare part number

Identification in connecting rod

645 65 4 663 672 681 690 699 708 718

Weight variation between connectirg rods in any engine may not exceed 9 g. T o determine weight group, weigh complete connecting rod without big end inserts.

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911

Crankcase, Crankshaft C O N N E C T I N G ROD W E I G H T GROUPS

- from 1978 Model

Connecting rods are in different weight groups, T h e weight group is indicated by the final digit of t h e part number. For connecting rods, which are supplied as spare parts, these final digits a r e stamped on the shank.

Weight Weight above g

group for installation

Service installation connecting rod P a r t No.

Connecting rod marking

Note Only connecting rods, which do not differ in weight by more than 9 g, may b e installed in o n e engine. To determine a weight group, weigh the complete connecting rod (without bearing shells).

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Crankcase and Crankshaft

P I S T O N S FOR K

JETRONIC ENGINES

Pistons for K Jetronic-equipped engines of Type 911/91 and 911/96 have a turbulence (whirl) cavity in the piston top. This provision ensures a particularly thorough blending of the fuel/air mixture.

Installation note: T h e piston must always be installed so that the flat spot in the piston top faces upward (towards t h e intake valve).

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911

Crankcase and Crankshaft

ASSEMBLY I N S T R U C T I O N S FOR P I S T O N S ON 9 1 1 SC ( 1 9 8 1 M o d e l s )

Domed surface on piston must f a c e intake valve.

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Crankcase and Crankshaft

M O D I F I E D C R A N K S H A F T DRIVE

1 9 7 8 MODELS

TOOLS

No.

Description

Installer for crankshaft seal

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Special Tool

9126

Note

911

Crankcase and Crankshaft

MODIFIED CRANKSHAFT DRIVE

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1 9 7 8 MODELS

Crankcase and Crankshaft

No.

Description

Note When Removing

Replace

Oil seal Thrust main bearing shells 1

Installing

Check for wear

Lubricate

Main bearing shells 2-7

Bearing sleeve, bearing 8

Lubricate

O-ring

Replace

Oil seal

Replace

C i rclip Drive gear for distributor Note installed position

Spacer

Timing gear Woodruff key Connecting rod nut

Tighten to specified torque. Lubricate bearing surface.

Connecting rod

Note installed positioi and weight

Connecting rod bearing shell

Check for wear

Connecting rod bolt Crankshaft

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Check for wear

Lubricate

Special Instruction

911

Crankcase and Crankshaft

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 MODELS Clamping Crankshaft

Special Tool P 209 a must be modified for new crankshaft.

Installing Seal

Drive in seal with Special Tool 9126.

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1978

Crankcase and Crankshaft

911

Installing Crankshaft Drive Gear for C o u n t e r c l o c k w i s e Rotating Distributor

Note As of the 1978 model year, the engines are equipped with a counterclockwise rotating distributor. Therefore a new crankshaft drive gear with modified teeth is required.

For counterclockwise rotating distributor (with Porsche emblem)

For clockwise rotating distributor (with VW emblem)

I n s t a l l i n g C i r c l i p on C r a n k s h a f t

Circlips are available in various thicknesses to take up axial play between distributor and drive gear.

The following circlips are available: Part No. 901 .102.148 .OO 901.102.148.01 901.102.148.02 901.102.148.03

Thickness mm 2.4 2.3 2.2 2-1

Code 0 1 .2 3

Install timing gear, spacer and drive gear for counterclockwise rotating distributor on crank shaft up to stop. Select proper circlip by first inserting i t to check its thickness. Circlip must take up play.

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CRANKSHAFT

Standard and Undersizes

(19 78 Models)

Size

Crankcase bore dia. bearings 1- 8

All main bearing journals d 1

Connecting rod bearing journals

Main bearing jaw- Oil seal journal rial d 3 of crank- dia. d 4

shaft bearing 8

Standard

- 0.25 - 0.50 - 0.75

- 1.00

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Seat for timing gear dia. d 5

Crankshaft pulley seat dia. d 6

Thrust bearing width A

Surface finish

Edge deburre d

Paint dot

Grind crankshaft oil seal surfaces only when deeply scored. Grind to dimensions of 2 9 , 5 m m and 89.5 m m respectively. Otherwise polish out to 3 microns. After grinding, chamfer oil holes to 0, 5 m m radius. Break all sharp edges to 0.2 - 0.5 m m radius. Maximum radial runout measured at bearings 1 and 7 is 0.04 mm. Tenifer treat crankshaft after grinding. Magnaflux to check for cracks. Do not straighten main bearing journals 3 and 5 after Tenifer treatment. All other main bearing journals can be straightened by applying pressure to the bearing journal webs.

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Undersize color codes 1st 2nd 3rd 4th

undersize undersize undersize undersize

blue paint dot green paint dot yellow paint dot white paint dot

Clutch

C L U T C H CHANGES

911

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. The clutch lever is now pulled by the clutch cable instead of the cable housing.

2. Pressure of the pressure plate (MFZ 225 KL) has been increased to a range of 650-720 kp (1430 -1584 Ibs.)

3. Clutch disc splines have been changed from 24 to 20 (an SAE designation).

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ADJUSTING CLUTCH

1. Turn self-locking adjusting nut until clutch pedal free travel is 20 25 m m (0.8 1.0 in.).

2. When checking, pull pedal in direction of arrow.

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REMOVING A N D I N S T A L L I N G T H R O W O U T BEARING

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Clutch

Description

Snap ring

Note when removing

Remove with snap ring Check for proper pliers while pushing seating.

Thrust washer

Groove must face the snap ring.

Throwout bearing

Should not be washed only wiped with dry rag. Grease guide tube contacting surface with multipurpose grease with MoS2 additive.

Spring washe~

Install in correct position.

Spacer Pressure plate

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References

installing

Check for wear and replace if necessary.

9.1-2/3

9.l- 2/3

9.1-2/3

Clutch

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 Removal

Lay the pressure plate onto the throwout bearing and push down by pressing against the thrust washer so that the snap ring can be reached.

2 ; Remove snap ring with snap ring pliers

Inst a l l a t i o n

Place spacer and spring washer on the throwout bearing in proper position.

Insert the throwout bearing into the diaphragm spring of the pressure plate.

Install thrust washer with the groove facing the snap ring and install snap ring while pushing the pressure plate and thrust washer downward.

and take the throwout bearing out together with the washers.

NOTE: Throwout bearings are packed with special grease and therefore may not be washed.

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CLUTCH

1 9 7 5 MODELS

911 S and Carrera

Pressure plate

MFZ 225 KSph

Pressure

714

Spring No.

3027 056 000

Part No.

915.116.OOl .I4

Drive shell Part No.

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- 785 kp

CLUTCH MODIFICATIONS

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1 9 7 8 MODELS

911

Clutch

Description

Note When Removing

Installing

Socket head screw Replace

Lock washer Pressure plate Starter gear ring Clutch disc Circlip Thrust washer Release bearing

Check

Washer Spring washer

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Install in correct position

Special Instructions

Kraftstoffanlage Fuel System Systeme d'alimentation Sistema d'alimentazione

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FUEL S Y S T E M

CONTENTS

INFORMATION, DESCRIPTION, TECHNICAL DATA -0 . 1

Description Fuel system changes

- 1972 model

Fuel injection pump changes

- 1972 model

Throttle valve housing and intake manifold changes Cold start enrichment system changes Fuel injection system, schematic Induction air preheating

- 1972 model

Continuous injection system (CIS) Engine cross section

1974 model

Continuous injection system (CIS)

- 1974 model

Fuel evaporative control system

SYSTEM CHECKOUT 1.1

Continuous i n j e c t i o n system (CIS) General checkout procedure Visual inspection Initial checks Pressure tests Leakage checks Injection valve, checking Auxiliary air .device, checking CIS testing Bnd adjustment specifications CIS testing and adjusting specifications

- 1974/75 models 1976/77 models

- 1978/79 models CIS testing and adjusting specifications - 1980 model Testing and adjusting values - 9 1 1 SC (1981 models with Oxygen CIS testing and adjusting specifications

Sensor Control)

Control pressure regulator (vacuum-controlled), checking "Cold" control pressure (vacuum-controlled control pressure regulator), checking Auxiliary air valve, checking Safety switch, checking CIS problems and remedies Automatic choke, troubleshooting

- 1976

model

Thermovalve, checking Downloaded from www.Manualslib.com manualssystem search engine Vacuum layout

- 1978 model

1.1 - 3 / 1

911

FUEL S Y S T E M Vacuum hose layout

;

- 1979 model

Fuel and vacuum lines layout

1980 model

SERVICING 2.1

Servicing informarion 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 Fuel injection nozzles, checking

2.2

Servicing continuous i n j e c t i o n system (CIS) CIS, disassembling and assembling

2.2

- 1/1

Mixture control unit, removing and installing

2.2

- 1/7

Throttle valve housing with control pressure regulator (throttle valve positionj. removing and installing

2.2

- 118

Control pressure regulator (warm running compensation), removing and installing

2.2

- 1/12

Fuel line system, bleeding

2.2

Mixture control unit, dismantling and assembling

2.2

Sensor plate, removing and installing

2.2

- 1/17 - 2/1 - 2/4

Air flow sensor housing, locating operating lever with follower

2.2 -2/6

Mixture control screw basic adjustment after replacement of follower

2.2

Fuel distributor pressure relief valve piston seal, replacing

2.2

- 2/7 - 2/8

Vacuum controlled (warm-up) control pressure regulator, removing and installing

2.2

Auxiliary air valve, removing and installing

2.2

- 3/1

Thermovalve, removing and installing

2.2

3/2

Diverter valve, removing and installing

2.2

3/3

1/9

Start (enrichment) valve; removing and installing Fuel filter, removing and installing Fuel pressure accumulator, removing and installing Injection valves, removing and installing; Plastic fuel lines, re p lacin g

Mixture control unit, disiassembling and assembling from April 1976

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2/9

modifications

911

FUEL S Y S T E M 2.3

Fuel tank Fuel tank plug with CIS filter, cleaning Fuel tank (80 l i t e r ) , removing and installing

2.4

- 1974 model

Fuel pump Fuel pump, removing and installing

1976 model

Layom drawing of Check valves on fuel pumps Replacing check valve 2.5

Oxygen sensor Oxygen sensor, removing and installing . Oxygen sensor control unit, removing and installing Frequency valve for oxygen sensor, checking

2.5

- 1/4

2.5

- 1/8

Throttle valve switch, checking and adjusting Removing and installing microswitch for acceleration enrichment of Oxygen Sensor control (from 1981 models) Correcting C O level setting on mixture control unit with shear-off screw

- (from 1 9 8 1 models)

ADJUSTMENT INSTRUCTIONS 3.1

Adjustment instructions for fuel injection system Fuel injection pump, adjusting with emission tester Idle, adjusting Microswitch, adjusting

- 1972 model

CIS adjustment instructions Idle, adjusting Full power position of throttle, adjusting Microswitch, adjusting Control pressure regulator (throttle valve position), checking and adjusting Hand throttle, adjusting Idle, adjusting

1978 model

- 1980 model Adjusting idle 9 1 1 SC - (from 1981 models) I d l e , adjusting

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Description

FUEL I N J E C T I O N PUMP CHANGES

911

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.

Pump designation (BOSCH number on data plate): 911

0408 1 2 6 0 1 5

911

0408 126014

911

0408 126013

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Description

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. The new levers require the use of modified protractors, special tool P 228 c . The protractor on the injection pump control lever has not been changed. The correlation checkout procedure remains same (see page SF 22). The intake velocity stacks are made of plastic. They form a single unit together. with the lower air assembly.

COLD START ENRICHMENT SYSTEM CHANGES

Fuel for cold start enrichment now is fed directly into each individual velocity stack. The discharge nozzles are bonded and can not b e exchanged.

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911

Description

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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

General Information Beginning with the 1972 models, all 2.4 liter fuel injection engines are equipped with an induction air preheating system. Induction air preheating provides even induction air temperatures in lower engine speed ranges resulting in improved performance, as well as lower exhaust emission values.

1 = Fresh air f l a p

A = Hot a i r

2 = Hot air f l a p

3 = Thermostat Downloaded from www.Manualslib.com manuals search engine

= Fresh a i r

911 Design

Description !

The induction air preheating system consists of: 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. It contains two flaps and a thermostat. On of the flaps (the fresh air flap) is controlled by the throttle linkage. The other flap (hot air flap) is controlled by the thermostat. 2 . A h o s e which fetds heated air from the left heat exchange. 3. A c a rn on the left throttle valve lever which controls the fresh air flap.

1 Control box 2 Hot air supply duct 3 Control, lever

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Description

A thermostat-controlled hot air flap maintains induction air temperature at 4 5 ' ~

Func t io n

(112'~). A second flap stops the flow of hot air from throttle valve position of about 20' and engine draws only fresh outside air at wide open throttle. Engine started, cold (below 4 5 ' ~(112OF) Throttle at idle position (fresh air flap closed)

Hot air flap open, engine draws hot air from heat exchanger. Engine cold (below 450C ( 1 1 2 ' ~ )

throttle in partial load

position Hot air flap open. It opens according to position of cam. Fresh outside air is added.

Fresh air flap is fully open in full throttle position.

Air t e m p e r a t u r e rises t o 45-50°C

(112OF

122OF)

Thermostat begins to close hot air flap at 45OC (112OF). It is fully closed at 50°C (122'~) and engine draws only fresh outside air. A bypass duct, closed by the hot air flap when cold, feeds additional air with increasing temperatures.

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Description

CONTINUOUS INJECTION SYSTEM (CIS)

Beginning with the January 1973 production, Type 911 T vehicles are equipped with the continuous injection system (CIS).

T h e working principle of this system depends on measuring the intake air flow rate to determine the amount of fuel to b e injected. The fuel distributor determines the quantity of fuel to be delivered depending on air flow rate and engine loading conditions.

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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 compensation) Heat exchanger-. Crankshaft Oil pump Oil screen Connecting rod Piston Cylinder Exhaust valve Valve guide Oil hose connection (oil tank - oil pump) Valve spring Rocker arm shaft Camshaft Rocker arm Intake valve Injection valve Intake pipe Intake housing Air sensor plate Mixture control unit

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Description

Mixture Control Unit

Air Flow Sensor and Fuel Distributor.

The air flow sensor consists of a venturi and a sensor plate which is attached to a lever.

The volume of intake air passing through the venturi determines. the position of the sensor plate.

The control plunger and the slotted metering cylinder are located in the center of the fuel distributor. Machined into the metering cylinder are 6 rectangular slots which act as metering ports. They can b e progressively opened'by the control plunger.

The metering ports open depending on the position of the sensor plate whose moyement is transmitted t o the control plunger through a lever

Intake air which passes through the air flow sensor exerts a pneumatic force F l on the sensor plate.

The pneumatic force is countered in the fuel distributor by hydraulic force F2 which is exerted against the control plunger through a port.

The sensor plate will yield until the pneumatic force and hydraulic force equalize.

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1 2 3 4 5 6 7

Venturi Sensor plate Lever Control plunger Slotted metering cylinder Metering port Fuel distributor

Description

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.

Weight of the sensor plate and lever F3 is equalized by the counter weight F4.

Each metering port in the fuel distributor is provided with a pressure regu1at:ing valve which keeps the pressure drop a t the metering port constant (pressure difference = pressure ahead of the metering port less pressure after the metering port) independent of the fuel transfer rate, primary system fuel pressure, and injection valve opening pressure.

T h e pressure regulating valves are flat seat valves with a steel diaphragm acting as a valve plate.

1 Pressure regulating valve 2 Control plunger 3 Metering port

By maintaining the pressure difference constant, it is possible to control the fuel flow rate by means of the size of the metering port crosssection alone.

The injection valves have no metering function.

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F u e l Flow 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. Control pressure can be varied by two (control) pressure regulators, one according to engine and outside temperatures, the other according to accelerator pedal movement.

throttle-actuated valve

' \ -- >

---

injection line

..--

- - *

start valve fuel distributor

fine-mesh filter

Primary system fuel pressure Supplied fuel Control pressure Return flow

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Description

Electric Fuel Pump A roller-type fuel pump is utilized.

Fuel Pressure Accumul.ator The fuel pressure accumulator is located in t h e primary circuit directly after the fuel pump. Its function is to delay the initial pressure surge when the pump starts. This delay is necessary to prevent the control plunger from being forced up before sufficient control pressure has been allowed to build up. It also serves as a reservoir to keep the system under sufficient pressure for a short period of t i m e when the engine is turned off.

Fuel Filter An in-1ine.filter with a paper cartridge is utilized.

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911

Description

Injection Valves 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. Opening pressure for the injection valves is approx. 3 bar.

Start (Enrichment) Valve T h e solenoid-operated start (enrichment) valve discharges supplemental fuel into the intake manifold when the engine is being started.

Control Pressure Regulator (Warm Running Compensation) The control pressure regulator for warm running compensation contains a bimetallic spring acting on a spring-loaded diaphragm. During engine warm-up, the bimetal spring presses against the valve spring causing the control pressure t o drop. This results in a lower hydraulic pressure F2, greater travel of the air flow sensor plate with unchanged amount of intake air, and increased metering port crosssection, making a richer fuellair mixture.

As the bimetal spring is heated, it gradually relaxes its pressure against the valve spring. Thus the control pressure norma.lizes again. Idle speed can b e increased during warm-up by opening the throttle manually (hand throttle).

1 Pressure regulating valve 2 Bimetal spring 3 Heater coil

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Description

Control Pressure Regulator (Throttle Valve Position) The control pressure regulator for throttle valve position is basically similar to the regulator for warn1 running con~pensation. It is attached to the throttle valve housing. A cam plate is attached to the throttle valve shaft and rides along with it, compressing the regulator spring to a greater or lesser degree. This changes the control pressure along with changed throttle valve position, adjusting the fuel/air mixture as required.

Auxiliary Air Device When decelerating from high rprn with throttle closed, considerable vacuum builds up in the intake manifold. The vacuum is channeled to an auxiliary air device. As the device opens, additional air bypasses the throttle creating a combustible mixture.

Idle Adjustment The adjusting method is same as that for carburetors. The idle air mass passes through the air flow sensor where it is measured. The closed throttle is bypassed through a bypass bore. The cross-section of this bore can be changed with the aid of an adjustment screw. A change in cross-section changes the engine speed without affecting the composition of the fuel/air mixture. The fuel/air mixture can b e adjusted within certain limits by means of a mixture adjusting screw to attain the required effect. Downloaded from www.Manualslib.com manuals search engine

911

Description

Thermoswitch

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. The thermoswitch is located in the left chain housing cover. A microswitch is connected in series with it. The microswitch is activated by the hand throttle lever when the latter is moved to at least 5O of the throttle valve position. The thermoswitch is active up to engine temperature of approx. + 45' C ( 1 1 3 ~F) and prevents the injection of supplemental fuel by the cold start enrichment valve when starting a hot engine.

Vacuum controlled warm- up regulator

Controll pressure changes of this warm-up regulator are made via intake manifold vacuum.

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CONTINUOUS INJECTION SYSTEM ( C I S )

Beginning with 1974 models, Type 911 and 911 S, vehicles are equipped with the continuous injection system.

Changes Effective with 1 9 7 4 Models

1. Cast intake pipes with mounting hole for injection valves.

2. Repositioning of the injection valves resulted in their being lengthened and injection lines shortened.

3. The diameter of intake pipes at the intake housing has been changed:

Intake pipe for Type 911 = 911S=

31 m m dia. 34.5mmdia.

4. Mixture control unit has been calibrated for 2.7 liter engines.

5. The pneumatic valve has been repositioned and also modified to the vacuum characteristics prevailing in the 2.7 liter CIS engines.

6. The cold start enrichment valve has been moved to the center of the intake housing to effect a better distribution of the fuel to the individual cylinders.

7. A thermoswitch has been mounted on the left chain housing cover to supplement the cold start enrichment valve.

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Description

911

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

General All vehicles are equipped with a sealed fuel tank venting system incorporating an activated charcoal filter. The closed system prevents fuel fumes from entering the atmosphere. The fumes are ducted into the activated charcoal filter with the aid of fresh air supplied by the engine cooling fan, and then to the engine air filter where they mix with the induction air and are burned with it.

Fuel tank

Expansion chamber

Activated charcoal filter

Cooling fan upper shroud with hose connector

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Hose from cooling fan to activated charcoal filter

Hose from activated charcoal filter to engine air filter

Engine air filter

Return hose connecting fuel tank with the expansion chamber

System Checkout

911

CONTINUOUS INJECTION SYSTEM ( C I S )

GENERAL CHECKOUT PROCEDURE Prerequisite for the CIS checkout is a properly functioning ignition system and proper mechanical condition of the engine. A complete CIS checkout should b e carried out in the below given sequence. However, specific problems can be analyzed by performing individual tests. In addition, the following should be noted: Certain tests require that the engine is cold (check control pressure "cold"). For this test, the engine should be out of operation for several hours, or overnight. The checkout should b e performed a t the same location where the car was parked for several hours. Erroneous test results will b e obtained if, for instance, the vehicle should b e brought into a heated garage from a cold outside environment. The remaining tests, with the exception of the idle adjustment, can b e performed with the engine warm or cold. The engine must b e at warm operating temperature when idling is adjusted. All tests, idle adjustment excepted, are accomplished with the engine turned off.

NOTE Always install new gaskets whenever fuel lines are loosened or detached. It is important to maintain the highest degree of cleanliness when servicing the CIS. T h e outside of the fuel lines must b e thoroughly cleaned before they are loosened.

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911

Syitem Checkout

VISUAL INSPECTION

The CIS should b e visually inspected prior to the initiation of work.

Visual inspection for leaks:

Checking f r e e movement of l e v e r in a i r flow sensor

.I.Check all fuel line connections for leaks.

2 . Check induction system (vacuum system) for

leaks between the mixture control unit and I engine (air duct between mixture control unit and throttle housing).

1.. Unhook rubber straps, remove air filter horn and withdraw cartridge.

2 . Raise lever of air flow sensor by hand 3. Check for leaks between intake manifold and

start (enrichment) valve (O-ring).

4. Check for leaks between intake manifold and

pipes. Replace porous rubber boots.

5. Check hose connections for leaks at: the intake manifold, vacuum hoses at the throttle housing, as well as the auxiliary air device. .

. . .. . .

G.'Check proper seating of rubber covers a t the injection 'valves.

7. Check attachment of intake pipes a t cylinder heads.

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An even amount of resistance should b e felt throughout the length of movement.

A quick downward movement of the lever will detach i t from the sluggish control plunger at which time no resistance should b e felt a t the lever.

Svstem Checkout

I n s p e c t i o n of 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 (sensor p l a t e i n p o s i t i o n of r e s t )

The fuel system must be depressurized when performing this check. To relieve the remaining pressure, slightly loosen the pressure line connection at the control pressure regulator for warm running compensation. When loosening the line, wrap the connection with a rag to keep fuel from spilling.

The upper edge of the sensor plate must now be flush with the root of the taper at a point shown i n the illustration. A lower positioning of up to 0,s mm is permissible.

If required, adjustment of the flexible stop can be corrected by bending the wire bow.

Since April of 1976 the spring-loaded stop of the sensor plate can be corrected with an adjusting screw.

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System Checkout

I N I T I A L CHECKS

The following tests are component tests. Final evaluation of individual parts is possible only upon completion of pressure checks. When performing the tests outlined below, remove the middle fuse from the rear fuse box to keep the heater coil in the control pressure regulator for warm running compensation from heating up.

Checking electric fuel pump

Minimum voltage at the connecting terminal is 11.5 volts.

Current draw when running is 8.5 amps maximum.

Check pump delivery rate: Disconnect fuel return line at the connector. Push a section (about 50 c m long) of normal fuel hose onto the connector and hold in a measuring glass. Switch the ignition on for the duration of the measuring period. See page 1.1 - 1/13 for specifications.

Modifications

1976 Model

Terminals 30 and 87a of the relay (rear of luggage compartment) must be bridged to check the fuel pump delivery rate, due to a safety switch on the mixture control unit (also refer to page 1.1 - 1/17).

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Checking Control Pressure Regulator (Warm Running Compensation)

1. Minimum voltage at the connecting terminal is 11.5 volts.

2 . Check heater coil continuity with the aid of a test buzzer or ohmmeter. (Check between wire terminal at the control pressure regulator and the ground .) The connecting wire must b e detached from the control pressure regulator. If the circuit is open, the control pressure regulator will have to be replaced.

Checking Start (Enrichment) Valve

Remove start (enrichment) valve (see page 2.2 - 1/10); the fuel line remains connected.

Hold the start (enrichment) valve in a receptacle and connect to battery Bt (upper fuse in rear fuse box in engine compartment, left side) and to ground with a piece of jumper wire. Briefly switch the ignition on. The start (enrichment) valve must spray fuel in an even conical pattern.

Remove jumper wire and switch the ignition on. After waiting about 10 seconds, wipe nozzle of start (enrichment) valve dry; no fuel should come out..

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System Checkout

PRESSURE T E S T S

TOOLS

No.

Description

Special Tool

Pressure tester

P 378

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Remarks

System Checkout

General 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 position, respectively. Thus, all pressure tests can be performed without reconnecting the lines. For better clarity, connecting points and lever positions are referenced in the instructions given below according to numbers shown in the adjacent illustration.

Connecting and Bleeding Pressure Tester

Detach pressure lines for control pressure regalators for warm running compensation and throttle valve position.

2. Insert a gasket in the special tool connector and screw into the control pressure connection of the mixture control unit in place of the banjo bolt.

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System Checkout

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 E 2. Allow pressure gauge to hang down (hose stretched) and switch the ignition on. Turn lever of three-way selector valve to. position 2 3 about 5 times at 10 -seconds intervals.

Checking "Cold" Control Pressure This test can b e performed on a cold engine only. It must definitely be performed when encountering starting or warm-up problems.

Turn selector valve to position the ignition on.

E 2. Switch

Pressure specifications for the given ambient air temperature are shown the diagram on page 1.1 - 1/13, Testing and Adjustment Specifications. Excessive deviations from the specified values are caused by a faulty control pressure regulator for warm running compensation which should be replaced in such cases. Downloaded from www.Manualslib.com manuals search engine

System Checkout

C h e c k i n g "Warm" C o n t r o l Pressure

Refer to page 1.1 1/15 for engines with vacuum controlled control pressure regulator for warm running compensation. This test can be lperformed on a warm or cold engine. 1. Detach connecting wire from control pressure regulator for warm running compensation. Connect the regulator to B+ by means of a jumper wire (fuse box in left side of engine cornpartmen$ Switch the ignition on. M3ke sure that the throttle plate is fully a t the idle stop (hand throttle must be fully in).

2. The control pressure will rise slowly and must

reach the idle value shown under testing and adjustment specifications, page 1 . 1 1/13.

3. Open throttle about halfway by hand. The

control pressure should now rise to the specified part -load value.

4. Open throttle fully (full power stop). The

control pressure should now drop to the fullpower value.

If /excessive deviation is encountered, proceed as follows: a. Idle value: Idle value can be corrected within certain limits. Refer to instructions for checking or adjusting control pressure regulator for throttle valve position. If the required pressure cannot be obtained, replace control pressure regulator for throttle valve position. b. Parkload value: Replace control pressure regulator for warm running compensation.

c Full-power value: Replace control pressure regulator formanuals throttle valve Downloaded from www.Manualslib.com search engineposition.

System Checkout

Checking System Pressure 1. Turn selector valve to position

3 and

switch the ignition on. 2. The system's pressure must a.gree with specifi-

cations on page 1.1-1/13. If it deviates from specifications, correct position of pressure relief valve in fuel distributor with shims.

Checking for Leakage 1. Detach electrical wire from the control pressure

regulator for warm running compensation. Using a jumper wire, connect the control pressure regulator for warm running compensation directly to B+ (fuse box on left side of engine compartment). Turn selector valve to position E 2 and switch the ignition on. Having attained the "warm" control pressure value (part-load value), switch the ignition off again and observe the pressure drop on pressure gauge (the pressure will drop considerably first). If the pressure continues to drop too rapidly (see testing and adjustment specifications), repeat check i n position X 3 of the selector valve to locate the problem. If the same results are obtained, four components can be responsible: electrib fuel pump Fuel distributor injection valves start (enrichment) valve Injection valves and start valve are judged i n separate tests. Replace electric fuel pump and seal of pressure relief valve in fuel distributor one after other and repeat e.ach test. 3 position of If leakage does not occur in the selector valve, the problem can be in the control pressure regulators for warm running compensation or throttle valve position.

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System Checkout

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. With the remaining pressure being 1 . 5 to 2.4 bar , no fuel should come out from the return connector of the control pressure regulator for warm running compensation. If some fuel should b e coming out, i t would indicate that the control pressure regulator for warm running compensation is leaking and should b e replaced in such case. If the leak is not in the control pressure regulator for warm running compensation, it will b e found in the control pressure regulator for throttle valve position, in which case the control pressure regulator for throttle valve position will have to b e replaced.

Checking Injection Valves Injection valves must b e removed for testing (see page 2.2 - 1/13).

Testing is accomplished with a Bosch jet tester EFEP 60 H, pressure gauge 0 to 6 bar, caliber 1.0, 100 mm dia., testing agent 01 61 v 11.

See testing and adjustment specifications for opening pressure.

Tight: At a pressure of 0.5 bar less than opening pressure there must not b e any drops falling within 1 5 sec..

See page 2 . 1

- 1 / 5 for testing procedure.

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911

System Checkout

C H E C K I N G A U X I L I A R Y AIR D'EVICE

1. Check idle rpm with control pressure regulator

for throttle valve position connected (engine warm).

2. Stop engine.

3. Remove filter housing with filter cartridge and duct.

4 . Disconnect hose leading to auxiliary air device

above throttle valve a t throttle valve housing and tightly seal the connector and hose.

5 . Install duct.

6 . Start engine and check idle rpm .

NOTE If a change in rpm is noted, the auxiliary air device is leaking. If the valve leaks considerably, it will not be possible to adjust idle speed. Replace auxiliary air device.

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C I S T E S T I N G AND 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

Electric fuel pump, fuel delivery

Page 1.1 - 1 / 4

min. 850 c m /30 seconds

Page 1.1 - 1/8 Page 1.1 - 1/16 a

Control pressure "cold" (at corresponding ambient air temperature) Diagram for Control Pressure Regulator Part No. 911. llO.927.00 (911.606.103.00) Bosch No. 0438.140. 001

Diagram for Control Pressure Regulator Part No. 911.606.103. 01 Bosch No. 0438.140.008

bar kp/cm2

Diagram for Control Pressure Regulator Part No. 911.606.105. 01 Bosch No. 0438.140. 009 Test vacuum: 520 - 546 mbar (390 - 410 mmHg)

Downloaded from www.Manualslib.com search engine only applicablemanuals for vacuum controlled

control pressure regulator

System Checkou:t

Test Step

Test Specification

References

Page 1.1 - 1/9

Control pressure "warm" Throttle position version Throttle valve position: Idle, test specification adjusting specification Partial,throttle Full throttle

2.8 t o 3.0 bar 2.85 to 2.95 bar 3; 4 t o 3.8 bar 2; 6 t o 3 . 0 bar

Vacuum controlled version Testing a t atmospheric pressure (no vzcuum)

2 7 t o 3.1 bar

T o perform vacuum test, connect vacuum pump t o control pressure regulator. Test pressure 520 - 546 mbar (390 410 mmHg)

3.4 t o 3.8 bar

System pressure Test specification Adjusting specification

Leak test (warm engine) Min. pressure after 1 0 minutes 20 minutes

Fuel injectors opening pressure

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Page 1.1 - 1/10 4.5 t o 5 . 2 bar 4: 7 to 4.9 bar Page 1.1 - 1/10

1 . 3 bar 1.1 bar

2: 5 to 3.6 bar

Page 1.1 - 1/11 Page 2 . 1 - 1/5

911

System Checkout C I S T E S T I N G AND 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

Electric fuel pump, fuel delivery

Control pressure "cold" (at corresponding ambient air temperature)

References

Test Specification

Page 1.1 - 1 / 4

min. 850 c m /30 seconds

Diagram for Control Pressure Regulator Part No. 911.606.105.03 and 911.606.105.04 Bosch No, 0438.140.017 and 0438.140. 033 Test vacuum: 520 - 546 mbar (390 - 410 mmHg)

Page 1.1 1/16 a

Page 1.1 - 1 / 9

Control pressure "warm" 1976 Model Testing atmospheric pressure (no vacuum)

2.7 to 3 . 1 bar

T o perform vacuum test, connect vacuum pump to control pressure regulator. Test pressure 520 - 546 mbar 2.7 to 3 . 1 bar (390 - 410 mmHg) At high idle speed (approx. 1800 rpm)

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3 . 4 to 3.8 bar

911

S y s t e m C h e c k o uI t Test Specification

Test Step

References

1977 Model 2.7 t o 3.1 bar

Testing at atmospheric pressure (no vacuum) To perform vacuum test, connect vacuum pump to control pressure regulator, Test pressure 520 - 546 mbar (390'- 410 mmHg)

3.,4 to 3.8 bar 4

Page 1.1 - 1/10

System pressure Test specification Adjusting specification

4.,5 to 5 . 2 bar 4.,7 t o 4.9 bar

Leak test (engine warm) Min. pressure after 1 0 min 20 min

Fuel injectors opening pressure

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Page 1.1 - 1/10

1.'3 bar 1.;1bar

2.5 t o 3.6 bar

Page 1.1 - 1/11 Page 2 . 1 - 1/5

System Checkout C I S T E S T I N G AND 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 Electric fuel pump fuel delivery Control pressure "cold" (at corresponding ambient air temp. )

3 min. 1000 c m /30 seconds

Part No. 911 606 105 05 Bosch No. 0 438 140 045 Test vacuum 460 - 600 mbar (350 - 450 mmHg)

Leak test (warm engine) Min. pressure after 10 min. 20 min. *

2.7 to 3 . 1 bar

3. 2 to 3. 6 bar

Page 1.1 - 1/10 4. 5 to 5. 2 bar

4 . 7 to 4 . 9 bar

Page 1.1- 1/10

1. 3 bar 1.1 bar

Fuel injectors opening pressure Downloaded from www.Manualslib.com manuals search engine

Diagram for Control Pressure Regulato~ (from January 1979) Part No. 9 1 1 606 105,06 Bosch No. 0 438 140 069 Test vacuum 450 - 550 mbar (340 - 420 mmHg)

Page 1.1 1/9

System pressure Test specification Adjusting specification

Page 1.1 - 1/4

Control pressure "warm"

T O perform vacuum test, connect vacuum pump to control pressure regulator

References

Diagram for Control Pressure Regulator

Testing at atmospheric pressure (no vacuum)

Test Specification

2, 5 t o 3.6 bar

Page 1.1 - 1/11 Page 2 . 1 - 1 / 5

911

System Checkout

C I S TESTING AND ADJUSTING SPECIFICATIONS (1980 Model with Oxygen Sensor)

Test Step Electric fuel pump, fuel delivery

Test Specification

References Page 1.1 - 1 / 4

min. 1000 cm5/30 seconds

Control pressure "cold" (at corresponding ambient air temperature)

Diagram for Warm- up Regulator Part No. 911. 606.105. 07 Bosch No. 0438 140 072

Page 1.1 - 1/8

Control pressure "warm"

3 . 4 to 3, 8 bar

Page 1.1 - 1/9

System pressure Test specification Adjusting specification

Page 1.1 - 1/10 4. 5 to 5. 2 bar 4 . 7 t o 4 . 9 bar

Page 1.1

Leak test (warm engine) Min. pressure after 1 0 min. 20 min.

1. 3 bar 1.1 bar

Fuel injectors opening pressure

2. 5 t o 3. 6 bar

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- 1/10

Page 1.1 - 1/11 Page 2 . 1 - 1 / 5

911

Checking T E S T I N G AND A D J U S T I N G VALUES (1981 Models with Oxygen Sensor Control)

9 1 1 SC

Test Step

Testing/Adjusting Value

Special Instruction

Electric fuel pump Delivery rate

at least 1000 cc/30 sec.

Page 1.1 1/4

Control pressure "cold"

Diagram for warm-up control Part No. 911.606.105.08 Bosch No, 0438.140.090

Control pressure "warm "

3.4

System pressure Test value Adjusting value

4.5 4.7

Leak test (engine warm) Min. Pressure after 10 min. after 20 min, Fuel injectors Opening pressure

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Page 1.1 - 1/8

... 3.8 bar

Page 1.1 - 1/9

... 5.2

Page 1.1 1/10

...

bar 4.9 bar Page 1.1

- 1/10

1.3 bar

1.1 bar

2.5

...

3.6 bar

Page 1.1 1/11 Page 2.1 - 1/5

911

Checking

Test Step

Testing and Adjusting Valuer

USA and Canada

Idle setting

Manual transm. to 1977 models

900

+- 50

Sportomatic to 1977 models

950

f 50

California imd High Altitude States

900

'1- 50

Idle speed (rpm)

1977 models

950

1978/79 models

950

f 50

900

2 50

1980 models

1 1

1000 950

1 9 8 1 models

CO content

(70)

1 1

+ 50

1. 5 to 2.0

1974 models 42.7 ltr. )

1.5 to 2.5

1. 5 to 2.5

1975 models

1.7 to 2. 0

1976 models

2.0 to 4.0

1977 models

11.5to3.0* 1.5 to 3.5

Measured in front of catalytqc converter and with oxygen sensor plug disconnected.

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900

1.5 to 2.0

Air pump disconnected.

f 50

1973 models (2.4 ltr. )

1978/79 models

900

+ 50

900250

2 50

1.5 to 2.0 2.0 to 4.0

11.5t03.0*

1.5 to 3.5

System Checkout 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. Refer to page 1.1 - 1/7.

Note Connect pressure line (of control pressure regulator only) to second connector of pressure tester since the throttle valve control pressure regulator has been eliminated.

C H E C K I N G " C O L D " C O N T R O L PRESS1JRE

Refer to page

i. 1- 1/16

C H E C K I N G " W A R M " C O N T R O L PRESSURE

This test can be done on a cold or warm engine.

1. Remove mounting plate cover in engine cornpartment. 2. Remove standard relay at center of relay plate.

Note The standard relay for the control pressure regulator of some vehicles is located to the rear, right side of the relay plate - and not as illustrated. Also refer to Group 9 , Page 0.1 - 4/3. CAUTION With the.JS76 Model the relay is in luggage cornpartrnent (rear relay as seen in driving direction). 3. Bridge terminals 87 a and 30 of a spare relay. 4. Place this modified relay in relay plate instead of the original relay.

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911

System Checkout--'

5. Turn on ignition (fuel pump runs).,

6. The control pressure rises slowly and must i 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.

CAUTION Reinstall original relay after testing!

C H E C K I N G " I D L E " C O N T R O L PRESSURE

Start engine. Control pressure must be 3. 6 i speed of 900 - 50 rpm. 1978 and later models: 3.4 i speed of 900 - 50 rpm.

- 0. 20 bar at idle

-t

0.20 bar a t idle

CAUTION Position selector valve a t 2 for this control pressure test.

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System Checkout 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 - up) c o n t r o l p r e s s u r e r e g u l a t o r )

TOOLS

No.

Description

Hand vacuum pump

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Special Tool

US 8026

Remarks

91,

System Checkout;

C H E C K I N G " C O L D " C O N T R O L PRESSURE (vacuum controlled (warm- up) control pressure regulator)

Note Engine must b e absolutely cold. From 1975 models diagram values are only for the vacuum controlled testing method,in the case of vacuum controlled (warm-up) contrbl pressure regulator.

5. Bridge electric safety circuit, by pulling off standard relay in trunk (rear relay looking forward) and replacing with a relay of which terminals 87 a and 30 are bridged or by pulling off wire plugs on air flow sensor.

1. Connect and bleed pressure tester. Set valve to position 2.

2. Remove hose between heater blow+ and warm air neck.

3. Pull off vacuum hose from (warm-qp) control pressure regulator and connect hose:/manual vacuum pump (US 8026) to connection of (warm-up) control pressure regulator.

6. Turn on ignition (fuel pump should run).

7. Adjust vacuum to specified value with the manual vacuum pump (9160) - see page 1.1 - 1/13.

8. Refer to diagram below "Testing and Adjusting Specifications" on page 4. I. - 1 / 1 3 for specified pressure corresponding with actual outside temperature.

4. Pull off wire plug from (warm-up) control pressure regulator. Downloaded from www.Manualslib.com manuals search engine

Checking

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. a) Pull off standard relay in luggage compart ment (rear relay as seen in driving direction). b) Bridge terminals 30 and 87a, turn on ignition. c) Connect test lamp to both auxiliary air regulator terminals from which the plugs have been pulled off.

4. Refer to "Troubleshooting Automatic Choke"

for other checks.

C H E C K I N G A U X I L I A R Y AIR VALVE Refer to "Troubleshooting Automatic Choke".

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Checking

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.

Turn on ignition; fuel pump should not run.

3. Lift sensor plate lever; slightest movement

should start fuel pump.

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Checking

CHECKING THERMOVALVE

1. Detach vacuum hose (1) at warm-up regulator.

4. Blow into detached vacuum hose (from warm-

up regulator) by mouth. Valve must open after 10 to 30 seconds, if thermovalve's ambient temperature is 20 to 30' C/68 to 86' F. Replace thermovalve, if necessary.

2. Bridge terminals 30 and 87a of fuel pump relay in luggage compartment (rear relay as seen in driving direction

3. Turn on ignition and stop time until switched in.

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System Checkout

C I S PROBLEMS A N D REMEDIES

A properly working ignition system and good mechanical condition of the engine are prerequisites for a successful CIS problem diagnosis.

Problem

Engine does not start or is difficult to start when cold Engine does not start or is difficult to start when warm Engine misses when car is driven Unsatisfactory engine performance Excessive fuel consumption Engine backfires into intake pipe -

Engine dieseling

I I I I

Rough idle during warmup Rough idle when warm Idle speed cannot be adjusted CO emissions too low at idle

I CO emissions too high at idle Downloaded from www.Manualslib.com manuals search engine

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

I 8

Air flow sensor plate not resting properly at stop Visual inspection

Visual check (adjust)

Basic adjustment (idle) too rich

CO test (adjust)

-Basi.c-a.djustm.ent..(id.le) -too-lea n...

.. . .

-CO-test-(-adjust)-

Dirty fuel system

Clean

Electric fuel pump not running

Check

Defective reversal valve in fuel pump

Replace fuel pump

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Throttle valve does not open fully

inoperative or hand throttle out of adjustment

Adjust

Checking

TROUBLESHOOTING A U T O M A T I C CHOKE

911

1 9 7 6 MODEL

Problem:

Speed remains too high at high engine temperatures or no speed increase on cold engine.

Possible Cause:

Auxiliary air regulator or auxiliary air valve defective.

Remedy:

1. Disconnect top control line at auxiliary air valve and plug.

P r o b 1 e m c o r r e c t e d : Replace auxiliary air valve. P r o b l e m u n c h a n g e d : Auxiliary air valve good. 2. C o 1d e n g i n e : If there is no increase in speed, auxiliary air regulator is defective.

W a r m e n g i n e: Disconnect one hose at auxiliary air regulatdr and plug both openings. S p e e d t o o h i g h : auxiliary air valve defective S p ee d d r o p s:

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auxiliary air regulator defective

VACUUM SYSTEM LAYOUT (1978 Models)

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1 2 3 4 5

- Throttle housing

Auxiliary air valve Auxiliary air regulator Thermo valve (Warm-up) control pressure regulator

6 7 8 9 10

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Ignition distributor

- Diverter valve

Deceleration valve Vacuum source for auxiliary air valve and auxiliary air regulator Vacuum source for power brake

System Checkout L A Y O U T O F FUEL A N D V A C U U M L I N E S

9 1 1 SC ( f r o m 1 9 8 0 M o d e l )

Fuel lines Vacuum lines Throttle housing Mixture control unit Fuel injector (Warm- up) control pressure regulator Cold start valve Auxiliary air valve Auxiliary air regulator

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8 - Frequency valve 9 - Ignition distributor Fuel pump 10 11 Fuel reservoir 1 2 - Fuel filter 1 3 - Deceleration valve 14 Vacuum booster

Servicing

911

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

Removing

1. Detach hot air hose between left heat exchanger and regulator housing, then remove hose between regulator housing and air cleaner intake.

2. Remove 3 retaining bolts from left velocity stack and remove regulator housing.

Installing Adjust fresh air flap (see page 2.1-1/2).

C H E C K I N G O P E R A T I O N OF I N D U C T I O N AIR P R E H E A T I N G S Y S T E M

1. Hot air flap must be open when engine is cold. This can be checked through the bypass hole in the regulator housing. The hot air flap closes the bypass duct and stays in place under spring tension.

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Servicing

2. Warm up engine at about 2500 rpm. The hot air flap must close after about 3-4 minutes. Check flap position through bypass hole.

fs controlled by a thermostat, does not work,, replace the regulator housing.

3. If the hot air flap, which

N o t e : The thermostat in the regulator housing can not be replaced. :Replace the entire control box.

A D J U S T I N G FRESH AIR FLAP

1. Adjust :fresh air flap with throttle valve

linkage set in idle position.

2. Adjust roller for fresh air flap lever with both nuts so that the roller touches the control lever without play. Lock the nut.

Note: After adjusting, check that the fresh air flap begins to open with throttle valves set at 20'.

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Servicing

911

REPLACING FRESH AIR FLAP LEVER

Caution Prevent nut from falling into regulator housing by holding nut of retaining bolt during removal. 1. Remove bolt and lever.

Note: Hold lock nut with punch or scriber. The nut can fall into the control box.

1 Nut Downloaded from 2 www.Manualslib.com Spring washer manuals search engine

3 Washer 4 Lever

5 Control box 6 Nut

911

Servicing

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. ASE 000 049.

Note: The hose clamps can be used only once.

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FUEL I N J E C T I O N TOOLS

Special Tool

Remarks

N 0.

Description

Injection nozzle tester with two pressure gauges

Use Bosch or similar injection nozzle tester. Pressure gauge range: 0-25 k g /cm 2 (0-355 psi)

Line with fittings

Use Bosch EF 8040/30 or similar

Pressure gauge 0-6 k p /cm 2 K1. 1.0 Downloaded from www.Manualslib.com manuals search engine

For CIS

servicing

C H E C K I N G FUEL I N J E C T O R S General

Instructions for checking the injectors apply to vehicles equipped with either the mec$anical or CIS fuel injection. The injector tester is used for checking opening pressure, spray pattern, and leakage of injectors. Fill container of the tester with testing oil and bleed tester prior to testing the injectors. Use only testing oil 0 1 6 1 v 11. Under no c i r c u m s t a n c e s should gasoline b e used.

When testing injectors for the mechanical injection system, use pressure gauge EF 1687 239 000 0 25 bar. When testing CIS injectors use pressure gauge with calibrations 0 - 6 bar. ,

Bleeding t h e Tester 1. Open bleeder screw.

2. Open pressure gauge valve.

Actuate hand lever until testing oil comes out of the bleeder without air bubbles.

Tighten bleeder screw.

Connect injector to pressure line but do not tighten connection. Actuate: hand lever until air bubbles cease to come out a t the coupling nut.

Tighten injector to pressure iine.

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Replace injector, if opening pressure is outside of these tolerances.

Checking Injectors Note

Caution

T h e injectors of one engine can b e replaced separately. Defective injectors cannot b e repaired, but must b e replaced.

When pressure gauge shut-off valve is open increase pressure slowly- to avoM damag.ing.the pressure gauge.

Checking Checking for Leaks Operate hand lever slowly (about 2 sec./stroke) with the pressure gauge shut-off valve open. In this manner a valve leaking because of a large particle of dirt can b e recognized (tight spray on valve, pressure built up to max. 1.5 bar).

Mechanical Fuel Injection 1. Open shut-off valve on pressure gauge until t h e pressure on t h e pressure gauge has dropped below 1 5 bar.

Checking Opening Pressure

Flush injector with the pressure gauge shutoff valve closed by moving lever back and forth several times quickly. Open pressure gauge shut-off valve and read opening pressure on pressure gauge while moving lever slowly (about 2 sec./stroke). T h e opening pressure is: 15 to 18 bar (mechanical injection system) 2, 5 t o 3, 6 bar (continuous fuel injection)

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2. Operate hand lever slowly until a pressure of 2.0 bar less than the measured opening pressure

is reached.

No drops should form on t h e valve within 1 5 seconds when the pressure is 2 bar less than t h e opening pressure.

911

Servicing

Continuous Fuel Injection

1. Close pressure gauge shut-off valve and flush injector by operating lever many times.

2. Open shut-off valve and increase pressure

slowly to 0.5 bar less than the previously measured opening pressure (but not below 2, 3 barJ, and hold. No drops should form on injector within 1 5 seconds.

Humming Test/Checking Spray Pattern

1. Close pressure gauge shut-off valve and flush injector by operating lever many times (0.5 sec./stroke)

2. Then reduce lever movement to about 1 sec./ stroke. This must cause injector to hum. No drops should form on injector. A tight spray pattern is not allowable. An atomized, one 0 sided spray pattern of about 35 is permissible.

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Servicing

DISASSEMBLING A N D REASSEMBLING

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!3II

911

Servicing

No.

Description

removing

Note when installing

References

Rubber strap

Intake horn

Filter cartridge

Duct

Hose clamp

Banjo bolt

Gasket

Stud

Gasket

Plug

Allen bolt

Spring

Washer

Mixture control unit.

Gasket

Allen bolt

Spring washer

Throttle valve housing

O-ring

Holder

Allen bolt

Spring washer

Microswitch

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Replace if necessary

Replace

Tighten lightly, then loosen by 1 turn

Page 2.2

- l/V

Page 2.2 - 1/7 Replace

Page 2.2 - 1/8 Replace

Page 3.2

- 1/4

911

Servicing

Description

removing

Note when installing

Reference

Allen bolt Lock washer

Replace

Washer Control pressure regulator for throttle valve posit ion Spring

Page 2.2

- 1/8

Page 2 . 2

- 1/10

Bolt Lock washer Terminal block Allen bolt Washer Auxiliary air device Spacer sleeve Allen bolt Spring washer Start (enrichment) valve O-ring Bolt Spring washer Washer Support Rubber/metal cushion

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Replace

911

servicing

Description

Note when removing

installing

Reference

Support Sheet metal screw Holder Hose clamp

Flame trap cartridge Plug Gasket

Replace

Allen bolt Spring washer Control pressure regula tor for warm running compensation Nut

Page 2.2

- l/9

Page 2.2

- 1/13

Intake pipe Hose clamp Rubber muff

Replace if necessary

Gasket Injection valve Rubber bushing Spring Pull rod Nut Spring washer Bracket Intake manifold

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911

Servicing

Designation

Note when removing

installing

References

Injection line

Supply line t o control pressure regulator for warm running compensa tion

Page 2.2

- 1/15

Supply line t o control pressure regulator for throttle valve position

Page 2.2

- 1/15

Page 2 . 2

- 1/15

Supply line from fuel filter to mixture control unit Supply line to start (enrichment) valve Return line from mixturc control unit to fuel tank Return line from control pressure regulator for throttle valve position to fuel tank Return line from control pressure regulator for W E running compensation to fuel tank Connector for return flow hoses Vacuum hose Vacuum hose Vacuum hose Vacuum hose

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Install in proper position

Servicing

REMOVING AND INSTALLING MIXTURE CONTROL U N I T

Removal Disconnect all fuel lines and hoses from the mixture control unit. Detach fuel supply line from fuel filter. NOTE Use rag to prevent fuel spillage.

2 . Unscrew 6 Allen bolts and remove with

spring and plate.

3. Remove mixture control unit together with

gasket.

Installation 1. Watch proper location of gasket. 2 . Tighten Allen bolts to bottom, then back off 1 complete turn. 3. Use new gaskets in fuel line connections.

4. Bleed fuel line system (see page 2.2

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- 1/17)

911

servicing

REMOVING AND I N S T A L L I N G T H R O T T L E VALVE HOUSING AND CONTROL 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 )

Removal 1. Disconnect fuel line, which connects mixture

control unit with the control pressure regulator for throttle valve positibn, from the mixture control unit. 2 . Disconnect fuel hose from reiulator .

3 . Remove 4 Allen bolts and withdraw throttle

valve housing with control pressure regulator for throttle valve position.

4 . Remove 2 Allen bolts and remove regulator from

throttle valve housing.

Installation 1. Check proper positioning of the O-ring for the throttle valve housing. 2 . Adjust control pressure regulator for throttle valve position (see page 3 . 2 .- 1/5). 3. Bleed fuel line system (see p&e 2 . 2

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- 1/17).

Servicing

911

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 PRESSURE R E G U L A T O R (WARM R U N N I N G COMPENSATION)

1. Disconnect ground strap from both batteries.

2 . Detach electrical connections

3 . Disconnect .fuel hose.

4. Remove Allen bolts.

5. Remove fuel l i n e which connects mixture control unit with t h e control pressure regulator for warm r u n n b g compensation from t h e mixture control unit.

NOTE Use rag t o prevent fuel spillage.

6 . Bleed fuel l i n e system (see page 2.2

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- 1/17).

Servicing

REMOVING A N D I N S T A L L I N G S T A R T (ENRICHMENT) VALVE

Removal 1. Disconnect ground strap from both batteries.

2. Remove auxiliary air device from throttle

valve housing.

3. Detach twin electrical connector from. t h e

start (enrichment) valve.

4 . Remove Allen bolts.

5 . Loosen hose c l a m p and detach fuel line.

1nstallatio.n Be sure O+ring is

prdperly .

NOTE Electr.iZ:al connector must point, upward.

Bleed fuel l i n e system (see page 2 . 2

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- 1/17).

servicing

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

1. Disconnect ground strap from both batteries.

2. Remove fuel line coupling nut.

NOTE Use rag to prevent fuel spillage.

Remove retaining clamp and hose clamp and remove filter. NOTE Use an appropriate vessel to collect fuel which may be running out.

Do not overtighten the retaining strap since this could deform the filter assembly.

5. Check all connections for leaks.

6. Bleed fuel line system (see page 2.2

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- 1/17)

911

Servicing

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. Unscrew coupling nut from f u d supply line at the fuel pressure accumulator.

NOTE Use rags to prevent fuel spillage.

2 . Remove attaching clamp.

3. Loosen hose clamp, withdraw fuel pressure accumulator and plug fuel hose with an appropriate plug.

4. Check all connections for leaks.

Arrangement from 19 77 Models 5. Bleed fuel line system (see page 2.2

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- 1/17).

REMOVING AND INSTALLING INJECTION VALVES

TOOLS

Description

Special Tool

Remover

P 384

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Remarks

911

Servicing

Removal 1. Unscrew coupling nut from the injection line

at the injection valve.

2. Install special tool P 384 and pull injection valve out.

3. If rubber bushing remains in the support sleeve,

take the bushing out with a screwdriver. NOTE Avoid damaging the supportirlg sleeve.

Installation 1. Inspect rubber bushing, replace if necessary. 2 . Use a drop of engine oil when installing the

bushing. 3. Press injection valve firmly into the supporting sleeve to stop. The rubber bushing must be seated below the bulge in the supporting sleeve:. 4. Check fuel lines for leaks. 5. Bleed fuel line system (see page 2.2 Downloaded from www.Manualslib.com manuals search engine

- 1/17).

Servicing

911

R E P L A C I N G P L A S T I C FUEL LINES

TOOLS

Description

Special Tools

Installer

P 385

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Remarks

servicing

The mixture control unit, control pressure regulator for throttle valve position and control pressure regulator for warm running compensation replacements are furnished with plastic fuel lines attached. Defective plastic fuel lines can b e replaced individually.

1. Using a soldering iron, heat defective fuel

line in the connector area and pull the l i n e off.

2. Mount replacement part in a vise with soft

jaw protectors.

3. Mount fuel line in special tool P 385, allowing

push-on section to protrude from the tool.

4. Push dry fuel line onto the connector.

NOTE Make sure that line is properly positioned.

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Servicing

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.

1. Remove intake horn with filter cartridge.

2 . S-witch the ignition on.

Press diaphragm up by hand to stop (for 1 second to a maximum of 5 seconds) until the fuel lines are filled and t h e injection valves spray fuel audibly.

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911

Repairs

D I S M A N T L I N G AND ASSEMBLING MIXTURE CONTROL U N I T

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Note during: No.

Description

removal

Plug

installat ion

remarks

Torque to 1.3 to 1.5 mkp

Seal A 10 x 13.51

Shim

Spring

Piston

Seal

Capscrew M 5 x 50

Fuel distributor

Seal

Nut

Washer

Capscrew

Insulator

Spring

Replace if necessary; install correctly

Clip

Replace if necessary; install correctly

Stop

Install correctly

Hex head screw

Torque to 50 55 cmkp and apply liquid thread locking compound

Washer

Sensor plate

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Replace 2.2

Use conical wood peg to drive out

2/8

Replace fuel distributor if damaged

Torque t o 3 2 cmkp

- 38

Don't let control plunger fall out

do not dismantle

Replace

Torque to 47 cmkp

- 53

Check, replace if necessary

Repairs

Note during:

No,

Description

removal

installation

Circlip

First remove this circlip

Install with sharp edgc facing outward

Cover

Seal

Spring

Ball

Coat with silicone grease

Circlip

First install this circlip with sharp edge facing outward

Cover

Seal

Replace

Ball

Coat with silicone grease

Capscrew

Torque t o 47 - 53 cmkp a n apply liquid thread locking compound

Check, replace if necessary

Counterweight

Operating lever

Check

Follower

Check if bearing play is too large, needle bearing is damaged, mixture control screw is damaged or rusted, replace parts if necessary

Plug

Air flow sensor hsg.

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Replace

Coat bearing bores with silicone grease

remarks

911

Rep 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

Removing

1. Remove fuel distributor.

2. Clamp mixture contrdl unit vertically in vise

with plastic guards on jaws. Clamp mixture control unit at bend i n narrow section of operating lever.

3. Loosen sensor plate mounting screw and re-

move sensor plate.

Installing

1. Clamp mixture control unit horizontally. Coat sensor plate mounting screw with "Loctite" or "Omnifit". Place new or old sensor plate in center of operating lever and slightly tighten screw by hand.

2. Measure gap between sensor plate and air venturi. A visible gap of about 0.10 mm

should be seen all around ,the sensor plate.

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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 - 1/3).

3. Clamp mixture control unit vertically in vise

with plastic guards an jaws. Clamp mixture unit a t bend in narrow section of operating lever (housing must be able to be moved toward vise). Torque hex head screw to 50 - 55 cmkp.

4. Recheck sensor plate adjustment.

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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

1. Apply "Loctite" or "Omnifit" to counterweight mounting screw and tighten m e w slightly.

2. Adjust operating lever in air flow sensor housing.

3. Tighten mounting screw to 47

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- 53 cmkp.

Repairing

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

Caution

This test requires that the sensor plate b e positioned correctly (rest position).

Never apply downward pressure t o adjusting wrench during adjustments, since this could change t h e injection timing.

1. Install mixture control unit.

6. Run engine to o g e r a t i n ~temperature (oil temperature 80 to 90 C) and adjust i d l e speed and CO level t o their final specified values.

2. Bleed fuel lines. (Disconnect injectors and hold in a container. Move sensor p l a t e by hand many times).

3. Use adjusting wrench P 377 to initially turn

the mixture control screw counterclockwise about 1 - 2 turns.

4. Turn on ignition, pull plugs off safety switch

on air flow sensor or fuel pump relay.

5. Turn mixture control screw clockwise until

the injectors just barely eject. From this point turn t h e mixture control screw back, i.e. counterclockwise, by one half turn. Install injectors.

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911

Repairs

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.

3. Remove spring and piston (if necessary, use

conical wood peg).

4. Replace seal on conical section of piston, being careful not do damage new seal and piston. 1. 2. 3. 4. 5.

Plug Seal Shim Spring Piston 6. Seal

5. Install plug with shim (as found while removing) and new seal. Torque screw to 1.3 - 1.5 mkp.

6. Check pressure of system (refer to page 1.1

1/10), correcting with shims if necessary.

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Repairing

DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL U N I T

MODIFICATIONS from April, 1976

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Repairing

Description

Note when removing

Remarks

installing

Plug

Torque to 13-15 Nm (1.3-1.5 kpm)

Seal

Replace

Shim 0.1 m m thick 0.5 m m thick

Quantity as required

Spring Pist on

Pull out with tapered wood dowel

Check, replace entire distributor if damaged (fitted part)

O-ring

Be careful not to damage piston

Replace

Fillister head cap screw Fuel distributor

Seal

Torque to 3.5 Nm (0.35 kpm) Be careful not to let control piston fall out

Check control piston, clean with gasoline, install with chamfer facing down. Replace

Plug Nut Washer Fillister head cap screw

Torque to 4.7-5.3 (0.47 -0.53 kpm)

Washer Insulator Fillister head cap screw

Torque t o 4.7-5.3 Nm (0.47-0.53 kpm)

Washer Plug connector

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Install in correct position

Never disassemble

Repairing

No.

Description

Note when removing

installing

Nut

Stop bracket

Plastic insulator

Nut

Adjusting screw

Leaf spring

Bolt

Spring washer

Sensor plate

Check, replace if necessary

Circlip

Sharp side faces out

End plate

Seal

Spring

Ball

Circlip

End plate

Seal

Ball

Fillister head cap screw

Counterweight

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Torque to 5.0-5.5 Nm (0.50-0.55 kpm) and apply liquid locking agent

Lubricate with (Bosch Ft 2 v 2) silicone grease

Torque to 4.7-5.3 Nm (0.47-0.53 kpm and apply liquid locking agent

Remarks

91,

1 No.

Repairing

Description

Note when removing

installing

iemarks

Pivot pin Operating lever Adjusting lever

Check whether bearing play is excessive or needle bearing is d a m aged, replace if necessary

Mixture control screw Air flow sensor housing

Lubricate bearing bores with (Bosch Ft 2 v 2) silicone grease

DISASSEMBLING AND ASSEMBLING INSTRUCTIONS

Engage adjusting lever in spring holder by applying sufficient pressure.

9 I

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Repairs

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

Removing

1. Disconnect battery.

2. Disconnect warm intake air connection.

3. Release fuel system pressure by loosening the warm-up regulator pressure line connection a t the mixture control unit. Wrap a rag around this connection when loosening to catch escaping fuel. Retighten lines afterwards.

4. Remove air pump air filter.

5. Remove left and right heater hoses, loosen clamp at heater blower and swing heater blower upward.

6. Loosen and remove clamp holding hoses and lines (I), vacuum hose clamp (Z), plug connector (3), fuel return line (4) and fuel feed line (5).

7. Loosen two socket head capscrews and remove warm-up regulator.

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Repairs

Installing

Torque fuel return line hollow bolt to 1.1 mkp.

Note The bottom of the warm-up regulator and the holding plate must b e clean to assure proper ventilation for the warm-up regulator.

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Repairs ~

REMOVING

A N D I N S T A L L I N G AUXILIARY AIR REGULATOR

Pull wire plugs off of auxiliary air regulator.

2. Loosen hose clamps.

Loosen socket head cap screws and remove auxiliary air regulator.

REMOVING A N D INSTALLING AUXILIARY AIR VALVE

1. Loosen hose clamps and pull hoses off of auxiliary air valve.

Loosen mounting screws and remove valve.

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911

Repairing

REMOVING AND INSTALLING THERMOVALVE

Removing

1. Remove formed hose, left heater hose and right heater hose. Disconnect electric wires, loosen clamp and remove heater blower.

2. Disconnect electric plug a t thermovalve.

Detach hoses, unscrew bolt and remove thermovalve.

Installing

Connect vacuum hoses properly. Outer connection on thermovalve (1) to control pressure regulator connection ( I ) , see photos below.

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Servicing

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.

2. Loosen nuts on air pump carrier and remove

diverter valve with holder, pulling off vacuum hose at same time.

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Servicing

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.

Use new rubber gasket during reassembly.

Tank plug tightening torque is 0.8

- 0.9

mkp.

1. Fuel tank 2. Rubber gasket 3. Tank plug with filter

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Repairing

911

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 )

Removing

1. Take off bottom guard.

6. Pull off connecting hose and remove fuel tank from above.

2. Open plug and drain fuel. Then detach fuel lines at tank

Note Observe safety regulations when draining fuel.

Installing

Pull off tank vent hose and fuel gauge wire plug (first unscrew cover on top of plug).

From 1980 models the tank vent neck as a 1 4 mrn diameter (1974 t o 1979 models: 9 mm diameter). After depletion of tanks with 9 mrn neck, only new tanks with 1 4 mrn neck will be available from parts. An adapter w i l l be required between the connector (Y-piece) and tank when installing this tank in cars prior t o 1980 model.

Remove holders for fuel tank, If necessary, loosen battery and push battery away. 1. paste new tank seal on tank. Install tank.

Loosen hose clamp on connecting hose between filler neck and tank.

2, Clean filter screen on fuel drain plug. Use a new

round cord seal and tighten drain plug t o specified torque (see page 2.3 - 1/2). Make sure hoses are connected correctly and tight.

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Repairs

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

Removing

1 9 7 6 MODEL

4. Loosen intake fuel hose clamp and remove

fuel pump. 1. Remove guard.

2. Loosen strap and pull fuel pump down a little.

Installing 1.. Install pressure fuel hose hollow bolt with new seals. Torque to 1 6 2 3 Nm/1.6 -

2.3 mkp.

3. Clamp intake fuel hose shut with a pinch clamp. Pull off wire connectors, remove pressure fuel hose and catch escaping fuel.

Note Hollow bolt seals have different thicknesses and must be installed correctly. Place thicker seal between coupling and pump body; thinner seal between coupling and head of hollow bolt.

2. Install wire connectors on to appropriate terminals.

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Repairs P

3. Pull cover over wire connectors and position

rubber ring for installation.

Note To prevent corrosion, make sure that cover fits properly.

4. Slide intake fuel hose on pump nipple and secure with hose clamp.

Remove pinch clamp from intake fuel hose.

Position fuel pump for installation (top electrical terminal inclined back about 0 35 )and secure with strap.

7. Check hose connections for leaks.

8. Install guard.

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Repairing

911

LAYOUT DRAWING OF CHECK VALVES ON FUEL PUMPS

No.

Note When:

Description Removing

Installing

Fuel pump (long neck version with integrated check valve)

Fuel pump

Check valve with seal

Always replace seal; tightening torque: 20 Nm

Seal

Always replace

Cap nut

Tightening torque: 20 Nm

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Special Instructions

Repairing

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. Catch escaping fuel.

3. Screw in new check valve with a new seal.For

iong neck version fuel pumps this new check. v a h e is installed in addirion to the check valve integrated in the pump.

4. Install fuel line and new seals, and secure with

cap nut.

Important: Make sure fuel hose is routed correctly and cannot rub before tightening cap nut.

5. Remove~shut-off d e v i c e - a d ckeck'.for leaks. .Ins t 2 1 bottom guard again;

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Servicing 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

Removing

1, Disconnect plug for oxygen sensor on left side

5. Pull off safety plug on oxygen sensor,

of engine compartment, Push wire grommet and plug through engine panel downward.

6. Remove oxygen sensor.

2. Lift car.

3, T a k e off left rear wheel.

4. Remove shield.

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SII

Servicing

Installing

1. Coat threads of oxygen sensor with Bosch paste VW 140 16 Ft.

Note Never allow assembly paste to get into slot of sensor,

2. Tighten sensor to specified torque Reference value: 50 - 60 Nm (36 - 43 ft lb).

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Servicing

A counter is installed behind the fresh air blower to monitor the operation time. It will turn on the oxygen sensor indicator lamp after car has been driven 30,000 miles. The counter must be reset to zero each time the oxygen sensor is replaced.

1. Remove right seat after loosening front and

rear screws on seat rails.

1. Disconnect battery ground.

2. Remove speedometer,

3. Press in reset button on counter against stop with an approx. 3 mm thick piece of wire. Counter will return to zero position and oxygen - sensor indicator light resumes its normal function.

2. Loosen screws on control unit. PulL off plug

and remove control unit.

RE-MOVI.NG A N D I N S T A L L I -N G C O N T R O L V N I T FOR ACCELERATION ENRICHMENT OF O X Y G E N S E N S O R C O N T R O L

1. Remove right seat. 2. Pull off plugs, unscrew bolt and remove control

unit.

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911

Servicing

C H E C K I N G F R E Q U E N C Y V A L V E FOR OXYGEN SENSOR

REMOVING AND I N S T A L L I N G T H R O T T L E VALVE S W I T C H

1. Pull off wire plug.

Removing

Remove air cleaner and cowl.

Disconnect holder for frequency valve, vacuum hoses for distributor, hose to vacuum booster and wire plug on throttle valve switch. Remove 4 socket head scre:cvs and remove throttle housing.

2. Connect ohmmeter on frequency valve. Coil resistance: 2 t o 3 ohms.

3, If necessary, replace frequency valve.

3, Remove mounting screws and remove switch.

Installing

Make sure O-ring is positioned properly on throttle housing.

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Servicing 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

TOOLS

No.

Description

Special Tool

Dial scale

from P 228 b

Pointer

from P 228 b

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Remarks

911

Servicing

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. Remove throttle housing.

2. Mount dial scale from Special Tool P 228 b on throttle valve shaft.

3. Set pointer (from Special Tool P 228 b) to 0.'

4. Connect standard buzzer or continuity tester to terminals 1 8 and 2 (idle contact) of throttle

valve switch.

5. Operate throttle valve. Switching point should 0 be between 2 and 3 . Adjust if necessary.

6. Check full throttle contact. Connect tester on terminals 1 8 and 3 of throttle valve switch. 0 The contact must be made between 30 and 35 . The full throttle contact is mounted with the idle contact an a base plate and therefore i t cannot be adjusted separately,

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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 ENRZCHMENT OF OXYGEN SENSOR C O N T R O L ( f r o m 1 9 8 1 M o d e l s )

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 ENRICHMENT ( f r o m 1 9 8 1 M o d e l s )

1. Connect standard buzzer on both contacts of microswitch (buzzer buzzes).

2. Operate throttle lever by hand. Microswitch

should function before the throttle opens (buzzer not buzzing). Adjust if necessary.

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911

Repairing

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 M o d e l s ) W I T H S H E A R - O F F SCREW

1. Remove entire mixture control unit.

2. Unscrew fuel distributor on air flow sensor.

3. Drill threaded part of shear-off screw with a 2 mm/5,'64 in. dia. drill bit (approx 3.5 mm/

9/64 in. deep).

4. Unscrew rest of shear-off screw with a suitable

screw extractor.

5. Install mixture control unit.

6. After correction of CO level setting install a new shear-off screw in access bore and tighten until screw shears off.

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(from 1981

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

Special Tools

P 228 c Prptractors

1. Bring engine to operating temperature (about 8 0 ~ ~ / 1 7 5 ~ ~ ) .

2. Connect emission tester according to the manufacturer' s instructions.

3. Attach protractor, special tool P 228 c , to

4, Using hand throttle or locally manufactured tool, open throttle gO;actuate gas pedal a few times to take strain off linkage.

the right throttle valve hosuing (if equipped with air conditioner, attach t o left throttle valve housing), Adjust pointer to 0'.

Note Hand throttle lever must b e all the way off.

5. Determine axhaust emission by road test or dynamometer test. Under partial load the 2400 rpm with a 9' throttle opening the ) be: exhaust emissions ( C ~ Oshould 911 T 9 1 1 E and S Carrera 2.7

1. 5 2.0

- 2.0 70CO - 2.5 qo CO (Europe 2.0-3.0) 2. 5 - 3.0 70CO

For typical road test see page SF 35,

Adjustment instructions for injection pump are shown on page SF 36.

Note T h e intake air preheating system eliminates the necessity for monitoring intake air temperature.

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Adjustment Instructions

A D J U S T I N G ENGINE IDLE

Special Tools

P 230 c Socket (9 mm)

1, Bring engine to operating temperature.

2. Check idle speed, If idle speed is too high or low, readjust air correction screws on throttle valve housings as needed. Turning screws in, lowers idle, Turning out, increases idle. Check air flow of individual cylinders at 1600-2000 rpm synchrometer, special tool P 235, See page SF 40 for adjusting instructions.

Note If resetting the air correction screws shows no reaction on the synchrometer. then the idle passages in the throttle valve housings are carboned up and must be cleaned.

3, Connect emission tester and check CO emissions. If CO valile is not within the prescribed limit, shut off engine and readjust idle speed injection quantity on pump.

Caution Do not start engine while adjusting idle speed injection quantity, 4, T h e idle adjusting screw can be reached with special tool P 230 c through a hole which is

covered by a plastic cap in the cooling air upper shroud.

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Adjustment Instructions

5. Remove cap.

6. Depress the spring-loaded idle adjusting screw with special tool P 230 c until you can

911

CO emissions

USA Europa Carrera 2.7

2 - 370

2,5

2 - 370

3.5

feel it engage with the slot of the centrifugal governor.

lean

rich

8. Idle speed can change after CO emissions

have been adjusted at idle speed (900 2 50 rpm).

9. Adjust idle speed by turning the air correction screws. Recheck with synchrometer.

Note

7. Turn adjusting screw counter-clockwise for a leaner mixture and clockwise for a richer mixture. Do not adjust by more than 1 notch at a time. A maximum of three notches is allowed to either the right or left of the basic adjustment.

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Adjustments at idle speed and under partial load should be made as quick as possible so that the velocity stack area does not heat up. Drive the car a short distance or run engine slightly faster (about 3000 rpm) before making another CO test on road or dynamometer. This will cool off the velocity stack area.

911

Adjustment Instructions

ADJUSTING MICRO SWITCH

1. Loosen lock nut and back off adjusting screw

until t h e micro switch is not closed in i d l e position.

BEGINNING W I T H 1 9 7 2 MODELS

3. T u m adjusting screw l / 4 turn farther in. Tighten lock nut.

Note T h e micro switch must b e readjusted whenever t h e throttle valve linkage or injection pump linkage has been reset.

2. Turn t h e adjusting screw from this position until t h e micro switch closes (listen for clich sound).

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Adjustment Instructions

911

IDLE A D J U S T M E N T

TOOLS

No.

Description

Adjusting wrench

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Special Tool

P 377

Remarks

Adjustment Instructions

1. Run engine to operating temperature (approx. 80' C).

2. Make sure that hand throttle :Lever is pushed down

to stop.

3. Connect CO-tester according to the manufacturer's instructions.

4. Turn adjusting screw, or bypass screw, resp. a t the throttle housing until the specified engine speed has been attained. See page 1.1 - 1/14 e for specifications.

Note Use an independent tachometer, such as that from the tester or similar.

5. Remove plug from mixture control unit between fuel distributor and venturi.

6 . Insert adjusting wrench P 377.,

7. Turning the wrench clockwise makes the mixture richer, and turning it counter-clockwise makes the mixture leaner.

Note The following points must be definitely noted: a) Always adjust CQ from lean to rich. E x a m p l e : It mixture is too rich, first turn idle control screw counterclockwise further than necessary and then clocltwise to specified position. b) Turn the adjusting screw very little because small adjustments result in considerable CO emission changes. C)

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The maximum permissible change a t the mixture adjusting screw is one-half turn.

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. If necessary, repeat the procedure.

11. Recheck idle speed and correct, if necessary.

12. Replace plug upon completion of the adjusting procedure.

A D J U S T I N G FULL POWER P O S I T I O N OF T H R O T T L E

Throttle linkage must be so adjusted that there is at least 1 mm clearance at the throttle valve lever when the accelerator pedal is in the fully depressed position.

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911

Adjustment Instructions

ADJUSTING MICROS WITCH

1. Disconnect electrical connections from microswitch.

2. Connect a standard buzzer to 'both contacts of the microswitch.

3. Prop up throttle. Place a 2 mm feeler gauge between idle stop screw and throttle valve lever.

Note This distance must b e measured exactly, sliding the feeler gauge in horizontally.

4. Turn adjusting screw a t the throttle valve lever to a point beyond the switch-off position of the microswitch (buzzer is off).

5. Turn adjusting screw back to the switch-on position (buzzer is on).

6. Close throttle valve and check if the microswitch

arm still has enough travel clearance in this position (at least 0. 5 mm).

Note Once the engine is installed in the car and hand throttle is adjusted, check if the microswitch is in the "on" position (buzzer on) with hand throttle fully on. If necessary, check hand throttle adjustment.

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Adjustment Instructions

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

1. Connect and bleed P 378 pressure tester and switch valve to position K 2.

2. Detach electrical wire from control pressure

regulator for'warm running compensation. Using a jumper wire, connect control pressure regulator for warm running compensation directly to B+ (fuse box on left side of engine compartment). Switch ignition on. Make sure that throttle is fully closed (hand throttle must b e pushed back all the way).

3. The control pressure will rise slowly and must reach the idle value shown under testing and adjustment specifications, page 1.1 - 1/13.

If the indicated value deviates, turn control pressure regulator for throttle valve position in the oval slots until the specified value is reached. Control pressure regulator for throttle valve position in direction of vehicle travel = higher pressure. Control pressure regulator for throttle valve position against the direction of vehicle travel = lower pressure.

5. If the specified pressure cannot b e attained in this way, replace the control pressure regulator for throttle valve position.

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911

Adjustment Instructions

ADJUSTING HAND THROTTLE

1. Fold center tunnel cover forward a t parking brake support.

2. When t h e engine is warm ( 8 0 ' ~ ) and hand

throttle completely pulled up, engine should b e running at about 3500 - 3800 rpm. NOTE T a k e care not t o overspeed t h e engine.

3. T h e hand throttle can b e adjusted by repositioning the clamping piece on t h e throttle control rod in t h e center tunnel.

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Adjusting Instructions

ADJUSTING IDLE, 9 1 1 SC

1 9 7 8 MODELS

TOOLS

No.

Description Adjusting wrench

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Special Tool P 377

Note

911

Adjusting Instructions

Adjusting Note Before starting with the idle adjustments, make sure that oil tank cap fits properly and its seal is in good condition. Leaks at oil tank cap would result in incorrect readings.

1. Run engine to operating temperature (approx. 80' c/176O F).

2. Connect CO tester according to instructions of the manufacturer.

4. Connect exhaust gas source line to test con3. Detach air hose a t diverter valve (arrow) and

insert an appropriate plug into hose.

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nection of catalytic converter.

5. Turn idle speed screw or bypass screw on throttle housing, until specified speed is reached. Test specifications, see page 1.1 - 1/14 e.

Note Use separate tachometer of tester or similar instrument.

8. Turning clockwise Turning counterclockwise

= rich mixture = lean mixture

Note a) Always adjust C O level from lean to rich. Example: When adjustment is too rich, first turn idle speed screw counterclockwise further than necessary and then clockwise to basic setting.. b) Do not apply pressure on adjusting wrench during adjustments (engine would die). c) Turn idle speed screw very little because even small adjustments result in considerable CO emission changes. 9. Remove wrench. 1 0 . Race engine briefly.

6. Remove plug in mixture control unit, between fuel distributor and air venturi.

7. Guide in adjusting wrench P 377.

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Adjusting Instructions

11. Wait until CO tester shows exhaust concentration a t i d l e speed. Test specifications, see page 1,l - 1/14 e. If necessary, repeat adjusting procedure.

12. Recheck idle speed and correct, if necessary.

13. After completion of adjustments, insert plug

in mixture control unit and attach air injection hose.

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Adjusting Instructions A D J U S T I N G IDLE SPEED 9 1 1 SC

1980 model

TOOLS

No.

Description

Adjusting wrench

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Special Tool

P 377

Remarks

91,

Adjusting Instructions

Adjusting

Note

4. Disconnect plug for oxygen sensor in engine

compartment on left side. Make sure that oil tank c a p and seal fit properly prior to adjustment of the i d l e speed. Leaks a t oil tank cap would cause incorrect measurement,

Requirements: Engine in perfect mechanical condition and ignition timing adjusted correctly.

1. Connect exhaust pickup line on test connection of catalytic converter.

5. Turn control screw or bypass screw on lhrottle housing until specified speed is reached. Adjusting values on page 1.1 1/13,

Note Use separate tachometer from tester or similar.

2, Run engine to operating iemperature (oil tempera0 ture about 90 C . oil temperature gauge on upper

end of range surrounded in white).

3. Connect CO tester according to instructions

supplied with equipment.

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Adjusting Instructions 6. Remove plug in mixture control unit, between fuel distributor and venturi.

7. Insert adjusting tool P 377

9fl

10. Accelerate engine briefly.

11. Wait until CO tester shows CO concentration at idle speed. See page 1 . 1 - 1/14 f for adjusting values. If necessary, repeat adjusting procedures.

12. Recheck idle speed and correct, if necessary.

13, After completion of adjustments insert plug in mixture control unit and connect electric plug for oxygen sensor.

8. Turn clockwise = richer mixture. Turn counterclockwise = leaner mixture.

Note Always conform with the following points. a) Always adjust CO level from lean to rich. E x a m p l e : If mixture is too rich first turn idle control screw counterclockwise further than necessary and then clockwise to specification. b) No force should be exerted on adjusting tool during adjustments (engine would die). c) Turn control screw only minimal amount, since even a slight turn will change the CO level considerably.

9. Remove adjusting tool.

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14. Coat threads of cap nut for testing connection on catalytic converter with Bosch assembly paste VS' 140 16 Ft.

Adjusting Instructions

A D J U S T I N G IDLE 9 1 1 S C

(from 1 9 8 1 Models)

Adjusting

Note

4. Disconnect oxygen sensor plug in engine

compartment on left side. Make sure oil tank cap and seal fit properly before adjusting idle. Leaks through oil tank cap would cause incorrect readings.

Adjusting requirement: ~ n g i n ein perfect working condition and ignition timing set correctly.

1. Connect exhaust gas tap on test connection of catalytic converter. 5. Turn control screw or bypass screw on throttle housing until specified engine speed is reached. See page 1.1 -. 1/14 f for adjusting value.

Note Use separate tachometer of tester or similar.

2. Run engine to operating temperature (oil temperature about 90' ~ / 1 9 4 ' F; oil temperature gauge

needle at upper end of field outlined in white).

3. Connect CO tester according to instructions

supplied with equipment.

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Adjusting Instructions

6. Check CO level. If CO level does not correspond with specified value, remove mixture control unit and remove threaded part of shear-off screw in access bore for mixture control screw (see page 2.5 - 1/8).

911

10. Accelerate engine briefly.

11. Wait until CO tester shows exhaust gas concentration a t idle speed. See page 1.1 - 1/14 f for adjusting value. Repeat adjusting procedure, if necessary.

r . Guide in Special Tool P 377.

12. Recheck idle speed and, if necessary, correct.

13. After finishing adjustments screw a new shear-off screw in access bore and tighten until screw shears off. Reconnect oxygen sensor plug.

14. Coat threads of cap nut for test connection on catalytic converter with Bosch VS 140 1 6 Ft or Optimoly HT grease.

8. Turning tool clockwise = richer mixture. Turning tool counterclockwise =leaner mixture.

Note The following points are important. a) Always adjust CO level from lean to rich. E x a m p 1e : If mixture is too rich, first turn idle control screw counterclockwise further than necessary and then clockwise to specified value.' b) Never exert force on special tool during adjustments (engine dies). c) Turn control screw only very slightly, since even a slight turn will change CO content in exhaust gas considerably.

9. Remove special tool.

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Getriebe Transmission Bo'ite de Vitesses Cambio \

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911

TRANSAXLE

CONTENTS 0

INFORMATION., DESCRIPTION, TECHNICAL DATA Information Transmission, 4 and 5 Speeds Sportomatic Description Transmission, 5 Speeds, Operation Transmission, 5 Speeds, Power Transfer Transmission with Oil Pump, Description Transmission with Oil Pump, General Instruction Typ 915, Transmission (1974 model) Typ 915, Transmission (1975 model) Typ 915, Transmission (1976 model) Sportomatic, General Sportomatic, Power Transfer Typ 925, Sportomatic Transmission (1974 model) Typ 925, Sportomatic Transmission (1975 model) Typ 925, Sportomatic Transmission (1976 model) Sportomatic 1977 Models General Information

Technical Data Transmission Diagrams, Manual Transmission Tightening Torques, Manual Transmission Tightening Torque Values, Transmission General Specifications, Transmission Tolerances and Wear Limits Transmission Diagrams, Manual Transmissions (1974 model) General Specifications, Transmission (1974 model) Transmission Diagrams, Manual Transmissions (1975 model) General Specifications, Transmission (1975 model) General Specifications, Transmission (1976 model) Transmission Diagram 915/44 Transmission Diagram 915/49 Transmission Diagram, 925/01 Sportomatic Transmission General Data

- Sportomatic Transmission

Tightening Torques, Sportomatic Transmission Transmission Diagram, 925/02 Sportomatic Transmission

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911

TRANSAXLE

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) 0.3

Special Tools Special Tools, SportomatIc Transmission

TRANSMISSION, 5-SPEED MAN~UAL 3.1

T r a n s m i s s i o n , d i s a i s e m b ~ i na~n d a s s e m b l i n g

Transmission, removing ahd installing Seal Ring for drive Shaft: pismantel and reinstall Selector Forks, adjust i Transmission Front cover,! disassembling and assembling Oil Pump in Front Cover, jdisassembling and assembling Gear Housing, disassembling and assembling Transmission Housing, disassembling and assembling Oil Lines for Supplemental Lubrication System, remove and install Transmission Housing wit$ Guide Tube for Throwout Bearing Transmissioncase with Bolted Guide Tube for Release Bearing Disassembling and assembling ~ra&missionCase with Servo Clutch(1977model) Input Shaft, disassembling and assembling Pinion Shaft, disassembling and assembling Synchronization, disassembling and assembling Disassembling and Assembling Synchronization (19 77 Models) I TRANSMISSION, SPORTOMATIC 4.1

Transmission,

disassembling and assembling

Torque Converter Housing; disassembling and assembling Transmission, removing and installing Transmission Front Cover,; disassembling and assembling Inte~mediatePlate, disassembling and assembling c) and assembling Input Shaft (3 Speed ~ ~ o r t b m a t idisassembling Pinion Shaft (3 Speed Spo$tomatic) disassembling and assembling Checking Clutch Play (1976 model) Checking Control Valve 4djustment (1976 model) 5

DIFFERENTIAL Differential, with manual transmission Differential, removing and installing Differential, diiarsernblin~and assembling Differential with electron~calspeedometer Tools Disassembling and Assembling Instructions Ring and Pinion Gear, adjusting - General Information Ring and Pinion Gear, adjbsting Pinion Shaft, adjust with universal Setting Gage VW 385 Differential,

orto to ma tic

with

Ring and Pinion Gear, adjlsting Ring and Pinion Gear, adjusting Downloaded from www.Manualslib.com manuals search engine

Transmission

- General-Information

3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1 3.1

- I/I

- 1/15 - 2/1

- 3/1 - 3/5 - 4/1 - 5/1 - 5/9

- 5/11 - 5/19 - 5/25 - 6/1

- 7/1 - 8/1 - 8/5

Manual Transmission

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. The 5 -speed transmission-is optional.

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911

Manual ~ransmissionj i

D ~ E S I G NA N D F U N C T I O N !

The five forward speeds and reverse a i e arranged in a double " Hshift pattern. I

1st speed:

left forward

2nd speed: left back 3rd speed:

straight forward

4th speed:

straight back

5th speed:

press right overcoming sphng detent, then straight forward

Reserve:

press right overcoming spring detent, then straight back

Clutch pedal must be fully depressed and selected gear fully engaged.

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911

Manual Transmission

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Manual Transmission

- Roller bearing

- Transmission housing 17 - Breather 18 - Seal 1 9 - Speedometer drive, Gear I

- 1st speed,

- Spider, 5th and reverse speeds

- Gear housing

- Flange nut

- Shift fork,

1 - Transmission front cover

- Reverse, Gear I 3 - 5th speed, Gear I,

fixed

Gear I, fixed

- 2nd speed, Gear I, fixed 8 - 3rd speed, Gear I, free 9 - Synchronizing ring 10 - Spider (Synchro hub) 11 - 4th speed, Gear I, free 7

12 - Pinion shaft ball bearing

- Roller bearing 1 4 - Flange nut

- Input shaft

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5th and reverse speeds

- 5th speed, Gear 11, free 24 - Roller bearing 25 - Shift fork, 1st and 2nd speeds 26 - Selector shaft 27 - Bearing retaining plate 28 - Ball sleeve 29 - Pinion shaft

- Differential

911

Manual Transmission:

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 synchronizing 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. Torque transfer occurs only through the respective gear pair. Engagement of the lst, 2nd, and 5th gears is made by repositioning the shifting sleeve or sliding gear located on the pinion shaft, and that of 3rd and 4th gears by one located on the input shaft. Power flow in reverse gear is from the input shaft through the reverse idler gear, the sIiding gear, to the pinion shaft.

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Transmission

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. These transmissions are identical in design and servicing to transmissions used in 1972 models. However, due to the increased power and torque of the 2.7 liter engines, they are equipped with an oil pump lubrication system.

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911

Transmission 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. The pump draws oil from the transmission oil -sump through a pickup tube and forces it through the passages in the pump cover and into the pressure lines. . Pressure created by the oil pump forces the transmission oil to pass through discharge nozzles which direct the oii spray to the lubrication points. Oil not used for lubrication cools the working parts and drains back into the transmission oil sump. A pressure relief valve opens at a press'ure of about 3, 4 atmospheres if a malfunction should occur in the oil supply system, such as a plugged pressure line. The oil then drains into the transmission oil sump.

The constant circulation of the transmission oil and spraying of the bearings and gears results in improved cooling and lubrication.

- Oil pump cover Oil pump gear I - Oil pump I1

1 2 3 4 -

Ball for pressure relief valve

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5 6 7 8

- Spring for pressure relief valve

- Bushing - Plug for pressure relief valve - Pickup tube

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.

2. Oil the O-rings lightly when installing the pickup tube and pressure lines since otherwise damage may

occur.

3. The gear housing should be assembled with the pressure line bolted in place. The pressure line must pass through the hole in shift fork for 3rd and 4th speed.

4. When installing the transmission front cover make sure that the coupling pin in the input shaft engages the coupling slot in oil pump gear I. If necessary, turn the input shaft slightly and push cover into place.

5. Work procedures differing from those applicable to transmissions in 1972 models, such as disassembly and reassembly of the oil pump, are described on pages that follow.

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911

Transmission

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Transmission

- Oil pump cover - Bushing

1 2 34

56 7 8 9 10

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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

Transmission

911

TYPE 9 1 5 TRANSMISSION ( 1 9 7 4 MODEL)

The following transmission versions are installed from 1974 models on: 4-speed transmission, 915/16 = S 5-speed transmission, 915/06 = SW S = standard equipment

SW = special order

These transmission versions differ from those used in 1973 models only in the aspect of gear ratios (see Technical Data, page 0.2 - 1/11).

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911

1I Transmission

Manual transmission 915 (1975 Models)

I 1

The following transmissions are installed.

I I

Transmission Type

No. of Gears

Application

I !

915/40

911 S, Carrera

ij I

915/45

911 S, Carrera

/ I

All transmission types are based on those of 1974 models and only differ slightly from d c h other.

1 The 3rd and 4th or 4th and 5th gears as well as the rear axle ratios have been changed dn the types 915/45 and 915/40 (refer to technical data on page 0.2 - 1/15). The shift and guide sleeves have also been reinforced, and the clutch release lever modified. i

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Manual Transmission

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. 5-speed transmission 915/44

This transmission model differs from the 1975 model by a new guide tube for the clutch release bearing, an easy to remove drive shaft seal and an electronic speedometer transmitter.

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911

Manual Transmission

MANUAL TRANSMISSION 9 1 5 ( 1 9 7 6 M O D E L )

The following transmission is available for the 1976 Model.

Transmission

No. of Speeds 5

915/44

For Model 911 S

MANUAL TRANSMISSION 9 1 5 ( 1 9 77 M o d e l ) For 1977 Models the following transmission type is installed. 5-speed transmission 915/61 with auxiliary clutch spring This tpansmission differs from the 1976 Model with modified synchronizers for 1st and 2iid gears, an asymmetric tooth profile of the clutch body for 1st gear and a modified operating an? guide sleeve for lst/2nd gear. iI

MANUAL TlUNSMISSION915 ( 1 9 7 8 / 7 9 M o d e l s ) F O ~the

1978/79 models the

5-speed transmission 915/61 has a silumin case and a modified clutch release lever.

MANUAL TRANSMISSION 9 1 5 ( 1 9 8 0 / 8 1 M o d e l s )

The following transmission type is installed in the 1980/ 81 models:

5-speed transmission 915/63

This transmission differs from those in 1978/1979 models only in the modified 2nd gead ratio. I

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Sportomatic

SPORTOMATIC

911

925

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 E 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. Only those repair procedures and service information which differ are included in this volume of the workshop manual.

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911 23-

I I I

Sportomatic

Speedometer drive

Fron't cover

Flange nut

18 -

Clutch plate / turbine Ahaft Oil seal

! !

Torque converter housi'r~~ I

Gear I, reverse gear

Torque converter

Input shaft

J'i Speedometer gear sha

Ball bearing race

Four point ball bearin gi

Intwmediate plate

Clamping plate

Gear I, 2nd gear

Roller bearing

Gear I, 3rd gear

Selector shaft

Transmission housing

Roller bearing

Shift fork, 3rd and 4th gear

Anchor block

Shift sleeve, 3rd and 4th gear

Oil seal

Gear I, 4th gear

Needle bearing sleeve

Thrawout fork

Ball bearing

Oil seal

Stator support

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911

! I

Oil seal

Expansion bolt

11 -

Axial needle bearing cage

Threaded stud

O-ring

Tapered roller bearing

13 -

Axle flange

Differential spider g e a

Temperature sending unit

Differential side gear

Temperature switch

Roll pin

Thrust washer

Anchor piece

Reverse idler gear

Shaft

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Needle bearing cage

Ring gear

Sportomatic

911

Power Transfer Power transfer from the engine through the torque converter and mechanical clutch is same in all driving ranges. In ranges L and D, the power is transfered from the fixed gears on the input shaft, through the synchronization components and free-wheeling gears on the pinion shaft, t o the pinion shaft. In ranges D3 and D4, the power transfers from the input shaft, through the synchronization components and fiee-wheeling gears, to the fixed gears on the pinion shaft. Reduction is accomplished by gears engaged in given driving range, Reverse gear reduction is over two stages. The power flows from the input shaft, through the intermediate shaft, t o the pinion.

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Transmission

TYPE 9 2 5 SPORTOMATIC TRANSMISSION ( 1 9 7 4 MODEL)

Beginning with 1974 mod.els, Type 911 and 911 S vehicles can optionally be equipped with the Type 925/02 transmission. This transmission versiori differs from that used in 1973 models only in the aspect of changed torque converter ratio (see Technical Data, page 9.2 - 2/6).

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Sportomatic

911

SPORTOMATIC 925 (1975 Models)

All 1975 models are available with a 3-speed sportomatic transmission (type 925/10) as optional extra equipment.

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Sportomatic

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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 (27:25 V)

Inner shift lever

Transmission case

Roller bearing

3rd gear shift fork

Anchor block

3rd gear shift sleeve guide

O-ring

Spacer

Needle bearing

Washer

Ball bearing

Release lever

Stator support

Oil seal

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Sportomatic

911

S P O R T O M A T I C 9 2 5 ( 1 9 7 6 MODEL)

From 1976 models all cars can be delivered with a 3-speed sportomatic transmission as optional extra equipment. For engines with a swept volume of 2.7 liters transmission 925/09 (mechanical speedometer drive) and 925/12 (electronic speedometer transmitter) are installed. The 3 liter Carrera engine requires a more powerful servo motor with a modified clutch linkage (Type 925/13). The torque converter has 4 additional drive shells.

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911

sportomatic

SPORTONIATIC TRANSMISSION 9 2 5 ( 1 9 7 6 MODEL) T h e following transmissions are available from 1976 Models. No. of Speeds

Transmission

For Model

; i

925/09 (mech. speedometer)

911

925/12 (electronic speedometer)

911 and 9 1 i S USA

925/13 (stronger converter drive)

Carrera 3.0;

! j

SPORTOMATIC TRANSMISSION 9 2 5 (19 77 Models) From 1977 Models t h e following transmission types a r e installed.

Transmission ~ y p e 925/15

- .

925/16

No. of Gears

Installed in

911

Carrera 3.0 911 S USA and 911 S Japan

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Transmission Diagram Ring Ratio 7 : 31

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5-speed-transmission

Transmission Diagram Pinion to Ring Ratio 7 : 31

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4-speed-transmission Type 91 5 Transmission

Transmission

DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING

TOOLS

Description

Special Tool

Driver Set

US 8050

T- handle

P 366

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Remarks

911

Technical Data T I G H T E N I N G TORQUES

Location

Description

Thread

Transmission housing (Oil drain)

Magnetic plug

M24

Transmission housing (oil filler)

Oil filler plug

Grade

ft Ibs

Tapered M 24 Tapered

. Transmission Nut, center housing side lock type and front cover. guide fork cover

M 8 x 1.25

Front cover

Backup light switch

M 18 x 1.5

Input shaft

Flange nut

M 30 x 1.5

8.8

Input shaft

Castellated nut

M 18 x 1. 5

6.8

M8x1.25

Retaining plate Nut and transmission support attachmen

x 12 CrNi 18-8

Pinion shaft

Flange nut

M 24 x 1.5

Guide fork, shifting .

Nut

M 6 x1.O

Shift detent, transmission housing

Nut

Transmission housing

Breather

M 16 x 1.5

Shift forks

x 1.25

Ring gear (differential)

locking differential) Ex ansion bolt/ Axle flange

of+

M 10 x 1.5

Starter

Nut

M I 0 x1.5

Pressure: line (input shaft)

Bolt, M 6x35

M 6 x1.0

8.8

Front cover

Plug for pressure relief valve

M 12 x 1.5

9 S 20 K

Oil pump cover

Self-locking nut

Pickup tube

Allen bolt

12.9

M 6 x 1.0

8.8

x 12 CrNi

M6x15 Pressure: line Guide tube release bearing

Bolt, M 6

x 12

Phillips head ctsk. screw

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M 6 x 1.0

8.8

M6x1.0

8.8-

General Specifications

Type 915 Transmission 911 T

911 E

911 S

Carrera 2.7

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 3rd gear 4th gear

1st gear 2nd gear 3rd gear 4th gear 5th gear

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> 100

52.570 30.570 20 (lo 12.. 5 70

General Specifications

Type 915 Transmission 911 T

911 B

911 S

Rear Axle Drive

Spira: bevel gears, differential

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

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approx 3 Itr (6.3 US pints) SAE 90 transmission oil, MIL-L 2105 B or MIL-L 2105 specification

Carrera 2.7

Technical Data

T a b l e of T o l e r a n c e s for T y p e 915 Transmission

Measuring point

Installed tolerances (new) mm

1. Backlash between Gear I and I1 1st gear 2nd gear 3rd gear 4th gear 5th gear

2. Free gears on pinion and input shafts 1st gear 2nd gear 3rd gear 4th gear 5th gear

3. Shift rods a. Side play in bushings

b. Runout

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Wear Limit

911

Technical Data

Measuring point

Installed tolerances (new) mm

Wear Limit mm

4. Side-play between

shift fork and shift sleeve: 5th and reverse gear 1st and 2nd gear 3rd and 4th gear

5. Outside diameter of synchronizing rings: (installed) When molyb denum coat (a) is worn off at any point

1st gear 2nd gear 3rd gear 4th gear 5th gear

6. Input shaft

a. Runout at the pilot journal

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0.1 max.

0.1 max. (straighten)

Transmission Diagram

4-speed-transmissi

Pinion to Ring Ratio 7 : 31

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

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Technical Data

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General Data

Type 915 Transmission (1974 model)

911 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 Reverse gear Climbing Ability (calculated) Vehicle Weight: empty according to DIN + 1/2 load 1st gear 2nd gear 3rd gear 4th gear 1st gear 2nd gear 3rd gear 4th gear 5th gear

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911 S

Carrera

General Data

Type 915 Transmission (1974 model) 911

Rear axle drive

911 S spiral bevel gears, differential

Final drive ratio Power transfer

double-joint half-axles, to rear wheels

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 Transmission and differential

approx. 3 Itr. (3.17 US gts.) SAE 90 transmission oil, MIL-L 2105 or MIL-L 2105 B specification

Transmission and differential, limited slip

approx. 3 Itr. (3.17 US gts.) SAE 90 transmission oil, M 2 C 119 A

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Carrera

Technical Data

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911

Transmission Diagram

911 S Type 9 i 5 i 4 0 Transmission

Pinion to Ring Ratio 8 : 31

a 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.

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Subject to change without notice

Technical Data

l ~ e n e r a Data l

Manual Transmission 915 (1975 Models) 911 S, Carrera

Ratios 1st 2nd 3rd 4th

gear gear gear gear

Reverse

1st gea 2nd gear 3rd gear 4th gear 5th gear Reverse

Final drive

Transmission and differential

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Approx. 3 liters (3.17 US gt.) of SAE 90 transmission oil meeting Specifications MIL -L-2105 or MIL-L-2105 B

Technical Data

General data

Manual transmission 915

- 1976,

1977, 1978 and 1979 models

Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse

Final drive ratio

Capacity

approx. 3 ltr. /3.15 US qt of SAE 90 transmission oil meeting API Classification GL 5 (or MIL-L 2105 B)

Transmission weight

56 kg/123 l b ready for installation with oil and starter

General data

Manual transmission 915

- 1980 model and 1981 models

Ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse

Final drive ratio

Capacity

Bpprox. 3 ltr. /3.15 US qt of SAE 90 transmission oil meeting API Classification GL 5 (or MIL-L 2105 B)

Transmission weight

56 kg/123 l b ready for installation with oil and starter

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911

Transmission Diagram Pinion to Rlng Ratio 8 : 31

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5-speed-transmission Type 915 /44 Transmission

Transmiss ion Diagram

4 -speed-transmission Type 91 5/49 Transmission

R* 3 1

IS euidina values, based on Remarks: This diagr;sm ou a medium effective rolling radius. slight deviations dueto tire tolerance variations in the rolling radius, wear and skidding of the wheels have not been taken into account.

out notice

5 130 135 140 145 150 1

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c3 (D

n 3 D

l-.

tl P rt

CD I . d

Technical Data

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911

Technical Data

r y General Data

1st gear 2nd gear 3rd gear 4th gear Reverse gear

I I

Torque converter ratio Final drive ratio

I Approx. 3.0 ltr (3.17 US qts) SAE 90 transmission oil, specification Mil-L 2105 or Mil-L 2105B

Filling Capacities

approx. 10 ltr. (10.5 US qts)

approx. 35 kmh (22 mph)

Two-start speed in L-range Stallspeed

;~c

In parenthesis; number of teeth

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approx. 11ltr (11.6 US qts) w/oil cooler

2500

- 2700 rpm

2900

- 3100 rpm

Technical a

T I G H T E N I N G TORQUES

Location Transmission housing (at stud for side and front cover, and fork piece)

Description

SPORTOMATIC

Thread

Nut

mkp

x l 2 CrNi 2.2-2.5 18.8

Transmission housing (oil filler plug)

Plug

M24 x 1 . 5 (1:16 tape]

Transmission housing (oil drain plug)

Plug with magnet

M24 x 1 . 5 (1:16 tape]

Transmission housing (breather)

Breather

M14x1.5 (1: 16 taper

Transmission housing

Backup light switch

Transmission housing

Bypass switch

Transmission housing (starter attachment)

Nut

Transmission housing (vacuum servo unit carrier and attachment)

Nut

Torque converter housing (attachment to transmission housing)

Nut

Torque converter housing (attachment of freewheeling support)

Allen-head bolt

Torque converter housing

Threaded coupling

Torque converter housing

Temperature sensor

Torque converter housing

Temperature switch

Torque converter housing (clutch pressure plate)

Allen-head bolt

Torque converter coupling plate

2-point bolt

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Mid grip nut

Nut

Grade

925

911

Technical Data

Location

Description

Intermediate plate (clamping plate)

Bolt

~ntermediateplate

Bellcrank shaft

Intermediate plate (shift detent)

Cover plug

Transmission front cover (speedometer drive retainer)

Bolt

Transmission front cover (9 mm dia ball - parking lock)

Cover plug

Angular drive in retaining bushing

Hollow bolt

Input shaft

Nut

Input shaft

Flanged nut

Pinion shafl:

Stretch bolt

Selector forks

Bolts

Differential (ring gear attachment)

Bolt

U - joint flange (in differential)

Stretch bolt

Transmission front cover (transmission c a r r i e ~ attachment)

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Thread

M8x1.25

M24x1.5

M18x1.5 M12x1.5 M8x1.25

M10x1.5

Technical Data

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911

Technical Data

General Data -

Sportomatic (1974 model)

Climbing ability

- percent

1st gear 2nd gear 3rd gear 4th gear ( ) in parentheses: brief climbing ability

Gear Ratios1st gear 2nd gear 3rd gear 4th gear Reverse gear

Torque converter ratio Final drive ratio Filling Capacities: Transaxle

approx. 2.5 ltr. (2.6 US gts.) SAE 90 transmission oil MIL-L 2105 or MIL-L 2105 B

Engine

approx. 13 ltr. (13.7 US gts.)

Tow-start speed in 'Z" (Low)

approx. 35 kmh (22 mph)

Stall speed Clutch speed (at full power)

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911

Technical Data

General Data

Sportomatic 925 (1975 Models)

Ratios 1st gear 2nd gear 3rd gear Reverse

Converter Final drive

Capacities Transmissi.on with final drive

Approx. 2.5 liters (2.65 US gt.) of SAE 90 transmiss.ion oil meeting Specifications of MIL-L-2105 or 2105 B

Towing speed in range '2"to start

Approx. 22 mph

Stall speed (rpm) Clutch speed (rpm)

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1900 1 2 0 0

California 1850 200

Technical Data

General Data

911

Sportomatic

Sportomatic 925 1976 and 1977 Models

I 925/12 19 76 Mod.

Ratios

925/17 1977 Mod.

1st speed 2nd speed 3rd speed Reverse

Final Drive Ratio Gearbox and Final Drive Capacity

about 2, 5 Itr. / 2, 6 U.S. 4t of SAE 90 Gear Lube meeting Specifications MIL-L 2105 or MIL-L 2105 B

1 Speedometer

Electronic

Converter Ratio about 2 5 mph

Tow-Start Speed in Range "L" Stall Speed (rpm) Transmission Weight (ready for installation with converter, starter and oil)

about 71 kg/156 Ib

Contact Pressure of Pressure Plate

7845 (800

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8630 N 880 kp)

6400 (652

7100 N 724 kp)

Transmission Diagram Pinion to Ring Ratio 8 : 27

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Sportomatic Type 925/09/ 12 /13 Transmission

Special Tools

SPECIAL T O O L S

SPORTOMATIC

Mandrel Mandrel Installer Centering mandrel Installer Assembly plate Input shafl holder Remover Support plate Mandrel Pilot mandrel Thrust piece Centering mandrel Installer Assembly sleeve Puller and installer Input shaft lock Socket, 32 mm Guide sleeve Thrust piece Thrust piece Installer Mandrel Bushing Gauge block Holder Dial gauge holder, spacer, feeler tip (w/o clamping adapter) Press plate Press plate Thrust piece Thrust sleeve V-block Thrust piece New special tools Downloaded from www.Manualslib.com manuals search engine

Manual Transmission

TRANSMISSION

TOOLS

No.

Description

Special Tool

Sleeve

P 382

Puller

P 386

Driver

P 381

Shift rod holder

P 260 a

P 37 a

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Remarks

911

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Manual Transmission

Special instructions see

Note when Description

Q~Y Removing

Installing

Self-locking nut

Replace if necessary, torque to specification

Washer

Clutch cable bracket

Self-locking nut

Replace if necessary, torque to specification

Washer

Place one on each side of ground strap.

Ground strap Front transmission cover Gear housing gasket -

Roll pin

Castellated nut

Replace.

Drive out.

Replace if necessary. Torque to specificatioi Replace, torque to specification.

Flange nut -

Roll pin

Bolt

Drive out.

Replace if necessary. Torque to specificatio~

Spring washer

Replace if necessary.

Shift fork, 5th and reverse gear

Readjust.

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911

Manual Transmission

Note when Description Removing

Installing

Special instructions see

Check for wear.

Sliding gear, 5th and reverse gear

Replace, oil lightly.

O-ring Thrust washer

111

5th and Reverse idler gear

Check for wear.

Needle bearing cage

Check for wear.

Intermediate ring

Needle bearing cage

Check for wear. --

Thrust needle bearing cage

Reverse speed, Gear I

Check for wear. -

Replace in pairs only. -

Shaft for 5th and Reverse idler gear

Remove together with Install together wit!? fixed Gear I of 5th fixed Gear I of 5th speed speed.

Gear I, fixed, 5th spee

Small flange faces gear housing. Replace in pairs only.

Gnide sleeve

Check for wear.

Gear 11, free, 5th speed

Cheek synchronization. Replace in pairs only.

I Needle bearing cage

Bushing

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Mark position for installation.

Install with same gear.

Mark position for installation.

Install with same gear.

Manual Transmission

Note when Description

Qty Removing

1 , 1

Installing

Thrust washer

Self -locking nut

Replace if necessary, torque to specification.

Washer

Cover with guide fork Gasket Self -locking nut

I I

Washer

Replace. lo

Replace if necessary, torque to specification.

10 I

Gear housing

Gasket

Nut

Seal

Move selector fork rod for 5th speed and reverse into neutral and remove. 1

Replace. Torque to specification. I

Replace.

Spring Short detent

Check for free movement.

Nut

Torque to specification.

Spring washer

Replace if necessary.

Nut

Torque to specification.

Lock washer

Replace.

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I I

911

Special instructions see

Manual Transmission

Note when Description Removing Input shaft

Installing

Remove together with pinion shaft, 1st and 2nd speed selector fork, and complete 3rd and 4th speed shift rod.

Pinion shaft 1st and 2nd speed selector fork

Check for wear, readjust.

Bolt

Torque to specification.

Spring washer

Replace if necessary.

Bolt

Torque to specification.

Spring washer

Replace if necessary.

3rd and 4th speed selector fork

Check for wear, readjust.

Shift guide

Check for wear, readjust.

3rd and 4th speed shift rod Plug

Torque to specification

Short detent

Check for free movement.

Bolt

Torque to specification

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Special instructions see

frianual T r a n s m i s s i o n

Note when Description Removing Seal

Installing Replace.

Spring Short detent

Check for free movement.

1st and 2nd speed selector fork rod Shim

Transmission housing

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Note thickness and

Recompute if

Special instructions

Manual Transmission

911

DISASSEMBLING AND ASSEMBLING MANUAL T R A N S M I S S I O N

Disassembling

4. Remove guide fork cover with gasket.

1. Block input shaft with special tool P 37a, engage 5th gear.

2. Remove castellated nut from input shaft, and flange nut from pinion shaft.

5. Remove nuts from gear housing. Pull housing and selector fork rod (5th and reverse speed), and selector fork rod with selector shaft off the studs (tap lightly with a plastic mallet, if necessary).

@,a:' ."%.

i -

Note Selector fork rod for 5th and reverse speed must be in neutral. Otherwise the gear housing will bind against the rod and cannot b e removed.

3. Mark needle bearing of 5th speed free gear;

it must be reassembled with same gear.

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911

Manual Transmission

6. Remove shift detent plug (3rd and 4th gear). Take out spring and detent.

10. Remove detent

11. Remove plug from shift detent (1st and 7. Remove bolt from selector fork of 1st and

2nd gear) and take out spring and detent.

2nd gear, gently spread clamping piece with screwdriver.

8. Remove retaining plates for input and pinion shafts.

12. Take out selector fork rod 1st and 2nd gear.

9. Take input and pinion shafts with complete selector fork rod (3rd and 4th speed) and selector fork (1st and 2nd gear) out of their seats.

13. Note the number and thickness of shims between transmission housing and retaining plates for reinstallation.

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Manual Transmission

Assembling

1. Place the same number and thickness of

911

Note To keep the selector fork from binding on the selector fork rod, slightly open the selector fork clamping piece with a screwdriver.

shims on the transmission housing studs as noted during disassembly or as determined while adjusting the pinion. 6. Insert input shaft and push into place together with the pinion shaft.

2. Insert 1st and 2nd speed selector fork rod.

3. Insert 1st and 2nd speed shift detent and spring.

4. Torque bolt to specification.

5. Insert pinion shaft with 1st and 2nd speed selector fork so that the pinion comes barely to rest in the bearing race of the transmission housing.

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7. Torque clamping plate nuts to specification.

8. Lightly tighten selector fork bolt (1st and

2nd speed).

9. Insert detent'from the top.

10. Unscrew bolts for 3rd and 4th speed 'selector fork and fork clamping piece. Push fork and clamping plate back so that the selector fork and rod can b e installed.

Manual Transmission

11. Lightly tighten selector fork and fork piece bolts.

12. Insert shift detent and spring, torque plug to specification.

13. Adjust selector forks (see 3.1-2/1).

14. Place transmission housing gasket on the studs.

20. Install thrust washer for 5th speed free gear.

21. Install needle bearing with 5th speed free gear.

22. Install guide sleeve for 5th and reverse speed, start flange nut on threads.

23. Install thrust needle bearing cage, idler gear with needle bearing cages and intermediate piece and thrust washer on the idler shaft.

15. Install gear housing together with selector fork rod (5th speed and reverse) and selector shaft. Tighten to correct torque.

16. Push selector fork rod in the ball slesve, and-selector shaft into the shift pawl guides.

24. Slide 5th speed and reverse sliding gear with selector fork on guide sleeve and selector fork rod.. SIightly open the selector fork clamping piece for easier assembly.

25. Lightly tighten selector fork bolt. 17. Install. guide fork cover and gasket. Tighten to correct torque. 26. Apply light coat of oil to the O-ring and install. 18. Install idler gear shaft turning the shaft until the pin in the gear housing prevents i t from turning.

19. Install reverse speed Gear I and start castellated nut on threads. Downloaded from www.Manualslib.com manuals search engine

Manual Transmission

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.

28. Adjust 5th and reverse speed selector fork (see page 3.1-2/2).

29. Secure castellated nut with roll pin; and flange nut by notching.

30. Insert actuating pin for backup light switch

with recessed end toward switch.

31. Place gear housing gasket on studs. Install front transmission cover, and tighten nuts to correct torque.

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911

M a n u a l Tr?nrrninsion

911

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.

915/02 915/12 915/08

733 7375 723 0507 783 0838 793 1031

Special transmissions

Removal

3. Pull oil seal out by turning the hex. bolt in

the puller. 1. Remove transaxle and detach transmission

from engine.

2. Screw puller P 386 firmly into the oil seal.

NOTE: If the (garter) spring should slide off during removal of the seal, pull i t off t h e input shaft with the aid of a wire hook.

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Manual Transmission

I n s t a l l a t i on 1. Push installation sleeve P 382 onto the input shaft splines.

2. Lightly oil the sealing lip of the oil seal and push th.e seal onto the installation sleeve.

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3. Drive oil seal into its seat with the aid of driver P 381.

Manual Transmission

911

A D J U S T I N G SELECTOR FORKS

Note Tighten input shaft flange nut to correct torque before adjusting selector forks.

4. position the 1st and 2nd speed selector fork so that the shift sleeve is exactly in the middle between the synchronizing rings. Tighten bolt to correct torque.

1. Install mounting plate P 260a. Install 5th speed synchro hub and 5th and reverse speed sliding gear. 5. Adjust 3rd and 4th speed selector fork in the same way as 1st and 2nd speed. Tighten bolt to correct torque.

6. Position 3rd and 4th speed shift guide flush with the selector fork. Make sure there is 2-3 mm (0.8-0.12 in.) clearance between the 3rd and 4th speed shift guide and the 1st and 2nd speed shift guide. They must not touch. (see illustration).

2. Block input shaft with P 37a and engage 5th speed. Tighten input shaft flange nut to correct torque.

3. Turn selector fork rod of 1st and 2nd speed left (in driving direction) to stop, then turn slightly back until the unmachined flat inner surface is almost vertical. 1 - Install aligned 2

- 2 to 3 mm play

Note Do not turn it back beyond the middle point or all the way to the right stop.

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7. To ensure proper synchronization, check ease of shifting. Readjust if necessary.

Manual Transmiasion

Adjusting 5th and Reverse Speed Selector Fork

1. Push the idler gear on shaft against fixed gear I of 5th speed. Ad just clearance between idler gear and sliding gear in neutral position. Clearance should be 1 m m (0.04 in.).

Caution Push the idler gear gently in direction of travel; there should b e no play between the shift fork and the sliding gear groove. This eliminates the possibility of the sliding gear hitting the idler gear in cases of tolerance build -up.

2. Tighten selector fork bolt to correct torque.

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911

Manual Transmission

DISASSEMBLING AND ASSEMBLING FRONT COVER

TOOLS

Description

Special Tool

Mandrel

P 374

Mandrel

P 369

Nr.

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Remarks

911

Manual Tranimirs.ion

Disassembling and Assembling Front Cover

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Manual Transmission

Note when Description Removing

Installing

Backup light switch

Torque to specificstion.

Actuating pin

Position properly.

Seal

Press out with small screwdriver.

Retainer

Drive fully into seat with P 374. Replace if necessary.

Thrust washer Speedometer drive Retainer

Seat properly.

O-ring

Oil lightly.

Positioning piece Worm shaft Sea!

Pry out with screwdriver.

Shift rod bushing Bushing

Transmission front cover

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Drive in with P 369 until fully seated. Replace.

Heat the cover to approx. 1 2 0 ' ~ (250'~) on hot plate then pull out; drill out if necessary.

Heat the cover to approx 1 . 2 0 ~ ~ (250'~) on hot plate. Drive on with suitable mandrel.

911 Special instructions see

Manual Transmission

DISASSEMBLING AND ASSEMBLING

Disassembling

3. Drive on seal for speedometer drive with

special tool P 374. 1. Heat transmission cover to approximately 1 2 0 ' ~ (250'~) and pull speedometer gear shaft bushing out; drill out, if necessary.

Assembling 1. Heat transmission cover t o approximately 1 2 0 ' ~ (250'~) and drive gear shaft bushing in with a suitable mandrel.

2. Drive on seal for shift rod with special tool P 369.

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911

Transmission

D I S A S S E M B L I N G A N D REASSEMBLING OIL P U M P

TOOLS

Description

Special

TOOI

Remarks

Support

Commercial, KUKKO Nr 22-1

Inside puller

Commercial, KUKKO Nr . 21-02

Drift

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P 368

Disassembly and Reassembly

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Transmission

Special instructions see

Note when

No.

Description

Allen bolt

Torque to specification.

Lock washer

Replace.

Pickup tube

removing

installing

1 -

O-ring

Replace. Oil lightly.

Plug for pressure relief valve

Spring

Ball

Self-locking nut

Ball and spring can fall out.

Torque to specification

Tighten cross-wise to specified torque Check oil. pump gears for fiee movement.

Washer --

Oil pump cover

Gasket

Oil pump gear I

Check freedom of movement. End play approx. 0.05 mm.

Oil pump gear I1

Check freedom of movement. End play approx 0.05 mm.

Note number and thickness for reassembly.

Recalculate thickness, if necessary.

Bushing

Transmission front cover

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Drive out with proper punch.

Drive in, properly oriented, with P 368.

I L l l out with KUKKO inside puller.

Drive i n , properly oriented, with P 368.

911

Transmission

I N S T R U C T I O N S FOR DISASSEMBLY A N D REASSEMBLY

Disassembly

Reassembly

Note the thickness and number of gaskets when removing the oil pump cover to simplify reassembly

Drive bushings into oil pump cover with special tool P 368, making sure that they are properly positioned and fully in. T h e milled ends of the oil pockets must point towards the pressure chamber or oil pump gears, respectively.

Note proper orientation of the bushings. Mark lubricating hole.

Use a KUKKO inside puller to remove bushings of oil pump gears from oil pump cover. Place a protector between the puller and the cover to avoid damage to the sealing surface.

See sketch for exact location.

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Transmission

2. Drive bushings into transmission front cover with special tool P 368, making sure that they are properly positioned and fully in. The milled ends of the oil pockets must point towards the pressure chamber or oil pump gears, respectively.

911

4. Install oil pump cover and tighten self-

locking nuts cross-wise to specified torque. Keep checking if the pump gears remain free. If necessary, remove cover again and insert gaskets as appropriate.

NOTE End play of oil pump gears should b e 0.05 mm.

5. Tighten plug of pressure relief valve to specified torque.

6. Lightly oil the O-ring for pickup tube.

7. Install Allen bolts for pickup tube, using new

lock washers, and tighten to specified torque. See illustration for exact location.

Install gaskets in same thickness as noted during disassembly.

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Transmission

DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING

TOOLS

Description

Special Tool

Driver Set

US 8050

T- handle

P 366

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Remarks

911

Manual Transmission

Disassembling and Assembling Transmission Housing

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a 1

Note when

Description

Roll pin

6 7

Short detent

Spring Long detent

Removing

Installing

Drive out.

Tension spring with P 366 and drive in.

Drive out with flat chisel.

Replace if necessary.

5th and reverse speed selector (shift) rod

Torque to specificstion.

Plug

Replace.

Washer

Bellcrank for accelerator linkage

Shaft

Washer

Retainer ring

Take out with small screwdriver.

Bearing outer race

Heat gear housing to approx 1 2 0 ~ ~ (250'~) and drive out with special tool US 8050.

Heat gear housing to approx 1 2 0 ' ~ (250'~) and drive in with special tool US 8050.

Heat gear housing to approx. 1 2 0 ' ~ (250°F) and drive out with special tool US 8050

Heat gear housing to approx 120°C (250'~) and drive in with special tool US 8050

Gear housing

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911

Manual Transmission

Special instructions see 3.1-4/5

DISASSEMBLING AND ASSEMBLING

~isassem'bling

Assembling

1. Drive shift detent securing roll pins out.

1. Heat housing t o approximately 1 2 0 ~ ~ (250'~) and drive bearing outer races-in with special tool US 8050.

2. Drive half-round dowel pin out. Note Detent components are under spring tension. Therefore, always remove the roll pin first, then the half-round dowel pin. 3. Heat gear housing to approximately 120°c

(250'~) and drive bearing outer races out using special tool US 8050.

., "

"" ;

Caution T h e bearing outer races differ in inside diameter. The race with the larger inside diameter belongs to the pinion shaft (lower shaft).

2. Install 5th and reverse speed shift rod. 3. Insert long detent and drive roll pin in.

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Manual Transmission

4. Install spring and sleeve, tension both with special tool P 366, and drive roll pin in.

5. Insert pin and detent (short), then drive the plug in.

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12 34 56 -

911

Gear housing Half-round dowel pin 3rd and 4th speed selector fork(shift) rod Short detent Roll pin Pin I - Sleeve 8 - Spring 9 - Long detent 1 0 - Roll pin 11 - 5th and reverse speed selector fork (shift) rod

Manual Transmission

F I N A L DRIVE HOUSING

TOOLS

Description

Special Tool

Mandrel

P 360a

Mandrel

P 375

Driver Set

US 8050

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Remarks

911

Manual Transmission

Disassembling and Assembling Final Drive Housing

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Manual Transmission

_II

Note when

Description

Input shaft oil seal

Removing

Installing

Drive out in direction of bell housing with an appropriate punch.

Install with P 360a. Sealing lip faces bell housing.

Snap ring

Throwout lever

Replace. Mark lever position on shaft to ensure proper reinstallation.

Seal

Replace if necessary. Drive out.

(

Lever shaft

Throwout fork

1 10 11

Bushing

Readjust if necessary.

Replace if necessary.

Readjust. Drive out with P 375. Drive in with P 375.

Cover tube Bushing

Drive out with P 375. Drive in with P 375.

Bushing Clean and torque to specification.

Breather

Position properly, torque to specification. Make sure it is properly seated.

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Special instructions see

9fl

Manual Transmission

Note when

Special instructions see

Description

Sna.p ring

Note proper seating.

Bea.ring outer race

Heat transmission housing to 120°c (250°F) on a hotplate and drive out with US 8050.

Heat transmission housing to 1 2 0 ~ ~ (250°F) on hotplate and drive in with US 8050.

Bearing outer race

Heat transmission housing to 120°c (250'~) on hotplate and drive out with

Heat transmission housing to 1 2 0 ~ ~ (250'~) on hotplate and drive in with

Needle bearing/ bushing

Drive out with appropriate mandrel.

Drive in with appropriate mandrel.

Transmission housing

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3.1-5/6

Manual Transmission

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

Disassembling

4. Remove bushing.

1. Drive out input shaft seal in direction of bell housing with an appropriate mandrel.

5. Using a small screwdriver, remove both snap rings from the housing for input shaft and pinion shaft bearings.

2. Drive roll pin out.

Note The retaining rings are pressed against the housing by the bearing outer races. For this reason, first loosen the bearing racer from the snap rings with a punch.

6. Heat housing t o approximately 1 2 0 ~ ~ (250'~) on a hotplate and drive out both bearing outer races with special tool US 8050.

Caution Mark throwout lever and shaft to ensure proper position when installing. 3. Drive out lever shaft bushings with special tool P 375.

7. Drive out shift rod needle bearing/bushing

from inside of housing using an appropriate mandrel.

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911

Manual Transmission

Assembling Caution When cleaning the final drive housing, do not use corrosive cleaning materials as they will damage the magnesium alloy.

3. Heat housing to approximately 1 2 0 ~ ~ (250'~) on a hotplate and drive both bearing outer races in with special tool US 8050.

1. Clean housing and check for wear, external damage, and cracks. If repair is due to broken pinion shaft of ring gear, check for damage in center web bearing bores. Replace the housing if necessary. 4. Install breather and torque t o specification.

2. Install bearing outer race snap rings in housing grooves.

Note Position the large snap ring so that its gap will rest in the groove in the housing. In no case should the snap ring gap appear at the sides where the groove is interrupted by a machined cut.

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Note The opening in the hex part of the breather must face forward in direction of travel (toward transmission front cover).

Manual Transmission

5. Install input shaft seal with P 360a. Sealing lip faces bell housing.

911

6. Drive in bushings for lever shaft with Special Tool P 375 (see drawing) and coat with grease having a lithium or silicone base.

1 2 3 4

- Bushing

- Lever shaft bushing - Cover tube - Transmission housing

7. Assemble clutch controls. Note Throwout fork and throwout lever must be adjusted on the lever shaft splines in order to attain proper lever travel. Important 8. After making repairs to transmission, apply new protective undercoating to the entire outside of the housing.

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911

Manual Transmission

The adjustment dimensions are: From top edge of the bell housing to the tip of the throwout fork = 70 m m

Modified Clutch Release Lever

- 1975 Models

The shape of the clutch release lever for transmission types 915/40/45 has been modified due to the location of the pipes of the new exhaust system. This makes it impossible to detach or attach the transmission without first removing the release lever.

After attaching the engine and .transmission together, the new release lever must be installed so that it runs parallel to the clutch cable sleeve flange.

Adjustment of the release fork and release lever as in the past is omitted.

From top edge of bell housing to the bottom throwout lever cut-out = 79 mm

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Transmission

NOTE

2. Remove retaining bolt of pressure line (spray nozzle for ring and pinion gears) from differential housing and pull the pressure line out.

Due to the simple attachment of the pressure lines, they can be replaced without removal of the gears.

Removal 1. Remove pressure line retaining bolt from gear housing and pull pressure line out.

Inst a l l a tion 1. Install new O-rings and oil lightly.

2. Tighten retaining bolts to specified

torque.

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Manual Transmission

911

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 TUBE FOR T H R O W O U T BEARING

TOOLS

No.

Description

Special Tool

Driver Set

US 8050

Thrust piece

P 254 d

Sleeve

P 381

Mandrel

P 375

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Remarks

911

Manual Transmission

Disassembling and Reassembling Differential Housing

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Manual Transmission

No.

Description Input shaft oil seal

Note when: removing installing Drive out inward with fitting pipe piece

Replace if necessary

Snap ring Throwout lever

Drive into seat with P 381

Mark lever position on shaft for reassembly

Readjust if necessary

Replace if necessary

Seal Drive out with proper punch

Replace if necessary

Throwout fork

Mark fork position on shaft for reassembly

Readjust if necessary

Bushing

Drive out with P 375

Drive in with P 375 in proper position

Bushing

Drive out with P 375

Drive in with P 375 in proper position

Bushing CDELRIN)

Pry out with angu.- Replace if necessary lar screwdriver by pressing around sides

Roll pin

Lever shaft

Cover tube

Drain plug

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Clean, torque to specification

Remarks

911

Manual Transmission

Note when:

No.

removing

Remarks

installing

Breather

Position properly and torque to specification

Snap ring

Remove with small screwdriver

Make sure it is properly seated

Bearing outer race

Heat differential housing to approx. 1200 C (248O F) and drf v e race out with US 8050

Heat differential housing to approx. 120° C (2480 F) and drive race in with US 8050

Bearing outer race

Heat differential housing to approx 120' 6 (248O F) and drive race out with US 8050

Heat differential housing to approx 120' C (248O F) and drive race in with US 8050

Differential housing

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Manual Transmission

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

Disass e m b l y

4. Using a small screwdriver, remove snap ring of input shaft bearing race.

1. Drive input shaft oil seal inward with the aid of a fitting pipe section.

NOTE: 2. Drive roll pin out with an appropriate punch.

The snap ring is pressed against the housing by the bearing race. It is necessary to first drive the bearing race away from the snap ring with the aid of a punch.

5. Heat differential housing t o approx. 120° C (248O F) and drive both bearing races out with thrust pieces US 8050 and P 254 d.

3. Drive out lever shaft bushings with P 375.

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911

Manual Transmission

Reassembly

3. Heat differential housing to approx. 120' C (248' F) and drive both bearing outer races into place with the aid of US 8050. "

1. Clean differential housing and check for wear, external damage, and cracks. If the repair is due to a damaged pinion shaft or ring gear (such as metal fracturing), check for possible damage to center web bearing bores. Replace the housing if necessary.

NOTE

. 2.

Pressure-cast housings - must not b e cleaned with corrosive liquids since these damage magnesium alloys. In addition, cleaned pressure castings must b e treated with seasonal corrosion preservatives of bitumen or wax base, such as TECTYL, following transmission repairs to restore the corrosion proofing.

, .

4. Install breather in proper position and torque

to specification.

2. Install snap ring securing the input shaft bearing race in the groove in housing.

NOTE The hole in the hex. head of the breather must face forward in direction of travel (toward transmission front cover).

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Manual Transmission

5. Drive input shaft oil seal into place with P 381.

7. Install clutch controls.

NOTE 6. Drive in bushings for lever shaft with Special Tool P 375 (see drawing) and coat with grease having a lithium or silicone base.

Throwout fork and throwout lever must be adjusted on the lever shaft.splines to attain proper clutch lever travel.

The dimensions are: From top edge of bell housing to the tip of the throwout fork = 70 mm.

1 2 3 4

- Bushing - Lever shaft bushing - Cover tube - Differential housing

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911

Manual Transmission

From top edge of the bell housing to the root of the claw in the throwout lever = 79 mm.

Modified Clutch Release Lever

.- 1975 Models

The shape of the clutch release lever for transmission types 915/40/45 has been modified due to the location of the pipes of the new exhaust system. This makes i t impossible to detach or attach the transmission without first removing the release lever.

After attaching the engine and transmission together, the new release lever must be installed so that it runs parallel to the clutch cable sleeve flange.

Adjustment of the release fork and release lever as in the past is omitted.

8. Coat guide tube for throwout bearing with

MoS2 multipurpose grease.

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Manual Transmission

T R A N S M I S S I O N C A S E W I T H BOLTED G U I D E T U B E FOR RELEASE BEARING

TOOLS

No.

Description

Special Tool

Thrust plate

US 8050

Thrust plate

US 8050

Thrust plate

US 8050

Mandrel

P 381

Mandrel

P 375

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Remarks

911

Manual Transmission

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Manual Transmission

Description

Note when Removing

Phillips ctsk. screw

Installing

Torque to specifications

Guide tube

Use hook to remove Install with MoS2 additive lubricant

Seal, drive shaft

Drive out with P 381

O-ring Pin

Replace, lubricate Drive out with appropriate drift

Circlip Release lever

Press in with P 381

Replace if necessary

Replace if necessary Mark for reinstalling with lever shaft

Seal

Adjust, if necessary

Replace if necessary

Lever shaft

Release fork

Mark for reinstalling with lever shaft

Replace if necessary

Bushing

Drive out with P 375

Drive in with P 375

Bushing

Drive out with P 375

Drive in with P 375

Bushing (Delrin)

Use angled screwdriver on both sides to pry out

Replace, if necessary

Cover tube

Plug

Snap ring

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Clean and torque to specifications Remove with small screwdriver

Install correctly

911

Special instructions see

911

Manual Transmission

Note when

No.

Removing

Installing

Heat case to approx 1 2 0 ' ~ / 2 4 8 ' ~ and drive in with US 8050

Bearing outer race

Heat care to approx 1 2 0 ' ~ / 2 4 8 ' ~ and drive out with US 8050

Bearing outer race

Heat case to approx Heat case to approx 1 2 0 ' ~ / 2 4 8 ' ~ and 1 2 0 ' ~ / 248% and drive in with drive out with US 8050 US 8050

Breather

Position correctly and torque to specifications

Transmission case

Check for damage

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:$pecial :instructions see

Manual Transmission

DISASSEMBLING AND ASSEMBLING 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. Assembling Clutch Release Components T o assure perfect clutch operation, release fork and release lever must b e matched with each other on the lever shaft splines. Specifications are: Approx. 71 m m from clutch bell housing flange surface to upper edge of release bearing surface on fork.

Approx. 91 m m from clutch bell housing flange surface to depression in lever.

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911

Manual Transmission

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. Removing 1. Remove engine/transmission assembly and separate transmission from engine.

Installing 1. Drive new seal in guide tube with special tool P 381.

2. Remove both Phillips countersunk bolts on guide tube. Pull out guide tube for drive shaft seal with a locally manufactured hock.

Place new rubber O-ring tube.

011 neck

of guide

Slide special tool P 382 over splines of drive shaft. Apply a light coat of lubricant to sealing lip of seal in guide tube and rubber O-ring on guide tube neck. 3. Remove seal with an appropriate mandrel or screwdriver. Special tool P 381 can b e applied.

Drive in guide tube until positioned correctly.

6. Install mounting bolts and torque to specifications. 7. Coat release bearing guide tube with MoS2 paste. Downloaded from www.Manualslib.com manuals search engine

Manual Transmission

TRANSMISSION CASE W I T H AUXILIARY C L U T C H SPRING ( 1 9 7 7 MODELS) . .

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911

911 No.

Manual Transmission

Description

Note when removing

Remarks

installing

Spring Circlip

Replace, if necessary

Adjusting lever

Adjust

Seal

Replac% if necessary omitted from March, 1979

Round pin Clutch release lever

Coat pin for spring with all -purpose lube containing MoS 2

Seal

Replace, if necessary

Circlip

Replace, if necessary

Washer Auxiliary spring Washer Adjusting bolt Nut

Torque to specifications

Nut

Torque to specifications

Washer

Replace, if necessary

Holder Base

Coat pin for spring with all-purpose lube containing MoS 2

Spring pin Lever shaft

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Replace, if necessary

911

Manual Transmission

No.

Description

Release fork

Seal

Bushing

Cover tube

Bushing

Note when removing

installing

Remarks

Replace, if necessary Drive out with P 375

Drive in with P 375 until positioned correctly

Drive out with P 375

Drive in with P 375 until positioned correctly Replace, drive in

DISASSEMBLING AND ASSEMBLING I N S T R U C T I O N S Disassembling 1. Disengage spring for adjusting lever and remove circlip.

2. Pull adjusting lever off of lever shaft.

3. Release auxiliary spring. This requires pressing clutch release lever toward front transmission cover with an appropriate tool.

Note When reaching the "dead point" the auxiliary spring will snap forward on its own.

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911

Manual Transmission

Assembling

1. Drive in bushings for lever shaft with Special Tool P 375 (see drawing) and coat with grease having a lithium or silicone base.

3. Locate clutch release lever with a round pin.

4. Tension auxiliary spring (must snap past the dead point to stop pin).

1 2 3 4

Bushing Bushing, lever shaft Cover. tube Transmission case

2. Install clutch release lever with spring and

adjusting screw on splines of lever shaft.

Note Only install adjusting lever after engine/transmission lever is installed in car,.

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Manual Transmission

RELEASE LEVER

1 9 7 8 MODELS

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911

911 No.

Manual Transmission --

Description

Qty.

Note W,hen Removing Installing Replace, if necessary

Circlip

Washer

Cover

Replace

Circlip

Replace, if necessary

Washer

Auxiliary spring

O-ring

Replace

Washer

Replace

Needle bushing

Release lever

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Drive out with Tool No. 9153

Drive in to correct position with Tool No. 9153

Special Instructions

Manual Transmission

DISASSEMBLING AND ASSEMBLING I N S T R U C T I O N S

Disassembling

Assembling

1. Remove upper circlip and drive pin down until cover falls out.

1. Drive pin into spring so that washe~and circlip can just b e installed.

Note This will deform the washer (item 8).

2. Drive in needle bearings to correct position

with Special Tool No. 9153. Note Lubricate needle bearings and bore of release lever with a waterproof lubricant (silicone or lithiumbased) before installation.

2. Remove lower circlip and pull out pin with spring.

3. Drive out needle bearings with Special Tool No. 9153.

.. 3

--.

,'i,

911

F o l d i n g Roof

S L I B S E Q L I E N T I N S T A L L A T I O N O F LOCATING. P I N FOR 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 coniigoratian.

Removal 1. Remove and slacken roof.

2. Drive hinge pin out of t h e rear roof frame and t a k e t h e f r a m e out.

3. Remove window l e d g e rails from right and left

side of rear compartment, detach and remove roll bar inner panel.

4. Pull off approx. 30 c m of weatherstrip from

roll bar center. Loosen leatherette and upholstery padding.

Installation 1. Replace right rear section of roof f r a m e with o n e containing a slot (Part # 911 565 212 4 5 ) .

NOTE: T h e right roof f r a m e section need not b e replaced providing that a slot is filed into t h e hinge pin h o l e so that t h e locating pin points exactly t o t h e r e a r when the. r o o i is locked tight.

. , .. .

.. ,,,

, . ..>.

' I

.A.

. . ~

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-... .: -

w . ~ e - z + ~ ; u 4 ~ - :

...

,,,

,. . ,,

W-,-.;W '

':~ 37':.:,>,;;..,',

911

F o l d i n g Roof

2. Install localing pin, Part # 911 565 145 10.

3. 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 il in.

~.~

tw%b%>.- -..-

;,.

# 911 565 133 40. with sheetmetal top edge and weld, or spotweld. Shorten upholstery padding t o fit t h e cover plate.

4. Align cover plate, Part

5. Prime sheetmetal parts with p r i m a . Attach

rubber mount, with large opening facing forward, t o t h e supporting p l a t e using sheetm e t a l screws.

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Folding Roof

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. Insert rubber grommet.

Install and fasten t h e roll bar inner panel. Glue t h e weatherstrip in.

Place roof in position ar.d check alignment of locating pin.

Requited parts: 1 Supporting p l a t e 1 Cover p l a t e 1 Rubber mount 1 Rubber g r o m m e t 1 Locating pin 1 Roof rail section

911 565 133 40 911 565 135 40 911 565 009 40 911 565 189 40 911 565 145 10 911 565 212 45

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911

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911

Removable Hardtop

lescription

Notes Removal

Installation

temovable hardtop Install with heatresistant adhesive

-leadliner Check, replace if necessary

Adjust to tension of windshield

'illister head screw M6x10 Masher ~ c a t i n gpin

Check, replace if necessary

hJasher Stop pad

Check, replace if necessary If required, install on stop pad to adjust height

Spacer

ioof edge guard

Loosen glued edge, remove metal screws

Glue properly to roof frame

Oval head metal scr 3.5 x 1 3

Washer Roof edge guard fro]

Replace i f damaged

Oval head metal sci 3.5 x 9.5 Replace i f necessary plug openings in rea and front roof edge guards

Cap Plug

Roof edge guard rea Oval head metal sc 3.5 x 9.5 Metal/plastic bearil left + right

Check, replace i f necessary

Cover

Check, replace if necessary

Fillister head screw M6x10

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Adjust so that roof and roll bar upper edges match

Remarks

Removable Hardtop

911

p~~

Notes

Description

Removal

Installation

loosen glued front and rear ends, rem o v e m e t a l screws

Glue end pieces properly, using foam rubber underneath if required. Adjust door window seal, then tighten. T r e a t rubber seal with, for e x a m p l e glycerine e t c .

Pull off

Glue on roof f r a m e along c o m p l e t e length of seal

Washer Roof f r a m e seal side. left and right

Oval head m e t a l screw 3 . 5 x 9.5 Sealing t a p e

Installed for hardtop roof only

Escutcheon, lock Oval head m e t a l screw 3.5 x 9 . 5

Removable hardtop escutcheon on windshield frame

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Remarks

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

rr,i,,,

Current Flow Diagram Type 911 SC USA Model 82 PART I

POWER SUPPLY, STARTER FUEL PUMP HEATER VENTlL4TOR IGNITION

PART II

HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER

PART Ill

REAR LIGHT, BRAKE LIGHT HORNS INTERIOR LIGHT IGNITION/STARTER SWITCH REAR WINDOW DEFOGGER

PART IV

OUTSIDE MIRROR FRESH AIR BLOWER CIGARETTE LIGHTER WINDSHIELD WIPER POWER WINDOWS

PART V

OXYGEN SENSOR SYSTEM INSTRUMENT, SENDER UNITS

PART VI

OXYGEN SENSOR SYSTEM HEADLIGHT WASHER

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Current Flow Diagram Type 911 SC USA Model 82

CONTINUATION OF WlRE (E. ti. PART V CURRENT TRACK 3)

WlRE CONNECTORS

ONE POLE A - NEAR REGULATOR PANEL B - BEHIND HEADLIGHT LEFT C -BEHIND HEADLIGHT RIGHT D - RFnlhD K S E BOX C - O h .LtiGAGC COMPARTMEhT F-OOH k - n F n l h D hSTR.MEhT PAhE-

- TWO POLE

A B C D E F G P T3

NO ACTUAL WIRE, BUT INTERNAL CONNECTION OR CONNECTION BETWEEN EQUIPMENT HOUSING AND GROUND

IMLLOW: 5A. WHITE: 6A. RED: 16A. BLUE: 24A1 FUSE 11 1 6 A

WlRE CROSS SECTION (E. G. 1.0 mm') COLOUR OF WlRE ( E G . GREENIYELLOWl

THREE.POLE A B

-BELOW REGULATOR PANEL - I N ENGINE COMPARTMENT LEFT - NEAR DISTRIBUTOR - I N TUNNEL REAR - BELOW REGULATOR PANEL - ON LUGGAGE COMPARTMENT FLOOR NEAR LEFT SEAT NEAR BATTERY

ON LUGGAGE COMPARTMENT FLOOR IN ENGINE COMPARTMENT

SIX POLE A - IN ENGINE COMPARTMENT LEFl B - I N ENGINE COMPARTMENT RIGHT

WlRE CONNECTOR (E.G. FOURTEEN POLE TERMINAL 6 )

G - BELOW INSTRUMENT PANEL H - BELOW INSTRUMENT PANEL

I - I N DOOR WELL LEFT K - I N DOOR WELL RlGHl T I 2 -TWELVE-POLE IN ENGINE COMPARTMENT T I 4 -FOURTEEN POLE ON REGULATOR PANEL GROUND TERMINALS 0 ON ENGINE

'2 IN LUGGAGE COMPARTMENT BATERY

IN ENGINE COMPARTMENT

ON LUGGAGE COMPARTMENT FLOOR

NEAR N S E BOX

WIRE COLOURS BK WT RE

- BLACK - WHITE - RED

GROUND (BODY) GN YE GR

GREEN YELLOW GREY

BR BL VI

- BROWN - BLUE - VIOLET

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CURRENT TRACK NUMBER

Current Flow Diagram Type 911 SC USA Model 82, Part I POWER SUPPLY, STARTER FUEL PUMP HEATER VENTILATOR IGNITION

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GENERATOR AND REGULATOR

!----l

THERMO SWITCH FOR COLD START VALVE

--.-.-.-

AIR FLOW SENSOR

FUEL PUMP

HEATER VENTLATOR

HEATER VENTIMTOR

*a f

IGNITION COIL

-z

a r C

CI "7

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m O -Y

a O u.

Current Flow Diagram Type 911 SC USA Model 82, Part II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER

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DIMMER HEADLIGHT FLASHER SWITCH

FUSE 4 5 A

FUSE 3 5 A

PARKING LIGHT CONTACT

FUSE 2 5 A F-.-.--

__j

LICENSE PLATE LIGHT

ASHTRAY LIGHT

r--1

L . . . -

IEATER CONTROL ASSEMBLY LIGHT

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-e

, dl

7$.%

Current Flow Diagram Type 911 SC USA Model 82, Part Ill REAR LIGHTS, BRAKE LIGHTS NORNS INTERIOR LIGHT IGNITION/STARTER SWITCH REAR WINDOW DEFOGGER

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911

Electrical Accessories

When installing antenna make sure there is perfect ground contact between base of antenna and fender.

Base ground to battery negative pole = 0 ohm.

Installed distance for automatic antenna.

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Current Row Diagram Type 911 SC USA, Model 82, Part IV

FRESH AIR BLOWER

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Current Flow Diagram Type 911 SC USA Model 82,Part V OXYGENSENSORSYSTEM INSTRUMENT. SENDER UNITS

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Current Flow Diagram Type 911 SC USA, Model 82,Part V

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Current Flow Diagram Type 911 SC USA Model 82, Part VI OXYGEN SENSOR SYSTEM HEADLIGHT WASHER

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Current Flow Diagram Type 911 SC USA, Model 82, Part VI .. r----

OXS CONTROL UNIT

_ _

HEADLIGHT WASHER SWITCH

L OXYGEN SENSOR

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Description of Relays a n d Fuses

L O C A T I O N OF RELAYS A N D F U S E S I N 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 MODELS

Beginning with 1974 models, the fuse box is located on the left side panel of the luggage compartment near the brake fluid reservoir. The plastic cover can b e removed from the fuse box by lightly pressing its top downward. The fuse box contains 18 fuses and, depending on options. 1 to 3 standard relays.

- Relay for air conditioning - Relay for fog lamps

- Relay for signal horn

Mounting space for 4 additional relays has been provided for possible expansion of the electrical system.

A fuse listing is contained in the wiring diagrams. T h e fuses are identified in the diagrams in an ascending numerical order whereby the forwardmost fuse in the vehicle bears the designation S 1.

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911

Description of Relays and Fuses

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.

- Vacant 2 - Relay for heated windshield 3 - Relay for emergency flasher 4 - ~ o g i c - r e l a yfor safety belt warning system 1

- Relay

- Cold start relay - control relay for two-stage heated reaI

for single stage heated rear window (not installed with two-stage version)

window (not installed with single stage version) 4 - voltage regulator

5 G

- CDS trigger unit - Rear fuse box

Vehicles not equipped with CIS (fuel injection) have the RPM-transducer installed adjacent to the two-stage heated rear window relay.

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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

Rear fuse box (fuses S 22 thru S 24 of wiring diagram)

Note T h e relay positions for the heater blower and warm-up regulator were interchanged in some vehicles.

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911

Descriptions/Relays and Fuses

L O C A T I O N OF RELAYS AN D F U S E S

1 9 7 6 MODEL

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.

T h e warm- up regulator relay is omitted. 1

Air conditioner relay

Foglight relay

Relay for 2- stage rear window defogger (omitted for single stage defogger).

Voltage regulator

Horn relay

Vacant

Electric window winder relay

6 7

Vacant Fuel pump relay

T h e fuel pump relay also controls t h e warm- up regulator and auxiliary air regulator. It has a red cover t o distinguish it from t h e standard relays.

T h e fuse box has 21 fuses. T h e last fuse (S 21) as seen in t h e driving direction is for t h e fuel pump for 1976 models.

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6 7

Relay p l a t e Relay for single stage rear window d e f o g g e ~ (omitted for 2- stage defogger) Relay for heater blower

CDI control unit Radio (interference) suppressor Rear fuse box (fuses S 22 thru S 24 of current flow diagram) Capacitor (only for Bosch CDI control unit)

- omitted as from 1978 models -

Description

Lighting System

911

HAZARD WARNING FLASHER

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. T h e new flasher c a n b e identified by its white plastic base, t h e old flasher was a l l b l a c k . T h e new l which is n e e d e d . flasher is additionally equipped with T e r m i ~ 58

NEW

OLD

S i n c e this modification required repositioning of t h e terminal tabs, it is not possible t o install t h e new hazard warning flasher into vehicles of pre- W73 vintage unless t h e new wire l o a m (with white coupling) is used or t h e terminals a r e changed in t h e coupling of t h e old l o o m t o m a t c h those in t h e new flasher. This would require removal of t h e brown wire, together with t h e flat terminal socket, from t h e plug- in connector (watch retention hook) and inserting it into t h e adjacent, formerly unused. r e c e p t a c l e .

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Description of Alternator

911

ALTERNATOR - 1 9 7 5 MODELS

An 840 W alternator ( s a m e s i z e as t h e 770 W alternator used previously) is installed as o f t h e 1975 model year. T h e 840 W allernator will b e replaced by one of 980 W later in the 1975 mode! year. This alternator will be 9.3 m m longer. T h e blower housing, already designed for this size, has a ring installed with t h e 840 X i alternator t o compensate lor t h e 9 . 3 nlrn deeper hole in the blower housing. This ring is t o be omittcd rvhen a 980 \I' alternator is service installed in such a vehicle. A new voltage regulator is also introduced for the 1975 models. It is applicable t o both new alternators (840 and 980 watts).

A modified hub extension is installed with t h e introduction of t h e 980 W Alternator. This part must also b e installed if a 980 I i alternator is service installed in a vehicle. If t h e former hub extension is left in t h e vehicle, there will b e a large g a p between it and t h e blower housing.

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Description

IGNITION SYSTEM MODII:I(IAl'IONS

1. A11 '311 models a r e equipped with a l h c a k e r less capacitor discharge ignition system ( s i m i l a r ta that of 930 Turhoi.

2. CDI unit and distributor h a v e been changed.

3. Ignition control: centrifugal a d v a n c e and vacuum retard.

4. Speed control: Electronic speed relay, cutout of iuei p u m p a t GS5O 150 1,'min.

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Ignition

911

1978 M O D E L S

5. Distributor turns counterclockwise. Consequently the brealierless CDI system cannot h e serviced installed in earlier vcliicles.

9fl

Description

Ignition

C h a n g e s t a I g n i r i o n S y s r e r r l - 1980 M o d e l

T h e 011 SC is equipped with a disuibuLor havlng a double vacuum unir for ierard and advance ignition conrrol.

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Starter

Technical Data

911

STARTER

General Information

Beginning with 1972 models, starter power output is increased from 0 . 8 HP t o 1.5 LIP. Bath starter types a r e basically af t h e s a m e design.

Specifications for GB 12 V 1 . 5 HP (BOSCH :I: U 001 312 100)

Voltage

12 v

Power rating

1 . 5 HP

No-load current draw !< 1 1 . 5 volts

- 80 amps 1300 - 9300 rpm G00 - 7 8 0 amps

No-load speed Stall torque current draw

16'

G volts

hlininlllni voltage for solenoid draw-ill

7.5 volts

Urilsli pressure

So0

A r n l a t i ~ r eend- play

0 . 1 - U.3 iilm

900 giarns

Beginning rvitll the end o f April 1973, only vehicles equipped for counlries in tlie northern henlispllere arid Canada continue t o b e equipped with t h e 1 . 5 1V starter. All athcr Type 9 1 1 T , E and S vcliiclrs will again be cq~lippcdwith t h e 0. 8 HP starter.

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DISASSEMBLING A N D ASSEMFLING STARTER

TOOLS

Special T o o l

Remarks

Press black Press pipe

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31.5 mrn dia.

Disassembling and Assembling Starter

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Starter

* r.

Description

Note when

Special instructions see

Qty

removing

installing

Lock washer

Retaining screw

Solenoid

Pull pinion engagement assembly forward.

~ u s cap t O-ring 2

Position rubber block tip i n field frame

Check solenoid current draw and free movement of core. Seal, lubri-

Seal. Replace if damaged.

Retainer Note number of shims. Adjust armature endplay to 0.1 - 0.3 mm (0.004 0.012 in.)

Bolt

T--F

Brush carrier plate

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Seal with paste.

Check bearing bushing, replace if necessary (remove with VW 401, VW 411, and vw 418a).

Ground-connecting surface t o field frame must b e free of paint or grease. Upon assembling, seal and lubric a t e lightly. Check position of rotation detent for proper ground t o field frame.

911

Starter

Nr.

Description

Specirl instructions see

Note when Qt: removing

installing

Check for cracks, dirt, and tight connection.

Brushes must move ireely i n holder. Replace in sets only.

Lift with wire hook.

Brush pressure ca. 800 900 grams (28-32 oz.).

Negative brush

20 -

Check for proper sealing.

21 22 -

23 -

Field frame

Check continuity. Replace coil if burned.

Insulating washer

Locate against brush carrier plate.

Thrust washer

Locate against commu-

27 28

29 -

Armature

Vertical runout 0.03 mm; minimum diameter 33.3 mm: if necessary, undercut segment insulation

Check for grounding. Check soldered pointc between segments and soldered tabs. Install armature together with actuating lever.

Replace if bent.

Engagement spring

7 Detent balls

Install packed in lithium grease.

Overrun clutch

Pivot bolt

Lock washer

34 -

Nut

Drive housing

Check for proper ground between brush end cover and drive housing.

Field coil

Grease lightly.

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Seal joining surfaces between solenoid and drive housing, and field frame and drive housing. Coat lightly with oil.

starter

911

Instructions for Removal and Installation

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. A battery-starter lead with a cross-section of 25 mm2 is used in conjunction with the 0.8 HP starter motor; this lead has a cross-section of 35 mm2 in vehicles equipped with the 1.5 HP starter motor. For e a s i a identification, both battery leads are color-coded about 800 mm from the starter connector:

25 mm2

white band yellow band

35 mm2

It is necessary to replace the battery-starter cable when replacing the 0.8 HP starter motor with the 1.5 HP unit in 1974 model and later vehicles.

The type of cable installed in pre-1974 vehicles must be determined in such cases, although no color coding will b e found.

Standard Equipment

To end of 1971 models

From 1972 model to May 1972

From May 1972

Starter Power Rating Cross-Section of Battery-Starter Cable

Excepted from the above are all vehicles equipped with the Sportomatic transmission, which were equipped exclusively with the 0.8 HP starters and 25 mm 2 cables; and Carrera 2.7 vehicles which were furnished only with the 1.5 HP starter and 35 mm2 cable.

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Lighting Equipment

S E A L E D BEAM IlEADLISlH'l'S

Replacing Sealed Beam

1. Unscrew retaining screw and remove l a m p

rim.

2 . Remove only t h e 3 screws (arrows) which

secure t h e l a m p unit retaining ring. remove retaining ring and withdraw sealed b e a m unit

3. Disconnent plug from rear o f unit

4. Attach plug t a rear of new unit.

5. Insert sealed b e a m unit and reatining ring tighten hold-down-screws.

6 . Install l a m p r i m and tighten retaining screw.

It is best t o first screw t h e Philips-headscrew i n by a few turns and t h e n t o seat t h e l a m p unit i n its upper retainer. Afterwards tighten t h e Philips-headscrew.

Beginning with t h e 1174 models, it is necessary t o use t h e extra- long Philips screwdriver when loosening a r tightening t h e headlamp retaining screw (Special Tool P 388).

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Lighting Equipment

FOG LAMPS AND FOG TAIL LAMP

Subsequent Installation

1. Disconnect battery ground strap.

2. Drill holes for l a m p mounting and rubber

grommets in front and rear bumper skirts. Make sure that t h e hole arrangement is m a d e exactly as in t h e illustration for e a c h of t h e two fog lamps. (Dimensions are in m m )

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911

Lighting Equipment

3 . 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 x 15 bolts with washers and lock washers on each lamp unit. Place a toothed washer between the lamp bracket and lamp mounting plate. Fasten the lamp lo the mounting plates with a lock ring and M 1 0 nut.

4. Thread the electrical wire through the bumper

skirt and the already present holes in the wheelhouse into the luggage compartment, then press the grommets into place. The windshield washer reservoir must be removed for this operation (see 4.4-1/1).

5. Remove loudspeaker cover and loudspeaker. This fog lamp switch should be installed between the rear window defroster switch and the cigarette lighter. A hole of 20 mm dia. has to be cut in the instrument panel cover; the holes are already made in the instrument panel and luggage compartment pan. Mark center of the hole by pushing a pin through the back of the instrument panel cover. Cut the hole by using a compass for marking and then carefully cutting the cover with a knife. or by using an appropriate rotary cutter and cutting the cover to the sheetmetal base.

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Lighting Equipment

9111

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. Insert switch assembly from t h e rear. fasten with ring nut. and screw t h e knob in.

6 . Remove luggage compartment lining and d e t a c h fuse box. Install t h e wires in such way

that t h e two two- pole connectors will b e located adjacent l o t h e fog l a m p wires. Fasten t h e wires along t h e front cross panel with the m e t a l tabs already there. T h e relay switch socket should b e pushed in from t h e franl and t h e relay switch then plugged into it. T h e wires a r e then pushed along t h e luggage compartment tloor t o t h e fog l a m p switch. T h e speedometer should b e removed during this installation. M a k e sure that t h e wire does not touch t h e windshield wiper drive components.

7 . Wires leading from t h e fog lamps should

connect brown with black, and white/yellow with blue. T h e brown ground wire should b e connected t o t h e ground bolt in t h e cross panel near t h e battery. Connect wirm t o fuse box as follows: NOTE:

red wire t o grey wire t o white wire t o white/green wire t o both whitelyellow wires

Fuse Fuse Fuse Fuse to Fuse

17 top # 2 bottom # 8 top # 1 top

1 bottom

Refasten fuse box and r e p l a c e luggage c o m partment lining.

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In vehicles manufactured t o U.S. specifications. t h e connections differ as follows: grey wire t o white wire Lo

Fuse # 6 bottom Ground (lengthen t h e wire)

T o preclude mistakes, n o t e that t h e fuses a r e numbered 1 thru 18 (in vehicles equipped with air conditioning t h e numbers g o thru 23). starting in front in the direction of travel. T h e fuse number c o d e is also used in t h e wiring diagram.

911

Lighting Equipment

The wires are connected to the switch as follows: blue/white wire to Terminal N grey wire to Terminal 58 A white/green wire is already installed in the vehicle; it is accessible through the loudspeaker cutout and can be found taped to the wire loom located ther-. Remove the tape and connect the wire to Terminal NR. The negative (- ) terminal at the switch should b e connected to the ground at the cigarette lighter through a resistor of 100 ohms. NOTE:

If only the fog lamps. or one fog tail lamp is installed, a simple push-pull switch is used instead of the pull-turn switch. In addition, the resistor in the ground wire connecting the switch and the cigarette lighter is not used.

8. Unfasten wire attached to the rear part of the left tail lamp assembly. Push rubber grommet into the 10 mm hole in the bumper skirt and lead the wire from inside out. Attach fog ta;l lamp bracket to the bumper skirt with 2 Allenhead bolts M G x 15, lock washers and washers.

Attach a connector to the white cable and fasten it to the skirt with one of the two bolts. Lead the white/green wire through the grommet into the lamp unit and connect. Install wedge.-base bulb (18 watts) and c l a e lamp unit. The lamp retaining nut should be tightened firmly for proper ground connection. Attach wire to lamp bracket with a wire clip.

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Lighting Ecluipmrnt

Reconnect battery and check l a m p operation. When t h e switch knob is pulled out, t h e fog 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.

10. A d j u s t i n g L a m p s

An optical l a m p adjuster should b e used for adjusting t h e fog lamps. When t h e driver's seat is occupied, t h e upper bright/dark intensity l i n e must b e on t h e marker line, extending horizontally over t h e entire screen. T h e lens of t h e fog tail l a m p must b e positioned vertically t o t h e road and a t a right angle t o t h e longitudinal vehicle axis.

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911

Windshield Wiper and Washer System

911

ADJUSTMENT INSTRUCTIONS

Beginning with February 1972 and the below given chassis serial numbers, all type 911 vehicles are equipped with madified windshield wiper arms:

VIN 911 T Coupe 911 T Targa !I11 E Coupe ill1 E Targa 911 S Coupe ill1 S Targa

When adjusting the new windshield wiper arms m a k e sure that t h e outer (left) arm does not rest against t h e decorative slrip, and t h e distance o f 2 0 n l m (35/32 in) is maintained between both arms. Check that hlades a r e positioned properly by opeiating t h e wipers for a few strokes. NOTE: Wlieil operating Lllc windshield wipers, m a k e sure the windshield is wet.

T h e diiference lor dimension a between t h e old and new wiper arms is: a a

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- approx. - approx.

35 lnin ( 1 3 / 5 in) (old) 60 m m ( 2 3 / S in) (new:

Windshield Wiper and washer System

W I N D S H I E L D WASHER P U M P

Removal and Installation

The windshield washer pump in 1974 model vehicles is located at the lock transverse panel near the battery. Both electrical wires and water hares must be detached prior to removal of the pump.

When connecting the wires, it is necessary to note the proper polarity, that is, the brolill wire nlust be connected to the terminal marked (-). The nipple marked D is connected to the hose leading to the spray nozzles through the T-joint. A hose leads from each :the connection B and a connection in the T-joint) to the threaded cap in the windshield washer reservoir which, effective with 1914 models, is located under the left front fender. An additional connection in the reservoir cap is a vent hose which leads to the water filler neck within the tank filler compartment.

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911

Windshield Wiper and Washer System

W A T E R RESERVOIR F O R W I N D S H I E L D WASHER S Y S T E M

Removal and Installation

T h e left front wheel must b e removed when removing the water reservoir. The bumper does not have to b e removed. The reservoir is attached to the vehicle by means of a strap which is bolted to t h e headlamp compartment. The reservoir can b e taken out rearward after the attachments are unfastened, the filler hose detached, and the threaded cap removed.

Make sure during installation that the mounting strap is seated properly in the support bracket.

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911

Windshield Wipers and Washer

911

I N T E R M I T T E N T WINIISHIELD WIPER S W I T C H

Removing and Installing Potentiometer

Removing and Installing Intermittent Relay

1. Disconnect battery ground strap.

1. Remove blower housing.

2. Remove clock.

Pull plug off of intermittent relay and unscrew mounting screws.

Pull off potentiometer knob, unscrew nut and take out potentiometer t o front.

-+-

Note T h e potentiometer on cars prior t o 1976 model is located next t o steering column on right side.

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Emission controls

Exhaust gas r e c i r c u l a t i o n canlrol

All 1975 models with California equipment have exhaust gas reciiculation (EGR) to reduce the pollution from exhaust gases. Parts af the EGR system are subject to a certain amount of wear and have to b e inspected and/or. replaced at certain intervals (see Group 1).

An elapsed mileage odometer is installed beneath the blower housing to control the inspection intervals. The EGR indicator lamp will light up after 30, 000 miles have been driven. After inspection of the EGR system, the elapsed mileage odometer must b e reset to zero als follows:

1. Disconnect battery ground strap. 2. Remove tachometer.

3. Using an appropriate tool (small screwdriver, punch or something similar) press the pin on the elapsed mileage odometer housing in to the stop.

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911

Emission controls

T h e EGK indicator l a m p comes o n when t h e ignit i o n is turned a n and goes out when the e n g i n e !;tarts. This wiring hookup provldes a method of checking t h e indicator l a m p before e a c h start.

A n altered elapsed m i l e a g e odometer is installed in a l l models in conjunction with t h e eleclronio speedometer, e f f e c t i v e with t h e 1976 model.

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Mounting, removal and installation of this switch is identical t o thal of t h e former elapsed m i l e a g e odometer. This also applies when resetting t o zero.

REMOVING AND I N S T A L L I N G SPEEDOMETER CABLE

Note 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.

Removing

1. Remove blower housing. Do not lock operating cables.

2. Detach speedometer cable atEGR elapsed mileage odometer switch. Tie a string to end of cable.

3. Remove tunnel cover in car. Remove gearshift lever housing. Take off plastic strap.

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..,

. w

- --

~ . -

Speedometer

4. Remove cover a t hack of tunnel.

T a k e off plastic strap.

5. Disconnect speedometer c a b l e beneath car a t

transmission.

6. Pull speedometer c a b l e loward rear out of car.

Installing

1. T i e string t o speedometer c a b l e and pull in c a b l e toward front.

2. Securespeedometer c a b l e l o car tunnel with 2 plastic straps.

Caution M a k e sure that c a b l e is installed without kinks or bends. Install seal at transmission.

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ELECTRONIC SPEEDOMETER

C h e c k i n g Electronic Speedolneter Sensor

Remove tunnel cover in front o f emergency seats. Disconnect the flat m a l e plugs a t the connector i n the tunnel and connect a test buzzer t o the wires leading back. Lift car a t rear axle and turn right rear wheel by hand. Lock l e f t rear wheel. The Ihuzzer must sound off 8 times for e a c h two revolutions of the wheel. If not, replace the sensor. The l e f t rear wheel need not b e locked, if a car is equipped with a l i m i t e d slip differential. In this case the buzzer sounds o i l 8 times for e a c h one revolution.

Checking Eleclronic Speedometer

I. Connect and disconnect very quickly the two wiles i n the tunnel that l e a d forward. A distributor c a n b e applied to help, if Lmth wires a r e connccled t o teiniinal 1 and the distrihulor housing, and the distributor shaft is turned by hand as quickly as possiblc. Remove the speedometer i l there is no dcflcction of the needle. Check a l l wire connections to the speedometer and replace the speedometer if necessarv.

Turn on the ignition for this test.

2. T h e aperation o r the eleilronic s p e e d o m ~ l c rof'l'ype !lll a n d Turbo C a r r e r a Models can also hc checked as follows:. Disconnect wire fronl terminal T D of tachonleter and instead connect l h e wire from terminal 31 b on t h e speeclameter

T h e specdometer must now show a reading according to the engine speed. If there is n o needle deflection, the speedometer must be replacod, Relation betwecn engine speed and speedometei reading: Speedometer reading ( M P W

engine speed (rpru) calibration n u n ~ b e r

Example:

T h e calibration number is cmbossed a n speerlorneter housing.

CAUTION

The testing method a t point 2 c a n no longer b e used on speedometers afier rnanufacruring date 1/77. There is danger of damaging a n electronic component in the speedometer. Downloaded from www.Manualslib.com manuals search engine

911

Instruments, Controls

Removing and Installing Eleclronic Speedometer Sensor

1. Remove right rear wheel.

2. Remove h e x head screw and l a k e holder off of sensor.

3. T a k e sensor wires out of holders and pull sensor

out of transmission case.

Separate connector in tunnel and pull out sensor wire toward rear.

Note T h e polarity need not b e observed when connecting the sensor wire.

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Electrical Accessories

911

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. This system consists of 2 inertia reel safety belts with automatic lockitg retractors, a control lamp with the inscription "Fasten Seat Belt". a seat contact switch built into the passenger seat, a new parking brake switch, and a modified buzzer. The three-pole buzzer can still be used as replacement for the formerly used two-pole buzzer in vehicles not equipped with the safety belt warning system. An electric switch is built into each safety belt buckle. The switch is closed when the belts are not worn, providing ground for Terminal G of the control lamp. If Terminal 50a does not have a ground connection through the handbrake switch at the same time, a transistor incorporated in the control lamp becomes conductive. Since the buzzer Terminal 86 is energized at all times, and Terminal 15 of the control lamp is energized when the ignition is on, the control lamp will light up and the buzzer sound off. When the belt is put on, the contact in the belt buckle opens and Terminal G ceases to have a ground connection. The passenger seat is equipped with a seat contact which breaks the ground connection from the belt buckle on passenger side to Terminal G in the control lamp when the seat is unoccupied. The reminder to wear seat belts is given by the control lamp with the inscription "Fasten Seat Belt" and the simultaneously audible sound of the buzzer whenever the ignition is switched on, the driver (and passenger) have not put the seat belts on. the parking brake is fully released. The former function of the buzzer remains unchanged.

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911

Electrical ~ 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 1074 models. The new system consists of 2 three-point seat belt assemblies with automatic locking retractors, a control lamp with the inscription FASTEN SEAT BELTS, a seat contact in each seat. and the so-called logic relay switch with an integrated buzzer. The formerly used separate buzzer is discontinued. Also, the control lamp circuit has been changed so that it cannot be used in cars of pre-1974 vintage.

The following steps must be performed to start the engine: 1. The engine can be started at any time when no load is placed on the seats (for instance, starting from

the outside). 2. Whenever a load is placed on a seat, the seat belt must be buckled. This applies to both driver's and passenger's seats. It may become necessary to buckle the seat belt when a heavier piece of luggage is placed upon it. Since the action sequence of "Occupy Seat - Fasten Seat Belt" is monitored by the logic relay switch, the engine will not start if either the driver or passenger should fasten the seat belt prior to occupying the seat. When the proper action sequence is not followed, the buzzer and the control lamp with the inscription FASTEN SEAT BELT are activated as soon as the ignitmn switch is turned on. 3. It is possible to restarl the engine without fastening the seat belt if the restarting occurs within 2 minutes of shutdown.

The accoustic and optical warning system will be activated whenever any of the fallowing conditions occur when the engine is running: 1. When a load is placed on a seat without buckling the seat belt.

2. If the action sequence of "Occupy Seat

Fasten Sent Belt" was not followed in that order.

3 . When the load is removed from a seat. in which the belt is buckled is then placed back on it.

for more than 1 0 seconds and

In all of the above cases the warning system can be activated only when the parking brake is in the off position. The waning condition can be cancelled by refastening the seat belts in proper sequence.

The buzzer integtated in the logic relay switch also is part of the ignition key warning system

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An improved interlock relay for the seat belt warning system was introduced around the middle of December 1973.

With the introduction of this relay, the warning system is only activated (engine running) if the seat belts are unfastened while the seats are occupied.

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911

Electric Accessories

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.

The belt contact switch on the passenger's side and both seat contact switches are omitted. A timer relay with a built-in buzzer replaces the interlnck relay. The connection between the seat belt warning system and starter is omitted, i.e. the starter can b e used any time.

"Fasten Seat Belt' warning light always lights up when the ignition is switched on and goes off in 4 to 8 seconds regardless if belts are worn or not. If the driver's belt is not worn a buzzer will also come on with the warning light. The passenger's belt has nothing to do with the warning system.

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Electrical Accessories

CONTROL ILLUMINATION

Beginning with t h e 1973 models t h e following controls a r e illuminated: 1.

Heater control lever on t h e center tunnel.

Fan control switch on t h e instrument panel.

Hazard warning flasher control switch.

All lamps a r e connected t o t h e instrument illumination circuit permitting d i m m i n g .

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911

Electrical Equipment

911

H E A D L I G H T WASHERS

Deprersing the switch in the instrument panel operates the water pump, which is bolted to the front hood lock panel. It is controlled by a relay located next to it. At a prersure of about 2.8 bar, a valve opens and a stream of high pressure water goes to the spray jets. T h e relay limits the washing phase to about 0 . 3 seconds. If this time is not sufficient to clean headlights, depress switch again. The container (in front of the left front wheel) holds about 9 liters (2.2 US gal.) of fluid. It is also used to provide fluid for the windshield washer.

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Electrical Accessories

SAFETY B E L T WARNING SYSTEM Removing and Installing Seat (Also s e e Group 8)

A two- pole connector is located under the seat. In the driver's seat t h e connector wire leads into t h e seat interior and is connected directly t o the safety belt buckle. In t h e passenger's seat a n additional seat contact is wired inbetween.

Prior to seat removal, t h e wire must b e disconnected a t t h e connector and also detached from its retainer on seat underside. T h e wire must b e reconnected upon installation of the seat: the polarity makes no difference.

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911

Electrical Accessories

Removing and Installing Safety Belt Buckle (Also see Group 8) T h e front plastic cover of t h e buckle can b e removed upon removal of both countersunk screws. Push rear cover to t h e side and remove buckle retaining screws. When detaching both wires, hold terminal tabs with needle pliers since otherwise t h e tabs c a n break off when t h e wires a r e being pulled off. T h e belt buckle should not b e disassembled unless it does not function properly.

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Electrical Accessories

When replacing the wedge-base bulb ( l 2 V . 1.2W). it is necessary to open the control lamp for access.

When installing the lamp, make sure that the rubber gasket is properly seated.

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911

Electrical Accessories

Removing and Installing S e a t Cont a c t in Passenger S e a t

Remove seat (see Group 8, page SB 2 1 and 22).

Remove seat recliner retaining screws and remove back rest. Remove seat cover to gain access to the seat contact. Make sure during installation that the seat contact is located in its original position in the seat. Reconnect both wires: polarity makes no difference.

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911

Electrical Accessories

Removing and Installing Safety Belt Lock i n t h e Sport S e a t

Remove both countersunk screws and take the plastic cover off. The rear cover should be pushed to the side to clear the lock assembly retaining bolt and permit its removal. Pry both wire retaining clips open to free the wire and detach it at the plug connector.

Removing and Installing Seat Cont a c t Switch i n Passenger's Seat (Sport S e a t )

Remove seat (see Group 8 , page SB 21 and 22). The seat contact switch is freely accessible on the seat underside and can be removed once the wires are disconnected. Make sure during installation that the seat contact switch is reillstalled in its original position (note dimemions). To prevent the seat contact switch from relocating itself sideways. it should be glued to the seat underside with a commercial adhesive. Polarity is of no consequence when the electrical connectiolls are made. .

(Dimensions shown are in mm)

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911

Electrical Accessories

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

Removing and Installing Logic Relay Switch

The logic relay switch rests in a socket which is attached to the luggage compartment floor and is accessible upon removal of the small combinalion instrument. The asymmetrically arranged contact prongs ensure proper installation of the relay, which is with the inscription facing rearward in relation to the direction of travel.

133 919 L31 Ij Log~k-Rela~s 1 2 ~ BOSCH GERMANY B 335 609 002 0 335 L12 0 0 2

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Electrical Equipment

S E A T BELT I N T E R L O C K S Y S T E M

Removing and Installing T i m e Relay The t i m e relay, installed since February 1975 is just as accessible as the logic relay after removal of the small combination instrument.

911

1 9 1 6 MODEL

Removing and Installing S e a t Belt/Brake Warning S y s t e m I n d i c a t o r Housing A housing containing the indicator lights for both warning systems (seat belts and brakes including parking brakes) is installed in the 1976 model. It replaces the previous FASTEN SEAT BELT indicator light. Consequently, the brake warning light in the combination instrument is no longer installed.

Removal and installation is t h e same as previously for the single indicator housing.

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Electrical Accessories

911

S A F E T Y BELT WARNING S Y S T E M 1 9 7 4 MODELS

Troubleshooting Safety Belt Warning System

If the starter does not work despite properly attached safety belts. proceed as follows to eliminate the problem: 1

Replace logic relay switch. If this does not correct the problem the malfunction may be in the following component areas: a b c d

in the in the in the in the tacts,

starter itself ignition/starter switch connecting wire between the two wires between belt and seat conand logic relay switch.

Other possible malfunction areas are: a

Malfunction in the optical and accoustic warning devices when belts are not buckled.

Activation of the warning devices despite proper handling of the safety belts.

In either case, first replace the logic relay switch and then, if necessary. check the electrical connections and wires in the safety belt warning system by following the wiring diagram.

Remove logic relay and connect jumper wire between terminal C and 50 in the logic relay socket. The jumper wire must be provided with flat contact tabs to ensure good connection. If starting is now possible, the defect will be found in the wires which connect the belt or seat contacts with the logic relay switch.

3 - Remove seats and check electrical connec-

tions according to the wiring diagram. If the starter fails to work despite the jumper wire connection, check starter. starter/ignition switch, or wires connecting the two.

NOTE Upon rectification of the problem be sure to remove the jumper wire and replace the logic relay switch. otherwise the entire safety belt warning system will remain inoperative.

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Electrical Accessories

CONTROL ILLUMINATION

I l l u m i n a t i o n of t h e H e a t e r C o n t r o l Lever

A square, illuminated plaque showing the function of the heater control lever is located on the center tunnel adjacent to the lever. The plaque can be lifted off to gain access to the wedge-base bulb (12V, 1 . 2 W).

l l l u m i n a t i o n of t h e F a n C o n t r o l Switch

Located behind the inscriptions "DEF. OFF" and "DEF. MAX. " in the lower part of the fan control switch are wedge-base bulbs (12V, 1.2 W), one on each side.

The socket-mounted lamps are seated in their receptables on the rear side of the switch. The bulbs are easily accessible from beneath the instrument panel without removing the knee guard.

Beginning with 1974 models, a third bulb is installed. It is located above the DEF.OFF field.

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911

Electrical Accessories

The control l a m p located in the hazard warning switch is connected to the light switch through a 150 Ohm resistor. Thus the l a m p fulfills the requirement of illuminating the hazard warning switch, although i t burns with less intensity.

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Electrical Equipment

HEADLIGHT WASHERS

Removing and Installing Spray Jets

Remove turn signal housing from bumper. Remove water container on left side of c a r (refer t o p a g e 4.4 - 1/11.

Push spring out toward rear and lift out spray jet. When installing n o t e that both jets a r e different for the l e f t and right sides.

Removing and Installing Water Pump 1

Disconnect hoses and electric wiring a t pump.

Loosen strap and remove pump. When installing m a k e sure that hoses and wiring a r e connected correctly.

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911

Electrical Equipment

Removing and Installing Switch

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Disconnect battery.

Pull out switch and disconnect wires.

Headlight cleaner

Adjusting spezifications Use a locally manufactured tool t o aim spray jets. This tool is inserted over the jet and extended by pulling out the mandrel.The jets are aimed correctly when the mandrel touches the center of the lens.

CAUTION When adjusting the jet insert, hold the spray jet tightly t o prevent damage to the jet.

Tool dimensions a = b =

c d e f g h i

= = = = = =

100 mm 10 m m 12.5 m m 5 mm 1+0.2 mm 10.5 m m dia. 115 m m 3 m m dia. 30'

A = M 4 nut, soldered B = M 4 knurled head screw

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Tube 14 x 1.5 mm

911

Electric Accessories

S e r v i c e I n s t a l l a t i o n of H e a d l i g h t Washers

beginning with 1974 Models

1 . Mark and drill nozzle mounting holes in bumper. T o locate hole centers place the rubber grommet on the bumper. Note that the nozzles and rubber grommets a r e different for left and right sides.

The spray jets are positioned slightly off center (of headlight) the distance between jets is 1250 mm (49 1 / 4 in.)

2. Remove bumper. If an angle drill motor is no}

available, the front apron will also have to b e removed.

3. Drill 25 m m (1 in.) hole for water feed hose

and insert grommet. (Be careful not to damage hoses in this area of cars equipped with an air conditioner.)

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911

Electric Accessories

4. Remove present fluid container and install new container.

I ,~.

-,.* f '. 7

c .

-3

5. Drill two holes on e a c h side of water pump bracket and bolt or rivet holder to lock panel. Location of bracket itself is different for cars with or with-out an air conditioner. Locate bracket in cars with an air conditioner so that the inlet adaptor of the pump has its opening a t the same height as the water feed hose.

6. Install front apron

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Electric Accessories

Install water feed hose on intake neck and molded hose on pressure adaptor af pump with hose clamps.Use longer molded hose o n models with air conditioners and shorten water feed hose to a length of about 1 0 0 mm/4in.

Insert molded hose (detach condenser blower of cars with an air conditioner), slide feed hose through grommet toward outside, clamp hose to water container adaptor with clamp and secure pump to bracket with clamp.

8. Connect both outlet hoses to adaptor (short hose left), locate hole for adaptor by placing in front of lock panel and drill 18 m m (3/4in.) dia. hole. Place adaptor and rubber grommet through hole and connect molded hose. Secure both hoses leading to nozzles with clamps. Insert pressure control valves on ends of hoses.

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911

Electric ~ 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.

Note Use a longer hose for cars without an air conditioner. Connect the open center connection of adaptor with S and the outlet adaptor of the water pump with P on valve adaptor.

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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 wires behind fusebox and secure with clamps. Install a n extra 3-position fusebox so that t h e b ~ a s srails on t h e back f a c e upward. Bridge adjacent fuse with a shunt. Connect gray wire t o fuse 2 (second fuse from front) a t top, red/white wire t o fuse 2 0 (center fuse of 3-position fusebox) a t bottom. Use 25 a m p e r e fuses.

Note Use open fuse connection of the 3-position fusebax already installed in cars with special equipment (e.g. air conditioner). Insfall 25 ainpcre f m c !

1 2 . Lvcate wirvs loward instrument pallcl, rcltmvi:

instrument and clock, take o i i s q u n r e covei lhctwcen tachometer and clock and p l a c e wires through o p m i n g . Connect switch and press into opening.

13. Connect battery. Fill fluid container and

check operation. A i m spray jets.

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~ l e c t r i c a lE q u i p m e n t

911

AUTOMATIC HEATING CONTROI

Removing and Installing Control Unit

1. Pry both side covers off of control unit.

2. Detach connecting rod between servo-motor and heater lever.

Removing and Installing Interior Sensor 1. Remove both Phillips screws and pull dawn

sensor carefully.

3. Remove t h e four bolts, lift control unit carefully and disconnect t h e three plugs a t t h e control unit. 4. Remove rubber seal and slide control unit

forward past heater and parking brake levers t o remove. 5. After installation of t h e control unit turn off t h e heater with the ignition on and l e t t h e heater lever m o v e a l l t h e way down. Check. whether both heater flaps a r e closed. If not, adjust t h e heater cables t o r e m o v e any play.

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Pull angled plug off of sensor.

911

Electrical Equipment

Removing and Installing Heat Sensor in Heater Flap Mousing

Loasen control unit and pull off t h e front 2- pole m a l e plug.

Loosen carpet along center tunnel and clear c a b l e up t o grommet in kick plate.

Pull both wires out of m a l e plug housing ( b e s u r e t o depress terminal retainer) and push out grommet.

4. Remove adaptor on left heater flap

housing.

Rivet new heat sensor t o adaptor rout c a b l e and press i n g r a m m e t .

5. Pull out c a b l e and r e m o v e rivets on t h e adaptor.

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(? '

Electrical Equipment

7. Install adapter. Make sure thar the heater

flaps are adjusted evenly on both sides.

8. Secure plug housing to cable. The black wire

must be located on the side of the housing with a tab.

9. Place cable inside of car, glue carpets. connect plug t o control unit and secure control mi1 again.

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911

Electrical Equipment

Disassembling and Assembling Control Unit

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911

Electrical Accessories

Note When

YO.

Removing

-1ousmg

:over