Porsche 911 1972 to 1989 - Repair, Service Manual, Wiring Diagrams and Parts Catalog

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PORSCHE 911 - REPAIR MANUAL - SERVICE MANUAL

- English Service Manual, Wiring Diagram and Spare Parts Catalogue to vehicles Porsche 911 1972 to 1989.

CONTENTS:

WORKSHOP MANUAL 1972-1983 (1005 pages)

GRP.1 (ENGINE & CLUTCH)
Engine
Description
Engine changes 1972 model
Oil tank changes 1972 model
Oil cooler system & 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 from 2.4 liter engine
Engine changes 1974 model
Cross section of engine with emission control equipment
Layout of EGR system
Engine cross section with emission control 1978-1979 model
Emission control layout 1980 model
Technical Data
General data
Power performance curves
Technical data type 911 T - Continuos injection system (CIS)
Technical data type 911/S/Carrera 1974 model
Full power performance 1974 model
Technical data - Type 911 S & Carrera 1975 model
Engine tightening data
Technical data - Type 911 - 1976 model
Technical data - Type 911 S - 1977 model
Technical data - Type 911 SC - 1978 model
Technical data - Type 911 SC - 1980 model
Technical data - Type 911 SC - 1981 model
Cooling System
Fan drive belt - Replacing / adjusting
Exhaust System & Heating
Exhaust system & heater blower, Removing & installing
Exhaust system 1978 model
Emission Control
Air injection components, removing & installing
Air pump belt, tensioning
Reactors & EGR equipment, removing & installing
EGR system
Reactor, checking for leaks
EGR system, checking
Air injection system, checking
Oil Circulation
Oil tank, removing & installing
Oil tank, removing & installing - 1973 model
Auxiliary pressure relief valve, removing & installing
Auxiliary pressure relief valve, disassembling & assembling
Oil cooler coil, removing & installing
Oil cooler, removing & installing
Oil tank, removing & installing - 1974 model
Pressure relief valve cooling coil, removing & installing - 1974 model
Pressure relief valve cooling coil, disassembling & assembling - 1974 model
Oil cooler coil, removing & 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
Camshaft Housing & Cylinder Head
Injection tube in camshaft housing, removing & installing
Chain tensioner, overhauling
Sealing cylinder head / camshaft housing mating surfaces
Valve springs, installed length
Adjusting timing
Cylinders & Pistons
Piston changes - 1972 model
Piston & cylinder dimensions - 1972 model
Piston & cylinder dimensions - 1973 model
Piston & cylinder dimensions - 1974 model
"LS" cylinders & pistons, installation instructions
Pistons & cylinders, measuring
Piston & cylinder sizes, 911 SC - 1978 model
Piston weight classes - 911 SC from 1981 models
Crankcase & Crankshaft
Crankcase, measuring & reconditioning
Modified flywheel installation - 1978 model
Flywheel with pilot bearing - 1980 model
Oil filter screen & 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 & undersize - 1978 model
Clutch
Clutch changes - 1972 model
Clutch free play, adjusting
Throwout bearing, removing & installing
Clutch - 1975 model
Clutch modified - 1978 model
GRP. 2 (FUEL SYSTEM)
Fuel System
Description
Fuel system changes - 1972 model
Fuel injection pump changes - 1972 model
Throttle valve housing & 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
General checkout procedure
Visual inspection
Initial checks
Pressure tests
Leakage checks
Injection valve, checking
Auxiliary air device, checking
(CIS) testing & adjustment specifications - 1974/75 models
(CIS) testing & adjustment specifications - 1976/77 models
(CIS) testing & adjustment specifications - 1978/79 models
(CIS) testing & adjustment specifications - 1980 model




Testing & adjusting values - 911 SC (1981 models with O2 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 & remedies
Automatic choke, troubleshooting - 1976 model
Thermovalve, checking
Vacuum system layout - 1978 model
Vacuum hose layout - 1979 model
Fuel & vacuum lines layout - 1980 model
Servicing

Regulator housing, removing & 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
(CIS), Dissasembling & assembling
Mixture control unit, removing & installing
Throttle valve housing with control pressure regulator
Control pressure regulator (warm running compensation), removing & installing
Start (enrichment) valve, removing & installing
Fuel filter, removing & installing
Fuel pressure accumulator, removing & installing
Injection valves, removing & installing
Plastic fuel lines, replacing
Fuel line system, bleeding
Mixture control unit, dismantling & assembling
Sensor plate, removing & installing
Air flow sensor housing, locating operating lever with follower
Mixture control screw basic adjustment after replacement of follower
Fuel distributor pressure relief valve piston seal, replacing
Vacuum controlled (warm-up) control pressure regulator, removing & installing
Auxiliary air valve, removing & installing
Mixture control unit, dissasembling & assembling - modifications from April 1976
Thermovalve, removing & installing
Diverter valve, removing & installing

Fuel Tank
Fuel tank plug with (CIS) filter, cleaning
Fuel tank (80 liter), removing & installing - 1974 model
Fuel Pump
Fuel pump, removing & installing - 1976 model
Layout drawings of check valves on fuel pumps
Replacing check valve
Oxygen Sensor
Oxygen sensor, removing & installing
Oxygen sensor control unit, removing & installing
Frequency valve for oxygen sensor, checking
Throttle valve switch, checking adjusting
Removing & installing microswitch for acceleration anrichment of oxygen sensor control ( from 1981 models)
Correcting CO level setting on mixture control unit - (From 1981 models) with shear-off screw
Adjustment Instructions For F.I. Systems
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 & adjusting
Hand throttle, adjusting
Idle, adjusting - 1978 model
Idle, adjusting - 1980 model
Adjusting idle 911 SC - (from 1981models)
GRP. 3 (TRANSMISSION & DIFFERENTIAL)
Description
Transmission, 5 Speed Overdrive
Transmission, 5 Speed , Power Transfer
Transmission With Oil Pump, Description
Transmission With Oil Pump, General Info
Type 915, Transmission - (1974 Model)
Type 915, Transmission - (1975 Model)
Type 915, Transmission - (1976 Model)
Sportomatic, General
Sportomatic, Power Transfer

Type 925, Sportomatic Transmission - (1974 Model)
Type 925, Sportomatic Transmission - (1975 Model)
Type 925, Sportomatic Transmission - (1976 Model)
Sportomatic 1977 Models - General Info
Technical Data
Transmission Diagrams, Manual Transmission
Tightening Torques, Manual Transmission
Tightening Torque Values, Transmission
General Specifications, Transmission
Tolerances & Wear Limits
Transmission Diagrams, Manual Transmission - (1974 Model)
General Specifications, Transmission - (1974 Model)
Transmission Diagrams, Manual Transmission - (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
General Specifications, Sportomatic (1974 Model)
Transmission Diagram, 3 Speed Sportomatic 925/10 (1975 Model)
General Specifications, 3 Speed Sportomatic 925/10 (1975 Model)
Specifications, 3 Speed Sportomatic 925/09, 012, 013
Transmission Diagram, 3 Speed Sportomatic (1976 Model)
Special Tools
Transmission, 5 Speed Manual
Transmission, Removing & Installing
Seal Ring For Drive Shaft, Dismantel & Reinstall
Selector Forks, Adjust
Transmission Front Cover, Dissasembling & Assembling
Oil Pump In Front Cover, Dissasembling & Assembling
Gear Housing, Dissasembling & Assembling
Transmission Housing, Dissasembling & Assembling
Oil Lines For Supplemental Lubrication System, Remove & Install
Transmission Housing With Guide Tube For Throwout Bearing
Transmission Case With Bolted Guide Tube For Release Bearing
Dissasembling & Assembling Transmission Case With Servo Clutch (1977 Model)
Input Shaft, Dissasembling & Assembling
Pinion Shaft, Dissasembling & Assembling
Synchronization, Dissasembling & Assembling
Dissasembling & Assembling Synchronization (1977 Model)
Transmission, Sportomatic
Torque Converter Housng, Dissasembling & Assembling
Transmission, Removing & Installing
Transmission Front Cover, Dissasembling & Assembling
Intermediate Plate, Dissasembling & Assembling
Input Shaft (3 Speed Sportomatic) Dissasembling & Assembling
Pinion Shaft (3 Speed Sportomatic) Dissasembling & Assembling
Checking Clutch Play (1976 Model)
Checking Control Valve Adjustment (1976 Model)
Differential, (Manual Transmission)
Differential, Removing & Installing
Differential, Dissasembling & Assembling
Differential With Electronical Speedometer
Tools
Dissasembling & Assembling Instructions
Ring & Pinion Gear, Adjusting - General Info
Ring & Pinion Gear, Adjusting

Pinion Shaft, Adjust With Universal Setting Gage VW 385
Differential, (Sportomatic Transmission)
Ring & Pinion Gear, Adjusting - General Info
Ring & Pinion Gear, Adjusting
GRP. 4 (FRONT AXLE)
Description
Front Axle Changes, From (1972 MODEL)
Self Leveling Hydropneumatic Suspension Strut, Operation General Outline
Operation Of The Self - Leveling Hydropneumatic Suspension KONI Suspension Struts
Cross-Section Of The Self - Leveling Hydropneumatic Suspension KONI Suspension Struts

Technical Data
Technical Data
Technical Data, (1974 Models)
Technical Data, (1975 Models)
Tightening Torque Values
Front Wheel Alignment
General
Sample Wheel Alignment Card
Front Axle
Dissasembling & Reassembling
Self - Leveling Hydropneumatic Suspension Struts, Check
Aluminium Auxiliary Supprot, Carrera 2.7
Disassembly & Reassembly Of Stabilizer (1974 Models)
Instructions For Removal & Installation
Shock Absorber / Spring Struts, USA Models Installation Instructions
Steering Wheel & Steering Wheel Column
Steering Wheel
Steering Shaft, Disassemble & Reassemble, Beginning With (1974 Models)
Instructions For Disassembly & Reassembly
GRP. 5 (REAR AXLE)
Description
Rear Axle Changer, Beginning With (1972 Model)

Technical Data
General Specifications
Technical Data From (1974 Model)
Technical Data From (1975 Model)
Technical Data From (1976 Model)
Tightening Torques
Rear Wheel Alignment
General Information
Wheel Alignment Data Chart
Rear Axle
Dismantle & Reinstall Rear Axle Control Arms From (1974 Model)
Instructions For Disassembly & Reassembly
Checking Parts
Axle Driveshafts
Axle Driveshafts, Lighter Version
GRP. 6 (BRAKES - WHEELS & TYRES)
Technical Data
General Data
Tightening Torques, Front & Rear Brakes
Brake Booster, Master Cylinder
Removing & Installing Brake Booster
Disassembling Brake Booster & Brake Master Cylinder Partially
Checking Brake Booster
Wheels & Tyres
Summary
Checking Steel - Disc Wheel

Mounting Instructions
Instructions For Installation Of Adhesive Weights In Light Alloy Wheels
Balancing Wheels
Collapsible Spare Tyre
Standard Wheels & Tyres, Overview, From (1973 Model)
Standard Wheels & Tyres, Overview, From (1975 Model)
GRP. 7 (MANUAL & PEDAL CONTROLS)
Technical Data
Tightening Torques
Manual Controls
Gear Shift Linkage, Disassemble & Reassemble
Gear Shift Linkage, Adjust
Notes For Disassembly & Reassembly
Gear Shift Linkage, Disassemble & Reassemble, From (1973 Models)
Instructions For Disassembly & Reassembly
Heater & Hand Controls From (1975 Models)
Dismantling & Assembling Heater & Hand Throttle Controls
Removing & Installing Heater & Hand Throttle Controls
Adjusting Heater Controls
Adjusting Hand Throttle Control
Heater Blower Switch, Remove & Install
Pedal Controls
Pedal Controls, Disassemble & Reassemble
Notes For Disassembly & Reassembly
Disassembly & Reassembly Of Pedal Controls (1974 Models)
Instructions For Disassembly & Reassembly
Adjusting Clutch
Adjusting Clutch From (1977 Models) (With Servo Clutch On Transmission)
GRP. 8 (BODY)
Description
Body Modifications - (1972 Model)
Body Modifications - (1973 Model)
Body Modifications - (1974 Model)
Bumpers
Front Spoiler - 911 S
Bumper, Removing & Installing (1973 Model)
Front Bumper, (1974 Model)
Rear Bumper, (1974 Model)
Front Spoiler, Installing
Hoods & Lids
Front Hood Lock, Removing & Installing
Hood, Opening With Broken Cable
Rear Lid With Spoiler
Doors
Inner Door Fittings, Removing & Installing (1974 Model)Front Bumper, (1974 Model)Front Bumper, (1974 Model)
Door Stop, Removing & Installing
Ridge Filler, Installing
Door Shell Preparation For Remote Control Outside Mirror

New Door Lock Controls, Service Installing
Door Window Lift Channel, Installing
Electric Window Regulators, Removing & Installing
Electric Cross Arm Window Controls, (1980 Models)
Electric Cross Arm Window Controls, Service Installing
Adjusting Door Window - Targa
Roof
Folding Roof Modifications, (1974 Model)
Folding Roof Lock Pin, Service Installing
Hardtop Roof
Folding Top To Hardtop, Switching
Interior Fittings
Interior Mirror, Installing
Targa Roof Adjustment, (1970 Model)
Top Wind Deflector Strip Modifications
Three Point Belt With Automatic Retractor & Warning System, Removing & Installing
Electric Window Regulator, Removing & Installing
Seat, Installing - (1973 Model)
Exterior Fittings
Oil Tank Filler Lid & Control, Removing & Installing
Rocker Panel Cover, Removing & Installing
End Plate, Removing & Installing
Carrera Emblems
Outside Mirror With Defogger & Remote Control, Removing & Installing
Exterior Mirror On Passenger's Door, Service Installing
Reference Dimensions For Repairs
Repair Dimensions (1972 Model)
Repairs
Rear Axle Cross Tube Rust Prevention
Galvanized Sheet Metal Instructions (1976 Model)
Rear Axle Cross Tube, Checking Alignment
Painting
Paints (1972 Model)
Paints (1974 Model)
Paints (1976 Model)
Paints (1978 Model)
Range Of Body Colours (1981 Models)
Metallic Paints
Metallic Paint - Wey On Wet Method
Targa Roll Bar Cover, Painting
Body Repairs
Front Body
Extra Attachment For Economical Repair Of Front End Damage
Universal Anchor ENS 937.900
Cobra 3 Straightener With Accessories
Rear Body
GRP. 9 (ELECTRICAL SYSTEM)
Description
Ignition Distributor, Current Flow Diagrams
Wiring Diagrams
Current Flow Diagrams
Relays & Fuses

Lighting
Alternator - (1975 Model)
Ignition System Modifications - (1978 Model)
Technical Data
Starter
Starter
Disassembling & Assembling
Removing & Installing
Lighting Equipment
Headlights (Sealed Beam). Replacing
Headlights, Adjusting
Fog Lamps & Tail Lamps
Windshield Wiper & Washers
Disassembling & Assembling
Adjustment instruction
Removing & installing
Water Reservoir For Windshield Wiper Switch
Removing & installing
Intermittent Windshield Washer System
Removing & installing
Instruments & Control System
Emission Controls
E.G.R. Control
Speedometer
Speedometer cable, removing & installing
Electronic speedometer
Electrical Accessories
Description
Safety belt warning system
Control illumination
Headlight washer
Safety Belt Warning System
Removing & installing
Troubleshooting
Control Illumination
Bulb replacement
Headlight Washers
Removing & installing
Adjusting specifications
Service installation
Automatic Heating Control
Removing & installing
Troubleshooting
Disassembling & assembling
Automatic Speed Control
Removing & installing
Troubleshooting
Removing & installing automatic antenna
911 Alarm system
Battery
Removing & installing
Ignition
Spark plug chart

Equipment tables - (1980 model)
Ignition leads
Ignition Distributor
Adjusting
Testing instructions
Ignition timing, adjusting - (1977 model)
Ignition timing curves, (1978 model)
Ignition timing, adjusting - (1980 model)
Ignition retard/advance, checking - (1980 model)
GRP. 0 (MAINTENANCE SPECIFICATIONS)
Technical Data
Engine
Fuel System
Electrical System
Transmission & Final Drive
Chassis
Capacities
Dimensions
Weights
Performance Data
Specification Changes From (1973 Model)
Carrera 2.7 Specifications
Specifications For - (1974 Models)
Filling capacities
Dimensions
Weights
Performance
Technical Data (1981 Model)
Maintenance
Service Schedule
Lubrication Schedule
Preventive Maintenance Schedule



WORKSHOP MANUAL 1984-1989   (716 pages)

AND MORE....