Porsche 911 TURBO - 1975 WORSHOP User manual

GENERAL Technical Date Page0.1
REPAIR GROUP
10
13
15
17
19
20
21
25
26
27
28
ENGINE
Engine-crankcase
Engine-Crankshaft, and moving parts
Engine-Cylinder Head, Valve drive
Engine-Lubrication
Engine-Cooling
Fuel Supply system
Turbocharger
Fuel system
ExhaustSystem
Starter, Power Supply
Ignition System
30
34
35
39
Clutch, Control
Mech.gear-shiftsystem-actuat., hous.
Mech.gear-shiftsystem-Gears, Shafts
Differential
TRAN S MISSION
40
4":>'
44
47
48
CHASSIS
Front Wheel Suspension
RearWheel Suspension
Wheels, Tires, measuringvehicle
Brakes,-Hydraulic -system
Steering
50
51
53
55
57
60
63
64
66
68
BODY
Body-Front Section
Body-Center Section
Body-RearSection
Lids
Doors
Sliding Roof
Bumpers
Glasses
Exterior equipment
Interior equipment
HEATING. VENTILATION.
AIR CONDITIONING Heater
Air Conditioaer 80
87
90
92
94
96
97
Instruments, Radio
Windshield Wipersand Washer
Exterior Lights
Interior Lights
Wiring
ELECTRICS

911 turbo Alphabetical Index Volume II
Page
Body, front section
..50-4
..50-1
..50-3
..50-5
..50-7
..50-7a
Body platform, front -type 911-turboBody platform and front section gauge P 863Dimensions for body platform.Repair control dimensions 911-turboRepair control dimensions 911-turbo, Model 78 onwards
Straightening attachments for type 911-turbo -ENS 77.303
Body, rear section
Transverse rear axle tube 911-turbo 53-1
Hood
Engine hood, removing and installing from Model 78 onward 55-1
Exterior equipment
66-3
66-1
Fitting stoneguard foil to rear turbo fender
Fitting turbo emblem.
Interior equipment
Central console, removing and installing 68-1
Heating
Automatic heating control, removing and installing
Automatic heating control, checking. 00-1
00-5
Fittings, instruments, radio
9()-3
9()-4
9()~1
Electronic tachometer, checking.Electronic tachometer, removing and installing generator
Position of relays in the vehicle.
Alphabetical Index
Printed in Germany -VII, 1989
1

Volume II Alphabetical Index 911 turbo
Page
97-1
97-13
97-19
97-17
97-29
97-25
97-23
97-7
97-31
97-11
97-9
97-27
97-5
97-61
97-79
97-115
97-153
97-197
Wiring
Current-flow diagram -911 turbo, Model 76Current-flow diagram -911 turbo, Model 77Current-flow diagram -911 turbo, Model 78Additional current-flow diagram -exhaust temperature monitoring -type 911 turbo
Additional current-flow diagram -automatic heating control.Additional current-flow diagram -electric windows.Additional current-flow diagram -rear window wiper.Additional current-flow diagram -refrigerant system with front condenser. ...
Additional current-flow diagram -air-conditioning system.Additional current-flow diagram -engine compartment light.Additional current-flow diagram -fog lamp.Additional current-flow diagram -headlight cleaning system.Additional current-flow diagram -intermittent wiper c!rcuit, Model 76Additional circuit diagram -alarm system, Model 85Circuit diagram, Model 86Circuitdiagram,ModeI87 Circuitdiagram,ModeI88Circuitdiagram,ModeI89
Alphabetical Index
Printed in Germany -VII, 1989
2

Body -Front Section
FLOOR/FRAME CHECKPOINTS AND FRONT BODY SECnON GAUGES P 863 AND 863a
As already announcedin the 1975 model information, checkpoints are welded to the floor/frame
assemblyfrom 1975 models. The extent of damage is quickly diagnosedwith the help of these
checkpoints and front body section gauge P683 a (consisting of former gauge P863 + additional
adaptor).
The carrier pin of Type 930 Turbo is 21 mm higher. When measuring with front body section
gauge P863,the distance between the upper edgeof the gauge and the collar on the carrier pin
is 21 mm or, with the adaptor installed onthe carrier pin, 13 rom.
The gauge can alsobe usedto repair light front section damage (upsetsupto 10 mm). Cars with
damage of this type no longer need to be installed on a straightening bench.
Installation of the gauge requires that the wheels, the guard, the carrier and the control armsbe
removed. The gauge is then bolted to the front axle take-up points and front floor/frame checkpoints,
asillustrated above.
The distance from the rear floor/frame checkpoints and rear axle take-up points for the transmission
to the engine suspensionis checked with a measuringstaff.
This gauge is for checking only. It mustbe removed for straightening and welding operations
to prevent it from becoming bent through body distortions.
Note:
Printed in Germany 50-1
Floor/Frame and Front BodySection Gauge

50 Body
FLOOR/FRAME ASSEMBLY DRAWING
Printed in Germany
Floor/F'rameAssemblyDrawing
50-2

Body
Dim. Designation mm
+
565.5 -2
AControl arm take-up, front, inner
!
1
Carrier take-up 726
! 2
Front floor plate checkpoints
c1200
! 2
DRear floor plate checkpoints 850
! 3
EEngine suspension 752
!. 3
FFront floor/inner control arm checkpoint 1327
!. 3
Rearfloor/ carrier checkpoint 1868 G
+
1528.5- 3
HAxle tube transmission/front. floor checkpoint
1346 "!. 3
1374
Axle tube transmission/inner engine suspension from 1978models 1557 :!: 3
1582
Rear floor/inner engine suspensioncheckpointKfrom 1978models
"to 3
1041
LFront floor/inner control arm checkpoint
+
1215 -2
Front floor/rear floor checkpoints
M
1355 ! 3
13~4_-
Rearfloor/inner engine suspensioncheckpoints
NU91ILlll8models
0 Axle tube transmission/inner engine suspension 1245 :: 3
1273
All distancesare measuredfrom center of hole andhorizontal.
Note
Distancesto engine suspensionbolts are measureddirect (at an angle).
Note
Lengthsmeasuredonthe left and right may not exceed the specified tolerances in difference
to each other.

Body -Front
FLOOR/FRAME ASSEMBLY TYPE 930 TURBO
In comparisonto the Type 911, the carrier pin <i the Type 930 Turbo is 21 mm higher. This has
causedchangesto the floor/frame assemblyin the area marked in white.
The border on the wheelhouseand floor plate is cut out about 70'mm higher than the control arm
to allow accessibility.
Note
If new wheelhousingsare required for repairs. make theseopeningsin the borders on both sidesand
weld the seamsto the floor plate.
Front Floor Assembly for Type 930 Turbo
50-4 Printed in Germany

Body
')"'
REPAIR REFERENCE POINTS FOR 930-turbo
Repair Reference Points for 930 Turbo 50-5

Printed in Germany III, 1978 RepairReferenceDimensions930 Turbo
From 1978 Models

Body
STRAIGHTENING BENCH ATTACHMENT SET ENS 77.303 FOR TYPE 930 TURBO
The illustrated take-up points differ from the attachment set for Type 911 and are applicable to Turbo
cars.
The auxiliary carrier pin is installed 21 mm (0.827') higher.
The brackets onthe rear axle crosstube are inclined upwards.
~""' The take-up pin for the transmissionsuspensionis located 25 mm (0.984') further forward.
TheenginemountforType3.0 Turboupto 1977modelconformswithType911.
The engine mount for Type 3.3 Turbo from 1978 model is moved further back by 30 mm (1.181 ").

REAR AXLE CROSS TUBE OF 930 TURBO
A newrear axle crosstube. PartNo. 930 331 010 00,
-Fig. A -is installed in the Type 930 Turbo.
This crosstube differs from the version for the
Type 911 -Fig. B -as follows.
1. New, larger holders fgr rear axle trailing
arms at an angle of 2 30' upwards.
Referencepoint: 6 mm above the horizontal
asmeasuredat the rear inner supportplate
of the holder's lower edge.
2. Newtransmissionsuspensiontake-uppin
(offset25 mmtowardfront).
Notes
1. The seatwells have dents on both sides of
the center t,'Jnnelabovethe holders for the
Type 930 Turbo (seefigure).
2. Large seatbelt reinforcement plates are
installed in all cars for Australia and France.
and in fact onthe transmissiontunnel. These
reinforcements are welded to the holders at
the rear axle crosstube to increase the
strength.
RearAxle CrossTube for 930 Turbo 53-1
Printed in Germany

Hoods and Lids
REMOVING AND INSTALLING ENGINE HOOD FROM 1978 MODELS, TURBO 3.3
Removing
1. Detach hosestrapsand ground wire at hinge..~. Caution
Refrigerant hosesmust not be detached from con-
denser, since otherwise-the high pressurerefrigerant
would escapeand the air conditioner would have
to berecharged.
Also make sure than fins of condenserare not bent.
Large area fin damage will impair the efficiency
of the ..ir conditioner.
4. Removewindshield wipex arms. Unscrewwinds-
hield wiper holders and lift off connecting link-
age.
2. Mark and disconnect wires leading to rear
window wiper and engine compartment lamp.
Removeengine compartment lamp for this
purpose.
5. Detachenginehoodathingesandremove.
3. If car has air conditioning. loosen condenser
screw from hood (seearrow). Lay downconden-
serin engine compartment carefully.
Printed in Germany -III, 1978 Removing and Installing Engine Hood 55 -1

Hoods and Lids
Disassembling Notes on Installing
1. Unscrewrear spoiler carrier from hood and re-
move with reinforcement rail, seearrow. Wheninstalling the windshield wiper shaft, it is
essentialto insert spacerin hood. Wiper arm
should be installed that, whenswitched off, wiper
blade will be parallel to side window weatherstrip
(distance approx. 40 mm).
Note
Whenpainting car, cover riveted weatherstrip
with tape.
2. Detachspoiler(polyurethanesection)from
carrier, seearrow.
Printed in Germany
Removing and Installing EngineHood
55 -2

Exterior Fittings
INSTALLING TURBO SIGN
There are nine 'Turbo" decals on each vehicle.
They are placed asfollows: one on eachdoor;
one on each front fender; two on each rear fender;
one for the rear lid. WorkSequence:
Observethe following to make sure that the
decals adhere well to the painted body.
1. Washand dry car. Remove wax and polish
in areasof decal.
2. Do not apply decal outdoors, if cold or moist.
The car and ambient temperature shouldbe
0 0
about20 C (68 F) for bestresults.
1. install the door decal, PartNo. 930.559.303/
304 00/01 so that the paper edges(top front/
rear front) rest on the door waistline strip.
Make surethe opening around the door handle
is equidistant. Pull paperhalf off adhesive
surface. Place decal on door handle and press
onlightly. While pulling paper off, pull decal
forward and presson (smooth by hand from
rear to front).
Smooth decal toward the outside with a
plastic squeegeePull off top protective paper
parallel to decal. Fold overlapping edgesof
decal.
3. Thethick beigepapercoversthe adhesive
surface.
4. Always start with the door decal and then
align the adjacent decal with this one.
5. Decals not pressedon firmly by rubbing
smooth canbe pulled off again for alignment.
Puncture air bubbles with a needle and press
smooth.
6. Removeexteriormirrorondoors.
Installing Turbo Sign 66 -1
Printed in Germany -1, 1976

Exterior Fittings
4. Install turbo sign decal -Part no. 930.559.307/
308 00/01 -below masking tape border parallel
to taillights. Make sure that the edgesof the
front and rear decals are parallel. Fold ends of
decal at water drain molding.
2. Install front fender decal -Part no. 930.559.
301/302 00/01 -after the door decal has been
installed. Start at the dooredge. Make sure
the point begins on the fender (not the head-
light rim). Align the top paperedge of the
front decal with the center of the headlight.
Pressover fuel tank cover and after the
protective paper hasbeen pulled off, cut
through decal which overlaps fuel flap cover.
3. Installrearfenderdecal-Part no. 930.559.
305/30600/01 -aligning it with the door
decal. To facilitate alignmentofthe front
fenderwithreartubodecal, maskingtape
canbeused.
Note
Whenapplying the turbo sign decal make sure
that the shadedareasare pressedon without folds;
folds between shadedareas cannot be avoided
completely.
5. Install rear lid decal -Part no.930.559.309 00/
01 -at same height as fender decals and fold
the ends.
66 -2 Installing Turbo Sign Printed in Germany

Exterior Fittings
INSTALLING TURBO DECALS ON REAR FENDERS
1. Using squeegepull upper lip of rubberguard
away from connector plate asfar asnecessary.
2. Cleananddrysurfacesfordecals.
3. Drawa pencil line 30 mm (1 1/8 iIi.) parallel
to wheel openiIig.
4. Peelprotective paper off decal and place
decal on surface so that it matches the drawn
line and its bottom is covered about 3 mm
(1/8 in.) by the rubberguard strip.
5. Smooth decal toward outside and rub out
bubbles with a squeegeeIf necessarypuncture
bubbles with a pin and presssmooth.
Installing Decal on Turbo RearFenders 66 -3
Printed in Germany -I. 1976

Interior Fittings
REMOVING AND INSTALLING CENTER CONSOLE
Removing
1. Unscrewcap.
Caution! The capillary tube must not be
bent sharply or separated. since
it would be destroyed.
2. Pull off air conditioner switch knobsand
remove round nuts. Unscrewleft and right
metal screws(arrow). Pressdownand remove
holder.
4. Removemounting screwsat front and rear
of center tunnel.
5. Pull up rubber cover on gearshift lever,
3. Disconnect wire plugs at bothswitches. Re-
move blower switch. Remove insulation tape
onwhite capillary tube and pull harnessout
of center console (disconnect battery).
6. Lift center console and swing over the re-
leased parking brake lever to one side.
Removing and Installing CenterConsole 68 -1
Printed in Germany -II, 1976

Interior Fittings
7. Openup the opening for the harnessto about
40 x 60 mm, so that the temperature switch
can be removed. This means first cutting the
proper depth with a sawand then cutting out
the metal with a shears. Remove center con-
sole.
Note
Openup the harnessopening of a new center
console to the specified size.
If only the temperature switch hasto be replaced,
the capillary tube' s front end in the floor plate
mustbe pulled out of the vaporizer housing. The
capillary tube is fastened to the harnessat several
points with an insulation tape. Cut through insula-
tion tape and then slide ona matching sleeve to
cover the entire length. Pullout temperature
switch and slide in the newcapillary tube through
the sleeve.
Printed in Germany
68 -2 Removing and Installing Center Console