Porsche 911 TURBO - 1989 Instruction manual

GENERAL Technical Date Page0.1
REPAIR GROUP
10
13
15
17
19
20
21
25
26
27
28
ENGINE
i:)lgine-crankcase
i:)lgine-Crankshaft, and moving parts
i:)lgine-Cylinder Head, Valve drive
i:)lgine-Lubrication
i:)lgine-Cooling
Fuel Supply system
Turbocharger
Fuel system
ExhaustSystem
Starter, PowerSupply
Ignition System
30
34
35
39
Clutch, Control
Mech.gear-shiftsystem-actuat., hous.
Mech.gear-shiftsystem-Gears, Shafts
Differential
TRAN SMISSION
40
42
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
FXterior equipment
Interior equipment
80
87
HEATING. VENTILATION.
AIR CONDITIONING Heater
Air Conditio;Ier
90
92
94
96
97
Instruments, Radio
Windshield Wipersand Washer
ExteriorLights
Interior Lights
Wiring
ELECTRICS

Page
General
10 -01
Adjustment values and limits
Adjustment values and limits from 1978models 10 -02
Specifications, general
Specifications, general from 1978 models
Tightening torques for engine
0.1
0.7
10 -03
Engine. Crankcase
10
10 -7
10 -8
10 -9
Engine. removing and installing
Engine/transmission unit, detaching and attaching
Engine/transmission unit, detaching and attaching from 1978 models
Engine, removing and installing -hydraulic
clutch mechanism, 5-speed, Model 89 onwards
Engine/gearbox assembly, separating and joining, Model 10 -14
Engine, Crankshaft, Pistons
Crankshaftsizes from 1978models 13 -4
13 -3
13 -
13 -6
13 -1
13 -7
13 -9
Flywheel, removing/installing or machining
Layout of oil pump from 1978models
Order of cylinders and air guide plates from 1978 .models
Pistonand cylinder sizes, installation notes
Pistonand cylinder sizes, installation notes from 1978models
Pistonsand cylinders, measuring
Weight classesof pistons -911 Turbo from 1980models 13 -9
Engine. Cylinder Head. Valyes
Chain tensioner. removing and installing
Timing. adjusting
15 -1
Valve clearance, adjusting
15 -1
15 -1
15 -1
15 -3
Valve spring sizes
Camshafts, timing
Alphabetical Index
Printed in Germany -VII, 1989
1

Page
FuelSupply
Delivery rate of fuel pumps. checking
Fuel pump. removing and installing
Pressuretest of pumps
20 -1
20 -5
25 -1
Turbocharger
21 -11
21 -4 a
21 -5
21 -20
21 -9
21 -19
21 -4
21 -12
21 -1
Air pressuresafety switch. checking
Bypassvalve, checking function
Bypassvalve, removing and installing
Charge air cooler, removing and installing from 1978 models
Chargepressure. checking
Chargepressuregauge. checking
Turbocharger. checking
Turbocharger, oil supply
Turbocharger. removing and installing
Turbocharger. survey
Valve housing. disassemblingand assembling
21 -3
21 -6
Fuel Mixture
25 -19
25 -18
25 -13
25 -13
Air cleaner, removing and installing from 1978models
Auxiliary air valve, removing and installing
Control pressure"cold", checking
Control pressure"warm", checking
Control pressure"warm-full throttle enrichment", checking
from 1978models 25 -14
Fuel delivery rate for control pressurecircuit. checking
Fuel distributor of mixture control unit. removing and installing
25 -14 b
25 -6 b
25 -1
Fuel system
Idle, adjusting 25 -
Idle, adjusting from 1978 models 25 -10 a
Alphabetical Index
Printed in Germany -VII, 1989
2

911 turbo Alphabetical Index Volume
Page
25 -6 d
25 -6
25 -6 a
25 -6 c
Mixture control unit, disassemblingand assembling
Mixture control unit, removing and installing
Off position of air flow sensorplate, checking and adjusting
Pistonpressureregulator with poppet valve, replacing
Pressuregauges, connecting and bleeding 25 -12
25 -14 a
25 -15
25 -16
25 -17
25 -17
25 -10
25 -11
Systempressure, checking
Testing and adjusting values for fuel injection
Testing and adjusting values for fuel injection from 1978 models
Thermo shift valve, checking
Thermo shift valve. removing and installing
Throttle bypassvalve, removing and installing
Tools for fuel pressuretest
Checking Lambda control function 25 -21
Checking Lambda probe 25 -22
ExhaustSystem
26 -23
26 -32
Air filter of air pump, removing and installing
Air injection, disassemblingand assembling
Air injection, disassemblingand assembling engine type 930/51
and930/52 26 -lB
26 -25
26.26.26.
Air injection lines and adapters, removing and installing
Air pump, removing and installing
Belt of air pump, checking and adjusting
Blow-off switching valve, removing and installing
Control valve, blow-off switching valve and check valve, checking 26 -26
26 -24
26 -28
26 -27
26 -27
Control valve, removing and installing
EGRvalve, checking
EGRvalve, removing and installing
Exhaustfilter, removing and installing
Exhaustsystem, disassemblingand assembling
Exhaustsystem, disassemblingand assembling
Exhaustsystem, surveyengine type 930/50
26 -2
26 -8
26 -1
Alphabetical Index
Printed in Germany -VII, 1989
3
.22.36
.24

911 turbo
Volume I Alphabetical Index
Page
26 -6Exhaustsystem, surveyengine type 930/52
Exhaustsystem, surveyengine type 930/51, 930/53 and930/54
Exhausttemperature. control
26-
26 -29
26 -30
26 -39
Exhausttemperature control, checking
Hoseconnection plan, California
26 -37
26 -38
26 -29
26 -11
26 -31
26 -40
Hoseconnection plan. Europe
Hoseconnection plan, USA+ Japan
Reactorand muffler cover
Reactor, removing and installing
Temperature sensorfor exhausttemperature control. removing
and installing
Thermo valve. operating and testing
Ignition System
28 -13
28 -5
28 -14
28 -1
28 -2 a
28 -2 b
28 -3
28 -4 a
28 -4 c
28 -6
Delayed ignition cut-out
Distributor, checking in car
Ignition systemfrom 1978 models
Ignition timing, adjusting
Ignition timing, adjusting from 1977models
Ignition timing, adjusting from 1978 models
Ignition timing control, checking
Ignition timing control, checking from 1977models
Ignition timing control, checking from 1978 models
Troubleshooting electronic ignition system
Clutch. Controls
30 -7
30 -13
30 -8
30
30-11
Clutch, adjusting from 1977models
Clutch, adjusting on cars with power assistancefrom 19'18models
Clutch, disassembling and assembling
Clutch disc, removing and installing
Clutch spring, removing and installing from 1978models
Specifications 30 -03

Page
30 -07
30 -03
30 -01
Specifications from 1978 models
Tightening torques for manual transmission
Transmission, type 930
Transmission type G SO/50 30 -02
Clutch mechanism, disassembling and
assembling, Model 89 30 -15
Manual Transmission, Controls, Case
Front transmissioncover, disassemblingand assembling
Shift base, disassembling and assembling 34-1
34 -15
34 -19
34-3
34-7
34 -14
Shift controls, adjusting
Timing case, disassemblingand assembling
Transmissioncase. disassemblingand assembling
Transmission casewith power clutch
Transmission casewith power clutch from 1978 models 34 -14 e
Manual Transmission, GearsandShafts
35 -1
35 -15
35 -9
35 -19
35 -7
35 -26
Change box, disassembling and assembling
Drive pinion, disassemblingand assembling
Drive shaft, disassembling and assembling
Seal for drive shaft, removing and installing
Selector forks, adjusting
Synchronization,checking
Synchronization, disassemblingand assembling 35 -23
Differential. Final Drive
39-17
39 -19
39-5
39-1
39 -9
39 -21
Backlash. adjusting
Backlashof ring gear. adjusting
Differential. disassemblingand assembling
Differential. removing and installing
Drive pinion and ring gear. adjusting
Locking differential. disassembling and assembling
Spacersfor ring gear adjustment. determining thickness 39 -17
Alphabetical Index
Printed in Germany -VII, 1989
5

Volume I Alphabetical Index 911 turbo
Page
Front Wheel Suspension
40 '
40 .
40.
40.
Front axle, disassemblingand assembling
Front axle, removing and installing
Specifications
Tightening torques for front axle
42 -8
42 -3
42 -1
42 .13
42 -01
42 -03
42 -14
Rear Wheel Suspension
Coil spring compressorP289, machining
Rear axle, disassembling and assembling
Rear axle, removing and installing
Rear wheel, bearings, adjusting
Specifications
Tightening torques for rear axle
Wheel bearing play, checking
Wheels, Tires, Axle Alignment
44 -1
Adjustment values for axle alignment
Axle alignment. checking
Specifications
44-2
44 -01
Notes on alignment 44 -4
Sample test card
Brakes -Mechanical Parts
46 -
46 -
46 -
46 -
46.
46.
46.
46.
Brake pads -remove and install
Brake pad thickness -check
Brake system -911 Carrera Turbo look
Front wheel brakes -changes for Turbo 3.3 ltr.
Front wheel brakes -disassemble and assemble
Rear wheel brakes -disassemble and assemble
Technical data
Tightening torque
Alphabetical Index
Printed in Germany -VII, 1989
6
.3.1.01
.02
2
1
04
4a
5
11
01
-03

911 turbo Alphabetical Index Volume
Page
Brakes -Hydraulic Parts
47-1
47-7
47-12
47 -01
Brake calipers -disassemble and assemble
Brake caliper sections -disassemble and assemble
Brake circuit failure indicator
Tightening torque
Steering
48 -01
48 -1
Specifications for steering
Steering. disassemblingand assembling
Tightening torques for steering 48-02
7
Alphabetical Index
Printed in Germany -VII, 1989

930 TURBO REPAIR MANUAL
This repair manual describesall of the important operations for which special instructions are
required to assureproper completions. This manual is essential for the shopforemen and
mechanics, who need this information to keep the vehicles in a safe operating condition. The
basic safety rules, of course, also apply to repairs onvehicles without exception.
The 930 Turbo Repair Manual only describesrepair operations which differ from those for 911
models. Refer to the 911 Repair Manual for all other information.
The information is groupedaccording to repair numbers,which are identical to the first two digits
of the repair time and warranty code.
The repair group index and register cardsare quick guidesto find information in the manual.
Discriptions of design and function canbe found in service training coursereference material.
This repair manual will be kept up to date with workshopbulletins; the information of these
bulletins will be made part of the manual from time to time. We recommend that the Workshop
Bulletins be filed in the special folder provided for this purpose.

REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL
930 -Turbo
Pleasefile the supplementsaccording repair groupsand make appropriate entries in the table below
Signature
SupplementNo. Filing Date
I
II
III
IV
v
VI
VII
VIII
IX
x
XI
XII
XIII
XIV

General
TECHNICAL DATA
(Referto appropriate repair group for adjusting and wear limit data.)
Note: USAvalues listed in brackets.
ENGINE
Internal engine code 930/50, since Nov. 75 930/52 (USA, 930/51)
from Aug. 1976 (USA 930/53) Japan930/54
mm/inch 95/3.74
mm/inch 70.4/2.77
3/.3
cm m. 2993/182.64
6.5: 1
Bore
Stroke
Sweptvolume
KW/HP
KW/HP
KW/HP
Compressionratio
Max. engine output according to
DilT 70020
Net power, SAEJ245
Grosspower, SAEJ245
Technical Data 0.1
Printed in Germany -11. 1976

General
Nm/kpm 343/35
Nm/ft. lbs 332/245
Nm/ft. lbs. 389/286
at engine speed
of 4000 rpm
Max. torque, DIN 70020
Net torque. SAE J245
~
Gross torque, SAE r 245
64/87 (58/82)
Max. liter output. DIN 70020 KW/l HP/l
rpm
rpm
+
7000 -200
207/456 (217/478)
210/463
rpm
Max. speed
Max. cruising speed
Cutoff speed of speedcontrol in
distributor (overrev governor)
Weight of engine with air cleaner (dry) kg/lbs
930/52
Engine Design
Engine block Diecast, light alloy,
two sections
Crankshaft
No. of crankshaftbearings
Conrods
Conrod bearings
Pistonpin bearings
Intermediate shaft bearings
Pistons
Forged(tenifer treated)
Eight
Forged steel
3 half-shell plain bearings
Press-fit bronze bushing
2-way plain bearing
Forged light alloy.
slipper skirt
Pistonpins
Pistonrings
Cylinders
Floating installation, snaprings
2 compressionrings, 1 oil
scraperring
Light alloy, nikasil coated
cylinders
Cylinder head
Valve seatinserts
Valveguides
Location of valves per cylinder
Exhaustvalve
Valve springs
Valve drive
Camshaft
Separate, light alloy heads
Shrink-fit, annealed
sintered steel
Press-fit, special bronze
1 intake and 1 exhaustvalve
suspendedin V
Natrium -filled, reinforced
insert ring
2 coil springsper valve
One eachoverhead camshaft
left and right
Cast, 4 bearings, runsdirectly in
camshaft housing
Chain
Camshaftdrive
Cooling
Engine Air cooled via axial
blower on alternator
6800
6000

General
Blower drive Belt off of crankshaft
Crankshaft/blowerratio ca. 1:1.67
1560 l/s at 6000 rpm of crankshaft
Air delivery rate
Engine Lubrication
Oil cooling Thermostatic control, oil cooler on engine
block in blower air stream, cooler coils in front
right wheelhouse
Full flow
0
ca. 4.0 at 80 C
bar
Elektric
0
ca. 150 C
1/1000 km
930/50 - ca. 1.0 to 2.0
Oil filter
Oil pressureat 5500 rpm
Oil pressuregauge
Max. oil temp.
Oil consumption
Exhaust System
930/52 -
(930/51 -
(930/53 and
930/54
Single pipe system with turbocharger,
bypassvalve and muffler
asabove. but with additional air pump
double-pipe system. 2 reactors. bypassvalve.
turbocharger and muffler, additional air pump)
as930/51. but with EGR)
Heating Warm air heater with automatic temperature
control. Warmand cool air mixable.
Fuel System
Fuelsupply
Fueloctane
2 elec. roller cell pumpsconnectedin line
96. premiumgrades(91-96)
RON
Electrics
Degree of suppression
Batteryvoltage
Battery capacity
ECERegulation No. 10
v12
Ah 66
Ah 88 (not with air conditioner)
980
Battery capacity
(optional extra)
Alternator/output w
Ignition
Transformer
CDI (w/o contacts)
Bosch
Firing order 1-6-2-4-3-5
Brakes
Footbrakes Hydraulic, dual-circuit disc brakes with
pneumatic booster, LHD only
282.5 inboard
Front brake disc diameter mm
290 inboard
Rearbrake disc diameter mm
228
mm
Effective front brake disc dia
Effective rear brake disc dia. 244mm
Printed in Germanv -II. 1977 Technical Data 0.3

General
Front brake disc thickness 20
mm
20
257
76
52.5
mm
cm2
2
cm2
Rearbrake disc thickness
Total effective braking surface
Padsurface per front wheel
Padsurface per rear wheel cm
Frontcaliper pistondia. mm
Rearcaliper piston dia. 38
mm
Mechanical acting on both rear wheels
mm
25
mm
cm2
Parking brakes
Parking brake drum diameter
Brake shoe width
Effective braking surface per wheel 85
Teves, Type T 52/7 inch
Brakepressurebooster
Pressureratio 1.8
Pedalratio (mechanical) 5.2
Dimensions (DIN -Curb Weight)
mm/inch 4291/168.94
mm/inch 1775/69.88
Length
Width
Height
Height
mm/inch
mm/inch
1320/51.97 (1340/52.76)
1304/51.34 with standard50 tires -only
up to 1977 Models
2272/89.45mm/inch
Wheelbase
Front track
Reartrack
mm/inch
mm/inch
Ground clearance mm/inch
mm/inch
1438/56.61 (1431/56.34)
1511/59.49(1501/59.09)
141/5.55 with series50 tires 15 inch
157/6.18(175/6.89)
Groundclearance -full load mm/inch
mm/inch
mm/inch
Curved ground clearance
Front overhang angle limited
by spoiler
120/4.72 with series50 tires 15 inch
127/5.00 (155/6.10)
51,5/2.03 (78/3.07)
15° (16°)
14° 30' with standard50 tires 15 inch
Rearoverhang angle limited
by apron
17°
(ISo)
16° with standard 50 tires 15 inch
(DIN 70020)
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
1140/2514 from Nov. 75 1195/2635
1470/3241 ..1525/3363(1400/3087)
600/1323 ..625/1378 (600/1323)
870/1918 ..900/1984 (840/1852)
Weights
Curbweight
Max. total weight
Max. frontaxleload
Max. rearaxle load
330/728 (205/452)
35/77 without exceeding max. total weight
Payload
Max. roof load including roof
Printed in Germany
TechnicalData
0.4

General
Capacities
Engine(as measuredwith oil dipstick
according to Owner's Manual) Brandname heavy duty oils meeting API Classifi-
cation SD or SEwith a viscosity of: SAE30 for summer,
SAE20 for winter, SAE20 W 20for permanent
0 0
temperaturesbetw. -15 and a C or SAE 10 W for
0
permanent temperatures below -15 C (10 W 50/15W 50/
20 W50 multi-grade oils upon approval)
1
1Ca. 13
Ca-.10
Total oil volume of system with oil
cooler coils
Oil change volume
Transmission and differential Refer to page 30-05
Fueltank 180, 8 liters in reserve
3
Brakefluid Ca. 240 (227)cm
Windshield washer 1
Ca.
8.5
Performance
Topspeed kph/mph Above 250/155 (245/152)
Acceleration from
0 -100 kph/62 mph sec 5.5 (5,7) DIN curb weight +
1/2 payload
24.0 (25,0)
4.4 ; kg/kW 6,0 (4,88; kg/kW 6,63)
sec
kg/HP
Km from standing start
Weight per horse-power
Hill climbing ability in 10
4-speed transmission 1st gear over 100
2nd gear 47
3rd gear 27
4th gear 16 (28)
(16,5)
0.5
Printed in Germany -11. 1976 Technical Data

General
SPECIFICATIONS -FROM 1978 MODELS, TURBO 3.3
(Adjustment values and wear limits are provided in pertinent repair groups)
Note: USAvalues in brackets
Engine
Factory engine code
Bore
Stroke
930/60 (USA930/61. Gal. 930/63). Japan930/62
from mod. 79 (USA930j94). Japan930/65
mm/inch 97 / 3.82
mm/inch 74.4/2.93
3 3
cm / inch 3299 / 201.3
Total displacement
Compressionratio
kW / HP
Max. engine power atenginespeed
rpm 5500
7.0: 1
221/300
(USA+ Japan195 / 265)
(195/261)
kW / HP
(Net power)
0.7Printed in Germany -IV. 1981 Specifications, General

General
Max. torque
(Net torque) Nm / kpm
Nm / ft Ibs 412/42 (395 / 40.3)
395 / 291 atenginespeed
rpm 4000
Max. liter output kW / 1 / HP 67 / 91
Max. pexmissiblespeed
Max. constantspeed 6700
6000
rpm
rpm
+
7000 -200
Governorcut-off speed
in distributor rpm
Engine weight (dry) with
muffler kg fIbs 230 / 507 (240 / 529)
Engine Design
4 stroke internal combustion
Type
Coolingsystem
Crankcase Air
Light alloy metal
Forged, 8 plain bearings
Plain bearings
Light alloy metal
Crankshaft bearings
Connecting rod bearings
Cylinders. single
Arrangement of valves per cylinder
Valve timing
Camshaft drive
1 intake valve
1 exhaustvalve
Vee suspension
One OHCleft and right
Chain
Camshaft bearings
Blower drive
Plain bearings
Belt in unit with alternator
Crankshaft/blower ratio
Lubrication
Fuel supply
Mixture
Charging
Approx.1 : 1.67
Dry sumpwith separate oil tank,
thermostat controlled oil cooling
and full flow oil filter, cooling tube
coil in front right wheel house
2 seriesconnected elec. pumps
Continuous fuel injection
KKK exhaust turbocharger
0.8 Printed in GermanySpecifications, General

General
Electric System
ECERegulationNo. 10
v12
Ah
Ah
Shielding class
Battery voltage
Battery capacitance
Battery capacitance (M-item)
66
88 (not with air conditioner)
Alternator power
Ignition system
Firing order
w980
CD! (breakerless)
1-6-2-4-3-5
Exhaust System, Heater Single pipe systemwith turbocharger.
bypassvalve and muffler. Secondaryair
il"jectiol! by auxiliary air pump in exhaust
system after each exhaustvalve.
(USA+ Japanalso with reactors)
Automatic temperature control for heater
(at DIN curbweight)
Dimensions
Wheelbase mm/inch
mm/inch
mm/inch
mm/inch
2272/89.45
Front track width
Reartrack width 1432/56.38
1501/59.09
4291/168.94
Length
Width mm/inch
mm/inch
m/ft
1775 69.88
1310 / 51.57 (1328 52.28)
Height
Turningcircle dia. 10.7/35.10
120/4.72
Groundclearance. full load mm/inch
Weights
kg/]
kg/]
kg/I
kg/]
1300 2867 (1295 2855)
1680 I 3704 (1500.700
I 1543 (625 I
1050 I 2315 (900 J
/ 3307)1378),
1984)
Curbweight by DIN
Max. total weight (static)
Max. front axle load (static)
Max. rear axle load (static)
Printed in Germany -III. 1978 Specifications, General 0.9
lbs
lbs
lbs
lbs

General
Capacities
Engine
Total amount of oil for system with
extra cooling pipe coil 1Approx. 13, exact amount determined
by reading on oil dipstick, measured
with engine running at idle speedand
having operating temperature
Approx. 10
1
Amount for oil change
Amount of oil between min. and
max. marks on dipstick 1 Approx. 2
Brandname heavy duty oils for internal combustion engines
acc. to API Classification Sf. Usefollowing viscosity mul-
ti-grade oils for year around operations (oil change every
20,000 km): SAE 10 W/50, 15 W/50 or 20 W/50. Do not
.0
uselatter 011for constanttemperatures below -15 C. On-
ly usebrand name oils tested and approved by Porsche.
Brandname single grade oils of API Classification SE
should only be used whenmulti-grade oils are not available
and normal operating conditions prevail, but the use of
suchoils will require observanceof the additional change
intervals according to seasonof year to prevent anydamage.
UseSAE30 oil for summer and SAE20 W for winter (pro-
0
tection only for temperatures below + 5 C!).
Transmission+ differential 1See page 30 -05
180, of which 8 Itr. in reserve
3
Fuel tank
Brake fluid tank cm
Windshield washer 1
Approx. 240 (227)
Approx.8.5
Performance
Top speed km/h / mph 260/162 (250 / 155)
Acceleration 0 -100 km/h
Km from standing start 5.4(5.6)
24.0 DIN curbweight +
1/2 payload
s
s
Printed in Germany
0.10 Specifications, General