Porsche 911 TURBO - 1989 Instruction manual

911 turbo FrontWheel,Suspension
Technical data
Wheel suspension independent wheel suspension with
control arms and spring struts
Suspension one round torsion bar per wheel, longitudinal
Torsion bar " 18.8mm
Height adjustment -
at DIN curb weight Page 44 -1
Shock absorbers double-action hydraulic
shock absorber struts
Manufacturer Bilstein -different configuration from Mod. 89
onwards
Anti-roll bar 0 18 mm -from Model 77 onward 0 20 mm
from Model 85 onward 0 22 mm
40 -01
Technical data
Printed in Germany -VII, 1989

40 General
TORQUE SPECIFICATIONS FOR FRONT AXLE
Location Designation Threads Class Torque
Nm ft Ib
Support bearing to
strut Nut M 14 x 1.5 880 58
Support bearingto
body Capscrew M 10 8.8 47 34
Carrier to body Bolt M 12 x 1.5 8.8 90 65
Carrier strut guard
to body Bolt M 10 8.8 47 34
Stabilizer and suspension Bolt M8 8.8 25 18
Guard Bolt M8 8.8 25 18
Stabilizer to carrier strut Bolt M8 8.8 25 18
Carrier strut,guard and
stabilizer to body Capscrew M 10 8.8 47 34
Carrier strut and guard toI
carrier Nut M 10 828 20
Control arm to body Bolt M 10 8.8 47 34
Ball joint to control arm M 45 x 8.8
Slotted nut 5250 181
Nut on stub axle Capscrew M7 10.9 15 11
M8 8
Ball joint to strut Uni stop nut 22 16
Brake disc to wheel hub Nut M8 8.8 23 17
Cover for brake disc Bolt M8 8.8 10 7
Caliper to stub axle Bolt
Capscrew M 12 x 1.5 8.8 70 51
Brake line Coupling M 10 x 1 12 9
Nut M 14 x 1.5 130 94Wheel to wheel hub
Printed in Germany
40-02 Technical Data

Front Wheel Suspension
REMOVING AND INSTALLING FRONT AXLE
Removing
1. Disconnect brake hose at brake line aft er
first depressingbrake pedal somewhatwith
pedal strut to prevent brake fluid from
escaping.
5. Placejack underneathcarrier.
6. Detach steering shaft at steering shaft
holder and lift joint off of steering shaft.
Dismantle steering shaft holders.
2. Unscrewstabilizeratsuspension.
7. Unscrewshockabsorberhexnuts.
3. Removeguard.
4. Unscrewmounting screwsat carrier and
control arms.
Removing and Installing FrontAxle 40-1
Printed in Germany

Front Wheel Suspension
8. Lowercompletefrontaxle assembly. Note
Do not turn the steering wheel quickly from
lock to lock whenthe car is raised, to
prevent tIle cup from popping off at the
steeritlg gear or tie rod (air compensation).
Installing
1. Raisecompletefrontaxle assembly.
2. Securetopof shockabsorberstobody.
3. Securebottom of front axle to body
(carrier and control arms).
4. Connectbrakehoses.
5. Bleedbrakes.
6. Torqueall mountingscra-lsto specifications.
40-2 Removing and Installing FrontAxle Printed in Germany

Front Wheel Suspension
T GalS
No.
Description Special Tool Remarks
Torquewrench1Commexcial item, up to 36 mkg
(261 ftlbs)
2Commercialitem Tie rod remover
Wrench P 280 b
3
Printed in Germany -II. 1976 Disassembling andAssembling FrontAxle 40-3

Front Wheel Suspension
Printed in Germany
40-4 Disassembling andAssembling FrontAxle

Front Wheel Suspension
Notes
No Designation Amt. Removing Installing
1CapscrewM 10 2Torque to
specifications
2Washer 2Replace, if
necessary
3Hexnut, self-
locking
2Torque to
specifications
4Washer 4
5Guard 1
6Strut 2
Hex hd screw 2Torque to
specifications
8Washer 2Replace, if
necessary
9Caliper 1
10 Spacer 1
111
Cap 1
12 Capscrew 1Torque to
specifications
13 Clampingnut 1
Tab disc14 1Must just barely turn
with screwdriver
15 Wheel hub 1Clean, check for wear'lfill hub with ca. 60 g
multi-purpose lubricant
16 Taperroller bearing 1Clean, check and
lubricate. If necessary.
replace.
17 Hex nut M 8 5Torque to
specifications.
Printed in Germany Dismantling and Assembling FrontAxle 40-5

Front Wheel Suspension
Notes
No. Designation Amt
IRemarks
Removing Installing
18 Washer 5Replace, if
necessary
19 Hex head screw 5
120 Brakedisc 1 Check for wear
and damage
121
Radial seal 1 Replace, if
necessary. Press
in until seal is
flush with hub.
Clean. checkfor
wearandlubricate.
Replace.if
necessary.
22 Taper roller
bearing
1
1Heat hub and
pressoff race Heat hub and
install race
123 Outerrace
1Heat hub and
pressoff race Heat hub and
install race
124 Outer race
Hex hd screw 3Torque to
specifications
125
Replace.if
necessary
26 Lockwasher 3
27 Guard 1
28 2Lubricate with MoS2°
Readjustheight
Controlscrew
2
129 I Adjusting lever
Replace,if
necessary
OWA gasket 2
30
Torque to specifications,
Replace, if necessary
131
Uni stopnut MS 1
Washer 1 32
Dismantling and Assembling FrontAxle
40-6 Printed in Germany

Notes
No. Description Amt Remarks
Removing Installing
33 Threaded pin 1Drive out Install with lubricant
Position it correctly.
Replace!
34 Hex nut 1Torque to
specifications
35 Lockplate 1 Replace, tab faces
up.
36 Supportdisc 1
37 Strut 1Check, replace if
necessary
38 Guard 1
39 Spacer Heat and install to
stop
1
40 Seal 1
41 Hex hd screw
M 10 3Torqueto
specifications
Lockwasher 2Replace if
necessary
42
Washer43 1
Guard44 1
45 Spacer 1
Check
46 Controlarm 1
Torsion bar 1
47 Check for damage,
replacing if necessary
Note mark for in-
stallation. Lubricate
48 1Replace
Cotter pin
Replace. if
necessary
Lockplate 1
49
40-7
Disassembling and Assembling Front Axle
Printed in Germany

40 Front Wheel Suspension
Notes
No Description Amt, Remarks
Installing
Removing
50 Nut 1Loosenwith
P 280 b Torque to
specifications.
Lubricate threads
51 Ball joint 1Check, replacing
if necessary
52 Hex hd screw
M 10 2Torque to
specifications
53 Washer 2Replace,if
necessary
54 Hedhd screw
M1O 2Torqueto
specifications
55 Washer 2Replace, if
necessary
56 Carrier 1Check for
damage
57 Adaptor 2
58 Capscrew 3Torqueto
specifications
59 Lockwasher 3Replace.if
necessary
60 Single-hole
pressureplate Mark for
reuse
1
Double-hole
pressureplate Mark for
reuse
61 1
62 Support with
rubberbearing 1Check, replacing if necessary
63 1
Spacer
II, 1976 -Printed in Germany
40-8 Disassembling andAssembling FrontAxle

911 turbo Rear Wheel, Suspension
Technical data
Wheel suspension independent wheel suspension with
semi-trailing arms
Suspension one round torsion bar per wheel, transverse
Torsion rod 0 26 mm -up to the end of Mod. 88
0 27 mm -from Mod. 89 onward*
Height adjustment -
at DIN curb weight Page 44 -2
Adjustment of spring strut angle Page 44 -2
Shock absorber double-action hydraulic shock absorbers
Bilstein -different configuration from Mod. 89
onward
Manufacturer
018 mm -up to the end of Mod. 84
0 20 mm -from Mod. 85 to end of Mod. 88
018 mm -from Mod. 89 onward**
Anti-roll bar
* Splines also modified in conjunction with new transverse rear axle tube
Angle also modified because of new transverse rear axle tube
42 -01
Technical data
Printed in Germany -VII, 1989

General
TORQUE SPECIFICATIONS FOR REAR AXLE
Location Designation Threads Class Torque
kpm ft. Ibs
Cover to body 8.8
10
Bolt MIO 4.7
6.0 34
Nut M 14 x I, 5
M 12 x I, 5
M 12 x I, 5
43
8,8
10,9
8,8
6,0
9,5
6,0
12,5
2,5
43
69
Excenter
Bolt
Bolt/capscrew
Bolt
M 12 x 1. 5 43
M 14 x I, 5 8.8
8
90
18
I
Trailing arm to crosstube
Strut to trailing arm
Strut to trailing arm
Caliper to trailing arm
Shock absorberto trailing arm
Shockabsorberto body Nut M 10 x 1
Coupling
Bolt
M 10 x 1
M8
1,4
2,5
8,3
10
18
60
8,8
12,9
8,8
Capscrew
Bolt
M 10
M8 2,5 18
M 14 x I, 5 13
Brakeline
Stabilizer to body
Propeller shaft flange
Guardand brake backplate to
trailing arm
Wheel to wheel hub Nut 94
217-231
M20 x I, 5
M6 10.9
8,8
30-32
Castle nut
0,5 4
61
Wheel hubto drive shaft
Brakedisc to wheel hub ctsk screw
M 12 x I, 5 8/8.8
8.8 8.5Nut 8.5 61
Bolt M 12 x I, 5
M 16 x I, 5 10.9
10.9
24.5
24.5 177
Bolt
177
Eccentricbolt M 16 x I, 5
Stabilizer to suspension
Stabilizer suspensionto
trailing arm
Adjusting lever to strut
Adjusting lever to strut

REMOVING AND INSTALLING REAR AXLE
Removing
1. Liftcar. 6. Removebrakedisc.
7. Lift rear axle strut with special tool P289.
Detach shock absorberat rear axle
trailing arm.
2. Detachbrakeline atcaliper andrearaxle
trailing arm. Firstdepressbrakepedal
somewhatwith pedalstrutto preventthe
brakefluid fromescapingoutofthe
reservoir.
3. Disconnectstabilizer atrearaxletrailing
arm.
4. Detachdrive shaftat transmissionflange.
8. Remove special tool P289. Pullout drive
shaft with joint toward inside of car.
9. Removecotter pin and castle nut at
parking brake cable. Pullout parking
brake cable on inside of car.
5. Removedrive shaftcastlenutcotterpin
andunscrewnut.
10. Detachrearaxletrailing armatcross
tubeandstrut. Removerearaxletrailing
arm.
42-1
Removing and Installing RearAxle
Printed in Germany

Rear Wheel Suspension
Installing
Slide in drive shaft throughrear wheel hub
before securing the shockabsorber.
2. Installspacerandparkingbrakecable.
3. Torqueaxlenutsto specifications.
4. Checkaxial play of wheelbearings.
Max. wheelbearingplayis 5/100mm.
Adjustplay if necessary.
5. Lockcastlenut.
6. Installbrakedisc, adjustparkingbrakes
andbleedbrakes.
7. Torqueall screwsandboltsto specifi-
cations.
42-2 Removing and Installing RearAxle Printed in Germany

TOOLS
48
No Special Tool
Description Remarks
1Torque wrench Commercial item, up to
750 Nm (75 kpm)
2Extention Commercia! item
3Hexagonsocket SW30 Commercial item
4P 289 Check tool, see page 42 -8
Strut retractor
5Dial gauge holder with
magnetic column Commercial item
6Dial gauge Commercial item
7Extractor with grip ring Commercial item
8Removal mandrel P 297 a
Printed in Germany 111,1981 Disassembling and Assembling Rear Axle 42-3

Rear Wheel Suspension
,
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Printed in Germany
Disassembling and Assembling Rear Axle
42-4

Notes
No. Description Amt. Remarks
Removing Installing
1Spacer 1
2Cotter pin 1Replace.if
necessary
3Castle nut 1Thrqueto
specifications
4Washer 1
5Screw M 6 2Torque to
specifications
6Brakedisc 1Check for wear
7Hex nut M 14 x 1.5
self-locking 1Torque to speci-
fications
8Hex hd screw 1
9Washer 2
10 Vibrationdamp. 1
11 Drive shaft 1Pullout on
inside of car
12 Gasket 1Pasteto drive
shaft
13 Cotter pin 1Replace
14 Castle nut M 6 1Screw onparking
brake cable until
cotter pin hole aligns
15 Washer 1
16
Parking brake
cable 1Pullout on inside
of car
17 Spacer 1Install correctly, large
pipedia. facesin.
18 Washer 1
Printed in Germany Disassembling and Assembling RearAxle 42-5

Rear Whee Suspension
NoteWhen:
Installing Special
Instructions
No Oty
Description Removing
19 Nut M 12 x 1.5 2Torque: 120 Nm page 42 -11
20 Lockwasher 2page42-11
21 Washer 4
22 Bolt 2 page 42 -11
23 Nut M 12 x 1.5 2Torque: 85 Nm page 42 -11/12
24 2Lockwasher page42 -11/12
25 Washer 1only with
camberexcenter
26 1
1Mark position for reinstallation page 42 -11/12
Camberexcenter
Toeexcenter
27 page 42 -101 Self-locking nut
M 14 x 1.5
28 Washer 1
page 42 -10
29 Bolt 1
page42 -10/12
30 1 Trailing arm
31 2
Flange block Pressin to stop
32 Wheel hub 1Drive out
with P 297 a Pressinto outer
wheel bearing
33 2
Spreader Install correctly
34 Spring 1
35 Spring retainer 2Install correctly
Spring 2
36
37 Pin 2Check for
correct fit in
spring retainer
1
38 Brake shoes
with adjuster
Disassembling and Assembling Rear Axle V, 1984 -Printed in Germany
42-6

Rear Whee Suspension
NoteWhen:
Installing Special
Instructions
No. Oty
Description Removing
39 Bolt 3Torque: 25 Nm
40 Lockwasher 3 Replace if
necessary
41 Brake backplate 1
42 Guard 1
43 Taper roller
bearing, outer 1Check, lubricate taper rollers with
multiple purpose
grease
44 Shaft seal 1Pressin to stop
45 Spacer 1Install in correct
position
46 Shaft seal 1 Pressinto stop
47 Taper roller
bearing, inner 1Check, lubricate
taper rollers.
Drive on hub
until bearing rests
on spacer.
Heat arm and
drive in with
suitable mandrel
48 Outer bearing race 1 Heatarm and
drive out
49 1 Heat arm and
drive out Heat arm and
drive in with
suitable mandrel
Outer bearing race
Strut angle
specified on page
42 -01 and 44 -1
50 1
Strut Two-piece rear
axle strut since
1977 models for
correction of
car height and
wheel load
difference with
an excenter
bolt. Struts ad-
justed in plant
that entire
rangefor higher
adjusting is
available.
Disassemblingand Assembling Rear Axle 42-7
V, 1984
Printed in Germany

Rear Wheel Suspension
)
MACHINING STRUT RETRACTOR P 289
Various modifications have beenmadeon the rear axle of 911/911 Turbo carssincethe beginningof
production.
Consequently the holder on P 289 must be adapted to the present state. If tool is not changed, the
light alloy rear axle trailing arms could be damaged when clamping the tool between spring strut and
trailing arm to tighten the mounting bolts.
Holder shape before machining
42-8 Disassembling and Assembling Printed in Germany