Porsche 912E Instruction manual

Workshop Manual
. ~: ~ -
DR. lNG. h. c. F. PORSCHE AG
STUTTGART-ZUFFENHAUSEN

912 E REPAIR MANUAL
This repair manual describes all important operations for which special instructions are required to
assure proper
completion. this manual is essential for the shop foremen and mechanics, who need
this information to
keep the vehicles in safe operating condition. The basic safety rules, of course,
also apply to repairs on vehicles without
exception.
The 912 E Repair Manual only describes repair operations which differ from those for 911 models;.
Refer to the 911 Repair Manual for all other information.
The information is grouped according to repair numbers, which are identical to the first two digits
of the repair time and warranty code.
The repair group index and alphabetical index are quick guides to find information in the manual.
Descriptions of design and operation can be found in service training course reference material.
This repair manual will be kept up to date with workshop bulletins; the information of these
bulletins will be
made part of the manual from time to time. We recommend that the Workshop .
~ulletins be filed in the special folder provided for this purpose.

REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL
912 E
Please file the supplements according to the repair groups and make appropriate entries in the table below.
Supplement No. Filing Date Signature
\
I
II
III
IV
v
VI
-
VII
VIII
IX
X
XI
XII
XIII
XIV

GENERAL
ENGINE
TRANSMISSION
CHASSIS
BODY
HEATING, VENTILATION,
AIR CONDITIONING
EL EC TRICS
Technical Date
Page 0.1
REPAIR GROUP
Engine -crankcase
Engine-Crankshaft, and moving parts
Engine-Cylinder Head,
Valve drive
Engine-Lubrication
Engine
-Cooling
Fuel Supply system
Fuel system, Fuel
Injection
Exhaust System
Starter, Power Supply
Ignition System
Clutch, Control
Mech. gear-shift system -actuat., hous.
Mech. gear-shift system -Gears, Shafts
Differential
Front Wheel Suspension
Rear Wheel Suspension
Wheels, Tires, measuring
vehicle
Brakes, -Hydraulic -system
Steering
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
Doors
Sliding Roof
Bumpers
Glasses
Exterior
equipment
Interior equipment
Heater
Air Conditioner
Instruments, Radio
Windshield Wipers and Washer
Exterior Lights
Interior Lights
Wiring
10
13
15
17
19
20
24
26
27
28
30
34
35
39
40
42
44
47
48
50
51
53
55
57
60
63
64
66
68
80
87
90
92
94
96
97

Anti-backfire Valve, Checking Operation
Auxiliary Air Regulator, Removing and Installing; Removing and
Installing Thermo
Time Switch
Axle Alignment Data
Belt Tension, Checking and Adjusting; Removing and Installing
Fan and Fan Housing
Brake Disks, Checking and Machining
Camshaft, Checking and Installing
Centrifugal Advance Curve
Clutch Disk, Checking; Installing Clutch
Clutch Disk, Removing and Installing
Clutch -J?cploded View
Clutch Play, Adjusting
Clutch, Removing and Installing; Checking Clutch
Cold Start Valve, Checking; Checking Cold Start Valve for Leaks,
Temperature Sensor
II
Cooling System -Exploded View
Connecting
Rods, Checking and Installing
Connecting
Rods, Reconditioning
Control Unit, Removing and Installing; Removing and Installing
Cold Start Valve
·crankcase a·nd Flywheel -Exploded View
Crankshaft and Connecting
Rods, Installation Notes
Crankshaft
End Play. Adjusting
Crankshaft, Disassembling and Assembling
Crankshaft, Reconditioning
Crankshaft Seal, Removing and Installing
Current Flow Diagram
Cylinder and Pistons -Exploded View
Cylinder Head and Valves -Exploded View
Cylinder Head and Valves, Installation Notes
Cylinder to Piston Play, Checking; Piston and Cylinder Installation Notes
Distributor, Installing
Distributor Drive Shaft, Removing and Installing
Engine Carrier, Removing and Installing
Engine, Removing and Installing
Equipment Charts -Fuel System/Fuel Injection
Equipment Charts -Ignition
Exhaust System -Exploded View
Contents
Page
24-9
24-4
44 - 01
19- 5
47- 1
15 - 16
28 - 5
30 - 4 '
30 - 1
30 - 2
30 - 5
30 - 3
24 - 8
19 - 1
13- 23
13 -24
24- 3
13- 8
13- 19
13 -12
13- 21
13 -22
13- 13
97 - 1
13- 2
15
-2
15- 5
13- 6
28 - 7
28 - 8
10 - 8
10 - 1
24 -
01
28 - 1
26 - 2

Exhaust System -Installation Notes; Checking Reactor for Leaks,
Checking f:GR'Operation, Removing and Installing
EGR Valve
Flywheel,
Checking~ Checking and Assembling Crankcase
Fuel Filter, Removing and Installing
Fuel Pressure, Checking
Fuel Pump Delivery Rate, Checking; Fuel Pump Test Specifications
Fuel Pump, Removing and Installing
Idle, Adjusting
Ignition Timing. Adjusting
Ignition Timing Control,
~hecking in Vehicle
Input Shaft Oil Seal, Removing and Installing
Intak
.. Air Sensor and Air Cleaner, Removing and Installing
Intake Air Sensor, Checking; Checking Throttle Valve Switch,
Checking Auxiliary Air Regulator, Checking Thermo Time Switch
Oil Circuit -Exploded View
Oil Pressure and Oil Pressure Switch, Checking
Oil Pump Housing and Cover, Oil Filter and Oil Pressure Switch,
Removing and Installing; Checking Oil Cooler
Piston, Checking; Checking Cylinder to Piston Play
Piston Marks; Checking Piston
Preassembled Crankshaft and Camshaft -Exploded View
Relays and Fuses, Location
Technical Data -Brakes, Hydraulics
Technical Data -Front .Wheel Suspension
Technical Data -Manual Transmission
Technical Data -Rear Wheel Suspension, Propeller Shaft
Technical Data -Steering
Technical Data -Wheels, Tires, Axle Alignment
Temperature Sensor II, Removing and Installing; Removing and
Installing Pressure Regulator
Thermostat, Checking; Adjusting Control Flaps
Thermo
Time Switch, Removing and Installing
Thermo
Time Switch, Checking
Throttle Housing, Removing and Installing
Throttle Valve Switch, Removing and Installing
Transmission Case, Disassembling and Assembling
Vacuum Advance Curve
Valv.e Clearance, Adjusting
Valve Guides, Checking; Replacing Valve Guides
Valve Guides, Replacing
Valve Seats, Refacing
Valv~- J:)P.C"'nnrli'H"'""""- n ... .t ... _, __ ,.,._, __ - ....
contents
Page
26-4
13- 11
20 - 4
24- 6
20 -3
20 - 1
24- 10
28 - 3
28 -4
35
-1
24- 1
24- 7
17- 2
17 - 7
17- 6
13- 5
13-4
13 - 14
90 - 1
47 - 01
40 - 01
30 - 01
42 - 01
48 - 01
42 -02
24-5
19 - 6
24-4
24 - 7
24-2
24 - 2
34-3
28 - 6
15 -10
15 - 8
15 -9
15.- 7

General
TECHNICAL DATA
(Refer to the different repair groups for adjustment data and wear limits.)
Engine
Bore
Stroke
Displacement
Compression ratio
Horse power SAE Net
Printed in Germany
mm/in.
mm/in.
3 3
em /in.
kW/HP
94/3.70
71/2.80
1971/120.3
7.6 : 1
64/86 at engine speed of
4900 rpm
Technical nat:~ _ (;pnpr"l
ll ,.

General
Torque SAE Net
Horse power per
liter SAE Net
Max. engine speed
Max. cruising speed
Cutoff speed
of speed limiter in
control unit
Engine weight with muffler (dry)
Engine Design
Crankcase
Crankshaft
Crankshaft bearings
Connecting rods
Connecting rods bearings
Piston pin bushing
Pistons
Piston pins
Piston rings
Cylinders
Cylinder head
Valve
seat inserts
Valve guides
Valve arrangement per cylinder
Exhaust Valves
Valve springs
Valve drive
Camshaft (021.109.101
K)
Camshaft bearings
Camshaft drive
0.2
Technical Data, General
Nm/ft lb
133/98
kW/HP
32.5/43.6
rpm ·5800
rpm 5000
rpm 5800
'!: 100
kg/lb 155/342
Light alloy, two
piece
Forged
4 plain bearings
Forged steel
at engine speed of
4000 rpm
Tri -metal plain bearing shells
Press fit steel bushing with lead/brass
bearing surface
Cast light alloy with steel insert
Floating type, locked by circlips
2 compression rings, 1 oil scraper ring
Special gray cast single cylinders
One per 2 cylinders, light alloy
Shrunk fit, annealed sinterred steel
Press fit, intake: special brass
exhaust: thermohedul
1 intake, 1 exhaust, parallel overhead
Sodium filled reinforced seat
1 coil spring per valve
1 camshaft, followers, push rods and
rocker arms
Gray cast, 3 plain bearings
Steel shells with white metal bearing surface
Bevel gears
Printed in Germanv

Timing with 1 mm valve clearance:
Ignition
Intake opens
Intake closes
Exhaustopens
Exhaust closes
Ignition coil
Speed limiter
Ignition timing .
Firing order
Ignition control
Dwell angle
Spark plugs
·Electrode gap
Cooling
Engine
Fan drive
Crankshaft/fan ratio
Air delivery
rate
En g 1n e Lub ri ~a t i on
Lubrication
Oil cooling
Oil filter
Oil pressure gauge
Max. oil temperature
Oil consumption
Emission Control
Heater
Printed in Germanv
General
BTDC
ABDC
BBDC
ATDC
Battery ignition
12 volt
+
5800 -100 rpm
0
27 BTDC at 3500 rpm
(vacuum hose disconnected)
1-4-3-2
CentrifuJal and vacuum
44
-50
M 14 x 1, 25 x 19, heat range 175
o. 7 mm (0.028 in.)
Air cooled
Fan on crankshaft
1 : 1
800 1/sec at 4600 rpm of crankshaft
Forced feed
by gear pump
Oil cooler in fan air stream
Full
flow
Indicator lamp
Up to red field
gt/600mi. 0.5 to 1.0
Air injection, thermoreactor and EGR
Warm air heater dependent on engine
temperature with
electric blower. Heating
can
be adjusted continuously with control
lever.
'T'orohn.:,... .... l n......... r ................... 1
\
(\ "

General
Fllel system
Fuel delivery
Fuel
octane
Electrical System
Battery voltage
Battery capacity
Battery capacity (optional extra)
Alternator output
Ignition
Ignition coil
Firing order
Ignition control
Dimensions
Length
Width
Height
Wheelbase
Track, front
Track, rear
Ground
clearance ·
Approach angle, front limited
by apron
Departure angle, rear
limited
by apron
Weights
Curb weight
Max. total weight
Max.
axle load, front
Max.
axle load, rear
Payload
Max. roof load incl. luggage
carrier
0.4 ·.
Technical Data. General
RON
v
Ah
Ah
w
AFC fuel injection into intake manifold
Electric roller
cell pump
91 (reg. grade fuels)
12
44
66
980, 70 A, 14 V (Bosch)
Battery ignition
12 V
Bosch
1-4-3-2
Centrifugal and vacuum
(DIN Curb Weight)
mm/in.
4291/168.94
mm/in.
1610/63.39
mm/in. 1340/52.76
mm/in.
2271/89.41
mm/in.
1360/53.54
mm/in.
1330/52.36
mm/in. 180/7.10
(unloaded)
mm/in. 140/5.51
(with max. payload)
160 (with
max. payload)
17°
(with max. payload)
(DIN 70020)
kg/lb 1160/2558
kg!lb 1400/3087
kg!lb 600/1323
kg!lb 815/1797
kg/lb 240/529
kg!lb
35/77
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