Porsche 924 Instruction manual

Workshop Manual
Volume I
Engine
DR. ING. h. c. F. PORSCHE Aktiengesellschaft

WORKSHOP MANUAL 924
This workshop manual describes all of the 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 a safe operating condition. The basic safety rules,
of course, also apply to repairs on vehicles without exception.
The information is grouped according to repair numbers which are identical to the first two digits
of the repair time and warranty code.
T he repair group index on page 1, an alphabetical index and the re gister table are quick guides
to find information in the manual.
Descriptions of design and function can be found in the service training course reference material .
This workshop manual will be kept up to date with workshop bulletins, which will be made part
of the manual from time to tim e. We recommend that these workshop bulletins be filed in the
special folder provided for this purpose.

GENERAL
ENGINE
TRANSMISS ION
CHASSIS
BODY
HEATING, VENTILATION,
AIR CONDITIONING
ELECTRICS
Lifting Car
Technical Data
Engine I Crankcase
Engine/ Crankshaft, Assembly
Engine I Cylinder Head and
Valve Drive
Engine I Lubrication
Engine I Cooling
Fuel Supply System
Fuel System (C
IS )
Exhaust System / Emission Controls
Starter, Power Supply
Ignition System
Clutch I Cont rols
Torque Converter
Manual Transmission I Controls,
Case
Manual Transmission I Gea rs, Shafts
Automatic Transm ission I Controls, Case
Automatic Transm ission I Gears, Valve Body
Differential
Front Wheel Suspension
Rear Wheel Suspension, Propeller s
haft
Wheels, Tires , Alignment
Brakes I Mechanical
Brakes I Hydraulics
Steering
Body -Front Section
Body - Center Section
Body -Rear Section
Lids
Doors
Hardtop
Bumpers
Windows
Exterior Equipment
Interior Equipment
Seats
Seat Covers
Heater
Ventilation
Air Conditioner
Instruments, Radio
Windshield Wipers and Washer
Exterior Lights
Interior Lights
Wiring
REPAIR
,,
Page O.l
0.3
GROUPS
10
13
15
17
19
20
25
26
27
28
30
32
34
35
37
38
39
40
42
44
46
47
48
50
51
53
55
57
61
63
64
66
68
72
74
80
85
87
90
92
94
96
97
· ~

General
Car, lifting
Technical data, general
Engine/Crankcase
Alternator belt, checking and adjusting
Engine, removing and installing
Tight ening torques
Tolerances and wear limits
Tools
Engine, Crankshaft, Pistons
Bearing caps · location
Bearing sleeve, removing and installing
Connecting rod bearing play, checking
Connecting rod , removing and installing
Crankcase and crankshaft , disassembling and assembling
Crankcase · tools
Crankshaft bearing play - checking
Cranks haft seal, removing and installing: Flywheel end
Pulley end
Crankshaft sizes
Fly wheel, removing and installing
Gear ring, replacing
Needle bearing, removing and installing
Oil
pump drive. installing
Oil
pump, removing and installing
Piston and connecting rod, disassembling and assemb ling
Piston and cylinder bore, checking
Piston, removing and installing
Pi
ston rings, removing and installing/checking
T ools
Printed in Germany - X, 1982
List of Contents-Volume I
Page
0.1
0.3
10 -8
10 - 2
10 -04
10 - 01
10 - 1
13 - 6
13 - 13
13 - 17
13 -16
13 -4
13 -3
13 - 7
13 -6
13 -9
13 - 10
13 - 11
13 -12
13 -12
13 -6
13 -8
13 -14
13 -18
13 -16
13 -
17
13 - 1

List of Contents-Volume I
Engine/Cylinder Head, Valve Drive
Camshaft, checking
Camshaft, removing and installing
Camshaft seal, removing and installing
Cylinder head, machining
Cylinder head, removing and installing
Cylinder head, removing and installing (1980 model)
Cylinder head tools
Distributor drive gear, removing and installing
Drive
belt, installing
Tappets, marking
Tools
Valve adjusting screw, tightening
Valve drive, disassembling and assembling
Valve
guides, checking
Valve guides, replacing
Valve
play, checking and adjusting
Valve seats, machining
Valve sizes
Valves,
machining and grinding
Valve springs, removing and installing
Valve stem seals, replacing
Engine/Lubrication
2
Lubrication system parts, removing and installing
Oil dipstick guide tube, installing
Oil filter. removing and installing
Oil pressure and oil pressure switch, checking
Tools
---
Page
15. 10
15. 9
15. 10
15. 18
15. 2
15 - 4
15 . 1
15 . 11
15. 5
15 . 13
15. 1
15. 13
15
. 6
15 . 14
15. 19
15 . 16
15. 13
15. 12
15. 12
15. 12
15 - 14
17 - 2
17 . 6
17 · 4 a
17 -8
17 . 5
17 - 1
Printed in Germany

List of Contents-Volume II
General
4-speed manual transmission 088/ A
5-speed manual transmiss
io n 016 Y
5-speed manual transmission
016/9 · 1980
5-speed manual transmission 016/9 -1981
Automatic transmission (refer to page 37 -01)
Clutch/Controls
Clutch, adjusting
Clutch, removing and installing (Type 088/A)
Clutch, removing and installing (Type 016 Y)
Clutch, removing and installing (Type 016/9)
Clutch controls, repairing
Clutch disc, removing and installing
Clutch pressure plate, checking
Drive plate, checking
Release bearing, removing and installing
Release lever. repairing
Technical data
Tightening torques
Tools
Torque Converter
Converter. checking
Converter, draining
Converter drive plate support assembly, removing and installing
Converter, installing
Converter oil seal, removing and installing
Manual Transmission/Controls,
Case
Differential, removing and installing
End plate, disassembling and assembling
End plate, disassembling and assembling (Type
016 /9)
End plate, replacing
Final drive case , disassembling and assembling (Type 016 Y)
Flange shaft seal , replacing
Front transmission cover. disassembling and assembling (Type 016 Y)
Gearbox, disassembling and assembling
Gearbox, disassembling and assembling (Type 016
Y)
Gearbox, disassembling and assembling (Type 016/9)
Gearbox, removing and installing
Gearbox, removing and installing (Type
016/9)
Printed in Germany · X, 1982
Page
30 -0 1
30 -02
30 - 02 a
30 -02 b
30 - 16
30 -3
30 -7
30 -8 c
30 -9
30 -3
30 -15
30. 14
30. 12
30 -13
30 - 01
30 -07
30 -03
30 -1
32. 3
32. 4
32. 1
38. 3
38 -4
34 -12
34 -19
34 -127
34. 24
34. 77
34 - 1
34. 69
34 - 13
34. 61
34 . 111
34. 11
34. 1 05

List of Contents-Volume II
Rear transmission cover. disassembling and assembling (Type 016/9)
Shift linkage, adjusting
Shift linkage, adjusti ng (Type 016/9)
Shift linkage, disassembling and assembling (Type 016 Y)
Transmission
case, disassembling (Type 016 Y)
Tools
Final drive housing, disassembling and assembling (Type
016/9)
Final drive housing, repairing
Transmission, disassembling and assembling
Transmission, removing and installing
Transmission, removing and installing (Type 016 Y)
Transmission, removing and installing (Type 016 /9)
Manual Transmission/Gears, Shafts
Drive pinion, disassembling and assembling
Dr i ve pinion, disassembling and assembling (Type 016 Y)
Drive
pinion, disass embling and assembling (Type 016 /9)
Input shaft, disassembling and assembling
Input shaft, disassembling and assembling (Type 016 Y)
Input shaft, disassembling and assembling (Type 016 /9)
Synchromesh rings, checking
Synchronization,disassembling and assembling (Type
016 Y)
Automatic Transmission/Controls, Case
Ca bles for throttl e and control pressu re , adjusting
Cable
for throttle and control pressure, adjusting (from 1979 model)
Ca ble for throttle and control pressure, removing and installing (from 1979 model)
Cutaway drawing
Operation, checking
Selector lever cable, adjusting
Selector lever cable, removing and installing
Technical data
Tighteni
ng to rques
Transmission, removing and installing
Troubleshooting
Page
34 -123
34 -6
34 -104
34 - 55
34 -73
34 -135
34 -135
34 -25
34 -7
34 - 3
34 -
51
34 - 101
35 -7
35 -57
35 -107
35 - 1
35 - 51
35 - 101
35-6
35 - 15
35 - 63
37. 6 c
37. 6 f
37
-6 d
37 .
01
37 - 7
37 -6 a
37 -1
37 .
02
37 -03
37 -13
37 -
11
2
Printed in Germany

Front Wheel Suspension
Ball joint installed in car, checking
Ball joint, replacing
Control arm installed in car, checking
Spring strut . disassembling and assembling
Technical data
Tightening torques
Wheel bearings, disassembling and assembling
Wheel
suspension, disassembling and assembling
R ear Wheel Suspension, Axle Shaft
Axle shaft, disassembling and assembling
Information on disassembling and assembling axle shaft
Rear axle, removing and installing (from 1978 model)
Technical data
Tightening torque
Tools
Tra iling arm, disassembling and assembling
Wheel
suspension, disassembling and assembling
List of Contents-Volume Il l
Page
40 -17
40 -18
40 -16
40. 7
40 -01
40 - 02
40 -1
40 · 13
40-20
Wheel suspension, disassemb ling and assernbling (from 1978 model)
42. 15
42 · 17
42. 21
42. 01
42 - 02
42 · 15
42 - 9
42 . 1
42 ·8
Wheels, Tire s, Axle Alignment
Axle alignment
Axle alignment information
Axle a lignment specifications
Colla psible wheel 924 . 944, 924 Turbo
General tire mounting information
Rear axle (up to 1978 model)
Rear axle (from 1978 model)
Te chnical data
Wheels, balancing
Wheel bolts for rims
Wheel rims/bolts/nuts 924, 944, 924 Turbo
Wheel rims, checking
Printed in Germany · X, 1982
44. 1
44. 1
44 -02
44 - 11
44. 7
44 - 2
44. 2
44 -01
44 -9
44 - 4
44-4
44 - 6

Li st o f Contents-Vo lu me Ill
Brakes/Mechanical
Brake pedal, removing and installing
Brake push rod, adjusting (to end of 1 979 model · 7"brake booster)
Brake push rod, adjusting
(from 1 980 model· 9" brake booster)
Front brake pads, removing and installing
F ront wheel brakes, disassembling and assembling
Parkingbrake, adjusting
Parking brake lever, disassembling and assembling
Rear wheel brakes, disassembling and assembling
Stop light switch adjustment, checking (from 1981 model)
Technical data
Tightening torques
Brakes/Hydraulics
Steering
2
Bleeding brakes and changing brake fluid
Brake booster, checking
Brake booster, removing and installing
Brake caliper, disassembling and assembling
Tightening torques
Information on removing and installing steering column and tube
Steering
column and casing tube, removing and installing
Steering
gea r, removing and installing
Technical data
Tightening torques
Page
46 - 13
46 -14
46. 15
46 -5
46 . 1
46 -17
46 -17
46 . 7
46. 15
46 -0 1
46 - 02
47 -8
47. 7
47 - 5
47 . 1
47 . 01
48 -10
48. 7
48. 1
48. 01
48 -02
Printed in Germany

List of Contents - Vo I um e IV
Body/General
Celette straightening bench
Cobra 3 straightening
unit with accessories
Dimensions
for floor assembly
Repair control dimensions
Repairing galvanized sheet metal parts
Special
tools and shop materials for body repairs
Univer sal anchorage ENS 937 .900
Front Body Section
Front body section damage, repairing
Gauge
for lock member
Modifications on side members
Template and welding
gauges 9112 / 9175 for front body section
Template 9120 for windshield
Rear Body Section
Lids
Modification on rear side panels
New rear body section parts, installing in cars before 1980 model
Rear body section damage, repairing
Reinforcement brackets on rear apron, installing
Side panel (complete fender). repairing
Template
for rear window
Lid lock, removing and installing
Rear lid and seal, removing and installing
Water trap
on lid lock, service installing
Printed in Germany - X, 1982
Page
50 . 011
50. 020
50 . 022
50 - 08
50 -03
50 - 05
50. 01
50. 021
50. 1
50. 6
50. 7
50 -4
50. 5
53 - 10
53. 11
53 - 1
53. 7
53. 5
53 . 15
53
-9
55-4
55. 1
55. 3