Manual Volume_4.pdf

Workshop Manual

DR. ING. h. c. F. PORSCHE

Aktiengesellschaft

The Workshop Manual is only for the internal use of the Porsche Dealer Organization,

@ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft

Sales, D-7140 Ludwigsburg

WKD 481 621

Print No. W 42-608-126-l

List of Repair Groups

General

Technical Data

Page 0.1

Repair Groups

Group

Maintenance. Selfdiaanosis

Engine

Engine, Crankcase

Engine, Crankshaft, Pistons

Engine, Cylinder Head and Valve Drive

Engine, Lubrication

Engine, Cooling

Fuel Supply

Air Flow Controlled Fuel Injection

Exhaust System/Emission Controls

Starter, Power Supply, Cruise Control

lanition Svstem

Transmission

Clutch, Controls

Torque Converter

Manual Transmission, Controls, Case

Manual Transmission, Gears, Shafts

Automatic Transmission, Contrds, Case

Automatic Transmission, Gears, Valve Body

Differential, Transaxle System

Chassis

Front Wheel Suspension

Rear Wheel Suspension, Axle Shaft

Wheels, Tires, Alignment

Antiblock System

Brakes, Mechanical

Brakes, Hydraulics

Steering

BdY

Body-Front Section

Body-Center Section

Body-Rear Section

Lids

Doors

Hardtop

Bumpers

Glasses, Window Control

Exterior Equipment

Interior Equipment

seats

Seat Covers

Heating,

Ventilation,

Air Condition

Heater

Ventilation

Air Conditioner

Electric8

Instruments, Fuel Gauge, Alarm System

Radio

Windshield Wipers and Washer

Exterior Lights, Lamps, Swftches

Interior Lights

Wiring

Printed in Germany - XX, 1987

928

Table of contents

Volume IV

Page

Front wheel suspension

Technical data .......................................

40-01

Tightening torques .....................................

40-02

Notes on front axle, 86 models onward ..........................

40-04

Disassembling and assembling wheel suspension .....................

40-l

Disassembling and assembling wheel suspension, until end of model year 85 ......

40-2

Disassembling and assembling wheel suspension, 86 models onward ..........

40-7

Disassembling and assembling wheel suspension (before and after model year 86)

40-13

Wheel suspension components - installation overview ..................

40-16

Modifications to mountings .................................

40-19

Closing slots in ball joints ..................................

40-23

Inspecting protective caps of ball joints on control arms and track rods .........

40-24

Modified steering knuckle, cars with floating brake calipers ................

40-25

Disassembling and assembling wheel bearing .......................

40-27

Removing and installing spring strut ............................

40-35

Disassembling and assembling spring strut, tools .....................

40-35

Disassembling and assembling non-adjustable spring strut ................

40-37

Disassembling and assembling adjustable spring strut ..................

40-39

Disassembling and assembling adjustable and non-adjustable spring struts .......

40-42

Coil springs for adjustable spring struts ..........................

40-46

Coil springs for non-adjustable spring struts ........................

40-47

Coil springs for non-adjustable struts/effect on car height .................

40-49

Dampers - installation overview ..............................

40-51

Rear Wheel Suspension, Axle Shaft

Technical data

Tightening torques

Disassembling and assembling rear suspension

Disassembling and assembling Hub assembly

Replacing upper control arm mount

Removing and installing spring strut

Disassembling and assembling spring strut

Damper installation overview

Removing and installing axle shaft

Disassembling and assembling axle shaft

Removing and installing rear axle assembly

......

42-01

......

42-02

......

42-1

......

42-7

......

42-13

......

42-14

......

42-15

......

42-l 8d

......

42-19

......

42-21

......

42-29

Wheels, Tires, Alignment

Wheels and tires, pressure

17-inch wheels

Alignment settings

.................

44-01

44-03

44-05

Table of contents

Printed in Germany - XXXV, 1996

Volume IV

Table of contents

928

Page

Sample measuring card ..................................

44-06

Alignment .........................................

44-1

Checking wheel rims ...................................

44-6

General assembly information, tires ............................

44-7

Wheel balancing ......................................

44-10

Installing and removing wheels on car ..........................

44-19

Tire pressure warning system - General .........................

44-21

Tire inflation pressure for vehicles with tire pressure warning system ..........

44-26

Tire pressure warning system short test .........................

44-28

Removing and installing pressure-operated switches (tire pressure warning system)

44-29

Removing and installing high-frequency sensor (tire pressure warning system)

44-32

Removing and installing tire pressure warning system control unit. ...........

44-33

Connector assignment of the control unit connector ...................

44-34

Notes on trouble-shooting - Tire pressure warning system ................

44-35

Tire pressure warning system (RDK) diagnosis. .....................

44-301

Aritiblock System

General

Design - ABS

Components - ABS

Important notes for troubleshooting and ABS test program

Important information for working on cars with ABS

Removing and installing hydraulic unit

Removing and installing electronic control unit

Removing and installing relais

Removing and installing sensors

Removing and installing speed sensor, 86 models onward

45-01

45-03

45-04

45-06

45-07

45-1

45-5

45-6

45-8

45-11

Brakes I Mechanical

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46-01

Technical data

46-02

Technical data, 86 models onward

46-05

Torque specifications

46-08

Table of contents

Prlnted In Germany - XXXV, 1996

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