Porsche 911 Carrera 4 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Porsche 911 Carrera 4 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 1332
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Porsche 911 Carrera 4 Workshop Manual – PDF DOWNLOAD
Structure of the Workshop Manual:
This Workshop Manual describes all of the important operations for which special instructions are required
to ensure proper completion.This manual is essential for 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 all repairs on vehicles, without exception.
Breakdown of the Workshop Manual:
1. Overview of repair groups
2. Record sheet for supplements
3. List of contents
4. Technical data
5. Repair groups
Breakdown of the repair groups:
1. Table of tightening torques
2. Special tools required
3. Exploded diagrams
4. Legends for the exploded diagrams
5. Notes on assembly/application of special tools
6. Diagnosis for the repair groups
- The Workshop Manual will be updated regularly by means of supplements which must be filed immediately
to maintain the usefulness of the manual. Appropriate entries must be made in the record
sheet to prove that the manual is complete. - The content of this Workshop Manual will be supplemented with Technical lnformation Bulletins,
which will be integrated into the manual from time to time.
TABLE OF CONTENTS:
Porsche 911 Carrera 4 Workshop Manual – PDF DOWNLOAD
Volume 1 – Engine, Fuel system 1
CARRERA 4 1
Structure of the Workshop Manual 2
List of Repair Groups 4
Survey of Information published since 1985 5
Table of contents 9
General 12
Technical Data 911 Carrera 4 13
Raising the vehicle 19
Maintenance and self-diagnosis 20
Vehicle maintenance up to model year 91 20
Operating instructions for system tester 9288 56
No diagnosis possible 64
Engine, Crankcase, Suspension 67
Tightening torques for the engine 67
Removing and installing the engine 71
Flanging on and off the engine/transmission assembly 78
Engine, Crankshaft, Pistons 80
Dismantling and assembling the crankcase 80
Dismantling and assembling the crankshaft 83
Normal and rework dimensions of crankshaft 85
Crankshaft-Standard and machined sizes 87
Weight groups of con rods 89
Disassembling and assembling the oil pump 90
Measuring and repairing the crankcase 92
Dismantling and assembling crankcase sections 96
Sealing the crankcase mating sections 103
Crankcase screw connection 104
Removing and installing the belt pulley with vibration absorber 107
Dismantling and assembling double-mass flywheel 109
Dismantling and assembling pistons, cylinders 116
Pistons and cylinders – Dimensions and identification 120
Assembly of piston pin retainer with special tool 9500 and 9500/1 122
Assembling the cooling air duct for cylinders 124
Removing and installing two-piece oil return pipes 125
Checking and adjusting drive belts 126
Engine, Cylinder head, valve drive 131
Engine control 131
Determining parallelity of chain sprockets 136
Dismantling and assembling the cylinder head 144
Camshafts, timing 143
Dismantling and assembling camshaft housing 146
Refacing the cylinder head 150
Replacing valve guides 151
Disassembling and assembling cylinder head 153
Removing and installing valve springs 156
Removing and installing valve stem seals 157
Assembling cylinder head, angle-controlled tightening method 158
Removing and installing the knock sensor 161
Dismantling and assembling hydraulic pump drive (power steering) 162
Engine Lubrication 167
Assignment – relief valve – safety valve 167
Dismantling and assembling the oil pump 169
Replacing oil tank 171
Fuel Supply 173
Checking the delivery quantity of the fuel pump 173
Checking the fuel pressure 174
Removing, dismantling and assembling fuel tank 176
Fuel System, Electronic Injection 181
Inspection and adjustment values 181
Injection system components – Removing and installing DME center section 182
Injection system components – Removing and installing DME lower section 186
Exhaust System 190
Starter, Power Supply, Cruise Control 191
Removing and installing the starter 191
Removing and installing generator 192
Ignition System 197
Accident risks related to electronic ignition systems 197
DME control unit coding 198
DME diagnosis/Troubleshooting 199
DME control units 233
Replacing plug connectors, plug leads and threaded sleeve 234
Determining engine speed sender clearance (Tiptronic vehicles) 237
CARRERA 2 240
Carrera 2 Table of contents 241
Engine, Crankcase, Suspension 242
Removing and installing the engine (Tiptronic vehicles) 242
Removing and flange-mounting the engine-transmission assembly 251
Starter, Power Supply, Cruise Control 253
Removing and installing the starter 253
Volume 2 – Manual Transmission 0
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 0
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmission 255
CARRERA 4 255
List of Repair Groups 256
Survey of Information 257
Table of contents 259
General data 261
Tightening torque for manual transmission G64 265
Tightening torque for front axle transmission Z64 267
Clutch, controls 268
Dismantling and assembling the clutch controls 269
Checking clutch drive plate for wear 271
Removing and installing release bearing 272
Identification of clutch pressure plates 275
Adjusting the clutch pedal 276
Manual transmission, controls, case 278
Dismantling and assembling the gearbox 278
Dismantling and assembling manual tranmission (modifications from 1991 model on) 286
Dismantling and assembling interaxle lock with Valeo inner discs 288
Removing and installing the sealing ring for the drive shaft 298
Dismantling and assembling the clamp plate 300
Dismantling and assembling the distributor housing 304
Dismantling and assembling the transfer box housing (from 1991 model on) 307
Dismantling and assembling the intermediate housing 309
Dismantling and assembling the gear housing 313
Dismantling and assembling the transmission case 316
Adjusting the gearshift assembly 321
Manual transmission, gears, shafts 322
Partially dismantling the gear set 323
Dismantling and assembling the drive shaft 326
Dismantling and assembling the driving shaft 339
Determining the adjusting disk “s” for the hollow shaft 344
Final drive, differential 346
Removing and installing the regulated limited-slip differential 346
Removing and installing contr limited-slip differential (from 1991 model on) 350
Dismantling and assembling the regulated limited-slip differential 352
Dismantling and assembling limited slip differential with Valeo friction linings 360
Adjusting the drive set (rear axle drive) 364
Removing and installing the front axle transmission 376
Removing and installing the center tube 379
Dismantling and assembling the front axle transmission 381
Dismantling and assembling the differential (front axle drive) 386
Adjusting the drive set (front axle drive) 390
PDAS diagnosis (overview) (Porsche dynamic all-wheel control) 404
CARRERA 2 405
911 Carrera 2 – Table of contents 406
Clutch, Controls 407
Technical data 407
Manual transmission, controls, case 412
Dismantling and assembling transmission 412
Removing and installing input shaft oil seal 420
Dismantling and assembling tensioning plate 422
Dismantling and assembling front transmission cover 426
Dismantling and assembling gear housing 430
Dismantling and assembling transmission case 433
Manual transmission – gear, shafts 437
Dismantling and assembling input shaft 437
Dismantling and assembling drive pinion 444
Final drive, differential 451
Removing and installing differential 451
Dismantling and assembling differential 454
Dismantling and assembling drivetorque controlled limited slip differential for Carrera RS 460
Dismantling and assembling limited-slip differential (locking value 40%) 468
Adjusting drive set 475
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 0
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmission 0
Volume 3 – Automatic Transmission 487
CARRERA 4 487
List of Repair Groups 489
Table of contents 490
Clutch, autom , torque converter 492
Technichal data 492
Removing and installing the torque converter 496
Automatic transmission, controls, case 497
Removing and installing the position switch on transmission 497
Adjusting cable for selector device 499
Removing and installing cable for selector mechanism 500
Removing and installing selector mechanism 504
Dismantling and assembling selector mechanism 505
Dismantling and assembling gear selecting system with keylock and shiftlock 508
Removing and installing lift solenoid for shiftlock 511
Removing and installling keyolock bowden cable 512
Checking keylock and shiftlock 514
Removing and installing rear transmission case 515
Removing and installing the intermediate plate 519
Dismantling and assembling intermediate plate 522
Dismantling and assembling the parking lock 525
Dismantling and assembling transmission 529
*Dismantling and assembling transmission 536
Automatic transmission, gears, shafts 543
Checking the ATF fluid level 543
Changing ATF fluid and cleaning the ATF strainer 544
Flushing ATF cooler and lines 546
Removing and installing ATF cooler 547
Removing and installing the inductive spped sendor 552
Removing and installing the wiring harness for the transmission 553
Removing and installing the hydraulic control unit 555
Removing and installing solenoid valves 559
Removing and installing the rotary shaft seal for the ATF pump 562
Removing and installing the ATF pump 563
*Dismantling and assembling 4th gear tower 564
*Dismantling and assembling output shaft and freewheel 569
*Dismantling and assembling clutch E 573
*Dismantling and assembling brake F 578
*Dismantling and assembling brake pack CD with spider shaft 583
*Dismantling and assembling spider shaft 586
*Dismantling and assembling brake C, C’ and D 589
*Dismantling and assembling clutch B 598
*Dismantling and assembling clutch A 603
*Determining the end clearance 607
Differential 0
Dismantling and assembling the long joint flange 0
Removing and installing the rotary shaft seal for the short joint flange 611
Sealing of the driving shaft 612
Removing and installing differential and drive pinion 615
Dismantling and assembling differential 620
Dismantling and assembling drive pinion 623
Adjusting drive set 627
Tiptronic Diagnosis (911 Carrera 2) 640
Tiptronic Diagnosis / Troubleshooting 640
Diagnosis Tiptronic 640
Troubleshooting mechanical / hydraulic section 672
Volume 4 – Chassis 0
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmission 0
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 684
CARRERA 4 684
List of Repair Groups 686
Survey of Information 687
Table of contents 690
Wheel suspension, front, axle shaft 692
Tightening torques for front axle 692
Installation instructions for wheel carrier 695
Dismantling and assembling wheel suspension 697
Removing and installing halfshaft 706
Dismantling and assembling spring strut 708
Wheel suspension, rear, axle shaft 710
Tightening torques for rear axle 710
Notes on recessed spring strut mount from 1991 model on 712
Dismantling and assembling wheel suspension 713
Replacing wheel bearings 719
Removing and installing spring strut 723
Dismantling and assembling spring strut 724
Removing and installing drive shaft 729
Wheels, tires, alignment 731
Wheels and tires 731
Adjustment values for alignment 732
Sample measuring card 734
Fitting 16″ and 17″ cup design wheels to the vehicle 735
Alignment 736
Tire fitting 743
Antiblock system 746
Acceleration sensors for longitudinal and transverse locks 746
Testing ABS in 911 Carrera 4 with ABS 2-LED Tester 751
PDAS diagnosis / Troubleshooting 753
Brakes, mechanical 808
Tightening torques for brake mechanisms 808
Technical data 809
Checking the thickness of the brake pads 811
Removing and installing the brake pads of the four-piston fixed-caliper brake 812
Adjusting the brake pressure rod / checking the brake light switch setting 814
Checking and adjusting the hand brake 815
Checking brake disc lateral runout 816
Checking brake disc thinckness 818
Dismantling and assembling front brake 819
Dismantling and assembling rear brake 820
Brake – hydraulics, regulator, booster 822
Tightening torques for brakes hydraulics 822
Information on four-piston fixed caliper 824
Brake fluid change / Bleeding the brake and lock control 825
Pressure tests on the booster circuit 833
Removing and installing pressure warning switch 837
Steering 841
Tightening torques for steering 841
Replacing the steering in case of accident damage 842
Inspection and installation work on the rack and pinion power steering 844
Assembling the track rods on the steering gear 846
Removing and installing steering gear 848
Removing and installing steering/ignition lock 852
Checking hydraulic operation of the steering system (pressure measurement) 854
CARRERA 2 859
Carrera 2 table of contents 860
Front wheel suspension 861
Wheel hub to wheel bearing screw connection 861
Wheel hub to wheel bearing bolt union on the Carrera RS 863
Antiblock System 868
ABS test on 911 Carrera 2 using ABS 2-LED tester 868
Brakes – mechanical brake system 864
Technical data 864
Brakes, hydraulics – regulator, booster 870
Quickfill brake master-cylinder (bleeding/note) 870
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmission 0
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 0
Volume 5 – Body 872
CARRERA 4 872
List of Repair Groups 874
Survey of Information published since 1985 875
Table of contents 879
Body, general 882
Repair inspection dimensions 882
Special tools and sheet metal working equipment for repairs 887
Safety notes 890
HS steel body panels 892
Body-Front Section 894
Partially renewing the front section 894
Completely renewing the front section 897
End part replacement 905
Partial replacement of wheel house and side member 910
Partial replacement of the fender connection plate 916
Body-Center Section 919
Partially replacing door sill with side member and floor pan 919
Partially replacing door sill with side member 925
Replacing door sill 929
Replacing the complete roof 932
Replacing part of roof 941
Removing cracking noises in the roof rail area 947
Body-Rear Section 950
Renewing the rear-axle cross tube 950
Renewing side panel with inner side section and side member 958
Renewing rear-axle cross-member 967
Partly renewing rear section of body 970
Renewing engine mount 976
Partly renewing side panel 979
Replacing threaded section of oil filler neck 984
Lids 987
Adjusting upper lock section 987
Dismantling and assembling front cover 988
Dismantling and assembling rear cover 993
Doors 997
Dismantling and assembling the doors 997
Adjusting height stop of door window 1003
Bumpers 1006
Removing and installing the front-end panels and bumper 1006
Removing and installing the tail panels and bumper 1010
Glazing, window control 1015
Removing and installing vehicle windows 1015
Removing and installing the windshield 1016
Removing and installing side windows 1022
Removing and installing the rear window 1026
Bonding the interior rearview mirror in place 1031
Exterior equipment 1035
Color range as from model 1989 1035
Color range as from model 1990 1036
Color range as from model 1991 1037
Color range as from model 1992 1038
Removing and installing the rear spoiler 1039
Removing and installing the sill cover 1045
Removing and installing the underbody cladding 1048
Bonding retainer bracket to side member panel 1052
Interior equipment 1055
Safety regulations for handling airbag vehicles 1055
Removing and installing airbag components 1057
Checking airbag system operation 1063
Center console / Information on acceleration sensors for longitud and transv locks 1064
Right-hand front floor sound deadening 1065
Checking safety belts 1066
Correct disposal of airbag units 1067
Replacing horn buttons on airbag steering wheel 1072
Replacing front cover rail and front compartment carpet 1074
Dismantling and assembling the glove compartment lis 1077
Diagnosis 1080
Seats 1107
Checking seat heating 1107
Calibrating controllable seat heating 1109
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmision 0
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 0
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 1140
CARRERA 4 1140
Survey of Information published since 1985 1142
List of Repair Groups 1145
Table of contents 1146
Air-conditioning system 1147
Technical data 1147
Removing and installing components of the heating/air-conditioning system 1148
Dismantling and assembling the heatting/air-conditioning unit 1150
Flap adjustment on the heating/air-conditioning unit 1156
Checking the refrigerating capacity 1158
Removing and installing heating fan motors with built-in heating/air-conditioning unit 1160
Safety regulations for handling the refrigerant R12 1163
Installation work on the air-conditioning system 1164
Modifying wiring loom of heater A/C unit 1172
Technical data as of Model ’93 1173
Pressure and temperature specifications 1174
Diagnosis / Troubleshooting 1176
Instruments, fuel gauge, alarm system 1184
Acceleration sensors for longitudinal and transverse locks 1184
Checking fuel tank sender unit 1185
Radio, telephone, on-board computer 1186
Telephone preparation kits M612 and M195 1186
Retrofitting of a telephone set 1191
Retrofitting of a CD changer 1197
Windshield wipers and washer 1200
Removing and installing the wiper motor 1200
Diagnosis 1202
Diagnosis / troubleshooting alarm system 1202
Volume 7 – Wiring 0
Volume 1 – Engine, Fuel system 0
Volume 2 – Manual Transmission 0
Volume 3 – Automatic Transmission 0
Volume 4 – Chassis 0
Volume 5 – Body 0
Volume 6 – Heating, Ventillation, AC 0
Volume 7 – Wiring 1222
CARRERA 4 1222
List of Repair Groups 1224
Table of contents 1225
Wiring 1226
Additional electrical equipment 1226
Repairing wiring harness No 2 and No 3 1227
Repairing wiring harness No 173 (DME wiring harness) 1231
Wiring diagram type 911 Carrera 4 model 89 1233
Table of contents 1234
Lights 1235
Alarm System, Central Locks, Mirror, Power Window Regulator 1236
Heater, AC, Coolant Fan, Rear Window Defogger 1237
ABS, Porsche Dynamic AWD Control 1238
Motor, Fuel, Ignition, Cruise Control 1239
Instruments, Sender, Central Informer 1240
Seats 1241
Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners 1242
Radio 1243
Fog light, Rear fog light 1244
Central electric 1245
Contruction Components 1246
Plug Connections and Ground Points 1247
Wiring diagram type 911 Carrera 2/4 model 90 1250
Table of contents 1250
Lights 1252
Alarm System, Central Locks, Mirror, Power Window Regulator 1253
Heater, AC, Coolant Fan, Rear Window Defogger 1254
ABS, Porsche Dynamic AWD Control (Carrera 4) 1255
ABS Carrera 2 1256
Motor, Fuel, Ignition, Cruise Control 1257
Instruments, Sender, Central Informer, On-board computer 1258
Seats 1259
Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top 1260
Radio 1261
Fog light, Rear fog light 1262
Central electric 1263
Contruction Components 1264
Plug Connections and Ground Points 1265
Trailer Coupling 1266
Rev-meter, On-board computer, Airbag 1267
Tiptronic (Carrera2) 1268
Wiring diagram type 911 Carrera 2/4 model 91 1270
Table of contents 1270
Lights 1272
Alarm System, Central Locks, Mirror, Power Window Regulator 1273
Heater, AC, Coolant Fan, Rear Window Defogger 1274
ABS, Porsche Dynamic AWD Control (Carrera 4) 1275
ABS (Carrera 2) 1276
Motor, Fuel, Ignition, Cruise Control 1277
Instruments, Sender, Central Informer, On-board computer 1278
Seats 1279
Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top 1280
Radio, Telephone 1281
Fog light, Rear fog light 1282
Central electric 1283
Contruction Components 1284
Plug Connections and Ground Points, Abbreviations 1285
Trailer Coupling 1286
Airbag 1287
Tiptronic (Carrera 2) 1288
Wiring diagram type 911 Carrera 2/4 model 92 1290
Table of contents 1290
Lights 1292
Alarm System, Central Locks, Mirror, Power Window Regulator, Inside Lights 1293
Heater, AC, Coolant Fan, Rear Window Defogger 1294
ABS, Porsche Dynamic AWD Control (Carrera 4) 1295
ABS (Carrera 2) 1296
ABS Turbo Look (Carrera 2) 1297
Motor, Fuel, Ignition, Cruise Control 1298
Instruments, Sender, Central Informer, On-board computer 1299
Seats 1300
Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top 1301
Radio, Telephone 1302
Fog light, Rear fog light 1303
Central electric 1304
Contruction Components 1305
Plug Connections and Ground Points, Abbreviations 1306
Trailer Coupling 1307
Airbag 1308
Tiptronic (Carrera 2) 1309
911 Carrera RS 1310
Wiring diagram type 911 Carrera 2/4 model 93 1312
Table of contents 1312
Lights 1314
Alarm System, Central Locks, Mirror, Power Window Regulator, Inside Lights 1315
Heater, AC, Coolant Fan, Rear Window Defogger 1316
ABS, Porsche Dynamic AWD Control (Carrera 4) 1317
ABS (Carrera 2) 1318
ABS Turbo Look (Carrera 2) 1319
Motor, Fuel, Ignition, Cruise Control 1320
Instruments, Sender, Central Informer, On-board computer 1321
Seats 1322
Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top 1323
Radio, Telephone 1324
Fog light, Rear fog light 1325
Central electric 1326
Contruction Components 1327
Plug Connections, Ground Points, M-Numbers, Abbreviations 1328
Trailer Coupling 1329
Airbag 1330
Tiptronic (Carrera 2) 1331
911 Carrera RS 1332
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V