Workshop Manual Curbo Carrera DR. ING. h. c. F. PORSCHE AG STUTTGART-ZUFFENHAUSEN US = Onder No. WkD Edition 1976 Printed in Germany Subject to changes.TURBO CARRERA REPAIR MANUAL ‘This repair manual describes all of the important operations for which special instructions are required to assure proper completions, This manual is essential for the shop foremen and mechanics, who need this information ta Keep the vehicles in a safe operating condition, ‘The basic safety rules, of course, also apply to repairs on vehicles without exception, ‘The Turbo Carrera Repair Manual onty describes repair operation: 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 register table are quick guides to find information in the manual . Descriptions of design and function can be found in service training course reference material, ‘This repair manual will be Kept up to date with workshop bulletins; the information in these bulletins will be made part of the manual from time to lime. We recommend that the Workshop Bulletins be filed in the special folder provided for this purpose,REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL ‘Turbo Carrera Please file the supplements according to repair groups and make appropriate entries in the table below. Supplement No. Filing Date Signature m vi a = vt vu i x1 xu xu xvELECTRICS GENERAL ‘Technical Date Page REPAIR GROUP Engine-Crankease 10 Engine-Crankshatt/ Assembly as Engine-Cylinder Head and Valve Drive 1B Engine-Lubrication a Engine-Cooling 19 ENGINE Fuel Supply system 20 Turbocharger a Fuel system (CIs) 25 Exhaust System 26 Starter, Power Supply 20 Ignition System 28 Clutch, Control 30 paaws Manual Transmission-Controls and Case 34 ras Manual Transmission-Gears and Shafts 35 Differential 29 Front Whee! Suspension 40 Rear Wheel Suspension 42 chassis Wheels, Tires, Alignment 44 Brakes, Hydraulic Components a Steering 48 Body-!vont Section 50 Bady-Center Seetion 51 Body-Rear Seetion 38 Lids 56 Doors 57 BoDy Sliding Roof 60 Bumpers 63 Glasses 6 Exterior Fittings 86 Interior equipment 68 HEATING, VENTILATION, Hester 80 AIR CONDITIONING Air Conditioner 7 Instruments, Radio 20 » Windshield Wipers and Washer Exterior Lights Interior Lights wiring930-turbo Alphabetical Index Alc filter, removing/installing (1978 mode!) ‘Air flow sensor plate, rest position, checking Air injection, disassembling/assembling 1978 mode! Air injection lines/adapters, removing/installing Air pump «air filter - drive belt, checking/adjusting += removing/installing Automatic heater control ~ checking = removing/installing Auxiliary air valve, removing/installing Auxiliary air regulator, removing/installing ‘Axle alignment specifications Body repair reference points =1978 mode! Boost pressure, checking Boost pressure gauge, checking Brakes - Mechanical Parts Brake pads - remove and install Brake pad thickness - check Brake system -911 Carrera Turbo Look Front wheel brakes - changes for Turbo 3.3 Ltr Front wheel brakes - disassemble and assemble Rear wheel brakes - disassemble and assemble Technical date Tightening torque Brakes - Hydraulic Parts Brake calipers disassemble and assemble Brake caliper sections - disassemble and assemble Brake ciruit failure indicator ‘Tightening torque Page 25-19 25- a 26-12 26-24 28-19 26-17 26-28 26-16 80-5 80-1 25-18 25-10 ees 45-2 46-1 46-04 6-40 48-5 46-11 46-01 46 -03 47-12 47-01 Printed in Germany - V, 1984Alphabetical Index Center console, removing installing Check valve, checking Clutch ~ adjusting (1977 moded) = adjusting (19 7% mode = assembly ~ assembly (398 model) + auillary release spring (1978 model) Control pressure, checking = cold = warm, full thottie enrichment (2978 model) contol valve, checking Control vatve (air injection) removing/ installing CCeankshatt Jounal, dimensions (1978 model) CCuzrent flow diagrams Cylinder air guide plates (1978 model) Differential disasembling /assembling = disassembling assembling (1978 model) = Limited slip = removing /inetalling Distributor, checking Diverter valve = checking > removing installing Drive pinion = adjusting ~ disessembling/assembling Drive shaft = disascmbling assembling = oll seal, removing/installing Page oe 26 = 20 0-7 50-18 a+ 2 30+ 8 20-11 25-18 25-13 25-14 26-20 26-18 nea oT a 1-6 30-5 w+ Ba woo m- 2 5 26-18 39-9 35-15 35-9 35-19 es 2 Printed in Germany930-turbe Alphabetical Index Electronic speedometer checking sensor, removing/installing Engine + hood, removing/installing + Femoving/installing Engine/transmission, detaching/attaching 1978 model EGR filter, removing/installing EGR valve ‘checking + removing/installing Exhaust system + disassembling/assembling layout + reactor, removing/instaling Floor assembly, front Floor/frame assembly, dimensions Floor/frame, front end gauge P 863 Flywheet machining removing/installing Front axle clisassombling/assembiing ~removing/installing Fuel delivery rate for control pressure circuit, checking Fuel injection (CIS), testing/adjusting pressure gauge, connecting/bleeding system pressure Page 90- 3 90-4 55-1 10-4 10-4 10-8 26-21 26-22 26-21 26-2 26-1 28-5 50-4 50- 2 50-1 13-3 13-3 40-3 40-1 25-14 28-15 25-12 25- ida Printed in Germany - 1M, 1981Alphabetical Index 930-turbo Page Fuel pump = delivery rate 20-1 + pressure 20-1 removing and installing 20-5 Fuel system 25-1 Hose layouts “USA. 26-29 = California 26-30 lle, adjusting 25-7 1978 model 25-108 Ignition (electronic troubleshooting 2-6 Ignition delayed cutoff 28-13 Ignition system (1978 model) 28-14 Ignition timing, adjusting 28-1 = 1977 made! 28- 2a 1978 model 28- 2b Ignition timing, checking 28-3 +1977 model 28- 4a 1978 mode! 28- 4c Intake air intercooler, removing/installing 21-21 Manifold pressure limiting switch, checking au Mixture control unit = fuel distributor 25- 8b = pressure relief valve 25- 6 removing/installing 25-6 lal pressure valve 25- Be 4 111, 1981 - Printed in Germany930-turbo Alphabetical Index il pump (1978 model) Pistons/Cylinders checking dimensions/instalation notes ddimensions/installation notes (1878 model) ‘weight classes 911 Turbo (1980 model) Pop-off valve/housing, disassembling/assembling Roar axle ‘ross tube dlisassombling/assembling removing/installing Rear fender decal, installing Rear wheel bearing, adjusting Rear wheel bearing play, checking Relay, locations Ring gear adjusting backlash shim thickness Steering, disassembling/assembling Straightening bench attachments for 930 Turbo ENS 77.903 Technical data bbrakes(hydraulic components) brakes (mechanical components) engine = front suspension general rear suspension steering wheels/tires Page 13-6 13-2 13-1 13-7 13-9 21-6 53-1 42-3 42-1 66-3 42-13 42-14 90-1 39-19 39-17 43-1 80- 7a 47-01 46-01 10-01 40-01 on 42-01 48-01 30-01 44-01 Printed in Germany - 1V, 1984General TECHNICAL DATA (Refer to appropriate repair group for adjusting and wear Limit data.) Engine Internal engine code 990/51 from Aug. 1976 930/53 Bore mm/inch — 95/3.74 stroke mm/inch ——1044/2."7 Displacement min. 2999/182.64 Compression ratio 6.521 Homepower SAE Net He 234 at engine speed of +5500 rpm Printed in Germany = 1978 ‘Technical Data otGeneral ‘Torque SAE Net Nan/fty the Output per ister KW/HP Max, engine speed rpm ‘Max, engine cruising speed rpm Cutoff speed of speed limiter in distetbutor ‘pm ‘Weight of engine with air cleaner (é#y) bg Engine Design crankease Geanishaft Grantshaft bearings Connecting rods Connecting rod bearings Piston pin bushings Intermediate shaft bearing: Pistons Piston pins Tiston rings Cylinders Cylinder head Valve sest Snserts Vaive guides Location of valves per cylinder Exhaust valve Valve springs Valve axive Camshaft Camshaft érive Engine cooling 282/28 at engine speed ‘of 4000 rpm 58/82 e700 000 00 200 aunyaTs iecast, Light alloy, two-piece Forged, journals surface-hazdened ight, plain Forged stect 2 layers split inserts Pressfit bronze 2, plain Forged light alloy, slipper shit Floating, secured by eirelips 2 compression rings, 1 oil sereper ing Light alloy, Nikasit coated Light attoy Shrunk-in, enneated sintered steel res fit, special bronze 41 sntake and 1 exhaust valve ‘overhead in V Sodium filled, reinforced seat 2 coll springs per valve ‘One each overhead camshaft, Teft and right Cast, 4 bearings, runs directly oa camshaft housing metal coain “Ait cooled by axsst Zan on alternator shaft 0.2 Technical Data Printed in GermanyGeneral Cooling fan drive Crankshatt/blower ratio Air flow rate Engine Lubrication lt cooling i filter Ol pressure at 5500 epm bar/pst Ot pressure gauge Max, oil temperature ll consumption at./600 mi. Exhaust System 930/81 (930/53 Heating Fuel System Fuel supply’ Fuel octane RON Electrics Battery voltage v Battery capacity An Alternator/output w Ignition ‘Transformer Firing order Brakes Foot brakes Front brake dise diameter mm Y-Belt from crankshaft approx, 1: 1.67 41560 Its/see at 6000 crankshaft rpm ‘Thermostatic control, oil cooler on crankease in fan ait stream, cooling colls in front right wheel-hovsing Full flow approx, 4.0/60 at 80°C (176°F) Hlectric approx, 150°C /300°F approx, 1,0 t0 2.0 double pipe system with turbocharger, waste gate, 2 reactors, muffler, air pump same as 980/81, but with EGR) Hot air heater with automatic temperature control, 2 electric roller-type pumps connected in series 91 - 96 (premium grade) w 6 80 CDI (breakerles) Basel 1 6224-375 hydraulic, dual-cireult dise brakes with power booster 282.5 vented SS Printed in Germany ~ 1, 1976 ‘Technical D: 0.8Rear brake disc diameter Effective front brake dise dia, Effective rear brake dise ofa. Front brake dice thickness Rear brake disc thickness ‘Total effective braking surface: Pad surface per front wheel ad surface per rear wheel Front caliper piston dia Rear caliper piston dia, Parking brakes Parking brake drum dlameter Brake shoe width Effective braking surface per wheel Power brake booster Pressure ratio Pedal « fo (mechanical) Dimensions Length wide Height Wheelbase rout track Rear track Grouné clearance (ful! 102¢) Curved ground clearance Front approach angle (Limited by spotter) Rear departure angle (limited by apron) Weights Curb weight Max. total weight Max, front axle lose Max, rear axle load Payload Max, roof load including roof luggage carrier 2 280 vented 228 2a 20,5 20 Mechanical, on rear wheels a0 25 8s Teves, Type T 52/7 (DIN-Curb Weighty mrafineh mm/ineh rom tnch smom/inch mm/ineh mam/toeh ram/ineh som/inel, (DIN T0020) kg/lbe kg/bs g/ibe kerbs kg/lbs kg/ibs 4291/188,94 1775/69,88 1940/52, 76 2272/89,45 1431/58.34 1501/5909 195/8,10 100/294 ae as? anaoosie 1400/3087 200/189 2840/1859, 205/462 35/17 without exceeding max. total weight 04 ‘Technical Data Printed in GermanyCapacities Engine (as measured with ofl dipstick according to Owner's Manual) ‘Total ofl capacity of system cooling coils Oil change capacity ‘Transmission and differential Fuet tank Brake fluid Windshteld washer Performance ‘Top speed Acceleration from 0 = 100 Xph/62 mph Km ftom standing start Weight per horsepower Hill elimbing ability in % ‘4>speed transmission General Brand name heavy duty oils meeting AP! Classification SD of SE with a viscosity of: SAE 90 for summer, SAE 20 for winter, SAE 20 W 20 for permanent temperatures betw, = 15° and 0° ¢ (+ 8” F and 92” £) or SAE 10 W for permanent temperatures below 15°C (+ 5° F) It/at approx, 19/19.8 teat approx, 10/10,6 Refer to page 90 ~ 05 lt/gal. 80/2141, 8 Liters/2,1 gal, in reserve i/pt approx, 0.2/0442 /gal. approx. 845/242 mph Above 152 sec 5,7 DIN curb welght + oe 25,0 1/2 payload 1b. /HP on Ast gear over 100, Princed in Germany Qnd gear 47 ard gear 28 4th gear 16,5 Technical Data 0.5General TECHNICAL DATA - 1978 MODEL (Refer to appropriate repair group for adjusting and wear limit data) Engine Internat engine code 930/61, Cal. 930/63, from 1979 models 930/64 Bore mmfineh 97/3.82 Stroke mmfinch 74.4/2.93, Total displacement em? inch? 3299/201.3 Compression ratio 70:1 Printed in Germany - III, 1981 Technical Data o7eee Torque SAE net Nee ibe Output per iter sew /He Max. engine speed ‘pm Max. engine cruising speed rpm Governor cutoff speed som {in distrisutor) Engine weight (dry} with muffler kgfibs Engine Design Type Cooling System Crankease Crankshatt Grankshstt bearings Connecting od bearings Oylinders, individual ‘Arrangement of valves per cylinder Valve actuation ‘Camshaft drive Camshatt bearings Cooling fan drive Crankshaft/blower ratio Fuel supply Mixture Induetion system ‘395/291 at engine speed of 4000 rpm 67/01 6700 6000 7000% 200 240/529 4 stroke internal combustion Air Light alloy Forged 8 plain main bearings Pain boarings Light alloy 1 intake valve 1 exhaust valve Vee configuration, overhead One each overhead camshaft OHG, left and right Chain Plain, directly on camshaft housing V-belt from crankshaft Approx 1: 1.67 Dry sump with separate oil tank thermostat controlled oil cooling and full flow oil filter, cooling coils in front right wheet house eleétrie pumps in series connected Continous injection system (CIS) KKK exhaust turbocharger SS 0.8 Technical Data Printed in GermanyGeneral Electric system Battery voltage Battery capacity Alternator output Ignition system Firing order Exhaust System Heating Dimensions Wheel bate Front tack width Rear track width Length wish Height Turning elrele dis. Ground clearance, full load Weights Curb weight Max, total weight Max, frot axle Load 1 rear axle Load a Ah (at DIN curb weight mm/ineh mm/ineh ‘mun/ineh m/inch mn nels mm inch mitt mm/inch (DIN 70020) kg/los kgs kgflbs kg/s 980 CDI (breakerless) 1- 3-5 Single pipe system with torbocharger, waste gate, muffler, air pump and 2 reactors Automatic temperature control for heater 2272 / 89.45 3432 / 56,98 1501 / 59.09 4291 / 168.94 1775 / 69,88 1528 / 52,28 20.7 / 5,20 320 /4, 1295 / 2855 3500 / 9807 e25 / 1978 900 / 198 ee Printed in Germany - 11, 1978 Technical Data 0.9General Capacities ‘Total amount of oll for system with cooling coils Amount for ofl change Amount of oil between min. and mex, marks on dipstick ‘Transmission + differential uel tank rake fluid tani Windshield washer Performance ‘Top speed Acceleration 0 = 100 km/ty (0-62 mph Kim fom standing start ler/at Approx. 19/14, exact amount determined by reading on off dipstick, measured with ‘engine running at idle speed and operating temperature e/a ‘Approx. 10/12 r/at Approx. 2/2 Sand name heavy duty olls for Internal combustion engines acc, to API Classificstion SE. Use following viseostty multi-geade ofls for year round operations (oll chenge every 25, 000 mt, /24, 000 kam) SAE 10 W/50, 15 W/50 of 20 W/50, Do not ube latter oll for constent tempezetures below = 15° C/+ 6°, Brand name single grade olls of AP! Classification SE should only be used when Iultigrade oll are not available and nosmat operating conditions Prevail. The use of such oils will require observance of additional change intervals according to season of year to prevent any damage. Use SAF 80 off fr summer and SAF 20 W for winter (only at ‘constant temperatures below + 6° C/+ 42°F). See page 20 - 05 Ie/at 80/21, of which @ 1tr/2 US gel, in reserve Ie/pt AppION. 0.2/0.4 evga. Approx. 8.5/2.2 ken/h / mph 250/155 5 5.6 DIN curb weight + 1/2 payload : m0 Ss 0.10 ‘Technical Data Printed in Germany10 ENGINE-ASSEMBLY Printed in GermanyGen ea 10 TECHNICAL DATA ~ ADJUSTING AND WEAR LIMIT DATA ENGINE VALVE DRIVE ‘Tappet clearance (cold engine) intake O.20 mm (measured betwe_ valve and rocker arm) Exhaust 0.10 mm ‘Timing at 1 mm tappet clearance Intake opens 3° aTpC. Intake closes Paspc Exhaust opens at°pBDc Exhaust closes 5° ppc Intake valve stroke in TDC overlap at 0.1 mm tappet clearance 0.85 ~ 0,80 mm Valve spring installation lengths Intake valve springs gg. + Exhaust valve springs Ignition Ignition Timing Adjustment (engine ofl temperature at least £09 C) Engine Type 990/50, 990/52 297 2 DTDC on crankshaft at 4000 spm (vacuum hove disconnected) Engine Type 990/51 (USA) 518° ATDC on crankshaft at 950 £ 50 2pm (vacuum ote connected) Engine Type 990/58 (USA) 7 £99 ATDE on crankshaft at 1000 2 50 spm (vacuum hose connected) Engine Type 980/54 (Japan) 15? 2 ATDC on crankshaft at 1000 > @wacuum hose connected) (Check ignition timing acvance (gnition timing must be adjust first) Engine Type 990/50, 920/52 0-8 49 on crankshaft at 900 + 60 spm {vacuum bose connected) Printed in Germany ~ IV, 1981 Technical Data 10-0110 General Information Engine Type 930/51 (USA) Engine Type 930/53 (USA) Engine Type 930/54 (Japan) ‘Spark plugs (electrode gap in mm} SINCE 1978 MODEL, TURBO 3.3 26 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) 29 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) 20 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) Bosch W 280 P 21 (0.6) IGNITION ignition Timing Adjustment (Engine Oil Temp, at Least Engine Type 930/60 Engine Type 930/61 (USA), 930/64 (USA) Engine Type 930/63 (California), 930/62 (Japan) 930/65 (Japan) Engine Type 930/66 Engine Type 930/68 (USA) Checking Ignition Timing (Ignition Timing Adjusted First) Engine Type 930/60 Engine Type 930/61 (USA) 930/64 (USA) Engine Type 930/63 (Californi 930/62 (Japan) 930/65 (Japan) Engine Type 930/66 Engine Type 930/68 (USA) 80° C) 29° before TDC at 4000 rpm [vacuum hose disconnected) 10 + 2° after TDC at 1000 + 50 rpm {vacuum hose connected) 5+ 1° after TDC at 1000 + 50 rpm {vacuum hose connected) 29 £ 1° before TDC at 4000 rpm (vacuum hose disconnected) 26 £ 1° before TDC at 4000 rpm {vacuum hose - red - disconnected) 0 # 2° at 1000 + 50 rpm {vacuum hose connected) 26 4° before TDC at 4000 rpm (vacuum hose disconnected) 31+ 4° before TDC at 4000 rpm (vacuum hose disconnected) 22° before TDC at 900 + 50 rpm (vacuum hoses connected) 1+ 2° after TDC at 900+ 50 rpm (vacuum hoses connected) 10-02 Technical Data VI, 1985 Printed in Germanycenerst 10) TORQUE SPECIFICATIONS FOR ENGINE Toraue Locetion Toresds | Nm fw Conrod mus" w10%126 | 60-55 36-40 Crankease w10 35 25 All bolts on crankcase and camhatt ma 25 8 owsing Oil iter screen cover ute we 10 7 Fiywnel wiaxts | 150 to8 trom 1978 nods Mioxi2s | 90 6 Bush and eed orig to cranks Ms 10 7 Pally to craniat miaxis | 0 38 {without ar condone) Double-et pulley to crane miaxts | 170 123, (with air conditioner) Sater vl plug to exankeae miexis | 60 23 Pressure allt vale plug to crankeae miaxts | 60 8 Adapter (on neck foro presure mia! | 3s 25 transmier to erankease ‘per in crankease return line mraxt | 20 87 Cylndor head nu tO socket | 33 2 Rocker arm sett MBsockat | 18 3 Aut on camshaft marx2, | 50 108 Bot on camshaft miaxie | 120 87 Cover to camshat housing me 8 8 Adapter on evlinde hex mioxt | 15 " tir inection) Ait line coupling on adaotr uxis | a2 6 Reactor to cylinder head me 20-28 we Spark plug miaxi2s | 25-30 18-22 Intake manifold me 25 | 3 | “Threads and bear surfaces lubricated with oil. ** Threads of eylinder head nuts coated with Optimoly HT. Printed in Germany ~ 111, 1981 Technical Data 10 0310 conere Toraus Loaation Trweods | Nm nb Consol for engine caer M10 “0 23 Wide clamping stap on blower houtng we es 5 we 12 8 Pulloy to stormator miex1 | aosev, | 20 Altern teu {Morro} miaers | aden | 20 Olt pressure contol switch to wrod | mox20 | max tt erankease Temporature transmitter to erankoase wraers | mox28 | mois | Ot pressure transmitter to adapter wieets | oe3s | mac 25 Volume transmitter (for oil level MS 24 7 | indieato to ol tank | Olt drain pug (to over for a maxis | a2 ~ finer econ) Oil drain plug (oil tank} M22x15 42 30 Oi ines to engine, lank, maox1s | 80-100 | 59.72 governor housing, ol eocer or | pipe ol cooler 1 Al bolts for exhaust system coated with Optimoly HT. 10-04 Technical Data Printed in Germanyroots we] Deserpcon syectat Tost | Remata T_, ‘ie wth appar plate - a | engine otaer i 11d see next page 2 | Adaperreagactaaer | uss Printed in Germany = 1, 1978 Removing and Installing Sngine10 Engine - crankcase Toots ‘« : : }#100 >| | 2 eo aa eee 7 4 2 é aueHee it ° cae lo 45° eg 14 5245" & No.] Deseription Special Tool Remarks a | engine notder oma modified 2 | support plate on1i/1 2 Removing and Installing Engine Printed in GermanyEngine- REMOVING AND INSTALLING ENGINE ‘The engine and transmission assembly is lowered to remove, ch up car Disconnect ground cable at battery 8, Remave air cleave engine block vent hose a pull off and plug opening at vent cover 5, > Cars with air conditioning only ~ Retach compressor atc: st connected to the hoses in the ear. engine wires at relay plate, at adapter plug, fee) sists ssceet aoa Quitian cone ae? caution ‘The alr conditioner system must be discliarged ff the comprersar hoses are disconnected BN Printed in Germany ~ Removing and Installing Engine 10-310 treine-crastcase 17. Unseren fuel hoses at filter end retura line, 8, Disconnect accelerator Linkage. 14, Loosen heater hoses at heat exchangers, and poll off. 8. Loosen rear tunnel cover serews and remove cover, 15. Remove rear stabilizer, 10, Pull boot off of body and slide it for over the selector rod. 16, Loosen ground strap at body. 11. Loosen socket head at screw of shift rod coupling and pull coupling off of the eats aad Li, Disconnect battery wires at starter. 18. Diseonnect accelerator linkage at operating lever. 18, Disconnect en cable at transmission, From 1977 Models ~ see figure. 132, Pull off wires of electronic speedometer sensor in funnel and remove rubber plug with wize plug. 18, Drain engine off and plug ol! hoses on ‘engine and oil tank, 10-4 Removing and Instalking engine Printed Ia Germany20, Loosen drive shait flange socket head 22, Looten engine carrler bolts, screws at transmission, 24, Lower car jack with engine/transmission assembly carefully and back it out. 21, Place car jack with appropriate attachment underneath engine/trans~ mission assembly at center point of gra~ vity and apply a little pressure. Caution Be careful not te damage secondary air injection pipes. Caution Ifthe car i moved with the engine transmission unit removed, the delve shafts must be suspended horizontally to prevent damage to dust covers. 22. Looten transmission carrier bolts. Printed in Germany = I, 1978 Removing and Installing Engine 10-510 tesioe-createsse Installing (Observe the following instructions when installing. 1. Caution! Don't clamp the heater ho necessary, slide them on the heat exchangers just before the engine/ ‘assembly is in its final position. 2, Torque specifications: Engine and transmisslon ccattler hex head screws 9.0 mkg (68 fb) Drive sha /Mange fil~ ster bead capscrews 8.8 mkg (60 F115) 2, Adjust elutch ~ see Repair Manual @11, Group 7, Page 3. 10-8 ‘Removing and Installing Engine Printed in GermanyDETACHING AND ATTACHING ENGINE AND TRANSMISSION Detaching 4, Poll transmission off of engine. 4, Remove wites st starter end backup Light switen, Attaching 2, Remove clutch retease lever cirelip and take off lever and rubber ring. Observe the following points, Clutch selease lever does not have to be removed from 3877 Models, 4, Coat all bearing surfsces of clutch release and drive shaft splines with @ multi-purpose lubricant containing McS,. 2, Place hub part of relesse bearing vertical and engage release fork when attaching 10 tub section, Check if in correct position through opening in transmission ease, Tersion relesse lever to keep bearing in place, 3, After attaching the engine and transmission, slide on release lever parallel to holder of clutch eable sleeve. 4, Torque engine mounting bolts and nuts to 4.5 mkg (39 ib). Printed inGermany - [, 1976 Detaching and Attaching Engine and Transmission 10-7Crankeas! 10 engine DETACHING (4978 MODEL) ND ATTACHING ENGINE/TRANSMISSLON UNIT Detaching 2, Place hub of release bearing upright end engage fork on ab when attaching. Chee sition through opening in transraisston 1, Disconnect wires frota starter and backup Light switeh, Remove clutch release spring, see page $0 - 12, Unscrew engine mounting bolt and auts, « Install clutch release spring, see page 90 = 12, 4, ‘Tighten engine mounting bolt and mts to 4,5 mikg (88 ft 1b}, Attsehing Note the following pots, ‘Le Gost all sliding surfaces of eluteh release as ‘well as splines of drive shaft with MoS multi-purpose grease, 8 —_Detaching and Attaching Engine/ Ii, 107 ~ Printed in Germany ‘Transmission Untt13 GINE-CRANKSHAFT ASSEMBLY printed ia GermanyEngine-crankshaft and moving parts 13 PISTON AND CYLINDER SIZES -930 TURBO Cytinder Cylinder Piston Di Cose Disa, in mm in mm Standard Size Stamped ° 95,000-95.010 94.938. 94947 1 96.010.95.020 94.943: : | 94.957 v 2 95.020.95.030 94.953 94.967 Clearance between cylinder and piston: 0.053-0.077 mm PISTON INSTALLATION NOTES Because the piston pin bore is offset, the piston - ‘must be installed correctly. The installation mark . ‘aces the clutch - see figure, x Printed in Germany Piston and Cylinder Sizes 13-1 Instaietion NotesCHECKING PISTONS AND CYLINDERS Cylinders D1 = Measuring point for wear and ovality ZF 20 mm below upper edge of evlinder sy = ‘The cylinder is worn if the measurement is 0.08 mm more than the size at instalation. eee ‘Measurements aro made in directions @ and ® to check ovality. The amount of deviation between @ and b should not exceed 0.04 mm. D2 ~ Measuring point for piston ring end gap Rings sid in at height of eylinder base gasket Pistons D = Measuring point for west ‘At lower edge of piston pin bore. Caution! Replace piston and cylinder if clearance ‘exceeds 0.15 mm. PISTON RING END GAP Piston Ring End Gap in mm, End Gap in mm (now {wear limith Compression ring, and Ud 015-03 og Ol seraper ring, uu 018-03 10 {see measuring point "02") PISTON RING SIDE CLEARANCE Piston Ring Side Clearance Side Clearance inmm (new) In.mm (wear limit) ‘Compression ring, 1 0.070 -0.102 02 ‘Compression ring, 1 0.040 0.072 02 il scraper ring, Hl 0.020 - 0.052 on 13-2 Checking Pistons and Cylinders 1, 1981 - Printed in GermanyFoe esi ess NEVTPEN SURF REMOVING AND INSTALLING FLYWHEEL Removing Installing 1. Loosen Alywheel mounting bolts (using special «1. The contact surlaces of crankshaft, flywheel tool P 238) and remove flywheel (take off inner and washer must be free of grease. stop pin of P 238), 2, Torque mounting bolts to specifications, MACHINING FLYWHEEL If severely scored or burnt, the Aywheel can be machined on a Lathe, ‘The ehip size should be kept as small as possible. Flywheel thickness wear limit is 9.9 mm. 3 Max, runott 0,1 mun 4 Lathe mounting points 1. Wear Limit 2 Smallest chip siz paving and installing Flywheel 19-3 Printed in Germany Macaining FlywheelEngine - Crankshaft and moving parts 13 vesresr*vnu6"es O66"RH"""TL6' way | Orr one"PS"* "122" oFe"eg***TZE" Es BE SE | wro- Be SE 008"63"* one" o0"65"*7083 "68 eoH'0s**onnrow ogres" runes ooraerurres «=F TB | ogy erro onvestrehee overages = BL cory = 090" *"090"82 NEs"EE"*"NBB"EE cIO"eE***t00"s GO0%O6***o8LGa EDUTEST*-os6"oR oGeteS"*-rLEHE oBstest tutes «= Bosepanis oP 3a pura suena zp venom, yoog form p "ea 809 > op teasnor of Boe) Ep steeof «get reBupzeag] ure Sorvog gen yeumaery — Super 9} 9S ourMf og NO = BuAEOG MEY peu HepIooMUOD —ujeaN MEN TI aIOqaseoyHerD] ante sazis¥sana (report ar 6rd aNv auvanvus - syxvao I, 1978 -Printed in Germany Crankshaft SizesAewemy uy porwtid eur M - soars apeysieei gest A Surface finish Paint dot Grind crankshaft ofl seal surfaces only when deeply scored, Grind to dimensions of 29,5 mm and 6.5 nam respectivel Otherwise polis out to 3 microns, AMler grinding, chamfer ofl Holes to 0, 5 smn radius, teak all sharp edges to 0,2 - 0,5 mo radius, Mawiomuea zadiel runout measured at bearings 1 and 7 is 0.04 mm, ‘Tenlfer treat cranishatt after grinding, Magnaflux to check for cracks, Do rot straighten hearing journals 9 and 5 after ‘niles seatmnent AIL other main bearing Journals eau be straightened by applying pressure to the bearing ournal webs Undersize color eoder dst undessize 2nd undersize Std undersize 4th undersize surface finish Page deburred blue paint dot _areen paint dot yellow paint dat white paint dot qyeusquery ‘aveoyuer ‘auydog el13 rocine, cranrense, crantkstatt Layout of Oil Pump - 1978 Modet Installation of Cylinders and Air Guide Plates 1978 Model 33-6 OW Pamp Printed In Germany Gylinder/Aic Guide PlatesEngine Cranksnote Pistons — JB PISTON AND CYLINDER SIZES - 1978 MODEL Cylinder Cylinder Dia. Piston Code inmm Dia, 0 in mm Stamped ° 97.000 -97.007 96.850 96.860 1 97.007 -97.014 96.357 96.867 2 97.014 -97.021 96.864 96.874 3 97.021 -97.028 96.871 96.881 7 ylinder/piston clearance: 0.025 - 0.052 mm. Printed in Germany - HII, 1981 Piston and Cylinder Sizes 13-715 ENGINE-CYLINDER HEAD AND VALVE DRIVE Printed in Germanyengine-cylinder Head Vatvedrive 15 CHECKING INSTALLED LENGTH OF VALVE SPRINGS Checking Note ‘Set tool P 10.¢ 10 “33,6”, 4. Install special tool P 10 ¢ with shim corres- ponding to valve, spring support washer, spring retainer and both valve keepers. 2, Read distance “A” on special tool P 10 ¢ and, if necessary, correct by removing or installing shims. Installation Sizes \nstll length of intake valve springs Install length of exhaust valve springs ADJUSTING TIMING Intake valve lift at TDC overlap with 0.1 mm valve clearance is 0.65 ta 0.80 mm. ADJUSTING VALVES Valves are adjusted with engine installed in car. Only following parts are removed air cleaner, relay plate cover, diverter valve and air pump. From 1978 Model, intake ait intercooler also has to be removed. REMOVING AND INSTALLING CHAIN TENSIONER, ‘Chain tencioners ean only be replaced after removal of engine. Printed in Germany - 1, 1981 Valve Spring Installation Data 16-1 Adjusting Timing20 SUPPLY Printed ia GermanySe () TOOLS No. Desexiption Special Too! Remarks Connecting aéapter ous For testing both fuel pumps in cconjunetion with P 978 Printed in Germany = 1, 1976 ‘Checking Fuel Pump Delivery 2+ Checking Pump Pressurecs sumnty 2O CHECKING FUEL PUMP DELIVERY Note Before checki ig fuel pump, check for velean fuel fter “electrical connections OK Teast 11.5 volts at both fuel pumps 1, Detach fuel return Hine (ef side of engine compartment), 4, Switeh on ignition for 20 seconds. Both pumps rust deliver 140 Liter/howr oc 2 30 seecnds, 0 ce in Note If delivery rate is less than this specification, check pressure of fuel pumps to determine which vel return Line with a sectlon of fuel Seen ve end im a measuring glass (contents about 1500 ce). CHECKING PUMP P 8, Bridge both fuel pump relays (90 end 81) or pull out plug on afr sen 11, Loosen intake fuel line Printed in Germany ~ 1, 1076 Checiing Fue! Pump Delivery 2-3QO seer sess 2, Connect pressure gauge of P 378 between Intake line and rear fuel pump in conjunction with Special Toot P 8114, 3, Turn ignition on (after first bridging relays oF pulling off plug at ei sensor contact). a. Read pressure gauges Pressure must be between 2 avd 4 bar. If less than 2 bar, the first pump (front) is defective. If more than 4 bax, the second pump (rear) is defective, Replace defective pumps and recheck pressure, ‘Cheek connections for leats after completing pressure test. 20-4 Checking Pump Pressure Printed in GermanyREMOVING AND INSTALLING FRONT FUEL PUMP Removing 1, Disconnect ground cable a1 bat 2, Remove bottom protection plate, 8, Clamp intake fuel hore shut, Loosen hose Me cn TER ‘clamp and pull off intake fuel hose, 4, Pull off rubber aps and remove nuts attaching 5, Remove hollow bolt for pressure fuel line, 8, Loosen pump clamp and remove fuel purmp, Instatiing 1, Always use new seals. 24 Install fuel pump so there is clearance all sound it, Printed tn Germany ~ Removing and Installing Fuel Pump 20> 52O seer suppy REMOVING AND INSTALLING REAR FUEL PUMP Removing 2. Disconnect ground cable at battery. 2, Remove hollow bott for pressure fuel 2, PulL off rubber caps and remove nuts attaching 4, Loosen intake fuel line and cateh escaping fuel. 5, Remove puts and take fuel pump off bracket. 6. Installing Always use new seals, 1g and Installing Fuel Pump Printed in Germany21 TURBOCHARGER Printed in Germanyturbocharger 21 REMOVING AND INSTALLING EXHAUST GAS TURBOCHARGER Removing 41, Disconnect hore (arrow) between turbo outlet and turbo outlet duet, Disconnect ofl pressure line (srrow) from engine, 4. Loosen muffler clamp and remove mesfler. 2, Loosen rear apron socket head serews and remove apron with seal. 5. Loosen hose between turbocharger inlet line and turbochargers Slide hore to left, Drain off in AP. 1p (arrow) between bypass line and coven mounting nuts (arrow) between Diseoonest oil return line at oil trap, Loosen drain tube of oil trap on bottom of turbo= charger and remove trap. turbo and muffler. ot Printed in Germany Removing and Installing Turbocharger 21-121 ruccharger 6, Loosen turbocharger to exhaust pipe mount bolts as well as mounting nuts on turbocharg holder. Remove turbocharger. Nate ‘When installing a new turbochsrger, the connections are located by turning the turbocharger com= pressor side to aliga it with the turbine side. 4) Loosen strap on turbocharger a little. by Install turbocharger on engine and align locetlon of connections. €) Secure rubber hoses and exhaust pipe and then ighten strap serews to specified torque (refer to page 21-3 ‘Always instail new oll drain plug seals, self locking nuts and gaskets ©) Before starting the engine for fret time, 1 ‘uedocharger lubrication off must be purnped for 90 seconds ~ which requires disconnecting ‘wires at manifold pressure iimiting steiteh and operating starter motors Installing 1, Be sure that hose connections are properly made ocharget outlet duet and turbo~ between 1 2, After {nsigllation, lubricate turbocharger with 2a tem of engine sls 1 =2 Removing and installing Turbocharger Printed in Germanyturbocarger OM TURBOCHARGER Ai 1 6, Engine oil { (under 4 Intet = SSS bgt gas outlet oil out i 1 Compressor housing 2 Bearing housing 9 Turbine housing 4 shaft beart 5 shaft 6 Compressor wheel 1 Turbine wheel Printed in Germany Turbocharger Drawing 21-321 tusvoenarger CHECKING TURBOCHARGER SHAFT END PLAY 1, Place dial gauge in hotder. Special toot P 207 can be used as a holder, 2, Set dial gauge on end of turbine whee! shaft, Press rotor shaft against dia gauge, read and note play. Press rotor shaft in opposite direction, read end note play, Difference of both readings fs the end play, Max. play: 0, 35 mm CHECKING TURBOCHARGER TURBINE RADIAL PLAY Radial play is checked on the turbine end only. Note Be sure not to rotate the turbine wheel at all uring these measurements. 1, Press turbine wheel toward side of housing, ‘check gap with a fecler gauge and note. Pres turbine wheel toward opposite side of, housing, check gap and note, Difference of both measurements ls the radia Play. Measure play at least at two different Tocations. Max. play: 0,65 mm 1-4 — Checking Turbocharger Printed in GermanyTurbocharger 21 CHECKING WASTE GATE OPERATION 4. Loosen and remove control line to waste gate 2. Run engine at idle speed. There must be noti- ceable vacuum in control line. With ineressing engine speed, vacuum changes to pressure (charging pressure) 3. Insert a plug in disconnected control line, 50 ‘that engine will not stall while checking waste gate operation. 4. Carefully blow compressed air in control line ‘opening of waste gate. Listen for sound of warte gate opening Caution Do.not.use mora then 1,6 bar (21 psi) air pressure In addition to sound of valve opening, check thet bypass line warms up (cold engine). I necessary, replace waste gate. —— Printed in Germany - 111, 1981 CChacking Waste Gate Operation 21-40eta eee REMOVING AND INSTALLING WASTE GATE (CHARGE PRESSURE CONTROL VALVE) Removing Engine Type 980/51 1, Detach vent tine and control line. Cnlock and remove thermag auts. 3. Remove waste gate, upper gasket, heat svard and lower gasket. Installing Use new gaskets, seals, thermag mats and Tockplates. roving and Installing Waste Gat Printed in Germany ~ 1, 1Printed in Germany Dismantling and Assembling Pop-off Valve urbocherger Or <7 ost 6 oO 8 6 SL Lt be 21aunecnerses DY No. | Description 7} pemovtag tating Remaris 1 | Hose clamp 2 2 | Rubber sleeve 1 Install correctly 3 | Hose clamp 2 4 | Hose 2 Instatl correctly 5 | aot 1 @ | washer 1 a | Hose clamp | Rubber sleeve 1 jastail eorxectly @ | Hose cramp 2 10 | Hose a ni | nut 2 2 | washer 2 as | att 2 14 | Washer 2 as | anti-bacifire valve [1 16 | Holder a a1 | Mantiotd pressere 1 Cheek see page 21-11 lirmiting switel: ae | Snap sing 1 19 | Filter soreen a 20) Seal 2 Replace aa | Nut 4 20 | washer 4 28 | cover L Printed in Germany Dismantling and Assembling Pop-olf Valve Housing 21-7DQ] rervecnasser Note when Nox} Description y+} pemaving pr Remaris Joa] Gasket a necessary replace 125 | Control piston 2 | Caution - under —_Lubsfeate slightly, spring pressure cheek movement in valve housing 26 | Spring 1 21 | Guide 1 28 | Nut 4 29 | washer 4 30 | Cover with control 1 tine connestion at | Gasket 1 Replace, If necessary 22} Pop-olf valve housing | 1 88 | Turbo boost pressure | 1 Cheek sender | Seat 1 Replace Q-8 — Dismentiing and Assembling Popraff Valve tTousing 1, 1976 = Printed tn Germanyturbocharger 24 TooLs No. } Description Special Too! | Remarks 2 | Manifold pressure tester aos | 2 | Threaded adapter e131 | for 1978 model Printed inGecmany + 11, 1978 ‘Checking Manifotd Pressure ass21 Turbocharger CHECKING MANIFOLD PRESSURE 1, Disconnect and remove electric plug and mant- fold pressure Limnlting switch, From 1978 Model, ‘witeh ts located behing pop-off valve housing as seen looking forward. = 2, Sorew adapter (with seal) of special tool in valve housing and tighten slightly From 398 Model, first install threaded adapter, Special Tool 9102/2. 3, Screw manifold pressure Limiting ewiteh in adapter and tighten only finger tight, counters holding adapter. 4, Route gauge hose with pressure gauge fra passenger compartment to eagine compart 5, Comnect gauge hore to adapter, counterholding the adapter. ‘Dubs 9.2 6, Cheek manifold presture in a road test of om a dynamometer, Manifold pressure: 0.70 ~ 0.85 bar (0.7 = 0.85 atm), Fully accelerate car in Ist or 2nd gear and reed charge pressure between 4500 and $500 zpm (2nd person), Manifold pressure can only be checked in the acceleration phase, If necessary, replace waste gate, ——— 22-10 Checking Manifold Pressure Printed in Germany21 Turboek ECKING FUNCTION OF MANIFOLD PRESSURE LIMITING 80 Cheeking 1, Remove manifold pressure Limiting switeh, 2, Clamp manifold pressure limiting switet. carefull 3, Connect chmmeter between switch housing and connecting terminat, Check that ohmmeter reads © obms, Insta tl on threads of switch. ‘ire valve (without valve insert) 5. Connect az pressure hose (at valve). pressure gauge 8, Increase pressmne carefully, Check that ohm= meter goes to QO at about 1,5 bare 11, Drop prestute slowly until obmmeter again ‘goes to 0, Now read pressure which should be between 2,1 and 1,4 bar, If necessary replace manifold pressure limiting swite, Printed in Germany Manifold Pressure Limiting Sulten eit21 Turbocharger so, | Description re peer aa ca ang Remarks 2 | Hottow bott 2 2 | Seat 2 Replace 3 | Oi presureiineto | 1 turbocharger hottow bot) 4 | Pressure sonsor 1 3 | Seat a Replace 8 | Adaptor a 7 | seat 2 Replace 2 | Adepter 1 & | Pater sereen 1 cheer a0 | Seat 1 Replace zi | Thermag mat 2 Replace ae | washer 18 | Gasket 1 Replace sa | clamp 2 Turbocharger as | Oi tank L 16 | Rubber grommet 1 ar | wut 2 Replace ae | Washer 2 1s | Bracket 1 20 | Bott 2 a1 | Wathee 1 22 | Hollow hott 2 23 | Sea 2 Replace 24} Ol tine 1 so Princed In Germany ‘Torbocharger Oil Supply a a3Turbocharger 21 le oz e & i i le le 9% Of 6% Bz Printed in Germany 4 2 3