Workshop manual DR. ING. h. c. F. PORSCHE KG STUTTGART-ZUFFENHAUSENPORSCHE WORKSHOP MANUAL 911 - FROM MODEL 1972 ON ‘This publication contains the essential removal, installation and adjustment procedures for the Porsche 911 vehicles sold in the USA and Canada. Components and procedures described in this manual are identical for all types unless differences are pointed out in the text, Tt is assumed that the reader is familiar with basic automotive repair procedures, Special tools required in performing certain service operations are identified in the manual and recommended for use. Use of tools or procedures other than those recommended in this repair manual may be detrimental to the vehicle's safe operation as well as the safety of the person servicing the vehicle. ‘The Workshop Manual 911 ~ from model 1972 on ~ is subdivided into 10 Assembly Groups, delive- red in supplements to volume I and I. survey of the individual Assembly Groups Engine and Clutch Code No. 1 Fuel System Code No. 2 ‘Transmission Code No. 3 Front Axle Code No. 4 Rear Axle Code No. 6 Brakes, Wheels, Tires Code No. 6 Pedal Controls and Manual Controls Code No. 7 Maintenance Jobs, Technical Data Code No... 0 Body Code No. 8 Electrical System Code No. 9 For identification of the volumes, the back of the folders is provided with a transparent pocket at the top for insertion of the pertinent type. To find the individual repair steps quickly, each Assembly Group of this Workshop Manual is sub- divided into "Main Groups", "Chapters" and "Sections" and provided with a very detailed list of contents; refer to example on next page. ‘Technical Information sheets should be filed at the beginning of their respective groups, The contents of the Technical Informations will be incorporated into the Workshop Manual at suitable intervals, The List of Contents will be edited whenever extensions and supplements are published, - XXXII, 1974 USA/CANMotor und Kupplung Engine and Clutch Moteur et Accouplement Motore e FrizioneENGINE 911 CONTENTS 0 - INFORMATION, DESCRIPTION, TECHNICAL DATA o2 02 Description Engine changes - 1972 model Oil tank changes - 1972 model fl cooler system and oil circuit schematic Of cooler schematic - 1973 model Of cooler schematic with cooling coil - 1974 model Engine, front view cross section Engine, side view cross section Specifications for 2.7 liter-engine where differ 2. 4 liter-engine Engine changes - 1974 model Cross section of engine with emission control equipment Layout of exhaust gas recirculation system Engine cross section with emission control - 1978/1979 models Emission control layout - 1980 model Technical data General data Power performance curves Technical data, Type 911 T - Continuous Injection system (CIS) Technical data, Type 911/S/Carrera - 1974 model Full-power performance - 1974 model Technical data, Type 911 § and Carrera - 1975 model, Engine tightening data ‘Technical data, Type 911 - 1976 model Technical data, Type 911 § - 1977 model Technical data, Type 911 SC - 1978 model Technical data, Type 911 SC - 1980 model Technical Data, Type 911 SC - from 1981 Models, 2 - COOLING SYSTEM, EXHAUST SYSTEM, EMISSION CONTROL 22 Cooling system Fan drive belt, replacing/adjusting o.1-4/t 0.15 2/2 0.1 - 2/2 0.1- 3/1 0.1 - 3/2 0.1- 4/1 o.1- 4/3 O.1- 5/1 O.1- 6/1 Oe 7/4 0.1- 7/2 O1- 7/3 O1- 1/4 0.2- 1/1 0.2-1/7 0.2- 3/L 0.2- 4/1 2-4/4 0.2~ 5/1 0.2 - 5/2 0.2 = 6/t 0.2- 7/2 0.2- 7/8 0.2- 7/5 0.2- 1/7 2-1/1911 3 ENGINE 2.2 2.8 Exhaust system and heating Exhaust system and heater blower, removing and installing Exhaust system - 1978 model Emission control Air injection components, removing and installing Air pump belt, tensioning Reactors and EGR equipment, removing and installing Exhaust gas recireulation system Reactor, checking for leaks Exhaust gas recirculation system, checking Air injection system, checking OIL CIRCULATION 31 3.2 3.8 34 a5 O41 cireulation : Ol tank, removing and installing Off tank, removing and installing - 1978 model Auxil{ary pressure relief'valve, removing and installing Auxiliary pressure relief valve, disassembling and assembling Oi cooler coil, removing and installing Oi cooler, removing and installing Oil tank, removing and installing - 1974 model Pressure relief valve cooling coil, removing and installing - 1974 model, Pressure relfef valve, disassembling and assembling - 1974 model Off cooler coil, removitg and installing - 1974 model Cooting coil oil lines, service installing - 1974 model Replacing ofl Lines to front oi cooler or to cooling coil Of cooler, removing/installing Auxiliary pressure relief/safety valves CAMSHAFT HOUSING AND CYLINDER HEAD Camshaft housing Injection tube in camshaft housing, removing and installing Chain tensioner, overhauling Sealing cylinder head/camshaft housing mating surfaces, 2.2-1/1 2.2- 1/5 2.3-1/1 2.3- 1/4 afl 2/6 3/l 3/2 3/8 a.1-a/t a1- 1/2 a1- 1/3 a+ 1/4 a.1- 1/5 BL - 2/1 3.2- 1/1 8.3- 1/1 8.4- 1/1 3.5- 4/1 3.5 -1/38 3,5 -1/5 3.6- 1/1 8.6 - 2/1 B1-a/l 5.1- 2/1 5,1- 2/7ENGINE 911 5.2 Cylinder head Valve springs, installed length 5.2- 1/1 Adjusting timing 5.8- 1/1 6 - CYLINDERS AND PISTONS 6.1 Cylinders and pistons Piston changes - 1972 model Piston and cylinder dimensions - 1972 model Piston and cylinder dimensions - 1973 model Piston and cylinder dimensions ~ 1974 model "LS" cylinders and pistons, installation instructions Pistons and cylinders, measuring Piston and cylinder sizes, 911 SC ~ 1978 model Piston weight classes ~ 911 SC from 1981 models 1 ~ CRANKCASE AND CRANKSHAFT 7.1 Crankease and crankshaft Crankcase, measuring and reconditioning nasa ‘Modified flywheel installation - 1978 model 11-2. Flywheel with pilot bearing - 1980 model V1 s/t Oil filter screen and suction plate, removing/installing Ta 1.8 Crankshaft Crankshaft changes - 1972 model 13-4 Crankshaft dimensions 1.3-1/2 Connecting rod changes - 1972 modet 7.3-1/8 Connecting rod weight groups 13-14 Connecting rod weight groups - 1978 model 1.3-1/5 Pistons for injection engines 1.8 2/1 Modified crankshaft drive - 1978 model 1.3-3/ Crankshaft specifications, standard and undersize - 1978 model 1.8 3/61 911 ENGINE 9 CLUTCH 9.1 Clutch Clutch changes - 1972 model Clutch free play, adjusting Throwout bearing, removing and installing Clutch - 1975 model Clutch modified - 1978 model $.1-1/1 9.1- 1/2 91-21 8.1- 3/1 9.1- 4/1vosine seinen OM | ENGINE CHANGES - BEGINNING WITH 1972 MODELS General Information Beginning with 1972 models, Type 911 engines have a cubic displacement of 2.4 Liters (2841 c/142.8 cu.in.)QI1 engine Description Individual changes and changed service operations are described on the pages that follow. Summary of Changes: 1. Technical Data 2. Crankease 3. Crankshaft 4. Connecting rods and bearings 5, Pistons 6. Location of oil tank and ofl lines ‘1, Clutch pressure plate, throwout bearing, and clutch dise 8, Ignition - see Group 9 (Electrical System) 9. Fuel system ~ see Group 2peseription 911 OIL TANK CHANGES - BEGINNING WITH 1972 MODELS General Information Beginning with 1972 models, the oil tank is located in right rear wheelhousing in front of the rear axle. ‘The oil filler neck is now accessible from the outside. It is located under a hinged lid in the right rear fender, The oil filter housing is separated from the tank and mounted on the right engine compartment wall, The auxilfary of! cooler under the right front fender continues to be standard equipment in Type 9118 vehicles,Description 911 souvoyo me 1 ot 8 4g88T/Do68 38 ¥ suodo) yeqsouzsa 6 duind SmBuonvog q 8 dumd omsioag_& u dumd To & oy tepwa1g aseoKEID - L —(PoyUROU oUTBUD) 49009 TO-B SEY To MOTE-TINd 9 sej009 To Arey (sT4GOW-ZL WOUd) SHIOIHGA $ I16 TAAL DILVWAHOS LINOWID 110 GNV WALSLS ONI1009 110911 1(wo Japour-~L ET woss)peseription OY 7 1314 1516 2 1 8910ENGINE CROSS-SECTION Air filter housing Cross-shaft Intake stacks Fuel injection pump Heat exchanger Camshaft Spur belt il screen (Crankshaft il pump, Ol screen in crankcase Connecting rod Piston cylinder Exhaust valve Valve guide il hose connector (ofl tank to ofl pump) Valve spring Rocker arm shaft Camshaft Rocker arm. Intake valve Fuel injector Upper air shroud ‘Throttle valve housing Fuel injection line Cold start enrichment nozzle Crankease ventilation filter ‘Air filter housing retaining clipsENGINE SIDE-SECTION 1. Air filter housing 2. Air inlet tube 3, Fuel injection lines 4. Oil pressure sensor 5. Crankease 6. Of pump 7. Pressure side (to lubrication points) 8. Suction side (to oil tank) 9. Connecting shaft 10. Oil screen 11, Of drain plug (magnetic) 12. Crankshaft 18. Connecting rod 14, Sprocket gear 15. Intermediate shaft 16. Heat exchanger 17, Exhaust muffler 18. Distributor drive gear 19. Belt pulley 20. V-belt 21. AC generator 22, Upper air shroudDeserintion OM SPECIFICATIONS FOR THE 2.7 LITER ENGINE WK 2.4 LITER ENGINE Crankease: Pistons: Cylinders: Ignition distributor: Ignition timing: Spark plugs: (gap in mm) Throttle valve housing: RE DIFFERING FROM THE Cylinder base bore in crankease increased from 92 mm dia to 97 mm dia. 90 mm dia instead 84 mm dia Piston pin offset by 0.4 mm instead 0.8 mm, Cylinder walls coated with NIKASIL compound. Cooling fins reduced from 15 to 11. Advance curve changed. TDC at 850 - 950 rpm BOSCH W265P21 (0.55) BOSCH W260T2 (0.1) BERU —268/14/3P (0.55) BERU —-260/14/3 (0.7) Idle air ports enlarged from 3,3 mm dia to 4mm dia,Description ff ENGINE CHANGES - BEGINNING WITH 1974 MODELS 1, Type 911, 911 8, and Carrera engines are equipped with NIKASIL light-alloy cylinders with a 90 mm bore. Pistons: Piston heads in Type 911 S engines ate marked “A 2", Rype 911 pistons, by comparison, have a deeper depression and a higher protrusion, without special markings. 8, Cylinder head: The mounting orifice for the injection valve is discontinued since the valve is relocated to the intake stack. 4, Type 9L1 and 911 S engines received modified camshafts with changed valve timing.sunt ae pod ysnewt 7 wyy dund yg ates 2949 € dund ny 1 LNANAINOA TOULNOD NOISSINA HLIM ANIONS 40 NOILDAS ssoudDescription compet ate-19n} 2Uj JO WOTIATTP pettoruoD 43 YFnoIyy poonpar st seB ysneyxo om] UT - YON - aptxo waSonu jo ynowe ay, *se8 ysoy YT poxtur axe pue Buysnoy AEH amp O}UF MOT soso ysneyxa Kem st UT toro Tened ye sadeys OMY wT prosrueat oyerUT oy wos uMoeA Xq pauado st eATeA YOR THI, :woTyeIadO area YOR & roy dod 3G BUN T WALSAS NOILVINOUIOTY SVD LSMVHXS 40 LNOAVTCROSS SECTION VIEW OF ENGINE WITH EMISSION CONTROL 911 sC (1978/1979 Models) 2Deseription 911 aur wonoafuy yang ot 2A ST soueauos onfqeres Keng bT Rim TorH0D aINNKIL ST aieyd 1oswes Zr Suysnoy aqnomy, TT YOUMs anyeA aMONIT, 0} 2aTea ate Arerqpeny g somqunstp wont g Tonuos cinnoeA 1 ‘2ATRA EIS PIOD 9 Suymoy oye1UT g yous amierodura: 110% yous own omens, g ro1ofur fond rosuas uaBKxo 1 (19POW og6r) OS IT6 TOULNOD NOISSIWA 4O ONIMVAG LNOAVT911 Technical Data adr ooze wd oogr ids 000% avy tet aut mT s/s 99t dq 2a oyu 13, du 03, Tet ast 1st ost sor opt "8 Toe Tish (up no g*@pt) 99 twee (ur smo grart) 99 Tee H'no g*2pT) 99 Tees CUT 4L*@) Uru yon UE LL"Z) UU BOL, (Cup uu") aU H*OL Cur tes) wor pg (ur te*s) uur pe (Cur te'e) war pg yjueq sod stapuryto 20m *TeuOZTOY 2 | 9 9 syteq ropurtdo Busoddo omy yy ouySua surfoseS oxons-moy $ 116 a 116 L 1t6 poad: aurfua @ (ays) (SQ) enbroy amore G@N avs) (sua) Supper reModosi0H one: uoysiexdui09 quouraoetdsip aurSua sons ‘108 quouroSueare sopurtd sropurtdo Jo roquinyy adhe ANIONG TAGOW ZL6T HLIM ONINNIOSG SHIOIHIA TL6 FdAkL - 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UE peOyIAO repuytho 10d ‘area ysneyxe T “OqEIT T spray sepuytdo owt paurypemt ‘92 "TX FTW a 1té ure ayoor pue Ws OATeA WaaMyaq pamnseOUL (*UF p00"0) aU OTD upeyo £q Bupsnoy yeysures Jo [eau aseq uy sBupz9q uyeid samp ur ‘T2998 yseo yueg, ropurto sad yousures T ‘OHO eaten sod sBuyzds too g 398 poouoyuyor UTA ‘payooo umnrpos aha pBIAAO seputtso ad eaten ysneyxo T ‘oyequr, t spray roputo OvUE pouryor ‘eg "EX FT HL L116 ysneyxe pue eae uy ‘ploo ‘eourivaqo antes ‘aarp yeusueD syeqsure Bupa area Buns ote sOaTeA ysnerpg quoweSuene eae A SOnTeA speang 8nd yredsTechnical Data gti of Foo ITRIVL of 88 © HOSOd urd 006 ® OLY 98 turnnoza pur [28x17 soogotte2o sunt HOSoM e°F16"0T" 0S ITIRWL Hosoa 8-8-Fe2-96T (sao) uroysAs oBreupstp aarytoedeo ur ¥*e = 0°S DLV g0% OIA gor OLY g0S Dd o 88 s 116 of Fo0h ITEEVN of Fo8@ © HOSOM dr 996 © DLV of twanoea pu TeBny029 vooeattezo guanaf HOSO 2"PL6"0T" 0S ITEUVL Hosoa 9-8-Fe GT (sao) aayehs areyostp aarytoedeo wut $3 - 8 Oa gh O18 oh OLY oof DLs oot of For ITmVN of F088 © HOSOm widz 906 ® OLY 6$ uumnoea pure reBnprsyua9 soossttezo sguanl i T'pLg* oT" os ITTV HOsod GBP BT (sao) urayshs oBreypstp aantoedeo wun 9° - 6% DIA ob OE Bt OLY 908 D8 o9T L rte argue Tread Super wopyusy orsea soueape sxeds (puri route) somaqnsia soursojsuen, uoryra8 repro Burts addy woud ‘souerea[o antes (ur 700°0) mt T*9 WHI OL depaA0 ye YA 2atea oeaUT sos09 neyX9 suado ysneyxa s980[9 79TUT suado yoqut ‘ouvrealo antes (“Ur 0F0°0) un Tayi Sure eateArechoicel vata QM 1 Horsepower Output Ne (DIN HP) —— Full-power Performance Type 911TUSA CT — 140 Ne 130: 1204 ~ 110: f 3 100: 2\e = { 2/3 | = 90: 18) 2 os -— 16] ze sot} Md. | | 2 a 70 : = t S o 2 60 280) = 2 260| & be 2 50: 240] B < 220] 8 0 Ne max = 140 PS (DIN) at 5600 rm | | TT Md max= 20 mkp at 4000 rpm B fe = pa o 2000 3000 4000-5000 60007000 e000 @ Engine Speed n (rpm) —————® ©Q11 —techaicar Date Full-power Performance Type 911E 1 180 170 = 1 | 160 = | — Ne 150 —— | _ | 140 4+— +— 4 & 130 = + z + 2 ry a O 120 + - + = o }—- + 4 Zz =z 3 110 T 22 = = —_|— +. o £ | a 3. 6 100 - — 18] & ~ ° 3 16] 3 90+ Md 2 3 a [ = 2 0 1 = 5 S i 2 is mt 2 70 1 T < t 280| 2 \ 2 60 — 260 + bel 240 § | og 50 220| § 200 ° 0 Ne max = 165 PS (DIN) at 6200 rpm 3 a Md max= 21mkp at 4500 rpm c { j g + + S 2000 3000 4000 5000 6000 7000 8000 2 ov Engine Speed n (rpm) ——————>Technical Data Horsepower Output Ne (DIN HP) ————_—______»> Full-power Performance Type 911S 190 | | = 180 ~ — | Ne! - 170 T — 160 ~ 150 +— 140 | 4 | 130 — 1 — - 120 ~ T 22 t _- 20 110 T = Mal + 18 T t T 16 100 Tt al 90 80 b _ — : 280 70 ant +260 - 240 60 { 220 | + | 200 Ne max = 190 PS (DIN) at 6500 rpm Md max = 22mkp —_ at 5200 rpm i 2000 3000 + 4000 5000 = 6000 7000 8000 Engine Speed n (mp) ——————_» on | Specific Fuel Consumption be (g/HPh) Torque Md (mkp)eee Full-power Performance Carrera i ; 220. - . —+S +160 | , 200- 140 + Ne 180. t— _ + 120 | 60, y | | | | 7 te | Ale 140-4 — — e +100 11S | = 1 15 r 420 ~ ~ 24$ | Mai e L 80 TO r pee 100-++— | F | | = | | Als p60! 80 —- — 2 oO z 3 | 3 | Tbe 260}°= & 2 = 60 | ef -+2404 + 400 & 5 hess 220: a ns wns | 2001 8 ga | 3 a= |_1_| 3 SoZ | ye - a911 Technical Data ooss. 001g jo wd: yreysyueso 3e 110 Ser/L9T LOT/8PT MOI/dH PU ‘GHz [AVS 04 Suppr099e 62 /9ur oTt/ost MOI/dH ‘000L NIC 04 Buppr0998 txeu ‘Suyjer ramodasion Tigre Te oner wopsserdui0g (Le"e90) L998 (6890) Lave (aap) 99 ‘Tenor “qwousorrdsi Gu) Pon (0°) POL (qour) uur “oyong (o9"8) 06 (ose) 06 (you) saat ‘910g yueq sed sropurtto ¢ djueq rod stapurtto g ‘weqwozOy “Teuozp0y juowofuene sopurré 9 9 sropurto yo zoquiny syueq rapuptso Buqsoddo omy WIM auTBu oustose oxyors-mox ody YOLOW VAIUUVOS TIE 116 STACOW FL6T HLIM ONINNIDGG SETOINTA IL6 ddAL YO VLVG TVOINHOILTechnical Data 911 L080 ys"0 - 0F70 670-40 D1d of OIG ob D€d ohZ Dad 68 Dav gos DEV 988 DLV 09 OLY of Gor/c8t cor /cet Stet YL aL 16 16 gr 9¥/e"29 8*6e/z"es 89/39 Ty/a"99 000% ooss 886/89T 860/89T 380/90 sea /7e VuaUAVvo/s Tt6 116 $1 repom souerea[o Bae MIU T*9 TEM depsex0-OaL ye axons aaTeA OxEIUT sosofo jsneyKa strado ysnenyg sosopo ayeqUT suado ayeyur reoueseopo Oatea WU T WPA Buy aATeA vxordde ‘sqi/B4 ‘y8yom ouySug sxordde ‘suoryrpucs ayggen pextur repun (Dg7W) uoR|dumsuoo Tan Now ‘suourazmnber ouP}90 I/M3 20 HI/aH 324 ‘g¥e favs 03 BuypIOD9e A1/MX 10 H1/aH1 ‘0B00L NIC 09 Suqpro99e sqndjno r9M0d o1syoads jo urdr yeysquezo ye 118 THN/*Y*aT JOU ‘GPG FAVS 0} BuIpIose an /andy “0Z00L Nic 03 Sumprosoe ronbioy “xeonl Technical Data 80 ¢9'se 80598 00 FFT T16 00 eet 116 00 81 SOT 116 00 PT gor TI se vor VUaUUVO/S TTS 807 S88 sto; 96 00 et 116 00 THT 16 00 TT gor tts 00 ot sor 116. 88 9°6 116 ura oaqea yeneya z0p unt Aves axeyuy 10g ssBumads oaqea Jo qpBuay potteysut quer “yeysures Yer “yeusues AyeusuIES Jo TELE pu wo yreM HoREoYTHUIpT Her “yeusures wr “yeysures unr ontea ysneysa um aba one Uy seoueseo [9 ATA ILE T*9 WEA YT area,O11 reenatcat Date Full-power Performance 911 4 180 so | = r | +120 160 . }—_— | 140 +100 | | 120 : t fF 80 2644 100: 22- 18-4 L eo | Hl L t ~ 240- r 40 220° ; : 200: eo | zez | [00 + a 2000 3000 4000 «= 5000S «6000-7000» 8000 Engine Speed n (rpm) -—#£_——_ Spec. Fuel Consumption be (g/HPh) Torque Md (mkp)recnaten vast | Full-power Performance 91S A 200 -f - +140 ~ — 180 T [170 | 60 Ne 140 > +100 | lal. —_—|— = a x L E 120 2415 sz - ——1-22- = p 8° i} Md $s sa 1004 te + ] 184 & r | e = + 60 80 a A <= oD | 2601 9 r | 1 tel 2 60 2401 § L 40 a 2201 [ 3 L gy | 2 ote +2004 § #2 | | {Tg £ 1 8 Zz5az z £00 Se 2000 _ 3000 4000» 5000» 6000s 7000S 8000 @ Engine Speed n (rpm)Technical Data 911 TECHNICAL DATA FOR 1975 911 § AND CARRERA MODELS ENGINE Type No. of cylinders Bore in mm (in, ) Stroke in mm (in.) Displacement in cm (in, °) Compression ratio Max, output: DIN HP or kW SAE NET HP or kW at crankshaft 1pm Max, torque: DIN in kpm or Nm SAE NET ft Ibs. or Nm at crankshaft rpm Max. output/liter: SAE NET in HP/liter or kW/liter RON fuel specification Fuel consumption (DIN) in liter/L00 km Approx, engine weight in kg (Ibs. ) Valve timing with 1 mm valve clearance (in crankshaft degrees): Intake opens Intake closes Exhaust opens Exhaust closes Intake valve lift at overlap TDC with 0,1 mm valve clearance (in mm) Valve lift at 0.1 mm clearance: Intake valve in mm Exhaust valve in mm Camshaft, right Camshaft, left Identification on face of camshafts: Camshaft, right Camshaft, left Valve spring sizes: Intake valve in mm Exhaust valve in mm Exhaust, heating USA California 91/48/48 6 90 (8.54) 70,4 (2.77) 2687 (163.97) 85:1 165/121. 5 187/115 5800 28/225 166 /225 4000 58, 5/43,2 OL 9.8 180 (397) 6° after TDC 50° after BDC 24° before BDC 2° before TDC 0.40 - 0,54 10.4 8.8 911 105 144 00 911 105 143 00 911 144 00 911 148 00 astos 35.5 0.3 Single pipe system with new heat ex- changers, heater blower, primary muff- ler and new exhaust muffler and air injec tion 91/44/49 6 90 (8. 54) 70.4 (2.77) 2687 (168,97) 85:1 160/118 152/112 5800 23/205 166/225 4000 53, 8/41.7 91 10.2 192 (428) 6° after TDC 50° after BDC 24° before BDC 2° before TDC 0.40 ~ 0,54 10,4 a8 911 105 144 00 911 105 143 00 911 144 00 911 143 00 357 95.5 . 8 0. 3 Double pipe system ‘with reactors and heat exchangers, heater blower and new exhaust muffler, exhaust gas recirculation and air injection911 Technical Data TIGHTENING TORQUES FOR ENGINE Torque Location Threads Nm 4 kpm Connecting rod nuts M 10 x1.25 50 5 Crankease bolts M10 35 3.5 ‘All bolts on crankcase and camshaft housing M8 25 2.5 Hexagon nuts (oil filter screen cover) Mé 10 1 Flywheel bolts M12x1,5 150 18 (from 1978 models) M 10 x 1,25 30 8 Pilot bearing to crankshaft Mé 10 1 Pulley to crankshaft (without air conditioner) Mi2x15 80 8 Double-belt pulley to crankshaft (with air conditioner) M12x1.5 a0 uw Safety valve plug to crankcase M18 x1.5 60 6 Pressure relief valve plug to crankease. 60 6 ‘Adapter (oil pressure sender) to crankcase Migx1 85 3.5 Adapter in crankcase (oll retum line) Mi2x1 120 a Cylinder head nuts M 10 socket head 33 3.8 Rocker arm shafts M 6 socket head 18 18 ‘Nut on camshaft M27 x2 150 16 Hex, head bolt on camshaft M12x15 120 32 Cover to camshaft housing M8 8 0.8 ‘Adapter to cylinder head (air injection) Mi1ox1 15 Ls Air line (coupling nut) to adapter M14x1.5 22 2.2 Reactor to cylinder head M8 20- 28 2.0 - 2.3} Spark plugs M14x1.25 25 - 30 2,5- 8.9Technical Data 911 ‘i Torque Location threads ani 4 Nm kpm Bracket for engine carrier M10 40 4 Wide clamp on fan housing Mé 6.5 0,65 MB w 12 Pulley to altemator M16 x1 aosev) 4 altemator| (Motorola) MMxLS 40 Bosch | 4 Ol pressure switch to crankease Mi0x1 max, 20 | max, 2 ‘Temperature sender to crankcase M14 x15 max, 25 | max. 2.5 Oil pressure sender to adapter M18 x15 max, 35 | max, 3.5 Oxygen sensor to catalytic converter M18 x1.5 50 - 60 5-6 Cap nut on catalytic converter MUMxL5 30 3.0 i drain plug (on cover for oil filter screen) M 2241.5 42 4.2 O11 drain plug (oil tank) M 22x15 42 4.2Technical Data 911 TECHNICAL DATA - TYPE 9115, ENGINE Type Bore Stroke Displacement Compression ratio Horsepower SAE Net at engine speed Torque SAE Net at engine speed Output per liter SAE Net 3245, Max, engine speed Cutoff speed of speed limiter in distributor Engine weight, dry Valve Drive Valve clearance, cold engine measured betw, valve and adjusting screw: Intake Exhaust, Valve timing at 1 mm clearance Intake opens Intake closes Exhaust opens Exhaust c loses Intake valve lift at TDC overlap with 0,1 mm valve clearance Identifying number on cam end face Camshaft, left Camshaft, right No, of bearings 1976 MODEL mm/in, mm/in. em’ yin. kw/HP rpm Nm/fab rpm kW/HP pm pm kg/tb mm mm gis 911 /82/84/89 90/8.54 10.4/2.77 2687/164.0 85:1 1i/15t 5800 228/168 4000 44/59 6700 6500 * 200 182/401 0.10 0,10 6° aTDC 50° apbe 24° aac 2° sTDC 0,40 - 0,54 911,143.00 911.144,00 3Technical Data 911 TECHNICAL DATA - TYPE 911 S, 1977 MODEL ENGINE Engine type Bore Stroke Displacement Compression ratio Power SAE Net at engine speed ‘Torque SAE Net at engine speed Output per liter Max, engine speed Cutoff speed of speed limiter in distributor Engine weight (dry) Valve drive Valve cleatance (on cold engine) measured betw. valve and adjus~ ting serew: Intake Exhaust Valve timing with 1 mm valve clearance Intake opens Intake closes Exhaust opens Exhaust closes Intake valve lift at TDC with 0,1 mm valve clearance mm/inch mm/inch em®/inch® kWw/HP rpm Nm/Ibit rpm W/HP 1pm rpm kg/tbs mm 6°, ATDe 50° ABDC 24° BDC. 2° rpc mm sus 91/85/90 90/3.54 10.4/2.77 2687/164,0 85:2 17/181 5800 228/168, 4000 44/59 6700 500 t 200 182/401 0,10 0,10 0,40 - 0,54Q11 —recnatcat vate Identifying number on cam end face Left camshaft Right camshaft Bearing journals Valve springs: free length Intake valve Exhaust valve Ignition Timing USA. Version (vacuum hose permanently plugged, vacuum advance inoperable) * California Version (vaccuum hose connected) Spark plugs Electrode gap Cooling - Fan Drive Crankshaft/fan ratio Air delivery rate Engine Lubrication i, pressure at 5000 rpm and 80° C/176" F Oil consumption (per 600 mites) mm itr. approx. approx. ous 911.148,00 911,144.00 8 35 = 0,3 35.57 0,3 0° - Zi mark - at 950 * 50 1pm 16° ATDC at 1000 * 50 pm Bosch W 225 T 30 -0.7- Beru 225/14/3A ~0.7- Bosch W 235 P21 ~ * Beru 235/14/3P ~ =) 55+) 1:18 1265/sec. at 6000 rpm crankshaft speed 5 bar/13.6 psi 1,5 ~ 2.0 Itr/atTechnical Data 911 TECHNICAL DATA, TYPE 911 SC - 1978 MODELS si sc ENGINE Engine type USA = 990/04 California ~ 930/08 Bore mm/inch 95,0/3.74 Stroke mi/ineh 10.4/2.97 ‘Total Displacement em’ /inch® 2994/182.7 Compression ratio 8.3 Net Horse power, SAE kw/HP 328/172 at engine speed rpm 5500 Torque, SAE Net Nm/Ib ft 281/115 at engine speed : rpm 4200 Output per liter, SAE Net KW/L BP/L 43/51 Max. engine speed pm "7000 Cut-off speed (overrev protection) Speed limited by cutting off fuel pump pm 6700 to 7000 Engine weight (dry) kg/lbs approx. 200/441 Valve drive Valve clearance (cold engine) measured between valve and rocker arm adjusting screw Intake mm 0,10 Exhaust mm 0,10 Valve timing with 1 mm valve 5 clearance Intake opens 1°prpc Intake closes 59° ABDC Exhaust opens 43° BBDC Exhaust closes 8° apc Intake valve lift at TDC overlap with 0,1 mm valve clearance mm 0,9 to1.1QM recnateat Date sui sc Identification on camshaft face Left camshaft 990.147.08 Right camshaft 990.148 .08 Number of bearings 4 Length of installed vaive springs . Intake valve mm 34.5 t 04 Exhaust valve mm 34.5% 0.38, Ignition CDI (breakerless) Basic ignition timing 5° BIDC at idle of (vacuum hose attached) 900 to 1000 rpm (oll femp. 80° C/ 176° F) Spark plugs/electrode gap mm Bosch W 145 T 90/0.8 (0.092 in.) Beru 145/14/3 /0.8 (0,082 inc.) Emission control 980/04 air pump and catalytic converter 930/05, 980/15 and 980/06 air pump, catalytic converter and EGR Cooling - Fan drive Crankshaft/fan ratio: approx. 1:18 Air delivery rate 1880 1/s at 6000 rpm of crankshaft Engine lubrication (Ot pressure at 5000 rpm, and oll temp, of 80° C (176° F) bar/psi approx. 4.5/66 il consumption 3/1000 km approx. 1.5 to 2.0 (US gt/600 mi.)Technical Data 91 TECHNICAL DATA, TYPE 911 SC ~ from 1980 Model Engine Engine type (intemal code) Bore stroke Total displacement Compression ratio Max, output per DIN 70020 Net horsepower per SAE J 245 at engine speed ‘Max, torque per DIN 70020 Net torque per SAE J 245 at engine speed Max. output per liter DIN 70020 SAE J 245 Max, engine speed Cut-off speed (engine speed limiter) Engine weight (dry), approx, Valve train Valve clearance (cold engine) measured between valve and rocker arm adjusting screw Intake Exhaust Valve timing with 1 mm valve clearance Intake opens before TDC Intake closes after BDC Exhaust opens before BDC Exhaust closes before TDC Intake valve lift at TDC with 0.1 mm valve clearance mm/inch mm/inch em®/inen® kW/HP kW/HP ‘pm Nin/kpmn Nm/ft lbs rpm kW/l, HPA W/1, HP/L rpm rpm kg/lbs mm mm 911 sc 930/07 95. 0/3.74 10. 4/2. 77 294/182. 7 99:1 132/180 128/172 5500 245/25 297/175 4200 44/60 42/51 7000 Speed limited by switching off f ShObS BFP 190/419 0.10 0.10 ° 7 ae 49° 3 L4t01.7911 Technical Data Identification on camshaft face Left camshaft Right camshaft Number of bearings Valve spring installed length Intake valve mm Exhaust valve mm Ignition Basic ignition timing ‘Spark plugs - electrode gap - mm Emission Control Cooling - fan drive Crankshaft/fan ratio approx. Air delivery rate Engine lubrication Oil pressure at 5000 rpm and 90° C/ 195° F ofl temperature bar/psi il consumption 1/2000 km (2 US gt. /600 mi.) 911 sc 980, 147. 08 980, 148, 08 four Thee 34, 34, CDI (breakerless) 5° BTDC at 900 to 1000 rpm {dle speed, vacuum hose ais- connected, 90° C/195° F oil temperature Bosch W 5 D (W 225 T 30) = 0,7 = Beru 14/5 D (225/14/3 A) = 0,7 - (Oxygen sensor and 8-way catalytic converter 1: 1.68 1500 1/sec. at 6000 rpm crankshaft speed approx. 4.5/6 approx. 1.50 2.0Technical Data 911 TECHNICAL DATA, TYPE 911 SC - from 1981 Models Engine Engine type (Internal code) Bore mm/inch stroke mm /inch, Total displacement em? /inch® Compression ratio Max, output ace, DIN 70020 kw/HP Net power ace, SAE J 245 w/e at engine speed 1pm Max, torque ace, DIN 70020 Nm/kpm Net torque acc, SAE J 245 Nm //ft Ibs at engine speed rpm Max, liter output acc. DIN 70020 kw, HPL SAE J 245 kWA, HPA ‘Max, engine speed 1pm Cut-off speed engine speed limiter pm Engine weight (dry) kp/tbs Valve train Valve clearance (cold engine): measured between valve and rocker arm Intake mm Exhaust mm Valve timing with 1 mm valve clearance Intake opens Intake closes Exhaust opens Exhaust closes intake valve lift at TDC overlap with 0,1 mm valve clearance mm 911 sc 980/16 95.0/3.74 104/277 2994/1827 98:1 132/180 128/172 8500 245/25 287/115 4200 44/60 42/51 6700 Speed Limited by switching off fuel pump 6500 * 200 approx, 190/419 0.10 0,10 7° before TDC 47° after BDC 49° before BDC 8° before TDC 1.41017O11 rechaicat Dara Identification on camshaft face Left camshaft Right camshaft Number of bearings Installed length of valve springs Intake valve mm Exhaust valve mm Ignition Basic ignition setting (vacuum hoses detached, ofl tempera~ ture approx, 90°C/195°F) ‘Spark plugs ~ electrode gap ~ mm Emission control Cooling - blower drive Crankshaft/fan ratio Air delivery rate Engine lubrication Ol pressure at 6000 rpm and approx, 90° C/195° F off temperature bar/psi il consumption Ite, /1000 km (2 US at/600 mi.) 911 sc 930.147, 08 930, 148, 08 fou 34,5 - 0.8 84,5 - 0.8 CDI (breakerless) 5° before TDC at 950 rpm Bosch W 5D (W 225 T 80) -0,7~ Beru 14/5 D (225/14/3 A) - 0.7 - Oxygen sensor with ‘8-way catalytic con- verter approx. 1: 1,68 1500 Itr, /sec, at 6000 rpm crank- shaft speed approx. 4. 0/58 approx. 1.5Cooling System, Exhaust, Emission contror OAM REPLACING AND ADJUSTING FAN DRIVE BELT Effective with the 1980 models all 911 SC engines have the larger fan from the 911 Turbo, New belt size: 9,5 x 710 mm, Note Only the approved belt from Goodyear, Part No. 999, 192, 176. 50, may be used for these engines, When installing the new belt for the first time, it must be much tighter than was formerly the case, Approximate rule: ‘Tighten belt as in the past (belt deflects by 10 to 15 mm at point midway between two pulleys), ‘Then remove 1 shim from the shims between the pulley sections (approx. 5 mm deflection) Adjusting instructions for engine prior to 1980 models with small fan: Check tightness by applying thumb pressure at point midway between both pulleys. Deflection: approx. 10 to 15 mm,Cooling System, Exhaust System, Emission Controt Oi REMOVING AND INSTALLING EXHAUST SYSTEM AND HEATER BLOWER 2% «293433 27 3095 2 | 35. | \e ass‘ooling System, Exhaust System, Emission Control 91 No.| Description Go| Notes Hy Remarks 1 | Hose clamp 2 2 | Hose (heater 1 Hose must not touch air/blower) anything 3 | Hose clamp 3 4 | Heater hose, left 1 5 | Clamp, adapter 1 6 | Adapter 1 1 | Screw 1 8 | Clamp 1 9 | Blower 1 Install correctly 10 | Sheet metal screw 2 aa | Washer 2 12 | Bolt 2 18 | Washer 2 14 | Heater air adapter 1 15 | Hose clamp a 16 | Heater hose, right 1 17 | Bott 2 18 | Lock washer 2 18a) Washer 1 39 | Clamp 1 20 | Nut (self-locking) 8 Replace if necessary 21 | Bolt 3 22 | Gasket 1 Replace 23 | Fillister head screw 2 24 | Clamp 2Q11 cooting system, exhaust system, emission Controt No, | Description Removal Pen Remarks 25 | Muffler 1 Check for leaks and damage 26 | Nut (elflocking) 6 Replace if necessary 27 | Bolt 6 28 | Primary muffler 1 29 | Gasket 1 Replace 30 | Gasket 1 Replace at | Nut 2 a2 | Bott 2 33 | Clamp 2 ; 34 | Flange 1 35 | seat 1 Replace 36 | support dise 1 at | Nut Getftocking 3 Replace if necessary 38 | Bott a 30 | Adapter 1 40 | Gasket 1 Replace 41 | Hose clamp 2 42 | Flex hose 1 49 | screw 2 44 | Washer 2 45 | clamp 2 46 | Adapter 2 47 | Heat exchanger 2 Check for damage 48 | Cable strap 1css ystems thee autem, anion cour ONY EXHAUST SYSTEM - 1978 MODELS (Engine Type 930/04, 06) 1 ~ Heat exchanger 3 ~ Catalytic converter 2 ~ Exhaust pipe 4 ~ Exhaust mufflerCooling System, Exhaust System, Emission Control Qf 1 REMOVING AND INSTALLING AIR INJECTION1 911 Cooling System, Exhaust System, Emission Control -_ Notes IN o.| Description ay. ae Remarks 1 | Bott 1 2 | Washer 1 Replace if necessary 3. | Plain washer 1 4 | vobert 1 Cheek tension Refer to page 2.3- Va 5 | Nut 3 6 | Washer 8 Replace if necessary 7 | Bracket 1 8. | Rubber/metal pad 1 Check, replacing if necessary 9 | Holder, air pump 1 10 | Hose clamp 2 11. | Hose 1 Check, replacing if necessary 12 | nat 1 18 | Washer 1 Replace if necessary 14 | Plain washer 1 18. | Bott 1 16 | Washer 1 Replace if necessery 17 | Plain washer 1 18. | Rubber bushing 2 Install correctly, lubricate lightly 19. | Spacer 2 20 | Air pump 1 21 | Winged nut 1 22, | Filter cover 1 28. | Filter cartridge 1 Replace if necessary 24 | Filter housing 1Cooling System, Exhaust System, emission contro: Qf] INe+} Description OT pemorat station Remarks las) wut 1 26 | Lock washer a 27 | Puttey 1 28 } Flat key 1 29 | Carrier, air pamp 1 jg0 | Seat 1 81 | Check valve J} 4 32 | Seat 1 Replace 38 | Air tine 1 34 } Jet 6 Torque 1.0 - 1.2 mkp 35 | Seal 6 Replace 86 } Pulley, engine 1Q11— cooting system, Exhaust system, Emission Control TENSIONING AIR PUMP BELT Adjusting 1. Loosen bolt. 2, Move air pump to left. 3, Tighten bolt, 4, The belt tension is correct, if the belt can be pressed together about 15 mm (5/8 in.) at its, centerpoint with considerable thumb pressure. Removing/installing pulley (California version),Cooling, exhaust and emission control systems REMOVING AND INSTALLING REACTORS AND EGR EQUIPMENTCooling, exhaust and emission control systems ot ra Note when No.] Description +) semoving ean Remarks 1 | kor filter 1 Replace every 80, 000 miles 2 | Nut (copper pita.) 4 Replace Bolt 4 Replace, if necessary| 4 | Socket head screw 2 5 | Clamp 2 6 | Muffler a Check for Leaks and damage 7 | Gasket 2 Replace 8 | Nut (copper pltd.) 3 Replace 9 | Bolt 3 Replace, if necessary) 10 | Heat exchanger 1 Check for leaks and damage 11 | Gasket 1 Replace 12 | Nut (copper pltd.) 6 Replace, torque to 2.3 mkp 13 | Washer 6 14 | Reactor 1 Allow it to cool down Check for leaks 2,8-8/1 to room temperature, Remove heat ex- changer and oil re~ turn Line 15 | Seal 8 Replace, install with| blue side facing to- ward cylinder head 16 | Nut (copper pitd.) 3] Replace 17 | Bot 8 - Replace, if necessary 18 | Heat exchanger 1 Check for leaks and damage1 Q11 — cooting, exhaust and emission control systems Note when .| Descripti 7 No.| Description 0) emoving ory Remarks 19 | Gasket 1 Replace }20 | Nut (copper pitd.) 6 Replace, torque to | 2.3 mkp 21 | Washer 6 22 | Reactor 1 Allow it to cool down Check for leaks 2,3-8/1 to room temperature. Remove heat ex- changer 23 | Seal 3 Replace, install with blue side facing to- ward cylinder head 24 | Nut 1 25 | Washer 1 26 | Bolt 1 27 | Vacuum hose for stagel | 2 Connect to top vacuum chamber 28 | Vacuum hose for stage I | 1 Connect to bottom vacuurn chamber 29 | EGR valve outlet pipe 1 Only detach at EGR valve 30 | Nut 2 a1 | washer 2 32 | Bolt 1 33 | Bolt 1 34 | BGR valve 1 Check, replacing if | 2,3-2/6 necessary 2,8-9/2 35 | Gasket 2 Replace, install one betw, holder and EGR line and the other betw, valve and holderCooling, exhaust and emission control systems ; Note when script 7 femarks aan OWT removing {installing Remarle 36 | EGR line 1 | Theright engine co- Check passage, 2,8-9/2 ver must be removed to replace EGR line cleaning if necessaryQ11 — cootsng, exaust and emission control systems EXHAUST GAS RECIRCULATION SYSTEM ‘Component parts of the exhaust gas recirculation system are subject to 4 certain amount of wear and must therefore be inspected and/or replaced after operation for 30,000 miles (also refer to Group 9). REMOVING AND INSTALLING EGR VALVE Removing 1, Disconnect vacuum hoses, 2. Detach EGR valve outlet pipe at valve. 8, Remove mounting bolts, Note: The replacement of gaskets requires detach- ing the EGR line at the EGR filter and clamp, Installing 1, Replace gaskets, Connect vacuum hoses as follows: Stage I - Upper chamber to left connection on throttle housing (es seen in driving direction). Stage II - Lower chamber to right connection on throttle housing (as ceen in driving direction).Cooling, exhaust and emission controt systems Qf CHECKING REACTOR FOR LEAKS Note ‘The reactor" s operation need not be checked. It only needs to be checked for leaks. 1, Let engine run at idle. 2, Insert appropriate plug in outlet pipe of muffler and check reactors for leaks by listen~ ing. Replace a leaky reactor,Q11 coring, exhaust and emission control systems CHECKING EXHAUST GAS RECIRCULATION SYSTEM 1, Let cold engine run at slightly higher idle. This will heat the outlet pipe from EGR filter to EGR valve, 2, Increase engine speed to about 4,000 rpm, The outlet pipe from the EGR valve to the intake housing must now be hot, too. Wf the outlet pipe between the EGR valve and in- take housing is not hot, the following conditions could be causing this: a) EGR valve defective b) EGR tines plugged ©) Vacuum bores in throttle valve housing plugged 4) Vacuum hoses plugged o leaking ©) EGR filter between muffler and EGR valve cloggedCooling, exhaust and emfssion control systems 911 CHECKING AIR INJECTION SYSTEM 1, Clean air filter of secondary air pump with compressed air, Replace if severely clogged. 2, Check air pump belt tension (max. deflection: 10-15 mm), 3, Loosen and disconnect air injection hose at air pump, Insert plug in hose. 4, Connect CO tester according to manufacturer's instructions. Note The CO should be checked immediately after a test drive as long as the engine is still at operating temperature, 5, Adjust CO to 1.5 - 2.0 % at idle speed of 900 * 50 rpm, 6, Reconnect air injection hose to air pump. 1. The CO must now drop below 1.0 % with the engine idling at 900 £50 rpm, If the CO is still above 1.0%, there is a defect in the air {injection system, Of course, the engine must be in perfect working condition in every other aspect, Ifnecessary, install a new pump to determine cause,oncirenstt — ONT OE REMOVING AND INSTALLING OIL TANK 1, Remove right rear wheel. 6. Loosen retaining strap. Caution Gover brake disc to prevent ofl spillage during removal of tank. 2, Drain oil from tank. retum line. ‘1, Pall tank partially out of the wheelhousing and remove ofl Line, breather hoses, and oil level gauge wires. Remove tank. 4, Detach return hose from oil tank. Make sure during installation that plastic caps between tank and body, and retaining strap liner are correctly seated. 5. In Type 911 S also detach the oil hose from bottom of tank. Coat oil hose connections with Molykote ot similar Iubricant when assembling.QO oucireust REMOVING AND INSTALLING OIL TANK (FROM 1973 MODEL ON) General: Beginning with the 1978 models, the oil tank is located in the right rear wheelhouse behind the rear axle. Removing 1. Remove right rear wheel. 2. Drain oil. 8. Detach oil hoses and pressure relief valve. 4, Detach ground straps from batteries. Dis connect electrical wires from the oil level sensor. 5. Detach tubular support from bumper outer part and longitudinal support. Turn support to the side. 6. Unscrew oil filter. 7. Disconnect off breather hoses from ofl tank. 8. Remove oil tank retaining nuts (accessible from engine compartment). 9. Remove oil tank. 10. Remove oil filter base. Installing Note the following during reassembly: 1. Properly position rubber seal fitting between wheelhouse panel and oil tank. Glue seal to the oil tank, 2. Make sure that O-ring is properly seated in the oil filter base.oucueut Qf REMOVING AND INSTALLING AUXILIARY PRESSURE RELIEF VALVE 1. Disconnect oil hoses. 2, Remove pressure relief valve from oil tank. Remove support bracket.1 QM ouciseas DISASSEMBLING AND REASSEMBLING AUXILIARY PRESSURE RELIEF VALVE Nr. | Description 0 | semoving Note when stenting | Bomerts 1 | Pig a 2 | seat ring 1 Replace 3 | spring 1 4 | Relief valve plunger | 3 5 | Relief valve housing | 1oncireut OY REMOVING AND INSTALLING OIL COOLER COIL Removing 1. Remove right front wheel. 2, Disconnect oil hoses. Caution: Counter with a second open-end wrench, 4, Remove oil cooler coil. Installing Apply counter-force at the oll lines during in~ stallation to prevent damage. Coat off hose connectors with Molybdenum, disulfide grease during installation. 8, Remove Allen bolts and retaining screw from the right bumper bracket.oi cireuit Qf] SS REMOVING AND INSTALLING OIL COOLER General: Beginning with the 1973 models, all six-cylinder engines are equipped with a two-piece ait shroud which simplifies the removal and installation of the ofl cooler. Removing 1, Remove air filter top. 4, Remove oil cooler air duct. 2. Remove front engine shroud. 5. Drain oil. 3. Remove right engine shroud. 6. Detach ofl hose from oil cooler and remove upper retaining nuts.Q11 on cient Installing Install new sealing rings at the ofl cooler. NOTE: When positioning the of! cooler on crankcase, make sure that sealing rings are properly seated.oucireut Off REMOVING AND INSTALLING OIL TANK BEGINNING WITH 1974 MODELS Removal 1, Remove right rear wheel. 2, Drain of, 8, Detach oil hoses and remove bolt from support tube of lower fender section. 4, Remove screws from support tube and turn it to the side, 5, Detach wires from ofl level sender. 6, Detach breather hoses and remove tank cover from tank, 7, Unscrew oil filter.QT on ctrenit 8, Open the lock plate, remove nut, and pull out support tube through the bottom, 9. Remove off tank retaining nuts and washers. Installation 1, Glue wheelhouse gasket to oil tank in proper position.on cient = QI REMOVING AND INSTALLING PRESSURE RELIEF VALVE OF COOLING COIL BEGINNING WITH 1974 MODELS Removal 1, Drain oil from tank, 2, Detach ofl lines, 8. Remove retaining clamp from upper oil lines. 4, Remove the valve, Caution: Catch spilling ofl.O4l Circuit 911 DISASSEMBLING AND REASSEMBLING PRESSURE RELIEF VALVE Beginning with 1974 Models No.| Description Qty removing area installing Remarks 1 Plug 1 | 2 | Gasket Joa Replace | 3 Spring joa | 4 | Plunger 1 5 | Pug 1 6 Gasket 1 Replace 7 | spring 1 8 | Plunger for presture | 1 relief valve 9 Valve housing 1oil circuit = OT REMOVING AND INSTALLING OIL COOLER COIL Beginning with 1974 models Removal 1, Remove right front wheel, 2, Disconnect ofl hoses, Caution: Counterhold with a second open~end wrench, Catch spilling ofl. 3, Remove retaining bolt and take cooler coil out. 4, Remove attaching bracket, Installation 1. Apply counter force when connecting oil Lines to prevent damage, 2, Coat ofl hose connectors with MOLYKOTE-A uring installation, 3, Mount cooler coil without stress,Oil Circuit Sii SERVICE INSTALLATION OF COOLING COIL OIL LINES BEGINNING WITH 1974 MODELS 6. Grind down or saw present spacers (three plastic bushings) to a thickness of 5mm (8/16 in.) 1, Raise car on hoist, Remove wheels on right side of car. 2, Drain oil from ofl tank. 7, Place rubber guards on oil lines. are at zeta ee) EU ene De to 8, Place both oil lines along rocker panel. ‘The top line must rest on fender connector plate, Install spacers and mounting clips. Only tighten mounting screws slightly. 4, Remove rocker panel cover. 5. Remove plugs in ofl line and cooling coil mounting points on front wheelhousing. 9, Connect pressure relief valve housing to ofl lines,QM cucucar 10, Slide in rocker panel cover between spacer and washer, Tighten cover. 15. Check for leaks, ‘This requires the enging oil temperature to be at least 83°C (82°F), so that the pressure relief valve will release the flow of ofl to the cooling coil, 11, Place oi hoses along rear wheelhousing and connect. If necessary, cut threads on stud, 12, Connect cooling coil to oil lines. 18. Fasten cooling coil and lines to wheel~ housing. 14, Tighten all ofl line connections,over Ot | REPLACING OIL LINES TO FRONT OIL COOLER OR TO COOLING COIL Installation of side tum signals from 1981 models on made it necessary to change the ofl lines to the front oil cooler or cooling coil in the front wheel well area. Only new version lines will be available from Parts after using up the former version ofl lines, ‘Changes made necessary when installing new lines in cars with old oil Lines (without side turn signals) are described in the following instructions, Removing 1, Lift car on platform hoist, Remove wheels on right side of car, Spray rust removing solution on ofl line connections,O11 oincireuse 2, Remove rocker panel cover by unscrewing end at front and rear, ~pulling off rubber guard and removing cover for Jack support, removing metal screws at top and loosening metal screws at bottom, Unscrew mounting bracket and clamps. Remove ofl lines, 8, Disconnect wires of automatic antenna (optional Installing extra equipment) inside of car, Unplug antenna wire on radio; removing right floor plate for this 1, When installing new lines in'cars without side purpose, Pull both wires out of holes in wheel tum signals proceed as follows with the mounting well. points in the wheel well, Point A Is still applicable. 4, Disconnect ofl lines on pressure relief valve Point BXC Not applicable; plug with 6 x 10 mm. housing, Catch escaping oil, hex, head bolts used in conjunction with a body sealing compound, Point D New (drill 2 5 mm dia, hole 255 mm/10 in, from wheel house/floor plate joint and 75 mm/3 in, from fender joint plate). 5, Disconnect ofl Lines on cooling coil or at ofl hoses for cars with a front oil cooler. Counterhold [- with a second open-end wrench, ;oncireur Off 1 Note Coat oll line connection threads with Optimoly HT or Molykote A prior to installing, Make sure cooling coil remains installed without stress, If necessary, change installed position so that wheel does not scrape on cooling coil when tured to full lock Position, 5. Mount oil Lines on wheel well, Use 6,8 x19 mm hex, head metal screw at new mounting point when installing new ofl lines in a car without side tum signals, 2, Install hoses on ofl lines for protection. 8, Route both ofl lines along side member trim, Upper Line must be on fender joint plate, Install spacers and clamps, Tighten mounting bolts only finger tight, 6, Reconnect automatic antenna wires, Check function of radio and antenna, ‘1, Push in rocker panel cover between spacer and washer, 4, Connect ofl lines on pressure relief valve housing and cooling coil or ofl hoses for cars with a front oil cooler,Qo cireuse 8, Finish installation of cover, Connect rubber guard on one end, bend back sharply and press on continuously. Lip must fit tightly on body at top, If necessary, realign, 9. Check system for leaks, This requires that engine oil temperature be at least 83° C/181° F s0 that the govemor can release flow to the cooling coil or front oil cooler, Correct oil level.oft Cireuit 91 REMOVING AND INSTALLING FRONT OIL COOLER (1980 Model) Removing 4, Loosen lower nuts and remove oil cooler upward, 1, Remove right front wheel, 2, Disconnect off hoses. Note Use # second wrench as a counterhold, Catch escaping olf. Installing 1. When installing counteshold at the cooler 1 connections to prevent damage. iil 8, Loosen outer nut on upper rubber mount, 2. Coat connections with Optimoly HT. |. Check connections for leaks, This requires that the regulator for the front oil cooler be open to have oil flowing through the cooler (engine oil temperature above 88° C/181° F)oft Cireutt 911 SPRINGS FOR PRESSURE RELIEF AND SAFETY VALVES OF ENGINE OIL CIRCUIT Tg EOE Pressure Relief Valve Safety Description to1977 | fiom 1978 } Valve Piston pressure relief valve 911. 107, 512, 00 Spring - old- 70 mm long 901. 107. 531. 00 Spring - new 86 mm long 930, 107. 531, 01 spring guide 930,107. 539, 00 Gasket 900.128, 072, 20 x x x Plug - old ~ without groove 999. 064. 010, 08 Plug ~ new ~ with groove 999, 064, 016. 02 Spring, safety valve 901. 107. 581. 00 Plug - new ~ with groove 999. 064. 016. 02 x Installation Note ‘The (86 mm long) spring for pressure relief valve may only be installed together with the spring guideCamshaft Housing and Cylinder Head 911 REMOVING AND INSTALLING INJECTION TUBE IN CAMSHAFT HOUSING Removing 1, Drill 9 mm deep hole in plug with a 4.8 to 5 mm dia, drill bit, Then cut M 6 threads with a bottoming tap. Pull out plug with an M 6 screw and spacer. CAUTION Be careful not to damage sealing surface when removing plug. 2, Loosen centering screws and slide injection tube out. Installing 1. Install injection tube, making sure that locating bore for plug is positioned correctly. CAUTION Separate bores must face upward toward intake valve covers, Double bores, not shown in illustration, face cam bearing surface.on Camshaft Housing and Cylinder Head 2. Lubricate new plug and hole, coat with a double component adhesive and install plug. CAUTION Upset plug before installation if it does not fit tightly in housirig, 8. Plug is pressed in about 0,3 mm deeper than sealing surface.Camshaft Housing and Cylinder Head 911 OVERHAULING CHAIN TENSIONER TOOLS Remarks Adjusting ring For chain tensioner 980 105 049 00 Clamp Assembly leverQ11 —camshars Housing and Cylinder Head OVERHAULING NEW VERSION CHAIN TENSIONER General Information Only the chain tensioner having Part No, 930.105, 049.00 or the repair kit having Part No. 911, 105, 901. 01 with modified parts are available from parts, Only the new version chain tensioners may be re~ paired, New Version Identification: a) Chamfer on upper part of housing b) Total height: 78.2 * 0,2 mm and Porsche trade- mark . ©) Mounting boss and housing have a stopcanis vowing wa opeser nen OI]1 1 eee erento ected wo, | pesripson 2 |aemoving — analing marcos 1 | Bleed screw 1 2 | seating rng 1 Replace 2 |ciamp 1 Clamp only with complete new pan 4 | snap rng 1 neptace 5. | spring resainer 1 6 | sing 1 replace : 17 | son cat. 1 & | o-ning 1 Replace 2 | o-ring 1 neplace xo | snap sing 1 replace 1 | piston 1 12 [intermediate piece | replace 18 | o-1ng 1 replace us | an, 5 mm 1 replace 15 | spring 1 replace 16 | cage 1 Replace 1 | spring 1 1s | spring euce 1 replace 10 | chain tensioner towing } 1 Lt iDISASSEMBLING AND Ass Disassembling 1, Clamp chain tensioner in a vise and remove upper circlip. Note spring retainer under pressure, 2, Remove spring retainer and spring. 8, Remove bleed screw id sealing ring. 4, Pull out aluminum piston carefully with suitable tool. 5, Push lower snap ring out of groove with a small screwdriver inserted through bleed screw bore. 6. Remove piston, intermediate piece with O-ring valve ball (5 mm) with spring, cage for ball, spring and spring guide. Note The intermediate piece could be stuck in the piston, If so, remove intermediate piece by lightly tapping piston against piece of wood, mshaft Housing and Cylinder Head 911 MBLING CHAIN TENSIONER Assembling 1. Clean parts thoroughly, check for wear and replace if necessary. Inspect piston spring for wear and deformation (bent), replacing if necessary. 2. Push chain tensioner piston with mounted alu- minum piston, without O-rings, into chain tensioner housing. Both pistons must move easily. It is especially important that the chain tensioner piston moves easily in the lower piston position, Remove any pressure spots on the pistons with emery cloth. 8, Install spring guide, spring. cage, spring, ball, intermediate piece with O-ring as well as piston and secure with snap ring. Note When installing intermediate piece in the piston make sure O-ring fits properly in groove. Give O-ring a light coat of oil, 4, Fill chain tensioner to upper edge with 15 W/50 engine oil and bleed, Bend the end of an approx, 1 mm dia, steel wire to make an inclined step and push it through the piston bore against the ball (see Workshop Manual 911, Volume 1, Page E 106). Move piston up and down slowly within the stroke range until no more air bubbles escape at the bores,oti Gamishaft Housing and Cylinder Head 5. Clean inner and outer grooves of aluminum piston, Install new, lubricated O-rings and make sure they are not twisted, Install alumi- num piston until the O-ring seals with the housing, Now open the bleed screw slightly and push down with Special Tool P 214 c until the tool rests on the edge of the chain tensioner, Then tighten bleed screw again without delay. Install spring, spring retainer and snap ring. INSTRUCTIONS FOR INSTALLATION OF CHAIN TENSIONER To prevent damage on the chain tensioner housing, it is not permitted to pre-load the timing chain with a screwdriver, Force from the serewdriver could deform the chain ten- sioner housing, which in tuim would cause the the aluminum piston (7) to seize, Only use special Tool 9182 for pre-loading,Camshaft Housing and Gylinder Head 911 SEALING CYLINDER HEAD/CAMSHAFT HOUSING MATING SURFACES Note Only Loctite No, 578 (green color) should be used as a sealing compound, Loctite No, 573 hardens only in conjunction with metal and exclusion of air, Not more than 10 minutes, should elapse between application of sealing compound coat and assembly of parts, otherwise the sealing ‘compound on metal would start to harden. Removing Old sealing Compound During repairs the old sealing compound does not have to be removed. Only grease has to be removed from the surface. A new coat of sealing compound should be applied immediately after the cleaning solution has dried, The new Loctite will dissolve the old compound remaining in the surface finish and become hard again after assembly, Should it be necessary to remove the old sealing ‘compound, the we of a fine steel brush is recommended for this work, Applying Sealing Compound . When applying the sealing compound by hand it 2, Apply a very thin coat of sealing compound on 4s recommended to use a short~pile velour roller, the mating surface of the camshaft housing. In addition, a tray will be required for the sealing compound with a ribbed surface for scraping off the roller.Camshaft Housing and cylinder Head QA CHECKING INSTALLED LENGTH OF VALVE SPRINGS Check distance A with Special Tool P 10 C. If necessary, correct by adding or removing chims, Note Make sure spring retainer has perfect fit in special tool, machining special tool if necessary. INSTALLED DIMENSIONS FOR 2,4 LITER ENGINE Vehicle oT sue ss ‘type ingine oust 91/52 911/58 ‘Type 911/61 911/62 911/63 Intake Valve 3570.3 mm 347 0.3mm 35.52 0.3 mm Exhaust Valve 35 70,3 mm 3470.3 mm 94.5 * 0.8 mm NOTE ‘The above values can also be applied to the 2.2 liter engines in the course of repair.1 O11 camsnast Housing and Cylinder Head INSTALLED DIMENSIONS FOR 2.7 AND 3,0 LITER ENGINES Vehicle sues 911 sc Type Engine gl 930 Type Intake Valve 3540,3mm | 84.5- 0.3 mm Exhaust Valve 35.50,3mm| 94.5 - 0,3 mm Note ‘The tolerances for cylinder heads of Carrera 3.0 and 911 SC models have been limited for manu- facturing reasons. The distance of 84, 5 mm must not be exceeded; the lower tolerance value would be ideal,Camshaft Housing and Cylinder Head 911 ADJUSTING TIMING (Camshafts with Hexagon Head Mounting Bolts for sprocket) TOOLS No. | Description Special Tool Remarks 1 | Holding wrench for 9191 sprockets 2 | Puller pale 8__ | Dial gauge holder P 207 4 _| Clamp for chain tensioner Pale 5 | Dial gauge with tip standard Tip length: approx, 40 mm 6 | Assembly lever 9182 7 | Peeler gauge Pals911 Camshaft Housing and Cylinder Head ADJUSTING TIMING (Camshafts with Hexagon Head Mounting Bolts for Sprocket) Basic Setting 1, Tum crankshaft until mark Z 1 on pulley is aligned with joint of crankcase or stripe on fan housing, 2, Position both camshafts so that punch marks face up. Engine has its basie setting (cylinder no, 1 ‘TDC and cylinder no, 4 = overlap) by adjusting mark Z 1 on pulley to joint and punch marks on camshafts to face up.Camshaft Housing and Cylinder Head oi 8, In the position described above on bore inthe «Fine Adjustment sprocket will be exactly aligned with a bore in the sprocket flange, Insert a locating pin in these 1, Check valve clearance and, if necessary, adjust exactly aligned bores, exactly to 0,10 mm with Special Tool P 213, pee Exact valve clearance for intake valves of one cylinders no, 1 and 4 is sufficient for timing adjustments, 4, Tighten hexagon bolts for sprockets finger tight hold with Special Toot P 9191, 2, Pre-load timing chains, Note To avoid damage on chain tensioner housing, it is not permitted to pre-load timing chains with a screwdriver. Supporting the screwdriver on the chain tensioner housing could deform the latter and cause seizure of the aluminum piston, Only use Special Tool 9182 for pre~loading, Note Should one of the camshafts be tuned out of basic setting position, proceed as follows, Remove locating pin from camshaft in basic setting position so that it cannot tum during che following adjustment, ‘Tum mislocated camshaft to basic setting position (punch mark faces up) with Special Tool 9191, ‘Then remove sprocket mounting bolt and locating pin, and tur crankshaft to mark Z 1 again,ott Camshaft Housing and Cylinder Head Left Gamshaft Adjustment (Cylinder No. 1) 8, Mount dial gauge on stud of camshaft housing with Special Tool P 207. Set dial gauge to zero on spring retainer of intake valve for cyl. no. 1 with valve closed and approx, 10 mm pre-load, 4, Now slowly tum crankshaft clockwise from Z 1 (TDC) by about 1 turn and observe dial gauge at same time. Continue turning until the mean value of the adjusting tolerance, e.g. 0,10 mm valve lift (for 930/16 engine), is reached. Adjusting Values lEngine 990/16 ideal value 1.4-1,7 mm 1,55 mm 5, Unscrew and remove mounting bolt on left sprocket and pull out locating pin with Special Tool P 212, 6, Tum crankshaft accordingly until mark Z 1 on pulley is exactly aligned with joint of crankcase, or stripe on fan housing. 7. Install locating pin again and tighten bolt finger tight, while holding, 8, Tum crankshaft clockwise two tums (720°) and re~ check setting, Indicated valve should be within tolerances, 9, Tighten bolt of left camshaft to final torque of 120 Nm (86 ft Ib), having a 2nd person hold with Special Tool P 9191. Right Camshaft Adjustment (Cylinder No. 4) ' 1, Set cylinder no, 4 to TDC (cyl. no, 1 overlaps). 2, Repeat adjusting procedures described in points 8 through 9 on cylinder no, 4,cylinders ana Pistons QYf PISTON CHANGES - BEGINNING WITH 1972 MODELS 1, New pistons with flatter piston tops to reduce compression ratio: out S 18:1 ILE = 80:2 sis = 85:2 Required fuel octane rating = 91 2, Changed piston ring, 8, New table of dimensions for pistons and cylinders beginning with 1972 models,911 Cylinders and Pistons PISTON AND CYLINDER DIMENSIONS Beginning with 1972 models Type 911 S Pistons Type 911 E Pistons Cylinder Cylinder Piston markings bore dia. diameter D 1 ‘Tolerances Standard 2 0,005 mm ° 84,000-84,010 88,950 1 84,010-84,020 83.900 2 84,020-84,080 83.970 Ast oversize oxKD1 84,250-84,260 84,200 1xD1 84,260-84,270 84,210 2xD1 84,270-84,280 84,220 2nd oversize OKD2 84,500-84.510 84.450 1KD2 84,510-84.520° 84.460 2KD2 84,520-84,530 84,470 Cylinder/piston clearance: 0.045-0,065 Piston weight: s54t3g ‘Tolerances Standard + 0,005 mm 0 84,000-84,010 88,970 1 84,010-84,020 83,980 2 84,020-84,030 83,990 Lst oversize ror 84,250-84,260 84.220 1KD1 84,260-84.270 84,230 2KD1 84,.270-84.280 84,240 2nd oversize oKD2 84,500-84.510 84.470 1KD2 84,510-84.520 84.480 2KD2 84,520-84.530 84,490 Cylinder/piston clearance: 0,025-0.045. Piston weight: antagCylinders and Pistons Type 911 T Type 911 T For piston and wear limits see page 6.1 - 4/1 Cylinder Cylinder markings bore dia. Standard (MAHLE 0 84,000-84.010 1 84010-84020 2 84,020-84,080 Ist oversize oKD1 84,250-84,260 1KD1 84,260-84,270 2kKDI 84.270-84,280 2nd oversize. 0 KD2 84,500-84,510 1KD2 84.510-84.520 2KD2 84,520-84.530 911 Piston diameter Di Cylinder/piston clearance: 0,025-0.045 Piston weight: 316 t 8g Standard (SCHMIDT) ° 84.000-84,010 1 84.010-84.020 2 84..020-84,030 dst oversize oD 84,250-84,260 1kD1 84.260-84,270 2KD1 84.270-84,280 2nd oversize. OKD2 84,500-84,510 1KD2 84,510-84,520 2KD2 84,520-B4,530 Tolerances + 0,007 ~ 0,008 88.970 83,980 83,990 84,220 84,230 84,240 84,470 84,480 84,490 Cylinder/piston clearance: 0.023-0.048 Piston weight: 315 t agO11 cytinders and Pistons CYLINDER HEIGHT TOLERANCE GROUPS 1972-models, 2.4 liters Cylinder Installation Height Code mark A A 85.400 - 85.425 85.425 - 85.450 Standard Cylinder Height RS RE 85,150 - 85,175 85.175 - 85.200 Reconditioned Cylinder HeightCylinders and Pistons O11 PISTON AND CYLINDER DIMENSIONS Beginning with 1973 models Cylinder Cylinder Piston markings bore dia, diameter D1 Type Carrera 2.7 Pistons Tolerances + 0,005 90.000-90.010 89.950 1 90.010-90.020 89.960 80 020-90 .030 89.970 Cylinder/piston clearance: 0.025 ~ 0.045 Piston weight 392 t 8 kg CYLINDER HEIGHT TOLERANCE OF 2,7 LITER ENGINES 85.450 Oversize pistons and cylinders are not provided.Permissible weight difference in pistons of one set: 6 g max. Cylinders and Pistons on PISTONS AND CYLINDER DIMENSIONS - BEGINNING WITH 1974 MODELS Type 911 and 911 S$ Pistons cylinder cylinder Piston markings bore dia, diameter Di Standard Tolerances stamped 0.0005 90,000-90.010 89.970 90,010-90.020 89.980 90,020-90.080 89.990 Cylinder/piston clearance: 0,025 ~ 0.045, PISTON AND CYLINDER DIMENSIONS “LS" Version Type 911 Pistons Cylinder Cylinder Piston markings bore diameter diameter Di Standard stamped 89.952- ° 90,000-90.010 30 "95, 89,962- 0.010: 1 90,010-90.020 55" nq 89.972- 2 -020-90.030 90.08 80 29.987 Cylinder/piston clearance: 0.035-0,060O11 cyiincers and pistons INSTALLATION INSTRUCTIONS FOR "LS" CYLINDERS AND PISTONS ‘The ALUSIL cylinder (eutectic aluminum-silicon alloy) and FERROCOAT piston combination is known as "LS" Cylinders and Pistons. In this system the surface coating is applied to the piston. ‘The assembly of the cylinder and piston must be made with particular care to avoid breaking the piston rings; the rings are chrome-plated and are thus harder and mote brittle. ‘when resistance is met while tightening the piston ring compressor, it is an indication that the rings are not seating properly in the grooves, In such case remove the ring compressor, check the piston ings for location, and repeat the procedure, carefully pushing the cylinder onto the piston, Installing Piston Rings ‘The piston rings can be installed in their grooves by hand and without the use of tools. When installing rings 1 and 2, make sure that the rings are placed in the sequence and position shown in the Mliustratfon, Installing Three-Part Ofl Ring ‘The ofl ring is made up of three parts, with each part installed separately. Install the expander first, then follow with the upper and lower rails. After installation check visually if the expander ends meet, Note Install gaps of individual ring parts as follows Offset expander to rails by at least 45°, Offset rails to each other by at least 90°,Cylinders and Pistons O47 PISTON AND CYLINDER SIZES - "LS" MAHLE Piston Type 911 § Cylinder Cylinder Piston Code Diameter diameter Da Standard Size amped — ° 90,000-90,012 89.960~ 89,972 1 90,032-90,024 89,972- 89,984 2 90,024-90,036 89, 984- 89,996 Cylinder/ piston clearance: 0.028 - 0.052 mm GAP OF "LS" PISTON RINGS Make Piston Ring Gap inmm Gap wear limits in mm Rring Top 0.2 -0.4 1.0 MAHLE + Neng Center 0.5 -0.35 1,0 SCHMIDT S$ 60 ring Bottom 0,4 = 1.4 2.0 (B-piece consisting of expander and 2 rails)Cylinders and Pistons oti CHECKING PISTONS AND CYLINDERS cylinder D1 Measuring point for wear and ovality 80 mm below top edge of cylinder ‘The cylinder is worn if this measurement is 0.08 mm. more than the new size specifications, Ovality is checked by measuring in directions a and b. The difference between a and b may not be more than 0,04 mm, D2 = Measuring point for piston ring end gap clearance Rings slid in to height of cylinder base gasket. Piston D = Measuring point for wear At height of lower edge of piston pin bore, Caution Replace pistons and cylinders if clearance exceeds 0.15 mm, PISTON RING END GAP Piston Ring End Gap mm (new size) Compression ring, I and II 0,1 -0.2 Ol scraper ring, I 0,15 - 0,3, Oil scraper ring, 1, S-piece "1S" ring 04 1 (see checkpoint "D 2" PISTON RING SIDE CLEARANCE Piston Ring SIDE Clearance in mm (new size) Compression ring, 1 0,070 ~ 0,102 Compression ring, 1 0,040 - 0.072 Of scraper ring, It 0,020 - 0,052 End Gap mm (wear Limit) SIDE Clearance in mm (wear Himit) 0.2 0.2 0.1Cylinders and pistons 911 PISTON AND Mahle Cylinder marking Standard size stamped 0 CYLINDER SIZES - 911 SC (from 1978 Model) Cylinder bore diameter mm 98. 000 - 95. 007 95.007 - 95, 014 95,014 - 95, 021, 95, 021 - 95, 028 Piston diameter D mm 94,965 - 94.975 94,972 - 94,982 94,979 - 94,989 94,986 - 94.996 Clearance between cylinder and piston: 0, 025 - 0.042 mm PISTON AND Ks cylinder marking Standard size stamped o CYLINDER SIZES - 911 SC (from 1978 Model) Cylinder bore Piston diameter mm diameter D mm 95.000 - 95. 007 95, 007 - 95, 014 95, 014 - 95.021, 95, 021 - 95.028 94,968 - 94,977 94,970 - 94.984 94,977 - 94,991. 94,984 - 94,998 Clearance between cylinder and piston: 0,023 - 0.044 mmO11 cyrinaers ana pistons PISTON WEIGHT GROUPS - from 1980 Model Installation Instructions: 1, Only pistons of one make and appropriate weight group may be used in one engine, 2. Piston pins must always remain with the corres- ponding pistons and should not be mixed up within an engine set. Watch this when disassemb- Ling and assembling an engine, marking parts if necessary. ‘Weight groups MAHLE Pistons Pistons weighed with attachments (piston pins, piston rings, snap rings) ‘Total Piston Weight in g Weight group Marking within a set Engine type 930/07 Standard production 686 10 640 -- 640 to 644 - 644 to 648 + Max, difference in weight 4 g 648 to 652 ++ For installation 686 to 644 --or- Max. difference in weight 8 g 644 to 652 tor t+Cylinders and Pistons 911 PISTON WEIGHT CLASSES - 911 SC from 1981 Models Weight Classes MAHLE Pistons Pistons weighed with attachments (piston pins, piston rings, snap rings) Total Piston Weight in g Code Weight Class within a set Engine type 930/16 (USA/Japan) Standard production 636 to 640 -- 640 to 644 - Max, difference in weight 4 g 644 to 648, + 648 to 652 +e For Service Sector 636 to 644 == or- Max, difference in weight 8 g 644 to 652 sorte Weight Classes KS Pistons Pistons weighed with attachments (piston pins, piston rings, snap rings) Total Piston Weight in g Code Weight Class Within a set Engine Type 990/16 ‘Standard Production 678 to 677 oo 877 to 681 s Max, difference in weight 4 g 681 to 685 + 685 to 689 +t L For Service Sector 673 to 681 - sore Max, difference in weight 8 g 681 to 689 forseankeese and riywheet Qf MEASURING AND RECONDITIONING CRANKCASE General ‘The main bearing bores must be measured whenever the crankcase is disassembled for repair. ‘These instructions apply as well to all pre~1972 model engines. Measuring 1, Attach ctankease half to bench mount and assemble both halves without the intermedi- ate shaft, Lightly tighten all crankcase studs and two M8 retaining nuts at Bearing 1, 2. Align both crankcase halves with the aid of a plastic mallet. The joint in Bearing 8 must not be offset in relation to each half, 3. Using the inside micrometer, cross-check bore of Bearing 8. Realign bore if necessary. 4, Tighten all crankcase studs and both M8 nuts to proper torque, 5. Measure all 8 main bearing bores with the inside micrometer. If the bores are too tight, they should be re~ amed with the main bearing reamer to stan- dard diameter of 62.000 mm Bore diameter for main bearings 1 - 8 is 62, 000 to 62.019 mm. If the bores are too large, they should be re~ amed to B-bearing oversize of 62.25 mm diameter. Control dimension for the B-bearing is 62.25 mm to 62,269 mm diameter. Reconditioning General ‘This procedure requires specfal tools and should only be performed by qualified personnel. Light-alloy (SILUMIN) crankcases must be reamed {in two steps when reaming to the B-bearing size. Lubricate reamer with cutting ofl during this proces dure. 1. Step 1 = 62,15 mm diameter 2. Step 2 = 62.25 mm diameter (B-bearing in- stallation dimension) 0O11 crsnkesse and Ftywheet Pressure-cast crankcases can be cut in one step and without oil to 62,25 mm diameter. Reaming 1, Attach self-made tool (see sketch below) to 4 oll screen attaching studs and fasten in bench vise. Sketch for Self-Made Tool ‘Tebar 40 x 80x 7mm All edges beveled 3. Insert rod (85 x 1200 mm) with main bearing reamer and ream Bearing 1 until Bearing 2 is guided (reamer centers automatically in bore of Bearing 1). 80 40 4, Insert end bearing bushing EL36 in bore of Bearing 1. Ream all bearing bores until reamer reaches 2, Insert end bearing bushing EL85 in bore of end bearing bushing of Bearing 8 Bearing 8,crankesse and riywheet QTf 1 6. Remove-end-bearing bushing from bearing bore # 8 and fully ream Bearing 8.Crankease and Flywheel on | MODIFIED FLYWHEEL INSTALLATION - 1978 MODELS 4 int Note When Now| Peseription C9) Removing Installing Special Instritctions 1 | Socket head 8 Torque 9 mkg 2 | Flywheel 1 3 | Bushing 1 4 | Crankshaft 1Crankease, sath on FLYWHEEL WITH PILOT BEARING/BUSHING FOR INPUT SHAFT - from 1980 Model Note When special Descripti ane Removing Installing Instructions Screw M 6x12 ‘Tighten to specified torque, lock with Loc tite 270 Bushing with needle First secure flywheel, bearing then bushing Bolt ‘Tighten to specified torque Flywheel CrankshaftCrankcase, Camshaft REMOVING AND INSTALLING OIL FILTER SCREEN AND SUCTION PLATE 911 Note When Special el | eeameeanee Removing Installing Instructions 1 Jon drain plug 2 |seal Replace 3 Nu Tighten to about 10 Nm, 7 lb 4 | Washer 5 |Cover for oil filter screen Check for deformation, replacing if necessary. Watch installed position, ofl drain plug must face in recess of suction plate 6 | Gasket Replace 7 [Oil filter screen with suction plate 8 | Gasket Replace911 crankoase, crankshart ASSEMBLY INSTRUCTIONS SEALING CRANKCASE MATING SURFACES Note Only wse Loctite No, 573 (green color) as a sealing ‘compound, Loctite No, 578 hardens only in conjunction with ‘metal and exclusion of air, Never wait longer than about 10 minutes between applying coat of sealing compound and assembling parts, since the sealing compound applied directly on the metal would begin to harden, Removing Old Sealing Compound During repairs the old compound need not be removed. It is only necessary to remove grease from the surface. and to apply a coat of new sealing compound after the grease removing solution has dried. The new Loctite will dissolve the old compound in the surface finish and harden again after assembly. Should it be absolutely necessary to remove the old sealing compound, a fine steel brush is recommended for this work, Applying Sealing Compound 1, When applying sealing compound by hand use a short-pile velour roller. In addition, a tray with a ribbed surface for scraping off the roller will be required for the sealing compound, 2, Apply a very thin coat of sealing compound with the velour roller,Crankease and Crankshaft © OY] CRANKCASE CHANGES - BEGINNING WITH 1972 MODELS Distributor mounting flange, CHANGED CRANKSHAFT - BEGINNING WITH 1972 MODELS Stroke = 10.4 mm Crankpin diameter = 51,990 - 51.971 Crankpin width = = 24 mm Beginning with 1972 models, all crankshafts have counterweights. See next page for crankshaft dimensions,To ott ccatcsc se ern quaujeaN sasTUOL ou Toye pouOMSreNs oq OU JsnUr ¢ PUL g TeUIOL Suro gT = souRTEqUN yeYSuEIS UIMUIT TEN *y aoujms yeni pur speumof Surzeeq Th (e9ST" T-pT9T"D 018" 62-008"6z (LPOT"T-PZOT*T) (SgLT*T-SOST*T) (esg"T-THG9"L) (esgg"Z-Tes9"2) Ta6"¥9-000°99 90°8Z-000"8% 096"63-£68"683 VRP oP Supeoq spuLeTp sna, yeas danind peysquer sworn ¢ = G = ssemySnor Buyusttod *yn0 ystiod eeg"2) mu g*¥9 pue (“UF TOT"T) WUE g*Gz Jo suoTstAUITD *pasoos Aqdaap tay tuo saaesans Teas To aJeUN|UEIO PUD fod way “yeysqueso omy apie HO *spoorg-A uo 1 pur 7 Supreag WIM ‘g pue > Supzeag ye pomseour “(*uF Zoo") tur HO") = Moun TeoTOA uM EP *sj9870 205 yoo 0} neue Toyuey, ‘Buppuys royy :030N ra (gtes*c-Pees"s) ote"F9-008"79 200" GF-£T0" SP sp spjourerp 79s se08 Soya, HEH H (gost T-LOT’D (ogto*G-EL10"@) (vETE*C-2PTs"Z) "UF OGG" OR-EFZ"OE —«TZS"T9-OPG'TS Tes" 9s-oRG'9G UE OB" T-s008"D (PgZ0"s-GLG0"G) (eeBs~e-OFGE"Z) “UT Osh" O8-86P"0E LLP"IS-087"TS TAP" 9s-osr'9g uur (ge0z"T-pote"D) (egeo*e~eeeo"s) (ret OGL" 08-EPL"OE —TZL*T9-OFL"TS -680"2) “UF TeL"9S-oFL"9¢ WUE (ugT@"T-Z022" TD) (ToFO"G-BgPO"S) (EBVE"C-LERZ"Z) "UE 996" 08-266"02 TL6"TS-088°TS TL6*9-O8e"9S Uru 8 fupeog BP TP yeqsyer uo sBujzeaq por sSuqeoq fg prmjoueyp © Bupeuu0g wyeur 1Y Buywoq UIE GHNOILIGNODAY UNV GUVGNVLS - SNOISNSWIG LavVHSXNVUS Cur gose'e ~STS%"2) anu 082" 29 ~692°29 22]s1940 Cur L993 6009") ‘urur g10°9 00°29 paepuess 8-1 sSupeog sopoueyp yeysqeesD (s6z0"0-) uur gy" 0- (uet0" 0-) wut 93" 0- (a600" 0-) lara gz" 0- prepueys daisCrankease and crantsnart — O14 CONNECTING ROD CHANGES - BEGINNING WITH 1972 MODELS TT i © | i 1 5 Distance between centers 127.8 - 0,05 mm (5.03) ~ (0,002 in.) Width of piston pin bushing 26.0 = 0.2mm (1.02) = (0,008 in.) Big end width 23.8 - 0.1mm (0.9870) = (0,004 in.) Big end diameter (without bearing insert) 56.019 ~ 56,000 mm (2.2055) ~ (2.2047 in.) Small end diamet 25,021 ~ 25,000 mm (0.9851) ~ (0,9843 in.) Piston pin bushing dia, (before installation) 25,035 = 25,055 mm (0.9856) = (0,9864 in.) (Press-fit interference in rod) 0.014 - 0,055 mm (0.0006) - (0.0022 in.) Inside diameter of installed piston pin bushing (finished) 22.033 ~ 22.020 mm (0.8674) - (0, 8689 in.) Piston pin clearance in bushing 0,020 - 0,039 mm (0.0008) = (0.0015 in.) Wear limit 0.055 (0022)QI crankcase ang crankshaft Connecting rods are assigned to weight groups. CONNECTING ROD WEIGHT GROUPS ‘The pertinent weight group can be identified in spare part end numbers, ‘The end number is stamped into connecting rods furnished as spare parts, Weight Weight | KD connecting rod Mentification more than up to soup spare part number | in connecting rod grams grams | for KD 645 654 1 911.108.015.821 at | 654 668 2 911.108.015.32 32 663 672 3 911,108.015.33, 33 672 681 4 911,103.015.94 34 681 690 5 si1.103.015.35 | 35 690 699 6 911,103.015.36 36 699 708 1 911.108,015.97 37 708 nt 8 911.103.015.398 38 ns m1 9 911,103. 015.39 39 Weight variation between connecting rods in any engine may not exceed 9 g. To determine weight group, welgh complete connecting rod without big end inserts.Crankcase, Crankshaft 911 CONNECTING ROD WEIGHT GROUPS - from 1978 Model Connecting rods are in different weight groups, ‘The weight group is indicated by the final digit of the part number. For connecting rods, which are supplied as spare parts, these final digits are stamped on the shank. weight : Weight oe SSenccany tar" | couecttng above g og installation Part No, Fog marking ooo | an 1 an, 109.015, 51 a oa | oon 2 309,015.52 v2 ot | 000 2 oan 209.035, 58 v9 so | os ‘ oan. va oo | oe 5 0,209. 018 85 ss or | oor 6 00,209. 018 86 ss or | oa 7 oso, 109.018. 57 a ce | 08 8 9,208. 018.58 ss mos | mag 9 oso, 108,018.59 S Note Only connecting rods, which do not differ in weight by more than 9 g, may be installed in one engine, To determine a weight group, weigh the complete connecting rod (without bearing shells),Crankcase and Crankshaft 911 PISTONS FOR K - JETRONIC ENGINES Pistons for K ~ Jetronfc-equipped engines of Type 911/91 and 911/96 have a turbulence (whi!) cavity in the piston top, This provision ensures a particularly thorough blending of the fuel/air mixture. Installation note: The piston must always be installed so that the flat spot in the piston top faces upward (towards the intake valve).O11 crankcase and crankshaft ASSEMBLY INSTRUCTIONS FOR PISTONS ON 911 SC (1981 Models) Domed surface on piston must face intake valve,MODIFIED CRANKSHAFT DRIVE - 1978 MODELS Crankcase and Crankshaft oti TOOLS. No. Description Special Tool Note Installer for crankshaft seal 91261 Q11 crankcase and Crankshaft MODIFIED CRANKSHAFT DRIVE - 1978 MODELS 15 13 14 3Crankease and Crankshaft 911 SW Note When . No. | Description 27+] pemoving eee Special Instructions| 1 | onseat a Replace 2 | Thrust main bearing | 2 | Check for wear Lubricate shells 1 3 | Main bearing shells | 12 Lubricate 2-7 4 | Bearing sleeve, 1 Lubricate bearing 8 5 | O-ring 1 Replace 6 | Ott seat 1 Replace 7 | Chrectip 1 8 | Drive gear for 1 distributor 9 | Spacer 1 Note installed position 10 | Timing gear 1 11 | Woodruff key 1 32 | Connecting rod nut | 12 ‘Tighten to specified torque. Lubricate bearing surface, 13 | Connecting rod 6 Note installed position| and weight 14} Connecting rod bea- | 12 | Check for wear Lubricate ring shell 16 | Connecting rod boit | 12 16 | Crankshaft 1 | Check for wearQ11 crankcase and crankshett INSTALLATION INSTRUCTIONS FOR MODIFIED CRANKSHAFT DRIVE - 1978 MODELS Clamping Crankshaft Special Tool P 209 a must be modified for new crankshaft, P209a 69-—————* Installing Seal Drive in seal with Special Tool 9126,Crankease and Crankshaft 911 Installing Crankshaft Drive Gear for Counter clockwise Rotating Distributor Note As of the 1978 model year, the engines are equipped with a counterclockwise rotating distributor, There~ fore a new crankshaft drive gear with modified teeth is required, For counterclockwise rotating distributor (with Porsche emblem) Installing Circlip om Crankshaft Circlips are available in various thicknesses to take up axial play between distributor and drive gear. ‘The following circlips are available: Part No. Thickness mm Code 901,102,148 ,00 24 ° 901.102.148.021 2.8 1 901.102.148,02 2.2 2 901,102,148 ,03 21 3a Install timing gear, spacer and drive gear for counterclockwise rotating distributor on crank ~ shaft up to stop, Select proper circlip by first inserting it to check its thickness. Circlip must take up play. For clockwise rotating distributor (with VW emblem)£66"62"**0R6"6Z OBETTS***TLE'TS O66*SS"**TLE* ES 00°T = evaroe**oesoe ovetest trates operesttttzctes «= 2 BE | cro Se 88 00s" 62***o1e" 63 oostes***oscres eartoe***oar*oe oarze"**turtcs ooregt**turtes «=f 8 FA | ogto~ epuoe’**oeutos oputas***Teu'2s opLtest**ien"es tS seto~ o90°8@***000°8 866"6G"**096"GS ETO"GH***ZOO"Gr OOOTOG™**0BL"6s E6ETOE"**ORG*OE OBs'Ge"**TLE'S 068°63"**TLO" 69 prepueys Buyzeaq yeus oP Vupem og pteipyeas, «sg p “ep ava PP TEP -yUEIO JOE PIE steumof Supeaq Tp steumof get sBurseaq “ep war Supwaq ysis, formd yeusyuery —BuqUr oj yeag TUM! 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