911 Turbo 1989 Workshop Manual

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GENERAL Technical Date Page 0.1
REPAIR GROUP
i:)lgine-crankcase 10
i:)lgine-Crankshaft, and moving parts 13
i:)lgine-Cylinder Head, Valve drive 15
i:)lgine-Lubrication 17
i:)lgine-Cooling 19
ENGINE Fuel Supply system 20
Turbocharger 21
Fuel system 25
ExhaustSystem 26
Starter, Power Supply 27
Ignition System 28
Clutch, Control 30
Mech.gear-shift system-actuat., hous. 34
TRAN S MISSION
Mech.gear-shift system-Gears, Shafts 35
Differential 39
Front Wheel Suspension 40

Rear Wheel Suspension 42
CHASSIS Wheels, Tires, measuringvehicle 44
Brakes,-Hydraulic -system 47
Steering 48
Body-Front Section 50
Body-Center Section 51
Body-Rear Section 53
Lids 55
Doors 57
BODY Sliding Roof 60
Bumpers 63
Glasses 64
FXterior equipment 66
Interior equipment 68
HEATING. VENTILATION. Heater 80

AIR CONDITIONING Air Conditio;Ier 87
Instruments, Radio 90
Windshield Wipers and Washer 92
ELECTRICS Exterior Lights 94
Interior Lights 96
Wiring 97
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Page
General
Adjustment values and limits 10 -01

Adjustment values and limits from 1978 models 10 -02
Specifications, general 0.1

Specifications, general from 1978 models 0.7
Tightening torques for engine 10 -03
Engine. Crankcase
Engine. removing and installing 10

Engine/transmission unit, detaching and attaching 10 -7
Engine/transmission unit, detaching and attaching from 1978 models 10 -8

Engine, removing and installing -hydraulic 10 -9
clutch mechanism, 5-speed, Model 89 onwards
Engine/gearbox assembly, separating and joining, Model 10 -14
Engine, Crankshaft, Pistons
Crankshaft sizes from 1978 models 13 -4

Flywheel, removing/installing or machining 13 -3
Layout of oil pump from 1978 models 13 -
Order of cylinders and air guide plates from 1978 .models 13 -6
Piston and cylinder sizes, installation notes 13 -1
Piston and cylinder sizes, installation notes from 1978 models 13 -7

Pistons and cylinders, measuring 13 -9
Weight classes of pistons -911 Turbo from 1980 models 13 -9
Engine. Cylinder Head. Val yes
Chain tensioner. removing and installing 15 -1
Timing. adjusting 15 -1
Valve clearance, adjusting 15 -1
Valve spring sizes 15 -1
Camshafts, timing 15 -3
Alphabetical Index 1
Printed in Germany -VII, 1989
Page
Fuel Supply
Delivery rate of fuel pumps. checking 20 -1
Fuel pump. removing and installing 20 -5
Pressuretest of pumps 25 -1
Turbocharger
Air pressure safety switch. checking 21 -11
Bypassvalve, checking function 21 -4 a
Bypassvalve, removing and installing 21 -5

Charge air cooler, removing and installing from 1978 models 21 -20
Charge pressure. checking 21 -9
Charge pressuregauge. checking 21 -19
Turbocharger. checking 21 -4
Turbocharger, oil supply 21 -12
Turbocharger. removing and installing 21 -1
Turbocharger. survey 21 -3
Valve housing. disassembling and assembling 21 -6
Fuel Mixture
Air cleaner, removing and installing from 1978 models 25 -19
Auxiliary air valve, removing and installing 25 -18
Control pressure "cold", checking 25 -13
Control pressure "warm", checking 25 -13
Control pressure "warm-full throttle enrichment", checking

from 1978 models 25 -14
Fuel delivery rate for control pressure circuit. checking 25 -14 b
Fuel distributor of mixture control unit. removing and installing 25 -6 b
Fuel system 25 -1
Idle, adjusting 25 -
Idle, adjusting from 1978 models 25 -10 a
2 Alphabetical Index

911 turbo Alphabetical Index Volume
Page
Mixture control unit, disassembling and assembling 25 -6 d

Mixture control unit, removing and installing 25 -6
Off position of air flow sensorplate, checking and adjusting 25 -6 a
Piston pressure regulator with poppet valve, replacing 25 -6 c
Pressuregauges, connecting and bleeding 25 -12
System pressure, checking 25 -14 a
Testing and adjusting values for fuel injection 25 -15
Testing and adjusting values for fuel injection from 1978 models 25 -16
Thermo shift valve, checking 25 -17
Thermo shift valve. removing and installing 25 -17
Throttle bypass valve, removing and installing 25 -10
Tools for fuel pressuretest 25 -11
Checking Lambda control function 25 -21
Checking Lambda probe 25 -22
ExhaustSystem
Air filter of air pump, removing and installing 26 -23
Air injection, disassembling and assembling 26 -32
Air injection, disassembling and assembling engine type 930/51

and 930/52 26 -lB
Air injection lines and adapters, removing and installing 26 -25
Air pump, removing and installing 26 .26.26.
.22.36
Belt of air pump, checking and adjusting

Blow-off switching valve, removing and installing .24
Control valve, blow-off switching valve and check valve, checking 26 -26
Control valve, removing and installing 26 -24
EGRvalve, checking 26 -28
EGRvalve, removing and installing 26 -27
Exhaust filter, removing and installing 26 -27
Exhaustsystem, disassembling and assembling 26 -2
Exhaustsystem, disassembling and assembling 26 -8
Exhaustsystem, survey engine type 930/50 26 -1
Volume I Alphabetical Index 911 turbo
Page
Exhaustsystem, survey engine type 930/52 26 -6
Exhaustsystem, survey engine type 930/51, 930/53 and 930/54 26 -

Exhausttemperature. control 26 -29
Exhausttemperature control, checking 26 -30
Hose connection plan, California 26 -39
Hose connection plan. Europe 26 -37
Hose connection plan, USA + Japan 26 -38
Reactor and muffler cover 26 -29
Reactor, removing and installing 26 -11
Temperature sensorfor exhaust temperature control. removing

and installing 26 -31
Thermo valve. operating and testing 26 -40
Ignition System
Delayed ignition cut-out 28 -13
Distributor, checking in car 28 -5
Ignition system from 1978 models 28 -14
28 -1
Ignition timing, adjusting
Ignition timing, adjusting from 1977 models 28 -2 a
Ignition timing, adjusting from 1978 models 28 -2 b
28 -3
Ignition timing control, checking
Ignition timing control, checking from 1977 models 28 -4 a
Ignition timing control, checking from 1978 models 28 -4 c
Troubleshooting electronic ignition system 28 -6
Clutch. Controls
Clutch, adjusting from 1977 models 30 -7
Clutch, adjusting on cars with power assistancefrom 19'18 models 30 -13
Clutch, disassembling and assembling 30 -8
Clutch disc, removing and installing 30
Clutch spring, removing and installing from 1978 models 30-11

30 -03
Specifications

Page
Specifications from 1978 models 30 -07

Tightening torques for manual transmission 30 -03
Transmission, type 930 30 -01
Transmission type G SO/50 30 -02
Clutch mechanism, disassembling and 30 -15

assembling, Model 89
Manual Transmission, Controls, Case

Front transmission cover, disassembling and assembling 34-1
Shift base, disassembling and assembling 34 -15
Shift controls, adjusting 34 -19

Timing case, disassembling and assembling 34-3
Transmission case. disassembling and assembling 34-7
Transmission case with power clutch 34 -14
Transmission case with power clutch from 1978 models 34 -14 e
Manual Transmission, Gears and Shafts
Change box, disassembling and assembling 35 -1
Drive pinion, disassembling and assembling 35 -15
Drive shaft, disassembling and assembling 35 -9
Seal for drive shaft, removing and installing 35 -19
Selector forks, adjusting 35 -7
Synchronization,checking 35 -26
Synchronization, disassembling and assembling 35 -23
Differential. Final Drive
Backlash. adjusting 39-17

Backlash of ring gear. adjusting 39 -19
Differential. disassembling and assembling 39-5

Differential. removing and installing 39-1
Drive pinion and ring gear. adjusting 39 -9
Locking differential. disassembling and assembling 39 -21
Spacers for ring gear adjustment. determining thickness 39 -17
Volume I Alphabetical Index 911 turbo
Page
Front Wheel Suspension
Front axle, disassembling and assembling 40 ' .3.1.01

Front axle, removing and installing 40 .
Specifications 40.
Tightening torques for front axle 40. .02
Rear Wheel Suspension

Coil spring compressor P 289, machining 42 -8
Rear axle, disassembling and assembling 42 -3
Rear axle, removing and installing 42 -1
Rear wheel, bearings, adjusting 42 .13
Specifications 42 -01
Tightening torques for rear axle 42 -03
Wheel bearing play, checking 42 -14
Wheels, Tires, Axle Alignment
Adjustment values for axle alignment 44 -1
Axle alignment. checking 44-2
Specifications 44 -01
Notes on alignment 44 -4
Sample test card
Brakes -Mechanical Parts
Brake pads -remove and install 46 - 2

Brake pad thickness -check 46 - 1
Brake system -911 Carrera Turbo look 46 - 04
Front wheel brakes -changes for Turbo 3.3 ltr. 46 - 4a
Front wheel brakes -disassemble and assemble 46. 5
Rear wheel brakes -disassemble and assemble 46. 11
Technical data 46. 01
Tightening torque 46. -03
6 Alphabetical Index
911 turbo Alphabetical Index Volume
Page
Brakes -Hydraulic Parts
Brake calipers -disassemble and assemble 47-1

Brake caliper sections -disassemble and assemble 47-7
Brake circuit failure indicator 47-12
Tightening torque 47 -01
Steering
Specifications for steering 48 -01
Steering. disassembling and assembling 48 -1
Tightening torques for steering 48-02

930 TURBO 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 to keep the vehicles in a safe operating condition. The
basic safety rules, of course, also apply to repairs on vehicles without exception.
The 930 Turbo Repair Manual only describes repair operations 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 cards are quick guides to find information in the manual.
Discriptions of design and function can be found in service training course reference material.
This repair manual will be kept up to date with workshopbulletins; the information of these
bulletins will be made part of the manual from time to time. We recommend that the Workshop
Bulletins be filed in the special folder provided for this purpose.

REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL
930 -Turbo
Please file the supplements according repair groups and make appropriate entries in the table below
SupplementNo. Filing Date Signature
II
III
IV
VI
VII
VIII
IX
XI
XII
XIII
XIV

General
TECHNICAL DATA
(Refer to appropriate repair group for adjusting and wear limit data.)
Note: USA values listed in brackets.
ENGINE
Internal engine code 930/50, since Nov. 75 930/52 (USA, 930/51)

from Aug. 1976 (USA 930/53) Japan 930/54
Bore mm/inch 95/3.74
Stroke mm/inch 70.4/2.77
cm / m.
3 .3
Sweptvolume 2993/182.64
Compressionratio 6.5: 1
Max. engine output according to
DilT 70020 KW/HP
Net power, SAE J 245 KW/HP
Gross power, SAE J 245 KW/HP
Printed in Germany -11. 1976 Technical Data 0.1

General
Max. torque, DIN 70020 Nm/kpm 343/35

at engine speed
Net torque. SAE J 245 Nm/ft. lbs 332/245
of 4000 rpm
Gross torque, SAE r 245 Nm/ft. lbs. 389/286
Max. liter output. DIN 70020 KW/l HP/l 64/87 (58/82)
Max. speed rpm 6800

Max. cruising speed rpm 6000
Cutoff speed of speed control in

+
distributor (overrev governor) rpm 7000 -200
Weight of engine with air cleaner (dry) kg/lbs 207/456 (217/478)

930/52 210/463
Engine Design
Engine block Diecast, light alloy,

two sections
Crankshaft Forged (tenifer treated)
No. of crankshaftbearings Eight
Conrods Forged steel
Conrod bearings 3 half-shell plain bearings
Piston pin bearings Press-fit bronze bushing
Intermediate shaft bearings 2-way plain bearing
Pistons Forged light alloy.
slipper skirt
Piston pins Floating installation, snaprings
Piston rings 2 compression rings, 1 oil
scraper ring
Cylinders Light alloy, nikasil coated

cylinders
Cylinder head Separate, light alloy heads
Valve seat inserts Shrink -fit, annealed

sintered steel
Valve guides Press-fit, special bronze
Location of valves per cylinder 1 intake and 1 exhaust valve

suspendedin V
Exhaustvalve Natrium -filled, reinforced

insert ring
Valve springs 2 coil springs per valve
Valve drive One each overhead camshaft

left and right
Camshaft Cast, 4 bearings, runs directly in

camshaft housing
Camshaftdrive Chain
Cooling
Engine Air cooled via axial

blower on alternator

General
Blower drive Belt off of crankshaft

Crankshaft/blowerratio ca. 1:1.67
Air delivery rate 1560 l/s at 6000 rpm of crankshaft
Engine Lubrication
Oil cooling Thermostatic control, oil cooler on engine
block in blower air stream, cooler coils in front
right wheelhouse
Oil filter Full flow
Oil pressure at 5500 rpm 0
bar ca. 4.0 at 80 C
Oil pressure gauge Elektric
0
Max. oil temp. ca. 150 C
Oil consumption 1/1000 km ca. 1.0 to 2.0
Exhaust System 930/50 - Single pipe system with turbocharger,

bypassvalve and muffler
930/52 - as above. but with additional air pump
(930/51 - double-pipe system. 2 reactors. bypassvalve.
turbocharger and muffler, additional air pump)
(930/53 and
as 930/51. but with EGR)
930/54
Heating Warm air heater with automatic temperature

control. Warm and cool air mixable.
Fuel System
Fuel supply 2 elec. roller cell pumpsconnectedin line
Fuel octane RON 96. premium grades(91-96)
Electrics
Degree of suppression ECE Regulation No. 10
Battery voltage v 12
Battery capacity Ah 66
Battery capacity
(optional extra) Ah 88 (not with air conditioner)
Alternator/output w 980
Ignition CDI (w/o contacts)

Transformer Bosch
Firing order 1-6-2-4-3-5
Brakes
Foot brakes Hydraulic, dual-circuit disc brakes with
pneumatic booster, LHD only
Front brake disc diameter mm 282.5 inboard

Rear brake disc diameter mm 290 inboard
Effective front brake disc dia mm 228
Effective rear brake disc dia. mm 244
Printed in Germanv
Downloaded from www.Manualslib.com manuals search-II.
engine1977 Technical Data 0.3
General
Front brake disc thickness mm 20
Rear brake disc thickness mm 20
Total effective braking surface cm2 257

2
Pad surface per front wheel cm 76
2
Pad surface per rear wheel cm 52.5
Frontcaliper pistondia. mm
Rear caliper piston dia. mm 38
Parking brakes Mechanical acting on both rear wheels

Parking brake drum diameter mm
Brake shoe width mm 25
Effective braking surface per wheel cm2 85
Brake pressure booster Teves, Type T 52/7 inch

Pressureratio 1.8
Pedal ratio (mechanical) 5.2
Dimensions (DIN -Curb Weight)
Length mm/inch 4291/168.94

Width mm/inch 1775/69.88
Height mm/inch 1320/51.97 (1340/52.76)
Height mm/inch 1304/51.34 with standard 50 tires -only

up to 1977 Models
Wheelbase mm/inch 2272/89.45

Front track mm/inch 1438/56.61 (1431/56.34)
Rear track mm/inch 1511/59.49 (1501/59.09)
Ground clearance mm/inch 141/5.55 with series 50 tires 15 inch
mm/inch 157/6.18 (175/6.89)
Ground clearance -full load mm/inch 120/4.72 with series 50 tires 15 inch
mm/inch 127/5.00 (155/6.10)
Curved ground clearance mm/inch 51,5/2.03 (78/3.07)
Front overhang angle limited 15° (16°)

by spoiler 14° 30' with standard 50 tires 15 inch
Rear overhang angle limited (ISo)

by apron 16° with standard 50 tires 15 inch
Weights (DIN 70020)

Curb weight kg/lbs 1140/2514 from Nov. 75 1195/2635
Max. total weight kg/lbs 1470/3241 ..1525/3363(1400/3087)
Max. front axle load kg/lbs 600/1323 ..625/1378 (600/1323)

Max. rear axle load kg/lbs 870/1918 ..900/1984 (840/1852)
Payload kg/lbs 330/728 (205/452)

Max. roof load including roof kg/lbs 35/77 without exceeding max. total weight
0.4 Technical
Downloaded from www.Manualslib.com Dataengine
manuals search Printed in Germany
General
Capacities
Engine (as measured with oil dipstick Brand name heavy duty oils meeting API Classifi-
according to Owner's Manual) cation SD or SE with a viscosity of: SAE 30 for summer,
SAE 20 for winter, SAE 20 W 20for permanent
0 0
temperatures betw. -15 and a C or SAE 10 W for
0
permanent temperatures below -15 C (10 W 50/15W 50/
20 W 50 multi-grade oils upon approval)
Total oil volume of system with oil

cooler coils 1 Ca. 13
Oil change volume 1 Ca-.10
Transmission and differential Refer to page 30-05
Fuel tank 1 80, 8 liters in reserve

3
Brake fluid cm Ca. 240 (227)
Windshield washer 1 8.5
Performance
Top speed kph/mph Above 250/155 (245/152)
Acceleration from
0 -100 kph/62 mph sec 5.5 (5,7) DIN curb weight +
1/2 payload
Km from standing start sec 24.0 (25,0)
Weight per horse-power kg/HP 4.4 ; kg/kW 6,0 (4,88; kg/kW 6,63)
Hill climbing ability in 10
4-speed transmission 1st gear over 100
2nd gear 47
3rd gear 27 (28)
4th gear 16 (16,5)
Printed in Germany -11. 1976 Technical Data 0.5

General
SPECIFICATIONS -FROM 1978 MODELS, TURBO 3.3
(Adjustment values and wear limits are provided in pertinent repair groups)
Note: USA values in brackets
Engine
Factory engine code 930/60 (USA 930/61. Gal. 930/63). Japan 930/62
from mod. 79 (USA 930j94). Japan930/65
Bore mm/inch 97 / 3.82
Stroke mm/inch 74.4/2.93

3 3
Total displacement cm / inch 3299 / 201.3
Compressionratio 7.0: 1
Max. engine power kW / HP 221/300 at enginespeed

(USA + Japan 195 / 265)
rpm 5500
(Net power) kW / HP (195/261)
Printed in Germany -IV. 1981 Specifications, General 0.7

General
Max. torque Nm / kpm 412/42 (395 / 40.3) at enginespeed

(Net torque) Nm / ft Ibs 395 / 291 rpm 4000
Max. liter output kW / 1 / HP 67 / 91
Max. pexmissiblespeed rpm 6700

Max. constantspeed rpm 6000
Governor cut-off speed +

rpm 7000 -200
in distributor
Engine weight (dry) with kg fIbs 230 / 507 (240 / 529)

muffler
Engine Design
Type 4 stroke internal combustion
Cooling system Air

Crankcase Light alloy metal
Crankshaft bearings Forged, 8 plain bearings
Connecting rod bearings Plain bearings
Cylinders. single Light alloy metal

Arrangement of valves per cylinder 1 intake valve
1 exhaust valve
Vee suspension
Val ve timing One OHC left and right
Camshaft drive Chain
Camshaft bearings Plain bearings
Blower drive Belt in unit with alternator
Crankshaft/blower ratio Approx.1 : 1.67
Lubrication Dry sump with separate oil tank,
thermostat controlled oil cooling
and full flow oil filter, cooling tube
coil in front right wheel house
Fuel supply 2 series connected elec. pumps
Mixture Continuous fuel injection
Charging KKK exhaust turbocharger
0.8 Specifications, General

Printed in Germany
General
Electric System
Shielding class ECERegulationNo. 10

Battery voltage v 12
Battery capacitance Ah 66
Battery capacitance (M -item) Ah 88 (not with air conditioner)

Alternator power w 980
Ignition system CD! (breakerless)

Firing order 1-6-2-4-3-5
Exhaust System, Heater

Single pipe system with turbocharger.
bypass valve and muffler. Secondary air
il"jectiol! by auxiliary air pump in exhaust
system after each exhaust valve.
(USA + Japan also with reactors)
Automatic temperature control for heater
Dimensions (at DIN curbweight)
Wheelbase mm/inch 2272/89.45

Front track width mm/inch 1432/56.38
Rear track width mm/inch 1501/59.09
Length mm/inch 4291/168.94
Width mm/inch 1775 69.88
Height mm/inch 1310 / 51.57 (1328 52.28)
Turning circle dia. m/ft 10.7/35.10
Ground clearance. full load mm/inch 120/4.72
Weights
Curbweight by DIN kg/] lbs 1300 2867 (1295 2855)
Max. total weight (static) kg/] lbs / 3307)1378),

1680 I 3704 (1500.700
Max. front axle load (static) kg/I lbs I 1543 (625 I

1984)
Max. rear axle load (static) kg/] lbs 1050 I 2315 (900 J
Printed in Germany -III. 1978

Specifications, General 0.9
General
Capacities
Engine
Total amount of oil for system with
extra cooling pipe coil 1 Approx. 13, exact amount determined
by reading on oil dipstick, measured
with engine running at idle speed and
having operating temperature
Amount for oil change 1 Approx. 10
Amount of oil between min. and
max. marks on dipstick 1 Approx. 2
Brand name heavy duty oils for internal combustion engines
acc. to API Classification Sf. Use following viscosity mul-
ti-grade oils for year around operations (oil change every
20,000 km): SAE 10 W/50, 15 W/50 or 20 W/50. Do not
.0
use latter 011for constant temperatures below -15 C. On-
ly use brand name oils tested and approved by Porsche.
Brand name single grade oils of API Classification SE
should only be used when multi-grade oils are not available
and normal operating conditions prevail, but the use of
such oils will require observance of the additional change
intervals according to seasonof year to prevent any damage.
Use SAE 30 oil for summer and SAE 20 W for winter (pro-
0
tection only for temperatures below + 5 C!).
Transmission + differential 1 See page 30 -05
Fuel tank 1 80, of which 8 Itr. in reserve

3
Brake fluid tank cm Approx. 240 (227)
Windshield washer 1 Approx.8.5
Performance
Top speed km/h / mph 260/162 (250 / 155)
Acceleration 0 -100 km/h s 5.4 (5.6) DIN curbweight +

Km from standing start s 24.0 1/2 payload
0.10 Specifications, General Printed in Germany

General
TECHNICAL DATA ADJUST-ING AND WEAR LIMIT DATA
ENGINE
VALVE DR.VE
Tappet clearance (cold engine)
Intake 0.10 mm
(measured bet", valve and rocker arm)
Exhaust 0.10 mm
Timing at 1 mm tappet clearance

0
Intake opens 3 ATDC
0
Intake closes 37 ABDC
0
Exhaustopens 27 BBDC
0
Exhaustcloses 5 BTDC
Intake valve stroke in TDC overlap at 0.1 mm tappet clearance 0.65 -0.80 mm
Valve spring installation lengths
Intake valve springs +

33.5 -0.3 mm
Exhaustvalve springs
Ignition
Ignition Timing Adjustment

(engine oil temperature at least 800 C)
Engine Type 930/50. 930/52 29 :!: 20 BTDC on crankshaft at 4000 rpm

(vacuum hose disconnected)
+ 0 +
Engine Type 930/51 (USA) 5 -3 A TDC on crankshaft at 950 -50 rpm
(vacuum hose connected)
+ 0 +
Engine Type 930/53 (USA) 7 -2 A TDC on crankshaft at 1000 -50 !pm
+ 0 +
Engine Type 930/54 (Japan) 15 -2 A TDC on crankshaft at 1000 -50 rpm
Check ignition timing advance

(ignition timing must be adjust first)
Engine Type 930/50,930/52 0 :!: 40 on crankshaft at 900 + 50 rpm

Printed in Germany -IV. 1981 Technical Data 10 -01

Genera nformation
Engine Type 930/51 (USA) 26 ::!:30 on crankshaft before TOG at 4000 rpm
Engine Type 930/53 (USA) 29 :t 30 on crankshaft before TOG at 4000 rpm

Engine Type 930/54 (Japan) 30 :t 30 on crankshaft before TOG at 4000 rpm

Spark plugs (electrode gap in mm) Bosch W 280 P 21 (0.6)
SINCE 1978 MODEL, TURBO 3.3
IGNITION
Ignition Timing Adjustment

(E n gin e 0 i I T e m p. at Lea st 800 C)
Engine Type 930/60 290 before TDC at 4000 rpm

Engine Type 930/61 (USA), 10:t 20 after TDC at 1000:t 50 rpm

930/64 (USA) (vacuum hose connected)
Engine Type 930/63 (California), 5:t 10 after TOG at 1000 :t 50 rpm

930/62 (Japan) (vacuum hose connected)
930/65 (Japan)
Engine Type 930/66 29 :t 10 before TOG at 4000 rpm

Engine Type 930/68 (USA) 26 :t 10 before TOG at 4000 rpm

(vacuum hose -red -disconnected)
Checking Ignition T ming

(Ignition Timing Adjusted First)
Engine Type 930/60 0 :t 20 at 1000 :t 50 rpm

Engine Type 930/61 (USA) 26 :t 40 before TOG at 4000 rpm

930/64 (USA) (vacuum hose disconnected)
Engine Type 930/63 (California) 31 :t 40 before TOC at 4000 rpm

930/62 (Japan) (vacuum hose disconnected)
930/65 (Japan)
Engine Type 930/66 2:t 20 before TOG at 900 :t 50 rpm

(vacuum hoses connected)
Engine Type 930/68 (USA) 1 :t 20 after TOG at 900:t 50 rpm

(vacuum hoses connected)
10-02 Technical Data VI, 1985- Printed in Germany

911 turbo General
Tightening torques for the engine
Hexagon nuts or M8
hexagon head bolts -
crankcase
Flywheel to
crankshaft M 12 x 1.5
Model 78 onward M 10 x 1.25
Sleeve with needle bearing M6

to crankshaft
Screw plug M 18 x 1.5
pressure relief and
safety valve
Screw neck in the left M 22 x 1.5 120 (88.5)
crankcase half
(oil return to oil tank)
Oil drain plug in the M 22 x 1.5 42 (31)
oil filter cover
Oil drain plug in the crankcase M 20 x 1.5 70 (51.5)
Oil drain plug in the M 22 X 1.5 42 (31)

oil tank

10 -04 Tightening torques for the engine
Downloaded from www.Manualslib.com manuals search engine Printed in Germany -VII, 1989
911 turbo General
Tightening torques for the engine 10 -05

General 911 turbo
I
Location Thread
Lambda probe to catalytic M 18 x 1.5

converter
Screw plug in catalytic M8x1 15 (11)
converter
Air-injection valve to cylinder 10x 1 15 (11)
head (union nut)
Line to air-injection valve M 14 x 1.5 22 (16)
Gearwheel to air pump 9.7 (7)
Fuel system
Screw neck to mixture 20 (15)

regulator
Injection line to mixture
regulator
930/66 20 (15)
930/68 14 (10)
Injection valve 7 (5)
Turbocharging
Charge air cooler M8 18 (13)

Oil line to turbocharger 20 (15)
Control line / vent line to 20 (15)
bypass valve
Restraining strap/turbocharger 12 (9)
. 10-06
Engine, Crankcase 10
TOOLS

Engine, Crankcase
T GalS
No. Description Special Tool Remarks
1 Engine take-up plate 9111 Modified
2 Supportplate 9111/1 Local manufacture
10 -2 Removing
Downloaded from www.Manualslib.com and Installing
manuals search engine Engine Printed in Germany
REMOVING AND INSTALLING ENGINE
The engine and transmission assembly is

lowered to remove.
Removing
Jack up car.
2. Disconnect ground cable at battery.
3. Removeair cleaner.
4. Loosenengine block vent hose at engine.

pull off and plug opening at vent cover.
5. -Cars with air conditioning only -

Detach compressor at console and leave
it conne;cted to the hosesin the car.
6. Remove relay plate cover and disconnect
engine wires at relay plate. at adapter plug.
relay plate socket and ignition control unit.
Caution
The air conditioner system must be discharged

if the compressorhosesare disconnected.
Printed in Germany -II. 1976 Removing and Installing Engine 10-3

1.
Engine-crankcase
7. Unscrew fuel hoses at filter and return line,
8. Disconnectacceleratorlinkage. 14. Loosenheaterhosesat heat exchangers.

and pull off.
9. Loosenrear tunnel cover screws and remove

cover.
15. Removerear stabilizer,
10. Pull boot off of body and slide it forward

over the selector rod.
16. Loosenground strap at body.
11. Loosen socket head at screw of shift rod

coupling and pull coupling off of the
17. Disconnect battery wires at starter.
transmission inner shift rod.
18. Disconnect accelerator linkage at

operating lever.
19. Disconnect clutch cable at transmission.

From 1977 Models -see figure.
12. Pull off wires of electronic speedometer

sensorin tunnel and remove rubber plug
with wire plug.
13. Drain engine oil and plug oil hoses on

engine and oil tank.
10-4 Removing and Installing Engine Printed in Germany

20. Loosendrive shaft flange socket head 23. Loosen engine carrier bolts,
screws at transmission.
21. Place car jack with appropriate 24. Lower car jack with engine/transmission
attachment underneath engine/trans- assembly carefully and back it out.
mission assembly at center point of gra-
vity and apply a little pressure.
Caution
Be careful not to damage secondary air
injection pipes.
Caution
If the car is moved with the engine/transmission

unit removed, the drive shafts must be suspended
horizontally to prevent damage to dust covers.
.
22. Loosen transmission carrier bolts.
Printed in Germany -III. 1978 Removing and Installing Engine 10-5

Engine-crankcase
Installing
Observe the following instructions when

installing.
1. Caution! Don't clamp the heater hoses.

If necessary, slide them on the heat
exchangers just before the engine/
transmission assembly is in its final
position.
2. Torque specifications: Engine and transmission

carrier hex head screws:
9.0 mkg (65 ftlb)
Drive shaft/flange fil-
lister be~ capscrews:
8.3 mkg (60 ftlb)
3. Adjust clutch -see Repair Manual 911, Group 7,

Page2.1 -2/3.
Removing and Installing Engine Printed in Germany

10-6
Engine-crankcase
D ET AC HIN G AN D A TT AC HIN G EN GINE AN D TRANSMISSION
Detaching 4. Pull transmission off of engine.
1. Removewires at starter and backuplight

switch.
2. Remove clutch release lever circlip and Attaching

take off lever and rubber ring. Observe the following points.
Clutch release lever does not have to be removed
from 1977 Models.
I, Coat all bearing surfaces of clutch release

and drive shaft splines with a multi-purpose
lubricant containing MOS2'
2. Place hub part of release bearing vertical

and engage release fork when attaching to
hub section. Check if in correct position
through opening in transmission case.
3. Loosenengine mountingbolts and nuts.
Note
Te~ion release lever to keep bearing in place.
3. After attaching the engine and transmission,

slide on release lever parallel to holder of
clutch cable sleeve.
4. Torqueenginemountingbolts and nuts to

4.5 mkg (33 ftlb).
-,.
Printed in Germany -II, 1976 Detaching and Attaching Engine and Transmission 10-7
Engine, Crankcase
DETACHING AND ATTACHING ENGINE/TRANSMISSION UNIT

(FROM 1978 MODELS, TURBO 3.3)
Detaching 2. Place hub of release bearing upright and enga-

ge release fork on hub when attaching. Check
proper position through opening in transmission
1. Disconnectwires from starterand backup
light switch.
case.
2. Removeclutch releasespring. seepage

30 -11.
3. Unscrewengine mounting bolt and nuts.
3. Install clutch releasespring. seepage30-11.
4. Tighten engine mounting bolt and nuts to

45 Nm (4.5 mkp).
Attaching
Note the following points.
1. Coat all sliding surfaces of clutch release as

well as spline of drive shaft with MoS2 multi-
purposegrease.
Detaching and Attaching Engine/Transmission Unit

Ill. 1978 - Printed in Germany
10 -8
Engine, removing and
installing
From Model 89 onward

hydraulically operated clutch
Special tools
88/400
10- 9
Engine, removing and installing
Hydraulic clutch mechanism Note

The engine/gearbox assembly is lowered out Cover the opening into the turbocharger.
of the car complete.
5. Disconnect the crankcase vent hose and the
Removing hose from the oil separator.
1. Raise the car at the jacking points.
2. Disconnect ground cable from the battery.
3. Disassemble the air-conditioning compres-

sor from the console and. with lines still con-
nected, lay it on the adequately protected
left-hand rear fender.
Note
If the hoses are disconnected from the com-
pressor, the air-conditioning system must be
bled again.
88/390
6. Remove the cover from the engine electric

system, separate the multiple plugs for engi-
ne cable harness and switchgear, as well as
the round connector.
85/336
4. Remove charge air cooler and air filter sy-

stem.
. 10 -10
7. Disconnect fuel hoses:
9. Undo the Phillips screws in the tunnel cover
and remove the cover. Separate the tacho-
A -from the fuel filter
generator plug connections in the tunnel
and pull the rubber bushing with cable con-
B -from the pressure accumulator
nector outwards.
C -in the return line. then pull out

10. Raise the car, undo the hexagon head
of the rubber bushing. (Fixed to the air
screw in the shift rod coupling and pull
pump).
away from the inner shift rod in the gear-
box.
88/391A
86/905
8. Disconnect the brake booster hose.
11. Drain engine oil and disconnect the oil

hoses from the engine and oil tank.
88/3918
88/401
10 -11
12. Disconnect the earth strap from the chassis. 17. Disconnect the clutch operating cylinder
and hang up with line connected.
13. Undo the heating hoses at the heat exchan-
gers and pull off. Note
The clutch must never be operated if the cylin-

14. Remove rear anti-roll bar.
der has been removed.
10009
18. Undo the fillister head screws connecting
the halfshaft flange to the differential.
15. Undo the connecting lines (3) at the
starter.
19. Position trolley jack with engine mounting
plate at the gravity center of the
16. Remove the safety strap and disengage the
engine/gearbox assembly and raise jack
accelerator tie rod. Unclip the line for the
until slightly pretensioned.
clutch operating cylinder.
Note
Make sure that the mounting plate is in the
correct position. Lock the lever in horizontal
position.
86/935

Installing
The following points must be observed when
installing:
1. Make sure that the brake line is routed cor-

rectly.
88/392
10 -259
2. Caution. Do not trap the heating hoses, sli-

de onto the heat exchanger just before the
engine/gearbox assembly is in the correct in-
stallation position.
88/393
Tightening torques:
20. Remove hexagon head bolts from gearbox

Hexagon head bolts for engine and gearbox
mount. carriers = 80 Nm (59 ft.lb.)
21. Remove hexagon head bolts from engine

Apply a film of Optimoly HT to the bolts (up to
carrier.
the hexagon head)
22. Lower jack with engine/gearbox assembly

Fillister head bolts for halfshaft flange M 10
carefully and move away to the rear.
83 Nm (61 ft. Ib).
If the car is moved without the engine/gearbox

Rectify pressure marks in the engine carrier
assembly, the halfshafts must be secured in a
plate on the crankcase.
horizontal position (to avoid damaging the rub-
ber boots).
10-13
Engine, Crankcase, Suspension 911 turbo
Engine/gearbox assembly, 3. Undo the 4 fastening nuts and separate the

separating and joining gearbox from the engine. Undo the upper
fastening nut on the starter motor with
Separating: Special Tool P 119.
1. Disconnect cables from starter motor and
reversing light switch. Joining
2. Undo hexagon head bolt. Remove bracket Note

and sealing cap. Pullout the clutch release Lubricate all sliding surfaces of the clutch me-
shaft with hexagon head bolt M 6 x 40. chanism and the splines of the drive shaft with
Olista Longtime 3 EP.
1. Guide the clutch release fork into the

release bearing and secure in the installation
position provisionally with suitable adhesive
tape.
86/868
86/869
2. Join the gearbox to the engine.
'0 3. Guide the clutch release shaft with seals into

the release fork.
4. Remove the tape through the assembly

opening.
5. Install needle bearing, sealing cap and

bracket and secure with a fastening screw
(M 6x 16).
8
10-14
Engine-crankshaft and moving parts
PISTON AND CYLINDER SIZES -930 TURBO
Cylinder Cylinder PistonDia. D

Code Dia. in mm in mm
Standard Size
Stamped
0 95.000-95.010 94.933-
94.947
1 95.010-95.020 94.943-
94.957
2 95.020-95.030 94.953-
94.967
Clearancebetweencylinder 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
faces the clutch -see figure.

CHECKING PISTONS AND CYLINDERS
Cylinders
Dl = Measuring point for wear and ovality
30 mm below upper edge of cylinder
The cylinder is worn if the measurement is

0.08 mm more than the size at installation.
Measurements are made in directions a and
b to check ovality. The amount of deviation
between a and b should not exceed 0.04 mm.
D2 = Measuring point for piston ring end gap

b _I
Rings slid in at height of cylinder base gasket. I
Pistons
D = Measuring point for wear
At lower edge of pistonpin bore.
Caution!
- -- ~).:- 0
Replacepistonand cylinder if clearance

exceedsO.15mm.
PISTON RING END GAP
Piston Ring End Gap in mm End Gap in mm

(new) (wear limjt)
Compression ring,
I and II 0.15 -0.3 0.8
Oil scraper ring,
III 0.15 -0.3 1.0
(see measuring point "D2")
PISTON RING SIDE CLEARANCE
Piston Ring Side Clearance Side Clearance

in mm (new) in mm (wear limit)
Compressionring. I 0.070 - 0.2
Compressionring. II 0.040 - 0.2
Oil scraperring. III 0.020 - 0.1
13-2 Checking Pistons and Cylinders IV. 1981 Printed in Germany

REMOVING AND INSTALLING FL YW HEEL
Removing Installing
1. Loosen flywheel mounting screws under 1. The bearing surfaces of crankshaft,
application of special tool P 238 and flywheel and pulley must be without
remove flywheel (take off inner stop grease.
pin of P238).
2. Torque mounting screws to specifications.
MAC HIN IN G FLYW HEEL
If severely scored or burnt, the flywheel's bearing surface for the drive shell can be machined on a
lathe.
The chip size should be kept as small as possible.
Flywheel thickness wear limit is 9.9 mm.
1 Wear limit 9.9 mm 3 Max. runout 0.1 mm

2 Smallest chip size 4 Machining take-up

Engine, Crankshaft, Moving Parts 911 turbo
Crankshaft -standard and machining dimensions

(from Model 78 onward, Turbo 3.3)
A
13 -4
Crankshaft -standard and machining dimensions (from Model 78 onward, Turbo 3.3)
911 turbo Engine, Crankshaft, Moving Parts
Only grind the bearing surfaces for rotary

f' shaft seals to the dimensions of 29.8 and 89.8
0:.' ~i
~'1 ~...
entered here if the scratches are too deep.
"'Ii ..it
~! ~I'
Otherwise, repolish as necessary, Rt = 3.
Hollow out oil holes with R 0.5 after grinding.
Sharp edges smoothed with R = 0.2...0.5.
Permissible radial run-out related to the mount

in max. 0.04.
Rule for the Tenifer treatment in accordance

with Tenifer 90 W PN 1053.
Do not dress main bearings 3 and 5 following

Tenifer treatment.
The other main bearing journals may be dres-

sed by means of caulking in the radii.
Color coding for subsequent machining stages
1 st machining stage Blue dot

2nd machining stage Green dot
I---~~ ."os#>
--~.-
Crankshaft -standard and machining dimensions (from Model 78 onward, Turbo 3.3) 13-5
Layout of Oil Purr;p from 1978 Models, Turbo :::.3
Order of Cylinders and Air Guide Plates

from 1978 Models, Turbo 3.3'
13 -6 Printed in Germany
Piston and cylinder dimensions from Model 78 onward, Turbo 3.3
Cylinder Nikasil F. Mahle

designation cylinders pistons
" 0D
Standard size
Stamped
0 97.000 -97.007 96.960
96.970
97.007 -97.014 96.967

96.977
2 97.014-97.021 96.974
96.984
3 97.021-97.028 96.981
96.991
Clearance: cylinder -piston 0.030 -0.047
13-7
Piston weight classes -911 Turbo from Model 80 onward
Rules for installation
1. The pistons installed in an engine must al- 2. Piston pins must always be matched to the
ways be made by the same manufacturer respective piston and must never be mixed
and of the appropriate weight class. up. even within the set for one engine. Al-
ways bear this in mind when dismantling
and assembling the engine and mark if ne-
cessary.
Weight classes MAHLE pistons
Piston weighed with accessories (piston pins, piston rings, circlips).
Total weight in g Identification code

Weight class
within a set
Engine type 930/00/65 930/66/68
Series production 601 to 605 616 620

605 to 609 620 624 -
perm. weight difference 4 g 609 to 613 624 628 +
613 to 617 628 632 ++
For CS 601 to 609 616 -624 --or-

perm. weight difference 8 g 609 to 617 624 -632 +or++
13 -8 Piston weight classes -911 Turbo from Model 80 onward

CHECKING INSTALLED LENGTH OF VALVE SPRINGS
Checking
Note
Set tool P 10 c to "33.5".
1. Install special tool P 10 c with shim corres-

ponding to valve, spring support washer, spring
retainer and both valve keepers.
2. Read distance "A" on special tool P 10 c and,

if necessary. correct by removing or
installing shims.
Installation Sizes
Install length of intake valve springs

+
A 33.5-0.3 mm
Install length of exhaust valve springs
ADJUSTING TIMING
Intake valve lift at TDC overlap with 0.1 mm valve clearance is 0.65 to 0.80 mm,
ADJUSTING VALVES
Valves'ilre adjusted with engine installed in car. Only following parts are removed
air cleaner, relay plate cover, diverter valve and air pump.
From1978Models. Turbo3.3. chargeair cooler also hasto be removed.
REMOVING AND INSTALLING CHAIN TENSIONER
Chain tensioners can only be replaced after removal of engine.
Printed in Germany -IV. 1981 15-1

Camshafts, timing
Type Camshaft Camshaft Identification code Inlet valve stroke Timing

Left SP No. Right SP No. on the face end at overlapping with 1 mm
of the camshaft TOC with 0.1 mm valve clearance
Left Right valve clearance
930/66 930 105 14301 930 105 14201 930 143 01 930 14201 *0.65 -0.80 I. open 30 aft. TOG
930/68 I. close 3~ aft. BOG
From July930 105 143 03 930 105 14203 930 143 03 930 14203 Ex. open 270 bet BOG
1984 Ex. close 50 bet.TOG
* Desirable setting 0.70
15- 3
Fuel Supply
TOOLS
Printed in Germany -II. 1976 20 -1

CHECKING FUEL PUMP DELIVERY
Note
Before checking fuel pump, check for:
-clean fuel filter

-electrical connections OK
-at least 11.5 volts at both
fuel pumps
1. Detach fuel return line

(left side of engine compartment).
4. Switch on ignition for 30 seconds. Both pumps

must deliver 140 liter/hour or 1170 cc in
30 seconds.
Note
If delivery rate is less than this specification,

check pressure of fuel pumps to determine which
pump is defective.
2. Extend fuel return line with a section of fuel
hose and place end in a measuring glass
(contents about 1500 cc).
CHECKING PUMP PRESSURE
3. Bridgeboth fuel pumprelays(30 and 87) or

pullout plug on air sensorcontact.
1. Loosenintake fuelline.
Printed in Germany -II, 1976 Checking Fuel Pump Delivery 20 -3

Fuel Supply
2. Connect pressuregauge of P 378 between intake

line and rear fuel pump in conjunction with
Special Tool P 9114.
3. Turn ignition on (after first bridging relays or

pulling off plug at air sensorcontact).
4. Read pressuregauge. Pressuremust be between

2 and 4 bar. If less than 2 bar, the first pump
(front) is defective. If more than 4 bar, the
second pump (rear) is defective. Replace
defective pumps and recheck pressure.
Checkconnectionsfor leaks after completing

pressuretest.
20.4 Checking Pump Pressure

Fuel Supply
REMOVING AND INSTALLING FRONT FUEL PUMP
Removing
1. Disconnect minus lead at battery.
2. Remove bottom guard.
3. Pinchsuctionhosewith a standardclamp.
Loosenhoseclip and pull off suctionhose.
4. Pull off capsand unscrewelectric connecting

wire.
5 .Unscrew capped nut, counterholding the

adapter. Remove pressureline.
6. Loosenhosestrapand remove fuel pump.
Installing
18
Always use new seals.
2. Install fuel pump that it is clear all around.
. Printed in Germany -II,

1976 Removing and Installing Fuel Pump 20 -5
Fuel Supply
REMOVING AND INSTALLING REAR FUEL PUMP
Removing
1. Disconnectminuslead at battery.
2. Unscrewcappednut, counterholdingthe adap-

ter. Removepressureline.
3~ Pull off caps and unscrewelectric connecting

wire.
Loosensuction line, counterholding the

adapter and catching the escaping fuel.
5. Unscrew hexagon nuts and take fuel pump off

of the console.
6. Loosenhoseclamp and take fuel pump off

of holder.
Installing
Always use new seals.
Removing and Installing Printed in Germany

20 -6
Downloaded from www.Manualslib.com manuals search engine Fuel Pump
REMOVING AND INSTALLING EXHAUST GAS TURBOCHARGER
Removing
1. Disconnect hose line between charge 5. Loosenhose line between inlet line and
pressureline and compressorhousing compressorhousing (turbocharger) and
(turbocharger) and oil pressureline slide hose to left.
(from engine).
Disconnect oil return line at oil tank
and loosen oil drain tube of oil tank at
bottom of turbocharger.
2. Loosen.ear apron fillister head screws and

remove apron with seal, disconnecting tail
foglights if necessary.
6. Loosen both clamps on oil tank, mounting

screws between turbine housing and
3. Loosen clamp between bypassline and exhaust exhaust gas line as well as mounting nuts
gas muffler as well as mounting nuts between on turbine holder. Remove exhaust gas
turbine housing and exhaust gas muffler. turbocharger.
4. Loosen clamp on exhaust gas muffler and

remove exhaust gas muffler.
Printed in Germany Removing and Installing Turbocharger 21-1

Turbocharger
Installing
1. Make sure that hose connections are made

properly between the charge pressureline
and inlet line to compressorhousing.
2. Lubricate exhaust gas turbocharger with 2 to

4cm3 of engine oil after installation.
Note
When installing a new turbocharger. the

connections are located by turning the
compressorhousing to align it with the
turbine housing.
a) Loosen strap on turbocharger somewhat.
b) Install turbocharger on engine and align

location of connections.
c) Secure rubber sleeves and exhaust pipe and

then tighten strap screws to specified torque
(refer to page 21 -5).
d) Before starting the engine for 1st time, the

turbocharger lubrication oil must be pumped
for 30 seconds -which requires disconnecting
wires at charging pressure safety switch and
operating starter motor.

Turbocharger
REMOVING AND INSTALLING EXHAUST GAS TURBOCHARGER

(USA and Japan only)
Removing
Disconnect hose (arrow) between turbo outlet

and turbo outlet duct. Disconnect oil pressure
line (arrow) from engine.
4. Loosenmuffler clamp and removemuffler.
2. Loosenrear apronsocketheadscrewsand
remove apronwith seal.
5. Loosenhosebetweenturbochargerinlet line
and turbocharger.
Slide hoseto left. Drain oil in oil trap.
3. Looseclamp (arrow)betweenbypassline and
muffler. Loosenmountingnuts (arrow)between Disconnect oil return line at oil trap, loosen
turbo and muffler. oil drain tube of oil trap on bottom of turbo-
charger and remove trap.
Printed in Germany -II, 1976 Removing and Installing Turbocharger 21 -2 a

Turbocharger
6. Loosenturbochargerto exhaustpipe mounting

bolts as well as mountingnuts on turbocharger
holder. Removeturbocharger. Note
When instaUing a new turbocharger, the connections
are located by turning the turbocharger com-
pressorside to align it with the turbine side.
a) Loosen strap on turbocharger a little.
b) 1nstaUturbocharger on engine and align
location of connections.
c) Secure rubber hoses and exhaust pipe and then
tighten strap screws to specified torque (refer
to page 21 -5).
d) Always instaU new oil drain plug seals, self-
locking nuts and gaskets
e) Before starting the engine for first time, the
turbocharger lubrication oil must be pumped
for 30 seconds -which requires disconnecting
wires at manifold pressurelimiting switch
and operating starter motor.
Installing
1. Be sure that hose connections are properly made

between turbocharger outlet duct and turbo -
chargeroutlet.
2. After inst.jllation, lubricate turbochargerwith

2 to 4cm of engineoil.
21 -2 b Removing and Installing Turbocharger Printed in Germany

Turbocharger
TURBOCHARGER
t Outletduct
1 Compressor housing
2 Bearing housing
3 Turbine housing
4 Shaft bearing
5 Shaft
6 Compressor wheel
7 Turbine wheel

Turbocharger
CHECKING TURBOCHARGER SHAFT END PLAY
1. Place dial gauge in holder. Special tool P 207

can be used as a holder.
2. Set dial gauge on end of turbine wheel shaft.

Pressrotor shaft against dial gauge, read and
note play. Pressrotor shaft in opposite direction,
read and note play. Difference of both readings
is 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 !!.9.!..
to rotate the turbine wheel at all
during these measurements.
1. Pressturbine wheeltowardside of housing.

check gap with a feeler gaugeand note.
2. Pressturbine wheeltowardoppositeside of
housing. check gap and note.
Difference of both measurements is the radial

play. Measureplay at least at two different
locations.
Max. play: 0,65 mm
21 -4 Checking Turbocharger
Printed in Germany
Turbocharger
CHECKING WASTE GATE OPERATION
1. Loosenand remove control line to waste

gate.
2. Runengineat idle speed. There mustbe noti-

ceable vacuumin controlline. With increasing
engine speed,vacuumchangesto pressure
(chargingpressure).
3. Inserta plug in disconnectedcontrol line, so

that engine will not stall while checkingwaste
gate operation.
4. Carefully blow compressed air in control line

opening of waste gate. Listen for sound of
waste gate opening.
Caution
Do ~ usemore than I, 5 bar (21 psi) air pressure"
In addition to sound of valve opening. check that

bypassline warms up (cold engine).
If necessary.replace wastegate.
Printed in Germany -IV. 1981 Disassembling and Assembling 21 -4 a

Downloaded from www.Manualslib.com manuals search engine Waste Gate
REMOVING AND INSTALLING WASTE GATE (CHARGE PRESSURE CONTROL VALVE)
Removing
Engine Type 930/50
1. Detachvent line and control line.
2. Unlock and removethermagnuts.
3. Removewastegate, uppergasket, heat

guardand lower gasket.
Engine Type 930/51
Installing
Use new gaskets, seals, thermag nuts and

lockplates.
Engine Type 930/53 and 930/54
Printed in Germany -II, 1976 Removing and Installing Waste Gate 21 -5

Turbocharger
21 -6 Dismantling
Downloaded from www.Manualslib.com and
manuals search Assembling Pop-off Valve Housing
engine Printed in Germany
Turbocharger
Notes
Designation Amt. Special Notes
Removing Installing
1 Warm gear clamp 2
2 Rubbersleeve 1 Install conectly
3 Worm gear clamp 2
4 Hose 1 Install correctly
5 Hex hd screw 1
6 Washer 1
7 Worm gear clamp 2
8 Rubber sleeve 1 Install correctly
9 Hoseclamp 2
10 Hose 1
11 Hex nut 2
12 Washer 2
13 Hex hd screw 2
14 Washer 2
15 Idle air control

valve 1
16 Holder 1
17 Charge pressure
safety switch 1 Check See page 21 -11
18 Circlip 1
19 Filter screen 1
20 Seal 2 Replace
21 Hex nut 4
22 Washer 4
23 Plug 1
Printed in Germany -I, 1976 Dismantling and Assembling Valve Housing 21- 7
Turbocharger
Notes
No.1 Designation Amt. Special Notes
Removing Installing
24 ~ Gasket 1 Replace. if
necessary
25 I Control piston 1 Caution- Lubricate
under spring slightly.
pressure check move-
ment in valve
housing
26 Spring 1
27 Guide 1
28 Hex nut 4
29 I Washer 4
30 Cover with control

line conn. 1
31 Gasket 1 Replace, if
necessary
32 I Valve housing 1.
33 Charging pressure 1 Check

sensor
34 \ Seal 1 Replace
21- 8 Dismantling and Assembling Valve Housing II, 1976 Printed in Germany
I
Turbocharger
TOOLS
No. Designation Special Tool Remarks
1 Chargepressuretester 9103
2 Threaded adapter 9103/1 For Turbo 3.3
Printed in Germany -llI, 1978 Checking Charge Pressure 21 -9

Turbocharger
MEASURING CHARGE PRESSURE
1. Disconnect and remove electric plug and 5. Connect test line to adapter. counterholding
charge pressure safety switch. From 1978 the adapter.
Models, Turbo 3.3, switch is located behind
valve housing as seenlooking forward.
Turbo 3.0
2. Screw adapter (with seal) of special tool in

valve housing and tighten slightly.
From 1978 Models, Turbo 3.3. first install
threaded adapter, Special Tool 9103/1.
Turbo 3.3
6. Checkchargepressurevalue in a road test or

on a dynamometer.Chargepressure:0.70 -
3. Screwchargepressuresafety switchin adap- 0.85 bar (0.7 -0.85 atm).
ter and tighten only finger tight, counterhold-
ing adapter. Fully accelerate car in 1st or 2nd gear and
read charge pressure between 4500 and 5500 rpm
(2nd person). Charge pressure can only be check-
ed in the acceleration phase.
4. Route test line with pressure gauge from pas-
senger compartment to engine compartment. If necessary. replace bypass valve (charge pres-
sure control valve).
21 -10 Measuring Charge Pressure Printed in Germany

Turbocharger
CHECKING FUNCTION OF AIR PRESSURE SAFETY SWITCH
Checking
1. Removeair pressuresafetyswitch.
2. Clamp air pressuresafety switchcarefully.
3. Connectbuzzerbetweenswitchhousingand
connectingterminal (buzzerbuzzes).
4. Install tubeless :tire rubber valve (without

valve insert) on threads of switch.
5. Connect -air pressurehose to pressuregauge

(at valve).
6. Build up pressurecarefully until at about

1.5 bar (atm). Buzzerstops.
7. Droppressureslowly until buzzerbuzzesagain.

Nowread pressurewhich shouldbe between
1.1 and 1.4 bar. Replaceair pressuresa~ety
switch if necessary.
Printed in Germany -If 1976 Checking Air PressureSafety Switch 21- 11

Turbocharger
21- 12 Turbocharger Oil Supply Printed in Germany

Turbocharger
Notes
Removing Installing
1 Hollow bolt 1
2 Seal 2 Replace
3 Oil pressureline
to turbocharger 1
4 Pressuresensor 1
5 Seal 1 Replace
6 Adaptor 1
7 Seal 2 Replace
8 Adaptor 1
9 Filter screen 1 Clean
10 Seal 1 Replace
11 Thexmagnut 2 Replace
12 Washer 2
13 Gasket 1 Replace
14 Clamp 2
15 Oil tank 1
16 Rubber grommet 1
17 Hex nut 2 Replace
18 Washer 2
19 Holder 1
20 Hex hd screw 1
21 Washer 1
22 Hollow bolt 1
23 Seal 2 Replace
24 Oil line 1
Printed in Germany ~ I, 1976 Turbocharger Oil Supply 21- 13

Turbocharger
No. Notes
Removing Installing
25 Oil line from pump

to tank 1
26 Adaptor 1
27 Seal 1 Replace
28 Hex hd screw 3
29 Washer 3
30 Oil pump 1 See page 21 -18
31 Gasket 1 Replace
21- 14 Turbocharger Oilengine

Supply II. 1976 - Printed in Germany
Downloaded from www.Manualslib.com manuals search
Turbocharger
PRESSURE OIL LINE CONNECTION FOR TURBOCHARGER WITH OIL PRESSURE

SWITCH
~ 3
5
8
Notes
No. Description Qty. Remarks
Removing Installing
1 Oil pressure switch 1
2 Adapter 1
3 Seal 1 Replace
4 Oil line 1
5 Seal 1 Replace
6 Adapter 1
7 Seal 1 Replace
8 Ball 1
Printed in Germany -II. 1976 Turbocharger -Oil Supply 21 -15

Turbocharger
Note when
Removing Installing
1 Hollow bolt 1
2 Seal 2 Replace
3 Adapter 1
4 Seal 1 Replace
5 Nut 3
6 Washer 3
7 Oil pump 1 Install dowel pin of oil

pump shaft between
socket head screws of
pulley (13)
8 Nut 2
9 Washer 2
10 Cover, flange 1
21 -16 Turbocharger Oil Pump Printed in Germany

Turbocharger
Note when
Description Qty. Remarks
Removing Installing
III Socket head screw 2
Washer 2
13 Pulley 1
'4 Drive belt, 80 teeth 1 Tighten. must deflect

by 6 to 8 mm at center
under thump pressure
15 Bolt 3
16 Washer 3
17 Flange 1
18 Oil seal 1 Replace, install properly

with VW 433
19 Gasket 1 Replace, coat both sides

with sealing compound
Printed in Germany -II. 1976 Turbocharger Oil Pump 21-17

Turbocharger
REMOVING AND INS T ALLIN G T URBOC HARG ER OIL PUM P
Removing
1. Detachguard at exhaustpipe.
2. Detachpressureand inlet lines at oil pump.
3. Loosenbolts and remove oil pump with gasket.
Installing
Observe the following when installing: Note
Keys of left camshaft must be installed to

protrude beyond face of camshaft by 8 mm. Key
1. Use newpapergasket.
slots also have to be positioned properly so that
oil pump cylindrical pin does not rest in a slot.
2. Install cylindrical pin of oil pump shaft

between keys of camshaft.
21- 18 Turbocharger Oil Supply Pr.imed in Germany

Turbocharger
CHECKING CHARGING PRESSURE GAGE
If the charging pressuregage in the tachometer

fails, check all wire connections on the tacho-
meter or charging pressuresensor against the
wiring diagram. Pull off wire on charging pres-
sure sensor.
Turn on ignition. The cl1 pressure gage

needle must deflect fully r0 Hold the disconnected
wire against ground. Th~~needle must return to
zero.
If the instrument meets these requirements, the
cause of trouble will be found in the charging
pressuresensor. Otherwise the gage would be
defect, and the tachometer would have to be
replaced.
Note
The resistance of the charging pressuresensor

(measured between the connecting lug and
housing) must be between about 5 and 13 ohms
at 200 C and atmospheric pressure.
Printed in Germany -II. 1976 Checking Charging PressureGage 21 -19

Turbocharger
REMOVING AND INSTALLING CHARGE AIR COOLER FROM 1978 MODELS

TURBO 3.3)
Removing
1. Loosenhose clamps on charge air cooler's 3. Unscrewhexagonheadbolts and remove char-

right side and pull off hoses. ge air cooler.
Loosen and remove hexagon head bolt.
4. Remove pressuretube to charge air cooler.

2. Detach hose between charge pressure control
valve and charge air cooler at charge air coo-
ler.
Loosen and remove hexagon head bolt.
Installing
1. Check all a-rings, replacing if necessary.
2. Lubricate a-rings with an acid -free lubricant

before installation.
3. To facilitate installation of pressure tube,

loosen hose clamps of rubber sleeve on intake
line and push back sleeve. Also press intake
pipe to the left a little.
21 -20 Removing and Installing Charge Air Cooler III, 1978 Printed in Germany
Turbocharger
4. Turn pressurepipe to one side, that marks on

charge air cooler and pressurepipe align or
pressurepipe is installed without stress.
Note
When replacing rubber seal on charge air cooler,

make sure that it is positioned correctly (arrows
face in forward direction).
Printed in Germany -Ill, 1978 Removing and Installing Charge Air Cooler 21 -21
Fuel system25
Printed in Germany Fuel system 25-1

25 Fuel system
No. Designation Notes

Amt. Special Notes
Removing Installing
1 Clamp 2
2 Vacuum hose 1
3 Hollow bolt 1
4 Seal 2 Replace
5 Fuel return line 1
6 Hollow bolt 1
7 Seal 2 Replace
8 Fuel feed line 1
9 Adaptor 1
10 Seal 1 Replace
Clamp 2
12 Vacuum line 1
13 Cap screw 2
14 Washer 2
Warm-up go\emor 1
16 Vacuum hose 1
7 Clamp 2
18 Control line,
bypassvalve 1
19 Vacuum hose,
distributor 1
120 Hex nut 4
Washer 4
122 Connector 1
23 Seal 1 Replace
24 Lock 1
25-2 Fuel system Printed in Germany

Fuel system
Notes
Removing Installing
25 Linkage 1
26 Hollow bolt 1
27 Seal 2 Replace
28 Fuelline 1
29 Cap screw 2
30 Washer 2
31 Cold starting valve 1
32 Seal 2 Replace
33 Flange 1
34 Rubber/metal pad 2
35 Clamp 2
36 Hose 1
37 Clamp 2
38 Hose 1
39 Injection valve 6
40 Seal 6 Replace
41 Hex nut 12
42 Washer 12
43 Air volume hsg. 1
44 Gasket 12 Replace, install

correctly
45 Flange 6
Printed in Germany Fuel system 25-3

Fuel system
25-4 Fuel system Printed in Germany

Fuel system
Notes
No Description Amt. Remarks
Removing Installing
1 Hollow bolt 6
2 Seal 12 Replace
3 Banjo Fitting 6
4 Injection lines
Cylinders 4 -6 1
5 Injection lines
Cylinders 1 -3 1
6 Hollow bolt 1
7 Seal 2 Replace
8 Hollow bolt 1
9 Seal 2 Replace
10 Fuel return line 1
11 Plug 1
12 Seal 2 Replace
13 Fuel feed line 1
14 Adaptor 1
15 Seal 1 Replace
16 Fillister head screw 15 Observeinstallation Page 25 -6

notes
17 Washer 15
18 Mixture control 1
unit
19 Plug (Allen bolt) 1
20 Seal 1 Replace
21 Gasket 1 Replace
22 Nut 1
23 Washer 1
Printed in G~many -I. 1976 Fuel system 25 -5

INSTALLATION NOTES -REMOVING AND INSTALLING MIXTURE CONTROL
1. Torque fillister headscrews1 through4 cross- 2. Tighten other fillister head screws and hex head
wise to 10 Nm (1.0 kpm). screws (5 mm longer) with spring and plain
washersto block and loosen again 1 trun each.
The 5th screw is a hex head screw due to the

lack of adequate space.
screw 14 screw 5
25 -6 Fuel system Printed in Germany

CHECKING AND ADJUSTING OFF POSITION OF AIR FLOW SENSOR PLATE
Checking
1. Pull off plug for safety switch on mixture con-

trol unit.
Turn on ignition and off again after approx.
10 seconds.
Upper edge of air flow sensorplate must be
flush with beginning of cone (relief funnel,
top) or max. 0, 5 mm higher (strive for lower
position).
2. Air flow sensorplate must be level and must

not protrude beyond cylindrical section of ven-
turi at any point of its periphery.
Adjusting
An excessively high air flow sensorplate can be

corrected. This is done by driving down the stop
spring guidepin accordingly, using a mandrel and
a light hammer.
Note
Adjust very carefully, so that guidepin is not

driven too deep. A void frequent adjustments
in both directions, since pressfit of pin will not
hold.
Printed in Germany -III, 1978 Checking and Adjusting Off Position of Air Flow SensorPlate 25 -6a
Fuel Mixture
REMOVING AND INSTALLING FUEL DISTRIBUTOR OF MIXTURE CONTROL UNIT
I' Notes
Removing Installing
1 Fillister head screw 3 Torque to 3, 5 Nm

(0, 35 kpm
I'Don' t disassem-
2 Fuel distributor 1 Caution! Do not If control piston has
let control piston been removed, clean ble
fallout thoroughly with un-
used gasoline before
installing
3 a-ring 1 Replace, lubricate

and install new o-ring
in groove of fuel dis-
tributor
4 Air flow sensor 1
25 -6b Removing and Installing Fuel Distributor in Mixture Control Unit Printed in Germany
REPLACING PISTON PRESSURE REGULATOR WITH POPPET VALVE
Note when
Special
No. Description Qty. Instructions
Removing Installing
1 Adapter with poppet 1 Torque 13 -15 Nm

valve (assembled unit) (1.3 -1.5 kpm)
2 Spring 1
3 Shim 3 Install same shims Check system

(0.1,0.15,0.3,0.4 removed (always 3) pressure
0.5 mm thick is req.)
4 Flat seal 1 Replace
5 a-ring 1 Replace
!3 Control piston 1 use tapered wood Check, if damaged

pin if necessary replace fuel distri-
butor (close toleran
ce part)
7 a-ring 1 Check, replace if

necessary
8 Set of parts 1
9 Fuel distributor 1 Never disassemble
Printed in Germany -III, 1978 Replacing Piston PressureRegulator with Poppet Valve 25 -6 c
Fuel Supply
DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL UNIT
~'.
2S-6d Disassembling and Assembling Mixture Control Unit Printed in Germany

Fuel Supply
Note When
No. Description Qty. Special
Removing Installing Instructions
1 Adapter with poppet 1 Torque 13 -15 Nm

valve (assembled unit) (1.3-1.5 kpm)
1a a-ring 1 Replace
Ib Set of parts 1
"«
2 Spring 1
3 Shim asrequired 3 Install same as Check system

(0.1, 0.15, 0.3,
0.4, 0.5 mm thick)
removed (always 3) pressure
.
4 Flat seal 1 Replace
5 Control piston 1 Use tapered wood Check, replace

pin fuel distributor if
damaged (close
tolerance part)
6 a-ring 1 Check, replace if

necessary
Adapter 1
8 Seal 1 Replace
9 Capscrew 1 Torque3.2 -3.8

Nm (0.32 -0.38
kpm)
10 Fuel distributor 1
11 Control piston 1 Don't let piston

fallout
12 Seal 1 Replace
13 Capscrew 2
14 Copperring (stand.) 2
~5 Allen key for mix- 1 Curved side of flan-

ture adjustments ge faces fuel distribu-
tor I
Printed in Germany -Ill, 1978 Disassembling and Assembling Mixture Control Unit 25 -6 "e
Fuel Supply
Note When
No. ~pecial
Description Qty. Instructions
Removing Installing
Gasket 1 Check, replace

if necessary
17 Capscrew 2
18 Lockwasher 2
19 Stop 1
20 Hex. head bolt 1 Torque 5.0 -5.5

Nm (0.50 -0.55
kpm)
21 Support disc 1
22 Sensorplate 1 Check, replace if

necessary. Cut edge
of sensorplate or
stamped code (--)
faces up
23 Circlip 1 First remove this Sharp edge side
circlip faces out ,
24 End plate 1
25 Seal 1
26 Spring 1
27 Ball 1 Lubricate with

Bosch Ft 2v2 (sili-
cone grease)
28 Circlip 1 Sharp edge side

faces out
29 End plate 1
30 Seal 1
31 Ball 1 Lubricate with

Bosch Ft 2v2 (sili-
cone grease)
32 Capscrew 2 Torque4.7 -5.3

Nm (0.47-0.53
kpm)
Disassembling Printed in Germany

25 -6 f
Downloaded from www.Manualslib.com manuals search engineand Assembling Mixture Control Unit
Note When
No. Special
Description Qty. Removing Instructions
Installing
33 Cylindrical pin 1
34 Adjusting lever 1 Check
35 Pivot fork lever 1
36 Spring 1
37 Spacer 2
38 Capscrew 2 Torque
4.7 -5.3 Nm
(0.47 -0.53 kpm)
39 Counterweight 1 Position correctly
40 Capscrew 1
41 Locknut 1
42 Plug 1 Turned approx. 15U!

toward venturi
43 Stop spring 1 Position correctly
44 Insulator 1
45 Air flow sensor 1 Lubricate bearing

housing bores with Bosch
Ft 2v2 (silicone
grease)
Printed in Germany -Ill, 1978 Disassembling and Assembling Mixturll Control Unit 25 -6 ~
Fuel Supply
DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL UNIT
1. Preassembleadjusting lever, spring and pivot 3. Makesure that springfits properly.

fork lever prior to installation in air flow sen-
sor housing.
2. Use an appropriate cylindrical pin for this pur-

pose, e.g. one from adjusting lever of 911 mix-
ture control unit or a standard 8 h 8 x 60 DIN 7
cylindrical pin (connecting pin). Both ends of
pin must be chamfered.
4. Guide assembled parts into air flow sensor

housing and push out cylindrical pin used for
assembly carefully with the original cylindri-
cal pin.

Fuel Supply
5. C enter adjusting lever in air flow sensorhou- 6. Align angular clearance between air flow sen-
sing and tighten mounting screws. sor plate and venturi. The angular clearance
must be uniform. It can be checked with a
0.10 mm feeler gauge. This requires that height
adjustment (off position) of air flow sensorplate
be correct.
Printed in Germany -III, 1978 Disassembling and Assembling Mixture Control Unit 25 -6 i
TOOLS
Printed in Germany Adjusting Idle 25 -7

Fuel system
ADJUSTING IDLE
Note
Test requirements: 5. Connect CO tester and separate tachometer

Engine must be in perfect mechanical condition according to manufacturer's instructions.
and ignition timing set correctly.
Separate 2-pole plug connector when connec-
ting tachometer. Use jumper wires to bridge
connectors and provide terminal for connecting
black/violet wire to tachometer or engine
1. Run engine to operating temperature (about tester. Black/violet wire normally goes to
80° C/1760F). terminal I of the distributor. The tachometer
or engine tester is connected to this wire,
which normally goes to terminal I of the
2. Remove air cleaner. distributor.
3. Detach air hose at air pump and plug open end

of hose.
(Only for 930/51. 930/52. 930/53 and 930/54.)
Warning
Never hold black/violet wire against any ground

while engine is running.
4. Check if manualacceleratorlever is at bottom

stop.
25 -8 Adjusting Idle II, 1976 - Printed in Germany

Caution
a) Always adjust CO from lean to rich.

Example: if idle screw setting is too rich,
first turn counterclockwise further than
necessaryand then clockwise to nominal
setting.
6. Turn air correction screw on throttle valve b) Never apply pressureto adjusting wrench while
housing until specified speed is reached. Use adjusting (engine stops).
special tool P 229 c.
c) Turn control screw very slightly as very small
turns alter amount of CO in exhaust gases
considerably. Maximum adjustment on
mixture control screw is 1/2 turn.
d) When checking (or adjusting) CO, plug

adjusting hole before taking CO reading. If
hole ist not plugged, extra air will be pulled
into control unit giving wrong reading.
7. Adjustco. 9. Removewrench,
Remove plug with seal in top of mixture
control unit. Caution
Never leave wrench in adjusting hole when
accelerating engine as this could severely damage
mixture control unit.
8. Guide adjusting wrench P 377 in. 10. Accelerate enginebrief! y.

Turning clockwise richens mixture; counter-
clockwise leans mixture.
Printed in Germany -n, 1976 Adjusting Idle 25 -9

Fuel system
11. Wait until CO tester showsa concentration of

exhaust gas at idle speed.
See Page 25-15 for adjusting data.
Repeatprocedure. if necessary.
12. Install air cleaner again and recheck idle speed

and CO content.
Caution
Adjustments must be completed as quickly as
possible to prevent overheating the intake ports.
REMOVING AND INSTALLING AUXILIARY AIR VALVE
2. Loosenclampsand disconnecthoses.
3. Pull off electric plug connectors.
4. Loosenfillister headscrewsand remove

auxiliary air valve.
25 -10 Adjusting Idle Printed in Germany

Downloaded from www.Manualslib.com Removing
manuals search
andengine
II
el upply
TI~ LE ROM
OL
Hexagc alIen key
r::::
Printed in Germany - Adjusl 19 Idle fr. ,78 Models, -11

Fuel Supply
ADJUSTING IDLE, FROM 1978 MODELS, TURBO 3.3
Note
Air cleaner must be installed for all adjustments.
1. Detach air hose from air pump and install a 3. Adjust mixture. Insert special tool 9156 into
suitable plug in open end of hose. spring-loaded alIen key in mixture control unit.
Pressdown special tool approx. 18 mm to en-
gage spring-loaded alIen key in mixture control
screw.
Turning clockwise enriches mixture; anticlock-

2. Turn control screw on throttle housing until wise leans micture.
specified speed is reached.
4. See notes on page 25 -9 and adjusting values

on page 25 -16.
Figure shows control screw withdut air cleaner
25 -10 b Adjusting Idle Printed in Germany

Fue System
ADJUSTING IDLE -US CARS SINCE 1986 MODEL
Engine Type 930/68
TOOLS
~(.
2
1 Adjusting wrench 9156
2 Adapter US 8040
3 CO tester US 4492
4 Special screwdriver P 229 b or

P 229 c

ADJUSTING IDLE
Note 3. Insert a suitable plug in the air hose

between the air pump and blowoff
Adjusting Requirements: switching valve.
Engine must be in perfect mechanical condi-

tion. Electric equipment must be switched
off during adjustments. Adjustments must
be completed as quickly as possible, to
avoid excessive heat in the intake ports
and consequently wrong CO values.
Adjustments must be performed with the

air cleaner mounted.
1. I nstall adapter US 8040 and CO tester

US 4492 on the test connection.
4. Run engine to operating temperature

(80 to 900 C oil temperature).
5. Turn control screw on the throttle

housing until specified engine speed of
900 :t 50 rpm is reached.
2. Disconnect plug for oxygen sensor and

connect CO tester to instructions
supplied with equipment.
Picture shows the control screw without

the charging air cooler and air cleaner.
Adjusting Printed in Germany

25-10d
Downloaded from www.Manualslib.com manuals search Idle
engine
Fue System
6. Check CO level. If the CO level is not

within specifications, correct the adjust-
ment on the mixture control unit.
Insert Special Tool 9156 in the spring
loaded wrench in the mixture control
unit. Press special tool down about 18
mm to have the spring loaded wrench
engage in the mixture control screw.
Turned clockwise = richer mixture.

Turned anticlockwise = leaner mixture.
CO level: 0.6:!: 0.2 % by volume.
Note
The charging air cooler, complete air

cleaner and lead-sealed wrench will have to
be removed (see page 25 -10 f), if the CO
level has to be corrected on the mixture
control unit.
7. After finishing adjustments, connect the

oxygen sensor plug, install the air hose
and screw the plug in the test connection.
Give threads of plug a thin coat of Bosch

VS 140 16 Ft or Optimoly Ht.
Torque: 15 Nm (11 ft. Ibs.),
Printed in Germany -VI, 1985 Adjusting Idle 25-10e

CORRECTING CO ADJUSTMENT ON MIXTURE CONTROL UNIT -US CARS
1. Remove the lead-sealedwrench and replace

it with a new wrench, Part No.
93011091001, if the CO level is not
within specifications.
2. Adjust CO and engine idle speed,
3. Apply one drop of Loctite No. 270 in the

bore of the adjusting wrench and close
the bore with a plug, Part No.
930 110921 00, after finishing adjust-
ments.
25-10f
Printed in Germany
TOOLS
Printed in Germany -I, 1976 Fuel PressureTool 25 -11

Fuel system
CHECKING PRESSURE
Note
For better understanding we have numbered

connections and lever positions of change-over
valve in the following text.
Connecting and Bleeding Pressure Gauge
1. Removeair cleaner. 3. Switch selector valve to position 2. Let

pressuregauge hang down (by its hose),
disconnect 2-pole plug at mixture control
unit (arrow) and turn on ignition (fuel pump
runs). Move change-over valve lever to
2. Remove line from mixture control unit to position 3 about 5 times at intervals of 10
control pressure regulator at control pressure seconds.
regulator. Connect selector valve into line as
shown (connection 1 to control pressureregula-
tor. Connection 3 to regulator feed line).
25 -12 Connecting and Bleeding PressureGauge II, 1976 - Printed in Germany

CHECKING "COLD" CONTROL PRESSURE CHECKING "WARM" CONTROL PRESSURE
This test can only be made on a cold engine. This test is carried out on a cold or warmengine.
This test is absolutely essential for start or warm-
up problems.
(Connect and bleed pressure gauge.)
1. Connectand bleed pressuregage.
2. Pull off 2-pole plugs at mixture control unit 1. Remove governor plate cover.
and warm-up regulator. and turn on ignition
(fuel pumps run).
2. Remove standard relay at center of

.governor plate.
(Only for Engine Type 930/50)
3. Bridge terminals 87 and 30 of a standard

relay.
(OIlly for Engine Type 930/50)
4. Install this auxiliary relay on governor

plate in place of original relay.
(Only for Engine Type 930/50)
3. Setcontrolvalve at position2.
4. Refer to diagram below testing and adjusting

values on page 25 -15 and 25 -16 for nomi-
nal pressureaccording to outside temperature
at the moment of testing.
5. Deviations meana defect in the warm-up

regulator, which mustbe replaced.
Printed in Germany -III. 1978 25 -13

Fuel System
5. Disconnect2-pole plug at mixture control FROM 1978 MODELS, TURBO 3,3

and turn on ignition (fuel pumpruns). ALSO MEASURING CONTROL PRESSURE
"WARM WITH FULL THROTTLE ENRICH-
MENT"
CHECKING CONTROL PRESSURE "WARM-

FULL THROTTLE ENRICHMENT"
1. Check control pressure"warm"(fuel pumpsmust

be running).
2. Disconnectpressurehosefor warm-up regulator
at thxottle housing.
6. Move change-over cock to position 2.

The control pressure will now rise slowly and
must reach the specified value when the warm-
up regulator has been controlled. The off time
varies according to ambient temperature. Re-
place warm-up governor if necessary.
3. Connecttester VW 1274with (locally made)

adapteron disconnectedhose(to warm-upre-
gulator).
Important
After test it is essential to reconnect two-pole plug

to mixture control and, for 930/50, genuine relay
on fuse/relay plate.
25 -14 IV. 1981 -Printed in Germany

4. Pumpwarm-upregulatorto approx. 0.5 bar CHECKING SYSTEM PRESSURE
(7 psi)pressure.
Note
'1~ Connect and bleed pressuregauge.
A pressureabove 0.8 bar (11 psi) could damage
the diaphragm in the warm-up regulator.
Move selectorvalve to position3. Disconnect

Control pressure will now drop and must reach
2-pole plug at mixture control unit and turn on
the specified value with warm-up regulator out
of action (see page 25 -16). If necessary, re- ignition.
place regulator.
.3. The system pressure must have now reached

the specified value.
Printed in Germany -IV. 1981 Measuring Control Pressure 25 -14 a
Downloaded from www.Manualslib.com manuals search engine "Warm/Full Throttle Enrichment"

Fuel Mixture
CHECKING FUEL DELIVERY RATE FOR CONTROL PRESSURE CIRCUIT
Requirements Fuel pumps in correct opera-

tional condition.
Checking
1. Connectand bleed pressuregauge.
4. Turn on ignition.
5. Move switching valve to position 2 and let

electric fuel pumps run exactly 1 minute by
pulling off two-pin plug on mixture control unit.
Stop by switching valve to position 3 and meas.
ure delivery rate.
2. Setswitchingvalve to position3.
Test value: 160 to 240 cc/minute.
3. Unscrewhose from Special Tool P 378 on

warm-up regulator and hold end in a measur-
ing glass with volume of at least 500 cc. If measured value is outside of tolerances, the
cause will be in the fuel distributor. Replace fuel
distributor.
25 -14 b Printed in Germany

Fuel Mixture
TESTING AND ADJUSTING DATA FOR CONTINUOUS FUEL INJECTION
Test Testing and Adjusting Data Special Notes
Electric fuel pump

.3
Delivery rate mm. 1170 cm / 30 s Page 20 -3
(valid for both pumps together)
Controlpressure"cold" Diagram for warm-up control Page 25 -13

(acc. to outsidetemp.) Part No. 911.606.105.02
and 930.606.105.00
Bosch ~o. 0438140 016
and 0 438 140 022
Control press:ure"warm" Page 25 -13

+ 2
Eng. Type 930/50 2,9 -0,20 bar (kp/cm
Eng. Type 930/51. 930/52. + 2
930/53. 930/54 2,8 -0,20 bar (kp/cm :
System pressure 6, 0 to 6, 7 bar (kpf cm2, Page 25 -14
Leak test
2
min. press. after 10 minutes: 1.7 bar (1. 8 kp/cm2)
.20 minutes: 1.5 bar (1.6 kp/cm )
Injection valves
Opening pressure 2,1 + 1,1 bar (kp/cm 2,
Idle adjustments
Idle speed 900 + 50 rpm
+ .
1000 -50 rpm (USA and Japan SInce
1977 Models
CO level Eng. Type 930/50 2 to 2, 5 0/0

Eng. Type 930/51 1 to 3 0/0 *
Eng. Type 930/52
930/53 2 to 4 0/0 * .:' air pump
Eng. Type 930/54 1 to 1. 5 0/0 * disconnected
(Japan)
Printed in Germany -II, 1976 Testing and Adjusting Data for 25 -15
Downloaded from www.Manualslib.com manuals search engine Continuous Fuel Injection
Fuel Mixture
TESTING AND ADJUSTING VALUES FOR FUEL INJECTION

(FROM 1978 MODELS, TURBO 3.3)
Test Phase Testing/AdjustingValue Special Note
Electric fuel pump

Delivery rate at least 1170 cc/30 sec. Page 20 -3
(for both pumps together)
Control pressure "cold" Diagram for warm-upregulator Page 25 -13

(equals outside temp.) PartNo. 930.606.105.03
BoschNo. 0 438 140 054
(emp?C 10 LV L.) 30 35
+ 2
Control pressure "warm" 3.65 -0.20 bar (kp/cm ) Page 25 -13
+ 2
"Full throttle enrichm." 2.9 -0.20 bar (kp/ cm )
2
System pressure Testing value 6.0 to 6.7 bar (kp/cm ) Page 25 -14 a
Adjustingvalue 6.2 to 6.5 bar (kp/cm2)
Leak Test
2
Min. press. after 10min. 1.6 bar (kp/cm~
after 20 min, 1.4 bar (kp/cm )
Fuel Injectors
Opening pressure 2.1 + 1.1 bar (kp/cm2,
3
Delivery rate- 160 to 240 cm fmin Page 25 -14 b
Control pressure
circuit
25 -16 Testing and Adjusting Values for Fuel Injection IV. 1981 - Printed in Germany
Fuel Mixture
T est Phase T esting/ Adjusting Value
Idle adjustment Engine Europe USA California I Japan I. Sweden Canada

(oil0 temp. 0approx. Type
90 C/195 F)
+ + 1 + ... +
Idle speed rpm 930 all 950- 50 1000- 50 1000- 50 1000;' 1000! 950-50
50 50
930/60 2t04* 1.5 to

2.5*
930/61 2 to 3 * 2 to 3 *
930/63/64
CO level in 0/0
930/62 1.5 to
930/65 2*
930/60 1.5 to 1.5 to

mod. 81 2.5 * 2.5 *
~, Air pump disconnected
Printed in Germany -IV, 1981 Testing and Adjusting Values for CIS Fuel Injection 25 -16a
Fue System
TESTING AND ADJUSTING VALUES FOR K-JETRONIC SINCE 1986 MODEL
Engine Type 930/68
Printed in Germany -VI, 1985 Testing and Adjusting Values for K-Jetronic 25-16c
Fuel System
Air pump disconnected.
* * Measured in front of catalytic converter

and oxygen sensor plug disconnected.
25-16d
Downloaded from www.Manualslib.com Testingsearch
manuals andengine
Adjusting Values for K-Jetronic Printed in Germany
911 turbo Fuel system
Test and adjustment specifications for K Jetronic
Test and adjustment specifications for K Jetronic 25 -16e

Fuel Mixture
REMOVING AND INSTALLING TEMPERATURE CONTROL SWITCH
Removing
Disconnectelectric wires, loosenhoseclamps

and unscrewthe hexagon head bolt.
CHECKING TEMPERATURE CONTROL VALVE
1. Detach vacuumhoses.
2. Blow air into vacuum hose taken off of the

t-adapter by mouth.
3. Valve mustnot be openwhenengineis

warm.
Valve must be open at an ambient tempera-
0
ture of less than 20 C.
Printed in Germany -II. 1976 Removing and Installing Temperature Control ValveChecking
25 -17
Downloaded from www.Manualslib.com manuals search engine Temperature Control Valve
Fuel Mixture
Note
A 0,5 mm long piece of resistance wire is in-

stalled in the plus lead running to the tempera-
ture control valve and represents a resistance of
3 ohms.
A 3 ohm resistor (about 10 watts) must always

be connected when connecting the temperature
control valve, e.g. to check while installed in
the car.
REMOVING AND INSTALLING AUXILIARY AIR VALVE
Removing
Detach vacuum hose, unscrew hexagon head bolt,

loosen hose clamp and remove the auxiliary air
valve.

REMOVING AND INS TALLIN G AIR CL EA NER (FROM 1978 MOD ELS, TURBO 3.3)
Note
When installing, be careful that spring-loaded

alIen key for idle adjustment on mixture control
unit is not damaged. 4. Unscrewhexagonnut slightly and remove air
cleaner.
1. Unscrew hexagon head bolts and detach vent
hose of air cleaner.
5. On cars with air conditioning, loosen compres-

sor and place to one side.
2. Loosenhoseclampsand pull off hoses.
3. Loosen vent hose clamp on oil filler neck and

pull off hose.
Note
Be careful not to damage rubber seal on charge air

cooler while removing and installing air cleaner.
Printed in Germany -Ill, 1978 Removing and Installing Air Cleaner 25 -19
911 turbo Fuel system
Checking the Lambda control function
Test conditions
-Engine at operating temperature
Correctly adjusted idle speed.
1. Run the engine at idle.
2. Connect a digital dwell angle meter between

pin A of the diagnosis connector in the
engine compartment and earth.
85/578
3. Read off the pulse duty factor in %.
4. If the Lambda control is operating properly,

the pulse duty ratio must be in the region of
45 % and 55 %.
25 -21
Checking the Lambda probe
Test conditions Voltage characteristic of the Lambda probe

at 600°C operating temperature
-Engine at operating temperature.
Correctly adjusted idle speed
1. Separate the Lambda probe plug connec-

tion on the left-hand side at the rear of the
engine compartment.
2. Connect a voltmeter between terminal 1 (pro-

be side of the connector) and earth.
,
Rich Lean
mixture mixture
3 2
3. The voltage must be in the region of 100 mV
-950 mV (0.1 V -0.95 V).

EXHAUST SYSTEM LAYOUT DRAWING -Engine Type 930/50
Heatexchanger
2 Bypassvalve (charge pressure control valve)
3 Bypassline
4 Exhaust gas turbocharger
5 Muffler
Printed in Germany -I, 1976 ~haust System Layout 26 -1

Exhaust system
26 -2 Dismantling and Assembling Exhaust Printed in Germany

Exhaust System 26
Notes
No. Designation Amt. Special Notes
Removing Installing
1 Hex nut 2
2 Hex head screw 2
3 Clamp 2
4 Thermag nut 4 Replace
5 Cap screw 1
6 Clamp 1
Muffler ]
8 Seal 1 Replace
9 Support 1
10 Gasket 1 Replace
11 Hex head screw 4
Thermag nut 2 Replace
13 Hex nut with

holder ]
14 Gasket 1
15 Worm gear clamp 2
Rubber sleeve 1 Install correctly
17 Intake line
18 Clamp 2
19 Rubber sleeve 1 Install correctly
[20 Pressureline 1
Hex nut 3
22 Washer :3 Replace
.23 Carrier, turbo

charger 1
Printed in Germany Dismantling and Assembling Exhaust 26-3

112
116
!21
Exhaust System
Notes
No. Disignation Amt. Special Notes
Removing Installing
24 Gasket 1 Replace
25 Turbocharger 1
27 Lockplate 4 Replace
28 Bypassline 1
29 Gasket 1 Replace
30 Thermag nut 4 Replace:
32 Bypassvalve (charge 1
pressure control valve)
33 Gasket 1 Replace
34 Guard 1
35 Gasket 1 Replace
36 Thermagnut 4 Replace
3E Bypassvalve housing 1
39 Gasket 1 Replace
41 Hex head screw 2
42 Guard 1
43 Hex nut 2
44 Capscrew 2
45 Clamp 2
47 Hex head screw 3
48 Gasket 1 Replace
26-4 Dismantling and Assembling Exhaust Printed in Germany

Exhaust System
Notes
No Designation Amt. Special Notes
Removing Installing
149 Thermag nut .1 Replace
50 Hex head screw 3
51 Gasket 1 Replace
52 Exhaustpipe 1
153 Seal 1 Replace
54 Support 1
55 Flange 1
157 Hex head screw 3
58 Gasket 1 Replace
59 Exhaustpipe 1
60 Hex nut 2
61 Washer 2
162 Hex head screw 2
63 Holder, muffler 1
Dismantling and Assembling Exhaust 26 -5

Printed in Germany
Exhaust System
EJ.{HAUST LINE SURVEY -ENGINE TYPE 930/52
1 Heat exchanger
2 Bypassvalve (charging pressure control valve)
3 Bypassline
4 Turbocharger
5 Exhaust muffler
26 -6 ExhaustLine Survey I, 1976 Printed in Germany

Exhaust System
EXHAUST SYSTEM LAYOUT -ENGINE TYPE 930/51.930/53.930/54
1 Heat exchanger
2 Wastegate
3 Bypassline
4 Turbocharger
Muffler
6 Reactor
Printed in Germany -II, 1976 Exhaust System Layout

Exhaust System
ExhaustSystem26
Note when
Removing Installing
2 Bolt 2
3 Clamp 2
5 Socket head screw 1
6 Clamp 1
7 Muffler 1
8 Seal 1 Replace
9 Support ring 1
10 Gasket 1 Replace
12 Holder, thermag nut 1 Replace
13 Bolt 4
14 Nut 3
15 Washer 3
16 Turbocharger 1 Installation
notes on
Page 21 -2 a
17 Carrier, turbocharger I 1
18 Gasket 1 Replace
19 Gasket 1 Replace
22 Bypassline 1
23 Gasket 1 Replace
Printed in Germany -I, 1976 26-9

26 ExhaustSystem
Note when
Descriptions Qty. Remarks
Removing Installing
26 Wastegate 1 Installation
notes on
Page 26 -13
27 Gasket 1 Replace
29 Bolt 3
30 Gasket 1 Replace
Thermagnut 3 Replace
32 Bolt 3
33 Gasket 1 Replace
34 Exhaustline 1
36 Bolt 4
37 Gasket 2 Replace
38 Heat exchanger 2
40 Washer 12
41 Reactor 2 Torque2.5 mkg Installation

(18 ft Ib) noteson
Page 26 -11
42 Gasket 6 Replace
43 Pipe 6
26 -10 Disassembling and Assembling ExhaustSystem Printed in Germany

J;'nnin~ T.m~ Q~n/~'
REMOVING AND INSTALLING REACTOR
TOOLS
1 Socketwrench 9110
INSTALLATION NOTES
Tighten nuts evenly to 2,0 -2,3mkg (15-17 ftlb),
Printed in Germany -IV. 1981 Removing and Installing Reactor 26 -11

Exhaust System
26 -18 Disassembling and Assembling Air Injection I, 1976 -Printed in Germany

Exhaust System
Note when
Removing Installing
1 Wing nut 1
2 Cover 1
3 Filter element 1 Check, replace if

necessary
4 Filter housing 1
5 Bolt 1
6 Washer 1
'1 Washer 1
8 Bolt 3
9 Washer 3
10 Bolt 2
11 Washer 2
12 Washer 2
13 Idler assembly 1 see Page 26 -21

(pulleys 2 + 3)
14 Drive belt, 72 teeth 1 Tighten, it must deflect

(Engine Type 930/53 by 6 to 8 mm (1/4 to
73 teeth) 5/16 in) at center under
thumbpressure.
15 Bolt 1
16 Washer 1
17 Washer 1
18 Spacer 1
19 Rubberbearing 1 Check, replace if

necessary
20 Bracket 1
21 Rubber bearing 1 Check, replace if

necessary
22 Washer 1
23 Nut 1
Printed in Germany -ll. 1976 Disassembling and Assembling Air Injection 26 -19
Exhaust System
Note when
I No. Description Qty. Remarks
Removing Installing
24 Washer 1
25 Washer 1
26 Bolt 1
27 Washer 1
28 Air pump 1

necessary
30 Spacer 1

necessary
32 Spacer 1
33 Air pump mount 1
35 Washer 3
36 Pulley 4 1
37 Hollow bolt 1
38 Seal 2 Replace
39 Adapter 1
40 Seal 1 Replace
41 Nut 3
42 Washer 3
43 Oil pump 1 Mount oil pump shaft

dowel pin between
socket head screws
of pulley 1.
44 Nut 2
45 Washer 2
46 Cover, flange 1
26 -20 Disassembling and Assembling Air Injection Printed in Germany

Exhaust System
Note when
Removing Installing
48 Washer 2
49 Pulley 1 1
50 Drive belt, 80 teeth 1 Tighten, it must

deflect by 6 to 8 mm
(1/4 to 5/16 in.) at
center under thumb
pressure
51 Bolt 3
52 Washer 3
53 Flange 1
54 Seal 1 Replace, install

correctly with VW 433
55 Gasket 1 Replace, coat both

sides with sealing
compound
REMOVING AND INSTALLING 2/3 IDLER SPROCKET ASSEMBLY
When removing or installing 2/3 idler sprocket

(pulley) assembly on Engine Type 930/53, note
that mounting bossesare offset to one side.
Printed in Germany -II, 1976 Disassembling and Assembling Air Injection 26 -21
Exhaust System
REMOVING AND INSTALLING AIR PUMP
Removing
1. Loosenbolts and hoseson diverter valve and 3. Loosennut on bracketand bolts on air pump
removevalve. mount.
2. Loosen clamps and remove hose between 4. Peel off toothed belt and remove air pump
mixture control unit and valve housing. with mount.
Installing
1. Install air pump with air pump mount and

install toothed belt.
2. Pressair pump to the left slightly and tighten

the bolt on air pump bracket. Under thumb
pressure, the toothed belt should deflect (at
midpoint) by 6 -8 mm (1/4 to 5/16 in.).
26 -22 Removing and Installing Air Pump Printed in Germany

REMOVING AND INSTALLING AIR FILTER OF AIR PUMP
Removing Note
1. Loosenand remove air hose between air pump Wheninstalling make surethat the air filter
and diverter valve. doesnot touch other parts.
2. Loosenclamp and remove air filter.
. Printed in Germany -It 1976

Removing and Installing Air Pump 26 -23
Exhaust System
REMOVING AND INSTALLING CONTROL VALVE
Removing
1. Loosenclampsand pull control line off.
2. Loosenbolts andremove control valve.
Installing
Connect control line hosesproperly.

Connect hose from diverter valve to control valve
at connection I (green ring).
REMOVING AND INSTALLING DIVERTER VALVE
1. Loosenandremove air hosesand control line.
2. Loosenbolts and removevalve.

REMOVING AND INSTALLING AIR INJECTION LINE AND ADAPTER
Removeheat exchangerandreactors. 4. Tightenadapters

to 1.0 -1.2 mkg
(7 -9 ft Ib).
2. Loosenand removecheck valve.
3. Loosenair injection line and connections

at adapters.
Note
Loosenthe oil line slightly at the front left

adapter and move aside for clearance.
Printed in Germany -II, 1976 26 -25

Exhaust System
CHECKING CONTROL VALVE. BLOW-OFF CONTROL VALVE AND CHECK VALVE
Note
In function the control valve, blow-off control

valve and the check valve are connected with
each other. A defective control valve could also
destroy the blow-off control valve as well as the
check valve.
Always check all three parts, if one of them
fails.
Checking Control Valve and Blow- Checking Check Valve

off Control Valve
1. Detachcontrol hoseat control line. The check valve should only be open in the air
injection direction and must be closed in the
opposite direction.
2. Feed pneumatic air having a max. pressure

of 1.0 bar (1.0 atm) into the disconnected
control line, whereby the blow-off control
valve must release air into open space.

REMOVING AND INSTALLING EXHAUST GAS FILTER
Removing
Unscrew couplings, while counterholding.
REMOVING AND INSTALLING EGR VALVE
Removing
1. Detach vacuumhoses.
2. Disconnectpipe at valve.
3. Unscrewmountingbolts.
Installing
1. Usenewgasket.
Printed in Germany -II, 1976 26 -27

Exhaust System
2. Connectvacuumhosesasfollows.
Step I -from upper diaphragm box to left

throttle housing connection (in driving
direction). Connections are marked
with red rings.
Step II -from lower diaphragm box to right

throttle housing connection (in driving
direction).
CHECKING EGR VALVE
2. Detachuppervacuumhoseat EGRvalve.
3. Connectupper vacuumhoseof StageI with

an approx. 1 meter long helping hose.
4. Start engineand let it run at idle speed.
5. Detach vacuum hose at distributor and connect

it to the helping hose using an appropriate piece
of pipe. Also check whether the valve stem
can be moved up.
This check can be repeated several times by

detaching and attaching the helping hose.
A mirror must be used to see the valve stem's

movement.
26 -28
Printed in Germany
~
REACTOR AND EXHAUST MANIFOLD GUARD
From 1977 Models all cars for exportation to

Japan will have a guard underneath the reactors
and exhaust manifold to conform with Japanese
legislation.
It is used to shield the radiation of heat and

thus prevent the ignition of waste paper and
similar items, which might be under a parked
car having hot reactors and mufflers.
EXHAUST GAS TEMPERATURE CONTROL
As a further measure against excessive tempera- The "EX" indicator lamp will flash while the
tures in the area of the exhaust manifold all engine is running. if the exhaust gas tempera-
0
Japan Models will have a system to control the ture reaches or passes750 C. and will go out
exhaust gas temperature. again when the temperature drops below this
value. Exhaustgas temperatures will never be
that high under normal driving conditions, but
instead only when engine loads are very high.
The flashing indicator lamp tells the driver to
reduce engine loads.
The "EX" indicator lamp will also flash while

the engine is running to show that the tempera-
ture sensorhas a defect.
The temperature sensoron the exhaust manifold

measuresthe exhaust gas temperature. Ii is
connected with an electronic control unit and
the "EX" indicator lamp installed in the instru-
ment panel. The control unit is installed next
to the timer relay for the seat belt warning
system.
Printed in Germany -II, 1976 Reactor and ExhaustManifold Guard 26 -29

Downloaded from www.Manualslib.com manuals search engine ExhaustGas Temperature Control
Exhaust System
CHECKING EXHAUST GAS TEMPERATURE CONTROL
1. The "EX" indicator lamp must come on when

turning on the ignition and go out when star-
ting the engine. If not. replace the bulb or
check the electric connections against the
wiring diagram.
2. If the "EX" indicator lamp flashes for an engin,

running at normal temperature, the tempera-
ture sensoris defect and must be replaced.
To check the control unit. pull off the 2-pole

plug in the temperature sensorline while the
engine is running. The "EX" indicator lamp
must flash. If not. the control unit has a de-
fect or the electric connections on the control
unit are wrong.
26 -30 Checking ExhaustGas Temperature Control Printed in Germany

Exhaust System
REMOVING AND INSTALLING TEMPERATURE SENSOR FOR EXHAUST GAS

TEMPERATURE CONTROL
Removing
Unscrewfillister head screws of rear panel

and remove panel with weatherseal.
2. Disconnect2-pole plug connection.
3. Unscrew hexagon head bolt on rear engine

guard.
4. Unscrewcoupling and removesensor.
Printed in Germany -II. 1976 26 -31

Exhaust System
DISASSEMBLING AND ASSEMBLING AIR INJECTION
26 -32 Disassembling and Assembling Air Injection Ill. 1978 - Printed in Germany
Note When Special
No. Description Qty.
1 Hexagon nut 1
2 Spring washer 1
3 Hose clamp 1
4 Air cleaner housing 1

lower section
5 Hose clamp 1
6 Hose 1
Winged nut 1
8 Cover 1
9 Filter cartridge 1 Check, replace if

necessary
10 Hex. head bolt 1
11 Spring washer 1
12 Washer 1
13 Bracket 1
14 Hex. head bolt 1
15 Spring washer 1
16 Washer 1
17 Air pump 1
18 Socket capscrew 3
19 Spring washer 3
20 Gear wheel 1
21 Hexagon nut 1
22 Spring washer 1
23 Washer 1
Printed in Germany -Ill. 1978 Disassembling and Assembling Air Injection 26 -33
26 Exhaust System
Note When Special

No. , Description Qty.
124 Rubber mount 1 Check.replaceif

necessary
25 Air pump holder 1
26 Spacer 1
Rubber mount 1 Check, replace if

necessary
128 Hexagon nut 1
129 Spring washer 1
30 Washer 1
31 Rubber mount 1 Check, replace if

necessary
32 Spacer 1

necessary
34 Spacer 1
35 Hex. head bolt 1
136 Spring washer 1
137 Washer 1

necessary
139 Spacer 1
,40 Console 1

necessary

necessary

necessary
44 Hollow bolt 1
45 Seal 2 Replace
26 -34 Disassembling and Assembling Air Injection Printed in Germany

Exhaust System
Note When
No. Description Qty. Special
46 Adapter 1
47 Seal 1 Replace
48 Hexagon nut 3
49 Spring washer 3
50 Oil pump 1 Install cyl. pin of

oil pump shaft be-
tween capscrews of
air pump drive gear
51 Hexagon nut 2
52 Spring washex 2
53 Interm. flange 1
cover
54 Socket capscrew 2
55 Spring washer 2
56 Gear wheel 1
57 Toothed belt 1 Check, replace if

necessary. tighten
58 Hex. head bolt 3
59 Spring washer 3
60 Intermediateflange 1
61 Gasket 1 Replace
62 Radial seal 1 Replace,position

correctly, use proper
tool, e.g. VW433
Printed in Germany -III, 1978 Disassembling and Assembling Air Injection 26 -35
CHECKING AND ADJUSTING TOOTHED BELT OF AIR PUMP
Checking
Toothed belt tightness is correct, if belt gives

under thumb pressure applied at point midway
between pullies by 6 to 8 mm.
Adjusting
1. Loosenhexagonhead bolt slightly (arrow).
2. Turn self-locking adjustingbolt until belt

tightnessis correct. Tighten hexagonheadbolt.
Checking Printed in Germany

26 -36
Downloaded from www.Manualslib.com manualsand Adjusting
search engine Toothed Belt of Air Pump
ExhaustSystem26
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Printed in Germany -Ill. 1978 Hose Connection Plan -California 26 -39
~
Exhaust System
OPERATING AND TESTING THERMO VALVE OF ENGINE TYPES 930/61,930/62

AND 930/63
Thermo valve in vacuum line between distributor

and throttle housing is closed on a cold engine.
This eliminates vacuum retard control and the

ignition timing moves toward advance by approx.
0
15 .which provides a fast idle speed after a cold
start.
After about 15 to 20 secondsthe thermo valve will

open and lets the vacuum take effect, which pulls
back the ignition timing toward retard to the speci-
fied value.
The thermo valve has to be replaced, if there is Figure showsthermo valve with charge air cooler
no movement toward advance and the related fast removed.
idle speed after a cold start.
Thermo valve can be replaced without removing
The thermo valve function can only be tested on charge air cooler.
a completely cold engine.
26 -40 OneratinQ and engine

TestinQ Thermo Valve Printed in Germany
Downloaded from www.Manualslib.com manuals search
ADJUSTING IGNITION TIMING
Specifications
0 0
Europe: 29 + 2 BTDC at 4000 rpm
0+ 0 +
USA: 5 -3 ATDC at 950 -50 rpm
1. Connect engine tester and tachometer. The

two-pole plug connection must be separated
near the CD! control unit, if the tester applied
does not call for tapping the engine speed
inductively by way of a pliers laid over the
ignition cable of cylinder number 1.
The red wires (voltage supply to control unit)

must be connected again with a helping wire.
The test line is connected to the black/violet
wire coming from the control unit, which
normally is connected to terminal 15 of a
coil type ignition. The other test wire is
connected to ground. Note
All tachometers can be used for this test, Depending on the type of tester used, the
which are suitable for connection to a normal tachometer in the car might have to be
coil type ignition. disconnected for testing.
Printed in Germany -I. 1976 Adjusting Ignition Timing 28 -1

Ignition System
Note
With the engine running the black/violet wire

delivers about 450 V against ground. When
connecting test equipment be careful that the
connecting terminal does not contact the car's
ground. A short circuit of this type could cause
damage on the ignition control unit.
EuropeVersion USAVersion
2. Disconnectvacuumhoseat distributor. 2. Do~ discormectvacuumhoseat distributor.
3. Make adjustmentswith the oil temperature 3. Make adjustments with the oil temperature
0 0 0
at about80 C. The 30 mark on the pulley at about 80 C. The notch on the pulley to
0
muststandstill 1 mm to the right of the the left of the Z1 mark (5 A TDC on crank-
notch on the fan housingwith the engine shaft) must be opposite the mark on the fan
0 +
running at 4000 rpm (1 mm = 1 on crank- housing at an engine speed of 950 -50 rpm.
shaft).
It is not necessaryto inspect or adjust the dwell

angle. and in fact not even possible on turbo
engines using contactless ignition systems.
28 -2
Adjusting Ignition Printed in Germany
Downloaded from www.Manualslib.com manuals search Timing
engine
Ignition System
ADJUSTING IGNITION TIMING FROM 1977MODELS
Specifications: The 2-pole plug connection near the CDI

+ 0
control unit (see Page 28 -1) has been deleted
Europe: 29 -2 BTDC at 4000 rpm from 1977 Models. The wires now lead over
+ 0 + the 14-pole plug on the regulator plate.
USA: 7 -2 ATDC at 1000 -50 rpm
+ 0 +
Japan 15 -2 ATDC at 1000 -50 rpm
Adjustments are made with an engine oil

temperature of about 800 C. The pertinent mark
on the pulley must be opposite the notch on the
blower housing at the specified engine speed.
For this reason a tachometer can no longer be

connected in the manner described on Page
28 -1. Instead a tester must be used, which
records the engine speed by way of prongs
placed around an ignition cable.
After adjustment of the ignition timing a check

The Europe version requires that the vacuum of the ignition timing advance control must be
hose be disconnected at the distributor; it re- made (see Page 28 -4 a).
mains connected for the USA and Japan versions.
Note
0
1 on the crankshaft correspondswith 1 mm on
the circumference of the pulley.
Printed in Germany -IL 1976 Adjusting Ignition Timing 28 -2 a

Ignition System
ADJUSTING IGNITION TIMING FROM 1978 MODELS
Adjusting Values:
0
Europe. 29 before TDC at 4000 rpm After adjustment of the ignition timing. check
R.o.W. ignition timing control (see page 28 -4 c).
+ 0 +
USA: 10 -2 after TDC at 1000 -50 rpm
+ 0 +
California, 5 -1 after TDC at 1000 -50 rpm
Japan:
Adjustments are made when engine oil has a tem-

perature of approx. 800 C. Pertinent mark on pul-
ley must align with notch in blower housing at
specified engine speed.
Europe version requires the detachment of vacuum

hose at distributor. It remains connected for USA,
California and Japan versions.
28 -2 b Adjusting Ignition Timing IV. 1981 - Printed in Germany

CHECKING IGNITION TIMING CONTROL
Requirements:Ignition timing is set correctly. Checktiming angle as follows.
EuropeVersion USA Version

..0 + 0 . 0+ 0
Igmtlon
+
angle must be 0 -3 at Idle speed of Ignition angle must be 26 -3 BTDC at engine
950 -50 rpm (vacuum hose connected) speed of 4000 rpm (vacuum hose disconnected)
If specificationsare not met, remove distributorand check on test bench.
CENTRIFUGAL ADVANCE CURVE TURBO ENGINE
BTDC
2~
15°, =:~:tt &
y
f-
1__-
-I
z I ~,o I I .~
I , ,~ ~ ~ .I
0 1000 2000 3000 4000

Distributor Shaft Speed (rpm)
Printed in Germany -I. 1976 CheckingIgnition Timing Control 28 -3

Ignition System
VACUUM ADVANCE CURVE TURBO ENGINE
v.OT (at correctly adjusted ignition timing and idling speed)
.-
20'= -
cO
.c:
'"
15~
.:.:
Q .-, ~~
cO
...
(J
10t!. cO
Q)
(J
5~ Q
cO
-J ~ ~ -
>
"0
-<
o~
-5-
-10;
0 100 200 300 400 Torr vacuum
n.OT vacuum
100 200 300 400 500 mbar vacuum
~
~ S c~
~~
l,~
~
IS
I~
28 -4 Checking Ignition Timing Control
"--
I~
CHECKING IGNITION TIMING ADVANCE CONTROL FROM 1977 MODELS
Requirement:Ignition timing adjustedcorrectly.
Checking Ignition Angle:
Europe: Japan:
The ignition angle must be 0 ~ 40 at idle The ignition angle must be 30 ~ 30 BTDC at
+
speed of 900 -50 rpm (vacuum hose connected). an engine speed of 4000 rpm (vacuum hose
disconnected)
.
USA:
The ignition angle must be 29 -:: 34 BTDC at If the reference value is not reached. remove
an engine speed of 4000 rpm the distributor and test it on a test bench.
(vacuum hose disconnected).
CENTRIFUGAL ADVANCE CURVE TURBO ENGINE FROM MODEL 77
BTDC
150 -~."
5'
0'
-50 --
0 500 1000 1500 2000 2500 3000 3500 4000
Printed in Germany -II, 1976 Checking Ignition Timing Advance Control 28 -4 a

VACUUM RETARD CURVE TURBO ENGINE FROM MODEL 77
ATDC
O'
0--
,-++
-.i- +
Torr vacuum -300

400 500
400
-..
mbar vacuum 300
APAN
t:tt
~
+m
ff4
,Id=i
'
H-
28 -4 b Checking Ignition Timing Advance Control
Printed in Germany
Ignition System
CHECKING IGNITION TIMING CONTROL FROM 1978 MODELS
Requirement: ignition timing correct.
Checking Ignition Angle:
Europe California. Japan:

+
At idle speed of 1000 -50 rpm ignition angle must At eng~e weed of 4000 rpm ignition angle must
0+ 0
be between 0 -2 . be 310 -4 before TDC.
(Vacuum hose connected.) (Vacuum hose disconnected, but high pressure
hose can remain connected as long as the test is
made without engine load.)
USA
At en§i~e weed of 4000 rpm ignition angle must If specified values are not reached, remove distri-
be 26 -4 before TDC. butor and check in a test bench.
(Vacuum hose disconnected.)
CENTRIFUGAL ADVANCE CURVE TURBO ENGINE FROM MODEL 78. EUROPE
BTDC
150 I
100
it
50 -
ATDC 500 1000 1500 2000 2500 3000 3500 4000

Printed in Germany -IV. 1981 Checking Ignition Timing Control 28 -4 c

Ignition System
VACUUM RETARD CURVE TURBO ENGINE FROM MODEL. 78. EUROPE
BTDC
50
f-
100 - -
Ij
CENTRIFUGAL ADVANCE CURVE TURBO ENGINE FROM MODEL 78.USA.

CALIFORNIA. JAPAN
28-4d Checking Ignition Timing Control Printed in Germany

VACUUM RETARD CURVE TURBO ENGINE FROM MODEL 78. USA
81DC
VACUUM RETARD CURVE TURBO ENGINE FROM MODEL 78, CALIFORNIA,
BTDC JAPAN
SO
00

50
1O0
150
ATDC
l 300 200 100 0
I
100
Vacuum -
200 300
J
400 mbar
Note
100 mbar = 75 Torr = 0.1 at
Printed in Germany -IV. 1981 CheckingIgnition Timing Control 28 -4 e
Ignition System
CHECKING DISTRIBUTOR IN CAR
Turning the distributor shaft will produce alternating Presentday workshop equipment is not
current in the built-in coil and feed it to the CDI sufficient to inspect distributors throughly.
control unit via a wire. with the aid of this alter-
nating current signal. which increases with the
engine speed, the ignition is released in the
Note
control unit.
Never make changes on the soft iron teeth

The theoretical functi on of the distributor's of the rotor or stator.
electromagnetic system can be checked by
measuring the alternating current.
If the starter is operated with the distributor

cap taken off, be careful that the spring
1. Disconnect 2 -pole plug connector at wire from holders do not protrude into the distributor
distributor to engine harness. where they could damage it.
2. Connecta multipurposetester to the plug and

adjustit to the alternating current.
3. Operate starter and read current on tester.

The current to be expected is usually around
0.1 V. An exact reading cannot be made.
because the current depends on the starting
speed and type of measuring equipment. The
distributor is defect and needs to be replaced
if there is considerably less or no current.
Printed in Germany Checking Distributor 28-5

Ignition System
TROUBLESHOOTING ELECTRONIC IGNITION SYSTEM BOSCH CDI)
T est Requirements:
Battery fully charged, fuel in tank, engine or

0
ambient temperature between 0 and + 40 c.
(Temperature has a heavy influence on the
measured values.)
Pay attention to the information on dangers for

any type of work on the CD! system (see Repair
Manual 911, Vol. II, Pages NE 23 and 24 .
Starter turns, engine does not start or develops

insufficient power
1. Connect spark gap to ignition transformer

terminal 4 and set it for 12 mm. Start engine.
12 mm spark exists?
yes
2. Check distributorcap. distributorrotor, igni-

tion lines and sparkplugs.
Resistanceof ignition line including plug:
4 kohms.
28 -6 Troubleshooting Electronic Ignition System Printed in Germany

Ignition System
Resistance of distributor rotor: 5 kohms
Spark from spark plug?
no
yes ...Repair high voltage end
3. Checkignitiontiming.
Timing correct?
no
, ~ Adjust timing
yes
4. Checkfuelsystem.
5. Check ignition transformer.

Disconnect plug and high voltage wire at
ignition transformer.

Ignition transformer primary (term. A and B):
0.10 to 0.165 ohms
Ignition transformer secondary (term. 4 and
A): 390 to 630 ohms
Resistancecorrect?
no
yes -Replace ignition transformer
6. Check wires and plugs of ignition system (CDI

control unit, ignition/starter switch, distribu-
tor, ignition transformer, tachometer) for
tightness and oxidation.
Everthing correct?
no
yes ~ Eliminate defects
28 -8 TroubleshootingElectronic Ignition System Printed in Germany

Ignition System
yes
7. For ignition failure:

Disconnect tachometer.
If ignition failure is gone, the tachometer
has a defect. If not, the tachometer is good.
Ignition failure eliminated?
I no
I -Replace control unit
yes
Engine must start or there must be engine

output. If not, there is a mechanical defect.
8. Disconnect wire plugs at air flow sensor

contact or bridge terminals 30 and 87 on base
of relay for fuel pump II.
Printed in Germany -II, 1976 Troubleshooting Electronic Ignition System 28 -9

Ignition System
Check voltage at disconnected control unit

plug between terminals 6 and 8 with the igni-
tion on. The voltage must equal the battery
voltage.
Voltage correct?
yes Eliminate break in supply line.
9. Check sensorresistance including sensorline

at disconnected control unit plug between
terminals 3 and 7.
Resistance:490 to 700 ohms.
28 -10 TroubleshootingElectronic Ignition System Printed in Germany

Ignition System
Resistance correct?
Lnn Repeat test at two-pole plug in sensorline.

yes
10. Check ground of sensorcoil including sensor

line at disconnected control unit plug be-
tween terminal 3 and car's ground
and
terminal 7 and car's ground.
Test values correct: Repair or replace wires

between plug and CD! control unit.
T est values incorrect: Replace distributor.
Printed in Germany -II. 1976 Troubleshooting Electronic Ignition System 28 -11

Ignition System
Resistance infinite?
yes Repeat test at 2-pole plug in sensorline

(see page 28 -11).
11. Check sensorsystem for mechanical damage.

Visual inspection: Is there clearance between
the rotor and stator?
Sensor system good?
no
yes --Replace distributor
12. Disconnect tachometer.

If there's an ignition spark now, the tacho-
meter is defective.
Tachometer good?
yes Replacetachometer
Continue at Point 5
. 28 -12 Troubleshooting Electronic Ignition System

Printed in Germany
DELAYED IGNITION CUT-OFF
A relay for delayed ignition cut-off will be An interruption in the diode could mean that
installed in all 1977 Turbo Models. there is no longer a guarantee for energization
of the alternator (charge indicator lamp does
not come on while switching on the ignition).
A break of the diode in the direction of blocking

will be noticed by considerable after-running
of the engine after switching it off.
When stopping the engine only the fuel pumps

are turned off at first. After a delayed-action
time of 3 to 5 secondsthe power supply for the
CDI control unit is broken automatically. In
this manner an orderly combustion of the resi-
dual fuel until the engine stops completely is
guaranteed.
A diode is connected to the battery charge

indicator lamp.
It prevents the feeding of voltage into the

car's electrical system from terminal D + of
the alternator via the charge indicator lamp
while the engine is stopping.
Printed in Germany -II, 1976 Delayed Ignition Cut-off 28 -13

Ignition System
IGNITION SYSTEM FROM 1978 MODELS
A left-turning distributor is installed on 3.3 liter Cars in California version are equipped with a
turbochargedengines. distributor having a double action pressure box
At idle speed the intake vacuum produces igni-

tion control toward retard, which is eliminated
again when the throttle is open just slightly.
The charge air pressureis used for full throttle

retard ignition control, to avoid coming into the
range of excessive advance ignition at full throttle
with the ignition timing which is 50 earlier than
the USA version.
An altered CDI control unit is being introduced

at the same time. It is identical with the unit
used in Type 911.
Speed governor (in distributor rotor):

+
7000 -200 rpm
Ignition System From 1978 Models Ill, 1978 - Printed in Germany

28 -14

911 Turbo 1989 Workshop Manual

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911 Turbo 1989 Workshop Manual

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Downloaded from www.Manualslib.

com manuals search engine

Front Wheel Suspension 40

HEATING. VENTILATION. Heater 80

Downloaded from www.Manualslib.com manuals search engine

Adjustment values and limits 10 -01

Specifications, general 0.1

Engine. removing and installing 10

Engine/transmission unit, detaching and attaching from 1978 models 10 -8

Engine/gearbox assembly, separating and joining, Model 10 -14

Engine, Crankshaft, Pistons

Crankshaft sizes from 1978 models 13 -4

Piston and cylinder sizes, installation notes from 1978 models 13 -7

Weight classes of pistons -911 Turbo from 1980 models 13 -9

Engine. Cylinder Head. Val yes

Chain tensioner. removing and installing 15 -1

Valve clearance, adjusting 15 -1

Valve spring sizes 15 -1

Delivery rate of fuel pumps. checking 20 -1

Fuel pump. removing and installing 20 -5

Air pressure safety switch. checking 21 -11

Bypassvalve, checking function 21 -4 a

Bypassvalve, removing and installing 21 -5

Charge pressure. checking 21 -9

Charge pressuregauge. checking 21 -19

Turbocharger, oil supply 21 -12

Turbocharger. removing and installing 21 -1

Valve housing. disassembling and assembling 21 -6

Air cleaner, removing and installing from 1978 models 25 -19

Auxiliary air valve, removing and installing 25 -18

Control pressure "cold", checking 25 -13

Control pressure "warm", checking 25 -13

Control pressure "warm-full throttle enrichment", checking

Fuel delivery rate for control pressure circuit. checking 25 -14 b

Fuel distributor of mixture control unit. removing and installing 25 -6 b

Idle, adjusting from 1978 models 25 -10 a

Downloaded from www.Manualslib.com manuals search engine

Mixture control unit, disassembling and assembling 25 -6 d

Pressuregauges, connecting and bleeding 25 -12

System pressure, checking 25 -14 a

Testing and adjusting values for fuel injection 25 -15

Thermo shift valve, checking 25 -17

Thermo shift valve. removing and installing 25 -17

Throttle bypass valve, removing and installing 25 -10

Tools for fuel pressuretest 25 -11

Checking Lambda control function 25 -21

Checking Lambda probe 25 -22

Air filter of air pump, removing and installing 26 -23

Air injection, disassembling and assembling 26 -32

Air injection, disassembling and assembling engine type 930/51

Belt of air pump, checking and adjusting

Control valve, removing and installing 26 -24

EGRvalve, checking 26 -28

EGRvalve, removing and installing 26 -27

Exhaust filter, removing and installing 26 -27

Exhaustsystem, disassembling and assembling 26 -2

Exhaustsystem, disassembling and assembling 26 -8

Exhaustsystem, survey engine type 930/50 26 -1

Exhaustsystem, survey engine type 930/52 26 -6

Exhaustsystem, survey engine type 930/51, 930/53 and 930/54 26 -

Exhausttemperature control, checking 26 -30

Hose connection plan, California 26 -39

Hose connection plan. Europe 26 -37