GENERAL Technical Date Page 0.1

REPAIR GROUP

101315171920

2125

26

2728

ENGINE

Engine-crankcaseEngine-Crankshaft, and moving partsEngine-Cylinder Head, Valve driveEngine-LubricationEngine -CoolingFuel Supply system

TurbochargerFuel systemExhaust SystemStarter, Power Supply

Ignition System

3034

35

39

Clutch, ControlMech. gear-shift system -actuat., hous.Mech.gear-shift system -Gears, ShaftsDifferential

TRAN S MISSION

40

4":>'

44

47

48

CHASSIS

Front Wheel SuspensionRear Wheel SuspensionWheels, Tires, measuring vehicleBrakes, -Hydraulic -system

Steering

505153555760

63

64

66

68

BODY

Body-Front SectionBody-Center SectionBody-Rear SectionLidsDoorsSliding Roof

BumpersGlassesExterior equipmentInterior equipment

HEATING. VENTILATION.AIR CONDITIONING

HeaterAir Conditioaer

8087

90

92

94

9697

Instruments, RadioWindshield Wipers and WasherExterior LightsInterior Lights

Wiring

ELECTRICS

911 turbo Alphabetical Index Volume II

Page

Body, front section

..50-4

..50-1

..50-3

..50-5

..50-7

..50-7a

Body platform, front -type 911-turbo Body platform and front section gauge P 863 Dimensions for body platform. Repair control dimensions 911-turbo Repair control dimensions 911-turbo, Model 78 onwards

Straightening attachments for type 911-turbo -ENS 77.303

Body, rear section

Transverse rear axle tube 911-turbo 53-1

Hood

Engine hood, removing and installing from Model 78 onward 55-1

Exterior equipment

66-3

66-1

Fitting stoneguard foil to rear turbo fender

Fitting turbo emblem.

Interior equipment

Central console, removing and installing 68-1

Heating

Automatic heating control, removing and installing

Automatic heating control, checking.00-100-5

Fittings, instruments, radio

9()-3

9()-4

9()~1

Electronic tachometer, checking. Electronic tachometer, removing and installing generator

Position of relays in the vehicle.

Alphabetical Index

Printed in Germany -VII, 1989

1

Volume II Alphabetical Index 911 turbo

Page

97-1

97-13

97-19

97-17

97-29

97-25

97-23

97-7

97-31

97-11

97-9

97-27

97-5

97-61

97-79

97-115

97-153

97-197

Wiring

Current-flow diagram -911 turbo, Model 76 Current-flow diagram -911 turbo, Model 77 Current-flow diagram -911 turbo, Model 78 Additional current-flow diagram -exhaust temperature monitoring -type 911 turbo

Additional current-flow diagram -automatic heating control. Additional current-flow diagram -electric windows. Additional current-flow diagram -rear window wiper. Additional current-flow diagram -refrigerant system with front condenser. ...

Additional current-flow diagram -air-conditioning system. Additional current-flow diagram -engine compartment light. Additional current-flow diagram -fog lamp. Additional current-flow diagram -headlight cleaning system. Additional current-flow diagram -intermittent wiper c!rcuit, Model 76 Additional circuit diagram -alarm system, Model 85 Circuit diagram, Model 86 Circuitdiagram,ModeI87 Circuitdiagram,ModeI88 Circuitdiagram,ModeI89

Alphabetical IndexPrinted in Germany -VII, 1989

2

Body -Front Section

FLOOR/FRAME CHECKPOINTS AND FRONT BODY SECnON GAUGES P 863 AND 863a

As already announced in the 1975 model information, checkpoints are welded to the floor/frameassembly from 1975 models. The extent of damage is quickly diagnosed with the help of thesecheckpoints and front body section gauge P 683 a (consisting of former gauge P 863 + additionaladaptor) .

The carrier pin of Type 930 Turbo is 21 mm higher. When measuring with front body sectiongauge P 863,the distance between the upper edge of the gauge and the collar on the carrier pinis 21 mm or, with the adaptor installed on the carrier pin, 13 rom.

The gauge can also be used to repair light front section damage (upsets up to 10 mm). Cars withdamage of this type no longer need to be installed on a straightening bench.

Installation of the gauge requires that the wheels, the guard, the carrier and the control arms beremoved. The gauge is then bolted to the front axle take-up points and front floor/frame checkpoints,as illustrated above.

The distance from the rear floor/frame checkpoints and rear axle take-up points for the transmissionto the engine suspension is checked with a measuring staff.

This gauge is for checking only. It must be removed for straightening and welding operationsto prevent it from becoming bent through body distortions.

Note:

Printed in Germany 50-1Floor/Frame and Front Body Section Gauge

50 Body

FLOOR/FRAME ASSEMBLY DRAWING

Printed in GermanyFloor/F'rame Assembly Drawing50-2

Body

Dim. Designation mm

+565.5 -2A Control arm take-up, front, inner

!

1Carrier take-up 726

! 2Front floor plate checkpointsc 1200

! 2D Rear floor plate checkpoints 850

! 3E Engine suspension 752

!. 3F Front floor/inner control arm checkpoint 1327

!. 3Rear floor/ carrier checkpoint 1868G

+1528.5- 3H Axle tube transmission/front. floor checkpoint

1346 "!. 3

1374Axle tube transmission/inner engine suspension

from 1978 models1557 :!: 31582

Rear floor/inner engine suspension checkpointKfrom 1978 models

"to 31041L Front floor/inner control arm checkpoint

+1215 -2Front floor/rear floor checkpointsM

1355 ! 313~4_-

Rear floor/inner engine suspension checkpointsNU91ILlll8models

0 Axle tube transmission/inner engine suspension 1245 :: 31273

All distances are measured from center of hole and horizontal.

Note

Distances to engine suspension bolts are measured direct (at an angle).

Note

Lengths measured on the left and right may not exceed the specified tolerances in difference

to each other.

Body -Front

FLOOR/FRAME ASSEMBLY TYPE 930 TURBO

In comparison to the Type 911, the carrier pin

Body

')"'

REPAIR REFERENCE POINTS FOR 930-turbo

Repair Reference Points for 930 Turbo 50-5

Printed in Germany III, 1978 Repair Reference Dimensions 930 TurboFrom 1978 Models

Body

STRAIGHTENING BENCH ATTACHMENT SET ENS 77.303 FOR TYPE 930 TURBO

The illustrated take-up points differ from the attachment set for Type 911 and are applicable to Turbo

cars.

The auxiliary carrier pin is installed 21 mm (0.827') higher.

The brackets on the rear axle cross tube are inclined upwards.~""'

The take-up pin for the transmission suspension is located 25 mm (0.984') further forward.

The engine mount for Type 3.0 Turbo up to 1977 model conforms with Type 911.

The engine mount for Type 3.3 Turbo from 1978 model is moved further back by 30 mm (1.181 ").

REAR AXLE CROSS TUBE OF 930 TURBO

A new rear axle cross tube. Part No. 930 331 010 00,-Fig. A -is installed in the Type 930 Turbo.This cross tube differs from the version for theType 911 -Fig. B -as follows.

1. New, larger holders fgr rear axle trailingarms at an angle of 2 30' upwards.Reference point: 6 mm above the horizontalas measured at the rear inner support plateof the holder's lower edge.

2. New transmission suspension take-up pin(offset 25 mm toward front).

Notes

1. The seat wells have dents on both sides ofthe center t,'Jnnel above the holders for theType 930 Turbo (see figure).

2. Large seat belt reinforcement plates areinstalled in all cars for Australia and France.and in fact on the transmission tunnel. Thesereinforcements are welded to the holders atthe rear axle cross tube to increase the

strength.

Rear Axle Cross Tube for 930 Turbo 53-1Printed in Germany

Hoods and Lids

REMOVING AND INSTALLING ENGINE HOOD FROM 1978 MODELS, TURBO 3.3

Removing

1. Detach hose straps and ground wire at hinge..~. Caution

Refrigerant hoses must not be detached from con-denser, since otherwise-the high pressure refrigerantwould escape and the air conditioner would haveto be recharged.

Also make sure than fins of condenser are not bent.Large area fin damage will impair the efficiencyof the ..ir conditioner.

4. Remove windshield wipex arms. Unscrew winds-hield wiper holders and lift off connecting link-

age.

2. Mark and disconnect wires leading to rearwindow wiper and engine compartment lamp.Remove engine compartment lamp for this

purpose.

5. Detach engine hood at hinges and remove.

3. If car has air conditioning. loosen condenserscrew from hood (see arrow). Lay down conden-ser in engine compartment carefully.

Printed in Germany -III, 1978 Removing and Installing Engine Hood 55 -1

Hoods and Lids

Disassembling Notes on Installing

1. Unscrew rear spoiler carrier from hood and re-move with reinforcement rail, see arrow.

When installing the windshield wiper shaft, it isessential to insert spacer in hood. Wiper armshould be installed that, when switched off, wiperblade will be parallel to side window weatherstrip(distance approx. 40 mm).

Note

When painting car, cover riveted weatherstripwith tape.

2. Detach spoiler (polyurethane section) fromcarrier, see arrow.

Printed in GermanyRemoving and Installing Engine Hood55 -2

Exterior Fittings

INSTALLING TURBO SIGN

There are nine 'Turbo" decals on each vehicle.They are placed as follows: one on each door;one on each front fender; two on each rear fender;one for the rear lid. Work Sequence:

Observe the following to make sure that thedecals adhere well to the painted body.

1. Wash and dry car. Remove wax and polishin areas of decal.

2. Do not apply decal outdoors, if cold or moist.The car and ambient temperature should be

0 0about 20 C (68 F) for best results.

1. install the door decal, Part No. 930.559.303/304 00/01 so that the paper edges (top front/rear front) rest on the door waistline strip.Make sure the opening around the door handleis equidistant. Pull paper half off adhesivesurface. Place decal on door handle and presson lightly. While pulling paper off, pull decalforward and press on (smooth by hand fromrear to front).Smooth decal toward the outside with aplastic squeegee Pull off top protective paperparallel to decal. Fold overlapping edges of

decal.

3. The thick beige paper covers the adhesivesurface.

4. Always start with the door decal and thenalign the adjacent decal with this one.

5. Decals not pressed on firmly by rubbingsmooth can be pulled off again for alignment.Puncture air bubbles with a needle and press

smooth.

6. Remove exterior mirror on doors.

Installing Turbo Sign 66 -1Printed in Germany -1, 1976

Exterior Fittings

4. Install turbo sign decal -Part no. 930.559.307/308 00/01 -below masking tape border parallelto taillights. Make sure that the edges of thefront and rear decals are parallel. Fold ends ofdecal at water drain molding.

2. Install front fender decal -Part no. 930.559.301/302 00/01 -after the door decal has beeninstalled. Start at the door edge. Make surethe point begins on the fender (not the head-light rim). Align the top paper edge of thefront decal with the center of the headlight.

Press over fuel tank cover and after theprotective paper has been pulled off, cutthrough decal which overlaps fuel flap cover.

3. Install rear fender decal -Part no. 930.559.305/306 00/01 -aligning it with the doordecal. To facilitate alignment of the frontfender with rear tubo decal, masking tapecan be used.

Note

When applying the turbo sign decal make surethat the shaded areas are pressed on without folds;folds between shaded areas cannot be avoided

completely.

5. Install rear lid decal -Part no.930.559.309 00/01 -at same height as fender decals and foldthe ends.

66 -2 Installing Turbo Sign Printed in Germany

Exterior Fittings

INSTALLING TURBO DECALS ON REAR FENDERS

1. Using squeege pull upper lip of rubber guardaway from connector plate as far as necessary.

2. Clean and dry surfaces for decals.

3. Draw a pencil line 30 mm (1 1/8 iIi.) parallelto wheel openiIig.

4. Peel protective paper off decal and placedecal on surface so that it matches the drawnline and its bottom is covered about 3 mm(1/8 in.) by the rubber guard strip.

5. Smooth decal toward outside and rub outbubbles with a squeegee If necessary puncturebubbles with a pin and press smooth.

Installing Decal on Turbo Rear Fenders 66 -3Printed in Germany -I. 1976

Interior Fittings

REMOVING AND INSTALLING CENTER CONSOLE

Removing

1. Unscrew cap.

Caution! The capillary tube must not bebent sharply or separated. sinceit would be destroyed.

2. Pull off air conditioner switch knobs andremove round nuts. Unscrew left and rightmetal screws (arrow). Press down and removeholder.

4. Remove mounting screws at front and rearof center tunnel.

5. Pull up rubber cover on gearshift lever,

3. Disconnect wire plugs at both switches. Re-move blower switch. Remove insulation tapeon white capillary tube and pull harness outof center console (disconnect battery).

6. Lift center console and swing over the re-leased parking brake lever to one side.

Removing and Installing Center Console 68 -1Printed in Germany -II, 1976

Interior Fittings

7. Open up the opening for the harness to about40 x 60 mm, so that the temperature switchcan be removed. This means first cutting theproper depth with a saw and then cutting outthe metal with a shears. Remove center con-sole.

Note

Open up the harness opening of a new centerconsole to the specified size.

If only the temperature switch has to be replaced,the capillary tube' s front end in the floor platemust be pulled out of the vaporizer housing. Thecapillary tube is fastened to the harness at severalpoints with an insulation tape. Cut through insula-tion tape and then slide on a matching sleeve tocover the entire length. Pullout temperatureswitch and slide in the new capillary tube throughthe sleeve.

Printed in Germany68 -2 Removing and Installing Center Console

Heater

AUTOMATC HEATER CONTROLS

Removing and Installing Control Unit

1 -Pry both side covers off of control unit.

2 -Detach connecting rod between motor andheater lever.

Removing and Installing InteriorSensor

1 -Remove both Phillips screws and pulldown sensor carefully.

3 -Remove the four hex head screws, liftcontrol unit carefully and disconnect thethree plugs at the control unit.

4 -Remove rubber seal and slide control unitforward past heater and parking brakelevers to remove.

2 -FUll angled plug off of sensor.

Removing and Installing Automatic Heater Controls 80-1Printed in Germany

Heater

Removing and Installing HeatSensor in Heater Flap Housing

1. Loosen control unit and pull off the front2-pole male plug.

2. Loosen carpet along center tunnel andclear cable up to grommet in heel plate.

3. Pull both wires out of male plug housing(be carefull that they don't grab hold)and press out the grommet.

4. Remove adaptor on left heater flap

housing.

~

6. Rivet new heat sensor, slide in cableand press in grommet.

5. Pullout cable and remove rivets on the

adaptor.

80-2 Removing and Installing Automatic Heater Controls Printed in Germany

Heater

7 Install adaptor. Make sure that the heaterflaps are adjusted evenly on both sides.

8. Secure plug housing to cable. The black wire

Place cable inside of car, paste carpets.connect plug to control unit and securecontrol unit again.

Removing and Installing Automatic Heater Control 80-3Printed in Germany

must be located on the side of the housingwith a tab.

Heater

TROUBLESHOOTING AUTOMATIC HEATER CONTROLS

Checking Interior Sensor Checking Heat Sensor in Heater

Flap Housing

1 -Remove interior sensor. 1 -Remove control unit.

2 -Connect ohmmeter to 2-pole plug ofheat sensor. The resistance must be135 ohm with warm engine at 1000C.Replace heat sensor if resistance is wayoff (see "Checking Interior Sensor").

2 -Using an ohmmeter with an appropriatetesting range, check the resistance bet-ween both coaxial connections on thesensor (use test points). The resistanceis very dependent on the temperature andshould be about 1.5 kOhm at roomtemperature. Replace the temperaturesensor if the resistance is about CD ohm(interuption in sensor) or about 0 ohm(short circuit in sensor).

Note

An interruption in one of the sensors or in thewires to the control unit will fake a too lowor, a short circuit, a too high inside tempera-ture. This will result in an improper movementof the heater lever up or down.

80-5Checking Automatic Heater ControlsPrinted in Germany

Checking Power Supply to ControlUnit

1 -Remove right side cover of controlunit.

2 -Disconnect 3-pole plug.

3 -Turn on ignition and parking lights.

4 -Connect test lamp between brown andred/white as well as brown and gray/bluecables. Test lamp must come on inboth cases.

If both temperature sensors and the powersupply function correctly. but the heatercontrols do not function properly. replacethe complete control unit.

80-6 Checking Automatic Heater Controls Printed in Germany

Instruments, Radio

LOCATION OF RELAYS IN CAR

Six standard relays are located in the fuse boxin the luggage compartment.

As for the Type 911. the standard relay for therear window defogger. the flasher relay. thetimer relay for the seat belt warning systemand the control unit for. the exhaust gas tempera-ture control system (Japan Version) are locatedon the luggage compartment floor plate. left-hand side as seen in the driving direction. Therelays are accessible from the luggage com-partment or after removal of the small com-bination instrument.

1 -Air conditioner relay (front in drivingdirection) optional extra equipment

2 -Foglight relay

3 -Horn relay

4 -Not occupied

5 -Electric window winder relay

From 1977 Models the fuse sequence haschanged as follows.6 -Fuel pump relay I (front)

7 -Fuel pump relay II (rear) 1. The fuses 16 and 21 (fuel pump and windowcontrols) have been exchanged against eachother.

2. The fuses 12 and 14 (sliding roof and rear windowwiper or blower and rear window defogger) havealso been exchanged against each other. Thismeasure was necessary to prevent that theengine would continue running several secondsafter the ignition was turned off, if the heaterblower was switched on.

-II. 1976 Location of Relays in Car 90 -1Printed in Germany

Instruments, Radio

1 -Fuse/relay plate

2 -Hot starting valve relay

3 -Warm-up governor relay

4 -Air control/charge pressure relay

5 -2-stage rear window defogger control

relay

6 -Voltage stabilizer

CD! control unit

8 -Radio suppression

Printed in GermanyLocation of Relays in Car!IO -2

90Instruments, Radio

Fuse/Relay Plate from 1976 Models

22 24,-Rear fusebox (fuses S to S

2 -Fuse/relay plate

-Relay. air control/charging pressure

4 -Relay. two stage rear window defogger

5 -Condenser, CDI control unit

6 -Radio suppressor

7 -Voltage stabilizer

CD! control unit

Location of Relays 90 -2 aPr inted in Germany -I, 1'..176

90 Instruments, Radio

Regulator Plate from 1977 Models

1 -Tail fuse box

2 -Regulator plate

3 -Air flow sensor/charging pressure relay

4 -Delayed ignition cut-off relay

5 -Two-stage rear window defogger relay (not applicable from 1978 Models)

6 -CDI control unit capacitor

7 -Radio shield

8 -Voltage regulator

9 -CDI control unit

Printed in GermanyIII, 1978 -90 -2 b Location of Relays in Car

Instruments, Radio

ELECTRONIC SPEEDOMETER

Checking Electronic Speedometer Sensor

Remove tunnel cover in front of emergency seats. Disconnect the flat male plugs at the connectorin the tunnel and connect a test buzzer to the wires leading back. Lift car at rear axle and turn rightrear wheel by hand. Lock left rear wheel,. The buzzer must sound off 8 times for each two revolutionsof the wheel. If not, replace the sensor.

The left rear wheel need not be locked, if a car is equipped with a limited slip differential. In thiscase the buzzer sounds off 8 times for each one revolution.

Checking Electronic Speedometer

Connect and disconnect very quickly the two wires in the tunnel that lead forward. A distributor canbe applied to help. if both wires are connected to terminal 1 and the distributor housing, and thedistributor shaft is turned by hand as quickly as possible. Remove the speedometer if there is nodeflection of the needle. Check all wire connections to the speedometer and replace the speedometerif necessary.

Turn on the ignition for this test.

Checking Electronic Speedometer 90 -3Printed in Germany -I, 1976

Instruments, Radio

Removing and Installing ElectronicSpeedometer Sensor

1 -Remove right rear wheel.

2 -Remove hex head screw and take holderoff of sensor.

3 -Take sensor wires out of holders andpull sensor out of transmission case.

4 -Separate connector in tunnel and pullout sensor wire toward rear.

Note

The polarity need not be observed whenconnecting the sensor wire.

. Printed in Germany90 -4 Removing and Installing Electronic Speedometer Sensor