Porsche Workshop Manual 911 1972

Workshop manual
DR. ING. h. c. F. PORSCHE KG

STUTTGART-ZUFFENHAUSEN
Downloaded from www.Manualslib.com manuals search engine

P O R S C H E WORKSHOP M A N U A L 9 1 1 - FROM MODEL 1 9 7 2 O N
This publication contains the essential removal, installation and adjustment procedures for the
Porsche 911 vehicles sold in the USA and Canada. Components and procedures described in this manual
are identical for all types unless differences are pointed out in the text. It is assumed that the reader is
familiar with basic automotive repair procedures. Special tools required in performing certain service
operations are identified in the manual and recommended for use. Use of tools or procedures other than
those recommended in this repair manual may b e detrimental t o the vehicle's safe operation as well as
the safety of the person servicing the vehicle.
The Workshop Manual 911 - from model 1972 on - is subdivided into 10 Assembly Groups, delive-
red in supplements to volume I and 11.
Survey of t h e i n d i v i d u a l Assembly Groups:
Engine and Clutch Code No. 1
Fuel System Code No. 2
Transmission Code No. 3
Front Axle Code No. 4
Rear Axle Code No. 5
Brakes, Wheels, Tires Code No. 6
Pedal Controls and Manual Controls Code No. 7
Maintenance Jobs, Technical Data Code No.. 0
Body Code No. 8
Electrical System Code No. 9
For identification of the volumes, the back of the folders is provided with a transparent pocket at
the top for insertion of the pertinent type.
To find the individual repair steps quickly, each Assembly Group of this Workshop Manual is sub-
divided into "Main Groups", "Chapters" and "Sections" and provided with a very detailed list of
contents; refer to example on next page.
Technical Information sheets should be filed at the beginning of their respective groups. The
contents of the Technical Informations will be incorporated into the Workshop Manual at suitable
intervals. The List of Contents will be edited whenever extensions and supplements are published.
- XXXII, 1974
USA /CAN

Motor und Kupplung
Engine and Clutch
Moteur et Accouplement
Motore e Frizione

ENGINE 911 1
CONTENTS
0 - INFORMATION, DESCRIPTION, TECHNICAL DATA
0.1 Description
Engine changes - 1972 model
Oil tank changes - 1972 model
Oil cooler system and oil circuit schematic
Oil cooler.schematic - 1973 model
Oil cooler schematic with cooling coil - 1974 model
Engine, front view cross section
Engine, ' side view cross section
Specifications for 2.7 liter- engine where differ 2.4 liter-engine
Engine changes - 1974 model
Cross section of engine with emission control equipment
Layout of exhaust gas recirculation system
Engine cross section with emission control - 1978/1979 models
Emission control layout - 1980 model
0.2 Technical data
General data
Power performance curves
Technical data, Type 9 1 1 T - Continuous Injection System (CIS)
Technical data, Type 911/S/Carrera - 1974 model
Full-power performance - 1974 model
Technical data, Type 9 1 1 S and Carrera - 1975 model
Engine tightening data
Technical data, Type 911 - 1976 model
Technical data, Type 9 1 1 S - 1977 model
Technical data, Type 9 1 1 SC - 1978 model
Technical data, Type 9 1 1 SC - 1980 model
Technical Data, Type 9 1 1 SC - from 1981 Models
COOLING SYSTEM, EXHAUST SYSTEM, EMISSION CONTROL
2.1 Cooling system

Fan drive belt, replacing/adjusting

ENGINE
2.2 Exhaust system and h e a t i n g

Exhaust system and heater blower, removing and installing
Exhaust system - 1978 model
2.3 Emission control
Air injection components, removing and installing
Air pump belt, tensioning
Reactors and EGR equipment, removing and installing
Exhaust gas recirculation system
Reactor, checking for 1e:aks
Exhaust gas recirculation system, checking
Air injection system, checking
3 - OIL CIRCULATION
3.1 O'il c i r c u l a t i o n ,
Oil tank, removing and installing
Oil tank, removing and installing - 1973 model
Auxiliary pressure relief valve, removing and installing
Auxiliary pressure relief valve, disassembling and assembling
Oil cooler coil, removing and installing
Oil cooler, removing and installing
3.2 Oil tank, removing and installing - 1974 model
3.3 Pressure relief valve cooling coil, removing and installing - 1974 model;
3.4 Pressure relief valve, disassembling and assembling - 1974 model
3.5 Oil cooler coil, removing and installing - 1974 model

Cooling coil oil lines, service installing - 1974 model
Replacing oil lines to front oil cooler or to cooling coil
Oil cooler, removing/installing
Auxiliary pressure relief/safety valves
5 - CAMSHAFT HOUSING AND CYLINDER HEAD
j
5.1 Camshaft housing
Injection tube in camshaft housing, removing and installing
Chain tensioner, overhauling
Sealing cylinder head/camshaft housing mating surfaces

ENGINE 911 1
5.2 Cylinder head
Valve springs, installed length
Adjusting timing
6 - CYLINDERS AND PISTONS
6.1 Cylinders and pistons

Piston changes - 1972 model
Piston and cylinder dimensions - 1972 model
"LS " cylinders and pistons, installation instructions
Pistons and cylinders, measuring
Piston and cylinder sizes, 911 SC - 1978 model
Piston weight classes - 911 SC from 1981 models
7 - CRANKCASE AND CRANKSHAFT
7.1 Crankcase and crankshaft

Crankcase, measuring and reconditioning
'Modified flywheel installation - 1978 model
Flywheel with pilot bearing - 1980 model
Oil filter screen and suction plate, removing/installing
Crankshaft
Crankshaft changes - 1972 model
Crankshaft dimensions
Connecting rod changes - 1972 model
Connecting rod weight groups
Connecting rod weight groups - 1978 model
Pistons for injection engines
Modified crankshaft drive - 1978 model
Crankshaft specifications, standard and undersize - 1978 model

Engine Description 911 1
ENGINE C H A N G E S - B E G I N N I N G W I T H 1 9 7 2 MODELS
General Information
Beginning with 1972 models, Type 911 engines have a cubic displacement of 2.4 liters
(2341 c/142.8 cu. in. )

911 Engine Description
Individual changes and changed service operations are described on the pages that follow.
Summary of Changes:
1. Technical Data
2. Crankcase
3. Crankshaft
4. Connecting rods and bearings
5. Pistons
6. Location of oil tank and oil lines
7. Clutch pressure plate, throwout bearing, and clutch disc
8. Ignition - see Group 9 (Electrical System)

9. Fuel system - see Group 2

OIL TANK CHANGES - BEGINNING W I T H 1 9 7 2 MODELS
General Information
Beginning with 1972 models, the oil tank is located in right rear wheelhousing in front of the rear axle.
The oil filler neck is now accessible from the outside. It is located under a hinged lid in the right rear
fender. The oil filter housing is separated from the tank and mounted on the right engine compartment
wall.
The auxiliary oil cooler under the right front fender continues to be standard equipment in Type 911s
vehicles.

OIL C O O L I N G S Y S T E M A N D OIL C I R C U I T S C H E M A T I C
T Y P E 9 1 1 S V E H I C L E S (FROM 7 2 - M O D E L S )
1 Auxiliary oil cooler 6 Full-flow oil filter

2 Oil canler (engine mounted! 7 Crankcase- breather- to - - -
3 Oil pump oil tank

a Pressure pump 8 Oil screen
b Scavenging pump 9 Engine thermostat (opens
4 Oil tank to oil cooler a t 83Oc/182'~
5 Housing with thermostat 10 Air cleaner
(opens to auxiliary oil 11 Oil tank breather to
cooler a t 8 3 ° ~ / 1 8 2 0 ~ air cleaner

OIL COOLER S C H E M A T I C
T Y P E 9 1 1 s VEHICLES (FROM 1 9 7 3 - M O D E L ON)
1. Oil tank
2. Pressure relief valve
3. Inlet pipe
4. Return pipe
5. Radiator coil

ENGINE CROSS - S E C T I O N
Air filter housing

Cross -shaft
Intake stacks
Fuel injection pump
Heat exchanger
Camshaft
Spur belt
Oil screen
Crankshaft
Oil pump
Oil screen in crankcase
Connecting rod
Piston
Cylinder
Exhaust valve
Valve guide
Oil hose connector (oil tank to oil pump)
Valve spring
Rocker arm shaft
Camshaft
Rocker arm
Intake valve
Fuel injector
Upper air shroud
Throttle valve housing
Fuel injection line
Cold start enrichment nozzle
Crankcase ventilation filter
Air filter housing retaining clips

Description 911 1

ENGINE S I D E - S E C T I O N
Air filter housing

Air inlet tube
Fuel injection lines
Oil pressure sensor
Crankcase
Oil pump
Pressure side (to lubrication points)
Suction side (to oil tank)
Connecting shaft
Oil screen
Oil drain plug (magnetic)
Crankshaft
Connecting rod
Sprocket gear
Intermediate shaft
Heat exchanger
Exhaust muffler
Distributor drive gear
Belt pulley
V-belt
AC generator
Upper air shroud

Description
S P E C I F I C A T I O N S FOR T H E 2 . 7 LITER ENGINE WHERE D I F F E R I N G FROM T H E

2 . 4 LITER ENGINE
Crankcase: Cylinder base bore in crankcase increased from

92 mm dia to 97 mm dia.
Pistons: 90 mm dia instead 84 mm dia Piston pin offset by

0.4 mm instead 0.8 mm.
Cylinders: Cylinder walls coated with NIKASIL compound.

Cooling fins reduced from 1 5 to 11.
Ignition distributor: Advance curve changed.
Ignition timing: TDC a t 850 - 950 rpm
Spark plugs: ( g a p i n m m ) BOSCH W 265 P 21 (0.55)

BOSCH W 260 T 2 (0.1)
BERU 265/14/3P (0.55)
BERU 260/14/3 (0.7)
T h r o t t l e v a l v e housing: Idle air ports enlarged from 3.3 m m dia to

4 mm dia.

Description 11
ENGINE CHANGES - BEGINNING W I T H 1 9 7 4 MODELS
1. Type 911, 911 S, and Carrera engines are equipped with NIKASIL light-alloy cylinders with a 90 m m
bore.
2. Pistons: Piston heads in Type 911 S engines are marked "A 2". Rype 911 pistons, by comparison, have a
deeper depression and a higher protrusion, without special markings.
3. Cylinder head: The mounting orifice for the injection valve is discontinued since the valve is
relocated to the intake stack.
4. Type 911 and 911 S engines received modified camshafts with changed valve timing.

Description

Description 911 1

LAYOUT DRAWING OF EMISSION CONTROL 9 1 1 SC
(1980 Model)
1 Oxygen sensor
2 Fuel injector
3 Thermo t i m e switch
4 Oil temperature switch
5 Intake housing
6 Cold start valve
7 Vacuum control
8 Ignition distributor
9 Auxiliary air valve
10 Throttle valve switch
11 Throttle housing
1 2 Sensor plate
1 3 Mixture control unit
1 4 ' 3- way catalytic converter
1 5 Muffler
16 Fuel injection l i n e

TECHNICAL DATA - T Y P E 9 1 1 V E H I C L E S B E G I N N I N G W I T H 1 9 7 2 MODELS
ENGINE
Type four-stroke gasoline engine with two opposing cylinder banks
Number of cylinders 6
Cylinder arrangement horizontal, three cylinders per bank
Bore 84 mm (3.31 in.) 84mm (3.31in.) 84 mm (3.31 in.)
Stroke 70.4 m m (2.77 in.) 70.4 mm (2.77 in.) 70.4 mm (2.77 in.)
Engine displacement 2341cc ( 1 4 2 . 8 ~ ~in.)

. 2341cc ( 1 4 2 . 8 ~ ~ 1in.)
. 2341cc ( 1 4 2 . 8 ~ ~in.)
.
Comprqsion ratio 7.5 : 1 8.0 : 1 8.5 : 1
Horsepower rating (DIN) 140 165 190
(SAE Net) 137 157 181
Maximum torque (DIN) 20 mkp 21 mkp 22 mkp
(SA E) 166 ft/lb 174 ft/lb 181 ft/lb
@ engine speed 4000 rpm 4500 rpm 5200 rpm

911 Technical Data

Lubrication dry sump dry sump dry sump
Oil cooling .oil cooler on crankcase in oil cooler on crankcase in oil cooler on crankcase in
f a n air stream fan air stream fan air stream; auxiliary
cooler in front of vehicle
Oil filter full flow full flow full flow
Oil consumption
Crankcase two-piece pressure casting two-piece pressure casting two-piece pressure casti~lg
of aluminum/magnesium of alurninum/magnesium of aluminum/magnesium
alloy alloy alloy
Crankshaft forged, surface- forged, surface- forged, surface-

hardened hardened hardened
Intermediate shaft
bearings two, plain-journal two, plain-journal two, plain- journal
Crankshaft bearings eight, plain- journal eight, plain- journal eight, plain- journal
Main bearings 1-7 split inserts, 3-layer split inserts, 3-layer split inserts, 3-layer
Main bearing 1 thrust bearing thrust bearing thrust bearing
Main bearing 8 one-piece bushing, one-piece bushing, one-piece bushing

hard -lead lined hard-lead lined hard-lead lined

Connecting rods forged steel forged steel forged steel, surface-
hardened (Tenifer)
Connecting rod
bearings split inserts, 3-layer split inserts, 3-layer split inserts, 3-layer
Piston pin bushings bronze, pressed-in bronze, pressed-in bronze, pressed -in
Pistons light alloy, die-cast light alloy, die-cast light alloy, forged
Piston pins floating, with circlips floating, with circlips floating, with circlips
Piston rings two compression rings two compression rings two compression rings
one oil scraper one oil scraper one oil scraper
Cylinders individual, grey cast iron individual, grey cast iron individual, grey cast iron
with integral cooling fins sleeve with finned light sleeve with finned light
alloy jacket alloy jacket
Cylinder heads light alloy, finned light alloy, finned light alloy (Y -alloy), finned
individual castings for individual castings for individual castings for
each cylinder each cylinder each cylinder
Valve seat inserts shrunk-in, grey -cast shr unk-in, grey-cast shrunk-in, grey-cast
iron iron iron
Valve guides shrunk-in, special bronze shmnk-in, special bronze shrunk-in, special bronze

Spark plug threads M 1 4 x 1, 25, machined into M 1 4 x 1,25, machined into M 1 4 x 1,25, machined into
cylinder heads cylinder heads cylinder heads
Valves 1'intake, 1 exhaust valve 1 intake, 1 exhaust valve 1 intake, 1 exhaust valve
per cylinder per cylinder per cylinder
Valve arrangement overhead in 'V" overhead in "V" overhead in 'V"
Exhaust valves sodium cooled, with sodium cooled, with sodium cooled, with
reinforced seat reinforced seat reinforced seat
Valve springs 2 coil springs per valve 2 coil springs per valve 2 coil springs per valve
Valve timing OHC, 1 camshaft per cylinder OHC, 1 camshaft per cylinder OHC, 1 camshaft per cylinder
bank bank bank
Camshafts cast steel, in three plain cast steel, in three plain cast steel, in three plain
bearings in base metal of bearings in base metal of bearings in base metal of
camshaft housing camshaft housing camshaft housing
Camshaft drive by chain by chain by chain
Valve clearance, cold, 0.10 mm (0.004 in.) 0.10 mm (0.004 in.) 0.10 m m (0.004 in.)
intake measured between valve stem measured between valve stem measured between valve stem
and exhaust and rocker arm and rocker arm and rocker arm

Valve timing with 1 m m
(0.040 in.) valve clearance
inlet opens 16' BTC 16' BTC 38' BTC
inlet closes 30" ATC 30' ATC 50' ATC
exhaust opens 42' BTC 42' BTC 40' BTC
exhaust closes 4 O BTC 4' BTC 20' ATC
Intake valve lift a t

overlap T C with 0.1 m m
(0.004 in.) valve clearance 2,4 - 2,8 mm
Ignition type capacitive discharge system capacitive discharge system capacitive discharge system
(CDS) (CDS) (CDS)
Firing order 1-6-2-4-3-5 1-6-2-4-3-5
Ignition transformer BOSCH BOSCH BOSCH
Distributor MARELLI 50.10.974.1 MARELLI 50.10.974.2 MARELLI 50.10.974.3

(either kind) BOSCH JFUDR6 BOSCH JFUDRG BOSCH JFUDRG
0231169003 0231169004 0231169005
Spark advance centrifugal and vacuum centrifugal and vacuum centrifugal and vacuum
Basic ignition timing 5' ATC @ 900 rpm 5' ATC @ 900 rpm 5' ATC @ 900 rprn
Dwell angle BOSCH 38'; 3' BOSCH 38': 3' BOSCH 38': 3O
MARELLI 40' f 3' MARELLI 40' 2 3' MARELLI 40' 3'

Horsepower Output N e (DIN HP)
b--

911 Technical Data
Full-power Performan
s
C1L
Engine Speed n (rpm) vJ

Full-power Performance Type 911 S
180
160
1 50
1 40
E
I 130
z
6 120
V
Q)
z 110
3
Q
6 100
CI
L
Q)
3 90
0
e
a
2 80
0
I
70
60
50
Md max = 22 mkp at 5200 rpm
I I I
Engine Speed n (rmp)

Technical Data 911 1
Full-power Performance Carrera
Engine Speed n (rpm) + aQ

Technical Data
T E C H N I C A L D A T A FOR CARRERA 2 . 7 FROM 1 9 7 3 MODEL
Engine
Number of cylinders 6
Bore, m m 90
Stroke, mm 70.4
Displacement, actual, c c 2687
Displacement, tax formula, c c 2653
Compression ratio 8.5 : 1
Max. horsepower, DIN HP or KW 210/154
at crankshaft rpm 630 0
Max. torque, DIN kpm or Nm 26/255
at crankshaft rpm 5100
Specific power output, DIN HP/1 or KW/1 78/57
Required fuel rating, min. RON 91
Nominal fuel consumption, ltr/100 km lo. a
Engine weight, kg or Ibs .
approx 182/402
CyIinders and Pistons
Cylinder material Light alloy with NIKASIL-coated cjlinder bore
Piston material Forged, aluminum alloy
Ignition
Ignition distributor BOSCH Nr. 023 1 1 6 9011

MARELLI M. 610 1 5 155
Breaker point gap 0.35 BOSCH and MARELLI
Dwell angle BOSCH 38 2 '3
MARELLI 37 '3
Basic ignition adjustment TDC at 900 + 50 rpm
Spark plugs (gap in mm) BOSCH W 265 P 2 1 (0.55)

BOSCH W 260 T 20 (0.7)
BERU 265/14/3P (0.55)
BERU 260/14/3 (0.7)
Fuel injection pump BOSCH No. 0408 126 019
PORSCHE No. 911 110 254 00

Technical a 911 1
TECHNICAL DATA, TYPE 9 1 1 T - USA C O N T I N U O U S I N J E C T I O N S Y S T E M
Internal designation
911/91 with manual transmission
911/96 with Sportomatic
Horsepower rating (DIN) in HP or KW max .

@ crankshaft rpm
Torque (DIN) in kpm or Nm

@ crankshaft rpm
Specific power output (DIN) in HP/liter

or KW/liter max .
Compression ratio
Required octane rating - research

Nominal fuel consumption (DIN) in ltr/100 km
Engine weight in kg or l b approx .
Valve Timing
Camshaft, left, part number

Camshaft, right, part number
Camshaft identification, left
Camshaft identification, right
Cam height and base circle radius, intake
Cam height and base circle radius, exhaust
Intake valve lift at TDC overlap, with 1 mm

valve clearance
intake valve
exhaust valve
Valve timing with 1 mm valve clearance, in

degfees of crankshaft rotation
exhaust opens 30' BBC
exhaust closes 10' BTC
intake opens 0' BTC
intake closes 32' ABC
Ignition timing 5' ATC

at idle speed (engine warm) 900 t 50 rpm
Spark plugs
BOSCH W 235 P 21
BERU 235/14/3P
Electrode gap 0.55 mm

911 Technical Data
Full-power Performance
Ne max = 140 PS (DIN1 at 5700 rpm

40
Md max = 20,5 mkp at 4000 rpm.
30 I
2000 3000 4000 5000 6000 7000 80(

peed n (rprn)
T E C H N I C A L DATA FOR TYPE 9 1 1 VEHICLES BEGINNING W I T H 1 9 7 4 MODELS
911 9 1 1 YCARRERA
MOTOR
Number of cylinders 6 6
Cylinder arrangement horizontal, horizontal,

3 cylinders per bank 3 cylinders per bank
Bore, mm (inch) 90 (3.54) 90 (3.54)
Stroke, mm (inch) 70.4 (2.77) 70.4 (2.77)
Displacement, actual, c c (CID) 2687 (163.97) 2687 (163.97)
Compression ratio
Horsepower r a t i n g , max .:
according to DIN 70020, HPIKW
according to SAE J 245, net HPIKW
all at crankshaft rpm of

Max. torque:
according to DIN 70020, kpm/Nm 24/235 24/235
according to SAE J 245, net lb.ft./Nm 168/228 168/228
all at crankshaft rpm of 3800 4000
S p e c i f i c power output:
according to DIN 70020, HP/ltr or KW/ltr 55.8/41 65/48
according t o SAE J 245, net HP/ltr or KW/ltr 53.2/39.8 62.2/46.5
Octane requirements, RON 91 91
Fuel consumption (UFG) under mixed traffic

conditions, approx. 12 - 14 13 - 15
Engine weight, kg/lbs, approx. 182/402 182/402
Valve timing with 1 mm valve clearance:
Intake opens lo ATC 6' ATC
Intake closes 35' ABC 50' ABC
Exhaust opens 29' BBC 24' BBC
Exhaust closes 7' BTC 2' BTC
Intake valve stroke at TDC-overlap with 0.1 mm valve clearance 0.7 - 0.9 0.40 - 0.54
model 75 0,5 - 0.7

c i a a 911 1

fl Technical Data

ine Speed n (rpml WV)
Technical Data
T E C H N I C A L D A T A FOR 1 9 7 5 9 1 1 S AND CARRERA MODELS

l1 1
ENGINE USA California
Type
No. of cylinders
Bore in mm (in. )
Stroke in mm (in. )
3 3
Displacement in cm (in. )
Compression ratio
Max. output:
DIN HP or kW
SAE NET HP or kW
at crankshaft rpm
Max. torque:
DIN in kpm or Nm
SAE NET ft lbs. or Nm
a t crankshaft rpm
Max. output/liter:
SAE NET in HP/liter or kW/liter
RON fuel specification
Fuel consumption (DIN) in liter/100 km
Approx. engine weight in kg (lbs. )
Valve timing with 1 mm valve clearance

(in crankshaft degrees):
Intake opens 6' after TDC 6' after TDC
Intake closes 50' after BDC 50' after BDC
Exhaust opens 24' before BDC 24' before BDC
Exhaust closes 2' before TDC 2' before TDC
Intake valve lift at overlap TDC
with 0.1 mm valve clearance (in mm)
Valve lift a t 0.1 mm clearance:
Intake valve in mm
Exhaust valve in mm
Camshaft, right
Camshaft, left
Identification on face of camshafts:
Camshaft, right
Camshaft, left
Valve spring sizes:
Intake valve in mm
Exhaust valve in mm
Exhaust, b e a t i n g Single pipe system Double pipe system

with new heat ex- with reactors and heat
changers, heater exchangers, heater blower
blower, primary muff- and new exhaust muffler,
ler and new exhaust exhaust gas recirculation
muffler and air injec- and air injection
tion

911 Technical Data
T I G H T E N I N G T O R Q U E S FOR E N G I N E
Torque
Location Threads
Connecting rod nuts
Crankease bolts
All bolts on crankcase and camshaft housing

Hexagon nuts (oil filter screen cover)
Flywheel bolts
(from 1978 models)
Pilot bearing to crankshaft
Pulley to crankshaft (without air conditioner)
Double-belt pulley to crankshaft

(with air conditioner)
Safety valve plug to crankcase
Pressure relief valve plug to crankcase
Adapter (oil pressure sender) to crankcase
Adapter in crankcase (oil return line)
Cylinder head nuts M 10 socket head
Rocker arm shafts M 6 socket head
Nut on camshaft
Hex. head bolt on camshaft
Cover to camshaft housing
Adapter to cylinder head (air injection)
Air line (coupling nut) to adapter
Reactor to cylinder head
Spark plugs


Technical Data
l1 1
TECHNICAL DATA - T Y P E 9 1 1 S, 1 9 7 6 MODEL
EN GIN E
Type
Bore
Stroke
Displacement
Compression ratio
Horsepower SAE Net
a t engine speed
Torque SAE Net
at engine speed
Output per liter SAE Net J245
Max. engine speed
Cutoff speed of speed limiter
in distributor
Engine weight, dry
Valve Drive
Valve clearance, cold engine
measured betw. valve and
adjusting screw:
Intake
Exhaust
Valve timing at 1 mm clearance
Intake opens 6O o ~ ~ ~ ~
Intake closes 500 ABDC
Exhaust opens :2 BBDC
Exhaust c loses 2 BTDC
Intake valve lift at TDC overlap

with 0 .I mm valve clearance
Identifying number on cam end face

Camshaft, left
Camshaft, right
No. of bearings

911 Technical Data
Valve spring sizes

Intake
Exhaust
Basic ignition timing
(vacuum hose connected) 5' ATDC a t
900 - 50 rpm
Spark plugs, gap 0.55mm/O.O22 in. Bosch W 235 P 21

Beru 235/14/3P
Cooling - Fan Drive

Crankshaft/fan ratio 1 : 1.8
Air delivery rate ltr/sec. 1265 at crank-
shaft speed of 6000 rpm
Lubrication
Oil pressure at 5000 rpm
and 80' ~ / 1 7 6 O ~ .
approx 5 atm/73, 5 psi
Oil consumption .
approx ltr/600 mi. 1.5 - 2.0

Technical Data
l1 1
TECHNICAL DATA - T Y P E 9 1 1 S , 1 9 7 7 MODEL
ENGINE
Engine type
Bore mm/inch
stroke mm/inch
3 3
Displacement c m /inch
Compression ratio
Power SAE Net kW/HP

at engine speed rpm
Torque SAE Net Nm/lbft

a t engine speed rpm
Output per liter kW/HP
Max. engine speed rpm
Cutoff speed of speed limiter

in distributor rpm
Engine weight (dry) kg/lbs
Valve drive
Valve clearance (on cold engine)
measured betw. valve and adjus-
ting screw: Intake mm
Exhaust mm
Valve timing with

1 mm valve clearance
Intake opens 6' ATDC
Intake closes 50; ABDC
Exhaust opens 2: BBDC
Exhaust closes 2 BTDC
Intake valve lift at TDC

with 0 , l mm valve
clearance

11 Technical Data
Identifying number on cam

end face
Left camshaft
Right camshaft
Bearing journals
Valve springs: free length

Intake valve mm
Exhaust valve mm
Ignition Timing
USA Version
(vacuum hose permanently
plugged, vacuum advance 0' - Z1 mark
+ -
inoperable) at 950 -50 rpm
* California Version 15' ATDC at

(vaccuum hose connected) 1000 - 50 rpm
Spark plugs
Electrode gap mm Bosch W 225 T 30 -0.7-
Beru 225/14/3A -0.7-
::@osch W 235 P 21 -0.6-)
:= Beru 235/14/3P -0.55-)
Cooling - Fan Drive
Crankshaftjfan ratio 1 : 1.8

Air delivery rate .
ltr 1265/sec. at 6000
rpm crankshaft speed
Engine Lubrication
Oil pressure at 5000 rpm and

80' ~ / 1 7 6 OF approx. 5 bar/73.5 psi
Oil consumption
(per 600 miles) approx. 1.5 - 2.0 ltr/qt

Technical Data 9fl 1
TECHNICAL DATA, TYPE 9 1 1 SC - 1 9 7 8 MODELS
ENGINE
Engine type -
USA 930/04
-
California 930/06
Bore
Stroke
Total Displacement
Compression ratio
Net Horse power, SAE
at engine speed
Torque, SAE Net
at engine speed
Output per liter, SAE Net
Max. engine speed
Cut-off speed (overrev
protection) Speed limited by
cutting off fuel pump
6700 to 7000
Engine weight (dry) approx. 200/441
Valve drive
Valve clearance (cold engine)
measured between valve and
rocker arm adjusting screw Intake mm'
Exhaust mm
Valve timing with 1 mm valve
clearance Intake opens IO~BTDC
Intake closes 53 ABDC
Exhaust opens 43' BBDC
Exhaust closes 3' ATDC
Intake valve lift at TDC

overlap with 0.1 mm valve
clearance

Technical Data
Identification on camshaft face

Left camshaft
Right camshaft
Number of bearings
Length of installed valve springs

Intake valve
Exhaust valve
Ignition CDI (breakerless)
Basic ignition timing 5' BTDC at idle of

(vacuum hose attached) 900 t o 1000 rpm
0
(oilotemp. 80 C/
176 F')
Spark plugs/electrode gap Bosch W 145 T 30/0.8

(0 ,,032 in.)
Beru 145/14/3 /0.8
(0 "032 inc.)
Emission control 930/04 air pump and

catalytic converter
930/05, 930/15 and
930/06 air pump,
catalytic converter
and EGR
Cooling - Fan drive
Crankshaft/fan ratio:
Air delivery rate
approx. 1 : 1.8
1380 l/s at 6000
rpm of crankshaft
Engine lubrication
Oil pressure at 5000 rpm and
oil temp. of 80' C (176' F) bar/psi approx. 4.5/66
Oil consumption 1/1000 km approx. 1.5 to 2.0
(US qt/600 mi.)

TECHNICAL D A T A , TYPE 9 1 1 SC - from 1980 Model
911 SC
Engine
Engine type (internal code) 930/07

Bore mm/inch 95.0/3.74
Stroke mm/inch 70.4/2,77
Total displacement 3 . 3
c m /inch 2994/182.7
Compression ratio 9.3: 1
Max. output per DIN 70020 kW/HP 132/180
Net horsepower per SAE J 245 kW/HP 128/172
a t engine speed rpm 5500
Max. torque per DIN 70020 Nm/kpm 245/25
Net torque per SAE J 245 Nm/ft Ibs 237/175
a t engine speed rP m 4200
Max. output per liter DIN 70020 kW/1, HP/l 44/60
SAE J 245 kW/1, HP/l 42/57
Max. engine speed : rpm 7000
Cut-off speed Speed limited by switching
(engine speed limiter) off fuel ump
*Pm 6300 t o g700
Engine weight (dry), approx. kg/lbs 190/419
Valve train
Valve clearance (cold engine)
measured between valve and rocker
arm adjusting screw Intake mm
Exhaust mm
Valve timing with 1 m m valve clearance
Intake opens before TDC
Intake closes after BDC
Exhaust opens before BDC
Exhaust closes before TDC
Intake valve lift at TDC with 0 . 1 mm mm
valve clearance

Ttchnical Data

Left camshaft
Right camshaft
Number of bearings four
Valve spring installed length
Intake valve
Exhaust valve

Basic ignition timing 5' BTDC at 900 to 1000 rpm
idle speed, vacuum hose dis-
0
connected, 90' C/195 F
oil temperature
Spark plugs - electrode gap - Bosch W 5 D (W 225 T 30)
- 0.7 -
Beru 14/5 D (225/14/3 A)
- 0,7 -
Emission Control Oxygen sensor and 3-way

catalytic converrer
Cooling - fan drive

Crankshaft/fan ratio approx. 1: 1.68
Air delivery rate 1500 l/sec. at 6000 rpm
crankshaft speed
Engine lubrication
Oil ressure at 5000 rpm and 90' C/
8
195 F oil temperature bar/psi approx. 4. 5/66
Oil consumption 1/1000 km approx. 1. 5 to 2. 0
(1 US qt. /600 mi. )

T E C H N I C A L D A T A , TYPE 9 1 1 S C - from 1981 Models
Engine
Engine type (internal code)

Bore mm/inch
Stroke mm/inch
Total displacement cm 3/inch 3
Compression ratio
Max. output acc. DIN 70020 k W/HP
Net power acc. SAE J 245 k W/HP
a t engine speed rPm
Max. torque acc. DIN 70020 Nm/kpm
Net torque acc. SAE J 245 Nm/ft lbs
a t engine speed rpm
Max. liter output acc. DIN 70020 k w h , HPA
SAE J 245 kWA, HP/I
Max. engine speed rPm
Cut- off speed Speed limited by
engine speed limiter switching off fuel
Pump
rpm 6500 f 200
Engine weight (dry) kp/lbs approx. 190/419
Valve train
Valve clearance (cold engine):
measured between valve and rocker arm
Intake mm
Exhaust mm
Valve timing with 1 mm valve
clearance
Intake opens 7' before TDC
Intake closes 47' after BDC
Exhaust opens 49' before BDC
Exhaust closes 3 before TDC
Intake valve lift at TDC overlap with
0.1 mm valve clearance mm

911 Technical Data

Left camshaft
Right camshaft
Number of bearings four
Installed length of valve springs

Intake valve mm
Exhaust valve mm
Basic ignition setting 5' before TDC

(vacuum hoses detached, oil tempera- at 950 rpm
ture approx. 9 0 ~ ~ / 1 9 5 ~ ~ )
Spark plugs electrode gap - mm Bosch W 5 D
-
a-
(W 225 T 30 ) -0.7
Beru 14/5 D
-
(225/14/3 A) 0.7 -
Emission control Oxygen sensor with
3-way catalytic con-
verter
Cooling -* blower drive

Crankshaft/fan ratio approx. 1: 1.68
Air delivery rate 1500 ltr. /sec. at

6000 rpm crank-
shaft speed
Engine lubrication
Oil pressure at 5000 rpm and approx
90' ~ / 1 9 5 OF oil temperature bar/psi approx. 4.0/58
Oil consumption ltr, /lo00 km approx. 1.5

( 1 US qt/600 mi.)

Cooling System, Exhaust. Emission Control 911
R E P L A C I N G AND A D J U S T I N G FAN DRIVE BELT
Effective with the 1980 models a l l 911 SC engines Adjusting instructions for engine prior to 1980
have t h e larger fan from t h e 911 Turbo, New belt models with small fan:
size: 9.5 x 710 mm.
Check tightness by applying thumb pressure at
point midway between both pulleys.
Note Deflection: approx. 10 t o 1 5 mm.
Only the approved belt from Goodyear, Part No.

999.192.176. 50, may b e used for these engines.
When installing t h e new belt for t h e first time,

i t must b e much tighter Than was formerly t h e
case.
Approximate rule:
Tighten belt as in t h e past (belt deflects by 1 0 to
1 5 m m a t point midway between two pulleys),
Then remove 1 shim from t h e shims between the
pulley sections (approx. 5 m m deflection).

Cooling S y s t e m , Exhaust System, Emission Control 943 11
>
0
ZW
ffi

Cooling System, Exhaust System. Emission Control
911
Notes
Description Remarks
Removal Installation
Hose clamp
Hose (heater Hose must not touch

air/blower) anything
Hose clamp
Heater hose, left
Clamp, adapter
Adapter
Screw
Clamp
Blower Install correctly
Sheet metal screw
Washer
Bolt
Washer
Heater air adapter
Hose clamp
Heater hose, right
Bolt
Lock washer
Washer
Clamp
Nut (self-locking) Replace if necessary
Bolt
Gasket Replace
Fillister head screw
Clamp

911 Cooling System, Exhaust System, Emission Control
Notes
No. Description Remarks
Muffler Check for leaks and

damage
Bolt
Primary muffler
Gasket Replace
Gasket Replace
Nut
Bolt
Clamp
Flange
Seal Replace
Support disc
Bolt
Adapter
Gasket Replace
Hose clamp
Flex hose
Screw
Washer
Clamp
Adapter
Heat exchanger Check for damage
Cable strap

Cooling System, Exhaust System, Emission Control 911 1
EXHAUST SYSTEM - 1 9 7 8 MODELS ( E n g i n e T y p e 9 3 0 / 0 4 , 06)
.1 - Heat exchanger 3 - Catalytic converter
2 - Exhaust pipe 4 - Exhaust muffler

Cooling System, Exhaust System, Emission Control
911 1
REMOVING A N D I N S T A L L I N G AIR I N J E C T I O N

911 Cooling System, Exhaust System, Emission Control
Notes
Description Remarks
Bolt
Washer Replace if necessary
Plain washer
V-belt Check tension Refer to

page 2.3-
f/4
Nut
Bracket
Rubber/metal pad Check, replacing if

necessary
Holder, air pump
Hose clamp
Hose Check, replacing if

necessary
Nut
Plain washer
Bolt
Plain washer
Rubber bushing Install correctly,

lubricate lightly
Spacer
Air pump
Winged nut
Filter cover
Filter cartridge Replace if necessary
Filter housing

Cooling System, Exhaust System, Emission Control
911 1
Description Notes
Removal Installation Remarks
Nut
Lock washer
Pulley
Flat key
Carrier, air pump
Seal
Check valve
Seal Replace
Air line
Jet Torque 1.0 -

1.2 mkp
Seal Replace
Pulley, engine

911 Cooling System. Exhaust System, Emission Control
T E N S I O N I N G AIR PUMP BELT
Adjusting
1. Loosen bolt.
2. Move air pump to left.
3. Tighten bolt.
4. The belt tension is correct, if the belt can be

pressed together about 1 5 mm (5/8 in.) at its
centerpoint with considerable thumb pressure.
Removing/ installing pulley (California version).

Cooling, exhaust and emission control systems
1
R E M O V I N G A N D I N S T A L L I N G R -E A C T O R S A N D E G R E Q U I P M E N T

911 1
Note when
Description Remarks
removing installing
EGR filter Replace every

30, 000 miles
Nut (copper pltd.) Replace
Bolt Replace, if necessar:
Socket head screw
Clamp
Muffler Check for leaks

and damage
Gasket Replace
Bolt Replace, if necessar:
Heat exchanger Check for leaks

and damage
Gasket Replace
Nut (copper pltd.) Replace, torque to

2.3 mkp
Washer
Reactor Allow it to cool down Check for leaks

to room temperature.
Remove heat ex-
changer and oil re-
turn line
Seal Replace, install with

blue side facing to-
ward cylinder head
Bolt - Replace, if necessary
Heat exchanger Check for leaks

and damage

(B Cooling, exhaust and emission control systems
Note when
Description Remarks
removing installing
Gasket Replace
Nut (copper pltd.) Replace, torque to

2.3 mkp
Washer
Reactor Allow it to cool down Check for leaks 2.3-3/1

to room temperature.
Remove heat ex-
changer
Seal Replace, install

blue s i d e facing to-
ward cylinder head
Nut
Washer
Bolt
Vacuum hose for stage I Connect to top

vacuum chamber
Vacuum hose for stage I1 Connect to bottom

vacuum chamber
EGR valve outlet pipe Only detach at EGR

valve
Nut
Washer
Bolt
Bolt
EGR valve Check, replacing if 2.3-2/6

necessary 2.3-3/2
Gasket Replace, install one

betw. holder and EGR
line and the other
betw. valve and h o l d e ~

911
Note when
removing installing
EGR line The right engine co- Check passage,

ver must b e removed cleaning if
to replace EGR line necessary

1 11 Cooling, exhaust and emission control systems
E X H A U S T GAS R E C I R C U L A T I O N S Y S T E M
Component parts of the exhaust gas recirculation system are subject to a certain amount of wear and must
therefore be inspected and/or replaced after operation for 30, 000 miles (also refer to Group 9).
REMOVING A N D I N S T A L L I N G EGR VALVE
Removing
1. Disconnect vacuum hoses.
2. Detach EGR valve outlet pipe at valve.
3. Remove mounting bolts.
Note: The replacement of gaskets requires detach-

ing the EGR line at the EGR filter and clamp.
Installing
1. Replace gaskets.
Connect vacuum hoses as follows:
Stage I - Upper chamber to left connection on

throttle housing (as seen in driving
direction).
Stage 11 - Lower chamber to right connection on

throttle housing (as seen in driving
direction).

911 1
C H E C K I N G R E A C T O R FOR LEAKS
Note
T h e reactor's operation need not be checked. It

only needs to b e checked for leaks.
1. Let engine run at idle.
2. Insert appropriate plug in outlet pipe of

muffler and check reactors for leaks by listen-
ing. Replace a leaky reactor.

911 Cooling, exhaust and emission control systems
C H E C K I N G E X H A U S T GAS R E C I R C U L A T I O N S Y S T E M
1. Let cold engine run at slightly higher idle. This

will heat the outlet pipe from EGR filter to
EGR valve.
2. Increase engine speed to about 4,000 rpm. The

outlet pipe from the EGR valve to the intake
housing must now be hot, too.
If the outlet pipe between the EGR valve and in- -

take housing is not hot, the following conditions
could be causing this:
a) EGR valve defective
b) EGR lines plugged
c) Vacuum bores in throttle valve housing plugged
d) Vacuum hoses plugged or leaking
e) EGR filter between muffler and EGR valve

clogged

Cooling, exhaust and emission control systems 11
C H E C K I N G AIR I N J E C T I O N S Y S T E M
..
1 Clean air filter of secondary air pump with
compressed air. Replace if severely clogged.
2. Check air pump belt tension (max. deflection:

10-15 mm).
3. Loosen and disconnect air injection hose a t

air pump. Insert plug in hose.
4. Connect CO tester according to manufacturer's

instructions.
Note
The CO should be checked immediately after a

test drive as long as the engine is still at operating
temperature.
5. Adjust CO to 1.5 - 2.0 70at idle speed of

900 ? 50 rpm.
6. Reconnect air injection hose to air pump.
7. The CO must now drop below 1.0 70with the

+
engine idling at 900 50 rpm. If the CO is
still above 1.0 70, there is a defect in the air
injection system. Of course, the engine must
b e in perfect working condition in every other
aspect. If necessary, install a new pump to
determine cause.

Oil Circuit 11
R E M O V I N G A N D I N S T A L L I N G OIL TA NK
1. Remove right rear wheel. 6. Loosen retaining strap.
Caution
Cover brake disc to prevent oil spillage
during removal of tank.
2 . Drain oil from tank.
3 . Loosen hose clamps and retaining clamp of

return line.
7. Pull tank partially out of the wheelhousing

and remove oil line, breather hoses, and
oil level gauge wires. Remove tank.
4. Detach return hose from oil tank.
Make sure during installation that plastic caps

between tank and body, and retaining strap
5. In Type 911 S also detach the oil hose
liner are correctly seated.
from bottom of tank.
Coat oil hose connections with Molykote or
similar lubricant when assembling.

911 Oil Circuit
R E M O V I N G A N D I N S T A L L I N G OIL T A N K ( F R O M 1 9 7 3 MODEL O N )
General:
Beginning with the 1973 models, the oil tank is located in the right rear wheelhouse behind the rear axle.
Removing
1. Remove right rear wheel. 5. Detach tubular support from bumper outer
part and longitudinal support. Turn support
2. Drain oil. to the side.
3. Detach oil hoses and pressure relief valve. 6 . Unscrew oil filter.
7 . Disconnect oil breather hoses from oil tank.
Remove oil tank retaining nuts (accessible

from engine compartment).
Remove oil tank.
Remove oil filter base.
Installing
Note the following during reassembly:
1. Properly position rubber seal fitting between

wheelhouse panel and oil tank. Glue seal to
the oil tank.
2 . Make sure that O-ring is properly seated in

the oil filter base.
4. Detach ground straps from batteries. Dis-

connect electrical wires from the oil level
sensor.

o i c i t 911 1
R E M O V I N G A N D I N S T A L L I N G A U X I L I A R Y PRESSURE RELIEF VALVE
1. Disconnect oil hoses.
2 . Remove pressure relief valve from oil tank.

Remove support bracket.

911 oil c i r c u i t
D I S A S S E M B L I N G A N D REASSEMBLING A U X I L I A R Y PRESSURE RELIEF VALVE
Note when:
Nr . Description
removing installing
Remarks
1 Plug
2 Seal ring Replace
1 Spring
5
11 Relief valve plunger
Relief valve housing

Oil Circuit 911 1
R E M O V I N G A N D I N S T A L L I N G OIL COOLER C O I L
Removing
1. Remove right front wheel.
2 . Disconnect oil hoses.

Caution :
Counter with a second open-end wrench.
4. Remove oil cooler coil.
Installing
Apply counter-force a t the oil lines during in-

stallation to prevent damage.
Coat oil hose connectors with Molybdenum

disulfide grease during installat ion.
3. Remove Allen bolts and retaining screw from
the right bumper bracket.

R E M O V I N G A N D I N S T A L L I N G OIL COOLER
General:
Beginning with the 1973 models, all six-cylinder engines are equipped with a two-piece air shroud which
simplifies the removal and installation of the oil cooler.
Removing
1. Remove air filter top. 4. Remove oil cooler air duct.
2 . Remove front engine shroud.
5. Drain oil.
3. Remove right engine shroud.
6 . Detach oil hose from oil cooler and remove

upper retaining nuts.

911 Oil Circuit
Installing
Install new sealing rings a t the oil cooler.

NOTE: When positioning the oil cooler on
crankcase, make sure that sealing rings are
properly seated.

Oil Circuit
REMOVING A N D I N S T A L L I N G OIL T A N K BEGINNING W I T H 1 9 7 4 MODELS
Removal
1. Remove right rear wheel.
2. Drain oil.
3. Detach oil hoses and remove bolt from

support tube of lower fender section.
4. Remove screws from support tube and turn it

to the side.
5. Detach wires from oil level sender.
6. Detach breather hoses and remove tank cover

from tank.
7. Unscrew oil filter.

Oil Circuit
8. Open the lock plate, remove nut, and pull out

support tube through the bottom.
9. Remove oil tank retaining nuts and washers.
Installation
1. Glue wheelhouse gasket to oil tank in proper

position.

Oil Circuit 911 1
R E M O V I N G A N D I N S T A L L I N G PRESSURE RELIEF VALVE O F C O O L I N G C O I L
BEGINNING W I T H 1 9 7 4 MODELS
Removal
1. Drain oil from tank.
2. Detach oil lines.
Remove retaining clamp from upper oil lines.
4. Remove t h e valve.
Caution:
Catch spilling oil.

Oil Circuit 911 1
D I S A S S E M B L I N G A N D REASSEMBLING PRESSURE RELIEF V A L V E
Beginning with 1974 Models
Note when:
Description Remarks
removing installing
Plug
Gasket Replace
Spring
Plunger
Plug
Gasket Replace
Spring
Plunger for pressure

relief valve
Valve housing

Oil Circuit 11
REMOVING A N D I N S T A L L I N G O I L COOLER COIL

Beginning with 1 9 7 4 models
Removal
Disconnect oil hoses.
Caution:
Counterhold with a second open-end wrench.
Catch spilling oil.
Remove retaining bolt and take cooler coil

out.
4. Remove attaching bracket.
Installation
1. Apply counter force when connecting oil

lines to prevent damage.
2. Coat oil hose connectors with MOLYKOTE-A

during installation.
3. Mount cooler coil without stress.

S E R V I C E I N S T A L L A T I O N O F C O O L I N G C O I L OIL L I N E S B E G I N N I N G
W I T H 1 9 7 4 MODELS
1. Raise car on hoist. Remove wheels on right 6. Grind down or saw present spacers (three
side of car. plastic bushings) to a thickness of 5mm
(3/16 in.)
2. Drain oil from oil tank.

7. Place rubber guards on oil lines.
3. Disconnect oil return hose from engine to Place both oil lines along rocker panel.
oil tank. The top line must rest on fender connector
plate. Install spacers and mounting clips.
Only tighten mounting screws slightly.
4. Remove rocker panel cover.
5. Remove plugs in oil line and cooling coil

mounting points on front wheelhousing. 9. Connect pressure relief valve housing to oil
lines.

11 Oil Circuit
10. Slide in rocker panel cover between spacer

and washer. Tighten cover.
15. Check for leaks. This requires the engine

0 0
oil temperature to b e at least 83 C (182 F),
so t h a t the pressure relief valve will release
the flow of oil t o the cooling coil.
11. Place oil hoses along rear wheelhousing
and connect. If necessary, cut threads on stud.
12. Connect cooling coil t o oil lines.
13. Fasten cooling coil and lines to wheel-

housing.
14. Tighten all oil line connections.

Oil Circuit 911 1
R E P L A C I N G OIL LINES T O F R O N T OIL COOLER OR T O C O O L I N G C O I L
Installation of side turn signals from 1981 models on

made it necessary to change the oil lines to the front
oil cooler or cooling coil in the front wheel well area.
Only new version lines w i l l be available from Parts after using up the former version oil lines.
Changes made necessary when installing new lines in cars with old oil lines (without side turn signals)
are described in the following instructions.
Old oil lines New oil lines
Removing
1. Lift car on platform hoist. Remove wheels on

right side of car. Spray rust removing solution
on oil line connections.

2, Remove rocker panel cover by
-unscrewing end at front and rear,
-pulling off rubber guard and removing cover for
jack support,
-removing metal screws at top and loosening
metal screws at bottom.
6. Unscrew mounting bracket and clamps. Remove

oil lines.
3. Disconnect wires of automatic antenna (optional Installing

extra equipment) inside of car. Unplug antenna
wire on radio; removing right floor plate for this 1. When installing new lines in'cars without side
purpose. Pull both wires out of holes in wheel -turn signals proceed as follows with the mounting
well. points in the wheel well, :
Point A Is still applicabbe.

4. Disconnect oil lines on pressure relief valve Point B+C Not applicable; plug with 6 x 10 mm
housing. Catch escaping oil. hex. head bolts used in conjunction
with a body sealing compound.
Point D New (drill a 5 r n dia. hole 255 mm/lO in.
from wheel house/floor plate joint
and 75 mm/3 in. from fender joint
plate).
5. Disconnect oil lines on cooling coil or at oil

hoses for cars with a front oil cooler. Counterhold
with a second open-end wrench.

Oil Circuit
Note
Coat oil line connection threads with Optimoly HT

or Molykote A prior to installing. Make sure cooling
coil remains installed without stress. If necessary,
change installed position so that wheel does not
scrape on cooling coil when turned to full lock
position.
5. Mount oil lines on wheel well. Use 6.3 x 19 mm

hex. head metal screw at new mounting point
when installing new oil lines in a car without
side turn signals.
2. Install hoses on oil lines for protection.
3. Route both oil lines along side member trim.

Upper line must be on fender joint plate.
Install spacers and clamps. Tighten mounting
bolts only finger tight.
6. Reconnect automatic antenna wires. Check

function of radio and antenna.
7. Push in rocker panel cover between spacer and

washer.
4. Connect oil lines on pressure relief valve housing

and cooling coil or oil hoses for cars with a front
oil cooler.

8. Finish installation of cover. Connect rubber
guard on one end, bend back sharply and press
on continuously. Lip must fit tightly on body
at top. If necessary, realign.
9. Check system for leaks. This requires that engine

oil temperature be at least 83' c/181° F so that
the governor can release flow to the cooling coil or
front oil cooler. Correct oil level.

Oil Circuit 911 1
REMOVING AND I N S T A L L I N G FRONT OIL COOLER ( 1 9 8 0 M o d e l )
Removing 4, Loosen lower nuts and remove oil cooler upward.
Use a second wrench as a counterhold. Catch

escapGg oil.
Installing
When installing counterhold a t t h e cooler

connections t o prevent damage.
Coat connections with Optimoly HT.

3. Loosen outer nut on upper rubber mount.
Check connections for leaks. This requires

that the regulator for t h e front o i l cooler b e
open to have oil flowing through the cooler
0 0
(engine oil temperature above 8 3 C/181 F).

Oil Circuit 911
S P R I N G S FOR PRESSURE RELIEF A N D S A F E T Y V A L V E S O F E N G I N E O I L C I R C U I T
Pressure Relief Valve Safety

No. Description Part No.
- from 1978 Valve
1 Piston pressure relief valve

2 Spring - old - 70 mm long
2 Spring - new - 86 mm long

3 Spring guide
4 Gasket
5 Plug - - without groove
old
5 Plug - new - with groove
6 Spring, safety valve
7 Plug - new - with groove
Installation Note
The (86 mm long) spring for pressure relief valve

may only be installed together with the spring
guide.

Camshaft Housing and Cylinder Head
911 1
REMOVING A N D I N S T A L L I N G I N J E C T I O N TUBE I N C A M S H A F T H O U S I N G
Removing
1. Drill 9 mm deep hole in plug with a 4.8 to

5 m m dia. drill bit. Then cut M 6 threads
with a bottoming tap. Pull out plug with an
M 6 screw and spacer,
CAUTION Be careful not to damage sealing

surface when removing plug.
2. Loosen centering screws and slide injection

tube out.
Installing
1. Install injection tube, making sure that

locating bore for plug is positioned correctly.
CAUTION Separate bores must face upward

toward intake valve covers. Double bores,
not shown in illustration, face cam bearing
surface.

11 Camshaft Housing and Cylimder Head
Lubricate new plug and hole;, coat with a

double component adhesive hind install plug.
CAUTION Upset plug befoie installation if it

does not fit tightly in housidg ,
Plug is pressed in about 0.3 p m deeper than

sealing surface.

Camshaft Housing and Cylinder Head 911 1
OVERHAULING CHAIN TENSIONER
TOOLS
-
No. Description Special Tool Remarks
-
1 Adjusting ring For chain lensioner 930 1 0 5 049 00
2 Clamp
3 Assembly lever

O V E R H A U L I N G NEW VERSION C H A I N T E N S I O N E R
General Information
Only the chain tensioner having Part No. 930.105.

049.00 or the repair kit having Part No. 911.105.
901.01 with modified parts are available from
parts.
Only t h e new version chain tensioner: may b e re-

paired.
New Version Identification:
a) Chamfer on upper part of housing
b) Total height: 78. 2 - 0 . 2 m m and Porsche trade-

i

Camshaft Housing and C y l i n d e r Head 911

911 Camshaft Housing and Cylinder Head
-
Note When: Special
No. Description
- Removing Installing Inst~uctions
1 Bleed screw
2 Sealing ring Replace
3 Clamp Clamp only with

complete new par1
4 Snap ring Replace
5 Spring retainer
6 Spring Replace
7 Piston (alum. )
8 O-ring Replace
9 0- ring Replace
10 Snap ring Replace
11 Piston
12 [ntermediate piece Replace
13 3-ring Replace
14 aall, 5 m m Replace
15 Spring Replace
16 Zage Replace
17 Spring
18 Spring guide Replace
19 Zhain tensioner housing

DISASSEMBLING AND ASSEMBLING C H A I N TENSIONER

4
Disassembling Assembling
1, Clamp chain tensioner in a vise and remove 1 . Clean parts thoroughly, check for wear and
upper circlip. replace if necessary.
Inspect piston spring for wear and deformation
(bent) , replacing if necessary.
Note
Spring retainer under pressure. 2. Push chain tensioner piston with mounted alu-
minum piston, without O-rings, into chain
tensioner housing. Both pistons must move
easily. It is especially important that the
2. Remove spring retainer and spring. chain tensioner piston moves easily i n t h e
lower piston position. Remove any pressure
spots on the pistons with emery cloth.
3. Remove bleed screw and sealing ring.
3. Install spring guide, spring. cage, spring,

ball, intermediate piece with O-ring as well
4. Pull out aluminum piston carefully with a as piston and secure with snap ring.
suitable tool.
Note
5, Push lower snap ring out of groove with a small
screwdriver inserted through bleed screw bore. When installing intermediate piece in the piston
make sure O-ring fits properly in groove. Give
O-ring a light coat of oil.
6. Remove piston, intermediate piece with O-ring

valve ball (5 mm) with spring, cage for ball,
spring and spring guide. 4. Fill chain tensioner to upper edge with 1 5 W/50
engine oil and bleed.
Bend the end of an approx. 1 m m dia. steel
wire to make an inclined step and push it through
Note the piston bore against the ball (see Workshop
Manual 911, Volume 1, Page E 106).
The intermediate piece could b e stuck in the piston.
If so, remove intermediate piece by lightly tapping Move piston up and down slowly within t h e
piston against piece of wood. stroke range until no more air bubbles escape
at the bores.

5. Clean inner and outer grooves of aluminum I N S T R U C T I O N S FOR : [ N S T A L L A T I O N

piston. Install new, lubricated O-rings and OF CHAIN TENSIONER
make sure they are not twisted. Install alumi-
num piston until the O-ring seals with the
housing, Now open the bleed screw slightly
and push down with Special Tool P 214 c
until the tool rests on the edge of the chain To prevent- damage on the chain tensioner
tensioner. Then tighten bleed screw again housing, it is not permitted. to pre-load the
without delay, timing chain with a screwdriver. Force from
the screwdriver could deform the chain ten-
Install spring, spring retainer and snap ring. sioner housing, which in turn would cause the
the a1umin;m piston (7) to seize. Only use
Special Tool 9182 for pre-loading.

SEALING CYLINDER HEAD/CAMSHAFT HOUSING M A T I N G SURFACES
Note
Only Loctite No. 573 (green color) should be used

as a sealing compound.
Loctite No. 573 hardens only in conjunction with
metal and exclusion of air. Not more than 10 minutes
should elapse between application of sealing compound
coat and assembly of parts, otherwise the sealing
compound on metal would start to harden.
Removing Old S e a l i n g Compound
During repairs the old sealing compound does not

have to be removed. Only grease has to be removed
from the surface. A new coat of sealing compound
should be applied immediately after the cleaning
solution has dried. The new Loctite will dissolve
the old compound remaining in the surface finish
and become hard again after assembly.
Should it be necessary to remove the old sealing
compound, the use of a fine steel brush is
recommended for this work.
Applying Sealing Compound
1. When applying the sealing compound by hand it 2. Apply a very thin coat of sealing compound on
is recommended to use a short-pile velour roller. the mating surface of the camshaft housing.
In addition, a tray will be required for the sealing
compound with a ribbed surface for scraping off
the roller.

C H E C K I N G I N S T A L L E D L E N G T H OF VALVE SPRINGS
Check distance A with

Special Tool P 10 C. If
necessary, correct by
adding or removing chims.
Note
Make sure spring retainer has perfect fit in special tool, machining special tool if necessary.
I N S T A L L E D D I M E N S I O N S FOR 2 . 4 LITER ENGINE
Vehicle 911 T 911 E 911 S

Type
Engine 911/51 911/52 911/53

Type 911/61 911/62 911/63
+- + +
-Intake Valve 35 0.3 mm
+ -
34 0.3 mm
+ 35.5
+-- 0.3 mm
Exhaust Valve 35 - 0.3 mm 34 - 0.3 mm 34.5 0.3 mm
NOTE
The above values can also be applied to the 2.2 liter engines in the course of repair.

C a m s h a f t 1-1,ousing a n d C y l i n d e r H e a d
I N S T A L L E D D I M E N S I O N S FOR 2 . 7 AND 3. 0 L I T E R E N G I N E S
Vehicle
TYP~
Engine
Type
Intake Valve
Exhaust Valve
Note
The tolerances for cylinder heads of Carrera 3.0

and 911 SC models have been limited for manu-
facturing reasons. The distance of 34.5 mm must
not be exceeded; the lower tolerance value would
be ideal.

91! 1
ADJUSTING TIMING
(Camshafts with Hexagon Head Mounting Bolts for Sprocket)
TOOLS
1 Holding wrench for 9191

sprockets
2 Puller P 212
3 Dial gauge holder P 207
4 Clamp for chain tensioner P 214
5 Dial gauge with tip Standard

Tip length: approx. 40 mrn
6 Assembly lever 9182
7 Feeler gauge P 213

911 C a m s h a f t H o u s i n g a n d C y l i n d e r H,ead
ADJUSTING TIMING
(Camshafts with Hexagon Head Mounting Bolts for Sprocket)
Basic S e t t i n g
1. Turn crankshaft until mark Z 1 on pulley is

aligned with joint of crankcase or stripe on fan
housing.
2. Position both camshafts so that punch marks face

up. Engine has its basic setting (cylinder no. 1
= TDC and cylinder no. 4 = overlap) by
adjusting mark Z 1 on pulley to joint and punch
marks on camshafts to face up.

3. In the position described above on bore in the Fine Adjustment

sprocket will be exactly aligned with a bore in
the sprocket flange. Insert a locating pin in these 1. Check valve clearance and, if necessary, adjust
exactly aligned bores. exactly to 0.10 mm with Special Tool P 213. '
Exact valve clearance for intake valves of

cylinders no. 1 and 4 is sufficient for timing
adjustments.
4. Tighten hexagon bolts for sprockets finger tight

hold with Special Tool P 9191.
2. Pre-load timing chains.
Note
To avoid damage on chain tensioner housing, it is

not permitted to pre-load timing chains with a
screwdriver. Supporting the screwdriver on the
chain tensioner housing could deform the latter
and cause seizure of the aluminum piston. Only
use Special Tool 9182 for pre-loading.
Note
Should one of the camshafts be turned out of basic

setting position, proceed as follows, Remove
locating pin from camshaft in basic setting position
so that i t cannot turn during rhe following adjustment.
Turn mislocated camshaft to basic setting position
(punch mark faces up) with Special Tool 9191.
Then remove sprocket mounting bolt and locating
pin, and turn crankshaft to mark Z 1 again.

11 Camshaft Housing and Cylinder Head
Left Camshaft Adjustment (Cylinder

No. 1 )
3. Mount dial gauge on stud of camshaft housing 7. Install locating pin again and tighten bolt finger
with Special Tool P 207. Set dial gauge to zero tight, while holding.
on spring retainer of intake valve for cyl. no. 1
with valve closed and approx. 10 mm pre-load.
0
8. Turn crankshaft clockwise two turns (720 ) and re-
check setting. Indicated vaiue should be within
tolerances.
9. Tighten bolt of left camshaft to final torque of

120 Nm (86 ft lb), having a 2nd person hold with
Special Tool P 9191.
4. Now slowly turn crankshaft clockwise from Z 1

(TDC) by about 1 turn and observe dial gauge a t
same time.
Continue turning until the mean value of the
adjusting tolerance, e. g. 0.10 mm valve lift
(for 930/16 engine), is reached.
Adjusting Values
Right Camshaft Adjustment (Cylinder
No. 4 )
Engine 9 30/16 1.4-1.7 mm
Ideal value 1.55 mm 1. Set cylinder no. 4 to TDC (cyl. no. 1overlaps).
5. Unscrew and remove mounting bolt on left 2. Repeat adjusting procedures described in points 3
sprocket and pull out locating pin with Special through 9 on cylinder no. 4.
Tool P 212.
6. Turn crankshaft accordingly until mark Z 1on

pulley is exactly aligned with joint of crankcase
or stripe on fan housing.

Cylinders and Pistons
l1 1
PISTON CHANGES - BEGINNING WITH 1 9 7 2 MODELS
1. New pistons with flatter piston tops to reduce compression

ratio:
511 T - 7.5: 1
911 E - 8.0: 1
911 S -- 8.5: 1
Required fuel octane rating = 9 1
2, Changed piston ring.
3. New table of dimensions for pistons and cylinders beginning with

1972 models.

PISTON AND CYLINDER DIMENSIONS
Beginning with 1972 models
Cylinder Cylinder Piston

markings bore dia. diameter D 1
T y p e 911 S Pistons
Tolerances
Standard -
4-
0.005 m m
0 84.000-84.010 83.950
1 84.010-84.020 83.960
2 84.020-84.030 83.970
1st oversize
0 KD1
1KD1
2KD1
2nd oversize
0 KD 2
1 KD 2
2 KD2
Cylinder/piston clearance: 0.04.5 -0.065

Piston weight: +
354 3 g
T y p e 911 E Pistons
Tolerances
Standard $ 0.005 m m
0 83.970
1 83.980
2 83.990
1st oversize
0 KD1 84.220
1 KD 1 84.230
2 KD 1 84.240
2nd oversize
0 KD2 84.470
1 ICD 2 84.480
2 KD2 84.490
Cylinder/piston clearance: 0.025 -0.045

Piston weight: 371 -t' 3 g

Cylinders and Pistons
1
markings bore dia. diameter
D1
Type 911 T
Tolerances
Standard ( M A H L E ) T0.005
0 84.000-84.010 83.970
1 84.010-84.020 83.980
2 84.020-84.030 83.990
1 s t oversize
0 KD 1 84.250-84.260 84.220
1 KD 1 84.260-84.270 84.230
2 KD 1 84.270-84.280 84.240
2nd oversize
0 KD 2 84.500-84.510 84.470
1 KD 2 84.510-84.520 84.480
2 KD 2 84.520-84.530 84.490
Cylinder/piston clearance: 0.025 -0.045

Piston weight: 376 2 3g
Type 911 T
Tolerances
Standard ( S C H M I D T ) + 0.007
- 0.008
0 84.000-84.010 83.970
1 84.010-84.020 83.980
2 84.020-84.030 83.990
1st oversize
0 KD 1 84.250-84.260 84.220
1 KD 1 84.260-84.270 84.230
2 KD1 84.270-84.280 84.240
2nd oversize
0 KD 2 84.500-84.510 84.470
1 KD 2 84.510-84.520 84.480
2 KD 2 84.520-84.530 84.490
Cylinder/piston clearance: 0.023-0.048

Piston weight: 375 4g
For piston and wear limits see p a g e 6 . 1

- 4/1
911 Cylinders and Pistons
CYLINDER HEIGHT TOLERANCE GROUPS

1972- models, 2.4 liters
Code mark
Standard Cylinder
Height
Cylinder
Installation
Height
Reconditioned
C y l i n d a Height

Cylinders and Pistons 911 1
PISTON AND CYLINDER DIMENSIONS
B e g i n n i n g w i t h 1973 m o d e l s

markings .
bore dia diameter D 1
T y p e C a r r e r a 2.7 P i s t o n s
Standard Tolerances
stamped 2 0.005
90.OOO-90.010 89.950
90.010-90.020 89.960
90.020-90.030 89.970
Cylinder/piston clearance: 0.025 - 0.045

Piston weight: 392 i 3 kg
C Y L I N D E R H E I G H T T O L E R A N C E OF 2.7 L I T E R E N G I N E S
Code
Cylinder
Installation Standard Cylinder
Height Height
Oversize pistons and cylinders are not provided.

PISTONS AND CYLINDER DIMENSIONS - B E G I N N I N G W I T H 1 9 7 4 MODELS
T y p e 9 1 1 and 9 1 1 S Pistons Cylinder Cylinder Piston

makings bore dia. diameter
D1
Standard Tolerances
stamped ? 0.0005
0 90.000-90.010 89.970
1 90.010-90.020 89.980
2 90.020-90.030 89.990
Cylinder/piston clearance: 0.025 - 0.045
P I S T O N A N D C Y L I N D E R D I M E N S I O N S "LS" V e r s i o n
T y p e 9 1 1 Pistons Cylinder Cylinder Piston

markings bore diameter diameter D l
. .
Standard
stamped
Permissible weight difference Cylinder/piston clearance: 0.035-0.060

in pistons of one set: 6 g max.
911 Cylinders and Pistons
I N S T A L L A T I O N I N S T R U C T I O N S FOR "LS" CYLINDERS AND P I S T O N S
The ALUSIL cylinder (eutectic aluminum-silicon alloy) and FERROCOAT piston combination is known
as "LS" Cylinders and Pistons.
In this system the surface coating is applied to the piston.
The assembly of the cylinder and piston must be made with particular care to avoid breaking the piston
rings; the rings are chrome-plated and are thus harder and more brittle.
When resistance is met while tightening the piston ring compressor, it is an indication 'that the rings
are not seating properly in the grooves. In such case remove the ring compressor, check the piston
rings for location, and repeat the procedure, carefully pushing the cylinder onto the piston.
I n s t a l l i n g Piston Rings
The piston rings can be installed in their grooves

by hand and without the use of tools. When
installing rings 1 and 2, make sure that the rings
are placed in the sequence and position shown
in the illustration.
I n s t a l l i n g T h r e e - P a r t O i l Ring
The oil ring is made up of three parts, with each

part installed separately. Install the expander
first, then follow with the upper and lower rails.
After installation check visually if the expander
ends meet.
Note
Install gaps of individual ring parts as follows:
Offset expander to rails by at least 45O.
Offset rails to each other by a t least 90'.

Cylinders and Pistons 911
P I S T O N AND CYLINDER S I Z E S - "LS" MAHLE
Piston T y p e 9 1 1 S Cylinder Cylinder Piston

Code Diameter diameter
Standard Size
stamped
0 90.000-90.012 89.960-
89.972
1 90.012-90.024 89.972-
89.984
2 90.024-90.036 89.984-
89.996
Cylinder/piston clearance: 0.028 - 0.052 mm
GAP OF "LS" P I S T O N RINGS
Make Piston Ring Gap in mm Gap wear limits

in mm
R ring Top 0.2 - 0.4 1.0
MAHLE + N ring Center 0.15 - 0.35 1.0

SCHMIDT
SS 50 ring Bottom 0.4 - 1.4 2.0
(3-piece consisting of
expander and 2 rails)

Cylinders and Pistons 91, 1
C H E C K I N G P I S T O N S A N D CYLINDERS
Cylinder
Dl Measuring point for wear and ovality
30 mm below top edge of cylinder
The cylinder is worn if this measurement is 0.08 mm

more than the new size specifications. Ovality is
checked by measuring in directions a and b. The
difference between a and b may not b e more than
0.04 mm.
D2 = Measuring point for piston ring end gap

clearance
Rings slid in to height of cylinder base gasket.
Piston
D = Measuring point for wear
At height of lower edge of piston pin bore.
Caution
Replace pistons and cylinders if clearance exceeds 0.15 mm.
P I S T O N RING END GAP
Piston Ring End Gap mm End Gap mm

(new size) (wear limit)
Compression ring, I and I1 0.1 - 0.2
Oil scraper ring, I11 -
0.15 0.3
Oil scraper ring, 111,
3-piece "LS" ring 0.4 - 1.4
(see checkpoint "D 2")
P I S T O N RING S I D E CLEARANCE
Piston Ring SIDE SIDE
Clearance in mm Clearance in mm
(new size) (wear limit)
Compression ring, I
Compression ring, I1
Oil scraper ring, I11

PISTON AND CYLINDER S I Z E S - 9 1 1 SC ( f r o m 1 9 7 8 M o d e l )
Mahle
Cylinder Cylinder bore Piston

marking diameter mm diameter D m m
Standard
size stamped
Clearance between cylinder and piston: 0.025 - 0.042 mm
P I S T O N AND CYLINDER S I Z E S - 9 1 1 SC ( f r o m 1 9 7 8 M o d e l )
KS
Cylinder Cylinder bore Piston

marking diameter m m diameter D mm
Standard
size stamped
Clearance between cylinder and piston: 0. 023 - 0. 044 mm

911 Cvlinders and Pistons
P I S T O N WEIGHT GROUPS - from 1980 Mode1
Installation Instructions:
1. Only pistons of one make and appropriate weight

group may be used in one engine.
2. Piston pins must always remain with the corres-

ponding pistons and should not b e mixed up
within an engine set. Watch this when disassemb-
ling and assembling an engine, marking parts
if necessary.
Weight groups MAHLE Pistons
Pistons weighed with attachments (piston pins, piston rings, snap rings)
I
Total Piston Weight in g
Weight group Marking
within a set
Engine type
Standard production
Max. difference in. weight 4 g
For installation
Max, difference in weight 8 g

P I S T O N WEIGHT CLASSES - 9 1 1 SC f r o m 1 9 8 1 M o d e l s
Weight Classes MAHLE Pistons
Total Piston Weight in g Code

Weight Class
Within a Set
Engine type
Standard production
Max. difference in weight 4 g
For Service Sector

Weight Classes KS Pistons
Total Piston Weight in g Code

Weight Class
Within a Set
Engine Type
Standard Production
For Service Sector

Crankcase and Flywheel 911 1
MEASURING AND R E C O N D I T I O N I N G CRANKCASE
General
The main bearing bores must be measured whenever the crankcase is disassembled for repair.
These instructions apply as well to all pre-1972 model engines.
Measuring
Attach crankcase half to bepch mount and 5. Measure all 8 main bearing bores with the
assemble'both halves without the intermedi- inside micrometer.
ate shafl.
Lightly tighten all crankcase studs and two M8 If the bores are too tight, they should be re-
retaining nuts at Bearing 1. amed with the main bearing reamer to stan-
dard diameter of 62.000 mm.
Align both crankcase halves with the aid of a
plastic mallet. The joint in Bearing 8 must Bore diameter for main bearings 1 r 8 is
not be offset in relation to each half. 62.000 to 62.019 mm.
Using the inside micrometer, cross-check If the bores are too large, they should be re-
bore of Bearing 8. Realign bore if necessary. amed to B-bearing oversize of 62.25 mm
diameter.
Control dimension for the B-bearing is

62.25 mm to 62.269 mm diameter.
Reconditioning
General
This procedure requires special tools and should

only be performed by qualified personnel.
Light-alloy (SILUMIN) crankcases must be reamed

in two steps when reaming to the B-bearing size.
Lubricate reamer with cutting oil during this procer
dure.
4. Tighten all crankcase studs and both M8 1. Step 1 = 62.15 mm diameter

nuts to proper tor q ue. 2. Step 2 = 62.25 mm diameter (B-bearing in-
stallation dimension)

1 911 Crankcase and Flywheel
Pressure-cast crankcases can be cut in one step

and without oil to 62.25 mm diameter.
Reaming
1. Attach self-made tool (see sketch below)

to 4 oil screen attaching studs and fasten
in bench vise.
S k e t c h for S e l f - M a d e T o o l
T-bar 40 x 80 x 7 mm
All edges beveled
Insert rod (35 x 1200 mm) with main bearing
reamer and ream Bearing, P until Bearing 2
is guided (reamer centers automatically in
bore of Bearing 1).
4. Insert end bearing bushing EL35 in bore of

Bearing 1.
5. Ream all bearing bores until reamer reaches

2. Insert end bearing bushing EL35 in bore of end bearing bushing of Bearing 8.
Bearing 8.

Crankcase and Flywheel 911 1
6. Remove-end-bearing bushing from bearing

bore # 8 and fullv ream bear in^ 8.

Crankcase and Flywheel 911 1.
M O D I F I E D FLYWHEEL I N S T A L L A T I O N - 1 9 7 8 MODELS
No. Description Qty . Removing

Note When
Installing Special Instructions
1 Socket head 9 Torque 9 mkg
2 Flywheel 1
3 Bushing 1
4 Crankshaft 1

FLYWHEEL W I T H P I L O T B E A R I N G / B U S H I N G FOR I N P U T S H A F T - from 1980 Model
-
Note When Special
No. Description
Removing Installing Instructions
Screw M 6x12 Tighten to specified

torque, lock with Loc-
t i t e 270
Bushing with needle First secure flywheel,

bering then bushing
Bolt Tighten t o specified

torque
Flywheel
Crankshaft

Crankcase, Camshaft 911
REMOVING AND I N S T A L L I N G OIL FILTER SCREEN A N D S U C T I O N P L A T E
-
Note When Special
No. Description
- Removing Installing Instructions
1 Oil drain plug
2 Seal Replace
3 Nut Tighten to about 1 0 Nrr

7 ft lb
4 Washer
5 Zover for oil filter scree Check for deformation,

replacing if necessary.
Watch installed position
oil drain plug must face
in recess of suction
plate
6 Replace
7 3 1 filter screen with

iuction plate
8 Replace
-
11 Crankcase, Crankshaft
ASSEMBLY I N S T R U C T I O N S
SEALING CRANKCASE M A T I N G SURFACES
Note
Only use Loctite No. 573 (green color) as a sealing

compound.
Loctite No. 573 hardens only in conjunction with
metal and exclusion of air. Never wait longer than
about 1 0 minutes between applying coat of sealing
compound and assembling parts, since the sealing
compound applied directly on the metal would begin
to harden.
Removing Old Sealing Compound
During repairs the old compound need not be removed.

It is only necessary to remove grease from the surface
and to apply a coat of new sealing compound after
the grease removing solution has dried. The new
Loctite w i l l dissolve the old compound in the surface
finish and harden again after assembly.
Should it be absolutely necessary to remove the old
sealing compound, a fine steel brush is recommended
for this work.
Applying Sealing Compound
1. When applying sealing compound by hand use 2. Apply a very thin coat of sealing compound with
a short-pile velour roller. In addition, a tray the velour roller.
with a ribbed surface for scraping off the roller
will be required for the sealing compound.

Crankcase and Crankshaft 91, 1
CRANKCASE CHANGES - BEGINNING W I T H 1 9 7 2 MODELS
Distributor mounting flange.
CHANGED CRANKSHAFT - BEGINNING W I T H 1 9 7 2 MODELS
Stroke = 70.4 m m
Crankpin diameter = 51.990 - 51.911
Crankpin width = 24 m m
Beginning with 1972 models, all crankshafts have counterweights.
S e e next page for crankshaft dimensions.

CRANKSHAFT DIMENSIONS - STANDARD AND RECONDITIONED
Main bearing Crankshaft

Step Crankshaft All main Connecting diameter d 3 Shoulder Timing gear pulley seat Thrust
diameter bearings rod bearings on crankshaft diameter seat diameter diameter bearing
Bearings 1- 8 d1 d2 Bearing 8 d4 d5 d6 Width A
Standard Standard mm 56.990-56.971 51.990-51.971 30.993-30.980 65.000-64.981 42.013-42.002 29.993-29.960 28.000-

62.000- in. (2.2437-2.2429) (2.0468-2.0461) (1.2202-1.2197) (2.5591-2.5583) (1.6541-1.6536)
62.019 mm
-0.25 mm (2 .44O9- mm 56.740-56.721 51.740-51.721 30.743-30.730
(-0 .OO98) 2.4417 in.) in. (2.2339-2.2331) (2.0382-2.0363) (1.2104-1.2098)
-0.50 mm Oversize mm 56.490-56.471 51.490-51.471 30,493-30.480 64.500-64.310

62.269-
(-0.0197) in. (2.2240-2.2233) (2 .O272-2.0264) (1.2005-1.2000) (2.5394-2.5319)
62.250 mm
-0.75 mm (2.4515- mm 56.240-56.221 51.240-51.221 30.243-30.230
2.4508 in.)
(-0.02%) in. (2.2142-2.2134) (2.0173-2.0166) (1.1907-1.1902)
Grind crankshaft oil seal s u r f x s only w h s deeply scorede Grind to

2 dimensions of 29.5 mm (1.161 in.) and 64.5 mm (2.539 in.)
%
Otherwise polish out.
-
Polishing roughness = 2 5 microns
N o t e : After grinding, Tenifer-harden the crankshaft, then polish all bearing journals and thrust surface A.
Magnaflux to check f o r c r a c k s .
Maximum vertical runout = 0 .O4 mm (0.002 in.), measured at Bearing 4 and 8, with Bearing 1 and 7 on V-blocks.
Maximum crankshaft unbalance = 10 cmg. Journal 3 and 5 must not b e straightened after the Tenifer treatment.

Crankcase and Crankshaft 911 1
C O N N E C T I N G ROD C H A N G E S - BEGINNING W I T H 1 9 7 2 MODELS
A Distance between centers 127.8 - 0.05 m m

(5.03) - (0.002 in.)
b Width of piston pin bushing 26.0 - 0.2 mm

(1.02) - (0.008 in.)
c Big end width 23.8 - 0.1 mm

(0.9370) - (0.004 in.)
D Big end diameter (without bearing insert) 56.019 - 56.000 m m

(2.2055) - (2.2047 in.)
E Small end diameter 25.021 - 25,000 m m
(0.9851) - (0.9843 in.)
f Piston pin bushing dia. (before installation) 25.035 - 25.055 m m

(0.9856) - (0.9864 in.)
(Press-fit interference in rod) 0.014 - 0.055 m m
(0 .OOO6) - (0.0022 in.)
G Inside diameter of installed piston pin
bushing (finished) 22,033 - 22.020 m m
(0.8674) - (0.8669 in.)
Piston pin clearance in bushing 0.020 - 0.039 m m
(0.0008) - (0.0015 in.)
Wear limit 0.055
(.0022)
911 Crankcase and Crankshaft
C O N N E C T I N G ROD W E I G H T GROUPS
Connecting rods are assigned to weight groups.
The pertinent weight group can be identified in spare part end numbers.
The end number is stamped into connecting rods furnished as spare parts.
- -
Weight Weight KD connecting rod Identification

more than up to group spare part number in connecting rod
grams grams for KD
--
645
65 4
663
672
681
690
699
708
718
-
Weight variation between connectirg rods in any engine may not exceed 9 g.
T o determine weight group, weigh complete connecting rod without big end inserts.

Crankcase, Crankshaft 911 1
C O N N E C T I N G ROD W E I G H T GROUPS - from 1978 Model
Connecting rods are in different weight groups,
T h e weight group is indicated by the final digit of t h e part number.
For connecting rods, which are supplied as spare parts, these final digits a r e stamped on the shank.
Weight
Service installation
Weight group Connecting
connecting rod
for rod marking
above g P a r t No.
installation
Note
Only connecting rods, which do not differ in weight by more than 9 g, may b e installed in o n e engine.
To determine a weight group, weigh the complete connecting rod (without bearing shells).

P I S T O N S FOR K - JETRONIC ENGINES
-
Pistons for K Jetronic-equipped engines of Type
911/91 and 911/96 have a turbulence (whirl)
cavity in the piston top. This provision ensures
a particularly thorough blending of the fuel/air
mixture.
Installation note:
T h e piston must always be installed so that the
flat spot in the piston top faces upward (towards
t h e intake valve).

ASSEMBLY I N S T R U C T I O N S FOR P I S T O N S ON 9 1 1 SC ( 1 9 8 1 M o d e l s )
Domed surface on piston must f a c e intake valve.

Crankcase and Crankshaft 911
M O D I F I E D C R A N K S H A F T DRIVE - 1 9 7 8 MODELS
TOOLS
No. Description . Special Tool Note
1 Installer for crankshaft seal 9126

MODIFIED CRANKSHAFT DRIVE - 1 9 7 8 MODELS

Crankcase and Crankshaft
Note When
No. Description Special Instruction
Removing Installing
Oil seal Replace
Thrust main bearing Check for wear Lubricate

shells 1
Main bearing shells Lubricate

2-7
Bearing sleeve, Lubricate

bearing 8
O-ring Replace
Oil seal Replace
C i rclip
Drive gear for

distributor
Spacer Note installed

position
Timing gear
Woodruff key
Connecting rod nut Tighten to specified

torque. Lubricate
bearing surface.
Connecting rod Note installed positioi

and weight
Connecting rod bea- Check for wear Lubricate

ring shell
Connecting rod bolt
Crankshaft Check for wear

I N S T A L L A T I O N I N S T R U C T I O N S FOR M O D I F I E D C R A N K S H A F T DRIVE - 1978

MODELS
Clamping Crankshaft
Special Tool P 209 a must be modified for new

crankshaft.
Installing Seal
Drive in seal with Special Tool 9126.

Installing Crankshaft Drive Gear for C o u n t e r c l o c k w i s e Rotating Distributor
Note
As of the 1978 model year, the engines are equipped with a counterclockwise rotating distributor. There-
fore a new crankshaft drive gear with modified teeth is required.
For counterclockwise For clockwise rotating

rotating distributor distributor
(with Porsche emblem) (with VW emblem)
I n s t a l l i n g C i r c l i p on C r a n k s h a f t
Circlips are available in various thicknesses to

take up axial play between distributor and drive
gear.
The following circlips are available:
Part No. Thickness mm Code
901 .102.148 .OO 2.4 0

901.102.148.01 2.3 1
901.102.148.02 2.2 .2
901.102.148.03 2-1 3
Install timing gear, spacer and drive gear for

counterclockwise rotating distributor on crank -
shaft up to stop. Select proper circlip by first
inserting i t to check its thickness. Circlip must L
take up play.

CRANKSHAFT - Standard and Undersizes
(19 78 Models)
Size Crankcase bore All main bearing Connecting rod Main bearing jaw- Oil seal journal Seat for timing Crankshaft pulley Thrust bearing
mm dia. bearings 1- 8 journals d 1 bearing journals rial d 3 of crank- dia. d 4 gear dia. d 5 seat dia. d 6 width A
d2 shaft bearing 8
Standard
- 0.25
- 0.50
- 0.75
- 1.00

I 1
Surface finish
7-
i
Edge deburre d
Paint dot
Grind crankshaft oil seal surfaces only when deeply Undersize color codes
scored. Grind to dimensions of 2 9 , 5 m m and 89.5 m m
respectively. Otherwise polish out to 3 microns.
1st undersize blue paint dot
2nd undersize green paint dot
After grinding, chamfer oil holes to 0, 5 m m radius.
3rd undersize yellow paint dot
Break all sharp edges to 0.2 - 0.5 m m radius.
4th undersize white paint dot
Maximum radial runout measured at bearings 1 and 7
is 0.04 mm.
Tenifer treat crankshaft after grinding.

Magnaflux to check for cracks.
Do not straighten main bearing journals 3 and 5

after Tenifer treatment. All other main bearing
journals can be straightened by applying pressure
to the bearing journal webs.

Clutch 911 1
C L U T C H CHANGES - B E G I N N I N G W I T H 1 9 7 2 MODELS
1. Clutch operating system has been redesigned. The throw-out fork and clutch lever are mounted and
secured with lock rings on a shaft which is splined on both ends and located in the transmission
housing. The clutch lever is now pulled by the clutch cable instead of the cable housing.
2. Pressure of the pressure plate (MFZ 225 KL) has been increased to a range of 650-720 kp
(1430 -1584 Ibs.)
3. Clutch disc splines have been changed from 24 to 20 (an SAE designation).

ADJUSTING CLUTCH
1. Turn self-locking adjusting nut until clutch

-
pedal free travel is 20 25 m m
-
(0.8 1.0 in.).
2. When checking, pull pedal in direction of arrow.

REMOVING A N D I N S T A L L I N G T H R O W O U T BEARING

1 Clutch
Note when
Description References
removing installing
Snap ring Remove with snap ring Check for proper 9.1-2/3
pliers while pushing seating.
Thrust washer Groove must face the 1 9.l- 2/3

snap ring.
Throwout bearing Should not be washed

only wiped with dry
rag. Grease guide
tube contacting sur-
face with multi-
purpose grease with
MoS2 additive.
Spring washe~ Install in correct 9.1-2/3

position.
Spacer
Pressure plate Check for wear and

replace if necessary.

Clutch
l1 1
I N S T R U C T I O N S FOR REMOVAL AND I N S T A L L A T I O N
Removal Inst a l l a t i o n
1. Lay the pressure plate onto the throwout 1. Place spacer and spring washer on the
bearing and push down by pressing throwout bearing in proper position.
against the thrust washer so that the
snap ring can be reached.
2 ; Remove snap ring with snap ring pliers 2. Insert the throwout bearing into the
and take the throwout bearing out diaphragm spring of the pressure plate.
together with the washers.
3. Install thrust washer with the groove facing

the snap ring and install snap ring while
NOTE: pushing the pressure plate and thrust washer
Throwout bearings are packed with downward.
special grease and therefore may not
be washed.

CLUTCH - 1 9 7 5 MODELS
1 911 S and Carrera
Pressure plate MFZ 225 KSph
Pressure 714 - 785 kp

Spring No. 3027 056 000
Part No. 915.116.OOl .I4
Drive shell
Part No.

CLUTCH MODIFICATIONS - 1 9 7 8 MODELS

911 Clutch
Note When Special

Description
Socket head screw
Lock washer Replace
Pressure plate
Starter gear ring
Clutch disc
Circlip
Thrust washer
Release bearing Check
Washer
Spring washer Install in correct

position

Kraftstoffanlage
Fuel System
Systeme d'alimentation
Sistema d'alimentazione

FUEL S Y S T E M 11
CONTENTS
-0 . 1 Description
Fuel system changes - 1972 model

Fuel injection pump changes - 1972 model
Throttle valve housing and intake manifold changes
Cold start enrichment system changes
Fuel injection system, schematic
Induction air preheating - 1972 model
Continuous injection system (CIS)
Engine cross section - 1974 model
Continuous injection system (CIS) - 1974 model
Fuel evaporative control system
1 - SYSTEM CHECKOUT
1.1 Continuous i n j e c t i o n system (CIS)
General checkout procedure

Visual inspection
Initial checks
Pressure tests
Leakage checks
Injection valve, checking
Auxiliary air .device, checking
CIS testing Bnd adjustment specifications - 1974/75 models
CIS testing and adjusting specifications - 1976/77 models
CIS testing and adjusting specifications - 1978/79 models
CIS testing and adjusting specifications - 1980 model
Testing and adjusting values - 9 1 1 SC (1981 models with Oxygen Sensor Control)
Control pressure regulator (vacuum-controlled), checking
"Cold" control pressure (vacuum-controlled control pressure regulator),
checking
Auxiliary air valve, checking
Safety switch, checking
CIS problems and remedies
Automatic choke, troubleshooting - 1976 model
Thermovalve, checking
Downloaded from www.Manualslib.com manualssystem
Vacuum search engine
layout - 1978 model 1.1 - 3 / 1
911 FUEL S Y S T E M ;
Vacuum hose layout - 1979 model

Fuel and vacuum lines layout - 1980 model
2 - SERVICING
2.1 Servicing informarion

Regulator housing, removing and installing
Induction air preheating system, checking
Fresh air flap, adjusting
Fresh air flap lever, replacing
Hose clamps for cold start enrichment, installing
Fuel injection nozzles, checking
2.2 Servicing continuous i n j e c t i o n system (CIS)

CIS, disassembling and assembling 2.2 - 1/1
Mixture control unit, removing and installing 2.2 - 1/7
Throttle valve housing with control pressure regulator (throttle valve positionj.
removing and installing 2.2 - 118
Control pressure regulator (warm running compensation), removing and
installing 2.2 - 1/9
Start (enrichment) valve; removing and installing

Fuel filter, removing and installing
Fuel pressure accumulator, removing and installing 2.2 - 1/12
Injection valves, removing and installing;
Plastic fuel lines, re p lacin g
Fuel line system, bleeding 2.2 - 1/17
Mixture control unit, dismantling and assembling 2.2 - 2/1
Sensor plate, removing and installing 2.2 - 2/4
Air flow sensor housing, locating operating lever with follower 2.2 -2/6
Mixture control screw basic adjustment after replacement of follower 2.2 - 2/7
Fuel distributor pressure relief valve piston seal, replacing 2.2 - 2/8
Vacuum controlled (warm-up) control pressure regulator, removing and
installing 2.2 - 2/9
Auxiliary air valve, removing and installing 2.2 - 3/1

Mixture control unit, disiassembling and assembling - modifications
from April 1976
Thermovalve, removing and installing 2.2 - 3/2
Diverter valve, removing and installing 2.2 - 3/3

FUEL S Y S T E M 911
2.3 Fuel tank
Fuel tank plug with CIS filter, cleaning
Fuel tank (80 l i t e r ) , removing and installing - 1974 model
2.4 Fuel pump
Fuel pump, removing and installing - 1976 model
Layom drawing of Check valves on fuel pumps
Replacing check valve
2.5 Oxygen sensor

Oxygen sensor, removing and installing .
Oxygen sensor control unit, removing and installing

Frequency valve for oxygen sensor, checking 2.5 - 1/4
Throttle valve switch, checking and adjusting
Removing and installing microswitch for acceleration enrichment of
Oxygen Sensor control (from 1981 models)
Correcting C O level setting on mixture control unit - (from 1 9 8 1 models)
with shear-off screw 2.5 - 1/8
3 - ADJUSTMENT INSTRUCTIONS
3.1 Adjustment instructions for fuel injection system

Fuel injection pump, adjusting with emission tester
Idle, adjusting
Microswitch, adjusting - 1972 model
CIS adjustment instructions

Idle, adjusting
Full power position of throttle, adjusting
Microswitch, adjusting
Control pressure regulator (throttle valve position), checking and adjusting
Hand throttle, adjusting
Idle, adjusting - 1978 model
- 1980 model
I d l e , adjusting
Adjusting idle 9 1 1 SC - (from 1981 models)

Description 911 2
FUEL I N J E C T I O N PUMP CHANGES - BEGINNING W I T H 1 9 7 2 MODELS
The 2 , 4 liter engines are equipped with changed injection pumps. The changes consist of a wider
contoured cam and modified centrifugal weights and springs.
Pump designation (BOSCH number on data plate):
911 T - 0408 1 2 6 0 1 5
911 E -- 0408 126014
911 S -
- 0408 126013

Description 911 2
C H A N G E S IN T H R O T T L E VALVE H O U S I N G S A N D I N T A K E M A N I F O L D S
Beginning with the 1972 models, throttle valve stops in the throttle valve housing are relocated to
the lever side. The new levers require the use of modified protractors, special tool P 228 c .
The protractor on the injection pump control lever has not been changed. The correlation checkout
procedure remains same (see page SF 22).
The intake velocity stacks are made of plastic. They form a single unit together. with the lower
air assembly.
COLD START ENRICHMENT SYSTEM CHANGES
Fuel for cold start enrichment now is fed directly into each individual velocity stack.
The discharge nozzles are bonded and can not b e exchanged.

Description

I N D U C T I O N AIR PREHEATING - B E G I N N I N G W I T H 1 9 7 2 MODELS
General Information
Beginning with the 1972 models, all 2.4 liter fuel injection engines are equipped with an induction
air preheating system.
Induction air preheating provides even induction air temperatures in lower engine speed ranges
resulting in improved performance, as well as lower exhaust emission values.
1 = Fresh air f l a p A = Hot a i r
2 = Hot air f l a p B = Fresh a i r
3 = Thermostat
2 911 Description
!
Design The induction air preheating system consists of:
1. A r e g u l a t o r h o u s i n g which is attached to the left velocity stalck by three 6 mm

bolts. It contains two flaps and a thermostat.
On of the flaps (the fresh air flap) is controlled by the throttle linkage. The other
flap (hot air flap) is controlled by the thermostat.
2 . A h o s e which fetds heated air from the left heat exchange.
3. A c a rn on the left throttle valve lever which controls the fresh air flap.
1 Control box
2 Hot air supply duct
3 Control, lever

Description
Func t io n A thermostat-controlled hot air flap maintains induction air temperature at 4 5 ' ~
(112'~). A second flap stops the flow of hot air from throttle valve position of about
20' and engine draws only fresh outside air at wide open throttle.
Engine started, cold (below 4 5 ' ~(112OF)

Throttle at idle position (fresh air flap closed)
. Hot air flap open, engine draws hot air from heat exchanger.
Engine cold (below 450C ( 1 1 2 ' ~ ) - throttle in partial load

position
Hot air flap open. It opens according to position of cam. Fresh outside air is added.
Fresh air flap is fully open in full throttle position.
Air t e m p e r a t u r e rises t o 45-50°C (112OF - 122OF)

Thermostat begins to close hot air flap at 45OC (112OF). It is fully closed at
50°C (122'~) and engine draws only fresh outside air.
A bypass duct, closed by the hot air flap when cold, feeds additional air with
increasing temperatures.

Description 2
CONTINUOUS INJECTION SYSTEM (CIS)
Beginning with the January 1973 production, Type 911 T vehicles are equipped with the continuous
injection system (CIS).
T h e working principle of this system depends on measuring the intake air flow rate to determine the
amount of fuel to b e injected.
The fuel distributor determines the quantity of fuel to be delivered depending on air flow rate and
engine loading conditions.

E N G I N E CROSS S E C T I O N
Air duct
Control pressure
regulator (throttle
valve position)
Throttle valve
Start (enrichment)
valve
Control pressure
regulator (warm
running compensa-
tion)
Heat exchanger-.
Crankshaft
Oil pump
Oil screen
Connecting rod
Piston
Cylinder
Exhaust valve
Valve guide
Oil hose connection
(oil tank - oil pump)
Valve spring
Rocker arm shaft
Camshaft
Rocker arm
Intake valve
Injection valve
Intake pipe
Intake housing
Air sensor plate
Mixture control unit

Description 9H 2
Mixture Control Unit
Air Flow Sensor and Fuel Distributor.
The air flow sensor consists of a venturi and a

sensor plate which is attached to a lever.
The volume of intake air passing through the

venturi determines. the position of the sensor
plate.
The control plunger and the slotted metering 1 Venturi

cylinder are located in the center of the fuel 2 Sensor plate
distributor. Machined into the metering cylinder 3 Lever
are 6 rectangular slots which act as metering 4 Control plunger
ports. They can b e progressively opened'by 5 Slotted metering cylinder
the control plunger. 6 Metering port
7 Fuel distributor
The metering ports open depending on the

position of the sensor plate whose moyement is
transmitted t o the control plunger through a lever
Intake air which passes through the air flow

sensor exerts a pneumatic force F l on the sensor
plate.
The pneumatic force is countered in the fuel

distributor by hydraulic force F2 which is exerted
against the control plunger through a port.
The sensor plate will yield until the pneumatic

force and hydraulic force equalize.

Description
The hydraulic pressure F2 will remain constant

in a warm engine although i t can b e lowered
through the reduction of control pressure, such
as during warm-up or due to the given position
of the throttle valve.
Weight of the sensor plate and lever F3 is

equalized by the counter weight F4.
Each metering port in the fuel distributor is

provided with a pressure regu1at:ing valve which
keeps the pressure drop a t the metering port
constant (pressure difference = pressure ahead
of the metering port less pressure after the
metering port) independent of the fuel transfer
rate, primary system fuel pressure, and injection
valve opening pressure.
T h e pressure regulating valves are flat seat

valves with a steel diaphragm acting as a valve
plate.
By maintaining the pressure difference constant,

it is possible to control the fuel flow rate by
means of the size of the metering port cross-
1 Pressure regulating valve
section alone.
2 Control plunger
3 Metering port
The injection valves have no metering function.

F u e l Flow
The fuel flows from the electric fuel pump through an accumulator and filter to the mixture control
unit.
A pressure regulator in the primary sjstem maintains constant pressure in the system.
From the mixture control unit, injection lines carry the fuei to the injection valves. In addition, a
separate line carries fuel to the start (enrichment) valve.
Control pressure can be varied by two (control) pressure regulators, one according to engine and outside
temperatures, the other according to accelerator pedal movement.
throttle-actuated valve
' -\
-
-
-. -- >
---
/
/
- - *
-
..--
injection line
- .
start valve
fuel distributor
fine-mesh filter
Primary system fuel pressure

I'
Supplied fuel
Control pressure
, Return flow
Description 911 2
Electric Fuel Pump
A roller-type fuel pump is utilized.
Fuel Pressure Accumul.ator
The fuel pressure accumulator is located in t h e

primary circuit directly after the fuel pump. Its
function is to delay the initial pressure surge
when the pump starts. This delay is necessary to
prevent the control plunger from being forced
up before sufficient control pressure has been
allowed to build up.
It also serves as a reservoir to keep the system

under sufficient pressure for a short period of
t i m e when the engine is turned off.
Fuel Filter
An in-1ine.filter with a paper cartridge is

utilized.

2 911 Description
Injection Valves
Since the injection, process is longer in a

continuous injection system, the injection valves
had to b e designed for a smaller fuel transfer rate
The injection valve permits fine atomization of

fuel when small amounts are transfered. Opening
pressure for the injection valves is approx. 3 bar.
Start (Enrichment) Valve
T h e solenoid-operated start (enrichment) valve

discharges supplemental fuel into the intake
manifold when the engine is being started.
Control Pressure Regulator

(Warm Running Compensation)
The control pressure regulator for warm running

compensation contains a bimetallic spring acting
on a spring-loaded diaphragm.
During engine warm-up, the bimetal spring

presses against the valve spring causing the
control pressure t o drop. This results in a lower
hydraulic pressure F2, greater travel of the air
flow sensor plate with unchanged amount of
intake air, and increased metering port cross-
section, making a richer fuellair mixture.
As the bimetal spring is heated, it gradually

relaxes its pressure against the valve spring.
Thus the control pressure norma.lizes again.
Idle speed can b e increased during warm-up by

opening the throttle manually (hand throttle).
- b
1 Pressure regulating valve
2 Bimetal spring
3 Heater coil
Description 911 2
Control Pressure Regulator
(Throttle Valve Position)
The control pressure regulator for throttle valve

position is basically similar to the regulator for
warn1 running con~pensation. It is attached to
the throttle valve housing.
A cam plate is attached to the throttle valve

shaft and rides along with it, compressing the
regulator spring to a greater or lesser degree.
This changes the control pressure along with

changed throttle valve position, adjusting the
fuel/air mixture as required.
Auxiliary Air Device
When decelerating from high rprn with throttle

closed, considerable vacuum builds up in the
intake manifold. The vacuum is channeled to
an auxiliary air device. As the device opens,
additional air bypasses the throttle creating a
combustible mixture.
Idle Adjustment
The adjusting method is same as that for carbure-

tors. The idle air mass passes through the air flow
sensor where it is measured. The closed throttle
is bypassed through a bypass bore.
The cross-section of this bore can be changed

with the aid of an adjustment screw. A change
in cross-section changes the engine speed with-
out affecting the composition of the fuel/air
mixture.
The fuel/air mixture can b e adjusted within

certain limits by means of a mixture adjusting
screw to attain the required effect.

2 911 Description
Thermoswitch
Beginning with 1974 models, engines equipped

with the continuous injection system (K-Jetronic)
are furnished with a thermoswitch which is
connected to the cold start enrichment valve.
The thermoswitch is located in the left chain
housing cover. A microswitch is connected in
series with it. The microswitch is activated by
the hand throttle lever when the latter is moved
to at least 5O of the throttle valve position. The
thermoswitch is active up to engine temperature
of approx. + 45' C ( 1 1 3 ~F) and prevents the
injection of supplemental fuel by the cold start
enrichment valve when starting a hot engine.
Vacuum controlled warm- up regula-

tor
Controll pressure changes of this warm-up regula-

tor are made via intake manifold vacuum.

CONTINUOUS INJECTION SYSTEM ( C I S )
Beginning with 1974 models, Type 911 and 911 S, vehicles are equipped with the continuous injection
system.
Changes Effective with 1 9 7 4 Models
1. Cast intake pipes with mounting hole for injection valves.
2. Repositioning of the injection valves resulted in their being lengthened and injection lines
shortened.
3. The diameter of intake pipes at the intake housing has been changed:
Intake pipe for Type 911 = 31 m m dia.

911S= 34.5mmdia.
4. Mixture control unit has been calibrated for 2.7 liter engines.
5. The pneumatic valve has been repositioned and also modified to the vacuum characteristics
prevailing in the 2.7 liter CIS engines.
6. The cold start enrichment valve has been moved to the center of the intake housing to effect a
better distribution of the fuel to the individual cylinders.
7. A thermoswitch has been mounted on the left chain housing cover to supplement the cold start enrich-
ment valve.

Description
911 2
FUEL E V A P O R A T I V E C O N T R O L S Y S T E M
General
All vehicles are equipped with a sealed fuel tank venting system incorporating an activated charcoal
filter. The closed system prevents fuel fumes from entering the atmosphere. The fumes are ducted into
the activated charcoal filter with the aid of fresh air supplied by the engine cooling fan, and then to
the engine air filter where they mix with the induction air and are burned with it.
1 Fuel tank 5 Hose from cooling fan to activated

charcoal filter
2 Expansion chamber
6 Hose from activated charcoal filter to
3 Activated charcoal filter engine air filter
4 Cooling fan upper shroud with hose 7 Engine air filter

connector
8 Return hose connecting fuel tank with the
expansion chamber

System Checkout 911 2
CONTINUOUS INJECTION SYSTEM ( C I S )
GENERAL CHECKOUT PROCEDURE
Prerequisite for the CIS checkout is a properly functioning ignition system and proper mechanical condi-
tion of the engine.
A complete CIS checkout should b e carried out in the below given sequence.
However, specific problems can be analyzed by performing individual tests.
In addition, the following should be noted: Certain tests require that the engine is cold (check control
pressure "cold"). For this test, the engine should be out of operation for several hours, or overnight. The
checkout should b e performed a t the same location where the car was parked for several hours. Erroneous
test results will b e obtained if, for instance, the vehicle should b e brought into a heated garage from
a cold outside environment.
The remaining tests, with the exception of the idle adjustment, can b e performed with the engine warm
or cold.
The engine must b e at warm operating temperature when idling is adjusted.
All tests, idle adjustment excepted, are accomplished with the engine turned off.
NOTE
Always install new gaskets whenever fuel lines are loosened or detached.
It is important to maintain the highest degree of cleanliness when servicing the CIS.
T h e outside of the fuel lines must b e thoroughly cleaned before they are loosened.

2 911 Syitem Checkout
VISUAL INSPECTION
The CIS should b e visually inspected prior to the initiation of work.
Visual inspection for leaks: Checking f r e e movement of l e v e r
in a i r flow sensor
.I.Check all fuel line connections for leaks.
2 . Check induction system (vacuum system) for 1.. Unhook rubber straps, remove air filter horn
leaks between the mixture control unit and and withdraw cartridge.
I
engine (air duct between mixture control unit
and throttle housing).
2 . Raise lever of air flow sensor by hand
3. Check for leaks between intake manifold and An even amount of resistance should b e felt
start (enrichment) valve (O-ring). throughout the length of movement.
A quick downward movement of the lever will

detach i t from the sluggish control plunger at
4. Check for leaks between intake manifold and which time no resistance should b e felt a t the
pipes. lever.
Replace porous rubber boots.
5. Check hose connections for leaks at: the intake

manifold, vacuum hoses at the throttle housing,
as well as the auxiliary air device.
.. . .
. . . .. .
..
. ..
G.'Check proper seating of rubber covers a t the
injection 'valves.
7. Check attachment of intake pipes a t cylinder

heads.

Svstem Checkout
I n s p e c t i o n of t h e f l e x i b l e s e n s o r p l a t e s t o p i n t h e a i r f l o w (sensor
p l a t e i n p o s i t i o n of r e s t )
The fuel system must be depressurized when

performing this check.
To relieve the remaining pressure, slightly

loosen the pressure line connection at the control
pressure regulator for warm running compensation.
When loosening the line, wrap the connection
with a rag to keep fuel from spilling.
The upper edge of the sensor plate must now be

flush with the root of the taper at a point shown
i n the illustration. A lower positioning of up to
0,s mm is permissible.
If required, adjustment of the flexible stop can

be corrected by bending the wire bow.
Since April of 1976 the spring-loaded stop of

the sensor plate can be corrected with an ad-
justing screw.

System Checkout
I N I T I A L CHECKS
The following tests are component tests. Final evaluation of individual parts is possible only upon
completion of pressure checks.
When performing the tests outlined below, remove the middle fuse from the rear fuse box to keep the
heater coil in the control pressure regulator for warm running compensation from heating up.
Checking electric fuel pump
Minimum voltage at the connecting terminal

is 11.5 volts.
Current draw when running is 8.5 amps

maximum.
Check pump delivery rate:
Disconnect fuel return line at the connector.

Push a section (about 50 c m long) of normal
fuel hose onto the connector and hold in a
measuring glass. Switch the ignition on for
the duration of the measuring period.
See page 1.1 - 1/13 for specifications.
Modifications - 1976 Model
Terminals 30 and 87a of the relay (rear of luggage

compartment) must be bridged to check the fuel
pump delivery rate, due to a safety switch on the
mixture control unit (also refer to page 1.1 - 1/17).

Checking Control Pressure Regulator
(Warm Running Compensation)
1. Minimum voltage at the connecting terminal

is 11.5 volts.
2 . Check heater coil continuity with the aid of

a test buzzer or ohmmeter. (Check between
wire terminal at the control pressure regulator
and the ground .) The connecting wire must b e
detached from the control pressure regulator.
If the circuit is open, the control pressure regu-
lator will have to be replaced.
Checking Start (Enrichment) Valve
Remove start (enrichment) valve (see page

2.2 - 1/10); the fuel line remains connected.
Hold the start (enrichment) valve in a receptacle

and connect to battery Bt (upper fuse in rear
fuse box in engine compartment, left side)
and to ground with a piece of jumper wire.
Briefly switch the ignition on.
The start (enrichment) valve must spray fuel
in an even conical pattern.
Remove jumper wire and switch the ignition

on. After waiting about 10 seconds, wipe
nozzle of start (enrichment) valve dry; no
fuel should come out..

System Checkout
PRESSURE T E S T S
TOOLS
1 Pressure tester P 378

System Checkout
General
The tester should b e connected into the control

pressure line at the mixture control unit.
The control pressure now is transmitted from the

mixture control unit, through the three-way
selector valve, to the control pressure regulators
for warm running compensation or throttle valve
position, respectively.
Thus, all pressure tests can be performed without

reconnecting the lines.
For better clarity, connecting points and lever

positions are referenced in the instructions given
below according to numbers shown in the adjacent
illustration.
Connecting and Bleeding Pressure

Tester
Detach pressure lines for control pressure regala-

tors for warm running compensation and throttle
valve position.
2. Insert a gasket in the special tool connector

and screw into the control pressure connection
of the mixture control unit in place of the
banjo bolt.

System Checkout
Connect pressure lines of control pressure

regulators for warm running compensation and
throttle valve position to second connector
using original banjo bolt and gaskets.
Turn selector valve to position E 2. Allow

pressure gauge to hang down (hose stretched)
and switch the ignition on. Turn lever of
three-way selector valve to. position 2 3
about 5 times at 10 -seconds intervals.
Checking "Cold" Control Pressure
This test can b e performed on a cold engine only.

It must definitely be performed when encountering
starting or warm-up problems.
Turn selector valve to position E 2. Switch

the ignition on.
Pressure specifications for the given ambient

air temperature are shown the diagram on
page 1.1 - 1/13, Testing and Adjustment
Specifications.
Excessive deviations from the specified

values are caused by a faulty control pressure
regulator for warm running compensation
which should be replaced in such cases.
System Checkout 11
C h e c k i n g "Warm" C o n t r o l Pressure
-
Refer to page 1.1 1/15 for engines with vacuum
controlled control pressure regulator for warm
running compensation.
This test can be lperformed on a warm or cold

engine.
1. Detach connecting wire from control pressure
regulator for warm running compensation.
Connect the regulator to B+ by means of a
jumper wire (fuse box in left side of engine
cornpartmen$ Switch the ignition on. M3ke
sure that the throttle plate is fully a t the
idle stop (hand throttle must be fully in).
2. The control pressure will rise slowly and must

reach the idle value shown under testing and
-
adjustment specifications, page 1 . 1 1/13. .
3. Open throttle about halfway by hand. The

control pressure should now rise to the speci-
fied part -load value.
4. Open throttle fully (full power stop). The

control pressure should now drop to the full-
power value.
If /excessive deviation is encountered,

proceed as follows:
a. Idle value: Idle value can be corrected

within certain limits. Refer to instructions
for checking or adjusting control pressure
regulator for throttle valve position. If
the required pressure cannot be obtained,
replace control pressure regulator for
throttle valve position.
b. Parkload value: Replace control pressure

.
c Full-power value: Replace control pressure
regulator formanuals
Downloaded from www.Manualslib.com throttle valve
search engineposition.
System Checkout
Checking System Pressure
1. Turn selector valve to position 3 and

switch the ignition on.
2. The system's pressure must a.gree with specifi-

cations on page 1.1-1/13. If it deviates from
specifications, correct position of pressure re-
lief valve in fuel distributor with shims.
Checking for Leakage
1. Detach electrical wire from the control pressure

regulator for warm running compensation. Using
a jumper wire, connect the control pressure
directly to B+ (fuse box on left side of engine
compartment).
Turn selector valve to position E 2 and
switch the ignition on.
Having attained the "warm" control pressure

value (part-load value), switch the ignition
off again and observe the pressure drop on
pressure gauge (the pressure will drop consid-
erably first). If the pressure continues to drop
too rapidly (see testing and adjustment speci-
fications), repeat check i n position X 3
of the selector valve to locate the problem.
If the same results are obtained, four compo-
nents can be responsible:
electrib fuel pump

Fuel distributor
injection valves
start (enrichment) valve
Injection valves and start valve are judged i n
separate tests. Replace electric fuel pump and
seal of pressure relief valve in fuel distributor
one after other and repeat e.ach test.
If leakage does not occur in 3 position of
the selector valve, the problem can be in the
control pressure regulators for warm running
compensation or throttle valve position.

System Checkout 11
To locate the problem, switch the ignition on

until control pressure has built up, then switch
the ignition off again. Detach return hose from
the control pressure regulator for warm running
compensation. With the remaining pressure being
1 . 5 to 2.4 bar , no fuel should come out
from the return connector of the control pressure
If some fuel should b e coming out, i t would in-

dicate that the control pressure regulator for
warm running compensation is leaking and should
b e replaced in such case.
If the leak is not in the control pressure regulator

for warm running compensation, it will b e found
in the control pressure regulator for throttle valve
position, in which case the control pressure
regulator for throttle valve position will have
to b e replaced.
Checking Injection Valves
Injection valves must b e removed for testing

(see page 2.2 - 1/13).
Testing is accomplished with a Bosch jet tester

EFEP 60 H, pressure gauge 0 to 6 bar, caliber
1.0, 100 mm dia., testing agent 01 61 v 11.
See testing and adjustment specifications for

opening pressure.
Tight: At a pressure of 0.5 bar less than opening

pressure there must not b e any drops falling within
1 5 sec..
See page 2 . 1 - 1 / 5 for testing procedure.

2 911 System Checkout
C H E C K I N G A U X I L I A R Y AIR D'EVICE
1. Check idle rpm with control pressure regulator

for throttle valve position connected (engine
warm).
2. Stop engine.
3. Remove filter housing with filter cartridge and

duct.
4 . Disconnect hose leading to auxiliary air device

above throttle valve a t throttle valve housing
and tightly seal the connector and hose.
5 . Install duct.
6 . Start engine and check idle rpm .
NOTE
If a change in rpm is noted, the auxiliary air
device is leaking. If the valve leaks considerably,
it will not be possible to adjust idle speed.
Replace auxiliary air device.

C I S T E S T I N G AND A D J U S T I N G S P E C I F I C A T I O N S ( 1 9 7 4 / 1 9 7 5 M o d e l s )
Test Step Test Specification References

-- -
6
Electric fuel pump, fuel delivery min. 850 c m /30 seconds Page 1.1 - 1 / 4
Control pressure "cold" (at correspond- Page 1.1 - 1/8

ing ambient air temperature) Page 1.1 - 1/16 a
Diagram for Control Pressure Diagram for Control Pressure
Regulator Regulator
Part No. 911. llO.927.00 Part No. 911.606.103. 01
(911.606.103.00) Bosch No. 0438.140.008
Bosch No. 0438.140. 001
bar
kp/cm2
Diagram for Control Pressure Regulator *

Part No. 911.606.105. 01
Bosch No. 0438.140. 009
Test vacuum: 520 - 546 mbar
(390 - 410 mmHg)
* only applicablemanuals
Downloaded from www.Manualslib.com for vacuum controlled
search engine control pressure regulator
2 9H
Test Step
System Checkou:t
Test Specification References
Control pressure "warm" Page 1.1 - 1/9
Throttle position version

Throttle valve position:
Idle, test specification 2.8 t o 3.0 bar
adjusting
specification 2.85 to 2.95 bar
Partial,throttle 3; 4 t o 3.8 bar
Full throttle 2; 6 t o 3 . 0 bar
Vacuum controlled version

Testing a t atmospheric
pressure (no vzcuum) 2 7 t o 3.1 bar
T o perform vacuum test,

connect vacuum pump
t o control pressure regu-
lator. Test pressure
520 - 546 mbar (390 -
410 mmHg) 3.4 t o 3.8 bar
System pressure Page 1.1 - 1/10

Test specification 4.5 t o 5 . 2 bar
Adjusting specification 4: 7 to 4.9 bar
Page 1.1 - 1/10

Leak test
(warm engine)
Min. pressure after
1 0 minutes 1 . 3 bar
20 minutes 1.1 bar
Fuel injectors Page 1.1 - 1/11

opening pressure 2: 5 to 3.6 bar Page 2 . 1 - 1/5

System Checkout 911 2
Electric fuel pump, Page 1.1 - 1 / 4

3
fuel delivery min. 850 c m /30 seconds
Control pressure "cold" Diagram for Control Pressure Regulator -

Page 1.1 1/16 a
(at corresponding ambient Part No. 911.606.105.03 and
air temperature) 911.606.105.04
Bosch No, 0438.140.017 and
0438.140. 033
Test vacuum: 520 - 546 mbar
(390 - 410 mmHg)
Control pressure "warm" Page 1.1 - 1 / 9
1976 Model
Testing atmospheric 2.7 to 3 . 1 bar
pressure (no vacuum)
T o perform vacuum test,
connect vacuum pump to
control pressure regulator.
Test pressure 520 - 546 mbar
(390 - 410 mmHg) 2.7 to 3 . 1 bar
-
At high idle speed
(approx. 1800 rpm) 3 . 4 to 3.8 bar

2 911 S y s t e m C h e c k o uI t
1977 Model
Testing at atmospheric 2.7 t o 3.1 bar

pressure (no vacuum)
To perform vacuum test,

connect vacuum pump to
control pressure regulator,
Test pressure 520 - 546
mbar (390'- 410 mmHg) 3.,4 to 3.8 bar
4 -
Test specification 4.,5 to 5 . 2 bar
Adjusting specification 4.,7 t o 4.9 bar
-
"
Leak test Page 1.1 - 1/10
(engine warm)
Min. pressure after 1 0 min 1.'3 bar
20 min 1.;1bar
I
opening pressure 2.5 t o 3.6 bar Page 2 . 1 - 1/5

System Checkout
Test Step I Test Specification I References
Electric fuel pump

fuel delivery 3
min. 1000 c m /30 seconds Page 1.1 - 1/4
Control pressure "cold"

(at corresponding ambient air temp. ) I
Diagram for Control Pressure Regulator Diagram for Control Pressure Regulato~
(from January 1979)
Part No. 911 606 105 05 Part No. 9 1 1 606 105,06
Bosch No. 0 438 140 045 Bosch No. 0 438 140 069
Test vacuum 460 - 600 mbar Test vacuum 450 - 550 mbar
(350 - 450 mmHg) (340 - 420 mmHg)
Control pressure "warm" -

Page 1.1 1/9
Testing at atmospheric pressure 2.7 to 3 . 1 bar
(no vacuum)
T O perform vacuum test, connect
vacuum pump to control pressure
regulator 3. 2 to 3. 6 bar

Test specification 4. 5 to 5. 2 bar
Adjusting specification 4 . 7 to 4 . 9 bar
Leak test Page 1.1- 1/10

(warm engine)
Min. pressure after 10 min. 1. 3 bar
20 min. 1.1 bar
*

opening pressure 2, 5 t o 3.6 bar
Page 2 . 1 - 1 / 5

2 911 System Checkout I
C I S TESTING AND ADJUSTING SPECIFICATIONS

(1980 Model with Oxygen Sensor)
Electric fuel pump, Page 1.1 - 1 / 4

fuel delivery min. 1000 cm5/30 seconds
-
Control pressure "cold" Diagram for Warm- up Regulator Page 1.1 - 1/8
(at corresponding ambient Part No. 911. 606.105. 07
air temperature) Bosch No. 0438 140 072
Control pressure "warm" 3 . 4 to 3, 8 bar Page 1.1 - 1/9

Test specification 4. 5 to 5. 2 bar
Adjusting specification 4 . 7 t o 4 . 9 bar

(warm engine)
Min. pressure after 1 0 min. 1. 3 bar
20 min. 1.1 bar

opening pressure 2. 5 t o 3. 6 bar Page 2 . 1 - 1 / 5

Checking 911 2
T E S T I N G AND A D J U S T I N G VALUES - 9 1 1 SC
(1981 Models with Oxygen Sensor Control)
Test Step Testing/Adjusting Value Special Instruction
Electric fuel pump

Delivery rate at least 1000 cc/30 sec. -
Page 1.1 1/4
Control pressure "cold" Diagram for warm-up control Page 1.1 - 1/8
Part No. 911.606.105.08
Bosch No, 0438.140.090
Control pressure "warm " 3.4 ... 3.8 bar Page 1.1 - 1/9
System pressure -
Page 1.1 1/10
Test value 4.5 ... 5.2 bar
Adjusting value 4.7 ... 4.9 bar

(engine warm)
Min. Pressure after 10 min. 1.3 bar
after 20 min, 1.1 bar
Fuel injectors -
Page 1.1 1/11
Opening pressure 2.5 ... 3.6 bar Page 2.1 - 1/5

911 Checking
Test Step I Testing and Adjusting Valuer
Idle setting USA and California imd

Canada High Altitude States
Manual transm. 900

+- 50 900 '1- 50
to 1977 models
Sportomatic 950 f 50
to 1977 models
-
Idle speed (rpm) 1977 models 950 50 1000 2 50

1978/79 models 950 f 50 950 + 50
1980 models 1
I
900 2 50 1
I
900250
1 9 8 1 models 1 900 f 50 900 + 50

1973 models 1.5 to 2.0 1. 5 to 2.0
(2.4 ltr. )
1974 models 1.5 to 2.5 1. 5 to 2.5

42.7 ltr. )
CO content (70) 1 1975 models I 1.7 to 2. 0 I 1.5 to 2.0
1976 models 2.0 to 4.0 * 2.0 to 4.0 *

1 1977 models 11.5to3.0* 11.5t03.0*
1978/79 models 1.5 to 3.5 * 1.5 to 3.5 *
* Air pump disconnected.
;k * Measured in front of catalytqc converter and with

oxygen sensor plug disconnected.

System Checkout 11
C H E C K I N G C O N T R O L PRESSURE OF V A C U U M - C O N T R O L L E D
C O N T R O L PRESSURE R E G U L A T O R
Connect and bleed pressure gauge.
Refer to page 1.1 - 1/7.
Note
Connect pressure line (of control pressure regula-

tor only) to second connector of pressure tester
since the throttle valve control pressure regulator
has been eliminated.
C H E C K I N G " C O L D " C O N T R O L PRESS1JRE
Refer to page i. 1- 1/16 a.
C H E C K I N G " W A R M " C O N T R O L PRESSURE
This test can be done on a cold or warm engine.
1. Remove mounting plate cover in engine corn-

partment.
2. Remove standard relay at center of relay plate.
Note
The standard relay for the control pressure regulator

of some vehicles is located to the rear, right side .
of the relay plate - and not as illustrated. Also
refer to Group 9 , Page 0.1 - 4/3.
CAUTION
With the.JS76 Model the relay is in luggage corn-
partrnent (rear relay as seen in driving direction).
3. Bridge terminals 87 a and 30 of a spare relay.
4. Place this modified relay in relay plate instead

of the original relay.

2 911 System Checkout--'
5. Turn on ignition (fuel pump runs).,
6. The control pressure rises slowly and must

i
stabilize at 2.9 - 0.20 bar. The regulating
time span varies with the ambienr temperature,
Replace control pressure regulator (for warm
running compensation) if necessary.
CAUTION
Reinstall original relay after testing!
C H E C K I N G " I D L E " C O N T R O L PRESSURE
Start engine.
Control pressure must be 3. 6

i
- 0. 20 bar at idle
-t
speed of 900 - 50 rpm.
4-
1978 and later models: 3.4 - 0.20 bar a t idle
i
speed of 900 - 50 rpm.
CAUTION
Position selector valve a t 2 for this control

pressure test.

System Checkout 91, 2
C H E C K I N G " C O L D " C O N T R O L PRESSURE
( v a c u u m c o n t r o l l e d ( w a r m - up) c o n t r o l p r e s s u r e r e g u l a t o r )
TOOLS
1 Hand vacuum pump US 8026

I! System Checkout;
,
C H E C K I N G " C O L D " C O N T R O L PRESSURE
(vacuum controlled (warm- up) control pressure regulator)
Note 5. Bridge electric safety circuit, by pulling off

standard relay in trunk (rear relay looking
Engine must b e absolutely cold. forward) and replacing with a relay of which
terminals 87 a and 30 are bridged or by pulling
From 1975 models diagram values are only for off wire plugs on air flow sensor.
the vacuum controlled testing method,in the case
of vacuum controlled (warm-up) contrbl pressure
regulator.
1. Connect and bleed pressure tester. Set valve

to position 2.
2. Remove hose between heater blow+ and warm

air neck.
3. Pull off vacuum hose from (warm-qp) control

pressure regulator and connect hose:/manual
vacuum pump (US 8026) to connection of 6. Turn on ignition (fuel pump should run).
(warm-up) control pressure regulator.
I
7. Adjust vacuum to specified value with the

manual vacuum pump (9160) - see page
1.1 - 1/13.
8. Refer to diagram below "Testing and Adjusting

Specifications" on page 4. I. - 1 / 1 3 for speci-
fied pressure corresponding with actual outside
temperature.
4. Pull off wire plug from (warm-up) control

pressure regulator.
Checking 11
C H E C K I N G A U X I L I A R Y AIR REGULATOR
1. Remove auxiliary air regulator.
Connect ohmmeter to both terminals of

auxiliary air regulator and check.
Specifications: approx 33 ohm
Check power supply of auxiliary air regulator.

a) Pull off standard relay in luggage compart -
ment (rear relay as seen in driving direction).
b) Bridge terminals 30 and 87a, turn on ignition.
c) Connect test lamp to both auxiliary air
regulator terminals from which the plugs
have been pulled off.
4. Refer to "Troubleshooting Automatic Choke"

for other checks.
C H E C K I N G A U X I L I A R Y AIR VALVE
Refer to "Troubleshooting Automatic Choke".

Checking
C H E C K I N G O P E R A T I O N OF S A F E T Y S W I T C H
1. Disconnect rubber straps and remove air

cleaner cover as well as-the air cleaner
cartridge.
2. Turn on ignition; fuel pump should not run.
3. Lift sensor plate lever; slightest movement

should start fuel pump.

Checking
CHECKING THERMOVALVE
1. Detach vacuum hose (1) at warm-up regulator. 4. Blow into detached vacuum hose (from warm-
up regulator) by mouth.
Valve must open after 10 to 30 seconds, if

thermovalve's ambient temperature is 20 to
30' C/68 to 86' F.
Replace thermovalve, if necessary.
2. Bridge terminals 30 and 87a of fuel pump

relay in luggage compartment (rear relay as
seen in driving direction .
3. Turn on ignition and stop time until switched

in.

System Checkout
C I S PROBLEMS A N D REMEDIES
A properly working ignition system and good

mechanical condition of the engine are pre-
requisites for a successful CIS problem diagnosis.
Problem
Engine does not start or is difficult to start when cold
Engine does not start or is difficult to start when warm
Engine misses when car is driven
Unsatisfactory engine performance
Excessive fuel consumption
Engine backfires into intake pipe

- -
Engine dieseling
I Rough idle during warmup
I Rough idle when warm
I Idle speed cannot be adjusted
I CO emissions too low at idle
I CO emissions too high at idle

Pneumatic valve leaking Function check
I
8 I Cold start enrichment valve does not open Visual inspection
I -
Cold start enrichment valve leaking Visual inspection
I
8 Defective injection valve Visual inspection
Air flow sensor plate or control plunger binding Function check

--
8 Air flow sensor plate not resting properly at stop Visual inspection
Throttle valve does not open fully Visual check (adjust)
Basic adjustment (idle) too rich CO test (adjust)

.- .-
-Basi.c-a.djustm.ent..(id.le) -too-lea n... .. . . -CO-test-(-adjust)-
Dirty fuel system Clean
8 Electric fuel pump not running Check
@ Defective reversal valve in fuel pump Replace fuel pump
F i i
inoperative or hand throttle out Adjust
of adjustment

Checking 911 2
TROUBLESHOOTING A U T O M A T I C CHOKE - 1 9 7 6 MODEL
Problem: Speed remains too high at high engine temperatures or no speed

increase on cold engine.
Possible Cause: Auxiliary air regulator or auxiliary air valve defective.
Remedy: 1. Disconnect top control line at auxiliary air valve and plug.
P r o b 1 e m c o r r e c t e d : Replace auxiliary air valve.

P r o b l e m u n c h a n g e d : Auxiliary air valve good.
2. C o 1d e n g i n e : If there is no increase in speed, auxiliary

air regulator is defective.
W a r m e n g i n e: Disconnect one hose at auxiliary air regulatdr and

plug both openings.
S p e e d t o o h i g h : auxiliary air valve defective
S p ee d d r o p s: auxiliary air regulator

defective

VACUUM SYSTEM LAYOUT (1978 Models)

1 - Throttle housing 6 - Ignition distributor
2 - Auxiliary air valve 7 - Diverter valve
3 - Auxiliary air regulator 8 - Deceleration valve
4 - Thermo valve 9 - Vacuum source for auxiliary air valve and auxiliary air regulator
5 - (Warm-up) control pressure regulator 10 - Vacuum source for power brake

System Checkout 9H 2
L A Y O U T O F FUEL A N D V A C U U M L I N E S - 9 1 1 SC ( f r o m 1 9 8 0 M o d e l )
Fuel lines
Vacuum lines
Throttle housing 8 - Frequency valve

Mixture control unit 9 - Ignition distributor
Fuel injector 10 - Fuel pump
(Warm- up) control pressure regulator 11 - Fuel reservoir
Cold start valve 1 2 - Fuel filter
Auxiliary air valve 1 3 - Deceleration valve
Auxiliary air regulator 14 - Vacuum booster

Servicing 911 2
R E M O V I N G A N D I N S T A L L I N G REGULATOR H O U S I N G
Removing
1. Detach hot air hose between left heat 2. Remove 3 retaining bolts from left velocity
exchanger and regulator housing, then stack and remove regulator housing.
remove hose between regulator housing
and air cleaner intake.
Installing
Adjust fresh air flap (see page 2.1-1/2).
C H E C K I N G O P E R A T I O N OF I N D U C T I O N AIR P R E H E A T I N G S Y S T E M
1. Hot air flap must be open when engine is

cold. This can be checked through the
bypass hole in the regulator housing. The
hot air flap closes the bypass duct and stays
in place under spring tension.

1 Servicing
2. Warm up engine at about 2500 rpm. The hot fs controlled by a

3. If the hot air flap, which
air flap must close after about 3-4 minutes. thermostat, does not work,, replace the
Check flap position through bypass hole. regulator housing.
N o t e : The thermostat in the regulator

housing can not be replaced. :Replace the
entire control box.
A D J U S T I N G FRESH AIR FLAP
1. Adjust :fresh air flap with throttle valve

linkage set in idle position.
2. Adjust roller for fresh air flap lever with

both nuts so that the roller touches the
control lever without play. Lock the nut.
Note:
After adjusting, check that the fresh air flap

begins to open with throttle valves set at 20'.

Servicing 911
REPLACING FRESH AIR FLAP LEVER
Caution
Prevent nut from falling into regulator housing
by holding nut of retaining bolt during removal.
1. Remove bolt and lever.

Note:
Hold lock nut with punch or scriber. The
nut can fall into the control box.
1 Nut 3 Washer 5 Control box

Downloaded from 2 Spring washer manuals search engine
www.Manualslib.com 4 Lever 6 Nut
911 Servicing
I N S T A L L I N G HOSE CLAMPS F O R COLD S T A R T ENRICHMENT
Tighten hose clamps with VW special tool

Nr. ASE 000 049.
Note:
The hose clamps can be used only once.

FUEL I N J E C T I O N
TOOLS
N 0. Description Special Tool Remarks
1 Injection nozzle tester with Use Bosch or similar injection

two pressure gauges nozzle tester. Pressure gauge
range: 0-25 k g /cm 2 (0-355 psi)
Line with fittings Use Bosch EF 8040/30 or similar
Pressure gauge 0-6 k p /cm 2 K1. 1.0 For CIS

11 servicing
C H E C K I N G FUEL I N J E C T O R S
General
Instructions for checking the injectors apply to vehicles equipped with either the mec$anical or
CIS fuel injection.
The injector tester is used for checking opening pressure, spray pattern, and leakage of injectors.
Fill container of the tester with testing oil and bleed tester prior to testing the injectors. Use only
testing oil 0 1 6 1 v 11.
Under no c i r c u m s t a n c e s should gasoline b e used.
When testing injectors for the mechanical injection system, use pressure gauge EF 1687 239 000
-
0 25 bar. When testing CIS injectors use pressure gauge with calibrations 0 - 6 bar. ,
Bleeding t h e Tester
1. Open bleeder screw. 2. Open pressure gauge valve.
Actuate hand lever until testing oil comes out

of the bleeder without air bubbles.
Tighten bleeder screw.
Connect injector to pressure line but do not

tighten connection. Actuate: hand lever until
air bubbles cease to come out a t the coupling
nut.
Tighten injector to pressure iine.

Replace injector, if opening pressure is outside
of these tolerances.
Checking Injectors
Note Caution
T h e injectors of one engine can b e replaced se- When pressure gauge shut-off valve is open
parately. increase pressure slowly- to avoM damag.ing.the
Defective injectors cannot b e repaired, but must pressure gauge.
b e replaced.
Checking
Checking for Leaks
Operate hand lever slowly (about 2 sec./stroke)
with the pressure gauge shut-off valve open. In
this manner a valve leaking because of a large
Mechanical Fuel Injection
particle of dirt can b e recognized (tight spray
on valve, pressure built up to max. 1.5 bar).
1. Open shut-off valve on pressure gauge until
t h e pressure on t h e pressure gauge has dropped
below 1 5 bar.
Checking Opening Pressure

2. Operate hand lever slowly until a pressure of
2.0 bar less than the measured opening pressure
is reached.
Flush injector with the pressure gauge shut-
off valve closed by moving lever back and
forth several times quickly.
No drops should form on t h e valve within 1 5
seconds when the pressure is 2 bar less than t h e
Open pressure gauge shut-off valve and read
opening pressure.
opening pressure on pressure gauge while
moving lever slowly (about 2 sec./stroke).
T h e opening pressure is:

15 to 18 bar (mechanical injection system)
2, 5 t o 3, 6 bar (continuous fuel injection)

911 Servicing
Continuous Fuel Injection
1. Close pressure gauge shut-off valve and flush

injector by operating lever many times.
2. Open shut-off valve and increase pressure

slowly to 0.5 bar less than the previously
measured opening pressure (but not below
2, 3 barJ, and hold.
No drops should form on injector within 1 5
seconds.
Humming Test/Checking Spray Pattern
1. Close pressure gauge shut-off valve and flush

injector by operating lever many times (0.5
sec./stroke) .
2. Then reduce lever movement to about 1 sec./

stroke. This must cause injector to hum. No
drops should form on injector. A tight spray
pattern is not allowable. An atomized, one
0
-
sided spray pattern of about 35 is permissible.

Servicing !3II 2
DISASSEMBLING A N D REASSEMBLING

911 Servicing
-
Note when
No. Description removing installing References
-
1 Rubber strap
2 Intake horn
3 Filter cartridge Replace if necessary
4 Duct
5 Hose clamp
6 Hose clamp
7 Banjo bolt
8 Gasket Replace
9 Stud
10 Gasket Replace
11 Plug
12 Allen bolt Tighten lightly, then Page 2.2 - l/V

loosen by 1 turn
13 Spring
14 Washer
15 Mixture control unit. Page 2.2 - 1/7
16 Gasket Replace
17 Allen bolt
18 Spring washer
19 Throttle valve housing Page 2.2 - 1/8
20 O-ring Replace
21 Holder
22 Allen bolt
23 Spring washer
24 Microswitch Page 3.2 - 1/4

-
Servicing
911 2
Note when
Description Reference
removing installing
Allen bolt
Lock washer Replace
Washer
Control pressure regula-

tor for throttle valve
posit ion Page 2.2 - 1/8
Spring
Bolt
Lock washer
Terminal block
Allen bolt
Washer
Auxiliary air device
Spacer sleeve
Allen bolt
Spring washer
Start (enrichment) valve Page 2 . 2 - 1/10

O-ring Replace
Bolt
Spring washer
Washer
Support
Rubber/metal cushion

911 servicing
Note when
Description Reference
removing installing
Support
Sheet metal screw
Holder
Hose clamp
Flame trap cartridge
Plug
Gasket Replace
Allen bolt
Spring washer
Control pressure regula

tor for warm running Page 2.2 - l/9
compensation
Nut
Intake pipe
Hose clamp
Rubber muff Replace if necessary
Gasket
Injection valve Page 2.2 - 1/13

Rubber bushing
Spring
Pull rod
Nut
Spring washer
Bracket
Intake manifold

911 Servicing
Note when
Designation References
removing installing
Injection line
Supply line t o control

pressure regulator for
warm running compensa
tion Page 2.2 - 1/15
Supply line t o control
throttle valve position Page 2.2 - 1/15
Supply line from fuel
filter to mixture control Install in proper Page 2 . 2 - 1/15
unit position
Supply line to start

(enrichment) valve
Return line from mixturc

control unit to fuel tank
Return line from control

throttle valve position
to fuel tank
Return line from control

pressure regulator for W E
running compensation
to fuel tank
Connector for return
flow hoses
Vacuum hose
Vacuum hose
Vacuum hose
Vacuum hose

Servicing 9H 2
REMOVING AND INSTALLING MIXTURE CONTROL U N I T
Removal
Disconnect all fuel lines and hoses from the

mixture control unit. Detach fuel supply line
from fuel filter.
NOTE
Use rag to prevent fuel spillage.
2 . Unscrew 6 Allen bolts and remove with

spring and plate.
3. Remove mixture control unit together with

gasket.
Installation
1. Watch proper location of gasket.
2 . Tighten Allen bolts to bottom, then back off

1 complete turn.
3. Use new gaskets in fuel line connections.
4. Bleed fuel line system (see page 2.2 - 1/17)

911 servicing
REMOVING AND I N S T A L L I N G T H R O T T L E VALVE HOUSING AND CONTROL

PRESSURE R E G U L A T O R ( T H R O T T L E V A L V E P O S I T I O N )
Removal
1. Disconnect fuel line, which connects mixture

control unit with the control pressure regulator
for throttle valve positibn, from the mixture
control unit.
2 . Disconnect fuel hose from reiulator .
3 . Remove 4 Allen bolts and withdraw throttle

valve housing with control pressure regulator
for throttle valve position.
4 . Remove 2 Allen bolts and remove regulator from

throttle valve housing.
Installation
1. Check proper positioning of the O-ring for the

throttle valve housing.
2 . Adjust control pressure regulator for throttle

valve position (see page 3 . 2 .- 1/5).
3. Bleed fuel line system (see p&e 2 . 2 - 1/17).

Servicing
911 2
R E M O V I N G A N D I N S T A L L I N G C O N T R O L PRESSURE R E G U L A T O R (WARM R U N N I N G
COMPENSATION)
1. Disconnect ground strap from both batteries.
2 . Detach electrical connections
3 . Disconnect .fuel hose.
4. Remove Allen bolts.
5. Remove fuel l i n e which connects mixture

control unit with t h e control pressure regulator
for warm r u n n b g compensation from t h e
mixture control unit.
NOTE
Use rag t o prevent fuel spillage.
6 . Bleed fuel l i n e system (see page 2.2 - 1/17).

11 Servicing
REMOVING A N D I N S T A L L I N G S T A R T (ENRICHMENT) VALVE
Removal
2. Remove auxiliary air device from throttle

valve housing.
3. Detach twin electrical connector from. t h e

start (enrichment) valve.
4 . Remove Allen bolts.
5 . Loosen hose c l a m p and detach fuel line. .
1nstallatio.n
Be sure O+ring is prdperly .
NOTE
Electr.iZ:al connector must point, upward.
Bleed fuel l i n e system (see page 2 . 2 - 1/17).

servicing 911
R E M O V I N G AND I N S T A L L I N G FUEL F I L T E R
2. Remove fuel line coupling nut.
NOTE
Use rag to prevent fuel spillage.
Remove retaining clamp and hose clamp and

remove filter.
NOTE
Use an appropriate vessel to collect fuel
which may be running out.
Do not overtighten the retaining strap since

this could deform the filter assembly.
5. Check all connections for leaks.
6. Bleed fuel line system (see page 2.2 - 1/17)

1 Servicing
R E M O V I N G A N D I N S T A L L I N G FUEL PRESSURE A C C U M U L A T O R
1. Unscrew coupling nut from f u d supply line at

the fuel pressure accumulator.
NOTE
Use rags to prevent fuel spillage.
2 . Remove attaching clamp.
3. Loosen hose clamp, withdraw fuel pressure

accumulator and plug fuel hose with an
appropriate plug.
4. Check all connections for leaks.
Arrangement from 19 77 Models

5. Bleed fuel line system (see page 2.2 - 1/17).

REMOVING AND INSTALLING INJECTION VALVES
TOOLS
No Description Special Tool Remarks
1 Remover P 384

911 Servicing
Removal
1. Unscrew coupling nut from the injection line

at the injection valve.
2. Install special tool P 384 and pull injection

valve out.
3. If rubber bushing remains in the support sleeve,

take the bushing out with a screwdriver.
NOTE
Avoid damaging the supportirlg sleeve.
Installation
1. Inspect rubber bushing, replace if necessary.
2 . Use a drop of engine oil when installing the

bushing.
3. Press injection valve firmly into the supporting

sleeve to stop.
The rubber bushing must be seated below the
bulge in the supporting sleeve:.
4. Check fuel lines for leaks.
5. Bleed fuel line system (see page 2.2 - 1/17).

Servicing 911 2
R E P L A C I N G P L A S T I C FUEL LINES
TOOLS
No Description Special Tools Remarks

-
1 Installer P 385

11 servicing
The mixture control unit, control pressure regula-

tor for throttle valve position and control pressure
regulator for warm running compensation replace-
ments are furnished with plastic fuel lines attached.
Defective plastic fuel lines can b e replaced indivi-
dually.
1. Using a soldering iron, heat defective fuel

line in the connector area and pull the l i n e
off.
2. Mount replacement part in a vise with soft

jaw protectors.
3. Mount fuel line in special tool P 385, allowing

push-on section to protrude from the tool.
4. Push dry fuel line onto the connector.
NOTE
Make sure that line is properly positioned.

Servicing 911 2
BLEEDING FUEL LINE S Y S T E M
T h e fuel injection system must b e bled (prior to

starting) whenever a fuel line system component
has been replaced.
1. Remove intake horn with filter cartridge.
2 . S-witch the ignition on.
Press diaphragm up by hand to stop (for 1

second to a maximum of 5 seconds) until the
fuel lines are filled and t h e injection valves
spray fuel audibly.

Repairs
D I S M A N T L I N G AND ASSEMBLING MIXTURE CONTROL U N I T

- Note during:
No. Description removal installat ion remarks
-
1 Plug Torque to 1.3 to
1.5 mkp
2 Seal A 10 x 13.51 Replace
3 Shim 2.2 - 2/8
4 Spring
5 Piston Use conical wood Replace fuel distribu-

peg to drive out tor if damaged
6 Seal
7 Capscrew M 5 x 50 Torque t o 3 2 - 38
cmkp
8 Fuel distributor Don't let control do not dismantle

plunger fall out
9 Seal Replace
10 Nut
11 Washer
12 Capscrew Torque to 47 - 53
cmkp
13 Insulator
14 Spring Replace if necessary;

install correctly
15 Clip Replace if necessary;

install correctly
16 Stop Install correctly
17 Hex head screw Torque to 50 55 -

cmkp and apply liquid
thread locking com-
pound
18 Washer
19 Sensor plate Check, replace if

necessary

Repairs
911
- Note during:
No, Description
- removal installation remarks
20 Circlip First remove this Install with sharp edgc

circlip facing outward
21 Cover
22 Seal Replace
23 Spring
24 Ball Coat with silicone

grease
25 Circlip First install this cir-

clip with sharp edge
facing outward
26 Cover
27 Seal Replace
28 Ball Coat with silicone

grease
29 Capscrew Torque t o 47 - 53
cmkp a n apply liquid
thread locking com-
pound
30 Pin Check, replace if

necessary
31 Counterweight
32 Operating lever Check
33 Follower Check if bearing play

is too large, needle
bearing is damaged,
mixture control screw
is damaged or rusted,
replace parts if neces-
sary
34 Plug
35 Air flow sensor hsg. Coat bearing bores

with silicone grease

Rep a i r s
I N S T R U C T I O N S FOR D I S M A N T L I N G A N D ASSEMBLING M I X T U R E C O N T R O L U N I T
REMOVING A N D I N S T A L L I N G SENSOR PLATE
Removing
1. Remove fuel distributor.
2. Clamp mixture contrdl unit vertically in vise

with plastic guards on jaws. Clamp mixture
control unit at bend i n narrow section of
operating lever.
3. Loosen sensor plate mounting screw and re-

move sensor plate.
Installing
1. Clamp mixture control unit horizontally.

Coat sensor plate mounting screw with "Loc-
tite" or "Omnifit". Place new or old sensor
plate in center of operating lever and slightly
tighten screw by hand.
2. Measure gap between sensor plate and air

venturi. A visible gap of about 0.10 mm
should be seen all around ,the sensor plate.

CAUTION
This test requires that the sensor plate be set at

the correct height (rest position).
The upper edge of the sensor plate must be flush
with the lower edge of venturi.
The height position can be corrected by bending

the wire clip (refer to page 1.1 - 1/3).
3. Clamp mixture control unit vertically in vise

with plastic guards an jaws. Clamp mixture
unit a t bend in narrow section of operating
lever (housing must be able to be moved to-
ward vise).
Torque hex head screw to 50 - 55 cmkp.
4. Recheck sensor plate adjustment.

L O C A T I N G OPERATING LEVER W I T H FOLLOWER I N AIR FLOW SENSOR H O U S I N G
1. Apply "Loctite" or "Omnifit" to counterweight

mounting screw and tighten m e w slightly.
2. Adjust operating lever in air flow sensor hous-

ing.
3. Tighten mounting screw to 47 - 53 cmkp.

Repairing 9H 2
B A S I C A D J U S T M E N T OF M I X T U R E C O N T R O L S C R E W A F T E R R E P L A C E M E N T O F
O P E R A T I N G LEVER
Caution Caution
This test requires that the sensor plate b e positio- Never apply downward pressure t o adjusting
ned correctly (rest position). wrench during adjustments, since this could
change t h e injection timing.
1. Install mixture control unit. 6. Run engine to o g e r a t i n ~temperature (oil

temperature 80 to 90 C) and adjust i d l e
speed and CO level t o their final specified
values.
2. Bleed fuel lines. (Disconnect injectors and

hold in a container. Move sensor p l a t e by hand
many times).
3. Use adjusting wrench P 377 to initially turn

the mixture control screw counterclockwise
about 1 - 2 turns.
4. Turn on ignition, pull plugs off safety switch

on air flow sensor or fuel pump relay.
5. Turn mixture control screw clockwise until

the injectors just barely eject. From this
point turn t h e mixture control screw back, i.e.
counterclockwise, by one half turn.
Install injectors.

911 Repairs
REPLACING P I S T O N SEAL OF FUEL DISTRIBUTOR PRESSURE RELIEF VALVE
1. Clean fuel thoroughly.
2. Remove plug, being careful of shim in plug.
3. Remove spring and piston (if necessary, use

conical wood peg).
4. Replace seal on conical section of piston, be-

ing careful not do damage new seal and piston.
1. Plug
2. Seal
3. Shim
4. Spring
5. Piston 5. Install plug with shim (as found while removing)
6. Seal and new seal. Torque screw to 1.3 - 1.5 mkp.
6. Check pressure of system (refer to page 1.1 -

1/10), correcting with shims if necessary.

Repairing 11
DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL U N I T
- MODIFICATIONS from April, 1976 -

Repairing
Note when
Description Remarks
removing installing
Plug Torque to 13-15 Nm

(1.3-1.5 kpm)
Seal Replace
Shim Quantity as
0.1 m m thick required
0.5 m m thick
Spring
Pist on Pull out with Check, replace entire

tapered wood distributor if damaged
dowel (fitted part)
O-ring Be careful not to Replace

damage piston
Fillister head cap Torque to 3.5 Nm

screw (0.35 kpm)
Fuel distributor Be careful not to Check control piston, Never disassemble

let control piston clean with gasoline,
fall out install with chamfer
facing down.
Seal Replace
Plug
Nut
Washer
Fillister head cap Torque to 4.7-5.3 Nm

screw (0.47 -0.53 kpm)
Washer
Insulator
Fillister head cap Torque t o 4.7-5.3 Nm

screw (0.47-0.53 kpm)
Washer
Plug connector Install in correct

position

-
Repairing 91, 2
Note when
removing installing
-
19 Nut
20 Stop bracket
21 Plastic insulator
22 Nut
23 Adjusting screw
24 Leaf spring
25 Bolt Torque to 5.0-5.5 Nm

(0.50-0.55 kpm) and
apply liquid locking
agent
26 Spring washer
27 Sensor plate Check, replace if

necessary
28 Circlip Sharp side faces out
29 End plate
30 Seal
31 Spring
32 Ball Lubricate with

(Bosch Ft 2 v 2)
silicone grease
33 Circlip
34 End plate
35 Seal
36 Ball
. 37 Fillister head cap Torque to 4.7-5.3 Nm

screw (0.47-0.53 kpm and
apply liquid locking
agent
-
38 Counterweight

1 Repairing
Note when
No. Description iemarks
removing installing
Pivot pin
Operating lever
Adjusting lever Check whether bearing

play is excessive or
needle bearing is d a m -
aged, replace if neces-
sary
Mixture control screw
Air flow sensor housing Lubricate bearing bores

with (Bosch Ft 2 v 2)
silicone grease
DISASSEMBLING AND ASSEMBLING INSTRUCTIONS
Engage adjusting lever in spring holder by 9

applying sufficient pressure.
I

Repairs
REMOVING A N D I N S T A L L I N G V A C U U M C O N T R O L L E D W A R M - U P REGULATOR
Removing
1. Disconnect battery.
2. Disconnect warm intake air connection.
3. Release fuel system pressure by loosening the

warm-up regulator pressure line connection a t
the mixture control unit. Wrap a rag around
this connection when loosening to catch
escaping fuel. Retighten lines afterwards.
4. Remove air pump air filter.
5. Remove left and right heater hoses, loosen

clamp at heater blower and swing heater
blower upward.
6. Loosen and remove clamp holding hoses and

lines (I), vacuum hose clamp (Z), plug connec-
tor (3), fuel return line (4) and fuel feed line
(5).
7. Loosen two socket head capscrews and remove

warm-up regulator.

1 Repairs '
Installing
Torque fuel return line hollow bolt to 1.1 mkp.
Note
The bottom of the warm-up regulator and the

holding plate must b e clean to assure proper
ventilation for the warm-up regulator.

Repairs
~ --
911 2
REMOVING A N D I N S T A L L I N G AUXILIARY AIR REGULATOR
Pull wire plugs off of auxiliary air regulator.
2. Loosen hose clamps.
Loosen socket head cap screws and remove

auxiliary air regulator.
REMOVING A N D INSTALLING AUXILIARY AIR VALVE
1. Loosen hose clamps and pull hoses off of

auxiliary air valve.
2. Loosen mounting screws and remove valve.

911 Repairing
REMOVING AND INSTALLING THERMOVALVE
Removing
1. Remove formed hose, left heater hose and

right heater hose. Disconnect electric wires,
loosen clamp and remove heater blower.
2. Disconnect electric plug a t thermovalve.

Detach hoses, unscrew bolt and remove thermo-
valve.
Installing
Connect vacuum hoses properly. Outer connec-

tion on thermovalve (1) to control pressure regu-
lator connection ( I ) , see photos below.

Servicing 11
REMOVING A N D I N S T A L L I N G DIVERTER VALVE
1. Loosen hose clamps and detach hose between

diverter valve and check valve as well as hose
between diverter valve and air pump.
2. Loosen nuts on air pump carrier and remove

diverter valve with holder, pulling off vacuum
hose at same time.

Servicing 11 2
C L E A N I N G FUEL T A N K PLUG W I T H B U I L T - I N C I S FILTER
Fuel supply problems can b e traced, among other

things, to a dirty filter in the fuel tank plug.
Use new rubber gasket during reassembly.
Tank plug tightening torque is 0.8 - 0.9 mkp.
1. Fuel tank
2. Rubber gasket
3. Tank plug with filter

Repairing 911 2
R E M O V I N G A N D I N S T A L L I N G FUEL T A N K ( 8 0 L i t e r S t e e l T a n k f r o m 1 9 7 4 M o d e l s )
Removing
1. Take off bottom guard. 6. Pull off connecting hose and remove fuel tank
from above.
2. Open plug and drain fuel. Then detach fuel

lines at tank
Note
Observe safety regulations when draining fuel.
Installing
From 1980 models the tank vent neck as a 1 4 mrn

diameter (1974 t o 1979 models: 9 mm diameter).
After depletion of tanks with 9 mrn neck, only new
Pull off tank vent hose and fuel gauge wire plug tanks with 1 4 mrn neck will be available from parts.
(first unscrew cover on top of plug). An adapter w i l l be required between the connector
(Y-piece) and tank when installing this tank in
cars prior t o 1980 model.
Remove holders for fuel tank, If necessary,
loosen battery and push battery away.
1. paste new tank seal on tank. Install tank.
Loosen hose clamp on connecting hose between

filler neck and tank. 2, Clean filter screen on fuel drain plug. Use a new
round cord seal and tighten drain plug t o speci-
fied torque (see page 2.3 - 1/2).
Make sure hoses are connected correctly and tight.

Repairs 11
R E M O V I N G A N D I N S T A L L I N G FUEL P U M P - 1 9 7 6 MODEL
Removing 4. Loosen intake fuel hose clamp and remove

fuel pump.
1. Remove guard.
2. Loosen strap and pull fuel pump down a

little.
Installing
1.. Install pressure fuel hose hollow bolt with

-
new seals. Torque to 1 6 2 3 Nm/1.6 -
2.3 mkp.
3. Clamp intake fuel hose shut with a pinch

clamp. Pull off wire connectors, remove Note
pressure fuel hose and catch escaping fuel. Hollow bolt seals have different thicknesses
and must be installed correctly. Place thicker
seal between coupling and pump body; thinner
seal between coupling and head of hollow
bolt.
2. Install wire connectors on to appropriate

terminals.

Repairs
P
3. Pull cover over wire connectors and position

rubber ring for installation.
Note
To prevent corrosion, make sure that cover fits
properly.
4. Slide intake fuel hose on pump nipple and

secure with hose clamp.
5. Remove pinch clamp from intake fuel hose.
6. Position fuel pump for installation (top

electrical terminal inclined back about
0
35 )and secure with strap.
7. Check hose connections for leaks.
8. Install guard.

Repairing 911 2
LAYOUT DRAWING OF CHECK VALVES ON FUEL PUMPS
-
No. Description Note When: Special
Installing Instructions
Removing
-
1 Fuel pump (long neck
version with integrated
check valve)
2 Fuel pump
3 Check valve with seal Always replace seal;

tightening torque:
20 Nm
5 Seal Always replace
I Cap nut Tightening torque:

20 Nm
-

11 Repairing
R E P L A C I N G C H E C K VALVE
Important: Observe safety pre-cautions for wdrk on

fuel systems!
1. Remove bottom guard.
2. Pinch fuel feed hose with a shut-off device and

remove pressure hose end by unscrewing cap nut
on fuel pump. Catch escaping fuel.
3. Screw in new check valve with a new seal.For

iong neck version fuel pumps this new check.
v a h e is installed in addirion to the check valve
integrated in the pump.
4. Install fuel line and new seals, and secure with

cap nut.
Important: Make sure fuel hose is routed correctly

and cannot rub before tightening cap nut.
5. Remove~shut-off d e v i c e - a d ckeck'.for leaks. .In-

s t 2 1 bottom guard again;

Servicing 11
R E M O V I N G A N D I N S T A L L I N G 0 X . Y GEN S E N S O R
Removing
1, Disconnect plug for oxygen sensor on left side 5. Pull off safety plug on oxygen sensor,
of engine compartment, Push wire grommet
and plug through engine panel downward.
6. Remove oxygen sensor.
2. Lift car.
3, T a k e off left rear wheel.
4. Remove shield.

2 SII Servicing
Installing
1. Coat threads of oxygen sensor with Bosch paste

VW 140 16 Ft.
Note
Never allow assembly paste to get into slot of

sensor,
2. Tighten sensor to specified torque

Reference value: 50 - 60 Nm (36 - 43 ft lb).

Servicing
A counter is installed behind the fresh air blower 1. Remove right seat after loosening front and
to monitor the operation time. It will turn on the rear screws on seat rails.
oxygen sensor indicator lamp after car has been
driven 30,000 miles. The counter must be reset
to zero each time the oxygen sensor is replaced.
1. Disconnect battery ground.
2. Remove speedometer,
3. Press in reset button on counter against stop

with an approx. 3 mm thick piece of wire.
Counter will return to zero position and oxygen
- -
sensor indicator light resumes its normal
function. 2. Loosen screws on control unit. PulL off plug
and remove control unit.
RE-MOVI.NG A N D I N S T A L L I -N G C O N T R O L
V N I T FOR ACCELERATION ENRICHMENT
OF O X Y G E N S E N S O R C O N T R O L
1. Remove right seat.
2. Pull off plugs, unscrew bolt and remove control

unit.

911
p
Servicing
-
C H E C K I N G F R E Q U E N C Y V A L V E FOR REMOVING AND I N S T A L L I N G T H R O T T L E

OXYGEN SENSOR VALVE S W I T C H
1. Pull off wire plug. Removing
Remove air cleaner and cowl.
Disconnect holder for frequency valve, vacuum

hoses for distributor, hose to vacuum booster
and wire plug on throttle valve switch.
Remove 4 socket head scre:cvs and remove
throttle housing.
2. Connect ohmmeter on frequency valve.

Coil resistance: 2 t o 3 ohms.
3, If necessary, replace frequency valve.
3, Remove mounting screws and remove switch.
Installing
Make sure O-ring is positioned properly on throttle

housing.

Servicing 911 2
C H E C K I N G AND A D J U S T I N G T H R O T T L E VALVE S W I T C H
TOOLS
-
1 Dial scale from P 228 b
2 Pointer from P 228 b

911 Servicing
C H E C K I N G AND A D J U S T I N G T H R O T T L E VALVE S W I T C H
1. Remove throttle housing.
2. Mount dial scale from Special Tool P 228 b on

throttle valve shaft.
3. Set pointer (from Special Tool P 228 b) to 0.'
4. Connect standard buzzer or continuity tester to

terminals 1 8 and 2 (idle contact) of throttle
valve switch.
5. Operate throttle valve. Switching point should

0
be between 2 and 3 . Adjust if necessary.
6. Check full throttle contact. Connect tester on

terminals 1 8 and 3 of throttle valve switch.
0
The contact must be made between 30 and 35 .
The full throttle contact is mounted with the
idle contact an a base plate and therefore i t
cannot be adjusted separately,

REMOVING AND I N S T A L L I N G M I C R O S W I T C H FOR A C C E L E R A T I O N
ENRZCHMENT OF OXYGEN SENSOR C O N T R O L ( f r o m 1 9 8 1 M o d e l s )
Pull off plugs and unscrew bolts.
C H E C K I N G AND A D J U S T I N G M I C R O S W I T C H FOR A C C E L E R A T I O N
ENRICHMENT ( f r o m 1 9 8 1 M o d e l s )
1. Connect standard buzzer on both contacts of

microswitch (buzzer buzzes).
2. Operate throttle lever by hand. Microswitch

should function before the throttle opens (buzzer
not buzzing). Adjust if necessary.

911 Repairing
C O R R E C T I N G C O LEVEL S E T T I N G ON M I X T U R E C O N T R O L U N I T - (from 1981

M o d e l s ) W I T H S H E A R - O F F SCREW
1. Remove entire mixture control unit.
2. Unscrew fuel distributor on air flow sensor.
3. Drill threaded part of shear-off screw with a

2 mm/5,'64 in. dia. drill bit (approx 3.5 mm/
9/64 in. deep).
4. Unscrew rest of shear-off screw with a suitable

screw extractor.
5. Install mixture control unit.
6. After correction of CO level setting install a

new shear-off screw in access bore and tighten
until screw shears off.

A D J U S T I N G FUEL I N J E C T I O N P U M P W I T H E M I S S I O N T E S T E R
Special Tools
P 228 c Prptractors
1. Bring engine to operating temperature

(about 8 0 ~ ~ / 1 7 5 ~ ~ ) .
2. Connect emission tester according to the

manufacturer' s instructions.
4, Using hand throttle or locally manufactured

tool, open throttle gO;actuate gas pedal a
3. Attach protractor, special tool P 228 c , to few times to take strain off linkage.
the right throttle valve hosuing (if equipped
with air conditioner, attach t o left throttle
valve housing), Adjust pointer to 0'.
5. Determine axhaust emission by road test or
dynamometer test. Under partial load the
2400 rpm with a 9' throttle opening the
Note exhaust emissions ( C ~ Oshould
) be:
Hand throttle lever must b e all the way off. 911 T 1. 5 - 2.0 70CO
9 1 1 E and S 2.0 - 2.5 qo CO (Europe 2.0-3.0)
Carrera 2.7 2. 5 - 3.0 70CO
For typical road test see page SF 35,
Adjustment instructions for injection pump are

shown on page SF 36.
Note
T h e intake air preheating system eliminates
the necessity for monitoring intake air
temperature.

Adjustment Instructions
A D J U S T I N G ENGINE IDLE
Special Tools
P 230 c Socket (9 mm)
1, Bring engine to operating temperature. Note

If resetting the air correction screws shows no
reaction on the synchrometer. then the idle
passages in the throttle valve housings are
2. Check idle speed, If idle speed is too high
carboned up and must be cleaned.
or low, readjust air correction screws on
throttle valve housings as needed. Turning
screws in, lowers idle, Turning out, increases
idle. Check air flow of individual cylinders
at 1600-2000 rpm synchrometer, special
tool P 235, See page SF 40 for adjusting 3, Connect emission tester and check CO
instructions. emissions. If CO valile is not within the
prescribed limit, shut off engine and readjust
idle speed injection quantity on pump.
Caution
Do not start engine while adjusting idle speed
injection quantity,
4, T h e idle adjusting screw can be reached with

special tool P 230 c through a hole which is
covered by a plastic cap in the cooling air
upper shroud.

Adjustment Instructions 911 2
5. Remove cap. CO emissions
USA -- 2 - 370
Europa - 2,5 - 3.5 70
6. Depress the spring-loaded idle adjusting Carrera 2.7 = 2 - 370
screw with special tool P 230 c until you can
feel it engage with the slot of the centrifugal
governor.
lean rich
8. Idle speed can change after CO emissions

have been adjusted at idle speed
(900 2 50 rpm).
9. Adjust idle speed by turning the air correction

screws. Recheck with synchrometer.
Note
Adjustments at idle speed and under partial
load should be made as quick as possible so
that the velocity stack area does not heat up.
Drive the car a short distance or run engine
slightly faster (about 3000 rpm) before making
7. Turn adjusting screw counter-clockwise for another CO test on road or dynamometer. This
a leaner mixture and clockwise for a richer will cool off the velocity stack area.
mixture.
Do not adjust by more than 1 notch at a
time. A maximum of three notches is
allowed to either the right or left of the
basic adjustment.

911 Adjustment Instructions
ADJUSTING MICRO SWITCH - BEGINNING W I T H 1 9 7 2 MODELS -
1. Loosen lock nut and back off adjusting screw 3. T u m adjusting screw l / 4 turn farther in.
until t h e micro switch is not closed in i d l e Tighten lock nut.
position.
Note
T h e micro switch must b e readjusted whenever
t h e throttle valve linkage or injection pump
linkage has been reset.
2. Turn t h e adjusting screw from this position

until t h e micro switch closes (listen for
clich sound).

Adjustment Instructions 911 2
IDLE A D J U S T M E N T
TOOLS
1 Adjusting wrench P 377

1. Run engine to operating temperature (approx.

80' C).
2. Make sure that hand throttle :Lever is pushed down

to stop.
3. Connect CO-tester according to the manufacturer's

instructions.
4. Turn adjusting screw, or bypass screw, resp.

a t the throttle housing until the specified engine
speed has been attained. See page 1.1 - 1/14 e
for specifications.
Note
Use an independent tachometer, such as that from

the tester or similar.
5. Remove plug from mixture control unit between

fuel distributor and venturi.
6 . Insert adjusting wrench P 377.,
7. Turning the wrench clockwise makes the mix-

ture richer, and turning it counter-clockwise
makes the mixture leaner.
Note
The following points must be definitely noted:
a) Always adjust CQ from lean to rich.

E x a m p l e : It mixture is too rich, first turn
idle control screw counterclockwise further
than necessary and then clocltwise to specified
position.
b) Turn the adjusting screw very little because

small adjustments result in considerable CO
emission changes.
C) The maximum permissible change a t the mix-

ture adjusting screw is one-half turn.

d) The air pump of engines with air injection
must be disconnected to adjust CO.
Disconnect pressure hose at pump and plug

hose.
Take the wrench out.
Accelerate engine briefly.
Wait until the CO-tester has stabilized for

idle speed reading.
Se page 1.1 - 1/14 e for specifications.
If necessary, repeat the procedure.
11. Recheck idle speed and correct, if necessary.
12. Replace plug upon completion of the adjusting

procedure.
A D J U S T I N G FULL POWER P O S I T I O N OF T H R O T T L E
Throttle linkage must be so adjusted that there is

at least 1 mm clearance at the throttle valve
lever when the accelerator pedal is in the fully
depressed position.

ADJUSTING MICROS WITCH
1. Disconnect electrical connections from micro-

switch.
2. Connect a standard buzzer to 'both contacts of

the microswitch.
3. Prop up throttle. Place a 2 mm feeler gauge

between idle stop screw and throttle valve
lever.
Note
This distance must b e measured exactly, sliding

the feeler gauge in horizontally.
4. Turn adjusting screw a t the throttle valve lever

to a point beyond the switch-off position of the
microswitch (buzzer is off).
5. Turn adjusting screw back to the switch-on posi-

tion (buzzer is on).
6. Close throttle valve and check if the microswitch

arm still has enough travel clearance in this
position (at least 0. 5 mm).
Note
Once the engine is installed in the car and hand

throttle is adjusted, check if the microswitch is in
the "on" position (buzzer on) with hand throttle
fully on.
If necessary, check hand throttle adjustment.

911
C H E C K I N G A N D A D J U S T I N G C O N T R O L PRESSURE REGULATOR
FOR T H R O T T L E VALVE P O S I T I O N
1. Connect and bleed P 378 pressure tester and

switch valve to position K 2.
2. Detach electrical wire from control pressure

regulator for'warm running compensation.
Using a jumper wire, connect control pressure
directly to B+ (fuse box on left side of engine
compartment). Switch ignition on. Make sure
that throttle is fully closed (hand throttle must
b e pushed back all the way).
3. The control pressure will rise slowly and must

reach the idle value shown under testing and
adjustment specifications, page 1.1 - 1/13.
If the indicated value deviates, turn control

pressure regulator for throttle valve position
in the oval slots until the specified value is
reached.
Control pressure regulator for throttle valve
position in direction of vehicle travel =
higher pressure.
Control pressure regulator for throttle valve
position against the direction of vehicle
travel = lower pressure.
5. If the specified pressure cannot b e attained in

this way, replace the control pressure regula-
tor for throttle valve position.

ADJUSTING HAND THROTTLE
1. Fold center tunnel cover forward a t parking

brake support.
2. When t h e engine is warm ( 8 0 ' ~ ) and hand

throttle completely pulled up, engine should
b e running at about 3500 - 3800 rpm.
NOTE
T a k e care not t o overspeed t h e engine.
3. T h e hand throttle can b e adjusted by re-

positioning the clamping piece on t h e
throttle control rod in t h e center tunnel.

Adjusting Instructions 911
ADJUSTING IDLE, 9 1 1 SC - 1 9 7 8 MODELS
TOOLS
No. Description Special Tool Note
I Adjusting wrench P 377

Adjusting Instructions
Adjusting
Note
Before starting with the idle adjustments, make

sure that oil tank cap fits properly and its seal
is in good condition. Leaks at oil tank cap would
result in incorrect readings.
1. Run engine to operating temperature (approx.

80' c/176O F).
2. Connect CO tester according to instructions

of the manufacturer.
4. Connect exhaust gas source line to test con-

3. Detach air hose a t diverter valve (arrow) and nection of catalytic converter.
insert an appropriate plug into hose.

5. Turn idle speed screw or bypass screw on 8. Turning clockwise = rich mixture
throttle housing, until specified speed is Turning counterclockwise = lean mixture
reached.
Test specifications, see page 1.1 - 1/14 e.
Note
Note
a) Always adjust C O level from lean to rich.
Use separate tachometer of tester or similar
Example: When adjustment is too rich, first
instrument.
turn idle speed screw counterclockwise further
than necessary and then clockwise to basic
setting..
b) Do not apply pressure on adjusting wrench

during adjustments (engine would die).
c) Turn idle speed screw very little because even

small adjustments result in considerable CO
emission changes.
9. Remove wrench.
1 0 . Race engine briefly.
6. Remove plug in mixture control unit, between

fuel distributor and air venturi.
7. Guide in adjusting wrench P 377.

11 Adjusting Instructions
11. Wait until CO tester shows exhaust concentra-

tion a t i d l e speed.
Test specifications, see page 1,l - 1/14 e.
If necessary, repeat adjusting procedure.
13. After completion of adjustments, insert plug

in mixture control unit and attach air in-
jection hose.

Adjusting Instructions 91, 2
A D J U S T I N G IDLE SPEED 9 1 1 SC - 1980 model
TOOLS
1 Adjusting wrench P 377

Adjusting
Note 4. Disconnect plug for oxygen sensor in engine

compartment on left side.
Make sure that oil tank c a p and seal fit properly
prior to adjustment of the i d l e speed. Leaks a t
oil tank cap would cause incorrect measurement,
Requirements:
Engine in perfect mechanical condition and igni-

tion timing adjusted correctly.
1. Connect exhaust pickup line on test connection

of catalytic converter.
5. Turn control screw or bypass screw on lhrottle

housing until specified speed is reached.
-
Adjusting values on page 1.1 1/13,
Note
Use separate tachometer from tester or similar.
2, Run engine to operating iemperature (oil tempera-

0
ture about 90 C . oil temperature gauge on upper
end of range surrounded in white).

supplied with equipment.

Adjusting Instructions 9fl 2
6. Remove plug in mixture control unit, between 10. Accelerate engine briefly.
fuel distributor and venturi.
11. Wait until CO tester shows CO concentration

7. Insert adjusting tool P 377 at idle speed. See page 1 . 1 - 1/14 f for ad-
justing values. If necessary, repeat adjusting
procedures.
13, After completion of adjustments insert plug

in mixture control unit and connect electric
plug for oxygen sensor.
14. Coat threads of cap nut for testing connection

on catalytic converter with Bosch assembly
8. Turn clockwise = richer mixture. paste VS' 140 16 Ft.
Turn counterclockwise = leaner mixture.
Note
Always conform with the following points.

a) Always adjust CO level from lean to rich.
E x a m p l e : If mixture is too rich first turn
idle control screw counterclockwise further
than necessary and then clockwise to speci-
fication.
b) No force should be exerted on adjusting tool

during adjustments (engine would die).
c) Turn control screw only minimal amount,

since even a slight turn will change the CO
level considerably.
9. Remove adjusting tool.

A D J U S T I N G IDLE 9 1 1 S C - (from 1 9 8 1 Models)
Adjusting
Note 4. Disconnect oxygen sensor plug in engine

compartment on left side.
Make sure oil tank cap and seal fit properly before
adjusting idle. Leaks through oil tank cap would
cause incorrect readings.
Adjusting requirement:
~ n g i n ein perfect working condition and ignition

timing set correctly.
1. Connect exhaust gas tap on test connection of

catalytic converter.
5. Turn control screw or bypass screw on throttle

housing until specified engine speed is reached.
See page 1.1 -. 1/14 f for adjusting value.
Note
Use separate tachometer of tester or similar.
2. Run engine to operating temperature (oil tempera-

ture about 90' ~ / 1 9 4 ' F; oil temperature gauge
needle at upper end of field outlined in white).

supplied with equipment.

Adjusting Instructions 911
6. Check CO level. If CO level does not correspond 10. Accelerate engine briefly.
with specified value, remove mixture control
unit and remove threaded part of shear-off screw
in access bore for mixture control screw (see page 11. Wait until CO tester shows exhaust gas con-
2.5 - 1/8). centration a t idle speed.
See page 1.1 - 1/14 f for adjusting value.
Repeat adjusting procedure, if necessary.
r . Guide in Special Tool P 377.
-- " -
12. Recheck idle speed and, if necessary, correct.
13. After finishing adjustments screw a new shear-off

screw in access bore and tighten until screw shears
off. Reconnect oxygen sensor plug.
14. Coat threads of cap nut for test connection on

catalytic converter with Bosch VS 140 1 6 Ft or
Optimoly HT grease.
8. Turning tool clockwise = richer mixture.

Turning tool counterclockwise =leaner mixture.
Note
The following points are important.
a) Always adjust CO level from lean to rich.

E x a m p 1e : If mixture is too rich, first turn idle
control screw counterclockwise further than
necessary and then clockwise to specified value.'
b) Never exert force on special tool during ad-

justments (engine dies).
c) Turn control screw only very slightly, since even

a slight turn will change CO content in exhaust
gas considerably.
9. Remove special tool.

Getriebe
Transmission
Bo'ite de Vitesses
\
Cambio

TRANSAXLE
911 3
CONTENTS
0 - INFORMATION., DESCRIPTION, TECHNICAL DATA
Information
Transmission, 4 and 5 Speeds
Sportomatic
Description
Transmission, 5 Speeds, Operation
Transmission, 5 Speeds, Power Transfer
Transmission with Oil Pump, Description
Transmission with Oil Pump, General Instruction
Typ 915, Transmission (1974 model)
Sportomatic, General
Sportomatic, Power Transfer
Typ 925, Sportomatic Transmission (1974 model)
-
Sportomatic 1977 Models General Information
Technical Data
Transmission Diagrams, Manual Transmission
Tightening Torques, Manual Transmission
Tightening Torque Values, Transmission
General Specifications, Transmission
Tolerances and Wear Limits
Transmission Diagrams, Manual Transmissions (1974 model)
General Specifications, Transmission (1974 model)
Transmission Diagrams, Manual Transmissions (1975 model)
Transmission Diagram 915/44
Transmission Diagram 915/49
Transmission Diagram, 925/01 Sportomatic Transmission .

General Data - Sportomatic Transmission
Tightening Torques, Sportomatic Transmission
Transmission Diagram, 925/02 Sportomatic Transmission
911 I TRANSAXLE
General Specifications, sp$omatic (1974 model)

Transmission Diagram, 3 $peed Sportomatic 925/10 (1975 model)
General Specifications, 31Speed Sportomatic 925/10 (1975 model)
General Specifications, 3;Speed Sportomatic 925/09, 012, 013
Transmission Diagram, 3 :Speed Sportomatic (1976 model)
0.3 Special Tools
Special Tools, SportomatIc Transmission
3 - TRANSMISSION, 5-SPEED MAN~UAL
3.1 T r a n s m i s s i o n , d i s a i s e m b ~ i na~n d a s s e m b l i n g
Transmission, removing ahd installing 3.1 - I/I

Seal Ring for drive Shaft: pismantel and reinstall 3.1 - 1/15
Selector Forks, adjust i 3.1 - 2/1
Transmission Front cover,! disassembling and assembling 3.1 - 3/1
Oil Pump in Front Cover, jdisassembling and assembling 3.1 - 3/5
Gear Housing, disassembling and assembling 3.1 - 4/1
Transmission Housing, disassembling and assembling 3.1 - 5/1
Oil Lines for Supplemental Lubrication System, remove and install 3.1 - 5/9
Transmission Housing wit$ Guide Tube for Throwout Bearing 3.1 - 5/11
Transmissioncase with Bolted Guide Tube for Release Bearing 3.1 - 5/19
Disassembling and assembling ~ra&missionCase with Servo Clutch(1977model) 3.1 - 5/25
Input Shaft, disassembling and assembling 3.1 - 6/1
Pinion Shaft, disassembling and assembling 3.1 - 7/1
Synchronization, disassembling and assembling 3.1 - 8/1
Disassembling and Assembling Synchronization (19 77 Models) 3.1 - 8/5
-
I
4 TRANSMISSION, SPORTOMATIC
4.1 Transmission, disassembling and assembling
Torque Converter Housing; disassembling and assembling

Transmission, removing and installing
Transmission Front Cover,; disassembling and assembling
Inte~mediatePlate, disassembling and assembling
Input Shaft (3 Speed ~ ~ o r t b m a t idisassembling
c) and assembling
Pinion Shaft (3 Speed Spo$tomatic) disassembling and assembling
Checking Clutch Play (1976 model)
Checking Control Valve 4djustment (1976 model)
5 - DIFFERENTIAL
Differential, with manual transmission
Differential, removing and installing
Differential, diiarsernblin~and assembling
Differential with electron~calspeedometer
Tools
Disassembling and Assembling Instructions
Ring and Pinion Gear, adjusting - General Information
Ring and Pinion Gear, adjbsting
Pinion Shaft, adjust with universal Setting Gage VW 385
Differential, with orto to ma tic Transmission
Ring and Pinion Gear, adjlsting - General-Information

Ring and Pinion Gear, adjusting
Downloaded from www.Manualslib.com manuals search engine I
Manual Transmission 911
FOUR AND FIVE SPEED TRANSMISSION ( T Y P E 9 1 5 )
Beginning-with 1972 models, all Type 911 vehicles are equipped with the new, reinforced 4-speed
transmission. The 5 -speed transmission-is optional.

911 Manual ~ransmissionj
i
D ~ E S I G NA N D F U N C T I O N
!
!
The five forward speeds and reverse a i e arranged in a double " Hshift pattern.
I
1st speed: left forward
2nd speed: left back
3rd speed: straight forward
4th speed: straight back
5th speed: press right overcoming sphng detent, then straight forward
Reserve: press right overcoming spring detent, then straight back
Clutch pedal must be fully depressed and selected gear fully engaged.

3 911 Manual Transmission '
I
-

Manual Transmission 911 3
1 - Transmission front cover 16 - Transmission housing
2 - Reverse, Gear I 17 - Breather
3 - 5th speed, Gear I, fixed 18 - Seal
4 - Roller bearing 1 9 - Speedometer drive, Gear I
5 - 1st speed, Gear I, fixed 20 - Spider, 5th and reverse speeds
6 - Gear housing 21 - Flange nut

7- 2nd speed, Gear I, fixed 22 - Shift fork, 5th and reverse speeds
8 - 3rd speed, Gear I, free 23 - 5th speed, Gear 11, free

9 - Synchronizing ring 24 - Roller bearing
10 - Spider (Synchro hub) 25 - Shift fork, 1st and 2nd speeds
11 - 4th speed, Gear I, free 26 - Selector shaft
12 - Pinion shaft ball bearing 27 - Bearing retaining plate
13 - Roller bearing 28 - Ball sleeve
1 4 - Flange nut 29 - Pinion shaft
15 - Input shaft 30 - Differential

Manual Transmission:
POWER FLOW
In all gears, power flow is from the input shaft to the pinion shaft through the respectively engaged
gear pair. The engaging and synchronizing parts for lst, 2nd, and 5th gears are on the pinion shaft,
and those for the 3rd and 4th gear are on the inpllt shaft.
Torque transfer occurs only through the respective gear pair. Engagement of the lst, 2nd, and 5th
gears is made by repositioning the shifting sleeve or sliding gear located on the pinion shaft, and
that of 3rd and 4th gears by one located on the input shaft.
Power flow in reverse gear is from the input shaft through the reverse idler gear, the sIiding gear, to
the pinion shaft.

Transmission 911 3
T Y P E 9 1 5 T R A N S M I S S I O N W I T H OIL P U M P
Carrera 2.7 vehicles are equipped with Type 915/08 and 915/18 transmissions.
These transmissions are identical in design and servicing to transmissions used in 1972 models.
However, due to the increased power and torque of the 2.7 liter engines, they are equipped with an
oil pump lubrication system.

911 Transmission
-
D E S C R I P T I O N OF T H E OIL PUMP L U B R I C A T I O N S Y S T E M
When the car is started, the input shaft sets the oil pump in motion. The pump draws oil from the trans-
mission oil -sump through a pickup tube and forces it through the passages in the pump cover and into the
pressure lines. .
Pressure created by the oil pump forces the transmission oil to pass through discharge nozzles which
direct the oii spray to the lubrication points. Oil not used for lubrication cools the working parts and
drains back into the transmission oil sump.
A pressure relief valve opens at a press'ure of about 3, 4 atmospheres if a malfunction should occur in the
oil supply system, such as a plugged pressure line. The oil then drains into the transmission oil sump.
The constant circulation of the transmission oil and spraying of the bearings and gears results in improved
cooling and lubrication.
1 - Oil pump cover 5 - Spring for pressure relief valve

2 - Oil pump gear I 6 - Bushing
3 - Oil pump I1 7 - Plug for pressure relief valve
4 - Ball for pressure relief valve 8 - Pickup tube
GENERAL I N S T R U C T I O N S FOR DISASSEMBLING A N D REASSEMBLING OF T R A N S -
M I S S I O N W I T H OIL PUMP
1. Disassembly and reassembly of a transmission with oil pump is the same as that of a unit without the
pump because the pressure line connections are of the slip-on type.
2. Oil the O-rings lightly when installing the pickup tube and pressure lines since otherwise damage may
occur.
3. The gear housing should be assembled with the pressure line bolted in place. The pressure line must
pass through the hole in shift fork for 3rd and 4th speed.
4. When installing the transmission front cover make sure that the coupling pin in the input shaft
engages the coupling slot in oil pump gear I. If necessary, turn the input shaft slightly and push
cover into place.
5. Work procedures differing from those applicable to transmissions in 1972 models, such as dis-
assembly and reassembly of the oil pump, are described on pages that follow.

911 Transmission

Transmission 18
1 - Oil pump cover

2 - Bushing
3- Oil pump gear I1
4 - Oil pump gear I
5- Plug for pressure relief valve
6 - Oil pump coupling pin
7 - Transmission front cover
8 - Gear housing
9 - Pressure l i n e
10 - Differential housing

Transmission 911 3
TYPE 9 1 5 TRANSMISSION ( 1 9 7 4 MODEL)
The following transmission versions are installed from 1974 models on:
4-speed transmission, 915/16 = S

5-speed transmission, 915/06 = SW
S = standard equipment SW = special order
These transmission versions differ from those used in 1973 models only in the aspect of gear ratios (see
Technical Data, page 0.2 - 1/11).

!
3 911 Transmission
1I
I
!
I
I
Manual transmission 915 (1975 Models) I
I
I
The following transmissions are installed. 1
I
I
Transmission Type No. of Gears Application I
!
915/40 5 911 S, Carrera

ij
I
915/45 ' 4 911 S, Carrera

I
/
!
I
I
I
All transmission types are based on those of 1974 models and only differ slightly from d c h other.
1
The 3rd and 4th or 4th and 5th gears as well as the rear axle ratios have been changed dn the types
915/45 and 915/40 (refer to technical data on page 0.2 - 1/15). The shift and guide sleeves have also
been reinforced, and the clutch release lever modified. i

M A N U A L T R A N S M I S S I O N 9 1 5 ( 1 9 7 6 MODEL)
The following transmission is available for the 1976 Model.
5-speed transmission 915/44
This transmission model differs from the 1975 model by a new guide tube for the clutch release
bearing, an easy to remove drive shaft seal and an electronic speedometer transmitter.

I
11 Manual Transmission
MANUAL TRANSMISSION 9 1 5 ( 1 9 7 6 M O D E L )
The following transmission is available for the 1976 Model.
Transmission No. of Speeds For Model
915/44 5 911 S
MANUAL TRANSMISSION 9 1 5 ( 1 9 77 M o d e l )
For 1977 Models the following transmission type is installed.
5-speed transmission 915/61 with auxiliary clutch spring
This tpansmission differs from the 1976 Model with modified synchronizers for 1st and 2iid gears,
an asymmetric tooth profile of the clutch body for 1st gear and a modified operating an? guide
sleeve for lst/2nd gear. iI
I
I
!
MANUAL TlUNSMISSION915 ( 1 9 7 8 / 7 9 M o d e l s )
F O ~the 1978/79 models the

1
has a silumin case and a modified clutch release lever.
MANUAL TRANSMISSION 9 1 5 ( 1 9 8 0 / 8 1 M o d e l s )
I
The following transmission type is installed in the 1980/ 81 models: i
I
i
I
This transmission differs from those in 1978/1979 models only in the modified 2nd gead ratio.
I
I
Downloaded from www.Manualslib.com manuals search engine I
Sportomatic 911 3
SPORTOMATIC 925
Beginning with Sept. 24, 1971 production, the Sportomatic transmission for 911 vehicles have been
modified. The modified transmission have the following designations:
911 T and E
911 S
Repair procedures for these transmission differ only slightly for those contained in the 911 Workshop
Manual, Volume I which applied t o models thru 1971.
Only those repair procedures and service information which differ are included in this volume of the
workshop manual.

I
I
I
911 Sportomatic
I
I
1- Speedometer drive 16 - Clutch plate / turbine Ahaft

,
2- Fron't cover 17 - Oil seal !
!
3- Flange nut 18 - Torque converter housi'r~~
I
Gear I, reverse gear Torque converter I
i
Input shaft Speedometer gear sha
J'i
Ball bearing race Four point ball bearin gi
Intwmediate plate Clamping plate
Gear I, 2nd gear Roller bearing
Gear I, 3rd gear Selector shaft
Transmission housing Roller bearing
Shift fork, 3rd and 4th gear Anchor block
Shift sleeve, 3rd and 4th gear Oil seal
Gear I, 4th gear Needle bearing sleeve
Thrawout fork Ball bearing
Oil seal Stator support

o t o t i 911 3

!
I
I
I
Oil seal 10 - Needle bearing cage
I
Expansion bolt 11 - Axial needle bearing cage
Threaded stud 12 - O-ring
Tapered roller bearing 13 - Ring gear
Axle flange 14 - Differential spider g e a
Temperature sending unit 15 - Differential side gear
Temperature switch 16 - Roll pin
Thrust washer 17 - Anchor piece
Reverse idler gear 18 - Shaft

Sportomatic 911 3
Power Transfer
Power transfer from the engine through the torque converter and mechanical clutch is same in all
driving ranges.
In ranges L and D, the power is transfered from the fixed gears on the input shaft, through the synchro-
nization components and free-wheeling gears on the pinion shaft, t o the pinion shaft. In ranges D3 and
D4, the power transfers from the input shaft, through the synchronization components and fiee-whee-
ling gears, to the fixed gears on the pinion shaft. Reduction is accomplished by gears engaged in given
driving range,
Reverse gear reduction is over two stages. The power flows from the input shaft, through the interme-
diate shaft, t o the pinion.

Transmission
TYPE 9 2 5 SPORTOMATIC TRANSMISSION ( 1 9 7 4 MODEL)
Beginning with 1974 mod.els, Type 911 and 911 S vehicles can optionally be equipped with the Type
925/02 transmission.
This transmission versiori differs from that used in 1973 models only in the aspect of changed torque
converter ratio (see Technical Data, page 9.2 - 2/6).

Sportomatic 911 3
SPORTOMATIC 925 (1975 Models)
All 1975 models are available with a 3-speed sportomatic transmission (type 925/10) as optional extra
equipment.

Sportomatic

Speedometer drive gear Turbine shaft
Front transmission cover Oil seal
Flanged nut Torque converter housing
Reverse gear Torque converter
Main shaft Speedometer drive shaft
Ball bearing Four-point ball bearing
Intermediate plate Clamping plate
2nd gear (22:29 M) Roller bearing
3rd gear (27:25 V) Inner shift lever
Transmission case Roller bearing
3rd gear shift fork Anchor block
3rd gear shift sleeve guide O-ring
Spacer Needle bearing
Washer Ball bearing
Release lever Stator support
Oil seal

Sportomatic 911 3
S P O R T O M A T I C 9 2 5 ( 1 9 7 6 MODEL)
From 1976 models all cars can be delivered with a 3-speed sportomatic transmission as optional extra
equipment. For engines with a swept volume of 2.7 liters transmission 925/09 (mechanical speedometer
drive) and 925/12 (electronic speedometer transmitter) are installed.
The 3 liter Carrera engine requires a more powerful servo motor with a modified clutch linkage (Type
925/13). The torque converter has 4 additional drive shells.

I
j
911 sportomatic I
SPORTONIATIC TRANSMISSION 9 2 5 ( 1 9 7 6 MODEL)
T h e following transmissions are available from 1976 Models.
Transmission No. of Speeds For Model ;

i
925/09 (mech. speedometer) 3 911 j
925/12 (electronic speedometer) 3 911 and 9 1 i S USA
925/13 (stronger converter drive) 3 Carrera 3.0;

!
j
SPORTOMATIC TRANSMISSION 9 2 5 (19 77 Models)
From 1977 Models t h e following transmission types a r e installed.
Transmission ~ y p e No. of Gears Installed in

- .
925/15 3 911
925/16 3 Carrera 3.0
911 S USA and 911 S Japan
,

Transmission Diagram 5-speed-transmission
Ring Ratio 7 : 31

Pinion to Ring Ratio 7 : 31 Type 91 5 Transmission

Transmission 911 3
DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING
TOOLS
Nr . Description Special Tool Remarks
1 Driver Set US 8050
2 T- handle P 366

3 911 Technical Data
T I G H T E N I N G TORQUES
I
Location Description Thread Grade ft Ibs
Transmission Magnetic plug M24

housing Tapered
(Oil drain)
Transmission Oil filler plug M 24
.
housing Tapered
(oil filler)
Transmission Nut, center M 8 x 1.25 x 12 CrNi
-
housing side lock type 18-8
and front cover.
guide fork cover
Front cover Backup light M 18 x 1.5
switch
Input shaft Flange nut M 30 x 1.5 8.8
Input shaft Castellated nut M 18 x 1. 5 6.8
Retaining plate Nut M8x1.25 8
and transmission support attachmen
4
Pinion shaft Flange nut M 24 x 1.5 8

Guide fork, Nut M 6 x1.O 8
shifting .
Shift detent, Nut
transmission
housing
Transmission Breather M 16 x 1.5
housing
Shift forks M8 x 1.25
Ring gear
(differential)
locking differential) 12.9

Ex ansion bolt/
Axle flange of+ M 10 x 1.5 8.8
Starter Nut M I 0 x1.5 . 8
Pressure: line Bolt, M 6x35 M 6 x1.0 8.8
(input shaft)
Front cover Plug for pressure M 12 x 1.5 9 S 20 K
relief valve
Oil pump cover Self-locking nut I M 6 x 1.0 I x 12 CrNi
Pickup tube Allen bolt

M6x15
Pressure: line Bolt, M 6 x 12 M 6 x 1.0 8.8
Guide tube release Phillips head M6x1.0 8.8-
bearing ctsk. screw
General Specifications Type 915 Transmission
911 T 911 E 911 S Carrera 2.7
Gear Ratios
1st gear
2nd gear
3rd gear
4th gear
Reverse
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse
Climbing Ability
(calculated)
I
Vehicle Weight:
empty according to DIN + 1/2 load
1st gear
2nd gear
3rd gear
4th gear
1st gear > 100 70

2nd gear 52.570
3rd gear 30.570
4th gear 20 (lo
5th gear 12.. 5 70

General Specifications Type 915 Transmission
911 T 911 B 911 S Carrera 2.7
Rear Axle Drive Spira: bevel gears, differential

Final drive ratio 7/31 = 4.429
Power transfer double-joint drive shafts, to rear wheels
Transaxle Weight
4-speed transmission 54 kg, ready with oil and starter
5-speed transmission 56 kg, ready with oil and starter
Filling Capacities
Transmission and differential . .
approx 3 Itr (6.3 US pints) SAE 90 transmission oil,
MIL-L 2105 B or MIL-L 2105 specification

Technical Data
T a b l e of T o l e r a n c e s for T y p e 915 Transmission
Installed Wear
Measuring
tolerances Limit
point
(new) mm mm
1. Backlash
between
Gear I and I1
1st gear
2nd gear
3rd gear
4th gear
5th gear
2. Free gears on
pinion and
input shafts
1st gear
2nd gear
3rd gear
4th gear
5th gear
3. Shift rods
a. Side play in
bushings
b. Runout

I
911 Technical Data

I
Installed Wear
Measuring
tolerances Limit
point
(new) mm mm
4. Side-play between
shift fork and shift
sleeve:
5th and reverse

gear
1st and 2nd gear
3rd and 4th gear
5. Outside diameter of
synchronizing rings:
(installed)
1st gear When molyb

2nd gear denum coat
3rd gear (a) is worn
4th gear off at any
5th gear point
6. Input shaft
a. Runout at the
pilot journal 0.1 max. 0.1 max.
(straighten)

Transmission Diagram 4-speed-transmissi
Pinion to Ring Ratio 7 : 31 Type 9l5/l6 Transmission
Remarks: This diagram shows guiding values, based on

a medium effective rolling radius. Slight deviations due
to tire tolerance variations in the rolling radius, wear and
skidding of the wheels have not been taken into account.
Subject to change without notice

I
Technical Data

General Data Type 915 Transmission (1974 model)
911 911 S Carrera

Gear Ratios
Type 915/16 transmission:
1st gear
2nd gear
3rd gear
4th gear
Reverse gear
Type 915/06 transmission:

1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gear
Climbing Ability
(calculated)
Vehicle Weight:
empty according to
DIN + 1/2 load
1st gear
2nd gear
3rd gear
4th gear
1st gear
2nd gear
3rd gear
4th gear
5th gear

General Data Type 915 Transmission (1974 model)
911 911 S Carrera
Rear axle drive spiral bevel gears, differential
Final drive ratio
Power transfer double-joint half-axles, to rear wheels
Transaxle Weight
4-speed transmission 54 kg (119 lb), ready with oil and starter
5 -speed transmission 55 kg (121 lb), ready with oil and starter
Filling Capacities
Transmission and differential approx. 3 Itr. (3.17 US gts.) SAE 90 transmission oil,
MIL-L 2105 or MIL-L 2105 B specification
Transmission and differential, approx. 3 Itr. (3.17 US gts.) SAE 90 transmission oil,
limited slip M 2 C 119 A

Technical Data 911

Transmission Diagram 911 S
Pinion to Ring Ratio 8 : 31 Type 9 i 5 i 4 0 Transmission
a medium effective rolling radius. Slight deviations due-

skidding ofthe wheels have not been taken into account.
-
I I I I Subject to change without notice .. ..

Technical Data
l ~ e n e r a Data
l Manual Transmission 915 (1975 Models)
911 S, Carrera
-
Ratios
1st gear
2nd gear
3rd gear
4th gear
Reverse
1st gea
2nd gear
3rd gear
4th gear
5th gear
Reverse
Final drive
Transmission and differential Approx. 3 liters (3.17 US gt.) of SAE 90 transmission oil
meeting Specifications MIL -L-2105 or MIL-L-2105 B

General data Manual transmission 915 - 1976, 1977, 1978 and 1979 models
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse
Final drive ratio
Capacity approx. 3 ltr. /3.15 US qt of SAE 90 transmission oil

meeting API Classification GL 5 (or MIL-L 2105 B)
Transmission weight 56 kg/123 l b ready for installation with oil and starter
General data Manual transmission 915 - 1980 model and 1981 models
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse
Final drive ratio
Capacity Bpprox. 3 ltr. /3.15 US qt of SAE 90 transmission oil

meeting API Classification GL 5 (or MIL-L 2105 B)
Transmission weight 56 kg/123 l b ready for installation with oil and starter

Pinion to Rlng Ratio 8 : 31 Type 915 /44 Transmission

Transmiss ion Diagram 4 -speed-transmission
Type 91 5/49 Transmission
R*
1 1
Remarks: This diagr;sm ou -
IS euidina values, based on
a medium effective rolling radius. slight deviations due-

skidding of the wheels have not been taken into account.
out notice
c3
(D
n
3
D
l-.
0
P
w
3
tl
P
rt
P
5 130 135 140 145 150 1 CD

I.
d

Technical Data 911

911 Technical Data
r y General Data
1st gear
2nd gear
3rd gear
4th gear
Reverse gear
I Torque converter ratio I

I Final drive ratio ;k
I
Filling Capacities Approx. 3.0 ltr (3.17 US qts)
SAE 90 transmission oil, speci-
fication Mil-L 2105 or Mil-L 2105B
approx. 10 ltr. (10.5 US qts) approx. 11ltr

(11.6 US qts)
w/oil cooler
Two-start speed in L-range approx. 35 kmh (22 mph)
Stallspeed 2500 - 2700 rpm 2900 - 3100 rpm
;~c In parenthesis; number of teeth

Technical a t 911 3
T I G H T E N I N G TORQUES - SPORTOMATIC 925
Location
Transmission housing (at

Description
Nut
Thread Grade 1 mkp
stud for side and front co-

ver, and fork piece)
Transmission housing
Mid grip nut
Plug M24 x 1 . 5
1
x l 2 CrNi 2.2-2.5
18.8
(oil filler plug) (1:16 tape]
Transmission housing Plug with magnet M24 x 1 . 5

(oil drain plug) (1:16 tape]
Transmission housing Breather M14x1.5

(breather) (1: 16 taper
Transmission housing Backup light switch
Transmission housing Bypass switch
Transmission housing Nut

(starter attachment)
Transmission housing (vacu- Nut

um servo unit carrier and
attachment)
Torque converter housing Nut

(attachment to transmis-
sion housing) Nut
Torque converter housing Allen-head bolt

(attachment of freewhee-
ling support)
Torque converter housing Threaded coupling
Torque converter housing Temperature sensor
Torque converter housing Temperature switch
Torque converter housing Allen-head bolt

(clutch pressure plate)
Torque converter coupling 2-point bolt

plate

11 Technical Data
Location Description Thread
Intermediate plate
(clamping plate)
~ntermediateplate
Bolt
Bellcrank shaft
II M8x1.25
M8x1.25
Intermediate plate Cover plug

(shift detent)
Transmission front cover Bolt

(speedometer drive retainer)
Transmission front cover Cover plug

(9 mm dia ball - parking
lock)
Angular drive in retaining Hollow bolt

bushing
I
Input shaft Nut M24x1.5
Input shaft Flanged nut I M18x1.5
Pinion shafl: Stretch bolt I M12x1.5
Selector forks Bolts M8x1.25
Differential Bolt
(ring gear attachment)
U - joint flange Stretch bolt M10x1.5

(in differential)
Transmission front cover

(transmission c a r r i e ~
attachment)

Technical Data 911

11 Technical Data
General Data Sportomatic (1974 model)

- -
Climbing ability - percent
1st gear
2nd gear
3rd gear
4th gear
( ) in parentheses: brief climbing ability
Gear Ratios-
1st gear
2nd gear
3rd gear
4th gear
Reverse gear
Torque converter ratio
Final drive ratio
Filling Capacities:
Transaxle approx. 2.5 ltr. (2.6 US gts.) SAE 90 transmission

oil MIL-L 2105 or MIL-L 2105 B
Engine approx. 13 ltr. (13.7 US gts.)
Tow-start speed
in 'Z" (Low) approx. 35 kmh (22 mph)
Stall speed
Clutch speed
(at full power)

911 Technical Data
General Data Sportomatic 925 (1975 Models)

Ratios
1st gear
2nd gear
3rd gear
Reverse
Converter
Final drive
Capacities
Transmissi.on with Approx. 2.5 liters (2.65 US gt.) of SAE 90 transmiss.ion oil meeting
final drive Specifications of MIL-L-2105 or 2105 B
Towing speed in Approx. 22 mph

range '2"to start
California
Stall speed (rpm) 1900 1 2 0 0 1850 200
Clutch speed (rpm)

Technical Data Sportomatic 911 3
General Data Sportomatic 925 1976 and 1977 Models
I
925/12 925/17
Ratios 19 76 Mod. 1977 Mod.
1st speed
2nd speed
3rd speed
Reverse
Final Drive Ratio
Gearbox and Final about 2, 5 Itr. / 2, 6 U.S. 4t of SAE 90 Gear Lube

Drive Capacity meeting Specifications MIL-L 2105 or MIL-L 2105 B
1 Speedometer Electronic
Converter Ratio
Tow-Start Speed about 2 5 mph

in Range "L"
Stall Speed (rpm)
Transmission Weight (ready for about 71 kg/156 Ib

installation with converter,
starter and oil)
Contact Pressure 7845 - 8630 N 6400 - 7100 N

of Pressure Plate (800 - 880 kp) (652 - 724 kp)

Transmission Diagram Sportomatic
Pinion to Ring Ratio 8 : 27 Type 925/09/ 12 /13 Transmission

Special Tools 11 3
SPECIAL T O O L S - SPORTOMATIC
Mandrel
Mandrel
Installer
Centering mandrel
Installer
Assembly plate
Input shafl holder
Remover
Support plate
Mandrel
Pilot mandrel
Thrust piece
Centering mandrel
Installer
Assembly sleeve
Puller and installer
Input shaft lock
Socket, 32 mm
Guide sleeve
Thrust piece
Thrust piece
Installer
Mandrel
Bushing
Gauge block
Holder
Dial gauge holder, spacer, feeler tip (w/o clamping adapter)
Press plate
Press plate
Thrust piece
Thrust sleeve
V-block
Thrust piece
New special tools

TRANSMISSION
TOOLS
1 Sleeve P 382
2 Puller P 386
3 Driver P 381
4 Shift rod holder P 260 a
P 37 a

Note when Special
Description Q~Y instructions
Removing Installing see
-
Self-locking nut 8 Replace if necessary,

torque to specification
. .
Washer 7
Clutch cable bracket 1
Self-locking nut Replace if necessary,

torque to specification
Washer Place one on each side

of ground strap.
Ground strap
Front transmission
cover
Gear housing gasket I Replace.
I
- -
Roll pin 1 Drive out. Replace if necessary.
Castellated nut 1 Torque to specificatioi
Flange nut Replace, torque to

specification.
-
Roll pin 1 Drive out. Replace if necessary.
Bolt 1 Torque to specificatio~
Spring washer Replace if necessary.
Shift fork, 5th and Readjust.

reverse gear

Note when Special

Description instructions
-
Sliding gear, 5th and Check for wear.
reverse gear
--
O-ring Replace, oil lightly.
Thrust washer 111

5th and Reverse idler Check for wear.
gear
Needle bearing cage Check for wear.
Intermediate ring 1
-
Needle bearing cage 1 Check for wear.
-- --
Thrust needle bearing 1 Check for wear.

cage
-
Reverse speed, Gear I 1 Replace in pairs only.
-
Shaft for 5th and 1 Remove together with Install together wit!?
Reverse idler gear fixed Gear I of 5th fixed Gear I of 5th
speed. speed.
-
Gear I, fixed, 5th spee Small flange faces
gear housing. Replace
in pairs only.
Gnide sleeve Check for wear.
Gear 11, free, 5th speed 1 Cheek synchronization.

Replace in pairs only.
-
I Needle bearing cage
Bushing
Mark position for
installation.
Mark position for

Install with same gear.
Install with same gear.

-
installation.

1,
Description
Thrust washer
Qty
Removing
Note when
Installing 1 Special
instructions
see
1Self -locking nut Replace if necessary,
a Washer
Cover with guide fork 1

torque to specification.
Gasket
I Replace.
Self -locking nut

I lo
Replace if necessary,
torque to specification.
Washer 10
I
Gear housing 1 Move selector fork
rod for 5th speed and
reverse into neutral
and remove.
Gasket 1 1 Replace.
Nut
I Torque to specification.
I
Seal Replace.
Spring
Short detent Check for free move-

ment.
I
Nut Torque to specification.
I
Nut Torque to specification.
Lock washer Replace.

Manual Transmission
Note when Special

Input shaft Remove together with

pinion shaft, 1st and
2nd speed selector
fork, and complete
3rd and 4th speed
shift rod.
Pinion shaft
1st and 2nd speed Check for wear, read-

selector fork just.
Bolt Torque to specification.
Bolt Torque to specification.
3rd and 4th speed Check for wear, read-

selector fork just.
Shift guide Check for wear, read-

just.
3rd and 4th speed

shift rod
Plug Torque to specification

ment.
Bolt Torque to specification

frianual T r a n s m i s s i o n
l1 3
Note when Special
Removing Installing
Seal Replace.
Spring

ment.
1st and 2nd speed

selector fork rod
Shim Note thickness and Recompute if

DISASSEMBLING AND ASSEMBLING MANUAL T R A N S M I S S I O N
Disassembling
4. Remove guide fork cover with gasket.
1. Block input shaft with special tool P 37a,

engage 5th gear.
5. Remove nuts from gear housing. Pull housing

and selector fork rod (5th and reverse speed),
and selector fork rod with selector shaft off
2. Remove castellated nut from input shaft, the studs (tap lightly with a plastic mallet,
and flange nut from pinion shaft. if necessary).
-.
.@,a:'
."%.
'
i - ,
Note
Selector fork rod for 5th and reverse speed must
be in neutral. Otherwise the gear housing will
bind against the rod and cannot b e removed.
3. Mark needle bearing of 5th speed free gear;

it must be reassembled with same gear.

6. Remove shift detent plug (3rd and 4th gear). 10. Remove detent .
Take out spring and detent.
11. Remove plug from shift detent (1st and

7. Remove bolt from selector fork of 1st and 2nd gear) and take out spring and detent.
2nd gear, gently spread clamping piece with
screwdriver.
8. Remove retaining plates for input and 12. Take out selector fork rod 1st and 2nd
pinion shafts. gear.
9. Take input and pinion shafts with complete

selector fork rod (3rd and 4th speed) and 13. Note the number and thickness of shims
selector fork (1st and 2nd gear) out of their between transmission housing and retaining
seats. plates for reinstallation.

Assembling Note
To keep the selector fork from binding on the
selector fork rod, slightly open the selector fork
1. Place the same number and thickness of clamping piece with a screwdriver.
shims on the transmission housing studs as
noted during disassembly or as determined
while adjusting the pinion.
6. Insert input shaft and push into place

together with the pinion shaft.
2. Insert 1st and 2nd speed selector fork rod.
7. Torque clamping plate nuts to

3. Insert 1st and 2nd speed shift detent and specification.
spring.
8. Lightly tighten selector fork bolt (1st and

4. Torque bolt to specification.
2nd speed).
5. Insert pinion shaft with 1st and 2nd speed 9. Insert detent'from the top.
selector fork so that the pinion comes
barely to rest in the bearing race of the
transmission housing. 10. Unscrew bolts for 3rd and 4th speed
'selector fork and fork clamping piece.
Push fork and clamping plate back so that
the selector fork and rod can b e installed.

11. Lightly tighten selector fork and fork piece 20. Install thrust washer for 5th speed free gear.
bolts.
12. Insert shift detent and spring, torque plug

21. Install needle bearing with 5th speed free
to specification.
gear.
13. Adjust selector forks (see 3.1-2/1). 22. Install guide sleeve for 5th and reverse
speed, start flange nut on threads.
14. Place transmission housing gasket on the

studs. 23. Install thrust needle bearing cage, idler
gear with needle bearing cages and inter-
mediate piece and thrust washer on the
idler shaft.
15. Install gear housing together with selector
fork rod (5th speed and reverse) and
selector shaft. Tighten to correct torque.
24. Slide 5th speed and reverse sliding gear
with selector fork on guide sleeve and
selector fork rod.. SIightly open the selector
fork clamping piece for easier assembly.
16. Push selector fork rod in the ball slesve,
and-selector shaft into the shift pawl
guides.
25. Lightly tighten selector fork bolt.
17. Install. guide fork cover and gasket.

Tighten to correct torque.
26. Apply light coat of oil to the O-ring and
install.
18. Install idler gear shaft turning the shaft

until the pin in the gear housing prevents
i t from turning.
19. Install reverse speed Gear I and start

castellated nut on threads.

27. Block input shaft with special tool P 37a,

and engage 5th gear. Tighten input shaft
castellated nut and pinion shaft flange nut
to correct torque.
28. Adjust 5th and reverse speed selector fork

(see page 3.1-2/2).
29. Secure castellated nut with roll pin; and

flange nut by notching.
30. Insert actuating pin for backup light switch

with recessed end toward switch.
31. Place gear housing gasket on studs. Install

front transmission cover, and tighten nuts
to correct torque.

M a n u a l Tr?nrrninsion 911
Effective with the listed transmission numbers, the input shaft oil seal can b e replaced without the need
for disassembling the transmission.
Transmission Type from transmission No.

915/02 733 7375
915/12 723 0507
915/08 783 0838
Special transmissions 793 1031
Removal 3. Pull oil seal out by turning the hex. bolt in

the puller.
1. Remove transaxle and detach transmission
from engine.
2. Screw puller P 386 firmly into the oil seal.
NOTE:
If the (garter) spring should slide off during

removal of the seal, pull i t off t h e input shaft
with the aid of a wire hook.

Manual Transmission
I n s t a l l a t i on 3. Drive oil seal into its seat with the aid of

driver P 381.
1. Push installation sleeve P 382 onto the input
shaft splines.
2. Lightly oil the sealing lip of the oil seal and

push th.e seal onto the installation sleeve.

A D J U S T I N G SELECTOR FORKS
Note
Tighten input shaft flange nut to correct torque 4. position the 1st and 2nd speed selector fork
before adjusting selector forks. so that the shift sleeve is exactly in the
middle between the synchronizing rings.
Tighten bolt to correct torque.
1. Install mounting plate P 260a. Install 5th

speed synchro hub and 5th and reverse speed
sliding gear.
5. Adjust 3rd and 4th speed selector fork in
the same way as 1st and 2nd speed. Tighten
bolt to correct torque.
6. Position 3rd and 4th speed shift guide flush

with the selector fork. Make sure there is
2-3 mm (0.8-0.12 in.) clearance between
the 3rd and 4th speed shift guide and the 1st
and 2nd speed shift guide. They must not
touch. (see illustration).
2. Block input shaft with P 37a and engage 5th

speed. Tighten input shaft flange nut to
correct torque.
3. Turn selector fork rod of 1st and 2nd speed

left (in driving direction) to stop, then turn
slightly back until the unmachined flat
inner surface is almost vertical.
1 - Install aligned
2 - 2 to 3 mm play
Note
7. To ensure proper synchronization, check
Do not turn it back beyond the middle point or ease of shifting. Readjust if necessary.
all the way to the right stop.

11 Manual Transmiasion
Adjusting 5th and Reverse Speed Selector Fork
1. Push the idler gear on shaft against fixed

gear I of 5th speed. Ad just clearance bet-
ween idler gear and sliding gear in neutral
position. Clearance should be 1 m m
(0.04 in.).
Caution
Push the idler gear gently in direction of
travel; there should b e no play between the
shift fork and the sliding gear groove. This
eliminates the possibility of the sliding gear
hitting the idler gear in cases of tolerance
build -up.
2. Tighten selector fork bolt to correct torque.

DISASSEMBLING AND ASSEMBLING FRONT COVER
TOOLS
Nr. Description Special Tool Remarks .
1 Mandrel P 374
2 Mandrel P 369

911 Manual Tranimirs.ion
Disassembling and Assembling Front Cover

Note when Special
Backup light switch Torque to specifics-

tion.
Actuating pin Position properly.
Seal Press out with small Drive fully into seat

screwdriver. with P 374.
Retainer Replace if necessary.
Thrust washer
Speedometer drive
Retainer Seat properly.
O-ring Oil lightly.
Positioning piece
Worm shaft
Sea! Pry out with Drive in with P 369

screwdriver. until fully seated.
Shift rod bushing Replace.
Bushing Heat the cover to Heat the cover to

approx. 1 2 0 ' ~ .
approx 1 . 2 0 ~ ~
(250'~) on hot plate (250'~) on hot plate.
then pull out; drill Drive on with suitable
out if necessary. mandrel.
Transmission front
cover

DISASSEMBLING AND ASSEMBLING
Disassembling 3. Drive on seal for speedometer drive with

special tool P 374.
1. Heat transmission cover to approximately
1 2 0 ' ~ (250'~) and pull speedometer gear
shaft bushing out; drill out, if necessary.
Assembling
1. Heat transmission cover t o approximately

1 2 0 ' ~ (250'~) and drive gear shaft bushing
in with a suitable mandrel.
2. Drive on seal for shift rod with special tool

P 369.

Transmission 911
D I S A S S E M B L I N G A N D REASSEMBLING OIL P U M P
TOOLS
Description I Special TOOI I Remarks
1 Support - .
Commercial, KUKKO Nr 22-1
2 Inside puller - Commercial, KUKKO Nr . 21-02
3 Drift P 368

Disassembly and Reassembly

Transmission 911 3
Note when Special
No. Description instructions see
removing installing
1 Allen bolt 2 Torque to speci-

fication.
2 Lock washer 2 Replace.
3 Pickup tube 1
-
4 O-ring 1 Replace. Oil

lightly.
--
5 Plug for pressure 1 Ball and spring can Torque to speci-

relief valve fall out. fication.
6 Spring
7 Ball
8 Self-locking nut Tighten cross-wise

to specified torque
Check oil. pump
gears for fiee
movement.
9 Washer
--
10 Oil pump cover
11 Gasket X Note number and Recalculate thick-

thickness for ness, if necessary.
reassembly.
12 Oil pump gear I Check freedom of

movement. End
play approx.
0.05 mm.
13 Oil pump gear I1 Check freedom of

movement. End
play approx .
0.05 mm.
14 Bushing 2 Drive out with Drive in, properly

proper punch. oriented, with
P 368.
15 Bushing I
L l out with
l Drive i n , properly
I KUKKO inside oriented, with
puller. P 368.
16 Transmission
front cover

911 Transmission
I N S T R U C T I O N S FOR DISASSEMBLY A N D REASSEMBLY
Disassembly Reassembly
Note the thickness and number of gaskets Drive bushings into oil pump cover with
when removing the oil pump cover to special tool P 368, making sure that they are
simplify reassembly . properly positioned and fully in. T h e milled
ends of the oil pockets must point towards the
pressure chamber or oil pump gears,
respectively.
Note proper orientation of the bushings. Mark

lubricating hole.
Use a KUKKO inside puller to remove

bushings of oil pump gears from oil pump
cover. Place a protector between the puller
and the cover to avoid damage to the sealing
surface.
See sketch for exact location.

Transmission 911
2. Drive bushings into transmission front cover 4. Install oil pump cover and tighten self-
with special tool P 368, making sure that locking nuts cross-wise to specified torque.
they are properly positioned and fully in. Keep checking if the pump gears remain free.
The milled ends of the oil pockets must point If necessary, remove cover again and insert
towards the pressure chamber or oil pump gaskets as appropriate.
gears, respectively.
NOTE
End play of oil pump gears should b e 0.05 mm.
5. Tighten plug of pressure relief valve to

specified torque.
6. Lightly oil the O-ring for pickup tube.
7. Install Allen bolts for pickup tube, using new

lock washers, and tighten to specified torque.
See illustration for exact location.
Install gaskets in same thickness as noted

during disassembly.

Transmission 911 3
DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING
TOOLS
2 T- handle P 366

11 - Manual Transmission
Disassembling and Assembling Transmission Housing

911 3
a
Manual Transmission
Note when Special

11 Roll pin Drive out. Tension spring with

P 366 and drive in.
3.1-4/5
Drive out with flat Replace if necessary.

chisel.
3 Short detent 1
6 / Spring
I
7 / Long detent I
9
I1 5th and reverse speed
selector (shift) rod
Plug
1
Torque to specifics-
tion.
Replace.
11 I Washer I
l2
13
I Bellcrank for
accelerator linkage
Shaft
I 1
14 Washer 1
15 Retainer ring 2 Take out with small

screwdriver.
16 Bearing outer race 1 Heat gear housing to Heat gear housing to

.
approx 1 2 0 ~ ~ .
approx 1 2 0 ' ~
(250'~) and drive (250'~) and drive in
out with special with special tool
tool US 8050. US 8050.
Heat gear housing to Heat gear housing to

approx. 1 2 0 ' ~ .
approx 120°C
(250°F) and drive (250'~) and drive in
out with special with special tool
tool US 8050 US 8050
18 1 Gear housing

DISASSEMBLING AND ASSEMBLING
~isassem'bling Assembling
1. Drive shift detent securing roll pins out. 1. Heat housing t o approximately 1 2 0 ~ ~
(250'~) and drive bearing outer races-in
with special tool US 8050.
2. Drive half-round dowel pin out.
Note
Detent components are under spring tension.
Therefore, always remove the roll pin first,
then the half-round dowel pin.
3. Heat gear housing to approximately 120°c

(250'~) and drive bearing outer races out
using special tool US 8050.
., -
" ""
;
Caution
T h e bearing outer races differ in inside dia-
meter. The race with the larger inside diameter
belongs to the pinion shaft (lower shaft).
2. Install 5th and reverse speed shift rod.
3. Insert long detent and drive roll pin in.

4. Install spring and sleeve, tension both with 1- Gear housing
special tool P 366, and drive roll pin in. 2 - Half-round dowel pin
3- 3rd and 4th speed selector fork(shift) rod
4 - Short detent
5- Roll pin
6 - Pin
I - Sleeve
8 - Spring
9 - Long detent
1 0 - Roll pin
11 - 5th and reverse speed selector fork (shift)
rod
5. Insert pin and detent (short), then drive

the plug in.

F I N A L DRIVE HOUSING
TOOLS
1 Mandrel P 360a
2 Mandrel P 375

Disassembling and Assembling Final Drive Housing

Manual Transmission
3
_II Description
Removing
Note when
Installing
Special
instructions
see
1 Input shaft oil seal Drive out in direc- Install with P 360a.
tion of bell housing Sealing lip faces
with an appropriate bell housing.
punch.
21
3
Snap ring
Throwout lever Mark lever position

Replace.
Readjust if necessary.
on shaft to ensure
proper reinstallation.
4 1 Seal Replace if necessary.
Drive out. Replace if necessary.
6 ( Lever shaft
7 1 Throwout fork Readjust.
8 I Bushing Drive out with P 375. Drive in with P 375.
1 Cover tube
10 I Bushing Drive out with P 375. Drive in with P 375.
11 I Bushing
Clean and torque to

specification.
13 1 Breather Position properly,

torque to specifi-
cation.
Make sure it is
properly seated.

3 9fl Manual Transmission
Note when Special

see
Sna.p ring Note proper seating. 1 3.1-5/6
Bea.ring outer race Heat transmission Heat transmission

housing to 120°c housing to 1 2 0 ~ ~
(250°F) on a hot- (250°F) on hotplate
plate and drive out and drive in with
with US 8050. US 8050.
Bearing outer race Heat transmission Heat transmission

housing to 120°c housing to 1 2 0 ~ ~
(250'~) on hotplate (250'~) on hotplate
and drive out with and drive in with
Needle bearing/ Drive out with Drive in with appro- I

bushing appropriate mandrel. priate mandrel.

D I S A S S E M B L I N G A N D ASSEMBLING F I N A L DRIVE H O U S I N G
Disassembling 4. Remove bushing.
1. Drive out input shaft seal in direction of bell 5. Using a small screwdriver, remove both snap
housing with an appropriate mandrel. rings from the housing for input shaft and
pinion shaft bearings.
2. Drive roll pin out.
Note
The retaining rings are pressed against the
housing by the bearing outer races. For this
reason, first loosen the bearing racer from the
snap rings with a punch.
6. Heat housing t o approximately 1 2 0 ~ ~

(250'~) on a hotplate and drive out both
bearing outer races with special tool
US 8050.
Caution
Mark throwout lever and shaft to ensure
proper position when installing.
3. Drive out lever shaft bushings with special

tool P 375.
7. Drive out shift rod needle bearing/bushing

from inside of housing using an appropriate
mandrel.

Assembling 3. Heat housing to approximately 1 2 0 ~ ~

(250'~) on a hotplate and drive both bearing
outer races in with special tool US 8050.
Caution
When cleaning the final drive housing, do not
use corrosive cleaning materials as they will
damage the magnesium alloy.
1. Clean housing and check for wear, external

damage, and cracks. If repair is due to
broken pinion shaft of ring gear, check for
damage in center web bearing bores. Replace
the housing if necessary.
4. Install breather and torque t o specification.
2. Install bearing outer race snap rings in

housing grooves.
Note
Position the large snap ring so that its gap will
rest in the groove in the housing. In no case
should the snap ring gap appear at the sides Note
where the groove is interrupted by a machined The opening in the hex part of the breather must
cut. face forward in direction of travel (toward
transmission front cover).

5. Install input shaft seal with P 360a. Sealing 6. Drive in bushings for lever shaft with Special
lip faces bell housing. Tool P 375 (see drawing) and coat with grease
having a lithium or silicone base.
1 - Bushing
2 - Lever shaft bushing
3 - Cover tube
4 - Transmission housing
7. Assemble clutch controls.
Note
Throwout fork and throwout lever must be adjusted
on the lever shaft splines in order to attain proper
lever travel.
Important
8. After making repairs to transmission, apply
new protective undercoating to the entire
outside of the housing.

The adjustment dimensions are: Modified Clutch Release Lever - 1975 Models
From top edge of the bell housing to the tip of
the throwout fork = 70 m m The shape of the clutch release lever for trans-
mission types 915/40/45 has been modified due to
the location of the pipes of the new exhaust
system. This makes it impossible to detach or
attach the transmission without first removing the
release lever.
After attaching the engine and .transmission to-

gether, the new release lever must be installed
so that it runs parallel to the clutch cable sleeve
flange.
Adjustment of the release fork and release lever

as in the past is omitted.
From top edge of bell housing to the bottom

throwout lever cut-out = 79 mm

Transmission 11
2. Remove retaining bolt of pressure line (spray

nozzle for ring and pinion gears) from differen-
NOTE tial housing and pull the pressure line out.
Due to the simple attachment of the pressure

lines, they can be replaced without removal
of the gears.
Removal
1. Remove pressure line retaining bolt from gear

housing and pull pressure line out.
Inst a l l a tion
1. Install new O-rings and oil lightly.
2. Tighten retaining bolts to specified

torque.

T R A N S M I S S I O N H O U S I N G W I T H G U I D E TUBE FOR T H R O W O U T BEARING
TOOLS
2 Thrust piece P 254 d
3 Sleeve P 381
4 Mandrel P 375

Disassembling and Reassembling Differential Housing

Note when:
No. Description Remarks .
removing installing
Input shaft Drive out inward Drive into seat with

oil seal with fitting pipe P 381
piece
Snap ring Replace if necessary
Throwout lever Mark lever posi- Readjust if necessary

tion on shaft for
reassembly
Seal Replace if necessary
Roll pin Drive out with Replace if necessary

proper punch
Lever shaft
Throwout fork Mark fork posi- Readjust if necessary

tion on shaft for
reassembly
Bushing Drive out with Drive in with P 375

P 375 in proper position
Cover tube

P 375 in proper position
Bushing CDELRIN) Pry out with angu.- Replace if necessary

lar screwdriver by
pressing around
sides
Drain plug Clean, torque to

specification

Note when:
No. Remarks
removing installing
Breather Position properly

and torque to
specification
Snap ring Remove with small Make sure it is

screwdriver properly seated
Bearing outer 1 Heat differential Heat differential

race housing to approx. housing to approx.
1200 C (248O F) and 120° C (2480 F) and
drf v e race out with drive race in with
US 8050 US 8050
Bearing outer 1 Heat differential Heat differential

race housing to approx . housing to approx .
120' 6 (248O F) and 120' C (248O F) and
drive race out with drive race in with
US 8050 US 8050
Differential
housing

D I S A S S E M B L I N G A N D REASSEMBLING D I F F E R E N T I A L H O U S I N G
Disass e m b l y 4. Using a small screwdriver, remove snap ring

of input shaft bearing race.
1. Drive input shaft oil seal inward with the aid

of a fitting pipe section.
NOTE:
2. Drive roll pin out with an appropriate punch.
The snap ring is pressed against the housing by
the bearing race. It is necessary to first drive
the bearing race away from the snap ring with
the aid of a punch.
5. Heat differential housing t o approx. 120° C

(248O F) and drive both bearing races out with
thrust pieces US 8050 and P 254 d.
3. Drive out lever shaft bushings with P 375.

3. Heat differential housing to approx. 120' C

Reassembly (248' F) and drive both bearing outer races
into place with the aid of US 8050.
" ,. - ..
1. Clean differential housing and check for wear,
external damage, and cracks. If the repair is
due to a damaged pinion shaft or ring gear
(such as metal fracturing), check for possible
damage to center web bearing bores. Replace
the housing if necessary.
NOTE
. ,
2. .I
, .
Pressure-cast housings
- must not b e cleaned
with corrosive liquids since these damage
magnesium alloys. In addition, cleaned
pressure castings must b e treated with seasonal
4. Install breather in proper position and torque
corrosion preservatives of bitumen or wax base,
to specification.
such as TECTYL, following transmission re-
pairs to restore the corrosion proofing.
2. Install snap ring securing the input shaft

bearing race in the groove in housing.
NOTE
The hole in the hex. head of the breather must

face forward in direction of travel (toward trans-
mission front cover).

Manual Transmission
5. Drive input shaft oil seal into place with 7. Install clutch controls.
P 381.
NOTE
6. Drive in bushings for lever shaft with Special
Tool P 375 (see drawing) and coat with grease Throwout fork and throwout lever must be
having a lithium or silicone base. adjusted on the lever shaft.splines to attain
proper clutch lever travel.
The dimensions are:

From top edge of bell housing to the tip of the
throwout fork = 70 mm.
1 - Bushing
2 - Lever shaft bushing
3 - Cover tube
4 - Differential housing

From top edge of the bell housing to the root Modified Clutch Release Lever .- 1975 Models
of the claw in the throwout lever = 79 mm.
The shape of the clutch release lever for trans-
mission types 915/40/45 has been modified due to
the location of the pipes of the new exhaust
system. This makes i t impossible to detach or
attach the transmission without first removing
the release lever.
After attaching the engine and transmission

together, the new release lever must be installed
so that it runs parallel to the clutch cable sleeve
flange.
Adjustment of the release fork and release lever

as in the past is omitted.
8. Coat guide tube for throwout bearing with

MoS2 multipurpose grease.

T R A N S M I S S I O N C A S E W I T H BOLTED G U I D E T U B E FOR RELEASE BEARING
TOOLS
1 Thrust plate US 8050
4 Mandrel P 381
5 Mandrel P 375


Note when Special -
Description
Removing Installing instructions see
Phillips ctsk. screw Torque to specifica-

tions
Guide tube Use hook to remove Install with MoS2

additive lubricant
Seal, drive shaft Drive out with Press in with P 381

P 381
O-ring Replace, lubricate
Pin Drive out with Replace if necessary

appropriate drift
Circlip Replace if necessary
Release lever Mark for reinstall- Adjust, if necessary

ing with lever
shaft
Seal Replace if necessary
Lever shaft
Release fork Mark for reinstall- Replace if necessary

ing with lever
shaft
Cover tube

P 375

P 375
Bushing (Delrin) Use angled screw- Replace, if necessary

driver on both
sides to pry out
Plug Clean and torque to

specifications
Snap ring Remove with small Install correctly

screwdriver

-
Note when :$pecial
No. Removing Installing :instructions see
-
17 Bearing outer race Heat care to approx Heat case to approx
1 2 0 ' ~ / 2 4 8 ' ~ and 1 2 0 ' ~ / 2 4 8 ' ~ and
drive out with drive in with
US 8050 US 8050
18 Bearing outer race Heat case to approx Heat case to approx

1 2 0 ' ~ / 2 4 8 ' ~ and 1 2 0 ' ~ / 248% and
drive out with drive in with
US 8050 US 8050
19 Breather Position correctly

and torque to
specifications
20 Transmission case Check for damage

-

DISASSEMBLING AND ASSEMBLING I N S T R U C T I O N S
On the 1976 model manual transmission 915 the

clutch release lever can b e preassembled and
adjusted.
Assembling Clutch Release Components
T o assure perfect clutch operation, release fork

and release lever must b e matched with each
other on the lever shaft splines.
Specifications are:
Approx. 71 m m from clutch bell housing flange
surface to upper edge of release bearing surface
on fork.
Approx. 91 m m from clutch bell housing flange

surface to depression in lever.

R E M O V I N G A N D I N S T A L L I N G D R I V E S H A F T SEAL - 1 9 7 6 MODEL
The drive shaft seal of 1976 model manual transmission 915 c a n b e replaced without having to
disassemble the transmission.
Removing Installing
1. Remove engine/transmission assembly and 1. Drive new seal in guide tube with special
separate transmission from engine. tool P 381.
2. Remove both Phillips countersunk bolts on 2. Place new rubber O-ring 011 neck of guide
guide tube. Pull out guide tube for drive tube.
shaft seal with a locally manufactured hock.
Slide special tool P 382 over splines of

drive shaft.
Apply a light coat of lubricant to sealing lip

of seal in guide tube and rubber O-ring on
guide tube neck.
3. Remove seal with an appropriate mandrel or
Drive in guide tube until positioned correctly.
screwdriver. Special tool P 381 can b e
applied.
6. Install mounting bolts and torque to

specifications.
7. Coat release bearing guide tube with MoS2

paste.

TRANSMISSION CASE W I T H AUXILIARY C L U T C H SPRING ( 1 9 7 7 MODELS)
. .

Note when
removing installing
Spring
Circlip Replace, if necessary
Adjusting lever Adjust
Seal Replac% if necessary
Round pin omitted from

March, 1979
Clutch release lever Coat pin for spring
with all -purpose lube
containing MoS
2
Seal Replace, if necessary
Circlip Replace, if necessary
Washer
Auxiliary spring
Washer
Adjusting bolt
Nut Torque to specifica-

tions

tions
Washer Replace, if necessary
Holder
Base Coat pin for spring

with all-purpose lube
containing MoS
2
Spring pin Replace, if necessary
Lever shaft

Note when
removing installing
-
20 Release fork
21 Seal Replace, if necessary
22 Bushing Drive out with Drive in with P 375

P 375 until positioned
correctly
23 Cover tube
24 Bushing Drive out with Drive in with P 375

P 375 until positioned
correctly
25 Bushing Replace, drive in

-
Disassembling
1. Disengage spring for adjusting lever and 2. Pull adjusting lever off of lever shaft.
remove circlip.
3. Release auxiliary spring. This requires

pressing clutch release lever toward front
transmission cover with an appropriate tool.
Note
When reaching the "dead point" the auxiliary spring

will snap forward on its own.

Assembling
1. Drive in bushings for lever shaft with Special 3. Locate clutch release lever with a round pin.
Tool P 375 (see drawing) and coat with grease
having a lithium or silicone base.
4. Tension auxiliary spring (must snap past the

dead point to stop pin).
1 - Bushing
2 - Bushing, lever shaft
3 - Cover. tube
4 - Transmission case
2. Install clutch release lever with spring and

adjusting screw on splines of lever shaft.
Note
Only install adjusting lever after engine/trans-

mission lever is installed in car,.

RELEASE LEVER - 1 9 7 8 MODELS

- --
Note W,hen Special

No. Description Qty. Instructions
Removing Installing
-
1 Circlip 1 Replace, if necessary
2 Washer 1
3 Cover 1 Replace
4 Circlip 1 Replace, if necessary
5 Washer 1
6 Auxiliary spring 1
7 O-ring 1 Replace
8 Washer 1 Replace
9 Pin 1
10 Needle bushing 2 Drive out with Drive in to correct

Tool No. 9153 position with Tool
No. 9153
11 Release lever 1
-

Manual Transmission f8
1. Remove upper circlip and drive pin down

until cover falls out.
1. Drive pin into spring so that washe~and cir-
clip can just b e installed.
Note
This will deform the washer (item 8).
2. Drive in needle bearings to correct position

with Special Tool No. 9153.
Note
Lubricate needle bearings and bore of release le-

2. Remove lower circlip and pull out pin with
ver with a waterproof lubricant (silicone or lithium-
spring.
based) before installation.
3. Drive out needle bearings with Special Tool

No. 9153.
.-
.
~
- , < <,, , -.P'.~I: &J+-
I
3 --. 2..:2....x :,*dt-
*,-4
Taw-
_)
*;*,2./
_'.
(r.
'
6
,
"-
.:
*.&
1 - Flush

DISASSEMBLING AND ASSEMBLING I N P U T S H A F T
TOOLS
Support plate
2 Socket P 252a
3 Thrust plate VW 401
4 Thrust p l a t e VW 402
5 Thrust disc VW 412
6 Thrust tube VW 415a
7 Press punch VW 407

I I I
8 1 Thrust tube I VW 416b I
10 V-blocks VW 406 Two each
11 Thrust tube VW 454

Disassembling and Assembling Input Shaft

-
Manual Transmission
Note when Special

911 3
Nr. Description instructions
-
1 Flange nut Remove with P 252a Torque to specifics- 3.1-6/6

tion, secure with
center punch.
-
2 Roller bearing Press off with VW Press in with VW 401,

401, VW 402, and VW 454, and VW
VW 412. 407.
-
3 Bearing inner race Keep together with Install as a matched
bearing to ensure set only. Heat to
correct installation approx. 1 2 0 (250'~)
~ ~
position. and drive on.
-
4 Four-point bearing
-
5 Bearing clamping plate
-
6 Bearing inner race Install as a matched
set only. Heat to
approx. 1 2 0 ' ~ (250'~)
and drive on.
-
7
- -Thrust washer
8 4th speed Check synchronization . 3.1-8/4
-
9 Needle bearing Fasten to respective Make sure bearings
gear and race with have not been inter-
mechanic's wire. changed.
-
10 Needle bearing race Fasten to respective Make sure races have
gear and bearing with not b e interchanged.
mechanic' s wire.
-
11 Shifting sleeve Check for wear.
-
12 Spider Check for wear.
-
13 3rd speed
-

Note when Special

Needle bearing Fasten to respective Make sure bearings

gear and race with have not been inter-
mechanic's wire. changed.
Needle bearing race Fasten to respective Make sure races have

gear and bearing with not been interchanged.
mechanic' s wire.
Thrust washer
2nd speed Check for wear. Re-

place in pairs only.
Roller bearing Press off with VW Press on with VW 416b

415a and VW 407 and VW 412
Input shaft Check for runout.

DISASSEMBLING AND ASSEMBLING I N P U T S H A F T
Disassembling 3. When removing other parts, wire needle

bearings races, and respective gears together
for correct reinstallation.
1. Mount support plate P 355a in a vise. Insert
input shaft and remove flange nut with
special tool P 252a.
4. Press roller bearing off input shaft with

thrust tube VW 415a and press punch VW 407.
Press roller bearing off input shaft with

thrust plates VW 401 and VW 402, and
thrust disc VW 412.
Assembling
Caution
Assemble all input shaft parts dry. Make sure
oil does not enter between the contact sur-
faces.

1.. Press roller bearing on with thrust disc Caution

VW 412 and press thrust tube VW 416b. When reinstalling needle bearings and races,
make sure they are not interchanged with those
of another gear.
3. Torque flange nut to specification with

special tool P 355a and P 252a.
4 . Rock flange nut in place with center punch.
2. Press roller bearing on with thrust plate

VW 401 and thrust tube VW 454 and press
punch V W 407.

Always check input shaft for runout when i t is
fully assembled and the flange nut torqued to
proper specification.
1. Remove the input shaft outer bearing races

from the transmission and final drive housings
and place them on the pinion shaft
(substitute bearings can b e used).
2. Place assembled pinion shaft with bearing

outer races on V-blocks VW 406. Check for
runout as shown in illustration. Maximum
runout= 0.1 mm(0.004in.).
3. The input shaft can b e straightened while

cold if the runout does not exceed 0.3 mm
(0.012 in.). Use press with V-blocks VW 406
and press punch VW 405.

- Manual Transmission
911 3
DISASSEMBLING AND ASSEMBLING PINION SHAFT
TOOLS
2 Thrust sleeve VW 24413
3 Thrust plate VW 401
4 Thrust p l a t e VW 402

p-
6 Thrust tube P 255a
7 Thrust tube VW 415a

Disassembling and Assembling Pinion Shaft

Note when Special
Description
Zemoving Installing instructions see
Roller bearing Press off pinionshaft Press on with V W 407

iyith VW 401, VW and VW 415 a.
112, and P 255 a.
Thrust washer
1st speed Check synchronization. From 1977 Models

Replace only in pairs. with asymmetric
tooth point of
clutch body
Needle bearing :asten to respective Make sure bearings

;ear with mecha- have not been inter-
lit' s wire, changed.
Shift sleeve Check for wear. From 1977 Models

with asymmetric
tooth point of 1st'
gear. Note direc-
tion of installation
(see Page 3.1-7/6)
Synchro hub Check for wear. From 1977 Models

reinforced
2nd speed Check synchronization.

Replace only in pairs.
Needle bearing !asten to respective Make sure bearings

;ear and race with have not been inter-
nechanic' s wire. changed.
Needle bearing race 'asten to respective Make sure races have

;ear and bearing not been interchanged.
vith mechanic' s
lire.
Thrust washer
3rd speed Large,smooth surface

must face thrust washer.
Replace only in pairs.
spacer bushing

911 Transmission
Note when
Description Qty .instructions
Removing Inst all ing :see
I
4th speed Large, smoothly ground
surface faces four-
point bearing. Replace
I
only in pairs.
I
Clamping plate
Bearing inner race Press off with VW Heat to approx. 1 2 0 ~ ~

401, VW 412, and (250°F) and drive on.
P 255a.
Four-point bearing
--
Roller bearing 1 Press off with VW Press on with VW 407 3.1-7/5

401, VW 412, and and VW 415a.
P 255a.
Speedometer drive, 1 Remove with puller. Heat to approx. 120°C 3.1-7/5

Gear I (250'~) and drive on.
Pinion shaft 1 Readjust if necessary. 5.1-4/1

DISASSEMBLING AND ASSEMBLING PINION S H A F T
1. Press roller bearing off pinion shaft with Assemble all pinion shaft parts dry. Make sure
thrust plate VW 401, disc VW 412, and tube that no oil enters between the contact surfaces.
P 255a. Pinion shaft and ring gear are marked with paired
numbers. Check that these numbers match be-
fore assembling.
1. Press roller bearing on with press punch

VW 407 and tube 415a.
2. Remove components from pinion shaft. Wire

needle bearings and races to respective gears
to prevent interchanging of parts during re-
assembly.
3. Remove speedometer drive Gear I.
Note
Install bearing so that the ring of the two part
roller cage faces the gears.

11 Manual Tr anrmirsion
2.. Press small roller bearing on pinion shaft

using thrust disc VW 412 and thrust sleeve
VW 2 4 b .
3. Heat speedometer drive gear I to 120°C

(250'~) and drive on.
Modifications from 1 9 7 7 Models
The asymmetrical pointed teeth of lst/2nd

gear operating sleeve must face toward 1st
gear wheel.

DISASSEMBLING AND ASSEMBLING SYNCHRONIZERS
TOOLS
Micrometer - Size: 75-100 mm

Disassembling and Assembling Synchronizers
Note when Special

Circlip Remove with pliers. Install with pliers.
Synchronizing ring Check for wear.
Brake band, only 1 Place on proper side

for 1st speed in 1st speed.
Brake band anchor

block, 2nd speed
Thrust block, 2nd

speed
Brake band anchor block, Position properly.

1st speed
Thrust block, 1 st Position properly.

speed
Gear, 2nd speed
Gear, 1st speed

D I S A S S E M B L I N G AND ASSEMBLING S Y N C H R O N I Z E R S
Disassembling
1. Remove the circlip from the gear. Check all 2. When assembling the 1st gear synchronizer,
parts for wear and damage and replace as make sure to install only one brake band
necessary. (see illustration).
Assembling
1. Place synchronizing ring on clutch carrier.

Make sure rough ring surface faces the shift
sleeve. Insert thrust block, anchor block,
and brake band(s). Note
Clutch carrier and brake band energizer
have matching contour and must b e installed
in such positions (see arrow).
3. Install retaining ring with retaining ring

.
plier

Checking 2. Maximum clearance between selector fork

and shifting sleeve of 1st through 5th speed:
Dimension a = 0.5 mm (0.02 in.).
1. Using a micrometer, check diameter of

installed synchronizing ring. Place micro-
meter at the highest point of the synchro-
nizing ring.
.y
-
i
7
w
r- - T i a
Diameter:
3rd, 4 t h and 5th speed = 76.3 t 0 .I8 rnrn
1st and 2nd speed = 86.37 t 0.17 mm

Manual Transmission
MODIFICATIONS - 1 9 7 7 MODELS
T h e synchronization for 1st and 2nd gears has 2. 2nd gear synchronizing parts.
been modified on the 1977 Models.
1. 1st gear synchronizing parts.
3. The installation diameter of the synchronizing

-
rings has not been changed (see Page 3.1 8/4).
Note
An altered anchor block (see photo) will b e

introduced later for 1st gear.

Sportomatic 911
DISASSEMBLING AND ASSEMBLING TORQUE CONVERTER HOUSING
TOOLS
Nr . Description Special Remarks

Tool
1 Installer P 358 a
3 Socket, 6 mm, 12-point US 103 C
4 Centering mandrel P 370
5 Mandrel P 362
6 Mandrel P 361
7 1 Support I Local purchase item
8 Internal puller --- Local purchase item

911 Sportomatic
Disassembling and Assembling T o r q u e Converter Housing

Nr. Description Q~Y. Note when Special
instructions
removing installing see
1 Socket-head bolt 6 loosen evenly in Tighten evenly in

criss-cross pattern criss-cross pattern
to specified torque.
2 Lock washer 6 Replace if necessary.
3 Pressure plate 1 Check wear,
4 Throwout bearing 1 DJ not wash in sol-

vents, only dry wipe.
5 Clutch disc 1 Check wear, check free

movement on splines
between clutch plate
and input shaft.
6 Oil seal 1 Remove with puller Install with P 362.
7 Needle bearing 1 Remove with puller ' Install with P 362,

lubricate with a mix-
ture of multi-purpose
grease and Molykote
type lubricant.
8 Socket-head bolt 8 Tighten evenly t o

specified torque.
9 Oil seal 8 Replace.
10 O i l seal 1 Remove together with Oil torque converter

freewheeling support seating surface,
drive in with P 358a.
11 Stator support 1 Using two (6x60) bolts,

drive out with alter-
nating forces applied
from turbine shaft side.
12 O-ring 1 Oil lightly

I I I I I
13 Snap ring 1 Replace. Check seating.
14 Turbine shaft 1 Drive out. Assure Check wear.

firm support
under torque con-
verter housing.
15 Ball bearing 1 Drive out with punch. Heat torque converter

housing t o 120°c, drive
in with P 359.

911 Sportomatic
-
Descriptiop Q~Y Note when Special

removing installing instructions
see
Oil seal 1 ( Push out with icrew-

driver
Oil torque con-
verter seating sur-
face, drive in
with P 359.
Temperature switch Tighten to correct

torque.
Oil seal Replace
Temperature sender Tighten to cor-

rect torque.
Oil seal Replace
Threaded coupling Tighten to cor-

rect torque.
Oil seal Replace
Torque converter
housing
-

Sportomatic 911 3
DISASSEMBLING AND ASSEMBLING T R A N S M I S S I O N
TOOLS
Nr. Description Special Remarks

Tool
I 1 I Assembly plate
2 Holding plate P 260
3 Sleeve P 364
1 4 1 ~nstaller I P 360 1 1
1 5 1 Thrust piece
6 Press plate VW 4 0 1
7 Remover P 353a
8 Input shaft holder P 37
9 Thrust sleeve VW 426

Sportomatic
Disassembling and Assembling Transmission

Sportomatic 911 3
Nr. 1 Description
removing
Note wh 1
installing
Special
instructions
see
I I1
2
Cap screw
Oil seal
Tighten t o correct
torque.
Replace
3 1 Spring
4 Ball, 9 m m
5 1 ~ o c knut Replace if necessary.

Tighten t o correct
torque.
6 1 Washer
-I---- Lock nut Replace if necessary.

Tighten to correct
torque.
-d----- Washer Place on ahead and

one behind the ground
strap.
Transmission fron
cover
l1 I Gasket Replace
12 Spring
Parking lock
lever
14 Parking lock pawl
15 Expansion bolt Engage 4th gear, Oil contact surface.

block input shaft Tighten to correct
with P 37. torque. Ensure cor-
rect seating of speedo-
meter drive gear,
,
16 Speedometer driv Must still have clea-
rance after expansion
bolt has been tightened
L Lock ring Replace

Note when Special
see
118 1 Shift fork for re- Push detent pin in. Check wear.
Remove with selector
gear.
Check wear.
20 Detent pin
lout.
Small end faces
21 Spring
22 Splined bushing Speedometer

drive groove
faces expansion
bolt head.
1- 123
Reverse idler gear
assembly
. Check wear.
24 Needle bearing cage Check wear.
Check wear.
Tighten t o correct
torque, secure with
center punch.
1
1I I27- Bypass bridging Tighten to correct
,
torque.
28 Plunger
1 2 9 1 Backup light switch Tighten to correct

torque.
Plunger
Tighten to correct
torque.
Replace.
no gear is engaged.
10il lightly.
Pull off studs with

components in
items 37-58.

Sportomatic 911 3
I Description
removing
Note wt
installing
Special
instructions
.
;
see
i-
Gasket Note quantity Recalculate if neces-
and thickness.
Tighten to correct
torque.
1 38 1 Spring
39 Ball, 9 mm
40 Reverse gear
shift rod
+
41 Detent
1 421 BOI~ Tighten to correct

torque
Spring washer Replace.
Shift fork, 1st

and 2nd gear
Mark for reassemb-
ly
I
Check wear.
Shift rod, 1st

and 2nd gear
Ball, 9 m m 1
Adjust.
.
Insert large detent with
some grease, install
spring and pin toge-
ther with spring.
48 1 Detent (large)
49 I Ball, 9 m m
Bolt Tighten to correct

I
torque.
51 Spring washer Replace.

I
52 Shift fork, 3rd Mark for reassemb- Check wear, readjust.

and 4th gear ly.
i
ll Shift rod, 3rd
and 4th gear
Shift fork rod anc

Ad just.
Insert before installing

selector lever intermediate plate.

911 Sportomatic
Description Q~Y Note when Special

see
Pinion shaft 1 Press out of

intermediate
Input shaft 1 plate with P 353a.
Spacer
Bearing inner race Press in with VW 401, 4.1 - 2/8

half 412 and 426.
Transmission hou-
sing

p o r t o a t i 911 3
D I S A S S E M B L I N G A N D ASSEMBLING T R A N S M I S S I O N
Disassembling 3. Lock input shaft with P 37 holder. Loosen

pinion shaft expansion bolt and remove to-
gether with speedometer drive gear.
1. Engage 4th gear (turn shift rod to the
right and pull outward).
4. Remove snap ring from reserve gear shift

rod and parking lock.
Gear I, reverse gear 5. Remove selector gear and shift rod for re-
Flanged nut verse gear; this requires pushing the detent
Reverse idler gear assembly pin in.
Reverse selector gear
Parking lock springs
Speedometer drive gear
Speedometer drive gear
Expansion bolt
Parking lock lever
Shift fork, reverse gear
Snap ring
2. Detach parking lock springs, remove

pawl and lever.

911
- - - Sportomatic
6. Remove splined bushing. Assembling
7. Remove reverse idler gear assembly to- 1. Insert input shaft spacer, slide pinion and
gether with needle bearing cages and input shafts into the bearings of the inter-
thrust needle bearing cage. mediate plate and splines of Reverse Gear
I respectively.
8. Remove input shaft flanged nut.
2. Hand tighten input shaft flanged nut.

9. Remove bypass (bridging) switch and
backup light switch. Pull out both con-
tact plungers.
3. Press bearing inner race half of the four-
point bearing into position using special
10. Withdraw gear assembly and intermediate tool VW 401, VW 412 and VW 426.
plate from transmission housing.
Caution
Note the quantity and thickness of gaskets

for proper reassembly.
11. Using special tool P 353a, press pinion

and input shafts out of the intermedi-
ate plate at the same time.
4. Engage 4th speed.

Sportomatic 11
5. Slide intermediate plate and gear assembly 9. Install reverse selector gear and shift fork.
into transmission housing. Then using four spa- Detent pin in shaft rod for reverse gear and
cer bushings on folur of the studs, tighten in- parking lock must be pushed in.
termediate plate in a criss-cross pattern.
Block input shaft with P 37 holder, slide

splined bushing into place, and tighten ex-
pansion bolt (without speedometer drive
gear) to correct torque.
Note
The expansion bolt is later removed when

installing selector gear and shift forks.
10. Remove pinion shaft expansion bolt and

oil bolt head contact surface. Install
bolt together with the speedometer drive
7. Remove intermediate plate with the assemb- gear. Make sure that the speedometer
led gears in order to install and adjust shift drive gear is properly seated on the end
forks. of the splined bushing.
8. Assemble selector lever. Tapered hole in 11. Lightly coat the O-ring for the selector
the shift rod must point in same direction lever guide fork with oil.
as the selector lever.
12. Place special tool P 364 on the input shaft.

Position the oil seal so the sealing lip is
toward the transmission. Then drive the
seal in place with special tool P 360
until the tool bottoms.

Sportomatic 911 3
DISASSEMBLING A N D ASSEMBLING T R A N S M I S S I O N FRONT COVER
TOOLS
Nr. Description Special Remarks

Tool
1 Mandrel P 218
2 Mandrel P 362
,

911 Sportomatic
Disassembling and Assembling Transmission Front Cover

Sportomatic 911 3
I
1
Description
Speedometer
removing installing
Tighten to specified
Special
instruct ions
see
drive retaining torque.

bolt
12 1 Washer
3 Speedometer Blind hole in guide
+
drive (complete) bushing lines up with
hole in cover.
Elbow adapter
Replace if necessary.
+
Guide bushing
-
0-ring Oil lightly.
Gear shaft
Drive in with P 218.
1 Heat cover to approx. Drive in to bottom

120' C (250' F) on a with P 362.
hot plate and pry out.
- -
1 Heat cover to approx. Heat cover to approx.

120° C (250' F) on a 120' C (250' F) and
hot plate and pull out. drive in with an appro-
Drill out if necessary. priate mandrel.

Sportomatic
D I S A S S E M B L I N G A N D ASSEMBLING
Disassembling 3. Heat transmission cover to approx. ,120' C

(250' F) on a hot plate'. Pull out or drill
out the gear shaft bushing,
1. Remove speedometer drive retaining bolt,
pull out elbow adapter and gear shaft.
Assembling
1. Heat transmission cover to approx. 120' C

(250' F) on a hot plate, drive gear shaft
bushing in.
Drive the thrust washer for reverse idler

'
gear in to bottom with special tool P 362.
2. Pry out thrust washer for reverse idler gear

assembly by prying on both sides.
Insert elbow adapter. Blirtd hole in guide

bushing must line up with hole in cover.

Sportoma t i c 911 3
4. Install shift rod seal with special tool P 218.

Sportomatic 911
DISASSEMBLING AND ASSEMBLING I N T E R M E D I A T E PLATE
TOOLS
Nr . Description Special Remarks

Tool
1 Centering mandrel P 372 In 2 parts.

2 Thrust piece P 371
3 Installation arbor P 262
4 Guide sleeve P 255

'3
1 911 Sportomatic
Disassembling and Assembling Intermediate Plate

Sportomatic 911 3
Description Note when Special
see
Bolt Tighten to specified

torque.
Washer
Clamping plate Check helicoil

inserts.
Four-point ball Check wear.

bearing Align center with
P 372,
Support plate Position properly

when installing.
Snap ring Remove with small

screwdriver.
Shaft for reverse Heat intermediate Heat intermediate

idler gear assembl plate to approx. plate to approx.
1200 C (250' F) 120' C (250' F)
and press out. and press in shaft.
Make sure it is
properly seated.
Thrust washer Stepdown side faces

front cover.
Grooved ball bea- Heat intermediate Heat intermediate

ring with Gear I plate to approx. plate to approx.
for reverse gear 1200 C (250' F) 120' C (250' F)
appropriate pipe appropriate pipe
section. section.
-
Roller bearing Heat intermediate Heat intermediate

outer race plate to approx, plate to approx.
120' C (250' F) 120' C (250' F)
appropriate pipe appropriate pipe
section. section.
Dowel Heat intermediate Heat intermediate

plate to approx. plate to approx.
120' C (250' F) 120' C (250' F)
and press out. and press in.
Spring anchor
stud

T e s c ript ion .
Qty Note when Special
removing
I installing instructions
see
7-
14
I
Bushing
Bushing
Drive in with
P 262.
Drive in with
P 262.
l5 I Bushing Drive in with
plate

D I S A S S E M B L I N G A N D ASSEMBLING I N T E R M E D I A T E P L A T E
Disassembling 4. Using special tools P 371 and P 255, press

Gear I for reverse gear off grooved ball bea-
ring.
1. Remove clamping plate retaining bolts

(arrows).
2. Using a small screwdriver, remove snap

ring which retains roller bearing outer
race.
Note
The snap ring may bind in the groove. There-

fore, relieve binding pressure by tapping the
bearing outer race away from the snap ring.
3. Heat intermediate plate t o approx. 1200 C

@50° F) and press or drive the parts out.

11 Sportomatic
Assembling
1. Using special tools VW 407 and P 255, 4. Press dowel pins in. They rnust protrude
press Gear I for reverse gear into grooved approx. 5 . 5 mm (0.22 in. ) on each side of
ball bearing. the intermediate plate.
5. Install clamping plate together with four-

point bearing and support plate.
6. Mount receptacle from special tool P 372

in vise and place bearing inner race of four-
point bearing on it.
Note
When installing the bushings, make sure, the

bushings do not protrude into the guide bores
of shift rods.
2. Using special tool P 262, drive bushings

for shift detents in.
a) Drive long bushing in until mandrel

bottoms.
b) Drive short bushing in t o the second

mark on the mandrel.
c) Drive the medium size bushing in to

the first mark on the mandrel.
Note
To center the bearing, use bearing inner race of

the four-point bearing which should be pressed off
3. Heat intermediate plate t o approx.
t h e pinion shaft. A spare bearing inner race can
120' C (250' F) and press or drive the
b e used for this purpose.
parts in.

Sportomatic 911 3
7. Place intermediate plate on top, insert
second bearing inner race, and center
four-point bearing with P 372.
8. Tighten bolts to correct torque.

MAIN SHAFT
TOOLS

-
1 Plate
-
Holder P 376
-
Thrust tube VW 416 b
-
-
Thrust disc I VW412 1
Socket wrench P 252
-
Torque wrench - Local purchase .
-
911 Sportomatic
DISMANTLING AND ASSEMBLING

Sportomatic 911
Notes
Description Remarks
Spacer
(2.6 mm thick)
Nut Unlock and loosen Torque to specifi-

with P 252 cations
Lockplate Replace
Roller bearing Press off VW 401 Install with VW 412,

and VW 412 VW 416 b and VW
401
Washer Install correctly,

bevel faces roller I
bearing
Spacer
Shift sleeve Check for wear
Shift sleeve guide Check for wear
3rd gear 27:25 V Check synchroniza-

tion; replace in
pairs only
Needle bearing Mark for Install with same

installation gear
Race, needle bearing Mark for Install with same

installation gear
Thrust washer
(2 mm thick)
2nd gear 22:29 M Check for wear;

replace in pairs
only
Main shaft with Check runout, replace

1st gear 16:34 DA if necessary

911 Sportomatic
D I S M A N T L I N G A N D ASSEMBLING I N S T R U C T I O N S
Dismantling Assembling
1. Clamp holder P 376 in a vise, install shaft

and unlock nut. Note
Before assembling, clean all shaft parts and dry.
1. Install roller bearing with special tools VW

412. VW 416 b and VW 401,.
2. Loosen nut with special tool P 252.
3. Remove roller bearing from shaft with special

tools VW 401 and VW 412.

Sportomatic 911
PINION SHAFT
TOOLS
1 Drive sleeve VW 244
2 Guide No. 9100 Consists of 2 pieces
4 Plate VW 401

DISMANTLING AND ASSEMBLING

- -
Notes
-No, Description Qty.
- Removal Installation
Remarks
1 Bearing inner race 1 Install with correct

adapter
2 Spacer (1 m m thick) 1
3 Roller bearing 1 Remove frompinion Install with VW 412.

shaft with VW 412 V W 244 and V W 401
and 9100
4 Thrust washer 1 Flat side faces needle

bearing
5 1st gear 16:34 DA 1 Check synchronization; From 1977 Models

replace in pairs only with asymmetrical
pointed teeth of
clutch body
6 Needle 2 Mark for installa- Install with same gear

tion
7 Race, needle bearing 2 Mark for installa- Install with same gear
tion
8 Shift sleeve 1 Check for wear From 1977 Models

with asymmetrical
pointed teeth for lsl
gear. Note directio
of installation (see
Page 3.1- l / 6 )
9 Shift sleeve guide 1 Check for wear
10 2nd gear 22:29 M 1 Check synchronization;

replace in pairs only
11 Needle bearing 2 VIark for installa- Install with same gear

:ion
12 Race, needle bearing 2 Uark for installa- Install with same gear
:ion
13 Thrust washer 1
(2 mm thick)
14 3rd gear 27:25 V 1 Check for wear; replace

in pairs only
15 Spacer 1
-
Notes
No. Remarks
-
16 Spacer
Shim Note number and Recalculate if

thickness for in- necessary
stallation
Roller bearing Remove from pinion Install with correcl:

shaft with VW 412 adapter
and 9100
Pinion shaft Check for wear;

measure thickness of
shims again if
necessary

Sportomatic I8
D I S M A N T L I N G AND A S S E M B L I N G I N S T R U C T I O N S
Dismantling Install roller bearing on pinion shaft with

appropriate adapter. The two-part roller cage
with ring faces the gears.
1. Remove roller bearing from pinion shaft with
special tools VW 412 and 9100.
2. Install small roller bearing with special tools

VW 412, VW 244 and VW 401.
Assembling
Pinions and ring gears are matched. Pair

numbers must agree with each other when
installing.
Note
Before installing, clean all pinion shaft parts

and dry.

Sportomatic 911 3
C H E C K I N G C L U T C H PLAY
Engine/transmission assembly installed
1. Raise car.
2. Press accelerator linkage operating lever on

transmission toward full throttle (bleeds servo).
Use left hand to press clutch intermediate
lever toward right rear wheel. Travel of
about 5 to 7 mm must be felt on the clutch
intermediate lever. 1f there is not enough
travel, remove engine/transmission assembly
and adjust clutch (basic adjustment 1 2 to
15 mm).
~ n g i n e / t r a n s m i s s i o na s s e m b l y r e m o v e d
1. Remove engine/transmission assembly.
2. Remove cotter pin from clevis pin for

actuating rod and intermediate lever and
pull out clevis pin.
3. Pull out actuating rod mounted on servo up

to stop and at the same time press inter-
mediate lever toward servo to stop.
In this position the actuating rod clevis must
b e located so that its bore is 1 2 to 15 mm
above the intermediate lever bore.

Sportomatic 911 3
C H E C K I N G C O N T R O L VALVE A D J U S T M E N T
This requires that the throttle operating linkage 2. Place a strip of 4 m m thick metal between
and engine idle speed are adjusted correctly. the stop and idle limit screw (this opens throttle
partially).
Full throttle position
(upshifting on acceleration)
To check the co~itrolvalve adjustment and make

changes if necessary, i t will be necessary to
remove various parts of the CIS (continuous fuel
injection) equipment.
a) Disconnect battery.
b) Remove air cleaner cover.
c) Remove heater blower.
d) Remove holder.
e) Detach No. 3 cylinder injection line a t
injector.
f) Remove No. 3 cylinder intake pipe.
There must b e a play of 1.5 mm between Using a 3 mm socket wrench loosen the cam
the control valve plunger and the throttle clamping screw and turn the cam until the
linkage cam in idle position. Use feeler gauge, control valve plunger just barely touches
lock plunger with lock nut. Make sure that the cam surface. Tighten cam clamping
the cam on the operating lever for the screw.
linkage is set back all the way.

911 sportomatic
Closed throttle position

Remove strip of metal at idle limit screw. The (downshifting on deceleration)
idle play set at 1.5 mm at the beginning could
The closed throttle position can be adjusted at
change because of c a m movement, but there
the self-locking control screw with a screwdriver,
must be a t least 1 mm of play.
without removing engine parts.
Basic a d j u s t m e n t
The closed throttle position can only b e checked

for correct adjustment by downshifting a car on
the road or possibly on a roller test stand. The
following information can be used as a reference
point for adjustments on a stationary car.
a) Start engine and allow t o idle.
b) Apply parking brakes.
c) Move lever to driving range.
There should b e 0.3 to 0.5 seconds from the

moment the shift lever is released t o the time
the clutch engages.
Road t e s t
Drive in range "D" at 4500 rpm and shift back to

range "L". Clutching should take place without
delay, yet the rear wheels should not lock.
The adjustment can be altered to suit the
customer.
a) Tighten control screw (turn clockwise) to

provide a softer, delayed clutch engagement.
b) Loosen control screw (turn counterclockwise)
to provide a firmer, quicker clutch engagement.
Caution
Only turn control screw 1 / 4 to 1 / 2 turn at a t i m e
in either direction, because this will b e sufficient
to alter the engagement considerably.

Final Drive - Manual Transmission 911 3
REMOVING AND INSTALLING FINAL DRIVE
TOOLS
Nr. Description Special Tool Remarks
Thrust p i e c e P 265c

d Final Drive - Manual Transmission
Removing and Installing Final Drive

Final Drive - Manual Transmission 911
Yr. 1 Description Q~Y

Removing
Note when
Installing
Special
Instructions
see
2
I1 Expansion bolt
Washer
2 Tighten to correct
torque.
5.l-1/4
Flange shaft
Self-locking nut Tighten to correct

torque.
5 ( Washer
Final drive side

cover
1 Replace if necessary.
Oil lightly.
8 1 Differential 1 Readjust if necessary.l 5 .I-5/5
8a Differential with Adjust; if necessary.

magnetic carrier disc .No adjusting necessary
when replacing magne-
tic carrier disc
-I
Knock out with drift. Install with P 265c
Bearing outer race Knock out with drift. Heat transmission 1

cover to approx. 1 2 0 ' ~
(250'~) and install
with appropriate
tubing.
---
Knock out with drift. Heat transmission

cover to approx. 120°C
(250'~) and install
with appropriate
tubing.

11 Final Drive - Manual Transmission
REMOVING AND INSTALLING
Removing 2. Apply light coat of oil to side cover seal.
1. Unscrew joint flange mounting bolt and remove

joint flange.
2. Drive seals and bearing outer races out of 3. Install seal in side cover with special tool
final drive housing and side cover with an P 265c.
appropriate drift.
Installing
M O D I F I C A T I O N ON D I F F E R E N T I A L
1. Install seal in final drive housing with

special tool P 256c.
The joint flanges and mounting bolts were also
changed with introduction on the new differential
(similar to 928). A M 10 x 80 hexagon head bolt
without washer is used on these transmissions to
mount the joint flanges instead of the expansion
bolt with washer.
Tightening torque value is different (see page 0.2-1/4).

I
DISASSEMBLING AND ASSEMBLING DIFFERENTIAL
TOOLS
Nr. Description Special Tool Remarks
1 Puller 40 - 1 9 (AUDI) or similar
2 Thrust piece P 263
3 Thrust p i e c e P 264b

3 9fl Final Drive - Manual Transmission
Disassembling and Assembling Differential

Final Drive - Manual Transmission
Special
911 3
Note when
.
\Tr Description Qty instruc .
1 Roll pin 1 Drive out. Replace if necessary
2 Shaft 1 Drive out. Note location of

roll pin bore. .
3 Anchor piece 1
4 Small differential 1 Coat thrust areas 3.1 -2/4

pinion (spider gear) with Molykote or
similar lubricant.
5 1 Threaded retainer 1 2 1 Position properly. 1 3.1 -2/5
6 Large differential 2 Coat thrust areas

pinion (side gear) with Molykote or
similar lubricant.
7 Tapered roller 2 Remove with puller Drive on with P 26413 3.1-2/4

bearing No. 40-19 and P 263
Shim 2 . Keep together with If necessary, re- 5.1-5/5

mechanic's wire for calculate thickness
reassembly.
Spacer washer 2 Keep together with If necessary, re- 5.1-5/5

mechanic's wire for calculate thickness
reassembly.
10 1
I
Lock plate 1
I
6 1
I
Replace
I
I
11 Bolt 12 Torque to specify
Ring gear 1 Check for wear Make sure ring gear 5.1 -4/1
and pinion have
matching pair num-
bers.
Differential
housing
-4 Pin 1 +
.5 Spacer 1 Mark for re- Determine thickness 5.1 - 5/5 *

installation again if necessary
--
16 Magnetic carrier 1 Determine thickness 5.1 - 5/5 *

disc again if necessary
: Parts only in conjunction with electronic speedometer

911 F i n a l D.ive - Manual Transmission
D I S A S S E M B L I N G AND ASSEMBLING D I F F E R E N T I A L
Disassembling Caution
Do not interchange spacer washexs and shims.
Attach tags to prevent mixing up right side with
left and vice versa.
1; Drive out differential pinion shaft roll pin.
4. Remove lock plates from ring gear retaining
bolts. Remove bolts and take off ring gear.
Assembling
1. Slide lock plates into groove:; in bolt heads.

Close open ends with pliers to firmly attach
the plates to bolt heads. Secure bolts by bend-
ing the plates down on one side of the hex
surface.
2. Drive out differential pinion shaft with a

mandrel and remove anchor piece.
3. Remove tapered roller bearing with a puller

and thrust piece P 263.
2. Coat thrust surfaces of the differential pinions
in the differential housing with Molykote or
similar lubricant. Insert large differential pinion
(side gears) through oval opening in the hous-
ing. Center the pinions by inserting the flange
shafts.
3. Insert small differential pinions through the

opening in the housing and position them
opposite each other so that bores align with
the bores in the housing.

Final Drive - Manual Transmission 911 3.
4. Insert threaded retainers with lock rings into
the large differential pinions (side gears) and
slide the anchor piece between the threaded
retainers (see illustration).
Caution
Position the locating hole of the differential
pinion shaft so it aligns with the hole of the
anchor piece.
5. Hold the anchor piece in place (so prevent
binding) and drive in the differential pinion
shaft.
Place marked or measured bearing shims

and spacer washers on the differential
housing. Install tapered roller bearing using
thrust piece P 264.
Re-adjust ring and pinion gears if necessary.
See "Adjusting Ring Gear and Pinion".
911 Final Drive/Manual Transmission
N o-te
With the 1976 Model the tapered roller bearing When replacing the magnetic carrier disc the
is pulled off through openings in the magnetic tapered roller bearing preload does not have
carrier disc with an extractor and special tool to be checked if the same shims are used
P 263. again.

TOOLS
No. ,Description Special Tool Remarks
1 Pressure pad
2 Puller
3 Pressure pad


Final Drive - Manual Transmission 911
Note When: Special

No. Description
Lemoving Installing Instructions
Roll pin
Shaft
Small differential gear Coat with MoS paste.
2
Replace only in sets
(with large differential
gears).
Large differential gear Coat with MoS paste.
2
Replace only in sets
(with small differential
gears)
Threaded retainer
Taper roller bearing inner Jull off with US 1078 Drive on with P 264 b.
race ind P 263.
Magnetic carrier disc
Washer dark for reinstallation. Determine new thickness, if
necessary.
Shim dark for reinstallation Determine new thickness, if
necessary,
Key
Lockplate Replace
Bolt Threads dry and without
grease. Tighten to 115.. .
.
120 Nm (83. .86 ft lb).
Ring gear Heat to about 120' ~ / 2 4 8 OF,
Tapped bores for ring gear
bolts must b e dry and without
grease. Watch pair code
number. Adjust, if ne-
cessary.
Differential case

3 911 Final Diive - Manual Transmission
Disassembling 2. Knock ring gear off of case with a suitable mandrel.
1. Pull off taper roller bearing inner races with a

puller (e. g. US 1078) and Special Tool P 263.
Assembling
1. Heat ring gear to about 120' ~ / 2 4 8 ' F and install.

Use locally made centering pins as guides.
Note
Claws of both arms must be machined, if necessary.
A - Centering pins (made locally)

2. Tighten ring gear bolts to specified torque value.
Push lockplate in groove of bolts, squeeze front
with pliers (so that lockplate is connected tightly
on bolts) and bend down over a hexagon s u ~ f a c e
to lock.

3. Coat differential gears with MoS paste.

2
4. Insert large differential gears with press-fit

threaded retainers through large opening in
differential case and locate with joint flanges.
6. Drive in differential shaft in correct position and

5. Insert small differential gears between large lock with roll pin.
differential gears and turn until bores of gears
are aligned with bores in case.
7. Drive on taper roller bearing inner races with

Special Tool P 264.

F
1 - Spacer S1
2 - Spacer S2
E - Adjusting value

A D J U S T I N G RING GEAR A N D P I N I O N
TOOLS
1 Holder P 259a
2. Sensor P 259b
3 Feeler gauge - 0.05 t o 1.0 m m
4 Dial indicator - 0 t o 1 0 m m scale
5 Washer - From P 357
6 Torque wrench US 8020 or similar 0 t o 60 cmkp
7 Bolt - M 1 0 x 110
8 Dial indicator holder - From P 259
9 Gauge block P 258c
10 Mandrel P 258 With bushings

ADJUSTING PINION SHAFT
By adding the design dimension "R" and the Caution

deviation "r" you get the adjusting dimension Tighten flange nut on input shaft to correct
" E . Dimension "E" is the distance from the ring torque before making any measurements.
gear center line to the face of the pinion at Install plate P 260a. Assemble 5th speed gears
which the ring and pinion set has been found to
with synchro hub and shifting sleeve. Engage
operate best.
5th gear. Block input shaft with holder P 37a
and torque flange nut to specification.
2. Place mandrel P 258 on gauge block P 258a.

Attach dial gauge to mandrel with a 1 mm
preload.
1 - Deviation r in 1/100 m m
2 - Mating number
Example
The pinion shaft face end shows the deviation
"T" to be 0.02 mm.
R (design dimension) 66.30 mm
1- r (deviation) t 0.02 mm
E (adjusting dimension) ----------mm
-66.32
- -
---
--
3. Install mandrel P 258, with tapered roller

bearings, in the differential housing so that
there is an axial preload of approx. 0.1 mm
when the side cover is installed. The mandrel
1. After finding the "Adjusting dimension E': should not have axial play during the
attach input and pinion shafts, without shims, measurement. Play can b e eliminated by
to final drive housing with clamping plates. using differential shims.
Caution
Make sure the dial indicator sensor does not
point into the center bore of the pinion shaft.

Final Drive - Manua.1 T r a n s m i s s i o n 911 3
4. Rotate the mandrel carefully until the sensor By adding the mandrel and gauge block dimen-
forms a right angle with the face of the sions the "actual adjusting dimension" is obtained.
pinion. At this point the dial indicator will
show the highest reading. A notch on the end Ex a m p l e :
of the mandrel shows the position of the dial Mandrel dimension 54.015 mm
indicator sensor. Record the reading. + Gauge block dimension + 12.595 mm
Actual adjusting dimension 66.610 mm
----------
If the pointer reads to the right (clockwise), the

Note the following when reading the dial distance is smaller than the "actual adjusting
indicator: .
dimension" (66.61 mm) Therefore subtract the
dial indicator reading from the "actual adjusting
dimension" to determine the distance from ring
gear center to face of pinion.
The distance from the center line of the mandrel
to its resting base is shown on the side of the
mandrel.
Example:
Actual adjusting dimension 66.61 mm
- Dial indicator reading -0.39 mm
Distance from ring gear center
to face of pinion 66.22 mm
--------- -
----- ---
The distance from the measuring surface of the

gauge block to its support surface is indicated
on the side of the gauge block. Adjusting dimension "E"
(as in example on P 5.1-
5/21 66.32 mm
- Distance from ring gear
center to face of pinion - 66.22 mm
Shim thickness 0.10 mm
- -
---------
---- ---
The pinion shaft must therefore be moved away

from the ring gear center by 0.10 mm. This can
be achieved by inserting a 0.10 mm thick shim.
(End numbers from 3 or more should be rounded
off to 5, and from 7 or more to 10).

911 Final Drive - Manual Tr~anrmission
Should the dial indicator read clockwise, the

deviation when added to the "actual adjusting
dimension" (mandrel dim. + gauge block dim.)
should not exceed 0.03 mm.
Shims are available in the following thicknesses:

0 .lo, 0.15 and 0.20 mm. Total thickness of
shims must not exceed 0.50 mm.
Adjusting dimension E should be rechecked

after shims have been installed. A deviation
of 0.03 mm is permissible. It is not necessary
to check the gear tooth contact pattern.

D E T E R M I N I N G T O T A L S P A C E R T H I C K N E S S F O R R I N G GEAR A D J U S T M E N T
1. Make sure that side bearing outer races are 5. If the nominal value of 0.30 to 0.40 rnrn is not
fully seated in the housing and side cover. reached, replace the (S ) spacer (ring gear side)
1
with an appropriate spacer.
2. Install a 3.5 m m spacer (S1) on the ring gear

side beneath the side bearing. Install a Example:
3.0 rnrn spacer (S ) on the opposite side
2
beneath the other bearing. Feeler gauge measurement 0.65 m m
- Nominal value for side
bearing preload 0.40 mrn
3. Install differential with side bearings in housing 0.25 rnm

and install side cover without O-ring and with-
out oil seal. Do not tighten.
T h e installed spacer S (3.5 rnrn) must therefore

1
b e replaced with one 0.25 m m thinner, that is,
4. Lightly tighten the side cover using two nuts i t should be 3.25 m m thick.
opposite each other. This preloads the side
bearings. Check the gap between the cover
and housing with a feeler gauge. The nominal
value for the side bearing preload is-0.30 to 6. Tighten side cover to correct torque.
0.40 mm.
7. Place washer from special tool P 357 on the

U-axle flange. Install the axle flange. Slightly
tighten the expansion bolt.

CAUTION CAUTION
When measuring differential drag, the pinion Do not interchange spacer washers after removal.
shaft must b e disengaged and the axle flange
oil seal must be removed from the side cover t o
prevent additional drag.
10. Measure the thickness of both spacers with a
micrometer. Add these measurements to
obtain the total thickness of the spacers for
8. Measure drag of t h e assembled differential ring gear adjustment.
with a torque wrench. The following values
must be obtained t o ensure proper side bearing
preload.
SKF bearings = 300 t o 420 Ncm Note

-
(26 37 in. Ib)
FAG bearings = 350 t o 650 Ncm In order t o check backlash correctly (a subsequent
-
(30 56 in. Ib) procedure), the spacer S1 should be 0 . 1 mm
(0.004 in. ) thinner than one half of the sum of
spacers S1 and S T h e spacer S should b e
2' 2
0 . 1 mm (0.004 in.) thicker than one half of
the sum of spacers S1 and S2.
Example:
Total thickness of spacers (S1 -I- S2) . . 6. 25

,
Thickness of spacer Sl = 3.025 mm
If the differential drag is not within tolerance,

replace the spacer washer. 6.25 mm = 3.125 mm
2 0.10 mm
Thickness of spacer S2 = 3.225 mm
9. Remove differential. Then pull off both side

bearings.

Spacers are available in increments of 0.10 mm
from 2.4 to 3.7 mm.
A shim, 0.25 mm thick, permits adjustments to

the nearest 0.05 mm. The rounded off spacer
thickness should n o t differ from t h e calculated
spacer thickness.
Exampl e:
Calculated spacer thickness
S l + S2 = 3.025 + 3.225 = 6.25 mm
Rounded off spacer thickness

Sl+ S2 = 3.0 + 3.25 = 6.25 mm
Before measuring, remove any burr that may be

on the edges of the spacer. Measure the thick-
ness of the two spacers with a micrometer a t
four different points; the thickness tolerance is
0.02 mm(0.008 in.).

. A D J U S T I N G RING GEAR B A C K L A S H
1. Install gear cluster with shims determined at 4. Block pinion shaft with holder P 259a.
t i m e of pinion shaft adjustment.
5. Place washer from special tool P 357 onto

Caution
the axle flange. Attach dial indicator with
Make sure pinion shaft flange nut is tightened
sensor P 259b. Bolt dial indicator holder over
to correct torque before making any adjust-
the axle flange with the 10 x 110 mm bolt.
ments.
The dial indicator should have a slight
preload.
2. Install differential with side bearings and

correct shims (S1 and S2).
3. Install side cover with oil seal. Apply light

coat of oil to seal.
Caution'
When tightening the nuts, take care that a
certain amount of side clearance exists.
Make sure the pinion shaft does not jam.
Tighten side cover bolts to correct torque.

6. Move dial indicator holder back and forth. 8. Spacers S1 and S2 can b e replaced with
Read backlash on dial indicator. special took P 263 and P 264b until proper
backlash is attained. Be sure that the total
spacer thickness is not changed.
7. Turn ring gear about 90° and measure back-

lash again. The readings must not vary by
more than 0.05 mm.
Caution
The accurate backlash is marked on the
ring gear.
Backlash tolerance: 0.12 to 0.18 mm.

Transmission and Differential 911
TOOLS
Special
Nr . Designation Tool Nr.
Remarks
1 Setting gage shaft VW 385/1
2 Gage block 1 VW 385/4 1

3 Gage contact plunger V W 385/14
f . Gage contact- extension VW 385/53 1 4 mm

I I
5 ' Master plate VW 385/52 R = 66.30 rnm
6 Dial indicator I --- I 3 mm range
7 Setting pad 50 rnm fl

911 Transmission and Differential
A D J U S T I N G P I N I O N S H A F T W I T H UNIVERSAL S E T T I N G GAGE V W - 3 8 5
Determine adjustment value E from known NOTE:

design value R = 66.30 mm by adding deviation The collar nut on the pinion shaft must
'Ywhich is shown on pinion face. definitely be tightened to specified torque prior
to measuring.
Fasten gear housing with 2 nuts. Install free gear
of 5th speed together with spider. Block pinion
shaft with clamp P 37a. Engage 4th speed and
tighten collar nut to specified torque.
2. Make sure that outer races of bevel roller

bearings are firmly seated in gear housing
and housing side cover.
-
1 Deviation 'k" in 1/100 mm
2 - Mating number
3. Move adjustable collar on setting gage VW

385/1 to dimension "a".
Example:
The pinion face shows deviation "r" to be N 1 0
R = Design value 66 .30 mm

r = Deviation + 0.10 mm
E = Adjustment value = 66.40mm
1. Assemble gear cluster without selector forks

or adjustment shims.
Tighten preload plate nuts to specified
torque.
a = c a . 52 mm

Transmission and Differential
911 3
4. Slide gage blocks VW 385/4 onto the setting 6. Place setting pad VW 385/17 on the pinion
gage shaft and screw contact plunger VW face.
385/14, together with the contact extension
VW 385/53 (14 mm), into place.
NOTE: Turn adjustable collar back to stop.
5 . Place master plate VW 385/52 (R = 66.30 mm)

in position and adjust dial indicator (3 mm
range) to 0 under a 1 mm preload (small
pointer on 1, long pointer on 0).
7 . Remove master plate and place setting gage in

6 1 ' 2' 4. 5 - 3 gear housing, making sure that the dial indi-
cator extension is oriented towards the setting
pad.
,,*:
a ...?2.;'!
.I
. h>'
, ,
,
~ .,-
1 = VW 385/1 Setting gage shaft

2 = VW 385/4 Gage block
3 = VW 385/14 Gage contact plunger
4 = VW 385/53 Gage contact extension
5 = VW 385/52 Master plate
6 = --- Dial indicator
8 . Insert housing side cover (without O-ring) and
tighten nuts to specified torque.

911 Transmission and Differential
Caution: If the value indicated on the gage deviates

Never use a hammer when installing the housing clockwise from the set design value (R= 66 .'30 mm),
side cover. This may cause the magnetically then the dimension is smaller than 66.30 mm,
attached setting pad to fall off the pinion. that is, the amount of deviation from 0 must b e
Bring side cover into proper place only by evenly subtracted from the value of 66.30 m m .
tightening the retaining nuts.
Example:
The small pointer on the indicator is between
9 . Using the spindle, pull the second gage block
1 and 2, 'and the long pointer shows 0.29 mm.
so far outwards that the setting gage shaft can
still b e barely turned.
Adjusted design value

(master plate VW 385/52)
minus measured value
Distance to pinion shaft face
Adjustment value (as example)

Distance to pinion shaft face
Shim thickness
This means that the pinion shaft must b e moved

away from the ring gear center by 0.39 mm.
This is accomplished by installing two 0.20 mm
Carefully turn setting gage until the gage
thick shims (end values of 3 or more should b e
contact extension is positioned perpendicular
rounded off to 5, and from 7 on to 10).
to the pinion shaft face. In this instance, the
indicator shows the highest reading which
is to b e noted.
Recheck adjustment value E (shown as 66.40 mm

in the example) upon installation of shims; a
Note the following points when reading the dial
deviation of 2 0.03 mm is permissible. A tooth
indicator:
contact pattern test need not b e performed.
The design value R = 66.30 mm was set by

means of the master plate VW 385/52.

Transmission and Differential
NOTE:.
If the shims were selected in proper thickness,
the d i a l indicator must show the value of devia-
tion "r" (shown in the example as 0.10 mm)
within a tolerance of -k 0.03 mm during the
recheck.

Sportomatic - Differential 911 3
A D J U S T I N G RING GEAR AND P I N I O N
G e n e r a1
Adjustment of the ring gear and pinion is important for quiet operation of the rear axle assembly. For
this reason the pinion shaft and ring is already matched as a pair during production. They are checked
on testing machines for correct contact pattern and low noise level in both directions of rotation. When
the ring gear and pinion is tested it is set according to t h e design dimension "R". Dimension "R" is the
distance from the face of the pinion to the ring gear center line. The pinion is then moved in or out of
mesh until the quitetest operation is determined. The deviation from the design dimension (the in or
out movement of the pinion) is called "r" and is etched on the face of the pinion. While making this
test, the ring gear backlash is kept within a tolerance of 0.12 - 0.18 mm. The ring gear and pinion
shaft is designed in such a way that the deviation "r" must always be added t o the design dimension "R".
Earlier pinion assemblies had either a plus (+) or a minus ( - ) etched in front of the deviation "r"
where as on the newer pinion assemblies , the letter "N" precedes the deviation "r" on the pinion shaft.
Ring gear and pinion sets are also stamped with a matching number and should always be replaced as a
complete set.
R Design dimension (59.70 mm for Sporto-

matic transmissions 925/00 and 925/01).
r Deviation from R indicated in 1/100 mm.
1 Deviation r
2 Matching set number
3 Backlash

A D J U S T I N G RING GEAR A N D P I N I O N
1. T h e design dimension "R" and the basic 3. T h e holder P 357a is needed for blocking the
approximation value have been changed pinion shaft when measuring gear backlash.
in the 925/00 and 925/01 transmission
versions.
Design dimension "R"

(formerly 54.20 mm)
Basic distance
(approximation value)
(formerly 55.70 mm)
2. When determining the "Actual Adjusting

Dimension", the gauge block P 258c must
be'used.
Adjustment is made in the same way as for
manual units. See Type 911 workshop
manual, volume I, 11 RA, page 46.
4. When measuring backlash, be sure to use the

modified dial indicator holder (must have a
second 6 . 5 m m hole - see illustration).
1- calibration surface for Type 915

transmission
2 - Calibration surface for Type 925
transmission
Note
When using gauge block P 258c, make sure to

use the appropriate calibration surface.

Vorderachse
Front Axle
~ s s i e uAV
Assale anteriore

F R O N T AXLE
CONTENTS
0.0 Information
0.1 Description
Front Axle Changes, from 1972 Model 0.1 - l/l
Self-Leveling Hydropneumatic Suspension Strut, Operation -
General Outline 0.1 - 2/1
Operation of the Self-Leveling Hydropneumatic KONI Suspension Struts 0.1 - 2/2
Cross-Section of Self-Leveling Hydropneumatic KONI Suspension Struts 0.1 - 2/5
0.2 Technical Data
Technical Data
Technical Data, 1974 models
Technical Data, 3975 models
Tightening Torque Values
1 - FRONT WHEEL ALIGNMENT
1.1 Alignment
General
Sample Wheel Alignment Card
2 - FRONT AXLE
2.1 Front A x l e w i t h Shockabsorbers or Suspension Struts

Disassembling and reassembling 2.1 - 111
Self-Leveling Hydropneumatic Suspension Struts, check 2.1 - 2/1
Aluminium Auxiliary Support, Carrera 2.7 2.1 - 3/1
Disassembly and Reassembly of Stabilizer 1974 Models 2.1 - 4/1
Instructions for Removal and Installation 2.1 - 4/4
Shock Absorber/Spring Struts, USA Models Installation Instructions 2.1 - 5/1
4 - STEERING WHEEL AND STEERING COLUMN
4.1 Steering Wheel
4.2 Steering Shaft

Steering Shaft, disassemble and reassemble, beginning with
1974-models
Instructions for Disassembly and Reassembly

Front A x l e Description 911 4
F R O N T AXLE C H A N G E S - BEGINNING W I T H 1 9 7 2 MODELS
1. BOGE shockabsorber struts are installed in front axles of all vehicles.

Available on special order are BILSTEIN or KONI shockabsorber struts, and BOGE or KONI
suspension struts.
2. The basic adjustment of suspension struts has been changed.

To attain the highest degree of driving comfort, damping forces have been reduced. This softer
adjustment can also be used in earlier models. In such cases make sure that struts of same setting are
used on both left and right side:
Two complete shockabsorber struts, or one complete shockabsorber strut and one strut
insert, or two strut inserts.
3. The ball joint mount in shockabsorber strut has been changed.

The ball joint assembly is now attached by a double-wedge arrangement. The former clamp-mount
in the shockabsorber strut is no longer in use.
4. Type 911 S vehicles have 15 mm dia. stabilizers in front and rear as standard equipment.

D e s c r i p t i o n of Front A x l e 911 4
D E S C R I P T I O N OF T H E SELF - LEVELING H Y D R O P N E U M A T I C S U S P E N S I O N
SYSTEM
General
Beginning with 1972 models, self-leveling hydropneumatic front suspension struts are optional equipment
for all Type 911 vehicles.
Operation - General Outline
As soon as the car begins to move, wheel oscillations caused by road bumps result in a pumping action
in the strut, raising the car's height to a predetermined level.
The struts will bring the car to a normal level after covering a distance of anywhere between 300 and
1500 yards, depending on the road irregularities encountered. When the car is driven on particularly
rough roads, the struts will pump the car, up to 10 mm more than the predetermined height. The height
remain constant overnight providing that the load is not increased after the car has been parked. Upon
removal of any load from the car, the suspension will first rebound, as in conventional systems, but will
quickly proceed to adjust itself to the predetermined height where it then will remain.
Should the suspension b e loaded beyond the permissible maximum, the pumping' effect will automatically
be relieved and height compensation stopped to prevent any overstressing of the system. Consequently, an
overload condition can be readily noticed by the reduced ground clearance, similar to cars with conven-
tional suspensions.
The suspension strut is filled with oil with the exception of two gas cushions. One of the gas cushions is
located in the high-pressure part, between the damping cylinder and outer cover. The gas (nitrogen) is
separated from the oil by a diaphragm. The second gas cushion is located in the low-pressure part above
the damping cylinder, within the oil reservoir, and is not separated from the oil.
The pressure of the gas cushions is such that the force it exerts on the piston is equal to 90 percent of the
empty weight of the vehicle.
A piston divides the damping cylinder. The space below the piston is in contact with the high-pressure
part, and the space above the piston with the oil reservoir. A pressure valve is located on the piston.
The hollow piston rod accomodated the pump cylinder whose upper section is limited by a suction valve
with a return flow orifice.
The pump rod is in the damper housing wh.ich is supported by the housing base. It also contains a needle
valve which is suspended in the pump rod with the aid of a spring.

911 D e s c r i p t i o n of F r o n t A x l e
Pump Action Under Load j
Irregularities in the road surface causei the piston rod to move in relation to the pump rod. Through this
motion, the pump rod displaces a certain amount of oil from the pump cylinder, through the pressure
valve, into the space below the piston!.
During the suction stroke, a certain amount of oil is sucked from the space above the piston through the
suction valve. I
Due to the reduced oil supply above tde piston, gas expands in the oil reservoir thus causing a pressure
drop. At the same time, gas is compressed in the high-pressure chamber. The force under the piston is
increased and the vehicle rises. This 4ycle repeats until the pump rod guide clears several orifices in the
pump rod. On the subsequent suction stroke, oil also flows from the high-pressure chamber through the .
orifices into the oil reservoir. The p u h p also is neutralized, and the vehicle is no longer raised.
,
A balance is thus achieved since at hiLher vehicle level a return flow orifice is cleared by the needle
valve permitting a small amount of oil to flow back to the oil reservoir.
In the balanced condition, the amound of oil pumped up equals the amount flowing back through the
return flow orifice. The vehicle is at its predetermined level,
i
A c t i o n on Rebound
When the load is decreased; the car will rise briefly. As a result: the needle valve will open the return
flow orifices until enough oil has returned to reestablish the normal oil level.
When the piston moves, the oil below ithe piston flows through the damper housing, creating a damping
action. T h e oil velocity is kept within specified limits, thus limiting piston speed.
The required damping and springing c~aracteristicsare achieved through exact calibration of passages
and valves, same as in conventional hjrdraulic shock absorbers.
In addition, the pumping action results in supplemental damping which increases in proportion to the
load. In other words, the damping effect is load -sensitive.

Description of Front A x l e 911 4
Springing Action
Pressure in the oil reservoir acts on the top surface of the piston and exerts a small downward force on
the piston. Pressure in the high-pressure chamber exerts a large upward force on the bottom surface of
the piston. The load capacity of the suspension element can b e obtained from the difference between
these two forces.
Suspension compression results in increased pressure below the piston and a pressure drop above it. The
spring rate of both gas cushions is cumulative. When the load increases, the displacement increases in
the oil reservoir and decreases in the high-pressure chamber.
During this action the spring rate of both gas cushions changes in such a way that the piston rod related
spring rate adjusts itself to the new load. Thus the spring rate of the suspension strut adjusts itself to :the
given load, maintains constant vehicle height, and has an optimal damping effect.
Compared with the conventional suspensions incorporating steel springs and dampers, this system offers
improved comfort characteristics.

Cross- Section of Self- Leveling Hydropneumatic KONI Suspension Strut
1. Low pressure chamber 7. Pump cylinder

2. High pressure chamber 8. Pressure valve
3. Return flow orifice 9. Main cylinder
4. Suction valve 10. Pump rod
5. Needle valve 11. Damper housing
6. Spring 12. Overload valve
G - Gas cushions
Technical Data 911
GENERAL S P E C I F I C A T I O N S
TYPE 9 1 1 VEHICLES - B E G I N N I N G W I T H 1 9 7 2 MODELS
Wheel suspension independent, with shockabsorber struts and

transverse control arms
Springing 1 round longitudinal torsion bar per wheel

(hydropneumatic suspension struts optional)
Shockabsorbers double-action hydraulic shockabsorber struts
Stabilizer 1 5 mm dia, standard in Type 911 S only

(optional in Type 911 T and 911 E)
Wheelbase 2271 m m (89.4 in.)
Track, front 911 T = 1360 mm / 53.54 in. (5 1 / 2 J x 1 5 rim)

(wheel center 108 mm above torsion bar center) 911 E &911 S = 1372 m m / 54.02 in.
(6 Jx15 rim)
Max. axle load, front 600 kp (1320 lbs.)
Mean steering ratio 17.78 : 1
Steering wheel turns, lock-to-lock approx. 3.1
Smallest turning circle approx, 10.7 m (35.1 ft.)
Nominal Adjustment Values and Wear

T o l e r a n c e ( a t DIN c u r b w e i g h t )
Toe angle, overall (pressed 15 kp)
Camber, front
Max. camber difference, left to right
Caster
Steering difference angle, front wheels turned O0 to 30'

20°
Front axle height adjustment (wheel center 108 m m 2 5 m m (4.25 2 0.20 in.)
above torsion bar center)
Height difference, left to right max. 5 mm (0.20 in.)
- 14 cmkp (6 - 1 2 in.lbs.)
Steering drag (measured at steering assembly
flange without t i e rods or damper connected)
I 8
Technical Data
TECHNICAL DATA - 1974.Models
Vehicle Type 9 11 1911 s I ~ a r r e r a
Wheel suspension independent, with shock absorber struts and transverse

control arms
Springing 1 round longitudinal torsion bar per wheel (hydropneu-
matic suspension struts optional)
Shock absorbers double-action hydraulic shock absorbers struts
Stabilizer, diameter front/rear 16 mm/--- 16 mrn/--- 20 mm/18 m m
Torsion bar dia. 18.8 mm same as 911 same as 911
Wheelbase 2271 m m 2271 m m 2271 m m
Track, front (wheel center 108 m m 1360 mm 1372 m m 1372 mrn
above torsion bar center) (5 1 / 2 Jx15 rim; (6 Jx15 rim) (6 Jx15 rim)
Max. axle load, front 600 k g same as 9 il s a m e as 911
Mean steering ratio (steering wheel
angle to road wheel angle) 17.78 : 1 same as 9 1 1 s a m e as 911
Steering wheel turns, lock- to-lock approx. 3 . 1 same as 9 1 1 same as 911

Tolerances (at DIN curb weight)
4-
Overall toe- in, front (pressed 1 5 kg) - 0' same as 9 1 1 same as 9 1 1
front wheel camber o
O
+ 10' same as 9 1 1 s a m e as 9 1 1
Max. camber difference, left t o right 10' same as 9 1 1 same as 9 1 1
Caster 6'5' f 15' same as 9 1 1 same as 911
Steering difference angle, front wheels
0
turned 20 0' t o 30' same as 9 1 1 same as 911
Front axle height adjustment (wheel
i -I-
center above torsion bar center) 108 m m - 5 mn same as 911 113 mm -5 mm
Height difference, left t o right max. 5 m m same as 9 1 1 same as 9 1 1
Steering drag (measured a t the steering
assembly flange with tie rods disconnected) 8 - 1 4 cmkp same as 9 1 1 same as 911

4 !ill, Technical Data 1
TECHNICAL DATA - 1975 kodels
Model
Wheel suspension
!
iI
911 I Carrera
Independent with. transverse control arms and

shock absorber struts
Springing I One round longitudinal torsion bar per wheel
shock absorbers i Double action hydraulic shock absorber struts
I
Stabilizer dia. front/rear I 20 mm/18 m m same as 911 S
Torsion bar dia. 18.8 m m same as 911 S
Wheelbase 1 2271 m m s a m e as 9 1 1 S
Track width, front 1
I
1372 m m with s a m e as 9 1 1 S
6 J x 1 5 wheel
Front axle height adjustment:
i
center of wheel above center of torsipn bar
+
93 - 5 mm
(at curb weight according to DIN)
I s a m e as 9 1 1 S
Max. axle load, front 1 600 k g (1323 lb) same as 9 1 1 S
Steering ratio (overall) 17.78 : 1 same as 911 S
i
No. of steering wheel turns from lock to lock approx. 3 . 1 same as 9 1 1 S
I
Adjusting, reference and wear specifications
(at curb weight according t o DIN) I
I
f 0'
Total t o e , front (wheels pressed together with 1 5 kg) s a m e as 9 1 1 S
Camber, front
I
i + 30' + 10' s a m e as 9 1 1 S
Max. camber difference between lef! and right 10' s a m e as 9 1 1 S
I
Caster i 6'5' f 15' s a m e as 9 1 1 S
I
T o e difference angle a t 20' lock
1 0' to 30' same as 9 1 1 S
Height difference between left and right max. 5 m m s a m e as 9 1 1 S
Steering drag (measured a t steering dear flange
I
with tie rods disconnected) 8 to 1 4 c m k p same as 9 1 1 S
i

TECHNICAL DATA - from 1976 Model
1976/77
Models From 1978
911 S 9 1 1 SC
Wheel suspension Independent wheel suspension on control arms

and spring/absorber struts
Springing One round torsion bar per wheel in forward
direction
Shock absorbers Double-action hydraulic shock absorbers
Stabilizer dia. front/rear 16 mm/--- 20/18 rnm
Torsion bar dia. 1 8 . 8 mm 18.8 mrn
Track width, front 1361 mm with 1361 m m with
rim 6 J x 15 rim 6 J x 1 5
Wheelbase 2272 m m 2272 mm
Front axle height (wheel center over torsion bar
center) (at DIN curb weight) 99
+- 5 mm
Height difference, left t o right max. 5 mm max. 5 m m

Max. axle load, front 600 kg model 1978/79:
600 kg/1323 lb
model 1980181: 650 kg/1433 l b
Steering ratio a t center (steering wheel lock to lock) 17.78 : 1 17.78 : 1
No. of steering wheel turns from lock to lock approx. 3 . 1 approx. 3. 0
Adjusting, reference and wear limit values

(at DIN curb weight)
Total toe, front (wheels pressed together with
1 5 kg/150 N) 0O
0
T o e difference angle a t 20 steering lock 0' to + 30'
30'
+- 10'
Camber of front wheels t
Max. camber difference, left t o right 10'

Caster 6'5' 2 15'
Steering drag (measured on flange of steering 0.8 to 1.4 Nm 0.8 to 1 . 4 Nm
gear with t i e rod disconnected) (8 to 1 4 cmkg) (8 to 1 4 cmkg)

T I G H T E N I N G TORQUES FOR FRONT AXLE AND STEERING
Location Description Thread Grade m k ~ ft. lbs.
Shockabsorber strut to upper mounting Nut M I 4 x 1.5 8 8

plate
Tie rod clamping sleeve Nut M 8 8.8 1.5
Strut upper mounting plate to body Allen bolt M 10 8.8 4.7
[Auxiliary support to body I Bolt I M12x1.5 1 8.8 I

1 Undershield fastener I Bolt I M 1 0 1 8 . 8 1 4.7
Undershield fastener Bolt M 8 8.8 2.5
Flanbloc attachment Bolt M 10 8.8 4.7
Auxiliary support attachment Bolt M 10 8.8 4.7
Steering unit attachment Bolt M 10 8.8 4.7
Tie rod to steering unit I Bolt 1 MI0 1 8.8 1 4.7
Stabilizer mount to body Bolt M 8 8.8 2.5
Stabilizer lever to stabilizer I Bolt 1 M 8 1 8.8 1 2.5
Wheelbearing clamping nut to axle I Allen bolt I M 7 1 10 K 1 1.5
Ball joint to shockabsorber strut Nut M 8 8 2.2
Ball joint to shockabsorber strut Bolt M10x30 10.9 4.5
Ball joint to transverse arm Notched nut I M 45 x 1.5 8.8 25
Plug for BOGE shockabsorber strut Plug 12 -F 2
Plug for KONI shockabsorber strut Plug 20
Wheel to hub Lug nut M 1 4 x 1.5 10 K 13
Brake disc to wheel hub Nut M 8 8.8 2.3
Cover shroud to steering knuckle Bolt M 8 8.8 2.5
Brake caliper to steering knuckle Bolt M 1 2 x 1.5 8.8 7.0

I
i
Technical Data
Ii
Location I Description Thread Grade

i
I
I
I
I
Hollow bolt to brake caliper I
I Hollow bolt M10xl
I
Steering coupling to steering shaft Bolt M 8 8.8
Steering shaft to steering unit i1 Bolt M 8 8.8

I
I
I
Steering support attachment j Allen bolt M 8 8.8
I I 1
I I I
U-joint to steering shaft Bolt M 8 8.8
Steering wheel attachment j Nut M18x1.5 8
Dust boot support to steering rack (1 Notched nut ( M 1 6 x 1.51 8
Ball joint to steering arm / Castellated nut M 10 x 1 8

j
Coupling flange to steering pinion j Nut M 10 8
(self-locking) 1
I
i
Housing cover to steering housing Bolt M 8 x 1 8.8
i
I
Centering screw to steering lock ! Stud M8 10.9
Lock nut for centering screw I ' Nut

I M 8
I*

Front Wheel Alignment 911
MEASURING FRONT AXLE
General Information
Beginning with 1972 models, caster and camber specifications for the front axle have been changed.
The new adjustment values have been indicated on the new wheel alignment chart by small triangles.
This acts as a quick reference for evaluating the alignment data.
SAMPLE
WHEEL A L I G N M E N T D A T A C H A R T
Name , Vehicle: Porsche type 911 - from model 72 on

Chassis NO r License plate No: miles:
Date : measured by:
Tires: M E A S U R I N G CHART
Moke:
Conditlon: 96 Difference angle at 200 turning radius I}
2 1 0 2 1 0 Empty weight
according to
Please note:
strur odiuatmcnt
t -
0 1 2
toe-in (pressed with 15 kp)
3
m
Caster results from totol.comber difference

at 20O left turning rodius ond 20O right turning
- 5-
colter
radius times 1,s
coster
comber
1 0 1 Reorwheel adjustment 1 0 1
toe4n
Copyright by Dr. Ing. h. c. F. Porxhe KG

Front Axle 911 4
R E M O V I N G A N D I N S T A L L I N G F R O N T A X L E BALL J O I N T
TOOLS
Nr. Descdption Special Tool Remarks
1 Wrench P 280b

R E M O V I N G A N D I N S T A L L I ~ G. F R O N T A X L E BALL J O I N T

Front A x l e 911
Note when Special
1.1 Description
removing installing
instructions
I
Drive out.
Torque to specification
Install with multipurpose

grease, noting proper
I
seating. Replace.
I
4 Cotter pin Replace.
5 Lock plate Replace if necessary.

I
6 Nut
L-
I
Ball joint
shockabsorber strut
(suspension strut)
Check, replace if worn.
Check, replace if
necessary.

4 911 Front Axle i
-
Assembling
I
1. Coat double-wedge bolt with multi@rpose
I
grease before assembling.
I
2. Installed position of the double-wedge is so

that the retaining nut points for warh in the
direction of travel.
The notch on the face of the double-wedge
piece and the wedge contour must ioint
toward the wheel stub axle.
3. Make sure the double-wedge bolt iS properly

seated by tapping with a hammer before
tightening the nut.
4. Torque Stop-nut to 2.2 mkp.

Front A x l e 911 4
C H E C K I N G SELF- LEVELING H Y D R O P N E U M A T I C S U S P E N S I O N S T R U T S
Special Tools:
P 301b Measuring Mandrel
1. Load the front axle with a ballast of 100 kp

(220 lbs) in such way that both wheels are
evenly weighted (distribute the load evenly in
the luggage compartment).
2. The best way to test the pumping action is by

driving the car.
Drive the car into level surface and push plug

gauges (special tool P 301b). from within the
compartment of the reinforcing support mem- Measure and note the distance from the ground to
ber, to the stop in left and right transverse the bottom edge of the fender across the front
support arm (grease the mandrels slightly to wheel center on left and right side. Remove
provide some adhesion). measuring mandrels (special tool P 301b).
N o t e : Before lowering the jack, measure the

distance from the wheel flange to the ground,
then measure again after lowering the jack to
determine the static deflection of the tires on
both sides of the car. The difference must b e
deducted from measurements obtained between
the ground and lower edge of fender.
Drive the car on a1 relatively straight but rough

-
Measure distance "a" from the ground verti- road over a distance of approc. 2 km (1 1/4 miles),
cally to the front wheel center. without hard braking, and stop car on a level sur-
face. Keeping car occupants in the car, have an-
Distance "b" eguals distance "a" less 124 mm other person make comparison measurements at
(5.0 in). Raise the car by the front center with both front fenders. The values should not differ
a jack until distance "b" is attained at the from the determinal nominal values by more than
measuring mandrels. 1 10 mm ( 13/32 in).
Front Axle 911 4
L I G H T - ALLOY A U X I L I A R Y CROSS MEMBER FOR CARRERA 2.7
General
Carrera 2.7 vehicles are equipped with a new, forged light-alloy auxiliary cross member.
Tightening torques for the front axle remain unchanged.
DISASSEMBLY AND REASSEMBLY
No. I Description
Qty I removing
Note when
installing
Special
instructions see
Adjusting screw Coat with multi-
2 1 Adjusting lever
1
Tighten to
specified torque.
- -
Spring washer Replace.

Bolt, M 10 x 20 Tighten to
I
specified torque.
I
7 Spring washer
- - -
8 1 Self-locking nut M 8 4 Replace if necessary.

9 1 Washer 8
10 Allen bolt M 8 4
11 Right brace 1
12 Left brace 1
13 Auxiliary cross
member

o n Axle 911 4
S T A B I L I Z E R 1 9 7 4 MODELS
General
Beginning with the 1974 models, all vehicles are equipped with a' new, one-piece front axle
stabilizer.
The stabilizer bar diameter is
1 6 mm in 911 and 911 S vehicles
20 m m in Carrera vehicles
The stabilizer is mounted in rubber bushings located in the transverse control arms and t h e auxiliary
support. It is attached by means of two clamps which are bolted to the modified support struts of the
auxiliary support.

911 Front A x l e
DISASSEMBLY AND REASSE$~BLY

Front Axle 911 4
-
Note during
No. Description References
removal installation
Bolt M 8 Tighten to specified

torque
Lock washer Replace
Washer
Bolt M 8 Tighten. to specified

torque
Lock washer Replace
Clamp
Stabilizer
Rubber bushing Check for wear Use rubber lubricant
Transverse
control arm
Auxiliary support

I
Front Axle I
I N S T R U C T I O N S FOR REMOVAL A N D I N S T A L L A T I O N
Removal
1. Remove stone guard.
2. Remove both support clamps from;auxiliary

support.
3. Remove stabilizer rearward by first pulling i t

out of one momting point in the (ransverse
control arm, and then out of the qther.
Installation
1. First push the stabilizer end into one mounting

point, then into the other. Use rubber lubri-
cant.

Front Axle
I N S T A L L A T I O N N O T E S FOR S H O C K ABSORBER/SPRING S T R U T S
With t h e 1975 Models a different height adjust-

ment was introduced. When installing t h e shock
absorber/spring struts, make sure that spacer,
Part No. 911,341.615.00, is installed between
t h e guard tube and support bracket.

Steering Wheel and Steering Column 911 4
STEERING COLUMN ARRANGEMENT BEGINNING W I T H 1 9 7 4 MODELS
-.
General
Beginning with 1974 models, the steering column attachment to the instrument panel has been changed.
A safety steering wheel has been introduced at the same time.
This modification necessitated changes in the following parts: steering shaft, steering shaft tube, and
the switch assembly mounted on the steering column.
This steering column version with safety steering wheel can be subsequently installed in 1968 and later
vehicles.

911 Steering Wheel and Steering Column
DISASSEMBLY A N D REASSEMBLY

Note when:
removing installing
Pad I 1 Pull off steering wheel Press into place
Nut, SW 27 1 Torque to specification
Spring washer 1 Replace if necessary
Safety steering wheel 1 Install with road wheels

hub and energy ab- in straight ahead posi-
sorbing support tion, release ring on
left side
Oval head screw

M 3.5 x 1 0
External tooth Replace if necessary
Contact ring Lightly grease contact

surface (such as KONDOR
T 250 contact grease) I
Billister head screw 1 4
Lock washer
1 Replace if necessary
Hub cover 1
Fillister head screw, 2 Replace if necessary

M4x10
Lock washer 2 Replace if necessary
Contact plate Lightly grease contact 1

surface (such as KONDOR
T 250 contact grease) I
Fillister head screw,

M3x8 1
Lock washer
1 Replace if necessary
Contact tab
I1
Fillister head screw,
M3x10 1
4 911 S t e e r i n g W h e e l and1 S t e e r i n g C o l u m n
Note when:
removing installing
Switch housing top
Switch housing bottom
Nut, M 8
Stud
Shear bolt, M 8 drill bolt head off. Tighten until bolt

head shears off
Lock washer Replace if necessary
Ignition steering lock
Fillister screw M 3
Ignition/starter switch
Self-locking nut M 8 Replace. Torque to

specification
Bolt M 8
Universal joint Check, replace if

necessary
Shear bolt M 8 Drill bolt head off Tighten until bolt

head shears off
Shear bolt M 8 Drill bolt head off, Tighten until bolt

or grind it off if head shears off
necessary. (Remove
tachometer.)

-
Note when:
removing installing
-
34 Steering shaft Remove from instru-
tube ment panel together
with steering shaft
and switches
-
35 Fillister head screw,

M3x8
-
36 Lock washer 2 Replace if necessary
-
37 Directional signal 1
and dimmer switch
-
38 Fillister head screw,
M8x3
-
39 Lock washer Replace if necessary
-
40 Wiper/washer switch
-
-
-
43 SEEGER retaining 1 Press out with a Press into seat
ring screwdriver
-
44 Steering shaft 1 Drive out of steering
shaft tube
-
Check, replacing if necess-
45 Ball bearing 1
.
ary Grooved ball bearings
with plastic inner races
- from 1975 models.
Replace if necessary. De-
46 Contact ring 1 leted from.1975 models.
-
47 Circlip Must be seated in
groove in steering
shaft groove
-
48 Ball bearing Check, replace i f
necessary
-
49 Circlip Must b e seated in
groove in steering
shaft groove
-

911 Steering Wheel and Steering Column
I
Disassembly 5. Drill off or grind off shear bolts in steering

switch attachment and ignition/starter switch.
1. Remove blower.
6. Detach wire connectors and multiple plugs.
2. Remove steering shaft cover and take off

universal joint retaining bolt.
7. Remove complete steering switch from instru-

ment panel.

Reassembly
1. Place contact ring and bearing together on the 3. Tighten shear bolts for steering tube attach-
steering shaft. ment until the heads break off.
2. Drive bearing into place with a pipe section

(inside dia. 24 mm, outside dia. 28 mm) .
NOTE
The pipe section should contact the bearing

inner race only.

Hinterachse
Rear Axle
Essieu AR
Assale posteriore

REAR AXLE 911 5
CONTENTS
0.0 General Information
0.1 Description
Rear Axle Changes- Beginning with 1972 Models
0.2 Technical Data

General Specifications
Technical Data from 1974 model
Technical Data from 1975 model
Tightening Torques
1 - REAR WHEEL ALIGNMENT
1.1 M e a s u r i n g R e a r A x l e
General Information
Wheel Alignment Data Chart
2 - REAR AXLE
2.1 Rear Axle Control A r m s

Dismantle and reinstall Rear Axle Control Arms from 1974 Model
Checking Parts
3 - AXLE DRIVESHAFTS
3.1 Axle Driveshafts

Axle Driveshafts - Lighter Version

Rear A x l e D e s c r i p t i o n 911 5
REAR AXLE CHANGES - BEGINNING W I T H 1 9 7 2 MODELS
1. Beginning with 1972 models, rear axle shockabsorbers have been modified. The outside diameter
and overall length of the shockabsorbers has been increased:
Outer diameter
new: 62 mm (2.44 in.)
old: 58 mm (2;28 in.)
Extended length
new: 599 "2.0 mm (23.59 0.08 in.)
old: 574? 2.5 mm (22.61 10.10 in.)
Closed length
new: 407.5 1 2 . 0 mm (16.04 f 0.08 in.)
old: +
390 2 2.5 mm (15.37 0.10 in.)
2. The BOGE shockabsorbers are standard on the rear axle. BILSTEIN or KONI shockabsorbers are
optional.
The various shockabsorber types can be distinguished by their color:

BOGE black
KONI red
BILSTEIN green
To allow for the larger shocks, the lower mount has been moved rearward 10 mm. The upper mounting
has also been moved slightly forward and in towards the vehicle longitudinal axis. This change was also
necessary due to the new transmission which has its axle flanges approximately 10 mm further to the
rear.
The shockabsorber mounting bolt has been changed from the former 12 mm diameter to 1 4 mm dia-
meter.

GENERAL S P E C I F I C A T I O N S
TYPE 9 1 1 VEHICLES - BEGINNING W I T H 1 9 7 2 MODELS
Wheel suspension independent, with longitudinal trailing arms

(radius arms)
Springing 1 round transverse torsion bar per wheel
Shockabsorbers double-action, hydraulic shockabsorbers
Stabilizer transverse, 1 5 m m (0.59 in.) dia, in Type

911 S only
Wheelbase 2271 mm (89.4 in.)
Rear trailing arm adjustment

(trailing arm inclination)
Track, rear 911 T 1342 mm/52.8 in.

(5 1/2 J x 1 5 rim)
911 E and 911 S 1354 m ~ i j 5 3 . 3in.
(6 J x 15 rim)
Max. axle load, rear 840 kp (1852 Ibs.)

T o l e r a n c e s ( a t e m p t y w e i g h t DIN)
0' to + 20 ' per wheel
Camber, rear +
-lo 10'

GENERAL S P E C I F I C A T I O N S BEGINNING W I T H 1 9 7 4 MODELS
Vehicle Type Carrera
Wheel suspension independent, with triangulated control arms
Springing 1 round transverse torsion bar per whee1,23 mm dia
Shock absorbers double-action, hydraulic shock absorbers
Stabilizer, transverse optional optional 18 mm dia.
Wheelbase 2271 mm same as 911 same as 911
Trailing arm adjustment 36' 30' to 37' same as 911 same as 911
(trailing arm inclination)
Track, rear (wheel center 1342 mm 1354 mm 1380 mm

12 mm below center of (5 1/2 J x 15 rim) (6 J x 15 rim) (7 J x 1 5 rim)
transverse tube)
Max. axle load, rear same as 911 same as 911
Nominal Adjustment
Values and Wear Tolerances
(at empty weight DIN)
Toe-in + 20' - 20' per wheel same as 911 same as 911
Camber, rear - lo+ 10' same as 911 same as 911

TECHNICAL DATA ( 1 9 7 5 MODELS)
Model 911 S 1 Carrera
Wheel suspension Independent with triangulated control arms
Springing One round transverse torsion bar per wheel
Torsion bar dia. 23 mm same as 911 S
Shock absorbers Double action hydraulic shock absorbers
Transverse stabilizer 18 m m dia. same as 911 S
Wheelbase 2271 mm same as 911 S
Trailing arm
inclination
coupe same as 911 S
Targa same as 911 S
Air conditioner same as 911 S
Sportomatic same as 911 S
Models with Bilstein same as 911 S

shock absorbers
Track width, rear 1342 mm 1368 m m

with with
6J x 15 wheel 7J x 1 5 wheel
Rear axle height adjustment:

center of wheel below center same as 911 S
of cross tube
Max. axle load, rear 840 kg (1852 lb) same as 911 S
Adjusting, reference and wear

specifications (at curb weight
according to DIN)
Toe same as 911 S
Camber, rear wheel same as 911 S

TECHNICAL DATA - from 1976 Model
1976/77 Models from 1978
Wheel suspension Independent on trailing arms
Springs One round transverse torsion bar p e r wheel

Torsion bar dia.
Shock absorbers
23 m m
I 24.1 mm
Double-action hydraulic absorbers
Transverse stabilizer dia. 18 mm
(optional)
Wheelbase 2272 mm
Trailing arm inclination
Coupe 42' 40 O
0
Targa + 0.5 + 0. 5O
0 0
Air conditioner + 0.5 + 0.5
0 0
Sportomatic + 0. 5 + 0.5
With Bilstein shock absorbers 41° 39 O
Rear track width 1342 m m with 1367 m m with
6 J x 1 5 wheels 7 J x 1 5 wheels
Rear axle height
Wheel center below cross tube center
+
37- 5mm
Max. rear axle load 78/79 model:
840 kg/1852 l b
1980 model:
880 kg/1940 l b
1 9 8 1 model:950 kg/2094 11
Adjusting, reference and wear limit specifications
(at DIN curbweight)
T o e per wheel
Camber of rear wheels

T I G H T E N I N G TORQUES
Location Description Thread Grade
Bearing cap to body Bolt M 10 8.8 33.9
Rear radius arm to axle cross Bolt M 14x1,5 10 K 65.1
Radius arm to spring plate Eccenter M 12x1,5 8.8 43.4
Radius arm to spring plate Bolt M 12x1,5 10 K 68.7
Brake caliper to arm Bolt M 12x1,5 8.8 50.6
Shockabsorber to arm Bolt M 14x1,5 8.8 90.4
Shockabsorber to body Nut M 10x1 8 18.1
Brake hose to brake lines Brake hose M 10x1 10.9
Stabilizer to body Bolt M8 8.8 18.1
CV flange attachment Allen bolt M 10 12 K 60.0

M8 12.9/10 30.4
Parking brake assembly to arn Bolt M8 8.8 18.1
Wheel to hub Wheel lug M 14x1,5 94.0
Wheel hub to axle Castellated nut M 20x1,5 10 K 217- 243
Brake disc to wheel hub Countersunk M6 8.8 3.6

screw 4 3 in. lbs.
Parking brake.cable housing Bolt M6 8.8 3.6

to arm 4 3 in. lbs.
Adjusting lever to spring strut Hex. hd. bolt M 16x1,5 10.9 177
/ Adjusting lever to spring strut Eccentric bolt M 16x1,5 10.9 177

I
Rear W h e e l A l i g n m e n t 911 5
MEASURING REAR AXLE
General Information
Beginning with 1972 models, rear axle camber specifications have been changed.
The specifications are listed on the new wheel alignment data chart by small triangles. This provides a
quick reference for evaluating the alignment data.
Namtr
-
Vehicle: Porsche type 911 - from model 72 on
Chassis N 0 t License d o t e N o : miles:
Dote : measured by;
Tires: MEASURING CHART

Moke:
Condition: % Difference ongle 01 20° turning radius I Vehicle: 1
-
7 .
1 "n - .1 .1 .7
7 I Empty weight I
Pleose note: toe-in
n q e n r - n shock obsorber
strut odiustment
0 ; ;
toe-in (pressed with 15 kp)
Caster results from totol.camber difference

of 200 left turning rodius and 20° right turning
radius times 1,s
coster coster
comber camber
1 0 1 Reor.wheel adiustment
toe-in
1 0 1 7
AQE~
Copyright by Dr. Ins. h. c. F. Porxhe KG

REAR AXLE C O N T R O L ARMS
TOOLS
Description Special Tool Remarks
Trailing arm positioner
Driver for removing rear wheel hub
Installer, rear wheel hub into control

arm
Torque wrench, 75 mkp
Rear axle control arm alignment gauge
Adapter for control arms beginning P 295 c Used with P 295 b

with 1974 models
5 911 Rear A x l e
-

Rear A x l e 911 5
Note when:
No. Description Qty removing installing Remarks
-
1 Brake line 1 Torque to specifica- 0.2 - 2/1

tion
Brake line retaining

clip
Brake hose
Bolt, M 12 x 1.5
I Pull out towards
center of vehicle
Torque to specifica- 0.2 - 2/1

tion
Brake caliper
Cotter pin 1 Replace
Castellated nut 1 Torque to specifica- 0.2 - 2/1

tion 2.1 - 1/6
Washer
Countersunk screw, Torque to specifica-

M 6 x 12 tion
Brake disk
Bolt, M 1 4 x 1.5 Torque to specifica-

t ion
Washer
Shock absorber
Wheel shaft
I Drive out towards
center of vehicle
Wheel hub 1 Drive out with 2.1 - 1/7

P 297 a

Note when:
Description removing installing Remarks
Bolt, M 8 Torque to specilica-

tion
Reinforcing cover
Cotter pin Replace
Castellated nut M 6
Washer
Expander Seat properly
Spring
Parking brake cable Pull out towards

vehicle center
Spacer tube Seat properly. Large

cross-section faces to-
wards vehicle center
Washer
Nut, M 8 Torque to specifica-

tion
Spring wahser Replace if necessary
Bolt, M 8
Backing plate with Remove whole assembly

brake shoes
Nut, M 1 2 Torque to specifica-
tion
Toothed washer Replace if necessary

Rear A x l e 911 5
Note when:
No. Description
removing installing
Washer
Bolt, M 1 2
Washer
Nut (thin), M 1 2 Torque to specifica-

t ion
Toothed washer
Eccentric bolt for

toe-in adjustment
Eccentric bolt for

camber adjustment
Self-locking nut, Replace, torque to

M 14 specification
Washer
Bolt, M 1 4
Axle control arm Check for deforma-

(aluminum) tion, replace if
necessary
Double-row ball Press out with Replace. Press in

bearing fitting thrust piece. with appropriate
thrust piece
Rubber mount If rubber mounts are

removed, install
new ones
Torsion plate
(trailing arm)

Rear A x l e
-
Disassembly
1. Detach drive shaft from transmission flange.

Use flat chisel in the area of the flange gasket
to separate shaft assembly from flange.
CAUTION
Do not damage the flange surfaces.
4. Remove brake disk.

2. Detach brak'e line from brake caliper and
control arm assembly (first depress brake
pedal with pedal holder to keep brake fluid
5. Raise torsion plate (trailing arm) with the aid
from draining out of the brake fluid reservoir).
of P 289. Remove shock absorber retaining
bolt.
3. Remove cotter pin from the castellated nut in

the wheel shaft and remove nut with the aid 6. Drive wheel shaft out towards vehicle center.
of P 42 a, P 36 b, P 44 a, and P 296.

7. Drive rear wheel hub out with the aid
of P 297a.
8. Remove cotter pin and castellated nut from

brake cable stub. Pull brake cable out
towards vehicle center.
9. Press ball bearing out with an appropriate

thrust piece (approx. 65 m m dia.).
Checking Parts
1. Check rubber mounts in rear axle control

arms for wear or damage, replace if necessary.
2. Install special tool P 295c (adapter for

mounting aluminum axle control arm) in
special tool P 295b. Marker in the P 295c
adapter must point towards the marker in
P 295b.

5 911 Rear A x l e
-
3. Using P 295b and P 295c, check axle control

arm for deformation.
If the control arm is in alignment, it will b e

possible to push the test mandrel in with the
rubber mounts installed. Deformed axle
control arms must b e replaced.
Reassembly
1. Using an appropriate press adapter (approx .

79 mm dia.), press the double-row ball
bearing fully in (apply pressure to bearing
outer race).
NOTE:
The double-row ball bearing must always b e

replaced because it is damaged during removal
from the axle control arm.
2. If the rubber mounts were removed, install

new ones by presSing them fully in.

Rear A x l e 911 5
3. Using P 2981, and the wheel shaft, press the
wheel hub into the double-row ball bearing.
NOTE:
Do not drive the wheel hub into the bearing with

a hammer since this will damage the bearing.

Axle D i v e h a t 911 5
AXLE DRIVESHAFTS - LIGHTER VERSION
General
Beginning with October 6, 1971 production, all 911 models have new and lighter axle driveshafts
. .
(approx 0.9 kp (2 lbs. ) lighter).
The CV (constant velocity) jojnts are 8 mm (0.31 in.) narrower (dimension A). As a result, the
axle shafts are 8 mm longer.
Installation Note:
From 1969 models on, old-type drive shafts

can be replaced with the new version on in-
dividual basis from 1969 models on.
When installing the newer axle drive shafts,

it is necessary to use the new socket head
bolts, M 1 0 x 48, as well as new supporting -
Dimension A new driveshaft version = 32 mm
plates. Dimension A - old driveshaft version = 40 mm

Brernsen, Rader, Reifen
Brakes, Wheels, Tires
Freins, Roues, Pneus
Freni, Ruote, Gomme

Brakes, Wheels, Tires 911 6
CONTENTS
0.0 Information
0.1 Description
0.2 Technical Data

General Data
Tightening Torques, front and rear brakes
1 - BRAKE BOOSTER, MASTER BRAKE CYLINDER
1.1 Brake Booster

Removing and Installing Brake Booster 1.1- 1/1
Disassembling Brake Booster and Brake Master Cylinder Partially 1.1- 2/1
Checking Brake Booster l+l- 311
4 - WHEELS AND TIRES
4.1 Wheels and Tires

Summary
Checking Steel-Disc Wheels
Mounting Instructions
Instructions for Installation of Adhesive Weights i n
Light-Alloy Wheels
Balancing Wheels
Collapsible Spare Tire (Spare tire in vehicles with 85-liter
fuel tank)
Standard Wheels and Tires, overview, from 1973 model
Standard Wheels and Tires, overview, from 1975 model

GENERAL D A T A - through 1977 model
Dimensions and Wear

Item
Adjustment Values Tolerances
Tandem Brake Master Cylinder

Bore
Stroke
Reduction ratio a t brake pedal
Clearance, actuating rod t o piston
Front Wheel Brakes

Brake disc outer diameter 282.5 m m , vented
Thickness, new 20.0 m m resp. 2 0 , s m m
Minimum thickness when reconditioned * 18.6 m m

Thickness tolerance max. 0.03 m m
Brake disc lateral runout max. 0.05 m m
Lateral runout when installed 0.2 m m
Caliper piston Q 48 m m
Brake lining rhickness 1 0 mm
Lining t o rotor clearance when released 0.2 mm
2
Lining area per wheel: Type 9 1 1 T and E 52.5 c m
2
Type 9 1 1 S 76.0 c m
Rear Wheel Brakes

Brake disc outer diameter 290 mm, vented
Thickness, new 20.0 m m
Minimum thickness when reconditioned * 18.6 m m
Thickness tolerance max. 0.03 m m
Brake disc lateral runout max. 0.05 mm
Lateral runout when installed max. 0.2 m m
Disc surface finish when reconditioned max. 0.006 m m
Caliper piston 9 38 m m
Lining thickness 1 0 mm
Lining to rotor clearance when released 0.2 mm
2
Lining area per wheel 52.5 c m
*The disc must always be machined on both sides by the same amount.

911 Technical Data
Item Dimensions and

Adjustment Values
P a r k i n g Bra.ke - I
Parking brake drum 0 , new 180 m m ; 1 8 1 mm

Parking brake lining thickness : 2.0 m m
General Information for Brakes with

Brake Booster
Brake Booster 1
!
Type T 52, 7 inch

Mean multiplication factor 2.2
Tandem Brake Master Cylinder
Bore 20.64 m m dia.

Stroke 20/12 m m
Play a t brake pedal with
brakes bled and engine stopped 1 0 mm

Technical Data 911
GENERAL D A T A - from 1978 Model
Description Specifications Wear Limits
Service brakes Hydraulic dual circuit brake system, separate

(foot- operated) circuit for each axle, brake booster, inboard
vented brake discs on front and rear axles
Brake booster dia. 7 inches
Brake master cylinder dia. 20.64 m m
Brake disc dia. , front 282.5 m m

rear 290 m m
Eff. brake disc dia. , front 228 m m

rear 244 mm
Brake caliper piston dia. , front 48 m m

rear 38 m m
2
Brake pad area/each front wheel 76.0 c m
2
Brake pad area/each rear wheel 5 2 . 5 crg
Total pad area 257 c m
Pad thickness, front 10 mm

rear 10 m m
Brake disc thickness when new

Front 20. 5 m m
Rear 20.0 m m
Min. brake disc thickness after machining *
Front 19.1 mm
Rear 18.6 mm
Max, brake disc thickness tolerance 0.02 mm
Max, brake disc lateral runout 0.05 mm
Max. brake disc lateral runout when installed 0.1 mm
Max. peak-to-valley surface finish after

machining 0.006 m m
Play a t brake pedal with brakes bled and engine
stopped 10 m m
* Brake discs must always b e machined on both sides by the same amount.

I
I
911 Technical Data I!
Description p e c i i t i o n I wear Limits
Parking brake Drum brake mechanical action on both rear

(hand- operated) wheels '
Brake drum dia. 180 m m

Brake shoe width 25 m m
2
Brake lining area per wheel 85 c m
Brake lining thickness 4 . 5 mm

T I G H T E N I N G TORQUES FOR FRONT A N D REAR BRAKES
Location Designation Thread Grade ft. lbs.
Tandem brake master cylinder Nut

to transverse wall
Attachment of piston rod Nut (flat)

to eyebolt end
Brake line connection Hollow bolt
Hollow bolt in caliper Hollow bolt
Caliper to steering knuckle Bolt
Lock nut to steering Allen bolt

knuckle
Brake disc to wheel hub Nut
Disc shroud Bolt
Caliper housing bolt Allen bolt

(front)
Caliper housing bolt Allen bolt

(rear)
Caliper to rear control Bolt

arm
Brake disc to rear wheel Countersunk bolt

hub
Brake carrier plate to Bolt

rear control arm
Shroud to brake carrier Bolt

plate
Parking brake cable to Bolt

control arm
Wheel to wheel hub Spherical flange nut
Bleeder valve in caliper

SW 7 wrench size

Brakes, Wheels, Tires 911 6
R E M O V I N G A N D I N S T A L L I N G BRAKE B O O S T E R

!
!
Brakes, Wheels, T i r e s I
-
Note when
removing installing
Install in correct position

Lock pin Pull back brake pedal
to stop, Lock pin must
now be installed with-
out tension, adjust
operating rod if ,
necessary
Lock clip Check for proper fit
Operating rod Adjust, if necessary
Socket head bolt Can only b e remo- Torque to specifica-

ved after removing tions
pedal assembly
Lock washer Replace, if necessary
Bolt Torque to specifica-

tions
Washer
Hose clamp
Bolt Torque to specifica-

tions
Washer
Brace

tions
Spring washer Replace, if necessary
Brake booster with

tandem master cylin-
der

Brakes, Wheels, Tires 911
REMOVING AND I N S T A L L I N G I N S T R U C T I O N S
Removing 5. Remove upper bolt for brace and nuts for

booster base.
1. Remove lock pin for operating rod.
Note
Brace and operating rod do not have to be

2. Remove mounting bolt for brake master cylin- detached a t pedal assembly to remove brake booster.
der (located inside on luggage compartment
floor plate).
3. Drain brake fluid reservoir with siphoning

device.
4. Disconnect stop light switch plugs. Loosen

vacuum hose clamp and remove brake line.
Installing
1. Install brake booster with brake master cylin-

der in reverse sequence.
2. Lock pin (item 1) for operating rod must b e
installed so that the spring can be inserted
Downloaded from www.Manualslib.com manuals search engine from above (see arrow, upper left picture).
I
I
I
911 Brakes, Wheels, T i r e s II
A D J U S T I N G BRAKE O P E R A T I N G ROD
Note
The operating rod must b e attached when the

brake pedal is a t its rest position without any
force applied to the operating lever. T h e play set
a t the factory must not b e changed.
1. Pull brake pedal back to stop.
2. Loosen nuts on operating rod. Adjust operating

rod until the lock pin for the operating lever
can be installed without tension.
3. Tighten nuts on operating rod.
4. T o verify the clearances required in the

brake booster, check the operating rod play
at the brake pedal by manual operation after
the brakes have been bled and the engine is
stopped. This play must be at least 1 0 mm.

Brakes, Wheels, Tires 911
DISASSEMBLING BRAKE BOOSTER A N D BRAKE M A S T E R CYLINDER ( P A R T I A L L Y )

i
1
911 Brakes, Wheels, Tires j

i
I
Notes
Designation iemoval Installation
Bolt cap
Filter screen
Hex. head screw Torque to specifi-

cations
Lockwasher Replace, if necessary
Washer
Tank
Plug
Hexagon nut Torque to specifica-

tions. Not too tight !
If staybolt is stretched
or broken, replace
brake booster.
Spring washer Replace, if necessary
Holder
Base
Lock Check for proper fit
Bearing pin Coat with all-purpose

lube containing MOS
2
Operating lever Coat ball socket with

all-purpose lube con-
taining MOS Make
2'
sure that piston rod
fits properly.
Bearing bushing
Snap ring

Brakes, Wheels, T i r e s 911 6
Notes
No. Designation
Hexagon nut Torque to specifica-

tions. Not too tight !
If staybolts are stret-
ched or broken, replac
brake booster.
Lockwasher Replace, if necessary
Tandem master Check, if necessary

cylinder repair or replace
Seal Replace
Brake booster Check, replace if

necessary
Check valve Check, replace if

necessary
Plug
Stop light switch Torque to specifi-

cations
Hose
Hose
Supply neck
0
Supply neck 75
Plug

Brakes, Wheels, T i r e s 911 6
C h e c k i n g Brake Booster
Depress and release brake pedal several times with the engine stopped to remove any vacuum out of the
booster.
Now depress brake pedal to braking position with medium effort and start engine.
If the brake booster functions properly, i t will be felt as the pedal gives slightly underneath the foot
(booster takes effect).
Troubleshooting Chart
Condition Cause Correction
1 - Pedal pressure unusually a - Vacuum line connections Tighten clamps

high, no support from loose
booster
b - Roller diaphragm loose Replace booster
c - Master cylinder seal - - Replace large seal, replace

leaking master cylinder
d - Vacuum check valve Check function of vacuum

malfunctions (closed check valve, by blowing
always) into valve in direction of
arrow. Valve must lift off
of seat. Valve must be tight
against direction of arrow
2 - Pedal pressure increases Pressure rod piston scored at Repair or replace master
very much at certain pe- one point. Once secondary cylinder
dal position cup passes this point, out-
side air comes into booster
through vent bore
3 - Pedal can be pressed to Cups leak Repair or replace master cylinder

stop without braking
effect
Brake fluid runs out at

vent bore

1
i
11 Brakes. Wheels. Tires 1I
I
Note
When a brake circuit fails or after repairs on the brake system, a brake warning light installed in the
,
dashboard comes on. 1
I
I
After brake repairs, the brake warning light can b e turned off by disconnecting the battery ground strap.
I
i

Wheels and Tires 1
C H E C K I N G WHEEL RIMS
Points for measuring radial and lateral runout on inside and outside shoulders of rim.
Distance "a" = 8 mm.
Max. permissible radial runout for steel rims 1.25 -mm

Max. permissible radial runout for aluminum rims 1.0 mm
Max. permissible lateral runout for steel rims 1.25 mm
Max. permissible lateral runout for aluminum rims 0.8 mm
Max. permissible radial and lateral runout .

for rim + tire 1.5 mm
(also refer to pages 4.1 - 1 / 3 and 4.1 - 1/4)
Note
Straightening of deformed rims is not permitted.
Check flanges of aluminum wheel rims for wear. The inside rim flange is more subject to -weaT.
Check with a standard 8 mm radius gauge. IF applicable, first remove sharp edges and b&s.
Wear limit = 1 mm.
Replace wheel rim, if necessary.
C h e c k i n g Rim F l a n g e S h a p e
New condition
-------- After wear
I)+ M a x wear 1 mm
1 Radius gauge 8 mm

!
911 Wheels and Tires I
GENERAL ASSEMBLY I N F O R M A T I O N O N T I R E S AND TUBES

1
Always a l s o use new t u b e s or rubber v a l v e s t e m s e a c h t i m e t i r e s !
are replaced! i
Tubes should only be used in "tubeless" tires in an emergency situation. I t cannot be recommended to
combine tires and tubes of different make. Tubes are not available for series 50 and 55 tires!
When mounting tubes with steel valve stems remember that valve core is screwed in o n l i after inflation
of the tire.
Be careful not to turn the tire valve when tightening the nut. I
i
i
"Tubeless" tires may only be mounted without tubes on rims with a double hump. If thid type rim is not
available, tMs tire must also be mounted with a pertinent tube. When necessary tubeless tires can be used on
an axle with. tube tire as long as the make, size and type are identical. ,
Double hump rims 012) were used on a general basis in the 1975 model year.
Original Porsche rims are identified by the Porsche part number in the wheel rim. ~ e a n ofh numbec
~
901.361. xxx. xx (rim without hump) or 911.361. xxx. xx (rim with double hump), where'by x = digit for
I
internal designation of version and paint. 1
Diecast rims are not always sufficiently leak-proof because of the coarser grain structur4 and consequently
can only be used for tubeless tires when tested accordingly. From1976 models on porsch4 diecast rims are
checked for leaks with a special fixture and therefore suitable for use with "tubeless" tirks.
Part numbers; of these rims:

1
I
I
Rim Size Untested Diecast Tires Leak-proof Diecast Tires
(tires with tubes) ("tubeless" tires) Ii
6 J x 1 5 (silver) 911.361.023.10
6 J x 15 (unpainted) 911.361.023.14
7 J x 1 5 (silver) 911.361.023.20
For cars, which have center pin wheel centering, we recommend always using rims wit4 centering pins.
Wheel nuts made of steel should be used on steel rims. I

Wheels and Tires 911 6
To prevent excessive loads on rubber tire valve
stems (tube or tubeless version) caused by position
of valve stem bore, 7 " and 8 " Porsche rims
must be fitted with a valve stem support, Part No.
911. 361. 561.00 or 01.
7 J x 1 5 diecast rims (ATS) sometimes have a special cast boss in area of the valve stem bore, so that safe
support can be guaranteed without a holding plate. On rims, which have this cast boss, the wall, thickness is
so great at the valve stem hole that the 3 mm wide bead ring on the valve stem should not be pulled in when
installing tubeless tire valves (as common on steel rims). Pulling in the valve stem bead would stretch the
valve stem excessively.
Check sealing surfaces of tire and wheel rim for dirt and damage when mounting a tubeless tire. In conjunction
with this point remember that the bead base of a tubeless tire provides the seal. If the bead flank is used for
sealing, air could escape when driving aggressively.
Check flanges of aluminum wheel rims for wear (see page 4.1 - 1/1).
Always coat tire beads with rubber lubricant when mounting.
Apply talcum powder inside of tire in tube type.
Inflate tubeless tires to about 4 bar/58 psi after mounting without valve core to guarantee proper fit on rim.
With 3.3 bar/48 psi pressure the tire bead should jump over the rim hump. Screw in valve core and inflate
tire to specified pressure.
M a x permissible radial and lateral runout of wheel (tire + rim) is 1.5 mm/O. 59 in. If necessary, turn tire
0
on rim 180 (uncontrolled matching) to reach an acceptable value.
Controlled matching: align highest point of rim (not marked on 911, determine) with green dot on side wall
of tire.

1
I
!
911 . . Wheels and Tires 1
I
New tires should be used on the front axle, since

I
1. the rear axle is more critical over stability and
I
2. the front wheels must first make a track on wet roads,
in which the rear wheels can follow.
!
(Not possible on cars with different size tires front and rear.) i
I
When replacing a defective tire, make sure difference in tread depth on one axle is not!
greater than 30 70. 1
!
B A L A N C I N G WHEELS
Max. permissible dynamic and static unbalance 5 grams.
Check radial and lateral runout of wheels when there is vibration and steering wheel sh: e in spite of perfect
wheel suspension parts, perfect wheel centering, correctly adjusted wheel bearing play ~d properly balanced
wheels.
Check on tires run warm (to exclude flat spots from standing) with a standard tester.
Max. permissible radial and lateral runout of wheel (tire +rim) = 1.5 mm.
Max. permissible radial and lateral runout of wheel rim =see page 4.1 - 1/1.
If testing is not performed on a stationary balancing machine, but direct on the car, a . :ry slight lateral
runout of wheel hub from manufacturing, wheel bearing play and also any error in whet centering w i l l
be reflected in the measured value. If these factors are eliminated or compensated and he value is still
greater than 1.5 mm, check whether an acceptable value can be reached by turning ti on rim 180'
(uncontrolled matching).
I N F O R M A T I O N ON C E M E N T E D W E I G H T S FOR A L U M I N U M WHEEL
General
Aluminum wheel rims may only be balanced with balance weights which are cemented The cemented type
balance weights supplied by Porsche are available in steps of 10 g from 10 to 80 g.

Installation
1. Determine exact position of balance weights (if

applicable first hold balance weights with pieces
of tape until correct position has been determined).
2. Prepare adhesive surface on rim. Adhesive sur-

faces must be absolutely clean and free of grease.
3. Pull off paper backing from adhesive surface of

weight and press weight on firmly.
Note
Pull off paper backing only immediately before

pressing on weight, since the effect of air over a
long time will impair the adhesion and there is
also danger of dirt getting on the adhesive surface.
1 Aluminum rim
2 Adhesive balance weight
The adhesive balance weight must be located

accurately on the flat surface of the rim. It must
rest uniformly on the entire bearing surface.
For rims of size 5 1/2 J x 1 4 the adhesive weights must
be contoured to the rim with a plastic hammer to match
the smaller radius (prior to pulling off the green paper
backing).
L
4. Check tight fit of balance weight after trfal run
on a balancing machine.
The newly installed balance weight must not
become loose from the rim when load is applied
transversely to it.
Note
Adhesive weights may only be installed on the outside

of 5 1/2 J x 1 4 aluminum hole- type wheel rims.
Weights with spring clips must be used on the inside of
these rims (as for steel hole-type rims).
From 1973 models on 5 1/2 J x 15 steel rims have tire valve holding sleeves instead of spring clips. The sleeve
is fitted from inside of the rim and held in position by the tube or valve stem. This sleeve can also be used
subsequently on older models.
I
I
911 Wheels and Tires I
COLLAPSIBLE SPARE TIRE
A spare wheel with a collapsible tire is used in cars with a 85 liter fuel tank to save spaye.
From 1974 models on a 80 liter steel tank and a collapsible tire/ wheel are standard in ai.1 models.
Rim size 5 1/2 J x 14, tire size 7.35/185 - 1 4 SST or from 1973 models on. I
-
Rim size 5 1/2 J X 15, tire size 165 - 15/4, 75/10.00 1 5 SST
,
i
When required the tubeless tire may be inflated to only 2.2 bar/32 psi. The tire will retyrn to its original
I
shape when discharging the air from the collapsible tire.
A collapsible tire cannot be repaired or mounted with conventional workshop equipment! Only the manu-
facturer should perform work on the collapsible tire/wheel. 1
I
I
This collapsible tire/wheel is only for an emergency situation and should not be used for!long driving. The
max. permissible speed with this wheel is 80 km/h (50 mph). I
Replacing:
Only new version collapsible tiredwheels will be available after depletion of

old stocks. Label on rim has been changed. Part number of collapsible tirejwheel
remains unchanged.

SURVEY OF WHEEL R I M S A N D T I R E S - from 1972 Models
Standard Rim Tire Optional Equipment

Rim Tire
St. 5 1/2 J x 15 165 HR 15 5 1/2 J x 15 LMg185 HR 1 5

6 J x 15 St 185/70 VR 15
Mod. 72 St. 6 J x 15 185/70 VR 15 6 J x 1 5 LMgs 185/70 VR 15
Mod. 73 LMg 6 J x 15
LMgs 6 J x 15 185/70 VR 15
SURVEY OF WHEEL R I M S A N D T I R E S - from 1974 Models
Standard Rim Tire Optional Equipment

Rim Tire
911 St. 5 1/2 x 1 5 6 J x 1 5 LMgs 185/70 VR 15

911 S LMg6 J x l 5 6 J x 15 LMgs 185/70 VR 15
Carrera Front LMgs 6 J x 15
Rear LMgs 7 J x 15
LMg Cast aluminum rim
LMgs Forged aluminum rim
St Painted steel rim
Winter tires and tire inflation values same as for 1975 models, see page 4.1 - 1/8.

I
i
1
Wheels and T i r e s 1
!
I
SURVEY OF WHEEL RIMS A N D T I R E S - f r o m 1 9 7 5 Mo.dels
I
i
TYPe Standard Rim Tire Optional ~ A u i ]nent

Rim i Tire
5
I
I-
911 S LMg 6 J x 1 5 185/70 VR 1 5 LMgs 6 J xi15
I
Carrera Front LMgs 7 J x 1 5 1&5/70 VR 15 i
I
Rear LMgs 8 J x 1 5 215/60 VR 1 5 i
I
Winter Tires *
Tire I Rim
Inflation Pressure for Cold Tires:
Front 2.0 bar/29 psi

Rear 2.4 bar/35 psi
Spare 2.2 bar/32 psi
LMg Cast aluminum rim
LM gs Forged aluminum rim
St Fainted steel rim
* SR or HR version

WHEELS A N D T I R E S - from 1976 Model
Optional
Standard Wheel Tire Wheels Tires
(check fender clearance and position of
wheels in wheel housings)
LMgs 6 J x 1 5
front 6 J x 1 5
rear 7 J x 1 5
front 7 J x 1 5
rear 7 J x 1 5
front 6 J x 1 5
rear 7 J x 15
front 7 J x 15
rear 8 J x 1 5
LMg = cast light alloy
Winter Tires "
Wheels
Tires
Type 911 S
Cold Tire Pressure
front 2. 0 bar/28 psi

rear 2. 4 bar/34 psi
spare wheel 2. 2 bar/31 psi
* = SR or HR version
WHEELS A N D T I R E S - from 1978 Model
i
Optional i
Type Standard Wheels Tires Wheels 1 Tires
I
I
911 SC front 6 J x 1 5 185/70 VR 15 front 6 J x 16 I 205/55 VR 16

rear 7 J x 1 5 215/60 VR 15 rear 7 J x 16
Winter TIres *
Tires
I Wheels
6Jx15
7Jx15
6 J x 1 5 front/
7 J x 1 5 rear
6Jx16
6 J x 16 front/
7 J x 16 rear
Cold Tire pressure:
front 2, 0 bar/28 psi

rear 2 . 4 bar/34 psi
spare wheel 2 . 2 bar/31 psi
* = SR or HR version
Hebelwerk
Pedal System and Levers
Pedalier et Leviers
Pedaleria e Leve

MANUAL AND PEDAL C O N T R O L S 911 7
CONTENTS
0.0 Information
0.1 Description
0.2 Technical Data

Tightening Torques
1 - MANUAL CONTROLS
1.1 Gear Shift Linkage in Manual Transmission

Gear Shift: Linkage, disassemble and reassemble
Gear Shift Linkage, adjust
Notes for Disassembly and Reassembly
Gear Shift Linkage, disassemble and reassemble, from 1973-model
1.2 Heater and hand t h r o t t l e controls from 1975 models

Dismantling and assembling heater and hand throttle controls
Removing and installing heater and hand throttle controls
Adjusting heater controls
Adjusting hand throttle control
Heater Blower Switch, remove and install
2 - PEDAL CONTROLS
2.1 Pedal Controls

Pedal Controls, disassemble and reassemble 2.1 - 111
Notes for Disassembly and Reassembly 2.1 - 1/6
Disassembly and Reassembly of Pedal Controls 1974 Models 2.1 - 1/7
Instructions for Disassembly and Reassembly 2.1 - 1/12
Adjusting Clutch 2.1 - 2/1
Adjusting Clutch from 1977 Models (with Servo Clutch on Transmission) 2.1 - 2/3

Technical Data 911
- -
T I G H T E N I N G T O R Q U E S FOR MANUAL A N D PEDAL C O N T R O L S
Location Designation Thread Grade
t
I
Support bracket to shift
lever housing
Shift lever housing to

center tunnel
Set screw in shift rod head
Set screw in shift rod coupling I

Allen bolt
Taper screw
Taper screw
Parking brake, heater, and
Set screw in throttle Pointed set screw

control rod
Parking brake switch to Countersunk screw

support bracket
Throttle pedal to body Bolt
Pedal assembly support

bracket to body
I Throttle shaft attachment
Ball socket lock nut I Nut

Levers 911 7
DISASSEMBLING A N D ASSEMBLING SHIFT LEVER ASSEMBLY
TOOLS
Nr . Description Special Tools Remarks
1 Assembly lever Locally manufactured
2 Installer P 299

D I S A S S E M B L I N G A N D A S S E M B L I N G S H I F T LEVER ASSEMBLY

Levers 911 7
Note when Special
Description Qty instructions
Shift knob 1
Shift knob retaining 1 Replace.
ring
Dust boot
Bolt, M8 -
Lock. washer 3 Replace.

Bolt, M6 2
Spring washer . 2
Ball socket 1 Use multipurpose grease

with molybdenum
additive.
Pin, 30 x 1 0 1 Drive out with punch. Replace if necessary.
Snap ring 4 Replace.
Guide pin
Spring - -
Stop plate 1 Use multipurpose grease

with molybdenum
additive.
Lock pawl return sprin 2
Lock pawl 1 Use multipurpose grease

with molybdenum
additive.
Spring seat, lower 1 Use multipurpose grease
with molybdenum
additive.
Spring
Spring seat, upper 1 Use multipurpose grease
with molybdenum
additive.
Gearshift lever
Support plate
Tapered bolt
Shift rod joint 1 Coat inner side with
multipurpose grease.
Guide bracket 1
Bushing
Nut, M8
Note when Special
Serrated washer Replace.

Bolt, M8 x 32
Clamping bolt
Tapered bolt
Shift rod coupling
Dust boot
Shift rod Lubricate pivot point.
I

Levers 911 7
DISASSEMBLING AND ASSEMBLING S H I F T LEVER ASSEMBLY
Disassembling
1. Clamp the shift lever into a vice equipped with

soft jaws. Drive off shift knob using the self-
made tool. See illustrations.
Drawing for s e l f - m a d e tool
1/4 inch flat stock, all edges rounded off.

Assembling
2. Pull retaining ring out of shift knob with a 1. Push lower spring seat on the shift lever
hook. compression spring until the spring is seated.
3. Remove shift boot. Pry plastic ball socket off 2. Coat the lower part of the shift lever well
shift lever with a screwdriver. with Molykote or similar lubricant. Insert
lever into shift bracket.
4. Clamp shift lever mounting bracket into vice.
Caution
Use car when removing the guide pin springs.
They are under tension and may fly out. Cover
the springs with a rag.
Remove the guide pin snap springs. Remove the
guide pin springs one at a time.
5. Remove remaining parts.

3. To install the guide pin springs:
a. Position the stop plate to the shift bracket

of the guide pins.
b. Insert the second guide pin with snap ring
at an angle.
Slip the spring over the pin.
c. Carefully push one end of the spring into
the cutout. Align the spring and push the
pin in completely. '
d. Install the spring on the other guide pin

in the same way.
4. Slide on the shift boot.
5. Insert new retaining ring into shift kncb (as

far as the stop).
6. Place shift knob on lever so that the shift pin

is in the correct position. Install using special
tool P 299.

Manual Controls 911 7
GEAR S H I F T ASSEMBLY E F F E C T I V E W I T H 1 9 7 3 MODELS
General
Beginning with the 1973 models, a ne1s pressure-cast shift lever housing is installed in all Type 911
vehicles equipped with a 5 -speed transmission.
This shift lever housing can also be installed in older vehicles from 1972 model year on.

D I S A S S E M B L Y A N D REASSEMBLY

Manual Controls 911
Jr . Description Qty
removing
Note when:
installing
Remarks
1 Shift knob 1
I I
2 1 Interference sleeve I 1
3 I Dust boot I
4 1 Allen bolt, M8xZO 1 3
5 Spring washer 3 Replace
6 1 Allen bolt, M6x20 1 2
7 1 Spring washer 1 I
Replace
8 1 Nut, M 6 I
9 Lock washer 2
LO Lock pawl carrier plate 1 Apply MoS2 multi-

with lock pawl purpose grease
L l Spring 2
Buffer plate
Guide plate Apply MoS2 multi-
1
purpose grease
14 Ball socket Apply MoS2 multi-

purpose grease
15 I Lock ring 1 Replace if necessary
L6 1 Pivot pin Check for wear Apply MoS2 multi-

purpose grease
7 Gear shift lever 1 Apply MoS2 multi-

purpose grease in the
pivot area
8 Roll pin 2 Drive out with Replace if necessary.

punch Install flush with shift
lever housing
9' Spacer X Note number of If necessary, redeterm

shims and their required number and
thickness thickness

7 911 Manual Controls
Note when:
Remarks
removing installing
Apply MoS2 multi-

purpose grease to
friction points
1 1
21 Shift lever housing
122 1 Set screw
2 3 16. rod head Apply MoS2 multi-

purpose grease to the
inner surfaces
Zd
1
125
Support bracket
Bearing bush
126 Nut, M 8
1 27 1 Schnorr lock washer
28 Bolt, M 8 x 32
29
30
Clamp
Set screw
s-I Torque to specifica-
1 1
31 Shift rod coupling
Apply MoS2 multi-

purpose grease to
friction points

Manual Controls 911 7
I N S T R U C T I O N S FOR DISASSEMBLY A N D REASSEMBLY
Disassembly
1. Remove shift knob (see 1.1 1/5). - 5. Take guide plate out of the shift lever housing
through the top.
2 . Mount shift lever housing in a vise.
3. Remove both lock pawl carrier plate re-

taining nuts (M 6). .
4. Open the vise slowly, holding the lock pawl

carrier plate with one hand.
6. Remove lock rings from pivot pin with a

screwdriver and pull pivot pin out of the
shift lever housing.
Caution:
The springs are under strong pressure and can 7. Take gear shift lever out of the housing.
cause the lock pawl carrier plate to snap out.

7 911 Manual Controls
Reassembly
1. Install gear shift lever, with forks and pin in

place, into the shift lever housing.
2 . Insert spacers. Select the spacers to achieve

a clearance of 0 to 0 . 1 m m between the forks
and housing.
5. Place gear shift knob onto the shift lever and

drive it into place with special tool P 299.
6. Install gear shift lever assembly in vehicle

and adjust (see 1.1 - 2/1).
3. When installing the lock pawl carrier plate,

place the lower part of the shift lever in the
vise.
Use vise jaw covers.
4. Firmly press the lock pawl carrier plate down

onto the shift lever base and tighten the M 6
retaining nuts.
Caution:
The springs are under heavy pressure and can
cause the lock pawl carrier plate to snap out.

Levers 911 7
A D J U S T I N G GEARSHIFT LINKAGE
1. Loosen shift rod clamp. Turn shift rod for 3. Lightly tighten the shift rod clamp.
selector shaft to the right in neutral position
(seen in direction of driving).
4. Check if equally long travel is evident in

gears 1 thru 4, and 5th and reverse gears can
be easily engaged. Correct the adjustment if
necessary.
5. Torque clamp nut to specification.
6. Shift into 5th gear. With the dust boot at the

shift rod coupling pushed back, check selector
shaft for rotational play. A definite amount of
play must be in evidence.
2, Move gearshift lever in neutral to the point

where the lower part of the shift lever is
positioned vertically and touching the left stop.

Controls 911 7
D I S M A N T L I N G A N D ASSEMBLING HEATER A N D HAND T H R O T T L E C O N T R O L S
( f r o m 19'75 M o d e l s )
General Notes
The hand throttle and heater controls are located on the parking brake holder.
The heater is regulated by two control levers infinitely, on the left and right
sides of the vehicle.
D I S M A N T L I N G AND ASSEMBLING
1 Heater control lever, right 6 Friction disc

2 Heater control lever, left 7 Disc
3 Hand throttle control lever 8 Shaft
4 Nut, self-locking 9 Spacer
5 Spring disc
a Release pressure for heater control friction clutch: 1 0 kp

b Release pressure for hand throttle control friction clutch: 6 kp
c Heater control knob (press fit)
d Hand throttle control knob (press fit)
Controls 11 7
REMOVING AND I N S T A L L I N G HEATER A N D HAND T H R O T T L E C O N T R O L S
Removing
1. Disconnect heater cables at rotary valves of

heater body (underneath vehicle).
2. Remove tunnel cover and parking brake boot.
3. Remove parking brake base screws.
4. Remove hand throttle lever self-locking nut.

Remove friction disc and discs. Disconnect
hand throttle lever.
5. Lift parking brake base to unlock and pull out

cable pin.
6. Disconnect wire connector a t operating seg-

ment of parking brake indicator lamp.
Remove parking brake base with heater cables.
Caution
If the parking brake base cannot be lifted high

enough to disconnect cable, disconnect the
parking brake compensator.

7 91, Controls
Installing
1. Pull heater cables into heater control lever,

The longer heater cabIe is connected to left
heater control lever.
2. Slide heater flap cables into guide tubes,

Lubricate cables at the same time with a
multi-purpose grease. Make sure that heater
flap cables do not tangle.
3. Install and lock parking brake compensator

(apply mu1ti-purpose grease).
Caution
Make sure that parking brake cables are located

properly.
4. Connect wire connector to operating segment

of parking brake indicator lamp.
Connect hand throttle lever.at parking brake

base and throttle linkage. Install parking brake
base on center tunnel.
Secure hand throttle lever. Tighten self-lock-

ing nut until hand throttle lever will not return
on its own when throttle is fully pulled out.

o n t r s 911 7
7. Check hand throttle position (refer to page
1.2 - 1/7).
8. Connect heater cables t o rotary valves at' heater

body. Install grommets on guide tubes.
9. Check heater flap settings (refer to page

-
1.2 1/6).
Replacing h e a t e r and hand t h r o t t l e control knobs
Drive knobs off heater and hand throttle control

levers with a piece of wood, or similar.
Drive knobs on with a plastic hammer.
Caution
Do not damage knobs.

A D J U S T I N G HEATER CONTROLS
Move both heater control levers to front stop,

slide to "off" position and tighten left and
right h e a t a cables to rotary valves underneath
vehicle.
Heater flap valves must be; fully open.
Check function of heater fl;ap.Heater flaps

and rotary valves must open and close com-
pletely when operated.
4. Tighten self-locking nut of heater controls so

that lever does not return on its own when
heater is on. On the other hand, the levers
should not be too hard to move.

Controls 911 7
ADJUSTING HAND THROTTLE CONTROL
1. Remove tunnel cover and parking brake base

cuff.
2. With a warm engine (approx. 80° C) and the

hand throttle control lever pulled out comple-
tely, the engine speed must b e between 3500
and 3800 rpm.
Caution
Do not race engine.
3. T h e hand throttle control adjustment can b e

corrected on the accelerator linkage nipple in
the vehicle's tunnel.

Pedal Controls 911 7
PEDAL C O N T R O L S
General
The clutch and brake pedals are mounted on a common clutch pedal shaft which is attached to the
support fixture,
The support fixture is bolted to the floor and brake master cylinder attachment to the brake master
cylinder is by two studs which extend through the transverse panel.
The throttle pedal cross-shaft rides in bushings mounted in the support fixture. The throttle pedal is
fastened to the floor by two M 6 bolts.

11 Pedal Controls
DISASSEMBLING A N D REASSEMBLING

Description I Q~Y
removing
Note when
installing
Special
instructions
see
Bolt, M 6 x 25
! Washer
Throttle pedal
Throttle pedal stop

Pull back to remove.
Ad just.
Throttle pedal pressure Detach. Lubricate ball socket with

rod multipurpose grease.
Throttle rod Detach. Install with some multi-

purpose grease, adjust if
necessary.
Clevis pin
I 1
Nut, M 8
Spring washer Use new spring washers.
Washer
1
Nut, M 8 Remove frontshroud of Torque to 2.5 mkp.
steering and dual master
cylinder.
Spring washer Use new spring washers.

I
Support fixture Remove together with Install in assembled
pedals. condition.
Cotter pin for Use new cotter pin,

actuating rod I I
Washer
Intermediate piece
Stop light actuating 1

washer
Nut, M 10 1

7 11 Pedal Controls
Note when Special

Master cylinder rod Assemble and install rod

prior to the installation of
the pedal assembly. Adjust
free play between rod and
piston in the brake master
cylinder.
Cross-shaft cotter pin Use new cotter pin.
Washer
Cross-shaft Check for wear. Install with multipurpose

grease.
Bushing Check for wear. Press in.

M4x10
Lock washer
Stop light switch Detach flat connector. Adjust switch, if neces-

sary.
Roll pin Drive out. Use new roll pin.
Clutch pedal lower part
Nut, M 1 4 x 1 . 5
t
Clutch pedal upper part Adjust length, if necessary.
I
. Clutch pedal shaft Check for wear. Install with multipurpose
grease.
Spring for clutch pedal

shaft
I
Bushing Check for wear. Lubricate with multigurpose
grease.
Nut, M 8

Description Q~Y
II Note when
I
Special
instructions
I I
Spring washer Use new spring washer.
Support tube Install with multipurpose

grease.
Bushing 2 Check for wear. Press in.
Rubber cushion 1 Checkforwearor Replace if necessary.

damage.
Brake pedal
Return spring
Bushing 2 Check for wear. Press in.

I I
Rubber cushion
I Check for wear or
damage.
Replace if necessary.

7 911 Pedal Controls
I N S T R U C T I O N S FOR REMOVAL A N D I N S T A L L A T I O N
Removing
1. Remove shroud covering steering and brake

master cylinder under the car.
2. Remove both M 8 retaining nuts from brake

master cylinder.
Note:
Do not detach brake lines or remove the brake
master cylinder. Remember to install the
master cylinder rod prior to installing the
pedal assembly.
Installing
1. Clean the parts, check for wear or damage,

and replace if necessary.
2. Press bushing in, lubricate bearing surface and

pedal shaft.
3. Remove M 8 retaining nuts from support fix-

ture and remove pedal assembly (first remove
clevis pin from clutch pedal shaft, and de-
tach throttle rod).

Pedal Controls 911
PEDAL CONTROLS
General
Beginning with the 1974 models, all Type 911 vehicles are furnished with a supplemental clutch pedal
spring to reduke the necessary pedal force. The pedal force decreases progressively as the clutch pedal
is pushed in.
In addition, the cars are equipped with a longer brake pedal. The pedal lever length is 250 mm, the
ratio 5.8:l.
TOOLS
No. Description Special Tool References
1 Installer --- Local manufacture


Note during
Description References
Bolt M 6 x 25 Tighten t o specified

torque
Washer
Throttle pedal Pull off rearward
Throttle pedal stop Adjust
Throttle control link Detach Grease ball socket with

multi-purpose grease I
I
Throttle control rod Detach Install with multipur -
pose grease, adjust if
necessary
Clevis pin
Nut M 8 Tighten to specified

torque
Lock washer Replace

I
Washer
Nut M 8 Remove steering and Tighten to specified

brake master cylin- torque
der stone guard first
Lock washer Replace
Support Remove together Install assembled
Dust boot
Cotter pin for

actuating rod
Use new cotter pin I
Washer
Intermediate piece
Nut M 1 0

7 11 Pedal Controls
Note during
Description
Actuating rod Assemble and insert

the actuating rod
prior to the installa.
tion of the pedal
assembly. Ad just
clearance between
the actuating rod
and piston in brake
master cylinder
Stoplight switch
actuating washer
Spring Detach with the aid Use locally -manu-

of a screwdriver factured tool
Cotter pin for Use new cotter pin

bell crank
Washer
Bell crank Check for wear Grease with multi-

purpose grease prior
to installation
Bushing Check for wear Press in
Rubber stop Replace if necessary
Slotted screw M 4 x 1 0
External tooth lock

washer
Stoplight switch Detach tab connector Adjust if necessary
Rollpin Drive it out Use new rollpin
Clutch pedal
Clutch pedal shaft Check for wear Use multipurpose

grease
Bushing Use multipurpose

grease
Nut M 8
Lock washer Replace

Pedal Controls 911
Qty I removal
Note during
installation
References
36 Support tube 1 Use multipurpose

grease
1 1 I
1
37 Bushing 2 Check for wear Press in
38 Rubber stop Check for wear and Replace if necessary

l ! damage
39 1 Brake pedal
40 1 Return spring
41 / Bushing 2 1 Check for wear Press in

I N S T R U C T I O N S FOR D I S A S S E M B L Y A N D REASSEMBLY
Disassembly Reassembly
1. Mount pedal support in a vise. 1. Grease both spring attachment studs (in the
pedal and pedal support) with MoS2 multi-
purpose grease.
2. Attach spring to pedal support with the aid of

2. Unhook the clutch pedal supplemental spring the installe~(see sketch for local manufacture
from pedal support with the aid of a screw- of tool).
driver while depressing the clutch pedal.
Caution
The spring is under tension and can jump out.
S k e t c h f o r l o c a l M a n u f a c t u r e of T o o l
Material:
Steel pipe , 15 mm dia., wall thickness 2 mm

Pedal Controls
ADJUSTING CLUTCH
Checking C l u t c h Free Play
-
The clutch pedal free play is 15 20 mm. It is
determined by pulling the clutch pedal out in
the direction of the arrow.
NOTE:
The clutch e e e play of 20 mm must not b e

exceeded since otherwise the clutch pedal
supplemental spring will become active without
actuation of the clutch pedal.
Adjusting Play
Use screwdriver to press release lever in direction

of engine against stop. Measure distance between
lever and transmission case. Release lever again.
Turn adjusting nut on end of cable (underneath
car) until lever travel is 4 mm (5/32 in. ).
Now check clutch play a t pedal and correct again,
if necessary.
Note
A new clutch lever is installed on all 1975

models.
Checking Clutch Pedal Travel
The test should b e accomplished when the trans-

mission is warm. Depress clutch pedal fully t o the
stop. With clutch pedal in this position, the
reverse gear should still engage clash-free.

Adjusting Clutch Pedal Travel
1. Detach floor mat and remove.
2. Loosen both travel stop retaining screws.
3. Push the travel stop plate up or down, as

required, until the adjustment is such that
the reverse gear can still be engaged clash-free.
4. Tighten the retaining screws, recheck clutch

pedal travel, and install floor mat.

Pedals 911 7
ADJUSTING C L U T C H ON MODELS W I T H AUXILIARY C L U T C H SPRING
Checking Clutch Play Basic Adjustment
Because of the auxiliary clutch spring t h e clutch 1. Detach clutch c a b l e or loosen completely a t
play cannot b e measured exactly a t t h e clutch holder.
pedal. This is why the clutch play of models
with a auxiliary clutch spring is checked a t the
transmission adjusting lever.
2. Adjust clutch play to 1.2 m m with a feeier
gauge and lock adjusting screw.
1. Check whether clutch cable is tight.
2. If cable has sufficient tightness, check clutch

play with a feeler gauge and, if applicable,
adjust i t t o 1.0 + 0.1 m m with t h e adjusting
screw.
3. Detach clutch cable.
4. Tighten clutch cable until clutch play is

1.0 m m .
Note
Make basic adjustment if c a b l e is loose (stretching
process).
Note
If there is not enough room for adjustment at

the clutch cable holder, adjustments must also
be made up front at the pedal assembly. Adjust
stop on floor plate until the release travejr at the
release lever is 25
4-
-
0.5 mm (Turbo 27 - 0.5 mm).
5. Measure release travel distance.
a ) Insert calipers as shown in the photo and

read distance I (e.g. 95.3 mm).
b) Depress clutch pedal and measure distance
11 with calipers as shown in the photo (e. g.
69.9 mm) .
c) Distance I minus distance I1 (e.g. 95.3
minus 69.9 = 25.4 mm) equals release
travel distance.

Auf bau
Body
Carrosserie
Carrozzeria

CONTENTS
0 - INFOKMATION. DESCRIP7'10NS. SPECIFICATIONS
0.1 Descriprions
Body modifications - EJ72 model
Body modiiicarions - 1973 model

Body modifications - 1!J74 model
1 - BUMPERS
1.1 Bumpers
Front spoiler - !)I1 S

Bumper, removing and installing - EJ73 model
Front b u m p e r - 1974 model

Rear bumper - 1!174 model
Front spoiler, installing
3 - 1iOODS AND LIDS
Front hood l o c k , r e t r ~ o v i n gand installing
Hood, o p e n i n g with broken c a b l e
Rear l i d with spoiler
4 - DOORS
Inner door fittings. removing and insralling - 1 9 7 4 nlodel
Door stop, removing and installing
Ridge f i l l e r , insralling
Door s h e e l prepararion for r e m o t e c o n u o l outside mirror
New door l a c k controls, service insralling
Door window lifr c h a n n e l , installing
Electric window regulators, r e m o v i n g and insralling
Electric cross a r m window controls - 1'380 model

Electric cross a r m window controls, service installing
Adjusting door window - Targa

7 - ROOF
Folding roof .modifications - 1974 model

Folding roof lock pin, service insralling
Hardtop roof
Folding top to hardtop, switching
9 - INTERIOR FITTlNGS
9.1 lnterior fittings

lnterior mirror, insralling
Targa roof adjustments - 1 9 0 model
Top wind deflector strip modifications
Three point belt with automatic retractor and warning system,
removing and installing
Electric window regulator, removing and installing
Seat, installing - 1973 model
10 - EXTERIOR FlTTINGS
10.1 E x t e r i o r f i t t i n g s
Oil tank filler lid and control, removing and installing
Rocker panel cover, removing and insralling

End plate, removing and installing
Carrera emblems
Outside mirror with defogger and remote control, removing and installing
Exterior mirror on passenger's door, service installing
18 - REFERENCE DIMENSlONS FOR REPAIRS
18.1 R e f e r e n c e d i m e n s i o n s
Repair dimensions - 1972 model
20 - REPAIRS
20.1 R e p a i r s
Rear axle cross tube rust prevention

Galvanized sheet metal instructions - 1976 model
Rear axle cross tube, checking alignment

22 - PAINTING
22.1 P a i n t s
Paints - 1912 model
Paints - 1914 model

Paints - 1916 model
Paints - 1978 model

Range of body paint colors - 11381 models
22.2 M e t a l l i c p a i n t s
Metallic paint - wet on wet method
Targa roll bar cover, painting
30 - BODY REPAIRS
3 0 . 1 Front body
SO. 2 Extra attachment for economical repair af front end d a m a g e
Universal anchor ENS 937.900
Cabra 3 s r a i g h r e n e r with accessories
3 0 . 3 Rear body

e c r i p i o n 911 8
BODY C H A N G E S - FROM 1 9 7 2 MODEL
Beginning with 1972 models. the following body and trim changes were made.
Body
1. T h e shape of the rear seat sheetmetal and upper rear wall has been changed. They are the same
shape for both Coupe and Targa models.
2. Rear crossmember moved forward: has modified shockabsorber cavities.
3. T h e rear seats were reshaped. The seat backs are positioned further to the rear.
4. Rocker panel and fender well provided with connecting points for oil tank and oil lines (911 S).
5. Rear torsion bar tubes provided with water drain holes.

6. Right rear fender with oil filler lid.
7. Muffling portion of heater pipe shortened 50 mm as of October, 1971.
As a result, the forward heating duct has been extended.
8. Inside area of door still galvanized
Changes in Type 911 S
Rocker panels provided with supports for externally located oil lines, right fender well does not
have oil line openings.
Engine compartment lid and bumper center section made of steel sheetmetal.
Front spoiler for Type 911 S (optional for other models).
Trim
Lettering, type identification, air inlet grille, and seat recliners in dull black finish.
Same basic trim for 911 T and 911 E.
Leatherette used on the instrument panel and seats (new leather-grained material).
Self-sealing clips in the door panel.
Door locks with vertically-positioned key slots.
Improved inside mirror attachment.
Seat belt mounting points in door lock posts dropped 90 mm lower in Coupe models beginning
with November 1971.
Targa moulding strip, depressed in the area of roof lock pawls.
Tubular crossmember under instrument panel discontinued (Targa).

New color numbering code in paint nomenclature plate; paints are tested according to VW
standards.

New t y p e door hingcs wl~iclia r e a l t a i h c d lo Ilic h i n g e post with i n t e r f e r e n c e pins instead of prcviou,ly
ilreil rivels. T h e hingcs call l i p installed in doors of older version h y filing t h e boll holes slightly.
Seats
1'373-modcli a r e e q l l i p p ~ dwith s p o r t seals tila1 a r e providcd with double rail loclis ;is of Sep-7%
Body S h e l l
Oil tank under right rear fender repositioned rcarivard
r e n d e r witholit filler neck lid
Exterior
Black front horn g i i l l .
Front bumpers in T y p e 911 E a n d 9 1 1 S vehicles equipped wilh spoiler.
Reinforced front and rear Ihonipers.
Franl and rear bumper horns nf energy ahiorliing lllalrrial e l f c c l i v e with Sep-1-72 production

Description 911 8
B O D Y C H A N G E S E F F E C T I V E WITIH 1 9 7 4 M O D E L S
T h e following body changes were effective with t h e 1974 models.
Body:
1. New transverse lock panel in front with lid lock cover, as well as brackets for c a r jack and roof
top.
2. Tank support modified for 80- liter tank (standard).
3. Battery support on left side for 66 or 88 Ah battery.
4. Front wheelhouse panels without battery compartments. Strong support plates for deformation tubes
or hydraulic dampers along t h e front and rear wheelhouse panels.
5. New seat rails (with forward inclination).
6 . Instrument panel with changed switch receptacles, as well as side- vent n u t l ~ l ~ .
7. Shorter front lid with new lid lock.

8. New front fenders with changed headlamp compartments. Large windshield washer reservoir under
t h e left front fender, with filler neck within t h e fuel filler compartment.
9. Rocker panel covers with protective strip.
1 0 . Aluminum bumpers with side boots and separate skirts, with rubber bumper guards in rear.
11. New towing hooks i n front and rear.
12. Seat belt anchorages along side members and center tunnel.
Appointments:
1. Foam- padded instrument panel with adjustable side vents and changed glove compartment door.
2. New door t r i m , door weatherstrip. and door handles.
3. Seats with integrated head restraints.
4. T a r g a with solid roof t o p (fiberglass). Folding roof (optional) with central anchorage in rear.
5. Rear panel with reflectors and PORSCHE lettering.
G. Seat belts with automatic action.
7 . Rear side window not operable in T y p e 911.
8. Front directional signals mounted in t h e bumper.
9. Black ornamentation for Carrera (instead of chrome).
1 0 . New paint finish colors.

FRONT SPOILER - TYPE 9 1 1 S
Beginning with 1972 models. Type 911 S vehicles are furnished with a front spoiler-type bumper
as standard equipment. This modification results in increased stability at high speed.
Initially made of fiberglass, these spoiler-type bumpers are made of steel sheetmetal from
chassis # 911 230 0385 - Coupe

911 231 0231 - Targa
The steel spoiler-type bumper can be optionally equipped with overrider horns.
NOTE
-
Thespoiler-type bumper can be installed in all vehicles from 1969 models on without further
modifications.
Steel spoiler-type bumper with bumper supports

Bumpers 911 8
REMOVING AND INSTALLING USA - T Y P E BUMPERS
General
Beginning with t h e 1973 models, a l l vehicles exported to t h e USA are equipped with bumpers with
energy-absorbing rubber bumper horns in front and rear, and reinforced bumper brackets. T h e bumper
horns deform under heavy impact. Additional rubber supports are mounted o n t h e rear bumper horn
brackets t o further support t h e bumper center section and upper part of bumper horns against t h e rear
transverse member.
Removing Front Bumper
1. Detach bumper from fender sides; detach

electrical wires if additional lamps a r e
installed.
2 . Detach bumper brackets from body (ahead of

t h e battery compartments). Remove bumper.
NOTE:
In vehicles equipped with air conditioning, it
will b e necessary t o detach i m p a c t protection
bars from t h e suspension control a r m attaching
points.

Disassembling Bumper
1. Unscrew bumper brackets ( M 8 nuts nd

Allen bolts).
2 . Detach bumper horns
3. Remove bumper t r i m strip
4 . Pull weather seal off bottom e d g e o f fender

and t h e lock t:ansvene panel.
Reassembling Bumper
1 . Insert weather seal into front lock transverse

panel, g l u e it in 1 t h e fenders.
-
--&
2 . install bumper trim strip (911 T)
~
-~-.1------- ~~.~~ -,;

13 T r i m strip containing a rubbei liner should b e
~ .,,
,- -=-.- 9 ins' -1led by first e c u r i n g t h e supporting strip
~~.. t o t h e bumper, then pressing and attaching
..
o n e end of t h e rubber strip, and finally bending
t h e rubber strip sides over nd sliding it onto
t h e supporting strip.
3. Insth 1 bumper horns.
NOTE:
If i m p a c t protection bars far t h e air conditionifin
system a r e t o b e installed, it will b e necessary
, first m a k e a n opening in t h e horn bottom
through which t h e bar wil pass for attachment
t o t h e horn, as shown in t h e illustration. T h e
other end of t h e bars is later secured t o t h e
I
outer contra1 arm mounting points.
! , r ~ r -,

Bumpers 911 8
Removing Rear Bumper
1. Detach bumper outer sections from support

pipe and bumper bracket sides.
2 . Detach bumper brackets from t h e longitudinal

members and r e m o v e c o m p l e t e bumper assembly
3. Remove rubber spacers from t h e brackets

Outer section of bumper with reinforced
bracket, rubber spacer, and rubber bumper
horn.
Disarselnbling Bumper
1. Pull weather seal off center panel and bottom

e d g e of fender.
2 . Remove cover plugs from t h e bumper horns,

unscrew Allen bolts. and t a k e bumper horns
off.
3. Remove sheetmetal screws connecting outer and

center sections.
4. Remove t r i m strip. reflectors, and end plates

from bumper outer sections.

8 911 Bumpers
Reassembling Bumper
NOTE:
When installing bumpers which were dis-
assembled for painting, it is best to reassemble
the parts off the vehicle and then mounting the
entire bumper assembly in its place. If the dis-
assembly involved repairs. it will be necessary to
first fit the bumper outer sections on the car,
making sure that they fit flush with the fenders
and tail lamp assemblies, as well as being
parallel to the fender bottom edge.
1. Glue weather seals to the bottom of the

fenders.
2 . Install reflectors, trim strips, and end plates

in outer sections
3. Slide sealing strip into center section and

glue weather seal in place.
4. Place center piece onto the outer section

brackets and lightly fasten at the bottom with
sheetmetal screws and nuts.
5 . Insert bumper horns and secure with Allen

bolts.
Place rubber spacers onto brackets.

Bumpers 911 8
ti. Attach bumper t o langiludinal members,
securing it by t h e brackets.
NOTE:
If t h e rear part of t h e bumper does not press
against t h e weathcr seal in t h e fender, that
distance must be rtduced by inserting spacers
between t h e bracket and longitudinal members,
a t t h e front bolt.
7 . ALLach bumper outer sections to support tubes

and fender brackets.
8 . Adjust distance belween outer sections and

center part by means of washers and tighten
sheetmetal screws.
,
,- -y,?j
:
F -
~
-
:u
'' 1
NOTE:
A tow hook c a n be installed on t h e right side
only, in t h e direction of travel. by fastening
it t o t h e longitudinal member together with
t h e bumper bracket. Allen bolts 8 x 35 m m .
washers, and spring washers should b e used lor
this purpose.

Bumpers 911
F R O N T BUMPERS E F F E C T I V E W I T H 1 9 7 4 MODELS

Note when:
Description removing installing Remarks
Front bumper Flanged studs of d e -

formation t u b e must fit
into cutouts. Sealing
strip must fit alround.
Grommet
Nut, M 8 Use self- locking nuts.
Washer
Sheetmetal nuts,
4.2 m m
Bumper strip Detach side and pull Press into grommets

off. bolt sides on.
Bumper strip plugs Replace if necessary
S h e e t m e t a l screws. Replace if necessary

4.2
Directional signal Remove bumper, t a k e Check for equal spacing

lamp out through back
S i d e cover Check far equal spacing
Washer
Nut, M 5 Use self-locking nuts
Boot Remove self- tapping Attach t o bumper

nuts from skirt
Self- tapping nuts
Sealing strip Fit well along t h e

fender
S h e e t m e t a l screw
S h e e t m e t a l nut, Replace if necessary

4.8 m m
Washer
Rubber washer Use in t h e area of t h e

lock transverse panel

Bumpers 911 8
Description
Qty I removing
Note when:
installing
Remarks
Front skirt Preassemble side

skirts. 1
Sheetmetal nut,
6.3
Sheetmetal m e w ,
6.3 x 19
Gasket Place against lock

transverse panel
Side skirt
I I
Insert, top 2 Install neatly
Insert, bottom 2 Install neatly

I I
Sheetmetal screw
4.8 x 1 3
Clip nut
I Replace if necessary
Washer
License plate
bracket
Sheetmetal nut
Sheetmetal screw
5.5 x 1 6
Washer
Rubber washer Place between skirt

and bracket
Bolt. 5 x 10
c a g e nut Replace if necessary.

Space according to holes
in license plate
Washer
Deformation tube 2 Check, replace if 1

necessary. Align bumper,
then attach. Remove
water reservoir

8 911 Bumpers
Note when:
Description Oty Remarks
removing installing
Hydraulic damper
(optional) I 2 Check, replace if
necessary. Align bumper,
then attach. Remove
water reservoir
Clamp I 2
Rubber buffer
I 2 Check. replace if
necessary
Insert with
sleeve
Check. replace if
necessary I
Washer I
Insert 2 Glue to deforma-
tion tube
Bolt. M 8 x 16 2
Side marker lamp 2

Bumpers 911 8
R E A R BUMPER E F F E C T I V E W I T H 1 9 7 4 M O D E L S

8 911
-
Bumpers
No, Description
-
1 Rear bumper Remove bumper strips Align bumper. Flanged

and license p l a t e lamps, studs of deformation
pull wires out tubes must fit into
oval holes
Grommet
Bumper guard
Nut. M 8
Washer
Rubber grommet
(wire passage)
License p l a t e l a m p Unscrew. Pull Lead wire through

wire out after installing guard
Humper strip Remove fasteners. Install neatly

pull off
C a p for towing
attachment
Bolt. 5 x 1 2
Bolt. 5 x 1 8 Install in front, a t

bumper strip 1
N u l . Irl 5
Rear skirt
Insert Position insert lip
Fillister screw
6 x 12
Washer

Bumpers 911 8
Note when:
Description Remarks
removing installing
Boot Detach from bumper Attach boot to both

on right, and from lower fender parts
lower fender on left.
press out
Self-tapping nut
Fender lower Fit against fender

section contour
Insert Replace damaged par1

Install neatly
Sheetmetal screw
4.8 x 16
Sheetmetal nut 4.8 Slip onto lower

parts
Washer
Bolt. M 6 x 12 Attach fender lower

parts to supporting
tubes
Lock washer
Washer
Deformation tube Remove oil tank Check, replace if

Hydraulic damper attachment at sup- necessary. Align
port tube, right side. bumper and fasten
Loosen 2 bolts in accordingly
engine compartment
Clamp
Rubbert insert Replace if necessary.
Rubber buffer Replace if necessary

8 911 Bumpers
/ NO. Description Qty removing

Note when:
installing
Remarks
Nut, M 8 10 Use self- locking nuts

I I I
Washer 10
I I I
Insert for
mounting p l a t e
Glue t o deformation
tube I

Installing Nose Spoiler 911 8
Description
Nose spoiler
Removal
Replace if
necessary
Notes
Installation
Bolt flush on sides

with apron
I
Remarks
Spacer Match chamfer
Washer
Nut
Insulator Use at front
Bolt 6 x 20 Replace i f Use at outer

necessary holes

REMOVING AND INSTALLING FRONT LID LOCK
Removal
2 . Loosen screw in c l a m p p i e c e , pull control wire

out.
3. Remove lock attaching bolts and t a k e lower part

of lock off.
4. Remove upper part of lock.
Installation
1. Lightly tighten upper part of lock t o lid.
2. Lightly tighten lower part of lock. Insert

control wire.
m
3. Adjust both lock parts t o center position cross-
and lengthwise, then tighten bolts.
Tighten c l a m p p i e c e securing screw and bend
w i r e a l l t h e way back.
4. Close lid. Adjust height of lower part of lock.

Adjust side stopper screws accordingly.
5. Install plastic cover.

O p e n i n g Lid L o c k w h e n C o n t r o l C a b l e b r e a k s
... . . , - .- l; l.-*i .
-37
.
press the boots out; remove bumper fasteners
from collision tubes).
2. Drill an 8 m m hole into the lock transverse

panel (see illustration).
3. Make a tool from steel wire of 5 -G m m dia.

and approx. 40 c m length.
4. Insert the self- made tool upward through the

hole and press the wire clamping piece to the
right. Open the lid.
5. Install new control wire and check lock foi

proper operation.
- -.
6. Close hole with plug (999 703 044 50).
, .
--- - -.-
~ w I . Install bumper.

Rear L i d w i t h S p o i l e r 911 8

8 911 Rear Lid w i t h S p o i l e r
Notes
Description Remarks
Rear lid Even gaps all around.

Adjust height with
washers a t hinges
Spoiler Loosen guard Align. Secure with

studs and lock nuts
Washer 5.3 m m
diameter
Lock nut Install with washer
Hex. head metal Install with washer

screw 4.8 x 16
Guard Remove metal screws,
loosen a t air inlet grill
Oval head metal
screw 2.9 x 9.5
Gas lift cylinder Gas lift cylinder must
Lift-O-Mat Part hold lid open. replace
No. 911 512 331 07 if necessary
Removing
1. Detach lid at hinges.
2 . Loosen lower air inlet grill screws.
3. Loosen all metal screws of guard. Bend open
guard, or loosen upper lid lock section and
remove guard.
4. Remove outer spoiler metal screws a s well as
the 4 lock nuts and remove spoiler
Installing
After assembling. bolt lid and ground wires to
hinges. Align lid.

R E M O V I N G A N D I N S T A L L I N G D O O R P A N E L E F F E C T I V E W I T H 1974 M O D E L S
General
Beginning with 1974 models, t h e doors h a v e new t y p e of door panel. door storage compartment, hand
grip. and inside door release.
Removal
1. Remove sheetmetal screws from below t h e

storage compartment, both end flanks, and in
front lbelow t h e cover. Remove t h e storage
compartment.
2 . Remove door ledge cover (unscrew door lock

button and sheetmetal screws a t both ends).
..,
3. Detach rear of storage compartment cover and I

remove.
4. Detach connecting rod a t t h e handle, unscrew

fasteners from handgrip top and bottom.
5. Remove window crank.
G. Remove supporting brackets.
7. Unhook door panel.
8. Remove control lever from door inner panel

and disconnect spring.
NOTE
Removal and installation of t h e remaining door
parts is described in volume I1 of t h e workshop
manual.

Installation
1. Attach threaded plate (see arrow) with

countersunk screw.
2. Install control lever with connecting rod, hook

spring to door inner panel.
3. Tightly glue weatherfoil to door inner panel.

-w
\ 1
4 ~ m door
~ gpanel on door.
5. Install supporting brackets according to the

location of holes in the storage compartment.
6 . Install hand grip and connect connecting rod.
I . Install folding cover and storage compartment.
8 . Install window crank and door ledge cover.

REMOVING A N D INSTALLING DOOR S T O P
Beginning with 1974 models, a l l Type 911 vehicles a r e equipped with a modified door stop. T h e door
stop link is attached t o the door hinge post with a rollpin.
T h e new door stops can b e installed in all vehicles, from 1970 niodel on, which h a v e t h e hinge
post attachment as shown in t h e illustration.
Special tools: P 290 and P 2YOa
Removal
1. Detach window l e d g e rail, door pocket, door

inner panel, and sealing foil as f a r as
necessary.
2 . Drive rollpin out with P 290 and P 290a.
3. Unscrew door stop from door f r a m e and t a k e

out.
Installation
1. Insert door slop and secure with self- locking

nuts.
2. T h e rollpin must b e so installed, that t h e slil

faces outside when t h e door is open. Drive
t h e pin fully in t o t h e upper ridge.
a = new version
h = old version

I N S T A L L I N G R I D G E FILLERS
Beginning with 1914 models, all Coupe vehicles are furnished with rubber ridge fillers which are glued
to the front and rear part of the window frame to reduce wind noise.
Make sure that the ridge fillers are glued into place with waterproof glue. such as the BOSTIK-
CYANDIT 202.

PREPARING D O O R SMELLS F O R R E M O I ' E C O N T R O L OU'ISIDE M I R R O R
1. From the center o l the hole for the first 3. Drill anoilier 5 m n dia. h o l e through the
moulding c l i p , draw a v e r t i c a l l i n e 85 rnm door panel and reiniorcement p l a t e (in front
(3 1 / 2 in. ) l o n g down t h e door panel. of tllc rear bottom hole). Secure t h e rein-
f o r c e m e n t plate wilh an appropriate pop
rivet.
2. Hold reinforcement p l a t e in position and inark

lioles as illusriared in picture. Then drill
holes according ro specifications. 4. Install a c a b l e c l a m p on t h e inside of the
CALITION: T h e disrance between the top e d g e reinforcernenr p l a t e (behind t h e lop door
of the large h a l e and the door m a t i n g e d g e hinge) so that the wires will not b e damaged
11must be a1 l e a s t 13 mm. T h e hole for t h e by the window regulator t e e t h .
c a b l e s c a n be opened up with a standard h o l e N u 1e : If l h c new iilirror is installed o n doors
sa;$ e . g. Black + Decker T y p e 21748 (see with old type mirrors, the lronr mountiiig
illustrarion). hole luusi be plugged (weided).
l l o l e pattern for passenger door mirror

(installation instructions, s e e 1 0 . 3 - 1 / 4 )

5. Cut opening (according t o specifications) for 6. 1f necessary for t h e harness opening, drill
operating switch in inner door panel, top. another 20 mrn dia. h o l e below t h e present
h o l e in t h e front inner door panel.
1 - For electric window winder.

2 - For outside mirror.
3 - For loudspeaker.

SERVICE INSTALLING N E W DOOR LOCK CONTROLS
All 1 9 7 1 models will have doors with a n improved, anti-theft lock control. T h e lock button lowers into
Ihe trim strip completely whcn the door is locked. Unlocking from t h e inside is by turning t h e new ro-
tary knob.
Installing
1. Remove trim strip and inside door panel. 4. Open up hole in trim strip t o 14.5 m m dia-
meter for lock button and insert new guide
sleeve.
2. Exchange lock button halder for new part
with a square pin and insert the new lock
button rod.
5. Install inside door panel, lock button and
trim strip.
6. Insert cover, mount rotary knob with fillister

head c a p screw M 5 x 1 2 m m and spring
washer, and press on cap.
3. Transfer center point of square pin t o door

panel. Cut a n opening of 65 m m diameter
in pressboard panel with a sharp compass.
Cut out door panel trim around the square pin.
_-~~~~_*:$L:~+-,w.
.'.3,
7. Check operation of door lock controls.
,
. .,
.
! . ~
.:
,..--'~.
'j - - . ... - . . . ~.
~
i
\

INSTALLING DOOR WINDOW L I F T CHANNEL
Assembling
1. P l a c e door window on soft m a t e r i a l and r e -

m o v e grease from low- edge.
2. Use new rubber insert. Part No. 9 0 1 542 491 21.

and fit i t on window glass t o m a t c h lift c h a n -
nel.
Note
C l e a n rubber insert with a c e t o n e before installing.

If wax coating is not c l e a n e d off, window glass
could disengage from lift channel.
3. Press i n window lift.channe1.
Note
T h e window lift c h a n n e l of a c o u p e must b e

installed so that t h e channel begins 88 m m b e -
hind e d g e of glass.
Coupe - window glass
T h e window lift channel of a T a r g a must b e

installed so that t h e glass fits fully in t h e plastic
guide.
Window l i f t channels must b e pressed in a l l t h e

way over their e n t i r e length. Light taps applied
t o t h e channels while pressing t h e glass i n will
f a c i l i t a t e installation.
4. P l a c e window in door and c o a t sliding surfaces

of window regulator with a multipurpose
grease.
Targa - window glass

Doors 911
REMOVING AND INSTALLING C L C C l ' R I C \WINDOIL' R E G U L A T O R S
General
Beginning with t h e April 26, 1112 production, new electric motors with an integral transmission, as well as
modified toggle switches with mounling framer a r e used. Electrical connections a r e made according t o
a new wiring diagram. Electric window regulators can b e installed in Coupe models o n l y .
T h e new regulators were first installed in l h c 911 T 911 210 2072

following vehicles: 911. C 911 220 0809
911 S 911 230 13111
Removing
1. Remove window ledge rail and lock hutton.
2. Rernove toggle swilclies. If possible, fiist

position window glass about 1 0 c m (4") above
its lowest position
3. Remove entire door panel and sealing foil
4 . Remove outer c h r o m e strip a t winrlow base.
Rear side of door panel will1 we:ither scals and

scli-sealing ~wuuntingclips.
5 . Remove all window frame fasteners. Pull t h e
frame out.
6 . Push window glass forward and detach irom

the regulator. Remove upper door well
weather seal and t a k e t h e glass oul.
1 Clip
2 Door panel
3 Door inner s h c c t l ~ l e t a lpanel

I . T a k e wires out of retainers, disconnect theln
from junction bar, and pull wire l a o m s our
together with caps. If the wire looin leading
from the door into the c a r ' s interior is t o be
removed, it will be necessary t o rake the door
off.
8. Llnscrew window iegulalor and relnove
9 . Rcmave srop wedge from door base
New motor and transmission with c a b l e layout.
Installing
I ! 1. Insert wire grommet in forward part 01 inner

sheetmetal panel of door. Lead t h e connecting
i
I wires into the car' s interior. Install door.
.. .
.
,..'
._
_
..
.I
2. lnsert window regulator and fasten. Install stop

wedge.
3. Run ihe regulalor with a batrery or baiiery

charger l o bring window t o aboul 10 c m ( 4 " )
above ils lawest position by connecting the
positive wire t o green and negarlve wire t o
black wiles in motor. If i h e regulator lmoves
up, switch the wires t o make if m o v e down.
4. Install carrier plate with junction bar.

5. Insert toggle switches, cover caps, and wire
looms. C o n n e c t a l l wires according 10 t h e
new supplemental wiring diagram in Group 9 ,
p a g e 0. 1 - 2/11. Fasten [he wire looms t o
carrier place and inner s h e e r m e t a l " a n d .
.
6. lnstall door well weather seal. Place window
glass in door well and a t t a c h i o rhe regulator.
(1
7 . Insert door window f r a m e in door and seal

along the outside and inside flanks of t o p
door e d g e with black, non- hardening putty.
Fasten lhe f r a m e in such position that
suilicient pressure will b e exerted against
t h e door weatherstrip.
Note
Do not bend t h e window f r a m e l o f i t .
8. C h e c k window regulalor (or proper operation

and f r e e m o v e m e n t . If necessary, readjust
regulator with adjusting screws so that the
top e d g e of t h e window is parallel with the
top part of t h e window frame.

911 Doors
!I. Clue the sealing Ioil in leak- free. C u t out

a seclioli in the toggle swilcb area.
1 0 . Install door inner panel, armrest with innei

door release, door pocket, folding compart-
ment, door l e d g e rail, and outside window
base chrome snip.
11. Connect toggle switches and install.
Note
When properly installed, all toggle switches

are positioned with t h e single connector facing
UP.
T h e rear toggle switch in driver's door actuates

rhe passenger side window,

ELECTRIC CROSS ARM WINDOW CONTROLS - f r o m l'j80 Model
Electric cross arm window conrrols a r e installed These new window co~nrrolshave an addilional
in a l l cars as of t h e 1080 model year. Tliese new guide r a i l , wliich is bolted on lhe door inside
window conrrols h a v e a different design for coupe panel (arrows).
and targa models. Targa window conrrols run
slower and have row adjuslable height l i m i t stop
brackets a1 lop. Coupe has one adjusrable stop
biacket
Coupe and T a r g a window controls use e l e c t r i c

motors, of diflereni power O L I I ~ L I and
~ S illerefore
callnot b e inrerclianged. As of November 20.197!1
new light weight motors a r e used, whose power
corresponds with rhe former versions.
T a i g a Version
Coupe m o ~ o r ,Part No. ! I l l . 624. 014/015 01
formerly 00
Targa motor, Part No. 911.624. 014/015 41
lormerly 40
These molars a r e i n ~ e r c h a n g e a b l ewirh rhe f o r m e r

versions.
In conjuncrion with rhe new window controls, t h e

door window glass has new o n e - p i e c e window l i f t
channels.
C o u p e Version
w
T a r g a window with new l i f t channel.

SERVICE I N S T A L L A T I O N ELECTRIC CROSS ARM WlNDOW CONTROLS
General Information
Electric cross arm window controls are installed

in all cars as of the 1980 model year. These new
window controls guarantee smoother door window
operation and in future will replace all parallel
arm window controls for Types 911 and 911 Turbo.
Later the Parts Catalog will be changed t o include

the mechanical cross arm window controls, which
replace the mechanical parallel arm window
controls after depletion of stocks and can be in-
stalled in all doors.
Service installation of these new cross arm window

controls will require exchange of the lift channels
on the door windows or use of new door windows. 7. Loosen old lift channels from window by
lightly tapping and then remove.
Removing
Installing
1. Remove inside door trim panel. Disconnect

window control and mirror switch. 1. Position new 1ift ( th cleaned (wax-
free) rubber insert on window glass and press
on tight.
2. Pull off door window water shields. The lift channel for Coupe door windows must
be positioned 8 mm behind the front edge
of the glass.
3. Loosen and remove door window frame.
4. Disconnect pazallel arm window control, de-

tach door window at guide and remove.
5. Remove window control and electric motor.
6. Remove height adjusting screw on Targa doors.

- - - - - D- o o r s
The plastic part of Targa window lift channels
will have to be coated with rain molding
cement, e. g. National Special Cemenr 6 7 0 ,
at the groove.
3. Find localion for holes on inside door panel

wilh a compass according to given dimensions
and drill two 7. 0 rnm (9/32 in. ) dia. holes.
Then install wlnaow glass so that i t rests firmly

in guide groove and channel.
Note
If door window sags at rear when operated, the

rear mounting hole (see broken line) must be ex-
2. Mount electric motor on new cross arm window tended upward.
control (arrows). Guide wire harness between
bolts so they will not interfere with moving
parts.
Set window control at center position for in-
stallation in door.

Doors 911 8
Note
A slot must be made according to given dimensions 8. Check door window for easy movement. Close
in door inside panel of Targa models. The stop bracket door and check entire periphery of glass and/or
for height control will be accessible through this window frame for neat fit at door weatherstrip,
opening. correcting window frame adjustment if necessary.
9. Install door window water shields and inside

door trim panel. Check operation of window con-
trol and mirror switch.
4. Check window guides for wear and replace if

velvet is partially worn. Glue at top when
inserting in door window frame.
5. Insert window control and bolt base plate.

Connect wire harness with switch.
6. Insert window glass and guide plastic rollers

of window control into window lift channel.
Mount short guide rail on inside door panel
with M 6 x 1 0 bolts and washers.
Lubricate moving parts with a multi-purpose
grease.
7. Install and secure door window frame.

A D J U S T I N G DOOR WINDOW - TARGA
The methods of adjustment have been improved since introduction of electric cross-arm window regulators
from 1980 models on. T h e Targa window regulators now have two adjustable stop brackets for height control.
The adjusting screw has been omitted.
Before beginning with adjustments the door gap to t h e rear fender and installed position of the Targa top
must be checked.
Adjusting procedures require that the hinge strip, door pocket with cover, grab handle, door inside trim
panel and plastic sheet be removed.
Adjusting Door Window

- Height Adjustment (arrow) - Inclination
Inclination of the door window glass can be regulated

with the guide rail. If the door window glass sags
1 excessively a t the rear during movement, the rear
P, bolt hole must be extended up.
Note
Lower window until stop bracket is accessible

through opening in door inside panel.
Targa version with stop bracket

Adjust height so that window glass is aligned with
roof seal and fits tight in profile seal along entire
length.

Folding Roof 911
M O D I F I C A T I O N S IN T A R G A F O L D I N G ROOF 1 9 1 4 MODELS
1. Beginning with 1974 models, new METALLASTIK

supports a r e used in t h e rear part of the folding
roof; the locating pins a r e covered with replace-
a b l e plastic sleeves.
B , .>
',
A
B
-
=
new version
old version
1-7 ,'i,
2 . Modified METALLASTIK mounts, with bigger

and longer receptacles, are used in t h e rollbar
t o accomodate t h e larger locating pins.
3. An additional support pin is provided in t h e

center joint of t h e rear roof frame. T h e pin
rests in rubber and provides additional rigidity
for t h e roof.
4. Modified weatherstripping is used along t h e

windshield frame and t h e front part of t h e
roll bar to improve sealing and tightness o f
t h e roof.
NOTE:
T h e new folding roof c a n b e used only in vehicles

which have t h e larger METALLASTIK sleeves in
t h e roll bar.

F o l d i n g Roof
911
S L I B S E Q L I E N T I N S T A L L A T I O N O F LOCATING. P I N FOR F O L D I N G R O O F
N O T E : Installation of t h e additional locating pin may h e accomplished only in folding roofs which
have t h e pressure-cast aluminum frame. T h e rear f r a m e section is of t h e triangular coniigora-
tian.
Removal
1. Remove and slacken roof.
2. Drive hinge pin out of t h e rear roof frame

and t a k e t h e f r a m e out.
3. Remove window l e d g e rails from right and left

side of rear compartment, detach and remove
roll bar inner panel.
4. Pull off approx. 30 c m of weatherstrip from

roll bar center. Loosen leatherette and up-
holstery padding.
..
Installation
1. Replace right rear section of roof f r a m e with

o n e containing a slot (Part # 911 565 212 4 5 ) .
. , .. . .. ,,,
w . ~ e - z + ~ ; u 4 ~ - :
. -... .: -
,
,. .
, ,
,. .
,,, ...
W-,-.;W
'
...
NOTE:
, . ..>. . . ' I ". . .
., , ,, 37':.:,>,;;..,',
':~
T h e right roof f r a m e section need not b e

replaced providing that a slot is filed into ~ ~
-
t h e hinge pin h o l e so that t h e locating pin
points exactly t o t h e r e a r when the. r o o i is
locked tight. , .A.
'1 ('

8 911 F o l d i n g Roof
2. Install localing pin, Part # 911 565 145 10.
3. Measure and mark t h e center of t h e roll bar.

=-
. Center t h e supparling p l a t e and weld il in.
.. ~-
.~
tw%b%>.- -..-
;,.
4. Align cover plate, Part # 911 565 133 40.

with sheetmetal top edge and weld, or spot-
weld. Shorten upholstery padding t o fit t h e
cover plate.
5. Prime sheetmetal parts with p r i m a . Attach

rubber mount, with large opening facing for-
ward, t o t h e supporting p l a t e using sheet-
m e t a l screws.

Folding Roof
911 8
6. Bend t h e inner panel front part t a m a t c h t h e

rubber mount.
Glue t h e leatherette covering t o t h e roll bar
and cut t h e access h o l e out. Insert rubber
grommet.
Install and fasten t h e roll bar inner panel.

Glue t h e weatherstrip in.
Place roof in position ar.d check alignment

of locating pin.
Requited parts:
1 Supporting p l a t e 911 565 133 40

1 Cover p l a t e 911 565 135 40
1 Rubber mount 911 565 009 40
1 Rubber g r o m m e t 911 565 189 40
1 Locating pin 911 565 145 10
1 Roof rail section 911 565 212 45

8 911 Removable Hardtop
Notes Remarks
lescription Installation
Removal
temovable hardtop
-leadliner Install with heat-
resistant adhesive
Check, replace if Adjust to tension of

necessary windshield
'illister head screw

M6x10
Masher
~ c a t i n gpin Check, replace if
necessary
hJasher
Stop pad Check, replace if
necessary
Spacer If required, install

on stop pad to ad-
just height
ioof edge guard Loosen glued edge, Glue properly to

remove metal screws roof frame
Oval head metal scr

3.5 x 1 3
Washer
Roof edge guard fro] Replace i f damaged
Oval head metal sci

3.5 x 9.5
Cap Plug Replace i f necessary

plug openings in rea
and front roof edge
guards
Roof edge guard rea

Oval head metal sc
3.5 x 9.5
Metal/plastic bearil Check, replace i f Adjust so that roof
left + right necessary and roll bar upper
edges match
Cover Check, replace if

necessary

M6x10

Removable Hardtop 911 8
p~~
Notes
Description Remarks
Washer
Roof f r a m e seal side. loosen glued front Glue end pieces pro-
left and right and rear ends, re- perly, using foam
m o v e m e t a l screws rubber underneath if
required. Adjust door
window seal, then
tighten. T r e a t rubber
seal with, for e x a m p l e
glycerine e t c .
Oval head m e t a l
screw 3 . 5 x 9.5
Sealing t a p e Pull off Glue on roof f r a m e
along c o m p l e t e length
of seal
Escutcheon, lock Installed for hard-

top roof only
Oval head m e t a l
screw 3.5 x 9 . 5
Removable hardtop escutcheon on windshield frame

Targa models (from 1974) can b e equipped with either a folding or solid roof. Two escutcheoils have t o
b e installed on the windshield frame for t h e roof locl<s ou models delivered with folding roofs. Adjust-
ments are the s a m e ior both folding and solid roofs.
Converting
1. Remove folding or solid roof. -2
2. Cut out and paste leatherette on windshield

frame for escutcheons.
3. Install escutcheons, Part No. 911 565 221 40,

with rust-proof metal screws 3.5 x 1 3 m m . ,",-."-- ' '.
. . . , ..
' "-
4. Install and lock roof. Place rubber washers on

the locating pins to adjust height.
5. Check visually if all windshield and roll bar

seals fit roof properly. If t h e seal lips a r e
pressed together, the particular windshield or
roll bar seal must be replaced.

S m a l l leaks can b e repaired by gluing pieces of
rubber on t h e roof - especially a t t h e curved
sections.
6. Close doors and remove inner door t r i m if t h e

window frames and door windows protrude or
do not align with t h e side roof frames correctly.
Loosen door window f r a m e screws and adjust
t h e door windows t o align with roof.
7 . Check lor leaks with a water test. If necessary.

repair leaks with rubber or a non-hardening
caulking compound.

REMOVING AND INSTALLING CABRIOLET TOP ( s i n c e 1 9 8 3 m o d e l s )
Removing
1. Remove mounting screws and push buttons on 2. Remove screws on rear wall t r i m panel at bottom
key boards and side trim panels. on left and right sides. Push u p and pull out rear
Pull off plugs on radio speakers and remove all wall trim panel forward.
parts.
3. Remove caps on tensioning bar with a suitable

tool.

4. Remove mounting screws on tensioning bar and Installing
bracket.
Installation is i n reverse sequence.
Adjusting
1 . 1 and 2 mm thick shims (max. 4 mrn) can be

used underneath the top hinges for correction of
height.
5. Open top locks. Remove mounting nuts and

screws on top mounts, guide arms tensioning
bar. L i f t top off of car.
2. The forward motion can be corrected slightly on

the supports of the operating levers, so that the
guide pins and locking hooks on the windshield
frame engage exactly.

3. Close top, pull down on grip plate with one hand
and lock lock simultaneously.
Repeat this step on the other side.
5. In order t o have a smooth contour on the front

top canvas cover between the front and rear
hoops, the eccentric has t o be adjusted accord-
4. If the top i s closed, make sure that there is equal
ingly.
distance from the top frame to the windows. I f
not, center door frames and windows t o the top
frame.

6 . To adjust the tension of the rear window, loosen
the mounting screws and then adjust the rear
window tension with the tensioning screws on
left and right sides.

REMOVING A N D INSTALLING TOP SEALS
Removing
1. Open t o p locks and unzip the zipper. Remove

nuts and washers on the B pillars and lift o f f
seals with profile section rails and t r i m forward.
2. Lay back top, loosen screws of top frame seals.

disconnect gluing on front hoop tips and take
off seals.

3. Remove rivets o f grip plates and mounting 5. Loosen seal o n hoop carefully
screws o f hoop t r i m .
4. Remove grip plates, unclip hoop t r i m and unscrew

locating pins and screws.

Roof 911 8
Installing
Installation i s in reverse sequence

All bearing surfaces for seals must be cleaned t o
remove sealing and adhesive compound
'.-
Adjusting
Seals have t o be adjusted after closing the top.

Adjust top frame seals so that door windows run
up into the provided sealing lips accurately.
Adjust B pillar seals so that door windows have
tight contact.

REMOVING AND INSTALLING FRONT TOP CANVAS COVER
Removing
1. Remove key boards. B pillar seals, top frame 3. Unscrew rnountlng screws on rear top t r l m
seais and seal on hoop.
See "Removing Top and Top Seals".
1 ' 1 ,?
2. Remove snaps or Tenax bases, mounting screws.

corners for tensioning cables and screws for ten-
sioning cable guides.
4. Disconnect front and rear cemented top canvas

cover and remove screws of mounting rails.

5. Loosen tensioning screws of tooth rails and remove 7. Disconnect cemented canvas cover on front
screws. hoop.
8. Disconnect rubber strap on roof liner
6 . Disconnect cemented top canvas cover on B

pillars and main hoop.
9. Unscrew screws of tensioning springs on top

frame.

Roof 911 8
10. Unscrew tensioning springs on tensioning 2. Guide tensioning cables into openings i n t o p
cables. Pull tensioning cables out of top frame canvas cover from front end.
and take o f f t o p canvas cover.
11. Disconnect tooth rails on top canvas cover and

remove tooth rails. 3. Mark center on rear hoop
Installing
1 . Guide rubber strap into t o p canvas cover.

4. Marl< center o n rear end o f t o p canvas cover. 6. Mount t o o t h rails. Guide mounting strips of t o p
Install and align t o p canvas cover that marks canvas cover underneath t o o t h rails, cut t o size,
are aligned. Canvas cover seam must run in groove apply coat o f cement, stretch, connect doubled
o f hoop edge. Only cement t o p canvas cover o n in teeth and bend down teeth.
threaded flange.
5. Cement t o p canvas cover o n f r o n t hoop after

stretching it.

7. Loosen tooth rails and fold back top canvas 9. Install snaps or Tenax bases and screws with
ccver. Insert seals a~;d coat canvas cover with cloth orotection washers.
cement.
Mount tooth rails and cement canvas cover on
the B oillars.
10. Cut front end of top canvas cover t o sire and

cement on top frame.
8. Stretch side canvas cover. Make a hole in the

cover with a pointed punch and mount corners
and tensioning cables with screws.

1 1 . id^ tensioning cables into t o p frame. Mount 14. Mount shim wedges with Screws.
tensioningcableguides and canvas cover with
screws and cloth protection washers.
15. cement
rear and front canvas cover on real-
hoop
12. Sew rubber strap on roof liner.
-- -
16. Install rear top trlm

13. clampr e x canvas cover on rear hoop w i t h
mounting rail and make hole i n canvas cover
with a suitable tool.

17. Screw on tensioning springs w i t h tensioning
cables. The bracket has two raised bosses, w i t h
which the tensioning force of the tensioning
cables can be adjusted. Mount tensioning
springs with bracket on the top frame.
18. See "Installing Top and Top Seals" for rest of

installing procedures.

REMOVING AND INSTALLING REAR TOP CANVAS COVER WITH TENSIONING
BAR AND MOUNTING R A I L
Removing Installing
1. Remove the key boards, side wall trim panels. Installation is in reverse sequence
rear wall t r i m panel. B pillar seals and front top
canvas cover on B pillars. See "Removing Top
Canvas Cover Seals and Front Top Canvas
Cover". Remove screws on main hoop and dis-
connect cemented points.
2. Disconnect canvas cover on B pillars and take

off canvas cover.

REMOVING AND INSTALLING REAR TOP CANVAS COVER WITHOUT TENSIONING
BAR AND MOUNTING RAIL
Removing
Remove key boards, side wall trim panels, rear 3. Unscrew snap heads and Tenax bases on ten
wall trim panel, B pillar seals, front canvas cover sioning bar.
and rear canvas cover on B pillars. See "Removing
Top Canvas Cover Seals. Front and Rear Canvas
Covers with Tensioning Bar and Mounting Rail".
Remove nuts on tensioning bar. Lift off shims.

clamping rails and seal.
4. Disconnect cemented canvas cover on tensioning

bar.

5. Disconnect and remove cemented mounting rail. 2 . Mark distance from rear window to cementing
edge of mounting rail on top canvas cover;
approx. 80 mm.
Installing
3. Cement mounting rail on top canvas cover accord-
ing to marks.
1 . Cut out protective coat on inside of top canvas
cover and ripper with a scissors,

4. Fit canvas cover on tensioning bar and cut t o 6. Fit in seal and clamping rails, and mount with
size. Cement canvas cover on outside of tension. washers and nuts.
ing bar from the center t o left and right sides.
Seam of canvas cover must run slightly higher
than lower edge of the tensioning bar.
7. Place rear end of canvas cover on car. Place

mounting rail with canvas cover on main hoop
and install screws. Press down on rear of tension-
5. Cut holes i n canvas cover for the staybolts and ing bar. If polyglass window does not have suffi-
cement canvas cover on inside of tensioning bar cient tension, disconnect canvas cover on the
main hoop again. Disconnect cemented mount-
ing rail and stretch the canvas cover.
8. For remaining installation procedures refer t o

"Installing Rear Canvas Cover w i t h Tensioning
Bar and Mounting Rail".
Install t o p canvas cover seals.

REPLACING ZIPPER SLIDE
Removing
1. Remove Tenax base and self-tapping screw w i t h 3. L i f t off end hook towards inside
cloth protection washer o n the side, where the
end hook i s located (on rear end o f front canvas
cover) and open up sewn seam.
4. Remove key board. Slide zipper slide down and

remove.
2. Fold open canvas cover and bend open claws

of end hook.

Installing
1. Press new zipper slide into real- zipper section. 3 . Insert end hook and bend down claws f r o m the
outside.
2. Insert zipper slide in front zipper section. 4. Mount pulling strap and snap head w i t h eye o n
zipper slide.

5. I f applicable, drill a hole i n the front of the key 7 . Install key board, Tenax base and self-tapping
board, where the snap base i s mounted with a screw with cloth protection washer as well as
self-tapping screw (see figure). front and rear canvas covers w i t h two seam
stitches.
6. Press snap head into snap base,

Roof 911 8
REMOVING AND INSTALLING ZIPPER
Removing
1. After removal of the rear top canvas cover with- 2. Cement canvas cover on zipper from above
out tensioning bar and without mounting rail.
cut out zipper from rear canvas cover.
r , .
3. Cement tensioning section
Installing
1. Canvas cover must be free of sewing yarn at cut

surfaces. Apply coat of cement on zipper and
canvas cover. Cement bottom of zipper on canvas
cover on one side.
4. Wait until cement i s dry and then sew zipper

and border. Cement tensioning bar and mount-
ing rail on canvas cover and install complete
Dart in car.

RECOMMENDED CEMENTS OR ADHESIVES
CementsIAdhesives:
Terocal 2444 for cementing seals
M a n u f a c t u r e r : Teroson Werke GmbH

6900 Heidelberg 1
Dekalin 3649 for installation of canvas on metal or plastic
M a n u f a c t u r e r : Deutsche Klebestoffwerke GmbH

Rodiger & Sohn
6450 HanauIMain

Interior Equipment 911 8
I N S T A L L l N G I N S I D E MIRROR
1. Remove screw &om mirror arm and take off NOTE

mirror base. Do not use adhesive plates on which the
backing was already partially removed or
plates from which the backing cannot be
fully removed. These conditions will cause
faulty bonding.
2. Remove adhesive plate and clean burr, if

any, from the mirror base collar.
7. Seal all sides of adhesive plate with a bead

o f weatherstrip adhesive ( 3 M # 8011 or
similar adhesive).
3. Carefully clean and degrease windshield
and mirror base (use alcohol, acetone,
etc. )
8. Place mounting base on windshield
4. Mark mounting surface for mirror base.

Upper edge of mirror base must be in
windshield center, 80 mm below wind- 9. Attach extension US 8015 to the wheel
shield seal. Mark location on outside of tensioner (Bosch part # 2 688 190 000) and
windshield. install mirror mounting base. Apply a pres-
sure o f 12 kp (26. 5 lbs) for 15 minutes.
CAUTION
To prevent damage t o windshield, compress
5. Heat mirror base on hot plate to approxi- the wheel tensioner against the floor tunnel.
mately ZOOo F. DO not compress against windshield.
NOTE
The adhesive area should be a shiny black
and without dull black spots.
6. Remove backing (white or beige) from ad-

hesive plate and place on mirror mounting
base.
10. Remove tool and attach mirror to base.

8 911 Interior Fittings
INSTALLING INTERIOR R E A R V I E W MIRROR
Note: Repair kit, Part No. 914 731 025 10, is required for the following operations,
1. Clean and degrease mirror base and windshield with acetone.
2. Cut strip of tape and paste on mirror base as illustrated.
3. Fill i n open surface on mirror base with a n adhesive t o height of tape.
4. Pull paper backing off tape.
5. Position mirror and press firmly so that tape surface rests completely flat on winshield.
6. Remove excess adhesive with cloth soaked i n aceton.
7. Adjust mirror carefully, because the adhesive requires 24 hours to dry completely.
8. If possible, the car should not be used fur several hours to let the adhesive settle and dry.

Interior Equipment 9~ 8
T A R G A ROOF A D J U S T M E N T S - FROM 1 9 7 0 MODELS
General
If wind noise or creaking should occur in a Targa roof due to changed position, the following adjustments
may become necessary to rectify the condition:
Creaking Noises
1. Remove folding top. Check front and rear tensioning rails for proper alignment, adjust i f necessary.
2. Check roof lochs, tighten retaining screws
3. Check hinges, removing pins i f loose: worn pins should be replaced.

Grease hinges lightly.
4. Check front locating pins for wear, replacing if necessary.
5. Check weatherstrip at windshield and roll bar ends, replacing if damaged or flattened.
NOTE
Lightly coat weatherstrip with glycerine during the winter season
6. If moulding strips in windshield frame show pressure marks, meaning improper tolerances at the
convertible top, straighten the strip with a piece o f hardwood, or remove strip and rework top sur-
face across windshield frame.
Wind Noises
1. Check convertible top for proper seating. Readjust i f it protrudes above the windshield frame or roll
bar, or i f it is uneven.
2. Check windows for proper sealing, readjust i f necessary.
3. Readjust proof side seal if necessary.
4. Using wide-grip flat pliers, lightly bend rear seating surface of the folding top downward. (Do not
bend the rounded sides).
5. Install convertible top and check positioning, readjusting door window frames if necessary.
Top Billows Out
The convertible top may billow out a high speeds with the fan on and windows closed (pressure in pas-
senger compartment).
Remedy:
1. Move rear support pin upward on convertible top
2. Check rear hinges, removing hinge pins i f loose; worn hinge pins should be replaced. Grease hin-
ges lightly.
3. If high pressure is exerted on the gasket at the LASTIK supports (roll bar), take gasket out o f the
supports and cut the base down as required. Glue it in place and secure with plastic rivets.

911 Interior Equipment
a Tensioning rail
h Roof l a c k pawl
c L Locating stud
d = Rear support pin
Rollbar weatherstrip, new version Windshield f r a m e weatherstrlp, new version

Interior Equipment
911 8
MOULDING C H A N G E S I N WlNDSlHlELD T O P
Beginning with chassis numbers 911 251 0143 911 T

9 1 1 221 0091 911 E
9 1 1 231 0059 911 S
moulding stiips with a 2 . 3 m m depression in t h e area o f t h e roof lock pawls a r e being installed on wind-
shield frame top in all Targa vehicles. These strips c a n also b e used on earlier vehicles, providing that
the channel going across the windshield frame is reworked accordingly.
NOTE
If the moulding strips show pressure marks

causing noise, do t h e following:
1. Reshape moulding strip with a p i e c e o f

hardwood, as necessary.
2. Replace windshield frame weatherstrip i f

d a m a g e d o r flattened. ( T h e convertible top
should rest only against the weatherstrip). A = New version
3. Further possible retification:

a - Remove old moulding strips
b - Partly loosen leatherette coverillg

c - Reshape top surface of windshield frame
t o accomodate new- type moulding
strips.
CAUTION
Support other side o f windshield frame t o pre-

vent damaging windshield when reshaping sur-
face.
d - Reglue l e a t h e r e t t e covering and install

new moulding strip.

Interior equipment 911 8
I N E R T I A REEL S A F E T Y B E L T W I T H A U T O M A T I C L O C K I N G R E T R A C T O R ( C O U P E )
-
Note when Special
Nr. Desciiption Qty instructians
-
1 Retaining bolt I I Use original self-locking

-
2 Spring washer 1 Replace if necessary.
-
3 Loop cover
-
4 Retaining bolt Use original self-lockin$

- bolt.
5 Flanged washer 2 Pasition properly.
- I
6 Washer
-
7 Retaining bolt
-
8 Serrated washer 1 Replace if necessary.
-
I
9 Spacer
-
10 Support plate Install together with
belt retractor.
-
11 Inertia reel belt with Check installation side.
automatic retractor Belts a r e different for
right and left side.
-

8 911 Interior ~ q u i p m e n t
I N E R T I A KEEL S A F E T Y B E L T W I T H A U T O M A T I C L O C K I N G R E T R A C T O R ( T A R G A )
N o t e when Special
Nr. Description installing instruction!
-
-
1 Retaining boll
i 1 Use original self-lackin)
bolt.
2 Spring wasl~cr Replace if necessary.

-
3 Loop cover
-
4 Loop retaining bolt Use original self-locliinj
bolt.
-
5 Flanged washers Position properly.
-
6 Washer
7 Protective washer
-
8 Spacer
-
9 Retaining bolt
-
10 Serrated washer Replace if necessar)
-
11 Inertia reel belt with Check inslallation side.
automatic retractor Gelts a r e ilifferent for
right and l e f t side.
-

R E M O V I N G A N D I N S T A L L I N G I N E R T I A REEL S A F E T Y B E L T W I T H A U T O M A T I C
LOCKING RETRACTOR AND ELECTRIC WARNING DEVISE
Removal (Coupe and Targa) 6 , Remove and reinstall buckle.
1. Detach belt from side of seat.
2. Remove loop cover from B-pillar or roll bar.
3
3. Remove loop retaining bolt. Remove flanged
washers, in T a r g a additionally l h e spaser l o c a -
ted under t h e perforated cover.
A
> 8
4 . Remove cove1 from side section; this requires'

removal of sheetmetal screws from the rosette
p l a t e and rocker panel. In the Targa vehicle,
remove covering strip from side cover as well
as sheetmetal screws from the rosette p l a t e in
t h e side cover and t a k e both parts o i l .
NOTE: T h e belt can b e pulled out through

t h e opening o n c e t h e plastic cover is 1 - Inertia r i d belt with auionlatic relractor
removed from t h e buckle assembly. 2 - Countersunk screws
3 - Cover
4 - Cover
5 - Retaining bolt
ti - Spring washer
5. Remove belt r e t ~ a c t o rretaining screws. 7 - Buckle assembly
N O T E The buckle assembly should not be dis-

assembled unless it does not function
properly.

8 911 Interior Equipment
a) Remove both countersunk screws from Installation (Coupe)

the cover and separate both halves.
1. Mount belt retractor on side panel togethet

with support plate, spacer, and serrated
washer.
b) Carefully detach buckle contact wires
from connecting tabs.
NOTE: T h e larger retractor plastic cover

should face to the rear, and t h e cover
holder upwards.
In addition, the retractor should b e
tilted forward about 15' in line with
the direction of pull.
NOTE: T o prevent damage to the contact plates.

hold the tabs with needle nose pliers when
disconnecting the wires
c) Press plastic cover off. Remove buckle

retaining bolt and take buckle out.
2 . Pull the belt through the upholstery cover.

Interior Equipment 911
3. Install yoke on door lock post; s e e sketch for l o c a - 5 . Install upholstery cover and rosette plate.
tion of washer.
6. Fasten belt t o mounting bracket in seat. S e e

sketch for installed position o i t h e spring
washer.
1 - Weld-nu1
2 - Retaining bolt
3 - Door lock post with ieinforcement 1 - Mounting bracket on seat outside
4 - Spacer 2 - Retaining bolt
5 - Cover 3 - Yoke
6 - Flanged washers 4 - Spring washer
I - Yoke
4. Pull t h e belt out horizontally and check un-

NOTE: T h e belt should not b e twisted. Sewn
reeling and retrieval of belt. T h e belt should
cnd should f a c e the seat
b e traveling. in center of retractor r e d , ii ne-
cessary, correct t h e 1 5 O installation position
of t h e retractor.

I . Install belt buckle assembly. S e e skelch for 9 . Join belt buckle covers and secure with
location of spring washer. countersunk screws.
1 0 . Put the belt on, adjust, and check operation.

When t h e belt is moved rapidly, the locking
retractor must lock, and must unreel easily
when moved slowly.
1 - Mounting bracket on seat inside

2 - Retaining bolt
3 - Latch
4 - Spring washer
8. Guide buckle contact c a b l e thiough the pla-

stic cover and connect to contact tabs.
NOTE: T o prevent d a m a g e t o the contact plates,

hold tabs with needle nose pliers when
connecting t h e wires. Also s e e Group 9.
p a g e 6 . 2 - 1/1.

Interior Equipment 911
Installation Instructions for T a r g a

Vehicles
1. Install retractor with retaining bolt and ser- 3. Attach yoke to roll bar. S e e sketch for l o c a -
rated washer. For clarity, the illustration tion of washers.
does not show side covering.
l - Yoke
NOTE: The larger plastic cover on retractor
2 - Cover
should f a c e back, and the retractor
3 - Flanged washers
should tilt forward by l Z O along t h e
4 - Roll bar reinforcement pan
direction of pull.
5 - Weld-nut
6 - Retaining bolt
7 - Spacer
8 - Protective washer
9 - Spacer
2. Pull belt end through the side covering and
rosette plate.

4. Pull t h e belt out horizontally and check un-

reeling and retraction. T h e belt should reel i n
center of r e t r a c t o r if not, correct t h e 12'
alignment of t h e retractor. For clarity, t h e
illustration does no1 show t h e side covering.
5. Install side covering, rosette plate, and

cover moulding.
NOTE: T h e electrical operation and auiline

dealing with the automatic retractor
is described i n Group Y .

Interior Equipment
911 8
REMOVING A N D INSTALLING ELECTRIC WINDOW REGULATORS
General
Beginning with t h e Apr- 26-72 production, new electric motors with a n integral transmission, as well as
modified toggle switches with mounting frames a r e used. Electrical connections a r e m a d e according t o
a ncw wiring diagram. Electric window regulators can b e installed in Caupe models only.
T h e new regulators were first installed in t h e 9 1 1 T USA 9 1 1 210 2012

following vehicles: 911 E 911 220 0809
911 S 9 1 1 230 1 3 9 1
1. Remove window l e d g e rail and lock button.
2 . Remove toggle switches. If possible, first

position window glass about 1 0 c m (4") above
its lowest position.
3 . Remove entire door panel and sealing foil
4 . Remove outer c h r o m e strip a t window base.
Rear side of door panel with weather scals and

self- sealing mounting clips.
5 . Remove all window frame fasteners. Pull t h e
frame out.
G . Push windaw glass forward and detach from

the regulator. Remove upper door well
weather seal and t a k e t h e glass out.
1 Clip
2 Door panel
3 Door inner sheetnietal panel

I . T a k e wires out of retainers, disconnect t h e m

from junction bar, and pull wire looms out
together with caps. If t h e wire l o o m leading
from t h e door into t h e c a r ' s interior is t o b e
removed, it will b e necessary t o t a k e t h e door
off.
8 . Unscrew window regulator and r e m o v e .
9 . Remove stop wedge from do01 base
New motor and lral~sniissionwith c a b l e l a y o i ~ t

Installation
7 I . Insert wire grommet in forward part of inner

sheetmetal panel of door. Lead t h e connecting
I
wires into t h e c a r ' s interior. Install door.
/~
4" , 2%
+ ~ .;: '. 2 . Insert window regulator and fasten. Install
3 . Run t h e regulatai wilh a battery or batter)

charger t o bring window t o about 10 c m (4")
above its lowest position by connecting t h e
,;oritive wire t o green and negative wire t o
black wires in motor. I f t h e regulatoi moves
ilp, swilch t h e wires lo m a k e it m o v e down.
?
-.'
4 . Install carrier p l a t e with junction bar

interior Equipment 911
8
5 . Insert toggle switches, cover caps. and wire
looms. Connect all wires according t o t h e
new supplemental wiring diagram in Group '3
Fasten t h e wire laoms t o carrier p l a t e and
inner sheetmetal panel.
G . Install door well weather s e a l . Place window

glass in door well and attach t o the regulator.
7. Insert door window f r a m e i n door a n d seal

along t h e outside and inside flanks of top
door e d g e with black. non- hardening putty.
Fasten t h e f r a m e in such position that
sufficient pressure will b e exerted against
t h e door weatherstrip.
NOTE:
Do not bend t h e window f r a m e t o f i t .
8 . Check window regulator for proper operation

and free movement. If necessary, readjust
regulator with adjusting screws so that t h e
t a p e d g e of t h e window i s parallel with the
top part of t h e window f r a m e .

8 911 Interior ~ q u i p m e n t
9. Glue t h e sealing foil in leak- free. Cut out

a section in t h e toggle switch a r e a .
1 0 . Install door inner panel, armrest with inner

door release, door pocket, folding cornpzrt-
ment, door l e d g e rail. and outside window
base chrome strip.
11. Connect toggle switches and install.
NOTE:
When properly installed, a l l toggle switches
a r e positioned with t h e single connector
facing up.
.:$! T h e rear toggle switch i n driver's door
actuates t h e passenger side window.
-

SEATS
General
Beginning with 1 9 7 3 models, a l l standard and sport t y p e seats h a v e new lo~lgitudinalseat adjuster lacks
on both sides of t h e seat. T h e upholstery materials were also changed.
T h e seat adjuster controls remain unchanged. In t h e new standard seats, t h e seat pan has a control c a b l e
interconnecting lock pawls on both sides of t h e seal so that movement of t h e lock pawl on t h e center
tunnel side of t h e seat is simultaneously transmitted t o t h e lock pawl on the outer side of t h e s e a t .
This modification includes new seat rails with adjuster locking slots, Part 911 521 0 5 1 01, for in-
stallation along t h e longitudinal side members.
In t h e new sport seats, t h e twin adjuster locks a r e locked by two pawls mounted on a bar so that t h e
pawls engage t h e rail locking slots on both sides simultaneously.
Installation d a t e for t h e new standard seats:
Installation d a t e for the new sport seats:
October 16. 1972
Seats wit11 changed upholstery materials a r e in-

stalled from August 1 9 7 2 .
S e a t rail support with seat contact c a b l e

8 911 Interior ~quiprnent
Installing Seats
1. At first, tighten seat rails only lightly. Check

sent adjustment positions throughout the entire
position range t o ensure that the lock pawls
engage and the seat moves easily on the o i l s .
The seat adjusting lever must return into its
normal position by itself. If this is not t h e
case, reposition the seat rails.
Standard seat - right side 2 . Torque a l l seat retaining bolts in seat rails
and seat rail supports t o 1 . 2 - 1 . 4 mkp.
3. Recheck seat repositioning
Sport seat - right side

R E M O V I N G A N D I N S T A L L l N G O I L FILLER LID A N D C O N T R O L
General
Beginning with 1972 models, o i l tanks in a l l T y p e 911 vehicles a r e located under the right rear fender,
adjacent t o side m e m b e r and wheel housing. T h e tank is fastened with retaining straps. T h e lid lock
support was being welded t o the o i l filler pan until September 24, 1971.
Removing
1. Open lid, remove screws, and t a k e lid o f f .

2. Detach remote control rod from connecting
clip i n lock lever and r e m o v e . T a k e g r a m -
m e t out.
3. Remove cotter key and clevis pin From the

lock lever
4. T h e boll- on lock support can be detached

only when the oil tank is removed
(2 x M 5 nuts).
Installing
1. Position o i l filler lid, together with M6 x 15

screws and spring washers, lightly tighten-
ning screws. Align l i d and tighten retaining
screws.
2. Insert rubber g r o m m e t in door lock post.
3. Replace connecting clip i f damaged. In-

stall lock lever
4. Connect remote control rod. Insthii ;.,a-

~ h e r ,spring and control knob from the door --
a DL.!+=
~ -
lock post side. .,
b iP
?;;::\ .
:I'!
5. Close o i l filler l i d . Bend lock lever as re- -ai,. ~~~~~
~-
,
-/
2
quued.
#-~-
.+-. ~- ~ ~ ~~
~~ ~~~-~

Exterior T r i m 911 8
R E M O V I N G AN13 I N S T A L L I N G R O C K E R PANEL C O V E R
Removal
1. Remove end pieces from both ends.
2. Take rubher strip off. Remove cover from

jacking point.
3. Remove shcetmetal screws from top and

bottom parts. take rocker panel cover off.
Installation is accomplished in reversed order.
NOTE
Insert one end of rubber strip onto the supporting
I
rail, bend the strip tightly back, and slide it onto
t h e supporting rail. T h e upper lip must rest closely
to t h e body. If necessary. straighten supporting rail.

Exterior Equipment 911 8
R E M O V I N G AND I N S T A L L I N G END PANEL
General
Beginning with 1974 models, an end panel will1 reflectors and PORSCHE lettering is mounted at the rear
cross panel. A sheetmetal shroud, serving as '.heat shield, is located below the panel; it is inserted
a b m e the m u i i h and secuci-d ;iXh bolts.
Removal
1. Remove rear bumper.
2. Unscrew heat shield and remove.
3. Remove self-locking nuts, washers, and rubber

spacers.
4. Remove end panel.
Installation
1. Lightly glue contoured rubber strip underneath.
2 . Insert end panel, watching for equal side and

height alignment with the tail lights.
3. Insert plastic washers, rubber spacers, and

washers on the mounting studs and secure with .
,-7
C \ .,
~ - ; L ;
~ ~
..
6 1
-2
self-locking M 4 nuts. Check installed location : 0

0
and correct if necessary. Moderately tighten

nuts cross-wise without creating stresses.
4; Insert heat shield and secure with bolts.
5. Install bumper.

8 911 Exterior Trim
REMOVlNG A N D INSTALLING T A I L PLATE A S FROM 1 9 1 8 MODELS
As from 1978 models t h e tail p l a t e is attached

t o the tail panel with 1 0 clips. Part No. '399 591
447 02.
. .
This facilitates installation, in that t h e bumper
and heat guard d o not h a v e t o be removed.
-
I XI
I. . -
~~~~
_ ___
LA'.
---~-1
/
~~ Square hales ipreviously slots] a r e punched in the
tail panel t o t a k e the clips.
Removing
d
1. Cover tail panel ahnve p l a t e with adhesive
t a p e t o prevent d a m a g e on t h e paintwork.
2. Use pertinent tools (screwdriver, putty knife.

etc.) t o pry tail p l a t e out of clips, first t o p
and then bottom.
Note
Only apply pressure a t reinforcements of p l a t e

t o prevent d a m a g e on plate. Be careful not t o
injure c o a t on back of reflector area by scrat-
ching, since otherwise t h e reflecting effect will
b e impaired.
3. T a k e clips out of tail panel, r e p l a c e damaged

clips, straighten t a i l panel if necessary and
e l i m i n a t e paint d a m a g e .
Installing
1. Insert clips into tail panel.
2. Hold tail p l a t e in position, align clips with

reinforcement pins and press on tail p l a t e
up t o stop.

Exterior Trim 911 8
L E T T E R I N G FOR CARRERA V E H I C L E S
Notes
The following points must be observed to ensure that the lettering adheres firmly to the paint:
1. Wash paint surface, removing wax, etc, with clean cleaning solvent. Dry the paint surface.
2. Do not affix the lettering in cold or damp weather. T h e temperature of the vehicle and
surrounding air should b e about +20°C.
3. Side lettering should be attached by two persons.
Affixing "Carrera" Side Lettering
1. Mark front and rear location of lettering above

door lower edge.
2 . Peeloff backing foil from the adhesive side.
3. Left door: Align starting letter "C" 1 c m

behind the forward door edge and
glue on. Stretch the foil forward
and back, and press into place.
Right door: Align point of letter "a'' at the

forward door edge and glue on.
Stretch the foil and press into
place.
4. Press lettering areas smooth in all directions.

then remove top foil.
5. Trim the lettering with a sharp knife, along

the fender contour in front, along the door
edge in rear, and along the wheel cutouts.
Press end sections into place.
6. Puncture air bubbles in lettering with a needle

and press smooth.

-.- - .-.- . -
mi.;- .. .:, .~. Atfixing "Porsche" Lettering on Engine (.ompart-
r--
i\ merit Lid
, ~ ~ il
1. Mark location of t h e lettering 25 mnl from
CS
I- - bottom e d g e of lid on both sides, and 35 m m
1 I from bottom of lid in t h e c e n t e r .
2 . Peel off backing foil and affix t h e lettering as

~ n a r k e d .Press it smooth and peel off t a p foil.
---* --- ----~- Affixing "Carrera RS" Lettering on ].id Spoiler

, -\
1. Ivlark location of the beginning of t h e lettering
95 & 1 6 0 m m below t h e spoiler inner edge, and
95 m m t o t h e right of t h e lid center.
, __. /
I
-
2 . Peel off backing foil and Elue t h e lettering
- optically horizontal t o t h e right.
Zolored Lettering
Carrera vehicles painte Prix white a r e

furnished with lettering i n colors matching t h e
respective wheel color (red - blue - green). All
other vehicles a r e furnished with black lettering
Removing Damaged Lettering
Heat t h e lettering with air heaters, infra-red l a m p s

etc, t o t h e point where it can b e peeled off witli-
out pulling t h e paint off in t h e process. Wash
remnants. of adhesive off t h e paint surface with
cleaning solvent.

Exterior Fittings 911 8
R I I M O V I N C A N D I N S T A L L I N G O U T S I D E REAR V I E \ \ : AilRROR W I T H D E F O G G E R
A N D REhfOTE CONTROL
Note when Special

Description instructions s e e
Removing Installing
Gasket Replace, if
necessary
Mirror base Guide in harnes!
Harness Pull wires out of

socket. Bend open
c a b l e c l a m p inside door
Mirror arm
Mirror housing
Carrier p l a t e Replace, if
defective
Mirror glass Remove carefully First check

reflection
Pi:illips head screw

5 x 14 m m
Install between
mirror housing
and a r m .
Phillips head screw
5 x 16 mm
Wave washer
Allen head screw Tighten until
5 x 35 m m mirror base is ti

8 911 Exterior Fittings
Removing
Note: If i t is necessary t o t a k e t h e harness out of
1. Use putty knife t o mirror glass clips out of
t h e door, r e m o v e t h e inner door trim and
carrier plate. Carefully d e t a c h t h e wire
bend open t h e c a b l e c l a m p behind t h e top
terminals from t h e glass.
door hinge.
T h e door must also b e removed. First
separate t h e connector in t h e side panel
storage pocket.
2. Remove the 3 Phillips head screws through

t h e openings in carrier plate. T a k e out
carrier p l a t e and disconnect socket/plug.
3. Unscrew mirror housing a t mirror arm.
4. Note color of wires in socket. Use a pointed

tool (scriber) to press in the tongues of each
wire terminal and pull out t h e wires.
A - Mirror c a b l e B - Loudspeaker wire
5. Unscrew Allen head screw on mirror base until

t h e mirror base and gasket can b e removed.
A - T o operating switch B - T o inside of c a r

Exterior Fittings 911 8
INSTALLING
4. Wrap foam t a p e around socket/plug and

T h e following points a r e important. insert it through oval opening in mirror
housing so that t h e mirror m o v e m e n t is
not restricted.
1. Use t h e c a b l e c l a m p (inside door behind t h e
Note: Check operation before attaching
top hinge) t o hold the harness away from t h e
mirror because t h e clips and terminals
teeth of t h e window regulator.
on t h e mirror glass a r e easily damaged.
2. Tighten t h e clamping jaw with the Allen

head screw until t h e mirror base is held
tight.
5. Install operating switch on t r i m strip so that

t h e switch pin engages in bore of t r i m strip.
3. Observe wire colors when assembling socket.

911 Exterior Equipment
S E R V I C E I N S T A L L I N G E X T E R I O R MIRROR ON P A S S E N G E R ' S DOOR
Note 3. Pull harness into mirror.
These instructions apply to all models equipped

with an exterior mirror, which is adjusted on the
4. Pull off door waistline strip. Remove inside
inside.
trim on doors (also loudspeaker if applicable).
Three new harnesses are required.

1 - Driver's door harness
2 -Luggage compartment floor harness
5. Drill holes in outside door panel according to
3 - Passenger's door harness
dimensions and with reinforcement plate - for
right door.
Installing
1. Paint mirror set to match car body color.
2. Install guide tube with spring and centering

disc, and tighten to torque of 15 + 3 Nm
(1.5 + 0.3 kpm). (Installed mirror can then
still be turned via the cams.)
6. Install reinforcement plate and secure with pop

rivets.

Lxtfrior Equipment
7. Lift ail1 door and mount mirror base with '3. Insert wire gromnlcl into door recess.
gasket on door. Glut cap url mounlillg screh
head. Guide set of wires through inside door
panel and insert r u h l w r g r o m m e t .
8. Press plug together and hold with self- adhesive

f o a m tape. Note colors of wires and wiring
diagram. Mount cover f r a m e to mirror glass
k&
carrier. C o n n e c t and insert mirror glass. 10. Instal1 door and guide wires t o l u g g a g e c o m -
partment floor plate. Install coupling plug
according to wiring diagram.
11. Disconnect wire harness on l u g g a g e c o m p a r t -

m e n t floor p l a t e at rear window defogger
switch and combination instrument, and pull
out. Pull in and connect new wire harness:
r e m o v e instruments for this purpose.

11 Exterior Equipment
12. Remove d r i i e r ' s door, a n d insert a n d connecl

new fxterior mirror \wire harness.
13. C u l a hole it1 l r i n of instrument panel,

connecl and inslall swilch.
14. C o n n e r t couplings of wire harnesses i n

luggage c o m p a r t m e n t floor p l a t e a n left and
right sides.
15. Attach dnor t r i m and check operation of

mirror cunlrols.

Reparatur-KontrollmaOe ab Modell 72
0
Check dimensions for bottom groups
from model 72 on
Cotes de contrde pour le groupe de

fonde a partir du modele 72
Printed in Germany 18.1-1/1

C H E C K I N G REAR A X L E C R O S S T U B E
Repairs 911 8
The rear axle tube for Types 911 and 911 Turbo c a n b e inspected for deformation with a locally m a d e
tool and a torsion bar.
Two pieces of round steel bar. 13 m m (1/2 in. ) dia. x 300 m m (12 in. ) long. are required for t h e locally
m a d e tool.
0
Machine one end of e a c h bar t o a point of about 60
T h e rear axle cross tube c a n be inspected after removal of the engine and rear axle.
1. Insert both round bars through t h e trailing arm

mounts. If both steel bar tips m e e t e a c h other
with the s a m e distance from t h e mount to t h e
tip, t h e mounts are okay. Deviations up to
max. 3 rnm (1/8 in. ) are permissible.
2. Guide torsion bar into splines of cross tube on

one side. Bar must be centered in tube with
distance between bar and tube equal around
entire circumference. Repeat procedure on
orher side. Slight deviations of about 3 mrn
(1/8 in.) are perrnissibie.

Repairs 911
I N S T R U C T I O N S FOR \v'ELDING G A L V A N I Z E D S H E E T M E T A L - 1 9 7 6 MODEL
For t h e 1 Y i C model t h e entire body is m a d e of steel s h e ~ galvanized

l an both sides. T h e zinc thickness
varies bclween 7.5 and 20 micromillimeters depending on t h e corrosion possibility ( e x c e p t t h e C o u p e ' s
roof). Together with other protective measures, such as cavity spraying, undercoating and modern
painting techniques, t h e body has a d e q u a t e protection against corrosion.
This means seversal changes for repairs on r h c e l i n e t a l parts.
- T h e zinc coat should b e ground down as l i i t l e as possible or d a m a g e d in any other manner.
- Never USE acids for c l e a n i n g .
- U s s welding techniques which cause t h e least possible d a m a g e t o t h e zinc c o a t . If a t a l l possible

r e p l a c e weldmg with other welding tcchniquer - iesistance welding (spot) - gas- arc welding/brazing.
Painting c a n bt- p e r f o r n ~ e dwith t h e s a m e materials as for s t e e l sheet.
Below a r c several explanations about r e c o m m e n d e d welding techniques.
RESISTANCE \dELDING
S e v e r a l points must b e observed when employing resistance welding (spot welding).
- D u e t o t h e improved e l e c t r i c a l conductivity of galvanized sheet i n comparison to blank steel sheet,

0
t h e current intensity will h a v e t o b e increased t o attdin t h e required welding t e m p e r a t u r e of 1300 C/
0
2372 F.
- T h e welding t i m e should b e as brief as possible t o k e e p the m e l t i n g zone around t h e welding spot

s m a l l . This will also m e a n that less zinc will stick t o t h e electrodes and thus longer operating t i m e s
a r e assured before m a i n t e n a n c e becomes necessary.
- Hard copper (copper-chrome-zirconiun, allays) is t h e best m a t e r i a l far electrodes. I t has high h e a t

o
2 ~ m a x i m u m s e r v i c e l i f e up t o 15, 000 spots.
physical properties (above 400 ~ / 7 5 F):
- T h e e l e c t r o d e welding surface shape c a n b e S h a p e 1 or S h a p e 2 (see sketch).
- Depending on t h e thickness of t h e material. t h e m a x . welding spot d i a m e t e r should b e 4 t o 5 m m

( 5 / 3 2 t o 3/16 in.) depending on prcssure applied to t h e electrode holder.
- Bull w ~ l dspots a r e not a c c e p l a b l e because thcse welding spots do not h a v e sufficient strength.
- Cool- off periods must b e scheduled i f welding equipment without water cooling is e m p l o y e d , so that
t h e electrodes a r e not deformed.

911 Repairs
- Never m a k e spot welds on edges of sheet m e t a l (spatter formation).
- C l e a n and dress electrodes on their flanks and tip surface only if t h e r e is a heavy c o a t of deposits.
T h e t i p surface of t h e electrodes becomes harder from spot welding; t h e layer underneath however
becomes softer.
- T h e distance between spots should b e about 20 m m ( 3 / 4 in.). If t h e spots a r e too close together, the
welding current will reduce the strength of the welding spots.
- Electrode arms should b e as short as possible t o increase t h e pressure a t t h e weld point.
GAS- ARC WELDING
For body repairs t h e only t y p e o f gas- arc welding a c c e p t a b l e is t h e MIG method (Metal Inert Gas) with
carbon dioxide (CO ) or mixed gases, e.g. corgon (argon, C O 0 ). Good welding is possible with
2 2' 2
these types o f gases. Mlxed gases increase t h e welding speed and t h e seams remain ductile.
Additional information for MIG welding galvanized steel sheet.
- Clean as much of t h e area t o b e welded as possible.

Optimum welding results require that t h e equipment b e adjusted correctly.
- Check adjustment by listening i f t h e arc has a steady crackling or hissing sound.
- Hold t h e torch a t a n angle of 15-80' and approximately 3 / 8 inch away from t h e m e t a l (dependent on
equipment being used).
If adjusted properly t h e gas shielding will surround the melting zone and hlow away t h e zinc oxide iapors
produced.
T o keep welding distortion t o a minimum, the work should b e allowed Lo cool dnwn after welding a
long seam.

Repairs 911 8
- T h e most suitable welding wire is of soft quality. 0.8 m m (0.031 in.) in diameter and has 0.8 qo
silicon and manganese additives.
- T h e gas shielding flow rate should be set at about 1 7 cu. ft. per hour.
- For large scale welding adequate ventilation must b e provided.
- Welding seams, if accessible, must be protected with zinc paint, cavity or undercoating materials.

Paint Finish QV 8
COLOR SELECTION - FROM 1 9 1 2 M O D E L
General
Beginning with 1912 models, a new numbering code is used in identifying paints on the paint nomen-
clature p l a t e . T h e change was necessary t o ensure right shipment o f paint when ordered for given ve-
hicle.
T h e new color code on t h e vehicle paint d a t a p l a t e is identical with the order numbers in the color c a -
talogue.
ldenlificalion o f t h e new 5-digit code numbers on the paint nomenclature p l a t e .
Example. 131 9 2
1. Three- digit paint numhel -

131 9 2 light ivory
2. Place o f application 131 -

9 2 Porsche company
3. Paint rnanulacturer 131 9 2 Glasurit company

-
Standard colors from 1972 model
131 light ivory
117 light yellow
114 signal yellow
018 1angerine
0 22 hahia red
0 25 aubergine
225 viper green
325 albert blue
415 sepia brown

8 911 Paint Finish
Optional colors from 1972 model:
019 gulf orange

024 fraise
116 signal orange

132 ivory
213 irish green
218 bush green
226 lind green

227 light green
3 26 icing blue
328 gulf blue
3 29 sea blue
341 Lilac
414 olive
622 beige grey
700 black
Metallic colors:
metallic gold
VW-metallic gold
metallic green
metallic blue
metallic gemini
to Sep-2nd metallic silver
from Sep-3rd VW-metallic silver
optional colors to sample

Paint Finish 911 8
COLOR SELECTION EFFECTIVE W I T H 1 9 7 4 MODELS
Standard colors beginning wit'n 1974 models:

027 India red
042 Peru red
117 Light yellow
137 Yellow green
156 Orange
336 Mexico blue
408 Cockney brown
516 Sahara beige
908 Grand-Prix white
Optional colors beginning with 1974 models:

009 Carmine red
024 FIaise
025 Aubergine
116 Signal orange
139 Blossom yellow
213 Irish green
227 Light green
253 Space green
328 Gulf blue
341 Lilac
351 Dark blue
354 Acid blue
414 Olive
700 Black
Metalljc colors:
Salmon dust
Silver-green diamond
Gemini metallic
Comet shower
Copper diamond
Silver metallic
viper green diamond
metallic blue

8 911 P a i n t i n g
PAINTS - 1 9 7 6 MODEL
027 indian red
Standard Colors:
106 talbot yellorr
continental orange
light yellow
,L ra b> speedway green
arrow blue
cockney brown
black
908 grand prix white
Optional Colors:
c a r m i n e red
Peru red
yellow green
irish green
daphne green
c a p p a florio
sahara beige
Metallic Colors:
viper green diamond
oak green
silver green diamond
minerva blue
diamond sarah
brown copper diamond

silver
platinum diamond
Note: S o m e of t h e m e t a l l i c colors h a v e new color codes because of a finer bronze powder.

E.g. silver green diamond before 250, now 266.
An extra "A" after t h e color code indicates a n acrylic paint.
All of t h e listed colors a r e standard for t h e Turbo Carrera.
C au tion : Most paints and their additives a r e combuslible or explosive.

T a k e every precaution when using them.

Paint 911 8
PAINTS - 1 9 7 8 MODELS
Standard india red
talbot yellow
continental orange
sebring green
fern green
olive green
royal blue
chocolate brown
mocca brown
cashmere beige
black
grand prix white
Metallic oak green
light green
c a r i b e blue
petrol blue
copper brown
silver

8 911 Paintwork
B O D Y P A l N T C O L O R S F O R 1979 + 1980 MODELS
S r a n d a r d C o l o r s f r o m 1979 M o d e l s : 027 india red
106 talbot yellow
273 olive green
305 ariow blue
408 cockney brown
451 m o c c a brown
502 cashrnire b e i g e
601 lilac
700 black
908 grand prix white
M e t a l l i c C o l o r s f r o m 1979 M o d e l s : 265 oak green
215 lind green
30 T light blue
304 minerva blue
316 petrol b l u e
443 copper brown
463 o p a l green
464 tabacco
108 black
936 silver
C o l o r s by S a m p l e :

painting 911 8
R A N G E OF BODY P A I N T C O L O R S - 1 9 8 1 MODELS
Standard Colors: Special Colors:
guards red metallic moss green

alpine white metallic light blue
mint green metallic minerva blue
royal blue metallic pacific blue
mocca black metallic rosewood
bamboo beige metallic platinum
black metallic black
grand prix white metallic wine red
caramel brown melallic pewter

Paint Finish 911 8
Metallic Paint
Wet-on-Wet Process
Until now, two different types of clear enamel with synthetic resin base were used in the course of
repairs:
1. 80° C clear enamel 77 - 84 0503
2. Two-component acryllic clear enamel 51 - 09168
with catalyst 40 - 22004
To simplifi pairiiing process, only the two-component acryllic clear enamel with catalyst will be offered
in the future.
The two-component clear enamel # 51 - 09168 will b e available in 1 liter cans, and the catalyst
# 40 -22004 in 0.125 liter cans. This provides for an easy preparation of the two-component enamel in
the right proportions.
This enamel can be air-dried or baked at 80° C.
Preparation: The spraying consistency is attained upon mixing.

Allow to age 15 - 20 minutes before applying.
Spraying pressure 5 atm
Nozzle size 1.2 mm
Application 1 1/2 - 2 cross-coats
Do not mix more enamel than can be used within a max. of 8 hours
The enamels should not be stored in excess of 1 year.

P A I N T I N G T A R G A ROLL BAR C O V E R
General Information
The Targa roll bar cover (rustproof steel) has a coat of flat black polyurethane textured paint. In addition
to metal parts, polyurethane paint can be used on parts made of fiber glass (Targa removable roo0 and
rigid expanded polyurethane.
Polyurethane paint is extremely scratch and wear resistant. c o l o ~fast and can be air dried.
Required for touch-up painting:
Polyurethane textured paint Part No. 911 096 160 02

Polyurethane hardener Part No. 911 096 220 04
Polyurethane thinner Part No. 911 096 330 03
Procedure:
Clean and degrease new part.

Grind off all textured paint from damaged part, grind out and clean damage spot (s) as required.
Priming Use Dupont 1005 (or equivalent) primer
Initial coat Mix polyurethane textured paint with hardener

Mixing ratio 5 : 1 or I : 2 parts by weight
Spray viscosity 20 to 25 seconds
Spray nozzle 1.5 mm dia ( 30 De Vilbiss or equivalent)
Spray pressure -
3 to 4 bar (45 60 psig)
Application 1 cross pattern
Flash off time 1 5 to 20 minutes in open air
Final coat Spray viscosity 45 to 50 seconds (using pressure gun)

Spray nozzle 1.5 mm dia. ( 30 De Vilbiss or equivalent)
Spray pressure 0.8 to 1.0 bar (12 - 1 5 psig)
Application 1 cross pattern
N o t e : Check texture pattern by spraying a test panel.
0 0
Drying Air drying approx. 1 2 hrs. at 20 C/68 F
Force drying 30 t o 40 min. at 80' ~ / 1 1 F6 ~
Complete hardness is reached in 5 to 7 days.

50 ~ o d yF r o n t s e c t i o n 911 8
S H O P M A T E R I A L S FOR B O D Y R E P A l R S
Hydraulic 10 ton straightener with accessories
Celette straightening bench
Set of attachments ENS 17.360
Universal anchor ENS 937.900
Front end gauge P863+ P 863a
Inert gas welder
Resistance spot welder
Gas welder
Hand grinder with inserts (grinding wheels and stones, steel

brushes, cutters)
Disc grinder
Angle grinder with accessories (180 m m dia. cutting wheels

and grinding paper)
Pneumatic hammer with inserts
Beam compass
Bubble level
Shoulder pliers
Air gun
Equipment and materials for permanent undercoating
for cavity sealing
for sealing

Floor Panel Assembly Dimensions 50

Floor Panel Assembly Dimensions 911 8
I Dimension Location I mm I inch
A Control arm mounts 565.5

t
-1 22 1 / 4 + 1/32
B Auxiliary support 726 11 28 1 / 2 + 1/32
C Front floor o l a t e 1200 12 47 1 / 4 + 1/16
Rear floor plate I 850 +2 1 3 3 1/2: 1/16
E Engine brackets 752 + 1 29 19/32 11/:
F Front floor plate - control arm mount 1327 + 3 52 1 / 4 '!1/8
Rear floor plate - auxiliary support 1 1868 + 3 1 7 3 1 / 2 + 1/8
H Axle tube/transmission mount - front floor plate 1550 13 + 1/8

6 1 1/32
I Axle tube/t~ansmission mount - engine bracket 1323 +5 52 3/32 + 3/11
Rear floor plate - engine bracket 1 1557 +5 1 6 1 5/16 + 3/1(

L Front floor plate - control arm mount 1041 3 41 + 1/8
M Front floor plate - rear floor plate 1215 1 2 47 27/32 + 1/:
N Rear floor plate - engine bracket 1355 !' 3 5 3 11/32 '! 1/1
0 Axle tube/transmission mount - engine bracket 1220

t
- 3 4 8 1/32 + 1/8
All dimensions are measured from center of holes.
Note
Dimensions to engine suspension points are measured diagonally
CAUTION
T h e difference between left and right longitudinal dimensions may not exceed t h e specified tolerances.

8 911 F r o n t ~ o d yE n d 50
F l o o r A s s e m b l y C h e c k p o i n t s a n d F r o n t Body G a u g e s P 8 6 3 a n d 8 6 3 a
As already announced ill the 1975 Model Iniormation, checkpoints a r e welded t o t h e frame/floor
assembly of 1975 models. These checkpoints and front body gauge P 8G3a (consisting of former gauge
P 863 and a n additional adaptor) m a k e it possible t o diagnose t h e d a m a g e quickly.
T h e gauge can also b e applied t o repair slight front end d a m a g e (Dents up t o 1 0 m m ) . It is no longer
necessary t o p l a c e a car with d a m a g e of this type on a n alignment bench.
Installation of this gauge requires removal of t h e wheels, guards, carrier and control arms. As
illustrated, t h e gauge is then bolted t o t h e front a x l e holder points and front floor p l a t e checkpoints.
A surveyor's rod is used t o measure t h e distances back t o t h e floor p l a t e checkpoints and rear a x l e
t u b e holder points for t h e transmission, from t h e engine suspension.
N o t e ! T h e g a u g e is for gauging only. It must b e removed for aligning and welding operations t o
prevent distortion through body stresses.
The auxiliary carrier pin for Type 9 1 1 Turbo is installed 2 1 m m higher. When measuring
with front end gauge P 863 the distance between upper edge of gauge and collar on
auxiliary carrier pin musr be 2 1 m m or, with adapter mounted on auxiliary carrier pin,
1 3 mm.

50 Body F r o n t 911
Replacing Part of Front Wheelhousing
Includes: Lock panel, front tank support and left or right tank support.

ody i i a n l
p- ..--
Includes: Lock panel, front tank support and left or right tank support.

50 Body ,Front 911
/Operation Areas Material

I
1. S e p a r a t i n g Cutting disc
Chiseling Pneumatic chisel

or hand chisel
Remove m e t a l scraps Welding torch,

undercoating and paint hand grinder
and pliers
2. P r e p a r i n g
(new parts)
Cutting and grinding Cutting disc, h a n d
grinder and m e t a l
cutlers
Apply rust prtvi-ntalive Paint
3. \Velrling
Spot weld Spot welder
Butt weld Spot welder
lvlIG welder
hood and fender Gar welder

conucciiun welded flush
4. Finishing
Grinding 1.4,5, 7 l land grinder
Welding seams 1 - 1 5 spots Car or MIC welder

burnt tlimugh
Sealing Inner and oulcr Undercoaiing (asphalt

PVC basis,
Preserving T e c t y l ctc.
(wax basis)

8 911 Body Front 50
1 - D a m a g e Diagnosis
When t h e extent of d a m a g e cannot b e defined exactly.
- Check floor p l a t e assembly.
Includes: Removing and installing front wheels, control arnis, auxiliary support and
protection plate.
2 - Alignment
Before t h e damaged parts a r e cut out, t h e dented portion is as close as possible aligned with
hydraulic alignment equipment.
3 - Preparations
Dismantle front bumper
left front fender
right front fender (loosen partially)
frant hood
lower hood lock and c a b l e
front apron
electrical items as required
4 - Separation of damaged parts
Note: Cut out badly damaged parts instead of unbolting.

R e p l a c i n g P a r t o f l'rolli \VhcelI~ousing
4a - Damaged parts c a n b e separated in any sequence in accordance k i t h Lhc operations

illustrate? below.
4 i. - Remove tenmining scraps oi metal. Align and grind down mating surfaces and flange.
5 - Cut floor p l a t e a t remaining portion of wheelhousing far enough so that t h e lock panel
can b e stuck through (see arrow).

8 911 Body, Front 50
Replacing Part of Front Wlieelhousing
6 - Check a x l e take- up points, aligning if necessary.
7 - Align and cut new parts.

(various cutting lines marked)
S - Bolt front hood.
9 - Install lack panel cutting bottonl lcli and riglit iS necessary.
1 0 - Install wheelhausing panel so that it overlaps c a n n e d o r plate. Saw cuts in hood crease and
fender mating surface and butt weld (Area A).

50 Body F r o n t 911
10 a - If t h e wheelliousing was dented a t t h e rear control arm bolting points and above, extend and
weld t h e new part overlapping t h e dented section. S e e broken line.
11 - Check Lake-up paints.

Body Front
12 - Align and spot weld front tank support.

13 - Align and spot weld l e f t tank support.
- Secure t u b e for hood release cable.
- Insert and spot weld reinforcement p l a t e .
- Weld jack and hardtop roof brackets.
14 - Finishing
Grind down welding seams in Area A. Clean and prime coat a l l other welding seams.
Weld burnt through welding spots. Apply undercoating. Seal seams and joints.

Body F r o n t s e c t i o n 911 8
E C O N O M I C A L REPAIRS W I T H C E L E T T E S T R A I G H T E N I N G BENCH FOR
TYPE 9 1 1 , 9 1 2 AND 9 3 0 TURBO
The attachment set ENS 11.360 was developed for body straightening work. The attachment set consists of
basic equipment, withwhich all important take-up points can be checked. This attachment set also has
attachments for simple repairs. With these parts it is no longer necessary to remove the engine and
transmission for front end body damage or the front axle for rear end body damage.
All mounting points must fit flat on the Celette straightening bench and bolting must b e possible without
stress.
T a k e - u p Points and Bolt S i z e
1. Control arm front

2. Auxiliary carrier front
3. Auxiliary carrier rear
4. Shock absorber top
5. Rear axle cross tube outer
6. Transmission suspension
I . Cross member upper
8. Engine mount
Attachment set ENS 17.360 basic equipment

Body Front S e c t i o n
P R E P A R I N G B O D Y FOR USE O F A T T A C H M E N T S E T
ENS 7 7 . 3 6 0
Remove: Bottom guard

Wheels
Front axle and steering gear assembly
Fuel tank
Rear axle arms and shock absorbers
Torsion bars ,
Engine
Transmission
Damaged body parts and equipment,
as necessary for straightening.
Preparing Celette straightening bench:

Bolting all attachments of set, except
for spring strut dome. Setting scale on
auxiliary carrier take- up ta 0.
Note: Horizontal position of a movable Celette

straightening bench must be checked
with a bubble level.

50 ~ o d y~ r o n ts e c t i o n 911 8
From 1977 models on (adjustable spring strut setting) the shoulder bolts of side rnember/rear axle cross tube
are 4 mm longer on both sides.
For these cars the bores in the take-ups of the attachment set must be enlarged by this amount. For the
previous models these enlarged holes must be adapted by using suitable washers.
Attachment set ENS 11.360 corresponds with version from 1977 models on. For cars up to 1976 models
the supplied washers must be used.

50 Body F r o n t S e c t i o n 911 8
A T T A C H M E N T S E T FOR T Y P E 9 3 0 T U R B O ENS 7 7 . 3 0 3
The illustrated take-up points differ from Type 9 1 1 attachment set and are used for Turbo models,
The auxiliary carrier pin is installed 21 mm higher.
The brackets on the rear axle cross tube are inclined upward.
The take-up point for transmission suspension is located further forward by 25 rnm.
The engine mount for Type 3.0 Turbo up to 1977 models corresponds with Type 911.
The engine mount for Type 3. 3 Turbo from 1978 models on is located further toward rear by 30 mm.

50 ~ o d yF r o n t s e c t i o n 9~ 8
E X T R A A T T A C H M E N T FOR E C O N O M I C A L REPAIR OF F R O N T E N D D A M A G E
With this set of straightening bench attachments it is not necessary to remove

the engine, transmission and rear running gear pars.
Its application requires that the rear end of the body is not damaged.
Remove: Bottom guard

Wheels
Front axle with steering gear
Fuel tank
Bearing (torsion bar) covers
Damaged body parts and equipment for
required for straightening
Preparation of Celette straightening bench: Bolt attachments for front control arms
and auxiliary carrier. Install and bolt
cross member with control pins.

911 Body Front S e c t i o n
Note: Before lowering the body on the straightening

bench the attachments must be secured on the
shoulder bolts.

50 Body Front s e c t i o n 911 8
After bolting down the set of attachments, check t h e central position of the transmission bolts with
the control pins.
Note: The horizontal position of a moving

Celette straightening bench must be
checked with a (bubble) level.

53 Body Rear s e c t i o n 911 8
E X T R A A T T A C H M E N T FOR E C O N O M I C A L R E P A I R S O F BODY REAR
S E C T I O N DAMAGE
With this attachment set i t is not necessary to remove the bottom guard and front axle. Its application
requires that the body front section is not damaged.
For serious body rear section damage, e.g. when the rear axle cross tube has to be replaced, it is not
recommended to use the economical extra attachment without removal of the front axle.
Remove: Engine
Transmission
Rear axle arms and shock absorbers
Bearing caps and torsion bars
Damaged body and equipment parts,
insofar as required for straightening.
Preparing Celette straightening bench: Bolting economical extra attachment.

Removing all other attachments in front
area. Bolting cross member, shock absorber
attachments and engine mount attachment
a t rear.

911 Body R e a r S e c t i o n
Economical extra attachment is bolted on auxiliary carrier pin.
Remove auxiliary carrier bolts and mount adapter with longer bolts supplied.

Body R e a r S e c t i o n 911
Lower body in horizontal position. Set attachment set to 0 on scale and tighten.
Note
The auxiliary carrier pin is installed 21 mm higher on Turbo cars. This deviation must be compensated for
when installing the adapter.

53 ~ o d yR e a r s e c t i o n 911 8
UNlVERSAL ANCHOR ENS 931.900
The mivenalmchor ENS 037.100 illustrated above can be used for additional anchorage a
on the Celerte straightening bench.

Universal anchor mounted on floor flange. Llndercoating should be renioved in this area to provide
greater holding forces.

53 Body R e a r s e c t i o n 911 8
COBRA 3 S T R A I G H T E N E R W I T H A C C E S S O R I E S
This straightener can be permanently anchored on the bench. The pulling direction can be adjusted by
swinging the beam even when anchored.

53 Body, Rear
BODY R E P A I R S - REAR

Body, Rear
Replacing Part of Inner S i d e Member
Includes: Wheelhousing inner and outer rear cross members, left or right engine brackets end plate
and rear fender.

53 Body Rear 911 8
Areas Material
. Separating Cutting disc

Re move m e t a l scraps Welding torch, hand
grinder and oliers
Undercoating and C l e a n and grind down
paint mating surfaces
. Preparing
(new parts)
Aligning, cutting Cutting

. disc, met;a1
and grinding cutters a n d hand grinder
Apply rust Paint

preventative
. Welding
Spot weld 3, 11, 12, 15, 1 6 Spot welder
Butt weld 4, 9, 1 0 Spot welder
Weld 1,2,5,6,7,8,13.14,17 MIG welder
Weld Area 3, top of lid and wheel, Gas welder
housing joint welded flush
. Finirhing
Grinding L 2 , 3,4,5, 6, 7, 8 Hand grinder
Welding seams 1- 1 8 welding spots Gas or MIG welder
burnt through
Sealing A l l surfaces Undercoating
inner and outer (asphalt - PVC basis)
Preserving Cavities T e c t y l etc.

(wax basis)

Body, Rear 53
1 - D a m a g e Diagnosis
2 - Alignment
Before the damaged parts c a n he removed by cutting,align t h e ented section with hydraulic
alignment equipment as well as possible.
3 - Preparation
Dismantle
Engine with transmission
Rear bumper
Left and right bottom fender sections
Left and right vent windows
Lower lid lock
Electrical items as required
4 - Separation of damaged parts
Note Cut out hadly damaged parts instead of unbolting.

Replacing Part of Inner Side Member
4a - Damaged parts can b e separated in any sequence in accordance with tile operaiions
illustrated.
Note Mating surfaces of supporting parts a r e offset t o each other s e e arrows.
5 - Remove remaining scraps of metal. Align and grind down mating surfaces and flange.
6 - Align car in both directions with side members.

Replacing PaIt of Inner S i d e Member
I - Align and weld new parts.
7a - Install side member with about 2 c m (4 inches) overlap. Align, Check engine compartment
i n longitudinal and diagonal direclion. Weld side member.
I b - Align and weld inner cross member. Install engine bracket suspension. Align and spot weld.

Body, Rear
Replacing Part of Inner Side Member
I c - Align wheelhousing panel, cut and weld with about 2 c m (4inches) overlap. Butt weld in
area of lid recess. Align wheelhousing panel with contour of lid.
Various marked cutting lines (broken lines).

8 911 Body. Rear 53
R e p l a c i n g P a r t of I n n e r S i d e M e m b e r
8 - Align and butt weld outer section of cross member at center cutting point. Spot weld
top and bottom of inner cross member section.
9 - Install and weld impact absorber holder.

- Weld impact absorber holder reinforcement t o cross member.
- Braze tube for lid release cable.

- Spot weld engine seal rails.
10 - Install and spot weld rear panel.

53 Body, Rear 911
R e p l a c i n g Part of I n n e r S i d e M e m b e r
11 - Align and cut rear fender.

- Cut along cutting l i n e t o wheel opening.
- Cut along cutting line from lid opening t o vent window so that it overlaps. Crimp new
part using crimping pliers.
- Shorten crimped sufaces t a an overlap of about 3 m m (1/8 inch).
11 a - C l a m p and tack weld fender. Watch lid joint.
11 b - Spot weld rain molding in lid opening. Gas weld s e a m t o wheel opening. MIG weld
overlap and align fender.
12 - Finishing: Weld burnt through welding spots. C l e a n welding seams and prime, apply
body solder if necessary. Seal seams and joints. Apply undercoating.

Elektrische Anlage
Electrical System
Installation electrique
lmpianto elettrico

ELEcTRlcAL SYSTEM 911 9
CONTENTS
0.1 Description
Ignition distributor, current flow diagram
Wiring diagram
Current flow diagram
Relays and fuses
Lighting
Alternator - 1975 model
Ignition system modifications - 1978 model
0.2 Technical data
Starter
1 - GENERATOR. VOLTAGE REGULATOR
2 - STARTER
2.1 Description
2.2 Disassembling and assembling
Spiral-drive starter BOSCH GB 1 2 V 1 . 5 HP
2. 3 Removing and installing
3 - LIGHTlNG EQUIPMENT
3.1 Description
3.2 Headlights
Headlights (sealed b e a m ) , replacing
Headlights, adjusting
3.3 Fog lamps and fog/tail l a m p
Subsequent installation - 1974 model

9 911 ELECTRICAL SYSTEM
4 - WINDSHIELD WlPER AND WASHER SYSTEM
4.1 Description
4.2 Disassembling and assembling
Adjustment instruction
Removing and installing
4.4 Water reservoir for windshield wiper switch
4.5 Intermittent windshield washer system
5 - INSTRUMENTS AND CONTROL SYSTEM
5.2 Emission controls
Exhaust gas recirculation control
5.3 Speedometer
Speedometer c a b l e , removing and installing
Electronic speedometer
6 - ELECTRICAL ACCESSORlES
6.1 Description
Safety belt warning system

Control illumination
Headlight washer
6.2 Safety belt warning system

Troubleshooting
6.3 Control illumination
Bulbs, replacing
6.4 Headlight washers

Adjusting specifications
Service installation

ELECTRICAL SYSTEM 911 9
6.5 Automatic heating control

Troubleshooting
Disassembling and assembling
6.6 Automatic speed control

Troubleshooting
Removing and installing automatic antenna
911 Alarm system
7 - WIRING HARNESS
8 - BATTERY
8.2 Battery - 1974 model
9 - IGNITION
9.1 Description
9.2 Spark plugs, ignition leads, connectors
spark plug chart

Equipment tables - 1980 model
Ignition leads
9.3 Ignition distributor

Adjusting
Testing instructions
Ignition timing, adjusting - 1977 model
Ignition timing curves - 1978 model
Ignition timing, adjusting - 1980 model
Ignition retard/advance, checking - 1980 model
Adjusting ignition timing from 1981. r..odels
Checking ignition timing control from 1981 models

Ignition Description 911 9
I G N I T I O N D I S T R I B U T O R FOR 2 . 4 L I T E R E N G I N E S -
BEGINNING W I T H 1 9 7 2 MODELS
General Information
Beginning with the 1972-model year, all Type 911 vehicles are equipped with either BOSCH or
MARELLI distributors described below.
In the new distributors. engine timing is changed by:
1 - Centrifugal weights (responding to engine speed)

2 - Vacuum control (responding to throttle valve position)
Speed limiters (engine governors) continue to b e used in the distributors. A cenhiiugal weight built into
the rotor of each distributor short-circuits the secondary side of the ignition system at a predetermined
cut-off speed. This prevents exceeding maximum engine speed. T h e distributors for the Type 911 T, E
and S 2.4 liter engines are identical with the exception of the rotors which have different cut-off
speeds.

9 911 Ignition Description
The vacuum control unit retards the ignition timing during idle and low speed ranges. T h e ignition
then fires 5O ATDC. This results in cleaner combustion, reducing the emission of harmful exhaust
pollutants. When the throttle opens, vacuum is reduced and the ignition timing is advanced by l o 0 .
Vehicle Type BOSCH Distributor MARELLI Distributor
Beginning with 1913 models, all BOSCH distributors used in Type 911 T . E and S vehicles are equipped
with a modified rotor. The new rotor can be installed in distributors used in 1912 model vehicles provi-
ding that t h e old dust cover is replaced with one of the new version.
NEW OLD
With this modification, BOSCH distributors are assigned a new part number.

Ignition Description 911 9
I G N I T I O N D I S T R I B U T O R FOR 2 . 7 LITER E N G I N E S
Beginning with 1974 models. Type 911 (2.7 liter) and 911 S (2.7 liter) engines are equipped with the
BOSCH or MARELLI distributors formerly used in the Type 911 T (2.4 liter) engines. Ignition timing
spark advance characteristics, and test specifications applicable to the 2.4 liter engine are also
continued.
The cutoff speed in both engine types is 6500 200 ipm.
The BOSCH or MARELLI distributors used in the 2.7 liter CARRERA engines differ from the above
described distributors due to a different spark advance characteristic.
Ignition timing a t idle is on TDC. Upon opening of the throttle valve, the drop in manifold negative
pressure (vacuum) results in the ignition point advancing by 10' crankshaft rotation.
The CARRBRA cutoff speed is 7300 rpm.
The distributor used in the 1973 model 2.7 CARRERA engines remains in use in 1974 model
engines as well.
DISTRIBUTOR - 1 9 7 6 MODEL
The distributor advance curves on pages 9.3 - 2/1, 9.3 - 2/3 and 9.3 - 2/4 also apply to the
1976 model 911 S.
The cutoff speeds of the speed limiter are for
911 S 6500 + 200 rpm

Description - C u r r e n t Flow D i a g r a m
911 9
How t o r e a d c u r r e n t f l o w d i a g r a m s
In previous wiring diagrams electrical components were shown in the approximate position as you would
find them on the car. However, to show the electrical connections between each component in the dia-
gram became more and more difficult as the number of components increased. The result was that it
was hard to trace electrical circuits.
To make reading wiring diagrams easier, we revised them completely. The result of intensive studies
is a new diagram called "current flow diagram".
Current flow diagrams are laid out by placing circuits of related components one next to the other. The
base of each circuit always starts with ground. The location of componerks on this diagram is no longer
related to where the components would be in the car. The layout of the circuits. however, is such that
each can be followed much easier to help in troubleshooting of electrical faults.
Looking at a current flow diagram you will find a yellow base line. The numbers in the yellow base line
characterize the current tracks in the diagram and are to locate each component that is listed in the
legend.
9.
The colored lines in the diagram represent wires in the car, the colors correspond w h the actual colors
of the wires. The small numbers in the wiring runs indicate the wiring gauge in mm The thin black
lines are not actual wires but internal connections, such as the ground connection of a lamp housing.
The base line for ground is the thin black line directly on top of the yellow base line.
Interrupted wires or connections end in a yellow square. Continuation of this interrupted circuit can be
found in the current track using the number in the square.
Each component in the diagram is iderkified with a letter, sometimes with a letter and a number. Com-
ponent definition can be found in the legend.

9 911 Description - Current Flow D i a g r a m
Most connectors or terminals are numbered. These numbers correspond with the numbers that are right
next to most connectors on electrical components, such as switches and relays. This numbering system
u used on most European cars. Listed below are the most commonly used terminals and their location.
T e r m i n a l No. Location
on coil, input from ignition switch

on relay and generator
on relay and generator
on coil, output to primary distributor lead
on coil, high temion output and on distributor high tension lead
on coil, input from ignition switch
on starter solenoid, input from battery, ignition starter switch, light switch,
dimmer relay, and twin horn relay
ground
windshield wiper switch and motor
on turn signal bulbs
-
on both terminals of starter solenoid ignition starter switch
on stoplight bulbs, steering ignition switch and windshield wiper switch
windshield wiper switch and motor
light switch and dimmer relay
dimmer relay, headlight low beam
headlight high beam
on taillight bulbs, light switch and front parking lights
light switch
relay

Description - Current Flow Diagram
911 9
Electrical Symbols
Antenna
Dipole antenna
Heating resistor (element)
Direct current
Danger1 High Voltage
Alternating current
Three-phase current Spark gap
Generator Condenser
Feedthrough (suppressor)
Battery cell condenser
Motor Coil. iron core
Measuring gauge
Transformer. iron core
Voltmeter
Diode
Zener diode
Transistor
Wiring
Thyristor
Wire crass section in mm'
Mechanical connection
Wire junction, fixed of components
Mechanical connection,
Wire connector, separable spring loaded contact
Time switch
Wire junction, separable
Suppression wire Manually operated switch
Wire crossing
Mechanically operated switch
Ground
Motor operated switch
Switch position, open
Relav coil
Switch position, closed
Solenoid coil
Multiple contact switch
Relay, electrothermal
Fuse
Light bulb Relay, electromagnetic
Glow lamp
Electromagnetic valve (jet)
Resistor
Boundary line for an assembly
Potentiometer
Horn
Tapped resistor
Loudspeaker
Thermal resistor,
automatically regulating
Electric wiring diagram (Part I) Type 911 T, 911 E, 911 S, Model 72
1 Battery 33 Emergency flasher switch FUSES:

(not applicable in Italy and France)
17 Headlights Fuse box I:
36 Door contact switch
18 Turn signal, parking and side marker 1 Interlor light, clock, luggage
iights 37 S w t c h for luggage compartment light
compartment light
(side marker lights U S A only) 39 Stop light switch
2 Emergency flasher
19 Tail, stop, turn, back-up and side 41 Back-up light switch
7 Fresh air fan
marker lights 42 Switch for glove compartment light 8 Stop, turn and b a c k ~ u plights
(srde marker lights U S A only) 48 Turn signallemergency flasher unit
9 Left front turn signal iight
20 Fog i g h t s (optional) 50 Headlight relay
1 0 Right front turn signal iight
21 License piate light 67 Tachometer
22 Luggage compartment light 68 Speedometer Fuse box II:
69 Electric clock 1 Hlgh beam, left
23 Interior light
78 Fuse box l ( 1 0 terminal) 2 High beam, right
24 Glove compartment light
79 Fuse box 1 1 (8 terminal) 3 Low beam. left
25 Ashtray light
84 Multi-connector (14 terminal) 4 Low beam, right
30 Flasher, d~mrner.wiper/washer switch 5 Side marker, left CAUTION!
with horn ring on steering column 85 Muitbconnector (6 terminal)
87 Connector (single contact) 6 Side marker, right Do not disconnect battery while the
31 Ignition starter switch and steering engine is running as this will damage
89 Ground connection~body 7 License plate light
lock
8 (Fog lights) the alternator.
32 Light switch 93 Rear fog light (optional)

Electric wiring diagram (Part Ill Type 911 T, 911 E, 911 S, Model 72
I @
43 Safety belt contact, driver side 77 Cigarette lighter FUSES:

1 Battery
(USA only) 78 Fuse box l ( 1 0 terminal) Fuse box I:
2 Starter
44 Safety belt contact, passenger side 80 Fuse ban 111 (3 terminal) 1 Interior light, clock, luggage
3 Alternator
(USA only) 81 Fan motor compartment light
4 Governor
45 Buzzer contact (USA only) 82 Rear window defogger eiemellt 2 Emergency flasher
5 Distributor
46 Seat contact, passenger side 84 Multi-connector (14 terminal) 3 (Electric windows)
6 Ignition transformer (USA only) 85 Multi-connector (6 terminal) 4 Cigarette lighter
7 Spark plugs 49 Horn relay 86 Multi-connector (4 terminal) 5 (Slidlng roof)
8 Fuel pump 51 Rear window defogger relay 87 Connector (single contact) 6 Windshield wiper, washer pump
9 High tension ignition rlnit
52 Auniljary starting relay 89 Ground connection-body 7 Fresh air fan
1 1 Speed switch (except 91 1 TV)
90 Optional horn 8 Stop, turn and back-up lights
12 Cold start solenoid (except 911 TV) 53 Buzzer (USA only)
92 A u x i l a r y combustion heater (optional) 9 Left front turn signal light
13 Shut-off solenoid (91 1 TV: solenoid 56 Oil temperature indicator
valve) 94 R a d ~ o(aptionall 10 Right front turn signal light
57 O i l pressure indicator
14 Thermo~timeswitch (except 91 1 TV) 95 O i l temperature switch sportomatic
58 O i l level indcator (ootional) Fuse box Ill:
15 Micro swltch
59 Indicator far fuel gauge 1 (Spartomatic)
30 Flasher, dimmer, wiperlwashor switch
60 Safety belt warning light (USA orilyl 2 Shut-off solenold, s o l e n o d valve.
with horn ring on steering column
65 Fuel gauge dial solenoid for cold starting unit
31 Ignition starter switch and steering
66 011 temperature gauge dial 3 Rear window defogger
lock
34 Switch far fan and auxiiary heater 69 Electric clock CAUTION!
35 Rear window defogger swttch 73 Wiper motor Do not disconnect battery while the
38 Parking brake contact 74 Washer pump engine is running as this will damage the
alternator.
40 Brake warning light switch (USA only) 75 Horns

Electric wiring diagram (Part I) Type 911 T, 911 E, 911 S, Carrera 2.7, Model 73
1 Battery 33 Emergency flasher swltch FUSES:

I 7 Headlights (not a p p c a b l e n Italy and France]
18 Turn s ~ g n a l p
. a r k n g and s d e marker 36 Door contact switch
hghts 37 S w ~ t c hfor luggage compartment light
( s d e marker hghts U S A only) 39 Stop lrght s w t c h
I 9 Tall. stop, turn, b a c k ~ u pand s d e 41 B a c k ~ u phght s w t c h
marker hghts
( s d e marker hghts USA only) 42 Swltch for glove compartment llght
20 Fag lights (opttonal) 48 Turn signaliemergency flasher u n :
21 License p a t e light 50 Headl~ghtrelay

22 Luggage compartment light 67 Tachometer
68 Speedometer
23 Interior l g h t Fuse box 11:
G8 Electrlc clock
24 Glove compartment hght
78 Fuse box ( 1 0 termndl) 1 i h g h beam, lelt
25 Ashtray hght 2 l i l g h beam, right
78 Fuse box I ( 8 termnal)
26 l l l u m ~ n a t ~ ofar
n h e a t ~ n glever 3 Law beam, c f t
84 Multbcmnectar (14 termnal)
( U S A only)
85 Ivluitbconnector (6 termnal) 4 Low beam. ~ l g h t
30 Flasher, ri~mmer,w p d w a s h e r s w t c l l CAUTION!
with horn r n g on steermg column 87 Connector (sngle c o n t a c t ] 5 S d e mdrker, left
31 l g n i m n starter s w t c h and s t e e r n y 89 Ground cannect~an-body i, Side marker, r g l ~ t
lock 93 Rear fog llght (opt~onal) i L ~ c e n s ep a l e g l ~ l
32 Light swltch 96 Resistor ( U S A only1 !: [Fog l ~ g l \ t s l

Electric wiring diagram (Part Ill Type 911 T, 911 E, 911 S, Carrera 2.7, Model 73
77 Cigarette lighter FUSES:

i Battery 43 Safety belt contact, driver side
(USA only) 78 Fuse box l ( l 0 terminal) Fuse box I:
2 Starter
44 Safety belt contact, passenger side 80 Fuse box 111 (3 terminal) 1 Interior light, clock, luggage
3 Alternator
(USA only) 81 Fan motor compartment light
4 Governor
45 Buzzer contact (USA only) 82 Rear window defogger element 2 Emergency flasher
5 Distributor
46 Seat contact, passenger side 83 Sportomatic (optional) 3 (Electric windows)
6 Ignition transformer (USA only) 84 Muti-connector (14 terminal) 4 Cigarette lighter
7 Spark plugs 49 Horn relay 85 Multi-connector (6 terminal) 5 ( S l ~ d ~ nroof)
g
8 Fuel pump 51 Rear window defogger relay 86 Multbconnector (4 terminal) 6 Windshield wiper. washer Pump
9 High tension ignition unit
52 Aux~llarystarting relay 87 Connector (single contact) 7 Fresh air fan
11 Speed switch (except 91 1 TV)
89 Ground conncction-body 8 Stop, turn and b a c k ~ u plights
12 C o l d start solenoid (except 911 TV) 53 Buzzer (USA only)
90 Optional horn 9 Left front turn signal light
13 Shut-off solenoid (91 1 TV: solenoid 56 O i l temperature indicator
valve) 92 A u x l i a r y combustion heater (optional) 10 Right front t u r n signal light
57 O i l pressure indicator
14 Thermo-time switch (except 91 1 TV) 94 R a d o (optionail
58 O i l level indicator Fuse box Ill:
15 M ~ c r oswitch 1 (Sportornatic)
59 Indicator for fuel gauge
30 Flasher, dimmer. wiperlwasher swltch 2 S h u t ~ o f fsolenoid, solenoid v s v e .
60 Safety b e t warning light (USA allly)
with horn ring on steering column solenoid for cold starting unlt
31 Ignition starter switch and steering 65 Fuel gauge dial
3 Rear window defogger
lock 66 O i l temperature gauge d ~ a l
34 Switch for fan and auxiliary heater 69 Electric clock CAUTION!
35 Rear window defogger switch 73 Wiper motor Do not disconnect battery while the
74 Washer pump engine is running as this will damage the
38 Parking brake contact
alternator.

Additional wiring diagram front and rear fog lights, Type 911
1 Fuse b o x I 6 ~ u l t i - c o n n e c t o I6
r terminal1
2 Fuse b o x l l 7 Ground connection-body
3 Fog lights 8 Connector (double contact)
4 Fog lights switch 9 Rear fog light
5 Relay 10 Ground connection ic~garettelighter)

Additional wiring diagram electric window opener, Type 911
1 Fuse b o x I 6 Switch f o r passenger side, right

2 Motor, drivei side 7 Ground connection. left
3 Motor, passenger side 8 Ground connection, r g h t
4 Switch f o r passenger side, left 9 Terminal s t i ~ p
5 Switch for driver side 10 Connector

Electric wiring diagram (Part I) Type 911 T with CIS, Model 73
33 Emergency flasher switch FUSES:

1 Battery
(not applicable in Italy and France)
17 Headlights Fuse box I:
36 Door contact switch
18 Turn signal, parking and side marker 1 Interior light, clock, luggage
lights 37 Switch far luggage compartment light compartment light
(side marker lights USA only) 39 Stop light switch 2 Emergency flasher
19 Tail, stop, turn, back-up and side 41 Back-up light switch 7 Fresh air fan
marker iights 42 Switch for glove compartment llght 8 Stop, turn and back-up lights
(side marker lights U S A only)
48 Turn signal/emergency flasher unit 9 Left front turn signal light
20 Fog hghts (optional) 10 Right front turn signal llght
50 Headlight relay
21 License plate light
67 Tachometer
22 Luggage compartment light
68 Speedometer
23 Interior light
69 Electric clock Fuse box II:
24 Glove compartment light
78 Fuse box l ( l 0 terminal) 1 High beam, left
25 Ashtray light
79 Fuse box 1 1 (8 terminal) 2 High beam, right
26 Illumination far heating lever
84 Multi-connector (14 terminal) 3 Low beam, left
(USA only)
85 Multi-connector (6 terminal) 4 Low beam, right
30 Flasher, d ~ m m e rwtperlwasher
, switch CAUTION!
with horn rincl on steertnq column 87 Connector (single contact) 5 Side marker, lett
89 Ground connection-body 6 Side marker. right D o not disconnect battery while the
31 Igntt~onstarter swftch and steerlng engine is running as this will damage
93 Rear fog light (optional) 7 License plate light
lock
8 (Fog lights) the alternator.
32 Light switch 96 Resistor (USA only1

Electric wiring diagram (Part II) Type 911 T with CIS, Model 73
43 Safety belt contact, driver side 77 Cigarette lighter FUSES:

1 Battery
(USA only) 78 Fuse box 1 110 terminal) Fuse box I:
2 Starter
44 Safety belt contact, passenger side 80 Fuse box 111 (3 terminal) 1 Interior light, clock, luggage
3 Alternator (USA only) compartment light
81 Fan motor
4 Governor 45 Buzzer contact (USA only) 2 Emergency flasher
82 Rear window defogger element
5 Distributor 46 Seat contact, passenger side 3 (Electric windows)
83 Sportomatic (optional)
6 Ignition transformer (USA only) 4 Cigarette lighter
84 Multi-connector (14 terminal)
7 Spark plugs 49 Horn relay 5 (Sliding roof)
8 Fuel pump 51 Rear window defogger relay 6 Windshield wiper, washer pump
9 High tension ignition unit 53 Buzzer (USA only) 7 Fresh air fan
87 Connector (single contact)
12 Cold start solenoid 56 Oil temperature indicator 8 Stop, turn and back-up lights
88 Gear lever contact SPM (optional)
13 Control pressure regulating valve 57 Oil pressure indicator (optional) 9 Left front turn signal light
58 Oil level indicator (optional) 89 Ground conneclion-body
with warm-up compensation 10 Right front turn signal light
59 Indicator for fuel gauge 90 Optional horn
14 Micro switch Fuse box Ill:
60 Safety belt warning light (USA only) 92 Auxiliary combustion heater (optional)
30 Flasher, dimmer. wiperlwasher switch 1 (Sportomatic)
with horn ring on steering column 65 Fuel gauge dial 94 Radio (optional) 2
31 Ignition starter switch and steering lock 66 Oil temperature gauge dial 3 Rear window defogger
34 Switch for fan and auxiliary heater 69 Electric clock CAUTION!
35 Rear window defogger switch 73 Wiper motor Do not disconnect ballery while the
38 Parking brake contact 74 Washer pump engine is running as this will damage the
alternator.

S U P P L E M E N T T O E L E C T R I C WIRING DIAGRAM
T Y P E 9 1 1 T W I T H C O N T I N U O U S I N J E C T I O N S Y S T E M ( C I S ) . 1 9 7 3 MODEL
-
Wiring in the area of fuse box 111 shown on page 0.1 2/15 differs in Type 911 T vehicles equipped with
the Continuous Injection System (CIS) due to the Utilization of differing components. The resulting
changes in the wiring diagram can b e seen in the circuit schematic shown below.
The red/white wire originally connected to fuse No. 2 now is connected to terminal No. 87 of the newly
added solenoid switch. The red/white wire currently attached to fuse No. 2 has no function in CIS-
equipped vehicles even though it continues to b e installed for production reasons.
T h e added solenoid switch is installed in the same place where the cold start enrichment solenoid
normally is located in vehicles equipped with the mechanical fuel injection system.
This wiring circuit ensures that the warm-up regulator does not come into action until electric current is
produced by the alternator, that is, only when the engine actually is running. This system prevents
preparation of an overly lean starting fuel/air mixture if a longer time lag should occur between the time
the ignition is switched on and the engine started.
1 Solenoid switch 13 Warm-up regulator

2 To voltage regulator, terminal D- (ground) 80 Fuse box 111
3 TO voltage regulator, terminal B / 6 1 84 14-pole connector, connector N O . 10

Micro w i t c h
Head lights
T u r n ribma1 and par1ang llghti
Tail, stop, turn, b a d - u p and side tmar1,cr :ights
Glove camparimen,
Ashiray h g h t
Sidr marker linhl
Windsilield wiper/warher switch
tiaihcr/dimmer rwilch
Horn hlliion
ignitioll i f a r k ? rwitcil and steering lock
Light %Witch
Emergency flasher switch
Switch far fan and auxiliaiy heaicr
Reai window defogger rwitcll
Door cantact rwrtch
Switch far luggagc compartment light
Switch far glove c o m p a r t n l r n t light
Parking bralie contact
s t o p light switch
Back-up light iwitcil
make warning light switch
T u m dgnallemergency flasher unit
urn relay
lieadlight relay
Rear window defogger relay
Relay far cuntro1 p r e i i w e reglllatlng valve
Oil temperature indicator
60 Oil pressure switch
61 Oil lewd indicator
62 indicator lor fuel gauge
63 Oil orenure indicator
6s rue1 gauge dial
67 011 te8nperature gauge dial
88 Tachometer
69 Speedometer
70 Electric clocl,
w
washer
i p e r lmotoi
pump
76
77
78 llorni
79 ciearette iiehfer
82 i u r e box 111 ( 3 terminal)

83 Fan motor
84 Reai window defuggcr e l e m e n t
85 G e a r l e v e r contact SPM (optional)
R6 Cunrlrcfoi SPM (double)
87 Multi-connector (14 tcrmlnal)
88 Multi-connecloi ( 6 terminal)
as ~ ~ ~ t i - ( 4~ terminal)
o ~ ~ n ~ ~ t ~ ~
90 Ground connection - bady

- -.
A D D l T l O N A L W I R I N G D I A G R A M , S E A T BELT W A R N I N G S Y S T E M
T Y P E 9 1 1 , 911S, M O D E L 7 4 - USA
r Door contact switch
r No 43 C a b l e /
g brake/brake warnir~g indicator light
Alternator charge indicator light
,--Seat belt warning light
/ / Oil pressure indicator light ,- Door contact switch
Oil pressure switch
No 9 1 C a b l e
Oil pressure gauge +
Ignition/starter switch 15
Turn signal/emergency flasher unit 49a

Brake warning light switch - p~
~-
No 2 C a b l e -
=-I Parking brake contacl

Seat belt warning system relay
Y
Interior light
Luggage and glove cornparlment lights
Ignition/starter switch 50-
" <
Starter 50 --I-<- t- to governor D+/61
Fresh air blower switch
i
i
Seat contact, driver side Safety belt contact passenger side
LSafety belt contact, driver side

--
,Temperature
- ,
Ashtray light
control lever- ,
illumination bulb
i; Seat contact passenger side
...,
-No 1 Cable
911 613.031 00
_______\_ -911.803.183.01

9 Current flow diagram. Type 911 USA. Model 74
Description Current track
E' - Headlight switch

E2 - Turn signal sw,lch
E3 - Emergency flasher swltch
E L Dimmer switch
E5 - H e a d g h t flasher switch
El9 - Parking light s w t c h
EZD- Instrument panel l i u m n a t l o n potentiometer
EZ6 - S w t c h for glove compartment light
F - Stop light swllch
F2 - Left door s w t c h
F3 - Right door switch
F I - B a c k ~ u phght switch
F5 - Switch for luggage compartment light
F6 - Brake warning switch
FP - Parking brake s w t c h
H - Horn switch
H z - Horns
H L Key warning buzzer contact
J1 - Hazard, turn signal flasher
J 4 - Horn relay
JZ5 - Headlight relay
Jn - Diode for seal belt warning system
K ' - High beam indicator I g h t
K 4 - P a r k n g lights indicator iight
K5 - Turn signal n d i c a t o r light
K C Hazard flasher Indicator light
K 7 - Parkina -
" brake brake warnino indicator iioht
L' - Sealed beam unlt ieft h e a d l o h t
L2 - Sealed beam unlt, right headlight
L6 - Speedometer ~ i i ~ m l n a t i oI gnh t
L' - Fuel gauge illuminatlon light
LB - Clock l l u m i n a t ~ o nlight
L I L Ashtray illumination light
L I b - Heater controi assembly l l u r n i n a t o n light
Lu - Temperature control lever i l l u m i n a t o n light
L 2 * - Oil temperature i n d c a t o r 8llumination light
LZ6 - Tachometer iliuminatlon I g h t
L2' - Oil pressure indicator illuminatlon light
M' - R ~ g hslopt / rear light
M4 - Left stop I rear light
M5 - Left front turn slgnal parking light
M6 - Left rear turn signal
M' - Right front turn Slgnai r p a r k n g iight
M B - Right rear turn slgnal
M I 1 - Frontside marker I g h t
MI2 - Rear side marker I g h t
MI6 - Left back-up light
M I 7 - Right back-up bght
Nb - Resistor
S2
to - Fuses
S" on the
fuse box
Ti - Cable conneclor, single
a - near regulator panel
b - behind seaied beam unit, left
c - behlnd sealed beam unit, right
d - behind fuse box
e - o nluggage compartment floor
f b e h i n d instrument panel
h - near iett rear lights
T" Cable connector, sixfold
- in the engine compartment, rear left
a
b - in the engine compartment, rear right
d - below instrument panel
e - below instrument panel
g - below Instrument panel
h - below instrument panel
TI" Cable connector, fourteenfoid
a - on regulator panel, front
b - on regulator panel. rear
W - Interior light
W3 - Luggage compartment ilght
W" Glove compartment iight
X - License plate light
Y - Ciock
Printed in Germany XXIX, 1974

Current flow diagram, Type 911 USA, Model 74 9

Current flow diagram, Type 911 USA, Model 74
Current track
9
-
A - Battery
S - Starter
C - Generator
C2 - Voltage regulator
D - lgnIt8on starter switch
E - W ~ n d s h e l dwiper s w t c h
EP - Fresh a r blower s w t c h
E l 5 - Rear wlndow defogger s w t c h
EZ4 - Left seat belt s w t c h
EZi - Right seat belt switch
E l ' - Left seat sensor switch
El2 - Right Seat ScnSOr switch
F1 - Oil pressure switch
G - Fuel sender unlt
G ' - Fuel gauge
G5 - Tachometer
Gb - Fuel pump
Go - 011 temperature sender unit
G 9 - Oil temperature i n d c a t o r
G I o - Oil pressure sender unit
G I 1 - Oil pressure i n d c a t o r
GI2 - Oli level sender unit
G'" 011e v e gauge
JP - Rear window defogger relay
J34 - Seat belt warning system relay with
integrated buzzer
K2 - Generator charge indicator light
K3 - 081 pressure n d c a t o r light
KO - Blower indicator g h t
Klo - Rear window detogger indicator light
K I 6 - L o w f u e l warnlng light
K w - Seat belt w a r n n g light
N - l g n i t o n transformer
N15 - High tensmn g n t i o n onit
0 - Dlstrbutor
P - Spark plug connector
S'? - Spark
Q Fuses plug
to - a n the
SI5 fusc box
SZ2- Fuses on the
S2" rear fuse box (regulator panel]
TI - Cable connector, s n g e
d - behind fuse box
e - a n luggage compartment floor
t b e h i n d Instrument panel
g - below shitt lever housing
T I - Cabie connector, douple
a - below regulator panel
b - in engine compartment, left
c n e a r e f t seat
d - below left seat
e n e a r left seat
t - near r g h t seat
g - below r g h t seat
h - near right seat
T b - Cabie connector, s x t o l d
b - in e n g n e compartment, right
c - b e l o w instrument panel
i - below instrument panel
h b e l o w instrument panel
T I d - Cable connector, fourteentold
a-- on reguiator panel, front
b - o n regulator panel, rear
U' - Cigar lighter

v - W n d s h i e d w p e r motor
V2 - Bower motor
Washcr
VL pump
Zl - Rear window defogger
Printed in Germany
XXIX, 1974 53b 53 53e 53e 1%

Additional current flow diagram CIS-injection
engine, Type 911, Model 74 9
F25 - Throttle valve switch

F26 - Thermo-switch for cold start valve
115 - Relay forwarnl-up regulator
N9 - Warm-up regulator
N" - Cold start d v e
523 - Fuse on the rear fuse box
T14b - Cable connector, fourteenfold
on regulator panel, rear

and Sportomatic, Type 911, Model 74
B - Starter
C - Generator
D - to ignition / starter switch
E" - Starter cutout switch (bypass switch)
E2' - Selector lever contact
F4 - Back-up light switch
F'3 - Oil temperature switch
FZ5 - Throttle valve switch (micro switch)
FZ6 - Thermo-switch for cold start valve
1'' - Relay for warm-up regulator
Kq - Oil temperature indicator light
MI6 - Left back-up light
M" - Right back-up light
N' - Control valve
Nq - Warm-up regulator
N17 - Cold start valve
S" - Fuse on the fuse box
SZ2 - Fuse on the rear fuse box (regulator panel)
S2' - Fuse on the rear fuse box (regulator panel)
T2 - Cable connector, double, below regulator panel
Tb - Cable connector, sixfold
a - in engine compartment, rear left
b - in engine compartment, rear right
T" - Cable connector, fourteenfold
a - on regulator panel, front
b - on regulator panel, rear
Printed in Germany - XXXI. 1974
--

and Sportomatic, Type 911, Model 74 9

Additional current flow diagram
automatic heating system, Type 911
D - to ignitionjstarter switch 6
El3 - Control unit for automatic
heating system 4.5
E2' - Instrument panel illumination
potentiometer 1
L6 - Speedometer illumination light 3
N" - Interior temperature sensor 5
N" - Exterior temperature sensor 4
S" - Fuses in the 4
SI2 - fuse box 5
TIe - Cable connector, single,
on luggage compartment floor 2

Current flow diagram, Type 911 USA, Model 75 9

Current flow diagram, Type 911 USA, Model 75 d
A - Battery
B - Generator
C Starter
C 2 -Voltage regulator
D - Ignition / starter switch
E - Windshield wiper switch
E9 - Fresh air blower switch
El5 - Rear window defogger switch
E" - Left seat belt switch
EZ5 - Right seat belt switch
E3' - Left seat sensor switch
El2 - Right seat sensor switch
F' - O i l pressure swttch
-
FZ6- Throttle
Fz5 Thermo-switch
valve switch
for cold start valve
G - Fuel sender unit

G' - Fuel gauge
G" -Tachometer
G6 -Fuel pump
GB -Oil temperature sender unit
G9 -Oil temperature indicator
GIo - Oil pressure sender unit
- 011 pressure
GI2 -Oil
G" level sender
indicator
unit
GI3 - Oil level gauge

J9 - R e a rwindow defogger relay
J I 4 - Relav for heater blower
1" -Relay for warm-up regulator
-Seat belt warning system relay with
integrated buzzer
K 2 - Generator charge indicator light
K 3 -Oil pressure indicator light
KB - Blower indicator light
K'O - Rear window defogger indicator light
KI6 -Low fuel warning light
K" -Seat belt warning light
N -Ignition transformer
NP - Warm-up regulator
N ' L High tension ignition unit
N" - Coldstart valve
0 - Distributor
P - Spark plug connector
Q - Spark plug
S" Fuses
to - on the
S15 fuse box
9 2 -Fuses on the
F- i -rear fuse box (regulator panel)
T' - Cable connector. single
d - behlnd fuse box
e - on luggage compartment fioor
f - behind instrument panel
g -
below shift lever housing
- below
T2 - aCable connector.
regulator
doubie
panel

r - near left seat
d -below left seat
e - near left seat
f - n e a r right seat
g -below right seat
h - near right seat
T6 - Cable connector, sixfold
b - in engine compartment, right
c - below instrument panel
f - below instrument panel
TI4 - Cable connector. fourteenfold
an regulator panel
U' - C ~ g a rhghter
V - Windshield wiper motor
V 2 - Blower motor
V L Heater blower
V5 - Washer pump
Z' - Rear window defogger

Current flow diagram, Type 911 USA, Model 75

Additional current flow diagram California,
Type 911, Model 75
F2'- Mileage counter switch (EGR)

Gv - Oil temperature indicator
K2' - EGR warning light
L7 - Fuel gauge illumination light
L2' - Oil temperature indicator
illumination light
L2' - Oil pressure indicator
illumination light

intermittent wiper operation, Type 911
Description
D
E
- to ignitionlstatter switch
- Windshield wiper switch
Current track
L
E3' - Potentiometer for intermittent
wiper operation
1'' - Relay for intermittent wiper
Operation
S i 3- Fuses in the
S" - fuse box
T' - Cable connector, single,
on luggage compartment floor
Tbc - Cable connector, sixfold.
below instrument panel

headlight washers, Type 911
A - to battery
D - to ignitionlstarter switch
E' - leadlight switch
E' - Dimmer switch
E3' - Headlight washer switch
JZ5 - to headlight relay (from model 76 to fuse S6)
1'' - Headlight washer relay
S" - to fuse S"
S2 - Fuses
S'' - in the
SIP- fuse box
T'f - Cable connector, single, behind instrument panel
- Cable connector. double, near battery
g - below instrument panel
V" - Headlight washer pump
J'"

headlight washers, Type 911

automatic heating system, Type 911
D - to ignitionjstarter switch 6
El3 - Control unit for automatic
heating system 4.5
E2' - Instrument panel illumination
potentiometer 1
L6 - Speedometer illumination light 3
N" - Interior temperature sensor 5
N" - Exterior temperature sensor 4
S" - Fuses in the 4
SI2 - fuse box 5
TIe - Cable connector, single,
on luggage compartment floor 2
i
N'"

electric sliding roof, Type 61
Ee - Switch for sliding roof
S" - Fuse in the fuse box
T' - Cable connector, single.
near sliding roof motor
V' - Sliding roof motor

Current Flow Diagrams 911 9
A D D I T I O N A L C U R R E N T FLOW D I A G R A M
ELECTRIC WINDOW CONTROLS
Modification - 1917 Models
The electric c o n n e c t i o , ~for the window regulating motor is no longer m a d e a t fuse S 16, but S 21 instead.

power windows, Type 911
A - to battery
ElP - Power window switch, driver side, for passenger side
E'O - Power window switch, driver side
E" - Power window switch, passenger side
IS' - Power window relay
SI2 - Fuses
S16 - in
S" - the
S'' - fuse box
T' - Cable connector, single, behind fuse box
a - in door well, left
b - in door well, right
V" - Power window motor, left
V" - Power window motor, right

power windows, Type 911

rear window wiper, Type 911
C - to generator
E" - Rear wiper switch
- Diode for rear wiper
S" - Fuses
S" - in the
S" - fuse box
S2' - Fuses in the
S2' - rear fuse box
T' - Cable connector, single
a - behind instrument panel
V'' - Rear wiper motor

windshield and rear window defoggers
Type 911
A - to battery
C - to generator
C2 - to voltage regulator
El6 - Windshield and rear window defogger switch
J" - Diode for windshield defogger
I" - Windshield defogger relay
1' - Relay for hvo-stage rear window defogger
KZ3- Windshield and rear window defogger indicator light
S'' - Fuses r E'"
S" - in
to - the
S2'- fuse box
S2'- Fuses in the
S2' - rear fuse box
a - below regulator panel
b - behind fuse box
T2 - Cable connector, double, below regulator panel
TI4 - Cable connector, fourteenfold
U' - to cigar lighter
Z' - Rear window defogger. stage 1
Z2 - Windshield defogger
Z' - Rear window defogger, stage 2

windshield and rear window defoggers
Type 911

9 Current flow diagram, Type 911 S, USA, Model 76
E - windshield wiper switch

E1 - Headlight switch
EZ - Turn signal switch
EJ - Emergency flasher switch
Ed - Dimmer switch
E5 - Headlight flasher switch
El* - Parking iight switch
EZO - l n ~ t r u m e npanel
t illumination potentiometer
~ 2 - Switch for glove compartment iight
6
F - Stop light switch
F2 - Left door switch
F3 - Right door switch
F4 - Back-up light switch
FS - switch tor luggage compartlnent iight
H - Horn switch
Hz - Horns
H& - Key warning buzzer contact
J' - Hazard / turn signal flasher
JL Horn relay
J's -
Headlight relay
J27 - Diode far seat beit warning system
K' - High beam indicator iight
K4 - Parking lights indicator light
KS - Turn signal indicator iight
~6 - Hazard flasher indicator light
L1 - Sealed beam unit, left headlight
L2 - Seaied beam unit, iight headlight
L6 - Speedometer iiiumination light
L' - Fuel gauge illumination light
La - Clock illumination light
L l s - Ashtray illumination light
Lib - Heater c o n t r a assembiy iliuminatian light
Lz1 - Temperature controi lever iiiuminatian light
~ 2 4 - Oil temperature indicator illumination iight
L26 - Tachometer illumination light
~ 2 7 - Oil pressure indicator illumination light
~2 - R i g h t s t o p i rear light
Md - Left stop1 rear iight
M I - Left front turn signal 1 parking light
M" Left rear turn signal
M7 - Right front turn signal 1 parking light
Mo - Right rear turn signal
Mu - Front side marker light
MI2 - Rear side marker light
MI6- Left back-up light
M v - Right back-up light T"'
Nb - Resistor
S2
:j
to - Fuses
Sn on the
S"
S'B fuse box
TI - Cable connector, single
a - near regulator panei T
b - behind sealed beam unit, left
c - behind seaied beam unit, right
d - behind fuse box
e - o n luggage compartment floor
1 - behind instrument panel
h - near left rear lights
T L Cable connector, sixfold
a - in the engine compartment, rear left
b - in the engine compartment. rear right
e - below instrument panel
g - below instrument panel
T I 4 - Cable connector, fourteenfoid
on regulator panel
W - Interior light
W3 - Luggage compartment iight
W L Giove compartment light
X - License plate light
Y - Clock
E'
0 Printed i n Germany XXXIV, 1975

Current flow diagram, Type 911 S, USA, Model 76 9

Current flow diagram, Type 911 S, USA, Model 76

automatic speed control, Type 911

automatic speed control, Type 911
E2' - Selector lever contact (Sportomatic)

E'' - Speed control switch
E'' - Control unit for speed control
F - Stop light switch
FJb - Clutch pedal switch T'
G2' - to speedometer (terminal 31 b)
G" - to speedometer (ground)
J5" Diode for speed control
N7 - to control valve
N" - Solencid valve for speed control
S" - Fuses in the T"
S12 - fuse box
T' - Cable connector, single, in tunnel
T3 - Cable connector, triple, in footwell, left
T4 - Cable connector, quadruple, below instrument panel
V'' - Control element
F'"
++

intermittent wiper operation, Model 76

intermittent wiper operation, Model 76
E - Windshield wiper switch
E3' - Potentiometer for intermittent wiper operation
J3' - Relay for intermittent wiper operation
SI3 - Fuses in the
S" - fuse box
a - on luggage compartment floor
d - behind fuse box
T'c - Cable connector, sixfold.
below instrument panel
V5 - Washer pump

air conditioner with front condenser

air conditioner with front condenser
A
B
D
-
-
- to battery
to starter
to ignitionlstarter switch, terminal 50
-
S'"
D - to ignitionlstarter switch, terminal 15
El0 - Blower switch
EJ3 - Temperature switch
FJ0 - Thermostat
Ja2 - Power supply relay
JS6 - Relay for condenser fan
N2' - Electromagnetic clutch
S" - Fuses
S'? - in
S'O - the
SIP - fuse T*
SZo- box
a - near regulator panel E'"
~-
e - on luggage compartment floor
P - Cable connector, double F'" ',=
a - near evaporator blower
b - near battery
T' - Cable connector, fourfold, below instrument panel
VIP - Condenser fan
VZ0 - Eva~oratorblower

Additional current flow diagram fog lights

Additional current flow diagram fog lights
A - to battery
E' - to headlight switch
E' - Fog light switch
JS - Fog light relay
K" - Fog light indicator light
L' - to left headlight
LZ2 - Left fog light
L2" Right fog light
S' -
SZ - Fuses
S5 - in
a - the
SB - fuse
S" - box
-
T - Cable connector
T' - Cable connector, double
a - in luggage compartment, left
b - in luggage compartment, right

engine compartment light
E' - to headlight switch I

LZ9 - Engine compartment light 3
S' - Fuse in fuse box 1
T'a - Cable connector, single.
near regulator panel 3
T6a - Cable connector, sixfold,
in engine compartment, rear left 2

remotely controlled outside mirrors, Type 911 9

remotely controlled outside mirrors, Type 911
to ignitionlstarter switch
to rear window defogger switch
Mirror control switch
Change-over switch for mirror control
to oil pressure indicator light
Magnetic clutch far mirror control, driver side
Magnetic clutch for mirror control, passenger side
Fuse on fuse box
Cable connector, sixfold
a - in mirror housing, driver side
b - in mirror housing, passenger side
Cable connector, ninefold
a - on luggage compartment floor, left
b - on luggage compartment floor, right
Mirror control motor, driver side
Mirror control motor, passenger side
Outside mirror defogger, driver side
Outside mirror defogger, passenger side

Current flow diagram, Type 911 S, USA, Model 77 g

9 Current Row diagram, Type 911 S, USA, Model 77
E - Windshieldwiperswitch
E 8 - Headl~ghtswitch
E 2 - Turnsignalswitch
E 3 - Emergencyfla~her~witch
E 4 - Dimmerswitch
E 5 - Headlightfiasherswitch
E 8 - Fresh air blowerswitch
E '5 - Rearwindow defaggerswltch
E 'Q - Parkinglightswitch
E 20 - Instrument panel iiiumination potentiometer
E 2s - Switchforglovecompartmentlight
F - Stop lightswitch
F 2 - Leftdoorswitch
F 3 - Rightdoorswitch
F " Back-uplightswitch
F 5 - Swit~hforluggagecompartmentl~ght
H - Hornswitch
H 2 - Horns
H 8 - K e y w a m n g buzzercontact
J - Hazard1 turnslgnal flasher
J 4 - Horn relay
J Q - Rearwndaw defogger relay
J 27 - Diode foiseat beitwarning system
K ' High beamindicatarl~ght
-
K " Parking lghtsindicatorlight
K - T ~ r n s l g n alnd~cator
l light
K 6 - Hazard flasher indicator light
K 8 - Blowerindicatorlight
K '0 - Rearwindowdefoggerindicatariight
L ' - Sealed beam unit.left headliaht
Clock illumination light

Ashtray illumlnatian light
Heatercontrol assembly illumination light
Temperaturecontrollever illumination light
Oil temperatureindicator illumination light
Tachometerliluminat~oniight
Oil p i e s u r e indicator illumination light
Rightstopi rear light
L e f t s t a p l rear light
Leftfrantturnsignali parking light
Leftrear turnsignal
R~ghtfrontturnsrgnall parking light
Rightrearturns~gnal
Frontsde marker light
Rear side marker light
Left back-upiqht
Right back-uplight
Resstar
Fuses
an the
fuse box
Fuseon therearfuse box
d b e h i n d fuse box
e - o n luggagecompartment floor
f - behind instrumentpanel
h n e a r leftrearlights
Cableconnector,daubie, on luggagecampal
Cable connector, sixfold
a - in the engine compartment. rear left
b i n theenginecompartment, rear right
d - belaw inslrumentpanel
e b e l o w instrument panei
g - beiow instrument panel
h b e l o w instrumentpanel
Cable cannectar, fourteenfold
on regulatorpanel
Cigarlighter
Blower motor
Interiorlight
Luggage compartment light
Giove compartment light
License plate light
Clock
Rear window defogger

Current flow diagram,
Type 911 S, USA, Model 77

Current flow diagram, Type 911 S, USA, Model 77 9
A - Battery
B - Starter
C - Generator
C 7- Voltage regulator
C -
l2 Capacitorforlgnition unit
D - Ignitiunl startorswitch
E - Windshield wiperswitch
E '6 - Heaterbiowersw!tch
E 2' - Left seat belt switch
E 3B - P~tentiometerforlntermittentwiperoperation
E - Outside mirrorcontrol switch
F ' - Oil pressure swi!ch
F - Parking brakeswitch
F 2L Thermo-switch forcold startvalve
F '
2 - Mileagecounterswltch (EGR)
G - Fuelsenderunit
G 1 - Fuel gauge
G 6 - Tachometer
G 6 - Fuel pump
G " - 011temperaturesender unit
G @ - Oil temperatureindicator
G '0 - Oil pressure sender unit
G - 01 pressure indicator
G '2 - Olevelsenderunit
G I:'- Oil level gauge
G 19 - Airmetercontact
G 2' - Speedometer
G 22 - Speedometersensor
J '4 - Relay forheater blower
J '8 - Relay forfuel pump
J 3' - Relay forintermittentwiperoperation
J 3.1 - Seat beltwarnlng system relaywith integrated buzzer
K 2 - Generatorchargeindicatorlight
K :' - 011pre~~ureindicatorlight
K 7 - Parkino" brake1 brake warnino iiaht
K 16 - Low fuelwarning light
K 9 - Seat beltwarnlng light
K 71 - EGRwarning light
N - Ignition transformer
N 1 - Warm-up regulator
N '5 - High tension ignition u n t
N l7 - Cold startvalve
N 2 - S~pplementaryarvalve
N 35 - Magnetic clutch for mirror control
N '$3 - Thermovalve
O
P -
- Sparkplugconnector
D~stributor
0 - Sparkplug
S 13 Fuses
s ,.: - on the
S '"fuse box
S 2 2 - Fuses on the
S 23 rear fuse box (regulator planel)
T 1 - Cableconnectarsnale
~ ~
. "
a - nearregulatorpanel
de - behlndfuse
- an box
luggagecompartmentflaoi
f - behind instrument panel

g - below shift leverhousing
T 2 - a - belaw regulator panel
Cabiecannectar,double
b - in enginecompartment, efi
c - near leftseat
d- on luggagecompartment floor
ik-
- below
in tunnel, rear
regulatorpanel
T 4 - Cable connector, quadruple, on luggage campartmentfloor

T 5 - Cable connector.sixfald
b - inenginecompartment, right
T " - Cableconnectar,fourteenfoid
o n regulatorpanel
V - Windshield wlpermotor
V " Heaterblower
V 5 - Washerpump
v 87 - Outside mlrror control motor
Z4 - Outside mtrror defogger

brake booster, Type 911
Description Current irack
F - Stop light switch 2.3

FP - Parking brake switch 3
Ge - to oil temperature indicate!
(terminal 15) 6
J3' - to seat belt warning system relay 5
K1 - to oil pressure indicator light 6
K' - Parking brakelbrake warning light 4
KIP - Seat belt warning light 5
M2 - Right stop light 7
M' - Left stop light 8
M6 - to left rear turn signal (ground) 6
Me - to right rear turn signal (ground) 6
S" - Fuses on the 4
S" - fuse box 1
T' - Cable connector, single, behind
instrument panel 3.6.7
a - in engine compartment, left 8
b - in engine compartment, right 7

speed limiter, Type 911
C - to generator
G6 - Fuel pump
GI9 - Air meter contact
G2' - to speedometer (terminal A)
J16 - Relay for fuel pump
P3 - Speed limiter relay
NP - to warm-up regulator
Sr6 - to fuse 16
T'a - Cable connector, single.
near regulator panel
T2k - Cable connector, double.
below regulator panel

Current flow diagram, Type 911 SC, USA, Model 78 9

9 Current flow diagram, Type 911 SC, USA, Modd 78
Description Currenttrack
E - Windshieldwiperswitch
E 8 - Headlightswitch
E 2 - Turn signalswitch
E 3 - Emergencyfasherswitch
E 4 - Dlmmerswitch
E 6 - Headi~ghtflasherswilch
E 9 - Fresh atr blower switch
E 1 6 - Rearwindawdefoggerswitch
E "8 Parkinglightswitch
E zo - Instrument panel illumination potentiometer
E 2s - Swit~hforgiovecompartmentlight
F - Stop ilghtswitch
F 2 - Leftdoorswitch
F 3 - Rightdoorswitch
F - Back~uplightswitch
F 5 - Swit~hforluggagecompartmentlight
H - Hornswitch
H 7 - Horns
H 6 - Keywarnlng buzzer contact
d 1 - Hazard 1 turn signal flasher
J 4 - Horn relay
J 4 - Rearwindow defogger relay
J 27 - Diode for seat beltwarning system
K 1 - High beamindicatarlight
K - Parking lightsindicator light
K 5 - Tumsgnal indcator light
K L Hazard flasher indtcatar light
K 8 - Blowerindicatorlight
K 10 - Rearwindowdefoggerlndicatorlight
L ' - Sealed beam unit.leftheadlight
L 2 - Sealed beam unit, rightheadlight
L 6 - Speedometer illumination light
L 7 - Fuel gauge illumination light
L 8 - Cl~ckill~m~nationlight
L '6 - Ashtray illumination light
L 1 6 Heater controiassembiy illuminationlight
L 2' - Temperaturecontrol lever illumination light
L 74 - Oiltemperatureindicatorilluminationlight
L 2s - Tachometerilluminationiight
L 27 - Oil pressureindicatoriliumnation light
M 2 - Rightstoplrear light
M 6 Leftstop1 rearlight
M 6 - Leftfrontturnsignal1parking ilght
M 8 - Left rearturn signal
M 7 - Rightlrmtturnsgnal 1 parking light
M B - Rightrearturn signal
M - Fmntslde markerlight
M 12 - Rearside markerlight
M 18 - Leftback~upiight
M 7 - Rlght back-up light
N 6 - Resistor
S 2
to - Fuses
S '2 anthe
S '5
fuse box
S - Fuseon therearfuse box
T - Cableconnectar, single
a n e a r regulator panel
b - behind sealed beam unit, left
c - behindsealed beam unit, r g h t
d - beh~ndfuse box
e o n luggage compartmentfiaor
f - behind instrumentpanel
T 26 - Cable connector, double, on iuggage compa rtmentfiaor
T 6 Cableconnector,sivfold
a i n theenylnecompartment, rear lefl
b - i n theenylnecampartment, rear r g h t
d -below instrument panel
e -below instrumentpanel
g b e l o w lnstrumentpanel
h b e l o w instrument panel
T 74 - Cableconnector,lourteenfold
on reguiatar panel
UI - Cigarilghter
V 9 - Blowermotor
W - interiorlight
W3 - Luggagecompartmentlight
W" Glove compartment i g h t
X - License platelight
Y - Clock
Z ' - Rearwindowdefogger
0 1~3157

Current flow diagram, 9
Type 911 SC, USA, Model 78

Current flow diagram, Type 911 SC, USA, Model 78 9
A - Battery
B - Starter
C - Generator
C 2 - Voltageregulalar
D - lgnitionlslarterswitch
E - W~ndsh~eldwiperswitch
E '6 - Heater blowelswitch
E 2.1 - Lefl~eatbellswitch
E 38 - P~tentiometerforintetmittentwiperoperatian
E 43 - O ~ t s l d emtrrorcontrol switch
F @ -
- Parking
Oilpressureswitch
brakeswitch
F 2s - Thermo~switchforcaldstartvalve
G - Fuelsenderunit
G 5 - Fuel
- Tachometer
gauge
G s - Fuel pump
G 0 - 011temperaturesenderunit
G Q - Oil temperature indicator
G 10 - Oil pressuresender unit
G ' - Oil pressure indlcatar
G 2 - Oii e v e s e n d e r m t
G '3 - Oil ieveigauge
G 21s' -
- Speedometer
Alrmetercontact
G 27 - Speedometersensor
J 'd - Relay farheater blower
J '6 - Relay farfuel pump
J 31 - Relayforintermittentwiperoperation
J 3'' - Seat b e t warning system relay with integrated buzzer
J - Speed switch
K 2 - Generatorchargendicatorlight
K 3 - Oil preSSUreindicatorlight
K 7 - Parking brake1 brake warnng light
K 16 - LOWfuelwarning light
K " Seat beltwarntng light
N - Ignition transformer
N @ - Warm-up regulator
N 15 - High tension ignition u n t
N '7 - Cold startvalve
N 21 - Supplementaryairvalve
N 35 - Magnetic clutch far mtrror contra1
N 43 - Thermovaive
TI:
P
0 -
- Distributor
Sparkpiug connector
Q - Sparkpug
S 13 Fuses
S 14 - on the
S '6 fuse box
S 22 - F u s e s o n the
S 2' rearfuse box(regulatarplane1)
11 - Cabiecannectar,single
a - nearregulatorpanel
d - behindfusebox
e - an luggagecompartmentfloar
f - behind nstrument panel
g - below shlfleverhousing
h - near oattery
12 - Cablecannectar.doub1e
a - below regulatorpanel
b - in enginecampartmenl.lett
c - nearleft seat
d - on luggagecompartmentfloor
e - near distributor
I - in tunnei, rear
k - belowregulatorpanel
T 6 Cable connector, quadruple. on luggage cornpartme!
T 6 - Cableconnectar,sixfald
a - inenginecompartment, right
T '6Cableconnector,fourteenfold
on regulator panel
V - Wlndshleld wiper motor

V 4 - Healerblower
V 5 - Washerpump
V " - Outslde m ~ r r o r ~ m t rmotol
ol
2'- Out~lde m~rrardefogger
Printed In Germany XXXVI, 1977

power windows
Type 911 from model 77

power windows
A - to battery
D - to ignitionlstarter switch (terminal X)
D - to ignitionlstarter switch (terminal 15)
El9 - Power window switch, driver side, for passenger side
E40 - Power window switch, driver side
E" - Power window switch, passenger side
J5' - Power window relay
SI2 - Fuse
S13 - Fuse
S" - Fuse
S" - Fuse
SI8 - Fuse
SZ' - Fuse
T' - Cable connector, single, behind fuse box
a - in door well, left
b - in door well, right
V" - Power window motor, left
VIS - Power window motor, right
x USA
x * Europa

Additional Current Flow Diagram
Air Conditioner (M 399)

Air Conditioner (M 399)
to battery
to starter (terminal 50)
to ignitionlstarter switch (terminal 15)
to ignitionlstarter switch (terminal 50)
Switch for AC
Temperature switch for AC
Thermo-switch for AC (excess temperature)
Relay for AC
Resistor for evaporator blower
Electromagnetic clutch
Fuse
Fuse
Fuse
Fuse
Fuse
Wire connector, single
a - near compressor
e - on luggage compartment floor
Wire connector, two-pale
a - near evaporator blower
Wire connector, four-pole, below instrument panel
Wire connector, six-pole, below instrument panel
Evaporator blower
N..
r-

Type 911SC USA, Model 80
Oxygen Sensor System

Additional Current Flow Diagram, Type 911 SC USA, Model 80
Oxygen Sensor System
CONTROL UNIT
~. ~
WIRE CONNECTORS
TI. 7 2 AND T6
IN ENGINE COMPARTMENT. LEFT

Current Flow Diagram
Type 911 SC USA Model 81
PART I POWER SUPPLY, STARTER

FUEL PUMP
HEATER VENTILPTOR
IGNITION
PART II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER
PART Ill REAR LIGHT, BRAKE LIGHT

HORNS
INTERIOR LIGHT
IGNITIONISTARTER SWITCH
REAR WINDOW DEFOGGER
PART IV OUTSIDE MIRROR

FRESH AIR BLOWER
CIGARETTE LIGHTER
WINDSHIELD WIPER
POWER WINDOWS
PART V OXYGEN SENSOR SYSTEM
INSTRUMENT, SENDER UNITS
PART VI OXYGEN SENSOR SYSTEM

WlRE CONNECTORS
TI - ONE POLE
A I.EAH REC LATOR VAhE.

B - B E 4 h D 3EAUI GnT A
NO ACTUAL WIRE, BUT
C - 0 t h h U hEAD-16 IT R C n T
D - W n l h D bS,.E BOA INTERNAL CONNECTION RED:
(YELLOW:
16A. BLUE:
5A. WHITE:
24111 BA.
E - 3 N LdGCAGC COMPARTMFhT F-03R OR CONNECTION
r - B t n a h D IhSTR-MthT PAhF. BETWEEN FUSE 11 1 6 A
EQUIPMENT HOUSING
T2 - TWO POLE AND GROUND WlRE CROSS SECTION
(E. G. 1.0 mm')
<m
A -BELOW REGULATOR PANEL U";F
B - IN ENGINE COMPARTMENT L E f l COLOUR OF WIRE (E. G. GREENIYELLOWI
C - NEAR DISTRIBUTOR
D - I N TUNNEL REAR
E - BELOW REGULATOR PANEL
F - ON LUGGAGE COMPARTMENT FLOOR
G - NEAR LEFT SEA1
T3 - THREE-POLE
A - ON LUGGAGE COMPARTMENT FLOOR

B - IN ENGINE COMPARTMENT
T6 - SIX POLE
A - I N ENGINE COMPARTMENT LEFT
WlRE CONNECTOR
(E. G. FOURTEEN POLE TERMINAL 6 )
-
H BELOW INSTRUMENT PANEL
I - I N DOOR WELL LEFT
K - I N DOOR WELL RIGHT
Ti2 - TWELVE-POLE
IN ENGINE COMPARTMENT
GROUND TERMINALS
0 ON ENGINE
O I N LUGGAGE COMPARTMENT
O EATERY
O IN ENGINE COMPARTMENT
@ O N LUGGAGE COMPARTMENT FLOOR
@ NEAR FUSE BOX
WlRE COLOURS GROUND (BODY)
BK - BLACK GN - GREEN BR - BROWN CURRENT TRACK

WT - WHITE YE - YELLOW BL - BLUE NUMBER
RE - RED GR - GREY VI - VIOLET 32 33 34

Current Flow Diagram Type 911 SC USA
Model 81, Part I
POWER SUPPLY, STARTER
FUEL PUMP
HEATER VENTILATOR
IGNITION

GENERATOR
m
1 SUPPLEMENTARY
AIR VALVE
r----.1 I1
P
L.- -,I
*:-+*
L a
ALARM SYSTEM mS.5
FUEL PUMP
HEATER VENTILATION ~
IGNITION COIL
- -"
r
TI
"
C
(il

Model 81, Part II
HEADLIGHT, FRONT TURN SIGNAL,
HAZARD FLASHER

Current Flow Diagram Type 911 SC USA, Model 81, Part II
HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER - 1

Model 81, Part Ill
REAR LIGHTS, BRAKE LIGHTS
HORNS
INTERIOR LIGHT
IGNITION/STARTER SWITCH

Current Flow Diagram Type 911 SC USA, Model 81, Part Ill
REAR LIGHTS, BRAKE LIGHTS+ HORNS 1. INTERIOR LG

I HT-+. ~GN~T~ON/STARTER
SWITCH

Model 81, Part IV
OUTSIDE MIRROR
FRESH AIR BLOWER
CIGARETE LIGHTER
WINDSHIELD WIPER
POWER WINDOWS

Current Flow Diagram Type 911 SC USA, Model 81, Part W
FRESH AIR BLOWER

Model 81, Part V
OXYGEN SENSOR SYSTEM

Model 81, Part VI

Type 911 SC Cruise control (Tempostat) -
BRAKE LIGHT
SWITCH
(811
05
r .-
RELAY 1 [
L..
TEMPOSTAT
(CRUISE CONTROL),
SWITCH

-
Additional Current Flow Diaaram
Type 911 SC 8 Fog light
LIGHT SWITCH
1
1511
ONLY CH, S, N
I
II
I1
I
II
I1
FUSE 2
II
!O
'ir
L. .j
'P

Type 911 SC 81
WlNDSHlELD AND
9
I WiNDSHlELD DEFOGGER
.J

Type 911 SC Air Condition AC FAN SWITCH
. -. . -. . -- -.. . -- -. -. -.
1
I
'? '>
4
2'
rwon ti,", rr,i,,,
TEMP. SWITCH
L~
-.
29 'p
WW, 80,
FAN MOTOR AC
FUSE 1 1 FUSE

PART I POWER SUPPLY, STARTER

FUEL PUMP
HEATER VENTlL4TOR
IGNITION
PART II HEADLIGHT, FRONT TURN SIGNAL, HAZARD FLASHER
PART Ill REAR LIGHT, BRAKE LIGHT

HORNS
INTERIOR LIGHT
PART IV OUTSIDE MIRROR

FRESH AIR BLOWER
CIGARETTE LIGHTER
WINDSHIELD WIPER
POWER WINDOWS
PART V OXYGEN SENSOR SYSTEM
PART VI OXYGEN SENSOR SYSTEM

HEADLIGHT WASHER

CONTINUATION
OF WlRE
(E. ti. PART V
WlRE CONNECTORS CURRENT TRACK 3)
TI - ONE POLE
A - NEAR REGULATOR PANEL

B - BEHIND HEADLIGHT LEFT
C -BEHIND HEADLIGHT RIGHT I
D - RFnlhD K S E BOX
C - O h .LtiGAGC COMPARTMEhT F-OOH
NO ACTUAL WIRE, BUT
INTERNAL CONNECTION
OR CONNECTION
rt
' ! IMLLOW: 5A. WHITE: 6A.
RED: 16A. BLUE: 24A1
k - n F n l h D hSTR.MEhT PAhE- FUSE 11 1 6 A
BETWEEN
EQUIPMENT HOUSING
T2 - TWO POLE AND GROUND
I
WlRE CROSS SECTION
(E. G. 1.0 mm')
A -BELOW REGULATOR PANEL
B - I N ENGINE COMPARTMENT LEFT COLOUR OF WlRE ( E G . GREENIYELLOWl
C - NEAR DISTRIBUTOR
D - I N TUNNEL REAR
E - BELOW REGULATOR PANEL
F - ON LUGGAGE COMPARTMENT FLOOR
G - NEAR LEFT SEAT
P - NEAR BATTERY
T3 - THREE.POLE
A - ON LUGGAGE COMPARTMENT FLOOR
B - IN ENGINE COMPARTMENT
T6 - SIX POLE
A - IN ENGINE COMPARTMENT LEFl

B - I N ENGINE COMPARTMENT RIGHT
. WlRE CONNECTOR
G - BELOW INSTRUMENT PANEL (E.G. FOURTEEN POLE TERMINAL 6 )
H - BELOW INSTRUMENT PANEL
I - I N DOOR WELL LEFT
K - I N DOOR WELL RlGHl
T I 2 -TWELVE-POLE
IN ENGINE COMPARTMENT
T I 4 -FOURTEEN POLE
ON REGULATOR PANEL
GROUND TERMINALS
0 ON ENGINE
'2 IN LUGGAGE COMPARTMENT
BATERY
a IN ENGINE COMPARTMENT
a ON LUGGAGE COMPARTMENT FLOOR
a NEAR N S E BOX
WIRE COLOURS
GROUND (BODY)
BK - BLACK GN - GREEN BR - BROWN CURRENT TRACK
WT - WHITE YE - YELLOW BL - BLUE NUMBER
RE - RED GR - GREY VI - VIOLET

Model 82, Part I
POWER SUPPLY, STARTER
FUEL PUMP
HEATER VENTILATOR
IGNITION

GENERATOR AND REGULATOR
!----l
1 1 THERMO SWITCH
FOR COLD START VALVE
--.-.-.-
AIR FLOW SENSOR
FUEL PUMP
HEATER VENTLATOR
HEATER VENTIMTOR
-
*-a
f l s IGNITION COIL
-z
a
r
C
CI
"7 -
D I
m O -Y I
a O u.

Model 82, Part II
HEADLIGHT, FRONT TURN SIGNAL,
HAZARD FLASHER

DIMMER HEADLIGHT
FLASHER SWITCH
FUSE 4 5 A
PARKING LIGHT
FUSE 3 5 A CONTACT
FUSE 2 5 A
F-.-.--
__j
LICENSE PLATE LIGHT .D -e
4
ASHTRAY LIGHT
r--1
7$.% , dl
L
.
.-
.-
IEATER CONTROL ASSEMBLY LIGHT

Model 82, Part Ill
REAR LIGHTS, BRAKE LIGHTS
NORNS
INTERIOR LIGHT

9 911 Electrical Accessories
When installing antenna make sure there is perfect

ground contact between base of antenna and fender.
Base ground to battery negative pole = 0 ohm.
Installed distance for automatic antenna.

Current Row Diagram Type 911 SC USA, Model 82, Part IV
15
bk
FRESH AIR BLOWER

Model 82,Part V
OXYGENSENSORSYSTEM
INSTRUMENT. SENDER UNITS

Current Flow Diagram Type 911 SC USA, Model 82,Part V

Model 82, Part VI
HEADLIGHT WASHER

Current Flow Diagram Type 911 SC USA, Model 82, Part VI
OXS CONTROL UNIT
.. . , . _ _ l l _ .
r---- 1
i
HEADLIGHT WASHER
SWITCH
L
OXYGEN
SENSOR

Description of Relays a n d Fuses 911 9
L O C A T I O N OF RELAYS A N D F U S E S I N T H E V E H I C L E E F F E C T I V E
W I T H 1 9 7 4 MODELS
Beginning with 1974 models, the fuse box is

located on the left side panel of the luggage
compartment near the brake fluid reservoir. The
plastic cover can b e removed from the fuse box
by lightly pressing its top downward.
The fuse box contains 18 fuses and, depending on

options. 1 to 3 standard relays.
1 - Relay for air conditioning

2 - Relay for fog lamps
3 - Relay for signal horn
Mounting space for 4 additional relays has been

provided for possible expansion of the electrical
system.
A fuse listing is contained in the wiring diagrams.

T h e fuses are identified in the diagrams in an
ascending numerical order whereby the forward-
most fuse in the vehicle bears the designation S 1.

9 911 Description of Relays and Fuses
Additional fuses and relays a r e located on the

luggage compartment floor (left, as seen in
direction of driving), as well as on the mounting
plate in the engine compartment.
1 - Vacant
2 - Relay for heated windshield
3 - Relay for emergency flasher
4 - ~ o g i c - r e l a yfor safety belt warning system
1 - Relay for single stage heated rear window

(not installed with two-stage version)
2 - Cold start relay
3 - control relay for two-stage heated reaI
window (not installed with single stage version)
4 - voltage regulator
5 - CDS trigger unit

G - Rear fuse box
Vehicles not equipped with CIS (fuel injection)
have the RPM-transducer installed adjacent to the
two-stage heated rear window relay.

T h e 1975 911 S and Carrera models have a modified relay plate.
1 - Relay plate
2 - Standard relay for 1-stage rear window defogger (deleted for 2-stage heater)
3 - Standard relay for heater blower
4 - Standard relay for warm-up regulator
5 - Control relay for 2-stage rear window defogger (deleted for 1-stage heater)
6 - Voltage regulator
7 - Capacitor discharge ignition control unit
8 - Radio (interference) suppressor
9 - Rear fuse box (fuses S 22 thru S 24 of wiring diagram)
Note
T h e relay positions for the heater blower and warm-up regulator were interchanged in some vehicles.

9 911 Descriptions/Relays and Fuses
L O C A T I O N OF RELAYS AN D F U S E S - 1 9 7 6 MODEL
Depending on the c a r ' s equipment, t h e relay

carrier in t h e fuse box is fitted with up t o 5 relays.
T h e warm- up regulator relay is omitted.
1 - Air conditioner relay 1 - Relay p l a t e

2 - Foglight relay 2 - Relay for single stage rear window d e f o g g e ~
(omitted for 2- stage defogger)
3 - Horn relay
4 - Vacant 3 - Relay for heater blower
5 - Electric window winder relay

4 - Relay for 2- stage rear window defogger
(omitted for single stage defogger).
6 - Vacant
5 - Voltage regulator
7 - Fuel pump relay
6 - CDI control unit
T h e fuel pump relay also controls t h e warm- up 7 - Radio (interference) suppressor
regulator and auxiliary air regulator. It has a
red cover t o distinguish it from t h e standard 8 - Rear fuse box (fuses S 22 thru S 24 of
relays. current flow diagram)
9 - Capacitor (only for Bosch CDI control unit)
- omitted as from 1978 models -
T h e fuse box has 21 fuses. T h e last fuse (S 21)

as seen in t h e driving direction is for t h e fuel
pump for 1976 models.

Description - Lighting System
911 9
HAZARD WARNING FLASHER
Beginning with 1 9 1 3 models, a l l T y p e 911 vehicles a r e equipped with a new hazard warning flasher.
T h e new flasher c a n b e identified by its white plastic base, t h e old flasher was a l l b l a c k . T h e new
flasher is additionally equipped with T e r m i ~ 58 l which is n e e d e d .
NEW OLD
S i n c e this modification required repositioning of t h e terminal tabs, it is not possible t o install t h e new
hazard warning flasher into vehicles of pre- W73 vintage unless t h e new wire l o a m (with white coupling)
is used or t h e terminals a r e changed in t h e coupling of t h e old l o o m t o m a t c h those in t h e new flasher.
This would require removal of t h e brown wire, together with t h e flat terminal socket, from t h e plug- in
connector (watch retention hook) and inserting it into t h e adjacent, formerly unused. r e c e p t a c l e .

Description of Alternator 911
ALTERNATOR - 1 9 7 5 MODELS
An 840 W alternator ( s a m e s i z e as t h e 770 W alternator used previously) is installed as o f t h e 1975 model

year. T h e 840 W allernator will b e replaced by one of 980 W later in the 1975 mode! year. This alterna-
tor will be 9.3 m m longer. T h e blower housing, already designed for this size, has a ring installed with
t h e 840 X i alternator t o compensate lor t h e 9 . 3 nlrn deeper hole in the blower housing. This ring is t o be
omittcd rvhen a 980 \I' alternator is service installed in such a vehicle.
A new voltage regulator is also introduced for the 1975 models. It is applicable t o both new alternators
(840 and 980 watts).
A modified hub extension is installed with t h e introduction of t h e 980 W Alternator. This part must also
b e installed if a 980 I i alternator is service installed in a vehicle. If t h e former hub extension is left in
t h e vehicle, there will b e a large g a p between it and t h e blower housing.

Description - Ignition 911 9
IGNITION SYSTEM MODII:I(IAl'IONS - 1978 M O D E L S
1. A11 '311 models a r e equipped with a l h c a k e r - 5. Distributor turns counterclockwise. Conse-

less capacitor discharge ignition system ( s i m i - quently the brealierless CDI system cannot
l a r ta that of 930 Turhoi. h e serviced installed in earlier vcliicles.
2. CDI unit and distributor h a v e been changed.
3. Ignition control: centrifugal a d v a n c e and

vacuum retard.
4. Speed control:
Electronic speed relay, cutout of iuei p u m p
'
a t GS5O 150 1,'min.

9 9fl Description - Ignition
C h a n g e s t a I g n i r i o n S y s r e r r l - 1980 M o d e l
T h e 011 SC is equipped with a disuibuLor havlng

a double vacuum unir for ierard and advance
ignition conrrol.

Starter - Technical Data 911 9
STARTER
General Information
Beginning with 1972 models, starter power output is increased from 0 . 8 HP t o 1.5 LIP. Bath starter types
a r e basically af t h e s a m e design.
Specifications for GB 12 V 1 . 5 HP (BOSCH :I: U 001 312 100)
Voltage 12 v
Power rating 1 . 5 HP
No-load current draw !< 1 1 . 5 volts 50 - 80 amps
No-load speed 1300 - 9300 rpm
Stall torque current draw 16' G volts G00 - 7 8 0 amps
hlininlllni voltage for solenoid draw-ill 7.5 volts
Urilsli pressure So0 - 900 giarns
A r n l a t i ~ r eend- play 0 . 1 - U.3 iilm
Beginning rvitll the end o f April 1973, only vehicles equipped for counlries in tlie northern henlispllere arid
Canada continue t o b e equipped with t h e 1 . 5 1V starter. All athcr Type 9 1 1 T , E and S vcliiclrs will
again be cq~lippcdwith t h e 0. 8 HP starter.

DISASSEMBLING A N D ASSEMFLING STARTER
TOOLS
Special T o o l Remarks
2l
3
Press black
Press pipe 31.5 mrn dia.

Disassembling and Assembling
Starter

Starter 911 9
1 Note when Special
*
r. Description Qty instructions
u Lock washer
Retaining screw
Position rubber block
tip i n field frame
Solenoid Pull pinion engage- Check solenoid current

ment assembly for- draw and free movement
ward. of core. Seal, lubri-
~ u s cap
t Seal. 1
O-ring Replace if damaged.
2 Retainer
Note number of shims. Adjust armature endplay
to 0.1 - 0.3 mm
-
(0.004 0.012 in.)
4 Bolt 2 Seal with paste.
Check bearing bush- Ground-connecting sur-

ing, replace if face t o field frame
necessary (remove must b e free of paint
with VW 401, or grease. Upon assem-
VW 411, and bling, seal and lubri-
vw 418a). c a t e lightly.
T--F Brush carrier plate Check position of ro-

tation detent for proper
ground t o field frame.

9 911
-
Starter
Note when Specirl

Nr. Description 1 Qt: instructions
-
18 Negative brush Check for cracks, Brushes must move

-
dirt, and tight ireely i n holder. Re-
19 connection. place in sets only.
-
20 Lift with wire Brush pressure ca. 800 -

hook. 900 grams (28-32 oz.).
-
21
-
Check for proper sealing.
22 Field frame Check for proper ground
between brush end cover
-
23
-
24
I Field coil
Insulating washer
and drive housing.
Check continuity. Re-

place coil if burned.
Locate against brush
carrier plate.
-
25 Thrust washer Locate against commu-
-
26 Armature I Vertical runout
0.03 mm; mini-
Check for grounding.
Check soldered pointc
mum diameter between segments and
33.3 mm: if necess- soldered tabs. Install
ary, undercut seg- armature together with
-
27
-
28
-
29
9 Engagement spring
ment insulation actuating lever.
Replace if bent.
-
30
-
-7Detent balls Install packed in lithium
grease.
31 Overrun clutch
-
32 Pivot bolt Grease lightly.
-
3-
3 Lock washer
34 Nut 1
-
35 Drive housing Seal joining surfaces
between solenoid and
drive housing, and field
frame and drive housing.
Coat lightly with oil.
-

starter 911 9
Instructions for Removal and Installation
Beginning with 1974 models, Type 911 and 911 S vehicles are equipped with the 0.8 HP starter motor.
The 1.5 HP starter, standard in the 2.7 liter Carrera vehicles, can be installed on special order.
A battery-starter lead with a cross-section of 25 mm2 is used in conjunction with the 0.8 HP starter
motor; this lead has a cross-section of 35 mm2 in vehicles equipped with the 1.5 HP starter motor.
For e a s i a identification, both battery leads are color-coded about 800 mm from the starter connector:
white band 25 mm2

yellow band - 35 mm2
It is necessary to replace the battery-starter cable when replacing the 0.8 HP starter motor with
the 1.5 HP unit in 1974 model and later vehicles.
The type of cable installed in pre-1974 vehicles must be determined in such cases, although
no color coding will b e found.
Standard To end of From 1972 model From May 1972

Equipment 1971 models to May 1972
Starter Power
Rating
Cross-Section
of Battery-Starter
Cable
Excepted from the above are all vehicles equipped with the Sportomatic transmission, which were
equipped exclusively with the 0.8 HP starters and 25 mm 2 cables; and Carrera 2.7 vehicles which
were furnished only with the 1.5 HP starter and 35 mm2 cable.

Lighting Equipment
-
S E A L E D BEAM IlEADLISlH'l'S
Replacing Sealed Beam
1. Unscrew retaining screw and remove l a m p

rim.
2 . Remove only t h e 3 screws (arrows) which

secure t h e l a m p unit retaining ring. remove
retaining ring and withdraw sealed b e a m unit
3. Disconnent plug from rear o f unit
4. Attach plug t a rear of new unit.
5. Insert sealed b e a m unit and reatining ring

tighten hold-down-screws.
6 . Install l a m p r i m and tighten retaining screw.

It is best t o first screw t h e Philips-headscrew
i n by a few turns and t h e n t o seat t h e l a m p unit
i n its upper retainer. Afterwards tighten t h e
Philips-headscrew.
Beginning with t h e 1174 models, it is necessary

t o use t h e extra- long Philips screwdriver when
loosening a r tightening t h e headlamp retaining
screw (Special Tool P 388).

Lighting Equipment 911 9
FOG LAMPS AND FOG TAIL LAMP
Subsequent Installation
1. Disconnect battery ground strap.
2. Drill holes for l a m p mounting and rubber

grommets in front and rear bumper skirts.
Make sure that t h e hole arrangement is m a d e
exactly as in t h e illustration for e a c h of t h e
two fog lamps.
(Dimensions are in m m )

9 911 Lighting Equipment
3 . Install the outer and Inner fog lamp mounting

plates. The plate with the larger bulge is
mounted outside. together with the rubber
gasket. Use two Allen-head, ivl 6 x 15 bolts
with washers and lock washers on each lamp
unit. Place a toothed washer between the lamp
bracket and lamp mounting plate. Fasten the
lamp lo the mounting plates with a lock ring
and M 1 0 nut.
4. Thread the electrical wire through the bumper

skirt and the already present holes in the
wheelhouse into the luggage compartment, then
press the grommets into place. The windshield
washer reservoir must be removed for this
operation (see 4.4-1/1).
5. Remove loudspeaker cover and loudspeaker.

This fog lamp switch should be installed
between the rear window defroster switch and
the cigarette lighter. A hole of 20 mm dia.
has to be cut in the instrument panel cover;
the holes are already made in the instrument
panel and luggage compartment pan. Mark
center of the hole by pushing a pin through
the back of the instrument panel cover. Cut
the hole by using a compass for marking and
then carefully cutting the cover with a knife.
or by using an appropriate rotary cutter and
cutting the cover to the sheetmetal base.

Lighting Equipment
9111
Vehicles manufactured t o U.S. specifications

a r e furnished with t h e h o l e already made; it
is covered with a plug.
Remove plug from luggage compartment

pan and install a grommet in its place, or
else cut a h o l e in t h e plug. Insert switch
assembly from t h e rear. fasten with ring nut.
and screw t h e knob in.
6 . Remove luggage compartment lining and

d e t a c h fuse box. Install t h e wires in such way
that t h e two two- pole connectors will b e
located adjacent l o t h e fog l a m p wires. Fasten
t h e wires along t h e front cross panel with the
m e t a l tabs already there. T h e relay switch
socket should b e pushed in from t h e franl and
t h e relay switch then plugged into it. T h e
wires a r e then pushed along t h e luggage
compartment tloor t o t h e fog l a m p switch. T h e
speedometer should b e removed during this
installation. M a k e sure that t h e wire does not
touch t h e windshield wiper drive components.
7 . Wires leading from t h e fog lamps should

connect brown with black, and white/yellow
with blue. T h e brown ground wire should b e
connected t o t h e ground bolt in t h e cross panel
near t h e battery.
Connect wirm t o fuse box as follows:

NOTE:
red wire t o Fuse 17 top
In vehicles manufactured t o U.S. specifications.
grey wire t o Fuse # 2 bottom
t h e connections differ as follows:
white wire t o Fuse # 8 top
white/green wire t o Fuse # 1 top
both whitelyellow wires to grey wire t o Fuse # 6 bottom
Fuse # 1 bottom white wire Lo Ground (lengthen t h e wire)
Refasten fuse box and r e p l a c e luggage c o m -

T o preclude mistakes, n o t e that t h e fuses a r e
partment lining.
numbered 1 thru 18 (in vehicles equipped with air
conditioning t h e numbers g o thru 23). starting in
front in the direction of travel. T h e fuse number
c o d e is also used in t h e wiring diagram.

9 911 Lighting Equipment
The wires are connected to the switch as

follows:
blue/white wire to Terminal N
grey wire to Terminal 58
A white/green wire is already installed in the

vehicle; it is accessible through the loud-
speaker cutout and can be found taped to the
wire loom located ther-. Remove the tape and
connect the wire to Terminal NR. The nega-
tive (- ) terminal at the switch should b e
connected to the ground at the cigarette
lighter through a resistor of 100 ohms.
NOTE:
If only the fog lamps. or one fog tail lamp is

installed, a simple push-pull switch is used
instead of the pull-turn switch. In addition,
the resistor in the ground wire connecting the
switch and the cigarette lighter is not used.
8. Unfasten wire attached to the rear part of the

left tail lamp assembly. Push rubber grommet
into the 10 mm hole in the bumper skirt and
lead the wire from inside out. Attach fog ta;l
lamp bracket to the bumper skirt with 2 Allen-
head bolts M G x 15, lock washers and washers.
Attach a connector to the white cable and fasten

it to the skirt with one of the two bolts. Lead
the white/green wire through the grommet into
the lamp unit and connect. Install wedge.-base
bulb (18 watts) and c l a e lamp unit. The lamp
retaining nut should be tightened firmly for
proper ground connection.
Attach wire to lamp bracket with a wire clip.

Lighting Ecluipmrnt 911 9
8. Reconnect battery and check l a m p operation.
When t h e switch knob is pulled out, t h e fog
lamps are switched on and t h e yellow control
light glows with reduced brightness. When t h e
knob is turned, t h e fog tail l a m p is switched
on and t h e yellow control light glows with
full intensity.
10. A d j u s t i n g L a m p s
An optical l a m p adjuster should b e used for

adjusting t h e fog lamps. When t h e driver's
seat is occupied, t h e upper bright/dark
intensity l i n e must b e on t h e marker line,
extending horizontally over t h e entire screen.
T h e lens of t h e fog tail l a m p must b e

positioned vertically t o t h e road and a t a
right angle t o t h e longitudinal vehicle axis.

Windshield Wiper and Washer System 911 9
ADJUSTMENT INSTRUCTIONS
Beginning with February 1972 and the below given chassis serial numbers, all type 911 vehicles are
equipped with madified windshield wiper arms:
VIN
911 T Coupe
911 T Targa
!I11 E Coupe
ill1 E Targa
911 S Coupe
ill1 S Targa
When adjusting the new windshield wiper arms m a k e sure that t h e outer (left) arm does not rest against
t h e decorative slrip, and t h e distance o f 2 0 n l m (35/32 in) is maintained between both arms.
Check that hlades a r e positioned properly by opeiating t h e wipers for a few strokes.
NOTE: Wlieil operating Lllc windshield wipers, m a k e sure the windshield is wet.
T h e diiference lor dimension a between t h e old and new wiper arms is:
a - approx. 35 lnin ( 1 3 / 5 in) (old)

a - approx. 60 m m ( 2 3 / S in) (new:

Windshield Wiper and washer System 911 9
W I N D S H I E L D WASHER P U M P
Removal and Installation
The windshield washer pump in 1974 model vehicles

is located at the lock transverse panel near the
battery.
Both electrical wires and water hares must be

detached prior to removal of the pump.
When connecting the wires, it is necessary to note

the proper polarity, that is, the brolill wire nlust
be connected to the terminal marked (-). The
nipple marked D is connected to the hose leading
to the spray nozzles through the T-joint. A hose
leads from each :the connection B and a connec-
tion in the T-joint) to the threaded cap in the
windshield washer reservoir which, effective with
1914 models, is located under the left front
fender. An additional connection in the reservoir
cap is a vent hose which leads to the water filler
neck within the tank filler compartment.

Windshield Wiper and Washer System 911 9
W A T E R RESERVOIR F O R W I N D S H I E L D WASHER S Y S T E M
T h e left front wheel must b e removed when

removing the water reservoir. The bumper does
not have to b e removed.
The reservoir is attached to the vehicle by means

of a strap which is bolted to t h e headlamp com-
partment. The reservoir can b e taken out rearward
after the attachments are unfastened, the filler
hose detached, and the threaded cap removed.
Make sure during installation that the mounting

strap is seated properly in the support bracket.

Windshield Wipers and Washer 911 9
I N T E R M I T T E N T WINIISHIELD WIPER S W I T C H
Removing and Installing Potentiometer Removing and Installing Intermittent

Relay
1. Disconnect battery ground strap. 1. Remove blower housing.
2. Remove clock. 2. Pull plug off of intermittent relay and

unscrew mounting screws.
3. Pull off potentiometer knob, unscrew nut and
take out potentiometer t o front.
-+-
Note
T h e potentiometer on cars prior t o 1976 model

is located next t o steering column on right
side.

Emission controls
Exhaust gas r e c i r c u l a t i o n canlrol
All 1975 models with California equipment have

exhaust gas reciiculation (EGR) to reduce the
pollution from exhaust gases.
Parts af the EGR system are subject to a certain

amount of wear and have to b e inspected and/or.
replaced at certain intervals (see Group 1).
An elapsed mileage odometer is installed

beneath the blower housing to control the inspec-
tion intervals. The EGR indicator lamp will light
up after 30, 000 miles have been driven. After
inspection of the EGR system, the elapsed mileage
odometer must b e reset to zero als follows:
1. Disconnect battery ground strap.
2. Remove tachometer.
3. Using an appropriate tool (small screwdriver,

punch or something similar) press the pin on the
elapsed mileage odometer housing in to the stop.

9 911 Emission controls
T h e EGK indicator l a m p comes o n when t h e igni-

t i o n is turned a n and goes out when the e n g i n e
!;tarts. This wiring hookup provldes a method of
checking t h e indicator l a m p before e a c h start.
A n altered elapsed m i l e a g e odometer is installed Mounting, removal and installation of this switch
in a l l models in conjunction with t h e eleclronio is identical t o thal of t h e former elapsed m i l e a g e
speedometer, e f f e c t i v e with t h e 1976 model. odometer. This also applies when resetting t o zero.

REMOVING AND I N S T A L L I N G SPEEDOMETER CABLE
Note
The blower housing of California equipped cars has to be removed to be able to detach the speedometer
cable at the EGR elapsed mileage odometer switch. Pull the speedometer out of the dashboard of all
other models to detach the speedometer cable.
-
Removing
r
\. ..,
0
-
4
.
w ~
- -- ~ ~~ ~ . -
1. Remove blower housing. Do not lock operating

cables.
2. Detach speedometer cable atEGR elapsed

mileage odometer switch. Tie a string to end
of cable.
3. Remove tunnel cover in car.

Remove gearshift lever housing.
Take off plastic strap.

Speedometer
4. Remove cover a t hack of tunnel.

T a k e off plastic strap.
5. Disconnect speedometer c a b l e beneath car a t

transmission.
6. Pull speedometer c a b l e loward rear out of car.
Installing
1. T i e string t o speedometer c a b l e and pull in

c a b l e toward front.
2. Securespeedometer c a b l e l o car tunnel with

2 plastic straps.
Caution
M a k e sure that c a b l e is installed without kinks or

bends.
Install seal at transmission.

ELECTRONIC SPEEDOMETER
C h e c k i n g Electronic Speedolneter Sensor
Remove tunnel cover in front o f emergency seats. Disconnect the flat m a l e plugs a t the connector
i n the tunnel and connect a test buzzer t o the wires leading back. Lift car a t rear axle and turn right
rear wheel by hand. Lock l e f t rear wheel. The Ihuzzer must sound off 8 times for e a c h two revolutions
of the wheel. If not, replace the sensor.
The l e f t rear wheel need not b e locked, if a car is equipped with a l i m i t e d slip differential. In this
case the buzzer sounds o i l 8 times for e a c h one revolution.
Checking Eleclronic Speedometer
I. Connect and disconnect very quickly the two wiles i n the tunnel that l e a d forward. A distributor c a n
b e applied to help, if Lmth wires a r e connccled t o teiniinal 1 and the distrihulor housing, and the
distributor shaft is turned by hand as quickly as possiblc. Remove the speedometer i l there is no
dcflcction of the needle. Check a l l wire connections to the speedometer and replace the speedometer
if necessarv.
Turn on the ignition for this test.
2. T h e aperation o r the eleilronic s p e e d o m ~ l c rof'l'ype !lll a n d Turbo C a r r e r a Models can also hc

checked as follows:.
Disconnect wire fronl terminal T D of tachonleter and instead connect l h e wire from terminal 31 b
on t h e speeclameter .
T h e specdometer must now show a reading according to the engine speed. If there is n o needle
deflection, the speedometer must be replacod,
Relation betwecn engine speed and speedometei reading:
engine speed (rpru)

Speedometer reading ( M P W =
calibration n u n ~ b e r
Example:
T h e calibration number is cmbossed a n speerlorneter housing.
CAUTION
The testing method a t point 2 c a n no longer b e used

on speedometers afier rnanufacruring date 1/77.
There is danger of damaging a n electronic compo-
nent in the speedometer.
9 911 Instruments, Controls
Removing and Installing Eleclronic

Speedometer Sensor
1. Remove right rear wheel.
2. Remove h e x head screw and l a k e holder off

of sensor.
3. T a k e sensor wires out of holders and pull sensor

out of transmission case.
4. Separate connector in tunnel and pull out

sensor wire toward rear.
Note
T h e polarity need not b e observed when connecting

the sensor wire.

Electrical Accessories 911 9
S A F E T Y BELT WARNING S Y S T E M
Beginning with January 1972, all USA export vehicles are equipped with the safety belt warning system
required by law. This system consists of 2 inertia reel safety belts with automatic lockitg retractors, a
control lamp with the inscription "Fasten Seat Belt". a seat contact switch built into the passenger seat,
a new parking brake switch, and a modified buzzer.
The three-pole buzzer can still be used as replacement for the formerly used two-pole buzzer in vehicles
not equipped with the safety belt warning system.
An electric switch is built into each safety belt buckle. The switch is closed when the belts are not worn,
providing ground for Terminal G of the control lamp. If Terminal 50a does not have a ground connection
through the handbrake switch at the same time, a transistor incorporated in the control lamp becomes
conductive. Since the buzzer Terminal 86 is energized at all times, and Terminal 15 of the control
lamp is energized when the ignition is on, the control lamp will light up and the buzzer sound off.
When the belt is put on, the contact in the belt buckle opens and Terminal G ceases to have a ground
connection.
The passenger seat is equipped with a seat contact which breaks the ground connection from the belt
buckle on passenger side to Terminal G in the control lamp when the seat is unoccupied.
The reminder to wear seat belts is given by the control lamp with the inscription "Fasten Seat Belt" and
the simultaneously audible sound of the buzzer whenever
the ignition is switched on,

the driver (and passenger) have not put the seat belts on.
the parking brake is fully released.
The former function of the buzzer remains unchanged.

9 911 Electrical ~ c c e s s o r i e s
S E A T BELT WARNING S Y S T E M 1 9 7 4 MODELS
The seat belt warning system has been changed effective with the 1074 models.
The new system consists of 2 three-point seat belt assemblies with automatic locking retractors, a
control lamp with the inscription FASTEN SEAT BELTS, a seat contact in each seat. and the so-called
logic relay switch with an integrated buzzer. The formerly used separate buzzer is discontinued. Also,
the control lamp circuit has been changed so that it cannot be used in cars of pre-1974 vintage.
The following steps must be performed to start the engine:
1. The engine can be started at any time when no load is placed on the seats (for instance, starting from
the outside).
2. Whenever a load is placed on a seat, the seat belt must be buckled. This applies to both driver's
and passenger's seats. It may become necessary to buckle the seat belt when a heavier piece of
luggage is placed upon it. Since the action sequence of "Occupy Seat - Fasten Seat Belt" is monitored
by the logic relay switch, the engine will not start if either the driver or passenger should fasten the
seat belt prior to occupying the seat.
When the proper action sequence is not followed, the buzzer and the control lamp with the inscription
FASTEN SEAT BELT are activated as soon as the ignitmn switch is turned on.
3. It is possible to restarl the engine without fastening the seat belt if the restarting occurs within 2 1
minutes of shutdown.
The accoustic and optical warning system will be activated whenever any of the fallowing conditions
occur when the engine is running:
1. When a load is placed on a seat without buckling the seat belt.
2. If the action sequence of "Occupy Seat - Fasten Sent Belt" was not followed in that order.
3 . When the load is removed from a seat. in which the belt is buckled for more than 1 0 seconds and
is then placed back on it.
In all of the above cases the warning system can be activated only when the parking brake is in the off
position. The waning condition can be cancelled by refastening the seat belts in proper sequence.
The buzzer integtated in the logic relay switch also is part of the ignition key warning system

An improved interlock relay for the seat belt warning system was introduced around the middle of
December 1973.
With the introduction of this relay, the warning system is only activated (engine running) if the seat belts
are unfastened while the seats are occupied.

9 911 Electric Accessories
S E A T BELT W A R N I N G S Y S T E M F R O M FEBRUARY 14, 1975
All models have a modified seat belt warning system as of February 24, 1975.
The belt contact switch on the passenger's side and both seat contact switches are omitted.
A timer relay with a built-in buzzer replaces the interlnck relay. The connection between the
seat belt warning system and starter is omitted, i.e. the starter can b e used any time.
"Fasten Seat Belt' warning light always lights up when the ignition is switched on and goes off
in 4 to 8 seconds regardless if belts are worn or not. If the driver's belt is not worn a buzzer will
also come on with the warning light. The passenger's belt has nothing to do with the warning
system.

CONTROL ILLUMINATION
Beginning with t h e 1973 models t h e following controls a r e illuminated:
1. Heater control lever on t h e center tunnel.
2. Fan control switch on t h e instrument panel.
3. Hazard warning flasher control switch.
All lamps a r e connected t o t h e instrument illumination circuit permitting d i m m i n g .

Electrical Equipment 911 9
H E A D L I G H T WASHERS
Deprersing the switch in the instrument panel operates the water pump, which is bolted to the front hood
lock panel. It is controlled by a relay located next to it. At a prersure of about 2.8 bar, a valve opens
and a stream of high pressure water goes to the spray jets. T h e relay limits the washing phase to about
0 . 3 seconds. If this time is not sufficient to clean headlights, depress switch again.
The container (in front of the left front wheel) holds about 9 liters (2.2 US gal.) of fluid. It is also used
to provide fluid for the windshield washer.

SAFETY B E L T WARNING SYSTEM
Removing and Installing Seat
(Also s e e Group 8)
A two- pole connector is located under the seat.

In the driver's seat t h e connector wire leads into
t h e seat interior and is connected directly t o the
safety belt buckle. In t h e passenger's seat a n
additional seat contact is wired inbetween.
Prior to seat removal, t h e wire must b e dis-

connected a t t h e connector and also detached
from its retainer on seat underside. T h e wire must
b e reconnected upon installation of the seat: the
polarity makes no difference.

Removing and Installing Safety Belt

Buckle
(Also see Group 8)
T h e front plastic cover of t h e buckle can b e re-

moved upon removal of both countersunk screws.
Push rear cover to t h e side and remove buckle
retaining screws.
When detaching both wires, hold terminal tabs
with needle pliers since otherwise t h e tabs c a n
break off when t h e wires a r e being pulled off.
T h e belt buckle should not b e disassembled un-
less it does not function properly.

When replacing the wedge-base bulb ( l 2 V . 1.2W).
it is necessary to open the control lamp for access.
When installing the lamp, make sure that the

rubber gasket is properly seated.

Removing and Installing S e a t Con-

t a c t in Passenger S e a t
Remove seat (see Group 8, page SB 2 1 and 22).
Remove seat recliner retaining screws and re-

move back rest. Remove seat cover to gain
access to the seat contact.
Make sure during installation that the seat con-
tact is located in its original position in the seat.
Reconnect both wires: polarity makes no difference.

Removing and Installing Safety Belt
Lock i n t h e Sport S e a t
Remove both countersunk screws and take the

plastic cover off. The rear cover should be
pushed to the side to clear the lock assembly
retaining bolt and permit its removal.
Pry both wire retaining clips open to free the

wire and detach it at the plug connector.
Removing and Installing Seat Con-

t a c t Switch i n Passenger's Seat
(Sport S e a t )
Remove seat (see Group 8 , page SB 21 and 22).
The seat contact switch is freely accessible on

the seat underside and can be removed once
the wires are disconnected.
Make sure during installation that the seat con-

tact switch is reillstalled in its original position
(note dimemions). To prevent the seat contact
switch from relocating itself sideways. it should
be glued to the seat underside with a commercial
adhesive.
Polarity is of no consequence when the electrical

connectiolls are made.
. ..
~~
(Dimensions shown are in mm)

S A F E T Y BELT W A R N I N G S Y S T E M 1 9 7 4 MODELS
Removing and Installing Logic

Relay Switch
The logic relay switch rests in a socket which is

attached to the luggage compartment floor and
is accessible upon removal of the small combina-
lion instrument. The asymmetrically arranged
contact prongs ensure proper installation of the
relay, which is with the inscription facing rear-
ward in relation to the direction of travel.
133 919 L31 Ij
Log~k-Rela~s 1 2 ~
BOSCH GERMANY 1
B 335 609 002
0 335 L12 0 0 2

S E A T BELT I N T E R L O C K S Y S T E M - 1 9 1 6 MODEL
Removing and Installing T i m e Relay Removing and Installing S e a t Belt/Brake

Warning S y s t e m I n d i c a t o r Housing
The t i m e relay, installed since February 1975 is
just as accessible as the logic relay after removal A housing containing the indicator lights for both
of the small combination instrument. warning systems (seat belts and brakes including
parking brakes) is installed in the 1976 model.
It replaces the previous FASTEN SEAT BELT
indicator light. Consequently, the brake warning
light in the combination instrument is no longer
installed.
Removal and installation is t h e same as previously

for the single indicator housing.

S A F E T Y BELT WARNING S Y S T E M 1 9 7 4 MODELS
Troubleshooting Safety Belt

Warning System
If the starter does not work despite properly attached Other possible malfunction areas are:
safety belts. proceed as follows to eliminate the
problem:
a - Malfunction in the optical and accoustic
warning devices when belts are not buckled.
1 - Replace logic relay switch. b - Activation of the warning devices despite

If this does not correct the problem the proper handling of the safety belts.
malfunction may be in the following com-
ponent areas:
In either case, first replace the logic relay switch
a - in the starter itself
and then, if necessary. check the electrical connec-
b - in the ignition/starter switch
tions and wires in the safety belt warning system
c - in the connecting wire between the two
by following the wiring diagram.
d - in the wires between belt and seat con-
tacts, and logic relay switch.
2 - Remove logic relay and connect jumper wire

between terminal C and 50 in the logic relay
socket. The jumper wire must be provided
with flat contact tabs to ensure good connec-
tion.
If starting is now possible, the defect will be
found in the wires which connect the belt or
seat contacts with the logic relay switch.
3 - Remove seats and check electrical connec-

tions according to the wiring diagram.
If the starter fails to work despite the jumper
wire connection, check starter. starter/igni-
tion switch, or wires connecting the two.
NOTE
Upon rectification of the problem be sure to
remove the jumper wire and replace the logic
relay switch. otherwise the entire safety belt
warning system will remain inoperative.

CONTROL ILLUMINATION
I l l u m i n a t i o n of t h e H e a t e r C o n t r o l
Lever
A square, illuminated plaque showing the

function of the heater control lever is located
on the center tunnel adjacent to the lever.
The plaque can be lifted off to gain access to

the wedge-base bulb (12V, 1 . 2 W).
l l l u m i n a t i o n of t h e F a n C o n t r o l
Switch
Located behind the inscriptions "DEF. OFF" and

"DEF. MAX. " in the lower part of the fan control
switch are wedge-base bulbs (12V, 1.2 W), one
on each side.
The socket-mounted lamps are seated in their

receptables on the rear side of the switch. The
bulbs are easily accessible from beneath the
instrument panel without removing the knee
guard.
Beginning with 1974 models, a third bulb is

installed. It is located above the DEF.OFF
field.

The control l a m p located in the hazard warning

switch is connected to the light switch through
a 150 Ohm resistor. Thus the l a m p fulfills the
requirement of illuminating the hazard warning
switch, although i t burns with less intensity.

HEADLIGHT WASHERS
Removing and Installing Spray Jets
1 - Remove turn signal housing from bumper.

Remove water container on left side of c a r
(refer t o p a g e 4.4 - 1/11.
2 - Push spring out toward rear and lift out spray

jet. When installing n o t e that both jets a r e
different for the l e f t and right sides.
Removing and Installing Water Pump
1 - Disconnect hoses and electric wiring a t pump.
2 - Loosen strap and remove pump. When install-

ing m a k e sure that hoses and wiring a r e
connected correctly.

Electrical Equipment
Removing and Installing Switch
1 - Disconnect battery.
2 - Pull out switch and disconnect wires.

Headlight cleaner 911 9
Adjusting spezifications
Use a locally manufactured tool t o aim spray

jets. This tool is inserted over the jet and ex-
tended by pulling out the mandrel.The jets are
aimed correctly when the mandrel touches the
center of the lens.
CAUTION
When adjusting the jet insert, hold the spray jet

tightly t o prevent damage to the jet.
Tool dimensions Tube 14 x 1.5 mm
a = 100 mm
b = 10 m m
c = 12.5 m m
d = 5 mm
e = 1+0.2 mm
f = 10.5 m m dia.
g = 115 m m
h = 3 m m dia.
i = 30'
A = M 4 nut, soldered
B = M 4 knurled head screw

Electric Accessories 911
S e r v i c e I n s t a l l a t i o n of H e a d l i g h t Washers
beginning with 1974 Models
1 . Mark and drill nozzle mounting holes in

bumper. T o locate hole centers place the
rubber grommet on the bumper. Note that
the nozzles and rubber grommets a r e
different for left and right sides.
The spray jets are positioned slightly off center

(of headlight) the distance between jets is
1250 mm (49 1 / 4 in.)
2. Remove bumper. If an angle drill motor is no}

available, the front apron will also have to
b e removed.
3. Drill 25 m m (1 in.) hole for water feed hose

and insert grommet. (Be careful not to damage
hoses in this area of cars equipped with an
air conditioner.)

9 911 Electric Accessories
4. Remove present fluid container and install

new container.
5. Drill two holes on e a c h side of water pump

bracket and bolt or rivet holder to lock panel.
Location of bracket itself is different for cars
with or with-out an air conditioner. Locate
bracket in cars with an air conditioner so
I
,~. that the inlet adaptor of the pump has its
-,.*
-- opening a t the same height as the water
3 feed hose.
f
'.
7 i
c . ':
6. Install front apron

Electric Accessories 911 9
Install water feed hose on intake neck and
molded hose on pressure adaptor af pump
with hose clamps.Use longer molded hose
o n models with air conditioners and shorten
water feed hose to a length of about
1 0 0 mm/4in.
Insert molded hose (detach condenser blower

of cars with an air conditioner), slide feed
hose through grommet toward outside, clamp
hose to water container adaptor with clamp
and secure pump to bracket with clamp.
8. Connect both outlet hoses to adaptor (short

hose left), locate hole for adaptor by placing
in front of lock panel and drill 18 m m (3/4in.)
dia. hole. Place adaptor and rubber grommet
through hole and connect molded hose.
Secure both hoses leading to nozzles with
clamps. Insert pressure control valves on
ends of hoses.

9 911 Electric ~ c c e s s o r i e s
9. Secure nozzles and rubber grommets to

bumper with spring locks, connect them to
pressure control valves and install bumper.
10. Disconnect hose at center connection of

adaptor and connect it to center
connection of valve adaptor.
Note
Use a longer hose for cars without an air

conditioner.
Connect the open center connection of

adaptor with S and the outlet adaptor of
the water pump with P on valve adaptor.

Secure relay t o l a c k panel with sheet m e t a l
screw. Disconnect battery ground cable.
Connect wires t o relay and water pump.
Connect brown wire l o body ground. Place
wires behind fusebox and secure with clamps.
Install a n extra 3-position fusebox so that
t h e b ~ a s srails on t h e back f a c e upward.
Bridge adjacent fuse with a shunt. Connect
gray wire t o fuse 2 (second fuse from front)
a t top, red/white wire t o fuse 2 0 (center
fuse of 3-position fusebox) a t bottom. Use
25 a m p e r e fuses.
Note
Use open fuse connection of the 3-position

fusebax already installed in cars with special
equipment (e.g. air conditioner). Insfall 25
ainpcre f m c !
1 2 . Lvcate wirvs loward instrument pallcl, rcltmvi:

instrument and clock, take o i i s q u n r e covei
BJ$$&#
, ~ ...~
.. ,
...",I'.~.i"'..
.. ~ . ,
i ).
i
~
lhctwcen tachometer and clock and p l a c e wires :;..'

through o p m i n g . Connect switch and press . ,, .
into opening.
13. Connect battery. Fill fluid container and

check operation. A i m spray jets.

~ l e c t r i c a lE q u i p m e n t 911 9
AUTOMATIC HEATING CONTROI
Removing and Installing Control Unit
1. Pry both side covers off of control unit.
2. Detach connecting rod between servo-motor

and heater lever.
Removing and Installing Interior Sensor
1. Remove both Phillips screws and pull dawn

sensor carefully.
3. Remove t h e four bolts, lift control unit

carefully and disconnect t h e three plugs
a t t h e control unit.
4. Remove rubber seal and slide control unit

forward past heater and parking brake levers
t o remove.
5. After installation of t h e control unit turn

off t h e heater with the ignition on and
2. Pull angled plug off of sensor.
l e t t h e heater lever m o v e a l l t h e way
down. Check. whether both heater flaps
a r e closed. If not, adjust t h e heater
cables t o r e m o v e any play.

9 911 Electrical Equipment
Removing and Installing Heat Sensor

in Heater Flap Mousing
1. Loasen control unit and pull off t h e front

2- pole m a l e plug.
2. Loosen carpet along center tunnel and clear

c a b l e up t o grommet in kick plate.
3. Pull both wires out of m a l e plug housing

( b e s u r e t o depress terminal retainer) and
push out grommet.
4. Remove adaptor on left heater flap

housing.
6. Rivet new heat sensor t o adaptor rout c a b l e

and press i n g r a m m e t .
/ (?
5. Pull out c a b l e and r e m o v e rivets on t h e 1 ' >
adaptor. i \

7. Install adapter. Make sure thar the heater
flaps are adjusted evenly on both sides.
8. Secure plug housing to cable. The black wire

must be located on the side of the housing
with a tab.
9. Place cable inside of car, glue carpets.

connect plug t o control unit and secure
control mi1 again.

Disassembling and Assembling Control Unit

-
Note When Special
YO.
- Removing installine lnstructions
1 -1ousmg
2 :over
3 <noh Pull off
4 ~ g h mask
t
5 Screw
6 Washer
7 Sw~tch
8 'h~llips screw
9 Zontrol unit
10 Ball socket see page 6 . 5 - 1/
11 :ard Push in complereiy
12 Bulb holder 12 v, 1.2 W
13 Bulb

9 w Electrical Accessories
Prior t o removing the connecting rod, d e t a c h

c l a m p a t ball socket with a screwdriver.
+
When replacing ball sockets adjusr t o 124 - 2 m m
as shown in figure.

TROUBLESHOOTING AUTOMATIC HEATING CONTROLS
Checking Interior Sensor Checking Heat Sensor in Heater

Flap Housing
1. Remove interior sensor. 1. Remove control unit.
2. Using a n o h m m e t e r with an appropriate 2 . Connect o h m m e t e r t o 2- pole plug of

testing range, check t h e resistance bet- h e a t sensor. T h e resistance must b e
0
ween both coaxial connections on t h e 135 ohm with warm engine a t 1 0 0 C/
o
sensor (use test points). T h e resistance 212 F. Replace h e a t sensor if resistance
is very dependent on t h e temperature and is way off (see "Checking Interior
should b e about 1.5 kOhm a t room Sensor").
temperature. Replace t h e temperature
sensor if the resistance is about w ohm
(open circuit in sensor) or about 0 ohm
(short circuit in sensor).
Note
An open circuit i n o n e of t h e sensors or in t h e

wires t o t h e control unit will show a too low
inside temperature or, a short circuit, a too
high inside temperature. This will result i n
a n improper movement of t h e heater lever
u p or down.

9 911 Eiectrical Equipment
Checking Power Supply t o Control

Unit
1. Remove right side cover of control unit.
2 . Disconnect 3-pole plug.
3. Turn on ignition and parking lights.
4. Connect test lamp between brown and

red/white as well as brown and gray/blue
cables. Test lamp must come on in both
cases.
If both temperature sensors and the power

supply operate correctly, but the heater controls
do not operate properly, replace the complete
control unit.

A U T O M A T I C S P E E D CONTROL
Removing and Installing Regulator Removing and Installing Engagement

Switch
1. Remove cover in luggage compartment. 1. Remove steering wheel and switch housing.
2. Pull plugs off of regulator. 2. Remove engagement switch screws and take
off switch.
3. Remove Phillips head screws and take out
regulator. 3. Detach plug. If car has an air conditioner,
loosen duct on driver's side.

Removing and Installing Clutch Removing and Installing Servo

Pedal Switch
1. Remove front t'unnel cover. 1. Take out hose between heater air connection
and blower motor.
2. Unscrew nuts on bracket, pull off wires and
remove bracket with switch. 2. Pull off plugs on servo and solenoid.
3. Unscrew mounting screws, detach vacuum

line (small hose) on servo.
When installing make sure switch is adjusted

correctly for clutch pedal. Adjust bracket in
slots so that switch is not damaged when
pulling back clutch pedal to check clutch
Play. Note
The vacuum hose is connected to an adaptor

near the throttle housing.

4. Unscrew holder on throttle lever. Removing and Installing C a b l e
1. Detach cable at throttle.
2. Unscrew cap on servo.
3. Press black clip together, slide in and detach

cable.
5. Pull off cable clip on holder upward and

remove servo with cable.

Electric Accessories 911 9
Troubleshooting Automatic Speed Control
1. Disconnect plugs a t speed control regulator. 4. T e r m i n a l 12 must g o directly t o ground.
5. Connect ohmmeter between terminal 11 and

ground. Move car; o h m m e t e r must deflect
periodically.
6. Connect ohmmeter between terminal 6 and

ground. Ohmmeter must show open circuit,
provided that the stop lights operate properly.
7 . Turn on ignition. Connect voltmeter between

terminal 6 and ground. Depress brake pedal;
instrument must show 1 2 volts.
2. Connect ohmmeter between ground and t e r m i -
nal 3 of plug. Ohmmeter must show s R .
Depress clutch. Ohmmeter now shows about 8. 1 2 volts must b e supplied t o terminal 9. if
1 0 ohms. If resistance remains a t oo R , t h e engagement switch is moved up.
either t h e clutch pedal switch or t h e solenoid
on t h e servo is defective or not connected.
Note
9. Supply 1 2 volts t o terminal 8. T e r m i n a l 8
On models with a sportomatic transmission operate
must b e dead when moving engagement
t h e selector lever. (If the selector lever is not
switch toward steering wheel.
moved, t h e ohmmeter will show a n additional
20 ohms.)
10. Supply 1 2 volts t o terminal 10. if engagement

switch is moved down.
3. Connect ohmmeter between terminals 3 and
I . Reading must b e between 11 and 1 7 ohms. If
T h e regulator must h e replaced if a l l readings
not, r e p l a c e servo.
a r e within specifications and t h e r e is still a
problem.

REMOVING AND INSTALLING AUTOMATIC ANTENNA
1. Disconnect battery. 5. Unscrew antenna and r e m o v e from below.
3. Disconnect control wlre for antenna on r a d m

and antenna wlre on r a d ~ o .
4. Disconnect front a r e a m a t and unscrew luggage

c o m p a r t m e n t trim.
Pull wires into wheel well.

When installing antenna make sure there is perfect

ground contact between base of antenna and fender.
Base ground t o battery negative pole = 0 ohm.
Installed distance for automatic antenna.

9 1 1 ALARM S Y S T E M
Function
The alarm system is switched on and off with a The alarm will be set off by opening the driver's
separate key. The alarm switch is located on the and/or passenger's door, the engine hood and when
f a c e of an opened driver's door. turning on the ignition.
After setting off the alarm system a separate alarm
horn will sound off intermittently for about 30 seconds
(or constant tone for Swiss version cars) and could be
set off again by the measures described above. At
the same time the engine cannot be started.
Setting off the alarm system with the doors is

accomplished via the door contact switches which
also operate the inside light. Consequently when
.. turning off the alarm system the driver's door must
only be opened far enough to insert the key in the
alarm switch lock.
Note
Spare keys are not available for the alarm switch.

The alarm switch must b e replaced, if the key is
lost.
0
The key must be turned clockwise 90 to switch on
the system.

Removing and Installing Alarm Switch Removing and Installing Alarm Control
Unit
1. T a k e off left door panel. 1. Disconnect and remove front area mat. Unscrew
luggage compartment trim.
2. Pull off rubber escutcheon on alarm switch and

unscrew hexagon nut. 2. Remove fresh air blower.
3. The alarm control unit is held by a holding

clip and can be pulled off in direction of
instrument panel.
3. Remove alarm switch through inside of door and

pull off flat plug.

Removing and Installing Alarm Horn Troubleshooting Alarm System
1. Unscrew bottom guard on front axle. Checking Alarm Switch
2. Unscrew alarm horn and pull off wire plug. 1. Remove alarm switch and measure ohm values
between contacts.
Alarm switch on
(key positioned horizontally)
= 2 to 3 k-ohms)
Alarm switch off

(key positioned vertically)
= 4 to 5.5 k-ohms
If measured values are higher or lower than

specified ohm values, replace alarm switch.

9 %I Electrical Accessories
Checking Lines and Connections
1. Remove alarm control unit. Pull off both plugs 3. Leave test l a m p connected on term. 30 and make
on alarm control unit. other l a m p connection on term. K 1. Lamp should
c o m e on.
2. Connect test l a m p p a x . 3 W) on double contact

plug (term. 30 and Hn). 4. Connect test l a m p on term. 30 and 31. Lamp
If l a m p comes on, there is battery voltage and should c o m e on.
wire to alarm horn is okay.
5. Connect test l a m o on term. 30 and T- . Open

and close both doors separately. Lamp should c o m e
on while opening.
6 , Connect test l a m p on term. 3 1 and 15. Lamp

should c o m e on when turning on ignirion.
Hn 15 T- 31 K1 7. Connect test l a m p on term. 30 and 6 1 (connect

on both terminals separately).
... .. . , . .
Lamp comes on and goes out when turning on

ignirion.
Lamp comes on and goes out after starting and

running engine a t high speed.

8.Connecttestlamponterm.30andMK.Operate Checking Function of Control Unit
trunk light contact switch by hand.
Lamp should come on and go out when pushing
in switch.
Note
9. Terminal E/A must be checked with an ohmmeter.

Connect meter between term. E/A and 31. It is recommended to use a test lamp instead of the
Alarm switch must be connected. a l a r n ~horn (no noise).
Test as described in point 1.1 (checking alarm 1, Connect eight-pin plug with alarm control unit.
switch). The same ohm values apply. Two-pin plug remains disconnected.
Connect red wire on two-pin plug and term. 30

of control unit with a piece of wire.
Connect test lamp between term. HN on control

unit and redjwhite wire of two-pin plug.
2. Turn on alarm system and open door wide. Lamp

should flash.
Also check passenger's door and trunk lid.

3. Set off alarm by opening a door. Leave system

turned on and close door again. The alarm must
last about 30 seconds.
Don' t turn off alarm system.
When opening door again, alarm should also be
set off again.
4. Turn on ignition after alarm has stopped. Lamp

should flash.
Start engine. Engine should not run.
5. Disconnect test l a m p and connect two-pin plug

on control unit.
Install control unit.
Check function of alarm horn by setting off alarm
system once again.
Replace alarm control unit if functions are not

fulfilled.
Note
Even wirh the alarm system turned off a defect in the

control unit could cause failure of the fuel pump
under certain circumstances.
If a new control unit were not immediately available,

help could be provided by the following measure.
Remove alarm control unit and pull off eight-pin

plug. Bridge both terminals 6 1 on plug wirh a piece of
wire. This will eliminate function of the alarm
system.

Battery 9ll 9
BATTERY - 1974 MODELS
Beginning with 1974 models, all vehicles are

furnished with only one battery. The battery has
a capacity of 66 Ah. A battery with a capacity
of 88 Ah is available on special order.
The battery is located in the left forward part of

the luggage compartment and is easily accessible
upon removal of the cover mat.
To remove the battery, disconnect battery leads

from the battery terminals, disconnecting the
ground strap first. Then remove the bracket
retaining bolt in the compartment floor and take
the bracket off.
A special tool for removal and installation of the

88 Ah battery is supplied with rhe car from
1981 models on.
Angled driver for hexagon socket with holder and

extension.

9 911 Battery
-
Note When: Special
NO. Description
-
1 Socket head bolt

M8x20
2 Washer A 8.4
3 Bracket
4 Rubber washer
18 x 5.5 x 1.5
-
To install battery place bolt head in angled driver

and holder.

Ignition system 911 9
SPARK PLUGS
Beginning with the 1972 models, the following spark plugs can be used in the 2.4 liter engines:
Vehicle Type Spark Plug Type Electrode Gap
BOSCH W 235 P 21
BERU 235/14/3 P
or similar
911 E and 911 S BOSCH W 265 P 21

BERU 265/14/3 P
or similar
Coat spark plug threads with a molybdenum paste (such as MOLYKOTE HTP-White or simi1ar):before
installing.
Torque spark plugs to 2.5 - 3 mkp (18.1 - 21.7 ft. lbs.).

9 911 Ignition System
SPARK PLUGS
The following spark plugs are approved for use in 1974 model engines:
Vehicle Type Spark Plug Type Electrode Gap
911 BOSCH W 215 P 21 0.55 mm

BERU 215/14/3P 0.55 mrn
911 S BOSCH W 235 P 21 0.55 mm

BERU 235/14/3 P 0.55 mm
Carrera 2.7 BOSCH W 265 P 21 0.55 m m

BERU 265/14/3 P 0.55 mm
Coat spark plug threads with a molybdenum paste (MoS2), such as MOLYKOTE HTP WHITE, prior to
installation.
Torque spark plugs to 2.5 - 3.0 mkp (24.5 - 29.4 Nm).
NOTE
Use only spark plugs approved by PORSCHE.

Ignition 911 9
SPARK PLUGS
Spark plugs - 1976 / 1977 models
Model Spark Plug Electrode Gap
911 S Bosch W 235 P 21 0.55 mm/0.022 in.

Beru 295/14/3P 0.55 mm/0.022 in.
Spark plugs - 1978f1979
911 SC Bosch W 8 D (W1 4 5 T 30) 0.8 mm/o.031 in.

Beru 14- 8 C (145/14/3 A) 0.8 mm/0.031 in.
Spark plugs - 1980
911 SC Bosch W 5 D (W 225 T 30) 0.7 mm/O. 028 in.

Beru 14- 5D (225/14/3 A) 0. 7 mm/O. 028 in.
Specifications concerning installation of plugs remain unchanged.

- Ignition System 911 9
Equipment Tables - 1980 Model
Ignition Transformer
Type/Model Version Remarks
9 1 1 SC 9 0 1 6 0 2 502 00
Bosch No. 0 221 1 2 1 001
r
Distributor
9 3 0 602 021 06 With double vacuum unit

30sch No. 0 231 304 016 (retard and advance) without
rev. l i m i t e r
Spark Plugs
9 1 1 SC Bosch W 5 D ( W 225 T 30) 0.7 m m

Beru 14/5 D (225/14/3A) (0.028 in. )

Control Unit
9 1 1 SC 930.602.702.0 Capacitor discharge ignition

Bosch No. 0 221 300 004 (CDI), breakerless

Ignition System 911 9
IGNITION LEADS
Beginning with 1972 models, ignition lead lengths are as follows:
From distributor to: Cylinder 1 = 330 m m (13 in.)

Cylinder 2 = 390 m m (15-11/32 in.)
Cylinder 3 = 510 mm (20- 5/64 in.)
Cylinder 4 = 880 mm (34-21/32 in.)
Cylinder 5 = 900 mm (35- 7/16 in.)
Cylinder 6 = 990 m m (38-63/64 in.)
These lengths must be maintained for proper radio noise suppression.

ADJUSTING AND CHECKING DISTRIBUTOR
Adjusting Ignition Breaker Points
1. Remove distributor cap, rotor, and dust

cover (BOSCII only). In MARELLI distributors,
loosen retaining screw in rotor.
2. Turn crankshaft pulley until a distributor

cam lifts the breaker arm to its highest
point.
3. Adjust gap with feeler gauge (basic setting):
BOSCH 0.35 m m
MARELLI 0.40 m m
4. Check dwell angle with an appropriate

tester and adjust, if necessary, by changing
breaker point gap:
BOSCH 38' 1 3O
MARELLI 40' t 3'
Large Beginning wi th 1973 model vt zles, the
. breaker point gap
- . = small dwell
angle following specifications apply t o MARELLI
Small breaker point gap = large dwell distributors!
angle Breaker gap 0.35 m m
Dwell angle 31° i 3O
5. Tighten breaker point plate retaining screw.
Note
Always check ignition timing after adjusting
dwell angle since dwell angle changes affect
timing.

Changing Breaker Points
1. Remove distributor cap. rotor, and dust

cova.
2. Remove slotted screws and disconnect wire

from Terminal 1. (In MARELLI distributor
loosen nut at Terminal 1.)
3. Remove breaker points.
Install in reversed order. Lightly coat t h e cam

with distributor c a m lubl:icant. Keep lubricant
off breaker points.

Adjusting Ignition
(All 2.4 and 2 . 1 l i t e r engines,
e x c e p t 2 . 1 CARRERA)
Check dwell angle before adjusting ignition

timing, correct if necessary.
1. Connect engine to engine tester.
2. The adjustment should be made with a

stroboscopic timing light when engine oil
temperature is 80° C (176O F). The notch
located to the left of the Z 1 mark on the
crankshaft pulley (5O crankshaft rotation after
TDC) must align with the notch in the blower
housing at 900 50 rpm. The vacuum hose
must remain connected to the ignition distrihu-
tor. Timing is changed by loosening the distri-
butor clamping nut and turning the distributor
body.
NOTE
The firing point may vary by ? locrankshaft

rotation at 900 rpm. The variation must he
within the tolerance limits of the spark advance
curve at 6000 rpm. The timing must not advance
past 38' of crankshaft rotation above 6000 rpm.

9 911 Ignition system
Adjusting Ignition
(2.7 liter engines)
The dwell angle must be checked, and corrected

if necessary, prior to adjusting the ignition timing.
Apply same values as those applicable to the
2.4 liter engines.
1. Connect engine to the engine tester.
2. The adjustment is to be made with a strobo-

scopic timing light when engine oil temperature
is 80' C (176O F). T h e Z1 mark on the crank-
shaft pulley must align with the notch in the
blower housing when the engine is running at
850 - 950 rpm. The vacuum hose must remain
connected to the ignition distributor. Timing
can h e changed by loosening the distributor
retaining nut and rotating the distributor body.
NOTE
The ignition timing may vary by 1 locrankshaft

rotation at 900 rpm. The variation must be within
the tolerance limits of the advance curve when the
engine is running at 6000 rpm. T h e timing must
not advance past 38O of crankshaft rotation at
speeds above 6000 rpm.

Checking Timing Advance Curve
1. Remove vacuum hose and compare advance

-
curve with chart below at 1000 1500 -
- -
2000 4000 6000 rpm. The readings must
be within the two lines on the chart.
Ignition Advance Curve for Distributor for 2.4 1- and 2.7 I-Engines Bosch and Marelli except Carrera
BTDC
Beginning with 1913 model vehicles, the following

specifications apply t o MARELLI distributors:
Breaker gap 0.35 mm

Dwell angle 370 r: 30

Checking Distributor Advance Curve

on T e s t Stand
The advance curves may b e checked only on a

test stand equipped with CDS hookup.
Centrifugal Advance
1. Remove distributor and mount in test stand.
2. Remove distributor cap and connect according

to test stand manufacturer. Terminal 4 of the
ignition transformer must be connected t o
the test stand spark display unit by an ignition
wire.
3. Position t h e test stand selector lever t o

"auxiliary ignition coil"; the CDS unit will
then be switched on.
4. Move distributor and bridge so that one of

the light-markers will stop at 0'.

Note Contact Bounce
The vacuum hose must be disconnected and
speed reduction avoided during this test.
The light marker must not deviate by more than

5. Increase speed and compare rpm with the loat 300 rpm, or 2O at 3500 rpm.
degrees of advance (BTDC) with the chart
below.
Degrees M e a s u r e m e n t Errors ( c a m d i s p l a c e -
Distributor Shaft RPM
Advance ment)
- 750 rpm
600 Run distributor at 300 rpm. The 6 visible light
markers on the protractor must be spaced at
900 - 1050 rpm
60° intervals (+ lodeviation per cam).
1000 - 1650 rprn
1950 - 2550 rprn
2550 - 3050 rpm
At 3500 r p m the advance must be between

14.3' and 15.1°.
Centrifugal Advance Curve for Distributor for 2.4 1- and 2.7 I-Engines Bosch and Marelli except Carrera
BTDC
Marelli 40 f 3O
Breaker Point Gap Bosch ,013" (.35 mm)
Contact Pressure ~osch 22.3-28.2 02
500 1000 1500 2000 2500 3000 3500 4000

Distributor Shaft Speed Irpm)
Beginning with 1973 model vehicles, the following specifications apply t o MARELLI distributors:
Breaker point gap: 0.35 mm Dwell angle: 3Io i 30

Vacuum
1. Connect vacuum line of test stand to

distributor vacuum chamber.
2. Set speed t o 300 rpm and do not change

during the test.
3. Check vacuum at the indicated degrees

advance (ATDC):.
Degrees
Vacuum
Advance
lo 85 - 110 Torr (3.3 - 4.3 in.)
4O 100 - 125 Torr (3.9 - 4 . 9 in.)
Vacuum Advance Curve for Distributor for 2.4 1- and 2.7 I-Engines Bosch and Marelli except Carrera
ATDC

Ignition System 911
Speed Limiter Dwell Angle
1. Mount c a p on distributor and connect accord- 1. Connect standard ignition condenser between
i n g ro rest stand manufacturer. T h e ignition Terminal 1 of t h e distributor and t h e ground.
lead must be removed from the spark display
unit and connected to the distributor c a p so
that connection is m a d e between ignition
transformer and distributor. 2. Position test stand selector lever to the
"Dwell Angle" position.
2. Adjust spark display to 5 m m distance.

3. Attach test stand connecting wire to Termi-
n a l 1 of the distributor.
3. Increase speed until sparks stop. T h e sparks

must stop a t the following speeds:
4. Adjust speed to 300 rpm and turn bridge so
that the end of a light marker lines up with
Distributor for t h e '0 mark on the protractor. T h e length of
Cut-off RPM
Vehicle Type t h e light marker indicates dwell angle.
+
911 T 3250-50 rpm
911 E 3550t50 rpm
+
911 S 3650-50 rpm
Remove t h e ignition condenser after completing
t h e test. Connect vacuum hose and adjust igni-
tion timing after reinstalling the distributor in
Beginning with 1973 models, speed limiter the vehicle.
tolerances are as follows:
Distributor for
Cut-off RPM
Vehicle Type
+
911 T 3250-100 rpm
+
911 E 3550-100 rpm
911 S 3650+100 rpm
Reginning with 1974 models, t h e cutoff speed for

T y p e 911 (2.7 l i t e n ) and 911 S (2.7 liters) engines
is
3250 2 1 0 0 rpm

9 9~ Ignition System
Ignition Advance Curves for
2.7 Liter C a r r e r a Engine
Testing is accomplished in s a m e m a n n e r as t h a t
for distributors in 2. 4 l i t e r engines. T h e values
differing from those a p p l i c a b l e to t h e 2. 4 l i t e r
engines a r e shown below.
Values shown in t h e a d v a n c e curve graph apply

t o a distributor installed i n t h e e n g i n e with the
v a c u u m hose detached. A prerequisite for t h e
test is proper adjustment of t h e ignition t i m i n g
a t i d l e speed.
I G N I T I O N D I S T R I B U T O R A D V A N C E C U R V E F O R 2. I L I T E R C A R R E R A E N G I N E -
B O S C H A N D M ARELLI
BTDC
Breaker Point Bosch ,013" 1.35 mm)

Marelli ,013" (.35mm)
Bosch 22.3-28.2oz
Marelli 22.3-26.5 oz
0 1000 2000 3000 4000 5000 6000 7000 8000

b -,
Engine s p e e d (rpm)

The mechanical advance curve g a p h applies to
a distributor mounted in the test stand.
Degrees Advance (BTC) Distributor Shaft Speed

lo 700 - 950 rpm
6' 1140 - 1380 rpm
8' 1350 - 1930 rpm
11° 2250 - 2770 rpm
The ignition advance point must b e between 11.80

and 13.3O at 3500 rpm.
C E N T R I F U G A L A D V A N C E C U R V E FOR 2 . 7 L I T E R CARRERA E N G I N E -
B O S C H AND M ARELLI
B TDC
Dwell Angle Bosch 38 ?3'

Marelli 37 i 3 O
Breaker Point Bosch ,013" 1.35 m m )
Marelli ,013" 1.35 mm)
0 500 1000 1500 2000 2500 3000 3500 4000

Distributor Shaft speed (rpm) -
b

Testing of vacuum advance is accomplished on

the distributor test stand.
Vacuum Advance (ATC) Vacuum

lo 40 - 65 Tort
4O 54 - 78 Torr
The advance point must b e between 4.3' and

5.7' when vacuum is at 1 0 0 Torr.
T h e distributor cut-off speed in 2.7 liter Carrera

engine is 3550 - 3150 rpm.
V A C U U M A D V A N C E C U R V E FOR D I S T R I B U T O R S I N 2 . 7 L I T E R CARRERA E N G I N E -
B O S C H A N D M ARELLI
ATDC
Vacuum (Tort) b

ADJUSTING IGNITION TIMING
(Type 911 S - 1977 Model)
USA Version California Version
o+ o o + o
Adjust t o 0 - 2 ( Z 1 mark) a t a n oil tempera- Adjust t o 1 5 - 2 ATDC a t an o i l temperature
0 0
ture of 80 C / l I G F and idle speed o f 9 0 0 t o of 80' ~ / 1 7 6 OF and idle speed of 950 t o 1050
1000 rpni. rpm.
T h e plug between the vacuum hose and vacuum No plug is installed between t h e vacuum hose
advance unit must he installed and may not h e and vacuuin advance unit. T h e vacuum hose
removed, not even while adjusting. must r e m a i n connected for adjustments.

VACUUM ADVANCE CURVE TYPE 911 S FROM MODEL 77

(CALIFORNIA )

Ignition System 911
CENTRIFUGAL ADVANCE CURVE T Y P E 9 1 1 S C - MODEL 7 8
BT D C
0 500 1000
Distributor Shaft Speed (rpm)
1500 2000 2500 3000
-+
3500 4000
VACUUM ADVANCE CURVE TYPE 911 S C - MODEL 7 8
BTDC
ATDC Vacuum (mbar) 100 200 300

Adjusting Ignition Timing as from 1978 Models
Adjusting value: T o measure engine speed, use a tester with an

o + o + inductive speed recorder (clips).
Europe: 5 - 2 BTDC at 900
+- 50 l / m i n
USA: 5' + 2' BTDC at 950 - 50 l / m i n
1. Adjustment must b e m a d e on an engine with

o o
oil temperature of approx. 80 C. T h e 5
mark o n pulley must align with notch on fan
housing a t specified engine speed.
2. After adjustment of ignition timing, check

ignition timing advance.
Europe: 35' 2' BTDC a t 6000 l / m i n

USA: 26' 2' BTDC a t 6000 l / m i n
(vacuum hose detached)
If these control values a r e not reached, remove

distributor and inspect in a test bench.
T h e vacuum hose of USA version models c a n Note

remain attached.
An inspection or adjustment of t h e dwell angle
is not possible and also not necessary on t h e
breakerless ignition system installed as from
1918 models.

lgnirion System 911 9
A d j u s t i n g l g n i r i o n T i m i n g - l1I80 M o d e l s
1. Run engine t o operating temperature (oil 3. Connect timing light.

0 0
temperature approx. 9 0 ~ / 1 9 4 ' F). A t specified engine speed ihe 5 mark on
pulley must be opposite notch on blower
housing.
2. Connect engine tester.
0
A d j u r i n g Values: 5 before TDC a t
+
950 - 50 rpm
Adjust idle speed after connecting the vacuum

hoses.
Pull off vacuum hoses.

+
Adjust speed t o 050 - 50 rpm

Checking Ignition Retard/Advance - 1980 ~ o d e l s
Requiremenrs: Checking Vacuum Advance

Ignition timing adjusted t o specifications.
Connect blue hose on connection 2. Adjust

speed t o 950 50 rpm.
0
1. Centrifugal Advance Ignition timing must be between 8 and 1 2 before
(vacuum hoses detached) TDC.
0
Ignition timing must b e between 1 5 and 20 Adjust idle speed after connecting vacuum hoses.
0
before TDC a t 3000 rpm or 19 and 25 before
TDC ar 6000 rpm. If specified values cannot be reached, remove
and check distributor on a test bench.
2. Vacuum Rerard/Advance
(measured a t idle speed)
Checking Vacuum Retard
Connect blue hose a t connection 1 of double

vacuuln box and disconnect red hose a t connec-
tion 2.
1 = Retard (blue)
2 = Advance (red)
0
Ignition t i m i n g must be between 3 and 7 -
after
TDC.

Ignition system 911
CENTRIFUGAL ADVANCE CURVE TYPE 9 1 1 S C - MODEL 1 9 8 0
VACUUM ADVANCE CURVE TYPE 9 1 1 SC - MODEL 1 9 8 0
BTDC
0 100 200 300 400 500
ATDC Vacuum (mbar) b

Ignition 911 9
Adjusting Ignition Timing from 1981.Models
0
1. Run engine warm (oil temperature about 90 C). 4. Connect ignition stroboscope lamp.
25' mark on pulley should be opposite notch on
fan housing at 4000 rpm.
2. Connect engine tester.
3. Pull off vacuum hose.
Loosen and turn distributor to correct ignition timing.
5. Connect vacuum hose.

9 911 Ignition
Checking Ignition Timing Control from

1981 Models
Requirements:
Ignition timing adjusted to specifications.
1. Centrifugal control (vacuum hose detached).
Ignition timing should b e 3 to before TDC at

*
idle speed (900 50 rpm).
At 6000 rpm ignition timing must not exceed

25' before TDC.
2. Vacuum control (vacuum hose connected).
At an engine speed of 4000 r m i nition timing

g g
should b e between 28 and 32 before TDC.

Ignition 911 9
C E N T R I F U G A L A D V A N C E C U R V E T Y P E 9 1 1 SC - from 1981 Models
BTDC
0 500 1000 1500 2000 2500 3000 3500

Distributor Shaft Speed (rpm) b
V A C U U M A D V A N C E C U R V E T Y P E a l l SC - from 1981 Models

BTDC
0 100 200 300 400 500

Vacuum (mbar) b

Wartungsarbeiten, Technische Daten
Maintenance, Specifications
Travaux d'entretien, Caracteristiques techniques
Lavori di manutenzione, dati tecnici

MAINTENANCE, SPECIFICATIONS 911 0
CONTENTS
0 - INFORMATION
0.0 Information
1 - TECHNICAL DATA
Specifications Engine
Fuel System
Electrical System
Transmission and Final Drive
Chassis
Capacities
Dimensions
Weights
Performance Data
Specification Changes, from 1973 model
Carrera 2.7 Specifications
Specifications for 1974 Models
Filling Capacities
Dimensions
Weights
Performance
Technical Data - 1981 Models
2 - MAINTENANCE
2.1 Service Schedule

Service Schedule
2.2 Lubrication Schedule

Lubrication Schedule
2.3 Service Schedule

Preventive Maintenance Schedule

TYPE 9 1 1 S P E C I T I C A T I O N S - BEGINNING W I T H 1 9 7 2 MODELS
MOTOR 911 T 911 E 911 S

Number of cylinders 6 6 6
Cylinder arrangement horizontal, three cylinders per bank horizontal, three cylinders per bank horizontal, three cylinders per bank
Bore 84 mm (3.31 in.) 84 mm (3.31 in.) 84 mm (3.31 in.)
Stroke 70.4 mm (2.77 in.) 70.4 mm (2.77 in.) 70.4 mm (2.77 in.)
Engine displacement 2341 c c (142.8 cu. in.) 2341 c c (142.8 cu. in.) 2341 c c (142.8 cu. in.)
Compression ratio 7.5 : 1 8.0 : 1 8.5 : 1
Cylinder pressure
Horsepower rating (DIN) 140 HP 165 HP 190 HP

(SAE NET) 133 HP 157 HP 181 HP
at engine speed of 5600 rpm 6200 rpm 6500 rpm
Maximum torque (DIN) 20 mkp 21 mkp 22 rnkp
WE) 166 ft. lbs. 174 ft. lbs. 181 ft. lbs.
at engine speed of 4000 rpm 4500 rpm 5200 rpm
Specific power output (DIN) 60 HP/ltr 70 HP/ltr 81 HP/ltr
55 HP/ltr 65 HP/ltr 75 HP/ltr
.93 HP/cu. in. 1.09 HP/cu. in. 1.26 HP/cu. in.
Maximum engine speed 6500 rpm 7100 rpm 7300 rpm

Cut off speed of ignition
distributor speed limiter 6500 1100 rpm 7100 2 100 rpm 7300 1100 rprn
Fuel coctanerequirement 91 , 91 91
Engine weight .
approx 183 kp (404 lbs) approx. 182 kp (402 lbs) .
approx 182 kp (402 lbs)
Nominal fuel comsumption 9.0 ltr/100 km 26.1 mpg 9,5'ltr/100 km 24.7 mpg 10.2 ltr/100 km 23.0 mpg
Cooling system air cooled by axial fan on alternator air cooled by axial fan on alternator air cooled by axial fan on alternator
shaft shaft shaft
Air fan drive by V-belt off crankshaft by V -belt off crankshaft by V-belt off crankshaft
Crankshaft to fan ratio approx. 1 : 1 . 3 approx. 1 : 1 . 3 approx. 1 : 1 . 3
Air flow rate .
approx 1230 Itr/sec .
approx 1380 Itr/sec approx. 1380 ltr/sec
@ 5800 rpm @ 6500 rpm @ 6500 rpm
Lubrication system dry sump dry sump dry sump

Oil cooling system oil cooler on crankcase in air stream oil cooler on crankcase in air stream oil cooler on crankcase in air stream
of fan of fan of fan plus auxiliary oil cooler in front
of vehicle
Oil pressure indication by warning light by warning light by gauge in kp/cm 2
Oil pressure: engine warm
8 0 ' ~ (175O~)at 5500 rpm 5.5 -7 k p /cm 2 (78-99 psi) 5.5-7 kp/cm2 (78-99 psi) 5.5-7 kp/cm2 (78-99 psi)
Max. oil temperature 130°C (265'~) 130°c (265'~) .
Qil filter type full flow full flow full flow

Oil consumption 1 1/2 - 2 ltr/100 km
11/2 - 2 US qts/600 m i
Crankcase two-piece pressure casting of two-piece pressure casting of two-piece pressure casting of
aluminum/magnesium alloy aluminum/magnesium alloy aluminum/magnesium alloy
Crankshaft forged, surface-hardened forged. surface-hardened forged, surface-hardened
Crankshaft bearings eight, plain journal eight, plain journal eight, plain journal
Main bearings 1-7 split shell, tri-metal inserts split shell, tri-metal inserts split shell, tri-metal inserts
Main bearing 1 thrust bearing thrust bearing thrust bearing
Main bearing 8 one-piece bushing, hard-lead lined one-piece bushing, hard-lead lined one-piece bushing, hard-lead lined
Connecting rods forged steel forged steel forged steel surface-hardened
Connecting rod bearings split shell, tri-metal inserts split shell, tri-metal inserts split shell, tri-metal inserts
Piston pin bushings bronze, pressed-in bronze, pressed-in bronze, pressed-in
Intermediate shaft bearings two, plain journal two, plain journal two, plain journal
Pistons light-alloy, die-cast light-alloy, die-cast light -alloy, die-cast
box -shaped
Piston pins floating, secured with circlips floating, secured with circlips floating, secured with circlips
Piston rings two compression rings, one oil two compression rings, one oil two compression rings, one oil
scraper scraper scraper

Cylinders individual, grey -cast iron with individual, grey-cast iron sleeve with individual, grey-cast iron sleeve with
integral cooling fins finned light alloy jacket finned light alloy jacket
Cylinder heads light alloy, finned individual castings light alloy, finned individual castings light alloy (Y -alloy) finned individual
for each cylinder for each cylinder castings for each cylinder
Valve seat inserts shrunk-in, grey-cast iron alloy shrunk-in, grey-cast iron alloy shrunk-in, grey -cast iron alloy
Valve guides shrunk-in, special bronze shrunk-in, special bronze shrunk-in, special bronze
Spark plug threads 14 x 1.25, machined into cylinder 1 4 x 1.25, machined into cylinder 14 x 1.25, machined into cylinder
heads heads heads
Valves 1 intake and 1 exhaust valve per 1 intake and 1 exhaust valve per 1 intake and 1 exhaust valve per
cylinder cylinder cylinder
Valve arrangement overhead in 'V" overhead in 'V overhead in 'V"
Exhaust valves sodium cooled, with reinforced seat sodium cooled, with reinforced seat sodium cooled, with reinforced seat
Valve springs 2 coil springs per valve 2 coil springs per valve 2 coil springs per valve
Valve timing OHC, 1 camshaft per cylinder bank OHC, 1 camshaft per cylinder bank OHC, 1 camshaft per cylinder bank
Ca'mshafts cast steel, in three plain journal cast steel, in three plain journal cast steel, in three plain journal
bearings in camshaft housing bearings in camshaft housing bearings in camshaft housing
Camshaft drive by chain by chain by chain

Valve timing with 1 mm
(0.039 in.) valve clearance
inlet opens 15' BTDC 18' BTDC 38' BTDC
inlet closes 2g0 ATDC 36' ATDC 50' ATDC
exhaust opens 41° BTDC 38' BTDC 40' BTDC
exhaust closes 5' BTDC 8' ATDC 20' ATDC
Intake valve lift at overlap TC with
0 .l m m (0.004 in.) valve clearance 2.3 - 2.7 mm (0.091 - 0.106 in.) 2.7 - 3 . 1 mm (0.106 - 0.122 in.) 5.0 - 5.4 mm (0.197 - 0.213 in.)
Valve clearance, cold, 0.10 m m (0.004 in.) measured 0.10 mm (0.004 in.) measured 0.10 m m (0.004 in.) measured
intake and exhaust between valve stem and rocker arm between valve stem and rocker arm between valve stem and rocker arm
Clutch single plate, dry, pull-actuated single plate, dry, pull-actuated single plate, dry, pull actuated
Pressure plate type MFZ 225 KL, Fichtel &Sachs MFZ 225 KL, Fichtel & Sachs MFZ 225 KL, Fichtel & Sachs
Plate pressure 650 - 720 kp (143 - 159 Ibs.) 650 - 720 kp (143 - 159 Ibs.) 650 - 720 kp (143 - 159 Ibs.)
FUEL S Y S T E M BOSCH intake manifold fuel injection BOSCH intake manifold fuel injection BOSCH intake manifold fuel injection
with double row six-plunger, with double row six-plunger, with double row six -plunger,
injection pump injection pump injection pump
Air cleaner induction air silencer with cartridge induction air silencer with cartridge induction air silencer with,cartridge
filter and induction air preheating filter and induction air preheating filter and induction air preheating
system system system

:uel pump 1 electric roll-cell pump 1 electric roll-cell pump 1 electric roll-cell pump
rransfer rate 125 ltr/h (128 qts/h) 125 ltr/h (128 qtsjh) 125 ltr/h (128 qts/h)
3perating pressure 1 kp/cm2 (14.2 psi) 1 kp/cm2 (14.2 psi) 1 kp/cm 2 (14.2 psi)
'ressure relief valve opens at .
approx 2 kp/cm2 (28.4 psi) . 2
approx 2 kp/cm (28.4 psi) approx. 2 kp/cm 2 (28.4 psi)
h e 1 filter fuel screen ahead of fuel injection fuel screen ahead of fuel injection fuel screen ahead of fuel injection
pump with built-in restrictor valve pump with built-in restrictor valve pump with built-in restrictor valve
SLECTRICAL S Y S T E M
3perating voltage 12 volts 12 volts 12 volts
3attery capacity 2 x 36 Ah 2 x 36 Ah 2 x 36 Ah
Senerator AC, 770 watts AC, 770 watts AC, 770 watts
~ o l t a g regulator
e same make as generator same make as generator same make as generator
[gnition type capacitive discharge system (CDS) capacitive discharge system (CDS) capacitive discharge system (CDS)
'iring order 1- 6- 2- 4- 3- 5 1- 6- 2- 4- 3- 5 1- 6- 2- 4- 3- 5
[gnition transformer BOSCH BOSCH BOSCH
3istributor MARELLI 50.10.974.1 MARELLE 50.10.974.2 MARELLI 5O.lO.974.3
:either kind) BOSCH JFUDR6 0231169003 BOSCH JFUDR6 0231169004 BOSCH JFUDRG 0231169005
jpark advance centrifugal and vacuum centrifugal and vacuum centrifugal and vacuum
3asic ignition timing 5O ATDC @ 900 rpm 5' ATDC d 900 rpm 5' ATDC @ 900 rpm
. .
. . .. . . . .
3well angle BOSCH 38'2 3O BOSCH 35' t 3' BOSCH 38' 3'
MARELLI 4O0 i 3' MARELLI M'.? 3' MARELLI 40' 3'

Spark plugs BOSCH W 235 P 21 BOSCH W 265 P 21 BOSCH W 265 P 21
(either kind) or similar BERU 265/14/3 P or similar BERU 265/14/3 P or similar
Electrode gap 0.5 - 0.6 mm 0.5 - 0.6 mm
Starter BOSCH 12 V, 1.5 HP BOSCH 12 V, 1.5 HP BOSCH 12 V, 1.5 HP
B u l b L i s t ( 1 2 V)
Headlamps (Halogen) H 1 (see USA table) 55 W, 2 each lamp 55 W, 2 each lamp
Driving lamps (Halogen)
H 1 and H 3 (see USA table)
Fog lamps 35 W
Stop lamp/tail lamp (see USA table)
~ i r e c t i o n a signals
l (see USA table)
~ a c k u plamp (see USA tab1 e)
Fog tail lamp (not for USA)
Interior lamp, luggage compart-
met lamp, glove compartment
lamp 10 W
Parking lamp, license plate
lamp (see USA table)
Instrument lamps, control
lamps, ashtray lamp 2W
Control lamp for ventilator
and auxiliary heater 1.2 W

Bulb List 911 T 911 E 911 S
Sealed beam headlamps

Fog lamps
Stop/tail lamp
Front turn signal/parking lamps
Rear turn signal
Backup lamp
Sidemarker lamp
Interior lamp, luggage compartment
lamp, glove compartment lamp
License plate lamp
Instrument lamps, control lamps,
ashtray lamp
Control lamp for ventilator and
auxiliary heater
Fuses
F u s e Box I
1 - Interior lamp, luggage compart-
ment lamp, glove compartment
lamp, clock
2 - Emergency flasher
3 - Power windows
4 - Cigarette lighter (auxiliary
heater)
5 - Sun roof, rear window wiper
6 - Windshield wipers, windshield
washer
7 - Fresh air fan, rear window
defroster

8 - Stop, rear turn ~ignal,
and backup lamps
9 - Left front turn signal lamp
10 - Right front turn signal lamp
F u s e Box I1
1 - High beam, left
2- High beam, right
3- Low beam, left
4- Low beam, right
5 - Parking lamp, left
6 - Parking lamp, right
7 - License plate lamp
8 - . Fog lamp
TRANSMISSION A N D
FINAL DRIVE
Type Transmission and differential Transmission and differential Transmission and differential
unitized in one assembly unitized in one assembly unitized in one assembly
Transmission 4 forward speeds, one reverse, 4 forward speeds, one reverse, 4 forward speeds, one reverse,
with Porsche synchronization with Porsche synchronization with Porsche synchronization
(5 speeds optional) (5 speeds optional) (5 speeds optional)

Gear ratio, reverse speed 3.325 : 1 3.325 : 1
Gear shift system shift linkage with floor mounted shift linkage with floor mounted shift linkage with floor mounted
gearshift lever gearshift lever gearshift lever
Rear axle drive spiral bevel gears, differential unit spiral bevel gears, differential unit spiral bevel gears, differential unit
Rear axle ratio 7/31, 4.429 : 1 7/31, 4.429 :1 7/31, 4.429 :1
Power transfer to rear wheels by drive shafts with to rear wheels by drive shafts with to rear wheels by drive shafts with
two CV joints per shaft two CV joints per shaft two CV joints per shaft
Gearbox weight approx. 49 kp (108 lbs), ready for approx. 49 kp (108 lbs), ready for approx. 49 kp (108 lbs), ready for
installation including oil supply installation including oil supply installation including oil supply
but without starter. but without starter. but without starter.
Limited slip differential ZE limited slip differential optional ZF limited slip differential optional ZF limited slip differential optional
with manual transmissions with manual transmissions with manual transmissions
Sportomatic Transmission
Type
Clutch (190 mm dia) hydraulic torque converter and vacuum hydraulic torque converter and vacuum hydraulic torque converter and vacuum
actuated single plate, dry clutch actuated single plate, dry clutch actuated single plate, dry clutch
MEZ 190K MFZ 190K MFZ 190K
Number of gears 4 forward, 1 revers% and parking lock 4 forward, 1 reverse, and parking lock 4 forward, 1reverse, and parking lock
Selector lever location floor mounted on center tunnel floor mounted on center tunnel floor mounted on center tunnel
Torque converter ratio 2.19 :1 2.10.: 1
Rear.axle ratio
. .. . -

Tow-start speed ,in 'i" 35 kmh (21 mph) 35 krnh (21 mph) 35 kmh (21 mph)
St allspeed approx. 2500 - 2700 rpm approx. 2500 - 2700 rpm approx. 2900 - 3100 rpm
Clutch speed approx. 3000 rpm approx. 3000 rpm approx. 3000 rpm
CHASSIS
Body characteristics welded assembly, sheet metal box welded assembly, sheet metal box welded assembly, sheet metal box
section, unitized with body section, unitized with body section, unitized.with body
Wheel suspension, front independent, with shockabsorber struts independent, with shockabsorber struts independent, with shockabsorber struts
and transverse control arms and transverse control arms and transverse control arms
rear independent, with triangulated independent, with triangulated independent, with triangulated
control arms control arms control arms
Springing, front 1 round longitudinal torsion bar 1 round longitudinal torsion bar 1 round longitudinal torsion bar
per wheel per wheel per wheel
rear 1 round transverse torsion bar per 1 round transverse.torsion bar per 1 round transverse torsion bar per
wheel wheel wheel
Rear control arm adjustment
(spring plate inclination)

Shockabsorbers front double-action hydraulic double-action hydraulic double-action hydraulic
shockabsorber strub shockabsorber strub shockabsorber strub
rear double-action hydraulic double-action hydraulic double-action hydraulic
shockabsorber shockabsorber shockabsorber
Stabilizers transverse, 15 mm
(0,59 in. ) dia
Steering rack-steering ZF rack-steering ZF rack-steering ZF
Mean steering ratio 17,78 : 1 ll,78 : 1 17,78 : 1
Steering wheel turns, lock-to-lock approx. 3 ' 1 approx. 3.1 approx . 3 , l
Smallest turning circle approx. 10,7 m approx. 1 0 , l m approx . 1 0 , l m

( 3 5 , l ft.) ( 3 5 , l ft. ) ( 3 5 , l ft.)
front + 0' 1 0 ' t o '

rear 0' t o + 20 ' per wheel 0' to + 20 ' per wheel O0 to + 20 ' per wheel
Chamber front oO + 10 ' o0 + 10 ' oO+ 1 0 '

rear - 10' - 110' - + 10 '
Caster 6O5'+15' 605'i15' 6'5' +15'
Indbation 55 ' 55 55 '
0
Difference angle, front wheels turned 20 0 to 30 ' Oto30' 0 to 30 '

Wheels steel, 5 1/2J x 15, optional 6J x 1 5 steel, 6J x 15 or optional light 6J x 1 5 light-alloy
steel or light alloy alloy
Tires 185/70 VR 1 5
Tire pressures (cold)

front 2.0 atrn (29 psi) 2.0 atrn (29 psi) 2.0 atrn (29 psi)
rear 12.4 atrn (35 psi) 2 . 4 atrn (35 psi) .2.4 atrn (35 psi)
Service brake hydraulic, dual-circuit, vented - hydraulic, dual-circuit, vented - hydraulic, dual-circuit, vented -
disc brakes on all four wheels disc brakes on all four wheels disc brakes on all four wheels
Total effective braking surface
(foot brake) 257 cm 2 (39.84 sg. in.)
Effective brake disc
diameter front 235 m m (9.25 in.) 235 m m (9.25 in.) 228 mm (8.98 in.)
rear 244 mm (9.61 in.) 244 mm (9.61 in.) 244 m m (9.61 in.)
Parking brake mechanical, to rear wheels mechanical, to rear wheels mechanical, to rear wheels
BODY
Type all-steel body, unitized with under- all-steel body, unitized with under- all-steel body, unitized with under-
bady, sloping front, fastback rear body, sloping front, fastback rear body, sloping front, fastback rear
in Coupe in Coupe in Coupe
Doors 2 doors attached to the body A-pillars 2 doors attached to the body A-pillars 2 doors attached to the body A-pillars

Door opening angle approx. 70' approx. 70° approx. 70'
Windows
Windshield one-piece, constant radius, convex one-piece, constant radius, convex one-piece, constant radius, convex
contour, laminated safety glass contour, laminated safety glass contour, laminated safety glass
Door windo'ws crankdown windows crankdown windows crankdown windows
--
Rear side windows open and lock in position open and lock in position open and lock in position
Rear window one-piece, convex contour, one-piece, convex contour, one-piece, convex contour,
electrically heated electrically heated electrically heated
Windshield wipers electric, 2 parallel wiping arms, electric, 2 parallel wiping arms, electric, 2 parallel wiping arms,
3 speeds 3 speeds 3 speeds
Front hood opens from front of vehicle, with opens from front of vehicle, with opens from front of vehicle, with
hydraulic stays, hood release under hydraulic stays, hood release under hydraulic stays, hood release under
instrument panel instrument panel instrument panel
Engine compartment lid opens from rear of vehicle, with opens from rear of vehicle, with open from rear of vehicle, with
hydraulic stays, lid release in left hydraulic stays, lid release in left hydraulic stays, lid release in left
rear door post rear door post rear door post
Heating hot air heating with remote control; hot air heating with remote control; hot air heating with remote control;
hot air mixable with outside air; hot air mixable with outside air; hot air mixable with outside air;
2 defroster outlets at the windshield, 2 defroster outlets at the windshield, 2 defroster outlets at the windshield,
and 2 hot air outlets into passenger and 2 hot air outlets into passenger and 2 hot air outlets into passenger
compartment leg area compartment leg area compartment leg area

Ventilation flap-controlled fresh air chamber, flap-controlled fresh air chamber, flap-controlled fresh air chamber,
3-speed fan, air distributor system, 3-speed fan, air distributor system, 3-speed fan, air distributor system,
centralized control unit centralized control unit centralized control unit
CAPACITIES
Engine approx. 8 ltr (8.5 US qts) premium .
approx 8 ltr (8.5 US qts) premium approx. 8 Itr (8.5 US qts) premium
quality HD oil according to API classi- quality HD oil according to API classi- quality HD oil according to API classi-
fication SD or SE; summer SAE 30, fication SD or SE; summer SAE 30, fication SD or SE; summer SAE 30,
winter SAE 20, below -15OC (+5OF) winter SAE 20, below - 1 5 ' ~ OF) winter SAE 20, below - 1 5 ' ~ OF OF)
SAE 1 0 W SAE 10 W SAE 10 W
first filling approx. 9 Itr (9.5 US qts)
with oil cooler
Engine together with Sportomatic
(torque converter in engine oil approx. 11 ltr (11.5 US qts)
circuit) approx. 10 Itr (10.5 US qts) approx. 10 Itr (10.5 US qts) with oil cooler
Transmission and differential approx. 3.0 Itr (3 US qts) SAE 30 trans- approx. 3.0 Itr (3 US qts) SAE 30 trans- .
approx 3.0 Itr (3 US qts) SAE 30 trans-
mission oil, specification MIL-L 2105 mission oil, specification MIL-L 2105 mission oil, specification MIL -L 2105
or MIL-L 2105 B or MIL-L 2105 B or MIL-L 2105 B
Fuel tank approx. 62 ltrs (16.4 US gals) including approx. 62 ltrs (16.4 US gals) including approx. 62 ltrs (16.4 US gals) including
6 ltrs (1.6 US gals) reserve 6 ltrs (1.6 US gals) reserve 6 ltrs (1.6 US gals) reserve
Fuel requirement: 91 octane (RON) Fuel requirement: 91 octane RON^ Fuel requirement: 91 octane (RON)
Brake fluid reservoir approx. 0.2 Itr (0.42 US pints) approx. 0.2 Itr (.0.42 US pints) approx. 0.2 ltr (0.42 US pints)
Windshield washer reservoir approx. 2.0 ltr (2 US qts) .
approx 2.0 ltr (2 US qts) .
approx 2.0 ltr (2 US qts)
DIMENSIONS
Vehicle empty according to DIN
Wheelbase 2271 mm (89.4 in.) 2271 mm (89.4 in.) 2271 mm (89.4 in.)
Track, front (wheel center 108 mm
above torsion bar center) 1360 mm (53.54 in.) 1372 mm (54.0 in.) 1372 mm (54.0 in.)
Track, rear (wheel center 12 mm
below transverse tube center) 1342 mm (52.82 in.) 1354 mm (53.34 in.) 1354 mm (53.34 in.)

Length, USA and Canada only 4163 mm (163.9 in.) 4163 mm (163.9 in.) 4163 mm (163.9 in.)
Width 1610 mm (63.39 in.) 1610 mm (63.39 in.) 1610 mm (63.39 in.)
Height (unladen) 1320 mm (51.97 in.) 1320 mm (51.97 in.) 1320 mm (51.93 in.)
. _. . -- . .
Ground clearance 150 mm (5.91 in.) 150 mm (5.91 in.) 150 mm (5.91 in.)
WEIGHTS
Unloaden weight 1061 kp (2340 lbs) 1061 kp (2340 lbs) 1061 kp (2340 lbs)
Maximum load capacity 280 kp (617 Ibs) 280 kp (617 lbs) 280. kp (617 lbs)
Total permissible weight 1400 kp (3086 lbs) 1400 kp (3086 lbs) 1400 kp (3086 lbs)
Maximum axle load, front 600 kp (1320 lbs) 600 kp (1320 lbs) 600 kp (1320 lbs)
rear 840 kp (1852 lbs) 840 kp (1852 lbs) 840 kp (1852 lbs)
Permissible trailer weight,

without brakes 480 kp (1058 lbs) 480 kp (1058 lbs) 480 kp (1058 lbs)
with brakes 600 kp (1320 lbs) 600 kp (1320 lbs) 600 kp (1320 lbs)

PERFOR ANCE DATA
Max. speed (with 4 or 5 208 kmh 220 kmh 230 kmh
speed transmission) 129 mph,, 137 mph 143 mph
with Sportomatic transmission ca. 5 kmh (3 mph) slower than shown above
1 km with standing start at
DIN empty weight + l / 2
loading capacity 30.0 sec 28.5 sec 27.5 sec
Weight-to-power ration DIN 7.5 kp/HP 6.37 kp/HP 5.52 kp/HP
Nominal fuel consumpti0.n 9.0 ltr/100 km 9.5 ltr/100 km 10.2 ltr/100 km
26.1 mpg(US) 24.7 mpg (US) 23.0 mpg (US)
Engine oil consumption -
1.5 2.0' Itr (1.5 - 2.0 US qts -
1.5 2.0 ltr (1.5 - 2.0 US qts -
1.5 2.0 Itr (1.5 - 2.0 US qts
per 600 miles) per 600 miles) per 600 miles)
m
'a
a
0
I-.
'-h
I-.
0
P,
rt
I-.
0
3
V)
(0
d
I.

Specifications
0
CARRERA 2 . 7 S P E C I T I C A T I O N S
Shown below are specifications which differ from Type 911 S/2.4
ENGINE TOURING SPORT
Bore mm
Stroke mm
Displacement ' CC
Compression ratio e
Compression pressure kp/ cm 2 max. difference between cylinders = 1.5 kp/
cm 2 , engine oil temp = 60°C (140'~) minimum
Horsepower rating (DIN) HP (KW)
Horsepower rating (SAE) HP (KW)
at engine speed of rpm
Max. torque mkp (Nm)
a t engine speed o f rpm
Specific power output (DIN) HP/ltr (KW/ltr)
Mean piston speed a t
maximum power m/sec
Mean pressure at
Md. max. kp/ cm 2
Max. permissible engine.speed rpm
Fuel octane requirements RON
Pistons light-alloy, forged
Cylinders light-alloy cylinders with Ni coating
Clutch Type MFZ 225 KL MFZ 225 KL
Clutch pressure kp 720 - 780 720 - 780
Fuel System
Injection pump BOSCH #
PORSCHE #

0 911 Specifications
TOURING SPORT
ELECTRICAL SYSTEM
Operating voltage v
Battery capacity Ah
Ignition distributor BOSCH
(either brand) MARELLI
Breaker point gap mm
(BOSCH and MARELLI)
Dwell angle BOSCH
MARELLI
Basic ignition timing TDC a t 900 rpm TDC at 900 rpm
(vacuum hose attached)
Spark plugs BOSCH
(gap in mm) BOSCH
BERU
BERU
TRANSMISSION AND DIFFERENTIAL

Ratios, 5 -speed transmission 1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse
Rear axle ratio

Climbing ability (calculated)
5-speed transmission, 1st gear
vehicle empty per DIN plus 2nd gear
1/2 load 3rd gear
4th gear
5th gear
CHASSIS
Stabilizer, front/rear m m dia.
Wheels, front, forged light -alloy
rear, forged light-alloy
Tires, front
rear
Tire pressure, front/rear kp/cm2 (bar) 2.0/2.0 (1.96/1.96)
Spare tire, Collapsible 5 1/2 J x 1 5 steel 6 J x 1 5 light-alloy
Torsion bar adjustment 36' 30' 33O

Specifications 911 0
TOURING SPORT
D I M E N S I O N S WHEN
E M P T Y PER DIN
Track, front
Track, rear, with 7 mm
spacer on each wheel
Wheel center above center
of front torsion bar
Wheel center below center
of rear transverse tube
Overall width
WEIGHTS
Engine weight
Empty, per DIN
Total permissible weight
Permissible axle load, front
rear
Power/weight ratio
PERFORMANCE D A T A
Max. speed kmh (mph)

Acceleration, 0 - 100 km (0-62 sec
mph) empty per DIN + 1/2 load
Standing kilometer sec
empty per DIN + 1 / 2 load
Nominal fuel consumption ltr./100 km
FILLING C A P A C I T I E S
Engine (initial filling)

Dipstick min/max Itr. (US guarts) 11/13 (12/13)
Oil change quantity ca. ltr. (US guarts 10 (10)
Transaxle (2 ca. Itr. (US pints) 3 (6.3)
Fuel tank Itr. (US gal.) 85 less 9 reserve 85 less 9 reserve
(22 less 2) (22 less 2)
(:) EP oil Mil-L 2105 or 2105 B

Limited-slip differential:
Kendall 80/90 M 2 C 119 A or
eguiralent .
Specifications 911 0
S P E C I F I C A T I O N S FOR 1 9 7 4 MODELS
Carrera
FILLING C A P A C I T I E S
Engine (initial filling) .

approx 11 Itr . same as 911 .
approx 1 3 Itr.
(11.6 US gts) premium (13.7 US gts)
(applies to dipstick check brand HD oil, API classi- with oil cooler
according to owner's fication SD or SE;
manual) summer SAE 30, winter
SAE 20, below -15' C
SAE 10 W
Engine with Sportomatic

transmission
. .
approx 2 Itr
(2.1 US gts) more
same as 911 same as 911
Transmission and . .
approx 3 ltr same as 911 same as 911
differential (3.2 US gts) per MIL-
L-2105 or MIL-L-2105B
SAE 90
Sportomatic transmission approx. 2.5 ltr. same as 911 same as 911

(2.6 US gts)
Fuel tank 80 ltr. (22 US gal. ) same as 911 same as 911

less 8 ltr. (2 US gal.)
reserve
Brake fluid reservoir .

approx 0.2 Itr. same as 911 same as 911
(0.4 US pt)
Windshield washer approx. 8.5 Itr. same as 911 same as 911

reservoir (9 US gts)
DIMENSIONS PER DIN

EMPTY WEIGHT
Wheelbase same as 911 same as 911
Length same as 911 same as 911
Width sama as 911 same as 911
Height same as 911 same as 911
Ground clearance same as 911 same as 911

0 SII Specif'ications
Carrera
Empty weight, per DIN same as 911 same as 911
with Sportomatic same as 911 same as 911

transmission
Max. permissible weight same as 911 same as 911
Permissible axle load,

front same as 911 same as 911
rear same as 911 same as 911
Trailer weight,
w/o brakes same as 911 same as 911
with brakes same as 911 same as 911
PERFORMANCE
Max. speed kmh (mph)

(with 4-speed or 5-speed
transmission)
with Sportomatic approx. 5 kmh same as 911 same as 911

( 3 mph) less
Acceleration, 0 - 1 0 0 kmh 8.5 sec. 7.6 sec. 6.3 sec.

(0 - 62 mph) per DIN
empty weight + 1/2 load
Standing kilometer 29.0 sec. 26.5 sec.

(per DIN empty weight
+ 1/2 load)
Specific power output
(per DIN 70020 empty
weight)
Fuel consumption 1 4 ltr/100 km 1 5 ltr/100 km 1 8 ltr/100 km

(average consumption in (17 mi. per US gal.) (16 mi. per US gal.) (13 mi. per US gal.)
highway traffic, incl.
maximum speed travel)
Oil consumption approx. 1.5 ltr/1000 km same as 911 same as 911

(2.5 US gts/1000 mi.)

T E C H N I C A L D A T A 1 9 7 5 MODELS
Carrera
CAPACITIES
Engine (initial filling) Approx. 1 3 liters (13, 8 US gt) of same as 911 S

brand name HD oils of API classifi-
(Measurement with dipstick cation SD or SE; SAE 30 for summer
according to operating instruc- SAE 20 for winter, SAE 10 W below
tions applies) -15O C (+ 5O F)
Engine with sportomatic .

Approx 2 liters (2.1 US gt) more same as 911 S
~iansmissionwith differential Approx.. 3 liters (3.2 US gt) accord- same as 911 .S

ing to MIL-L-2105 of MIL-L 2105 B
SAE 90
Sportomatic transmission Approx. 2.5 liters (2.65 US gt) same as 911 S
Fuel tank 80 liters (21 US gal.) including same as 911 S

8 liters (2.1 US gal.) in reserve
Brake fluid reservoir .

Approx 0.2 liters (0.21 US gt) same as 911 S
Windshield washer reservoir Approx. 8.5 liters (2.2 US gal.) same as 911 S
DIMENSIONS A T CURB
WEIGHT A C C O R D I N G
T O DIN
Wheelbase 227i mm (89.4 in.) same as 911 S
Length 4291 mm (168.9 in.) same as 911 S
Width 1610 mm (63.3 in.) 1652 mm
Height 1320 mm (51.9 jn.) same as 911 S
Ground clearance 180 mm (7.1 in.) same as 911 .S
Ground clearance a t full load 140 mm (5.5 in.) same as 911 S

Carrera
WEIGHTS
Curb weight according to DIN 1160 kg (2552 lb) same as 911 S
with sportomatic transmission 1160 kg (2552 Ib) same as 911 S
Max. total weight 1400 kg (3086 lb) same as 9Tl S
Max. axle load, front 600 kg (1323 lb) same as 911 S

rear 840 kg (1852 lb) same as 911 S
Trailer load, without brakes :* 480 kg (1058 Ib) same as 911 S

with brakes 800 kg (1763 Ib) same as 911 S
Max. roof load :: 35 kg (77 Ib) same as 911 S

(coupe only)
PERFORMANCE
Top speed 134 mph same as 911 S

(with 4 or 5 speed transmission)
with sportomatic About 3 mph slower same as 911 S
Acceleration from 0 to 62 mph 8 - 4 seconds same as 911 S

a t DIN curb weight plus 1/2
payload
Kilometer from standing start 29.0 seconds same as 911 S

(DIN curb weight plus 1/2
payload)
Weight/power ratio same as 911 S

(curb weight DIN 70020)
same as 911 S
Fuel consumption 13-15 1/100 km) same as 911S

(average consumption on (13.7-16 US gt/62 mi.)
highways and country roads)
Oil consumption Approx. 1.5 1/1.6 US gt same as 911 S

1000 km/620 mi.
* Never exceed max. total weight. Note

Grades up to 16 70. Installation of extra equipment (air conditioner
etc.) reduces payload.

TECHNICAL DATA - 1976/1977 Models
Capacities
Engine (initial filling) approx. 13 ltr. (13. 75 US qt) of brand

name HD oil per API Classifications
(measured with oil dipstick per SD or SE; summer SAE 30, winter SAE
operating instructions) -
20, below 15' C/+ 5' F SAE 10 W
E n e e with Sportomatic approx. 2 ltr. (2.1 US qt) more
Transmission and differential approx. 3 ltr. (3.2 US qt) per MIL-L

2105 or MIL-L 2105 B, SAE 90; f o ~
locking differential gear lube per
M2C28B, SAE 90
Sportomatic transmission approx. 2. 5 ltr. (2. 6 US qt)
Fuel tank 80 ltr. (21. 1 US gal. ), of which 8 ltr.

(2.1 US gal. ) in reserve
Brake fluid reservoir approx. 0.2 ltr. (6. 75 fl oz)
Windshield washer tank approx. 8. 5 ltr. (2. 2 US gal. )
Dimensions a t D I N Curb Weight
Wheelbase mm/inch 2272/89.45
Length mm/inch 4291/168.94
Width mm /inch 1610/63. 39
Height mm/inch 1340/52.76
Ground clearance
Ground clearance a t
max. total weight

Weight
Curb woight per DIN kg/lb
Max. total weight kg /lb
Max. axle load, front kg/lb

rear kg/lb
Max. roof load *(only coupe) kg/lb
Performance
Max. speed (with 5 speed transm. ) km/h/mph above 220/136.7
With Sporiomatic km/h/mph 215/133.6
-
Acceleration 0 100 k m / h a t
DIN curb weight -t 1 / 2 payload sec.
Kilometer from standing start

(DIN curb weight + 1 / 2 payload) see. 29. 0
Weight-to-power kg/HP 6. 8
(curb weight DIN 70020) kg/kw 9.24
Fuel consumption (average value, ltr/100 km -

1 5 15
highways and country roads) miles/US gal. 15.6 18 -
Oil consumption ltr/1000 km approx. 1.5
(US qt/620 mi. )
* Max. total weight must not b e exceeded.
CAUTION
Installation of extra equipment (air conditioner, etc. )

reduces the payload.

TECHNICAL DATA - 1978/1979 Models
Capacities
Engine (initial filling) approx. ' 1 3 Itr. /13.75 US qt of

brand name HD per API Classification
(measured with oil dipstick per operating SD or SE; summer SAE 30, winter SAE
instructions) 20, below - 15' C (+ 5' F) SAE 1 0 W
Transmission and differential approx. 3 Itr. /3. 2 US qt per MIL-L 2105

or MIL-L 2105 B, SAE 90; with locking
differential gear lube per M2C28B, SAE 90
Fuel tank 80 ltr. /21.1 US gal. , of which 8 1tr.l

2.1 US gal. in reserve
Brake fluid reservoir approx. 0.2 Itr. /6.75 US f l oz
Windshield washer tank approx. 8.5 Itr. /2.2 US gal.
D i m e n s i o n s a t DIN C u r b W e i g h t
Wheelbase mm/inch
Length mm/inch
Width
Height
Ground clearance at
max. total weight

Weight
Curb weight per DIN kg/lbs
Max. total weight kg/lbs
Max. axle load, front kg/lbs

rear kg/lbs
Max. roof load ?only coupe) kg/lbs
Performance
Max. speed (with 5 speed transm. ) km/h/mph
Acceleration 0 - 100 km/h a t DIN

curb weight + 1 / 2 payload sec.
Kilometer from standing start (DIN

curb weight + 1 / 2 payload) sec.
Fuel consumption (average values, ltr/100 km

highways and country roads) miles/US gal. 14.7 - 16. 8
Oil consumption ltr/1000 km approx. 1. 5
US qt /6OO mi.
* Max. permissible total weight must not b e exceeded.
CAUTION
When installing extra equipment (air conditioner,

etc. ) the payload will b e less.

TECHNICAL DATA - 1980 Models
Capacities
Engine (initial filling) approx. 1 3 ltr. of brand n a m e

HD oil per API Classification
(measwed with oil dipstick per SD or SE; summer SAE 30, winter
operating instructions) SAE 20, below - 15Oc/+ 5' F
SAE 10 W
Transmission and differential approx. 3 ltr. per MIL-L 2105 or

MIL-L 2105 B, SAE 90, with
differential lock gear lube M2C28B
SAE 90
Fuel tank 80 ltr. /21.1 US gal. , of which 8 ltr. /

2 . 1 US gal. in reserve
Brake fluid reservoir approx. 0.2 ltr. /6.75 f l o z
Windshield washer tank approx. 8. 5 ltr. /2. 2 US gal.
Dimensions a t DIN Curb Weight
Length mm/inch 4291/168.94
Width mmjinch 1652/65.04
Height mm/inch 1320/51.57
Ground clearance
(at max. total weight) m m/inch 120/4.72

Weight
Curb weight per DIN kg/lbs
Max. total weight kg/l bs
Max. axle load, front kg/lbs

rear kg/lbs
Max. roof load*(only coupe) kgjlbs
Performance
Max. speed (with 5 speed transm. ) km/h/mph
Acceleration 0 - 100 km/h a t

DIN curb weight + 1 / 2 payload sec.
Kilometer from standing start

(DIN curb weight + 1 / 2 payload) sec.
Fuel consumption
(acc. DIN 70030, Part 1 )
a t 90 km/h 1/100 km
a t 55.9 mph miles/US gal. 25.5
city driving 1/100 km 17.3
miles/US gal. 13.8
Oil consumption 1/1000 km approx. 1 . 5

US qt/620 mi.
" Max. permissible total weight must not be exceeded.
CAUTION
Installation of extra equipment (air conditioner, etc. )

will reduce payload.

Technical Data 9n 0
TECHNICAL DATA - 1981 Models
Capacities
Engine (new filling) approx. 1 3 liters/13.7 US 9t
(measured with oil dipstick Oil grade: see

according to operating operating instructions
instructions)
Transmission and differential approx. 3 Iiters/3.2 US qt

Oil grade: see operating instructions
Fuel tank approx. 80 liters/21.1 US gal.,

of which 8 liters/2.1 US gal. in reserve
Brake fluid reservoir approx. 0.2 liters/6.75 f l oz
Windshield washer approx. 8.5 liters/2.2 US gal.
D i m e n s i o n s a t DIN C u r b w e i g h t
Length mmjinch 4291/168.94
Width mm/inch 1652/65.04
Height
Ground clearance mm/inch 120/4.72

(at max. total weight)

B) 911 Technical Data
Weight
Curbweight acc. DIN
Max. total weight
Max. axle load, front

** .
rear
**
Max. roof load

*
(only coupe)
Performance
Max. speed
(with 4 or 5 speed manual
transmission)
Acceleration from 0 to 100 sec.

km/h a t DIN curbweight
plus 1/2 payload
Kilometer from standing start sec.

(DIN curbweight plus 1 / 2
payload)
Oil consumption ltr. /lo00 km approx. 1.5

(1 US qt/600 mi.)
* Max. total weight must not be exceeded.
** Up to 16 10gradient.
Important
~nstallationof extra equipment (air conditioner, etc. ) will

reduce the payload.

Maintenance 9fl 0
S e r v i c e S c h e d u l e , T y p e 9 1 1 T , 9 1 1 E, a n d 9 1 1 S ( b e g i n n i n g w i t h 1 9 7 2 m o d e l s )
I 1000 miles
1 A. Before Road or Dynamometer Test
Maintenance required
then at and every
1 0 000 miles
1. Front wheel bearing play : Check.
I 2. Steering : Check all connections and rubber boots

for thightness and for leaks. 1 -
I / 3. V-belt and injection pump

spur belt: Check.
I-/
- I
4. Valve adjustment (rocker arm
shafts for tightness) ': Check. I
I
I
1
I
5. Ignition points and timing :
6. Fuel and air filter cartridges :

Check (engine at operating temperature.)
Replace.
I
I -
I
I I
1
1
7. Flame trap cartridge :
8. Clutch pedal free play:

Clean.
Check.
I
I
-I
-
I 9. Complete brake system (incl. wear
and leaks) :
-
Check.
-
-- -
-
m 10. Reflectors and operation of lights: Check.
11. Horn, wipers and washer : Check.
m 12. Battery electrolyte level : Check.
B. During Road or Dynamometer Test

m 1. Test engine performance, foot and parking brakes, clutch operation and m
gear shifting.
2. All instruments, control and

warning lights : Check.
C. After Road or Dynamometer Test

1. Engine idle and exhaust emission : Check.
Note: The recommended service intervals apply under normal driving conditions. The condition of tires, brakes and clutch lining depends greatly on the amount
of driving and on driving habits and should possibly be checked at shorter intervals. A complete maintenance sewice as well as protection against corrosion
should be carried out at least once a year, preferably before the winter.
Necessary at first maintenance only.

L u b r i c a t i o n S c h e d u l e f o r T y p e 9 1 1 T, 911 E, a n d 9 1 1 S ( b e g i n n i n g w i t h 1 9 7 2 m o d e l s )
I at
1000 miles
Engine
Service required
I
then at and every
10 000 miles
II
Engine oil : Change (oil at operating temperature), at least twice a year,
preferably once before summer and once before winter. I I
I
-
Oil strainer and magnetic
drain plugs : Clean.
Oil filter : Replace.

I I
Lubricate: Accelerator linkage.
Transmission
Transmission oil : Change (oil at operating temperature.)
Magnetic drain plug : Clean. I --- I

Miscellaneous
Lubricate : Door and hood hinges and locks. m
Note: The recommended service intervals apply under normal driving conditions. The condition of oil, and wear and tear items depends greatly on the amount .
of driving and on driving habits. Therefore, oil, and wear and tear items should be checked more frequently and possibly changed at shorter intervals. A complete
lubrication and maintenance service should be carried out at least once a year, preferably before the winter. The same applies to protective undercoating for
the vehicle.

I. Required Maintenance for the Emission Control System
at 1,000 miles Maintenance service required ;hen at 10,000 miles and every 20,000 miles
Check-kadjust Valves (check rocker arm shafts for tightness *) Check-!- adjust
Adjust V-belt Check
Retorque Manifold mounting b d t s
Change Engine oil Change
Replace Oil filter Replace
Clean Oil strainer Clean
Clean Magnetic drain plug Clean
Check-kadjust E n g w e Check+ adjust
Check+adjust Exhaust emission Check+ adjust -
Check-kadjust Hand throttle lever Check+adjust
Check Auxiliaryxby-pass valve for overrun Check
Fuel filter Replace
Check Fuel cap, tank, Lines and connections Check
Air filter cartridge Replace
Check Dwell angle Adjust
Check Timing Adjust
Spark plugs Replace
Ignition wiring Check
Distributor cap/rotor Check
Crankcase vent hoses Check
Filter for crankcase ventilation system Clean
Evaporative emission control system Check
Activated charcoal filter Replace
Note: The recommended service intefials apply under normal driving conditions. When driving on dusty roads check air filter cartridge
more often and replace if necessary. The condition of tires, brakes and clutch lining depends greatly on the amount of driving and on
driving habits and should possibly be checked at shorter intervals. A complete lubrication and maintenance service as well as protection
against corrosion should be carried out at least once a year, preferably before the winter.
* Necessary at first maintenance only.

It. Required Maintenance Service
pp -
- -- -
at 1,000 miles Maintenance service required then at and every 10,000 miles
Change Transmission oil Change
Door and hood hinges and locks Lubricate

-- - - -
Check+ adjust Front wheel bearing play
Steering gear and tie rod-connections and rubber boots Check for tightness and leaks
Adjus: Clutch pedal free play Adjust
Check Brake system complete (includes wear and leaks) Check
Check Operation of lights Check
Check Reflectors Check
Check Horns, wipers and washer Check

- -
Check Battery electrolyte level Check
During mad or dynamometer test:
Check Foot and parking brakes Check

Clutch operation and gear shifting
Check All instruments, control and warning lights Check
Note: The recommended service intervals apply under normal driving conditions. The condition of oil, and wear and tear items depends
greatly on the amount of driving and on driving habits. Therefore, oil, and wear and tear items should be checked more frequently and
possibly changed at shorter intervals. A complete lubrication and maintenance service should be carried out at least once a year,
preferably before the winter. The same applies to protective undercoating for the vehicle.

I. Required Maintenance for the Emission Control System (from 1975 model)
at 1,000 miles Maintenance service required then at and every additional at and
15 000 miles every 30 000 miles
Change Engine oil Change
Clean Magnetic drain plugs Clean
Replace Engine oil filter Replace
Adjust Y-belts (including V-belt for air pump), Adjust or replace
check tension and condition if necessary
Valve clearance (additionally at 1,000 miles:
Check+adjust Check+ adjust
Check rocker arm shafts for tightness)
~eti~hkn Manifold mounting bolts
Compression Check
Spark plugs Replace
Ignition distributor: ignition points, dwell angle and Adjust with electronic
timing equipment
lgnition wiring, distributor cap and rotor Check visually,
replace if necessary
Fuel filter Replace
EGR system Check visually
EGR system filter Replace
Check visually Evaporative control system (incl. fuel cap, tank and
connections) Checkvisually
Crankcase ventilation hoses Check visually
Filter for crankcase ventilation system Clean
Exhaust system (incl. thermal reactor, where applicable) Check for damage
Engine idle, hand throttle lever and exhaust
Check+adjust Check and adjust
emission (CO and HC)
Air cleaner filter element (at least after two years) Replace
Air pump, control valves, air injection hoses and
connections Check
Filter element for air pump Replace
Anti-backfire valve Check
Regular maintenance of the emission control system at 15000-mile intervals is necessary to keep your emission control system war-
ranty valid. Details are in your Emission Control System brochure, which you receive with your Owner's Manual.

II. Required Maintenance and Lubrication Service (from 1975 model)
at 1,000 miles Maintenance service required then at and every

15- .
000 miles
.. ..... - -
Door hinges and locks Lubricate

Accelerator linkage Lubricate
Door and Targa top weatherstrips: Remove rubber
residue from contacting areas and coat with talc Maintain
or other suitable rubber lubricant
Change Transmission dl (clean magnetic drain plugs) Change
Windshield washer, operation and fluid level Check and correct
Check+adjust Front wheel bearing play
Front axle: steering gear, tie-rod connections and
rubber boots
~~- - - - ~ -
Check for tightness and leaks
Check-tadjust Clutch pedal free play Adjust
Brake system, all lines and hoses (incl. wear and leaks) Check
Check Operation of lights, horns, wipers and washer Check
Check Headlight adjustment Check and correct
Ignition/steering lock and buzzer alarm Check
Safetv belt warnina liaht and buzzer alarm Check --
Batterv electrolvte level Check

- .. - -..
Check and correct pressure Tires Check and correct pressure
During road or dynamometer test:

Check Braking, clutch, steering, heating, ventilation systems Check
Check All instruments, control and warning lights Check
. .. -
The recommended service intervals apply under normal driving conditions. If you drive mainly in dusty areas, check the air cleaner
element more often and replace if necessary. The condition of oil,and wear-and-tear items (such as tires, brakes, clutch lining) depend
greatly on the amount of driving and on driving habits. Therefore, oil and wear-and-tear items should be checked more frequently, and
if necessary replaced at shorter intervals. Also, the battery electrolyte level should be checked more often. A complete maintenance
and lubrication service should be performed at least once a year, preferably before the winter. The same applies to protective under-
coating for the vehicle.

Porsche Workshop Manual 911 1972

Uploaded by

Copyright:

Available Formats

Porsche Workshop Manual 911 1972

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Porsche Workshop Manual 911 1972

Uploaded by

Copyright:

Available Formats

Workshop manual

DR. ING. h. c. F. PORSCHE KG

Downloaded from www.Manualslib.com manuals search engine

Survey of t h e i n d i v i d u a l Assembly Groups:

Engine and Clutch Code No. 1

Fuel System Code No. 2

Transmission Code No. 3

Front Axle Code No. 4

Rear Axle Code No. 5

Brakes, Wheels, Tires Code No. 6

Pedal Controls and Manual Controls Code No. 7

Maintenance Jobs, Technical Data Code No.. 0

Body Code No. 8

Electrical System Code No. 9

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

0 - INFORMATION, DESCRIPTION, TECHNICAL DATA

2.1 Cooling system

Downloaded from www.Manualslib.com manuals search engine

2.2 Exhaust system and h e a t i n g

3.2 Oil tank, removing and installing - 1974 model

3.4 Pressure relief valve, disassembling and assembling - 1974 model

3.5 Oil cooler coil, removing and installing - 1974 model

Downloaded from www.Manualslib.com manuals search engine

6 - CYLINDERS AND PISTONS

6.1 Cylinders and pistons

7.1 Crankcase and crankshaft

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

4. Connecting rods and bearings

6. Location of oil tank and oil lines

7. Clutch pressure plate, throwout bearing, and clutch disc

8. Ignition - see Group 9 (Electrical System)

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

1 Auxiliary oil cooler 6 Full-flow oil filter

3 Oil pump oil tank

Downloaded from www.Manualslib.com manuals search engine

T Y P E 9 1 1 s VEHICLES (FROM 1 9 7 3 - M O D E L ON)

Downloaded from www.Manualslib.com manuals search engine

Air filter housing

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Air filter housing

Downloaded from www.Manualslib.com manuals search engine

S P E C I F I C A T I O N S FOR T H E 2 . 7 LITER ENGINE WHERE D I F F E R I N G FROM T H E

Crankcase: Cylinder base bore in crankcase increased from

Pistons: 90 mm dia instead 84 mm dia Piston pin offset by

Cylinders: Cylinder walls coated with NIKASIL compound.

Ignition distributor: Advance curve changed.

Ignition timing: TDC a t 850 - 950 rpm

Spark plugs: ( g a p i n m m ) BOSCH W 265 P 21 (0.55)

T h r o t t l e v a l v e housing: Idle air ports enlarged from 3.3 m m dia to

Downloaded from www.Manualslib.com manuals search engine

ENGINE CHANGES - BEGINNING W I T H 1 9 7 4 MODELS

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Type four-stroke gasoline engine with two opposing cylinder banks