Porsche 964 (911 Carrera 4) 1989 – 1994 Workshop Manual

Todd Mitchell (photo)
By Todd Mitchell
On: Monday, November 20, 2023 5:30 PM
porsche 911 1972 1983 service repair manual

This extensive digital factory Workshop Manual offers complete technical coverage for the Porsche 911 Carrera 4 (964 series), built between 1989 and 1994. As the official service documentation, it contains the precise, step-by-step instructions required to perform both routine maintenance and complex overhauls safely and effectively. Whether you are a professional mechanic, a restoration specialist, or a dedicated DIY enthusiast, this manual provides an encyclopedic look at the mechanical and electrical systems of the all-wheel-drive 964.allcarmanuals+3

Please note: This is the official technical Workshop Manual used by service professionals. It is significantly more detailed than a standard owner’s handbook, focusing on component teardowns, diagnostics, and factory rebuild specifications.

The complete workshop documentation is organized into seven distinct volumes, covering the following critical areas:

  • Volume 1 – Engine: Comprehensive procedures for servicing, adjusting, removing, and rebuilding the 3.6-liter naturally aspirated flat-six engine.5150motorsport+1
  • Volumes 2 & 3 – Transmissions: Detailed technical information for both manual (G64 series for all-wheel drive) and automatic (Tiptronic) transmissions, including clutch replacement and drivetrain servicing.p914-6info+1
  • Volume 4 – Chassis: In-depth instructions for the suspension, steering, brakes, wheel hubs, and alignment procedures.allcarmanuals+1
  • Volume 5 – Body: Technical guidelines for exterior panels, structural repairs, doors, glazing, and interior trim.p914-6info+1
  • Volume 6 – HVAC: Dedicated service information for the heating, ventilation, and air conditioning systems.scribd+1
  • Volume 7 – Electrics: The complete electrical guide, featuring wiring diagrams, component locations, and step-by-step electrical troubleshooting and diagnostic procedures.allcarmanuals+1
  • Specifications & Data: Includes critical factory specifications such as fluid capacities, exact tightening torques, wear limits, and nominal values required for precision assembly.

Whether you are performing a full engine rebuild, tracing a complex electrical fault, or simply completing a routine brake service, this 7-volume Porsche 964 workshop manual is the ultimate reference guide for keeping your Carrera 4 performing at its best.

CONTENTS:
WORKSHOP MANUAL 1989-1994 (1332 pages)

  • VOLUME 1
  • Volume 1 – 911 Carrera 4 (964)
  • Structure of the Workshop Manual
  • List of Repair Groups
  • Survey of Information published since 1985
  • Table of contents
  • General
  • Technical Data 911 Carrera 4
  • Raising the vehicle
  • Maintenance and self-diagnosis
  • Vehicle maintenance up to model year 91
  • Operating instructions for system tester 9288
  • No diagnosis possible
  • Engine, Crankcase, Suspension
  • Tightening torques for the engine
  • Removing and installing the engine
  • Flanging on and off the engine/transmission assembly
  • Engine, Crankshaft, Pistons
  • Dismantling and assembling the crankcase
  • Dismantling and assembling the crankshaft
  • Normal and rework dimensions of crankshaft
  • Crankshaft-Standard and machined sizes
  • Weight groups of con rods
  • Disassembling and assembling the oil pump
  • Measuring and repairing the crankcase
  • Dismantling and assembling crankcase sections
  • Sealing the crankcase mating sections
  • Crankcase screw connection
  • Removing and installing the belt pulley with vibration absorber
  • Dismantling and assembling double-mass flywheel
  • Dismantling and assembling pistons, cylinders
  • Pistons and cylinders – Dimensions and identification
  • Assembly of piston pin retainer with special tool 9500 and 9500/1
  • Assembling the cooling air duct for cylinders
  • Removing and installing two-piece oil return pipes
  • Checking and adjusting drive belts
  • Engine, Cylinder head, valve drive
  • Engine control
  • Determining parallelity of chain sprockets
  • Dismantling and assembling the cylinder head
  • Camshafts, timing
  • Dismantling and assembling camshaft housing
  • Refacing the cylinder head
  • Replacing valve guides
  • Disassembling and assembling cylinder head
  • Removing and installing valve springs
  • Removing and installing valve stem seals
  • Assembling cylinder head, angle-controlled tightening method
  • Removing and installing the knock sensor
  • Dismantling and assembling hydraulic pump drive (power steering)
  • Engine Lubrication
  • Assignment – relief valve – safety valve
  • Dismantling and assembling the oil pump
  • Replacing oil tank
  • Fuel Supply
  • Checking the delivery quantity of the fuel pump
  • Checking the fuel pressure
  • Removing, dismantling and assembling fuel tank
  • Fuel System, Electronic Injection
  • Inspection and adjustment values
  • Injection system components – Removing and installing DME center section
  • Injection system components – Removing and installing DME lower section
  • Exhaust System
  • Starter, Power Supply, Cruise Control
  • Removing and installing the starter
  • Removing and installing generator
  • Ignition System
  • Accident risks related to electronic ignition systems
  • DME control unit coding
  • DME diagnosis/Troubleshooting
  • DME control units
  • Replacing plug connectors, plug leads and threaded sleeve
  • Determining engine speed sender clearance (Tiptronic vehicles)
  • CARRERA 2
  • Carrera 2 Table of contents
  • Engine, Crankcase, Suspension
  • Removing and installing the engine (Tiptronic vehicles)
  • Removing and flange-mounting the engine-transmission assembly
  • Starter, Power Supply, Cruise Control
  • Removing and installing the starter
  • VOLUME 2
  • Volume 2 – 911 Carrera 4 (964)
  • List of Repair Groups
  • Survey of Information
  • Table of contents
  • General data
  • Tightening torque for manual transmission G64
  • Tightening torque for front axle transmission Z64
  • Clutch, controls
  • Dismantling and assembling the clutch controls
  • Checking clutch drive plate for wear
  • Removing and installing release bearing
  • Identification of clutch pressure plates
  • Adjusting the clutch pedal
  • Manual transmission, controls, case
  • Dismantling and assembling the gearbox
  • Dismantling and assembling manual tranmission (modifications from 1991 model on)
  • Dismantling and assembling interaxle lock with Valeo inner discs
  • Removing and installing the sealing ring for the drive shaft
  • Dismantling and assembling the clamp plate
  • Dismantling and assembling the distributor housing
  • Dismantling and assembling the transfer box housing (from 1991 model on)
  • Dismantling and assembling the intermediate housing
  • Dismantling and assembling the gear housing
  • Dismantling and assembling the transmission case
  • Adjusting the gearshift assembly
  • Manual transmission, gears, shafts
  • Partially dismantling the gear set
  • Dismantling and assembling the drive shaft
  • Dismantling and assembling the driving shaft
  • Determining the adjusting disk “s” for the hollow shaft
  • Final drive, differential
  • Removing and installing the regulated limited-slip differential
  • Removing and installing contr. limited-slip differential (from 1991 model on)
  • Dismantling and assembling the regulated limited-slip differential
  • Dismantling and assembling limited slip differential with Valeo friction linings
  • Adjusting the drive set (rear axle drive)
  • Removing and installing the front axle transmission
  • Removing and installing the center tube
  • Dismantling and assembling the front axle transmission
  • Dismantling and assembling the differential (front axle drive)
  • Adjusting the drive set (front axle drive)
  • PDAS diagnosis (overview) (Porsche dynamic all-wheel control)
  • CARRERA 2
  • 911 Carrera 2 – Table of contents
  • Clutch, Controls
  • Technical data
  • Manual transmission, controls, case
  • Dismantling and assembling transmission
  • Removing and installing input shaft oil seal
  • Dismantling and assembling tensioning plate
  • Dismantling and assembling front transmission cover
  • Dismantling and assembling gear housing
  • Dismantling and assembling transmission case
  • Manual transmission – gear, shafts
  • Dismantling and assembling input shaft
  • Dismantling and assembling drive pinion
  • Final drive, differential
  • Removing and installing differential
  • Dismantling and assembling differential
  • Dismantling and assembling drivetorque controlled limited slip differential for Carrera RS
  • Dismantling and assembling limited-slip differential (locking value 40%)
  • Adjusting drive set
  • VOLUME 3
  • Volume 3 – 911 Carrera 4 (964)
  • List of Repair Groups
  • Table of contents
  • Clutch, autom., torque converter
  • Technichal data
  • Removing and installing the torque converter
  • Automatic transmission, controls, case
  • Removing and installing the position switch on transmission
  • Adjusting cable for selector device
  • Removing and installing cable for selector mechanism
  • Removing and installing selector mechanism
  • Dismantling and assembling selector mechanism
  • Dismantling and assembling gear selecting system with keylock and shiftlock
  • Removing and installing lift solenoid for shiftlock
  • Removing and installling keyolock bowden cable
  • Checking keylock and shiftlock
  • Removing and installing rear transmission case
  • Removing and installing the intermediate plate
  • Dismantling and assembling intermediate plate
  • Dismantling and assembling the parking lock
  • Dismantling and assembling transmission
  • *Dismantling and assembling transmission
  • Automatic transmission, gears, shafts
  • Checking the ATF fluid level
  • Changing ATF fluid and cleaning the ATF strainer
  • Flushing ATF cooler and lines
  • Removing and installing ATF cooler
  • Removing and installing the inductive spped sendor
  • Removing and installing the wiring harness for the transmission
  • Removing and installing the hydraulic control unit
  • Removing and installing solenoid valves
  • Removing and installing the rotary shaft seal for the ATF pump
  • Removing and installing the ATF pump
  • *Dismantling and assembling 4th gear tower
  • *Dismantling and assembling output shaft and freewheel
  • *Dismantling and assembling clutch E
  • *Dismantling and assembling brake F
  • *Dismantling and assembling brake pack CD with spider shaft
  • *Dismantling and assembling spider shaft
  • *Dismantling and assembling brake C, C’ and D
  • *Dismantling and assembling clutch B
  • *Dismantling and assembling clutch A
  • *Determining the end clearance
  • Differential
  • Dismantling and assembling the long joint flange
  • Removing and installing the rotary shaft seal for the short joint flange
  • Sealing of the driving shaft
  • Removing and installing differential and drive pinion
  • Dismantling and assembling differential
  • Dismantling and assembling drive pinion
  • Adjusting drive set
  • Tiptronic Diagnosis (911 Carrera 2)
  • Tiptronic Diagnosis / Troubleshooting
  • Diagnosis Tiptronic
  • Troubleshooting mechanical / hydraulic section
  • VOLUME 4
  • Volume 4 – 911 Carrera 4 (964)
  • List of Repair Groups
  • Survey of Information
  • Table of contents
  • Wheel suspension, front, axle shaft
  • Tightening torques for front axle
  • Installation instructions for wheel carrier
  • Dismantling and assembling wheel suspension
  • Removing and installing halfshaft
  • Dismantling and assembling spring strut
  • Wheel suspension, rear, axle shaft
  • Tightening torques for rear axle
  • Notes on recessed spring strut mount from 1991 model on
  • Dismantling and assembling wheel suspension
  • Replacing wheel bearings
  • Removing and installing spring strut
  • Dismantling and assembling spring strut
  • Removing and installing drive shaft
  • Wheels, tires, alignment
  • Wheels and tires
  • Adjustment values for alignment
  • Sample measuring card
  • Fitting 16″ and 17″ cup design wheels to the vehicle
  • Alignment
  • Tire fitting
  • Antiblock system
  • Acceleration sensors for longitudinal and transverse locks
  • Testing ABS in 911 Carrera 4 with ABS 2-LED Tester
  • PDAS diagnosis / Troubleshooting
  • Brakes, mechanical
  • Tightening torques for brake mechanisms
  • Technical data
  • Checking the thickness of the brake pads
  • Removing and installing the brake pads of the four-piston fixed-caliper brake
  • Adjusting the brake pressure rod / checking the brake light switch setting
  • Checking and adjusting the hand brake
  • Checking brake disc lateral runout
  • Checking brake disc thinckness
  • Dismantling and assembling front brake
  • Dismantling and assembling rear brake
  • Brake – hydraulics, regulator, booster
  • Tightening torques for brakes hydraulics
  • Information on four-piston fixed caliper
  • Brake fluid change / Bleeding the brake and lock control
  • Pressure tests on the booster circuit
  • Removing and installing pressure warning switch
  • Steering
  • Tightening torques for steering
  • Replacing the steering in case of accident damage
  • Inspection and installation work on the rack and pinion power steering
  • Assembling the track rods on the steering gear
  • Removing and installing steering gear
  • Removing and installing steering/ignition lock
  • Checking hydraulic operation of the steering system (pressure measurement)
  • Carrera 2
  • Carrera 2 table of contents
  • Front wheel suspension
  • Wheel hub to wheel bearing screw connection
  • Wheel hub to wheel bearing bolt union on the Carrera RS
  • Antiblock System
  • ABS test on 911 Carrera 2 using ABS 2-LED tester
  • Brakes – mechanical brake system
  • Technical data
  • Brakes, hydraulics – regulator, booster
  • Quickfill brake master-cylinder (bleeding/note)
  • VOLUME 5
  • Volume 5 – 911 Carrera 4 (964)
  • List of Repair Groups
  • Survey of Information published since 1985
  • Table of contents
  • Body, general
  • Repair inspection dimensions
  • Special tools and sheet metal working equipment for repairs
  • Safety notes
  • HS steel body panels
  • Body-Front Section
  • Partially renewing the front section
  • Completely renewing the front section
  • End part replacement
  • Partial replacement of wheel house and side member
  • Partial replacement of the fender connection plate
  • Body-Center Section
  • Partially replacing door sill with side member and floor pan
  • Partially replacing door sill with side member
  • Replacing door sill
  • Replacing the complete roof
  • Replacing part of roof
  • Removing cracking noises in the roof rail area
  • Body-Rear Section
  • Renewing the rear-axle cross tube
  • Renewing side panel with inner side section and side member
  • Renewing rear-axle cross-member
  • Partly renewing rear section of body
  • Renewing engine mount
  • Partly renewing side panel
  • Replacing threaded section of oil filler neck
  • Lids
  • Adjusting upper lock section
  • Dismantling and assembling front cover
  • Dismantling and assembling rear cover
  • Doors
  • Dismantling and assembling the doors
  • Adjusting height stop of door window
  • Bumpers
  • Removing and installing the front-end panels and bumper
  • Removing and installing the tail panels and bumper
  • Glazing, window control
  • Removing and installing vehicle windows
  • Removing and installing the windshield
  • Removing and installing side windows
  • Removing and installing the rear window
  • Bonding the interior rearview mirror in place
  • Exterior equipment
  • Color range as from model 1989
  • Color range as from model 1990
  • Color range as from model 1991
  • Color range as from model 1992
  • Removing and installing the rear spoiler
  • Removing and installing the sill cover
  • Removing and installing the underbody cladding
  • Bonding retainer bracket to side member panel
  • Interior equipment
  • Safety regulations for handling airbag vehicles
  • Removing and installing airbag components
  • Checking airbag system operation
  • Center console / Information on acceleration sensors for longitud. and transv. locks
  • Right-hand front floor sound deadening
  • Checking safety belts
  • Correct disposal of airbag units
  • Replacing horn buttons on airbag steering wheel
  • Replacing front cover rail and front compartment carpet
  • Dismantling and assembling the glove compartment lis
  • Diagnosis
  • Seats
  • Checking seat heating
  • Calibrating controllable seat heating
  • VOLUME 6
  • Volume 6 – 911 Carrera 4 (964)
  • Survey of Information published since 1985
  • List of Repair Groups
  • Table of contents
  • Air-conditioning system
  • Technical data
  • Removing and installing components of the heating/air-conditioning system
  • Dismantling and assembling the heatting/air-conditioning unit
  • Flap adjustment on the heating/air-conditioning unit
  • Checking the refrigerating capacity
  • Removing and installing heating fan motors with built-in heating/air-conditioning unit
  • Safety regulations for handling the refrigerant R12
  • Installation work on the air-conditioning system
  • Modifying wiring loom of heater A/C unit
  • Technical data as of Model ’93
  • Pressure and temperature specifications
  • Diagnosis / Troubleshooting
  • Instruments, fuel gauge, alarm system
  • Acceleration sensors for longitudinal and transverse locks
  • Checking fuel tank sender unit
  • Radio, telephone, on-board computer
  • Telephone preparation kits M612 and M195
  • Retrofitting of a telephone set
  • Retrofitting of a CD changer
  • Windshield wipers and washer
  • Removing and installing the wiper motor
  • Diagnosis
  • Diagnosis / troubleshooting alarm system
  • VOLUME 7
  • Volume 7 – 911 Carrera 4 (964)
  • List of Repair Groups
  • Table of contents
  • Wiring
  • Additional electrical equipment
  • Repairing wiring harness No. 2 and No. 3
  • Repairing wiring harness No.173 (DME wiring harness)
  • Wiring diagram type 911 Carrera 4 model 89
  • Table of contents
  • Lights
  • Alarm System, Central Locks, Mirror, Power Window Regulator
  • Heater, AC, Coolant Fan, Rear Window Defogger
  • ABS, Porsche Dynamic AWD Control
  • Motor, Fuel, Ignition, Cruise Control
  • Instruments, Sender, Central Informer
  • Seats
  • Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners
  • Radio
  • Fog light, Rear fog light
  • Central electric
  • Contruction Components
  • Plug Connections and Ground Points
  • Wiring diagram type 911 Carrera 2/4 model 90
  • Table of contents
  • Lights
  • Alarm System, Central Locks, Mirror, Power Window Regulator
  • Heater, AC, Coolant Fan, Rear Window Defogger
  • ABS, Porsche Dynamic AWD Control (Carrera 4)
  • ABS Carrera 2
  • Motor, Fuel, Ignition, Cruise Control
  • Instruments, Sender, Central Informer, On-board computer
  • Seats
  • Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top
  • Radio
  • Fog light, Rear fog light
  • Central electric
  • Contruction Components
  • Plug Connections and Ground Points
  • Trailer Coupling
  • Rev-meter, On-board computer, Airbag
  • Tiptronic (Carrera2)
  • Wiring diagram type 911 Carrera 2/4 model 91
  • Table of contents
  • Lights
  • Alarm System, Central Locks, Mirror, Power Window Regulator
  • Heater, AC, Coolant Fan, Rear Window Defogger
  • ABS, Porsche Dynamic AWD Control (Carrera 4)
  • ABS (Carrera 2)
  • Motor, Fuel, Ignition, Cruise Control
  • Instruments, Sender, Central Informer, On-board computer
  • Seats
  • Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top
  • Radio, Telephone
  • Fog light, Rear fog light
  • Central electric
  • Contruction Components
  • Plug Connections and Ground Points, Abbreviations
  • Trailer Coupling
  • Airbag
  • Tiptronic (Carrera 2)
  • Wiring diagram type 911 Carrera 2/4 model 92
  • Table of contents
  • Lights
  • Alarm System, Central Locks, Mirror, Power Window Regulator, Inside Lights
  • Heater, AC, Coolant Fan, Rear Window Defogger
  • ABS, Porsche Dynamic AWD Control (Carrera 4)
  • ABS (Carrera 2)
  • ABS Turbo Look (Carrera 2)
  • Motor, Fuel, Ignition, Cruise Control
  • Instruments, Sender, Central Informer, On-board computer
  • Seats
  • Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top
  • Radio, Telephone
  • Fog light, Rear fog light
  • Central electric
  • Contruction Components
  • Plug Connections and Ground Points, Abbreviations
  • Trailer Coupling
  • Airbag
  • Tiptronic (Carrera 2)
  • 911 Carrera RS
  • Wiring diagram type 911 Carrera 2/4 model 93
  • Table of contents
  • Lights
  • Alarm System, Central Locks, Mirror, Power Window Regulator, Inside Lights
  • Heater, AC, Coolant Fan, Rear Window Defogger
  • ABS, Porsche Dynamic AWD Control (Carrera 4)
  • ABS (Carrera 2)
  • ABS Turbo Look (Carrera 2)
  • Motor, Fuel, Ignition, Cruise Control
  • Instruments, Sender, Central Informer, On-board computer
  • Seats
  • Rear Spoiler, Two-Tone Horns, Wipe-and Wash Cleaners, Sun Roof, Convertible Top
  • Radio, Telephone
  • Fog light, Rear fog light
  • Central electric
  • Contruction Components
  • Plug Connections, Ground Points, M-Numbers, Abbreviations
  • Trailer Coupling
  • Airbag
  • Tiptronic (Carrera 2)
  • 911 Carrera RS

Language: English
File: PDF

Porsche 964 (911 Carrera 4) 1989 – 1994 Workshop Manual

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