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

This Workshop Manual describes all of the important operations for which special instructions are required to ensure proper completion. This manual is essential for shop foremen and mechanics who need this information to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply to all repairs on vehicles, without exception.

Workshop Manual in PDF format, to vehicles Porsche 964 Carrera 4 and 964 Carrera RS.

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