Porsche 924 Instruction manual

Workshop Manual

Volume I

Engine

DR.

ING.

PORSCHE

Aktiengesellschaft

WORKSHOP

MANUAL

924

This workshop manual describes

all

the

important operations for which special instructions

are

required

assure proper

completion.

This manual is essential for

the

shop foremen and mechanics,

who

need this information to keep

the

vehicles in a safe operating condition.

The

basic safety rules,

course, also apply

repairs on vehicles without exception.

The

information

grouped according

repair numbers which

are

identical

the

first two digits

the

repair

time

and warranty code.

repair group index on

page

alphabetical

index and

the

gister

table

are

quick guides

to find information in

the

manual.

Descriptions of design and function

can

found

the

service training course reference

material

This workshop manual will

kept

date

with workshop bulletins, which will

made part

the

manual from

time

tim

recommend

that

these workshop bulletins

filed in

the

special folder provided

for

this purpose.

GENERAL

ENGINE

TRANSMISS

ION

CHASSIS

BODY

HEATING,

VENTILATION,

AIR

CONDITIONING

ELECTRICS

Lifting

Car

Technical

Data

Engine I

Crankcase

Engine/

Crankshaft, Assembly

Engine I Cylinder Head and

Valve

Drive

Engine I Lubrication

Engine I Cooling

Fuel Supply System

Fuel System (C

)

Exhaust System / Emission Controls

Starter,

Power Supply

Ignition System

Clutch

Cont

rols

Torque

Converter

Manual Transmission I Controls,

Case

Manual Transmission I

Gea

rs, Shafts

Automatic

Transm

ission I Controls,

Case

Automatic

Transm

ission I Gears,

Valve

Body

Differential

Front Wheel Suspension

Rear Wheel Suspension, Propeller s

haft

Wheels,

Tires

Alignment

Brakes I

Mechanical

Brakes I Hydraulics

Steering

Body -Front

Section

Body

Center

Section

Body

-Rear

Section

Lids

Doors

Hardtop

Bumpers

Windows

Exterior Equipment

Interior

Equipment

Seats

Seat

Covers

Heater

Ventilation

Air Conditioner

Instruments, Radio

Windshield Wipers and Washer

Exterior Lights

Interior Lights

Wiring

REPAIR

Page

O.l

0.3

GROUPS

General

Car,

lifting

Technical

data,

general

Engine/Crankcase

Alternator

belt,

checking

and

adjusting

Engine, removing

and

installing

Tight

ening

torques

Tolerances

and

wear

limits

Tools

Engine,

Crankshaft,

Pistons

Bearing

caps

location

Bearing sleeve, removing

and

installing

Connecting

rod

bearing

play,

checking

Connecting

rod

, removing

and

installing

Crankcase

and

crankshaft

, disassembling

and

assembling

Crankcase

tools

Crankshaft

bearing

play

checking

Cranks

haft

seal,

removing

and

installing: Flywheel

end

Pulley

end

Crankshaft

sizes

Fly

wheel,

removing

and

installing

Gear

ring, replacing

Needle

bearing,

removing

and

installing

Oil

pump

drive. installing

Oil

pump,

removing

and

installing

Piston

and

connecting

rod,

disassembling

and

assemb

ling

Piston

and

cylinder

bore,

checking

Piston,

removing

and

installing

ston

rings,

removing

and

installing/checking

ools

Printed

Germany

- X, 1982

List

Contents-Volume

Page

0.1

0.3

10 -8

- 2

-04

- 1

13 - 6

13 -

13 -16

-4

-3

13 - 7

13 -6

13 -9

13 -

13 -12

-6

13 -8

13 -14

13 -18

13 -16

13 -

13 - 1

List

Contents-Volume

Engine/Cylinder

Head,

Valve Drive

Camshaft,

checking

Camshaft,

removing

and

installing

Camshaft

seal,

removing

and

installing

Cylinder

head,

machining

Cylinder

head,

removing

and

installing

Cylinder

head,

removing

and

installing

(1980

model)

Cylinder

head

tools

Distributor

drive

gear, removing

and

installing

Drive

belt,

installing

Tappets,

marking

Tools

Valve

adjusting

screw,

tightening

Valve drive, disassembling

and

assembling

Valve

guides,

checking

Valve

guides,

replacing

Valve

play,

checking

and

adjusting

Valve

seats,

machining

Valve sizes

Valves,

machining

and

grinding

Valve springs,

removing

and

installing

Valve

stem

seals, replacing

Engine/Lubrication

Lubrication

system

parts,

removing

and

installing

Oil

dipstick

guide

tube,

installing

Oil filter. removing

and

installing

Oil

pressure

and

oil

pressure

switch,

checking

Tools

---

Page

15.

- 4

. 1

15.

. 6

15.

17 - 2

17 . 6

· 4 a

-8

17 . 5

- 1

Printed in

Germany

List

Contents-Volume

General

4-speed manual transmission

088/

5-speed manual transmiss

n 016 Y

5-speed manual transmission

016/9

1980

5-speed manual transmission

016/9

-1981

Automatic

transmission (refer

page

37 -01)

Clutch/Controls

Clutch, adjusting

Clutch,

removing and installing (Type

088/A)

Clutch, removing and installing (Type

016

Clutch, removing and installing (Type

016/9)

Clutch controls, repairing

Clutch disc, removing and installing

Clutch pressure plate, checking

Drive plate, checking

Release

bearing, removing and installing

Release

lever. repairing

Technical data

Tightening torques

Tools

Torque Converter

Converter. checking

Converter, draining

Converter drive plate support assembly, removing and installing

Converter, installing

Converter oil seal, removing and installing

Manual Transmission/Controls,

Case

Differential, removing and installing

End plate, disassembling and assembling

End plate, disassembling and assembling (Type

016

/9)

End plate, replacing

Final drive

case

, disassembling and assembling (Type

016

Flange shaft

seal

, replacing

Front

transmission cover. disassembling and assembling (Type

016

Gearbox, disassembling and assembling

Gearbox, disassembling and assembling (Type 016

Gearbox, disassembling and assembling (Type

016/9)

Gearbox, removing and installing

Gearbox, removing and installing (Type

016/9)

Printed

Germany ·

1982

Page

-0

-02

30 -

-02

30 - 16

-3

-7

-8

-9

-3

30 -15

30.

-13

-07

-03

-1

32.

38.

-4

-12

-19

-127

34.

- 1

34.

. 111

34.

List

Contents-Volume

Rear transmission cover. disassembling and assembling (Type

016/9)

Shift

linkage, adjusting

Shift

linkage, adjusti

(Type

016/9)

Shift

linkage, disassembling and assembling (Type

016

Transmission

case,

disassembling (Type

016

Tools

Final drive housing, disassembling and assembling (Type

016/9)

Final drive housing, repairing

Transmission, disassembling and assembling

Transmission, removing and installing

Transmission, removing and installing (Type

016

Transmission, removing and installing (Type

016

/9)

Manual Transmission/Gears, Shafts

Drive

pinion,

disassembling and assembling

pinion,

disassembling and assembling (Type

016

Drive

pinion,

disass

embling and assembling (Type

016

/9)

Input

shaft, disassembling and assembling

Input

shaft, disassembling and assembling (Type

016

Input

shaft, disassembling and assembling

(Type

016

/9)

Synchromesh rings, checking

Synchronization,disassembling and assembling (Type

016

Automatic

Transmission/Controls,

Case

bles

for

throttl

e and

control

pressu

, adjusting

Cable

for

throttle

and

control

pressure, adjusting

(from

1979

model)

ble

for

throttle

and

control

pressure, removing and installing

(from

1979

model)

Cutaway drawing

Operation, checking

Selector lever cable, adjusting

Selector lever cable, removing and installing

Technical data

Tighteni

rques

Transmission, removing and installing

Troubleshooting

Page

-123

-6

34 -104

-73

-135

34 -135

-25

-7

- 3

34 -

101

-7

-57

-107

- 1

101

35-6

37.

6 c

37.

6 f

-6

37 .

- 7

37 -6 a

37 -1

37 .

-03

37 -13

37 -

Printed

Germany

Front

Wheel

Suspension

Ball

joint

installed

car,

checking

Ball

joint,

replacing

Control

arm

installed

car,

checking

Spring

strut

. disassembling

and

assembling

Technical

data

Tightening

torques

Wheel bearings, disassembling

and

assembling

Wheel

suspension,

disassembling

and

assembling

ear

Wheel

Suspension,

Axle

Shaft

Axle

shaft,

disassembling

and

assembling

Information

disassembling

and

assembling

axle

shaft

Rear

axle,

removing

and

installing

(from

1978

model)

Technical

data

Tightening

torque

Tools

Tra

iling

arm,

disassembling

and

assembling

Wheel

suspension,

disassembling

and

assembling

List

Contents-Volume

Page

-17

-18

-16

40.

40 -01

-1

· 13

40-20

Wheel

suspension,

disassemb

ling

and

assernbling

(from

1978

model)

42.

42 ·

42.

42 -

42 · 15

- 9

42 . 1

·8

Wheels, Tire

Axle

Alignment

Axle

alignment

Axle

alignment

information

Axle a

lignment

specifications

Colla

psible

wheel

924

944,

924

Turbo

General

tire

mounting

information

Rear

axle

(up

1978

model)

Rear

axle

(from

1978

model)

chnical

data

Wheels,

balancing

Wheel

bolts

for

rims

Wheel

rims/bolts/nuts

924,

944,

924

Turbo

Wheel rims,

checking

Printed

Germany

· X, 1982

44.

-02

44.

44 - 2

44.

-01

-9

- 4

44-4

- 6

o f

Contents-Vo

Ill

Brakes/Mechanical

Brake pedal, removing and installing

Brake push

rod,

adjusting

(to

end

979

model ·

7"brake

booster)

Brake push rod, adjusting

(from

980

model·

brake booster)

Front

brake pads, removing and installing

ront

wheel brakes, disassembling and assembling

Parkingbrake, adjusting

Parking brake lever, disassembling and assembling

Rear wheel brakes, disassembling and assembling

Stop

light

switch adjustment, checking

(from

1981 model)

Technical data

Tightening torques

Brakes/Hydraulics

Steering

Bleeding brakes and changing brake

fluid

Brake booster, checking

Brake booster, removing and installing

Brake caliper, disassembling and assembling

Tightening torques

Information

on removing and installing steering

column

and tube

Steering

column

and casing tube, removing and installing

Steering

gea

r, removing and installing

Technical data

Tightening torques

Page

-14

46.

-5

. 1

-17

. 7

46.

-0

47 -8

47.

- 5

. 1

-10

48.

-02

Printed

Germany

List

Contents

Body/General

Celette straightening bench

Cobra 3 straightening

unit

with

accessories

Dimensions

for

floor

assembly

Repair

control

dimensions

Repairing galvanized sheet metal parts

Special

tools

and shop materials

for

body

repairs

Univer

sal

anchorage ENS

937

.900

Front

Body

Section

Front

body

section damage, repairing

Gauge

for

lock

member

Modifications

side members

Template and welding

gauges

9112

9175

for

front

body

section

Template

9120

for

windshield

Rear

Body Section

Lids

Modification

rear side panels

New rear

body

section parts, installing

cars before

1980

model

Rear

body

section damage, repairing

Reinforcement brackets

rear apron, installing

Side panel (complete fender). repairing

Template

for

rear

window

Lid

lock,

removing and installing

Rear

lid

and seal, removing and installing

Water trap

lid

lock,

service installing

Printed

Germany -

1982

Page

50 . 011

50.

020

50 .

022

50 -

-03

50 -

50.

021

50.

-4

50.

53 -

53.

- 1

53.

. 15

-9

55-4

55.

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