Workshop Manual Curbo Carrera DR. ING. h. c. F. PORSCHE AG STUTTGART-ZUFFENHAUSEN US = Onder No. WkD Edition 1976 Printed in Germany Subject to changes.TURBO CARRERA REPAIR MANUAL ‘This repair manual describes all of the important operations for which special instructions are required to assure proper completions, This manual is essential for the shop foremen and mechanics, who need this information ta Keep the vehicles in a safe operating condition, ‘The basic safety rules, of course, also apply to repairs on vehicles without exception, ‘The Turbo Carrera Repair Manual onty describes repair operation: which differ from those for 911 models, Refer to the 911 Repair Manual for all other information, ‘The information is grouped according to repair numbers, which are identical to the first two digits of the repair time and warranty code. ‘The repair group index and register table are quick guides to find information in the manual . Descriptions of design and function can be found in service training course reference material, ‘This repair manual will be Kept up to date with workshop bulletins; the information in these bulletins will be made part of the manual from time to lime. We recommend that the Workshop Bulletins be filed in the special folder provided for this purpose,REGISTRATION OF SUPPLEMENTS FILED FOR REPAIR MANUAL ‘Turbo Carrera Please file the supplements according to repair groups and make appropriate entries in the table below. Supplement No. Filing Date Signature m vi a = vt vu i x1 xu xu xvELECTRICS GENERAL ‘Technical Date Page REPAIR GROUP Engine-Crankease 10 Engine-Crankshatt/ Assembly as Engine-Cylinder Head and Valve Drive 1B Engine-Lubrication a Engine-Cooling 19 ENGINE Fuel Supply system 20 Turbocharger a Fuel system (CIs) 25 Exhaust System 26 Starter, Power Supply 20 Ignition System 28 Clutch, Control 30 paaws Manual Transmission-Controls and Case 34 ras Manual Transmission-Gears and Shafts 35 Differential 29 Front Whee! Suspension 40 Rear Wheel Suspension 42 chassis Wheels, Tires, Alignment 44 Brakes, Hydraulic Components a Steering 48 Body-!vont Section 50 Bady-Center Seetion 51 Body-Rear Seetion 38 Lids 56 Doors 57 BoDy Sliding Roof 60 Bumpers 63 Glasses 6 Exterior Fittings 86 Interior equipment 68 HEATING, VENTILATION, Hester 80 AIR CONDITIONING Air Conditioner 7 Instruments, Radio 20 » Windshield Wipers and Washer Exterior Lights Interior Lights wiring930-turbo Alphabetical Index Alc filter, removing/installing (1978 mode!) ‘Air flow sensor plate, rest position, checking Air injection, disassembling/assembling 1978 mode! Air injection lines/adapters, removing/installing Air pump «air filter - drive belt, checking/adjusting += removing/installing Automatic heater control ~ checking = removing/installing Auxiliary air valve, removing/installing Auxiliary air regulator, removing/installing ‘Axle alignment specifications Body repair reference points =1978 mode! Boost pressure, checking Boost pressure gauge, checking Brakes - Mechanical Parts Brake pads - remove and install Brake pad thickness - check Brake system -911 Carrera Turbo Look Front wheel brakes - changes for Turbo 3.3 Ltr Front wheel brakes - disassemble and assemble Rear wheel brakes - disassemble and assemble Technical date Tightening torque Brakes - Hydraulic Parts Brake calipers disassemble and assemble Brake caliper sections - disassemble and assemble Brake ciruit failure indicator ‘Tightening torque Page 25-19 25- a 26-12 26-24 28-19 26-17 26-28 26-16 80-5 80-1 25-18 25-10 ees 45-2 46-1 46-04 6-40 48-5 46-11 46-01 46 -03 47-12 47-01 Printed in Germany - V, 1984Alphabetical Index Center console, removing installing Check valve, checking Clutch ~ adjusting (1977 moded) = adjusting (19 7% mode = assembly ~ assembly (398 model) + auillary release spring (1978 model) Control pressure, checking = cold = warm, full thottie enrichment (2978 model) contol valve, checking Control vatve (air injection) removing/ installing CCeankshatt Jounal, dimensions (1978 model) CCuzrent flow diagrams Cylinder air guide plates (1978 model) Differential disasembling /assembling = disassembling assembling (1978 model) = Limited slip = removing /inetalling Distributor, checking Diverter valve = checking > removing installing Drive pinion = adjusting ~ disessembling/assembling Drive shaft = disascmbling assembling = oll seal, removing/installing Page oe 26 = 20 0-7 50-18 a+ 2 30+ 8 20-11 25-18 25-13 25-14 26-20 26-18 nea oT a 1-6 30-5 w+ Ba woo m- 2 5 26-18 39-9 35-15 35-9 35-19 es 2 Printed in Germany930-turbe Alphabetical Index Electronic speedometer checking sensor, removing/installing Engine + hood, removing/installing + Femoving/installing Engine/transmission, detaching/attaching 1978 model EGR filter, removing/installing EGR valve ‘checking + removing/installing Exhaust system + disassembling/assembling layout + reactor, removing/instaling Floor assembly, front Floor/frame assembly, dimensions Floor/frame, front end gauge P 863 Flywheet machining removing/installing Front axle clisassombling/assembiing ~removing/installing Fuel delivery rate for control pressure circuit, checking Fuel injection (CIS), testing/adjusting pressure gauge, connecting/bleeding system pressure Page 90- 3 90-4 55-1 10-4 10-4 10-8 26-21 26-22 26-21 26-2 26-1 28-5 50-4 50- 2 50-1 13-3 13-3 40-3 40-1 25-14 28-15 25-12 25- ida Printed in Germany - 1M, 1981Alphabetical Index 930-turbo Page Fuel pump = delivery rate 20-1 + pressure 20-1 removing and installing 20-5 Fuel system 25-1 Hose layouts “USA. 26-29 = California 26-30 lle, adjusting 25-7 1978 model 25-108 Ignition (electronic troubleshooting 2-6 Ignition delayed cutoff 28-13 Ignition system (1978 model) 28-14 Ignition timing, adjusting 28-1 = 1977 made! 28- 2a 1978 model 28- 2b Ignition timing, checking 28-3 +1977 model 28- 4a 1978 mode! 28- 4c Intake air intercooler, removing/installing 21-21 Manifold pressure limiting switch, checking au Mixture control unit = fuel distributor 25- 8b = pressure relief valve 25- 6 removing/installing 25-6 lal pressure valve 25- Be 4 111, 1981 - Printed in Germany930-turbo Alphabetical Index il pump (1978 model) Pistons/Cylinders checking dimensions/instalation notes ddimensions/installation notes (1878 model) ‘weight classes 911 Turbo (1980 model) Pop-off valve/housing, disassembling/assembling Roar axle ‘ross tube dlisassombling/assembling removing/installing Rear fender decal, installing Rear wheel bearing, adjusting Rear wheel bearing play, checking Relay, locations Ring gear adjusting backlash shim thickness Steering, disassembling/assembling Straightening bench attachments for 930 Turbo ENS 77.903 Technical data bbrakes(hydraulic components) brakes (mechanical components) engine = front suspension general rear suspension steering wheels/tires Page 13-6 13-2 13-1 13-7 13-9 21-6 53-1 42-3 42-1 66-3 42-13 42-14 90-1 39-19 39-17 43-1 80- 7a 47-01 46-01 10-01 40-01 on 42-01 48-01 30-01 44-01 Printed in Germany - 1V, 1984General TECHNICAL DATA (Refer to appropriate repair group for adjusting and wear Limit data.) Engine Internal engine code 990/51 from Aug. 1976 930/53 Bore mm/inch — 95/3.74 stroke mm/inch ——1044/2."7 Displacement min. 2999/182.64 Compression ratio 6.521 Homepower SAE Net He 234 at engine speed of +5500 rpm Printed in Germany = 1978 ‘Technical Data otGeneral ‘Torque SAE Net Nan/fty the Output per ister KW/HP Max, engine speed rpm ‘Max, engine cruising speed rpm Cutoff speed of speed limiter in distetbutor ‘pm ‘Weight of engine with air cleaner (é#y) bg Engine Design crankease Geanishaft Grantshaft bearings Connecting rods Connecting rod bearings Piston pin bushings Intermediate shaft bearing: Pistons Piston pins Tiston rings Cylinders Cylinder head Valve sest Snserts Vaive guides Location of valves per cylinder Exhaust valve Valve springs Valve axive Camshaft Camshaft érive Engine cooling 282/28 at engine speed ‘of 4000 rpm 58/82 e700 000 00 200 aunyaTs iecast, Light alloy, two-piece Forged, journals surface-hazdened ight, plain Forged stect 2 layers split inserts Pressfit bronze 2, plain Forged light alloy, slipper shit Floating, secured by eirelips 2 compression rings, 1 oil sereper ing Light alloy, Nikasit coated Light attoy Shrunk-in, enneated sintered steel res fit, special bronze 41 sntake and 1 exhaust valve ‘overhead in V Sodium filled, reinforced seat 2 coll springs per valve ‘One each overhead camshaft, Teft and right Cast, 4 bearings, runs directly oa camshaft housing metal coain “Ait cooled by axsst Zan on alternator shaft 0.2 Technical Data Printed in GermanyGeneral Cooling fan drive Crankshatt/blower ratio Air flow rate Engine Lubrication lt cooling i filter Ol pressure at 5500 epm bar/pst Ot pressure gauge Max, oil temperature ll consumption at./600 mi. Exhaust System 930/81 (930/53 Heating Fuel System Fuel supply’ Fuel octane RON Electrics Battery voltage v Battery capacity An Alternator/output w Ignition ‘Transformer Firing order Brakes Foot brakes Front brake dise diameter mm Y-Belt from crankshaft approx, 1: 1.67 41560 Its/see at 6000 crankshaft rpm ‘Thermostatic control, oil cooler on crankease in fan ait stream, cooling colls in front right wheel-hovsing Full flow approx, 4.0/60 at 80°C (176°F) Hlectric approx, 150°C /300°F approx, 1,0 t0 2.0 double pipe system with turbocharger, waste gate, 2 reactors, muffler, air pump same as 980/81, but with EGR) Hot air heater with automatic temperature control, 2 electric roller-type pumps connected in series 91 - 96 (premium grade) w 6 80 CDI (breakerles) Basel 1 6224-375 hydraulic, dual-cireult dise brakes with power booster 282.5 vented SS Printed in Germany ~ 1, 1976 ‘Technical D: 0.8Rear brake disc diameter Effective front brake dise dia, Effective rear brake dise ofa. Front brake dice thickness Rear brake disc thickness ‘Total effective braking surface: Pad surface per front wheel ad surface per rear wheel Front caliper piston dia Rear caliper piston dia, Parking brakes Parking brake drum dlameter Brake shoe width Effective braking surface per wheel Power brake booster Pressure ratio Pedal « fo (mechanical) Dimensions Length wide Height Wheelbase rout track Rear track Grouné clearance (ful! 102¢) Curved ground clearance Front approach angle (Limited by spotter) Rear departure angle (limited by apron) Weights Curb weight Max. total weight Max, front axle lose Max, rear axle load Payload Max, roof load including roof luggage carrier 2 280 vented 228 2a 20,5 20 Mechanical, on rear wheels a0 25 8s Teves, Type T 52/7 (DIN-Curb Weighty mrafineh mm/ineh rom tnch smom/inch mm/ineh mam/toeh ram/ineh som/inel, (DIN T0020) kg/lbe kg/bs g/ibe kerbs kg/lbs kg/ibs 4291/188,94 1775/69,88 1940/52, 76 2272/89,45 1431/58.34 1501/5909 195/8,10 100/294 ae as? anaoosie 1400/3087 200/189 2840/1859, 205/462 35/17 without exceeding max. total weight 04 ‘Technical Data Printed in GermanyCapacities Engine (as measured with ofl dipstick according to Owner's Manual) ‘Total ofl capacity of system cooling coils Oil change capacity ‘Transmission and differential Fuet tank Brake fluid Windshteld washer Performance ‘Top speed Acceleration from 0 = 100 Xph/62 mph Km ftom standing start Weight per horsepower Hill elimbing ability in % ‘4>speed transmission General Brand name heavy duty oils meeting AP! Classification SD of SE with a viscosity of: SAE 90 for summer, SAE 20 for winter, SAE 20 W 20 for permanent temperatures betw, = 15° and 0° ¢ (+ 8” F and 92” £) or SAE 10 W for permanent temperatures below 15°C (+ 5° F) It/at approx, 19/19.8 teat approx, 10/10,6 Refer to page 90 ~ 05 lt/gal. 80/2141, 8 Liters/2,1 gal, in reserve i/pt approx, 0.2/0442 /gal. approx. 845/242 mph Above 152 sec 5,7 DIN curb welght + oe 25,0 1/2 payload 1b. /HP on Ast gear over 100, Princed in Germany Qnd gear 47 ard gear 28 4th gear 16,5 Technical Data 0.5General TECHNICAL DATA - 1978 MODEL (Refer to appropriate repair group for adjusting and wear limit data) Engine Internat engine code 930/61, Cal. 930/63, from 1979 models 930/64 Bore mmfineh 97/3.82 Stroke mmfinch 74.4/2.93, Total displacement em? inch? 3299/201.3 Compression ratio 70:1 Printed in Germany - III, 1981 Technical Data o7eee Torque SAE net Nee ibe Output per iter sew /He Max. engine speed ‘pm Max. engine cruising speed rpm Governor cutoff speed som {in distrisutor) Engine weight (dry} with muffler kgfibs Engine Design Type Cooling System Crankease Crankshatt Grankshstt bearings Connecting od bearings Oylinders, individual ‘Arrangement of valves per cylinder Valve actuation ‘Camshaft drive Camshatt bearings Cooling fan drive Crankshaft/blower ratio Fuel supply Mixture Induetion system ‘395/291 at engine speed of 4000 rpm 67/01 6700 6000 7000% 200 240/529 4 stroke internal combustion Air Light alloy Forged 8 plain main bearings Pain boarings Light alloy 1 intake valve 1 exhaust valve Vee configuration, overhead One each overhead camshaft OHG, left and right Chain Plain, directly on camshaft housing V-belt from crankshaft Approx 1: 1.67 Dry sump with separate oil tank thermostat controlled oil cooling and full flow oil filter, cooling coils in front right wheet house eleétrie pumps in series connected Continous injection system (CIS) KKK exhaust turbocharger SS 0.8 Technical Data Printed in GermanyGeneral Electric system Battery voltage Battery capacity Alternator output Ignition system Firing order Exhaust System Heating Dimensions Wheel bate Front tack width Rear track width Length wish Height Turning elrele dis. Ground clearance, full load Weights Curb weight Max, total weight Max, frot axle Load 1 rear axle Load a Ah (at DIN curb weight mm/ineh mm/ineh ‘mun/ineh m/inch mn nels mm inch mitt mm/inch (DIN 70020) kg/los kgs kgflbs kg/s 980 CDI (breakerless) 1- 3-5 Single pipe system with torbocharger, waste gate, muffler, air pump and 2 reactors Automatic temperature control for heater 2272 / 89.45 3432 / 56,98 1501 / 59.09 4291 / 168.94 1775 / 69,88 1528 / 52,28 20.7 / 5,20 320 /4, 1295 / 2855 3500 / 9807 e25 / 1978 900 / 198 ee Printed in Germany - 11, 1978 Technical Data 0.9General Capacities ‘Total amount of oll for system with cooling coils Amount for ofl change Amount of oil between min. and mex, marks on dipstick ‘Transmission + differential uel tank rake fluid tani Windshield washer Performance ‘Top speed Acceleration 0 = 100 km/ty (0-62 mph Kim fom standing start ler/at Approx. 19/14, exact amount determined by reading on off dipstick, measured with ‘engine running at idle speed and operating temperature e/a ‘Approx. 10/12 r/at Approx. 2/2 Sand name heavy duty olls for Internal combustion engines acc, to API Classificstion SE. Use following viseostty multi-geade ofls for year round operations (oll chenge every 25, 000 mt, /24, 000 kam) SAE 10 W/50, 15 W/50 of 20 W/50, Do not ube latter oll for constent tempezetures below = 15° C/+ 6°, Brand name single grade olls of AP! Classification SE should only be used when Iultigrade oll are not available and nosmat operating conditions Prevail. The use of such oils will require observance of additional change intervals according to season of year to prevent any damage. Use SAF 80 off fr summer and SAF 20 W for winter (only at ‘constant temperatures below + 6° C/+ 42°F). See page 20 - 05 Ie/at 80/21, of which @ 1tr/2 US gel, in reserve Ie/pt AppION. 0.2/0.4 evga. Approx. 8.5/2.2 ken/h / mph 250/155 5 5.6 DIN curb weight + 1/2 payload : m0 Ss 0.10 ‘Technical Data Printed in Germany10 ENGINE-ASSEMBLY Printed in GermanyGen ea 10 TECHNICAL DATA ~ ADJUSTING AND WEAR LIMIT DATA ENGINE VALVE DRIVE ‘Tappet clearance (cold engine) intake O.20 mm (measured betwe_ valve and rocker arm) Exhaust 0.10 mm ‘Timing at 1 mm tappet clearance Intake opens 3° aTpC. Intake closes Paspc Exhaust opens at°pBDc Exhaust closes 5° ppc Intake valve stroke in TDC overlap at 0.1 mm tappet clearance 0.85 ~ 0,80 mm Valve spring installation lengths Intake valve springs gg. + Exhaust valve springs Ignition Ignition Timing Adjustment (engine ofl temperature at least £09 C) Engine Type 990/50, 990/52 297 2 DTDC on crankshaft at 4000 spm (vacuum hove disconnected) Engine Type 990/51 (USA) 518° ATDC on crankshaft at 950 £ 50 2pm (vacuum ote connected) Engine Type 990/58 (USA) 7 £99 ATDE on crankshaft at 1000 2 50 spm (vacuum hose connected) Engine Type 980/54 (Japan) 15? 2 ATDC on crankshaft at 1000 > @wacuum hose connected) (Check ignition timing acvance (gnition timing must be adjust first) Engine Type 990/50, 920/52 0-8 49 on crankshaft at 900 + 60 spm {vacuum bose connected) Printed in Germany ~ IV, 1981 Technical Data 10-0110 General Information Engine Type 930/51 (USA) Engine Type 930/53 (USA) Engine Type 930/54 (Japan) ‘Spark plugs (electrode gap in mm} SINCE 1978 MODEL, TURBO 3.3 26 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) 29 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) 20 + 3° on crankshaft before TDC at 4000 rpm (vacuum hose disconnected) Bosch W 280 P 21 (0.6) IGNITION ignition Timing Adjustment (Engine Oil Temp, at Least Engine Type 930/60 Engine Type 930/61 (USA), 930/64 (USA) Engine Type 930/63 (California), 930/62 (Japan) 930/65 (Japan) Engine Type 930/66 Engine Type 930/68 (USA) Checking Ignition Timing (Ignition Timing Adjusted First) Engine Type 930/60 Engine Type 930/61 (USA) 930/64 (USA) Engine Type 930/63 (Californi 930/62 (Japan) 930/65 (Japan) Engine Type 930/66 Engine Type 930/68 (USA) 80° C) 29° before TDC at 4000 rpm [vacuum hose disconnected) 10 + 2° after TDC at 1000 + 50 rpm {vacuum hose connected) 5+ 1° after TDC at 1000 + 50 rpm {vacuum hose connected) 29 £ 1° before TDC at 4000 rpm (vacuum hose disconnected) 26 £ 1° before TDC at 4000 rpm {vacuum hose - red - disconnected) 0 # 2° at 1000 + 50 rpm {vacuum hose connected) 26 4° before TDC at 4000 rpm (vacuum hose disconnected) 31+ 4° before TDC at 4000 rpm (vacuum hose disconnected) 22° before TDC at 900 + 50 rpm (vacuum hoses connected) 1+ 2° after TDC at 900+ 50 rpm (vacuum hoses connected) 10-02 Technical Data VI, 1985 Printed in Germanycenerst 10) TORQUE SPECIFICATIONS FOR ENGINE Toraue Locetion Toresds | Nm fw Conrod mus" w10%126 | 60-55 36-40 Crankease w10 35 25 All bolts on crankcase and camhatt ma 25 8 owsing Oil iter screen cover ute we 10 7 Fiywnel wiaxts | 150 to8 trom 1978 nods Mioxi2s | 90 6 Bush and eed orig to cranks Ms 10 7 Pally to craniat miaxis | 0 38 {without ar condone) Double-et pulley to crane miaxts | 170 123, (with air conditioner) Sater vl plug to exankeae miexis | 60 23 Pressure allt vale plug to crankeae miaxts | 60 8 Adapter (on neck foro presure mia! | 3s 25 transmier to erankease ‘per in crankease return line mraxt | 20 87 Cylndor head nu tO socket | 33 2 Rocker arm sett MBsockat | 18 3 Aut on camshaft marx2, | 50 108 Bot on camshaft miaxie | 120 87 Cover to camshat housing me 8 8 Adapter on evlinde hex mioxt | 15 " tir inection) Ait line coupling on adaotr uxis | a2 6 Reactor to cylinder head me 20-28 we Spark plug miaxi2s | 25-30 18-22 Intake manifold me 25 | 3 | “Threads and bear surfaces lubricated with oil. ** Threads of eylinder head nuts coated with Optimoly HT. Printed in Germany ~ 111, 1981 Technical Data 10 0310 conere Toraus Loaation Trweods | Nm nb Consol for engine caer M10 “0 23 Wide clamping stap on blower houtng we es 5 we 12 8 Pulloy to stormator miex1 | aosev, | 20 Altern teu {Morro} miaers | aden | 20 Olt pressure contol switch to wrod | mox20 | max tt erankease Temporature transmitter to erankoase wraers | mox28 | mois | Ot pressure transmitter to adapter wieets | oe3s | mac 25 Volume transmitter (for oil level MS 24 7 | indieato to ol tank | Olt drain pug (to over for a maxis | a2 ~ finer econ) Oil drain plug (oil tank} M22x15 42 30 Oi ines to engine, lank, maox1s | 80-100 | 59.72 governor housing, ol eocer or | pipe ol cooler 1 Al bolts for exhaust system coated with Optimoly HT. 10-04 Technical Data Printed in Germanyroots we] Deserpcon syectat Tost | Remata T_, ‘ie wth appar plate - a | engine otaer i 11d see next page 2 | Adaperreagactaaer | uss Printed in Germany = 1, 1978 Removing and Installing Sngine10 Engine - crankcase Toots ‘« : : }#100 >| | 2 eo aa eee 7 4 2 é aueHee it ° cae lo 45° eg 14 5245" & No.] Deseription Special Tool Remarks a | engine notder oma modified 2 | support plate on1i/1 2 Removing and Installing Engine Printed in GermanyEngine- REMOVING AND INSTALLING ENGINE ‘The engine and transmission assembly is lowered to remove, ch up car Disconnect ground cable at battery 8, Remave air cleave engine block vent hose a pull off and plug opening at vent cover 5, > Cars with air conditioning only ~ Retach compressor atc: st connected to the hoses in the ear. engine wires at relay plate, at adapter plug, fee) sists ssceet aoa Quitian cone ae? caution ‘The alr conditioner system must be discliarged ff the comprersar hoses are disconnected BN Printed in Germany ~ Removing and Installing Engine 10-310 treine-crastcase 17. Unseren fuel hoses at filter end retura line, 8, Disconnect accelerator Linkage. 14, Loosen heater hoses at heat exchangers, and poll off. 8. Loosen rear tunnel cover serews and remove cover, 15. Remove rear stabilizer, 10, Pull boot off of body and slide it for over the selector rod. 16, Loosen ground strap at body. 11. Loosen socket head at screw of shift rod coupling and pull coupling off of the eats aad Li, Disconnect battery wires at starter. 18. Diseonnect accelerator linkage at operating lever. 18, Disconnect en cable at transmission, From 1977 Models ~ see figure. 132, Pull off wires of electronic speedometer sensor in funnel and remove rubber plug with wize plug. 18, Drain engine off and plug ol! hoses on ‘engine and oil tank, 10-4 Removing and Instalking engine Printed Ia Germany20, Loosen drive shait flange socket head 22, Looten engine carrler bolts, screws at transmission, 24, Lower car jack with engine/transmission assembly carefully and back it out. 21, Place car jack with appropriate attachment underneath engine/trans~ mission assembly at center point of gra~ vity and apply a little pressure. Caution Be careful not te damage secondary air injection pipes. Caution Ifthe car i moved with the engine transmission unit removed, the delve shafts must be suspended horizontally to prevent damage to dust covers. 22. Looten transmission carrier bolts. Printed in Germany = I, 1978 Removing and Installing Engine 10-510 tesioe-createsse Installing (Observe the following instructions when installing. 1. Caution! Don't clamp the heater ho necessary, slide them on the heat exchangers just before the engine/ ‘assembly is in its final position. 2, Torque specifications: Engine and transmisslon ccattler hex head screws 9.0 mkg (68 fb) Drive sha /Mange fil~ ster bead capscrews 8.8 mkg (60 F115) 2, Adjust elutch ~ see Repair Manual @11, Group 7, Page 3. 10-8 ‘Removing and Installing Engine Printed in GermanyDETACHING AND ATTACHING ENGINE AND TRANSMISSION Detaching 4, Poll transmission off of engine. 4, Remove wites st starter end backup Light switen, Attaching 2, Remove clutch retease lever cirelip and take off lever and rubber ring. Observe the following points, Clutch selease lever does not have to be removed from 3877 Models, 4, Coat all bearing surfsces of clutch release and drive shaft splines with @ multi-purpose lubricant containing McS,. 2, Place hub part of relesse bearing vertical and engage release fork when attaching 10 tub section, Check if in correct position through opening in transmission ease, Tersion relesse lever to keep bearing in place, 3, After attaching the engine and transmission, slide on release lever parallel to holder of clutch eable sleeve. 4, Torque engine mounting bolts and nuts to 4.5 mkg (39 ib). Printed inGermany - [, 1976 Detaching and Attaching Engine and Transmission 10-7Crankeas! 10 engine DETACHING (4978 MODEL) ND ATTACHING ENGINE/TRANSMISSLON UNIT Detaching 2, Place hub of release bearing upright end engage fork on ab when attaching. Chee sition through opening in transraisston 1, Disconnect wires frota starter and backup Light switeh, Remove clutch release spring, see page $0 - 12, Unscrew engine mounting bolt and auts, « Install clutch release spring, see page 90 = 12, 4, ‘Tighten engine mounting bolt and mts to 4,5 mikg (88 ft 1b}, Attsehing Note the following pots, ‘Le Gost all sliding surfaces of eluteh release as ‘well as splines of drive shaft with MoS multi-purpose grease, 8 —_Detaching and Attaching Engine/ Ii, 107 ~ Printed in Germany ‘Transmission Untt13 GINE-CRANKSHAFT ASSEMBLY printed ia GermanyEngine-crankshaft and moving parts 13 PISTON AND CYLINDER SIZES -930 TURBO Cytinder Cylinder Piston Di Cose Disa, in mm in mm Standard Size Stamped ° 95,000-95.010 94.938. 94947 1 96.010.95.020 94.943: : | 94.957 v 2 95.020.95.030 94.953 94.967 Clearance between cylinder and piston: 0.053-0.077 mm PISTON INSTALLATION NOTES Because the piston pin bore is offset, the piston - ‘must be installed correctly. The installation mark . ‘aces the clutch - see figure, x Printed in Germany Piston and Cylinder Sizes 13-1 Instaietion NotesCHECKING PISTONS AND CYLINDERS Cylinders D1 = Measuring point for wear and ovality ZF 20 mm below upper edge of evlinder sy = ‘The cylinder is worn if the measurement is 0.08 mm more than the size at instalation. eee ‘Measurements aro made in directions @ and ® to check ovality. The amount of deviation between @ and b should not exceed 0.04 mm. D2 ~ Measuring point for piston ring end gap Rings sid in at height of eylinder base gasket Pistons D = Measuring point for west ‘At lower edge of piston pin bore. Caution! Replace piston and cylinder if clearance ‘exceeds 0.15 mm. PISTON RING END GAP Piston Ring End Gap in mm, End Gap in mm (now {wear limith Compression ring, and Ud 015-03 og Ol seraper ring, uu 018-03 10 {see measuring point "02") PISTON RING SIDE CLEARANCE Piston Ring Side Clearance Side Clearance inmm (new) In.mm (wear limit) ‘Compression ring, 1 0.070 -0.102 02 ‘Compression ring, 1 0.040 0.072 02 il scraper ring, Hl 0.020 - 0.052 on 13-2 Checking Pistons and Cylinders 1, 1981 - Printed in GermanyFoe esi ess NEVTPEN SURF REMOVING AND INSTALLING FLYWHEEL Removing Installing 1. Loosen Alywheel mounting bolts (using special «1. The contact surlaces of crankshaft, flywheel tool P 238) and remove flywheel (take off inner and washer must be free of grease. stop pin of P 238), 2, Torque mounting bolts to specifications, MACHINING FLYWHEEL If severely scored or burnt, the Aywheel can be machined on a Lathe, ‘The ehip size should be kept as small as possible. Flywheel thickness wear limit is 9.9 mm. 3 Max, runott 0,1 mun 4 Lathe mounting points 1. Wear Limit 2 Smallest chip siz paving and installing Flywheel 19-3 Printed in Germany Macaining FlywheelEngine - Crankshaft and moving parts 13 vesresr*vnu6"es O66"RH"""TL6' way | Orr one"PS"* "122" oFe"eg***TZE" Es BE SE | wro- Be SE 008"63"* one" o0"65"*7083 "68 eoH'0s**onnrow ogres" runes ooraerurres «=F TB | ogy erro onvestrehee overages = BL cory = 090" *"090"82 NEs"EE"*"NBB"EE cIO"eE***t00"s GO0%O6***o8LGa EDUTEST*-os6"oR oGeteS"*-rLEHE oBstest tutes «= Bosepanis oP 3a pura suena zp venom, yoog form p "ea 809 > op teasnor of Boe) Ep steeof «get reBupzeag] ure Sorvog gen yeumaery — Super 9} 9S ourMf og NO = BuAEOG MEY peu HepIooMUOD —ujeaN MEN TI aIOqaseoyHerD] ante sazis¥sana (report ar 6rd aNv auvanvus - syxvao I, 1978 -Printed in Germany Crankshaft SizesAewemy uy porwtid eur M - soars apeysieei gest A Surface finish Paint dot Grind crankshaft ofl seal surfaces only when deeply scored, Grind to dimensions of 29,5 mm and 6.5 nam respectivel Otherwise polis out to 3 microns, AMler grinding, chamfer ofl Holes to 0, 5 smn radius, teak all sharp edges to 0,2 - 0,5 mo radius, Mawiomuea zadiel runout measured at bearings 1 and 7 is 0.04 mm, ‘Tenlfer treat cranishatt after grinding, Magnaflux to check for cracks, Do rot straighten hearing journals 9 and 5 after ‘niles seatmnent AIL other main bearing Journals eau be straightened by applying pressure to the bearing ournal webs Undersize color eoder dst undessize 2nd undersize Std undersize 4th undersize surface finish Page deburred blue paint dot _areen paint dot yellow paint dat white paint dot qyeusquery ‘aveoyuer ‘auydog el13 rocine, cranrense, crantkstatt Layout of Oil Pump - 1978 Modet Installation of Cylinders and Air Guide Plates 1978 Model 33-6 OW Pamp Printed In Germany Gylinder/Aic Guide PlatesEngine Cranksnote Pistons — JB PISTON AND CYLINDER SIZES - 1978 MODEL Cylinder Cylinder Dia. Piston Code inmm Dia, 0 in mm Stamped ° 97.000 -97.007 96.850 96.860 1 97.007 -97.014 96.357 96.867 2 97.014 -97.021 96.864 96.874 3 97.021 -97.028 96.871 96.881 7 ylinder/piston clearance: 0.025 - 0.052 mm. Printed in Germany - HII, 1981 Piston and Cylinder Sizes 13-715 ENGINE-CYLINDER HEAD AND VALVE DRIVE Printed in Germanyengine-cylinder Head Vatvedrive 15 CHECKING INSTALLED LENGTH OF VALVE SPRINGS Checking Note ‘Set tool P 10.¢ 10 “33,6”, 4. Install special tool P 10 ¢ with shim corres- ponding to valve, spring support washer, spring retainer and both valve keepers. 2, Read distance “A” on special tool P 10 ¢ and, if necessary, correct by removing or installing shims. Installation Sizes \nstll length of intake valve springs Install length of exhaust valve springs ADJUSTING TIMING Intake valve lift at TDC overlap with 0.1 mm valve clearance is 0.65 ta 0.80 mm. ADJUSTING VALVES Valves are adjusted with engine installed in car. Only following parts are removed air cleaner, relay plate cover, diverter valve and air pump. From 1978 Model, intake ait intercooler also has to be removed. REMOVING AND INSTALLING CHAIN TENSIONER, ‘Chain tencioners ean only be replaced after removal of engine. Printed in Germany - 1, 1981 Valve Spring Installation Data 16-1 Adjusting Timing20 SUPPLY Printed ia GermanySe () TOOLS No. Desexiption Special Too! Remarks Connecting aéapter ous For testing both fuel pumps in cconjunetion with P 978 Printed in Germany = 1, 1976 ‘Checking Fuel Pump Delivery 2+ Checking Pump Pressurecs sumnty 2O CHECKING FUEL PUMP DELIVERY Note Before checki ig fuel pump, check for velean fuel fter “electrical connections OK Teast 11.5 volts at both fuel pumps 1, Detach fuel return Hine (ef side of engine compartment), 4, Switeh on ignition for 20 seconds. Both pumps rust deliver 140 Liter/howr oc 2 30 seecnds, 0 ce in Note If delivery rate is less than this specification, check pressure of fuel pumps to determine which vel return Line with a sectlon of fuel Seen ve end im a measuring glass (contents about 1500 ce). CHECKING PUMP P 8, Bridge both fuel pump relays (90 end 81) or pull out plug on afr sen 11, Loosen intake fuel line Printed in Germany ~ 1, 1076 Checiing Fue! Pump Delivery 2-3QO seer sess 2, Connect pressure gauge of P 378 between Intake line and rear fuel pump in conjunction with Special Toot P 8114, 3, Turn ignition on (after first bridging relays oF pulling off plug at ei sensor contact). a. Read pressure gauges Pressure must be between 2 avd 4 bar. If less than 2 bar, the first pump (front) is defective. If more than 4 bax, the second pump (rear) is defective, Replace defective pumps and recheck pressure, ‘Cheek connections for leats after completing pressure test. 20-4 Checking Pump Pressure Printed in GermanyREMOVING AND INSTALLING FRONT FUEL PUMP Removing 1, Disconnect ground cable a1 bat 2, Remove bottom protection plate, 8, Clamp intake fuel hore shut, Loosen hose Me cn TER ‘clamp and pull off intake fuel hose, 4, Pull off rubber aps and remove nuts attaching 5, Remove hollow bolt for pressure fuel line, 8, Loosen pump clamp and remove fuel purmp, Instatiing 1, Always use new seals. 24 Install fuel pump so there is clearance all sound it, Printed tn Germany ~ Removing and Installing Fuel Pump 20> 52O seer suppy REMOVING AND INSTALLING REAR FUEL PUMP Removing 2. Disconnect ground cable at battery. 2, Remove hollow bott for pressure fuel 2, PulL off rubber caps and remove nuts attaching 4, Loosen intake fuel line and cateh escaping fuel. 5, Remove puts and take fuel pump off bracket. 6. Installing Always use new seals, 1g and Installing Fuel Pump Printed in Germany21 TURBOCHARGER Printed in Germanyturbocharger 21 REMOVING AND INSTALLING EXHAUST GAS TURBOCHARGER Removing 41, Disconnect hore (arrow) between turbo outlet and turbo outlet duet, Disconnect ofl pressure line (srrow) from engine, 4. Loosen muffler clamp and remove mesfler. 2, Loosen rear apron socket head serews and remove apron with seal. 5. Loosen hose between turbocharger inlet line and turbochargers Slide hore to left, Drain off in AP. 1p (arrow) between bypass line and coven mounting nuts (arrow) between Diseoonest oil return line at oil trap, Loosen drain tube of oil trap on bottom of turbo= charger and remove trap. turbo and muffler. ot Printed in Germany Removing and Installing Turbocharger 21-121 ruccharger 6, Loosen turbocharger to exhaust pipe mount bolts as well as mounting nuts on turbocharg holder. Remove turbocharger. Nate ‘When installing a new turbochsrger, the connections are located by turning the turbocharger com= pressor side to aliga it with the turbine side. 4) Loosen strap on turbocharger a little. by Install turbocharger on engine and align locetlon of connections. €) Secure rubber hoses and exhaust pipe and then ighten strap serews to specified torque (refer to page 21-3 ‘Always instail new oll drain plug seals, self locking nuts and gaskets ©) Before starting the engine for fret time, 1 ‘uedocharger lubrication off must be purnped for 90 seconds ~ which requires disconnecting ‘wires at manifold pressure iimiting steiteh and operating starter motors Installing 1, Be sure that hose connections are properly made ocharget outlet duet and turbo~ between 1 2, After {nsigllation, lubricate turbocharger with 2a tem of engine sls 1 =2 Removing and installing Turbocharger Printed in Germanyturbocarger OM TURBOCHARGER Ai 1 6, Engine oil { (under 4 Intet = SSS bgt gas outlet oil out i 1 Compressor housing 2 Bearing housing 9 Turbine housing 4 shaft beart 5 shaft 6 Compressor wheel 1 Turbine wheel Printed in Germany Turbocharger Drawing 21-321 tusvoenarger CHECKING TURBOCHARGER SHAFT END PLAY 1, Place dial gauge in hotder. Special toot P 207 can be used as a holder, 2, Set dial gauge on end of turbine whee! shaft, Press rotor shaft against dia gauge, read and note play. Press rotor shaft in opposite direction, read end note play, Difference of both readings fs the end play, Max. play: 0, 35 mm CHECKING TURBOCHARGER TURBINE RADIAL PLAY Radial play is checked on the turbine end only. Note Be sure not to rotate the turbine wheel at all uring these measurements. 1, Press turbine wheel toward side of housing, ‘check gap with a fecler gauge and note. Pres turbine wheel toward opposite side of, housing, check gap and note, Difference of both measurements ls the radia Play. Measure play at least at two different Tocations. Max. play: 0,65 mm 1-4 — Checking Turbocharger Printed in GermanyTurbocharger 21 CHECKING WASTE GATE OPERATION 4. Loosen and remove control line to waste gate 2. Run engine at idle speed. There must be noti- ceable vacuum in control line. With ineressing engine speed, vacuum changes to pressure (charging pressure) 3. Insert a plug in disconnected control line, 50 ‘that engine will not stall while checking waste gate operation. 4. Carefully blow compressed air in control line ‘opening of waste gate. Listen for sound of warte gate opening Caution Do.not.use mora then 1,6 bar (21 psi) air pressure In addition to sound of valve opening, check thet bypass line warms up (cold engine). I necessary, replace waste gate. —— Printed in Germany - 111, 1981 CChacking Waste Gate Operation 21-40eta eee REMOVING AND INSTALLING WASTE GATE (CHARGE PRESSURE CONTROL VALVE) Removing Engine Type 980/51 1, Detach vent tine and control line. Cnlock and remove thermag auts. 3. Remove waste gate, upper gasket, heat svard and lower gasket. Installing Use new gaskets, seals, thermag mats and Tockplates. roving and Installing Waste Gat Printed in Germany ~ 1, 1Printed in Germany Dismantling and Assembling Pop-off Valve urbocherger Or <7 ost 6 oO 8 6 SL Lt be 21aunecnerses DY No. | Description 7} pemovtag tating Remaris 1 | Hose clamp 2 2 | Rubber sleeve 1 Install correctly 3 | Hose clamp 2 4 | Hose 2 Instatl correctly 5 | aot 1 @ | washer 1 a | Hose clamp | Rubber sleeve 1 jastail eorxectly @ | Hose cramp 2 10 | Hose a ni | nut 2 2 | washer 2 as | att 2 14 | Washer 2 as | anti-bacifire valve [1 16 | Holder a a1 | Mantiotd pressere 1 Cheek see page 21-11 lirmiting switel: ae | Snap sing 1 19 | Filter soreen a 20) Seal 2 Replace aa | Nut 4 20 | washer 4 28 | cover L Printed in Germany Dismantling and Assembling Pop-olf Valve Housing 21-7DQ] rervecnasser Note when Nox} Description y+} pemaving pr Remaris Joa] Gasket a necessary replace 125 | Control piston 2 | Caution - under —_Lubsfeate slightly, spring pressure cheek movement in valve housing 26 | Spring 1 21 | Guide 1 28 | Nut 4 29 | washer 4 30 | Cover with control 1 tine connestion at | Gasket 1 Replace, If necessary 22} Pop-olf valve housing | 1 88 | Turbo boost pressure | 1 Cheek sender | Seat 1 Replace Q-8 — Dismentiing and Assembling Popraff Valve tTousing 1, 1976 = Printed tn Germanyturbocharger 24 TooLs No. } Description Special Too! | Remarks 2 | Manifold pressure tester aos | 2 | Threaded adapter e131 | for 1978 model Printed inGecmany + 11, 1978 ‘Checking Manifotd Pressure ass21 Turbocharger CHECKING MANIFOLD PRESSURE 1, Disconnect and remove electric plug and mant- fold pressure Limnlting switch, From 1978 Model, ‘witeh ts located behing pop-off valve housing as seen looking forward. = 2, Sorew adapter (with seal) of special tool in valve housing and tighten slightly From 398 Model, first install threaded adapter, Special Tool 9102/2. 3, Screw manifold pressure Limiting ewiteh in adapter and tighten only finger tight, counters holding adapter. 4, Route gauge hose with pressure gauge fra passenger compartment to eagine compart 5, Comnect gauge hore to adapter, counterholding the adapter. ‘Dubs 9.2 6, Cheek manifold presture in a road test of om a dynamometer, Manifold pressure: 0.70 ~ 0.85 bar (0.7 = 0.85 atm), Fully accelerate car in Ist or 2nd gear and reed charge pressure between 4500 and $500 zpm (2nd person), Manifold pressure can only be checked in the acceleration phase, If necessary, replace waste gate, ——— 22-10 Checking Manifold Pressure Printed in Germany21 Turboek ECKING FUNCTION OF MANIFOLD PRESSURE LIMITING 80 Cheeking 1, Remove manifold pressure Limiting switeh, 2, Clamp manifold pressure limiting switet. carefull 3, Connect chmmeter between switch housing and connecting terminat, Check that ohmmeter reads © obms, Insta tl on threads of switch. ‘ire valve (without valve insert) 5. Connect az pressure hose (at valve). pressure gauge 8, Increase pressmne carefully, Check that ohm= meter goes to QO at about 1,5 bare 11, Drop prestute slowly until obmmeter again ‘goes to 0, Now read pressure which should be between 2,1 and 1,4 bar, If necessary replace manifold pressure limiting swite, Printed in Germany Manifold Pressure Limiting Sulten eit21 Turbocharger so, | Description re peer aa ca ang Remarks 2 | Hottow bott 2 2 | Seat 2 Replace 3 | Oi presureiineto | 1 turbocharger hottow bot) 4 | Pressure sonsor 1 3 | Seat a Replace 8 | Adaptor a 7 | seat 2 Replace 2 | Adepter 1 & | Pater sereen 1 cheer a0 | Seat 1 Replace zi | Thermag mat 2 Replace ae | washer 18 | Gasket 1 Replace sa | clamp 2 Turbocharger as | Oi tank L 16 | Rubber grommet 1 ar | wut 2 Replace ae | Washer 2 1s | Bracket 1 20 | Bott 2 a1 | Wathee 1 22 | Hollow hott 2 23 | Sea 2 Replace 24} Ol tine 1 so Princed In Germany ‘Torbocharger Oil Supply a a3Turbocharger 21 le oz e & i i le le 9% Of 6% Bz Printed in Germany 4 2 321 rurrocharger i Note when | oe |Description a lgniee ae emarls 25 | outine fom pump | 1 | to tank Adaptor 2 ar | sea 1 Replace as} att 2 20 | Wemner 2 so | on pump 3 see page 21-15 ar | Gasset 1 Replace 21-14 Turbochaiger OW Supply Printed in GermanyTurbocharger 21 PRESSURE OIL LINE CONNEGTION FOR TURBOCHARGER WITH OIL PRESSURE SWITCH (ACCESSORY Notes No. | Description oy. | pemoving ae Remaris 1 | it pressure switel 2 | Adapter 1 8 peo a Replace 4 | ontine 1 5 | Seat Replace 6 | Adapter 1 Es 1 Replace Printed in Germany i, 1878 ‘Turbocharger ~ Off Supply{Uae se] esstpton a neste 1 Hollow bolt if | 2 se 2 sepice 2) Adapter : «| seat : aepise 6 | wane 2 > | ot amp : ist ove pln fo pup iat beech vote heed aon of paty 2 | wn 2 9 | water 2 xo | cove, name : 1-16 ‘Turbocharger Ol Pump Printed in GermanyTorbocharger 21 as | Gasket with VW 432 Replace, coat both sides} with sealing compound No, | Deseription ae eae _|sem ui | Socket head screw | 2 12 | Washer 2 13 | Potey 1 14 | drive bett, 80 tects | 2 ‘Tighten, must deflect by 6 10 8 mm at center under thump pressure 15 | Bort 3 a6 | washer 3 ar | mange 1 ae | onseat 1 Replace, install propery Printed In Germany ~ 1, 3976 ‘Turbocharger Oi Pump 2-1721 rurocharger REMOVING AND INSTALLING TURBOCHARGER OIL UMP Removing 1. Detach guard at exhaust pipe. 2, Detach pressure and inlet lines at ofl pump. 3, Loosen bolts and remove oll pump with gasket. Installing Observe the following when Instalin Note Keys of left camshaft must be intalled to protrude beyoud face of camshaft by 8 mm. Key ae Pre are slots also have to be positioned properly so that ‘oil pump cylindrical pin does not rest in a slot. 2, Install cylindrfcat pin of oil pump shart between keys of camshaft, oy - 18 ‘Turbocharger O Supply Printed in GermanyTurbocharger 21 CHECKING BOOST PRESSURE GAUGE 1 boost pressure gauge in tachometer fails check eil wire connections on tachometer or boost pressure sender against wiring diagram, Pull of ‘wire on boost pressure sender. ur on ignition, Boost pressure gauge needle deflect fully, Hold aisconnected wire against ‘ground, Needle must retum to 2e10, f gauge & OK, trouble is In pressure sender. Tf gauge Is defective, tachometer will have to bs replaced, Nate Resistance of boost pressure sender (measured between connecting lug and lousing) must be between 5 and 12 ohms at 20° C(€8" F) and atmospheric pressure. Printed in Germany ~ 1976 chee Boost Pressure Gauge21 rrocharses REMOVING AND INSTALLING INTAKE AIR INTERCOOLER (1978 MODEL) Removing 1, Loosen hose clemgs on right side of int 8, Umorew bolts and remove intake air inter Intercooler and pull aff hoses. cooler. Looten and remove bolt, = ub 4, Remove turbo outlet duct to Intake air tp 2, Detach hose between waste gate and intake air cool intercooler at intake aij cooler, Looten and remos Installing 1, Cheek all o- replacing sf necessary, mbricate O-rings with lubricant before 8, To facilitate installation of turbo outlet duct, ooten hore clamps of rubber sleeve on turbo Intake duct and push back sleeve, Also press intake duct to the Left a little, 21-20 Removing and installing dntake 1,978 « in Germanyrorbocha: 21 4, Turn turbo outlet duct to one side, so that marks on intereaoler and turbo outlet duet liga or tarbo outlet duct is installed without ‘when replacing rubbe cooler, make sure that {is positioned correctly (atrows face in forward direction). Printed in Germany - 1, 1978 Removing and Installing Intake Air Intezccole:25 FUEL SYSTEM (CIS) Printed in Germanyret seren 2H 251 Fuel system Printed in Germany25 rect system Note: 0. Description mt. | pemoving Rana Remake 1 | ciamp 2 2 | vacunm hove 4 3 | Hollow bott 1 a | seat 2 Replace 5 | Fuel return tine 1 6 | Hotiow bait 1 1 | seat 2 Replace 8 | Fuel feed tine 1 9 | Adaptor 1 no | Seat 1 Replace ta | ctamp 2 22 | vacuum tine 1 lis | alten bott 2 ha | Washer 2 | Warmeup gowmer | 1 16 | vacuum hose 2 a7 | clamp 2 18 | conttol tine, (do waste gate) 2 a2 | Vacuum hose, stsbuioe 1 20 | Nut +} 21 | washer 4 22 | connector 1 23 | Seat 3 Replace 24 | Locke elip 1 Fuel system Printed in GermanyO65 Notes 0.] Deselptlon Amt. | semarke Hes pera Removing Installing 2s | Linkage 1 | | 26 | Htlow bot 2 i at | sea 2 eplace | Jos au ee 28 | Fact line L | | Feo | auen tote | 2 ao | waster 2 | at Cold start valve 4 seal replace 3s | range 1 rber/metat ped | 2 os | clome 2 fwe 1 a | clamp oe | nove 1 39 Injection valve pa 0 | seat ¢ seplace af wun | 42 | Water | we 3 | Thole rave 1 novsing at] Gasket » replace, stall correctly Printed in GermanyQB ue anton 22 27 28 25 24 10 17 16 Printed in Germanyreimen DB No.) Description amt. Se cama | semants Hotlow bolt ‘ je} ss ® Replace | aano nicuing 6 | 4 | injection sines Cylinders 4 = qe 5 | injection tines Cylinest =a | 2 6 | somo bose 1 7 Seat | 2 Replace 8 | Hollow bolt 1 9 Seal | 2 Replace yo) Fuctretumiine | 2 a Plug 1 | i | seat 2 replace 3a | uel feed tne 1 | 4 Adaptor 1 seat 1 neplace raiser nead screw | 18 Observe installation | Page 25 - 6 Washer 1s 8 | wxturecontion | sit Mug (atten bot | 2 ao | seat a | seplace Gasket 1 replace v2 wt 3 23 | Washer 1 ie z L Printed in Germany Fuel system 25-525 tue suten Now| Descxlption ee eee Le 24 | Mixture contro} Hatt lower 1 25 | Rubber/metat pad 4 26 | Nut 7 27 | Washer 2 ae | Bracket 1 INSTALLATION NOTES - REMOVING AND INSTALLING MIXTURE CONTROL 4, Torque filister head sorews 4 through 4 cross- wie to 20 Nm @.0 kpm), 2, Tighten other fillistor head screws and hex head screws (5 mm longer) with spring and plain ‘washers to block and loosen again 1 trun each. ‘The 6th screw is a hex head screw cue to the lack of adequate space, eee eee eee 6 Fuel system Printed in GermanyKING AND ADJUSTING AIR FLOW +L, Pall off plug for safety switch on mixture con ‘rol unit, ‘Tam ignition on and off again after approx, 10 seconds. Upper edge of air low sensor plate must be fDush with beginalng of cone oF max. 0.5 mn zher (ty for lower position). [Ai flow sensor plate must be Level 2 fn the venturi cone, The edges of the plate must not touch the sides of the come and restrict the fee movement of the plate and Lever Adjusting An excessively high ais flow sexsor plate setting can be corrected by driving down the stop spring guide pin accordingly, using a drift and a light Note Adjust very carefully, so that guide pin is not riven too deep, Av both directions, since press fit of pin will not hold if frequent adjustments in cect synem 2S SENSOR PLATE AT REST POSITION Printed in Germany = Ty oe zs ‘Checking and Adjusting Air Flow Sensor 6a Plate at Rest PositionD5 re system REMOVING AND INSTALLING FUEL DISTRIBUTOR OF MIXTURE CONTROL UNIT Notes Now| Deseriptlon Calsenne ae Remarks 1 | Filister bead serew | 3 Torque to 0, 85 mkg (2,5 8) 2 | Fuel distrtbuter 1 | Caution! Donot —1f control piston har | Don't dis tet control piston been removed, clean | assemble fil out thoroughly with unused gasoline before instal ling 3 | Onting 1 Replace, lubricate and ostall new O-ring in groove of fuel distribu~| tor 4 | Air tow sensor a ss Gb Removing and Installing Fuel Distributor én Mixture Control Unit Printed in Germany25 reer system DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL UNIT 14 42 4116/15 10 9 « 65 2 341ai 1 f I ge el . Disassembling and Astembling Mixture Control Unit Printed In Germanyruct sytem 20 REPLACING PRESSURE RELIEF AND RESIDUAL PRESSURE VALVES Ro, | Description Remarks 7 i Removing Installing : a | Adapter with residual | 4 Torque 1.9 + 1.5 mkg pressure valve (assembled (9.4 ~ 10,8 15) 2 | spring 1 5 3 Install same anime re~ | Check system moved (always 2) 4 | Fiat seat 1 Replace 5 | ong. Replace 5 | Piston 1 | Use tapered wood Check, if damaged peg fmecessary replace {uel distributor (cloce tolerance part) 7 1 Check, replace if set of parts 1 9. | Fuel distefbutor 1 Do not disassemble Printed in Germany - 11, 1975 Replacing Pressure Relief and Residua 25-6 Pressure Valvesreat sytem 20 5. Center adjusting lever in alr flow sensor 6. Align anguler cleszance between air flow housing and tighten mounting serews, sengot plate end venturi, ‘The angular clearance be uniform, tt can be checked with a 0 mm feeler gauge, This requires that eight adjustment Gest position) of alr flow sensor plate be correct, inted in Germany - 11, 1978 Disassembling and Assembling Mixture Control Unit25 rue system DISASSEMBLING AND ASSEMBLING MIXTURE CONTROL UNIT 1, Preassemble adjusting lever, spring and pivot 8. fork lever prior to installation in air low Jake suze that spring fits properly 2, Use on appropriate cylindrical pin for this pur- pose, e.g. obe from adjusting lever of 912 a mixtuce control anit or a standard & h 8 x 60 DIN 7 cylindrical pin, Soth ends of pin must be chamfered, Guide assembled parts into air flow sensor housing and push out eylindrical pin used for assembly carefully with the original cylindri- cal pin, eee eee ea eee 25+ 8h Dissssembling and Assembling Mixture Control Unit Printed in Germanynet system 29 No, | Desertpsion eet an ea Remarks as. | cytinarical pin 1 24 | adjusting lever 3 cheek 25 | Pivot fork lever 1 36 | spring 1 ot | Spacer 2 8 | eilister head serew 2 ‘Torque 047 0.63 mkg (8.4 = 8.8 fb) 29 | counterwe 1 Position contectly 40 | Fister nead screw 1 a1 | tocknut 2 Plug, sefety switeh 1 Turned approx. 16° toward venturi 43. | stop spring a 1 Lubricate bearing bores | with silicone grease Printed in Germany - 1, 1878 saqeembling and Ascombling aby Miture Contzol UnitTOOLS neneen 25 Special Toot | Remarks | 2 | Adjusting wench 2 | spectal screwdriver P ee] Printed in Germany ‘Adjusting ate Btstem 25 nu DIUSTING IDLE Test requirements Engine must be in perfeet mechanical condition anc ignition timing set correctly, 2, Rutt engine to operating temperature (abou! 80” cre), Remove air cleaners 4, Check If menual accelerator lever ie at bottorn stop, nect CO tester and separate tachometer according to manufacturer's instruc Separate 2-pole plug connector when connec tng tackometer. Use jumper wites to bridge connectors and provide terminal for connecti black/iolet wire te tachometer or engine tester, Black/ violet wire normally goes to termina! 1 of the distributor, The tachometer ‘oF engine tester is connected to this wire, which normally goes to terminal 1 of the distrtbutor. Warning Never hold black/viotet wire against any ground while engine is running. Adjusting rele 1, 1916 = Printed in Germany4 |, Turn air correction te ve om throttle valve housing until spucified speed is reached, Use special tool P 220 ¢ 7, Adjust CO, Printed in Germany = Remove plug with seal in top of mixture control units Guide sejusting wrench P 977 tn. Turing clockwice rehens mixture; counter clockwise leans mixture. ruet system 25 caution 1) Always adjust CO from Jean to rich, Example; if idle serew setting i 109 rich, first tarn counterelackwise farther than necessary and then clockwise to nominal setting. >) Never apply pressure to adjusting wrench while adjusting (engine stops). ¢) Turn control serew very slightly as very smail turns alter amount of CO in exhaust gases considerably, Maximurn adjustment on anixtore contro} serew is 1/2 turn mhen checking (or adjusting) CO, plug adjusting hole before taking CO reading. If hole ist not plugged, extre air will be pulled into control unit giving wrong reading. Remove wrench. Caution Never leave wrench in adjusting note when accelerating engine as this could severely damage mixture control unit, 10, Accelerate engine briefly. Adjusting Idle25 rect system 11, Wait until CO tester shows a concentration of exaust gas at idle speed, See Page 25 ~ 19 for edjusting data, necessary repeat procedure, 430, install air cleaner again and recheck idle speed and CO content. Caution Complete adjustments as quteily as possibte to prevent overheating intake ports, REMOVING AND INSTALLING AUXILIARY AIR VALVE 1, Remove air cleaner. + Loosen clamps and disconnect hoses. 8, Pull off electric plug connectors, 4, Loosen socket head screws and remove wiliary aiz valve. 25-10 Adjusting tale Printed in Germany Removing and installing Auxiliary Air Valve25 Fuel system ADJUSTING IDLE (1978 MODEL} Too special Tool Remarks | [= I | Description Allen key Printed in Germany - 11, 1978 Adjusting Idle 1978 Model 25 -25 rect onten ADJUSTING IDLE 3978 MODEL Note Ai cleaner must he installed far all adjustments. 8, Adjust mixture, Trsert special tool 9156 fata suitable plug in open end of hese, springeloaded Allen key in mixtare control walt, Press down special tool Tum control screw on throttle housing » specified speed is reached. 4, See notes on pa on page 25 ~ 16, 3 and adjusting velues Figure shows contral serew without ait cleaner 5-106 Adjusting idle Printed in GermanyFuel System ADJUSTING IDLE — US CARS SINCE 1986 MODEL. Engine Type 930/68 25 TOOLS v No. | Description Special Too! Remarks 1 | Adjusting wrench 9156 2 | Adapter us 8040 3 | CO tester Us 4492 4} Special screwariver P229bor P229¢ Printed in Germany V1, 1985 ‘Adjusting Idle 25-10625 Fuel system ADJUSTING IDLE Note 3. Insert a suitable plug in the air hose between the air pump and blowoff Adjusting Requirements: switching valve. Engine must be in perfect mechanical condi- tion. Electric equipment must be switched off during adjustments. Adjustments must be completed as quickly as possible, to avoid excessive heat in the intake ports and consequently wrong CO values. Adjustments must be performed with the air cleaner mounted 1. Install adapter US 8040 and CO tester US 4492 on the test connection. 4, Run engine to operating temperature (80 to 90° C oil temperature). 5. Turn contro! screw on the throttle housing until specified engine speed of 900 = 50 rpm is reached. 2, Disconnect plug for oxygen sensor and connect CO tester to instructions supplied with equipment. Picture shows the control screw without the charging air cooler and air cleaner. 25-10d — Adjusting Idle Printed in GermanyFuel System 25 6. Check CO tevel. If the CO level is not within specifications, correct the adjust: ment on the mixture control unit. Insert Special Tool 9156 in the spring loaded wrench in the mixture control unit, Press special tool down about 18 mm to have the spring loaded wrench engage in the mixture control screw. Turned clockwise Turned anticlockwise icher mixture. leaner mixture. CO level: 0.6 + 0.2 % by volume. Note ‘The charging air cooler, complete air cleaner and \ead-sealed wrench will have to be removed (see page 25 - 10 fi, if the CO level has to be corrected on the mixture control unit. 7. After finishing adjustments, connect the ‘oxygen sensor plug, install the air hose and screw the plug in the test connection. ive threads of plug a thin coat of Bosch VS 140 16 Ft or Optimoly Ht, Torque: 15 Nm (11 ft. Ibs.). ee Printed in Germany - VI, 1985 Adjusting Idle 25-10e25 ruet system CORRECTING CO ADJUSTMENT ON MIXTURE CONTROL UNIT — US CARS. 1. Remove the lead-sealed wrench and replace it with a new wrench, Part No. 930 110 910 01, if the CO level is not within specifications, 2, Adjust CO and engine idle speed. 3. Apply one drop of Loctite No. 270 in the bore of the adjusting wrench and close the bore with a plug, Part No, 930 110 921 00, after finishing adjust- ments. 25-104 Correcting CO Adjustment on Mixture Control Unit Printed in Germany US CarsTOOLS Fuel System 25 No.| Description Special Tool Remarks Presure gauge Pama Printed in Germany + 1, 1976 Fuel Pressure Tool E25 » system CHEGKING PRESSURE Note For better understanding we have mumberedé ‘connections and lever positions of change-over valve in the following text, Connecting and Bleeding Pressure Gauge 1, Remove air cleaner, 8, Switch selector valve to position 2, Let pressure gauge hang down (by its Rose), disconnect 2-pole plug at mixture control uait (arrow) and turn on ignition (fue) pump runs), Move change-over valve lever to 2, Remove Line ftom mixture cortral unit to position 3 about § times at intervals of 10 ‘control pressuve regulator at control presswre seconds. regulator, Connect selector valve into Line as Shown (connection I to control pressure regula nection 8 to regulator feed ine). ad ‘Comecting and Bleeding Pressure Gauge Printed in GermanyCHECKING “COLD” CONTROL PRESSURE “This test ean only be mado on a cold engine. ‘This testis absolutely essential for starting or warm-up problems. 1. Connect and bleed pressure geuse, 2. Disconnect 2:pole plugs at mixture controt Unit and control pressure reguletor, anc turn fon ignition (fuel purnps run). cuctsysem 25 CHECKING "WARM" CONTROL PRESSURE {cold or warm engine) “This tes is carried out on # cold oF warm engine. Connect, and bleed orassuce.gauee.. 1, Disconnect 2-pole plug (arrow) at mixture control unit and turn on ignition {fuel pumps eun) 4, Refer to Testing and Adjusting Dats on Page 25-15 and 25 - 16 far nominal pressure ‘corresponding with outside temporature at moment of testing. 6, Any variations mean control pressure regulator must be roplaced. Printed In Germany - i, 9981 2. Move selactor valve to position 2. ‘Control pressure will now rise slowly and must reach specified value when control pressure regulator has been controlled. Off time varies according to ambient temperature. If necessary, replace control pressure regulator. Caution Be sure to connect 2:pole plug to mixture ‘eontrol unit. ‘Checking Cold Control Pressure Checking Warm Control Pressure25 rveisysten FROM 1978 MODELS, TURBO 3.3 ALSO MEASURING CONTROL PRESSURE “WARM WITH FULL THROTTLE ENRICHMENT” CHECKING CONTROL PRESSURE "WARM - FULL THROTTLE ENRICHMENT” 1.Check contro! pressure “warm” (fuel pumps must be 4, Pump warm-up regulator to approx. 0.5 bar (7 psi) runnigh. pressure, 2. Disconnect pressure hose for warm-up regulator at, throttle housing. Note A pressure sbove 0.8 bar (11 psi) could damage the diaphragm in the warm-up regulator. Control pressure will now drop and must reach the specified value with warm-up regulator out of action (ee page 25 - 16). If necessary, replace regulator. 3. Connect tester VW 1274 with (locally made) adapter ‘on disconnected hose (to warm-up regulator) 25-14 Checking Warm Control Pressure Printed in Germany Checking Control Pressure “Warm - Full Throttle Enrichment”Se CHECKING SYSTEM PRESSURE 1. Connect and bleed pressure gauge. 2, Move selector valve to position 3. Disconnect 2-pole plug at mixture control unit and turn on ignition. 3. System presture must have now reached specified value. SSgESEEEEEECS ECE Ce an Printed in Germany 111, 1981 Checking System Pressure 2-14325 oven CHECKING FUEL DELIVERY RATE FOR CONTROL PRESSURE CIRCUIT ture Requirements: Fuel pumps in correct operational condition. Checking 1. Connect and bleed pressure gauge, 4. Turn on ignition. 5. Move switching valve to position 2 and let electric fuel pumps run exactly 1 minute by pulling off two-pin plug on mixture contrat unit, Stop by switching valve to position 3 and measure dolivery rate. Test value: 160 to 240 cc/minute If measured valug is outside of tolerances, the cause will be in the fuel distributor. Replace fuel 3. Unscrew hose from Special Tool P37 on warm- _cistibutor. up regulator and hold end in a measuring glass with volume of at least 500 cc. 25-14 Checking Fuel Delivery Rate Printed In Germany for Control Pressure Circuittutsveen QB TESTING AND ADJUSTING DATA FOR CIS FUEL INJECTION Test Testing and Adjusting Data [ Special Notes Electric fuel pump dolivery rate min, 1170.6? /30s Page 20- 3 (valid for both pumps together) Control pressure “cold’ Diagram for warm-up control Page 25-13 (acc, to outside temp.) Part No. 911.606.105.02 ‘and 930,606.105.00 Bosch No. 0 438 140 016 ‘and 0-438 140 022, Controt pressure “waren” Page 25-13, Engine Type 930/51, 930/53 2.83.0 bar (aten) System pressure 6.0-6.7 bar (atm) Page 25-148 Leak test min, pressure after 10 minutos: 17 bar (1.8 atm) 20 minutes: 1.8 bar (1.6 atm} Injectors opening pressure 24-32 dar (atm) Idle adjustments Idle speed 900 - 950 rpm 960 - 1050 rpm (1977 Model) CO level Engine Type 930/51 1 to 3%" 930/53 2 10.4 %* * sir pump dis connected Printed in Germany ~ IH, 1981 Testing and Adjusting Oats for 25-15 CIS Fuel injectionOB cuisyeem TESTING AND ADJUSTING DATA FOR CIS FUEL INJECTION (1978 MODEL) Test Testing/Adjusting Data [Special Notes Electric fusl pump. Detivery rate at least 1170/em? /30 see. Page 20. 3 (for both pumps together! Control pressure “cold” (eccording to outside temp.) Diagram for control pressure Page 25-13 regulator Part No, 930.608.105.903 Bosch No. 0 438 140 054 Contro! pressure “warm’* 3.68 0.20 bar page 25 - 13 “Full throttle enrichment” 29% 0.20 bar System pressure Page 25-149 Testing value 6.0 to. 6.7 bar Adjusting value 6.2 10.6.5 bar Leak Test Min. press. after 10 min 16 bar after 20 min, 14 bar Fuel Injectors Opening pressure 2414 bar Dativery rate 160 to 240 em? min JPage 25 - 14» Control pressure 25-16 Testing and Adjusting Data for CIS Fuel Injection IM, 1981 - Printed in Germanyeuisyem OB Test Testing/Adjusting Data late adjustment Engine Type usa California (oil temp. approx. 90° C/ 195° F) Idle speed rom 930 all 1000 50 1000 * 50 CO level in % 930/61 “ . 2103) 2103 930/63/64 * Air pump disconnected eee ere eee eee Printed in Germany - 111, 1981 Testing and Adjusting Data for 25-16a CIS Fuel InjectionFuel System 25 TESTING AND ADJUSTING VALUES FOR KJETRONIC SINCE 1986 MODEL. Engine Type 930/68 Test Step Specifications Remarks Electric fuel pump Delivery rate at least 1500 cc / 30 see. Page 20-3 (valid for both pumps together) Control pressure “cold” Diagrem for warm-up regulator Page 25 - 13 (equal to outside temperature) | Part No. 930.608.105.08 Bosch No, 0.438 140 153 1- without charging pressure 2- with charging pressure Control pressure “warm” 3.75 + 0.20 bar {kp/em2) Page 25-13 “full throttle enrichment’* 2.90 + 0.20 bar (kp/em2) System pressure Test value 6.7 to 7.4 bar (kp/em2) Page 25-144 Adjusting value 6.9 to 7.1 bar {kp/em2}) Leak test Minimum pressure after 10 minutes 1.6 bar (kp/em2) after 20 minutes 1.4 bar (kp/em2) Fuel injectors Opening pressure 2.7 + 1.1 bar (kp/om2) Control pressure circuit Delivery rate 160 to 240 cc / min. Page 25-14 b Printed in Germany - VI, 1985 ‘Testing and Adjusting Values for K-Jetronic ~ Since 1986 Model 25-16¢25 fuel Test Step. System Specifications Idle speed {approx 90° C oil temperature) rpm Eng. Type Europe USA California Japan ‘Sweden Canada 930 all 930/68 95050 1000250 100050 1000 900250 +50 1000 250 95050 CO level in % by volume ** Measured in front of catalytic converter 930/60 930/61 930/63 930/64 930/62 930/65 930/60 models 8182 930/66 models 83/84 930/68 1986 modal Air pump disconnected. 2104" 1.50 25" 1.5 t0 25° ‘and oxygen sensor plug disconnected. 2t03* 2103" = — ap 0.640.2 1.5 to 25" —————— 25-16d Testing and Adjusting Values for K-Jetronic Printed in GermanyREMOVING AND INSTALLING THERMO-VALVE Removing Disconnect plug, loosen hose clamps and remove mounting bolt. CHECKING THERMO-VALVE La Detach vacuum hoses. 2. Blow air (by moutty Into vacua hore taken off Teadapter. 8, Thermosvalve must not be open when engine warm, Termo~valve must De open zt an ambient temperature of less than 20° ¢ (68° FD, Printed in Germany - 1976 Removing and Instalting Thermo-Vaive cr Checking Thermo-Valve25 ruei system Note ‘A-0,5 mm long piece of resistance wire (9 ohms) {s Installed in Jead cunning to thermo: salve. AQ olim resistor (about 10 watts) must always be used when checking thermo-vaive, e.g. to check while installed in car. REMOVING AND INSTALLING AUXILIARY AIR VALVE Removing tach vacuum hose, remove bolts, loosen ose e.amp and remove auxiliar 25718 Checking Theemo-Valve Printed in Germany Removing and Installing AuxiBary Alr Valveretsytem 25 REMOVING AND INSTALLING AIR CLEANER (1978 TURSO 3.3) Note When installing, key for idle adjustin not damaged, ful that spring-loaded Allen (on mixture control unit i 4, Unscrew nut slightly and remove air cleaner, 1s Uncerew bolts and detach vent hose of air 5, Om cars with aix conditioning, looser com pressor and place to one side, 8, Loosen vent hose clamp on oll filler neck and pul off hose, Note Be careful not to damage rubber seal on ind ig and tnstalling air air cooler while re Printed in Germany - Ul, 1976 Removing and Installing Air Cleaner 25-1926 EXHAUST SYSTEM Printed in GermanyFXHAUST SYSTEM LAYOUT Printed in Germany Exhaust System Layout 20-1Printed in Germany oS seez Ww ue oe ee ? a Of Ob E> a 5 3 x asen 26 T 1 | Thermag mut 2 | Replace 20 | casket Joa] Replace a1} Thermag nut ee Replace ee Bolt 4 las Nat 3 —— 18 | Gasket | Replace 19 Gasket | 1 Replace 20 | Thermag nut 4 Replace | | 22) bypass tine ‘i Printed in Germany Disassembling and Assembling Exhaust SystemNog] Descriptions | nemoving a eae Remarks 24 | Thermag nut 4 Replace | los) Lockptate 4 Replace 23 | waste gate 1 Installation notes on a7 | Gasket 1 Replace Thermag nut 3 Replace 29] pot 3 30 | Gasket 1 Replace at | Thermag nut 3 Replace s2 | Bott 3 38 | Gasket a Replace 34 | Exhaust Line 1 35 | Thermag aut 4 Replace a6 | Batt 4 a7 | casket 2 Replace 38 | Heat exchanger 39] Thermag aut 2 Replace 40 | washer rr) 42] Resetor 2 Torque 245 mkg Installation 28 fy notes on Page 26 = 5 42 | Casket 6 Replace 43] Pipe 6 SSS rrr ere EY 26-4 Disassembling and Assembling Exhaust System Printed in GermanyREMOVING AND INSTALLING REACTOR TooLs 2. No. Description Special Tool Remarks 1 Socket wrench Peri0 INSTALLATION NOTES Tighten nuts evenly to 2.0 - 2.3 mkg {15-17 fe Ib). Printed in Germany - IM, 1981 Removing and Installing Reactor 26-5exhasst system 26 Note when Noe} Description ‘ ; lemarke pt FT Removing Installing ome 1 | vatve nage 1 2 | Hottow bore 2 3) Seat 2 Replace 4) Contot tine 1 5. | abbr grommet 1 6 | Hottow bott 1 1 | seat 2 Replace s | vesttine 1 a | aubner grommet 1 16 | Locknut 6 Replace 11 | water 6 12 | Waste gste cover | 1 | Caution! anstattation Cover under ring notes on tension, Pages 28 - 9 13 | Skim 2 16 | spring 2 15 | es, 1 Replace self-locking 1 | wather 1 27 | Piston 2 28 | Diaphoegm 1 Replaces Mount Installation textile side (printed) | notes on facing pistons Pages 20 - 19 | Diaphragm plate a 20 | vaive 1 Check, replace Af necexaty. ax | Thermag nut 8 Replace 22 | waste gate base 1 Mount correctly with} Installation respect to waste gate | notes on valve Pages 28 = 8 Pncealiseesnaiy Dilascrabling and Asrembling Waste Gate 2672G crouse system ] Note when fo. | Description i Rem: : ee 29+) Removing Instating 23 | vaive gasket 1 Replace | 2x | waste gate vatve 1 See Page 26-9 | housing | asia 26-8 Disassembling and Assembling W Printed in Germanyena syten DE DISASSEMBLING AND ASSEMBLING WASTE GATE 1, Join waste gate base to valve housing and ‘Mount waste gete cover in press when assembling. Lighten mounting nuts slightly. 2, Align base and valve housing with a mandrel or long shaft drill of 10 mm (5/18 in.) dia meter, Tighten mounting nats evenly. Diaphregm installed correctly. Printed in Germany Disassembling and Assembling Waste Gate26-12 Disassembling and Assembling As Injection Printed in Germanymuaon system 26 Now} Description oy. fe ede eng Remarks 2] wing nut 1 2 | cover 1 3 | Filter element : Check, replace if necessary 4 | Fiter housing a 5 | sot a 6 | wesher a 7 | wether a 8 | Bott 3 | washer 3 10 | ott 2 a | Washer 2 32 | washer 2 13 | Wher asembiy 1 see Page 26 = 15 pulleys 2+ 3) 34 | Drive belt, 72 teeth | 1 ‘Tighten, sit must deflect GEngine Type 820/58 by 6 to.8 mm (1/4 to 7B teeth) 5/16 in) at center under thumb pressure 1s | bolt a 16 | washer e- 17 | Wather 1 12 | Spacer 1 12 | Rubber beating 1 Check, replace if necessary 20 | Bracket ct %2 | Rubber bearing 1 Check, replace if necessary 22 | washer a 23 | mu a Printed in Germany - 1, 1976 Disassembling and Assembling Air Injection 26 ~ 19.26 exaust system No.} Description eee gra bie eee Remarks 24 | washer a 28 | washer 1 26 | Batt a 27 | Washer 1 28 | Air pump 1 29 | Rubber bearing 1 Check, replace tf necessary sc | Spacer 1 a2 | Rubber bearing a Cheek, replace tf necessary 22 | Spacer 1 33 | Air pomp mount a 34 | Socket head screw 2 38 | Washer 8 36 | Pulley 1 87 | Hollow bott 1 se | Seat 2 Replace [22 | Adapter 1 40 | seat a Replace aa] nut 3 42 | Washer 3 43} oll pump 1 Mount off pump shaft aowel pin between socket head screws of pulley 1, aa] Not 2 45] washer 2 46 | Cover, flange 1 26-14 Disessembling ang ASembling Air Injection Printed in Germanyexaust system QO 7 Note when No.| Description ty. marks | oe NT Removing Installing ee 47] Socket head screw | 2 48 | Washer 2 43 | Pattey 3 50 e belt, 86 teeth | ‘Tighten, it must deftect by 8 to 8 mm G/4 to 5/16 ing) at ' center under thm’ pressure js | aot 8 32 | washer 3 53 | range 1 sa | seat 1 Replace, instal correctly with Vw 439 55 | Gasket 1 Replace, coat both sides with sealing compound REMOVING AND INSTALLING 2/3 IDLER SPROCKET ASSEMBLY When removing or installing 2/3 ldter sprocket {puttey) assembly on Engine Type 990/58, note that mounting Goes are fftet 19 one side. Frinted in Germany ~ Disassembling and Assembling Air Injection 25 = 18ZG rrravs system REMOVING AND INSTALLING AIR PUMP Removing 1, Loosen bolts and hoses on diverter valve and 8, Laoten nut on bracket ané bolts on air pump semove valve mount, 2, Loosen clamps and remove hote between 4, Peet off toothed Belt and remove afr pump mixture control unit and valve housing. ‘with mous: Installing 1, Install air pump with air pump mount and Install toothed belt. 2, Press alr pump to the left slightly and tighten the bolt on air pump bracket, Under thumb pressure, the toothed belt should deflect (at mldpoint) by 6 + mm (1/4 10 5/16 Ine). 36 Removing and Installing Ais Pump Printed in GermanyExhaust system QO REMOVING AND INSTALLING AIR FILTER OF AIR PUMP Removing Note 1, Loosen and remove air hose between air pump When installing make sure that the air filter and diverter valve, doet not tonch other parts, Printed in Germany Removing and Instaiting Air Pump 26-1726 exnoost system REMOVING AND INSTALLING CONTROL VALVE Removing 4, Loosen clamps and pull contral line off, 2. Loosen bolts and remove control valve. Installing Connect control line hoses properly. Connect hose from diverter valve to control valve at connection 1 (green ting). REMOVING AND INSTALLING DIVERTER VALVE 1 Loosen and remove alt hoses end control lines 24 Loosen bolts and remove valves 26-18 — Removing and Installing Control Valve Printed in Germany Removing and Installing Diverter Valvetenaust system QO REMOVING AND INSTALLING AIR INJECTION LINE AND ADAPTER 1, Remove heat exchanger and reactors, fb. 2, Loosen and remove check valve, 9, Loosen air Injection line and connections at adapters, Note Loosen the olf line slightly at the front left adapter and move aside for clesrance. Se sly Printed in Germany = 3, 1978 Removing znd Installing Ait injection 26-19 Line and AdapterQE orcrarst system CHECKING CONTROL VALVE, DIVERTER VALVE AND CHECK VALVE Note In operation control valve, diverter valve and cheek valve are connected with each other. A defective conteal valve could also destcoy diver tet valve as well as check valve. Always check all thie parts, if one of them falls, Checking Control Valve and Divert Cheeking Check Valve valve 1, Discansect conta ssure tine. Check valve should only open in direction of air injection, It must be closed in opposite direction, 2, Inject compressed air having a max. pressure of 1.0 bar (1,0 atm) Into disconnected con trol line, Check if diverter valve blows off Checking Control Valve and Diverter Valve Printed in eer eeeexnauss system 26 REMOVING AND INSTALLING EGR FILTER Removing Unscrew coupling muts. REMOVING AND ALLING EGR VALVE Removing 1. Detach vacuum noses. 2, Disconnect pipe at valve, 8. Unscrew mounting bots. Installing 1, Use new gasket, Printed in Germany = 1, 197) Removing and Installing EGR Filter Removing and Installing EGR Valve26 rrasse system 2, Connect vacuum hones as follows Ast stage ~ fom upper vacuum unit to I throttle hovsing conection (1 Giving direction). Connection are marked with red rings, 2nd stage from lower vacuum unit to night throttle housing connection (ia driving dizection). CHECKING GR VALVE 1, Remove sir cleaner. 2, Detach upper vacitum hose at £ 8, Connect upper vacuum hose of Ist stage with an approx. 1 meter (3 feet) long hose, 4, Start engine and lel [1 up at idle spe Detach vacuum hore at distributor connect it to hose using an appropri of tubing, Also check whether valve stem can be moved up, a Repeat this cheek several times by detaching and attaching hote, A inlior must be used to see movement, Removing and Installing EGR Valve Printed in Germany Checking EGR ValvePrinted in Germany - Ul, 197826 ervouss syeiem DISASSEMBLING AND ASSEMBLING AIR INJECTION 14 Disastembling and Assembling Air Injection Printed in Germanytrnaust system 26 2 Notes Remark: oe SY | Removing Installing, x a put 1 Spring washer 1 a | Mose clamp 1 4 | Air cleaner housing 1 Lower section 5 | Hose clamp 1 6 | Hose 1 1 | wing mt 1 2 | co 1 » | ritter cartridge a Check, replace if a0 | Bott 1 a1 | Spring washer 12 | washer 11 | Bracket aa | ott 1 15 | spring washer 1 16 | Washe a ar | Ais pump Fl 18 } Socket bd, ser 2 0 | sprocket 1 1 | Nat 1 spring washer zl 3 | Washer 1 Printed in Germany = 11, 1978 Disassembling embling Air Injection 26 - 25QS cvrvasse system Notes Xo. | Description y Remarks | esr 28 | removing Installing 24 | Rubber mount 1 26 | Air pump holder 1 spacer Rubber mount i Check, replace necessary 28 1 29 | spring washer 1 30 | washer 1 1. | rubber mount 1 Cheek, replace 22 | spacer 1 35 | Rubber mount a cheek, 24 | spacer 1 25 | Bolt 1 38 washer 1 28 | Rubber mount 1 Check, replace if 29 | spacer 1 40 | Mount 1 Rubber mount 1 Check, replace if necessary ubber mount 1 Check, replace if 4 1 check, replace if 44 | Hollow bot el ————— 26 Disaserabling and Assembling Air Injection Printed in Germanyst system DE Ex No, | Deseription ay. Notes Remarks fa | ec C8 | removing Insel Remas Seal 2 Replace 40 | Adapter 1 at | seat 1 Replace as | nut 49 | spring washer 3 50 | olf pump 1 Install c ump shaft betw capscrews of ais pump drive gear si | nut Spring washer 2 5a. | intermediate 1 Socket hd. eapserewe 2 Spring washer 2 56 | Sprocket 1 57 | Drive belt 1 Check, replace if necessary, tighten 58 | sot 3 50 | Spring washer . Intermediate flange 1 Gasket i Replace ez | of seal 1 Replace, position comectly, use proper tool, e.g. VW 433 Printed in Germany - Ul, 1978 Disassembling aud Assembling Air injection 26 - 2726 exrarse system CHECKING AND ADJUSTING DRIVE BELT OF AIR PUMP checking Drive belt tightness 1s contect if belt gives under thumb pressure applied at polnt midway bet sprockets by € to 8 mm. Adjusting Loosen bolt slightly (arrow), aml 7m 2, Turn self sting bolt until belt Lughtness is conect, Tighten bolt ocking ad) ‘Checking and Adjusting Drive Belt of Air Pump Printed in Germany26 Exhaust system apa Nog Sages ney aayea roueaa ~ dund ay - soweat2 Ty sopooo9my sp areyUL SaqvA toRRINIS9I = aaqes io-doa sagen sum own, sonqrnsrp worstsSt papea ne Arereny = sowenfon ae Areppxny = sore yeaq Z0y wor Z0qO> conan ay vsn - 4n04¥v1 aon 26-29 Hose Layout ~ USA Printed in Germany ~ u, 19782G exnaust system B HOSE LAYOUT - CALIFORNIA Be ot ¢ 2 & | ee | | < il 26-30 Hose Layout ~ California Printed In Germanyexraust system 26 OPERATING AND TESTING THERMO TIME VALVE OF ENGINE TYPES 930/61 AND 920/68 Thermo time valve in vacuum Une between distributor and throttle housing is closed on a cold engine, ‘This eliminates vacuum retard conttol and the {ignition timing moves toward advance by approx. 15°, which provides a fast idle speed after a cold start. After about 15 to 20 seconds the thermo time valve will open and let the vacuum take effect, which pulls back ignition timing toward retard to the specified value, ‘The thermo time valve has to be replaced, if there is no movement toward advance and the related fast idle speed after a cold start, ‘The thermo time valve operation can only be tested on a completely cold engine, Printed in Germany = 11, 1978 Operating and Testing Thermo Time Valve 20 Figure shows thermo time valve with intake air intercooler removed ‘Thermo time valve can be replaced without re~ ‘moving intake intercooler,28 IGNITION SYSTEM Printed in Germanyvten_ 28 ADJUSTING IGNITON TIMING Specifications: 5° 29° arDc at 950 * 50 rpm 1, Connect engine tester or tachoineter. This equires separating a 2-pole plug connector near CDI control unit, ‘The connection can be made again with jumper wites, with 2 conection to black/ violet wites, Tachometer or engine tester is connected to this wire, whfch in turn usually foes to terminal 1 of the distributor, Standard tachometers/engine testers normally connected to standard coll-type ignition, can also be connected heres Note Depending on type of tester used, tachometer installed in car could return to off during test. “This 1s not important to test, Printed in Germany ‘Adjusting Ignition Timing 28-1warning With the engine running the black/ violet wire is charged with about 450 V, When connecting, test equipment be careful that the connecting terminal does not touch car's ground, A short circuit of this type could damage ignition control unit. 2, Do not disconnect vacuum hose at distributors 3, Make adjustments with the ol! temperature at about 80° C/176" F, The notch o the pulley to the left of the 21 mark (5° ATDC fon crankshaft) must be opposite the mark ‘on the fan housing at an engine speed of ‘950 * 50 rpm Note Since the turbo engine uses breakerless ignition, there is no dwell angle adjustment. ss 25-2 Adjusting Ignition Timing Printed in Germanyrgottion synen 2B ADJUSTING IGNITION TIMING + 1947 MODESS 2-pole plug connector near CDI contro! unt Page 28 ~ 1) has been deleted from 13) Jodels, Wises now routed over 1dpole plug on ° are at 1000 > 50 rpm Adin rature of about 80° C (176° F), Pestinent mark on pulley must be opposite notch on blower housing, 1 specified engine speed. can no longer be 1, Instead ‘of this reason a tactiom connected as described 0 a tester must be used, Which records engine speed pickup placed around an ignition cable, After adjust ment of ignition timing a check of ignition timing advance control must be made (see Page 28 - 1). Note ° on crankshaft corresponds to 1mm on pulley Printed in Germ 1976 Adjusting Igaition Timing 28-28QB rcostsos system ADJUSTING IGNITION TIMING - 1978 MODEL ‘Timing Data: 108 2° ATDC st 950 - 1050 rpm ‘vacuum horee ON California: 5 + 1° ATDC at 960 ~ 1050 zpm Vacuum hotes ON us! ‘Adjustments are made when engine ofl is at a temperature of approx. 80° C (70? F), Pertinent tnarkc on pulley must align with note fn blower housing at specified engine speed, After adjustment of the ignition timing, cheek ignition timing advance (see page 28 = 4 ¢). —_—— 28- 2b Adjusting Ignition Timing WL, 1978 = Printed in GermanyQB sevition system VACUUM RETARD CURVE TURBO ENGINE apc “Advance at Ditibuter Shaft if 10 se | | i L | Por: vacmm "100 200. 300. 400 mba? vacuum 100 200 305 400 300 —_—_—SSSSeSSSSSSSSSSSSSSSSSSSSSsSSseseesee 28-4 — Checking Ignition Timing Control Printed in GermanyCHECKING IGNITION TIMING CONTROL equttements Ignition timing i set eorecty. Cheek tlming angle follow Ignition angle must be 26° 6° B1DC at engine ‘peed of 4000 rpm (vacuum hee disconnected). If specifications are not met, remove distributor and check on test bene! CENTRIFUGAL ADVANCE CURVE TURBO ENGINE BID 20° 15 "advance at Distributor Shalt o 1000) 2000 ‘3000 ‘4000 Distributor Shaft Speed (gpm), 0 ye Printed in Germany Checking Ignition Timing Controlrgnttion system 2B NG = 1977 MODELS Prerequisite: Igaltion timing adjusted correctly. Checking Ignition Advance Mf specification is not reached, remove distri= tion advance must be 29 * 8° BTDC at an butor and ehieck on test bench, 1e speed of 4000 rpm (vacuum hose disconnec = INE FROM MODEL 17 CENTRIFUGAL ADVANCE CURVE TURBO sipe 1s o Distributor Shaft Speed (rpm) =1, 1976 Checking Ignition Timing a8 -4e2B revision system VACUUM RETARD CURVE TURBO ENGINE FROM MODEL 77 arve 0 T RE NONE AT t COON co i faleta Cl ot. f 2 Biccenenccell alata 3 Co mana : | If Ha wre t an HHT : Creed CoE Q 4 = . | | wll I COPE COT Tur vacuum "180 0 60 769 mbar vacuum 200 ~2~*« 400 ‘500, he — 28-4b Checking Ignitfon Timing Printed in Germanyraaition system 2B CHECKING IGNITION TIMING 1978 MODELS Requirement: ignition timing correct. Checking Ignition Advance usa california At engine speed of 4000 rpm ignition advance [At engine speed of 4000 spm ignition advance must be 24° £ 4° before TDC must be 32° 4° before TDC. (Vacuum advance hose disconnected) (vacuum advance hose disconnected, but retard hose can remain connected as long as the test made without engine load. ) 4 Ty tT 5° I Piotr yrs ATDC 500 1000 1500 20002500 3000 35004000 — a as Distributor Shaft speed (rpm) ————— Printed in Germany ~ 1, 1978 Checking Ignition Timing 28-428 ipeiion yuen VACUUM RETARD CURVE - TURBO ENGINE 1978 - USA BIDC s = 10°. cor 15°. ATDC mbar Vacuum _100____200 VACUUM RETARD/ADVANCE CURVE - TURBO ENGINE 1978 - CALIFORNIA BrDC i o. ‘at Distributor Shaft 10°; as "ATDG 300 200 100 ° 100 200 300 +400 mbar eee Pressure | Vaqum | ee 28-4d Checking Ignition Timing Printed in Germany28 Ignition System CHECKING DISTRIBUTOR IN CAR ‘Turning distributor shaft sends an altemating ‘current signal to the CDI control unft, This alter= hating, current signal whieh. increases with engine speed, triggers the control unit to release ignition spark. Distributor operation can be checked by messuring alternating current, 1. Disconnect 2-pote plug connector at wire from distributor to engine hanes. 2, Connect a multipurpose tester to the plug and adjust st to measure AC voltages Note This distetbutor test requires a voltmeter which ‘measures very smnall AC voltage readings. 3, Operate starter and cead voltage « The proper voltage ts usually about 0.1 V. An exact reading cannot be made, because voltage ‘depends on starting speed and type of measu~ ring equipment, Distsibutor is bad and needs to be replaced if there is no voltage or much less than O41 Vs Note Never make changes on soft iron teeth of rotor cor stator. If starter fs operated with distributor eap taken off, be careful that cap holding springs do not fall Into distributor. Printed in Germany Checking Distributor 28-5TROUBLESHOOTING ELECTRONIC IGNITION SYSTEM (8OSCH CDI) "Testing Prerequisites Battery fully charged, fel in tank, engine or ambient temperature between © and + 40°C/22 fand 104° Fe (Temperature has a direct influence on measu~ zed values). Note especially information on possible dangers when doing any type of work on CDI system (see Workshop Manual 821, Vol. Il, Pages SL 23 and 2a. Starter turns, engine does not start or develops insufficient power 1, Connect spark gap tester to ignition trans~ former terminal 4 and set it for 12 mm, Start engine, 12 om spark present? yes Le Ga to Point 8 2, Check distributor cap, distributor rotor, {Ignition cables and spark plugs. Resistance of ignition cable including plug: 4k ohms, 1, 1976 Printed in Germanygation sytem 28 Resistance of distributor rotor: 5% ohms spark fe n spark plug? 3, Check ignition timing. Timing correct | «Check fuel system. Engine receiving sufficient fuel 8 8 yes © repair fuel system, 5. Check ignition transformer. Disconnect plug and high voltage wire ion transformer, Printed in Germany ~1, 1976 roubleshooting Electonic Ignition System 28 =anion sven 2B | = 45, For ignition fatlure: Disconnect tachometer, If ignition failure is gone, tachometer is defective. If not, tachometer is good. Ignition failure eliminated? Le Replace control unit Engine must statt or there must be adequate {ignition voltage to engine. If vot, there Is @ mechanical defect. 8, Disconnect plug at alt flow sensor contact of bridge terminals 80 and 87 on base of relay for fuel pump Ile Printed in Germany ‘Troubleshooting Electronic Ignition System.QB tsnirion sytem Check voltage at disconnected cont Is 6 and 8 ‘voltage correct ' « Check sensor resistance including sensor line at disconnected control unit plug terminals 3 and 7. Reslstance: 490 to 700 ohms. Troubleshooting Electronic Ignition Systemlgnttion system 2 ve = Resistance cortect? yes Aepeat test at tworpole plug in sensor line, v 10, Check ground of sensor coll including sen~ & sor line at disconnected control unit plug between terminal 9 and car's ground and terminal 7 and car's ground ‘Test values correct: Repair ot replace wites be tween plug and CDI control unit. ‘Test values incorrect: Replace distributor. ‘youbleshooting Flectronte Ignition System 28 ~ 11Resistance infinite? yes Repeat test at 2pole plug in sensor Tine (see 4 11, Cheek sensor system for mectanical damag inspection: Is there clearance between tor and stator page 28-11). Sensor system good? yes = Replace distributor 12, Disconnect tachometer, 1f there is an ignition spark now, tachome= ter is defective, Tachometer good? yes L- —— replace tachometer Go to Point 28 +12 Troubleshooting Electronte Ignition System Printed in GermanyDELAYED IGNITION CUTOFF A time delay relay for ignition cutoff will be ‘An open circuit in diode could prevent energizing installed in 1977 Turbo Carrera Model, fof altemator (charge indicator light does not come on while turning on ignition) « ‘A break in diode in blocking direction will be noticed by extended engine tun-on after turning itoff. when stopping engine, only fuel pumps are tumed off at fist. Afler a time delay of 3 to § seconds power supply for CDI control sit is broken automatically. This delay allows any residual fuel to he completely burned before engine stops. A diode is connected to battery charge indica~ tor light. It prevents voltage feedback into car's electrical system from terminal D + of alternator via charge {indicator light while engine is stopping. Printed in Germany ~ 1, 1976 Delayed Ignition 28-1830 TRANSMISSION GENERAL cLuTcH CLUTCH CONTROLS Printed in GermanyGeneral 30 TRANSMISSION TYPE 920 ‘The Turbo Carrera transmission is designated 990/20, 4 speed transmission final drive ratio 9/38 For 1977 model, following transmission Is installed: 990/394 speed with final drive ratio of 9/98 For 2078 model, following transmission fs installed: 990/24 = 4 speed with final drive ratio of 9/38 —— ‘Technical Data $0 ~ OF Printed in Germany = 11, 1978MANUAL TRANSMISSION TIGHTENING TORQUES, General Data 30 Location Description Thread Grade Torque Nm ftlbs Drive shaft Nut m30x15 | 88 210 192 Drive shaft Nut m20x15 | c35V 160 - 180 | 116-130 Driven shaft Nut maxis | 8 100 - 200 | 137-145 Stub axle Stretch bolt miox1s | 38 26-30 | 19.22 [Stub axle Bolt mioxis | 38 39-46 | 2803 Transm, case Vent miax1s | 9820K 20-30 | 14.22 Gearshift rod Conical ser. maxi25 | 88 23-28 | 17-19 Shift cover Selflacking Max126 | x12¢r nut No 188 22-25 | 1618.5 [Gear housing Backup light Miaxts | Ms 25-35 | 185-25 switeh Gearshift forks Nut Mex1.0 a8 an ese (Clamp, gears, transm. | Nut M8 x1.25 22-25 | 16185 case, front and side Shift lock, transm. Bott Mioxis | 88 isi | 11-413 Selector forks Bolt Mexi25 | 88 24-26 | 17419 Differential (ring Bolt Mi2xt25 | 119 138 - 140 | 98-101 gear attachment} Bolt mizx125 | 129 150 - 160] 108-116 ‘Transm, housing Plug with M2ax1s | st3758 (oil drain plugh ‘magnet Con. 1:16 20-25 | 14-18,5 ‘Transm. housing Plug msox1s | 58 (oil filer plug) Con. 1:16 20-25 | 14-185 Reverse gear Lock Plug miexts | 58 20-25 | 14185 Printed in Germany 1M, 1981 Technical Data 30-03BO cenerat vers Location Description | Thread Grade Torque Nm felbs Guide tube Bott Mex1o | a8 8-10 6-7 Jciutch and starter Bott msxio | a8 20-25 14-185 lecar starter Nut Mioxis | 8 46-50 33-36 Holder to base Nut Me 38 6 4 Base to tunnel Allen bolt | M8 88 2 15 Shift rod end Connecting | M8 88 18 " Coupling Connecting | M8 a8 18 " Clamp Bolt Me 88 25 185 30-04 Technical Data Printed in Germanycunt __ 30 General Data ‘Manual Transm, 930/30, 980/38 and 930/34 ratio Ist gear 2nd gear rd gear 4th gear Reverse (92/20 = 0,625) Climbing ability in te ast gear ‘2nd gear ard gear ath gear above 100 at 2 6 Final drive spiral cut bevel gears Final dive ratio 1078 models 1071 models 1078 models 9/98 = 4.222 9/98 = 4.202 9/98 = 4.222 Power transmission Double constant velocity Joint shafts to rear wheels Transmission weight (ary) w/o statter 59 kg/117 Tb Filling capacity Approx. 8.7 litess SAE 90 oil of API Cl GLS5 (or Mil-L 2205 B) pata for transmission type 990/94 are in parentheses. ee Printed in Germany - 1, 1978 ‘Technical Data 30 - 05General 30 General Data cisteh plate, Pressure spring No. Clutch dise spring No. spline proiile Single disc, dry, pull-type MFZ 240 Ficlitel + Sachs 887 - 979 kg (955 - 2158 1b) 3027 076 000 240 SD, spring torsion damper 0 ~ § 10962 SAE 24/48 22 teeth General Da Clutch (2978 Model) Design Pressure plate. Contact pressure spring No. Clutch dise Spline profile Single disc, dy, pull-type ‘MFZ 240 Fichtel + Sachs 1142 - 1099 kg (2518 ~ 2476 1b) 3027 076 202 240 GUD, mubbe SAE 24/38 torsion spring 22 teeth Printed in Germany 1, 1978 recht ical Data 80+ 07clutch, Control 30 >} 102 1 — le? ¥ | were 2 w —- aaeee Ol Tf t + P201a No. | Description specist Toot remake a | moter Min, tength 250 mm Feeler gauge 3 | spac 5. | Guide mandre Commercial item from 1978 model) Paoa 9102 Local manufacture (68 mm long Printed in Germany = 1, 1978 Removing and Installing Clutch Disc 3-.—™L™mUmUCS 90-2 Removing and Installing Clutch Dise Printed in Germanyetre 30 Notes when No. | Description ary. Remarks Removing Installing + | clutch botts 6 Unscrew evenly Tighten evenly and. torque: 2.0.2.5 mkg diagonally (14-185 ft lbs) a | Clutch bolts 9 Unscrew evenly Tighten evenly and torque: 2.0.2.5 mkg DIN 931 from diagonally. (14 185 ft lbs) Trans. No. 778 (0018 or 776 1011 2 | Washer 6 Replace, if needed ls | Ring gear 1 4 | Pressure plate 1 Check for wear 15 | Throwout bearing 1 Don't wash. Wipe Don't apply with dry rag. Coat pressure - danger guide tube contact of damage! surface with MoS. lubricant. 6 | ctuteh aise 1 (Check for wear. Center with clutch centering tool 9102 Printed in Germany ~ Il, 1981 Removing and Installing Clutch Dise 30-3BO cteren. contrat REMOVING AND INSTALLING Removing Note 1, Hold flywheel with toothed segment P-207 CCluteh linings cannot be replaced. ‘and spacer sleeve. Make sure that spacer sleeve IF applicable, the entire dise isto be replaced. fits engine with adequate clearance. { &. 2, Loosen bolts holding clutch pressure plate to 8. Check dise with lining for lateral runout. ‘flywheel evenly and diagonally one or two Permissible lateral runout on 225 mm ‘threads, until the spring pressure stops (pre: diameter is max. 0.6 mm. vents distortion on clutch pressure plate) CHECKING CLUTCH DISC 1, Check teeth, The clutch dise must move casily in axial direction on drive shaft with cout radial play. 2. Check rivets. Replace clutch disc if in doubt 3. Check clutch lining. If cluteh fining has oit spots, is burnt, torn or worn at spots, install a now disc 4, Check lining thickness, Thickness of disc ‘with riveted lining (no tension) is 10.1 0.3 mm. Wear limit (no tension) is 8.5 mm for symmetrical wear 30-4 Removing and Installing Clutch Disc Printed in GermanyCHECKING CLUTCH PRESSURE PLATE/DISC ‘The MEZ clutch pressure plate from Fichtel and Sachs is not designed for reconditioning or repairing. ‘The inspection is limited to dry cleaning and removing dust with compressed air and emery cloth, and a thorough visual 1 examination. 1, Clean eluteh, If necessary, clean bearing surface of pressure plate with emery cloth, Remove burnt spots by polishing, Clean entire assembly thoroughly with compressed air. 24 Check ends of diaphragm springs for traces ‘of wear from clutch release bearing, Wear ‘up to a depth of 3 mm is not serious, 4, Cheek spring connections between pressure plate and cover for cracks, Check tightness ‘of rivet connections, Replace pressure plates with damaged or loose rivets 3, Check friction surface of pressure plate for cracks, bumt spots and wear, Check with steel ruler, Pressure plates which are tapered up to 6,3 mm toward inside, can still be ed (check with feeler gauge blade), Printed in Germany Removing and Installing Clutch Pressure Plate and Disc 30 -Installing 1, After cleaning, check eluteh contact surface of flywheel for wear, Ifnecessary, machine surface and smooth with emery cloth, Replace the flywheel, if necessary, 2, Lubricate needle bearing in flywhee! with about 1 em® (1,5 grams) of Mes, grease, 3, Install clutch with special tool 9102 to center in flywheel. Center elutch pressure plate on flywheel. 5, Tighten bolts evenly and diagonally to prevent distortion on cover. Tighten bolts to speci= fled torque. Use Special Tool P 201 a and a spacing sleeve to hold the flywheel. 90-6 Removing and Installing Cluteh Pressure Plate and Dise Printed in GermanyADJUSTING CLUTCH - 19 MODEL (with auxiliary clutch spring on trans~ Note ‘With auxiliary eluteh spr porsible to accurately check clutch free play at elutch pedal, Consequently eluteh free play nsmission adjusting, has to be checked at 4 lever. Cheek and adjust clutch, see Workshop Manual 911, Main Group 7 = Page 2.1 = 2/2, Printed in Germany ~I, 1976 90-73O crien, contrors DISASSEMBLING AND ASSEMBLING CLUTCH , aa af : ro ’ 4 Disassembling and Assembling Clute Printed in GermanyCluteh, conrois 3O No.| Description ay, Note When Special Removing Installing Instructions 1 | Bott ° 2 | washer 9 I necessary, replace 2. | Pressure plate 1 4 | Drive plate 1 (Check for wear, center with a mandrel 5 | Starter gear ring 1 6 | Release bearing 1 Only possible, Check, replace Don’t apply when pressure if necessary. pressure plate not load- Do not wash, danger of ed (without only wipe off damage! brackets) dry. Coat slid ing surfaces for guide tube with MoS. multi- purpose grease 7 | Capscrew 9 8_| Flywheel 1 DISASSEMBLING AND ASSEMBLING CLUTCH 1. Three brackets be used to facilitate installation of clutch pressure plate. ‘These clips are mounted on al spare part cluten pressure plates and must be removed after installa tion. Its recommended to keep these clips on hand for later repair jobs. 2, Since the clutch concerned is pulled and the release bearing is designed accordingly, the release bearing must never be subjected to pressure in direction of drive plate. Consequently never place removed pressure plate on release bearing. When installing or assembling engine and transmission ‘also make sure that release lever is not exerting ‘force on bearing, Printed in Germany 111, 1981 Disassembling and Assembling Clutch 30 9cluten, Controls GO REMOVING AND INSTALLING CLUTCH RELEASE SPRING (FROM 1978 MODELS) Removing 1. Loosen clutch cable at holder and detach at release lever. 2, Remove adjusting lever, by taking off the circlip and, if applicable, disconnecting spring for adjusting lever (since October, 1978) 3. Press release lever forward with a suitable tool (to disengage). Note Spring stretches when passing “top dead center” and the release lever will snap forward. Checking and Lubricating 1. Check movement of release lever on release lever shaft, correcting if not easy enough. 2. Coat following sliding and bearing surfaces with a waterproof lubricant, for example: Staburags NBU 12/300 KB from Klber or a multi-purpose grease. — Release lever bore. — Release lever shaft (also splines for adjusting lever). — Release spring bearing surface on console. — Clutch cable mounting point on release lever Installing 1. Slide release lever with spring on to lever shaft and mount adjusting lever. Printed in Germany - V, 1984 Removing and Installing Clutch Release Spring 30-1130 ciuren, controls 2. Press back release lever with a suitable tool until release spring passes the top dead center point (lever snaps against stop on console) 3. Remove adjusting lever again and mount as close as possible to release lever. 4, Make basic clutch adjustment. 30-12 Removing and Installing Clutch Release Spring Printed in GermanyADJUSTING CLUTCH - 178 MODEL (with auxiliary eluteh spring on Checking Cluten Play Basic Adjustment of the auxiliary eluteh spring it is no 41, Detach clutch cable or loosen completely at ble to exaetly determine clutch play holder. at clutch pedal. Consequently the clutch play of cars with auxiliary clutch spring ‘will have to be checked at transmission adjusting lever, 0.2 mm with a Adjust cluteh play to 1 feeler gauge and counterlock adjusting bolt. 1, Check whether clutch cable is tight, If cable is tight enough, check eluteh pl with a feeler gauge, to 1.04 0,1 mm with adjusting bolt. if necessary readjusting a, Attach cluteh cable, 4, Tighten clutch cable at hold is1,0mm, until cluteh play Note Make basie adjustment, if eable is Ioose (hanging). Printed in Germany - 0, 1978 ‘Adjusting Clutch 80 = 19BO cisten, controis Note . Measure release travel Clutch cable tightness is correct if, when engaged, 4) Apply calipers with clutch engaged (see the release lever just lifts off of stop. figure) and read distance 1 (e.g. 101.9 ram), b) Disengage clutch and measure distance 1 Note as shown in figure (e.g. 74.7 mm), If adjusting room on eluteh cable bold sufficient, also adjust front edals, For this purpose, adjust stop on floor plate so that elease lever is 27 2 0.5 mm, it release travel on ¢) Dimension 1 Less dimension Il (in exemple, 301.9 mm minus 74,7 mm = 27.2 mm) gives the release travel, 80-14 Adjusting Clutch Printed in Germany34 MANUAL TRANSMISSION CONTROLS CASE Printed in GermanyManual Transmission, Controls/Case Printed in Germany Disassembling and Assembling Front Transmission Cover 3434 Manual Transmission, Controls/Case Notes Now} Description amt) pemoving oe Remarks 1 | Selector 10d 2 | bry out with Ute proper sized seal serewdtivers aft, Drive in to stop. Reverse gear 1 | Drive out. Heat cover to shaft about 1200 C (260°F) Drive in, 3 | Operating 1 | Drive out Heat cover to lever spacer about 220°C (250°F) Drive in, 4 | Transmission a front coves DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling Assembling 1, Using screwdriver, pry out seal for main Using a proper sized drift, drive selector selector rod, shaft seat in to stop. 2, Drive out reverse gear shaft and operating 4 ae lever spacer. 2&4-2 Disassembling and Assembling Front Transmission Cover Printed in Germanyseanvat transmission, consoisvease 3M TOOLS No.] Description special Too! Remarks a | Drift Part of P 254 2 | Driver P 25d a | Driver P2sde Printed in Germany Disassernbling and Assembling Transmission Housing 30-334 Menus Transmission, Controls/case 34-4 Disassembling and Assembling Transmission Housing Printed in GermanyBq — sacuar transmission, Controls/Case DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling Note 1, Remove snap rings for bearing outer races ‘The bearing outer races have different with P 254 b or 254 c inside diameters, The bearing outer race with the Largest inside diameter belongs to the driven shaft cylindrical rot bearing. Assembling 1, Heat gear housing to about 1207 ¢ and drive in outer races with P 254 b ar P 254 ¢. 34-6 Disassembling and assembling Transmission Housing Printed in GermanyManual Transmission, Controls /Case 34 Notes Now) Description Am Removing Installing. ciel a | Cotter pin a Replace 2 | Washer 1 a | Operating Lever 1 4 | Operating lever 1 Coat with shaft universal subrfeant 5 | Washer 1 6 | pug 1 ‘Torque to specifications 7 | Cotter pt a Replace a | Pin 1 9 | Reverse operating 1 lever 10 |] Reverse tod a. an | snap ring 2 | Remove with instal small setew> comrectly. driver, 12 | outer race with 1 | Drive out with Heat gear hsg. to snap ring P 284 b. about 1200C (250°F) and dive ka with P 254 b, 13 | outer race with snap ring 1 | Drive out with Heat gear hsg. to P254e about 120°C (2500F) and deive dn with P 254.0, 14 | Operating lever spacer| 1 | Drive out from inside 15 | Gear housing 1 Printed in Germany Disassembting and Assembling ‘Transmission HousingManual Transmission, Controis/case roos wos] Description speciat Too. | Remark a | Driver Posid 2 Hook - Local Manufac. 3 | antes par 4 Driver 7 Praga 5 | briver 0 285 6 Printed in Germany Disassembling and Assembling Transmission Case 34-7Manual Transmission, Coatrots/case OM Notes eo No. | Deseription | Am pemoving aa Rem: a | capscrew 2 ‘Torque to specifications 2 | nockwasher 2 Replace, if necessary 3. | Guide tube 1} Lubricate with MoS, paste 4 | Tube, arive a | Putt ont shaft seal with hook Light coat of ol! for seal and Mp 5 | Cirelip 1 6 | Release lever 1 Adjust 7 | seat 1 8 | Key 1 8 | Lever shan 1 Coat with a Mos, Inbeteant 10 | Release fork 1 Adjust a1 | cuore 1 12 | Bushing (Long) 1 | Drive out Delve in with with P P15 correctly, 13 | Bushing 1 | Drive out Drive dn with with P35. P 875 conrectly. 14 | Bearing sleeve | 1] pum out anglea (Detein) serewsériver a5 | vent a Install correctly an torque to specifications 16 | Hex ha screw 1 Torque to specifications ar | washer 1 18 | Holder a I Printed in Germany Disassembling and Assembling Transmission Case 4-934 Manual Transmission, Controls /Case Notes ‘o.| Description mt, femarks cea eee Amt removing tntalting e 19 | Electronic speedo~ meter sensor 1 20 | Spiral pin 3 21 | Hex he screw ‘Torque to specifications 22| spring 28 | Lock 3 | Ping 1. | pritt out 25 | Spiral pin 2 26 | Lock 2 at | Plug with 1 Torque to ‘magnet specifications 28 | shaft seat a Drive in with P2656 29 | Outer race 1 Meat transm, case to about 120°C and rive in, 20 | Outer race 1 | Drive out Heat ease to about with P 254¢, 190°C and drive in with P 254 a, 81 | Outer race 1 | Drive out with Feat case to about appropriate 120°C and drive in, pressure pad, 82} Guide ring 1 | Delve out with Heat ease to about appropriate 120°C and drive in, pressure pad. 98.) ‘Transmission 1 SS Disassembling and Assembling Transmission Case sa-10) Printed in GermanyManual Transmission, Controts/case OG DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling 4, Drive out bearing race of drive pinion bearing with P 254d, 24 Drive out spiral pin for release fork Assembling 1L, Clean transmission case and check for wear, exterfor damage and cracks. If drive pinions or ring gears are damaged (e.g, broken), check if the bearing bores fn the center housing web have been damaged (ceplace case if necessary). Wao «Heat transmision case to about 120°C we ~ and drive in drive pinion bearing outer race with P 254 a, Printed in Germany Disassembling and Assembling Transmission Case 4-113, Screw in vent correctly (bore in hexagon must 5, Drive in lever shaft bushings with P 375, face forward toward transmission cover). 4, Install selector rod locks 1 > eating sleeve (Delrin 2 = Lever shaft bushing (short) = Transmission Case 4 = Guard 5 f = Lever shaft bushing (Long) ‘34-12 Disassembling and Assembling Transmission Case Printed in Germany8. Adjust rele distances are 7 ind release levers. The 1. Drive in stub axle seal with P 265 ¢. ve shaft seal guide tube of the drive shaft, Printed in Germany Disessembling and Awsembling Transmission Case 94-19Bq stanuar transmission, Controis, care TRANSMISSION CASE WITH AUXILIARY CLUTCH SPRING 94-14 —_Disatsembling and Assembling Transmission Case 1976 - Printed in GermanyManual Transmission, Controls, Notes No.] Description 9+ | semoving renin Remarks 1 | cfrerip 1 Replace, if necessary 2 | Adjusting tever 1 Adjust 3 | Seal 1 Replace, if necessary 4 | Dowel pin 1 5 | Clutch release 1 Coat pin with # mult lever purpose grease con= taining Mos, 8 | seat 1 Replace, if necessary + | caetip 1 Replace, if necessary 8 | washer 1 9 | Auxiliary spring 1 10 | Washer a an | Adjusting bott 1 xo] nut 1 Tighten to specified torque 13 | Nut 4 ‘Tighten to specified | torque as | washer 4 Replace, if necessary 15 | base 1 Goat pin with @ multi purpose grease con= taining Mos, 16 | spring pin 1 Replace, if necessary at} Lever shaft 1 Coat bearing surfaces and splines with multi= purpose grease con= taining Mos, 1s | Release fork 1 w | seat 1 Replace, if necessary Printed in Germany ~ Disassembling and Assembling Transmision Case 34-14 aT o.| Description Notes marks oes eee 9+) removing Installing R 20 | oushing 2 J etre oat with rive in with P95 | Pars until pestioned | conectly 21 | Cover tube 1 sushing 1 | Drive out with Drive An with P 915 | pars until positioned conectly 23 | Bushing L Replace, étive in with mandrel I - Q4-14b Disassembling and Assembling Transmission Case Printed in GermanyManasi Transmission, Costrots, case _ OM TRANSMISSION CASE WITH AUXILIARY CLUTCH SPRING 1978 MODELS Printed in Germany - Il, 1978 Disassembling and Assembling Trans- Bette mission CaseManual Transmission, Controls, Case 34 DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling ‘Take tension off spring to remove release lever. ‘This Is done by pressing clutch release lever to~ ‘ward front transmission cover with an appro~ priate tool, Note Spring will snap back on its own when reaching, “dead point”, Assembling Drive in lever shaft bushings with Special Tool P 875 until they are positioned correctly (see drawing). Note uly install adjusting lever after engine/transmis~ son assembly has been {astalled in ear, Adjust cluteb, see Workshop Manual 911, Main Group 7 Fage 2.1 = 2/8, Printed in Germany = 1, 1976 Disassembling and Assembling Transmission Case 34 = 14eission, Controls, Case Description lay. Bee erin Remarks 1 | circtip 1 2 | Adjustn 1 a | Bort 1 4 | spring washer 5 | Spring mount a 6 | Auxiliary spring a 1 | seat Replace | Release lever 1 9 | Nut 1 20 | spring washer 1 a1 | base 1 12 spring pin 1 Lever shaft 2 14 | o-ring Replace Release fork 2 16 | scat 1 Replace ar | seat a Replace 38 | Bushing 2 | Drive out with Drive in to proper Special Tool position with 3167 9187 29 | ousting 1 Drive in with suitable mandrel ‘34-147 — Disasembling and Assembling Tram Printed in Germany mission CaseManoat Transmission, Controls, core OF DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Install release lever with spring (see pag 80 = 11). Disassembling 1, Remove release lever with spring (see page 2, Drive out bushings with US 050/12 and Us 8050/2. sembling Drive in bushings for lever shaft with US 8050/12 and US 8050/1 (see érawing) and coat with a grease having a lithium er ico 1 = Bushing for lever shaft 2 = Bushing for lever shaft Printed in Germany - 0, 1978 Disassembling and As 34 14g ‘Transmission CaseManual Transmission, Controls/Case 34 TOOLS No.] Description Special Too! Remarks 1 | Instahing tever Local manufacture 2 | Driver P 299 Printed tn Germany Disassembling and Assembling Gearshift Base84-16 Disassembling and Assembling Gearshift Base Printed in GermanyManual Transmission, Controls/care & Notes o.,Deseiption mts mara 7 ae Removing. Installing, 7 Ks 1 | Gears knob 1 eck for damage dea tightness 2 | Toteance Hing 1 Teplace 3 | sea 1 a| capcrew ex 20 | 3 Targue to feocket hd) specication 5 | washer 8 Replace, a 6 | capcrew wex20 | 2 Torque to (coke bd) ‘pectfcation | washer 2 Replace, if sy 8 | earth base 1 2 | tex mt se 2 10 | Lockvasher 2 replace, if necmry 11 | omer 1 12 | Pad plate 1 ord and ath gear pening faces eight ID ailing cretion. Goat ine with MS, Ibricant, 15 | att socket 1 Apnly Mos, Iebveant ui] Key 2 | deve outwith replaces amopsiate — neceuaty. Drive punch tn Key wnt fun abate 15) sing 1 Bend, if necetry. | ‘Adj lttlonl tore 16| setetor Lever 1 Coat bearing suraces | with os, Intent 17] shin X | Notenumba—Redetermine find thins eee. Max. ay 0.1 mm, =. Printed in Germany Disassembling and Assembling Gearshift Base atNotes a No.] Description Amt.| pemoving ae Remark 18 | Lock 2 Replace, if necessary 19 | wamer 1 20 | Fork a Coat bearing surfaces with MoS, Iubrfcant | DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling Assembling 4, Drive out gearshift knob with dismantling. 1, Clamp gemshift base in a vise, Move lever (see local manufacture sketch). selector lever in shifting direction, Pressure must build up from min, 250 g to max, 600 g. Bend spring in gearshift base if necessary. Local Manufacture Sketch b+ | fh Break all edges 6 mm thick flat steel wry 2, Max. pressure transverse to shifting. direction is 60 g. ‘GIs Disassembling and Asombling Gearhint Base Printed in GermanyManual Transmission, Controis/Case OM ADJUSTING GEARSHIFT MECHANISM Ly Loosen selector rod clamp, Turn selector rod for transmission’ inuet selector lever left in neu tral to stop (at seen in driving dizection), 2, Mave selector lever in neutral position so that the lower part of the selector lever is vertical and on rigth stop (2rd and 4th gear), 3, Tighten selector rod clamp slightly, 4. Check if shift travel is just as large in Ast ‘through 4th gears and if reverse is easy to engage. Correct adjustments if necessary. 15, Tighten hex nut on elamp to specffications. Printed in Germany ‘Adjusting Gearshift Mechanism 34-1935 MANUAL TRANSMISSION SHAFTS Printed in Germanyroous hk SoA 7 : ¥ ug. } Ne Now iption special Toot | Remarks 1 | Holder No, 9106 | Printed in Germany Disassembling and Assembling Gears/ShaftsManual Transmission, Gears /Shafts tre 35:0 Disassembling and Assembling Gears/Shafts Printed in GermanyManual Transmission, Gears/Shafts 35 Notes No. Deseription 4!| removing ae Remarks 1 | Hex nut 8 ‘Torque to specifications | 2 | Washer 9 3 | Washer 2 One in front and cone behind ground strap 4 | Ground strap 1 5 | Holder 1 6 | Hotder 1 | 7 | Front transm, cover 1 2 | Reverse gear 1 1 9 | casket 1 Replace a0} Nut 1 | Block trans Replace, Torque to rission with specifications 2 gears and loosen an | Rev, gear I a | Pry off wien 2 screwdrivers 12 | setf-locking 4 Replace, if hex rit necessary Torque to speeifleations 13] washer 4 1d] Selector cover with fork 1 15 | Gasket 1 Replace 1s | Pug 1] Cautiont Torque to Under spring, specifications. tension. a7] Spring 1 18] Lock a Move reverse selector rod to off position and Insert Printed in Germany Disassembling and Assembling Gears/Shatts 35-3Notes so. | Description mt. Remarks ee ee Am) Removing Installing 20 | Backup tight 1 ‘Torque to switch specifications 20) Pin 1 Install comectly. long end faces in ar | Hex nut 20 Torque to specifications 22 | washer 10 22] Gear housing 1 | Move setector rods to off position and 24 | Gasket 1 Replace 25 | Transmission case 1 with change gear 35-4 Disassembling and Assembling Gears/Shatts Printed in GermanyREMOVING AND INSTALLING INSTRUCTIONS Removing 3, Pull off cylindrical roller bearing toward front, 1, Loosen nuts for drive pinion and drive shaft, Place reverse gear shaft or ather corresponding shaft in bore of gear housing, Slide on reverse gear Tl as illustrated and place in 4th, 4, Remove aM parts from drive pinion and ive shaft, and mark needle bearings for installation (also refer to "Dismantling and Asembling Drive Pinion and Drive Shaft"), 2, Unscrew reverse gear lock plug. 5, Loosen clamp nuts and remove drive pinion and drive shaft. Note Plug is under heavy spring tension, Prevent spring and plug from jumping away when ‘unscrewing (danger of injuries). 6, Remove shims, Note number and thickness for installation. Printed in Germany Disassembling and Assembling Gears/Shafts 8555BB casas tranmision, Geaee/snatts Installing 5, Install nut for drive pinion with a fluid adhesive (Loctite No, 72 or similar) and torque to speci 11, Install shims in number and thickness as fications, Clean threadiwith Locquie Primer noted of as determined while adjusting the (or similar) to assure perfect lock, pinion. 6, Torque drive shaft nut to specified data, 2. Install preassembled drive pinion and drive shaft, and torque clamp mts to spectfi cations, 44 Lock nuts. 3, Install drive pinion and drive shait as follows. a, th speed gear TI bi Needle cage, spacer, 4th speed gear T ¢_ Operating sleeve for 3rd and 4th speed 4, Gearshift sleeve, selector fork and selector rod for Sré and 4th speed ce. Bushing, spacer, needle cage, rd speed gear I f, Spacer, nd speed gear TL iB. Thrust washer, 2nd speed gear 1 hh, Bushing, needle cage, 2nd speed gear 4 Operating sleeve for 1st and 2nd speed i, Gearshift sleeve, selector fork and selector rod for Ist and 2nd speed k, Bushing, spacer, needle cage, 1st speed gear Ik 1, Thust washer rm, Spacer, ist speed gear I 1, Cylindrical roller bearing Note Heat all press fit parts to about 120°C, 4, Adjust selector forks (see page 95-7). En Disassembling and Assembling Gea Printed in GermanyADJUSTING INSTRUCTIONS Note ‘Torque delve pinion and drive shaft nuts to 6, Install operating lever for reverse gear. specifications to adjust selector Forks. Reinstall reverse gear 1, Install reverse gear selector rod. 2, Install Special Too! 9106 and assemble reverse gears I and IT, 3, Install reverse gear IT as shown in illustration, 17, Adjust reverse gear selector rod. 8, Adjust selector rods, s0 that there fs play of 0,5 mm at tightest position between selector rod forks. 4, Place in 4th gear and torque muts to specifi~ cations. 5, Remove reverse gear Il again, Printed in Germany ‘Adjusting Selector Forks 95-7BH Manuat transmission, Gears/Shatts 9, Adjust gearshift sleeves so that they are at dead center between the synchronizing. rings in idle position, 10, Torque hex head screws of selector forks. to specifications. Note Conrect deviations in adjustments after completion of shifting controls, because hey are estential for proper functioning of the synchronization. ee 35-8 Adjusting Setector Forks Printed in GermanyrooLs re] Description Special Toot | Remarks 1 | Hotder No. 9104 2 | Socket wrench No. 9105 35-9 Pelated in Germany Disassembling and Assembling Drive Shaft‘Transmission, Gears/Shafts Many a a am Ss | 6 Lt oz iz BE RmE oT cel ee. Printed in Germany ‘a5-10 Disassembling and Assembling Drive ShaftNotes at No. | Description amt] scmoving ee Remarks a | nut 1 ‘Torque to speeificatlons and tock « 2 | Rev, gearr 1 | Pry off with Collar faces out, 2 screwdrivers, 3 | cyl. otter 1 | Remove with Heat sbout 120%. bearing extractar and drive on, 4 | astgearr 1 | Remove with Replace in palrs extractor only. Collar faces 5 | Spacer 1 6 | and gear t 1 Replace in pairs only. Faces same direction as countergear. 7 | Thrust washer 1 8 | ad gear a Cheek synchro, Replace in paits aly. 9 | Needle cage a | Mark to i= Assemble with stsll correctly same gear. iw | spacer 4 an | ard gear bush 1 12 | Gearshift sleeve a 18 | Operating sleeve a 14 | ath geart 1 Cheek synchro, Replace in pairs only. t 1s | spacer 1 16 | Needte cage a | Mark to i= Assemble with same. stall correctly. gear. at] wut 1 | Loosen with Torque to 9204 + 9105 specifications and lock. Printed in Germany Disassembling and Assembling Drive Shaft 35-11BB vassat reammssion, Goars/statte Notes to. | Deseription sa emarks Now fe Amt.) Removing nstanting ae 18 | cytindsteat 1 | Remove with Heat to about roller bearing spare sleeve 320°C and ive on. 19 | Inner race 1 | Remove with Heat, to about spare sleeve 120°C and drive on. 20 | 4-point bearing a a | inner race. a | Remove with Heat to about spare sleeve 320°C and eeive one 20 | Thrust washer 1 | Remove with Ground side spare sleeve faces necdle bearing 29 | 4th gear bush 1 | Remove with Hea to about spare sleeve 120°C and dive on 24 | Drive shaft 1 check runout —— ees 35-12 Disassembling and Assembling Drive Shaft Printed in GermanyMarval Transmission Gearssnerts BS DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling 2. Press off 4th speed bushing. 4-point bearing and eylindrical roller bearing with a spare Note operating sleeve. For better understanding the blowup drawing shows the entire drive shaft without a clamping plate ‘The parts up to and including number 16 are dismantled and assembled without removing the drive shaft (refer to “Removing and Installing Change Gear”). ‘ese, 1, Clamp special tool no. 9104 in a vise, insert drive shaft and loosen nut with special too! no. 9105. Assembling 1. Torque nut to specifications and lock. Note Special Too! 9105 cannot be used to unscrew and tighten the collar nut due to the longer drive shaft in transmission type 930/34 for Turbo 3.3 It For this purpose cut through the socket wrench at ap- proximately center and weld in a suitable piece of pipe {86 mm dia x 4 mm x 25 mm long). A torque wrench and an open-jawed or ring wrench could also be used instead of the special tool. Printed in Germany - 111, 1981 Disassembling and Assembling Drive Shaft 35-13‘roo! Description Special Yoo! Remarks 1] culde steve No. 9108 Printed in Germany Disassembling and Assembling Drive PinionQB ensat veapemtsston, ceare/Shatt SS so wea rE 2 ; nk a ~ — ay nn 35-16 Disassembling and Assembling Drive Pinion Printed In GermanyNotes No, |Description Amt, Remarks a *- TRemoving Installing a Joy, solter bearing 1 [Remove with Heat to about 120° ¢ extractor and drive on 2 | Thrust washer 1 Plane ground side faces eedle bearing 0 1 Check synchro, replace} 1977 Models - with in pairs only asymmetrically profiled teeth on clutch body 3 | 1st speed gear 4 | Needle cage 1 5 | spacer 4 6 | steve, ast speed 1 Heat about 120° © and drive on 1 | operating sleeve 1077 Modele-with, asymmetrically Jed teeth on 2. Note ine stalled direction (page 35-18) 8 | Guide sleeve 1 2nd speed 1 Cheek synetuo, replace sn pairs only 10 2 11 | Sleeve, 2nd speed 1 a2 | ard speed gear 1 1 Replace in pairs only. Let tered side faces in same direction as count 18 | spacer 1 14 | 4th speed gear 1 a Replace in pairs only. Let} tered side faces in same direction as countergea 36 | Searing inner race 1 jove with Heat about 1200 © and drive on 16 | 4-point bearing 1 a1 | Searing inner race 1 | Remove with Heat about 120° C and 8108 drive on Printed in Germany Disassembling and Assembling Drive Pinion 85417Notes Removing Installing ee No.] Description amt] 18 | cy. roller bearing 1 | Remove with Heat about 120% 9108 and delve on. Installed race faces gear set. 19 | pave pinion 1 ‘Adjust if necessary « Note pair codes. DISASSEMBLING AND ASSEMBLING INSTRUCTIONS assembling Assembling Note 1L, Meat cylindrical roller bearing to about 120° and drive on. “The blow-up drawing shows the entire drive pinion without clamping plate for better Note understanding. ‘The patts up to and including number 14 are Install bearing so that the two-part taken off and installed on an installed drive roller cage with installed race faces pinion (refer to ‘Removing and Installing gear set. Change Geat"). 41, Remove cylindrical roller bearing and Modification - 1977 Model four point bearing with special tool paren atta Asymmetrically profiled teeth of 1s1/2nd gear = operating sleeve must face toward Ist gear i TH a EEN 435-18 Disassembling and Assembling Drive Pinion Printed in GermanyTOOLS Manual T. nsmission, Gears/Shafts 35 Description Spectal Tool Remarks a] ewe Pressure sleeve - Manufsetured locally from 4 mm dia. welding wire aa 30-11 ‘or manufactured locally Printed in Germany [Removing and Installing Drive Shaft Seal 35-19BB vena teanemiesion, Gease/snatts No.] Description aml pemoviog Remarks 1] Seat 1 Ludrleate slighty. 2] sea 1} Remove with, priveinto op | screwdriver with pressure sleeve. | a | Pipe 1 Removing and Installing Drive Shaft Seal Printed in GermanyManual Transmission, Gears/siaits BD. REMOVING AND INSTALLING INSTRUCTIONS Removing 5, Pry off seal with screwdriver, Do not use tube as leverage, Use a piece of wood for 1, Remove engine/transmission assembly and this purpose. ‘unbolt transmission, 2. Unscrew guide sleeve capserews and remove guide sleeve. Installing 1, Drive in seal to stop with piece of pipe. 2 Pull out drive shaft seal tube with local manufactured hook, 4, Remove teal, Printed in Germany Removing and Installing Drive Shaft Seal 25-21BE sranuat transmission, Gears/shatts 2. Install rubber seal. 8, Lubricate rubber seal and sealing lip. 4, Insert tube with rubber seal and seal, 5, Install guide sleeve for release bearing and coat with MoS, pastes 6. Bolt transmission to engine and instal ‘this assembly. ee 25-22 Removing and Installing Drive Shaft Seal Printed in GermanyManual Transmission, Gears/Shafts 35 Notes Now| Deteription mt, Remarks 7 “I Am Removing Instalting Remarks 1 | snap ring 2 | Remove with Install correctty, small serew= must fil properly. ariver 2 | Lockwasher 1 3. | Synchronizer ring 1 Cheek for wear, Install correctly. | 4 | stop 2 t 5] Lock 1 Install correctly 6 | stop 1 | Install correctly 7] Gear ee Disassembling. and Assembling Synchronization Printed in Germany 35-28Check the following points to assure perfect synchronization, 1, Check diameter of installed synchronizing ing with a micrometer. Apply the mfcro~ meter at the highest position of the synchronizing ring. Diameter: Ist and 2nd gear ‘rd and sth gear 2, Max. play between selector fork and operating sleeve of Ist through ath gears is0,5 mm, —— SSSSSSSSSSSSSSsSSSSSes 35-28 Checking Synchronization Printed in Germanyasus 3D DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Manual Transmission, G Disassembling 2, Insect lockwasher and install snap ring so t the opening is well located in the ares of 1. Lift out snap ring with a small screwdriver the guide grooves tnd remove lockwasher. MODIFICATIONS > 1977 MODELS Assembling synchrontzation for 2st and 2nd gears has been changed. 1. Insert synchronizing ring on eluteh ig ting correct position, and install lock, stop and ‘ck straps (or just ane lock strap for 1st 1, Synchronizer parts for 1st g gear). ngs 26). 3. Installed diameter of synchroni has not been changed (see Page 25 ‘and Assembling Synchronization 35-25DIFFERENTIAL FINAL 39 priv Printed in Germanypitterentist, Fisar vive BQ TOOL No.| Description Special Too! Remarks 1 | Driver P 265 © Removing and Installing Differential 39-1 Printed in Germany39-2 Removing and Installing Differential Printed in GermanyDifferential, Final Drive 39 Notes io. | Description rt cemarks iz oa Amt Removing stalling 1 | streteh bott 2 ‘Torque to specifications 2 | Washer 2 3 | Flange 2 4] Bex mut 2 Torque to specifications washer w Replace if necessary 6 | side cover 1 | Drive off with plastic hammer a] seat o Replace, lubricate slightly s | shaft seal 1 | drive ovt punch Drive im with P2656 9 | outer race 1 Heal cover about 120°C and drive in with corresponding, presure pad 10 | Differential a ai | Transm, case 1 Printed in Germany Removing and Instalting Differential 59-8REMOVING AND INSTALLING INSTRUCTIONS Removing 1, Loosen flange stretch bolt and remove flanges Installing 1, Heat transmission cover to about 120°C and drive in bearing outer race. 2, Drive in flange seal with P 205 ¢. 39-4 Removing and Installing Differentiat Printed in Germanypirteentis, en ove BQ Too.s Nos] Description spectal Toot | Remarks a | Diver 264 b 2) Driver prea a | paracter Kukko No, 20/1 Printed in Germany Disassembling and Asembling Differential 39BQ vitrerentiat, rimat drive Oe” 39-6 Disassembling and Assembling Differential Printed in Germanypifferential, Final Drive 39 Notes gear with threaded aise surface with MoS, paste (on | Description mt Remarks Noe} Deseriptos Amt) removing stalling a] Spiral pia a Replace, if necessary 2 | Differential pin 1 ‘pital pin bore aligns with bore in anchor 3 | Anchor 1 4 | Differential gear, 2 | rum and Coat semiround small remove surface with MoS, paste 5 | Large differential 2 Coat semtround housing 6 | small taper roller 1 | Remove with Install with P 264 b bearing 20/1 and P 263 7 | Magnetic support a Watch magnetized aise parts 8 | shim x | Mark for reuse, ‘Determine thickness again if necessary 9 | Spacer 1 | Mark forreuse, Determine thickness again if necesary a0 | Key 1 Replace, if necessary an | Large taper roller 1 | Remove with Install with P 264 b bearing 20/1 + P 269 az | spacer 1 | Mark for reuse Determine thickness again if necessary 1s] Lockplate 6 Replace 14 | Hex head serew 2 ‘Threads dry and free of grease, Torque to | specifications as | Ring gear 1 ‘Threaded bores for ring gear bolts éty and free of grease. Note pair codes, ae | Differential 1 Printed in Germany Disassembling and Assembling Differential 39-7BQ viterention, rina drive DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling 1, Remove taper roller bearing with an extracter and P 263, Note ‘The claws of both arms must be machined. Assembling 1, Slide lockplate into groove of hex head screws, plnch front part together with a pliers to secure lockplate to hex head serew and lock by pulling down over hexagon surface, 2, Coat semiciteular surfaces of differential gears with MoS, paste. Disasiombling and Assembling Differential 28, Insect Lange differential gears with press {it threaded dises through oval opening in differential housing and align with anges. ike 4, Place tmall differential gears between the lange differential gears and turn until the gear bores align with the bores in the housing. 5, Install taper roller bearing with P 264 b. Printed in GermanyTOOLS Differential, Final Drive ‘ones | @ th = 39 No. | Description Special Too! Remarks 1 Mandrel P 263 2 | Puller us 1078 3 | pitt P 264 b Printed in Germany - 1, 1981 Disassembling and Assembling Differential 39-88BQ oistorensias Fine! ovive Printed in Germany 39-8b _ Disassembling and Assembling Differential i, 1981 -Differential, Final Drive 39 No.) Description ay. Special Removing Installing Instructions 1 | Spiral pin 1 2 | Pin 1 3. | Small differential 2 Coat with MoS. pinion paste. Only replace in sets (with large differential pinions) 4 | Large cifferential 2 Coat with MoS pinion paste, Only replace in sets (with small differential pinions 5 | Threaded piece 2 6 | Taper roller bear 2 [Put off wien Knock on with P 264 ing inner race Kukko 20/1 and P 263 7. | Magnetic carrier plate 1 Position correctly 8 | Washer x [Mark to install later If necessary, determine thickness 9 | Spacer x. [Mark to instal ater If necessary, determine thickness 10 | Key 1 11] Lockpiate 6 Replace 12 | Bott 2 “Threads dry and free of grease. Tighten to 13.5 14 mkp (98 - 101 felbs.) 13 | Ring gear 1 Tapped holes for ring gear bolts dry and free of grease ‘Watch pairing codes. Read. just if necessary. 14 | Differential housing 1 Printed in Germany uy, 1981 Disassembling and Assembling Ditterential 39-86DISASSEMBLING AND ASSEMBLING DIFFERENTIAL 3, Knock ring gear off of housing, Disassembling 1. Knock out spiral pin for differential pins. 2. Pull off tapered roller bearing inner races with Assembling ‘a puller (e.g. Kukko No. 20/1) and special tool P 263. 11. Mount ring gear, using locally manufactured cen- tering pins as guides. ‘A ~ Centering pins (made locally) Note Claws of both arms might have to be machined. 39-8d Disassembling and Assembling DitfereDifferential, Final Orive 39 2. Tighten ring gear bolts to specified torque. Slide lockplate into groove of bolts, squeeze front end with a pliers (to firmly unite lock: plate with bolts) and lock by bending lockplate down over side of bolt head. 3. Coat di ential pinions with MoSp paste. 4. Install large differential pinions with press- fit threaded plates through large ope differential housing and locate with joint flanges. 5, Install small differential pinions between large differential pinions and turn, until bores of pinions align with bores in housing Printed in Germany ~ 1H, 1981 lock with spiral pin. P 264, Disassembling and Assembling aise ay 6. Knock in differential pins in correct position and 7. Knock on tapered roller bearing inner races with 39-80Recommended Order for Readjustment of Pinion/Ring Gear If itis necessary to adjust the drive pinion and ring gear, the following procedures ere recommended for efficiency. * Dterin otal sti eens “So (Sy. lus Sp) for specified pre-load of tapered roller bearings! 2. Determine shim thickness "S 2, Split rotal shim thickness “Soy” into Sand Sp thatthe specified backlash is provided between ring gear and drive pinion. Objective of adjustments must be to each the position of quietest running, as had been determined on special testing machines during production. ‘Absolute cleanliness is required during all assembly and testing procedures to attain good results Repairs on the final drive will only require readjustment of drive pinion and ring gear, when parts have been replaced which directly influence the adjustment. Refer to the following table to avoid unnecessary adjustments! Adjust Ring Gear Drive Pinion (S, +82) dev. “(Sq Replaced Part: ‘Transmission case x x Side case cover x x Large cyl. roller bearing x x ‘and four-point bearing for drive pinion Drive pinion/ring gear x x Differential housing x ‘Tapered roller bearing for x differential Printed in Germany ~ III, 1981 ‘Adjusting Drive Pinion and Ring gear 39-9BQ oitterensias Finat ovive ADJUSTING DRIVE PINION AND RING GEAR. General Notes Drive pinion and ring gear settings are important for a long service life and quiet running of the final drive, This is why drive pinions and ring gears are matched during production and checked ‘on special testing machines for the most favorable surface appearance and low noise levels in oth directions of rotation. The position of quietest running is determined by moving the drive pinion in an axial direction, keeping the ring gear within specified backlash tolerances. The Geviation “r from the design distance “R'is measured and written on the face side of the drive pinion, Ring gears and drive pinions are designed so that deviation "ris always added to design distance "R", js always considered plus “To distinguish this pinion from former pinions, of which deviation “r” was either plus or minus, “1p on the head of the pinion is preceded by a capital “NN. Each pair of drive pinions and ring gears receives a pair code and may only be replaced together. = Design distance (81.69 or 82.29 mm) = Deviation from R - quoted in 1/100 mm 1 = Deviation r 2= Pair code 3= Backlash 39-10 Adjusting Drive Pinions Printed in GermanyTOOLS Ditterensiai, Fina drive OD No. | Description Special Tool Remarks h | cause vw36/1 2 | conterina aise 9109 ls | Master gauge vw 386/54 R-81.69 ls | dist oouse Commercial item Is | iat gouge Commerial item 3 mm range 5) Gauge plunger vw 305/18 17 | iat gauge extention vw 385/56 30 mm long le | Gauge plate yw 985/17 lo | Clock gauge hotder vws3s7 ho | steeve ous 11 | Adjusting device vw 521/64 12 | Messuring tever vw 388 13 | Gauge plunger e196 Printed in Germany 1M, 1981 Adjusting Drive 39-11BQ oirterentias Final ovive [ADJUSTING DRIVE PINION Distance “Eis caloulated by adding together dasign 1. Install preassembled drive pinion and drive distance “A and deviation “ras indicated on face shaft without shims and torque clamping of drive pinion plate nuts to specifications. = 81.69 mm for transmission type 930/32 2, Install 4 th gear with opereting and guide = 82.29 mm for transmission type 930/30/33/34 sleeves, and place in 4 th, 3, Slide 48 x 4 x 148 mm piece of pipe onto drive pinion. Deviation “rin 1/100 mm 2 = Pair code Examples IN 1B is the deviation “ron face of drive pinion. 4 Install thrust washer and oylindrical roller bearing, A = Design distance 81.69 mm (transm, type 930/32) 5, Mount gear housing and secure with two nuts. 1 = Deviation E = Pinion setting 6. Install reverse gears I and IIL 7. Place appropriate pin or reverse gear shaft in bore of transmission case and slide in reverse gear Il N12 is the deviation “son face of drive pinion. R= Design distance 82.29 mm (transm, type 930/30/33/34 1 = Deviation 0.12 Pinion setting 82.41 mm 39-12 Adjusting Drive Pinion8, Torque drive pinion nut to specifications. 1. Set master gauge VW 385/30 to pinion setting (82.41 mm in example) and place on master ‘mandrel. Set dial gauge (3 mm range) at zero 9, Make sure that the taper roller bearing with 1 mm preload. ‘outer races fit tight in transmission case and side cover. 10, Set adjusting ring of universal gauge | ‘VW 3865/1 to distance “a”. Hak _ pte 14, Remove master gauge after setting dial gauge. a = about 58 mm 16, Place gauge plate VW 385/17 on head of drive pinion, 11. Slide centering dises 9109 on gauge. Screw in gauge plunger VW 385/14 ‘with 30 mm dial gauge extention ‘Vw 385/56, 12, Intall taper coller bearing from differential, or spare taper roller bearing, on centering discs, Printed in Germany ~ IH, 1981 Adjusting Drive Pinion 39-1316, Place gauge mandrel in transmission case. 19, Turn master mandrel carefully until dial gauge ‘The dial gauge extention is near the gauge extension is vertical to face of drive pinion head plate. [At this moment the dial gauge needle will reach its ‘maximum point of deflection {inflection}, so that ican be read, Note ‘Measured value always deviates from sot value in clock- wise direction (small dial gauge needle between 1 and 2}, ie. in setting the dial gauge with 1 mm preload the value deviating from 1 must be added to shim thickness $3 Example: If small dial gauge needle is between 1 and 2 and large needle points 2 0.37 mm, with 1 mm dial gauge preload 17. Install side transmission cover without the shim thickness is 0.37 mm, whereby the thickness seal and tighten the 4 nuts crosswise. is always rounded off to the nearest 0,05 mm (e.g. 0.37 mm 100.35 mm) Note 20. Recheck distance “E" after installing shims. Do not use a hammer to set up the side transmission A deviation of * 0.03 mm is permissible. cover (this could cause the gauge plate, held by a ‘magnet, to fall down). Position the cover by tightening the nuts evenly. 18, Pull second centering disc so far out with the spindle that the gauge mandrel can just barely be ‘turned by hand. 39-14 Adjusting Drive Pinion Printed in GermanyADJUSTING RING GEAR Determining total shim thickness "Sip" (Sy +Sy }- Ring gear must be ceadjusted after replacement of ‘ransmission case, side transmission cover, ‘tapered roller bearing for differential, differential housing oF pinior / ring gear set Note Drive pinion must be removed to determine preload of tapered roller bearing for differential. 1. Make sure tapered roller bearing outer races fit tight in transmission case or side transmission 2. Install pertinent differential with one each 2.5 mm thick spacer on the ring gear end and opposite end. 3. Insert differential in transmission case and turn several times, 4. Install side transmission cover and tighten all huts to specified torque. Note Unscrew one stud to mount dial gauge holder. 39 Differential, Final Drive 5. Place gauge WW 386/17 on collar of differential 6. Mount dial gauge holder VW 387 with dial gouge and extension on case and set dial gauge at zero with 2 mm preload. ‘A = Dial gauge extension 30 mm long B © Gauge plate VW 385/17 7. Move differential up and down. Read and note play con dial gauge. Note Do not turn differential while measuring play, since this would cause wrong readings. Printed in Germany - 111, 1981 ‘Adjusting Ring Gear Determining S,. (S; + S» ) 30-1539 Differential, Final Drive 8. Calculate “Seog ” "Seoul thickness + measured value + tapered rollar bearing preload Example. Shim thickness 5.00 mm Measured value 0.82 mm Preload (constant value) 9.33 mm "Stot” 6.15 mm 9, Remove differential, pull off both tapered roller bearings and split up total shim thickness "S,o4"" 2s follows, Because of backlash adjustment later spacer Sy is selected 0.20 mm thinner than spacer Sp Example: ‘Total thickness of spacers Sy + Sp ‘Thickness of spacer S, 6.18 mm. 6.15.0 2 = 3.075mm = 9.20. mm, 2.875 mm Thickness of spacer Sp 618mm 2 3.075 mm + 0,20. mm 3.275 mm Note ‘Spacers are availabe in thicknesses of 2.4 to 3.7 mm, in steps of 0.10 mm. ‘A.0.25 mm thick shim permits spacing with 0.05 mm. Round off the spacer thicknesses to the available dis tance that the total shim thickness Sy and Sz is not changed. Example’ Calculated spacer thicknesses 81 +8) =2875+3.275=6.15 mm Rounded off spacer thicknesses S +82 = 2.85 +3.30=6.15 mm Measure thickness of shims at several points with a ‘micrometer. Max. permissible deviation 0.02 mm. Check shims for burrs and damage. ——— 39-16 Adjusting Ring Gear fra reer eee ee Printed in GermanyDitterentia Fin! orive BQ ADJUSTING BACKLASH Backlash should be 0.14 to 0.20 mm 6. Turn differential in both directions several times to settle the tapered roller bearings. 1. Install pinion/ring gear set with shims “Sq ” used for pinion setting, 7. Mount dial gauge holder VW 387 with dial gauge and plain extension that dial gauge axis and lever are Note at right angles, Collar nut of drive pinion must be tightened to spe cifled torque prior to measuring backlash. 2. Install differential with tapered roller bearings and spacers (S} + Sp } in case. 3, Mount side transmission cover an¢ tighten all nuts 10 specified torque. Note When tightening nuts check frequently that there is still a certain amount of backlash, Never let the drive pinion start to clamp, 4, Screw gauge lever VW 388 and adjuster VW 521/4 to- gether and adjust lever length to 101 mm (measured ‘from large hexagon surface to upper edge of ball) with gauge plunger 9196. Distance 101 mm 5. Insert adjuster with clamping bush (special too! 8, Turn ring gear carefully against stop and set dial 9148) in differential and clamp tight. gauge to zero, Turn back ring gear and read backlash, Note value, Note Hold drive pinion tight while measuring. This is done by clamping a suitable screwdriver between transmis sion ease and reverse gear Ih Printed in Geemany - 1H, 1981 Adjusting Backlash 39-17BQ oitterentias Finat Drive 9. Repeat measurement three times, turning ring gear 90 each time. Measures values must not deviate ‘among each other by more than 0.05 mm. Note Backlash required is inscribed in ring gear. 10, If specified backlash is not reached, change spacers (81 and Sy ) again. However, do not change total shim thickness (oq) 39-18 Adjusting Backlash Printed in GermanyDifferentiai, Finat vrive OD) ADIUSTING RING GEAR BACKLASH 1, Asemble change gear with those shims determined for the deive pinion setting. Note ‘Make sure that the drive pinion nut is torqued to specifications before adjusting the back= lash, 2, Install differential with taper roller bearings and calculated spacers ($ 1 and 5 2) and poaltion side transmission cover, 3, Torque side transmission cover hex nuts to specifications. Note When tightening the nuts keep checking f ‘there is stil a certain amount of backlash, Never allow the drive pinion to jam, 4, Slide dise from speetal tool P 357 onto a stub axle and secure flange on ring gear end, 5, Block differential with two screws which are screwed in through the flange. Only tighten screws slightly against side transmission cover, SOE 6, Install local manufactured dial gauge holder, as illustrated In figure, and check backlash, ‘The check at the reverse gear II must show the following backlash 0,88 40,1 mm Transmission type 930/20 0,38 70,1 mm Transmission type 980/32 ‘This backlash Is equivalent to 0.26 or 0,20 mm on the ring gear. Printed in Germany ‘Adjusting Ring Gear Backlash 3919)TOOLS No, | Description special Toot Remarks 1 | Adaptor - Local manufacture, ‘The adaptor can be made of flat fon 90 x 15 x 120 mm, It must have a 1/2 in, square opening in the middle, Printed in Germany Disassembling and Assembling Limited ip Differential 39-22ntial, Final Drive 39 distere eg € ¢ 9 £ 8 OW Printed in Germany 39-22 Disassembling and Assembling Limited Slip DiDifferential, Final Drive 39 No. | Description ay. a ee Remarks 1 | Socket head screw ‘Torque to 1,4 mig a0 ft iby } 2 | Housing cover 1 3. | Thrust washer Insert properly 4 | Outer splined dise 2 wavy, 5 | Outer splined dise 2 6 | Inner splined dise 4 (molybdenum surface) Outer splined ise 4 8 | Pressure ring 2 9 | cesr 2 10 | Threaded dise 2 | Press on gear Install properly at | Pinion 4 | a2 | Differential shaft | 29 | Differential housing | 1 Printed in Germany Disasembling and Assembling Limited Slip Differential 39-23DISASSEMBLING AND ASSEMBLING LIMITED Effect) Disassembling 1, Remove ring gear, 2, Loosen socket head bolts on housing flange and remove caver. Remove all inside parts, Caution Note sequence of dise installation, so that differential maintains proper locking effect, Assembling 1. Cheek all parts for wear or damage, and replace if necessary, a, Differential Housing Cheek guide grooves for outer splined discs and pressure rings for wear. 4 2. 4 SLIP DIFFERENTIAL (40% Locking Pressure Rings ‘The guide tabs and bearing surfaces must not show excessive wear or scoring, They ‘must also move easily in differential housing, Differential Gears ‘The bearing surfaces for the thrust washers must not be worn and the inner splined dises must move easily on the serratfon of the v Outside 7. In 1978 models, which are equipped with initial version spring plates *, the lockplate must still move in the recess after engag: ‘ment of the spreader spring. This guarantees gap X between the lock- plate and spring plate and deformation of the spreader spring is not possible. * Also refer to Group 47. a= Spring plate b = Spreader spring c= Lockplate 8, Depress brake pedal of stopped car firmly several times, to move brake pads into their normal operating position. Then check brake fluid level in tank, adding brake fluid if necessary. Breaking in Brake Pads Factory new brake pads will require about 200 km of operation before reaching their most favorable friction and wear values. Only then will the pads have adapted them- selves to the brake discs and the squeaking noise will now disappear. Try to avoid full stop emergency braking during the breaking in period. ee 46-4 — Removing and Installing Brake Pads Printed in Germanyorakes, MechenicalParts 4B MODIFIED FRONT WHEEL BRAKES FOR 3.3 LITER TURBO ‘The front wheel brake disc/hub connection is changed since the production of 1981 models. The flange and ring connection has been changed to a brake dise shell connection a on the 911/3.0 Ite. Turbo, By designing the new brake discs with a shell the total distance (brake disc - hub) is 21 mm longer. Consequent- ly the installation of 21 mm spacers is omitted. It is not permitted to aditionally install spacers with the wheel hub. Conversion to new brake discs/whee! hubs is only permitted on both sides simultaneously for 3.3 liters cars be- fore 1981 models. Removing grease caps is different due to the modified hubs. Old Version New Version Printed in Germany - V, 1984 Disassembling and Assembling Front Wheel 46-44Toois No. Description Special Too! Remarks 1 Slide hammer vw771 2 Puller 9165 Only required up to end of 1980 models Printed in Germany HII, 1981 Disassembling and Assembling Front Wheel 46-5 Brakes4G ersten. mecnanicat parts O | | 101615 987 7 Note “The front whee! brake applicable up to end of 1980 models is shown. From 1981 models the brake disc/ ‘hes! hub connection is changed (see page 46 - 4). 46-6 Disassembling and Assembling Front Wheel Brakes: Printed in GermanyBrakes, Mechanical Parts 4O NoteWhen: Special tee moma | 1! Removing Installing Instructions 1 | Bolt |; 2 Torque: 70 Nm | 2. | Washer 2 Replace, | | if necessary 3 | Spacer 2 Between caliper | | and steering | | knuckle | | | 4 | Brake caliper =| 1 | | | alt | eee lene | i | onrearaxle | up toend of | | | (21 mm) 1980 models | | 6 | Hub cap 1 | See text Different | ae | 7 | ut with socket | 1 Adjust whee! 7 | | screw bearing play | Torque socket | screw to 15 Nm 8 | Pressure dise ja] | 9 | Wheel bearing, = | 1 | Check, replacing outer ; | if necessary | 10. | Wheel hub 1 2 versions 11 | Screw 12 Install screws | Only version and tighten Up to end of | uniformly. 1980 models | Torque: 10 Nm 12 | Lockpiate 12 Replace | | [13° | Ring 7 || | foie la] coer vaer | wai | and damage. | If applicable, mark for reinstall | | | | | | L | a Printed in Germany - V, 1984 Disassembling and Assembling Front Wheel Brakes 46 79G crores, Mechanical Parts Note When: | Seeciat | [ No. | Description Qty. | Removing Installing Instructions 15 | nue ls Torque: 231Nm | 16 | Washer | 5 Replace, if j ray 17 | po Is | 18 | Brake flange 1 | Only version up to end of 1980 models 19 | Screw 13] Torque: 10 Nm 20 | Washer 3 Replace, if | reneary | 21 | Guard 1 Machine or Page 46 - 10 reowcnit’ | bei a | | | t L Se . = Se 46-8 Disassembling and Assembling Front Wheel Brakes Printed in Germanyrakes Mechanical Parts 4G DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES Disassembling Version B 1. Unserew and plug brake line to prevent brake fluid Grease caps with welded tapped adapters are install from flowing out of reservoir. Unscrew brake ed since Chassis No. 93 Z BS 000094 caliper. (October, 1980). These caps can be knocked out with special tool WW 771, without puller 9165, 2, Remove spacer (cars up to end of 1980 model year), but do not use sharp edged tools. Burrs could cause wheels to have lateral runout, 3. Remove great cap according to version Version A Up to end of 1960 model year. Knock out gest cap with special Toot VW 771 used in conjunction wth 9168, | Versione ‘The first 1981 model cars (up to sbove mentioned ‘chassis number) still had grease caps without the tapped adapter. These caps have been ground to the smallest possible diameter at the pressing-in point to reduce the pressing force They can be removed with a screwdriver. 4, Unscrow adjusting nut for wheel bearings. Remove wineel hub with brake disc. 5, Separate brake disc and wheel hub, Printed in Germany Disassembling and Assembling 46-94G srokes, Mechanical Parts DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES Disassembling 1. Check condition of all parts and replace, if necessary. Note: Bridges of brake calipers have cast bosses since 1984 models and this has changed the brake guards, Only brake calipers or caliper bridges with cast bosses are available for replacements after depletion of stocks in older models. In this case the new brake guard must also be installed or the old guard changed accordingly (cut off) 2. Clean centering surface for brake disc on wheel hub and apply a very thin coat of Optimoly TA. 3. Conversion to new brake discs/wheel hubs on 3.3 liter cars before 1981 model is only permitted simultaneously on both sides. 4, Brake discs must not be mounted on the wrong side, since inboard vent bores arranged evolvently. Identification: evolvent shape and part number. Part number is located on the brake disc. Spare part for left side = 3rd group number uneven Spare part for right side ~ 3rd group number even Examples Left brake disc part no.: 930 351 047 00 or 930.351 04701 Right brake disc part no.: 930 351 048 00 or: 930 351 048 01 46-10 Disassembling and Assembling Front Wheel Brakes Forward Direction 5. Note torque specifications. Install taper roller bearings with a multi-purpose grease. 6. Adjust wheel bearing play that finger pressure applied to a screwdriver is just adequate to move pressure disc. Do not support screwdriver on hub. To adjust, first tighten nut slightly to keep bearings from seizing, Drive in hub cap of version C with a piece of pipe to avoid damaging the threads. 7. Make sure brake hose is positioned correctly, when screwing on brake line. Bleed brakes. V, 1984 Printed in GermanyPrinted in Germany = m1, 1978 Disassei sembling Rear Wheel Brakes 46 = 114G rakes, Mechanical Parts | | Note When: Special No. | Description ty. | Removing Installing Instructions 1 | Screw | 2 Torque: 60 Nm 2 | Washer 2 Replace, if | | necessary 3. | Brake caliper 1 | | 4 | Spacer 1 Wider than on i front axle | (28 mm) | 5 | Screw 2 | 6 | Brake disc | 1 | Setback brake Check for wear | | and damage | | 7 | Spring }2] Hooks must be in \ holes provided in | brake backplate | 8 | Support sleeve 1 9 | Adjusting nut 1 10 | Adjusting screw 1] [11 | Return spring a} | 12. | Brake shoe 2 Replace, if | necessary. Wear | limit: 2 mm 13. | Return spring 1] 14 | Pressure bar 1 15 | Pivot pin 1 Lubricate lightly 16 | Pin 1 Lubricate lightly | | |17 | Operating lever | 1 | | | 18. | Screw 4 Torque: 25 Nm 19. | Washer 4 | 20. | Brake backplate | 1 }21 | Guara 4 Machine or Page 46-13 | } | replace, if (assembling) | | necessary _——— 46-12 Disassembling and Assembling Rear Wheel Brakes —-V, 1984 Printed in GermanyBrakes, Mechanical Parts 46 DISASSEMBLING AND ASSEMBLING REAR WHEEL BRAKES. Disassembling 1. Remove spacer. Do not use sharp edged tools. Burrs could cause wheel to have lateral runout. 2. Turn parking brake adjuster in loosening direction. Unscrew two countersunk screws. 3. Unscrew brake line from brake hose. To prevent brake fluid tank from draining, sorew a shortened, plugged piece of brake line in brake hose. 4, Press out brake line holding clip from rear control arm, 5, Unscrew brake caliper and remove brake disc. Ifa tight fitting brake disc cannot be removed even after applying light knocks with a plastic hammer, screw hexagon head bolts in two 8 mm diameter threads of brake disc uniformly to press off the disc Assembling Note Bridges of brake calipers have cast bosses since 1984 models and therefore the quards have also been changed. Only brake calipers or caliper bridges with cast bosses will be available for replacements after depletion of stocks in older models. In this case the new brake guard must also be used or the old guard changed accordingly (cut off. 1. Lubricate adjuster, pin of expander lever and sliding surfaces of parking brake shoes slightly. Printed in Germany - V, 1984 Disassembling and Assembling Rear Wheel Brakes 46-1346-14 Disassembling and Assembling Rear Wheel6. Clean brake disc centering surface on wheel hub and apply a very thin coat of Optimoly HT. 7. Assemble brake disc and brake caliper. Tighten bolts to specified torque, Do not mix up left and right side dises, since inboard vent passages have an evolute shape. Identification: evolute shape and part number. Part number is located on brake disc. Spare part for loft side + 3rd group number uneven Spare part right side + 3rd group number even Example: Part No, 930 352 045 00 Part No, 930 352 046 00 Brake dise, left Brake dise, right Forward Direction Brakes, Mechanical Parts 8. Adjust parking brake. Bload service brakes. Printed in Germany - 111, 1981 Disassembling and Assembling 46 46-15Brakes, Hydraulic Parts 4 5 10 11 9 1617 7 3610 11 5 1512 131416 4 8 18192 1 Note Blow-up view shows brake caliper of rear axle with 30 mm diameter piston (front axle piston diameter: 38 mm) and retaining tab of cross spring facing up. On brake caliper of front axle retaining tab is down, i.e. front bridges with spring plates are reversed. Disassembling and Assembling Brake Caliper Sections — page 47 - 7. $$ SSSSSSSSSses Printed in Germany ~ V, 1984 Disassembling and Assembling Brake Calipers 47-147 General TORQUE SPECIFICATIONS FOR HYDRAULIC BRAKE PARTS Description ‘Threads cass Tore mg (ft 1b) Master cylinder to Nat Ma 8 2.5.18) Stop Light switch to op light switch M lost master eylinder Brake bocster uns M8 to base Brake Quid reservotr | Bolt Me 0,2 1.5) ‘ork and pivot to Nut Mio 8 3.5 (25) operating tod Brake booster to. | Nut Me 8 2.5 (08) floor plate | Brace to base Bolt M10 88 63) Brake lines to Coupling M 10d 12 9) master cylinder, hoses and calipers Distributor to bolt 6 8.8 rear axle cross tube Bleeder sexewe on Bleeder terew M 10x1 a brake calipers 8-8) Brake caliper half Socket head bolt M 12x25 88 6.0 (43) to bridge spring plate to Flat head serew M6 bridge ‘Adapter to brake Hollow bolt M 10x1 1.6 a2) caliper Printed in Germany - V, 1984 Technical Data 47-- 0147 erekes/Hydraulic Parts Note When: Special No. | Description Qty] Removing Installing Instructions 1 | Cross spring 1 Replace if necessary, Position correctly (flat side faces brake disc). 2 | Lockplate 1 Lockplate must still} Not applicable move after cross spring) if openings of has engaged, to excludg spring plate deformation of the | (no, 18) take ‘ross spring. over cross spring funet. 3. | Brake pad 2 | Mark for rein- Check, replacing if stallation later necessary. Wear if applicable, limit 2mm. 4 | Connecting line 1 Down 5 | Screw 8 Torque: 60 Nm (43 ft. Ibs.) 6 | Brakecaliper half, | 7 outer (marked with Porsche) 7 | Bridge Bottom on front axle, | Page 47-5 without opening top on rear axle 8 | Bridge 1 Page 47-5 with opening 9 | Brake caliper half, | 1 New version (without inner (with mounting no. 12-15), can be eyes) installed retroactively, 10 | Dust cap 2 11 | Bleeder screw 2 Up 12 | Hollowunion bolt | 1 Torque: 16 Nm ) (12 ft. Ibs.) ) ) omitted 13. | Ring connector 1 ) since Dec. ) 1984 14. | Seat 1 Replace ) SSS 47-2 Disassembling and Assembling Brake Caliper VI, 1985 - Printed in Germanya 4 escripti c iat | Tightening Torque J Location py cription | Threads Material | ne aa { Brake force regulator M10x1 4 (0) to connector or ring adapter Ring adapter to brake Hollow M10x1 /56 16 (2) master cylinder union bolt -) Printed in Germany 47-02 Technical DataBrakes/Hydraulic Parts 47 Note When: Special No. | Description Qty] Removing Installing Instructions 15 | Seal 1 Replace Omitted since Dec. 1984 16 | Screw 4, | Heat to approx. Install with Loctite 150° C No. 270. | 17 | Spring plate with | 1._| Heat screws to Assemble with correct | Page 47 -5 retainer approx. 150°C. bridge. Lock screws with Loctite No. 270. 18 | Spring plate with 1 | Heat screws to Assemble with correct | Use lockplate openings approx. 150°C. bridge (openings for | (no. 2), if cross spring). Lock | there are no serews with Loctite | openings to No. 270. service as a cross spring lock, see page 47 -5. 19 | Spacer 8 Do not drive into (dowel sieeve) brake caliper sections against stop. About ‘one half each should be in the brake caliper section and bridge. Printed in Germany - VI, 1985 Disassembling and Assembling Brake Caliper 47-347 rakes, Hydraulic Parts DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS Disassembling 1. Clamp caliper in a vise with soft jaws and 3. Drive off brake caliper halves from bridge detach connecting line. by applying knocks from a plastic hammer alternately. 4. Countersunk screws of spring plate are locked in bridge with Loctite 270. To 2. Unscrew bolts holding halves of brake unscrew, heat screws to approx. 150 °C. caliper. This is necessary to prevent stripping threads in bridge. 47-4 Disassembling and Assembling Brake Calipers Printed in GermanyBrakes, Hydraulic Parts 47 Assembling Initial Version 1. After replacing or loosening, lock counter: sunk screws for spring plate with Loctite 270. Install spring plate with retaining tab on. bridge without opening, Note Following changes have been made on spring plates since the beginning of standard production. pertinent openings protects the cross TS 7 below), — The countersink to take the mounting serews is larger for all spring plates since 1984 models and therefore the bridges had to be changed, too. Spring plates with larger countersinks (present version 12.8 — 0.2 mm diameter; was 11.5 + 0.5 mm) cannot be used on old bridges. Spring Plates with Larger Countersink | — | 7 t 0128 —_ a Printed in Germany - V, 1984 Disassembling and Assembling Brake Calipers 47-5.47 srake, Hydraw Parts 2, Assemble brake caliper. 3. Replace seals on hollow bolt and adapter. 4, Check piston. position — see page 46 - 3. 5. When installing brake pads, check for correct play between pad and recess, correct position of cross spring and clearance of lockplate in case of initial version spring plates (see pages 46 - 2 10 46 -4), 6. Bleed brakes. ee ‘47-6 Disassembling and Assembling Brake Calipers Printed in Germany_ .=EarlhdrimcGr Note The blow-up view shows the outer front axle brake caliper half. Piston diameter on front axle = 38 mm Piston diameter on rear axle = 30 mm Mount piston and bleeder valve in correct position, depending on installation of brake caliper half on right or left side (setback surface on face of piston faces brake disc inlev/bleeder valve faces up} Printed in Germany - V, 1984 Disassembling and Assembling Brake Caliper Section 47-741 Brakes, Hydraul ic Parts i | | | No. | Deserption ;" | Piston | 2 | | ) | | | | | | 2 | Dirt scraping ring | 2 | | | ie 13 | seat \2 } | | | | | [4 |orkecaizernat | 1 | a Qty. | Removing Press out of brake caliper half with compressed air: Use wood base danger of injury! See page 47-9 Lift out with a plastic rod Special Instructions Installing Use brake cylinder paste. Check piston position {position of machined piston | face) already while pressing in — page 46 -3 | feplce. | Pearce Pe earn | rave, | | eetirin ate | | See pages | 47-9 and | 47-10 under “cleaning and inspecting” ee 47-8 Disassembling and Assembling Brake Caliper Half Printed in Germanyee AT, DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS Disassembling 1. Place brake caliper section on a wooden board with the piston facing down and press out piston with compressed air. 2. Clamp brake caliper section in a vise with the cylinder bores facing up. Use a vise with soft jaws. Note Make sure surface of brake caliper section is not damaged and consequently the Cleaning and Inspecting corrosion inhibiting coat is not injured. 1. Clean ali parts with alcohol and dry with compressed air. Never use rags, 3. Remove dirt scraping ring by deforming since even minute particles of lint would the support ring of the dirt scraping ring lead to leakage. all around with a suitable tool (e. g. thin punch) to such an extent, that the 2. Inspect connection threads and spacer scraping ring can be removed. sleeves (dowel sleeves) for damage as Be careful not to damage seat surfaces. well as cylinder bores and pistons for scoring and corrosion. Printed in Germany - V, 1984 Disassembling and Assembling Brake Calipers. 47-9AT crakes, Hydraulic Parts Note Machining cylinder bores and pistons is not approved. Replace pistons or complete brake caliper section, as applicable. 3. If the brake caliper section is in good condition, check whether connecting bore between the cylinder bores is plugged. Clean bores with compressed ai 4, Clean new seals and scraping rings with alcohol and dry with compressed air. Assembling 1. Give eylinder bores, pistons and seals a thin coat of brake cylinder paste. 2. Place seals in grooves of cylinder bores, 3. Mount dirt scraping rings in correct position with a suitable pressure pad. Drive in dirt scraping rings at least so far, that they do not protrude beyond the machined surface of the brake caliper section Pre pms. 47-10 Disassembling and Assembling Brake Calipers Note: Mount dirt scraping ring in brake caliper section that the ring’s printed part number faces in. The sealing lip then faces out (in contradic- tion to the normal position of a radial shaft seal) and prevents the entry of dirt and water. 4, Press in piston by hand slowly. Check position of the milled surface on the piston’s face during this step (see page 46 - 3). If it is necessary to turn the piston after installation in the brake caliper section, a suitable tool (e. 9, ATE piston turning pliers) must be used. Printed in GermanyBrakes, Hydraulic Parts UO 7. Check for teaks (high pressure test) with a pressure tester. High Pressure Test Produce a pressure of 50 to 100 bar in the braking system with a pedal prop. The produced pressure must not drop by more than 10 % during the testing time of 10 minutes with a constantly applied pedal force. Note: ‘A brake force regulator is integrated in the rear axle brake circuit of cars with Turbo Look. When connecting a pressure tester ‘on the rear axle brake circuit of these cars, the produced pressure must not exceed 70 bar. 5. Assemble brake caliper (see page 47 - 1). 6, Recheck piston position in oar after installation of the brake caliper. Install brake pads. Bleed brakes. Printed in Germany - V, 1984 Disassembling and Assembling Brake Calipers 47-11AT craces, Hydraulic Parts BRAKE CIRCUIT FAILURE INDICATOR (UNTIL END OF 1983 MODELS) Each of both brake circuits has @ brake light The brake circuit failure indicator has to switch on the brake master cylinder, which be cancelled by disconnecting the battery also functions as a brake warning switch in after repairing the brake system. cars up to the end of 1983 models. Beginning with 1984 models it is no longer necessary to disconnect the battery, since the brake indicator lamp (triple chamber light) goes out as soon as the brake fluid level in the tank has reached the minimum level An indicator lamp (bottom part of a double chamber light) installed in the instrument panel comes on when a brake circuit fails. 47-12 Brake Circuit Failure Indicator Printed in Germany48 STEERING Printed in Germ a48SPECIFICATIONS Steering Steering whee! Steering ratio in center steering wheel angle to wheel angle Tuening circle dia, Track circle dia Non of steering wheel turns from lock to lock Friction torque of steering measured on flange of steering gear without connected tie rods General Rack-and-pinion 380 mm (14.961" dia lattice steering whee! with impact pad 177831 10.8 m (35.4 feet) 10.35 m (33.9 feet) approx. 3.0, 0.8 to 1.4 Nov to 14 kpem/ 7 t0 12 in. Ibs. 48 Printed in Germany Specitications 48-0148 Steering Notes fo, | Designation mt cemarls Oe ee Am) Removing Instatling Rs 1 | capserew 2 Torque to specifications 2 | Lockwasher 5 Replace, if necessary a | Cover 1 Must ft on steering shaft bearings ccorectly 4 | Hex hd screw 2 Torque to M10 x 35 specifications 5 | washer Replace, if necessary 6 | Cotter pin 2x25 | 2 Replace 7 | caste nut 2 Torque to Mi0x 1 specifications 8 | Hex nut 2 Torque to M14 x15) specifications 9 | Ban joint 2 Cheek, replacing | Ball joint must show ifnecessary, Check | frictional torque when seal for tight Gt | moving, Replace if and damages has axial play or no Z| frictional torques 0 | Holder 2 Replace, if necessary at | Seat 2 Check for damage, replacing if necessary az | spacer 2 Torque to 1s | He rod 2 specifications ad | steering shaft a Check, replacing holder with rubber if necessary bearing 15 | seal 1 Install correctly —_—SSSSSSSSSSSeSeeeSeesesesesee 48-2 Dismantling and Assembling Steering Printed in GermanyAB covers TORQUE SPECIFICATIONS FOR STEERING Location Designation Threads | Material Torque Nm ft Ibs Steering gear Bolt mio |ae 4734 Tie rod to rack: Ball socket M16 x 1.5] C35K 150 108 Ball socket to Castle aut mioxt |3 45 33 steering arm. Ball socket to Nut M14 15]04 Ge) ad tie rod (lock rut) Steering coupling Bott ma 8.8 2 18 to steering shaft ‘Steering shaft to Bolt Me 8 2 18 steoring gear ‘Steering shaft Screw Me a8 2 8 mount Universal joint Bolt Ma es 2014 to steering shaft (lubricated with Optimoly HT) Coupling flange Nut mio |B 45 33 to drive pinion (seltocking) Case cover to Bolt ms jag 1% steering gear Steering wheel Nut mex 15/8 5036 Centering screw stud us 109 2-3 1422 to steering lock Lock nut on een Nut ma 8 13 tering screw 48-02 Technical Data V, 1984 -Printed in Germany48 Steering Notes 04} Designation mt, Remarks Oe Arte) Removing Installing x 16 | Hex hé screw 4 ‘Torque to M 8x42 specifications at | tockplate 2 Replace as | stop 4 19 | Steering coupling 1 \iswal inspection, replacing if necessary 20 | steering shat 1 21 | Steering gear 1 Check fletionat torque, replacing or repairing if necessary DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Assembling 1, Clamp steering box in a vise with protective Jaws for the rack, 2, Screw tie rod with spacer in racic and tighten to specified torcue. Machine open end socket for torque wrench for this purpose. Note Omitting hex nut has made the former instructions for te rod ball joint adjustments invalid. Only the spacer Is available for replacements. Printed in Germany Disassembling and Assembling Steering 48°3850 BODY, FRONT SECTION Printed in Germanyyeeros 0) FLOOR/FRAME CHECKPOINTS AND FRONT BODY SECTION GAUGES P 869 AND 5833 [As aleeady announced in the 1975 model information, checkpoints are welded to the floor/frame assembly from 1975 models, The extent of damage is quickly diagnosed with the help of these checkpoints and front body section gauge P 689 a (consisting of former gauge P 869 + additional adaptor). ‘The carrier pin of Type 920 Turbo is 21. mm higher. When measuring with front body section gauge P £63,the distance between the upper edge of the gauge and the cotlar on the earriet pin is 21 mm of, with the adaptor installed on the carrier pin, 13 mm. “The gauge can also be used to repair light front section damage (upsets up to 10 mm), Cars with damage of this type no longer need to be instatled on 4 straightening bench. Installation of the gauge requires that the wheels, the guard, the carrier and the control arms be removed, ‘The gauge is then bolted to the ont axle take-up points an front floor/ frame checkpoints, a illustrated above, ‘The distance from the rear flooe/Irame checkpoints and rear axle take-up points for the transmission to the engine suspension is checked with « measuring staff. Note: This gauge is for checking only, It must be removed for straightening and welding operations to prevent it from becoming bent through body distortions. Printed in Germany Floot/rame and Front Body Section Gauge 50-150 0s; FLOOR/FRAME ASSEMBLY DRAWING 50-2 Floar/Frame Assembly Drawing Printed in GermanyBody 50 im. | Destgnaton am | contol sm ake fot ner 3 | camer enp 28 a‘ Front Moor plate checkpoints 100 +2 D_ | _ Ret or pate cheep wo te © | gine pension mie F Front floor/ inner control arm cheekpoiat - [ yaar = 8 G Rear floor/ carrier checkpoint a 1868 = 3 vt | Ane tbe tant fot Mor cheep ast 8 Tate tbe tarniion/ inc gies sory mats Ba x [tse door/neeogie nareon CHIH yp moda st 1 [__stnt s/c onl am heen won fa w_| fk Rowea or ehcergans ms | fess tor/inner engin spenon choos sare a ba (© | Axle tube tranemtsston/iner engine suspension = ae All distances are measured from center of hole and horizontal. Note Distances to engine suspension bolts are measured direct (at an angle). Note Lengths measured on the left and right may not exceed the specified tolerances in difference to each other. Printed in Germany ~ 11, 1976 Floor/ Frame Assembly Drawing 50-3BO soa = even FLOOR/FRAME ASSEMBLY TURBO CARRERA {In comparison to the Type 911, the carrier pin of the turbo Carrera is 21 mm higher, This has ‘caused clanges to the floot/frame assembly in the area marked in white, ‘The border on the wheelhonse and floor plate is cut out about 7 mm higher than the controt arm. to allow accessibility. Note new wheethousings are required for repairs, make these openings in the borders on both sides and weld the seams to the floor plate. a ‘50-4 Front Floor Assembly for turbo Carrera Printed in Germany50 Boay VAGOW abet - SNOISNaIG JONauaaaY UIVEaY 50 Repair Reference Dimensions - 1978 Model + UL, 1978 Printed in Germanysory 5O STRAIGHTENING BENCH ATTACHMENT SET ENS 77.303 FOR TYPE 930 TURBO ‘The illustrated ta Turbo cars. up points differ from the attachment set for Type 911 and are applicable to “The auxiliary carries pin is installed 24 mm (0.827) higher. “The brackets on the rear axle cross tube are inclined upwards. “The take-up pin for the transmission suspension is located 25 mm (0.984) further forward “The engine mount for Type 3.0 Turbo up to 1977 model conforms with Type 911 ‘The engine mount for Type 3.3 Turbo from 1978 model is moved further back by 30 mm (1.181) Printed in Germany - ll, 1981 ‘Attachment Set ENS 77.303 50-78 for Type 930 TurboSS sooss and uses Disassembling Notes on Installing 1, Unscrew rear spoiler easrier from hood When installing the rear window wiper shaft, itis remove with reinforcement, see arrows, essential to insert spacer in hood, Wiper arta should be installed so that, when switched off, wiper blade will be parallel to side weatherstrip (distance approx, 40 mm/1 9/26 in,), Note When painting car, cover riveted weatherstrp with tape, 2, Detach spoiler (polyurethane section) from caurler, see arrows, Removing and Installing Engine Hood Printed in Germany80D 53 SECTION rinted in GermanyREAR AXLE CROSS TUBE OF A new rear axle cross tube, Part No, 990 331 010 00, = Fig. A 5 Installed in the Type turbo Carrera ‘This cross tube differs from the versfon for the ‘Type 911 - Fig, B - as follows. New, langer holders for rear axle trailing arms at an angle of 2° 30° upwards. Reference point: 6 mm above the horizontat as measured at the rear inner support plate of the holder's lower edge. New transmission suspension take-up pin (offset 25 mm toward front). Notes 1, The seat wells have dents on both sides of the center tinnel above the holders for the Type turbo Carrera (see fh Large seat belt reinforcement plates are installed in all cats for Austealia and France, and in fact on the transmission tunnel, These reinforcements are welded to the holders at the rear axle eros tube to inerease the strength, TURBO CARRERA Printed in Germany Rear Axle Cross Tube for turbo Carrera sot66 EXTERIOR FITTINGREAR FENDERS INSTALLING TURBO DECALS ON 1, Using squeege pull upper Lip of eubber guard away from connector plate as far as necessary. Clean and dry surfaces for decals, 8, Draw a peneit tine 30 mr (11/8 in.) parallel to witeel opening. 1 protective paper off decal and place decal on surface so that it matches the érawn Line and Its bottom is covered about 8 api by the rubber guard - Smooth deal toward outside and rub ovt bubbles with a squeege, If necessary puncture bubbles with a pin and press smooth, Printed in Germany Installing Decal on Turbo Rear Fenders 60-32, Install front fender decal = Part no, 930,554 301/902 00/01 = after the door decal has been installed, Start at the door edge. Make sure the point begins on the fender (not the head= light rim), Align the top paper edge of the front decal with the center of the headlight. Press over fuel tank cover and after the protective paper has heen pulled off, eut through decal which overlaps fuel flap cover, Install rear fender decal ~ Part no, 910,553, 305/308 00/01 ~ aligning & with the door @ecal, To facilitate alignment of the font fender with rear tubo decal, masking tape can be used. Installing Tusbo Sign 4, Install tuxba sign decal ~ Past no, 9190,559,907/ 308 00/01 = below masking tape border parallel to tail Lights, Make sure that the edges of the front and rear decals are parallel, Fold ends of decal at water drain molding, Note ‘when applying the turbo sign decal make sure that the shaded areas are pressed on without folds, folds between shaded areas cannot be avoided completely. Printed in Germany7, Enlarge opening for hamess to about 40 x 60 nperature switch ean be re~ his means frst cutting to proper depth with a saw and then cutting out metal with shears, Remove center console. moved, Note only temperature switch has to be replaced, capillary tube bulb must be pulled out of eva~ porator housing, Capillary tube i fastened to harness at several points with insulation tape, CCut through insntation tape and then slide on matching sleeve to cover entize length, Pull out temperature switch and slide In new capil ary tube through steve. Open up hamess opening of new center console to specified size. Removing and Installing Center Console Printed in GermanyA TOMATIC 80 HEATER Printed in Germanyvee BO AUTOMATC HEATER NTROLS Removing and Installing Control Unit A+ Pry both side covers off of control unit. 2 = Detach connecting red between motor and eater lever, Removing and Installing Interior Sensor 1 = Remove both Phillips serews and pull down sensor carefully. 3 = Remove the four hex head screws, lif ‘control unit carefully and disconnect the three plugs at the control unit. 4 = Remove rubber seal and slide control unit forward past heater and parking brake ever to remove, 2 ~ Pull angied plug off of sensor, Printed in Getmany ‘moving and Installing Automatic Heater Controls 0-180) a Removing and Installing Heat Sensor in Heater Flap Housing 1. Loosen control unit and pull off the front 2-pole male plug. 2. Loosen carpet along center tunnel and clear cable up to grommet in heel plate. 3, Pull both wires out of male plug housing (be carefull that they don"t grab hold) nd press out the grommet. 4, Remove adaptor on left heater flap housing, 8, Pull out cable and remove rivets on the adaptor, 6, Rivel new heat sensor, slide in cable and press in grommet. 80-2 Removing and tnstailing Automatic Heater Controls Printed in GermanyHeater 7. Install adaptor, Make sure that 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 tabs 8, Place cable inside of car, paste carpets, connect plug to control unit and secure control unit aga 80 Printed in Germany Removin, 20-9sere 80 TROUBLESHOOTING AUTOMATIC HEATER CONTROLS Checking Interior Sensor Checking Heat Sensor in Heater Flap Housing 1 Remove interior sensor. 1 = Remove control unit. = Using an ohmmeter with an appropriate 2 = Connect chmmeter to 2-pole plug of testing range, check the resistance bet= heat sensor, The resistance must be ‘ween both coaxial connections on the 1185 ohm with warm engine at 100°C, sensor (use test polnts), The resistance Replace heat sensor if resistance is way is very dependent on the temperature and off (see "Checking Interior Sensor’), should be about 1.5 kObm at room temperature, Replace the temperature sensor If the resistance fs about an ohm (nteruption in sensor) or about O om (hort eireuit in sensor). o Note ‘Seige \ ‘An interruption in one of the sensots ot in the — Wires to the control unit will fake a too low of, a short circuit, a too high inside tempera ture. This will result in an improper movement of the heater lever up oF dawn. Printed in Germany ‘Checking Automatic Heater Controls 80-5BO wv Cheeking Power Supply ta Control unit 1 ~ Remove right side cover of contal unit. 2 ~ Disconnect Spole plug. 3. > Tum on gnition and parking lights. 4 Connect test lamp between brown and red/white as well as brow and gray/blue cables, Test lamp must come on in Dott eases If both temperature sensors and the power supply fimetion correctly, but the heater controls do not function properly, replace ‘the complete control unit, 80-6 Checking Automatic Heater Controls Printed in Germany90 MENTS, RADIO Printed in Germanyrostruments, redo QO LOCATION OF RELAYS IN CAR Six standard relays are located in the fuse box in the luggage compartment. 1 ~ Air conditioner relay (front in driving direction) optional extra equipment 2 = Foglight zetay 3 = Hom relay 4 = Not occupied 5 ~ Electric window winder lay 6 ~ Fuel pump relay F (front) 17 = Fuel pump relay It (reat) ‘The standard relays for the rear window defogger, turn signal/emergency flasher lights and seat belt warning system are located on left side of Iuggage compartment floor as seen in driving direction - same a8 for the Type 911, The re~ lays are accessible from the luggage compart ment or after removal of small combination instrument. On the 1977 Models the fuse sequence has changed a3 follows: 1, The fuses 16 and 21 (fuel pump and window controls) have been interchanged, 2, The fuses 12 and 14 (sliding roof and rear window wiper or fan and rear window de~ fogger) have also been interchanged. This was necessary to prevent the engine from running for several seconds after the igal- ton was turned off with the heater fan tumed on, Printed inGermany - 1, 1978 Location of Relays in Car 90-190 struments, Radio Fuse/Relay Plate from 1976 Models 1 = Rear fusebox (fuses &* to 84 2 Fuse/relay plate 3 Relay, air conttot/charging pressure 4 = Relay, two stage rear window defogger 5 = Condenser, CDI control unit 6 = Radio suppressor 7 = voltage stabilizer 8 = CDK control unit 90-2 Location of Relays Printed in GermanyInstruments, Radio Relay Plate = 1977 Models 1 2 3 4 5 6 8 ° ~ Rear fuse holder ~ Relay plete ~ Airflow sensor/turbo boost pressure relay ~ Delayed ignition cut-off relay ~ Tworstage rear window defogger relay = CDI control unit eapacitor (not applicable from 1978 mode!) ~ Radlo suppressor = Voltage regulator = CDI contro! unit 90 Printed in Germany = 11, 1978 Location of Relays in Car 90 = 2ataatraments, vacio QO ELECTRONIC SPEEDOMETER Checking Electronic Speedometer Sensor Remove tunnel cover in front of emergency seats, Disconnect the flat male plugs at the connector An the tunnel and connect a test buzzer to the wites leading back, Lift car at rear axle and turn right rear wheel by hand, Lock left rear wheel, The buzzer must sound off & times for each two revolutions of the wheel, If not, replace the sensor. ‘The left rear wheel need not be locked, if a car is equipped with a limitedslip differential, tn this case the buzzer sounds off 8 times for each one revolution, Checking Electronic Speedometer Connect and disconnect very quickly the two wires in the tunnel that lead forward, A distributor can be applied to help, if both wires are connected to terminal 1 and the distributor housing, and the ‘distributor shaft is tumed by hand as quickly as possible, Remove the speedometer if there is no deflection of the needle, Check all wire connections to the speedometer and replace the speedometer if necessary. ‘Turn on the ignition for this test Printed in Germany Checking Electronic Speedometer 80-3GO nsrerments, naaio Removing and Installing Electronic Speedometer Sensor A Remove right rear wheel, 2 = Remove hex head screw and take holder off of sensor. 3. = Take 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 ‘The polarity need not be observed when cconnecting the sensor wires 90-4 Removing and Installing Electronic Speedometer Sensor Printed in GermanyQZ exes Current flow diagram 930 Turbo USA, Model 76 tb -) Description Current wack Windshiea wiper switch 9 = Heaatant seh 8.8.9.1, 15,20 SMe agnalSutch ae = Emergency flasher suiten 34,25, 2, 31,96 = Bimmer ston ae = Headlight faster switen ‘ = Parking ight suits is = nstrument paral iluminaton potertometer 2 = Sith Yor ove compartment get “ = Sop ght ste 50 = Letfacor ews & = Rant eoor stem 3 = ESCH pgm awlich 8 = Suite fr luggage compartment ight a = Wavtela pressure ming suri o = Fu pump s = Air meter contact 58 = Fut pump 5 = Hovnfownn 3° = Hove 38 97,98 = Key warning buzzer cont a = Hazard tim aga flasher 53,34, 95, = Hem ray ed = fsiy boest swt air meter contact er s6 = fag} ortuel pump 5283 ~ block for sea bal warring eystem « Relay for us puma 56.58 = Hign beam indent 2 = Barking ight ngoator bght : = Tin Banal necator hohe 21,29 = Hazata tashornceator ght 24 = Sealed beam om ett ead ght 37 = Seale beam un ight nega 83 = Speeciomater amination sph 2 = F0' gauge summation tgs 2 = Ges enalon ht 2 & = Aanivay iluminavon eght = Heater convo assembly ilu naton ight 2 o = Temperature canto love lumsnation ight a = Oi temperature indeator summation ign 2 = Tachometer amination ight 2a = Gitpreesure incato lumen tight 2 = Right stop rear light 47,80 1 = Uettstop! reer ight 1351 = Keston tur gna’ parking tant 125 = Lt rear turn sgl ze : = Fight front tur sgra sparking ant $5.41 = High rear ur sgh x rent sige mater Paht 12.18 Fear sia marker apt 1438 = Contac hohe 8 = Right baci font & Ne = Resistor 2 Re Warmup regulator Ne = Supplementary ai vave 5 se Funes os BD Bra Su onthe 3.31, 25,48 fe Bato & 2243 3 box e T= Cee connactorsinale 42 = near regulator panel “4 & = Behind Seal beam ont et ths, g = Heng said bam ani rahe ist & = behind fuse box e 1 ~ on ugaage comnariment oor 22, 40,44, 45,46 f= Benin netument pane! 6.22, 24,38 1 = near et veer hot 2 1 = Cable connncton double 5's in engine compartment 88 1 = boning fuse box 58,57 1 = Cableeonmoster snot ; 2° ir engine compartment rear et 8,19, 24,28, 45,51 = in engin compartment eat ght 0.1, 39, 40,80 6 = below instrument panel 4.6,28,30.538 © = balow insvument pane! 25,9, 92 88 4 = Below inturent panel Brats 22 fh = below insttument pare! a TH Caite connacton, fourverfld ‘on reguator panel 48,55, 57,58 W. = Imerer bgt 38 40,47) We = Luggage compartment iat 2 We = Glave comasriment ght a X= Lcenes pate ant 30 Y 2 lat 46-V 7 tt eee: eee mm mg EO || (8 bom Ca] ol ® - | | Lo] eae GF ze E EEb*Description = aostery = Starter Wotage tequator Capacitor for gnion unt Igntion starter suites = Wingstield wiper such Fre lowe teh Front and ear window defogger switch Guia miror contol switch Brake warning switch Perkong Broke switch ~hermersorteh for cold str valve = Fue! cender unt Fost gauge (i temperature nateator, i pressure sender unt (i pressure nestor Di evel sender unt > = Sieve: gauge | = Speedometer G2 ~ Speedometer sensor Ji = Seatbelt warning system clay ‘wth intagated buzzer J Diode lor indshios detogger = Realy fr windshieisdaroager Ji = Relay for two-stage rear window detogger ie = Generator charge indicator ant Ks = OWrpresaure nciator igh >= Parking brake / brake warning Fight Blower inseator tant X= Seat bot waming ght Winall nd fea window dogger nett Nit = igh tension ignition unt Re = Golostan vane © = Distributor | P= Spark plug connector & = Spark pug Se Roe St = fuse box 82 ~ Fuses S* = rear fuse box T= Cable connector, single 2 stnear regulator panel 4 — behind fuse box | below regulator pans! 1? ~ cable comector, double Ts = Gable connoctorourtold, on liggage compartment facr Te ~ Gable connector. sata 1 = botow instrument panel Ti = Cable connector, fourteentold, on cegulator panel = Cigar lighter ve = Water pump Yo" = Outsise mirar control mator 2: Rear window cetoggen stage = Windsnaid datogger 22 Rear window cetogger, tage 2 Curent race 108 106, s07 88,100, 102 3, 100, 108 nie 79.80.81 ron 88 or ee 103, 108 08 85 98 9 8 78 co 54,65, 6, 69 28 88 2 9 Be 63 109; 110,911 7 22 ut 7 8 119, bret 70,2801 70.71.86, 87, 90 4 68 it 8 % a 7a,00,81 82.63.88, 108, 95.7, 98, 102, 108 18,80 a 65 e 83.67 Current ow diagram 97-3Additional current flow diagram intermittent wiper operation, Model 76 ition = to gntionftarter switch E = Windshield wiper switch E% — Potentiometer for intermittent wiper operation ~ Rolayforinteomttant wiper operation S% = fuse box T! = Cable connecter, angle 4 = behind fuse box = Cable connector, xo, below intrument panel V_ = Windshield winer motor VS ~ Washer pump ah Currant wack 1 25.7.9ab oF \0 eee = hh a ) Le ll tt! @ : = Lhe | it (Oey a |. | > | | ilillceaeeaes - 8 ii rl | || eee en me —— raion a iL a panne ; * ee te te _ S| | = —_— 7" : au : a cr . i - i= © ee ce ae a eeAdditional current flow diagram air conditioner with front condenser Deseriation A = to battery 8 = tostater D_ = toignitionjstartarswite, terminal 50 D_ ~ to gniionfetartor avite, terminal 15 E* ~ Blowor ewiteh © ~ Temperature aviteh F Thermostat P Power supply rotay = Relay for condenser fan IN ~ Electromagnetic clutch 3! Fuses Sin 3! = the 9! — fuse S® — box Tl = Cable connector, single a ~ near regulator panel © = on luggage compartment floor TF ~ Cable connector, double 8 ~ near evaporator blower b= near battery T! Cable connector, fourfold, below instrument panel VW" = Condenser fan V™ ~ Syaporater blower h’\\ Current tacTblv ut a bij fest iy pH mime at 1 emer SL = i eee Nee tee er! ce + Spa Th feo A g : Ap entered tne mS) ome ee as rl To | |Additional current flow diagram fog lights to headlight eviteh relay Fog light indicator light 1 eft headight Left fog tight Fight fog ight Cable connector Cable connacter, double a Current tracka f= som om on MF | ‘ss a i u A (o_o é u -Additional current flow diagram engine compartment light Deseriation Current track E) = to hesclight swteh 1 L” = Engine compartment ight 3 8! — Fuse In fuse box regulator ble eonnactar, sido in engine compartment. rear left 2 Cables | t } 97QP cases Current flow diagram 930 Turbo USA, Model 77 Deserntion Windehisid wipar swten = Hessler een = Emergency faser switch = Bimmer seh = Hosaliget faster sutton Perkin lant swien = Isstument pane! iuminaton potentiometer = Synteh Yor love compartment ight = Staplghtsanien = Leifdoor swten = figrteorswien S aekupightawich Swit or luggage compartment ight Mantel presscretimting ston ‘bemeter contact = Secosometer = Speodemeta’sansor = Feeloamo' = Key warring buzzercontact Hiker umsigsat ashor = Relay boost swith /airmetercontact = Felayror uel pur = Diacb or seat bot vacning system = Rolay ortuelpumott Wah ber inccator gt = Parking gh neato ght = Turn signal indicator baht = Hazard flasher ndestr bat = Stes Sam unt et moadght = Sealog Beam unt igh Reslight = Speesemeteriluminaton ight Fest gauge iluminaton baht + Elect iuminaton ght 2 Asha iturin amt = ate contol assembly urination ght = Temparotre canal lever sluminaton ight = Giltemperature nciestortumnaton ight Tachometer iumiaton ight = Gifarssuteindeator tarination Mant = Fight sto rear ight = Cetstop! roar ignt = Let ont wen signal! parong Ht = Lett tear urn signal Aight ont torn signal pking bht = fant rear tars sal = Frontside marker ht = Rear ede marker vant = Cot sete bone = Aight packs ght So ont So hee Sh 7 box 1) 7 CSbie connector, single f= near regulator pant 5 = Behin seated beam unt et 6 ~ Bohind Seales beam Ut ght 6 — Bend fuse box © = on lgeage compartment foor > Send natant pane! hh near lt ear ight Ts = Cable sonnsctor doutle namely can 4 —hehind fone box Te ~ Cable connector sno oe engine compartment ear iett 5 = in angina compartment rear rant 4 = bolow nsroment pane! & — below instment gene! G = below instrument pant & = below iatument pane TH = Cable donnecion touraertold Sr regulator panel Ww. imensr bat We = Luggage compartment ight We = Glove compermant rant 11) current ack oo, 8.6.9, 19,15,20 2 24, 25,28, 31, 98 re)IeEE ee ——————R———e——ee—ee Descriptio 8 — Sterer © — Generate > = Wotage regulator (e — Capactororigition unt = leniton ‘starter wtch Windshield wiper switch 2 Spat bet sien E% — Front and rear window detog ES — Quisise miror antral swteh Fr = Ollpressue swteh = Parting brake suiton £2 — Thamocetoh for cole sta valve & — Fuelsender unt & = Fusion G Ol temperature sender unit Se. — Oitemporatreinciestor Gre — Oi praseue sender unt &!' — Oi pressure meator G2 — Gileve sendor unt Gi? = Ottevel gauge Ge = Charging prossure sensor (Ge = Charing pressure incieator 8 — Relay forintermttant wperoperation ‘3 = Seat ett warning system clay J = Bieds tordelayeaigntion sutett 1:8 = Diode tor winded dotogaer 39 = Relay forwindshisia defogger 4:8 = Relay for worstage rear window defogger 6 Gelayed action ety torlgntion eutot ik? = Generator cargo indicator ight Ki = Ol presewe ndeator ight i? — Barking brake rake warning Eoht Ke — Biowerindlostor ight, ‘te — ow fue! warning i ks — Seatbelt wamng ant 2 — Windshield ard ear window defogger indicator ight N= anton transformer Nie = High tension ignition unit Nev = Colastat vate No = Magnetic dutch for miror contre = ostroutor P= Spark alug connector = Spare alue Si — Poses s s = fee box = Foves on the Cable connect, single 1 — behind fuse bow ' = onlugage compariment toor Senna instrument pan! |= below regulator pane! ~ able connector covbie 8 ~ below regulator panet Ts Goble connectortourtald on luggage compartment oor 18 — Gable conector site = inengine compartment, ght ‘T¥ — Cable connector, fourasntols, on regulator UL! — cigartigtor Y— Windsmits wiper mator vs = Washer pimp Vir = Outs mir conioi moto 2) Rear window defogger tage ¢ 22 = Windshiel defogger 25 = Rearwindow detooger 24 Gutede mero detogger 02 13.114 104108 135 53,66, 85,67, 90,82 776 3 66,68, 70 73,80,81 109, 10 98,00 100 193 101 oe v2 86,07, 89,90, 108 eet 66,67, 69,70,71 102 8 oe 65 Her0 a Hote 7178 63.02 185 00,02, 89,90, 95 6870 67,08 2a,88 83,24, 85,86, 92 rare 190,102,103, 108 tana ne.7 22,09, 86 87 o A a 28,69, 8 Curent fw diagram 97-15a (keQZ viens Current flow diagram 930 Turbo USA, Model 78 we Deseripton = Wincsiela wiper switch = Heaatgnt sen = umnsigns gtey = Erorgeney tasherswitoh = Headlight tasher switch = Parking ght sich ~ Ipstument pare luminedon potentiometer = Swen for glove compariment ight = Stepiighiowten = Usifasor swith = Rightdoorswiten = Backup phtswten = Switch fortuggage compartmentignt = Mantolé pressure eiing switch = Fesipume = Sactasmoter = Sheodemete sensor S fomevaten Key warning buzzer contact = Nota urs signal fishor = Reta bodstewten act = Retayfortusl pur! Broder seatbelt wering system olay fore: puma igh beam indicator ont Boring ight ato ight = Kern sgnalindater ight = Haze taser neta tant = Seales beam unt let hesnpht = Seales Bear unt sight Read ght = Speedometer iuminaton ight = Feel gavoe tummaton Vane = Gicokiminavon bgt = Ashvey tumnaton ight = Henter contol assert ituination ight ="Temperatue cone ever umneton ight = Si temperature Indicator numimeton ght = Tachometer amination fant = OitpressureIndeator ation ight = Fight sto roar ight = tehtsop rear Fok = Letront ten sgn parking ght 2 istic waa pane = Right rent un signal parking Hight = Right rar turn = Font sae meric ig = Rear sige marker wht tot eeekop grt = Right back ane = Rossin = Warm reguitor = Eoetabe = Supplementary sir vatve = Thetmovatve connector, single 2° near regulator pane! © = Behind sesleg am unt et © behind Seales beam uni ght & = Behind ase bon © = on luggage comparment oor Benita nevment pared b= neartet rear ign ~ Gabie connector double 5 = boning tise box = an luggage compsriment tor ~ Gabie contector sont in engine compartment roar ett 5 = in engine compartmont fear oaht 4 = below ntrument pant f= below instrument panel 4 = Blom newer pana ~ Cable eamector, ourtenold Sn regulator para = intenor ght = Langage compartment ight = Glove Gomperient rah Curent wack 99 86,9, 91,16,20 ae 24,25, 28, 33,36 ae : 13 20 ae S52 as “ thas ig.at a 22,42, 44, 45,46 6,22 24,35 En ss 2 58.58 80 8, 19,24, 26,48 51 10,1730, 46,80 4.5, 28,30, 99 25,31 3,98 ati ae 49,57,50,60 45,4847 2 ai a : 4 jnmys ——a a me Se Ve a tm 2 fo . : e BY j Lr —se — iL Paper SON : |es I Doveription| A ~ Battany B= Stare © Generator Ge = Votage regulator 1D —igntion stron switen F< Windshial wiperewien Es ~ Fresh air blower switen Saat belt satch Em — Frontand rear wingow detogge switch 6 = Dulside minor contol switch Fi = Ol pressure switch Es = Parkng brake switch st Thermessuitch for col star vane G —Fuct send unis = Fuel gauge Ge = Tachometer = oiltemporature sender unt G* = Oitemperaturencestor Gee Oirprescuresondor unt Ge = Ol pressure nda GH = Gi leveisendor unt G® = ollevelasuge G= — Charging pressure sensor Ge — Charging prossuraimciestor 31 — Relay frintermttent wiper operation ‘Je = Seat bit waning system relay 38 = Diode tar detayer ignition eutott 418 = Diode for winasniels detooger 10 — Relay forwindsnied detogger {Ja = Relay fr two-stage rer window defogger J) = Delavedtacton relay frigniion curt ks < Generator charge insieatorignt > = ot presse incicator ight, i? = Barking brake wake warring Wont Ke = Blowerindieatorignt Kit Low fuel waning iat Ki = Saat bat warning ight = — Windshield and roar window detogger inscater ight N= lgnton tanstormer Nw = igh tension ignition unt No = Cold sta vaive Ne — Magnetic clutch formiror contol = Bistoutor = Spark pug connector = Sparkpiua = roses = onthe = fine box 58 = Fuses onthe Se = roar fusebox T! = Cable connect, single 4 bahia tse bow { — onluggage compartment fact 1 = boning natument panel |= below regulator pane! Ts ~ cable connector double 2 = below regulator panel © = nearltt sat © — anluggage compartment oor T+ = Cablo connector fourold on Lggage compartment foor T+ = Cable connector entata b= inengine compartment. ant 18 = below instrument pans 1 = below instrument panel 1h — botow instrument pane! ‘T1 — Cable connector, oureentol, on regulator pans! Ur = cigs ter V_ = Windshield wpermotor ve = Blowermoter Ye = Washer pomp Yer = Outede mer contre! motor 2! = Rearwindow dstogger, sage 1 22 = windsnista detogger 25 = Rear window deronger, stage 2 2+ = Outside minor detogger a AE GON MEDO VOR, Vlodel (GS current race 15 113,114 s04108 104,105, 07 arse 13,84, 06,07, 90.02 7376 & 68,68, 70, 79,80, 83 02 os 100, 110 93,90) 0 for 00 100 103 tot ae 7 He 101 26,87, 88, 00, 25,09 10 Ca 63,66 80,67, €8, 70,74, 117,199,128 102 101 8 7 & es Sita e198 mm a He-24 Nevtzs uie-124 ee 83 n76 n e302 6,90, 02 80, 00.05 68,70 67.68 oe 78.79 85,84 85, 86,92 486,91, 118 fre 100, 12 103,108, 293,116,197 fd 52,69, 06,87 7a78.78 2 7 & 63 58.60 7 Curent tow diagram 9728 E > o— Cho‘KA nn 97 Additional current flow diagram, tear window wiper, Turbo from model 77 Current track Vi Rese wiper motor 24bE ll = ——— TO i — it: pa Sees — pe ot pot ta —— % lA\ Additional current flow diagram, NG Power windows, Turbo from model 77 tion Curent track a 9 cy (terminal » 1 = 10 ignition/starter sites (terminal 18) 2 ~ Powsr window switch, driver side, for passenger side 56 E — Power window snitch, diver side 9,10 ES! _ Power window switch, passenger slde 56 f= Power window relay a4 S — Fuse 2 2 1 8 9 5 T! = Cable comocioy single, behind fuse box 3 TP Coble connector, sixfold 8 = In door wal et 5.6.8 > = indoor wel 5.67 Vi" — Power window moter, left 9.10 V = Bower window motor, righ 56mv Additional current flow diagram, headlight washers, Turbo Deseriation Current trace A. ~ tobattery 7 E'~ Headlight witch 12 BP — Headlight waaner switch 3 ” light washer olay 4 8” ~ tofuse 8” 1 St — Fuses 2 8% = inthe 5 ‘8! — fuse box 6 T. Cable connector, double, near battery 6 le connector, sixfold 9 ~ bolow instrument pane! 12 VW!" Headlight washer pump| ee E i : ee o————__| < |e 2 ec! ee IAdditional current flow diagram, automatic heating system, Turbo Deseription Curent trace 6 45 potentiometer t Lt ~ Speedometer il Gl IN = Interior tempera 5 NP — Exterlor tomperat 4 4~4\9 Additional Current Flow Diagram Air Conditioner (M 559), Turbo from model 77 Description current track A ~ obatery ° B ~ to starter (terminal 50) 2 1D = toigntion/starter switch (terminal 18) 1 D_ = toigntion/sterer switch (terminal 50} 4 E® Switch for AC p B Temperature awiteh for AC 9 BP ~ Relay for AC 45 J Relay for condenser fan 10,11 N® ~ Resistor for evaporator blower 5.6 IN ~ Eloctromagnetieelvtch 9 Ss” Fuso 3 ao 2 SY ~ Fuse 7 8” - Fuse 6 Ss” Fu 8 T) ~ Wire connector, single 2 near compressor 9 {© ~ on luggage compartment floor 249 TF ~ Wire connector, two-pole a= nr eva 8 b = near bat 1 TF ~ Wire connector, fourpole, below instrument panel 5.80 TH ~ Wire connecter. sixple, below instrument panel 4 Ve = Condenser fan 1" Vv ~ Evaporator blower 8“yb Se < 7 i ipa soe = —— ee = oe oe: —