964 Volume 5 Body

964 Volume 5 Body
List of Repair Groups
Carrera 4
General
Technical Data
Group
Repair Groups
Volume 1
Engine,
Maintenance
Volume II
Transmission
(manual)
Volume III
Transmission
(automatic)
Volume
IV
Chassis
Volume VI
Body
Volume VI
Heating, Ventilation,
Air Condition
Electrics
Volume VII
Electrics
Wiring Diagrams
Page 0.1
Maintenance, Self-diagnosis
Engine, Crankcase, Suspension
Engine, Crankshaft, Pistons
Engine, Cylinder Head and Valve Drive
Engine, Lubrication
Engine, Cooling
Fuel Supply
Fuel System, Electronic Injection
Exhaust System/Emission Controls
Starter, Power Supply, Cruise Control
Ignition System
Diagnosis
03
10
13
15
17
19
20
24
26
27
28
Clutch, Controls
Clutch
Manual Transmission, Controls, Case
Manual Transmission, Gears, Shafts
Differential, Transaxle System, All-Wheel Drive
Diagnosis
30
32
34
35
39
Clutch, Controls
Torque Converter
Automatic Transmission, Controls, Case
Automatic Transmission, Gears, Shafts
Differential, Transaxle System
Diagnosis
30
32
37
38
39
Front Wheel Suspension
Rear Wheel Suspension, Axle Shaft
Wheels, Tires, Alignment
Antiblock System
Brakes. Mechanical
Brakes, Hydraulics. Regulator, Booster
Steering
Diagnosis
40
42
44
45
46
47
48
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
50
51
53
55
Doors
Electric Sunroof
Hardtop
Bumpers
Glasses. Window Control
Exterior Equipment
Interior Equipment
Seats
Seat Covers
57
60
61
63
64
66
68
72
74
Heater
Ventilation
Air Conditioner
Diagnosis
Instruments, Fuel Gauge, Alarm System
Radio, Telephone, On-board-computer
Windshield Wipers and Washer
Exterior Lights, Lamps, Switches
Interior Lights
Diagnosis
80
85
87
Wiring
90
91
92
94
96
97
Interior
Airbag
Center
Safety
Equipment
Precautions
Components
Steering
Console
Wheel
/
Information
for -Removing
Working
-Removing
About on and
Cars
and
AxialInstalling.
Installing.
withand
Airbag
Lateral
Acceleration
Sensors.
.68
-1
.68-
Diagnosis.
Seat Belts -Inspecting.
3
.68-
4
.68-
9
.68-11
.068-
2
1
List of Contents
Printed
in Germany
-III,
1989
The Carrera 4 Repair Manual also has the contents for the Carrera 2.
Descriptions of repairs in this manual are based on the Carrera 4.
"Carrera 4" appears in the top line of each page.
Deviating descriptions of repairs for the Carrera 2 are provided after those for the Carrera 4. A yellow
sheet separates the repair descriptions for both models. "Carrera 2" appears in the top line of all
pages after the separating sheet. Page numbers begin with 100 for additional identification.
Page
Body -General
Special
Repair
Control
Tools
and
Dimensions.
Sheet
Metal
Machines
for
Repairs
50 -01
50 -07
Body -Front
Section
Front End of Car -Replacing
Partially.
Front End of Car -Replacing
Completely
.
50 -1
50 -5
Bumpers
Front Spoiler and Bumper -Removing
Windows,
Windshield
Rear
Windows- Side
and Installing
63 -
1
Window Controls
Windows
-Removing
Removing
-Removing
and and
Installing.
Installing. and
Installing.
64 -1
64 -2
64 -8
Rear
Window
Exterior
-Removing
and
Installing.
64 -12
Equipment
Body
Paint Colors
-1989
Models
Onward
66 -01
Body
Paint Colors
-1990
Models
Onward
66 -02
Rear Spoiler
-Removing
66-
1
1
List of Contents
Printed in Germany -III,
and Installing.
1989
911 Carrera
Body, General
4
Dimensions
for floor
N
Point 12 -Point
15
1492 :t 3 (1482
:t 3)
0
Point 18 -Point 15
1696 :t 3 (1653
:t 3)
p
Point 20 -Point
5
914.5 (913)
R
Point 17 -Point
18
1245:!:
2
s
Point 17 -Point
19
1328:!:
2
All dimensions are measured from or to center of hole
Note
The dimensions are measured directly and are therefore oblique dimensions. The measurements in
brackets are measured horizontally.
Important
The deviation between left and right must not exceed the specified tolerances for the
length dimensions.
Repair control dimensions
50 -03
General Information
Sheet Metal Machines
911 Carrera 4
(Standard):
236
-50
8
5
238
308-50
.50
235
-50
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911 Carrera 4
Dimensions
for assembly
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Repair control
dimensions
Printed in Germany -1988
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Body, General
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50-130
Point
Description
(left/right)
1
Center
2
3
4
Mounting
bumper/impact
5
Mount -outer
cross member
FA
6
7
Mount -inner
cross member
FA
Mounting
hole -wheel
11
Mounting
hole -switchboard
12
Mount -transmission
13
14
Mount -outer
15
16
17
Mount -engine
Jacking
point -lifting
platform,
18
Jacking
point -jack,
rear
19
Jacking
point -lifting
platform,
20
Hole -front
hole -final
absorbing
tube, front
front section
Mount -FA side member
Mount
FA spring
strut
cross member
cross tube RA
Mount -RA spring
Center
house
strut RA
bearing
of bumper/impact
absorbing
tube, rear
jack, front
rear
final section
FA = Front axle
RA = Rear axle
50.131
50 -05
911 Carrera 4
General Information
Special Tools and Sheet Metal Machines for Repairs
Special Tools:
gA~
307 .50
A = P 290 (special tool for removing and installing door hinge pins)
B = P 852 (gage for windshield)
c
= P 853 (gage for rear window)
D = P 854 (gages for left and right rear side windows)
E
=
P 856 (gage for rear opening
-Targa)
Special Tools and Sheet Metal Machines for Repairs
Printed in Germany
-111,1989
50 -07
911 Carrera 4
Sheet Metal Machines
General Information
(Standard):
13
(fi)
10. I
1'--
~ ~I
w
237 -so
Accessories:
Electric Tools:
1 = Drill
8 = Welding
2
=
Right angle grinder,
large
3
=
Right angle grinder,
small
4
5
"7 Grinder
= Hot air blower
Pneumatic Tools:
9
= Chisel
10 =
11
Mechanical
spot cutter (for drill)
Body
saw
= Welding
spot cutter
Tools:
6 = Punch
Welding Tools:
7 = Shouldering pliers
12
=
Spot welding
13
=
Inert gas welder
tongs
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"/
911 Carrera 4
Partially replacing
Body
-Front
Section
front section
The following chassis parts are required for partial repair of the front section
D
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10
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B
--
188-50
A
End panel
B
Connection plate
c
Front wheel house
D
Front side member
50 -1
911 Carrera
4
Partially replacing
Body
-Front
Section
front section
Replacing
end panel and connection
No.
Procedure
Instructions
Position vehicle
on the alignment bench
Position vehicle. with units installed. on the rational
Remove damaged
parts from the
plate, partially replacing
wheel house and side member.
straightening brackets and secure.
Using chassis saw, weld-point miller and angled grinder,
separate the damaged parts from the chassis.
chassis
1
Clean welding areas
Remove underseal from welding areas with hot-air
blower or rotary brush.
2
Fasten end section to the
straightening bracket
3
4
Weld end section onto
Align spare-wheel well with end section, secure with
spare-wheel well
clamps and spot weld.
Weld in connection plate
Align connection plate, fasten to spare-wheel well, end
section and wheel house with clamps and spot weld.
5
Weld in wheel house
Cut and align wheel house and side member. Offset
wheel house to the outside and fasten to the chassis
with clamps. Spot weld the wheel house to the end
section. Using the saw, cut to fit the fender connection
areas and butt weld.
6
Weld in side member
Align the side member with the wheel house in such a
and grind butt-weld joint
way that the ends connecting with the end sections form
smooth.
an offset to the seams of connection plate and wheel
house. Butt weld side member and end sections. Spot
weld side member, wheel house and end section. Grind
butt-weld seams on side member smooth.
50 -3
911 Carrera 4
Body -Front
Replacing Complete
Cutting
Front End of Car
Off Front End of Car Body
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Section
Replacing
Complete
Front End of Car
Printed in Germany -111,1989
~
312
50 -5
Body -Front
Replacing
Cutting
Complete
Section
911 Carrera 4
Front End of Car
Off Front End of Car Body
Remove all assemblies and attachments in and on the front end body section!
No.
Procedure
Instructions
Set up car on straightening
Set up and mount car, with the rear-mounted units, on
bench
the rational straightening bracket set.
Cut through A-pillars
Cut through A-pillars with a body saw as close as possible to the front end body section.
2
Cut through entrance
cover
Cut through outside of entrance cover up to the side
member with a body saw and remove in area of side
member to body and side member to front end body
section spot welding connections.
3
Drill off welding spots of
side member
Drill off welding spots between side member and body
(inside ar1d outside) as well as side member and front
end body section with a welding spot cutter.
4
Drill off welding spots of
floor plate assembly
Dr!" off welding spots between body floor plate and
front end body section floor plate with a welding spot
cutter.
5
Drill off welding spots of
Drill off welding spots between body seat carrier and
seat carrier
extension (on front end body section floor plate) with a
welding spot cutter.
Grind off inert gas welding seam between seat carrier
and extension.
6
Remove data plate
Drill off rivets and remove data plate.
~
Body -Front Section
911 Carrera 4
Replacing
Complete
Front End of Car
The following body replacement parts and special tools are required for replacement of the complete
"front end body section",
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c
A = Special
Tool P 852 (gage for windshield
opening
313.50
in body)
B = Front end body section
C = Eentrance
Replacing
-rr
~
--::.~
cover
Complete
Printed in Germany
Front End of Car
-111,1989
50 -7
Body
Replacing
Complete
-Front
Section
911 Carrera 4
Front End of Car
Fitting Front End Body Section on Body
,.
..1
50 -8
Replacing Complete
Front End of Car
Printed in Germany
-111,1989
Body -Front
Section
911 Carrera
Replacing
Complete
4
Front End of Car
Printed in Germany
-111,1989
Body
Replacing
Complete
-Front
Section
911 Carrera
4
Front End of Body
Fitting Front End Body Section on Body
Remove factory-applied
primer from all welding surfaces of the front end body section with a rotary
brush!
No.
Procedure
Instructions
Clean welding surfaces of
Clean welding surfaces on the body with a hot air
body
blower or rotary brush to remove undercoating,
paint,
body cavity sealing compounds and residual cement.
2
Align A-pillars of body
Align A-pillars with help of Special Tool P 852 (gage for
windshield opening in body) and prepare the mating surfaces for welding.
3
Align side members
and floor plate of body
Align side members to be parallel to each other and
parallel in height to the straightening bench.
Prepare the entire floor plate assembly in the area of
connection on the front end body section for welding.
4
Set up front end body section on straightening bench
and fit on body
Set up front end body section on the straightening
bench loosely. Place Special Tool P 852 in the body
opening for the windshield. Fit front end body section
on the body. Mount front end body section on the
straightening brackets correctly.
5
Install doors to check total
The gap between the door and entire body must be
body contour with the front
parallel all around.
Remove doors again after checking.
end body section
6
Butt weld A-pillars in area of
the door openings
Butt weld the joints between t.,e A-pillar and body as
well as A-pillar and front end body section in the door
opening area with a solid welding seam from an inert
gas welder, with Special Tool P 852 installed.
7
Open outside panels of
A-pillars
Cut approx. 20 mm wide openings in the outside panels
of A-pillars (body) and fold up outside panels to weld
the inside panels.
8
Weld inside panels of
A-pillars
Butt weld inside panels of A-pillars (body and front end
body section) with a solid welding seam from an inert
gas welder.
50 -10
Replacing
Complete
Front End of Body
Printed in Germany
-111,1989
No.
911 Carrera
9
Body -Front
4
Section
Procedure
Instructions
Close and weld outside
Close, straighten and inert gas weld outside panels of
panels of A-pillars
A-pillars with solid welding seams. Butt weld body
A-pillars and front end body section A-pillars with solid
welding seams from an inert gas welder. Grind down
welding seams and install Special Tool P 852 to check
the body opening for the windshield.
10
Plug weld front end body
Align front end body section side members inserted in
section side members with
the body side members. Plug weld front end body section side members and body side members with an inert
body side members
gas welder.
11
Plug weld front end body
section floor plate with
body floor plate
Align overlapping area of the body floor plate and front
end body section floor plate. Plug weld front end body
section floor plate and body floor plate with an inert gas
welder.
12
Plug and solid seam weld
Plug weld left and right collar on cap-profile of the body
body seat carrier with
seat carrier on the front end body section extension with
front end body section
an inert gas welder. Inert gas weld face of the body seat
I
carrier on the front end body section extension with a
extension
solid welding seam.
13
14
Inert gas weld body floor plate on front end body section
Inert gas weld floor plate
in area of side members
floor plate in area of the side members from underneath
fromt underneath
with a solid welding seam.
Produce reinforcement
Produce one each reinforcement bracket made of 1.25
brackets for A-pillars'
mm thick, galvanized sheet metal for the inside of left
and right A-pillars.
15
ment brackets on A-pillars
Inert gas weld the reinforcement brackets above the
welding seams on the insides of the A-pillars with
all around
welding seams all around to strengthen the welding.
Solid seam weld reinforce-
Grind down welding seams.
16
Weld in entrance covers
Fit in and tack weld entrance covers. Spot weld entrance
covers on side members at top. Plug weld entrance
covers on fender end plates with an inert gas welder.
Inert gas weld entrance covers on A-pillar connection
plates with interrupted solid welding seams. Inert gas
weld entrance covers on side members at bottom with
interrupted solid welding seams. Butt weld entrance
covers on body entrance covers with inert gas welding
solid welding seams. Grind down welding seams.
Replacing
Complete
Front End of Body
Printed in Germany -111,1989
50 -11
911 Carrera 4
Removing
and installing
Bumpers
front spoiler and bumper
63 -3
Bumpers
911 Carrera 4
i~~*
I~ji=
""
Glasses
Removing
and installing
911 Carrera 4
the windshield
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43
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6
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64-115
911 Carrera 4
Glasses
Removing and installing
No.
the windshield
Action
Procedure
Remove the windshield wiper
Unscrew the hexagon nut,
remove spring washer and wiper.
Open the door window
Lower the door window.
Remove internal
Remove the interior mirror upwards from the fastening
plate parallel to the window.
mirror
Remove defroster panel
-countersunk screws
2
3
4
-defroster
defroster panel.
panel
Remove the central nozzle
Press 2 fastening nuts downwards and pull out the
-fastening lugs
-central nozzle
central nozzle.
Remove
Unscrew a hexagon nut from the threaded bolts for the
the upper part of the
central switchboard fastening on each side of the recess
switchboard
5
-hexagon
6
7
-cover
-self-tapping
screws
8
-self-tapping
screws
9
-upper
10
Undo 5 countersunk self-tapping screws and remove the
for the central nozzle. Remove 2 cover panels. Undo
the self-tapping screws below the cover panels. Undo 2
nuts
panels
self-tapping screws from the top of the switchboard fastening. Remove the upper part of the switchboard.
part of switchboard
Pull off the windshield
antenna
Disconnect the windshield antenna plug from the
antenna amplifier. (The antenna amplifier is mounted in
the -x -area on the body, under the upper part of the
plug
switchboard).
Cut through the rubber seal
Fit the angled blade (E) into the cutter (A). Sharpen the
blade with a grinding stone with the cutter running.
Insert the blade into the rubber seal, set the vibration
controller to position 6 and cut through the rubber seal
between windshield and body all round.
Note: The windshield antenna cable in the -x -area
must not be damaged.
Removing
and installing
Printed in Germany
-1988
the windshield
64 -3
Glasses
No.
Action
12
Remove the windshield
911 Carrera
Procedure
Remove any rubber
from the body
13
14
Stick adhesive tape
To protect the paintwork, apply adhesive tape to the
to the body
visible area of the body round the window cutout.
Cut awayadhesive sealant
Fit the scraper (0) to the cutter (A) and cut away the ad-
on the body
hesive sealant on the body until a covering residual
layer remains.
Clean the body round
the window cutout
Clean the body round the window cutout thoroughly
with cleaning solution (H).
Note: No cleaning solution may remain on the body.
Apply a coat of primer
to any damaged areas
on the body
Apply body primer (G) to any lacquer damage round the
window cutout which will not be visible.
Cut away the adhesive
Cut away the adhesive sealant from the windshield with
sealant on the windshield
(only if the windshield
a fixed blade. A covering residual layer may remain.
Note: If the vehicle is fitted with a Sekuriflexwindshield,
is undamaged)
under no circumstances may the protective foil on the
sealant side be damaged.
Clean the windshield
Rub the windshield thoroughly with cleaning solution
(H).
Note: No cleaning solution may remain on the winds-
hield.
4
911 Carrera 4
No.
Glasses
Action
Procedure
Check the windshield
the edge of the windshield all round for damage. If the
for notches
windshield is damaged and has notches, this must not
Inspect
be reinstalled.
Clean the rubber seal
Clean the window channel in the rubber seal with cleaning solution (H)
Note: No cleaning solution may remain in the window
channel.
15
Perforate the rubber seal
Perforate the rubber seal in the area of the antenna
cable for the cable to pass through (see Item 17).
Apply adhesive sealant
Insert a cartridge with adhesive sealant (F) into the glue
into the window channel
gun (C) and apply the sealant all round the window
channel of the rubber seal (you require approx. 85 mm
of the rubber seal
adhesive sealant).
Note: The windshield must be installed into the vehicle
max. 4 hours after the adhesive is applied.
,
16
Mount the rubber
seal onto the
windshield
17
Pull the antenna
cable, including plug,
through the hole in the
rubber seal
18
Lay anassembly cord
Lay the assembly cord into the rubber seal to fit the
into the rubber seal
windshield.
The ends of the cord must cross over around the middle
of the roof area.
Position the doublesuction cups to the outside
of the windshield
19
Apply adhesive sealant
Using the glue gun (C), apply the adhesive sealant (F) to
to the body
the body all round the area of the window cutout
(approx. 70 ml adhesive sealant).
Glasses
No.
911 Carrera 4
Action
Procedure
Mount the windshield
Lay the preassembled, prepared windshield into the
into the body
window cutout, align and press down with the doublesuction cups (8). From inside the vehicle, fit the rubber
seal by pulling the assembly cord against the fold in the
body.
Clean the window
Emergent adhesive sealant must be removed immediately and the window area cleaned with cleaning solution
(H).
Connect the windshield
antenna plug to the
antenna amplifier
Install the upper
part of the switchboard
Switchboard fastening: 2 self-tapping screws .at the top,
one self-tapping screw each on the right-hand side and
left-hand side, 2 hexagon nuts in the middle. Replace
the left and right cover panels.
Install the central nozzle
Press the fastening lugs downwards and slide the
central nozzle into the recess on the switchboard.
Install the
Secure the defroster panel with 5 countersunk
defroster panel
tapping screws.
Fit the internal mirror
Slide the internal mirror into the fastening plate parallel
self-
to the windshield.
Install the windshield wipers
Mount the winshield wipers. fit spring washers and
secure with hexagon nuts.
Glasses
911 Carrera 4
Note: Vehicles fined with Airbag
The following outline conditions must be observed to ensure that the bonded connection is adequately strong for vehicles with Airbag:
Hardening time
10 h
Temperature
at least 15°C
Relative humidity
at least 40%
Should the temperature or relative humidity be lower than these values, the hardening time is longer.
These vehicles must not be put into operation before the hardening time has expired.
Vehicles without Airbag may be put into operation after the assembly work has been completed.
Removing
and installing
Printed in Germany
-1988
the windshield
64 -7
Glasses
Removing
and installing
911 Carrera 4
the rear side-window
64
64 -8
Removing and installing
the rear side-window
Printed in Germany
-1988
911 Carrera 4
Removing
No.
Glasses
and installing
rear side-windows
Action
Procedure
Remove the trim
Using a wood or plastic spatula, ease the trim around
the upper cover plate out of the rubber seal carefully.
1
-upper
2
-rear
3
4
-lower
-front
cover plate
trim
cover plate
Lay a cloth between trim and rubber seal and remove
the trim by pulling the cloth along the rubber seal.
trim
Cut through the rubber seal
Fit the angled blade (E) into the cutter (A). Sharpen the
blade with a grinding stone with the cutter running.
Insert the blade into the rubber seal, set the vibration
controller to position 6 and cut through the rubber seal
between rear side- window and body all round.
6
Remove rear side-window
Remove any
residual rubber from
the body
7
8
Stick adhesive tape
To protect paintwork, cover the body in the visible area
to the body
of the window cutout with adhesive tape.
Cut down adhesive sealant
Fit the scraper (0) into the cutter (A) and cut down the
on the body
adhesive sealant on the body until a covering residual
layer remains.
Removing
Printed
Clean the body around
Clean the body round the window cutout with cleaning
the window cutout
solution (H).
Note: No cleaning solution may remain on the body.
and installing
in Germany
-1988
rear side-windows
64
-9
Glasses
No.
911 Carrera 4
Action
Procedure
Apply coat of primer
to damaged areas on the body
Apply body primer (G) to damaged covering lacquer in
areas round the window cutout which will not be visible.
Cut down the adhesive
Using a fixed blade, carefully remove the adhesive
sealant on the rear
sealant round the rear side-window. A covering residual
side- window
layer may remain.
Clean the rear
Rub down the rear side-window thoroughly with clea-
side-window
ning solution (H)
Note: No cleaning solution may remain on the window.
Clean the rubber seal
Clean the window channel in the rubber seal with cleaning. solution (H)
Note: No cleaning solution may remain in the window
channel.
9
Apply adhesive sealant
into the window
channel of the rubber seal
Insert a cartridge with adhesive sealant (F) into the glue
gun (C) and apply the sealant all round the window
channel of the rubber seal.
Note: The rear side-window must be installed in the
vehicle max. 4 hours after the adhesive has been
applied.
10
Mount the rubber seal
round the rear side-window
11
Mount the trim onto the
Press the rear trim (2) into the rubber seal. Join the front
rubber seal
trim (4) to the upper cover plate (1) and lower cover
plate (3), press into the rubber seal, join to the rear seal
(2) and finally press the complete trim into the rubber
seal.
12
Lay an assembly cord
into the rubber seal
64 -10
Removing
and installing
rear side-windows
Printed in Germany
-1988
(
911 Carrera 4
Glasses
No.
Action
Procedure
13
Apply adhesive sealant
to the body
Using the glue gun (C) apply adhesive sealant (F) to the
Install the rear sidewindow into the body
Position the assembled, prepared rear side-window into
the body cutout, align and press down.
From inside the vehicle, fit the rubber seal by pulling out
the assembly cord against the fold in the body.
Clean the window
Emerging adhesive sealant must be removed immediate-
body all round the window cutout.
ly and the respective area on the window cleaned with
cleaning solution (H).
Removing
and installing
Printed in Germany
-1988
rear side-windows
64-11
Glasses
Removing
and installing
911 Carrera 4
the rear window
64 -117
64 -12
Removing and installing
the rear window
Printed in Germany
-1988
911 Carrera 4
Glasses
Removing and installing the rear window
No.
Action
Procedure
Remove the rear wiper
Lift the caps, unscrew the hexagon nut, remove screen
washer and upper wiper arm. Remove the sleeve,
unscrew the hexagon nut, take out spring washer and
lower wiper arm.
1
Open the door window
Lower the door window.
Remove the rear wall panel
Tilt the rear seat-back forwards. Undo the 4 self-tapping
screws from the rear wall panel and slide the panel
upwards out of the retainer.
2
3
Separate the plug connection
The plug connection for the rear-window defroster is
for the rear-window defroster
located under the rear wall panel in the area -x-
Cover body with adhesive tape
To protect the paintwork. apply adhesive tape to the
upper roof area of the window cutout.
4
Cut through the rubber seal
Fi~the angled blade (E) to the cutter (A). Sharpen the
blade on a grinding stone with the cutter running. Insert
the knife into the rubber seal. set the vibration control to
position 6 and cut through the rubber seal between rear
window and body all round.
Note: Do not damage the wiring for the rear window in
the -x -area (e.g. heating, high-mounted brake lights).
5
Remove the rear window
Pull the rubber seal
away from the bodywork
6
7
Fit adhesive tape
To protect the paintwork, fit adhesive tape to the body
to the body
in the visible area of the window cutout.
Cut down the adhesive sealant
Fit the scraper (0) into the cutter and cut away the adhesive sealant on the body until a covering residual layer
on the body
remains.
Removing
and installing
Printed in Germany -1988
the rear window
64 -13
Glasses
No.
911 Carrera 4
Action
Procedure
Clean the window cutout
in the body
Clean the window cutout in the body thoroughly with
Apply primer to any
damaged areas on the body
cleaning solution (H).
Note: No cleaning solution must be left on the body.
Apply body primer (G) to any damaged areas in the
cover lacquer round the window cutout which will not be
visible.
Separate the plug
rear window wiring
Separate plug connections for the rear window wiring by
disconnecting the flat plugs from the sockets at the rear
window
Cut down adhesive
Use a fixed blade to carefully cut down the adhesive
sealant on the rear
sealant on the rear window. A covering residual layer of
window
adhesive may remain.
Clean the window
Rub the rear window thoroughly with cleaning solution
connection for the
(H).
Note: No cleaning solution may remain on the rear
window.
Check the rear window
for notches
,
Check all round the edge of the rear window for
damage. If the rear window is damaged and has
notches, this may not be reinstalled.
Clean the rubber seal
Clean the window channel in the rubber seal with cleaning solution (H)
.Note: No cleaning solution may remain in the window
channel.
8
Perforate the rubber seal
Perforate
the rubber
(body channel to the
channel
cable channel)
(rear-window
seal in the -x -area
from the body
to the cable channel for cables to pass through
defroster)
Perforate rubber seal
(cable channel to
Perforate
the window channel)
the rear-window
Apply adhesive sealant
Fit a cartridge with adhesive sealant (F) into the glue
gun (C) and apply all round the window channel of the
to the window channel of the
rubber seal.
window
the rubber
(refer to Item 10).
channel
seal from the cable channel
to the
in the areas for cable connections
defroster
to
(refer to Item 11).
rubber seal.
Note: The rear window must be installed into the vehicle
max. 4 hours after the adhesive has been applied.
911 Carrera 4
No.
9
Glasses
Action
Procedure
Fit the rubber
seal round the rear window
10
Pull the cables for the
rear-window defroster
through the holes in the
Pull the cable through the holes from the body channel
to the cable channel.
rubber seal
Lay the cable into the cable
channel of the rubber
seal according to the
connections
12
Connect the cable to the
Pull the cable through the holes from the cable channel
terminals for the rear-
to the window channel and join to the terminals for the
window defroster
rear-window defroster.
Lay the assembly cord
into the rubber seal.
The ends of the cord must cross over around the
bottom middle (area of the rear wall panel).
In order to align the sealing lip along the roof, lay a
second. thinner cord in this area of the rubber seal.
Position the doublesuction cups to the
outer side of the rear window
13
Apply adhesive sealant
Using the glue gun (C) apply adhesive sealant all round
to the body
the window cutout on the body.
Install the rear
Lay the rear window into the window cutout of the body,
window into the body
align and press down with the double-suction cup (8).
From inside the vehicle, pull the rubber seal in position
by pulling the assembly cord against the fold in the body
.Align the sealing lip in the roof area by pulling out the
secondcord.
Clean the window
Any emergent adhesive sealant must be removed immediately and the area on the window cleaned with cleaning solution (H).
Removing
and installing
Printed in Germany
-1988
the rear window
64 -15
Glasses
No.
Action
911 Carrera 4
Procedure
Restore the plug
connections for the
rear-window defroster
Install the rear
wall panel
Slide the rear wall panel into the retainer from above
and secure with 4 self-tapping screws. The self-tapping
screws must have fabric washers. Tilt rear seat-backs
upwards. Install rear wiper.
Mount rubber sleeve,
Fit lower wiper arm, mount spring washer and secure
with hexagon nut. Slide on the sleeve, fit other upper
wiper arm, mount spring washer and secure with
hexagon nut. Close cap .
Indian
911 Carrera 4
AuBenausstattung
Body paint colors model 1989 onward
Standard:
Special:
Grand prix white
908
Silver metallic
980
Black
700
Diamond-blue metallic
697
Dark blue
347
Dove-blue metallic
378
BOK
Pebble-grey metallic
693
Linen
6OM
Slate metallic
220
Apricot-beige
548
Velvet-red metallic
81L
Murano green
22C
Linen metallic
550
Pine-green metallic
22E
Cognac-brown
40L
red
metallic
Salmon-silver metallic
Body paint colors model 1989 onward
Printed in Germany -111,1989
81 K
66 -01
AuBenausstattung
911 Carrera 4
Body paint colors model 1990 onward
Standard:
Special:
Grand prix white
908
Silver metallic
980
Black
700
Diamond-blue metallic
697
Dark blue
347
Dove-blue metallic
378
Indian red
BOK
Pebble-grey metallic
693
Linen
6OM
Slate metallic
220
Apricot-beige
548
Velvet-red metallic
81L
Murano green
22C
Linen metallic
550
Pine-green metallic
22E
I
Cognac-brown metallic
40L
marine blue metallic
35V
911 Carrera
Exterior Equipment
4
19
Take-up plate
1
20
Liner
6
The distance between
the rear spoiler and rear
lid can be adjusted by
inserting liners (up to 3
on each side) between
the take-up plates and
rear lid.
21
Hexagon head screw
2
M5
22
2
Washer
A5.3
23
1
Microswitch
See adjusting rear
spoiler
24
Stud
1
25
Hexagon nut
M5
1
26
Washer
1
A 5.3
27
1
Microswitch
See adjusting rear
spoiler
28
Stud
29
Plate nut
30
Electric lead terminal
3
31
Plug
1
32
Fillister head screw
3
1
Produce plug connection on wire harness
M 6 x 12
33
3
Washer
A 6.4
Removing
and Installing
Printed in Germany -111,1989
Rear Spoiler
66 -3
Exterior Equipment
66
-4
911 Carrera 4
Removing
and Installing
Printed
Rear Spoiler
in Germany
-111,1989
Exterior Equipment
911 Carrera 4
Note When:
No.
Description
47
Arced toothed
Oty.
1
element
Removing
Installing
Insert tab (A) of arced
toothed element (47) in
opening (B) of guide
lever (C) on linkage (50)
48
Spring
49
Washer,
black
50
Linkage
1
51
Pad
2
5 x 10 x18.5
52
Combination screw
M 6 x 18
3
53
Gearbox motor
1
Sleeve for
1
541
gearbox motor
A
1
Tab on arced
tooth element
B
1
Opening in
guide lever
c
1
Guide lever on
linkage
Removing and Installing
Printed in Germany -111.1989
Rear Spoiler
66
-5
Exterior Equipment
Adjusting
911 Carrera 4
Rear Spoiler
The rear spoiler running out and running in travel can be limited and therefore adjusted by determining the switching points of two micro-switches.
Adjusting
In
Micro-switch
for Spoiler Running
Adjusting
Micro-switch
for Spoiler Running
Out
Operate the service switch to run in the spoil-
Operate the service switch to run out the spoil-
er until tab (A) of the arced tooth element (47)
er until lever (39) touches pad (51). Adjust the
switching point of micro-switch (23) on stud
is disconnected
in opening (8) of guide lever
(C). Unscrew hexagon nut (25). Adjust the
(24). Recheck adjustment by operating the
switching point of micro-switch
service switch.
(27) on stud
(28). Tighten hexagon nut (25) again. Recheck
adjustment by operating the service switch.
66 -6
Removing and Installing
Printed
Rear Spoiler
in Germanv
-111.1989
911 Carrera
4
Interior Equipment
Safety Precautions
for Working
on Cars with Airbag
Airbag units are pyrotechnical items of Danger
Class T 1. Handling, transportation and stor-
When storing airbag units it is very important
age are subjected to the legislation for explosives.
(danger of injury from an ejected airbag unit
in case of accidental ignition).
The mentioned legislative measures refer to
the Federal Republic of Germany. Always
Airbag units may not be stored together with
other products in danger clssification (paint,
conform with the pertinent legislation in other
etc.).
to make sure that the padded sides face up
countries.
The beginning of work on pyrotechnical items
must be reported to the Trade Supervisory
Office (official authorities) 14 days in advance.
Shipping
The shipment of airbag units may only take
place in the officially approved packaging for
transportation. Airbag units may not be transported together with other dangerous items.
Within a company transportation is only permitted in the trunk or cargo room of a vehicle
with use of the above mentioned packaging
for transportation. Transportation in the passenger compartment is forbidden.
Storage
Storage of airbag units must be in conformance with the second ordinance of the legisation for explosives. According to this ordinance small amounts of substances and items
may be stored at certain locations without a
special storage permit. For pyrotechnical
items of Danger Class T 1 this would be max.
20 kg (gross) in a workroom or max. 200 kg
(gross) in a storeroom. Airbag units must be
stored locked.
Safety Precautions
for Working
on Cars with Airbag
68
-1
.
Interior Equipment
Installation
911 Carrera 4
and Repairs
Testing and installing may only be carried out
Additional trim, 1abels or anything similar may
by qualified personnel.
not be installed on the steering wheel or in the
area of the front passenger's airbag.
The following precautionary measures are always mandatory prior to working on the airbag system as well as work on neighboring
No modifications or changes may be made on
the wiring and components of the airbag
parts. where there is danger that power sup-
system.
plying parts could get too close to the airbag
system.
1. Turn oft ignition
The battery must always be disconnected before beginning with straightening and welding
2. Disconnect and cover battery ground pole.
work with use of an electric welder.
After disconnecting the battery installation or
If welding is required in the immediate vicinity
repairs on the vehicle with use of a hammer
or similar tools may first be begun after
of crash sensors and control, these parts
must be removed first.
waiting 20 minutes. This is necessary to interrupt power supply of the airbag system and to
guarantee that accidental ignition is not poss-
Electric leads of other electrical equipment
items may not be routed in the vicinity of the
I
ible.
airbag wire harness.
Installation of airbag units must commence im-
Airbag components
mediately after removal from the location of
they must always be replaced.
may never be repaired;
storage. Under no circumstances may they be
left unattended. Airbag units must be placed
Note
under lock immediately when installing proce-
Hands must always be washed thoroughly
dures are interrupted.
after touching triggered airbag units.
Airbag units must never have contact with
Scrapping
Airbag Units
grease, oil, cleaning solutions or similar products.
Non-ignited airbag units are a source of
Airbag units must never be subjected to tem-
danger, even for the environment. Non-ignited
airbag units may not be scrapped. They must
peratures above goo C (1950 F), not even
be sent to Porsche or a responsible importer.
briefly.
Shipment of airbag units is permitted only in
Airbag units, crash sensors and control units,
which have fallen from a height of more than
the officially approved packaging for transportation.
0.5 meter (1.5 feet), may no longer be install-
ed.
68 -2
Safety Precautions
for Working
on Cars with Airbag
911 Carrera
Interior Equipment
4
Removing and Installing Airbag Steering Wheel
Removing
Note
1. Disconnect battery and cover pole or battery.
Steering wheel must be mounted in such a
2. Remove driver's airbag unit (see page
are not pinched.
manner that electric leads of the contact unit
68 -4).
3. Unscrew and remove hexagon nut with the
spring washer.
276-68
2. Install hexagon nut with spring washer and
tighten with 45 Nm (32.5 ft. Ibs.).
276-68
3. Install driver's airbag unit.
4. Mark position of steering wheel to steering
4. Check function of horn.
shaft for reinstallation.
Installing
1. Mount steering wheel in straight ahead position of the road wheels or according to the
removal marks in such a manner, that the
upper steering wheel spokes are horizontal.
Removing
and Installing
Airbag Steering Wheel
68
-3
,
~
Interior Equipment
Removing
and Installing
Airbag Components
Removing
and Installing
Driver's Airbag Unit
Disconnect battery and cover pole or battery.
2. Unscrew two mounting screws with a Torx T
30 screwdriver socket.
911 Carrera 4
Note
The airbag unit must always be laid aside in
such a manner that the padded side faces up.
Note
Screws must be replaced each time they are
loosened. Only use screws with a collar from
1990 models on.
275-68
Airbag units must be placed under lock when
removed for a long time. Confrom with the
safety precautions.
Tightening torque for mounting screws:
10 Nm (7 ft. Ibs.).
3. Disconnect plug.
274-68
Interior Equipment
911 Carrera 4
Removing and Installing
Contact Unit
1. Remove airbag steering wheel (see page
5. Disconnect plug.
68 -3).
2. Loosen and take off trim panel.
279-68
Note
Turn front wheels to straight ahead position
and move the contact unit to center position
(about 4 1/2 turns from left or right final stop)
3. Unscrew mounting screws.
prior to installation of the contact unit. The
precise center position is indicated by both
arrows.
278-68
4. Take off contact unit and pull out connection leads.
280-68
A new contact unit is arrested in center position. The arrest is removed only after installation of the contact unit.
Removing and Installing Airbag Components
--D,;nt~ri
;n ~..rrn~nv
-III
10AO
-
68
-5
Interior Equipment
Removing and Installing
911 Carrera
Crash Sensors
Note
Note
Crash sensors are mounted in the luggage
Use a 1/4 inch socket to tighten the shear-off
compartment on left and right sides in front of
nuts.
the spring strut domes.
Mounting points on the body must show blank
The installed position is given by installation.
metal.
Plugs are located at the left on the firewall and
at right below the central electric board.
1. Disconnect battery and cover pole or battery.
2. Disconnect plug.
3. Unscrew shear-off nuts with Special Tool
9259.
281-68
Special Tool 9259
4
911 Carrera 4
Interior Equipment
68
10. Remove top airbag flap (4 screws). Press
Removing and Installing
Passenger's Airbag Unit
flap forward after loosening the 4 screws
and pull it out downward (flap is attached
1. Disconnect battery and cover pole or battery.
2. Remove glove box.
on a brace).
11. Unscrew mounting screws (5 mm hexagon
socket) .
3. Pull off plugs on unit.
283-68
282-68
Note
4. Unscrew M 8 mounting bolt.
5. Remove radio and holding frame.
The hexagon socket head screws are microencapsulated. Use new screws for installation.
Tightening
torque:
6 Nm (4.3 ft. Ibs.).
6. Remove heater/air conditioner controls and
holding frame.
Note
There is one each screw for the knee guard
12. Remove airbag unit downward.
Always lay the airbag unit aside in such a
manner that the airbag faces up.
underneath the holding frames.
7. Remove ashtray.
8. Remove knee guard.
9. Remove bottom airbag flap (3 screws).
~
~
D
284.68
.
Removing
and Installing
Control
Unit
Note
Note
The control unit is located on a cross panel
The 6-pin plug is arrested with a red lock,
behind the center console.
which is destroyed when removed. Plug must
be arrested with a green lock after installation.
1. Disconnect battery and cover pole or battery.
6. Guide connection leads for the crash sen2. Remove center console.
sors back into the passenger compartment.
3. Remove glove box.
7. Loosen straps along the wire harness.
4. Remove central electric board
8. Unscrew shear-off nuts with Special Tool
9259.
5. Disconnect plugs for left crash sensor, contact unit, right crash sensor and passenger's
9. Unscrew
hexagon
nuts with a wrench
socket.
airbag unit as well as 2-pin and 6-pin plugs
Note
for the main wire harness.
Install shear-off nuts diagonally.
10. Remove
control
water protection
unit together
with the
cap.
Note
Mounting points on the body must show blank
metal.
Use a 1/4 inch hexagon socket to tighten the
shear-off nuts.
Shear-off nuts are installed without washers.
M 6 hexagon nuts are installed with A 6.4
285-68
washers to DIN 125.
2-pin and 6-pin plugs underneath the center
Tightening torque for M 6 nuts: 10 Nm (7 ft.
console.
Ibs.).
911 Carrera 4
Center Consolse
Innenausstattung
/ Information
about Axial and Lateral Acceleration
If applicable, conform with the following points
Sensors
Installation
when working near the center console.
Always conform with the following points
when installing:
Location
The sensors are installed on a sheet metal
Park car on level ground (level floor)
console on the tunnel underneath the center
console. These sensors are required for all
2. Check levelness of the sheet metal console
with a bubble level. Replace a bent sheet
wheel drive and antiblock systems.
metal console.
1 -Lateral
acceleration
sensor
3. Connecting leads must not be mixed up.
2 -Axial
acceleration
Plug receptacles have different colors for
identification.
Black plug receptacle for the lateral
sensor
acceler-ation sensor.
Gray plug receptacle for the axial
acceleration sensor.
4. Sensors must not be subjected to any type
of extreme acceleration such as from
throwing, falling or knocking.
5. Sensors must always be inspected after an
accident. Sensors must be replaced if they
are not within specifications.
Checking
Checking is required to guarantee the
follow-ing points.
Correct location (position) of sensors
Function of sensors
Electric leads (plugs) connected on the
correct sensor (mix-up test)
290- 45
Testing is described
(Volume
IV -Chassis).
in Rep. Gr. 45
Inspecting
Checking
Seat Belts
Function
Checking
Condition
It must be possible to have the belt strap roll
A visual inspection of the seat belt must not
off of the automatic reel via the reversing
produce any damage or signs of wear on the
fitting without hesitation when pulling the seat
belt uniformly and the tongue of the seat belt
belt strap. The seat belt must be replaced, if
the belt strap is damaged in the form of cuts,
must be heard engaging in the belt lock. The
fringing, torn seams, rubbing spots or similar
automatic reel must lock when the seat belt
strap is pulled suddenly.
conditions.
Additional
Checking
for Seat Belts with Overload Indicators
(Tear Seams) -
Airbag Equipment
The tear seam on the belt strap above the holder must not be damaged in addition to the fact that
these seat belts must have perfect function and condition. The tear seam serves as an overload indicator, which reports an overloaded condition and therefore the necessity to replace a seat belt.
1 = Anchorage point for holder
2 = Anchorage
3
=
bolt
Holder
4 = Plastic cap
5 = Indicator (tear seam)
6 = Belt strap
6&-261
Inspecting Seat Belts
68-11
Diagnosis
The airbag system is monitored continuously
by a diagnosing unit in the control unit. An occurring fault is indicated by a control lamp in
the instrument cluster.
The airbag control lamp lights up for about 5
seconds after turning on the ignition and then
goes out. This control lamp lights up again for
about 5 seconds while starting the engine.
If the lamp lights up again, this indicates a
fault in the system. Fault can be read with a
9288 System Tester or 9268 Flashing Code
Tester.
Note
The control unit needs 70 seconds to be able
to recognize all faults in the system. The ignition must be turned on at least 70 seconds to
guarantee that every possible source of fault
is checked during the vehicle test.
Fault does not exist means, that there is no
fault at the moment of checking (e.g. loose
contact or when faults had been eliminated).
D 68 -1
Fault Code Table
Fault Code
Fault Description
Crash sensor left: closed 1 time
12
Crash sensor left: closed several times
13
Crash sensor right: closed 1 time
14
Crash sensor right: closed several times
15
Crash sensor left: closed continuously*
16
Crash sensor right: closed continuously*
17
Crash sensor left: contact resistance against battery voltage
18
Crash sensor right: contact resistance against battery voltage
19
Crash sensor left: contact resistance against ground
20
Crash sensor right: contact resistance against ground
21
Crash sensor left: short against battery voltage
22
Crash sensor right: short against battery voltage
25
Crash sensor left: ground resistance excessive
26
Crash sensor right: ground resistance excessive
27
Crash sensor left: break in power supply lead
28
Crash sensor right: break in power supply lead
29
Crash sensor left: line resistance excessive
30
Crash sensor right: line resistance excessive
33
Ignition capacitor 1: capacity insufficient
34
Ignition
35
Ignition capacitor 1: contact resistance excessive
36
Ignition capacitor 2: contact resistance excessive
37
Ignition pill circuit 1: contact resistance against battery voltage
38
Ignition pill circuit 2: contact resistance against battery voltage
/
capacitor
2: capacity
insufficient
* Fault Codes 15 and 16 also appear as Fault Code 60. Replace crash sensor and cancel the fault
memory. Repeat diagnosis. Replace control unit. if Fault Code 60 appears again.
D 68 -2
Diagnosis
-..III
"",a
Fault Code
Fault Description
39
Ignition pill circuit 3: contact resistance against battery voltage
40
Ignition pill circuit 1: short against battery voltage
41
Ignition pill circuit 2: short against battery voltage
42
Ignition pill circuit 3: short against battery voltage
43
Ignition pill circuit 1: contact resistance against ground
44
Ignition pill circuit 2: contact resistance against ground
45
Ignition pill circuit 3: contact resistance against ground
46
Ignition pill circuit 1: short against ground
47
Ignition pill circuit 2: short against ground
48
Ignition pill circuit 3: short against ground
49
Ignition pill circuit 1: break
50
Ignition pill circuit 2: break
51
Ignition
52
Ignition pill circuit 1: resistance insufficient
53
Ignition pill circuit 2: resistance insufficient
54
Ignition pill circuit 3: resistance insufficient
55
Ignition pill circuit 1: resistance excessive
56
Ignition pill circuit 2: resistance excessive
57
Ignition pill circuit 3: resistance excessive
58
Warning lamp: short against battery voltage or ground
59
Warning lamp: break
60
Diagnosis unit: faulty
61
Firing order correct (after crash)
62
Ignition current correct (after crash)
65
Ignition pill current flows (after crash)
pill circuit
3: break
Ignition pill circuit 1: driver's airbag
Ignition pill circuits 2 and 3: passenger's airbag
D68-3
Diagnosis
,,-,
:A "'A1..,
III .,,-
-
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