1989-1994 Porsche 964 (911 Carrera 4) Workshop Manual PDF

1989-1994 Porsche 964 (911 Carrera 4) Workshop Manual PDF scr1

1989-1994 Porsche 964 (911 Carrera 4) Workshop Manual PDF Free Download

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

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

CONTENTS:
WORKSHOP MANUAL 1989-1994 (1332 pages)

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

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Free download 1989-1994 Porsche 964 (911 Carrera 4) Workshop Manual PDF
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