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Page 2: ...c Transmission Controls Case Automatic Transmission Gears Shafts Differential Transaxle System Diagnosis Transmission automatic 40 42 44 45 46 47 48 Volume IV Chassis Front Wheel Suspension Rear Wheel...
Page 3: ...Airbag Steering Wheel Removing and Installing Airbag Components Removing and Installing Center Console Information About Axial and Lateral Acceleration Sensors SeatBelts Inspecting Diagnosis 68 1 68 3...
Page 4: ...ication Page 50 01 50 07 Body General Repair Control Dimensions Special Tools and Sheet Metal Machines for Repairs Body Front Section Front End of Car Replacing Partially Front End of Car Replacing Co...
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Page 6: ...Point 18 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 a...
Page 7: ...General Information 911 Carrera 4 Sheet Metal Machines Standard 236 50 8 5 238 50 308 50 235 50...
Page 8: ...911 Carrera 4 Dimensions for assembly J f r c v 1 1 I I 1 P2 5 I J d P3 PS p li 19 1245 t2 P19 132B t2 P6 10 P1B 3756 5 t4 1 722 2 P18 P17 Repair control dimensions Printed in Germany 1988 l_...
Page 9: ...g strut Mount outer cross member FA Mount inner cross member FA Mounting hole wheel house Mounting hole switchboard Mount transmission cross member Mount outer cross tube RA Mount RA spring strut RA M...
Page 10: ...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 re...
Page 11: ...Welding spot cutter for drill Electric Tools 1 Drill 2 Right angle grinder large 3 Right angle grinder small 4 7 Grinder 5 Hot air blower Pneumatic Tools 9 Chisel 10 Body saw 11 Welding spot cutter W...
Page 12: ...ion Partially replacing front section The following chassis parts are required for partial repair of the front section D c o 0I r 0 0 10 A I I b B 188 50 End panel A B Connection plate c Front wheel h...
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Page 14: ...section secure with clamps and spot weld 3 Weld end section onto spare wheel well Weld in connection plate 4 5 Weld in wheel house Weld in side member and grind butt weld joint smooth Align connectio...
Page 15: ...lacing Complete Front End of Car Cutting Off Front End of Car Body 2 1 h I I l 0 1 001 C C c r _000 c 0 u 1 f O 0 i v oi I c i i QI 8 c C c P 10 7 3 BV T 11 2 Co o 312 50 5 Replacing Complete Front En...
Page 16: ...o 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 Drill off welding spots between side member and body insi...
Page 17: ...lacement parts and special tools are required for replacement of the complete front end body section 4 J 0 V 0 c 313 50 A Special Tool P 852 gage for windshield opening in body B Front end body sectio...
Page 18: ...Body Front Section 911 Carrera 4 Replacing Complete Front End of Car Fitting Front End Body Section on Body 1 Replacing Complete Front End of Car Printed in Germany 111 1989 50 8...
Page 19: ...Body Front Section 911 Carrera 4 Replacing Complete Front End of Car Printed in Germany 111 1989...
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Page 22: ...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 Set up front end...
Page 23: ...eld reinforce ment brackets on A pillars all around Plug weld left and right collar on cap profile of the body seat carrier on the front end body section extension with an inert gas welder Inert gas w...
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Page 26: ...Bumpers 911 Carrera 4 63 3 Removing and installing front spoiler and bumper...
Page 27: ...Bumpers 911 Carrera 4...
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Page 29: ...Glasses 911 Carrera 4 Removing and installing the windshield 1 1 c c C r I A A i r c ii i f I 11 I ji I J CCc C cccccc c cCCC I 43 9 6 Wfj ij 64 115...
Page 30: ...o the self tapping screws below the cover panels Undo 2 self tapping screws from the top of the switchboard fa stening Remove the upper part of the switchboard 5 6 7 8 9 10 Disconnect the windshield a...
Page 31: ...ly 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 w...
Page 32: ...ive sealant F into the glue gun C and apply the sealant all round the window channel of the rubber seal you require approx 85 mm adhesive sealant Note The windshield must be installed into the vehicle...
Page 33: ...amplifier Switchboard fastening 2 self tapping screws atthe 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 pane...
Page 34: ...0 h at least 15 C Temperature 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 oper...
Page 35: ...Glasses 911 Carrera 4 Removing and installing the rear side window 64 Removing and installing the rear side window Printed in Germany 1988 64 8...
Page 36: ...e 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...
Page 37: ...tion 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...
Page 38: ...lean the window 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...
Page 39: ...Glasses 911 Carrera 4 Removing and installing the rear window 64 117 Removing and installing the rear window Printed in Germany 1988 64 12...
Page 40: ...he rubber seal To protect the paintwork apply adhesive tape to the upper roof area of the window cutout Fi the angled blade E to the cutter A Sharpen the blade on a grinding stone with the cutter runn...
Page 41: ...r window 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 Check the rear window for notches Clean the rubber seal Clean...
Page 42: ...lip along the roof lay a second thinner cord in this area of the rubber seal 12 Lay the assembly cord into the rubber seal Position the double suction cups to the outer side of the rear window Using...
Page 43: ...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 Fit lower wiper...
Page 44: ...e metallic 697 Dark blue 347 Dove blue metallic 378 Indian red BOK Pebble grey metallic 693 6OM Slate metallic 220 Linen Apricot beige 548 Velvet red metallic 81L Murano green 22C Linen metallic 550 P...
Page 45: ...metallic 980 Black 700 Diamond blue metallic 697 Dark blue 347 Dove blue metallic 378 Indian red BOK Pebble grey metallic 693 Slate metallic 220 Linen 6OM Apricot beige Velvet red metallic 81L 548 Li...
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Page 48: ...id 2 21 Hexagon head screw M5 22 Washer A5 3 2 See adjusting rear spoiler Microswitch 23 1 24 25 Stud 1 Hexagon nut M5 1 26 Washer A 5 3 1 See adjusting rear spoiler Microswitch 1 27 Stud 1 Plate nut...
Page 49: ...Exterior Equipment 911 Carrera 4 Removing and Installing Rear Spoiler Printed in Germany 111 1989 66 4...
Page 50: ...47 in opening B of guide lever C on linkage 50 Spring Washer black Linkage 1 48 49 50 51 2 Pad 5 x 10 x18 5 52 Combination screw M 6 x 18 3 53 1 541 1 A 1 B Gearbox motor Sleeve for gearbox motor Tab...
Page 51: ...run in the spoil er until tab A of the arced tooth element 47 is disconnected in opening 8 of guide lever C Unscrew hexagon nut 25 Adjust the switching point of micro switch 27 on stud 28 Tighten hexa...
Page 52: ...ry 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 trans ported...
Page 53: ...supply of the airbag system and to guarantee that accidental ignition is not poss ible Electric leads of other electrical equipment items may not be routed in the vicinity of the I airbag wire harness...
Page 54: ...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...
Page 55: ...de in such a manner that the padded side faces up 2 Unscrew two mounting screws with a Torx T 30 screwdriver socket Note Screws must be replaced each time they are loosened Only use screws with a coll...
Page 56: ...o center position about 4 1 2 turns from left or right final stop prior to installation of the contact unit The precise center position is indicated by both arrows 3 Unscrew mounting screws 278 68 280...
Page 57: ...s Note Use a 1 4 inch socket to tighten the shear off nuts Mounting points on the body must show blank metal The installed position is given by installation Plugs are located at the left on the firewa...
Page 58: ...plugs on unit 283 68 Note The hexagon socket head screws are micro encapsulated Use new screws for installation Tightening torque 6 Nm 4 3 ft Ibs 282 68 4 Unscrew M 8 mounting bolt 5 Remove radio and...
Page 59: ...ic board 8 Unscrew shear off nuts with Special Tool 9259 5 Disconnect plugs for left crash sensor con tact unit right crash sensor and passenger s airbag unit as well as 2 pin and 6 pin plugs for the...
Page 60: ...metal console 1 Lateral acceleration sensor 2 Axial acceleration sensor 3 Connecting leads must not be mixed up Plug receptacles have different colors for identification Black plug receptacle for the...
Page 61: ...e tongue of the seat belt must be heard engaging in the belt lock The automatic reel must lock when the seat belt strap is pulled suddenly Additional Checking for Seat Belts with Overload Indicators T...
Page 62: ...s 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 sec...
Page 63: ...e Crash sensor left ground resistance excessive 25 Crash sensor right ground resistance excessive 26 Crash sensor left break in power supply lead 27 28 Crash sensor right break in power supply lead Cr...
Page 64: ...circuit 3 short against ground 49 Ignition pill circuit 1 break 50 Ignition pill circuit 2 break 51 Ignition pill circuit 3 break 52 Ignition pill circuit 1 resistance insufficient 53 Ignition pill c...
