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Description
Porsche 911 Workshop Manual 1970-1980 – PDF DOWNLOAD
FILE DETAILS:
Porsche 911 Workshop Manual 1970-1980 – PDF DOWNLOAD
Language : English
Pages : 1005
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Porsche 911 Workshop Manual 1970-1980 – PDF DOWNLOAD
This publication contains the essential removal, installation and adjustment procedures for the
Porsche 911 vehicles sold in the USA and Canada. Components and procedures described in this manual
are identical for all types unless differences are pointed out in the text.
- It is assumed that the reader is familiar with basic automotive repair procedures. Special tools required in performing certain service operations are identified in the manual and recommended for use.
- Use of tools or procedures other thanthose recommended in this repair manual may be detrimen~al to the vehicle’s safe operation as well as the safety of the person servicing the vehicle.
The Workshop Manual 911 – from model 1972 on – is subdivided into 10 Assembly Groups, delivered
in supplements to volume I and II.
General Information:
- Beginning with 1972 models, the oil tank is located in right rear wheelhousing in front of the rear axle.
The oil filler neck is now accessible from the outside. It is located under a hinged lid in the right rear
fender. The oil filter housing is separated from the tank and mounted on the right engine compartment
wall. - The auxiliary oil cooler under the right front fender continues to be standard equipment in Type 911S
vehicles.
TABLE OF CONTENTS:
Porsche 911 Workshop Manual 1970-1980 – PDF DOWNLOAD
INDEX......................................................................................................................... 4 GRP.1 (Engine & Clutch)................................................................................................... 3 ENGINE................................................................................................................ 4 DESCRIPTION....................................................................................................... 4 Engine changes 1972 model..................................................................................... 8 Oil tank changes 1972 model................................................................................... 10 Oil cooler system & oil circuit schematic..................................................................... 11 Oil cooler schematic 1973 model............................................................................... 12 Oil cooler schematic with cooling coil 1974 model............................................................. 13 Engine, Front view cross section.............................................................................. 14 Engine, Side view cross section............................................................................... 16 Specifications for 2.7 liter engine where differ from 2.4 liter engine........................................ 18 Engine changes 1974 model..................................................................................... 19 Cross section of engine with emission control equipment....................................................... 20 Layout of EGR system.......................................................................................... 21 Engine cross section with emission control 1978-1979 model.................................................... 22 Emission control layout 1980 model............................................................................ 23 TECHNICAL DATA.................................................................................................... 24 General data.................................................................................................. 25 Power performance curves...................................................................................... 30 Technical data type 911 T - Continuos injection system (CIS).................................................. 35 Technical data type 911/S/Carrera 1974 model.................................................................. 37 Full power performance 1974 model............................................................................. 40 Technical data - Type 911 S & Carrera 1975 model.............................................................. 42 Engine tightening data........................................................................................ 43 Technical data - Type 911 - 1976 model........................................................................ 45 Technical data - Type 911 S - 1977 model...................................................................... 47 Technical data - Type 911 SC - 1978 model..................................................................... 49 Technical data - Type 911 SC - 1980 model..................................................................... 51 Technical data - Type 911 SC - 1981 model..................................................................... 53 COOLING SYSTEM.................................................................................................... 55 Fan drive belt - Replacing / adjusting........................................................................ 55 EXHAUST SYSTEM & HEATING.......................................................................................... 56 Exhaust system & heater blower, Removing & installing......................................................... 56 Exhaust system 1978 model..................................................................................... 60 EMISSION CONTROL.................................................................................................. 61 Air injection components, removing & installing............................................................... 61 Air pump belt, tensioning..................................................................................... 64 Reactors & EGR equipment, removing & installing............................................................... 65 EGR system.................................................................................................... 69 Reactor, checking for leaks................................................................................... 70 EGR system, checking.......................................................................................... 71 Air injection system, checking................................................................................ 72 OIL CIRCULATION................................................................................................... 73 Oil tank, removing & installing............................................................................... 73 Oil tank, removing & installing - 1973 model.................................................................. 74 Auxiliary pressure relief valve, removing & installing........................................................ 75 Auxiliary pressure relief valve, disassembling & assembling................................................... 76 Oil cooler coil, removing & installing........................................................................ 77 Oil cooler, removing & installing............................................................................. 78 Oil tank, removing & installing - 1974 model.................................................................. 80 Pressure relief valve cooling coil, removing & installing - 1974 model........................................ 82 Pressure relief valve cooling coil, disassembling & assembling - 1974 model................................... 83 Oil cooler coil, removing & Installing - 1974 model........................................................... 84 Cooling coil oil lines, service installing - 1974 model....................................................... 85 Replacing oil lines to front oil cooler or to cooling coil.................................................... 87 Oil cooler, removing / installing............................................................................. 91 Auxiliary pressure relief / safety valves..................................................................... 92 CAMSHAFT HOUSING & CYLINDER HEAD.................................................................................. 93 Injection tube in camshaft housing, removing & installing..................................................... 93 Chain tensioner, overhauling.................................................................................. 95 Sealing cylinder head / camshaft housing mating surfaces...................................................... 101 Valve springs, installed length............................................................................... 102 Adjusting timing.............................................................................................. 104 CYLINDERS & PISTONS............................................................................................... 108 Piston changes - 1972 model................................................................................... 109 Piston & cylinder dimensions - 1972 model..................................................................... 111 Piston & cylinder dimensions - 1973 model..................................................................... 112 Piston & cylinder dimensions - 1974 model..................................................................... 113 "LS" cylinders & pistons, installation instructions........................................................... 114 Pistons & cylinders, measuring................................................................................ 115 Piston & cylinder sizes, 911 SC - 1978 model.................................................................. 117 Piston weight classes - 911 SC from 1981 models............................................................... 119 CRANKCASE & CRANKSHAFT............................................................................................ 120 Crankcase, measuring & reconditioning......................................................................... 120 Modified flywheel installation - 1978 model................................................................... 123 Flywheel with pilot bearing - 1980 model...................................................................... 124 Oil filter screen & suction plate, removing / installing...................................................... 125 CRANKSHAFT........................................................................................................ 126 Crankshaft changes - 1972 model............................................................................... 127 Crankshaft dimensions......................................................................................... 128 Connecting rod changes - 1972 model........................................................................... 129 Connecting rod weight groups.................................................................................. 130 Connecting rod weight groups - 1978 model..................................................................... 131 Pistons for injection engines................................................................................. 132 Modified crankshaft drive - 1978 model........................................................................ 134 Crankshaft specifications, standard & undersize - 1978 model.................................................. 139 CLUTCH............................................................................................................ 141 Clutch changes - 1972 model................................................................................... 141 Clutch free play, adjusting................................................................................... 142 Throwout bearing, removing & installing....................................................................... 145 Clutch - 1975 model........................................................................................... 146 Clutch modified - 1978 model.................................................................................. 147 GRP. 2 (Fuel System)...................................................................................................... 149 FUEL SYSTEM........................................................................................................... 149 DESCRIPTION....................................................................................................... 153 Fuel system changes - 1972 model.............................................................................. 153 Fuel injection pump changes - 1972 model...................................................................... 153 Throttle valve housing & intake manifold changes.............................................................. 154 Cold start enrichment system changes.......................................................................... 154 Fuel injection system, schematic.............................................................................. 155 Induction air preheating - 1972 model......................................................................... 156 Continuous injection system (CIS)............................................................................. 159 Engine cross section - 1974 model............................................................................. 169 Continuous injection system (CIS) - 1974 model................................................................ 170 Fuel evaporative control system............................................................................... 171 SYSTEM CHECKOUT................................................................................................... 173 General checkout procedure.................................................................................... 173 Visual inspection............................................................................................. 174 Initial checks................................................................................................ 175 Pressure tests................................................................................................ 177 Leakage checks................................................................................................ 181 Injection valve, checking..................................................................................... 182 Auxiliary air device, checking................................................................................ 183 (CIS) testing & adjustment specifications - 1974/75 models.................................................... 184 (CIS) testing & adjustment specifications - 1976/77 models.................................................... 186 (CIS) testing & adjustment specifications - 1978/79 models.................................................... 188 (CIS) testing & adjustment specifications - 1980 model........................................................ 189 Testing & adjusting values - 911 SC (1981 models with O2 sensor control)...................................... 190 Control pressure regulator (Vacuum - controlled), checking.................................................... 192 "Cold" control pressure (Vacuum - controlled control pressure regulator), checking............................ 194 Auxiliary air valve, checking................................................................................. 196 Safety switch, checking....................................................................................... 197 (CIS) problems & remedies..................................................................................... 199 Automatic choke, troubleshooting - 1976 model................................................................. 201 Thermovalve, checking......................................................................................... 198 Vacuum system layout - 1978 model............................................................................. 202 Vacuum hose layout - 1979 model............................................................................... 203 Fuel & vacuum lines layout - 1980 model....................................................................... 204 SERVICING......................................................................................................... 205 Regulator housing, removing & installing...................................................................... 205 Induction air preheating system, checking..................................................................... 205 Fresh air flap, adjusting..................................................................................... 206 Fresh air flap lever, replacing............................................................................... 207 Hose clamps for cold start enrichment, installing............................................................. 208 Fuel injection nozzles, checking.............................................................................. 209 (CIS), Dissasembling & assembling............................................................................. 213 Mixture control unit, removing & installing................................................................... 219 Throttle valve housing with control pressure regulator........................................................ 220 Control pressure regulator (warm running compensation), removing & installing................................. 221 Start (enrichment) valve, removing & installing............................................................... 222 Fuel filter, removing & installing........................................................................... 223 Fuel pressure accumulator, removing & installing ............................................................. 224 Injection valves, removing & installing...................................................................... 225 Plastic fuel lines, replacing................................................................................. 227 Fuel line system, bleeding.................................................................................... 229 Mixture control unit, dismantling & assembling................................................................ 230 Sensor plate, removing & installing......................................................................... 233 Air flow sensor housing, locating operating lever with follower............................................... 235 Mixture control screw basic adjustment after replacement of follower.......................................... 236 Fuel distributor pressure relief valve piston seal, replacing................................................. 237 Vacuum controlled (warm-up) control pressure regulator, removing & installing................................. 242 Auxiliary air valve, removing & installing................................................................... 244 Mixture control unit, dissasembling & assembling - modifications from April 1976.............................. 238 Thermovalve, removing & installing........................................................................... 245 Diverter valve, removing & installing........................................................................ 246 FUEL TANK......................................................................................................... 247 Fuel tank plug with (CIS) filter, cleaning.................................................................... 247 Fuel tank (80 liter), removing & installing - 1974 model..................................................... 248 FUEL PUMP......................................................................................................... 249 Fuel pump, removing & installing - 1976 model................................................................ 249 Layout drawings of check valves on fuel pumps................................................................. 251 Replacing check valve......................................................................................... 252 OXYGEN SENSOR..................................................................................................... 253 Oxygen sensor, removing & installing......................................................................... 253 Oxygen sensor control unit, removing & installing............................................................ 255 Frequency valve for oxygen sensor, checking................................................................... 256 Throttle valve switch, checking adjusting.................................................................... 257 Removing & installing microswitch for acceleration anrichment of oxygen sensor control ( from 1981 models).... 259 Correcting CO level setting on mixture control unit - (From 1981 models) with shear-off screw................. 260 ADJUSTMENT INSTRUCTIONS FOR F.I. SYSTEMS.......................................................................... 261 Fuel injection pump, adjusting with emission tester........................................................... 261 Idle, adjusting............................................................................................... 262 Microswitch, adjusting - 1972 model........................................................................... 264 (CIS) ADJUSTMENT INSTRUCTIONS................................................................................. 265 Idle, adjusting........................................................................................... 265 Full power position of throttle, adjusting................................................................ 267 Microswitch, adjusting.................................................................................... 268 Control pressure regulator (throttle valve position), checking & adjusting................................ 269 Hand throttle, adjusting.................................................................................. 270 Idle, adjusting - 1978 model.............................................................................. 271 Idle, adjusting - 1980 model.............................................................................. 275 Adjusting idle 911 SC - (from 1981models)................................................................. 278 GRP. 3 (Transmission & Differential)...................................................................................... 280 Description........................................................................................................... 281 Transmission, 5 speed overdrive................................................................................... 283 Transmission, 5 speed , power transfer............................................................................ 287 Transmission with oil pump, description........................................................................... 288 Transmission with oil pump, general info.......................................................................... 290 Type 915, Transmission - (1974 model)............................................................................. 293 Type 915, Transmission - (1975 model)............................................................................. 294 Type 915, Transmission - (1976 model)............................................................................. 295 Sportomatic, general.............................................................................................. 297 Sportomatic, power transfer....................................................................................... 302 Type 925, Sportomatic Transmission - (1974 model)................................................................. 303 Type 925, Sportomatic Transmission - (1975 model)................................................................. 304 Type 925, Sportomatic Transmission - (1976 model)................................................................. 307 Sportomatic 1977 models - general info............................................................................ 308 Technical data........................................................................................................ 309 Transmission diagrams, manual transmission........................................................................ 309 Tightening torques, manual transmission........................................................................... 309 Tightening torque values, transmission............................................................................ 312 General specifications, transmission.............................................................................. 313 Tolerances & wear limits.......................................................................................... 315 Transmission diagrams, manual transmission - (1974 model)......................................................... 317 General specifications, transmission - (1974 model)............................................................... 319 Transmission diagrams, manual transmission - (1975 model)......................................................... 321 General specifications, transmission - (1975 model)............................................................... 323 General specifications, transmission - (1976 model)............................................................... 324 Transmission diagram 915/44....................................................................................... 325 Transmission diagram 915/49....................................................................................... 326 Transmission diagram, 925/01 sportomatic transmission............................................................. 327 General data - sportomatic transmission........................................................................... 328 Tightening torques, sportomatic transmission...................................................................... 329 Transmission diagram, 925/02 sportomatic transmission............................................................. 331 General specifications, sportomatic (1974 model).................................................................. 332 Transmission diagram, 3 speed sportomatic 925/10 (1975 model)..................................................... 333 General specifications, 3 speed sportomatic 925/10 (1975 model)................................................... 334 Specifications, 3 speed sportomatic 925/09, 012, 013.............................................................. 335 Transmission diagram, 3 speed sportomatic (1976 model)............................................................ 336 Special tools......................................................................................................... 337 Transmission, 5 speed manual.......................................................................................... 338 Transmission, removing & installing............................................................................... 338 Seal ring for drive shaft, dismantel & reinstall.................................................................. 350 Selector forks, adjust............................................................................................ 352 Transmission front cover, dissasembling & assembling.............................................................. 354 Oil pump in front cover, dissasembling & assembling............................................................... 358 Gear housing, dissasembling & assembling.......................................................................... 363 Transmission housing, dissasembling & assembling.................................................................. 368 Oil lines for supplemental lubrication system, remove & install................................................... 376 Transmission housing with guide tube for throwout bearing......................................................... 377 Transmission case with bolted guide tube for release bearing...................................................... 385 Dissasembling & assembling transmission case with servo clutch (1977 model)....................................... 391 Input shaft, dissasembling & assembling........................................................................... 398 Pinion shaft, dissasembling & assembling.......................................................................... 405 Synchronization, dissasembling & assembling....................................................................... 411 Dissasembling & assembling synchronization (1977 model)........................................................... 415 Transmission, sportomatic............................................................................................. 416 Torque converter housng, dissasembling & assembling............................................................... 417 Transmission, removing & installing............................................................................... 420 Transmission front cover, dissasembling & assembling............................................................. 429 Intermediate plate, dissasembling & assembling................................................................... 434 Input shaft (3 speed sportomatic) dissasembling & assembling..................................................... 441 Pinion shaft (3 speed sportomatic) dissasembling & assembling.................................................... 446 Checking clutch play (1976 model)................................................................................. 450 Checking control valve adjustment (1976 model).................................................................... 451 Differential, (Manual transmission)................................................................................... 453 Differential, removing & installing............................................................................... 453 Differential, dissasembling & assembling.......................................................................... 457 Differential with electronical speedometer........................................................................ 462 Tools............................................................................................................. 463 Dissasembling & assembling instructions........................................................................... 466 Ring & pinion gear, adjusting - general info...................................................................... 468 Ring & pinion gear, adjusting..................................................................................... 470 Pinion shaft, adjust with universal setting gage VW 385........................................................... 479 Differential, (Sportomatic transmission).............................................................................. 484 Ring & pinion gear, adjusting - general info...................................................................... 484 Ring & pinion gear, adjusting .................................................................................... 485 GRP. 4 (Front Axle)....................................................................................................... 486 DESCRIPTION........................................................................................................... 488 Front axle changes, from (1972 MODEL)............................................................................. 488 卥汦敶敬楮朠桹摲潰湥畭慴楣畳灥湳楯渠獴牵琬灥牡瑩潮敮敲慬畴汩湥.............................................................................. 489 Operation of the Self - leveling hydropneumatic suspension KONI suspension struts................................. 490 Cross-section of the Self - leveling hydropneumatic suspension KONI suspension struts............................. 492 TECHNICAL DATA........................................................................................................ 488 Technical data.................................................................................................... 493 Technical data, (1974 models)..................................................................................... 494 Technical data, (1975 models)..................................................................................... 495 Tightening torque values.......................................................................................... 497 FRONT WHEEL ALIGNMENT................................................................................................. 499 General........................................................................................................... 499 Sample wheel alignment card....................................................................................... 499 FRONT AXLE............................................................................................................ 500 Dissasembling & reassembling...................................................................................... 500 Self - leveling hydropneumatic suspension struts, check........................................................... 504 Aluminium auxiliary supprot, carrera 2.7.......................................................................... 505 Disassembly & reassembly of stabilizer (1974 models).............................................................. 506 Instructions for removal & installation........................................................................... 509 Shock absorber / spring struts, USA models installation instructions.............................................. 510 STEERING WHEEL & STEERING WHEEL COLUMN................................................................................ 512 Steering wheel.................................................................................................... 512 Steering shaft, disassemble & reassemble, beginning with (1974 models)............................................ 511 Instructions for disassembly & reassembly......................................................................... 516 GRP. 5 (Rear Axle)........................................................................................................ 518 DESCRIPTION........................................................................................................... 520 Rear axle changer, beginning with (1972 model).................................................................... 520 TECHNICAL DATA........................................................................................................ 521 General specifications............................................................................................ 521 Technical data from (1974 model).................................................................................. 522 Technical data from (1975 model).................................................................................. 523 Technical data from (1976 model).................................................................................. 524 Tightening torques................................................................................................ 525 REAR WHEEL ALIGNMENT.................................................................................................. 526 General information............................................................................................... 526 Wheel alignment data chart........................................................................................ 526 REAR AXLE............................................................................................................. 527 Dismantle & reinstall rear axle control arms from (1974 model).................................................... 527 Instructions for disassembly & reassembly......................................................................... 532 Checking parts.................................................................................................... 533 AXLE DRIVESHAFTS...................................................................................................... 536 Axle driveshafts, lighter version................................................................................. 536 GRP. 6 (Brakes - Wheels & Tyres).......................................................................................... 537 TECHNICAL DATA........................................................................................................ 539 General data...................................................................................................... 539 Tightening torques, front & rear brakes........................................................................... 541 BRAKE BOOSTER, MASTER CYLINDER........................................................................................ 544 Removing & installing brake booster............................................................................... 544 Disassembling brake booster & brake master cylinder partially..................................................... 548 Checking brake booster............................................................................................ 551 WHEELS & TYRES........................................................................................................ 553 Summary........................................................................................................... 553 Checking steel - disc wheel....................................................................................... 553 Mounting instructions............................................................................................. 554 Instructions for installation of adhesive weights in light alloy wheels........................................... 554 Balancing wheels.................................................................................................. 554 Collapsible spare tyre............................................................................................ 555 Standard wheels & tyres, overview, from (1973 model).............................................................. 557 Standard wheels & tyres, overview, from (1975 model).............................................................. 559 GRP. 7 (Manual & Pedal Controls).......................................................................................... 563 TECHNICAL DATA........................................................................................................ 565 Tightening torques................................................................................................ 565 MANUAL CONTROLS....................................................................................................... 566 Gear shift linkage, disassemble & reassemble...................................................................... 566 Gear shift linkage, adjust........................................................................................ 578 Notes for disassembly & reassembly................................................................................ 570 Gear shift linkage, disassemble & reassemble, from (1973 models).................................................. 572 Instructions for disassembly & reassembly......................................................................... 576 HEATER & HAND CONTROLS FROM (1975 MODELS)............................................................................. 579 Dismantling & assembling heater & hand throttle controls.......................................................... 579 Removing & installing heater & hand throttle controls............................................................. 580 Adjusting heater controls......................................................................................... 583 Adjusting hand throttle control................................................................................... 584 Heater blower switch, remove & install............................................................................ 585 PEDAL CONTROLS........................................................................................................ 586 Pedal controls, disassemble & reassemble.......................................................................... 586 Notes for disassembly & reassembly................................................................................ 590 Disassembly & reassembly of pedal controls (1974 models).......................................................... 591 Instructions for disassembly & reassembly......................................................................... 596 Adjusting clutch.................................................................................................. 597 Adjusting clutch from (1977 models) (with servo clutch on transmission)........................................... 599 GRP. 8 (Body)............................................................................................................. 601 DESCRIPTION........................................................................................................... 605 Body modifications - (1972 model)................................................................................. 605 Body modifications - (1973 model)................................................................................. 606 Body modifications - (1974 model)................................................................................. 607 BUMPERS............................................................................................................... 608 Front spoiler - 911 S............................................................................................. 608 Bumper, removing & installing (1973 model)........................................................................ 609 Front bumper, (1974 model)........................................................................................ 614 Rear bumper, (1974 model)......................................................................................... 618 Front spoiler, installing......................................................................................... 622 HOODS & LIDS.......................................................................................................... 623 Front hood lock, removing & installing............................................................................ 623 Hood, opening with broken cable................................................................................... 624 Rear lid with spoiler............................................................................................. 626 DOORS................................................................................................................. 627 Inner door fittings, removing & installing (1974 model)Front bumper, (1974 model)Front bumper, (1974 model)....... 627 Door stop, removing & installing ................................................................................. 629 Ridge filler, installing.......................................................................................... 630 Door shell preparation for remote control outside mirror.......................................................... 631 New door lock controls, service installing........................................................................ 633 Door window lift channel, installing.............................................................................. 634 Electric window regulators, removing & installing................................................................. 635 Electric cross arm window controls, (1980 models)................................................................. 639 Electric cross arm window controls, service installing............................................................ 640 Adjusting door window - targa..................................................................................... 643 ROOF.................................................................................................................. 644 Folding roof modifications, (1974 model).......................................................................... 644 Folding roof lock pin, service installing........................................................................ 645 Hardtop roof...................................................................................................... 648 Folding top to hardtop, switching................................................................................. 651 INTERIOR FITTINGS..................................................................................................... 676 Interior mirror, installing....................................................................................... 676 Targa roof adjustment, (1970 model)............................................................................... 678 Top wind deflector strip modifications............................................................................ 680 Three point belt with automatic retractor & warning system, removing & Installing................................. 681 Electric window regulator, removing & installing.................................................................. 689 Seat, installing - (1973 model).................................................................................. 693 EXTERIOR FITTINGS..................................................................................................... 695 Oil tank filler lid & control, removing & installing.............................................................. 695 Rocker panel cover, removing & installing......................................................................... 696 End plate, removing & installing.................................................................................. 697 Carrera emblems................................................................................................... 699 Outside mirror with defogger & remote control, removing & installing.............................................. 701 Exterior mirror on passenger's door, service installing........................................................... 704 REFERENCE DIMENSIONS FOR REPAIRS...................................................................................... 707 Repair dimensions (1972 model).................................................................................... 707 REPAIRS............................................................................................................... 708 Rear axle cross tube rust prevention.............................................................................. 708 Galvanized sheet metal instructions (1976 model).................................................................. 709 Rear axle cross tube, checking alignment.......................................................................... 708 PAINTING.............................................................................................................. 712 Paints (1972 model)............................................................................................... 712 Paints (1974 model)............................................................................................... 714 Paints (1976 model)............................................................................................... 715 Paints (1978 model)............................................................................................... 716 Range of body colours (1981 models)............................................................................... 718 METALLIC PAINTS....................................................................................................... 712 Metallic paint - wey on wet method................................................................................ 719 Targa roll bar cover, painting.................................................................................... 720 BODY REPAIRS.......................................................................................................... 721 Front body........................................................................................................ 721 Extra attachment for economical repair of front end damage........................................................ 737 Universal anchor ENS 937.900...................................................................................... 743 Cobra 3 straightener with accessories............................................................................. 745 REAR BODY............................................................................................................. 746 GRP. 9 (Electrical System)................................................................................................ 755 DESCRIPTION........................................................................................................... 756 Ignition distributor, current flow diagrams....................................................................... 759 Wiring diagrams................................................................................................... 765 Current flow diagrams............................................................................................. 776 Relays & fuses.................................................................................................... 861 Lighting.......................................................................................................... 865 Alternator - (1975 model)......................................................................................... 866 Ignition system modifications - (1978 model)...................................................................... 867 TECHNICAL DATA........................................................................................................ 756 Starter........................................................................................................... 869 STARTER............................................................................................................... 756 Disassembling & assembling........................................................................................ 870 Removing & installing............................................................................................. 874 LIGHTING EQUIPMENT.................................................................................................... 875 Headlights (sealed beam). replacing............................................................................... 875 Headlights, adjusting............................................................................................. 875 Fog lamps & tail lamps............................................................................................ 876 WINDSHIELD WIPER & WASHERS............................................................................................ 881 Disassembling & assembling........................................................................................ 881 Adjustment instruction........................................................................................ 875 Removing & installing......................................................................................... 882 Water reservoir for windshield wiper switch....................................................................... 883 Removing & installing......................................................................................... 883 Intermittent windshield washer system............................................................................. 884 Removing & installing......................................................................................... 884 INSTRUMENTS & CONTROL SYSTEM.......................................................................................... 885 Emission controls................................................................................................. 885 E.G.R. Control................................................................................................ 885 Speedometer....................................................................................................... 887 Speedometer cable, removing & installing...................................................................... 887 Electronic speedometer........................................................................................ 889 ELECTRICAL ACCESSORIES................................................................................................ 885 Description....................................................................................................... 891 Safety belt warning system.................................................................................... 891 Control illumination.......................................................................................... 895 Headlight washer.............................................................................................. 896 Safety belt warning system........................................................................................ 897 Removing & installing......................................................................................... 897 Troubleshooting............................................................................................... 904 Control illumination.............................................................................................. 905 Bulb replacement.............................................................................................. 905 Headlight washers................................................................................................. 907 Removing & installing......................................................................................... 907 Adjusting specifications...................................................................................... 909 Service installation.......................................................................................... 910 Automatic heating control......................................................................................... 915 Removing & installing......................................................................................... 915 Troubleshooting............................................................................................... 921 Disassembling & assembling.................................................................................... 918 Automatic speed control........................................................................................... 923 Removing & installing......................................................................................... 923 Troubleshooting............................................................................................... 926 Removing & installing automatic antenna....................................................................... 927 911 Alarm system.............................................................................................. 929 Battery........................................................................................................... 935 Removing & installing......................................................................................... 935 Ignition.......................................................................................................... 937 Spark plug chart.............................................................................................. 937 Equipment tables - (1980 model)............................................................................... 940 Ignition leads................................................................................................ 942 Ignition distributor.............................................................................................. 943 Adjusting..................................................................................................... 943 Testing instructions.......................................................................................... 947 Ignition timing, adjusting - (1977 model)..................................................................... 955 Ignition timing curves, (1978 model)......................................................................... 957 Ignition timing, adjusting - (1980 model)..................................................................... 959 Ignition retard/advance, checking - (1980 model).............................................................. 960 GRP. 0 (Maintenance Specifications)....................................................................................... 965 TECHNICAL DATA........................................................................................................ 967 Engine............................................................................................................ 967 Fuel system....................................................................................................... 971 Electrical system................................................................................................. 972 Transmission & final drive........................................................................................ 975 Chassis........................................................................................................... 977 Capacities........................................................................................................ 981 Dimensions........................................................................................................ 981 Weights........................................................................................................... 982 Performance data.................................................................................................. 983 Specification changes from (1973 model)........................................................................... 984 Carrera 2.7 specifications........................................................................................ 985 Specifications for - (1974 models)................................................................................ 988 Filling capacities............................................................................................ 988 Dimensions.................................................................................................... 988 Weights....................................................................................................... 989 Performance................................................................................................... 989 TECHNICAL DATA (1981 MODEL)........................................................................................... 998 MAINTENANCE...........................................................................................................1000 Service schedule..................................................................................................1000 Lubrication schedule..............................................................................................1001 Preventive maintenance schedule...................................................................................1002 Main Index.................................................................................................................... 0
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