Porsche 912E Manual de instrucciones

Workshop Manual

DR.

lNG.

PORSCHE AG

STUTTGART-ZUFFENHAUSEN

912

REPAIR

MANUAL

This repair manual describes

all

important operations for which special instructions are required to

assure proper

completion.

this

manual

essential

for

the shop foremen and mechanics,

who

need

this information to

keep

the vehicles in safe operating

condition.

The

basic safety rules,

course,

also apply to repairs on vehicles without

exception.

The

912 E Repair Manual only describes repair operations which differ from those

for

911 models;.

Refer to

the

911

Repair Manual

for

all

other

information.

The

information

grouped according to repair numbers, which

are

identical to the first two digits

the repair

time

and warranty

code.

The

repair group index and

alphabetical

index

are

quick guides to find information in

the

manual.

Descriptions

design and operation

can

found in service training course reference

material.

This repair manual will be kept

date

with workshop bulletins; the information

these

bulletins will be

made

part

the manual from

time

time.

recommend that the Workshop .

~ulletins

be filed in the special folder provided

for

this purpose.

REGISTRATION

SUPPLEMENTS

FILED

FOR

REPAIR

MANUAL

912

Please file the supplements according to the repair groups and

make

appropriate entries in

the

table

below.

Supplement No. Filing Date Signature

III

VII

VIII

XII

XIII

XIV

GENERAL

ENGINE

TRANSMISSION

CHASSIS

BODY

HEATING,

VENTILATION,

AIR

CONDITIONING

TRICS

Technical

Date

Page

0.1

REPAIR

GROUP

Engine

-crankcase

Engine-Crankshaft, and moving parts

Engine-Cylinder Head,

Valve

drive

Engine-Lubrication

Engine

-Cooling

Fuel Supply system

Fuel system, Fuel

Injection

Exhaust System

Starter, Power Supply

Ignition System

Clutch, Control

Mech.

gear-shift

system

-actuat.,

hous.

Mech.

gear-shift

system -Gears, Shafts

Differential

Front Wheel Suspension

Rear Wheel Suspension

Wheels, Tires, measuring

vehicle

Brakes, -Hydraulic -system

Steering

Body-Front

Section

Body-Center

Section

Body-Rear

Section

Lids

Doors

Sliding Roof

Bumpers

Glasses

Exterior

equipment

Interior

equipment

Heater

Air Conditioner

Instruments, Radio

Windshield Wipers and Washer

Exterior Lights

Interior Lights

Wiring

Anti-backfire Valve, Checking Operation

Auxiliary Air Regulator, Removing and Installing; Removing and

Installing Thermo

Time

Switch

Axle Alignment Data

Belt Tension, Checking and Adjusting; Removing and Installing

Fan and Fan Housing

Brake Disks, Checking and Machining

Camshaft, Checking and Installing

Centrifugal Advance Curve

Clutch Disk, Checking; Installing Clutch

Clutch Disk, Removing and Installing

Clutch -J?cploded View

Clutch Play, Adjusting

Clutch, Removing and Installing; Checking Clutch

Cold Start Valve, Checking; Checking Cold Start Valve for Leaks,

Temperature Sensor

Cooling System -Exploded View

Connecting

Rods,

Checking and Installing

Connecting

Rods,

Reconditioning

Control Unit, Removing and Installing; Removing and Installing

Cold Start Valve

·crankcase

a·nd

Flywheel -Exploded View

Crankshaft and Connecting

Rods,

Installation Notes

Crankshaft

End

Play. Adjusting

Crankshaft, Disassembling and Assembling

Crankshaft, Reconditioning

Crankshaft Seal, Removing and Installing

Current Flow Diagram

Cylinder and Pistons -Exploded View

Cylinder Head and Valves -Exploded View

Cylinder Head and Valves, Installation Notes

Cylinder to Piston Play, Checking; Piston and Cylinder Installation Notes

Distributor, Installing

Distributor Drive Shaft, Removing and Installing

Engine Carrier, Removing and Installing

Engine, Removing and Installing

Equipment Charts -Fuel System/Fuel Injection

Equipment Charts -Ignition

Exhaust System -Exploded View

Contents

Page

24-9

24-4

19-

47-

28 - 5

30 - 4 '

30 - 1

30 - 2

30 - 5

30 - 3

- 8

- 1

13-

-24

24-

13-

-12

13-

-22

13-

97 - 1

13-

-2

15-

13-

28 - 7

28 - 8

10 - 8

10 - 1

24 -

28 - 1

26 - 2

Exhaust System -Installation Notes; Checking Reactor

for

Leaks,

Checking f:GR'Operation, Removing and Installing

EGR

Valve

Flywheel,

Checking~

Checking and Assembling Crankcase

Fuel Filter, Removing and Installing

Fuel Pressure, Checking

Fuel Pump Delivery Rate, Checking; Fuel Pump Test Specifications

Fuel Pump, Removing and Installing

Idle, Adjusting

Ignition Timing. Adjusting

Ignition Timing Control,

~hecking

in Vehicle

Input Shaft Oil Seal, Removing and Installing

Intak

Air Sensor and Air Cleaner, Removing and Installing

Intake Air Sensor, Checking; Checking Throttle Valve Switch,

Checking Auxiliary Air Regulator, Checking Thermo

Time

Switch

Oil Circuit -Exploded View

Oil Pressure and Oil Pressure Switch, Checking

Oil Pump Housing and Cover, Oil Filter and Oil Pressure Switch,

Removing and Installing; Checking Oil Cooler

Piston, Checking; Checking Cylinder to Piston Play

Piston Marks; Checking Piston

Preassembled Crankshaft and Camshaft -Exploded View

Relays and Fuses, Location

Technical Data -Brakes, Hydraulics

Technical Data -Front .Wheel Suspension

Technical

Data -Manual Transmission

Technical

Data

-Rear

Wheel Suspension, Propeller Shaft

Technical

Data -Steering

Technical Data -Wheels, Tires, Axle Alignment

Temperature Sensor II, Removing and Installing; Removing and

Installing Pressure Regulator

Thermostat, Checking; Adjusting Control Flaps

Thermo

Time

Switch, Removing and Installing

Thermo

Time

Switch, Checking

Throttle Housing, Removing and Installing

Throttle Valve Switch, Removing and Installing

Transmission Case, Disassembling and Assembling

Vacuum Advance Curve

Valv.e Clearance, Adjusting

Valve Guides, Checking; Replacing Valve Guides

Valve Guides, Replacing

Valve Seats, Refacing

Valv~-

J:)P.C"'nnrli'H"'""""- n

...

,.,._,

....

contents

Page

26-4

13-

- 4

24-

20 -3

- 1

24-

28 - 3

28 -4

-1

24-

17-

17 - 7

17-

13-

13-4

90 - 1

47 -

40 -

30 -

42 -

48 -

42 -02

24-5

- 6

24-4

24 - 7

24-2

24 - 2

34-3

28 - 6

15 -10

- 8

15 -9

15.-

General

TECHNICAL

DATA

(Refer to

the

different repair groups for adjustment data and wear

limits.)

Engine

Bore

Stroke

Displacement

Compression

ratio

Horse power

SAE

Net

Printed in Germany

mm/in.

3 3

/in.

kW/HP

94/3.70

71/2.80

1971/120.3

7.6

: 1

64/86

engine speed

4900

rpm

Technical

nat:~

(;pnpr"l

General

Torque

SAE

Net

Horse power per

liter

SAE

Net

Max. engine speed

Max. cruising speed

Cutoff speed

speed

limiter

control unit

Engine weight with muffler (dry)

Engine

Design

Crankcase

Crankshaft

Crankshaft bearings

Connecting rods

Connecting rods bearings

Piston pin bushing

Pistons

Piston pins

Piston rings

Cylinders

Cylinder head

Valve

seat

inserts

Valve guides

Valve arrangement per cylinder

Exhaust Valves

Valve springs

Valve drive

Camshaft (021.109.101

Camshaft bearings

Camshaft drive

0.2

Technical

Data, General

Nm/ft

133/98

kW/HP

32.5/43.6

rpm ·5800

rpm 5000

rpm 5800

'!:

100

kg/lb

155/342

Light alloy, two

piece

Forged

4 plain bearings

Forged steel

engine speed

4000 rpm

Tri

-metal

plain bearing shells

Press

fit

steel bushing with lead/brass

bearing surface

Cast light alloy with steel insert

Floating type, locked by circlips

2 compression rings, 1 oil scraper ring

Special gray cast single cylinders

One per 2 cylinders, light alloy

Shrunk fit, annealed sinterred steel

Press fit, intake: special brass

exhaust: thermohedul

1 intake, 1 exhaust, parallel overhead

Sodium filled reinforced

seat

1 coil spring per valve

1 camshaft, followers, push rods and

rocker arms

Gray cast, 3 plain bearings

Steel

shells with white

metal

bearing surface

Bevel gears

Printed in

Germanv

Timing with 1

valve

clearance:

Ignition

Intake opens

Intake closes

Exhaustopens

Exhaust closes

Ignition coil

Speed

limiter

Ignition timing .

Firing order

Ignition control

Dwell angle

Spark plugs

·Electrode gap

Cooling

Engine

Fan drive

Crankshaft/fan ratio

Air delivery

rate

En g 1n e Lub

t i

Lubrication

Oil cooling

Oil filter

Oil pressure gauge

Max. oil temperature

Oil consumption

Emission

Control

Heater

Printed

Germanv

General

BTDC

ABDC

BBDC

ATDC

Battery ignition

12 volt

5800 -100 rpm

BTDC

3500 rpm

(vacuum hose disconnected)

1-4-3-2

CentrifuJal and vacuum

-50

M 14 x 1, 25 x 19,

heat

range 175

o. 7 mm (0.028

in.)

Air

cooled

Fan on crankshaft

1 : 1

800

1/sec

at 4600 rpm

crankshaft

Forced feed

gear pump

Oil cooler in fan air stream

Full

flow

Indicator

lamp

to red field

gt/600mi.

0.5

1.0

Air

injection, thermoreactor and

EGR

Warm air heater dependent on engine

temperature with

electric

blower. Heating

can

adjusted continuously with control

lever.

'T'orohn.:,...

....

n.........

...................

General

Fllel

system

Fuel delivery

Fuel

octane

Electrical

System

Battery voltage

Battery capacity

Battery capacity (optional extra)

Alternator output

Ignition

Ignition coil

Firing order

Ignition control

Dimensions

Length

Width

Height

Wheelbase

Track, front

Track, rear

Ground

clearance

Approach angle, front

limited

apron

Departure angle, rear

limited

apron

Weights

Curb weight

Max. total weight

Max.

axle

load, front

Max.

axle

load, rear

Payload

Max. roof load

incl.

luggage

carrier

0.4

·.

Technical

Data.

General

RON

AFC

fuel injection into

intake

manifold

Electric roller

cell

pump

(reg.

grade fuels)

980,

14 V (Bosch)

Battery ignition

12 V

Bosch

1-4-3-2

Centrifugal and vacuum

(DIN

Curb Weight)

mm/in.

4291/168.94

mm/in.

1610/63.39

mm/in.

1340/52.76

mm/in.

2271/89.41

mm/in.

1360/53.54

mm/in.

1330/52.36

mm/in.

180/7.10

(unloaded)

mm/in.

140/5.51

(with

max.

payload)

160 (with

max.

payload)

17°

(with

max.

payload)

(DIN

70020)

kg/lb

1160/2558

kg!lb

1400/3087

kg!lb 600/1323

kg!lb 815/1797

kg/lb

240/529

kg!lb

35/77

t...

.....

..:l

-----~-

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