Porsche 924 (1976-1988) - Workshop Manual - Wiring Schematics - Parts Manual

PORSCHE 924 - WORKSHOP MANUAL - SERVICE MANUAL

- English Workshop Manual, Wiring Schematics and Spare Parts Catalogue to vehicles Porsche 924.

INDEX:

-WORKSHOP MANUAL 1982 (1113 pages)

CAR, LIFTING
Technical data, general
ENGINE/CRANKCASE
Alternator belt, checking and adjusting
Engine, removing and installing
Tightening torques
Tolerances and wear limits
Tools
ENGINE, CRANKSHAFT, PISTONS
Bearing caps - location
Bearing sleeve, removing and installing
Connecting rod bearing play, checking
Connecting rod, removing and installing
Crankcase and crankshaft, disassembling and assembling
Crankcase - tools
Crankshaft bearing play - checking
Crankshaft seal, removing and installing: Flywheel end
Pulley end
Crankshaft sizes
Flywheel, removing and installing Gear ring, replacing
Needle bearing; removing and installing
Oil pump drive, installing
Oil pump, removing and installing
Piston and connecting rod, disassembling and assembling
Piston and cylinder bore, checking
Piston, removing and installing
Piston rings, removing and installing/checking
Tools
ENGINE/CYLINDER HEAD, VALVE DRIVE
Camshaft, checking
Camshaft, removing and installing
Camshaft seal, removing and installing
Cylinder head, machining
Cylinder head, removing and installing
Cylinder head, removing and installing (1980 model)
Cylinder head tools
Distributor drive gear, removing and installing
Drive belt, installing
Tappets, marking
Tools
Valve adjusting screw, tightening
Valve drive, disassembling and assembling
Valve guides, checking
Valve guides, replacing
Valve play, checking and adjusting
Valve seats, machining
Valve sizes
Valves, machining and grinding
Valve springs, removing and installing
Valve stem seals, replacing
ENGINE/LUBRICATION
Lubrication system parts, removing and installing
Oil dipstick guide tube, installing
Oil filter, removing and installing
Oil pressure and oil pressure switch, checking
Tools
General
4- speed manual transmission 088/A
5- speed manual transmission 016 Y
5-speed manual transmission 016/9 - 1980
5-speed manual transmission 016/9 - 1981
Automatic transmission (refer to page 37 - 01)
CLUTCH/CONTROLS
Clutch, adjusting
Clutch, removing and installing (Type 088/A)
Clutch, removing and installing (Type 016 Y)
Clutch, removing and installing (Type 016/9)
Clutch controls, repairing
Clutch disc, removing and installing
Clutch pressure plate, checking
Drive plate, checking
Release bearing, removing and installing
Release lever, repairing
Technical data
Tightening torques Tools
TORQUE CONVERTER
Converter, checking Converter, draining
Converter drive plate support assembly, removing and installing
Converter, installing
Converter oil seal, removing and installing
MANUAL TRANSMISSION/CONTROLS, CASE
Differential, removing and installing
End plate, disassembling and assembling
End plate, disassembling and assembling (Type 016/9)
End plate, replacing
Final drive case, disassembling and assembling (Type 016 Y)
Flange shaft seal, replacing
Front transmission cover, disassembling and assembling (Type 016 Y)
Gearbox, disassembling and assembling
Gearbox, disassembling and assembling (Type 016 Y)
Gearbox, disassembling and assembling (Type 016/9)
Gearbox, removing and installing
Gearbox, removing and installing (Type 016/9)
Rear transmission cover, disassembling and assembling (Type 016/9)
Shift linkage, adjusting
Shift linkage, adjusting (Type 016/9)
Shift linkage, disassembling and assembling (Type 016 Y)
Transmission case, disassembling (Type 016 Y)
Tools
Final drive housing, disassembling and assembling (Type 016/9)
Final drive housing, repairing
Transmission, disassembling and assembling
Transmission, removing and installing
Transmission, removing and installing (Type 016 Y)
Transmission, removing and installing (Type 016/9)
MANUAL TRANSMISSION/GEARS, SHAFTS
Synchromesh rings, checking
Synchronization, disassembling and assembling (Type 016 Y)
AUTOMATIC TRANSMISSION/CONTROLS, CASE
Cables for throttle and control pressure, adjusting
Cable for throttle and control pressure, adjusting (from 1979 model)
Cable for throttle and control pressure, removing and installing (from 1979 model)
Cutaway drawing
Operation, checking
Selector lever cable, adjusting
Selector lever cable, removing and installing
Technical data
Tightening torques
Transmission, removing and installing
Troubleshooting
FRONT WHEEL SUSPENSION
Ball joint installed in car, checking
Ball joint, replacing
Control arm installed in car, checking
Spring strut, disassembling and assembling
Technical data
Tightening torques
Wheel bearings, disassembling and assembling
Wheel suspension, disassembling and assembling
REAR WHEEL SUSPENSION, AXLE SHAFT
Axle shaft, disassembling and assembling
Information on disassembling and assembling axle shaft
Rear axle, removing and installing (from 1978 model)
Technical data
Tightening torque
Tools
Trailing arm, disassembling and assembling
Wheel suspension, disassembling and assembling
Wheel suspension, disassembling and assembling (from 1978 model)
WHEELS, TIRES, AXLE ALIGNMENT
Drive pinion, disassembling and assembling
Drive pinion, disassembling and assembling (Type 016 Y)
Drive pinion, disassembling and assembling (Type 016/9)
Input shaft, disassembling and assembling
Input shaft, disassembling and assembling (Type 016 Y)
Input shaft, disassembling and assembling (Type 016/9)
Axle alignment
Axle alignment information
Axle alignment specifications
Collapsible wheel 924, 944, 924 Turbo
General tire mounting information
Rear axle (up to 1978 model)
Rear axle (from 1978 model)
Technical data Wheels, balancing
Wheel bolts for rims.
Wheel rims/bolts/nuts 924, 944, 924
Turbo Wheel rims, checking
BRAKES/MECHANICAL
Brake pedal, removing and installing
Brake push rod, adjusting (to end of 1979 model - 7"brake booster)
Brake push rod, adjusting (from 1980 model - 9" brake booster)
Front brake pads, removing and installing
Front wheel brakes, disassembling and assembling
Parking brake, adjusting
Parking brake lever, disassembling and assembling
Rear wheel brakes, disassembling and assembling
Stop light switch adjustment, checking (from 1981 model)
Technical data
Tightening torques
BRAKES/HYDRAULICS
Bleeding brakes and changing brake fluid
Brake booster, checking
Brake booster, removing and installing
Brake caliper, disassembling and assembling
Tightening torques
STEERING
Information on removing and installing steering column and tube
Steering column and casing tube, removing and installing
Steering gear, removing and installing
Technical data Tightening torques
BODY/GENERAL
Celette straightening bench
Cobra 3 straightening unit with accessories
Dimensions for floor assembly
Repair control dimensions
Repairing galvanized sheet metal parts
Special tools and shop materials for body repairs
Universal anchorage ENS 937.900
FRONT BODY SECTION
Front body section damage, repairing
Gauge for lock member Modifications on side members
Template and welding gauges 9112/9175 for front body section
Template 9120 for windshield
REAR BODY SECTION
Modification on rear side panels
New rear body section parts, installing in cars before 1980 model
Rear body section damage, repairing
Reinforcement brackets on rear apron, installing
Side panel (complete fender), repairing
Template for rear window
LIDS
Lid lock, removing and installing
Rear lid and seal, removing and installing
Water trap on lid lock, service installing
DOORS
Door lock and inside control, removing and installing
Door outside handle, removing and installing
Door, removing and installing
Door trim panel, removing and installing
Door window and regulator, removing and installing
Electric outside mirror, removing and installing
Electric outside mirror, service installing
Electric window controls, removing and installing
Manual control outside mirror, removing and installing
Modifications on electric window controls
Outside mirror, installing on passenger's door
Outside mirror, removing and installing
Window guides, removing and installing
HARDTOP
Stay in removable roof, service installing
Straps for removable roof, service installing
BUMPERS
Bumper, removing and installing
Hole pattern for spray jets in USA absorber bumper, drilling
Bumper, disassembling and assembling (front)
Bumper, disassembling and assembling (rear)
WINDOWS
Windshield, removing and installing
INTERIOR LIGHTS
Bulb survey chart
Oil pressure gauge light
WIRING
Central relay/fuse plate, removing and installing
CIS wire harness, removing and installing
Current flow diagrams
Extra wire harness for air conditioner
Extra wiring diagram for air conditioner
Ground points on car
Tools for removal of plugs
Wiring diagram symbols and explanations



 
    -PARTS CATALOG 1976-1988 (1056 pages)
 
MAIN GROUP 0: ACCESSORIES AND OTHERS
001: Tools, Stickers
002: Inst Set, Snow Chains, Rack Roof System
003: Radio, Loudspeaker, Antenna
004: Lacquers
005: Securing Liquid, Sealing Compound
MAIN GROUP 1: ENGINE
101: Replacement Engine, Crankcase
102: Crankshaft
103: Cylinder Head, Camshaft, Valve
104: Engine Lubrication
105: Water Cooling
106: Air Filter System
107: K-Jetronic, Supercharging
109: Engine Suspension
198: Repair Kits
MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM
201: Fuel System, Tank, Etc.
202: Exhaust System, Muffler, Turbo Charger
298: Repair Kits
MAIN GROUP 3: TRANSMISSION
301: Central Tube, Clutch
302: Replacement Transmission, Transmission Case
303: Gear Sets, Shafts
304: Transmission Control
305: Differential
306: Transmission Suspension
307: Central Tube, Automatic Transmission
308: Replacement Transmission
309: Transmission Case, Automatic Transmission
310: Shift Mecanism, Automatic Transmission
311: Differential, Automatic Transmission
312: Transmission Suspension, Automatic Transmission
398: Repair Kits
MAIN GROUP 4: FRONT AXLE, STEERING
401: Cross Member, Track Control Arm, Steering Knuckle
402: Springs, Shock Absorber, Stabilizer
403: Steering
MAIN GROUP 5: REAR AXLE
501: Rear Axle
502: Stabilizier, Vibration Damper
MAIN GROUP 6: WHEELS. BRAKES
601: Wheels
602: Disk Brake, Front
603: Brake, Rear
604: Brake Master Cylinder, Reservoir Brakeservo
698: Repair Kits
MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER
701: Shift Mecanism, Hand Brake Lever
702: Pedal System
MAIN GROUP 8: BODY
801: Body, Frame, Interoir And Exterior Panelling
802: Bumper
803: Cover
804: Doors
805: Glasses
806: Concealing Headlamps
807: Linings, Carpet
808: Seats
809: Dashboard, Rear-View-Mirror, Center Console, Etc.
810: Insignias, Trim Frame
811: Lifting Roof
812: Seat Belt
813: Ventilation, Heating, Air Conditioner
898: Repair Kits
MAIN GROUP 9: ELECTRICAL EQUIPMENT
901: Electrical Equipment-Engine
902: Alternator, Starter, Battery, Harnesses
903: Switch, Fuse Box, Relay, Horn
904: Windshield Wiper System, Headlight Washer System
905: Headlamp, Electrical Motor, Concealing Headlamps
906: Instruments
910: Electric Fan
998: Repair Kits
MSP-PAGES
V-PAGES

BUY HERE