Workshop Manual A Carrovn Ff Dr. Ing. h.c. F. Porsche Aktiengesellschaft911 Carrera 4 Structure of the Workshop Manual Structure of the Workshop Manual This Workshop Manual describes all of the Important operations for which special instructions are re- quired to ensure proper completion.This manual Is essential for shop foremen and mechanics who need this information to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply to all repairs on vehicles, without exception. Breakdown of the Workshop Manual Overview of repair groups Record sheet for supplements List of contents Technical data Repair groups oe en Breakdown of the repair groups 1. Table of tightening torques 2. Special tools required 3. Exploded diagrams 4. Legends for the exploded diagrams 5. Notes on assembly/application of special tools 6. Diagnosis for the repair groups The Workshop Manual will be updated regularly by means of supplements which must be filed imme- diately to maintain the usefulness of the manual. Appropriate entries must be made in the record sheet to prove that the manual is complete. The content of this Workshop Manual will be supplemented with Technical Information Bulletins, which will be integrated into the manual from time to time. Descriptions of design and function can be found in the service training course reference material. ‘Structure of the Workshop Manual Printed in Germany ~ 1988Structure of the Workshop Manual 911 Carrera 4 Layout of the exploded diagram a) 3a © erm can ©, Disassembling and assembling transmission 10 Flt hed crow 2 Tate wat 10 omy 1+ | uae : ‘ing he ge a riage 9) 19 | tary ssa ' (ero postion tn Spots To ase Pack | popes) | Gomes 14 | seer save 1 | ruta ae: | Pra tn Socal | tara pibe fog Semen Te | rey Impressum, supplement number, year of printing Diagram item number in the order of disassembling Special notes to be observed when installing or removing A - Repair group, numbers B - Repair groups, text C - Type of vehicle to repaired D - Page number E - Operation F G H- The notes on assembly/application of special tools which are given after the exploded diagram are always arranged in the order of text > diagram. Structure of the Workshop Manual Printed in Germany ~ 1988List of Repair Groups Carrera 4 General Technical Data Page 0.1 Repair Groups Group Volume 1 Maintenance, Self-diagnosis 03 Engine, Crankcase, Suspension 10 Engine, Engine, Crankshaft, Pistons 13 Maintenance Engine, Cylinder Head and Valve Drive 45 Engine, Lubrication 17 Engine, Cooling 19 Fuel Supply 20 Fuel System, Electronic Injection 24 Exhaust System/Emission Controls 26 Starter, Power Supply, Cruise Control 27 Ignition System 28 Diagnosis Volume II Clutch, Controls 30 Clutch 32 Transmission Manual Transmission, Controls, Case 34 (manual) Manual Transmission, Gears, Shafts 35 Differential, Transaxle System, All-Wheel Drive 39 Diagnosis Clutch, Controls 30 Volume It Torque Converter 32 Automatic Transmission, Controls, Case 37 Transmission Automatic Transmission, Gears, Shafts 38 (automatic) Differential, Transaxle System 39 Diagnosis Volume IV Front Wheel Suspension 40 Rear Wheel Suspension, Axle Shaft 42 Chassis Wheels, Tires, Alignment 44 Antiblock System 45 Brakes, Mechanical 46 Brakes, Hydraulics, Regulator, Booster 47 Steering 48 Diagnosis Volume VI Body-Front Section 50 Body-Center Section 51 Body Body-Rear Section 53 lids 55 Doors 57 Electric Sunroof 60 Hardtop. 61 Bumpers 63 Glasses, Window Control 64 Exterior Equipment 6 Interior Equipment 68 Seats 72 Seat Covers 74 Volume VI Heater 80 Ventilation 85, Heating, Ventilation, Air Conditioner a7 Air Condition Diagnosis Electrics Instruments, Fuel Gauge, Alarm System 90 Radio, Telephone, On-board-computer 91 Windshield Wipers and Washer 92 Exterior Lights, Lamps, Switches 94 Interior Lights 96 Diagnosis Volume Vil Wiring 97 Electrics Wiring Diagrams Printed in Germany, 1988Survey of Information Published in Technical Manual beginning in 1985 1 (sl | [8 | || |S) Remarks, | TY! er =| Model, el No. 15 5| || Also refer to. | Date 1985 | — Oil Pump with Intake Plate T 1/85 ‘© | New version 9 04.85 and Filter Screen | | | | = Camshaft Sprocket ja] | 1/85| @| | @| Threads not lubricated |10.04.85, Installation ie | with oil ~ Engine Carrier/Engine Mounts Q | 2/85 al © | Optimoly HT 07.06.85, ~ Scrapping Exhaust Valves ja} | s/s | || Sodium filled valves 1.08.85 | 4 1986 I] ] = Thermo Valve | 1/86 © Hose routing 18.04.86 Temperature Switch | | ~ Leakage Q | 2/86 @| 1987 Models on * 06.86 Lower Valve Cover Gasket | Oil Pressure Swith Ql) | 36 1984 Models on |07.07.86 Oil Pressure Warning Lamp Flickers | | — New Nuts and New Cylinder Te | 1/96 @ | Torque angle 30.12.86 Head Tightening Specifications | | | | ~ Modification on Bypass Valve T, | 206] |e | [Noise 130.12.86 | jet | tatees| fea] T 1987 see Fe | ~ Oil Pipes |Q) | 87 @| | @/1987 Modelteakage 18.06.87 Chain Tensioner | | | | | | | | al 1 1988 || | | tes | be 1989 fe) il | ~ Additional Sealing on Crankcase It} | yo! e| | @/ stastic 732 ATV 22.05.89, | | ~ Protection and Conservation Agent T 2189 © Type 959: VW-Part No.: 31.05.89 for Engines / Type 959 | AKR 320 KD 604 = Thightening Torque of Conrod Nuts bE | 3/89} @ @| | @|New grade 12.9: 15 Nm 20.12.89 | | and 2 x 90° | | — Camshaft housing cover T| | ole Additional washers: 28.02.90 6,2x20x4 (aluminium) | | | | | 1 1990 | | | | | | | | | ‘$ = Conversion instructions or workshop campaign z V= Brochure ®= Supplement or change for TVA! SERVICE Copyright by Dr. Ing. h. e. F. Porsche Aktiengeselischaft Printed in Germany 1Survey of Information Published in Technical Manual beginning in 1985 feats 8] | |3| S| | 8 | Remarks, | |=) =) Model, Ql) | No. 5/5) 5 Also reter to... Date _ ees ae pote Sacer 1985 | | — Misfiring Because of Q 15.02.85 Ground Strap Corrosion | ~ Fuel Injector Survey a | |15.02.85 L-vetronic | | = Throttle Housing lee | Bypass air screw 10.04.85 Corroded Spark Plug Connectors a e| 10.04.85 ~ Settings of DME Control Units in 18.07.85 ~ List of Factory Tested an T | Invalid/...T1-1/86 08.07.85 Approved Spark Plugs ~ Retrofitting - Catalysor Tle 20.12.85 — Retrofitting - Catalysor Tle | 20.12.85 ~ Retrofitting - Catalysor Tle | Invalid/..11-1/87 (20.12.85 | | fal t 1986 feet | ~ Ignition Delay Relay \a 1/86 | | | @ | 1985-1986 Models/ |16.01.86 le| lle Relay voltage 9 volts | ~ List of Factory Tested an Approved Le 1/86| |e | | Invalidy...T1-1/88 (30.04.86 Spark Plugs | | Vole | | ~ BatterieDischarging [Q} 2186] | @) | ¢/ Removing battery 18.04.86 — Mixture Preparation {a} | 36] je 1986 Model/'mixture 20.06.86 Engine Stalls While Declutching | | too rich" ~ Catalytic Converter Cars Qi; | aes} je} 20.06.86 Poor Pickup lesa — Engine Damage Q) | 5/86| |e) |¢|Foreign particles in in- |20.06.86 Engine Repairs | take system ! ~ Information for Cars T| 26.06.86 with Catalytic Converter les Turbocharger a © [foreign particles /10.10.86 Compressor Wheel Damage | — Faulty Wire Bridge - Terminal 28 al Terminal 28/resistance 25.11.86 Lean Hesitation, CO Adjustment | 1987 Eel ~ Additional Air Pump. la 1/87, | | | @|Fuel return line | 20.02.87 Maintenance | i | ~ Troubleshooting Q 287 || | Plug connections 20.02.87 Fuel Systern/Engine Electrical System | (cleanliness) LI Sie Seen eed | || # =Conversion instructions or workshop campaign | | V=Brochure | |©=Supptement or change for TV! Copyright by Dr. Ing. h. c. F. Porsche Aktiengesellschaft Printed in GermanySurvey of Information Published in Technical Manual beginning in 1985 x S| | |g 8 15 | Remarks, s\n] [=| Model, No. [5 |5| [5 | Also reter to... Date — Engine Power 37] [@ 1986-1987 Models) 31.03.87 Fuel/Air Mixture ‘term, 28/oxygen sensor Troubleshooting + 487| | NTC HI | 22.05.87 Temperatur Sensor | | Service Installation - |T]| #| 187] |@ (25.10.87 Catalytic Converter | | ~ Starting Motor a] 5/87| |e 1987 Model/115 mm |31.08.87 Transmission Cars || | ~ Battery 1Q} | 687} ©) | @ Only coupefinside lights | 16.10.87 Discharging hey ~ Battery Discharging a] 7/87} @| | @|Checking battery con- 24.11.87 New Cars. | dition | 7988 | Fuel Grade Q) 1/88| @| |@|Exhaust tailpipe dis- 19.02.88 Exhaust System coloration/unleaded ~ Survey of Factory Tested and ie 188} 0) |e 06.07.88 Approved Spark Plugs | | | | Survey of Contro Units \T| | 28} |e |; le (06.07.88 ~ Fuel/Air Mixture ja 2/88} @| Hose to thermo valve 19.09.88 Throttle Valve Housing \ | | disconnected Starter Q 3/88) | 911 Turbo starter gear- 30.12.88 Starter Gear Ring | et ring/...Q1-5/87 1 | | 1 1989 Tee ~ Unleaded Gasoling [T| | 189/@ @ | @|Fuct grade table 31.01.89 Regular RON 91 / Euro Premium RON j | | 95 / Premium RON 98 | | | | | - New Catalytic Converter Conversion Kit | T 2/89 o with plastic filling tube. 12.06.89 90.113.911.03, | | | ~ Spark Plug connectors which are T| | 3/89|@ | | | Engine Nos.: 62 K 00607,02.05.89 hard to remove || |to 62 K 00788 | — DME Control Unit Tl @| 4po;e | with green dot. 08.06.89 = Lighting up of Waring Signs and T| | safe | | [Carrera 4 |12.06.89 Faults in OME Fault Memory ial Service Installation of Catalytic Tle| esole Carrera 4 M’B9 (K) |05.10.89 Converter 964.113.911.00 | ~ Fuel Hose to Rear Fuel Pump T| +| 7/89 © |Hose laid differently. 13.11.89 | | [setae fet ESC @ =Conversion instructions or workshop campaign V=Brochure ‘®= Supplement or change for TVQI SY SERVICE Copyright by Dr. Ing. h. o. F. Porsche Aktiengeselischatt Date 30.04.90 Printed in GermanySurvey of Information Published in Technical Manual beginning in 1985 airflow sensor in tight loop. coat with Optimoly HT |31.08.90 M’84 (E)-'89 (K) spare |16.11.90 part: 930.606.915.00 ~ Securing heat shield to exhaust system |T * BT | |8| pomarts, | =| Model, E ‘ No. |&|%| || Also refer to Date 1990 | ~ Cable harness connector at the Tle! | | | a — Engine Temperature Sensor (NTC) II | | | Cable cluster mounted [21.02.90 | | 1 = Conversion instructions or workshop campaign | | V= Brochure || @=Supplement or change for TVO! 30.04.90 | 31.12.90 SERVICE = Copyright by Dr. Ing. hc. F, Porsche Aktiengesellschaft Printed in Germany 3 | | | | 1 Date911 Carrera 4 Table of contents volume | The workshop manual of the Carrera 4 also includes that for the Carrera 2. ‘The Carrera 4 acts as the basis for description of the repairs in the manual. “Carrera 4" also appears on every page in the header line. Deviating descriptions for repairs on the Carrera 2 follow those of the Carrera 4. These repair de- scriptions for both models are separated by a yellow sheet. “Carrera 2" appears on all pages in the header line after the separating sheet. The page number starts with 100 as an additional distinction. Page General Technical data eee eee eee 0-2 Wecking|upithe vehicio star eee peter eae epg arene 0-8 Maintenance and self-diagnosis Vehicle maintenance up to Model Year 91 +. 03-4 Operating instructions for system tester 9288 03-35 No diagnosis possible - 03 - 43 Engine, crankcase, suspension Tightening torques for engine 210-4 Removing and installing the engine... .. 2.2.20... eee e eee vee 102 5 Flanging on and off the engine/transmission assembly ..............---- 10-12 Engine, crankshaft, pistons Dismantling and assembling the crankcase Dismantling and assembling the crankshaft Normal and rework dimensions of crankshaft. Crankshaft - standard and machined sizes Weight groups of con rods Disassembling and assembling the oil pump 2213-11 Measuring and repairing the crankcase . 13-19 Dismantling and assembling crankcase sections » 13-23 Sealing the crankcase mating sections . . . » 213-31 Crankcase screw connection......... » 18-33 Removing and installing the belt pulley with vibration absorber . . 13-37 Dismantling and assembling double-mass flywheel... . . + 13 - 38a Dismantling and assembling pistons, cylinders ...... . 213-39 Pistons and cylinders - Dimensions and identification . . . . . . 13- 42a Assembly of piston pin retainer with special tool 9500 and 9500/1 13-43 Assembling the cooling air duct for cylinders 213-45 Removing and installing two-piece oil return pipes 13-48 Checking and adjusting drive belts . - 13-47 Table of contents 1 Printed In Germany - XXII, 1995volume | Table of contents 911 Carrera 4 Page Engine, cylinder head, valve drive Engine control... .....-- 2. 15-4 Determining parallelity of chain sprockets . 15-2 Dismantling and assembling the cylinder head . . . . 15-9 (Camshaitsy timing stg eee er 15-8 Dismantling and assembling camshaft housing . . . . 15- 10a Refacing the cylinder head .............. Bunoe 15 - 106 Replacing valve guides ..............0. 15 - 10 Disassembling and assembling cylinder head 15-11 Removing and installing valve springs 15-14 Removing and installing valve stem seal . 15-15 Assembling cylinder head, angle-controlled tightening method . . . . 15-16 Removing and installing the knock sensor . . 15-19 Dismantling and assembling hydraulic pump drive (power steering) . 15-21 Engine Lubrication Assignment - relief valve - safety valve... . . 7-4 Dismantling and assembling the oil pump see seeeeee 7-3 Replacing oll tank 0... eee eee vee 17-5 Fuel supply Checking the delivery quantity of the fuelpump .. 2.2. .....0....004 .. 20-4 Checking the fuel pressure ............ 20- 3 Removing, dismantling and assembling fuel tank . 20-5 Fuel system, electronic injection Inspection and adjustment values . 24-4 Injection system components - Removing and instaling DME center section ...... 24- 3 Injection system components - Removing and installing lower DME section ...... 24- 7 Exhaust system Exhaust system... eee eee 26-1 Starter, Power Supply, Cruise Control Removing and installing the starter . 27-4 Removing and installing generator. 27-3 2 Table of contents Printed in Germany - XXII, 1995911 Carrera 4 Table of contents volume | Page Ignition system Accident risks related to electronic ignition systems... 2... eee BBO DME control unit coding . 2B- 2 DME control units see Seer 28-3 Replacing plug connectors, plug leads and threaded sleeve . . . 28-5 Determining engine speed sender clearance (Tiptronic vehicles) 28-9 DME diagnosis/Troubleshooting .. 2.2... eee eee eee D24/28-1 Table of contents 3 Printed in Germany ~ XX, 1993911 Carrera 4 General Printed in Germany ~ 1988 0.1General 911 Carrera 4 Technical Data - 911 Carrera 4 (Adjusting values and wear limits are included in the respective repair groups) Note: USA values in brackets (engine type M 64/01) Drive unit Internal engine designation Mesjo1 Number of cylinders 6 Bore mm (in) 100 (3.94) Hub mm (in) 76.4 (3.01) Displacement (actual) om? (in.9) 3600 (219.7) ‘Compression ratio 11.034 max. engine power kW (HP) 184 (250) as per 80/1269 EWG Net power, SAE J 1349 KW (HP) 184 (247) at engine speed rpm 6100 max. torque Nm (kpm) 310 (31.6) As per 80/1269 EWG Net torque, SAE J 1349 Nm (lb) 310 (228) at engine speed rpm 4800 max. specific power output KWA (PSA) 51.1 (69.4) Net power, SAE J 1349 KWA (PS) 51.1 (68.6) Fuel grade RON (MON) — 95/85 max. permitted speed tpm 6700 Engine weight (dry) kg (Ibs) 240 (529) 02 Technical Data Printed in Germany ~ 1988911 Carrera 4 General Engine design Type Crankcase Crankshaft Crankshaft bearings Connecting rods Conrod bearings Pistons Cylinders Cylinder head Valve guides Valve arrangement Valve timing Camshaft Camshaft drive Valve clearance 6-cylinder, four-stroke internal combustion engine with 2 horizontally opposed cylinder banks (fat engine) Light alloy, two-piece Forged, supported by 8 bearings Friction bearings Forged Friction bearings Light alloy, pressed Light alloy, individual cylinders Light alloy, individual cylinder heads with ceramic exhaust port liners Press-fitted 1 inlet, 1 exhaust, suspended V formation ‘One overhead camshaft each on right and left Cast Double chain 0.10 mm (inlet, exhaust cold) Timing Inlet opens 4 degrees before TDC Inlet closes 56 degrees after BDC Exhaust opens 44 degrees before BDC Exhaust closes 4 degrees after TDC Intake system With controlled tuning flap Technical Data 0.3 Printed in Germany - 1988General Engine cooling Type Blower drive Transmission ratio: crankshaft/blower Air delivery rate Engine lubrication Type Oil cooling Oil fiter il pressure at n = 5000 rpm Oil pressure indicator Oil consumption Exhaust system Emission contro! 911 Carrera 4 Alr-cooled system Via V-belts from the crankshaft approx. 1:1.60 1010 I/sec at 6100 rpm of the crankshaft Dry sump lubrication with isolated oil reservoir Thermostatically controlled, front oil cooler in the front right-hand fender, 2-stage electric blower In the return line approx. 5.0 bar at 90 degrees oil temperature 05 bar electric and oil pressure warning lamp Up to 1.51 / 1000 km Single-branch system joined together outside the heat exchanger, 3-way catalytic converter with closed-loop Lambda control, intermediate and final mufflers, partial encapsulation of the engine Closed-loop Lambda control with 3-way catalytic converter (metal carrier). Heating Engine-dependent hot air heating with additional electric blowers and automatic temperature control Fuel system Type DEE (Digital Engine Electronics) Fuel supply 1 electric roller cell pump 04 Technical Data Printed in Germany ~ 1988911 Carrera 4 General Electrical system Interference suppression Battery voltage v Battery capacity Ah Alternator output AW Ignition Firing order Ignition timing control Spark plugs Spark gap mm (in) Body construction Dimensions (at DIN curb weight) ECE-R 10 and 72/245/EEC 12 72 115/1610 3-phase current DEE, dual ignition, knock sensor controller 1-6-2-4-3-5 via DME Bosch FR § DTC. 0.8 + 0.1 (0.032 + 0.004) Integral steel body, rear spoiler, coupé Length mm 4250 Width mm 1652 Height mm 1320 Wheel base (design) mm 2272 Front track with rim mm (in) 1380 (54.1) 6x16 Rear track mm (in) 1374 (54.1) 8d x 16 mm (in) 1369 (63.9) 73x 16 Technical Data 05 Printed in Germany ~ 1988General 911 Carrera 4 Dimensions Ground clearance (at max. permitted weight) mm 120 Ramp angle (at max. permitted weight) 12.0 degrees Front overhang angle (at max. permitted weight) 125 degrees Rear overhand angle (at max. permitted weight) 12.0 degrees Weights (as per DIN 70020) Front curb weight kg (lbs) 600 (1322) Rear curb weight kg (lbs) 850 (1872) Total curb weight kg (Ibs) 1450 (3194) max. total weight kg (bs) 1790 (3943) max. front axle load kg (ibs) 760 (1674) max. rear axle load kg (ibs) 1050 (2313) max. roof load including roof rack kg (ibs) 75 (165) with original Porsche roof transport system max. trailer load, without brakes* kg (Ibs) 500 (1101) max. trailer load, with brakes* —_kg (Ibs) 1200 (2643) max. carftrailer weight kg (ibs) 2990 (6586) max. drawbar load kg (Ibs) 75 (165) *Up to 16% gradient 0.6 Technical Data Printed in Germany ~ 1988911 Carrera 4 Filling capacities Engine Engine oll capacity General Only use approved engine oils. Refer to Technical Information Handbook approx. 11.5 | (approx. 9 | for oil change) determined by measurements with the oil dipstick as per Owner's Manual Transmission with differential Front axle 1.21 Rear axle 3.81 Fuel tank approx. 77 | (approx. 10 | reserve) Brake-fluid reservoir approx. 0.75 | Washer fluid for windshield and headlights approx. 7.4 | Intensive washing approx. 0.7 | Power-assisted steering approx. 1.0 | Performance Top speed km/h (mph) 260 (162) Acceleration from 0.100 km/h ss 59 Kilometer from standing start ss 25.5 Hill climbing Manual transmission In% 1. gear 86% 2. gear 41% 3. gear 24% 4. gear 15% 5. gear 11% Technical Data 0.7 Printed in Germany ~ 1988General 911 Carrera 4 Raising the vehicle The vehicle must only be lifted using the illustrated jacking points. When driving onto a lifting platform, make sure that there is enough clearance between the platform and the vehicle. front Rear At the jacking point At the jacking point 132903 13903 0.8 Printed in Germany ~ 1988Maintenance Schedule The recommended Service intervals apply under normal driving conditions and do not take into account any Optional Equipment. Dusty areas require more frequent checking and possible replacement of the air filter element. Tyre, clutch and brake wear as well as the condition of the engine oil are all largely dependent on driving habits, and are also affected by arduous operating conditions; this could mean shorterintervals between services and replacement of parts, This applies, naturally, also to; “Battery: check fluid level and, if necessary, top up." Vehicles with a low yearly mileage (kilometres) should be serviced at least once a year. The extent of maintenance can depend onthe driving Conditions. Your Official Porsche Centre will be pleased to inform you of the contentsof the yearly service check. Aspartof this servicing, after the frst 2 years the Porsche Dealer will make out a Status Report Thisisintended to ensure thatthe conditions for the Long-life guarantee are not jeopardized. If required by the condition of the vehicle, a full upper- and lower-body cleaning may be necessary. Exchange and new spare parts receive the same contents of service as components of new vehicles, ‘The terms “inspect” and ”check” include all associated work suchas adjustments, readjustments, corrections and replenishment. They do not include the repair, replacement or overhaul of components or assemblies. 3000 to 4000 km / 2000 to 2500 miles Servicing .justment incl. tyre condition, tyre pressure 3 Diagnosis System: read out system faults. _ _ 5 Ghange engine oil and oil fiter = 6 Check valve clearance ~ = 7 Vebelt: check tonsion — 7 aaasaci0) Visual inspection — ~ _ 12 Windscreen washer. headlight washer: chock function, fuid level and - a nozzle adjustment, regard antifreeze content for tine winter season _ _ Lighting system: check function ~ 23 Brake hoses and lines: visual inspection for leaks, clearance; damage, 14 Check brake ful level en = Transmission /axle drwes: Visual inspection for leaks, check ol levels 79 Exhaust system: visual inspection for leaks and damages ~ 20 Gheck screw connections for tightness and attachment Exhaust emissions test on vehicles without catalytic con ~ 26 Test drive: Brake pedal and hand brake, brake power assist unit, clutch, automatic speed control, steering, heating, air concitioner and instruments~ check function : Drive train, fongit nd lateral i ip differential: check for noises and operation 29 Visval inspection for leaks: oils and fivids — 29 Service every 20000 km / 12000 miles Diagnosis system: read out system taulte _ 5 whange engine 0 a ~ 6 Check valve clearance 7 V-belt: check condition and tension 70 — 4 = a Visual inspection for leaks oll and fluids = 12 Air filler: replace fer element 2 ase ventilation: check tightness of hose connections 7 12 Fuel system: visual inspection for leaks, damages, - ary clearance and tightness of hose connections: intake air: check hoses, lines and connections for ighiness = = iz Hand brake: check free travel of hand brake lever 13 pedal: check play of Brake pedal. — Brake hoses and lines: visual inspection for leaks, clearance, damage, and corrosion. 14 Check brake fluid love. Brake system: visual inspection of brake pads and discs 8 Hydraulic clutch actuator: visual inspection for leaks, chesk final position of clutch pedal a7 Throttle actuator: check cables, linkages and joints for smooth running, 7 16 full throttie opening and resonanz flap movement _ : Steering gear, check screw connections for fi Visual inspection of the bellows for damage 18 check play, tightness and dust caps ee e Power-assisted steering: visual inspection for leaks and check fuld level 18 Ball joints: visual inspection of dust caps for damage Fa Wishbone: check screw connections for tightness 8: visual inspection for leaks, check ol levels 6 ection of sleeves for leaks 19Service every 20000 km / 12000 miles Exhaust system: visual inspection for leaks and damages, check screw connections for tightness and attachment 20 ‘Tyres: check condition, correct tyre pressure ___ 20 Door arrester: check function and lubricate 7 20 Door hinges: lubricate 20 Check door., front hood locks and safety hooks on front hood for lightness and function 20 Safely belt: check function and condition 24 ‘Seals for doors, hood and root: remove abraded rubber, apply sultable agent fo lubricate seals 2 Check tunction of the vehicle lighting. All headlights: check setting = Hom: check function indscreen washer, headlight washer: check function, fluid level and aa nozzle adjustment, regard antifreeze content for the winter season Intensive cleaner: check function and fluid level - 24 Battery: check fluid level 24 ‘All other electrical equipment as well as control- and warninglights: check function 24 Heater, ventilation and air conditioner: check function and refrigerant level 24 Exhaust emission unit: check if catalytic. converter, oxygen sensor and channeled filler inlet are positioned, 25 visual inspection of all electrical connections, check function of oxygen sensor ignition circuit 1 and 2: check function 25 Exhaust emissions test: test CO content 26 {measure before and behind the catalytic converter if equipped), Perform system adaptation Test drive: Brake pedal and hand brake, brake power assist unit, clutch, automatic speed control, 29 ring, heating, air-conditioner and instruments: check function Drive train, longitudinal and lateral limited slip differential: check for noises and operation 28 Visual inspection for leaks: oils and fluids ~ _ 29 Additional service every 40000 km / 24000 miles 29 Change fuel fter Additional service every 80000 km / 48000 miles 30 Manual transmission and axle drives: change oil Yearly service after the first 2 years File Status Report for Long-life guarantee _ = Service every 2 years at Change brake fluid911 Carrera 4 Maintenance 03 Front axle: Checkir Use a visual or electronic axle measuring unit to check and/or adjust the toe. Refer to the operating instructions for the respective axle ‘measuring unit for the measuring procedure. The following preconditions must be fulfilled before checking the toe for the front axle: the toe - Curb weight of car according to DIN 70020 = ready-to-drive car with full fuel tank, spare wheel and tools. - Correct joint and wheel bearing play (wheel bearing play cannot be adjusted). - Correct tire pressure 1. Bounce the vehicle at rear and front axles 2- 3 times and allow to return under its own po- wer. 2. Check the front toe with the steering wheel in the straight ahead position and adjust the tie rods if necessary. (Refer to the next page for wheel alignment values) Necessary preparations First check whether the steering wheel is off- set in relation to the steering gear. This requi- res removing the underside trim panel and centering the steering gear in middle position with Special Tool 9116. If adjustment is neces- sary, try to get the optimum position for the steering wheel. Then remove ST 9116. Clamp the steering wheel in middle position before adjusting toe. Maintenance Printed in Germany ~ I, 1989 03-303 Maintenance 911 Carrera 4 Wheel alignment values The following values apply at curb welght as per DIN 70020 (vehicle with full fuel tank, spare wheel and tools). Rgatfication and) max. deviation between left “and right Front axle Toe (total) - unpressed +25 6! Toe difference angle at 20° lock 40° + 30° Inuenced by eerhate arms Camber O° + 10° 10° Caster 4° 25’ + 15° 15° Rear axle Toe per wheel +189 +5' 10° ‘Camber - 20’ + 10° 20° Tire condition / inflation pressure Tires constitute a safety element and they can only fulfil the demands made on them if the inflation pressure Is correct and there is adequate tread depth. The spectfied inflation pressures are minimum pressures; under no circumstances should the tire pressure be allowed to sink below these levels as this will not only detrimentally affect the driving be- havior, but also increases the risk of serious tire damage. Valve caps protect the valves from dust and dirt and therefore prevent leakage. Always screw caps on tightly and replace any that are missing. For safety reasons, a tire-pressure check should always be accompanied by a visual inspection to en- ‘sure adequate tread depth and a check for objects piercing the tire, slits, cuts, cracks and bulges in the side wall (cord break). Inflation pressure with the tires cold (summer and winter tires). Front 25 bar Rear 3.0 bar Collapsible spare wheel front/rear 25 bar 03-4 Maintenance Printed in Germany - Ill, 1989911 Carrera 4 Maintenance 03 Diagnosis system: Read out the fault memory The procedure for reading out the fault memo- ry is described in the operating instructions for System Tester 9288. A copy of the opera- ting instructions is supplied with each tester. The System Tester 9288 is connected to the vehicle via a 19-pole socket outlet. ease Aliso refer to repair group 03, self-diagnosis for operating instructions. Maintenance Printed in Germany — 1988 03-503 Maintenance 911 Carrera 4 Replacing engine oil and filter Precondition: engine at operating temperature 1. Remove engine guard. Undo the drain plugs in the crankcase and thermostat hou- sing and drain out the engine oil. Drain plug - thermostat housing 2. Undo oil drain plug at oil filter console and drain remaining used oil into a suitable con- tainer. 03-6 3. Undo the oil filter with a standard clamping band, e.g. Hazet 2171 - 2. Catch any remai- ning oil reas 4. Clean the drain plug. Always replace the sealing rings. Tightening torque for the drain plug on the crankcase 70 Nm (52 ftlb) Drain plug on the thermostat housing 65 Nm (48 ftlb) and oil filter console plug 31 Nm (23 ftlb) 5. Apply a light film of oil to the seal on the oil filter, install by hand, turning until the seal makes contact. Finally, tighten by a further approx. 1/2 turn. 6. Fill with approx. 6 liters of engine oil. Run the engine at idle and top up with approx. 3 liter. The oil-change volume amounts to ap- prox. 9 liter. Only use approved engine oils. Refer to the Technical Information Hand- book. Check the oil level at operating temperature and at idle speed. Check the engine, oil reservoir, lines and front oil cooler for leaks (visual inspection) Maintenance Printed in Germany — Xitl, 1991911 Carrera 4 Maintenance 03 Checking and adjusting the valve clearance Note Always check or adjust the valve clearance with the engine cold (approx. 20 °C). Check by inserting the feeler gauge between the end face of the stem and the cap of the valve adjusting screw. It the spark plugs are not removed when the valves are adjusted, the engine must only be rotated at the bottom pulley or at the internal multi-tooth end of the gener- ator shaft. Check hex nut on alternator shatt for tight fit after the adjustment has been com- pleted, Valve clearance with the engine cold Intake 0.1mm Exhaust 0.1mm The clearance is adjusted according to the fir- ing order 1-6 -2- 4-3-5, The piston for the respective cylinder must be in top dead center of the compression stroke as both valves are then closed. The TDC marking for each cylinder can be found on the pulley Cylinder designation Firing order 1-6-2-4-3-5 1. Cylinder 1 is the first to be adjusted. For this, turn the crankshaft to the right with the V-belt pulley until both valves of the cylinder are closed (overlapping cylinder 4) or until the distributor arm is aligned with the mark- ing on the distributor housing. The TOC marking (21) on the pulley must be level with the crankcase seam or the locating mark on the blower housing Maintenance Printed in Germany ~ XVill, 1992 03-703 Maintenance 911 Carrera 4 TDC marking - pulley Distributor marking - cylinder 1 2. Check the valve clearance with P 213 b; if necessary, undo the hexagon nut on the ad- justing screw and correct the valve clearance by turning the adjusting screw with a suitable screwdriver, hold the adjust- ing screw firmly and tighten the counternut. 7720 3. Check the clearance again. 4, Now, continue turning the crankshaft clock- wise with the pulley as far as the next mark- ing (120°). The valves for cylinder 6 can be adjusted in this position. 5, Tum the crankshaft to the next marking (120°) to bring cylinder 2 to firing point. 6. Repeat this procedure accordingly to adjust the other valves (cylinders 4, 3 and 5) 7. Always replace the valve-cover seals and the self-locking nuts. Tightening torque 9.7 Nm (7 ftlb) 03-8 Maintenance Printed in Germany ~ 1988911 Carrera 4 The following assembly operations must be carried out before adjusting valves: ‘Assembly work from above: 1. Remove the rear wheels 2. If the vehicle is fitted with a catalytic con- verter, separate the plug connection to the Lambda probe, removing the hot-air blower beforehand. lilustration shows the engine removed —_swass Maintenance Printed in Germany ~ Vi, 1990 Maintenance 03 3. Push the probe cable with rubber grommet downwards through the engine paneling on the left-hand side. 4, Undo the front fastening screws on the en- gine side paneling beforehand. (4 screws M 6 x 10) Assembly work from below. 1. Remove the engine guard. 2. Remove the exhaust system complete (ex- cept heat exchanger). 3, Remove the side encapsulation panels from the engine. 4, Undo the side engine paneling, 5. Disconnect the spark plug sockets from the upper and lower ignition circuits. 6. Remove the valve covers for intake and ex- haust. Note The clearance for intake and exhaust valves can now be checked and/or adjusted from below. 03-903 Maintenance 911 Carrera 4 Installation of ignition leads on exhaust valve covers differs, so that valve covers must not be mixed up when installed. Check for perfect seating of spark plug con- nectors and routing of ignition leads. s1093 Right Side - Cyl. 4-6 03 - 10 Maintenance Jobs Printed in Germany ~ VI, 1990911 Carrera 4 Maintenance 03 Checking and/or adjusting alternator, fan wheel and air conditi pressor drive belts ing com- Caution: Make sure the ignition key is pulled off whenever measurements are made. Checking used drive belts {alternator and fan wheel) Use belt tension measuring instrument (Spe- cial Tool 9574) to check tension. A description of how to use the Special Tool is contained in Repair Group 13, page 13 - 30. Retensioning the belt is only required if the belt tension displayed at the measur- ing instrument is less than 15 scale incre- ments when the engine is cold and less than 20 scale increments when the engine is hot. Retensioning the belts Retension belts as described in the General Adjustment Notes section. Before measuring the belt tension, start engine and let engine idle briefly. Tension: Cold engine: 15 to 23 scale increments Engine at operating temperature: 20 to 28 scale increments Fitting a new belt (alternator and fan wheel) When fitting a new belt, be sure to observe the correct assembly sequence in order to avoid any loss of belt tension during vehicle operation. 1. Fit new belt, Adjust tension by inserting or removing shims as required. Shims are available for belt tensioning in thicknesses of 0.5 mm and 0.7 mm. The 0.7 mm shim is identified by a 2 mm dia. drill hole. 2. Before measuring the belt tension, start engine once more and run engine at idle briefly. Tension: Cold engine: 23 to 35 scale increments 3, Run engine at idle for approx. 15 minutes or test drive vehicle for approx. 10 miles. Check tension again. Specification: 28 to 40 scale increments Retension if required. Test requirement: Engine at operating tem- perature Adjustment specifications for A/C com- pressor drive belt Specification: 30 to 35 scale increments Retension if required. Maintenance operations Printed in Germany - XXII, 1994 03 - 10a03 Maintenance 911 Carrera 4 General adjustment notes 4, Use only V-belts that have been approved Fan wheel and alternator have separate by the manufacturer. drives Note Rotate engine only at lower belt pulley or by operating the starter. After completing all operations, check to make sure that hexagon head nut has been tightened suffi- ciently on alternator shaft. 263-27 Alternator drive components Fan wheel drive components Adjusting the V-belts 1. Use polygon wrench (999 571 052 02) to lock shaft and undo hexagon head nut. Remove shims and pulley half. 2. If belt tension is below specification, remove one shim from between pulley halves and refit in front of front pulley halt. Tighten hexagon head nut to 50 + 5 Nm. 3. Three additional M 6 screws have to be undone for V-belt and fan wheel. 03 - 10b Maintenance operations Printed in Germany - XXil, 1994911 Carrera 4 V-belts for the power steering pump: Check condition 1. Remove the engine guard. 2. Undo the final-muffler bracket and remove from the final muffler and engine. Remove the left-hand top engine cover panel and the toothed-belt guard. s4a03 3. Check the toothed belt for wear and dama- ge by cranking the engine. The belt tension is not adjustable. Replacing spark plugs: Unscrew spark plugs with standard commerci- ally available socket wrench insert form Mes- sers. Snap-on Order Nr. $ 97 06 and exten- sion Snap-on, Order No. FXW4. Maintenance 03 Replacing the spark plugs for the upper ig- nition circuit 1. Remove the heating blower 2. Remove the air-filter cover and filter insert Replacing the spark plugs for the lower igni- tion circuit 1. On vehicles with catalytic converter, separa- te the plug connection for the Lambda pro- be, removing the hot-air blower beforehand. 2. Push the probe cable with rubber grommet downwards through the left-hand side engi- ne paneling. 3. Remove the exhaust system complete (sepa- rating point downstream of catalytic conver- ter) 4, Remove the side engine encapsulation pa- nels. Note 1. Do not use any lubricant on the plug thread. 2. With spark plugs which are difficult to remo- ve, use Special Tool (disassembly clamp) 9513, order no. 000.721.951.30 Maintenance Printed in Germany ~ VII,1990 03-1103 Maintenance 911 Carrera 4 Visual inspection for leaks: Oils, fluids This check can be carried out after the engine guard has been removed. Air filter: Replacing the filter insert 1. Release the retaining clips and remove the housing cover with filter insert 2, Take out the filter insert and clean the insi- de of the filter housing with a non-fibrous cloth. 3. Install a new filter insert (Fins in horizontal position) Check that the hose connections are fitted se- curely through-out the entire intake system Crankcase ventilation Check that all hose connections are se- curely fitted Fuel system: Visual inspection for leaks, damage, free io and secure fitting of the line connec- tions Intake air guide: Check that hoses, lines and connections are fitted securely 03-12 Maintenance Printed in Germany ~ 1988911 Carrera 4 Maintenance 03 Parking brake: Check the free movement of the parking- brake lever The parking brake is fitted with asbestos free brake pads. This type of parking brake must never be adjusted in such a way that the brake pad has to “grind itself free" in opera- tion. If it is possible to raise the lever by more than 4 notches, using average force, without any sign of a braking effect, the parking brake needs adjustment. Adjusting the parking brake: 1. Remove the rear wheel. 2. Release the parking brake and push the disk- brake pads on rear wheels back until the brake disk can be turned freely. 3. Undo the adjusting nuts on the turnbuckle (arrow) until the cable is slack. Note Remove the tray behind the brake lever (2 fas- tening screws) to gain access to the turnbuckle. 4. Insert a screwdriver through the hole in the brake disk and turn the adjusting device until the wheel is locked. Then undo the ad- justing device again until the wheel can be turned freely, then undo by a further 2 notches. 5, Pull up the brake lever by 2 notches and turn the adjusting nut on the turnbuckle until both wheels can still just be turned by hand. 6. Release the parking brake and check whether both wheels turn freely. Maintenance Printed in Germany ~ 1988 03-1303 Maintenance Foot brake: Check the play in the brake pedal The brake pedal has no stop. As the brake pedal has no support facility in the initial posi- tion if the brake push-rod is adjusted correct- ly, the permanently set air play in the brake unit is guaranteed. If the brake pedal plate is pushed down by hand, you can feel a push rod play of approx. 8 mm. If the push rod is adjusted at the swivel head (9), this alters the position of the brake pedal. In this case, you must also check the setting for the stopamp switch The push rod is correctly adjusted if the plate of the brake pedal is approximately level (+3 mm with the plate on the clutch Pedal. (Clutch pedal in initial position), 911 Carrera 4 Check the setting for the stop-lamp ‘switch The stop lamp must light up after the brake pedal has travelled 6 - 16 mm (measured at middle of the pedal brake). If the stop lamp lights up with less than 6 mm. travel, turn the stop-lamp switch (2) to the right until it responds within the toleran- cerange. (Do not damage electric cables and connectors). If the adjusting range of the stop- lamp switch is inadequate, adjust the brake pedal with the swivel head on the push rod (shorten the push rod) If the stop-tamp switch lights up after 16 mm travel, adjust the brake pedal with the swivel head on the push rod, (lengthen the push rod) until the stop lamp switch responds within the tolerance range. 03-14 Maintenance Printed in Germany ~ 1988911 Carrera 4 Check the brake-fluid level 1. With the ignition switched on, pump the brake pedal repeatedly until the electric motor in the pump unit can be heard to start. Note The pump unit is located at the front of the luggage compartment and supplies the brake booster and the valve block for the differential lock (interaxle and wheel-to-wheel) via a diaphragm pressure accumulator. 09 2. Once the pump unit has switched off, the brake-fluid level must be between the min. and max. markings on the reservoir. Never fill to above the max. marking as brake fluid may be discharged through the vent line. Only use brake fluid DOT 3 or DOT 4 (SAE J 1703). 03 Brake system: Visual inspe and brake n, checking the brake pads ks for wear Note Brake pads must be replaced for the complete axle when the brake- pad warning lamp lights up, but at the latest when the pads have worn down to 2 mm. If the brake-pad wear is indi- cated by the warning lamp, the warning con- tact (sensor including cable and connector) must also be replaced. It is possible to avoid replacing the warning contact if the brake pads are replaced when worn down to 2.5 mm at the latest. Warning contacts must be replaced if the core of the cable has been exposed. If only the plastic part of the warning contacts has been rubbed, however, it is not necessary to replace it. Maintenance Printed in Germany ~ 1988 03-1503 Maintonance 911 Carrera 4 1. Remove the wheels to check the brake pads. 2. Check the brake pads for wear by means of a visual inspection. The wear limit has been reached when the brake pad is wom down to 2 mm. Throttle control: Check bowden cables, linkages, joints for Smooth operation. Check the tuning flap and full-throttle positio Checking the tuning flap: Each time the ignition is switched on, the tuning flap is opened and closed once by a vacuum. The opening and closing noise can be heard in the engine compartment. 03-16 Maintenance Printed in Germany ~ 1988911 Carrera 4 Maintenance 03 Hydraulic clutch control: Visual inspection for leakage, check final position of the pedal The clutch pedal has no stop. It is in its initial position when the master cylinder is in its initial posi- tion. The push rod cannot be adjusted. The preload on the servo spring, however, can be adjusted. The servo spring must fulfil 2 functions: to assist the pedal force and return the pedal. If the clutch pedal does not return correctly, reduce the preload on the servo spring slightly. To do this, undo Allen screw No. 1 slightly until you can find a good compromise between return and pedal- force assistance. Maintenance 03-17 Printed in Germany - 198803 Maintenance Steering gear: Check that the screw connections are secure. Inspect the boots for damage Tie rod knuckles: Check play, fastening and dust caps Check that all connections to the steering gear and tie rods are secure and that the dust caps, boots and joints are in working order and do not leak. The rubber dust caps and boots on the steer- ing gear and the tie rods may be damaged by outside influences, e.g. stone throw or during assembly work. If a rubber cap is damaged, the joint or tie rod must be replaced as the joint may be destroyed by the penetration of dirt or moisture. Power-assisted steering Visual inspection for leaks and checking the fluid level General Insufficient oil in the hydraulic system causes damage to the power-assisted steering. As a result of the high oil pressure in hydraulic sys- tem, even small leaks can lead to a drain on the fluid and damage the servo pump. Grunting noises when locking the steering or foam in the reservoir indicate lack of oil and/or aspirated air. Before filling the reser- voir, however, any leaks on the intake side must be repaired and the faulty part replaced on the pressure side. 911 Carrera 4 Note The tension of the toothed belt is not adjus- table but check its condition. Check the steering system for leaks (visual inspection) With the engine at idle, turn the steering wheel to the stop and hold it there. This causes the Greatest possible line pressure to build up. Check all ine connections for leaks in this position, tighten if necessary. Carry out this test for max. 10 s. If the test period is longer, make a short pause after ap- Prox. 10 s. Check the fluid level for the power-assisted steering The reservoir with a transparent upper part is installed on the right-hand side of the engine compartment. With the engine at idle, check the ATF-fluid (ATF-Dexron II D) without moving the steering. The correct level is be- ‘tween the min. and max. marks on the reser- volr. 03-18 Maintenance Printed in Germany ~ 1988911 Carrera 4 Maintenance 03 Axle joints: Visual Inspection for damage to the dust caps Check the dust caps for the axle joints (ball joints) on the wheel suspension as follows: - _ Drive the vehicle onto the lifting platform, steering lock released. - Turn the front wheels as far as the stop. - After cleaning, carry out a visual inspection of the visible areas to the left and right. Press the rubber caps back with your figures and look for concealed cracks. - After turning the front wheels to the stop in ‘the other direction, check the remaining rubber caps. Note It is not possible to carry out a visual inspec- tion on a small area around the brake cover panels. Check this area by touch. If a rubber cap Is found to be leaky, the respective joint must be replaced as it will be destroyed by the penetration of dirt or mols- ture. Axle links: Check that screw connections are secure Transmission/final drive Visual inspection for leaks, check oil level (Refer to Page 03-30 for notes on this) Drive shafts: Visual inspection for leaks and damage to the boots Maintenance Printed in Germany ~ 198803 Maintenance Exhaust system: Visual inspection for leaks and damage, check that screw connections are fitted se- curely and examine the mounting . Check that the exhaust flange is fitted secu- rely and inspect the entire exhaust system for leaks. xs ger / cylinder head flange is fitted securely. 2 Check that all flange connections in the exhaust system as well as the Lambda probe and emission test plug are fitted secu- rely. = Check that all screws on the flange, primary muffier (catalytic converter) / heat exchan- ger are fitted securely. Inspect the mounting points for the exhaust system. Tightening torques: 1 - Heat exchanger - cylinder head 23 Nm (17 ftlb) 2 - Flat flange gasket between the left-hand side of the heat exchanger and catalytic converter 23 Nm (17 ftib) 3 - Spherical flange straps 20.5 Nm (15 ftlb) 4- Clamping band for the intermediate muffier 14 Nm (10 ftlb) Tires: Check condition, inflate to correct pressure Refer to the check for the “front axle" on Page 03-4. Check that the mounting on the heat exchan- 911 Carrera 4 Door arrester: Check function and lubricate Functional check: When the door is opened completely, it must be retained by the door arrester. The retaining force (35 N) of the door arrester must be over- come to close the doors. The door arrester must not make any noise when opening and closing the door. Lubrication: Kliber Costrak AK 6/300, part number 999.917.751.00 Oil the door hinges Check that the doors and the safety catch for the front hood are fitted securely and are in working order Test for secure fit: The fastening screws for the door lock, front hood lock and rear hood lock, as well as the fastening nuts for the upper parts of the front and rear hood locks must be tightened with 9.7 Nm (7 fb). Functional check: Door lock When the door is closed, the door lock must, engage into the lock striker in two stages and disengage again when the door opener (inside and outside) is operated. Maintenance Printed in Germany - 1988911 Carrera 4 Maintenance 03 Front and rear hood locks. When the hoods (front and reat) are closed, the hood locks must engage as the upper part of the locks are inserted and must disengage again when the hood release Is pulled. Safety catch - front hood ‘Once the hood release has been pulled, the front hood must be held down by the safety catch. At its lowest point, the safety catch must hook into the retaining plate. When the hood is open, the retractor spring must pull the safety catch back to the basepla- te on the upper part of these locks as far as the stop. Safety belts: Check function and condition Functional check: When the belt strap is pulled evenly, it must roll smoothly from the seat belt retractor through the guide fitting, and the plug-in latch of the safety belt must be heard to engage in the lock. The seat belt retractor must block if the belt strap Is pulled jerkily. Condition check: The belt strap must be Inspected for damage. It must be replaced i there is any damage in the form of cuts, fraying, separating seams, etc. Seals for doors, hoods and roof: Remove scuffed rubber, apply a suitable Preservative to maintain seals Cleaning: Remove scuffed rubber and soiling with benzine. Care: Maintain seals with glycerine, talcum or similar preservatives. Maintenance Printed in Germany ~ 1988 03 - 21403 Maintenance 911 Carrera 4 Checking the lighting system: Adjust headlights Note Not for USA vehicles 1. Undo the fastening screw holding the trim ring. tl! ie Gey i i De We, t i Nf Adjust vehicles with headlight vertical aim con- Xt Wi? ‘trol with the control switch in position 0. USA vehicles s/00 y . Ease the trim ring back at the bottom with a hardwood spatula or similar. » Clean the lens and switch on dipped beam = Using a headlight aiming device, adjust the headlights with the vehicle in running condi- tion (full fuel tank, driving seat occupied or loaded with 75 kg, tires inflated to the cor- rect pressure. 01505 03-22 Maintenance Printed in Germany ~ 1988