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Porsche 912E Workshop Manual

Porsche 912E Manual Online:

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Porsche 912E User Manual
Porsche 912E User Guide
Porsche 912E Online Manual

Text of Porsche 912E User Guide:

  • Porsche 912E, 30 clutch, Controls No. Description Qty, Removing Note when Installing Remarks 1 Bolt 6 Loosen alternately Torque crosswise to 23. 5 M 8 X 15 1 to 2 threads cross- Nm (2.5 mkg). wise. 2 Washer 6 3 Diaphragm spring 1 Mark for installation. Check rivets. Clean clutch bearing surface in fly- wheel. Check for wear. Remove surface cracks and scoring by grinding or turning. 4 Clutch disc 1 Check for wear. Check teeth. Disc must be easy to slide on input shaft without too much rad

  • Porsche 912E, 10 , General 11-Compression pressure (with open throttle and engine at operating temperature, all spark plugs removed, practically no blowby with gauge in spark plug seat, engine cranked by starter motor) •••• ' •• Pressure Pressure difference between cylinders Cylinders and Pistons 2 oversizes, each with 0.5 mm greater diameter !-Cylinder • • • • • • • • ••••••• Out-of-round 2-Cylinder/piston • • • • • • • • • • • Clearance 3-a) Upper piston ring ••••�

  • 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, Check

  • 26 Exhaust System INSTALLATIO·N NOTES Tighten reactor mounting nuts crosswise and evenly. Keep to torque specifications. CHECKING REACTOR FOR LEAKS Note The reactor 's operation need not be checked. Only check it for leaks. 1. Run engine at idle spee?. 2. Insert an appropriate plug in the muffler's outlet pipe and c

  • Porsche 912E, REMOVING AND INSTALLING FUEL PUMP Removing 1. Disconnect battery ground strap. 2. Remove guard. 3. Pinch suction line with a commercial hose clip and loosen hose clamp. 4. Loosen pressure hose clamp and pull off hose. Catch escaping fuel. ' .. . , ._,_ .. .., A,. . - ,~~ ...... -~- Printed in Germany Fuel System 20 5. Remove rubber boots and detach electrical connections. 6. Loosen fuel pump strap and remove pump. Installing 1. Slide fuel pump onto suction hos

  • Porsche 912E, 28 Ignition Vacuum Advance Curve for Distributor ATDC oo r\ ~ 1- ' I' f\. ' ~--~ ~~ ~~ a:l .s::. t-(/.) .... 0 - [\ 1\ """ :I ""' 1-..0 " ' 't: ~ - (/) t-6 ~ - a:l -Q) ' (.) c co t-> "'0 <( t- ~, Vacuum CTorr) 50 I 100 150 Vacuum Cmbar) 100 200 28 - 6 Vacuum Advance Curve 200 Bosch 0 231176 060 I 300 250 ... ,.. 30 0 400 Printed in Germany

  • Porsche 912E, Timing with 1 mm valve clearance: Ignition Intake opens Intake closes Exhaust opens 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 1 n e L u b ri ~a t i on Lubrication Oil cooling Oil filter Oil pressure gauge Max. oil temperature Oil consumption Emission Control Heater Printed in Germanv General BTDC ABDC BBDC ATDC Battery ignition 12 volt + 5800 - 100 rpm 0 27 BTDC at 3500 rpm (vacuum hose disconnected) 1-4-3-2 CentrifuJal and v

  • Porsche 912E, Checking piston ring side clearance. Side Clearance Wear Limit mm mm Upper compression ring 0.04-0.07 0.12 Lower compression ring 0.04-0.07 0.10 Oil scraper ring 0.02-0.05 0.10 Inspect and fit pistons. Depending on given .. tolerances,. some piston pins can be pushed into the cold piston by hand. This is normal, even if the pin should slide out of the piston under its own weight. It is not appropriate in such cases to replace either the piston pin or piston, or both. CHECKING CYLINDER TO PISTON CLEARANCE The cylinder

  • Porsche 912E, 15 Engine, Cylinder Head, Valves CHECKING VALVE GUIDES 1. Remove deposits with cleaning reamer. 2. Place cy Iinder head on mounting plate US 4420 and iasten with bracket. 3. Insert new valve in guide. End of valve stem must be flush with guide. 4. Determine side play. Intake Exhaust Wear valve · valve guide guide limit Side play 0.30 mm 1.2mm Inside 8,02mm 9.02mm 9.06mm diameter dia. dia. dia. REPLACING VALVE GUIDES Worn or damaged valve guides can be replaced with the universal cy

  • 24 Fuel System, Fuel Injection CHECKING FUEL PRESSURE 1. Loosen injector supply line plug. 2. Connect the pressure gauge of P 378 with an appropriate adapter or a similar pressure gauge (rated 1, 0) to the injector supply line. 3. Disconnect vacuum hose between air distributor and pressure regulator. 24 - 6 Checking Fuel Pressure 4. Detach hose between throt

  • Porsche 912E, Gauges, Instruments, Radio 90 LOCATION OF RELAYS AND FUSES Up to three relays can be installed in the fusebox located in the luggage compartment. 1 - Open . 2 - Fogiight relay (optional) 3 - Hom relay 4 - Open 5 - Electric window regulator relay (optional) 6 - Open 7 - Open The hazard light relay is on the luggage compart- ment floor to the left as seen in the driving direction - same as Type 911. The fusebox holds 18 fuses. They are numbered consecutively on the current flow diagram, whereby the fuse up front as seen in the driving direction is designated S 1. P

  • Porsche 912E, 13. Engine, Crankshaft, Pistons CRANKSHAFT END PLAY End play : New : Wear limit: Adjusting End Play 0,07 - 0,13 mm 0,15 mm 1. Install flywheel with two spacers, but. without the seals for crankshaft and flywheel, 2. Install dial gauge holder with a dial gauge on crankcase. 3., Move. crankshaft back and forth, Read end play on dial gauge. 4. Determine thickness of third shim. · Dial gauge reading - 0.10 mm mean end play = 3rd shim thickness 5, Remove flywheel. 13 -12 Adjustin9; Crankshaft End Play 6. Insert seals fo

  • Porsche 912E, 24 Fuel System, Fuel Injection REMOVING' AND INSTALLING THROTTLE VALVE HOUSING Removing 1. Loosen and remove hose between intake air sensor and throttle valve housing. 2. Detach return spring, disconnect operating cable, pull off vacuum hoses, loosen mounting screws and remove throttle valve housing with gasket. Installing 1. When installing make sure that the gasket is positioned correct! y between air distri- butor and throttle valve housing. Screws must not

  • ADJUSTING IGNITION TIMING Check the dwell angle before adjusting the ignition timing and, if necessary, correct it + 0 to 47 - 3 • 1. Connect engine to engine tester. 2. The timing is adjusted on a warm engine 0 0 (oil temperature approx. 60 C/140 F) with a stroboscopic timing light. Pull off vacuum hose at either distributor or throttle housing. 3. A

  • Porsche 912E, TECHN.IC-!'\L DATA Front suspension Springing Torsion bars Height setting (at DIN curb weight) Difference in height left to right Wheelbase Track Shock absorbers Make Stabilizer Printed in Germany Front Wheel Suspension Independent. with shock absorber struts and transverse control arms One round torsion bar per wheel in driving direction 18.8 mm dia. 40 99 ! 5 mm from center of wheel to center of torsion bar 5 mm 2271 mm 1360 mm Double action. hydraulic Boge 16 mm dia. Tec

  • Porsche 912E, Adjusting Clutch Play Pull out clutch pedal in direction of arrow to check. The specified play Is 20 to 25 mm. The clutch cable is adjusted by the counternuts on the end of the cable. 1. Press in clutch lever to center rib by hand. 2. Pull out engaging cable with pivot in opposite direction. There must be about 4 mm of play between the lever and pivot. To facilitate adjustments, a 4 mm dia. spacer (drill bit) can be placed between the lever and pivot. Printed in Germany Clutch, Controls 30 Adjusting Clutch Play 30 ·- 5

  • Porsche 912E, General 10 TOLERANCES AND WEAR LIMITS l The term ''wear limits" indicates parts which are near or have already reached the dimensions given should j not be reinstalled during an overhaul. When determining the wear limit of pistons and cylinders, the oil 1 consumption of the pertinent engine must be taken into account. ; Note: The values are in mm if not otherwise specified. Cooling System Thermostat • · ••••••••••• Opening temp. Fan/pulley ••• ': •••••••• Imbalance Oil Circuit l-OU p~essure bSAE 30 oils only) at

  • Porsche 912E, Engine, Crankshaft, Pistons 13 TOOLS 4 3 No. Description Special Remarks Tool 1 Inside micrometer us 1032 2 Feeler gauge Commercial item 3 Micrometer 75 - 100 mm us 1075 4 Piston pin drift VW 207c 5 Angled circlip pliers Commercial item 6 Piston ring compressor US 1008a 7 Piston ring pliers Commercial item L . Prlnte.d In r.P.r m!>nv

  • Porsche 912E, 13 Engine, Crankshaft, Pistons REGRINDING CRANKSHAFT Main bearing Crankpin journals Main bearing Standard 1st Undersize 2nd Undersize 3rd Undersize journals (d 1) 1, 2and3(d) Nominal Lapped Nominal dia. mm dia. mm dia. mm 60.00 59.990 50.00 59.971 59.75 59.740 49.75 59.721 59.50 59.490 49.50 59.471 59.25 59.240 49.25 59.221 d 3 _ 42,006 mm d. 41,995 ? Lapped dia. mm 49.996 49.983 49.746 49.733 49.496 49.483 49.246 49.233 2,5 r=--mm 2,0 journal 4 ( d 2) Nominal Lapped dia. mm dia.mm 40.00 40.000 39.984 39.75 39.750 39.734 39 • .50 39.500 39.484 39.25 39.250 39.234 Careful grinding of main bearing and

  • Porsche 912E, 10 Engine, Crankcase 23. Loosen bolts at transmission carrier. 24. Loosen bolts at engine carrier. 25. Lower floor jack with engine/transmission assembly carefully and roll out toward rear. Caution Do not place engine on the reactors, which would cause them to leak. If vehicle is to be moved (with the engine/trans- mission removed), drive shafts must be supported so that they hang horizontally to prevent damage to drive shaft boots, Installing Note the following points on installation. Caution 1. Be careful not to pinch the heater hoses, Connect them to the heat exchan

  • Porsche 912E, 13 Engine, Crankshaft, Pistons No. Description Special Remarks Tool 1 Support vw 457 (adapter) plates 2 Not applicable 3 Tube 60 mm dia. VW 415a 4 Guide sleeve, tapered VW 428a 5 Crankshaft holder vw 801 6 Connecting rod aligning and vw 214f reaming set 7 Press plate vw 402 8 Tube. vw 421 9 Tube vw 416b 10 Press block vw 409 11 Circlip pliers VW 161a 12 Feeler gauge Commercial item 13- 18 Tools Printed in Germany

  • Porsche 912E, 20 Fuel System 2. Tighten suction hose clamp: 3. Make electrical connections. Watch polarity marks. 4. Install rubber boots. Note Make sure that the boot,s fit properly to prevent corrosion on the terminals. 5. Connect pressure hose and hold tight with hose clamp. 6. Remove commercial hose clip. 20 - 2 Removing and Installing Fuel Pump 7. Check hose connections for leaks. 8. Install guard. 9. Connect battery ground strap. Printed in Germanv

  • 34 Manual Transmission, Controls, Case No. Descriptiqn Qty. Note Remarks Removing Installing 18 Bearing outer race 1 Heab case to 0 approx. Heat case to approx. 120 C/248 F and 120°C/248°F and drive out with drive in with us 8050. us 8050. 19 Breather 1 Install correctly and torque to specifications. 20 Transmission cas

  • Ignition 28 EQUIPMENT CHARTS Ignition Coil Type/Model Version Remarks 912 E 022 905 115 c Distributor Type/Model Version Remarks 912 E 923 602 021 00 Centrifugal and single (without speed limiter) action vacuum control (retarded) Spark Plugs Type/Model Version*) Remarks - 912 E Bosch W 175 M 30 M 14 X 1.25 X 19.0 Beru 175/14/3 L threads 0.

  • Porsche 912E, 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. mm/in. 3 3 em /in. kW/HP 94/3.70 71/2.80 1971/120.3 7.6 : 1 64/86 at engine speed of 4900 rpm Technical nat:~ _ (;pnpr"l ll , .

  • Porsche 912E, 47 Brakes, Hydraulics Parking Brake-s Brake drum dia. Brake shoe width Effective braking surface per wheel *) Machine brake disks uniformly on both sides. 47 - 02 Technical Data 180 mm 25 mm 2 85 em Printed in Germany

  • Porsche 912E, . REMOVING AND INSTALLING CONTROL UNIT Removing 1. Disconnect plug at control unit by pushing back spring and pulling out of socket at the same time. 2. Loosen screws and remove control unit. Installing Connect plug at control unit and press into socket until the spring clip engages with an audible cW:k. ·"' Fuel System, Fuel Injection 24 REMOVING AND INSTALLING COLD STARTING VALVE Removing Disconnect electrical plug and fuel lines, loosen screws and remove cold startin

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