User manual PORSCHE 944 WORKSHOP MANUAL 1991

[. . . ] This level of knowledgeis necessaryin order to carry out the work described. Warning notes The warning notes and safety instructionsare classified by the respective signalisingword (Danger, Warning, Caution)besidethe warning symbol. Warns against death or very serious injury which will certainly occur if the instructions are not observed. Warns against death or very serious injury which may occur if the instructions are not observed. Warns against minor injury or damage to property instructions are not observed. if the To prevent injuryand restricted operating and traffic safety of the vehicle, or damageto the vehicle as the result of incorrect work, read these instructions carefullyand observe them withoutfail. It is not possiblefor PorscheAG to give a detailed evaluationof all danger situationsfor the personscarrying out the work. It is therefore imperativethat all personscarrying out repair and maintenance work on Porschevehiclesuse their specialistknowledgeto ensure that their own safety is not at risk and the procedure chosenwill not have any negativeeffects on the vehicle -especially with regard to safety. It is therefore expresslyspecified that all work involvedin the work proceduresdescribed shouldbe carried out onlyin accordancewith the valid guidelinesand regulationsof the local authorities responsible with respect to health and accidentpreventionand environmen- Foreword Printed in Germany -44, 2001 vorwort -1 page 1 www. WorkshopManuals. co. uk Foreword 911 Carrera (996) tal protection, and in compliancewith the legal requirementsof individualcountries. Notes Notes contain advisoryinformationrelated to the work procedure which makes the fitter's work easier. [. . . ] Always replacebellows cardan for shaft. i 01 ~' 2. Slide assemblysleeve 9255 over the shaft splines, lightly lubricate sleeve with Vaseline and push on the bellowsto the stop. ( \n 235_98 A A -Assembly sleeve 9255 236_98 3902 19 Printed Removing and installing cardan shaft -14, 1998 C4S39105 39 -107 in Germany www. WorkshopManuals. co. uk Final drive -Differential, differential lock 911 Carrera 4 (996) 3. 3 g of Olista Longtime 3EP. A -Bellows B -Cardan shaft C -Central shaft groove 240_98 Tighteningtorques: Cardan shaft on transmission flange (MID) = 45 Nm (33 ftlb. ) A -Bushing 238_98 4. Grease splines of the cardan shaft with Olista Longtime 3 EP. Slide shaft into the central shaft splines and fit on the transmissionside. Push bellowsforward until it engagesin the groove of the central shaft. Check whether the bellows is seated properly by pulling on it. Transmissionsupport; transmissioncarrier on transmission mount (M 10) = Transmissionsupport on body (MID) = 65 Nm (48 ftlb 65 Nm (48 ftlb. ) 8 39 -108 39 02 19 C4539105 Removing and installing cardan shaft Printed in Gennany -14, 1998 www. WorkshopManuals. co. uk 911 Carrera 4 (996) Final drive -Differential, differential lock 39 82 19 Tools Removingand installing sealing ring for cardan flange 276_98 Item Designation Special tool Explanation commerciallyavailable (refer to Technical Equipment Manual, Chapter 2. 4, No. 64). wrenchinsert A Socket B Pressure piece puller C Three-arm 9639 Commercially available (refer to Technical Equipment Manual, Chapter 2. 4, No. 112-1) 39 82 19 Printed Removing and installing sealing ring for cardan flange -14, 1998 C4S39109 39 -109 in Germany www. WorkshopManuals. co. uk Final drive -Differential, differential lock 911 Carrera 4 (996) Removing and installing sealing ring for cardan flange Removal 1. Place oil collection tray under the transmission. \ \. Engage gear and firmlyset the handbrake. Uniformlytighten fastening screws for long-neckpipe in diagonallyopposite 256_98 '\\ A -Special tool VW457 4. Removesnap ring and take out viscous coupling with supporting ring. 255_98 8 sequence. 4. Fill in oil for final drive (refer to Servo No. 39 90 55). 8 39 60 19 Printed Removing and installing the viscous clutch -14, 1998 C4S39113 39 -115 in Germany www. WorkshopManuals. co. uk Tightening torques: Long-neckpipe on final drive (M8 x 36) Front transmission support on final drive (M10) Oil drain plug on final drive (M18 x 1. 5) = 25 Nm (19 ftlb. = 65 Nm(48 ftlb. : = 28 Nm {21 ftlb. : 39 -116 Removing and installing the viscous clutch 39 60 19 Printed in Gennany -14, 1998 C4S39113 www. WorkshopManuals. co. uk 911 Carrera 4 (996) Final drive -Differential, differential lock 39 60 01 Checking function of installed viscous clutch 2000 1500 r:;;;; ~ 1000 m - 500 0 1 2 3 4 5 6 7 8 9 A (km/h) 191_98 A = Ground speed of the front axle in kilometres/hour B = Traction of the front wheels in (N) Testing conditions: Test only with viscous clutch at room temperature Test duration max. 45 seconds (determine measuredvalue after 20 seconds) Repeat measurementafter viscous clutch has cooled down for one hour 1. ConnectPorsche System Tester 2 and select "Actual values" menu (ABSspeed). Drive front wheels of the vehicle onto the roller brake tester. Switch the engine off, set the hand brake and shift the transmissionto neutral. 39 60 01 Printed Checking function of installed viscous clutch -14, 1998 C4S39117 39 -117 in Germany . -~ ' 1 www. WorkshopManuals. co. uk 4. Whenthe brake-tester rollers have started, switch the ignition on and press the Continue key» of the Porsche System Tester 2. The Tester then returns to the point at which diagnosis was interrupted. Drive front wheels via the rollers of the brake tester (max. [. . . ] Fit differentialinto the transmissionhousing and turn it through several revolutions. Installthe side transmissioncover without sealing ring and tighten all hexagon-head bolts to 25 Nm (19 ftlb. ). 365_99 A = Dial gauge extension (approx. 30. . . 40 mm long) B = Finaldimensionplate VW 385/17 8. Movethe differentialup and down with special tool VW 521/4. [. . . ]