Also refer to Repair Group 03, Diagnosis, for operating instructions, repair group D, volume 8 diagnosis. Starting with Model Year '95, the diagnostic socket is located on the left-hand side of the center console and is fitted with a plugged-on cover. Clean drain plugs. Always replace the seals. Tightening torque of drain plugs is Precondition: Engine at operating tempera- 50 Nm 37 ftlb. Fill with approx. Run engine at idle and top up with approx.
Crankcase drain plug 3 liters. The oil change capacity is approx. Use only approved engine oils. Re- fer to Technical Information Handbook. Check engine, oil reservoir, lines and front oil. J Check hose connections of entire intake system for tight fit! Particle filter:.
Replacing filter element Installation. Place particle filter into housing duct. Note Assembly mark faces up.
Fit housing cover into housing duct from conditioning housing. Removal Fig. Remove cover for heating and air condition- cover ing system. Screw out knurled nut and dis- engage retaining clamps from housing cover using a screwdriver. Lift off housing cover. The assembly mark of the particle filter is visible from outside in the housing cover.
Checking used drive belts Fitting a new belt alternator and fan wheel alternator and fan wheel Use belt tension measuring instrument Spe- When fitting a new belt, be sure to observe cial Tool to check tension.
Fit new belt. Adjust tension by inserting or Retensioning the belt is only required if removing shims as required. The ments when the engine is cold and less 0. Before measuring the belt tension, start Retensioning the belts engine once more and run engine at idle Retension belts as described in the General briefly.
Adjustment Notes section. Before measuring the belt tension, start Tension: engine and let engine idle briefly. Cold engine: 23 to 35 scale increments. Run engine at idle for approx. Cold engine: Specification: 28 to 40 scale increments Engine at operating 20 to 28 scale increments Retension if required.
General adjustment notes 4. Use only V-belts that have been approved Fan wheel and alternator have separate by the manufacturer. 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. Use polygon wrench 02 to lock shaft and undo hexagon head nut. Remove shims and pulley half. If belt tension is below specification, remove one shim from between pulley halves and refit in front of front pulley half.
Tighten hexagon head nut to 50 :t 5 Nm. Three additional M 6 screws have to be undone for V-belt and fan wheel. Replacing spark plugs 5. If spark plugs are difficult to remove, use Special Tool disassembly clamp , Remove both rear mufflers Part No. Remove engine guard. Unscrew spark plugs with commercially available Snap-on socket, Part No. S , and Snap-on extension, Part No.
FXW 4. Note 1. Undo rear muffler at tightening strap and lift off rear muffler. Remove rear muffler brack- Do not use any lubricant on the plug threads. Undo hot-air hose from right-hand heat exchanger cyls. Undo both left and right-hand engine covers from camshaft housing, hydraulic pump sup- port bracket as well as front and rear en- gine cover.
Leave engine cover suspended at ignition cables. The parking brake is fitted with asbestos-free brake linings. The parking brake must never be adjusted in such a way that the lining has to "grind itself free" in operation. If the brakes do not show any effect when the parking brake lever is pulled up by more than 4 notches using medium force, the parking brake must be readjusted.
Insert a screwdriver across the hole in the Adjusting the parking brake: brake disc to reset the adjuster until the wheel is locked. Then undo the adjuster 1. Remove rear wheels. Now undo by a further two notches. Release parking brake lever and push back disc brake pads until the brake disc rotates 5. Pull up parking brake lever by two notches freely. Undo the adjusting nuts on the turnbuckle by hand.
Release parking brake lever check if both Note wheels rotate freely. Remove the cassette box behind the parking brake lever to gain access to the turnbuckle. The fastening screw is located below the rub- ber insert. Brake system:. The brake pads must be replaced on both sides of one single axle as soon as the brake pad wear warning lamp lights up or, at the latest, when the pads have worn down to a thickness of 2 mm.
If pad wear is indicated by the wear warning lamp, the warning contact sensor complete with wire and connector must be replaced. Replacement of the warn- ing contact s can be avoided by replacing the brake pads at the latest when they are worn to a thickness of 2. Warning con- tacts must be replaced if the wire core is ex- posed.
Replacement is not necessary, how- ever, if rubbing wear is limited to the plastic part of the warning contact only. Remove rear wheels to check rear brake pads. The front brake pads are visible with the wheels fitted. The wear limit is reached as soon as the remaining pad thickness is down to 2 mm. Brake hoses and pipes: Miscibility of brake fluids:.
This corrosion means that Super DOT 4 can be used to top up the brake fluid-level in vehicles with brake Checking the brake fluid level systems containing the old type of brake fluid Top up brake fluid if required refer to marks until the next time a brake fluid change is due. Both brake fluids are coloured amber. Never top up beyond the MAX mark as this may cause brake fluid to escape past the bleed hole.
A 2-year change interval applies to this brake fluid. Checking pedal final position pedal return! To ensure correct clutch operation, the follow- return force ing items must be observed, among others, when the pedals are adjusted: Caution: The boost spring has two functions: boosting the pedal force and and returning Correct bleeding of hydraulic clutch circuit the pedal to the home position.
Pull pedal back into the home position with a Tightness of hydraulic system minimum force of 30 N use a spring scale. The pedal must not yield in this position. Pedal return into home position To do so, undo Allen screw No. Installation position of pedal assembly matches standard specifications.
Checking resonance flap for operation When the ignition is switched on, the reso- nance flap is closed by vacuum action. When the ignition is switched off, the resonance flap is opened rest position.
The opening and closing noise is audible in the engine compart- ment. Steering gear: Checking the bellows for damage. Check that joints, dust seals and bellows ope- rate correctly and that the dust seals and bel- lows do not leak. The rubber dust seals and bellows at the stee- ring gear and tie rods can be damaged by out- side impacts, e. If the dust seals leak, the joint or the respective tie rod must be replaced as Correct fluid level:. In the case of reservoirs with a transparent Power steering: upper section first version used , the fluid le- vel must be between the min.
Checking fluid level marks on the reservoir. The reservoir is located on the right-hand side If the reservoir does not have a transparent in the engine compartment. Unscrew the lid and wipe the dipstick clean. Note on toothed belt for power steering pump The tension of the toothed belt cannot be adju- sted but its condition must be checked. This means that Pentosin can be used to top up the fluid level in vehicles before the aforementioned introduction date.
On vehicles with Pento- sin filling, always fill or top up the brake system with Pentosin. Axle joints: Suspension alignment wheel align- ment specifications : Visual inspection of dust seals for leaks Check bolt connections of front and rear Check dust seals of axle joints ball joints of suspension geometry wheel alignment for front and rear suspension as follows: tight fit. After cleaning the components, check condition visually. Press rubber dust seals Transmission I final drive: with the fingers to detect any hidden cracks.
Visual inspection for leaks, checking oil levels Proceed as follows on front axle: Turn front wheels to full lock. Visually in- For further notes, refer to page 03 After turning the front wheels to the op- posite full lock, check the other half of the rubber dust seals. Visual inspections are not possible in a small area around the brake cover panels. Check this area by feeling with your fingers. If the rubber dust seals leaks, the joint or the respective steering arm must be replaced as ingress of dirt or moisture will lead to destruc- tion of the joint.
Checking A TF fluid level. The specified fluid level is of great importance L If required, top up with A TF fluid across the Tor proper operation of the automatic transmis- quick-fill device. Visual inspection of cup seals for leaks Transmission guard is removed and damage.
Vehicle must be on a level surface Exhaust system: Engine is idling Visual inspection for leaks and damage, check bolt connections for tight fit and Parking brake is pulled examine mountings. Selector lever is set to "P" 1. Check exhaust system for tight fit and complete exhaust system for leaks. Check ATF temperature C mountings of exhaust system. Check all flange connections of exhaust sys- tem as well as oxygen sensor and emission test plugs for proper tightening. Tightening torques: 1 -Heat exchanger to cylinder head 23 Nm 17 ftlb.
Tires: Tire pressure of cold tires approx. Tire condition inch and inch wheel inch and inch wheels summer tires Tires are safety-relevant items that are only inch winter tires capable of meeting the requirements imposed front 2. The tire pressures indicated are minimum inch wheels summer and winter tires pressures.
The tires must never be run at lo- front 2. Collapsible spare tire. Valve caps protect the valve against dust and fronVrear 2. When the hoods front and rear are closed, the hood locks must engage as soon as the Check door and hood locks and upper lock sections move into their seats and safety catches of front hood for must disengage again when the hood release secure fit and correct operation is pulled. Checking for secure fit: Safety catch -front hood The fastening screws of the door lock, front and rear hood locks as well as the fastening After the hood lock has been released, the nuts for the upper lock sections of the front front hood must be held down by the safety and rear hoods must be tightened to 10 Nm catch.
At the same time, this safety catch 7 ftlb. Functional check: When the hood is open, the retractor spring must pull the safety catch back to the stop Door lock against the baseplate of the upper lock sec- tion.
When the door is closed, the door lock must engage into the lock striker in two stages and disengage again when the door opener in- side and outside is operated. When the belt is pulled evenly, the belt strap must roll smoothly off the belt retractor across the guide fitting, and the plug-in latch of the seat belt must engage audibly into the lock.
The seat belt retractor must lock if the belt strap is pulled wi1h a jerk. The belt strap must be inspected visually for damage. If damage such as cuts, fraying, sep- arating seams etc.
Coat seals with glycerine. Maintenance Carrera A -Lateral and vertical adjustment B -Vertical adjustment. Use a standard 5 mm ball socket screwdriver for adjustment. The vehicle must be placed on a level sur1ace. Using a headlight aiming device, adjust headlights with vehicle in roadwonhy condition full fuel tank, driver's seat occu- pied or loaded with 75 kgs. Adjust headlights with control switch set to the 0 position. Adjusting headlights Note U.
Note 2. Rotate upper adjustment thumbwheel side To comply with legal requirements, a bubble and height adjustment, refer to p. To allow the side adjustment to be checked, an adjustable slide 8 is fitted to the side of the reflector.
This slide is factory-set to the "zero adjustment mark" after the headlight has been adjusted. Rotate lower adjustment thumbwheel height adjustment, Fig.
Repeat items 2 and 3 if required. Adjustment: 1. The vehicle must be placed on a level sur- face. Adjust with the vehicle in roadworthy condition full fuel tank, driver's seat loaded with one person or 75 kgs, tire pressure meets specifications using a headlight adjuster. Note The side adjustment of the headlights is marked by the adjustable slide. This zero adjustment mark is factory-preset and must not be altered. Readjustment should be limited to accident repairs or replacement of headlight assemblies.
Adjusting the zero adjustment mark: 1. After having completed the headlight adjust- ment, unlock headlight inside luggage com- partment and lift out headlight. Turn adjustment screw of slide for check- ing the side adjustment with "Torx Tamper Resistent T 40" special tool until the "zero adjustment mark" lines up with the reflector. Refit headlight. Adjusting foglamps Check operation of all other electri- cal devices as well as warning and 1.
Using a headlight aiming device, adjust hazard lamps headlights with vehicle in roadworthy condi- tion full fuel tank, driver's seat occupied or loaded with 75 kgs, tires inflated to correct pressure.
Checking operation 1. Measure CO and HC values with engine at operating temperature and both ignition cir- cuits in operation. Use System Tester to switch off igni- tion circuit 1.
Switch ignition circuit 1 back on and switch off ignition circuit 2. Windshield washer, headlight washer system: 5. Measure CO and HC value. Checking operation, fluid levels and nozzle The CO and HC values must not change sig- adjustment nificantly when the engine is running with only one ignition circuit. Check operation of service and parking brake, clutch, automatic speed control, steering, heater, air conditioning and instruments. It is recommended to run a test drive once with the engine guard removed to allow the engine and transmission to be checked for leaks and to avoid any additional assembly work if leaks are detected.
Do not exceed a vehicle speed of 95 mph. Filling capacity: approx. When changing the ATF fluid, the vehicle must be on a level surface, the engine must b. Drain ATF fluid. Clean ATF pan thoroughly. With the engine stopped, start by filling in ATF fluid up to the Tightening torque: 8 Nm 6 ftlb. Place two magnets into the grooves in the ATF pan, place gasket into position and attach pan using the mounting brackets in such a manner that the short legs are pushed onto the ATF pan.
Screw in ATF drain plug with new seal. Tightening torque: 40 Nm 29 ftlb. Screw in banjo bolt for oil level pipe com- plete with new seals. Start engine with selector lever set to "PH and allow engine to idle. Observe ATF level in oil level pipe and immediately top up to the C Max mark if required. The ATF level in the transmission may vary according to the fluid temperature. The marks on the oil level pipe refer to ATF tempera- tures of C and eo.
The fluid level must now between the 80' C mark and the Min and Max marks. To determine the ATF temperature exact- ly. Toothed belt for power steering: 3. Undo air cleaner housing from intake air rail and unhook clamps from air flow sensor. Checking condition Lift up air cleaner housing and take out. Remove transmission guard from transmis- housing. Be careful not to lose the a-ring in the air sion. Undo three M 6 x 15 mm hexagon head 4. Undo both M 8 x 30 mm hexagon head bolts from toothed belt cover.
Refer to Fig No. Lift toothed belt The figure shows the engine removed from cover out of engine compartment. Rotate engine and check toothed belt for wear and damage. Unhook clamps of air cleaner cover. Remove housing cover and filter element.
Replacing oil filter on engine housing Replacing oil filter on thermostat housing 1. Undo hot-air hose at 1. Remove right-hand side member panel. Undo hexagon head bolt at crankcase and 2. Undo oil filter with Special Tool Catch remain- ing oil in a pan.
Apply a thin coat of oil to seal of new oil filter. Tighten oil filter manually until seal 3. To tighten fully, turn by approx. Apply a thin coat of oil to new oil filter. Tighten oil filter manually until seal is Check oil level at operating temperature and seated firmly. To tighten fully. Check approx. Always replace engine, oil reservoir, pipes and front oil cooler a-rings for oil pipe. Changing transmission oil Note manual transmission Due to the length of the transmission, the oil Filling capacity: 3.
MIL-L B. It is therefore very important to top up very slowly, observing the specified oil quantity. Remove transmission guard. Drain oil with vehicle on a level surface and transmission at operating temperature.
Clean filler and drain plugs, replace seals and tighten bolts to 30 Nm 22 ftlb. Slowly fill in 3. Clean filling and drain plugs, replace seals and tighten bolts to 50 Nm 37 ftlb. Fill in transmission oil with the vehicle on a level surface until the oil overflows at the neck. Replacing fuel filter Battery: 1.
Take Checking electrolyte level out housing cover and filter element. Separate air cleaner housing from intake air rail and unhook from air flow sensor. Lift up To avoid short circuits, the battery must al- air cleaner housing and take out housing. Undo fuel lines, using a second wrench to lock.
Drain remaining fuel into a suitable 1. Open luggage compartment lid. Remove covers. Undo clamp and remove fuel filter. Undo and pull off ground connector.
Checking electrolyte level. Check electrolyte level of all cells. If the electrolyte level has dropped below the minimum mark, top up with distilled water to the max. Excessively low battery electrolyte level reduces the battery capacity and the life of the battery.
Check fuel and injection lines for leaks and tight fit! Changing brake fluid To monitor the escaping brake fluid for cle- vacuum brake booster anliness, freedom from air bubbles and to determine the brake fluid used, use a reci- Important notes pient bottle.
Use only new DOT 4 brake fluid. Observe Also drain some brake fluid at the bleeder change interval and brake fluid quality.
Refer to page 03 for further 50 c. Total brake fluid quantity approx. Switch off and disconnect bleeder device. Top up brake fluid if required. Procedure for changing brake fluid. Fill reservoir with new brake fluid up to up- per edge.
Connect bleeder device to re- servoir. Switch on bleeder device. Bleeder pressu- re approx. Proceed with brake fluid change on the in- dividual calipers no particular sequence required. Open each bleeder valve until clear, bub- ble-free brake fluid escapes or until the re- spectiye change quantity per caliper is re- ached approx.
Make sure all brake calipers are bled on both bleeder valves. Observe correct fluid change intervals and fluid grade. Refer to page 03 for further information Total brake fluid quantity for brake fluid change approx. Brake fluid change procedure Important notes To allow the brake fluid to be changed in a Depressurize booster circuit before rapid and practical manner, a filling and bleed- changing the brake fluid. Do not depressurize by actuating the brake pedal but rather at the bleeding valve of the If the booster circuit has not been depres- pressure accumulator.
This will allow part of surized completely, do not actuate the the old brake fluid to be drained. After the pump has switched off, pull off electrical connector and release pressure completely Changing the brake fluid: 1 st step from accumulator vent valve. Open bleeder With the booster circuit depressurized, top up valve slowly and keep bleeder hose in with fresh brake fluid to upper edge of reser- place.
Connect bleeder device to Caution: A pressure of up to bar is reservoir. Bleeding pressure: approx. Use a recipient bottle to allow the escap- ing brake fluid to be checked accurately for cleanliness and freedom from bubbles and to determine the quantity of brake fluid used. Fluid change quantity per wheel: approx. Bleed at both bleeder valves on each wheel. Caution: Pump the break pedal at least 10 times over its full travel after operning the first bleeder valve.
This additional operation is only necessary for vehicles Remove hose clamp from over- flow hose vent. Fill pressure accumulator completely by. After the pump unit has switched off, cor- With the bleeder device switched on, drain rect brake fluid level. Never top up be- approx. For this purpose, connect electrical connector to pressurizing pump with ignition key in position 1.
As soon as the specified quantity has been drained, pull off connector and close bleeder valve. Location Thread Tightening torque Nm ftlb. First stage: 30 22 Final stage: 1 x :t 20 rotating angle Final check 60 refer to page d. Crankcase M 10 x 1. Hexagon head nuts or M8 23 17 hexagon head bolts to crankcase. Double mass flywheel M 10 x 1. V-belt pulley to M 14 x 1. Plug -pressure relief M 18 x 1.
Oil drain plug for crankcase housing M 20 x 1. Oil drain plug for thermostat housing M 20 x 1. Screw-in neck in left-hand crankcase section oil return to oil tank M 22 x 1. Screw-in flange in right-hand crankcase section oil feed to oil pump M 24 x 1. Cylinder and cylinder head. First stage: 20 15 Final stage: 1 x t2 rotating angle Camshaft housing!
Knock sensor bridge to cylinder bank M6 9. Sprocket to camshaft M 12 x 1. Flange stud slider and tensioning rail to crankcase 30 Fan wheel for alternator cooling t t 0. Cataly1ic converter final muffler ball clamp Belt monitor to bracket M6 9. To avoid injury, slide a suitable protective cover over the upper lock section protruding from the engine compartment cover, e.
Disconnect plugs, remove air conditioning compressor from console and leave it at- tached to the hoses connected to it. The compressor may be placed on a suitable rigid support on the left-hand side panel. Drain reservoir of power steering pump draw off fluid.
Pull spark plug connectors off cyls. Place suitable pan under hydraulic pump. Disconnect hoses and catch remaining oil in a pan. Always plug pump openings and hoses to prevent dirt ingress.
Remove hot air blower. Disconnect plug from intake rail. Take care 1 -to carbon canister not to lose the plug seal. Undo cover of electrical system of engine compartment. Disconnect connectors care- fully to avoid breakage. Release connector A before pulling it off.
Remove right-hand cover next to air conditioning compressor, unlatch oxygen sensor plug and disconnect plug. JI Unlatch throttle operating cable from pedal return lever, back off lock nut and take off ball joint. Raise vehicle Undo fuel return and fuel supply line. Remove engine I transmission guard and rear underbody paneling.
Release ball clamps and remove tailpipes from rear mufflers. Remove both rear mufflers. The rear mufflers engage into their backets at the top. Undo drive shafts at the transmission flange and place them on the side sections of the subframe. Protect the drive shafts against damage. Undo hexagon head screw and pull selec- tor rod coupling off the internal shift rod.
Remove hot air hoses, hot air pipes, hot 22a. Loosen fastening nut no. Remove toe eccentric A area. Rotate toe control arm 2 towards the out-side detaching it from the cross member. Important: While doing so, the rubber boot of the ball joint must be rotated as well arrow ; otherwise, the boot might get damaged.
Remove complete stabilizer assembly. Mark position of toe eccentrics A area. Detach toe control arm 2 on the other side as well and rotate it downwards. Remove rear cross member. Disconnect oil return line from gearbox. Release right-hand sill cover and engine Release hose clamp and pull hose off the oil from thermostat housing.
When the en- oil pipe. Catch remaining oil in a pan. Undo wire of term. Undo oil return line, using a second Undo ground strap between body RH wrench to lock. Pull throttle operating cable out of its guide. Place engine jack complete with engine mounting plate, applying a slight preload. Note Working from the engine a. Observe position of mounting plate.
Lock compartment, unbolt the clutch slave cylin- lever in horizontal position. The support blocks on the mounting plate face down. Do not actuate the clutch pedal after the slave cylinder has been removed. Attach a note to this effect inside the vehicle. When lowering the assembly, take care not to damage the lower spark plug connector cyl. Caution When the vehicle is placed back on its wheels, the rear crossmember and both steer- ing arms 2 should by all means be refitted to provide sufficient rigidity.
Unbolt transmission crossmember 6 bolts. Unbolt engine mount. Use long- reach socket. Installation 4. Tighten the toe eccentric A area in zero. Observe the following aspects during position. Tightening torque: Nm. Zero position: Toe control arm 2 and rear. Replace all fastening nuts. To obtain this zero position, lift wheel carrier 2.
Fit toe control arms 2 to cross member. Note The toe eccentrics can also be tightened after Note the vehicle has been put on its wheels and Before fitting toe control arms 2 to the cross has been rocked back and forth approx. Check whether all plugs have been re- Required quality The quality category is moved completely from the oil hoses and oil pipes and especially from the bends of indicated on the screw head.
Replace eccentric, if required e. Tighten the fastening screw of the gearshift In this case, transfer the position marks to the rod coupling. Tightening torque 23 Nm new eccentrics.
Important: 7. Fit accelerator cable from below. Make sure To tighten the eccentric A area , proceed the rubber sleeve fits properly. Put the metal lid in place from below. The holding brackets on the lids must face upwards into the engine compartment. As shown in the figure, the holding brackets must be positioned at a right angle to the direction of travel in the "a" area.
Only in this area is a tight fit ensured. Remove wire from starter and wire from 3. Undo 4 fastening nuts and separate trans- reverse light switch. Use Special Tool P to undo upper fastening nut on 2. Remove M 6 x 16 hexagon head bolt, starter.
Pull out release shaft using a M 6 x 40 hexagon head bolt. Note: Apply a very thin coat of Olista Longtime 3 EP to input shaft splines for corrosion protection only. Engage release fork in release bearing and use a length of suitable adhesive tape to locate it provisionally in the installation posi- tion. Fit needle-roller bearing, mount cover and bracket and tighten with M 6 x 16 hexagon head bolt also refer to assembly notes, Group 30, page 30 Part No. FM 14 2 required. Left-hand crankcase section Note: Unless Indicated otherwise, apply Loctlte to all stud threads when reassembling the engine!
Note: No. Designation Oty. Removal Installation. Using a 5 mm dia. Peen circumference of spray jet. Remove cover, spring and ball. Inser1 a M 5 tap finishing tap No. If required, use M 6 tap taper tap No. Bond new spray jet in place using Loctite or Loctite Observe installation position, ball points towards bearing saddle.
Bore must be free from Loctite. Oversize spray jets are available from the Parts Department. Right-hand crankcase section Note: Unless Indicated otherwise, apply Loctlte to all stud threads when assembling the engIne! Loctite hardens only when contact with metal is made and air ingress is prevented. After having applied the sealant, bolt up the crankcase sections within approx. In case of repairs, the old sealant coat must not necessarily be removed.
It is sufficient to de-grease the surface and apply the new coat of sealant after the solvent has evaporated. New Loctite will soften the old sealant em- bedded in the machining marks and will cure after assembly. Should it be required to remove the old seal- ant, it isrecommended to use a fine-mesh wire brush or Loctite adhesive remover For manual application, it is recommended to use a short-pile paint roller and to pour the sealant into a dish with grooves at its cir- cumference for squeezing excess sealant off the roller.
Apply a uniform coat of Loctite sealant to the left-hand crankcase section using the paint roller. Use a small paint brush to apply sealant to the areas around the bolt holes. Mounting Sequence of Bolts.
Lubricate 11 bolts and 24 round seals light- 4. Insert the prepared bolts into the right crank- ly with oil. Note Lubricate seals with oil only immediately be- fore installation: never keep lubricated seals in storage for a long time. Guide round seals over the threaded zone with the tapered adapter of Special Tool P , and slide on to the reduced shaft head end of the bolts.
O-ring must not be pushed on to the bolt collar 10 mm dla. Slide the tapared adapter with mounted and lubricated round seal on the threaded end.
Prepare left and right crankcase sections for assembling. Coat mating surfaces and bear- ing seats of the left section lightly with Loctite No. Slide round seal off of the tapered adapter Special Tool carefully, with A-end thin wall of the cylind- rical sleeve. Install insulators dry and press on lightly with the cylindrical sleeve's B-end. Remove tapered adapter and slide round sleeve into final position carefully with the 9.
Install multiple-tooth nuts threads lubricated B-end thick wall of the cylindrical sleeve, with oil finger tight. Proceed with both studs for the right crank- case section near bearing no. Mount M 10 x 1 ,25 hexagon nut and A Tighten bolts and studs with 50 Nm A second person should always counterhold while tightening, to avoid damaging the a-rings while turning the bolts. Use a M 14 wrench socket from "Snap-on". Engine, Crankcase, Suspension Carrera Note After fitting the right crankcase half, a tube should be pushed on to connecting rod cylin- ders 1 and 4 as damage protection.
If this is not done, the sealing surface may be dam- aged when the crankcase is turned. Insert the pre-assembled anchorage bolts into Right half of crankcase the right half of the crankcase from below. Place conical sleeve on thread Installation of lower anchorage bolts on end using special tool P Remove conical sleeve.
Additional a-rings 6 x 2. Sealing is no longer provided by Q-rings on the cylinder but by seal rings in the crankcase. Insert seal rings into groove dry. Grease seal rings slightly, but only just before installing cylinders.
Whenever the crankcase is dismantled in the course of reblJilding the engine, measure the main bearing bores. Measuring 1. Attach crankcase to engine support P 3. Tighten all through bolts and 4 additional using mounting hardware P band hexagon nuts M 8 at bearing 1 an j bear- assemble both housing sections. Lightly tighten all through bolts and four M 8 fastening nuts at bearing 1 flywheel side 4.
Applying light blows with a plastic mallet, If the bearing bores are too narrow, use a align both crankcase sections. The gap at standard reamer to ream bores to standard bearing bore 8 must not show any offset dia. Use an internal measuring device to Specified size for bearing bores 1 to 8 is measure bearing bore 8 diagonally and The checking dimension for 8 bearirlgs is General Reaming of the light-alloy Silumin crankcase for B bearings is done in two steps.
When reaming the bearings. Reaming 1. Fit shop-made tool to crankcase and tighten 3. Place end bearing bushing EL 35 in bearing in a vise. Now attach and align both guides for sup- 5.
Remove end bearing bushings after tighte- port of the guide rod. Insert guide rod complete with reamer into bearing 8 and ream all bearing bores slowly and steadily. Have an assistant apply liberal amounts of white spirits for greasing while the bearing bores are reamed to the correct size.
Note When tightening the guides. The crankcase sections are machined as a unit and must always be fitted in combina- tion with each other. Intermediate shaft matching number. Running surfaces of main and big end bear- ing journals are polished after nitriding treat- ment. The con-rods are allocated to weight classes. The last digit of the part number indicates the weight class. The last digit is marked on the shaft of con-rods supplied as spare parts.
The weight difference between con-rods installed in the same engine must not exceed 6 g. To determine the weight class, weigh the entire con-rod without the bearing shells. Type 1 and 2 con-rods are no longer available as spare parts. If con-rods need to be replaced, a complete set of type 3 con-rods must be installed.
From engine no. Weight Weight group Part no. Code from to for spare part of replacement on grams grams con-rod con-rod 1 Designation Qty. Final tightening sequence: 1 x 90' :t 2' tightening angle, threads and seating face lightly oiled.
Determine type of knurled ring bolt To determine if a 3-ring knurled bolt or a 4-ring knurled bolt has been fitted with the knurled ring bolt connect- ing rod bolt being pressed in place, the groove dia- meter has to be measured.
If dimension X Note: The bolts cannot be replaced on connecting rods fitted with 3-ring knurled bolts. In this case, the entire connect- ing rod assembly has to be replaced. The 4-ring knurled bolt is also available as a spare part.
Press out both 4-ring knurled bolts simultanteou:5Iy. Operation Instructions. Note: To avoid damaging the separation joint, use an aluminum sleeve, e. Press in 4-ring knurled bolt until it is seated at the stop. When reassembling the connecting rod, always make sure the matching numbers are located on the same side.
Tightening specifications Apply a thin coat of oil to threads and seating surfaces. Initial tightening: 30 Nm 22 ftlb. Final tightening: 1 x 90'. Checking Scribe a mark on connecting rod and connecting rod nut. Tighten to 60 Nm 44 ftlb. Deform oil seal at crankcase cutout using a The oil seal must be pressed in until it is drift or a cross-cut chisel and lever out with recessed 2 mm below the flange of the a screwdriver. Clean oil seal seating surface in crankcase.
If required, deburr outer edge with a scraper and remove burrs. Coat running surface for sealing lip with oil and install oil seal w.
The following marks are stamped on the upper piston crown section installation position :. Letter "E" in the middle towards inlet , with change level 10 internal Mahle 10 to the right; the tolerance group 0, 1, 2, 3 is indi- cated to the left of the "E", and the weight class is indicated next to the tolerance group. The signs -- minus minus to indicate the weight group may also appear in vertical direction. Engine, Crankshaft, Pistons Carrera The following IDs are stamped in the opposite side of the knock sensor bridge mounting lug:.
Cylinder dia. All cylinder height tolerance groups 5 or 6 are further subdivided into the cylinder diameter tolerance group. Fit only cylinders of the same height group 5 or 6 to one single side of the engine. Hazet U Observe this when dismantling and assem- bling the engine and mark parts accordingly.
Caution: Make sure the snap ring is preassembled with the tapered assembly sleeve on a solid support but only immediately before fitting the assembly to the piston pin bore. Kind of tough to do that with a paper manual. Surely using this repair manual is an inexpensive way to keep your car working properly. It is this level of detail. Click here for information about the manufacturer.
This manual can be viewed on any computer, as well as zoomed Take a closer look at the sample image for the most accurate information on the use of the book and printed. Along with more than illustrations that guide the reader through each service, repair and maintenance procedure. All pages are printable, so print off what you need and take it with you into the garage or workshop. Furthermore, you can save it on every computer, iPad, hard disc, etc. Porsche Workshop Manuals.
You will surely enjoy browsing through the pages and learning how to repair the different parts of your car. It makes you up-to-date and more knowledge. Our manuals are compiled in pdf format and can be opened with every pdf-reader. You may also like documents download: Porsche workshop manuals. After your payment via PayPal or credit card, you will have instant access to your download. Dont need to wait for shipping. Download link for the manual will appear on the checkout page after your payment is completed.
Additionally a few seconds after your payment you will receive an email with your instant manual download link. You have three days after payment to download and save your manual.
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