911 turbo Front Wheel, Suspension

Technical data

Wheel suspension independent wheel suspension with

control arms and spring struts

Suspension one round torsion bar per wheel, longitudinal

Torsion bar " 18.8mm

Height adjustment - Page 44 -1

at DIN curb weight

Shock absorbers double-action hydraulic

shock absorber struts

Manufacturer Bilstein -different configuration from Mod. 89

onwards

Anti-roll bar 0 18 mm -from Model 77 onward 0 20 mm

from Model 85 onward 0 22 mm

Technical data 40 -01

Printed in Germany -VII, 1989
40 General

TORQUE SPECIFICATIONS FOR FRONT AXLE

Location Designation Threads Class Torque

Nm ft Ib

Support bearing to Nut M 14 x 1.5 8 80 58

strut

Support bearing to Capscrew M 10 8.8 47 34

body

Carrier to body Bolt M 12 x 1.5 8.8 90 65

Carrier strut guard Bolt M 10 8.8 47 34

to body

Stabilizer and suspension Bolt M8 8.8 25 18

Guard Bolt M8 8.8 25 18

Stabilizer to carrier strut Bolt M8 8.8 25 18

Carrier strut,guard and Capscrew M 10 8.8 47 34

stabilizer to body

Carrier strut and guard toI Nut M 10 8 28 20

carrier

Control arm to body Bolt M 10 8.8 47 34

Ball joint to control arm Slotted nut M 45 x 5 8.8 250 181

Nut on stub axle Capscrew M7 10.9 15 11

Ball joint to strut Uni stop nut M8 8 22 16

Brake disc to wheel hub Nut M8 8.8 23 17

Cover for brake disc Bolt M8 8.8 10 7

Caliper to stub axle Bolt M 12 x 1.5 8.8 70 51

Capscrew

Brake line Coupling M 10 x 1 12 9

Wheel to wheel hub Nut M 14 x 1.5 130 94

40-02 Technical Data Printed in Germany

 Front Wheel Suspension

REMOVING AND INSTALLING FRONT AXLE

Removing

1. Disconnect brake hose at brake line aft er 5. Place jack underneathcarrier.

first depressingbrake pedal somewhat with
pedal strut to prevent brake fluid from
escaping.
6. Detach steering shaft at steering shaft
holder and lift joint off of steering shaft.
Dismantle steering shaft holders.

2. Unscrewstabilizer at suspension.

7. Unscrewshockabsorberhex nuts.

3. Removeguard.

4. Unscrew mounting screws at carrier and

control arms.

Printed in Germany Removing and Installing Front Axle 40-1

 Front Wheel Suspension

8. Lowercomplete front axle assembly. Note

Do not turn the steering wheel quickly from

lock to lock when the car is raised, to
prevent tIle cup from popping off at the
steeritlg gear or tie rod (air compensation).

Installing

1. Raisecomplete front axle assembly.

2. Securetop of shockabsorbers
to body.

3. Secure bottom of front axle to body

(carrier and control arms).

4. Connectbrakehoses.

5. Bleedbrakes.

6. Torque all mountingscra-lsto specifications.

40-2 Removing and Installing Front Axle Printed in Germany

 Front Wheel Suspension

T GalS

Description Special Tool Remarks

1 Torque wrench Commexcial item, up to 36 mkg

(261 ftlbs)

2 Tie rod remover Commercial item

3 Wrench P 280 b

Printed in Germany -II. 1976 Disassembling and Assembling Front Axle 40-3
No.
 Front Wheel Suspension

40-4 Disassembling and Assembling Front Axle Printed in Germany

 Front Wheel Suspension

No Notes
Designation Amt.
Removing Installing

1 Capscrew M 10 2 Torque to
specifications

2 Washer 2 Replace, if
necessary
3 Hex nut, self- 2 Torque to
locking specifications

4 Washer 4

5 Guard 1

6 Strut 2

Hex hd screw 2 Torque to

specifications

8 Washer 2 Replace, if
necessary

9 Caliper 1

10 Spacer 1

Cap 1

12 Capscrew 1 Torque to
specifications

13 Clamping nut 1

14 Tab disc 1 Must just barely turn

with screwdriver

15 Wheel hub 1 Clean, check for wear'

fill hub with ca. 60 g l
multi-purpose lubricant

16 Taperroller bearing 1 Clean, check and

lubricate. If necessary.
replace.

17 Hex nut M 8 5 Torque to

specifications.

Printed in Germany Dismantling and Assembling Front Axle 40-5

111
 Front Wheel Suspension

Notes
No. Designation Amt
Removing Installing

18 Washer 5 Replace, if
necessary

19 Hex head screw 5

120 Brake disc 1 Check for wear

and damage

Radial seal 1 Replace, if

necessary. Press
in until seal is
flush with hub.

22 Taper roller 1 Clean. check for

bearing wear and lubricate.
Replace. if
necessary.

123 Outer race 1 Heat hub and Heat hub and

press off race install race

124 Outer race 1 Heat hub and Heat hub and

pressoff race install race

125 Hex hd screw 3 Torque to

specifications

26 Lockwasher 3 Replace. if
necessary

27 Guard 1

28 Control screw 2 Lubricate with MoS2°

Readjust height

129 I Adjusting lever 2

30 OWA gasket 2 Replace, if

necessary

Uni stop nut MS 1 Torque to specifications,

Replace, if necessary

32 Washer 1

40-6 Dismantling and Assembling Front Axle Printed in Germany

IRemarks
121
131
 Notes
No. Description Amt Remarks
Removing Installing

33 Threaded pin 1 Drive out Install with lubricant

Position it correctly.
Replace!

34 Hex nut 1 Torque to

specifications

35 Lockplate 1 Replace, tab faces

up.
36 Support disc 1

37 Strut 1 Check, replace if

necessary

38 Guard 1

39 Spacer 1 Heat and install to

stop

40 Seal 1

41 Hex hd screw 3 Torqueto

M 10 specifications

42 Lockwasher 2 Replace if
necessary

43 Washer 1

44 Guard 1

45 Spacer 1

46 Control arm 1 Check

47 Torsion bar 1 Check for damage,

replacing if necessary
Note mark for in-
stallation. Lubricate

48 Cotter pin 1 Replace

49 Lockplate 1 Replace. if
necessary

Printed in Germany Disassembling and Assembling Front Axle 40-7

40 Front Wheel Suspension

Notes
No Description Amt, Remarks
Removing Installing

50 Nut 1 Loosen with Torque to

P 280 b specifications.
Lubricate threads

51 Ball joint 1 Check, replacing

if necessary

52 Hex hd screw 2 Torque to

M 10 specifications

53 Washer 2 Replace, if
necessary

54 Hed hd screw 2 Torqueto

M1O specifications

55 Washer 2 Replace, if
necessary

56 Carrier 1 Check for

damage

57 Adaptor 2

58 Capscrew 3 Torqueto
specifications

59 Lockwasher 3 Replace. if
necessary

60 Single-hole 1 Mark for

pressureplate reuse

61 Double-hole 1 Mark for

pressureplate reuse

62 Support with 1 Check, replacing

rubber bearing if necessary

63 Spacer 1

40-8 Disassembling and Assembling Front Axle II, 1976 -Printed in Germany
911 turbo Rear Wheel, Suspension

Technical data

Wheel suspension independent wheel suspension with

semi-trailing arms

Suspension one round torsion bar per wheel, transverse

Torsion rod 0 26 mm -up to the end of Mod. 88

0 27 mm -from Mod. 89 onward*

Height adjustment -
at DIN curb weight Page 44 -2

Adjustment of spring strut angle Page 44 -2

Shock absorber double-action hydraulic shock absorbers

Manufacturer Bilstein -different configuration from Mod. 89

onward

Anti-roll bar 018 mm -up to the end of Mod. 84

0 20 mm -from Mod. 85 to end of Mod. 88
018 mm -from Mod. 89 onward**

* Splines also modified in conjunction with new transverse rear axle tube

Angle also modified because of new transverse rear axle tube

Technical data 42 -01

Printed in Germany -VII, 1989

 General

TORQUE SPECIFICATIONS FOR REAR AXLE

Location Designation Threads Class Torque

kpm ft. Ibs

Cover to body Bolt MIO 8.8 4.7 34

Trailing arm to cross tube Nut M 14 x I, 5 10 6.0 43

Strut to trailing arm Excenter M 12 x I, 5 8,8 6,0 43

Strut to trailing arm Bolt M 12 x I, 5 10,9 9,5 69

Caliper to trailing arm Bolt/capscrew M 12 x 1. 5 8,8 6,0 43

Shock absorberto trailing arm Bolt M 14 x I, 5 8.8 12,5 90

Shock absorber to body Nut M 10 x 1 8 2,5 18

Brake line Coupling M 10 x 1 1,4 10
Stabilizer to body Bolt M8 8,8 2,5 18
Propeller shaft flange Capscrew M 10 12,9 8,3 60
Guard and brake backplate to Bolt M8 8,8 2,5 18
trailing arm

Wheel to wheel hub Nut M 14 x I, 5 13 94

Wheel hub to drive shaft Castle nut M 20 x I, 5 10.9 30-32 217-231

Brake disc to wheel hub ctsk screw M6 8,8 0,5 4

Stabilizer to suspension Nut M 12 x I, 5 8/8.8 8.5 61

Stabilizer suspensionto Bolt M 12 x I, 5 8.8 8.5 61
trailing arm
Adjusting lever to strut Bolt M 16 x I, 5 10.9 24.5 177
Adjusting lever to strut Eccentric bolt M 16 x I, 5 10.9 24.5 177

I
 REMOVING AND INSTALLING REAR AXLE

Removing

1. Lift car. 6. Removebrake disc.

7. Lift rear axle strut with special tool P 289.

2. Detachbrake line at caliper and rear axle Detach shock absorber at rear axle
trailing arm. Firstdepressbrake pedal trailing arm.
somewhatwith pedal strutto preventthe
brake fluid from escapingout of the
reservoir.

3. Disconnectstabilizer at rear axle trailing

arm.

4. Detachdrive shaft at transmissionflange.

8. Remove special tool P289. Pullout drive

shaft with joint toward inside of car.

9. Remove cotter pin and castle nut at

parking brake cable. Pullout parking
brake cable on inside of car.

5. Removedrive shaftcastle nut cotter pin

and unscrewnut.

10. Detachrear axle trailing arm at cross

tube and strut. Removerear axle trailing
arm.

Printed in Germany Removing and Installing Rear Axle 42-1

 Rear Wheel Suspension

Installing

Slide in drive shaft through rear wheel hub

before securing the shock absorber.

2. Install spacerand parking brakecable.

3. Torque axle nutsto specifications.

4. Check axial play of wheelbearings.

Max. wheelbearing play is 5/100 mm.
Adjust play if necessary.

5. Lock castle nut.

6. Install brake disc, adjustparking brakes

and bleed brakes.

7. Torque all screwsand bolts to specifi-

cations.

42-2 Removing and Installing Rear Axle Printed in Germany

 TOOLS

4 8

No Description Special Tool Remarks

1 Torque wrench Commercial item, up to

750 Nm (75 kpm)

2 Extention Commercia! item

3 Hexagon socket SW 30 Commercial item

4 Strut retractor P 289 Check tool, see page 42 -8

5 Dial gauge holder with Commercial item

magnetic column

6 Dial gauge Commercial item

7 Extractor with grip ring Commercial item

8 Removal mandrel P 297 a

Printed in Germany 111,1981 Disassembling and Assembling Rear Axle 42-3

 Rear Wheel Suspension

=
~-
,
, .
2

R ~ 0
,-
~~~ 8

H,---8 ~ ~

~---'-\
2 2~="'." t
'", *
"'." -;;:~ ..
~
0

~- ':. ~

In-
N

IW)~
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~
~~ i-"
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~
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~-
11 .-.c ~~r ."., ,
.. 81)
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R'
~~
~-
- .N
-CO)

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e "
./ ,-ft

, 42-4 Disassembling and Assembling Rear Axle Printed in Germany

 No. Notes
Description Amt. Remarks
Removing Installing

1 Spacer 1

2 Cotter pin 1 Replace. if

necessary
3 Castle nut 1 Thrque to
specifications

4 Washer 1

5 Screw M 6 2 Torque to
specifications

6 Brake disc 1 Check for wear

7 Hex nut M 14 x 1.5 1 Torque to speci-

self-locking fications

8 Hex hd screw 1

9 Washer 2

10 Vibration damp. 1

11 Drive shaft 1 Pullout on

inside of car

12 Gasket 1 Paste to drive

shaft

13 Cotter pin 1 Replace

14 Castle nut M 6 1 Screw on parking

brake cable until
cotter pin hole aligns

15 Washer 1

Parking brake 1 Pullout on inside

cable of car

17 Spacer 1 Install correctly, large

pipe dia. facesin.

18 Washer 1

Printed in Germany Disassembling and Assembling Rear Axle 42-5

16
 Rear Whee Suspension

No Note When: Special

Description Oty
Removing Installing Instructions

19 Nut M 12 x 1.5 2 Torque: 120 Nm page 42 -11

20 Lockwasher 2 page42-11

21 Washer 4

22 Bolt 2 page 42 -11

23 Nut M 12 x 1.5 2 Torque: 85 Nm page 42 -11/12

24 Lockwasher 2 page 42 -11/12

25 Washer 1 only with

camber excenter

26 Camberexcenter 1 Mark position page 42 -11/12

Toe excenter 1 for reinstallation

27 Self-locking nut 1 page 42 -10

M 14 x 1.5

28 Washer 1

29 Bolt 1 page 42 -10

30 Trailing arm 1 page 42 -10/12

31 Flange block 2 Pressin to stop

32 Wheel hub 1 Drive out Pressinto outer

with P 297 a wheel bearing

33 Spreader 2 I nstall correctly

34 Spring 1

35 Spring retainer 2 Install correctly

36 Spring 2

37 Pin 2 Check for

correct fit in
spring retainer

38 Brake shoes 1
with adjuster

42-6 Disassembling and Assembling Rear Axle V, 1984 -Printed in Germany

 Rear Whee Suspension

No. Note When: Special

Description Oty
Removing Installing Instructions

39 Bolt 3 Torque: 25 Nm

40 Lockwasher 3 Replace if
necessary
41 Brake backplate 1

42 Guard 1

43 Taper roller 1 Check, lubricate

bearing, outer taper rollers with
multiple purpose
grease
44 Shaft seal 1 Pressin to stop

45 Spacer 1 Install in correct

position

46 Shaft seal 1 Pressinto stop

47 Taper roller 1 Check, lubricate

bearing, inner taper rollers.
Drive on hub
until bearing rests
on spacer.

48 Outer bearing race 1 Heat arm and Heat arm and

drive out drive in with
suitable mandrel

49 Outer bearing race 1 Heat arm and Heat arm and

drive out drive in with
suitable mandrel

50 Strut 1 Strut angle Two-piece rear

specified on page axle strut since
42 -01 and 44 -1 1977 models for
correction of
car height and
wheel load
difference with
an excenter
bolt. Struts ad-
justed in plant
that entire
range for higher
adjusti ng is
available.

Printed in Germany V, 1984 Disassembling and Assembling Rear Axle 42-7

 Rear Wheel Suspension

MACHINING STRUT RETRACTOR P 289

Various modifications have been made on the rear axle of 911/911 Turbo cars since the beginning of
production.

Consequently the holder on P 289 must be adapted to the present state. If tool is not changed, the
light alloy rear axle trailing arms could be damaged when clamping the tool between spring strut and
trailing arm to tighten the mounting bolts.

Holder shape before machining

42-8 Disassembling and Assembling Printed in Germany

)
 DISMANTLING AND ASSEMBLING INSTRUCTIONS

Disassembling Assembling

1. Drive out rear wheel hub with special 1. Heat trailing arm. Insert outer bearing
tool P 297 a. races and drive in with an appropriate
mandrel.

2. Install parking brake with anchorand

guard on trailing arm. Install inner
crossspring.

2. Pull wheelbearingsoff of rear wheelhub.

Use extracter with grip ring. Only grabhold
of bearing at rollers.

3. Lubricate bearing surfaces of trailing arm

with a multi-purpose lubricant (fill space
between both bearing surfaces in arm).

4. Placeouter bearing in arm. Lubricate

taper rollers.

3. Heattrailing arm (heatingplate, oven).

5. Pressin outer shaft seal to correct
Drive outerbearingraces out of trailing
arm. position.

6. Presswheel hub into outer wheelbearing.

Printed in Germany Disassembling and Assembling Rear Axle 42-9

 Rear Wheel Suspension

9. Bolt rear axle trailing arm on body

(refer to information note for point 11).
Slide in propeller shaft with drive shaft.

10. Adjust rear wheel bearings.

11. Adjust parking brake. Bleed brakes.

Torque all screws and bolts to
specifications.

Note:

The bolting and tightening torques for rear

axle trailing arms to rear axle cross tube
and rear axle trailing arms to spring struts
have been changed.

Rear Axle Trail Arm to

7. Install spacer. Rear Axle Cross Tube

8. Lubricate inner taper roller bearing and Tightening torque increased from 60 to
drive it onto the wheel hub until bearing 100 Nm. This requires the use of a higher
rests on spacer. self-locking nut (12 mm instead of 9 mm,
length of threads now 80 mm instead of
75 mm).

Mount parts with the 12 mm high nut and

80 mm long bolt.

There is not sufficient space for this in

911 Sportomatic models. In this case the
increased tightening torque may also be
applied on the 9 mm high nuts. However,
tightening the 9 mm high nut with a torque
of 100 Nm (10.0 kpm) is only permissible
once, so that these nuts must always be
replaced after loosening or removing.

42-10 Disassembling and Assembling Rear Axle V, 1984 -Printed in Germany

ing
 Rear Wheel Suspension

Rear Axle Trai ng Arm to Spring Strut

Self-locking nuts are used instead of hexagon nuts with lockwashers (Schnorr) on rear axle
trailing arm/spring strut connections and toe excenters beginning with December of 1983.
The tightening torque value was also increased.
The new bolts and self-locking nuts can be installed retroactively.
The higher torque value is applicable to old and new version bolting.
It is recommended to replace removed self-locking nuts.

Survey of Changes

Rear Axle Trailing Arm -Spring Strut

Old New

1 .1 Bolt 900.083.019.08 900.083.025.08

(M 12 x 1.5 x 35) (M 12 x 1.5 x 40)

1.2 Nut M 12 x 1.5 900.076.035.02 900.910.085.02

(hex. nut) (self-locking nut)

Lockwasher 999.523.109.02 none

1.3 Washer 901.333.143.01 same

(bolt head and nut ends)

Tightening torque 90 Nm 120 Nm

Printed in Germany -V I 1984 Disassembling and Assembling Rear Axle 42 -11

 Rear Whee Suspension

2. Toe Excenter
Old New

2.1 Excenter 901.333.133.05 same

2.2 Nut M 12 x 1.5 900.076.035.02 900.910.085.02
(hexagon nut) (self-locking nut)

Lockwasher 999.523.109.02 none

Tightening torque 60 Nm 85 Nm

3. Camber Excenter
Old New

3.1 Excenter 901.333.133.04 same

3.2 Nut M 12 x 1.5 900.078.017.02 same
3.3 Lockwasher 999.523.109.02 same
3.4 Washer 901.333.143.01 same

Tightening torque 60 Nm 85 Nm

. 42-12 Disassembling and Assembling Rear Axle

 ADJUSTING REAR WHEEL BEARINGS

The spacer between both rear wheel bearings is de- 3. Continue turning nuts until an axial play of 4/100
signed to be shortened in length permanently when to 1/100 mm is reached (while turning the torque
tightening the castle nut more than a certain tor- could rise up to 45 kpm/325 ft. Ibs.).
que (normally more than 300 Nm /217 ft.lbs.)

Note
1. Tighten castle nut to 20 kpm (145 ft. Ibs.). Check
axial play (specification: more than 5/100 mm). Check play several times while tightening and also
Replace spacer, if length had already been short- observe the cotter pin hole.
ened (axial play less than 5/100 mm).

4. Insert cotter pin. Loosen nut when nut is offset

to cotter pin hole. Tighten nut to specified tor-
que (30 to 32 kpm/217 to 231 h. Ibs.) and then
Note tighten further until nut can be locked.

Dial gauge holder must be mounted on trailing arm

or spring strut. 5. Check axial play. Play must not exceed 5/100 mm.
Repeat adjusting procedures from point 3, if play
is greater.

Note

No axial play can be accepted, if a wheel bearing

friction force of max. 1.5 kp (3.2 Ibs.) is not ex-
ceeded with cotter pin inserted and tightening torque
of at least 32 kpm (231 ft. Ibs.) (adjustment of
axial play and possibly further tightening to next
cotter pin hole).

2. Tighten castle nut to 30 kpm (217 ft. Ibs.). Re-

check axial play.

. Printed in Germany -V, 1984

CHECKING WHEEL BEARING PLAY

1. Remove wheel and take off brake liners.

2. Secure dial gauge holder with dial gauge

to rear axle trailing arm or strut.

3. Check axial play.

Adjust play if it is more than 0.05 mm

(see page 42 -13).

Printed in Germany
911 turbo General

Technical Data (Model 75)

Rims and Tires

Rims Forged aluminum

Standard tires -front wheels 185/70 VR 15 on 7" aluminum rim

rear wheels 215/60 VR 15 on 8" aluminum rim

Cold tire inflation -front 2.0 bar

rear 2.5 bar

Special tires -front wheels 205/50 VR 15 on 7" aluminum rim

rear wheels 225/50 VR 15 on 8" aluminum rim

Cold tire inflation -front 2.0 bar

rear 2.5 bar

Winter tires -front and rear See page 44 -05

Cold tire inflation Sameasstandardtires

Spare wheel * Collapsible tire on 5 1/2 J 15 steel rim,
compressor supplied

* When using special tires together with a limited slip differential, the collaspible tire
(spare wheel) can only be used on front axle wheels.

44 -01
 General 911 turbo

Technical Data (Model 76)

Rims and Tires Turbo Turbo Carrera (USA)

Rims Forged aluminum Forged aluminum

Standard tires
Front wheels 205/50 VR 15 on 7" rims 185/70 VA 15 on 7" rims
Rear wheels 225/50 VR 15 on 8" rims 215/60 VA 15 on 8" rims

Special tires
Front wheels 185/70 VA 15 on 7" rims -
Rear wheels 215/60 VA 15 on 8" rims

Tire inflation pressure (cold)

Front wheels 2.0 bar 2.0 bar
Rear wheels 2.5 bar 2.5 bar

Winter tires (front + rear)

See page 44 -05

Tire inflation pressure (cold) Sameasfor standardtires

Spare wheel * Collapsible tire on 51/2 J x 15 steel rim, incl. compressor
* When using standard tires 50 % in conjunction with a Not applicable in the USA.
limited slip differential, the collapsible tire wheel can
only be used on the front axle wheels.

44 -02 Technical Data (Model 76)

Printed in Germany -VII, 1989
911 turbo General

Technical Data (Model 77)

44 -03
 General 911 turbo

Technical data (Model 78 onward)

Wheels and tires

Wheels Forged alloy

Tires: front axle 205/55 VR* 16 on 7 J x 16 rim

Rear axle 225/50 VR* 16 on 8 J x 16 rim

Model 86 onwards
245/45 VR* 16 on 9 J x 16 rim

Spare wheel Folded tire 165/15 on 51/2 x 15 rim

Compressor provided

Winter tires Page 44 -05

* ZR from current Model year 1989 onwards. Refer to Technical Information, Group 4 for
notes on replacement, also for vehicles prior to Mod. 78.

2.5 on the front axle for 911 turbo with tuned engine
(243 kW) and for 911 Carrera/911 Turbo lowered versions -with or without tuned engine.

*** The tire pressure is determined by the code on the tire specifying the max. permitted
tire pressure.

"Max. press. 36 psi" = 2.5 bar

"Max. press. 44 psi" = 3.0 bar

Max. press. 44 psi" = 3.0 bar are the only tires fitted to vehicles from Model 86 onwards.

**** 165 -154 PA 83 P tires -2.2 bar

165 -15 8 PA 89 P tires -2.5 bar

44 -04 Technical data (Model 78 onward)

Printed in Germany -VII, 1989
911 turbo General

Technical data

Winter tires*

Observe tachometer assignment if 50 series summer tires, 15 inch version were fitted (Model 76 and
Model 75 with special tires).

Tires** Rims -possible and recommended sizes. Recommended

sizes in bold print.

195/65 R 15 M +891 T 6 J x 15 H2 front and

front and rear 7 J x 15 H2 rear

195/65 R 15 M + S 91 T front 6 J x 15 H2 front or 7J x 15 H2 front

215/60 R 15 M + S 93 T rear 7 J x 15 H2 rear 8 J x 15 H2 rear

205/55 R 16 M + S 88T 6 J x 16 H2 front and or 7 J x 16 H2 front and

front and rear 7 J x 16 H2 rear 8 J x 16 H2 rear

205/55 R 16 M + S 88 T front 6 J x 16 H2 front or 7 J x 16 H2 front

225/50 R 16 M + S 92 T rear 7 J x 16 H2 rear 8 J x 16 H2 rear

Tire pressure -cold tires: Turbo 3.0 I Turbo 3.3 I (Mod. 78 onward)
(bar) front 2.0 bar 2.0 bar
rear 2.5 bar 3.0 bar

* Refer to the Technical Information (TI), Group 4 for notes and recommendations with
respect to winter tires and snow chains, as well as approved disk wheels (rims).
Only forged alloy disk wheels or the explicitly
approved cast wheels may be installed.

The only M + S tires of version H which may be used are those specified in the
recommendation (TI).

The technically permitted maximum speed for winter tires is indicated by the figure (speed index) af-
ter the dimension code:

Q = Max. 160 km/h

T = Max. 190 km/h
H = Max. 210 km/h

Technical data 44 -05

Specifications for alignment

The following values apply to a car at curb weight as per DIN 70020 (full fuel tank, with spare wheel
and tools).

(Values in brackets: for turbo Carrera USA, turbo Canada, Japan up to end of Model 82 only.
The specifications are the same as those for rest of the world vehicles from Model 83 onward).

Front axle

Height adjustment:

Wheel center over center of torsion bar

T De -unpressed

Toe difference angle at 200 lock

Front wheel chamber with wheels

straight

Caster

* The height specifications only apply to new vehicles. Run-in vehicles may be up to 10 mm lower,
i.e. the tolerance may be up to 15 mm lower. This must, however, be the same for both axles.

44 -1
 The following values apply to a car at curb weight as per DIN 70020 (with full fuel tank, spare wheel
and tools).

(Values in brackets: for turbo Carrera USA, turbo Canada, Japan up to end of Model 82 only.
The specifications correspond to those of rest of world vehicles from Model 83 onward.

Rear axle

Height setting

Center of transverse tube via center

of rear wheel

Spring strut setting **

Angle of spring strut

Turbo 3.0
Torsion bar" 26 mm
(up to end of Mod. 77)

Turbo 3.3
Torsion bar 0 26 mm
(from Model 78 to end of Mod. 88)

Torsion rod 027 mm

(Mod. 89 onward)

Toe per wheel + 10'+ 10' 10'

Camber Up to end of Mod. 77 -50 :t 10' (O°:t 10') 20'

Mod. 78 onward (Turbo 3.3) -3O':t 10' (0° :t 10') 20'

* The height settings only apply to new vehicles. Run-in vehicles may be up to 10 mm lower, i.e. a

tolerance may be up to 15 mm lower. This must, however, be the same for both axles.

** 10 Alteration of the spring strut angle corresponds to approx. 7 -9 mm alteration in vehicle height.

44 -2
Sample test card

Date: measured by

Rims and tires

MEASURING CHART
(damage and
treads)

1 2 0 I 2
200 left turn-in
measured right
2 0

+
0 I 2
Toe-in (not pressed)

Wheel load in kg'

Max. difference between
left and right: 20 kg
(911 Turbo max. 10 kg)

cosIer

51
4 -
~"
3~
~
2 .]

-3.20
Printed in Germany

Sample test card 44 -3

Printed in Germany -VII, 1989

 Wheels, Tires, Measuring vehicle 911 turbo

Notes on alignment

Because of the type of seal installed between steering gear and tire rods. the rubber boot becomes
twisted when adjusting the toe and may be damaged.

To prevent this, pull the rubber boot away from the recess in the tie rod.

Always replace the rubber boot when adjustment has been completed.

44 -4 Notes on alignment
td in Germany -VII, 1989
 Genera

TECHNICAL DATA FOR TURBO 3.3 -SINCE 1978 MODELS

* The internal ratio (boosting factor) in the brake booster has been changed:
formerly 2.25, since 1985 models 3.0. Code since 1985 models: label showing 3.0 ratio.
It is possible to install the modified brake booster in older models (beginning with 1978).

Printed in Germany -V, 1984 Technical Data 46 -01

 General

* Brake disc must only be machined symmetrically, i. e. uniformly on both sides.

Deburr vent holes after machining.

46 -02 Technical Data Printed in Germany

 911 turbo General

TORQUE SPECIFICATIONS FOR MECHANICAL BRAKE PARTS

Location Description Threads Class Torque

Nm (ft Ib)

Nut on steering Socket hd. screw M7 10.9 15 (11)

knuckle

Brake caliper to Bolt. M 12x1.5 8.8 70 (51)

steering knuckle Socket hd. screw

I Brake flange/brake Bolt M8 8.8 23 (17)

disc to hub

Brake disc to Bolt M6 8.8 10 (7)

brake flange

Splash shield toI Bolt M8 8.8 10 (7)

steering knuckle

I Splash shield and Socket hd. screw M8 8.8 25 (18)

brake backing
plate to control arm

I Brake disc to wheel Flat hd. screw M6 8.8 5 (3.6)

hub

Brake caliper toI Bolt. M12x1.5 8.8 60 (43)

control arm Socket hd. screw

Wheel to wheel hub Wheel nut M14xl.5 130 (94)

II
 Brakes/Mechanica Parts 911 turbo

INFORMATION ON BRAKES OF 911 CARRERA TURBO-LOOK

The 911 Carrera in Turbo-look has the

brake system of the Turbo 3.3.

However I the rear wheel brake circu it has

a brake force regulator as in the 911 Carrera.
The brake force regulator is located on the
luggage compartment floor immediately
behind the brake master cylinder.

It is bolted on the brake master cylinder

of RHO cars.

The second number next to the switching

pressure (separated by an arrow showing
the direction of flow) indicates the reduc-
ing factor.
S means a reducing factor of 0.46.
Brake force regulators with the code "3"
(reducing factor = 0.3) must never be used.

Brake force regulator switching pressure =

33 bar. The switching pressure was changed
to 55 bar with the 1985 models. The brake
force regulator with a 55 bar switching
pressure can also be installed in Turbo-
Look cars before 1985 models. The switch-
ing pressure is stamped on the brake force
regulator.

46 -04 Information on Brakes of 911 Carrera Turbo-look VI, 1985- Printed in Germany
 CHECKING THICKNESS OF BRAKE PADS

Cars without Brake Pad 2. Visually inspect brake pads for wear.
Wear Indicator

Brake pads must be replaced when thickness

of 2 mm is reached.

Cars with Brake Pad Wear

Indicator
(since 1984 Models)

All brake pads of one axle must be replaced

when the brake pad wear indicator lamp
comes on and, however, not later than after
reaching a thickness of 2 mm. If brake pad
wear is indicated by the lamp, the warning
contact (sensor with lead and plug) must
also be replaced. The warning contact need
not be replaced, if brake pads are replaced The wear limit is reached when the pads have
at latest when reaching a thickness of a remaining thickness of 2 mm.
2.5mm.
Warning contacts with ground cores of
leads must be replaced. Replacements,
however, are not necessary when only the
plastic part of the warning contact is
ground.

1. Remove wheels to check brake pad

thickness.

Printed in Germany -V, 1984 Checking Brake Pads 46-1

 Brakes, Mechanical Parts

REMOVING AND INSTAlliNG BRAKE PADS -TURBO 3.3, BEGINNING WITH

1978 MODELS

Removing 3. Pullout brake pads with a suitable tool,

e. g. Hazet 1966 -2 impact puller with
If brake pads are supposed to be reused, mark 4 mm pin diameter.
them when removing. It is not permissible to
shift pads from outside to inside or vice versa
and from right to left wheel or vice versa,
becausethis could cause uneven braking
effect.

1. Compress spreader spring at center and

remove from holding tab.

I nsta Iii ng

Note:
2. Pull warning contact out of pad plate in Replace brake pads, which show deep
cars with a brake pad wear indicator. cracks, are loose on the brake pad plates or
This is done by pulling brake pad out of are splattered with oil. In this case, too, it
brake pad recess slightly or disengaging is necessaryto replace all four pads of one
lead in clip on brake line. axle.

Note:
Replace warning contacts, if the lead's core 1. Push back piston to initial position with
is ground through or ground. The warning piston setback tool.
contact is still usable, if only the plastic part
of the warning contact has signs of grinding.

. 46-2 Removing and Installing Brake Pads Printed in Germany

 Note Rear Axle

To prevent brake fluid from spilling, draw

off some of brake fluid from tank before
pushing back piston. This requires a syringe
used exclusively with brake fluids. Brake
fluid is poisonous and therefore must not
be drawn out through a hose by mouth.

2. Clean seat and guide surface of brake pads

in caliper with gasoline or a cylindrical
brush. Never use solutions containing
mineral oils or sharp edged metal tools.

Brake pad recessplay: 0.4 to 0.6 mm.

3. Check position of piston. Edges of

shoulder on piston must be parallel to
guide surface of brake pad. The shoulder
(setback surface) must face down on rear
axle and up on front axle (toward brake
disc inlet).

Front Axle 4. Install brake pads. Guarantee a play of

0.4 to 0.6 mm for brake pads in recess
by pertinent steps, if necessary (replace-
ment of spring plates *, cleaning guide
surfaces on brake pads, replacement of
brake pads).

Note

Apply a light coat of grease on seats and

guide surfaces to prevent seizure of brake
pads in brake calipers due to corrosion.
Use Optimoly HT (Cu Paste) or Plastilube
(Schillings, Postfach 1703,7080 Aalen).

5. Press warning contact into inner pad

plate of cars with a brake pad wear
indicator.

* Also refer to Group 47,

Printed in Germany V, 1984 Removing and Installing Brake Pads 46-3

 Brakes, Mechanica Parts

6. Lubricate engaging eyes of spreader spring

in bridge with Optimoly HT or Plastilube.

Install new spreader spring that its flat side

faces brake disc. If installed incorrectly,
proper fit of brake pads cannot be
guaranteed. In addition, high spot at center
of cross would scrape on brake disc.

Brake Disc

a = Spring plate
b = Spreader spring
c = Lockplate

Outside

8. Depress brake pedal of stopped car

firmly several times, to move brake pads
into their normal operating position.
Then check brake fluid level in tank,
adding brake fluid if necessary.

Breaking in Brake Pads

Factory new brake pads will require about

200 km of operation before reaching their
most favorable friction and wear values.
Only then will the pads have adapted them-
selves to the brake discs and the squeaking
7. In 1978 models, which are equipped with noise will now disappear. Try to avoid full
initial version spring plates *, the lockplate stop emergency braking during the breaking
must still move in the recessafter engag- in period.
ment of the spreader spring.
This guarantees gap X between the lock-
plate and spring plate and deformation
of the spreader spring is not possible.

* Also refer to Group 47.

46-4 Removing and Installing Brake Pads Printed in Germany

 Brakes, Mechanical Parts

MODIFIED FRONT WHEEL BRAKES FOR 3.3 LITER TURBO

The front wheel brake disc/hub connection is changed since the production of 1981 models. The flange and
ring connection has beenchanged to a brake disc shell connection as on the 911/3.0 Itr. Turbo.

By designing the new brake discs with a shell the total distance (brake disc -hub) is 21 mm longer. Consequent-
ly the installation of 21 mm spacers is omitted. It is not permitted to additionally install spacers with the
wheel hub.
Conversion to new brake discs/wheel hubs is only permitted on both sides simultaneously for 3.3 liters cars be-
fore 1981 models.

Removing greasecaps is different due to the modified hubs.

Old Version

New Version

Printed in Germany V, 1984 Disassembling and Assembling Front Wheel 46.4a

 Brakes, Mechanical Parts

TOOLS

No. Description Special Tool Remarks

1 Slide hammer VW 771

2 Puller 9165 Only required up to end of

1980 models

Printed in Germany -IV. 1981 Disassembling and Assembling Front Wheel Brakes 46 -5
 Brakes, Mechanical Parts

it)

co

=
-m

"'C~ -
It)
~

'- -
0

b
-ro..

-
~

~
~

-(W')

0)
-,'. v
o~
N
~

-
N
C")

-
-N 1)--

Note

The front wheel brake applicable up to end of 1980 models is shown. From 1981 models the brake disci
wheel hub connection is changed (see page 46 -4).
 Brakes, Mechanica Parts

No,
Note When: Special
Description Oty Instructions
Removing Installing

1 Bolt 2 Torque: 70 Nm

2 Washer 2 Replace,
if necessary

3 Spacer 2 Between caliper

and steering
knuckle

4 Brake cal iper 1

5 Spacer 1 Less width than Only version

on rear axle up to end of
(21 mm) 1980 models

6 Hub cap 1 Seetext Different

versions

7 Nut with socket 1 Adjust wheel

screw bearing play.
Torque socket
screw to 15 Nm

8 Pressuredisc 1

9 Wheel bearing, 1 Check, replacing

outer if necessary

10 Wheel hub 1 2 versions

11 Screw 12 Install screws Only version

and tighten up to end of
uniformly. 1980 models
Torque: 10 Nm

12 Lockplate 12 Replace

13 Ring 1

14 Brake disc 1 Check for wear 2 versions

and damage.
If applicable,
mark for
reinstallation

Printed in Germany -V, 1984 Disassembling and Assembling Front Wheel Brakes 46-7
 Brakes, Mechanica Parts

Note When: Special

No. Description Qty Removing Installing Instructions

15 Nut 5 Torque: 23 Nm

16 Washer 5 Replace, if
necessary
17 Bolt 5

18 Brake flange 1 Only version

up to end of
1980 models

19 Screw 3 Torque: 10 Nm

20 Washer 3 Replace, if
necessary
21 Guard 1 Machine or Page 46 -10
replace, if Point 1
necessary

46 -8 Disassembling and Assembling Front Wheel Brakes Printed in Germany

 Brakes, Mechanical Parts

DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES

Disassembling Version B

1. Unscrew and plug brake line to prevent brake fluid Greasecaps with welded tapped adapters are install.
from flowing out of reservoir. Unscrew brake ed since ChassisNo. 93 Z BS 000094
caliper. (October, 1980).These caps can be knocked out
with special tool VW 771, without puller 9165.

2. Remove spacer(cars up to end of 1980 model year).

but do not use sharp edgedtools. Burrs could
causewheels to have lateral runout.

3. Remove greasecap according to version.

Version A
Up to end of 1980 model year. Knock out greasecap
with special Tool VW 771 used in conjunction
with 9165.

Version C

The first 1981 model cars (up to above mentioned

chassis number) still had greasecaps without the
tapped adapter. These caps have beenground to the
smallest possible diameter at the pressing-in point
to reduce the pressingforce.
They can be removed with a screwdriver.

4. Unscrew adjusting nut for wheel bearings.

Remove wheel hub with brake disc.

5. Separate brake disc and wheel hub.

Printed in Germany Disassembling and Assembling 46-9

.,---~ ""-__1 n__I__-
 Brakes, Mechanical Parts

DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKES

Disassemb ng "
'- "," '-..~
1. Check condition of all parts and replace, >" -~
6""
~, CO))
'- \
tR.."'" (9)'-
I
I
if necessary.
OJ \ "'" .OJ{-'" (" .\J
Note: -""" (Q)
'.."" CO)
~\ (Q)~
Bridges of brake calipers have cast bosses
since 1984 models and this has changed the ~
~. '"..~
'" \\.\ (Q~
?
brake guards.
Only brake calipers or caliper bridges with ~~~~=--~~-
~~=::-: -
:::;-.--c: --
~
cast bossesare available for replacements
after depletion of stocks in older models.
In this case the new brake guard must also -::~.~
--- ---
be installed or the old guard changed
accordingly (cut off). ,---" ,f=)-- \
---"" ,, --
2. Clean centering surface for brake disc on
wheel hub and apply a very thin coat of
Optimoly TA.
Forward Direction
3. Conversion to new brake discs/wheel hubs
on 3.3 liter cars before 1981 model is only
permitted simultaneously on both sides. 5. Note torque specifications. I nstall taper
roller bearings with a multi-purpose grease.
4. Brake discs must not be mounted on the
wrong side, since inboard vent bores 6. Adjust wheel bearing play that finger
arranged evolvently. pressure applied to a screwdriver is just
Identification: evolvent shape and part adequate to move pressure disc. Do not
number. support screwdriver on hub. To adjust,
first tighten nut slightly to keep bearings
Part number is located on the brake disc, from seizing.
Drive in hub cap of version C with a piece
Spare part for left side of pipe to avoid damaging the threads.
-3rd group number uneven

Spare part for right side

-3rd group number even

Examples:

Left brake disc part no.: 930351 04700

or 930351 04701

Right brake disc

part no.: 930 351 048 00
or: 930351 04801
7. Make sure brake hose is positioned
correctly, when screwing on brake line.
Bleed brakes.

46 -10 Disassembling and Assembling Front Wheel Brakes V, 1984 Printed in Germany
 Brakes, Mechanical Parts

an
'\1

<0

--;;.--~-~
-
~

- .-
co
roo

.-
M

tv v ,...
...
N

N --
N

- -
~

-
0
~
~
-
0)
0N

--
N

Printed in Germany -III, 1978 Disassembling and Assembling Rear Wheel Brakes 46 -11
~
 Brakes, Mechanical Parts

Note When: Special

No Description Oty. Removing Installing Instructions

1 Screw 2 Torque: 60 Nm

2 Washer 2 Replace, if
necessary
3 Brake cal iper 1

4 Spacer 1 Wider than on

front axle
(28mm)
5 Screw 2

6 Brake disc 1 Set back brake Check for wear

and damage

7 Spring 2 Hooks must be in

holes provided in
brake backplate
8 Support sleeve 1

9 Adjusting nut 1

10 Adjusting screw 1

11 Return spring 1

12 Brake shoe 2 Replace, if

necessary. Wear
limit: 2 mm

13 Return spring 1

14 Pressure bar 1

15 Pivot pin 1 Lubricate lightly

16 Pin 1 Lubricate lightly

17 Operating lever 1

18 Screw 4 Torque: 25 Nm

19 Washer 4

20 Brake backplate 1

21 Guard 1 Machine or Page 46 -13

replace, if (assembling)
necessary

8
46-12 Disassembling and Assembling Rear Wheel Brakes V, 1984 -Printed in Germany
 DISASSEMBLING AND ASSEMBLING REAR WHEEL BRAKES

Disassembling 5. Unscrew brake caliper and remove brake

disc. If a tight fitting brake disc cannot
be removed even after applying light
1. Remove spacer. Do not use sharp edged knocks with a plastic hammer, screw
tools. Burrs could cause wheel to have hexagon head bolts in two 8 mm diameter
lateral runout. threads of brake disc uniformly to press
off the disc.
2. Turn parking brake adjuster in loosening
direction. Unscrew two countersunk
screws.

Assemb ng

3. Unscrew brake line from brake hose. To

prevent brake fluid tank from draining, Note:
screw a shortened, plugged piece of brake
line in brake hose. Bridges of brake calipers have cast bosses
since 1984 models and therefore the guards
have also been changed.
Only brake calipers or caliper bridges with
cast bosseswill be available for replacements
after depletion of stocks in older models.
In this case the new brake guard must also
be used or the old guard changed accordingly
(cut off).

1. Lubricate adjuster, pin of expander lever

and sliding surfaces of parking brake
shoes slightly.

4. Press out brake line holding clip from

rear control arm.

Printed in Germany -V, 1984 Disassembling and Assembling Rear Wheel Brakes 46-13
 Brakes, Mechanical Parts

2. Assemble spreaderlever. 4. Press down lower parking brake shoes with a

screwdriver. Install assembled adjuster. Mount
lower spring.

3. Install front (long) return spring with parking

brake shoes on brake backing plate. Install
rear return spring and upper spring. 5. Check parking brake shoes, adjuster, return
springs and springs for proper position,
correcting if necessary.

Note

Make sure that hooks of springs are positioned in

holes provided in brake backing plate.

46-14 Disassembling and Assembling Rear Wheel Printed in Germany

 Brakes, Mechanical Parts

6. Clean brake disc centering surface on wheel 8. Adjustparking brake. Bleedservicebrakes.

hub and apply a very thin coat of Optimoly
HT.

Assemble brake disc and brake caliper. Tighten

bolts to specified torque. Do not mix up left
and right side discs, since inboard vent passages
have an evolute shape.
Identification: evolute shape and part number.

Part number is located on brake disc.

Spare part for left side

-3rd group number uneven

Spare part right side

-3rd group number even

Exemple:

Brake disc, left Part No. 930 352 045 00

Brake disc, right Part No. 930 352 046 00

Forward Direction

Printed in Germany -IV, 1981 Disassembling and Assembling Rear Wheel Brakes 46 -15
 General

TORQUE SPECIFICATIONS FOR HYDRAULIC BRAKE PARTS

Location Description 11ueads Class Torque

mkg (ft Ib)

Mastercylinder to Nut M8 8 2.5 (18)

vacuum booster

Stoplight switch to Stoplight switch M lOxl 1.5+ 0.4

mastercylinder (11 + 2.9)

Brake booster unit Nut M8 8 2.5 (18)

to base

Brake fluid reservoir Bolt M6 8.8 0.2 (1.5)

Fork and pivot to Nut M 10 8 3.5 (25)

operating rod

Brake booster to Nut M8 8 2.5 (3.8)

luggage compartment
floor plate

Brace to base Bolt M 10 8.8 4.6 (33)

Brake lines to Coupling M lOxl 2 (9)

master cylinder.
hosesand calipers

Distributorto Bolt M6 8.8 0.6 (4)

rear axle cross
tube

Bleeder screws on Bleeder screw M lOxl 0.8 -1.1

brake calipers (5.8 -8)

Brake caliper half Socket head bolt M 12x1.5 8.8 6.0 (43)
to bridge

Springplate to Flat head screw M5 0.4 (2.9)

bridge

Adapterto brake Hollow bolt M lOxl 1.6 (12)

caliper

Printed in Germany -V, 1984 Technical Data 47 -01

 Genera Notes

Printed in Germany
47-02 Technical Data
 5 10 11 9 1617 7 3610 . 11 5

e
0
fJ--
(t-
:>
..
i~~..

4tt ~"'-.J'-'

c:. /r---~
~ 'oj

--IJ
L
15 12 1314 16 4 8 1819 2 1

Note:
Blow-up view shows brake caliper of rear axle with 30 mm diameter piston (front axle piston
diameter: 38 mm) and retaining tab of cross spring facing up. On brake caliper of front axle
retaining tab is down, i. e. front bridges with spring plates are reversed.
Disassembling and Assembling Brake Caliper Sections -page 47 -7.

Printed in Germany -V, 1984 Disassembling and Assembling Brake Calipers 47-1
.-~:~:~:=:::~:::
r
 Note When: Special
No. Description Oty.! Removing Installing Instructions

1 Cross spring 1 Replace if necessary.

Position correctly
(flat side faces brake
disc).

2 Lockplate 1 Lockplate must still Not applicable

move after cross spring if openings of
has engaged, to excludE spring plate
deformation of the (no. 18) take
cross spring. over cross
spring funct.

3 Brake pad 2 Mark for rein- Check, replacing if

stallation later necessary. Wear
if applicable. limit 2 mm.

4 Connecting line 1 Down

5 Screw 8 Torque: 60 Nm
(43 ft. Ibs.)

6 Brake cali per half,rked 1

outer (ma with
Porsche)

7 Bridge Bottom on front axle, Page 47 -5

without opening top on rear axle

8 Bridge 1 Page 47 -5
with opening

9 Brake cal iper half, 1 New version (without

inner (with mounting no. 12 -15), can be
eyes) installed retroactively.

10 Dust cap 2

11 Bleeder screw 2 Up
12 Hollow union bolt 1 Torque: 16 Nm )
(12 ft. Ibs.) )
) om itted
13 Ring connector 1 ) since Dec.
)1984
14 Seal 1 Replace

Disassembling and Assembling Brake Caliper VI, 1985 Printed in Germany

47-2
 i I Note When: Special
No. Description Oty. Removing Installing Instructions

15 Seal 1 Replace Omitted since

Dec. 1984

16 Screw 4 Heat to approx. Install with Loctite

1500 C No. 270.

17 Spring plate with 1 Heat screws to Assemble with correct i Page 47 -5

retainer approx. 1500C. bridge. Lock screws
with Loctite No. 270.

18 Spring plate with 1 Heat screws to Assemble with correct Use lockplate
openings approx. 1500C. bridge (openings for (no. 2), if
cross spring). Lock there are no
screws with Loctite openings to
No. 270. service as a
cross spring
lock, see
page 47 -5.

19 Spacer 8 Do not drive into

(dowel sleeve) brake cal iper sections
against stop. About
one half each should
be in the brake cal iper
section and bridge.

Printed in Germany -V I, 1985 Disassembling and Assembling Brake Caliper 47-3

 Brakes, Hydraulic Parts

DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS

Disassembling

1. Clamp caliper in a vise with soft jaws and 3. Drive off brake caliper halves from bridge
detach connecting line. by applying knocks from a plastic
hammer alternately.

4. Countersunk screws of spring plate are

locked in bridge with Loctite 270. To
2. Unscrew bolts holding halves of brake unscrew, heat screws to approx. 150 DC
caliper. This is necessaryto prevent stripping
threads in bridge.

47-4 Disassembling and Assembling Brake Calipers Printed in Germany

 Brakes, Hydraulic Parts

Assembling nit ia Version

1. After replacing or loosening, lock counter.

sunk screws for spring plate with Loctite
270.
Install spring plate with retaining tab on
bridge without opening.

Note

Following changes have been made on spring

plates since the beginning of standard
production.

A lockplate for protection of the cross

spring is required on spring plates with
opening in initial version.
In the modified version a spring plate with
pertinent openings protects the cross
spring.
A conversion is only possible with con-
formance with point 4 on page 47 -4 and
use of correct spring plate (see note
below).
Modified Version

The countersink to take the mounting

screws is larger for all spring plates since
1984 models and therefore the bridges
had to be changed, too.
Spring plates with larger countersinks
( present version 12.8 -0.2 mm diameter;
was 11.5 + 0.5 mm) cannot be used on
old bridges.

Spring Plates with Larger Countersink

Printed in Germany -V, 1984 Disassembling and Assembling Brake Calipers 47-5
 Brake, Hydraulic Parts

2. Assemble brake caliper.

3. Replace seals on hollow bolt and adapter.

4. Check piston position -see page 46 -3

5. When installing brake pads, check for

correct play between pad and recess,
correct position of cross spring and
clearance of lockplate in case of initial
version spring plates (see pages 46 -2
to 46 -4).

6. Bleed brakes.

Disassembling and Assembling Brake Calipers Printed in Germany

47-6
 Brakes, Hydraulic Parts

Note:

The blow-up view shows the outer front axle brake caliper half.

Piston diameter on front axle = 38 mm.

Piston diameter on rear axle = 30 mm.

Mount piston and bleeder valve in correct position, depending on installation of brake
caliper half on right or left side (setback surface on face of piston faces brake disc
inlet/bleeder valve faces up).

Printed in Germany -V I 1984 Disassembling and Assembling Brake Caliper Section 47-7
 Brakes, Hydraulic Parts

Note When: Special

No, Description Oty Removing Installing Instructions

1 Piston 2 Press out of brake Use brake cylinder

caliper half with paste. Check
compressed air. piston position
Use wood base - (position of
danger of injury! machined piston
face) already
while pressing in -
page 46 -3

2 Dirt scraping ring 2 See page 47 -9 Replace.

Position correctly
-see page 47 -10

3 Seal 2 Lift out with a Replace.

plastic rod Coat with brake
cylinder paste.

4 Brake cal iper half 1 See pages

47 -9 and
47 -10 under
"cleaning and
inspecting"

47-8 Disassembling and Assembling Brake Caliper Half Printed in Germany

 DISASSEMBLING AND ASSEMBLING BRAKE CALIPERS

Disassembling

1. Place brake caliper section on a wooden

board with the piston facing down and
press out piston with compressed air.

4. Lift out sealswith a plastic rod.

2. Clamp brake caliper section in a vise with

the cylinder bores facing up.
Use a vise with soft jaws.

Note:

Make sure surface of brake caliper section

is not damaged and consequently the Cleaning and nspecting
corrosion inhibiting coat is not injured.
1. Clean all parts with alcohol and dry
with compressed air. Never use rags,
3. Remove dirt scraping ring by deforming since even minute particles of lint would
the support ring of the dirt scraping ring lead to leakage.
all around with a suitable tool (e. g. thin
punch) to such an extent, that the 2. I nspect connection threads and spacer
scraping ring can be removed. sleeves (dowel sleeves) for damage as
Be careful not to damage seat surfaces. well as cylinder bores and pistons for
scoring and corrosion.

Printed in Germany -V, 1984 Disassembling and Assembling Brake Calipers 47-9
 Brakes, Hydraulic Parts

Note: Note:

Machining cylinder bores and pistons is not Mount dirt scraping ring in brake caliper
approved. Replace pistons or complete brake section that the ring's printed part number
caliper section, asapplicable. faces in.
The sealing lip then faces out (in contradic-
tion to the normal position of a radial shaft
3. If the brake caliper section is in good seal) and prevents the entry of dirt and
condition, check whether connecting bore water.
between the cylinder bores is plugged.
Clean bores with compressed air.

4. Clean new sealsand scraping rings with

alcohol and dry with compressed air.

Assembling

1. Give cylinder bores, pistons and seals a

thin coat of brake cylinder paste.

2. Place seals in grooves of cylinder bores.

3. Mount dirt scraping rings in correct position

with a suitable pressure pad.
Drive in dirt scraping rings at least so far,
that they do not protrude beyond the
machined surface of the brake caliper
section.

4. Pressin piston by hand slowly.

Check position of the milled surface on
the piston's face during this step (see
page 46 -3). If it is necessaryto turn
the piston after installation in the brake
caliper section, a suitable tool (e. g.
ATE piston turning pliers) must be used.

Disassembling and Assembling Brake Calipers Printed in Germany

47-10
 Brakes, Hydrau c Parts

7. Check for leaks (high pressure test) with

a pressuretester.

High Pressure Test

Produce a pressure of 50 to 100 bar in the

braking system with a pedal prop. The
produced pressure must not drop by more
than 10 % during the testing time of
10 minutes with a constantly applied
pedal force.

Note:

A brake force regulator is integrated in the

rear axle brake circuit of cars with Turbo
Look. When connecting a pressure tester
on the rear axle brake circuit of these cars,
the produced pressure must not exceed
70 bar.

5. Assemble brake cal iper (see page 47 -1).

6. Recheck piston position in car after

installation of the brake caliper.
Install brake pads.
Bleed brakes.
 Brakes, Hydraulic Parts

BRAKE CIRCUIT FAILURE INDICATOR (UNTIL END OF 1983 MODELS)

Each of both brake circuits has a brake light The brake circuit failure indicator has to
switch on the brake master cylinder, which be cancelled by disconnecting the battery
also functions as a brake warning switch in after repairing the brake system.
cars up to the end of 1983 models. Beginning with 1984 models it is no
longer necessaryto disconnect the battery,
since the brake indicator lamp (triple
chamber I ight) goes out as soon as the
brake fluid level in the tank has reached
the minimum level.

An indicator lamp (bottom part of a double

chamber light) installed in the instrument
panel comes on when a brake circuit fails.

47-12 Brake Circuit Failure Indicator Printed in Germany

 SPECIFICATIONS

Steering Rack-and-pinion

Steering wheel 380 mm (14.961") dia.,

lattice steering wheel
with impact pad

Steering ratio in center

steering wheel angle to
wheel angle 17.78 : 1

Turning circle dia. 10.8 m (35.4 feet)

Track circle dia. 10.35 m (33.9 feet)

Non of steering wheel turns

from lock to lock approx.3.0

Friction torque of steering

-measured on flange of
steering gear without
connected tie rods 0.8 to 1.4 Nm/8 to 14 kpcm/
7 to 12 in. Ibs.

Printed in Germany Specifications 48-01

 General

TORQUE SPECIFICATIONS FOR STEERING

Location Designation Threads Material

Torque
Nm ft Ibs

Steering gear Bolt. M 10 8.8 47 34

Tie rod to rack Ball socket M 16 x 1.51c35K 150 108

Ball socket to Castle nut M 10 x lti 45 33

steering arm

Ball socket to Nut M14x1.51o4 45 33

tie rod (lock
nut)

Steering coupling Bolt M8 18.8 25 18

to steering shaft

Steering shaft to Bolt M8 8.8 25 18

stecringgear

Steering shaft Screw M8 18.8 25 18

mount

Universal joint Bolt M8 8.8 20 14

to steering shaft
(lubricated with
Optimoly HT)

Couplin flange Nut M 10 8 45 33

to drive pinion
(seif-ioc king)

Casecover to Bolt M8 8.8 15 11

steering gear

Steering wheel Nut M 18 x 1.518 50 36

Centering screw Stud M8 10.9 2-3 1.4 -2.2

to steering lock

Lock nut on cen Nut M8 8 18 13

tering screw

48-02 Technical Data V. 1984 -Printed in Germany

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Printed in Germany -I, 1976 Dismantling and Assembling Steering 48-1

-,..
 Steering

Notes
No. Designation Amt. Remarks
Removing Installing

1 Capscrew 2 Torqueto
specifications
2 Lockwasher 2 Replace, if
necessary
3 Cover 1 Must fit on steering
shaft bearings
conectly

4 Hex hd screw 2 Torque to

M 10 x 35 specifications

5 Washer 2 Replace. if
necessary

6 Cotter pin 2 x 25 2 Replace

7 Castle nut 2 Torque to

M 10 x 1 specifications

8 Hex nut 2 Torqueto

M 14 x 1.5 specifications

9 Ball joint 2 Check, replacing Ball joint must show

if necessary. Check frictional torque when
seal for tight fit moving. Replace if it
and damage. has axial play or no
frictional torque.
10 Holder 2 Replace, if
necessary

11 Seal 2 Check for damage.

replacing if
necessary

12 Spacer 2

Torqueto
13 Tie rod 2 specifications

14 Steexing shaft 1 Check, replacing

holder with rubbex if necessary
bearing

15 Seal 1 Install correctly

48-2 Dismantling and Assembling Steering Printed in Germany

 Steering

Notes
No. Designation Amt Remarks
Removing Installing

16 Hex hd screw 4 Torqueto

M 8 x 42 specifications

17 Lockplate 2 Replace

18 Stop 4

19 Steeringcoupling 1 Visual inspection,

replacing if necessary

20 Steering shaft 1

21 Steeringgear 1 Check frictional

torque, replacing or
repairing if necessary

DLSASSEMBLING AND ASSEMBLING INSTRUCTIONS

Assembling Note

1. Clamp steeringbox in a vise with protective Omitting hex nut has made the former instructions
jaws for the rack. for tie rod ball joint adjustments invalid. Only
tne spacer is available for replacements.

2. Screw tie rod with spacer in rack and tighten

to specified torque.
Machine open end socket for torque wrench
for this purpose.

Printed in Germany -If 1976 Disassemblingand AssemblingSteering 48 -3