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924 1978 1985
User Manual
18 pgs359.77 Kb0
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Porsche 924 1978 1985 User Manual

Technical specifications

924 models 78-85
924 turbo models79-84
924 Carrera GT m odels 81
Contents
Page
General
Engine
Page Transmission and clutch
Torque specifications for manualtransmission,
Technical data - clutch .................................................10
Technical data - 4-speed manual transmission 924 ........................11
Technical data - 5-speed manual transmission 924 ........................11
Torque specifications -automatic transmission 924 .......................11
Torque specifications - autom. transmission actuating elements 924 ......11
Torque specifications - accelerator actuation (automatic) 924 ...........11
Torque specifications-central tube (automatic) 924 ......................12
Technical data-automatic transmission 924 ...............................12
Pressure-testing hydraulic control unit .................................12
Torque specifications - manual transmission 924 turbo ...................13
Torque specifications - clutch, central tube,
transmission suspension, shift actuation 924 turbo ......................13
Torque specifications -manual transmission type 016G 924 turbo ..........13
Torque specifications - Clutch, central tube, transmission
suspension and shift actuation type 016G 924 turbo ......................13
Technical data - 5-speed manual transmission 924 turbo ..................13
Front axle, steering, rear axle and wheels
Torque specifications -front axle 924/924 turbo .........................14
Torque specifications -steering 924/924 turbo ...........................14
Torque specifications -rear axle 924/924 turbo ..........................14
Technical data-front axle 924 ...........................................14
Technical data-front axle 924 turbo .....................................14
Technical data-steering 924 .............................................14
Technical data-steering 924turbo ........................................14
Technical data - rear Axle 924...........................................14
Technical data - rear axle 924 turbo ....................................14
Checking disk wheels ....................................................15
Tires, wheels, tire pressures ...........................................15
Wheel alignment adjustment values 924/924 turbo .........................15
Page Brake system
Torque specifications-mech. brake system ................................15
Torque specifications - hydr. brake system ..............................15
Technical data - brake system 924........................................15
Technical data -brake system 924 turbo/CarreraGT ........................15,16
Air conditioning
Technical data - air conditioning as from Model 79 ......................17
Torque specifications - air conditioning ................................17

Electrical system

Relays ..................................................................17
Fuses ...................................................................17
General technical data
Performance figures .....................................................18
Dimensions ..............................................................18
Weights .................................................................18
Filling capacities.......................................................18
2
Important Conversion Factors and New Dimensioning Units
Pressure Technical atmosphere at(kp/cm2) Bar (bar) Output Horsepower HP Kilowatt (kW) Force Kilopond kp Newton (N) Torque Kilopondmeter kpm Newtonmeter(Nm) '
Conversion factors
at(kp/cm2) in bar x 0.981 kp in N x 9.81 HP in kW x 0.736 kpm in Nm (ftlb) x 9.81 m/s in km/h x 3.6 at in mmHG x 735.56 km/h in mph (miles) x 0.621 °F (Fahrenheit) in°C (°F-32)x 0.555 I in U.S. gal x 0.264 I in Imp. gal x 0.22
To convert tightening torques from kpm into Nm, the conversion factor 10 can be used. This is sufficient for workshop applications.

Survey of Type Designations

Model year desig­nation
1978­1979
1980 924 Europe, RoW 924
1981­1982
1983­1985
1979­1980
1981­1982
1982­1984
Former units Present units
Vehicle type designation Engine
924 Europe, RoW 924 USA, Japan, Calif.
USA, Canada, Japan
924 Europe, RoW 924 USA, Canada, Japan
924 Europe, RoW XK/XJ 1984 92/125 84.4/86.5 9.3:1 K-Jetronic XK 000001 onwards WPO ZZZ 92 Z DN 40 0001 -9999
924 turbo, Europe,RoW 924 turbo, USA, Canada
Japan
924 turbo, Europe, RoW 924 turbo, USA, Canada Japan
924 turbo, Italy M31/03 1984 130/177 84.4/86. 5 8.5:1 K-Jetronic 3103 0001-9999 WPO ZZZ 93 Z DN 10 0001 -9999
Displa-
type
cem-
desig-
ent
nation
act. Cm
XK/XJ
1984
XG/XE
1984
XK/XJVC1984
1984
XK/XJVC1984
1984
M31/01
1984
M31/02
1984
M31/03
1984
M31/04
1984
DIN-kW
Stroke/
(HP)
Bore (mm)
3
92/125
84.4/86.5
85/115
84.4/86.5
92/125
84.4/86.5
85/115
84.4/86.5
92/125
84.4/86.5
85/115
84.4/86.5
125/170
84.4/86..
110/150
84.4/86.
130/177
84.4/86.
115/156
84.4/86.
Compression ratio
9.3:1
8.5:1
9.3:1
9.0:1
9.3:1
9.0:1
5 7.5:1 5 7.5:1
5 8.5:1 5 8.0:1
Fuel-induction system
K-Jetronic K-Jetronic K-Jetronic
K-Jetronic
K-Jetronic
K-Jetronic K-Jetronic
K-Jetronic K-Jetronic
K-Jetronic K-Jetronic
Engine numbers Chassis numbers
XK 000001 onwards XG 000001 onwards XG 000001 onwards
XK 000001 onwards
VC 000001 onwards
XK 000001 onwards VC 000001 onwards
31010001-9999 31020001-9999
31030001-9999 31040001-9999
9248100001-99999 924 82 00001-99999 924 83 00001-99999 (Japan)
92 АО 410001-9999
92 АО 43 0001-9999
WPO ZZZ 92 Z BN 40 0001-9999 WPO AAO 92 0 BN 45 0001 -9999
93 АО 14 0001-9999 93 А015 0001-9999
WPO ZZZ 93 Z BN 100001-9999 WPO AAO 93 0 CN 15 0001 -9999
Engine Number Codes
e.g. XK 000001
Code letters
Code letters engine type
Techn. data
Serial no. continuous irrespective of model year, when code letters identical. With new code letters/engine type, serial no. starts again at 000001.
Fitted in vehicle type Engine no.
Letters range engine type
XK
92KW/125HP
XJ
92kW/125HP
XG
85KW/115HP
XE
85kW/115HP
VC
85kW/115HP
Engine number codes (8-digit) 924 turbo
3 1 01 0001 -9999 Europe/Rest of World (left and right-hand drive) 31 02 0001-9999 USA/California/Canada/Japan 31 03 0001-9999 Europe/Rest of World (left and right-hand drive) 31 04 0001-9999 USA/California/Canada/Japan Serial no. Type designation
Chassis Number Codes, Models 78...79
1. Chassis no. codes (10-digit)
924 8 1 00001 Type Model year Model version Serial no. 8 = 1978 1 = Europe, 00001 to 99999 9 = 1979 Rest of World 2 = USA, Serial no.starts California at beginning again for 3 = Japan each model year and country category
924-Europe, Rest of World 924-Europe,Rest of World right-hand drive 924-USA, Japan 924 California 924-USA, Canada California, Japan
3101 = T25kW (170 HP) 3102 = 110 kW (150 HP) 3103 = 130 kW (177 HP) 3104= 115 kW (156 HP)
000001 onwards 000001 onwards 000001 onwards 000001 onwards 000001 onwards
Chassis Number Codes, Model Year 80
The following changes are effective from model year 1980 for the chassis no.:
1. The 1st and 2nd digits signify basic type.
2. The 3rd digit signifies model year, internationally established as A for 1980.
3. The 4th digit indicates the factory. For model year 1980 the code is 0.
4. The 5th digit, in conjunction with digits 1 and 2, provides further identification of the vehicle. The 6th digit indicates the engine version.
5. The remaining 4 digits form the serial no.
The example below makes the changes clear:
924___________________
00001 |_________Model year 1980 92 A041 0001
924 turbo_____________
9249400001 |_________Model year 1980 93 A014 0001
Model year 1979 924 91
Model year 1979
Chassis Number Codes, Model 80
Chassis number codes 924
92 АО 41 0001 – 9999 92 АО 42 0001 - 9999 92 АО 43 0001 - 9999
44 0001 – 9999
92 АО
Europe / Rest of World And beyond if more than 9999 vehicles USA/California /Canada /Japan And beyond if more than 9999 vehicles Serial no. Engine version 1 2000 cm3 92kW/125HP 2 2000 cm3,92kW/125HP 3 2000 cm 4 2000 cm3, 85kW/115HP Type supplement (this number designates model 924 in conjunction with first 2 digits) Place of production (Factory code initially designated as 0.) Model year A =1980 В = 1981 Type code (vehicle model)
3
, 85kW/115HP
3
The 924 turbo is designated type 931 internally.
1. Chassis no. codes (10-digit)
93 А0 14 0001- 9999 93 А0 15 0001 –9999
Europe/Rest of World USA/California/Canada/Japan Serial no. Engine version 4= 2000 cm3 125 kW/170 HP 5 = 2000 cm3, 110 kW/150 HP Type supplement Place of production Model year A =1980 B = 1981 Type code
Chassis Number Codes as from Model 81 Chassis number codes 924
WPO ZZZ 92 Z С N 40 0001 - 9999 WPO AAO 92 О С N 45 0001 – 9999
|
Chassis number codes 924 turbo
WPO ZZZ 93 Z С N 100001 - 9999 Europe/Rest of World WPO AAO 930 С N 150001 – 9999 USA/Canada/Japan
Europe/Rest of World USA/Canada/Japan Serial no. Code for body type and engine Indicates vehicle type together with digits 7 and 8 Place of production Model ye ar (B = 81, С = 82, D = 83, E = 84, F = 85) Test code Vehicle type together with 12th digit Filling code or VDS code for USA and Canada versions World manufacturer code
Manual and automatic transmissions 924/924 turbo
Model Ident.
088/6 088/A 016Z 016Y 016/8 016/9
016/8 016/8
016/9 016/9
016/9
For repair purposes these transmissions differ only slightly from model 80.
087/3 087/6
924 turbo
G31/01 G31/02 016G 016G
Type Fitted in model year
letters
YR
4-speed
XT
4-speed
VA
5-speed
VB
5-speed
VQ
5-speed
VR
5-speed
MD
5-speed
4Q
5-speed
MF
5-speed
5Q
5-speed
ME
5-speed
RKRLAutomatic
Automatic
MB MX
Europe, RoW USA, Japan Europe, RoW USA Europe, RoW USA, Japan
Europe, RoW Europe, ROW with
lock USA USA, Japan
with lock Japan
Europe, RoW USA, Japan,
California
5-speed
Europe,
5-speed
RoW USA,
5-speed
Japan USA
5-speed
Japan
78/79 78/79 78/79 78/79 80 80
from 81 82
from 81 82
from 81
from 78 from 78
79.. .84 up to 80 81/82 81/82
Transmission Number Codes 924
Model
Number Transmission type Vehicle type
year 1978,
YR1902 8
1979
XT XX XX 8 RK XX XX 8 RL XX XX 8
VA 00001-99999 VB 00001-99999
1980
VQ XX XX 0 VR XX XX 0 RK XX XX 0
RL XX XX 0
1981
MD XX XX 1 MFXXXX1 ME XX XX 1 RK XX XX 1
RLXXXX1
1982 М019 02 2 4Q
XX XX X
MF XX XX X 5Q XX XX X
ME XX XXX 016/9 - 5-speed 924 Japan RK XX XX X RL XX XX X
1983 MD 19 02 3 4Q
XX XX X
RK XX XX X 087/3 - Automatic (up to
RCC XX XX X 087/3 - Automatic (from
1984,
MD19024 016/8 - 5-speed 924 Europe/RoW
1985
4Q XX XX X 016/8- 5-speed w.
RCC XX XXX 087/3 - Automatic 924 Europe/RoW
088/6 - 4-speed 088/A - 4-speed 087/3 – Automatic 087/6 - Automatic Production year
8 = 1978, 9 = 1979 Production month Production day Identifying letters
016Z - 5-speed 016Y - 5-speed Serial number 016/8-5-speed 016/9-5-speed 087/3–Automatic
087/6– Automatic 016/8-5-speed 016/9-5-speed 016/9-5-speed 087/3 – Automatic 087/6 – Automatic
016/8 - 5-speed 016/8 5-speed w.
Differential lock 016/9 - 5-speed
016/9 - 5-speed w. Differential lock
087/3 - Automatic 087/6 - Automatic 016/8 - 5-speed 016/8- 5-speed w. Differential lock
09.1982)
10.1982)
Differential lock
Transmission Number Codes 924 turbo
Model
Number Transmission type Vehicle type
year
1979,
31 01 00001 (12) -
1980
99999 3102 00001 (12)­ 99999
1981 31 01 00001 (12)
-99999 016 G 000001
-99999
1982 31 01 00001 (12)
-99999
016G 00001
-99999 016G 00001
-99999 016G 00001
-99999
1983
31 01 00001 (12)
1984
-99999 31 01 00001 (12)
-99999
G31/01 - 5-speed
G 31/02 - 5-speed Differential lock
G31/01 - 5-speed
MB = 016G - 5-speed MX = 016G - 5-speed
G31/01 - 5-speed
MB = 016G - 5-speed
MX = 016G - 5-speed
6Q = 016G - 5-speed with differential lock
G31/01 - 5-speed
G31/01 - 5-speed
924 Europe/RoW 924 USA/Japan 924 Europe/RoW 924 USA/Japan
924 Europe/RoW 924 USA/Japan
924 Europe/RoW 924 USA/Japan 924 Europe/RoW
924 USA/Japan 924 Europe/RoW 924 USA/Canada 924 Japan 924 Europe/RoW 924 USA/Japan/Canada
924 Europe/RoW 924 Europe/RoW
924 USA/Canada
924 USA/Japan
924 Europe/RoW 924 USA/Japan/ Canada 924 Europe/RoW 924 Europe/RoW
924 Europe/RoW
924 Europe/RoW
924 Europe/RoW
924 turbo Europe/RoW
924 turbo USA/Japan
924 turbo Europe/RoW
924 turbo USA/Can. 924 turbo Japan
924 turbo Europe/RoW
924 turbo USA/Can.
924 turbo Japan
924 turbo USA/ Canada/Japan
924 turbo Italy
924 turbo Italy
4
Engine Data
,
(
,
(
)
)
Engine type
Model year
No. of cylinders 4 4 4 4 4 4 4
Bore mm/in. 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 Stroke mm/in. 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 Displacement (actual) Cm3/in
Compression ratio 9.3:1 8.5:1 9.0:1 7.5:1 7.5:1 8.5:1 8.0:1 Max. engine power, 80/1269/EWG kW/HP 92/125 85/115 85/115 125/170 110/150 130/177 115/156 (Net Power, SAE J1349) kW/HP 82/110 121/162 106/143 126/169 115/154
At engine speed max. Torque 80/1269/EWG Nm/kpm 165/16.8 156/15.9 156/15.9 245/25 206/21 250/25.5 210/21.4
Net Torque, SAE J1349)Nm/ftib 151/111.3 237/175 199.4/147 242/184.5 203.3/154.8 At engine speed Rpm 3500 3500 3500 3500 3500 3500 3500 Max. specific power DIN 70020 kW/l(HP/l) 46/63 43/58 43/58 63/86 55.4/75.6 65.5/89.2 58/78.6
SAE J 1349 Fuel octane rating RON 98 90 91 98 91 98 91 Max. perm. engine speed Rpm 6500 6500 6500 6500 6500 6500 6500
Idle speed Rpm 950±50 950±50 750...800 900 ± 50 900 ± 50 <900 <900 Engine weight (dry) Kg 136 142 142 165 165 165 165
Rpm 5800 5750 5750 5500 5500 5500 5750
kW/l(HP/l
924 XK 924 XJ 78…85
3
1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06
924 XG 924 XE 78…79
41/55 61/82 54.6/72.1 63.5/85.2 55.9/75.1
924 VC
80...82
M31/01 turbo
79...80
M31/02 Turbo
73...80
M31/03 turbo
81..84
M31/04 turbo
81.„82
Technical Data Type 924 Engine Type XK/XJ
Engine design
Design Crankcase Crankshaft Connecting rods Pistons Camshaft Camshaft drive Cylinder head Valve arrangement Valve timing Valve play Timing with engine warm Intake opens Intake closes Exhaust opens Exhaust closes
Engine cooling Engine lubrication
Oil filter Oil pressure at 5000 rpm Oil pressure indicators Oil consumption l/1000 km
Exhaust system Heater Fuel system
Fuel delivery Fuel grade RON Fuel consumption
Electrical system
Interference suppression Battery voltage V Battery capacitance Ah Alternator/output A/W Ignition Ignition sequence
Ignition timing Spark plugs Electrode gap mm
Power transmission
Clutch Pressure plate
4-cylinder,4- stroke spark-ignition engine, in line 1 -piece gray cast iron cylinder/crank- case with aluminum oil pan forged, 5 plain bearings Forged steel Cast light-alloy Case-hardened steel without bearing shells, running in cylinder head by means of toothed belt, with tightening roller Light alloy 1 intake, 1 exhaust in line overhead by overhead camshaft and bucket tappets Intake 0.20 mm, Exhaust 0.45 mm (1 mm stroke, zero play) 6 degr. Before TDC 42 degr. After BDC 47 degr. Before BDC 2 degr. After TDC closed coolant system Forced oil circulation system with crescent pump in full flow approx. 7 bar for oil temperature between 80... 100° С Indicator lamp and pressure gauge up to 1.5 Manifold, single pipe up to front muffler, front, center and final muffler Warm water heater with heat exchanger and blower
K-Jetronic 1 electric fuel delivery pump 98 Refer to "Operating Instructions"
ECE-R 10 and 72/245/EWG 12 45 (opt. Extra 63) 75/1050 Battery ignition system/TSZ ignition system 1-3-4-2 10° CA before TDC at 950 ± 50 rpm without vacuum pipe Bosch W5D, Beru 14-5 DU
0.7 ± 0.1 Front-mounted engine, transmission mounted at rear end, bolted together by a connecting tube to form a rigid drive unit transaxle. Front engine, clutch, torsionally elastic drive shaft to transmission mounted in connecting tube, rear transmission interlocked with axle drive, twin drive shaft to rear wheels.
Single-disk dry clutch with disk spring, in compact design, arranged at engine end (MF215K)
5
Technical Data for the 924 Carrera GT
Main data of the 924 Carrera GT model 81 compared with the basic 924 turbo
Engine type 924 Carrere GT
Max. engine power kW/HP 154/210 130/177
at engine speed rpm 6000 5500 max. torque Nm/kpm 280/28.5 250/25.5
max. specific power kW/l, HP/I 77.6/105.8 65.5/89.2 Engine weight kg 175 165
Boost pressure bar 0.75 0.64 Clutch contact force N 7800...8500 7200...7900
Clutch disk TD225 GUD 225 Stabilizer, rear
Wheels and tires
924 Carrera GT Wheels Tires
5-hole wheels LMgs7Jx15 215/60 VR 15 Rim offset 23.3 mm (924 turbo 53 mm)
Engine number code 924 Carrera GT
31 50 0001 -9999 Europe/RoW
Transmission number code 924 Carrera GT
31 03 00001 (12) - 99999 G31/03 - 5-speed Europe/RoW
∅
M31/5O
16mm 14mm
with differential lock
924 turbo M31/03
Torque Specifications - Engine 924/924 turbo
Location Thread Tightening torque Nm (ftib) Bearing housing to crankcase M12 80 (59) Bearing housing 5 to crankcase M10 65(48)
Connection rod bolted joint M10x1 60(44) Oil suction line to crankcase M6 10(7.5) Oil drain line to crankshaft bearing
housing Housing to oil pump M 6 8(6) Oil pump to crankcase М6 10(7.5) Oil pan to crankcase M8 15(11) Oil pan to crankcase M6 8(6) Oil drain screw M26 x 1.5 40(29) Flywheel to crankshaft M12x1.5 100 (74) Toothed belt pulley to crankshaft M16X1.5 250 (184) V-belt pulley to toothed belt pulley M8 20(15) Water pump to crankcase M8x72 M8x65 22(16) Water pump to crankcase M6x35 M6x45 9(7) Water pump pulley to hub M8x12 20(15) Connection piece to oil pan M26X1.5 110(81) Oil return line from turbo-charger to oil pan Oil return line from turbocharger to bracket Screw connector oil filter to oil filter bracket Bracket for oil filter to crankcase Oil lines to bracket for oil filter M18X1.5 55 (41) Oil supply line to bracket for oil filter 85 (63) Oil line to bracket for turbocharger 40 (29) Connecting piece to bracket for turbocharger Camshaft bearing housing to cylinder head Camshaft bearing housing to cylinder head Cylinder head cover to cylinder head М68(6) Oil pressure sensor to cylinder head M10x1 15(11) Toothed belt gear М12Х1.5 80 (59) Tensioning roller thermostat housing М10 40 (29) Flange for heater on cylinder head М6х35 10 (7.5) Coolant governor М6 10 (7.5)
Coolant governor to cylinder head М8х35 М8х25 20(15) Spark plug M14 x 1.25 30(22)
Distributor bolt s М8 20...22(15...16) Telethermometer transmitter M10x1 8(6) Suction pipe and hoisting bracket to cylinder head Exhaust manifold to cylinder head М8 25(18) Toothed belt cover to cylinder head M6x25 10(7.5) Toothed belt cover to oil pump M6x25 10(7.5) Throttle valve connector piece to suction line Engine bracket to engine nock М10 42(31) Engine mounting to engine bracket M12x1.5 61(45) Engine mounting to frame М10 42(31) Clutch housing to engine M12 75(55) Clutch housing to engine М10 45 (33) Insulating connector piece to cylinder head Injection valve to insulating connector piece Fuel lines to mixture control unit M12x1.5 20(15) Injection lines to injection valve 10(7.5) Injection lines cyls. 1-4 to mixture control unit Fuel line to warm-up regulator and mixture control unit warm-up regulator Fuel line to warm-up regulator 14(10) Fuel line to cold-start nozzle and mixture control unit Fuel line for timing valve to mixture control unit Fuel line to timing valve 12.5 (9) Oxygen sensor to front of exhaust pipe 50...60 (37...44) Control line to bypass valve M12x1.5 20(15) Screw plug to bracket for oil filter M42X1.5 120 (88) Oil filter 20(15) Turbocharger turbine casing M6 M8 12(9) 25(18) Turbocharger compressor casing 7(5) Exhaust manifold flange Turbo charger M10 35(26) (from model year 81 ) M10 50(37) Boost pressure safety switch M10xl 15(11)
Vent casing on bypass valve M12x1.5 20(15)
Coat all threads of exhaust system with Optimoly HT
M6 10(7.5)
95(70)
85 (63)
¾
-16 UNF
¾
-16 UNF-2 В
M14X-1.5 40.. .45 (29...33)
М6 10(7.5)
М8 16...20(12...15)
M8x72 М8 24(18)
M8x40 22(16)
M8x1 9(7)
M8x1 9(7)
M8x1 9(7)
M8x1 9(7)
To firm fit max. 20 (15)
60 (44)
22...25(16...18)
6.0...7.0 (4.5...5.0)
6
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