(I) 857 E61, E63 E84, E87 892,895 E98,

(I) 857 E61, E63 E84, E87 892,895 E98,

REVISIONS
SERVICE GUIDE 972
(I)
Pages:
Title Page, E Table of C ontents
E 5, 8 9, 8 10, 8 15, E 16, 829 8 36, 847 E 54,
857 E61, E63 E84, E87 892,895 E98,
E 101, E 102"
F Table of Contents,
F3 FB, F'11, F1?, F18, F23 F26, F29, F30.
Please Ínsert the above pages
pages where appropriate.
Printed in Germany
into the appropriate grous of the 912 ServÍce Guide, discarding obsoiete
Dr " ing" h" c " F" Porsche KG
February 196?
\-.*""
INTRODUCTION
TO THE PORSCHE FOREMAN AND MAINTENANCE TECHNICIAN
similiarity between the 912 and 1600 SC engÍne. Thus you will
fÍnd many familiar instructions in this Service Guide for the 912 engine.
As you already know, there is great
Chassis design of the 912 Porsche Ís basÍcally the same as that of the Type 911. Consequently, you
may apply the workshop manual for the Type 911, in combination with this Service Guide for the
912 engine, to the 912 Porsche as well.
The choÍse of arrangÍng your Porsche manuals is being left to your discretion. You may remove from
your 9l1-Workshop Manual the chapter dealÍng wÍth the 911 engine and replace Ít with thÍs Service
Guide for the 912 engine, thus having a complete 912 Workshop Manual; you may supplement your
911 Workshop Manual wÍth this Service Guide for the 9L2 engine to have both rypes in a sÍngle book;
oÍ you Ínay retain your 911 Workshop Manual and tttis Service Guide for 912 engines Ín separate books
to have ample space in each book for the inclusion of notes and supplements.
All
pages of this Service Guide for the 912 engine have been marked
"9ï2" to preclude mÍsfiling.
The procedures, tool. application and identification have, of course, been adopted from the g11 Workshop Manual.
We hope that this Service CuiO" fo, the 912 engine
Porsche cars.
will aid you in your-efforts to skÍlfully service all
DR. - ING. h. c, F.
\_-
PORSCHE KG.
l'ilra
lo B
ooks
\---
SERVICE GUIDE
DR. lNG. h.c. F. PORSCHE KG
5T
Subjecr ro Changes
Printing
No. W 32L
Edition 1966
Technical Stage as of September
by Dr,
tuttgart 1 966
GARY T. COOPER
1ó591 Tl3:ir IANE
HuNTTNcToN BiAcHí
cA!f[
FFE N
HAUSE N
Printed in Germany
1"966
- Ing. h. c. Ferdinand Porsche
S
*\*
UTTGART .ZU
A
11
rights
reserved
[-
A 5 5 E M B I.Y GUIDE
DR. lNG. h.c. F. PORSCHE KG
ST
Edition 1 I66
Subject to Modification
Printing
No. W
321
UTTGART -ZU FFE N HAU
Technical Stage as of September L966
by Dr.
- Ing. h. c. Ferdinand Porsche
Snrttgart 1966
SE
N
Printed in Germany
A
11
rights
reserved
CONTENTS
GROUP
Engine
A
E: ENGINE AND CLUTCH
ssembly
Engine Serial Number, location
CylÍnders and MaÍn Bearings, numerical designation
E
1
E
2
a
Engine, cross-sectional view
E
(J
Engine, descrÍptíon
E
4
Service Operations:
En
2Ên
1
Engine, removing and installir:g
Engine, dÍsassembling and rea.ssemblÍng
COOTING
SY
S
E8
E 10
.
TEM
ServÍce Operations:
En Cooling Air Shrouds, removing and installÍng
En Cooling Blower HousÍng, removing and installing .. . , ,
5 En Cooling Blower, removing and ínstalling
6 En Cooling Blower Impeller, removing and installing , . ., .
7 En Air Hose Connecting Duct, removing and ÍnstallÍng
8 En LowerDuct with Air Gates (Export;, installing
9 En Air Gate Assembly (Type 3568/T6), instatling
10 En V-belt Tension, checking
L1 En V-belt Tensíon, adjustÍng
3
E
18
4
E
2L
23
24
E
25
E
26
E
26
E
27
E
27
TING SYSTEM
EXHA UST A ND HEA
E
E
Heatini System, Type 3568/T6, description . . ...
description
HeatÍng System, Export,
E
E
29
32
Service Operations:
12 En Exhaust Muffler (with 3568/T6 heater)n removing and Ínstalling ., .,.
13 En Heat Exchanger and Exhaust Pipe (with 3568/T6 heater), removíng and
stallíng
..
En
15 En
34
in-
....
E
Exhaust Muffler (with Export heater), removing and installing . . .. .
Heat Exchanger and Exhaust Pipe (with Export heater), rem. and Ínst.
16 En Heater Control Cable, removing and installing. . .. .
1? En Control Lever Assembly, disassembling and reassembling
14
E
.....
35
36
E
36
E
37
E
3B
ENGINE LUBRICA TlON SYSTEM
Oil Circuitn diagram
Oil Circuit, descrÍption
. . o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . .
E 39
E4A
.
Service Operations:
En Oil Strainer, removing and Ínstalling . .., .
En OiI Pressure RelÍef Valve and Bypass Valve,
En Oil Cooler, removing and installing .. .. .
21 En Oil Pump. removing and installing . ....
18
19
20
E4L
removÍng and installing , .. . ..
Second Edition of this paBe, March 1967
.
tr
L
Ác)
'XLt
844
845
22En
Bypass
Oil Filter, changing cartridge
846
CYLINDER HEADS AND VALVES
Service Operations:
23
En
24
25
Eï
846
848
849
851
E52
E53
E54
Rocker Arm Carrier, removing and installing .....
Rocker A rm Carrier, disassemblÍng and reassembling .
En Cylinder Heads, removing and installing . ....
26En Valve Springs, removing and Ínstalling.....
27 En Valve Guides. checking for wear
28 En Valve Seats, checking and reconditioning .
29 En Valves, refacing
30 En Valves. seating
3L En Valves, inspecting
32 En Valves, testing for leakage
33 En Valves, adjusting clearance
34 En Valve Timing and Clearance, checkÍng . ... .
35 En Cylinder Heads, reconditioning and exchange ..,.
CY LINDERS A
F,55
F,55
855
E 56
857
E58
ND PISTONS
Service Operations
En
En
En
En
40 En
36
37
38
39
Cylinders. removing and installing . ..
Cylinders. inspectÍng
PÍstons, removing and installÍng ,. . ..
..
Pistons, inspectÍng
Piston Size Table
E
59
E
60
E
61
E
64
E
65
CRA NKCA SE
ServÍce OperatÍons:
En Crankcase, disassembling and reassembling .
Ên Distributer Pinion Shaft, removing and installÍng
En Oil Seal at Bearing 4, removÍng and installing .... .
44 En BearÍng 4, removing and Ínstalling ,. . . .
45 En Timing GeaÍ Cover, removing and installing ... ..
46 En Flywheel, removing and installing . .. ..
47 En Crankshaft Pulley, removing and installing .....
48 En Oil Seal at Flywheel, removing and Ínstalling . .., .
49 En Camshaft, removing and installing . ....
50 En Crankshaft with Connecting Rods, removing and Ínstalling
51 En Connecting Rods, removing and installing
52 En ConnectÍng Rod Bushings, installing
53 En Connecting Rods, measurÍng and realigning
4L
42
43
E
66
E
69
E
70
E
7T
E
E
..
,. .,
,72
?3
E
75
E
75
E
76
E
77
E
7B
E
79
79
E
CRA NKSHAFT
Service Operátions:
54
55
56
En
En
Ën
Crankshaft (plain-bearing), disassembling and reassemblÍng
Crankshaft Ênd PIay, checking and adjusting
E
BO
E
81
Crankshaft, reconditÍonÍng . ... .
Crankshaft Journal and Bearing DÍmensions
E
B3
E
B3
CLUTCH
Clutch Descriptioir
8?
Service Operations:
En
En
59 En
60 En
6L En
62 Hn
63 En
57
58
Clutch, removing and installing
C1utch Disc, inspecting . .
,,, ,.
Ë,
8B
E
B9
Clutch Assembly, ÍnspectÍng
E
90
Clutch, adjrtsrÍng
Clutch Free Play, adjusting at clutch lever .
Cïuaeh Free Playu adjusting at clutch pedal , o.....
E
9L
E
9L
E
9T
E
92
E
oe
Lr a)
E
94
E
o(
E
L05
Clurch Pedal Travel Limiter, checking and adjir"dting
64 En Clutch Cable, removing and installÍng .. ...
Clutch Servíce Diagnosis
Tolerances and Wear LÍmÍts .
Torque Values for Bolts and Nuts
tl(J