PORSCHE 924 924 Turbo 1976-1988 Repair Service Manual
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🏷️ Basic Information Identification Make: Porsche Model: 924 Model Variant: 924 Turbo Production Years Covered: 1976-1988 Codes Internal Project Code: Type 931 (for Turbo) 👋 Introduction Market Position Vehicle Segment: Sports Coupe / Grand Tourer Target Audience: Enthusiasts seeking performance, handling, and a classic Porsche driving experience Competitive Analysis Key Competitors: Datsun 280ZX, Toyota Celica Supra, Mazda RX-7, Chevrolet Camaro, Ford Mustang Key Features Design Philosophy: Transaxle layout for near 50/50 weight distribution, front-engine rear-wheel drive, aerodynamic styling Turbocharger Advantage: The 924 Turbo offered significantly improved performance over the base model, making it a more direct competitor to other sports cars of its era Manual Utility: Provides crucial technical data and repair procedures for owners and independent mechanics working on these increasingly classic vehicles 📋 Manual Details Coverage Areas Primary Coverage: Porsche 924 and 924 Turbo models Geographic Coverage: Global (technical information generally applicable) Page Count Estimated Page Count: Likely 800-1200 pages (typical for comprehensive workshop manuals of this era, specific count not provided but implied by scope) Manual Type Type: Factory-style Repair and Service Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: 2.0L Water-Cooled I4 (Naturally Aspirated and Turbocharged variants) Engine Lubrication: Oil pump, oil pan, oil filter, oil cooler (if equipped), oil pressure and flow diagnostics Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation, temperature sensors, flushing and filling procedures Fuel System: Fuel tank, fuel pump, fuel lines, fuel injectors (CIS or L-Jetronic variants), fuel pressure regulator, carburetion (early models) or injection diagnostics Exhaust System: Exhaust manifolds, catalytic converter (later models), mufflers, exhaust pipes, oxygen sensors, emissions control integration Emission Control: PCV system, EGR system, evaporative emission control system, catalytic converter operation, diagnosis of emission-related faults Ignition Starter System: Distributor, ignition coil, spark plugs, ignition timing, starter motor, starter solenoid, battery system, charging system (alternator) Clutch: Clutch disc, pressure plate, release bearing, clutch hydraulics, adjustment and replacement procedures Torque Converter: Operation, diagnosis, and potential issues related to automatic transmission integration Manual Transmission: Gearbox overhaul, shift linkage, bearing replacement, gear oil specifications and change intervals Automatic Transmission: Transmission overhaul, fluid types, torque converter lock-up (if applicable), shift control diagnostics Differentials: Rear axle assembly, differential oil, bearing adjustment, potential for limited-slip differential information Suspension: Front MacPherson struts, rear trailing arm suspension, springs, shock absorbers, bushings, ball joints, wheel bearings, alignment adjustment Wheel Tire Alignment: Wheel specifications, tire pressure recommendations, camber, caster, toe adjustments, alignment procedures Brake System: Front disc brakes, rear drum or disc brakes (depending on year/spec), brake fluid type, bleeding procedures, caliper and master cylinder overhaul, parking brake system Steering: Rack and pinion steering system, power steering pump (if equipped), steering column, tie rod ends, steering fluid Body Accessories: Door mechanisms, window regulators, seals, trim, bumpers, hood and trunk latches, interior components, exterior trim removal and installation Heater Ventilation: HVAC system operation, blower motor, heater core, ventilation controls, ducting, cabin air filter (if equipped) Air Conditioner: AC system components, refrigerant types, servicing and charging procedures, diagnostic troubleshooting for AC faults Electronics: Basic electrical system troubleshooting, fuses, relays, lighting system, instrument cluster, gauges, power windows, central locking (if equipped) Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, belt adjustments and replacement Repair: Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component repair and replacement Troubleshooting: Diagnostic procedures for common issues across all major vehicle systems Diagnostics: Step-by-step diagnostic routines for engine performance, electrical faults, fuel system issues, etc. Installation: Procedures for replacing major components and accessories Technical Depth Depth: Comprehensive, from basic maintenance to major component overhaul and detailed diagnostics Illustrations: Detailed exploded views, step-by-step procedure illustrations, and diagnostic flowcharts Printability: Allows printing of selected pages or the entire manual Searchability: Implied PDF format allows for keyword searching within the document 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, suitable for clear viewing and printing of diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: Initially 'Zentpe' for base, 'Z7G' or similar for Turbo variants Configuration: Inline-4 Cylinder Displacement: 1984 cc (2.0 Liters) Bore X Stroke: 80.0 mm x 99.3 mm Compression Ratio: 8.5:1 (Turbo) Performance Horsepower Turbo: 170-177 bhp @ 5500 rpm (depending on market and specific year) Torque Turbo: 210-225 Nm (155-166 lb-ft) @ 3000 rpm (depending on market and specific year) Fuel System Fuel Delivery: Bosch K-Jetronic Fuel Injection (CIS) with turbocharger and intercooler Octane Rating: Premium Unleaded Gasoline (91+ AKI) Engine Lubrication Oil Type: API SG or higher, SAE 20W-50 or 10W-40 recommended Oil Capacity: Approx. 5.5 Liters (5.8 Quarts) with filter change 🔧 Transmission Standard Type: 5-speed Manual Transaxle Optional Type: 3-speed Automatic Transaxle (e.g., VW's 016) Features Layout:...
Front disc brakes, rear drum or disc brakes (depending on year/spec), brake fluid type, bleeding procedures, caliper and master cylinder overhaul, parking brake system
Steering:
Rack and pinion steering system, power steering pump (if equipped), steering column, tie rod ends, steering fluid
Body Accessories:
Door mechanisms, window regulators, seals, trim, bumpers, hood and trunk latches, interior components, exterior trim removal and installation
Heater Ventilation:
HVAC system operation, blower motor, heater core, ventilation controls, ducting, cabin air filter (if equipped)
Air Conditioner:
AC system components, refrigerant types, servicing and charging procedures, diagnostic troubleshooting for AC faults
Electronics:
Basic electrical system troubleshooting, fuses, relays, lighting system, instrument cluster, gauges, power windows, central locking (if equipped)
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, belt adjustments and replacement
Repair:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component repair and replacement
Troubleshooting:
Diagnostic procedures for common issues across all major vehicle systems
Diagnostics:
Step-by-step diagnostic routines for engine performance, electrical faults, fuel system issues, etc.
Installation:
Procedures for replacing major components and accessories
Technical Depth
Depth:
Comprehensive, from basic maintenance to major component overhaul and detailed diagnostics
Illustrations:
Detailed exploded views, step-by-step procedure illustrations, and diagnostic flowcharts
Printability:
Allows printing of selected pages or the entire manual
Searchability:
Implied PDF format allows for keyword searching within the document
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, suitable for clear viewing and printing of diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Initially 'Zentpe' for base, 'Z7G' or similar for Turbo variants
Configuration:
Inline-4 Cylinder
Displacement:
1984 cc (2.0 Liters)
Bore X Stroke:
80.0 mm x 99.3 mm
Compression Ratio:
8.5:1 (Turbo)
Performance
Horsepower Turbo:
170-177 bhp @ 5500 rpm (depending on market and specific year)
Torque Turbo:
210-225 Nm (155-166 lb-ft) @ 3000 rpm (depending on market and specific year)
Fuel System
Fuel Delivery:
Bosch K-Jetronic Fuel Injection (CIS) with turbocharger and intercooler
Octane Rating:
Premium Unleaded Gasoline (91+ AKI)
Engine Lubrication
Oil Type:
API SG or higher, SAE 20W-50 or 10W-40 recommended
Oil Capacity:
Approx. 5.5 Liters (5.8 Quarts) with filter change
🔧 Transmission
Standard
Type:
5-speed Manual Transaxle
Optional
Type:
3-speed Automatic Transaxle (e.g., VW's 016)
Features
Layout:
Rear-mounted transaxle (gearbox and differential combined) for balanced weight distribution
Fluid Type Manual:
GL-4 or GL-5 Gear Oil (e.g., SAE 75W-90 or 80W-90)
Fluid Capacity Manual:
Approx. 2.0 Liters (2.1 Quarts)
Fluid Type Automatic:
Dexron III or equivalent ATF
Fluid Capacity Automatic:
Approx. 3.0-3.5 Liters (3.2-3.7 Quarts) for torque converter and gearbox
📐 Dimensions
Exterior
Length:
4215 mm (165.9 inches)
Width:
1715 mm (67.5 inches)
Height:
1285 mm (50.6 inches)
Wheelbase:
2400 mm (94.5 inches)
Weights
Curb Weight Turbo:
Approx. 1210 kg (2668 lbs)
Gross Vehicle Weight Rating Gvwr Turbo:
Approx. 1650 kg (3638 lbs)
Wheel Bolt Pattern:
5 x 130 mm
Wheel Offset:
ET 23.3 (for 15-inch wheels)
Tire Sizes:
185/70 VR 15 (front) / 205/60 VR 15 (rear) common for Turbo
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public data for this era, but designed to Porsche's safety standards of the time.
Active Features
Braking System:
Front ventilated discs, rear discs (later models) or drums; power assisted
Steering System:
Rack and pinion, often with power assist
Passive Features
Seatbelts:
Three-point retractable seatbelts
Body Construction:
Reinforced passenger cell, energy-absorbing crumple zones
💡 Technology Features
Infotainment
Audio System:
Typically an AM/FM radio with cassette player, often with optional amplifier and upgraded speakers
Instrumentation:
Comprehensive analog gauges including tachometer, speedometer, oil pressure, coolant temperature, fuel level, and boost gauge (Turbo models)
Driver Assistance
Cruise Control:
Optional on some models
ABS:
Anti-lock Braking System was optional and became more common on later models.
Connectivity
Original Connectivity:
Limited to basic electrical systems; no modern connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or 12 months, whichever comes first
Air Filter Replacement:
Every 30,000 km (18,000 miles) or as needed based on conditions
Spark Plug Replacement:
Every 30,000 km (18,000 miles)
Timing Belt Replacement:
Critical: Every 60,000 km (36,000 miles) or 4 years due to interference engine design. Failure can cause severe engine damage.
Fluid Specifications
Coolant:
50/50 mix of G11 (or equivalent) coolant and distilled water
Brake Fluid:
DOT 4 brake fluid
Power Steering Fluid:
ATF Dexron II/III or compatible
Known Issues
Fuel System Leaks:
Aging rubber fuel lines and seals are prone to leaks; inspect regularly.
Timing Belt Tensioner:
Failure of the tensioner can lead to premature belt wear or breakage.
Catalytic Converter Clogging:
Can occur in older vehicles due to engine issues or simply age, leading to reduced power.
Cooling System Leaks:
Original hoses and water pump can degrade; regular inspection is vital.
Rust And Corrosion:
Areas prone to rust include wheel arches, rocker panels, and around windows. Proper storage and rust prevention are important.
Electrical Gremlins:
Aging wiring insulation and corroded connectors can lead to intermittent faults.
📚 Vehicle History
Brand Heritage
Porsche Legacy:
Porsche, renowned for sports car engineering, racing heritage, and quality craftsmanship
Model Evolution
924 Origins:
Developed by Porsche for Volkswagen as a sporty coupe, it became a Porsche model when VW canceled its plans. Known for its front-engine, rear-wheel-drive transaxle layout.
924 Turbo Introduction:
The 924 Turbo (Type 931) was introduced in 1979 to boost performance and compete with more potent sports cars, featuring a turbocharged version of the Audi-derived 2.0L engine.
Major Updates During Production:
Engine power increases, aerodynamic refinements (e.g., revised front spoiler), interior updates, and braking system improvements over its lifespan.
Production
Manufacturing Location:
Neckarsulm, Germany (initially by Audi NSU, later by Porsche)
Production Volume:
Total 924 production around 138,000 units; 924 Turbo production around 11,000 units.
🏆 Awards & Recognition
Recognitions
Historical Reception:
While the base 924 was criticized for its VW underpinnings, the 924 Turbo (931) was generally well-received for its performance and Porsche handling, bridging the gap to the 944.
Motorsport Participation:
The 924 platform was used in various motorsport applications, including endurance racing, demonstrating its robustness and potential.
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