Aftersales Training Air Cooled Engine Repair Types: 964 & 993 P10-L Porsche Aftersales Training

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Aftersales Training Air Cooled Engine Repair Types: 964 & 993 P10-L Porsche Aftersales Training ® AfterSales Training Air Cooled Engine Repair Types: 964 & 993 P10-L Porsche AfterSales Training Student Name: ________________________________________________ Training Center Location: ________________________________________________ Instructor Name: ________________________________________________ Date: ___________________ Important Notice:The contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-of-world English speaking market. The electronic text and graphic files were then imported by Porsche Cars N.A, Inc. and edited for con- tent. Some equipment and technical data listed in this publication may not be applicable for our market. Specifications are sub- ject to change without notice. We have attempted to render the text within this publication to American English as best as we could. We reserve the right to make changes without notice. © 2004 Porsche Cars North America, Inc. All Rights Reserved. Reproduction or translation in whole or in part is not permitted without written authorization from publisher. AfterSales Training Publications Dr. Ing. h.c. F. Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile. The third party trade- marks contained herein are the properties of their respective owners. Porsche Cars North America, Inc., believes the specifica- tions to be correct at the time of printing. However, specifications, standard equipment and options are subject to change with- out notice. Part Number - PNA P10 L01 Edition -6/04 Table of Contents Description Page Engine Type Designations . .1 911 Carrera (964) Engine . .5 911 Carrera (993) Engine . .49 Conversion Charts . .65 Air Cooled Engine Repair Air Cooled Engine Repair Engine Type Designations Engine Number Identification Digit: 123 45678 Example: 65V 00136 Engine Type: (6 = 6 Cyl. Engine) Engine Version: Model Year: Serial Number: 911 Engine Type Designations Model Year 1984-98 Model Engine Displ. Engine Power Installed In Year Type Liters kW / HP 1984 930.20 3.2 170/231 911 Carrera - RoW 930.21 3.2 152/207 911 Carrera - USA/Canada/Japan 930.66 3.3 221/300 911 Turbo - Worldwide 1985 930.20 3.2 170/231 911 Carrera - RoW 930.21 3.2 152/207 FRG/USA/Canada/Japan (with catalytic converter) 930.26 3.2 170/231 Sweden /Switzerland /AustraIia 930.66 3.3 221/300 911 Turbo - Worldwide 1986 930.20 3.2 170/231 911 Carrera - RoW 930.21 3.2 152/207 911 Carrera USA/Canada/Japan 930.26 3.2 170/231 911 Carrera Sweden./Switzerland/Australia 930.66 3.3 221/300 R0W/Canada 930.68 3.3 208/282 911 Turbo - USA (with catalytic convverter) 1987 930.20 3.2 170/231 911 Carrera - RoW 930.25 3.2 160/217 USA / Japan 930.26 3.2 170/231 Sweden 930.66 3.3 221/300 RoW/Canada 930.68 3.3 210/282 USA (with catalytic converter) 1988 930.20 3.2 170/231 911 Carrera - RoW 930.25 3.2 160/217 USA/Japan/Canada/Australia/RoW (with catalytic conv.) 930.26 3.2 170/231 Sweden 930.66 3.3 221/300 Turbo RoW 930.68 3.3 210/282 Turbo USA/Canada 1989 930.20 3.2 170/231 911 Carrera - RoW 930.25 3.2 160/217 USA/Canada/Japan/Australia/RoW (with catalytic conv.) 930.66 3.3 221/300 911 Turbo - RoW 930.68 3.3 210/282 911 Turbo - USA M 64.01 3.6 184/250 911 Carrera 4 (964) - Worldwide 1990 M 64.01 3.6 184/250 911 Carrera (964) 2/4 with manual transmission - Worldwide M 64.02 3.6 184/250 911 Carrera (964) 2 with tiptronic transmission - Worldwide 1991 M64.01 3.6 184/250 911 Carrera (964) 2/4 M64.02 3.6 184/250 911 Carrera (964) 2 M30.69 3.3 235/320 911 Turbo (964) Air Cooled Engine Repair Page 1 Engine Type Designations Model Engine Displ. Engine Power Installed In Year Type Liters kW / HP 1992 M64.01 3.6 184/250 911 Carrera (964) 2/4 M64.02 3.6 184/250 911 Carrera (964) 2 M64.03 3.6 191/260 911 Carrera (964) RS M30.69 3.3 235/320 911 Turbo (964) 1993 M64.01 3.6 184/250 911 Carrera (964) 2/4 M64.02 3.6 184/250 911 Carrera (964) 2 M64.03 3.6 191/260 911 Carrera (964) RS M64.50 3.6 265/360 911 Turbo (964) 1994 M64.01 3.6 184/250 911 Carrera (964) 2/4 USA M64.02 3.6 184/250 911 Carrera (964) 2 USA M64.05 3.6 200/272 911 Carrera (964) RoW M64.06 3.6 200/272 911 Carrera (964) RoW & Taiwan with Tiptronic M64.50 3.6 265/355 911 Turbo USA/CDN 1995 M64.05 3.6 200/272 911 Carrera (964) RoW M64.06 3.6 200/272 911 Carrera (964) RoW M64.20 3.7 220/300 911 Carrera (993) RS RoW M64.07 3.6 200/272 911 Carrera (993) USA M64.08 3.6 200/272 911 Carrera (993) USA 1996 M64.21 3.6 210/285 911 Carrera (993) /C4 /C4S RoW M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic M64.23 3.6 210/285 911 Carrera (993) /C4/C4S USA M64.24 3.6 210/285 911 Carrera (993) USA Tiptronic M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN 1997 M64.21 3.6 210/285 911 Carrera (993) /C4 /C4S RoW M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic M64.23 3.6 210/285 911 Carrera (993) /C4/C4S USA M64.24 3.6 210/285 911 Carrera (993) USA Tiptronic M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN 1998 M64.21 3.6 210/285 911 Carrera (993) /C4/C4S RoW M64.22 3.6 210/285 911 Carrera (993) RoW Tiptronic M64.23 3.6 210/285 911 Carrera (993) /C4 & C4S USA/CDN M64.24 3.6 210/285 911 Carrera (993) USA/CDN Tiptronic M64.60 3.6 300/408 911 Turbo (993) RoW and USA/CDN Page 2 Air Cooled Engine Repair Engine Type Designations Notes: Notes: Air Cooled Engine Repair Page 3 Engine Type Designations Notes: Notes: Page 4 Air Cooled Engine Repair 911 Carrera (964) Engine Subject Page General Information . .7 Engine M64.01/02 . .7 Engine M64.01/02 Engine Data . .9 Crankcase . .10 Connecting Rods . .11 Pistons . .11 Cylinders . .12 Knock Bridge . .13 Pulley . .13 Cylinder Head . .14 Valves . .15 Camshaft Housing . .16 Chain Drive . .17 Chain Tensioners . .19 Engine Lubrication . .20 Oil Thermostat . .21 Cooling . .22 Exhaust System . .23 Engine Paneling . .24 Engine Suspension . .25 Technical Data . .27 Engine Tolerances and Specifications . .30 Setting Engine Timing . .43 Air Cooled Engine Repair Page 5 911 Carrera (964) Engine Notes: Notes: Page 6 Air Cooled Engine Repair 911 Carrera (964) Engine Engines 1988 Model G Conrod bolts tightened with torque and torque angle = 20 Nm and 1 x 90° 1989 Model G 911 Carrera (no modifications) G 911 Carrera 4 (964) (introduction) 1990 Model G 911 Carrera 2 (964) (introduction) with rear wheel drive, 5-speed manual or Tiptronic transmission Engine Types: M64.01 - Manual Transmission M64.02 - Tiptronic Transmission G Stronger piston pin circlips G M 64.02 changed ratio for cooling fan Engine M64.01/02 – 911 Carrera 2/4 (964) 1989-94) General The engine 911 Carrera (964) engine is a further develop- ment of the previous 911 Carrera engine. The 1984 - 911 Carrera 3.2 liter engine featured the following changes from the prevoius 911 SC engine: G One engine type worldwide G Double ignition, i.e. two spark plugs for each G Displacement increased by changing stroke from 70.4 combustion chamber to 74.4 mm G Knock regulation G New crankcase with improved basic strength and new G Exhaust ports in cylinder heads designed as ceramic sealing cap for intermediate shaft port liners G Crankshaft from 911 Turbo with modified flywheel instal- G Camshaft drive with help of duplex roller chains, lation hydraulic chain tensioner acting on tensioning rails and G New flywheel for DME additional guide rails G G New connecting rods (unchanged from 911 Turbo) Vibration damper on crankshaft G G New drive belt pulley Separate drive for engine fan and alternator G G New pistons Oil Cooler with two-stage blower in front end of car on G New cylinders right-hand side G G Modified cylinder heads Two-stage resonance intake system G G New chain tensioner with hydraulic damping via lubricat- Digital Motor Electronics (DME) ing oil circuit G Modified lubricating circuit Notes: G New crankcase and oil tank venting G Fan wheel with ventilation slots G Modifications on heater blower, heat exchanger and exhaust system G Combination of fuel injection and ignition in DME (Digital Motor Electronics) Yearly Changes 1986 Model G Turbo engine with catalytic converter only for USA 1987 Model G Cylinder head tightened with torque and torque angle = 15 Nm and 1 x 90 (retroactively since 1984 models) Air Cooled Engine Repair Page 7 911 Carrera (964) Engine Engine Type M64.01/02 Components Engine Type M64.01/02 Components 1 - Hot air blower 27 - Crankcase venting 2 - Throttle valve assembly 28 - Oil tank venting 3 - Resonance flap control switch 29 - Fuel tank venting 4 - Air Cleaner 30 - Speed sender 5 - Electric tank venting valve 31 - Knock sensor 1 6 - Air conditioner compressor 32 - NTC 2 7 - Fuel feed pipe 33 - Fuel pressure testing connection 8 - Fuel collection pipe, right 34 - Fuel return pipe 9 - Final muffler 35 - Oxygen sensor 10 - Tailpipe 36 - Catalytic converter 11 - Engine carrier 37 - Fuel injector 12 - Intermediate muffler 38 - Fuel collection pipe, left 13 - Drive belt tightness monitor 39 - Carbon canister connection 14 - Double ignition distributor 40 - Heater blower control resistor 15 - Heating control temperature switch Notes: Engine Type M64.01/02 Components 16 - Air flow sensor 17 - Idle speed control 18 - Bypass air pipe for oil tank venting 19 - Combination oil temperature and pressure switch 20 - Heat exchanger, left 21 - Heat exchanger, right 22 - Engine oil feed from oil tank to engine 23 - Power steering pump 24 - Engine oil return to thermostat 25 - Engine cover, right 26 - Vacuum reservoir for resonance flap control Page 8 Air Cooled Engine Repair 911 Carrera (964) Engine Longitudinal Section of the Engine Full-Load curve of the M64.01/02 Engine Type M64.01/02 Side View Cutout Cross Section of the Engine Engine Data Displacement 3.6 I (76.4 mm stroke, 100 mm bore dia.) Rated power 184 kW / 247 H.P.
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