Porsche 911 (964):
1989, 1990, 1991, 1992, 1993, 1994
Please read these warnings and cautions before proceeding with maintenance, repair or modification work.
- Some repairs may be beyond your capability. If you lack the skills, tools and equipment, or a suitable workplace for any procedure described in this book, we suggest you leave such repairs to an authorised and experienced repair facility.
- Do not reuse any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins.Always replace these fasteners with new parts.
- Never work under a lifted car unless it is solidly supported on stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a car that is supported solely by a jack. Never work under the car while the engine is running.
- If you are going to work under a car on the ground, make sure that the ground is level. Block the wheels to keep the car from rolling. If electrical power is not needed, disconnect the battery negative (-) cable (ground strap) to prevent others from starting the car while you are under it.
- Always observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Gloves or other protective clothing should be worn whenever the job requires working with harmful substances.
- Do not attempt to work on your car if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may keep you from being fully alert.
- Greases, lubricants and other automotive chemicals can contain metals and toxic substances, many of which are absorbed directly through the skin. Before use, read the manufacturer’s instructions carefully. Avoid direct skin contact. Always wear hand and eye protection.
- Friction materials such as brake or clutch discs contain asbestos fibers or other particles which are hazardous as dust in the air. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. Use an aspirator when working on brake pads. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
- Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.
- Disconnect the battery negative (-) cable (ground strap) whenever you work on the fuel system or when removing electrical components. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
- Never run the engine unless the work area is well ventilated. Carbon monoxide kills.
- Car batteries produce explosive hydrogen gas. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
- Connect and disconnect battery cables, jumper cables or a battery charger only with the ignition switched off, to prevent sparks. Do not quick-charge the battery (for boost starting) for longer than one minute, and do not allow charging voltage to exceed 16.5 volts. Wait at least 1 minute before boosting the battery a second time.
- Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the car. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
- Catch draining fuel, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.
- Dispose of automotive fluids (fuel, oil, brake fluid, hydraulic fluid, coolant) or rags soaked in such fluids in a manner approved by local, national and international regulations.
- Many air conditioning systems are filled with R-12 refrigerant, which is hazardous to the earth’s atmosphere. The A/C system should be serviced only by trained technicians using approved refrigerant recovery and recycling equipment, and trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants.
- Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.
- Some aerosol tyre inflators are highly flammable. Be extremely cautious when repairing a tyre that may have been inflated using an aerosol tyre inflator. Keep sparks, open flame or other sources of ignition away from the tyre repair area. Inflate and deflate the tyre at least four times before breaking the bead from the rim. Remove the tyre completely from the rim before attempting any repair.
- Do not touch or disconnect any high voltage cables from the coil, distributor, or spark plugs while the engine is running or being cranked by the starter. The ignition system produces high voltages that can be fatal.
- The Porsche Supplemental Restraint System (SRS) automatically deploys an airbag in the event of a frontal impact. The airbag is inflated by an explosive device. Handled improperly or without adequate safeguards, the system can be very dangerous. The SRS should be serviced only by an authorized Porsche dealer.
- SRS airbags that have been activated during an accident must always be replaced. Only trained personnel should work on or replace the airbag unit. Improper removal or installation of the airbag unit or other SRS components may result in inadvertent activation or may render the system useless. The Porsche authorized dealer has the proper training, specialized test equipment and repair information to service the SRS.
- Porsche part numbers listed in this book are for identification purposes only, not for ordering. Always check with your authorized Porsche dealer to verify part numbers and availability before beginning service work that may require new parts.
- Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly and do not attempt shortcuts. Use tools appropriate to the work and use parts that meet or exceed Porsche specifications. Makeshift tools, parts and procedures will not make good repairs.
- Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque specification listed.
- Remove all electronic control units before exposing the car to high temperature, such as from a paint-drying booth or a heat lamp. On-board control units must never be exposed to temperature in excess of 176°F (80°C).
- Before doing any electrical welding, disconnect the battery negative (-) cable (ground strap).
- Do not connect the battery or switch the ignition on while the airbag unit is removed from the steering wheel. Doing so will register an SRS fault and turn on the SRS warning light. See an authorized Porsche dealer to erase the fault memory and reset the SRS.
- Disconnecting the battery may erase fault code(s) stored in control unit memory. Check for fault codes prior to disconnecting the battery cables.
- Disconnecting the battery will set the radio into code mode. Early radios had to be taken back to the dealer to reset. Later ones come with a code card in the car to reset.
- Do not disconnect the battery with the engine running. The electrical system will be damaged.
- Do not run the engine with any of the spark plug wires disconnected. Catalytic converter damage may result.