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Porsche 911 1986 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: 911 Model Variant: G-Series (Third Generation) Year: 1986 Codes Chassis Code: 911 (G50 Transmission) 👋 Introduction Market Position Positioning: Essential resource for owners...
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Sku: 370178
Porsche 911 1986 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
911
Model Variant:
G-Series (Third Generation)
Year:
1986
Codes
Chassis Code:
911 (G50 Transmission)
👋 Introduction
Market Position
Positioning:
Essential resource for owners and mechanics of the iconic 1986 Porsche 911 Carrera, a pivotal year marking the introduction of the G50 transmission.
Competitive Analysis
Value Proposition:
Provides factory-accurate information that aftermarket manuals often lack, ensuring the integrity and correct servicing of a classic Porsche.
Key Features
Ease Of Use:
Organized for clarity with sequential procedures and detailed diagrams, making complex tasks manageable for experienced DIYers and professionals.
Accuracy:
Directly from Porsche, ensuring unparalleled accuracy for specifications, diagnostic procedures, and repair sequences.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Printed Manual
Page Count
Estimated Page Count:
Approximately 1000+ pages (typical for full factory service manuals of this era)
📖 Manual Coverage
Systems Covered
Engine:
3.2L Flat-6 (Carrera), including M930/20 and M930/21 variants, fuel injection, ignition, cooling, lubrication, exhaust, and emissions control.
Transmission:
G50 5-speed manual transmission, including clutch, shifter mechanism, and gearbox components.
Suspension:
Front and rear suspension systems (McPherson struts front, trailing arms rear), shock absorbers, springs, bushings, alignment procedures, and steering components.
Brakes:
Hydraulic brake system, front and rear discs, calipers, master cylinder, brake lines, parking brake, and bleeding procedures.
Electrical:
Full electrical system schematics, wiring diagrams, battery, charging system (alternator), starting system, lighting, instrumentation, wipers, horn, and accessory circuits.
Body:
Body panel removal and installation, glass replacement, door mechanisms, hinges, locks, trim, bumpers, and structural components.
HVAC:
Heating, ventilation, and air conditioning (if equipped), including refrigerant system, blower motor, and climate controls.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, and Bosch K-Jetronic fuel injection system components and diagnostics.
Procedures Included
Maintenance:
Routine scheduled maintenance, fluid changes (oil, brake fluid, coolant), filter replacements, spark plug service, belt adjustments, and lubrication points.
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation across all covered systems.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common and uncommon faults and malfunctions.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, and other critical technical data for proper repair and adjustment.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format Details:
N/A (This is a printed manual)
Print Quality
Print Quality:
High-quality reproduction of original factory documentation, featuring clear text and diagrams.
Binding Type
Binding Type:
Likely a durable comb binding, perfect binding, or hardcover, designed for workshop use.
Paper Type
Paper Type:
Durable, high-quality paper suitable for workshop environments, often slightly thicker than standard paper to withstand handling.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated, Air-Cooled Flat-Six
Displacement:
3164 cc (3.2 Liters)
Bore X Stroke:
95 mm x 74.4 mm
Compression Ratio:
10.3:1
Engine Code Variants:
M930/20 (US/Japan), M930/21 (Europe)
Performance
Horsepower:
207 hp @ 5900 rpm (M930/20), 217 hp @ 5900 rpm (M930/21)
Torque:
265 Nm (195 lb-ft) @ 4800 rpm (M930/20), 284 Nm (209 lb-ft) @ 4800 rpm (M930/21)
Fuel System
Fuel Injection:
Bosch CIS-K Jetronic (Continuous Injection System)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Pump Type:
In-tank electric fuel pump
Other
Ignition System:
Electronic ignition with distributor and coil
Cooling System:
Air-cooled with oil cooler
Oil Capacity:
8.5 Liters (9 US Quarts) with filter change
Engine Mounting:
Rubber isolation mounts
🔧 Transmission
Standard
Transmission Type:
G50 5-Speed Manual Transaxle
Gear Ratios G50:
1st: 3.000, 2nd: 1.750, 3rd: 1.240, 4th: 0.960, 5th: 0.770, Reverse: 3.000
Final Drive Ratio:
3.444:1 (31/9 teeth)
Optional
Optional Transmission:
None for 1986 model year Carrera; G50 was the significant update.
Features
Clutch Type:
Single dry plate, hydraulically operated diaphragm spring clutch
Transmission Fluid Type:
API GL-5 SAE 90 Hypoid Gear Oil (e.g., Porsche Part # 000 043 205 32)
Transmission Fluid Capacity:
3.0 Liters (3.2 US Quarts)
📐 Dimensions
Exterior
Length:
4271 mm (168.1 inches)
Width:
1651 mm (65.0 inches)
Height:
1310 mm (51.6 inches)
Wheelbase:
2271 mm (89.4 inches)
Ground Clearance:
Approx. 130 mm (5.1 inches)
Weights
Curb Weight:
Approx. 1210 kg (2668 lbs) for Coupe
Gross Vehicle Weight Rating:
Not typically published in easily accessible formats for this era, but significant for load limits.
🛡️ Safety Features
Ratings
Crash Test Data:
Modern crash testing standards were not applied to vehicles of this era. Primarily relied on passive safety design elements of the time.
Active Features
Braking System:
Four-wheel disc brakes with internally vented rotors (front and rear).
Steering:
Rack and pinion, power assisted (standard on 1986 Carrera).
Passive Features
Seat Belts:
Three-point inertia-reel seatbelts with height adjustment.
Body Structure:
Reinforced chassis and crumple zones designed to Porsche's safety standards of the period.
Fuel Tank Protection:
Under-car steel shield protecting the fuel tank.
💡 Technology Features
Infotainment
Audio System:
Typically an original Porsche AM/FM cassette player with optional amplifier. Modern head unit upgrades are common.
Speakers:
Factory speaker placement (e.g., dashboard, door panels).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was standard equipment for the 1986 model year.
Cruise Control:
Optional on some models, integrated into steering column controls.
Connectivity
Connectivity Features:
None by modern standards. Primarily mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or annually, whichever comes first. Frequent track use may require more frequent changes.
Air Filter Replacement:
Inspect every 10,000 miles (16,000 km), replace as needed or every 20,000 miles (32,000 km).
Spark Plug Replacement:
Every 20,000-30,000 miles (32,000-48,000 km) depending on plug type (original spec likely Bosch W-series).
Brake Fluid Flush:
Every 2 years or 24,000 miles (38,000 km).
Valve Adjustment:
Recommended every 30,000 miles (48,000 km) due to tappet clearances.
Fluid Specifications
Engine Oil Specification:
Multi-viscosity oil, SAE 20W-50 or 15W-50 recommended, meeting Porsche A40 specification (or equivalent vintage spec like VW 501 01).
Coolant Specification:
Not applicable (air-cooled engine).
Brake Fluid Specification:
DOT 4.
Known Issues
Oil Leaks:
Common due to age and material degradation of seals and gaskets (e.g., crankshaft seals, valve cover gaskets).
Heater Boxes:
Flaps within the heater boxes can seize or break, impacting airflow and heat distribution.
Fuel Line Deterioration:
Original fuel lines can degrade over time, requiring replacement with modern, compatible materials.
Transmission Synchros:
While the G50 is robust, synchros can wear, especially with aggressive driving or improper shifting.
Cis System Tune Ups:
Requires periodic checks and adjustments of mixture and idle speed for optimal performance and emissions.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Porsche has a storied history of performance, engineering excellence, and motorsport success, with the 911 being its enduring icon.
Model Evolution
G Series Generation:
The 1986 model falls within the third generation (G-Series) of the 911, which ran from 1974 to 1989. This generation saw continuous evolution, culminating in the introduction of the G50 gearbox and the 3.2L engine.
1986 Key Updates:
Introduction of the new Getrag G50 5-speed transaxle, replacing the older 915 gearbox. Revised engine management for the 3.2L flat-six. Minor cosmetic updates, including larger impact-absorbing bumpers (mandated by US regulations) and often updated interior trim.
Production
Production Years G Series:
1974-1989
Manufacturing Location:
Stuttgart, Germany
🏆 Awards & Recognition
Recognitions
Classic Car Status:
The 1986 Porsche 911 Carrera is widely regarded as a highly collectible classic sports car, celebrated for its timeless design, driving dynamics, and air-cooled engine character.
Automotive Press Reviews:
Consistently praised by automotive journalists of the era for its performance, handling, and build quality, solidifying its place in automotive history.
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