1986 Porsche 911 Repair Manual

The 1986 Porsche 911 Repair Manual provides comprehensive technical information for maintaining and repairing the iconic air-cooled sports car. This manual covers the 911 Carrera models featuring the 3.2-liter flat-six engine, G50 manual transmission, and classic rear-engine layout. Below are essential sections for maintenance procedures, technical specifications, troubleshooting, and repair guidelines.

Vehicle Specifications

Key technical data for the 1986 Porsche 911 models including engine performance, dimensions, and capacities.

Engine Maintenance

Regular maintenance procedures for the air-cooled 3.2L engine including oil changes, valve adjustments, and timing.

1. Oil Change: Drain oil, replace filter (oil cooler included), refill with 20W-50 mineral oil.
2. Valve Adjustment: Check and adjust valve clearance every 15,000 miles.
3. Spark Plugs: Replace every 30,000 miles with recommended Bosch plugs.
4. Ignition Timing: Set to 5° BTDC at idle with vacuum disconnected.
5. Compression Test: Perform every 60,000 miles to monitor engine health.

WARNING! Engine components become extremely hot during operation. Allow sufficient cooling time before performing maintenance.

Transmission Service

G50 manual transmission maintenance including fluid changes, clutch replacement, and shift linkage adjustment.

1. Transmission Fluid: Drain and refill with 75W-90 GL-5 gear oil every 30,000 miles.
2. Clutch Replacement: Inspect clutch disc and pressure plate; replace if worn.
3. Shift Linkage: Adjust for precise gear engagement and smooth operation.
4. Transmission Mounts: Check for wear and replace if deteriorated.
5. CV Joints: Inspect boots and lubricate as needed.

CAUTION! Use proper jack stands when working under vehicle. Transmission components are heavy.

Brake System

• Brake Pads: Replace when thickness reaches 3mm minimum.
• Brake Discs: Resurface or replace if below minimum thickness specification.
• Brake Fluid: DOT 4 fluid; replace every 2 years.
• Bleeding Procedure: Start from farthest wheel (right rear) to nearest (left front).
• Parking Brake: Adjust cable tension for proper engagement.
• Brake Lines: Inspect for cracks or corrosion; replace if damaged.
• Master Cylinder: Check for leaks and proper fluid level.

Electrical System

Diagnosis and repair of electrical components including charging system, ignition, and lighting.

Battery: 12V 70Ah; maintain clean terminals and proper charge level.

Alternator: Output 90A; test voltage output (13.8-14.4V at 2000 rpm). Starter: Inspect brushes and solenoid operation. Fuse Box: Located under dashboard; use correct amperage fuses. Wiring: Check for corrosion and damaged insulation, especially in engine compartment.

Suspension & Steering

Maintenance of torsion bar suspension, shock absorbers, and power steering system.

1. Shock Absorbers: Replace if leaking or poor damping performance.
2. Torsion Bars: Adjust ride height using factory specifications.
3. Ball Joints: Check for play and replace if worn.
4. Power Steering: Check fluid level and belt tension.
5. Wheel Alignment: Set to factory specifications for optimal handling.

Tip: Always perform wheel alignment after suspension component replacement.

Fuel System

Bosch K-Jetronic continuous injection system maintenance and troubleshooting.

1. Fuel Filter: Replace every 15,000 miles or as needed.
2. Fuel Pump: Test pressure (75-80 psi) and volume output.
3. Injectors: Clean or replace if spray pattern is poor.
4. Warm-up Regulator: Check function for proper cold start operation.
5. Fuel Lines: Inspect for leaks and deterioration.
6. Fuel Tank: Clean and inspect for rust or damage.
7. Air Flow Sensor: Clean and lubricate moving parts.

WARNING! Relieve fuel system pressure before servicing. No smoking or open flames near fuel system work.

Cooling & Heating

Air cooling system maintenance and cabin heating system service.

Body & Interior

Care and maintenance of body panels, paint, and interior components.

CAUTION! Use proper techniques when handling glass and trim to avoid damage.

Tools & Equipment

Special tools required for Porsche 911 service including metric tools, torque wrenches, and factory specialty tools.

Troubleshooting Guide

Reset: Disconnect battery for 10 minutes to reset electronic systems if needed.

Service: Contact authorized Porsche service center for complex diagnostics.