1987 Porsche 924S Repair Manual

The 1987 Porsche 924S is a front-engine, rear-wheel-drive sports car featuring a 2.5L inline-4 engine, 5-speed manual transmission, independent suspension, disc brakes, and classic Porsche styling. This comprehensive repair manual covers all major systems including engine, transmission, suspension, brakes, electrical, and bodywork. Below are essential sections for maintenance, troubleshooting, and repair procedures.

1. Vehicle Specifications 2. Engine System 3. Transmission & Drivetrain 4. Suspension & Steering 5. Brake System 6. Electrical System 7. Fuel System 8. Cooling System 9. Body & Interior 10. Maintenance Schedule 11. Troubleshooting Guide

Vehicle Specifications

Key technical data for the 1987 Porsche 924S.

Specification	Details
Engine Type	2.5L Inline-4, water-cooled
Power Output	150 hp @ 5800 rpm
Torque	195 Nm @ 3000 rpm
Transmission	5-speed manual, rear-wheel drive
Brakes	Front and rear disc brakes
Suspension	Independent front and rear
Fuel Capacity	16.4 gallons (62 liters)
Curb Weight	2650 lbs (1202 kg)
Wheelbase	94.5 inches (2400 mm)
Top Speed	130 mph (209 km/h)

Engine System

Complete engine maintenance and repair procedures.

Oil Change: Drain plug under oil pan; refill with 5W-40 synthetic (5.5 quarts).
Spark Plugs: Replace every 30,000 miles; gap 0.7-0.8 mm.
Timing Belt: Replace every 60,000 miles; align marks on cam/crank pulleys.
Valve Adjustment: Check every 15,000 miles; intake 0.15-0.20 mm, exhaust 0.25-0.30 mm.
Compression Test: Should read 150-175 psi across all cylinders.

WARNING! Always disconnect battery before working on engine. Allow engine to cool before servicing.

Transmission & Drivetrain

Manual transmission maintenance and clutch replacement.

Transmission Fluid: Use GL-4 75W-90; drain/fill every 30,000 miles.
Clutch Replacement: Remove transmission; align clutch plate with alignment tool.
Shift Linkage: Adjust for precise gear engagement.
Drive Shaft: Inspect U-joints for wear; replace if excessive play.
Differential: Check fluid level; use GL-5 80W-90 gear oil.

CAUTION! Support transmission properly during removal to prevent damage.

Suspension & Steering

Front Suspension: MacPherson struts with lower control arms.
Rear Suspension: Independent with semi-trailing arms.
Shock Absorbers: Replace in pairs; check for leaks.
Ball Joints: Inspect for play; replace if worn.
Steering Rack: Power-assisted; check fluid level regularly.
Wheel Alignment: Toe: 0° ± 0.2°, Camber: -0.5° ± 0.3°.
Tire Pressure: 32 psi front, 36 psi rear (cold).

Brake System

Hydraulic disc brake maintenance and repair.

Front Brakes: Ventilated discs, single-piston calipers. Rear Brakes: Solid discs, single-piston calipers.

Brake Pad Replacement: Remove caliper, compress piston, install new pads. Rotor Inspection: Minimum thickness 20.4 mm front, 8.4 mm rear. Brake Fluid: DOT 4; flush every 2 years. Parking Brake: Adjust cable tension for proper engagement.

Electrical System

12-volt electrical system diagnostics and repair.

Battery: 12V 60Ah; located in front trunk; check terminals for corrosion.
Alternator: Output 90A; test voltage (13.5-14.5V when running).
Starter: Check solenoid engagement; test draw current (< 150A).
Fuses: Located in dashboard panel; use correct amperage replacements.
Lighting: Check headlight alignment; replace bulbs with correct wattage.

Tip: Use multimeter for electrical diagnostics; always disconnect battery first.

Fuel System

Fuel injection system maintenance and component replacement.

Fuel Filter: Replace every 30,000 miles; located near fuel tank.
Fuel Pump: In-tank electric pump; test pressure (28-33 psi).
Injectors: Clean every 60,000 miles; check spray pattern.
Throttle Body: Clean with appropriate cleaner; do not damage throttle plate.
Fuel Lines: Inspect for leaks; replace if cracked or brittle.
Air Filter: Replace every 15,000 miles; use OEM filter for best performance.

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

Cooling System

Radiator, thermostat, and coolant maintenance.

Coolant: Use 50/50 mix of antifreeze and distilled water. Radiator: Check for leaks; clean fins regularly. Thermostat: Opens at 80°C; replace if engine overheats. Water Pump: Check for bearing play and leaks. Hoses: Inspect for cracks; replace every 4 years.

Body & Interior

Exterior and interior component repair and maintenance.

Body Panels: Aluminum hood and decklid; steel body. Paint Care: Use pH-balanced car wash soap; wax regularly. Interior: Leather seats require conditioning every 6 months. Windows: Regulator mechanism may need lubrication. Trim: Use plastic-safe cleaners for dashboard and trim.

Maintenance Schedule

Interval	Service Required
Every 5,000 miles	Oil and filter change
Every 15,000 miles	Air filter, spark plugs, valve adjustment
Every 30,000 miles	Fuel filter, transmission fluid, brake fluid
Every 60,000 miles	Timing belt, water pump, coolant flush
Every 2 years	Brake fluid replacement
As needed	Tire rotation, wheel alignment, brake inspection

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, fuel pump, ignition	Check battery voltage; listen for fuel pump; test spark.
Overheating	Coolant leak, thermostat	Check coolant level; test thermostat; inspect radiator.
Brake vibration	Warped rotors	Resurface or replace brake rotors.
Poor fuel economy	Dirty air filter, O2 sensor	Replace air filter; test oxygen sensor.
Transmission noise	Low fluid, worn bearings	Check fluid level; inspect for metal particles.
Electrical issues	Alternator, ground connections	Test alternator output; clean battery terminals.

Professional Service: For complex issues, consult certified Porsche technician.

Parts Source: Genuine Porsche parts recommended for optimal performance.