924Board.org

[Mikri184]

Technical specifications
924 models 78-85
925 turbo models79-84
924 Carrera GT models 81


Contents
Page General
Important conversion factors and new dimensioning units..................3
Survey of type designations .............................................3
Engine number codes .....................................................3
Chassis number codes models 78...79......................................3
Chassis number codes model 80 ...........................................3
Chassis number codes from model 81.......................................4
Manual and automatic transmissions 924/924 turbo ........................4
Transmission number codes 924............................................4
Transmission number codes 924 turbo .....................................4
Engine
Engine data..............................................................5
Technical data 924 engine type XK/XJ ....................................5
Technical data 924 CarreraGT. ...........................................6
Torque specifications - engine 924/924 turbo ............................6
Tolerances and wear limits ..............................................7
Repair stages tor crankshaft ............................................7
Checking pistons and cylinder bores 924 .................................8
Checking pistons and cylinder bores 924 turbo ...........................8
Checking valve dimensions and valve guides ..............................8
Adjusting screw notching ................................................8
Checking and adjusting valve play, reworking intake valve ...............8
Reworking valve seats ...................................................8
Tightening specifications-cylinder head bolts 924 .......................8
Machining the cylinder head mating face .................................8
Main testing and adjusting values for engine ............................9
Measuring boost pressure 924 turbo ......................................9
V-belt dimensions and coolant mixing table ..............................9
Page Transmission and clutch
Torque specifications for manualtransmission,
central tube, clutch and actuating elements 924 ........................9
Technical data - clutch .................................................10
Technical data - 4-speed manual transmission 924 ........................11
Technical data - 5-speed manual transmission 924 ........................11
Torque specifications -automatic transmission 924 .......................11
Torque specifications - autom. transmission actuating elements 924 ......11
Torque specifications - accelerator actuation (automatic) 924 ...........11
Torque specifications-central tube (automatic) 924 ......................12
Technical data-automatic transmission 924 ...............................12
Pressure-testing hydraulic control unit .................................12
Torque specifications - manual transmission 924 turbo ...................13
Torque specifications - clutch, central tube,
transmission suspension, shift actuation 924 turbo ......................13
Torque specifications -manual transmission type 016G 924 turbo ..........13
Torque specifications - Clutch, central tube, transmission
suspension and shift actuation type 016G 924 turbo ......................13
Technical data - 5-speed manual transmission 924 turbo ..................13
Front axle, steering, rear axle and wheels
Torque specifications -front axle 924/924 turbo .........................14
Torque specifications -steering 924/924 turbo ...........................14
Torque specifications -rear axle 924/924 turbo ..........................14
Technical data-front axle 924 ...........................................14
Technical data-front axle 924 turbo .....................................14
Technical data-steering 924 .............................................14
Technical data-steering 924turbo ........................................14
Technical data - rear Axle 924...........................................14
Technical data - rear axle 924 turbo ....................................14
Checking disk wheels ....................................................15
Tires, wheels, tire pressures ...........................................15
Wheel alignment adjustment values 924/924 turbo .........................15
Page Brake system
Torque specifications-mech. brake system ................................15
Torque specifications - hydr. brake system ..............................15
Technical data - brake system 924........................................15
Technical data -brake system 924 turbo/CarreraGT ........................15,16
Air conditioning
Technical data - air conditioning as from Model 79 ......................17
Torque specifications - air conditioning ................................17
Electrical system
Relays ..................................................................17
Fuses ...................................................................17
General technical data
Performance figures .....................................................18
Dimensions ..............................................................18
Weights .................................................................18
Filling capacities.......................................................18


Important Conversion Factors and New Dimensioning Units
Former units Present units
Pressure Technical atmosphere at(kp/cm2) Bar (bar)
Output Horsepower HP Kilowatt (kW)
Force Kilopond kp Newton (N)
Torque Kilopondmeter kpm Newtonmeter(Nm) '
Conversion factors
at(kp/cm2) in bar x 0.981
kp in N x 9.81
HP in kW x 0.736
kpm in Nm (ftlb) x 9.81
m/s in km/h x 3.6
at in mmHG x 735.56
km/h in mph (miles) x 0.621
F (Fahrenheit) inC (°F-32)x 0.555
I in U.S. gal x 0.264
I in Imp. gal x 0.22

To convert tightening torques from kpm into Nm, the conversion factor 10 can be used. This is sufficient for workshop applications.

Survey of Type Designations
Model year desig-nation Vehicle type designation Engine type desig-nation Displa-cem-ent act.
Cm3 DIN-kW (HP) Stroke/ Bore (mm) Compression ratio Fuel-induction system Engine numbers Chassis numbers
1978-1979 924 Europe, RoW 924 USA, Japan, Calif. XK/XJ XG/XE 1984 1984 92/125 85/115 84.4/86.5 84.4/86.5 9.3:1
8.5:1 K-Jetronic
K-Jetronic
K-Jetronic XK 000001 onwards
XG 000001 onwards
XG 000001 onwards 9248100001-99999
924 82 00001-99999
924 83 00001-99999 (Japan)
1980 924 Europe, RoW 924 USA, Canada, Japan XK/XJ VC 1984 1984 92/125 85/115 84.4/86.5 84.4/86.5 9.3:1
9.0:1 K-Jetronic
K-Jetronic XK 000001 onwards
VC 000001 onwards 92 АО 410001-9999
92 АО 43 0001-9999
1981-1982 924 Europe, RoW 924 USA, Canada, Japan XK/XJ VC 1984 1984 92/125 85/115 84.4/86.5 84.4/86.5 9.3:1
9.0:1 K-Jetronic
K-Jetronic XK 000001 onwards
VC 000001 onwards WPO ZZZ 92 Z BN 40 0001-9999
WPO AAO 92 0 BN 45 0001 -9999
1983-1985 924 Europe, RoW XK/XJ 1984 92/125 84.4/86.5 9.3:1 K-Jetronic XK 000001 onwards WPO ZZZ 92 Z DN 40 0001 -9999

1979-1980 924 turbo, Europe,RoW
924 turbo, USA, Canada Japan M31/01 M31/02 1984 1984 125/170 110/150 84.4/86.. 84.4/86. 5 7.5:1
5 7.5:1 K-Jetronic
K-Jetronic 31010001-9999
31020001-9999 93 АО 14 0001-9999
93 А015 0001-9999
1981-1982 924 turbo, Europe, RoW 924 turbo, USA, Canada Japan M31/03 M31/04 1984 1984 130/177 115/156 84.4/86. 84.4/86. 5 8.5:1
5 8.0:1 K-Jetronic
K-Jetronic 31030001-9999
31040001-9999 WPO ZZZ 93 Z BN 100001-9999
WPO AAO 93 0 CN 15 0001 -9999
1982-1984 924 turbo, Italy M31/03 1984 130/177 84.4/86. 5 8.5:1 K-Jetronic 3103 0001-9999 WPO ZZZ 93 Z DN 10 0001 -9999

Engine Number Codes
e.g. XK 000001
Code letters
engine type Serial no. continuous irrespective of model year, when code letters identical. With new code letters/engine type, serial no. starts again at 000001.

Code letters range engine type Techn. data Fitted in vehicle type Engine no.
Letters
XK
XJ
XG
XE
VC 92KW/125HP
92kW/125HP
85KW/115HP
85kW/115HP
85kW/115HP 924-Europe, Rest of World
924-Europe,Rest of World right-hand drive
924-USA, Japan
924 California
924-USA, Canada California, Japan 000001 onwards
000001 onwards
000001 onwards
000001 onwards
000001 onwards
Engine number codes (8-digit) 924 turbo
3 1 01 0001 -9999 Europe/Rest of World (left and
right-hand drive)
31 02 0001-9999 USA/California/Canada/Japan
31 03 0001-9999 Europe/Rest of World (left and
right-hand drive)
31 04 0001-9999 USA/California/Canada/Japan
Serial no.
Type designation
3101 = T25kW (170 HP)
3102 = 110 kW (150 HP)
3103 = 130 kW (177 HP)
3104= 115 kW (156 HP)

Chassis Number Codes, Models 78...79
1. Chassis no. codes (10-digit)

924 8 1 00001
Type Model year Model version Serial no.
8 = 1978 1 = Europe, 00001 to 99999
9 = 1979 Rest of World
2 = USA, Serial no.starts
California at beginning again for
3 = Japan each model year and country
category




Chassis Number Codes, Model Year 80
The following changes are effective from model year 1980 for the chassis no.:
1. The 1st and 2nd digits signify basic type.
2. The 3rd digit signifies model year, internationally established as A for 1980.
3. The 4th digit indicates the factory. For model year 1980 the code is 0.
4. The 5th digit, in conjunction with digits 1 and 2, provides further identification of the vehicle. The 6th digit indicates the engine version.
5. The remaining 4 digits form the serial no.
The example below makes the changes clear:
924___________________Model year 1979 924 91 00001
|_________Model year 1980 92 A041 0001
924 turbo_____________Model year 1979 9249400001
|_________Model year 1980 93 A014 0001

Chassis Number Codes, Model 80
Chassis number codes 924
92 АО 41 0001 – 9999
92 АО 42 0001 - 9999
92 АО 43 0001 - 9999
92 АО 44 0001 – 9999 Europe / Rest of World
And beyond if more than 9999 vehicles
USA/California/Canada/Japan
And beyond if more than 9999 vehicles
Serial no.
Engine version
1 2000 cm3 92kW/125HP
2 2000 cm3,92kW/125HP
3 2000 cm3, 85kW/115HP
4 2000 cm3, 85kW/115HP
Type supplement (this number designates model 924 in conjunction with first 2 digits)
Place of production (Factory code initially designated as 0.)
Model year A =1980
В = 1981
Type code (vehicle model)


The 924 turbo is designated type 931 internally.
1. Chassis no. codes (10-digit)
93 А0 14 0001- 9999
93 А0 15 0001 –9999 Europe/Rest of World
USA/California/Canada/Japan


Serial no.
Engine version
4= 2000 cm3 125 kW/170 HP
5 = 2000 cm3, 110 kW/150 HP
Type supplement
Place of production
Model year A =1980
B = 1981
Type code

Chassis Number Codes as from Model 81
Chassis number codes 924
WPO ZZZ 92 Z С N 40 0001 - 9999
WPO AAO 92 О С N 45 0001 – 9999 Europe/Rest of World USA/Canada/Japan
| Serial no.
Code for body type and engine
Indicates vehicle type together with digits 7 and 8
Place of production
Model year
(B = 81, С = 82, D = 83, E = 84, F = 85)
Test code
Vehicle type together with 12th digit
Filling code or VDS code for USA and Canada versions
World manufacturer code

Chassis number codes 924 turbo
WPO ZZZ 93 Z С N 100001 - 9999 Europe/Rest of World
WPO AAO 930 С N 150001 – 9999 USA/Canada/Japan

Manual and automatic transmissions 924/924 turbo
Model Ident.
letters Type Fitted in model year
088/6
088/A
016Z
016Y
016/8
016/9
016/8
016/8

016/9
016/9

016/9 YR
XT
VA
VB
VQ
VR
MD
4Q

MF
5Q

ME 4-speed
4-speed
5-speed
5-speed
5-speed
5-speed
5-speed
5-speed

5-speed
5-speed

5-speed Europe, RoW
USA, Japan
Europe, RoW
USA
Europe, RoW
USA, Japan
Europe, RoW
Europe, ROW with lock USA
USA, Japan
with lock
Japan 78/79
78/79
78/79
78/79
80
80
from 81
82

from 81
82

from 81

For repair purposes these transmissions differ only slightly from model 80.
087/3 087/6 RK
RL Automatic
Automatic Europe, RoW
USA, Japan, California from 78
from 78

924 turbo
G31/01 G31/02 016G 016G MB MX 5-speed 5-speed 5-speed 5-speed Europe, RoW USA, Japan USA Japan 79.. .84 up to 80 81/82 81/82


Transmission Number Codes 924
Model year Number Transmission type Vehicle type
1978, 1979












1980



1981 YR1902 8
XT XX XX 8
RK XX XX 8
RL XX XX 8







VA 00001-99999
VB 00001-99999

VQ XX XX 0
VR XX XX 0
RK XX XX 0
RL XX XX 0
MD XX XX 1
MFXXXX1
ME XX XX 1
RK XX XX 1 RLXXXX1 088/6 - 4-speed
088/A - 4-speed
087/3 – Automatic
087/6 - Automatic
Production year
8 = 1978,
9 = 1979
Production month
Production day
Identifying letters

016Z - 5-speed
016Y - 5-speed
Serial number
016/8-5-speed
016/9-5-speed
087/3–Automatic
087/6– Automatic
016/8-5-speed
016/9-5-speed
016/9-5-speed
087/3 – Automatic
087/6 – Automatic 924 Europe/RoW
924 USA/Japan
924 Europe/RoW
924 USA/Japan







924 Europe/RoW
924 USA/Japan

924 Europe/RoW
924 USA/Japan
924 Europe/RoW
924 USA/Japan
924 Europe/RoW
924 USA/Canada
924 Japan
924 Europe/RoW
924 USA/Japan/Canada
1982 М019 02 2 4Q XX XX X 016/8 - 5-speed
016/8 5-speed w. Differential lock 924 Europe/RoW
924 Europe/RoW
MF XX XX X 5Q XX XX X 016/9 - 5-speed
016/9 - 5-speed w. Differential lock 924 USA/Canada
924 USA/Japan
ME XX XXX 016/9 - 5-speed 924 Japan
RK XX XX X RL XX XX X 087/3 - Automatic
087/6 - Automatic 924 Europe/RoW
924 USA/Japan/ Canada
1983 MD 19 02 3 4Q XX XX X 016/8 - 5-speed
016/8- 5-speed w. Differential lock 924 Europe/RoW
924 Europe/RoW
RK XX XX X 087/3 - Automatic (up to 09.1982) 924 Europe/RoW
RCC XX XX X 087/3 - Automatic (from 10.1982) 924 Europe/RoW
1984, 1985 MD19024 016/8 - 5-speed 924 Europe/RoW
4Q XX XX X 016/8- 5-speed w. Differential lock 924 Europe/RoW
RCC XX XXX 087/3 - Automatic 924 Europe/RoW

Transmission Number Codes 924 turbo
Model year Number Transmission type Vehicle type
1979, 1980 31 01 00001 (12) -
99999
3102 00001 (12)-
99999 G31/01 - 5-speed

G 31/02 - 5-speed
Differential lock 924 turbo Europe/RoW

924 turbo USA/Japan
1981 31 01 00001 (12)
-99999
016 G 000001
-99999 G31/01 - 5-speed

MB = 016G - 5-speed
MX = 016G - 5-speed 924 turbo Europe/RoW

924 turbo USA/Can. 924 turbo Japan
1982 31 01 00001 (12)
-99999
016G 00001
-99999
016G 00001
-99999
016G 00001
-99999 G31/01 - 5-speed

MB = 016G - 5-speed

MX = 016G - 5-speed

6Q = 016G - 5-speed with differential lock 924 turbo Europe/RoW

924 turbo USA/Can.

924 turbo Japan

924 turbo USA/ Canada/Japan
1983 1984 31 01 00001 (12)
-99999
31 01 00001 (12)
-99999 G31/01 - 5-speed

G31/01 - 5-speed 924 turbo Italy

924 turbo Italy


Engine Data
Engine type

Model year 924 XK
924 XJ
78…85 924 XG
924 XE
78…79 924 VC

80...82 M31/01 turbo

79...80 M31/02
Turbo
73...80 M31/03 turbo

81..84 M31/04
turbo
81.„82
No. of cylinders 4 4 4 4 4 4 4
Bore mm/in. 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41 86.5/3.41
Stroke mm/in. 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32 84.4/3.32
Displacement (actual) Cm3/in3 1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06 1984/121.06
Compression ratio 9.3:1 8.5:1 9.0:1 7.5:1 7.5:1 8.5:1 8.0:1
Max. engine power,
80/1269/EWG kW/HP 92/125 85/115 85/115 125/170 110/150 130/177 115/156
(Net Power, SAE J1349) kW/HP 82/110 121/162 106/143 126/169 115/154
At engine speed max. Torque, Rpm 5800 5750 5750 5500 5500 5500 5750
80/1269/EWG Nm/kpm 165/16.8 156/15.9 156/15.9 245/25 206/21 250/25.5 210/21.4
(Net Torque, SAE J1349) Nm/ftib 151/111.3 237/175 199.4/147 242/184.5 203.3/154.8
At engine speed Rpm 3500 3500 3500 3500 3500 3500 3500
Max. specific power,
DIN 70020 kW/l(HP/l) 46/63 43/58 43/58 63/86 55.4/75.6 65.5/89.2 58/78.6
(SAE J 1349) kW/l(HP/l) 41/55 61/82 54.6/72.1 63.5/85.2 55.9/75.1
Fuel octane rating RON 98 90 91 98 91 98 91
Max. perm. engine speed Rpm 6500 6500 6500 6500 6500 6500 6500
Idle speed Rpm 950±50 950±50 750...800 900 ± 50 900 ± 50 <900 <900
Engine weight (dry) Kg 136 142 142 165 165 165 165

Technical Data Type 924 Engine Type XK/XJ
Engine design
Design
Crankcase
Crankshaft
Connecting rods
Pistons
Camshaft
Camshaft drive
Cylinder head
Valve arrangement
Valve timing
Valve play
Timing with engine warm
Intake opens
Intake closes
Exhaust opens
Exhaust closes
Engine cooling
Engine lubrication
Oil filter
Oil pressure at 5000 rpm
Oil pressure indicators
Oil consumption l/1000 km
Exhaust system 4-cylinder,4- stroke spark-ignition engine, in line
1 -piece gray cast iron cylinder/crank- case with aluminum oil pan
forged, 5 plain bearings
Forged steel
Cast light-alloy
Case-hardened steel without bearing shells, running in cylinder head
by means of toothed belt, with tightening roller
Light alloy
1 intake, 1 exhaust in line overhead
by overhead camshaft and bucket tappets
Intake 0.20 mm, Exhaust 0.45 mm
(1 mm stroke, zero play)
6 degr. Before TDC
42 degr. After BDC
47 degr. Before BDC
2 degr. After TDC
closed coolant system
Forced oil circulation system with crescent pump
in full flow
approx. 7 bar for oil temperature between 80... 100° С
Indicator lamp and pressure gauge
up to 1.5
Manifold, single pipe up to front muffler, front, center and final muffler
Heater
Fuel system
Fuel delivery
Fuel grade RON
Fuel consumption
Electrical system
Interference suppression
Battery voltage V
Battery capacitance Ah
Alternator/output A/W
Ignition
Ignition sequence
Ignition timing
Spark plugs
Electrode gap mm
Power transmission



Clutch
Pressure plate Warm water heater with heat exchanger and blower
K-Jetronic
1 electric fuel delivery pump
98
Refer to "Operating Instructions"

ECE-R 10 and 72/245/EWG
12
45 (opt. Extra 63)
75/1050
Battery ignition system/TSZ ignition system
1-3-4-2
10° CA before TDC at 950 ± 50 rpm without vacuum pipe
Bosch W5D, Beru 14-5 DU
0.7 ± 0.1
Front-mounted engine, transmission mounted at rear end, bolted together by a connecting tube to form a rigid drive unit transaxle. Front engine, clutch, torsionally elastic drive shaft to transmission mounted in connecting tube, rear transmission interlocked with axle drive, twin drive shaft to rear wheels.
Single-disk dry clutch with disk spring, in compact design, arranged at engine end
(MF215K)

Technical Data for the 924 Carrera GT
Main data of the 924 Carrera GT model 81 compared with the basic 924 turbo
Engine type 924 Carrere GT M31/5O 924 turbo M31/03
Max. engine power kW/HP 154/210 130/177
at engine speed rpm 6000 5500
max. torque Nm/kpm 280/28.5 250/25.5
max. specific power kW/l, HP/I 77.6/105.8 65.5/89.2
Engine weight kg 175 165
Boost pressure bar 0.75 0.64
Clutch contact force N 7800...8500 7200...7900
Clutch disk TD225 GUD 225
Stabilizer, rear  16mm 14mm

Wheels and tires
924 Carrera GT Wheels Tires
5-hole wheels LMgs7Jx15 215/60 VR 15
Rim offset 23.3 mm (924 turbo 53 mm)

Engine number code 924 Carrera GT
31 50 0001 -9999 Europe/RoW

Transmission number code 924 Carrera GT
31 03 00001 (12) - 99999 G31/03 - 5-speed Europe/RoW
with differential lock

Torque Specifications - Engine 924/924 turbo
Location Thread Tightening torque Nm (ftib)
Bearing housing to crankcase M12 80 (59)
Bearing housing 5 to crankcase M10 65(4
Connection rod bolted joint M10x1 60(44)
Oil suction line to crankcase M6 10(7.5)
Oil drain line to crank-shaft bearing housing M6 10(7.5)
Housing to oil pump M 6 8(6)
Oil pump to crankcase М6 10(7.5)
Oil pan to crankcase M8 15(11)
Oil pan to crankcase M6 8(6)
Oil drain screw M26 x 1.5 40(29)
Flywheel to crankshaft M12x1.5 100 (74)
Toothed belt pulley to crankshaft M16X1.5 250 (184)
V-belt pulley to toothed belt pulley M8 20(15)
Water pump to crankcase M8x72 M8x65 22(16)
Water pump to crankcase M6x35 M6x45 9(7)
Water pump pulley to hub M8x12 20(15)
Connection piece to oil pan M26X1.5 110(81)
Oil return line from turbo-charger to oil pan 95(70)
Oil return line from turbocharger to bracket 85 (63)
Screw connector oil filter to oil filter bracket ¾ -16 UNF To firm fit max. 20 (15)
Bracket for oil filter to crankcase ¾ -16 UNF-2 В 60 (44)
Oil lines to bracket for oil filter M18X1.5 55 (41)
Oil supply line to bracket for oil filter 85 (63)
Oil line to bracket for turbocharger 40 (29)
Connecting piece to bracket for turbocharger M14X-1.5 40.. .45 (29...33)
Camshaft bearing housing to cylinder head М6 10(7.5)
Camshaft bearing housing to cylinder head М8 16...20(12...15)
Cylinder head cover to cylinder head М6 8(6)
Oil pressure sensor to cylinder head M10x1 15(11)
Toothed belt gear М12Х1.5 80 (59)
Tensioning roller thermostat housing М10 40 (29)
Flange for heater on cylinder head М6х35 10 (7.5)
Coolant governor М6 10 (7.5)
Coolant governor to cylinder head М8х35 М8х25 20(15)
Spark plug M14 x 1.25 30(22)
Distributor bolts М8 20...22(15...16)
Telethermometer transmitter M10x1 8(6)
Suction pipe and hoisting bracket to cylinder head M8x72 М8 24(1
Exhaust manifold to cylinder head М8 25(1
Toothed belt cover to cylinder head M6x25 10(7.5)
Toothed belt cover to oil pump M6x25 10(7.5)
Throttle valve connector piece to suction line M8x40 22(16)
Engine bracket to engine nock М10 42(31)
Engine mounting to engine bracket M12x1.5 61(45)
Engine mounting to frame М10 42(31)
Clutch housing to engine M12 75(55)
Clutch housing to engine М10 45 (33)
Insulating connector piece to cylinder head 22...25(16...1
Injection valve to insulating connector piece 6.0...7.0 (4.5...5.0)
Fuel lines to mixture control unit M12x1.5 20(15)
Injection lines to injection valve 10(7.5)
Injection lines cyls. 1-4 to mixture control unit M8x1 9(7)
Fuel line to warm-up regulator and mixture control unit warm-up regulator M8x1 9(7)
Fuel line to warm-up regulator 14(10)
Fuel line to cold-start nozzle and mixture control unit M8x1 9(7)
Fuel line for timing valve to mixture control unit M8x1 9(7)
Fuel line to timing valve 12.5 (9)
Oxygen sensor to front of exhaust pipe 50...60 (37...44)
Control line to bypass valve M12x1.5 20(15)
Screw plug to bracket for oil filter M42X1.5 120 (8
Oil filter 20(15)
Turbocharger turbine casing M6 M8 12(9) 25(1
Turbocharger compressor casing 7(5)
Exhaust manifold flange Turbo charger M10 35(26)
(from model year 81 ) M10 50(37)
Boost pressure safety switch M10xl 15(11)
Vent casing on bypass valve M12x1.5 20(15)

Coat all threads of exhaust system with Optimoly HT

Tolerances and Wear Limits when installed
(new) wear limit
Cooling system
Coolant thermostat Open. Temperature 80...93C or 85...102C
Cap for cooling system
Pressure relief valve
Vacuum valve
opens at overpress 0.9...1.15bar
opens at vacuum p ress. 0.06...0.1 bar
Oil circuit
Oil consumption
l/1000 km
1.51
Oil pressure (only for SAE 20 W/20 oils)
at 80°С oil temperature: at 2000 rpm

Overpress.
3...6 bar
2.0 bar
Oil dipstick
upper mark
oil content
5.001

lower mark oil content 3.801
Oil pump:
Casing/gear wheels Axial play 0.03...0.07
Gearwheels Backlash of teeth 0...0.13
Oil filter:
Bypass valve opens Overpress. 2.2...3.2 bar
Oil pressure switch
opens at Overpress. 0.3...0.6 bar
Valve timing
Bore for camshaft
Inner diameter
26.00...26.021
Camshaft Diameter 25.94...25.96
Camshaft Axial play 0.05. ..0.16 0.2
(Measured on center bearing, Runout Max. 0.02
bearings 1 and 5 on
prisms
Bore for bucket tappet Inner diameter 38.5. ..38.525
Bucket tappet Diameter 38.45...38.47
Cylinder head with valves
Mounting face valve seat: Distortion max. 0.1
a) Intake Width 2.0
b) Exhaust Width 2.4
c) Intake Seating angle 45°
d) Exhaust Seating angle 45°
Valve guides
Intake and exhaust Inner diameter 9.000...9.015
Valve stem:
Intake Diameter 8.97
Exhaust Diameter 8.95
Valve guide/valve stem Play
Intake 0.4 0.8
Exhaust Compression Overpress. 0.5 8...11 bar 1.0 6 bar
Pressure difference between individual cylinders in max. 3 bar
Pistons with connecting rode
Cylinder/piston Play 0.03 0.08
Cylinder/piston 924 turbo Play 0.048...0.072 0.12
Weight difference of an engine's pistons for repairs max. 14g
Piston rings Vert. play 0.04...0.07 . 0.1
Piston rings Gap width О.3...0.5 1.0
Con rod weight Standard 815...927g
Weight difference of an
engine's con rods new Eg
for repairs 8g
Con rod bush Diameter 24.012...24.018
Piston pin Diameter 23.996...24.000
Con rod bush/piston
pin Radial play 0.01 ...0.02
Crankshaft and cylinder block
Crankshaft (measured on 2nd, 3rd or Runout max. 0.06
4th bearing, bearings 1 and 5 on prisms)
Con. rod journal Diameter 47.95...47.97
Con rod/crankshaft Radial play Axial play 0.02...0.07 0.05...0.08 0.1 0.4
Crankshaft bearing journal Diameter 59.95...59.97 (63.95. ..63.97*)
Crankshaft bearing/ crankshaft Radial play 0.02...0.08 0.16
Crankshaft bearing 3/ crankshaft Axial play 0.1 ...0.19 0.25
Cylinder bore out-of-round 0.04
Cylinder block/crank- shaft bearing bore Diameter 68.000...68.019

924turbo
Turbocharger Radial play max. 0.42
Turbocharger Axial play max. 0.16

Repair Stages for Crankshaft (Dimensions in mm)
(from engine no. XK 00 32 14)
Crankshaft bearing Journal Crankshaft con rod Journal
Journal  Max. out-of-round Journal  Max.
Original size 64.OO: -0,03
-0,05 0.03 46.00 -0,03
-0,05 0.03
Repair stage I 63.75: -0,03
-0,05 0.03 47,75 -0,03
-0,05 0.03
Repair stage II 63.50: -0,03
-0,05 0.03 47,50 -0,03
-0,05 0.03
Repair stage III 63.25: -0,03
-0,05 0.03 47,25 -0,03
-0,05 ' 0.03
Permitted vertical runout for crankshaft max. 0.06 mm, measured at main bearings 2, 3 and 4, bearings 1 and 5 on prisms.

Checking Pistons and Cylinder Bores 924
Checking pistons
Measure approx. 16 mm from lower edge, offset 90' to piston pin axis. Deviation from prescribed dimension (see table): max. 0.04 mm

Checking cylinder bores Measure at 3 points, transversely - "A" –and longitudinally - "B". Deviation from prescribed dimension (see table): max. 0.08 mm


Repair stage Tolerance group identification Cylinder bore (mm) Piston diameter (mm) Mahle pistons/KS pistons

601 86.5 +0,015
+0,005 86.48 ± 0.007
Stand.dmens. 602 86,5 +0,025
+0,025 86.49 ± 0.007
603 86.5 +0,035
+0,025 86.50 ± 0.007
626 86.75 +0,015
+0,005 86.73 ± 0.007
1st oversize 627 86.75 +0,025
+0,015 86.74 ± 0.007
628 86.75 +0,035
+0,025 86.75 ± 0.007
651 87.00 +0,015
+0,005 86.98 ± 0.007
2nd oversize 652 87.00 +0,025
+0,015 86.99 ± 0.007
653 87.00 +0,035
+0,025 87.00 ± 0.007
The tolerance group identification is stamped into the cylinder block on the starter motor side, just under the cylinder head.

Checking Pistons and Cylinder Bores 924 turbo
Checking pistons
Measure approx. 13 mm from lower edge, offset 90° to piston pin axis. Deviation from prescribed dimension (see table): max. 0.04 mm
Checking cylinder bores Measure at 3 points, transversely - "A" –and tongitudinally - "B". Deviation from prescribed dimension (see table): max. 0.08 mm

Repair stage Marking on piston head Piston  (mm) Cylinder bore (mm) Tolerance group identi-fication
Stand. dimension 86.5 |
||
||| 86.45
86.46
86.47 86.51
86.52
86.53 601
602
603
1st Rep. stage 86.75 |
||
||| 86.70
86.71
86.72 86.76
86.77
86.78 626
627
628
2nd Rep. stage 87.0 I
||
||| 86.95
86.96
86.97 87.01
87.02
87.03 651
652
653
3rd Rep. stage 87.5 I
||
||| 87.45
87.46
87.47 87.51
87.52
87.53 701
702
703
Note
Only pistons from a single manufacturer (Mahle or KS) may be used in one and the same engine.

Valve Dimensions

924 924 turbo
Intake valve Exhaust valve Intake valve Exhaust valve
a) 40mm  33mm  40mm  36 mm
b) 8.97 mm  8.95 mm  8.97 mm  8.95 mm
c) 137.2mm 136.95 mm 133.2 mm 133.35 mm
d) 2.2...3.0 mm 2.2...3.0 mm 2.2...3.0 mm 2.2...3.0 mm
 45° 45° 45° 45°

Checking Valve Guides
Insert new valve into guide until valve stem end is flush with end of guide. Ascertain play.

Wear limit for intake valve guide 0.8 mm
Wear limit for exhaust valve guide 1.0 mm

Adjusting Screw Notching
The number of notches indicates the thickness of the valve adjusting screws.
Higher number of notches = thicker adjusting screw

New adjusting screw
Part no. Identi-fication
046.109.453.D 046.109.453.E 046.109.453 F 046.109.453 G 046.109.453 С 1 notch
2 notches
3 notches
4 notches
without notch The replacement adjusting screw will continue to be available, but without any marking (previously white dot of paint).

Checking and Adjusting Valve Play Reworking Intake Valves
Valve play is checked and adjusted with the engine at operating temperature (oil temp. approx. 80°C.)
Intake valve: 0.20 mm
Exhaust valve: 0.45 mm
Basic valve play setting (for engine overhaul etc.)
With engine cold
Intake valve: 0.10mm
Exhaust valve: 0.40 mm When reworking the valve, dimension a = 3.5 mm must not be exceeded.
Note
Exhaust valves must not be reworked. Only grinding to size is permitted.

Reworking Valve Seats
Valve seats with traces of wear or burning may be reworked until the wear limit "b" is reached. If the wear limit is exceeded, the cylinder head should be replaced, as the prescribed valve play can no longer be set, and valve seat rings cannot be replaced using conventional workshop equipment.
924
Intake valve seat Exhaust valve seat
a)  38.5 mm a)  31.5 mm
b) max. 3.3 mm b) max. 3.9 mm


Caution
If a valve seat has been reworked, the valve adjusting screw of the bucket tappet belonging to that valve must be exchanged for a replacement adjusting screw, 046 109 453 С (without marking).
924 turbo
New dimension, measured from cylinder head mating face to valve head:
Intake 5.0mm Wear limit: Intake 5.3mm
Exhaust 4.7mm Exhaust 5.2 mm
Carry out check with new valve. Keep material loss to a minimum.
Tightening Specifications - Cylinder Head Bolts • 924
Tightening sequence for cylinder head



Tightening specifications using the turning angle method-924-inductlon engine
Tightening is performed in two stages, following the sequence shown in the diagram at each stage. Reverse sequence when undoing the bolts.
Turning angle tightening method
Tightening in two stages (with screws with internal serrations)
1st stage 65 Nm
2nd stage 180°= 1/2 tum
Tightening specifications for cylinder head bolts - 924 turbo
1. Tighten cylinder head bolts in prescribed sequence, in stages, to 40 Nm, 80 Nm and 110 Nm.
2. Retighten cylinder head bolts after at least 60 minutes (to allow for settling of cylinder head). To do so, loosen bolt no. 1 (see tightening sequence) approx. ½ a turn and tighten to 110 Nm. Repeat this procedure with the remaining bolts in the prescribed sequence. Bring engine up to operating temperature (oil temperature approx. 80° С). Allow engine to cool and give cylinder head bolts a final tightening as described under 2.

Machining the Cylinder Head Mating Face

Permissible unevenness of mating face: 0.1 mm
Max. reworking depth 0.4 mm
Peak-to-valley height = 0.015 mm
Size Worn A = 139.55mm

Main Testing and Adjusting Values for Engine
Engine type 924 Engine type 924 turbo
XK,XJ XG,XE VC M31/D1/02 M31/03/04 Mod. 81 (Sweden, Australia)
Electric fuel pump Delivery rate
Min. 750 cm3/30 s
as XK, XJ
as XK, XJ Electric fuel pump Delivery rate
min. 1050cm3/30s
as 01/02
as 01/02
System pressure test value 4.5...5.2 bar as XK, XJ as XK, XJ System pressure test value 5.8...6.5 bar as 01/02 as 01/02
Adjust, value 4.7...4.9 bar as XK, XJ as XK, XJ Adjust, value 6.0...6.3 bar as 01/02 as 01/02
Control pressure cold (approx. 20° C) 1.3...1.7bar as XK, XJ 1.7...2.1 Control pressure cold (approx. 20° C) 2.0...2.4 bar 2.4...2.8 1.3...1.7
Control pressure warm 3.4...3.8 bar as XK, XJ as XK, XJ Control pressure warm without overpressure 3.45...3.85 bar as 01/02 3.1 ...3.5
Leakiest Leak test
Min. pressure after 10 min. 1.7 bar as XK, XJ as XK, XJ Min. pressure after 10 min. 2.0 bar as 01/02 as 01/02
Min. pressure after 20 min. 1.5 bar as XK, XJ as XK, XJ Min. pressure after 20 min. 1.7 bar as 01/02 as 01/02
Opening pressure of inject valves 2.5...3.6 bar as XK, XJ as XK, XJ Opening pressure of injection valves 2.7...3.8 bar as 01/02 as 01/02
Ignition timing with vacuum hose disconnected 10° CA before
TDC for
950 ± 50 rpm Ignition timing with vacuum hose disconnected M31/01 25° CA before TDC at 2000 rpm M31/02 20° CA before TDC at 2000 rpm Digital advance unit (DZV)
Ignition timing with vacuum hose connected 3° CA after TDC for
950 ± 50 rpm 0° CA = TDC for
950 ± 50 rpm


Test Testing and Adjusting values 924 Special notes
Idle speed setting
Idle speed rpm
950 ± 50 rpm
750...800 rpm (from mod. 81 USA, California, Canada)
1000 + 50 rpm (from mod. 81, Japan, automatic) All consumers switched off
CO content % 1.0...2.0%
USA and Canada
Mod. 78 0.5... 1.0 % * (measured upstream of cat.)
Mod. 79 0.7... 1.1 % * (measured upstream of cat.)
Mod. 80 0.6...1.0 % (measured upstream of cat.)
from mod. 81 0.5...1.0 % (measured upstream of cat.)
*Air pump and activated charcoal container not connected
Plug connector for oxygen sensor not connected
California
Up toMod.79 max. 0.7 %* (measured upstream of cat.)
Mod. 79 0.8... 1.2 %* (measured upstream of cat.)
Mod. 80 0.6...1.0 % (measured upstream of cat.)
Frommod.81 0.5...1.0 % (measured upstream of cat.) Plug connector for oxygen
Japan
Mod. 78 0.5...1.0 %* (measured upstream of cat.)
Mod. 79 0.7... 1.1 %* (measured upstream of cat.)
Mod. 80 0.6....1,0 % (measured upstream of cat.)
From mod. 81 0.6... 1.0 % (measured upstream of cat.) Plug connector for oxygen sensor not connected
Test Testing and Adjusting Values 924 turbo (GT) Special notes
Idle speed setting from mod. 81 (DZV ignition system) with cold intake airtemp. Sensor
Idle speed rpm 900 ± 50 rpm
Mod. 79/80 (Europe, USA, Japan and Canada)
< 900 rpm from mod. 81 ignition marking in insp. aperture
CO content % 0.5...1.0
Mod. 79/80 (Europe, USA, Japan and Canada) 0.5...1.5 from mod. 81
1.0. ..2.0 Australia, Sweden measured upstream of cat., plug connector for oxygen sensor not connected

Measuring Boost Pressure 924 turbo
Model 79/80 from Model 81
Europe USA Europe USA
0.67...0.73bar 0.43...0.47bar 0.62...0.68 bar 0.43...0.47 bar

924 Саггега GT 0.72...0.78 bar

V-Belt Dimensions
924 V-belt for alternator mm 9.5 x 888 LA without teeth
V-belt for alternator as from mod. 81 mm 9.5 x 888 LA with teeth
V-belt for air-conditioning compressor mm 12.5х900 LA without teeth
V-belt for compressor as from mod. 79 mm 13/12.5 x 875 LA With teeth
V-belt for air pump (air injection) mm 9.5 x 771 LA
924turto V-belt for alternator as from mod. 81 mm 9.5 x 1048 LA without teeth mm 9.5 x 1050 LA with teeth

Coolant Mixing Table
Frost protection to Antifreeze Water Antifreeze Water
-25°С 40% 60% 2.81 4.21
-30°C 45% 55% 3.21 3.81
-35°С 50% 50% 3.51 3.51





Page Transmission and clutch

Torque Specifications Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (4-speed transmission type 088)

Location Thread Tightening torque Nm (ftib)
Side transm. Flange M8 25(1
Side transm. cover M8 27 (20)
Cover for shifting shaft M6 8(6)
End shield M8 24(1
Drive shaft M8 24 (1
Drive shaft M8 24(1
Oil filler screw M24 25(1
Oil drain screw M24 25(1
Reverse gear pin M8 25(1
Reversing lever bearing M10X1.5 35(26)
Shifting lock M14X1.5 30(22)
Reversing lever M18x1.5 30(22)
Crown gear M10x1 85...100 (63...74)
Flanged shaft to diff. gear M8 25(1
Protective tube to trans-mission case M7 10...16 (7.5...12)
Joint shaft M8 42(31)
Shifting lever mounting M8 21 (15)
Joint rod to intermediate shifting lever M8 21 (15)
Joint rod to transmission case M8 14(10)
Reversing light switch M18x1.5 30(22)
Exhaust line to transmission M10 45(33)
Exhaust line to Transaxle system M8 10 (7.5)
Front muffler to exhaust pipe M8 20(15)
Central tube housing to transmission case M12 85 (63)
Central housing to transmission case M10 42(31)
Shift lever plate to central tube M8 21 (15)
Central shaft to trans-mission shaft M8x35 30 (22)
Central tube flange to clutch housing M10X35 42(31)
Clutch housing to engine flange M10x1.5 M12x1.5 45 (33)
75(55)
Transmission bearing to body M10 42(31)
Bearing bracket to transmission M8 25(1
Clutch lever M8 15(11)
Clutch to flywheel M8 32 (24)
Guide tube to clutch housing M7 10...16(7.5...12)
Support strut to tans-mission (USA) M10 42 (31)
Arrester to central tube (USA) M8 20(15)
Torque Specifications - Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (5-speed transmissions type 016 Z and 016 Y)
Location Thread Tightening torque Nm (ftib)
Drive shaft M30 x 1.5 220...240 (161 ...175)
Drive shaft M22 x 1.5 160...180 (110...133)
Driving shaft M24 x 1.5 200...220 (147...162)
Flange shaft to diff. gear M10X1.5 47...50 (35...37)
Shift lock/rear axle and wheel housing M10X1.5 15...18 (11 ...13)
Mounting of casing and cover M8х1.25 22...25(16...1
Crown gear/diff. Gear M12 x 1.25 150...160 (111 ...118)
Locking pawl/rear axle casing M6x1 8...10(6...7.5)
Reversing light switch/ wheel housing M18X1.5 25...32 (18...24)
Oil filler screw/wheel housing M24 x 1.5 (tapered) 20...25 (15...1
Oil drain screw/rear axle casing M25X1.5 (tapered) 20...25(15...1
Tension plate, rear axle casing, wheel housing M8х1.25 22...25(16...1
Joint shaft M8 42(31)
Exhaust tine to transmission M10 45(33)
Exhaust line to transaxle system M8 10(7.5)
Front muffler to exhaust pipe M8 20(15)
Central shaft to trans-mission shaft M8x35 35 (26)
Central tube flange to clutch housing M10X35 42 (31)
Clutch housing to engine flange M10x1.5 M12x1.5 45(33)
75(55)
Clutch lever M8 15(11)
Clutch to flywheel M8 32 (24)
Guide tube to clutch housing M7 10...16 (7.5...12)
Transmission bearing to transmission M10 42(31)
Transmission bearing to rear axle transverse tube M10 42(31)
Central tube to trans-mission case M12x1.5 85 (63)
Shifting rod to inner shifting rod/transmission M8 18(13)
Bearing bracket to floor unit - center M6 9(7)
Angled linkage to guide rod BM10 23(17)

Torque Specifications - Manual Transmission, Central Tube, Clutch and Actuating Elements 924 (5-speed transmissions type 016/8 and 016/9)
Location Thread Tightening torque Nm (ftib)
Oil filler screw to transmission case M24 25(1
Oil drain screw to transmission case M24 25(1
Protective tube to transmission case M7 10...16 (7.5...12)
Shifting shaft to transmission case M6 6...10(4.5...7.5)
End shield to transmission case M8 24 (1
Ball bearing to drive shaft M10 50(37)
Cover to end shield M8 25(1
5th gear wheel to driving shaft M10 50 (37)
Shifting lock to end shield M18 30 (22)
Shift travel limiter to M18 30(22)
End shield M14
Reverse transfer lever to end shield M10 35(26)
Reverse gear pin to end shield M8 20(15)
Flanged shaft to diff. gear M8 25(1
Side transmission cover to transmission case M8 25(1
Crown gear to diff. casing M10 85...100 (63...74)
Reversing light switch to transmission case M18 30(22)
Joint shaft M8 42(31)
Joint rod to transmission case M8 21 (15)
Joint rod to transmission case M8 14 (10)
Shift lever plate to central tube M8 21 (15)
Exhaust line to transaxle system M8 10(7.5)
Front muffler to exhaust pipe M8 20(15)
Central tube housing to transmission case M12 85 (63)
Central tube housing to transmission case M10 42 (31)
Shifting rod mounting M8 21 (15)
Central shaft to trans-mission shaft M8x35 35(26)
Central tube flange to clutch housing M10x35 42(31)
Clutch housing to engine M10x1.5 M12x1.5 45(33) 75(55)
Clutch bearing to body M10 42(31)
Bearing bracket to transmission M8 25(1
Clutch lever M8 15(11)
Clutch to flywheel M8 32(23)
Guide tube to clutch housing M8 10...16 (7.5...12)

Clutch 924

Design



Pressure plate
Contact pressure
Clutch disk
Clutch drive plate with riveted on lining Thickness untensioned (new)
Wear limit


Lateral runout
Clutch play at clutch pedal Single-plate dry clutch with disk spring, compact design
MF215K
4810.. .5490 N
215mm

10.1-0.4 mm
8.5 mm with asymmetrical wear
Max. 0.6 mm with  2OO mm
20-25 mm

Clutch 924 turbo
Design


Pressure plate
Contact pressure
Clutch disk
Clutch drive plate with riveted on lining Thickness untensioned (new)
Wear limit
Lateral runout
Clutch play at clutch pedal
Single-plate dry clutch with disk spring, hydraulically actuated, extended design
MFZ225
7200.. .7900 N
 225 mm

8.1 ± 0.3 mm
6.3 mm with asymmetrical wear
Max. 0.6 mm with  225 mm
Approx. 3 mm
Technical Data 4-Speed Manual Transmission Type 924 YR (924 XT*)
Ratios
1st gear
2nd gear
3rd gear
4th gear
R.gear
10:36 i=3.60
16:34 i=2.125
25:34 i = 1.360
30:29 i = 0.966
12:42 i=3.50
Final drive Hypoid drive, 12 mm offset
Final drive ratio 9:35 i= 3.8888
Climbing ability in %
1st gear
2nd gear
3rd gear
4th gear
54 (49.5)
28 (26)
16 (14.5)
9.5 (9)
Power transmission Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (20 mm Ø) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels
Transmission weight (dry) 45 kg (99 Ibs)
Filling capacity Approx. 2.6 liters multi-grade transmission oil, SAE 75 W-9O, API classification GL 5 (or MIL-L 2105 В) or 80 W90-GL 4

Technical Data 5-Speed Manual Transmission Types 016 Z and 016 Y *
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
R. Gear
14:39(14:39) i= 2.7857 (2.7857)
18:31 (19:32) i = 1.7222 (1.6842) 23:28(27:30) i= 1.2174 (1.1111)
29:27 (31:25) i = 0.9310 (0.8064)
34:24 (35:21) i = 0.7059 (0.6000)
46:21-16:14 i= 2.5034
Final drive Helical bevel gear differential
Final drive ratio 7:33 i= 4.7143 (7:35 i= 5.000)
Power transmission Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø20 mm) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels
Getriebegewicht (trocken) 45 kg (99 Ibs)
Filling capacity Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-9O, API Classification GL 5 (orMIL-L2105B)
"Specifications for USA in brackets

Technical Data 5-Speed Manual Transmission Types 016/8 and 016/9 *
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
R. gear
Final drive
10:36 i= 3.600
16:34 i=2.125
24:35 (25:34) i = 1.458 (1.360) 28:31(30:29) i= 1.107 (0.966)
35:30 (37:27) i = 0.857 (0.729)
12:42 i= 3.500
Hypoid drive, 12 mm offset
Final drive ratio 9:35(9:37) i= 3.889 (4.111)
Climbing ability in %
1st gear
2nd gear
3rd gear
4th gear
5th gear
59 (57)
32(30)
21 (1
14(11.5)
9.5(7)
Power transmission Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 20 mm) to transmission mounted in 4 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels
Transmission weight (dry) 55 kg (121 Ibs)
Filling capacity Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-9O, API Classification GL 5 (or MIL-L 2105 В) or 80 W90-GL4
"Specifications for USA in brackets
Torque Specifications - Automatic Transmission 924
Location Thread Tightening torque Nm (ftib)
Oil filler transmission case M24X1.5 20 (15)
Flange shaft to differential M8х1.25 25(1
Locking plate to adjusting ring M6x1 8(6)
Planetary gear to axle drive M8х1.25 29(21)
Governor cover to axle housing M8х1.25 9(7)
Cover for diff. pinion to axle housing M8х1.25 25(1
Cover of axle housing to axle housing M8х1.25 25(1
Crown gear to differential M10x1 78...93 (58...69)
Governor shaft to governor housing M5х0.8 3.5 (3)
Screw plug tor measuring connection M10x1 15(11)
Lever for hand slide valve to transmission case M6x1 3.5 (3)
Detent segment to lever for hand slide valve M16X1.5 20.5 (15)
Lever of kickdown valve to shaft of accelerator rod M8х1.25 17(13)
Detent spring to trans-mission case M8х1.25 20.5 (15)
Pump to transmission case M6x1 7.0(5)
Slide valve case to transmission case M6x1 3.5(3)
Oil strainer to slide valve case M5х0.8 3.5(3)
Oil pan to trans-mission case M8х1.25 20.5 (15)
Intermediate plate to transmission case M5х0.8 3.5(3)
Facing plate to slide valve case M5х0.8 3.5(3)
Supporting plate to duct plate M5х0.8 -3.5(3)
Intermediate and duct plates to slide valve case M5х0.8 3.5(3)
Cover plate to pump housing M4х0.7 1.4(1)
Adjustment brake strap 2nd gear M12X1.5 19.6(14)
Converter to drive plate M8 21 (15)

Torque Specifications -Automatic Transmission Actuating Elements 924
Location Thread Tightening torque Nm (ftib)
Shift lever guide to shift bracket M6 9(7)
Locking segment to shift bracket M6 10 (7.5)
Mount of shift actuation and side seal guide M6 10(7.5)
Retaining bracket to transmission M8 21 (15)
Cable to bracket M8 8±1 (6±1)
Cable to retaining bracket M8 8±1(6±1)
Cable to transmission lever M8 5±1(4±1)

Torque Specifications -Accelerator Actuation (Automatic Transmission) 924
Location Thread Tightening torque Nm (ftib)
Guide pulley to bracket M6 9(7)
Guide pulley bracket to intake pipe M6 9(7)
Control cable to bracket M8 5(4)
Control cable to transmission M10 30(22)
Control cable to central tube M4 1.4(1)
Rubber to lever for accelerator actuation M6 9(7)
Rubber to lever M6 9(7)
Support to bracket for guide pulley M6 9(7)
Support for guide pulley to crankcase M8 21 (15)
Accelerator pedal to floor plate M6 5(4)

Torque Specifications-Central Tube (Automatic Models) 924
Location Thread Tightening torque Nm (ftib)
Torque converter mounting to rear bell M8x25 21 (15)
Mounting of central shaft to flange shaft M8 35 (26)
Central tube flange to clutch bell M10x35 42(31)
Central tube housing to transmission case M12X1.5 85 (63)
Central tube housing to transmission case M10x-1.5 42(31)
Torque converter to driver plate M8x12 21(15)
Mounting of central shaft to clamper M8 35 (26)
Damper to flywheel M8x18 21 (15)
Cover to clutch housing 6.3х19 5(4)
Stop basket to damper M8x25 21 (15)
Technical Data - Automatic Transmission 924
Internal designation RK(RL)
Number of speeds 3 forward, 1 reverse and parking lock
Ratios: Driving position 1 i = 2.5517
Driving position 2 i= 1.4483
Driving position D i=1.0000
Driving position R i= 2.4615
Clutch Hydrodynamic torque converter
Torque converter ratio 2.2 (up to mod. 79 = 2.1 from mod. 80 = 2.44)
Stall speed 2600 ± 200 (up to mod. 79 = 2100 ± 200 from mod. 80 = 2450 ± 200)
Torque conv. code letter К (up to mod. 79 = J, from mod. 80 = M)
Final drive Hypoid drive set
Hypoid offset 44mm
Axle ratio 11/38(11/41)
Filling capacities Final drive approx. 11 multi-grade gear oil, SAE 75 W-90, API classification GL 5 (or MIL-L 2105 В)
Automatic section 61 total filling capacity with ATP Dexron, torque converter capacity 2.51, change quantity approx. 2.81, observe marking on top-up reservoir
Specifications for USA in brackets


Pressure-Testing Hydraulic Control Unit
Up to model 80
From model 81
Selector
Lever.
Pos. Accel. pedal pos. Main press. In bar Overpressure (kg/cm2) Test con-dition Selector
lever pos Accel.. pedal pos. Main press. In bar Overpressure (kg/cm') Test-condition )
D Idle
(zero accel.) 2.95 ± 0.05 D Idle
(zero accel.) 2.95 ± 0.05
Speed more than 50 km/h* Speed more than 50 km/h*
D Full accel. 6.85 ± 0.05 (590+005) D Full accel. 6.85 ± 0.05 (5,90 ± 0,05)
R Idle
(zero accel.) 7.35 ± 0.3 Vehicle stationary R Idle
(zero accel.) 9.6 ± 0.3 (9.4 ± 0.3) Vehicle stationary
R Full accel. over 18 at stall speed R Full accel. over 18 at stall speed
•Specifications for USA in brackets

Torque Specifications - Manual Transmission 924 turbo (Types G31/01, G31/02, G31/03)
Location Thread Tightening torque Nm (ftib)
Drive shaft M 30 x 1.5 220 (162)
Driving shaft M 24 x 1.5 220 (162)
Flange shaft to diff. gear M10x1.5 46(34)
Shift lock/rear axle and wheel housing M10x1.5 18(13)
Mounting of casing and cover M 8х1.25 25(1
Crown gear/diff. gear M 12 x 1.25 150(111)
Locking pawl/rear axle casing M6x1 10 (7.5)
Reversing light switch/ wheel housing М18х1.5 30(22)
Oil filler screw/wheel housing М24Х1.5 (tapered) 25(1
Oil drain screw/rear-axle casing М25х1.5 (tapered) 25(1
Tension plate, rear axle casing, wheel housing M 8х1.25 25(1
Joint shaft to joint flange M 8х1.25 42(31)

Torque Specifications - Clutch, Central Tube, Transmission Suspension, Shift Actuation 924 turbo (Type G31/01, G31/02, G31/03)
Location Thread Tightening torque Nm (ftib)
Clutch
Guide tube to clutch housing M7 12(9)
Clutch and ring gear mounting M8 25(1
Flywheel to crankshaft M12 100 (74)
Clutch housing to engine M12 M10 75(55) 45 (33)
Clutch release shaft with clutch casing M6x35 M6 9.5 (7) 7.5(5)
Clutch operating cylinder to clutch housing M8x28 21 (15)
Central tube
Central shaft to trans-mission input shaft M10x46 80 (59)
Central tube flange to clutch housing M10x35 42(31)
Central tube flange to transmission case M12 85 (63)
Transmission suspension
Transmission bearing to rear axle transverse tube M10 42(31)
Transmission bearing to transmission M10 42(31)
Shift actuation
Bearing support to center of floor unit M6x10 9(7)
Shifting rod to transmission M8 18(13)
Angled joint to guide rod BM 10 23(17)

Torque Specifications - Manual Transmission 924 turbo (Type 016G)
Location Thread Tightening torque Nm (ftib)
Oil filler screw to transmission case M24 25(1
Oil drain screw to transmission case M24 25(1
Cover for shifting shaft to transmission case M6 6...10 (4.5...7.5)
End shield to transmission case M8 24(1
Bait bearing to transmission input shaft M10 50 (37)
Cover to end shield M8 25(1
5th gear wheel to driving shaft M10 50(37)
Shifting lock to end shield and transmission case M18 30(22)
Shift travel limiter to end shield M18
M14 30(22)
Reverse-transfer lever to end shield M10 35(26)
Reverse gear pin to end shield MS 20(15)
Flange shaft to differential M8 25(1
Transmission side cover to transmission case M8 25(1
Crown gear to differential casing M10 85...100 (63...74)
Reversing light switch to transmission case M18 30 (22)
Joint shaft to joint flange M8 42(31)

Torque Specifications - Clutch, Central Tube, Transmission Suspension and Shift Actuation 924 turbo (Type 016G)
Location Thread Tightening torque Nm (ftib)
Clutch Guide tube to clutch housing M7 12(9)
Clutch and ring gear mounting M8 25(1
Flywheel to crankshaft M12 100 (74)
Dutch housing to engine M12 M10 75(55) 45(33)
Clutch release shaft with clutch housing M6x35 M6 9.5 (7) 7.5 (5)
Clutch operating cylinder to clutch housing M8x28 21 (15)
Central tube
Central shaft to transmission input shaft M10x46 80 (59)
Central tube flange to clutch housing M10x35 42(31)
Central tube housing to transmission housing M12x75 M12x80 M10X60 85(63) 85(63) 42(31)
Transmission suspension
Transmission bearing to body M10 42(31)
Bearing to support bracket M8 23(17)
Support bracket to M8 25(1
Transmission Shift actuation
Joint rod to transmission case M8 14(10)
Joint rod to inter-mediate shifting lever M8 21 (15)
Shifting rod mounting M8 21 (15)
Shift lever plate to central tube M8x12 21 (15)
Intermediate shifting lever to shifting shaft M8 22.5 (17)

Technical Data- 5-Speed Manual Transmission G 31/01, G31/02* and G31/03
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
R.gear
10:36 i= 3.6000
16:34 i= 2.1250
24:35 i=1.4583
28:31 i=1.1071
37:27 i = 0.7297
12:42 i= 3.5000
Final drive Hypoid drive, 12 mm offset
Final drive ratio 9:35 i = 3.8889
Power transmission Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 25 mm) to transmission mounted in 3 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels
Transmission weight (dry) 55 kg (121 Ibs)
Filling capacity Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-90, API classification GL 5 (or MIL-L21O5 B)

Technical Data - 5-Speed Manual Transmission 016G
Ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
R.gear
12:38 i= 3.1666
18:32 i=1.7777
23:28 i=1.2174
29:27 i = 0.9310
34:24 (35:21) i = 0.7059 (0.6000)
12:16-22:48 i= 2.9091
Final drive Helical bevel gear differential
Final drive ratio 8:33 i = 4.1250 (7:33 i= 4.7143)
Power transmission Front engine and transmission (at rear) bolted together by means of a connecting tube to form a rigid drive unit. Front engine, clutch, torsionally elastic shaft (Ø 25 mm) to transmission mounted in 3 bearings, rear transmission interlocked with drive axle, twin articulated drive shafts to rear wheels
Transmission weight (dry) 45 kg (99 Ibs)
Filling capacity (specifications for USA in brackets) Approx. 2.5 liters multi-grade transmission oil, SAE 75 W-90, API classification GL 5 (orMIL-L2105B)

Torque Specifications - Front Axle 924/924 turbo
Location Thread Tightening torque nm (ftib)
Control arm to cross member M12x1.5 65 ± 10 (48 ± 7.5)
Clip to control arm M10 46(34)
Control arm to steering knuckle M10 50+10 (37+ 7.5)
Cross member to body M10 42(31)
Track rod to steering knuckle M12x1.5 30+20(22+15)
Clip for stabilizer to M8 13(10)
Body (up to Oct. 81) M8 20(15)
Stabilizer suspension to control arm (up to Oct. 81 ) M10 20 ± 5 (15 ± 4)
McPherson strut bearing to shock absorber strut M14x 1.5 77+3(57+2)
Fillister head screw to clamping nut M7 13+3(10+2)
Cover plate to steering knuckle M7 10(7.5)
Floating caliper to steering knuckle M12x1.5 85 (63)
McPherson strut to steering knuckle M12x1.5 100 (74)
McPherson strut to body M8 25 ± 4 (18 ± 3)
Spoked wheel to brake disk (LA wheel) M14X1.5 130 (96)
Disk wheel to brake disk (st. Wheel) M14X1.5 110(81)
Guide joint to control arm M7 25(1
Stabilizer suspension to body M8 23(17)
Clip for stabilizer to suspension M8 23(17)
Stabilizer bearing to control arm M8 23(17)

Torque Specifications - Steering 924/924 turbo
Location Thread Tightening torque Nm (ftib)
Track rod to steering knuckle M12X1.5 30+20(22+15)
Universal shaft to steering gear M8 30+5(22+4)
Steering gear to cross member M8 20+4(15+3)
Cover for pinion bearing M6 7±1(5±1)
Cover for thrust piece bearing M6 7±1(5±1)
Check nut for adjusting bolt M10x1 25 ± 5 (18 ± 4)
Track rod to steering rack M22X1.5 50 ± 7 (37 ± 5)
Track rod joint to track rod M14X-1.5 30+10(22+7.5)
Steering wheel to steering column M16X-1.5 45 ± 10 (33 ± 7.5)
Steering column switch to jacket tube M8 15±4(11 ±3)
Support bearing to body M6 5 (4)
Universal shaft to steering column M8 30 ± 5 (22 ± 4)

Torque Specifications - Rear Axle 924/924 turbo
Location Thread Tightening torque Nm (ftib)
Bearing flange to transverse tube M10 46(34)
Bearing flange to body M12x1.5 70(52)
Thrust bearing to bearing flange M10 46 (34)
Thrust bearing to body M10 46(34)
Support bearing to body M10 46(34)
Support bearing to strut M8 23(17)
Axle control arm to rear axle strut M12X1.5 90(66)
Axle control arm to rear axle strut M12X1.5 103(76)
Axle control arm to transverse tube M12X1.5 61(45)
Vibration damper to axle control arm and body M12X1.5 61(45)
Universal shaft to final drive and rear wheel shaft M8 42(31)
Adjusting lever to spring strut M16x1.5 245 (180)
Stabilizer suspension to rear axle strut and stabilizer M10 46(34)
Fastening clip to transverse tube M8 23(17)
Wheel bearing cover to axle control arm M10 58(43)
Wheel hub to rear wheel shaft M24 x 1.5 380 + 70 (280 + 52)
Brake drum to rear wheel shaft M24X1.5 350 ± 50 (258 ±37)
Cover plate to brake carrier M6 10(7.5)
Floating caliper to brake carrier M12X1.5 85 (63)
Brake line to floating caliper/ slave cylinder M10x1 14(10)
Mounting bracket for brake line to brake carrier M6 10(7.5)
Brake disk to wheel hub M6 5.0 (4)
LA wheel to wheel hub M14X-1.5 130 (96)
Steel wheel to wheel hub M14X-1.5 130 (96)
LA wheel to brake drum M14х1.5 130 (96)
Steel wheel (4-hole) to brake drum M14X1.5 110(81)

Technical Data - Front Axle 924
Wheel suspension Wheels independently suspended on control arms and spring struts (McPherson design)
Springing One coil spring per wheel, coaxial with spring strut
Shock absorbers Double-acting hydraulic shock absorber struts
Stabilizer
Up to end model 77 Model 78
Model 79
Model 80

Model 81
some of model 82 up to end Sept. 81
In model 82 from Oct. 81 Standard  Optional extra  — 20 mm
— 22 mm
— 23 mm
— 23 mm
(21 mm) (23 mm)*
21 mm 23 mm**


20mm 21.5mm

Specifications for USA, Canada, Japan in brackets *Not as indiv. optional extra M 404 **0nly for export in conjunction with optional extra M 471

Technical Data - Front Axle 924 turbo
Rest of world (USA, Canada, Japan- opt. extra) USA, Canada, Japan- basic model(from model 81 see ROW)
Wheel suspension Wheels independently suspended on control arms and spring struts (McPherson design)
Springing One coil spring per wheel, coaxial with spring strut
Shock absorbers Double-acting hydraulic shock absorber struts
VW (Opt. extra Koni) VW (Opt. extra Koni)
Stabilizer Ø 23 mm USA, Canada Japanlrommod.81 21 mm (opt. extra for USA, Canada, Japan from mod. 81 23mm in conjunction with Koni shock absorber and 14 mm rear stabilizer) from mod. 82 21.5mm 21 mm

Technical Data - Steering 924
Steering wheel 2 spokes 383 mm up to end model 81
3 spokes 380 mm from model 82
Optional extra
4 spokes 362 mm
3 spokes 380 mm
Steering wheel ratio in the middle 19.15:1
Turning circle diameter 10.08 m
Track circle diameter 9.21 m
Steering wheel turns from lock to lock 4.02

Technical Data - Steering 924 turbo
Rest of world (USA, Canada, Japan - opt. extra) USA, Canada, Japan - basic model (from model 81 see ROW)
Steering wheel Ø 380mm 360 mm (opt. extra) 380mm 360 mm (opt. extra)
Steering wheel ratio in the middle 22.39:1 19.15:1
Turning circle Ø 10.3 10.08 m
Track circle Ø 9.5m 9.21 m
Steering wheel turns from lock to lock 4.02 4.02
Technical Data - Rear Axle 924
Wheel suspension

Springing

Torsion bar





Shock absorbers

Stabilizer up to end model 77
from model 78

Spring strut adjustment (angle of spring strut) up to end model 77
From model 78
With 22 mm torsion bar
with 23.5 mm torsion bar
(for relevant models see above)
Independent wheel suspension on semi-trailing arms
One round torsion bar per wheel, transverse

22mm
23.5 mm in conjunction with stabilizer
14 mm
23.5 mm from model 81 USA, Canada, Japan from chassis no. 92 АО 430199 (Sept. 79)
Double-acting hydraulic shock absorbers
Standard Opt. extra 018 mm
Standard Opt. extra 014 mm*

23°


23°40'
19°

* Model 80 for USA, Canada, Japan not as individual optional extra (M 404)
Model 81 and some of 82 (up to end Sept. 81 ) only export in conjunction with M471
Technical Data - Rear axle 924 turbo
Rest of world (USA, Canada, Japan - opt. extra) USA, Canada, Japan - basic model (from model 81 see ROW)
Wheel suspension
Springing
Shock absorbers


Torsion bar Ø
Spacers
Stabilizer Ø
Independent wheel suspension on semi-trailing arms
One round torsion bar per wheel, Transverse
Double-acting hydraulic shock absorbers
F+S F+S
(Opt. extra Koni) (Opt. extra: Koni)
23.5 mm 23.5 mm
21mm per wheel -
14mm -
USA, Canada, Japan from model 81 — (Opt. Extra for USA, Canada, Japan from model 81 14 mm in conjunction with Koni shock absorbers and 23 mm front stabilizer)
Checking Rims
Points for measuring vertical and lateral runout on outer and inner rim shoulders. Dimension "a" = 8mm
Max. permissible vertical and lateral run-out
With light alloy rims = 1.0 mm
With steel rims = 1.25 mm Note
It is not permitted to straighten twisted rims.


Tires, Wheels, Tire Pressures
Information about permitted lire/wheel combinations is contained in the vehicle documents or Technical Information bulletins.

Tire pressures (summer and winter tires) measured with tires cold
924 924 turbo
front 2.0bar(29psi) front 2.0bar(29psi)
rear 2.0bar(29psi) rear 2.5bar(36psi)
Spare wheel 2.2bar(32psi) Spare wheel 2.2bar(32psi)
924 up to model 79 Rims Tires
Front and rear 51½Jx14 165 HR 14
from model 79 6Jx14 185/70 HR 14
924 turbo from model 79
front and rear 6Jx15 185/70 VR 1572

Wheel Alignment Adjustment Values 924/924 turbo
The following values apply to curb weight in accordance with DIN 70020 (car with full fuel tank, spare tire and tool kit)
Adjustment value and tolerance Max. difference left to right
Front axle Toe-in (pressed with 150 N/15 kp) +10'±5'
Track difference angle at 20' lock -40' to -1º50' may be affected only by replace-ment of steering arms
Camber -20'±15' 10'
Caster +30’
2°30'
-15’ 30'
Rear axle Toe-in per wheel 0°±5' 10'
Camber -25'±30' (-1°±20') 30'
Spring strut adjustment* (angle of spring strut) Up to end of model 77 From model 78 23° 0.5°
With Ø 22 mm torsion bar 23°40' 0.5°
With Ø 23.5 mm torsion bar Application of Ø 23.5 mm torsion bar: in conjunction with Ø 14 mm stabilizer from model 81, all USA, Canada, Japan models from chassis no. 92А0 43 0199 (Sept. 79) 19° 0.5°

Vertical adjustment** (from model 7 Center of strut bearing (torsion bar center) under wheel center Adjustment value and tolerance 3.5 ± 10 mm (8 ±10 mm) Max. difference left to right 10 mm 10 mm
Specifications for USA, Canada, Japan in brackets
* 1' change in spring strut angle corresponds to approx. 6 mm change in vehicle height with  22 mm torsion bar 5mm change in vehicle height with  23.5 mm torsion bar
** For USA, Canada, Japan this figure may vary slightly. The important factor is
the bumper height. The distance from the measuring platform (level road . surface) to top edge of bumper must be 522 ± 20 mm.

Brakes

Torque Specifications-Mechanical Brake System 924/924 turbo
Location Thread Tightening torque
Nm (ftib)
Fillister head screw to damping nut M7 13+3(10+2)
Floating caliper to steering knuckle M12x1.5 85 (63)
Brake disk to wheel hub M8 23(17)
Cover plate to steering knuckle M7 10(7.5)
Wheel hub to rear wheel shaft Brake drum to rear wheel shaft M24x1.5
M24x1.5 380 + 70 (280 + 52)
350 ± 50 (258 ± 37)
Mounting bracket for brake line to brake ca
_________________
Life is to short to be looking for something?

[Mike924]

This looks pretty involved, Mikri. What's it all about?
_________________
1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

[Mikri184]

This is everything you could ever wish to know, about our cars, It didnt come through the way I have it formatted, I am reworking it, and will try and repost
It is abit on the confusing side. I am no expert, on doing web publishing, so it got all mixed up in the transfer. Once I have it figured out. I think it will be veyuseful to everyone who owns a 924
_________________
Life is to short to be looking for something?

[Smoothie]

There's a PDF version of the specs floating around on the internet somewhere. I don't recall the address off hand, but a Yahoo search on "924 technical specs" (or something similar) might get it. I was looking at it 1 or 2 years ago.
_________________
"..it's made in Germany. You know the Germans always make good stuff."


'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

[-nick]

The Russian Porsche Club - www.porsche-club.ru has a downloadable zipped copy of it on their website. I think it's a regular .doc file when you unzip it. You just have to navigate the pages in Cyrillic first.

nick

[J1NX3D]

i found it ages back doing a search on these boards.
_________________
'86 944

[Mikri184]

Well I have this info via disk. it was posted on my original web site, (the one Porsche shut down). This info, is different than the info on the pet cd, or the factory manuals I have on disk. As far as I know it was never released from Porsche. I think this info should be on this borad somewhere. if it was possible. I was shocked when I found it, as I beleived all these things I had were gone for good.
_________________
Life is to short to be looking for something?

[ug]

[Smoothie]