This DIY repair and service manual by Haynes, covers all 1976-1982 Porsche 924 cars, including Turbo, with 4-cylinder, 2.0L (1984cc) OHC engines. Transmissions covered include the 4- and 5-speed manual and the RL-Series automatic transmission. Note: this manual DOES NOT cover the 924S with 2.5L engine.
Book Excerpt: 1976-1982 Porsche 924, 924 Turbo 2.0L Repair Manual ENGINE

ENGINE BLOCK | MEASUREMENTS AND CHECKS

1. When the engine block has been stripped and cleaned, place it back on your engine stand with the cylinders facing up.
2. Assemble your tapered bore gauge and insert it in the cylinder bore of the number 1 cylinder (photo).
3. Measure the diameter along the front to the rear and side to side axes of the cylinder bore. As shown in Fig. 1.15, these measurements must be done at a distance of 10mm (approx. 3/8 in) from the top of the cylinder, at the center of the cylinder bore, and at a point about 10 mm (approx. 3/8 in) from the bottom of the bore.
4. Divide a sheet of notebook paper into a grid four spaces down by seven across and record the piston/cylinder numbers (1 through 4) down the left-hand side of the grid. In the first three spaces, record the three measurements (in millimeters) for each of the bores.
5. On the right side of the engine block, just above the place where the alternator is located, you will find a three digit number stamped into the front right side of the engine block. Record this number in the fourth space (honing group). Using this number for each of the bores, refer to the chart in Fig. 1.16 or 1.17 to determine the bore of the cylinders when the engine was assembled at the factory. Write this diameter (in millimeters) in each of the fifth spaces.
6. When this has been done for all four cylinders, compare each of the three measurements you made on each cylinder to the measurement made at the factory (space 5) and record the largest difference between your measurements and the original bore in the sixth space.
7. If the largest deviation (difference) in diameter is less than 0.08 mm (0.003 in), the cylinders do not need to be honed or rebored.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS

ELECTRIC FUEL PUMP | ELECTRICAL TESTING

1. Disconnect the electrical connector at the air flow sensor. 1979 and later models do not have this connection.
2. Disconnect the electrical connectors at the fuel pump (as appropriate).
3. Switch on the ignition. Do not engage the starter motor.
4. Connect a voltmeter to the ends of the plug connector or the screw ends on the wires. A reading of not less than 11.5 volts should be seen.
5. Measure current consumption by connecting one lead on the fuel pump to one lead of the plug and placing a voltmeter in the circuit between the other two leads. A reading of not more than 8.5 amps should be seen.
6. If current consumed is greater than the above figure, replace the fuel pump.
7. Restore all connections to their proper locations after switching off the ignition.

FUEL TANK SENDING UNIT | REMOVAL AND INSTALLATION

1. Disconnect the negative lead from the battery.
2. Remove the carpeting over the fuel tank.
3. Remove the sound deadening blanket, and plywood cover over the gas tank.
4. Remove the plastic cover from the fuel tank sending unit. It is located on the left side of the fuel tank area. A flat-blade screwdriver may be used to gently pry on an edge, but be careful not to scratch the paint or deform the cover (photo).
5. Unplug the three wires from the spade connectors on top of the sending unit. Hook the wiring loom in an out of the way location.
6. A special wrench, part number 2012, may be used to unscrew the sending unit. If one of these is not readily available, use a large channel lock pliers or other such wrench whose jaws cross the diameter of the sending unit hole and engage the slots on each side (photo).
7. The sending unit is loosened by a quarter turn counter, clockwise. Lift it out slowly, allowing the gasoline to drain out.
8. Installation is the reverse of removal. Make sure that the sending unit is completely engages before connecting the wires. The loom is hooked up in the follow order:
   • (blank): brown
   • purple/black
   • yellow/black
   
   The letters are stamped on the raised portion in the center of the sending unit top.

Subject: 1976, 1977, 1978, 1979, 1980, 1981, 1982 Porsche 924, 924 Turbo service, maintenance, repair. ISBN-10: 185010073X | ISBN-13: 9781850100737 | Haynes 80030