Info

No.

Description

Special Tools

Remarks

1

Multi-purpose tool

VW 771

2

Puller

9165

3

Pressure piece

P 85

4

Pressure piece

9154

5

Pressure plate

VW 447 i

6

Pressure piece

VW 433

7

Pressure plate

VW 511

Notes :

- The exploded drawing shows the front-wheel bearing arrangement of cars with sliding calipers.

- If the front axle is equipped with floating calipers, brake caliper, brake disk, guard and steering knuckle are of different appearance and size.

- The following components of four-piston fixed-caliper brakes differ in appearance and size: brake disk, brake caliper, mounting bolts for caliper, outer wheel bearing, wheel hub, guard and steering knuckle.

No.

Description

Removing

Instal1ing

1

Mounting bolt (hex bolts for sliding and floating calipers)

(Panhead bolts for four-piston fixed caliper)

2

Coat threads with Optimoly HT. Torque: 85 Nm (62 ftlb)

2

Spring washer or washer of four-piston fixed caliper

2

Renew if necessary

3

Brake caliper

1

Do not remove brake hose when working on front-wheel suspension, attach to suitable point with wire

4

Hub cover

1

Drive out with multi-purpose tool VW 771 and 9165

5

Clamping nut with Allen bolt

1

Adjust play in wheel bearing. Tighten Allen bolt, torque: 15 Nm (11 ftlb)

6

Thrust washer

1

7

Outer wheel bearing (larger as of 86 models)

1

Inspect, renew if necessary, apply coating of Shel1 Retinax A multipurpose grease

No.

Description

Removing

Installing

8

Front-wheel hub (modified wheel bearing, 86 models onward. No. of teeth on impulse ring for ABS: 45 instead of 90).

1

Clean centering surface for brake disk and apply thin coat of Optimoly TA assembly paste. Pack wheel bearing and wheel hub with Shell Retinax A

9

Radial seal

1

Press out with screwdriver. Take care not to damage seat and impulse ring (vehicles with ABS)

Renew. Press in with VW 433 and 9154. Place VW 511 under wheel hub as support. Pack recess with Shell Retinax A

10

Wheel bearing, inner

1

Inspect, renew if necessary, apply coat of Shell Retinax A

11

Countersunk bolt

2

12

Brake disk

1

If difficult to remove, see P. 46-11

13

Bearing race for outer wheel bearing

1

Heat wheel hub to 120 to 150°C

Heat wheel hub to 120 to 150°C

Models earlier than end of 85

Press out with pressure piece 9154. Place pressure plate VW 511 beneath wheel hub as support

Place in position, press in with pressure piece 9154

86 models onward

Drive out by placing drift in each of the grooves in turn

Place in position, press in with suitable pressure piece, e.g. VW 432

No.

Description

Removing

Installing

14

Bearing race for inner wheel bearing

1

Heat wheel hub to 120 to 150°C. Press out with P 85 and 9154. As of 86 models, the race can also be removed using a drift placed in the grooves.

Heat wheel hub to 120 to 150°C. Place in position and press in with pressure plate VW 447 i and pressure piece 9154. Use VW 511 as support.

- sliding caliper

- floating caliper

- four-piston fixed caliper

2 4 4

Torque: 15 Nm (11 ftlb). Coat thread with Optimoly HT.

16

Spring ring or spring washer

2-4

Renew if necessary

17

Guard (depending on brake system)

1

18

Steering knuckle (design depends on brake system)

1

Inspect front wheel bearing for 15 wear. Remachining is impermissible

Bearing race for outer wheel bearing

2.Use a large screwdriver to lever off radial seal. Take care to avoid damaging the seat of the seal and the impulse ring of cars with ABS.

Bearing race for inner wheel bearing

3.Separate brake disk and wheel hub. Heat wheel hub to 120-150°C.

Bearing race for inner wheel bearing

3.Separate brake disk and wheel hub. Heat wheel hub to 120-150°C.

4a.Cars earlier than end of model year 85: press bearing races out of wheel hub.

Bearing race for outer wheel bearing

NOTES ON DISASSEMBLY AND ASSEMBLY

Disassembl ing

1.Drive off hub cover with multipurpose tool VW 771 and 9165.

2.Use a large screwdriver to lever off radial seal. Take care to avoid damaging the seat of the seal and the impulse ring of cars with ABS.

4b.86 models onward: place drift in each of the grooves in turn and drive bearing races out of hub.

Note:

The bearing race for the inner wheel bearing can be pressed out using P 85 and 9154 as before (cars earlier than 86).

l.Heat wheel hub to 120-150°C.

2a.Install outer bearing race and (cars earlier than end of 85) press in until seated with pressure piece 9154.

3. Position inner bearing race and press in until seated with pressure piece 9154 and pressure plate VW 447 i. Place VW 511 beneath wheel hub as support.

2b.86 models onward: place the outer bearing race in the wheel hub and press in until seated with suitable pressure piece, e.g. VW 432.

4.Press in radial seal until flush with hub.

6.Tighten cap bolt of clamping nut to 15 Nm (11 ftlb), without turning the clamping nut.

7.Recheck setting by moving thrust washer, readjust if necessary.

5.Adjust front wheel bearing, noting the following points: Tighten clamping nut slightly, turning the hub. Slacken clamping nut until the thrust washer can just be moved with a screwdriver under finger pressure. Do not use hub as a lever for screwdriver.

TOOLS

No.

Description

Special Tools

Remarks

1

Press-out tool

VW 267 a

Tensioning device

VW 340

Porche version manufactured by Klann, desription/suppl ier see Workshop Manual (Workshop Equipment 3, Group 4}.

3

Sickle wrench DIN 1810 dia. 80/90

Commercially available, e.g. Saltus

Printed in Germany - XIII, 1986 Removing and Installing 40 - 35

Spring Strut

Disassembling and Assembling Snrina Strut

REMOVING AND INSTALLING SPRING STRUT

1.Working from engine compartment, remove three self-locking nuts on wheel arch.

2.Remove wheel, unscrew flange lock nut and press off upper ball joint with VW 267 a

3.Unscrew self-locking nuts from upper control arm (inside engine compartment).

4.Remove damper mounting bolt.

Installing

Renew all self-locking nuts. Coat rubber bush in mounting eye with Molykote U.

No.

Description

Removing

Instal1ing

1*

Self-locking hex nut

1

Extend coil spring with VW 340 or Klann KL - 0014

Renew and tighten to 60 Nm (44 ftlb)

2*

Washer

2

3*

Damper mounting, upper

1

Coat rubber bush with Molykote U

4

Spring plate, upper

1

5

Coil spring

1

Note arrangement and assembly instructions

6

Protective tube

1

Overall length approx. 170 mm

7**

Booster spring

1

Note installation position

8*

Stop washer

1

Install with grooves down

9*

Supporting cover

1

Boge only

10

Spring plate, lower

1

Mark installation position

Install right way round

11

Damper

1

Check efficiency, renew if necessary. Standard: Boge (black)** Optional : Bilstein (green)

* Same parts as those used in adjustable spring strut

** Same parts as those used in adjustable spring struts earlier than end of model year 1985

Note When:

No.

Description

Qty.

Removing

Instal1ing

1*

Self-locking hex nut

1

Extend coil spring with VW 340 or Klann KL-0014

Renew and tighten to 60 Nm (44 ftlb)

L

Washer

2

Spring plate, upper

1

Coat rubber bush with Molykote U

Ceil spring

1

Note arrangement, tolerance group and assembly instructions. Different spring rates (spring hardness)

r 0

Protective tube

1

Overall length approx. 150 mm

1

Booster spring, up to end of Mod. yr. 85* natural color (35 mm spring travel) 86 models onward black (39 mm spring travel)

1

Note installation position

8*

Stop washer

1 (2)

Install with grooves down,2 washers in 928 S4 "Club Sport Version

9*

Supporting cover

1

Boge only

1C

Spring plate, 1 ower

1

Mark installation position

Instal1 right way round. Boge: black Bilstein: yellow

* Same parts as used in non-adjustable spring strut.

* Same parts as used in non-adjustable spring strut.

Note When:

No.

Description

Qty.

Removing

Installing

11

Adjustment nut

1

Grease thread, recess and contact surface for spring plate with Optimoly TA

Boge and Bilstein are different

12

Threaded ring

1

Boge only. Install with inner bevel down. Coat thread with Optimoly TA

13

Damper

1

Damper design modified, 86 models onward

Damper installation overview P. 40 - 51

Spring installation overview, note P. 40 - 46

NOTES ON DISASSEMBLY AND ASSEMBLY

l.Mark position of lower spring plate relative to damper for reinstallation.

2.Using Porche version Klann spring tensioning device (see Workshop Manual) or VW 340, extend coil spring.

Remove self-locking nut from piston rod.

Remove washer and upper damper mounting.

VW 340

3.When using special tool VW 340, release coil spring by unscrewing each of the expansion bolts in turn.

Note:

A great deal of caution is required when working with the extremely powerful coil spring.

Testing Dampers

Dampers can only be tested properly on a testing machine. Dampers which no longer perform adequately cannot be identified by visual inspection or function testing, which will, however, identify completely defective units.

Note:

Differences between dampers, P. 40 - 51

Boge Pressureless Damper

With damper in installation position, extend and compress by hand. The damper must move smoothly and with uniform resistance throughout its travel. The extension and compression stage damping must be clearly perceptible up to the limit positions. Dampers which have been stored for an extended period should be operated several times in their installation position. Renew leaking dampers

Boge Gas-pressure Dampers

With damper in installation position, extend and compress by hand. The damper must move smoothly throughout its travel. The expansion and compression stage damping must be clearly perceptible up to the final position.

Because of the gas pressure, resistance increases as the piston rod moves further into the damper. Dampers which have been stored for lengthy periods should be operated several times in their installation position.

Renew leaky dampers.

Dampers in which the gas pressure has diminished (damper does not return automatically to the extension-stage stop), but which bear no indication of oily leaks and which fulfill all other requirements can be reused. Dampers which show traces of oil loss and which have depressurized must be renewed.

Bilstein Dampers

Worn Bilstein Dampers can be identified with ease. Measure distance X with damper fully compressed (i.e. as far as possible). If distance X exceeds 35 mm (29.5 mm when new), the damper must be replaced.

Assembling l.Note arrangement of coil springs. See P. 40 - 46 for adjustable spring strut.

See pp. 40 - 47 to 40 - 49 for non-adjustable spring struts. End of coil spring points toward upper spring plate.

2.If parts which affect the height setting of adjustable spring struts have been replaced, begin by moving the adjuster nut to its original position. After installation, readjust height setting as necessary, see Item 5. Lubricate threaded ring or thread and adjuster nut and recess with Optimoly TA.

Note (for information only)

During original assembly of the struts, the adjuster nut is mounted as follows:

Boge spring strut: threaded ring flush with adjuster nut at top (arrow) or threaded ring approx. 5 mm lower.

Bilstein strut: adjuster nut screwed down to bottom.

3.To avoid dislocation of the lower spring plate of non-adjustable spring struts, only 2 spacers may be used per strut for height adjustment. When converting from Bilstein to Boge dampers (pressureless), the white/green spring can be reused if a spacer is installed (P. 40 - 47 to 40 - 49).

4.Because of the 14° offset of upper spring plate to mounting eye (of control arm) when the strut is installed, it may be necessary to determine the position of the lower spring plate as follows when the strut is assembled:

Mount upper spring plate on car. With lower spring plate and coil spring at damper installation position, set damper on lower control arm.

Move end of coil spring to upper spring plate stop. Turn lower spring plate until the spring touches the lower stop as well. Mark position of lower spring plate to damper. Assemble struts as marked.

Note:

- Adjustable spring struts can also be brought to their installation positions by turning the adjuster nut (hold strut at bottom). Turn nut in the direction which allows end of spring to remain against spring-plate stop.

- If a Klann spring tensioner is used (no vise required) the strut can be brought to its installation position with the spring pre-tensioned. Screw self-locking nut onto piston rod (risk of accident).

5.Adjust height setting of adjustable spring struts as neccessary.

Note:

Moving the adjuster nut (spring pre-load) through 5 mm adjusts the vertical setting by approx. 10 mm.

In this context, note the following:

Any one-sided height adjustment also changes the wheel loading. When the load on any one wheel is changed the loads on the other wheels also change. If no wheel-load meter is available, the 2 height adjuster nuts on a common axle should be changed by the same amount to keep the wheel- load difference from left to right within permissible limits. (Difference from left to right per axle, max. 20 kg).

COIL SPRINGS FOR ADJUSTABLE SPRING STRUTS

Two types of front-axle springs are available. The springs have different spring rates (spring hardness). The springs are color-coded.

The springs with green and brown codes are subdivided in tolerance groups.

When repairs are carried out, always install springs with the same color code. As the vehicle height can be adjusted, it is not necessary to select spring groups to suit certain models (e.g. left-hand or right-hand drive).

Coil Spring Part No. 928 343 511 06 (green)

Used in: 928 S with pressureless Boge dampers from September 1983 to end of model year 85.

928 S with Bilstein dampers from February 1984 onward.

Group

Color code

Spring force F where

Ordering

Free length

length Lj = 191 mm

index

(new springs)

1

1 x green

6377 - 6573 N

201

approx. 350 mm

2

2 x green

6574 - 6769 N

202

approx. 350 mm

3

3 x green

6770 - 6965 N

203

approx. 350 mm

Coil Spring Part No. 928 343 511 09 (brown)

Used in: 928 S with Boge gas-pressure dampers as standard and optional extra (sporty - 86 models onward

Group

Color code

Spring force F where length L^ = 191 mm

Ordering index

Free length (new springs)

1*

1 x brown*

6375 - 6570 N

401

approx. 340 mm

2

2 x brown

6571 - 6766 N

402

approx. 340 mm

3

3 x brown

6767 - 6963 N

403

approx. 340 mm

COIL SPRINGS FOR NON-ADJUSTABLE SPRING STRUTS

Three types of front-axle springs are available. The different types are color-coded - blue, white, white/green.

The springs with blue and white coding are subdivided in tolerance groups.

When repairs are carried out, always install springs with the same color coding. As the car tends to settle in the course of its service life and installation of a single spring could upset the vehicle height, we recommend replacement in pairs.

Coil Spring Part No. 928.343.511.01 (blue)

Used in: 928/982 S with Boge dampers

As of start of range up to following chassis numbers:

92 AO 80 0645 928 Europe/rest of the world/Japan 92 AO 81 0714 928 USA 92 AO 82 0127 928 S

Group

Color code

Installed in

Spring force F where length L^ = 217 mm

Ordering index

1

1 x blue

Vehicles

6377...6573 N

301

without air

conditioner

2

2 x blue

Vehicles with

6574...6769 N

302

3

3 x blue

air conditioner

6770...6965 N

303

For a brief period, group 1 springs with spacers were installed in vehicles equipped with air conditioners.

Group 2 and 3 springs without spacers can be installed in these vehicles.

Coil Spring Part No. 928.343.511.03 (white)

Used in: 928/928 S with Boge dampers as of following chassis numbers:

92 AO 80 0646 928 Europe/rest of the world/Japan 92 AO 81 0715 928 USA 92 AO 82 0128 928 S

Group

Color code

Installed

in

Spring force F where

Ordering

length Lj = 211 mm

index

1

1 x white

L-H drive

cars

6377...6573 N

901

2

2 x white

R-H drive

cars

6574...6769 N

902

Group 1 springs with cars. Refer to table

Springs with 3 white of cars. Use group 2

spacers have also been i when replacing.

dots (discontinued) were springs as replacements.

stalled in right-hand drive installed in a small number

Coil Spring Part No, 928.343.511.04 (white/green) Used in: 928/928 S with Bilstein dampers for all cars.

Group

Color code

Installed in

Spring force F where

Ordering

length L^ = 205 mm

index

1

1 x white/

all cars

6377...6630 N

none

green

Effect on Height of Front Axle

1. Front Axle Springs

Springs with approx. 200 N more force at a standard test length (e.g. tolerance group II springs as opposed to group I) increase the height of the front axle by approx. 5-15 mm.

Placing a spacer beneath the lower spring plate increases the height of the front axle by approx. 10 mm. A maximum of 2 spacers per spring strut is permissible.

3.Gas-pressure Dampers (Bilstein)

If Boge dampers are replaced by Bilstein dampers and no further changes implemented, i.e. the same coil springs are reused, the front axle is raised by approx. 10 mm because of the gas pressure in the latter dampers. We recommend use of springs Part No. 928.343.511.04 in conjunction with the gas-pressure dampers.

DAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES

Front axle

Non-adjustable front-axle spring strut

Re

ar Si

axl ngl Do

Ga

ipe ure s P Bo

les res ge Bi

s sure 1 stein

Paint coding, Identification

928/928 S standard

X

0

X 0

X 0

X 0

black* black**

928/928 S optional extra

X

0

X 0

X 0

X 0

green green

Adjustable front-axle spring strut

928 S standard until end of model year 85

X

0

X 0

X 0

X 0

black* black**

928 S optional extra until end of model year 85

X

0

X 0

X 0

X 0

gold gold

928 S standard 86 models onward

X

0

X 0

X 0

X 0

grey grey

928 S optional extra 86 models onward alternative

X X

0

X 0

X 0

X 0 X 0

X 0

X 0

red red gold gold

Optional Extra = Sport Tuning

When removed, the pressureless damper will remain in any desired position. When the gas pressure damper is removed it extends to the expansion stage stop.

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