Removing Drip Rails Porsche 928

Put cowl panel complete with weatherstripping into place and screw in hex sheetmetal screws with washers. Tighten right-hand and left-hand sides of cowl panel with one sheetmetal screw and washer each. Attach adhesive strips and sealing strips. Install upper cover molding complete with sleeves to the locating clamps. Push RH and LH drip moldings onto the retaining rails. Push sleeves into place to ensure smooth transition of upper cover molding to RH and LH drip moldings. Position windshield...

Taking Apart The Rear Interior Of A Porsche 928

Porsche 911 Windshield Post Repair Panel

DISASSEMBLING AND ASSEMBLING HEATER EVAPORATOR 1. Take off expansion valve. Remove temperature switch and pull out capillary tube from guide tube carefully. Remove capillary tube. Disconnect vacuum unit from defroster flaps. 3. Pry off retaining clips and remove sealant from joint. Take apart heater evaporator and remove interior parts. 1. Take off expansion valve. Remove temperature switch and pull out capillary tube from guide tube carefully. Remove capillary tube. Disconnect vacuum unit from...

Checking Air Flow Sensor

Pull off plugs on air flow sensor. 2. Connect ohmmeter on connections 6 and 9. Specification 200 400 ohms Connections 6 and 8 Specification 130 - 260 ohms Connections 8 and 9 Specification 70 140 ohms Connections 6 and 7 Specification 40 - 300 ohms Connections 7 and 8 Specification 100 - 500 ohms Specification 2-3 k-ohms at 20 C 68 F Beginning with manufacturing date 042 (stamped in housing of air flow sensor). 1. Pull off plugs on air flow sensor. 2. Connect ohmmeter on connections 6 and 9....

Test point 16 leads K and L

The diagnostic connection between the EZK control unit and the diagnosis tester is by way of the two leads K and L. If diagnosis is not possible, perform the following checks 1. Continuity test (refer to wiring diagram) Lead L Pin 7 (19-pole diagnosis socket) Lead K Pin 8 (19-pole diagnosis socket) 2. Ground short test (refer to wiring diagram) LeacLL The voltage at Pin 7 (19-pole diagnosis socket) must be > 8 V with the ignition switched on. Lead K The voltage at Pin 8 (19-pole diagnosis...

Removing And Installing Engine

Use fender and bumper protective covers. 2. Disconnect battery ground cable at spare wheel well. 5, Detach windshield washer hoses and engine compartment light wires. 6. Disconnect engine hood supports at top, loosen engine hood bolts and remove engine hood. 7. Remove cap from coolant expansion tank. 8. Remove air intake hoses and entire air cleaner assembly. 9. Raise car. Place piece of wood (locally manufactured) on central tube and rear tunnel brace. 3. Loosen and remove engine compartment...

Porsche 928 Engine Compartment Lid Switch

If cylinder heads had been machined or ground, check that thermostat housing fits correctly afterwards. It must not be installed with tension. If necessary, correct by machining mounting bores. 19-10 Disassembling and Assembling Thermostat Housing COOLING-AIR FLAP C0NTR0L,'87 MODELS ONWARD The cooling air which enters through the new front air dam is regulated from the radiator intake by cooling air control flaps actuated by an electric positioning motor. The control unit for the flaps and...

Checking And Adjusting Microsw1tches On Throttle Housing

Check microswitch A (idle contact). a) Place degree disc of special tool P 228 c on operating lever. a) Place degree disc of special tool P 228 c on operating lever. 2. Check microswitch A (idle contact). 3. Check microswitch B (Full throttle contact). The microswitch will already switch when play in accelerator linkage is eliminated by force on the pedal. The throttle valve should still be closed. Connect a standard buzzer or ohmmeter on both contacts of microswitch. Power must be flowing...

Clutch Linkage Versions

The following modifications have been made to the clutch linkages since the beginning of production. Ball stud (no. 3) for release lever changed from 10 mm dia. to 19 mm dia. Release lever fitted with plastic bushing (no. 2) to take ball stud. Release bearing (no. 5) with vulcanized rubber pads to suppress noise and prevent turning. b large width Available 19 mm dia. Available. Ball socket bushing not available for version 2 (see page 30-21) With vulcanized rubber pads as turning locks (won't...

Info

REMOVING AND INSTALLING HEATER AIR CONDITIONER 2. Disconnect battery ground strap from body. If car has electric seats, run back seats all the way to facilitate work. 3. Pull off impact pad from steering whee and remove horn wires. Mark position of steering wheel to steering shaft. Unscrew nut and take off steering wheel with washer. 2. Disconnect battery ground strap from body. If car has electric seats, run back seats all the way to facilitate work. 3. Pull off impact pad from steering whee...

Removing And Installing Central

Remove self-locking nuts from spring struts in trunk. 3. Disconnect multiple plugs in spare wheel well and pull out downward. 4, Detach parking brake cable at fastener. 6, Remove upper mounting screws of drive plate housing. 9. Remove entire exhaust system, by removing bolts on exhaust manifold and holder, and then pulling exhaust system out of rubber holder. Two people will be required to remove and install a complete exhaust system. 10, Remove exhaust system heat shields. 13, Mark location of...

Breakdown of the repair groups

Notes on assembly application of special tools 6. Diagnosis for the repair groups The Workshop Manual will be updated regularly by means of supplements which must be filed immediately to maintain the usefulness of the manual. Appropriate entries must be made in the record sheet to prove that the manual is complete. The content of this Workshop Manual will be supplemented with Technical Information Bulletins, which will be integrated into the manual from time...

285 V 246 V

If the voltage does not change when the vehicle is raised (by the same amount on left and right), this means that the sensor is faulty. Read out fault memory (in PSD system) with System Tester 9288 after eliminating the fault and erase the fault memory as required. PSD - Diagnosis with system tester 9288 General information The PSD ABS control unit is suitable for self-diagnosis. This means that the control unit can detect, store and output certain faults of the PSD and the ABS. Diagnosis is...

Wiring Diagram Type 928 S Model

The wiring diagram comprises 11 individual wiring diagrams. They are subdivided into coordinate fields. Each individual wiring diagram comprises a part of the central electrical system within a dash-dot frame. This part of the central electrical system shows all the lines and relays required for individual wiring diagram. The ground-connecting points are designated with MP and their location is shown in a vehicle diagram. The 10-pole plugs on central electrical system are clipped together from...

Oil Level Switch

OIL TEMPERATURE SWITCH IMZ49I---------- 13eO 13eO PUMP LOCK DIFFERENTIAL - - 170Q 17 PUMP RELAIS LOCK DIFFERENTIAL ------ 1600 16dO- SWITCHING DEVICE. REDUCED DRIVING UOHT --------------- 7dN- CONTROL FOR ADDITIONAL AIR CONDITIONER----17dN----12dN- CONTROL TIRE PRESSURE CONTROL UNIT------7cP 7cM SEAT MEMORY CONTROL UNIr LEFT---10dP-10dP IN PASSENGER'S FOOTWELL ON CONTROL UNIT CONSOLE IN PASSENGER'S FOOTWELL ON CONTROL UNIT CONSOLE

Test point

Rear axle Comply with note under test point 10 Front left ABS valve (DTC 31). DTC 33 For troubleshooting, proceed as for DTC 31, but use PIN 2 Instead of To check the internal resistance of the ABS valve (after pulling off the 12-pin plug at the hydraulic unit), measure between PIN 5 and PIN 4 (instead of PIN 1 and PIN 4). Certain faults in the ABS valve area (short circuit to plus or short circuit to ground in a control wire) may also be shown as valve relay faults by the 9288 system tester. A...

Service Installing Side Guard Strips

Drill 10 mm dia. holes for the sockets and one 6.5 mm dia. door hole at rear. In longitudinal direction drill holes that rear door hole is at center of seal recess and all strips begin about 3 to 4 mm behind the door or fender edge. (outer edge of door shoulder to center of strip) Press in sockets and make sure that tongues engage behind metal edge. When service installing these strips, first draw the door's strip on the door according to specified dimensions and then align and drill holes for...

Porsche 928 Gear Repair

Unscrew pressure line and return line at steering gear. 6. Remove five bolts from reinforcement plate on 9. Now remove the four mounting nuts and take engine carrier. steering gear out of studs on engine carrier. 1. Slide universal joint on to steering gear in correct position (steering wheel and steering gear in center position). Nuts on steering should only be screwed on slightly (facilitates assembly). 2. Mount steering gear. Produce 8 mm clearance between steering gear and universal joint...

Installation Notes

Arrangement of Bimetal Plate Sets for Tensioning Roller Use correct adjusting screw to match number of plate sets. 8 plate sets adjusting screw 928. 105.075.00 7 plate sets adjusting screw 928.105. 075.01 Installing Tensioning Roller Housing 1. Fill one third of housing with SAE 90 transmission oil. 2. Hold housing at an angle and slide in entire piston with bimetal plate sets and support disc. 3. Push piston in housing until oil leaves the discharging bore and piston is felt to be against the...

Removing And Installing Blower

Air Conditioners With Flaps

Mark position of engine hood and remove engine hood. 2. Take off right windshield wiper arm. 6. Remove three mounting screws from blower. a) To accomplish this, open flap of intake housing (move control switch lever to AIR COND. ). Unscrew mounting screw with a screwdriver inserted through open flap. Cars without an air conditioner have a hole in the intake housing, which is sealed with a plug. 2. Take off right windshield wiper arm. 3. Remove cover above blower. Unscrew...

Check Engine Lamp

As from model year '91, Californian legislation prescribes a warning lamp which lights up If a part relevant to the exhaust gas fails. As a function check of the warning lamp, it lights up when the Ignition is switched on and goes out once the engine is running when this is started without depressing the accelerator. The warning lamp has a flashing code to indicate a defective fault path. To trigger off the flashing code, fully depress the accelerator pedal with the engine off and the ignition...

Tachometer Repair Porsche 928

UPSHIFT INDICATOR (Only USA in Cars with Manual Transmission) Description and Information The Signals are - engine speed, on Troubleshooting - engine temperature, The upshift indicator is an illuminated arrow integrated in the tachometer. The upshift indicator will light up when it is practical and economical to shift up into the next higher gear. It works in gears 1 through 4 and remains illuminated until the next higher gear is engaged or the operating condition causing illumination of the...

928 Fan Final Stage Plug Diagram

3.) Engine-compartment lid switch Pin 6, plug II and pin 7, plug I Engine-compartment lid closed Reading ohm Engine-compartment lid open Reading 0 ohm - 20 ohm 4.) Temperature switch intake automatic transmission Temperature switch, automatic transmission > 110 C reading 0 ohm < 105 C reading ohm If the values stated are not reached, the sender in question is defective. Function-testing the flap positioning motor 7 (ground) of plug I to pin 5 (0 ) of plug I (approx. 2-4 seconds). The flap...

Adjusting Shift Forks

Insert locking sleeve and spring for no-play arrest of 2nd and 3rd gear rod and move to correct installed position with a locally manufactured holder. A Locally manufactured holder made of 10 x 20 x 45 mm flat steel, with 6,5 mm dia. mounting hole and 2.5 mm chamfer in area of locking sleeve, 1. Adjust operating sleeves with the shift forks that they are exactly in the middle between synchromesh rings in neutral position. 2. Tighten mounting bolts with torque of 25 Nm (18 ftlb). Deviations in...

Adjusting Pinion

Distance E must be calculated from the given design distance R+deviation r inscribed on face of pinion. 3, Install one side cover without O-ring and R for Type G 28. 03 72.70 mm secure with two bolts. R for Type G 28. 05 70. 70 mm 4. Set adjusting ring of universal master gauge VW 385 1 at distance a. 1 Deviation r in 1 100 mm Deviation r on face of pinion is N 18. 5. Install centering discs VW 385 4 on universal master gauge and attach gauge plunger VW 385 14 with dial gauge extension 9150 (20...

Radio

PAGE 02 CENTRAL ELECTRIC (USA, JAPAN) PAGE 1 FRONT END AND ENGINE, ELECTRONIC INGNITION LH INJECTION PAGE 1A FRONT END AND ENGINE (USA, JAPAN) PAGE 2 PASSENGER COMPARTMENT AND INSTRUMENTS PAGE 4 PASSENGER COMPARTMENT AND REAR END PAGE 5 HEATING - VENTILATING - AIR CONDITIONING PAGE 8 ADDITIONAL WIRING DIAGRAM FOR BURGLAR ALARM PAGE 02 CENTRAL ELECTRIC (USA, JAPAN) PAGE 1 FRONT END AND ENGINE, ELECTRONIC INGNITION LH INJECTION PAGE 1A FRONT END AND ENGINE (USA, JAPAN) PAGE 2 PASSENGER...

Assessing the Condition of the Steering System of an Accident Vehicle

The steering gear may remain on the car if all the following conditions are met - No visible damage to front-axle components such as wheels, king pins, control arms, steering arms, tie rods, to frontaxle crossmember, steering shaft, as well as to the suspension mountings at the body. - No inadmissible increase of torque and no binding or stiffness when the steering gear is turned from lock to lock. When moving the steering form lock to lock, the front wheels must be off the ground (front axle...

Porsche 928 Cylinder Head Resurfacing

Cylinder head refacing dimensions and identification Engrave on exhaust side between cylinder 2 and 3 as well as 6 and 7, respectively, on the casting lug below the cylinder head cover sealing surface. Height of N character 6 mm Machining cylinder-head mating face (32-valve engines) 7.Roughen valve guides with Special Tool 3120. It is essential to use petroleum as a lubricant when roughening valve guides. During this operation, withdraw reamer frequently to remove chips. Once bore has been...

Test point 5

Load signal From LH control unit terminal 25 a lead runs to EZK control unit ter- Fault code 2 21 minal 9 and transmits a signal representing actual load. If a fault occurs here, check the wiring and the plug contacts. If the load signal is not present at the EZK control unit, the ignition is retarded in the part-load operating range by up to 25 CS (full load mapped zone, as protective circuit). Renew the control unit if necessary. Test point 6 Transmission protection switch To protect the...

Pressure And Temperature Specifications

High-pressure in the refrigeration circuit plotted against air-intake 2.Set temperature regulator to max. cooling output. After running for approx. 10 minutes at a speed of 2000 rpm with compressor switched on, the pressures and temperatures must be as shown in the graphs below. Low-pressure in the refrigeration circuit plotted against air-intake temperature. Temperature of air at the central vent plotted against air-intake temperature. Printed in Germany - XIII, 1986 Pressure and Temperature...

Specifications For Air Conditioner

Refrigerant capacity Refrigerant oil in compressor Power requirement of compressor clutch Seal on receiver-drier Relief valve on compressor 350 cm 12 ounces of Suniso No. 5 GS or Texaco Cappela E or similar Seal ruptures at 117 3 C 242 * 5 F -a pressure of approx, 45 bar 64 0 psi Valve opens at pressure of 31 to 35 bar 440 to 500 psi temperature of 95 lo 105 C 203 to 221 F TIGHTENING TOItOl'BS - AIR CON 1)1 T) ON El

Checking Control Panel

The test is conducted with the connector housing withdrawn. 3.Connect voltmeter to Ter. 1 (plus) and Ter. 4 (minus) If there is no reading, check wiring to seat control unit, if necessary replace seat control unit. 4.Connect ohmmeter to Ter. 1 and Ter. 4. Reading approx. 240 ohm Press key 3. 5.Connect ohmmeter to Ter. 2 and Ter. 4. Reading ohm Press memory key. Reading approx. 0 ohm

Checking burglar alarm

There is a relay in the central console of USA vehicles which operates fog lamps and brake lamps as an visual warning in addition to the alarm horn. 2. Terminal 30 Battery voltage 3. Terminal 15 Battery voltage with ignition switched on 4. Terminal 61 Battery voltage with engine running 5. Terminal T Ground with doors open or rear hood open. 6. Terminal MK Ground with engine hood open or radio removed. 7. Terminal A Ground with key in lock cylinder (doors or rear hood) turned in open direction....

928 Spoiler Adjustment

Rear Window Removal For Porsche 928

Insert, align and secure lower trim panel with Removing Side Rear Spoiler 1. Lift spoiler with a narrow putty knife about 5 cm behind the spoiler's front edge enough that the Phillips screw underneath is accessible and can be unscrewed. 2. Provide access to second metal screw (arrow) about 25 cm behind spoiler's front edge and remove screw. 1. Lift spoiler with a narrow putty knife about 5 cm behind the spoiler's front edge enough that the Phillips screw underneath is accessible and can be...

Bumpers

Removing and installing bumper 63-2 Removing and installing nose panel, '87 models onward 63-4a Disassembling and assembling Removing and installing Removing and installing power window operating switch 64-1 Installing adhesive plate for inside rear view mirror 64-2 Bonding the interior rearview mirror in place 64-2a Removing and installing Removing and installing the bonded windshield 64-7 Removing and installing the bonded rear side Removing and installing windshield - 2-pack Removing and...

Correct disposal of airbag units

Airbag units are pyrotechnic objects and can represent an environmental hazard on account of their character as explosion-risk bodies and because of the materials they contain. For this reason, airbag units which have not yet been ignited, or complete vehicles containing such units must not be treated as normal'' waste or disposed of on any other final refuse dumps. To avoid possible misues, the airbag units must first be rendered harmless by electrical ignition, making sure that all the...

Removing and installing the pressure reservoir

Brake Bleeder Collection Bottle

Pull off plug on the pump motor with the ignition key in position 0. 2. Completely depressurize the system. For this purpose, slowly open the bleeder valve on the lock solenoid valve and drain the brake fluid into a collection bottle. Important The system Is under a pressure of up to 180 bar. Wear goggles and protective gloves. 3. Undo the pressure reservoir (No. 5). Use a universal filter wrench - e.g. Hazet 2171-2 -for this purpose. Important Never loosen at the filler screw X, as the gas...

Removing And Installing Transmission

Remove battery (only for cars with bolted bat 1. Disconnect ground strap at battery. 2. Loosen rear wheels. Engage 5th gear. 6, Turn one rear wheel (holding wheel on opposite side) to position coupling bolt between input shaft and drive shaft, and remove bolt. 3. Loosen parking brake cable at connector. Unscrew locknut and pull out cable toward rear (only for cars with welded battery console). 4. Remove nuts on spring struts in luggage compartment. 7. Move shift lever to neutral and...

Connection in the 928 S

The diagnosis socket in the 928 S 4 is located on the retaining plate of the EZK control unit. After connecting the tester, the following display must appear. If this ts not the case, check the tester terminals and or the power supply to the diagnosis socket in the car by referring to the circuit diagram.

Testing Setting Motor

3.Air-distribution slide at center, bottom, bottom top and top. Temperature regulator slide at 18. Open central vent. 4.Connect voltmeter to terminal 3 (minus) and terminal 11 (plus). 6.Connect voltmeter to terminal 3 and vehicle ground. 5.Connect ohmmeter to terminal 4 and terminal 12. Set temperature regulator slide to 18. Set temperature regulator slide to 30. 7.Connect voltmeter to terminal 8 and vehicle ground. 8.Connect voltmeter to terminal 2 and vehicle ground. Set temperature regulator...

Disassembling And Assembling Synchronizers

The transmission of the 928 is equipped with modified Porsche synchronization for all forward speeds. One of the changes is the omission of circlips, which previously were used to keep the synchronizing ring thrust blocks and shift bands from moving axially. In the new system this is accomplished by a shift sleeve with beveled flanks. Synchronizer ring Thrust block Shift band Stop 2 bevelled flanks Asymmetrical shift band Two straight flanks Short side of shift band must be to right of thrust...

Test point 11

Defective control unit Renew control unit Fault, Fault Code Possible Causes, Elimination, Remarks Test point 12 No power supply to LH control unit (V) Connect voltmeter to terminals 17 and 4 of LH control unit plug with a test lead. Checking current path according to wiring diagram. b) Power supply through LH relay XXV At the LH control unit, connect a voltmeter to terminals 17 and 9, and run to terminal 21 (ground on body) using test leads. The LH relay must be energized. Display battery...

Checkin6 Seat And Mirror Position Control System

1984 Porsche 911 Heater Control

Use the adapter cable (special tool 9269) to check the seat control unit. Precondition for testing charged battery Ter. 30 and Ter. 31 can be picked off at the 2-pole plug for a number of test steps. 2.Lay seat on a trolley and position trolley beside car. 3.Connect adapter cable to seat. 5.Detach control unit, open flap and attach by means of cable clips. 6.Disconnect plug 1. Connect voltmeter to terminal 1 (plus) and Ter. 3 (minus) in plug receptacle. Reading battery voltage Connect voltmeter...

Porsche 928 Engine Rotation

Printed in Germany - XII, 1986 Camshaft Setting, Checking and 15 - 131 CHECKING AND ADJUSTING CAMSHAFT SETTING, 85 86 MODELS ONWARD Timing belt tensioned as specified. Specification 5.0 + 0.3 scale gradations. l.Turn engine in direction of rotation to TDC (cylinder No. 1). Both distributor fingers point left in forward direction of travel. 2.In this position, the marks on the camshaft gears and the flange bearings must also be aligned. 3.At the same time, check the marks (older engines) or...

Adjusting Selector Lever Cable

Note Bolt for range selector lever must be 2, Place range selector lever on transmission tightened for adjustments. 3. Adjust ball end on cable that attachment is possible without tension. 4. Pry off plug carefully with two screwdrivers applied on cable outlet and bar. 2. Remove bolt for range selector lever and pull off lever. 5. Remove switch mounting screws and take off switch. 3. Unlock plug by turning white plastic ring (arrow) upwards in direction of...

Location Of Fuses And Relays In Car 19 80 Model

Fuses are numbered in order from left to right and appear on current flow diagrams as S 1 through S 34. S 1 - Front fog lights S 2 - Not used S 3 - License plate lights, engine compartment light S 4 - Switch lights (front fog lights, tail fog light, hazard lights, rear window wiper, rear window defogger). light for cigarette lighter S 5 - Cigarette lighter S 6 - Windshield wipers, pump for cleaning solution S 7 - Not used S 8 - Sunroof S 9 - Backup lights, mirror control, rear window wiper,...

Porsche 928 Diag

1984 Porsche 928 Wiring Diagram

Check pilot pressure valve operation as described below Use System Tester 9288 to activate transverse lock solenoid (Drive links Check transv. lock menu) with 1 - 2 pulses. Then switch to pressure reduction position and read off gauge pressure after a short interval (to allow for gauge damping). For specifications, refer to p. D39-215. 3. Follow check by bleeding the transverse lock and correcting the reservoir level. - Connect System Tester 9288 along with adapter line 9288 1 to diagnosis...

Safety regulations for handling airbag vehicles

The airbag units are pyrotechnical objects of danger class T 1. Handling, transport and storage are subject to the Law on Explosives. When storing the airbag units, it must be ensured that the padded side faces upward (risk of injury as the result of the airbag unit being catapulted up in the event of accidental ignition). The listed legal regulations apply to the Federal Republic of Germany. The respectively applicable regulations must be observed in all other countries. The airbag units must...

Porsche 928 Rear Side Glass Trim

To the window channel of the rubber seal Place cartridge with window adhesive into bonding gun (C) and apply a continuous bead of adhesive to the window channel of the rubber seal. Press upper trim section (2) into rubber seal. Assemble lower trim section (4) to upper corner section (1) and lower corner section (3), press into rubber seal, assemble to upper trim section (2) and press fully assembled trim molding fully into rubber seal. Place assembly cord for fitting of the rear side window...

Conventional adjustment of tire pressure

If the Pressure Loss fault display appears, tire pressure at the affected wheel must be increased by 0.3 bar or at least to the specified pressure at that wheel. Since diffusion losses are approximately the same at the two wheels on any one axle, the tire pressure at the other wheel should therefore be increased by the same amouint. But do not reduce the tire pressure if too high a value is measured. The specified tire pressures at 20C are front 2.5 bar, rear 3.0 bar 2.5 bar for 17 summer...

Abs Components

Porshe 928s Electrical Diagram

The electronic control unit is located above the hood release handle on driver's side of car (above central electric board in RHD cars). The control unit uses the speed sensor signals to calculate the necessary control and regulation commands for the hydraulic unit. The hydraulic unit is located on the left front wheel house wall. It processes the electric signals coming from the electronic control unit. The hydraulic unit can change the hydraulic pressure to the wheel brake cylinders...

Runout of removed

Lable Parts Dial Caliper

If the brake disc runout exceeds 0.1 mm, remove the brake disc and check runout of the wheel hub. Mark position of disc with regard to wheel hub. 3. Engage dial gauge holder, e.g. Ate Part No. 03.9314-5500.3 01, into brake caliper, determine center position and fit by turning the wing screw. If required, fit dial gauge holder with Ate conversion kit, Part No. 03.9314-5510.3 01 (longer wing screw and bracket for dial gauge if required). Four-piston fixed...

Replacing Ball Stud

Original version with 10 mm ball diameter. M 6 threads (originally this version was without threads, also refer to Replacing Ball 1. Unscrew ball stud after removing clutch (air cleaner removed . 2 - Modified version, 19 mm ball diameter, M 6 threads without washer (was used briefly in standard production). Modified version, 19 mm ball diameter, M 6 threads with washer. Present version, 19 mm ball diameter, M 8 threads with washer. Ball studs are locked with Loctite so that removal must be done...

Equipment required for LHEZK testing

Diagnostic tester 9288 (9268) with connecting leads 1 digital-display multimeter, internal resistance at least 10 MC2 1 Bosch L-Jetronic test lead, Bosch No. 1684 463 093 (check lead for correct polarity at plugs). 2 control-unit plug test leads (to be made up in your own workshop) with two No. 17.457.2 tab connectors, to avoid damage to the contacts in the control-unit plug during testing. 2 adapter test leads, consisting of 4 N 017.483.1 plug connectors with 2 leads ap-prox. 150 mm long,...

Removing And Installing Throttle Housing

928 Starter Solenoid

Take off air cleaner assembly. 2, Disconnect brake booster hose on connecting adapter of intake distributor. a) Disconnect hose from A C solenoid valve on intake distributor, b) Loosen hose clamps on intake pipes and push back rubber sleeves on intake pipes. 1, Connect wires on microswitches as follows Term. 18 black and term, 2 black white on microswitch A (idle contact). Term. 18 black and term. 3 wiite on microswitch B (full throttle contact). 24 - 14 Removing and Installing

Machining Flywheel

The bearing surface for the drive plate on the flywheel can be machined in a lathe when seriously scored or burnt. The metal removal should be kept as small as possible. Wear limit for flywheel thickness 11.8 mm. 2 Smallest possible metal removal Bearing surface machining specifications Surface finish + waviness 0.008 mm. MACHINING FLYWHEEL - Beginning with 1984 Models Engine Type M 28.21

Above Ezk Lh Control Unit

UNDER THE WIPER SYSTEM COVER DN ORIVER'S DOOR - AT SUPPORTING TUBE STEERING CONSOLE ON DRIVER'S DOOR------ SIDE MARKER LIGHT LEFT REAR------- SIDE MARKER LIGHT RIGHT REAR-- BRAKE PAD WEAR CONTACT. SPEED SENSOR LEFT FRONT BRAKE PAD WEAR CONTACT. SPEED SENSOR RIGHT FRONT BRAKE PAD WEAR CONTACT. SPEEO SENSOR LEFT REAR BRAKE PAD WEAR CONTACT. SPEED SENSOR RIGHT REAR FRONT END ENGINE WIRE HARNESS INSTRUMENT PANEL - REAR WIRE HARNESS SEAT DRIVER'S SIDE------

Wheel balancing General

If the wheels are too unbalanced, this not only causes vibrations and shaking of the steering wheel but also results in higher wear on various chassis components. Even if wheels are balanced correctly, uneven running and steering can be caused by excessive geometry faults radial and lateral run-out and irregularities in tires, e.g. material accumulating in one place when rolling under diverse suspension conditions . Extreme care, compliance with instructions and procedures, as well as the...

Removing And Installing Steering Tube

If applicable, take off cover on steering intermediate shaft. 3. Disconnect battery ground wire at body. If car has electric seats, move them completely back to make assembly work easier. 4. Pull off impact pad on steering wheel and remove horn wires. Mark position of steering wheel on steering shaft. Unscrew hexagon nut and take off steering wheel with washer. 5. Unscrew cover underneath instrument cowl not on older models and cover underneath steering column switch.

Removing And Installing Selector Lever Cover Frame

Removal of the new version with locks, on the other hand, requires unlocking both locking bars. 3. Move selector lever to position R, disconnect gate and push forward as far as possible. 4, Push front locking bar forward against stop with a suitable tool e. g. scribe . 3. Move selector lever to position R, disconnect gate and push forward as far as possible. 4, Push front locking bar forward against stop with a suitable tool e. g. scribe . At the beginning of standard production cover frames...

Machining cylinder heads

As a rule, both cylinder heads must be machined by the same amount to ensure correct seating of the regulator housing. Machine sealing surface of the cylinder head only until a straight surface is obtained. Max. wear limit 146,6 mm. Note for machining of the sealing surface Max. roughness 0.015 mm It machining causes the actual value to be below the tolerance applicable to new parts, use a 1.4 mm thick cylinder head gasket available from the parts service when fitting the cylinder head....

Getting Correct Co Level Porsche 928

Repair Porsche 911 Window Pillar

It is recommended to use the test connection in area of air cleaner housing, if there is suspicion of erratic engine running or when troubleshooting. CO testing pipe for cylinders 1 - 4 is on righthand side, or lefthand side for cylinders 5 - 8. 2. Disconnect oxygen sensor plug and connect CO tester according to supplier's instructions. 3.Install Special Tool US 4492 on CO testing pipe. 4. Check CO. If CO level deviates from specified value, correct the adjustment on air volume sensor. Use...

Replacing Dampers And Slides

Pull piston end brake pad out of piston, 2. Press out damper in direction of brake hose connection. Make sure that bearing surface in housing is not damaged. 1. Coat damper with brake cylinder paste. 2. Insert damper in housing from the brake hose connection side. Then guide slide from piston side into damper so far, that it is positioned between the lips provided for this purpose arrow visible lip .

Replacing Belts For Alternator And Power Steering Pump

924 Starter Removal

Loosen alternator holt, swing alternator in if necessary, detach alternator vent cover and remove belt. 2. Loosen power steering pump bolts, swing pump in and remove belt. 4. Loosen alternator holt, swing alternator in if necessary, detach alternator vent cover and remove belt. 2. Loosen power steering pump bolts, swing pump in and remove belt. 3. Loosen auxiliary air pump bolt, swing pump in and remove belt. Replacing Belts for Alternator and Power Steering Pump 13 - 17

J

Drain Plug Location 1988 Porsche 924s

Remove mounting bolts from rear housing cover. Take off housing cover, applying light taps with a plastic hammer when necessary. 1. Place O-ring in fronr of housing and push in cylinder block. 2. Align cylinder block so that bore of oil suction tube faces down. 6. Pull out oil suction cube with pulling hook. Assembling Compressor Coat all gaskets and seals with clean r frig r t' See page 87 - 01 for types of oil. 2. Align cylinder block so that bore of oil suction tube faces down. 7. Remove...

T

The amount of protrusion can be corrected by tapping with a plastic hammer against face of drive shaft. Check for easy movement of drive shaft bearings by turning shaft by hand. Shaft must turn easily and without binding at any point. If bearings or shaft are damaged, replace entire central tube with shaft and bearings. There are no plans for replacement of individual parts. Checking Drive Shaft Automatic Transmission At the beginning of standard production, manufacturing methods made it...

Checking Fuel Pump Delivery

Hold end of fuel return hose from pressure regulator in a measuring glass approx. 1500 cc . 3, Unplug fuel pump relay from central- electric board. 5. Let fuel run into measuring glass for 30 seconds. See page 24-1 for test values. 1. Disconnect fuel return line in engine compartment. 4. Bridge terminals 30 and 87 with an extra wire. 1. Disconnect fuel return line in rear of engine compartment while counterholding essential . CHECK FUEL PUMP DELIVERY - LH-JETRONIC Beginning with 19 84 Models...

Porsche 928 Clutch Dowel Pins

Connect release lever at ball stud. Place ball stud and ball socket opposite each other and press down release lever toward the rear until the lever engages. 10. First mount coupling on central shaft I. Center bores of coupling on shafts accurately. Install cover for clutch bell housing and slave cylinder. Location of slave cylinder piston rod can be checked through inspection hole. 11. Install lower body brace, if applicable, positioning correctly....

Tire and wheel overview tire specification character

For a tire and wheel overview for summer and winter tires, refer to the relevant Technical Information T , Group 4. When replacing summer tires, check for the correct tire specification character. The specification characters N 0, N 1, or N 2, respectively, help to distinguish summer tires approved by Porsche from other versions of identical tire type and the same tire size. The tires approved by Porsche are also identified in the corresponding Tl. NO, N1 and N2 tires must not be mixed on one...

Bleeding the pressure reservoir

To charge the pressure reservoir, the ignition must be switched on. When the pressure reservoir has been charged, the pump cuts out reservoir pressure is then approx. 180 bar. Connecting the bleed cylinder. Carefully open the bleed connection and allow the pressure level to drop gradually. While this ts being done, the ignition must remain switched off, to ensure that pressure is completely reduced and air expelled from the reservoir. Repeat this procedure several times, making sure that the...

Checking And Adjusting Tension Of Alternator Polyrib Belt

Remove locking pin from - Special Tool and push measuring pin opposite locking pin out as far as it will go. Align drag needle with measuring needle. If necessary, adjust belt tension. The new Poly-rib belts in used '85 models onward 32-valve engines have 6 ribs previously 5 . 1.Contact must be established between the entire surface of the sliding shoe and the belt. While the measurement is being taken, do not allow the Special Tool to turn or its position on the 2.The lower tolerance...

Pressure switch

2 pressure-operated switches offset by 180 must be checked per wheel If the OPEN display appears, - the distance or offset between switch and HF sensor Is too great or - the pressure-operated switch is defective b Tyre pressure less than switching pressure Required display OPEN If the CLOSED display appears, the pressure-operated switch is defective. For practical purposes, the test pressures as used in the short test Page 44-28 are used as tire pressures. Align pressure-operated switch with HF...

Removing And Installing Brake Pedal

Stop Light Switch Installation

Disconnect return spring on brake pedal. Remove shaft for brake and clutch push rod. 1. Move back seat and steering wheel up to make job easier. 2. Disconnect return spring on brake pedal. Remove shaft for brake and clutch push rod. 4. Remove circlip and move bearing shaft toward outside until brake pedal has been run out. 1. Check all bushings and stops for clutch and brake pedals, replace if necessary. Lubricate all bearing and sliding surfaces with a multi-purpose grease. 3. The guide rod...

Possible faults

Break in the circuit Short-circuit to ground If this load signal Is not received by the EZK control unit, ignition is retarded in the partial load area and full load area. Control value for an intact load signal In the event of a fault, check the cable harness with reference to the circuit diagram. This error code indicates a fault in the area of the transmission safeguard switch. These error codes indicate a fault in the area of the knock sensors. Error testing of the knock sensors is an...

Removing And Installing Actuator

1.Remove front left-hand wheel-arch inner panel. 2.Open multi-pin plug holder and disconnect plug. 4.Press retainers together and push Bowden cable up out of holder. 5.Remove footrest in driver's side footwell. 6.Remove carpet and insulator from wheel-arch sidewall far enough to gain access to 3 mounting nuts. 8.Remove actuator complete with holder.

Adjusting Brake Pressure

With the pedal released, the pressure rod must exert no pressure on the brake unit. With brakes bled and engine switched off, move pressure rod at brake pedal by hand to check play and assure adequate clearance at the brake unit. l.Pull brake-pedal arm back to stop. 2.Slacken pressure rod locknut and adjust pressure rod until pivot pin of adapter at brake-pedal arm is slack, or until the specified play is attained at least 10 mm at the pedal . 3.Tighten pressure rod locknut. If a mechanical...

Alarm System 928

The alarm system is switched on and off when locking and unlocking the doors with the S key long key . Beginning with 1981 models the alarm system is also switched off by unlocking the tailgate and switched on by locking the tailgate by way of an additional locking movement with the S key. 2. Disconnect two-pin plug underneath glove box on right side and remove glove box. 3. Pull off heating hose on right side. 4. Press alarm control unit off of brace at the retainer clamp with a screwdriver....

Removing and installing the fuel tank gauge unit

Porsche 928 How Remove Engine

When working on the fuel system, observe relevant safety requirements. Do not remove the gauge unit while the tank is full. 2. Before fitting a new tank gauge unit, remove the transport protector. 2. Undo union nut using Special Tool 9190. Take gauge unit complete with gasket. 1. Always use a new gasket. Coat threads and seating area of union nut with Optimoly TA. 1. Remove luggage compartment floor covering. Remove cover of fuel tank gauge unit. Undo hose clamp, disconnect fuel return hose and...

Adjusting Backlash

Install drive pinion with shims S3 determined for drive pinion adjustment and tighten all bearing cap bolts to torque of 30 Nm 22 ftlb . 3. Install side transmission covers, placing determined shim Stot on ring gear end and tightening all bolts to torque of 22 Nm 16 ftlb . 4. Turn differential in both directions several times to settle taper roller bearings. 5. Install gages, setting gage plunger VW 388 to distance a 80 mm. 6. Turn ring gear carefully to stop by hand and set dial gage to...

Connecting the ignition device Drivers side

Porsche 928 Center Console Plug

Direct to 2-pin plug ol contact unit below steering column . With ignition cable to both gas generators. Run the ignition device out through the door gap to a point in front of the vehicle. Connect the ignition device to a car battery and operate the switch. The driver's side and passenger's side airbag units must be ignited separately. After igniting the passenger's side airbag unit, check that both gas generators have ignited can be identified by both Ignition cable plugs having melted .

Checking the ABS operation

If service operations not directly related to parts of the ABS have been carried out on the brake system, a simple functional check is sufficient. I.e. after starting the engine, the warning lamp in the instrument cluster must go off if the ABS system is o.k. Operations of this type include replacement of brake pads, brake hoses, brake discs, brake booster, tandem master cylinder, brake cables and components of the parking brake as well as brake pipes that are not screwed into the hydraulic...

CChecking the hot wire signal V

Connect the plug to the air mass sensor. Take out LH relay XXV entfernen and bridge terminals 87 and 30 at the base of the relay. Connect terminals 6 and 7 at the LH control unit plug with a voltmeter. Display 1.6 V Blow on the hot wire In the air mass sensor and watch the voltmeter. The voltage reading must change. 1.6 - 5 V d Checking the hot wire burn-off circuit visual check Run the engine with the air mass sensor installed and connected. When an engine temperature of gt 60 C is reached,...

Bleeding steering system

To refill the entire system after installing new steering equipment or lines or after a heavy loss of hydraulic fluid, start engine briefly and switch off again immediately after starting. Repeat this process several times. This will cause the fluid level in the reservoir to drop quickly keep the level up to the max. mark by continously adding fluid. Do not allow the reservoir to empty. 2. Continue the process described in point 1 until the fluid level in the reservoir stops dropping, then...

Important notes for alignment

Porche 924 1987 Cradle Srares

The following must be observed during alignment 2. Height setting alteration in wheel load Corresponds to the specified value. The tolerance range may be used to reduce the difference in wheel load. Should be within the tolerance range for the specified vehicle height. Is lost if the vehicle or front axle have been raised. Is recovered after a longer journey or longer operating period. Exact value can be achieved by pulling the front axle downward in a precisely defined way. Description in the...

Relay Chart 928s

Fresh Air Fan Location 1976 Porsche 911

Location of Fuses and Relays in Car - 1980 Model I II - Rear window defogger XV - Bridge extra cleaning pump III - Not connected XVI - AFC fuel injection IV - Not connected XVII - Fuel pump V Hazard light flasher XVIII - A C condenser fan VI - Window control XIX XX- Headlight combination VII - Headlight cleaner pump XXI - Fresh air blower VIII - Not connected XXII - Defroster XIII - Wiper intermittent action XIV - Bridge start relay for automatic Rear window wiper relay is located on left side...

Glove Box Lamp

HEATED SPRAY JET RIGHT------------ 6cO DOOR DRIVER'S SIDE---------------------7cQ DOOR PASSENGER'S SIDE 7rl COUNIRY CODING RHD---6dL LICLNSE PALTE LIGHTS DOOR CONTACT SWITLH TAILGATE RtAR WIRE HARNESS B-PILLAR B-PILLAR TAILGATE SIDE MARKER LAMP LEFT REAR SIDE MARKER LIGHT RIGHT REAR -7cQ -6cO - 7rL -7cQ -6dQ

Removing and installing the passenger airbag unit

Disconnect the battery and cover the terminal or battery. 2. Remove the instrument panel. 3. Disconnect the plug-in connections at the unit. The airbag unit must always be put down so that the airbag is facing up. The fixing screws are micro-encapsulated. Use new screws for installation.

Checking And Adjusting Rest Position Of Air Flow Sensor Plate

Air Flow Sensor Location

Pull off high tension wire 4 from distributor and operate starter approx. 10 seconds. 2. Upper edge of air flow sensor plate must be flush with beginning of venturi cone or at most a max. of 0.5 mm higher strive for lowest position . 3. Air flow sensor plate must be horizontal and centered in venturi. An excessively high air flow sensor plate setting can be corrected by driving down the stop spring guide pin with a drift and light hammer. Adjust very carefully, so that guide pin is not...

Removing And Installing Differential

2, Unscrew axle Hange bolt and remove axle flange. Preload of the tapered roller bearings could cause tension on the case when tightening bolts for the side covers, which later could impair installation of the rear cover. Consequently the rear cover should be installed before tightening the bolts. Drive in axle flange seal with US 8050 10.

Always use new rubber valves when replacing tires

928 Club Sport Wheels

Attention When fitting tires, always comply with any Instructions on the side walls with regard to direction of rotation or side-specific assembly e.g. arrow or outer inner When fitting tubeless tires, check that the sealing areas of the tire and the disk wheel are clean and look for any damage. With regard to this, always bear in mind that a tubeless tire is sealed by the bead base. If the side wall of the bead were used for sealing, it would be possible for air to escape under extreme driving...

Flushing Atf Cooler And Lines

928 Porsche Braided Fuel Lines

Disconnect return line on transmission case and take off short hose on return line. If ATF smells burnt and there are metal particles, sludge or liner abrasion in oil pan, it is not sufficient to only replace the valve body or transmission. The ATF cooler and lines will also have to be flushed with ATF. 4. Catch ATF running out of feed line. 3. Attach extra hose from ATF charger see Workshop Equipment Group of Special Tool Catalog on return line and flush cooler as well as lines with the...

Troubleshooting Centpal Locking System

Porsche 928 Vacuum Diagram

Unlock driver's door with key Passenger's door is not unlocked Car was not used for longer than 2 days permissible vacuum loss . Start engine briefly and then check lock action. If system is in good condition, it should be possible to operate lock about 10 times. Disconnect blue control line in footwell on left side. Connect vacuum pump to blue hose leading to vacuum tank. Run engine briefly or build up 400 to 500 mbar with pump and observe pressure gauge. Gauge must remain constand without...

Vehicles with PSD

Porsche 928 Psd

The lock control assembly is located on an additional PCB in the ABS control unit. This PSD ABS control unit has 55 pins. Previous ABS control unit versions had 35 pins. When repairs are required, make sure the PSD ABS control unit is not confused with the PDAS ABS control unit fitted to the 911 Carrera 4. To tell the two versions apart, refer to the Part Nos. Control unit for 928 with PSD 928 618 Control unit for 911 Carrera 4 964 618 Notes on ABS troubleshooting for vehicles with PSD General...

1979 Porsche 928 Fuel Pump Delivery Rate

TESTING AND ADJUSTING SPECIFICATIONS FOR CIS 197 8 1979 Models Automatics Electric fuel pump Delivery rate with 1 fuel pump with 2 fuel pumps at least 1120 cc 30 sec. at least 1360 cc 30 sec. Control pressure cold ambient temperature Diagram for control pressure regulator Part No. 928.606.109, 02 Bosch No. 0438. 140. 053 Test vacuum 430 - 600 mbar 350 - 450 mmHg

Installing Camshaft Drive Belt And Adjusting Timing

Engine Porsche 911 Timing Marks

Make sure new drive belts are retightened after driving car approx. 1,000 km. 1. Line up TDC mark on vibration damper with red indicator on cover by turning crankshaft clockwise. 4. Tighten camshaft drive belt to specifications with special tool 9131. 5. Turn engine clockwise two turns to align red indicator and TDC mark. Never turn engine anticlockwise, since this could destroy the camshaft drive belt tensioner. 7. Now tighten camshaft drive belt again. 8. Turn engine clockwise two turns to...

Testing the engine temperature sensor

Fuel Line Repair 911 Porcshe

The switching point must be just before full njtjon Qfi Disconnect plugs from the EZK control unit and the LH control unit. Connect an ohmmeter between terminal 13 and terminal 5 on the LH control unit plug. Short-circuit to ground Short-circuit to positive Break in the circuit Defective engine temperature sensor In the event of an error, check with reference to the circuit diagram. When measuring the resistance of the engine temperature sensor, always measure between the contact lug and the...

Removing And Installing Lower Cover

Instrument Console Porsche 928

A Temperature orifice B Plastic valve C Filler D Oil deflector 3. Remove holder and leaf spring. 4. Remove combination bolts and take off cover with oil tube. A Temperature orifice B Plastic valve C Filler D Oil deflector 1. Check for proper seating of temperature orifice, plastic valve, filler and oil deflector. 2. Mount lower cover, guiding oil tube into bore. 3. Install combination bolts, but do not tighten tighten bolts with 8 Nm 6 ftlb only after...

Porsche 924 Fuel Pump Pressure Switch

Handle Bar Warmer Wiring Diagram

Connect and bleed pressure tester P 378, Set switching valve at position 2. If the control pressure regulator is vacuum controlled, the charts will only show values for the vacuum test method. 5, Produce specified vacuum with the hand vacuum pump, or adjust see Testing and Adjusting Specifications , 1. Connect and bleed pressure tester P 378, Set switching valve at position 2. Engine must be cold for this test, which is absolutely essential for cars...

Disassembling And Assembling Differential

Porsche 928 Side Mirror Modified

Heat ring gear to approx. 100 C 212 F and install. Use local manufactured centering pins as guides. 1. Pull off tapered roller bearing inner race with 2. Drive ring gear from housing with a suitable an extractor US 1078 and Special Tool P 263. mandrel. Claws of both legs might have to be machined. 1. Heat ring gear to approx. 100 C 212 F and install. Use local manufactured centering pins as guides. A - Centering pins local manufacture 2, Tighten ring gear bolts to specified torque. Slide...

Troubleshooting

Battery Hold Down 928 Porsche

Disconnect plug I and plug II from control unit. Connect voltmeter to pin 7 ground of plug I and pin 5 plus of plug II Set the air-distribution slide switch to up down. Connect voltmeter to pin 2 plus and pin 7 minus of plug I 2. Connect voltmeter to pin 4 plus and pin 7 ground of plug I Function-testing the individual senders with an ohmmeter. 1. Temperature sender, cooling water A resistance of between 1000 ohm and 4000 ohm, depending on engine temperature, should be measurable between pin 1...

Service Installing Rear Window Wiper

Porsche 928 Outside Mirror

Mark second hole outside distance 47 mm and also drill. To prevent damage, the surface being drilled should be covered with tape. 5. Open up both holes with a hole saw , Make sure that holes don't have runout. Remove burrs. i. Remove trim from rear lid at bottom, pulling out spreader rivets and pushing trim forward out of holding clips. 2. Mark hole for wiper mount on inside of panel seam with a scribe and suitable template, e, g. a cardboard strip, whose width equals the hole's inside...