Removing And Installing Heaterair Conditioner

If car has electrically adjustable seats, move seats to rearmost, lowest position easier access). 7.Remove air ducts to the side vents and to the glove compartment vent. 9.Remove bracket for left-hand oddments tray. 10.Unscrew bracket holding control unit of cruise control and move to right. 11.Remove blower cover in engine compartment. 13.Disconnect plug from thermo-bimetal switch and antifreeze unit. 14.Unscrew low-pressure and high-pressure lines from expansion valve...

Disassembling And Assembling Gear Assembly

Remove snap ring and take off clutch K 1 and shims. 1. Lubricate and install axial bearing and split needle bearing. 1. Slide Special Tool 9307 on to the output shaft and position the entire gear assembly upright carefully. 2, Install sun gear and thrust washer. Coated side of thrust washer faces sun gear. 3, Heat ball bearing to about 120 C and press on with a suitable piece of pipe. 4, Install hollow shaft in one-way clutch that shaft turns in direction of arrow. After installation of hollow...

Safety regulations for handling the refrigerant R12

The used refrigerante R12 is known as a safety refrigerant. In other words, this refrigerant Is non-combustible, non-explosive, nontoxic, non-irritating, odorless and tasteless. Nevertheless, you should observe the following points 1. Any contact with fluid or gaseous refrigerants must be avoided. Affected skin areas must be treated like frost injuries wash off immediately with cold water and then consult a physician. Protective goggles must be worn to protect the eyes. If refrigerant should...

Safety notes

Observe the following safety notes when performing body repairs Removal of components may change the gravity center of the vehicle. The vehicle may therefore have to be tied down by additional measures on the lifting platform. If welding or other spark-generating operations are performed in the vicinity of the battery, the battery must be removed as a rule. Rooms designated for body repairs may not be used to stock other vehicles without protection (risk of fire damage due to sparks, battery,...

Removing And Installing Intake Air Sensor

Remove air cleaner upper section and air filter cartridge. 2. Disconnect carbon canister hose and unscrew captive bolts. Pull off multiple pin plug and remove lower section with intake air sensor. 3. Unscrew bolts on intake funnel and take intake air sensor and gasket off of air cleaner lower section. Check seal in air sensor housing and make sure of correct fit. Printed in Germany - iv, 1980 Removing and Installing Pressure Regulator 24-9 Removing and Installing Intake Air Sensor

Modification On Unfinished Door Shell

The opening for the door safety light must be made in spare doors at the door pillar as shown in the case of former version door shells for cars from 1980 models. TROUBLESHOOTING CENTRAL LOCKING SYSTEM - From 1980 Models The central locking system only works with the ignition turned off. If the ignition is turned on, the window lifting relay will interrupt the power supply to the controls. Check fuse no. 21 and both line fuses (0. 4 A fine wire fuses) of left and right controls. They are...

No Work stepInstructions

Clean the vision areas Excess adhesive sealing compound must be removed immediately and the affected vision areas cleaned with cleaning solution (F3). Remove the cover on the instrument panel Inser the A-column panels, clip in the headlining again by pressing up and insert sheet metal screws. Push the inside mirror onto the fixing plate parallel to the windshield. Secure the sun visor bearings with sun visors on the right and left with three slotted oval trim-head tapping screws in each case....

Installing Automatic Transmission Section

If transmission (A) section is installed, the following parts must be transferred from the defective transmission to the new transmission. 1 Front converter housing with mounting 4 Bearing assembly with drive pinion and 1. Take transmission section out of crate and remove protective caps. The outer seal between the transmission case and final drive is missing on transmission section for manufacturing reasons. 2. Drive in outer seal to correct position with Special Tool 9180 (also refer to page...

Removing And Installing Selector Lever Cover Frame

Porsche 928 Pff 928

Remove selector lever grip and take off rubber boot. 2. Move selector lever to position 2 and push rear locking bar forward against stop with a suitable tool (e. g. scribe). 6. Move selector lever to position N and remove frame inclined toward rear. 1. Move selector lever to position 3. 6. Move selector lever to position N and remove frame inclined toward rear. 1. Move selector lever to position 3. 1. Remove selector lever grip and take off rubber boot. 2. Move selector lever to position 2 and...

Removal

Remove air intake hoses and air filter sys- 5. Disconnect electrical connections, remove tem as a unit. retainers and extract injection valves. 2. Slacken holder of exhaust sampler and hose clamps on intake pipe and lift off intake manifold. 3. Remove both untion nuts from fuel-distribution pipe, using a second open-end wrench to counter the nuts. Catch the fuel from the pipe in a suitable container. 4. Remove ignition lead and cable clip from distribution pipe. Disconnect distribution pipe...

Modifications On Shift Valve Housing

The shift valve housing has an additional plastic brake band holder from transmission numbers 169 0626 A 22. 01 Europe, Rest of World and 169 3254 A 22,02 USA, Japan. The cast brake band holders have been omitted on these housings. 1 - Old version with cast brake band holders 2 - New version (install only with plastic brake Only the new version will be available after depletion of old version shift valve housing stocks. Old and new version shift valve housings are interchangeable, however the...

D30

2 - Operation of ABS rear-axle solenoid 3 - Ground, ABS solenoid valve, front right 5 - Operation of pump motor relay on hydrau 7 - Operation of valve relay on hydraulic unit 9 - Ground of acceleration sensor 10 - Speed sensor output at rear right for RDK (tire pressure monitoring system) control unit 12*- Speed sensor output at rear left for RDK control unit* 15 - Voltage supply (+5V) for acceleration sen 16*- Speed sensor output at front right for RDK control unit* 1 additionally for vehicle...

Notes For Disassembly And Assembly

It is essential to maintain absolute cleanliness during all work on the shift valve casing. If possible, spread a plastic sheet on the workbench beneath the parts (moleskin cloths are particularly suitable). After disassembly, wash all parts and blow through with compressed air. 1.Remove plastic valve and chip screen. A - Plastic valve B - Check valve C - Shift pin D - Lock valve K 1 E - Chip screen 2.Remove both mounting screws (arrowed). 3.Hold shift valve casing and sensor housing together...

Info

Voltage supply for the lock hydraulics (energy production) is via a fuse and a relay. The relay and fuse are located in the spare-wheel well. PSD - Fault display I Troubleshooting procedure If the ABS PSD control unit detects a fault in the electronically controlled limited-slip dif- Read out the DTC memory with system tester 9288 and remedy the fault if necessary. This is described on Page D39-223 ff. ferential (PSD), the PSD is switched off for safety reasons and the following fault display...

Note

Porsche 911 Windshield Post Repair Panel

From 1987 models on*, the front brake caliper piston diameters were changed to 44 36 mm (previously 42 36 mm). During the 1989 model year, a further modification was introduced. The piston seal was changed from the scraper ring type to the protective cap type. (Technical Information Gr. 4 No. 1 89) Notes on replacement refer to Pages 47-04 47-05. * On some cars (those for the USA, Canada, Australia and Arab countries), fixed calipers with piston diameters of 42 36 mm were still used in the 1987...

Manual Transmission Controls Case

Disassembling and assembling transmission 34-201 Disassembling and assembling manual transmission ('87 models onward) 34-214a Adjusting shift Adjusting Adjusting gearshift ('86 models Adjusting gearshift ('87 models Disassembling and assembling upper transmission cover with reverse gear arrest . . . 34-219 Disassembling and assembling upper transmission cover ('87 models onward) 34-220 Dismantling and assembling housing cover with oil pump 34-221 Replacing O-ring for spray tube (type G28 57)...

Disassembling Left Control Half And Removing Axial Seat Control Motor

1, Undo threaded connection at front of joint. 2. Turn up height control on transmission tube 4 - Self-locking screw M 6 3. Loosen motor carrier console and unscrew motor (3 self-locking screws). In this position the M 6 countersunk screws holding the seat carrier console could be replaced, if damaged. Disassembling Left Control Half and 72-5 and Removing Axial Seat Control Motor

Test point 15 Engine speed signal from EZK

Use an ohmmeter at the injection valve connection contacts to measure the coil resistance. Important the EZK control unit plug must be attached and the LH control unit plug detached. At the LH control unit plug, connect terminals 17 and 1 with the engine tester leads, using the test leads. Adjust the oscilloscope as stated by its manufacturer. Start the engine with the starter motor. A control signal must be visible on the oscilloscope. Adjust the oscilloscope in...

Safety measures

Porsche 911 Measures

- Ignition and preparation should only be carried out by property qualified personnel under the supervision of a second, responsible person. - All other generally applicable accident prevention regulations must be complied with. - Only ignite airbag units which are in original condition and properly installed. - If ignition fails to occur, do not approach the vehicle until approx. 3 minutes have elapsed. - Allow airbag units to cool down after ignition and observe them carefully. - Avoid skin...

Display resistance

Porsche 928 Engine Lift Points

Test values at 0 C 4.4 - 6.8 kQ If the values are not reached, check directly at the engine temperature sensor. Do not connect both contact tabs to the ohmmeter, but chect each contact tab saeparately against ground (there are 2 independent temperature sensors). Note temperature sensor II supplies the cylinder head temperature to the control unit. It is responsible for mixture enrichment during cold starts and when the engine is warming up.

Check auxiliary control unit burglar alarm

The auxiliary control unit is accommodated in The output signals may only be checked with the central console. the relay fitted. b) burglar alarm primed after closing the rear hood approx. 25 seconds after the internal lighting has gone out (short pulse of approx 0.5 seconds only). 2. Terminal 6 Ground if ground at terminal 9. Remove the relay and check the input signals at the base. 1. Terminal 1 Ground with rear hood open or for as iong as the internal lighting is switched on by means of the...

Closing Slots In Ball Joints

As of September 1982, plastic sealing cord is used to close the slots for the outer setting eccentrics of the front-axle ball joints of new cars. In this way, dirt is prevented from penetrating the joint, making the eccentric easier to operate when servicing. If work has been carried out on the front axle, and especially after realignment of the wheels, close the slots for the outer eccentrics with permanently-elastic sealing material on all cars (arrows). The sealing cord, part No. AKD...

Tire pressures on cars with RDK Important notes

The tire pressure control system takes the effect of tire temperature on tire pressure into account. Despite this, it is possible for the tire not to reach the nominal pressure only in a particular vehicle operating situation. In other words, a pressure loss display may not necessarily appear immediately the car Is driven away. It may also fail to appear after switching the ignition off and on and driving the car away a second time. This merely indicates that the same vehicle operating...

List of Repair Groups

General Technical Data Page 0.1 Engine Engine, Crankcase 10 Engine, Cylinder Head and Valve Drive 15 Air Flow Controlled Fuel Injection 24 Exhaust System Emission Controls 26 Starter, Power Supply, Cruise Control 27 Transmission Clutch, Controls 30 Manual Transmission, Controls, Case 34 Manual Transmission, Gears, Shafts 35 Automatic Transmission, Controls, Case 37 Automatic Transmission, Gears, Valve Body 38 Differential, Transaxle System 39 Chassis Front Wheel Suspension 40 Rear Wheel...

Mk 61

Schulman Telescope

Pull off both plugs on alarm control unit. Contact switch can only be replaced together with the lock cylinder. 3. Leave test lamp connected on term. 30 and make other connection on term. E, 2. Connect test lamp (max. 3 W) on term. 30 and Hn of two-pin plug. When lamp comes on, there is battery voltage and wire to alarm horn and term. 31 on disconnected eight pin plug is okay. Activate the alarm system with S key on both doors and the tailgate. Lamp must come on briefly. 4. Connect test lamp on...

Combined plug connections distinguishing line features

There are several combined plug connections of the same type in the lines for brake-pad wear, speed sensors and HF sensors. The lines in this area can be distinguished from one another as follows For brake-pad wear 2 lines protected by The HF sensor connectors have 1 pin and 1 socket. The connectors for the speed sensors have 2 pins with 2 sockets on the other side. Use 1 or 2 auxiliary cables (own construction) for measurements on the control unit connectors and plug connections with the same...

Removing and installing pressureoperated switches

Removing and installing high-frequency sensor (tire pressure warning system) The front and rear high-frequency sensors (HF sensors) (2) have different cable lengths. The rear sensors have shorter cables. The distance between HF sensor (2) and the pressure-operated switch (3) is approx. 6 2 mm. This distance is maintained as long as the HF sensor holder is not out of shape. 1 Remove the HF sensor fastening screws from the holder. 2. Slide the HF sensor (2) out of the holder. 3. Undo and separate...

Disassembling and assembling manual transmission 87 models onward

Once the selector rodas are in position, secure the oil funnel at mounding holes A. As of MY '92, an oil catcher spray tube is fitted in addition to the oil catcher cone. to faciliatate assembly, turn the transmission on the support until the weight of the layshaft causes ist to fall into the installation position. 17. Install preselect spring, selector rods, selector forks and detente. 17. Install preselect spring, selector rods, selector forks and detente.

A 54 3

Install adjusted complete part in car and mount on clutch pedal. 4. Take piece of wire out of guide rod and adjust clutch pedal to final position. 5. Mount clutch push rod on pedal. Check push rod adjustment and correct if required. 2. Adjust clutch power spring. Distance A between inside of spring retainer and center of bearing shaft should be 43 mm*. If necessary, correct by turning the winged nut. * As of MY '92, dimension A is 21 mm. At the same time, the parts listed under item 1 have been...

Engine tightening torques 32valve engine

Screw-in flange to radiator to engine Oil hose to screw-In flange at upper crankcase section Temperature switch to coolant radiator Regulator housing for coolant circuit to engine Temp, sender unit -coolant temperature M 18 x 1.5 M 20 x 1.5 M 48 x 1.5 M 18 X 1.5 M 18 x 1.5

Removing And Installing Hydraulic Unit

Porsche 928 Gts Power Steering Unit

Turn off ignition and disconnect battery ground wire on body. 2. Remove left intake hose on air cleaner, loosen power steering supply tank on bracket (hoses remain connected), pull off ignition leads on ignition coil and take off left front wheel. 3. Disconnect brake lines as well as brake pressure regulator (no. 4 9) on hydraulic unit. This is done by uncliping brake lines in holders on wheel housing (locks are opened from above). Insert plugs in open brake lines and connections immediately...

If tire pressures are too low the cars road behavior is adversely affected In addition wheels and tires may suffer

If the information system indicates a loss of pressure several times in rapid succession, or if the pressure is indicated as well below the nominal value, this suggests that tjre damage has occurred or that the tire valve or the wheel rim are damaged (see Page 44 - 26). Very slight tire pressure loss occurs all the time, since a small amount of air escapes through the tire rubber (this process is known as diffusion). To avoid damaging the pressure sensing switches, never Inflate tires to a...

Design

The major components of ABS are hydraulic unit, electronic control unit, four speed sensors * and wire harness with relays and overvoltage tripout (on central electric board). These components are integrated in the conventional braking system of cars beginning with 1984 models. The conventional braking system of cars beginning with 1984 models has been changed as compared to that of older models in brake circuit division (now by axles), stepped brake master cylinder (piston diameter of both...

Removing And Installing Governor

Porsche 928 Drain Plug Atf

Loosen intermediate muffler shield and push aside as far as possible. 2. Unlock plug for starter locking and backup light switch by turning up white plastic ring in direction of arrow. Pry off plug carefully with two screw-drivers applied on both sides. 3. Press in cover and remove snap ring with cover. 5. Turn axial holder counterclockwise with a screwdriver inserted in slot (corresponding with position B in sectional view). Absolute cleanliness is necessary for installation of governor. If...

O

Vend Porsche 928

Hall sender knock sensor 2 knock sensor 1 hall sender knock sensor 2 knock sensor 1 potentiometer not applicable with cat. conv. ox gen sensor only wi hcat. conv cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder positioner potentiometer not applicable with cat. conv. ox gen sensor only wi hcat. conv cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder positioner

Test point

Injection circuit The ignition circuit monitoring relay is mounted on the retaining plate shut down for the LH and EZK control units. If an ignition circuit fails, the power supply to the injector valves is interrupted. At the same time one of the two colored LEDs integrated into the relay lights up. Injection circuit I shut down - red LED lights up. Injection circuit I shut down - green LED lights up. Fo troubleshooting, see 928 Repair Manual volume l-A, pages 28-77

Removing And Installing Cable On Vacuum Servo

1981 Porsche 928 Engine Diagram

Press clip out of cap and take cap off of cable. Make sure cable is installed without sharp bends. Cable should have approx. 1 mm play on throttle mounting point. Under no circumstances should the cable be tight when the engine is stopped. TROUBLESHOOTING AUTOMATIC CRUISE CONTROL (TEMPOSTAT) First check the following points when the automatic cruise control malfunctions. 1. Check fuse no. 10 (no. 7 beginning with 1981 models). This fuse is also for the stop lights. 4. Check that electric...

Characteristics of the refrigerant R

Trade designation Frigen R 12, Freon R 12 Chemical designation CCI2F2 (Dichlorfluor- methane) or CF2CI2 (Difluordichlormethane) R 12 is colorless, odorless, non-toxic, non-combustible and heavier than air. Boiling point - 30 C at atmospheric pressure. At higher pressure, R 12 is also still fluid at higher temperatures (e.g. in the pressure bottle). Chemical behavior with respect to other substances 1. R 12 does not attack most metals, particularly iron, copper, brass and aluminum, but lead may...

Accurate adjustment of tire pressures with the 9288 system tester

In view of tire pressure gauges' display tolerances and the difficulty of measuring the temperature of the air In the tire accurately, cars with what appear to be correctly adjusted tire pressures are very often only just above the switching threshold of the diaphragm-pattern pressure sensing switches. When a slight centrifugal force acts on the diaphragm at high speed, an entirely justifiable tire pressure warning is displayed. To avoid this problem, tire pressures in the workshop should...

Checking Multiple Pin Plug Of Control With A Voltmeter Or Test Lamp

Connect tester between terminals 9 and 12. Display 0 volt. Push lever on tempostat switch forward (set). Display battery voltage. 5. Connect tester between terminals 10 and 12. Display 0 volt. Push down lever on tempostat switch (repeat). Display battery voltage. There should be battery voltage at terminal 5. 2. Connect tester between terminals 6 and 12. There should be battery voltage when operating the brake. 3. Connect tester between terminals 8 and 12. Display battery voltage. Pull back...

Test point 16 Injector valves Control system VQ

If the engine can be run, pull off the injector valve plugs one after the other. If the injector valve is in good working order and combustion in that cylinder is correct, engine speed will fall. If the engine cannot be run, check a) Power supply Pull off injection valve plug (to do this, first remove the cover over the ring pipe). Remove LH relay XXV and bridge terminals 87 and 30 at the relay base. Connect voltmeter to the valve plug contacts and ground, using the test leads. Display battery...

A Power supply V

Disconnect the plug at the air mass sensor and connect the voltmeter to plug terminals 2 and 4 using the test leads. Use the test leads to connect terminals 17 and 21 on the LH control unit plug after it has been disconnected. Display battery voltage Remove LH relay XXV and bridge terminals 87 and 30 at the relay base. Display on voltmeter connected to air mass sensor plug battery voltage. If there is a battery voltage display, check the LH relay and its activation. If there is no display,...

Checking And Adjusting Drive Belt

Loosen and remove drive belt cover upper sections on both sides. 2. Turn engine in direction of rotation to TDC (cylinder 1). In this position marks on camshaft sprockets must be aligned with marks on flange bearings. 3. Turn engine two more turns until TDC mark is reached again and check drive belt for damage and wear at the same time. 4. Check drive belt tightness between tension roller and camshaft sprocket on relaxed section of belt with Special Tool 9131. Drive belt tightness is correct...

Read out the tire pressure loss event memory Important notes

From control unit version 02 on, the RDK control unit contains an event memory which stores data on any pressure losses at one or more tires during the last 8 journeys made by the vehicle. It also indicates the road speed at which the event occurred, and whether either one or two pressure-sensing switches were open. This event memory permits conclusions to be reached regarding unnatural pressure losses at one or more wheels. Eliminate the cause of any unnatural pressure loss immediately....

Checking Selector Cable And Backup Light Switch Operation

Move lever to Turn off engine. Correct adjustment of selector lever and selector cable is absolutely necessary for proper Operation of transmission, 8. Adjust selector cable if necessary. 1. Place selector lever in N_, Apply parking and foot brakes. Start engine and idle at about 1000 - 1200 rpm. 2. Move lever to R_. Engine speed must drop as gear engages. Backup lights must light. 3. Move lever to P Engine speed should increase as reverse gear disengages. 4. Move lever to R Engine...

Removing and installing the front sensors

The front sensors are located on the left and right in the driver and passenger footwelis on The installation position is defined by the 1. Disconnect the battery and cover the terminal or battery. 2. Remove the tire pressure warning system (RdK), mirror and ABS control units. 3. Disconnect the plug-in connection. The plugin connection is located on the reinforcement of the front car strut. 4. Undo the tear-off nut with special tool 9259. 5. Undo the hexagon nut with the socket insert. 1....

Disassembling And Assembling Bumpers

The high beam and fog headlights as well as the turn signals are removed or installed with the carrier. Wires are fastened to the carrier with hose clips for protection. The carrier and or panel do not have to be removed to replace single parts. Auxiliary headlights can be replaced after unscrewing the radiator grill and cover frame. Single turn signal lamps and fog headlights can be replaced from underneath the fender. Mark wires to prevent mixups Until introduction of new PU trim, a...

Lever Cable

T14 Pin Connector Porsche 928

Disconnect selector lever cable at transmission and detach cable sleeve at holder. 7. Take off ball head, hexagon nut and mounting parts, 8. Mount wire on cable and pull out selector lever base by applying a jerk forwards. Lower central tube and transmission slightly for this purpose. If light opening of gate and letter N are not exactly opposite each other in cover frame, remove cover frame again and reposition selector lever base in slots. 5. Install cover frame and place selector lever 9,...

Removing and installing the control unit

Porshe 928s Electrical Diagram

The control unit is located on the tunnel below the center console. 1. Disconnect the battery and cover the terminal or battery. 2. Remove the side paneling of the center console on the left and right. 4. Disconnect the plug-in connections at the left front sensor, contact unit, right front sensor, right front sensor, passenger airbag unit and the 2-fold and 6-fold plug-in connections to the main cable bundle. 2-fold and 6-fold plug-in connections under the right side paneling The 6-fold...

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....

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...

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

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

Resurface Cylinder Head Quotes

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

Porsche 928 Climate Control Fix

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...

Replacing Fender On 928 Porsche

REPLACING FENDER END SECTION (OUTER SIDE PANEL) 1. Straighten tail panel and inner frame, and replace outer tail panel if necessary. Check installed position of impact tube mounts. Place car on a platform and take off wheels. Unscrew rear cover in wheel house and remove Remove bumper panel, member and impact tubes (absorbers). Remove side panel trim, side window, luggage compartment cover and insulation material to an extent as required. 1. Cut off fender end section with a cutting wheel,...

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...

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------