H

Fault, DTC Possible causes, remedy, notes 4. Check whether the valve relay is energized (voltage is present at the solenoid valves). To make this check, connect all plugs and the relay. Push back the protective tube on the transverse lock valve plug (in the wheel housing at the rear left). Switch the ignition off, then on again. Battery voltage must be present at the black wire. If no voltage is present continue with DTC 34 (valve relay). Comply with the testing notes. If voltage is present,...

Installing

When installing, ensure that engine temperature is less than 74 C. Flap positioning motor moves to 0 position. 4.) Set adjusting arm so that the air flaps are in the 0 position when the actuating rod is installed. The positioning motor moves to the 30 position. 6.) Check distance a a 16.5 2 mm. The 100 position is set off the 0 or 30 position. Printed in Germany-XVII,1987 Removing and Installing 19 - 19

Note

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 VII, 1983 - Printed in Germany

Info

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. 19-8 Disassembling and Assembling Thermostat Housing VII, 1983 Printed in Germany

Viii

23 parking light, right 9- power window motor, left 12 power window motor, right 9- power window relay 13 power window switch. right 11 rear window defogger switch 7- rear window wiper motor 9 seat rail limit switch 6- seat relay 19- side marker, front left 4 side marker, rear right 18 - sliding roof motor 16 sliding roof switch 9--starter blocking relay (cars with automatic 1 0- temperature switch, coolant 7 temperature switch. evaporator 9 temperature switch, refrigerant 11 tempostat (cruise...

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...

Sa

When tightening nuts for side transmission covers, always remember that there is a Never let the drive pinion and ring gear 2. Measure backlash and, if necessary, change shims Sj and S2 again until specified play is reached. 3. Check backlash at four places on periphery, turning ring gear by 90 each time. Measurements must not deviate from each other by more than 0.05 mm.

Removing And Installing Singledisk Clutch

'87 MODELS ONWARD ENGINE TYPE M 28 .41 Removing 2.Remove complete lower engine guard. 3.Unbolt clutch actuating cylinder, disconnect clutch hose holder from oil pan and allow cylinder to dangle with line connected. Never depress the clutch with actuating cylinder disconnected. 4.Unbolt starter motor, withdraw and leave on bracket. 5.Unbolt exhaust flanges on left and right manifolds and detach air injector. 6.Remove cover from clutch housing. 7.Remove clamping sleeve cap screws and push sleeve...

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)...

General

Accidents or driving conditions similar to accidents may cause various types of damage to steering gears. If the outside of the steering gear is undamaged, tracing of damage is sometimes difficult and requires considerable effort. This, however, constitutes an incalculable risk for the safety of the vehicle as it may lead to steering failure. Due to the fact that a comprehensive check of all steering gear components requires considerable effort and is therefore not normally justifiable or even...

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...

Test point 14 Fuel pump voltage V

Fuel pump relay XX (XXVI) is activated by the LH control unit against ground. To check fuel pump activation, connect terminals 200 and 17 at the LH control unit plug with the test leads and switch on the ignition. The relay will be energized and the pump will run. If the pump does not run Check fuse No. 42 (38). If the fuse is in good working order, remove the fuel pump relay and connect terminals 87 and 30 at the base of the relay. The fuel pump must then run. If the pump runs, check the relay...

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...

Cd

Ignition pulse to control unit 2 (right) Possible Causes, Elimination, Remarks Test point 1 Idle speed contact Q Ground short Break Check with circuit input test, using 9288 system tester or 9268 tester 9268 tester Select the test step and depress the accelerator pedal. 9288 display Idle speed contact closed Idle speed contact open 9268 display 1332 (idle speed contact closed) 0000 (idle speed contact open). disconnect the plugs from the EZK and LH control units. Using test leads, connect...

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...

If the 9288 system tester is connected make quite sure that no speed range is selected at the automatic transmission

Not all system faults are identified by the RDK control unit as faults. This applies to the RDK control unit itself. If the fault display RDK SHUT DOWN appears and no fault is stored in the control unit, the following points must be checked or confirmed before the RDK control unit is replaced a. Is the control unit plug attached correctly and are the connection contacts between the plug and the control unit in good condition b. When the ignition is switched on, a voltage higher than 9 Volt must...

Ca2

The length of the wires for the push button switch should be about 2 meters, in order to be able to watch the throttle while operating the switch. 3. Turn on ignition and press push button switch with engine stopped. The vacuum servo should move the throttle uniformly to full load position. This requires vacuum. To avoid damaging the female plugs in the multiple pin plug, suitable plugs or the wires described below must be used. Remove insulation on wires with an insulating diameter of approx....

Test point 6

Right front sensor - Renew front sensor, Possible Causes, Elimination, Remarks Lett front sensor Contact resistance to Ub Check front sensor at plug connection with ohmmeter. 1. Ohmmeter at terminal 1 and terminal 2 Display 10 kfl 2. Ohmmeter at terminal 2 and terminal 3 Display 0 0.5 il If measured values are within tolerance, renew the control unit if out of tolerance, renew the front sensor.

Journey 8 of 8 last journey made

Pressure loss detected by 2 switches Right rear wheel (RR) No pressure loss Pressure loss detected by 2 switches Drive - 8 - of 8 RL pressure loss 2 switches open v 270 km h 168 mph > pressure loss 1 switch open v 100 km h 62 mph > pressure loss 2 switches open v 270 km h 168 mph

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...

Co

The diagram shows the interrelations of braking force, cornering force and slip. An increase in braking force causes a very fast reduction in cornering force and consequently in directional control and steerability of wheels. It is well known that absolutely no steering correction is possible when wheels have locked (100 slip the car slides straight ahead in spite of turned front wheels. The operating range of ABS is designed to always provide sufficient cornering force with simultaneous...

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...

Call up the Switch Inputs menu with the Pressure Switch display

Pressure Switch FL closed FR open RL open RR closed Coniune N 3. By pushing the car or, if It is on a hoist, by turning one wheel (for instance a rear wheel), position one of the pressure sensing switches precisely opposite its high-frequency transmitter. This adjustment can be carried out with the aid of the tester at the correct wheel position the display for the RL or RR pressure sensing switch changes from Open nach Closed (assuming that the tire pressure is correct in case of doubt,...

Mk 61

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...

Machining the cylinder head mating surface

Checking the cylinder head for distortion Check the sealing surface of the cylinder head for distortion using a feeler gauge and straightedge. Distortion limit of mating surface 0.05 mm. Warped cylinder heads may be repaired by machining the mating surface. Admissible distortion after machining 0.03 mm 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...

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,...

Important notes when working on vehicles with the tire pressure warning system

Always carry out a tire pressure warning system short test on the respective wheel every time a wheel or tire is changed. After the wheels have been finally balanced or after running on the test bench, erase the fault memory in the tire pressure warning system control unit. If Club-sport vehicles are fitted with winter tires, remove the spacer on the rear axle if necessary. This is only necessary if the vehicle is fitted with permitted rims having a different offset, if the spacers are not...

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...

Adjusting Shifts

Insert locking sleeve and spring for no-play arrest of 2nd and 3rd gear shift rod and move to correct installed position with a locally manufactured holder (see page 34-215 . 3 - Shift rod, 4th and 5th gears 7 - Shift rod, 2nd and 3rd gears 1. Adjust preselector spring (2) with adjusting pin (1) enough that it just barely touches the roller of preselector lever (4). In this position shift arm (6) and preselector lever (4) will engage in openings of 4th and 5th gear shift rod. 2. Measure force...

Flushing the airconditioning system with refrigerant R 12

If humidity has entered the system during assembly of the air-conditioning system or as result of r placement of individual parts, the following procedure must be followed when refilling the system 3. Fill approx. 500 g refrigerant. 4. Switch on the air-conditioning system and allow the compressor to run for approx. 1 min. Ensure that valves 6 and 7 are closed on the service unit.

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....

Instructions

Lift rearview mirror off the subplate, following a line parallel to the windshield. Unscrew sheetmetal screw from A-pillar. Unclip front clips by pulling down right and left-hand sides of headlining. Press top of A-pillar linings to the inside and pull out. Cover instrument panel to avoid staining or damaging the panel. Attention The door windows must not be closed before the curing time has elapsed. Cover body in visible area of windshield aperture with adhesive tape to protect the paintwork....

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

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...

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...

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...

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

L

Initiate the testing step for the air-conditioning control to the LH control unit (terminal 14). Initiate the testing step for speed reduction on automatic vehicles. Set the air distribution slide switch to up down. Switch on the air-conditioning system briefly (AC pushbutton). The LED must go out and the following display will appear. This testing step does not apply to vehicles with manual gearboxes. Press the green key untii the clear symbol appears. After a short period, the display 1000...

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...