Porsche 928 Gts Distributor Positions

1. Remove air guide hoses.

2. Unscrew two self-tapping screws and take off upper air guide section from above.

Porsche 928 Starter Motor Location
5. Turn engine in direction of rotation to TDC (cyl. 1). Marks on camshaft and flange bearings must be aligned in this position.

CHECKING AND ADJUSTING TOOTHED BELT (32 VALVE ENGINE)

1. Remove air guide hoses.

2. Unscrew two self-tapping screws and take off upper air guide section from above.

3. Unscrew and take off distributor caps and toothed belt cover upper section on righthand side.

4. Unscrew and push toothed belt cover upper section on lefthand side forward.

3. Unscrew and take off distributor caps and toothed belt cover upper section on righthand side.

4. Unscrew and push toothed belt cover upper section on lefthand side forward.

8. Slide special tool on released belt section of toothed belt {sliding shoe on smooth surface, roller must fit in tooth gap).

9. Press down tester on housing (arrow 1) slowly until gauge tip resting on air pump bracket (arrow 2) engages.

6. Turn engine two more turns until TDC mark is reached again and then continue turning while checking toothed belt for wear and damage.

7. Prepare Special Tool 9201 for checking. Pull out lock pin on special tool and move testing pin opposite the lock pin to starting position. Place drag needle on gauge needle.

6. Turn engine two more turns until TDC mark is reached again and then continue turning while checking toothed belt for wear and damage.

7. Prepare Special Tool 9201 for checking. Pull out lock pin on special tool and move testing pin opposite the lock pin to starting position. Place drag needle on gauge needle.

8. Slide special tool on released belt section of toothed belt {sliding shoe on smooth surface, roller must fit in tooth gap).

9. Press down tester on housing (arrow 1) slowly until gauge tip resting on air pump bracket (arrow 2) engages.

Read test value without tension in tester, i.e. tester must be kept horizontal to the toothed belt. Tester must not rest on the plastic cover,

Sliding shoes must rest on belt with their entire surface. Special tool must not be turned or moved on the belt during the entire checking procedures.

Checking and Adjusting Toothed Belt

Note

The drag needle must always be placed on the gauge needle after the lock pin has engaged to exclude erroneous gauge readings (turn anticlockwise).

10. Pull out lock pin to have gauge tip disengage.

Important

Engine must be turned to position described in point 5 for this test.

Repeat test one or two for checking!

Correct belt tightness if necessary.

Adjusting

The toothed belt adjusting screw is located on bottom of engine at front righthand side.

Loosen lock nut of adjusting screw and turn adjusting screw until correct toothed belt tightness is reached. Tighten lock nuit. Turn engine two more turns and recheck belt tightness.

Screw tightened - belt tightened. Screw loosened - belt loosened

Note

Never turn engine anticlockwise, because toothed belt could jump off if tightness were insufficient.

REPLACING TOOTHED BELT (32 VALVE ENGINE)

1. Remove air cleaner intake hoses.

2. Unscrew air guide on radiator at top and bottom, and remove.

3. Loosen and take off drive belts for alternator, power pump, air pump and air conditioner compressor.

4. Disconnect cables for throttle, cruise control and automatic transmission. Remove retainers and clamp on console and place cables outside.

5. Loosen and remove fan console on engine.

6. Pull off left and right ignition leads on distributor cap. Unscrew and place distributor cap aside.

7. Take off both distributor rotors. Disconnect plugs for A/C compressor and toothed belt tightness indicator.

8. Unscrew toothed belt cover upper section on both sides and take off righthand upper section.

9. Unscrew power pump on console and let it hang down on its hoses.

10. Remove clutch slave cylinder. Take off clamp on clutch hose holder and remove push rod. Let cylinder with connected line hang down.

Note

Camshafts may be turned without damaging the valves after aligning the 45° mark.

12. Mount Special Tool 9161 / 1 with original screws to hold the crankshaft.

14. Loosen and unscrew guide tube for oil dipstick.

15. Unscrew console with alternator on engine.

13. Unscrew bolt {wrench size 27 mm) on crankshaft and take off both pulleys, vibration damper and collar.

14. Loosen and unscrew guide tube for oil dipstick.

15. Unscrew console with alternator on engine.

Never operate clutch pedal after removing the slave cylinder.

11. Align mark for 45° before TDC (cyl. 1) on vibration damper with red needle by turning crankshaft clockwise.

16. Undo center toothed belt cover, remove left-hand upper section and center toothed belt cover.

17. Slacken toothed belt by turning toothed-belt tensioner.

18. Unboit and remove tensioning roller bracket.

19. Remove toothed-belt from right-hand side over cylinder 1 - 4 camshaft sprocket, water-pump sprocket, cylinder 5 - 8 camshaft sprocket, oil-pump sprocket and crankshaft sprocket.

Installing

1. Installation of toothed belt is the reverse of the above sequence.

2. Turn camshafts to mark and hold firmly in this position.

3. Then turn engine in direction of rotation to ignition TDC (cyl. no. 1).

Note

Damage may be caused to the valves if the camschafts move suddenly.

4 Once the toothed belt is in position, adjust the settings. See page 15 -101 to 15 -104.

Special note on toothed belt and drive belt

As a rule, make sure the toothed belt and drive belt are not kinked during assembly, packing and storage. Improper handling may cause preliminary damage to the camshaft toothed belt that may be the cause for incipient damage.

Replacing toothed belt

Printed in Germany - XXXI, 1993

TOOLS - CYLINDER HEAD {32-VALVE ENGINES)

No.

Designation

Special Tool

Remarks

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