Test point

Fuel pump relay Start engine - the fuel pump must operate during engine starting. Switch off ignition. Disconnect control unit plug. Use a test lead to connect terminal 36 and terminal 24 of the control unit plug. Using an additional test lead, connect terminal 3 of DME plug to ground (e.g. door stop). The pump must run. Check in accordance with wiring diagram Test point 22 Tank ventilation valve (V) To activate the tank ventilation valve directly, System 9288 may be used, selecting the Drive...

Tire condition tire pressure

Tires are safety-relevant items that are only capable of meeting the requirements applicable if they are run at the correct tire pressure and with sufficient tread depth. The tire pressures indicated are minimum pressures. The tires must never be run at lower pressures since this affects roadhoiding in a negative manner and may lead to severe tire damage. Valve caps protect the valve against dust and dirt and therefore help prevent leaks. Always screw on caps tightly and replace missing caps....

Machining cylinder bores in upper crankcase section

The upper crankcase section is an aluminium alloy product and contains minute particles of pure sili-cium. In order to have an usable cylinder surface finish, the cylinder bores have to be machined in a manner that the silicium particles protrude out of the aluminium and therefore pistons and piston rings only have contact with the silicium. If it is necessary to machine cylinder bores, they can be restored with a SUNNEN CK-10 CV - 616 cylinder repairing machine for installation of oversize...

Camshaft references

Marking between thrust bearing and cam of cylinder 1 or on rear face Camshaft timing 1 mm stroke, zero clearance Inlet opens Inlet closes Exhaust opens Exhaust closes 7.5 CR after TDC 52 0 CR after BDC 31 CR bef. BDC 1 CR after TDC Inlet opens Inlet closes Exhaust opens Exhaust closes 7.5 CR bef. TDC 370 CR after BDC 31 0 CR bef. BDC 1 0 CR after TDC

Checking belt condition

Visual inspection must not indicate any damage or wear of the belt. Should damage such as cuts, fraying, split seams, chafing etc. be evident on the belt strap, replace the seat belt immediately. Additional checks on seat belts with overload indicator (tear seam) -Airbag equipment After checking operation and condition of this seat belt type, make sure the tear seam above the holder of the belt strap is not damaged. The tear seam serves as an overload indicator to highlight overloading and,...

Adjusting gearshift

Set manual shift lever (No. 3) to idle position. The transverse selector shaft is now in the 3rd and 4th gear shift plane. With the gearshift mechanism adjusted correctly, the shift lever (No. 3) is not Inclined in transverse direction. Undo lock nuts (No. 1) and turn centerpiece of the joint rod (No. 2) until no transverse inclination remains anymore at the shift lever (No. 3). 2. To adjust shift lever, move the shift lever support mount (arrow) to the front or rear until the inclination is...

Fitting toothed belt for balance shaft Note

Handle balance shaft toothed belt with care, avoid twisting or turning as this may cause excessive running noise. Store separately. When replacing the toothed belt, do not undo the mounting bolts of the balance shaft drive sprockets. 1. Rotate crankshaft clockwise until the TDC mark on the camshaft drive sprocket lines up with the mark on the toothed belt cover. The TDC mark on the flywheel (center notch of double-mass flywheel) must also line up. 2. Rotate both balance shafts (without toothed...

Note

Tighten down fastening bolts to specified torque only after the hydraulic engine mounts have been fitted to the front-axle crossmem-ber. The control arm mount must be fitted in exactly the same position marked before removal. 4. Check wheel alignment. Adjust if required. 5. Replace all gaskets, seals and O-rings before refitting. Check for correct location of the radiator in the rubber mounts. 6. Tighten nuts and bolts to specified torque. Tightening torques 7. Add coolant and bleed cooling...

Dismantling and assembling door rearview mirror

Separate mirror base from mirror housing Press mirror glass down into mirror housing. Insert a screwdriver across the bottom aperture into the mirror housing and loosen mirror glass retainer by turning the retaining ring. Disconnect plug for mirror glass heater. Push back sealing cushion on wiring harness. Insert a small screwdriver from the wiring harness side to disengage the insert, pressing at the cables at the same time. Note The insert is now in the preengagement position. To remove the...

Adjusting the front wheel bearings

Wheel bearing clearance is adjusted correctly when the thrust washer may be moved by applying finger pressure using a screwdriver (but not by rotational or levering action). 1. Take off wheel. Lever off hub cap with two tire irons or Special Tool VW 637 2 (lever). 2. Remove pan head screw of clamping nut. Tighten clamping nut somewhat, rotating the hub at the same time. 3. Loosen clamping nut far enough to allow the thrust washer to be shifted barely with a screwdriver. When shifting the...

Removal

Place protective covers on fenders and remove hood. Disconnect battery ground strap. Open tie-wraps at bulkhead. Disconnect cable from cruise control actuator motor and remove hood. 2. Undo fuel lines betwen engine and body, using a second wrench to lock. Catch remaining fuel in a suitable container. Do not kink fuel lines. 3. Disconnect cable for throttle operation. Pull off oxygen sensor connector and undo bracket from manifold. Pull vacuum hose off pressure regulator. 4. Undo ground cable...

Manual Transmission Operation Housing

Removing and installing gear set 34 - 3 Removing and installing drive shaft seal if transm. has not been dismantled 34 - 7 Removing and installing 5th and 6th gear 34 - 9 Determining snap rings for tapered roller bearing and 6th gear gearwheel 34-17 Removing and installing drive pinion and drive shaft 34-19 Dismantling and assembling end Recalculating adjusting shim Dismantling and assembling end shield 34-31 Dismantling and assembling transmission housing 34-37

Determining snap rings for tapered roller bearing and 6th gear gearwheel

Press on tapered roller bearing until it is seated against the stop. Determine dimension between tapered roller bearing inner race and installed snap ring (push up), using a depth gauge, and determine ring thickness according to table. Press on 6th gear gearwheel until it is seated against the stop. Determine the thickest snap ring that can barely be inserted and install snap ring. End play must not be more than 0.05 mm. The following snap rings are available as spare parts Thickness in mm 2.11...

Removal and installation notes

If repairs are limited to the drive pinion and drive shaft, it is not required to remove 1. Determine snap rings for tapered roller bearings and 6th gear gearwheel (refer to page 34-17). 2. Install drive pinion with shift fork and shift rod for 1 st 3nd gear without driver into end shield. 3. Heat 6th gear gearwheel to approx. 120 C and press on. Installation position Flange must face tapered roller bearing 5. Insert drive shaft complete with shift fork and 3rd 4th gear shift rod obliquely into...

Aligning the upper and lower parts of the crankcase Note

When assembling, make sure that there is no offset between the crankcase halves on the facing surface (on the oil pump side). 1. Using a plastic hammer, align the slightly tightened lower part of the crankcase (tightening torque 10 - 20 Nm 7 -15 ftlb.) with the upper part of the crankcase. Carry out the finger-nail test at the joint. 2. Tighten the crankcase with the specified tightening torque (3 stages). 3. Smooth any slight remaining offset at the joint with oil stone. Aligning the upper and...

Dismantling and assembling pistons connecting rod

Tightening torque 1 st stage 25 Nm (18 ftlb) 2nd stage 1 x 90 tightening angle Threads and mating surface must be oiled lightly Lever out, making sure snap ring does not spring away, e.g. by covering with a rag Oil lightly. Observe installation position and tolerance groups Connecting rod with connecting rod bolts Observe matching number, identification S 3 engraved on side Piston ring, 1 st groove Plain compression ring with internal chamfer, 0.4 wide, 45 Piston ring, 2nd groove Taper faced...

Precautions

Increased demands of modern engines on the ignition systems and a desire for freedom from maintenance have led to the introduction of electronic ignition systems in standard production some time ago. Normally the ignition power of electronic systems (of almost all makes) is greater than that of conventional systems and further power increases can be expected in the future. This places electronic ignition systems in a power range where touching live parts or terminals may be hazardous (this...

Crankshaft and cylinder block

Measure at bearing 2, 3 or 4 Bearings 1 and 5 on prisms Crankpin Main bearing web Crankshaft main bearings crankshaft Crankshaft main bearings crankshaft Cylinder bore Balance shaft bearing bore in crankcase or balance shaft cover Bore for bushing in bearing housing Balance shaft 51.971 to 51.990 0.027 to 0.069 0.080 to 0.240

Installation Note

The cylinder head may be fitted with the engine remaining in the car. 1. Place cylinder head gasket into correct position. 2. Fit cylinder head. Tightening sequence 3. Replace gaskets, seals and O-rings before fitting the cylinder head. Tighten nuts and bolts to the specified torque. 4. Top up coolant and bleed cooling system. Warm up engine to operating temperature, check coolant level again and top up if required. For unbolting, follow opposite sequence.

Checking the ATF level

Correct ATF level is an essential prerequisite for proper operation of the automatic transmission. At 80 C operating temperature, the ATF level must be between the 80C min. and max. marks. A Check range at 80'C ATF temperature B Quick-fill device To determine the precise ATF temperature, use System Tester 9288. If required, top up with ATF fluid across the quick-fill device.

Removing and installing transmission Model G 44 Removal

Undo drive shafts at transmission end and suspend horizontally on vehicle. 2. Disconnect connector for reverse light switch. 3. Push shift rod bellows to the rear and unscrew clamping screw. Disconnect shift rod from intermediate lever. 4. Unscrew pan head screws of clamping sleeve across inspection holes and push clamping sleeve towards transmission. To fit the pan head screw into the central tube housing, use an extension with swivel joint (16 angle). Order No. SXW 10 Supplier's address...

Important Vehicle Information

Always turn off the ignition or disconnect the battery for resistance tests. (If this is not done, the tester may be destroyed). Always disconnect the rpm sensor plug for compression tests. (If this is not done, hazardous high voltages and insulation damage to the ignition coil, high-voltage distributor and ignition leads may result). The specified ignition coil (refer to Order No.) must not be replaced by a different coil. Never connect a suppression capacitor to ignition coil teminals 1 and...

Checking and adjusting Poiyrib drive belt of AC compressor

When adjusting the Poiyrib drive belt, the belt thickness must be taken into account. Determine belt thickness with a caliper gauge. The following adjustment specifications are applicable in accordance with the belt thickness determined Scale value indications for Special Tool 9201 Belt thickness Scale value Link rod (mm) After fitting a new Poiyrib drive belt, compensate the settling of the belt as follows Run engine at idle for approx. 15 min. or test drive vehicle for approx. 15 min. Then...

Removing and fitting door outer handle

1 Release mounting screw of Unscrew mounting screw of door outer handle from Disengage door outer handle Push door outer handle forward and take out of from door door hole pattern. Release mounting of door Undo socket hex head screws for mounting of door lock lock outer section and remove outer section and pull plastic grommet for forced-air plastic grommet for forced-air venting off the door, venting Unclip intermediate section from door outer handle Unclip deflection lever at door lock inner...

Diagnosis Troubleshooting Airbag Software level B

The airbag system is continuously monitored by a diagnosis unit in the control unit. If a fault occurs, it is indicated by a script in the instrument cluster. In the event of a fault, the cental warning light and this script come on. The airbag script comes on for approx. 5 seconds* after the ignition is switched on and then goes off again. Should the warning lamp come on again later, this indicates a fault in the airbag system. The fault can be read out with System Tester 9288.

Brakes mechanical

Technical Torque specifications - mechanical brake system 46-05 Checking thickness of brake pads 46 - 1 Removing and installing brake pads 46-3 Adjusting the brake Checking stop light switch Checking and adjusting the parking brake 46 - 7 Checking brake disc lateral Checking brake disc The following topics of Repair group 46 are described in the Repair Manual Type 944, vol. 3 Front-wheel brakes, disassembling and assembling 46- 9 Rear-wheel brakes, disassembling and assembling 46 -11 Brake,...

When you start the engine again only 2nd gear and reverse are available Caution The reverse gear interlock monitor is

The test drive should be used to check if the customer complaint situations actually occur when the vehicle is driven. It is actually preferrable to have the customer drive the car and to check for any potential faults, malfunctions or even for incorrect operation by the driver. Check all functions of the transmission during the test drive All shifts, including in kickdown position in the automatic gate, as well as shifts in the manual gate Various driving speeds Driving in reverse (uphill if...

Dismantling and assembling camshaft drive

Tensioning lever for toothed belt tensioner Treat carefully, do not twist or turn Heat shaft bolt area with hot air gun Use Loctite 270 to bond into crankshaft. Pack lubricating groove with Op-titemp PU 035 grease, Part No. 000 043 110 00. Tightening torque 45 Nm (33 ftlb). Apply a thin coat of Opti-moly HT to mount area. Lettering points to the front. Hexagon head bolt with captive washer M 6x 42 Special note on toothed belts and drive belts As a rule, make sure the toothed belts and drive...

Start of diagnosis

To assess a Tiptronic transmission for which complaints have been received, the information about the fault and the fault occurrence should be as complete as possible. To avoid extra damage during test drives or faulty diagnosis results, the following items must be checked and corrected (if required) prior to the test drive 1. Read out fault memory with System Tester 9288 and correct fault. Battery, connectors, ground points O.K. 2. External damage, leaks at transmission (ATF leaks) or final...

Model 92 Sheet

Cooe number of pins designation. function BRAKE PAD WEAR CONTACT FRONT RIGHT COMBI. LEAD BRAKE PAD WEAR CONTACT FRONT LEFT COMBI. LEAD BRAKE PAD WEAR CONTACT REAR RIGHT COMBI. LEAD COMB. LEAD RIGHT WH PASSENGER COMP. COMB. LEAD LEFT WH PASSENGER COMP. BRAKE PAD WEAR CONTACT REAR LEFT COMBI. LEAO WH HEATER. AIR CONDITIONING, PASSENGER COMP. WH PASSENGER COMPARTMENT ENGINE HOOD SEAT RIGHT WH PASSENGER COMPARTMENT SEAT LEFT WH PASSENGER COMPARTMENT REAR WINDOW WIPER. HIGH MOUNTED STOP LIGHT WL...

D 3738212 inside

Possible causes, elimination, remarks The diagnostic connection between the Tiptronic control unit and the tester is made across the K and L wires. If it is not possible to start the diagnosis with the System Tester 9288, the following checks should be made 1) Check adapter lead 9288 1 for continuity - Check K and L wire at adapter lead 9288 1 for continuity. Socket 3 (8-pin connector) to pin 7 (19-pin connector) Socket 7 (8-pin connector) to pin 8 (19-pin connector) Bushing 3 L wire Bushing 7...

Adjustment of end stop and rotary support

To prevent the headlights from vibrating, the rotary support must be preloaded slightly when it is up against the end stop. 2. Remove cap at pop-up headlight. 3. Mark motor position on knurled wheel. 4. Turn back 2 turns at the knurled wheel. 5. Adjust stop so that the rotary support is up against the stop without play as well as without preload. If the adjustment range of the end stop is not sufficient, adjust at the joint rod. To adjust the cover ring with reference to the fender aperture,...

Checking seat heating

Disengage seat heating switch and pull out switch (take care not to damage the wire). 4. Connect voltmeter to term. 1 (positive) and term. 2 (negative). If no voltage is displayed, check power supply according to wiring diagram. 5. Connect voltmeter to term. 2 (negative) and term. 3 (positive). Display, depending on potentiometer setting approx. 2 - 3 V 6. Push tip switch into on position and keep it in this position. 7. Push tip switch into off position and...

Engine Cylinder Head Valve Drive

Replacing the camshaft toothed belt (with hydraulic belt tensioner) 15 - 1 Adjusting and checking the camshaft - 3 Camshaft adjustment gauge Fitting the Fitting the camshaft Camshaft Machining the cylinder head mating Removing and installing cylinder Dismantling and assembling camshaft drive 15-25

Adjustment overview

When assembling the transmission, the drive pinion and ring gear or drive set only require adjustment if parts have been replaced which have a direct influence on the setting of the final drive. Refer to the following table to avoid unnecessary adjustment procedures Drive pinion adjusting shim S4 Tapered roller bearing for drive pinion Tapered roller bearing for differential Synchronizer hub for 1st and 2nd gear Practical procedure when readjusting the drive set If it becomes necessary to...

Upshifting is not prevented no manual program

Detectable faults Open circuit short to ground short to positive 1) Signal comes from ABS. ABS o.k. 2) Check signal with Tester 9288, raising vehicle and rotating right-hand front wheel manually. 3) Check wiring according to wiring diagram. Check for continuity Pin 12 Tiptronic control unit connector to ABS control unit connector pin 23 4) Check signal with oscilloscope (Tiptronic control unit connector pin 12) (Ignition on)

Ir

CONNECTION AIRBAG WIRING LOOM PASSENGER COMPARTMENT AIRBAG WARNING LAMP INSTRUMENT CLUSTER DIAGNOSIS PLUG CRASH SENSOR BOn CRASH SENSOR MHT CRASH SENSOR MKT CRASH SENSOR LEFT CRASH SENSOR LEFT CRASH SENSOR LEFT passenger's sce. b4teh tablet 3 1 passenger's see. bnton tablet 3 3 passemr-s sce. bftek tafcet 2 1 passeiws sce. bftw t e1 7 7 omr's sc. stem tablet v2 drwrs sce. wtek tablet vi WELDING PDINT CONNECTION WITH FELD INDICATION I I CONNECTION WITH FIELD DATA GP GROUND POINT YE YELLOW RE RED...

Suspension alignment General

Use optical or electronic wheel alignment equipment to check the suspension alignment. For measuring operations, refer to the operating instructions of the equipment manufacturer. The following requirements must be met prior to the wheel alignment procedure Vehicle curb weight acc. to DIN 70020, i.e. vehicle in roadworthy condition with full fuel tank and spare wheel Axle joints and wheel bearing play o.k. Tire pressure to specification, virtually uniform tread depth on all tires If the front...

Adjusting ring gear

Measuring And Adjusting Backlash

Determine total shim thickness S tot Si S2 . The ring gear must be readjusted if the transmission housing, transmission side cover, tapered roller bearings for differential, differential housing or drive set have been replaced. The drive pinion must be removed in order to determine the preload of the differential tapered roller bearings. 1. Make sure the bearing outer races of the tapered roller bearings are well seated in the transmission housing or transmission side cover, respectively. 2....

Wheels and tires of the 968 CS

For black body color, wheels are painted silver. Wheel mounting nuts without theft protection apart from exceptions indicated . 7 1 2 J x 17 in., wheel offset 65 with 225 45 ZR 17 tires 9 J x 17 in., wheel offset 55 with 255 40 ZR 17 tires Observe country-specific usage details Difference angle at 20 turning radius 0 2 10 Vehicle Empty weight according to DIN 70020 with full fuel tank, spare wheel and tools Refer to instructions in Repair Manual for height...

Torque specifications rear axle

Axle control arm to rear axle strut locking nut camber eccentric Axle control arm to rear-axle strut locking nut Axle control arm to transversale tube Stabilizer suspension to rear axle strut an stabilizer Stabilizer fastening clip to rear axle transversale tube Universal shaft to transmission and rear wheel shaft Brake line to brake caliper and brake hose Mounting bracket for brake pipe to trailing arm Individual suspension with light-alloy semi-trailing arms The front and rear suspensions of...

Dismantling and assembling transmission housing

When replacing cover, adjust ring gear Pack space between sealing lip and dust lip with multi-purpose grease. Use Special Tool 9534 to drive in to stop Before screwing in, coat with Loctite 271. Tightening torque 10 Nm 7 ftlb May also be replaced if transmission has not been dismantled. Do not fit until gear set has been installed refer to page 34-7 . Pack space between dust lip and sealing lip with multipurpose grease Pull out with internal puller 30 - 37 mm e.g. Kukko 21 5 , VW 771 15 and VW...

Removing and installing antenna

Cut out roof liner in antenna area at right angles to the direction of travel at a length of approx. 15 cm. 2. Remove upper section of weatherstrip of rear cover. 3. Detach roof liner in spotweld flange area. i i i i i i i m i i i i i i i i m i i . i . r i i i i i i i m i i i i i i i i m i i . i . r 5. Undo screw connection of antenna wire. 6. Undo mounting nut with double socket 17 mm A F .

Model 93 Sheet

SOLENOID VALVE 1 SWITCHING POINT CONTROL SOLENOID VALVE 2 SWITCHING POINT CONTROL SOLENOID VALVE B SWITCHING POINT CONTROL SOLENOID VALVE 4 SWITCHING POINT CONTROL SENSOR IPTCI TRANSMISSION TEMPERATUR CONNECTION TRANSMISSION PASSENGER COMPARTMENT 33 50140 27 45 30 11 32 3 21 29 10 48 12 4 13 55 4 3 25 31 23 51 E 39 49 1 CONNECTION TRANSMISSION PASSENGER COMPARTMENT CONNECTION TRANSMISSION PASSENGER COMPARTMENT NNECTION TRANSMISSION SENGER COMPARTMENT

Removing and fitting side member panel

Hexagon head sheetmetal screw B 6.3 x 16 Hexagon head sheetmetal screw B 6.3 x 16 Hexagon head sheetmetal screw B 6.3 x 16 Preload clips by inserting a screwdriver and unclip them using a second screwdriver Removing and installing badge on cover Removing and installing wheel housing liner Combination sheetmetal screw 4.8 x 19 Removing and installing wheel housing liner Removing and installing wheel housing liner

Cylinder head

Cylinder head to crankcase upper section Camshaft adjuster -VarioCam to cylinder head Inlet flange for heater to cylinder head Camshaft gearwheel to camshaft multi-tooth bolt Distributor rotor to camshaft gearwheel 60' torque angle 2nd stage 90' torque angle 3rd stage 25 - 30 18 - 22 grease thread lightly with Molykote paste HTP white

Changing the transmission oil Rearaxle drive Tiptronic

Porsche 968 Oil Line Replacement

Capacity approx. 0,7 I Oil quantity Hypoid transmission oil SAE 75 W 90 to API GL5 MIL-L 2105 B , or SAE 90 1. Drain oil with the car standing on a level surface and the transmission at operating temperature. 1 - Tightening torque 40 Nm 30 ftlb 2 - Tightening torque 50 Nm 37 ftlb 2. Clean filler and drain plugs, replace seals and tighten screws to specified torque. 3. With the vehicle on a level surface, fill in transmission oil until it overflows at the filler plug neck.

Test points 11 and

The idle stabilizer is designed as a twin-winding actuator with one opening winding and one closing winding. Using the System Tester 9288, actuation of the idle stabilizer may be read directly In the Drive links menu item. If no higher pulse is present, check the following Connect voltmeter with disconnected plug of idle stabilizer terminal 2 and engine ground. Ignition on. Check power supply in accordance with wiring diagram. Checking the control signal Using the System Tester 9288, the idle...

DME control units as of Model Year 92 Engine Type M 444344

Removing and installing knock sensor 1. To remove and install the knock sensors, unbolt the intake rail from the engine. Refer to page 15-21 to 15-22. The coolant hoses remain connected. The intake rail remains in the engine compartment. 2. Undo and take out knock sensors. Disconnect connector. 3. Reinstall with a new genuine M 8 x 30 bolt micro-sealed without washer. Tightening torque 20 Nm 15 ftlb. Note Handle the knock sensor very carefully. The knock sensor must never drop to the ground...

Removing and installing hydraulic control unit Removal

Disconnect connector from transmission Note socket, turning bayonet lock to the left and The control unit is removed along with the Pullin9 off connector, B ATF pan mounting hexagon head nut with washer 2. Remove breather hoses from reservoir and remove ATF pan complete with reservoir. 4. Unscrew hexagon nut for socket. 6. Screw out six fastening screws 12 mm head dia. and take offcontrol unit along with wiring harness. Do not leave control unit suspended at wiring harness 1. Set selector...

Cabrio MODEL 93 SHEET

NOT WITH - MARKED LEADS ARE WRING LOOM PASSENGER COMPARTMENT CABLE LAYOUT DIFFERING FROM SERIES VARIANT WIRING AS STANDARD WELDING POINT CONNECTION WITH FIELD INDICATION I I CONNECTION WITH FELD DATA GP GROUND POINT CLOSED MICROSWITCH OPENED IN ENDPOSITION ROOF ELOSED CLOSED MICROSWITCH OPENED IN ENDPOSITION ROOF ELOSED OPEN MEROSWITCH OPENED IN ENDPDSITION ROOF OPEN

Crankshaft Standard and Repair Dimensions

Repair Dimensions

Crankshaft conrod bearing journal d 2 0 69.971 69.990 69.721 69.740 69.471 69.490 51.971 51.990 51.721 51.740 51.471 51.490 It is recommended to check the availability of bearing sizes prior to machining the crankshaft. Crankshaft - Standard and Repair Dimensions 13 - 31 Crankshaft - Standard and Repair Dimensions

Routing the sensor wire at the Tiptronic transmission

Porsche Transmission Diagram

Assembly of the sensor wire to the transmission has been modified. When repairing the Tiptronic wiring harness on vehicles featuring the former type of fitting, adopt the new fitting type. 1. Fit three wire clamps Part No. 999 651 262 09 . 2. Connect sensor wire to rpm sensor. 3. Attach wire with three wire clips Part No. 999 651 162 40 . 4. Attach sensor wire with two U-clamps to the reinforcing webs of the transmission housing. Routing the sensor wire at the Tiptronic transmission Heating,...

Repairing the Tiptronic wiring harness

Tiptronic Solenoid Remove

Undo right-hand side trim in Tiptronic control unit area. Also remove vibration damper on Cabriolet vehicles. 6. Disconnect transmission wiring connectors. 7. Detach wiring harness from transmission and push it out across hole in passenger compartment. 8. Cut off wiring harness to transmission at a distance of 310 mm from control unit connector. 9. Remove cloth tape along a length of approx. 30 mm. 10. Strip all wires except sensor wire to speedometer along a...

Possible fault displays

- Check door contact wires to alarm control unit plug II terminal 21 for short to ground. - Turn off engine, only switch on ignition. - Turn off engine, only switch on ignition. Fault summary is displayed if several drive links actuators are triggered simultaneously, e.g. if turn signals are on while the function display is checked. - Check wiring to alarm control unit plug I, terminals 8, 9, 10, 11, 12, and plug II, terminal 20, for short to positive. Check connector II, terminal 24 and...

Replacing ignition switch

Requirements for Keylock - vehicles - When removing and installing the ignition switch, the lock barrel must be fitted to the steering lock housing. - The Keylock bowden cable may remain fitted. 1. Pull connector off ignition switch. Uncllp connector housing from steering column housing. 2. Turn ignition key No. 3 to position 0 key can be pulled off . Turn out fastening screws No. 1 of ignition key No. 2 . Extend ignition key carefully. In case of Keylock vehicles, the steering lock housing...

Pin assignments of alarm control unit connector

11 - Motor Closed Actuator door lock 12 - Motor Open Actuator door lock 13 - Rear cover unlocking switch 5 - Luggage compartment contact 10 - Central locking system position switch 11 - Central locking system button 12 - Central locking system position switch 20 - Central locking system button light

Checking Thickness of Brake Pads

Removing and installing brake pads Note The brake pads are changed in the usual manner known from other Porsche models fitted with four-piston fixed calipers. This is why only a short description of the operations is given. Please make sure the following is observed at all times use correct brake pad quality refer to spare parts catalog . Replace damping plates or vibration dampers with new parts whenever the brake pads are changed. The damping plates and vibration dampers are protected by an...

Crankcase markings

Engine Number Porsche 968

Upper and lower crankcase section and balance shaft cover 1. The upper and lower crankcase sections as well as the balance shaft cover are machined as a unit and must always be fitted as a unit. Observe correct identification marking. The engine number is engraved on the right-hand rear end of the engine when seen in the direction of travel. 2. When the components have been fitted, it must be possible to read off the markings of both balance shaft covers from above.

Removing and installing door mirror Removing the door mirror

Undo mirror base mounting Lift off door mirror Disconnect connector Cover mirror housing in the mirror base mounting area to avoid damage. Lift protective cap carefully off the mirror base mounting. Release socket head screw for mirror base mounting. Lift door mirror and lift it off the door. Disconnect connector for mirror electronics. Reconnect connector Position door mirror Tighten mirror base Turn mirror housing back into initial position Reconnect connector of mirror electronics. Adjust...

Tiptronic warning lamp comes on transmission is in emergency mode

Detectable faults Open circuit short to gound, short to positive 1 Check operation with Tester 9288 drive link test Triggering cycle of valves is audible as a clicking noise near the transmission. 2 Pull connector off Tiptronic control unit. a Measure resistance between pin 16 and pin 19. Nominal value 34 Ohms, tolerance 10 b Check that pins 16 and 19 are free from shorts to ground. 3 Also pull off connector at transmission. - Check wiring Tiptronic control unit connector pin 16 to transmission...

Removing and installing drive pinion and drive shaft

Removing Snap Ring From Rear Axle

Do not confuse with catch No. 1 on page 34 - 5. Tighten to 70 Nm 52 ftlb Replace only as a unit with driver for 5th and 6th gears also refer to page 34-12 Cutout must engage into reverse gear return lever Take out along with shift rod No. 9 Shift rod 3rd and 4th gear with shift lever Replace only as a unit with driver for 3rd and 4th gear If required, redetermine thickness refer to page 34 - 17 Replacement is only possible if end shield has been removed. Press off using a suitable shop press...

Replacing part of door sill with side member and floor pan

Fitting part of door sill with side member and floor section into body Perform straightening operations and adjust body with attachment set Perform all straightening operations on the bodywork. Adjust body with attachment brackets. Trial-fit door into body aperture. The door gap between door and body must be uniform along the entire surround. Clean welding areas Using a hot air gun or rotary wire brush, remove under- sealing, paint etc. from welding areas of body. Remove factory primer from...

Checking the Tiptronic transmission

Check percentage reading actual values with Tester 9288 If there is no display 1 Measure voltage signal at Tiptronic control unit connector pin 11 using a voltmeter. The signal should range from 1 V at idle to about 10 V at full throttle with the ignition on . 2 Check wiring from Tiptronic control unit connector pin 11 to DME pin 52 for continuity and shorts to ground. If voltage o.k. Tiptronic control unit faulty Fault, fault code Possible causes, elimination, remarks Test point 9 Tiptronic...

Wheels and tires

Tires are safety-relevant items that are only capable of meeting the requirements aplicable if they are run at the correct tire pressure and with sufficient tread depth. The tire pressures indicated are minimum pressures. The tires must never be run at lower pressures since this influences roadholding in a negative manner and may lead to severe tire damage. Valve caps protect the valve against dust and dirt and therefore help prevent leaks. Always screw on caps tightly and replace missing caps....

Diagnosis troubleshooting alarm system

The alarm control unit is diagnosable. It can be read out only with System Tester 9288. The menu includes the following functional groups For some of the faults, two types of causes must be distinguished - The fault displayed is an actual fault that has to be remedied. - The fault displayed is a fault condition that has been caused deliberately, e.g. by leaving the open glove compartment open. Troubleshooting requires that the person performing the tests - is familiar with the location of...

Checking headlight beam adjuster

Unlatch headlights and turn into fitting position. 3. Disconnect both connectors from actuators. 4. Measure voltage between term. No. 1 positive and term. No. 3 negative . If no voltage is present at the terminals, check power supply according to wiring diagram. 5. Voltmeter to term. 1 positive and term. 2 negative . Potentiometer in position 0 approx. 0 V Potentiometer in position 1 2.5 V to 3.0 V Potentiometer in position 2 4.2 V to 5.0 V If the values are not reached, check directly at...

Adjusting the popup headlight mechanical system

Porsche 968 Headlights Repair

The installed pop-up headlight assembly is comprised of 1. Sheetmetal console fitted to body 2. Joint rod provides link between return lever and rotary support 3. Mounting saddle of electric motor 6. Electric motor with deflection lever The headlight position with regard to the fender aperture is adjusted with the headlight folded down 1. In longitudinal axis of the vehicle at the console. Adjust the headlight in such a manner that the upper edge of the headlight does not protrude above the...

Adjustment of headlights fitted with headlight beam adjuster

Basic headlight adjustment is carried out in position 0. 2. Adjust headlights with the vehicle in road-worthy condition using a headlight aimer. Driver's seat loaded with one person or 75 kgs. The tire pressure must meet the specifications. Potentiometer position of headlight adjuster relative to load state 1 or 2 persons without luggage. Position 1 3 or 4 persons without with luggage. Position 2 1 or 2 persons without luggage. Position 1 2 persons with luggage. Position 2 Lowering in position...

Diagnosable DME Control Unit

A self-diagnosis feature with fault memory is incorporated into the DME control unit to permit certain faults to be detected and stored. The DME control unit has a permanent positive connection to prevent deletion of detected and stored faults when the Iginition is switched off. Detected faults remain stored in the fault memory for at least 50 engine starts. If the DME control unit plug or the battery is disconnected, the fault memory will be cleared. Tester Connections The diagnostics socket...

Removing and fitting front spoiler and bumper

Sheetmeal screw washer assembly B 4.8 x 16 Oval-head sheetmetal screw B 4.2 X 9.5 Insert into front spoiler and reconnect electrical connector Insert into front spoiler and reconnect electrical connector Sheetmetal screw washer assembly B 4.8 x 19 Before fitting, apply sealing compound e.g. adhesive sealer, part no. 999.915.400.40 in a continuous bead to seal the mounting flange

Fuel system

Closed cooling system with antifreeze protection down to - 30 C nordic countries - 40 C Electric fan with temperature switch Forced-feed circulation lubrication with crescent-type gear pump External, thermostatically controlled air oil cooler Full-flow type 0.6 8 bar, min. 3.0 bar at 3,000 rpm 0 5 bar, electric gauge with warning light contact 2 Twin-tube mainfolds, downpipe to catalytic converter, center muffler, rear muffler Oxygen sensor control with 3-way catalytic converter metal carrier...

Pin assignment of DME control unit plug

944 Non Turbo Dme Diagram

2 Ground, ignition output stage MP IX 4 Idle speed positioner, opening winding 9 Speed signal from speedometer 10 Ground, electronics MP VIII 12 Positive terminal, Hall sender throttle 14 Ground, injection valves MP IX 22 Idle speed positioner, closing winding 24 Ground of remaining output stages MP IX 28 Oxygen sensor idle CO potentiometer 30 Ground NTC shield knock sensor Engine in perfect running condition Battery charged V Voltmeter C2 Ohmmeter Oscilloscope V Voltmeter C2 Ohmmeter...

Machining the cylinder head mating

Checking cylinder head for distortion Using a feeler gauge and ruler or straight edge, check the cylinder head mating face for distortion. Admissible distortion of the mating face 0.05 mm Distorted cylinder heads may be repaired by machining the mating face. Admissible distortion after machining 0.03 mm. Reface cylinder head mating face only until the surface is level. Max. wear limit 146,6 mm Note for refacing the mating face Max. roughness 0,015 mm If the new-dimension tolerance is exceeded...

Checking and adjusting the camshaft setting

Check requirements Belt tension o.k. 1. Turn engine in sense of rotation until cylinder no. 1 is at firing TDC TDC mark on flywheel center notch with engine fitted double-mass flywheel . Camshaft position with cyl. 1 at firing TDC. With the engine removed, transfer TDC flywheel mark with a color pen to the sensor ring gear. Set TDC flywheel mark opposite crankcase mark. 2. Align dial gauge with shop-made extension length 205 mm to piston pin cyl. 1 . Preload 3 mm. Align second dial gauge to...

Applying TDC mark to camshaft sprocket

Camshaft sprockets supplied by the spares department do not have the TDC marks. The TDC mark is applied after the camshaft has been adjusted on the new engine. 1. Place new camshaft sprocket exactly over old camshaft sprocket and transfer TDC mark to new sprocket using a color pen. 2. Fit new camshaft sprocket and adjust camshaft according to instructions on page 15 - 4 to 15 - 6 in Repair Manual. 3. Following item 13, page 15-6, apply the final TDC mark to the new camshaft sprocket, using a...

Checking operation of lighting system

Release pop-up headlights and tilt forward. 6. Adjust headlights with the car in roadworthy condition fuel tank filled, driver's seat loaded with one person or 75 kg, tire pressure set to specified values , using a headlight aiming device. 2. Release pop-up headlights and tilt forward. 4. Tilt back pop-up headlights. 5. Clean light-diffusing lens and turn on low beam. Adjustment is performed with the headlight beam adjuster switch set to position 0. Adjusting auxiliary headlights and fog...

Checking idle speed and CO level on vehicles with catalytic converter

Idle and CO level adjustment is no longer possible on vehicles fitted with catalytic converter. When checking the idle CO level, the oxygen sensor is not disconnected. Perfect condition of the mechanical engine components. Loads must be turned off while checks are made. Perform checks as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would give faulty CO level readings. Ambient temperature 15-35 deg. C. 1. Connect commercially available exhaust gas adapter to...

Dismantling and assembling end cover Tools

Lever out e.g. using arm of puller 9884 When replacing bearing and end cover, recalculate thickness. Make sure it is seated correctly in the correct position. Take out, remove upsetting marks if required Cylindrical roller bearing outer race Using Tool 30-205, press in to stop, inserting Special Tool 9535 at collar stop to support cylindrical roller bearing. Cylindrical roller bearing outer race Pull out using internal puller 23.5 30 mm e.g. Kukko 21 4 Removal damages the bearing, i.e. the...

Adjusting the clutch pedal Note

Adjustment Note

The following items are essential requirements for smooth clutch operation and must therefore be observed whenever the pedal is adjusted - Correct bleeding of clutch hydraulics. - Tightness of hydraulic system. - Correct setting of pushrod and boost spring. - Pedal position according to standard setting. 1. Adjusting pedal position pushrod dimension A LHD 147 mm RHD 109.5 mm . If repairs on the master cylinder have been carried out, the pushrod must be readjusted. Move the sound insulation in...

Dismantling and assembling drive shaft Tools

4th gear loose gearwheel with spring Insert spring before installing gearwheel Oil with transmission oil. Fit with the same gearwheel as before. Check for wear. Fit with the same gearwheel as before. When replacing the synchronizer hub No. 8 , redetermine thickness Press off with tools VW 412 and VW 401 Heat to approx. 100 C and press on, observing correct position 3rd gear synchronizing ring molybdenlum-coated Check for wear. Fit with the same gearwheel as before. Oil with transmission oil and...

Test point 33 Leads K and L

Porsche 9288 Tester

The diagnosis connection between the DME control unit and testers is established by means of the two leads K and L. If no diagnosis is possible, the following points must be checked 1. Continuity test refer to wiring diagram Leads L Pin 7 19-pin diagnostic socket Leads K Pin 8 19-pin diagnostic socket 2. Ground short test refer to wiring diagram Leads L The voltage at pin 7 19-pin diagnostic socket must be gt 8 V when the ignition is on. Lead K The voltage at pin 8 19-pin diagnostic socket must...

Adjusting guide rail for balance shaft toothed belt

Tighten mounting bolts of guide rail lightly. 6. Fit sprocket and balance shaft toothed belt Fit sprocket for balance shaft drive and and adjust according to specification, toothed belt. Refer to pages 13 - 7 to 13 - 10. Put balance shaft toothed belt under preload. 2. Using a feeler gauge, measure and adjust clearance between toothed belt and guide rail. 3. Check clearance of guide rail over a length of 7 teeth dimension A . The adjusting dimension must be 1 0.5 mm. 4. To achieve the...

Technical data

Hypoid bevel-gear drive with 12 mm offset approx. 2.75 liter hypoid oil SAE 75 W 90 or API classification GL5 or MIL-L 2105 B Tightening torques for manual transmission G 44 Selector shaft cover to transmission housing Lock bolts to transmission housing and end shield Deflection lever for reverse gear to end shield Threaded flange for guide plate to transmission housing Side transmission cover to transmission housing Crown wheel to differential housing Verbus-Ripp bolt

Changing the transmission oil Manual transmission

Capacity approx. 2,75 I Oil quantity Hypoid transmission oil SAE 75 W 90 to API GL5 or MIL-L 2105 B 1. Drain oil with the car standing on a level surface and the transmission at operating temperature. 2. Clean drain and filler plugs, tighten plugs to 35 Nm 22 ftlb . 3. With the vehicle on a level surface, fill in transmission oil, until it overflows at the filler plug neck. On initial production cars, the thread of the filler plug in the lateral transmission covers was located 6 mm too high....

Camshaft Position Sensor 968 Porsche

Porsche 968 Throttle Body Cable Assembly

Place protective covers on fenders and disconnect ground cable from battery. 2. Remove air cleaner assembly complete with air mass sensor. Remove engine covers. 3. Undo distributor cap, pull off plug connectors, unclip cover for fuel rail and put aside along with ignition leads. 4. Pull off connector for oil temperature sender and camshaft adjuster. Unscrew fuel return and feed lines from fuel pipe, making sure a second wrench is used to lock. Undo fuel rail at intake distributor and take...

Removing and Installing Clutch

Disconnect battery ground cable. 2. Remove full set of power unit undertray panels. 3. Disconnect oxygen sensor connector and pull cable downwards. 4. Remove exhaust mainfold complete with catalytic converter. 5. Undo starter mounting bolts, remove heat shield and move starter to the side. 6. Unbolt clutch slave cylinder and hang to one side, the line remaining connected. Attach note in interior of vehicle Do not operate clutch pedal. 7. Remove cover of clutch housing. 8. Pull out release...

Checking crankshaft bearing clearance

Bearing Clearance Measuring

The Plastlgage method Is a simple way of checking bearing clearance. Plastlgage is available in three different sizes for measuring ranges from 0.025 to 0.230 mm. 1. Remove crankcase lower section. 2. Remove oil from bearing shell and bearing journal. 3. Place Plastigage having width of bearing on crankshaft journal in axial direction. Install crankcase lower section carefully and tighten to specified torque. Do not turn crankshaft while measuring. 4. Remove crankcase lower section. Read width...

Aligning the thermostat housing

Porsche 9262

Fit preassembled housing to crankcase and tighten hexagon head bolts lightly. Screw in oiled assembly pin 9262 1 manually, center and tighten hexagon head bolts crosswise. If a resistance is felt when the assembly pin is withdrawn, the fitting operation must be repeated. 2. Fit oil pressure release valve with new seal and oiled seals. Dismantling and assembling oil pressure release valve Before dismantling the oil pressure release valve, use a suitable tool, e.g. a round wooden or plastic...

Transmission

Porsche 911 Crossmember Removal

Remove and take out air filter assem-bly.Pull off ignition cable from distributor to ignition coil. 7. Unscrew cover panel in passenger footwell and lift out. Unscrew support panel for DME control unit and pull off control unit plug. Disconnect electrical plug. 8. Remove engine undertray panel and front undertray cover. 9. Open coolant drain plug and drain coolant. Remove alternator vent hose. 10. Loosen radiator hose at bottom right-hand side of radiator and at engine and pull off hose....

DMEDiagnosis Troubleshooting

Porsche Aktiengesellschaft Test Point Description Page Important Vehicle Test Pin assignments of DME Control Unit Effects of Faults Cross Reference 1 Power 2 Engine Temperature Sensor 3 Throttle 4 Oil Temperature 5 Rpm 6 Speed signal 7 Air flow 8 Oxygen 9 Oxygen 10 Ignition timing 11 Opening winding of idle 12 Closing winding of idle 13 Triggering of AC 14 Knock sensor 15 Knock sensor 16 Control unit 17 Hall 19 Idle CO 20 Control unit 21 Fuel pump relay DME 22 Tank ventilation...

Operating instructions for System Tester 9288

The Systemtester 9288 BOSCH KTS 301 is a microprocessor-controlled self-diagnosis tester. All systems which have a diagnosis interface as per ISO Standard can be tested with this tester. The following tests are possible Reading out the fault memory Sensor and status checks, tire-pressure monitoring RDK The Systemtester 9288 is a high-quality piece of electronic equipment. In order to prevent damage to the equipment as a result of improper use, please read the information in the operating...

Checking oil pressure

Remove oil pressure transmitter and screw oil pressure tester VW 1342 together with M 10 x 1 adapter, and M 10 x 1 M 18 x 1.5 adapter, in its place in the oil water cooler housing. 2. Run engine to operating temperature 80' C oil temperature , checking the temperature with, for example, an oil temperature tester Special Tool 9122 9122 2 . 3. At idle speed the oil pressure should be 2.5 bar or more. Have a second person accelerate the engine speed to 4000 rpm. Read oil pressure from tester....

Checking clutch free play and pedal end position

The clutch master cylinder is provided with internal stops. Free play adjustment is therefore no longer required. The pedal end position must still be checked, however, for smooth clutch operation. Depress clutch pedal at the pedal plate for a couple of millimeters and release again. The pedal must return to its initial position end position of clutch master cylinder under its own force. Pull back and check at pedal plate if pedal has actually reached the end position. On vehicles with cruise...

Crankcase Tools

Crankcase - Tools Printed in Germany - XI, 1994 Plastigage for measuring the bearing clearances V 161 - green V 162 - red V 163 - blue Commercially available, e.g. Matra-Werke Dieselstrasse 30 - 40. Frankfurt Main Retaining bracket for locking the flywheel Commercially available, e.g. Hazet 794-U-3

Locking the flywheel for assembly work

Engine with double-mass flywheel is installed 1. Disconnect ground cable from battery. Remove starter. 2. Place Special Tool 9206 1 into position and lock. 4. Fit hexagon head bolt with Special Tool 9538 1 to engine support adapter and lower engine mount. 3. In case of Tiptronic transmissions, use old Special Tool 9206. Locking the flywheel for assembly work

Adjusting Special Tool 9201

Fritz Staeger Berlin

The measuring gauge has been preset to a display of 4.0 dial values and allows the Special Tool 9201 to be checked and to be set to 4.0 dial values, respectively. Adjustment of the device is required after If major damage is present or if the display deviates by more than approx. 2.0 dial values, the devices cannot be adjusted any more. Return the device to the manufacturer for repair. - Hex socket head screwdriver 1.5 A F for new tools - or screwdriver 1.6 x 40 x 0.4 for older tools 1. Adjust...

Replacing the brake fluid Bleeding the brakes

Porsche 968 Clutch Bleeder Location

Total quantity for brake fluid change approx. 1 I. The brake fluid must be replaced at least every 2 years. Sequence of operation for bleeding and brake fluid change - Fill reservoir with new brake fluid up to the upper edge. Connect bleeding device to expansion tank. Turn bleeding device on. Bleeding pressure approx. 1,5 bar. - Continue bleeding or changing the brake fluid, respectively, on the other brake calipers no special sequence to be observed . Open...

Replacing the coolant and bleeding the cooling system

Porsche 968 Cooling System

Drain cooling system only with engine cooled off . Set heater lever to hot, open drain plug at radiator and loosen coolant hose at auxiliary plastic flange of coolant pump. 2. Screw drain plug into radiator. Tightening torque 5 Nm 4 ftlb . Fit coolant hose to flange 3. Leave heater lever in hot position or set to the hot position now and screw out bleeder screw. Fill up with coolant slowly until coolant overflows at the bleeder flange. 4. Turn bleeder screw a few turns in. Start engine and...