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...

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...

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.

Country codes

The System Tester 9288 may be used to encode three pre-set alarm versions - Alarm horn max. 30 sec. interval. - Interior light flashes in an asynchronous manner with turn signals (if in door contact position). - Alarm hom max. 30 sec. continuous. USA - Alarm horn max. 4 mins. interval. - Interior light flashes in an asynchronous manner with turn signals (if in door contact position). When replacing the control unit, activate one of the preset country codes according to the national C number. C...

General Auxiliary tools

Use of the following auxiliary tools is recommended when checking the Tiptronic Diagnosis Tester 9288 with connection cable Voltage and resistance meter (internal resistance > 10 Mi2) Jump lead with matching spade connectors General information Do not run resistance measurements on live wiring If poor terminal connections are found, - check connector terminals for tight fit, tight wire connections, deformation and corrosion - Before replacing the transmission or the Tiptronic control unit,...

Checking stop light switch adjustment

A mechanically operated stop light switch fitted to a bracket above the brake pedal plate is used. With the brake pedal in home position (pedal not depressed), the distance from the stop light switch to the brake pedal must be 5 mm. If required, change position of the stop light switch by turning the mounting nuts until the specified 5 mm are reached. Lock mounting nuts against each other. Checking stop light switch adjustment

Instructions

Using a hot air gun or rotary wire brush, remove under-sealing, paint etc. from welding areas of body. Remove factory primer from welding areas of spare parts, using a rotary wire brush. Offer up side member spare parts to body side member, making a butt joint. Attach side member spare parts to straightening brackets for impact pipe mount. MIG-weld side member spare parts to body side members, running a butt full seam. Offer up cross member with closing section to body and MIG-weld to body...

Test point

Check Engine A ground signal is fed from the control unit - terminal 21 - to the warning lamp Check Engine lamp, causing this lamp to come on when an emis- Fault code 1 45 sion contro1 component fails. If the Check Engine warning lamp fails, this fault is stored in the fault memory. Check by supplying ground to disconnected DME control unit plug terminal 21 and switching on ignition. The Check Engine lamp must now come on. To replace a faulty display lamp, always use the specified lamp. Reading...

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

Layout of the exploded diagram

Disassembling and assembling transmission y Manual Transmission, Controls, Case Disassembling and assembling transmission Disassembling and assembling transmission Printed In Germany - VII, 1988 C - Type of vehicle to repaired F - Impressum, supplement number, year of printing G - Diagram item number in the order of disassembling H - Special notes to be observed when installing or removing The notes on assembly application of special tools which are given after the exploded diagram are always...

Installation

Insert ignition steering lock with lock pin disengaged into vehicle - steering lock position II. 2. Align steering lock housing, pin of steering lock must engage easily. Tighten shear bolts, taking care not to shear the bolts. 3. For Keylock vehicles, screw in bowden cable at ignition steering lock position II (selector lever must not be in position P). Then move selector lever to position P and turn ignition steering lock to position 0.

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...

Possible cause

4.7 Vehicle moves off in 3rd gear 4.9 Upshift 1-4 and engine stalls Idle speed too high Dampfer A faulty Clutch A damaged Shift valve 1-2 stuck Pressure reducer valve 1 stuck Shift valve 2-3 stuck Clutch E damaged Shift valve 3-4 stuck Brake C' damaged in this case, 1 -2 shift operations will also be impaired Shift valve 2-3 stuck Internal leak in HCU Adjust engine Replace HCU Replace transmission Shift valve 1-2 and 2-3 stuck Replace HCU

System check

The System check menu item may be used to check all components triggering an alarm (except Term. 15). In this case, the alarm horn is only triggered twice for a short interval. The following display appears after the System check menu item has been called The individual components that may trigger an alarm (except Term. 15) can now be checked. E.g. if a door is opened, an alarm is triggered. At the same time, triggering of the alarm is stored in the result memory. After the check has been...

Lights

CONTROL UNIT LIGHT COMBINATION ION CESI RELAY FOG LIGHT TURN SIGNAL DIMMER SWITCH CUTOFF IF HIGH BEAM l ugh beam CONTROL UNIT LIGHT COMBINATION ION CESI RELAY FOG LIGHT TURN SIGNAL DIMMER SWITCH CUTOFF IF HIGH BEAM l ugh beam All LIGHT ASSEMBLY RIGHT All LIGHT ASSEMBLY RIGHT

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...

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...

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,...

Porsche 968 Central Warning Light On

The central warning lamp must light along with the airbag warning lamp if an error is stored in the error memory. 4. Make sure that no covers, decals or similar items are fitted at the steering wheel and in the passenger airbag area. 5. Check components visually for damage and modifications. 6. After checking the system, confirm the check in the appropriate fields of the warranty and service booklet. * As of manufacturing date 2 - 06 - 92 approx. 2.5 sec

Test Point 3

Voltage failure - Refer to Test Point 2. Position of the drives This fault is also stored if, for example, the driver's door is open unplausible wlien the key is usecl actuate the central locking system from the - Disconnect plug II from control unit. Attach Special Tool 9540 at wiring harness. With the doors unlocked, ground must be present at pin 10. At the same time, no ground must be present at pin 12. With the doors locked, ground must be present at pin 12. At the same time, no ground must...

The following topics of Repair group 15 are described in the Repair Manual Type 944 vol 1 A

Cylinder head, disassembling and Valve springs, removing and installing with Sauer tool 15-118 Valve springs, removing and installing, removing valve stem seal 15-121 Checking valve Checking valve-seat wear limit 15 -130 Valve seats, checking and Checking and adjusting installation length of valve springs 15-133

Tiptronic warning lamp comes on transmission is in emergency mode

Detectable faults Open circuit short to ground, short to positive 1) Check operation with Tester 9288 (drive link test) Triggering cycle of vlaves is audible as a clicking noise near the transmission. 2) Pull connector off Tiptronic control unit a) Measure resistance between pin 24 and pin 19. Nominal value 34 Ohms, tolerance 10 b) Check that pins 24 and 19 are free from shorts to ground. - Check o.k. Tiptronic control unit faulty 3) Also pull off connector at transmission. - Check wiring...

Transmission

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. Catch...

Upshifting in curves is not prevented

Detectable faults Open circuit short to ground, short to positive 1) Check sensor with Tester 9288 (actual values) (Nominal value around 0 g with vehicle on level surface. Sensor can be checked by raising the vehicle on one side). 2) Remove connector from sensor. Check sensor supply (5 V) to pin 3 and ground at pin 1 with the ignition switched on. 3) Check wiring according to wiring diagram Check continuity from pin 45 Tiptronic control unit connector to pin 3 sensor Pin 40 Tiptronic control...

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)

Vehicles without airbag

Adjust clearance between steering column switch and steering wheel. Tighten steering column switch screw. 4. Fit connectors of ignition steering lock, instrument cluster and buzzer contact. Using a depth gauge, set dimension 45 0.5 mm. Tighten steering column switch. Measure between beginning of steering shaft and center of steering column switch. 4. Fit connectors of ignition steering lock, instrument cluster and buzzer contact. 5. Check ignition steering lock...

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...

Removing and installing gear set

Do not confuse with shift catch (No. 2) Tightening torque 70 Nm (52 ftlb) Do not confuse with shift catch (No. 1) Tightening torque 70 Nm (52 ftlb) Insert with Loctite 573 and tighten to 25 Nm (18 ftlb) May be replaced without dismantling the transmission (refer to page 34-7) Replace, fit only after gear set has been installed as It may otherwise be damaged. Pack space between sealing lip and dust lip with multi-purpose grease

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...

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....

This is how the information is processed in the Tiptronic control unit

Adaption of shift characteristics (transmission and torque converter) shift characteristics TC characteristics computer controlled maintenance of recommended max. engine speeds The Tiptronic control unit is located in the luggage compartment, on the right side. The following parameters are constantly supplied to the Tiptronic control unit Time for change of resistance at potentiometer No. of pulses at pole wheel of transmission shaft Signal from transverse acceleration sensor Change of no. of...

Engine Design

Engine type Crankcase Crankshaft Crankshaft bearings Connecting rods Con-rod bearings Pistons Cylinders Cylinder head Valve guides Valve arrangement Valve gear Balance shafts Balance shaft bearings Balance shaft drive Valve clearance Basic valve timing 4-cylinder 4-stroke otto-cycle engine with 2 balance shafts Plain bearings Light-alloy, forged Light-alloy Light-alloy 2 intake, 2 exhaust, overhead in V inclination 2 overhead camshafts, hydraulic flat-base tappets Without bearing shells,...

Leaks

9.1 ATF drips from torque converter bell housing Pump housing leaky Torque converter leaks at weld joint Seals under fastening screws of pump damaged Replace pump assembly Replace torque converter 9.2 Transmission oil drips from torque converter bell housing 9.4 Oil drips from leak detection point (to the right of ATF pan) 9.5 Oil loss at transmission connector 9.6 Oil loss across or at breather Transmission (ATF) leak Differential leak (75W90 transmission oil) Oil level too high Incorrect oil...

Wheel alignment values

Ride height and spring brace settings Production running gear (strut height not adjustable) Sport-type running gear M 030 (height-adjustable spring struts) * max. ride height difference left to right 10 mm. On U.S. vehicles, the bumper height is used as a reference (refer to page 44-4). The distance from the measuring surface (road surface or any level surface) to the measuring point must be 543 20 mm at the rear axle. At the front axle, the distance must be 611 20 mm. For measuring points,...

Example

(Ride height adjustment on one wheel) measure to wheel center a 300 mm specified height E 147 10 mm Value (from tire contact 153 10 mm area to measuring point) If required, correct height (p.44-8). used to determine the ride height. For settings, For height adjustment, undo lock nut and turn spring cup accordingly. Use suitable hook wrench or Special Tool VW 637 2 (lever). - to the right - vehicle height is increased - to the left - vehicle height is reduced

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)

Technical data

Tightening torques for central tube and transmission suspension (Tiptronic) and ATF pipes Damper element to central shaft (clamping screw) Torque converter mount to central shaft (clamping screw) Clutch housing to central tube flange Torque converter mount to central tube housing Transmission mount to bracket (collar screw without washer, property class 10.9)* Transmission mount to transmission support ATF pipes at auxiliary ATF cooler (clamp fitting) ATF pipes at transmission and ATF cooler...

Cleaning the entire engine oil system after an engine failure bearing failure

This cleaning sequence is only intended to give pointers as to whereyou may find chips. The actual amount of work involved will depend oneach individual case of engine damage. - Oil pressure relief valve (crankcase) The following parts must be dismantled, inspected and cleaned thoroughly - Oil restraining valve in cylinder head The following parts must be cleaned thoroughly and or rinsedthrough repeatedly All oil bores may be rinsed through thoroughly with benzine and a commercially available...

Dismantling and assembling front cover

Adjust cover at hinges according to fender contours and front spoiler Separate from valve and pull out of cover frame complete with grommet Push through cover frame complete with grommet, push onto valve and fit with ear clamp Unclip from cover hinge and separate from hose Push onto hose and clip into cover hinge Clip wire into place according to wiring diagram Unclip from cover in upward direction Remove from engine compartment light and pull out of cover frame complete with grommet Route in...

Faults that cannot be detected by selfdiagnosis

The Tiptronic control unit cannot detect and store all potential faults. If a fault is found and if no fault has been stored, the tester may be used to run a system check to indicate any faults that may be present. Some of these faults are stated below. No diagnosis possible, test point 0 No diagnosis is possible if the diagnostic leads are faulty If terminal 30 is inoperative, all faults that may have been stored are erased after the ignition is switched off. If terminal 15 is inoperative, the...

Powerassisted steering Checking fluid level General

Damage to the power-assisted steering system is often due to lack of oil in the hydraulic system. Even minor leaks may cause fluid to escape due to the high hydraulic system pressure, thus damaging the power pump. Grunts that become audible when turning the steering wheel or foaming in the reservoir indicate lack of oil and or air drawn into the system. Before topping up the reservoir, however, remedy any leaks present on the intake side and replace damaged parts on the feed side.

Adjusting lift solenoid of Shiftlock

After fitting the lift solenoid, push it all the way down in the slots of the gate guide (No. 5). Tighten fastening screws (No. 3) only lightly. Fit the angular lever (No. 2) to the gate guide (No. 5) using the 8 mm stud (assembly tool No. 1). Apply current to lift solenoid (apply system voltage, observe correct polarity) and slide along inside slots until the locking idler lightly touches the surfaces a and b of the ratchet (No. 4). Tighten fastening screws (No. 3) to 2.8 Nm (2 ftlb) in this...

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...

Replacing lock barrel of ignition steering lock

- When removing and installing the lock barrel, the ignition switch must be fitted to the steering lock housing. 1. Screw stud for lock barrel out of steering lock housing. 2. Drill steering lock housing with 3 mm dia. drill acc. to figure. 3. Using a scriber or a similar tool, disengage the lock barrel across the 3 mm bore and pull it out. For Keylock vehicles, observe the following Ignition key in 0 position. To keep the lock pin in the unlock position, make sure ignition key has not been...

Changing the brake fluid bleeding the brakes

Universal shaft to steering gear and steering shaft Track rod to steering rack (not for power steering) Steering column switch to jacket tube Pressure and return line to steering gear Left-hand drive Right-hand drive Ring hose nipple for suction hose to servo pump Rack-and-pinion steeering with hydraulic assist (power steering). 380 mm 0 4-spoke leather-trimmed steering wheel with airbag 360 mm 0 3-spoke leather-trimmed steering wheel without airbag 18.85 1 (left-hand drive) 18.96 1 (right-hand...

Torque specifications hydraulic brake system

Brake pressure line to brake master cylinder, hydraulic unit, brake hose, distributor and brake caliper Brake power regulator to brake master cylinder or hydraulic unit Brake master cylinder to brake booster Mounting bracket to rear-axle trailing arm Torque specifications - hydraulic brake system

Adjusting drive pinion

Determining total shim thickness Stot (S3 plus S4) (Adjusting preload of tapered roller bearings drive pinion). 1. Fit tapered roller bearing outer races without adjustment shims into the transm. housing and into the end shield, respectively. 2. Insert fully assembled drive pinion. Place end shield into position and tighten bolts to 25 Nm (18 ftlb). 3. Fit measuring tools. Set dial gauge (3 mm measuring range) to zero at a preload of 1 mm. Length of dial gauge extension is approx. 30 mm....

Adusting the deflection lever and joint rod

The headlight motor must be in the pop-up headlights raised position. Move motor electrically in this position. Tighten the deflection lever to the motor in such a manner that it forms a straight line with the joint rod and is in the position just ahead of the top dead center. Tightening torque 10 Nm (7 ftlb) The pop-up headlight motors rotate in different directions - The left-hand motor rotates clockwise - The left-hand motor rotates counterclockwise Adjustment of end stop and rotary support...

Removing and Installing Clutch

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 lever...

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.

Removing and installing control unit Note

The control unit is fitted on the passenger side ahead of the glove box. 1. Disconnect battery and cover terminal or battery, respectively. 2. Undo shear-off nuts (2 pc.) with Special Tool 9259. 3. Undo hexagon head nuts (2 pc.) with socket wrench. 4. Push back rubber grommets and release connector latch. The mounting locations at the body must be cleaned down to the bare metal. To tighten the shear-off nuts, use a 1 4 inch Allen key. Fit shear-off nuts diagonally. The shear-off nuts are fitted...

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....

No Operation Instructions

5 Offer up lock panels to body Offer up spare lock panels to body lock panels, side and weld to body members and lower closing panel. MIG-weld spare lock panels to body lock panels, running a full seam. Spotweld lock panels to side members and closing panel. Plug weld lock panels to lower side members, using MIG- equipment. Offer up corner sections to body and weld to body Offer up corner sections to lock panels and closing panel.

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. Unclip 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...

Removing and installing knock sensor

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 from greater heights as this may damage...

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...

Removing and installing front impact sensors Note

The front impact sensors are placed high up on the left and right wheel house walls in the driver and passenger footwells. The Installation position is determined by the mounting. 1. Disconnect battery and cover terminal or battery, respectively. 2. Remove control unit for cruise control and disconnect connectors T 19 and T 28 for left-hand front sensor only . 3. Disconnect connector for front impact sensor. 4. Undo shear-off nuts using Special Tool 9259. To tighten the shear-off nuts, use 1 4...

Construction Components

Position in field in designation. function vehicle note wiring diagramm CABRIO MOTOR POWER WINDOW PASSENGER'S SIDE CABRIO MOTOR POWER WINDOW DRIVER'S SIDE CABRIO CONTROL RELAY ROOF WITH MICROSWITCHES PRESSURE SWITCH AIR CONDITIONING SYSTEM OIL PRESSURE SENDER PRESSURE SWITCH CATALYTIC CONVERTER MONITOR I ONLY JAPANI position in field in designation, function vehicle note wiring diagramm MOTOR LIFTING ROOF WITH CONTROL RELAY AND MICRO SWITCH RELAY START LOCK ONLY AUTOMATIC-TRANSMISSION RELAY...

Replacing the coolant and bleeding the 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...

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...

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 washer,...

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 Inspecting Seat Belts Checking Function It must be possible to have the belt strap...

Exterior equipment

Body paint colors beginning with 1992 models 66-01 Removing and installing plastic end and side applicates Cabriolet 66 - 1 Removing and Installing tank flap Cabriolet 66 - 3 Removing and installing door Removing and fitting side member panel 66 - 9 Removing and fitting side member Removing and installing badge on Removing and installing wheel housing liner 66-21 Safety Precautions for Working on Cars with Airbag 68-49 Replacing cover for passenger airbag 68-51 Removing and installing Airbag...

Standard Colors Special Colors

Grand Prix white 908 Slate gray metallic 22D Black 700 Slate grey metallic 23F Maritime blue 38B Oakgreen metallic 22L Indian red 80K Horizon blue metallic 37X Signal green 22S Cobalt blue metallic 37U Mint green 22R Coral red metallic 82H Rubystone red 82N Polar silver metallic 92E Midnight blue pearl effect 39C Water-base paints are applied exclusively by the manufacturer during production spraying. For repair of water-base paints, conventional refinishing paints matching the color of the...

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...

Noises

High-pitched noise in all shift positions, particularly while oil is cold. Oil pump intake noise Correct oil level Replace HCU Replace pump 10.2 High-pitched, chirping noise varying with rpm in all shift positions, particularly when oil is hot, may appear after longer driving periods, sometimes in conjunction with interruption of power flow Replace oil strainer if no friction lining residues are found in the oil sump, in all other cases, replace the complete transmission assembly.

Checking seat heating

Right Angle Drainer For Roof

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 keep...

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...

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 applies...

Adjusting Special Tool 9201

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...

Checking brake disc lateral runout

Measuring requirements No tilt play present at wheel. If required, adjust wheel bearing clearance of front wheels. 2. Fit adapter plate Special Tool 9510 1 to wheel hub. Tightening torque of wheel nuts mounting nuts 130 Nm 96 ftlb . If required, fit dial gauge holder with Ate conversion kit, Part No. 03.9314-5510.3 01 longer wing screw and bracket for dial gauge if required . 4. Fit dial gauge with a slight preload. Place measuring pointer on maximum diameter of braking surface. 3. Engage...

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...

Note

Differences between the signals indicated and those specified may be due to interference from a control unit connected to the K and L wires see wiring diagram for systems capable of diagnosis . Disconnect connectors from the control units in turn and repeat checks of K and L wires. Start with the alarm control unit as described below. When the last control unit has been disconnected, at least one of the units disconnected must be connected up again. Otherwise, there will be no signal. 4...

B

K LEAO -O CHECK-ENGWE L LEAD SOUL KNOCKNG YES NO . OXYGEN SENSOR POTENTIOMETER IDLE SPEED CO FUEL WJECTOR 1 10 -SWITCH LFT1NG C THROTTLE VALVE SIGNAL NPUT TRANSMSSION CONTRa HALL SENDER DHE-RELAY pO' THROTTLE VALVE POTENTIOMETER j-ol GROUND IGNITDN -oj GROUND FUEL NJECTORS -O, GROUND OTHER ANAL STAGES O O.E SPEED POSITIONER aOSE aE SPEED POSITIONER OPEN 1 I CONNECTION WITH FIELD DATA GP GROUND POINT WELDING POINT CONNECTION WITH FIELD INDICATION

Adjusting Keylock bowden cable

If the ignition lock cannot be turned to the 0 position with the selector lever set to ,,P, the bowden cable position should be corrected as follows 1. Set selector lever to P position. Set ignition lock to II position and turn to 0 again. 2. To adjust cable, turn the cable sleeve at the slide housing No. 1 until the distance A between the notch at the locking slide No. 2 and the mark edge of the gate No. 3 is 6 mm. When turning the sleeve, lock at the square of the slide housing No. 4 to keep...

Diagnosis airbag

Diagnosis Troubleshooting Airbag D 68 -1 Control arm mount to control arm caster eccentric Heat sink for hydraulic bearing to cross member Stabilizer suspension to control arm Mc Pherson strut bearing to shock absorber strut Mc Pherson strut to steering knuckle 968 968 CS with M 030 special running gear Mc Pherson independent suspension with light-alloy A-arms Identification of coil spring color lines Spring rate N mm Spring wire 0 mm Outside 0 mm The front and rear suspensions of the 968 CS...

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 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....

Dismantling and assembling suspension

Undo only if rear-axle trailing arm, wheel bearing or wheel hub is to be replaced. Loosen nut before raising the vehicle. Actuate brakes when undoing the nut. Replace after each removal. Coat threads with Optimoly HT. Tighten to 500 Nm 369 ftlb Support plate on transmission side on wheel side 2 versions transmission side and wheel side Raise trailing arm, e.g. with tensioning device VW 655 3 to unload bolt Coat threads with Optimoly HT. Tighten to 123 Nm 91 ftlb Coat threads and bolt stem with...

Camshaft adjustment gauge shopmade

Porsche 968 Chain Tension 9530

If color marks or casting lugs are missing on the camshafts, use the camshaft adjusting gauge shop-made for referencing the camshafts. 2. After having placed the camshafts into the timing chain, the attribution of the cams of cylinder 1 may be checked with the gauge. Rotate both camshafts against each other so that the lower chain section is tensioned Check again after the bearing saddles have Mounting saddles for removal and installation of camshafts Used In conjunction with tensioning pins...

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...

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...

Torque specifications mechanical brake system

Fillister head screw to clamping nut Air deflector to spring strut Spoiler to front-axle trailing arm Mounting bracket for brake pipe to rear-axle trailing arm Cover plate to brake carrier or control arm Speed sensor to steering knuckle and rear-axle trailing arm Torque specifications - mechanical brake system Torque specifications - mechanical brake system

Checking and adjusting balance shaft toothed belt tension

The toothed belt tension must be checked 5. The TDC mark on the flywheel double- and adjusted only when the engine is cold mass flywheel must also line up. 1. Undo and remove air cleaner assembly and engine underside protection. 2. Remove Poly-Rib belt or power pump belt, respectively. Before undoing the lock nuts, always start by slightly loosening the hexagon head bolts of 3. Remove toothed belt cover. Undo idler until the idler no longer places a preload on the toothed belt. 4. Rotate...

Airbag

Crash sensor left crash sensor right airbag warning lamp instrument cluster diagnosis plug CRASH SEN50R RWT CRASH SENSOR fWT CRASH SENSOR RWT CRASH SENSOR LEFT O CRASH SENSOR LEFT CRASH SENSOR LEFT q PASSENGER'S SEE. WTON TABLET 3 1 PASSENGER'S SEE. IN TON T WXT J 2 PASSEH3ER -S SEE, DITCH TABLET 2 1 PASSEKZR S SEE. 01 TUN TABLET 2 2 lt S CHVER'S SEE. IGMTEN TABLET V2 DRIVER'S SEE. KJflTON TABLET VI O HAZARD LIGHT AKBA6 O RELAIS TERM.66 TERM 15 pCj - RK31 L LEAD K LEAD 1 i connection with field...

Test point 33 Leads K and L

Porsche 968 Check Engine

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...

Removing and installing differential

Differential Porsche 944

Must always be replaced, tighten to 25 Nm 18 ftlb. Lever out with VW 681 with the transmission remaining fitted. Make sure the sealing face of the cover is not damaged. Replace. Pack space between dust lip and sealing lip with multi-purpose grease. Drive in with Special Tool 9346 until it is seated against the stop. Remove output shaft refer to page 39 - 207 . If the transmission remains installed, use a suitable lever e.g. hook of twin-arm puller to lever it out carefully. If the transmission...

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 molybdenium-coated Check for wear. Fit with the same gearwheel as before. Oil with transmission oil and...

Replacing the brake fluid Bleeding the brakes

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...

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...

Plug Connections

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...

Adjusting the clutch pedal 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 pushnod 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...

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 oil pressure

Porsche 968 Idle Speed

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 Thickness of Brake Pads Note

All brake pads on one axle must be replaced when the brake pad wear warning lamp comes on or, at the latest, if a residual pad thickness of 2 mm is reached. If the warning lamp indicates worn brake pads, the warning contact sender incl. electric lead and plug must also be replaced. Replacement of the warning contact can be prevented if the brake pads are replaced at the latest when they are worn to a thickness of 2.5 mm. If the electric lead of the warning contact has rubbed off to expose the...

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

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...

Replacing cover for passenger airbag

When the airbag was triggered while no passenger was in the car, damage to the instrument panel is minimal. In this case, if may be sufficient, following detailed inspection of the instrument panel, to replace only the cover. Check the instrument panel on the passenger side for cracks and other accident-related damage. The instrument panel must be free from bending traces and cracks. Minor deformations of the instrument panel can be straightened. 1. Disconnect battery negative terminal and...

Dismantling and assembling door outer handle Dismantling door outer handle

1 Remove lock barrel To separate the lock barrel from the door outer handle, drive out the lock pin using a drift. 2 Remove escutcheon Undo bolts and lift off escutcheon. 3 Remove operating lever Cut rivet connecting door outer handle and operating lever using a hacksaw. Pull out both rivet sections, pull operating lever and tensioning spring out of the door outer handle. Note When sawing off the rivet, lock the rivet stud to keep it from turning. 4 Fit operating lever Insert operating lever,...

Fitting the camshaft seal

Place sealing washers or lock pins, respectively, into bearing surfaces and fit bearing saddle, applying some Loctite 574. Tightening torque 20 Nm 15 ftlb . 2. The seal cover may only be used with Special Tool 9234 after the bearing saddle has been tightened. If the sealing cover leaks with the engine fitted to the vehicle, fit the sealing cover as follows 1. Place sealing washers or lock pins, respectively, into bearing surfaces. 2. Coat bearing saddle with Loctite 574 and fit saddle. Place...

Removing Porsche 968 Steering Wheel

Porsche 964 Airbag Steering Wheel

Observe safety precautions for airbag vehicles Repair Group 68 . For removal and installation of airbag steering wheel, refer to page 68 - 53. 3. Remove shrouding of airbag contact unit or steering column switch. 5. Remove steering column switch. Take off switch cover and steering lock shroud. 6. On vehicles with Keylock, remove the bowden cable for the steering lock. Before removing the cable, turn ignition key to II position ignition on . Then remove bowden cable...