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)

Bonding the interior rearview mirror in place

5 Apply adhesive to bonding Apply a drop of adhesive (E) to the bonding plate of the plate rearview mirror. 6 Bond rearview mirror in place Press bonding plate of rearview mirror against primered Note Press mirror in place for approx. 40 - 50 sec. Bonding strength 60 after 1 hour 100 after 24 hours Bonding the interior rearview mirror in place

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...

Test point

Oil temperature sensor Using System Tester 9288, the oil temperature may be read directly in the Actual values menu item. As an alternative, connect an ohmmeter between terminal 47 and terminal 30 of the disconnected DME control unit plug. Display at 60*C 3.8 kii 85 C 1.5 kil 100'C 930ii If the above values are not reached, check directly at oil temperature sensor. Note The engine temperature sensor informs the control unit of the actual oil temperature. Changes of the oil temperature cause the...

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....

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 wiring harness

Disconnect battery and cover terminal or battery, respectively. 2. Remove fresh-air fan for access to wiring harness . 3. Remove control unit and disconnect connectors for control unit - LH front sensor next to Centr. Electr. Syst. - Contact unit below dashboard - RH front sensor next to control unit The safety bracket orange of the 6-pin connector is destroyed during dismantling. When fitting the assembly, lock the connector with a new safety bracket blue . 5. Disconnect wiring connection...

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...

Tiptronic warning lamp comes on transmission is in emergency mode

Specification Engine may be started in P or N positions only Actual status Engine may also be started in selector lever positions other than P and N Detectable faults Open circuit, short to ground, short to positive 1 Check adjustment of bowden cable to position switch. - If required, run electrical test as described under Test point 12, item 4 2 Pull off start relay G 20 in Central Electrical System - Ground must only be present at relay base terminal 85 when the selector lever is set to P or...

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...

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...

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 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...

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...

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...

Lift solenoid for Shiftlock Notes for Shiftlock

When the vehicle is moving slowly faster than at walking pace , the selector lever may be moved from the ,,N position to a driving stage without having to actuate the service brake. The solenoid for energization of the P N lock operates with a delay of approx. one second. This means that shifts from ,,R via ,,N to ,,D and back again may be made without having to actuate the brakes. This is a significant advantage for maneuv-ring and for moving off when the car is stuck e.g. in winter .

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...

Parking brake

Checking free play of parking brake lever The parking brake system is fitted with asbe-stos-free brake pads. The parking brake fitted with asbestos-free brake pads must not be adjusted in such a manner that the pads must grind free in operation. If the parking brake lever can be pulled by more than 4 teeth under moderate pulling force without showing any sign of braking effect, the parking brake must be readjusted. 2. Release parking brake lever and push back rear-axle disc until the brake pads...

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...

Dismantling and assembling door rearview mirror

2 Fit mirror housing complete with mirror base Engage outside sensor into mirror housing Fit mirror glass complete with adjusting motor Tighten fastening screws of reinforcing plate and mirror housing seal. Clamp 14 mm socket hex head wrench in a vise. Grease centering washers of stud for mirror base mirror housing union. Assemble mirror housing, mirror und base and stud. Place stud onto socket hex head wrench. Tighten by applying axial force and rotating the door mirror by 90 . Tighten...

Installation and Repairs

Testing and installing may only be carried out by qualified personnel. The following precautionary measures are always mandatory prior to working on the air-bag system as well as work on neighboring parts, where there is danger that power supplying parts could get too close to the airbag system. 2. Disconnect and cover battery ground pole. After disconnecting the battery installation or repairs on the vehicle with use of a hammer or similar tools may first be begun after waiting 20 minutes....

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...

Removal

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...

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...

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 ring...

Porsche 968 Air Bag Fault 10 Ignition Circuits

Interface Obd Connecteur Porsche 944

The control unit needs approx. 70 seconds to identify all faults in the system, and the ignition must therefore be switched on for at least this time to ensure that all poosible sources of defects can be checked. After a fault in the airbag system has been identified and rectified, the fault memory must be erased. Following an accident in which the airbag system was activated, the following components must be removed and replaced If non-activated airbag units have to be removed, they must be...

Adjusting ring gear

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....

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 Voltage failure Term. 3 0 with active alarm system Luggage comp. open during activation Input 3 to positive during activation closed loop interrupted during activation Radio contact to ground during...

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...

Body dimensions

1 Center impact pipe absorber front 2 Front side member take-up hole 7 Platform lift take-up, Car jack, front 8 Platform lift take-up, Car jack, rear 10 Strengthening member take-up 12 Transmission support take-up 13 Rear side member take-up hole 14 Center impact pipe absorber rear

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

Test point 0 K and L wire

Connecteur Prise Obd Porsche 968

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 K wire - Check ground and terminal 15 at...

Wiring

Wiring Harness Porsche 964 Front Lamp

Passenger compartment wiring harness for 968 CS 97-01 Repairing the Tiptronic wiring Routing the sensor wire at the Tiptronic Wiring diagram mod.'93 Wiring diagram mod. '94 Wiring diagram mod. '95 Passenger compartment wiring harness for 968 CS When replacing the passenger compartment wiring harness, the spare wiring harness must be modified as only the harness for the 968 is supplied by the spares department. Modifications are required at the clock connector. 1. Open 7-pin coupling housing...

Technical Data 968 968 CS

Brake booster light weight built Boost coefficient Brake master cylinder aluminum design 0 in mm Brake power regulator in rear axle circuit switchover pressure reduction coefficient Hydraulic dual-circuit brake system with black white , brake booster, vented brake discs with fixed caliper on front and rear axle. The pushrod brake circuit is allocated to the front wheels. The values in brackets are valid for the 968 968 CS models with M 030 special running gear. The brake disc used for the M 030...

Checking idle and CO level of vehicles without catalytic converter Engine Type M 444344

No provisions for idle speed adjustment are made any more. Adjustment at the throttle body is therefore no longer performed. Perfect condition of the mechanical engine components. Loads must be turned off while adjustments are made. Perform adjustments as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would give faulty CO level readings. Ambient temperature 15 to 35 deg. C. 1. Warm up engine to operating temperature. Oil temperature 70 to 90 deg. C , check with...

Removing and installing torque converter Removing

Remove transmission refer to page 37-201 . 2. Remove converter, with transmission in horizontal position. Do not damage converter bearing assembly and rotary shaft seal. 1. Carefully insert converter, with transmission in horizontal position. Turn the converter to and fro until the gear toothing engages and the installation position is reached. 2. Make sure the converter does not drop out.

Fitting the camshafts

Porsche 968 Timing Chain

Rotate engine in direction of rotation to approx. 45 before firing TDC cylinder 1 . 2. Compress VarioCam camshaft adjuster and lock with Special Tool 9530. The oil check valve in the camshaft adjuster may drop out when the adjuster is compressed. Retain oil check valve and take it out if required. 3. Place inlet camshaft and exhaust camshaft into timing chain. Place both camshafts into timing chain in such a manner that the color marks or casting lugs line up with the chain links marked. The...

Removing and installing transmission

Remove rear muffler and heat shield. 2. Unbolt drive shafts on transmission side and suspend horizontally on vehicle. 3. Pull off rpm sensor inductive sensor and unclip wire from transmission housing. On USA vehicles, remove support at rear transmission cover. 4. Disconnect wiring connectors at transmission. 6. Disconnect selector lever cable from lever and bracket from transmission. The ball socket keeps the cable from jumping out of position. 7. Remove cover for service hole and undo...

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...

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

Operating instructions for System Tester 9288

Porsche 944

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 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.

Pin assignment of DME control unit plug

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 V Voltmeter ii Ohmmeter Oscilloscope V Voltmeter ii Ohmmeter Oscilloscope 41 Coolant temperature switch 115'C 42 Position...

Changing engine oil and engine oil filter

Undo and remove oil filler cap. 2. Remove oil drain plug from oil pan and drain engine oil. 3. Undo oil filter with oil filter wrench Special Tool 9204 . Drain remaining oil into suitable container. 4. Clean drain plug. Always replace seal. Tightening torque 50 Nm 37 ftlb . 5. Oil seal of oil filter lightly, tighten by hand until seal is seated, tighten by one more turn. Use oil filter wrench to check tight seating of filter afterwards. Guide value for tightening torque 20 Nm 15 ftlb . 6....

Lifting the vehicle

The car jack, the trolley jack and the support plates of the lifting platform may only be used to lift the car at the jacking points shown below. The jacking point at the front side member may still be used to raise the vehicle on the lifting platform. Never raise the vehicle at the oil pan or the transmission since this may cause severe damage. Maintenance Working instruction Maintenance every 20,000 km 12,000 mis Type The terms inspect and check include all associated work such as...