Technical Bulletins

JANUARY 1988-DECEMBER 4988

PORSCHE CARS NORTH AMERICA SERVICE INFORMATION

Numtoer

Description

Model

Page

Group 0

8801

New Vehicle Storage

All

1

8802

Used Vehicle Storage

Ail

3

8803

Maintenance Requirements — M.Y. 1989

AU

5

8804

interpretation of Fault Codes with Tester 9268

928 S4

19

8305

Use of Tester 9268 on 1989 Model Year Cars

928 S4

21

Group 1

8801

Poly Rib Pulley Bolts Changed

924S, 944, 944S,

23

944 Turbo

*8802

Replacing Oil Pressure Reducing Valve

924S, 944, 944S,

25

and Pressure Relief Vaive

944 Turbo

8803

Mechanical Changes to the Engine

4 Cylinder

27

8804

Poly Rib Belt Tensioning Procedure

924S, 944, 944S,

35

944 Turbo/Turbo S

8805

High Engine Operating Temperature

928 S4

37

880.6

Oil Drain Holes in Pistons

928 S4

39

*8807

Replacement of Camshaft Drive Beit/

944S

41

Checking and. Adjustment

8808

Cam Housing Gasket Installation

924S, 944, 944 Turbo,

55

928 2 Valve Engine

8809

Cylinder Wail Preparation

924S, 944, 944S,

57

944 Turbo, 928

8810

Troubleshooting Engine Cooling Flap and Fan System

928 S4

59

8511

Camshaft Basic Setting

944S

63

8812

Mechanical Tensioner Material Changed

924S, 944,

65

944 Turbo/S

*8813

New Oil Cooler O-Rings

924S, 944, 944S,

67

944 Turbo

8814

Cam Belt Tensioner Roller Noise

944S

69

8815

Part Number on Poly Rib Belt invalid

924S, 944, 944S,

71

944 Turbo/S

8816

Reinforced Head Cover Gasket

928 S4

73

8817

Diagnosing Condition of Toothed Drive Belts

944S

75

8818

New Thin Shank Connecting Rod

924S, 944, 944S,

77

944 Turbo/S

"8819

Oil Pump/Crankcase Sealing

924S, 944, 944S,

79

Surface Alignment

944 Turbo/S

8820

Camshaft Beit Adjustment

924S, 944, 944S,

81

944 Turbo/S

8821

Cylinder Head Modified

928 S4

83

8822

High Engine Operating Temperature

928 S4

85

Group 2

3801

Checking Batteries on New Cars

All

87

8802

Tapping Noise from injection Valves

928 S4

89

8803

Starter Solenoid Troubleshooting and Replacing

924, 944, 944S,

944 Turbo

Number Description Mode! Page Group 2 (continued)

8804 Tester 9268 Cable Connection 944S, 928 S4 93

8805 Spark Plugs Ail 95

8806 Survey of OME, LH/EZF and LH/EZK Control Units All 99

8807 Poor Starter Engagement 911 Carrera 103

8808 Handling of Polyamide Fuel Lines 4 Cylinder & 105

8 Cylinder

8809 Starter Cable Routing 928 S4 107

8810 Calibrating Fuel Level System 928 S4 109

8811 Engine Performance 911 Turbo 111

8812 Constant Current Draw 928 S4 113

Group 3

8801 Determining Synchronizing Ring Damage All 115

8802 Shift Rod Rattle 911 Carrera 121

8803 New Shift Rod Seal 911 Carrera 123

8804 Measuring Clutch Lining Thickness 924S, 944,944S, 125

944 Turbo

"8805 Lubrication of Clutch Parts Ali 127

8806 Transmission Noise 911 Carrera Coupe, 129

Targa

8807 Transmission Jumps Out of 1st or 2nd Gear 911 Carrera 131

8808 ATF Loss from Vent of Automatic Transmission 924S, 944 133

8809 Different 'Ro' Value for Pinion 944S ' 139

8810 2nd Gear Brake Piston Rod Length 924S, 944 141

8811 Determining Rubber Clutch Hub Damage All 143

8812 Adjusting Ring Gear 911 Carrera 145

8813 Manual Transmission Oil All 147

Group 4

8801 Summer Tires/Wheel Rim Summary All 149

8802 Shock Absorbers — M.Y. 1988 All 163

8803 Brake Pad Pin Lock Changed 924S, 944,944S 165

8804 Front Brake Pads Changed 944 Turbo S 167

8805 Strut Mount with Additional Washer 944,944S, 944 Turbo 169

8806 Turbo S Wheels 944 Turbo S 171

8807 Club Sport Wheels. 928 S4 173

8808 Alignment Procedure 928 S4 175

8809 New CV Joint Grease Alf 177

8810 Brake Pads without Asbestos Ail 179

8811 Tire Manufacturers Customer Service Ail 187

Phone Numbers

8812 Winter Tire/Wheel Rim Summary All 189 *8813 Wheel/Tire QeneraMnformation AIS 199

Group 5

8801 Rear Fender Replacement 944 Turbo S 205

8802 Air Draft and Wind Noise in Door Area 911 Carrera, 207

911 Turbo

Group 6

8801 Replacing Cabrioiet Rear Bow 911 Cabriolet 209

Number Description

Model

Page

Group 6 (continued)

8802

Windshield Mounting

944, S44S, 944 Turbo

215

8803

Modifications of Lifting Roof

924S, AIS 944

217

8804

Adjustable Sliding Roof Wind Deflector

928 S4

219

8805

Window Opener Relay 1989 Model

928 S4

221

8806

Noisy Cabriolet Top Transmission Gears

911 Cabriolet

223

8807

Windshield Sealing

944, 944S/T

225

8808

Service Information Video Tape

.911 Cabriolet

227

"Electrically Operated Cabriolet Top"

Group 7

8801

Seat Heating Operation

928 S4

229

8802

Paint for Leather Repairs

Ali

231

8803

Troubleshooting Seat and Mirror

928 S4

233

Control System

Group 8

8801

A/C Compressor Survey

Ail

245

8802

Fresh Air Fan Changes Speed

928 S4

247

8803

Fuse for Front A/C Condenser Fan

911 Carrera,

249

911 Turbo

8804

Seat Beit Fastener Touching

911 Carrera,

251

Heater Control

911. Turbo '

8805

Bimetal Temperature Switch Modified

928 S4

253

8806

Volume of Refrigerant F312

928 S4

255

Group 9

88G1

Third Stoplight Mounting Frame

924S, 944, 944S,

257

944 Turbo

8802

CD Piayer Transport Screw

AH

259

8803

Replacement Central Warning Control Units

928S

261

8804

Whistling Noise from Radio

911 Carrera,

263

911 Turbo, 928 S4

8805

Interior Light/Alarm System

928S, 928 S4

265

Self-activation

8806

Telephone Installation

All

267

8807

Loudspeaker Grille Mounting

928 S4

269

8808

Repairing Loudspeaker Mounting

928S, 928 S4

271

8809

Alpine CD-2 Radio Security Code

AIS

273

Group X

8801

Turbo Model Designation

944 Turbo S

275

8802

Technical Bulletin Index (No longer valid)

Pare identifier uirib^r with Tester 9268

From Model Year 1988

The chart below should help the technician diagnosing and repairing some fault codes indicated on tester 9268.

Fault Gode

Part/System Checked

Fuil load contact {ground, contact}

Load signal from LH control unit

Knock-sensor S

Knock sensor if

Half sender signal

Possible Cause

Starting engine with accelerator pedaf fully depressed. (Full load position)

Possibiy a system related coda May not indicate a malfunction.

Repair Instructions

Check throttle valve switch according to EZK/LH test plan (WKD 493 921). Test steps 5 and 12. If no problem is found, instruct owner to ¡start engine without depressing accelerator pedal

1} Check, control units ground (MP IX).

2) Disconnect and check EZK/LH plugs.

3)_ Connect ohmmeteron EZK plug term Sand LH plug.term.

25. Reading: 0 ohms. If reading is not 0, check wiring, important." Fauit memory must be read prior to this test, since disconnecting EZK/LH plugs erases -the memory.

Knock sensor wiring and/or connections.

Pinched wire in the area of the drive beit cover.

Check plug connections on knock sensor, (visual inspection).

1} Check Hall sender wiring for correct routing. 2) Check Hall sender signal according to EZK/LH test plan (WKD 493 921) Test step 7.

*Fault code for intermittent fault

PCNA Technical Bulletins are intended for use by professional technicians, not a "Do-it-yourseifer." They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in tie proper service of a vehicle. Speciai tools may be required to perform certain operations identified in these bulletins, use of tools and procedures other than those recommended in these bulletins may be detrimental to the safe operation of your venicie. Properly trained technicians have the equipment, tools, safety Instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your Porsche Dealer for information on whether your' vehicle may benefit from the information. Part numbers listed in these bulletins are for reference only. Always check with yourauthorized Porsche deater to verifycorrect part numbers.

«1988 Porsche Cars North America, Inc.

Page 1 of 1 December 2, 1988

Figure 3

Figure 1

©1938 Porsche Cars North America, Inc.

Figure 2

Page 1 of 1 December 23, 1988

Model

928 S4

Group 0

Part Identifier

0300

Number

8805

Use of Tester 9268 on 1989 Model Year Cars

System adaption MUST be performed on every scheduled Maintenance Service on 1989 model 928 S4.

Diagnosis Tester 9268 can be used to perform this function in conjunction with two adapter cables (included in 1989 tool package):

Figure 2

For diagnosis and system adaption instructions with tester 9268 refer to 928 Workshop Manual, Volume 1, Group 03 starting on page 03-1.

For additional information on diagnosing fault memories on 1989 Model Year vehicles refer to: Service Information Technik 928 S4 '89 (WKD 495 521).

Figure 3

Figure 1

PCNA Technical Bulletins are intended for use by professional technicians, not a "Do-it-yourselfer." They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Special tools may be required to perform certain operations identified in these bulletins. Use of tools and procedures other than those recommended in these bulletins may be detrimental to the safe operation of your vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properlyand safely. If a condition is described, do not assume that the bulletin applies to your vehicle, orthat your vehicle wit! have that condition. See your Porsche Dealer for information on whether your vehicle may benefit from the Information. Part numbers listed m these bulletins are tor reference only. Always check with yourauthorized Porsche dealer to verify correct part numbers,

©1938 Porsche Cars North America, Inc.

9288/1 Part Number 000 721 928 81 (Figure 1) 9268/2 Part Number 000 721 926 82 (Figure 2)

> new 19 pin diagnosis plug Is located underneath the radio booster cover next to the passenger seat {Figure 3).

The 12 pin test plug on the control unit bracket is discontinued^

Part: Identifier

1935

Number

8805

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