Alternator removing and installing Printed In Germany XX 1988

928 602 503 00 Bosch No. 0 221 122 001 With two ballast resistors (0.4 and 0.6 ohms) 928 602 032 01 Bosch No. 0 237 401 006 Centrifugal advance and vacuum retard control See note on next page 928 602 702 02 Bosch No, 0 227 100 008 The fuel pump relay is designed to turn off the fuel pumps when engine reaches a speed of ap-prox. 6300 rpm, This type of speed control is required, since ignition failure could destroy the catalytic converter required for emission control.

Check Engine Lamp

As from model year '91, Californian legislation prescribes a warning lamp which lights up If a part relevant to the exhaust gas fails. As a function check of the warning lamp, it lights up when the ignition is switched on and goes out once the engine is running when this is started without depressing the accelerator. The warning lamp has a flashing code to indicate a defective fault path. To trigger off the flashing code, fully depress the accelerator pedal with the engine off and the ignition...

Checking pistons and cylinder bores

Piston Valve Cutouts

PISTON ARRANGEMENT - 1980 1981 1982 1983 Models Engine M 28 13 and M 28 14 M 28 19 and M 28 20 USA, Canada, Japan Compression ratio 9 1 95 mm diameter (M 28 13, M 28 14) 97 mm diameter (M 28 19, M 28 20) Europe and Rest of World Compression ratio 10 1 97 mm diameter Europe and Rest of World Compression ratio 10 1 95 mm diameter Since 1980 models pistons and piston pins are paired according to weight. Pistons are weighed with components (piston pins, piston rings, cir-clips). Piston pins must...

Ddd

Move selector valve to position 2 and wait until warm control pressure is reached. 4. Take off bridge at terminals 30 and 87. 5. Observe pressure drop on pressure gauge and compare it with Testing and Adjusting Data on page 25 - 6, 1. Check valve in pressure neck of electric fuel pump(s). 3. O-ring in system pressure regulator. Possible Leaks in Control Pressure Circuit Pressure relief residual pressure valve. 6. If pressure drop is too fast, repeat test with control pressure circuit broken by...

For Model 89 onwards

The coding connector is fitted to the mounting plate for the LH and EZK control units. Rest of world without catalytic converter, manual transmission Rest of world without catalytic converter, automatic transmission Rest of world, USA with catalytic converter, manual transmission Rest of world, USA with catalytic converter, automatic transmission Fuel grade 91 RON, with catalytic converter, manual transmission Fuel grade 91 RON, with catalytic converter, automatic transmission

Info

CAUTIONS v U F.N R K A RING ELICC TRONIC IGNITION SYST fc' VI VS The 9 28 is equipped with an electronic ignition system. The ignition output of this transistorized ignition coil ignition system is so high, that with the engine running there could be dangerous current in the system. Consequently, any work on the ignition system requires that the ignition be turned off or battery ground cable disconnected. Such jobs would include the following, 1. Connecting engine testing equipment (timing...

Installing

Rib Relay The Box Diagram

Check and adjust the poly-rib drive tension for the alternator, see Page 13 - 18 b. Tightening torque of the fastening screws M 10 45 Nm. 4. Undo both nuts and the alternator adjustment screw. Loosen the bracket on the console, swivel the alternator inwards and remove the poly-rib drive belt. 5. Disconnect the electrical connectors from the oil pressure sensor. 6. Undo the alternator's fastening screw and pull out forwards. Remove the alternator downwards. 7. Remove the air box and detach...

Installing camshaft seal 87 models onward

Seal Power Piston Installation Direction

Place sealing washers lock pins M 28.49 50 as of MY '92) into bearing seats and fit bearing saddle with Loctite 574. Tightening torque 20 Nm (15 ftlb) 2. After torquing the bearing bridge, install sealing cover with the aid of Special Tool 9234. If the sealing cover of an engine as of model year 85 (32 valve engines) leaks with the engine installed, the procedure for installing the cover is as follwos 1. Place camshafts and sealing washers in bearing. 2. Apply Loctite 574 to bearing bridge and...

Machining cylinderhead mating face 32valve engines

Cylinder Head Diagram For Porsche

Checking the cylinder head for distortion Check the sealing surface of the cylinder head for distortion using a feeler gauge straightedge. Distortion limit of mating surface 0.05 mm Cylinder heads with distorted mating faces can be remachlned and reused. Admissible distortion after machining 0.03 mm. As a rule, both cylinder heads must be machined by the same amount to ensure correct seating of the regulator housing. New-part size A 147 0.1 mm Wear limit A 146.6 mm Machine sealing surface of...

Modified breather for crankcase and cylinder heads

Crankcase Breather Exhaust

TESTING OXYGEN SENSOR OPERATION, '87 MODELS ONWARD .Connect exhaust tester to an extraction point in engine compartment. 4.The voltage must be in 0.1 V to 1.0 V range (depending on concentration of oxygen in exhaust) Voltage characteristic of oxygen sensor for working temperature of 6G0 C, Rich mixture Lean mixture (air deficiency) (excessive air) 5.Disconnect vacuum line from fuel pressure regulator. The voltage 3.Connect voltmeter to terminal 1 signal must increase, .Precondition as for the...

Note

The system must be calibrated if the fuel tanks, tank sensor or backlit instrument cluster have been replaced. 2. Fill with exactly 15 I (3.96 gallons) fuel. 3. Wait for at least 1 minute. Vehicle must remain stationary. 4. Pull the operating lever for the backlit instrument cluster, turning the ignition on at the same time. The following response appears in the left and right display boxes* 5. Press the reset button in the center console until 15 appears in the center display box.

Removing and installing the fuel tank gauge unit

Porsche 996 Fuel Tank Replacement

When working on the fuel system, observe relevant safety requirements. Do not remove the gauge unit while the tank is full. 2. Before fitting a new tank gauge unit, remove the transport protector. 2. Undo union nut using Special Tool 9190. Take gauge unit complete with gasket. 1. Always use a new gasket. Coat threads and seating area of union nut with Optimoly TA. 1. Remove luggage compartment floor covering. Remove cover of fuel tank gauge unit. Undo hose clamp, disconnect fuel return hose and...

Ro

CORRECTING CO LEVEL ON AIR FLOW SENSOR 3. Close hole providing access to mixture control screw with a new plug after finishing adjustments. Press in plug flush. 2. Drill hole in plug with a 2 mm dia. drill bit (up to stop on steel insert). 3. Pull out plug with a left-turning drill (no. 2). 2. Adjust engine idle speed and CO level. Turn mixture control screw accordingly with a screwdriver. Turning clockwise richer mixture Turning anticlockwise leaner mixture If CO level is not the specified...

S

HOSE PLAN FOR K-JETRONIC SYSTEM 9 2 i 1 - From fuel tank 1 - To fuel tank 4 - Fuel pressure reservoir 9 - Solenoid valve 10 - Hose orifice A - Intake distribution housing D - Solenoid valve (only for A C) E - Booster valve (vacuum control) F - Blowoff switching valve G - From auxiliary air pump ARRANGEMENT OF CHECK VALVES ON FUEL PUMPS Fuel pump (long neck version with integrated check valve) Fuel pump (new version since 1981 models) Conform with safety regulations for working on fuel systems...

Test point

Injection circuit The ignition circuit monitoring relay is mounted on the retaining plate shut down lor the LH and EZK control units. If an ignition circuit fails, the power supply to the injector valves is interrupted. At the same time one of the two colored LEDs integrated into the relay lights up. Injection circuit I shut down - red LED lights up. Injection circuit I shut down - green LED lights up. Fo troubleshooting, see 928 Repair Manual volume l-A, pages 28-77

Worldwide model 92 onward

Camshaft, right Cylinder bank 1 - A Intake shaft Exhaust shaft Identification code on the rear End face Camshaft, left Cylinder bank 5 - 8 Intake shaft Exhaust shaft Identification code on the rear end face Valve timing, 1 mm stroke, zero play Intake opens Intake closes Exhaust opens Exhaust closes

Removal

Remove air intake hoses and air filter sys- 5. Disconnect electrical connections, remove tem as a unit. retainers and extract injection valves. 2. Slacken holder of exhaust sampler and hose clamps on intake pipe and lift off intake manifold. 3. Remove both untion nuts from fuel-distribution pipe, using a second open-end wrench to counter the nuts. Catch the fuel from the pipe in a suitable container. 4. Remove ignition lead and cable clip from distribution pipe. Disconnect distribution pipe...

Troubleshooting

Short circuit to + Ub Short circuit to ground Measure voltage Display Battery voltage Measure resistance to ground Display 0 ft Measure resistance between E1 and E2 Short circuit to + Ub Short circuit to ground Measure voltage Display Battery voltage. Measure resistance to ground Display 0 ft Measure resistance between E1 and E2 Short circuit to + Ub Shortcircuit to ground Measure voltage Display Battery voltage Measure resistance to ground Display 0 a Measure resistance between terminal AL and...

Machining the cylinder head mating surface Printed in Germany XXIX 1992

1984 944 Timing Belt Remove

Bimetal plate (8 plate sets of 5 each, coated alternately) (7 plate sets of 5 each, coated alternately) Fill one third of housing with transmission oil SAE 9 0 Printed in Germany - IV, 1980 Disassembling and Assembling Tensioning Roller Housing 15-21 Arrangement of Bimetal Plate Sets for Tensioning Roller Use correct adjusting screw to match number of plate sets. 8 plate sets adjusting screw 928. 105.075.00 7 plate sets adjusting screw 928.105. 075.01 Installing Tensioning Roller Housing 1....

Machining the cylinder heads

As a rule, both cylinder heads must be machined by the same amount to ensure correct seating of the regulator housing. Machine sealing surface of the cylinder head only until a straight surface is obtained. Max. wear limit 23.6 mm. Note for machining of the sealing surface Max. roughness 0.015 mm If machining causes the actual value to be below the tolerance applicable to new parts, use a 1.4 mm thick cylinder head gasket (available from the parts service) when fitting the cylinder head....

O

The new cylinder heads can be installed in pairs on older engines or only on one engine side together with the old version. The progressive valve springs with accessories must always be used on the new cylinder heads on both sides. Old valve springs, discs, stem seals, guides and washers are still availabe. installed Length of 9 2 8 S Valve Springs with 1 White Stripe Beginning with 3.81 Installed Length of 9 2 8 S Valve Springs with 2 or 3 White Stripes Beginning with 3.82 New Valve Springs -...

Machining cylinder heads

As a rule, both cylinder heads must be machined by the same amount to ensure correct seating of the regulator housing. Machine sealing surface of the cylinder head only until a straight surface is obtained. Max. wear limit 146,6 mm. Note for machining of the sealing surface Max. roughness 0.015 mm It machining causes the actual value to be below the tolerance applicable to new parts, use a 1.4 mm thick cylinder head gasket available from the parts service when fitting the cylinder head....

Modified breather for crankcase and cylinder heads Engine Type M 284950

Cylinder Breather

1 Oil filler neck de-icer valve is deleted. 2 Hose connection between oil filler neck and throttle body modified, throttle bore - 0 5 mm - for this breather hose is now located in the oil filler neck. 3 Additional breather hose between right-hand and left-hand rocker cover, throttle bores in the rocker cover for cylinder nos. 1 to 4 are deleted.

Checking and adjusting camshaft setting Type 928 GTS 54 I

Porsche 928 Oil Pan Gasket

Along with the introduction of new camshafts as of MY '92 for engine type M 28.49 50 928 GTS, the camshaft timing was changed. Cylinder bank 1 4 Checking and setting dimension 1.83 0.1 mm Cylinder bank 5 8 Checking and setting dimension 2.08 0.1 mm To adjust the camshafts, proceed in the order described on page 15 - 134. Checking and adjusting camshaft setting, Type 928 GTS 5,4 I REMOVING AND INSTALLING LUBRICATING SYSTEM PARTS 17-2 Removing and Installing Lubricating System Parts 7 j Oil level...

Engine type M 28 4142474950

Electric fuel pump Delivery quantity Fuel pressure Engine standstill Fuel pump relay bypassed Idle and CO level adjustment is no longer possible on vehicles fitted with catalytic converter Measured before catalytic converter and Lambda probe connector not disconnected Only CO adjustment is possible on vehicles iflditaui catalytic converter. Only CO adjustment is possible on vehicles iflditaui catalytic converter.

NJUUULMM

The flashing code is listed in the Diagnosing Troubleshooting plan on page D 24 28-7. The fault can also be read direct using System Tester 9288. After a repair the fault memory must be Effect of faults Fault Connections to plugs, EZK control 1 Idle speed 2 Full load 3 Engine temperature sensor 4 Idle and full load 5 Load 6 Transmission protection 7 Knock sensor 8 Knock sensor 9 Control unit knock 10 Hall 11 Control unit 12 Permanent power 13 Engine speed reference mark 14 Ignition circuit...

Modifications to the cylinder head 32 valve

CYLINDER HEAD, INSTALLING 32-VALVE ENGINES Cylinder head attached by means of threaded studs The cylinder head can only be installed with the engine removed from the vehicle. 1.Place cylinder head gasket in correct position. Torquing sequence 4 steps see Fig. INSTALLING CYLINDER HEAD 32 VALVE ENGINE Hexagon cylinder-head bolts The cylinder head can also be installed with the engine in place. If both cylinder heads are to be removed and installed, it is advisable to remove the engine first. 1....

Coding for LH control unit

Porsche 911 Bosch 0438140 Funktion

REMOVING AND INSTALLING ROTARY IDLE ACTUATOR '87 MODELS ONWARD ENGINE TYPE M28. 41 42 Removing 1.Disconnect battery ground strap behind tool tray. Place fender and bumper guards in position. 7.Mark vacuum hoses and disconnect. Break electrical connection between thermostatic switch and intake pipe. 2.Unbolt and remove transverse strut. Car must be standing on its wheels, transverse strut is under tension. 3.Remove air intake hoses and air filter as a complete unit. Disconnect vacuum hose from...

Checking pistons and cylinder bores Type 928 GTS 54 I

928 Porsche Oversize Piston

REMACHINING CYLINDER BORES IN THE CRANKCASE TOP HALF The crankcase top half is made of an aluminum alloy which contains minute particles of pure silicon. In order to give the cylinder the proper surface qualities, the cylinder bores must be machined until the silicon particles protrude from the aluminum so that the pistons and rings only make contact with the silicon. If it is necessary to remachine the cylinder bores, they can be regenerated with the SUMMEN CK - 10 CV - 616 cylinder borer, so...

LHEZKDiagnosis Troubleshooting

Trouble Shooting Power Supply

Porsche Aktiengesellschaft Test point Description Page Precautions, Groups Important vehicle information, Groups Testing requirements, Groups Control unit Effect of faults cross-reference Fault Plug connections at LH control 1 Power 2 Idle speed 3 Full load 4 Engine temperature sensor 5 Air mass 6 Idle speed control 7 Oxygen regulation control, 8 Oxygen regulation control, 9 Open circuit at oxygen 10 Fuel injection circuit shut 11 Control unit 12 No power 13 Ground and plug 14...

Cleaning of engineoil system Printed In Germany XX 1988

Firebird Pressure And Return Line

CHANGING COOLANT AND BLEEDING COOLING SYSTEM 1, Set heater lever at warm and run engine 5. Replace seals for drain plugs on crankcase and briefly. O-ring for drain plug on radiator. 2. Take off cap on expansion tank. Torques Radiator plug - 1. 5 to 2. 0 Nm 13 to 17 in. lb Crankcase plug - 45 to 50 Nm 33 to 36 ft lb 3. Unscrew drain plug on radiator and catch coolant. d. Add coolant until level reaches edge of filler opening heater lever must be at warm . 7. Run engine to operating temperature...

T

CONNECTING AND BLEEDING PRESSURE TESTER VW 1318 Unscrew tank cap to let pressure escape from fuel tank prior to disconnecting fuel lines. 4, Connect adapter of 9114 1 M 8 x 1 M 10 x 1 between disconnected control pressure line and left test line of P 378 c. 5. Connect adapter M 12 x 1,5 and test line on pressure tester. 1. Unscrew control pressure line and standard adapters M 10 x 1 M 8 x 1 on control pressure regulator. 2. Remove original hose on pressure tester VW 1318 it is not needed . 3....

Ca2

Tempostat Volt

The length of the wires for the push button switch should be about 2 meters, in order to be able to watch the throttle while operating the switch. 3. Turn on ignition and press push button switch with engine stopped. The vacuum servo should move the throttle uniformly to full load position. This requires vacuum. To avoid damaging the female plugs in the multiple pin plug, suitable plugs or the wires described below must be used. Remove insulation on wires with an insulating diameter of approx....

Control unit Final stage

Engine Temperature Sensor Mark

CAUTIONS WHEN REPAIRING ELECTRONIC IGNITION SYSTEMS Modern engines requiring more from ignition systems and the objective of low or no maintenance have led to the application of electronic ignition systems in standard production some time ago. Normally the ignition output of an electronic system will be higher than that of a conventional system, whereby even greater ignition output is feasible. Consequently electronic ignition systems are in an output range, where touching current carrying...

Camshaft installation type 928 S4 928 GTS 54 I15 124a

Pictures 928 Head Tools

REMOVING AND INSTALLING CAMSHAFTS 32 VALVE ENGINE 1. Unscrew and remove cross member. Car standing on its own wheels. Cross 2. Remove air intake hoses and complete air cleaner. 3. Loosen hose clamps on intake air distributor and take off intake air distributor. 4. Remove distributor cover, distributor rotor, toothed belt upper section and cylinder head cover. 5. Turn crankshaft clockwise to align the 45 before TDC mark cylinder no. 1 on vibration damper with cast boss of middle toothed belt...

Calibrating the tank sensor system for Model 89 onwards

Air Intake Funnels

928.618.106.01 Bosch No. 0280.002.101 928.606.121.01 Bosch No. 0280.203.009 928.606.110.01 Bosch No. 0280.150.154 928.606.125.01 Bosch No. 0280.130.023 928.606.123.01 Bosch No. 0258.001.017 928.608.104.01 Bosch No-0580.464.017 928.618.106.04 Bosch No. 0280.002.104 928.606-121.02 Bosch No. 0280.203.015 928.606.124.01 Bosch No. 0258.003.003 Temperature Time Switch in Thermostat Housing 928.110.202.00 Bosch No. 0280.161.008 928.110.198 10 Bosch No. 0280.160.215 928.606.102.01 Bosch No....

Control unit

928.618.123.04 Spare part 928.618.123.04 Transistor ignition control unit two Equipment table Engine type M 28.45 46 Control units Engine type M 28.41 42 Control units REPLACING SPARK PLUGS 32 VALVE ENGINE 1, Unscrew suction pump on left side of intake air distributor and clamp on vacuum hose. 2. Unscrew spark plug with a standard wrench car tool set has a special spark plug wrench . 3. Lubricate spark plug threads with a light coat of grease , e.g. white Molykote HTP Paste. EIK CONTROL UNIT...

Assembly notes Dismantling

Jetronic Remove Plug

Pull off pulley along with flange washer, e.g. with two-way bearing puller CORA No. 47-100 Supplier Messrs. Albert Schrem Postfach 1504 D-7928 Giengen 1 After assembly, the distributor rotors must point towards the housing notches. Set engine to cylinder no. 1 firing TDC and install distributor in this position. Set up distributor shafts in basic position. Fit pulley and toothed belt. Removing and installing TDC sender Removal 1. Remove air cleaner assembly. 3. Unscrew TDC sender and pull out...

Checking valve guides

Porsche Exaust Valve

Remove deposits with a cleaning reamer. 2. Place new valve in valve guide and check that valve stem end is flush with cylinder head camshaft housing mating face. 3. Check clearance with dial gage holder VW 387 and dial gage. Wear limit 0.80 mm. Checking Installed Length of Valve Springs 1. Install Special Tool 9138 with shims belonging to a pertinent valve, spring retainer and both keepers. 2, Read distance from Special Tool 9138 and, if necessary, correct by adding or removing shims. Shims...

Bosch 221-122-001 Coil Resistance

930 Turbo Adjusting Ignition Timing

Run engine to operating temperature oil temperature about 80 to 90 C 176 to 194 F . Unlike capacitor discharge ignition systems, testing equipment e.g. tachometer can be connected to ignition coil terminals 1 and 15 of transistorized ignition coil systems. 2. Connect engine tester or timing light and tachometer. A positive terminal for connection of testing equipment is located above ignition control unit in engine compartment. 3. Detach both vacuum hoses at distributor. 4, Adjust ignition...

Workshop Manual

PORSCHE Aktiengesellschaft Coolant thermostat Opening temperature 81 - 85 C High pressure valve Opening pressure 0. 9 - 1.15 bar Low pressure valve Opening pressure 0. 07 - 0,12 bar Valve Timing Camshaft bore Camshaft Camshaft 0.10 - 0,18 0. 010 0. 038 - 0. 018 - 0.034 0. 02 Tolerances and Wear Limits 10 - 01 Conrod bushing piston pin Radial play tmeasured on 2nd, 3rd or 4th bearings, 1st and 5th bearings running in vees Conrod bearing journal Conrod bearing crankshaft...

Removing and installing flywheel and ball bearing

Connecting Rod Bearing Bolt

Piston ring Groove 2 Tapered face scraper ring Replace, tighten to specified torque. Lubricate threads and bearing surface Check for distortion and parallel deviation. Make sure that narrow side with small chamfer faces neighboring connecting rod. Wide side with large chamfer faces crankshaft cheek Heat piston to approx. 60 C 140 F if hard to install, lubricate siightly Lubricate slightly. Position correctly. Note tolerance group Printed in Germany-XIX,1987 Disassembling and Assembling 13 - 13...

Testing and adjustment values for Type 928 S 4 928 GT 928 GTS 541

0227 400 035

24 - 212 Equipment Chart - LH-Jetronic XIX,1987 - CHECKING IDLE - USA - and cars with catalytic converters '87 MODELS ONWARD ENGINE TYPE M28. 41 42 It is no longer necessary to adjust the idle speed and CO level of USA cars and cars with catalytic converters. Do not disconnect the oxygen sensor plug for the idle speed CO level check. Engine in perfect mechanical condition. Switch off all consumers during adjustment. Make adjustments as quickly as possible to avoid excessive heat at intake ports...

Bosch No 0280161008

Bosch 406 Temp Sensor Location

Vacuum Control Switzerland, Sweden, Australia Manual Transm. LH-JETRONIC AIR FLOW LAYOUT -928 S - R. o. W. - 1984 Models Engine Type 28-21 22 3 - Heated wire air flow sensor 7 Electronic ignition control unit 8 Electric air valve air conditioner a Temperature sensor I intake air for ignition P Auxiliary air pump LH-JETRONIC FUEL FLOW LAYOUT -928 S - R. o. W. - 1984 Models Engine Type 28-21 22 Engine Tester with oscilloscope, e. g. 1010 1019, Bosch Mot 300 400 Multiple tester internal resistance...

Replacing toothed belt

Improvised Hydraulic Cylinder

TOOLS - CYLINDER HEAD 32-VALVE ENGINES DISASSEMBLING AND ASSEMBLING CYLINDER HEAD 32-VALVE ENGINES Remove with the aid of a magnet, do not mix up Always renew, press in with press-in tool, Special Tool 9225 1, oil sealing lip Printed in Germany - XVI,1987 Disassembling and Assembling 15 - 111 TOOLS - CYLINDER HEAD 32-VALVE ENGINES 15 - 112 Tools - Cylinder Head XIX,1987 - Printed in Germany Removing and Installing Valve Springs REMOVING AND INSTALLING VALVE SPRINGS WITH SPECIAL TOOL MADE BY...

Machining Cylinder Head Maiting Face

Valve Seat Wear Measuring Tools

2.Use the valve to be installed and measure from the end of the valve stem to the contact face of the valve spring stop in the cylinder head. Distinguishing feature, cylinder head Exhaust manifold attachment, 2-bolt flange l.The valve seats of the 4-valve-per-cylinder heads can be machined. Do not machine past the wear limit, as otherwise the function of the hydraulic valve tappets is no longer assured. 3.While measuring, hold the valve firmly against the valve seat. Printed in Germany-XIX,1987...

Engine tightening torques 32valve engine

928 GTS 5.4 I Engine Type M 28.49 50 Connecting rod bolts forged con-rods Verbusrip nut Camshaft bearing saddles to cylinder head Hex socket head bolts for chain tensioner Camshaft bolt union Cylinder head cover Spark plugs Flywheel bolts 1st stage 2nd stage 3rd stage 4th stage 90 torque angle 90 torque angle 90 torque angle 90 torque angle 90 torque angle