The new sports car from Porsche

The 4,5 liter, all light alloy V-eight engine develops 230 HP, It is front-mounted and connected to the rear-mounted transmission/drive unit with a transaxle tube. This system is also used on the Porsche 924 and results in a 50/50 weight distribution with excellent traction for the rear drive wheels. The smooth-running, high torque engine provides OUTSTANDING performance from 0 to 100 km/b (62.1 mph) in 7.5 seconds and a top speed of 230 km/h (143 mph}.

ENGINE Page

General Information 1

Crankcase — Crankshaft 5

Cylinder Heads — Cam Timing 9

Lubrication 18

Cooling System 24

Ignition System 28

Fuet System 30

Exhaust System 35

Engine Suspension — Specifications 37

TRANSMISSION

Transaxle System — Power Flow 41

Clutch — Operation 44

General Information 49

Gearshift 54

Synchronization 58

Pinion Shaft — Differential 65

Electronic Speedometer 68

Transmission Suspension — Disassembling Transmission 69

Specifications 71

CHASSIS

General Information 75

Front Axle 76

Steering 78

Rear Axle 86

Alignment 90

Brakes 92

Specifications 98

BODY

General Information 101

Body Shell 103

Floor/Frame Assembly 105

Central Locking System 109

Door Trim, Key, Lock, Weatherstrips 112

Bumpers — Windows 114

Switches and Instruments 116

Headlights, Lights 118

Washer System 123

Heater and Air Conditioner 127

Interior — Radio, Seats, Seat Belts etc 132

Panel Alignments — Damage Diagnosis 138

Specifications 141

ELECTRICAL SYSTEM

General Information 142

Central Fuse/Relay Board 143

Central Warning System 144

Wiring Diagrams (Entire Car) 145

Wiring Diagrams (Individual):

Windows — Outside Rear View Mirror 157

Rear Window Defogger 158

Tempostat (Cruise Control) 159

Instrument Cluster — Central Warning System — Indicator Light Board 162

ENGINE Cross Section

928 Porsche Ignition System Diagram

The Porsche 928 is equipped with a water-cooled, 8-cylinder 90° V-engine with a displacement of 4.5 liters, continuous fuel injection, breakerless transistor ignition, hydraulic valve lifters and wet sump lubrication.

Front Engine Longitudinally Mounted

The engine is longitudinally mounted in the front of the car. Technical Data:

Displace

Stroke

Bore

Output

Torque

Compres

Fuel Octane

ment

HP at

kpm at

sion

Rating

cm3

mm

mm

R.P.M.

R.P.M.

ROZ

4474

78.9

95

230

35

8.5 : 1

91

5250

3600

The aluminium crankcase is split horizontally with a separate bolt-on cast aluminium oil sump.

The 95 mm dia. cylinder bores are surrounded by coolant.

The material used for the case upper section is an aluminium alloy with a high silicone content which makes liners made of gray cast iron or steel unnecessary. The cylinder bores are machined so that the pistons and rings only rub against the silicone particles.

The crankcase lower section made of silumin is bolted to the upper section with M 10/M 12 studs and M 8 bolts. Loctite 573 is used as a sealant for the mating surface.

The lower section of the oil sump is divided into four chambers and covered with a wire screen. The oil drain plug is located on Thn left side and the oil filler tube and oil level sending unit are threaded into the top of the sump.

Crankshaft

The crankshaft runs on 5 main bearings and has 6 counterweights.

Main bearing # 3 is the thrust bearing. The main bearing journals have a diameter of 70 mm; 52 mm for the conrod journals.

The toothed belt sprocket and vibration damper are mounted on the front end of the crankshaft with an M 18 x 1.5 bolt and a spring washer, and located with a woodruff key. Degree marks are stamped along the circumference of the vibration damper.

The flywheel for the twin-disc clutch is mounted with 9 Allen head bolts. A grooved ball bearinq is pressed into the crankshaft as a guide bearing for the drive shaft.

Connecting Rods

The connecting rods are made of sinter-forged steel. Two connecting rods are mounted on each conrod journal (cyl. 1/5; 2/6; 3/7; 4/8),

Make sure that conrods are installed correctly when assembling.

The connecting rod ends are offset. Make sure that the narrow side with the small chamfer faces the neighboring connecting rod, while the wide side the targe chamfer faces the crankshaft web.

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Li

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Va

Smart Car Conrod Bolt Torque

The conrod bolts have locating splines and must be tightened to a torque of 5.8 Mkpm (42 ft/lbs}. Lubricate threads and thrust surface with oil,

Mahle pistons — chrome plated KS pistons — iron coated

Pistons

The aluminium pistons (compression ratio 8.5 : 1) have a coated friction surface.

Mahle pistons — chrome plated KS pistons — iron coated

Cut-outs for the exhaust and intake valves are cast into the piston crown at an angle of 20°. The piston pin bore is offset from center by 1.5 mm

Piston rings:

Groove 1 — Taper faced ring

Groove 2 — Taper faced oil scraper ring

Groove 3 — 3-piece steel band ring

Piston Assembly

The piston must be installed with the valve pockets facing toward the exhaust manifold. Important! Make sure that the connecting rods are correctly installed to the pistons.

Cylinder bores and piston diameters come in 3 tolerance groups.

Tolerance Group Cylinder Bore Piston Dia. ± 0.007

0 95.000 94.964

1 95.010 94.974

2 95.020 94.984

Tolerance groups are stamped in the piston crown or cylinder block.

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