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Porsche 1985 928, Workshop Manual

The Porsche 1985 928 Workshop Manual is a comprehensive guide for owners looking to maintain and repair their classic car. This manual includes detailed instructions and diagrams to help users with all aspects of vehicle maintenance. Download the manual for free from manualshive.com for easy access.

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Summary of Contents for 1985 928

Page 1: ...Workshop Manual DR ING h c F PORSCHE Aktiengesellschaft...

Page 2: ...l is only for the internal use of the Porsche Dealer Organization 1977 Dr Ing h c F Porsche Aktiengesellschaft Sales D 7140 Ludwigsburg All rights reserved Printed in Germany Xx 1988 WKD 481 621 Print...

Page 3: ...ission Contrds Case 37 Automatic Transmission Gears Valve Body 38 Differential Transaxle System 39 Chassis BdY Front Wheel Suspension 40 Rear Wheel Suspension Axle Shaft 42 Wheels Tires Alignment 44 A...

Page 4: ...40 35 Disassembling and assembling non adjustable spring strut 40 37 Disassembling and assembling adjustable spring strut 40 39 Disassembling and assembling adjustable and non adjustable spring struts...

Page 5: ...ng system control unit 44 33 Connector assignment of the control unit connector 44 34 Notes on trouble shooting Tire pressure warning system 44 35 Tire pressure warning system RDK diagnosis 44 301 Ari...

Page 6: ...es I Hydraulics Tightening torques 47 01 Notes on brakes 86 models onward 47 03 Disassembling and assembling floating frame caliper 47 l Disassembling and assembling fist caliper 47 7 Replacing damper...

Page 7: ...er drier Removing and installing compressor Disassembling and assembling compressor Regulators and control unit of automatic air conditioner Disassembling and assembling center vent and switch Automat...

Page 8: ...s 87 115 Pressure and temperature specifications 87 116 Troubleshooting 87 118 Auxiliary air conditioner 87 120 Removing and installing magnetic clutch 87 126 Technical Data of air conditioning system...

Page 9: ...79 80 models onward 86 models onward Independent suspension double control arrr with coil spring and internal damper 1 coil spring per wheel Double action hydraulic dampers See page 40 51 dia 26 mm d...

Page 10: ...g strut to body Self locking hex nut Self locking hex nut VM 10 8 46 33 Spring strut and stabilizer linkage to lower control arm VM 12x1 5 8 85 62 Stabilizer clamp to longitudinal member Hex bolt M 10...

Page 11: ...on steering axle upper control arm a Roadspeed sensor to steering knuckle Description Hex bolt Panhead bolt Countersunk bolt Panhead bolt Wheel nut Hex nut self locking Hex nut self locking Hex nut s...

Page 12: ...40 Front Wheel Suspension 928 NOTES ON FRONT AXLE 86 MODELS ONWARD New front wheel suspension 1 2 13 9 40 04 Notes on Front Axle 86 Models Onward Printed in Germany...

Page 13: ...tween bearings increased 10 2 mm before 16 mm Shorter than before Ball joint inclined outward Adjustment 2 pipe gas filled dampers Boge standard and optional previously standard Z pipe pressureless Bo...

Page 14: ...joint external contour smaller shorter than before modified mounting point for spring strut because con trol arm shorter but strut position same as in cars earlier than 86 models Remarks Only for Bog...

Page 15: ...nt Wheel Suspension 40 TOOLS No Description Special Tools Remarks 1 Press out tool VW 267 a 2 Track rod puller e g Nexus 168 1 Printed in Germany XIII 1986 Disassembling and Assembling 40 1 Wheel Susp...

Page 16: ...928 b e kZ ZY _ z cz Fyz lo L 4 n 5 g c J I 9 S I h _ 2 _ I _i F 1 p Y n A 7 16 6 I 0 fT 2s I tc I jq a U fl i 3a 1 5 24 23 22 0 40 2 Disassembling and Assembling Wheel Printed in Germany Suspension U...

Page 17: ...r guide plate 928 S floating caliper brake ItY 3 3 2 1 1 2 1 1 1 1 Note When Removing load ball joint by axerting pressure on Jpper control arm to ease installation see removing as for 36 models onwar...

Page 18: ...tion overview pages 40 16 to 40 18 inspect renew if necessary reworking is impermissible inspect for damage reworking is imper missible See page 40 25 renew torque 120 Nm 88 ftlb lubricate sliding suf...

Page 19: ...torque 46 Nm 33 ftlb Coat threads with 3ptimoly HT do not apply Optimoly HT to bolt shank Screw in until only 2 threads are visible Do not tighten to 120 Nm 88 Fltb until assembly is completed and spr...

Page 20: ...Installing do not mix up with washer No 20 renew if damage sus pected No reworking is permissible Tighten bolts No 19 of bearing clamp No 21 as specified When replacing do not con fuse with control a...

Page 21: ...40 0 c flGPJ I _SZ _cc it i J a A 6 A 9 2ygq i 15 _ 1 1 I 20 12 6L M 13 I 11 I 10 3 1 z i II _ I 28 25 2423 5 4 1916 17 16 6 26 Printed in Germany XIII 1986 Disassembling and Assembling 40 7 Wheel Su...

Page 22: ...k nuts No 17 on caster and camber eccentrics Installing Renew torque 46 Nm 33 ftlb oat speed sensor and hole in steering knuckle with Molykote 0ngterm 2 Renew O rina of soeed sensor Tightening torque...

Page 23: ...earlier than 1986 Spare part number on linkage Tightening torque for upper and lower mountings 85 Nm 62 ftlb Install right way round Cranked end at top at spring strut mounting and tilted forward no d...

Page 24: ...r slots of ball Dints page 40 23 hen replacing note age 40 21 P il nspect renew if ntecessary Close slot P age 40 23 WI m f m P i C t H m 0 t i hen replacing do not ix up with version or cars earlier...

Page 25: ...HT on bolt shank is im permissible Screw in until only 2 threads are visible Do not tighten to 120 Mm 88 ftlb until assembly is completed and springs have settled do not mix up with Masher No 27 chec...

Page 26: ...sus pected No reworking is permissible Tighten bolts No 23 of bearing clamp No 25 as specified When replacing do not mix up with control arm for cars earlier than model year 86 Part marked Porsche bef...

Page 27: ...until end of model year 85 p l FF Mounting 86 models onward Beforehand open plug in connector of ABS and brake pad wear cable and disconnect 3 493 Z Disconnect ground lead 86 models onward Remove spe...

Page 28: ...ssembly parts Never use Optimoly HT on contact surfaces of steel to light alloy as moisture will produce corrosion When applied to threads this lub ricant has no effect on tightening torques Optimoly...

Page 29: ...ning and to allow installation of collar nuts also for disassembly apply pressure to upper control arm to load ball joints a Note Spray adjustment control arm with threaded section plate on lower ecce...

Page 30: ...stabilizer knuckle shorter and less cranked than 86 models onward until end of model year 79 solid stabil izer 80 models onward tubular stabilizer Version B 86 models onward shorter than until end of...

Page 31: ...B 86 models onward 1 Upper control arm 2 Lower cdntrol arm I No Porsche inscription Dim X 191 mm With Porsche inscription Dim X 179 arm I 3 Track rod Dim X approx 245 mm Dim X approx 235 mm Printed in...

Page 32: ...a I 4 Stabilizer linkage Spare Part No arrow Spare Part No arrow 928 343 069 00 928 343 069 01 Dim X approx 135 run Dim X approx 142 rmn A Dim a 95 3 mm Dim b 38 z 1 mm I 5 Stabilizer Dim a 102 3 mm...

Page 33: ...uspension This modification included redesigning retaining clamps and camber and caster eccentrics retaining clamp with modified mounting point for spring strut as control arm shorter but same strut p...

Page 34: ...ric The original type of mounting has now been discontinued The modified versions may be retrofitted to these cars Original and modified parts are not interchangeable This means that when a modified m...

Page 35: ...a danger of mixing up modified and new current parts Example if the wrong clamp is mounted the installation position of the spring strut is incorrect and the clearance between spring strut and upper c...

Page 36: ...rd part No AKD 522 009 used to seal the 924 and 944 taillamps is suitable for this application Before sealing ensure that slots are dry and free of grease If eccentric does not move freely dirt in slo...

Page 37: ...nks and joints as well as the leaktightness of the protective caps We recommend that the protective caps of the joints be checked whenever work is carried out on the front axle visual inspection Inspe...

Page 38: ...een discontinued and are no longer available as spare parts It is permissible to install the newest steering knuckle on one side only Disassembly Lower Ball Joint When the securing nut is slackened ca...

Page 39: ...1 Multi purpose tool 2 Puller 3 Pressure piece 4 Pressure piece 5 Pressure plate 6 Pressure piece 7 Pressure plate 7 6 5 3 Special Tools VW 771 9165 P 85 9154 VW 447 i VW 433 VW 511 Remarks Printed i...

Page 40: ...pped with floating calipers brake caliper brake disk guard and steering knuckle are of different appearance and size The following components of four piston fixed caliper brakes differ in appearance a...

Page 41: ...f 86 models WY 2 2 1 1 1 1 1 Note When Removing Do not remove brake hose when working on front wheel suspension attach to suitable point with wire Drive out with multi purpose tool VW 771 and 9165 Ins...

Page 42: ...with Pack recess with a ABS Shell Retinax A If difficult to re move see P 46 11 Heat wheel hub to Heat wheel hub to 120 120 to 150 c to 150 C Press out with pressure piece 9154 Place pres sure plate V...

Page 43: ...to 150 C Press out with P 85 and 9154 As of 8C models the race can also be re moved using a drift placed in the grooves Heat wheel hub to 120 to 150 C Place in position and press in with pressure pla...

Page 44: ...ess bearing races out of wheel hub Bearing race for outer wheel bearing 2 Use a large screwdriver to lever off radial seal Take care to avoid damaging the seat of the seal and the impulse ring of cars...

Page 45: ...outer bearing race in the wheel hub and press in until seated with suitable pressure piece e g VW 432 Assembling 3 Position inner bearing race and press in until seated with pressure piece 9154 and p...

Page 46: ...ront wheel bearing noting the following points Tighten clamping nut slightly turning the hub Slacken clamping nut until the thrust washer can just be moved with a screwdriver under finger pressure Do...

Page 47: ...nch DIN 1810 dia 80 90 Special Tools VW 267 a VW 340 Remarks Porche version manu factured by Klann desription supplier see Workshop Manual Workshop Equipment 3 Group 4 Commercially avail able e g Salt...

Page 48: ...arch Z Remove wheel unscrew flange lock nut and press off upper ball joint with VW 267 a 3 Unscrew self locking nuts from upper control arm inside engine compartment 4 Remove damper mounting bolt Inst...

Page 49: ...928 Front Wheel Suspension 40 I 7 4 WY a 9 I_ 54 YaEuD I I 4zmps p 11 Printed in Germany XIII 1986 Disassembling and Assembling 40 37 Non Adjustable Spring Strut...

Page 50: ...stall right way position round Installing Renew and tighten to 60 Nm 44 ftlb Coat rubber bush dith Molykote U Note arrangement and assembly instructions Overall length approx 170 mm Note installation...

Page 51: ...7 _ 6 4 9 i g 1 L r ll 12 I I I I I I i i i I I I I I i M y 2 4 q P e y 3 i m 2 t ib 4 w gF _c r 7 13 a 2 Stop washers No 8 in 928 S 4 Club Sport Version Printed in Germany XX 1988 Disassembling and A...

Page 52: ...d coil spring with VW 340 or Klann KL 0014 lark installation losition Same parts as used in non adjustable spring strut Installing Renew and tighten to 60 Nm 44 ftlb Coat rubber bush with Molykote U N...

Page 53: ...contact surface for spring plate with Dptimoly TA Boge and Bilstein are different Boge only Install with inner bevel down Coat thread with Optimoly TA Damper design modi fied 86 models onward Damper i...

Page 54: ...ing nut from piston rod Remove washer and upper damper mounting _ g JJf 1 ST 4 _ 4 1 J y L r c 1 LJ ij 0 KL 0014 Klann jy I z I c d Ti 9 1 y r I c F _ g y yzri c zT I lilCq N 3xgzrA r 3 When using spe...

Page 55: ...hand The damper must move smoothly throughout its travel The expansion and compression stage damping must be clearly perceptible up to the final position Because of the gas pressure resis tance incre...

Page 56: ...tom _ W _ 2 If parts which affect the height setting of adjustable spring struts have been replaced begin by moving the adjuster nut to its original position After instal lation readjust height settin...

Page 57: ...end of spring to remain against spring plate stop If a Klann spring tensioner is used no vise required the strut can be brought to its instal lation position with the spring pre tensioned Screw self l...

Page 58: ...eless Boge dampers from September 1983 to end b of model year 928 S with Bilstein dampers from February 1984 onward Group 3 Color code 1 x green 2 x green 3 x green Spring force F where Ordering lengt...

Page 59: ...Spring Part No 928 343 511 01 blue Used in 928 982 S with Boge dampers As of start of range up to following chassis numbers 92 A0 80 0645 928 Europe rest of the world Japan 92 A0 81 0714 928 USA 92 A...

Page 60: ...01 R H drive cars 6574 6769 N 902 Group 1 springs with spacers have also been installed in right hand drive cars Refer to table when replacing Springs with 3 white dots discontinued were installed in...

Page 61: ...he front axle by approx 10 mm A maximum of 2 spacers per spring strut is permissible g s p F a w I w M 3 Gas pressure Dampers Bilstein If Boge dampers are replaced by Bilstein dampers and no further c...

Page 62: ...standard X X 86 models onward 0 0 a 928 S optional extra X X 86 models onward 0 0 alternative x x ie pipe ressureless JGas pressure x x 0 0 0 0 x x x x 0 0 0 0 x x x x 0 0 0 0 v v grey grey red red re...

Page 63: ...on links and upper wishbones coil springs and internal dampers 1 coil spring per wheel double action hydraulic dampers page 42 18 d 021 mm 0 22 5 x 3 5 mm tubular stabilizers modified in course of mod...

Page 64: ...Brake caliper to wheel carrier Hex bolt Wheel carrier to lowe suspension link Locknut Upper suspension link to transverse member upper suspension link to wheel carrier Locknut Propshaft or rear axle...

Page 65: ...izer Speed sensor to wheel carrier Angle bracket to wheel carrier Angle bracket to transverse member Guard to wheel carrier Description Locknut Hex bolt Hex bolt Hex bolt Locknut Cap bolt Hex bolt Loc...

Page 66: ...pecial Tool Remarks 1 Punch I 407 Thrust plate VW 402 3 Tube VI 41s a 4 Punch Vii 408 a 5 Support ring 1 440 6 Thrust tube h 155 I Remover installer VW 459 2 Part of VW 459 8 Tllrust tube P 2M Prmred...

Page 67: ...RCBI Wheel Suspension Axle Shaft 12 10 71 ln Yf I 9 m r b 27 1 j i 3 yI_ c j p z b 23 Ai T rn 42 24 40 31 A 4 32 30 38 29 28 1 2 42 2 I i5ascnhlinc 3nd Asscnlhlins licar Surpnciiin Primmed in Germany...

Page 68: ...Locknut 3 Replace tighten to specified torque 6 Warhei 73 7 Plug 1 a cover 1 9 Locknut 2 Rrplace tighten to specified torque 10 Washer 2 11 Pivot pin 1 I2 Washer 1 13 cone washer 2 14 Spring strut 1 I...

Page 69: ...26 Locknut 1 Tighten to specified tOrq e 29 Eccentric disc 1 30 Eccentric bolt 1 31 Locknut 1 Tighten specified to tOrq e 32 Washer 1 33 Eccentric bolt 1 Lubricate with MoSz greare 34 Lower control ar...

Page 70: ...brake disk after removing two countersunk screws 4 Remove parking brake shoes and expansion lever Pull parking brake cable out of its guide in wheel carrier 5 Remove wheel carrier Printed in Germany...

Page 71: ...IJ to rubber bushing of stabilizer linkage and rubber bushings No 39 and 40 of lower control arms page 42 2 before installing suspensions links in car N See Table of Consumables Tech nical Information...

Page 72: ...ension Axle Shaft 42 TOOLS N I Description Punrh Base plate Drive sleeve Tube Extractor ipecial Tool Remarks VW 407 VW 441 VW 244 b VW 415 a Standard Printed in Germany Disanrvnhling and Asscmhling ll...

Page 73: ...42 Rear Wheel Suspension Axle Shaft 928 pcz _ i p1 P a 42 8 Disassembling and Assembling Hub Assembly Printed in Germany...

Page 74: ...hereby suitable base ball bearing inner PM3 race must be on VW 415 a 6 Circlip 1 Replace if necessary 7 Brake backing plate 1 Insert wheel hub in ball bearing before pressing in 8 Ball bearing 1 lleat...

Page 75: ...X4 b and suitable barc pl itL 2 Remove circlip 4 Press hearing inner iace off of wheel hub with an extractor and Special Tool VW 407 _ a pi _ c _y 1 2 iv 0 s 4 P r T l 3 Press out Ihall hearing with...

Page 76: ...hub carrier to 120 150 C 248 302 F install ball bearing and then pres on slightly l VW441 L L me c rAh I_ a a At i 2 Press in wheel hub after installation of circlip and brake backing plate Printed i...

Page 77: ...aligned 2 Press in link pin far enough so that bolt can be installed without applying force Note Rubber mcwnts used for lower control arms have a long service life but if they do have to be replaced t...

Page 78: ...Tool VW 415 a as a base PIT J c I I c Press in mount using waxfree Capella Oil B ITexaco and Special Tools VW 415 a and 408 a Position correctly Apply pressure pad to conical end of metal bushing to p...

Page 79: ...w permanently elastic seal on the mounting plate 300mm long and circular in shape with for example Prestik 4 mm dia Item No 0593 from Bostik Coat rubber mount on mounting eye with Molykote U 2 Tighten...

Page 80: ...sioiyng device Sickle wrench DIN 1810 dia 80 90 Special Tools VW340 Remarks Porsche version by Klann see Workshop Manual Workshop Equipment 3 group 4 for description supplier commercially available e...

Page 81: ...42 Rear Wheel Suspension Axle Shaft 928 r 7 I 13 14 T r 3 15 i J J 16 i t 5 s 6 6 42 16 Disassembling and Assembling Spring Strut Printed in Germany...

Page 82: ...spring Protective tube tY 3 3 1 1 1 1 1 1 1 1 1 1 1 Note When Removing jtretch coil spring rith VW 340 or Klann L 0014 Installing renew torque 46 Nm 33 fltb renew torque 58 Nm 42 ftlb coat with Molyk...

Page 83: ...with grooves down Coat contact surface for adjuster nut with Optimoly TA Note remarks on page 42 18c Boge only Coat thread with Optimoly TA See remarks on page 42 18c Check freedom of movement to fac...

Page 84: ...te Distinguishing features of dampers see page 42 18d Boge Dampers Pressureless With damper in installation position extend and compress by hand The damper must move smoothly and with uniform resistan...

Page 85: ...ossible If dimension X is larger than 18 mm new damper 8 5 mm the damper must be replaced Assembling Rear axle springs are available in three versions The versions are color coded The springs with gre...

Page 86: ...ing chassis numbers 92 ES 840 416 928 S Europe r o w 92 ES 849 568 928 S Japan 92 ES 860 562 928 S USA in the current 84 model year the coil springs both spring plates of the supporting plate and the...

Page 87: ...928 S standard X xx x black until end of model 0 00 0 black year 85 928 S optional x x x x gold extra until end of 0 0 0 0 gold model 85 year 928 S standard X X x x 9rw 86 models onward 0 0 00 grey 9...

Page 88: ...ssion end and self locking nut on wheel end Note Self locking nut is accessible after removing wheel cover Wheels do not have to be removed 2 Run out axle shaft on right and left sides toward inside L...

Page 89: ...uspension Axle Shaft 42 l TOOLS NO 1 I 2 3 4 Descriprion pecial Tool Circlip pliers Punch VW 161 a VW 408 a Plate ueeYe VW 401 VW 455 Remarks Printed in Germany _ 11 1 7g Disassembling and Assembling...

Page 90: ...J i cdc r cl Suapvnsion Arlc Sllafr I 2x 3 l v 1 6 Tg j J a a I _ 7 0 y y i zd x_ 5y Q 1 I 7 0 fj In a 42 22 Disassembling and Assembling Axle Shaft Printed in Germany...

Page 91: ...s 2 Replace if necessary 1 Check r nout Modified Axle Shaft Dust Cover Versions Axle shafts with welding on one side are installed since 1082 models The transmission end shaft is still bolted as befor...

Page 92: ...nd boor be clean and free of grease Adhesive 3 M Scotch Seal 750 available in 5 oz tubes 2 Squeeze new clamp with a special pliers e g VW 1275 between machined shoulders of sealing flange 3 i ephce ga...

Page 93: ...6 Position dust boor correctly lnsrall lamp Disassembling loin1 musl be disassembled TOreplace grease when seriously conraminared or when bearing surfaces and balls have ro be inspected for wear or da...

Page 94: ...Assembling 1 Check joint ball hub ball cage and balls for pitting and scoring Excessive radial play in joint will be noticed by knocking noises when acceleraring decelerating Replace joint in such a c...

Page 95: ...balls are at same distance as orbits arrows 1 Check funcrion of joint Constanr velocity joint has been assembled carrecrly if ball hub can be pushed back and forrh by hand over rhe entire axial compe...

Page 96: ...nr is il itic pend from wilt in iwri wlill pi ilii r 0 m r axle CTO ln r l l r 6 Disconnect slabilizer at Inwer control arm 7 1 _ _ c l I 7 Slipport transmission from tabiii7er I h ilk pecinl fool lJS...

Page 97: ...r Y c cro rncmhcr I l n c fl i jad llnd rnratil Til T 3x e rm Ill l hsx Al l p i tilrn of r llr axle cmsi mcmkr JPC IC VC rc r lwillg I halt of war il C Lrtl l 11 11 11 1 11 ILower rcnr 2x1 carefully...

Page 98: ...bolts and align axle to original position as marked Tighten bolts IO specified rorque 3 Align transmission suspension see point 8 Refer COGroup 34 if nanmission suspensiorl has to be completely aligne...

Page 99: ...e pressure of cold tires appror 20X summer and winter tires 15 and 16 inch front rear 17 inch front rear Summer tires 2 5 bar pas pressure 2 5 bar pos pressure Winter tires 2 5 bar pos pressure 3 0 ba...

Page 100: ...orrect tire specification character The specifica tion characters N 0 N 1 or N 2 respectively help to distinguish summer tires approved by Porsche from other versions of identical tire type and the sa...

Page 101: ...alve points to the bottom Tighten the wheel in this position After balancing mount the wheel to the ve hicle in an identical position valve faces to the bottom color coded wheel stud and lock ing whee...

Page 102: ...face 173 10 mm on lateral subframe Toe in each wheel lO k5 10 10 Camber 40 f 10 HeigM adjustment settings apply to new cars After cars have been driven for a period the heigM may be max 10 mm less in...

Page 103: ...1 0 I la rh l arlimn nt 1 0 I 10d en Empty 1e1 1 sccodng to 8 x020 pm I IYe Ian Ipsrl d and lb 5 0 5 3 s E 2 i 1 10 0 1 1 0 I 5 0 G 3 9 2 9 t 1 0 I t 12 0 3 The caster adjustment setting has been cha...

Page 104: ...patch to measuring surface 173 10 mm on lateral subframe 10mm Toe in each wheel lo 5 Camber 4O k 10 Height adjustment settings apply to new cars After cars have been dri 10 10 i for a period the heigh...

Page 105: ...for 1991 models on to 4 1 previously 3 30 30 This changed caster value can be adoopted retrospectively on cars back to 1986 models inclusive from introduction of vertical ball joint at front axle subf...

Page 106: ...e steering wheel and steering for track adjustment Before starting to adjust the wheel values for front or rear axles it may be advisable or necessary to check the rear axle height setting at DIN curb...

Page 107: ...downward in a precisely defined way Description in the following text fnfloenced vehicle height Existing height value after the vehide or front axle have been raised Never use this height value as a s...

Page 108: ...nge An increase in spring pretension raising the vehicle on one side causes an increase in wheel load An alteration in wheel load always acts on the wheel diagonally opposite In other words if the whe...

Page 109: ...and right 10 mm 2a If the vehicle height at the front axle is deter mined by the coil spring and cannot be ad justed It is only possible to make a correc tion by replacing the front axle coil springs...

Page 110: ...able range is not reached if height is adjusted according to regulations Rear axle 1 At actual vehicle helght Page 44 2 I44 2a measure from tire contact surface to measurlng polnt on the cross member...

Page 111: ...are both adjusted by means of eccentrics on the lower control arm Tighten self locking hexagon nuts with 120 Nm 83 5 ft lb Seal the slit openings for the adjusting eccen trics Page 40 23 Note If vehic...

Page 112: ...ition with steering wheel lock and adjust the toe with the tie rods Track difference It is not possible to adjust the track difference can only be affected by replacing steering arms Rear axle Adjust...

Page 113: ...ged rims should never be straightened Distance a 8 mm Check flanges of aluminum wheel rims for wear The inside rim flange is nwre subject to wear Use a standard 8 or 10 mm radius gauge for checking Re...

Page 114: ...nsuitable assembly compound Is used the following may occur Tire may rotate on the wheel bead core may break during fitting and the rim surface may be damaged by aggressive substances Caution Use only...

Page 115: ...out of the wheel tire rim is 1 25 mm Try to achieve values less than 1 Omm and greater than 0 5 mm If necessary turn the tire on the rim by 90 or 180 to obtain an acceptable value uncontrolled match...

Page 116: ...relative to the wheel hub or brake disc In addition rotate the valve so It Is In the upper posftion or in the case of 174nch wheels In the lower posltlon before the wheel is tightened on the wheel hu...

Page 117: ...nd lateral run out on wheels without flat spots with a radial run out measurement gauge e g VAG 1435 Tfy fo achieve values of less than 1mm and greater rhan 0 5 mm Tires must be matched to achieve min...

Page 118: ...ire assembly compound refer to page 44 7 to keep the tire from rotating on fhe wheel during the first drive as this would render all Ihe careful work useless 20 mm tire s ip on the wheel may be enough...

Page 119: ...l wheel fixture wheel lying position the valve op posite the mechanic then pull the wheel in this position in the direction of the mechanic and clamp firmly Check the radial and lateral run out during...

Page 120: ...electronic fine bal ancing of the wheels on the vehicle Refer to the equipment s operating instructions for procedure If all wheels are to be finely balanced begin at the front axle 4a Fine balancing...

Page 121: ...ann finish balancer use the special mounting forks with spigots Hofmann Part No 641 4113 which fit into the recess of the wheel mount arrow 6 c i 88 265 Notes Make sure that no parts are damaged by th...

Page 122: ...tions If the balancing result is still not completely acceptable e g 5 g even after calibration alter the balance weight according to the balance correction table and eliminate the residual imbalance...

Page 123: ...the actual conditions Subsequently with a good balance result slowly increase the speed to 190 km h and pay par ticular attention to the areas where there are obvious vibrations in the steering wheel...

Page 124: ...the risk of contamination The self adhesive weight must be fitted care fully on the smooth ring surface of the wheel It must fit evenly over the entire contact area Check that the balance weight is fi...

Page 125: ...ts front face and should then be rounded arrow Tire assembly Fit wheel to assembly stand and coat in side of wheel and both tire beads with tire assembly compound Replace the valve whenever a tire is...

Page 126: ...the addi tional tire lever below the hump When inflating the tlre the beads must Jump over the hump at a positive pres sure of 4 5 bar at the latest The bead still located in the drop center must the...

Page 127: ...rag or a leather cloth between the wheel and the tire lever In addition make sure the tire remains in the drop center opposite the disassembly head Fig 1018 44 Use Special Tool 9539 to facilitate this...

Page 128: ...ys use a perfect condition Special Tool P 300 Other rocker wrenches wrench rockers or wheel bolt wrenches mav not be used Intoact tools nut never be used regardless of circumstances x I s C 1 L 1 2 Lu...

Page 129: ...apter M 402 H 1 Grind off calotfe with the mentioned tools Work with a speed of approx 450 rpm to guarantee good chip removal Also bleed tool The calotte will jump off of the wheel bolt after complete...

Page 130: ...sure with a greater degree of accuracy and reliability than any pressure tester in the on board tool set at the garage or in the workshop automatically allows for temperature s influence on the air pr...

Page 131: ...ent cluster Arrow Display boxes for the information system fault display tire pressure warning system 3 Warning lamps 5 2 pressure operated switches per wheel offset by 180 6 1 HF sensor per wheel hig...

Page 132: ...the wheel turns the pressure operated switches are led past the HF sensor At the same time the resonant circuit of the pressure operated switch enters the effective range of the HF sensor s electroma...

Page 133: ...osition see page 44 33 2 Instrument cluster 3 Deflector for pressure operated switch 4 High frequency sensor front 5 High frequency sensor rear 5 I 7 6 l 6 Pressure operated switch 2 5 bar front 7 Pre...

Page 134: ...arted Tire pressure monitoring starts after the car has been driven for approx 20 m and when a minimum speed of 5 kph has been reached Display A Arrow indicates wheel with low tire pressure cause in w...

Page 135: ...2 1 k 24 I 1 2 G 5 z IL I 2 P E 32 2 L d s 2 i m i z i sti j Es gPE gs5 n m 3 g g SB h z3 3 S g mr 2 g acjg z ZZF msc 600 Fi z zc GJ k zzg 3rnZ ES c 5 5335025 ti k 5 s a E zi z 0 II E g I 2 3 z E E 1...

Page 136: ...d tires may suffer damage a loss of pressure several times in raoid suc xssion or if the ores as well hem or that the tire valve or the wheel rim are damaged see Page 44 26 Very slight tire pressure l...

Page 137: ...ire pressure further at the affected axle Repeat this procedure until no further warning is displayed However do not exceed maximum tire pressures of 3 5 bar at the front wheels and 4 0 bar at the rea...

Page 138: ...of the tester at the correct wheel position the display for the RL or RR pressure sensing switch changes from Open nach Closed assuming that the tire pressure is correct in case of doubt slightly inc...

Page 139: ...pressure sensing switch for the wheel convemed is faulty and must be replaced Check pressure sensing switch by using the 9288 sys tem tester see Page 44 311 Do not drive the car at wthan Above this s...

Page 140: ...t 44 a Removing and installing pressure operated switches tire pressure warning system Special tools No i 1 4 Removing and installing pressure operated switches tire pressure warning system Printed in...

Page 141: ...e tire momring unif at the central point belween both pressure opera red swirches The deflector arrow must remain fitted while removing and fining the tire to protect the pressure operated switch The...

Page 142: ...services of a second mechanic to counter the pressure operated switch while you tighten the fastening nut Tighten ing torque for the fastening nut 20 Nm 15 ftlb Note The pressure operated switch must...

Page 143: ...s approx 6 2 2 mm This distance is maintained as long as the HF sensor holder is not out of shape 1 Remove the HF sensor fastening screws from the holder 4 Carry out HF sensor test after installation...

Page 144: ...losses on the last 8 occasions that the car was driven can be read out with the 9288 sys tem tester Page 44 302 Removing Unscrew and remove the screws holding the RDK control unit Remove control unit...

Page 145: ...not in use 13 Ground 14 not in use 15 not in use 16 not in use 17 HF transmttter FR 16 HF transmitter RL 19 Data line to diagnosis L 20 Data line to diagnosis K 21 not in use 22 to alternator terminal...

Page 146: ...everal combined plug connections of the same type in the lines for brake pad wear speed sensors and HF sensors The lines in this area can be distinguished from one another as follows Sheathed lines fo...

Page 147: ...unit If Club sport vehicles are fitted with winter tires remove the spacer on the rear axle if necessary This is only necessary if the vehicle is filed with permitted rims having a different offset I...

Page 148: ...the number of systems capable of self diagnosis will be increasing in the forseeable future di agnosis of the relevant system will be filed at the end of the respective repair group as of now The pag...

Page 149: ...sis with the 9288 system tester must be carried out with the ignition switched on and the car standing still 1 Connect the 9288 tester to the diagnosis socket under the booster cover next to the passe...

Page 150: ...out tire pressure loss event memory 5 m on desired menu Menu 1 Fault memory From Page 44 305 on Menu 2 Sensors Checking HF sensor and speed sensor Page 44 310 Menu 3 Switch inputs Pressure switch test...

Page 151: ...n by foreign bodies and check the wheel for leaks Perform the quick RDK test Page 44 28 in order to determine whether a pressure sensing switch is faulty If necessary localize the faulty pressure sens...

Page 152: ...control unit software status R 02 on introduced during 1991 model year the road speed when the fault first occurred is memorized If the 9288 system tester is connected make quite sure that no speed ra...

Page 153: ...also be checked via menu 2 sensors In this case HF sensor defective appears regardless of wheel position if there is discontinuity Open HF sensor connector on the wheel carrier Check cable path for d...

Page 154: ...fault code 1 for all faults but use PIN 17 of the control unit plug ABS speed sensor rear len Fault code 5 Open circuit short to ground Check speed signal via menu 2 sensors If no bar diagram appears...

Page 155: ...nsmitters There Is no fault in the vehicle Fault present First try replacing the ABS control unit then the tire pressure warning system control unk ABS speed sensor rear right Fault cc de 6 proceed as...

Page 156: ...rument Fault code 9 Open circuit 1 Short to ground In the case of discontinuity ground fault or short circuit check the line from PIN 3 of the tire pressure warning system control unit connector to PI...

Page 157: ...line to the control unit Tire pressure greater than switching pressure above the Refer to menu 1 fault memory to remedy faults for fault HF sensor code1 4 a Open pressure operated switch Tire pressur...

Page 158: ...Fault Remedies Preconditions Pressure switch 2 pressureoperated switches offset by 180 must be checked per wheel Align pressure operated switch with HF sensor Then a tire pressure greater than switchi...

Page 159: ...s to say journey 8 is shown on the system tester s display The event memory cannot be erased If the button is pressed the next wheel for which a tire pressure loss event was recorded will be displayed...

Page 160: ...kph Right rear wheel RR No pressure loss Left front wheel FL Pressure loss detected by 1 switch at 100 kph l Right front wheel FR Pressure loss detected by 2 switches at 270 kph Journey 7 of 8 At all...

Page 161: ...of 8 No pressure loss at any wheel Display after Journey 1 Displayed data Drive 6 of 8 no pressure loss as for journeys 7 and 6 No pressure loss but with the appropriate journey number Journey 5 of 8...

Page 162: ...ly applied even in a curve It is not possible to retrofit ABS in cars built before model year 84 as the body has undergone a number of changes since then Modifications 86 models onward As of model yea...

Page 163: ...Wheel The diagram shows the interrelations of braking force cornering force and slip An increase in braking force causes a very fast reduction in cornering force and consequently in directional contro...

Page 164: ...pared to that of older models in brake circuit division now by axles stepped brake master cylinder piston diameter of both pistons formerly the same and brake force regulator see page 47 la a 1 Brake...

Page 165: ...el house wall It processes the electric signals coming from the electronic control unit The hydraulic unit can change the hydraulic pressure to the wheel brake cylinders independently of pressure in t...

Page 166: ...heel hubs or wheel end shafts on rear axle and produce an alternating voltage for each pulse tooth This alternating voltage changes its frequency to indicate speed acceleration and deceleration of whe...

Page 167: ...sters i e Bosch K 7 VAG 1516 and Bosch ABS 2 LED Vehicles with PSD may only be tested with the ABS 2 LED tester in conjunction with the 55 pin adapter lead refer to drawing 499 45 ABS testing on vehic...

Page 168: ...ake system a simple functional check is sufficient I e after starting the engine the warning lamp in the instrument cluster must go off lf the ABS system is o k Operations of this type include replace...

Page 169: ...ous ABS control unit versions had 35 pins When repairs are required make sure the PSD ABS control unit is not con fused with the PDAS ABS control unit fifed to the 911 Carrera 4 To tell the two versio...

Page 170: ...t Not only PSD system faults are stored in the ABS PSD control unit but also some ABS system faults Fault displays via the instrument cluster On vehicles with PSD an ABS fault is indicated not only by...

Page 171: ...D 31 ABS valve front left ABS 32 ABS valve front right ABS 33 ABS valve rear axle ABS 34 Valve relay hydraulic unit ABSIPSD 35 Return pump hydraulic unit ABS System allocation PSD PSD PSD PSD ABSIPSD...

Page 172: ...olders on wheel housing locks are opened from above Insert plugs in open brake lines and connections immediately danger of dirt entering system If plugs are not available for brake lines first drain t...

Page 173: ...be replaced see page 45 6 I I w sres Note Never loosen or tighten bolts marked with arrows 7 Disconnect ground wire on pump motor and loosen two mounting bolts 8 Loosen mounting bolt as well as bracke...

Page 174: ...ith clips and engage locks Note Make sure brake lines are routed correctly 6 Connect 12 pin plug and secure cable release Mount cover on hydraulic unit 7 Mount wire harness on hydraulic unit bracket l...

Page 175: ...rearmost position and raise steering wheel to facilitate work 2 Dpen retaining spring clamp and disconnect plug from electronic control unit 3 Unscrew mounting nuts and remove electronic control unit...

Page 176: ...ct control unit when replacing the units as it may be confused with other ABS control units The only outward differences of the control units are the Bosch and Porsche part nos respectively 2 Take ele...

Page 177: ...out and insert ABS relay respectively electronic relay with overvoltage protection Note The relay is located in the lower row of the Central Electrical System f i versiort up to endo MY S Relay No Xl...

Page 178: ...l 1 Remove the wheel housing cover 2 Remove the cover hood a 3 Pull out fuse for solenoid valves No 7 or for the pump motor No 8 with the ignition switched off Installation Proceed in reverse order a...

Page 179: ...steering knuckle 3 Remove front exhaust shield to make procedures easier Unclip wires on wheel housings and pull out with rubber grommet in direction of wheel Also pull out rubber grommet for brake l...

Page 180: ...and pulse gear is given by design and cannot be adjusted 3 Route wires correctly insert rubber grommets and clip rubber mount in holder Install exhaust shield Connect wire plug and press into holder...

Page 181: ...urrs on magnetic edge of speed sensor before installing 1 Coat speed sensor and bore in wheel carrier with Molykote Longterm 2 Replace O ring of speed sensor 2 Insert speed sensor in wheel carrier wit...

Page 182: ...ng Note Do not remove speed sensor from its protective package until shortly before installation loss of permanent magnetism Before installation check that no forei n bodies metal shavings 7 have been...

Page 183: ...n wheel carrier and tighten Allen bolt to secure Torque 10 Nm 7 ftlb Note The distance between speed sensor and impulse ring is a design feature and cannot be adjusted 3 Place cable in clip on wheel c...

Page 184: ...n via air guide ducts In all cars sliding brake calipers are mounted on the rear axle Brake pads with differing friction values are used It is essential to ensure that the appropriate parts are instal...

Page 185: ...c unit cars with ABS for rear axle brake circuit Since 1984 models optionally extra with ABS which is integrated in the con ventional brake system 9 inches 10 inches internal ratio 3 0 for floating fr...

Page 186: ...rake discs after machining Play on brake pedal with brakes bled and engine stopped H a n d b r a k es parking Mechanical action on both rear wheels Brake drum dia Brake shoe width Brake surface per wh...

Page 187: ...th four piston fixed calipers front and rear Push rod braking circuit for front wheels A braking force regulator is bolted on the main brake cylinder or on the hydraulic unit with ABS system for the r...

Page 188: ...250 8 mm 246 mm 86 models each fixed caliper 2x42 2x36mm 87 models onward each fixed caliper 2x44 2x36mm each fixed caliper 2 x 30 2 x 28 mm 126 cm2 86 cm2 424 cm2 13 mm 13 mm 32 mm 24 mn a Wear Limi...

Page 189: ...cifications 30 6 mm 22 6 mm 0 02 mm 0 05 mm 0 1 mm 0 006 mm approx 10 mm usually i e without any means of support for foot brake arm determined by permanently set clearance at points inside braking un...

Page 190: ...uckle Locking paw1 for handbrake to bearing bracket Propshaft or rear axle to wheel hub Wheel to wheel hub Description Allen head screw Hex screw cap screw Hex screw cap screw Guide pin Hex screw Hex...

Page 191: ...lever Guard to wheel carrier Speed sensor to wheel carrier and steering knuckle Description Locknut Locknut Hex bolt Socket head screw Thread M8 VFM 8 M6 M6 Material 8 i 8 8 8 Torque Nm ftlb 23 17 i I...

Page 192: ...4 mm 16 bar 0 46 front rear front rear 322 mm 299 mm 259 6 mm 246 mm front 2x44 2x36mm rear 2x30 2x26mm front 302 cm mar 172 cm2 474 cm front rear approx 12 mm approx 12 mm Remarks dimenslon 926 GTS W...

Page 193: ...ke handbrake Parking brake drum 0 Brake shoe width Brake lining thickness Remarks dimensions 926 GTS L 32 mm 24 mm 30 6 mm 22 6 mm 0 02 mm 0 05 mm 0 05 mm 0 1 mm 0 006 mm approx 10 mm Wear limtt 926 G...

Page 194: ...ed below This will depend on the location of the warning contact in the brake pad The pad end take up bore has been moved 1 5 mm in direction of the pad back plate as from April of 1982 Tolerances on...

Page 195: ...ause uneven braking effect 1 Pull warning contact out of pad plate Note Replace warning contacts when core of wire has been ground through or down The warning contact can still be used when plastic pa...

Page 196: ...n values are installed depending on version Make sure that all four wheels have brake pads of same type to correspond with brake caliper combination Floating frame caliper front axle Floating frame ca...

Page 197: ...HT copper paste or Plastilube 6 Insert inner brake pad 7 Install cross spring retaining pins and spring lock or lock wire with wire guide plate 8 Press warning contact into pad in correct 9 position D...

Page 198: ...ow of spring until it disengages in the housing borer Then remove spring toward outside et same time without applying force Never bend spring by applying force 3 Remove any dirt on guide pins between...

Page 199: ...ring floating frame caliper disc brakes on all wheels Rear axle pads for pairing floating caliper disc brakes on front axle end floating frame caliper disc brakes on rear axle see page 46 3 Check 20 p...

Page 200: ...e adjusts itself correctly 9 Check level of brake fluid in reservoir top up to MAX mark with fresh brake fluid if necessary lO Check operation and efficiency of brakes check system for leaks Running i...

Page 201: ...ote Renew warning contacts if the core wire has been abraded away or ground through If there are rubbing marks on the plastic part of the warning contact it can be reused 3 Pull the brake pads out wit...

Page 202: ...eir bores Make quite sure that the brake piston seals are not damaged Check that the brake calipers are installed in the correct positions The small pistons must be at the side where the brake disk en...

Page 203: ...foil must be pulled off before in stallation 5 Insert the brake pads Make sure that the correct grade of brake pad is used Note When damper plates are installed the brake carrier plates back of brake...

Page 204: ...itions Secure the warning contact lead to the brake caliper and if two warning contact leads are pre sent from 1989 models on to the cross spring as well Note If tolerances are unfavorable the spreade...

Page 205: ...r i _i I 7 7 C C y y i I i I 1 1 ii I yj I yj w4 w4 Installing 1 Check all bushings and stops for clutch and brake pedals replace if necessary Lubricate all bearing and sliding surfaces wth a multi p...

Page 206: ...nd assure adequate clearance at the brake unit The minimum play is 10 ana 3 Tighten pressure rod locknut If a mechanical stoplamp switch is fitted check switch setting page 46 10a Adjusting l Pull bra...

Page 207: ...is correctly adjusted the permanently set clearances in the brake booster are assured When the brakes have been bled and with the engine switched off a pressure rod play of approx 10 mm can be felt a...

Page 208: ...s installed as stoplamp switch With the pedal arm against its stop initial position there must be a 5 mm gap between stoplamp switch and brake pedal arm If necessary adjust position of stoplamp switch...

Page 209: ...htly seated that light blows with a nylon headed hammer do not move it screw hex bolts uniformly into the two 8 mm threads of the disk and press disk off It is possible that the bolts do not sit squar...

Page 210: ...ft hand disks Distinguishing feature involute shape and spare part number The spare part number is in scribed on the brake disk Spare part left hand side 3rd group number is odd Spare part right hand...

Page 211: ...928 Brakes Mechanical 46 gc c3 y c 0 A 7 z s i Q s i rA Z J L L 2 i i cz i L 3 E g c9 r L e 4 fl y 1 a 9 v Printed in Germany VI 1982 Disassembling and Assembling Rear Wheel Brake 46 13...

Page 212: ...disc 1 Set back brake Check for wear and damage 6 Spring 2 Position correctly 7 Support bushing 1 8 Adjusting nut 1 9 Adjusting screw 1 10 Return spring 1 11 Brake shoe 2 Replace if necessary Wear li...

Page 213: ...plastic hammer screw two bolts in the 8 mm tapped borer of the brake disc to wess off the disc Assembling 1 Lubricate slack control and sliding surfaces of brake shoes lightly 2 Install spreaders bra...

Page 214: ...ston fixed caliper brake Make sure the spreader spring locating lug at the mounting plate of the fixed caliper is not damaged when the dial gauge holder is fitted in place Floating caliper and sliding...

Page 215: ...ly The dial gauge kit may also be used to check the brake disc lateral runout 1038 48 VW 387 Km 48 6 Excessive wheel hub runout Replace wheel hub Wheel hub runout o k Cleaning level and centering surf...

Page 216: ...ke Mechanical 926 a Checking brake disc thickness Measure brake disc thickness in approx 6 places within the braking surface using a micrometer 46 16 Checking brake disc thickness Printed in Germany X...

Page 217: ...28 Brakes Mechanical 46 DISASSEMBLING AND ASSEMBLING PARKING BRAKE LEVER a a T r 15 3 14 a l I 24 I 1 R 3 2a 8 2 1 11 Printed in Germany VII 1963 Disassembling and Assembling Parking Brake Lever 46 19...

Page 218: ...itch must parking brake switch respond before first catch align bracket if necessary 4 Parking brake 1 IeVer 5 Sleeve 1 Paste on sides 6 Lock nut 1 Replace if necessary Torque 23 Nm 17 ftlb 7 Bearing...

Page 219: ...ion of contact switch It should respind before the first catch If necersary adjust switch holding bracket Checking and Adjusting Parking Brake The parking brake has to be adjusted if with medium force...

Page 220: ...turn adjusting nut that the wheels can just be turned by hand with 4 teeth the wheels must be stopped 2 F B f rr g I 6 Release parking brake lever and check whether wheels turn easily 7 Lock adjusting...

Page 221: ...loating and four piston fixed calipers Brake hose rear to four piston fixed caliper Locknut to pressure rod brake unit Bleeder screws in sliding and floating calipers Bleeder screw in four piston fixe...

Page 222: ...aulic unit Hydraulic unit bracket to wheel arch Hydraulic unit to hydraulic unit bracket T distributor to bracke Housing caliper to bracket Description Hex nut Hex bolt Screw in regulator Hex nut Hex...

Page 223: ...h Loctite 270 When installing the brake pistons use Unisilikon TK 44 N 2 brake cylinder paste this also applies to earlier types of brake caliper if repairs become nec essary Unisilikon paste is avail...

Page 224: ...the con trary Replacement The front wheel brake calipers with 44 36 mm diameter pistons can be retrofitted as a pair only to 1986 model cars It is forbidden to mix the 36 42 mm diameter and 36 44 mm...

Page 225: ...ous version The scraper ring made a sliding contact seal with the piston surface a Replacement Make sure that the two brake calipers on an axle are both of the same pattern l Notes on brake system fro...

Page 226: ...928 Brakes Hydraulics Regulators Booster 47 _ c 52 f a Printed inGermany IV 1980 Disassembling and Assembling Floaring Frame Caliper 41 1...

Page 227: ...r installatior of brake caliper Replace if wire core is ground through Check replacing if necessary Wear limit 2 mm It is better to mount pad after installaim of brake caliper Position slides correctl...

Page 228: ...n Special Removing Installing Instructions 1 1 SCil 1 Remove with a Replace install with plastic rod brake cylinder paste 15 iJust cap 1 16 illeeder screw 1 1 Slide 2 Replace if necessary Printed inGe...

Page 229: ...I j A j 2 Drive brake cylinder off of caliper frame with a plastic hammer applied at different points all around Place a piece of wood in caliper frame to prevent damage 3 Press piston out of cylinder...

Page 230: ...tion 20 chamfer 3 Install mounting frame Be careful not to da mage slides i T j ri j 1 2 P in y A i h e L J 4 I I 4 r c t 2 Drive brake cylinder with guide spring on to caliper frame with a soft mandr...

Page 231: ...14 1 2 Brake hose installation changed during 1983 model year Brake hose mounted on modified fist caliper connection with a hollow union bolt from this time on to guarantee correct installed position...

Page 232: ...ack milled surfacefacesdown to brake disc inlet side Reference point is edge on bottom of housing page47 11 5 Brake pad inner 1 Pull out of piston Check replacing with riveted retaining if necessary W...

Page 233: ...ons 10 SeaI 1 Remove with a Replace install with plastic rod brake cylinder paste 11 Dust cap 1 12 Bleeder valve 1 13 Damper sleeve 2 Replace when torn Page47 12 brittle or swollen rubber 14 Slide 2 R...

Page 234: ...nly halfway at first and take sealing lip of dust cover out of piston groove 4 Remove seal with a plastic needle Assembling 1 Apply a very thin coat of brake cylinder paste on cylinder bore piston and...

Page 235: ...piston pliers Set back surface of piston faces down to brake disc inlet side A reference point is the edge on bottom of housing see arrow Arrow a brake disc inlet side 6 Replace damaged dampers and g...

Page 236: ...onnection Make sure that bearing surface in housing is not damaged Installing 1 Coat damper with brake cylinder paste 2 Insert damper in housing from the brake hose connection side Then guide slide fr...

Page 237: ...rew in brake pressure regulator see point 5 3 Detach vacuum hose with check valve at brake booster Pull off vacuum line on branch plug for warning device and hose for clutch control mm k I e 4 Pull br...

Page 238: ...3 Press the fluid reservoir into the sealing plugs in the master brake cylinder Use new sealing plugs each time the fluid reservoir is removed When pressing in the reservoir must pass 2 detents befor...

Page 239: ...nd using a hose clamp fix pressure rod for master cylinder in this position Place a strip of 2 mm sheet beneath clamp 4 So that brake pressure rod piston rod protrudes as little as possible toward the...

Page 240: ...r if damaged The 10 boosters are fitted with 2 mm seals or 1 mm seals as of model year 85 Use a 4 mm seal or two 2 mm seals for 9 boosters 2 Install brake booster and tighten securing nuts Check that...

Page 241: ...Inlet of push rod brake circuit 4 Outlet to left rear wheel Installing 1 Check brake pressure regulator car application on page 47 18 2 Install brake pressure regulators The mounting plate has a reta...

Page 242: ...isconnect brake pressure regulator on brake master cylinder or hydraulic unit never turning on the hexagon Plug open connection with a plug a 47 18 Removing and Installing Brake Pressure Regulator Pri...

Page 243: ...1s a pair Jnder no circumstances may 33 and 55 bar regulators le used together in a car I essure and reduction led on cap 55 or 33 switchover pressure bar 5 reduction factor 0 46 For a brief period b...

Page 244: ...d caliper brakes Installation Cars with ABS Screwed into port h of hydraulic unit Cars without ABS Screwed into master cylinder inter piston circuit Identification Remarks Switchover pressure and redu...

Page 245: ...ar axle overpressure is reduced To check the braking force regu lators of diagonally split braking circuits the pressure which is not reduced front axle and the re duced pressure rear axle must be rea...

Page 246: ...ometers of pressure tester Test II Increase input overpressure shown on manometer of front brake caliper unregulated wheel to 100 bar Read output overpressure on manometer of rear brake caliper regula...

Page 247: ...t increases while the force exerted on the brake pedal remains constant renew the braking force regulator When replacing see note on page 47 18al18b 2 After testing and removal of the equipment bleed...

Page 248: ...Porsche brake fluid The brake fluid is available under Part No 000 043 202 04 Container contents 5 liters as of May 1992 This special brake fluid may also be used on pre MY 93 vehicles However the tw...

Page 249: ...bbles in the brake master cylinder If there is a bleeder valve on the master cylinder begin bleeding of brakes on this valve Note There is no difference in bleeding procedures for cars with ABS 7 It i...

Page 250: ...ot drop during the next 5 minutes There is a leak in the brake or clutch system if pressure does drop during the test time 9 Install dust caps on bleeder valves Draw off brake fluid in tank which is h...

Page 251: ...ydraulic assistance power steering Steering wheel dia Steering wheel ratio at center Turning circle dia wall to wall Turning circle dia curb to curb Steering wheel turn from lock to lark 380 mm 15 in...

Page 252: ...16x 1 5 16MnCr5 150 1081 Universal joints to steering Self locking nut VM8 8 28 20 and intermediate shafts Pressure and return lines to steering gear Hollow bolt M 14x 1 5 30 22 Steering wheel to stee...

Page 253: ...n accident ve hicle requires replacement or may be used as t is 8 Assessing the Condition of the Steering System of an Accident Vehicle The steering gear may remain on the car if all the followlng con...

Page 254: ...e shop is refused by the customer or insurance company for financial reasons an expert or a this is not possible in foreign contries the importer should be consulted to be charged to the refusing part...

Page 255: ...TOOLS NO Description Special Too Remarks 1 Torque wrench Srahlwille 730 R 20 or Hazet 6292 1 CT 2 Wrench socket 9183 3 Tie rod puller e g Nexur 168 l Primed in Germany 111 EI Removing and InsraIling S...

Page 256: ...48 Steering I 2 il 1 i ij e I 4 w 7 l i c f i a 48 2 Removing and Installing Steering fear 1 lR76 Printed in Germany...

Page 257: ...to torque 6 Seal 4 Replace 7 Tie rod assembly 1 Torque 150 Nm lOB ftlb Tighten while holding rack and use torque wrench with special tool 9163 8 stop 2 8a Spacer 2 9 Tie rod 1 Note arrangement Note a...

Page 258: ...te position completely and coat of universal with VW steering joint gear lube AOF Page 48 6 086 000 19 O ring 4 Replace if necessary Not for new Position correctly steering gears with bushings in moun...

Page 259: ...rods with a standard extractor 3 Pull back hose strap with harness after removal of screw on side 4 Remove bolts from stabilizer mounts Let stabi lizer hang down 5 Unscrew pressure line and return li...

Page 260: ...steering wheel and steering gear in cen ter position Nuts on steering should only be screwed on slightly facilitates assembly 2 Mount steering gear Produce 8 mm clearance be tween steering gear and u...

Page 261: ...ng stop has also been changed be cause of changes on the steering gear rack deep bore drilled and 15 mm longer smaller diameter on ends of rack Stop of Changed Version Part No 928 347 329 03 or Presen...

Page 262: ...Part No 928 347 010 22 former version and interim solution are no longer available They should be replaced with the new current version The steering gears of the new version 928 347 010 24 and 928 34...

Page 263: ...licable to steering gears 928 347 010 26 928 347 010 27 as of MY 91 or 928 GTS The new steering stop may only be installed together with the new dust cover When installing a solid stop for the first t...

Page 264: ...48 Steering 928 NSTALLATION OVERVIEW Ai 928 347 329 03 et 928 347 329 04 paqe 48 6 C 48 6d Steering Stops Installation XIII 1986 Printed in Germany Overview...

Page 265: ...t of reservoir 2 Remove splash shield r w 4 c kc g i 1 I 1 y R Loosen front bolts on power steering pump a little 4 Remove rear bolt from power steering pump 5 Remove v belt 6 Take off left upper sect...

Page 266: ...o remove tension Also check tightness of alternator belt slight correc tions could be made 1 Tighten two bolts on front holder only insert rear one belt tightnersl 6 Bolt on splash shield Add hydrauli...

Page 267: ...i j r i 3 Ii6 2 i Body of power steering pump is made of aluminum af of 1981 models to reduce weight Worn seals can be replaced on these aluminum power steering pumps but pump has to be disassembled...

Page 268: ...essary Pull out of radial groove with pliers while holding down cap no 5 to prevent it from popping up and cawng injury Bevel faces inside Of pump Only press on far enough that hook snap ring can be i...

Page 269: ...installed large dia positions 14 O ring 1 small dia 15 Support ring 1 small dia 16 Shaft seal 1 Lift out being Pack space careful not to between both damage bearing sealing lips with surface multi pur...

Page 270: ...and keep clamping force as low as possible B jT u 1 4 n y g t 1 4 r 3 Pull hook snap ring out of radial groove with pliers Press down on cover during this step to prevent snap ring from popping up an...

Page 271: ...support ring and O ring in radial grooves of body use plastic needle or air pressure y z bl i 6 _ d r s j Bores for dowel pins in body for wear Bearing sleeve Bearing surfaces and radial grooves of s...

Page 272: ...mpellers move easily Note Lubricate all parts lightly with ATF before installing 3 Install drive shaft face plate and rotor assembly in body Slide face plate on dowel pins with wide element opposite v...

Page 273: ...O rings with ATF Note Check order of support and O rings A Support ring B O ring Since March 1983 or Pump Number 866201 the cover end support ring has been omitted modified radial sroove in case 6 Pre...

Page 274: ...king hexagon nut to 50 Nm 36 ftlb Use a suitable sleeve or cover woodruff key groove with a narrow strip of tape to avoid damaging shaft seal on groove 11 Install power pump Fill and bleed steering sy...

Page 275: ...resealed page 48 8a Replacement steering gear and servo pumps are available on an exchange basis in a num ber of countries In some cases it may be possible to have the steering gear and the servo pum...

Page 276: ...d level must be between the two marks If necessary top up with ATF DEXRON II D Version A Version B Bleeding steering system 1 To refill the entire system after installing new steering equipment or lin...

Page 277: ...l continues to drop keep adding fluid unit1the level in the resewoir remains con stant and air bubbles cease to rise in the hy draulic fluid when the steering wheel is turned 5 When the engine is stop...

Page 278: ...ressure hoses no 2 and no 5 are connected on pressure gauge in correct position opposite sides as for 944 Connection of high pressure hoses on pressure gauge no 3 a on the other hand can be made on an...

Page 279: ...with sealing head on one end and M 16 x 1 5 with flat seal on other end 3 Pressure gauge 0 250 bar Old version no longer available 3a Pressure gauge 0 160 bar V A G 1402 Order No Z 401 103 WE from Vo...

Page 280: ...are marked with numbers for better understanding of the following instructions Old Version V A G 1402 l 3nm z y P r I Shut off valve open II Shut off valve closed II I Damping orifice IV From pressur...

Page 281: ...te Use adapter no 4 for old version pressure gauge and connect high pressure hose no 5 on connection V of pressure gauge 4 Screw connector with high pressure hose no 5 on steering gear seal required 1...

Page 282: ...ated on the nameolate Specification 110 to 110 bar for power steering pump 928 347 089 01 as of MY 91 Identification Nameplate on pump Pad No and pressure specification are indicated on the nameplate...

Page 283: ...h a manner that steering wheel spokes are horizontal 2 Install hexagon nut with spring washer and tighten to specified torque 3 Mom1 horn wiiec on impact pad and pxss impact pad on to retaining pins 4...

Page 284: ...l 2 Mandrel VW 295 3 Mandrel VW 214 f 20 4 Pressure pad VW 433 5 SleWle 30 21 6 Locally made tool Half of an approx 4 mm thick washer welded on steering wheel mounting nut M 18 x 1 5 hexagon nut Print...

Page 285: ...48 Steering 928 T f i r ffsj 3 n 1 1 3 1 4 29 4 5 l9 3013 1 7 e 417 a 48 16 Repairing Steering and Intermediate Shafts with Steering Tube Printed in Germany...

Page 286: ...t M 18 x 1 5 1 Torque 50 Nm 36 ftlb 7 Washer 1 Replace if necessary a Steering wheel 1 Steering wheel Remove tool spokes horizontal 9132 immedi with steering gear in ately after center position instal...

Page 287: ...1 Replace if necessary changed as soon as steering 22 Setscrew 1 shaftlinter mediate shaft corm is disconnected 23 Intermediate steering 1 Changed from shaft steel to forged aluminum to save weight Sh...

Page 288: ...31 aall 2 32 Spring 1 33 Self locking nut 1 34 Washer 1 35 Adjusting lever 1 36 Bracket 1 37 Stud 1 38 Screw M 3 5 x 10 3 Same part ar no 40 39 Contact ring 1 Position correctly 10 Screw M 3 5 x 10 3...

Page 289: ...has electric seats move them completely back to make assemblv work easier 4 Pull off impact pad on steering wheel and remove horn wires Mark position of steering wheel on steering shaft Unscrew hexago...

Page 290: ...u ment cowl for this purpose t 9 Remove 5 switches in instrument cowl by pulling off switch knobs compressing both spring clips of each switch pulling out switches and pulling off plugs Remove rubber...

Page 291: ...in the steering tube against the stop on the steering shaft mount Push down very carefully to prevent changing sit of mount Installing 1 Insert seal in firewall in correct position Coat pertinent are...

Page 292: ...tch and tighten mounting bolt Screw on cover sl Connect battery ground wire 8 If applicable mount cover on intermediate shaft Install universal joint between steering and intermediate shafts First sli...

Page 293: ...nstall mounting nut with washer and torque to 50 Nm 36 ftlbl If necessary correct position of steering wheel after test drive not positioned horizontally before removal and slightly different universa...

Page 294: ...spring and shims if applicable in steering shaft 4 Drive upper steering shaft bearing out of outer tube with a suitable piece of pipe A p A l F TJ e 3 If steering shaft has three bearings also refer t...

Page 295: ...ng shaft bearing into steering protective tube against stop with Special Tool 30 21 q y m l 5 Clamp steering tube in a vise on the steering lock housing Slide steering shaft into steering tube complet...

Page 296: ...p Install steering wheel and check eary movement of steering shaft and locking effect of steering wheel lock 7 b Axial Play Distance Excessive Move intermediate shaft on steering shaft in direction of...

Page 297: ...v yytiill T 1 Screw stud in control lever Threaded part must protrude slightly arrow 2 Mount bracket on steering tube Give sliding surfaces a thin coat of Optimoly HT paste Insert control lever with...

Page 298: ...t the locking position is reached with a medium amount of force When more force is applied it should be possible to turn the control lever further in locking direction a Printed inGermany VI 1982 Repa...

Page 299: ...ring wheel and remove horn wires Mark position of steering wheel on steering shaft Unscrew hexagon nut and remove steering wheel with washer 4 Unscrew cover underneath instrument cowl not on older mod...

Page 300: ...a standard internal claw puller e g puller 62 020 from Schrem in Giengen in upper steering shaft bearing Spread puller enough so that bearing inner race is not pulled out of bearing outer race while d...

Page 301: ...p 14 Install steering column switch and covers Connect battery ground wire 15 Install universal joint between steering and intermediate shafts If necessary adjust 8 mm gap fsee page 48 23 16 Install s...

Page 302: ...teering 48 a Dismantling and assembling steering wheel height adjuster of airbag vehicles l Dismantling and assembling steering wheel height adjuster of airbag vehicles 48 33 Printed in Germany XXVII...

Page 303: ...Steering 928 Dismantling and assembling steering wheel height adjuster of airbag vehicles 48 34 Dismantling and assembling steering wheel height adjuster of airbag vehicles Printed in Germany XXVII 19...

Page 304: ...sole 1 Removal nstallation T if not present retrofit to modified steering wheel height adjuster p 48 40 Affected pans No 1 2 4 and 6 always fit a new spring making sure it is not bent when fitting fit...

Page 305: ...stem the following safety requirements must be observed at all times 1 Switch off ignition 2 Disconnect and cover negative battery terminal After the battery has been disconnected assembly operations...

Page 306: ...8 page 48 34 do not have to be dismantled any further 2 Turn adjuster lever of height adjuster to the open position For dismantling sequence refer to explosion drawing on page 48 34 Assembly 1 If requ...

Page 307: ...r lever No 4 in open position lever points straight down into pilot bush ing Nr 9 and into eccentric No 6 The wider side of the eccentric must face down If required turn eccentric accordingly Place a...

Page 308: ...and the clamping action at the adjuster mechanism is fully operative in the closed position Following careful adjustment tighten the lock nut No 10 This causes the setting nut No 12 to be locked 8 Che...

Page 309: ...the modified design should also be adopted for vehicles prior to MY 92 equipped with airbag Required parts New lever new eccentric two spring washers and one spring clip Parts identification No Desig...

Page 310: ...l year Wkh this system the igni tion key can be pulled out only if the selector fever was moved to position P beforehand This ensures that the vehicle does not move off unintentionally Note The cable...

Page 311: ...er be turned to position 0 stop Carefully screw in the adjusting screw until the ignition lock can be locked again using greater force Then screw in the adjusting screw by an additional approx l 2 tur...

Page 312: ...oval and installarion of hearer blower and air distribution housing as well as disassembly and assembly of healer Several poinrs will not apply CO cm wirhouL an air conditioner Printed inGermany II 19...

Page 313: ...drier Relief valve on compressor a 950 gramS 33 5 ounces of R 12 350 cm3 12 ounces of Suniso Nn 5 GS or Texaco Cappela E or similar apprux 50 watrs sea1 at ruprures 117 2 30 C 242 50 I a pressure of...

Page 314: ...h KSS lii IillC II cxpansiw valve Pressureline co receiver drier Hose LOc0mpress0r condenser compressor Suctiuu line 10 expansion valve z d x s 2 1 I 1 2 Li F to Isj 5 Y X 1s 8 K 14 20 LNF 1 1 1 3 4 X...

Page 315: ...Air Conditioner 87 REFRIGERANT SYSTEM LAYOU 1 Compressor 2 Condenser 3 Far 4 Receiver drier 5 Expansion valve 6 Evaporator Printed in Germany Ii 1979 Refiigeranr System Layout 87 1...

Page 316: ...87 Air Conditioner r I istl r j i d 1 I LV yu r 91 ix L eJ 4 5 r I ZO L r ol I I P i 87 2 Vacuum sysrem LqKnN Printed in Germany...

Page 317: ...led condi tion The maximum permissible temperature of a filled refrigerant bottle must not exceed 45 c 2 When performing repairs on the air condi tioning system the refrigerant must be syp honed off f...

Page 318: ...t higher temperatures e g in the pressure bottle Chemical behavior with respect to other substances 1 R 12 does not attack most metals particu larly iron copper brass and aluminum but lead may react w...

Page 319: ...wing procedure must be followed when re filling the system 5 Syphon off the refrigerant 6 Fft new fluid reservoir 7 Evacuate 6 Fill 1 Connect the service unit 2 Evacuate 3 Fill approx 500 g refrigeran...

Page 320: ...er 928 Installation work on the air conditioning system Service unit SECU 87 12 Gjljl yj 10 11 g Ijl y m 17 I 16 5 7 23 18 ii i i 6 1 90 4b Installation work on the air conditioning system Printed in...

Page 321: ...igerant inlet 11 Shut off valve refrigerant outlet 12 Connectiong piece refrigerant inlet from refrigerant botttle 13 Connection piece refrigerant outlet to refrigerant bottle 14 Moisture indicator 15...

Page 322: ...system Extreme cleanliness must therefore be ob served for all work No parts of the system must be cleaned inside with hot steam under any circumstances Only nitrogen must be used for cleaning When re...

Page 323: ...t has been syphoned out of the circuit The red pilot lamp then lights up 4 Close shutoff valves 4 5 and 6 5 Open the refrigerating oil drain cock 15 and drain off syphonad off refrigerating oil 6 Dete...

Page 324: ...reached only after a very long time or if the pressure increases to over 0 2 bar absolute approx 10 minutes after switching off the pump the circuit possesses a leak and must be sealed Flushing the a...

Page 325: ...the value specffied on the top edge of the scale stops over the sight glass Note It must be noted that the rotary scale is de signed for use of different refrigerants The re frigerant designations ar...

Page 326: ...ent refrigerant in the service unit close the bottle valve The system switches off automatically when the refriger ant has been syphoned off up to the bottle valve 5 Close the refrigerant inlet shut o...

Page 327: ...lling cylinder shut off valve 22 2 Switch on the service unit The green pilot lame liahts LID a 3 After cleaning the refrigerant condition shown by the moisture indicator close the shut off valve The...

Page 328: ...0 2 8 Air Conditioner 87 b l 1 t4 3 y e P Pi E m 4 2 2 2 5 z x 4 v Printed inGermany 11 qyq Removing and insmlling I leater Svaporaror x7 5...

Page 329: ...k off Replace if nccissaiy ilxrrumcnr panel ride vent and hearer air Replace il r cressary Replace if necessary Deiroircr vent righr Replace if necessary Reinforcemenr Heater air cond Removing and Ins...

Page 330: ...928 Air Condirioner 87 I addirion IO seal also use non hardening bluwei swilch shaft Adapter for air duct Side vent left 0 Printed in Germany il 1978 Removing and InsraIling liearer Fvaporaror 87 _ 7...

Page 331: ...ll oil impacT pad Irom srecring wheel and remove horn wires Mark ponirion of sreeriug wheel IO steering shaft Cnscrew tnut and rake off steering whrel wirh wasin 4 Remove ccwrr undcmealh inrrrurnenr c...

Page 332: ...ulf swncl knobs cr mprcssm spring clips pulling ou swliches and pulling off PlUfiS Pull OLli plugs frotn ruYptac es 0 hack l incrrumenr cowl prinred circuit and lifr oil insrrumenr cowl Mark plugs fo...

Page 333: ...unting screws on frame tunnel al ICir anrl ri hi side as well as vn insrrumcul panel Rc novc radio nlounring nut on holder nor applicnblc to plq in version Disronnccr or pull oii followlnji plug conne...

Page 334: ...er console 18 Unscrew holder from control unit for temposrar cruise conrrol and receiver of radio and lilt off IO the right side 19 Disconnect sreering prorecrion tube from insrrumenr panel 3 filliste...

Page 335: ...nel 22 Remove connecring hosesberween side nozzles glove box nozzle and heater air conditioner Remove defroster nozzles 23 Remove cover over blower 24 Remove IWOscrews on rubber connecm between blower...

Page 336: ...i Drracll cooianl lvxos li i ib hear exchanger CC tkmove imounrinS lnuts frow iieaicr air cwdiliuner Pull off water drain KWZ Lilt OUIhcalcr air oundiiioner a 7 w InsraIling I llcplnce O rinss on air...

Page 337: ...ilnriun cw ileatcr air conditioner h slall dcirosrer enlr Install inrlrlxmem panel Attach connccring hoofs 10 sidr venlilation luriall slcering proteclive tube on insrrumcnr panel Du noL ycr righren r...

Page 338: ...fog light and rail fog light switches Plug with black violet wire belongs IO from fog light switch Align instrumenr cowl with instrument panel and tighten mounting screws 3 fillisrer head screws of s...

Page 339: ...air conditioner have a hole in the intake housing which is sealed with a plug 2 Take off right windshield wiper arm 3 Remove cover above blower Unscrew mounr ing screws from apron ourer section on fen...

Page 340: ...ant R 12 If humidity has entered the system during as sembly of the air conditioning system or as re sult of replacement of individual parts the fol lowing procedure must be followed when re filling t...

Page 341: ...Installation work on the air conditioning system Service unit SECU 12 y y cj j p j i xl_ 17 iii j__j j ijli Ij iij j _ _ 5 a 1 16 18 19 20 97 16 Installation work on the air conditioning system Printe...

Page 342: ...erant inlet 11 Shut off valve refrigerant outlet 12 Connectiong piece refrigerant inlet from refrigerant botttle 13 Connection piece refrigerant outlet to refrigerant bottle 14 Moisture indicator 15 D...

Page 343: ...system Extreme deanliness must therefore be ob served for all work No parts of the system must be cleaned inside with hot steam under any circumstances Only nitrogen must be used for cleaning When rep...

Page 344: ...t has been syphoned out of the circuit The red pilot lamp then lights up 4 Close shut off valves 4 5 and 8 5 Open the refrigerating oil drain cock 15 and drain off syphoned off refrigerating oil 6 Det...

Page 345: ...e reached only after a very long time or if the pressure increases to over 0 2 bar absolute approx 10 minutes after switching off the pump the circuit possesses a leak and must be sealed Flushing the...

Page 346: ...so that the value specified on the top edge of the scale stops over the sight glass Note It must be noted that the rotary scale is de signed for use of different refrigerants The re frigerant designat...

Page 347: ...nt refrigerant in the service unit close the bottle valve The system switches off automatically when the refriger ant has been syphoned off up to the bottle valve 5 Close the refrigerant inlet shut of...

Page 348: ...ylinder shut off valve 22 2 Switch on the service unit The green pilot lamp lights up l 3 After cleaning the refrigerant condition shown by the moisture indicator close the shut off valve Note The uni...

Page 349: ...table adhesive e g Locrire Super Bonder 414 REMOVING AND INSTALLING AIR DISTRIBUTION HOUSlNG Removing 1 Disconnecr battery ground 2 Remove blower 3 Disconnect vacuum hose from vacuum unit of control f...

Page 350: ...r 7 qQq iR upW TQ I _ i F 6 Lift out air distributor housing afrer removal of mounting nurs f p _ _ I 1 1 I C 1 I I Installing 0 To seal the air disrriburor housing use a non hardening caulking compou...

Page 351: ...928 Air Condirioner 7 j y d i i i vi II spy 3 Z 2 Kc FJ 3 k G l 2 v Lo 3 c 9 s Lo kg311 g j i J c 7 FY l y N 2 N Printed in Germany II 7 r Disassembling and Assembling Hearei Evaporarur H7 l...

Page 352: ...e aid position correctly 6 Pin I 7 Push nut 1 Replace 8 Foorwell housing 1 9 i notwe11 flap 1 1 ExPansiai valve 1 Replace all 4 O rings 11 O ring 2 b epLXe 12 SCK 2 13 Temperature switch 1 14 screw 1...

Page 353: ...Air Condirioncr 87 Replace il imxisary Position correctly kiri sLlr 113 li YIT j _ 1 ils i r ih i l il r Trcil Printed in Germany _ 11 I Disair nlhli rg allii Asscrmhliug i iiaicr tlaporaror jr 2...

Page 354: ...Vat uum unir for 1 Check operation shut off flap 42 Push IIUL 1 Replace same as no 33 43 Shur Off flap lever 1 Same as no 34 44 Rubber connector 1 45 Push nut 3 Replace 46 Kuhher washer 3 47 Vacuum u...

Page 355: ...ir from defroster flaps 2 Remove pinson vacuum unit of footwell flap Pry off push nur uniformly and remove foot well housing with footwell flap 3 Pry off reraining clips and remove sealant from joinr...

Page 356: ...plugs L1nscrew lefr and right brackers on condenser Unscrew upper fan moun ings 3 mscrew lower mounring 4 LOOWI wire harness on lock cmv member and remove cover AiggF3 yQm _ j C 4 y g y Pi _ 2 I I 5 P...

Page 357: ...eceiver drier 2 Remove air inlet grill 3 Remove upper and lower condenser fan mountings and push fan IO one side 4 Pull off wire plugs for temperarurc and low piessure swirches Unscrew right hraclw fo...

Page 358: ...essure switch on receiver drier 2 Remove air inler grill r F pm f a r F 3 Remove condenser fan 4 Loosen upper lefr and right hrackers on lock cross member and turn to on e side 5 Remove hose lines ar...

Page 359: ...Conditioner 87 0 7 Remove lower mounting screws on condenser Pull out condenser with receiver drier from above a 8 Take off receiver drier a Primed in Germany 111 1980 Removing and lnsrallmg Condense...

Page 360: ...RESSOR Removing 1 Discharge air condirioner 2 Remove spash shield underneath radiator 3 Looren compressor and rake off belt 4 Remove holder from condenser ar rop right 5 Disconnect hoses 81 28 Removin...

Page 361: ...rt plugs in connections and lines a New compresson are under pressure Consequenrly unscrew plugs slowly until refrigerant is heard IO have escaped Remove plugs only afrer releasmg pressure Insrall and...

Page 362: ...r washer puller 95456 03060 6 sea1 puller 15456 02060 I Oil pipe pulling hook Local manulacl uie 8 Seal installer 05456 0801 0 Thrur washer insraller Local manufacrure 10 Thrust washer pad 1545ti 0 1...

Page 363: ...nditioner 928 r _ Gk v J y p 3 4 Xl yf 0 g 4 r a g 1 r L g 0 p mc T Iv zi I t s 3 Y LC _ _ _ g i b yp i I5 N y Lk m c 4 rd 2 r 4 y y c mL N m 1z i 32 Disassembling and Assembling Compressor Printed in...

Page 364: ...rniil CO 016 0 040 in j S Circlip 1 6 Pulley 1 Bevel faces shaft end Replace pulley asrernb ly with ball bearing if friction suilace is wom or oil splatrered 7 Circlip 1 Bevel faces rhafl end s Coil...

Page 365: ...1 0 SCEW 4 Tighten to 26 Nm 1Y fr lb 1 Housing rear coven 1 2 O ring 2 13 Oil 0u1e1 race pump 1 4 Oil inner ace pump 1 5 Dowel pin 4 6 Valve plare gasker 2 I Valve plate Iear 1 8 Sucrion valve 2 9 Cyl...

Page 366: ...Removing Installing Instrucrionr 39 O ring 1 40 Suction service valve 1 41 O ring 1 42 Cap sucrion valve 1 43 Cap discharge valve 1 44 aP 2 45 valve core 2 46 safety valve 1 47 SC31 1 a Printed inGer...

Page 367: ...ling Magneric Clutch 1 Counterhold with correct wrench depending on version to loosen or tighten mounting nut e rrc y fq m a w Ie _ 4 _ I L 2 Remove clutch plare with puller i i l b AL f j r j 1 3 Rem...

Page 368: ...y between clutch plare and pulley is 0 4 0 1 0 mm 0 016 IO 0 040 in Disassembling Compressor Remove any plugs from line connections to let residual gas escape 1 Drain refrigerating oil never reuse 2 R...

Page 369: ...C 4 Renlovt cial will pullrr nl A 4 w q 1 1 i A Thrust washer B Puller 5 Remove nwuoring bolls from rear lbousin cover Take off housing cover applying light taps with a plarric hammer when necessary 8...

Page 370: ...l rrlr vrol ing oil prior 10 ior1allarion See pageRI ni lor type d oil j 1 Place O ring in froni of hnur ng and push in cylinder block 7 Remove cylinder block from housing Never disassemble cylinder b...

Page 371: ...haft nur until groove for circlip is visible Turn real on shaft with tool until seal engages 4 Guide in thrust washer with assembly tool carefully lnserr circlip and take off thrust pad 6 Insrall wood...

Page 372: ...parts will rhen have the following oil quantities Condenser E pOKGOI Receiver drier and lines Remainder in comprersor approx 30 cc l ounce approx 60 cc 2 ounces approx 10 cc o 34 o ce approx 250 cc 8...

Page 373: ...TROL UNIT OF AUTOMATIC AIR CONDITIONER Control Switch opened Inside Sensor Control Ilnil Outside Sensor f i a fm 9y q I Q P I i R I A 1 d I I I I ix 4a r Printed in Germany Iv 1980 Regulators and Cont...

Page 374: ...Pry out center vent with a putty knife 2 Pull off cover frame starting at top T T t 2 d 1 I 1 __ i i I 8 y y 3 Loosen Ul l rl n n e c tlo b Jxl wires can remain wnnected 4 Loosen and pull out control...

Page 375: ...el Wires remain connected 5 Lift center console far enough and pull back toward rear so that inside sensor is accessible 6 Press out inside sensor from inside The mounting ring is pressed on and held...

Page 376: ...l off of outside sensor housing Disconnect plugs 3 Unscrew valve carrier 2 screws 4 Unscrew mounting bolt of valve being replaced and disconnect by moving up Pull off vacuum line and electric wire Rem...

Page 377: ...a 928 Air C i nditioner 87 18 16 15 17 14 19 13 12 a Printed in Germany IV 1980 Disacsembling and Arwmhlin C enter Vent and Switch xs 47...

Page 378: ...Metal i rL w I illg pxt OIwraliug lever Microswitch Microswitch hoidcr Holder Vacuum unit for center vent Rivet Flap clinter YE i Pin Bushing Clip I cn o5 ir ic lnst llling Special Instructions 7 B Vi...

Page 379: ...up a vacuum of abour 400 mbar The relation of the slide posirion of rhe control switch o the positions of rhe flaps is shown in the table below Hearer remains switches off Blower switch in off positio...

Page 380: ...87 Air Conditioner N 0 87 50 Service Installing Air Conditioner Printed in Germany...

Page 381: ...red 14 x 18 5 Mount pressure gauge between high pressre hoses and place on a base e g toolbox next to driver s door Nate Use adapter no 4 for old version pressure gauge and connect high pressure hose...

Page 382: ...sure and Sucrion Lines 1 Take off engine cover 2 Remove air cleaner 3 Unscrew guard underneath radiator 4 Drain coolant from radiator 5 Unscrew air inler grill 6 Remove plug on radiator and screw in r...

Page 383: ...r F f s r c i J _ y xT y 2 TX i i T r i G I 8 L nscrew front rigbr radiator hose Disconnect plug and plus terminal Ilnscrew TCI control unit Detach coolant Ihose ar l adapter under neath cross member...

Page 384: ...screw Align pipes and hoses and tighten screws or nuts 15 Connect cover behind firewall on tread plate Insert and connect heater and vacuum hoses 16 Screw on cover of rread plate L Insert new vacuum l...

Page 385: ...Remove pulley lnsrall compressor pulley in place of spacer and tighten ECEWI 2 Unscrew clutch operating cylinder or cover for can with auromatic rransmisnion and inrrall 1001 for holding flywheel wit...

Page 386: ...7 Air Conditioner 928 a a I a W a 81 56 Service Installing Air Conditioner Printed in Germany...

Page 387: ...328 Air Colldilioner 87 Note When I Special Printed in Germany III 1 cJ Service Installing Air Conditioner 87 57...

Page 388: ...87 Air Conditioner 9 2 8 7 I 9 e J 12 10 11 6 5 a l 81 58 Service Installing Air Condirioner Printed in Germany...

Page 389: ...M 10 Jasher olt M 10 x 40 ornpressor use NW 13 ose NW 10 lolr M 8 x 22 iasher tlUt lolt M 8 x 20 Uasher to11M 8 x 22 riasher iasher ompressor console XY 2 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 Note When e...

Page 390: ...and listen for escaping refrigerant Remove plugs only 2 Bolt console at tapped holes provided for rhir purpose afrer releasing pressure YF Jp yp P 6 Connect and tighten hoses on compressor prior to in...

Page 391: ...side up and connect on suction line Route hose on pressure side Toward front between wheel housing and radiaror 8 lnsrall belts in order of compressor alternaror air pump and power steering pump and...

Page 392: ...87 Air Conditioner 928 a cTg z fqYpqJ J Y I a a Sl i izgg p I I I 4 i 1 j 8 r y 5 _ 1 i j I 9 a 81 62 Service Installing Air Condirioner Printed in Germany...

Page 393: ...25 1 5 Washer 1 6 Rubber washer 1 7 Pa 1 8 N M 6 2 Y Lockwasher 2 O Washer 2 l Rubber pad 2 2 NM M 6 2 3 Lockwasher 2 4 Washer 2 15 Tank 1 16 O ring 10 6 x 1 8 1 17 LOW switch pressure 1 Tighten to 18...

Page 394: ...Installing Inrrructions 23 Washer 2 24 screw M 6 x 20 2 Tighten to 8 Nm 0 8 kpm 25 Washer 2 26 Rubber grommet 2 27 Ilolder right 1 28 Holder left 1 29 Screw M 6 x 20 2 30 Washer 2 31 Rubber grommet 2...

Page 395: ...inlet and bolt rank Be careful nor to damage condenser plates Straighten deformed plates with a plate comb 3 Install rubber grommets in holes provided in CIOSSmember _ __ _ e y yrz z 1_ ir r 5 _I_ _ r...

Page 396: ...cl condenser inler wirh hose leading IO compressor 6 Boll condenser fronl below 7 Install low prcssurc swircb 10 rirl q bclon s 1 1 a switch f y v f y x Tc A 8 Loosen wire harness on lock cmss member...

Page 397: ...t low pressure swiwh temperature switch and fan wirb wire harness Hold wire plugs on left and right sides wiih clamps 11 Insrall fan from above carefully IO prevenr damaging the condenser plares 12 Bo...

Page 398: ...87 Air Conditioner In Y Q 12 i N 1 16 a 81 68 Service installing Air Conditioner Printed in Germany...

Page 399: ...ing Electric Air Valve 1 Install cross member 2 Mark hose between throrrle bypass valve and inrake branch and unscrew Cut ou a piece abour 20 mm long ar marked position Printed inGermany III 1919 Serv...

Page 400: ...all wire harness connecring both angled plugs on electric air valve Screw wire clip on engine with standard ground wire Connect plug from engine wire harness and insulated plug with magnetic coupling...

Page 401: ...ey puller 05456 21060 5 Thrust washer puller 95456 03060 6 sea1 puller 95456 02060 7 Oil pipe pulling hook Local manufacture 8 Seal installer R5456 08010 I Thrust washer insraller Local manufacrure O...

Page 402: ...87 Air Conditioner 928 G P DZ r z a r 7 L3 Jy Fi Yf 1ia Y i i q c T 2 yI i 7 87 72 Disassembling and Assembling Compressor Primed in Germany...

Page 403: ...Dusl ring 13 Oil filler crew 14 15 16 sea1 Woodruff key Ciiclip 1 Tighten IO l i Nm 1 7 kpm Check for damage Adjust play berween pulley and coupliog co 0 4 1 0 rnlli Bevel faces shaft end lieplace pul...

Page 404: ...et a1ve pla1e front il suction tube ring ylinder block J ring lousing cover from lousing crew ressure connection Y 1 1 1 4 1 2 1 1 4 2 1 2 2 1 1 1 1 1 1 1 2 1 Nole When emoving Insralling Don I damage...

Page 405: ...Special Removing Installing Inntrucrionr 39 O ring 1 40 Suction cormection 1 41 O ring 1 42 Plug suction end 1 43 Plug pressure end 1 44 cap 2 43 Spring valve 2 46 safety valve 1 47 sea1 1 Prinred inG...

Page 406: ...Removing and Installing Magnetic Coupling 1 Counrerhold with perrinent wrench depending on version co loosen or tighten mounting nur F b i yfi a 2 Remove coupling plare with puller 3 Remove ball beari...

Page 407: ...just play wirh ser of shims P J G y_ 7sp L a 3 6 lri h 1 i I 1 e i i Disassembling Compressor Remove any plugs from line connections 10 let residual gas escape 1 Drain refriperaring oil never reuse 2...

Page 408: ...rust washer B Puller 4 Remove seal wirh puller 4 4 A I 4 i tp tIi 5 Llnscrew mounting bolrs from rear hourinS cover Take off housing cover applying light knocks with a plastic hammer when EGSC3iY 87 7...

Page 409: ...ck Assembling Compressor Note Coat all gaskers and seals with clean refrigerating oil prior IO insrallarion See page 87 01 for rypes of oil 1 Place O ring in fronr of housing and push in cylinder bloc...

Page 410: ...5 Press in thrust washer with thrust pad and nut so far until groove for circlip is visible lnserr circlip and take off rhrust pad 4 Guide in rhrust washer with assembly tool care lully 6 Install woo...

Page 411: ...FOR AUTOMATIC AIR CONDITIONER Control Switch opened Inside Sensor 1 y q m I _ w Y 1 1 y F f T 5 r F _ y jy _ l Control Unit Outside sensor I _ J 1 q _ i _ d i 19 I 1 hinted inGermany IV 1080 Regulato...

Page 412: ...Removing and Installing Control Switch 1 Press out center nozzle wirh a putty knife 3 Loosen and remove vonrrol board w res can remain connected 4 Loosen and pull OUI control switch Pull elf plugs Rem...

Page 413: ...accessible 6 Press out inside sensor from inside The mounting ring is pressed on and held in posi tion by retaining tabs Note Some cars since standard production of 1980 models have an inside sensor w...

Page 414: ...and pull off of outside sensor housing Disconnect plugs Removing and Installing Solenoid Valves 1 Remove tray 2 Unscrew trim panels on left and right sides of center console 3 Unscrew valve carrier 2...

Page 415: ...928 Air Condirioner 87 a 19 I J _ r 4 IF L ii h i f i a j J 4 5 3 T 2 6 5 li lk 10 li 12 1 N_ Printed in Germany IV 1980 Disassembling and Assembling Center Nozzle x7 87 and Switch...

Page 416: ...87 Air Condirioner Y28 ISpecial _ 87 88 Disassembling and Assembling Cenrer Nozzle and Switch Primed in Germany l...

Page 417: ...Air Conditioner l AUTOMATIC AIR CONDITIONER 84 MODELSONWARD l Printed in Germany XIII 1986 Automatic Air Conditioner 87 89...

Page 418: ...050 g 950 g 1200 g 1150 g Refrigerant in compressor Type 6 E 171 280 k 20 C C Densoil 6 Type 10 PA 20 C 120 20 C C Densoil 6 Safety valve at fluid tank The safety valve opens at a pressure of 40 5 bar...

Page 419: ...ery line Expansion valve intake line Expansion valve evaporator Description Union nut Union nut Union nut Union nut Union nut Gland screw Gland screw Gland screw Thread Torque in Nm ftlb 7 8 x 14 UNF...

Page 420: ...87 Air Conditioner 928 DISASSEMBLING AND ASSEMBLING HEATER AIR CONDITIONER a 6 7 1 I c p L A j g 2 12 10 yj kny 16 rl a 87 92 Disassembling and Assembling Heater Air Conditioner Printed in Germany...

Page 421: ...Self tapping screw Cover Cover Self tapping screw Solenoid valve Holder Vacuum hose Vacuum hose Vacuum hose Vacuum hose Connector Header 18 Plug 19 Vacuum hose ItY 1 1 6 9 3 8 1 1 5 5 1 1 1 3 1 1 1 1...

Page 422: ...87 Air Conditioner 928 46 4 i 57 56 r i 34 i 6 I 25 31 27 36 38 i 37 5 a 87 94 Disassembling and Assembling Heater Printed in Germany Air Conditioner...

Page 423: ...older for cable Plug Pin Linkage Clip Setting motor Hose Water drain hose Cable connector Castellated nut lock Housing footwell Sheet metal Footwell flap Clamp Qtr 3 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1...

Page 424: ...46 Clip 4 47 Linkage 2 48 Evaporator 1 49 Holder 1 50 O ring 2 renew 51 Rubber grommet 2 check that grommet is correctly seated 52 Rubber grommet 1 check that grommet is correctly seated 53 Housing fr...

Page 425: ...emove air ducts to the side vents and to the glove compart ment vent 8 Remove defroster vents 9 Remove bracket for left hand oddments tray lO Unscrew bracket holding control unit of cruise control and...

Page 426: ...lating air flap blue water valve white and vacuum line black 18 Pull off water drain hose 19 Withdraw heater air conditioner 15 Detach coolant hoses 16 Unscrew 4 upper and 2 lower mounting nuts Remove...

Page 427: ...Slacken compressor Vee belt and remove belt _ 4 f y Y 9 I e A rl j b h i _ 7 _ 4 Disconnect hoses S Disconnect plug type 6 Slacken hose clamp onnectors I c 1 1 t 7 I 7 Unscrew compressor mounting bolt...

Page 428: ...sor and tighten clamps Adjusting Vee Belt Check tension at a point halfway between pulleys by pressing belt with thumb Deflection approx 10 mm see also page 13 18 l 87 100 Removing and Installing Cond...

Page 429: ...LUID TANK l Discharge air conditioner 2 Remove air intake screens 3 Disconnect plug for temperature and low pressure switch i I 8 Plug connectors and lines 4 Detach bracket at top right of lock transv...

Page 430: ...is opened REMOVINGAND INSTALLING ANTIFREEZE UNIT l Remove lower cover in engine compartment Z Disconnect cable plug 3 Unscrew mounting bolts 7 Plug connectors and lines 4 Carefully withdraw capillary...

Page 431: ...lines 10 These values are approximations If a replacement compenent is fitted top up the oil by an amount equal to the quantity left in the component removed The correct amount of oil can be poured di...

Page 432: ...r flap C Defroster flap D Footwell flap E Bulkhead F Setting motor H Heating valve V Evaporator 1 Intake line 2 Non return valve 3 Test socket 4 Vacuum tank 5 To cruise control actuator 6 Distribution...

Page 433: ...nnection r F F T i I I 2 Pump until vacuum is estab lished 3 If no vacuum is created use fuel line clamps for example to close distribution manifold lines one by one until leak is located 4 Eliminate...

Page 434: ...87 Air Conditioner FLAP POSITION PROGRAM Temperature regulator at max cooling output Flap A open recirculating air closed fresh air a 87 106 Flap Position Program Printed in Germany...

Page 435: ...closed Heating closed open valve O 20 ope 20 100 closed Blower off stage 4 stages l 4 Compres off on on sor BS Blower switch AC Air conditioner switch TR Temperature regulator The figures from 0 100 i...

Page 436: ...urized Switch ignition on Open central vent l Set slide 2 to max cooling out put Set slide 3 to Off The positions of the flaps must be as follows 2 Set slide 3 for air supply to central vent Flap A fr...

Page 437: ...s Press AC button At lo flap A switches to recirculating air If the specified statuses are not attained check operating switch solenoid valves and setting motor Note The position of the fresh air re c...

Page 438: ...at centre bottom bottom top top and defrost Reading Battery voltage If no voltage is registered check whether fresh air blower relay switches If the fresh air blower relay does not switch test the sig...

Page 439: ...ator slide to 27 The setting motor moves toward heating Voltage is interrupted at 10 ll Connect voltmeter to terminal 10 and terminal 4 Reading Battery voltage 12 Connect voltmeter to terminal 11 and...

Page 440: ...regulator slide to 30 Reading approx 1750 100 Ohm Note The resistance must change by approx 1000 Ohm If the values at terminals 1 2 6 9 11 12 13 14 and 15 are not attained the operating switch is def...

Page 441: ...ge of some 1000 Ohm is important If no change in resistance is recorded the operting switch must be checked separately If the ohmmeter reads infinity there is an interruption in the sensor chain which...

Page 442: ...ng Battery voltage Set temperature regulator slide to 27 The setting motor moves toward heating Voltage is interrupted at 10 lO Connect voltmeter to terminal 10 and vehicle ground Reading 0 volt Close...

Page 443: ...linkage until holes are aligned 4 1 4 fy Fig k yq hr i I r 3 I 4 3 Move lever downward to maximum cooling position 4 0n right hand side remove securing screw of lever system 5 Press lever 1 forward a...

Page 444: ...am OK Magnetic coupling engages Condenser clean After running for approx 10 minutes at a speed of 2000 rpm with compressor switched on the pressures and temperatures must be as shown in the graphs bel...

Page 445: ...efrigeration circuit plotted against air intake temperature Temperature at central vent OC 15 0 10 5 Temperature of air at the central vent plotted against air intake temperature Printed in Germany XI...

Page 446: ...defective Insufficient Cooling output Connect service device Witch on air conditioner and check pressure readings l Low pressure normal High pressure too high The system is overfilled Discharge air c...

Page 447: ...refrigerant Fit replacement fluid tank Recharge air conditioner 928 Air Conditioner 87 a Note If the air conditioner is refilled the air conditioning compressor may only be switched on for the first t...

Page 448: ...g and Installing Evaporator l Remove rear seat backrests 2 Remove air intake screen 3 Remove upper cover 4 Remove lower cover 4 Remove lower cover S Withdraw temperature sensor 1 i A a _ _ G Unscrew A...

Page 449: ...on l Remove air intake screen 2 Remove upper cover 3 Unscrew M 6 Allen head bolt 4 Unscrew M 5 Allen head bolts Note Tightening torques M 5 bolt 6 Nm 4 ftlb M 6 bolt 9 Nm 7 ftlb Renew all 4 O rings a...

Page 450: ...ower 3 Disconnect plug in connector to series resistors Removing and In stalling S e r i e s Resistors l Remove covers see section headed Removing and Installing Evaporator P Disconnect plug in connec...

Page 451: ...Remove radio P Beginning at top pull frame up and out 3 Pull socket housing off switch and regulator 4 Disconnect cable to clock a 5 Remove control knobs 6 Unscrew covers with special tool P 9245 y I...

Page 452: ...when unscrewing or tightening threaded couplers Renew O rings Checking Control Unit Note The control unit is located to the right of the blower l Remove covers see section headed Removing and Installi...

Page 453: ...te If the readings under points 4 and 5 are not attained check temperature regulator separately Terminals I and II 10 kOhm 10 O 10 kOhm 2 10 Terminal II and 7 Connect ohmmeter and minus a Reading at 2...

Page 454: ...nation Special Tools Remarks 1 2 Strap wrench Clutch plate puller 95458 02070 Source see Workshop Manual 95458 03064 3 Pliers for cir commercially clips available 87 126 Removing and Installing Magnet...

Page 455: ...Tightening torque 16 Nm 12 ftlb 2 Remove clutch plate with puller 4 4 lfF FGhd _ h d 3 Remove shims 4 Remove circlip and take off pulley s Unscrew cable holder 6 Remove circlip and lift off magnetic...

Page 456: ...rance between clutch plate and belt pulley is 0 4 0 7 mm If necessary correct clearance by inserting or removing shims Install both circlips with bevelled edges facing upward a 87 I28 Removing and Ins...

Page 457: ...valve on fluid tank 10 PA 20 C 860 g 1050 g 160 f 20 cc ND 6 The valve opens at a positive pressure of 41 to 43 bar and closes again as soon as the pressure drops below this value Note When fitting th...

Page 458: ...2 Set temperature control to max cooling position 3 Set fresh air blower to stage 2 After an operating time of approx 10 mins at an engine speed of 2 000 rpm and with the compressor switched on the pr...

Page 459: ...e in refrigerant circuit vs ambient temperature Ambient temperature 134187 Temperature at center nozzle Ambient temperature 1342 87 Air temperature at center nozzle vs ambient temperature Pressure and...

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