Porsche 1986 928 Workshop Manual Download Page 15

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Summary of Contents for 1986 928

Page 1: ...Workshop Manual l 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 resewed Printed in Germany XX 1986 WKD 481 621 Print...

Page 3: ...c Transmission Controls Case 37 Automatic Transmission Gears Valve Body 38 Differential Transaxle System 39 Front Wheel Suspension 40 Rear Wheel Suspension Axle Shaft 42 Wheels Tires Alignment 44 Anti...

Page 4: ...housing 37 125 Disassembling and assembling front converter housing 87 models onward 37 l 30 Removing and installing rear transmission case 37 131 Removing and installing rear transmission 37 135 Dis...

Page 5: ...ferential Disassembling and assembling bearing assembly Disassembling and assembling bearing assembly Determining thickness of shims for bearing assembly Adjusting drive pinion and ring gear Adjusting...

Page 6: ...ard as 28 02 but rear axle transmission ratio 13 33 928 S USA series 85 models for Japan 928 S Special option Europe 85 models rest of the world 928 S Special option M 251 Europe 85 models rest of the...

Page 7: ...1 Front converter casing 3 Final drive 2 Automatic transmission Type Key number Equipment Installed In model a A28 12 928 S 4 USNJap 87188 A28 14 928 S 4 R d W 87188 A28 16 928 S 4 worldwide 89 90 91...

Page 8: ...peed automatic A 22 three speed automatic G 28 five speed manual transmission 72227012 01 722316 02 A28 01 7222702501 72231602 A28 07 722 270 14 01 722 318 02 A 28 02 03 7222702601 72231602 A28 11 722...

Page 9: ...ial 2 ZF limited slip differential 3 proportional slip differential Model year Serlal number J 1988 e g 00903 K 1989 L 1990 M 1991 Note As from model 88 the gear box number will be readable from below...

Page 10: ...I 4 1 oo 5 59 15 33 i 2 200 14 33 i 2 357 A 28 02 05 08 13 33 i 2 538 A 28 03 06 09 11 14 16 18 A 28 01 A 28 02 03 05 06 08 09 l 1 2200 2600rpm 2200 2600rpm up to MY 86 approx 2 7 I from MY 87 to 90 a...

Page 11: ...to transmission case Support flange to transmission case Plug brake band B 1 mount Catch plate on range selector shaft Bolt M6 M6 M6 8 8 8 8 8 8 8 6 8 6 8 6 8 6 8 6 Bolt Leaf spring to transmission ca...

Page 12: ...modulating governor and operating pressure Plug M8xl 13 9 Vacuum unit bracket Kickdown solenoid valve End plate on valve body housing Bokt Solenoid Bolt M6 8 8 8 61 M14x1 5 20 14 M4 8 8 3 3 2 3 End p...

Page 13: ...case Bearing assembly to rear transmission case Final drive to transmission case Collar nut drive pinion ATF filler tube to ATF pan ATF reservoir to ATF pan Thread MlOxl ME M8 M8 M 10 ME M 10 M 26x 1...

Page 14: ...ter 32 a TOOLS No Description Special Tool Remarks 1 Transmission holder 9216 2 Grip plate 9301 3 Mandrel 9310 4 Depth gauge Standard tool a Printed in Germany VIII 1984 Removing and Installing Torque...

Page 15: ...32 Torque Converter 928 REMOVING AND INSTALLING TORQUE CONVERTER I i I I i y i c 0 I 9 1 4123 I j a 32 102 Removing and Installing Torque Converter Printed in Germany...

Page 16: ...alling Lift out carefully with Special Tool 9301 Tightening torque 46 Nm 34 ftlb Tightening torque 23 Nm 17 ftlb Renew if badly worn or if particles are found in ATF Lubricate drive flange and bearing...

Page 17: ...ng bolts 4 Remove mounting bolts for converter casing and remove casing Installinq Note 5 Measure installation depth of converter and make a note for reassembly Up to 86 models approx 16 mm 87 models...

Page 18: ...times until the kerosine drained from the converter is clean 2 Attach Special Tool 9301 to torque converter 3 Coat drive flange and bearing pin of converter with MoS2 multi purpose grease 4 Place tran...

Page 19: ...ition P and press out cover frame carefully with a suitable screwdriver applied at the left rear corner 6 Move selector lever to position N and remove frame inclined toward rear Installing 1 Move sele...

Page 20: ...Move selector lever to position 3 and push rear locking bar toward rear until it engages a 9 Attach gate in selector lever install rubber boot in correct position and install selector lever grip IO M...

Page 21: ...tion and remove mounting screws 6 Loosen intermediate muffler shield and push aside as far as possible 7 Disconnect selector lever cable on trans mission lever and detach cable sleeve on brackets 23 7...

Page 22: ...econd person must pull wire and cable 4 Install selector lever base in correct position watching mark and tighten mounting screws with 15 Nm ll ftlb 5 Install cover frame and selector lever grip Place...

Page 23: ...ector lever to position N 2 Place range selector lever on transmission in N Note Bolt for range selector lever must be tightened for adjustments 3 Adjust ball end on cable that attachment is possible...

Page 24: ...ck plug by turning white plastic ring arrow upwards in direction of arrow IWJ I 4 Pry off plug carefully with two screw drivers applied on cable outlet and bar fy y q i3 w y _ YQ 2 a of j gg y g 5 Rem...

Page 25: ...Move range selector lever to position N 3 Install and tighten range selector lever screw with 10 Nm 7 ftlb 4 Adjust switch and connect plug see page 37 109 5 Attach selector lever cable on selector ra...

Page 26: ...pin made of 4 mm dia welding wire for 4 mm dia drill through lug into locating bore in switch housing 2 Tighten switch mounting screws with 10 Nm 7 ftlb and pull out locating pin 3 Press on plug and t...

Page 27: ...7 Backup lights must be on in position R 1 Move selector lever to position R Engine speed must drop as gear engages 2 Move selector lever to position P Engine speed should increase as reverse gear dis...

Page 28: ..._ F _1 __ t i T s Y I h b I yi 13 e LI j 4 F T a 1 32 valve engines up to 86 models d A tr CA I 32 valve engines 87 models onward 3 Sever bowden cable behind threaded connector 4 Disengage control cab...

Page 29: ...ear Installing l Carefully feed control cable through sleeve from rear 2 Install clamp correctly and attach spherical head with hex nut A Clamp 3 Attach Bowden cable to transmission 4 Adjust cable for...

Page 30: ...for faultless operation of the transmission l Set idle speed 2 Take up play in throttle cable 3 Adjust spherical head of control cable until cable can be installed without strain 32 valve engines up...

Page 31: ...rols Case 37 a TOOLS No Description Universal transmission jack Holding chain Special Tool 9164 Remarks Standard e g from Hahn Metallbau GmbH 7012 Fellbach a Printed in Germany VIII 1984 Removing and...

Page 32: ...r and lower air cleaner housings 6 Disconnect oxygen sensor wire on central fuse relay panel and pull out from below USA cars 7 Remove engine air guide 8 Remove complete exhaust assembly with shields...

Page 33: ...Mark position of toe eccentric and rear axle cross member for reinstallation and remove entire rear axle 15 Remove clamo bolt Printed in Germany VI II 1984 Removing and Installing Transmission 37 119...

Page 34: ...locking bar of guide in direction of arrow arrow A and turning guide counter clockwise arrow 6 Pull out guide from above carefully Disconnect control cable on operating rod a 37 120 Removing and Inst...

Page 35: ...two bolts and place a suitably thick block of wood between central tube and brace 25 Pull back transmission and lower carefully Installing Note Installation is in reverse order of removal procedures b...

Page 36: ...ftlb 7 Push wire harness upwards through opening in spare wheel well 8 Lift transmission and hold in installed position with Special Tool 9164 9 Lower universal transmission jack 10 Install rear axle...

Page 37: ...turns 3 Lift transmission in middle of case far enough that there is a gap between both transmission mounts and the cross member Measure this gap on both sides and take up difference with shims 4 Pla...

Page 38: ...ransmission Controls Case 37 a TOOLS H Lq a f 4 n a a Description Support rail Special Tool Remarks Standard e g Kukko Size 1 a Printed inGermany VIII 1984 Disassembling and Assembling Front 37 125 Co...

Page 39: ...Automatic Transmission Controls Case 928 DISASSEMBLING AND ASSEMBLING FRONT CONVERTER HOUSING 1 i i I 4 3 i 2 45 6 6 a a a a 37 126 Disassembling and Assembling Front Converter Housing Printed in Germ...

Page 40: ...1 4 Grooved ball 1 Press off with Heat to approx bearing support rail 120 C 250 F e g Kukko and push on to size 1 drive flange 5 Circlip 1 6 Circlip 1 7 Grooved ball 1 Press out with Heat case to bea...

Page 41: ...1 j i SLl x 17 T i 7 I 6 i II iI Assembling 1 Install both circlips in converter housing 2 Heat grooved ball bearing to about 120 C 250 F and press bearing on drive flange against shoulder with a sui...

Page 42: ...groove ball bearing over inner race until bearing contacts circlip c r T _ 71_ 1 1 m p 7 T yj s i I Note Place a suitable pressure piece beneath the drive flange bearing to keep it from moving out as...

Page 43: ...atic Transmission Controls Case 928 DISASSEMBLING AND ASSEMBLING FRONT CONVERTER CASING 87 MODELS ONWARD 37 130 Disassembling and Assembling Front Converter Casing 87 Models Onward XVI 1987 Printed in...

Page 44: ...f with puller e g Kukko size 1 Removing Note when Installing Press in after insert ing deep groove ball bearing No 5 Heat casing to approx 120 C and press in as far as possible with a suitable piece o...

Page 45: ...sing puller e g Kukko size 1 pull deep groove ball bearing off drive flange r ll 11 i 1 a II i rz i i r i f f k 7 71 2 I i i Assembling l Heat converter casing to approx 120 C and install both deep gr...

Page 46: ...will go Note To prevent the deep groove ball bearing No 51 movino out as the flange is pressed position a suitable piece of pipe against the bearing outer race as a support Printed in Germany XVI 198...

Page 47: ...atic Transmission Controls Case 37 a TOOLS No Description 1 2 Pressure pad Mandrel i 1 Special Tool I Remarks 9180 l P 254 a Printed in Germany VI I I 1984 Removing and Installing Rear 37 131 Transmis...

Page 48: ...ontruIs Case 928 REMOVING AND INSTALLING REAR TRANSMISSION CASE 9 6 2 I 9 I 3 da p I _1 j c s 5 _ 7T ji 1 ii k I I i i i 1 I iJ Ii k I1 L I a 1 I I I r 5 37 132 Removing and Installing Rear Transmissi...

Page 49: ...lb Torque 42 Nm 30 ftlb Insert after installing case Replace Drive out with suitable screw driver Replace drive in to correct position with Special Tool 9180 l and coat sealing lip with ATF Drive out...

Page 50: ...talling I Drive in inner seal to correct position with Special Tool 9180 I Note Hold seal on special tool with a small amount of grease and drive in seal that sealing lip faces automatic transmission...

Page 51: ...epth gauge 5 Centering pins 6 Puller 7 Pressing in tool 8 Pressure pad Special Tool 9216 9301 9310 9321 9180 l Remarks Standard tool Standard tool Made locally steel pipe 45 x 5 x 40 mm with welded co...

Page 52: ...c Transmission Controls Case 928 REMOVING AND INSTALLING REAR TRANSMISSION 24 25 23 26 r T A I J 1r y22 i _ ir z 19 1 18 11 12 13 14 15 16 i li 37 136 Removing and installing Rear Transmission Printed...

Page 53: ...6 1 Note Installation Torque 46 Nm I33 ftlb Engage parking lock and unscrew If necessary pull out with s suitable puller 1 Torque 46 Nm 33 ftlb Torque 46 Nm 33 ftlb Torque 46 Nm 33 ftlb Replace coat...

Page 54: ...g Installing Note number and thickness for reinstallation Lift out carefully with Special Tool 9301 Recalculate if necessary Replace coat with ATF Replace coat with ATF Tightening torque 6 Nm 4 4 ftlb...

Page 55: ...suitable puller if necessary c b 1 M 7 T m I 6 CT r G i r r k y 2 d I r f 1 4 A Bolt 10 x 30 with centering bore 5 Position transmission upright and remove converter mounting bolts through openings in...

Page 56: ...uter seal must be installed that sealing lip and spring supporting the sealing lip face final drive 2 Mount Special Tool 9301 on torque converter 3 Coat drive flange and bearing journal of converter w...

Page 57: ...s of shims for bearing L assembly Measure distance from tapered A I 4 A r i roller bearing surface to bearing flange i surface with a depth gauge for example I 1 34 55 mm Since the distance specified...

Page 58: ...on to speci fied torque and lock by upsetting the flange 9 Adjust drive pinion and ring gear see page 39 125 10 Install transmission and check adjustment of selector lever and control pressure ca bles...

Page 59: ...port Mandrel Measuring bridge Depth gage Circlip pliers Spacer sleeve Measuring device Centering pins Special Tool Remarks 9216 I 9316 9119 9313 9312 9320 9321 Commercia Commercia lly available llv av...

Page 60: ...lts and support with Special Tool 9216 remove ATF pan with ATF reservoir Z Remove final drive with bearing assembly see page 39 101 3 Remove rear transmission case see page 37 131 4 Remove front conve...

Page 61: ...O Remove starter interlock switch after unscrewing mounting bolts a r 7 3 c1 6 j d 1 7 I s p 4 Zl Remove vacuum control unit after unscrewing socket head bolts 22 Remove pressure unit B 1 and modulati...

Page 62: ...lock with paw1 and expander spring 25 Remove plastic guide and roller p y pLypc z 1 4 I i I c f f p Lx K g n _ q c K r 7 26 Remove secondary pump by unscrewing hex nut from axial holder and removing...

Page 63: ...d remove with oil tube The oil tube has been discontinued as of model year 87 28 Remove circlip and sprung linkage The circlip has been discontinued as of model year 87 Linkage is staked to detente pl...

Page 64: ...er drive gear was fitted as of approx December 1986 With this design remove spacer A Spacer 8 Circlip 33 Remove axial holder 34 Remove helical gear with shims Note thickness of shims for reinstallatio...

Page 65: ...cover 1 7 a z fl 38 Grasp gearset at input shaft and carefully pull forward and out 39 Pull clutch K 1 with brake band B 1 from gearset 40 Remove plates B 3 41 As of transmission No 379 225 remove da...

Page 66: ...hrust washer a 47 Withdraw pressure unit B 2 48 Unscrew hex bolts Screw two approx 80 mm long bolts into two opposite holes and release flange from casing by tapping the two bolts with a hammer 5lil T...

Page 67: ...e installation l Insert guide ring and with Special Tool 9119 drive in sealing ring right way round sealing lip arrowed facing outward toward brake band piston cover Z Insert O ring and sealing ring S...

Page 68: ...Position support flange so holes are aligned Tighten mounting bolts Tightening torque 11 Nm 8 ftlb that G Position thrust washer right way round positioning lug engages support flange p T y q P 2 i z...

Page 69: ...nd B 2 as close together as possible at the support lugs and insert right way round in case lO Place greased split radial bearing on output shaft lZ Carefully place gearset without clutch K 1 in trans...

Page 70: ...ght way round v IT I 15 As of transmission No 379225 install damping spring A Damping spring l 2 3 4 5 Inner plate 2 1 mm thick Outer plate 7 7 mm thick Outer plate 2 3 or 2 8 mm thick Outer plate 2 8...

Page 71: ...3 0 3 5 mm thick as required to correct play 18 Place axial bearing in planet carrier Check that lubricating pressure rings are correctly seated insert with grease A seal The difference between the t...

Page 72: ...measured 23 Push pressure pin into pressure unit 8 1 replace O rings 24 Insert pressure unit screw in threaded plug or transmission protection switch in 87 models onward and tighten Tightening torque...

Page 73: ...13 on prepared face and with depth gage measure to clutch K 1 e g 123 6 mm The difference between the two measurements is the axial play B without axial bearing rotation washer or shim Example b 123 6...

Page 74: ...al in position Tighten mounting bolts Tightening torque 13 NM 10 ftlb Insert these spacers as calculated thickness in example 3 8 mm A Centering pins 9321 1 Axial bearing 2 Rotation washer 3 Shim 29 T...

Page 75: ...since approx December 1986 31 Install helical gear and axial holder a I 7 I d A I J a Printed in Germany XVI 1987 Disassembling and Assembling 37 161 Transmission 32 Insert 0 ring and install centrif...

Page 76: ...l cover out so and tighten hex bolts that it makes contact with Tightening torque 8 Nm circlip around entire 5 9 ftlb circumference 35 Install backer and insert O ring 37 Recheck seating of axial hold...

Page 77: ...be is discontinued as of 87 models f P 1 J L 1 gr a 1 b r LL 39 Insert detente plate with shaft screw in socket head bolt and tighten Tightening torque 8 Nm 41 Place correct number of shims on 5 9 ftl...

Page 78: ...m for bearing assembly 10 Shim for axial play C 11 Rotation ring C Axial play Use a depth gage to measure from bearing surface of taper roller bearing to bearing face of bearing assembly e g 34 55 mm...

Page 79: ...L s r b t Use a depth gage to measure from case bearing face to inner race of cylindrical roller bearing e g 15 9 ml Distance b minus distance a equals distance C Example Distance a 15 9 mm Distance b...

Page 80: ...socket head bolts Tightening torque 8 Nm 5 9 ftlb Place starter interlock switch in position and slightly tighten mounting bolts do not tighten fully Place range selector lever in position such that...

Page 81: ...down while ensuring that piston pressure pin enters brake band do not damage sealing ring with lip Brake band pistons with removable pressure pins were installed as of transmission No 788 606 To corre...

Page 82: ...and remove 51 Measure and adjust play L of brake band Note The thread of Special Tool 9320 has a 1 mm lead which means that one full turn equals 1 mm travel Turn screw of Special Tool by hand until r...

Page 83: ...l is too short fit a brake band piston with shorter pressure pin As of l transmission No 788 606 use appropriate shims to correct travel 54 Install pressure pin with larger diameter toward brake band...

Page 84: ...ake band piston cover B 2 and insert circlip 58 Measure play L at brake band B 2 and adjust press brake band B 2 toward brake band piston at support lug as arrowed so that brake band piston contacts b...

Page 85: ...ay L to 6 7 mm by changing pressure pin in brake band piston 82 59 Insert one way valve and filler 60 Insert brake band guide 61 Insert temperature throttle and push into oil duct until throttle is fl...

Page 86: ...rt oil tube in casing bore 63 Insert combination bolts and tighten nuts slightly do not tighten fully 64 Engage return spring 65 Place leaf spring with holder in position and tighten mounting bolts sl...

Page 87: ...nsert combination bolts and tighten to 8 Nm 5 9 ftlb Note length of bolts The three arrowed bolts are only 50 mm long the remaining 12 bolts are 55 mm long Begin by tightening the two bolts A B slight...

Page 88: ...ust play to 0 4 1 0 mm with selector in N position Plastic clips are available in three thicknesses 70 Place ATF filter in position insert cross recess head screws and tighten to 4 Nm 2 95 ftlb a 71 I...

Page 89: ...ough selector into hole in shift valve casing and tighten mounting bolts to 8 Nm 5 9 ftlb Remove holding pin Note Once the transmission has been installed check settings of cables for selector lever a...

Page 90: ...matic Transmission Gears Valve Body 38 a TOOLS 1 NO Description Special Tool Remarks 1 Pressure tester v 90 2 Hoses 9170 3 Adapters 9300 l Printed in Germany VI II 1984 Checking Transmission Operation...

Page 91: ...oil and missing or loose mounting bolts B Transmission Fluid Level The specified fluid level is extremely important for proper operation of an automatic transmission so that following test must be car...

Page 92: ...ransmission on a longterm basis After correcting ATF level to specifications operate brake pedal leave selector lever in each position R N D N R several seconds and then return it to N IO that working...

Page 93: ...are very high D Test Drive Take the vehicle for a test drive only if transmission not obviously damaged During test driving it is important to pass through all the automatic transmission ranges and m...

Page 94: ...190 211 131 115 177 197 122 107 58 64 env 63 62u 68 45 39 58 63 42 36 126 143 122 106 118 133 144 99 207 216 203u 183 193 213 189 171 69w 75 env 68 TransmissionType TransmissionType 6 C A 28 03 O km...

Page 95: ...suring the operating pressure The 10 bar pressure wswr is applted for modulatmg and governor pressure tests Pressure gauges are best connected that they can be read by driver durtng a test drove if a...

Page 96: ...nnections for modulating and governor pressures Connection for operating pressure Note Do not let hoses hang through too much or rest on the exhaust svstem Printed in Germany VII 1983 Checking Transmi...

Page 97: ...he pressure gauge with vacuum line interrupted Note When working on K Jetronic engines disconnect the vacuum line from the intake manifold and plug socket with a suitable bolt e g plug for test connec...

Page 98: ...s brought to the necessary value by the centrifugal governor Measuring Governor Pressure Since governor pressure is derived from operating pressure operating pressure must be checked simultaneously or...

Page 99: ...ns ATF temperature approx 8O C selector lever at D speed approx 140 km h vacuum line discon nected from modulating pressure sensor ATF temperature approx 8O C selector lever at D engine idling vacuum...

Page 100: ...ring conditions ATF temperature approx 80X Selector lever in position D driving speed approx 140 km h Vacuum line disconnected at the modulating pressure cell ATF temperature approx 80 C selector leve...

Page 101: ...k whether vacuum line from intake branch to vacuum box is plugged If yes replace 3 Check operating pressure If too low or not available a Disassemble and clean shift valve housing and service valve Re...

Page 102: ...e band Condition Transmission slips during 2nd 3rd shift or slips at first and then grabs hard Cause Correction 1 Check modulating pressure adjusting if necessary 2 Check whether temperature orifice i...

Page 103: ...w in all selector lever positions for a brief period immediately after starting engine especially when car had not been used for a while Cause Correction Torque converter drains partially via leaky or...

Page 104: ...ssure acceptance piston in shift valve housing moves easily and is in correct installed position replacing shift valve housing if necessary Note If there is a hard engagement jolt when quickly shiftin...

Page 105: ...rned replace pressure element a Condition Jolts when shifting in partial load range Cause Correction 1 Check adjustment of control pressure cable 2 Check modulating pressure adjusting if necessary 3 C...

Page 106: ...djust control pressure cable 2 Check governor pressure and replace centrifugal governor if governor pressure is too low 3 Service control pressure valve Condition Upshifts only in lower speed range of...

Page 107: ...alve removed connect to power supply and check operation Fit replacement if necessary 3 Check that control pressure cable is not disconnected broken or maladjusted 4 Check that kickdown control slide...

Page 108: ...on solenoid valve for damage 2 Check whether kickdown switch sticks in pressed position replacing if necessary 3 Check whether solenoid valve sticks in open position replacing if necessary Condition P...

Page 109: ...g b With engine stopped 1 a Clean and service centrifugal governor 2 b Service blocking piston in lower cover Condition Engine cannot be started with selector lever in P and N Cause Correction 1 Adjus...

Page 110: ...se of the ratio A different car should be used for comparison Condition 3rd gear too loud Cause Correction 1 Replace rear planet gear set Condition Whining noise only when changing gears with full loa...

Page 111: ...box Condition Oil lost between torque converter and primary pump oil escaping through vent grid Cause Correction 1 Install oil drain plug on torque converter with a new seal as well as Hylomar on thr...

Page 112: ...B 3 adjust play to smallest value Condition Light grinding noise in selector lever positions P and N Cause Correction This noise concerns a normal rolling noise from the front gear set which cannot b...

Page 113: ...s for ATF reservoir and removing mounting bolts 3 Unscrew mounting bolts and remove shift valve casing Installing l Ensure that plastic poppet valve and chip screen for shift valve B 2 are correctly s...

Page 114: ...14 Nm 8 ftlb 6 Top up ATF Note The full throttle control pressure can be changed by turning the socket head bolt arrowed Turning the bolt clockwise makes the full load or kick down upshifts earlier Tu...

Page 115: ...Nm 5 9 ftlb 6 Top up ATF Note The full throttle control pressure can be changed by turning the socket head bolt arrowed Turning the bolt clockwise makes the full load or kick down upshifts earlier Tu...

Page 116: ...G AND ASSEMBLING SHIFT VALVE HOUSING 18 1 234 5 678 9 i 4 I F 1 I cb y I I c l A4 i i L F c r i s_ i J hi c F i w I_ 1 L r 4 L 4 4 i s I 1 6 p k c m 16 Ii 15 14 13 ml 1 Ii a 0 a PrintedinGermany VIII...

Page 117: ...38 Automatic Transmission Gears Valve Body 928 a DISASSEMBLING AND ASSEMBLING SHIFTVALVE HOUSING _ _ 1 a 38 126 Disassembling and Assembling Shift Valve Housing Printed in Germany...

Page 118: ...underneath ball no 5 I9 Plastic valve 1 Install in flight without correct position bore do not mix up with valve without bore O Throttle check 1 valve 21 Check valve 1 Install with spring 22 Lubricat...

Page 119: ...uld be especially suitable After disassembling all parts must be washed and dried with compressed air 1 Remove plastic valve A Plastic valve 8 Check valve C Operating pin D Blocking valve K 1 2 Remove...

Page 120: ...arefully and check whether valve ball arrow is in correct installed position I _ _ _ _ z r LL h 4 Place pick up housing on shift valve housing 5 Hold shift valve housing and pick up housing together a...

Page 121: ...matic Transmission Gears Control 38 a DISASSEMBLING AND ASSEMBLING SHIFT VALVE CASING 87 MODELS ONWARD l a Printed in Germany XVI 1987 Disassembling and Assembling 38 130 a Shift Valve Casing 87 Model...

Page 122: ...ears Control 928 DI SASSEMBLING AND ASSEMBLING SHIFT VALVE CASING 87 MODELS ONWARD 19 26 27 20 I I I I a 7 i d r Q 1 qy j q 18 A I A a 38 130 b Disassembling and Assembling Shift Valve Casing 87 Model...

Page 123: ...8 Note When emoving aptive Installing Insert taper spring with large diameter downward beneath ball No 5 Insert right way round do not mix up with valve with bore Install with spring Install with spri...

Page 124: ...and blow through with compressed air l Remove plastic valve and chip screen rn r j y mz I z r E z 4 s q Lkz q rc g J T sl g ZI r_p L 3 g _ G HL cQ 2 I fP I l I 3 ii T e _ 2 Remove both mounting screws...

Page 125: ...ressure valve captive B Overpressure modulating valve captive C Bleed valve captive 3 Carefully place back plate on shift valve casing and check that valve ball arrowed is in its installation position...

Page 126: ...hat housing and casing can still be moved against each other 7 Insert plastic valve yellow in casing with bore and chip screen right way round A Plastic valve B Chip screen a 38 130 f Disassembling an...

Page 127: ...ating of temperature orifice plastic valve filler and oil deflector 2 Remove ATF filter 3 Remove holder and leaf spring 0 w 6 w ry m 4 Remove combination bolts and take off cover with oil tube l ew y...

Page 128: ...ift valve housing 4 Mount leaf spring with holder and install bolt but do not tighten tighten bolt with 8 Nm 6 ftlb only after installing the shift valve housing 5 Install shift valve housing and tigh...

Page 129: ...928 Automatic Transmission Gears Valve Body 38 a DISASSEMBLING AND ASSEMBLING LOWER COVER 2 A we r _ 1 _ I I f r Printed in Germany VI II 1984 Disassembling and Assembling 38 133 Lower Cover...

Page 130: ...8 Nm 6 ftlb 4 Cover 1 5 Gasket 1 Replace if necessary 6 Transfer plate 1 7 Filter screen 2 8 Valve 1 Position correctly check for tight fit 9 Holder 1 Position correctly IO Plug 1 I1 Spring 1 I2 Shift...

Page 131: ...r possible Never use cloths losing lint 1 Squeeze both tabs together and remove injector 2 Remove filter screens and valve 3 Take off circlip Remove blocking valve with spring and shaft Assembling 1 I...

Page 132: ...injector in correct position until position both tabs arrows engage 4 Place transfer plate and gasket on lower cover 5 Align gasket with transfer plate by inserting two bolts 6 Mount cover and tighta...

Page 133: ...c Transmission Gears Valve Body 38 a TOOLS h c I I I i P No Description Special Tool Remarks Filler Commercially available e g Dresser Wayne Model 3009 Printed in Germany VIII 1984 Replacing ATF and F...

Page 134: ...ld be changed every 20 000 km without replacement filter If the ATF is to be changed the vehicle must be standing on level ground the transmission must be hot and the engine switched off Unscrew drain...

Page 135: ...r and top up with the rest of the ATF without delay Up to 85 models yF r _ 86 models onward Operate service brake and set the selector lever to each position for a few seconds Recheck ATF level N 0 t...

Page 136: ...mission Gears Regulation 928 a Up to 85 models 86 models onward 1 max at 80 C ATF temperature 2 min at 80 C ATF temperature 3 max at ZO 30 C ATF temperature 38 140 ATF and Filter Changing l XII 1986 P...

Page 137: ...cooler and 3 Attach extra hose from ATF charger see Workshop Equipment Group of Special Tool Catalog on return line and flush cooler as well as lines with the charger lines will also have to be flush...

Page 138: ...in direction of arrow Pry off plug carefully with two screw drivers applied on both sides 3 Press in cover and remove snap ring with cover I p 1 4 Loosen nut for axial holder 5 Turn axial holder coun...

Page 139: ...l governor lightly in and out while turning axial holder clockwise until governor engages firmly position A in section drawing 4 Press in cover and insert snap ring 5 Press out cover again until it re...

Page 140: ...e centrifugal weight A and at same time check movement of governor valve in openings arrows Note It should be possible to move governor valve easily If necessary wash governor and dry thoroughly with...

Page 141: ...r as possible 2 Adjust modulating pressure see page 38 108 2 Pull off vacuum hose on vacuum modulator 3 Remove socket head screws and remove with holder a 4 Pull out vacuum modulator Installing 1 Moun...

Page 142: ...atic Transmission Gears Valve Body 38 a TOOLS NO 1 2 J 1 Description Special Tool I Remarks Guiding sleeve Centering pins 9319 9321 Printed in Germany VIII 1984 Removing and Installing Primary Pump 38...

Page 143: ...8 Automatic Transmission Gears Valve Body 928 a REMOVING AND INSTALLING PRIMARY PUMP 12 13 14 15 11 III L 16 1 a i L A p I r i p j a I 6 a 38 150 Removing and Installing Primary Pump Printed in German...

Page 144: ...1 2 1 1 20 1 1 Removing Note When Installing I 1I Replace install with grease Insert right way round Insert right way round Sealing lip must face toward cover Tightening torque 20 Nm 15 ftlb Check be...

Page 145: ...front transmission cover 4 Screw two bolts in threaded holes and pull bolts to withdraw cover 5 Press spring plate down and remove circlip 6 Unscrew mounting bolts and remove pump screw two bolts in...

Page 146: ...y the stator shaft during this step Tighten mounting bolts to 20 Nm 14 ftlb 4 Install seals on piston that sealing lips face down direction of arrow h 5 Apply Special Tool 9319 on front cover and coat...

Page 147: ...ip down and pull off special tool 10 Push down on diaphragm spring with circlip until circlip engages in its groove 11 Install teflon rings with grease making sure gap of rings arrow remain together I...

Page 148: ...matic Transmission Gears Valve Body 38 DISASSEMBLING AND ASSEMBLING SECONDARY PUMP 2 1 4 3 1 3 5 pc I L 6 a II c 1 I I J 01 8 6 i Printed inGermany VIII 1984 Disassembling and Assembling 38 155 Second...

Page 149: ...er plate 1 3 Gear driven 1 Coat with ATF 4 Gear driving 1 Coat with ATF drive dog must engage in groove 5 Circlip 1 6 Cover 1 7 Spring 1 8 O ring I 1 Replace coat with ATF 9 Piston 10 Teflon ring l Re...

Page 150: ...928 Automatic Transmission Gears Valve Body 38 a TOOLS No Description Special Tool Remarks Assembly stand 9314 a Printed in Germany VI I I 1984 Disassembling and Assembling 38 157 Gear Assembly...

Page 151: ...SEMBLING GEAR ASSEMBLY 23 4 j h is US 3 I L rz 2 J Y l _ _ 5 t G I i c _r d c 1 i i i r A 10 9 i v q i ld r _ _ _ 11 12 14 13 I i 1 r i lL e u Z L j j G IiT 1 I i B i 1 r _ _ _ l I jwr I 1516 5 17 18...

Page 152: ...if tion necessary 5 Snap ring 1 Remove with a Check for correct suitable screw fit driver 6 Front gear set 1 7 Axial bearing 1 a Drive shaft 1 9 Axial bearing 1 IO Lubricating ring 2 Replace install...

Page 153: ...embly with drive shaft facing up 3 Take off parts separately 4 Remove snap ring and take inner plate carrier with one way clutch out of connecting carrier Assembling 2 Remove snap ring Note Coat all b...

Page 154: ...ngs on output shaft 5 Install drive shaft and axial bearing 5 L _ n I YJ a i I r b k A 6 Install front gear set and secure with snap ring Press snap ring into groove with a screwdriver 7 Lift gear ass...

Page 155: ...ft with a small amount of grease 10 Take gear assembly off of Special Tool 9314 and install axial bearing on drive shaft with a small amount of grease A I I 1 I 3 _ I _ r j A _ I i p 4 _ y 6 j T it 9...

Page 156: ...ission Gears Valve Body 38 a TOOLS a No Description t 1 Lockplate 2 Feeler blade gauge I Special Tool 9322 Remarks Sixteen 16 Standard tool Printed in Germany VIII 1984 Disassembling and Assembling 38...

Page 157: ...38 Automatic Transmission Gears Valve Body 928 DISASSEMBLING AND ASSEMBLING ONE WAY CLUTCH ii I A 1 i 1 a 2 a 38 164 Disassembling and Assembling Printed in Germany One way Clutch...

Page 158: ...necessary 4 Support 1 Position correctly 5 One way clutch 1 Use Special inner race Tool 9322 6 Shim 1 7 Roller cage 8 Cyl roller 1 16 I 9 Spring I 16 IO O ring 1 1 Replace install after checking axial...

Page 159: ...sembling Note Check bearing surfaces and inner race of one way clutch for wear If bearing surface of cylindrical rollers on inner race of one way clutch shows strong scoring or notching replace the en...

Page 160: ...Push cylindrical rollers against springs and apply Special Tool 9322 with bend facing out 5 Install one way clutch inner race while turning in direction of arrow 6 Remove Special Tool 9322 7 Install s...

Page 161: ...install connecting carrier on one wav clutch 10 Install snap ring and press into groove with a screwdriver ffq yy p4 _ b me I _ 1 4 Checking and Adjusting One wav Clutch Axial Play 1 Check play betwee...

Page 162: ...a TOOLS 2 ff b 1 3 _ l j z 1 j t No Description Special Tool Remarks 1 Assembly tool 9315 2 Assembly sleeve 9317 3 Assembly sleeve 9318 4 Feeler blade gauge Standard tool Printed in Germany VIII 1984...

Page 163: ...38 Automatic Transmission Gears Valve Body 928 DISASSEMBLING AND ASSEMBLING CLUTCH K 1 L m m m s 1 i i 5 38 170 Disassembling and Assembling Printed in Germany Clutch K 1...

Page 164: ...eck for burnt spots and wear If less than 2 mr thick replace Place in ATF about 1 hour before installing Check for burnt spots and bending Check for burnt spots and bending Position correct that curve...

Page 165: ...ion Piston Seal Seal Plate carrier Qty Note When Removing Installing 1 Install with Special Tools 9317 and 9318 1 I Position correctlv coat with ATF Position correctly coat with ATF L Special Instruct...

Page 166: ...piston will vary If new springs are required the same quantity of springs must be installed Assembling 1 Install seals in piston that sealing lips face down direction of arrow 2 Apply Special Tools 9...

Page 167: ...7 Install diaphragm spring with curved surface on piston as shown in figure 1 Diaphragm spring 8 Assemble set of plates as shown in layout drawing and install in plate carrier Note New inner plates m...

Page 168: ...usted with a snap ring which is available in 3 thicknesses 2 0 2 5 3 0 mm However if the specified play cannot be reached with snap rings the center outer plates must also be used for adjusting Printe...

Page 169: ...on Gears Valve Body 38 0 TOOLS No Description 1 Assembly tool 2 Assembly sleeve 3 Feeler blade gauge I Special Tool 9315 9317 Remarks Standard tool Printed in Germany VI II 1984 Disassembling and Asse...

Page 170: ...38 Automatic Transmission Gears Valve Body 928 0 DISASSEMBLING AND ASSEMBLING CLUTCH K 2 i 7 r 9 l l i J a 2 3 5 38 178 Disassembling and Assembling Printed in Germany Clutch K 2...

Page 171: ...Redetermine thickness if necessary Check for burnt spots and bending Check for burnt spots and wear Replace if thickness is less than 2 mm Place in ATF about 1 hour before installing Check for burnt...

Page 172: ...928 11 I Description Note When Seal SeaI Plate Carrie1 I Removing Instal ing 1 1 1 Position correctly coat with ATF Coat with ATF must not turn on its own Special Instructions 38 180 Disassembling an...

Page 173: ...gm spring and springs Note The quantity of springs for clutch piston will vary If new springs are required the quantity must not be changed 2 Install seal in piston that sealing lip faces down directi...

Page 174: ...hragm spring that each spring is centered by a guide pin 6 Apply and tighten Special Tool 9315 7 Install snap ring 8 Assemble set of plates as shown in layout drawing and install in plate carrier Note...

Page 175: ...ote Play A can be adjusted with a snap ring which is available in 3 thicknesses 2 0 2 5 3 0 mm However if specified play cannot be reached with snap rings the center outer plates must also be used for...

Page 176: ...ool Remarks 1 Holder 9216 2 Centering pin 9321 3 Puller Standard tool 4 Pressing in tool Made locally 45 x 5 x 40 mm steel pipe with welded cover and 11 mm dia bore 5 Depth gauge I Standard iool a Pri...

Page 177: ...39 DifferentiaI Transaxle System 928 a REMOVING AND INSTALLING FINAL DRIVE r I 14x3 I I i IL L3 c i r 2 j if 1 1 18 16 15 14 13 1 1 Q j 39 102 Removing and Installing Final Drive Printed in Germany...

Page 178: ...1 1 Torque 46 Nm 33 ftlb 1 Torque 46 Nm 33ftlb 1 2 Torque 46 Nm 33 ftlb 2 1 1 Replace coat with ATF check for correct fit X Note quantitiy and thick Redetermine lf ness for reinstallation necessary 1...

Page 179: ...smission Qtv Note When Removing Installing If necessary If necessary pull out with press in with suitable puller locally made tool Note quantity Redetermine and thickness for if necessary reinstallati...

Page 180: ...y on drive pinion 3 Engage parking lock and remove collar nut for drive pinion 4 Remove mounting bolts for bearing assembly and pull off bearing assembly if necessary use a suitable puller 4 k i Qf5 I...

Page 181: ...ifferential Transaxle System 929 a 2 Tighten flange nut for drive pinion to speci fied torque and lock by upsetting the flange 9 a 39 106 Removing and InstallIng flnal drive a Printed in Germany XXXI...

Page 182: ...8 Differential Transaxle System 39 e TOOLS a 0 I No Description Special Tool Remarks 1 Pressure pad 9147 2 Pin From P 254 a Printed in Germanv VI I I 1984 Disassembling and Assembling Final Drive 39 1...

Page 183: ...erentiaI Transaxle System 928 DISASSEMBLING AND ASSEMBLING FINAL DRIVE r J y 7 l5 Jr I 4 r 2 d L 4 Y IrC 127 235 I I _ I8 8 20 1 a I t X a a 39 108 Disassembling and Assembling Final Drive Printed in...

Page 184: ...1 Replace 6 Plug 1 Torque 22 Nm 17 ftlb 7 Plug 1 Torque with magnet 22 Nmfl7 ftlb a Shield 1 9 Bolt 2 Torque 46 Nm 33 ftlb IO Joint flange 2 I1 Bolt 12 Torque 23 Nmll7 ftlb 12 Washer 12 13 Holder 1 I4...

Page 185: ...for reinstallation I7 Seal 2 Drive out with a Drive in with suitable screw Special Tool driver 9147 I8 Tapered roller 2 Mark for Install in same bearing outer race reinstallation bearing cap Heat bea...

Page 186: ...drive in a vise with a suitable fixture 1 Install shield s k _ L L f I s fp ff g _ t A rl t I I I 4 A MY _ 6i A Iron angle 2 Drive in seal for joint flange with Special Tool 9147 2 Remove bolt for joi...

Page 187: ...tem 39 __ _ I _ q e i I j I 9 1 i f i 2 2 v No Description Special Tool Remarks 1 Pressure pad P 263 2 Puller Standard tool 3 Pressure pad P 264 b Printed in Germany VI II 1984 Disassembling and Assem...

Page 188: ...erential Transaxle System 928 l DISASSEMBLING AND ASSEMBLING DIFFERENTIAL Y CY j c _ z F c 9 I_ 1 It qp 7 lb11 1 12 13 13 12 9 11 1 I 6 3 2 39 114 Disassembling and Assembling Differential Printed in...

Page 189: ...1 3 Magnet carrier plate 1 4 Lockplate 6 Replace 5 Bolt 12 Threads must be dry and greaseless Torque 150 Nm 108 ftlb 6 Ring gear 1 Tapped holes for ring gear bolts must be dry and greaseless Note pair...

Page 190: ...l case Note When Removing Installing Coat oval surface with MoS paste Replace only in pairs Special Instructions Modified needle bearing mount as from Model 86 The spacer sleeve is no longer required...

Page 191: ...all large differential gears with press fit threaded plates through large opening in differential case and hold with joint flanges Assembling 1 Install ring gear on case and tighten ring gear bolts to...

Page 192: ...gears and turn until bores of position and lock with key gears are aligned with bores in case _ r m e p L f i 1 f ___ d _ c U i I 3 CA b A d 1 z y 3 C I J 1 c 7 Drive on tapered roller bearing inner...

Page 193: ...nsaxle System 39 a TOOLS I yh A 1 r 7 PA f b p 4 2 ah No Description i 1 Puller 2 Depth gauge Special Tool e g Kukko size 2 Standard tool Printed in Germany VIII 1984 Disassembling and Assembling 39 1...

Page 194: ...39 Differential Transaxle System 928 DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY r T i Y p f T x3 l a 39 120 Disassembling and Assembling Bearing Assembly Printed in Germany...

Page 195: ...1 to 4 2 Tapered roller 1 Heat to approx bearing inner race 120 C 250 OF and install 3 Adjusting ring X 4 Tapered roller 1 Heat to approx bearing inner race 120 C 250 oF and install 5 Pinion 1 Press...

Page 196: ...cial tool e g Kukko size 2 fz I F 72 _ Assembling Note Bearing flange is only available as a complete unit with tapered roller bearings and adjusting ring for replacements 1 Heat tapered roller bearin...

Page 197: ...Consequently the thickness of shims has to be determined again after repairing or replacing a bearing assembly Use a depth gauge to measure distance from tapered roller bearing surface to tearing fla...

Page 198: ...4 Dial extension gauge 30 mm 9323 5 Adjusting gauge VW 385130 6 Dial gauge Standard 3 mm range 7 Dial gauge Standard 10 mm range 8 Feeler gauge Standard 0 05 to 1 O mm 9 Clamping sleeve 9145 10 Adjust...

Page 199: ...as had been determined by the special testing machine in manufacturing Absolute cleanliness is essential for all assembly jobs and testing procedures to guarantee perfect results After working on the...

Page 200: ...ng is determined by moving the pinion in an axial direction whereby the ring gear is lifted out of the no play meshing position far enough so that the backlash will be kept with specified tolerances D...

Page 201: ...ue e g DM 75 is recorded instead of deviation r N Since this DM value is equal to adjusting distance E R r the adjusting distance does not have to be figured out for these drive pinions ring gears R D...

Page 202: ...Adjusting distance R r e g 75 05 mm 2 Pair number three digits 001 999 3 Backlash Note The missing 5 mm thick gauge plate VW 385 17 must also be considered for adjustments with these drive pinions rin...

Page 203: ...n face of pinion R design distance 74 70 mm r deviation 0 18mm E adjusting distance 74 88 mm Missing special tool 5 00 mm Adjustment of master 79 88 mm gauge Pinion Ring Gear Marked D M On these drive...

Page 204: ...and secure with two bolts 9 Pull out centering plate of master gauge with the spindle that master gauge can s II just be turned by hand 10 Set Special Tool VW 385 30 to adjusting distance E 5 mm for...

Page 205: ...inion head At this moment dial gauge needle will reach its point of reverse direction at which dial gauge must be read Note The measured value will always deviate from the set distance in clockwise di...

Page 206: ...ate shim thickness Sges Sges gap 0 30 mm bearing preload 2 Install differential with ring gear in case Example 3 Install side transmission cover ring gear end without shims and tighten all hexagon hea...

Page 207: ...etermined on ring gear end and tighten all hexagon bolts to 23 Nm 17 ftlb 4 Turn differential in both directions several times to settle tapered roller bearings 5 Install measuring tools Set Special T...

Page 208: ...shim thickness measured backlash backlash inscribed on ring gear Example Sges measured backlash inscribed backlash by way of example S 0 95 mm 0 88 mm 0 07 mm 0 20 mm 0 27 mm On the basis of experien...

Page 209: ...change shims S and Sz again until specified play is reached 3 Check backlash at four places on periphery turning ring gear by 90 each time Measurements must not deviate from each other by more than 0...

Page 210: ...928 Differential Transaxle System 39 DISASSEMBLING AND ASSEMBLING CENTRAL TUBE 6 7 Printed in Germany VI I I 1984 Disassembling and Assembling 39 137 Central Tube...

Page 211: ...4 Central pipe Nite when Qty Removing Replacing 1 Tighten only after driver plate 5 has been fitted to flywheel Tightening torque 80 Nm 1 1 X 1 1 Torque 20 Nm 1 4 Torque 45 Nm 4 1 1 2 2 1 prijfen ggf...

Page 212: ...d or shaft are damaged There are no replacement parts available 1 Check easy movement of central shaft bearings by turning shaft by hand Shaft must turn easily and without restriction at any point 2 P...

Page 213: ...djusted after replace ment of engine flywheel or central tube This adjustment is not necessary after replacement of transmission or transmission oarts 1 Circlip 2 Bushing 3 Holding flange 4 Drive plat...

Page 214: ...smission on central tube to specified torque Screw in clamping sleeve mounting bolt by hand do not tighten 4 Push drive flange with bushing but without shims on to central shaft and install circlip 5...

Page 215: ...Determine distance X 0 X A B 0 3 mm preload A B Preload x 12 5 mm 5 4 mm 7 1 mm 0 3 mm 7 4 mm Install shim having thickness X in example 7 4 mm a Shims are available in thicknesses of 0 2 mm 0 5 mm a...

Page 216: ...Diffarantiil transaxle system 39 PSD diagnosis Troubleshooting PSD Electronically controlled Porsche limited slip differential PSD diagnosis Troubleshooting Printed in Germany XXXV 1995 D39 201...

Page 217: ...r of controlled limited slip differential __ __ __ _ _ D39 202e Checking locking torque friction coefficient of transverse lock __ D39 203 Checking pilot pressure valve in the lock hydraulics lock ope...

Page 218: ...k hydraulics 4 Pressure pump with pressure warning switch 5 Lock solenoid valve 6 Pressure reservoir 7 Supply tank 8 Wheel speed sensor l The lock hydraulics No 4 to Wb 7 is located on a joint bracket...

Page 219: ...is mounted on a welded on bracket below the let hand seat Lock hydraulics The lock hydraulics is accessible in the let hand rear wheel housing afler removal of the wheel housing cover Voltage supply...

Page 220: ...ooting procedure Read out the DTC memory with system tester 9288 and remedy the fautt if necessary This is described on Page 039 223 ff If only the PSD is switched off ABS OK and no fault is stored in...

Page 221: ...duced and the air is expelled from the reservoir 0 Repeat this procedure several times making sure that the ignition is switched on off at the ap propriate stages in the procedure 2 Bleeding the valve...

Page 222: ...assembly of the cylinder 3 Mount the measuring cylinder on the trans mission and tighten the knurled nut Note If the transmission is installed it is recommen ded to use two studs M8 x 45 with continu...

Page 223: ...928 Differential Transaxle System 39 Checking locking torque friction coefficient of transverse lock Tools r 9 I 183 D3 a PSD Diagnosis I Troubleshooting D39 203 Printed in Germany XXVII 1991...

Page 224: ...s by approx 4 mm 2 PC 950913 951 O l 9509 4 NO138112 000 721 950 93 000 721 951 Ol 000 721 950 94 1 pc commercially availa ble refer to shop ma nual Depending on the type of torque wrench used corre s...

Page 225: ...hes must be used Checking a Procedure I Execution Notes 1 Carry out general preparations according to right hand column Remove rear wheels Fit torque adapter plate Special Tool 951011 with original wh...

Page 226: ...der Connect System Tester 9266 to diag nosis socket Bleed pressure gauge To keep the reservoir level from dropping too far low volume connect a bleeder unit to the reservoir Bleeding pressure approx 1...

Page 227: ...ylinder replacing the bleeder valve Important note Tighten Nos 4 and 6 carefully and use a second wrench to lock when tightening making sure the parts do not bind If this is not observed the fitting N...

Page 228: ...approx 1 5 to 2 0 bar Connect System Tester 9288 along with adapter line 9288 l to diagnosis socket located next to the passenger s seat under the booster cover Clock lock solenoid valve complete wit...

Page 229: ...essure transverse lock Specified value approx 3 0 4 5 ba Execution I Notes Observe testing conditions indicated in opposite column Switch on System Tester Select Check transv lock Fully close transver...

Page 230: ...ue measure at several locations angular positions within one wheel revolution After the actual locking torque has been reached immediately read off the pressure at the pressure gauge Record both actua...

Page 231: ...he tolerance band boundary value window Measurement 4 Minimum locking torque of 500 Nm 369 ftlb must be ensured Equivalent pressure 60 bar or higher Measurement 5 pilot pressure valve Proceed to press...

Page 232: ...on I Notes Open measuring line and transverse lock cylinder carefully observing pilot pressure Remove measuring line and fit bleeder valve Bleed transverse lock using System Tester 9288 with bleeding...

Page 233: ...928 Differential Transaxle Svstem 39 Locking torque to pressure limits Locking torque Nm ftlb Pressure bar l PSD Diagnosis Troubleshooting D39 213 Printed in Germany XXVII 1991...

Page 234: ...ransmission side If pilot pressure is too high squeal noises may result Due to wear and vehicle dynamics constraints zero pilot pressure is also to be avoided When replacing components do not confuse...

Page 235: ...nect ring flange No 3 to measuring line No 2 Proceed by fitting this assembly complete with banjo bolt seals and fitting Nos 4 5 and 6 to the lock cylinder replacing the bleeding valve Connect high pr...

Page 236: ...air bubbles Use collector bottle For this purpose leave bleeding device connected to reservoir and leave bleeding line clamped Bleed ing pressure approx 1 5 2 0 bar Close bleeding valve and press sto...

Page 237: ...sor is out of specifications it has to be replaced Installation The sensor is fastened onto a welded in sup port 2 bolts The correct installation position sensor in horizontal position will be obtaine...

Page 238: ...PSD control unit connector and con nect it to the 55 pin ABS 2 LED adapter lead Note The following tests can be carried out with or without the ABS 2 LED tester being connected The 3 outputs are ident...

Page 239: ...ng point Read off and record sensor voltage value 4 Lower left front side of vehicle Then raise vehicle at the front right end in the same manner by approx 150 mm Read off and record sensor voltage va...

Page 240: ...or fault are stored in the fault memory of the ABS PSD control unit The fault mem ory in PSD system must therefore be read out with System Tester 9288 and erased after the fault has been eliminated Se...

Page 241: ...anguage in question The diagnosis socket is located next to the passenger s seat underneath the booster co ver Positive potential is permanently connec ted to the PSD ABS control unit in order to prev...

Page 242: ...wire from diagnosis 5 Operation of pump motor relay on hydrau lit unit 6 Free 12 Speed sensor output at rear lefl for RDK control unit 13 Free 14 Free 7 Operation of valve relay on hydraulic unit 8 F...

Page 243: ...32 Free 33 Free 34 Signal from lateral acceleration sensor 35 Operation of instrument cluster PSD off 36 Free 37 Ground ABS solenoid valves front let rear axle 36 Free 39 Free 40 Indicator lamp green...

Page 244: ...sensor front left sssssssssssssssssssssss 5 Speed sensor front right sssssssssssssssssssssss 21 22 5 Speed sensor rear right sssssssssssssssssssssss DTC 23 a Speed sensor rear left 24 55 ABS valve fro...

Page 245: ...n sensor short circuit discontinuity Lateral acceleration sensor signal implausible Transverse lock deviation Control unit defective Speed sensor front left Speed sensor front right Speed sensor rear...

Page 246: ...247 Troubleshooting aids When measuring with the multimeter at the control unit plug make up 1 or 2 auxiliary leads in your own workshop each with 2 flat pin plugs No 17 457 2 to avoid damaging the p...

Page 247: ...h the ABS 2 LED tester Test drive after eliminating the fault Clear the DTC memory after eliminating the fault Perform a test drive and then read out the DTC memory again If necessary e g in the case...

Page 248: ...ath plug on transverse lock solenoid valve and localize the discontinuity by reference to the wiring diagram 2 Pull off valve relay No 1 on the hydraulic unit Remove wheel housing cover at the front l...

Page 249: ...ck the protective tube on the transverse lock valve plug in the wheel housing on the rear lefl Switch off the ignition then switch k on again Battery voltage must be present at the black wire If no ba...

Page 250: ...l load position PIN 34 at control unit PIN 2 at sensor 1 Check power supply approx 5 Volt at the sensor plug after de taching it with the ignition switched on PIN 1 and PIN 3 Note The sensor is locate...

Page 251: ...eleration sensor to control unit are incorrect The sensor has a mechanical defect or its installation position is in correct I Check lateral acceleration sensor Pages D39 219 039 222 2 Replace the sen...

Page 252: ...r wheel speed sensor Fault in transverse lock plates Insufficient hydraulic pressure builds up at plates e g because thrust bearing bolt of engaging lever is wrongly adjusted enga ging lever makes con...

Page 253: ...r ground connection may occur not only at the affected compo nents but also at other important grounding points ground contact is present at control unit plug PINS 3 52 and 37 These wires are connecte...

Page 254: ...it with PSD 928 618 __ 911 Carrera 4 control unit 964 618 1 I Pull off the control unit plug Measure the internal resistance I check continuity between PIN 50 and PIN 48 on the plug Nominal value 600...

Page 255: ...at the speed sensor side Depending on the tester select special input or secondary screen Check by turning the lefl front wheel by hand ABS tester in program switch position 6 I rotary switch for whee...

Page 256: ...2 Speed sensor signal If the ASS tester is used turn the wheel selector switch to the rear right wheel General procedure as for DTC 21 test point 6 1 Internal resistance continuity between PIN 44 and...

Page 257: ...de scribed in point 1 by measuring at PIN 19 If a fault is detected interrupt the circuit as described in point 1 in or der to localize the incorrect short circuit to plus or to minus 3 Check resistan...

Page 258: ...fe rential lock is pulled off while the ignition is switched on the valve relay will be de energized It is not re energized when the plug is re conneded until the ignition has been switched off and on...

Page 259: ...out the display of two faults is possible ABS valve and valve relay 1 Switch off the ignition Pull off the control unit plug Check the control circuit wire with relay from PIN 20 to PIN 7 for any disc...

Page 260: ...s conect proceed with 3 If incorrect values are obtained localize the fault as appropriate From PINS 19 22 2 to PIN 17 ABS valves wiring From PIN 21 to PIN 23 Lock valve wiring Re ABS valves wires Pul...

Page 261: ...to ground If necessary interrupt the circuit at the hydraulic unit plug 12 pole and localize the fault by reference to the wiring diagram 4 Check whether voftage is present at terminal 87 of the relay...

Page 262: ...he so lenoid valves Connect all plugs and the relay Push back protective tube on the transverse lock valve plug at the rear leff in the wheel housing Switch the ignition off then switch it on again Ba...

Page 263: ...heck wiring between terminal 65 at the relay base and PIN 5 on the control unit plug and between terminal 66 and PIN 20 If the wiring is in working order Replace the motor relay 2 Pull off the motor r...

Page 264: ...d plus wire 2 contact re sistance Bridge terminals 30 and 87 at the relay base and check whether volt age is present at the connection point 3 If voltage is present but the return pump is not running...

Page 265: ...on the high pressure pump The operating pressure is between 140 and 180 bar The pump is activated via a pressure warning switch The solenoid valve familiar from the ABS system controls the functions...

Page 266: ...is depressurized the follo wing faults are possible Brake fluid reservoir No 12 empty system leaks Voltage supply for high pressure pump No 1 not OK check pump relay No 38 and fuse in the luggage comp...

Page 267: ...re pump No 1 removed do not set down the pump upside down with the pressure reservoir connection facing down If this is not observed the pump might not function after instal lation air in the pump Fas...

Page 268: ...1 2 a 3 4 5 Pressure gauge High pressure measuring line Ring flange Banjo bolt Seal Special tool Order number Explanation 9509 000 721 950 90 9509 i 000 721 950 91 999 215 027 02 930 110 547 00 N 013...

Page 269: ...pressure warning switch of the pump assembly Connect pressure gauge 9509 in combina tion with the high pressure measuring line 9509 l No ring connection No 3 ban jo bolt No 4 and two seal rings No 5...

Page 270: ...ssary 3 Tests Note Operation of the pump is regulated by means of the ignition key for testing purposes Position 0 Pump off Position 2 Pump on until switched off by the pressure warning switch Depress...

Page 271: ...display PSD off lights up Read off the pressure on the pressure gauge Refer to Page D39 255 for nominal values c Checking the switching points of the pressure pump Cut out pressure Turn the ignition k...

Page 272: ...s been achieved not below 140 bar in 30 minutes not below 100 bar in 3 hours Replace pressure reservoir if the gas filling pres sure has reached or fallen below the wear limit If the actual values dev...

Page 273: ...measuring line 950911 No 2 without ring connector to the pump assembly Repeat the test If the nominal values are now achieved replace the lock solenoid valve If the nominal values are not achieved th...

Page 274: ...itch Important First clean the area around the pressure warning switch and cover it with lint free cleaning cloths to trap the small amount of residual brake fluid that emerges 12 i I Installing 1 Scr...

Page 275: ...lowly open the bleeder valve and hold the bleed hose firmly Important A pressure of up to 180 bar is present in the system Wear goggles and protective gloves 5 If necessary connect pressure gauge spec...

Page 276: ...Hazet 2171 2 for this purpose Important Never loosen at the filler screw X as the gas pressure will escape abruptly in this case i Installation 1 Screw in the pressure reservoir No 5 with new O Ring...

Page 277: ...protective gloves Note tr a filling and bleeding untt is not connected always check the level in the fluid reservoir between bleeding processes and top up with brake fluid if necessary 3 Repeat the l...

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Porsche 1986 928, Workshop Manual

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Summary of Contents for 1986 928

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