manualshive.com logo in svg

Porsche 928 -, Workshop Manual

Share
Download
Porsche 928 - Workshop Manual Download Page 1

Summary of Contents for 928 -

Page 1: ...Workshop Manual srs 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 1986 WKD 461 621 Print...

Page 3: ...eakdown of the repair groups 1 Table of tightening torques 2 Special tools required 3 Exploded diagrams 4 Legends for the exploded diagrams 5 Notes on assembly application of special tools 6 Diagnosis...

Page 4: ...VIhan _I Raw Man sea SmaM skew DIY umbllW nd urmllq wmunl lon II1 1 n mv m laa Y 29 t Do A Repair group numbers B Repair groups text C Type of vehicle to repaired D Page number E Operation F Impressum...

Page 5: ...he information is grouped according to repair numbers which are identical to the first two digits of the repair time and warranty code The repair group index an alphabetical index and the register tab...

Page 6: ...III Drive Train IV Chassis Heating Air Conditioning V Bodywork Car Electrics VI Car Electrics Circuit Diagrams VII Car Electrics Circuit Diagrams 88 Models Onward Please file the pages in the volumes...

Page 7: ...n Controls Case Automatic Transmission Gears Valve Body Differential Transaxle System Front Wheel Suspension Rear Wheel Suspension Axle Shaft Wheels Tires Alignment Antiblock System Brakes Mechanical...

Page 8: ...structions for system tester 9288 Engine Crankcase Tolerances and wear limits Technical data Engine torque specifications 0 Removing and installing engine Engine removing and installing Engine Cranksh...

Page 9: ...nd cylinder bores 32 valve engines 13 246 Checking pistons and cylinder bores Type 928 GTS 54 I 13 24e Remachining cylinder bores 13 25 Engine cylinder head valves Volume I Table of contents 928 0 Val...

Page 10: ...32 valve engines Tools Installing cylinder head Modifications to the cylinder head 32 valve Cylinder head installing Tools Disassembling and assembling valve drive Disassembling and assembling valve...

Page 11: ...thermostat Disassembling and assembling visco fan Disassembling and assembling thermOstat housing for cooling system ATF Disassembling and assembling thermostat housing for cooling system Disassemblin...

Page 12: ...ermany on July 5 1910 The new units have to be applied in official and business transactions by the end of the allocated transition period on December 31 1917 some even earlier The new units are deriv...

Page 13: ...e by adding prefixes in front of the unit symbols Prefixes Examples 1 Unit m meter By adding prefix k kilo we have km kilometer 7 1 000 m 2 Unit s second By adding prefix m milli we have ms millisecon...

Page 14: ...z 2 mm cm 9 dnr etc degree minute secondj I No longer acceptable p for 0 001 mm 0 001 mm 1 Num Nu longer acceptable qm qmm qcm etc No longer acceptable cbm cmm can etc Iti Ltr 11 1 dm3 1 tad 1 m m lo...

Page 15: ...ceptable Sec sec hr No longer acceptable No longer acceptable p kp Mp dy atm at ata atu atu InmHg mrr essure or YaC Um mus be specified e g 2 atii e 2 bar pressure 3 bar 0 4 atu so 4 vac m 6 bar 5 ata...

Page 16: ...ar 1 kp cm 1 at 1 bar 750 Torr No Ion kp cm g er acceptable kp mm No longer acceptable P Poise cP kg s m dyn s cd 1 Pa s 10 P s 0 1 kg s m2 No longer acceptable St Stokes cSt E Engler degree 1 cm2 s 1...

Page 17: ...erence 1 C lK Electric cuuent strength A ampere j PA mA etc Electric v volt uV mV etc 1 1 A voltage Electric resistance fL Ohm ma k Q etc lfi 1 V A Electric C Coulomb Ah As lC lAE charge electrical qu...

Page 18: ...ion When driving car on hoist platform make sure that there is sufficient space between h t and car Front On car jack pick up point On rear axle ccntrol arm bracket 0 Printed in Germany Lifting Car 0...

Page 19: ...car jack Use an appropriate piece of wood between jack lifting J 5 T plate and pick up point 4 _S 6 fy XL I On CIOSSmember for rear axle control arm P Note Never raise car on engine oil pan or transm...

Page 20: ...wer output IN 70020 SAE J 245 Engine speed limit by electronic cut off of fuel pumps Engine weight dry Engine Design W Crankcase Crankshaft Connecting rods Pistons 4414 212 91 8 5 1 kW IIP 169 230 kW...

Page 21: ...cal fan with viscous coupling electric fan and thermo switch for air conditioning Engine Lubrication Oil filter Oil pressure at 5000 rpm Oil pressure indication Indicator lamp and pressurr gage Oil co...

Page 22: ...k plugs Spark plug gap Transmission Clutch Double disc diaphragm spting dry clutch Pxssure plate MFZ Z 215 KS ph Body Type Coupe with integral steel body 2 doors rear lid and retractable hadlights Alu...

Page 23: ...ax ro3f load including roof rack Max trailer load without trailer brakes with trailer brakes Max towing weight Max tongue weight kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb...

Page 24: ...1 SE viscosity swnmrr SAE iii winter SAL 20 at continuous temperatures between 15 C and 0 C SAC 20 1 20 or SAE 10 W for continuous temperatures below 15 C multi grade oils 15 ii SO or 20 W 50 when app...

Page 25: ...ngine speed limit Engine weight dry Engine Design YP Crankcase Crankshaft Connecting rods Pistons mm in mm in cm3 in 3 crn3 kW HP kW HP w 17O 231 165 220 5250 5500 Nm kpm 360 3 l Nm ft lbs 348 265 rPm...

Page 26: ...rpm Oil pressure indication Oil consumption Exhaust System Emission control Heating l 1000 km qtj600 mi Closed cooling system Imechan ical fan with viscous coupling electric fan and rhermo witch for c...

Page 27: ...d to a rigid central tube to make up a rigid drive unit trans axle Front mounted engine clutch torsion drive shaft to transmission running in rigid central tube rear mounted transmission and final dri...

Page 28: ...extta equipment front ear total kg lb 745 1643 kg lb 145 1643 kg lb 1520 3351 153i33D5automatics Max curb weight with extra equipment kg lb 1540 3395 Max axle load front rem kg lb kg lb Max total wei...

Page 29: ...s to API classification SE For all year operation multigrade oils of viscosity SAE 15 w 50 I 20 w 50 latter oil not for constant tem peratures below 15 C S F Emergency use of single grade HD oil to AP...

Page 30: ...DIN 70020 SAE J 1349 Speed limit through ignition cut off at Engine weight dry Engine Design Type Crankshaft Connecting rods Pistons mm in mm in cm3 iw3 m3 kW HP 1781242 k HP 1741234 w 5250 Nm kpm 38...

Page 31: ...opens 11 ATDC Intake closes 46 ABDC Exhaust opens 25 86DC Exhaust closes 2 ATDC Automatic hydr adjustment Closed cooling system mechanical fan with visco coupling also electric fan and thermo switch...

Page 32: ...ecting tube to make up a rigid drive unit transaxle Front mounted engine clutch torsional elastic drive shaft to transmission running in connecting tube rear mounted trans mission final drive unit dou...

Page 33: ...ad front rear Max total weight Max roof load Max trailer load without trailer brakes with trailer brakes Max towing weight Max tongue weight mm in mm in mm in mm in mm in mm in mm in mmlin kg 725 kg 7...

Page 34: ...Approx 7 5 level on dipstick is important Approx 16 Hypoid oil SAE 75 W90 to MIL L 2105 B API classification GL 5 I Approx 3 8 I Approx 86 of which 8 liters in reserve I Approx 0 2 I Approx 6 water I...

Page 35: ...d Engine weight dry 0 Engine Design Tvpe Crankcase Crankshaft Connecting rods Pistons Cylinders mm in mm in cm3 in 3 cm3 kW HP kW HP rpm Nmlkpm Nm ft Ibs w kW I HP l kW I HP I rm kg M 28121 Automatic...

Page 36: ...BBDC 25 BBDC Exhaust closes 4 BTDC 2 ATDC Automatic hydraulic adjustment Closed cooling system mechanical fan with viscous coupling a additional series connected electric fan and therm0 switch for ca...

Page 37: ...less l 3 7 2 6 5 4 8 Front mounted engine rear mounted transmission bolted to a rigid central tube to make up a rigid drive unitltransaxle Front mounted engine clutch torsion drive shaft to transmissi...

Page 38: ...oad Without brakes With brakes Max car trailer weight Max drawbar load mm in 44471175 08 44621175 67 mm in 1836172 28 mm in 1282150 47 mm in 2500 98 43 mm in 1549 60 98 mm in 1521 59 88 mm in 12014 72...

Page 39: ...Itr km h mph sec sec sec 56 Quality HD multigrade oils to API classification SE or SF according to plant approval list Emergency use of single grade oils only when multigrade oils are not available an...

Page 40: ...railer Transmission oil capacity with differential manual transmission Reservoir for windscreen and headlamp wash system Ah A W 72 86 models onward 115 1610 85 models onward 85 models onward 795 735 7...

Page 41: ...ada Japan 100 3 94 Displacement rounded down cc 78 9 3 11 4957 302 5 4898 Compression ratio 10 10 1 Max power 80 1269 EC kW HP 2151292 Net power SAE J 1349 kW HP 215 288 at engine speed vm 5750 Max to...

Page 42: ...standing start CLIt BING PERFORMANCE Ist gear 2nd 9ear 3rd gear 4th gear 5th gear km h mph S 14 2 14 9 2 overhead camshafts and hydraulic bucket tappets Toothed belt and internal chain Intake opens 1...

Page 43: ...tria Switzerland lOOl3 94 78 913 11 49571302 5 4898 9 3 1 2121288 5750 400 40 8 2700 42 8 58 1 Bore Stroke a Displacement actual Displacement rounded down Compression ratio Max power 80 1269 EC at eng...

Page 44: ...s 50 degrees after BDC Exhaust opens 30 degrees before BDC Exhaust closes 5 degrees before TDC Fuel octane rating PERFORMANCE RONIMDN 91 82 unleaded Maximum speed Acceleration 0 100 km h 0 100 mph Kil...

Page 45: ...ssion ratio Max power 80 1269 EC Net power SAE J 1349 at engine speed kW HP kW HP w 10 0 1 235 320 235 316 6000 Australia 221 300 2211296 Max torque 80 1269 EC 430 43 9 Net torque SAE J 1349 Nm kpm 42...

Page 46: ...Toothed belt and internal chain Intake opens 11 degrees after TDC Intake closes 36 degrees after BDC Exhaust opens 17 degrees before BDC Exhaust closes 2 degrees before TDC RON MON 95 85 unleaded Aust...

Page 47: ...3 5th gear 15 km h mph Manual trans Australia 270 265 168 165 set 5 9 6 0 set 5 7 5 7 set z5 4 25 4 set 14 2 14 1 to DIN 700 20 kg kg lbs kg lbs kg lbs Manual trans 820 760 770 1580 1590 1920 1900 Aut...

Page 48: ...ower SAE J 1349 at engine speed Max torque 60 l 269 EWG Net Torque SAE J 1349 at engine speed Max specffic output DIN 70020 SAE J 1349 Speed limitation by fuel interruption Idling speed Motor weight d...

Page 49: ...ne speed Max torque 80 l 269 EWG Net Torque SAE J 1349 at engine speed Max liter output DIN 70020 SAE J 1349 Torque limitation via fuel cutoff Idle speed Engine weight dry mm in mm in c c cu in RONIMO...

Page 50: ...ying system errors An amended part number MentMes the control unit capable of diagnosis A special developed diagnostic tester special tool No 9268 is then used to read out the error memory and to test...

Page 51: ...iagnosis mode 1 Continuous error 2 Occasionally occuring error 3 Actuator input signal testing 4 System adaption 5 No error Function display LED off Flashing LED LED on Test sequence terminated igniti...

Page 52: ...in the car Pin 1 Terminal 15 Pin 2 Terminal 31 Pin 5 Terminal 30 Pin 9 Hall generator ignition off After connecting the tester the following dis play must appear If this is not the case check the tes...

Page 53: ...n 7 Pin a Pin 9 Pin 10 Pin 11 Pin 12 Switch on the ignnion Round plug Pin 4 Display I Pin 1 Pin 7 Pin 6 Pin 2 Unused The ignition must not be switched off during the entire error diagnosis procedure U...

Page 54: ...ontrol unit takes place first foflowed by that of the EZK control unk If an error is displayed make a note of the error e g 1211 0 The error is displayed until the green key is pressed again on the te...

Page 55: ...st then appear Display This shows that diagnosis of the DME control unit has been terminated a If one or several errors max 3 in the LH con trd unit and max 5 in the EZK control unit has have been dis...

Page 56: ...erate and it is therefore possible to determine whether they are in proper electrical working order or whether they are defective An error display by the tester is not possible in this mode but tester...

Page 57: ...residual amount of fuel is injected during this testing step The testing steps remain in operation until the green key is pressed again on the tester and the clear symbol appears The next testing step...

Page 58: ...s press the green key until the clear symbol appears initiate the idle contact testing step Display I Press the accelerator pedal slightly After approx 20 mm the LED must go out and the following disp...

Page 59: ...and the follow down ing display will appear Display Switch on the air conditioning system briefly AC pushbutton The LED must go out and the following display will appear 71 Display If this is not the...

Page 60: ...not apply to vehicles with manual gearboxes Press the green key until the clear symbol ap pears After a short period the display 1000 will ap pear i e output terminated Switch off the ignition The fu...

Page 61: ...Press the green key until the clear symbol ap pears After a short period the display 1000 will appear i e output terminated Switch off the ignition The functional check of actuator and input sig nals...

Page 62: ...leeding Resonance flap 1331 1332 1333 1334 1335 Speed signal from EZK to LH control unit Idle contact Full load contact Air conditioning control to the LH control unit terminal 15 Air conditioning con...

Page 63: ...daption and all consumers must be switched off The idle contact must also be Press the yellow key repeatedly until the func tion symbol appears on the function display Display flflz Q l Press the gree...

Page 64: ...mperature While the engine is running press the yellow and green keys simultaneously until the knock detection function svmbol appears on the func tion display Display The engine must be at operating...

Page 65: ...s is displayed in per mil 23 knocks have been counted in this example Knock detection must be carried out until the function display switches over from the clear symbol to the knock detection symbol T...

Page 66: ...icate the error path but not a defective com ponent Possible causes of inadequate supply voltage Battery exhausted Poor contact to the grounding strap Note Poor contact in the control unit The entire...

Page 67: ...valve open R COO Switchover must occur even ff the throttle valve is only slightly open approx 1 Testing the idle contact Ignition off In the event of an error check with reference to the circuit diag...

Page 68: ...hrottle valve open R IOn The switching point must be just before full load in the event of an error check with reference to the circuft diagram Error code 1114 This error code indicates a fault in the...

Page 69: ...the contact lug and the housing as this con tains two temperature sensors independent of one another Error code 1121 This error code indicates a fault in the area of the air flow sensor Fiy The engine...

Page 70: ...inal 30 and terminal 67 into the relay socket It must be possible to measure a voltage be tween terminals 6 and 7 on the disconnected LH control unit plug Display 1 5 V 1 6 V Blow onto the hot wire in...

Page 71: ...k the cable har ness wtth reference to the circuit diagram Error code 1123 This error code indicates that the Lambda con trol has detected that the mixture is too rich Possible causes for too rich a m...

Page 72: ...probe Air infiltration on the intake side Short circuit to ground Short circuit to positive Break in the circuit Air infiltration on the exhaust side before the Lambda probe Injection valve does not o...

Page 73: ...between pin 1 and ground The voltage will be in the range of approx 150 mV 900 mV according to the mixture com oosition Check the cable harness to the LH control unit with reference to the circuit di...

Page 74: ...low sensor 1122 1123 Rotary idle controller Lambda control detects too rich a mixture 1124 Lambda control detects too lean a mixture 1125 Lambda probe Full load contact a The digit 2 may also appear i...

Page 75: ...of the idle contact ponent Possible faults Short circuit to ground Switch stuck Note Testing the idle contact Ignition off The entire error memory must be read out before trouble shooting Disconnect...

Page 76: ...l load contact Possible faults Short circuit to ground Switch stuck Testing the full load contact Ignition off Disconnect the plugs from the EZK control unit and the LH control unit Connect an ohmmete...

Page 77: ...he engine temperature sensor between the contact lug and the housing as this contains two tempera ture sensors independent from one another The engine temperature sensor advances the spark angle when...

Page 78: ...unit and the EZK con trol unit More detailed information is then given by error code 2112 or 2113 Possible faults Break in the circuit Shon circuit to ground If this load signal is not received by th...

Page 79: ...ror code 2132 These error codes indicate a fault in the area of the knock sensors Error code 2131 Knock sensor 1 Error code 2132 Knock sensor 2 Error testing of the knock sensors is an active error te...

Page 80: ...gnal Possible faults Short circuit to ground Break in the circuit Testing the Hall generator signal Disconnect the plug from the EZK control unit a Connect an oscilloscope to terminal 22 and ter minal...

Page 81: ...tards the ignition by approx 6 for all cylinders in the upper partial load or full load areas Error code 2141 This error code indicates a fault in the control unit If this error code appears replace t...

Page 82: ...e full load contact Load signal from the LH control unit Transmission safeguard switch Knock sensor I Knock sensor II Knock control in the control unit Hall generator signal EZK control unit The digit...

Page 83: ...or code has appeared Proceed as follows Press the yellow key repeatedly until the func tion symbol see display appears on the func tion display Display Press the green key until the clear signal ap pe...

Page 84: ...e test drive minimum 6 minutes 3 At the end of the test drive run the engine for at least 60 seconds without opening the throttle valve After the test drive read out the error memory once again 03 40...

Page 85: ...s Systems 928 S4 I928 GT 928 GTS 5 4 I LH Jetronic EZK ABS I lock Airbag Alarm system RDK Ignition on Engine standing still Engine running to n 2500 rpm to n c 2600 rpm no yes yes yes 03 40b Operating...

Page 86: ...928 Self diagnosis 03 Operating Instructions for System Tester 9288 a Operating Instructions for System Tester 9288 Printed in Germany XXI 1989 03 41...

Page 87: ...ionfor input and OUtpUt devices connection 0 vehicle Specific adapter lead Plug in piogramme module isee O Figure2 a C MOS Da not touch plug Function DO matrix 5 x 8 4 lines each with 20 dwracterr For...

Page 88: ...es No After a ShrJti pause fix S temte ter 9288 repons all the sys terns that are instailed in the particular vehicle If a system is pre ceded by e this means that at least 1 error is store in that pa...

Page 89: ...ShingCode Fault code 12 fter tile 1stdisplayed error the allowinginstruCtion appears pii Proceed with key1 piyy Return to diSrJl 3 NO of e ror with key 3 Proceed with key 1 Fault memory 1 Erase 3 DO n...

Page 90: ...input 1sselected b pressing key Repeat until this display appears Input SiQrwk testing completed Return A N Press k N ior return to menu 3 4 system adaptation When fhefuncfion Sysrem adaptation is tri...

Page 91: ...K DCLIME control unit TOthis end opera e the S stemte ter 9288 as described in 3 1 until the following display appears Kl Proceed with key The following menu display appears p I 2 Proceed With key 2 C...

Page 92: ...awrement displays Key 3 1 using key 9 a displays can be Stored manually The fallowing dispiays are stored automatically EC A3e iit 3 8 Showstoredmearurementdisplays Key 6 using the keys c or the store...

Page 93: ...volume Axial play Radial play Diamerer Axial play Inside dia Diameter Runour Cylinder Head and Valves Bearingsurface Valve sear Intake Exhausr Make Exhaust Ourer correcrion angle Inner correction angl...

Page 94: ...on pin Diameter Conrod bushing piston pin Radial play Crankshafr and Engine Block Crankshafr Runour 0 04 0 06 max 0 08 measured on 2nd 3rd or 4th bearings 1st and 5th bearings iunnmg in vees Conrod be...

Page 95: ...928 Engine Crankcase 10 DESIGNATION OF CYLINDERS l Printed in Germany VII 1983 Technical Data lo 02a...

Page 96: ...step 2 steps 1st step 2nd step A Pre loading cylinder head gasket 1st Step 2nd step 3rd step 6 Gasket left in preloaded condition 30 minutes C Final tightening Nuts unscrewed one after the other by l...

Page 97: ...1 C 6398 M 28 16 80 C 8051 M 28 17 80 C 9155 M 28 18 1st step 20 14 6 2nd step 50 36 5 3rd step 90 65 7 torquing by angle of rotation 1st step 2nd step 3rd step 4th Step Only in conjunction with new s...

Page 98: ...sure relief valve plug Bypass valve adapter Water drain plug in engine block 90 9 01 M 10x 1 25 295 29 5 M18x1 5 60 6 0 M22x1 5 50 5 0 MZOx1 5 80 8 0 M48x1 5 35 3 5 M 18x 1 5 40 4 0 M 18x 1 5 70 7 0 M...

Page 99: ...valve Oxygen sensor air line Exhaust gas test nut on catalytic converter Exhaust gas test plug on catalytic converter Temperature sensor II to thermostat housing Temperature valve to connector CO tes...

Page 100: ...lt union Cylinder head cover Spark plugs Flywheel bolts M 12 x 1 5 M 10 M8 M 10 x 1 25 M 10 x 1 25 M6 M8 M6 M8X1 MlOxl M 10 x 1 5 M6 M 14 x 1 25 M 10 x 1 25 Tightening torque Nm ftlb 1st stage 30 22 2...

Page 101: ...housing for coolant circuit to engine Temp sender unit coolant temperature Check valve Air line Oxygen sensor Exhaust gas takeoff plug to catalytic converter Temp sensor NTC II to regulator housing 1...

Page 102: ...8 49 50 Intake rail mounting Hall sender mounting CO branch line mounting to exhaust manifold All other nuts and bolts Ii M 10 Thread M8 M8 M8 M6 Tightening torque Nm Mb 20 15 without washer 20 15 ori...

Page 103: ...Engine Crankcase 10 TOOLS NO 1 r 1300 q Description Adapter for removal and installation of engine 9137 Y Usedin conjunction with shop hoist Printed m Germany Removing and Installing Engine 10 1...

Page 104: ...led 5 Detach windshield washer hosesand engine compartment light wires 6 Disconnect engine hood supports at top loosen engine hood bolts and remove engine hood 7 Remove cap from coolant expansion tank...

Page 105: ...I J L J L s s _ _ ii 12 Drain engine oil 1 7 Remove lower body brace rip r f A C e r r 1 I c k 1 _ _ q 1 c 4 3 P e 1 14 Detach exhaust pipes at Exhaust manifolds and beat shields on left and right sid...

Page 106: ...pressing release lever down in direction of clutch 22 Open clamps for starter wires on steering cross member tsF QWRff h J y _ cy L i i 1 c us I P It _ 1 C e h rF 4 A 23 INemovesocket head halts and...

Page 107: ...ator Disconnect plug leading to compressor on right drive belt cover I I i i 1 28 l oosen c lpress r IemOYCfrom console and suspend it with the hosesconnected pf ffy wi f dq i Y rI 1 I 3 i a i 1 i _ 1...

Page 108: ...and re fi moving the engine muunts I i j Place engine on front cross member carefully Remove second mount accordingly 1 _ 7 _y m I w I fi it 1 J 7 f T A 3 k 1 3 32 Detach all coolant hosesat radiator...

Page 109: ...Open hose clamp and remove hose between heater valve and neck y y I j 42 Disconnect n wire plug of transmitter wire to distributor and plug for engine wire harness 43 Rcrnovc controi unit 44 Detach i...

Page 110: ...ting cable for accelerator pedal and cruise control remove holder and clamp and place cables outside 50 Be sure to cover condenser on cars with ail conditioning to prevent damage when re moving and in...

Page 111: ...Installing Note the following for installation 1 Tighten nuts and bolts to specified torques 2 Add coolant until level is at edge of filler opening position heater lever at warm 3 Run engine to operat...

Page 112: ..._rl c I 1 7 i ii 0 7 J 3 i l No Designation Engine lifting tackle Please note Special Tool Remarks 3033 VW Special tool If necessary use a commercially available carabiner 650 kg load bearing capacit...

Page 113: ...ct hoses for wind screen washer heated spray nozzles and cable for engine compartment light 6 lJnhook accelerator spring retain ing clamp at bottom unscrew hood mounts and lift off hood 7 Remove air i...

Page 114: ...t and right of crank case upper half 12 Drain engine oil Only if engine is to be overhauled 13 Disconnect exhaust flanges on left and right of exhaust manifold and unscrew air in jector 14 Disconnect...

Page 115: ...tch housing Unscrew bolts holding driving plate unscrew pan head screw of bearing sleeve push driven plate back along central shaft 22 The pins for the oil temperature sensor must point downward befor...

Page 116: ...ipe stub on en gine and remove Pull under pressure line for automatic transmission from underpressure distributor 26 Unscrew bolts for clutch housing engine housing top and bottom e g jointed socket w...

Page 117: ...h at bottom left of cooler 29 Detach oil hoses for engine cooling and ATF cooling from top and bottom of cooler countering with second open ended wrench r 31 Disconnect bleed hose from top left of coo...

Page 118: ...leed hose from cooling water expansion tank at engine and remove 34 Disconnect fuel supply line countering with second open ended wrench 36 Detach filter housing from air pump 37 Remove scavenging val...

Page 119: ...h in suitable container Dis connect hose clamp from reservoir and remove reservoir 41 Remove cover of central electrics unit Disconnect plug type connectors for Lambda probe probe heating and electron...

Page 120: ...lock improvised between central pipe and cross member 47 Tilt engine carefully toward front lifting slightly Once engine housing and clutch housing separate engine can be hoisted out of vehicle Note C...

Page 121: ...L 10 20 Engine Removing and Installing 0 Printed in Germany Installation Note the following l Push transmission to rear Place wooden block improvised 25 mm thick between drive shaft casing and cross m...

Page 122: ...el using the six bolts and only tighten the pan head screw of the clamp ing sleeve afterwards Tightening torque 80 Nm 5 Top up coolant level to lip Set heater lever to warm 6 Run the engine until it r...

Page 123: ...928 Engine Crankshaft Pistons 13 TOOLS NO Description Special Tool Remarks 1 Engine holder 9121 2 Engine support 9128 Printed in Germany TOOIS 13 1...

Page 124: ...istons 928 USING ENGINE SUPPORT SPECIAL TOOL 9128 We recommend using the engine support as from the state cylinder heads installed when assembling the engine a 13 2 Using Engine Support Special Tool 9...

Page 125: ...gage Standard 4 Dial holder gage VW 387 5 Dial gage Standard 6 Holder for loosening oil pump 9157 drive gear 7 Puller spindle us 1039 8 Internal extractor Standard e g Kukko No 2112 14 5 to 18 5mm 9...

Page 126: ...928 a DISASSEMBLING AND ASSEMBLING CRANKCASE AND CRANKSHAFT 1 dr L L i q z r _e I Ii L G 11 A 1 11 I 71 1 c g y _ z C 7 xL l A 1 hi j a L a a 13 4 Disassembling and Assembling Crankcase and Crankshaft...

Page 127: ...ng surface section to remove grease 10 Main bearing shell 4 Lubricate half 11 Thrust bearing half bearing 3 1 Lubricate 12 Shaft seal flywheel end 1 ReplaCE 13 Shaft seal 1 Replace pulley end 14 Crank...

Page 128: ...1 Lubricate shell half bearing 31 18Crankcase upper 1 Clean sealing surface section to remcNe grease 19 Kev 2 Install facing forward 20 Dowel pin 4 21 Dowel pin 2 22 Dowel pin 2 23 Dowel sleeve 2 24...

Page 129: ...emove grease from the surface so that after the cleaning solution has dried the new coaf of sealant can be applied The new Loctite will dissolve the old sealant in the surface finish and dry again aft...

Page 130: ...e oil from bearing shell and bearing journal Use Special Tool VW 381 to check end play Play of new bearings 0 110 to 0 312 mm Wear limit 0 40 mm 3 Place Plastigage having width of bearing on crankshaf...

Page 131: ...Pistons 13 INSTALLING CRANKSHAFT SEAL FLYWHEEL END mb Fw z 1 fl Align seal with Special Tool 9126 INSTALLING CRANKSHAFT SEAL PULLEY END Align seal with Special Tool 9125 Printed in Germany Installing...

Page 132: ...instruc tions Tighten to sequence 2 Install crankcase lower section 3 Install mounting nuts by hand 4 Install oil pump body lightening first both upper bolts to specified torque Note This is how cran...

Page 133: ...to four digits and the X embossed ahead of the number was there fore deleted Tlghtenlng sequence tlghtenlng torque lQ Number l lO in 3 steps M 12 x 1 5 thread 1st step 30 Nm 22 Alb 2nd step 55 Nm 41 f...

Page 134: ...be kept as small as possible Wear limit for flywheel thickness 11 8 mm 27 r3 1 Wear limit 11 8 mm 2 Smallest possible metal removal 3 Max runout 0 05 mm Bearing surface machining specifications Surfac...

Page 135: ...h mark Tighten multi tooth bolts in two stages 1st stage 2nd stage 40 Nm 30 ftlb 90 Nm 66 ftlb Removing and installing grooved ball bearing Removing Pull out grooved ball bearing with an internal extr...

Page 136: ...13 Engine Crankshaft Pistons 928 a a a 13 12 Disassembling and Assembling Pistons and Connecting Rods Prinred in Germany...

Page 137: ...g Replace tighten to specified torque Lubricate threads and bearing surface Always replace worn bearing shells Check for distortion and parallel devia tion Make sure that narrow side with small chamfe...

Page 138: ...ring Groove 3 Crankcase upper section Note When Removing Installing 8 Install oil ring springs first then oil rings Check to ensure that ends of springs butt against each other 16 1 Check cylinder bo...

Page 139: ...urfaces of valve pockets face down Installing Piston with Connecting Rod 1 Install both upperopiston rings that their gaps are offset by 120 2 Install three piece oil scraper ring as follows Spring of...

Page 140: ...Different tolerance groups could be used in one engine Checking Connecting Rod Radial Play 1 Remove connecting rod cap clean bearing shell and connecting rod bearing journal t remove oil Place Plastig...

Page 141: ...power steering pump bolts swing pump in and remove belt 3 Loosen auxiliary air pump bolt swing pump in and remove belt 4 Loosen alternator bolt swing alternator in if necessary detach alternator vent...

Page 142: ...ll belts is checked by applying thumb pressure to belt at point midway between two pulleys Belts must give by approx 10 mm 1 Crankshaft 2 Fan 3 Auxiliary air pump 4 Air conditioner compressor 5 Power...

Page 143: ...928 Engine Crankshaft Pistons 13 TOOLS T i i c4 6 Y p QY k t 44 f r No Designation Special Tool Remarks Tester for belt tension 9201 Printed in Germany XVI 1987 Tools 13 18 a...

Page 144: ...age and read value from dial Settings New belt Used belt 9 2 8 4 0 8 If necessary adjust belt tension l Contact must be established between the entire surface of the sliding shoe and the belt While th...

Page 145: ...cessary unscrew cowl and take off polyrib drive belt 3 Unscrew lock nut and bolts on power pump push in pump and take off drive belt 32 VALVE ENGINE 4 Unscrew adjusting nut and bolt on air pump swing...

Page 146: ...i r 4 T j c 7 __T s 2 3 Description Flywheel stop Flywheel stop beginning with 1983 models Special Tool 9161 9161 l Remarks In conjunction with new cover on clutch housing starter mounted on clutch ho...

Page 147: ...stons 928 STOPPING FLYWHEEL FOR ASSEMBLY JOBS 1 Unscrew clutch slave cylinder and remove with line connected 2 Guide in special tool and mount with standard bolts 13 20 Stopping Flywheel for Assembly...

Page 148: ...ranknhafr Connecring rod Journal Dia d 2 Thrust Bearing Width Standard 2 g 69 Y71 69 990 51 971 51 990 max 30 08 0 25 F 69 121 69 140 51 721 41 740 0 50 z z ouN 5 69 411 69 490 51 471 51 490 0 75 226...

Page 149: ...13 Engine Crankshaft Pistons c L z G S rF k rn L zn 0 c z v1 E 9 0 0 3 3 emL L n 0 55 0 0 u zc S N 928 13 22 Crankshaft Journal Sizes xx 1988 Printed in Germany a...

Page 150: ...ng the pistons Measure approx 62 mm from piston crown 90 deg offset to piston pin axis Checking the cylinder bores Measure approx 62 mm from upper edge of cylinder bore in transverse direction of cyli...

Page 151: ...ne Type M 28 19 20 USA Repair size Piston dia Cylinder bore Kolbenschmidt mm Tolerance group identification Standard 96 975 97 000 0 96 985 0 007 97 010 0 005 1 96 995 97 020 2 1st oversize 97 475 97...

Page 152: ...28 19 M 28 20 Piston Weight Tolerances Since 1980 models pistons and piston pins are paired according to weight Pistons are weighed with components piston pins piston rings cir clipsl If pistons and p...

Page 153: ...M 28 21 22 Sweden Switzer land and Australia compression ratio 9 3 1 Nominal diameter 97 0 mm 32 VALVE ENGINES Engine M 28 43 44 Japan Compression Nominal diameter USA Canada and ratio 10 0 1 100 0 m...

Page 154: ...for pistons as of engine numbers M 28 43 as of 81 G 00594 00622 M 28 44 as of 81 G 06311 06378 The valve cutouts for the valves are of equal size on both sides The installation position is indicated...

Page 155: ...41 42 47 Repair size Piston dia mm Kolbenschmidt Cylinder bore mm Tolerance group identification Standard 99 980 100 000 0 99 990 k 0 007 100 010 0 005 1 100 000 100 020 2 1st oversize 100 480 100 500...

Page 156: ...approx 50 mm from piston crown 90 deg offset to piston pin axis Checking the cylinder bores Measure approx 50 mm from upper edge of cylinder bore in transverse direction of cylinder block Prior to mea...

Page 157: ...the SUMMENCK 10 CV 616 cylinder borer so that oversize pistons can be installed Individual cylinder bores can be remachined as required as the oversize pistons are of the same weight as the standard...

Page 158: ...inding head Grinding oil Felt inlay Silicone compound Storage box for felt inlays Set of stone holders for felt inlays instead of grindstones Set of stone holders for grindstones for 3 different types...

Page 159: ...icles from previous honing with filtered hon ing oil 3 Wipe the cylinder bores dry and apply a thin coating of thoroughly mixed silicone compound Note If the silicone compound is too thick honing oil...

Page 160: ...uge shows approx 20 30 Set the advance wheel scale to 20 The machine will switch off automatically after approx 80 seconds The cylinder surface is now matt and dull Before starting on the next cylinde...

Page 161: ...heel setting Surface roughness A lst roughing to A 100 40 mm CK 3000 or CK 2600 70 mm 160 mm 125 CK CV 49 CK 57 CV 5 21 mm C 30 J 55 30 40 0 07 mm 10 strokes Approx 7 8my a B finishinS B 100 48 mm dto...

Page 162: ...0 5 nnn of the remachined cylin der bores must be champfered to 3o 1 I I I Y 0 I t I Before reassembly thoroughly clean both halves of the crankcase so as to remove all trace of abrasive par ticles a...

Page 163: ...Wrench socket 9133 2 Spark plug wrench Standard e g Hazet 767 1 3 Valve spring compressor us 1020 or P 200 a 4 Valve grinder Standard 5 Thrust plate for installation 10 101 of valve shaft real 6 Valv...

Page 164: ...15 Engine Cylinder Head Valves 928 G a iT D d I z I Y N a a 15 2 Disassembling and Assembling Valve Train PIinred in Germany...

Page 165: ...rive 4 Woodruff key 2 5 Camshaft oil seal 2 Replace drive in to stop 6 spacer 6a spacer 1 1 Install on camshaft right side 7 O ring 2 Replace lubricate slightly 6 Distributor drive gear 1 9 spacer 1 1...

Page 166: ...tion correctly do not cover oil feed bore 26 Hydraulic valve lifter 16 Position SOthat Check oil bore faces P 21 Lifter sleeve 16 Do not mix up lifters and sleeves 28 Gasket 8 kPl8X 29 Left camshaft 1...

Page 167: ...Seal 48 Dowel pin Qty 20 Removing Note When Installing 2 1 Replace position COWCtly 32 Position correctly 16 16 16 Position correctly Springs with red dot face down and springs with green dot face up...

Page 168: ...linder Head Valves 928 DISASSEMBLING AND ASSEMBLING VALVE DRIVE Camshaft Housing for Cylinder Bank l 4 Beginning with 1979 Models 1 cI L I 1 8 9 a 15 6 Disassembling and Assembling Valve Drive Printed...

Page 169: ...I2 Washer A 6 4 13 Camshaft bearing Qb 6 6 15 1 a 1 1 1 1 Note When Removing Installing Torque 40 Nm 29 ftlb Torque 20 Nm 14 ftlbl Do not mix up store so that oil bores face up Always replace TOP face...

Page 170: ...oat of oil install together with spacer and drive in flush I5 spacer 1 I6 O ring 1 Reolace 23 x 2 r 1 1 1 1 1 1 i I7 SeaI 1 I8 O ring 1 Replace I9 Camshaft 1 Lubricate bearing surfaces with oil check...

Page 171: ...inder Head Valves 15 DISASSEMBLING AND ASSEMBLING VALVE DRIVE Camshaft Housing Cylinder Bank 5 8 Beginning with 1979 Model 2 P d 25 24 23 25 Printed in Germany VII 1963 Disassembling and Assembling Va...

Page 172: ...up lifter store that oil bore faces up 6 Gasket for 1 Always replace camshaft housing TOP faces up when installed 7 Bolt 1 Torque M 10 x 95 65 Nm hold on washer with hexagon 8 Washer with 1 Position...

Page 173: ...t 1 Lubricate bearing surfaces with oil check mark on rear camshaft bearing 23 Bolt 3 M6x22 Note When Special uo Description Qty Removing Installing Instructions I4 Shaft seal 1 Replace give sealing l...

Page 174: ...PLAY OF CAMSHAFT Check axial play in conjunction with dial gauge holder VW 367 New Part Play Wear Limit 0 09 0 12 mm 0 20 mm If necessary replace flange bearing and or camshaft bearing cover a 15 6f C...

Page 175: ...3114 15 16 928 105 155 07 928 105 173 01 928 S R o W 1980 1981 1982 1983 models M 28 11 12 928 105 187 03 928 S USA Japan Canada 1980 1981 1982 1983 models M 28 1 g 20 928s R O w 1984 models M 28 2112...

Page 176: ...opens 38 BBDC Exhaust closes 2 BTDC Intake opens 12 ATDC Intake closes 48 ABDC Exhaust opens 32 BBDC Exhaust closes 6 BTDC Intake opens 9 ATDC Intake closes 52 ABDC Exhaust opens 37 BBDC Exhaust clos...

Page 177: ...Note Never use any lubricant for the installation of cylinder head nuts and washers Only the threads of the studs must be given a light coat of engine oil Washer must not turn when tightening cylinder...

Page 178: ...seal 2 Valve stern seal 924 as intermediate pan 3 Original valve stem seal rin 4 l h N 3 2 1 15 8 Disassembling and Assembling Valve Train Printed in Germany Shorten plastic sleeve from Type 924 by ap...

Page 179: ...emove deposits with a cleaning reamer 2 Place new valve in valve guide and check that valve stem end is flush with cylinder head camshaft housing mating face Valve seats may be machined down to the we...

Page 180: ...necessary correct by adding or removing shims Shims are available in thicknesses of 0 5 and 1 0 mm 928 Models 197811979 Intake valve 39 6 0 5 mm Exhaust valve 36 6 0 5 mm 928 Models 1980 Intake valve...

Page 181: ...cessary to have large valve spring bearing surfaces on the cylinder heads Qr Q I O d c L i p f z fl New V m Old Version New Version The new cylinder heads can be installed in pairs on older engines or...

Page 182: ...prings 1 or 2 White Stripes Intake valve 41 0 0 5 mm Exhaust valve 40 0 0 5 mm New installed lengths are not given on Special Tool 9138 l Valve Spring Adjuster so that when reaching 41 5 or 40 5 mm on...

Page 183: ...928 Engine Cylinder Head Valves 15 REMOVING AND INSTALLING CAMSHAFT DRIVE BELT AND WATER PUMP Printed in Germany VII 1983 Removing and Installing Camshaft Drive 15 9 Belt and Water Pump...

Page 184: ...ad Valves 928 REMOVING AND INSTALLING CAMSHAFT DRIVE BELT AND WATER PUMP g z g yy I 13 T 3 25 26 p j 47 I 29 22 SIB 5 L 4 114 a 1 e Ai lo 15 10 Removing and Installing Camshaft Drive Belt and Water Pu...

Page 185: ...asher 1 9 Pulley 1 10 Pulley 1 11 Vibration damper 1 12 Collar washer 1 13 Adjusting screw 1 14 BoltMEx62 1 14a BoltM8x45 1 Install with Loctite 574 14b Bolt M 8 x 55 2 15 Washer 4 16 Tensioning rolle...

Page 186: ...ing roller 1 Check for easy mo ement turning by hand Tensioning roller mw turn sily and without restriction at any point 27 Circlip 20 x 1 75 1 Position correctly 28 Tensioning roller carrier 1 29 Cam...

Page 187: ...pecial NO Description Qty Removing Installing Instructions 40 Bolt 1 M6x12 41 Washer 1 42 Camshaft drive belt 1 cover 43 Bolt 2 44 Washer 2 45 Pump brace 1 46 Bolt 2 M6x12 47 Washer 2 48 Camshaft driv...

Page 188: ...shaft sprockets are aligned with marks cast on the camshaft bearing caps Install camshaft drive belt always pre loaded by hand in the following order First on sprocket 11 oil pumpsprocket 2 then over...

Page 189: ...wise two turns to align red indicator and TDC mark Note 7 Now tighten camshaft drive belt again Never turn engine anticlockwise since this could 8 Turn engine clockwise two turns to align red destroy...

Page 190: ...o High Torque Drive HTDI Old Tooth Shape HTD Tooth Shape Old Camshaft Sprocket HTD Camshaft Sprocket I 1 i l A i 3 L 1 1 1 I I 1 It1 1 a N o t e New HTD drive belts can also be used on older engines i...

Page 191: ...TT scF 4L T VP yy a ew o L d 4 I2 s jp m 11 ys j Printed in Germany VI 1982 Checking and Adjusting Drive Belt 15 17 3 Turn engine two more turns until TDC mark is reached again and check drive belt f...

Page 192: ...front right hand side Loosen locknut of adjusting screw and turn adjusting screw until drive belt tightness is correct Tighten locknut Turn engine two turns and recheck tightness of drive belt Screw t...

Page 193: ...928 Engine Cylinder Head Valves 15 l TOOLS c j jq I j i k w i x d NO Description Special Tool Remarks 1 Belt tightness tester 9201 Printed in Germany VI 1982 TOOIS 15 18a...

Page 194: ...3 Unscrew drive belt guard upper section on both sides and remove 4 Turn engine in direction of rotation to TDC cylinder 1 In this position marks on camshaft sprockets should conform with marks on fl...

Page 195: ...with their complete surface The special tool must not be turned or moved on the belt while checking 9 Pull out lockpin to have the gauge button disengage again Important This test requires the engine...

Page 196: ...ss is correct Tighten nut again Turn engine two more turns and recheck drive belt tightness Tightening screw tightening belt Loosening Screw loosening belt Note Never turn engine anticlockwise since d...

Page 197: ...tolerance applicable to new pans use a 1 4 mm thick cylinder head gasket available from the parts service when fitting the cylinder head New part size A 24 0 1 mm Wear limit A 23 6 mm Note When machi...

Page 198: ...15 Engine Cylinder Head Valves 928 a c b f 7 i a P T Q 1 6 Z a a 15 20 Disassembling and Assembling Tenslonang Roller Housing Printed in Germanv...

Page 199: ...se clamp 1 6 Bellow 1 Check replacing if necessary 7 Circlip 1 Position correcrly 8 Piston 1 Y Bimetal plate 40 8 plate sets of 5 each coated alternately 7 plare sets of 5 each 35 Watch arrangement se...

Page 200: ...Tensioning Roller Housing 1 Fill one third of housing with SAE 90 trans mission ail 2 Hold housing at an angle and slide in entire piston with bimeral plate sets and support disc 3 Push piston in hous...

Page 201: ...elt as specified 2 Remove oil filler plug 1 and bleeder screw 2 a 1 3 Pour oil from oil can into oil filler opening a slowly until oil runr out of bleeder screw bore 4 Screw in and tighten oil filler...

Page 202: ...15 Engine Cylinder Head Valve Drive 928 DISASSEMBLING AND ASSEMBLING TENSIONING ROLLER HOUSING Beginning with 1983 Models 4 17 16 1 L i n i c _ 6 5 L I j...

Page 203: ...13 5 16 Bleeder screw M6xlO 17 Seal A 6 5 x 9 5 QiV 1 1 1 1 1 1 1 1 35 1 1 1 1 1 1 1 1 Note When Removing Installing Lubricate guide sleeve with oil Replace Lock nut after adjusting while holding adju...

Page 204: ...alves 15 REPLACING VALVE GUIDES TOOLS NO 1 2 1 3 4 5 Description Special Tool Pressing out base 9220 Countersink 9220 l Pressure pad 9221 Driver 9224 Reamer 3015 Remarks Printed in Germany VI I I 1984...

Page 205: ...the camshaft side with a countersink Special Tool 9220 l until guides are flush with the cylinder head Note Be careful not to damage guide collar for spring retainers 4 Loosen valve guides from camsh...

Page 206: ...01 mm Outside diameter of service valve guide ground accordingly to 13 07 13 09 mm 7 Coat valve guides with tallow insert with a light knock align and press into cylinder head against stop from camsha...

Page 207: ...l not be sufficient 9 If absolutely necessary valve guides can be reamed out with Special Tool 3015 Procedures Always ream out valve guides with petroleum as a lubricant Back out reamer frequently to...

Page 208: ...noses at the air bleed ports for the intake hoses with the crankshaft at the ignition TDC for cylinder no 1 these noses must be aligned with the recesses in the camshaft sprockets Note Maintenance too...

Page 209: ...928 Engine Cylinder Head Valves 15 TOOLS 32 VALVE ENGINE a Description Belt tightness tester Special Tool Remarks 9201 Printed in Germany x 1984 Tools 15 101...

Page 210: ...__i p f L i 0 I 7 n ll 1 i k y qy YT F c I 15 y _ v I 3 Unscrew and take off distributor caps and toothed belt cover upper section on righthand side 4 Unscrew and push toothed belt cover upper sectio...

Page 211: ...y c j r r 8 Slide special tool on released belt section of toothed belt sliding shoe on smooth surface roller must fit in tooth gad 9 Pressdown tester on housing arrow 1 slowly until gauge tip resting...

Page 212: ...value 5 0 0 3 Correct belt tightness if necessary Adjusting The toothed belt adjusting screw is located on bottom of engine at front righthand side Loosen lock nut of adjusting screw and turn adjustin...

Page 213: ...mission Remove retainers and clamp on console and place cables outside 5 Loosen and remove fan console on engine 6 Pull off left and right ignition leads on distributor cap Unscrew and place distribut...

Page 214: ...bration damper with red needle by turning crankshaft clockwise Note Camshafts may be turned without damaging the valves after aligning the 45 mark 12 Mount Special Tool 9161 1 with original screws to...

Page 215: ...elt is the reverse of the above sequence 2 Turn camshafts to mark and hold firmly in this position 3 Then turn engine in direction of rotation to ignition TDC cyl no 1 Note Damage may be caused to the...

Page 216: ...2 VALVE ENGINES i w i 2 A d y Is No Designation 1 Puller for valve stem seals Press in too 1 sterh seals for valve Valve spring device installation 3 Special Tool Remarks 9237 9225 l 9242 or US 1020 u...

Page 217: ...15 Engine Cylinder Head Valve Drive DISASSEMBLING AND ASSEMBLING CYLINDER HEAD 32 VALVE ENGINES 5 6 7 10 a 15 110 Disassembling and Assembling Cylinder Head Printed in Germany...

Page 218: ...that seating is correct 3 Spring plate 16 4 Valve spring 16 set 5 Valve spring retainer 16 6 Washer X Note number Redetermine if necessary 7 Valve stem 16 seal Always renew press in with press in too...

Page 219: ...iption pecial Tool Remarks Assembly bridge Lever Magnetic disassembly head Assembly head Base Bolts 15 Supplier Sauer Hamburg II II I II II II Improvised tool Commercially available M8x40 12 Tools Cyl...

Page 220: ...r to pry taper valve keepers from valve stem 4 Use the magnetic disassembly head to withdraw all the valve spring parts 5 Attach assembly head to lever Press clamping arms together and insert taper va...

Page 221: ...l i _ C v il h 7 k 14 4 REMOVING AND INSTALLING VALVE STEM SEAL 85 86 MODELS ONWARD ENGINE TYPE M 28 43 44 45 46 Pull off valve stem seal with Special Tool 9237 o s 1 Oil valve stem and install valve...

Page 222: ...m Seal 15 112 c 87 Models Onward l Oil valve stem and install valve Place 1 mm thick washer on the cylinder head mating face Push assembly sleeve over valve stem Oil sealing lip of valve stem seal and...

Page 223: ...to measure the rocker clearance 3 Attach dial gage holder VW 387 to cylinder head Align dial gage parallel to valve head i 4 Measure rocker play at 10 mm valve lift distance between valve head and val...

Page 224: ...a REPLACING VALVE GUIDES TOOLS No Description 2 3 4 Press out base Thrust piece Thrust piece Reamer Special Tool 3120 VW Special Tool Remarks See drawing Printed in Germany XIX 1987 Cylinder Head Too...

Page 225: ...ess out device for valve guides I 1 8 t t e 1 r t e c t i L I L 4 I I _ _ BB a GB __ 69 Material wood 50 l rir 73 301 Materfal St 37 26 JI 1 13 g 6 TX x5 0 04 b 2 p R2 3 15 112 f Cylinder Head Tools R...

Page 226: ...alves 15 a DRAWING Thrust piece for pressing out valve guide Thrust piece for pressing in valve guide r 8 L 3 I I lo Y v 1 b 46 8 O I Material 1 a Printed in Germany XIX 1987 Cylinder Head Tools 15 11...

Page 227: ...correct size Loading must be 0 06 0 08 mm for both intake and exhaust valve guides Example Bore in cylinder head measured 11 020 mm Machine outside diameter of KD valve guide to 11 080 or 11 10 mm Rep...

Page 228: ...ce bore has been reamed finish with dry reamer 8 The valve seat rinos must be remachined when the valve guides have been replaced It is not sufficient to grind in the valves with grinding paste Note D...

Page 229: ...s obtained Max wear limit 146 6 mm Note for machining of the sealing surface Max roughness 0 015 mm If machining causes the actual value to be below the tolerance applicable to new parts use a 1 4 mm...

Page 230: ...nce bore has been reamed finish with dry reamer 8 The valve seat rings must be remachined when the valve guides have been replaced It is not sufficient to grind in the valves with grinding paste Note...

Page 231: ...st be ma chined by the same amount to ensure correct seating of the regulator housing Machine sealing surface of the cylinder head only until a straight surface is obtained Max wear limit 146 6 mm Not...

Page 232: ...e for the removed material when facing the cylinder heads The CS cylinder head seals can be req nized by means of the changed part numbers These cylinder head seals can also be in stalled in 4 valve e...

Page 233: ...28 43 44 45 46 M 28 41 42 Bearing bridge attachment M 6 M8 0 Exhaust manifold attachment bolt flange 3 bolt flange l The valve seats of the 4 valve per cylinder heads can be machined Do not machine p...

Page 234: ...ample a Neway valve grinder or a Hunger valve seat machining tool 2 Machine the valve seats with a 45 valve reseating tool Afterwards machine the face to the specified face width with a 60 reseating t...

Page 235: ...t surface VALVE DIMENSIONS VALVE DIMENSIONS 928 S 85 86 MODELS ONWARD ENGINE TYPE M 28 43 44 45 46 Dim Intake Exhaust a 35 mm 32 mm b 6 97 mm 6 94 mm C 112 2 mm 111 2 mm a 45O 45O VALVE DIMENSIONS 928...

Page 236: ...ODELSONWARD ENGINE TYPE M28 41 42 Note Do not use Special Tool 9240 or 9240 l to measure the installation length of valve springs as of model year 87 Checking and adjusting length of valve springs see...

Page 237: ...If the valve stem Free length protrudes beyond the upper edge of the special tool install Outer spring shims to take up the excess Wire dia 0 5 nnn thick shims are available Outer spring Inner spring...

Page 238: ...ing to approx 50 mm 3 Install valve and press against valve seat Install plate valve spring retainer secondary spring and spring plate with ground surface 4 Install conical valve keepers with Special...

Page 239: ...lation length Intake 35 5 0 5 mm Exhaust 34 5 0 5 mm 6 Add or remove shims to correct installation length 7 Do not mix up valves after measuring a Printed in Germany XIII 1986 Checking and Adjusting I...

Page 240: ...NSTALLING CYLINDER HEAD 32 VALVE ENGINE TORQUING BY ANGLE OF ROTATION y _ 4 No Description Angle of rotation meter Special tools a Remarks commercially available e g Stahlwille No 715 20 a 15 116 d To...

Page 241: ...3 New bolt length M 12 x 199 M 12 x 149 The tightening sequence remains unchanged 1st stage 20 Nm 15 ft lb 2nd stage 90 torque angle 3rd stage 90 torque angle Note If oil and water have been mixed the...

Page 242: ...alled with the engine removed from the vehicle l Place cylinder head gasket in correct position i 7 m F i LI y v L I 4 2 Install cylinder head Torquing sequence 4 steps see Fig Sequence for removal re...

Page 243: ...gasket in position right way round Install cylinder head Torquing sequence 3 stages Qemoval sequence reverse order 1st stage 20 Nm 15 ftlb 2nd stage 90 of turn 3rd stage 90 of turn 1st stage 20 Nm 15...

Page 244: ...ENGINE 2 I Y d 1 3 _ _ p 4 I 3 a 1 A I i 4 Description Special Tools Remarks Set of tools for 9226 for 85 86 models installing camshaft 9 8 for 87 models Pressure piece for 9234 seal ring Drift for s...

Page 245: ...Cylinder Head Valves 928 DISASSEMBLING AND ASSEMBLING VALVE DRIVE 32 VALVE ENGINE 14a 15a 1 I I 13 i v 15 28 d r b 10 23 32 28 26 31 8 4 6 7 3 15 120 Disassembling and Assembling Valve Drive Printed i...

Page 246: ...ruff key 1 6 BoltM6x18 3 7 Rear toothed belt 1 cover 8 Dowel sleeve 2 9 Shaft seal 1 Always replace First oil sealing lip and then drive in seal with 9233 and 9234 0 Bolt with attached 3 washer 1 Plug...

Page 247: ...ng number 15a Bearing cap for 4 Check code and exhaust camshaft pairing number 16 Exhaust camshaft 1 Oil bearing surfaces Check code 17 Intake camshaft 1 Oil bearing surfaces Check code 18 Timing chai...

Page 248: ...der head 1 7 Spark plug 4 Torque 25 to 30 Nm 18 to 22 ftlb Coat threads with Molykote HTP Paste a Threaded insert 12 9 Plug 1 i0 Round seal 1 Replace if necessary 1 Plug 1 Install with Loctite 270 2 C...

Page 249: ...on rear end face 291 04 293 04 291 04 293 04 291 09 293 09 Left hand camshaft Cylinder bank 5 8 Intake shaft Exhaust shaft 928 105 292 04 928 105 292 04 928 105 292 09 928 105 294 02 928 105 294 02 2...

Page 250: ...shaft Exhaust shaft 928 105 272 00 928 105 272 03 928 105 274 00 928 105 274 03 Identification code on the rear end face 272 00 272 03 274 00 274 03 Valve timing 1 mm stroke zero play Intake opens 11...

Page 251: ...clockwise to align the 45 before TDC mark cylinder no 1 on vibration damper with cast boss of middle toothed belt cover Note At the 45 mark camshafts can be turned without damaging the valves 6 Loose...

Page 252: ...f wire after removinq 12 Hold both camshafts in bearings with Special Tool 9226 Unscrew and remove all other bearing bridges and bearing caps 13 Release special tool uniformly and remove both camshaft...

Page 253: ...lugs u w f y F Note The crankshaft must be at the 45 before ignition TDC cylinder 1 mark so that the valves do not contact the piston crown 15 Secure camshafts in cylinder head with Special Tool 9226...

Page 254: ...ealing ring on the camshaft input side Oil sealing lip before assembly Note The camshaft adjustment gauges for cylinders 1 and 5 are discontinued as from model year 87 engine type M 28 41142 2 The tim...

Page 255: ...4 h i Note If the sealing cover of an engine as of model year 85 32 valve engines leaks with the en gine installed the procedure for installing the cover is as foliwos 1 Place camshafts and sealing wa...

Page 256: ...pipe and take off intake air distributor 4 Unscrew suspension eye on engine only at rear left 5 Pull off spark plug connectors and take ignition leads out of holder on cylinder head cover Unscrew and...

Page 257: ...ether with a suitable piece of wire after removing Chain tensioner piston on righthand side for cylinders 1 to 4 presses the chain up on lefthand side for cylinders 5 to 8 down Tighten chain tensioner...

Page 258: ...TOOLS FOR CAMSHAFTADJUSTMENT 32 VALVE ENGINES a NO Designation Special tool Remarks 1 Gauge holder VW 387 2 Gauge commercially available 3 Gauge inset 9232 a Printed in Germany XII 1986 Camshaft Sett...

Page 259: ...ote Both distributor fingers point left in forward direction of travel wc yw Ks wc yw Ks fl _ fl _ fi fi y y _ _ t t ll ll _ _ _ _ m _ m _ f f 2 In this position the marks on the camshaft gears and th...

Page 260: ...mm pretension on hy draulic tappet of cylinder 1 intake valve Cylinder bank 1 4 Correct setting 1 6 0 1 mn Place gauge on hydraulic tappet of cylinder 6 intake valve Cylinder bank 5 8 Specified value...

Page 261: ...mponents are not aligned proceed as follows Adjusting Cylinder bank 1 4 l Install 3 extra M5 x 15 bolts to hold camshaft wheel so as to prevent the camshaft wheel or camshaft turning when the retainin...

Page 262: ...nd check set tings of cylinder bank 5 8 as described above cylinder bank l 4 Specified value 2 0 0 1 mm cylinder No 1 20 after TDC CHECKING AND ADJUSTING CAMSHAFT SETTING 87 MODELSONWARD ENGINE TYPE M...

Page 263: ...inder Head Valve Gear 928 l CYLINDER HEAD COVER DISASSEMBLING AND REASSEMBLING 32 VALVE ENGINES 14 13 IA 3 Yx 1 2 5 6 7 12 ll lo 6 9 _ 15 136 Cylinder Head Cover Disassembling and Printed in Germany a...

Page 264: ...Screw 3 5 Washer 3 6 Gasket 3 7 Cylinder head 1 cover 8 Seal 1 9 Gasket 4 10 Locknut 2 11 Guard 2 12 Oil separator 1 13 Connection 2 Connection stub stub on oil separator with throttle 6 5 mm I4 0 rin...

Page 265: ...identification code SP has been embossed as a suffix to the serial number Scope of modification engine New camshafts with different valve timing adjustment EZK control unit see Page 28 73 LH control u...

Page 266: ...28 105 29405 Or 928 105 274 01 Identification on 292 06 272 01 the rear face surface 294 05 274 01 Timings 1 mm stroke zero play Intake opens 3 crank angle after TDC 3 crank angle after TDC Intake clo...

Page 267: ...justment value 3 1 c 0 1 mm Camshaft adjustment is performed in the same order as described on Page 15 134 As from Model 89 GT version Engine type M 28 47 Note The same camshafts as in engine type M 2...

Page 268: ...ts as of MY 92 for engine type M 28 49 50 928 GTS the camshaft timing was changed Adjusting Cylinder bank 1 4 Checking and setting dimension 1 83 kO 1 mm Cylinder bank 5 8 Checking and setting dimensi...

Page 269: ...928 Engine Lubrication 17 REMOVING AND INSTALLING LUBRICATING SYSTEM PARTS a Printed in Germany VII 1983 Removing and Installing Lubricating System Parts 17 I...

Page 270: ...brication 928 26 47 49 25 60 59 55 61 5 6 2 _ e 24 23 36 35 34 2 2 27 29 15 16 R 5 6 7 6 4 l d 32 I 0 3 31 17 20 16 19 4 2 I 10 9 2 17 2 Removing and Installing Lubricating System Parts VI 1982 Printe...

Page 271: ...lt 3 6 washer 3 7 Oil level supply switch 1 8 Gasket 1 Replace 9 Bolt 5 Install at depressions of oil pan llo1t 25 1 Washer 30 2 Washer 30 3 Oil pan 1 Check 4 Oil gasket pan 1 Replace 5 Bolt 8 6 washe...

Page 272: ...insert Thermostat spring Plug sea1 Spring Bypass valve piston Plug Spring Pressure relief valve piston Adapto 1ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Note when emwing Installing Check Replac...

Page 273: ...Only use together 55 Woodruff key 1 with light alloy gear 56 Bolt 3 57 Washer 3 57 a Round cord seal 3 58 Oil housing pump 1 59 Inner rotor 1 Lubricate 60 Outer rotor 1 Lubricate chamfered side must b...

Page 274: ...pump mounting bolts and remove oil pump Installing Note Measure axial play before instal lation The measurement must be carried out with the pump dry in other words without oil l Use gauge holder VW...

Page 275: ...FOR OIL PUMP 1 Lubricate sealing lip with oil and slide seal over Special Tool 9195 on to the drive shaft inner race 2 Knock in seal flush with a suitable pressure pad e g VW 420 a Printed in Germany...

Page 276: ...ALLING 83 MODELS C MWARD u rii Ir z 50 A r d Y 46 45 44 a i 7 SP6 42 72 i 4 g z 3 1 39 f I G 42 _ 1 r 24 I I 23 22 34 I 3a I 6 5 I I t 15 17 16 21 20 A 6 g 9 i 19 l2 kll 14 10 2 1 a a 17 6b Lubricatio...

Page 277: ...er 2 4 Tube 1 5 Seal 1 fit replacement 6 Hex 3 bolt M5x12 7 Spring washer 3 3 Oil level 1 switch 3 Seal 1 fit replacement 10 Hex 5 bolt install in oil pan recesses M6x25 with washer 11 Hex 25 bolt M6x...

Page 278: ...sensor 20 Gasket 1 fit replacement 21 Threaded 1 tighten to correct plug torque setting 22 Gasket 1 fit replacement 23 Spring for 1 thermostat 24 Regulator 1 insert 25 Spring for 1 thermostat 26 Thre...

Page 279: ...Washer Toothed wheel for oil pump Shim ring 22 x 16 x Woodruff key Hex bolt M a x 45 Washer ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 r Note when Removing check for wear use commer cially available oil filt...

Page 280: ...O Ring 1 fit replacement 51 Shaft seal 1 fit replacement use drift 9195 to fit seal flush with oil pump body seep 17 6a Note The short circuiting vatve Nos 26 to 29 is deleted on the engines for the...

Page 281: ...il filter with a standard strap wrench or us 4462 4 Clean drain plug Replace seal Tighten drain plug to 4 0 0 3 29 2 ft lb 5 Lubricate gasket on oil filter slightly install by hand until gasket contac...

Page 282: ...17 Engine Lubrication 928 I i j i y i z i NO Description Special Tool Remarks 1 Oil pressure tester VW 1342 17 8 Checking Oil Pressure VI 1982 Printed in Germany...

Page 283: ...tion with M 10 x 1 adapter Part No 999 105 013 02 and M 10 x 1 M 18 x 1 5 adapter Part No 901 101 175 01 in plug opening for oil thermostat housing in place of the oil pressure sensor Mount oil filter...

Page 284: ...ring 4 Compression spring 5 Ball l Remove cylinder head cover Screw a hex bolt e g M 6 x 40 down into spring guide Slacken threaded rod 2 turns and lift out valve guide 2 Use a magnet to withdraw comp...

Page 285: ...e cleaned thoroughly and or rinsed several times Note All oil feeder holes may be flushed thoroughly with a commercially available oil gasoline syringe and benzine Oil sump Oil inlet pipe Crankcase Cr...

Page 286: ...Unscrew coolant drain plugs on left and right hand sides of crankcase and catch coolant O ring for drain plug on radiator Torques Radiator Plug 1 5 10 2 0 Nm 13 to 11 in lb Cmdwase Plug 45 IO 50 Nm 33...

Page 287: ...5 us qt CHECKING COOLING SYSTEM FOR LEAKS Note Engine must be cold for leak test Check coolant and warm water hoses for proper routing porosity swelling tears and cafe Re place damaged hoses 1 3etach...

Page 288: ...2 x3 4 Build up about 1 bar pressure in cooling syrrem by pumping Pressure valve in cap must open be tween 0 1 and 1 15 bar 5 Visually inspect rhe following parts for leaks Engine block Wager pump Cyl...

Page 289: ...Engine Cooling 928 CHECKING COOLANTTHERMOSTAT Begins to open approx 83 f 2 Ends approx 98 Opening travel distance A at least 8 mm q r 5gi i 4 19 2b Checking Coolant Thermostat VI 1982 Primed in Germa...

Page 290: ...928 Engine Cooling 19 co 1 s 0 i Printed in Germany Disassembling and Assembling Viscuous Fan 19 3...

Page 291: ...th Loctite 270 or inclined no mope 211 than 45 10 Fan 1 11 Circlip 1 Position correctly 12 Ball bearing small 1 Pull out with e g Check replace if diameter inner race Kukko internal necessary Drive in...

Page 292: ...ti rr I a Pull out grooved ball bearings with an internal I extractor e g Kukko i i w4 in xm i 1 I Pull off viscuous coupling with a double arm extractor e g Kukko 20 10 width 120 mm depth 100 mm a Pr...

Page 293: ...ling DISASSEMBLING AND ASSEMBLING THERMOSTAT HOUSING FOR COOLING SYSTEM AFCI 124 66 I I _ C k 14 A Jg 5 1 I 0 19 6 Disassembling and Assembling Thermostat Housing for Cooling VI 1982 Printed in German...

Page 294: ...Seal 1 Replace 8 Temperature sensor 1 9 Seal A 14 x 18 1 Replace 10 Temperature time 1 switch for cold start VA 11 Retaining 1 12 Bolt M 6 x 25 2 13 WasherB 6 2 14 Cover for thermostat 1 housing 15 Ro...

Page 295: ...d or ground check that thermostat housing fits correctly aftw wards It must not be installed with tension If necesrary correct by machining mounting bores i W 19 8 Disassembling and Assembling Thermos...

Page 296: ...switch for cold start valve 14 Retainer 15 Bolt I6 WasherB 6 17 18 Cover for governor housing Round seal 19 Thermostat insert O Bolt 1 WasherA 8 4 22 23 24 Governor housing O ring 53 x 7 Gasket my 1 1...

Page 297: ...ed or ground check that thermostat housing fits correctly afterwards It must not be installed with tension If necessary correct by machining mounting bores 19 10 Disassembling and Assembling Thermosta...

Page 298: ...I IE Retainer Bolt 1E Washer8 6 17 Cover for gov housing 1E Round seal 19 Thermostat it 20 Bolt 21 22 Nasher A 8 4 Governor hoi 23 l ring 53 x 7 24 Sasket my 1 1 1 2 2 1 2 2 1 1 1 1 1 1 2 2 1 1 1 2 2...

Page 299: ...ned or ground check that thermostat housing fits correctly afterwards It must not be installed with tension If necessary correct by machining mounting bores 19 10 Disassembling and Assembling Thermost...

Page 300: ...ned by a linkage connected to the positioning motor crank The crank position which corresponds to the flap pos ition is stored mechanically on a control disk integrated in the pos itioning motor 0 30...

Page 301: ...ion Tightening torque 30 Nm 22 ftlb Pressure sender Frigen Tightening torque 30 Nm 22 ftlb M 4 nut 1 Nm 0 7 ftlb Temperature switch intake a Tightening torque 40 Nm 30 ftlb Engine compartment lid swit...

Page 302: ...rate protective circuits each module controls a separate cooler fan 1 r rvq y y UhiLtidUi 4 If a fault occurs the cooling air flaps are opened to the 100 setting and the intact fan operates at full sp...

Page 303: ...l unit 2 Pressure sender Frigen 3 Engine fan 4 Output stage 5 Flap positioning motor 6 Temperature sender cooling water 7 Engine compartment lid switch 8 Temperature switch intake 19 14 Tightening Tor...

Page 304: ...Temperature sender cooling water Flap position 100 r 3 4 i L 30 70 75 80 85 90 95 100 C Cooling water Fan voltage A 12v 8V 4v IL 70 75 80 85 90 95 100 C Cooling water a Printed in Germany XVII 1987 F...

Page 305: ...mperature switch automatic transmission Flap position Temperature switch automatic transmission Fan voltage A 12v 8V w 4v 1 ii t 105 110 C Temperature switch automatic transmission 19 16 Function Char...

Page 306: ...ooling 19 a Pressure sender Frigen Flap position c c 5 5 10 10 15 15 20 20 bar bar Fan voltage 12v 8V 4V i i Frigen pressure i t 5 10 15 20 bar Frigen pressure a Printed in Germany XVII 1987 Function...

Page 307: ...0 30 t 80 82 5 85 87 5 90 oc Intake temperature cooling water temperature a Fan voltage A 12v 8V 4v r i ii 80 a2 5 85 87 s 90 oc Intake temperature Fan voltage A 12v 8V 4v 80 a3 a5 87 5 90 OC Cooling...

Page 308: ...C 1 1 2 3 4 5 5 1 Re connect connector Switch ignition on Flap positioning motor moves to 0 position Tighten securing nuts 3 nuts Set adjusting arm so that the air flaps are in the 0 position when the...

Page 309: ...nting bolts I w w a 3 Cut cable holders 4 Remove plugs from fans 5 Remove hose clamp from air filter auxiliary air pump 6 Remove hose clamp from oil reservoir servo oil When installing fans ensure tha...

Page 310: ...e and installing front air Repair Group 66 Removing and installing PU part see Repair Group 63 Remove securing bolts Disconnect plug of flap positioning motor at coupling u 1 I__ L __ 4 I 3 A 2 L_ rO_...

Page 311: ...ading battery voltage 2 Connect voltmeter to pin 4 plus ard pin 7 ground of plug I Igrition on Reading battery voltage Ignition off Reading 0 V Function test of AC button Connect voltmeter to pin 7 gr...

Page 312: ...n Frigen pressure Reading 1 5 bar 22 ohm f 4 ohm 5 bar 53 ohm t 4 ohm 10 bar 92 15 bar 125 ohm ohm f 5 5 ohm ohm Engine compartment Pin 6 plug II and Engine compartment Reading m ohm Engine compartmen...

Page 313: ...he flap positioning motor moves to the 30 position Connect pin 7 plug I and pin 1 100 approx 2 4 seconds The flap positioning motor moves to the 100 position 1 C F Bi If the flap positioning motor fai...

Page 314: ...pin 3 ground and pin 4 plus of the fan output stage plug connector Reading battery voltage 3 Connect voltmeter to pin 3 ground and pin 2 plus Ignition on Reading battery voltage c Engine temperature z...

Page 315: ...8 Press AC button Set the air distribution slide switch to up down Reading approx 7 V If both fans refuse to operate when the AC button is pressed while the ignition is on the output stage is defecti...

Page 316: ...Workshop Manual DR ING h c F PORSCHE Aktiengesellschaft...

Page 317: ...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 318: ...nsmission Controls Case Automatic Transmission Gears Valve Body Differential Transaxle System Front Wheel Suspension Rear Wheel Suspension Axle Shaft Wheels Tires Alignment Antiblock System Brakes Mec...

Page 319: ...Checking fuel pressure Removing and installing pressure regulator Removing and installing intake air sensor Removing and installing cold start valve Removing and installing auxiliary air regulator Re...

Page 320: ...and cars with catalytic converters Adjusting idle without catalytic converter Fuel path LH Jetronic Modified breather for crankcase and cylinder heads Testing oxygen sensor operation Testing oxygen s...

Page 321: ...tion and oxygen sensors Exhaust system Emission Controls Replacing filter element of air pump Checing tightness of exhaust flanges Hose Layout Intermediate and or final mufflers single pipe system Rep...

Page 322: ...mponents Cautions when repairing electronic ignftion systems Adjusting ignition timing Distributor specifications Removing and installing distributor Replacing spark plugs Removing and installing vacu...

Page 323: ...Replacing spark plugs EIK control unit coding Checking the transmission protection switch automatic transmission Equipment table Equipment table Type 928 GT 928 GTS 54 I Ignition circuit temperature...

Page 324: ...ear wheel house be hind lock pillar nS 1 Take off cover 2 Detach fuel liner while counterholding Catch escaping fuel 3 Loosen clamp and take off fuel filter 4 Install new filter noting direction of fl...

Page 325: ...atch direction of flow arrow faces fuel distriburor 6 Check for leaks REMOVING AND INSTALLING FUEL PUMP Removing 1 Disconnect ground wire ar battery 2 Take cover off of fuel rank at bottom 3 Pinch int...

Page 326: ...return line from fuel distributor and connect a suitable test hose in its place test hose wirh 12 mm dia ring connecror z y 3 s 1 a 3 Bridge iuel pump relay rocker rern i nali 30 and X7 I Hold end II...

Page 327: ...nd of fuel return hose from pressure regu lator in a measuring glass approx 1500 cc 3 pluo boa 4 Bridge terminals 30 and 81 with an extra wire i f il y _ me 1 r rc pm IL j 101 1 Iiamy T N A i z 1 _ i...

Page 328: ...re for 30 seconds 1 Disconnect fuel return line in rear of engine compartment while counterholding essential vF wim 7w l T I I J y 4 7 l cl1 L1 r p 2 Connect a commercially available fuel hose 3 Hold...

Page 329: ...20 Fuel Supply 928 m 7 1 42 I i I IF l 4 I 51 i i I 20 6 Hose Diagram for CIS I 1980 Printed in Germany...

Page 330: ...928 Fuel Supply 20 l x s FJ LL z 2 E E A I I I I I I I I I I i am nmrmmc Printed inGermany IV 1980 Hare Plan for K Jetronic System 928 20 7...

Page 331: ...rsion with inte grated check valve Fuel pump new version since 1981 models Check valve with seal S 4 Cap nut lty 1 1 1 2 1 Note when Removing Installing Always replace seal Torque 20 Nm 14 ftlb Always...

Page 332: ...ith ring adapter and new seals and secure with cap nut 2 Pinch fuel intake hose with a standard hose clamp Important and detach hose Make sure fuel hose is routed correctly and cannot rub before tight...

Page 333: ...20 Fuel Supply 928 a DISASSEMBLING AND ASSEMBLING ACCELERATOR PEDAL 20 10 Disassembling and Assembling Accelerator Pedal Printed in Germany...

Page 334: ...ing Instructions Adjust push rod to 48 I 1 mm for LHD lbetween ball head centers and connect Check replace if necessaryand lubri cate with multipur pose grew ADJUSTING FULL LOAD POSITION OF THROTTLE T...

Page 335: ...e on fuel pump 7 Unscrew bolt at upper fuel tank mounting point 4 Fold back floor mat Remove cover on fuel lever transmitter Disconnect hose and electric wire plug on fuel level transmitter 5 Unscrew...

Page 336: ...seal fits correctly in tank filler neck j I _ _ kS 4 9 Remove fuel tank from below Installing 1 Check suspension points for correct fit before installing fuel tank Printed in Germany VI 1982 Removing...

Page 337: ...sconnect ground wire at battery 2 Draw off fuel 3 Remove bottom tank cover Pinch fuel intake hose with a standard hose clamp 4 Disconnect 4 mounting points of suspension straps and let complete suspen...

Page 338: ...8 Fuel Supply 20 a REMOVINGAND INSTALLING FUEL TANK SENSOR TOOL 1 a 7 a No Designation Special tool Remarks Pin wrench 9190 a Printed in Germany XII 1986 Fuel Level Sensor 20 15 Removing and Installin...

Page 339: ...nnector 2 Undo union nut using Special Tool 9190 Take gauge unit complete with gasket Installation 1 Always use a new gasket Coat threads and seating area of union nut with Optimoly TA Note TO facilit...

Page 340: ...INE TYPE M28 41 42 1 Fuel tank 2 Expansion tank 3 Hose 4 Rollover valve 5 Activated charcoal cannister 6 Breather line 7 Diaphragm valve 8 Solenoid valve 9 LH Jetronic control unit 10 Throttle housing...

Page 341: ...Note Terminate calibration mode by switching off the ignition or starting the engine 4 Pull the operating lever for the backlit instru ment cluster turning the ignition on at the same time The follow...

Page 342: ...928 Electronic Fuel Injection 24 a AFC EOUIPMENTTABLE Printed in Germany VII 1983 AFC Equipment Table 24 01...

Page 343: ...sec Fuel pressure engine stopped Fuel pump bridged Check value for idle 2 5 2 0 2 bar approx 2 bar Leak test Min pressure after 20 minutes 1 bar Idle adjustments Idle speed co level 750 2 50 rpm from...

Page 344: ...928 Electronic Fuel Injection 24 ADJUSTING IDLE USA AND JAPAN from 1980 Models with L Jetronic TOOLS Primed inGermany IV 1980 Adjusting Idle USA and Japan 24 3...

Page 345: ...uel Injection 928 l _ Yj a NO 1 2 3 I J diS Description I Special Tool Ball screwdriver 9187 Oil temperature tester 9 122 CO Lest line US 8023 Remarks or us 8025 24 4 Adjusting Idle USA and Japan Prin...

Page 346: ...or SUN 120 239 on test connection of catalytic converter 3 Run engine to operating emperarure oil remperature approx 80 C Use special roo1 US 8025 4 Connect CO tearer I0 supplier s instrucrions 5 Tur...

Page 347: ...ure conrrol screw accordingly I Turning clockwise richer mixture Turning anticlockwise leaner mixture 8 After finishing adjustment reconnect the oxy gen sensor plug 9 Coat threads of plug far Iest con...

Page 348: ...ic Fuel Injection 24 ADJUSTING IDLE SPEED AND CO USA AND JAPAN B e g i n n i n g w i t h 1 9 8 3 M o d e I s LJetronic TOOLS Printed in Germany VII 1993 Adjusting Idle Speed and CO USA and Japan 24 6a...

Page 349: ...928 NO Description Special Tool Remarks 1 CO adjusting tool 9187 2 Oil tester temperature 9122 or US 8025 3 Adapter us 8040 4 Exhaust probe us 4492 24 6b Adjusting Idle Speed and CO Printed in German...

Page 350: ...d up foot support in footwell on passenger s side and disconnect oxygen sensor plug 3 Connect exhaust probe US 4492 on exhaust source line 2 Take off cwer of exhaust source line in engine compartment...

Page 351: ...oxygen sensor plug after finishing adjustments 4 Run engine to operating temperature oil temperature approx 80 Cl Use Special Tool US 8025 5 Connect CO tester to supplier s instructions 8 Turn contro...

Page 352: ...CHECKING FUEL PRESSURE USAand Japan from 1980 Models with L Jerronic TOOLS NO Description 1 Pressure gauge with hose from pressure tester Special Tool P 378 Remarks Printed inGermany Iv 1980 Checking...

Page 353: ...ng cap nut 2 Connect pressure gauge with hose from pressure tester P 318 on the test connection 3 Fold up foot support in foorwell of passenger s side and pull fuel pump relay off of central elecrric...

Page 354: ...pper section and air filter cartridge 2 Disconnecr carbon canister hose and unscrew captive bolts Pull off multiple pin plug and remove lower section with intake air sensor r I I If I y r qFfy r r b J...

Page 355: ...blue wire plug unscrew fuel line and moonring bolts REMOVING AND INSTALLING AUXlLIARY AIR REGULATOR 1 Take off air cleaner assembly 2 Pull off black wire plug loosen hose clamps unscrew rocket head bo...

Page 356: ...oving Pull off electric plug and unscrew temperature SX 1 Disconnecr ground wire at battery 2 Pull off vacuum hose and disconnect fuel lines not forgetting to counrerhold Catch escaping fuel Innrallin...

Page 357: ...uter Retaining plate Fuel injector Hose sleeve Fuel distributor line 3Y Note When Removing Installing Always replace Position COT rectly Check replace if necessary Position 0x1 rectly in casr boss of...

Page 358: ...n hose adapter against srop by hand Hose sleeve must be a tight fir REMOVING AND INSTALLING FUEL INJECTORS Note Only four left 01 right fuel injectors can be removed together Cut off wire straps Pull...

Page 359: ...distributor and rhrorrle housing Remove intake distributor from above 4 Pull off hoses and disconnect throttle cable Pull wires off of microswitches unscrew mounting bolts and remove throttle housing...

Page 360: ...ADJUSTING MICROSWITCHES ON THROTTLE HOUSING TOOLS y A T _ Ill Il o O UiLlI JJJ NO Description Special Tool Remarks 1 Degree disc from P 228 c 2 Indicator Made locally Printed inGermany IV 1080 Checkin...

Page 361: ...operating lever b Mourn and align locally made indicator The microswitch will already switch when play in acceleraror linkage is eliminated by force on the pedal The throttle valve should still be cl...

Page 362: ...rature time switch Check by measuring resistance between terminal G and ground housing below 30 C 86 F 0 ohms above 40 C 104 F 100 160 ohms rerminal W and ground housing below 30 C 8t F 0 ohms above 4...

Page 363: ...d connect a test Specification 40 to 75 ohms lamp on both cootac s of disconnected plug 2 Check power supply Starr engine Test lamp should come on at coolant temperature below 30 C 86 F and L come on...

Page 364: ...cient CHECKING PRESSURE REGULATOR 1 Take off air cleaner assembly 2 Connect pressure gauge with hose from pressure tester P 378 on testing connection r M f I pp w c I s 3 s4 wqe i f I I c b l_ r i I y...

Page 365: ...ecification 130 260 ohms Connections 8 and 9 Specification 70 140 ohms Connections 6 and 7 Specification 40 300 ohms Connections 7 and 8 Specification 100 500 ohms Connections 27 and 6 Specification 2...

Page 366: ...c 2 2 s 2 EZ ei i 5 Gi g c I a 0 s 2 a 2 g 5 3 g 2 s 2 z 5 2 zd m g2 u u sac 5 o gz 2 x g 0 s g g a __ p Gi z s al z z 5 _o s M so c w 2 5 a j UG u 2 e a c E G 6 iL t z i i 7 2 i c I j i c ij E z if E...

Page 367: ...24 Air Flow Controlled Fuel Injection 9 28 HOSE DlAGRAM FOR AFC a I b Ln h 1 iA e j h4q 3 I I d i 4 I i 24 22 Hone Diagram for AFC Printed in Germany...

Page 368: ...928 Air Flow Conrrolled Fuel Injection 24 a L I 2 2 E w 0 z 3 E I t r x a Printed inGermany IV 1980 Hose Diagram for AFC 24 23...

Page 369: ...t UP to stop on steel insert 3 Pull out plug with a left turning drill no 2 3 Close hole providing access to mixture control screw with a new plug after finishing adjust ments Press in plug flush Inst...

Page 370: ...erature Sensor Double Func Throttle Switch Auxiliary Air Regulator 928 606 141 OO Bosch No 0280 214 001 928 606 126 00 931 606 119 00 928 606 102 00 Bosch No Bosch No Bosch No 0280 130 032 0280 120 30...

Page 371: ...take air distributor 2 Throttle housing 3 Heated wire air flow sensor 4 Air cleaner 5 Ejector 6 To brake booster 7 Electronic ignition control unit 8 Electric air valve air conditioner 9 Auxiliary air...

Page 372: ...ectors A From fuel tank 2 Fuel filter 7 Pressure regulator feed 3 Pressure damper 8 Fuel cooler 8 To fuel tank return 4 Fuel line 9 LH air flow sensor Cyl 5 8 10 Throttle housing 5 Fuel line 11 Blowof...

Page 373: ...24 LH Jetronic LH JETRONIC C 2 R I C c f a 7 P r P 9 24 104 LH Jetronic Printed in Germany...

Page 374: ...ages securely 4 LH control unit 1 5 Control unit holder 1 6 Plug connector 8 7 Bolt 8 8 Washer 8 9 Distributing 2 injection tube IO Hose sleeve 8 II Thrust plate 8 12 Fuel injector 8 13 Hose clamp 4 I...

Page 375: ...31 Nut 32 Washer 33 Holder 34 Fuel line 35 Fuel line 36 Fuel cooler 37 38 39 40 41 42 43 44 Hose clamp Hose Hose Plug connector 4uxiliary air regulator lug connector Throttle switch Bolt 1 1 1 1 1 1...

Page 376: ...clamp 2 49 Connecting hose 1 50 Plug connector 1 51 Air flow sensor 1 52 O ring 1 dust guard 53 O ring 1 5fl Air guide housing 1 55 Seal 1 56 Temperature 1 sensor I 57 Plug connector 1 58 Plug connec...

Page 377: ...ronic No 1684 463 093 Pressure gauge with hose from pressure tester P 378 F4 Y L Two test lines made locally for measuring 3 2 on multiple pin plugs of control units and plug connectors with same type...

Page 378: ...Throttle switch 6 Auxiliary air regulator 7 Control units ignition LH 8 Temperature sensor II 9 Temperature sensor I 10 Fuel line 11 Fuel injectors right 12 Blowoff switching valve 13 Ignition control...

Page 379: ...wer supply for electronic ignition and LH control units 2 LH Jetronic relay XVI power supply for LH control unit and air flow sensor 3 Fuel pump relay XVII power supply for fuel pump auxiliary air reg...

Page 380: ...High fuel consumption Poor power output Engine hesitation X Check with suitable tester LH Jetronic Possible Causes of Defects F E Z E z gt z F 29 g 5 E 0 i y Y z 2 m 2 al 0 11 E n k F u Tj 5 2 e I z...

Page 381: ...tion battery voltage If value deviates from specification measure voltage on plug X connected on central electric board between terminal 8 and ground 4 3 2 1 I I I X I I I 8 7 6 5 l Connect terminal 1...

Page 382: ...6 Pull off relay XVI for this purpose and bridge terminals 30 and 87 Specification battery voltage 4 Measure resistance for idle mixture position Connect ohmmeter on terminals 6 and 3 of air flow sens...

Page 383: ...ignition Observe heated wire with help of a mirror 24 114 Troubleshooting LH Jetronic Printed in Germany Heated wire must glow about 1 second after waiting approx 4 seconds Check activation and wires...

Page 384: ...an no pickup in cold state In case of interruption wires could be bridged for emergency operation of the car TEST POINT 5 Throttle Switch 1 Idle Speed Contact Pull off multiple pin plugs on LH and ele...

Page 385: ...f engine can be operated pull off plugs on injectors separately If fuel injectors are okay engine speed should drop each time If engine cannot be operated measure voltage on one plug of injectors agai...

Page 386: ...ope will display the following oscillographs STARTER SPEED IDLE SPEED ACCELERATION DECELERATION Note If engine does not start or the idle speed drops exchange test connections on adapter line and chec...

Page 387: ...ing and remove hose on blow off switching valve 3 Unscrew unlosable hexagon head screws 13 mm wrench size in lower air cleaner housing and remove lower housing with heated wire air flow sensor Pull of...

Page 388: ...Germany VI I I 1984 Troubleshooting LH Jetronic 24 119 TEST POINT 10 Fuel Pressure 1 Unscrew cap nut on injection line Note Be careful that sealing ball does not fall out when removing the cap nut Cat...

Page 389: ...ernator could cause engine misfiring 1 Remove drive belt and alternator 2 Start engine If misfiring is eliminated check alternator and regulator l If pressure rises to less than 4 bar check fuel filte...

Page 390: ...econdition as for the brief test 2 Disconnect oxygen sensor plug 3 Connect voltmeter to sensor half of plug and earth 4 The voltage must be in the 0 1 V 1 0 V range depending on level of oxygen in the...

Page 391: ...Disconnect oxygen sensor plug 3 With a length of cable briefly connect cable of control unit side of plug to ground The CO value must increase l If there is no change in the CO value check connection...

Page 392: ...mp Delivery rate Fuel pressure engine stopped Fuel pump bridged Check value for idle Leak test Min pressure after 20 minutes Idle adjustments Idle speed rpm co l Specifications at least 1350 cc 30 sec...

Page 393: ...LESPEEDANDCO beginning with 1984 models Engine Type M 28 21122 TOOLS i No Description Special Tool Remarks 1 CO adjusting tool 9187 2 Oil temperature tester 9122 l e 24 122 Adjusting Idle and CO 1984...

Page 394: ...doors Part No 999 703 163 40 f y L q 1 I 4 t i i _ _ cvli W J 21 r ri I q 3 Install air intake hose 5 Connect CO tester and separate tacho meter to supplier s instructions 6 Turn control screw or byp...

Page 395: ...r flow sensor and turn idle speed potentiometer accordingly Turning clockwise richer mixture Turning counterclockwise leaner mixture CO specifications 0 5 1 5 R o W 0 5 1 O Australia Switzerland Swede...

Page 396: ...Loosen bottom hose clamp and take heated wire air flow sensor off of lower air cleaner housing Installing 1 Check O ring in air guide housing for damage and correct fit Lubricate O ring with silicone...

Page 397: ...and pull off plugs Press bar in direction of arrow while pulling off plugs 5 Remove fuel cooler a First unscrew right refrigerant line coupling completely while holding on hexagon of line b Unscrew b...

Page 398: ...sing connecting wires on air flow sensor and air cleaner Tighten lower air cleaner housing mounting screws Install filter element and upper air cleaner housing connecting hose from blowoff switching v...

Page 399: ...ectric fuel pump delivery rate l Fuel pressure engine off fuel pump bridged Overpressure at idle speed Leak test minimum pressure after 20 minutes Idle speed adjust ment Idle speed in rpm l min a CO c...

Page 400: ...61 008 0280 160 215 Hot wire air volume meter NTC Temperature sensor II dual function Throttle switch Idle adjuster 928 606 141 00 928 606 126 00 944 606 113 01 928 606 161 00 Bosch No Bosch No Bosch...

Page 401: ...ls No Description Special Tool Remarks 1 Oil temperature tester 9122 9122 1 or US 8025 with test probe 2 Adapter US 8040 3 Exhaust probe us 4492 1 Screwdriver 9230 5 7 mm hexagon key e g Hazet 428 7 j...

Page 402: ...122 9122 l to check oil temperature 15 to 30 C 2 Disconnect oxygen sensor plug and connect CO tester according to supplier s instructions Note It is recommended to use the test connection in area of a...

Page 403: ...testing pipe after finishing adjustments 6 Connect separate tachometer to supplier s instructions Idle speed adjusting value 680 20 rpm 7 Check and adjust idle speed This requires stopping the idle s...

Page 404: ...nic Fuel Injection 928 6i J h ks I l 1 9 Restore idle speed charging control after finishing adjustments remove locally made wire on test jacks 10 Recheck adjusted values 24 206 Adjusting Idle Printed...

Page 405: ...up to stop on steel insert 3 Pull out plug with a lefthand spiral drill size no 2 q T rc 3 Install a new plug in bore affording access to CO adjusting screw after finishing adjustments Press in plug...

Page 406: ...ilter neck D from activated charcoal cannister E to automatic transmission F to ECU 1 fuel pump 2 fuel filter 3 3a pressure damper 4 left hand injection line 5 righ hand injection line 6 test point 7...

Page 407: ...en end wrench to counter the nuts Catch the fuel from the pipe in a suitable container 4 Remove ignition lead and cable clip from distribution pipe Disconnect distribution pipe from intake pipes and l...

Page 408: ...a Idle speed rpm Idling speed mm CO values min 1250 cm3 30 s 3 8 0 2 bar approx 3 3 bar 3 0 bar without catalytic converter Catalytic converter vehicles 775 25 775k 25 675 25 675k 25 0 5 IF 0 4 1 2 H...

Page 409: ...nction 928 606 141 00 928 606 126 00 928 606 157 00 928 606 lbi 01 Bosch no Bosch no Bosch no Bosch no 0280 14 001 0280 130 032 0280 120 322 lJ280 140 515 Electric injection valve LH Jetronic Ignition...

Page 410: ...in perfect mechanical condition Switch off all consumers during adjustment Make adjustments as quickly as possible to avoid excessive heat at intake ports which would produce wrong CO values Intake ai...

Page 411: ...n perfect mechanical order Switch off all consumers during adjustment Make adjustments as quickly as possible to avoid excessive heat at intake ports which would result in incorrect CO readings Intake...

Page 412: ...lue spare part No 944 606 935 01 in CO adjustment screw apperture Recheck idle speed Connect separate rev counter in accordance with manufacturer s instructions Idle speed 675 25 rpm Printed in German...

Page 413: ...24 Electronic Fuel Injection LH Jetronic 928 FUEL PATH LH JETRONIC 928 S 87 MODELS ONWARD ENGINE TYPE M28 41 42 I 7 A I1 w a 24 216 Fuel path LH Jetronic Printed in Germany...

Page 414: ...Idle speed actuator C Intake jet pump D Pressure damper E Pressure regulator F Vacuum valve G Electric tank breather valve H Oil filler neck I Secondary air valve K Vacuum operated switch valve tune...

Page 415: ...ection between oil filler neck and throttle body modified throttle bore 0 5 mm for this breather hose is now located in the oil filler neck 3 Additional breather hose between right hand and left hand...

Page 416: ...g 3 Connect voltmeter to terminal 1 sensor half of plug and ground 4 The voltage must be in 0 1 V to 1 0 V range depending on concen tration of oxygen in exhaust Voltage characteristic of oxygen senso...

Page 417: ...1 of control unit side of plug to ground The CO reading must increase Note Do not conduct this test for any longer than required to detect a change in the CO reading of the exhaust tester If there is...

Page 418: ...Switching diagram l m 006 aa 4 2 1 m 06 7 06 5 3 2 1 Type R o W without catalytic converter manual transmission R o W without catalytic converter automatic transmission R c W with catalytic converter...

Page 419: ...thout catalytic converter manual transmission Rest of world without catalytic converter automatic transmission Rest of world USA with catalytic converter manual transmission Rest of world USA with cat...

Page 420: ...nd and right hand injection valve covers Remove both union nuts from fuel distribution line counterholding with a second open ended wrench Catch any escaping fuel in a suitable container Disconnect di...

Page 421: ...manifold Take care to ensure that the vacuum hoses and breather hoses are correctly routed 2 Carry out visual inspection to check for leaks 3 Check that vacuum hoses and hose clamps are correctly seat...

Page 422: ...Exl regulator to mixture control Coupling nut 15 II MlOxl Feed line to cold start valve Hollow bolt 15 II M 10x 1 5 to mixture control Coupling nut 15 11 MlOxl Return line to mixture control Hollow bo...

Page 423: ...using making sure that each box is still connected to Ihe camshaft drive belt cover 2 Release rubber fasteners take off air cleaner upper section and remove filter element 3 Make sure that filter elem...

Page 424: ...25 Fuel System 928 ADJUSTING IDLE AND CO TOOLS No Description 1 Adjusting wrench 2 Oil temperature tester Special Tool 9134 9122 Remarks or US 8025 25 2 Adjusting Idle and CO Primed in Germany...

Page 425: ...3 Detach air hose at diverter valve and insert a suitable plug 4 Install air cleaner upper section and air intake hose 5 Run engine to operating temperature 60 to 90 C 176 to 194 F oil temperature Us...

Page 426: ...rich first turn mixture control screw counterclock wise further than necessary and then clockwise to adjust to specifications b lust turn control slightly since the smallest adjustment will change CO...

Page 427: ...st 1120 cc 30 sec at least 1360 cc 30 sec Diagram for control pressure regulator Part No Y28 606 109 02 Bosch No 0438 140 053 Test vac m 460 600 mbar 350 450 rnrnHg 2 8 3 2 bar Conrrol pressure warm T...

Page 428: ...engine warm Min pressure after 10 minutes 20 minutes 30 minutes Fuel injectors Opening pressure Specilicariou 5 2 5 8 bar 5 3 5 5 bar 2 0 bar 1 7 bar 1 6 bar 3 0 4 1 bar Eressurer listed in Test Valu...

Page 429: ...with pressure without vacuum Conllecl Yacuum pump on intake pressure connection of control pressure regulator Tes pressure 450 550 mb 340 420 mmHg Specification at least 1360 cc 30 seconds Diagram fo...

Page 430: ...engine warm Min pressure after 10 minutes 20 minutes 30 minutes Fuel injectors Opening pressure Soecification 5 2 5 8 bat 5 3 5 5bar 2 0 bar 1 7 bar 1 6 bar 3 0 4 1 bar Pressures listed in Test Value...

Page 431: ...essure watm Test with pressure without vacuum Connect vacuum pump for test on intake pressure connection of warm up control Test pressure 450 550 mbar 340 420 mmHg Specification at Ieasr 1360 cc 30 se...

Page 432: ...ngine warm Min pressure after 10 minutes 20 minutes 30 minutes Fuel injectors Opeding pressure Specification 5 2 5 8 bar 5 3 5 5 bar 2 0 bar 1 7 bar 1 6 bar 3 0 4 1 bar Pressures listed in Test Value...

Page 433: ...ent temp l Control pressure warm Test with pressure without vacuum connect YaC m pump for test on intake pressure connection of warm up control Test pressure 460 600 mb 350 450 mmHg at least 1120 cc 3...

Page 434: ...engine warm Min pressure after 10 minutes 20 minutes 30 minutes Fuel injectors Opening pressure Specification l I Remarks 5 2 5 8 bar 5 3 5 5 bar 2 7 bar 2 6 bar 2 5 bar 3 0 4 1 bar Pressures listed i...

Page 435: ...ure warm Test with atmospheric pressure without vacuun i 1 I Connect vacuum pump u test on intake connection of warm up regulator With test pressure 460 600 mbar 350 450 mm I Hg l L Specification at l...

Page 436: ...rm Min prensure after 10 minutes 20 minutes 30 minutes Fuel injectors Opening pressure Specification a I Special Instructions 5 2 5 8 bar 5 3 5 5 bar 2 7 bar 2 6 bar 2 5 bar 3 0 4 1 bar Pressures list...

Page 437: ...S Europe USA Japa f Canada 700 5 800 2 50 700 E 750 550 700 6 2 0 to 3 0 2 0 to 4 0 1 0 to 2 0 0 4 to 0 8 1 5to 2 5 Australia Sweden 700 50 700 50 700 50 2 0 to 3 0 1 o to 2 0 l 1 oto 2 0 Special Inst...

Page 438: ...928 Fuel System 25 TOOLS t I w J I d 4 NO Description Special Tool P 318 9114 l 1 1 UsedwithP378a Remarks Printed in Germany I 1978 Pressure Tests 25 7...

Page 439: ...1 Unscrew control pressure line and standard adapter from control pressure regulator 2 Screw adapter 1 from Special Tool 9114 l with a seal in control pressure regulator and connect left hose from Spe...

Page 440: ...t a Remove cover in footwell on front passenga s side r i 4 e J j L 3 c 6 t b Pull off fuel pu p relay a c Bridge terminals 30 and 87 with a piece of wire Fuel pump or pumps must now run 3 Position se...

Page 441: ...ve at uosition 3 4 System pressure should now agree with speci fications 2 Electric plug remains connected on control pressure regulator 3 Bridge terminals 30 and 81 4 Set selector valve at position 2...

Page 442: ...6 6 If pressure drop is too fast repeat test with con trol pressure circuit broken by moving selector valve to position 3 If results are the same leak is in system pressure circuit If results of secon...

Page 443: ...tem CHECKING CONTROL PRESSURE COLD Vacuum Controlled Control Pressure Regulator a TOOLS NO Description Special Tool Remarks 1 Hand vacuum pump 9160 or US 8026 25 12 Checking Control Pressure Cold Prin...

Page 444: ...rhe charts will only show values for rhe acwm rest method 1 Connect and bleed pressure rester P 378 ser switching valve ar position 2 5 Produce specified vacuum with the hand vacuum pump or adjust se...

Page 445: ...ssure Specification 0 5 0 8 bar note brief delayed action time 3 If applicable replace hot start valve or check temperature switch i e temperature switch must have switched to through flow Iground CHE...

Page 446: ...928 Fuel System 25 TOOLS L NO I 3 Description Pressure tester VW 1318 Connectors P378c Adapter 9114 l Remarks 3 Printed in Germany VII 1983 Pressure Tests with VW 1318 25 12c...

Page 447: ...x 1 5 with seal on control pressure regulator and connect right test line of P 378 c 4 Connect adapter of 911411 IM 8 x 1 I M 10 x 1 between disconnected control pressure line and left test line of P...

Page 448: ...g connections 30 and 87 with a piece of wire Fuel pump or fuel pumps should now 3 Bleed pressure tester Let pressure gauge hang down Move lever for switching over valve between valve opened and valve...

Page 449: ...ve position 2 Electric wire plug remains connected on control pressure regulator 3 Bridge safety circuit 4 Set lever to opened valve position Control pressure will now rise slowly and reach the specif...

Page 450: ...rive for lowest 2 position c 1 3 Air flow sensor plate must be horizontal and centered in venturi Adjusting An excessively high air flow sensor plate setting can be corrected by driving down the stop...

Page 451: ...1 5 mkg 9 4 10 8 ft lb Shim as req 0 1 0 15 1 3 0 4 0 5 mm thick Install same as Check system removed always 3 pXCS E Flat seal 1 O ring 1 Pressure relief valve 1 piston Replace Replace O ring 1 Llse...

Page 452: ...air regulator and air distributor fuel supply line on cold start valve and on cars with an auto matic transmission vacuum line 6 Loosen upper hose clamp on connector between air distributor and throt...

Page 453: ...trol unit crosswise to 1 0 mkg 7 ft lb 3 Tighten hex head bolts with spring in area of sensor plate lever bearings to compressed length of spring and then loosen by one turn 4 Tighten fuel lines and i...

Page 454: ...l System 25 a DISASSEMBLIhG AhP SSEMBLING MIXTURE CONTROL UNI I 42 z 16 17 18 19 8 11 r 45 _ _ a i 1 44 c c I iG L P J 22 36 a Printed in Germany I 1978 Disassembling and Assembling Mixture Control Un...

Page 455: ...re relief valve 1 Pull out with tapered Check replace fuel piston wooden peg distributor if damaged close tolerance part 6 O ring 1 Check replace if necessary I Adapter 1 8 Seal 1 Replace 9 Fillister...

Page 456: ...1 1 1 1 1 2 Note When iemoving Installing Check replace if necessary Stamped edge of sensor plate ox stamped code I faces up First take off this Sharp edge side faces circlip 0 t Check replace if eces...

Page 457: ...pscrew 0 47 0 53 mkg 3 4 3 8 ft lb 39 Counterweight 1 Position correctly SO Fillister head 1 CS PSCEW 41 Locknut 1 42 Plug safety switch 1 Turned toward air No electrical venturi by approx function 19...

Page 458: ...fit properly 2 This requires a suitable cylindrical pin e g pin from adjusting lever of 911 mixture con trol unit or a standard 8 h 8 x 60 DIN 7 cylin drical pin Both ends must be chamfered 4 Guide pr...

Page 459: ...ng bolts 6 Center gap between sensor plate and venturi 0 The gap must be uniform and can be checked with a 0 10 mm feeler gauge blade This re quires that the sensor plate be adjusted to car rect heigh...

Page 460: ...ING AND INSTALLING FUEL INJECTORS 1 Unscrew coupling nut of fuel injection line counterholding on fuel injector 2 Unscrew fuel injector with a deep socket Printed in Germany I 1978 Removing and Instal...

Page 461: ...through the floor board 4 Lift car 5 Pull off safety plug on oxygen censor 6 Unscrew oxygen ienmr q 4r yI T 7 Installing 1 Coat threads of oxygen senxx with Bosch Paste VS 140 16 Ft or Oprimoly HT No...

Page 462: ...tron on elapsed mileage switch against stop wirh a suitable tool The elapsed mileage switch will rerun to zero and the oxygen sensor indicator light will again operate normally REMO NG AND INSTALLING...

Page 463: ...TIGHTNESS OF EXHAUST FLANGES 1 Check bolts between exhaust manifold pipes and catalytic converter 2 Check bolts at intermediate muffler outlet 3 Check bolts at main muffler inlet r c d rw mw x j i Y...

Page 464: ...928 Exhaust System 26 1 w IV II 0 3 1 k IhI 1 I hinted in Germany I 19 HOE Layout 26 3...

Page 465: ...26 Exhaust System 928 z 2 T 5 x E g 2 o a I I m 0 Q r1 d I 9 w 1 L9 c lsi l c 63 w 36 4 Hose Connection Plan US4 Japan Printed in Germany...

Page 466: ...26 Exhaust system REPLACING INTERMEDlATE AND OR FINAL MUFFLERS Single Pipe System m 26 6 Replacing lntermediare and or Final Mufflers Single Pipe System Printed in Germany...

Page 467: ...ons 2 Install new parts on car using old mounting parts when possible 3 Align exhaust assembly with the connecting sleeve to remove stress whereby distance between bolr on rear axle beam and exbaw pip...

Page 468: ...26 Exhaust System 928 REPLACING CENTER AND OR FINAL MUFFLERS Twin Pipe System TYPO 928 N I S A i a 26 8 Replacing Center and or Final Mufflers Twin Pipe System Printed in Germany...

Page 469: ...ral points to hold in installed position Replacing Final Muffler 1 Remove final muffler with intermediate muffler heating front connecting pipe with a welder if necessary 2 Cut through center of weldi...

Page 470: ...f pipes on new final muffler in area of welding 5 Mark off distance of about 10 mm on end of final muffler pipe to have minimum insertion depth of 10 mm Install final and intermediate mufflers and ali...

Page 471: ...TTERY 1 Lift luggage compartment trim on left hand side remove cover plate take out spare wheel and open battery box lid 2 Disconnect battery ground wire at body Unscrew and remove battery cover Fi l...

Page 472: ...ing the specific gravity will not only supply information on charge condition of battery but also any possible defects a Specific Gravity of one cell much lower than that of other cells short circuit...

Page 473: ...928 starter Power Supply Tempostat 27 l AUTOMATIC CRUISE CONTROL TEMPOSTAT Printed in Germany VI 1982 Automatic Cruise Control Tempostat 27 3...

Page 474: ...27 starter Power Supply Tempostat 928 AUTOMATIC CRUISE CONTROL ITEMPOSTATJ f 1213 I 18 27 4 Automatic Cruise Control Tempostat Printed in Germany 4 1...

Page 475: ...lug 10 Grommet 11 Cable 12 Lock washer 13 Bolt 14 Bolt 15 Washer 16 Tempostat control 17 Plug 18 Steering column switch 19 SCWd 20 Clutch pedal switch 21 Bolt 22 Washer 23 Vacuum reservoir 24 Vacuum l...

Page 476: ...glove box Removal and installation are described on page 94 4 of this repair manual 2 Unscrew side trim panels on center console 3 Unscrew control mounting bolts Remove control on side of passenger s...

Page 477: ...mission will have bridged Two mounting planes are provided to adjust the wirer instead of the switch switch The switch must have switched completely contacts made when clutch pedal is in off position...

Page 478: ...ath the vacuum servo holder e Y l a I I I 1 4 Remove entire air cleaner 5 Unscrew cable on throttle 3 Pull vent tube underneath the vacuum servo o t of the grommet Turn vacuum servo so that connection...

Page 479: ...ble REMOVING AND INSTALLING CABLE ON VACUUM SERVO 1 Prv cover off of vacuum servo Note Make sure cable is installed without sharp bends Cable should have approx 1 mm play on throttle mounting point Un...

Page 480: ...nd check for leaks 3 Visually inspect acwm hoses for bends or twisting 4 Check that electric connection on vacuum servo fits tight 5 Check function of microswitch on clutch pedal Switch must have swit...

Page 481: ...g the switch 3 Turn on ignition and press push button switch with engine stopped The vacwm servo should move the throttle uniformly to full load position This requires vacuum Note To avoid damaging th...

Page 482: ...attery voltage 5 Connect tester between terminals 10 and 12 Display 0 volt Push down lever on tempostat switch repeat a There should be battery voltage at terminal 5 2 Connect tester between terminals...

Page 483: ...14 ohms resistance value of vacuum red Display should move to infinite ohms switch interrupted 3 Connect ohmmeter between terminals 11 and 12 speed sensor Push car slowly or turn one rear wheel and h...

Page 484: ...STALLING STARTER 6 Remove mounting bolts l Disconnect battery Z Disconnect all cables to starter 3 Detach stabilizer 4 Remove clip from clutch hose bracket 5 Unbolt clutch actuating cylinder a Printed...

Page 485: ...MODELSONWARD CONTROLUNIT As of model year 88 the 928 models are fitted with an l Detach right hand side panel from center console electrically controlled tempostat 2 Remove mounting bolt 3 Remove cont...

Page 486: ...eft hand whekl arch inner panel 2 0pen multi pin plug holder and disconnect plug 3 Disengage cable 4 Press retainers together and push Bowden cable up out of holder 5 Remove footrest in driver s side...

Page 487: ...actuator complete with l Remove front left hand wheel arch holder inner panel 9 Unscrew attachment bolts Z Disengage cable 3 Press retainers together and push Bowden cable up out of holder 4 Disengage...

Page 488: ...cable check to ensure that it is routed free of kinks Adjusting Bowden Cable l Turn adjusting lever on actuator clockwise as far as it will go 2 Turn setscrew to adjust Bowden cable so that there is p...

Page 489: ...utomatic transmission If these checks do not reveal any fault continue by testing the multi pin plug of the control unit TEMPOSTAT CONTROLUNIT PIN ASSIGNMENT 1 Ter X 2 Not occupied 3 Switch off 4 Swit...

Page 490: ...oltmeter to ter 6 and ter 12 Reading 0 volts Press operating switch toward resume Reading battery voltage 6 Connect voltmeter to ter 8 and ter 12 Reading 0 volts Press brake pedal Reading battery volt...

Page 491: ...ct ohmmeter to ter 1 and ter 7 Reading 2 6 ohm 14 Connect ohmmeter to ter 5 and ter 6 Reading 30 40 ohm 15 Connect ohmmeter to ter 2 and ter 4 Reading 2 4 kohm 16 Connect ohmmeter to ter 2 and ter 3 R...

Page 492: ...lternator see Page 13 16 b Tightening torque of the fastening screws M 10 45 Nm a 4 Undo both nuts and the alternator adjust ment screw Loosen the bracket on the con sole swivel the alternator inwards...

Page 493: ...01 006 Remarks Centrifugal advance and vacuum retard control see note on next page Spark Plugs Type Model 928 Version Remarks Bosch A 145 T 30 0 7 0 1 mmp1ug Beru 145 14 3 A gap Control Unit Type Mode...

Page 494: ...to turn off the fuel pumps when engine reaches a speed of ap prox 6300 rpm This type of speed control is required since ignition failure could destroy the catalytic converter required for emission co...

Page 495: ...l distributor ignition cabira etc j If testing the ignition system 01 making engine adjustmcntr requires turning on the ignition dangerous voltage will he on the primary and secondary side of the enti...

Page 496: ...connected to ignition cable of cylinder number 1 r Unlike capacitor discharge ignition systems testing equipment e g tachometer can be connected to ignition coil terminals 1 and 15 of transistorized i...

Page 497: ...i 50 rpm Remove distributor and check it in a distributor test bench if specifications in points 5 and 6 cannot be held Note 1 Ignition must be off when connecting tester to ignition coil 2 The dwell...

Page 498: ...28 Ignition System 928 CENTRlFl GAL A VAK E CURVE FOR ISTRIBUTOH HTDC 200 150 10 50 0 ulstnh Si lff i i vr i V _ yYlii i 28 6 Distributor Sprcificatlons Printed in Germany...

Page 499: ...928 Ignition System 28 VACUUM RETARD CURVE FOR DISTRII UT R Printed in Germany Distributor Specificatiorls 2r...

Page 500: ...tor cap rotor and dust cap Detach vacuwn hoses and wires 3 Unscrew mounting bolt and remove distributor 4 When installing the distributor rotor make sure that it faces the cylinder 1 mark on distribut...

Page 501: ...II P 4 I 4 Loosen and pull out air cleaner lower section clamping bolt in intake branch Loosen air cleaner lower section bolts and remove air cleaner lower section to the right p Y _ I 5 Unscrew spark...

Page 502: ...vacuum unit 4 When installing engage hole of pull rod in pin on stator of transmitter This can be done more easily by turning rtator against left stop and holding in this position 3 Press up and remov...

Page 503: ...test values Note especially information concerning dangers of electronic ignition systems see page 28 3 Starter turns engine will not start or does not develop sufficient power 1 Connect spark gap te...

Page 504: ...Ohms Resistance of distributor rotor 5 k Ohms Spark at spark plug I repair secondary side t 3 Check ignition timing Timing correct IYe I adjust timing 4 Check fuel system Engine receiving sufficient f...

Page 505: ...0 45 ohm 0 6 ohm resistor 0 55 0 65 ohm F Ignition coil primary term 1 and 15 0 33 0 46 ohm Ignition coil secondary term 1 and 4 I 12 k Ohms Resistances value correct Y replace resistor 01 ignition c...

Page 506: ...age at term 15 at least 3 V at battery voltage of at least 11 volts measure at same time Voltage correct go to point 11 no c Check voltage drop at wires and connections on ignition switch resistors ig...

Page 507: ...rter Measured voltage must be same as battery voltage measured at same time Starting voltage good 1 yes L Eliminate break in supply line or contact 15a in starter relay 8 Measure sensor resistance inc...

Page 508: ...mechanical damage Visual inspection gap between rotor and stator Pull off sensor lines from distributor and repeat test on sensa system Resistance between 485 and 100 ohms 1 Y 0 Replace sensor line Re...

Page 509: ...ltage at ignition control unit plug terminal 15 against ground Voltage must be same as battery voltage Voltage Correct Yes 1 I 0 Check voltage drop in line from ignition switch to control unit and eli...

Page 510: ...against ground Voltage correct I Replace control unit 13 Check dwell angle short test on warm engine Dwell angle 25 39O at 1500 50 rpm Dwell angle 33 40 at 5000 _50 rpm Dwell angle correct ly Ino 28 1...

Page 511: ...ine power must be adequate If not there is a mechanical defect 14 Ignition failure a Disconnect tachometer 12 pin plug on in strument cluster right or plug C on central fuse relay panel Ignition failu...

Page 512: ...odel Y28 Version Remarks 928 60250300 Bosch No 0 221 122 001 With two ballast resistors 0 4 ohm and 0 6 ohm Version 928 602 032 03 Bosch No 0 237 405 010 Remarks Centrifugal and acwm advance and retar...

Page 513: ...nit Type Model 928 1 Version 928 60270202 Bosch No A 227 010 123 Remarks Transistor coil ignition The vacuum control of the distributor is changed from 140 240 range mbar to 360 470 mbar beginning wit...

Page 514: ...se Vacuum retard degrees of retard adjustmenr at idle speed re ard 928 M 28 13 14 23 BTDC at 3000 rpm ye Ye 750 f 50 8 to 10 BTDC at idle speed 29 to 34 BTDC at 6000 rpm Vacuum hose of CO 2 0 CO 1 8 t...

Page 515: ...nt is located in engine compartment I 7 1 1 j i I 5 Adjust ignition timing IO 23 before TDC al an engine speed of 3000 RPM Loosen and rum distributor to change ignition riming 6 Arrach vacuum hoses ag...

Page 516: ...cuum connerrions 1 Advance 2 Retard Idle speed vacuum available at connection 2 can be used to check ignition advance This requires connecting the vacuum hose from retard unit to the advance unit Afte...

Page 517: ...CURVE TYPE 928 from 1980 Models 0 500 1000 1500 2000 2500 3000 3500 Dirtriburar Shaft Speed rpm b VACUUM ADVANCE CURVE TYPE Y 28 from 1980 Models BTDC ATDC 100 200 300 400 500 Vacuum mbar b Printed i...

Page 518: ...28 Ignition System 928 VACUUM ADVANCE CURVE TYPE 928 f r o m 19 8 1 M o d e I s BTDC ATDC 100 Vacuum mbar 200 300 500 600 a a 28 26 Checking Distributor VI 1982 Printed In Germany...

Page 519: ...ks With two ballast resistors 0 4 ohm and 0 6 ohm a Distributor Type Model Version Remarks 928 S 92860203206 Bosch No 0237401018 Centrifugal and vacuum advance control Distributor rotor without speed...

Page 520: ...28 Ignition System 928 Control Unit Type Model 928 Version 928602 70202 Bosch No A227010123 Remarks Transistor coil ignition a a a 28 28 Ignition Components Printed in Germany...

Page 521: ...EGINNING WITH 1983 MODELS Ignition timing without vacuum 20 BTDC at 3000 rpm Idle speed Centrifugal control without vacuum Vacuum control at idle speed 650 f 50 rpm 4 to 8 BTDC at idle speed 24 to 28...

Page 522: ...928 Ignition System 28 THE USA PAGES 28 31 TO 28 34 HAVE BEEN LEFT BLANK Printed in Germany VI I I 1984 28 30 a...

Page 523: ...928602 03300 Bosch No 0237404013 92860203206 Bosch No 0 237 401 018 Remarks Centrifugal and vacuum advance and retard control Distributor rotor with speed governor for 6500 260 rpm Centrifugal and va...

Page 524: ...28 Ignition System 928 Control Unit Type Model 928 Version 92860270202 Bosch No A227010123 Remarks Transistor coil ignition l 28 32 Ignition Components Printed in Germany...

Page 525: ...BEGINNING WITH 1983 MODELS Ignition timing without vacuum 20 BTDC at 3000 rpm Idle speed 650 f 50 rpm Centrifugal control 4 to 8 BTDC at idle speed without vacuum 24 to 28 BTDC at 5000 rpm Vacuum cont...

Page 526: ...TYPE 928 S fro m 19 8 3 M o d e I s USA Canada Japan 0 500 1000 Distributor Shaft Speed rpm VACUUMADVANCECURVETYPE928S from 1983 Models USA Canada Japan BTDC 150 5 ATDC 100 200 300 400 500 Vacuum mbar...

Page 527: ...1 Distributor I Type Model I Version 928s 1 928602011 02 928 S USA Japan a L Spark Plugs 928602 032 07 Bosch No 0 237 401 019 I I Remarks Double distributor 2 x 4 cylinders with mutual drive shaft Onl...

Page 528: ...00 spare part 928 618 123 02 LH Jetronic control unit 928 S FGR R o W 928 618 124 00 spare part 928 618 124 03 EZF control unit Australia New Zealand Switzerland Sweden Hongkong 928 618 124 02 spare p...

Page 529: ...stem 28 l Control unit Final stage Type Model 928s 928 S USA Japan Version 928 602 706 01 928 602 702 02 Remarks Transistor ignition 2 pieces Transistor ignition a Equipment table 28 37 Printed in Ger...

Page 530: ...n of your country when repairing and testing ignition systems Always turn off the ignition or disconnect the battery when working on the ignition system Such jobs include the following Connecting engi...

Page 531: ...2 Engine temperature sensor double NTC 3 Intake air temperature sensor 4 Speed and reference mark sensors 5 Throttle switch 6 Power supply relay 7 Final stages 8 Distributor 9 Ignition coils 10 Igniti...

Page 532: ...ECTRONIC PERFORMANCE CURVE CONTROLLED IGNITION SYSTEM 6 452 1 d I c Pykj I ii I I i 4 t i 1 llai t I 13 l ky z 10 12 11 20 i i I i I y j i 1 I i c I I 1 t j I 1 r A I NJ 1 l 28 40 Electronic Ignition...

Page 533: ...3 Bolt 4 4 Washer 4 5 Control unit 1 6 Bracket for control 1 units 7 Bolt 1 8 Washer 1 9 Speed reference 1 mark sensor IO I Plug for speed 1 1 reference mark sensor 2 Bracket 1 3 Bolt 1 4 Washer 1 5...

Page 534: ...head screw 30 Washer 31 Holder 32 Cable holder 33 Distributor 34 Socket head screw 35 Distributor rotor 36 Dust cap 37 Seal L Qty Qty 1 10 2 1 1 1 1 1 2 2 2 1 1 1 2 2 2 2 1 10 2 1 1 1 1 1 2 2 2 1 Not...

Page 535: ...asher Holder right Hexagon nut Bolt Ignition coil Spark plug connector Spark plug Hex head screw Washer Holder for ignition cables Holder Holder Plug Temperature sensor I I Seal Plug Throttle switch T...

Page 536: ...on ignition coil high voltage distributor ignition cables etc Piece of wire must be inter ference suppressed with a shielding sleeve of at least 2 k ohms 8 Never replace specified ignition coil with a...

Page 537: ...plug Take off vacuum connection REMOVING AND INSTALLING TRANSISTORIZED IGNITION CONTROL UNIT Removing 1 Take off left front cover by disengaging locks on both sides with a screwdriver and taking off...

Page 538: ...REFERENCE MARK SENSOR Removing 1 Remove air cleaner 2 Disconnect plug 3 Remove screw Pull out sensor while turning back and forth at same time Note Sensor distance cannot be adjusted The sensor distan...

Page 539: ...tor and pull out of engine block 3 Turn distributor rotor that it points to housing notches after installation Installing Note 1 Set cylinder 1 at TDC 2 Check seal on distributor replacing if necessar...

Page 540: ...28 Ignition System Dismantling and assembling distributor As of MY 84 Engine Type M 28 21 22 28 48 Dismantling and assembling distributor Prinied In Germany M IX 1992...

Page 541: ...utor and pull out of engine block 3 Turn distributor rotor that it points to housing notches after installation Installing Note 1 Set cylinder 1 at TDC 2 Check seal on distributor replacing if necessa...

Page 542: ...m l REMOVING AND INSTALLING TDC SENSOR Removing 1 Remove air cleaner 2 Detach test cbnnection 3 Unscrew TDC sensor and pull it out of housing k 3 3 G y R m a 28 48 Removing and Installing TDC Sensor P...

Page 543: ...section Seal cvy 1 1 2 2 2 1 1 2 2 1 2 1 1 Toothed belt Part No 928 602 541 00 Removal Pull off along with pulley Pull off Pull off Range washer and pulley prior to removal L l nstallatlon Must always...

Page 544: ...ert Schrem Postfach 1504 D 7928 Giengen 1 Assembly Set up distributor shafts In basic position Fit pulley and toothed belt After assembly the distributor rotors must point towards the housing notches...

Page 545: ...em 28 Removing and installing TDC sender Removal 1 Remove air cleaner assembly 2 Undo test connection 3 Unscrew TDC sender and pull out of housing a Removing and installing TDC sender 28 48 PrIMed In...

Page 546: ...t leads made locally for tests on a multiple pin plugs of control units and plug connections with same contact version tlat contacts f A 1 Highly flexible lead 2 Alligator clips standard 3 Flat male p...

Page 547: ...ts electronic ignition LH injection 8 Temperature sensor I I 9 Temperature sensor I 10 Fuel line 11 Fuel injectors right 12 Blowoff switching valve 13 Ignition control unit 14 Ignition controls 15 Spe...

Page 548: ...or electronic ignition and LH control units 2 LH Jetronic relay XVI power supply for LH control unit and intake air sensor 3 Fuel pump relay XVI I power supply for fuel pump auxiliary air regulator an...

Page 549: ...Erratic idling Poor engine pickup Engine misfiring High fuel consumption Poor engine output Engine hesitation Engine knocks when accelerating POSSIBLE CAUSES OF DEFECTS 1 2 3 4 5 6 7 8 9 10 X x x X X...

Page 550: ...e running 1 Ground connection between engine and body at bottom right 1 2 Output ground connection on camshaft housing near blowoff switching valve 1 l Ground connection of ignition control units next...

Page 551: ...c ignition control unit To remove push back lock and swing out plug 2 4 Plug connection on temperature sensor II engine temperature 0 2 2 Plug connection on intake air sensor 2 5 Plug connection on te...

Page 552: ...ug on electronic ignition control unit 2 Turn on ignition Measure voltage between terminals 25 and 12 2 1 11II I 20 v8 II I II I a a 778 5 r Only connect tester with help of test leads Specification b...

Page 553: ...now battery voltage replace electronic ignition relay VI I I 2 Connect positive tester lead on terminal 7 with help of locally made test lead and negative tester lead on terminal 19 of electronic igni...

Page 554: ...al 19 on the electronic ignition plug or on the speed reference mark sensor plug connection TEST POINT 4 Pressure Sensor Integrated in Electronic Ignition Control Unit Connect adjustable ignition timi...

Page 555: ...pplying vacuum to the control unit check vacuum hose between electronic ignition control unit and intake air distributor for leaks TEST POINT 5 Temperature Sensor I Intake Air Temperature 1 Check plug...

Page 556: ...ts 2 Connect ohmmeter between terminals 23 and 12 of disconnected electronic ignition control unit plug Specifications 0 Cl 32 F 4 4 to 6 6 kn 15 to 30 C 59 to 86 OF 1 4 to 3 6 kn 40 Cl 104 OF 0 9 to...

Page 557: ...t Switching over must take place already with a throttle gap of approx lo 2 Full Load Contact 2 1 Connect ohmmeter on electronic ignition plug between terminals 17 and 12 Throttle closed inf ohms Thro...

Page 558: ...l 18 on plug with a piece of wire This should retard the ignition timing by approx 10 3 Connect idle speed contact terminal 2 with ground Engine should begin to surge i e injection signal will be cut...

Page 559: ...ning Resistance value 1 k ohm Holding hooks must engage firmly when installing 3 Check distributor rotor Shielded resistance 1 k ohm Check visually for damage and tight fit 4 Check spark plug connecto...

Page 560: ...ppressor on pertinent distributor terminal 4 8 Check control signal for ignition control units 8 1 Pull off multiple pin plugs on ignition control units ff f 5 _ vl l g Q L f I 7 i 1 8 2 Connect oscil...

Page 561: ...f misfiring has been eliminated check alternator and regulator TEST POINT 9 Octane Loop An additional single pin plug is located on the bottom of the multiple pin plug for the electronic ignition cont...

Page 562: ...SA 944602 11500 Bosch No 0221 118322 2 ignition coils without ballast resistors Distributor Cap Type Model 928 S USA Version 928602211 01 Bosch No 1 235 522 395 Remarks Only high voltage distribution...

Page 563: ...928s USA 928 S USA Mod 85 Mod 86 Final stage control unit 928 618 124 05 EZF ignition 928 618 123 03 LH Jetronic control unit 928 618 123 04 Spare part 928 618 123 04 Remarks Transistor ignition contr...

Page 564: ...MY 88 Version 928 618 124 10 928 618 124 11 928 618 124 11 928 618 123 10 928 618 124 12 928 618 124 14 928 618 124 15 928 618 123 11 Remarks EZK control unit Spare part LH Jetronic control unit EZK c...

Page 565: ...ntake air distributor and clamp on vacuum hose 2 Unscrew spark plug with a standard wrench car tool set has a special spark plug wrench 3 Lubricate spark plug threads with a light coat of grease e g w...

Page 566: ...B 42 I 070503 1 gem42 m 705 1 Do 3 4 2 m 0503 1 DO6 m 7 5 31 R o W without catalytic converter manual transmission R o W without catalytic converter automatic transmission R o W with catalytic convert...

Page 567: ...transmission Rest of world without catalytic converter automatic transmission ox 6 4 2 I 070503 1 l fjzz 162 24 1 resistor 150 n Rest of world USA with catalytic converter manual transmission Rest of...

Page 568: ...el well 2 Connect voltmeter sleeves to terminals 1 and 2 3 Switch on ignition Display approx 5 V 4 Connect ohmmeter plugs to terminals 1 and 2 Note The switch Is checked with the engine running Apply...

Page 569: ...2 3 Switch on Ingnition Display approx 5 V 87 4 1 4 Connect ohmmeter plugs to terminals land2 26 72 l Checking the transmission protection switch automatic tmnsmission Printed in Germany XXII 1989 The...

Page 570: ...SPORT Control units Type I Model Version Remarks 928 S 4 Club Sport 928 618 124 13 EZK control unit Cut off speed as from Mod 89 928 618 124 16 at 6775 Vmin 928 S 4 Club Sport 928 618 123 12 LH Jetro...

Page 571: ...S of MY 92 928 GTS 5 4 I Engine Type M 28 49 50 Control units and spark plugs Type I Model 928GTS 928GTS 928 GTS Verslon Remarks 928 618 124 30 EZK control unit cutoff speed 6600 rpm 928 618 123 30 LH...

Page 572: ...rature sensor with standard tool e g Hazet 4550 l 1 I I Installing 1 Join connection from above and clip in 2 Apply a film of Molykote HTP white paste to the thread of the union nut Tightening torque...

Page 573: ...tion circuit monitoring 1 Terminal 31 ground 2 Ground must be present at terminal AL when the ignition is switched off 3 Battery voltage must be present at terminals 87 15 Al and A2 when the ignition...

Page 574: ...minal 61 less than 3 5 Possible test Measure voltage Display Battery voltage Measure resistance to ground Display 0 D Measure resistance between El and E2 Measure voltage Display Battery voltage Measu...

Page 575: ...LH EZK Diagnosis Troubleshooting y 928 54 928 GT Dr Ing h c F Porsche Aktiengesellschaft...

Page 576: ...ad contact 13 Engine temperature sensor II 14 Air mass sensor I 5 Idle speed control activation 16 Oxygen regulation control rich 17 Oxygen regulation control lean 18 Open circuit at oxygen probe 18 F...

Page 577: ...the equivalent national regulations must be complied with whenever work on or inspection of the ignition system takes place The ignition must always be switched off ignition or power source before wo...

Page 578: ...erminal 4 while the engine is running l There must be no electrical flashover from coil terminal 4 to coil terminals 1 and 15 or the control unit could be damaged beyond repair To avoid destruction of...

Page 579: ...fferent instructions for connection to the vehicle these instrucitons should always be followed carefully to ensure correct tester connection The following sensor signals can be checked with the oscil...

Page 580: ...or the battery are disconnected the fault memory will be erased Diagnostic tester To call up the contents of the fault memory on 1988 model cars a new diagnostic taster special tool number 9268 was d...

Page 581: ...always indicate that the component in question is defective It can also suggest a fault in the corresponding control unit or the connecting leads paths between the component and the control unit No t...

Page 582: ...elay XXV which pre viously had a burn off function only This change was necessary to permft self diagnosis from the 1988 model year on From the 1990 model year on the connections to the central electr...

Page 583: ...nverter ECE automatic transmission no catalytic converter Worldwide automatic transmission with catalytic converter Worldwide automatic transmission with catalytic convener Fuel grade 91 octane RM wit...

Page 584: ...6 5 z 5 z E s E 5 E E 5 G s b f E I x it sl f2 2 k s 2 0 E E 2 2 i 5 Et 5 E 6 m 5 2 k 2 52 z a 9 3 2 8 0 E 0 e m CD r co 0 0 x x Irregular idling Poor pick up Misfiring High fuel consumption x x x x x...

Page 585: ...2 x x Ei rm P e 2 5 I 2 x x II ZZ 8 is 5 cc ill 2 _m 2 a Ei 2 9 2 m 6 iii E a x 6 w E g z F v m a E w 2 F G 5 5 2 5 I Ei I E m Y M E G z 0 II III z E 6 I c b E 2 II D 0 x x x x x x x x x x x x x x x x...

Page 586: ...LH control unit Fault memory LH control unit 928 S4 GT Idle contact 0 en E circuit 5 art oxygen sensor control lean Engine temperature ymr 2 Injector circuit switched off Ignition circuit monitoring...

Page 587: ...l Intake pipe resonance flap Power supply terminal 15 EZK relay XVI 87 OtXlO 89 I El la I J lo si I I 3 Im I Sl El I IO3 I Ki lo I 19 I I r 31 I2 I2 I I j 2 I I 2 Isr Sl Ir cm r 31 12 90 C Speed from...

Page 588: ...Select the test step and depress the accelerator pedal 9268 display Idle speed contact closed Idle speed contact open 9268 display 1332 idle speed contact closed 0000 idle speed contact open No displ...

Page 589: ...minals 1 and 2 of the throttle valve swftch using test leads Display Throttle valve closed 10 Q n Throttle valve opening angle 1 m 51 c3 ia Idle speed contact Q Open circuit Fault code l 15 Test proce...

Page 590: ...23 22 21 2Q 19 w 16 17 16 15 14 13 12 11 10 9 6 7 6 5 4 3 2 1 j 4 4 Display Throttle valve closed mS1 Throttle valve after opening by approx two thirds of its travel 10R If the full load contact valu...

Page 591: ...30 C 1 4 3 6kS1 40 C l l 3 k J 80 C 250 2900 100 C loo 210n If the values are not reached check directly at the engine tempera ture sensor Do not connect both contact tabs to the ohmmeter but chect ea...

Page 592: ...ass sensor and connect the voltme ter to plug terminals 2 and 4 using the test leads Use the test leads to connect terminals 17 and 21 on the LH control unit plug after it has been disconnected Displa...

Page 593: ...engine by switching off the ignition After a delay of approx 4 seconds the hot wire must glow for approx 1 s burn off function e Emergency operating program The emergency operating program stored in t...

Page 594: ...With the engine running the following display must be seen Test point 7 Oxygen regulation 0 Control rich Fault code l 23 Frequency approx 100 Hz If there is no audible pulse in spite of the power supp...

Page 595: ...V Disconnect the oxygen sensor plug close to the central electrics Connect voltmeter at the sensor end to the single plug pin and ground Test connection 1 Sensor voltage 2 3 Sensor heating Start the...

Page 596: ...heck its coding see testing plan page D24 28 8 before replacing it The ignition circuit monitoring relay is mounted on the retaining plate for the LH and EZK control units If an ignition circuit fails...

Page 597: ...h a test lead Display battery voltage Checking current path according to wiring diagram b Power supply through LH relay XXV At the LH control unit connect a voltmeter to terminals 17 and 9 and run to...

Page 598: ...Above the central electrics At the air mass sensor a g pin plug only 5 contacts are occupied in the plug housing At temperature sensor II a Z pin plug At the engine speed reference mark sen sor a 3 p...

Page 599: ...rt the engine with the starter motor A control signal must be visible on the oscilloscope Test point 16 Injector valves Control system V Q If the engine can be run pull off the injector valve plugs on...

Page 600: ...in accordance with the manufac turer s instructions Important Tester leads must not have any contact with ground Start the engine If the injection output stage is working correctly and the tester con...

Page 601: ...res sure value at the test pressure gauge nomi nal value 3 8 0 2 bar Test pressure 3 3 0 2 bar Maximum permissible pressure drop with engine warm 0 5 bar In 30 minutes If pressure drops below the spec...

Page 602: ...cluster Using a felt marker or similar mark a central line on the surface of the flap shaft this makes it easier to detect opening movement Start the engine the flap will open and close again as the...

Page 603: ...he tester 1 1 1 I t Test point 20 Fuel tank venting V When the engine is at regular operating temperature and the throttle valve is opened idle speed contact the solenoid valve is acd vated by the LH...

Page 604: ...of the two leads K and L If no diagnosis Is possible the following tests must be carried out 1 Continuity test refer to wiring diagram a L Pin 7 IQ pole diagnostic socket Pin 16 LH plug adK Pin 6 19...

Page 605: ...upply and after each inspection Idle speed control value with engine at regular operating temperature GT 775 k 25 min S4 675 25lmin b Idle speed CO value on cars without cata lytic converter The CO le...

Page 606: ...pedal with the engine off and the lgni tion on for 3 seconds until the Malfunction Indicator Lamp flashes Then remove foot from accelerator If no fault is recorded i e no warning came from the indicat...

Page 607: ...gs EZK control unit 4 Idle speed contact 5 Full load contact 6 Engine temperature sensor II 7 Idle and full load contact 7 Load signal 7 Transmission protection switch 7 Knock sensor I 8 Knock sensor...

Page 608: ...3 5 8 2 2 E 6 m v s E 2 2 2 0 2 2 2 E x 9 I N 02 Fi E L52 I L x Test point Engine will not start Engine hard to start Irregular idling x x x x Poor pick up x x x x Misfiring x x x High fuel consumpti...

Page 609: ...t t 8 x x D t 2 HI 8 F s 2 z 5 iz z2 2 i F 5 w 2 x x x F Z 0 5 E 5 0 75 s E EJ 2 x x x x x x x x 111 k VI 5 a 2 E m zi c E z _ x x x x x x x x c 1 F m Y u x Fi 2 z 0 II 111 5 5 E 6 II G z 5 E s II...

Page 610: ...Llsignal 1 temperature sensor 2 1 Fault memory EZK control unit Fault memory EZK control unit 928 S4 GT Idle Or full load contact 1 2 Transmission safety switch I Knock sensor 1 I 1 Control unit 1 fa...

Page 611: ...7 XXII Diagnosis plug term 11 Ignition pulse to control unit 1 left Permanent positive 30 J 7 El El zI I El 31 I I I I I SGJ 76 I 21 I 3 I I i 90 ct C C C C Diagnosis K lead Shielding Knock sensor 1 S...

Page 612: ...ontrol units Using test leads connect ohmmeter between terminals 8 and 18 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 2Q 19 Display Throttle valve closed Throttle valve opening angle z IOR l mQ If th...

Page 613: ...full load contact closed No display Disconnect the plug from the EZK and LH control unit and connect the ohmmeter with terminals 18 and 26 using test leads Display Throttle valve closed ms2 Throttle...

Page 614: ...5 Load signal Fault code 2 21 To identify a ground short Test as stated in test point 1 or 2 EZK test plan From LH control unit terminal 25 a lead runs to EZK control unit ter minal 9 and transmits a...

Page 615: ...ion P or N m Ohm switch open Display in position D 1 Ohm switch closed If these values are not reached measure directly at the switch or renew Knock sensor I sensor signal is not plausible Check Knock...

Page 616: ...ir cuit Test point 9 Control unit knock sensor Fault code 2 33 This fault causes the ignition to be retarded by 6 Renew the control unit Test point IO Hall signal Fault code 2 34 To check the Hall sig...

Page 617: ...unit plug connect the voltmeter with terminals 18 and 35 by means of the test leads Display battery voltage No display check according to wiring diagram b Power supply through EZK relay At the contro...

Page 618: ...r lead to control unit plug termi nal 6 u T 35 34 33 32 31 30 2 9 28 27 26 25 24 23 22 21 20 19 0 1 ii I 2 18 17 16 15 14 13 12 11 10 9 6 7 6 5 4 3 2 1 I 4 Crank the engine with the starter motor The...

Page 619: ...est point 14 ignition circuit monitoring refer to test point 10 LH test plan If the exhaust gas temperature changes for in stance on account of misfiring the faulty injec tion circuit is shut down The...

Page 620: ...camshaft for cylinders 5 8 5 6 34 The high tension power supply for ignition cir cuit I comes from the coil installed at the front right the high tension power supply for igni tion circuit II comes fr...

Page 621: ...esistor 3 kQ Inspect for damage tracking or oxidation c Activating the high tension side To speed up troubleshooting in the ignition sys tem the ignitrion trigger signal can be simu lated To do this d...

Page 622: ...gnosis socket Pin 7 EZK plug K Pin 8 19 pole diagnosis socket Pin 1 EZK plug 2 Ground short test refer to wiring diagram U The voltage at Pin 7 19 pole diagnosis socket must be 8 V with the ignition s...

Page 623: ...Workshop Manual DR ING h c F PORSCHE Aktiengesellschaft...

Page 624: ...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 625: ...Controls Case Automatic Transmission Gears Valve Body Differential Transaxle System Front Wheel Suspension Rear Wheel Suspension Axle Shaft Wheels Tires Alignment Antiblock System Brakes Mechanical B...

Page 626: ...tch diamenter and dowel pin centered Clutch linkage versions Ball stud versions Replacing ball stud Removing and installing clutch housing Checking clutch discs Checking clutch pressure plate Checking...

Page 627: ...ng Removing and installing final drive housing Removing and installing rear transmission case and rear converter housing Disassembling and assembling rear converter housing Disassembling and assemblin...

Page 628: ...l transmission 39 65 General 5 speed manual transmission type G 28 30 0201 Technical data 30 0203 Torque specifications 30 0205 Manual Transmission Controls Case Disassembling and assembling transmiss...

Page 629: ...tial disassembling and assembling 40 lock up 39 212a Dismantling and assembling the proportional slip differential 39 212i Dismantling and assembling lim slip differential with Valeo friction discs 39...

Page 630: ...928 General 30 a FIVE SPEED MANUAL TRANSMISSION TYPE G 28 03 a a This transmission was installed worldwide in 928 cars UP to June 13 1980 a Primed in Germany VI 1982 Technical Data 30 01...

Page 631: ...to transmission type G 28 03 but has the following modifications 1 Transmission moved forward by 30 mm 2 Drive shaft longer 3 Transmission case with modified ribs and hexagon head bolts instead of st...

Page 632: ...PE G 28 08 i L a t 3 C C a Transmission Type Installed In G 28 08 928 S 1983 Model This transmission is similar in design and repairing procedures to transmission type G 28 05 but the ratios are diffe...

Page 633: ...M 12x 1 5 5 8 19 14 Bolt M6xl 8 8 9 7 12 9 16 12 Bolt M6xl 8 8 9 7 Ring gear Bolt M 12 x 1 25 12 9 165 119 Side covert Bolt M8x 1 25 8 8 22 16 transmission case Rear cover Nut MEx1 25 8 8 22 161 tran...

Page 634: ...Central tube clutch housing Bolt M 10x 1 5 8 8 43 31 Selector rod bearing any Iselector rod coupling Bolt M 8 x 1 25 25 18 Ball socket guide tube Nut BM 10 25 I181 Guide tube bracket to body or centr...

Page 635: ...without hypold offset 12 33 i 2 7500 up to Jan 13 1981 11 30 i 2 7272 since Jan 14 1981 Multigrade gear lube SAE 75 W 90 API Classification GL 5 or MIL L 2105 B Oil capacity approx 3 8 liters 21 Numbe...

Page 636: ...50 2 z z vor 33 20 bivor 2 5882 1 650 4 2705 2 2727 1 650 1 oooo 3 7499 Final drive Drive pinion without hypoid offset Final drive ratio Transmission oil 15 34 i 2 2666 Multigrade gear lube SAE 75 W...

Page 637: ...g central tube Bolt M 10x 1 5 8 8 Engine clutch housing Bolt M 12 x 1 5 Clutch housing cover Bolt M8x 1 25 Clutch flywheel Bolt MEx1 25 8 8 8 8 8 8 Ball stud clutch housing Ball stud Flywheel cranksha...

Page 638: ...3 21 1 Front converter housing 2 Rear converter housing 3 Automatic transmission 4 Rear transmission case 5 Final drive Transm TWX 1 Installed In A 22 01 928 from 1980 models A 22 02 928 19780979 mode...

Page 639: ...MATICTRANSMISSION 1 Front converter housing 2 Automatic transmission 3 Final drive Transmission Type I Installed In A 28 01 928 S standard from 1983 models 30 08 Technical Data Transmission Type A 28...

Page 640: ...x1 25 8 8 19 23 14 17 Clutch housing Bolt MlOxl 5 8 8 39 46 central tube 28 33 Central tube Bolt M 10x 1 5 10 9 54 64 transmission 39 461 Flange central shaft Bolt M 10x 1 5 12 9 80 58 Bolt double cla...

Page 641: ...Nm ftlb Bearing assembly rear transmission case Pinion output shaft Transmission without fixed governor see page 39 24 a Bolt M8x1 25 10 9 27 32 20 23 Nut M 26 x 1 5 L 35 v 200 240 145 174 Pinion out...

Page 642: ...without hypoid offset 1Z 33 2 750 2350 200 rpm 197811979 mod 2470 200 rpm from 1980 models Converter ratio Final drive oil capacity 2 00 Approx 2 liters Z 1 US qt of hypoid gear lube API classificati...

Page 643: ...ter Automatic transmission Type A 28 01 Fully automatic four speed planetary gear transmission Drive pinion without hypoid offset 15 33 i 2 2000 2200 2600 rpm i 2 12 approx 3 liters of hypoid gear lub...

Page 644: ...ushed over the pin 2 without any load being present Then preload the pushrod by rotating by one turn and lock with nut 3 To boost foot pressure a boost spring is fitted to reduce the pedal force requi...

Page 645: ...inspect position of release lever The wear limit has been reached for cars up to and including 1982 models when front edge of lever just appears in inspec tion hole Beginning with 1983 models there w...

Page 646: ...rew on clutch slave cylinder until escaping fluid is without air bubbles Depress clutch pedal several times during this step 3 If necessary air still in system operating travel too Press push rod into...

Page 647: ...30 Clutch Controls 928 REMOVING AND INSTALLING CLUTCH PEDAL 2F 3 13 19 1 11 1 16 30 2b Removing and Installing Clutch Pedal VII 1983 Printed in Germanv...

Page 648: ...er 1 Replace if necessary 6 Washer 1 7 Shaft 1 Coat with multi purpose grease 8 Retainer 1 Replace if MXSSXy 9 Washer 1 10 Guide rod 1 Insert assembly clutch power spring wire see page assy 30 2 11 Re...

Page 649: ...2 bl 2 mm thick between two pedals 15 Clutch pedal 1 Spacers pedal adjustment are available 16 Bushing 2 Replace if necessary 17 Bushing 1 Replace if MXSSXy 18 Bushing 1 Replace if necessary 19 Stop...

Page 650: ...spring has an assembly bore Operate clutch pedal far enough press down until bore has cleared the bearing Insert 3 mm dia wire through bore in this positionl to take spring force off of pedal 4 Remove...

Page 651: ...be pushed in fully if surfaces on bearing shaft and console are aligned 3 Place complete clutch power spring guide rod in console and mount on clutch lever 4 Take assembly wire out of guide rod and mo...

Page 652: ...clutch pedal enough press down until bore has cleared the bearing Insert 3 mm dia wire through bore in this position 4 Remove complete clutch power spring guide rod This requires removing the retainer...

Page 653: ...pedal to final position 5 Mount clutch push rod on pedal Check push rod adjustment and correct if required 3 Spring retainer 4 Washer 5 Winged nut 6 Guide rod 7 Bearing sleeve 2 Adjust clutch power s...

Page 654: ...clutch housing On cars with LH Jetronic pull speed reference mark sensor for electronic ignition out of crankcase upper section while turning back and forth after loosening the screw 3 Remove lower bo...

Page 655: ...each other for installation later For dowel pin centered clutches drive the cylindrical pins in direction of pressure plate with a punch far enough so that they are beyond the centering bore of the fl...

Page 656: ...ft I and remove downward 9 Unscrew the clutch mounting bolts one after the other by 1 to 1 l 2 turns until pressure is removed from the pressure plate Disconnect release lever at ball stud by pushing...

Page 657: ...e are offset 180 opposite each other 4 Note marks when installing pressure plate intermediate ring and flywheel Guide centering pins of a dowel pin centered clutch into the flywheel Beginning with 198...

Page 658: ...direction of pressure plate This alone will guarantee proper function of the clutch and stop brackets 1 Intermediate ring housing 2 Intermediate ring stop 3 Adjusting element 4 Fork 5 Gap of 0 7 to 1...

Page 659: ...nifolds and detach air injector 6 Remove cover from clutch housing 7 Remove clamping sleeve cap screws and push sleeve back along central shaft II If long clamping sleeve is fitted remove plug in cent...

Page 660: ...sleeve are fitted with out grease and must not be greased elther when repairs are made in this area Installing 1 Install pre loaded pressure plate with driven plate in clutch housing center drive plat...

Page 661: ...rear of the flywheel en gine side through the bore to the centering pin approx 4 mm 7 Insert slave cylinder into clutch bell housing and tighten cover Then fit slave cylinder into place 30 66 Removing...

Page 662: ...928 Clutch Controls 30 iii Ar I Printed inGermany IV lq80 Disassembling and Assembling Clutch Diameter Centered 30 I...

Page 663: ...cate pre load washer in area no 12 and no 15 with Optimoly HT 8 Clutch disc II 1 Inspect thin coat of Hub length spring loaded Optimoly HT on 20 mm 0 85 1 15 mm splines watch posi tion to no 10 page 3...

Page 664: ...d Coat with solid white or present paste AOS version 1260006 Press in with VW 421 17 Bolt 6 18 Washer 6 Replace if necessary 19 Starter ring 1 See note After installing give teeth light coat of Optimo...

Page 665: ...30 Clutch Conrrols 30 10 Disassembling and Assembling Printed in Germany Clutch Dowel Pin Centered...

Page 666: ...Pressure plate with 1 See note Check for wear three centering bores Give preload washer light coat of Optimoly HT in area of no 12 and no 15 8 Clutch disc II 1 spring loaded Inspect Lubricate See pag...

Page 667: ...slave cylinder areas for piston rod with release bearing solid white paste with MO 15 Washer 1 Position correctly 16 Ball socket bushing 1 Position correctly Coat with solid white paste AOS 1260006l P...

Page 668: ...changed the dowel pin centering of the clutch in such a manner that the intermediate ring can now only be installed in correct position to the flywheel Survey of Changed Parts Description Up to Dec 19...

Page 669: ...I I Z tW 928 116 011 24 Liner springs with each 2 spring plates 0 85 1 15 mm Hub length 20 mm 928 116 011 27 or 928 116 011 33 Liners riveted alternately with only every second rivet Gap between liner...

Page 670: ...ined as follows Press down clutch ring from starter ring side against stop Determine gap distance on guide with a feeler gauge blade New version at least 1 2 mm Old version at least 1 O mm 4 Short dri...

Page 671: ...8 116 011 28 or 928 116 011 34 Central shaft I 928 421 235 12 928 421 235 13 or 928 421 235 16 Release bearing tube 928 116 087 13 or 928 116 087 11 modified Modified see remarks Present Modified Sinc...

Page 672: ...mes installed together with new clutch parts The modified central shaft 928 421 235 13 was replaced with central shaft 928 421 235 16 hard nicle plated same size asfrom June of 1983 Central shaft 928...

Page 673: ...out down ward without interference Preload pressure plate carefully until 4 mm thick locally made wire tool can be slid underneath heads of mounting bolts 1 r 9 E 1 c t ca 32 l Assembling 1 Install d...

Page 674: ...ressure plate in area of release bearing with Optimolv HT Mount release bearing with washer and release lever on pressure plate Gap of circlip should be between retainer on release bearing or offset t...

Page 675: ...central shaft I fl Pressure plate and intermediate plate are also marked with dots of white paint residual unbalance heavy side which are mounted offset 180 opposite This must be con sidered when repl...

Page 676: ...prevent turning Part Description 1 Release lever 2 Bushing 3 Ball stud see page 30 21 4 Washer 5 Release bearing Original Version b small width snap ring 10 mm dia Without turning lock b large width A...

Page 677: ...ry Heat a removed clutch housing up to about 250 C 480 OF to facilitate removal of the ball stud 2 Clean threads with for example Loctite Cleaner 0706 prior to screwing in a new ball stud 19 mm dia in...

Page 678: ...ounting bolts for central tube to clutch housing and clutch housing to engine 3 Remove both mounting bolts of transmission mounts on rear axle cross member Tl 7 4 Apply tire iron con transmission and...

Page 679: ...ness of clutch discs Measure distance from lining to highest point rivet on all four linings Replace clutch discs when less than 0 3 mm Note See page 30 14 for former version clutch discs Since clutch...

Page 680: ...e plates with damaged or loose rivets CHECKING CLUTCH INTERMEDIATE PLATE Clutch intermediate plates have not been designed to permit overhauling or repairing Checking is limited to dry cleaning and re...

Page 681: ...928 Clutch Controls 30 a OVERHAULING CLUTCH SLAVE CYLINDER a Printed in Germany VI 1982 Overhauling Clutch Slave Cylinder 30 25...

Page 682: ...cylinder Qty 1 1 1 1 1 1 1 1 1 1 Removing Note When Installing Replace concave side faces in make sure of proper fit Replace coat very slightly with brake cylinder paste Position correctly Special In...

Page 683: ...d riied head side 1 Lining 2 Clutch disc lining spring Dimension X is approx 1 4 mm for new clutch discs If dimension X is down to 0 3 mm the clutch disc is worn and must be replaced Please note that...

Page 684: ...nverter 32 e TOOLS Ilo Description Special Tool Remarks 1 Transmission holder 9162 2 Deprh gauge __ Sandaid roul 3 Grip plare 9301 I Mandrel I310 e Printed in Germany 111 1 1 Removing and Installing C...

Page 685: ...32 Torque Converter 928 K P PI _i NY P T a m iglz m lL L I a3 co 32 2 Removing and Installing Converter Printed in Germany...

Page 686: ...ne holder 1 7 Nut 8 8 Front converter housing 1 3 Torque converter 1 Remove upward Replace when wear carefully with is excessive I ATF Special Tool 9301 has meral parricks Lubricate input flange and s...

Page 687: ...ench when loosening or tightening see page 31 14 6 Note installed depth of conwrier iabout 4 1 mm for reinstalling II a i Jyi rs _ K y g l l 3 Install lransmission in assembly stand wirh Special Tool...

Page 688: ...s mission rorque converter will have 1 be re placed 4 Run in conveyer carefully turning it back and forth slighrly Also be careful nor I damage seal while running in converter 1 Mount Special Tool 930...

Page 689: ...tic drain plug for differential and tighten them to torque of 1 9 to 2 3 mkg 14 to 17 ft lb I Drain oil when transmission has reached operating temperature Oil has to be drained from transmission and...

Page 690: ...on Controls Cake 34 TOOLS i p 2 _ 3s 3 i i Description Transmission support US 618 Support bracket US 618 Z Support bracket US 618 4 Special Tool Remarks Printed inGermany Iv 1980 Removing and Install...

Page 691: ...ut shaft and drive shaft and remove bolt 3 Loosen parking brake cable at connecror Unscrew locknut and pull out cable toward rear only for cars with welded battery console 1 r 4 Remove nuts on spring...

Page 692: ...in horizontal position 14 Disconnecr srabilizer bar at lower control arm 15 Support transmission with special tool US 8031 attached to stabilizer bar mv B we L T d J _ 16 Remove both bolts of transmi...

Page 693: ...be removed Mark roe eccen tric for installation later and remove eccentric bolts 18 Mount transmission supporl bracker on wanr mission Remove 6 bolts between central tube and transmission as well as S...

Page 694: ...of case enough so 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 9 8I Y I nq I 1 I I I f s z JL z t r qy a...

Page 695: ...928 Manual Transmission Controls Care 34 a Printed in Germany Iv 1980 Disassembling and Assembling Shift Linkage 34 8 c...

Page 696: ...over 5 Sleeve 1 6 Dust cover 1 7 SW V 1 Self locking 2 versions replace if necessary self locking polyamide plug not self locking use Loctite 270 a Locknut 2 Replace if necessary 9 Ball socket 1 Lift...

Page 697: ...od 1 17 Nut 1 First adjust shift lever lateral angle and then tighten nut to specified torque 18 Lockwasher 1 Replace if necessary 19 Bolt 1 20 Shift rod coupling 1 Push in shift rod flush Adjust shif...

Page 698: ...Assemble guide tube with bracket guide tube bearing and ball socket Assemble selector lever selector rod and guide tube lubricating all bearing surfaces with white paste AOS 1260006 Don t tighten loc...

Page 699: ...wise against stop and hold Turn selector rod with selector lever until the selector lever is inclined to the left by 2 to 3 Clamp selector rod flush with the bearing unit in this position arrow forwar...

Page 700: ...socket while tightening the lockout ball socket horizontal shift lever with guide rod on rtop of reverse or 1st gear lock Horizontal Ball Socket Position Slide special tool VW 402 between central tube...

Page 701: ...acket and apply section of special tool without pin close to the shift lever with the radius on the central tube Some other support could also be used Requirement shift rod approximately parallel to c...

Page 702: ...1 support 9149 2 Extractor 9148 3 Spindle US 1078 4 Operating lever 9155 5 Press tool P 263 8 Holder 9144 7 Coupling spare part 8 Arbor US 8050 9 9 Pin US 8050 10 Puller input shaft 9140 11 Slide ham...

Page 703: ...34 Manual Transmission Controls Case 928 a I Q L 3l 29 r R 27 42 43 34 10 Disassembling and Assembling Transmission Printed in Germany...

Page 704: ...4 Case cover 1 5 Gasket 1 6 Vent 1 7 Roll pin 1 Engage 5th gear and drive out 8 Split pin 1 First drive out roll pin no 7 9 Internal selector rod 1 Position correctly depression for set screw lust fa...

Page 705: ...1 Remove toward rear Selector fork for 2nd and 3rd gears 27 Selector rod with 1 Remove toward rear selector fork for 1st and reverse gears 28 Detent 1 29 Circlip 1 30 Countershaft 1 31 O ring 1 Replac...

Page 706: ...Removing Note When Installing Torque 30 Nm 22 ftlb Hollow side feces bearing cover Turn and remove bearing unit with VW 771 Press out with 9148 and P 263 Insert with 9144 Note quantity and If necessa...

Page 707: ...A1 for shift finger and only then when spring is relaxed split pin B for spring support Disassembling order is important since otherwise the accelerated split pin IB could cause injury 4 Drive out spl...

Page 708: ...k thrust washer for cluster gear on case with a little grease 2 Place assembled cluster gear in case 3 Drive in assembled input shaft without synchromesh parts over outer race of grooved ball bearing...

Page 709: ...ve for 4th and 5th gears from slipping 12 Position reverse gear wheel correctly with a suitable screwdriver unscrew centering pins for bearing unit and turn latter together with the shims until the re...

Page 710: ...in seal for internal selector rod with Special Tool US 8050 g 17 Engage neutral 18 Install selector rods selector forks and shift interlock components 1 Plug 2 Selector rod 4th and 5th gear 3 Detent p...

Page 711: ...al Tool 9155 and install pin for shift finger The torsion spring will be under tension in this position and cavity for pointed screw in internal selector rod faces left looking forwardl A Spring conca...

Page 712: ...n my Removing Installing Instructions 1 Vent 1 2 Bolt 2 Torque 9 Nm 3 Washer 2 4 Gear lock 1 Check locking paw1 for easy m0 eme t 5 Leaf spring 1 Position correctly 6 Case cover 1 hinted in Germany VI...

Page 713: ...a a 0 92x hlanual Tran nlisrion C earr and Shafts 35 TOOLS NO Description Support rail Mandrel Special Tool VW451 VW401 Printed in Germany Disassembling and Assembling Input Shaft 35 1...

Page 714: ...35 Manual Transmission Gears and Shafts 28 a b i yY co F y I i r P a Q K I y 2 g _ RS 2 Disarsemblinp and Assembling Input Shaft Printed in Germany...

Page 715: ...rox 100 C 212 F and drive on Modification from Tranrm No 118 LO 13 A new input shair with modified clutch body and a new synchronizer ring for 5th gear are installed from Transmission No 118 1093 This...

Page 716: ...ts 35 TOOLS 1 b i x I _ _ i b 1 g 7 f I h Y 1 I 1 2 3 r NO Description Special Tool Remarks 1 Retainer 9142 2 Support rail VW 457 3 separator us 1103 4 Wrench 9143 a hinted in Germany VI 1982 Disassem...

Page 717: ...35 Manual Transmission Gears and Shafts 928 s I t s I m 5 it 7 Ki v L l 1 4 r 5 1 2 z g 7 G V i s I c J z 35 6 Disassembling and Assembling Pinion Shaft Printed in Germany...

Page 718: ...th speed 1 Check synchronization replace in pairs only 8 Thrust washer 1 9 Needle bearing 1 Mark for Install with same gear reassembly O Inner race 1 Mark for Heat to approx reassembly 100 C ZIZ F ins...

Page 719: ...XI X Note quantity and If necessary thickness for remeasure thickness reassembly 24 Lock nut 1 Tighten to specified torque lock by staking 25 Reverse gear 1 Cavity faces lock nut 26 Tapered roller bea...

Page 720: ...e support Iv I N 1 rll n i d A bp d I A Standard U steel U 200 approx 260 mm long 2 Unscrew lock nut with special tools 9142 and 9143 e Pi i I i A j _ a i _i I t f 4 3 Press off bearing cover with a s...

Page 721: ...ecified torque with Special Tools 9142 and 9143 2 Lock lock nut by staking collar 3 Press assembled gear set together with an appropriate piece of pipe e g VW 519 Approx 5 tons of pressure 35 10 Disas...

Page 722: ...sed on the pinion shaft A Distance from pinion head to bearing surface of lock nut B Distance A r pinion shaft deviation r Pinion shaft deviation e g N 12 1 Design specification Transmission Type G 28...

Page 723: ...ansm No 118 1092 X 108 85 8 4 Work out distance X Type G 28 03 from Tranrm No 118 1093 X 108 70 8 5 Work out distance X Type G 28 05 from Transm No 110 50011 x 110 70 B Example Type G 28 03 up to Tran...

Page 724: ...up all play Since a circlip on the pinion shaft prevents axial movement gear set must be adjusted to take up all play between gear set and circlip I 1 Press assembled gear set together with an appropr...

Page 725: ...transm no 118 1092 0 4 to 0 6 mm from rransm no 118 lo 13 1 Measure distance 7 between input shaft and Note hub with a feeler gage Do not measure distance between synchronizer ring and shift sleeve o...

Page 726: ...izer ring Thrust block Shift band stop Installation Note 2nd Gear Synchronizer ring Thrust block Shift band stop Installation Note 3rd Gear Synchronizer ring Thrust block Shift band stop 1 groove on f...

Page 727: ...ring No grooves Thrust block 2 bevelled flanks Shift band 2 separate shift bands stop Bevelled flanks Note See below Fifth gear synchronizer ring is identical with fourth Fifth gear synchronizer ring...

Page 728: ...ngs to gilarantee perfect synchronization Check installed diameter of installed synchroni zation ring with a micrometer Micrometer must be applied at highest point of synchronization ring a Installed...

Page 729: ...35 Manual Transmission Gears and Shafts 928 a a a a 35 2 Disassembling and Assembling Synchronization Printed in Germany...

Page 730: ...928 Manual Transmission Gears and Shafts 35 a TOOLS 1 support rail 2 Mandrel Special Tool Remarks VW 451 VW 407 a Printed in Germany Disassembling and Assembling Countershaft Hub Gears 35 21...

Page 731: ...35 Manual Transmission Gears and I I 928 __ a 35 22 Disassembling and Assembling Countershaft Hub Gears IV 1980 Primed inGermany...

Page 732: ...off with Replace only in pairs VW 407 and large shoulder faces VW 457 3rd gear 8 3rd gear 1 Press off with Replace only in pairs VW 407 and small shoulder faces VW 451 stop 9 Countershaft hub 1 DlSAS...

Page 733: ...928 Automatic Transmission Controls Case 37 TOOLS T r I I _ z No Description Special Too1 Remarks 1 Removal plate 9163 2 Chain 9164 Primed in Germany I 1978 Removing and Installing Transmission 37 1...

Page 734: ...ery 2 Unscrew self locking hexagon nuts from spring struts in trunk 3 Disconnect multiple plug in spare wheel well and pull o t toward rear 4 Detach parking brake cable and lock b n 7 pf c g q frr r 7...

Page 735: ...Unscrew oil filler tube iron1 oil pan and drain ATF f u i FY i i i it _ 4 t T fp I I G 9 L nscrew feed and stun Iincs for ATF conler 10 Remove CIOSSmember i dmF 1 flI L R lm b rc d y gy G I I 7 a 1 11...

Page 736: ...capscrew can be removed 15 Detach brake calipers and suspend that brake hoses are without tension 16 Detach axle shafts from transmission and suspend in horizontal position Il Detach holder for parki...

Page 737: ...wo bolts holding rear axle cross member to frame e 9 I 23 Mark position of fear axle cross member for reinstallation 24 Place jack underneath rear axle cross mem ber and remove mounting bolts from cro...

Page 738: ...ol 9164 28 Lower rransmission a lirrle detach selector lever cable and disconnect cable sleeve O Rctnove six bolls of central robe This re quires lowering rransmission as fas a possible F I When lower...

Page 739: ...adjustmenr between drive shafr coupling and transmission input shaft Perform following sLeps 1 Loosen 6 bolts 2 attaching drive plate IO rorque converter 1 through opening arrow 2 Remove 8 bolts hold...

Page 740: ..._ I I a 1 _r __ 5 b I i I _ I d J 3 Install accessible bolts on central illbe and tighten hand tight 1 Lift transmission aod re move pieceof rend from central tube 5 Lower transmission until all lbol...

Page 741: ...hten all bolts to specified torque 10 Lower universal transmission lift Note Watch marks for correct reins allation 11 Position rear axle and tighten all bolts except for the two transmission mount bo...

Page 742: ...ecI selccror lever cable ar transmission and derach cable sleeve ar holder 2 Remove selector lever grip and rake off rubber cover 3 Remove cover frame see page 31 10 a 4 Pull bulb holder carrier out o...

Page 743: ...ver base 6 Adjust selector lever cable and check adjust menI see pages 31 11 EO31 12 lnslalling 1 Arrach cable sleeve on selecror lever base tightening the hexagon nut carefully 2 Push cable on 10 sel...

Page 744: ...lock old version Cover frame wirh lock new version 3 Move selector lever to position R disconnect gate and push forward as far as possible 4 Push front locking bar forward against stop with a suitabl...

Page 745: ...down on right side 5 Push down on left rear comer until frame firs in center console correctly 6 Move selector lever between R and P connect gate on selector lever and push for ward 1 Push front lock...

Page 746: ...E b cd 1 Place selector lever in 4 Adjust cable so that ball socket attaches to operating lever without tension 2 Detach cable from operating lever on trans 3 Place selector operating lever on trans i...

Page 747: ...r lever in J Apply parking and foot brakes Start engine and idle at about 1000 1200 rpm 2 Move lever to Engine speed must drop as gear engages Backup lights must light 3 Move lever top Engine speed sh...

Page 748: ...n lever Unscrew ball socket and locknur Pull off rubber grommer 2 Detach cable at throttle valve lever 3 Remove circlip for cable sleeve and pull cable WI forward being careful nor IO bend cable Ad 4...

Page 749: ...oosened for adjurrmenrs under no circumstances should bolt be tightened againsr stop inside transmission damager opera ting lever Use second wrench A adjusring bolt B clamping bolt Ball socket of cabl...

Page 750: ...Loosen adjusting screw INSTALLING NEUTRAL PARK STARTING 3 Inserr 4 mm dia pin from I S 8030 tool set SWITCH through drive dog into locaring hole in case 1 lnsrall switch and mounting bolts for same 2...

Page 751: ...928 Auromaric Transmission Conrrolr Case 37 TOOLS l No Description Special Tool Remarks 1 Take up rail VW 451 Printed inGermany 111 1979 Disassembling and Assembling From Converter 31 11 Housing...

Page 752: ...37 Automatic Transmission Controls Case 928 37 18 Disassembling and Assembling Front Converter Housing VI 1982 Printed in Germany...

Page 753: ...irclip 1 0 Grooved balls bearing 1 Drive out with Replace Heat suitable mandrel housing to approx 120 C and press in with a suitable piece of pipe Support input flange 11 Front converter housing 1 If...

Page 754: ...ange against shoulder with a suitable piece of pipe applied on bearing inner race 3 Hear converter housing to about 120 C 240 F and press in drive flange with grooved ball bearing against circlip 4 ln...

Page 755: ...nsmission Conrrols Case 37 TOOLS P zry Ik 2 s I I NO Description Special Tool Remarks I Knurled head bolt 9303 a Printed inGermany 111 1979 Removing and Insralling Final Drive Housing and Rear Convert...

Page 756: ...ic Transmission Controls Care 128 q D lr r 0 Lh rl j i 6 1 1 6 L gzz 51 2 ty I F yv 3 g _ 0 Q fZ fpFgi y L i 0 7 I 37 22 Removing and lnntalling Final Drive Housing and Rear Converter Housing Printed...

Page 757: ...h 2 approx 60 mm long bnlrs 5 Final drive housing 1 6 Piston 1 7 Spring 1 8 O ring 1 Replace Coat with ATF Y Cenrrifugal gavernor 1 10 Bolt 2 Tighten to specified rorqw 11 Washer 2 12 Screw 1 Tighten...

Page 758: ...torque 17 Washer 11 18 Rear converter housing 1 Must face up in assembly stand Loosen by apply ing light knocks wirh a plastic hammer and re mOYe S Shitn X Nore thickness DeEermine thickness for rein...

Page 759: ...pplying light knocks wirh a plastic hammer Installing 1 Install rhe number of shims noted while removing or the shims calculared for the axial play on rhe input shaft 3 Align piston ring on input shaf...

Page 760: ...gainst srop Pressure pin should he flush with face of special tool If nor insrall a different pressure pin For this reason pressure pins are available in three differenr lengths which are idenrified b...

Page 761: ...928 Automatic TransmisrionlControls Case 37 a t 2 N I D p i ii _A 0 VI d Printed in Germany VI 1982 Removing and Installing Rear Transmission Case and Rear Converter Housing 37 26a...

Page 762: ...ue 27 to 32 Nm 20 to 23 ftlb 3 Washer 10 4 Thrust ring 1 Pull out with two approx 60 mm long bdts 5 O ring 1 Replace coat with ATF 6 Rear transm case 1 7 Piston 1 8 Spring 1 9 Support ring 1 10 Diaphr...

Page 763: ...asket 1 19 Bolt 11 Torque 27 to 32 Nm 20 to 23 ftlb 20 Washer 11 21 Rear converter housing 1 Must face up in assembly stand Loosen with light taps from a plastic hammer and remove 22 Shims X Note thic...

Page 764: ...Y28 Auromaric Transmission Conrrols Case 37 a a Primed in Germany Ill 1980 Disassembling and Assembling Rear Converter Housing 37 27...

Page 765: ...37 Aurorrraric Transmission Conrrols Cast I 28 Ij 2a isasrcmbling and Assembling Rear Converter Ilousing Printed in Germany...

Page 766: ...lnserr ATF pump in converter housing carefully and tighten mounting bolts to specified torque A Suds 2 Screw in IWO approx 50 mm long bolts opposite each other and drive out pump by lightly tapping on...

Page 767: ...n Conrrols Case 37 a TOOLS a No Descriprion Special Tool Remarks 1 Thrust tool 9180 Consisrinp of thrust pad and rhrusr sleeve 2 Mandrel P 254 Printed in Germany 111 Wl 1 Disassembling and Assembling...

Page 768: ...37 Automatic Transmission Controls Care 028 6 a 96 69 2 1 3 31 32 Disassembling and Assembling Final Drive Housing a Printed in Germany...

Page 769: ...928 Automatic Transmission Controls Case 37 JO I Description a Printed inGermany 111 1979 Disassembling and Assembling Final Drive Housing 37 33...

Page 770: ...nner seal to correct position with Special Tools 9180 and P 254 m B s 1 c 9 l r i 2 j 9 j q e m 2 Drive in outer seal to couect position with Special Tool 9180 5 y i c K v r d Jcb i 4 Note Nore Instal...

Page 771: ...romaric Transmission Controls Case 37 a TOOLS NO a l 1 2 Descriprion Special Tool Remarks Assembly sleeve 0305 Assembly 1001 9304 a Printed inGermany 111 1979 Disassembling and Assembling Transmission...

Page 772: ...37 Automatic Transmission Conrrols Case 928 a I r b L J 0 vi kR9 c 31 36 Disassembling and Assembling Tranrmission a Printed in Germany...

Page 773: ...ighten to specified torque 1 Oil Filter 1 Replace every 40 000 kmj25 000 aili N I 1 11 1 1 1 1 li I I 1 1 z 3 Sp CXI 2 1 Bolt 11 Tighten IO specified torque 3 Valvi body housing 1 Page 38 21 1 Kickdow...

Page 774: ...37 Automaric Transmission Controls Care 928 31 38 Disassembling and Assembling Transmission Printed in Germany...

Page 775: ...n parts because even minure confaminarion e g linl could lead 10 disturbances 1 Detach final drive and remove hearmg assembl wirb drive pinion see page 30 22 2 Remove final drive housing cenrrifugal g...

Page 776: ...ove brake band B 3 forward 16 Pull input shaft out of gear assembly A Pressure pins 13 Swing transmission in assembly stand to horizonral position 17 Hold brake band B 1 on the drum with a snap ring f...

Page 777: ...n tram mission case F GTi 1 _ D J r v p I c h a _ I 1 7 4 6 Lubricare and install radial bearing 1 Hold brake band B 1 sreel band with smoorh liner on brake band drum wirh the snap ring for piston of...

Page 778: ...is A Pull up input shaft against the stop and repeat measurement This dwance is B Axial play will be the dlfference between A a d B Adjust axial play to 0 4 0 6 mm by using shims of pertinent thicknes...

Page 779: ...ne by moving piston of brake band B 2 into lifr position wirh air pressure supplied through lift pressure bore and checking distance b Then move rhe brake band piston inro shill posirion with air pres...

Page 780: ...re Dead travel L excessive use longer pressure pin Dead travel L insufficient use shorter pressure Hold the adjusting screw to prevenr maladjust men Tighten COUD UIand grind off head of adjusting scre...

Page 781: ...I28 Auromaric Transmission Conrrols Case 37 0 9 I i i iL Q CT L2 9 i ggg DWJ Primed inGermany III 1879 Disassembling and Assembling Transmission Case 37 45...

Page 782: ...c 6 Washer 2 7 Anri rertarr and 1 Adjust Page 37 15 backup light swirch 8 Bolt 1 Tighten to specified C Iq t 9 Washer 1 LO Holder 1 Remove together with leaf spring and roller running on needle bearin...

Page 783: ...Plug 1 Tighien spe cified LO 1orque 26 Seal 1 Replace 27 St21 1 Drive out with Drive in to correct suitable screw position wirh suitable driver 1001 lip faces out 28 Snap ring 1 29 Cover 1 30 Seal 1 R...

Page 784: ...retainer 1 41 Pressure unil 8 2 1 Do nor mix up wirh pressure unit B 1 42 Pressure unit B 1 1 Do nor mix up with identified by a groove pressure unit B 2 all around 43 Seal 1 Replace coat with ATF 44...

Page 785: ...and remove both resswe unirs 1 Pressure unir B 1 2 Pressure unit 6 2 3 Pull our spring for bearing pin fror lever of brake band B 3 and drive OUI pin downward m w pJ 1 Assembling 1 Install catch plat...

Page 786: ...on needles 3 Install leaf spring and roller running on needles 4 Install holder and tighten bolr to specified rorque 5 Push spring on to bearing pin and attach in trans mission case Tension spring wi...

Page 787: ...lubricating circuit This rubber insert can be service insralled in rrans mission without one Iy p slb 1 L _ _I Ji t j 1 Pressure unit B 1 2 Pressure unir 6 2 A Rubber inserr Pressure unirs B 1 and B...

Page 788: ...parts must be transferred from the defective transmission to the new transmission 1 Front converter housing with mounting parts 2 Torque converter 3 ATF tank 4 Bearing assembly with drive pinion and m...

Page 789: ...he transmission case and final drive is missing on transmission section for manufacturing reasons 2 Drive in outer seal to correct position with Special Tool 9180 also refer to page 37 34 Note The out...

Page 790: ...front converter housing see page 32 1I 4 Redetermine thickness of shims for bearing assembly and install bearing assembly see pages 39 24 and 39 29 5 Adjust drive pinion and ring gear ree page 39 311...

Page 791: ...on Gears Valve Body 38 a TOOLS NO Description Special Tool Remarks 1 Gauge ser us 1090 2 Gauge and coupling VW 1318 or P 318 3 Hose adapters and bracket us 8030 hinted in Germany 11 1979 Checking Tran...

Page 792: ...ge e g leaks on transmission ATF or final drive hypoid oil and missing or loose mounting bolts B Transmission Fluid Level The specified fluid level is extremely importanr for proper operation of autom...

Page 793: ...heck all the engine power is convened into heat in the converter which is why this check must nor last longer than 5 seconds Rear wheels mu not be permitted to turn for rhis check Also engine must be...

Page 794: ...d value by about 300 rpm slip is in transmission If srall speed is correcr alltl lop speed is still nor reached one way clurcl is locking in both direc Cons or has seized This xi 1 usually be noticed...

Page 795: ...16 21 2 3 2 42 48 26 30 1 Kinte shift poilirr and compare 10 char above Shifts should be smooth Shifts should take place quickly and wirhout lag in power trans mxsion 2 Listen toi any sign of engine s...

Page 796: ...F system a main pressure b governor pressure c modulator pressure 69 PI i 1 x 7 i I A p i I c Y f 1 ki I Gauge and coupling from VW 1318 plus brackei and pars from US 8030 Note After removing gauges i...

Page 797: ...essure must be measured at full throttle in D range ar 88 km h 55 mph with vacuum line connected see page 38 9 Adjust if necessary Correct modulator pressure automarically affects main pressure 3 Conn...

Page 798: ...s Checking Governor Pressure Not adjustable Adjusting Modulator Pressure 1 Compress circlip and remove vacuum modulator cw er 2 Slightly pull adjuring key out and turn screw 3 After adjusring push key...

Page 799: ...5 c j z WY z 2 x e 2 u SE e Z 95 z 2 y1 z e 2 t g 1 N n r i n 6 j 0 0 m_ F 2 r 2 z NcoOdLc A iLA r NcoO s cop NY lrl d A N d ti 6 AuiAAAA d 2 c i c i n n qzi m NC rn Q Lc S Coc Ncom d 2 N N m d AuiAA...

Page 800: ...g pressure safety valve in shift valve housing uppcr section 2 Check whether vacuum line from intake branch to vacuum box is plugged If yes replace 3 Check operating pressure If too low or not availab...

Page 801: ...n slips during Ist Znd shift or in 2nd and 3rd gear Correction 1 Check modulating and operating pressures adjusting if necessary 2 Replace shift valve housing also replacing sealing bushings on plug t...

Page 802: ...lating pressure 1 Check modulating pressure adjusting if possible 2 Remove and service modulating pressure control valve 3 Check and clean modulating pressure safety valve in shift valve housing upper...

Page 803: ...t 2 Remove brake band piston B 3 and check seal 3 Replace one way clutch in gear set Jondition Strong jolt when engaging selector Lever in D orrection 1 Adjust idle speed and CO level to specification...

Page 804: ...tion 1 Replace seal on release end of 8 2 2 Replace brake band piston B 2 Condition No upshifts Correction 1 Check govemor pressure If there is no govrrnur pressure reading continue with point 1 If go...

Page 805: ...edal to kickdown and check whether throttle is against full throttle stop adjusting if necessary 3 Check governor pressure and replace centrifugal governor if governor pressure is too high Condition N...

Page 806: ...d valve sticks in open position re placing solenoid valve if necessary 4 Check movement of control pressure valve cleaning shift valve housing and servicing valve if necessary or re placing shift valv...

Page 807: ...ervice blocking piston in rear transmission case Condition Engine cannot be started with selector lever in P or N Correction 1 Adjust selector lever cable and starter interlock switch 2 Replace starte...

Page 808: ...ous spots Heplace primary pump ifs nccrssary 3 Apply a good coat of iiyloma tn threads of hottom mounting bolts Condition Oil leak behind starter interlock and backup light switch Coircction Replace O...

Page 809: ...ng bolts and remove oil pan with gasket Note Ii ATF smells burnt and there is metal abrasion in oil pan sludge or an unusual large amount of burrs it is not sufficient to only replare shift valve hous...

Page 810: ...sealing husbings from plug tubes 3 Guide in shift valve housing carefully Make SUE in particular that range valve engages correctly in catch plate Installing 1 Fit new sealing bushings on both ends of...

Page 811: ...ut 9 Add ATF as specified As from May I 1979 a rubber insen is insraIled IO eliminate hydraulic noise in rhe lubricating circuir Rubber inserra can be service installed in a trans mission without one...

Page 812: ...housings y s s i _ US j y I I 1 Old version with cast brake band holders arrow 2 New version install only with plastic brake band holder a Only the new version will be available afrer de pletion of o...

Page 813: ...matic Transmission Gears Valve Body 38 a TOOLS a 1 i i 9 I I dri A I i NO Description Special Tool Remarks Filler Standard e g Dresser Wayne Model 3009 hinted in Germany VI 1982 Replacing ATF and Filt...

Page 814: ...bjected to severe operating conditions trailer hauling etc Car must be on level surface when replacing ATF Also have transmission at operating temperature and engine stopped Unscrew oil filler tube fr...

Page 815: ...lever in each position several seconds Then recheck ATF level Note ATF level in transmission will change with any change in ATF temperature Max and min marks on tank are in reference to an ATF tempera...

Page 816: ...udge in oil pan it is not sufficient to only replace the valve body or transmission The ATF cooler and lines will also have to be flushed with ATF on return line and flush cooler as well as lines with...

Page 817: ...928 Auromaric Transmission Gears Valve Body 38 16 17 kz Jr 8 115 I 1 9 MT2 P B 8 q l o 1 f I It Bm 6 Printed in Germany 111 1979 Disassembling and Assembling Centrifugal Governor 38 29...

Page 818: ...irclip 1 6 Spring 1 7 Shift valve 1 Check for easy move ment and damage 8 no1r 2 Tighten to specified COrq t 9 Luckwasher 2 Replace if necessary LO Governor housing 1 Position correcrly on flange 11 F...

Page 819: ...Autoroaric Transmission Gears Valve Body 38 a Printed in Germany III 1Wg Dirassernbling and Assernhlirig Centrifugal Governor 38 31...

Page 820: ...ng Clean all pars in clean gasoline thoroughly Check shift valve and governor valve for damage and easy movement in their bores 1 Place filler screen in seat provided for this pur pose in oil bore and...

Page 821: ...928 Automatic Transmission Gears Valve Body 38 0 TOOLS NO Description 1 Assembly tool Special Tool 9307 I Remarks Printed in Germany III 1979 Disassembling and Assembling Gear Assembly 38 33...

Page 822: ...4 1 zq c 2 c1 cl 4 L 3 IQ g i L i 11 10 g p j m a 24 25 j 28 tic I ill 0 27 c ip 28 7 r f g i 21 f I p 46 m Ill g p 9 77 1 1 I i I 2dL1 3 j ilk 22 il p yj _ 1 ii 23 21 20 f T nlTm 18 38 34 Disassembli...

Page 823: ...Axial bearing 1 I Shim x Note quanrity Redetermine thickness and thickness if necessary for reinsralling 8 Axial bearing 1 9 sun gear 1 0 Radial bearing 1 1 Circlip 1 2 Shim X Note quantity Redetermin...

Page 824: ...An aramide plastic washer without turning lock is installed instead of metal thrust washer betw rear pla net set and in termediate shaft for transm type A 22 04 as well as for type 22 01 from 1981 mo...

Page 825: ...ing and split needle bearing illi I I i h F _ _ II b i 9s fi la Ty f I I ji xiihm r c 2 Inrrall sun gear and rhrw washer Coared side oi thrust washer faces sun gear 3 Heat ball bearing to about 120 C...

Page 826: ...that spline of inner plate carrier engages in inner plates i i a w w s 7 9 install radial bearing berween hollow shaft and supporr flange 10 Insrall oil distribution sleeve in support flange K 2 so fa...

Page 827: ...er plate carrier to shoulder of planet gear carrier WT fl f fF i 1 a I y j 1 _ f Insrall shims to adjust play IO specified value of 0 3 IO 0 4 mm 13 Check axial play of sun gear Measure distance d fro...

Page 828: ...tance c f play Adjust play 10 specified value of 0 2 IO 0 3 mm by installing shims underneath rhe axial bearing 14 Install planer gear carrier turning ir back and forth IO have inner plate carrier eng...

Page 829: ...uromaric Transmission Gears Valve Body 38 TOOLS N 1 2 Description Assembly sleeve Assembly tool pecial Tool Remarks I 9308 9309 Printed inGermany III 1979 Disassembling and Assembling Clutch K 1 38 41...

Page 830: ...38 Automatic Transmission Gears Valve Body Ii 2 8 a 0 T c 0 LA LA fF a e p a 7 L kp _mC h a a a 38 42 Disassembling and Assembling Clutch K 1 Printed in Germany...

Page 831: ...a 928 AurorriaLic Transmission Gears Valve Body 38 UO uescrlprlon a Printed inGermany III 199 Disassembling and Assembling Clutch K 1 38 43...

Page 832: ...r is positioned correctly in the groove and its lip faces down in direction of arrow 2 Release press carefully and remove spring re rainer and springs Note Never use sharp edged rools a install seals...

Page 833: ...hou pressure 5 Assemble plates according co exploded view and install assembly in clutch drum Press up outer plares all rhe way and measure disrance b from upper edge of clulch drum to plate assembly...

Page 834: ...12 Automatic Transmission Gears Valve Body 38 e z if2 5 fg p 0 j lT r L3v r c A p 0 j T 0 c v g qz q ul ygj I 4qjsJL tfgg CJ Printed in Germany 111 1970 Disassembling and Assembling Clutch K 2 38 41...

Page 835: ...er 5 Snap ring 1 6 Lipped seal 1 Replace Sealing lip faces supporr flange 7 Lipped seal 1 Replace Sealing lip faces down 8 Spring X Note quantity Install same quanriry for reinsralling as removed 9 ou...

Page 836: ...e supporr flange down slightly in a Note press wirb a suitable thrust pad e g VW 511 The quantity of springs for clutch pistons will vary If new springs are required rhe same quantity as removed must...

Page 837: ...in an ATF bath prior to installation Measure distance b from upper edge of outer 0 plare carrier to bearing surface of support Lange with a depth gauge Clurch play 7 is a b If applicable adjust play...

Page 838: ...TF IO seals and insrall piston in support flange pressing rhe sealing lip into he supporr flange with a pencil OI ball point pen and moving in the piston care fully withour Ming 9 lnsrall snap ring in...

Page 839: ...I 28 Differential Tr lnsaxle Syrtcm NO Description 1 Mandred US SOSO lO 2 Pin Sprcial Tool Printed in Germany Removing and Installing Differential 39 1...

Page 840: ...39 Dlfferential Transaxle System 928 I 77 e yBq l yF9 i yqg t _ _ 6 f j 2z g N P a 39 2 Removiq and Installing Differential Printed in Germany...

Page 841: ...led on reassembly same side Note number and thickness for reassembly on each side Determine again if necessary Prrss out with suitable screw driver Mark for reassembly Tighten to specified torque Repl...

Page 842: ...aqx Prcload of the tapered roller bearings could cause tension on the case when tightening bolts for the side covers which later could impair installation of the rear cover consequently the rear cover...

Page 843: ...928 Differential Transaxle System 39 a TOOLS 0 No Description Special Tool Remarks 1 Mandrel P 263 2 Extractor US 1018 3 Drift P 264 b Primed in Germany Disassembling and Assembling Differential 39 5...

Page 844: ...39 Dlfierential Transanle System 928 Y f p 17 eu t f l J m am I F I i id i co fJ c _s L c a 9 0 L y r 1 39 6 Disassembling and Assembling Differential Printed in Germany...

Page 845: ...ghten to specified torque 6 Ring gear 1 Heat to approx 100 C 212 F Tapped holes for ring gear bolts must be dry and greaseless Note pair number Adjust if necessary I Roll pin 1 8 Differential gear sha...

Page 846: ...Claws of both legs might have to be machined lid c _ yrc SC m n 1 Assembling 1 Heat ring gear to approx 100 C 212 F and install Use local manufactured centering pins as guides A Centering pins local m...

Page 847: ...s fit threaded plates through opening in differential case and hold with joint flanges e b 5 Install small differential gears between large differential gears and turn until bores of gears are aligned...

Page 848: ...39 Differential Tranraxle System 928 39 10Disassembling and Assembling Differential Printed in Germany...

Page 849: ...er Dial gauge extension 20 mm Dial gauge Gauge plate Master gauge Feeler gauge Clamphg sleeve Adjusting device Adjustable lever Universal dial gauge holder Holder Dial gauge Special Tool VW 385 l VW 3...

Page 850: ...tions of rotation The position of quietest running is determined by moving the drive pinion in an axial direction keeping the ring gear within specified backlash tolerances The deviation t from the de...

Page 851: ...roller 2 Determine shim thickness S 3 3 Divide total shim thickness 5 tot in Sl and S2 so that there is the specified amount of backlash between the ring gear and drive pinion The goal of adjustments...

Page 852: ...on the adjustment Refer to the following table to avoid unnecessary adjustments Transmission case I X 1Side transmission cover x Bearing bracket with taper roller bearing for drive pinion X Drive pin...

Page 853: ...2 a b g PERaR 1 Deviation r in l 100 mm 2 Pair code a 5 Example Deviation Y on face of pinion is N 18 R Design distance 72 70 mm I Deviation 0 18 mm E Adjusting distance 72 88 mm 6Omm Install centerin...

Page 854: ...72 70 mm I 0 18 mm E 72 88 mm adjustment of master gauge 10 Install master gauge and set dial gauge 3 mm range at zero with 1 mm pre load 0 4 u I L Bmr I k I F o 11 Install gauge plate VW 385 17 on p...

Page 855: ...ad anriclockwise red range 13 insert a shim wirh thickness 3 equalling the determined deviation between rhe bearing cap and lransmission case Round off to the nearerr 0 05 mm e g 0 22 mm becomes 0 25...

Page 856: ...m Bearing pre lOad 0 30 mm 1 Install differential with ring gear in case sm 0 95 mm _ 2 Install ride transmission cover ring gear end without shims and tighten all bolts to specified torque 3 Guide in...

Page 857: ...ned shim I m 91 Stotal on ring gear end and tighten all bolts to specified torque 4 Turn differential in both directions several times to settle tapered roller bearings 5 Install gauges setting adjust...

Page 858: ...ed for SI and S2 stat 1 measured backlash specified backlash inscribed on ring gear X 0 66 lift consrant Note In the interest of economical procedures the shift rods and shift forks should be installe...

Page 859: ...marks 1 Transmission holder 1162 2 Puller V s 1018 3 Depth gauge ___ Standard 4 Cenrering pins __ Made locally 5 Installer Made locally steel pipe 45 x 5 x 40 mm with welded cover and 11 mm dia bore P...

Page 860: ...39 Differential Tranoaxle System 9 2 R Jj f pz x Lq x c j qFJ I I l m co in 39 22 Removing and Installing Final Drive for Printed in Germany...

Page 861: ...4a and tighten to specified torque Lock collar of nut 6 Bolt 6 Torque 27 32 Nm 20 23 ftlb 7 Circlip 6 Position correctly Hollow ride faces flange 8 Bearing assembly 1 Pull out with a Press in with loc...

Page 862: ...y stand with Special Tool 9162 and drain oil from final drive j r JyqpZ c i I 1 yj q i f I _ a 3 Engage parking lock and remove collared nut 4 Pull out bearing assembly with a suitable pullel k g US 1...

Page 863: ...ion Type A 22 01 up fo DB Mfg No 5797 without fixed governor 200 240 Nm 145 175 ftlb Transmission Type A 22 01 from DB Mfg No 5796 with fixed governor 280 Nm 200 ftlb l Note The DE manufacturing numbe...

Page 864: ...ransaxle System 39 a TOOLS NO Description l 1 separaror 2 Depth gauge Special Tool us 1103 ___ Remarks Standard Printed inGermany _ 11 1979 Disassembling and Assembling Bearing Assembly 39 25 for Auto...

Page 865: ...39 Dlfferenrial Trannaxle System 928 31 26 Disassembling and Assembling Bearing Assembly Printed in Germany for Automatic Transmission...

Page 866: ...available as complete part positions 1 4 2 Bearing inner race 1 Heat to approx 120 C 248 F and drive on 3 Adjusting ring X 4 Bearing inner race 1 Heat ro appror 100 C 212 F and drive on 5 Pinion 1 Pr...

Page 867: ...ed roller bearings and adjusting ring for replacements 1 Hear tapered roller bearing inner race to approx 100 C 212 F and drive on 2 Press on assembled bearing with VW 415 a approx 5 Kl S force 2 Pres...

Page 868: ...acing a bearing assembly Use a depth gauge to measure distance from taper roller bearing surface to bearing flange surface e g 34 55 mm Since the design calls for a distance of only 34 1 0 05 mm a shi...

Page 869: ...13 Dial gauge Dial gauge Standard 10 mm range Feeler gauge Sleeve Clamping arbor Adjustable lever Dial gauge holder Lever Made locally Special Tool Remarks VW 385 l VW 385 4 VW 385 14 1168 VW 385 30 9...

Page 870: ...oothes1 running is derermined by moving the pinion in an axial direction whereby the ring gear is lifled out of the no play meshing poritiou far enough so that the backlash will be kept within specifi...

Page 871: ...rive pinion Objective of adjustments must be to regain the maximum degree of quiet running as had been determined by the special testing machine in manufacturing a Absolute cleanliness is essential fo...

Page 872: ...1 Deviation 1 in l 100 mm 2 Pair number Note The design of the drive pinion will not allow use of the 5 mm thick Special Tool VW 385 17 normally applied for adjustments a 41 mm Since Special Tool VW 3...

Page 873: ...mm for missing Special Tool VW 385 11 Example 12 Turn measuring bar carrfully until dial gauge exrension is vertical I face of pinion head At rhis moment dial gauge needle will reach in point of reve...

Page 874: ...m as shim thickness S3 with 1 mm dial gauge pre load 13 Install the determined shim lhickness S between transmission case and final dri e housing 14 Recheck disrance after installation of shims v h de...

Page 875: ...ron bar 6 Calculate shim thickness Stota Storal gap 0 30 mm bearing preload 2 Install differential with ring gear in housing Example G P Bearing preload 1 25 mm 0 30 mm 0 95 mm 3 Install side cover ri...

Page 876: ...g 3 Install side cover using total shim thickness S tal as determined on ring gear end and tighten all bolts to specified torque 8 Hold pinion with locally made lever and turn back ring gear carefully...

Page 877: ...e in backlash by splitting shims Sl and Sz is only an example and doer not have to he made strict according to procedures S1 Sges total shim thickness measured backlash a backlash inscribed on ring ge...

Page 878: ...S1 and S2 again until specified play is reached 3 Check backlash at four places on periphery turning ring gear by 90 each time Measare ments must not deviate from each other by more than 0 05 mm 39 4...

Page 879: ...ential Transaxle System 39 fl hi y i ii I g L m I_ c p 1 Automatic transmission 2 Central tube 3 Drive plate housing Printed in Germany II 1974 Removing and Insralling Central Tube Automaric Transmiss...

Page 880: ...strap 2 Remove self locking nuts from spring struts in trunk 3 Disconnect multiple plugs in spare wheel well and pull out downward 4 Detach parking brake cable ar fasrener 5 Remove air cleaner 6 Remo...

Page 881: ...7 P 8 Re r uvr lower body IhIXE Q 1 I Rrnmve enrirc cxhaus sysiem hy wowing bolts 011cxhausi rmailllold and holder and I pulling exhaust nys cni WI of ml hc holder I TWO people will he required 10 rer...

Page 882: ...eccentric bolls and l rear axle C OES member for reinstallation 12 Derach feed and rerun lines for ATF cooler and plug bores in COIIV IP housing A To cooler inlet bottom connection B From cooler ourl...

Page 883: ...iI is imporrallr IO he careful rhar the engine check valve for air injection does noi damage rhe brake line 18 Lower transmission only so far char selecro lever cable and cable sleeve on holder can he...

Page 884: ...lightly and lower with universal transmis sion jack Note Two persons will be required to remove can tral tube Note To avoid placing the driver plate of the fly wheel under strain start by tightening t...

Page 885: ...Differential Transaxle System 39 DISASSEMBLING AND ASSEMBLING CENTRAL TUBE AUTOMATIC TRANSMISSION e 7 a a 13 gT 14 15 Rimed in Germany Vi 1982 Disassembling and Assembling Central Tube Autom Transm 3...

Page 886: ...ling 9 Torque 32 39 Nm 24 ftlb 29 ftlb 9 Replace 1 Torque 80 Nm 59 ftlb 1 Replace if necessary 1 X 1 1 4 Torque 39 46 Nm 29 ftlb 34 ftlb 4 1 1 Torque Nm 80 59 ftlb 1 2 1 Check replacing if necessary N...

Page 887: ...corrected by rapping wirb a plastic hammer against face of drive shaft Check for easy movcmen of drive shaft bearings by ruming shaft by hand Shaft must turn easily and without binding ar any poinr If...

Page 888: ...al length of coupling 130 00 mm Total length of shortened coupling 125 50 mm When installed shortened end faces torque convw ter When using the shortened coupling procedures for measuring the drive sh...

Page 889: ...nce X must be checked and adjusted after replace mem of engine central tube coupling front converter housing or drive shaft for converwr 1 C lip 2 Bushing 3 Coupling flange 4 Drive plate 5 Drive shaft...

Page 890: ...xample Measured value 6 1 mm Ruler thickness 5 5mm Disrance A 12 2 mm 3 Push coupling on to drive shaft and mount transmission on central tube Tighten bolts to specified totque 4 screw in coupling scr...

Page 891: ...ce as far in as possible Note Remember thickness of ruler used for measuring a Example Measured value Ruler thickness Distance B 12 9 mm 5 5 mm 7 4 mm Determining Distance X X A B 0 5 mm pre load A 1...

Page 892: ...Tool Remarks 1 COnlleCtOr __ Local manufacture Connecror of joint flange can be made of 30 x 15 x 120 mm flat steel and mw have a l 2 square opening in the middle Printed in Germany 111 1919 Disassemb...

Page 893: ...39 Differential Transaxle System 926 fg ll II 69 0 9 I 8 39 56 Disassembling and Assembling Limited Slip Differential Locking Ratio 40 VI 1962 Printed in Germany...

Page 894: ...ctly 4 Spring retainer 2 Position correctly 5 outer plate 6 6 Inner plate 2 Imolybdenum coated 7 Thrust ring 2 8 Differential gear 2 9 Splined nut 2 Press O t of Press in to correct differential fear...

Page 895: ...f inner plates musk DOI be seriously worn 2 Lubricate all sliding surfaces of plares thrust rings and differential shafrs with SAE 90 hypoid gear lube prior 10 insrallarion 3 Remove all inner parts No...

Page 896: ...toward plate assembly If the thickest outer plates are installed and the specified torque is still not reached all plates are worn and must be replaced 5 Check torque slip with one differential gear h...

Page 897: ...r shields 2 Remove rear axle Note Let fear axle of can with a bolted battery console hang down on the trailing links and supporr same tie up 3 Remove transmission see page 34 3 4 Remove clutch see pag...

Page 898: ...ube mounting bolts Installing 1 Adjust selecror linkage if necessary 2 Brush a thin coat of Optimoly HT paste on spline of central shaft 3 Wrap strips of rape around insularion sheet and coat bearing...

Page 899: ...928 Differential Trannaxle System 39 7 I r i k yF I 4 I O q e yg I my _ p e r hl flyw m a Printed inGermany IV 1980 Disassembling and Assembiing Central Tube Manual Transmission 39 63...

Page 900: ...f ailgle joint Coat ball shell and On cars produced and angle joint with suitable ball head of ball up to 7 8 78 mou open end wrench joint while lube paste of guide tube is on and drive on carefully b...

Page 901: ...by tapping with a plartic hammer against face of drive rh ift Check easy movement of drive shaft bearings by tlirning shaft by hand Shaft mu9 turn easily and without restriction at any point If bearin...

Page 902: ...ion Type G 28 85 models onward are arranged by repair groups and ZOO series page numbers To keep the documents in correct order please file all pages with ZOO series page numbers behind the yellow Mar...

Page 903: ...928 S 4 Eur 1R o W 1987166 G 28113 5 Speed 926 S 4 USA Japan 1987188 G 28155 5 Speed 928 S 4 Clubsport i 988 928 54 928 GT i 989 90 9i worldwide G 28l57 5 Speed 928 GTS worldwide 1992 93 Model 88 I89...

Page 904: ...13 Zl 4 iz ihay iz x ihay 2221 33 21 17 144 12 5882 1 5714 4 0672 22 38 1 7272 1 5714 2 7142 26 32 1 2307 1 5714 1 9339 29 27 0 931O 1 5714 1 4629 Final drive ratio 11 30 i 2 7272 G28 10 55 11 29 i 2...

Page 905: ...24 i 45a3 I i 3577 direct 11 OOOO Final drive Final drive ratio Transmission oil Bevel gear without hypoid offset 11 30 i 2 7272 Multigrade transmission oil SAE 75 W 90 API classification GL 5 or MIL...

Page 906: ...ack up light switch to housing Plug to transmission housing Selector fork to selector rod Designation Threaded plug Hex bolt Hex bolt Hex bolt Hex bolt Hex bolt Hex bolt Back up light switch Plug Hex...

Page 907: ...rive pinion bearing uniU transmission case Lock nut on drive Dinion Ring gear differential housing Description Nut Bolt Nut Bolt Threads Pitch M14xl M6x1 25 M 32 x 1 5 M 12 x 1 25 class 10 9 12 9 Torq...

Page 908: ...emarks 1 Holding plate 9149 2 Bracket 9144 3 Impact tool VW 771 4 Extractor 9148 5 Extractor 9140 6 Clamping sleeve Spare part 7 Driver 9223 a Operating lever 9155 9 Centering pins 9321 IO Spring scal...

Page 909: ...8 DISASSEMBLING AND ASSEMBLING TRANSMISSION ir 1 _ I 3 4 41 B _ in _t Y 5 I II I 4 n 4 l3 spE 7 69 68 58 s LIL 80 YJ l9 I j 1 i 4 b f1 7 I l l p T T 61 47 1 62 60 6359 40 34 202 Disassembling and Asse...

Page 910: ...over 1 5 Gasket 1 Replace 6 Vent 1 7 Spring 1 8 Locking sleeve 1 Lubricate thoroughly 9 Bolt 2 Torque 10 Nm 7 ftlb 0 Washer 2 1 Guide sleeve 1 2 Lockpin 1 Position correctly 3 Spring 1 4 Ball 1 5 Gask...

Page 911: ...bricate thoroughly Torque 19 Nm 14 ftlb Engage 5th gear and drive out counterholding shift rod with suitable tool Engage 4th gear and drive out counterholding shift rod with suitable tool Replace Lubr...

Page 912: ...que 25 Nm 18 ftlb 38 Washer 1 39 Shift rod 1 Pull out toward 2nd and 3rd gears rear 10 Shift fork 1 Adjust 2nd and 3rd gears 11 Lock 2 12 Shift rod 1 Pull out toward 1st and reverse gears rear 13 Shif...

Page 913: ...on 1 Remove with Install with 9144 9144 53 Needle cage 2 54 Thrust ring 1 55 Shim X Note number and If necessary thickness for determine again reassembly 56 Thrust washer 1 57 Needle cage 2 58 Synchro...

Page 914: ...ning lock faces case opening stick on case with a little grease 66 Needle cage 2 67 Washer 1 68 Cap nut 1 Torque 50 Nm 36 ftlb 39 Nut 1 Torque 50 Nm 36 ftlb 70 Preselector spring 1 with stud 71 Take u...

Page 915: ...bly stand with Special Tool 9149 and drain oil J c a L C y y c j I 1 _ S TI 2 Remove differential see page 39 201 Note 3 Remove shift rods shift forks and locks Always counterhold on interior shift ro...

Page 916: ...removed with Special Tool VW 771 6 Remove circlip for input shaft 7 Pull out input shaft and bearing cap with Special Tools 9140 and 9148 Note Always first remove countershaft and lower countershaft t...

Page 917: ...lete input shaft over bearing outer race against stop alternately with a piece of suitable pipe or a mandrel 5 Insert O ring for bearing cap and lubricate with a light coat of oil 6 Mount bearing cap...

Page 918: ...3 12 Mount Special Tool 9144 on drive pinion bearing cap and move in drive pinion carefully with 4th gear engaged Check that reverse gear is positioned correctly A Soecial Tool 9321 Note When installi...

Page 919: ...se gear shaft to correct installed position and install clamp 1 Clamp 2 Thrust washer 15 Turn bearing assembly and shims S3 to installed position tighten mounting bolts to torque of 30 Nm and remove S...

Page 920: ...ve long 4 Spring long 5 Plug 6 Shift rod 2nd and 3rd gears 7 Locking sleeve short 8 Spring 9 Lock long 10 Shift rod 4th and 5th gears 11 Locking sleeve short 12 Spring short 13 Plug 20 Mount interior...

Page 921: ...ual Transmission Controls Case 928 a 21 Install lockpin in correct position 22 Adjust preselector spring and shift forks see page 34 215 a 34 214 Disassembling and Assembling Printed in Germanv Transm...

Page 922: ...34 DISASSEMBLING AND ASSEMBLING MANUAL TRANSMISSION 87 MODELS ONWARD NW I 12 G x 4 1 r 10 40 I P 11 41 in _ Gc 36 42 37 g25 27 6260 46 Printed in Germany XVI 1987 Disassembling and Assembling 34 214 a...

Page 923: ...Compression spring 20 Locking sleeve 3ty 1 1 2 2 1 1 1 12 12 1 1 1 1 1 1 1 1 1 1 1 l Note when Removing nstalling Clean tightening torque 22 Nm 16 ftlb Replace Tightening torque 10 Nm 7 ftlb Replace...

Page 924: ...cone A Oil catcher cone B Oil catcher spray tube 14 Place layshaft in installation posfiion and install axle with O ring lightly oil O Ring Note to faciliatate assembly turn the transmission on the su...

Page 925: ...g sleeve long 4 Compression spring long 5 Threaded plug 6 Selector rod 2nd and 3rd gear 7 Locking sleeve short 8 Compression spring 9 Lock long 10 Selector rod 4th and 5th gear 11 Locking sleeve short...

Page 926: ...sion housing and is sealed with an O ring A Breather B O ring apply a thin coat of transm oil Note l Observing correct position push breather into the housing until it is seated against the stop The b...

Page 927: ...1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Removing Installing Select 5th gear and drive out Hold selector rod with suitable tool while driving out Select 4th gear and drive out Hold selector rod with suitable to...

Page 928: ...funnel Reversing shaft Drive pinion ty 1 1 1 1 2 1 1 1 1 1 1 7 7 7 1 1 TRemoving l Note When c Installing Tightening torque 25 Nm 18 ftlb IWithdraw toward rear Itdjust a Idithdraw toward rear I3rease...

Page 929: ...1 1 1 1 1 1 1 1 T Note When Removing Installing Note number and thick ness for reassembly Mark for reassembly Withdraw with two flat pliers Lower layshaft on to base of transmission and withdraw with...

Page 930: ...WY 1 1 1 1 1 1 1 1 1 1 Removing Drive out with suitable mandrel Drive out with suitable mandrel nstalling Adjust Tightening torque 50 Nm 37 ftlb Tightening torque 50 Nm 37 ftlb Press in with Special...

Page 931: ...drain oil Ti A J a T s _ t r Tr f _ Z Installing differential see page 39 201 3 Remove selector rods selector forks and detente Printed in Germany XV1 1987 Disassembling and Assembling 34 214 g Manua...

Page 932: ...circlip for bearing cover and remove cover with two suitable flat nosed pliers 6 Withdraw drive pinion with Special Tools 9140 and 9148 Note It is essential to remove the layshaft axle beforehand and...

Page 933: ...0 0 1 4 Insert O ring for bearing cover oil lightly 5 Install bearing cover and circlip 0 I lO Screw centering pins 9321 for 6 Swivel transmission on support until input shaft points downward installa...

Page 934: ...mbly and turn the latter with shims until the reverse idler shaft can be installed pqq v A gj v ygy j I 2 b_ A Special Tool 9321 Note When installing drive pinion it is essential to ensure that the do...

Page 935: ...20 x 45 mm flat steel with 6 5 mm dia mounting hole and 2 5 mm chamfer in area of locking sleeve 1 Adjust operating sleeves with the shift l forks that they are exactly in the middle between synchrom...

Page 936: ...ector spring 2 with adjusting pin 1 enough that it just barely touches the roller of preselector lever 4 In this position shift arm 5 and preselector lever 4 will engage in openings of 4th and 5th gea...

Page 937: ...rive pinion if necessary and note whether shift arm has access to 4th 5th gear shift rod and lst reverse gear shift fork in 2 3 shift position as well as access to 2nd13rd gear shift rod in 4 5 shift...

Page 938: ...ised holder see page 34 215 3456 7 3456 7 i 87 models onward 2 Carry out rough adjustment of preselect spring 2 To do so screw adjustor pin 1 into case until approx 20 mm project 86 Models 1 Adjusting...

Page 939: ...pring force of preselect spring Specified force 60 SON To measure attach Special Tool 9155 to internal selector arm attach commercially available spring balance O lOON beneath ball pull internal selec...

Page 940: ...ed recheck the clearance s 0 2 0 1 mm between selector finger and selector rod and readjust if necessary see Step 3 6 As a check select each gear in turn with Special Tool 9155 turn drive pinion durin...

Page 941: ...ption Qty Note When Removing Installing Special Instruction 1 Vent 1 2 Bolt 2 Torque 9Nm 7 ftlb 3 Washer 2 4 Gear arrest 1 Check that locking paw1 moves easily 5 Leaf spring 1 Install in correct posit...

Page 942: ...g washer 4 Gear lock 5 Leaf spring 6 Circlip 7 Roller lever 8 Case cover 6 q 9 5 7 6 4 g a I Qtr 1 2 T Removing Note When Note When Installing Installing Tightening torque 9 Nm 6 6 ftlb a Check that l...

Page 943: ...929 Manual Transmission Operation Housing 34 l Dismantling and assembling housing cover with oil pump l l Dismantling and assembling housing cover with oil pump 34 221 Printed in Germany XXXI 1993...

Page 944: ...racket 1 4 Thrust spring 1 5 Valve 1 6 Roll pin 1 Fitting depth 3 0 5 mm 7 Adapter sleeve 1 Fitting depth 4 0 5 mm 6 Roll pin 1 Press in flush 9 Pan head screw 3 Tighten to 10 Nm 7 ftlb IO Washer 3 I1...

Page 945: ...8 57 1 Remove spray tube undoing hexagon head bolt and pulling out tube 2 Coat new O ring with transmission oil and push tube carefully into the housing Tighten hexagon head bolt to 10 Nm 7 filb A O r...

Page 946: ...Manual Transmission Gears and Shafts 35 a TOOLS No Description 1 Take up rail 2 Pressure pad Special Tool VW 457 VW 407 Remarks Printed in Germany X 1984 Disassembling and Assembling Drive Shaft 35 2...

Page 947: ...5 Manual Transmission Gears and Shafts 928 DISASSEMBLING AND ASSEMBLING DRIVE SHAFT 4 1 Y y t 111 r w I a41 L sc s w e e I1 l d I J a 35 202 Disassembling and Assembling Printed in Germany Drive Shaft...

Page 948: ...Installing 2 Install with bearing greas 1 1 Mark for reassembly Mount with same gear Check for wear 1 1 Press off with VW 457 Heat to approx 100 and VW 407 C 21 2 F and drive on 1 Note As of MY 92 a...

Page 949: ...pad and Special VW 457 Lm n J ebA pJp nm p L7 I 6 hi we w Assembling 1 Heat grooved ball bearing to approx 100 C 212 F and drive on 2 Check synchronizing ring by pressing ring against taper of gear wh...

Page 950: ...LS 2 P I I CF f p i i _ a i c i I1 g i 1 A 3 3 O q 1 4 i VO Description 1 Holder 2 Wrench socket 3 Holding rail 4 Separator Special Tool 9219 9218 VW 457 Remarks Standard a Printed in Germany _ X 984...

Page 951: ...and Shafts 928 DISASSEMBLING AND ASSEMBLING DRIVE PINION 44 43 42 41 40 39 38 37 36 35 a 28 27 26 25 24 232Z C eC C L r i Fii 1p J q b F i je g I 1 I 7621 a a 35 206 Disassembling and Assembling Prin...

Page 952: ...ove with Special Tool 9218 and 9219 Remove together with guide sleeve and synchromesh parts Mark for reinstallation Mark for reinstallation Mark for reinstallation Mark for reinstallation Mark for rei...

Page 953: ...1 1 1 1 1 1 1 Note When Removing Mark for reinstallation Installing Heat to approx lOO C install with original gear Remove together with guide sleeve and synchromesh parts Insert right way round Mark...

Page 954: ...s lark for reinstallation lark for reinstallation lark for reinstallation lark for reinstallation ress off together with learing cover Installing Install with original gear Heat to approx lOO C instal...

Page 955: ...Shafts 928 Qty 1 1 Removing Note When Installing Press off I Press off with suitable Heat to approx 100 C press off tool Adjust if necessary note pairing code l 35 210 Disassembling and Assembling Dri...

Page 956: ...k nut for drive pinion with Special Tools 9219 and 9218 2 Press off gear wheels with Special Tool VW 457 and a pertinent support F _ L I L FL A Standard U iron U 200 approx 260 mm long 3 Press off bea...

Page 957: ...ear wheels and measuring gaps A with a feeler gage blade Assembling Note Installed distance new 0 9 to 1 5 mm Wear limit 0 6 to 0 7 mm If drive pinion has to be adjusted it must only be assembled afte...

Page 958: ...lar _ 1 i _ wry q J fi 1 L _ 1 j T i _ i d J I _ y i Nf j I I i i d h 4 Modification 87 models onward The tips of the teeth of the 1st and reverse gear operating sleeve have been modified Note install...

Page 959: ...928 Manual Transmission Gears and Shafts 35 a TOOLS b Remarks...

Page 960: ...35 Manual Transmission Gears and Shafts 928 DISASSEMBLING AND ASSEMBLING COUNTERSHAFT Jr li zi P w f Ta 1 _ q gg a r Z Y Lp r 9 35 216 Disassembling and Assembling Countershaft Printed in Germany...

Page 961: ...28 Manual Transmission Gears and Shafts 35 0 TOOLS No Description Special Tool Remarks 1 Take up rail VW 457 2 Mandrel VW 407 Printed in Germany X 1984 Disassembling and Assembling 35 215 Countershaft...

Page 962: ...35 Manual Transmission Gears and Shafts 928 DISASSEMBLING AND ASSEMBLING COUNTERSHAFT 1 y wa 9s G I 2 c a A 4 5 6 35 216 Disassembling and Assembling Countershaft Printed in Germany...

Page 963: ...928 Manual Transmission Gears and Shafts 35 0 30 1Description Printed in Germany X 1984 Disassembling and Assembling Countershaft 35 217...

Page 964: ...UNTERSHAFT Disassembling 1 Remove circlip 2 Press off gear wheels with a suitable mandrel and Special Tool VW 457 rnLE m r 7 Assembling Heat gear wheels to approx 100 C 212O F and install to correct p...

Page 965: ...Manual Transmission Gears Shafts 35 a DISASSEMBLING AND ASSEMBLING LAYSHAFT 87 MODELS ONWARD I 7 q f3 z a y 1 8 Printed in Germany XVI 1987 Disassembling and Assemblin 3 35 219 Layshaft 87 Models Onw...

Page 966: ...3rd gear 9 Layshaft Note When Removing Press off with VW 407 and VW 457 Press of with VW 407 and VW 457 Press of VW 407 and VW 457 Installing Always replace as a pair collar toward a spacer Rlways re...

Page 967: ...928 DifferentiaI Transaxle System 39 l TOOLS NO Description Special Tool Remarks 1 Pressure pad 9147 2 Rod From P 254 a Printed in Germany X 1984 Removing and Installing Differential 39 201...

Page 968: ...39 Dlfferential Transaxle System 928 REMOVING AND INSTALLING DIFFERENTIAL 7 i 777 P L4 f cyf t1 L 1 1 11 F I u 0 CI zz I A 1398 7 a 39 202 Removing and Installing Printed in Germany Differential...

Page 969: ...sket 1 Replace 6 Bolt 2 Torque 43 Nm 31 ftlb 7 Joint flange 2 8 Bolt 12 Torque 22 Nm 16 ftlb 9 Washer 12 10 Bearing cap 2 Mark for Must be installed reassembly on same side 11 O ring 2 Replace coat wi...

Page 970: ...Drive in with suitable screw Special Tool 9147 driver I4 Taper roller bearing 2 Mark for Install in same outer race reassembly bearing cap heat bearing cap to approx 100 Cl 212 F and press in with a p...

Page 971: ...e taper roller bearings could cause tension on the case when tightening bolts for the side case covers which later could impair installation of the rear case cover Consequently the rear case cover sho...

Page 972: ...nut Note If the gearbox is installed it is recommended to use two studs M 8 x 45 wfth continuous thread to secure the measuring cylinder 4 Screw in the adjusting screw at the maasur ing cylinder until...

Page 973: ...alling the proportional slip differential Tool l Z Zaswing cylinder Sonderwerkzeug Bestellnummer Erhterung 9147 000 721 914 70 from P254 9514 000 721 951 40 a Removing and installing the proportional...

Page 974: ...Differential Transaxle System 929 Removing and installing the proportional slip dlfferentlal 39 2066 Removing and installing the proportional slip differential Printed in Germany XXN 1989 a...

Page 975: ...with suitable mandrel dentify for red installation Uote number and thick less for re installation per side Renew coat with gear Determine anew if net v Irive out with a suitable Drive in with special...

Page 976: ...moved or determine in 222 and lock with hexa stallation position for re in gon nut stallation 20 Hexagon nut 1 Tighten with 85 Nm 21 Sealing ring 1 Renew 22 Bellows 1 Oil slightly and press in home wi...

Page 977: ...n position of the thrust bearing for re installation under all circum stances Always renew the output cylinder as well if the bellows No 22 leaks 1 Adjusting the thrust bearing required only tf the pl...

Page 978: ...S Measuring range for tranverse lock 928 S 4 926 GT and 911 Carrera 4 1 Spacer tappet 2 Adjusting screw 2a Measuring groove on adjusting screw 3 Knurled nut 4 Thurst bearing 5 Hexagon nut 6 Sealing ri...

Page 979: ...ng sure that the ignition is switched on or off a1the appropriate stages in the procedure 2 Bleeding the valve block and the locking line to the lock slave cylinder l Connect the 9288 system tester Sw...

Page 980: ...em 32 a TOOLS 2 f L _ I a 3 1 2 I i 1 b q a _ p 1 No Description Special Tool Remarks 1 Pressure pad P 263 2 Extractor Standard 3 Pressure pad P 264 b a Printed in Germany X 1984 Disassembling and Ass...

Page 981: ...Differential I Transaxle System 928 a DISASSEMBLING AND ASSEMBLING DIFFERENTIAL 1 15 1 1 8 14 8 3 9 1 12 13 lb1113 12 Y i i L 3sti a 39 208 Disassembling and Assembling Printed in Germany Differentia...

Page 982: ...1 1 1 1 2 2 T Note When Removing use suitable extractor and P 261 to remove Installing drive on with P 264 b fit replacement threads must be dry and free of arease Torque setting 165 Nm 120 4 ftlb Th...

Page 983: ...ng Installing Apply MoS vex surfa e to con Only replace as a pair Needle bearing changed from 86 models onward The new needle bearings mean that the spacer need no longer be fitted The new needle bear...

Page 984: ...ess fit threaded plates through large opening in differential case and hold with joint flanges 4 Lr s pm e A Ed k 1 m Assembling 1 Place ring gear on case and tighten ring gear bolts to torque of 165...

Page 985: ...s in case 6 Drive in differential shaft in correct position and lock with pin _I F r 1A i i s qQ b3 r y y pj y f I I I I i _ sl mw 2 5 Install needle cages and spacer _ _I i hWA 7 If Yb 1 4 I e j 1 7...

Page 986: ...Designation Special tool Remarks 1 Connector Improvised tool The connector for the flexible flange may be fabricated from a 6 x 18 piece of flat steel l Printed in Germany XII 1986 Limited Slip Diffe...

Page 987: ...8 DISASSEMBLING AND REASSEMBLING LIMITED SLIP DIFFERENTIAL 0 6 7 9 r Y fi I r J i lo y 1 1 1p ty i m p P az I 1 1 1 gi 1 c 1 I I I x4 r a m 39 212 b Limited Slip Differential 40 Lock up Printed in Ger...

Page 988: ...ring 8 9 10 11 12 Axial bevel gear Screw disk Bevel pinion Differential axle Differential housing 2 1 2 2 2 2 2 2 2 4 2 1 Note when ush out of axial install in cor eve1 gear corect oosition Installin...

Page 989: ...easily in the differential housing c Axle bevel gears The contact surfaces for the take up plates should not be worn and the inner plates must move easily on the splines d Plates Check inner and oute...

Page 990: ...using a Example a 110 80 mm 2 Measure the cover at b Example b 29 20 tmn 1 Disk spring 2 Outer plate 3 Inner plate 4 Take up disk Reestablishing the thickness of the plate package if new parts have be...

Page 991: ...ied install thicker or thinner outer plates e less than 5 20 mm install thinner plates e greater than 5 20 mn install thicker plates Outer plates of thicknesses 1 9 mn 2 0 mn and 2 1 mm are available...

Page 992: ...Connector improvised Note If the specified torque is not at tained with the thickest outer plates all the plates are worn and require replacement Printed in Germany XII 1986 Limited Slip Differential...

Page 993: ...Tools Order Number Remarks 105 _ Sickle spanner Thrust piece Thrust piece Measuring fixture Connection piece P263 P264b 9508 i 000 721 263 00 000 721 264 20 000 721 950 81 commercially available 2 par...

Page 994: ...928 Dismantling and assembling the proportional slip differential 39 212j Dismantling and assembling the proportional slip differential a Printed in Germany XXN 1989...

Page 995: ...ease surface and fix position of the fever seg ments with adhesive tape Installing Press on home with special toot P264b Press on home with sui table pipe piece cYe c __ _ I _ II ___ and secure with t...

Page 996: ...on Heat up to approx 120 C threads for ring gear screws must be dry and free of grease Pay attention to pair number Readjust if net essafy Tighten with 10 Nm Redetermine thickness i necessary Oil with...

Page 997: ...r 34 Housing Note when QtY Removing Installing 1 1 4 Replace only In sets with axle bevel gears 1 Replace only in sets with taper pinion 1 X Note thickness for Redetermine thickness i re installation...

Page 998: ...1 Determine the axial play of the axle bevel gears and adjust to 0 05 0 15 mm by insert ing the corresponding friction washers No 16 33 Note If parts e g differential housing or bevel gears are replac...

Page 999: ...ates Inner plate Gylon her plate Sinrefed coating 4 Determine the thickness of plate assembly c Thrust ring Assembly thickness Fit the thrust ring and determine the dimen sion A a Dismantling and asse...

Page 1000: ...thickness marked on toot 33 80 mm Adjust the thickness of the plate assembly to the calculated value c L 0 1 mm by means of the outer adjusting plate No 18 5 Installation position of Gylon inner plate...

Page 1001: ...position of the lever disk L 7 Setting the basic locking torque Limited slip differential completely as sembled with engaging bearing and taper roller bearing inner raceways Measure the cranking torqu...

Page 1002: ...sickle spanner Then back off the adjusting nut to the locking groove at which the torque is just below the cranking torque of 20 Nm Secure the adjusting nut with a tab washer A Tab washer B Adjosring...

Page 1003: ...Transaxle System 39 Dismantling and ass controlled lim slip differential with Valeo friction discs Dismantling and ass controlled lim slip differential with Valeo friction discs Printed in Germany XX...

Page 1004: ...Thrust ring Inner disc Valeo Outer disc 1 5 mm Outer disc Adjusting disc cny 1 Removal Note 1 Installation Large flat side faces disc pack 39 212t Dismantling and ass controlled lim slip differential...

Page 1005: ...nces between the types of inner discs used 288 39 New Valeo inner disc 2 Determine thickness of disc pack Pack thickness new 35 2 0 2 mm Wear limit 33 8 mm Measure complete disc pack without thrust ri...

Page 1006: ...has been reached all inner discs must be replaced To adjust the discs to the specified pack thickness use the outer adjusting disc No 4 3 Oil discs with transmission oil before fitting 4 The oil bore...

Page 1007: ...ge 9150 5 Dial gage Standard 3 mn 6 range Gage plate VW 385 l 7 7 Master gage VW 385130 8 Feeler gage Standard 0 05 to1 mm 9 Bushing 9145 10 Locking sleeve VW 52114 11 Adjustable lever VW 388 12 Gage...

Page 1008: ...using and to the selector rods selector forks Size a Specified size determined by design factors 68 65 mm Size b Flange area bearing cover to end of drive fit tapered roller bearing Size c Length of n...

Page 1009: ...bearing assembly pressing it on to drive shaft 3 Measure e g 44 20 mm Note Shims from 2 20 mm to 3 30 mm are available in 0 1 mm graduations plll r 1 i ff 2 d 8 k I i em 4 Measure c e g 22 18 mm 5 Cal...

Page 1010: ...pe G 28 11 from Transm No 11 F 05069 to 11 F 05322 had been assembled with bearing assemblies for which the following adjustment has to be made to determine the thickness of shim S5 S5 112 00 b c S3 0...

Page 1011: ...hickness S3 3 Determine shim thickness SS 4 Divide total shim thickness Stot in SJ and S2 so that there is the specified amount of backlash between the ring gear and drive pinion The goal of adjustmen...

Page 1012: ...position of quietest running is determined by moving the pinion in an axial direction keeping the ring gear within specified backlash tolerances The devitation r from the design distance R is measure...

Page 1013: ...the adjustment Refer to the following table to avoid unnecessary adjustments Replaced Part Transmission case vvIdhi gear Ring Gear 6 S 2 Drive Pinion with Adjusting Distance E SS X I x X X X X X X X...

Page 1014: ...distance R r r Deviation from R With the new system e g E 71 15 it is no longer necessary to look for the corresponding design distance R E the adjusting distance can be applied direct on the master...

Page 1015: ...cap without an O Ring and bolt down with two hexagon head bolts 6 Set adjusting ring of universal gage VW 38511 to distance a 7 Slide centering discs VW 385 4 on to univer sal gage and screw in gage...

Page 1016: ...m the set distance E in antilockwise direction small needle of dial gage will be between 0 and i i e if the dial gage has a preload of 1 mm the value deviating from 1 must be added to shim thickness 5...

Page 1017: ...end without shims and tighten all bolts to torque of 22 Nm 16 ftlb 3 Guide in second side transmission cover without shims carefully 4 Check gap between transmission case and side transmission cover w...

Page 1018: ...que of 22 Nm 16 ftlb 4 Turn differential in both directions m several times to settle taper roller bearings 6 Turn ring gear carefully to stop by hand and set dial gage to zero 7 Hold drive pinion wit...

Page 1019: ...red backlash specified backlash e g 0 20 mm Sl 0 95 mm Q 8 mg 0 07 mm s amm 0 27 mm Determining Shim Thickness S2 Opposite Ring Gear s2 stat s Example Stot 0 95 mm Sl 0 2Z mm S2 Q am Note Experience w...

Page 1020: ...ge shims St and S2 again until specified backlash is reached 3 Check backlash on periphery four times by turning ring gear 90 each time The four measurements must not deviate from each other by more t...

Page 1021: ...Workshop Manual l DR ING h c F PORSCHE Aktiengesellschaft...

Page 1022: ...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 1023: ...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 1024: ...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 1025: ...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 1026: ...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 1027: ...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 1028: ...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 1029: ...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 1030: ...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 1031: ...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 1032: ...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 1033: ...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 1034: ...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 1035: ...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 1036: ...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 1037: ...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 1038: ...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 1039: ...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 1040: ...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 1041: ...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 1042: ...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 1043: ...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 1044: ...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 1045: ...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 1046: ...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 1047: ...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 1048: ..._ 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 1049: ...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 1050: ...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 1051: ...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 1052: ...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 1053: ...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 1054: ...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 1055: ...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 1056: ...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 1057: ...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 1058: ...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 1059: ...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 1060: ...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 1061: ...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 1062: ...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 1063: ...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 1064: ...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 1065: ...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 1066: ...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 1067: ...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 1068: ...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 1069: ...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 1070: ...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 1071: ...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 1072: ...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 1073: ...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 1074: ...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 1075: ...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 1076: ...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 1077: ...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 1078: ...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 1079: ...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 1080: ...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 1081: ...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 1082: ...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 1083: ...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 1084: ...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 1085: ...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 1086: ...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 1087: ...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 1088: ...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 1089: ...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 1090: ...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 1091: ...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 1092: ...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 1093: ...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 1094: ...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 1095: ...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 1096: ...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 1097: ...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 1098: ...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 1099: ...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 1100: ...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 1101: ...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 1102: ...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 1103: ...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 1104: ...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 1105: ...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 1106: ...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 1107: ...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 1108: ...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 1109: ...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 1110: ...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 1111: ...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 1112: ...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 1113: ...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 1114: ...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 1115: ...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 1116: ...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 1117: ...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 1118: ...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 1119: ...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 1120: ...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 1121: ...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 1122: ...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 1123: ...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 1124: ...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 1125: ...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 1126: ...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 1127: ...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 1128: ...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 1129: ...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 1130: ...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 1131: ...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 1132: ...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 1133: ...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 1134: ...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 1135: ...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 1136: ...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 1137: ...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 1138: ...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 1139: ...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 1140: ...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 1141: ...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 1142: ...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 1143: ...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 1144: ...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 1145: ...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 1146: ...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 1147: ...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 1148: ...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 1149: ...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 1150: ...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 1151: ...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 1152: ...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 1153: ...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 1154: ...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 1155: ...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 1156: ...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 1157: ...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 1158: ...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 1159: ...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 1160: ...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 1161: ...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 1162: ...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 1163: ...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 1164: ...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 1165: ...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 1166: ...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 1167: ...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 1168: ...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 1169: ...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 1170: ...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 1171: ...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 1172: ...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 1173: ...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 1174: ...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 1175: ...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 1176: ...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 1177: ...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 1178: ...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 1179: ...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 1180: ...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 1181: ...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 1182: ...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 1183: ...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 1184: ...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 1185: ...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 1186: ...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 1187: ...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 1188: ...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 1189: ...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 1190: ...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 1191: ...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 1192: ...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 1193: ...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 1194: ...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 1195: ...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 1196: ...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 1197: ...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 1198: ...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 1199: ...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 1200: ...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 1201: ...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 1202: ...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 1203: ...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 1204: ...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 1205: ...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 1206: ...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 1207: ...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 1208: ...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 1209: ...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 1210: ...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 1211: ...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 1212: ...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 1213: ...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 1214: ...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 1215: ...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 1216: ...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 1217: ...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 1218: ...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 1219: ...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 1220: ...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 1221: ...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 1222: ...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 1223: ...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 1224: ...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 1225: ...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 1226: ...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 1227: ...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 1228: ...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 1229: ...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 1230: ...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 1231: ...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 1232: ...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 1233: ...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 1234: ...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 1235: ...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 1236: ...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 1237: ...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 1238: ...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 1239: ...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 1240: ...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 1241: ...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 1242: ...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 1243: ...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 1244: ...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 1245: ...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 1246: ...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 1247: ...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 1248: ...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 1249: ...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 1250: ...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 1251: ...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 1252: ...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 1253: ...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 1254: ...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 1255: ...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 1256: ...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 1257: ...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 1258: ...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 1259: ...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 1260: ...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 1261: ...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 1262: ...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 1263: ...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 1264: ...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 1265: ...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 1266: ...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 1267: ...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 1268: ...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 1269: ...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 1270: ...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 1271: ...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 1272: ...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 1273: ...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 1274: ...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 1275: ...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 1276: ...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 1277: ...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 1278: ...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 1279: ...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 1280: ...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 1281: ...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 1282: ...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 1283: ...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 1284: ...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 1285: ...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 1286: ...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 1287: ...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 1288: ...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 1289: ...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 1290: ...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 1291: ...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 1292: ...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 1293: ...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 1294: ...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 1295: ...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 1296: ...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 1297: ...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...

Page 1298: ...L HAZARD FLASHER PART V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER PART VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT CENTRAL LOCKING SYSTEM PART VII DOOR LIGHT SEAT BELT O...

Page 1299: ...T C IN SPARE WHEEL WELL D IN CONSOLE T7 SEVEN POLE A BEHIND LUGGAGE COMPARTMENT COVERING LEFT B BEHIND LUGGAGE COMPARTMENT COVERING RIGHT T14 FOURTEEN POLE IN ENGINE COMPARTMENT RIGHT T18 EIGHTEEN POL...

Page 1300: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part I POWER SUPPLY STARTER IGNITION FUEL PUMP l Current Flow Diagram 97 87...

Page 1301: ...ii T3 45 AUTOMATIC GEARBOX r 1 o ye _ I RESISTOR L 1g 0 iE ji 52 F 7 I 1 0 u l ii 1 I 15 l 5 bk x Ii4 lB c 4 2i Tl r IBUTOR DI I STF I i r iI i w bl D _ c c cs STARTER _I__ _i f ii i I i i li 25 GENE...

Page 1302: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part II FUEL INJECTION SYSTEM Current Flow Diagram 97 89...

Page 1303: ...rnibk rnibk 1 1 1 1 h j I i 13 i _i R b 0 q75 bk C C 6 1 5 br 8 i i 11 I I Tlh z r 1 ii 1 Ll z 0 1 I I I I VIIH g I K L _I AIR FLOW SENSOR Ef 7 ii 1 1 P I 15 br I 1 L 4 5 6 7 8 9 10 11 12 II 15 br 1...

Page 1304: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part Ill IGNITION STARTER SWITCH LIGHT SWITCH HEADLIGHT PARKING LIGHT Current Flow Diagram 97 91...

Page 1305: ...I 3 k Vdl k i ssP i _ i R 5 ia t i 4 M _I CONCEALING HEADLIGHT 56a i i i b I Lj bi rj re RADIO I il n HEADLIGHT LEFT HEADLIGHT RIGHT MOTOR L L _ _ _ _L _ _ I IGNITION STARTER SWITCH l 1 23 4 5 6 7 89...

Page 1306: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part IV FOG LIGHT LICENSE PLATE LIGHT FRONT TURN SIGNAL HAZARD FLASHER Current Flow Diagram 97 93...

Page 1307: ...R bi tl j it y I 1 11 1 R 0 s bk hl 7 7 0 e 5 i ii li ji A I w 0 s 5 11 hkihl bk bl 0 t Y i 2 I 1 r LICENCE PLATE E g y y ob f 7 2 Fi f y Ii t a SW 1 a 1 z II s k u c Y i cl I s E 1 z s E z 16 I I gy...

Page 1308: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER Current Flow Diagram 97 95...

Page 1309: ...0 LAMP CONTROL UNIT Ilk1 11 ____ INTERVAL WIPING POTENTIOMETER i d Zr mIl ii u z g rc DWC a I TA Tit 2 6 I cy r rc tk u 12 E r G 1 61 i 9 ii A t 1 zi r 2 d m 1 T 075 I 0 n u IF T t W bk E 075 Y 5 g r...

Page 1310: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT SEAT BELT Current Flow Diagram 97 97...

Page 1311: ...j k d B 0 19 t 9 c7 II T 5 I I 1 WI CENTRAL LOCKING SYSTEM CONTMOL MOTOR LEFT __ _ 1 B I 4 I 11 r wt iI 7 z0 5 111 0 r c 2 5 zr t a e 1 i j 2 i I 1 pl I i i F j j z 5 1 f 0 5 t r 9 I 31 REAR WINDOW I...

Page 1312: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part VII DOOR LIGHT SEAT BELT OUTSIDE MIRROR POWER WINDOWS BRAKE PADS Current Flow Diagram 97 99...

Page 1313: ..._ 5 Ilk I Tit 1 s i dlE I T2 1 9 1 1 s LJII I i i j r Ii p j f I 0 5 bl I T6 wt 0 75 45 0 5 Y w b bk z E i 5 t I tiM E k zzt _ _ _ sn 4 OIL 05 tJr _ WI 6 4 e 5 gr I L 5 g tN I T 1e b 15 t 4 1 II tII E...

Page 1314: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part VIII AUTOMATIC AIR CONDITIONER Current Flow Diagram 97 101...

Page 1315: ...r 11 1 1 1 1 __ll l _ ll l 1 I I r I P I T T TI I f I VER i 9 I I I I _ _ _ I I 1 I b L lll 0 I ___ ___ _ ___ __ t l __ __ _ I _ L L e _ 10R i I I I I r I j I 5 I yz J2 2 I 1 I C 3 A i j b LA u F i g...

Page 1316: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part IX AUTOMATIC AIR CONDITIONER SENDER UNITS Current Flow Diagram 97 103...

Page 1317: ...l yn bl I I T TlB a 5 0 75 vllbk yc bk LOW PRESSURE SWITCH AC I v WV4 k 5 1 ZG s 1 ti i i 2 B E A 0 1 0 bllbk t z1 5 b gn 7 r pJ ii r iA 2 2 z 2 2 g4 28 10 B z 5 B B I 21 4 E Ai i ___ j 8 s ii ii dJ 1...

Page 1318: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part X CENTRAL WARNING UNIT INSTRUMENT CLUSTER Current Flow Diagram 97 105...

Page 1319: ...j3M AR i eM o c z 6 1 L rl 1 L L u J 1 1 II I I 45 I II I L I I 1 I I I I d I I I 0 S bllbk I I I 5 05 111 k i T bI 5 CENTRAL WARNING RESET BUTTON OS 05 LIGHT b m3 L FLUID LEVEL il PARKING BHAKE o o L...

Page 1320: ...Wiring 97 Current Flow Diagram Type 928 USA Model 81 Part XI CLOCK CIGARETTE LIGHTER TEMPOSTAT CRUISE CONTROL HORNS RADIO POWER SEAT Current Flow Diagram 97 107...

Page 1321: ...0 b POWER SEAT 05 brilc b 0 75 3 II br 7 iQ i L L i bh i k 4 IILl2 TEMPOSTAT CONTROL UNIT _ l i j 7 5 br bk 1 I I fl a z z m 9 L 5 Ei F I CRUISE CONTROL YTm T21 bllwf i 05 7 Q i i _1 ilv TEMPOSTAT MOT...

Page 1322: ...Wiring 97 Additional Current Flow Diagram Type 928 USA Model 81 HEATING VENTILATION AC Additional Current Flow Diagram 97 109...

Page 1323: ...H AIR BLOWER SWITCH n r H I 5 k ldWl 5 5 rl I E 9 5 d cr a 2 1 5 bi 4 TlC 0 tl tb br c II 9 2 LT z g b 5 I E 2 bl 1 Ti Y 1 s II E 5 1 dr I j i i I gi 2 2 E 0 Y w i I g I 5 z F3 r 1z g j gi I5 _ j EE 5...

Page 1324: ...5 I 5 bl W T 20 Ii r I t IS g b 2 gr l 3 M I gi J G 2 I 5 I c T2 TT r S A 7 I 87 j _ YC 15 b II I 1L t I I bl 1 5 bk t T3 a 61 Td J bl II 5 2 TZE 2 SEAT RELAY 2 I 1 3 L I L j F J K E 0 52 h W I T w l...

Page 1325: ...SA Model 81 Sliding Roof ml 115 __ _ _ _ _ 30 15 IX 31 7 _p x_ 2 0 I II FUSE 8 1 16A I I I 1 IJ 5 Ll bk SWITCH r28 br k Tara r2a l 10 1 2 3 4 5 I SLIDING ROOF OPTIONAL Printed in Germany V 1981 Additi...

Page 1326: ...0 15 O iS 0 15 0 15CT J br 0 j ml JT ji iL s 1 tl il bwt I 2 3 s q 1 1 i L I II 2 j 3 J cLTiz d 5 E y 7 ti z I iz z I j ti s t 2 P r k gr 7 14 g 1 I 5 gL _I s h s i A4 1 i I SUPPRESSOR A IGNITION STAR...

Page 1327: ...Wiring 97 Additional Current Flow Diagram Type 928 USA Model 81 BAD10 WITH 4 LOUDSPEAKERS AND BOOSTER Additional Current Flow Diagram 97 117...

Page 1328: ...0 75 15 b Wl I 0 75 bi P 1 _ 0 75 hk I 075 I a 1 T41 r3 49 SPEAKER BALANCE 075 bk S rJ 4k A T44 0 75 bk bh W _ 4 _ _ OTF 75 I SUPPRESSOR RADIO J 0 75 0 15 0 75 bi bk I2 II T2 0 15 0 75 IGNITION STARTE...

Page 1329: ...GNAL HAZARD FLASHER PART V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER PART VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT CENTRAL LOCKING SYSTEM PART VII DOOR LIGHT SEAT BEL...

Page 1330: ...C IN SPARE WHEEL WELL D IN CONSOLE T7 SEVEN POLE A BEHIND LUGGAGE COMPARTMENT COVERING LEFT B BEHIND LUGGAGE COMPARTMENT COVERING RIGHT T14 FOURTEEN POLE IN ENGINE COMPARTMENT RIGHT T18 EIGHTEEN POLE...

Page 1331: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part I POWER SUPPLY STARTER IGNITION FUEL PUMP Current Flow Diagram 97 121...

Page 1332: ...PUMP RELAY AUTOMATIC GEARBOX bk l 21 br a a i E Y k 2 F ii i II i i II z hk h 7 z j I t r I iI i i Ki 1 35 b_ GENERATOR REGULATOR br SPARK PLUG ll 3 i 1 2 3 4 56 7 8 9 10 11 12 13 14 15 18 17 18 19 20...

Page 1333: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part II FUEL INJECTION SYSTEM Current Flow Diagram 97 123...

Page 1334: ..._ 15 xx _ _ _ ___ ____ __ _ _ _ x 31 _ _ aI __ 1 1 1 0 i I P z I I I 0 75 0 75 rcibl IS j 29 ___ _ _ _ o CONTROL UNIT _ _ r 1 I II il I i N v 0 75 3 1s b 1 18 15 br I 1 T AIR FLOW SENSOR 1 2 3 4 5 6 1...

Page 1335: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part III IGNITION STARTER SWITCH LIGHT SWITCH HEADLIGHT PARKING LIGHT Current Flow Diagram 97 125...

Page 1336: ...I I I I 1 5 I I I I I I I s I 5 N lllk n 1 s w II 5 b _ j HEADLIGHT 15 wt 56s l i i RADIO I WEADLIGHT RIGHT MOTOR 1 P t i 5 I P R _ _ _ IO 1 i I AL 1 L L _ I_ I_ __ 1 IGNITION STARTER SWITCH 0 1 23 4...

Page 1337: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part IV FOG LIGHT LICENSE PLATE LIGHT FRONT TURN SIGNAL HAZARD FLASHER Current Flow Diagram 97 127...

Page 1338: ...r 0 5bkibl I j I 31 FOG LIGHT SWITCH II 45 C I Is5 I I I flJ3 N3 82 0 75 IP b J 2 I o L Er7 iij 1 c1 z s 2 11 15 L I X l 2s I y i I Ii ji z T 12 a LT so 5 i 2 II z 1 p 15 9 bh W twwt a L R TURN SIGNA...

Page 1339: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER Current Flow Diagram 97 129...

Page 1340: ...IELD WIPER SWITCH L _ 53 IT6 475 Pi I 915 Y bk qr rC2 I7 5 82a qPJ rlh i SWITCH i L 7 I fJ i Ilk 5j53 J IO LAMP CONTROL UNIT _ r 5 CJ E 0 2 f F I i 5 z B 2 i 0 E ci i f aI g L a z z 2 II i INTERVAL WI...

Page 1341: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part v1 l WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT SEAT BELT Current Flow Diagram 97 131...

Page 1342: ...il bi hb 2 I i IH 7 5 i It I 7 g 13 a 2 3 J bS l I I Y J REAR WINDOW DEFOGGER SWITCH I u o 5 q75 y ll t lj II h 5 0 E Ifs 1 J 1 I i i f i a I p al j E z bIa FL I 4 r L 15 l 2 z r i 4 L aa SL a i 3 LL...

Page 1343: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Par N1 DOOR LIGHT SEAT BELT OUTSIDE MIRROR POWER WINDOWS BRAKE PADS Current Flow Diagram 97 133...

Page 1344: ...j I I 2 I POWER WINDOW SWITCH POWER WINDOW SWITCH 45 45 b bk 0 0 s 45 br bn h 8 5 0 E I f 1 1 j gi I z Y 09 ii r3r L Tc 1 s I 5 45 bl T Elb p jj O b PI T8 I8b J e iT r7l l 1 5 4 l I m I 15 18b qn I Tl...

Page 1345: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part vlll AUTOMATIC AIR CONDITIONER Current Flow Diagram 97 135...

Page 1346: ...a b Q o 4 1 R bk l i LJkill 1 Y I T __ HEATER CONTROL ASSEMBLY 12L l ll 1 1 T f 1 bi m 111 5 TF iI L L ii r 4 I x1 i I i 2 Y 2 k Y ar 7 pi X lo 8i o E 5 E i 1 I B I 075 I 3 11R H3R k 4kL AIL _ __ hL _...

Page 1347: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part IX AUTOMATIC AIR CONDITIONER SENDER UNITS Current Flow Diagram 97 137...

Page 1348: ...SSURE i SWITCH AC i lh Ii 1 j I g a i II i j 5 hc v WI 5 a Ei L gff E z I i Y J L P 5 m E 2 5 2s 20 P8 1 _ iw J _ I I j II i Is L k d 8 2 i 3 c2Y z 3 6 2 5 IO FRESH AIR BLOWER MOTOR t iI i 2 5 br 0 5...

Page 1349: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part X CENTRAL WARNING UNIT INSTRUMENT CLUSTER Current Flow Diagram 97 139...

Page 1350: ..._ d y Cl t h i l Y m9 7 bl Wl H ii i l l I l 1 g m I 1 I 1 _ _ _ 3L 45 5 45 5 I l 8 I I a I I Yi i i I 5 Lo 0 123 456 7 6 9 10 11 I CLNTHAL LYAHNINC LIGHT RLStI HIJITON MILEAGE PARKING BRAKE 12 13 14...

Page 1351: ...Wiring 97 Current Flow Diagram Type 928 USA Model 82 Part XI CLOCK CIGARETTE LIGHTER TEMPOSTAT CRUISE CONTROL HORNS POWER SEAT Current Flow Diagram 97 141...

Page 1352: ...4 25A T2h T2 TEMPOSTAT CONTROL UNIT POWER SEAT CRUISE CONTROL CLOCK I9 24 bl I 0 s 1 I 3 f y i j I i j a a s r 1 Li4p 1 t 5i L J 0 i b zl 5i oe Z gL I TEMPOSTAT MOTOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 1353: ...ng 0 15 30 i 30 _ ___ __ _ A I 31 x _ _ _ _ __ 31 FUSE 14 8A I T _ r rj 5 o yaa I VERTICAL hT ADJUSTMENT SWITCH LEFT I II 1 b rd II 1 s bl 5 2 T21k 1 5 9 g E 2 I I 1 J P ii il 7 1s L f I5 I b i i L L...

Page 1354: ...nt Flow Diagram USA Model 82 Sliding Roof 30 15 x 31 I i I in IO FUSEa 16A i I i 2 5 bk L i i _ _ SWITCH 5 l2n 97 Wiring II 40 1 2 3 4 5 I sumh G ROOF OPTIONAL Printed in Germany Va 1981 Additional Cu...

Page 1355: ...75 0 75 0 75 0 75 9 1 1 i ZL i 2 Alif l dk Dk rD bk T4F Tdd T441 TZ 0 1 2 3 4 56 7 8 9 OPTIONAL 10 u 0 rem A IGNlTlONiSTARTER SWITCH R WIRE CONNECTORS T4 FOUR POLE D IN CENTER CONSOLE YELLOW G IN CENT...

Page 1356: ...Wiring 97 Additional Current Flow Diagram Type 928 U A Model 82 RADIO WITH BOOSTER Additional Current Flow Diagram 97 149...

Page 1357: ...r I T2h 0 75 I I T2 44 I 0 75 br wt I T41 5 1 0 rO tJk CI IGNITION STARTER SWITCH WIRE CONNECTORS T2 TWO POLE L _ NEAR FUSE RELAY BOARD hi J 7 4 O IS b1 W L 1 A T4 185 0 75 h r4i Td 0 h br I1 0 5 t N...

Page 1358: ...97 Automatic gearbox30 __ rq x IA6 P 2 m 5 2 2 e p 2 cr g Kl U6 6 g r y M I 1 5 3 CLOCK n 9 k l T h 4 WC I i ili Ill g I ig 95 45 DI LIl M b I P e w 5o r ji c t G 1 I EE 1 j 50 E 2 Co 9 CIGARETTE LIG...

Page 1359: ...Wiring 97 Additional Current Flow Diagram Type 928 USA Alarm system Additional Current Flow Diagramm Alarm system 97 153...

Page 1360: ...F 5 z j 3 I k 075 475 b IIYC Tj i I I Ti 0 75 015 h 111 I WI I TZ Tic T3 31 TJf or5 I 1 s 1hl I II I1 WIRE CONNECTORS T3 THREE POLE A IN DOOR DRIVER SIDE B BELOW INSTRUMENT PANEL ZZZEFI C IN DOOR PASS...

Page 1361: ...GNAL HAZARD FLASHER PART V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER PART VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT CENTRAL LOCKING SYSTEM PART VII DOOR LIGHT SEAT BEL...

Page 1362: ...C IN SPARE WHEEL WELL D IN CONSOLE T7 SEVEN POLE A BEHIND LUGGAGE COMPARTMENT COVERING LEFT B BEHIND LUGGAGE COMPARTMENT COVERING RIGHT T14 FOURTEEN POLE IN ENGINE COMPARTMENT RIGHT T18 EIGHTEEN POLE...

Page 1363: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part I POWER SUPPLY STARTER IGNITION FUEL PUMP Current Flow Diagram 97 157...

Page 1364: ...10411 L li i f I I tlwye T21 T2a AUTOMATIC GEARBOX M y Ilk l bkl I1 I I II II 8 1 iI 7 0 i tilj 8 RESISTOR DII r I I i i j T t _ i jl i i I u bi q7s 5br ye 0 75 Ye 2 k z CJ G w 91 7 Si zi I 51 i S j G...

Page 1365: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part II FUEL INJECTION SYSTEM Current Flow Diagram 97 159...

Page 1366: ...i 5 7 15 1 br hr II 475 475 0 75 0 75 0 75 0 75 0 75 0 75 0 15 L AIR FLOW SENSOR AIR FLOW SENSOR __ 2 II 3 11 3 I 0 75 w E wvbk o 075 Q W 32 WO 2 l zi ys ES rz gt E i 1 02 I3 I 1 i IL L II j E j 0 15...

Page 1367: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part Ill IGNITION STARTER SWITCH LIGHT SWITCH HEADLIGHT PARKING LIGHT Current Flow Diagram 97 m...

Page 1368: ...A p3 bk i 56 J c _i HEADLIGHT LEFT I I I I I I f I I 0 0 s 0 i iv 56 3 if i brire 3 b 1 j L RIGHT _ CONCEALING HEADLIGHT MOTOR 30 _ c4 i0 _ I t w 1 3 1 qr Wbk 5 P f I I R X _ I_ ____ _ x q 4 b t_ _ _...

Page 1369: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part IV FOG LIGHT LICENSE PLATE LIGHT FRONT TURN SIGNAL HAZARD FLASHER Current Flow Diagram 97 163...

Page 1370: ...1 k i r ii L j INSTRUMENT CLUSTER ILLUMINATION POTENTIOMETER 95 0 s hkh bk tll Lb x 7 x17 0 5 bkihl R IT 0 5 bL hl 58 7 1 S Wl C r h T2r 15 qn w 3c a I 1 j 11 I I i t I t 5 u i 0 z s r 2 7 T r I OT5...

Page 1371: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER Current Flow Diagram 97 165...

Page 1372: ...E I 82a r SWITCH n LAMP CONTROL UNIT 1 1 2 _ __ hk n z A 4 li i f I i _ _ _ _i w Ok I1 O IS bWbl 5 tsl 0 E r7 g 7 i j iI_j 1 I 5 G 0 5 Z j 4 IL B 2 7 9 1 q J g i CL3 ti INTERVAL WIPING POTENTIOMETER T...

Page 1373: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT CENTRAL LOCKING SYSTEM Current Flow Diagram 97 167...

Page 1374: ...r 45 Dh T d I I 0 fL1 I5 I I l WI 45 Y A REAR WINDOW DEFOGGER SWITCH I g z I 0 aj IQ 2 7 3Mi 9 I w ih 0 s II Ii iI II 5 1 5 5 g 1 a I I p l z E L J IL 0 CErUTRAL LOCKING SYSTEM 0 NTROL MOTOR RIGHT j t...

Page 1375: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part 11 DOOR LIGHT SEAT BELT OUTSIDE MIRROR POWER WINDOWS BRAKE PADS Current Flow Diagram 97 169...

Page 1376: ...iI ii j I I J t 0 s 5 0 s bl E 0 15 15 1 5 i WI bk hk hk ii j i wt g a 95 i bl n T41 T44c e 0 s i I 2 81 Y 0 T2k r 2k T6 18A 1 6th t 5 15 15 ii q 1 i n re g hl iv L T20 I I 1 I I k 05 I dl b hk L Q5...

Page 1377: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part vlll AUTOMATIC AIR CONDITIONER Current Flow Diagram W 171...

Page 1378: ...2 il 0 0 _ z uw i i 4 i I 1I 1 I 1 1 I t 3 h L 5 j B z 4 J E I 1 r q t I k 2z g Q 75 J IO I io 2 z x I 5 62 T 1 c i jE IS _ImZ g j 9 q5 v 4 4t lZ f p iv i ig 0 r tjT i r 1 1 x p_ 1 l 4 X l I f I 1 5 i...

Page 1379: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part IX AUTOMATIC AIR CONDITIONER SENDER UNITS a Current Flow Diagram 97 173...

Page 1380: ...Yj I LOW PRESSURE SWITCH AC r ip J L 2 3 hc UY Es 22 dg g r pg t 4 1 KG qr kil I 1 El 2i t s z g v blltrk i I I I L I 2 b j d 1 6 t 3 v E c 65 g4 58 o t 5 5 B 1 iii ZI 1 I I _ _ j al I I 3 is i 2 i t...

Page 1381: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part X CENTRAL WARNING UNIT INSTRUMENT CLUSTER Current Flow Diagram 97 175...

Page 1382: ...45 5 0 5 0 5 0 5 C fFflp 5L __ __ l swm kjJ m B w I I a I L Bw 17sw N G s p 11 r t II II u 0 0 1 5 II I II 1 i 7 E a b r I I _ 10 11 3 1 CENTRAL WARNING LIGHT RESET BUTTON 1 PARKING BRAKE j j I I cr b...

Page 1383: ...Wiring 97 Current Flow Diagram Type 928 S USA Model 83 Part XI CLOCK CIGARETTE LIGHTER TEMPOSTAT CRUISE CONTROL HORNS POWER SEAT Current Flow Diagram 97 m...

Page 1384: ...ROL UNIT _ ___ ____ 1 1 T2h T2 CRUISE CONTROL SWITCH POWER SEAT r21 IT2 45 0 5 t I t n hr TEMPOSTAT MOTOR El II20 I I B 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 I CLOCK CIGA...

Page 1385: ...hkiN 2 I T2 II r rl 4h t Y F J 2 Im zs t5 In 6 Y r3 Rd CDk P IGNITION STARTER SWITCH R 015 415 th 1 il Tl II T 18b 0 I5 0 is k r I 5 01 iv rs h Ei II 1 t i g 0 E 5 2 K 2 iG WIRE CONNECTORS T4 FOUR PO...

Page 1386: ...Wiring 97 l Additional Current Flow Diagram Type 928 S USA Model 83 RADIO WITH 8 LOUDSPEAKERS AND BOOSTER HIFI l 1 Printed in Additional Current Flow Diagram 97 181...

Page 1387: ...T44 075 075 075 075 0 5 0 5 0 15 0 15 SUPPRESSOR RADnO w 8 J 11 mL B 2 iif Y i 01 b 4 5 lT 5 r3 w 0 TS hr wI I T3 40 SPEAKER BALANCE l J ii 75 bk W rJ 4k I T k 0 75 II SWITCH VUIRE CONNECTORS l Z TWO...

Page 1388: ..._ jj 3O J5 3 yg 74 i s 5 nL _ i Wa 15 it WT 7 __ _ I ii 6 f i sL 2 CLOCK n P T3 4 Q lh1 12 I 72 F 8 I ii i h Tl I 95 9 I I tMt l 3 5 50 r 2 w Wk 5 i j d0 g tT 0 5 g 7 2 15 jg Y 8 k d cn 0 CIGARETTE LI...

Page 1389: ...i li t 0 x w 0 75 1 d 5 J Ii 1 ii i i j 075 0 75 SPEAKER BALANCE INI 6 T43 Tci 0 75 475 r 11 1 i i 1 SUPPREssOR j 10 v I I IGNITION STARTER SWITCH Fi WIRE CONNECTORS T4 FOUR POLE D IN CENTER CONSOLE Y...

Page 1390: ...Wiring 97 Additional Current Flow Diagram Type 928 S Model 83 RADIO WITH 8 LOUDSPEAKERS AND BOOSTER HIFI Additional Current Flow Diagram 97 187...

Page 1391: ...2 0 1 L F 11 1_ I f T il i 0c td i L i I I SUPPRESSOR RADIO i I r II IGNITION STARTER SWITCH 1 c I I i 1 1 v fl 1 r4q 1 l r 2 I I il 11 1 T2 4 1 p T2 I t c 4 T T i WIRI CONNECTORS I I T2 TWO POLE L NE...

Page 1392: ...Wiring 97 Current Flow Diagram Type 928 USA Symbols and Explanation I l Current Flow Diagram 97 l...

Page 1393: ...istor sender unit e 9 part VIII current track 6 i Inductance coil Et4 Temperature switch N Horn B Pressure switch Kl Loudspeaker t Tz wire Connector e g seven pole terminal 2 Temperature switch therma...

Page 1394: ...or light N Ignition coil NC Resistor Ng Warm up regulator N 7 Cold start valve N Supplementary air valve N4 Transistor ignition unit 0 Distributor P Spark plug connector Q Spark plug S 2 Fuse Tld Wire...

Page 1395: ...Wiring 97 Current Flow Diagram Type 928 USA Part I Current Flow Diagram 97 3...

Page 1396: ...I i rs 1 T I Td 01 r K2i I Tl i L a I 1 I i J i N17 r I B i l a v T bjr 0f f r 7 I F I i I _i 1 i i G6 l i i GZ II L j i _ j P D I A _ 35 5 I 12 3 4 56 7 8 9 10 11 12 13 14 15 16 17 20 2 l 22 23 24 25...

Page 1397: ...t switch illumination L Left fog light L 3 Right fog light M Left parking light M3 Right parking light Ml Front side marker light s Fuse S 4 Fuse to Fuse S 9 Fuse T Wire connector two pole a behind ac...

Page 1398: ...Wiring 97 Current Flow Diagram Type 928 USA Part II Current Flow Diagram 97 5...

Page 1399: ...k l L i i 1 i 30 x T 4n T2r 5 9 i i j i t r4n T w 1 r T4h 0 75 r Pq p i 1 i ii i j i 0 75 L T4n 1 6br Li I I I I I I I I P H L Y A 56 r t 0 t 0 1 00 1 00 2 5 2 5 i i 1 i i i 1 23 4 5 6 7 89 10 11 12 1...

Page 1400: ...light K6 Hazard flasher indicator light Kl7 Fog light indicator light L29 Engine compartment light M5 Left front turn signal M6 Left rear turn signal S Fuse s3 Fuse S4 Fuse 519 Fuse S30 Fuse S3 Fuse S...

Page 1401: ...Wiring 97 Current Flow Diagram Type 928 USA Part Ill Current Flow Diagram 97 7...

Page 1402: ...OLL _ JllL KS L E3 _ _ r Xii 49 l M6i 7 I i I i V3 J L r r7 4 L m IX 49049 t 1LI _ t t _ T i 1 l 1 liL2El 1 J 0 i i 1 3 I ELI 12 OP TrJ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2...

Page 1403: ...brake light Ml Side marker light Ml6 Left back up light Ml7 Right back up light S6 Fuse S9 Fuse SIO Fuse S O Fuse S32 Fuse 533 Fuse T Wire connector two pole d near fuse relay board t near right front...

Page 1404: ...Wiring 97 Current Flow Diagram Type 928 USA Part IV Current Flow Diagram 97 9...

Page 1405: ...ie k 4 i 535 15 0 I P i _ 5tJ s I Tec B y Fe F4 iiiii a I T6c I z fr5 ra 78 1 T t Y H I I E 441 _ _ _ _ _ _ _ _ bi J li A 3 Sk3 K41 v E FL i E31 1 I j i 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 I7 18 19...

Page 1406: ...aner pump relay K O Rear window defogger indicator light K g Seat belt warning light L3 Make up mirror illumination 57 Fuse 95 Fuse S Fuse s 3 Fuse T2p Wire connector two pole neardriverseat T6 Wire c...

Page 1407: ...Wiring 97 Current Flow Diagram Type 928 USA Part V Current Flow Diagram 97 l 1...

Page 1408: ...1 Tbj S23 ln81 1 66j J43 _ I f r 5 L I I I I I I III 3 0 6 o Y 9 I iE34 j s I I jr L j ii w i l 9 F 0 6 7 p y i i i k j L b i w I Ea I k F Li i _ _ 1 2 3 4 56 7 6 9 10 11 12 13 14 15 16 l7 16 19 20 2...

Page 1409: ...netic clutch for mirror control Se Fuse 1 Fuse T4 Wire connector four pole a behind side covering right b in console right c in console right d in console right e in console right T 2 Wire connector t...

Page 1410: ...Wiring 97 Current Flow Diagram Type 928 USA Part VI l Current Flow Diagram 97 13...

Page 1411: ...31 S2l I I I L5 L6 L4 L3 0 I E5t 1 Td l i I I J ___ __ r 4c 1 15 4 E 59 1 I I i iJ f 5 1 I5 I M I5 1 s T 12b i I T 120 15 id i I 1 M vi5 i i 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 t Outsid...

Page 1412: ...essure sender unit GQQ Coolant level sender unit GQQ Cleaning water level sender unit J 3 Fresh air blower relay J35 Speed relay for AC JQQ Cooling fan relay J76 Defroster relay N S Supplementary air...

Page 1413: ...Wiring 97 Current Flow Diagram Type 928 USA Part VII Current Flow Diagram 97 15...

Page 1414: ...PS RP3 RDI I I 0 3by O1 0 G 1 lW rQ 1 i G2 1 i k_ i F48 lz li I I A w C t i I P gk i i i i J L GlO 1 _ r pi F45 I _ i i G32 G j i i 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 I C urrent Flow Di...

Page 1415: ...ight K7 Brake warning light Kl4 Parking brake indicator light Kl6 Low fuel warning light K28 Coolant temperature warning light K32 Brake pads warning light K33 Brake fluid level warning light K34 Stop...

Page 1416: ...Wiring 97 Current Flow Diagram Type 928 USA Part VIII Current Flow Diagram 97 17...

Page 1417: ...2a 4 r 7 II 7 7 qa 4 i K r El 5L e e 7L r I I I I i 1 G35i I i I I I I I I I 15 _ _ _ _ _ i 7 123 5 5 s 0 5 A I I 8 w 05 45 5 1 I I I E71 I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 1418: ...illumination light L3 Rear ashtray illumination light R Radio R Loudspeaker front left R3 Loudspeaker front right R4 Loudspeaker rear left R5 Loudspeaker rear right R6 Speaker balance S5 Fuse S35 Fuse...

Page 1419: ...Wiring 97 Current Flow Diagram Type 928 USA Part IX Current Flow Diagram 97 19...

Page 1420: ...1 E20 l ri i i i 0 6 E4r3 _ _ _ _ q7a T4 li iIt 0x2 0 75 llti 1 I i j R2 __ f w a m VlO O5 r 1 i__ i x i i I L s i i 9 i P k i it i i i i UI U3 1 5 I 1 HI _H1 F T i I f A A 1 6 H r I k4 i c i Ro 15 1...

Page 1421: ...Backrest limit switch driver side J77 Seat relay driver side S 4 Fuse T Wire connector two pole i near driver seat k in driver seat I in driver seat m in driver seat n in driver seat 0 near passenger...

Page 1422: ...m Type 928 USA Part X Wiring W Jo _ _ _ __ _ _ l _ __ __ ___ _ scj a 15 X 15 31 x 31 ___ I I n 7 7 y 1 4 L i B r ln r II J r2 I I 1 jEm I 1 1 2 34 5 6 7 8 9 10 11 Power seat Printed in Germany Current...

Page 1423: ...Wiring 97 Additional Current Flow Diagram Type 928 Remotely Controlled Outside Mirrors Additional Current Flow Diagram Outside Mirrors 97 23...

Page 1424: ...mirror control passenger side S9 Puse S18 Fuse T 2 Wire connector twelve pole a in foot well driver side b in foot well passenger side V Mirror control motor driver side V2 Mirror control motor passen...

Page 1425: ...Wiring 97 Additional Current Flow Diagram Type 928 Automatic Transmission Additional Current Flow Diagram Autom Transmission 97 25...

Page 1426: ...h engine J O Starter interlock relay JSO Central warning unit k Instrument cluster K3 Oil pressure indicator light L 9 Selector lever illumination N5 Solenoid valve S12 Fuse T4 Wire connector four pol...

Page 1427: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Symbols and Explanation Current Flow Diagram 97 27...

Page 1428: ...c Q l r t T a t l T t o T El4 Ft 4 El 4 0 M 0 G 0 j T x _ a TIP SWITCH 9 SWITCH TIP SWITCH MANUALLY OPERATED SWITCH TIP SWITCH MECHANICALLY OPERATED E G LIMIT SWITCH TEMPERATURE SWITCH PRESSURE SWITC...

Page 1429: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Index Current Flow Diagram 97 29...

Page 1430: ...20 MILEAGE RESET SWITCH VIII 36 OIL LEVEL INDICATOR LIGHT VII 14 OIL LEVEL SWITCH VIII 27 OIL PRESSURE INDICATOR VIII 33 OIL PRESSURE INDICATOR LIGHT VII 15 OIL PRESSURE SENDER UNIT VI 3 OUTSIDE MIRR...

Page 1431: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part I POWER SUPPLY STARTER IGNITION FUEL PUMP Current Flow Diagram 97 31...

Page 1432: ...FUEL PUMP RELAY d T5 pal U6 F 7 RESISTOR t i 1 0 Sn ii 0 75 lJJ wyo 3 5 z 2 CJl w I 91 81 Ei 31 5 i In DK 3TF I r i 1 i f i _ _i 9 re e I II 1 0 a w bl rc re 3s bk t b r 7 zz i i i zt i aI L Y Y i I...

Page 1433: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part II IGNITION STARTER SWITCH LIGHT SWITCH HEADLIGHT PARKING LIGHT a a Current Flow Diagram 97 33...

Page 1434: ...AL A i 30 X I I I I I I I I I I I I I I I I I I I I P Wbk H i f llJ _ _ X l 0s T4h bk 5 PARKING LIGHT CONTACT i I m T II 0 5 f CJ z 5 r c L 4 ul c II G is is s i 3E z B i zlz 1s br T4n 5c I I HEADLIGH...

Page 1435: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part III FOG LIGHT LICENSE PLATE LIGHT CONCEALED HEADLIGHT FRONT TURN SIGNAL HAZARD FLASHER Current Flow Diagram 97 35...

Page 1436: ...I m re W bh I I I I I TURN SIGNAL Ix s IX l T 1 964 0 bkh bk bl r _5aL R 9 ii IC 1 4 P bT 111 I _ LICENCE PLATE 0 75 bk t 4 2 I 0 L 2r7 2i 1 6 iii CONCEALING HEADLIGHT ENGINE COMPARTMENT 1 LIGHT EMER...

Page 1437: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part IV REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER Current Flow Diagram 97 37...

Page 1438: ...WITCH I i K E zr c Sil li GL i c z 0 9 0 5 i r I i i w z INTERVAL WIPING r u POTENTIOMETER e f 1 I j r DWW I T73 o 5 t W tJk Y r Zi j f Y 2 m WC I Tk O b w p pJ Yk I i 4 T7 g W E I 1 L i z 2 P IT q7s...

Page 1439: ...Printed L Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part V WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT SEAT BELT Current Flow Diagram 97 39...

Page 1440: ...j B 9 0 5 3 tN WL ll a 9 i _ j 5 r f jr f L 6 c b 2 is 6 f b rr j Hi E 0 E 1 fr k ib7 2 i x x I i 5 IWVI W W REAR WINDOW DEFOGGER 0 5 1 I i 27 r i i 1 tr I Ll ii 3 I it j Pi IL F z z s 0 5 br d g 3 CA...

Page 1441: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part v1 OUTSIDE MIRROR POWER WINDOWS SLIDING ROOF BRAKE PADS l Current Flow Diagram 97 41...

Page 1442: ...ro L 3 POWER WINDOW SWITCH RIGHl I v 1 1 1 h t i 11 _i 4 I T w 1 1 T L k a 1 3I t l c L j I SLIDING ROOF SWITCH r 1 k 0 5 b 1T 1 L 1 t 3 i Ta 1 5 Jdb I T 2 I 5 gritlr L M w i 2 Is bk I 3 gr td P gr bl...

Page 1443: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part VII FRESH AIR BLOWER AIR CONDITIONER SENDER UNITS Current Flow Diagram 97 43...

Page 1444: ...l v M VA t 5 EG pr I I II zi i i 2 z d d qs 0 5 F W Ii bk t z 0 el 1 I L z I _ 4 l 1 i f i s I I i A w 3 bk Tl iJ i 6 t 3 TlC co Sk 2s 4g 9 2 o rr L 5 7 i s I1 5 C 1 i O bl Vl t 5 B 9 ii iI l iTi1 A J...

Page 1445: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part VIII CENTRAL WARNING UNIT INSTRUMENT CLUSTER Current Flow Diagram 97 45...

Page 1446: ...I Q5 l lJh Iv7 5 9 3mn 4 5L I I I 1 I I I L L I I I I 0 5 C hi II br w b WI II _ 11sw _ 0 s tJr SW jiW I e i a FLUID LEVEL PARKING BRAKE 1 ENTRAL WARNING LIGHT I I RESET BUTTON w 0 5 bk br 1 2 3 4 5...

Page 1447: ...Wiring 97 Current Flow Diagram Type 928 USA Model 79 Part IX CLOCK CIGARETTE LIGHTER TEMPOSTAT CRUISE CONTROL HORNS RADIO Current Flow Diagram...

Page 1448: ...r _____r_r__ 1 I I i 1 1 it I _ I j D3 nI 7 I s 1 i 63 PEAKER BALANCE or lJk bl 1 I 5 t wyc a 1 iI y I t i i gi Ii I i L lJJ II i wi _ i L 9 L l 0 1 5br h bk 1 r v yH 1 i VA 0 5 1 i ib i 5 1 g I Oi 3...

Page 1449: ...11 r z 0 4 t i L JZ 1 k J I I 5 I k bl 5 1 G T 0 52 b W I r 0 s G 12 iZ Li 12 j2 6 5 2 15 tli vA t T4 Ba T2la t Y I 8 1 ii gr 1 W II M 1 6 fi 2 1 T k SWITCH LEFT Ta T2 5 T ii 2 go 0 5 0 5 br WI I I I...

Page 1450: ...L HAZARD FLASHER PART V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER PART VI WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT CENTRAL LOCKING SYSTEM PART VII DOOR LIGHT SEAT BELT O...

Page 1451: ...WHEEL WELL D IN CONSOLE T7 SEVEN POLE A BEHIND LUGGAGE COMPARTMENT COVERING LEFT B BEHIND LUGGAGE COMPARTMENT COVERING RIGHT T14 FOURTEEN POLE IN ENGINE COMPARTMENT RIGHT TiB EIGHTEEN POLE A IN FOOT...

Page 1452: ...Wiring 97 Current Flow DiagramType 928 USA Model 80 Part I POWER SUPPLY STARTER IGNITION FUEL PUMP Current Flow Diagram 97 53...

Page 1453: ...7 wKl 9U6 II 0 s o 0 5 Ye brlya P gr br s y 0s bk l gr br a p If z AUTOMATIC GEARBOX 1 0 bkl I1 I II II B I I I I I I I 0 e e _i bklya RESISTOR I DII l cL I I i 1 I bl re re 0 GENERATOF REGULATOF SPAR...

Page 1454: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part II FUEL INJECTION SYSTEM Current Flow Diagram 97 55...

Page 1455: ...wll I 0 75 w E Wlibk 6 0 75 a W 32 WO aJ 3l ZP si EI yz g k 02 x3 l 0 _ E 1 E y j 0 75 I JL 0 75 VP q 7 i j j FL I g 5 1 p 55 24 7 L T T II q l illi 0 I sln rr Tlh i zlr I 7 i 2 L Ai c 0 I7 L L I i 4...

Page 1456: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part Ill IGNITION STARTER SWITCH LIGHT SWITCH HEADLIGHT PARKING LIGHT Current Flow Diagram 97 57...

Page 1457: ...USE 2 P 16A L I I 56 I OM7 l8 Ml M3 M2 i c j AL j 1 CONCEALING HEADLIGHT PARKING L GHT s E I CONTACT i PA c t I 0 10 HEADLIGHT LEFT MOTOR _ _ _ i _ _l IGNITION STARTER SWITCH I i 1 23 4 I t Printed in...

Page 1458: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part IV FOG LIGHT LICENSE PLATE LIGHT FRONT TURN SIGNAL HAZARD FLASHER Current Flow Diagram 97 59...

Page 1459: ...RN SIGNAL I r r 5 I II ii IL I i _ t t Y El g y5 2 15 5 br 0 E z E v T z o Tf I i J t b1 _ f t v g 0 P bk t Y 2 I E i1 g i i 5 m E I 2 I 5 t LICENCE PLATE r4h FOG LIGHT SWITCH ra _ _ I EMERGENCY FLASH...

Page 1460: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part V REAR LIGHTS LAMP CONTROL UNIT WINDSHIELD WIPER Current Flow Diagram 97 61...

Page 1461: ...i 1 5 bh bllbr DkiW bi re I I_ 63 8 11i2 _I 0 75 15 Ly5 19 qr tM bi l y b f l T jI f FFq751 f Q T gj j 1 DhiW t Tit 11I 1 LU I IND SHIELD 2 x 5 a g4 I 2 i_ R z z INTERVAL WIPING POTENTIOMETER 1 I j I...

Page 1462: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part Vi l WASHER PUMPS REAR WINDOW WIPER REAR WINDOW DEFOGGER INTERIOR LIGHT SEAT BELT Current Flow Diagram 97 63...

Page 1463: ...5 5 2 4 _ ii k S j a 3 Y t 2 0 1 I 0 br i 1 I i D i fz 0 5 br i An i 1 T6 l L i _ A pi c 5 2 yNDow 1 7 J5 I T Pi bi 5 lx 3 116 0 s WY_ 05 05 ye vi3 T15 IaL f i r 11 07s075 i I 11111 _ II L I CZENTRAL...

Page 1464: ...Wiring 97 a Current Flow Diagram Type 928 USA Model 80 PartVII DOOR LIGHT SEAT BELT OUTSIDE MIRROR POWER WINDOWS BRAKE PADS Current Flow Diagram 97 65...

Page 1465: ...U 1 5 cl I T3 4c 1 s r br I T 16b 1s blr t r I 1 s h I T 4c 15 1 5 11l br 16 15 tqr tJbr r M i L _I POWER WINDOW MOTOR POWER WINDOW MOTOR LEFT RIGHT T l Y t r L j bl hk i P2 5 I M E OE p L 5c 4 05 rl...

Page 1466: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Partvlll AUTOMATIC AIR CONDITIONER Current Flow Diagram 97 67...

Page 1467: ...64 i T td 475 bh ib L _ HEATER CONTROL ASSEMBLY _ _ I _ __ _ _ ___ _ _ ____ TEMP CONTROL LEVER J _ Z T iji a 6 1II is 9Z Jm z Y 2 4 _ j Q E_ _I SK q 3 ti 2 E 1 f 2 u 1 z Il 2 B 1 1u OE f r wno 9 1 L 1...

Page 1468: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part IX AUTOMATIC AIR CONDITIONER SENDER UNITS a Current Flow Diagram 97 69...

Page 1469: ...1 SWITCH AC i I I I br t z 3 E 9 WI CA1 II Ei 4 E 5 z r 1 iTi1 1 I ccl I 3 P f ii5 d i b on Y Y r YJ L i l 2 3 CJY i i c 5 ES 58 ho c i_ 2 5 5 2 r ZI 2 P I i ii b 4 gFE s 3 k 2 Ii0 5 re 3 0 r F I 7 w...

Page 1470: ...Wiring 97 Current Flow Diagram Type928 USA Model 80 Part X CENTRAL WARNING UNIT INSTRUMENT CLUSTER Current Flow Diagram 97 71...

Page 1471: ...II I B F ____________ ____ b e bl BRAKE FLUID LEVEL PARKING BRAKE __ 1 r P ENTRAL WARNING LIGHT II RESET BUTTON OS OS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 1472: ...Wiring 97 Current Flow Diagram Type 928 USA Model 80 Part XI CLOCK CIGARETTE LIGHTER TEMPOSTAT CRUISE CONTROL HORNS RADIO POWER SEAT Current Flow Diagram 97 73...

Page 1473: ...CONTROL UNIT _ 1 7 iii I _ v0 5 bk cl m TEMPOSTAT CRUISE CONTROL SWITCH Xl7 e49 E 8 P 7 24 x0 5 bkihlbk hl r I 5 I ij q50 s bWbl bkilll 5 or I ei I i I 1 II F I t i 0 I POWER SEAT dTa Tz Y Ii 15 blh I...

Page 1474: ...Wiring 97 l Additional Current Flow Diagram Type 928 USA Model SO HEATING VENTILATION AC Additional Current Flow Diagram 97 75...

Page 1475: ...i LOW PRESSURE SWITCH AC M 1 5 Mq KVWI 4 4 i f fi SOLENOID VALVE u E i t b 1 1 u rl 111 1 TlC Y E 1 s rv 3 or I FL 7 i zi 2 2 E _I 6 I 5 7 5 4 cn g 12 r 2 gi BE i i A g d 5 1 I if Is 8 e u 1 j iii I P...

Page 1476: ...SWITCH LEFT 1 r3 an VJ 01 ia TCL I 5 bl c 5 2 T2c I 5 9 2 II t i 5 t K 7 L J5 Li k 5 0 6 2 hrA 4 f Tit qs tlriw r I 2 5 co T 2P f j II 5 hkB 9 i i K 7 yg L 4 J_ a SWITCH LEFT Y B 1 sI5 hk W WV l T4 8...

Page 1477: ...Current Flow Diagram Type 928 USA Model 80 Sliding Roof 30 FUSE 6 I 16A 1 1 I 1 11 P Ll RVl EV2 L SWITCH 0 40 1 2 3 4 5 97 Wiring I SLIDING ROOF 1 Printed in Germany IV 1980 Additional Current Flow Di...

Page 1478: ...T j jT jTZ 07s 075 0 75 075 0 75 0 75 q75 q75 0 75 0 75 r ET T I T4 fh IT ok5 0 75 0 75 0 75 0 I t d tl OF 0 r5 y Dr t1 w 5 7 zr 1 3 II 1 11 i i I J I 03 A bE bl Wl ww I 0 75 llk ll I xl 075 qnrlwt I...

Page 1479: ...Wiring 97 l Additional Current Flow Diagram Type 928 USA Model 80 RADIO WITH 4 LOUDSPEAKERS AND BOOSTER Additional Current Flow Diagram 97 83...

Page 1480: ...G ct a 5 E O E ISUPPRESSOR RA DIO fs 0 7s tJ _ J j t L 1 _ i 0 15 br wl T4 Ia I qrs br Tdd h 0 s trr 1 tJ T K 0 75 q7s 0 75 br Vit gniwt I I Tit ii 6 75 br 3 P rH tlk r __ iI I 1 _ 1 0 rt l u IGNITION...

Page 1481: ...Workshop Manual DR ING h c F PO R S C H E Aktiengesellschaft...

Page 1482: ...is only for the internal use of the Porsche Dealer Organization 0 1977 Dr Ing h c F Porsche Aktiengesellschaft Sales D 7140 Ludwigsburg All rights reserved Printed in Germany XX 1988 WKD 481 621 Prin...

Page 1483: ...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 Antibl...

Page 1484: ...928 Table of contents Volume VIII Wiring Page Wiring diagram 928 GTS model 94 97 459 Table of contents Printed in Germany XXXII 1993 1...

Page 1485: ...TS model 92 93 Sheet 1 F 4 5 The connector designation on cable 0 5 RE BK is incorrect The correct designation is F 11 Please alter the wiring diagram accordingly Modifications in wiring diagram 928 G...

Page 1486: ...Engine Cooling Heater Air Conditioner Outside Mirror Power Seat Seat and Mirror Memory Radio Telephone Antilock System Airbag Porsche Lock Differential Trailor Coupling Brake Pad Wear Indicator Motor...

Page 1487: ...e lines and relays required for the individual wiring diagram The ground connecting points are designated with GP and their location is shown in a vehicle diagram The lo pole plugs on central electric...

Page 1488: ...I x lv LIGHT C OMBINATION BACKUP LIGHT TURN SIGNALS HEAOLIGHT ASSEMBLY LEFT FOG LIGHT VIII SUPPLY x CENTRAL ELECTRIC B m B m I GP IX WL 1 GP III GP xI GP v UNMARKED LEADS ARE WRING LOOM 3 GP II GP I S...

Page 1489: ...I t 1 II _ _ 2 0 BK WT GN 0 75 BKIWT 05RE BK nr 5 P I I f a 1 I TI 1 IU lcll BACKUP LIGHT T7 SWITCH M4811 I I I I I I I il I I I LTll I I s12 L 14 I I 27 1 25 BK BL ONLYM 1 Al2 I I I 1 I I s24 I I I...

Page 1490: ...IE23 1 8 41 GP II II T GP I lax 6 7 I I II I I ill nl II II It r 7 k t I Y GP V OS9 c 2 2 7 iir I i uppL i I I II III I I I I II 2 4p x I A L FLASHER XIII y L l ib i Y 2 I XXIII XXIV LIGHT COMBINATION...

Page 1491: ...ITCH IM4811 I I b 4 7 WL 16 LICENSE PLATE LIGHTS 1 TH r BACKUP LIGHT ONLY M249 CENTRAL ELECTRIC m B a a fGP VI TAIL LIGHTS LE FT j JJ ERcK P LAMP STOP LIGHTS 0 75 GR BC II I I UKN bIbNAt STOP LIGHTS 3...

Page 1492: ...r 1 m 1 I 2 5OKlYE IIGI PUSH BUTTON SWITCH FOR SUN ROOF IM6501 1 I I I I GP v POTENTIOMETER FOR WIPING WASHING WINDSHIELD WIPER MOTOR WIPE WASH SWITCH l 2 1 LJJIO 5 IllJ I W 1 5WGR _ L24 J I I I nr I...

Page 1493: ...IPER RELAY REAR WINOOW WIPER MOTOR 1 T ER INTff Xl 31 IGROUNO I t I E A i K 1 I HEAOLIGHT CLEANERS VII 1 I r t y I 4 d rtJ t s I I I GP IX I GPV 1 GP n cl cl CONNECTING POINT CONNECTING POINT GP VI MA...

Page 1494: ...IOE MARKER LIGHT WASHING FLU10 LEVEL CENTRAL LOCKING SYSTEM PARKING BRAKE FAILURE STOP LIGHT COOLING WATER LEVEL COOLING WATER PRESSURE TOOTHED BELT TENSION I I I I I I I I I I 2 1 i BUTTON TOP1 Iw w...

Page 1495: ...1 8 I 2 WL 4 I T5 r I CENTRAL ELECTRIC RELAY FOR FCU _ _ I RELAY SOCKET ONLY FOR L 10 d XIX TIMING RELAY IM215 M5531 1 21 22 23 24 25 26 27 2E 25 3c llll I El3 W25 I pg COOLANT TEMP CChC D v 7 4 LOWW...

Page 1496: ...C C AIR CONDITIONING SYSTE 2 II I I 05BR I I CbO1813 1 0 5 GR GN 1051 1043 FOR637 M53 II Sl I I I I Iill A 1 ypg T35 F T W 1 I E B 6Z s g iw d j I 5 jj 1 YJ TIONER Ii L _f SUPPLY x I 7 E I 1 MICRO SWI...

Page 1497: ...F 32 BAR ON 26EAR ON 18 BAR 1 25BKlWT I I t OFF 14 BAR 3 LEVEL PRESSURE SWITCH 637 M53 DNAL AIR CONCIITIONER M570l i 3 I SUPPLY x I 31 I I 1 BLOWER SWITCH GP IIFOR LHO EVAPORATOR SENSOR E 0 RESISTANCE...

Page 1498: ...A 8 2 WAY SWITCH i r 5 5 8 4 f s z Y z 7 o k 2 2P SEAT CUSHION HEIGHT CONTROL REAR 7 I I y I I 0 m OISCONNECTING POlNl 1 i L 15ER II15AE T37 1 MIRROR I 15BKlW n CONNECT IONPOWER SEAT LEI FT WL 343 NOT...

Page 1499: ...ARD LEFT L T20 1 GP 4 WAY SWITCH 4 WAY SWITCH 1 ORT SEAT 1383 M38 71 T20 4 3 r 14 WL ON SWI i I 8 1s RE 3I 1 5OR 15 EKNI CONNECTION POWER SEAT LEFT 1581 X 1 WL ON SWlTC tl 1 1 1 I y T 7 T j i WL 343 I...

Page 1500: ...1 I GROUND FIREWALL LHO j STEERING CONSOLE _ _ j ZJ E 1 0 5EL RE 1 I SEAT SIDE ELEMENT HEATING t l t CENTRAL ELECTRIC p 1 or sz I 0 5IE RI 11 A n o 5M 1 I iC 30 A SEAT SIDE a 13 l ELEC HEATING ELEMEN...

Page 1501: ...3 4 22 iT lO R q l i L ZOLV cj h WAY SWITCH 54 1 SEAT SIDE ELEMENT HEATING SEAT SIDE ELEMENT HEATING I ELEC HEATING ELEMENT FOR SEAT CUSHION I L WAY SWITCH WAY SWITCH b WAY SWITCH 56 OISCONNECTING POI...

Page 1502: ...CO_ E ANKR USA M33bM692 CD CHANGER I ROOSTER 15 A F 40 I 21 7 I i I I I f ___ l_ s j FRONT LEFT HIGH RANGE RADIO SPEAKER FRONT RIGHT HIGH RANGE RADIO SPEAKER MIDDLE RANGE SPEAKER ITERM 15 I CENTRAL M...

Page 1503: ...B CENTRAL ELECTRIC GP VI 5 0 5 E 0 5 GR Z NOT CURRENTL C CONNECTEO 05WT 1 1 WL 167RlGHT FRONT RlGHl HIGH RANGE RADIO SPEAKER SEPARATING FILTER OOOR LEFT 11 61 ii ii k o R F LTER q MIDOLE RANGE SPEAKE...

Page 1504: ...NG SENSOR IM2211 i 1 00K 0R I I I 1 I I I I I I 1 iQ 1 I 1 I I I I 1 i j II I I I r 73 Y 0 5M K 1 5 elm 11 0 5EWYE 9 0 5RE 3 05 WWT 12 r 10 b5 x RI 74 75 76 WIRE CONNECTOR a IOOFX I i i K 5 E E g z 9...

Page 1505: ...Eclm IO CENTRALELECTW I I I 1 rlz REAA FOG UMT L 512ysins ClPmmL UNT ST mm I n T13 yTuw SKiNAL REAR RIGHT n L T22 h TWi SIXAL FcLfR LEFT n 525 ysue CcwTmL INT sm FUIIIERLMT RMT r n Tllueu E ccNTFaL LN...

Page 1506: ...7 I I I I II I I I I I I I 0 75 BR III II I E 16 SoLEN fJv L e y llh GP V Bi _ __ c s ba 52 22 WL 3 Es r 441 5 r I 0 75 RE 0 I I I i n cnl RUISE 17 I IId ONTROL SWITCH Xl IW ATIII II M F I CONTROL UN...

Page 1507: ...K VENT TEMPERATURE OOUBLE NTC I s ENSOR POTENTlOMETEf NOT APPLICABLI WITH CAT CONV I I 1 I r 075 QE RE u I m 250wRE 1 a b BRIOGE Xemm I I NOT APPLEABLE I I I I I l J I III I I vv S tl T C cd I id I l...

Page 1508: ...GL TE 6 SPEEOOMETERSGNA 05 GWWT I2 CENTRAL LDCKING 0 5 EUVGV a tIMiT SWITCH OFF 0 5 BRA 2 UNPRPlE CENTRIL LOX 0 5 WVRE TERM 30 3 1 2 0 RE K11 I 05 BR RE 0 5 OR GN 05 ER WT 05 OR W i j PROIE i 5 CENTRU...

Page 1509: ...MLTER s1hV 0 5 GWWT u CENTRAL LOXING 1 LIMUSWITCH OFF 0 5 BR GN I NPRH CENTRULox 2 0 OR I p f GP VLHD GP VLHD I GP IV RHD GP IV RHD 0 5 DR RE IIJ PRIML 0 SRR V 5 CENTRAL LOCK d ENGM HO00 0 5 BR WT 0 5...

Page 1510: ...T21 a 2 Tf2 l m 1 Y321 1 H2s 25A Cl 30 30 K14 tmx 30 VI 30 30 xl 30 L 15 F2L it25 Ml2 2 7 SILKMARtW LIGHT LEFT 8 SIOE MARK RL RlGttl WIPER INTERMITTENT CONTROL FRESH AIR BLOWER 9 ASHTRAY INSTRUMENT L...

Page 1511: ...7 Tli 1 I I 2 I I c 3 3 4 FE FL P 2 I d SUPPLY Iy x y I i R j u PS 36 x0 Si 72 s Pj t XI WIPER INTERMITTENT CONTROL XII FRESH AIR BLOWER XIV OEF xv ABS lM5931 XVI TWO TONE HORNS s 11 y 1 r 1 m Sk2 38...

Page 1512: ...RQUE 1 ONVERTER LEFT SIDE P 36 OOOME TER RESET SWITCH UNOER THE IFISTRUMENT SCUTTLE JKL 21 22 POTENTIOME TER INSTRUMENT LIGHT 8 0 BY STEERING COLUMN LEFT OE 2 POTENTIOME TER IDLE SPEED CO bdL 660 IN P...

Page 1513: ...Il P LIGHT TAILGAT DESIGNATION FUNCTION pVg oE IN NOTE FIELDIN WIRING DIAGRAM LHD RHO TWO TONE HORNS I II l2 3141516l7l I I 4 4 I I 1 I I I I 8 19 II 71181 1 I 1 I dl K I I I I I I II I IN 1 1I I2 I3...

Page 1514: ...PER SYSTEM COVER I cv I f TIE 19 T20 T21 T2l 23 T2b T7h T29 4 AIR CONOITIONING SYSTEM 8cN RCN IN CENTRE CONSOLE F33 T30 6 AIR CONOITIONING SYSTEM 8CN 8cN IN CENTRE CONSOLE F33 34 T31 4 INSIDE TEMP SEN...

Page 1515: ...rflMPARTM flN I FFT 71ITPFN l N PTRI IT M l INT ABBREVIATIONS CODE MEANING CODE MEANING M 061 ENGLAND VERSION M 139 AOJUSTAELE SEAT HEATING SEAT LEFT M 193 JAPAN VERSION M 195 TELEPHONE PREPARATION CE...

Page 1516: ...Instrument Cluster and Sensor Engine Cooling Heater Air Conditioner Outside Mirror Power Seat Seat and Mirror Memory Radio Telephone Antilock System Tire Pressure Control Airbag Porsche Lock Different...

Page 1517: ......

Page 1518: ...he lines and relays required for the individual wiring diagram The ground connecting points are designated with GP and their location is shown in a vehicle diagram The IO pole plugs on central electri...

Page 1519: ...OTOR III II 1IIIllll 7 I I I i I I I I I I I I I I I I I I I I I I III I I HEADLIGHT yERTICA_L AIM CONTROL I I I i I I CZli my I I I I I II I I I I I to YE OK I I 2 l I I r n na d AU I I m 3 5 I I lrr...

Page 1520: ...T5 bl I I BACKUPLIGHT T7 SWITCHIM4811 81 c g yzf d T19 i r l L WL 16 r I cuzr CT KT21 I I d 19 I 1 PLATE LIGHTS 1 I GP VI WL 4 LAMP LIGHTS XXIII XXIV LIGHTCOMBINATION _ BACKUPLIGHT WI n lll ONLYM249...

Page 1521: ...II I 1 I I I I I I IL III I I I Ilt I d I I I I T 2 I IIl25 I I II I I BACKUPLIGHTXVIII ONLYM249 FOGLIGHT VIII FOGLIGHT IV xxIII x Iv LIGHT ZOMBINATION _ OAYTIMERUNNING LIGHTIII B SUPPLYx B B v STOP L...

Page 1522: ...25 WBL CNYMZ49 1 Ju12 rZ 24 I r 24 I ra I I TZI PLATE LIGHTS WL 4 El PGPVI TAIL LIGHTS LEFT i I aa i x I _ d I I CENTRALELECTRIC A I FLASHERXIII XXIII xxiv LIGHTCOMBINATION STOP Ll HTS BACKUPLIGHT XV...

Page 1523: ...y u iz2 T I jj j Lzi 4 jj x 6 2 5 BR I T U2 15WEK Gp IV s j I 1 I m 15 WIE I i 53 3 1 5 vBL m 0243 1 I I 115 I 125 4 1 1 1 WIPE WASH SWITCH F E I 0 5 0RN l A L I j j jjj _ x j ji ii I _ _ _ j iiiiI i...

Page 1524: ...I FCR RHO ERI Ma ERZ ITERCHANGEO GPV I ONLY RHO 1 25B 1 25m I I WIPERRELAY U23 42 pJ I 1 a Y LH I 5 T8 I I GP VI I I I I I I I I REARWINOOW WIPERMOTOR e _ I L q _ _ 1 I _ HEAOLIGHTCLEANERS VII GP V P...

Page 1525: ...FAILURESIDEMARKERLIGHT __ _ __ IlIe PteSSURE PORSCHE LOCKOIFF FUNCTION WASHINGFLU10LEVEL CENTRALLOCKING SYSTEM AIRBAG PARKINGBRAKE STOPLIGHT SWITCH FAILURE STOP LIGHT COOLING WATER LEVEL COOLINGWATER...

Page 1526: ...4 us3 I J 629 I EQ P21 cw25 1 IFI I 43 r 1 I II III I IIIIII I IIll I 025 1 l t I l E22 1 I I I I I I I I III I I I I I I I CEl2 II I I I c l I I I I I 14 1 11 1 I III i n w12 u 0 75BR RE 1 1 1 1 l l...

Page 1527: ...L La14 INSIDETEMP SENSOR T h OSYE 1 BLOWER INSIOE SENSOR c a I I j I j I j j i j i j j jj CONTROL UNIT i ii AIR C NOITIONING8 j i i SYSTEM I I Iill i ii jj j j I j j j L i m j i I i i j jj iI i i T3E...

Page 1528: ...mr I 6 0 RE jlQJ _ l O2 T35 5 2 I J I I I w24 022 If 11 4 OILTEMPERATURE lM2491 SWITCH TORQUE CONVERTER 1 r 1 IONAL AIR CONDITIONER I SUPPLYx 1 1 I n I M5701 1 BLOWERSWITCH EVAPORATORSENSOR RESISTANCE...

Page 1529: ...ii 1 i jj jij J j ij 5 j 0 5 WT Ij j 3 05W i j i jji jj ii ii i i l I I m I I 1 SEAT BACKREST CONTROL SEAT CUSHION HEIGHTCONTROLREAR b 5 6 7 I I j 7 j E BK GN ii 15 Q I m i DISCONNECTING POINT Y l I I...

Page 1530: ...64 T20 T20 HEIGHT 4 WAY SWITCH 45 k6 7 z f ii jj A zl ORT SEAT 383 M387 SEAT CUSHION CONTROL REAR l nn WL ON SWITCH SEAT BACKREST CONTROL ONNECTION POWER jEAT LEFT WL 343 NOT APPLICABLEWITH Ml39 M340...

Page 1531: ...LELECTRIC CENTRALELECTRIC I j jj jj a B B II M p j j I j jj j i 14 jj j j f Ljj II e I ii L 1 j jl i j j I I r 0 5w B jj SEAT SIDE ELEC HEATING E 1EMENT I 4 jj ij 9 L L I I ELEMENT HEATING FOR SEAT CU...

Page 1532: ...CH 4 WAY SWITCH 4 WAY SWITCH f i j I Ili i i i j il OGH Y 1 2 r _ _ j pi i _ ii loGN ii 1 22 I 30 A 5 44 t5A 13 I SEAT SIOE ELEMENTHEATING ELEC HEATINGELEMENT L WAY SWITCH FORSEAT CUSHION _ 4 WAY SWIT...

Page 1533: ...L j d s gj 1 1 1 j d MIOOLERANGE SEPARATING FILTER MIOOLERANGE SPEAKER OOOR R UGHT SPEAKER 1 II 1 I I I I I II _ I 61 62 63 I 64 65 66 6 i OEEPRANGE SPEAKER REARLEFT 1 58 CONNECTION PLAN BOOSTER MIDDL...

Page 1534: ...ELEPHONERECEIVEF e 1 II _ TAINED IN 7 e _ I j _ _ _ _ 1612 7 I I j j c iiii _ jj i b NNA NSIONWIRE I __ _ _ CONNECTKN CABLE j __ _ __ _ TELEPHliE RECMRPLATES WR HG LMNFoR TElEFmNE REcENER j iijj j jx...

Page 1535: ...HYORAULIC UNIT ABS i i II IIIII II II c 9 I f s z2 _ T23 WI I 0 5k G OSEwuE I 9 COC 1 L I N I i j 0 5BK RE _ I I 0 5ellwl I XI 1 I I I I I i l I 15 EWE I3 2 0 RE u I 0 5VVN I n 11 I II 7 I III II 6 I...

Page 1536: ...TH HORNCONTAC I_ WL 3 _ F _ 2 2 Ii AIRBAGPASSENGE R S ONLY LHO III I 0 5 WI34 I 05twvE 0 5 RE I w I I SIDE I _ I 7 ii ui _ L ili i I _ i T RIllHl CRASH A CRASHSENSOR LEFT TRAIL ERCOUP M208 LUGSOCKET r...

Page 1537: ..._ I IAKltK __ 7i 04 I J _ I I II ENGINE SPEED SENSOR _ _ l l p g i u l II 35 0OK 1 y li I y 0 16ix j jj _ I a MORE I GP Ill q ml I b I IL 1 1 11 i _ _ _ TRANSMISSION PROTECTION I I SWITCH it LUNNtLlU...

Page 1538: ...GPIII j m us iv IllI II 8 I I I _ II II I i MASS AIRFLOW SENSOR i PT 11 I I I I II I I I I I I nun IL I I I II II l 3 IIIII I I I I I I I I n I I I I I I I j I n crm m1 83 I t I I II t WL 15 II I I I...

Page 1539: ...S 7 1 I OWWT 0 5 BR EL 4 I REAR LOCK 1 I CENTRAL hK NG Lllrf SWITCH CN TERM 30 1 0 WWT 0 5 WRE 0 5 GVWT pzJ GPV 05l WT 12 0 5 GN WY TLRN SIGNALS 0 5 WGN CENTRAL LmQNB LIMIT SWmCH DFF 0 5 BR wd 2 q UN...

Page 1540: ...T PASSENGER S SIOE 0 5 WWT lb CENTRAL LUKUlG 1 LMITSWITCHON NAA iB 1 0 BKM 0 5 WRE b SPEEDXlETERSlGNL 05GNAfl 12 CENTPALLaKlNG LIMIT SWllCH XF rngg 0 5 BR F d 2 q Ulf RI E CENTRALLOCK I 2 2 0 BR 1 GPV...

Page 1541: ...O LCENSE PLATE LlGHTS 1 RIARFOGLGHT 12 TURNSI AL FRONTLEFT 13 TURN SGNAL FXARLEFT IL TURN SKXAl FRONTBENT 8 TURNSIB4llEARRlG T 16 REARWNY WCSF BR WARNWFLASHR n EKJNECOMPARTMNT Uc T 1E WWER WN Iw REGUL...

Page 1542: ...BLOWER FLASHER OEF ABS MS931 TWO TONE HORNS XVI85 so18 KICKOOWN CONTROL BACKUP LIGHT lM2491 N mlmv 30MC21 21 PA X SUPPLY r m i z 7 _ n 7 7 D 22 K27 I ij 1 1TK jj RP a rn I j jj 30 23 xv COB ii j j SIM...

Page 1543: ...TWEL L ONSIDE 0 52 57 A8 46 41 A 55 56 N11 c 94 I I I L 8 I IKI 3133 OILLEVELSWITCH ml PDFCCI IDF CFMC D 1 3eN 0 I 3eN 01 ON OIL PAN FRONT I I I 1 P26 ID I I I L Y8 L ILI IYI nil TFMPFRATIIRF WITrH IM...

Page 1544: ...OLEBELOW RADIO P 23 25 7cP 7cM ONINTRUMENT PANEL K 76 78 N22 075 0 84 85 JK 1 2 co 20 8cP 8cM ON STEERING PROTECTIVE TUBE 0 29 30 B 11 12 6CL bcL ON WINDSHIELD WASHER TANK MN 28 29 LIGh u L m 8 nL LLL...

Page 1545: ...TRIGHT ca5 T26 2 HEATEOSPRAY JET LEFT 6 0 6 0 UNOERTHEWIPERSYSTEM COVER Cl2 T27 2 HEATEOSPRAY JET RIGHT bc0 bC0 UNDERTHE WIPERSYSTEM COVER Cl1 T D T29 4 AIR CONOITIONING SYSTEM acN acN IN CENTRECONSOL...

Page 1546: ...8 TRAILERCOUPLING M 215 SAUDI ARABIA VERSION M 249 AUTOMATIC TRANSMISSION M 261 OUTSIOEMIRRORFLAT PASSENGER S SIOE M 340 ADJUSTABLESEAT HEATINGSEAT RIGHT M 383 SPORTSEAT LEFT M 387 SPORTSEAT RIGHT M 4...

Page 1547: ...Lights USA Body instrument Cluster and Senders Engine Cooling Heater Air Conditioner Outside Mirror Power Seat Seat and Mirror Memory Radio Telephone Antilock System Tire Pressure Control Airbag Porsc...

Page 1548: ...lines and relays required for the individual wiring diagram The ground connecting points are designated with GP and their location is shown in a vehicle diagram The IO pole plugs on central electrica...

Page 1549: ...f r I I I 4 7T LJ LJ I 1 EALEOHEAOLIGHT L I 0 h 31 GROUND 6 I II rlr AOOITIONAL HIGHBEAMS I FOGLIGHT IV FOGLIGHT x III XXIV tl HT COMBINATION SUPPLYx ONLYM249 SIOEMARKER LIGHT ASSEMBLYLEFT GPI 1 I 1 C...

Page 1550: ...IGHTS RIGHT _ t 2 5 1 s 5 0 75EwTx r 9 lb P Y I Zb 1 2 3 4 5 6 8 I III I I I hi I i IA I BACKUPLIGHT T i SWITCHIM4811 WL 16 I I I I I I I II I I I Iii iilii 4 oeR I GPVI L J LIGHTCOMBINATION I I I I B...

Page 1551: ...ALEO HEAJLIGHT 7 3 3 GPI C 90 d II xI FLAS r k 7 3 i I y A BACKUPLIGHT XVIII ONLY 249 B B Y J T I3 089 6 L p 87 Bb l K H IIBhsS d 8 5 xw 85 t t r l xxIII X IV LIGHT CI OMBINPTION i L J I o _ FOGLIGHT...

Page 1552: ...R LIGHT TURNSIGNALS 23 2 11 t K95 J m m B w Q A I 5 E N D 5 525 r BACKUPLIGHT SWITCHIM4811 LICENS PLATELIGHT II TAIL LIGHTS LEFT 7 BACKUPLAMP BACKUPLIGHT XVIII ONLYM249 i I s e STOP LIGHTS I CENTRALEL...

Page 1553: ...ITCH FORSUNROOFIM6501 15 16 _ L C POrEh lOMETERFOR WIPING WASHING 1 WIPERMOTOR II e r L Cl1 I I WINOSHIELO 17 42 F WIPE WASH SWITCH J L j 1 5WBL 122 r 77 I 18 19 0 5 Bwwl 5 A i s 265 m J TL A _ I E S...

Page 1554: ...OI I 30 I GP II q CONNECTING POINT GPVI GPVU M4RKED 0 CONNECTION WITH FELD DATA GP I 1s AREWIREHARNESS3 GP GROUNO POINT 1 I F G H J K L M N 0 P L GP VI REARWINDOW WIPERRELAY REARWINDOW WIPERMOTOR c I...

Page 1555: ...TIRE PRESSURE PORSCHE LOCKDIFF FUNCTION WASHINGFLUIDLEVEL CENTRALLOCKING SYSTEM AIRBAG PARKINGBRAKE STOP LIGHTSWITCH FAILURESTOP LIGHT COOLING WATER LEVEL COOLING WATER PRESSURE OILLEVEL T7 Tb4Frl RF...

Page 1556: ...LHO I I TIMINGRELAYlt iDI215 M5531 r l I 1I I I I IIIIII I l E22 1 I I I COOLANT TEMP pFiJ CATALYTIC CONVERTER CONTROL IM 1931 SWITCHING UNIT2 I II THERMOELEMENT NO 2 I _ r4z 7 1 I F f I I III III1 I...

Page 1557: ...R I I I i 9 4 lst I I I I CONTROL UNIT 4lR CONDITIONING SYSTE I I I I rsole43 EN I I I n I t FW 637M538 I pl il mKq yldQ 1 r 36 MICROSWITCH CENTRALNOZZLE ADDITIONAL AIRCONDITIONER I I j b J J L j _ I...

Page 1558: ...0 WL 1 53 J 0 5 w6N 2 e Y Y ii r 1088 W 55 I 1 B 058W34 mrnvl A99 000 St2 w 2 6418 35 2 4 CL _ IJ i 1 17 Ia I I A _ 1 _i_ _z_ CONDITIONER OILTEMFF ERATURE 11 12491 SWiTCHTORQUE CONVERTER SUPPLYx MS70...

Page 1559: ...T20 CHANGEOVER SWITCH R TZ 1 14 SPORTSEAT M383 M3871 MIRRORSWITCH HElGHT C Tk Kg SEAT BACKREST CONTROL WL 337 M340 M 7N v OISCONNECTING POINT CONNECTION POWER SEAT LEF WL 343 NOTAPPLICABLE WITHMl39 M3...

Page 1560: ...liv 15 RE HElGHl I I 1 5OR 15 BUVI SEAT BACKREST CONTROL CONNECTION POWER SEAT LEFT WL 343 NOT APPLICABLEWITH Ml39 M340 M586 M513 2 SEAT LUMBARlM5Bbl HEIGHTCONTROL IM5131 P n cl I 25GR I 1 15BK I I SE...

Page 1561: ...TING MIRROR C lb Tf YIICH 1 L 11 i I5 BR 2 0508 jT I OlSCONNECTlNG POINT EAT BACKREST L A 5 A 1 I Y SEA m ELEC HtATlNG ELEMENl rr3R SEAT CUSHIUN r 56 i 1 ___ I 1 GROUND STEERINGCONSOLE LHD FIREWALLRHO...

Page 1562: ...IT SEAT PASSENGERS SSIDE Sl f I 54 fll fllNNFTTlNl POINT T SEAT HEATERSWITCH II SEAT SIDE E MENT HEATING ELEC HtAllNG ELEMENI b017SEAT CUSHIUN 1 L WAY SWITCH WAY SWITCH I CONTROLUNIT SEAT DRIVERS SSID...

Page 1563: ...RE RADO CO CHANGER I BOOSTER 15 A F24 _ I 21 FR0E TLEFT HIGHRANGE RAOIOSPEAKEF FRONTRIGHT HIGHRANEE RAOIO SPEAKER t4DOLERANGi SPEAKER I I TERM15 I I CENTRALELI MIOOLE RANGE SPEAKER pg L WL b9LEFT I Q...

Page 1564: ...FUSE INBATTERY COMPARTMENT 0 5 YE 1 0 5 GR NOT CURRENTIYCONkNECTED 0 5 WT J FRONTRIGHT HIGHRANGE RAOIOSPEAKER fllOOLERANGE SPEAKER TELEPHONE PREPARATIONCELLULAR M I 95 Motorola II WL 69 LEFT 1 5 I 1 5...

Page 1565: ...ALVE j ji ij i i i K I AIRBAG LEFT I a I 0 5BWRC Y ml 0 50x nr k I 76 HYDRAULICUN17 ABS 1 5 GNP4 0 5 ix I 3 _ I I 0 5 lwwl XI I I lb I 2 5 WWT 1 0 5 WGN I I I i 0 15 GN BL WIRECONNECTOR 71 x ORE I L 1...

Page 1566: ...I GROUNDABS I I 111 0 5 WT I I 0 5 GN n r15 31 30 biti I 0 0 0 0 0 L 05 WGN q I 0 5 YVWT P I i I 0 5 W YE 1 I I I 0 5 08 L I I I I CONTROL UNIT I _____ i rGP IV XV ABS WLBCONTRa NT STOP t Z TS IYKt P...

Page 1567: ...o I I L E el pJii I4 1 j A d e a 2 TIE I IT7 7 II i E 2 l Tjl 3 4 STARTER r 8 l i i I 83 84 I f 4 I II I II I I Gp I I I I I J _ I I I I I TRANSMISSION I II I PROTECTION SWITCH i i 1 85 I 861 ILlk III...

Page 1568: ...III II I II ENGINESPEEDSENSOR IT45 I I I 27 U 0 75BR L 3 4 iEl 5 6 MASSAIR FLOW SENSOR j j i j ye T47 I B4 I I 0o 0 0 L e wa I 0 75 BK I I 0 75 WBK 85 85 F M F I CONTROLUNIT a TANK VENTING VALVE A I I...

Page 1569: ...Y 0 5 BLlWT 10CENTRAL LOCKlNG LMIT SWITCH a4 CE 0 5 R m 0 5 G IX TERM 30 K14J I I f 10 EK WT GPV 0 5 BL RE SPEEmMETERSGNAt 05GNNT 2 CENTPAL LC XNG TURN SIGNALS K I LMIT SWITCH OFF 2 0 5 m WI 0 UPRM 1...

Page 1570: ...l r I i 111 9 3 9 3 9 91 9 9 9 10 0 5 BL WT 8 CENTR L LUWNG LMITSWITCHON 05WRE SPEEmMETERSlGNAL OSGNNT OSGR rn I CENTRALLKKlNG LMil SWITCHCFF 2 r CRt z CENTRAL LCXK I L CENTRALELECTRICS v F 3 E OSBR R...

Page 1571: ...R Ill DAYTIME RUNNING LIGHT T I l R i II i Y RP 16 _ I _ 1 m j _ jj _x Sk6 sB S zB il 24 TWCTIIlEHWi5 25 NYDE LffiHTS O AGNOSIS CONNCCTaV W RUMNT CLUSTER 26 TAJLGATEUNLCCKffi T7 CONCEALER HEMLGHTEOTDR...

Page 1572: ...INDOWDEFOGGER III DAYTIMERUNNING LIGHT IV FOGLIGHT iPUT F I 1 _ R ii LA ML4 16 5 6 TX Ii f i n 4P St x2 i is I X SUPPLY XI WIPERINTERMITTENT CONTROL XII FRESHAIR BLOWER XIII XIV FLASHER OEF xv ABS MS9...

Page 1573: ...T I CRUISECONTROL CONTROL UNIT L 8 L w a rm IlCFrmrrl m CONTROLUNITALARM SYSTEM CONTI lt UNITAIRBAG CONTRljt UNITPOWERWINOOWS SUNROOF 16dQ 1 1 IN DRIVER SFOOTWELLBELOWTHE FOOTREST I I 7 w I IU rFUTDF...

Page 1574: ...91 92 OP 84 85 PARKINGBRAKECONTACT POTENTIOMETERIDLESPEEOCO I I I E 21 22 10 88 POTENTIOMETER EXTRA AIRCONOITIONING SYSTEM F 37 3a POTENTIOMETER FOR HEADLIGHTVERTICALAIM CONTROL 01 POTFNTIOMETER FOR...

Page 1575: ...GINE C 26 INSTRUMENTPANEL REAR WIREHARNESS 761 761 14 SEAT DRIVER SSIDE IOeO IoeL _ I_ I_ 14 SEAT PASSENGER SSIDE IOet IOeO 1UNDERTHE 12 DOORPASSENGER SSIOE 7CL 7CD AES TRAILERCOUPLING WIRECONNECTOR i...

Page 1576: ...IGHTSUSPENSION STRUT MOUNT 5cP 5cP IN ENGINECOMPARTM ONLEFT SUSPENSION STRUTMOUNT M 061 ENGLANDVERSION M 139 AOJUSTABLESEAT HEATING SEAT LEFT M 193 JAPAN VERSION M 195 TELEPHONEPREPARATIONCELLULAR IMO...

Page 1577: ...ghts USA Body Instrument Cluster and Senders Engine Cooling Heater Air Conditioner Outside Mirror Power Seat Seat and Mirror Memory Radio Telephone Antilock System Tire Pressure Control Airbag Porsche...

Page 1578: ...the lines and relays required for the individual wiring diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The lo pole plugs on central electr...

Page 1579: ...I I I II I II I I I I I I IIII IIII II I I _I l t I I2 J j I I I I 10 WT EK a I Ll 5 3 011A I 31 aa 0112 I I I I K I 1 I II I I I II III Ill I II I I XXIII XwdIV n Y a n 1 2 3 4 5 6 7 3 3 0 I I F IYL...

Page 1580: ...WWT I I I I I I I 1 r t c Y _ 2 s G6 B 1 I NYYI 8 13 OfJKlWT m P 1 z 1 I T 1 LJ LJ I I 7 i t I 1 I I N13 r 525 r 1 I I I I I I I I I I I Illll I III I Il 408R GP VI WL 4 IC 5 i c c P4z 10 B1 1RE 0 75...

Page 1581: ...i c22 J I I I I I I L _ A I I Cl 0122 I CZlj CONCEALED HEADLIGHT my I r 7 us 1 tall I I 11 s 1 02lJ I 011 I L I I I n co1 Tr GP I II I I 31 GROUND L 4 70 p i 3 10WTm GPV f 82 3 I 2y E 56 I XXIII XXIV...

Page 1582: ...N SXiNALS f LOW BEAN 13 TAIL LIGHTS RIGHT BACKUP LAMP BACKUP LIGHT SWITCH IM4811 LICENSE PLATE LlGHl BACKUP LIGHT XVIII ONLY M249 I P VI TAIL LIG TS LEFT BACKUP LAMP STOP LIGHTS _ _ _I T MEIJNNING j L...

Page 1583: ...1 I I I I I I 023J 1 III 05YE d H53 I 1 IIX r WINDS1 lIELO WIPER MOTOR 021 an3 I I L 024 1 1 L 115 L25A WIPE WASH SWITCH _ L I 5 WBl L 22 0 5 ERNT 05ewWT na izg r 1 3 MlY r 1 5 WER l2Ll J al I II cm...

Page 1584: ...ONTROL UNIT POWER WINOOW REGULATOR SUN ROOF I I I FCRRHO Fi Elirn L WI cc dNiim WITHAn 2 GP V 2 L 3 I i2 4 REAR WINOOW WIPER RELAY 31 IGROUNDI REAR WINOOW WIPER MOTOR 2u MP IXI MP III MP X MP V _ I IN...

Page 1585: ...ARGO 4 PSO WARNING FUNCTION REAR LIGHT TIRE PRESSURE PORSCHE LOCK OIFF FUNCTION WASHING FLU10 LEVEL STOP COOLING WATER LEVEL COOLING WATER PRESSURE TERM 30 TERM 30 TERM 31 TERM 31 I I I I I I I I I TE...

Page 1586: ...TRICS aatr P I MRL4S8 i RELAY SOCKET OMIY FOR LHO TIMING RELAY IM2 15M5531 I t 1 m ls l OIL LEVEL SWITCH COOLANT TEMP SENDER I I M234 I h 27 l OIL PRESSURE CATALYTIC CONVERTER THERMOELEMENT MONITOR NO...

Page 1587: ...5 EK WT u 12 0 5 YE 11 1 0 5 WRE x I I si 2 A 0 5 YE SYSTEM 1 I I Cmm i l I n CONTROL UNIT AIR CONDITIONING 1 C b J 1 I 0 5 GR 2 0 5 RE I I 3 0 5 BWRE I i I 1 0 8 0 5 OR 9 9 0 5 BUM I m 0sOR t _ MICR...

Page 1588: ...ALAIR OITIONER MS701 I I i L l SUPPLY x I L JI L AG L L I E 1 I BLOWER SWITCH EVAPORATOR SENSOR RESISTANCE GROUP GP II FORLHU GP I FOR RHO T GP II NTIOME T T I 7s FY w 0 1 Y 13 a 10 m n i LA I 3 5 y T...

Page 1589: ...M513 I T I t q MIRROR ORIVER S SIOE I 1 1 i 2 WAY SWITCH Q A 1 2 3 5 6 CONNECTION POWER SEA TLEFT SEAT CUSHION HEIGHT CONTROL REAR I Tlzt I 1 5 t WGN 158R 4 M iz 1 15RE Ix 15eKM n 1 c9 50 MP IX WIRING...

Page 1590: ...AL WITH LEFT A I CENTRAL ELECTRICS B B COMFORTSEAT STANDARO LEFT T20 GP IV PORTSEAT 1383 M3871 I 2 WAY SWITCH LL I 6 7 WlRlNG LOOM ON SWITCH G WAY SWITCH 4 WAY jr j i y tfy a I III i I I T I T20 v WIR...

Page 1591: ...CKREST 54 6 Y SEA1 JISCONNECTING POINT 0 2 SEAT BACKREST Ji GROUND FIREWALL LHO I STEERING CONSOLE I 55 SEAT SIDE ELEMENT HEATING ELEC HEATING ELEMENl FOR SEAT CUSHION I I 56 GROUND STEERING CONSOLE L...

Page 1592: ...ER ryn r h WAY SWITCH 4 WAY SWITCH 1 r m SEAT HEATER SWITCH r 1 k zk _ _ _ _ _ 2 i oyAzty kL _ ll f _ 2 gji _ 142 5I f 1 11 112 I _ _ CONTROL UNIT SEAT ORIVERS S SIDE 1 N 1 to OK 2 5 N YE _ _ 256 I I...

Page 1593: ...647 I GP V I 0 5 GR NOT CURRENTLYCONNECTEO 0 5 WT L FRONT LEFT HIGH RANGE RADIO SPEAKER FRONT RIGHT HIGH RANGE RAOIO SPEAKER L CENTRAL ELECTRICS MIODLE RANGE SPEAKER MIOOLE RANGE SPEAKER GP I TELEPHON...

Page 1594: ...YORAULIC UNIT ABS I I I n 1 I 7 m CIISCONNECTIF III III II I III OS WT II I t C I I I I I I I I 5 mj 1 POINT II II I hlrl 2 I OSBL I I I 75 r GP IV 76 WIRE CONNECTOR 7 COMBINATION LEADS I Y ii f J 1 7...

Page 1595: ...I a7 6 31 30 I iii lk I 1 I _ i I GP V I 0 5 BK WT P14 40 I I I I v 3 111 0 5 GNlBK 05 WT ex 0 5 BLrlE 0 5 vlim 05VVGi 0 5 Vi WT I I I I I 0 5 VI YE II 20 I 3 d 29 I 28 XV ABS n I I OSER I CONTROL UN...

Page 1596: ...ION PROTECTION SWITCH I I I I I I II II II I II_m WL 1 I M Jd 1 1 j WL 15 2 i 1 LH CONTROL UNIT TEMPOSTAT _ SWITCH ee I o 0 75 REfwT J d IL _ 14 j 05BK 11 i 9 _ Eh s E c F B _ _ _ _ _ p Ill 1 rI 4 y I...

Page 1597: ...7 I GP Ill ztt I Q XGR BK u AIR FLOW SENSOR v III 0 75 BR 4 5 II II WL 15 I L 1 I II I I II I I I II LH CONTROL UNIT t TANK VENT I I I I I I TEMPERA cl ID c bl TURE SENSOR Lr JJJ1 flu WI 075 WWT 4k 07...

Page 1598: ...I 075WRE z 0 75 GN RE I I I n_Icm vT I I II 1 1 1 058 WT I I I 0 5 WWT 10 I I I I CENTRAL tuWNG LIMIT SWITCH ON lURNSIO ALS la LEFT 10 EWWT TURN suuts RIGHT Y I GP V 0 5 GWWT 0 5 ER GN 0 5 m m 20 NPR...

Page 1599: ...T TERM 30 TURN SKyA b 10 WWT u lu p qm J 3 2oRE I I F I I I I _I m F m E P 3 F i I d g GPV LHO GPIV RHO 0 5 EL K 6 0 SPEECQMETERSWAL a 5 ONE IT 12 cmTR u LOrmNG 1 LIMIT SWITCHCn F 0 5 mm 2 UNPRME CMTR...

Page 1600: ...2s 25A l 11 30 30 KU 621 Y30 VI 30 30 XII30 L 15 FZL I 25 HI2 24 7 5lOEMARKERLMT LEFT 8 sax MARKER LMT MMT 9 ASHTRAY INSWMENT UGHTS 10 KENSE PLATEUMTS II REAR FCCLCflT I2 TURNsmb t FRONT LEFT 13 TURNS...

Page 1601: ...NT CONTROL XII FRESH AIR BLOWER XIII FLASHER XIV OEF xv ABS lM5931 XVI TWO TONE HORNS XVII KICKOOWN XVIII BACKUP LIGHT lM2491 s 11 7 I L m j 4s s z RR gj _ 4s I 1 K I wd zs z r l b I m 8 8 w 46 Q j aa...

Page 1602: ...ER 1A O 66 69 I I I I STEERING IGNITION LOCK HEAOLIGHT VERTICAL AIM CONTROL LH JETRONIC CONTROL UNIT AIR FLOW SENSOR SOLENOIO CLUTCH COMPRESSOR SOLENOIO VALVE ABS B 14 16 A4 A 6 7 7dL 7dO INPASSENGER...

Page 1603: ...x L vv uuvv RIVER S SIDE I I I F 11 nr r 1 I INE COMPARTMENTLIGHT DDCCCI IX CChlrlCD OIL I L_IJ I L JLI LI OIL LEVEL SWITCH TEMPERATURE SWITCH 1M2491 POTENTIOMETERINSTRUMENTLIGHT POTENTIOMETERIOLE SPE...

Page 1604: ...TFNT F rnhl m F I c22 I _ _ II C I I C I _ 9 T30 16 IP R CONOITIONING SYSTEM 8cN 8cN IN CENTRE CONSOLE F33 34 T31 1 4 1 INSIDE TEMP SENSOR FOR AIR CONOITIONIER 8cN 8CN IN CENTRE CONSOLE BC33 T32 3 AU...

Page 1605: ...CH WIRING LOOM LIGHT EMITTING OIOOE LEFT HAN0 ORIVE GROUNO POINT LOW FREOUENCY FOG LIGHT NUMBER FA FL FR CP ww CES AOL CLS FRONT AXLE FRONT LEFT FRONT RIGHT CONNECTING POINT WORLOWIOE CENTRAL ELECTRIC...

Page 1606: ...LHD vehicles the control unit of the cruise control is fitted below the footrest The alarm control unit is fitted below the right hand seat Please alter the circuit diagrams accordingly Modifications...

Page 1607: ...41 50 Outside Mirror Power Seat Sheet 7 51 60 Seat and Mirror Memory Sheet 8 61 70 Radio Alarm System Sheet 9 71 80 Antilock System Tire Pressure Control Airbag Porsche Lock Differential Trailor Coup...

Page 1608: ...nd relays required for the individual wiring diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The lo pole plugs on central electrical system...

Page 1609: ...RD LIGHT SWITCH _ zjgqgp I TURNSIGNAL DIMMERSWITCH I I I I I IEI I I I I I I I I I I 1 I ALE0 HEAOLIGHT CT z _ I I I I I I I III1 t I 1 I I I I I I 12 I I 1 I I 4 6 ONLY Mi 23 I I Y I A u a7 06 B IO l...

Page 1610: ...lsL ONLYH 5 p I IL FLOCtR LAMP 1 2 3 4 5 6 7 8 9 IC I t I I I I II I I I I I I I I 1 g 4 743 CT21 S CT22 PLATE LIGHT v2 15 CDWT I I I I I II II Le 4 0Rf 2 I I 1 I ii T I I c Q i I I 1 I i r i r l I i...

Page 1611: ...I l CONCEALED HEADLIGHTRIGHT CONCEALED HEADLIGHT _ __ r 14n I I lTll T ll I I I 1 r IIIwll I 1 Al 1 I L r I 1 ii 6 CONCI LEFT iALE HEAOLIGHT I l u 31 GROUND I v I I I 1 I I I I t I I I 1 r I II I 1 I...

Page 1612: ...IGHT 17 SWITCH IM4BI 8 F I Ir 0 c CI f WH a f 26 E I I 22 I Q B I u I WH 16 14n I I J i lltf I WH 39 I I I I 31k TB F 20 i PLATE UGHTS r I 4oaR WH 4 I MP VI TAIL L ZZHTS LEFT LIGHTCOMBINATION BACKUPLl...

Page 1613: ..._ I a _ 53 I 1 i 0 HEATEDSPRAY JET LEFT T42 REARWlNilOW PUSHBUr TONSWITCH FORSUNROOFIM6501 1 ER1EXCt Ahm0J WIHEFQ It I FORI 653 V PwGcrol I 17 POTENTIOMETER FOR WIPING WASIiING n 42 WlPE WASH SWITCH I...

Page 1614: ..._ 4 K _ P II MP VI bIRE n4luF is El cmTR4 ELEcTaC 5 II AOOlTiONALCLEANINGIX MP IXI I I FLUIDPUMP I I I I I I 30 4 31 IGROUNOI I _ _ MP II q WELIIWG POUdT MP VI I 9 REARWINDOW TS WIPERMDTOR MAREEG IS A...

Page 1615: ...I I I I I 1 I I I I WH 4 I I I I I I I I I I I I I I II lttli ZElgS3 YIYIWUIV I I I E i ifI g 9 li yT5 r PSO WARNINGFUNCTION WASHINGFLU10LEVEL CENTRALLOCKS I I BRAKEPA0 2 TERM 30 TERM 30 TERM 31 TERM...

Page 1616: ...R G3 rl 4 WH 12 WH 4 li TOOTHEDBELT TENSIONSWITCt 7 SEAT BELT I RELAY SOCKET ONLY FOR LHD TIMINGRELAYIN21 S M553 BRIDGE ONLYROW n 5i iiT I p I i _ I ifjf 1 1 0 J 4 ji ij 86 i izi 1 0 _ I 2 Bl I P21 wz...

Page 1617: ...I I I I I MI GROUND POINT 1 WH WIREHARNESS I 1 L INSlOETEMP SENSOR BLOWER INSlOE SENSOR CONTROL UNIT TEMPERATUREFi I I j i jj I II i k 7 0 5wai 4 cw 043 lcrl MICROSWITCH CENTRALNOZZLL AOOITIONAL AIRCO...

Page 1618: ...lIDNER MS701 I tt _ z i i j 1 i i f p W y j j I 1 I I BLOWERSWITCH EVAI SENtin RESISTANCEGROUP i I I I ii I AIRFLAPMOTGR nYR0 II 7 m3 it 20 WBK n I COOLANT FAN 1 n 1 f ss 33 z aa 1 I I I I COOLANT FAN...

Page 1619: ...ELDDATA MP GROUNO POINT WH WIREHARNESS r INVERSELY10 WITH LEFT T4 T21 u 0 WH221 WH 227 c CHANGEOVER SWITCH MIRRDRSWITCH I I I Lu B P T6 MP V WH 16 l a T20 MP 4 l i 520 w SPORT SEAT M383 M3871 SEATCUSH...

Page 1620: ...ECTRIC MPV WH 227 1 1 MP 1 COMFORT SEAT S ANDARLlLEFT 1 ORTSEAT 383 M3871 WAY SWITCH 4 WAY SWITCH y L jj i t i f I i c L j j j 4 4 3 WIREHARNE 3 ONSWITCH Ij H j SEAT CUSHION I 251 i 5 HEIGHTCONTROL RE...

Page 1621: ...IG q r I I iili i a r 1 e I I j j fj q 81Ii 3 pci Ex i _ i i v i iiii i _ p i i i i gdbrjrj h h 4 i ikin r Uh U iii J _ _ I z yy f i z SEAT SIDE I 1 ELEMENTHEATING ELEC XAllNG ELEMENT FOR SEAT CUSHIO...

Page 1622: ...k L II i 1 ELEC HEATINGELEMENTFORSEAT CUSHION f J i SEAT SIDE ELEMENTHEATING ELEC HEAIINGELEMENTFORSEAT CUSHION 231 HEATINGELEMENTFORBACKREST 4 WAY SWITCH I 1 0 BK 2 5 REM 1 ISW I mffi Pm7 CRMCXN Wti...

Page 1623: ...QVE Rl P i j z j Q i ii i i i jj Jil 2bj i i i ji i L r _ 41 II I 7 ANTENNA EXTENSIONWIRE 1M3261 0 II i FRONTLEFT 1 2 FRONT RIGHl _I I L I OEEP RANGE I SPEAKER I WH 63 1M3 261 I REARLEFT yH69LEFT u RE...

Page 1624: ...M FRONTRIGHT L I I I I 0 I I 21 I I I I 15emw t ITJ Fz5 I I OEEPRANGE SPEAKER REARRIGHT 1 I gA KEERRAHGE 156 15GRm r Y MP v r I I I 4 ii CENTRALELECTRIC s B I MP IX MP lll MP xl MP V T 33 MP I MP VI M...

Page 1625: ...i i i i _ _ _ j _ _ 1 ii_ CON SOLUNITABS Xi PINPLUG ijj CONTROLUNITABS PORSCHE LOCKOIFF 55 PIN PLUG lCOMPARTM NO VARIANT WITH 35 CONTACTCONNECTOR 1 COMPARTM NO VARlANT W 55 CONTACT CONNECTOR i j_j_ Gm...

Page 1626: ...T WH 180 l I a I lEEI I II III IIIIII III T24 0 5 BIVRE 4In 7 N I WH 161 CRASH SENSORRIGHT _ r I I A 1 m q I f I 025 I I 4 I II 5 I 5 I kPoRSCHE l593 71 72 73 74 75 7E 7 7f II III I I II III I 3 _ _ L...

Page 1627: ...lGHT OISTRIBUTOARlEHT t II aI 6l I c g J i i 7b 7 jl i _i x Y 1 STARTER TRANSCIISSION SAFETY SWITCH morlf 9a E WIRECONNECTOR WH3 T 7 I _ I F i ff CRUISECONTROL SWITCH IMCSCt 88 LKLtISt LUN IKUL Mb541...

Page 1628: ...R RlEHT Lp ll iib li j j g I I I wi Izz i i iiiii i i i n rC 5 i I Y r R 1 y emCaM Rdti Ni 1 m _ r MP 1 MP IV Ml Vll4V k pi ZSBR I I COOINGELEMENT f 3 zs 2 0 75m r SSE s2 I II SPEEOSENDER I II 1 B 3 j...

Page 1629: ...OrlYHN MGH BEAM BIL 6 FOGLIGHT 024 WI 30 XV 30 F25 622 823 K24 I XI WIPER INTERMITTENT CONTROL X SUPPLY 1mn KD S25D21 WA L I L T12 Z4 eg2 1 zTH25 25A CII 30 30 K14 VI 87 x30 VII 30 30 x1130 F26 I 25 X...

Page 1630: ...VI XVII TWO TONE HORNS KICKDOWN III2491 AOOlTlONAL CLEANING FLUIDPUMP 13 XVI30 0 Ab 37 l 7 7 l m k2 6 2 VR 2 c 26 r 2 rl I 7 il I I ji RI 4 3s R RR ONY 208 2 _ I F m K L z5 m t qc q IPiP sY2 Pt 4F epj...

Page 1631: ...DESIGNATION FIELD SHEET OILPRESSURESENDER P27 4 OILTEMPERATURESWITCH TORQUECONVERTER P35 36 5 011LEVELSWITCH PZ6 4 POTENTIOMETERFORINSTRUMENTLIGHT EEZ 13 POTENTIOMETER IDLESPEEDCO OPBB 10 POTENTIOMETE...

Page 1632: ...9 MIRRORMEMORYSWITCH ASIAbO 7 STARTER AE83 84 10 DRIVECRUISECONTROL CONTROL A890 10 DRIVETAILGATEUNLOCK 011 12 3 ORIVECEYTRALLOCKSLEFT OOOR Fll 3 ORIVCCENTRALLOCKSRIGHTDOOR MN11 3 CONTROL UNITABS PSD...

Page 1633: ...FUNCTION F I oE IIM NOTE LHCI RHIXIB Tl 2 GLOVEBOX LAMP 7cL 7ctl ABOVE EZK LHCONTROL UNIT CDI T2 3 ENGINECOMPARlMENT LAMP HEATEO SPRAY JET RIGHT 6 0 6 0 UNDERTHE WIPER SYSTEMCOVER c4 1 T3 26 OOORORIVE...

Page 1634: ...NGER SSIOE 7cL 7cP IN PASSENGER SOOOR C42 C5l G63 J1L14 T23 21 ABS 7dQ 7dQ FOOTWELLAT LEFT SIDEPANEL K74 76 F30 124 6 TRAILERCOUPLING 661 668 UNOERTHEcENIRAL ELECTRIC OP74 125 126 2 HEATEDSPRAY JET LE...

Page 1635: ...70 71 80 81 90 91 100 Lights Row Lights USA Body Instrument Cluster and Senders Engine Cooling Heater Air Conditioner Outside Mirror Power Seat Seat and Mirror Memory Radio Alarm System Antilock Syste...

Page 1636: ...s required for the individual wiring diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The lo pole plugs on central electrical system are cli...

Page 1637: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 1 Lights Row Coordinates l 10 Current Flow Diagram 97 311...

Page 1638: ...________ _i 1 yf j _ hjj I o pt i hl i i i I i le i i j ii jqEE NEE YIP 455E li I EF I LJ a I 11 1 I _ l tbG dNU I I __ I L J cu 1 1 I I Y _ a Eb YPV 2 3 I 5 f 1s a tr wy y II 1 P 5 s AWIr oNAL HlGld...

Page 1639: ...EIAII tIP LIGHT 7 bv H M Oll i A 3 4 I 571 _ _ _ J _I__ I 3 5 11 L 7 5 B 9 OUIYn _ SIC S 7 i 115 ii 1 5Iti IIT I I L JS 117 _ __I_ _ ___ _ _ _ _ i _ I 1 1 I I _ Ld __ _ t A 3 __ _ FLATi LIGtIrI 8 1 I...

Page 1640: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 2 Lights USA Coordinates 1 IO Current Flow Diagram 97 313...

Page 1641: ...IMYfR CW Y I ENGIM m JMCnR MEN LwlP 4 FOG LIGHT SWI U w I h AOlJITlWd HlGh Bt lC XC AMF CONLEA tD it aOl lGW RlGtlT CONLt l r 1 III AUI 114 1 ML Eli m I I _ r f y t f It I l a r SUP I I JV l s Fe UP 2...

Page 1642: ...UF XINP OIMMER W Yr T I I I8 1 I I1 11 t Ii iI 1 i I I I I Jo II 18 I I UUR CON1 Ai T 1F TURN OIGNALS SIUE MARKER LIW T 5TOP LIGHTS UPChtlP LAMP hAZARC i dl 1 e m RhiKtlP LIGHT I SWlTi H f 14811 PLATE...

Page 1643: ...Wiring 97 l Wiring Diagram Type 928 S Model 89 Sheet 3 Body Coordinates II 20 Current Flow Diagram 97 315...

Page 1644: ...I I 0 5w 05W 05W 05W 15 16 I PUSH BUTTON SWITCh FOR Ulu 4UOF iM6501 t t 7 tx k 4 a _ n WIOF Ill I I I I L L I I I II I 1 I 05 YE 022 27J IO RC 01 PI PI A yL y I L l k 1 I r I I t I lb I 1 I Ill PCIT N...

Page 1645: ...I I 1 1 Ikai 11 ti B i 1 I1 13 21 Yill BULGB N 4 2 i t I 1111 I2 I 12 i 1 14 I I 15 I I I l 116 I I t I I s m 1 JJJ 1 5 r J 11 __1d j0 5 1 2t _ REAR WINWW WIPER RELAY E 5 t I J T k 25 mm _ _ If _ lC 1...

Page 1646: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 4 Instrument Cluster and Senders Coordinates 21 30 Current Flow Diagram 97 317...

Page 1647: ...I I I PSO WARNING FIJNLTION REAR LIGHT TIRE PRESSURE PORSCHE LOCK OIFF FUNCTION WASHING FLUID LEVEL CENTRAL LOCKS 24 I 25 _ 26 j I 27 28 29 30 I AIRGAG PARKING BRAKE STOP LiGHT SWITCb STOP LIGHT BULB...

Page 1648: ...rtm u I 711S l L DII Row 220 5 HVLU s A I OSEWwf 0 I m 1 05GwFf 5 a F m _ l 05GR BK 5 L i c qp I I 1 Pm rri22 IIIIIs KS 1 I i t OIL LEVEL SWITCH 1 ti ft COOLANT TEMP SENOER 4 r I WI2 O EfwRE LE4 I I I...

Page 1649: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 5 Engine Cooling Heater Air Conditioner Coordinates 31 40 Current Flow Diagram 97 319...

Page 1650: ...I I I I I I I 2 3 4 51 _ 4 _pw I 1 I LIJN rwt UNIT I I I I I I 05 auG r leb rI Ii m I I 1 0 5 m 1 c 5 Rz 3 0 T MIRE 0 C j X 9 10 050 7 B x x g 38 5 cl m 4 I 1 I I T35 MICRO SW ICH CENTRAL NUZ 8 4 N4 E...

Page 1651: ...IT _H L F L LIF CONVERTER i 31 __ 3 3E _ 3 4c AI I rl rn Inrrlnrlrn INALAIR CONDI MINER BLOWER SWI CH EVI SEF 4PORATrlK rsm Rt jiS 4 Cf IROUF n n I I I 1 IIIIIIIIIII I L 7 MR FLPP M 1 ZK I I 1 20RRAK...

Page 1652: ...Wiring w Wiring Diagram Type 928 S Model 89 Sheet 6 Outside Mirror Power Seat Coordinates 41 50 Current Flow Diagram 97 321...

Page 1653: ...m vs II 1p MP N KS 3 2 TZO CHANGEOVER SdI TCH I R L u P MP IV FE s KS 167 SPORT SEAT lM383 M3871 MIRROR SWITCH SEAT BACKREST CONTROL Z WA LWlTtH SEAT CUSHION HEKjHT CDNTROL REAR 15m r 151 KS 337 J t m...

Page 1654: ...dDARD LEFT T20 I III 1 I I I 3 15x 15 OR 4 WA f SWITCH KS 3 3 I TZO ORTSEAT 383 M3871 SEAT Cl ISHION HEIGHT CONTROL REAR Z WAY SWlTtH WIRE HARNESS ON SLJITCH SEAT BACKREST CONTROL KS 227 I CONNECTION...

Page 1655: ...Wiring Y f Wiring Diagram Type 928 S Model 89 Sheet 7 Seat and Mirror Memory Coordinates 51 60 Current Flow Diagram 97 323...

Page 1656: ...b 11 05YuPf I Lu n 1 A I 1 1 I iiO rSdU k I I I I _ r I SEAT HEAT SIDE ELEMENTS l 19 n lC 4 km _ I T GROUNO STEERlffi CONSOLE LHO F HEWALL RHO ELEL HEATING ELEMENT CONNECTION SEAT BACKREST I I ELEi HE...

Page 1657: ...ii g SEAT HEATER SIUE ELEMENTS 79 iI II I lTT 1 1 f fJ b l tom I n j j dl jl c 1 I i J L J u I I I P I I WAY SWITLH j SEAT HEATEP SIOE ELENEIJTS ELEL HEATING ELEMLNT 7 WAY SlvllLH O WAY S ITCH 4 WAY S...

Page 1658: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 8 Radio Alarm System Coordinates 61 70 Current Flow Diagram 97 325...

Page 1659: ...T 63 j KS 03 iM4L6 8RlOti NOT M3261 1 i RAOQ P 1 64 65 FKEdUENC t SWITCH OO ii RIGtiT HIGH RANGE RADIO SPE IhER FRONT MGHT ANTCYWP EXTChlSIOtd WIAt 0f 32bl I I I I 22 I 66 KS 69 LEFT I REAR RIGHT OEW...

Page 1660: ...__ _ _ __ __ KS 4 1 Lzzz I f REQUENC SWlTCH DO ii RlGtiT HIGH RANGE RAOIO SPEAhER FRONT RlGHT MIOOLE RANGE SPEAKER OCEP RANG SPEAtiER IIODLE WiNbE SPEAKER HIGH RANGL A010 SPtA ER 0 75 RE 15 II 075 YE...

Page 1661: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 9 Antilock System Tire Pressure Control Porsche Lock Differential Trailor Coupling Coordinates 71 80 Current Flow Diagram 97 327...

Page 1662: ...NNECTOR i IIICOMPARTM NO VARlANT WITH 55 CONTACT CONNECTOR _ jj _ A A F I 6 c t I 11 I I I I I I I I muIIl40 SYRAP rz __ HYORPlli h UNIT hQ Pm flr21e 9 01 ABS r k _ _ I I_ I I I 05WT I OSGk Eu I 05U f...

Page 1663: ...ING i _ 1 2 i a n I f TRAILERCOUPLING IM 208 ACCELERATING KS 180 _ A ffi 161 i74 I II T I I GROUNLI ABS I I L I I L I t t 1 __ ___ _ _ I I I 1 I MP v I E s121 RIJK TIREPRESSURE CONTROL CtNTRAL ELEKTRI...

Page 1664: ...Wiring 9f Wiring Diagram Type 928 S Model 89 Sheet 10 Motor Fuel and Ignition Cruise Control Coordinates 81 90 Current Flow Diagram 97 329...

Page 1665: ...ITIIIN FINAL STAGE LEFT MP III 831 STARTER SPEEU SENOER I T45 _ r _ ozwT 1 I 1 ir i w I o nm 2 Y 17 TRANSMISSION SAFETY SWITCH rrr I I I w LnrX KS 12 p n KS4 T Yi I II I T51 I 1s mm I KICKDOWN lM249i...

Page 1666: ...TRIEIL T R RlEHT w 5 COOING LL EMENT z i c4 P t ON FINAL 8 8 81 81 _ 8 II I I MP III 6 r lR MASS SENSOR 4 111 L L ESONANCE FL I TANK vu47 TEMPERATURE OOUPLE NTC nn CLITI rm AP VI 8 SENSOR I I I I III...

Page 1667: ...Wiring 97 Wiring Diagram Type 928 S Model 89 Sheet 11 Central Electric Coordinates 9 l 100 Current Flow Diagram 97 331...

Page 1668: ...29 RAOATWFAN2 Km 11 m Ml 0 Y5 T24 WI30 F 4 Hl2 YVI30 XYI XIB TX M1 GU LX Llv LII 87 xv KICKO l dN t 42491 XIII 2VERsmS XIV r PRE Roii STAR1 EP FOG i IGtI tm53 us MRWAPAHI F m X XII FRESH AIR BLOWER TW...

Page 1669: ...SC YP I u zszg g g R 5 P D i 1 m 2 E XII XIV xv XVI XIII 2 wxvls KEKO lWN IN2491 EZK YRE ROW STAR1 Et X XI PI Li I 6 h z a FRESH AIR BLOWER SUPPRBSOR TWO TONt li04NS I I L XXIII XXIV LIGHT LklRINATION...

Page 1670: ...Wiring df Wiring Diagram Type 928 S Model 89 Sheet 12 Constr Components Plug Connections Ground Points Current Flow Diagram 97 333...

Page 1671: ...OVE EZK LH CONTRM UNIT _ _ _ _ _ 02 T2 33 EMjlNE COMPARTMENT LAMP HEATED SPRAY ET RIGHT 610 6 0 UNDER THE WIPER SYSTEM COVER C4 C T3 18 DOOR DRIVER 5 SIOE _ 7cn 7CL ABOVE PARCEL SYELF OAIVER S SIOE HI...

Page 1672: ...IN C dTRE CONS f _ __ ___ _ _ __ _ __ 8133 rj2 _ 3 AUTOMATIC TRANSMISSION 16dO 16d0 UNOER THE SFA f WHEEL COVER 035 086 133 3 FPONT EN0 MlSTRUMENT PANEL WIRE HARNESS 6dl 6d0 UNOEPTHE CENTRAL ELECTRIC...

Page 1673: ...t heater switch Terminal E becomes Terminal P becomes E A Terminal A becomes Sheet 7 K L 54 55 and 56 57 Seat heater switch drawn incorrectly See model 90 Sheet 8 N O 65 Terminal 7 on the controller n...

Page 1674: ...AGE 9 71 80 PAGE 10 81 go PAGE11 91 100 PAGE 12 LIGHTS ROW LIGHTS USA BODY INSTRUMENTCLUSTER AND SENDERS ENGINE COOLING HEATER AIR CONDITIONER OUTSIDE MIRROR POWER SEAT SEATAND MIRROR MEMORY RADIO ABS...

Page 1675: ...diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The 1O pole plugs on central electrical system are clipped together from 3 parts Part 1 wit...

Page 1676: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 1 LIGHTS ROW COORDINATES l 10 l Current Flow Diagram 97 283...

Page 1677: ...Ll I It All1 ILt I T UlMMt f _ _ JJ i jiY f ifl 7 f UJ I IJI 4 A 3 5 31 B n m 0 m 0 05 M OL r 9 P CO HEAflllrrtlI lY t z I I I I II I I I 1 CONCEALkO RIGHT I CONIEAI MOTOR r t MP II ALkU tll AULIbHl C...

Page 1678: ...T5 1 _ J HAIAKII llC1H1 SWIILti r OOOR LONTACT LEFT 23 J OOOR CONTACT RIGHT 7 1 5 rOUN IHY LOUING NOTAPPLEMILEWIT MD 11 HIR HIiLl I CHT SWI I IH TURN SIGNAL r OIMMEH SWlTCh _ _ IM0611 HEAULIGH I UlMt...

Page 1679: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 2 LIGHTS USA COORDINATES l 10 Current Flow Diagram 97 285...

Page 1680: ...GHT RIGHT CONCEALEO HtAULILHT MOTOR r l Mt II Cut I IIIIIlllI I I I I I I I I I I I II IIlrtl II I I t I I I I I III m m m 41 i I I I I I I 36 I 1II II I I I I I I I I I I I I I I I I I I I I I I I I...

Page 1681: ...tlblil SWITCH r 7 IIAZARO LIGHT SWITCH l I i 2 1 L pJ I I I I I I I I I F z r E a 3 m e I A 2 7 A 0 24 521 i PLATL LIGHTS 1 I II 3h I I I I I I I I I I I I I I I I I I I I 1 I I I I I I I II I Ls72 T...

Page 1682: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 3 BODY COORDINATES ll 20 Current Flow Diagram 97 287...

Page 1683: ...501 STEERING 1 I I zqjJ I I POTENTIOMETER I WIPING WASHING a pm i I I I I w r Y a OS L19E P I 15bNai l ii I 4 _7 III II I I I 2 e R I 1 11 5 51 i o TI a J p I I I I I I 05WT 11 1 I I naI 111 03 ItLcil...

Page 1684: ...BOXLAMP r FUSE I 8 c I t I I El3 I m I I 774 r I 775 r I I I I 8 I 0 5 m o 125 BK BL TJ 25BA 65 7 MP VI I A I I r I 14 1 I I I I I I I In i REAR WINOOW WIPER RELAY Rt AR WINOOW WIPFR MOTOR MP IX IIKS...

Page 1685: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 4 INSTRUMENTCLUSTER AND SENDERS COORDINATES 21 30 Current Flow Diagram 97 289...

Page 1686: ...I p 0 5 VBL m i L I PP 2 29 mm 00 15 PI Y i I YL i 1 gyzszs I l 2 0 5 bNzt l l 7 7 m Wl 1 ddou m 4 r I I v 1 I05DWWT Ls OSYF I C6 A AxKm T27 c 05RF w 1 0 KS 15 11111 1 374P2156 I 8 1 I BLACK J I CENT...

Page 1687: ..._ la I Ill I I I I I I J h II I III I I F l 1 r I I KS 15 Wl J I I ml l kl MP V COOLAN TCMP OIL PRESSURE SEN ItK SENDER OIL LEVEL SWl 1 CH I CENTRL INFORMER L ir I I P 4 u cmO6bb O OW U 4 0 lTt 11 7 1...

Page 1688: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 5 ENGINE COOLING HEATER AIR CONDITIONER COORDINATES 31 40 Current Flow Diagram 97 291...

Page 1689: ...s I OSRI wT I 05w 0 5 BR L BLOWER INSlOE SENSOR r E 0 5 M Da I 0 5 Km I t 8 I 0 XL L 0 5 YE 3 I 058R I I p P 1 CONTROL UNIT 8 1 4 0 5 LR _ L 05GR l l WATER MVC J 4 REI AY IV ADOITIONALAIR CONOITIONER...

Page 1690: ...I I I I I I I I I J IIIII rx I I 024 co27 I 025 I III L 1 OIL SC PERATURE lM2491 SWITC 34 TORWUE LONVERTER _ I RELAY IV ONALAIR CONDITIONER IM570 RELAY FLAP CONrROL 1 MP II FOR 1Hrl MF II MP I KIH HH...

Page 1691: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 6 OUTSIDE MIRROR POWER SEAT COORDINATES 41 50 Current Flow Diagram 97 293...

Page 1692: ...5 ttrl SPORTSEAT M383 M3871 E L 1 r 0 II 075 WT f F v F 3 O75WT r EhT BAfKHt S I 1 C ONIHUL k 1 I KS 7 7 E m m _ i StA I IIJSHILIN 1 9 3 G HClldl I LllNl HLlt t AR 0 3 MIKRLIH E 1 4 IIKIV R S ax F3 t...

Page 1693: ...EATER RELAY SWllLH _ WIRt HARNF S KS 3 I 1 h WAY SWlTlH MP IV I d s 0 I WAY SWITCH I 7 110 0 i A F 6 1 c SEAT CUSHION 1 5 RE HEIGHT CONTROL REAR J I 4 L 5 I I WIRE HARNESS nN swlrrH CONTROL WAY Wl II...

Page 1694: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 7 SEATAND MIRROR MEMORY COORDINATES 51 60 Current Flow Diagram 97 295...

Page 1695: ...10 A I Lb II 11 r 15 54 121 A L T 7 GROUNO STttRlNb CONSOLE LHO FIREWALL RHO 1 0OK I 2 5 RE YI I 1 I II xi 1 YZ y 5 c iBg 0 J 1 E G 2 d 8 g z r8 r ONNECTION SEA I BACKRkST MQTQKZLEFt LXrlQUTMlRIIORLEf...

Page 1696: ...i a ELEC HEATING ELtMtNI FOR SFAT TUSHION ELCl HtAIlNCl tthMtNI f OHM UACKRIST l 1 A CONNLC TIUN SCAT HAIKRFSI CmTROL UNIT SEAT m Ll G flRIVFRS 5 SlflF S x1 n 7 x7 6 _ I iY r I I I I I t i I flNNt Ii...

Page 1697: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 8 RADIO COORDINATES 61 70 Current Flow Diagram 97 297...

Page 1698: ...I 1 _ I _ B PILLAR LEFT DEEP RANGE TUNER B PILLAR RIGHT ANTENNA WINOSHIELD Y 1234 Jr Cl5 25RElBK y z KT3 KAN lf y 1 q CII RANGE 15UH ANltNNA WINDSHIft 0 TATA s e k z g i 55 57 L I TE _ _ 1 j Il E EFT...

Page 1699: ...I l I I MIOOLE RANGE TUNER RiCElVEH 30 25FE RlAH L AAT I 65 15 GN 1 I 5 I r 150R CI AN I LNNA 7 r f p5 y AMPI IkIt H ANTENNA KS 4 WINDSHIELD III a I rxi RkAH Ltk I I T 5 cl 15 BRAK 6E 1 I I 31 IO 22...

Page 1700: ...Wiring 97 Wiring Diagram Type 928s Model 88 page 9 ABS ALARM SWITCH TRAILER HITCH COORDINATES 71 80 Current Flow Diagram 97 299...

Page 1701: ...KS 182 10 M UK OA UWGN 1 14 I I I I 1 76 77 T o5ORlWT l l II nc0 5 ll c II H 15 05Ok RI I I 4n x 3 F25 j L 1 i lr 5 A wT e c Y DC IO A 31MASSE ZE WV Frn 1MT I mvnL 78 MP IX MPIO TX MP V I r 1 10GRm s2...

Page 1702: ...iP XII T23 TT i k Nslo II I I t 14 f F F En SUSPENSION 71 71 J L1 1 L Ik I I REAR RIGHl REAR LEFT FRONT RIGHT FRONT LEFT 7 TRAILER HITCH IM 208 S El l SFNSOR 8 HYORAULIC UNIT I USA I I I 11 ZOWT I 11...

Page 1703: ...Wiring 97 Wiring Diagram Type 928s Model 88 page 10 MOTOR FUELAND IGNITION CRUISE CONTROL COORDINATES 81 90 Current flow Diagram 97 301...

Page 1704: ...TRANSMISSION PROTECTION SWITCH I I p I I I I II r I 0 _I I 4 y k m T c I I I I I I II III L I II I In I I II I 0 75 RE Yf I L 8 r E 0 0 71 w7 _ I L WILl OSGR CRUISE CONTROL SWITCH lM454 CONTROL UNIT C...

Page 1705: ...T 2 km 52 52 22 g g II I I I Ll trlr 075 Jr II II y 23 I SPEEOSENOER 075 RR 6 I I t L t I t I O I I I I I I I I I I A 7 I 7 I I 0 75 mm I I I I I I I I I I MP IX I I AIR MASS SENSOR N LAp k 5 bT TANK...

Page 1706: ...Wiring 97 Wiring Diagram Type 928s Model 88 page 11 CENTRAL ELECTRIC COORDINATES 91 100 Current Flow Diagram 97 303...

Page 1707: ...HIGH BEAM 022 023 SWITCH FUR on E3 i 86 REARWMaW WPER I 51 Y 11 REARWNDOW WITR T2b oa 34 ILRN SIGNAL FRMI LEFT PI1 754 I3 m 1s 54 23 12 BMRwLM4P MRwlR niY F14 xx86 XY 15 35 IWN SIGNAL WAR MT m I 6zZ...

Page 1708: ...VI ABS IM5931 FLAP CONTROL 2VERSIONS EZK PRE ROW KICKDOWN 1M2491 SIARTLR I TOG LIGHT IMss3 SN M193 MPhNWI s25 FP 1 mtn 7 I r I I i2 36 M RZ k E 32 33 SlM 32 If z i BN P i 6wX a LULXI 2 d G5 z yi 37 4...

Page 1709: ...Wiring 97 Wiring Diagram Type 928 S Model 88 page 12 CONSTR COMPONENTS PLUG CONNECTIONS GROUND POINTS Current Flow Diagram 97 305...

Page 1710: ...PASSENGER SSIOE 7cL 7cQ ABOVE EZK tt C UNTRCIL UNIT Jl Ml T5 3 COUNTRY COOING RHO 6dL 6dQ BEHIND CONTROL UNIT CONSOLE 63 T6 T7 4 TRANSMISSION 16dO 16dO UNOER THE SPAEEWHEELCOVER 05 J2 T8 2 LICENSE PA...

Page 1711: ...ONUlTl0NEH 8rN BcN IN CENTRE CONSOLE EC33 l3 3 AUTOMATIC TRANSMISSION 16dO 16dO UNOER THE SPARE WHEEL COVER 035 086 T33 1 ALARM SYSTEM ENGINE HOODCONTACT 6dL 6dQ UNDER THE CFNTRAL FLFCTRICS I 38 T34 R...

Page 1712: ...E 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 LAMPS ROW LAMPS USA BODY INSTRUMENTS AND INDICATORS VENTILATION HEATING AC MIRROR SEATADJUSTMENT SEAT AND MIRROR MEMORY RADIO ABS ALARM SYSTEM TRAILER COUPLING...

Page 1713: ...g diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The 1O pole plugs on central electrical system are clipped together from 3 parts Part 1 w...

Page 1714: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 1 LAMPS ROW Current Flow Diagram 97 257...

Page 1715: ...s I 025 I I I I m3 32 cm I t 1 cmy 1 2L I I paY I I I I 391 I I I 1 I 1 II III I I I I I I I I I _ 1 I I I I I I I I I I I I I IlA II III1 COLDING HEADLAMP LEFT HEADLAMP UNIT LEFT AUnILIARY HIGH BEAM...

Page 1716: ...1 2 2 3 z w m z JL I a 24 523 KS 16 l I rf fAMp i1 1 l OoR i ipl II CT22 c T15 LT2J 15WWS I I I I I III1 4 40GR 9 e MPVI 2 5 IKS 4 II t H H h I71 I L BACKUP LAMP CLEARA NCE LAMP LAMPUNf T LEFT BACKUP...

Page 1717: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 2 LAMPS USA Current flow Diagram 97 259...

Page 1718: ...LDING HEADLAMP MOTOR 0 I a i r ofl I 30 5 wvsw 4 2 m I M I Ic 5 t I a FOLDING HEADLAMP LEFT 1 I 4 I I I I I I I II I IIII I 1 P11_ I I I I I I 1 I I I 0 HEADLAMP UNIT LEFT COMBINATION TURN SIGNAL Y RE...

Page 1719: ...SIiNAL x DOOR CONTACT P I 2 29 BACKUP LAMP BACKUP LAMPSWITCH IM481 I El 36 A I I I II I I I 1 24 7 27 I I 1 I I I T ICENSE PLATE 1 I I I I I It I II 34 I I I II I I I I I II I I 1 i v 4 2 90 L31 Al K...

Page 1720: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 3 BODY Current Flow Diagram 97 261...

Page 1721: ...H 6 w STEERING IGNITION LOCK _ _ YI I 15 sdm c A 2 g g F N 1234 i ES mmmm NNNN llliL PNw l I1 7 11 PUSHBUTTON SW TCH SLIDE ROOF IM 650 m t h L J NNN Las I i T I I m m m m I 14 t I I L I I I I I I I 02...

Page 1722: ...1 I 14 16 1 18 0 5 BR KS 4 I z r z GLOVE BOX LAMP 9 0 5 GNlSW 26 I 1 El3 I 14 1 I I I I I I I 72 12s SWAL r I I I I I In b b J II I REAR WIPER MOTOOR MP VI WIRING HARNESS ON CENTRAL ELECTRIC UNIT MP I...

Page 1723: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 4 INSTRUMENTS AND INDICATORS Current Flow Diagram 97 263...

Page 1724: ...I Klb I 251 7 3 0 I E B I L _ _ _ I I I II CENTRAL INFORMATION 312 13 I I II f _ I 31 YELLOW 1 i I t _I I o w o TX e 5 E J L 13 16 21 19 20 22 14 23 6 25 4 10 18 m I I 00 OS WGN I I I OS SC w 0 5 m ws...

Page 1725: ...MdTlON I Y tiiii iI 0 5 BLa I I 0 5 RT I I I I E d KS 1 WI K J K 6 I 5 5 THERMOELEMENTS _ 5 NR 2i_j L E3 ___ _ YELLOW I I I I L p y p 21 3 1 17 9 8 5 n 7 ri 1s13 1 21 19 20 2 Y 23 6 25 10 10 I 0 5GWRT...

Page 1726: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 5 VENTILATION HEATING AC Current Flow Diagram 97 265...

Page 1727: ...15 17 I8 19 C 1 I I I I L INTERNAL SENSOR CONTROL UNIT I I I I I I I E22 I MICROSWITCH CENTRAL NOZZL E AUXlLlARY AIR CONDITIONING SYSTEM iM570 I RELAY IV I I I I HEATER MV5 Elb IMPACTWALL 2 1 s I LLiF...

Page 1728: ...cD 4RY AIR IONING SYSTEM lM5701 MMtltH jm EVAPORATOR _ _ RESSISTANCE GROUP 1 I i rn N 2 3 1 m I E MP II MP ONL Y LHO AIR FLAP MOTOR 1 BLOWER 1 2 0 OR SW i I I I 1 BLOWER 2 KS1 8 OS mm s s giig r3 10 W...

Page 1729: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 6 MIRROR SEATADJUSTMENT Current Flow Diagram 97 267...

Page 1730: ...M383 M3871 II L 1 eu I I In I I L I I __ 7 ADJUSTMENT 4 WA 1 MP IV t 8sz II I I ATSWITCH 3z MIRROR SWITCH _ W R N 2 WAY SWITCH SEAT HEIGHT ADJUSTMENT REAR DRIVER SIDE t r L ti 123 SEPARAIING POINT EL...

Page 1731: ...RING HARNESS 14 i 7 5RT _ j SEAT HEIGHT LYl ItfA I I u BR m _ WAY SWITCH I I I5 I2 I4 ADJUSTMENT _ 1 SEPARATING POINT ELECTRIC HEAT P I WIRING HARNES ATSwl m SEAT HEIGHT ADJUSTMENT LEFT KS 343 I ADJUS...

Page 1732: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 7 SEAT AND MIRROR MEMORY Current Flow Diagram 97 269...

Page 1733: ...UNIT MIRROR 1 rp J C 15 l 4 l 1 56 I 1 I _ u II n 6 F II NE II s 1 II b IIc s n2 IIP II II 2 II v 07s wsm I4 075 w w 13 I 3 Hotmz Iilk I nmgong splqel Itah OX swr aT 6 d H r nh I I 1 a 6hlA i L i I G...

Page 1734: ...6 HEATER ELEMENTS BACKREST F I 7 58 5s 60 15RT n 10 et WIRING HARNESS NR 232 II 5 6 7 3 4 b v o I 05 SW L _ 7 I A 4 I I I tP 2 II I I I I I WIRING HARNESS NR 231 I I I I I I I I I I I I I IJ CONNECTOR...

Page 1735: ...Wiring 97 Wiring Diagram Type 928 S Model 87 page 8 RADIO Current Flow Diagram 97 271...

Page 1736: ...OR LEFT DOOR RIGHT MlDDLE RANGE SPEAKER MIDDLE RANGE SPEAKER TWEETER TWEETER TO BOOSTER BZW KS 66 B PILLAR LEFT m 1 54 cI1 B PILLAR RlGHT BOOSTER M 494 j LOWRANGE I la I I I SPEAKER I 5 BR Is BR WS LO...

Page 1737: ...I n I u t I BCWER I 1 l d LEiOORSPEAKER R GHT D2 I I iAm H we CONNECTIONPLAN RECEIVER 30 3 2 w CONNECTIONPLAN I 15 m jsBR i SPEAKER FRONTRIGHT SPEAKER REARRlGHl BLACK b s RT RED y ER FRONTLEFT SPEAKE...

Page 1738: ...Wiring 97 Wiring Diagram Type 928s Model 87 page 9 ABS ALARM SYSTEM TRAlLER COUPLING Current Flow Diagram 97 273...

Page 1739: ...I I 76 ALARM CONTROl 7 s m l l l 1 I 75 71 7s 3C I I I c 31 GROUND I SEE 1 PAGE 1 FIELD H6 MP II MP VI cl WELDING POINT 1 MP VO 0 CONNECTION WITH FIELD INDICATION I MP I MP GROUND TERMINALS 1 m m I K...

Page 1740: ...I MP VI t Ku f LTG MP VI mm LTG MP XI mm LTG zo AT 1 2 0 RT J n il i I ri i I lig 05 SWIRT 1 b d I i I I t I i I i J REAR RIGHT REAR LEFT FRONT REAR FRONTLEFT WHEEL SENSOR 1 31 GROUND MP V Y TRAILER C...

Page 1741: ...Wiring 97 Wiring Diagram Type 928s Model 87 page 10 ENGINE COMPARTMENT TEMPOSTAT Current Flow Diagram 97 275...

Page 1742: ...c 7 1 STARTER _ KS 1 I TRANSMISSION SWITCH II 4 I u i j j 32 3 25 29 2 b 3 1 x I I x I I II I II I I I I I II 3 1 j y WIRE CONNECTOR III 4 P I I II I II I I 075 RT I Y I I I 2 _ r I 15 mm A Isl I I I...

Page 1743: ...I I I I I I 0 75 RTlGE P I I 2 CONTR L UNIT 0 75 WV I I I l t RESOO LAP VT IIII 3 I 3 2 6 30 A EPIC 9 a VENT I WI I 8 TEMPERA TURE SENSOR z 4 i l Yn Rl I Cwzr 0 75 BR WS S 0 71 GNlsl 15 I 8r I POTENTI...

Page 1744: ...Wiring w Wiring Diagram Type 928s Model 87 page 11 CENTRAL ELECTRICAL SYSTEM Current Flow Diagram 97 277...

Page 1745: ...II ml WI _ 811 33 AUX HIGH BEAM 022 023 011 PI2 34 TURN SIGNAL FRONTLEFT PI 10 INSTRUMENT CLUSTER WA PA REAR WINDOW WIPER SWITCH 11 REAR WINDOW WIPER T24 12 BACKUPLIGHT MIRROR XXI 30 F14 13 AUX AC UT2...

Page 1746: ...CK DOWN M 249 EZK X FRESHAIR BLOWER XII HORN XIII 2 VERSIONS XIV XI SUPPRESSOR I I 2 xxv LH JETRONIC d 1 XXIII XXIV LIGHT COMBINATION RELAY sbb XIX HEADLAMP CLEANER xx FUEL PUMP XXI XXII INTERIOR LIGH...

Page 1747: ...4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 LAMPS ROW LAMPS USA BODY INSTRUMENT CLUSTER INDICATORS VENTILATION HEATING AIR CONDITIONING ELECTRICALLY OPERATED SEATS RADIO ABS ALARM SYSTEM TRAILER COUPLING ENGINE DIG...

Page 1748: ...ng diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The IO pole plugs on central electrical system are clipped together from 3 parts Part 1...

Page 1749: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 1 LAMPS ROW Current Flow Diagram 97 235...

Page 1750: ...I II I II III1 III I I I I I kl I I I JUA 1 L51 15gr ws I II 1 1 1 1 11 K CEN RAL INFORMATOR II 4 l HEADLAMP UNIT LEFT I I 1 1 1 1 r YELZOW20 27 iVS 1 5br I 2 Nyyo RELA y ORI 1 I r n r r r P Y II 8 H...

Page 1751: ...Wiring 97 Wiring Diagram Type 928s Model 86 page1 LAMPS USA Current flow Diagram 97 237...

Page 1752: ...OLDING HEADLAMP MOTOR i 1 w5Ys sw 1 II III nf arcRrpp 1 yjcl3 y b JcJfK 6 c221c25 211c23 141 j FOG L r 9 lri 2 E dKS 171 I 15 CA I J I I I I IGNITIONSWITCH I5 A 16 81 811 COMB INSTR 8 I J J r22 IGNITI...

Page 1753: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 2 BODY Current Flow Diagram 97 239...

Page 1754: ...I I I I I III COMB INS7R I I I l I I J Y _ III I REAR WIPER MO EkzIIlIlIE L 2s RELAy 5 F36 I j llFl j d j yzs IF 2 j L I I _ 2 5rtlsw I I I II I I I I I I I o IllllV A22 F 68 I y3 5 p yl c BlZ 3 I I...

Page 1755: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 3 INSTRUMENT CLUSTER INDICATORS Current Flow Diagram 97 241...

Page 1756: ...zq UQ 2 A9 9 G w In 5 3 1 0 z 7 i 1 I K15 3 Kll 53 2 L 2 L s m 2 I I 71 1 Y QSg gn bl fl hl nn 7 423 M A 4Fer 0 JITI CENTRAL INFORMATION cl 0 bl ALTERNATOR 61 64 II I 1 G km Ez ul v I 23 5 x Ml1 M Et...

Page 1757: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 4 VENTILATION HEATING AIR CONDITIONING ELECTRICALLY OPERATED SEATS Current Flow Diagram 97 243...

Page 1758: ...TSR T zb in IIIIII 1 MlRROR IMAGE AYUI AUXILIARY ___ M 139 M34a F l III IGNITION SWITCH X r E LH CONTROL UNIT 76 CENTRAL NOZZLE lllllllll L YI m l Obr II I i SEPARATING POINTI CONOITIONING SYSTEM M57...

Page 1759: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 5 RADIO Current Flow Diagram 97 245...

Page 1760: ...DOOR LEFT DOOR RIGHT M 327 M 328 M 330 I WJOST ER M494 KS3 M327 M328 M330 II II 75hr MT iCENTRAi o 7 7 hr 1 CONNECTION DIAGRAM BOOSTER DOOR RIGHT SPEAKER PLUG FRONT RIGHT hr WC hl WC WIRE CONNECTOR I...

Page 1761: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 6 ABS ALARM SYSTEM TRAILER COUPLING Current Flow Diagram 97 247...

Page 1762: ...d 5 2 k f L P 5 KS4 CABLt 0 1 bi 0 75 brlrt _________ _ rO 75 brl 0 75br L1 0 br P 0 5 brlws P RPM SENSOR STOP LtGHTSWdTCH lA I D5 El F l DOOR CONTACT LEFT RIGH I 0 S brhs 1 5 1 TEMPOSTATCONTrC9 UNtT...

Page 1763: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 7 ENGINE DIGITAL ENGINE ELECTRONICS Current Flow Diagram 97 249...

Page 1764: ...c I I I I II COUPLING kMP b P iv H L TEMPOSTA T _ _ _ UNIT SWITCH d F 1 Y XJ I I I I kz 7 b f IGNITIONSWITCH 1 R T SPEEOOMETE ACTUATOR I I 1 Ill I I I I I I I I 1 I L 1 Lb I 625 I IXnr hr 1r tld 2 X l...

Page 1765: ...Wiring 97 Wiring Diagram Type 928 S Model 86 page 8 CENTRAL ELECTRICAL SYSTEM Current Flow Diagram 97 251...

Page 1766: ...IV 30b Elb F5 4 P15 m OI 9 III r I a 9 z 2 X FRESH AIR BLOWER C6 C6 C6 C6 c7 c5 C6 C6 C6 c5 XXIII XXIV 30M XXIII XXIV 86 M XXIII XXIV 30b M c7 c5 C6 C6 C6 C6 El6 Cl8 E16 E16 I II BACK WINDOW HEATER UX...

Page 1767: ...GE 1 PAGE 2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 6 LAMPS BODY INSTRUMENT CLUSTER INDICATORS VENTILATION AND HEATING RADIO ABS ALARM SYSTEM TRAILER COUPLING ENGINE DIGITAL ENGINE ELECTRONICS CENTRAL...

Page 1768: ...ring diagram The ground connecting points are designated with MP and their location is shown in a vehicle diagram The 1O pole plugs on central electrical system are new They are clipped together from...

Page 1769: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 1 LAMPS Current Flow Diagram 97 215...

Page 1770: ...III I I 30 IPI I I I k h 1 5y s 2 i j I I II 33 II Ilk I I II I I PI II P71 0I IIIII I Iona11 ii II I II I I I II II FOLDING HEADLAMP LEFT I o l I I I II III l I 33 n1c r 7 I I I IllIll I III I II 35...

Page 1771: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 2 BODY Current Flow Diagram 97 217...

Page 1772: ...W LIFT _ r MIRROR 1 1 HATCHBACK UNLOCKING SWITCH RIGHT REAR WIPER MOTOR REP A WIPER RELEAY IL0 15qnlsw r 2 5 SW qELAY1 0 w 1c11 a UI 1 1 y FII I I h d r I I IhIlL ii iil b II I I I I I I I L I t 1 25b...

Page 1773: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 3 INSTRUMENT CLUSTER INDICATORS Current flow Diagram 97 219...

Page 1774: ...t 2 B s 2 x 2 P u s 9 WA TER 011 IIIII Ir0 5svWl I I SWITCH TRANSMITTER TRANSMITTE SWITCH TRANSMITTER TRANSMITTE r I b 6 w THE MOELEMENTS THE MOELEMENTS CATALYSTMONITOR CATALYSTMONITOR IllI II rO Sbl...

Page 1775: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 4 VENTILATION AND HEATING Current Flow Diagram 97 221...

Page 1776: ...JUSTMENT RIGHT SEATHEATER AN SEATADJUSTMENT MIRROR IMAGE ENTRAL ELECTRICAL SPORTS SEAT AUXILIARYAIR CONDITIONING SEAT HEATER SWITCH TIME DELAY RELAY BLOWERSWITCH LONGITUDINAL ADJUSTMENT IMPACT WALL SE...

Page 1777: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 5 RADIO Current Flow Diagram 97 223...

Page 1778: ...l I I I I2 1 iI EXTENSION I I ISI I I I I I I I I I II IP PARTS IrrrhlO 928645 612 03 II 121 I V i I4 1 z l ANTENNA I INTERFERENCE III IIIIII Ili H l II11111111 II t fEXTENSION ONLYFOR RL IIINTERFEREN...

Page 1779: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 6 ABS ALARM SYSTEM TRAILER COUPLING Current Flow Diagram 97 225...

Page 1780: ...I YE 2 2 2 2 g J i uil jyy u llc 3 G I II II I E l J I I I 0 75brlrt II I U 13 br I I I 0 0 75br _ _ 8 n I 3 I 1Ohr I GROUND s25 11 CONNECTION I c pm l IA641 EZF CONTROL UNIT 25 I c m DOOR CONTACT LEF...

Page 1781: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 7 ENGINE DIGITAL ENGINE ELECTRONICS Current Flow Diagram 97 227...

Page 1782: ...UNIT n IGNITION TRIGGER UNIT n TEMPERATURE SENSOR DOUBLE NTC I A AIR VOLUME METER I ILL I I 1 IL YI I ruN SWITCH FTARTER BACKUP LAMP GEAR THROTTLE VALVESWITCH UZZERCoNTACT H THANGE INDICATOR SWITCH T...

Page 1783: ...Wiring 97 Wiring Diagram Type 928 S Model 85 page 8 CENTRAL ELECTRICAL SYSTEM Current Flow Diagram 97 229...

Page 1784: ...lT s El6 XIX P lJ El6 G OUND CONNECTION A S OF56 31 H69 30 rJ30 H68 J30H69 x XT9 2 00 2 9 zV h z Z hrr vJ L bQL nr a PG r JrSGr 9h Ll s 2 3 w w G 2222iFtZfS llllllll l R Q II II l llll n 121314152 2 2...

Page 1785: ...LECTRIC CENTRAL ELECTRIC USA JAPAN FRONT END AND ENGINE ELECTRONIC INGNITION LH INJECTION FRONT END AND ENGINE USA JAPAN PASSENGER COMPARTMENT AND INSTRUMENTS PASSENGER COMPARTMENT PASSENGER COMPARTME...

Page 1786: ...LECTRIC CENTRAL ELECTRIC USA JAPAN FRONT END AND ENGINE ELECTRONIC INGNITION LH INJECTION FRONT END AND ENGINE USA JAPAN PASSENGER COMPARTMENT AND INSTRUMENTS PASSENGER COMPARTMENT PASSENGER COMPARTME...

Page 1787: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 01 CENTRAL ELECTRIC Current Flow Diagram 97 191...

Page 1788: ...WIPER RETURN 16 A TWO TONE HORNS ELECTRIC ANTENNA ELECTRICSEATOPERAllON 25 A nnm 4Ei13r5 FUEL PUMP 16A INSTRUMENTS AND INDICA TOR 8 A A LAMPS RIGHTANU LEFT 1 m PUSH BUTTON 8 PANEL LIGHT LIGHT SWITCH S...

Page 1789: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 02 CENTRAL ELECTRIC USA JAPAN Current Flow Diagram 97 l 93...

Page 1790: ...PER RETURN ELECTRIC SEAT OPERA TION FUEL PUMP INSTRUMENTS AND INDICATOR LAMPS RIGHT AND LEFT VII TERM 30 v m 25 A 16 A 16A 25 A 25 A 25 A 16 A 25 A 16A 8A TO RAIL TERM 3 3b WIPER INTERMITTENT A TION C...

Page 1791: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 1 FRONT END AND ENGINE ELECTRONIC INGNITION LH INJECTION Current Flow Diagram 97 195...

Page 1792: ...ISTRISUTOR I DISTRIrTUTOR II 1 IGNITION IGNITII CO L u IGNITIONCOIL I CONTROL UN T I CONTRO I i r ON L UNIT n I t AUXILIARY A R VALVE OIL LEVEL SWITCH 2 WIRE HAUN SS L I I SPARK PLUGS dII r r I c7 R q...

Page 1793: ...Wiring Diagram Type 928 S Model 84 page 1A FRONT END AND ENGINE USA JAPAN Wiring 97 Current Flow Diagram 97 197...

Page 1794: ...COOLANT PRESSURE SWITCH CENTRAL ELECTRIC TERM 30 Nr 1 WIRE HARNESS CONTROL UN T OIL LEVEL SWITCH Nr 13 WIRE HARNESS h Z WIRE HARNES BRAKEPAD WEAR INDICATOR d Iu I llJllIlllll II _ I 1 1 Nr3 WIREHARNES...

Page 1795: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 2 PASSENGER COMPARTMENT AND INSTRUMENTS Current Flow Diagram 97 199...

Page 1796: ...E 33 E 34 A 3G WIRE UISCONNECTED IN r Nr 172 WIRE HAXNkSS CONJ NCTION WITH M 124 I NOTBY DNL Y MSS3 tl576 PUSH BUTTON PARKING BRAKE I FRONT FOG s EvER CONIACT 1 A z REAR H553 M576 rn r LIGHT SPEEDOMET...

Page 1797: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 3 PASSENGER COMPARTMENT Current Flow Diagram 97 201...

Page 1798: ...ADIO wm T PUSH BUTTON SWITCH FOR RIGHT OOOR CONTACT WINDOW REGULA TOR RIGHT CONNECTION POINT Il PAGE 2 SECTION A 12 FLOOR LAMP I CHANGE MI OVER SWITCH Nr 166 WIRE HARNE Nr167 WIRE HARNESS Nr 167 WIRE...

Page 1799: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 4 PASSENGER COMPARTMENT AND REAR END l Current Flow Diagram 97 203...

Page 1800: ...31 WIRE HAK INSIDE LIGHT LID E HARNESS Nr 12 WIRE HARNESS Nr 5 WIRE HARNESS k8 WIRE HARNESS Nr 16 W R SERVICE SECTOR SOLUTION co cANTENNA pAGE6 E I AH W ND W WlPER REL A Y II FUEL LEVEL IY PUMP yD A...

Page 1801: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 5 HEATING VENTILATING AIR CONDITIONING Current Flow Diagram 97 205...

Page 1802: ...R MAGNETIC ELECTRIC COUPLING AIR VALVE SWITCH REGULATOR BLOWER SWITCH RESISTOR GROUP FRES HAIR BLOWER ADDITIONAL FAN N 186 WIRE HARN INSIDE SENSOR WIRE HARNESS WIRE HARNESS N3 WIRE HARNES CONNECTION P...

Page 1803: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 6 RADIO Current Flow Diagram 97 207...

Page 1804: ...CONTROL 14 PINJ PAINTDOTELUE WlRE HARNESS Nr3 WIRE HARNE PAINT DOT It Nr167 WIRE H Vc 11 BROWN HiFi System M 490 REAR RIGHT hr67 WIRE HARNESS Nr 167 WlflE HARNESS ONNECTION POINT RI MlDRANGE TOSPEAKER...

Page 1805: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 7 ASS Current Flow Diagram 97 209...

Page 1806: ...r 10 3 I i l L l 1 L l LA I RR RL FR FL Nt 121 WIRE HARNESS CENTRAL ELECTRIC PLUG Y WIRE BRANCH STARTER z Nr 2 WIRE HARNESS TERM 30 PAGE 1 SECTION F 2 SPEED SENSOR v GROUND VALVE COVER XI GROUND STEER...

Page 1807: ...Wiring 97 Wiring Diagram Type 928 S Model 84 page 8 ADDITIONAL WIRING DIAGRAM FOR BURGLAR ALARM Current Flow Diagram 97 211...

Page 1808: ...CONTROL UNIT _ 1 I D 1 flflm 1 D r fEJ 7 DooRLoCK r F 7 DOOR CONTACT ENGINE COMPARTMENT r TWO TONE HORNS x CENTRAL ELECTRICPLUG 1 1 IIII I YTII b I 26 ZL Nr 182 WIRE HARNESS hlr F WIDC Y lL A ECC I T...

Reviews:

No comments

Brands by name

Popular brands

Load more brands