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Porsche 944 Turbo 1988, Руководство по ремонту

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Porsche 944 Turbo 1988 Скачать руководство пользователя страница 216

Содержание 944 Turbo 1988

Страница 1: ...Workshop Manual DR lNG h c F PORSCHE Aktiengesellschaft...

Страница 2: ...and 924 The information in this manual is organized in repair groups according to work position numbering The two digit numbers of the repair groups correspond to the first digits of the work positio...

Страница 3: ...rs Shafts Differential I Transaxle System Front Wheel Suspension Rear Wheel Suspension Axle Shaft Wheels Tires Alignment Anti Blocking System Brakes I Mechanics Brakes I Hydraulics Steering 10 13 15 1...

Страница 4: ...re checking Balance shaft drive disassembly and assembly Installing bearing bridges of compensating shafts Refacing the flywheel Engine I Cylinder Head Valve Drive Camshafts checking and adjusting too...

Страница 5: ...21 9 21 10 21 11 21 12a 21 13 24 1 24 2 24 3 24 5 24 9 CO level correcting on air flow sensor USA and catalytic converter vehicles 24 13 24 14 Idle actuator removal and installation Exhaust System Ex...

Страница 6: ...d installing Gearbox disassembling and assembling Rear transmission cover disassembling and assembling End plate disassembling and assembling Transmission housing disassemblig and assembling Oil pump...

Страница 7: ...e measuring chart up to end of MY 89 Sample measuring chart as of MY 90 Adjustment values for wheel alignment Vehicle measurement Brakes I Mechanical Parts Technical Data Tightening Torques Brake pads...

Страница 8: ...ation Spoiler and bumper removal and installation USA Exterior Equipment Rocker panel covers removing and installing Rear apron spoiler removing and installing Finishes available 1986 models onward Tu...

Страница 9: ...944 turbo Genera1 Printed in Germany 0 1...

Страница 10: ...ine weight dry E n g i n e D e s i g n Type Crankcase Crankshaft Crankshaft bearings 0 2 Technical Data M44 51 mm in mm in cm 3 in 3 4 100 3 94 78 9 3 11 2479 151 8 0 1 kW HP kW HP rpm Nm kpm 162 220...

Страница 11: ...owers Camshaft Shell hardcast Camshaft bearings Camshaft runs in camshaft housing without bearing she 11 s Camshaft drive Toothed belt with tensioning roller Balance shaft drive Toothed belt with tens...

Страница 12: ...n C o n t r o 1 He a t n g F u e S y s t e m Fuel preparation Fuel supply M298 and USA as standard cat conv instead of primary muffler cat conv in bypass line M298 and USA 3 way cat conv controlled ai...

Страница 13: ...k mm in Rear track mm in Ground clearance at max tot weight mm in Bed clearance at mm in max tot weight Overhang angle front rear We i g h t Curb weight per DIN 70020 kg lbs Curb weight axle load kg l...

Страница 14: ...0 60 mph 1 4 mile Kilometer from standing start H i 1 1 c 1 i m b i n g In slip limit DIN curb weight 1 2 of payload 0 6 Technical Data 1200 2646 2800 6173 50 110 944 turbo 84 for Italy up to 100 km h...

Страница 15: ...944 turbo Genera1 DESIGNATION OF CYLINDERS Printed in Germany Technical Data 0 7...

Страница 16: ...performance The most significant modifications or distinguishing features exact description in information brochure WKD 495010 87 955 1 Engine 250 HP 184 kW catalyst version for FRG others in accordan...

Страница 17: ...50 VA 16 rear 9 J x 16 ET 60 mm with 245 45 VA 16 Brake system front axle brakes similar to 928 S4 with asbestos free brake pads Wheel suspension at front and rear axle bearings with harder rubber co...

Страница 18: ...at right 8 Technical data Engine type M 44 52 Turbo special model S Performance 250 HP 184 kW at 6000 rpm Torque 350 Nm at 4000 rpm Compression ratio 8 0 1 Fuel 95 RON Unleaded Leaded Curb weight 1 35...

Страница 19: ...ft vehicle only at illus trated jacking points When driving vehicle onto lift ing platform make sure of sufficient space between pl at form and vehicle F r o n t On inside side member R e a r On side...

Страница 20: ...underneath jacking points on sides of vehicle Never jack on engine oil pan or transmission as this can cause serious damage I m p o r t a n t Avoid damage by inserting block of wood between vehicle a...

Страница 21: ...00 rpm Positive pressure Dipstick Upper mark Lower mark Va 1 v e T i m i n g Camshaft bore Camshaft Camshaft Cam follower bore in camshaft housing Cam followers Camshaft Contents Contents Inside dia D...

Страница 22: ...Seat angle Inside dia Diameter Diameter Clearance 1 7 2 5 45 45 30 60 9 0 015 8 97 0 012 8 95 0 012 10 bar positive pressure and above P i s t o n s a n d C o n n e c t i n g R o d s KS Pistons Cylind...

Страница 23: ...90 a Connecting rod bearing I Radial play 0 034 0 092 crankshaft End play 0 100 0 400 Crankshaft bearing journal Diameter 69 971 69 990 Crankshaft bearing crankshaft Radial play 0 020 0 098 Crankshaft...

Страница 24: ...led crankcase upper section Hex bo1t 2 steps 1st step 15 11 M8 2nd step 20 14 Balance shaft 2 steps 1st step 15 11 1 8 bearing bridges 2nd step 30 3 22 2 nuts on crank case upper section Left and righ...

Страница 25: ...rocket to 210 145 M 16xl 5 crankshaft Sensor to 8 6 M 6 holder Pulley to 8 6 M6 sprocket Cyli nder head Tightening to crankcase cylinder head upper section gasket 1st step 20 14 2nd step 50 36 3rd ste...

Страница 26: ...l 5 bolts in camshaft housing Camshaft 8 6 M 6 bearing to camshaft housing Knock sensor Use original bolt 9 6 6 M 8 without washer Camshaft sprocket to camshaft polygon 65 70 M 10 socket head bolt 47...

Страница 27: ...33 M10 roller to water pump housing Oil pump to 8 6 M6 crankcase 45 33 1 10 Tensioning 45 33 M10 roller to oil pump housing Dri ve belt 8 6 M6 cover Spark plugs 25 30 M14x1 25 18 22 Alternator 45 33 1...

Страница 28: ...bo1t coolant line to exhaust turbocharger Connection stud to exhaust turbocharger Coupling nut coolant lead to exhaust turbocharger All other bolts and nuts M 6 M 8 t 10 Printed in Germany Tightening...

Страница 29: ...Engine type M 44 51 52 Fuel system Cap nut at fuel collection pipe 10 010 Thread M 12 X 1 5 M 10 M8 M6 M6 M5 MB M 12 M 12 X 1 5 Tightening torque Nm ftlb 30 22 Stage 1 60 torque angle Stage 2 20 15 St...

Страница 30: ...Special Tool Remarks Engine suspension Used together fixture 3033 with a shop hoist e g Bilstein K750 H No t e If necessary connect engine suspension fixture and shop hoist with standard spring loade...

Страница 31: ...separate cable harness and push both cables with the rubber grommet through the fire wall Open wire straps 5 Unscrew and remove cover in foot well of passenger side Unscrew carrier for DME and knock...

Страница 32: ...10 Unscrew and remove distributor cover Remove oil fi lter and ATF supply reservoir 11 Disconnect throttle operating cable Disconnect oxygen sensor plug connection and loosen wire straps Unscrew coola...

Страница 33: ...nscrew fan motor brackets on radiator and remove from below 16 Loosen coolant hoses on coolant pipe cross member and remove cross member 944 turbo 17 Unscrew and remove coolant hose and vent hose on r...

Страница 34: ...in G ermany Engine I Crankcase 10 21 Loosen poly rib drive belt tensioner on a c compressor and remove belt Unscrew compressor on console and allow it to hang down to the side refrigerant hoses remain...

Страница 35: ...xle cross member with steering gear and power pump from below 944 turbo 27 Unscrew deflection plate on starter and clutch housing and remove toward rear 28 Disconnect electrical connect ions on starte...

Страница 36: ...ve ar d brake booster Remove diagnosis plug from holder downward Engine I Crankcase 10 36 Connect Special Tool 3033 in transporting bracket of engine as described below Pulley Flywheel Pos 3 Pos 11 In...

Страница 37: ...ting bolts first but do not tighten N o t e Tighten mounting bolts to final torque only after installation of hydraulic engine mounts on front axle cross member Tightening torque of mounting bolts 42...

Страница 38: ...y reservoir with ATF and bleed steering system 8 Run engine to operating temperature Check engine oil and coolant level correcti ng if necessary Engine I Crankcase Printed in Germany Removing and Inst...

Страница 39: ...Deflection approx 5 mm Ad j u s t i n g 1 Remove engine splashguard 2 Loosen upper mounting bolt or nut slightly 3 Loosen connecting rod bolts slightly Loosen connecting rod nuts and turn connecting r...

Страница 40: ...ial tool and push out test pin opposite lockpin completely Line up drag needle with gage needle 4 Slide special tool onto belt Press in gaging pin arrow slowly until lockpin is felt to engage and read...

Страница 41: ...stons TOOLS No Description Special Tool Remarks 1 Drive belt tightness 9201 tester cj usting gage 9207 L 3 Adjusting wrench 9244 Printed in Germany Tools for Checking and Adjusting Tightness of Toothe...

Страница 42: ...er upper section and air cleaner lower section together with air flow sensor 2 Remove poly rib drive belt or power steering pump drive be1t N o t e Before unscrewing locknuts always loosen connecting...

Страница 43: ...lt cover 7 Prepare Special Tool 9201 for testing operation Pull out lockpin on special tool and push out test pin opposite lockpin completely Line up drag needle with gage need e B Slide special tool...

Страница 44: ...tightness of toothed belt Set distance between guide roller and toothed belt in area of lower balance shaft to 0 5 mm using Special Tool 9207 or a 0 5 mm feeler gage blade pre tensioning upper belt s...

Страница 45: ...ull contact on t he drive belt The special tool must not be turned or moved on belt whi le checking Engine I Crankshaft Pistons 13 Idler pull ey Printed in Germany Checking and Adjusting Tightness of...

Страница 46: ...n crown go offset from piston pin axis Note code 0 0 005 1 2 0 0 005 1 z Checking cylinder bores Measure approx 65 mm from upper edge of cylinder bore transverse to engine block Mount lower crankcase...

Страница 47: ...SEMBLING AND ASSEMBLING PISTONS AND CONNECTING RODS 30 31 33 35 40 42 39 41 5 29 26 22 21 25 24 32 36 31 38 l 34 1 2 3 4 6 7 11 13 8 9 1012 20 15 14 19 18 17 16 Printed in Germany Disassembling and As...

Страница 48: ...mbling Balance Shaft Drive 944 turoo Installing Coat threads with Loctite 574 torque 45 Nm 33 ftlb counterhold with Special Tool 9200 Position correctly Position correctly locating tab inserts into un...

Страница 49: ...pper balance shaft housing 21 End ring 22 Round seal Printed in Germany Engine I Crankshaft Pistons 13 Note When Qty Removing Installing 3 1 1 Replace making sure of correct fi 1 Replace lightly coat...

Страница 50: ...ng Balance Shaft Drive 944 turbo Installing Replace insert in bearing bridge take up bore with grease Tightening torque 30 3 Nm 22 2 ftlb Check for correct fit Check for correct fit Lightly coat threa...

Страница 51: ...2 Sleeve Printed in Germany Engine I Crankshaft Pistons 13 Note When Qty Removing Installing 1 1 Replace oil lubricate sealing 1i p Observe marking arrow Rotational direction counter clockwise 3 3 1 1...

Страница 52: ...and must always be installed together Check identification codes I n s t a 1 1 i n g B e a r i n g B r i d g e s o f B a 1 a n c e S h a f t s In installed position it must be possible to read the id...

Страница 53: ...charger Before installing the balance shaft it is vital to ascertain that the seal ring is in posi tion in the take up bore of the bearing bridge use grease Assembly note Whenever performing repairs...

Страница 54: ...with one another as described below Hand tighten all hexagonal head bolts 2 Mount bearing housing with a lightly oiled 0 ring but without tightening mounting bolts 3 Tightening torque forM 6 bolts 10...

Страница 55: ...rface In the flywheel may be refaced on a lathe Remove as little material as possible Wear limit for flywheel thickness 25 2 mm 1 1 Wear limit 25 2 mm 2 Remove as little material as possible 3 Max run...

Страница 56: ...OOLS No Description 1 Belt tightness tester 2 Adjusting wrench Printed in Germany Engine I Cylinder Head Valve Drive Special Tool Remarks 9201 9244 Checking and Adjusting Tightness of Camshaft Drive B...

Страница 57: ...age 2 The TDC mark on flywheel and the cast boss on the clutch housing must likewise be aligned 3 Turn engine counter clockwise on crankshaft approx 10 crankshaft degrees which equals approx 1 5 teeth...

Страница 58: ...ng testing A d j u s t i n g 6 To tighten turn tensioning roller counter clockwise To loosen turn tensioning roller clockwise Move tensioning roller accordingly wi th Special Tool 9244 adjusting wrenc...

Страница 59: ...ial Tool 9138 1 and if necessary correct by installing or removing shims Shims are available in thicknesses of 0 5 and 1 0 mm Intake valve Exhaust valve 41 0 0 5 mm 40 0 0 5 mm N o t e The outer valve...

Страница 60: ...camshaft are no longer identical with the seal and spacer for the upper balance shaft they were previously Marking arrow points in direction of turning of camshaft Lubricate sealing l ip with oil and...

Страница 61: ...rication 17 4 Clean drain plug making sure to replace seal Tightening torque 50 Nm 36 ftlb 5 Give gasket on oil filter a light coat of oil Screw filter on by hand until gasket makes contact and then t...

Страница 62: ...YSTEM FOR LEAKS 1 Inspect visually for leaks Water 60 55 50 2 Check cooling and heating hoses for correct routing porosity swelling tears and rubbing damage Replace damaged hoses 3 Tighten hose clamps...

Страница 63: ...el lines making sure to counterhold Catch escaping 1 Inspect visual ly for leaks fuel 2 Loosen clamp and remove fuel 2 Ti ghten coupling nuts and hose filter clamps 3 Install new fi lter checking dire...

Страница 64: ...old end of hose in a measuring glass volume approx 1500 cm3 2 Pull off DME relay on central electric board and bridge terminals 30 and 87 b with a piece of wire Let fuel run 30 seconds at least 850 Re...

Страница 65: ...I I I I I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _J A Charging air cooler 8 Air flow sensor C Throttle housing 0 Intake pipe E To charging pressure control valve F To brake booster G Idle actuator A H Air...

Страница 66: ...charger 21 TOOL Measuring charging pressure No Description Special Tool Remarks 1 Pressure gage 9103 2 with adapter Use pressure hose from Speci a1 Tool 9103 Printed in Germany Charging Pressure Measu...

Страница 67: ...21 Turbocharger 944 turbo TURBOCHARGER SYSTEM DISASSEMBLY AND ASSEMBLY 3 20 26 25 12 21 2 5 4 8 9 29 30 10 22 11 23 38 36 Turbocharger System Disassembly and Assembly 35 r 37 T 44 Printed in Germany...

Страница 68: ...12 Cooling water pipe 13 Seal ring 14 Pan head bolt M8 X 25 15 Washer 16 Pan head bolt M8 X 125 17 Washer 18 Pan head bolt M8 X 35 Printed in Germany Qty 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 Turbochar...

Страница 69: ...l ring 31 Hose clamp 32 Ventilation 1ine 33 Threaded connection 34 Seal ring 35 Hex bolt M6 X 20 36 Washer 37 Oi1 return line 21 4 944 turbo Note When Qty Removing Installing 1 1 1 Always replace Make...

Страница 70: ...r 41 Hex bolt M10 x 55 42 Pan head bolt M10 X 55 43 Washer 44 Engine support Printed in Germany Qty 1 1 3 2 1 1 1 Turbocharger Note when Removing Installing Always replace Make sure of correct seating...

Страница 71: ...pressure damper Disconnect cable on cruise control motor 944 turbo 5 Pull off spark plug connectors Unscrew distri butor cap Detach fuel collection pipe with fuel injectors and ignition leads on inta...

Страница 72: ...ter 12 Unscrew flange between turbo charger and exhaust assembly with the M8 bolt on engine block Turbocharger 21 13 Unscrew exhaust flange on turbine housing coolant lines and oil pressure line on tu...

Страница 73: ...em from falling out e g with grease 4 Check and if necessary replace locknuts for exhaust flanges 5 Tighten the M8 bolt of the exhaust flange on engine block only after installation of all bolts for e...

Страница 74: ...d note reading The difference between the readings obtained is the end play Max play 0 16 mm MEASURING EXHAUST TURBOCHARGER RADIAL PLAY Radial play is measured only on the turbine side Set dial gage m...

Страница 75: ...0 rpm With engine type M 44 52 the boost pressure remains constant at 5 800 rpm 1 75 bar absolute value and drops only after this value has been passed Note Measure charging pressure only under dry ro...

Страница 76: ...connection on by pass air valve Loosen and remove hose clamps on charging air guide pipe throttle housing and bypass air valve 3 Loosen hose clamps on air intake cowl remove hose connections from cowl...

Страница 77: ...1 a t o n 1 Make sure of correct seating of hoses and hose clamps 2 Fill and bleed cooling system N o t e c h e c k i n g F u n c t 0 f T u r b o c h a r g e r c 0 0 1 a n t p u m p 1 Turn on ignitio...

Страница 78: ...gon head screw 2 M6x20 2 Washer A 6 4 2 3 Housing 4 0 ring seal 28 x 2 5 5 Thermostat for turbo charger cooling system 6 Water pump Turbo charger cooling system components removing and installing Prin...

Страница 79: ...nd lift out 3 Loosen hose clamps for charging air duct and unscrew hex bolts on cooler 4 Remove cooler with rubber connection towards the front Turbocharger 21 I n s t a 1 1 a t i o n Make sure of cor...

Страница 80: ...h screwdriver Remove air 2 Tighten hose clamps cleaner upper section 3 Remove air filter cartri dge and clean inside of air cleaner lower section with a cloth that will not leave l int 4 Install air f...

Страница 81: ...pped fuel pump bridged 2 3 2 7 bar Test value at idle spped Approx 2 bar 1 leak test m1n1mum pressure after 20 min 1 bar Idle adjustment Idle speed in rpm 840 40 co 1eve1 in 1 0 1 5 0 6 0 2 Measured u...

Страница 82: ...o L Jetronic Fuel Injection 24 CHECKING FUEL PRESSURE TOOLS No Description Special Tool Rer 1arks Pressure meter with p 378 or VW 1318 hose from pressure tester Printed in Germany Checking Fuel Pressu...

Страница 83: ...ut 2 Connect pressure meter with hose from Special Tool P 378 or VW 1318 on test connection 3 Pull of DME relay on central electric board and bri dge terminals 30 and 87 b with a piece of wire Fuel pu...

Страница 84: ...24 IDLE ADJUSTMENTS T o o 1 s No Description Special Tool Remarks 1 Oil temperature 9122 9122 2 tester with sensor 2 Articulated screw 9230 driver l 3 Lead Made locally or use test relay 9246 Printed...

Страница 85: ...ter with sensor to measure the oil temperature 2 Check CO level If CO level is not within specified range correct setting on air flow sensor using Special Tool 9230 articulated screwdriver 24 6 Idle A...

Страница 86: ...er 1367 for example Printed in Germany 1 1987 L Jetronic Fuel Injection 24 S Turn control screw bypass on t hrottle housing until specified speed of 840 40 rpm is reached 6 Restore operati on of idle...

Страница 87: ...ls T o o 1 s No Description 1 Oil temperature tester with sensor 2 Exhaust tester 3 Wire lead 4 Articulated screw driver Printed in Germany 2 Special Tool 9122 9122 2 i us 4492 9230 Idle Adjustments U...

Страница 88: ...kewed CO levels Ambient temperature 15 to 35 C I 59 to 95 F 1 Push exhaust take up hose or CO tester US 4492 onto CO collecting pipe 2 Run engine to operating temper ature oil temperature 70 to 90 C 1...

Страница 89: ...ect a separte tachometer per instructions supplied with unit Idle speed adjustment level 840 40 rpm Check and if necessary adjust engine idle speed This requires stopping the operation of the idle spe...

Страница 90: ...screw bypass on throttle housing until specified speed of 840 40 rpm is reached 9 Restore operation of idle charging control after compl eting adjustments by removing wire lead or test relay from diag...

Страница 91: ...hole in plug down to stop steel insert 3 Pull out plug using size 2 screw extractor I n s t a 1 1 a t i o n 1 Install air flow sensor 2 Adjust CO level and engine idle speed Turn CO setti ng screw usi...

Страница 92: ...ibution pipe with fuel injectors and ignition leads on intake air distributor and cam shaft housing 944 turbo 4 Carefully remove fuel distribution pipe with fuel injectors and ignition leads from inta...

Страница 93: ...guide pipe and remove I n s t a 1 1 a t i o n 1 When installi ng idle actuator take note of flow through arrow direction Arrow points to intake air distributor 2 Take care to position vacuum hoses and...

Страница 94: ...r head flange 3 Check tightness of all flange connections from exhaust system turbocharger and bypass valve 4 Check tightness of bolts on primary muffler catalytic converter I final muffler flange Che...

Страница 95: ...never be disconnected while the engine is running 1 Open engine hood and remove battery cover 2 Loosen and remove ground lead Printed in Germany C h e c k i n g A c i d L e v e 1 Unscrew all caps and...

Страница 96: ...er The voltage must not drop below a minimum of 9 6 Vwith a load current of approx 110 A If the voltage is lower at this load approx 8 to 10 seconds the battery has either been discharged or is defect...

Страница 97: ...ve the left hand charge air guide tube 85 158 4 Remove the lower part of the air filter with air flow sensor Alternator removing and installing Printed in Germany Ill 1988 85 13 5 Remove the lower par...

Страница 98: ...ross strut and remove cross strut 11 Detach the inlet air box between air flow sensor and turbo charger compressor housing and put on one side Note Seal the compressor housing with a suitable plug 27...

Страница 99: ...of the console 88 14 15 Put the alternator on one side and remove the air box Alternator removing and installing Printed In Germany Ill 1988 88 15 16 Undo connectors Installation Poly rib belt tension...

Страница 100: ...Bosch No resistors 0 221 118 322 D i s t r i b u t o r Cap Type I Model Version Remarks 944 turbo 944 602 251 00 Only high voltage Bosch No distribution 1 235 522 325 S p a r k P 1 u g s Type I Model...

Страница 101: ...r e C o n t r o 1 U n i t Type I Model Version Remarks 951 618 113 02 944 turbo Bosch No 0 261 201 013 K n o c k S e n s o r Type I Model Version Remarks 951 606 141 00 Tightening 944 turbo until mod...

Страница 102: ...n a 1 Type I Model Version Remarks 944 turbo 928 609 105 03 Without auxiliary Beru No spark gap 0 300 322 101 R e v o 1 u t i o n S e n s o r Type J Model Version Remarks 944 turbo 944 606 115 00 R e...

Страница 103: ...gulations in each country concerning working with and testing ignition systems Always switch off the ignition disconnect ignition or power supply before working on ignition systems This includes work...

Страница 104: ...rbo 5 4 1 Battery 2 Ignition lock 3 DME Control unit Ignition System 0 3_5 1 1 0 0 3 4 Ignition coil 5 Distributor 6 Spark plug 0 28 Printed in Germany Accident Hazards with Electronic Ignition System...

Страница 105: ...ts 7 When testing compression pull out control unit plug or firmly connect ignition coil terminal 4 to a ground with auxiliary cable to preclude hazardous high voltage and damage to insulation on igni...

Страница 106: ...ssenger side 4 OT sensor connection 5 Timing valve 6 Idle actuator under intake air distributor 7 Knock sensor 8 Fuel pressure test connection 9 Ignition coil Ignition System 28 10 Distributor cap 11...

Страница 107: ...ONTROL UNITS 1 Fold back mat in passenger side footwell Unscrew and remove footwell cover 2 Unscrew control unit bracket and fold forward 3 Pull out control unit plug and unscrew control unit 28 8 Rem...

Страница 108: ...ve plug connection on air flow sensor 3 Take out air filter housing lower section and unscrew air flow sensor Ignition System 28 REMOVING AND INSTALLING TEMPERATURE SEN SOR NTC II 1 Remove air filter...

Страница 109: ...m as from and set to one side Detach spark mod 88 20 Nm plug connector for cylinder 3 2 Unscrew knock sensor and pull upwards Disconnect plug connector Use care when working on knock sensor For instan...

Страница 110: ...tem 28 REPLACING SPARK PLUGS 1 Pull off spark plug connector 2 Unscrew spark plug with a standard wrench A spark plug wrench is part of the tool kit supplied with the vehicle 3 Lightly coat spark plug...

Страница 111: ...4 463 093 Pressure gage VAG 1318 Two auxiliary electric leads locally made for tests on multiple pin plug of control units and on plug connections with the same contacts 944 turbo 1 Highly flexible li...

Страница 112: ...4 5 6 Reference mark rpm sensors view of disconnected plug connector 3 2 1 Idle actuator view of dis connected plug connector 3 4 5 Printed in Germany Ignition System Air flow sensor view of dis conne...

Страница 113: ...cket A USA lead free engines 13 NTC II 28 14 Plug Connections 944 turbo 14 ti signals injection valves 3 4 15 ti signals injection valves 1 2 16 Ground 17 Ground 18 Voltage supply relay G5 87 19 Groun...

Страница 114: ...nal output 18 Test socket I full load signal output 20 Vehicle ground electronic ground connection Printed in Germany Ignition System 21 Angle sensor 22 Angle sensor 23 Angle sensor ground angle senso...

Страница 115: ...w sensor Ignition system Reference mark sensor RP 1 sensor Supply vo1tage control unit I fuel pump Ground and plug connections TEST CONDITIONS Engine in good mechanical condition Battery charged 11 X1...

Страница 116: ...engine for firm seating good contact and cleanliness N o t e Ignition System 28 Check plug connection for OME and K CP control unit behind passenger side footwe 11 cover Check 14 pole plug connection...

Страница 117: ...otentiometer 944 turbo Plug connection for timing valve Piug connection for air flow sensor Knock sensor between cyls 2 and 3 NTC II in engine block at cyl 1 Plug connection for idle actuator 28 18 Te...

Страница 118: ...__ Indication B attery voltage Printed in G ermany Ignition System 1 3 Measure voltage on K CP plug between terminals 6 and 14 25 24 23 22 21 20 19 18 17 16 15 14 c J t l c l c l 13 12 11 10 9 7 4 3...

Страница 119: ...uel pump should run If not check fuel pump and leads to fuel pump 28 20 Test Point 3 RP 1 Sensor 944 turbo TEST POINT 3 RPM Sensor No t e The function of the rpm and reference mark sensors can only be...

Страница 120: ...sor 1 Carry out testing as for rpm senscr Connection to control unit plug term 25 positive connection term 26 negative connection 2 Start engine A singl e sine wave should become visible on the screen...

Страница 121: ...rk plug connectors and leads for damage and burned spots Shielding resistance 1 Kohm 3 Check distributor cap and rotor for damage burnt spots and dirt Shielded resistance 1 Kohm 4 Check ignition coil...

Страница 122: ...a voltmeter to terminals 9 and 5 ground on the reverse of the control unit with suitable measuring tips Control value 5 0 5 V 4 Dismount air filter and connect voltmeter with terminals 7 and 5 grounc...

Страница 123: ...m pressure tester P 378 or VW 1318 3 Remove DME relay from central electric system and bridge terminals 30 and 87 b w ith auxiliary cable Fuel pump should now operate 28 24 Test Point 7 Fuel Pressure...

Страница 124: ...air circulation bol t After a short deviation the idl e speed should re adjust itself to approx 840 rpm 4 In order to check the activation of the idle actuator by the control unit connect a new or cor...

Страница 125: ...r with terminals 1 and 2 on plug and switch on ignition Indication approx 5 V 28 26 Test Point 9 Throttle Switch 944 turbo 2 2 Switch off ignit ion and pull plug connector on K CP control uni t Connec...

Страница 126: ...ve 2 injection valve plugs 4 1 Connect terminals Band Con testing socket with voltmeter Indication approx 5 V 4 2 Open throttle valve fully for a short period do not overrev engine Indication voltage...

Страница 127: ...5 30 C 59 86 F 40 C 104 F 80 C 176 F 100 C 212 F 4 4 6 8 1 4 3 6 1 1 3 250 390 160 210 Kohm Kohm Kohm ohm ohm If the control values are not reached carry out measurement directly on temperature sensor...

Страница 128: ...jectors are intact engine speed will drop each time 2 If engine cannot be run measure voltage on plug connections of injectors Indication Battery voltage 3 Measure coil resistance on fl at male plugs...

Страница 129: ...l operate on a safety system basic charging pressure up to approx 0 3 bar overpressure and 6 later ignition which means significantly reduced performance No t e A defect stored in memory is erased whe...

Страница 130: ...ntrol unit is defective 1 Check plug connection on knock sensor for correct seating and inspect spring contacts 2 Remove plug connector on K CP control unit Connect ohmmeter to terminals 11 and 13 Con...

Страница 131: ...in open position The exhaust system should be cold for testing the charging pressure control valve 1 Lift vehicle start engine and let idle 2 Check bypass pipe for warming If the bypass pipe heats up...

Страница 132: ...nk code defect indication Testing 1 Pinch off actuating line to charging pressure control valve with hose clamp 2 Test drive vehicle and measure charging pressure with pressure gage P9103 2 If chargin...

Страница 133: ...nect red green lead and ground on volt meter Indication Battery voltage 3 Apply battery voltage and ground to timing valve The valve must audibly switch Timing valve inner resistance 18 45 ohms 28 34...

Страница 134: ...Printed in Germany Ignition System Exhaust system obstructed catalyti c converter models 28 1 Connect pressure gage P9103 2 at exhaust collection pipe in engine compartment 2 Test drive vehicle Test v...

Страница 135: ...ir valve and apply approx 0 5 bar negative pressure with vacuum hand pump The bypass air valve should open with the applied negative pressure remaining present 2 Install bypass air valve start engine...

Страница 136: ...o charging pressure control valve for flow through and damage Testing Charging pressure control valve sticks in closed position or the membrane leaks The exhaust system should be cold during testing o...

Страница 137: ...closed 3 Apply approx 0 6 bar pressure max 1 0 bar to charging pressure control valve w ith the hand pump The bypass pipe shoul d then likewise heat up charging pressure control valve open When the ap...

Страница 138: ...Actuation line to timing valve is broken or throttle at connection C of timing valve is blocked 1 Remove timing valve and check throttle at connection C R w 2 Check l ead from pressure pipe to timing...

Страница 139: ...CP control unit defective N o t e Replace control unit Flashing code 3 3 may be caused by a detective throttle valve potentiometer Therefore first check the throttle valve potentiometer in accordance...

Страница 140: ...low 1000 m 3300 ft above sea level The altitude correction box is located above the K CP control unit 1 Let engine idle Remove oxygen sensor plug connector and measure CO before catalytic converter 2...

Страница 141: ...sible on the screen 1 1 If no signal is present replace DME control unit 944 turbo No t e The engine can be operated without the K CP control unit in an emergency or for troubleshooting purposes In or...

Страница 142: ...on on oxygen sensor The CO value should set itself to the control value of 0 6 0 2 If there is no change in the CO level there is a defect in the oxygen sensor or in the DME control unit DME C o n t r...

Страница 143: ...s apply as for the oxygen sensor function test 2 Disconnect oxygen sensor plug connector 3 Connect voltmeter at terminal 1 plug half to sensor The voltage should be in the area of 0 1 V to 1 0 V Senso...

Страница 144: ...944 turbo with oil cooler 44 turbo and lim slip differential without oil cooler 944 turbo without oil cooler 944 turbo but with lim slip differential standard option 30 793 Model year until mod 86 as...

Страница 145: ...iff As regards design and repair work there are onlj a small number of differences between the 083 0 transmission and the 016 R turbo transmission The most important differences are no transmission oi...

Страница 146: ...r as from mod 88 mod 89 90 91 Apart from a few deviations transmission 016 R code AOR is identical to the turbo transmission 016 R code SR with regard to construction and repair The most significant d...

Страница 147: ...5 944 turbo S 9 35 i 3 889 944 S Front mounted engine and rear mounted transmission bolted together via a torque tube to form a rigid drive unit Front mounted engine clutch torsionally elastic shaft 2...

Страница 148: ...haft Cover to end plate Pan head bolt 5th gear to drive Hex bolt pinion Shift lock to end Threaded plate and trans sleeve mission housing Shift travel stop Stop screw to end plate Operating lever Phi...

Страница 149: ...sing Cooling coil to Pan head cover and oil hex bolt pump Oil pump cover Hex bolt to side trans mission cover Cooling coil Locknut bracket to transmi ssion housing Cooling coil Pan head shackle to bol...

Страница 150: ...ress ion springs 0 2nd step Four heavy sets of springs E Printed in Germany 111 1988 Clutch Single plate dry clutch with diaphragm springs cold version located on engine end hydraulic operation GMFZ 2...

Страница 151: ...5 housing 6 5 Protective panel Hex bolt M10 8 8 42 to clutch housing 4 2 Release lever shaft Hex bolt M6x35 8 8 9 5 with clutch housing 0 95 Hex nut M6 8 7 5 0 75 Reference mark Pan head I M8 20 rpm a...

Страница 152: ...sion bearings to trans ission mount Bracket to trans ission and trans ission bearings SHIFT Hex bolt Hex bolt Hex bolt Joint rod to trans Ball end ission housing bolt Joint rod to Hex nut intermediate...

Страница 153: ...red to operate the pedal there is a spring which reduces pedal force This spring has to be pre tensioned to the correct level for this purpose Distance A is measured in engaged state clutch pedal at f...

Страница 154: ...Wear 1imit 18 mm 34 mm 944 turbo Clutch drive plate removed C h e c k Measure the distance between the surface of the lining and the head of the rivet with a depth gauge or slide caliper dimension X N...

Страница 155: ...k must also be carried out on earlier cars with single part exhaust cross pipe l Remove and install intake air manifold 2 Remove and instal l guard for brake master cylinder 3 Remove and install singl...

Страница 156: ...ent point 4 starter cable is best once the central tube has been discon nected from clutch housing See item 15 5 Remove engine ground 30 4 6 Detach both shields from starter and clutch housing and wit...

Страница 157: ...ube 16 Separate central tube and clutch housing pushing sel ector rod to rear at the same time 17 Turn central t ube clockwise through 90 and pull to rear Note pos i ti on of catch hooks N ote Do not...

Страница 158: ...ch plate Tighten bolts uniformly in diagonally opposite sequence Tightening torque 25 Nm 18 ftlb Counter by holding hex bolt of front pulley 30 6 Removing and Installing Clutch 944 turbo Note Replace...

Страница 159: ...etween turbo charger and exhaust system first 3 Align bypass valve between clutch housing and body 4 Tighten the M6 bolts connecting bypass line exhaust cross pipe uniformly to the specified torque 10...

Страница 160: ...n plug 2 Filler plug 2 With car parked on level surface and trans mission at operating temperature drain oil from transmission 3 Clean filler and drain plugs and install Tight ening torque 24 Nm 18 ft...

Страница 161: ...944 turbo Manual Transmission I Operating Housing REMOVING AND INSTALLING COOLING COIL 1 2 17 14 Printed in Germany 4 3 5 15 11 12 11 16 13 9 Removing and Installing Cooling Coil Type 016 R 34 34 3...

Страница 162: ...er 1 Pan head 1 bolt Sleeve 1 Pan head 2 bolt Shackle 1 Bracket 1 Cooling coil 1 Hose section 1 Hose section 2 0 ring 1 0 ring 1 Clip 2 Removing and Installing Cooling Coil Type 016 R 944 turbo Instal...

Страница 163: ...iption 1 Assembly stand 2 Assembly sleeve 3 Puller hook 4 Shift grip Printed in Germany Manual Transmission I Operation Housing Special Tool Remarks vw 540 9178 vw 681 9155 Removing and Installing Gea...

Страница 164: ...ssion 1 Operation Housing REMOVING AND INSTALLING GEARBOX 34 6 16 17 13 6 7 3 2 4 I 1 l I 1 15 14 13 Removing and Installing Gearbox Type 016 R 20 5 I 944 turbo 21 12 11 10 9 1 8 II 18 r 19 18 17 16 P...

Страница 165: ...ng 34 Qty 1 1 1 1 1 1 1 3 3 1 1 1 2 12 Note When Removing Installing Remove with vw 681 Install only after installing gear set Oil sealing lip Drive 1 5 mm into housing with Special Tool 9178 and suit...

Страница 166: ...case housing is to be replaced and deviation 11 r11 is not on ring gear check location of drive pinion before removing gearbox actual distance Removing and Installing Gearbox Type 016 R 944 turbo Inst...

Страница 167: ...ssion in assembly stand with Special Tool VW 540 and drain oil 2 Remove cooling coil 3 Remove threaded sleeve and lock ing parts for reverse gear lock 4 Take out selector shaft hex bolts and remove co...

Страница 168: ...unting bolts to a torque of 24 Nm 17 7 ftlb 3 Drive input shaft seal 1 5 mm into housing with Special Tool 9178 and suitable pipe section 4 Run a check by shifting throgh all gears with Special Tool 9...

Страница 169: ...ansmission 1 Operation Housing DISASSEMBLING AND ASSEMBLING GEARBOX 1 2 3 6 l l Printed in Germany 9 10 11 13 15 1216 17 37 30 31 l f tll v 32 33 35 34 26 27 2928 Disassembling and Assembling Gearbox...

Страница 170: ...ng 1 Pull off with Inner race two arm puller 10 Clutch body 1 for 5th gear 11 Synchromesh 1 l ring 12 Adapter 1 sleeve 13 Circlip 1 14 5th gear wheel 1 with sliding sleeve and synchronizer 34 12 Disas...

Страница 171: ...r rod for 5th gear 1 Install with gear 1ube 1 1 Tightening torque 30 Nm 22 ftl b Do not confuse with bolt position 20 1 0 2 mm thick replace do not confuse with seal ring position 21 1 Tightening torq...

Страница 172: ...rod 1 with selector fork for 1st and 2nd gear 35 Drive pinion 1 36 Dowel sleeve 2 37 End plate 1 34 14 Disassembling and Assembling Gearbox Type 016 R Installing Insert in selector rod with a little...

Страница 173: ...with a large screwdriver and prying off cover 2 Clamp input shaft in a vice and unscrew input shaft bolt Fit vice with soft jaws 3 Clamp gearbox in vice on end plate and unscrew cover fastening bolts...

Страница 174: ...synchromesh ring 7 Knock out 5th gear selector for dowel sleeve Counterhold with hammer so that selector rod bore in end plate is not widened 8 Remove circl ip for synchronizer 9 Remove 5th gear wheel...

Страница 175: ...ex bolt Make sure vice is fitted with soft jaws 13 Pull off 5th gear wheel w ith thrust piece VW 431 A Two arm puller as commonly used for example Kukko 20 10 if necessary grind down claws slightly or...

Страница 176: ...remains in sl iding sleeve Do not lose small locking piece 19 Unscrew bolt for operati ng lever 20 Pull drive p1n1on and input shaft forward sl ightly Remove input shaft together with 3rd and 4th gea...

Страница 177: ...ver see Page 34 32 5 Engage reverse gear and dis connect spring clamp on one side and then swing in drive pinion 6 Insert 1st and 2nd gear selector fork and selector rod and push drive pinion in fully...

Страница 178: ...th small lock piece insert with grease 12 Lock 3rd and 4th gear selector fork on selector rod with a pin counter holding with a hammer 13 Lock dog for 1st and 2nd gear selector rod onto rod with a pin...

Страница 179: ...ion If necessary drive on against stop with a suitable mandrel 18 Tighten hex bolt for drive pinion to a torque of 70 Nm 51 ftlb 19 Clamp input shaft in a vice so that shafts are vertical 20 Lightly g...

Страница 180: ...F and mount if necessary driving on until reaching the stop with a suitable pipe section 27 Heat second ball bearing inner ring to about 120 C 248 F and install 28 Install dowel sleeves position gaske...

Страница 181: ...944 turbo Manual Transmission I Operation Housing DISASSEMBLING AND ASSEMBLING REAR HOUSING COVER 6 Printed in Germany 7 3 5 Disassembling and Assembling Rear Housing Cover Type 016 R 2 4 34 1 34 23...

Страница 182: ...1 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 0 i s a s s e m b 1 y 1 Knock out pressure plate with suitable mandrel and remove circlip 2 Press out ball bearing inserting inner race of ball bearing for this...

Страница 183: ...mb 1 y 1 Heat cover to approx 120 C 248 F insert bearing and press in with VW 30 205 2 Insert circlip into groove Press in pressure plate and caulk three points to lock Printed in Germany Disassembli...

Страница 184: ...o Description 1 Pressing tool 2 Pin 3 Pressing tool Printed in Germany Manual Transmission I Operation Housing 1 3 2 Special Tool Remarks vw 472 p 254 p 254 b Disassembling and Assembling End Plate Ty...

Страница 185: ...mission I Operation Housing 944 turbo DISASSEMBLING AND ASSEMBLING END PLATE 2 3 29 4 5 6 11 12 6 7 8 9 10 17 28 27 16 34 28 Disassembling and Assembling End Pl ate Type 016 R 23 1 26 22 21 19 20 Prin...

Страница 186: ...sing 34 Qty 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Note When Removing Installing Available only as complete spare part Tightening torque 30 Nrn 22 ftlb Replace Tightening torque 30 Nm 2 ftlb Do not confu...

Страница 187: ...24 Synchromesh 1 Check for wear ring 25 Reverse gear 1 26 Cylinder 1 Press out Press into correct roller bearing with P 254 position with P 254 outer race and P 254 b and P 254 b 27 Tapered roller 1 P...

Страница 188: ...P 254 and P 254 b 2 Press out tapered roller bearing outer race with suitable mandrel crosswise A s s e m b 1 y 1 Press in cylindrical roller bearing outer race to correct position with P 254 and P 25...

Страница 189: ...ar along with synchronizer The flattened side of the synchromesh ring must point to gear set 5 Lightly grease locking piece and insert in correct position 6 Adjust operating lever Insert reverse gear...

Страница 190: ...threaded sleeve loosen at least l 4th turn Screw in bolt and tighter to torque of 35 Nm 25 ftlb Install 5th gear arrest Engage reverse gear several times and check reversing mechanism for ease of mov...

Страница 191: ...nd plate housing depth a 119 35 mm Difference 0 25 mm If new end plate is deeper install thicker shim S4 If old end bracket is deeper install thinner shim S4 Example Old shim Difference New shim S4 Re...

Страница 192: ...ternal puller 46 56 mm 12 Internal puller 30 37 0101 13 Counter support Printed in Germany Manual Transmission I Operation Housing 34 ill 12 Special Tool Remarks vw 771 vw 681 vw 295 p 254 30 505 9247...

Страница 193: ...tion Housing DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING 6 4 5 3 20 19 21 22 11 12 8 7 9 10 28 34 36 18 14 29 Disassembling and Assembling Transmission Housing Type 016 R 944 turbo 16 27 23 15 1...

Страница 194: ...ation Housing 34 Note When Qty Removing Installing 1 Tightening torque 24 Nm 17 7 ftlb 1 Tightening torque 24 Nm 17 7 ftlb 1 When replacing adjust gear ring 1 1 Clean 1 Drive in to stop with vw 2062 P...

Страница 195: ...reinstall ation Pull out with i nterna1 puller 34 38 Di sassembling and A ssembling Transmi ssion H ousing Type 016 R 944 turbo Installing Engage retainer in vent pipe Replace packing space between se...

Страница 196: ...puller Tool 9247 1 and P 254 and VW 771 1 Pull out with Drive in with Special i nterna1 puller Tool 9247 2 and P 254 and V 771 1 When replacing Heat housing and measure installed press in with Special...

Страница 197: ...71 15 A Internal puller 3 Remove rear needle bearing for input shaft with an internal claw puller for example Kukko 21 5 slide hammer VW 771 and threaded sleeve VW 771 15 4 Knock out tapered ro1ler be...

Страница 198: ...nce the tapered roller bearing outer race for the drive pinion bearing must be installed with a very tight press fit it is essential to carefully heat the transmission housing before installation In o...

Страница 199: ...Use Special Tool 9247 3 and pin P 254 Hold preloading under the press for about 2 more minutes unti l heat transfer has taken place 2 Knock in rear needle bearing for input shaft using Special Tool 9...

Страница 200: ...is recommended Use thrust pad VW 30 205 and mandrel 30 505 6 Dri ve in seal ring for flange shaft up to stop with mandrel vw 2062 N o t e It is recommended to install the seals for the flange shafts...

Страница 201: ...Prior to assembly give guide pin a good coat of transmission oil 1 Speedometer socket 2 Speedometer pinion A Prior to assembly lubricate this area well with trans mission oil 34 44 Disassembling and A...

Страница 202: ...urbo Manual Transmission I Operation Housi ng 34 DISASSEMBLING AND ASSEMBLINGOIL PUMP 18 3 6 13 4 5 17 1 2 15 7 8 14 19 16 11 10 Pri nted in Germany Disassembling and Assembl ing Oil Pump 34 45 Type 0...

Страница 203: ...Pull out with suitable internal puller 17 Bushing 1 Pull out with suitable internal puller 18 0 ring 1 19 Side trans 1 mission cover 34 46 Disassembling and Assembling Oil Pump Type 016 R Installing...

Страница 204: ...Assembly 1 Drive bushing into side trans mission cover in correct position until stop with suit able mandrel see sketch NG300 2 Set end play of pump to 0 05 0 1 mm with suitable paper gasket Gaskets...

Страница 205: ...gage 3 Pressing plate 4 Pipe section 5 Separator Printed in Germany Manual Transmission I Gears and Shafts 35 4 1 Special Tool Remarks VW 161 a As commonly used vw 401 vw 519 For example Kukko 15 17...

Страница 206: ...on I Gears and Shafts DISASSEMBLING AND ASSEMBLING INPUT SHAFT 35 2 l i 12 11 11 ___10 0 I I 3 o 4 5 6 7 I a 9 L _ ____j Disassembling and Assembling Input Shaft Type 016 R 944 turbo ___ c if d b a C...

Страница 207: ...Transmission I Gears and Shafts 35 Note When Qty Removing Installing 1 1 End play 0 1 to 0 4 nm 1 Oil with transmission oil 1 Check for wear 1 Re determine thick ness 1 Press off Position correctly w...

Страница 208: ...r wheel A s s e mb 1 y 1 Assemble sliding sleeve and synchronizer for 3rd and 4th gears It is not necessary to pair in a certain position However the wide collar of the hub must face the 4th gear whee...

Страница 209: ...lar of hub must face 4th gear wheel 4 Measure end play of synchro nizer with a feeler gage blade and adjust by selecting the correct circlip End play should be between 0 and 0 05 mm The lower value is...

Страница 210: ...0 44 mm If this tolerance can not be reached recheck adjustment of synchronizer C h e c k i n g S y n c h r o m e s h R i n g s 1 Clean synchromesh rings and gears 2 Press dry synchromesh rings on ta...

Страница 211: ...g plate 4 Feeler blade gage 5 Separator 6 Pressing tool Printed in Germany Manual Transmission 1 Gears and Shafts 35 6 Special Tool Remarks vw 457 vw 519 vw 401 As commonly used For example Kukko 15 1...

Страница 212: ......

Страница 213: ...Manual Transmission I Gears and Shafts 35 Note When Qty Removing Installing 1 Press off with Replace if necessary vw 457 Always replace both bearings at same time 1 Check end play 1 Lubricate with gea...

Страница 214: ...Shafts Type 016 R 944 turbo Installing Check for wear Insta11 warm and press on Large collar faces 2nd gear wheel Adjust end play Thickness always 2 4 nm Re determine thick ness Check for wear Insta11...

Страница 215: ...tion of pinion shaft actual location before removing gear box D i s a s s e m b 1 y 1 Press off inner race of tapered roller bearing with 1st gear Use support rails VW 457 2 Press off sliding sleeve a...

Страница 216: ...ered roller bearing with a separator for example Kukko 15 17 Gr 1 A s s e m b 1 y 1 Heat inner race for tapered roller bearing to approx 120 C 248 F and press it on 2 Heat gear wheel for 4th gear to a...

Страница 217: ...following circlips are avail able Replacement Part No 016 311 363 AA 016 311 363 AB 016 311 363 AC 016 311 363 AD 016 311 363 AE 016 311 363 AF 016 311 363 AG 016 311 363 AH 016 311 363 AJ Thickness m...

Страница 218: ...B Thickness mm 1 65 1 70 1 75 6 Assemble sliding sleeve and synchronizer for 1st and 2nd gears It is not necessary to pair in a certain position Insert lock pieces and install springs with a 120 offs...

Страница 219: ...e following circlips are avail able Replacement Part No 016 311 327 016 311 327 A 016 311 327 B Thickness mm 1 50 1 55 1 60 9 Heat inner race for tapered roller bearing to approx 120 C 248 F and press...

Страница 220: ...nchromesh rings and gears 2 Press dried synchromesh rings onto tapers of gears and measure clearance 11 a11 with a feeler gage blade Clearance nan 1st and 2nd gears 35 16 New Distance Wear Limit 1 0 t...

Страница 221: ...944 turbo Differential I Transaxle System 39 REMOVING AND INSTALLING DIFFERENTIAL 16 17 14 Printed in Germany 1 21 12 11 10 9 1 8 13 19 18 17 16 Removing and Installing Differential Type 016 R 39 1...

Страница 222: ...ector 1 shaft complete Dowe1 sleeve 2 Hex bolt 12 Removing and Installing Differential Type 016 R 944 turbo Installing Install only after installing gear set Oil sealing lip Drive 1 5 mm into housing...

Страница 223: ...htening torque 24 Nm 17 7 ftlb 2 Lubricate shaft 9 Tightening torque 24 Nm 17 7 ftlb 1 Evenly coat sealing surface w ith Loctite 573 or 574 1 Remove gear Light coat of oil for box before tapered rol l...

Страница 224: ...nting bolt for flange shaft and take off flange shaft counterholding with a mandrel 2 Unscrew final drive cover mounting bolts and pry off cover with two tire irons A s s e mb 1 y 1 Tighten mounting b...

Страница 225: ...tem 39 TOOLS 3 No Description Special Tool Remarks 1 Two arm extractor As commonly used Pressing tool i 3 Pipe section Printed in Germany for example Kukko 44 2 vw 40 105 vw 40 21 Disassembling and As...

Страница 226: ...erential I Transaxle System DISASSEMBLING AND ASSEMBLING DIFFERENTIAL 3 4 14 12 6 15 s tl 2 10 9 12 11 39 6 Disassembling and Assembling Differential Type 016 R 944 turbo 13 11 J 13 8 9 10 Printed in...

Страница 227: ...prox 100 C two arm puller and 212 F and press on Special Tool with Special Tool VW vw 40 105 40 21 1 Remove with suitable Heat to approx 100 C two arm puller and 212 F and press on Special Tool g with...

Страница 228: ...I Transaxle System 944 turbo Note When Description Qty Removing Shim 2 Locking pin 1 Housing 1 Disassembling and Assembling Differential Type 016 R Installing Determine new thickness When replacing ad...

Страница 229: ...ifferential in a vice and unscrew ring gear bolts Fit vice with soft jaws 2 Take ring gear off of housi ng 3 Pull off inner races for large and small tapered roller bear ings Use a suitable tw o arm e...

Страница 230: ...h pipe sections VW 40 21 2 Install differential gears Install large differential gears with correct shims Install small differential gears with 180 offset hold thrust washers in place with a small amo...

Страница 231: ...mall differential gears outwards and check play of large differential gears by hand arrows 4 Adjust play to maximum of 0 10 mm by inserting a shim of the correct thickness No t e Adjustment is also co...

Страница 232: ...ing locking ratio 40 Tools No Description Connector 130 I 10 5 t 75 105 Special tool I I Remarks Own construction The knuckle flange connector can be manufactured from 6 x 18 bar steel Llmlted slip di...

Страница 233: ...em 944turbo Limited slip differential dismantling and assembling locking ratio 40 39 12 b 13 4 5 6 I r i 11 12 11 l 8 7 6 5 4 3 2 1 Limited slip differential dismantling and assembling locking ratio 4...

Страница 234: ...ed 8 Thrust ring 2 9 Shaft bevel gear 2 10 Threaded disk 2 Press out of the shaft Press in in the correct bevel gear position 11 Bevel pinion 4 12 Differential shaft 2 13 Differential housing 1 Note T...

Страница 235: ...to move them in the differential housing c Shaft bevel gears The thrust surfaces for the thrust washers must not be worn down and it must be easy to move the inner plates on the teeth of the bevel ge...

Страница 236: ...e housing side These limited slip differentials are identified by a yel low dot on the differential housing A Diaphragm spring B Yellow dot 42 39 Re specifying the thickness of the plate package The t...

Страница 237: ...mple b 73 20 mm 3 Measure dimension e must be 4 2 mm e a b Example a 77 50 mm b 73 30 rnm e 4 20 mm 10923 45 39 e2 e2 e 4 2 mm Note Install thicker or thinner outer plates if dimen sion e is too great...

Страница 238: ...this Mount a second flange with own construction connector and crank the differential with a torque wrench A torque of 10 35 Nm must be achieved A Connector own construction e5 1os Note If it is not p...

Страница 239: ...944 turbo TOOL 14 12 Printed in Germany Differential I Transaxle System 39 1 15 9 8 11 Adj usting Drive Pinion and Ring Gear 39 13 Type 016 R...

Страница 240: ...521 8 8 Dial gage extension vw 385 15 9 3 mm 9 Gage plunger vw 385 14 10 Dial gage _ 11 Adju stabl e lever gage vw 388 12 Dial gage extension 13 14 15 39 14 Dial gage Adjusting device vw 521 4 Torque...

Страница 241: ...in both directions of rotation The position of quietest running is determined by moving the drive pinion in an axial direction while keeping the ring gear far enough out of the play free gearing to k...

Страница 242: ...esting machine Ro 59 65 mm type 016 RIS and 083 F transmission Ro 58 15 mm type 083 D transmission ___Po Sets supplied with vehicles Note rm 1 2 3 In series production the location of the drive pinion...

Страница 243: ...al shim thickness Stot in S3 and S4 in such a way that the distance from the center of the ring gear to the pinion face corresponds to the installed distance E de termined during production S3 Shim fo...

Страница 244: ...nt of the final drive Refer to the following table to avoid unnecessary adjustment work Ring Gear Pinion 51 S2 Deviation 11r11 Transmission X housi ng End plate Differential X housing Tapered roller b...

Страница 245: ...position This would include both tapered roller bearings for drive pinion and transmission housing Removing Differential Complete universal gage as shown in tool list insert in transmission housing a...

Страница 246: ...pered roller bearing outer race without shims into transmission housing or end plate 2 Install completely assembled drive pinion Mount end plate and tighten bolts to a torque of 24 Nm 17 7 ftlb 3 Turn...

Страница 247: ...f gage VW 385 1 to distance a A approx 50 mm 3 Complete universal gage as shown 4 Use dial gage extension VW 385 15 with length of 9 3 mm 5 Set universal master gage to dimension Ro 59 65 mm type 016...

Страница 248: ...tip runs on gage plate on pinion head and displays maximum deflection point of reversal The measured value is dimension e For example 0 46 mm D e t e r m i n i n g T h i c k n e s s o f S h i m S3 IS3...

Страница 249: ...shims it is possible to measure any thickness for S3 Measure shim thickness at many different points with a micrometer In addition check shims for burrs and damage Install only shims in perfect condit...

Страница 250: ...be preloaded by the rotation and can settle 2 Apply universal gage and check distance 3 If shims have been selected correctly the dial gage read counterclockwise should display the value of deviation...

Страница 251: ...ffer ential 1 Remove drive pinion 2 Remove seals for shaft flanges 3 Remove outer rings of tapered roller bearings for differential Remove shims 4 Drive in tapered roller bearing outer races without s...

Страница 252: ...ickness 11 Stot determined Cin this example 1 92 mm behind tapered roller bearing outer race end cover S2 side Lubricate both tapered roller bearings with hypoid oil 12 Remount cover 13 Guide adjustin...

Страница 253: ...axis and the lever a approx 79 mm 3 Carefully turn differential counterclockwi se with adjusting device VW 521 4 until ring gear rests on drive pinion 4 At this point set dial gage to 0 with 2 mm pre...

Страница 254: ...ance Sl S2 Lift 0 15 mm constant value Example Stot 1 92 1 001 Lift 0 15 mm t ean backlash 0 84 mm S2 1 23 mm The following shims are available Replacement Part No 113 517 201 A 113 517 202 A 113 517...

Страница 255: ...the differing tolerances Measure thickness of shims at several different points with a micrometer In addition check shims for burrs and damage Install only shims in perfect condition Install shims S1...

Страница 256: ...twin tube gas shock type Manufacturer identification standard optional Fichtel und Sachs Koni black yellow and or yellow height adjustable for sports type running gear M030 of Koni yellow height adjus...

Страница 257: ...aster eccentric I I Contra1 arm to Self M10 12 I 50 l steering knuckle locking 37 I Hex nut Cross member to H ex bolt M12 8 8 85 body 62 Guard plate for H ex bolt 1 6 8 8 10 hydr mounting 7 to cross m...

Страница 258: ...eering knuckle 7 Fixed caliper to Hex bolt M12x1 5 8 8 85 steering knuckle Pan head 62 Spring strut to Self locking M12x1 5 10 100 steering knuckle hex nut 73 7 Spring strut to Hex nut M8 8 25 body 18...

Страница 259: ...Front wheel suspension 944 turbo The front axle modifications for 944 turbo special model s M 758 40 04 1 7 The front axle modifications for 944 turbo special model 5 M 758 Printed in Germany Ill 198...

Страница 260: ...Page 40 6 I 40 7 4 Adjustable spring seats Vehicle height ad See repair group justable thus enabling 44 for height ad compensation for differ justment ences in wheel load left to right 5 Steering knuc...

Страница 261: ...mping nut Tighten clamping nut slightly turning hub at same time 3 Unscrew clamping nut until pressure plate can barely be moved by finger pressure applied to a screwdriver Do not support screwdriver...

Страница 262: ...aps and joints for function and leakage We recommend that a visual check for leakage be carried out on joint caps every time work is performed on the front axle C h e c k n g C a p s o n C o n t r o l...

Страница 263: ...ust be possible to move the shock absorber across its entire stroke without jerking The stages of pull and push absorption must be clearly felt up to the stop Because of the gas pressure it becomes mo...

Страница 264: ...h Optimoly TA 87 992 1 Mount the larger spring diameter to the upper spring seat 2 If parts are replaced which influence the height adjustment coil spring threaded ring lower spring seat adjust the sp...

Страница 265: ...ure that the difference in wheel load between right and left does not assume unacceptable proportions The exception being a combination of springs one in use for a long time and one new one lf wheel l...

Страница 266: ...tively tolerance of spring rate A 944 Turbo with standard and with sport type shocks up to end of MY 88 B 944 Turbo with sport type running gear M 030 as of MY 87 and standard for MY 89 944 Turbo with...

Страница 267: ...standard for MY 89 Group Length removed Spring force F at Color dot Order Index Length L1 220 mm 1 approx 329 mm 3050 3150 N 1white 1 yellow 101 approx 329 mm 3150 3250 N 2 white 1 yellow 102 Coli spr...

Страница 268: ...gas shock absorber painted yellow Setting Basic setting adjusted approx 1 2 turn Application installation 944 turbo up to end of MY 88 Spare parts refer to the spare parts catalog for the appropriate...

Страница 269: ...ted yellow Adjustable height SP No embossed above the height adjustment thread on the shock absorber tube Adjusting rebound travel Settings Adjusted approx 3 4 turn from the basic setting right hand s...

Страница 270: ...absorbers axle by axle with the same number of turns Harderrebound Turn to the left counter clockwise Softerrebound Turn to the right clockwise Note When setting always use the original adjust ing whe...

Страница 271: ...nal up to end of MY 88 Flchtel und Sachs Konl grey green dot yellow or or stripe on yellow with 2 white lower mounting eye color dots offset by 180 for sports type running gear M 030 of MY 87 88 MY 89...

Страница 272: ...8 46 to body 34 Mount to body Hex bolt M10 8 8 46 34 Mount to strut Locknut M8 8 23 17 Trailing arm to Locknut Ml2xl 5 10 90 rear axle strut camber 66 eccentric Trailing arm to Locknut Ml2xl 5 10 103...

Страница 273: ...e tube with the piston rod right down to the bottom Turn the protec tive tube without using force until the ad justment device latches in Mark the latching position on the protective and shock absor b...

Страница 274: ...ft 3 After adjusting pull the protective tube pis ton rod upwards again to disengage the ad justment device Replace additional rubber spring Koni vibration shock absorbers I adjusting Koni shock absor...

Страница 275: ...ust and dirt and therefore help prevent leaks Always screw on caps tightly and replace missing caps For safety reasons do not limit tire checks to checking the tire pressure but also check for suffici...

Страница 276: ...me tire size The tires approved by Porsche are also Iden tified In the corresponding Tl Important note From MY 87 the rim offset of the wheels has been changed Wheels designated for cars as of MY 87 m...

Страница 277: ...l nTrrl JI I IL I I u l l l toe In l l j l l l l fl Tl l l toe out 0 20 right tum in measured lett II Q 2 u c 3 G u z caster I 2 2 1 0 l u l u l 1 t 1 1 fl i j l l j l l l o 2 toe in not pressedl 0 I...

Страница 278: ...e In 1 1 1 1 1 j l ll l l j 11 Litl l d uJ u t o l n 1 1 1i j l l fl 1 1 1 1 lo out 20 right tum ln measured left 3 l cuter 0 2 2 1 0 l u JJJut 1TI I rf ri lil 0 1 7 toe in not pressed 0 7 20 left tur...

Страница 279: ...values Front axle Toe unpressed Toe difference angle at 20 steering lock Camber Caster Rear axle Toe each wheel Camber 44 2 Adjustment value and tolerance max difference up to end of MY 89 10 5 40 to...

Страница 280: ...Height adjustment Bolt bottom edge measured from rear steering arm under wheel center p 44 7 130 10 mm height adjustment center of brace bearing center of torsion bar below wheel center value 3 5 10...

Страница 281: ...wheel alignment and adjust if necessary Set steering wheel and steering gear to the middle position at toe Before adjusting front and rear wheel alignment it is advisable or necessary to check the hei...

Страница 282: ...ial compression of a spring Is reduced on one side Oowerlng the vehicle this reduces the wheel load An alteration In wheel load Is always felt diagonally on the other side of the axle That means If th...

Страница 283: ...and at the middle of the wheel both measured from the wheel contact area Setting Page 44 3 If necessary correct the rear vehicle height by means of eccentric screw B on the two part _ shock absorber u...

Страница 284: ...r axles Height correction To compensate for differences when Install ing only one new spring 2 Height correction or fine adjustment Only If necessary or desirable Measuring point Is the bottom edge of...

Страница 285: ...e camber is adjusted by turning the ec centric screw arrow Remove the brake cool ing air guide for this if necessary Note For the 944 turbo special modei S M 758 avoid damaging the brake line bending...

Страница 286: ...he eccentric use a 19 mm open end wrench In area C or a 32 mm open end wrench In area D Tightening torque for hexagon nuts A 85 Nm Vehicle measurement Printed In Germany Ill 1988 Adjusting the toe Pre...

Страница 287: ...fluenced by replacing the steering arms 44 10 Rear axle Adjusting the camber Loosen stabilizer suspension and the screw connection between shock absorber and con trol arm Adjust to the specified value...

Страница 288: ...tandard specification of some models Brake booster Qlght weight built Boost coefficient Brake master cylinder aluminum design 0inmm Brake power regulator In rear axle circuit switchover pressure reduc...

Страница 289: ...cm2 424 cm2 424 cm2 Brake pad thickness new front 28 mm 32 mm 32mm rear 24mm 24mm Min brake disc thickness after refacing front 26 6 mm 30 6 mm 30 6 mm 26 mm 30 mm 30mm rear 22 6 mm 22 6 mm 22mm 22mm...

Страница 290: ...laced Warning contact replacement is not necessary if brake pads are replaced no later than with a thickness of 2 5 mm Warning contacts whose electric lead core is ground worn must be replaced Replace...

Страница 291: ...round through or down to the bare core The warning contact may be reused If grinding marks are limited to the plastic sec tion of the warning contact 3 Pull out brake pads using a pad removal tool For...

Страница 292: ...prox 10 mm approx 10 mm with brakes bled and engine standing still Parking brake Drum brake with mechanical action on both rear wheels hand brake Parking brake drum dia 180 mm 180mm 181 mm 181 mm Brak...

Страница 293: ...backing AJways replace the vibration dampers that feature a backing coat whenever the brake pads are removed or replaced For fixed calipers with scraper ring piston seals a version without coating is...

Страница 294: ...he brake disc Note In addition the larger pistons of the front calipers of vehicles made up to the end of MY 86 feature a small recess that points towards the entry side of the brake disc towards the...

Страница 295: ...grease A 3 1 Piston 2 Noise suppressor 3 Brake pad Removing and Installing brake pads Printed In Germany N 1991 6 Coat engaging lugs of the expander spring with Optimoly TA or Plastllube If required...

Страница 296: ...rmly to allow the brake pads to settle In the operat Ing position Check brake fluid reservoir level and refill if necessary Running In the brake pads New brake pads require a running In period of appr...

Страница 297: ...ing knuckle 7 Air guide plate Hex bolt M6 10 to spring strut 7 Wheel hub to rear Locknut M22 X 1 5 8 500 wheel shaft 370 Brake line holder Hex screw M6 8 8 10 to trailing arm 7 Cable holder to Hex scr...

Страница 298: ...l Torque in Nm ftlb Parking brake cable Nut M6 8 8 5 to clamping lock 6 3 Brake power assist Hex nut M8 8 21 to connector 15 5 Connector to Hex nut M8 8 21 fi rewa11 15 5 Pivot end on Hex nut M10 8 35...

Страница 299: ...operated manually A d j u s t i n g 1 Adjust length of brake push rod by turning pivet end Length from contact surface of brake power assist on connector mounting piece to the bearing pin center of p...

Страница 300: ...sting nut on clamp far enough so that cable is under no tension 4 Using a screwdriver inserted through the hole in the brake disk turn adjusting device so that the wheel can no longer be turned Now tu...

Страница 301: ...wheel hub with five M8 bolts To remove the brake disc the wheel hub has to be removed 944 944 S 944 turbo as of MY 87 and all 944 S2 models Mounted on wheel hub with two M6 countersunk screws The brak...

Страница 302: ...iper with 85 Nm Parts replacement note For the 944 turbo four brake disc ver sions for the front axle are available up to end of MY 86 II Model Year 87 and 88 I as of MY 87 I modified cup height Ill M...

Страница 303: ...944 repair manual for dismantling and assembly procedures for the rear wheel brakes Differences between the 944 turbo and 944 Four piston fixed caliper with larger brake pads Thicker brake disk with l...

Страница 304: ...Brake hose to Brake hose M10 X 1 14 1 4 fixed caliper 10 Bleeder bolt to Bleeder bolt M10 8 12 0 8 fi xed caliper 1 2 6 8 8 Brake master Hex nut r18 8 21 2 1 cylinder to brake 15 5 power assist Brake...

Страница 305: ...urbocharger coolant pump and run out brake guard plate after loosening fastening bolts If necessary replace guard plate I Fuel collecting pipe II Intake air distributor intake pipe III Bracket for tur...

Страница 306: ...bolt threads lightly with Loctite 270 When assembling the brake pis tons always use Unisilikon TK 44 N 2 brake cylinder paste Unlsilikon paste is available from the spare parts department Part No 000...

Страница 307: ...de and 0 36 40 mm on the other side is not permitted Modification II As of MY 89 and for the 944 turbo special model S M 758 the piston diameter at the front axle was increased to 44 36 mm The modifie...

Страница 308: ...end of MY 88 944 turbo Front axle Jurfd 238 asbestos type Rear axle Jurid 238 asbestos type or Front axle Textar T400 asbestos free Rear axle Textar T400 asbestos free Combination of asbestos free and...

Страница 309: ...ster cylinder On vehicles with ABS the brake power con troller Is screwed Into port h of the hydraulics unit For notes on removing and Installing refer to page 47 02 r Swltchover pressure of the brake...

Страница 310: ...ptional 360 mm 0 4 spoke 360 mm 0 4 spoke with raised hub Steering wheel Left hand steering 18 85 1 ratio in center Right hand steering 18 96 1 Turning circle diameter 10 75m Track circle diameter 10...

Страница 311: ...7 bearing 5 Cover for thrust Hex bolt M6 8 8 7 piece bearing 5 Steering wheel to Hex nut M16x1 5 17 H 2 45 steering column 33 Steering column Hex bolt M5 4 switch to outer 3 tube Outer tube to body He...

Страница 312: ...return Hollow core M12 X 1 5 6 8 20 1i nes on steering bolt 14 gear Feed line on power Hollow core M14 X 1 5 6 8 30 steering pump bolt 22 Ring hose nipple Hollow core M16 X 1 5 6 8 45 for intake hose...

Страница 313: ...asis in various countries In countries that do not operate an exchange part scheme the steering gear as well as the power steering pump may in certain cases be reconditioned by an authorized ZF dealer...

Страница 314: ...ine is started for a short mo ment start the engine again and let it run at idle speed 3 Turn steering wheel rapidly from lock to lock several times to allow air to escape from the cylinders When reac...

Страница 315: ...en a stopped engine and running engine exceeds 10 mm too much air is trapped in the hydraulic fluid 6 After wiping off dipstick screw cap on supply tank and remove again engine must be idling If neces...

Страница 316: ...cable Removal 1 Raise concealed headlights Cover bumpers to avoid damaging the paint finish Remove cover strips 2 Undo fastening nuts and remove bolts Replacing front hood cable Printed In Germany Ill...

Страница 317: ...ith a fine Phil lips screwdriver then remove the cover plate from the vehicle 4 Open the hood lock with a suitable tool and raise the hood 55 2 88158 5 Remove the complete air filter system and undo t...

Страница 318: ...stall the new hood cable in reverse order Replacing front hood cable Printed in Germany Ill 1988 2 Insert the cover plate from the front Start turning the fastening screws Adjust cover plate level wit...

Страница 319: ...lashguard and lower trim panel 2 Remove plugs unscrew nuts and bolts and detach lower trim panel from vehicle Printed in Germany I n s t a 1 1 a t i o n Before installation inspect all fasteners and i...

Страница 320: ...944 turbo Bumpers REMOVING AND INSTALLING SPOILER AND BUMPER Printed in Germany Removing and Installing Spoiler and Bumper 63 63 3...

Страница 321: ...AND INSTALLING SPOILER AND BUMPER 19 17 25 12 43 29 27 28 24 32 33 31 34 44 42 13 41 40 17 8 7 20 48 45 16 63 4 Removing and Installing Spoiler and Bumper 11 1 10 9 T 33 34 5 6 20 1 4 944 turbo 2 23 2...

Страница 322: ...Backing 42 Nut 43 Washer 44 Sheet metal screw 45 Turn signal light 46 Backing 47 Nut 48 Light 49 Backing 50 Nut 51 Towline eye Printed in Germany Qty 2 1 2 2 2 2 2 4 4 2 6 6 1 Bumpers Note When Remov...

Страница 323: ...944 turbo Bumpers REMOVING AND INSTALLING USA SPOILER AND BUMPER Printed in Germany Removing and Installing USA Spoiler and Bumper 63 63 9...

Страница 324: ...NSTALLING USA SPOILER AND BUMPER 29 27 24 18 19 17 12 30 28 32 33 31 35 39 34 43 13 44 42 63 10 r 54 20 40 17 45 Removing and Installing USA Spoiler and Bumper 1 ItT 5 6 20 1 944 turbo 33 34 21 4 23 2...

Страница 325: ...Cutter 10 Spring washer 83 7 11 Sheet meta1 screw 83 9 Y 19 12 Spring 13 Cable clamp 14 Nozzle 15 Washer 16 Nut 17 Hose clamp 18 Hose Printed in Germany Qty 1 2 6 6 2 2 2 2 1 1 1 4 6 2 2 2 4 1 Bumper...

Страница 326: ...ex head sheet 6 metal bolt B2 4 8 X 13 Bumper 1 Cover 1 Impact tube I L Washer 4 Bolt 4 M8 X 25 Washer 8 4 2 Pan head bolt 2 M 8 X 70 Air duct 1 Sheet metal 2 nut 4 8 X 19 Spacer 4 Hex bolt 16 4 Air d...

Страница 327: ...Cover 10 Spring washer 83 7 11 Sheet metal screw 83 9 X 19 12 Spring 13 Cable clamp 14 Nozzle 15 Washer 16 Nut 17 Hose clamp 18 Hose Printed in Germany Qty 1 2 6 6 2 2 2 1 1 1 4 6 2 2 2 4 1 Bumpers No...

Страница 328: ...26 Impact absorber 2 27 Washer 4 28 Bolt M8 x 25 4 29 Washer 8 4 2 30 Pan head bolt 2 M8 X 70 31 Air duct 1 32 Sheet metal 2 nut 4 8 X 19 33 Spacer 4 34 Hex bolt 6 4 35 Air duct 1 36 Sheet metal 2 nu...

Страница 329: ...et metal screw 45 Turn signal light 46 Backing 47 Nut 48 Light 49 Backing 50 Nut 51 Side marker light 52 Mount 53 Knurled nut 54 Sheet metal screw Printed in Germany Qty 2 1 2 4 4 4 2 4 4 2 6 6 2 2 4...

Страница 330: ...remove rocker panel covers from vehicle 2 Unscrew plastic mounting nuts for rear rocker panel covers remove washers and detach rocker panel covers from vehicle I n s t a 1 1 a t i o n Prior to instal...

Страница 331: ...ing and Installing Rear Apron Spoiler 2 Open trunk lid and lift trunk floor cover out of vehicle Unscrew mounting nuts on rear side pieces and remove rear apron spoiler from vehicle I n s t a 1 l a t...

Страница 332: ...allic FINISHES AVAILABLE 87 MODELS ONWARD Standard Black L 041 Alpine white L 90E Lemon yellow L MIA Azurite blue L Y5D Malven red L Y3E lndid red L M3A Printed in Germany 11 1987 Special Zermatt silv...

Страница 333: ...lm and position film parallel with edge of fender 4 Use a plastic spatula or the like to squeeze moisture from beneath the film Work from the middle towards the edges and ensure that no air bubbles ar...

Страница 334: ...2 Insert aiming tool in spray jet With the help of the aiming tool turn spray jet so that the telescopic extension of the tool points to the middle of the lens Wiper and Washer System 92 3 Activate cl...

Страница 335: ...ssure full fuel tank person or a weight of about 70 kg 155 lbs in driver 1 s seat 1 Turn on low beams USA version high beams and clean lens 2 Correct a1m1ng with an optical headlight aimer Rest of Wor...

Страница 336: ...m e n t s Proper tire inflation pressure full fuel tank person or a weight of about 70 kg 155 lbs in driver s seat 1 Unscrew and remove transparent covers 2 Correct aim with an optical headlight aime...

Страница 337: ...GHT LINKAGE Lubricate linkage of concealed headlights with a standard multi purpose grease at each inspection or after every engine cleaning Exterior Lights Lamps Switches Printed in Germany Lubricati...

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