Replacing Latch On Rear Lid Lock Upper Section
If the edge of the plastic latch in lock upper section is worn and this is impairing the lock's function, the latch of an installed lock upper section can be replaced. 2, Remove plastic latch, making sure that the spring behind is not lost. 1. Drive rivet pin out of housing from the riveted side with a 3 to 4 mm dia. punch. Counter-hold the opposite side 3. Install new latch with spring, pushing in the spring with a small screwdriver until the latch bore aligns with the housing. 4. Press in...
Central Electric Power Supply For Lh Fuel Injection And Electronic Ignition
1 Electronic ignition relay VIII power supply for electronic ignition and LH control units power supply for LH control unit and intake air sensor power supply for fuel pump, auxiliary air regulator and fuel injectors power supply for electronic ignition and LH fuel injection
Removing And Installing Outside Mirror
1. Pry off clips on mirror glass with a putty knife on backplate and disconnect contact plugs on glass carefully. 4, Unscrew fillister head screw on mirror base so that mirror can be removed with the liner. 2. Unscrew 3 screws through holes in backplatE, take off foam rubber part and pull off wire plugs. 1. Pry off clips on mirror glass with a putty knife on backplate and disconnect contact plugs on glass carefully. 2. Unscrew 3 screws through holes in backplatE, take off foam rubber part and...
Info Wdg
6. First press side pads up and in, and then pull them out. 7, Press the steel wire from Repair Kit 477 898 Oil through windshield weatherstrip at an Lvpper corner and setiifit it in'Side erf S pecrai' Tool VW 1351 similar to a screwdriver . Now pull the wire toward the inside and hold it on the weatherstrip with the special tool. Use the grip to pull the wire in up to this point. Repeat this procedure around entire windshield. To prevent the weatherstrip from sticking together again, press out...
Removing And Installing Instructions
1. Remove exhaust assembly with heai shields. 3. Remove transmission see page 34 - 3 . 6. Remove ashtray and unscrew guide tube mount from body only for cars manufactured up to August 7,1978 . Let rear axle of cars with a bolted battery console hang down on the trailing links and support same tie up . 1. Remove exhaust assembly with heai shields. 3. Remove transmission see page 34 - 3 . 6. Remove ashtray and unscrew guide tube mount from body only for cars manufactured up to August 7,1978 . Let...
Removing And Installing Sill Covers
3.Remove screw holding cover strip in place. 1.Use a hot-air blower to heat sill cover on door to approx. 70 C, carefully detach with a suitable tool and pull off. 2.Remove sill strip mounting screws from front fender, use a hot-air blower to heat sill strip to approx. 70 C, carefully detach, unclip and remove. 66 - 20 Removing and Installing Sill XIII, 1986 - Printed in Germany Covers 4.Unclip trim strip and remove upper securing screws of sill cover. 5.Remove lower securing screws from sill...
Manual transmission Gears and shafts 1
Disassembling and assembling input shaft 35-1 Disassembling and assembling pinion shaft 35-5 Determining shim thickness Determining shim thickness Measuring Distance Z between input shaft and pinion shaft 35-15 Disassembling and assembling Disassembling and assembling countershaft Hub Gears 35-21 Automatic transmission Controls, Case Removing and installing Removing and installing selector Removing and installing selector lever cover frame 37-1 Oa Adjusting selector Cable and backup light...
D30
2 - Lateral acceleration sensor 3 - Slave cylinder, transverse lock 3a- Pilot pressure valve in lock hydraulics 4 - Pressure pump with pressure warning switch The lock hydraulics No. 4 to No. 7 is located on a joint bracket in the left-hand wheel well. Brake fluid is used as the operating medium. Further information on P. D39-247. The control unit is located in the driver's foot-well - near the A-pillar - above the front cover opening handle.
Installing camshaft seal 87 models onward
1. Place sealing washers lock pins M 28.49 50 as of MY '92 into bearing seats and fit bearing saddle with Loctite 574. Tightening torque 20 Nm 15 ftlb 2. After torquing the bearing bridge, install sealing cover with the aid of Special Tool 9234. If the sealing cover of an engine as of model year 85 32 valve engines leaks with the engine installed, the procedure for installing the cover is as follwos 1. Place camshafts and sealing washers in bearing. 2. Apply Loctite 574 to bearing bridge and...
Additional electrical equipment
Repairing wiring harness no. 121 Note As of Model Year '93, the combination wirings for ABS, BVA brake pad wear indicator and RDK tire pressure monitoring system are incorporated into the wiring harness. If the wiring is damaged, the integral wirings can be cut off and may be replaced by repair wires. Carry out the following functional check after the repair - BVA The warning lamp must go off when the engine is running and if the pads are o.k. - RDK The warning lamp must go off within the...
Checking the ignition circuit monitoring relay
Note 6. The resistance between E1 and E2 is The ignition circuit monitoring relay is fitted to approx. 5-10 ft measured at the disconnec- the mounting plate for the LH and EZK control ted reiay socket - Signals at the ignition circuit monitoring 2. Ground must be present at terminal AL when the ignition is switched off. 3. Battery voltage must be present at terminals 87, 15, A1 and A2 when the ignition is switched on. 4. Battery voltage must be present at terminals 61 and AL when the engine is...
Info Lus
Front converter housing Torque converter Remove upward carefully with Special Tool 9301 Replace when wear is excessive or ATF has metal particles. Lubricate input flange and shaft bearing journals with a multipurpose grease containing MoS . Place transmission upright and run in carefully with Special Tool 9301.
Method Of Operation
The manual adjustment facility has been retained. This function always takes priority over automatic adjustment and is always possible regardless of vehicle status. To store a position in the memory, press the memory key and the key for the desired position. The memory key must be pressed before the position key. Both keys must be held down simultaneously for at least 0.2 seconds. Positions can be stored in the memory regardless of vehicle status. To assume a stored position automatically, hold...
Info Nca
TECHNICAL DATA - 928 S - '87 88 models Adjustment specifications and wear limits are listed in the individual repair groups . Note USA values are stated in parentheses Displacement rounded down cc Compression ratio Net torque, SAE J 1349 Nm lbft Max. specific power, DIN 70020 kW L HP L Manual transmission M 28 41 Automatic transmission M 28 42 Worldwide
Info Igc
The high-tension power supply for ignition circuit I comes from the coil installed at the front right, the high-tension power supply for ignition circuit II comes from the coil installed at the front left. Connect and adjust the engine tester in accordance with the manufacturer's instructions note that the 4-cylinder measuring range must be selected . To display the ignition pattern for ignition circuit I right side , connect the tester to the ignition lead for cylinder 1 and the front right...
Error codeError path
2121 Load signal from the LH control unit 2126 Transmission safeguard switch 2133 Knock control in the control unit 2134 Hall generator signal 2141 EZK control unit The digit 2 may also appear in the second error code digit position e.g. 2212 , indicating sporadic error, i.e. an occasionally occurring fault. This does not apply to error code 1000 and 1500. The error memories of the LH control unit and the EZK control unit must each be reset individually. Once error diagnosis has been terminated...
Porsche 928 Felt Guides
Set of stone holders for felt inlays Set of stone holders for grindstones Set of felt holders instead of guide shoe CK - 3000 or CK - 2600 MB - 30 or MAN - 845 C30 - F 85 1 Set AN - 30 CK - 3130 A 1 Set C30 - J55 shorten to 70 mm long C30 - J84 shorten to 70 mm long C30 - C03 - 81 Remove the upper guide shoe for all honing and lapping processes. The excess must be removed from the bronze strip of main guide shoe No. 3 until the strip is flush with the guide shoe - base. Rough milling - see...
Removing And Installing Power Steering Pump
1. Detach intake hose to air cleaner on left side. Draw hydraulic fluid out of reservoir. 4. Remove rear bolt from power steering pump. 1. Detach intake hose to air cleaner on left side. Draw hydraulic fluid out of reservoir. 3. Loosen front bolts on power steering pump a little. 4. Remove rear bolt from power steering pump. 6. Take off left upper section of drive belt cover to facilitate procedures. If hose is routed too close to exhaust manifold, the hose could come loose from its holder and...
Wiring Diagram Type 928 S Model 86 page 4
VENTILATION, HEATING, AIR CONDITIONING ELECTRICALLY OPERATED SEATS Printed in Germany-XI, 1985 sw-black ws-white rt-red gn green ge yellow gr-grey br brown bl blue li violet mp ground Termin__als Current Row Diagram 97-243 Printed in Germany-XI, 1985 sw-black ws-white rt-red gn green ge yellow gr-grey br brown bl blue li violet mp ground Termin__als Current Row Diagram 97-243 Wiring Diagram Type 928 S Model 86 page 5
Info Rov
Springs with approx. 200 N more force at a standard test length e.g. tolerance group II springs as opposed to group I increase the height of the front axle by approx. 5-15 mm. Placing a spacer beneath the lower spring plate increases the height of the front axle by approx. 10 mm. A maximum of 2 spacers per spring strut is permissible. If Boge dampers are replaced by Bilstein dampers and no further changes implemented, i.e. the same coil springs are reused, the front axle is raised by approx. 10...
Fitting the 17 Inch Wheels Cup Design to the Vehicle
On the 17 Cup Design wheels, the valve No. 1 and the locking wheel nut cannot be arranged on the same side as on previous models . For correct installation, the valve No. 1 must face the color-coded stud No. 2 . Be sure to fit the locking wheel nut to the color-coded stud Nr. 2 . Fitting and tightening procedures of all other wheel types 16-inch Design 90 etc. for stationary balancing remain unchanged. This means Coded stud, valve and locking wheel nut are located on the same side. When...
Replacing Upper Control Arm Mount
Press out mount with Special Tool VW 408 a, using Special Tool VW 415 a as a base. Press in mount, using waxfree Capelia Oil 8 Texaco and Special Tools VW 415 a and 408 a. Position correctly. Apply pressure pad to conical end of metal bushing to prevent any change in position between the metal bushing and rubber mount.
Notes 1
The RDK control unit is in the footwell on the driver's side, above the base of the storage compartment. On right-hand drive cars, the RDK control unit Is attached to the right side panel in the driver's footwell. When the RDK control unit is removed or installed, the ignition must be switched off. Remove the storage compartment 4 retaining nuts . From software status R 02 on, the RDK control unit has an event memory for tire pressure losses. This was introduced during the 1991 model year...
Info Ahb
Adjusting mechanism of steering wheel height adjuster open. 1. Remove knee protector strip. The fastening screws and nuts arrows are accessible after removal of the center console cover and of the air outlet nozzle. If the steering wheel height adjuster is modified to the new version, assembly may be started from item 2 immediately after removal of the knee protector strip e.g. if the adjuster lever through bolt union is disconnected . This means that adjuster mechanism items No. 10 to 18 page...
Auxiliary Air Conditioner
An auxiliary evaporator for increased refrigeration output is available as an option M 570 . The auxiliary evaporator with 3-stage blower is installed instead of the rear parcel shelf. 7.Remove mounting screws 6 screws . The tightening torque for the M 6 Allen-head bolt is 9 Nm 7ftlb . Renew 0-rings in the connections in the lines to the expansion valve. Removing and Installing Expansion Valve M 5 bolt 6 Nm 4 ftlb M 6 bolt 9 Nm 7 ftlb 1.Remove evaporator see page 87 -120 . 3.Disconnect plug-in...
Technical data of air conditioning system As of MY 93
Refrigerant charge Refrigerant R 134 a 860 g with auxiliary air conditioning 1050 g Refrigerant oil in compressor 160 20 c.c. ND 8 Safety valve The valve opens at a positive pressure of 41 to 43 bar and on fluid tank closes again as soon as the pressure drops below this value. When fitting the refrigerant lines, coat the fittings and O-rings with refrigerant oil. Dispose of the refrigerant oil as hazardous waste. Technical data of air conditioning system Pressure and temperature specifications...
Test Point 3 Ozu
Voltage failure - Refer to Test Point 2. Position of the drives This fault is also stored if, for example, the driver's door is open unplausible when the key is used to actuate the central locking system from the - Disconnect plug II from control unit. Attach Special Tool 9540 at wiring harness. With the doors unlocked, ground must be present at pin 10. At the same time, no ground must be present at pin 12. With the doors locked, ground must be present at pin 12. At the same time, no ground...
Adjusting Brake Pressure Rod 1
86 Models Onward without stop on brake-pedal arm It is only necessary to adjust the brake pressure rod if - the brake booster is replaced - brake pressure rod adapter has been removed. 1.Adjust length of brake pressure rod by turning adapter or pressure rod. Length a must be 158 2 mm measured from the bearing face of the brake booster on the body to the center of the adapter pivot pin. If the car has manual transmission and the brake pedal is more than 8 mm lower than the clutch pedal, correct...
Info Ppx
Commercially available, e. g. Dresser-Wayne Model 3009 After drainage approx. 8.0 1 After oil change approx. 6.0 1 Turn crankshaft until the converter drain plug is visible and can be removed. Types of oil ATF Dexron B - sperm-oil free The ATF and the filer must be changed every 40,000 kilometers. If a vehicle is subjected to particularly severe wear and tear e.g. used for towing the ATF should be changed every 20,000 km without replacement filter If the ATF is to be changed, the vehicle must...
Interior Equipment
Removing and installing rear side trim panel 68-1 Safety regulations for handling airbag vehicles 68-3 Removing and installing the airbag steering wheel 68-5 Removing and installing airbag Checking the airbag system to ensure that long-term functioning is guaranteed 68-11 Checking the safety Correct disposal of airbag units 68-15 Diagnosis Troubleshooting Airbag D68 - 1 Removing and installing power Removing seat backrest Disassembling seat Disassembling left seat track and removing fore aft...
Replacing Front End Partially
1. Cut off end plate at body floor plate. 1. Cut off end plate at body floor plate. The best method of repairing a damaged front end, of which the side members are bent or distorted in area of front axle or engine mounts, would not be replacing up to the deformation border, but complete replacement of side members and wheel houses at original connection points of floor or firewall. These repairs can be best performed with help from the Celette straightening bench and pertinent attachment set...
Removing And Installing Brake Pressure Regulator
1. Remove intake hoses and air cleaner upper section. 2. Drain both chambers of brake fluid tank by pumping out brake fluid through bleeder valves of front and rear wheel brake calipers diagonal brake circuit division . 1. Check brake pressure regulator car application on page 47-18. 2. Install brake pressure regulators. The mounting plate has a retaining tab for each brake pressure regulator to guarantee correct installed position and prevention of turning when tightening bolts 3. Detach brake...
Wiring Diagram Type 928 S Model 86 page 3
Wiring Diagram Type 928 S Model 86 page 4 VENTILATION, HEATING, AIR CONDITIONING ELECTRICALLY OPERATED SEATS
Disassembling And Assembling Gear Assembly 1
4. Remove snap ring and take inner plate carrier with one-way clutch out of connecting carrier 4. Remove snap ring and take inner plate carrier with one-way clutch out of connecting carrier 1. Clamp Special Tool 9314 in a vise on both surfaces with plate facing up and mount gear assembly with drive shaft facing up. Coat all bearing surfaces and sliding surfaces with ATF when assembling. 1. Place one-way clutch with connecting carrier on Special Tool 9314. 2. Mount sun gear and install axial...
Wiring Diagram M 28 21 Porsche
TECHNICAL DATA - TYPE 928 S - 1984 W86 Models Adjusting specifications and wear limits are listed in each individual repair group. Displacement rounded off cm3 Compression ratio Max. engine power 80 1269 EC kW HP Net torque, SAE J 1349 Nm ft. lbs. Speed limit by stopping fuel feed rpm M 28 21, Automatic M 28 22 USA, Japan, Canada M 28 19, Automatic M 28 20
PSD Electronically controlled Porsche limitedslip differential
PSD Component PSD - fault display troubleshooting 1 Bleeding condition of lock Re-bleeding lock operating hydraulics point 2 on P. D39-202d 2 Measuring plate wear of controlled limited-slip differential D39-202e 3 Checking locking torque friction coefficient of transverse lock D39-203 4 Checking pilot pressure valve in the lock hydraulics lock operation D39-215 5 Lateral acceleration sensor 6 PSD - Diagnosis with system tester 7 Checking lock Pressure test on lock Replacing the pressure warning...
Info Ndm
Parts are deleted as of MY '85. Adjustment of the driver plate including pre-1985 models is no longer required. Removing and installing central tube autom. transmiss. Replace entire central tube with shaft and bearings, if bearings and or shaft are damaged. There are no replacement parts available. tapping face of central shaft with plastic hammer. 1. Check easy movement of central shaft bearings by turning shaft by hand. Shaft must turn easily and without restriction at any point. 2. Position...
Porsche 928 Door Handles
3. Detach connecting rod from outside door handle to lock. Unscrew and pull out outside door handle. 4. PjII off connecting hoses to control valve driver's door and vacuum control passenger's door , and unscrew control parts. 5. Unscrew self-locking screws on lock outside section. Unscrew inside door control and remove with inside lock parts. loses are connected on control valve in driver's door in red, blue and green as seen locking forward. In the passenger's door the red hose is connected on...
Removing And Installing Rear Side Trim Panel
1. Disconnect and remove luggage compartment cover, tool plate, floor mat, spare wheel cover, edge guard on B pillars, parking brake cable cover, emergency seat cushions and backrests. 2. Remove seat belt on side member and seat well at outside arrows . 6. Make sure trim panel engages in proper holders in area of wheei house. 3. Remove escutcheon for seat belt and grab handle arrows . 4. Remove screws arrows and pry off trim panel at top with a suitable tool clips and pull forward slightly....
Replacing Valve Guides
4. Loosen valve guides from camshaft end with brief hammer knocks on Special Tool 9224 and press out rest of guides toward combustion side with a press. 1. Clean and inspect cylinder head. Cylinder heads are not suitable for replacement of valve guides, if their valve seats and sealing surfaces can no longer be machined. 2. Machine off protruding valve guides from the camshaft side with a countersink, Special Tool 9220 1, until guides are flush with the cylinder head. Be careful not to damage...
Bleeding Clutch
An electric bleeder is recommended for fast and accurate bleeding. 1. Fill tank to upper edge with brake fluid. Remove strainer. Connect bleeder. 4. Install slave cylinder and repeat bleeding procedures. 2. Turn on bleeder and open bleeder screw 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 slave cylinder against stop and release again slowly...
Disassembling And Assembling Parking Brake Lever
1. Remove parking brake lever parking brake cable trim. Unscrew mounting bolts and take out complete parking brake lever. 2. Pull off sleeve forward from parking brake lever pasted on sides of lever - loosen first . 3. Remove bearing shaft and move out locking element. 4. Unscrew push button locked with Loctite . Take off washer, spring and guide sleeve toward front and push rod toward rear. 1. Lubricate all sliding and bearing surfaces with multi-purpose grease. 2. Pawl must move easily even...
Removing Seat Backrest Motor
1. Open zipper. Bend open metal tabs at bottom of backrest and disconnect backrest cover. 2. Disconnect side cheek and strip on backrest springs. 3. Detach pasted padding, unscrew cover and remove. 4. Unscrew gear wheels or remove circlip and take off gear wheels. 6. Detach front seat cover and pull up far enough, that motor is accessible from front and can be removed.
Troubleshooting Car Radio
Charged battery, ignition key turned to radio position, antenna run out. 1. Are stations received only on some of tlie four wave ranges MW, LW, SW, USW 2. Are any stations at all received 3. Check operating voltage at radio. Is there 12 volts at radio housing Replace fues or eliminate interruption in wire , 4. Turn loudness control on radio Lo full volume. Is there loud noise in loudspeakers in all wave ranges f Check loudspeaker connection and loudspeakers. Connect test loudspeaker. Is there...
Aiming Headlights
4. Aim headlights with optical aiming equipment. Tire pressure correct, fuel tank full, driver's seat occupied by a person or weight of approx. 70 kg 155 lb . Adjusting screw A vertical adjustment adjusting screw B - lateral adjustment 5. Reinstall trim ring and headlight cover. If equipped with headlight beam adjuster, turn adjuster knob so that white dot on knob faces forward audible click . 2, Turn on headlights low beams . Clean lenses Remove 3 Phillips screws arrows and take off headlight...
Porsche 928 Day Time Running Light
OTENTIOMETER HEADLIGHT VERTICAL AIM CONTROL-DE1 DTENTIDMETER WIPE WASH SYSTEM-B16 OTENTIUMETER ADDITIONAL AIR CONDITIONER-F37.38 UMP PORSCHE LOCK DIFFERENTIAL -B77.78 - UMP RELAY PORSCHE LOCK DIFFERENTIAL ----B79.80 - REAR WINDOW DEFOGGER DAYTIME RUNNING LIGHT ADDITIONAL CLEANING FLUID PUMP - SUPPLY -
Machining valve seats
Before refacing the valve seats, check dimension A to avoid carrying out work that may be unnecessary if the wear limit has been exceeded. Valve seats may be machined down to the wear limit A 14,5 mm size new 13.65 0.45 . Check with a new valve. Distance A must not be exceeded, as otherwise the function of the hydraulic valve tappet would not be assured. Remove no more than the absolute minimum amount of metal in order to prevent premature wear. 1. Remove deposits with a cleaning reamer. 2....
seat and mirror memory
sk biack wt white re red ffl green ye yellow s grey bff brown 8l blue vi vdlet sk biack wt white re red ffl green ye yellow s grey bff brown 8l blue vi vdlet
Checking Thickness Of Brake Pads
All brake pads on one axle must be replaced when brake pad indicator comes on, however at latest when pad thickness is worn to 2 mm. If the indicator lamp reports the brake pad wear, the warning contact sensor plus wire and plug must also be replaced. The complicated and expensive replacement of the warning contact can be avoided by replacing the brake pads at the latest when thickness is 4 mm or 2.5 mm for version described below . This will depend on the location of the warning contact in the...
Adjusting Backlash Fus
4. Turn differential in both directions several times, to settle tapered roller bearings. 5. Install measuring tools. Set Special Tool VW 388 to distance a 80 mm. 1. Place shims determined for pinion adjustment between transmission case and final drive housing. Install final drive housing and tighten all mounting bolts to specified torque. 3. Install side cover, using total shim thickness Stotai as determined on ring gear end and tighten all bolts to specified torque. 4. Turn differential in...