Vag 1402
3. Screw high-pressure hose No. 5 with flange No. 6 to power pump required seal 14x18 . 4. Fit high-pressure hose No. 2a or 2b 1.5 m long to pressure line, using the banjo bolt and adapter No. 1. Required seals 2 x 14 x 18 and 1 x 18 x 22 or 1 x 16x20. 5. Install pressure gauge between high-pressure hoses and place on a support e.g. tool box . A helper is required to read off the pressures. Make sure the hose section of the pressure line is not kinked. In addition, the tester hose must be kept...
Important information
If admission pressure is too high before a valve is replaced , again build up a slight pressure and, unlike previous test, cause pressure to fall by switching off ignition. Loss of admission pressure should not exceed 0.5 bar within 5 minutes. After removing manometer, select System Tester menue for drive links bleeding and let off brake fluid from bleed valves of longitudinal and transverse lock servo cylinders until no more air bubbles appear. Disconnect System Tester and correct brake fluid...
Power supply and earthground
Pins occupied at control unit and sensor plug are the same as for the lateral acceleration sensor. 17 Longitudinal acceleration sensor Implausible signal Signals from longitudinal acceleration sensor to control unit are incorrect. Sensor has a mechanical fault, installed position is incorrect or connecting wires have been accidentally interchanged. 1. Check lateral and longitudinal acceleration sensor, Page 45 - 1 45 - 5. 2. Renew sensor if necessary. Repairs to the sensor are not permitted. 3....
Installation 1
3. Introduce drive shaft and tighten pan-head screws to 42 Nm 31 ftlb M 8 or 80 Nm 59 ftlb M 10 , respectively. 4. Coat seating surface of new M 22 x 1.5 lock nut with Optimoly HT and tighten to 460 Nm 339 ftlb . 1. Coat teeth, thread and stem of drive shaft with Optimoly HT. 2. Put shims on pan head screws and coat threads lightly with Optimoly HT. Insert pan head screws with shims into drive shaft flange, making sure the flange cover is not greased inadvertently. Wheels and tires Tire...
Tightening torques for mechanical brake system
Brake calipers to front and rear axles Brake disk to wheel hub front and rear axle Brake cover plate to front and rear axles
Checking the locking torque friction coefficients of the longitudinal and
In the event of functional problems or irregularities, perform or verify test points 1, 2 and 3 before the locking torque test locking torque in relation to pressure . - No fault stored in the control unit fault memory t - Perfect bleeding condition of the lock control - Thickness of the disk assemblies ok wear assessment If the friction coefficient curves deviate from the setpoint in the locking torque test, the lock is not functioning optimally. Only a large deviation of the actual value from...
specified torque
and apply a thin coat of Optimoly HT to the threads. Put pan head screws with support plates into halfshaft flange, making sure the flange cover is not greased accidentally . 3. Put halfshaft into position and fit pan head screws. Coat mounting surface of new M 22 x 1.5 lock nut with Optimoly HT and fit lock nut. 4. Fit joint carrier ball joint to wheel carrier. Taper of ball joint and wheel carrier must be free from grease. Apply a coat of Optimoly HT to ball joint threads. Replace lock nut.
Pressure gauge connection
- Depressurize the booster circuit. To do this, disconnect the electrical plug at the pressure pump pump assembly and then press the brake pedal approx. 25 times. The system is depressurized as soon as the brake pedal feels hard when operated. In order to disconnect and plug the electrical plug onto the pressure pump, press in the center on the plug locking clip. Connect pressure gauge 9509 No.1 at the screw coupling mini measuring connection No. 3 of the pressure accumulator with the...
Explanation of special tool 9514
The scope of delivery of special tool 9514 comprises the parts A-B-C. The assembly consisting of A-B-C is used for transverse lock measurement. Only Part A is needed for longitudinal lock measurement. B Flange for transverse lock testing 3 Two surfaces for fixing the measuring cylinder for longitudinal lock measurement 4 Measuring groove on adjusting screw 5 Separating line for LS and QS measuring ranges 6 LS Longitudinal lock measuring range 7 QS Transverse lock measuring range also for PSD of...
Prepare vehicle for testing transverse locks
- Remove rear left-hand brake caliper do not open brake hydraulics and insert retaining block - Special Tool 9509 5 - into brake caliper instead of brake disc. - Connect manometer to transverse lock cylinder, first removing ignition key for safety reasons. - Plug System Tester 9288 into diagnosis socket. - Disconnect ground cable and retainer A from left-hand rear axle link arrows , first extending brake hose retainer B . This means brake line or brake hose does not have to be opened when...
Test pointTitlePage
Overview of diagnosis Troubleshooting on PDAS and Connector assignment of PDAS ABS control Important vehicle 1 PDAS diagnosis with system tester Important information for diagnosis troubleshooting with system tester Fault memory Possible fault 2 Bleeding condition of lock post-bleeding the hydraulics of the lock actuation system 3 Measuring disk wear at the longitudinal and transverse locks D39 45-21 4 Checking locking moment friction coefficient of longitudinal and transverse 5 Checking admisi...
Dismantling and assembling wheel suspension 1
Coat thread and nut mating surfaces with Optimoly HT. Tighten to 460 Nm 339 ftlb Coat thread with Optimoly TA. Tighten to 10 Nm 7 ftlb Coat thread and stem with Optimoly HT. Tighten to 200 Nm 147 ftlb Coat thread and stem with Optimoly HT. Tighten to 200 Nm 147 ftlb Coat thread and stem with Optimoly HT. Tighten to 200 Nm 147 ftlb To remove the rear-axle trailing arm, removal of the rear-axle spring brace and of the following parts items no. 16 to no. 21 is not required If the trailing arm has...
Adjusting Brake Push Rod Checking Stop Light Switch Adjustment
Adjusting Brake Push Rod Checking Stop Light Switch Adjustment Checking Stop Light Switch Adjustment The brake push rod is adjusted correctly, if the brake pedal plate is at the same height 3 mm as the clutch pedal plate clutch pedal in neutral position . If the stop lights light up after 16 mm pedal travel, adjust the brake pedal on the pivot head of the brake push rod lengthen the push rod until the stop light switch responds in tolerance range. The brake pedal does not have a stop. The...
Lateral runout of wheel hub max 005 mm
0,1 mm, remove the brake disc and check lateral runout of the wheel hub. Mark position of disc with regard to wheel hub. 7. Check wheel hub runout as follows Measure once outside arrow and once within wheel stud area of hub face. To fit the dial gauge, use either a magnetic universal dial gauge holder or the dial gauge holder VW 387.
Checking brake disc thickness
Measure brake disc thickness in approx. 8 places within the braking surface using a micrometer. Dismantling and assembling front brake 1. Remove brake caliper do not disconnect brake hose or brake line remove brake hose retainer from spring strut . 2. After removing the countersunk head screw s , take off brake disc. If the brake disc is binding and cannot be freed with light plastic hammer blows, screw two hexagon head bolts evenly into both 8 mm threads of brake disc and press off brake disc....
Wheel Alignment General Information
Wheel alignment is applicable for both the 911 Carrera 4 and 911 Carrera 2. Check wheel alignment of a vehicle with an optical or electronic alignment tester. Procedures are described in the operating instructions supplied with a pertinent tester. The following requirements must be fulfilled prior to checking the wheel alignment. - Vehicle at curb weight according to DIN 70020, which means a ready-to-drive vehicle with full fuel - Correct joint and wheel bearing play wheel bearing play cannot...
Dismantling 1
2. Take lock spring arrow off brake hose and remove bracket 7 from rear-axle trailing arm. 3. Unbolt brake caliper from rear-axle trailing arm and suspend at wheel housing. 4. Remove parking brake assembly from rear-axle trailing arm. Carrera 4 Table Of Contents Carrera 2 Addendum 42 Rear Wheel Suspension, Axle Shaft 5. Unbolt stabilizer bar mounts arrow from stabilizer bar. Raise rear-axle trailing arm somewhat, extend mount and let hang down. 6. On the 911 Carrera with Tiptronic, disconnect...
Removing and Installing Brake Pads of Four Piston Fixed Caliper Brakes
Brake pads are replaced in the same manner as for other Porsche vehicle types with four piston fixed caliper disc brakes. There is only a brief description of procedures for this reason. However, always pay attention to the following points. Use specified brake pads see Parts Catalog . Replace damping plates each time brake pads are replaced. Damping plates are covered with an adhesive and protective sheet. This protective sheet must be pulled off prior to installation. Pad backplates backs of...
911 964 Accelerator Sensor
Possible Causes, Elimination, Remarks 2 Lateral acceleration sensor Short-circuit Break in circuit Wiring between control unit and lateral acceleration sensor not in working order break, short to positive side or to earth ground , or the lateral acceleration sensor itself is damaged. The following wiring is installed - Power supply to sensor 5 Volt PIN 15 at control unit - PIN 3 at sensor PIN 9 at control unit - PIN 1 at sensor - Signal from sensor to control unit 2,7 0.14 Volt with car in...
Important Information for Working on Wheel Alignment of Vehicle
Conform with the following points when checking adjusting wheel alignment. Height Adjustment Wheel Load Change Changing the height on one side will simultaneously cause a change in wheel load. A wheel load change on one wheel will also change the wheel loads of the other wheels. Wheel loads are increased by increasing the installed spring preload on one side vehicle lifted . Left rear spring preload C is increased. This causes the wheel load - to increase at left rear C and right front B and -...
Dismantling and assembling spring strut
A Initial version B Modified version as of Model '91 Before undoing the lock nut, preload coil spring with spring ten-sioner and take load off piston rod Use new lock nut. Coat thread with Optimoly HT. Tighten to 58 Nm 43 ftlb Observe references acc. to spare parts catalog Record adjusting distance position Coat spring mounting face with Optimoly TA. Install in correct position guide pointing towards spring Observe references acc. to spare parts catalog Preload coil spring with spring...
If no fault is found proceed with 2
If a break or short to the positive side or to earth ground is present, pull off the motor relay. Check the wiring between terminal 85 at the relay base and PIN 5 at the control unit plug, and and between terminal 86 and PIN 20. If the wiring is in working order renew the motor relay. 2. Pull off the motor relay. The car's electrical system voltage app. 12 Volt must be present at terminal 87 of the relay base. 3. Bridge terminals 30 and 87 at the relay base. If the return pump does not run,...
Dismantling and assembling wheel suspension
Before lifting the vehicle, undo the nut, actuating the brakes at the same time. Coat thread and nut seating face with Optimoly HT. Tighten to 460 Nm 339 ftlb . Coat thread with Optimoly HT. Tighten to 10 Nm 7 ftlb . Ball joint and steering arm tapers free of grease. After inserting into the steering arm, coat thread with Optimoly HT. Tighten to 65 Nm 48 ftlb . Replace. Coat thread with Optimoly HT. Tighten to 46 Nm 34 ftlb . Replace. Tighten to 46 Nm 34 ftlb . In case of replacement, observe...
Front Axle 1
Prepare the car for checking and adjusting of the wheel positioning values. Place front wheels on rotating plates or something similar. Bottom front and rear wheel suspension of car 2 or 3 times and have spring force move the car up to ride level height each time. Camber is adjusted by displacing the spring strut to the wheel carrier. This requires unscrewing two mounting bolts with Special Tool 9265 1. Apply excentric socket 9265 on the upper mounting bolt head fillister head bolt and turn to...
Bosch Kdas 0003 7
Always conform with the following points when installing. - Electric leads plugs connected on the correct sensor mix-up test Testing requires use of a 55-pin ABS 2 - LED adapter lead see point 1. , multimeter, garage jack and measuring tape. The 55-pin adapter lead, which is required for the ABS test of Carrera 4 models instead of the 35-pin adapter lead , has 3 outlets which were integrated for testing of axial and lateral acceleration sensors. Robert Bosch GmbH Dept. KH VKD 3 P. 0. Box 41 09...
Installation instructions for wheel carrier
Carrera 4 Table Of Contents Carrera 2 Addendum 911 Carrera 4 Front Wheel Suspension, Axle Shaft Dismantling and assembling wheel suspension Tools commercially available e.g. Nexus 168-1 commercially available fork aperture approx. 20 mm e.g. Nexus 169-1. Used to press the ball joint off the wheel carrier
Testing ABS in 911 Carrera 4 with ABS 2LED Tester Important information on ABS
1. If any work is carried out on the hydraulic unit, speed sensors or cable harness, or if any units are replaced, e.g. during accident repairs, a function check with the ABS Tester must be performed. This prevents any mixing up of the electrical and hydraulic lines and ensures that the hydraulic unit functions correctly. 2. If a fault is indicated during operation without any prior assembly work , diagnosing and troubleshooting with System Tester 9288 is possible. In this case select system...
List of Repair Groups Carrera 4
Engine, Cylinder Head and Valve Drive Starter, Power Supply, Cruise Control Differential, Transaxle System, All-Wheel Drive Automatic Transmission, Controls, Case Automatic Transmission, Gears, Shafts Brakes, Hydraulics, Regulator, Booster Instruments, Fuel Gauge, Alarm System Survey of Information Published in Technical Manual beginning in 1985 - Summer Tires 205 55 VR 16 and 225 50 VR 16 - Turbo Brake Calipers Front and Rear - Brake Lines Visual Inspection On Car - Testing Criteria and...
Control arm with mounting boltsmounting nut
993 olive-colored. Bore diameter of wheel carrier mount 12 mm 964 gold-colored. Bore diameter mount 10 mm Stabilizer bar stabilizer bar mount Tensioning disc ABS gear 964 45 teeth 911 Carrera 4 Front Wheel Suspension, Axle Shaft 4. Fit spring stmt support mount to spring strut tower in correct position. 5. Bleed front brake circuit conventional method . 6. When assembling or replacing components that affect the vehicle height, check wheel alignment and vehicle ride height. When replacing parts...