Cabrio MODEL 93 SHEET 11
NOT WITH - MARKED LEADS ARE WRING LOOM PASSENGER COMPARTMENT CABLE LAYOUT DIFFERING FROM SERIES VARIANT WIRING AS STANDARD WELDING POINT CONNECTION WITH FIELD INDICATION I I CONNECTION WITH FELD DATA GP GROUND POINT CLOSED MICROSWITCH OPENED IN ENDPOSITION ROOF ELOSED CLOSED MICROSWITCH OPENED IN ENDPOSITION ROOF ELOSED OPEN MEROSWITCH OPENED IN ENDPDSITION ROOF OPEN
Crankshaft Standard and Repair Dimensions
Crankshaft conrod bearing journal d 2 0 69.971 69.990 69.721 69.740 69.471 69.490 51.971 51.990 51.721 51.740 51.471 51.490 It is recommended to check the availability of bearing sizes prior to machining the crankshaft. Crankshaft - Standard and Repair Dimensions 13 - 31 Crankshaft - Standard and Repair Dimensions
Routing the sensor wire at the Tiptronic transmission
Assembly of the sensor wire to the transmission has been modified. When repairing the Tiptronic wiring harness on vehicles featuring the former type of fitting, adopt the new fitting type. 1. Fit three wire clamps Part No. 999 651 262 09 . 2. Connect sensor wire to rpm sensor. 3. Attach wire with three wire clips Part No. 999 651 162 40 . 4. Attach sensor wire with two U-clamps to the reinforcing webs of the transmission housing. Routing the sensor wire at the Tiptronic transmission Heating,...
Repairing the Tiptronic wiring harness
2. Remove trunk floor carpeting. 3. Undo right-hand side trim in Tiptronic control unit area. Also remove vibration damper on Cabriolet vehicles. 6. Disconnect transmission wiring connectors. 7. Detach wiring harness from transmission and push it out across hole in passenger compartment. 8. Cut off wiring harness to transmission at a distance of 310 mm from control unit connector. 9. Remove cloth tape along a length of approx. 30 mm. 10. Strip all wires except sensor wire to speedometer along a...
Possible fault displays
- Check door contact wires to alarm control unit plug II terminal 21 for short to ground. - Turn off engine, only switch on ignition. - Turn off engine, only switch on ignition. Fault summary is displayed if several drive links actuators are triggered simultaneously, e.g. if turn signals are on while the function display is checked. - Check wiring to alarm control unit plug I, terminals 8, 9, 10, 11, 12, and plug II, terminal 20, for short to positive. Check connector II, terminal 24 and...
Replacing ignition switch
Requirements for Keylock - vehicles - When removing and installing the ignition switch, the lock barrel must be fitted to the steering lock housing. - The Keylock bowden cable may remain fitted. 1. Pull connector off ignition switch. Uncllp connector housing from steering column housing. 2. Turn ignition key No. 3 to position 0 key can be pulled off . Turn out fastening screws No. 1 of ignition key No. 2 . Extend ignition key carefully. In case of Keylock vehicles, the steering lock housing...
Pin assignments of alarm control unit connector
11 - Motor Closed Actuator door lock 12 - Motor Open Actuator door lock 13 - Rear cover unlocking switch 5 - Luggage compartment contact 10 - Central locking system position switch 11 - Central locking system button 12 - Central locking system position switch 20 - Central locking system button light
Checking Thickness of Brake Pads
Removing and installing brake pads Note The brake pads are changed in the usual manner known from other Porsche models fitted with four-piston fixed calipers. This is why only a short description of the operations is given. Please make sure the following is observed at all times use correct brake pad quality refer to spare parts catalog . Replace damping plates or vibration dampers with new parts whenever the brake pads are changed. The damping plates and vibration dampers are protected by an...
Crankcase markings
Upper and lower crankcase section and balance shaft cover 1. The upper and lower crankcase sections as well as the balance shaft cover are machined as a unit and must always be fitted as a unit. Observe correct identification marking. The engine number is engraved on the right-hand rear end of the engine when seen in the direction of travel. 2. When the components have been fitted, it must be possible to read off the markings of both balance shaft covers from above.
Removing and installing door mirror Removing the door mirror
Undo mirror base mounting Lift off door mirror Disconnect connector Cover mirror housing in the mirror base mounting area to avoid damage. Lift protective cap carefully off the mirror base mounting. Release socket head screw for mirror base mounting. Lift door mirror and lift it off the door. Disconnect connector for mirror electronics. Reconnect connector Position door mirror Tighten mirror base Turn mirror housing back into initial position Reconnect connector of mirror electronics. Adjust...
Tiptronic warning lamp comes on transmission is in emergency mode Dtz
Detectable faults Open circuit short to gound, short to positive 1 Check operation with Tester 9288 drive link test Triggering cycle of valves is audible as a clicking noise near the transmission. 2 Pull connector off Tiptronic control unit. a Measure resistance between pin 16 and pin 19. Nominal value 34 Ohms, tolerance 10 b Check that pins 16 and 19 are free from shorts to ground. 3 Also pull off connector at transmission. - Check wiring Tiptronic control unit connector pin 16 to transmission...
Removing and installing drive pinion and drive shaft
Do not confuse with catch No. 1 on page 34 - 5. Tighten to 70 Nm 52 ftlb Replace only as a unit with driver for 5th and 6th gears also refer to page 34-12 Cutout must engage into reverse gear return lever Take out along with shift rod No. 9 Shift rod 3rd and 4th gear with shift lever Replace only as a unit with driver for 3rd and 4th gear If required, redetermine thickness refer to page 34 - 17 Replacement is only possible if end shield has been removed. Press off using a suitable shop press...
Dismantling and assembling door rearview mirror 1
Dismantling and assembling door rearview mirror 2 Fit mirror housing complete with mirror base Engage outside sensor into mirror housing Fit mirror glass complete with adjusting motor Tighten fastening screws of reinforcing plate and mirror housing seal. Clamp 14 mm socket hex head wrench in a vise. Grease centering washers of stud for mirror base mirror housing union. Assemble mirror housing, mirror und base and stud. Place stud onto socket hex head wrench. Tighten by applying axial force and...
Replacing part of door sill with side member and floor pan 1
Fitting part of door sill with side member and floor section into body Perform straightening operations and adjust body with attachment set Perform all straightening operations on the bodywork. Adjust body with attachment brackets. Trial-fit door into body aperture. The door gap between door and body must be uniform along the entire surround. Clean welding areas Using a hot air gun or rotary wire brush, remove under- sealing, paint etc. from welding areas of body. Remove factory primer from...
Checking the Tiptronic transmission
Check percentage reading actual values with Tester 9288 If there is no display 1 Measure voltage signal at Tiptronic control unit connector pin 11 using a voltmeter. The signal should range from 1 V at idle to about 10 V at full throttle with the ignition on . 2 Check wiring from Tiptronic control unit connector pin 11 to DME pin 52 for continuity and shorts to ground. If voltage o.k. Tiptronic control unit faulty Fault, fault code Possible causes, elimination, remarks Test point 9 Tiptronic...
Model 93 Sheet 15
I I CONNECTING POINT GP GROUND POINT NOT WITH MARKED LEADS ARE WIRING LOOM PASSENGER COMPARTMENT OODR CONTACT SWITCH DOOR CONTACT SWITCH PASSENGER'S SIDE DRIVER'S SIDE Sheet 2 11 - 20 Instrument Cluster and Sensor Sheet 3 21 - 30 Heating, Airconditioning, Ventilating, Power Sheet 4 31 - 40 Two-Tone Horns, Mirrors, Lifting Roof, Power Window Regulator, Tailgate Unlocking Plug Connections, Ground Points, M-Numbers, Abbreviations USA For v hicul s with V.I.N.s from WPO AA2 96 RS 82 0061 to WPO AA2...
H
CONTROL UNIT LIGHT COMBINATION ION CESI RELAY FOG LIGHT TURN SIGNAL DIMMER SWITCH CUTOFF IF HIGH BEAM l hghbeam CONTROL UNIT LIGHT COMBINATION ION CESI RELAY FOG LIGHT TURN SIGNAL DIMMER SWITCH CUTOFF IF HIGH BEAM l hghbeam
Wheels and tires
Tires are safety-relevant items that are only capable of meeting the requirements aplicable if they are run at the correct tire pressure and with sufficient tread depth. The tire pressures indicated are minimum pressures. The tires must never be run at lower pressures since this influences roadholding in a negative manner and may lead to severe tire damage. Valve caps protect the valve against dust and dirt and therefore help prevent leaks. Always screw on caps tightly and replace missing caps....
Bonding the interior rearview mirror in place 1
5 Apply adhesive to bonding Apply a drop of adhesive E to the bonding plate of the plate rearview mirror. 6 Bond rearview mirror in place Press bonding plate of rearview mirror against primered Note Press mirror in place for approx. 40 - 50 sec. Bonding strength 60 after 1 hour 100 after 24 hours Bonding the interior rearview mirror in place
Diagnosis troubleshooting alarm system
The alarm control unit is diagnosable. It can be read out only with System Tester 9288. The menu includes the following functional groups For some of the faults, two types of causes must be distinguished - The fault displayed is an actual fault that has to be remedied. - The fault displayed is a fault condition that has been caused deliberately, e.g. by leaving the open glove compartment open. Troubleshooting requires that the person performing the tests - is familiar with the location of...
Model 92 Sheet 10
sensor rear right _ H crash sensor left crash sensor right airbag warning lamp instrument cluster diagnosis plug CRASH SEN50R RWT CRASH SENSOR fWT CRASH SENSOR RWT CRASH SENSOR LEFT O CRASH SENSOR LEFT CRASH SENSOR LEFT q PASSENGER'S SEE. WTON TABLET 3 1 PASSENGER'S SEE. IN TON TABLET J 2 PASSEH3ER S SEE, DITCH TABLET 2 1 PASSEKZR S SEE. GMTDN TABLET 2 2 lt S CHVER'S SEE. IGMTEN TABLET V2 DRIVER'S SEE. KMTON TABLET VI O HAZARD LIGHT AKBA6 O RELAIS TERM.66 TERM 15 pCj - RK31 L LEAD KIEAO 1 i...
Body Paint Colors Beginning With Standard Colors
Midnight blue pearl effect 39C
Checking headlight beam adjuster
2. Unlatch headlights and turn into fitting position. 3. Disconnect both connectors from actuators. 4. Measure voltage between term. No. 1 positive and term. No. 3 negative . If no voltage is present at the terminals, check power supply according to wiring diagram. 5. Voltmeter to term. 1 positive and term. 2 negative . Potentiometer in position 0 approx. 0 V Potentiometer in position 1 2.5 V to 3.0 V Potentiometer in position 2 4.2 V to 5.0 V If the values are not reached, check directly at...
Adjusting the popup headlight mechanical system
The installed pop-up headlight assembly is comprised of 1. Sheetmetal console fitted to body 2. Joint rod provides link between return lever and rotary support 3. Mounting saddle of electric motor 6. Electric motor with deflection lever The headlight position with regard to the fender aperture is adjusted with the headlight folded down 1. In longitudinal axis of the vehicle at the console. Adjust the headlight in such a manner that the upper edge of the headlight does not protrude above the...
Adjustment of headlights fitted with headlight beam adjuster
Basic headlight adjustment is carried out in position 0. 2. Adjust headlights with the vehicle in road-worthy condition using a headlight aimer. Driver's seat loaded with one person or 75 kgs. The tire pressure must meet the specifications. Potentiometer position of headlight adjuster relative to load state 1 or 2 persons without luggage. Position 1 3 or 4 persons without with luggage. Position 2 1 or 2 persons without luggage. Position 1 2 persons with luggage. Position 2 Lowering in position...
Diagnosable DME Control Unit
A self-diagnosis feature with fault memory is incorporated into the DME control unit to permit certain faults to be detected and stored. The DME control unit has a permanent positive connection to prevent deletion of detected and stored faults when the Iginition is switched off. Detected faults remain stored in the fault memory for at least 50 engine starts. If the DME control unit plug or the battery is disconnected, the fault memory will be cleared. Tester Connections The diagnostics socket...
Removing and fitting front spoiler and bumper
Sheetmeal screw washer assembly B 4.8 x 16 Oval-head sheetmetal screw B 4.2 X 9.5 Insert into front spoiler and reconnect electrical connector Insert into front spoiler and reconnect electrical connector Sheetmetal screw washer assembly B 4.8 x 19 Before fitting, apply sealing compound e.g. adhesive sealer, part no. 999.915.400.40 in a continuous bead to seal the mounting flange
Removing and fitting rear spoiler and bumper
Insert into rear spoiler and reconnect electrical connector Insert into cap and reconnect electrical connector Sheetmetal screw washer assembly B 4.8 x 16 Z 2 Sheetmetal screw washer assembly B 4.8 x 16 Z 2 Sheetmetal screw washer assembly B 4.8 x 13 Z 1
Fuel system
Closed cooling system with antifreeze protection down to - 30 C nordic countries - 40 C Electric fan with temperature switch Forced-feed circulation lubrication with crescent-type gear pump External, thermostatically controlled air oil cooler Full-flow type 0.6 8 bar, min. 3.0 bar at 3,000 rpm 0 5 bar, electric gauge with warning light contact 2 Twin-tube mainfolds, downpipe to catalytic converter, center muffler, rear muffler Oxygen sensor control with 3-way catalytic converter metal carrier...
Changing engine oil and engine oil filter
1. Undo and remove oil filler cap. 2. Remove oil drain plug from oil pan and drain engine oil. 3. Undo oil filter with oil filter wrench Special Tool 9204 . Drain remaining oil into suitable container. 4. Clean drain plug. Always replace seal. Tightening torque 50 Nm 37 ftlb . 5. Oil seal of oil filter lightly, tighten by hand until seal is seated, tighten by one more turn. Use oil filter wrench to check tight seating of filter afterwards. Guide value for tightening torque 20 Nm 15 ftlb . 6....
Pin assignment of DME control unit plug
2 Ground, ignition output stage MP IX 4 Idle speed positioner, opening winding 9 Speed signal from speedometer 10 Ground, electronics MP VIII 12 Positive terminal, Hall sender throttle 14 Ground, injection valves MP IX 22 Idle speed positioner, closing winding 24 Ground of remaining output stages MP IX 28 Oxygen sensor idle CO potentiometer 30 Ground NTC shield knock sensor Engine in perfect running condition Battery charged V Voltmeter C2 Ohmmeter Oscilloscope V Voltmeter C2 Ohmmeter...
Checking the ATF level 1
Correct ATF level is an essential prerequisite for proper operation of the automatic transmission. At 80'C operating temperature, the ATF level must be between the 80 C min. and max. marks. To determine the precise ATF temperature, use System Tester 9288. If required, top up with ATF fluid across the quick-fill device. A Check range at 80'C ATF temperature B Quick-fill device
Machining the cylinder head mating
Checking cylinder head for distortion Using a feeler gauge and ruler or straight edge, check the cylinder head mating face for distortion. Admissible distortion of the mating face 0.05 mm Distorted cylinder heads may be repaired by machining the mating face. Admissible distortion after machining 0.03 mm. Reface cylinder head mating face only until the surface is level. Max. wear limit 146,6 mm Note for refacing the mating face Max. roughness 0,015 mm If the new-dimension tolerance is exceeded...
Checking and adjusting the camshaft setting
Check requirements Belt tension o.k. 1. Turn engine in sense of rotation until cylinder no. 1 is at firing TDC TDC mark on flywheel center notch with engine fitted double-mass flywheel . Camshaft position with cyl. 1 at firing TDC. With the engine removed, transfer TDC flywheel mark with a color pen to the sensor ring gear. Set TDC flywheel mark opposite crankcase mark. 2. Align dial gauge with shop-made extension length 205 mm to piston pin cyl. 1 . Preload 3 mm. Align second dial gauge to...
Applying TDC mark to camshaft sprocket
Camshaft sprockets supplied by the spares department do not have the TDC marks. The TDC mark is applied after the camshaft has been adjusted on the new engine. 1. Place new camshaft sprocket exactly over old camshaft sprocket and transfer TDC mark to new sprocket using a color pen. 2. Fit new camshaft sprocket and adjust camshaft according to instructions on page 15 - 4 to 15 - 6 in Repair Manual. 3. Following item 13, page 15-6, apply the final TDC mark to the new camshaft sprocket, using a...
Weights to DIN 70020
75 165 with genuine Porsche roof transportation system
Checking operation of lighting system
2. Release pop-up headlights and tilt forward. 6. Adjust headlights with the car in roadworthy condition fuel tank filled, driver's seat loaded with one person or 75 kg, tire pressure set to specified values , using a headlight aiming device. 2. Release pop-up headlights and tilt forward. 4. Tilt back pop-up headlights. 5. Clean light-diffusing lens and turn on low beam. Adjustment is performed with the headlight beam adjuster switch set to position 0. Adjusting auxiliary headlights and fog...
Checking idle speed and CO level on vehicles with catalytic converter
Idle and CO level adjustment is no longer possible on vehicles fitted with catalytic converter. When checking the idle CO level, the oxygen sensor is not disconnected. Perfect condition of the mechanical engine components. Loads must be turned off while checks are made. Perform checks as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would give faulty CO level readings. Ambient temperature 15-35 deg. C. 1. Connect commercially available exhaust gas adapter to...
Dismantling and assembling end cover Tools
Lever out e.g. using arm of puller 9884 When replacing bearing and end cover, recalculate thickness. Make sure it is seated correctly in the correct position. Take out, remove upsetting marks if required Cylindrical roller bearing outer race Using Tool 30-205, press in to stop, inserting Special Tool 9535 at collar stop to support cylindrical roller bearing. Cylindrical roller bearing outer race Pull out using internal puller 23.5 30 mm e.g. Kukko 21 4 Removal damages the bearing, i.e. the...
Adjusting the clutch pedal Note
The following items are essential requirements for smooth clutch operation and must therefore be observed whenever the pedal is adjusted - Correct bleeding of clutch hydraulics. - Tightness of hydraulic system. - Correct setting of pushrod and boost spring. - Pedal position according to standard setting. 1. Adjusting pedal position pushrod dimension A LHD 147 mm RHD 109.5 mm . If repairs on the master cylinder have been carried out, the pushrod must be readjusted. Move the sound insulation in...
Note
Brake pads must be replaced for the complete axle when the brake-pad warning lamp lights up, but at the latest when the pads have worn down to 2 mm. If the brakepad wear is indicated by the warning lamp, the warning contact sensor including cable and connector must also be replaced. It is possible to avoid replacing the warning contact if the brake pads are replaced when worn down to 2.5 mm at the latest. Warning contacts must be replaced if the core of the cable has been exposed. If only the...
Dismantling and assembling drive shaft Tools
4th gear loose gearwheel with spring Insert spring before installing gearwheel Oil with transmission oil. Fit with the same gearwheel as before. Check for wear. Fit with the same gearwheel as before. When replacing the synchronizer hub No. 8 , redetermine thickness Press off with tools VW 412 and VW 401 Heat to approx. 100 C and press on, observing correct position 3rd gear synchronizing ring molybdenlum-coated Check for wear. Fit with the same gearwheel as before. Oil with transmission oil and...
Test point 33 Leads K and L
The diagnosis connection between the DME control unit and testers is established by means of the two leads K and L. If no diagnosis is possible, the following points must be checked 1. Continuity test refer to wiring diagram Leads L Pin 7 19-pin diagnostic socket Leads K Pin 8 19-pin diagnostic socket 2. Ground short test refer to wiring diagram Leads L The voltage at pin 7 19-pin diagnostic socket must be gt 8 V when the ignition is on. Lead K The voltage at pin 8 19-pin diagnostic socket must...
Adjusting guide rail for balance shaft toothed belt
1. Tighten mounting bolts of guide rail lightly. 6. Fit sprocket and balance shaft toothed belt Fit sprocket for balance shaft drive and and adjust according to specification, toothed belt. Refer to pages 13 - 7 to 13 - 10. Put balance shaft toothed belt under preload. 2. Using a feeler gauge, measure and adjust clearance between toothed belt and guide rail. 3. Check clearance of guide rail over a length of 7 teeth dimension A . The adjusting dimension must be 1 0.5 mm. 4. To achieve the...
Technical data 1
Hypoid bevel-gear drive with 12 mm offset approx. 2.75 liter hypoid oil SAE 75 W 90 or API classification GL5 or MIL-L 2105 B Tightening torques for manual transmission G 44 Selector shaft cover to transmission housing Lock bolts to transmission housing and end shield Deflection lever for reverse gear to end shield Threaded flange for guide plate to transmission housing Side transmission cover to transmission housing Crown wheel to differential housing Verbus-Ripp bolt
Adjusting and checking the camshaft setting Tools
Dial gauge insert for push-rod stroke measurements Dial gauge insert for push-rod stroke measurements Adjusting and checking the camshaft setting
Note Fhs
Do not apply pressure to inner surface of the tensioner housing. Press only on outer edge of the tensioner housing. 7. Tighten vise slowly until resistance is felt. Wait for a couple of seconds and then tighten somewhat more. 8. Continue to tighten in this order until the push rod housing bores are flush with each other and the push rod may be locked with Special Tool 9530 upper Fig. .