Replacing cover for passenger airbag
When the airbag was triggered while no passenger was in the car, damage to the instrument panel is minimal. In this case, if may be sufficient, following detailed inspection of the instrument panel, to replace only the cover. Check the instrument panel on the passenger side for cracks and other accident-related damage. The instrument panel must be free from bending traces and cracks. Minor deformations of the instrument panel can be straightened. 1. Disconnect battery negative terminal and...
Cylinder head with valves
Outer correction angle Inner correction angle Valve guides Valve stem Inlet Exhaust
Dismantling and assembling door outer handle Dismantling door outer handle
1 Remove lock barrel To separate the lock barrel from the door outer handle, drive out the lock pin using a drift. 2 Remove escutcheon Undo bolts and lift off escutcheon. 3 Remove operating lever Cut rivet connecting door outer handle and operating lever using a hacksaw. Pull out both rivet sections, pull operating lever and tensioning spring out of the door outer handle. Note When sawing off the rivet, lock the rivet stud to keep it from turning. 4 Fit operating lever Insert operating lever,...
Fitting the camshaft seal
1. Place sealing washers or lock pins, respectively, into bearing surfaces and fit bearing saddle, applying some Loctite 574. Tightening torque 20 Nm 15 ftlb . 2. The seal cover may only be used with Special Tool 9234 after the bearing saddle has been tightened. If the sealing cover leaks with the engine fitted to the vehicle, fit the sealing cover as follows 1. Place sealing washers or lock pins, respectively, into bearing surfaces. 2. Coat bearing saddle with Loctite 574 and fit saddle. Place...
Removal Hpj
2. Remove steering wheel. Observe safety precautions for airbag vehicles Repair Group 68 . For removal and installation of airbag steering wheel, refer to page 68 - 53. 3. Remove shrouding of airbag contact unit or steering column switch. 5. Remove steering column switch. Take off switch cover and steering lock shroud. 6. On vehicles with Keylock, remove the bowden cable for the steering lock. Before removing the cable, turn ignition key to II position ignition on . Then remove bowden cable...
Wheels and tires of the 968 CS
Wheels painted in body color. For black body color, wheels are painted silver. Wheel mounting nuts without theft protection apart from exceptions indicated . 7 1 2 J x 17 in., wheel offset 65 with 225 45 ZR 17 tires 9 J x 17 in., wheel offset 55 with 255 40 ZR 17 tires Observe country-specific usage details Difference angle at 20 turning radius 0 2 10 Vehicle Empty weight according to DIN 70020 with full fuel tank, spare wheel and tools Refer to instructions in Repair Manual for height...
Dismantling and assembling pistons connecting rod
Tightening torque 1 st stage 25 Nm 18 ftlb 2nd stage 1 x 90 tightening angle Threads and mating surface must be oiled lightly Lever out, making sure snap ring does not spring away, e.g. by covering with a rag Oil lightly. Observe installation position and tolerance groups Connecting rod with connecting rod bolts Observe matching number, identification S 3 engraved on side Piston ring, 1 st groove Plain compression ring with internal chamfer, 0.4 wide, 45 Piston ring, 2nd groove Taper faced ring...
Note Ijg
The control unit needs approx. 70 seconds to identify all faults in the system, and the ignition must therefore be switched on for at least this time to ensure that all poosible sources of defects can be checked. After a fault in the airbag system has been identified and rectified, the fault memory must be erased. Following an accident in which the airbag system was activated, the following components must be removed and replaced If non-activated airbag units have to be removed, they must be...
Adjusting ring gear
Determine total shim thickness S tot Si S2 . The ring gear must be readjusted if the transmission housing, transmission side cover, tapered roller bearings for differential, differential housing or drive set have been replaced. The drive pinion must be removed in order to determine the preload of the differential tapered roller bearings. 1. Make sure the bearing outer races of the tapered roller bearings are well seated in the transmission housing or transmission side cover, respectively. 2....
Changing the brake fluid bleeding the brakes
Use only new DOT brake fluid. Observe change intervals and brake fluid grade. Total brake fluid quantity for fluid change approx. 1 liter. On vehicles up to MY '92, the brake fluid must be replaced every 2 years as a minimum. As of MY '93, the brake fluid change interval has been increased to 3 years - along with the use of special DOT 4 brake fluid. The 3-year change interval is valid as of MY '93, but only in conjunction with the use of the special Porsche brake fluid. The brake fluid is...
Adjusting gearshift
1. Set manual shift lever No. 3 to idle position. The transverse selector shaft is now in the 3rd and 4th gear shift plane. With the gearshift mechanism adjusted correctly, the shift lever No. 3 is not Inclined in transverse direction. Undo lock nuts No. 1 and turn centerpiece of the joint rod No. 2 until no transverse inclination remains anymore at the shift lever No. 3 . 2. To adjust shift lever, move the shift lever support mount arrow to the front or rear until the inclination is 85'. The...
Fill In ATF fluid
With the engine stopped, start by adding ATF fluid via the quick-fill adapter up to mark 1 on the reservoir. A Quick-fill adapter B Filler hose C Filling mark With selector lever set to ,,P, start engine and let engine idle, observing ATF level at reservoir and topping up to mark 1 immediately if required.
Tiptronic warning lamp comes on transmission is in emergency mode
Detectable faults Open circuit, short to positive Pull off transmission connector. Measure voltage at pin M. System voltage 1 No voltage Pull off Tiptronic control unit connector. Check wiring from Tiptronic control unit pin 19 to transmission connector pin M. Wiring o.k. Tiptronic control unit faulty 2 Voltage cannot be switched off warning lamp does not come on when fault occurs Pull off Tiptronic control unit connector No voltage at pin M Tiptronic control unit faulty Voltage at pin M Short...
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 Voltage failure Term. 3 0 with active alarm system Luggage comp. open during activation Input 3 to positive during activation closed loop interrupted during activation Radio contact to ground during...
Possible cause 1
Accelerator cable adjusted incorrectly Accelerator cable adjusted incorrectly Adjust accelerator cable, refer to diagnosis item 8 Replace HCU Adjust accelerator cable Refer to diagnosis item 8 Full-load and kickdown shifts too lengthy Modulating pressure too high Damper faulty Friction discs damaged Damper faulty Modulating valve binding Pressure reducer valves 1 and 2 binding Modulating pressure too low Damper faulty Friction discs damaged Replace HCU Replace HCU Replace transmission Full-load...
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...
Instructions Nhk
Mark position of adhesive plate on outside of windshield. Cabriolet Dimension A 623 mm Dimension B 84 mm Coup Dimension A 623 mm Dimension B 142 mm Remove adhesive residue from windshield mechanically using a scraper. Remove adhesive residue from bonding plate of rearview mirror mechanically using a scraper. Roughen bonding plate of rearview mirror mechanically using sanding paper. Clean bonding plate of rearview mirror using cleaning solution A . Clean bonding area of windshield using cleaning...
Body dimensions
1 Center impact pipe absorber front 2 Front side member take-up hole 7 Platform lift take-up, Car jack, front 8 Platform lift take-up, Car jack, rear 10 Strengthening member take-up 12 Transmission support take-up 13 Rear side member take-up hole 14 Center impact pipe absorber rear
Camshaft references
Marking between thrust bearing and cam of cylinder 1 or on rear face Camshaft timing 1 mm stroke, zero clearance Inlet opens Inlet closes Exhaust opens Exhaust closes 7.5 CR after TDC 52 0 CR after BDC 31 CR bef. BDC 1 CR after TDC Inlet opens Inlet closes Exhaust opens Exhaust closes 7.5 CR bef. TDC 370 CR after BDC 31 0 CR bef. BDC 1 0 CR after TDC
Test point 0 K and L wire
The diagnostic connection between the Tiptronic control unit and the tester is made across the K and L wires. If it is not possible to start the diagnosis with the System Tester 9288, the following checks should be made 1 Check adapter lead 9288 1 for continuity - Check K and L wire at adapter lead 9288 1 for continuity. Socket 3 8-pin connector to pin 7 19-pin connector Socket 7 8-pin connector to pin 8 19-pin connector Bushing 3 L wire Bushing 7 K wire - Check ground and terminal 15 at...
Replacing part of door sill with side member and floor pan
The following body spare parts are required for this sectional repair A Floor pan center B Side member center C Web panel Replacing part of door sill with side member and floor pan Cutting part of door sill with side member and floor pan out of body Replacing part of door sill with side member and floor pan Cutting part of door sill with side member and floor pan out of body Remove all ancillaries and accessories, including the interior, from center body area and front fender area Place vehicle...
Wiring
Passenger compartment wiring harness for 968 CS 97-01 Repairing the Tiptronic wiring Routing the sensor wire at the Tiptronic Wiring diagram mod.'93 Wiring diagram mod. '94 Wiring diagram mod. '95 Passenger compartment wiring harness for 968 CS When replacing the passenger compartment wiring harness, the spare wiring harness must be modified as only the harness for the 968 is supplied by the spares department. Modifications are required at the clock connector. 1. Open 7-pin coupling housing...
Example
Rear left spring preload C is increased. This causes the wheel load - to be increased at LH rear C and RH front B - to be reduced at RH rear D and LH front A Increasing the built-in spring preload on one side raising the vehicle causes the wheel load to be increased. Reducing the built-in spring preload on one side lowering the vehicle causes the wheel load to be reduced. A change of the wheel load affects the diagonally opposite side of the other axle side. I.e. if the wheel load is reduced or...
ir
connection airbag wiring loom passenger compartment airbag warning lamp instrument cluster diagnosis plug CRASH SENSOR R amp T CRASH SENSOR RGTT CRASH SENSOR RO T CRASH SENSOR LEFT CRASH SENSOR LEFT CRASH SENSOR LEFT PASSENGER'S SCE. B4TEH TABLET 3 1 PASSENGER'S SEE. BNTON TABLET J 2 PASSEMR-S SCE. BfTEK TAfcET 2 1 PASSEICER'S SCE. BfTW T E1 2 2 OMR'S SC. STEM TABLET V2 DRWR'S SCE. Win TABLET VI welding point connection with feld indication i i connection with field data gp ground point ye...
Dismantling and assembling suspension
Taper of ball joint and operating lever must be gree from grease. Tighten to 50 Nm 37 ftlb Grease stem and threads with Optimoly HT. Coat stem of ball joint of axle strut with Tectyl underbody wax To remove the strut, the steering knuckle and the subsequent parts Nos. 22 to 26 do not have to be removed If the steering knuckle has been separated from the strut, the wheel alignment must be checked and or corrected Replace. Tighten to 120 Nm 88 ftlb Use only genuine bolt. Coat threads with...
Technical Data 968 968 CS
Brake booster light weight built Boost coefficient Brake master cylinder aluminum design 0 in mm Brake power regulator in rear axle circuit switchover pressure reduction coefficient Hydraulic dual-circuit brake system with black white , brake booster, vented brake discs with fixed caliper on front and rear axle. The pushrod brake circuit is allocated to the front wheels. The values in brackets are valid for the 968 968 CS models with M 030 special running gear. The brake disc used for the M 030...
Dismantling and assembling camshaft drive Tools
Toothed sector with hexagon bolt M 12 x 1.5x60 Assembly tool for toothed belt tensioner Dismantling and assembling camshaft drive
Checking idle and CO level of vehicles without catalytic converter Engine Type
No provisions for idle speed adjustment are made any more. Adjustment at the throttle body is therefore no longer performed. Perfect condition of the mechanical engine components. Loads must be turned off while adjustments are made. Perform adjustments as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would give faulty CO level readings. Ambient temperature 15 to 35 deg. C. 1. Warm up engine to operating temperature. Oil temperature 70 to 90 deg. C , check with...
Test point 13
Activation of AC relay Using the System Tester 9288, activation of the AC relay may be Fault code 1 29 checked directly in the Drive links menu item. If no sound is audible, check the following 1 AC switch signal DME plug disconnected, ignition on, connect voltmeter between terminal 40 and terminal 24. AC switch on Display approx. 12 Volt If not Check in accordance with wiring diagram If the air conditioning system is inoperative, the fault may be due to the 115 C coolant temperature switch. To...
Removing and installing torque converter Removing
1. Remove transmission refer to page 37-201 . 2. Remove converter, with transmission in horizontal position. Do not damage converter bearing assembly and rotary shaft seal. 1. Carefully insert converter, with transmission in horizontal position. Turn the converter to and fro until the gear toothing engages and the installation position is reached. 2. Make sure the converter does not drop out.
Fuel vacuum line routing Engine Type M 444344
A - Air flow meter B - Throttle body C - Idle speed positioner D - Inlet manifold E - Overflow valve F - Tank venting valve G - Vacuum valve H - Heating I - Brake booster K - Oil separator
Note Mkf
Check with Tester 9288 actual values . Store faults as of engine speed 2800 rpm 1 Pull connector off Tiptronic control unit. a Measure resistance between pin 2 and pin 38. Nominal value approx. 1.1 kfi b Check that pin 2 and pin 38 are free from shorts to ground. 2 Also pull off connector from speed sensor, transmission. Check for continuity at Tiptronic control unit connector pin 2 to speed sensor connector pin 1 Check for continuity at Tiptronic control unit connector pin 38 to speed sensor...
Fitting the camshafts
1. Rotate engine in direction of rotation to approx. 45 before firing TDC cylinder 1 . 2. Compress VarioCam camshaft adjuster and lock with Special Tool 9530. The oil check valve in the camshaft adjuster may drop out when the adjuster is compressed. Retain oil check valve and take it out if required. 3. Place inlet camshaft and exhaust camshaft into timing chain. Place both camshafts into timing chain in such a manner that the color marks or casting lugs line up with the chain links marked. The...
Removing and installing transmission
1. Remove rear muffler and heat shield. 2. Unbolt drive shafts on transmission side and suspend horizontally on vehicle. 3. Pull off rpm sensor inductive sensor and unclip wire from transmission housing. On USA vehicles, remove support at rear transmission cover. 4. Disconnect wiring connectors at transmission. 6. Disconnect selector lever cable from lever and bracket from transmission. The ball socket keeps the cable from jumping out of position. 7. Remove cover for service hole and undo...
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...
Crankcase Tools
Crankcase - Tools Printed in Germany - XI, 1994 Plastigage for measuring the bearing clearances V 161 - green V 162 - red V 163 - blue Commercially available, e.g. Matra-Werke Dieselstrasse 30 - 40. Frankfurt Main Retaining bracket for locking the flywheel Commercially available, e.g. Hazet 794-U-3
Operating instructions for System Tester 9288
The Systemtester 9288 BOSCH KTS 301 is a microprocessor-controlled self-diagnosis tester. All systems which have a diagnosis Interface as per ISO Standard can be tested with this tester. The following tests are possible Reading out the fault memory Sensor and status checks, tire-pressure monitoring RDK The Systemtester 9288 is a high-quality piece of electronic equipment. In order to prevent damage to the equipment as a result of improper use, please read the information in the operating...
Checking the ATF level
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 80C min. and max. marks. A Check range at 80'C ATF temperature B Quick-fill device To determine the precise ATF temperature, use System Tester 9288. If required, top up with ATF fluid across the quick-fill device.
Test point 6
Speed signal Using System Tester 9288, the speed signal may be read directly in Speedometer the Actual values menu item. As an alternative, check with an oscillo- To do so, connect oscilloscope to terminal 9 and terminal 24 of the control unit plug. Turn left front wheel manually. The following signal must now be displayed Fault, Fault Code Possible Causes, Elimination, Remarks Test point 7 sensor V Q Disconnect plug at air flow sensor, connect voltmeter to plug ter- Fault code 121 minais 2 and...
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 V Voltmeter ii Ohmmeter Oscilloscope V Voltmeter ii Ohmmeter Oscilloscope 41 Coolant temperature switch 115'C 42 Position...
Test point 17
Hall signal To check the Hall signal, disconnect plug at the cylinder head be- Fault code 1 34 hind the camshaft sprocket and insert 3-pin adapter lead VW 1501 . Connect oscilloscope to terminals 1 and 2 of the adapter lead, start If the Hall system is O.K., the following signal must be displayed Fault, Fault Code Possible Causes, Elimination, Remarks If the DME control unit detects a missing Hall signal, ignition timing is retarded by approx. 6 in all rpm ranges. Using the System Tester 9288,...
Test point 10
Ignition timing change Using the System Tester 9288, the ignition timing change signal may Fault code 1 26 be modified directly in the Input signals menu item. On Tiptronic vehicles, ignition is retarded when a gear change is made. When the Ignition timing change fault message occurs, check wiring continuity between DME plug and Tiptronic connector. DME control unit plug Pin 51, Tiptronic control unit plug Pin 32 Caution, observe connection between plugs. This fault causes the Tiptronic to...
Installation
1. Rotate flywheel until assembly mark roll pin hole with large chamfer points down. 1. The flywheel must be separated from the damper across the starter aperture 9 bolts . The clutch housing is unbolted from the engine and remains fixed to the central tube. 3. When fitting engine and clutch housing, make sure that both marks are lined up with each other. Tighten fastening bolts evenly. 4. Before installing the engine, coat the clutch housing engine bolts with Optimoly TA. Clutch housing to...
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....
Lifting the vehicle
The car jack, the trolley jack and the support plates of the lifting platform may only be used to lift the car at the jacking points shown below. The jacking point at the front side member may still be used to raise the vehicle on the lifting platform. Never raise the vehicle at the oil pan or the transmission since this may cause severe damage. Maintenance Working instruction Maintenance every 20,000 km 12,000 mis Type The terms inspect and check include all associated work such as...