Workshop
Manual
a
DR. ING. h. c. F. PORSCHE
a
Aktiengesellschaft
List of Repair Groups General
Technical
Data
Page 0.1 Group
Repair Groups Maintenance,
Self-diagnosis
03
Engine
Engine, Crankcase Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Air Flow Controlled Fuel Injection Exhaust System/Emission Controls Starter, Power Supply, Cruise Control Ignition System
10 13 15 17 19 20 24 26 27 28
Transmission
Clutch, Controls Torque Converter Manual Transmission, Controls, Case Manual Transmission, Gears, Shafts Automatic Transmission, Controls, Case Automatic Transmission, Gears, Valve Body Differential, Transaxle System
30 32 34 35 37 38 39
Chassis
Front Wheel Suspension Rear Wheel Suspension, Axle Shaft Wheels, Tires, Alignment Antiblock System Brakes, Mechanical Brakes, Hydraulics Steering
40 42 44 45 46 47 48
BUY
Body-Front Section Body-Center Section Body-Rear Section Lids Doors Hardtop Bumpers Glasses, Window Control Exterior Equipment Interior Equipment Seats Seat Covers
50 51 53 55 57 61 63 64 66 68 72 74
Heating, Ventilation, Air Condition
Heater Ventilation Air Conditioner
80 85 a7
Electrics
Instruments, Fuel Gauge, Alarm System Radio Windshield Wipers and Washer Exterior Lights, Lamps, Switches Interior Lights Wiring
90 91 92 94 96 97
Printed in Germany - Xx, 1987
928
Table of contents
Volume
VII
Wiring Wiring Wiring Wiring Wiring Wiring Wiring
diagram diagram diagram diagram diagram diagram
928 928 928 928 928 928
S4 Model 88 SWGT Model 89 S4IGT Model 90 S4/GT Model 91 GTS Model 93 GTS Model 9312
Table of contents Printed
in Germany
97 a7 97 97 97 97
-
281 309 339 367 397 427
1 - XXX,1992
929
Structure
of the WorkshoD
Manuel
Structure of the Workshop Manual This Workshop Manual describes all of the important operations for which special instructions are required to ensure proper completionThis manual is essential for shop foremen and mechanics who need this information to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply to all repairs on vehicles, without exception.
Breakdown of the Workshop Manual 1. 2. 3. 4. 5.
Overview of repair groups Record sheet for supplements List of contents Technical data Repair groups
Breakdown of the repair groups 1. 2. 3. 4. 5. 6.
a
Table of tightening torques Special tools required Exploded diagrams Legends for the exploded diagrams Notes on assembly/application of special tools Diagnosis for the repair groups
The Workshop Manual will be updated regularly by means of supplements which must be filed immediately to maintain the usefulness of the manual. Appropriate entries must be made in the record sheet to prove that the manual is complete. The content of this Workshop Manual will be supplemented which will be integrated into the manual from time to time. Descriptions
Structure
with Technical
Infomation
Bulletins,
of design and function can be found in the service training course reference material.
of the Workshop
Printed in Germany
- XXII. 1989
Manual
Structure
of the Workshoo
Manual
928
*
Layout of the exploded diagram
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A B C D E F G H
-
Y-,29 Do t?
wmunl..lon -&
Repair group, numbers Repair groups, text Type of vehicle to repaired Page number Operation Impressum, supplement number, year of printing Diagram item number in the order of disassembling Special notes to be observed when installing or removing
The notes on assembly/application of special tools which are given after the exploded always arranged in the order of text + diagram Structure
diagram are
of the Workshop Printed in Germany
Manual - XXII. 1989
WORKSHOP
MANUAL
928
This workshop manual describes all of the important operations for which special instructions are required to assure proper completion. This manual is essential for the shop foremen and mechanics, who need this information to keep the vehicles in a safe operating condition. The basic safety rules. of course, also apply to repairs on vehicles without exception.
The information is grouped according to repair numbers which are identical of the repair time and warranty code.
The repair group index. an alphabetical formation in the manual.
Descriptions
of design and function
index and the register
to the first two digits
table are quick guides to find in-
can be found in the service training
course reference
material.
This workshop manual will be kept up to date with workshop bulletins. which will be made part of the manual from time to time. We recommend that these workshop bulletins be filed in the special folder provided for this purpose.
SUPPLEMENTTO 928 REPAIR MANUAL
(XVIII)
Information Overview
Sheet of Repair
- Extension Manual
I
= Drive
Unit
Volume
I - A = Drive
Unit
II III
Volume Volume
IV
Volume
V
928 Repair
Manual
= Drive
Train
= Drive
Train
= Chassis,
Heating,
= Bodywork,
Air
Conditioning
Car Electrics
Volume
VI
= Car Electrics
(Circuit
Diagrams)
Volume
VII
= Car Electrics
(Circuit
Diagrams,
Please
file
the
to 7 Volumes
Volumes:
Volume
Volume
of the
pages in the volumes
of the Repair
'88 Models
Manual
as follows:
l.Please file pages 20 - 1 to 28 - 71 of the original the new Volume I-A - Drive Unit.
Volume
2.The new Volume VII Car Electrics (Circuit contains pages 97 - 281 to 97 - 305.
'88 Models
Diagrams,
Onward)
I - Drive
Onward)
Unit
in
List of Repair Groups General
Technical
Data
Page 0.1 Group
Repair Groups Selfdiagnosis
03
Engine
Engine, Crankcase Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Air Flow Controlled Fuel Injection Exhaust System/Emission Controls Starter, Power Supply, Cruise Control Ignition System
10 13 15 17 19 20 24 26 27 28
Transmission
Clutch, Controls Torque Converter Manual Transmission, Controls, Case Manual Transmission, Gears, Shafts Automatic Transmission, Controls, Case Automatic Transmission, Gears, Valve Body Differential, Transaxle System
30 32 34 35 37 38 39
Chassis
Front Wheel Suspension Rear Wheel Suspension, Axle Shaft Wheels, Tires, Alignment Antiblock System Brakes, Mechanical Brakes, Hydraulics Steering
40 42 44 45 46 47 48
Body
Body-Front Section Body-Center Section Bodv-Rear Section Lids. Doors Hardtop Bumpers Glasses, Window Control Exterior Equipment Interior Equipment Seats Seat Covers
50 51 53 55 57 61 63 64 66 68 72 74
Heating, Ventilation, Air Condition
Heater Ventilation Air Conditioner
80 85 87
Electrics
Instruments, Fuel Gauge, Alarm System Radio Windshield Wipers and Washer Exterior Lights, Lamps, Switches Interior Lights Wiring
so 91 92 94 96 97
Maintenance,
Printed in Germany
- XX, 1987
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
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928
Table of contents
Volume
I
Page
General International Unit System Lifting Car Technical Data, General Technical data - Type 928 GT - 89 model Technical Data - Type 928 GTS - 1992 Model Year
.O.Ol .O.l .0.3 .0.35 .0.36
Maintenance, Self-diagnosis LWEZKcontrol unit error diagnosis Connection in the 928 S 4 Starting error diagnosis Functional check of actuator and input signals Test code list System adaption Knock detection Trouble-shooting Error code list for the LH control unit Trouble-shooting, EZK control unit Error code list for the EZK control unit Resetting the error memory Operating instructions for system tester 9288
.03-l .03-3 ,035 .03-7 .03-13 .03-15 .03-17 .03-19 03-27 .03-29 .03-37 .03-39 .03-41
Engine ! Crankcase
0
Tolerances and wear limits Technical data Engine torque specifications Removing and installing engine Engine, removing and installing
Engine, Crankshaft,
1o-01 1O-02a 1O-03 10-l IO-11
Pistons
Tools ; Engine support (special tool 9188) Crankcase tools Disassembling and assembling crankcase and crankshaft Sealing upper and lower crankcase sections Checking crankshaft bearing clearance Installing crankshaft oil seals Installing upper and lower crankcase sections Machining flywheel Machining flywheel - 1984 models
13-I 13-2 13-3 13-4 13-7 13-8 13-9 13-10 13.IOb 13.10b
a
Table of contents Printed
in Germany
1 - XXVII, 1991
Volume
I
Table of contents
928 0 Page
Removing and installing flywheel ............................. Removing and installing pilot bearing ........................... Disassembling and assembling pistons and connecting rods .............. Installing piston and connecting rod ............................ Tolerance group of pistons and cylinders ......................... Checking connecting rod bearing clearance ....................... Replacing hefts for air pump, alternator and power steering pump ........... Checking and adjusting belt tightness ........................... Checking and adjusting tension of alternator poly-rib-heft ................ Replacing drive belts for alernator, power pump air, pump and A/C compressor Crankshaft tools ...................................... Installing flywheel stop ................................... Crankshaft journal sizes .................................. Checking piston and cylinder bore ............................ Piston arrangement .................................... Piston sizes, 84/85/86 models onward .......................... Notes for installing pistons (32 valve engines) ...................... Pistons, 87 models onward ................................ Checking pistons and cylinder bores (32~valve engines) ................. Checking pistons and cylinder bores Type 928 GTS (54 I) .............. Remachining cylinder bores ................................
Engine,~cylinder
....
13-11 13-11 13-13 13-15 13-16 13-16 : 13-17 13-18 13-18b 13-18~ 13-19 13-20 13-21 13-23 13.24a 13-24b 13-24~ 13-24~
0
13-246 13 - 24e 13-25
head, valves
Valve tools Disassembling and assembling valve drive Checking end play od camshaft Camshaft survey Disassembling and assembling valve train Disassembling and assembling valve drive Machining valve seats Checking valve guides Removing and installihg valve springs Checking and installing length of valve springs Removing and installing camshaft drive beit and water pump Installing camshaft drive belt and adjusting timing Drive belts with HTD teeth (beginning with 1983 models) Checking and adjusting drive belt Machining cylinder head Disassembling and assembling tensioning roller housing Bleeding tenisoning roller housing (from 1983 models) Disassembling and assembling tensioning roller housing
....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... .......
15-i 15-3 15-81 156g 15-7 15-8 15-8a i5-8a 15-8b 15-8b 15-9 15-14 15-16 15-17 15-19 15-20 15-23 15.24
a 2
Table of contents Printed in Germany - XXVII, Is91
928
Table of contents
Volume
I
Page Cylinder head tools ............................... Replacing valve guides ............................. Checking TDC marks on camshaft sprockets ................. Tools (32 valve engine) ............................. Checking and adjusting toothed belt ...................... Replacing toothed belt ............................. Tools - cylinder head (32 valve engines) .................... Disassembling and assembling cylinder head ................. Tools - cylinder head (32.valve enginges) ................... Tools-cylinder head, removing and installing valve springs ......... Removing and installing valve springs ..................... Removing and installing valve stem seal .................... Installing valve stem seal, ‘87 models onward ................. Checking valve guides ............................. Cylinder head - Tools replacing valve guides ................. Machining cylinder-head maiting face ..................... Checking valve seat wear limit ....... : ................. Checking and machining valve seats ..................... Valve dimensions 928 S ‘85/‘86 models onward ................ Checking and adjusting installation length of valve springs (32~valve engines) Tools-Installing cylinder head .......................... Modifications to the cylinder head (32 valve) ................. Cylinder head, installing ............................ Tools - Disassembling and assembling valve drive .............. Disassembling and assembling valve drive .................. Camshaft installation overview ......................... Camshaft installation overview Type 928 S4, 928 GTS (5,4 I) ........ Removing and installing camshafts ...................... Installing camshaft seal ............................. Removing and installing chain tensioner for camshafts ............ Camshaft setting, checking and adjusting ................... Cylinder head cover, dismantling and reassembling .............. 928 54 Club Sport-Version ........................... Camshaft installation .............................. Checking and/or adjusting camshaft settings ................. Checking and/or adjusting camshaft settings, Type 928 GTS (5,4 I)
Table of contents Printed
in Germany
.15-27 .15-28 .15-31 .15-101 15-102 .15-105 .15-109 .15-110 .15-112 .15-112a .15-112b .15-112b .15-112~ .15-1126 .15-112e .15-112j .15-113 .15-114 .15-115 .15-116 .15-116d .15-116e .15-117 .15-119 15-120 15-124 .15-124a .15-125 .15-128a .15-129 .15-131 .15-137 .15-139 .15-140 .15-141 .15-142
3 - XXVII, 1991
Volume
I
Table of contents
928
Page
Engine, Lubrification Removing and installing lubricating system pans Oil pump, removing and installing Replacing shaft seal for oil pump Lubrification system components, removing and installing Changing engine oil and engine oil filter Checking oil pressure Checking oil pressure Cleaning oil check valve for hydraulic valve tappets Cleaning of engine-oil system
17-l 17-6 17-6a 17-6b 17-7 17-8 17-9 17-10 17-11
Engine, Cooling Changing coolant and bleeding cooling system Chaning cooling and bleeding cooling system Changing coolant and bleeding cooling system Checking coolant system cap : Checking coolant thermostat Disassembling and assembling visco fan Disassembling and assembling thermOstat housing for cooling system (ATF) Disassembling and assembling thermostat housing for cooling system Disassembling and assembling thermostat housing for cooling system - Notes Cooling-air flap control, â&#x20AC;&#x2DC;87 models onward Tighening torques, overview Function charts Removing and installing cooling-air flap motor Removing and installing fans Removing and installing cooling-air flaps Troubleshooting Function-testing senders Function-testing flap positioning motor Function-testing the output stage
4
19-1 19-2 19.2a 19-2b 19-3 19-6 19-8 19-10 19-11 19-11 19-15 19-19 19-20 19-21 19-22 19-23 19-24 19-25
Table of contents Printed
in Germany
- XXVII, lB91
928
NEW
General
INTERNATIONAL
UNIT
SYSTEM
The â&#x20AC;&#x153;Legislation Concerning Units of Measurementâ&#x20AC;? was passed in the Federal Republic of Germany on July 5. 1910. The new units have to be applied in official and business transactions by the end of the allocated transition period on December 31. 1917 (some even earlier).
The new units are derived
Basic
from the international
system of basic units.
Units
Substance quantit
l Prinred in Germany
International
Cnit System
0.01
9 28
General
Decimal
multiples
and parts of units can be made by adding prefixes
in front of the unit symbols.
Prefixes
Examples:
1. Unit m (meter).
By adding prefix
k (kilo) we have km (kilometer
2. Unit s (second).
By adding prefix
m (milli)
0.02
International
Unit System
we have ms (millisecond
7 1,000 m).
= l/1000
s).
Primed in Germany