Page 1

Workshop

Manual

a

DR. ING. h. c. F. PORSCHE

a

Aktiengesellschaft


The Workshop Manual is only for the internal use of the Porsche Dealer Organization.

@ 1977

Dr. Ing. h.c. F. Porsche Aktiengesellschaft Sales, D-7140 Ludwigsburg

All rights reserved.

Printed in Germany

WKD 461 621 Print No. W 42-608-126-i

Xx, 1988


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


Workshop

Manual

srs

DR. ING. h. c. F. PORSCHE

Aktiengesellschaft


The Workshop Manual is only for the internal use of the Porsche Dealer Organization.

@ 1977

Dr. Ing. h.c. F. Porsche Aktiengesellschaft Sales, D-7140 Ludwigsburg

All rights reserved.

- Printed in Germany

WKD 461 621 Print No. W 42-606-126-l

XX, 1986


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

@)34

@ M.“Lw bn.ml*.lm. Co”uc4,.au

0

*11CmT.” 1

@334

@I M.“cdTnra”lMn.Cam,,.ce”

@L,. I I< @am¶ion -NW

16

A., ’ J *.

f-.; (7,

,QffL 3 511,

-f

“‘*$.$;p,” .-“\ ) r,$ .p

*p

6

SslliW nrg HBea.(W”hoM *cm.?

I 5 B 7

Warher FbngL smal

8 9

s-mm Bmmsr

0

FYllserbad -

2

ovids tute RCMVIhan _I

3

Raw Man sea

I

SmaM skew

snexl #“a

‘i

~,,.

4613 45

2 1

2I? 1 1s1417

..,..._:., ..mbllnp ~“Srnhlon d.rd ,_ & m”n.nbllq

DIY.umbllW .nd .urmllq II1,-1 n”mv.m,.laa

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


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


928

Gellera1

rlw iollo,i~~ing list is J rurvcy of in~purt2nt units usal 11-~~qucntly iu n~otor vcliiclc

List

of

repair upcralions.

L’nits

actor

Basic Unit

rngth

Other Acceptable

,U”L mm, etc.

Llnits

cm. dm, km

I No longer acceptable: p for 0.001 mm 0.001 mm - 1 ,Num

.z

rea

mm

2 . cm

9

dnr’ etc.

ohme

Nu longer acceptable: qm, qmm. qcm etc.

No longer acceptable: cbm. cmm, can etc.. Iti., Ltr. 11 = 1 dm3

:ane 3gle

rad (radiant)

’ (degree) ’ (minute) ” [secondj

1 tad = 1 m/m lo =T/l80

Iad

lo = 60' 1' = 60"

n not acceptable

llid 1gle

sr Isteradiant)

for inch

m2/m2

1 sr = 1 m2/rn2

g. mg. dag etc. t. kt, Mt etc.

No longer acceptable: pound, hundredweight. double-hundredweight

Weight is given in kg

Printed in Germany

International

Unit System

“.“3


928

General

For time data. e.g. abbreviated

in m

No longer acceptable: Sec., sec., hr.

No longer acceptable:

No longer acceptable: p. kp. Mp, dy”

atm. at. ata. atu. atu, InmHg. mrr.

essure or YaC”Um mus be specified, e.g.: 2 atii e. 2 bar pressure = 3 bar 0.4 atu so.4 vac”“m = 6 bar 5 ata s 5 bar

a

0.04

Internation

Unit System

Printed in Germany


928

Factor

General

Basic Unit

Other Acceptable

Units

Remarks

1 1 1 1

Mechanical stress (strength)

N/In2

Dynamic viscosity

N/m2 mbar bar = bar =

= 1 Pa = 100 Pa 2 1 kp/cm = 1 at 750 Torr

N/In2

No Ion er acceptable: kp/cm g , kp/mm’

mPa s. pPa s

No longer acceptable: P (Poise). cP. kg s/m’. dyn s/cd 1 Pa s = 10 P =s 0.1 kg s/m2

cm2/s.mm2/s

Kinematic viscosity

No longer acceptable: St (Stokes), cSt, E (Engler degree) 1 cm2/s = 1 St

No longer acceptable: kpm. kpcm. etc. 1 Nmr0.1 kpm 1 Nm = 1 kgm2/s2

Murk, energy8 heat quantity

I (Joule)

ml. kJ etc. Nm, kWh, Ws

No longer acceptable: kpm, erg. cal, kcal, PSh. We (thermal unit) 1 1: 1 Nm = 1 Ws 11~0.1 kpm 1 cal = 1 WE.a4.19 1 PSh =sO. 736 kii’h

Specific fuel consumption

<g/kWh

g/kWh.

iv juattj

mW. kW etc.

kg/J

No longer acceptable: g/PSh. kg/PSh

No longer acceptable: PS 1 PS --0.7X6

Printed in Germany

J

International

kW

Unit System

4 0.05


928

General

IFactur

llasic Unit

Otiw

Weight coefficient

kg/”

kg/k W

Temperature

K (Kelvin)

Acccptahli.

I~!nits

So longer acceptable: kg/i's

“C

so longtr acceptable: OK (deg’rtt Kcl,vin,, gtd. itemperature diiference, 1°C=lK

Electric cuuent strength

A (ampere j

PA,

Electric voltage

v (volt)

/uV, mV. etc.

Electric resistance

fL (Ohm)

ma

Electric charge. electrical quantity

C (Coulomb)

Ah, As

Electric capacitance

F (Farad)

PF, pF.

Sound level

phon

dB (decibel)

Light flux

Im (Lumen)

1 lm = 1 cd LI

Light intensity

I\ (LUX)

1 Ix = 1 in, a-

0.06

International

Unit Systsnl

mA etc.

, k-Q etc.

1 ” = 1 \:‘;A

lfi

= 1 V/A

lC=lAE

mF

1 F = 1 C,‘!.

Prinred I” Germany


928

General

LIFTING

1.

Lifting

CAR

with

--~ -4 ~;. ~.. ‘,p’ .__~

hoist

Only use lift points shown.

Caution When driving car on hoist platform, make sure that there is sufficient space between h&t and car.

‘<%A

) I!7’;’ 1 -*-7~~ q /+?-1 _,-. , _ . --, _ I- j

Front Y?w4

On car jack pick-up

point.

F‘-

!*

-

&

‘, ‘,,; -i, : .I 4) 1 1 .’ ‘1, .:‘/ ? :+I

p

I

/

..J--‘- ;

wmy!Ry On rear axle ccntrol

arm bracket.

-46

- _-~~ h-

-

f

0 Printed in Germany

Lifting Car

0.1


General

2.

Lifting

928

with

floor

jack

Side Front OI rear on pick-up points for car jack. Use an appropriate piece of wood between jack lifting plate and pick-up point.

(5 ,‘T --.$4

+J

,_S\

6”

(

XL?” fy

On CIOSSmember

for rear axle control

,,,

I

arm. P

Note Never raise car on engine oil pan or transmission. since this could cause serious damage.

0.2

Lifting

Car

Primed in Germany

--


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1990 Porsche 928 Service Repair Manual  
1990 Porsche 928 Service Repair Manual  
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