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Porsche 928 - WORKSHOP MANUAL 1977 Workshop Manual

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DR. ING. h. c. F. PORSCHE
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Summary of Contents for Porsche 928 - WORKSHOP MANUAL 1977

  • Page 1 Workshop Manual DR. ING. h. c. F. PORSCHE Aktiengesellschaft...
  • Page 2 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 Xx, 1988 All rights reserved. - Printed in Germany WKD 481 621 Print No. W 42-608-126-l...
  • Page 3 List of Repair Groups General Technical Data Page 0.1 Repair Groups Group Maintenance. Selfdiaanosis 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 lanition Svstem Transmission...

  • Page 4: Table Of Contents

    Table of contents Volume Page Front wheel suspension Technical data 40-01 ........Tightening torques 40-02 ........Notes on front axle, 86 models onward 40-04 ......Disassembling and assembling wheel suspension ..... 40-l Disassembling and assembling wheel suspension, until end of model year 85 ..40-2 Disassembling and assembling...
  • Page 5 Volume IV Table of contents Page Sample measuring card ........44-06 Alignment ......... 44-1 Checking wheel rims 44-6 ........General assembly information, tires ......44-7 Wheel balancing 44-10 ........Installing and removing wheels on car ......44-19 Tire pressure warning system - General ......
  • Page 6 contents Table of Volume Page Technical data as of MY ‘92 46-011 Checking thicknesss of brake pads 46-1 Removing and installing brake pads (Floating frame caliper disc brakes) 46-2 Removing and installing brake pads (floating caliper disc brakes) 46-5 Removing and installing brake pads (four-piston fixed caliper) 46-6b Removing and installing brake pedal 46-8...
  • Page 7 Volume IV Table of contents Page Bleeding steering system 48.8k Checking hydraulic function of steering (pressure test) 48-9 Removing and installing steering wheel 48-14 Repairing steering and intermediate shafts with steering tube 48-l 5 Replacing upper steering shaft bearing 48-30 Dismantling and assembling steering wheel height adjuster of airbag vehicles 48-33...
  • Page 8 Table of contents Volume Page 87-115 Adjusting temperature mixture flaps ......Pressure and temperature specifications ......87-116 87-118 Troubleshooting ........Auxiliary air conditioner 87-120 ........87-126 Removing and installing magnetic clutch ......Technical Data of air conditioning system as of MY ‘93 ....87-129 Table of contents Printed...

  • Page 9: Front Wheel Suspension

    Front Wheel Suspension TECHNICAL DATA Front Axle Suspension Independent suspension, double control arrr with coil spring and internal damper. Springs 1 coil spring per wheel Dampers Double-action hydraulic dampers Make/installation See page 40 - 51 Stabilizers until end of model year dia.
  • Page 10 Front Wheel Suspension TIGHTENING TORQUES FOR FRONT AXLE Location Description Thread Material Torque Nm (ftlb) Upper control Self-locking VM 14x1.5 140 (103) arm to body hex nut Lower control Hex bolt M 12x1.5 10.9 120 (88) arm to body, rear Lower control Hex bolt M 12x1.5...
  • Page 11 Front Wheel Suspension Location Description Thread Material Torque Nm (ftlb) Brake caliper Hex bolt M 12x1.5 85 (62) steering knuckle Panhead bolt Brake disk Countersunk 10 (7) wheel bolt Panhead bolt Panhead bolt 10.9 15 (11) clamping Wheel to wheel Wheel nut M 14x1.5 130 (95)

  • Page 12: Notes On Front Axle, 86 Models Onward

    Front Wheel Suspension NOTES ON FRONT AXLE, 86 MODELS ONWARD New front wheel suspension Printed in Germany Notes on Front Axle, 86 Models Onward - 04...
  • Page 13 Front Wheel Suspension Front Axle Modifications, Models Onward No./Description Most Important Modifications Remarks 1 Steering knuckle Attachment points brake Four-piston fixed caliper caliper, 86 models onward Studs wheel bearing (clearance and diameter outer bearing) Locator ball joint No. 10 of the mounting Outer wheel bearing...

  • Page 14: Models Onward

    Front Wheel Suspension No./Description Most Important Modifications Remarks Coil springs spring rate increased Only for Boge gas dampers. Combination with dampers up to 86 models or Bilstein dampers imper- missible P. 40 - 46 Stabilizer linkage longer than before P. 40 - 16/ 40 - 18 Stabilizer modified knuckle...
  • Page 15 Front Wheel Suspension TOOLS Description Special Tools Remarks Press-out tool VW 267 a Track rod puller e.g. Nexus 168 - 1 40 - 1 Printed in Germany - XIII, 1986 Disassembling and Assembling Wheel Suspension...
  • Page 16 Front Wheel Suspension &&& kZ%ZY -_ .cz& ~=L-‘-“/ ~$/g=+ -. ‘I -/ S\ ~, _ ‘2, ‘_ I* _ i ,;p: n” ‘/-&&A fT>- ‘; : *\, <;*., ,$ jq * a \U---fl I& 1: -, 5 23 22 40 - 2 Disassembling and Assembling Wheel...
  • Page 17 Front Wheel Suspension Note When: Description Removing Installing Locknut renew, torque: 46 Nm (33 fltb) Washer Flange locknut load ball joint renew, torque: 65 Nm (for steering axerting pressure (47 ftlb). Exert knuckles without Jpper control pressure on upper push-off lug for control arm to load...
  • Page 18 Front Wheel Suspension Note When: Description Removing Installing Hex bolt Stabilizer when replacing, do not linkage confuse with version 86 models onward. Installation overview, pages 40 - 16 to 40 - 18 Upper control inspect, renew if necessary, reworking is impermissible Spring strut Steering...
  • Page 19 Front Wheel Suspension Note When: Description lemoving Installing Clamp see pages 40 - 19 and 40 - 20 Locknut renew, torque: 46 Nm (33 ftlb) Hex bolt iex bolt Coat threads with (10.9, 80 nnn long] 3ptimoly HT (do not apply Optimoly HT to...
  • Page 20 Front Wheel Suspension Note When: Description Removing Installing Washer do not mix up with w;;x. 4 mm washer No. 20 dia. approx. 25 nm Guard Lower control renew if damage sus- with* pected. No reworking spoiler is permissible. securing bolts Tighten bolts No.

  • Page 21: Disassembling And Assembling Wheel Suspension (Before And After Model Year 86)

    Front Wheel Suspension ,+& c ‘-flGPJ ~._SZ &-- -_cc ,-/it =-.+:. --- -!i< ?2ygq) " M-13 > i I I~\;“~: _ <:',, ‘1 25 2423 1916 17 16 Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 7 Wheel Suspension, 86 Models Onward...
  • Page 22 Front Wheel Suspension Note When: Description Installing Removing Locknut Renew, torque: 46 Nm (33 ftlb) Washer Speed sensor :oat speed sensor hole in steering with O-ring mounting bolt knuckle with Molykote -0ngterm 2. Renew O- rina of soeed sensor. Tightening torque Illen-head bolt...
  • Page 23 Front Wheel Suspension Note When: Description lemoving Installing Washer only on rear control arm mounting Locknut renew, torque: 85 Nm (62 ftlb) Washer Rir guide plate Hex bolt Stabilizer link- when replacing, do not confuse with version cars earlier than 1986.
  • Page 24 Front Wheel Suspension Note When: Description ?emoving nstalling Locknut only slacken part enew, torque: 120 Nm of control arm with 38 ftlb) :lamp and ball joint [mounting) must be replaced Caster or camber oat sliding surfaces eccentric (outer f eccentric adjust- eccentric - camber...
  • Page 25 Front Wheel Suspension Note When: Description Lemoving Installing Hex bolt (10.9/ coat thread with Opti- 80 mm long) moly HT (Optimoly on bolt shank is im- permissible).* Screw in until only threads are visible. Do not tighten to 120 Mm (88 ftlb) until assembly is completed...
  • Page 26 25 as specified. locknuts When replacing, do not mix up with control arm for cars earlier than model year Part marked "Porsche" (before 86 model years, without Porsche inscription). Installation overview, see pages 40 - 16/ 40 - 17 40 - 12...
  • Page 27 Front Wheel Suspension INSTRUCTIONS FOR ASSEMBLY AND DISASSEMBLY Disassembling l.Unbolt brake caliper and move aside without imposing strain brake hose. Mounting: until end of model year ’ p!l!FF-/-- Z.Disconnect ground lead (86 models onward). Remove speed sensor. Mounting: 86 models onward Beforehand, open plug-in...
  • Page 28 Front Wheel Suspension 4.Use VW 267a to press out ball Installing joint. Take care not to damage protective caps of joints. Note: (Steering knuckle with cap nut, see page 40 - 25). collar nuts When using Optimoly HT or TA difficult to remove, assembly...
  • Page 29 Front Wheel Suspension Close slots outer cams (page 2.When installing lower control 40 - 23). arm, screw bolts of rear bearing clamp into body until only threads are visible. Do not tighten the two bolts specified torque until assembly is completed and springs have settled.

  • Page 30: Wheel Suspension Components - Installation Overview

    Lower control longer than 86 shorter than until models onward, end of model year identification bears marking "Porsche" inscrip- tion longer than shorter than until Track models onward end of model year shorter than 86 longer than...
  • Page 31 Wheel Suspension Version Version until end of model year 86 models onward 1 Upper control 2 Lower cdntrol No "Porsche" With "Porsche" inscription inscription Dim. X = 191 mm Dim. X = 179 arm 3 Track Dim. X approx. 245 mm Dim.
  • Page 32 Front Wheel Suspension Version Version until end of model year 86 models onward 4 Stabilizer linkage Spare Part No. (arrow) Spare Part No. (arrow) 928 343 069 00 928 343 069 01 Dim. X approx. 135 run Dim. X approx 142 rmn 5 Stabilizer Dim.

  • Page 33: Modifications To Mountings

    Front Wheel Suspension MODIFICATIONS TO MOUNTINGS/NOTES FOR REPLACEMENT Until model mounting: with trailing .,I..3 llYlll,l ball joints were installed on theYfFokraxle. A; of Seotemt )er 1983, steel mountings were used instead of aluminum. This change also necessitated a modification of the camber and caster eccentric retaining clamps.
  • Page 34 Front Wheel Suspension Mountings until Model Year (Parts Overview, page 40 - 19) Original Version Modified Version 3, ~~ G ,& 9 / ? \’ “-iF &A .-,: , A'-' 1" ‘“: 3+4” ,/- -\ 4 j4 4.J ,I’ The position of the eccentrics has been changed to suit...
  • Page 35 Front Wheel Suspension Mountings, Models Onward Parts Overview Mounting 928.341.049.08 Clamp, left 928.341.091.06 Clamp, right 928.341.092.06 Camber and caster 928.341.466.01 eccentrics As with the steel mountings in cars earlier than model year 86, the caster is set at the inner and the camber at the outer eccentric.

  • Page 36: Closing Slots In Ball Joints

    Front Wheel Suspension CLOSING SLOTS IN BALL JOINTS As of September 1982, plastic sealing cord is used to close the slots the outer setting eccentrics of the front-axle ball joints of new cars. this way, dirt is prevented from penetrating the joint, making eccentric...

  • Page 37: Inspecting Protective Caps Of Ball Joints On Control Arms And Track Rods

    Front Wheel Suspension INSPECTING PROTECTIVE CAPS OF BALL JOINTS ON CONTROL ARMS AND TRACK RODS The rubber protective caps of the front-axle ball joints may be damaged by external influences, e.g. flying stones, or during assembly. a protective cap is damaged, the joint in question - upper...

  • Page 38: Modified Steering Knuckle, Cars With Floating Brake Calipers

    Front Wheel Suspension MODIFIED STEERING KNUCKLE, CARS WITH FLOATING BRAKE CALIPERS To avoid damaging the rubber boot of the lower ball joint (mounting) with commercial puller, the steering knuckle has a press-off (only steering knuckles floating brake calipers). Steering knuckles without press-off lug have been discontinued...
  • Page 39 Front Wheel Suspension TOOLS i, 1 P__*- Description Special Tools Remarks VW 771 Multi-purpose tool Puller 9165 Pressure piece P 85 9154 Pressure piece Pressure plate VW 447 i Pressure piece VW 433 VW 511 Pressure plate 40 - 27 Printed in Germany - XIII, 1986...
  • Page 40 Front Wheel Suspension ’ lLi6 Notes: The exploded drawing shows the front-wheel bearing arrangement of cars with sliding calipers. the front axle is equipped with floating calipers, brake caliper, brake disk, guard and steering knuckle are of different appearance size. The following components of four-piston...

  • Page 41: Disassembling And Assembling Wheel Bearing

    Front Wheel Suspension Note When: Description Removing Installing Mounting bolt Coat threads with (hex bolts Optimoly HT. Torque: sliding 85 Nm (62 ftlb) floating calipers) (Panhead bolts four-piston fixed caliper) Spring washer Renew if necessary washer of four- piston fixed caliper Brake caliper Do not remove brake...
  • Page 42 Front Wheel Suspension Note When Description Removing Installing Front-wheel Clean centering (modified wheel surface brake bearing, disk and apply thin models onward. coat of Optimoly No. of teeth assembly paste. Pack impulse ring rheel bearing ABS: 45 instead wheel hub with Shell Retinax of 90).
  • Page 43 Front Wheel Suspension Note When: Description Removing Installing Bearing race for Heat wheel hub to Heat wheel hub to 120 inner wheel 120 to 150°C. Press to 150°C. Place bearing out with P 85 and position and press 9154. As of 8C with pressure plate...
  • Page 44 Front Wheel Suspension NOTES ON DISASSEMBLY AND ASSEMBLY Disassembling 4a.Cars earlier than end of model l.Drive hub cover with multi- year press bearing races purpose tool VW 771 and 9165. out of wheel hub. Bearing race for outer wheel bearing 2.Use a large screwdriver...
  • Page 45 Front Wheel Suspension 4b.86 models onward: place drift in each of the grooves in turn and drive bearing races out of hub. Note: The bearing race for the inner wheel bearing can be pressed using P 85 and 9154 as before (cars earlier than 86).
  • Page 46 Front Wheel Suspension 4.Press in radial seal until flush 6.Tighten cap bolt of clamping with hub. to 15 Nm (11 ftlb), without turning the clamping nut. 7.Recheck setting by moving thrust washer, readjust necessary. 5.Adjust front wheel bearing, noting the following points: Tighten clamping...
  • Page 47 Front Wheel Suspension TOOLS +-$I> ““““““““““““““““““““. Description Special Tools Remarks Press-out tool VW 267 a Tensioning device VW 340 Tensioiyng device Porche version manu- factured by Klann, desription/supplier see Workshop Manual (Workshop Equipment 3, Group 4). Sickle wrench Commercially avail- DIN 1810 dia.

  • Page 48: Removing And Installing Spring Strut

    Front Wheel Suspension REMOVING AND INSTALLING SPRING STRUT Removing l.Working from engine compartment, 3.Unscrew self-locking nuts from remove three self-locking nuts upper control arm (inside engine wheel arch. compartment). Z.Remove wheel, unscrew flange 4.Remove damper mounting bolt. lock nut and press upper ball joint...

  • Page 49: Disassembling And Assembling Non-Adjustable Spring Strut

    Front Wheel Suspension -’ I_ -5 4 -YaEuD -I-. 4zmps.p * “- Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 37 Non-Adjustable Spring Strut...
  • Page 50 Front Wheel Suspension Note When: Description Removing Installing Extend coil spring Renew and tighten Self-locking with VW 340 or 60 Nm (44 ftlb) Klann KL - 0014 Washer Damper mounting, Coat rubber bush dith Molykote upper Spring plate, upper Note arrangement Coil spring assembly...
  • Page 51 Front Wheel Suspension r---1 ‘* -y>-2 e-y-3 ” ib -4 6----- “” - ‘r ‘-7 ‘: 928 S 4 "Club Sport-Version" 2 Stop washers No. 8 in 1988 Disassembling and Assembling 40 - 39 Printed in Germany - XX, Adjustable Spring Strut...
  • Page 52 Front Wheel Suspension Note When: Description Removing Installing Self-locking Extend coil spring Renew and tighten with VW 340 or 60 Nm (44 ftlb) Klann KL-0014 Washer Damper mounting, Coat rubber bush upper with Molykote Spring plate, upper Ceil spring Note arrangement, tolerance group...

  • Page 53: Disassembling And Assembling Adjustable Spring Strut

    Front Wheel Suspension Note When: Description QtY. 1emoving Installing Grease thread, Adjustment cess and contact surface spring plate with Dptimoly Boge and Bilstein different Threaded ring Boge only. Install with inner bevel down. Coat thread with Optimoly Damper design modi- Damper fied, 86 models...
  • Page 54 Front Wheel Suspension NOTES ON DISASSEMBLY AND ASSEMBLY Disassembling VW 340 l.Mark position lower spring plate relative damper reinstallation. .-g- ” )’ 2.Using Porche version Klann spring ‘-‘ST 4 _’ tensioning device (see Workshop ,1 : -J-y .-. ‘..+ Manual) or VW 340, extend coil...
  • Page 55 Front Wheel Suspension Testing Dampers Because gas pressure, resis- tance increases as the piston Dampers can only be tested properly moves further into damper. on a testing machine. Dampers which Dampers which have been stored no longer perform adequately cannot lengthy periods should...
  • Page 56 Front Wheel Suspension Assembling N o t e (for information only) l.Note arrangement coil springs. During original assembly struts, adjuster mounted See P. 40 - 46 for adjustable as follows: spring strut. Boge spring strut: threaded ring See pp. 40 - 47 to 40 - 49 for non-adjustable spring...
  • Page 57 Front Wheel Suspension 4.Because 14" offset N ote: upper spring plate to mounting control arm) when Adjustable spring struts also be brought their installation strut installed, may be necessary determine positions by turning adjuster position lower spring (hold strut bottom). Turn direction which...
  • Page 58 Front Wheel Suspension COIL SPRINGS FOR ADJUSTABLE SPRING STRUTS Two types front-axle sprin s are available. The springs have different spring rates (spring hardness 7 . The springs color-coded. The springs with green and brown codes subdivided tolerance groups. When repairs carried out, always...

  • Page 59: Coil Springs For Adjustable Spring Struts

    Front Wheel Suspension COIL SPRINGS FOR NON-ADJUSTABLE SPRING STRUTS Three types front-axle springs available. The different types color-coded - blue, white, white/green. The springs with blue and white coding subdivided tolerance groups. When repairs carried out, always install springs with same color coding.
  • Page 60 Front Wheel Suspension 928.343.511.03 Coil Spring Part (white) Used 928/928 S with Boge dampers as of following chassis numbers: 928 Europe/rest world/Japan 92 A0 80 0646 928 USA 92 A0 81 0715 92 A0 82 0128 928 S Group Color code Installed Spring...
  • Page 61 Front Wheel Suspension Front Effect Height Axle Front Axle Springs a standard test length (e.g. Springs with approx. 200 N more force group increase height tolerance group springs as opposed front axle by approx. 5 - 15 mm. Spacer Placing a spacer beneath lower...

  • Page 62: Dampers - Installation Overview

    Front Wheel Suspension DAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES Front axle Rear axle ISinole oioe pipe )ie’ 'ressureless JGas pressure Boge Bilstein Non-adjustable front- Paint coding, axle spring strut Identification 9281928 black* standard black** 9281928 green green optional extra Adjustable front-...
  • Page 63 Rear wheel, suspension proPshaft Technical Data Rear Axle Wheel suspension Independent wheel suspension with lower diagonal suspension links and upper wishbones, coil springs and internal dampers. 1 coil spring per wheel Dampers double-action hydraulic dampers Make/Installation page 42 - 18 d Stabilizers 0 22.5 x 3.5 mm (tubular stabilizers) modified in course of model year 1981...
  • Page 64 Rear Wheel Suspension, Propshaft TIGHTENING TORQUES FOR REAR AXLE Location Description Thread Material Torque (ftlb) Tranverse member Hex bolt M 10 46 (33) body Light alloy casting Hex bolt M 10 46 (33) (suspension link bearing) lower control arm (86 models onward) body...
  • Page 65 Rear Wheel Suspension, Propshaft Location Description Thread Torque Material (ftlb) 58 (42) Rubber bushing Locknut 12 x 1.5 piston (spring strut) 85 (62) Transmission bearing Hex bolt M 12 x 1.5 rear-axle trans- verse member 46 (33) Stabilizer bearing Hex bolt M 10 body 46 (33)
  • Page 66 Rear Wheel Suspension. Axle Shaft TOOLS Remarks Special Tool Description V”. “I\’ 407 Punch VW 402 Thrust plate VI\’ 41s a Tube Vii’ 408 a Punch “1% 440 Support ring “h ,155 Thrust tube Part of VW 459 VW 459/2 Remover/installer P 2M Tllrust...
  • Page 67 RCBI Wheel Suspension. Axle Shaft ‘:ln ?Yf- ‘b ‘ ,* -1&j- j ,$ &p- ‘yI_ .,,, c,, *A i.‘? T+ : :b rn 42, 24-~ 31 ~ 42 - 2 I,i5ascnhlinc 3nd ,Asscnlhlins licar Surpnciiin Primmed in Germany...
  • Page 68 Rear Wheel Suspension, Axle Shaft Special Note When Description Instructions Installing Removing Replace if necessary. Self-locking Tighten to specified torque Washer Tighten to specified socket head bolt torque Check for damage Axle shaft Locknut Replace. tighten to specified torque Warhei Plug cover Locknut...
  • Page 69 Rear Wheel Suspension, Axle Shaft Special Note When: Removing Installing Instructions Description Straightening upper control arm permitted Position correctly upper arm mount Tighten to specified Bolt torque Washer Replace and tighten Locknut to specified torque Bolt Check for damage page 42 Stabilizer suspension Tighten to specified...
  • Page 70 Rear Wheel Suspension, Propshaft NOTES ON DISASSEMBLY AND ASSEMBLY Disassembling l.Remove propshaft with drive shaft. 5.Remove wheel carrier. 2.Remove brake caliper. 3.Take brake disk after removing countersunk screws. 4.Remove parking brake shoes expansion lever. Pull parking 6.Unscrew eccentric bolts brake cable guide stabilizer...
  • Page 71 Rear Wheel Suspension, Propshaft Notes Wheel 2.Coat shanks camber and track Suspension, eccentric bolts with Optimoly Models Onward. (instead of multi-purpose grease with MoS2) and coat thread with The exhaust system has been Optimoly HT. Apply a coating modified as of model year Molykote IJ to...
  • Page 72 Rear Wheel Suspension, Axle Shaft TOOLS Remarks Description ipecial Tool N”. VW 407 Punrh VW 441 Base plate VW 244 b Drive sleeve Tube VW 415 a Standard Extractor Printed in Germany Disanrvnhling and Asscmhling llub Assembly 42 - 7...

  • Page 73: Rear Wheel Suspension, Axle Shaft

    Rear Wheel Suspension, Shaft Axle pcz’“‘:, _ 42 - 8 Disassembling and Assembling Assembly Printed in Germany...
  • Page 74 Hear WbEe.1 Suspension, Anlc Shaft Special C;ote wren Description Installing Instructions izelmoving Replace if necerrary, Self-locking tighten to specified turqw Washer head boll Tighten to specified Socket torque Check for damage Axle shaft wt’hce1 hub Press off with Press on wit11 whereby VW 244b VW 244 b.
  • Page 75 Rear \\‘hccl Suspension. Aulc Shalt l,,SrASSC\,li,.,NG AN,, ASSEhliiLiSG liLI:i hSS,:Vli,.Y Disassembling 1. Prerr out rchcel hub with VII’ X4 b and suitable barc pl;itL% 4. Press hearing inner iace off of wheel hub with an extractor and Special Tool VW 407. 2.

  • Page 76: Disassembling And Assembling Hub Assembly

    Rear Wheel Suspension. Axle Shaft Assembling 1. Heat hub carrier to 120 - 150° C (248 - 302’ F). install ball bearing and then pres on slightly. L ,- $ ,! me- VW441 --+c- %.r Ah I_ a-a:. At- . i 2.
  • Page 77 Rear Wheel Suspension, Axle Shaft REPLACING LOWER DIAGONAL CONTROL ARM LINK PIN J b- z,:.;! Removing 1. Remove bolt from link pin. 2. Place lower control arm on Special Tool VW 402. Press cut link pin with Special Tool VW 407. <*-.

  • Page 78: Replacing Upper Control Arm Mount

    Rear Wheel Suspension, Axle Shaft REPLACING UPPER CONTROL ARM MOUNT Removing Installing Press out mount with Special Tool VW 408a. using Press in mount, using waxfree Capella Oil B Special Tool VW 415 a as a base. ITexaco) and Special Tools VW 415 a and 408 a Position correctly.

  • Page 79: Removing And Installing Spring Strut

    Rear Wheel Suspension, Axle Shaft REMOVING INSTALLING SPRING STRUT Removing Installing 1. Replace self-locking nuts. Check spring 1. Unscrew three self-locking nuts from spring strut in luggage compartment. strut seal, making a new permanently elastic seal on the mounting plate 300mm long and circular in shape with, for example,...
  • Page 80 Rear Wheel Suspension, Propshaft TOOLS Description Special Tools Remarks VW 340 Tensioning device Tensioiyng device Porsche version Klann, see Workshop Manual (Workshop Equipment group description/ supplier. Sickle wrench commercially available, DIN 1810 e.g. Saltus dia. 80/90 XIII, 1986 42 - 15...
  • Page 81 Rear Wheel Suspension. Axle Shaft r --7 ,~s+-----6 ~..T-, r( - -3 i.~ J 16---i-> Printed in Germany 42 - 16 Disassembling and Assembling Spring Strut...

  • Page 82: Disassembling And Assembling Spring Strut

    Rear Wheel Suspension, Propshaft Note When: Description Removing Installing Locknut renew, torque: 46 Nm fltb) Washer Cover Dirt excluder Locknut jtretch coil spring renew, torque: 58 Nm rith VW 340 or Klann ftlb) :L - 0014 Washer Mounting plate Rubber coat with Molykote...
  • Page 83 Rear Wheel Suspension, Propshaft Note When: Installing Description Removing Circlip Check installation Secondary spring position stop Install with grooves down Lower spring Coat contact surface adjuster with plate Optimoly Note remarks on page 42 - 18c Boge only Support cover Coat thread with...
  • Page 84 Rear Wheel Suspension, Propshaft NOTES ON DISASSEMBLY AND ASSEMBLY Disassembling Testing Dampers l.Using Porsche-version Klann Dampers can only be tested properly spring tensioning device (see on a test bench. Although ineffi- Workshop Manual) or VW 340, cient dampers cannot be identified,...
  • Page 85 Rear Wheel Suspension, Propshaft piston increases as the Assembling moves into damper. dampers have been stored a long time, Rear-axle springs available pump in and out several times three versions. versions installation position. color-coded. Replace leaky dampers. The springs with green, yellow dampers...
  • Page 86 Rear Wheel Suspension, Propshaft Coil spring (yellow) 928/928 S from 79 models until current 84 model year (see note below), Part No. 928.333.531.12 L1 = F where Color Order 253.5 code index 2 1 yellow yellow 4710 4811 ..4810 ..4910 4911 .

  • Page 87: Damper Installation Overview

    Rear Wheel Suspension, Propshaft DAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES Yllb UnIF Rear axle Single pipe Bbge Bilstein Non-adjustable front- Paint coding, axle spring strut Identification 928/928 black* black** standard 928/928 green green optional extra Adjustable front- axle spring strut black*...

  • Page 88: Removing And Installing Axle Shaft

    Rear Wheel Suspension, Axle Shaft REMOVING AND INSTALLING AXLE SHAFT Axle Shaft Bolted Both Sides Axle Shaft Welded Side Removing Removing 1. Remove socket head bolts on transmission 1. Remove cylinder head bolts on transmission and wheel ends. and self-locking nut on wheel end.
  • Page 89 Rear Wheel Suspension. Axle Shaft TOOLS Remarks pecial Tool Descriprion VW 161 a Circlip pliers VW 408 a Punch VW 401 Plate VW 455 .ueeYe Printed in Germany _ 11, 1!)7g 42 - 21 Disassembling and Assembling Axle Shaft...
  • Page 90 !I 2x J ..= i:cdc \$r~~cl Suapvnsion. Arlc Sllafr -~,. ~.-. ,, (v . . 1 6”. Tg%&j. .‘! ‘J’!$ :; ,,>“a .~ : <-- :<,_:7 ‘y$y=-, ‘: ‘zd -=5y ‘---. Printed in Germany Disassembling and Assembling Axle Shaft 42 - 22...
  • Page 91 Rear Wheel Suspension. Axle Shaft Note When Special Description Q’y. Removing Installing Instrucrions Circlip Replace, make sure of c011ect Constant velocity joint Pack 80 grams of grease in each joint groove on outside diameter of joinr to ourside of propeller shaft.
  • Page 92 Rear Wheel Suspension. Axle Shaft DISASSEMBLING ASSEMBLING AXLE SHAF’I Assembling Disassembling 1. Seal large diameter end of new dust boor with 1. Clamp axle shaft in a vise fitted with soft an adhesive. This requires that seats of sealing jaws. Range and boor be clean and free of grease.
  • Page 93 Rear Wheel Suspension, Axle Shaft Press constant velocity joinr on 10 shall. Install a Disassembling Assembling Consianr new circlip. Velocity Join, Disassembling loin1 musl be disassembled TO replace grease when seriously conraminared or when bearing surfaces and balls have ro be inspected for wear or darnaxe 1.
  • Page 94 A.$~ lh':~; i"I~cc~l Suwe tbrir,n. *xlc Sl~nlr !I 28 -.. -. _,,. ^.__” -.. .- .-. ,-~ .._ _---_T1__ ._I -... -- ~. -*-.- _.“~---.----.---- 2. ‘Tilt ll;lil jhlll% !,‘,I IIS I,+ c,L:r II ’ ,!I! :sl:~u,+: ,I_ Ilisrnil II/II- Willl “i;” anti iYll,\ ia, )<~‘I,, ,“““‘i,,;~ (niiows~.
  • Page 95 Rear Wheel Suspension. Propeller Shall 5. Swing in ball hub with cage. TO accomplish Check funcrion of joint. Constanr velocity this, swing out hub from cage so far that balls joint has been assembled carrecrly, if ball are at same distance as orbits (arrows). hub can be pushed back and forrh by hand over rhe entire axial compensarion distance.
  • Page 96 .f.$ ilr;,, \,‘,!r,c, c>I.:,I-f.Qi bY,C s,,:,,, !I 2 s ,_.. --...-. _,..-. --_- XI:h,ii”,NC1 AN” INS7 A,.L.I‘li~ ,‘I ” 5. Dicrnnncct 2x1~ sIIwII% :\I Ir:~~iimii~inr :is:il ‘itic-. Removing pend from wilt in iwri :wlill pi>ilii<,r 0 ,m ,r axle CTO>, ln,r,l!l’<r. 1.
  • Page 97 Rear Ik’hecl S~irpc~~i~ol~. lxic ?I~.itt ~. I Il\<‘rch I\\<, i11l,lllilll1~ IhClll’ (1, rear ilX,C CIOS? I,‘. l’,n<c fl”“i llnd‘rnratil Til‘,T ;3x,e <rm, ,,,c,,:,>cr ,,r ,re,, 85 Ib,5 IhililS IOf tr:l,,s”,,~<,<m Ill~l~!hsx. Al.?,l p”i,tilrn of r(‘llr axle cmsi 111’W,,,‘. mcmkr. JPC~,IC~VC rc~r~.~lwillg -I halt<...
  • Page 98 Rear Wheel Suspension, Propeller Shaft 2. Move in rear axle. Install mounting bolts and align axle to original position as marked. Tighten bolts IO specified rorque. 3. Align transmission suspension (see point 8. ). Refer CO Group 34 if nanmission suspensiorl has to be completely aligned,...
  • Page 99 Owner’s Manual. Always use the new tire pressures indicated above. Relevant adhesive labels are available from all official Porsche dealers. In some cases, only allowed up to 2.5 bar (36 psi) in the U.S.A. This depends on the tire in question since earlier tires have a sidewall lettering that limits the admissible tire inflation pressure (max.
  • Page 100 Porsche from other versions of identical tire type and the same tire size. The tires approved by Porsche are also identified in the corresponding NO, Nl and N2 tires must not be mixed on one and the same vehicle, even if they are of the same make.
  • Page 101 Wheels, Tires, Alignment the 17 Inch Wheels (Cup Design) to the Vehicle Fitting Important note On the 17” Cup Design wheels, the valve (No. 1) and the locking wheel nut cannot be Fitting (and tightening) procedures of all arranged on the same side (as on previous other wheel types (16lnch Deslgn 90 etc.) models).
  • Page 102 Wheels, Tires, Alignment data Wheel alignment measuring The following values apply at empty weight in accordance with German DIN 70020 standard (car with full fuel tank, spare wheel and tools). Adjustment values Max. difference and tolerance between left/right Front axle HeigM adjustment: From wheel contact patch to 180+20mm’...
  • Page 103 Wheels. Tires. Allanment Specimen measuring chart* Pa...:. Yshic.: All POrBcheTypes928 LICMCL Illme NO: mil.rlt.: oata: ..“..d by: RlrnS Md ll,LI !Fa2$’ MEASURING CHART “en,& Empty 1e1 1 sccodng DiRsrani* mg,. -3 200 tYlnine .di”, to 8,. x020 pm I”,, IYe, Ian”, Ipsrl d?..
  • Page 104 Wheels, Tires, Alignment Wheel alignment measuring data The following values apply at empty weight in full fuel tank, spare wheel and tools). Adjustment values Max. difference and tolerance between left/riaht Front axle Height adjustment: (@pz- 10mm From wheel contact patch to Measuring surface on rear control arm p Toe-in, no pressure applied - l’f...
  • Page 105 Wheels, Tires, Alignment Specimen measuring chart* MEASURING &ART Rlmr and t,r.r i,..~.., 1 :oe,rr &Td;;b’“‘~ I----I I :- ‘“’ ‘ ‘0 Q IT Jf ’ 2j ; 1 g 0% j” :. : 1 2 3 i 0’ ’ The caster adjustment setting has been changed for 1991 models on to 4’ + 1’ (previously 3’...
  • Page 106 Alignment General Use an optical or electronic axie measuring device to align the vehicle. Refer to the operating instruc- tions for the axie measuring device for the measuring procedure. The following precondtions must be fulfilled before starting alignment: Vehicle at curb weight as per DIN 70020, Le. ready for the road with full tank, spare wheel and tads.
  • Page 107 Wheels, Tires, Alignment Important notes for alignment The following must be observed during alignment: fnfloenced vehicle height 1. Actual vehicle height 2. Height setting / alteration in wheel load Existing height value after the vehide or front axle have been raised. Never use this height value as a starting point.
  • Page 108 Wheels, Tires, Alignment For the pulling down procedure, fasten the An alteration in wheel load always acts on the engine support (prop device) lo-222 A to the wheel diagonally opposite. In other words, if stabilizer. Use suitable hooks or straps. The the wheel load of one wheel is increased or transport lugs (strap No.
  • Page 109 Wheels,Tlres, Alignment 2a) If Check/adjust height the vehicle height at the front axle is deter- Note mined by the coil spring and cannot be ad- justed. It is only possible to make a correc- The adjustment facility is used to correct dif- tion by replacing the front axle coil springs ferences between left and right wheel loads.
  • Page 110 Wheels, Tires, Alignment Rear axle 1. At actual vehicle helght (Page 44 - 2 I44 - 2a) measure from tire contact surface to measurlng polnt on the cross member. Note If Bilstein spring struts are installed, the adju- sting range for lowering the vehicle is limited by a stop for the adiustinq If Boae srxina nut.
  • Page 111 Wheels, Tires, Alignment Wheel alignment values Important notes Note Only check and/or adjust wheel alignment If vehicles have aluminium joint ceniers, values if the specified preconditions have always turn the caster eccentric from small been fulfilled (Page 44 - 1 under general) and values towards large caster values, i.e.
  • Page 112 Wheels, Tires. Alianment Adjusting toe Rear axle Preparation: Center steering gear wfth Adjust camber Special Tool 9116. If the steering wheel is The camber is adjusted by means of an eccen- offset, relocate at the best value. tric screw on the inner link bearing. Then remove Special Tool 9 7 16.

  • Page 113: Checking Wheel Rims

    Wheels, Tires, Axle Alignment CHECKING WHEEL RIMS Refer to drawing for lateral and radial runout measuring points on inside of rim. Max. permissible lateral and radial runout aluminum rims = 1.0 mm Max. permissible lateral and radial runout rim with tire = 1 .25 mm lalso refer to page 44 - 8) Note...
  • Page 114 Wheels. Tires. Allrrnment General assembly information, tires Always use new rubber valves when replacing tires. Attention: When flttlng tires, always comply with any Instructions on the slde walls wlth regard to dlrection of rotatlon or side-specific assembly (e.g. arrow or “outer/Inner”) When fitting tubeless tires, check that the sealing areas of the tire and the disk wheel are clean and look for any damage.

  • Page 115: General Assembly Information, Tires

    Wheels, Tires, Alignment Mount the tire in a beneficial position to the rim (matching) in order to achieve optimum smooth run- ning. The following text describes both uncontrolled matching and controlled matching with identifica- tion marking or using a wheel-balancing machine with matching program. Afterfitting, inflate tubeless tires to appmx.
  • Page 116 Wheels, Tires. Allanment Cast fight-alloy disk wheels must not be fitted to the vehicles with four-piston fixed ca/ipers (as from Model 86). Club Sport version wheels (larger cutouts) have a different rim offset (see Page 44-01). New tires should always be fitted to the front axle wherever possible (V the same wheels are fiied to rear and front axles), as 1.
  • Page 117 Wheels, Tires, Alignment Wheel balancing General If the wheels are too unbalanced. this not only causes vibrations and shaking of the steering wheel but also results in higher wear on various chassis components. Even if wheels are balanced correct/y, uneven running and steering can be caused by excessive geometry faults (radial and lateral run-out) and irregularities in tires, e.g.
  • Page 118 Wheels, Tires, Alignment Procedure for optlmblng the wheels The complete procedure is subdivided into 4 working steps 1. Fitting the tire to the rim 2. Stationary balancing of the wheel (eliminating static and dynamic imbalance) with optimization of smooth running 3.
  • Page 119 Center from the inside outwards using a stepped ring (cylindrical ring commercially available Porsche version, e.g. from Messrs. Schenck or Messrs. Hofmann). Do not center from the outside as we// d) Clamp the wheel onto the balancing machine as specified (valve always pointing upwards, the...
  • Page 120 Wheels, Tires, Alianment Further to 3: (Fitting the wheel to the vehicle) Fasten the wheel to the wheel hub as prescribed (also see Page 44 - 9 - General assembly instmc- tions, tires). Always fit the best wheels on the left. - Valve must point up or, for 17.inch Cup Design wheels, down (same position as on the balancing equipment).
  • Page 121 Wheels, Tires, Alignment Mounting points for fine balancing Front axle As from Mod. 136 before Mod 86 at the outer eccenter (arrow) ‘, j .L, 7.. ,.,. : ..urc’. “~; /,’ ‘1 J .~*.: ,I .2;;* - .‘l,& ‘c ‘,” Rear axle When using the Hofmann finish balancer, use the special mounting forks with spigots (Hofmann Part No.

  • Page 122: Wheel Balancing

    Wheels, Tires, Alignment Further to 4 a: (Fine balancing of the front wheels) - Position one or both measuring jacks (see mounting points). - Set the sensitivity controller to position 5.5 for Hofmann, or 5 for Schenck. Make a measurement run.
  • Page 123 Wheels, Tires, Alignment Further to 4 b: (Fine balancing of the rear wheels) - Position measuring jack right and left (see mounting points).The driven axle may only be balanced if both wheels are jacked up simultaneously. - Set the sensitivity controller to position 3 for Schenck or 3.5 for Hofmann Make a measurement run at a speed of 130 km/h or 1150 1200 rpm (wheel rotations) with the Schenck RAW 04, in top gear or in the top driving position.
  • Page 124 Wheels, Tires, Alignment Notes for fitting the self-adhesive Notes for fitting the clamp weights weights - When fling clamp weights, unseat the tire Determine the precise location of the balance with a tire caliper after letting out the air. weights (possibly by fitting balance weights provisionally with tape until the correct posi- - Use a tire unseating caliper for this, e.g.
  • Page 125 Wheels, Tires, Allgnment Tire fitting The following assembly and dlsmantling procedures refer to the 17-inch Cup Design wheels with asymmetrlc hump. Notes I tools Tire assembly Avoid damaging the wheel paintwork. Fit wheel to assembly stand and coat in- side of wheel and both tire beads with tire To remove 1 fit a tire.
  • Page 126 Wheels, Tires, Alignment To facilitate assembly, position the addi- When starting to fit the second bead, the assembly arm should be located opposite tional tire lever below the hump. the valve. Then place the second bead as flat as possible onto the wheel, guide it across the assembly head and tie it down with Special Tool 9539, keeping it offset by approx.
  • Page 127 Wheels, Tires. Alignment Lift the flrst side of the tire over the as- sembly head (Fig. 1017 44). Place a rag or a leather cloth between the wheel and the tire lever. In addition, make sure the tire remains in the drop center opposite the disassembly head (Fig.
  • Page 128 Wheels, Tires, Axle Alignment INSTALLING REMOVING WHEELS ON CAR General Information: Aluminum wheel nuts may only be loosened and tightened with Special Tool P 300. Aluminum wheel nuts could shear through: use of unsuitable tools (wheel nuts held by only about 2/3rds of total depth),...
  • Page 129 Wheels, Tires. Axle Alignment Delivery Supply Sources Sauer-Werkzeug GmbH & Co. KG Humboldrtr. 2000 Hamburg Tel.: 040/223322 2296666 Telex: 214120 Order Numbers: 303 017 - Compass raw 17.5 303 161 -Adapter, size 1 or on commercial market Manufacturer: The Cooper Group Deutschland GmbH...
  • Page 130 Wheels. Tires. Alianment Tire pressure warning system - General General A tire pressure warning system is fitted to 928 S 4 vehicles as standard, from Mod. 1989 onwards, initially excluding USA and Canada, however. The tire pressure warning system is another development which constitutes a significant contribution towards road safety.
  • Page 131 Wheels, Tires, Alignment Tire pressure warning system - Uiagramatic view l- Control unit 4 - ABS control unit 2 - Instrument cluster 5 - 2 pressure-operated switches per wheel Arrow = Display boxes for the information (offset by 180”) system (fault display - tire pressure warning system) 6 - 1 HF sensor per wheel (high frequency sensor)
  • Page 132 Wheels, Tires, Alianment Tire pressure warning system Description Two pressure-sensitive switches are allocated to each wheel, fitted to the rim well, 180” apart. The pressure-sensitiie switches are subjected to the tire inflation pressure and act as switches for a reso- nant electric circuit, integrated pthe The resonant circuit remains closed as long as the tire inflation pressure remains above a specific setpoint value for the switch.
  • Page 133 Wheels, Tires, Alignment Tire pressure warning system components ~---.- ----- ” , ., ,,,“,,, .“’ liXOP -c+. ss-~- ‘I $‘\ 6 - Pressure-operated switch 1 - Control unit (Position see page 44 - 33) 2.5 bar, front 2 - Instrument cluster 7 - Pressure-operated switch 3 Deflector for pressure-operated switch 3.0 bar, rear...
  • Page 134 Wheels. Tires. Alicmment RDK - possible fault displays and their causes Possible RDK fault displays Tire pressure at each wheel is monitored by two pressure sensing switches installed in the wheel. If the tire oressure droos below the nominal value to which the oressure sensina switch is set, or if a fault develops.
  • Page 135 Wheels, Tires, Alignment 8 F3 r’ z .- E “, iti;; g’; I! 2 .- 3 ;z ii 3 E ,E 1 XL 3 7 I E ,E, U,’ 24 +I ;i;& Es?+ n m 3 G ‘5 .“SB “,h %S”, z3.3 * m r...
  • Page 136 Wheels, Tires, Alignment Tire pressures on cars with RDK Important notes The tire pressure control system takes the effect of tire temperature on tire pressure into account. Despite this, if is possible for the tire not to reach the nominal pressure only in a particularvehicle operating situation.
  • Page 137 Wheels, Tires, Alignment A: Conventional adjustment of tire pressure if the “Pressure Loss” fault display appears, tire pressure at the affected wheel must be increased by 0.3 bar or at least to the specified pressure at that wheel. Since diffusion losses are approxi- mately the same at the two wheels on any one axle, the tire pressure at the other wheel should therefore be increased by the same amouint.
  • Page 138 To avoid this problem, tire pressures in the workshop should always be adjusted as follows with the Porsche 9288 system tester, and not with a conventional tire pressure gauge: 1. Connect the Porsche 9298 system tester and select the RDK control unit. 2. Call up the “Switch inputs” menu with the “Pressure Switch” display.
  • Page 139 Wheels, Tires, Alignment Quick test of RDK Whenever a wheel or tire is changed, it is essential lo perform a quick test of the tire pressure con- trol system. If only one wheel was removed, the quick RDK test need only be performed at this wheel. A short test drive for a distance of at least 20 meters, at a road speed of 5 and 4Uph and at the following tire pressures is sufficient:...
  • Page 140 Wheels, Tires, Alignment Removing and installing pressure-operated switches (tire pressure warning system) Special tools Removing and installing pressure-operated switches (tire pressure warning system) 44 - 29 Printed in Germany - XXII,1989...
  • Page 141 Wheels, Tires, Alignment Removing and installing pressure-operated switch (tire pressure warning system) Important note/preparation The tire must be removed from the rim before removing or installing a pressure-operated switch. The following points must be observed under all circumstances when dismounting or mounting the tire: - Clean dirty wheels before removing the tire.
  • Page 142 Wheels, Tires, Alignment Removing and installing pressure-operated switches tire pressure warning system) 1. Turn the rim and clamp onto mounting unit. Remove the deflector from the pressure- operated switch. 2. Remove pressure-operated switch with Special Tool 9274/9273. Hold the pressure- operated switch with Special Tool 9273 while undoing fastening nut.
  • Page 143 Wheels, Tires, Alignment Removing and installing high-frequency sensor (tire pressure warning system) Notes The front and rear high-frequency sensors (HF sensors) (2) have different cable lengths. The rear sensors have shorter cables. The distance between HF sensor (2) and the pressure-operated switch (3) is approx. 6 2 2 mm This distance is maintained as long as the HF sensor holder is not out of shape.
  • Page 144 Wheels, Tires, Alignment Removing and installing RDK control unit Notes The RDK control unit is in the footwell on the driver’s side, above the base of the storage compart- ment. On right-hand drive cars, the RDK control unit is attached to the right side panel in the driver’s footwell.
  • Page 145 Wheels, Tires, Alignment Connections at RDK control unit plug 1 Data line to 20 Data line to diagnosis (K) instrument cluster 21 not in use Plug 2 PIN 10 22 to alternator, terminal 61 2 Data line to 23 not in use instrument cluster Plug 2 PIN 11 24 not in use...
  • Page 146 Wheels, Tires, Alignment Notes on trouble-shooting - Tire pressure warning system Aids Combined plug connections - distin- guishing line features Use 1 or 2 auxiliary cables (own construction) for measurements on the control unit connec- tors and plug connections with the same con- tacts (flat contacts).

  • Page 147: Tire Pressure Warning System Short Test

    Wheels, Tires, Alignment Important notes when working on vehicles with the tire pressure warning system Always carry out a tire pressure warning system short test on the respective wheel every time a wheel or tire is changed. After the wheels have been finally balan- ced or after running on the test bench, erase the fault memory In the tire pressure warning system control unit.
  • Page 148 Tire pressure warning system (RDK) diagnosis General The system tester 9288 will be usad for PORSCHE DIAGNOSIS from Mod. 89 onwards. PORSCHE DIAGNOSIS can be used for all systems capable of self diagnosis. Capable of self diagnosis means: the control unit can detect. store and output system errors Read out tire pressure loss event memory (from control unit version R02 on (introducing during 1991 model year).
  • Page 149 Wheels, Tires, Alignment Areas of application for the 9298 system tester on the RDK tire pressure control sys- Reading out the fault memory Reading out the tire pressure loss event memory, from control unit version R 02 on (introduced during 1991 model year) Checking the correct functioning of various components with the tester Switch inputs can be checked...
  • Page 150 Wheels, Tires, Alignment 4. Selection from menu 3. Select vehicle type and system (RDK) Note: Possible RDK menus / Explanation If the display shows: 1 = Fault me- Read out fault memory / No Data Exchange Possible eliminate fault Restart: >...
  • Page 151 Wheels, Tires, Alianment Important notes on the diagnosis and assessment of RDK faults When the RDK control unit plug is disconnected, the display panel shows “RDK SHUT DOWN” after the engine has been started. This display is supplied from the instrument panel.
  • Page 152 Wheels, Tires, Alignment Menu 1 = Fault memory Reading out fault memory / eliminating faults Important notes Faults which were not present during the last journey and the test conditions applying them cam nnt be measured (with one exception). The relevant fault should therefore be &pe&&y&...
  • Page 153 Wheels, Tires, Alignment (Menu 1 = fault memory) Fault/Fault code Possible causes Remedy/Remarks HF sender rear left Fault code - 1 - Short to ground . may also be checked via menu 2 = sensors. In this case, HF sensor defective appears regardless of the wheel position if there is a ground fault.
  • Page 154 Wheels, Tires, Alignment Fault/Fault code Possible causes Remedy/Remarks HF sender Proceed as for fault code - 1 - for all faults, but use PIN 35 of rear right the control unit plug. Fault code - 2 - HF sender - proceed as for fault code 1 for all faults, but use PIN 34 of front len the contrd...
  • Page 155 Wheels, Tires, Alignment Fault/Fault code Possible causes Remedy/Remarks - If the ABS is also deactivated, look for the fault in the area of the speed sensor or in the fault path between ABS control unit and speed sensor. - If no fault found, repeat. If the fault is still apparent, try replacing the ABS contrd unk.
  • Page 156 Wheels, Tires. Atienment Fault!Fault code Possible causes Remedy/Remarks ABS speed sensor - proceed as for fault code - 5 - for all faults. front right Fault code - 8 - Connector assignment: ABS control unit 55-pole PIN 53 ABS control unk 35- pole PIN 23 Tire pressure warning system contrd unit PIN 28 RDK control...
  • Page 157 Wheels, Tires, Alignment Menu 2 = Sensors Check HF sender and ABS speed sensor Component to be tested/ Preconditions Remarks Fault I Remedy 1 = HF sender Each test with attenuated - Required display: and unattenuated HF sensor OK* for attenuated HF sensor OK for unattenuated HF sensor - If display shows: defective,...
  • Page 158 Wheels, Tires, Alignment Menu 3 = Input signals Pressure switch Important notes - A defectiie pressure-operated switch adopts a condition which is defined by the HF sensor as being a standard operational condition. Example: if the pressure-operated switch diaphragm deformed, the switch assumes the dosed state, therefore OK state, even k the tire pressure is too low.
  • Page 159 Wheels, Tires, Alignment Menu l* = Events Read out the tire pressure loss event memory Important notes From control unit version 02 on, the RDK control unit contains an event memory which stores data on any pressure losses at one or more tires during the last 6 journeys made by the vehicle. It also in- dicates the road speed at which the event occurred, and whether either one or two pressure-sensing switches were open.
  • Page 160 Wheels, Tires, Alignment Procedure: call up the event menu. Press the > key repeatedly until the event memory is read out in full. The tester indicates this (test end). Example Event Displayed data 8 RL Drive Journey - 8 - of 8 (last journey made) pressure loss Left rear wheel (RL)
  • Page 161 Wheels, Tires, Alignment Event Displayed data Journey - 6 - of 8 Drive At all wheels no pressure loss No pressure loss Journey - 5 - to journey - 1 - of 8 as for journeys 7 and 6 No pressure loss at any wheel No pressure loss but with the appropriate journey number...

  • Page 162: General

    Antiblock System General As of MY ‘84, the Porsche 928 S is optionally available with anti-lock system (Af3S) (option M593). As of model year 1986, the 928 S is fitted with ASS as standard equipment worldwide The anti-lock braking system represents an important contribution...
  • Page 163 Antiblock System DIRECTIONAL CONTROL AND STEERABILITY WHILE BRAKING Acceleration and braking forces have to be transmitted to the road surface by the tires. When a free-rolling wheel is slowed down by applying the brakes, there is slip, i. e. the difference between wheel circumferential speed and vehicle soeed.

  • Page 164: Design - Abs

    Antiblock System DESIGN The major components of ABS are: hydraulic unit, electronic control unit, four speed sensors wire harness with relays and overvoltage tripout (on central electric board). These components are integrated in the conventional braking system of cars beginning with 1984 models.

  • Page 165: Components - Abs

    Antiblock System A B S COMPONENTS Control Unit The electronic control unit is located above the hood release handle on driver’s side of car (above central electric board in R H D cars). The control unit uses the speed sensor signals to calculate the necessary control and regulation...
  • Page 166 Antiblock System Speed Sensors Speed sensors are arranged on all four wheels. These inductive sensors are held in area of pulse gear rings of front wheel hubs or wheel end shafts on rear axle and produce an alternating voltage for each pulse tooth. This alternating voltage changes its frequency indicate speed, acceleration and deceleration...
  • Page 167 Antiblock Svstem Important information on troubleshooting and ABS test program General ABS testing on vehicles with PSD repairs to the After certain ABS system Following repairs affecting the ABS (refer to functional check on page system (cf. page 45 - 07) a functional 45 - 07) a test program using an ABS test using the ABS 2-LED tester must be run.
  • Page 168 Antiblock System Important information for repairs of vehicles fitted with ABS When working on vehicles equipped with ABS, observe the following items: Checking the ABS operation Welding When welding with arc welding equipment, If service operations not directly related to disconnect the connector of the electronic...
  • Page 169 Antiblock System Vehicles with PSD The lock control assembly is located on an additional PCB in the ABS contrd unit. This PSD/ABS control has 55 pins, unit Previous ABS control unit versions had 35 pins. When repairs are required, make sure the PSD/ABS control unit is not con- fused with the PDAS/ABS control unit fifed to the 911 Carrera 4.
  • Page 170 Notes on ABS troubleshooting for vehicles with PSD General PSD = Electronically controlled Porsche limited-slip differential. One control unit controls both the PSD and ABS. The PSD is accommodated on an additional prin- ted-circuit board in the ABS control unit.
  • Page 171 Antilock brake system Possible fault displays via system tester 9288 DTCs of the PSD and ABS System allocation Fault type Transvene lock valve Lateral acceleration sensor - short circuit/discontinuity Lateral acceleration sensor - signal implausible Transvene lock - deviation Control unit - defective ABSIPSD Wheel speed sensor, front left ABSIPSD...
  • Page 172 Antiblock System REMOVING AND INSTALLING HYDRAULIC UNIT Removing 4 - From brake master cylinder, front wheel circuit (code V) 5 - Brake line front left (code I) 1. Turn off ignition and disconnect battery 6 - Brake line front right (code r) ground wire on body.
  • Page 173 Antiblock System take 6. Unscrew cable release and off 12.pin plug (no. 3). Note: Both relays for pump motor (2) or solenoid valves (1) can be replaced (see page 45 - 6). < Note: sres Never loosen or tighten bolts marked with arrows.
  • Page 174 Antiblock System Installing 4. Finish installation of hydraulic unit on bracket. Tighten three mounting bolts. 1. Tilt down hydraulic unit bracket on wheel side. 5. Mount brake pressure regulator and brake lines on hydraulic unit in correct position. If applicable, hold brake lines in brackets on wheel housing wall with clips and engage locks.
  • Page 175 Anti-lock Braking System REMOVING AND INSTALLING ELECTRONIC CONTROL UNIT Removing Note: In left-hand drive cars, the elec- tronic control unit is mounted the driver's side above the hood- release handle on the side panel. In right-hand drive cars, control unit is located above the central...
  • Page 176 ABS control units. outward The only differences of the control units are the Bosch and Porsche part nos., respectively. 1. Pii electronic control unit bracket. 2. Take electronic control unit off the bracket after having undone the fastening nuts.
  • Page 177 Antiblock system Removing installing relay Modified version General (MY ‘85 to MY ‘89) Relay No. XVII The anti-lock system is fitted with three relays. Starting with MY ‘85, the fuse is no longer The ABS relay (power supply for electronic located inside the relay but rather in the control unft and scavenge pump motor relay) Central Electrical System.
  • Page 178 Antilock brake system Pump motor relay I valve relay Removal 3. Pull out fuse for solenoid valves No. 7 or 1. Remove the wheel housing cover. for the pump motor No. 8 with the ignition switched off. 2. Remove the cover hood. Installation Proceed in reverse order.
  • Page 179 Antiblock Svstem REMOVING AND INSTALLING SPEED SENSORS ON FRONT AND REAR AXLES Removing Installing Front Axle Removing 1. Take off front wheel. Remove intake hose on air cleaner. 4. Unclip wire on side member and in holders 2. Turn off ignition, take wire plug out of on steering knuckle.
  • Page 180 Antiblock System 3. Route wires correctly (insert rubber grommets and clip rubber mount holder). Install exhaust shield. Connect wire plug and press into holder. Install front wheel and intake hose. 4. Check operation wrth ABS tester. Rear Axle 1. Coat speed sensor and bore in steering knuckle with Molykote Longterm Removing...
  • Page 181 Antiblock System 1. Coat speed sensor and bore in wheel 4. Unclip wire in holders on wheel carrier. carrier with Molykote Longterm Loosen socket head screw and pull speed Replace O-ring of speed sensor. sensor out of wheel carrier. 2. Insert speed sensor in wheel carrier without application of force and tighten...
  • Page 182 Anti-lock Braking System REMOVING AND INSTALLING SPEED SENSORS ON FRONT AND REAR AXLES, 86 MODELS ONWARD Front Axle l.Coat speed sensor and hole steering knuckle with Molykote Longterm 2. Renew speed sensor Removing ring. l.With ignition switched off, open ABS cable plug-in connector the steering...
  • Page 183 Anti-lock Braking System Rear Axle l.Coat speed sensor and hole wheel carrier with Molykote Long- Removing term 2. Renew speed sensor O-ring. 1. Remove wheel. 2.With ignition switched off, open ABS cable plug-in connector wheel carrier and disconnect cable. Open clip speed sensor cable.
  • Page 184 Brakes/Mechanical Parts GENERAL Braking System Until Model Year 1985 Until end of model year 1985 and depending on type and model year, front-axle disk brakes use either sliding or floating calipers. brake disks are ventilated. The brakes of the 928 S (with floating calipers) have...
  • Page 185 Brakes/Mechanical TECHNICAL DATA Wear Remarks Description Limit Specifications Hydraulic, dual circuit braking system Foot brakes with disc brakes and diagonal division up to end of 1983 models: axle circuit division since 1984 models, brake booster, floating frame caliper disc brakes on front axle and floating frame or fist caliper disc brakes on front axle.
  • Page 186 Brakes/Mechanical Description Remarks Wear Limit Specification Pad thickness Front, floating frame 13 mm floating caliper 13 mm Rear 13 mm New brake disc thickness Front, floating frame 20 mm grooved disc 20.5 mm floating caliper 32 mm Rear 20 mm Min.
  • Page 187 Brakes/Mechanical Parts TECHNICAL DATA 86 MODELS ONWARD Description Remarks Wear Limits Specifications Foot brake Hydraulic, dual-circuit braking system with separate front/rear axle braking circuits (black/white), brake booster, ventilated brake disks with four-piston fixed calipers front rear. Push-rod braking circuit front wheels.
  • Page 188 Brakes/Mechanical Parts Description Remarks Wear Limits Specifications Brake disk dia. front 304 mm rear 299 m Effective brake disk dia. front 250.8 rear Piston dia. in caliper 86 models, each fixed caliper front 2x42+2x36mm front 87* models onward each fixed caliper 2x44+2x36mm rear...
  • Page 189 Brakes/Mechanical Parts Description Remarks Wear Limits Specifications Min. brake disk thickness* after machining 30.6 mm front 30 mm rear 22.6 mm 22 mm Max. brake disk thickness tolerance 0.02 Max. brake disk lateral runout 0.05 mm Max. lateral runout installed brake disk 0.1 mm**...
  • Page 190 Brakes/Mechanical Parts TORQUE SPECIFICATIONS FOR MECHANICAL PARTS OF BRAKING SYSTEM Location Description Thread Material Torque Nm (ftlb) Panhead screw of Allen-head screw 10.9 15 (11) clamping Brake caliper Hex screw/cap M 12x1.5 85 (62) steering knuckle screw Brake caliper Hex screw/cap M 12x1.5 85 (62) wheel...
  • Page 191 Brakes/Mechanical Parts Location Description Torque Thread Material Nm (ftlb) Locking paw1 to Locknut 23 (17) handbrake lever Guard to wheel Locknut, VFM 8 carrier Hex bolt I:;’ Socket-head Speed sensor to wheel 10 (7) carrier and steering screw knuckle Torque Specifications 46 - 09 Printed...
  • Page 192 Brake - Mechanical Technical data as of MY ‘92 Wear limit Remarks, dimenslon Designation 926 GTS 926 GTS Hydraulic twin-circuit brake system with front axte/ Operating brake rear axle circuit division. Vacuum booster, internally (foot brake) vented brake discs with four-piston fixed caliper on front and rear axles.
  • Page 193 Brake - Mechanical Designation Remarks, dimensions Wear limtt 926 GTS 926 GTS Brake disc thickness new front 32 mm rear Min. brake disc thickness * after machining 30.6 30.0 front 22.6 22.0 rear Thickness tolerance of 0.02 brake disc max. Runout of 0.05 brake disc max.
  • Page 194 Brakes/Mechanical CHECKING THICKNESS OF BRAKE PADS All brake pads on one axle must be replaced when “brake pad” indicator comes on. however at latest when oad thickness is worn to 2 mm. If the indicator lamp reports the brake pad wear, the warning contact (sensor plus wire and plug) must also be replaced.
  • Page 195 Brakes/Mechanical REMOVING AND INSTALLING BRAKE PADS (Floating Frame Caliper Disc Brakes) Removing Note If brake pads can be reused, mark them for reassembly when removing. Pads must not be moved from outside to inside and vice versa or from right to left wheels.
  • Page 196 Brakes/Mechanical 4. Remove inner brake pad with a pulling hook or Installing impact puller. Replace brake pads, which show deep cracks, have become loose from backplate or are covered with oil. Also in this case replace all four pads of one axle. Brake pads with different friction values are...
  • Page 197 Brakes/Mechanical 5. Insert outer brake pad and press floating caliper 3. Clean bearing and guiding surfacesof brake pads in frame in direction of brake disc so far. that pin brake calipers with gasoline or a cylindrical brush. engages in groove of pad backplate. Never use solutions containing mineral oil or sharp edged metal tools.
  • Page 198 Brakes/Mechanical REMOVING AND INSTALLING BRAKE PADS (Floating Caliper Disc Brakes) Removing When brake pads can be used again, they must be installed on same wheel (otherwise non-uniform braking effect). 1. Pull warning contact (wear sensor) out of inner pad plate. Note Replace warning contacts with ground through or down wire cores.
  • Page 199 Brakes/Mechanical Installing 1. Push beck piston completely with special tool. Check 20” piston position end adjust with special piston pliers, if necessary. Stepped surface of piston feces down toward brake disc inlet side. Edge on bottom of housing (see arrow) can be used es a reference point. ._ ~, ~.
  • Page 200 Brakes/Mechanical Parts 5.Insert plugs in guide sleeves. 6.Engage housing retaining spring. Check that spring locates prdperly in hole. Do not use force to bend spring. 7.Insert warning contact: renew if necessary. 8.Press brake pedal several times so that piston and housing align brake pads with...
  • Page 201 Brakes. Mechanical Removing and installing brake pads (four-piston fixed caliper disk brakes) Removing Note If the brake pads are to be installed again, they must be marked with their positions when removed. It is forbidden to interchange the inside and outside brake pads or those from the left and right wheels, and this can re- sult in uneven braking.
  • Page 202 This can also be checked at the arrow Asbestos-free brake pads are also availa- above the PORSCHE logo; this arrow shows ble for cars with fist-type and floating cal- the direction of brake disk rotation. iper disk brakes.
  • Page 203 Brakes. Mechanical 4. Installing new damper plates in the pistons. 5. Insert the brake pads. Make sure that the correct grade of brake pad is used. When installing, make sure that the internal Note diameters of the spring and piston are cor- rectly matched together (Technical Informa- When damper plates are installed, tion Gr.
  • Page 204 Drakes, Mechanical 6. Grease the spreader spring retaining lugs 7. Press the warning contact(s) Into the pad with Optimoly TA or Plastilube. If new plate in the correct positions. Secure the spreader springs are installed, the flat side warning contact lead to the brake caliper and, if two warning contact leads are pre- should face the brake disk.
  • Page 205 Brakes/Mechanical REMOVING INSTALLING BRAKE PEDAL 4. Remove circlip and move bearing shaft toward Removing outride until brake pedal has been run out. 1. Move back seat and steering wheel up to make job YF-7~~ YF-7~~ easier. If applicable, remove shelf. ‘:y,, : I_ y r, i’,_i ‘:y,, : I_ y r, i’,_i ‘.
  • Page 206 Brakes/Mechanical Parts ADJUSTING BRAKE PRESSURE ROD Until Model Year (Stop on brake-pedal arm) Note: With the pedal released, pressure rod must exert no pressure on the brake unit. With brakes bled and engine switched off, move pressure rod at brake pedal by hand to check play and assure...
  • Page 207 Brakes/Mechanical Parts ADJUSTING BRAKE PRESSURE ROD Adjusting l.Adjust length of brake pressure Models Onward rod by turning adapter (without stop on brake-pedal arm) pressure rod. Length a must be 158 + 2 mm measured from the bearing face of the brake booster on the body to the center of the...
  • Page 208 Brakes/Mechanical Parts CHECKING SETTING OF STOPLAMP SWITCH In 1984 models onward, mechanically operated switch mounted on a bracket above the brake-pedal arm is installed stoplamp switch. With the pedal arm against stop (initial position), there must be a 5 mm gap between stoplamp switch and brake-pedal...
  • Page 209 Brakes/Mechanical Parts DISASSEMBLING AND ASSEMBLING FRONT WHEEL BRAKE Disassembling 2.Take brake disk after removing countersunk bolt (s). l.Remove brake caliper (do not a brake disk is so tightly seated disconnect brake hose) and place that light blows with a nylon- on upper control arm or attach...
  • Page 210 Brakes/Mechanical Parts 3. Install brake disk and brake caliper. Tighten caliper retai- ning bolts, torque: 85 Nm (62 ftlb). Ventilation ducts of brake disks used with floating-caliper and fixed-caliper brakes involute: do not mix up right- hand and left-hand disks. Distinguishing feature: involute...
  • Page 211 Brakes/Mechanical gc===c3- ,A& >\. .--. 7--z= - -‘i: ~~ Q J&-L&$-; i rA ’ ‘L ‘i”cz”“; r --L-e- E--: ” ;‘“a ‘- fl?. - ..- ., ~~~~ 1 (v---- Printed Germany - VI, 1982 46.13 Disassembling and Assembling Rear Wheel Brake...
  • Page 212 Brakes/Mechanical Special Note When: Removing Installing Instructions Description QfV. Tighten Bolt specified torque Washer Replace, if necewxy Floating frame caliper Suspend from suitable point car that brake hose is without tension Bolt Brake disc Set back brake Check for wear and damage Position correctly...
  • Page 213 Brakes/Mechanical DISASSEMBLING ASSEMBLING REAR WHEEL BRAKE Note: Disassembling Install springs in correct position 1. Disconnect floating frame caliper. ,,.~~~:; 2. Turn parking brake slack control toward loosening direction. Remove brake disc after unscrewing ,,‘. countersunk bolts. If a seized brake disc can’t be removed even with light knocks...

  • Page 214: Checking Brake Disc Lateral Runout

    Brake - Mechanical Checking brake disc lateral runout 1. Measuring requirements: No tilt play 4. Fit dial gauge with a slight preload. Place present at wheel. If required, adjust measuring pointer on maximum diameter of wheel bearing clearance of front wheels. braking surface.
  • Page 215 Brake - Mechanical 7. Check wheel hub runout as follows: Measure once outside (arrow) and once inside wheel stud area of hub face. Lfft off dial gauge carefully in cutout area of wheel hub. To fii the dial gauge, use either a magnetic universal dial gauge holder, e.g.

  • Page 216: Checking Brake Disc Thickness

    Brake - Mechanical Checking brake disc thickness Measure brake disc thickness in approx. 6 places within the braking surface using a micrometer. 46 - 16 Checking brake disc thickness Printed in Germany -XXIX, ,os*...

  • Page 217: Disassembling And Assembling Parking Brake Lever

    Brakes/Mechanical DISASSEMBLING ASSEMBLING PARKING BRAKE LEVER -.-a-* .-*-* -*./ 14-a 1 11 Printed in Germany . VII, 1963 Disassembling and Assembling Parking Brake Lever 46-19...
  • Page 218 Brakes/Mechanical Note When: Special Description Removing Installing Instructions Bolt Torque: 25 Nm 118 ftlbl Replace Lock washer “eCSS%y Washer Only used in some Sometimes cases washer is used to align parking brake lever Switch must Bracket parking brake switch respond before first catch;...
  • Page 219 Brakes/Mechanical DISASSEMBLING ASSEMBLING PARKING BRAKE LEVER Disassembling Checking Adjusting Parking Brake 1. Remove parking brake lever/parking brake cable The parking brake has to be adjusted. if with medium force the parking brake lever can be pulled trim. Unscrew mounting bolts and take out up more than 2 teeth without any braking...
  • Page 220 Brakes/Mechanical 5. Pull up parking brake lever 2 teeth and turn adjusting nut that the wheels can just be turned hand (with 4 teeth the wheels must be stopped). ,B~< f;*.,~ ‘.’ rr- ,#$.,.‘2~ %/.,&$$g~ ““I 6. Release parking brake lever and check, whether wheels...
  • Page 221 Brakes/Hydraulic Parts (Regulators, Booster) TIGHTENING TORQUES FOR BRAKES, HYDRAULIC PARTS Location Description Thread Torque (ftlb) Brake unit to bulkhead 23 (17) Hex nut DIN 934 Brake line to master Union 10 x 1 cylinder, brake hoses, brake booster, T-dis- tributor and hydraulic unit.
  • Page 222 Brakes/Hydraulic Parts (Regulators, Booster) Location Description Thread Torque (ftlb) Master cylinder Hex nut 23 (17) vacuum booster DIN 934 Stoplamp switch MlOxl 15 + 4 master cylinder (11 + 3) tapered Regulator to wheel Hex bolt 23 (17) arch Screw-in regulator Screw-in MlOxl...
  • Page 223 The two halves of the brake caliper must fixed calipers have an arrow mark above the not be separated. Porsche logo to indicate the correct direction of brake disk rotation. The piston sealing rings, dirt scraper rings and spring plates can be changed while the fixed caliper is assembled.
  • Page 224 Brakes, Hydraulics, Regulator, Booster Modifications to four-piston fixed calipers Modification Modification During the 1989 model year, the front and rear From 1987 models* on, the pistons in the wheel brake piston seals were modificed. A front wheel fixed brake calipers were revised change was made from a scraper ring to a in design to minimize wear and optimize effi- protective cap version.
  • Page 225 Brakes, Hydraulics, Regulator, Booster Previous version The scraper ring made a sliding-contact seal with the piston surface. Replacement Make sure that the two brake calipers on an axle are both of the same pattern. 47 - 05 Notes on brake system from 1966 models on Printed Germany - XXV, 1eec...
  • Page 226 Brakes/Hydraulics. Regulators. Booster c *,, ‘. _ ,&f------ Printed inGermany - IV. 1980 Disassembling and Assembling 41 - 1 Floaring Frame Caliper...
  • Page 227 Brakes/Hydraulics. Regulators, Booster Note When: Special Removing Installing InstruCfions Description New models have Lock Replace necessary lock wire with wire guide Replace Retaining necessary Replace Cross spring “eCeSSWy Check, replacing Inner brake pad necessary. Wear limit: 2 mm. It is better to mount pad after...
  • Page 228 Brakes / Hydraulics. Regulators, Wooster Special Note When Descriptior 01)‘. Instructions Installing Removing Remove with a Replace. install with 1‘1 SCil brake cylinder paste plastic rod iJust cap illeeder screw Replace. if necessary Slide Uisassembling and Assembling Floating Printed inGermany - IV, 1980 4’- Caliper...
  • Page 229 Brakes / Hydraulics. Regularors, Bcosrer DISASSEMBLING ASSEMBLING FLOATING FRAME CALIPER Disassembling 3. Press piston out of cylinder with compressed air. 1. Press caliper frame off of mounting frame. Warning Support piston on piece of wood. 1, ‘i <. 'a?. ,) .. ' :j .~~,;...
  • Page 230 Brakes / Hydraulics. ~egularors, 6ooster Assembling 1. Apply a very thin coat of brake cylinder paste Install mounting frame. Be careful not to da- to cylinder bore, piston and seal. Press piston mage slides. into cylgder in approximately correct posi- tion (20 chamfer).
  • Page 231 Brakes/Hydraulics, Regulator, Booster Brake hose installation changed during 1983 model year. Brake hose mounted on modified fist caliper connection with a hollow union bolt from this time on to guarantee correct installed position. in Germany - VIII, 1984 Disassembling and Assembling Fist Caliper Printed...
  • Page 232 Brakes/Hydraulic, Regulator, Booster Note When: Special Description Qty. Removing Installing Instructions Housing retaining spring Replace, necessary. Make sure of correct Plug Replace, if necessary Guide Replace, if necessary. Tighten to specified torque (15-~20 11 - 14 ftlb) Housing (caliper) Note 20” piston position.
  • Page 233 Brakes/Hydraulic, Regulator. Booster Note When: Special Qty. Removing Installing Description Instructions SeaI Remove with Replace, install with plastic brake cylinder paste Dust cap Bleeder valve Damper sleeve Replace when torn, Page47.12 brittle or swollen rubber Replace if necessary Page 47 - 12 Slide Printed in Germany...
  • Page 234 Brakes/Hydraulic, Regulator, Booster DISASSEMBLING ASSEMBLING FLOATING CALIPER Disassembling 2. Push dust cover on inside of piston so far that large diameter sealing lip (arrow) extends over the piston. Remove housing retaining spring. Pull plugs out of guides. Remove guide pins. Remove housing.
  • Page 235 Brakes/Hydraulic, Regulator, Booster 4. Press piston into housing slowly. Small diameter sealing lip should settle in groove of piston. t .P---- -- ---+’ -, f&-” :/: +2-j 5. Adjust 20’ piston position precisely with piston pliers. Set back surface of piston faces down to brake disc inlet side.
  • Page 236 Brakes/Hydraulic, Regulator, Booster REPLACING DAMPERS SLIDES Removing 1. Separate housing from holder. Pull piston brake pad out of piston. 2. Press out damper in direction of brake hose connection. Make sure that bearing surface housing is not damaged. Installing 1. Coat damper with brake cylinder paste.
  • Page 237 Brakes/Hydraulics, Regulator, Booster REMOVING AND INSTALLING BRAKE MASTER CYLINDER Removing 5. Detach brake lines. 1. Remove intake hoses and air cleaner upper Up to 1983 models. section. 2. Drain both chambers of brake fluid reser- voir by pumping out brake fluid via pertinent bleeder screws depending on brake...
  • Page 238 Brakes, Hydraulics, Regulator, Booster 6. Remove the master brake cylinder at its Note flange with a l/4-inch ratchet, a 13 mm Use only brake fluid or brake cylinder paste as socket wrench insert and a suitable exten an aid to installation. Substances containing sion.

  • Page 239: Removing And Installing Brake Booster

    Brakes/Hydraulic Parts (Regulators, Booster) REMOVING AND INSTALLING BRAKE BOOSTER Removing 4.So that brake pressure (piston rod) protrudes as little as possible toward the footwell l.Remove master cylinder (see page from the booster, adjust adapter, 47 - 13) depress brake pedal again correct position...
  • Page 240 Brakes/Hydraulic Parts (Regulators, Booster) 6.If necessary, unclip brake line 3.Install brake pressure regulator from right-hand front wheel from and master cylinder. Always renew holder on bulkhead seal ring between brake booster carefully push toward engine. and master cylinder. Mount brake Position hose for clutch...
  • Page 241 Brakes/Hydraulic, Regulator, Booster REMOVING INSTALLING BRAKE PRESSURE REGULATOR Regulator Wheel House Installing Removing 1. Check brake pressure regulator/car application 1. Remove intake hoses and air cleaner upper on page 47 section. 2. Install brake pressure regulators. The mounting 2. Drain both chambers of brake fluid tank by...
  • Page 242 Brakes/Hydraulics, Regulators, Booster 2. Unscrew brake line on brake pressure Installing regulator, counterholding on hexagon of regulator. 1. Screw in brake pressure regulator. Mount brake line on brake pressure regulator while counterholding on the hexagon. Note: Place cloths underneath to avoid damage from 2.
  • Page 243 Brakes/Hydraulic Parts (Regulators, Booster) BRAKING-FORCE REGULATORS - INSTALLATION OVERVIEW Braking-Force Regulators Until Model Year (Diagonal braking circuits/2 regulators per vehicle) 3" Brake Boos 10" Brake Boosters ‘S r ,eplace x-eviously previously replace installed installed Switchover pressure in bar Part 128.355.083.02 (928.355.083.01) 328.355.083.02 i;;,,,tT,;:d...
  • Page 244 Brakes/Hydraulic Parts (Regulators, Booster) Models Braking-Force Regulators, Onward (stage-type tandem master cylinder, separate brake circuits each axle, 1 screw-in regulator per car) Switchover pressure Installed Part 33 bar 84 models 928.355.305.00 928.355.305.01 33 bar models 86 models onward (with 951.355.305.00 18 bar four-piston fixed-...
  • Page 245 Brakes/Hydraulic Parts (Regulators, Booster) INSPECTING BRAKING-FORCE REGULATOR General Preparation A braking-force regulator is inte- l.Connect brake calipers concerned grated in the brake lines to the and pressure tester by screwing left-hand and right-hand rear test adapters into holes wheels (diagonal braking circuits).
  • Page 246 Brakes/Hydraulic Parts (Regulators, Booster) 2.Connect line from tester (mini- Test ature coupling) to test adapter. Build up input overpressure (shown on manometer) of front brake caliper (unregulated wheel) accordance with table. Read output overpressure on manometer of rear brake caliper (regulated wheel) (specified...
  • Page 247 Brakes/Hydraulic Parts (Regulators, Booster) Adjustment l.If the measured values do not correspond to those stated in the table or if the pressure in the regulated circuit increases while the force exerted on the brake pedal remains constant, renew the braking-force regulator.
  • Page 248 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 available under Part No. 000.043.202.04. Container contents: 5 liters (as of May, 1992).
  • Page 249 Brakes/HydrauIic,ReguIator,Booster 3. Switch on bleeder. Move selection control lever to filling and bleeding position. 6. Operate the brake pedal firmly several times during bleeding procedures and with the bleeder valves open, in order to remove all air bubbles in the brake master cylinder.
  • Page 250 Brakes/Hydraulic, Regulator, Booster set lever to leak test. 8. Now The pressure value dis- played on the operating pressure gauge must not drop during the next 5 minutes. There is a leak in the brake or clutch system, pressure does drop during the test time.

  • Page 251: Technical Data

    Steering TECHNICAL DATA Steering Rack-and-pinion type with tie rods and hydraulic assistance (power steering) Steering wheel dia. 380 mm/15 Steering wheel ratio at center 11.15 : 1 Turning circle dia. (wall-to-wall) 11.5 mm. I ft Turning circle dia. (curb-to-curb) 9.fi m/31,5 Steering wheel turn from lock 3.13...

  • Page 252: Torque Specifications

    Steering STEERING TORQUE SPECIFICATIONS Location Description Threads Material Torque Nm (ftlb) Steering gear to engine carrier VM 10 Self-locking 46 (33) Tie rod to steering Self-locking VM 12x1.5 65 (47) Universal joint to steering gear Self-locking VM 8 28 (20) Tie rod to ball joint M 14x 45 (33)
  • Page 253 Steering Replacing the steering in case of accident damage A. General Accidents or driving conditions similar to accidents may cause various types of damage to steer- ing gears. if the outside of the steering gear is undamaged, tracing of damage is sometimes difficult and requires considerable effort.
  • Page 254 Steering Permanent deformation or cracking Steering gear mounts Tie rods Steering arms King pins Control arms If the above criteria are sufficient for a decision, if is recommended to exchange or replace the steering gear. C. Exceptional regulations I order processing If the by the shop is refused by the customer or insurance steering...
  • Page 255 Sreering TOOLS Description Special Too! Remarks Torque wrench (Srahlwille 730 R/20 or Hazet 6292-1 CT) Wrench socket 9183 Tie rod puller e.g. Nexur; 168-l Primed in Germany - 111. ~!“EI Removing and InsraIling Srcering Gear...
  • Page 256 !I 2 il Steering ‘; -:* e.;-: l--(&i *> c---&f 1,. lR76 Printed in Germany 48 -2 Removing and Installing Steering fear...
  • Page 257 Steering Note When: Special Dexription Removing Installing Instructions Replace. Tighten Self-locking specified torque Self-locking Replace. Watch position Torque: of universal 28 Nm/20 ftlb joint Page 48 .6 Replace necessary Washer SetSCrWd Tighten specified Hollow bolt torque Replace Seal Torque: Tie rod assembly 150 Nm/lOB ftlb.
  • Page 258 Steering Note When: Special Installing Instructions Description Removing oty. Replace. Tighten Self-locking specified torque Reinforcement plate Note position Run o”t rack ends Steering gear completely and coat of universal with VW steering joint Page 48 .6 gear lube AOF 086 000 Replace if necessary.
  • Page 259 Steering REMOVING INSTALLING STEERING GEAR Removing 1. Draw hydraulic fluid out of tank. 2. Press out tie rods with a standard extractor. 5. Unscrew pressure line and return line at steer- ing gear. 3. Pull back hose strap with harness after removal of screw on side.
  • Page 260 Steering 9. Now remove the four mounting nuts and take 6. Remove five bolts from reinforcement plate on steering gear out of studs on engine carrier. engine carrier. Installing 1 Slide universal joint on to steering gear in correct position (steering wheel and steering...
  • Page 261 Steerino 3. Fill system with hydraulic fluid, bleed and check for leaks as well as correct oper- ation (see page 48 - 9) 4. If necessary (with new parts), adjust toe. In remember conjunction with this matter, taht there are different steering stop ver- sions (see text below).
  • Page 262 Steering Cross Reference Survey: Steering Gear Version Steering Gear stop Spacer Identification (LHD only) Part No. Part No. (left and right) 1. Old version 928.347.010.22 928.347.329.00 926.347.331 .oo Rack 795 mm long Rack end dia. left 26 mm, right 25 mm 2.
  • Page 263 Stesrlng lnstructlons for Repalr Sector: Only the new steering stop 928.347.329.04 and the new bellows 928.347.191.03 are supplied for steering gear 928.347.010.24. The bellows 928.347.191.03 and the steering stop 928.347.329.04 are also applicable to steering gears 928.347.010.26 / 928.347.010.27 (as of MY ‘91 or 928 GTS). The new steering stop may only be installed together with the new dust cover, When installing a solid stop for the first time, stops and dust covers must be replaced on both sides.
  • Page 264 Steering NSTALLATION OVERVIEW 928.347.329.03 (paqe 48 - 6 C) 928.347.329.04 in Germany 1986 - Printed XIII, Stops, Installation - 6d Steering . Overview...
  • Page 265 Steering REMOVING INSTALLING POWER STEERING PUMP Removing I. Detach intake hose to air cleaner on left side. Draw hydraulic fluid out of reservoir. 2. Remove splash shield. r-‘-“‘.” w.. 4 ..c; ,&g: 5. Remove v-belt. .i , :>, 1 ,y..,,? I+ 1””...
  • Page 266 Steering 8. Remove suction hose after loosening clamp. Install this pressure hose leaving not mope than mm between inner wheel well and hose. Note: If hose is routed too close to exhaust manifold, hose could come loose from its holder and cause failure of the power...
  • Page 267 Steering REPLACING SEALS FOR ALUMINUM POWER STEERING PUMP i . . -’ ,/ @& 15 lb lb Note: Body of power steering pump is made of aluminum af of 1981 models to reduce weight. Worn seals can be replaced on these aluminum power steering pumps,...
  • Page 268 Steering Note When: pecial Description Removing Installing wructions Self-locking Hold on pulley Replace M 14 x 1.5 with open-end necessary. wrench Torque: 50 Nm (36 ftlbl Use standard puller, e.g. Kukko 20/l Woodruff Replace necessary Pull out of radial Hook snap ring groove with...
  • Page 269 Steering Note When: Special -Removing Description oty. Installing Instructions Remove with p. 48-89, point Support ring, Replace large dia. plastic needle or watching out for air pressure different diameters and installed O-ring, positions large dia. O-ring, small dia. Support ring. small dia.
  • Page 270 Steering REPLACING SEALS FOR ALUMINUM POWER STEERING PUMP Disassembling Power Steering Pump B & 1. Use a standard puller (e.g. Kukko 20/l) to take + ,?jT “u;:; pulley and woodruff key off removed pump. 4 /n @y+g:; ~~ t $1 4 r,--% 3.
  • Page 271 Steering 4. Drive out drive shaft with face plates and rotor Inspecting Components set by tapping with plastic hammer. Clean parts with a cleaning fluid and check visually. Checking Points: Drive shaft: bearing surface of shaft seal and bearing sleeve (for wear). Threads, taper and groove...
  • Page 272 Steering Note: Assembling Power Steering Pump Lubricate all parts lightly with before installing. 1. Insert dowel pins in body 2. Install ten impellers in slots of rotor so that their polished and round outer surfaces face the cam ring. Make sure impellers move easily.
  • Page 273 Steering 4. Install cam ring. Cast arrow in cam ring circum- 6. Press face plate on to rotor set. Dowel pins must ference indicates pump driving direction. Since the engage in bores provided for this purpose. Slot pump turns clockwise, arrow must be on cover must be aligned...
  • Page 274 Steering 10. Install front bracket. Install woodruff key and 8. Pack multi-purpose grease in shaft seal between pulley.Tighten self-locking hexagon nut to both sealing lips and install seal on drive shaft. 50 Nm (36 ftlb). Use a suitable sleeve or cover woodruff key groove with a narrow strip of tape to avoid damaging...
  • Page 275 Steerlng Checking and adjusting the rack-and-pinion power steering Checking drive belt tenslon General Defects in the power steering arise as the re- Tension is correct when light thumb pressure applied at a point midway between the two sult of a oil in the hydraulic system.
  • Page 276 Steerlna Checking fluld level of power steering 1. Pull cap of hydraulic fluid off or unscrew reservoir. Note Reservoir is mounted on wheel housing in En- gine compartment. The reservoir installed in cars earlier than model year 83 has a fluid- level mark (version A).
  • Page 277 Steerlna 3. Quickly turn steering wheel several times from lock to lock, to drive all air out of the cylinders (when end position of piston is reached, do not pull harder on steering wheel than required to turn steering; avoid building up unnecessary pressure at this stage).
  • Page 278 Steering TOOLS Note: All parts (1 through 61 can be used for 928 and 944 cars. Pressure gauge is connected between pressure line and steering gear (944: between power pump and pressure line). If old pressure gauge no. 3 (see below1 is used, make sure high pressure hoses no.
  • Page 279 Steering TOOLS Description Special Tool Remarks Adapter For pressure gauge 3: local manufacture (see sketch, page 48.9). For pressure gauge 3 a: local manufacture. deviates from sketch. Threads not M 18 x 1.5 (for gauge no. 3) but M 16 x 1.5. Standard.
  • Page 280 Steering CHECKING HYDRAULIC FUNCTION OF STEERING (PRESSURE TEST) Installing Pressure Gauge General Information I, Unscrew bolts from stabilizer bearings and pull Tester (pressure gauge) is installed between pressure down stabilizer far enough that pressure line line and steering gear (rotary piston valve).
  • Page 281 Steering -- .-.- ;;.-3-P~l.~~~r~suF~#~~~~ quire loosening mounting clamp of lines. pressre hoses and place on a base (e.g. Connect 1.5 meter long high pressure hose toolbox) next to driver’s door. no. 2 to pressure line using the hollow bolt Note and adapter no.
  • Page 282 Steering Checking the delivery pressure of the Checking Delivery Pressure of Power Pump power steering pump 1. With the engine running at idle, close shu- 1. Run engine at idle speed. Shut-off valve toff valve (lever position II) and read off must be open (lever position I).
  • Page 283 Steering REMOVING INSTALLING STEERING WHEEL Removing Installing 1. Pull impact pad off of steering wheel and 1. Install steering wheel with road wheels poin- take off horn wires. ting straight ahead or according to disassembly mark in such a manner. that steering wheel spokes are horizontal.
  • Page 284 Steering TOOLS Description Special Tool Remarks Circlip pliers Standard tool Mandrel VW 295 Mandrel VW 214 f/20 Pressure pad VW 433 SleWle 30-21 Locally made tool Half of an approx. 4 mm thick washer welded on steering wheel mounting nut (M 18 x 1.5 hexagon nut) Printed Germany...
  • Page 285 Steering 3013 5’ ‘: ‘f i 41 7 ~~ffsj~3 ; n : ,/ Printed in Germany Repairing Steering and Intermediate Shafts 48.16 with Steering Tube...
  • Page 286 Steering Note When: Special Description Removing Installing Instructions oty. Self-locking Replace, torque: Watch installed 28 Nm (20 ftlbl position universal joint no. 4. see page 48.23 Washer Replace if necessary Setscrew Produce 8 mm gap Universal joint for short version with tool 9208 (page 48...
  • Page 287 Steering Special Note When: Removing Installing Instructions Description 6 mm (one thick Washer 4 mm and one thin 2 mm1 for leather or 4 mm (one thick 4 mm) for leatherette Steering tube with steering lock Seal Replace if necessary; position correctly Steering...
  • Page 288 Steering Note When: Special Description Qty. Removing Installing Instructions Steering shaft mount, Drive out with Drive in with VW 433 a suitable pipe UPPer aall Spring Self-locking Washer Adjusting lever Bracket Stud Screw M 3.5 x 10 Same part ar no.
  • Page 289 Steerinq REMOVING INSTALLING STEERING TUBE Removing 4. Pull off impact pad on steering wheel remove horn wires. Mark position of steering wheel on steering shaft. Unscrew hexagon 1. Remove universal joint after unscrewing and take off steering wheel with washer. hexagon head setscrews.
  • Page 290 Steering 9. Remove 5 switches in instrument cowl 6. Unscrew mounting bolts for instrument cowl pulling off switch knobs, compressing both spring clips of each switch, pulling out switches ._.~~ and pulling off plugs. Remove rubber cover (ignition lock cover). 7.
  • Page 291 Steering Move up steering tube combined with steering 11. Pull off plugs on ignition switch. Disconnect spring for steering wheel height control with and intermediate shafts. To prevent seizure piece of suitable wire. intermediate shaft on firewall while moving keep to the following procedures.
  • Page 292 Steering 3. Mount steering tube with appropriate spacers, see 8. If applicable, mount cover on intermediate pager 48 17 and 18. Only tighten the socket shaft. head bolts finger fight. Install universal joint between steering intermediate shafts. First slide up universal joint on intermediate shaft fully...
  • Page 293 Steering 9. Install steering wheel so that its spokes are horizontal when road wheels are pointing straight ahead or by mark made during removal operations. Install mounting nut with washer and torque 50 Nm (36 ftlbl. If necessary, correct position of steering wheel after test drive...
  • Page 294 Steering REMOVING INSTALLING STEERING SHAFT/STEERING SHAFT BEARINGS ADJUSTING AXIAL PLAY OF STEERING SHAFT Removing 1. Pull intermediate and steering shafts down out of steering tube quickly l&clip and support removed, steering wheel lock unlocked). This will also remove the lower steering shaft bearing.
  • Page 295 Steering 4. Move steering shaft down out of steering tube partially (at most up to stop of shaft on lower bearing). Install support, spring and shims (basic set: 4 x 1.5 mm and 1 x 0.5 mm) on steering shaft. Mount intermediate shaft on steering...
  • Page 296 Steering 7. b) Axial Play (Distance) Excessive: Move intermediate shaft on steering shaft in direction of steering wheel until the axial play is correct. Torque hexagon nut to 28 Nm (20 ftlb). If the steering shaft opening is not sufficient for adjustment, use a larger shim set (6.5 mm basic set).
  • Page 297 Steering DISASSEMBLING ASSEMBLING STEERING WHEEL HEIGHT CONTROL Disassembling Assembling 1. Move steering wheel height control lever to release 1. Screw stud in control lever. Threaded part must protrude slightly (arrow). position. Remove balls and spring. Make sure that a cloth held above the area of the balls (to prevent injury) and catch the first...
  • Page 298 Steering 4. Tighten mounting nut of control lever so that the locking position is reached with a medium amount of force. When more force is applied, it should possible to turn the control lever further in locking direction. Printed inGermany VI, 1982 Repairing Steering...
  • Page 299 Steering REPLACING UPPER STEERING SHAFT BEARING 4. Unscrew cover underneath instrument cowl (not 1. Remove universal joint after unscrewing on older models) and cover underneath steering hexagon head setwews. column switch. q..~“q&+’ :,” ,- . ;>‘,,+,_j i .$.- %.Tp 1 &y2d;,., ..* ;,,,,.
  • Page 300 Steering 7. Remove steering column switch after disconnecting 9. Unlock steering lock and push steering shaft plug connector and pulling off plugs, lifting instru- into steering protective tuba far enough so that ment cowl for this. intermediate shaft in engine compartment rests on camshaft...

  • Page 301: Replacing Upper Steering Shaft Bearing

    Steering 14. Install steering column switch and covers Connect battery ground wire. 15. Install universal joint between steering and intermediate shafts. If necessary, adjust 8 mm gap fsee page 48 - 23). 16. Install steering wheel so that its spokes are horizontal when road wheels point straight ahead or according to mark made before...
  • Page 302 Steering Dismantling and assembling steering wheel height adjuster of airbag vehicles Dismantling and assembling steering wheel height adjuster of airbag vehicles 48 - 33 Printed in Germany - XXVII, 1991...
  • Page 303 Steering Dismantling and assembling steering wheel height adjuster of airbag vehicles 48 - 34 Dismantling and assembling steering wheel height adjuster of airbag vehicles Printed in Germany - XXVII, 1991...
  • Page 304 Steerina Designation Removal nstallation Spring clip if not present, retrofit to modified steering wheel height adjuster (p. 48 40 ). Affected pans: No. 1. 2, 4 and 6. Spring washer Spring always fit a new spring, making sure it is not bent when fitting Adjuster lever fit modified version only...
  • Page 305 Steering Dismantling and assembling instructions Important notes Adjuster lever positions If the scope of assembly deviates from the fol- lowing instructions, the safety requirements Adjusting mechanism of steering wheel height for the operation of vehicles with airbag equip- adjuster closed. ment must be observed.
  • Page 306 Steering Assembly 1. Remove knee protector strip. The fastening 1. If required, fit parts No. 10 to No. 18 screws and nuts (arrows) are accessible (p. 48 34). after removal of the center console cover and of the air outlet nozzle. 2.
  • Page 307 Steering 4. Insert eccentric (No. 6) with small washer (No. 5) and large washer (No. 8) as well as needle-roller bearing (No. 7) into through bolt (No. 13). Use multi-purpose grease. 6. Install spring washers (2 PC.) and spring clip. 5.
  • Page 308 Steering 7. Adjust setting nut (No. 12) of the through bolt carefully. Proceed as follows: Tighten setting nut until both the steering wheel height adjuster operates perfectly in the open position and the clamping action at the adjuster mechanism is fully operative in the closed position.
  • Page 309 Modifications to the steering wheel height adjuster As of MY ‘92, axial locking of the operating level (No. 4) was improved by a spring clip (No. 1) This has entailed modification of the operating lever (No. 4) and of the eccentric (No.
  • Page 310 Lenkung Adjustment specification for Keylock cable Fit the Keylock cable on the steering lock General Screw in the Keylock cable No. 37 (see Page Vehicles with automatic transmissions for the 48-42) only with the steering lock in position USA and Canada have been equipped with “2”...
  • Page 311 Lenkung Adjustment and testing specification for Keylock cable Move the selector lever to position “P”. Turn the ignition key to position 2 (ignition on), Unscrew the adjusting screw (arrow) until the ignition key can no longer be turned to position 0 (stop)”...
  • Page 312 Hearer Refer to Repair Group 8’7 for removal and installarion of hearer. blower and air distribution housing, as well as disassembly and assembly of healer. Several poinrs will not apply CO cm wirhouL an air conditioner. 80 - 1 Hearer, Blower. Air Disrrihurion Housing Printed inGermany - II, 1979...
  • Page 313 Condiriuner SPECIFICATIONS FOR AIR CONDITIONER Refrigeranr capacity 950 gramS/33.5 ounces of R 12 Refrigeranr oil in compressor 350 cm3/12 ounces of Suniso Nn. 5 GS or Texaco Cappela “E” or similar Power requiremenr of apprux. 50 watrs comprrsroi clutch 117 2 30 C/242 + 50 I; = Seal on receiver-drier sea1 ruprures...
  • Page 314 /,‘. z-3$ 3, ; / /j 28 ~:.~/1i/lIi/Ji,~~~, ._,-,_. _._--- ______. _I -.-._._; ,-.,,--._-“_ ‘!‘,<;,,‘:‘rN,iNc: ~,‘,~i!!~,,,‘,iS :,I,? ~:o\,~,‘,‘li’iNi,l iorq UC Tl1EU.k blitteriai LUi. 111 il’l, Nm (I I lh) ‘2;’ 1.: ,‘KSS,lii. IillC II, z/d-x :,,s 2” Li :; F cxpansiw valve (to- Pressure line co...
  • Page 315 Conditioner REFRIGERANT SYSTEM LAYOU? 1 - Compressor 2 - Condenser 3 - Far. 4 - Receiver-drier 5 - Expansion valve 6 - Evaporator Refiigeranr System Layout Printed in Germany - Ii. 1979...
  • Page 316 Conditioner r.91 ix”! istl L.eJ r ?.j i”,d .ZO[ L& r.ol "1 I? I 87 - 2 Printed in Germany Vacuum sysrem LqKnN...
  • Page 317 Air Conditioner Safety regulations for handling the refrigerant The used refrigerante R12 is known as a 4. Refrigerant bottles must not be thrown and safety refrigerant. In other words, this refriger- must not be exposed to the sun or other ant Is non-combustible, non-explosive, non-...
  • Page 318 Air Conditioner Characteristics of the refrigerant R 12 Trade designation: Frlgen R 12, Freon R 12 4. Moisture in the refrigerant leads to decom- position of the refrigerant oil and to icing of CCl2F2 (Dichloffluor- Chemical designation: the expansion valve. For this reason, dis- methane) or CF2Cl2 mantled lines and assemblies and test instru- (Diuordichlormethane)
  • Page 319 Air Conditioner Flushing the air-conditioning system with refrigerant R 12 If humidity has entered the system during as- 5. Syphon off the refrigerant sembly of the air-conditioning system or as re- 6. Fft new fluid reservoir. sult of replacement of individual pans, the fol- lowing procedure must be followed when re- 7.
  • Page 320 Air Conditioner Installation work on the air-conditioning system Service unit SECU .,:.:. :.:.: .,.,..,.,.::,., Gjljl$:, yj: :;g Ijl ?<,$ y/~/::: , ;I:::: :::;; ;;;;; ~~ii/~i~~i ,:.:.:,:,:.:.: 6~:: 1 Installation work on the air-conditioning system 87 - Printed in Germany - XXV. 1990...
  • Page 321 Air Conditioner 1 - Pressure gauge, low-pressure 2 - Pressure gauge, high-pressure 3 - Torrmeter 4 - Shut-off valve, low pressure (blue) 5 - Shut-off valve, high-pressure (red) 6 - Shut-off valve, torrmeter (black) 7 - Shut-off valve, vacuum pump (yellow) 8 - Connection piece, low-pressure 9 Connection...
  • Page 322 Conditioner Installation work with intervention in the refrigerant system General work sequence The contents of the air-conditioning system must be disposed of in accordance with the 1. Syphon off refrigerant. relevant regulations before all work on the air- conditioning system which necessitates open- 2.
  • Page 323 Air Conditioner Note Syphoning off refrigerant Do not use syphoned-off refrigerating oil again. 1. Connect the selvlce unit to the system. 7. Fill in new refrigerating oil (syphoned-off Note volume + 10 cm3) Check on the fluid reservoir whether the sight glass is still transparent.
  • Page 324 Evacuating the air-conditioning sys- Flushing the air-conditioning system Note 1. Syphon off any existing pressure. Flushing the air-conditioning system serves the purpose of drying the circuit. 2. Switch on the vacuum pump (turn the main switch to the left). 1. Evacuate. 3.
  • Page 325 4. Set the required refrigerant quantity on the Filling the air-conditioning system filling cylinder with the rubber ring (differ- Note ence with respect to the refrigerant level in the filling cylinder). The air-conditioning system must be evacuated and filled. There must be sufficient 5.
  • Page 326 Air Conditioner Topping up the air-conditioning sys- Empty the service unit Note Note If the filling cylinder is full of refrigerant and it There is not sufficient refrigerant in the system is necessary to syphon off more refrigerant, if gas bubbles are visible in the sight glass of the clean refrigerant can be filled into a re- the fluid reservoir when the air-conditioning frigemnt bottle.
  • Page 327 Air Conditioner Cleaning the refrigerant Note If the syphonecl-off refrigerant is heavily con- taminated, it must be pumped through the fll- ter systems several times. The cleaning condition can be seen at the moisture indicator (14). 1. Open the filling cylinder shut-off valve (22). 2.
  • Page 328 0 2 8 Conditioner -& b--~--l 1 --v) 3. ‘y-., Printed inGermany - 11, ~qyq Removing and insmlling I-leater/Svaporaror...
  • Page 329 !/ !’ ii Iz i r c.Y 0 71 d i t i 0 II c r Don L hrcak off Replace, if nccissaiy Replace. il r~cressary ilxrrumcnr panel/ride vent and hearer/air Replace, if necessary Deiroircr vent, righr Replace, if necessary Reinforcemenr Heater/air cond.
  • Page 330 Condirioner I” addirion IO seal, also use non-hardening bluwei swilch shaft Adapter for air duct Side vent, left 87 _ 7 Removing and InsraIling liearer/Fvaporaror Printed in Germany - il. 1978...
  • Page 331 Conditioner !I 2 R REMOVING iNS1’ALLING HEATER/AIR CONDIIIONER 4. Remove ccwrr undcmealh inrrrurnenr cowl 1. Discharge air conditioner. (only on new models) and cover undcmearh sreerinq column swlrch. 2. D,sconnecr battery ground strap from body. II car has elecLric seats. IUII back seats all the way to lacilirate work.
  • Page 332 Conditioner 6. Remove insrrumenr cowl mounring screws Remove 5 swircher from illstrumrtll cowl hy pulling ulf swncl~ knobs. cr~mprcssm~ spring clips. pulling ou! swliches and pulling off PlUfiS. 7. Lift insrriimenr cowl, pull off plugs and K- move steering column switch. Pull OLli plugs frotn ruYptac,es 0”...
  • Page 333 !, 2 x Conditioner 11. .l’akc oii tray and ~$ovc hox. Rewove shift 14. Remove remaining ccurer console mounting ,rver lk1113b mt, il,iSl CC’Y(‘I. screws on frame tunnel al ICir anrl ri~!hi side< as well as vn insrrumcul panel. Rc~novc radio nlounring nut on holder (nor applicnblc to plq- 12.
  • Page 334 Conditioner 19. Disconnect sreering prorecrion tube from 16. Disconnect cable from heater flaps on heater/ insrrumenr panel (3 fillister head screws) air conditioner unit. ?cpyT!p &yiy~i. *.:. ‘< ,T ; t. ,,4c; 1‘. y:’ j. : & 20. Unscrew mounting screws of insrrument panel (2 each on left and right sides).
  • Page 335 Conditioner Remove cover over blower. 21. Pull off yellow and green vacuum hoses from vacuum boxes of fwtwell flap and defroster flaps. Remove instrument panel. Remove IWO screws on rubber connecm~ Remove connecring hoses berween side nozzles/glove box nozzle and heater/air between blower and hearer/air conditioner.
  • Page 336 !I 28 Conditioner InsraIling 25. Pry off wiper linkage lrom wiper mcli~r (facililares asscn~hly). Pull ofr plugs from resistor block/safely switch and vacuum hoiu (violer) from vacuum unir of [main shul-off nap. ilnscrcw and plu): LOW pressure I. llcplnce O-rinss on air condiilwer. Inslall air ~~~‘litllliOiier.
  • Page 337 “‘7, s-~’ .,I, ,! I,,/ ,’ !I 2 8 -.-.l.- . ,__- ,nr!,!ll COLl / lil’<‘T l~il>WCi f ,>lll,lll, ,:I,:? /~,,I 18 ,:I, i.,li~,;1,,, \I.# ,,.,, ,,;q’, ,!rl*LI. Y:‘c’,1l”1, ,,ilS ~pI~s:r 0: !;..ihtk,r bl0v.l ,~,,l:bj sti:: 11 81~1 Aila< II rnnncci~~~~ iuxes lor sit’e and glove box ,r~iw, 1111 ,t li1pLI;IILlr Sb.,i<d i:i?li,,(.<.i...
  • Page 338 Conditioner 14. Tighten center console screws. starring ar install instrument cowl (incl. steering column center nozzle/instrument panel. switch and covers). When installing switches. be careful not to mix up plugs for front fog light and rail fog light switches! Plug with black/violet wire belongs IO from fog light 15.
  • Page 339 Conditioner REMOVING INSTALLING BLOWER Removing mounting screws from blower. 6. Remove rhree a) To accomplish this. open flap of intake housing (move control switch lever to 1. Pull off ignirion key. Mark posirion of engine “AIR COND. “). Unscrew mourning screw hood and remove engine hood.
  • Page 340 4. Switch on the airconditioning system, Note motor speed approx. 2060 rpm. Open the Valves 6 and 7 must never be opened simul- filling valve 2 and low-pressure valve 7. taneousfy when the compressor is running. 5. Observe the sight glass in the fluid reservoir. The filling operation is complete il no gas bubbles are formed.
  • Page 341 Air Conditioner Installation work on the air-conditioning system Service unit SECU ~‘. .,,:,::::;_:::::_:::::: .~.,,:,~.~. ,:,:.~.: :,.:::: &::; y;; y:;~,~ -p& cj:,'j ,:::" j:i::; xl_ 5:;; :a:<: ~1~;:: ‘@, iii:;* :j__j::;;: ) :j;ijli; Ij;iij;;j 97 - 16 Installation work on the air-conditioning system Printed in Germany - XXIV, 1989...
  • Page 342 Air Conditioner 1 - Pressure gauge, low-pressure 2 - Pressure gauge, high-pressure 3 Torrmeter 4 - Shut-off valve, low pressure (blue) 5 - Shut-off valve, high-pressure (red) 6 Shut-off valve, torrmeter (black) 7 - Shut-off valve, vacuum pump (yellow) 8 - Connection piece, low-pressure 9 - Connection piece, high-pressure...
  • Page 343 Air Conditioner Installation work with intervention in the refrigerant system General work sequence The contents of the air-condtfioning system must be disposed of in accordance with the 1. Syphon off refrigerant. relevant regulations before all work on the air- conditioning system which necessitates open- 2.
  • Page 344 Air Conditloner Note Syphoning off refrigerant Do not use syphonedoff refrigerating oil again. 1. Connect the service unit to the system. 7. Fifl in new refrigerating oil (syphoned-off Note volume + 10 cm3) Check on the fluid reservoir whether the sight glass is still transparent.
  • Page 345 Evacuating the air-conditioning sys- Flushing the air-conditioning system Note 1. Syphon off any existing pressure, Flushing the air-conditioning system serves the purpose of drying the circuit. 2. Switch on the vacuum pump (turn the main switch to the left). 1. Evacuate 3.
  • Page 346 Air Conditioner 4. Set the required refrigerant quantity on the Filling the air-conditioning system filling cylinder with the rubber ring (differ- Note ence with respect to the refrigerant level in the filling cylinder). The air-conditioning system must be evacuated and filled. There must be sufficient 5.
  • Page 347 Air Conditioner Empty the servlce unit Topplng up the air-conditioning sys- Note Note If the filling cylinder is full of refrigerant and it There is not sufficient refrigerant in the system is necessary to syphon off more refrigerant, if gas bubbles are visible In the sight glass of the clean refrigerant can be filled into a re- the fluid reservoir when the air-conditioning frigerant bottle.
  • Page 348 Air Conditioner Cleaning the refrigerant If the syphonec-off refrigerant is heavily con- taminated, it must be pumped through the fil- ter systems several times. The cleaning condition can be seen at the moisture indicator (14). 1. Open the filling cylinder shut-off valve (22). 2.
  • Page 349 Condirioner I. Close main shur-off ilap. Lift apron ourer REMOVING INSTALLING secrion. Lift out blower. DISTRIBUTION HOUSlNG Removing NoLe Be careful nor to damage apron outer section. 1. Disconnecr battery ground -’ 2. Remove blower ::--‘- & 3. Disconnect vacuum hose from vacuum unit of control flap (only air conditioner) ar connecror --‘I, of hoses.
  • Page 350 Condirioner 5. Rcmovc mounring nuts and ~crcws iron] central Installing fuse/relay plate. Lower cenrral iuse/relny plate. To seal the air disrriburor housing. use a non- r-.7;:qQq”iR.~.; -’ ‘----upW- hardening caulking compound in addirion ro rhe I’ ‘-\.F., gaskel. t‘ .,;*,;;;/A .‘_.
  • Page 351 Condirioner \j *.y ~‘(“d i ,*,;- i; .: vi’/ . I I,$ / spy; G;;- c;;- kg311 c-7 FY ” (i .J- ?$ :l#y+&) ” :. ,?---------------- Printed in Germany - II. ~7:r H7 - l!) Disassembling and Assembling Hearei/Evaporarur...
  • Page 352 Conditioner Special Nore When Descriprion l”EIT”CL,OIIS Installing Removing if necessary Replace. Self-locking Washer screw 5 x 20 Replace, if necessary r1ore clamp Check for damage aid Wan3 drain huse position correctly Replace Push nut Foorwell housing i;notwe11 flap Replace all 4 O-rings 1”...
  • Page 353 Condirioncr Replace, il imxisary Position correctly ,kiri!sLlr 113,) li.YIT ,~‘i>\,l~il:, r~<Trcil:; ~1: ils.‘i,(.r ih,’ Printed in Germany _ 11, I:;:$, Disair~nlhli~rg allii Asscrmhliug i~iiaicr/tlaporaror...
  • Page 354 Condirioner Special Nore When Descriprion Installing Insrrucrions Removing Rubber washer Check operation Vat uum unir for shut-off flap Replace (same as Push IIUL no. 33) Same as no. 34 Shur-Off flap lever Rubber connector Replace Push nut Kuhher washer Vacuum unir for f001wc11 flap Outler ueck Printed in Germany...
  • Page 355 Conditioner DISASSEMBLING ASSEMBLING HEATER/EVAPORATOR Disassembling 3. Pry off reraining clips and remove sealant from joinr. Take apart heater/evaporator and remove interior parts. 1. Take off expansion valve. Remove temperarure switch and pull out capillary tube from guide tube carefully. Remove capillary lube.
  • Page 356 Conditioner REMOVING INST’ALLING CONDENSER LOOWI wire harness on lock cmv member 1. Remove air inlet grill. and remove cover. -AiggF3 yQm?~~( ,:’ 2. Pull off hose clamps on radiator. Disconnecr ,/’ wire plugs. L1nscrew lefr and right brackers ,’ on condenser. Unscrew upper fan moun[ings.
  • Page 357 !1 2P Air Condilio,ler n II M 0 v , \I (7 A ?I D I h! r i .li L I I r\ C, ,! I: C ,: I \ !: R - D RI r: R 1. Discharge air cundirioner. 6.
  • Page 358 ‘1 28 Conditioner REMOVING INSTALLING CONDENSER 6. Remove low pressure switch on receiver-drier. 1. Discharge air conditioner. ~#r~F’pm~; 2. Remove air inler grill. ./“;r / F” ,.,: 3. Remove condenser fan. 4. Loosen upper lefr and right hrackers on lock cross member and turn to on e side.
  • Page 359 Conditioner 7. Remove lower mounting screws on condenser. Pull out condenser with receiver-drier from above. 8. Take off receiver-drier Removing and lnsrallmg Condenser Primed in Germany - 111. 1980 87 - 27...
  • Page 360 Conditioner REMOVING INSTALLING COMPRESSOR Removing 1. Discharge air condirioner. 4. Remove holder from condenser ar rop right. 2. Remove spash shield underneath radiator. Looren compressor and rake off belt. 5. Disconnect hoses. Removing and lnsralling Compressor Printed in Germany...
  • Page 361 Conditioner Insralling New compresson are under pressure. Consequenrly unscrew plugs slowly until refrigerant is heard IO have escaped. Remove plugs only afrer releasmg pressure. Insrall and tighren hoses prior to insrallarion. ( .; \ .#‘&-.r‘+ b “TT‘ ~~ ,d .g-~ 6.
  • Page 362 ‘1 28 Conditioner TOOLS Descriprion Special Tool Remarks IHolding wrench 95458-02070 Holding wrench Local manufacture from 024 Sankyo compressor Puller "5456-03064 WO0diUff key puller Cl5456-21060 Thrusr washer puller 95456-03060 sea1 puller !15456-02060 Oil pipe pulling hook Local manulacl uie Seal installer 05456-0801"...
  • Page 363 Conditioner r .-.-._. J\\\ (&y p- -3. : ~&Gk Xl. yf r.,, ’ a\ “/ 0 -& g- 4% :,‘+ ‘L ‘T Iv ?? #p!mc? / I-- 3’ LC-_--._ _ g b yp ;-(I5 & +$y; / ,Lk-m- ‘c 4 r d ‘2. ,r/ 4% y&’...
  • Page 364 :i 28 Conditioner Note When Special Desciipliorl 3”. Qry. Removing Insralling Instructions Tighren 10 17 Nm (12 fr lb) Lockwasher Clutch plate Check for damage Se, of shims between Adjust play pulley and coupling I” 0.4 1. 0 rniil CO. 016 - 0. 040 in. j Circlip Bevel faces shaft end Pulley...
  • Page 365 Condilioner Note When Special Descriprion 1". Qry. Removing Insralling lnstrucrionn Thrust washer Don’ r damage sealing surfaces. Check for scratches, replacing sea1 both pans if necessary. Lubricate wirh refriger- ant oil O-ring 2’ to 26 Nm SCEW Tighten (1Y fr lb) coven.
  • Page 366 Conditioner Nore When Special Description Qfy. Removing Installing Instrucrionr O-ring Suction service valve O-ring Cap, sucrion valve Cap, discharge valve valve core safety valve SC31 Disassembling and Assembling Compressor Printed inGermany - III. 1980...
  • Page 367 Conditioner !,ZP DISASSEMBLING ASSEMBLING COMPRESSOR Removing Innralling Magneric Clutch 1. Counterhold with correct wrench depending 2. Remove clutch plare with puller. on version to loosen or tighten mounting nut. rrc* -i”: ’ *y+fq- b, ,,/’ ” ‘,m.- -a.- <+&j??? ---~----w%-.Ie,_ f!# .;...
  • Page 368 Conditioner 4. Install ball hearing. If necessary. adjust play with set of shims, cc - j M i... -J$c -~ +.- $h!, ,~;;~T+ Play between clutch plare and pulley 0.4 ~0 1. 0 mm (0.016 IO 0. 040 in. ). Disassembling Compressor Remove any plugs from line connections...
  • Page 369 iloodllioni’r !, 2 R 4. Renlovt~ cial will, pullrr. 3. 1’1,ll OIli ll,lllSi iun\,,e, Will, j-i,llC,. ‘. nl’“;*+. .“’ ‘\ ‘, *,’ “q ‘1, :i.’ .’ 5. Remove nwuoring bolls from rear lbousin~ cover. Take off housing cover. applying light taps with a plarric hammer when necessary.
  • Page 370 !I 28 Condiiiollrr 6. Pull out oil suclion rube with pulling hook. Assembling Compressor Note ; ;( Coar all gaskcrs and seals wilt) clea~l rrlr~~vrol- 1..._ I 9, $h ing oil prior 10 ior1allarion. page RI - ni lor d oil. j (See type\ 4’...
  • Page 371 Conditioner 3. Place seal in assembly 1001 and push on 10 5. Press in thrust washer with thrust pad and input shaft. nur until groove for circlip is visible. Turn real on shaft with tool until seal engages. lnserr circlip and take off thrust pad.
  • Page 372 Conditioner 7. Add refrigerant oil. Checking Volume System There is no way of checking rhe oil level in the 8. Turn assembled compressor wirh a torque wrench. air conditioner compressor. The compressor of a newly installed air conditioner has a total oil Torque must not exceed 17.
  • Page 373 Conditioner REGULATORS CONTROL UNIT OF AUTOMATIC CONDITIONER Inside Sensor Control Switch (opened) Outside Sensor Control Ilnil , ,’ f :’ -&‘. /’ ‘4a,, “-Q-P ,fm@9y.+q .- I. : i ’ #” ‘?“1, ; / ; d! .\’ I I :. ix’...
  • Page 374 <..s~Ib!ili~t:lcr - “-“t S,tLcl8siid V;iIvec SF-+. c- .y?,Tp= 1 ..I -‘; b, .’ ” i’ 8’ ‘:;y +-‘/-y ,: ’ 3. Loosen ‘Ul~l rl~n,n”e c”“tlo, ,b”Jxl (wires can remain wnnected). I’cv3twell flap (yellow) 4. Loosen and pull out control switch. Pull off Defroster tlap (green) Center nozzle stage I...
  • Page 375 Conditioner Removing Installing Inside Note SellSOr Some cars since standard production of 1980 1. Remove control switch models have an inside sensor with a separate blower. 2. Remove tray and glove box. 3. Unscrew trim panels on left and right sides of center console.
  • Page 376 Conditioner Removing Installing Outside Sensor Outside sensor is located in fresh air hose of 3. Unscrew valve carrier (2 screws). alternator. 1. Unscrew cover in front left wheel house. 2. Loosen hose straps on fresh air hoses and pull off of outside sensor housing.
  • Page 377 C.i~nditioner 18%' Printed in Germany - IV, 1980 Disacsembling and Arwmhlin~ C.enter Vent and Switch xs - 47...
  • Page 378 ‘3 2 5 Ilir Couditiw,er Ni>, E WIE” Special I<cn:o5;ir!ic ,> lnst.llling Instructions Centc,~ vmt Metal i<:rL!w :;<~!,,I,, illg pxt OIwraliug lever Microswitch Microswitch hoidcr Holder Vacuum unit for center vent ,‘I Rivet Flap, clinter YE”i 1’ Bushing Clip “7 - .,&B Printed in Germany Visassembling and Asiembling...
  • Page 379 Condirioncr Check all functions of vacuun~ controlled flaps prior to insrallarion of center console. For lhis purpose connect a vacuum hand pump in the sucrion line ahead of rhe check valve and build up a vacuum of abour 400 mbar. The relation of the slide posirion of rhe control switch [o the positions of rhe flaps is shown in the...
  • Page 380 Conditioner 87 - 50 Service Installing Air Conditioner Printed in Germany...
  • Page 381 Steering 3. Pull down pressure line, which does not re- 5. Mount pressure gauge between high quire loosening mounting clamp of lines. pressre hoses and place on a base (e.g. Connect 1.5 meter long high pressure hose toolbox) next to driver’s door. no.
  • Page 382 Conditioner Note When Special Description InsraIling Removing Inrrrucrions O-ring I. 5 x 1.8 O-ring 7.5 x 1. 8 Installing Pressure Sucrion Lines 1. Take off engine cover. 6. Remove plug on radiator and screw in rempera- ture switch (torque: 39 Nm or 3.9 kpm). Connect provided plug with protective sleeve.
  • Page 383 Condirioner 7. Unscrew cover for tread plate in firewall. Pull 9. Guide large diameter sucrioll line through am vacuum hoses and heater hoses from tread opening in firewall with connection plate. Llnscrew holder for heater hose. facing expansion valve and then position between engine and righr wheel housing.
  • Page 384 Conditioner 13. Position heater pipe line with hose above 15. Connect cover behind firewall on tread lines on wheel housing. plate. Insert and connect heater and vacuum hoses. 14. Place new mounting parts on lines and install nuts and screw. Align pipes and 16.
  • Page 385 Conditioner Insralling Pulley Compressor 1. Remove belts from power steering pump, 3. Remove pulley. lnsrall compressor pulley air pump and alternator. in place of spacer and tighten ECEWI. 2. Unscrew clutch operating cylinder (or cover 4. Reinstall operating cylinder or cover. for can with auromatic rransmisnion) inrrall...
  • Page 386 Conditioner 81 - 56 Service Installing Air Conditioner Printed in Germany...
  • Page 387 Colldilioner Note When Special Service Installing Air Conditioner Printed in - III. 1~cJ Germany...
  • Page 388 Conditioner 9 2 8 ;';I '$ $ \ :$&; :e,/ Service Installing Air Condirioner 81 - 58 Printed in Germany...
  • Page 389 Conditioner Note When ipecial nsrrucrions emoving Installing 011 M 10 x 25 Jasher I”[ M 10 Jasher lasher olt M 10 x 40 ‘ornpressor use NW 13 ose NW 10 lolr M 8 x iasher ;tlUt lolt M 8 x 20 Uasher to11 M 8 x 22 riasher...
  • Page 390 Conditioner ‘J 28 Installing Compressor Console Compressor 1. Remove air pump wirhout air cleaner. 5. New compressor is under pressure! Unscrew plugs on compressor slowly and listen for escaping refrigerant. Remove plugs only afrer releasing pressure. 2. Bolt console at tapped holes provided for rhir purpose.
  • Page 391 Conditioner Install compressor in console. Route hose on suction side up and connect on suction line. Route hose on pressure side Toward front between wheel housing and radiaror. 8. lnsrall belts in order of compressor. alternaror, air pump and power steering pump. and tighten. Service Installing Air Conditioner Printed in...
  • Page 392 Conditioner cTg!z =-*, a&,* --a ) - fqYpqJ$J Y I” +$izgg!;:*p@,, ,Sl’ .- * I ;‘ ,,)I ./ I .’ i 1: j.’ ;: 8 r y -5 ‘; ~‘. ;;,” _ ‘: ;: ,) :: :’ ;) ,: 1;’ i :‘j ” ” :: ‘,‘I ; ). ‘* ~ / Service Installing Air Condirioner Printed in Germany...
  • Page 393 Conditioner Special Nore When Descriprion Qty. lnrrructions InsraIling Removing Screw M 6 x 12 Lockwasher Tighten to 10 Nm Selflocking nor M 6 (1.0 kpm) Screw M 6 x 25 Washer Rubber washer Pa” N”!M Lockwasher Washer Rubber pad NM M 6 Lockwasher Washer Tank...
  • Page 394 I, 2 8 Conditioner Special Note When Descriprion Removing Installing Inrrructions Washer to 8 Nm Tighten screw M 6 x 20 (0. 8 kpm) Washer Rubber grommet Ilolder. right Holder. left Screw M 6 x 20 Washer Rubber grommet Condenser O-ring 10.6 x 1.
  • Page 395 !1 28 Conditioner lnsralling Condenser 3. Install rubber grommets in holes provided 1. Install remperarure switch on tank. CIOSS member. 2. Connect condenser outlet with rank inlet and bolt rank. _.~__~. _. .~e .-.- .-.” --’ ” y+yrz-z--.-- .1_.,,,, .,; ;ir .
  • Page 396 'I 28 Condirioner 7. Install low prcssurc swircb 10.rirl,q bclon,~s 1~1 5. Slide in condenser ahead of radiaror. Connect switch) rank with pressure line leading to expansion valve. Connecl condenser inler wirh hose y!! ;v/.,, leading IO compressor. /“” x,,,./; ;,Tc /’...
  • Page 397 !! 28 Conditioner 10. Mount wire harness on fan housing wilh a strap 13. Rolt fan from above. Bolt condenser ar rap wirb left and righr holders. Connect low pressure swiwh. temperature switch and fan wirb wire harness. Hold wire plugs on left and right sides wiih clamps.
  • Page 398 Conditioner < 1 - 16 Service installing Air Conditioner 81 - 68 Printed in Germany...
  • Page 399 Conditioner Special Installing Electric Valve 1. Install cross member. 2, Mark hose between throrrle bypass valve and inrake branch. and unscrew. Cut ou[ a piece abour 20 mm long ar marked position. 81 - 69 Printed inGermany - III, Service Installing Air Conditioner 1919...
  • Page 400 Conditioner 8. Install a tighten all removed a loosened 3. Remove hose wirh r-adapter between rhrorrle part% bypass valve and air guide housing. Take off r-adapter and shorren long hose by about 30 mm. 4. Mounr electric air valve on cmss member. Flush.
  • Page 401 Condirioner TOOLS ,’ ,@.’ Dencriprion Special Tool Remarks Holding wrench 95458-02070 Source of supply see Workshop Han, book Local manufacture from !124 Sankyo Holding wrench compressor 95458-03064 Puller Woodruff key puller 05456-21060 95456.03060 Thrust washer puller sea1 puller 95456-02060 Oil pipe pulling hook Local manufacture R5456-08010...
  • Page 402 Conditioner Fi Yf 1 ia ($ Y ,“@ G ,--r; ‘L3 Jy r’-’ -.- \i $q” .~~ c-. T-2 ~yI.+ 87 - 72 Disassembling and Assembling Compressor Primed in Germany...
  • Page 403 Conditioner Note When Special Description Remnvino T”*tal,in” lllsIrllrfiO”C Tighten IO l’i Nm (1. 7 kpm) Lockwasher Check for damage Coupling Adjust play berween Ser of shims pulley and coupliog co 0.4 1~ 0 rnlli Bevel faces shaft end C.irclip lieplace pulley assemtv Pulley...
  • Page 404 Conditioner pecial Nole When ‘0. Nescriprion !‘Y. emoving Insralling atrucrions Don’ I damage sealing ‘hut washer surfaces. Check for scratches. replacing both parrs if necessary, Lubricate with refriger sting oil l-ring Tighren IO 26 Nm crew (2. 6 kpm) ouung coveI, rea.1 m-ring il pump ouwr race...
  • Page 405 Conditioner Special Noit! When Description ~CZY. Installing Inntrucrionr Removing O-ring Suction cormection O-ring Plug. suction end Plug, pressure end Spring valve safety valve sea1 Disassembling and Assembling Compressor Prinred inGermany 111, 1~”...
  • Page 406 Conditioner 9 26 DISASSEMBLING ASSEMBLING COMPRESSOR Removing Installing Magnetic Coupling 1. Counrerhold with perrinent wrench depending 2. Remove coupling plare with puller. on version co loosen or tighten mounting nur. 3. Remove ball bearing ,F!b . i’\ &+-.?yfi& ~ “~’ a ’...
  • Page 407 Conditioner If necessary. adjust play wirh ser of shims 4. Install ball bearing. ,&.y_” 7sp- .J.G+& “a-. ‘lri ‘\ ~6”, . . -1.” .‘, h;,,- 1,:. ” .,.e, i...i--- 5. Play between coupling plare and pulley is 0. 4 IO 1.0 mm. Disassembling Compressor Remove any plugs from line connections...
  • Page 408 Conditioner 3. Pull out rhrusr washer with puller. 4. Remove seal wirh puller. ?\ / . .\ @&A”. ,I +4\, ’ i’ “< tp ..& :, t I i’ 5. Llnscrew mounting bolrs from rear hourinS cover. Take off housing cover. applying light knocks with a plastic hammer when “EGSC3iY.
  • Page 409 Conditioner 6. Pull OUI oil suction tube wirh pulling hook. Assembling Compressor F-p :, .-; Note , ,- ! -1 .f~ -A L 4~ Coat all gaskers and seals with clean refrigerating oil prior IO insrallarion. 4 ,.;&. ~<-. -.a-, (See page 87 - 01 for rypes of oil).
  • Page 410 Conditioner 9 2 8 3. Place seal in assembly tool and push on to input 5. Press in thrust washer with thrust pad and nut shaft. so far. until groove for circlip is visible. Turn seal on shaft with tool until seal engages. lnserr circlip and take off rhrust pad.
  • Page 411 Conditioner REGULATORS CONTROL UNITS FOR AUTOMATIC CONDITIONER Inside Sensor Control Switch (opened) 1 -=-y-q w-Y\\ ’ “m .- 1 ‘\. “‘.; .,,y’ ~ /?f@--T?“5 -.~F:~ _;,, ::l/ .‘- --;- Outside sensor Control Unit [:;I , .’ .- .q$- - _ ‘.
  • Page 412 Conditioner Solenoid Valves r-7. -yf?* ,cv ;. . T,, 7;7’ i ,,; 1. 2 ::;?“I --cc&- .4 - <-.-- - (; II 3 1’ E i F , .’ >k A ‘: ;>: *1~?z-e----J , ,g l.S!i Loosen and remove vonrrol board (w,res can ‘1 ‘-\...
  • Page 413 Conditioner Note Removing Installing Inside SellSOr Some cars since standard production of 1980 models have an inside sensor with a separate 1. Remove control switch. blower. 2. Remove tray and glove box. 3. Unscrew trim panels on left and right sides of Y ,;...
  • Page 414 Conditioner Removing Installing Outside Sensor Outside sensor is located in fresh air hose of alter- 3. Unscrew valve carrier (2 screws). nator. 1. Unscrew cover in front left wheel house. 2. Loosen hose straps on fresh air hoses and pull off of outside sensor housing.
  • Page 415 Condirioner h!i~,f ,&” “,^ _, ‘r ; 4 *IF. -“ 'i:* -- a,, j :L-ii li ~lk$ "li -‘ Printed in Germany - IV, 1980 Disassembling and Assembling Center Nozzle x7 - 87 and Switch...
  • Page 416 Condirioner Special ,.,” ._..^. Disassembling and Assembling Cenrer Nozzle 87 - 88 Primed in Germany and Switch...

  • Page 417: Automatic Air Conditioner 84 Models Onward

    Conditioner AUTOMATIC AIR CONDITIONER 84 MODELS ONWARD 87 - 89 Automatic Conditioner Printed in Germany - XIII, 1986...

  • Page 418: Technical Data

    Air Conditioner Technical data of air conditioning system up to June, 88 as of July, 88 Refrigerant volume Refrigerant 1050 g 950 g with auxiliary A/C system Refrigerant 1200 g 1150 g 280 k 20 C.C. Densoil 6 Refrigerant in compressor Type 6 E 171 120 + 20 C.C.

  • Page 419: Tightening Torques

    Conditioner GHTENING TORQUES Location Thread Description Torque in Nm (ftlb) 7/8”x 33 (24) Compressor - intake Union line 3/4”x 24 (17) Compressor - delivery Union line 3/4’ ’ x 16 24 (17) Condenser - inlet Union 314” x 16 24 (17) Condenser - fluid Union...
  • Page 420 Conditioner CONDITIONER DISASSEMBLING AND ASSEMBLING HEATER-AIR ? '-. p----L ,A’ yj&kny\, Printed in Germany 87 - 92 Disassembling and Assembling Heater- Conditioner...
  • Page 421 Conditioner Note Whc Description temoving installing Vacuum unit Speed fix .enew Rubber washer Self-tapping screw Self-tapping screw Cover Cover Self-tapping screw Solenoid valve Holder Vacuum hose Vacuum hose Vacuum hose Vacuum hose Connector Header Plug Vacuum hose 87 - 93 - XIII, 1986 Disassembling...
  • Page 422 Conditioner “i” ?- ! Printed in Germany 87 - 94 Disassembling and Assembling Heater- Conditioner...
  • Page 423 Conditioner Note Wh Description Removing installing Castellated *enew lock Vacuum unit Sheet-metal Antifreeze unit Do not damage capillar, tube. lush in to mark Guide tube Expansion valve Holder cable Plug Linkage Clip Setting motor Hose Water drain hose Cable connector Castellated 'enew lock...
  • Page 424 Conditioner Note When: 'Installing Description Removing renew if necessary Clamp Housing, rear renew Sealing profile renew Sealing profile Heat exchanger Vent body Clip Linkage Evaporator Holder renew O-ring check that grommet Rubber grommet is correctly seated check that grommet Rubber grommet is correctly seated Housing,...
  • Page 425 Conditioner REMOVING AND INSTALLING HEATER-AIR 8.Remove defroster vents. CONDITIONER 9.Remove bracket left-hand l.Disconnect battery. car has oddments tray. electrically adjustable seats, move seats to rearmost, lowest position (easier access). 2.Discharge conditioner. 3.Drain coolant. 4.Remove instrument scoops. S.Remove center console. 6.Remove instrument panel.
  • Page 426 Conditioner *.! 1 > !!‘! :i ; , T.v, -. h ‘y @;.IAQ. I+: -Y 17.Detach vacuum hoses for fresh air/recirculating flap (blue), water valve (white) vacuum line (black). 18.Pull water drain hose. 19.Withdraw heater-air conditioner. 15.Detach coolant hoses. 16.Unscrew 4 upper and 2 lower mounting...

  • Page 427: Removing And Installing Compressor

    Conditioner REMOVING AND INSTALLING COMPRESSOR l.Drain conditioner. 2.Unbolt guard beneath cooler. 3.Slacken compressor Vee belt remove belt. _ -.. .y,- ~-.; +4,, ,,.-.-. . . -- ‘. S.Disconnect plug-type :onnectors. ‘: ,‘. 6.Slacken hose clamp. ‘(. ;’ “-.. ._-. .‘7 ~_-~-- 4.Disconnect hoses.

  • Page 428: Removing And Installing Condenser

    Conditioner REMOVING AND INSTALLING CONDENSER l.Discharge conditioner. 2.Remove air intake screens. 3.Remove fluid tank (see page 87 - 101). 8.Insert plugs in connections lines. -3:. .’ \?$$ Note: I ,.__ :: New compressors are pressurized. Always unscrew caps slowly until refrigerant escapes with...

  • Page 429: Removing And Installing Fluid Tank

    Conditioner 6.Remove condenser lower mounting REMOVING AND INSTALLING FLUID TANK screws. l.Discharge conditioner 2.Remove air intake screens. 3.Disconnect plug temperature and low-pressure switch. 7.Remove condenser by lifting uoward. 8.Plug connectors and lines. 4.Detach bracket at top right lock transverse member and swing aside.

  • Page 430: Removing And Installing Antifreeze Unit

    Conditioner REMOVING AND INSTALLING ANTIFREEZE UNIT l.Remove lower cover in engine compartment. Z.Disconnect cable plug. 3.Unscrew mounting bolts. h.lJnscrew mounting bolts. Note: Always a replacement fluid tank the system is defective or if the coolant circuit opened. 7.Plug connectors and lines. 4.Carefully withdraw capillary...
  • Page 431 AIrConditioner Removing and Installing expansion valve Dlstrlbutlon of oil In retrlgeratlon clrcult I. Remove blower cover in engine compart- Compressor ment. Evaporator 2. Disconnect high and low-pressure lines. Condenser Fluid tank / lines 10 % These values are approximations. If a replacement compenent is fitted, top up the oil by an amount equal to the quantity left in the component removed.

  • Page 432: Vacuum System - Schema

    Conditioner VACUUM SYSTEM - SCHEMA A - Fresh air/recirculating flap 1 - Intake line 2 - Non-return valve B - Temperature mixer flap C - Defroster flap - Test socket 4 - Vacuum tank D - Footwell flap actuator E - Bulkhead 5 - To cruise control 6 - Distribution...

  • Page 433: Checking Vacuum System

    Conditioner CHECKING VACUUM SYSTEM l.Connect vacuum handpump to test connection. F.-T ;~ i 2.Pump until vacuum is estab- lished. 3.If no vacuum is created, fuel-line clamps, example, to close distribution manifold lines one by one until leak located. 4.Eliminate any leaks found.

  • Page 434: Flap Position Program

    Conditioner FLAP POSITION PROGRAM Temperature regulator at max. cooling output Flap A: open - recirculating closed - fresh Printed in Germany 87 - 106 Flap Position Program...
  • Page 435 Conditioner FLAP POSITION PROGRAM defrost closed open open 10 - 100 closed max. O-100 heating output O-20 ope open closed 20-100 closed O-20 Heating closed open 20-100 valve closed Blower stage stages Compres- BS - Blower switch AC - Air-conditioner switch TR - Temperature regulator...
  • Page 436 Conditioner CHECKING FLAP POSITION PROGRAM Flap A - recirculating Flap C - closed Flap D - closed Flap E - open Water valve - closed 2.Set slide 3 for supply central vent. Flap A - fresh air. The other flaps remain positions as for...
  • Page 437 Conditioner 6.Set slide 3 to defrost. The position of the temperature mixer flap can be tested by inser- Flap A - recirculating air. ting a finger between setting motor Flap E closes. and air deflector chamber. Water valve opens. Compressor switchs Blower switchs...
  • Page 438 Conditioner CHECKING OPERATING SWITCH Note: With operating switch removed and no voltage is registered, check connections made, use a volt- whether fresh-air blower relay meter to test voltages at the 15- switches. the fresh-air blower pole plug. relay does not switch, test signal at terminal...
  • Page 439 Conditioner 8.Connect voltmeter to terminal ll.Connect voltmeter to terminal and terminal and terminal Air-distribution slide to cen- ter, bottom, bottom/top and top. Reading: Battery voltage Temperature regulator slide Reading: Battery voltage 12.Connect voltmeter to terminal and terminal ;h;;;;;tribution slide Move temperature regulator slide to 27.
  • Page 440 Conditioner 15.Disconnect cable plug. Connect ohaaneter to terminal 13 and ter- minal Move temperature regulator slide to 18. Reading: approx. 750 + 100 Ohm Move temperture regulator slide to 30. Reading: approx. 1750 + 100 Ohm Note: The resistance must change by approx.

  • Page 441: Testing Setting Motor

    Conditioner TESTING SETTING MOTOR Note: Resistance increases temperature drops and decreases temperature rises. A resistance change of some 1000 Ohm is important. no change resistance is recorded, operting switch must be checked separately. the ohmmeter reads infinity, there is an interruption in the sensor chain...
  • Page 442 Conditioner Set temperature regulator slide to 27. Setting motor moves to- ward heating. Voltage is inter- rupted at 20%. 9.Connect voltmeter to terminal and vehicle ground. Temperature regulator slide to 18. Reading: Battery voltage. Set temperature regulator slide to 27. The setting motor moves toward heating.

  • Page 443: Adjusting Temperature Mixture Flaps

    Conditioner ADJUSTING TEMPERATURE MIXTURE FLAPS 6.Turn linkage until holes aligned. l.Set setting motor to maximum cooling output. 2.Disconnect setting motor linkage. -1)4 fy’ .‘~yq hr.. .,=,$ ;;.,,i:;,,: * ‘.-. ‘. ‘3 ,..,: > 4‘ 7.Engage pin. -I-- ..3.Move lever downward to maximum...

  • Page 444: Pressure And Temperature Specifications

    Conditioner PRESSURE AND TEMPERATURE SPECIFI- l.Switch on air conditioner. CATIONS 2.Set temperature regulator to max. cooling output. General preconditions: 3.Set fresh-air blower to stage - Vee-belt properly tensioned. - Vacuum system OK. After running approx. minutes at a speed of 2000 rpm with - Flap position program OK.
  • Page 445 Conditioner Low-pressure in the refrigeration circuit plotted against air-intake temperature. Temperature at central vent Temperature of air at the central vent plotted against air-intake temperature. - XIII, 1986 Printed in Germany Pressure and Temperature 87 - 117 Specifications...

  • Page 446: Troubleshooting

    Conditioner AIR CONDITIONER, TROUBLESHOOTING Insufficient Cooling output Complete cooling failure Connect service device. Witch on air conditioner and check l.Rupture element in fluid tank ruptured. pressure readings. The system has overheated. Check l.Low pressure normal. High pressure too high. operation and direction rotation of cooling...
  • Page 447 Conditioner Ice accretion on expansion valve. Heat expansion valve with a hot-air blower. The cooling efficiency the air conditioner must return normal. Cause: moisture refrigerant. replacement fluid tank. Recharge conditioner. Note: the air conditioner is refilled, the air-conditioning compressor only be switched on for the first...

  • Page 448: Auxiliary Air Conditioner

    Conditioner 4.Remove 4.Remove lower lower cover. cover. AUXILIARY AIR CONDITIONER An auxiliary evaporator increased refrigeration output available as an option (M 570). auxiliary evaporator with 3-stage blower installed instead of the rear parcel shelf. Removing Installing Evaporator l.Remove rear seat backrests.
  • Page 449 Conditioner Removing 4.Unscrew M 5 Allen-head bolts. stalling Expansion Valve l.Remove intake screen Note: Tightening torques 2.Remove upper cover. bolt: 6 Nm (4 ftlb) bolt: 9 Nm (7 ftlb) Renew all 4 O-rings. 3.Unscrew M 6 Allen-head bolt. 1986 Printed in Germany - XIII, Auxiliary Conditioner...
  • Page 450 Conditioner Removing Removing stalling Blower stalling S e r i'e Resistors l.Remove evaporator (see page 87 - 120). l.Remove covers, see section headed Removing and Installing Evaporator. E.Disconnect cable from blower. P.Disconnect plug-in connector. 3.Disconnect plug-in connector series resistors. ‘, ,,,A, .
  • Page 451 Conditioner Removing stalling Blower Switch Temper- ature Regulator l.Remove radio. P.Beginning at top, pull frame up \.:y and out. i \ ‘_ 3.Pull socket housing switch and regulator. Special tool P 9245 4.Disconnect cable to clock. 5.Remove control knobs. 6.Unscrew covers with special...
  • Page 452 Conditioner Removing Checking Control stalling Solenoid Unit Valve Note: Note: The solenoid valve is located The control unit is located to the beneath the passenger seat. right of the blower. l.Remove passenger seat. seat electrically adjustable, move seat to highest position facilitate removal.
  • Page 453 Conditioner 4.Connect voltmeter to minus terminal 4. Switch on ignition and blower auxiliary conditioner. Reading: Battery voltage 5.Connect ohmmeter to terminal and minus. Reading: 10 kOhm + 10% 6.Connect ohmmeter to terminal and terminal Reading: 1 - 10 kOhm + lo%, depending on setting temperature...
  • Page 454 Conditioner TOOLS Designation Special Tools Remarks 95458 - 02070 Source: Strap wrench Workshop Manual 95458 - 03064 Clutch plate puller Pliers cir- commercially clips available 87 - 126 Removing and Installing XVI,1987 - Printed in Germany Magnetic Clutch...

  • Page 455: Removing And Installing Magnetic Clutch

    Conditioner REMOVING AND INSTALLING MAGNETIC CLUTCH l.Use strap wrench to counterhold when loosening or tightening mounting nut. Tightening torque: 16 Nm (12 ftlb) s.Unscrew cable holder 2.Remove clutch plate with puller. 6.Remove circlip and lift magnetic coil. ,-’ 4!lfF!FGhd ‘. ..~ _ --~ \\3!’...
  • Page 456 Conditioner Installing Install both circlips with bevelled edges facing upward. The clearance between clutch plate and belt pulley is 0.4 - 0.7 mm. clearance necessary, correct inserting or removing shims. Printed in Germany 87 - I28 Removing and Installing Magnetic Clutch...
  • Page 457 Air Condition Technical data of air conditioning system As of MY ‘93 Refrigerant R 134 a Refrigerant charge 860 g with auxiliary air conditioning 1050 g Refrigerant oil in compressor 160 f. 20 cc. ND 6 10 PA 20 C Compressor type Safety valve...
  • Page 458 Air Condition Pressure and temperature specifications Refrigerant R 134 a 1. Turn on air conditioning GeneralTesting Requirements: 2. Set temperature control to max. cooling position. - V-beit tightened properly. 3. Set fresh-air blower to stage 2. -Vacuum system o.k. After an operating time of approx. 10 mins.. at -Solenoid clutch energized an engine speed of 2,000 rpm and with the...
  • Page 459 Air Condition 40 “c Ambient temperature 1341 87 Low pressure in refrigerant circuit vs. ambient temperature Temperature at center nozzle Ambient temperature 1342~87 Air temperature at center nozzle vs. ambient temperature 07 - 131 Pressure and temperature specifications Printed in Germany - XXXI.

This manual is also suitable for:

1986 9281985 928928

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