Porsche 928 - WORKSHOP 1977 Instruction manual

Workshop Manual
DR. ING. h. c. F. PORSCHE Aktiengesellschaft

The Workshop Manual is only for the internal use of the Porsche Dealer Organization,
@ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft
Sales, D-7140 Ludwigsburg
All rights reserved. - Printed in Germany Xx, 1988
WKD 481 621
Print No. W 42-608-126-l

List of Repair Groups
a
General Technical Data Page 0.1
Repair Groups Group
Maintenance. Selfdiaanosis 03
Engine Engine, Crankcase
Engine, Crankshaft, Pistons
Engine, Cylinder Head and Valve Drive
Engine, Lubrication
Engine, Cooling
Fuel Supply
Air Flow Controlled Fuel Injection
Exhaust System/Emission Controls
Starter, Power Supply, Cruise Control
lanition Svstem
10
13
15
17
19
20
24
26
27
28
Transmission Clutch, Controls 30
Torque Converter 32
Manual Transmission, Controls, Case 34
0 Manual Transmission, Gears, Shafts 35
Automatic Transmission, Contrds, Case 37
Automatic Transmission, Gears, Valve Body 38
Differential, Transaxle System 39
Chassis
BdY
Front Wheel Suspension 40
Rear Wheel Suspension, Axle Shaft 42
Wheels, Tires, Alignment 44
Antiblock System 45
Brakes, Mechanical 46
Brakes, Hydraulics 47
Steering 48
Body-Front Section 50
Body-Center Section 51
Body-Rear Section 53
Lids 55
Doors 57
Hardtop 61
Bumpers 63
Glasses, Window Control 64
Exterior Equipment 66
Interior Equipment 68
seats 72
Seat Covers 74
Heating,
Ventilation,
Air Condition
Electric8
Heater
Ventilation
Air Conditioner
Instruments, Fuel Gauge, Alarm System
Radio
Windshield Wipers and Washer
Exterior Lights, Lamps, Swftches
Interior Lights
Wiring
80
85
87
90
91
92
94
96
97
l
Printed in Germany - XX, 1987

928 Table of contents Volume IV
Front wheel suspension
Page
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 wheel suspension, 86 models onward .......... 40-7
Disassembling and assembling wheel suspension (before and after model year 86) 40-13
Wheel suspension components - installation overview .................. 40-16
Modifications to mountings ................................. 40-19
Closing slots in ball joints .................................. 40-23
Inspecting protective caps of ball joints on control arms and track rods ......... 40-24
Modified steering knuckle, cars with floating brake calipers ................ 40-25
Disassembling and assembling wheel bearing ....................... 40-27
Removing and installing spring strut ............................ 40-35
Disassembling and assembling spring strut, tools ..................... 40-35
Disassembling and assembling non-adjustable spring strut ................ 40-37
Disassembling and assembling adjustable spring strut .................. 40-39
Disassembling and assembling adjustable and non-adjustable spring struts ....... 40-42
Coil springs for adjustable spring struts .......................... 40-46
Coil springs for non-adjustable spring struts ........................ 40-47
Coil springs for non-adjustable struts/effect on car height ................. 40-49
Dampers - installation overview .............................. 40-51
Rear Wheel Suspension, Axle Shaft
Technical data
Tightening torques
Disassembling and assembling rear suspension
Disassembling and assembling Hub assembly
Replacing upper control arm mount
Removing and installing spring strut
Disassembling and assembling spring strut
Damper installation overview
Removing and installing axle shaft
Disassembling and assembling axle shaft
Removing and installing rear axle assembly
Wheels, Tires, Alignment
Wheels and tires, pressure
17-inch wheels
Alignment settings
...... 42-01
...... 42-02
...... 42-1
...... 42-7
...... 42-13
...... 42-14
...... 42-15
...... 42-l 8d
...... 42-19
...... 42-21
...... 42-29
.................
.................
.................
44-01
44-03
44-05
Table of contents
Printed in Germany - XXXV, 1996
1

Volume IV Table of contents 928
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 ......................... 44-21
Tire inflation pressure for vehicles with tire pressure warning system .......... 44-26
Tire pressure warning system short test ......................... 44-28
Removing and installing pressure-operated switches (tire pressure warning system) 44-29
Removing and installing high-frequency sensor (tire pressure warning system) 44-32
Removing and installing tire pressure warning system control unit. ........... 44-33
Connector assignment of the control unit connector ................... 44-34
Notes on trouble-shooting - Tire pressure warning system ................ 44-35
Tire pressure warning system (RDK) diagnosis. ..................... 44-301
Aritiblock System
General
Design - ABS
Components - ABS
Important notes for troubleshooting and ABS test program
Important information for working on cars with ABS
Removing and installing hydraulic unit
Removing and installing electronic control unit
Removing and installing relais
Removing and installing sensors
Removing and installing speed sensor, 86 models onward
Brakes I Mechanical
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 46-01
Technical data 46-02
Technical data, 86 models onward 46-05
Torque specifications 46-08
45-01
45-03
45-04
45-06
45-07
45-1
45-5
45-6
45-8
45-11
2 Table of contents
Prlnted In Germany - XXXV, 1996

929 Table of
contents
Volume IV
a
Technical data as of MY ‘92
Checking thicknesss of brake pads
Removing and installing brake pads (Floating frame caliper disc brakes)
Removing and installing brake pads (floating caliper disc brakes)
Removing and installing brake pads (four-piston fixed caliper)
Removing and installing brake pedal
Adjusting brake pressure rod (until end of model year 85)
Adjusting brake pressure rod (86 models onward)
Checking stoplamp switch setting
Disassembling and assembling front wheel brake
Disassembling and assembling rear wheel brake
Checking brake disc lateral runout
Checking brake disc thickness
Disassembling and assembling parking brake lever
Checking and adjusting parking brake
Page
46-011
46-1
46-2
46-5
46-6b
46-8
46-9
46-10
46-10a
46-l 1
46-13
46-16
46-18
46-19
46-21
Brakes I Hydraulics
Tightening torques ................................... 47-01
Notes on brakes, 86 models onward .......................... 47-03
Disassembling and assembling floating frame caliper ................. 47-l
Disassembling and assembling fist caliper ....................... 47-7
Replacing dampers and slides ............................. 47-12
Removing and installing brake master cylinder .................... 47-13
Removing and installing brake booster. ........................ 47-15
Removing and installing brake pressure regulator ................... 47-17
Braking-force regulators - installation overview (until end of model year 83) ..... 47-18a
Braking-force regulator installation overview (84 models onward) .......... 47-1813
Testing braking-force regulator ............................. 47-19
Notes on bleeding brakes and changing brake fluid .................. 47-22
Steering
Technical data
Torque specifications
Removing and installing steering gear
Steering stop versions
Removing and installing power steering pump
Replacing seals for aluminium power steering pump
Notes on power steering:
Checking drive belt tension
Checking steering system for leaks
48-01
48-02
48-l
48-6a
48-7
48.8a
48-8i
48-81
48-81
Table of contents
Printed in Germany-XxX”, ,996
3

Volume IV Table of contents 928
Bleeding steering system
Checking hydraulic function of steering (pressure test)
Removing and installing steering wheel
Repairing steering and intermediate shafts with steering tube
Replacing upper steering shaft bearing
Dismantling and assembling steering wheel height adjuster of airbag vehicles
Heater
Heater, blower, air distribution housing ................... 80-l
Air Conditioner
Specifications ......................................
Tightening torques ....................................
Refrigerant system layout ................................
Vacuum system layout .................................
Safety regulations for handling refrigerant R12 .....................
Installation work on the air-conditioning system (Service unit SECU)
Removing and installing heater I evaporator ......................
Removing and installing blower .............................
Removing and installing air distribution housing ....................
Disassembling and assembling heater I evaporator ..................
Removing and installing condenser fan
Removing and installing receiver-drier .........................
Removing and installing compressor ..........................
Disassembling and assembling compressor ......................
Regulators and control unit of automatic air conditioner ................
Disassembling and assembling center vent and switch
Automatic air conditioner 84 models onward ......................
Technical data ......................................
Tightening torques ....................................
Disassembling and assembling heater / air conditioner
Removing and installing heater I air conditioner ....................
Removing and installing compressor ..........................
Removing and installing condenser ...........................
Removing and installing fluid tank. ...........................
Removing and installing antifreeze unit .........................
Removing and installing expansion valve / Distribution of oil in refrigeration circuit
Vacuum system - schema ................................
Checking vacuum system ................................
Flap position program ..................................
Checking flap position program .............................
Checking operating switch. ...............................
Testing setting motor ..................................
87-01
87-02
87-l
87-2
87-3
87.4b
87-5
87-16
87-17
87-l 9
87-24
87-25
87-28
87-31
87-43
87-47
87-89
87-90
87-91
87-92
87-97
87-99
87-100
87-101
87-102
87-103
87-104
87-105
87-106
87-l 08
87-110
87-113
Page
48.8k
48-9
48-14
48-l 5
48-30
48-33
4 Table of contents
Printed In Germany-XXX”, ,996

928 Table of contents Volume IV
Page
Adjusting temperature mixture flaps ............................ 87-115
Pressure and temperature specifications .......................... 87-116
Troubleshooting ....................................... 87-118
Auxiliary air conditioner ................................... 87-120
Removing and installing magnetic clutch .......................... 87-126
Technical Data of air conditioning system as of MY ‘93 .................. 87-129
a
Table of contents 5
Printed in Germany - XXXV, 1995

l
928 Front Wheel Suspension
40
TECHNICAL DATA
Front Axle
Suspension
Springs
Dampers
Make/installation
Stabilizers
until end of model year 79
80 models onward
86 models onward
Independent suspension, double
control arrr with coil spring and internal
damper.
1 coil spring per wheel
Double-action hydraulic dampers
See page 40 - 51
dia. 26 mm
dia. 28 mmx 4 (tubular stabilizer)
dia. 28 mm x 4 (tubular stabilizer)
with modified knuckle
a Printed in Germany - XIII, 1986 Technical Data 40 - 01

40
Front Wheel Suspension 928
TIGHTENING TORQUESFOR FRONTAXLE
Location Description Thread Material
Upper control
arm to body VM 14x1.5 8
Lower control
arm to body,
rear
Self-locking
hex nut
Hex bolt M 12x1.5 10.9
Lower control
arm to body,
front
Hex bolt M 12x1.5 8.8 85 (62)
Guard to
longitudinal
member
Self-locking
hex nut VM 10 8 46 (33)
Spring strut
to body Self-locking
hex nut
Self-locking
hex nut
VM 10 8 46 (33)
Spring strut
and stabilizer
linkage to
lower control
arm
VM 12x1.5 8 85 (62)
Stabilizer
clamp to
longitudinal
member
Hex bolt M 10 8.8 46 (33)
Stabilizer
linkage to
stabilizer
Self-locking
hex nut VM 12x1.5 8 85 (62)
Upper and
lower control
arms to
steering
knuckle
Flange
locknut M 12x1.5 8 65 (47)
Guard to
steering
knuckle
Hex bolt M7
Cable holder
to steering
knuckle
Hex bolt M7
8.8
8.8
Torque
Nm (ftlb)
140 (103)
120 (88)
15 (11)
15 (11)
0
40 - 02 Tightening Torques Printed in Germany

928 Front Wheel Suspension
40
Location
Brake caliper to
steering knuckle
Brake disk to
wheel hub
Panhead bolt to
clamping nut
Wheel to wheel
l
hub
Steering track
rod to steering
arm
Rubber bushing
of piston rod
of spring strut
Ball joint,
(mounting) to
lower control
arm
Support plate
on steering
axle (upper
control arm)
a Roadspeed sensor
to steering
knuckle
Description
Hex bolt
Panhead bolt
Countersunk
bolt
Panhead bolt
Wheel nut
Hex nut,
self-locking
Hex nut,
self-locking
Hex nut,
self-locking
Hex nut,
self-locking
Panhead bolt
Thread
M 12x1.5
M6
M7
M 14x1.5
VM 12x1.5
VM 12x1.5
VM 12x1.5
VM 12x1.5
M6
Material
8.8
8.8
10.9
Al
8
8
10
8
8.8
Torque
Nm (ftlb)
85 (62)
10 (7)
15 (11)
130 (95)
65 (47)
60 (44)
120 (88)
85 (62)
10 (7)
Printed in Germany - XIII, 1986 Tightening Torques 40 - 03

40
Front Wheel Suspension 928
NOTES ON FRONT AXLE, 86 MODELSONWARD
New front wheel suspension
1 2
13
9-
40 - 04
Notes on Front Axle, 86 Models Onward Printed in Germany

928 Front Wheel Suspension
40
0 Front Axle Modifications,
86 Models Onward
No./Description
1 Steering knuckle
l
- Wheel bearing
- Steering offset
2 Upper control arm
a 3 Dampers
Most Important Modifications
Attachment points for brake
caliper
Studs for wheel bearing
(clearance and diameter for
outer bearing)
Locator for ball joint
No. 10 of the mounting
Outer wheel bearing larger.
Distance between bearings
increased
- 10.2 mm before - 16 mm
Shorter than before. Ball
joint inclined outward
Adjustment
2-pipe gas-filled dampers
(Boge) standard and optional
previously
standard:
Z-pipe pressureless (Boge)
optional:
l-pipe gas-filled (Bilstein)
Remarks
Four-piston fixed
caliper, 86 models
onward
Adjust as before
(every 20000 km)
For braking system
(four-piston fixed
caliper)
Heights and wheel
geometry unchanged
Distinguishing
feature,
P. 40 - 16/17
Table P. 40 - 51
Combination with
coil springs up to
86 models imper-
missible
Printed in Germany - XII 1, 1986 Notes on Front Axle, 40 - 05
86 Models Onward

40
Front Wheel Suspension 928
No./Description
4 Coil springs
7 Stabilizer linkage
- Stabilizer
8 Steering track rods
9 Mounting (steel)
11 Camber and caster
eccentrics (same
parts)
12 Lower control arm
13 Spring strut
stirrup
Most Important Modifications
spring rate increased
longer than before
modified knuckle
approx. 1Omn shorter than
before
upright ball joint (pre-
viously trailing ball joint)
external contour smaller
shorter than before
modified mounting point for
spring strut, because con-
trol arm shorter but strut
position same as in cars
earlier than 86 models
Remarks
Only for Boge gas
dampers.
Combination with
dampers up to 86
models or Bilstein
dampers imper-
missible P. 40 - 46
P. 40 - 16/ 40 - 18
P. 40 - 16/18
P. 40 - 16/17
P. 40 - 19 to
40 - 21
External eccentric
A = camber
eccentric
Internal eccentric
B = caster
eccentric
P. 40 - 21
Distinguishing
feature/code P. 40
- 16/17
Distinguishing
feature/code
P. 40 - 19 to
40 - 21
a
40 - 06 Notes on Front Axle, 86 Models Onward Printed in Germany

928 Front Wheel Suspension
40
TOOLS
No. Description Special Tools Remarks
1 Press-out tool VW 267 a
2 Track rod puller e.g. Nexus 168 - 1
Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 1
Wheel Suspension

40
Front Wheel Suspension 928
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-
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24 23 22
0
40 - 2 Disassembling and Assembling Wheel Printed in Germany
Suspension, Until End of Model Year 85

928 Front Wheel Suspension
40
No
-
1
l
3
3i
4 Locknut
5 Washer
6 Locknut
Description
Locknut
Washer
Flange locknut
(for steering
knuckles without
push-off lug for
ball joint)
or
Flange locknut
Cap locknut (on
steering knuckles
with push-off lug
for the lower
ball joint). (See
page 40 - 25)
Washer, 928 S
only (floatin
caliper brake 3
Air guide plate,
928 S (floating
caliper brake)
ItY
-
3
3
2
1
1
2
1
1
1
1
Note When:
Removing
load ball joint by
axerting pressure on
Jpper control arm
to ease installation,
see removing as for
36 models onward
(p. 40 - 8)
Installing
renew, torque: 46 Nm
(33 fltb)
renew, torque: 65 Nm
(47 ftlb). Exert
pressure on upper
control arm to load
ball joint
renew, torque: 140 Nm
(103 ftlb)
only on rear pin of
control arm
renew, torque: 85 Nm
(62 fltb)
Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 3
Wheel Suspension, Until
End of Model Year 85

40
Front Wheel Suspension 928
No
-
7
8
9
10
11
12
13
14
15
Description
Qtr
Hex bolt
Stabilizer
linkage
Upper control
arm
Spring strut
Steering knuckle
Locknut
Caster/camber
eccentrics
Camber/caster
eccentric
Ball joint
(mounting)
Note When:
Removing Installing
when replacing, do not
confuse with version
for 86 models onward.
Installation overview,
pages 40 - 16 to
40 - 18
inspect, renew if
necessary, reworking
is impermissible
inspect for damage,
reworking is imper-
missible
See page 40 - 25
renew, torque: 120 Nm
(88 ftlb)
lubricate sliding suf-
faces of eccentric ad-
justment range with
Optimoly TA. Cover
ball joint slots. See
pages 40 19, 40 - 20
and 40 - 23
see pages 40 - 19 and
40 - 20 for position
and types.
inspect, renew if
necessary. Cover slot,
see pages 40 - 19,
40 - 20 and 40 - 23
0
40 - 4 Disassembling and Assembling Wheel Printed in Germany
Suspension Until End of Model Year 85

928 Front Wheel Suspension
40
No
-
16
17 Locknut
18 Hex bolt
19
20
21
22
Description
Clamp
iex bolt
(10.9, 80 nnn long]
dasher approx.
S mm thick, dia.
approx. 30 nm
Bearing clamp
Hex bolt
(100 mm long)
!U
-
1
2
2
2
2
1
2
* See notes on page 40 - 14
Note When:
lemoving Installing
see pages 40 - 19 and
40 - 20
renew, torque: 46 Nm
(33 ftlb)
Coat threads with
3ptimoly HT (do not
apply Optimoly HT to
bolt shank).* Screw in
until only 2 threads
are visible. Do not
tighten to 120 Nm (88
Fltb) until assembly
is completed and
springs have settled
do not mix up with
Masher No. 23
inspect for damage.
Tighten to specified
torque
Coat thread with Opti-
moly HT. (Do not apply
Optimoly HT to bolt
shank).* Torque: 85 Nm
(62 ftlb)
Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 5
Wheel Suspension Until End of
Model Year 85

40
Front Wheel Suspension 928
No.
23
24
25
Description
Washer
w;;x. 4 mm
dia. approx.
25 nm
Guard
Lower control arm
with*
spoiler
securing bolts
cup washers
securing brackets
locknuts
BY Note When:
Removing Installing
do not mix up with
washer No. 20
renew if damage sus-
pected. No reworking
is permissible.
Tighten bolts No. 19
of bearing clamp No.
21 as specified. When
replacing, do not con-
fuse with control arm
for 86 models onward.
Installation overview,
Pages 40 - 16 to
40 - 18
* 928 S only (floating caliper brakes)
40 - 6 Disassembling and Assembling Wheel Printed in Germany
Suspension, until End of Model Year 85