User manual PORSCHE 928 WORKSHOP MANUAL

[. . . ] PORSCHE Aktiengesellschaft The Workshop Manual is only for the internal use of the Porsche Dealer Organization. @ 1977 Dr. Porsche Aktiengesellschaft Sales, D-7140 Ludwigsburg All rights resewed - Printed in Germany XX, 1986 WKD 481 621 Print No. W 42-608-126-l List of Repair Groups General RepairGroups Maintenance, Self-diagnosis Technical Data Paae 0. 1 Group 03 10 13 15 17 19 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 Contrds Starter, Power Supply, Cruise Control Ignition System Clutch, Controls Torque Converter Manual Transmission, Controls, Case Manual Transmission, Gears, Shafts Automatic Transmission, Controls, Case Automatic Transmission, Gears, Valve Body Differential, Transaxle System Front Wheel Suspension Rear Wheel Suspension, Axle Shaft Wheels, Tires, Alignment Antiblock System Brakes, Mechanical Brakes, Hydraulics Steering Body-Front Section Body-Center Section Body-Rear Section Lids Doors Hardtop Bumpers Glasses, Window Control Exterior Equipment Interior Equipment Seats Seat Covers 20 24 26 27 28 30 Transmission 32 34 35 37 38 39 40 Chassis 42 44 45 46 47 48 50 51 53 55 57 61 63 64 66 68 72 74 80 85 Heating, Ventilation, Air Condition Electrics Heater Ventilation Air Conditioner Instruments, Fuel Gauge, Alarm System Radio Windshield Wipers and Washer Exterior Lights, Lamps, Switches Interior Lights Wiring 87 90 91 92 94 96 97 Printed in Germany - XX, 1997 928 a Table of contents Volume III Page General Data Technical data Tightening torques 30-0101 30-0105 Torque Converter Removing and installing torque convener Removing and installing selector lever cover frame Removing and installing selector lever cable Adjusting selector lever cable Removing and installing starter locking and backup light switch Adjusting starter locking and backup light switch Checking adjustment of selector lever cable and starter locking / backup light switch Bowden cable for control pressure, removing and installing (service solution) Bowden cable for control pressure, adjusting Removing and installing transmission Adjusting transmission suspension Disassembling and assembling front convener housing Disassembling and assembling front converter housing (`87 models onward) Removing and installing rear transmission case Removing and installing rear transmission Disassembling and assembling transmission 32-101 37-101 37-103 37-105 37-107 37-109 37-l 11 37-113 37-115 37-l 17 37-123 37-125 37-l 30 37-131 37. 135 37-143 Transmission I Gears, Valve Body 38-101 38-l 10 38-11 Oa 38-111 38-123 38-l 25 38-130a 38-131 38-133 38-137 38-141 38-143 38-145 38-147 Checking transmission operation . . . . . . . . . . . . . . . . . . . . Checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ] Place outer race of one-way clutch on inner plate carrier and install roller cage in correct oosition. 6. Push cylindrical rollers against springs and apply Special Tool 9322 with bend facing out. Note: Install O-ring only after checking of one-way clutch. Install one-way clutch inner race while turning in direction of arrow. axial play Printed in Germany - VI I I, 1984 Disassembling and Assembling One-way Clutch 38-167 38 Automatic Transmission/Gears, Valve Body 928 8. Install support that pin engages in bore (arrow) of one-way clutch outer race. /'p4* ", (_ -. `- . . I _ `1 `-4 `* Checking One-wav and Clutch Adjusting Axial Play: 9. Place shims (if available) on outer race of one-way clutch and install connecting carrier on one-wav clutch. 1. Check play between one-way clutch and connecting carrier with a feeler gauge. I , 10. Install snap ring and press into groove with a screwdriver. 2. Adjust play to 0. 05 shims. 0. 2 mm with 3. Install O-ring, 38 168 Disassembling ans Assembling One-way Clutch Printed in Germany 928 Automatic Transmission/Gears, Valve Body 38 a TOOLS 2 ff+-+----+b , ' l , , /'. 1' , j\ . -. 1 !' _- , ??+\ 3 ;, "j \ . . . /z No. t 1 2 3 4 Description Assembly Assembly Assembly tool sleeve sleeve Special Tool 9315 9317 9318 - Remarks Feeler blade gauge Standard tool - Printed in Germany VIII, 1984 Disassembling Clutch K 1 and Assembling 38 - 169 38 Automatic Transmission/Gears, Valve Body 928 DISASSEMBLING AND ASSEMBLING CLUTCH K1 L. -. -. m. -. -. -. -. - . m. m. s. 1. i 38-170 i Disassembling Clutch K 1 and Assembling 5 ( Printed in Germany 928 Automatic Transmission/Gears, Valve Body 38 No. Iescription Qty, T Removing Note When: Installing Redetermine thickness, if necessary Check for burnt spots and bendil "!3 Special Instructions ;nap ring X I(Iuter plate 1 4. 5 or 5. 0 mm thick (optiona to adjust play) nner plate 2. 1 mm thick) 5 a Iuter plate 4 Check for burnt spots and wear. Place in ATF about 1 hour w before installing Check for burnt spots and bending 3. 0 or 3. 5 mm thick (optional to adjust play) 5 ~Outer plate ~ 12. 0 mm thick) 1 I Check for burnt spots and bending Position correct Iv that curved surface faces piston Install with Special Tool 93' 15. I checking for correct fit I IDiaphragm spring a I!Snap ring Special Tool 9315 Diaphragm Spring spring Vote quantity for reinstallation a Printed in Germany VIII, 1984 Disassembling Clutch K 1 and Assembling 38-171 38 Automatic Transmission/Gears, Valve Body 928 1 No. 10 11 12 ' 13 Description Qty. Removing Note When: Installing Install with Special Tools 9317 and 9318 Special Instructions Piston 1 Seal 1 I Position correctlv. coat with ATF " Position correctly. coat with ATF Seal Plate carrier L a 38. 172 Disassembling Clutch K 1 and Assembling Printed in Germany 928 Automatic Transmission/Gears, Valve Body 38 l DISASSEMBLING AND ASSEMBLING CLUTCH K1 Disassembling 1. Apply Special Tool 9315 on diaphragm spring and tighten until snap ring can be removed. 2. Apply Special Tools 9318 and 9317 in outer plate carrier. 3. Install piston carefully and press into outer plate carrier without canting. 2. [. . . ] To do this, attach the electrical plug. As soon as the pump is heard to switch off, pull off the electrical plug and reduce the pressure at the bleeder valve of the lock solenoid valve. Slowly open the bleeder valve and hold the bleed hose firmly. Important: A pressure of up to 180 bar is present in the system. Wear goggles and protective gloves. 0 D39 - 258 PSD diagnosis/Troubleshooting Printed in Germany - XXXV. [. . . ]