Detailed instructions for use are in the User's Guide.
[. . . ] 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 . . . . . . . . . . . . . . . . . . . . Disassembling and assembling shift valve casing (`87 models onward) Removing and installing lower cover . . . . . . . . . . . . . . . . . . [. . . ] 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 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. Removing
Note When: Installing Install with Special Tools 9317 and 9318
Special Instructions
Piston
1
Seal
1
I
Position correctlv. 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. Install piston carefully and press into outer plate carrier without canting.
2. Remove diaphragm
spring and springs
Note: The quantity of springs for clutch piston will vary. If new springs are required, the same quantity of springs must be installed. Install seals in piston that sealing lips face down (direction of arrow).
Note: Coat seals and sliding surfaces on Special Tools 9318 and 9317 with ATF.
Printed in Germany - VI I I, 1984
Disassembling
and Assembling
Clutch
K1
38
173
38
Automatic
Transmission/Gears,
Valve
Body
928
4. Install springs in piston and place on diaphragm spring, whereby each spring must be centered by a guide pin.
Checking
Play (0. 7 to 1. 2 mm) of Clutch:
1. Push up snap ring around entire periphery with a suitable screwdriver. Install diaphragm spring with curved surface on piston as shown in figure.
t
a
2. Check play "A"
with a feeler gauge blade.
1 = Diaphragm
spring
8. Assemble set of plates as shown in layout drawing and install in plate carrier.
a
Note: New inner plates must be placed in ATF about 1 hour before installing.
38
174
Disassembling
and Assembling
Clutch
K1
Printed , n Germanv
928
Automatic
Transmission/Gears,
Valve
Body
38
Note: Play "A" can be adjusted with a snap ring which is available in 3 thicknesses (2. 0 / 2. 5 / 3. 0 mm). [. . . ] The exact work procedures and nominal values are stated on Pages D39-251 D39-256.
If necessary, top up the brake fluid level at intervals so that the brake fluid reservoir is not drained completely. The lock hydraulics must be at zero pressure when connecting and removing the pressure gauge. Afler the testing and assembly work has been completed, correct the brake-fluid level when the pressure reservoir is fully charged.
2389-039
4. Partially bleed the lock hydraulics as follows: Wfih the ignition switched on, open the bleeder valve on the lock solenoid valve. [. . . ]