Porsche 968, repair e-manual

Content

General

• Technical data

Maintenance, self-diagnosis general

• Maintenance
• Operating instructions for system tester 9288

Engine, crankcase, engine mounts

• Tolerances and wearlimits
• Tightening torques for engine
• Removing and installing engine (manual transmission)
• Removing and installing engine (Tiptronic transmission)

Engine, crankshaft, pistons

• Adjusting guide rail for balance shaft toothed belt
• Checking adjustment of balance shafts
• Fitting toothed belt for balance shaft
• Adjusting special tool 9201
• Checking and adjusting balance shaft toothed belt tension
• Crankcase markings
• Locking the flywheel for assembly work
• Engine support
• Crankcase - tools
• Machining cylinder bores in upper crankcase section
• Crankcase - installation length or protrusion length of studs
• Dismantling and assembling crankcase, crankshaft
• Aligning the upper and lower parts of the crankcase
• Crankshaft - standard and repair dimensions
• Dismantling and assembling pistons, connecting rod
• Checking piston and cylinder bore
• Dismantling and assembling balance shaft drive
• Removing and installing double-mass flywheel and grooved ball bearing

Engine, cylinder head, valve drive

• Replacing the camshaft toothed belt (with hydraulic belt tensioner)
• Adjusting and checking the camshaft setting
• Applying TDC mark to camshaft sprocket
• Camshaft adjustment gauge (shop-made)
• Fitting the camshafts
• Fitting the camshaft seal
• Camshaft references
• Machining the cylinder head mating face
• Removing and installing cylinder head
• Valvedimensions
• Dismantling and assembling camshaft drive
• The following topics of Repair group 15 are described In the Repair Manual Type 944, vol. 1 - A:
• Cylinder head, disassembling and assembling
• Valve springs, removing and installing with Sauer tool
• Valve springs, removing and installing, removing valve stem seal
• Checking valve guides
• Replacing valve guides
• Checking valve-seat wear limit
• Valve seats, checking and machining
• Checking and adjusting installation length of valve springs

Engine, lubrication

• Removing and installing lubrication system components
• Dismantling and assembling oil pressure release valve
• Removing and installing oil restraining valve
• Checking oil pressure
• Cleaning the entire engine oil system

Engine, cooling

• Mixing table
• Cecking cooling and heating system for tightness

Fuel supply

• Fuel vacuum line routing
• The following topics of Repair group 20 are described In the Repair Manual Type 944, vol. 1 - A:
• Replacing fuel filter, checking injection lines for leaks and tightness

Fuel system - electronic injection

• Testvalues
• Checking idle and CO level of vehicles without catalytic converter
• Checking idle and CO level of vehicles with catalytic converter
• Removing and installing DME injection system components
• Removing and installing injection valves
• The following topics of Repair group 24 are described in the Repair Manual Type 944, vol. 1 - A:
• Checking fuel pressure

Ignition system

• Replacing spark plugs
• DME control units as of Model Year ’92
• Removing and installing knock sensors
• DME-diagnosis / troubleshooting

General

• Technical data

Clutch, operation

• Identification of clutch pressure plates
• Removing and installing clutch
• Adjusting the clutch pedal

Manual transmission, operation, housing

• Removing and installing transmission
• Adjusting gearshift
• Removing and installing gear set
• Removing and installing drive shaft seal if transm. has not been dismantled
• Removing and installing 5th and 6th gear
• Determining snap rings for tapered roller bearing and 6th gear gearwheel
• Removing and installing drive pinion and drive shaft
• Dismantling and assembling end cover
• Recalculating adjusting shim "S4"
• Dismantling and assembling end shield
• Dismantling and assembling transmission housing

Manual transmission, gears, shafts

• Dismantling and assembling drive shaft
• Dismantling and assembling drive pinion

Differential / transaxle system

• Removing and installing differential
• Dismantling and assembling differential
• Adjusting drive set

Front wheel suspension

• Torque specifications - front axle
• Technical data 968/968 CS
• Adjusting the front wheel bearings
• Dismantling and assembling suspension
• The following topics of Repair group 40 are described in the Repair Manual Type 944, vol. 3:
• Wheel bearings, disassembling and assembling

Rear wheel suspension, drive shaft

• Torque specifications - rear axle
• Technical data 968 / 968 CS
• Dismantling and assembling suspension
• The following topics of Repair group 42 are described in the Repair Manual Type 944, vol. 3:
• Aluminium trailing arms, disassembling and assembling

Wheels, tires, alignment

• Wheels and tires
• Fitting 16" and 17" cup design wheels to the vehicle
• Wheel mounting as of MY '94
• Wheels and tires of the 968 CS
• Sample measuring chart
• Adjustment values for wheel alignment
• Suspension alignment
• Tire fitting

Anti-lock braking system

• The following topics of Repair group 45 are described in the Repair Manual Type 944, vol. 3:
• General
• Position of ABS components
• Important notes - troubleshooting and ABS test program
• Hydraulic unit, removing and installing

Brakes, mechanical

• Technical data
• Torque specifications - mechanical brake system
• Checking thickness of brake pads
• Removing and installing brake pads
• Adjusting the brake pushrod
• Checking stop light switch adjustment
• Checking and adjusting the parking brake
• Checking brake disc lateral runout
• Checking brake disc thickness
• The following topics of Repair group 46 are described in the Repair Manual Type 944, vol. 3:
• Front-wheel brakes, disassembling and assembling
• Rear-wheel brakes, disassembling and assembling

Brake, hydraulics, regulator, booster

• Torque specifications - hydraulic brake system
• Changing the brake fluid / bleeding the brakes
• The following topics of Repair group 47 are described In the Repair Manual Type 944, vol. 3:
• Brake booster, removing and installing

Steering

• Torque specifications - steering
• Technical data 968 / 968 CS
• Removing and installing ignition steering lock
• Replacing igniton switch
• Replacing lock barrel of igniton steering lock
• The following topics of Repair group 48 are described In the Repair Manual Type 944, vol. 3:
• Power steering gear, removing and installing
• Power pump, removing and installing
• Checking hydraulic operation of the steering system (pressure measurement)

Body, general

• Safety notes
• Checking dimensions for body repairs
• Checking dimensions for body repairs - Cabriolet
• Special tools and metalworking repair tools

Body, front

• Replacing part of front end

Body, center

• Replacing part of door sill with side member and floor pan
• Replacing complete roof

Body, rear

• Replacing part of rear end

Lids

• Dismantling and assembling front cover

Doors

• Removing and fitting door outer handle
• Dismantling and assembling door outer handle

Convertible top

• Removing and installing convertible top

Bumpers

• Removing and fitting spoiler and bumpers
• Removing and fitting rear spoiler and bumper

Glasses, window control

• Bonding the interior rearview mirror in place
• Removing and installing windshield - 2-pack adhesive
• Removing and installing rear side window - 2-pack adhesive

Exterior equipment

• Body paint colors beginning with 1992 models
• Removing and installing plastic end and side applicates — Cabriolet
• Removing and installing tank flap — Cabriolet
• Removing and installing door mirror
• Removing and fitting side member panel
• Removing and installing badge on cover
• Removing and installing wheel housing liner

Interior equipment / airbag

• Inspecting seat belts
• Safety precautions for working on cars with airbag
• Replacing cover for passenger airbag
• Removing and installing airbag steering wheel
• Removing and installing airbag components
• Checking airbag system operation
• Correct disposal of airbag units
• Repairing horn buttons on airbag steering wheel

Seats

• Checking seat heating
• Calibrating controllable seat heating

Diagnosis airbag

• Diagnosis /troubleshooting airbag

Air Conditioning

• Technical data of air conditioning system as of MY ’93
• Pressure and temperature specifications

Radio, telephone, in-board computer

• Removing and installing antenna

Exterior lights, lamps, switches, outside

• Adjusting the pop-up headlight mechanical system
• Checking headlight beam adjuster Instruments, fuel gauge, alarm system
• Diagnosis / troubleshooting alarm system

Wiring

• Passenger compartment wiring harness for 968 CS
• Repairing the tiptronic wiring harness
• Routing the sensor wire at the Tiptronic transmission
• Wiring diagram mod. ’92
• Wiring diagram mod. ’93
• Wiring diagram mod. ’94
• Wiring diagram mod. ’95

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