General968 Table of contents volume page General Technical data . : cece eee of Maintenance, Self-diagnosis general Maintenance... 2.2.2... - 8-4 Operating instructions for system tester 9268 . » 03-19 Engine, Crankcase, Engine Mounts Tolerances andwearlimits ......... - 10-4 Tightening torques for engine. 2. 10-5 Removing and instaling engine (manual transmission)... - 10-9 Removing and installing engine (Tiptronic transmission) . . . ~ 10-13 Engine, Crankshaft, Pistons ‘Adjusting guide rail for balance shaft toothed belt 2138-4 Checking adjustment of balance shafts . . - 13-3 Fitting toothed belt for balance shaft . 13-5 ‘Adjusting Special Tool 9201. . . . cee eee e eee WET Checking and adjusting balance shaft toothed belttension 0... ss sss sees 18+ 8 Crankcase markings 13-13 Locking the fywheel for assembly work . 13-15 Engine support . o0 13-17 Crankcase - Tools . . . 13-19 Machining cylinder bores in upper crankcase section -. 18-21 Crankcase - Installation length or protrusion length of studs . . «13-246 Dismantling and assembling crankcase, crankshaft 18-25 ‘Aligning the upper and lower parts of the crankcase . - 13-29 Crankshaft - Standard and Repair Dimensions... . ~ 13-31 Dismantling and assembling pistons, connecting rod 13-33 Checking piston and cylinder bore . 13-37 Dismanting and assembling balance shaft dive... cece ee 18-89 Removing and installing double-mass fiwheel and grooved bal! bearing ~ 13-43 Engine, Cylinder Head, Valve Drive Replacing the camshaft toothed belt (with hydraulic belt tensioner) 15-1 ‘Adjusting and checking the camshaft setting . 5-3 ‘Applying TDC mark to camshaft sprocket . 15-7 Camshaft adjustment gauge (shop-made) . . . -. 15-9 Fitting the camshafts. ....... 15-11 Fitting the camshaft seal. . 15-15 Table of contents Printed in Germany — Xi, 1994volume 1 Table of contents 968 page Camshattreferences . wee 15-17 Machining the cylinder head mating face . .. 215-19 Removing and installing cylinder head. . - 15-21 Valvedimensions........----. 0. = 15-240 Dismantling and assembling camshaft drive = 15-25 The following topics of Repair group 15 are described In the Repair Manual Type 944, vol. 1 - A: Cylinder head, disassembling and assembling 215-115 Valve springs, removing and installing with Sauer tool errr ener ris 116) Valve springs, removing and installing, removing valve stem seal. 15-121 Checking valve guides . . 15-123 Replacing valve guides. . . . == 15-125 Checking valve-seatwearlimit. 0... sev. Bo : cee 15-130 Valve seats, checking and machining.......... Boabe5ooe we 15-181 CChecking and adjusting installation length of valve springs = 15-133, Engine, Lubrication Removing and installing lubrication system components .. . . . eee Ee 7-4 Dismantling and assembling oil pressure release valve... . . . « seve eee e ee A728 Removing and installing oll restraining valve . . veceee eee e M727 Checking oil pressure cece eee ATs 9 leaning the entire engine ollsystem sss ss sss vcs evceeeveeeee 7 Engine, Cooling Mixingtable. 6.00... 2.20. eee 219-4 Cecking cooling and heating system for tighiness oso. seve cece ee eee Qed Fuel Supply Fuel vacuum line routing . 220-4 The following toples of Repair group 20 are described In the Repair Manual Type 944, vol. 1 - A: Replacing fuel fter, checking injection lines for leaks and tightness - 20-102 Fuel System - Electronic Injection Testvalues 60... 0... 000% cece Bhd Checking idle and CO level of vehicles without catalytic converter - seven BA 2 Checking idle and CO level of vehicles with catalytic converter... 2.0... 00... 242 3 2 ‘Table of contents Printed in Germany — x1, 1994968 Table of contents volume | page Removing and installing DME injection system components . . 24-5 Removing and installing injection valves . - he 9 ‘The following topics of Repair group 24 are described In the Repair Manual Type 944, vol. 1 - A: Checking fuel pressure... eee eee eee 24-103, Ignition system Replacing spark pigs... eee eee eee eee eee B41 DME control units as of Model Year ‘92 +. B38 Removing and installing knock sensors . . . -. B- 5 DME-Diagnosis / Troubleshooting . pocoD . 02428-1 ‘Table of contents 3 Printed in Germany ~ Xi, 1994General 968 Technical Data - Type 968 - Model 92 (For adjusting values and wear limits, refer to the relevant Repair Groups) Note: U.S. values are indicated In brackets Power unit Internal engine code No. of cylinders Bore mm (in.) Stroke mm (in.) Displacement (real) c.c(cu.in.) Compression ratio Max. engine power 10 80/1269 / EEC kWiHP Net Power, to SAE J 1349 kW (HP) at engine speed ‘pm Max. torque t0 BO/1269/EEC Navkpm Net torque, to SAE J 1349 Nm (lbft) at engine speed ‘pm Max. liter output DIN 70020 KWA/ hpi SAE J 1349 Wal (HP/I) Torque limitation by fuel cutout ‘pm Idle speed M 44.43 ‘pm Idle speed M 44.44 ‘pm Engine weight (dry) kg Manual transmission Tiptronic M 44.43 M 44.44 4 104 (4.08) 88 (3.46) 2,990 (182.5) 11.034 176/240 176 (236) 6,200 305/31.0 305 (225) 4,100 58.9/80.3 58.9 (78.7) 6,700 + 20 840+ 40 880+ 40 172 02 Technical Data Printed in Germany « i, 1991General Engine Design Engine type Crankcase Crankshaft Crankshaft bearings ‘Connecting rods ‘Con-rod bearings Pistons Cylinders Cylinder head Valve guides Valve arrangement Valve gear Camshaft Camshaft drive Balance shafts Balance shaft bearings Balance shaft drive Valve clearance Basic valve timing ‘4-cylinder 4-stroke otto-cycle engine with 2 balance shafts Light-alloy, two-piece Forged, 5 main bearings Plain bearings Forged Plain bearings Light alloy, forged ght.alloy Lightalloy Pressed in, special brass 2 intake, 2 exhaust, overhead in V inclination 2 overhead camshafts, hydraulic flat-base tappets ‘Without bearing shells, located in cylinder head Toothed belt and internal chain with electric/hydraulic adjustment Forged Plain bearings with bearings shells Toothed belt ‘Automatic adjustment (hydraulic) Intake opens 7.5 deg. after TOC Intake closes 52 deg. after BDC Exhaust opens 31 deg. before BDC Exhaust closes 1 deg. after TDC Torque valve timing Intake opens 7.5 deg. before TDC Exhaust closes 37 deg. after BDC Exhaust opens 31 deg. before BDC Exhaust closes 1 deg. after TDC ‘Technical Data 03 Printed in Germany - 1, 1991,General Engine cooling Type Fan drive Engine lubrication Type ii cooling Oil fiter Oll pressure Oil pressure indicator Oil consumption Exhaust system Emission contro! Heating Fuel system Injection system Fuel delivery Fuel octane requirements RON/MON Closed cooling system with antifreeze protection down to - 30°C (nordic countries - 40°C) Electric fan with temperature switch Forced-feed circulation lubrication with crescent-type gear pump External, thermostatically controlled ait/oll cooler Fulllow type 0.6... bar, min. 3.0 bar at 3,000 rpm 0...5 bar, electric gauge with warning light contact, Up to 1.5 1/ 1,000 kms. 2 Twin-tube mainfolds, downpipe to catalytic converter, center muffler, rear muffler Oxygen sensor control with 3-way catalytic converter (metal carrier) Hot-water heating with heat exchanger and fan DME 1 electric feed pump 98/88 Premium, unleaded 04 Technical Data Printed in Germany - 1, 1991968 General Electrica! equipment Suppression rating Battery voltage v Battery capacity An Alternator output AW Ignition Firing order Spark plugs Electrode gap mm (in.) Body type ECE-R 10 and 72/245/EEC 12 63 Manual transmission (64 Tiptronic) 15/1610 AC via DME 1-3-4-2 Bosch WR 7 DTC 3-ground electrode 0.7 + 0.1 (0.028 + 0.004) Unit-construction all-stee! body, rear spoiler, Coupé Cabriolet Dimensions (at DIN curb weight) Length mm in.) 4320 (170.1) Width mm (in.) 1735 (68.31) Height mm in.) 1275 (50.20) Wheelbase mm (in.) 2400 (94.49) Track front with rim mm (in.) 1472 (58.2) 73x16 eT 52 1457 (57.7) TH2dx17 ET 6S Track rear mm (in) 1450 (57.1) 8dx 16 ET s2 1445 (57.0) 9x17 ET55 Technical Data 05 Printed in Germany - I, 1991General 968 Dimensions Ground clearance (at max. total weight) mm (in) 125 (4.92) Ramp angle (at max. total weight) deg 11.0 Front overhang angle {at max. total weight) deg. 145 Rear overhang angle {at max. total weight) deg 155 Weights (to DIN 70020) ‘Coupé Manual transmission RoW Curb weight front kg (Ibs) 670 (1477) Curb weight rear kg (ibs) 700 (1543) Curb weight total kg (bs) 1370 (3020) Max. total weight kg (Ibs) 1700 (8747) Max. axle load front kg (tbs) 820 (1807) Max. axle load rear kg (ibs) 990 (2182) Max. roof load incl. roof rack —_kg (Ibs) 75 (165) with genuine Porsche roof transportation system 0.6 Technical Data Printed in Germany - Il, 1991Printed In Germany - 1, 1981, 968 General YL Capacities Engine Use only approved engine olls. Refer to Technical Information manual Engine ol quantity approx. 6.5 | (with fier) Refer to measurement level on oil dipstick according to Owner's Manual Transmission with differential approx, 2.75 | Tiptronic approx. 71 Final drive approx. 0.7 | Fuel tank approx. 74 | (reserve approx. 8 I) ~ Brake fluid reservoir approx. 02 | Washer fluid reservoir and headlight washer system approx. 65 | Engine coolant approx. 7.8 | Power-assisted steering approx. 1.01 Performance ‘Manual transmission Max. speed km/h (mph) 252 (156) ‘Acceleration 0 to 100 km/h 8 65 1000 m from standing start 8 266 - Climbing performance Manual transmission In% 1st 60% 2nd 48% 3rd 30% ath 21% sth 18% eth 12% ~ Technical Data o7General Lifting the vehicle The car jack, the trolley jack and the support plates of the tifting platform may only be used to lif the car at the jacking points shown below. rear eres The jacking point at the front side member ‘may stil be used to raise the vehicle on the liting platform. Never raise the vehicle at the oll pan or the transmission since this may cause severe damage. 08 Printed in Germany ~ Il, 1991PORSCHE L Maintenance ‘Working instruction 1 order no. Vehicles as from model year 1992 VIN O Maintenance every 20,000 km/12,000 mis (working position 03 20 00..) ‘The torms “inspect” and “check” include ‘and replenishment. They do not include the ‘The maintenance points stated above are valid fr all vehicle fp of the model ine in question, Cante’s stamp Type => associated work such as adjustments, readjustments, corractions placement or overhaul of components or assemblies 011 Turbo io 028 Diagnosis system: Read out fault memory ‘Change engine ol and oil flier ‘Check valve clearance ‘V-belt or Polyrib belt: Check condition and wnsion| “Toothed belt for eamehalts: Check condition and tension “Teothed belt for power steering: Check condition “Toothed belt tensioner: Check oll level ‘Change spark plugs (only on vehicles without catalybe converte) (Check boost pressure safety switch Visual inspection for leaks. Oils and fuids Coolant hoses: Check condition Radiator: Visual inspection for external fouling Coolant: Check level and antifreeze content Air filter. Replace fiter element (Crankcase ventlation: Check tghtness of hose connections Fuel system: Visual inspection for damage, correct poston and tightness of connections Intake air system: Check hoses, lines and connections for tightnoss. Handbrake: Check tree travel of handbrake lover ‘Brake system: Visual inspection of brake pads and disks for wear ‘Brake hoses and lines: Visual inspecton for damage, correct positon and corrosion, check brake fluid level For 928: Visual inspection of components for Tire Pressure Monitocing stom ‘Clutch: Check play or final positon of clutch pedal Throttle valve actuation: Check for ease of movement and full throttle position elele ° lelele Fosonance flap: Check operation ‘Stooring gear: Visual check of bellows for damage Track rod inks: Check play and dust caps Power steering: Chock fd level ‘Axle joints: Visual inspection of dust caps for damage ‘Scrow connections of suspension adjustment system: Check for tightness front and rear Front wheel bearings: Check play Manual vansmission/axle dives: Check ol evel ‘Automatic vansmission: Check fvid level Drive shafts: Visual inspection of sleeves for leaks and damage Exhaust system: Visual inspection for leaks and damage, check attachment ‘Tires: Check concition and pressure (928 with system tostor) Door hinges: Lubricate ‘Check door, ld locks and safety hooks on front lid for tightness and operation Hinges for rear id: Lubricate ‘Safety belts: Check operation and condition Copyright by Dr. Ing. hc. F. Porsche AG KO-Technix Printad in Germany - 891 Wo 436 620Pecumpton Maintenance every 20,000 km/12,000 mis Type => 3} “oe HEH soak Suchen cree slelele access eae ce ‘Al'headights: Check setting i months top up with ant-freeze as necessa a lejelele eens eee Sees zi Additional: | | E CO every 40,000 km/24,000 mis | | Automatic transmission; Change fivid, clean ATF strainer or change filter «| Replace {uel filter els] ‘Ait fiter: Replace fiter element ‘Auxliary air pump: Replace fitor eloment “Toothed belt for balance shalts: Chock condition and tonsion| “Toothed bal for camshafts: Cheek condition Replace spark plugs (only in vehicles with catalytic converter) OO. every 80,000 km/48,000 mis Manual vansmission/ale dives: Change all ‘Automatic wansmission: Change oil axle dive elu e ieee ie ‘Toothed bolt for camehalts: Replace (Chock tonsion of balanco shal el alte 3,000:4,000 km/2,000-2:500 mis replaced) * | CO every 100,000 km/60,000 mis | Replace toothed belt for camshats (check tansion after 3,000-4,000 kmy/2.000-2.500 mis) a OC Yearly ~ after the first 2 years File Status Repor for Long ile quarantee CO every 2 years Change brake tuid ‘Change cootant OD after 4, 8 and 10 years, thereatter every 2 years {Check atbag syetam ial a Sonate (machi) ae el | 7 ee Test drive: E [| Foot rake and handbrake, cich, automatic sped conta, seen, heating, elele| Bircondboning and insturens,Gheckeperaton |elelele Veal inspection freaks: Ol and slelsle ‘Signature (final contro!)PORSCHE Con's stamp Maintenance Working instruction to order no. vin CG Maintenance 3,000 to 4,000 km/2,000 to 2,500 mis Type — (working position 03 01 00.) ‘The terms “inspect” and “check’ include all associated work such as adjustments, readjustments,co land replenishment. They do not include the repair. replacement or overhaul of components or assembles, ‘Tha maintanance points stated above are valid forall vehicle types of the model ine in question, [911 Turbo. at (s2e ‘Tires: Check condition and pressure (928 with systom tester) Front axle: Check toe adjustment Diagnosis system: Read out fault mem \-belt and Polyrib belt: Check tension “Toothed bel for camshatts: Check tension “Toothed belt lor balance shats: Check tension Visual inspection for leaks: Ois and fluids Coolant: Check level ‘Windshield washer, headight washer: Check fluid level, in winter months topup with ant-tresze as necessary Check operation of lighting eystem Exhaust system: Visual inspection for leaks and damage lelele “Test idle speed Perform system adaptation, on vehicles without catalytic converter. Test GO content (Convertible top: Check operation Signature (mechanic): —— Test drive: Foot brake and handbrake, clutch, automatic speed control, steering, heating, ai conditioning and instruments. Check operation _ Visual inspection for leaks: Os and fds. Signature (inal contol): Copyright by Di. Ing. he F. Porsche AG KO-Technik Printed in Germany - 891 WD 436 5201 Recommended Yearly Maintenance Vehicles with a low yearly mileage between two Type > required service intervals (working position 08 50 00..) ‘The terme “inepeet” and “chock” include all associated work such as adjustments, readjustments, corections nd replonishmont, They da nat inelide the repair, replacoment or overhaul of components or assembles. ‘The maintenance poinis stated above are valid fr all vhsle types of the model ine in question. Visual inspection for leaks: Os and fds Diagnosis system: Read out fault memory Handbrake: Check free travel of handbrake lever ‘Brake system: Visual inepection of brake pads and disks for wear le (0 [e |e fe [211 Turbo ielelelesi le (e (e [oe s26 ‘Cheek brake fui love ‘Steering gear: Visual ingpaciion of bellows for damage Track rd joints: Check play and dust caps elele ‘Axle joints: Visual inspection of dust cape for damage elele Drive shafts: Visual inspection of cup eeals for leaks and damage . ust system: Visual inspection for leaks and damage, chock attache . . Tires: Check condition and pressure (928 with system tester) ‘Seals for doors, compartment lids and roof: remove abraded rubber Analy suitable lubricant ‘Check operation ol ighting eystom ‘Windshield washer, neadight washer. Check fuid level and nozzle settings in the winter ‘months top up with antfreoze a Baitery: Check electrolyte love ‘All other electrical equipment as well as indicator and warning lights: Chock operation File Status Report for Long ie quarantee (ater the fist 2 years) Signature (mechanic) Test drive: Foot brake and handbrake, clutch, automatic speed conto, steering, heating, ai conditioning and instuments: Check operation Visual inspection for leaks: Oils and fds ‘Signature (final control)968 Maintenance 03 Diagnosis system: Read out the fault memory ‘The procedure for reading out the fault memory is described in the operating instruc- tions for System Tester 9288. A copy of the ‘operating instructions is supplied with each tester. ‘The System Tester 9288 is connected to the vehicle via a 19-pole socket outlet. Toothed belt for for balance shafts Checking the belt tension Checking and adjustment operations are iden- tical to those for the 944 S 2. Adjustment value: (For new and used toothed belts) 27+ 0.3 scale values Checking and adjusting tightness of power steering pump drive belt Checking Check tightness by applying thumb pressure on belt at point midway between two pulleys, Deflection: approx. 5 mm. Adjusting 1. Remove splash shield. 2. Loosen upper mounting bolt or nut slightly. Maintenance Printed in Germany ~ 11991 03-103 Maintenance 68 3. Loosen hexagon head bolts of connecting rod slightly. Loosen lock nuts of connecting rod and turn connecting rod accordingly until the correct belt tightness is reached. 4, Tighten mounting bolts and nuts after finishing adjustment. Polyrib drive belt of alternator or a/c compressor 1. Loosen hexagon head bolts of connectrod slightly. Loosen lock nuts of connecting rod and turn back connecting rod one turn (re- duces tension), 2. Prepare Special Tool 9201 for checking. Pull out lockpin on special tool and slide out testing pin opposite the lockpin completely. Place drag needle on indicator needle Slide special tool on to the drive bett. Push in testing point (arrow) slowly until the lock- pin is felt to engage, and read the displayed value from the dial gage. esr Note ‘The slides must have complete contact on the bett surface. ‘The special tool must not be turned or moved ‘on the belt while checking, ‘Maintenance Printed in Germany ~ 1.1991968 Maintenance 03 ‘Adjustment value without alr conditioning ‘Tum link rod until an adjustment value of 9.5, scale values is reached. Adjustment value with alr conditioning Adjustment specification modified, refer to page 03 - 18a. Changing engine oil and engine oll filter Requirements: Engine at operating temperature. 1. Undo and remove oil filer cap. 2. Remove oil drain plug from oll pan and drain engine oil. 8. Undo oil fitter with oil filter wrench (Special Tool 9204). Drain remaining oil into suitable container. 4. Clean drain plug. Aways replace seal. Tight- ening torque: 50 Nm (37 fb). 5. Oil seal of oil filter lightly, tighten by hand Until seal is seated, tighten by one more turn. Use oil filter wrench to check tight seat- ing of fitter afterwards. Guide value for tight- ening torque: 20 Nm (15 ttlb) 6. Fill in engine oil, warm up engine to opera- ting temperature and check tightness. 7. Check oil level with engine tuned off. Parking brake: Checking free play of parking brake lever ‘The parking brake system is fitted with asbe- stos-free brake pads. The parking brake fitted with asbestos-ree brake pads must not be adjusted in such a manner that the pads must “grind free” in operation. It the parking brake lever can be pulled by more than 4 teeth under moderate pulling force without showing any sign of braking ef- fect, the parking brake must be readjusted. Adjusting the parking brake 1. Remove rear wheels. 2. Release parking brake lever and push back rear-axle disc until the brake pads rotate freely. 9. If required, slacken adjusting nut at tension jack of parking brake lever far enough to re- ease the tension of the cable. 4, Use a screwdriver to reach through the bore in the brake disc and reset the adjus- ter until the wheel can no longer be turned. Then turn adjuster back again until the ‘wheel can be rotated freely. Now turn back by two more teeth (loosening). Repeat oper- ation on the other wheel. 5. Tighten parking brake lever by two teeth and turn adjuster nut at tension jack of Parking brake lever until both wheels can hardly be rotated manually any more. 6. Release parking brake lever and check it both wheels rotate freely again. 7. Lock adjusting nut at tension jack. Maintenance Printed in Germany ~ XI, 1994 03-303 Maintenance 268 Brake system: Visual Inspection, checking the brake pads and brake disk for wear Note Brake pads must be replaced for the com- plete axle when the brake-pad warning lamp lights up, but at the latest when the pads have worn down to 2 mm. If the brakepad ‘wear is indicated by the warning lamp, the ‘warning contact (sensor including cable and connector) must also be replaced. It is possible to avoid replacing the warning con- tact if the brake pads are replaced when wor down to 2.5 mm at the latest. Warning con- tacts must be replaced if the core of the cable has been exposed. If only the plastic part of the waming contacts has been rubbed, how- ever, itis not necessary to replace it. 1. To check the rear brake pads, remove the rear wheels*. The front pads can be checked with the wheels remaining on the car. 2. Check the brake pads for war by means of a visual inspection. ‘The wear limit has been reached when the brake pads is worn down to 2 mm. * Note instructions on page 44 - 03 (fitting of Cup-Design wheels). sre Checking the brake fluid ‘The brake fluid level must be between the min, and max. mark on the reservoir. Use only DOT 4 brake fluid. eco 03-4 Maintenance Printed in Gormany ~ Xl, 1994968 Maintenance 03 Clutch: Checking clutch free play and pedal end ing cl Play and pedal en The clutch master cylinder is provided with in- temal stops. Free play adjustment is therefore no longer required. The pedal end position must stil be checked, however, for smooth clutch operation. Depress clutch pedal at the pedal plate for a couple of milimeters and release again. The pedal must return to its initial position (end posttion of clutch master cylinder) under its own force. Pull back and check at pedal plate if pedal has actually reached the end posttion. ‘On vehicles with cruise control, check cruise control switch position if required. Steering gear: Checking rubber boots visually for cracks ‘and damage Tie rod ends: Checking free play and dust bellows Check all unions to steering gear and tie rods as well as operation and sealing quality of dust boots, rubber bellows and joints. ‘The rubber boots and bellows at the steer- ing gear and the tie rods may have been damaged due to esteral forces, e.g. by stone hips or when working on the axle. If the dust boot is found to be leaky, replace the joint or tie rod, respectively, since the joint will then deteriorate rapidly due to ingress of dirt and water. Power-assisted steering: ‘Checking fluid level General Damage to the power-assisted steering sys- tem is often due to lack of oil in the hydraulic system. Even minor leaks may cause fluid to ‘escape due to the high hydraulic system pres- sute, thus damaging the power pump. ‘Grunts that become audible when turning the steering wheel or foaming in the reservoir indi cate lack of oll and/or air drawn into the sys- tem. Before topping up the reservoir, how- ever, remedy any leaks present on the intake side and replace damaged parts on the feed side. Note For adjustment of the drive belt, refer to page 03 - 1. Checking fluid level of the power steering system The reservoir is fitted on the right-hand side of the engine compartment (on the wheel housing panel) Maintenance Printed in Germany ~ 1, 199103 Maintenance 968 With the engine at idle, check the ATF-tluid {ATF-Dexron II D) without moving the steer- ing. The correct level is between the min. and ‘max. marks on the reservoir. Axle Joints Visual Inspection for damage to the dust caps ‘Check the dust caps for the axle joints (ball joints) on the wheel suspension as follows: = Drive the vehicle onto the lifting plattform, steering lock released. = Turn the front wheels as far as the stop. = After cleaning, carry out a visual inspec- tion of the visible areas to the left and right. Press the rubber caps back with your figures and look for concealed cracks. After turning the front wheels to the stop in the other direction, check the remaining rubber caps. Note It is not possible to carry out a visual inspec- tion on a small area around the brake cover Panels. Check this area by touch. Wa rubber cap is found to be leaky, the re- spective joint must be replaced as it will be destroyed by the penetration of dirt or ture. 03-6 Maintenance Printed in Germany ~ Il, 1991sce Maintenance 03 Adjusting the running gear: Checking nut and bott connections of front ar running gear adjusters for tightness, When checking the specified tightening tor- ques, use a second wrench to lock so as not to give false readings of the adjustment values. Front axle: Connection of strut to steering knuckle (camber adjustment). Tightening torque 120 Nm (88 fb) (Fastening screw and camber eccentric). Start by checking the tightening torque of the bottom bolt connection. Upper bolt connection (camber eccentric): Lock at eccentric bolt. Caster adjustment (eccentric at A-arm and moun), Tightening torque 100 Nm (74 fib). Lock at caster eccentric. Rear axl Connection of trailing arm to rear axle radius rod (camber and kingpin inclination adjust- ment). 'ightening torques: Lock nut to camber eccentric = 90 Nm (66 fb) Fastening screw = 103 Nm (76 ft). Start by checking the tightening torques of the fastening screws Adjusting the front wheel bearings ‘Wheel bearing clearance is adjusted correctly when the thrust washer may be moved by ap: plying finger pressure using a screwdriver (but not by rotational or levering action). 1. Take off wheel. Lever off hub cap with two tire irons or Special Too! VW 637/2 (lever). 2. Remove pan head screw of clamping nut. Tighten clamping nut somewhat, rotating the hub at the same time. 3, Loosen clamping nut far enough to allow the thrust washer to be shifted barely with a screwdriver. ‘When shifting the washer, do not use the hub as a support for the screwdriver. 4 Tighten pan head screw of clamping nut to 13 + 3Nm (10 + 2 tb) without rotating the clamping nut 5. Recheck adjustment by shifting the thrust. washer, correct if required. Drive shafts: Check rubber boots visually for leaks or damage. Maintenance Printed in Germany ~ 1, 199103 Maintenance oe Changing the transmission oll (Manual transmission) Capacity: approx. 2,75 1 Ol quantity: Hypoid transmission oil SAE 75 W 90 to API GLS5 or MIL-L 2105 B 1. Drain oil with the car standing on a level surface and the transmission at operating temperature, 1. Magnetic drain plug 2.- Filler plug 2. Clean drain and filer plugs, tighten plugs to 35 Nm (22 tb). 3, With the vehicle on a level surface, fil in transmission oil, until it overtiows at the filler plug neck. Note ‘On initial production cars, the thread of the fil ler plug in the tateral transmission covers was located 6 mm too high. When filing those transmissions with 2,75 | of transmission oil, the oil level is 6 mm below the filler neck bore ‘The relevant transmissions are identified by a + 6 mark above the filer plug. 03-8 Maintenance Printed in Germany — Vi, 1992968 Maintenance 03 Changing the transmission oil (Rear-axle drive / Tiptronic) Capacity: approx. 0,71 ‘Ol quantity: Hypoid transmission oil SAE 75 W 90 to API GLS (MIL-L 2105 B), or SAE 90 1. Drain oil with the car standing on a level surface and the transmission at operating temperature. 1 - Tightening torque 40 Nm (30 ftb) 2 - Tightening torque 50 Nm (37 ftlb) 2. Clean filler and drain plugs, replace seals and tighten screws to specified torque. 3. With the vehicle on a level surface, fill in transmission oll until it overtiows at the filer plug neck. Checking the ATF level Correct ATF level is an essential prerequisite for proper operation of the automatic transmis- sion ‘Check requirements: Vehicle must be on a level surface Engine running at idle Handbrake pulled Selector lever set to "N” ATF temperature approx, 80°C. ‘At 80°C operating temperature, the ATF level ‘must be between the 80°C min. and max. marks. ‘A= Check range at 80°C ATF temperature B = Quick-fil device To determine the precise ATF temperature, use System Tester 9288. It required, top up with ATF fluid across the quick ill device. Maintenance Printed in Germany ~ Vil, 1902 03-903 Maintonance eos Tire condition / tire pressure Tires are safety-relevant items that are only capable of meeting the requirements applicable if they are run at the correct tire pressure and with sufficient tread depth. ‘The tire pressures indicated are minimum pressures. The tires must never be run at lower pressures since this atfects roadholding in a negative manner and may lead to severe tire damage. ‘Valve caps protect the valve against dust and dirt and therefore help prevent leaks. Always screw on caps tightly and replace missing caps. For safety reasons, do not limit tire checks to checking the tire pressure but also check for sufficient tread depth, ingress of foreign matter, pinholes, cuts, tears and bulges in the sidewalls (cord break)! (16' and 17" summer and winter tires) Tire pressure for cold (approx. 20°C) front 2.5 bar excess pressure rear 25 bar excess pressure Spare tire front/rear 25 bar excess pressure 03- 10 Maintenance Printed In Germany ~ I, 1991968 Maintenance 03 Checking door, hood locks and ‘safety catches of front lid for tight- ness and operation Checking for tightness: ‘The fastening screws for door lock, front lid lock (Coupé and Cabriolet) and rear lid lock (Cabriolet), the fastening nuts for the upper lock sections of the front lid (Coupé and Cabriolet) and the rear lid (Cabriolet) as well as the fastening nuts for the tailgate locks (Coupé) must be tightened to 9.7 Nm (7 fib). Operational check: Door lock ‘The door lock must latch across the striker in two steps when the door is closed and must unlatch again when the door release (inside ‘and outside) is actuated. Front and rear lid lock When closing the lids (front and rear), the lid locks must latch when the upper lock seo- tions or the lock pins engage, and must be released again when the lid lock release is actuated. Front lid safety catch ‘After releasing the lid lock, the front lid must be held down by the safety catch. The lowest Point of the safety catch must engage in the locator. With the lid open, the return spring must pull the safety catch back to the stop of the baseplate of the upper lock section. Seat belts Checking operation and condition Checking belt operation: The belt strap must reel off the belt retractor ‘smoothly across the deflection fitting and the belt lock tab must engage into the belt lock with an audible click. When pulling the belt abruptly, the belt retractor must lock, thus preventing further unreeling of the belt. Checking belt condition: Visual inspection must not indicate any damage or wear of the belt. ‘Should damage such as cuts, fraying, split seams, chafing etc. be evident on the belt strap, replace the seat belt immediately. Maintenance Printed in Germany ~ 1, 1991 03-1103 Maintenance 68 Additional checks on seat belts with ‘overload Indicator (tear seam) — Airbag equipment After checking operation and condition of this seat belt type, make sure the tear seam above the holder of the belt strap is not damaged. ‘The tear seam serves as an overload in- dicator to highlight overtoading and, hence, to indicate that replacement of the belt is required. = Location of holder Fastening screw Holder Plastic cover, indicator (tear seam) = Belt strap Door, hood and roof rubber seals Removing rubber abrasion, coating seals with suitable product Cleaning: Remove rubber abrasion and dirt with petroleum ether. Maintenance: Coat seals with glycerine, talcum or similar rubber care product. 03-12 Maintenance Printed in Germany - i, 1991268 Maintenance 03 Checking operation of lighting system: Adjusting the headlights 1, Raise pop-up headlights, 2. Release pop-up headlights and tit forward. 3, Remove cover shroud. 4. Tilt back pop-up headlights. 5. Clean light-diffusing lens and turn on low beam. 6. Adjust headlights with the car in roadworthy condition (fuel tank filled, driver's seat loaded with one person or 75 kg, tire pres- sure set to specified values), using a head- light aiming device. Note Adjustment is performed with the headlight beam adjuster switch set to position 0. Adjusting auxiliary headlights and fog lights Note ‘Auxiliary headlights and fog lights can only be adjusted together. 1. Remove turn signal lights. 2. Turn on high beam. Maintenance. Printed in Germany ~ i, 1991 03-1303 Maintenance 08 - 3. Adjust with the car in roadworthy condition Pop-up headlights: (refer to headlight section), using a head- light aiming device. Greasing the linkage Grease ball joints of link rod using commer- cial multi-purpose grease. Headlight washer: ‘Adjusting the headlight washer Jets Sc ‘Special Adjusting Tool 3019 A = sae Note — Adjustment is not performed horizontally and vertically via one adjusting screw each. Instead, horizontal and vertical adjustments 1. Insert Special Too! into sprayer jt. are made simultaneously References: 2, Rotate jet insert using the tool until the tele- ‘Turning both screws in the same direction scopic extension points to the center of the Lateral adjustment light-cftusing lens. Turning both screws in opposite directions: Y Height adjustment. 3, Start washing operation and check opera- tion of spray et Adjust in such a manner that the center of the light beam is within the reterence marks around the central mark on the screen of the headlight aiming device 4. Check adjustment of fog lights. 03-14 Maintenance - Printed in Germany ~ It, 1991968 Maintenance 03 Replacing the fuel filter 1. Undo fuel pipes, using a second wrench to lock. Drain overflowing fue! into a suitable ‘container. 2. Undo hose clamp and take off fuel fitter. 3. Install new filter. Observe direction of flow = direction of arrow. 4, Start engine and check fuel lines and fuel filter, respectively, for leaks. Replacing the air cleaner cartridge. 1. Unhook clamps. Take out housing lid and cartridge. 2. Clean inside of fiter housing with a lint-free rag. 3. Install new cartridge. Observe installation position. Put housing lid in place and engage clamps. Check for correct seating of alr cleaner upper section. Replacing the camshaft toothed belt (with hydraulic belt tensioner) Refer to Vol. 1, Repair Group 15, page 15 - 1. Maintenance Printed in Germany ~ 1, 1991, 03-1603 Maintenance 968 Replacing the brake fluid / Bleeding the brakes Notes Use only clean DOT 4 brake fluid. Total quantity for brake fluid change approx. 1 1. The brake fluid must be replaced at least every 2 years. ‘Sequence of operation for bleeding and brake fluid change — Fill reservoir with new brake fluid up to the upper edge. Connect bleeding device to expansion tank. Tum bleeding device on. Bleeding pres- sure approx. 1,6 bar. — Continue bleeding or changing the brake fluid, respectively, on the other brake calipers (no special sequence to be ob- served). Open each bleeder valve until clear brake fluid or until the corresponding brake fluid change quantity per caliper (approx. 250 cm?) is reached. note that each four- piston fixed caliper must be bled at both bleeder valves. = To check that escaping brake fluid is clean and free from ait bubbles, and to determine the brake fluid quantity used, Use a suitable receiver bottle. — After fitting a new brake master cylinder, depress brake pedal fully several times with the bleeder valves open during the bleeding operation. This allows trapped ali to escape from the brake master cylinder. — When changing the brake fluid, also drain some brake fluid from the clutch slave cylinder. — Turn off and disconnect bleeding device. If required, top up with fresh brake fluid. 03-16 Maintenance Printed in Germany ~ i, 1991968 Maintenance 03 Replacing the coolant and bleeding the cooling system 1. Drain cooling system (only with engine cooled off). Set heater lever to “hot”, open drain plug at radiator and loosen coolant hose at auxiliary plastic flange of cootant pump. 2. Screw drain plug into radiator. Tightening torque: 5 Nm (4 ftlb). Fit coolant hose to flange 3. Leave heater lever in “hot” position or set to the hot position now and screw out bleeder screw. Fill up with coolant slowly until coolant overflows at the bleeder flange. Drain some coolant until the coolant level has settled halfway down in the reservoir (this is required to keep the reservoir from ‘overflowing when the engine warms up). 4, Turn bleeder screw a few tums in. Start en- gine and run at accelerated idle to warm it Up to operating temperature (until radiator fan has switched on and of) ‘As soon as no more air bubbles escape at the bleeder bore, tighten bleeder screw. Tightening torque 15 + 3Nm (11 + 2 ft). Top up coolant level to “max.” mark on reservoir. Check coolant level again after a test drive. If required, top up with coolant. Maintenance Printed in Germany 03-1703 Maintenance Replacing spark plugs 1. Pull off spark plug leads. 2, Remove spark plugs using a commercially avall. plug wrench (e.g. Hazet No. 767-1). A spark plug wrench is supplied with the toolkit 3. Apply a light coat of Molykote paste HTP White to the plug threads. Tightening torque: 25 to 30 Nm (18 to 22 ftlb) Maintenance Operations Printed in Germany ~ il, 1991968 Maintenance 03 Checking and adjusting Polyrib drive belt of A/C compressor When adjusting the Polyrib drive belt, the belt thickness must be taken into account. Deter- mine belt thickness with a caliper gauge. The following adjustment specifications are ap- plicable in accordance with the belt thickness. determined: Scale value indications for ‘Special Tool 9201 Belt thickness Scale value Link rod (mm) eons 44-48 85 Bi Alter fiting a new Polyrib drive belt, compen- 49-52 95 = sate the settling of the belt as follows: 53-56 95 add 1 tun Run engine at idle for approx. 15 min. or test drive vehicle for approx. 15 min. Then allow engine to cool down to ambient temperature and correct setting according to the specifica- tions applicable to the respective belt thick- ness. Maintenance operations 03 - 18a, Printed in Germany XI, 1994968 Self-diagnosis 03 Operating instructions for System Tester 9288 8500 Operating Instructions for System Tester 9288 03-19 Printed in Germany = i, 199103 Self-dlagnosis 968 1. General information 111 Application The Systemtester 9288 (BOSCH KTS 201) i¢a miroprocessorcon ‘wolled solf-diagrosis tester. Alleystoms which have legrossintertaceasperiSOStandardcan be tested with tis tester. The folowing tests are possible: (© easing out she faut memory Testing ofthe actuators the cut inputs ‘Sytem adaptation Engine-knock detection ‘Sensor and satus chacks,tke-pressure monitoring (ROK) eoee 112 Construction (Fig. 1) ‘The Systortster $288 is 2 high-quality piece of electronic eauip- rent In order to prevent damage tothe equipment as aresut ofr rope ue, pease ead theinfermation nthe operating instructions xelully and comply with it. In addition, the instretons (speciation) ofthe veicle aut ‘ure ae also to be observed. tthe tester shoulda chock the follwing pintsbeforesundingitin for repair: Has the tester been operated incorrecty? 2. Is the battery sufficiently charged? 4s the adapter cable OK? (Please note wien checking theadepter cable theta highly sensi- tiveslectoniematchingceuitis installed inthe vicinity ofthe 19- pale pug) No. | Decription Fuvetion Remarks Key key + | co indicator Dot matic 5 x8 Uf the Systemtester 9288 is switched on ‘ines each with 20 characters without the program module, folowing Foreign languages posible the self-test the tester switches off auto- ‘mination ‘matically and informs the user that the rogram modula is ot fited. 2 | Keyboors Keys, 2.3 = Solection key Kays < = = Previous pouernest page | Switeting on: = Press any key Switehng off; = 100 satter ast Ker = Help menu © Muinaton | (buts) depresson of key Sereens stored Cntotunt overview Setting up printer ‘Sovtching of nit Retura to the nest higher program level follwing {ermination of 2 tet sequence oF, during 3 test fequenee, return to the las display Storing inication Key G = Ploying beck stored eeading ifn data stream Hows cross the ees, interface ‘The as fel in tho top right-hand corner is filed completly, this means thet this 8 ‘stored igure and not an actual, feat figue. 2 | Power supety the vitge isnot suet, "charge battery” appears on the dspay this Fited accumulator with NiCd bates. The Systemtester 9288 must be swiched off uring the intial battory charging process. (Charging time > 8 hours ‘Connection to vehicle battery by moans of vebiclespecific adopter ead (se 1.4) Discharged upon delivery. Felowing charge: Operating tim: 428 hours without scale iumination 42 hours with ecaleiumination ‘Connection tough 1SO-iterace (Charging votage supply ‘ot dona, the nit witches eet of, Battery charger facessony) For test operation and for charging the Nica batterie, 4 | comecton for Input and ouput devices ‘Connection facility for Print 1.9 Epson, IBM, Hewlett Packard (HP) ‘The Systemtester 9288 transmits data with the fllowing configurations 8 data bits / start bt / 1 stop bit / No pat for priter matching) 5 | Connecton tor vericie Reading out the data Input for flashing-code support specie adapter lead 6 | Prup:in programme module | Operating syst Pug in module: (soe als Figure 21 LCD erie Keyboard AS cmos Intectace communication o not touch plug 1 ‘Computtions and data conversions remove rubber protector, Insert module fal 03 - 20 ‘Operating Instructions for System Tester 9288 Printed in Germany ~ I, 1991968 Self-diagnosis 03 1.3 Battery charger run off meine voltage (Figure 3) = Accessory ~ tem 1 Charger with connecting cable, 1.8: long tem 2. 8-pin AMP plug 14 Vehicle-specitic adapter cable Porsche No, 000 721 928.81 ‘U5 Connecting tead (Figure 4) = Sel-tsrication — {or printer, programme load station or sir nit. For interface-trunk assignment, see manual of corresponding unit Pinter cable for standard D 25 BOSCH No, 1 684.465 193, Printer eable fr EPSON BOSCH No. 1 684.465 194 2, Connection ‘The following points must be observed: ~ No gearmustbe engagedionthe vehile Automatic in postion N-F) ~ Danger of Accident ~ ALL workon the veiclemust only be carried outwith the ignition switched of [Alter having connected the vehicle-speciie adapter cable, the in structions sted under "3" are displayed onthe Systemtestr 9268: 21 Charging with the battery charger (Fig. 3) Connecting the Systemtester 9288 to the battory charger. (Fig. es 8). 22 Diagnosis Connecting the Syetemtester 9288 to the dagnosi plug inthe veh- ‘ee by means ofthe vehci- specie adapter cab. ‘Switch onthe tester and proceed according tothe instuctonscis- played. 3. Testing Scope of module: Guidance hough the menu, communication with the ECU, reading fut the eror memory and salecion ofthe “Help” menus, ecustor ‘agnosis, cxcuitnputsand system adaptation engine-knockdetec tion, sensor and event check forthe tire-pressure monitor (ROK). 231 Reading-out the error memory Connect the Systomtester 8288 (soe 2) ‘Sith onthe Systerteter, (possile wth every key) Disa: PORSCHE Eprom modul eng Mod. into, xxx Wa specie instruction does nat appear ina splay itis aways pos sible to proceed by pressing the button > ‘Due tothe fact that the Systamtostr 3288 can store error diplays {see Chapter 37), tho following cisplay wil appear if rors have boon store inthe image memory: ‘Stored dlepaye erased? 1 yes 3= no Koy 3 Disa: Printout splays: 4 H = Help manu {se0 3.5) orkey 1 Display: Vehicle types 1200s 2911 Corea s 3= 52884 ‘Section ofthe vehicle ype with ky 1,2 or 3 -Aaterthe vohicle ype hasbeen selected the folowing instruction appears Connect adopter cable to veh lug Ignition “ON Alter completion: = The following then appears: wait for Dats Break off tet ‘After a short pause, the Systertester 9288 report all the 5ys- toms that arelnstale inthe partieuar voice fa eyster ispre- coded by "2 *, this means that at least 1 err is stored in that partial system, Examples: [tastated systems oH ek | 3= ROK 1 2 3 ‘The partiuar system con be selected by means of key, 2.03. Alte selection for nstance with ke), the felling display ap pears ui System: L01 UH JeT Ser. No: 92861812313 RB. No: 0280002507 Operating Instructions for System Tester 9288 Printed in Germany ~ 1, 1991 03-2403 ‘Alter pressing the key > , selection menu is ceplayed: Menu 1 = Fout memory 2 Dive links 3 Input signals = < Men 1 System adaptation Inthe example press key. There then flows the splay ofthe numberof errs which ae stored (f an ‘Number of faults | ate Procoed with key > ‘Adana info 10 very espay with key} contoue: > Proceed with key > ror output 1 Engine temperature sensor 2 ‘Short to ground rot present It key is pressed instead of the > key the corresponding ear code seplay appears (the lst two digits ofthe flashing code Foul cade: = 14 — Proceed with key > Further erors are displayed i thoy exist 2 idle contact ‘Short to ground present Whey lie preseedinetead ofkey > the corresponding err-coce eplay appears (the lst two digits ofthe flashing code Fault code: ~ 12 ~ Self-diagnosis 968 Alter the let splayed eo, the flowing instruction appears: Repair faut accord Ing t repaie instructions Continue: > Proceed with hey > Fault repered? Yves Retura to display "No.of erors” with hey 3. Proceed wih key 1: Fault memory Y= Erase 3 = Do not ease It key 9 is presse: = Return to manu “eror memory". ‘The ertor memory ie not erased! Proceed with key 1 Fault memory has been cldzed Retur: N “The test scope “Read-out enor memory i terminated at thie point 22 Actuator diagnosis Han actuators lected, this is triggered by theECUso hatitean be checked for coroct functioning “The varius actuators components ae gone tough one aftr ‘he other ond oe selected withthe > kay (Operate the Systemtester 9288 a: described under 31 unite following menu dpiay appears: Menu ] Fault memory 2= Drive inks 3 lnput signals > ‘Aster pressing Key 2, the splay forthe frst setutor appears: Injctor tosetvate T= stan Continue: > It key > pressed, the net actutor is seocte, Pressing key 1 esis inthe following instruction: Con injectors be | 03 - 22 Operating instructions for System Tester 9288 Printed in Germany ~ I, 1991968 Self-diagnosis 03 Key selects the next actuator (e.g, le actuato. Following in sition Repair felt accord- ing 0 repaie instevtions Continue: > After pressing key >, the following displey appears: Injector to ectivate 1 Start Continue: > Proceed with key 1 Can injectors be heard ft? tee 30 Proceed wih key 11 the next actuator ate stabilizer to activa T= Start Continue: 5 Proceed with key 1 ‘Can ite stabilizer bbe heard felt? Tye 32m By resing key th next actustorisselectd, Aer presing key 3. the net intrtion appears: Repair faut aczord- ing t repair instrctions Continue: > Procoed with key > tale stobitzer Va Stert Conte: > ‘Alter pressing key 1, the following display appears: Cen ae stabitaee be heard / elt? i 32h By pressing kay, the next actuatorisslectod. The actuators are selected one after the other and triggered uni the folowing cis- ay appears ive tok tat completed a 7 N ‘By pressing the key N, the operator i etured tothe menu 33 Circuit inputs In adition tothe actustor, the Systemtester 9288 can also check ecu inputs. To tis end, operate the Systemtester 9288, In accordance with 3.1 unt hs menu display appears: Meow 1 = Fault marory 2 = Otive Kinks 3 Input signals > Press key 3 lal contact 1 Stat Continue: > By pressing kay > the ext crit input is slated ‘The ext sisplay appears when key is pressed. Activate acc pel fale coetact, = dosed = Continue: > (Operate the accelerator pedal, the fllowing display appears: ‘tivate aco peal lee contact = open ~ Continue: > ‘The nen circuit input selected by pressing key =. Repeat util this elsply appears: Input sigoats testing completed Return: N Press key N for return to menu 34 Systom adaptation When the function “System adaptation is triggred the ECU istrs the base aie requirement ofthe engine. To this end, operat the Systemtester 9288 as per 31 until the following menu sspiay spears: Proceed with key > = Menu | 1 = System adaptation Operating Instructions for System Tester 9268 Printed in Germany ~ i, 1991, 03-2303 Self-dlagnosis 968 Proceed with key 1 Prerequisite: Eng. at oper. temp. with at consumers tnd ignition oft. Proceed with key > ‘System adoption 12 stan Return N I key Nis pressed It key tie prossod ‘Start engine | Following engine start there appears: System is being adapted Please wait Alter approx, 30 secs there appears System sdoptation completed et: N tis impossiba to carry ot eystem adaptation fide contact not ‘dosed, or defective), the following display appears: No system adoptation possible Ie contact? After compieton of the system adaptation, tum 1 the menu with key 35 Engine-knock registration ‘Te engin-knock ropistration function can only be tiggered through the EZK or DME contl oni “The particular sytem con be selected by means of key 1 20F 3 For istonce with key 2 the following display appears: Pa System: EO1EZK Sor. No: 92861812415) RB. No: 0227400186 Proceed with key > ‘The following menu display appears: = Menu 4 = faut memory 2 = Keock registrtion Proceed with key 2 ‘condition Engine st operating temperate Proceed with key = = Start krock registration before test erve | 7 Proceed with key = = A normal tat dive lea pre- requisite Proceed with koy = <_ Stop the test ive ony ifthe display wit the no. of knocks comes on. Proceed with key > Knock registration v=Sian Return: N Pressing key 1 activates the engine-knock counter: Kock epstrtion ‘To his end, operate the Systertester 9288 os described in 31 In progress Lunt the following spay appeas: Please wait! Instated systems. ScaeeeeeeEeEEEEl eer 22 82k 53> fOK 03-24 ‘Operating instructions for System Tester 9288 Printed in Germany ~ Ul, 1991968 The knock counter registers 10,000 ignitons before the display With the actual rumba of combustion "knocks" appess. Number Knocks: ax ‘combustion: ooo Continue: S Proceed with key > Knack registration completed Return: N 1 knock egstrtion is impossible (ve to lack of engine-speed signal) the folowing display appears: No knack regi. ‘ation possible RPM signal? Following completion of the knock registration test, tun the rena with key 36 Help menu ‘The “Help” menu canbe selected rom every splay by resting ‘ay H: Return tothe ltl clplay with key N. Help menu 1 lyination 2 = Display stored 3=Ctlunitchat > Proceed, or instance with key 1 Key ‘The seslilominationis itched on and the tester rotunsto the rovousaispay (or wih key 2: Data display stored 1 Print 22 Cleat Proceed with key 1 ‘Stored displays are printed out (printer connected Proceed with Key 2 ‘Stored cplays are erased wit the “Help® menu, for instance Help mena 1 = tumination 2 = Display stored 35 Cr unit chart > ifthekey > isprosed, further section ofthe*Help* menuisdis- played Self-dlagnosis 03 “= _Help mena 4 Printer eating 2.= Switen off equip. 3 = Baud Rate Proceed for instance with key 1 Printer setting tas 2= HP Quiet vet 3 = EPSON ‘The selection of the printer results in the tester being setup for ‘the printer type in question 37 Store measurement leplays Key 9) Using key , all ciples can be stored manual. ‘The following csplays ee stored automaticaly = ECU-eentty = Intatied systems = Allexsting eos han the memory imi reached, the flowing instruction is ddsplayed Data display mem. fall Return: N 28 Show stored measurement displays (Key G) Using the keys < or >, the stored displays forthe slated sys- tem ean be shown. ‘The sored dieplaye can be caled up by means of the G ey. ‘The system selection LH-EZK- ROK takes place with the keys 2ork 4, Service and wear parts (BOSCH) Fig. | 80ScH Par No. | Designation — | Comment V3 | 1687 335 002 | NC-battery. 47 | 1604489 152 | Plog | dia | 160495 170 | Soca Spe 412 | 1620 582.008 | Screwed ep 604.465 199 | Printer cable (Stanerd 025) 906405 194 | Printer eaie (€PsoN) 41. Service parts (Posshe) Designation Porsche PartNo. | Special too Na ‘Systeme 9208 | 0007219280 | 9280 Aiapiereabe | 00072192881 | 9288/1 Batter chergw | 00072192882 | 9288/2 Made (0) 000721 9288 | 9280/4 Modste(rusa) | 000721'92885 | 9286/5 Meds 000721 928898 | 9288/6 Modul th 00:721'82087 | 9268/7 Mod (6) Goo2is26es | 9288/8 Operating Instructions for System Tester 9268 Printed in Germany ~ 1, 1981 03 - 25Engine, Crankease, Engine Mounts 10 Tolerances and Wear Limits Engine M 44.43/44 Cooling Coolant thermostat Cooling system cap Pressure relief valve Vacuum relief valve it circuit ll consumption Oil pressure at 80 deg. C oll temperature: at 5,000 rpm Ol volume Quantity difference at ol gauge Oil thermostat Valve gear ‘Camshaft bore ‘Camshaft ‘Camshaft Flat-base tappet bore Flat-base tappet Camshaft ‘opening temperature ‘opens at excess pressure of opens at partial vacuum of 17,000 km, excess pressure ‘opening temperature inside dia. dia, axial end play Inside dia. dia. runout When fitting Wear (new) limit 81 to 85°C 1.8 to 1.5 bar 0.4 bar approx. 1.5 approx. 4 bar 651 approx. 1.5 | 95° + 4°C 28 + 0.021 mm -0 28 - 0.04 mm = 0.055 0.08 to 0.18 mm 96 + 0.015 mm + 0.005 95 ~ 0.025 mm - 0.041 0.02 mm Tolerances and Wear Limits Printed in Germany ~ 1, 1991, 10-110 Engine, Crankease, Engine Mounts 968 Tolerances and Wear Limits Motor M 44.43/44 Cylinder head with vaives Sealing surface distortion Valve seat width inlet exhaust Seat angle Outer correction angle Inner correction angle Valve guides inside dia Valve stem: Inlet dia Exhaust dia, (stem end) Valve guide/valve stem rocking clearance Inlet Exhaust Compression fons with connecting rods When fitting Wear (new) fimit ‘max. 0.05 mm 1.5 mm 1.8 mm 45° 30° or 7 + 0.015 mm 6.98 - 0.012 6.974 + 0.006 tapered stem 08 08 8 bar and 65 bar above Cylinder/piston clearance 0.008 to 0.032 approx. 0.080 Piston rings vertical clearance Groove 1. 0.040 to 0.075 Groove 2 0.030 to 0.065, Groove 3 0.020 to 0.055, Piston rings gap width Groove 1 0.20 0.0.50 Groove 2 0.20 t0 0.55 Groove 3.0.30 t0 0.90 10-2 Tolerances and Wear Limits Printed in Germany ~ Il, 1991968 Engine, Crankcase, Engine Mounts 10 Tolerances and Wear limits Engine M 44.43/44 When fitting Wear (new) litt ‘Small end bush dia. 24 + 0.018 + 0.028 Piston pin dia. 24 - 0.004 ‘Small end bush/piston pin _radial clearance 0.018 to 0.032 Crankshaft and cylinder block Crankshaft runout 0.04 max. 0.06 measure at bearing 2, 3 or 4 Bearings 1 and 5 on prisms Crankpin dia 51.971 to 51.990 Con-rod bearing/crankshaft radial clearance 0.027 to 0.069 axial clearance 0.080 to 0.240 Main bearing web dia. 69.971 to 69.990 Crankshaft main bearings! crankshaft radial clearance 0.028 t0 0.070 0.16 Crankshaft main bearings! crankshaft axial bearings 0.060 to 0.192 0.40 Cylinder bore ovality 0.010 0.020 Balance shaft bearing bore in crankcase or balance shaft cover dia, 34,000 to 34.019, Bore for bushing in bearing housing dia. 34.000 to 34.019 Balance shaft dia 30.975 to 30.991 Tolerances and Wear limits Printed in Germany 1, 1991, 10-3968 Engine, Crankcase, Engine Mounts 10 Engine tightening torques Location Thread Tightening torque Nm (ftib) Crankshaft’ crankcase Crankease bolt joints top M12x15 30 (22) Ast stage and bottom section (studs) 60° torque angle 2nd stage M10 | 2015) 1st. stage 50 (37) 2nd stage M8 20 (15) M6 40 (7) Rotation body on balance shaft | M6 10 (7), secured with Loctite 270 Cover for balance shaft M6 10 (2) housing to upper crankcase section Hexagon head bolt Ms 20 (15) head bolt Maxs8 15 (11) 1st stage (bearing saddle) | 33 (24) 2nd stage Left-hand and right-hand Me | 20 (15) bearing housing to upper crankcase section | ‘Sprocket on balance shaft M10 45 (33) Tensioning pulley to M10 45 (33) bearing housing Water pump to crankcase M6 10 (7), secured with Loctite 270 Idler pulley to M10 45 (83) water-pump housing Tensioning pulley to M10 45 (33) oll pump housing il pump to Me 10 (7) crankcase M10 45 (33) Toothed belt tensioner to Me 20 (15) crankcase Tensioning pulley to M10 45 (33) tensioning lever Connecting-rod bolts M10 x 1.25 25 (18) + 90° torque angle (forged con-rods) Verbus-Ripp nut Engine tightening torques 10-5 Printed in Germany ~ 1, 199110 Engine, Crankcase, Engine Mounts 968 Location Thread Tightening torque Nm (ib) Oil pan to M6 hand-tight Tet stage crankcase 4@) 2nd stage 10 (7) ard stage Oil pan insert to M5 6 (4), secured with Loctite 270 oll pan ll drain plug M 20x15 50 (87) LH + RH engine support M10 48 (35) to crankcase Flywheel to crankshaft M 10x 1.25 40 (29) 1st stage 90 (66) 2nd stage Sonsor brackets to Ma 20 (15) crankcase Sensor to bracket Me 10 (7 Sprocket to crankshaft M 16x15 210 (185) Flywheel to M6x 25 13 (10) sprocket Grade 109 Mounting of M6 86) belt cover Bracket for alternator to M10 45 (33) crankcase Water temperature gauge M10x1 35 (26) Temperature sender Mi2x15 15 (11) (coolant or oi) Knock sensor Me 20 (15) Genuine bolt without washer Oil pressure sender M 18x15 35 (26) Housing insert in Me 10 (7), mating flange sealed oil pump housing with Loctite 574 Radiator fanlthermostat MB 20 (15) housing to crankcase Plug at oil/coolant M 18x15 35 (26) radiator housing Coolant vent Maxt 1243 +2) plug Olt fiter M 20x15 45 (33) pressure relief valve 20 (18) 10-6 Engine tightening torques Printed in Germany ~ I, 1991Engine, Crankcase, Engine Mounts 10 968 Location Thread Tightening torque Nm (ftIb) Cylinder head Cylinder head to crankcase upper section Engine type M 44.43/44 M12 20 (15) 1st stage 60" torque angle 2nd stage 90° torque angle ard stage Camshatt support to Ms 20 (15) cylinder head Camshaft adjuster - Mé 10(7) VarioCam to cylinder head Socket head bolts M6 10 (7) for chain tensioner / oil pipe Banjo bolt / oi Maxt 10(7) Cylinder head cover Mé 10(7) Intake pipe to cylinder head Me 2015) Inlet flange for Ms 20°15) heater to cylinder head Flange for Me 2015) coolant pipe Toothed belt cover to M6 10(7) cylinder head Hall sender / M6 10(7) mounting Camshaft gearwheel M10 65 - 70 (48 - 52) to camshaft ‘multi-tooth bolt Distributor rotor M4 4) to camshatt gearwheel Transport bracket to M6 10 (7) cylinder head Spark plugs M 14x 1.25 25 - 30 (18 - 22); grease thread lightly with Motykote paste HTP (white) Engine tightening torques Printed in Germany ~ i, 1991 10-710 Engine, Crankcase, Engine Mounts Location Thread Tightening torque Nm ({tib) Fuel system Mounting of Moxie 10 pressure regulator to fuel collection pipe Cap nut to M12x15 129) fuel collection pipe Exhaust system Plug nut to M14x15 30 (22) catalytic converter All other nuts and bolts: M6 8+ 2(6+1) Me 20+2(15 +1) M10 40+5 (2944) Coat all nut and bot unions. with Optimoly HT 10-8 Engine tightening torques Printed in Germany - il, 1991968 Engine, Crankcase, Engine Mounts 10 Removing and installing engine (manual transmission) Engine Type M 44.43 Note ‘The engine is removed from above. The clutch housing remains fitted to the engine. Removal 1. Place protective covers on fenders and re- move hood. Disconnect battery ground strap. Open tie-wraps at bulkhead. Dis- ‘connect cable from cruise control actuator motor and remove hood. 2. Undo fuel lines betwen engine and body, using a second wrench to lock. Catch remai- ning fuel in a suitable container. Do not kink fuel lines. 8. Disconnect cable for throttle operation. Pull off oxygen sensor connector and undo bracket from manifold. Pull vacuum hose off pressure regulator. 4, Undo ground cable and wire clamp from clutch housing. Pull off vacuum hose from brake booster. 5. Disconnect twin- and mutti-plug connectors. Disconnect vacuum hose from tank vent valve and manifold. 6, Remove and take out air fter assem- bly.Pull off ignition cable from distributor to Ignition coil. 7. Unscrew cover panel in passenger footwell and lft out. Unscrew support panel for DME control unit and pull off control unit plug. Disconnect electrical plug. 8, Remove engine undertray panel and front undertray cover. 9. Open coolant drain plug and drain coolant. Remove altemator vent hose. 10. Loosen radiator hose at bottom right-hand side of radiator and at engine and pull off hose. Catch remaining coolant in a suita- ble container. 11. Pull off electrical connectors from fan mo- tors. Undo bracket for fan motors from ra~ diator and take out from below. 12. Unbolt radiator bracket. Loosen radiator hose and vent hose on upper left-hand side of radiator and pull off. Pull off electri- cal connector from temperature switch of radiator. 13. Unclip radiator cover and lift radiator care- fully out from above. Separate radiator hose from reservoir and pull off Removing and installing engine (manual transmission) 10-9 Printed in Gormany - Vil, 190210 Engine, Crankcase, Engine Mounts 968 14. Suspend engine at front transport bracket using support 10 - 222A and keep suspen- ded in installation position. Check for cor- rect position of support. 18. Mark installation position of left-hand and right-hand control arm mounts on body. Undo and remove control arm mounts. 15. Remove Poly-Rib belt tensioner from A/C compressor and take off drive belt. Remove compressor from console and su- spend out of the way. (Do not undo retrige- rant hoses). 16. Unbott stabilizer bar from body. Undo hose clamps between steering ATF radiator and power steering pump top-up reservoir and pull off hoses. 17. Slacken power pump belt and lit power steering pump off the console, taking the spacer bushing out from the front. Leave po- wer steering pump suspended at steering. Remove oil pipes from oil cooler at engine console. 19. Unbott universal joint from steering rack, hydraulic engine mounts from engine supp- rts and front-axle cross member from bo- ‘dywork. The front-axle cross member re- mains suspended on the vehicle along with the steering rack and the power pump. / q \ | AAR. \ “BINS | | a Hl ‘si ‘ er Kl Z 20. Disconnect electrical connections from star- ter and remove starter. Remove wire clamp from clutch housing. 10-10 Removing and installing engine (manual transmission) Printed in Germany - Vil, 1992968 Engine, Crankcase, Engine Mounts 10 at 22. 23. 24, 25. 26. Remove clutch slave cylinder from clutch housing (pipe remains connected). Undo and remove bracket for piping from upper clutch housing section. Unbolt exhaust system from exhaust mani- fold flange and mount and remove exhaust system complete with oxygen sensor as- sembly. Remove cover for clutch housing. Screw hex socket head bolts out of clamping slee- ve and push clamping sleeve along with central shatt to the rear. ‘Screw out upper central tube / clutch hou- sing fastening bolts. Undo coolant hose for heater above ex- haust manifold and at oylinder head. Engage engine support (VW Special Tool 3033) into engine transport brackets as fol lows: Pulley side: Position Flywheel side: Position 11 In position 3, the threaded rod is "below" the support. In position 11, the threaded rod is “above” the support 27. Slightly preload engine with shop crane, e. g.- Bilstein K 750 H, and remove support bracket 10 - 222 A. The threaded rod for support bracket 10 - 222 A remains in the front mounting eye. 28. Screw out bottom central tube / clutch hou- sing fastening botts. 29. Pull engine forward, push rubber bellows ‘out of bulkhead towards engine compart- ment and pull wiring harness carefully out of passenger's footwell Lit out engine in upward direction, Installation When installing the engine, observe the following: 1. Insert wiring hamess for DME control unit ca- refully into passenger side footwell. 2. Start by screwing in the central tube / clutch housing fastening bolts but do not tighten them yet. Note Tighten down fastening bolts to specified torque only after the hydraulic engine mounts have been fitted to the front-axle crossmem- ber. 3. Install control arm. ‘The control arm mount must be fited in ex actly the same position marked before remo- val. 4, Check wheel alignment. Adjust it required. 5. Replace all gaskets, seals and O-rings befo- re refitting. Check for correct location of the radiator in the rubber mounts. Removing and installing engine (manual transmission) Printed in Germany - Vi, 1982 10-1110 Engine, Crankcase, Engine Mounts 968 6. Tighten nuts and bolts to specified torque. Tighteningtorques: Clamping sleeve to central shaft Mio Central tube to clutch housing M10 Control arm to body = M10 Steering universal joint M 8 Cross member to body M12 ‘80 Nm (59 ftlb) 42 Nm (31 ftlb) 46 Nm (34 flo) 30+ 5Nm (22+ 41) 85 Nm (63 flo) 7. Add coolant and bleed cooling system. 8. Top up reservoir with ATF fluid and bleed steering system. 9. Warm up engine to operating temperature, check engine oil and coolant levels again, top up if required. 10-12 Removing and installing engine (manual transmission) Printed in Germany - Vi, 1992968 Engine, Crankcase, Engine Mounts 10 Removing and installing engine (Tiptronic Transmission) Engine Type M 44.44 Note When removing and installing the engine on vehicles with Tiptronic transmission, certain de- viations from the instructions for manual trans- mission versions must be observed. Removal 1. The flywheel must be separated from the damper across the starter aperture (9 bolts). The clutch housing is unbotted from the en- gine and remains fixed to the central tube. 2, Remove ATF lines from cross member, cylin- der head and radiator. Plug oil apertures to avoid dirt ingress. Remove protective shield from clutch housing. Installation Flywheel / damper intallation note 1. Rotate flywheel until assembly mark (roll pin hole with large chamfer) points down. 2. Also rotate damper until positioning groove points down, Removing and installing engine (Tiptronic Transmission) Printed in Germany - Vi, 1992 10-1310 Engine, Crankcase, Engine Mounts 3. When fiting engine and clutch housing, ma- ke sure that both marks are lined up with each other, Tighten fastening bolts evenly. 4, Before installing the engine, coat the clutch housing/engine bolts with Optimoly TA. Tighteningtorques: Clutch housing to engine M12 75 Nm (65 fb) Damper to flywheel M8 21 Nm (15 tb) ATF lines to radiator 24. Nm (18 tb) 968 10-14 Removing and installing engine (Tiptronic Transmission) Printed in Germany - Vil, 1992968 Engine, Crankshaft, Pistons 13 Adjusting guide rail for balance shaft toothed belt Engine Type M 44.43/44 1, Tighten mounting bolts of guide rail lightly. 6. Fit sprocket and balance shaft toothed belt Fit sprocket for balance shaft drive and and adjust according to specification. toothed belt. Refer to pages 13 - 7 to 13 - 10. Put balance shaft toothed belt under preload. 2. Using a feeler gauge, measure and adjust clearance between toothed belt and guide rail. Adjusting dimension: 1 0.5 mm 8, Check clearance of guide rail over a length of 7 teeth (dimension A). The adjusting dimension must be 1 £05 mm. 4, To achieve the correct adjustment, slide the guide rail in the bolt holes. ighten both hexagon head bolts of the uide rail and check setting dimension again. Take off toothed belt and sprocket and tighten both pan head screws. Adjusting guide rail for balance shaft toothed belt 13-1 Printed in Germany ~ IV, 1992968 Engine, Crankshaft, Pistons 13 Checking adjustment of balance shatts 1. Undo and remove engine underside protec- tion and upper toothed bett cover. 2. Rotate crankshatt clockwise until TOC mark ‘on camshaft drive sprocket is lined up with the mark on the toothed belt cover. The TOC mark on the flywheel (center notch on double-mass flywheel) must also line up. 8. The mark on the upper balance shaft drive sprocket must line Up with the mark on the rear toothed belt cover. The Fig. shows the sprocket position with the toothed belt cover removed. 4, Remove plug cap from lower toothed belt cover. Check position of marks of lower balance shaft drive sprocket across inspection hole. Mark on sprocket must line with mark on rear toothed belt cover. Checking adjustment of balance shatts Printed in Germany ~ Iv, 1982 13-368 Engine, Crankshaft, Pistons 13 \g toothed belt for balance shaft Note Handle balance shaft toothed belt with care, avoid twisting or turning as this may cause excessive running noise. Store separately. When replacing the toothed belt, do not undo the mounting bolts of the balance shaft drive sprockets. 1, Rotate crankshaft clockwise until the TOC mark on the camshaft drive sprocket lines Up with the mark on the toothed belt cover. The TDC mark on the flywheel (center wor notch of double-mass flywheel) must also line up. 2. Rotate both balance shafts (without toothed belts) until the marks on the balance shaft drive sprockets are lined up with the marks on the rear toothed belt cover. 3. Fit the toothed belt: ‘When fitting the toothed belt, make sure the belt side with the color-coded tooth faces towards the outside. 4, Adjust toothed belt tension according to specification. Refer to page 13 - 7 to 13 - 10. Fitting toothed belt for balance shaft 13-5 Printed in Germany ~ IV, 1992968 Engine, Crankshaft, Pistons 13 Adjusting Special Too! 9201 The measuring gauge has been preset to a display of 4.0 dial values and allows the Special Tool 9201 to be checked and to be set to 4.0 dial values, respectively. ‘Adjustment of the device is required after: = approx. 100 measurements = hard shocks ~ minor damage If major damage Is present or if the display deviates by more than approx. 2.0 dial values, the devices cannot be adjusted any more. Return the device to the manufacturer for repair. ‘Address: Fritz Staeger vahnstrasse 68 - 72 D-1000 Berlin 47 Phone: 030/6291-266 Fax: 030/6291277 Adjustment Tools required: — Hex socket head screwdriver 1.5 AIF (for new tools) ~ of screwdriver 1.6 x 40 x 0.4 (for older tooks) ~ Measuring gauge 9201/2 41, Adjust to zero, rotating dial ring of dial ‘gauge until pointer and zero line up. 2, Place measuring gauge 9201/2 Into posi- tion, making sure both measuring mating faces on the sliding blocks are centered, (Measuring gauges of the new type are made of one piece, allowing them to be placed into position easier) 3. Measure as when using the tool on the toothed belt, ie. press in measuring button Until engagement of the lock pin is felt, and read off displayed value on the dial gauge. Adjusting Special Too! 9201 Printed in Germany ~ 1v, 1992 13-713 Engine, Crankshaft, Pistons 968 4. Ifthe display is beyond the measuring range of 4.0 + 0.3 dial values, readjust dial gauge. To do s0, use hex socket head screwdriver or standard screwdriver, respec- tively, to turn the adjusting screw until the specified value of 4.0 dial values is ob- tained. The measuring gauge 9201/2 rests between the measuring pointer of the tester. 5. Follow adjustment with another test. 13-8 Adjusting Special Too! 9201 Printed in Germany - WV, 1992968 Engine, Crankshaft, Pistons Checking and adjusting balance shaft toothed belt tension Tools No. | Designation Special tool [Order number | Explanation 1| Tester for belt 9201 (000.721.920.10 | tension 2| Adjusting gauge 9207 (000.721.920.70 Checking and adjusting balance shaft toothed belt tension Printed in Germany ~ IV, 199213 Engine, Crankshatt, Pistons Checking and adjusting balance shaft toothed belt tension Note The toothed belt tension must be checked and adjusted only when the engine is cold (room temperature). 1. Undo and remove air cleaner assembly and. engine underside protection. 2. Remove Poly-Rib belt or power pump belt, respectively, Note Before undoing the lock nuts, always start by slightly loosening the hexagon head bolts of the link rod. 8. Remove toothed belt cover. Undo idler until the idler no longer places a preload on the toothed bett. 4, Rotate crankshaft clockwise until TDC mark. ‘on camshaft drive sprocket lines up with mark on toothed belt cover. 5. The TOC mark on the flywheel (double- mass flywheel) must also line up. 6. Check basic position of balance shaft drive sprockets. The marks on the sprockets must line up with the marks on the rear toothed belt cover. 13-10 Checking and adjusting balance shaft toothed belt tension Printed in Germany ~ IV, 1992968 Engine, Crankshaft, Pistons 13 7. Prepare Special Tool 9201 for check. Pull out lock pin of Special Tool and push ‘measuring pin opposite the lock pin all the ‘way out. Align non-retum pointer to measur- ing pointer. 8, Push Special Tool onto toothed belt. Push ‘measuring button (arrows) slowly in until engagement of the lock pin is felt and read off displayed value on dial gauge. Note To avoid reading errors, the non-return Pointer must always be aligned to the measur- ing pointer after the lock pin has engaged (turn counterclockwise). Adjusting value: (new and used belts) 2.7 * 0.3 dial values If required, correct toothed belt tension. Adjusting 9. The sliding blocks must rest on the belt along their entire surface. During the measuring process, the Special Tool must neither be twisted nor moved on the belt. 10. When tensioning, rotate tensioning pulley clockwise. When slackening, rotate tension- ing pulley counterclockwise. Tighten hexagon nut to 45 Nm (33 ftlb), using a second wrench to lock. 11. Alter the toothed belt has been adjusted, follow by adjusting the idler. Using Special Tool 9207 or a feeler gauge (0.5 mm), set idler pulley to a clearance of 0.5 mm to the toothed belt in bottom balance shaft area and preload upper toothed belt train by Oto 1 mm at same time. Tighten idler pul- ley In this position. if the adjustment travel {is not sufficient, turn idler pulley by 180° and repeat adjustment. Tighten hexagon head nut to 45 Nm (33 ftlb), using a second wrench to lock. 1 - Idler pulley 2 - Balance shaft 3 - Tensioning pulley Checking and adjusting balance shaft toothed belt tension 13-11 Printed in Germany ~1V, 198213 Engine, Crankshat, Pistons ose 12, Fit toothed belt cover. Install Poly-Rib belt ‘oF power pump belt, respectively, and ad- Just according to specification. Fit belt or power pump belt, respectively, and adjust according to specification. Fit engine under- tray and air assembly. 13-12 ‘Checking and adjusting balance shatt toothed belt tension Printed In Germany ~ WV, 1992eee Engine, Crankshaft, Pistons 13 Crankcase markings Upper and lower crankcase section and balance shaft cover 1. The upper and lower crankcase sections ‘as well as the balance shaft cover are machined as a unit and must always be fitted as a unit. Observe correct identifica. tion marking. 2. When the components have been fitted, it must be possible to read off the markings of both balance shaft covers from above. Engine number The engine number is engraved on the right- hand rear end of the engine when seen in the direction of travel. Crankcase markings Printed in Germany ~ 1, 1982 13-13968 Engine, Crankshaft, Pistons 13 Locking the flywheel for assembly work Tools No. | Designation Special tool [Order number | Explanation 1,| Toothed segment 208i (000.721.920.61 | Engine installed 2| Toothed segment with hex. | 9538/1 (000.721.953.81 | Engine removed head bolt M 12 x 1.5 x 60 Locking the flywheel for assembly work Printed in Germany ~ IV, 1992 13-1513 Engine, Crankshaft, Pistons 968 Locking the flywheel for assembly work {Engine with double-mass tlywheet is Engine removed installed) 4. Fit hexagon head bolt with Special Tool 1. Disconnect ground cable from battory 9598/1 to engine support adapter and lower Remo station engine mount. 2. Place Special Tool 9206/1 into position and lock. 3. In case of Tiptronic transmissions, use old Special Too! 9206. 13-16 Locking the fiywheel for assembly work Printed in Germany ~ IV, 1992eee Engine, Crankshaft, Pistons 13 Engine support Tools No. | Designation | Special toot Order number | Explanation 1] Engine support | 9127 (000.721.912.70 2|| Engine support adapter o197 (000.721.919.70 Engine support 13-17 inted in any ~ WV, 198213 Engine, Crankshaft, Pistons Crankcase - Tools 1 TYPE PG-1 13-1913 Engine, Crankshaft, Pistons 968 No. | Designation ‘Special tool (Order number | Explanation 1| Plastigage for measuring Viet - green | Commercially available, the bearing clearances Viie2-red | e.g, Matra-Werke Vi163-blue | Dieselstrasse 30 - 40. Frankfurt/Main 2] Thrust piece for seal 9517 000.721.951.70 3} Assembly tool 9517/1 000.721.951.71 4] Dial gauge holder vw 387 vw 387 5| Dial gauge Commercially available 6| Retaining bracket for lock- | 9130 000.721.913.00 ing the flywheel 7| Piston ring compressor Commercially available, e.g. Hazet 794-U-3 8| Thrust piece 9202 (000 721 920 20 9| Belt tension tester 9201 000 721 920 10 10) Adjusting gauge 9207 (000 721 920 70 11] Measuring gauge 9201/2 000 721 920 12 12| Retaining wrench 9200 (000 721 920 00 13-20 Crankcase - Tools Printed in Germany ~ Xi, 1994968 Engine, Crankshaft, Pistons 13 Machining cylinder bores in upper crankcase section ‘The upper crankcase section is an aluminium alloy product and contains minute particles of pure sil cium. In order to have an usable cylinder surface finish, the cylinder bores have to be machined in a man- ner that the silicium particles protrude out of the aluminium and therefore pistons and piston rings only have contact with the silicium. Itt is necessary to machine cylinder bores, they can be restored with a SUNNEN CK-10 / CV - 616 cylinder repairing machine for installation of oversize pistons. Standard size 100.00 mm Oversize 1 100.50 mm ‘Single cylinder bores can be machined as required, since pertinent oversize pistons weigh the same as standard pistons. Prior to machining cylinder bores It Is recommended to check the stocks on hand for pert nent tolerance groups and, If necessary, to hone the bore for a certain piston size which Is avallable. There could be problems in supplying pistons of certain tolerance groups depend- Ing on circumstance: The following procedures are necessary: Rough turning to 0.1 mm before finished size. Dressing to 0.02 mm before finished size. Polishing to finished size. Lapping with Sunnen silicium mixture. Machining cylinder bores In upper crankcase section 13-21 Printed in Germany — XI, 199413 Engine, Crankshaft, Pistons 968 Procedures It Is absolutely necessary to bolt the upper and lower crankcase sections together with help of the bearing studs prior to machining. Tightening sequence: Nos. 1 to 10 in 2 steps: Thread M 12x 1.5, ‘st step 30 Nm (22 ftib) 2nd step 60 deg. rotating angle Nos. 11 to 17 in 2 steps Thread M 10x 15 st step 20 Nm (15 ftlb) 2nd step 50 Nm (37 ftlb) Tools Machine CK-10 with fitter CV-616 with filter Grinding attachement —_ CK-3000 or CK-2600 9 oil MB-20 Fett inserts, C30-F 85 1 set Silicium mixture AN-30 Storage box AN-35 for felt inserts Stone holder set for fel inserts instead CK-3035 A 1 set of honing stones Stone holder set for honing stones for CK-3035 A3 set different stones (types) Felt holder seat instead of guide shoe CK-3190 A 1 set Roughing stone set _C30-J 55 ++ shorten to 70 mm length Dressing stone set. __C30-J 84 ++ shorten to 70 mm length Polishing stone set. C30-C 03 - 81 13-22 Machining cylinder bores In upper crankcase section Printed in Germany ~ XI, 1994968 Engine, Crankshaft, Pistons 13 Honing Procedures Perform all honing and lapping jobs without the upper dressing guide shoe. ‘The protrusion of the bronze bar on main guide shoe no. 3 has to be eliminated; flush with guide shoe base. Setting up machine Roughing adjustment — table described in column 1. Dressing adjustment — table described in column 2. Polishing adjustment — table described in column 3. Lapping - uncovering the silicium crystals. 1. Set up machine as described in column 4 of test sheet. 2, Thoroughly remove all abrasive residue form previous honing jobs with fitered honing ol. 3. ipe cylinder bores dry and apply a thin coat of thoroughly mixed silicium mixture. Note: If the silicium micture is too consistent, it can be diluted by adding fresh honing oil and mixing thor- oughly. 4, Holders with felt inserts are now placed in th grinding attachment instead of guide shoe and honing stones. Adjusting to the cylinder diameter is made with a gage as for the guide rails and honing stones. 5. Soak felt inserts in fitered honing oil and coat with silicium mixture, 6. Stop grining oil feed; cylinders are lapped without grinding oil! Machining cylinder bores in upper crankcase section 13-23 Printed in Germany — Xl, 199413 Engine, Crankshaft, Pistons 968, Machinging cylinders Guide grinding attachment into bore. Turn feed wheel! anticlockwise until felt inserts rest on walls. Start machine and keep turning handwhee! anticlockwise until needle of load instument reaches ap- prox. 20 to 30 %. Now set scale of feed wheel to 20. ‘The machine stops on its own after about 80 seconds. The cylinder surface will now be dull and with- out gloss. First coat felt inserts with new silicium mixture before going on the next cylinder. Note It holder with felt inserts are not being used, they must be kept in the storage box to avoid contact with dirt. Never reuse old silicium mixture. 13-24 Machining cylinder bores in upper crankcase section Printed in Germany — Xi, 1904968 Engine, Crankshaft, Pistons 13 Machining Cylinder Bores with SUNNEN - 10/CV 616 1. Roughing 2. Dressing | 3. Polishing 4, Lapping too to 02 Cylinder dia. ‘Standard 100.00 mm Cylinder dia. Oversize 1: 100.50 mm | 100.40 mm 100.48mm | 100.50 mm 100.50 mm Cylinder length 145 mm Honing head type CK - 3000 or ato. ato. ato. CK - 2600 Travel scale for stone length 70 mm 70 mm 70mm 70 mm ‘Adjustment on scale 160 mm 160 mm 160 mm 125mm Speed (rpm) 125 CKICV yascKicv | 125CKiCv 125 CKIC4 Strokes per minute 49 CKIST CV 49 CKIS7 CV | 49.CKIS7CV 73. CK/80 CV Feed 4 3 3 3 Stone protrusion top | 21 mm 21mm 21mm 2mm Roughing stone c30-J55 Dressing stone ca0-Je4 Polishing stone © 30-C03-81 Fett insert © 30-F 85 Display % 30-40 30-40 20-30 20-30 Material removed 0.07 mm 0.03 mm, 0.01 mm aprox. 20 lines Adjustment on feed wheel 10 lines 10 tines 10 lines 80 sek. runn. t ‘Surface finish (Rt) approx. 7-8 my | approx. 2my | approx. 0,6-0,8 my| approx. 1-2 my Machining cylinder bores In upper crankcase section 13 24a Printed in Germany — X1, 199413 Engine, Crankshaft, Pistons 968 A chamfer of 0.5 mm x 30° has to be ma- chined on the upper cylinder wall of machined cylinder bores after finishing the honing proce- dures. 30 0.5 Clean upper and lower crankcase sections thoroughly to remove abrasion residue and silicium paste prior to assembling. 13+ 24b Machining cylinder bores In upper crankcase section Printed in Germany ~ XI, 1994Engine, Crankshaft, Pistons 13 Crankcase - Installation length or protrusion length of studs Caution: Unless indicated otherwise, lock all studs with Loctite 270 when reassembling the engine! Crankcase - Installation length or protrusion length of studs Printed in Germany — Xt, 1994Printed in Germany ~ Xi, 1994968 Engine, Crankshaft, Pistons 13 Dismantling and assembling crankcase, crankshaft Dismantling and assembling crankcase, crankshaft 13-25 Printed in Germany ~ V, 198213 Engine, Crankshaft, Pistons Note: No. | Designation Qty. | Removal Installation 1 | Pan head screw 9 Tightening torque | M 10 x 1.25 x 62 90 Nm (66 ft) 2 | Double-mass flywheel 1 | 3. | Tiptronic fywheel 1 4 | Pan head screw 9 Tightening torque M 10x 1.25 x 20, 90 Nm (66 ft) 5 | Roll pin 6 x 16 1 6 | Shaft seal 1 Replace, apply a thin coat of oll to sealing lip 7 | Deep-groove ball bearing 1 8. | Hexagon head nut 1 = 9 | Washer A 6.4 1 10. | Hexagon head bolt 5 M6x35 11 | Washer A 64 5 12. | Hexagon head bolt 1 M 8x55 Ol suction pipe mounting 13 | Hexagon head bolt 6 Maxss 14 | Washer 6 18. | Hexagon head bolt 1 Maxss 16 | Hexagon head nut M 10 7 ~ 17 | Washer 7 Rounded side faces up 18 | Hexagon head nut 10 Lettering faces up | Mi2x15 19. | Washer 10 Rounded side faces up 20 | Lower crankcase section 1 Clean and degrease sealing surface, apply Loctite 574 to seal 13-28 Dismantling and assembling crankcase, crankshaft Printed in Gor any ~ V, 1992968 Engine, Crankshaft, Pistons No. | Designation ty. Removal Installation 21 | Crankshaft 22. | Closed main-bearing bushing, bearing No. 1 23. | Main bearing No. 2 24 | Thrust bearing No. 3 | (pilot bearing) 25 | Main bearing No. 4 | | 26 | Main bearing No. 5 7 28 | Roll pin 4x 8 ‘Check end clearance and radial play Make sure the bearing engages in the roll pin Place bearing insert without lubrication groove into lower crankcase section Place bearing insert without lubrication groove into lower crankcase section Place bearing insert without lubrication groove into lower crankcase section Place bearing insert without lubrication groove into lower crankcase section Clean and degrease sealing surface in oll suction passage and flywheel areas Check for correct seating Dismantling and assembling crankcase, crankshatt Printed In Germany - V, 1992 13-2713 Engine, Crankshaft, Pistons 968 Dismantling and assembling crankcase and crankshaft Main bearing no. 1 ‘The closed main bearing sleeve for bearing No. 1 has a lubricating groove around one halt Main bearings no. 2, 4 and 5 When installing iis important, that bearing shells with lubricating grooves are placed in the upper crankcase section and bearing shells without lubricating grooves in the lower crankcase section. Tightening sequence - tightening torque Tightening sequence: Nos. 1 to 10 in 2 steps: Thread M 12x15 ist step 30 Nm (22 ttlb.) 2nd step 60 deg, rotating angle Nos. 11 to 17 in 2 steps: Thread M 10 1st step 20 Nm (15 ft.) 2nd step 50 Nm (37 ttib) 13-28 Dismantling and assembling crankcase and crankshaft Printed in Germany ~ Vil, 1993,968 Engine, Crankshaft, Pistons 13 Checking crankshaft bearing clearance ‘The ,Plastigage method Is a simple way of checking bearing clearance. Plastigage is available in three different sizes for measuring ranges from 0.025 to 0.230 mm. Type Color Measuring Range PGA green 0.025 to 0.075 mm PRA red 0.05 to 0.15 mm PBA blue 0.10 to. 0.23 mm Checking radial clearance 1, Remove crankcase lower section. 2. Remove oil from bearing shell and bearing seo1s9 journal. ‘Checking axial clearance 3. Place Plastigage having width of bearing on Use special tool VW 387 to check axial clear- crankshaft journal in axial direction. Install ance. crankcase lower section carefully and tighten to speciied torque. Play of new bearings: 0.110 to 0.312 mm Wear limit: 0.40 mm Note Do not tum crankshaft while measuring. 4, Remove crankcase lower section. Read width of flattened Plastigage from measur- ing scale. Corresponding value on measur- ing scale equals the bearing clearance. Play of new bearings: 0.020 to 0.098 mm Wear limit: 0.16 mm woot Checking crankshaft bearing clearance 13- 28a Printed in Germany ~ IV, 1992968 Engine, Crankshaft, Pistons 13 Aligning the upper and lower parts of the crankcase Note ‘When assembling, make sure that there is no offset between the crankcase halves on the facing surface (on the oil pump side). 1. Using a plastic hammer, align the slightly tightened lower part of the crankcase (tightening torque 10 - 20 Nm/7 - 15 ttlb.) with the upper part of the crankcase. Cary ‘out the finger-nail test at the joint. 2. Tighten the crankcase with the specified tightening torque (3 stages). rasta 3. Smooth any slight remaining offset at the joint with oil stone. Aligning the upper and lower parts of the crankcase 13-29 Printed in Germany -V, 1992968 Engine, Crankshaft, Pistons 13 Crankshaft — Standard and Repair Dimensions Size Crankshaft Crankshaft Thrust bearing 3 bearing ‘conrod bearing width Journal d 1 Journal d 2. Standard] 69.971...69.990 51.971...51.990 30.00 - 30.052" +025 | 69,721...69.740 51.721..51.740 +050 | 69.471...69.490 51.471..51.490 Crankcase bore & ‘Standard 75.000...75.019 Oversize 72.250...75.269 * Thrust bearing 3 Reconditioned size 30.200...30.239 Note Itis recommended to check the availability of bearing sizes prior to machining the crank- shaft. Crankshaft - Standard and Repair Dimensions 13-31 Printed in Germany — V, 190213 Engine, Crankshaft, Pistons 968 Grind bearing surface for oil seals to dimen- sion 89.8 only if score marks are too deep. In other cases, repolish if required Rr = 0.8...2. { 4 Oil bores are rounded to R 0.5 after grinding, Remove sharp edges with R = 0.2...0.5. Max permissible radial runout relative to sup- port in —-—-— max. 0.04. Color coding or repair stages: 1st repair stage blue color dot 2nd repair stage green color dot 13-32 Crankshaft - Standard and Repair Dimensions Printed in Germany ~ V, 1992968 Engine, Crankshaft, Pistons 13 Dismantling and assembling pistons, connecting rod Dismantling and assembling pistons, connecting rod 13-33 Printed in Germany ~ V, 199213 Engine, Crankshatt, Pistons 968 Note: No. | Designation [aty. | Removal | Installation 1 | Connecting rod nut 8 Replace. Tightening torque: 1st stage: 25 Nm (18 ftlb) 2nd stage: 1 x 90° tightening angle Threads and mating surface must be oiled lightly | 2 | Connecting rod cap 4 | Observe correct | matching numbers 3 | Lower big end bearing 4 | Always replace used insert bearing inserts 4 | Snap ring 8 | Lever out, making sure Observe correct snap ring does not spring | seating away, e.g. by covering with a rag 5 | Piston pin 4 6 | Piston 4 | Mark installation position il lightly. Observe | | installation position | and tolerance groups 7 | Connecting rod with con- 4 Observe matching necting rod bolts number, identification S 3 engraved on side 8 | Upper big end bearing 4 | Always replace used insert bearing inserts 9 | Small end bushing i o4 10 | Piston ring, 1st groove 4 Lettering faces up Plain compression ring | with internal chamfer, 0.4 wide, 45° 11 | Piston ring, 2nd groove =| 4 Lettering faces up Taper faced ring with =| internal chamfer | 0.8 wide, 45° 12 | Piston ring, 3rd groove 4 Lettering faces up Narrowland spring-loaded oil ring with tubular spring | 13-34 Dismantling and assembling pistons, connecting rod Printed in Germany ~ V, 19928 Engine, Crankshaft, Pistons 13 Assembly notes Reinforced connecting rods ‘Adopted for production from Oct. 1, 1993, as of the following engine numbers: 42 R 00 598 (engine type M 44/43) 42 R50 621 (engine type M 44/44) Identification mark: Reinforced transition area from stem to bolt head seating surface 1=New 2-= Former version If at least one of the connecting bott unions is undone during an engine rebuild, the new rein- forced connecting rods must always be fitted throughout (if the engine was equipped with the former connection rod version). These connecting rods are retroactively ap- plicable for spare purposes for all models as of Model Year 1992 (N). Connecting rod installation position ‘The matching numbers must be fitted so that they face each other and remain legible. ‘The matching numbers of the four connecting rods must be located in one line, ie. all matching numbers must be located on the same side. ‘Crankcase - Installation length or protrusion length of studs 13-35 Printed in Germany ~ Xi, 199413 Engine, Crankshaft, Pistons Piston installation position The arrow (rubber stamp) points towards the pulley. If the arrow is no longer visible, make sure the tolerance group mark also points towards the pulley. 13-36 Crankease - Installation length or protrusion length of studs Printed in Germany ~ XI, 1994968 Engine, Crankshaft, Pistons 13 Checking piston and cylinder bore Engine type M 44.43/44 Repair size Piston @ Cylinder bore Tolerance groups (mm) (mm) Code Kolben Schmidt AG Standard 103.980 104.000 ° 103.990 [+ 0.007 104.010 f+ 0.005 1 104.000, 104.020 2 Oversize 1 104.480, 104.500 10 104.490 }+ 0.007 104510 f+ 0.005 = 11 104.500 104.520 12 Checking pistons Checking cylinder bore Measure at a distance of 12.1 mm from the bottom of the piston skit, offset from the pis- ton pin axis by 90°. —— Lt cr) Se Note Measure approx. 61 mm from top edge of cyl- inder bore, across the cylinder block. For measurement, mount lower crankcase section and tighten with prescribed tightening torque. Itis recommended that the stocks of the relevant piston tolerance group are checked before machin- ing the cylinders. I necessary, hone to the piston size available. In some cases, certain tolerance groups may be in short supply. Checking piston and cylinder bore Printed in Germany ~ V, 1992 13-97968 Engine, Crankshaft, Pistons 13 Dismantling and assembling balance shaft drive Dismantling and assembling balance shaft drive Printed in Germany ~ Vi, 199213 Engine, Crankshaft, Pistons 68 Beachte: |Nr. | Benennung Stick} Ausbau Einbau 1 | Lock nut 1 Check, replace if required) 2 | Washer A 10.5 1 3 | Pulley 1 Check 4 | Lock nut 1 Check, replace 5 | Washer A 10.5 1 6 | Tensioning pulley 1 Check 7 | Hexagon head bott 2 Coat threads with Loctite| M 10x35, 574, Tightening torque | 45 Nm (33 fb). | | Use retaining wrench | 9200 to lock. | 8 | Washer 2 9 | Flange washer 2 Upper balance shatt: Install in correct postion, Locating tab engages in- to drive gear groove that is not marked. °O" mark is visible in large opening of} flange washer } Lower balance shaft: Install in correct position. Locating tab engages in- to "0" drive gear groove. The “O" mark is visible in the rectangular cutout of | the flange washer. 10. | Drive gear for balance 2 Check smoothness of ba-| shaft lance shatt seating face, machine it required. Ap- ply a thin coat of Optimo- HT to seating face. 11 | Woodrutt key 2 12 | Cover 1 13-40 Dismantling and assembling balance shaft drive Printed in Germany ~ Vi, 199213 968 Engine, Crankshaft, Pistons Beachie: Nr. | Benennung Stick] Ausbau Einbau 13. | Shatt seal 2 Replace, apply oil to sea- ling tip. Seal for upper balance shaft: 30x 47x7 Seal for lower balance shaft: 30x 48 x7 14 | Spacer sleeve 2 15 | Hexagon head bolt 1 MB8x35 16 | Washer A 8.4 1 17. | Upper bearing housing 1 18 | Gasket 1 Replace 19. | Onring 56.7 x 3.53 1 Replace, oil lightly. Do not twist ring when fiting, 20 | Bearing sleeve 1 21. | Hexagon head bot 1 M8x60 22 | Washer A 8.4 1 23. | Lower bearing housing 1 24 | Gasket 1 Replace 25 | O-ting 56.7 x 3.53 1 Replace, oil lightly. Do not twist ring when fitting. | 26 | Bearing sleeve 1 Dismantling and assembling balance shaft drive Printed in Germony ~ Vl, 1992 13-41968 Engine, Crankshaft, Pistons 13 Removing and installing double-mass flywheel and grooved ball bearing Removal 1. Fit double-mass flywheel to engine support adapter using Special Too! 9538/1. 2. Unbolt clutch pressure plate evenly and take off pressure plate complete with drive plate. 3. Undo cylinder bolt (multi-tooth bolt) from double-mass flywheel and lift off. Caution! Take care not to damage the reference mark sender. Installation Tighten cylinder botts in two steps. 1st step 40 Nm (30 ftlb.) 2nd step 90 Nm (66 ftlb.) Removing and installing grooved ball bearing Removal Pull out grooved ball bearing with internal puller, e.g. Kukko 21/2 (14.5 to 18.5 mm). Installation Push in with Special Tool VW 295 A unti its seated against the stop. Removing and installing double-mass flywheel and grooved ball bearing 13-43 Printed in Geemany ~ Vil, 1993968 Engine, Cylinder Head, Valve Drive 15 Replacing the camshaft toothed belt (with hydraulic belt tensioner) Removal 1. Tum engine in direction of rotation and set cylinder 1 to firing TDC. Refer to Figs. on page 15 - 4. 2. Remove engine undertray. Slacken and take off Poly-Rib belt for air conditioning compressor / alternator and belt for power pump. 3. Loosen crankshaft bolts, remove toothed belt cover, guide rail (balance shaft toothed belt) as well as toothed belt. 4. Take guide rail off coolant pump housing and toothed belt tensioner off support. The toothed belt tensioner may be taken off in forward direction without having to lock the parts. 5. Remove tensioner lever and take off toothed belt. Pre-tensioning the hydraulic toothed belt tensioner 6. After removal, the hydraulic toothed belt tensioner must be pre-tensioned in a vise. Fit aluminum jaws into vise. Insert the crank- shaft bolt washer (part no. 944.102.210.02) at the lower section of the tensioner hous- Note Do not apply pressure to inner surface of the tensioner housing. Press only on outer edge of the tensioner housing. 7. Tighten vise slowly until resistance is felt. Walt for a couple of seconds and then tighten somewhat more. 8. Continue to tighten in this order until the push rod /housing bores are flush with each other and the push rod may be locked with Special Tool 9530 (upper Fig.) Note Never continue to rotate engine If the toothed camshaft belt is not fitted or has not been ing to protect the tensioner bottom. tightened since this may lead to valve damage. Replacing the camshaft toothed belt (with hydraulic belt tensioner) 15-1 Printed In Germany - Hl, 1991,15 Engine, Cylinder Head, Valve Drive 968 Installation 9. When refitting the toothed belt, observe the following sequence: — Crankshaft drive pinion — Install and lock tensioning lever (Preload the lock ring, replace if required) — Camshaft drive pinion = Coolant pump recirculation gear = Tensioning pulley 10. Install hydraulic toothed belt tensioner and rotate Special Too! 9530 to pull tool out. Rotate crankshaft by two turns and check TDC marks on flywheel and camshaft tive pinion, respectively 15-2 Replacing the camshaft toothed belt (with hydraulic belt tensioner) Printed in Germany = 1, 1994Engine, Cylinder Head, Valve Drive Adjusting and checking the camshaft setting Tools 15 No. | Designation Special tool [Order number | Explanation 1| Dial gauge support wy 387 ww 387 2| Dial gauges | |commercial tems 3| Dial gauge insert for push- | 9232 000.721.923.20 | rod stroke measurements 4| Flange 9529 (000.721.952.90 Dial gauge insert for push- shop-made rod stroke measurements (approx. 205 mm long) ‘Adjusting and checking the camshaft setting Printed in Germany - 1, 199115 Engine, Cylinder Head, Valve Drive 968 Checking and adjusting the camshaft setting Engine Type M 44.43/44 Check requirements: Belt tension o.k. Visual check of TOC marks 1. Tum engine in sense of rotation ‘TDC mark on flywheel (center notch) with until cylinder no. 1 is at firing TDC engine fitted (double-mass flywheel). Note Distributor rotor points up. With the engine removed, transfer TOC flywheel mark with a color pen to the sensor Camshaft position with cyl. 1 at firing TDC. ring gear. 15-4 Checking and adjusting the camshaft setting Printed in Germany - 1, 1991262 Engine, Cylinder Head, Valve Drive 15 Set TDC flywheel mark opposite crankcase ‘8. Remove distributor rotor and fit camshaft mark. ‘gear with 3 auxilary bolts (M 5 x 15) to prevent the camshaft gear and the cam- shaft, respectively, from turning when the ‘central camshaft bolt is undone. ‘Adjusting with dial gauges 2. Align dial gauge with shop-made extension (length 205 mm) to piston pin (cyl. 1). Preload 3 mm, Align second dial gauge to hydraulic tappet of cyl. 1 inlet valve. The dial gauge must be set up perpendicular to the inlet valve. Preload: 3 mm. 4, Undo central camshaft bolt, using a suitable retainer to keep the camshaft from turing. Rotate engine against the sense of rotation ntl the camshaft gear is against the stop within the woodrutf key groove. 5, Tighten auxiliary bolts to 6 Nm (4 ftlb) and Central bott to approx. 40 Nm (29 fib). Checking and adjusting the camshaft setting 15-5 Printed In Germany ~, 198115 Engine, Cylinder Head, Valve Drive 968 6, Remove oil ine from camshaft adjuster. Connect flange (Special Too! 9529) to cam- shaft adjuster and pressurize (pressure tlow approx. 3.0 bar). A consistent supply of com- pressed aris required since air can escape across a vent hole. 7. Turn engine in sense of rotation until maxi mum piston stroke is reached. 8. Set dial gauge of hydraulic tappet of cyl. 1 inlet valve to zero. 9. The crankshatt is now rotated from the fir- ing TOC (cyl. 1). Observe dial gauge of cyl 1 inlet valve at the same time. Rotate until a stroke of 0.39 + 0.03 mm is reached. Note Do not rotate crankshaft against the sense of rotation, 10. Undo central bott and auxiliary bolts, making sure the setting of 0.99 + 0.03 mm on the dial gauge does not change. 11. Continue to rotate the crankshaft slowly until maximum piston stroke on the dial ‘gauge is reached. This crankshaft position corresponds to the oyl. 4 firing TDC setting of the camshatts 3 ZN XN S (o OD 12. Tighten auxiliary bolts and central bot. Tightening torque of central bot 65 (48) to 70 Nm (62 fb). 19. To verity the setting, rotate crankshaft by two more tums and check setting. 14. Remove Special Too! and auxiliary bolts and reinstall distributor rotor. 15-6 Checking and adjusting the camshaft setting Printed in Germany ~ it, 1991968 Engine, Cylinder Head, Valve Drive Applying TDC mark to camshaft sprocket Engine Type M 44.43/44 Note Camshaft sprockets supplied by the spares department do not have the TDC marks. The TDC mark is applied after the camshaft has been adjusted on the new engine. 1. Place new camshaft sprocket exactly over ‘old camshaft sprocket and transfer TOC mark to new sprocket using a color pen. 2. Fit new camshaft sprocket and adjust camshaft according to instructions on age 15 - 4 to 15 - 6 in Repair Manual 8, Following item 19, page 15 - 6, apply the final TOC mark to the new camshaft sprock- et, using a three-square file and referring to page 15 - 4, Fig. 1 15 Applying TDC mark to camshaft sprocket Printed in Germany ~ IV, 1992 15-7968 Engine, Cylinder Head, Valve Drive 15 Camshaft adjustment gauge (shop-made) Engine Type M 44.43/44 Tools A - Exhaust Scale 1:1 E - Inlet Note 1. If color marks or casting lugs are missing on the camshafts, use the camshaft adjust- Ing gauge (shop-made) for referencing the camshatts. 2. After having placed the camshafts into the timing chain, the attribution of the cams of cylinder 1 may be checked with the gauge. Rotate both camshafts against each other 0 that the lower chain section is tensioned. Check again after the bearing saddles have been tightened. Camshaft adjustment gauge (shop-made) 15-9 Printed in Germany ~ Iv, 1992968 Engine, Cylinder Head, Valve Drive 15 Fitting the camshafts Tools 2 1 3 No. | Designation Special tool | Order number | Explanation 1 | Mounting saddles for e248 (000.721.924.80 | Used in conjunction removal and installation with tensioning pins of of camshafts Special Tool 9226 2| Thrust piece for seal 9204 000.721.928.40 3| Assembly sleeve for seal | 9233 000.721.928.30 4| Assembly tools | 9530 000.721.953.00 | For fiting of *VarioCam” | camshaft adjuster and hydraulic toothed belt tensioner Fitting the camshafts 15-11 Printed in Germany ~ IV, 199215 Engine, Cylinder Head, Valve Drive 968 Fitting the camshafts 1, Rotate engine in direction of rotation to approx. 45° before firing TOC (cylinder 1) 2. Compress “VarioCam” camshatt adjuster and lock with Special Tool 9530. Note The oil check valve in the camshaft adjuster may drop out when the adjuster is com- pressed. Retain oil check valve and take it out if required. 4, Place *VarioCam” camshaft adjuster between the camshafts into the chain, 9. Place inlet camshaft and exhaust camshaft into timing chain. Place both camshafts into timing chain in such a manner that the color marks or cast- ing lugs line up with the chain links marked. Note The distance between the inlet camshaft mark. and the exhaust camshaft mark is 7 chain ‘outer links. 5. Oil bearing surfaces of camshaft, cylinder head and cams. Fit camshafts with assemb- ly saddles, Special Tool 9248, used in con- junction with tensioning pins of Special Too! 9226, to oylinder head. 15-12 Fitting the camshafts Printed in Germany ~ IV, 1992968 Engine, Cylinder Head, Valve Drive 6. Fit camshaft bearing saddles and bearing covers. The bearing saddles or covers are machined as a unit with the cylinder head and must always be fitted as @ unit. Observe correct identitication character and matching number. Tighten bearing saddles oF covers to 20 Nm (15 ftlb). 7. When fiting, apply Loctite 574 to the seal- ing surfaces of the front and rear double bearing saddles. 8. Fit “VarioCam” camshaft adjuster to cylinder head. Take out Special Tool 9530. Fit oil pipe. Tightening torque of banjo bolt 10'Nm (7 fb). 15 9. Use Special Tool 9233 (assembly sleeve) and thrust piece 9234 to press the seal into the drive side of the camshaft. Oil sealing lip before fiting the seal Note It a damaged toothed belt has caused the valves to be damaged by the pistons, it is mandatory to replace the timing chain. Visually check chain sprockets and chain ten- er thoroughly. Fitting the camshafts Printed in Germany ~ 1V, 1992 15-13968 Engine, Cylinder Head, Valve Drive 15 Fitting the camshaft seal 1. Place sealing washers or lock pins, respec- tively, into bearing surfaces and fit bearing saddle, applying some Loctite 574. Tightening torque: 20 Nm (15 ftlb) 2, The seal cover may only be used with Special Tool 9234 after the bearing saddle has been tightened. Engine fitted Note If the sealing cover leaks with the engine fitted to the vehicle, fit the sealing cover as follows: 1. Place sealing washers or lock pins, respec- tively, into bearing surfaces. 2. Coat bearing saddle with Loctite 574 and fit saddle. Place a 0.02 mm feeler gauge between bearing saddle and cylinder head and manually tighten bolts lightly. 3. Oil sealing cover lightly and press in manually. Tighten bearing saddle to specified torque. () Tightening torque: 20 Nm (15 ftlb) 1g the camshaft seal 15-15 ted in Germany ~ WV, 199268 Engine, Cylinder Head, Valve Drive 15 Camshaft references Camshaft Worldwide references as of MY '92 Engine Type 968 M 44.43/44 Camshatts Inlet camshaft 944,105.277.09 Exhaust camshaft 944,105.275.10 Marking between 277.09 thrust bearing and cam 275.10 of cylinder 1 or on rear face Camshaft timing 1mm stroke, zero clearance Basic timing | Inlet opens 7.8° CR after TOC Inlet closes 52° CR after BDC Exhaust opens 31° CR bef. BDC Exhaust closes 1°CR after TOC Torque timing Inlet opens 75° CR bef. TDC Inlet closes 37° CR alter BDC Exhaust opens 31° CR bef, BDC Exhaust closes 4° CR after TOC Camshaft references 15-17 Printed in Germany ~ IV, 1982968 Engine, Cylinder Head, Valve Drive 15 Machining the cylinder head mating face Checking cylinder head for distortion Using a feeler gauge and ruler or straight edge, check the cylinder head mating face for distortion. Admissible distortion of the mating face: 0.05 mm. Distorted cylinder heads may be repaired by machining the mating face. Admissible distortion after machining: 0.03 mm. Machining the cylinder head Reface cylinder head mating face only until the surface is level. Max. wear limit: 146,6 mm Note for refacing the mating face: Max. roughness = 0,015 mm. If the new-dimension tolerance is exceeded during machining, a cylinder head gasket with a thickness of 1.4 mm must be fitted. New dimension A = 1470.1 mm Wear limit A =146.6 mm Machining dimension and identification of cylinder head New dimension: 147 0.1 mm Gasket 24.4 mm Identification : none Refacing dimension : 146.8...146.6 mm Gasket 1.4mm Identification iN Identification ,N” To be applied on the exhaust side between cylinder nos. 2 and 3, on the boss below the mating surface of the cylinder head cover. Height of stamped character ,.N” 6 mm Machining the cylinder head mating face Printed in Germany - Iv, 1992 15-19968 Engine, Cylinder Head, Valve Drive 15 Removing and installing cylinder head Engine Type M 44.43/44 Removal 1. Place protective covers on fenders and di connect ground cable from battery. 2, Remove air cleaner assembly complete with air mass sensor. Remove engine covers. 8. Undo distributor cap, pull off plug connec tors, unclip cover for fuel rail and put aside along with ignition leads. 4. Pull off connector for oil temperature sender and camshaft adjuster. Unscrew fuel return ‘and feed lines from fuel pipe, making sure a ‘second wrench is used to lock. Undo fuel rail at intake distributor and take out along with injector valves. Put fuel rail complete with wiring harness to the rear. Do not kink fuel lines. 5. Remove engine undertray. Undo exhaust sy- stem at exhaust manifold / exhaust pipe flan- ge. 6. Pull off coolant hose between reservoir and. thermostat housing and catch coolant in a suitable container. 7. Remove ATF reservoir trom body. Remove coolant pipe with heater valve. Bend heat shroud slightly forwards 8. Pull connector off idle speed positioner and throttle valve switch. Unhook throttle valve operating gear and remove bracket comple- te with idler. Pull vacuum hose off intake rail and throttle body. Remove coolant hose from reservoir at throttle body. a 9. Remove oil dipstick. Pull vacuum non-return valve from brake booster. Remove coolant hose between radiator and cylinder head from breather flange. Undo intake rail at lett- hand engine mount. Removing and installing cylinder head Printed in Germany ~ Vl, 1992 15-2415 Engine, Cylinder Head, Valve Drive 968 10. Remove bracket for oxygen sensor connec- tor from intake rail. Loosen breather hose at oil separator and coolant hoses at con- necting flange and pull off. Remove wiring harness bracket from connector flange. 11, Detach and remove intake rail from cylin- der head. Remove rocker cover, toothed belt cover and camshaft sprocket console. 12, Rotate engine in direction of rotation and set engine to firing TDC of cylinder No. 1 Slacken camshaft toothed bett and pull belt off camshatt sprocket. Refer to page 15-110 15-4. 13. Take out distributor rotor. Tighten cams- hatt sprocket with three M 5 x 20 mm auxi- liary screws to keep the basic camshaft setting from shitting when the central cams- hatt bolt is removed. 14, Undo central bolt, making sure a second wrench is used to lock. Remove camshaft sprocket and rear console. Disconnect con- ector for Hall sender unit. 1. Remove ,VarioCam* camshatt adjuster from cylinder head. Remove bearing cap from cylinders No. 1 and 3. Retain both ‘camshatts in bearings using Special Tool 19226. Undo and lift off front twin bearing saddle and remaining bearing caps. For in- stallation of camshafts, refer to page 15 - 11 to 15+ 13. 16. The rear twin bearing saddle may remain attached to the cylinder head. Loosen Spe- cial Tool 9226 in a uniform manner and re- move both camshafts complete with cams- haft adjuster and put them aside. 17. Undo cylinder head. Undoing sequence: From outside to inside. Lift off cylinder he- ad. (it tolerances are too narrow, the right- hand engine bracket must be separated from the hydraulic mount) Note If traces of oil ngress in the water are found, the cylinder head must be examined closely by visual inspection for hairline cracks. For this purpose, check the cooling system for tightness. Run tightness check with tester VW 1274 across the reservoir (max. pressure 1 bar). The camshaft cap must be removed for visual checking. 15-22 Removing and installing cylinder head Printed in Germany ~ Vi, 1992968 Engine, Cylinder Head, Valve Drive 15 Note The cylinder head may be fitted with the engi- ne remaining in the car. 1. Place cylinder head gasket into correct posi- tion. 2. Fit cylinder head. Tightening sequence: For unbolting, follow opposite sequence. Cylinder head tightening specifications Englne Type M 44.43/44 1st stage 20 Nm (15 ftlb) 2nd stage 60° tuming angle ard stage 90° tuming angle Note Do not use any lubricant when fitting the cylin- der head nuts and washers. Only the threads of the studs should receive a thin coat of engi- ne oil. 3, Replace gaskets, seals and O-rings before fiting the cylinder head. Tighten nuts and bolts to the specified torque. 4, Top up coolant and bleed cooling system. Warm up engine to operating temperature, check coolant level again and top up if requi- red. Removing and Installing cylinder head Printed in Germany ~ Vil, 1992 15-23968 Engine, Cylinder Head, Valve Drive Valve dimensions Valve dimensions Engine type M 44.43/44 Dimens. | Inlet 15 Valve dimensions Printed in Germany ~ Vi, 1983, 15+24a968 Engine, Cylinder Head, Valve Drive Dismantling and assembling camshaft drive Tools 15 No. | Designation 1| Toothed sector 2 | Toothed sector with hexagor bolt M 12x 1.5 x 60 3| Assembly tool for toothed belt tensioner -| Spacer sleeve — | Piston retracting too! ‘Special tool 9206/1 9238/1 9530 (Order number 000.721.920.61 000.721.953.81 000.721.953.00 Explanation Engine installed refer to page 15 - 30 refer to page 15 - 30 Dismantling and assembling camshaft drive Printed in Germany — Vil, 1993, 15-2515 Engine, Cylinder Head, Valve Drive 968 Dismantling and assembling camshaft drive 15-26 Dismantling and assembling camshaft drive Printed in Germany - Vil, 199215 968 Engine, Cylinder Head, Valve Drive Beachte: Nr_| Benennung StUck| Ausbau Einbau 1 | Hexagon head bott 1 Tightening torque M 16x 15x60 210 Nm (155 ft) 2 | Washer 1 Pulley 1 4 | Panhead screwM6x25 | 8 Tightening torque 15 Nm (11 fb) 5 | Tabwasher 1 6 | Pulley 1 7 | Gear drive for balance 1 shafts 8 | Flange washer 1 9 | Hexagon head bott 1 Tightening torque M 10x30 45 Nm (33 ftlb) 10. | Washer A 10.5 1 41 | Pulley 1 12 | Lock nut M 10 1 13. | Washer A 10.5 1 14 | Pulley 1 15 | Hexagon head nut 2 16 | Washer A 8.4 2 17 | Hydraulic toothed bet ten- | 1 sioner 18 | Snap ring 14x 1 1 19. | Shim 14x 20x 05 1 20 | Tensioning lever for toot- 1 hed belt tensioner 21 | Shim 14x 20x05 1 22 | Lock nut 1 Tightening torque 45 Nm (33 ftlb) 23. | Washer 24 | Hexagon head bolt 1 M 10x 45 Dismantling and assembling camshaft drive Printed in Germany ~ Vi, 1992 15-2715 Engine, Cylinder Head, Valve Drive 968 Beachte: Nr. | Benennung Stick] Ausbau Einbau 25 | Tensioning pulley 1 26 | Lock nut 2 27 | Locking clamp 28. | Camshaft toothed bet 29. | Hexagon head nut 30 | Washer A 8.4 31 | Console 32. | Shaft bolt M 10 ‘Treat carefully, do not twist or turn Heat shaft bolt area with | Use Loctite 270 to bond hot air gun Into crankshaft. Pack lu- bricating groove with Op- titemp PU 035 grease, Part No. 000 043 110 00. Tightening torque 45 Nm (33 ftIb). 33 | O-ring 12x 1.5 2 Replace 34 | Camshaft drive gear 1 Apply a thin coat of Opti- ‘moly HT to mount area. Lettering points to the front. 35 | Woodrutf key 5 x 5 x 22 1 36. | Support washer 1 37 | Round seal 1 Replace 38. | Pan-head screw 2 39. | Hexagon head bolt with 1 captive washer M6x 42 40 | Hexagon head bolt 1 M6x70 41 | Guide rail 1 For adjustment, refer to page 13-1 15-28 Dismantling and assembling camshaft drive Printed in Germany ~ Vl, 1982968 Engine, Cylinder Head, Valve Drive 15 ] Note: No. | Designation Qty. | Removal Installation 42 | Spacer sleeve 1 43 | Combination screw 2 44 | Toothed belt cover 1 45 | Anti-chafing protection 1 46 | Spacer 3 Special note on toothed belts and drive belts As a rule, make sure the toothed belts and drive belts are not kinked during assembly, Packing and storage. Improper handling may ‘cause incipient damage to the camshaft toothed belts and may eventually lead to engine damage. Dismantling and assembling camshatt drive 15-29 Printed in Germany ~ Vit, 199315 Engine, Cylinder Head, Valve Drive 968 Assembly note Slackening camshaft toothed belt 1. Remove idler pulley. Fit spacer sleeve (shop-made too!) with a M 10 x 55 hexagon head bot. 2. Align piston retracting tool between spacer sleeve and toothed belt tensioning lever. ‘Compress toothed belt tensioner slowly until a resistance is felt. Wait for a few seconds and rotate somewhat more. 3. Keep on rotating in this sequence until the pushrod-to-housing holes are lined up and the pushrod can be locked with Special ‘Too! 9530. Mlustration shows tensioned bett tensioner locked with Special Too! 9530, assembly tool (pin). Note Never rotate the engine if the camshaft toothed belt Is not fitted or tensioned as this may cause damage to the valves. The piston retracting tool is available from tool suppliers. Order No.: 03.9314-4950.3/01 Supplier: Messrs. Alfred Teves GmbH Postfach 900 120 D-60441 Frankfurt 90 15-30 Dismantling and assembling camshaft drive Printed in Germany ~ Vil, 1983Engine - Lubrication 17 Removing and installing lubrication system components Tools No. | Designation Special tool | Order number | Explanation 1| Oil filter wrench 9204 | 000.721.920.40 2| Assembly pin e262ht | 000.721 s26.21 3| Screwdriver insert for plug / thermostat | 995-17 e.g. Hazet, available from tool shops Removing and installing lubrication system components Printed in Germany ~ IV, 1992 7417 Engine - Lubrication 68 Removing and installing lubrication system components 7-2 Removing and installing lubrication system components Printed in Germany ~ 1v, 198217 968 Note: No. | Designation ty. | Removal Installation 1 | OW fiter 1. | Use Special Toot 9204 | Oil gasket lightly, tighten- ing torque 20 Nm (16 filb) | 2 | Oil pressure sender unit 1 Tightening torque 35 Nm (26 fb) 3 | Seal 1 Replace 4 | Plug 1 Tightening torque M 42x15 50 (37 flb) + 10 Nm (7 fib), use screwdriver insert (17 mm dia.) (e.g. Hazet 985-17) 5 | Seal A 42 x 49 1 Replace 6 | Spring 1 (Check for correct seating 7 | Thermostat 1 8 | Pan head screw with 1 Tightening torque captive washer 28 Nm (21 fib) M8x25 9 | o-ring 2 Replace 10 | Oil pressure release valve | 1 Tightening torque 45 Nin (83 ftib) 11 | Seal A 20 x 24 1 Replace 12 | Oxing 2 Replace 13. | Hexagon head bolt 4 Tightening torque M8x25 28 Nm (21 fib) 14 | Washer 4 18 | Thermostat housing 1 Align with assembly pin 9262/1 16 | Profiled gasket 1 Replace 17 | Flange 1 Preassemble in thermo- stat housing, press in to stop 18 | O-ring 2 Replace, oll lightly 19 | Cover 3 Bonded in place with Loctite 649 Removing and installing lubrication system components Printed in Germany ~ 1V, 1982 17-317 Engine - Lubrication Assembly note Aligning the thermostat housing 1. Fit preassembled housing to crankcase and tighten hexagon head bolts lightly. Screw in oiled assembly pin 9262/1 manually, center and tighten hexagon head bolts crosswise. {fa resistance is felt when the assembly pin is withdrawn, the fitting operation must be repeated. 2. Fit oll pressure release valve with new seal and ciled seals. Tightening torque 45 Nm (33 ftlb). 968 7-4 Removing and installing lubrication system components Printed in yany ~ WV, 1992ees Engine - Lubrication 17 Dismantling and assembling oil pressure release valve - = Note: No. Qty. | Removal Installation 1 | Slide valve housing 1 2 | Thrust spring 1 3. | Damping plunger 1 4 | Slide plunger 1 | 5 | O-ring 1 Replace, oll lightly 6 | O-ing }o4 Replace, oil lightly 7 | Snap ring 1 | May remain in slide valve | Check for correct seating housing 8 | Seal A20x 24 1 | Always to be replaced 9 | Plug with grooved pin 1 Tightening torque 45 Nm (33 ftlb) Dismantling and assembling oll pressure release valve 17-5 Printed in Germany ~1V, 199217 Engine - Lubrication Assembly notes Note Before dismantling the oll pressure release valve, use a suitable tool, e.g. a round ‘wooden or plastic rod, to check if the slide plunger (4) slides smoothly in the slide valve housing (1). If It sticks or binds, the oil pres sure release valve must not be fitted anymore Dismantling 1. Tighten oil pressure release valve at hexagon in a vise. 2. Put on protective gloves and pull slide housing out of plug. Note The slide valve housing (1) can only be pulled off with difficulty since the O-ring (5) must be destroyed in the process. In addition, the valve is springloaded, Assembly 1. Ol O-ring (6) lightly and fit to slide housing. 2. Coat damping plunger (3) and slide plunger (4) with oil and preassemble them in the slide valve housing. 3. Grease slide valve housing (1) well in Oring area, e.g. using Optimol Olit 2 EP or TLWW 735. 4, Fit thrust spring (2), press slide valve hous- ing into plug, using a vise and protecting the housing in a suitable manner (e.g. with ‘a wooden or plastic block etc.) 5. Apply a thin oil coat to O-ring (6) and fit to slide valve housing. 17-6 ismantling and assembling oil pressure release valve Printed in Germany ~ WV, 1982968 Engine - Lubrication Removing and installing oil restraining valve = a Zz 2 3 5 - Threaded pin 2 - Spring guide 3 - O-ting 4 — Thrust spring 5 - Ball 1. Remove cylinder head cover. Screw one hexagon head bolt, e.g. M 6 x 40, into spring guide from above. Undo threaded pin by two turns and pull out spring guide in upward direction. 2. Take out thrust spring and ball using a mag- hot. Clean ball seat, ball, thrust spring and oil duct thoroughly. The ball seat remains in cylinder head and must not be damaged. 3, Replace O-ting before fiting and oil lightly Tightening torque for threaded pin: 3.5 Nm (3 fb) 17 Removing and installing oil restrai Printed in Germany ~ IV, 1992 17-7968 Engine, Lubrication 17 Checking oll pressure 1, Remove oil pressure transmitter and screw oll pressure tester VW 1342 together with M 40x 1 adapter, and M 10 x 1/M 18x 1.5 adapter, in its place in the oilwater cooler housing. 2. Run engine to operating temperature (80° C oil temperature), checking the temperature with, for example, an oil temperature tester (Special Tool 9122 + 9122/2). 3. At idle speed the oil pressure should be 2.5 bar or more, Have a second person accelerate the en- gine speed to 4000 rpm. Read oil pressure from tester. The value should be greater than 4.5 bar. 4. Install oil pressure transmitter with a new A 18 x 24 seal. Tightening torque: 35 Nm. Checking oll pressure 17-9 Printed in Germany ~ Vil, 1983968 Engine, Lubrication 17 Cleaning the entire engine oll system after an engine failure (bearing failure) Note This cleaning sequence is only intended to give pointars as to whereyou may find chips. ‘The actual amount of work involved will de- pend oneach individual case of engine dam- age. Replace the following parts: - Hydraulic valve tappets - Oil pressure reliet valve (crankcase) filter The following parts must be dismantled, In- spected and cleaned thoroughly: - Oil pump - Thermostat housing - Oil restraining valve in cylinder head The following parts must be cleaned thor- oughly and/or rinsedthrough repeatedly: Note: All oll bores may be rinsed through thoroughly with benzine and a commercially available oivbenzine syringe. - Oil pan - Ol intake pipe = Oil drain pipe - Crankease - Crankshatt = Cylinder head - Oil lines - Oil cooler - Oil filler neck Change oll flter and engine oll after approx. 500 km. Note: After an engine failure, the entire intake sys- tem must be inspected for foreign bodies and/or oil and cleaned before assembly. Cleaning the entire engine oll system after an engine fallure (bearing fallure) 17-4 Printed in Germany ~ Vi, 1993968 Engine - Lubrication 19 Mixing table (Averagevalues) Antitreeze-Coolingwater Antitreeze protection to Antifreeze Water Antifreeze Water 30°C 45% 55% 3.5 liters 43iters -35°C 50% 50% 3.9Iiters 3.9iters 40°C 55% 45% 4S ters 35iters Checking cooling and heating system for tightness 1. Check visually for leaks. 2. Check coolant and heater hoses for proper routing, porosity, cracks and chafing. Repla- ce all damaged hoses. 8. Retighten hose clamps. ~ Mixing table 19-1 Printed in Germany — IV, 1982Fuel vacuum line routing Engine Type M 44.43/44 Fuel Supply 20 A. Air flow meter 1- Fuel pump B - Throttle body 2 - Fuel fter C- Idle speed positioner 3 - Injection tine D- Inlet manifold 4 Pressure regulator E - Overfiow valve 5 - Expansion tank F - Tank venting valve 6 - Roll-over valve G - Vacuum valve 7- Carbon canister H- Heating 8 - Return to tank | - Brake booster K - Oil separator Fuel vacuum line routing 20-4 Printed in Germany ~ 1V, 1992Fuel System - Electronic Injection 24 968 Test values Engine Type M 44.43/44 Test operation Test values Special remarks Electric fuel pump Min. feed Fate 850 cc/30 s Fuel pressure (Engine standstil) DME relay jumpered 3.8 + 0.2 bar Check value at idle 33 +02 bar Leak test Min. pressure after 20 min, 2.0 bar Idle speed, rpm without cat. conv. with cat. converter_| *Idle speed can only be Engine type M 44.43 | 840 + 40** 840 + 40** checked. (Manual transmission) Idle adjustment is no longer performed. Engine type M 44.44 | 880 + 40** 880 + 40** Miptronic) CO values % 05.1.5 04..1.2* * Measured ahead of catalytic converter, oxygen sensor HC values ppm $300 -s300* ‘connector not disconnected CO adjustment is no longer performed Test values 24-1 Printed tn Germany ~ 1, 199124 Fuel System - Electronic Injection 968 Checking idle and CO level of vehicles without catalytic converter Engine Type M 44.43/44 Note No provisions for idle speed adjustment are made any more. Adjustment at the throttle body is therefore no longer performed. Adjusting the idle CO level ‘Adjustment requirements Perfect condition of the mechanical engine components. Loads must be turned off while adjustments are made. Perform adjustments as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would give faulty CO level readings. Ambient tempera- ture 15 to 95 deg. C. 1. Warm up engine to operating temperature. (Oil temperature 70 to 90 deg. C), check with oll temeprature tester (Special Too! 9122 and 9122/2). 2. Cheok CO level. if the CO level is not within the specified adjustment range, correct ad- justment at CO potentiometer. Remove plug from inlet bore to CO level adjuster screw. 3. The CO potentiometer is located behind the right-hand pop-up headlight. Turning clockwise - richer mbaure ‘Tuming counterclockwise - leaner mixture Check idle speed. Connect separate tachometer according to manufacturer's instructions. Idle speed: Engine Type M 44.43 840 + 40 pm Engine Type M 44.44 880 + 40 pm 24-2 Checking idle and CO level of vehicles without catalytic converter Printed In Germany - 1, 1991968 Fuel System - Electronic Injection 24 Checking idle speed and CO level on vehicles with catalytic converter Engine Type M 44.43/44 Note Idle and CO level adjustment is no longer possible on vehicles fitted with catalytic con- verter. When checking the idle CO level, the ‘axygen sensor is not disconnected. Check requirements Perfect condition of the mechanical engine ‘components. Loads must be turned off while checks are made. Perform checks as rapidly as possible to avoid excessive heat buildup in the inlet ducts as this would glve faulty CO level readings. Ambient temperature 15 - 35 deg. C. 1. Connect commercially available exhaust gas adapter to test connector of catalytic converter. M_ haa 2. Warm up engine to operating temperature. (Oil temperature 70 to 90°C), check with oll temperature tester (Special Tool 9122 and 9122/2). ‘3. Do not disconnect oygen sensor connector. Connect CO level measuring instrument and separate tachometer according to manufacturer's instructions. CO check value: 0.4...1.2% Idle speed: Engine Type M 44.43 Engine Type M 44.44 840 40 rpm 880 +40 mpm Checking idle speed and CO level on vehicles with catalytic converter Printed in Germany ~ i, 1991,968 Fuel System - Electronic Injection 24 Removing and installing DME injection system components Removing and installing DME injection system components Printed in Germany ~ Il, 1991 24-524 Fuel System - Electronic Injection 968 Removing and installing DME injection system components 24-6 Removing and installing DME injection system components Printed in Germany ~ tl, 199124 968 Fuel System - Electronic Injection T T_ Note: _ No. | Designation Qty. | Removal Installation 1 | Pan head screw 2 M5x10 | 2 | VarioCam script 1| 3 | Pan head screw 2 | 5x35 | 4 | Washer 2 5 | Cover 1| 6 | Spacer bushing 2| 7 | Fuel return tine 1 | use a second wrench to | use a second wrench to | lock when removing lock when removing 8 | Fuel supply line 1 | usea second wrench to | use a second wrench to lock when installing Jock when installing 9 | Hexagon head bolt 4 Mex 12 10 | Fuel distributor pipe 1 11 | Retaining clip 4 12 | Injection valve | 4 Replace seals. Apply a light coat of oil | to the seating bore 13 | Hexagon head bolt 2 M6x 12 14 | Pressure regulator 1 Replace seal Apply a tight coat of oi! | to the seating bore 48 | Cap nut 1 | usea second wrench to | Tightening torque lock when removing 12. Nm (@ lb). Use a second wrench to lock 16 | Ball 1 17 | O-ing 1 18 | Hose clamp 2 19 | Air mass meter 1 20 | Shroud 1 21 | Hose clip 5 Removing and installing DME injection system components Printed in Germany ~ Il, 1991 24-724 Fuel System - Electronic Injection 968, “Noes ™™~—<“i=‘—SsSOSSCSY | | Removal Installation _ | 24 | Hexagon head bolt 1 M8x 40 25. | Clamp 1 26 | Idle speed positioner 1 27 j Hose 1 28 =| Pan head screw 4 | | M6x25 30. | Retaining bracket 1 21 | Tote bedy ‘ | 32. | Round seal 82 x 25 a always to be replaced 33 | Round seal 65 x 3 1 always to be replaced a 2 M4x10 | 35 | Throttle switch: | 1 24-8 Removing and installing DME injection system components Printed in Germany ~ il, 1991968 Fuel System - Electronic Injection Removing and installing injection valves Removing 1. Detach and remove cover for injection val- ves and plug leads. Unclip plastic cover and leave suspended at plug leads. 2. Pull off vacuum hose at pressure regulator and electric connector at oll temperatur sen- sor (cylinder head). ‘3. Undo fuel distributor pipe at intake dis- tributor and take out from above. Pull off electrical connector and retaining clamp at injection valve. Take out injection valve and catch overflowing fuel in a suitable container. 1. Replace injection valve seals. Oil seating bore of seals lightly 2. Check visually for leaks. 24 Removing and installing injection valves Printed in Germany ~ tl, 1991968 Ignition System 28 Replacing spark plugs 1. Pull off spark plug leads. 2, Remove spark plugs using a commercially avail. plug wrench (e.g. Hazet No. 767-1). A spark plug wrench is supplied with the tool kit. 3. Apply a light coat of Molykote paste HTP White to the plug threads, Tightening torque: 25 to 30 Nm (18 to 22 ftlb) Replacing spark plugs Printed In Germany - i, 1981 28-4968 Ignition System 28 DME control units as of Model Year ’92 Engine Type M 44.43/44 Model Production control unit Introduction date Remarks 92 944.618.123.00 Start of production July, "91 944.618.123.01 approx. September, '91 944.618.123.02 December, '91 Spare control unit 944.618.123.02 DME control units as of Model Year "92 28-3 Printed in Germany ~ WV, 199228 968 Ignition Syst Removing and installing knock sensor 1. To remove and install the knock sensors, tunbolt the intake rail from the engine. Refer to page 15 - 21 to 15 - 22, The coolant hoses remain connected. The intake rail remains in the engine compart- ‘ment. 2. Undo and take out knock sensors. Discon- nect connector. 3. Reinstall with a new genuine M 8 x 30 bolt (micro-sealed) without washer. Tightening torque: 20 Nm (15 ftlb.) Note Handle the knock sensor very carefully. The knock sensor must never drop to the ground from greater heights as this may damage the piezocrystal. - Removing and installing knock sensor 28-5 Printed in Germany ~ Vil, 1993DME-Diagnosis / Troubleshooting Dr. Ing. h.c. F. Porsche AktiengesellschaftDME-Diagnosis 24/28 968 Test Point Description Page Precautions a 2 Important Vehicle Information Test Requirements. Pin assignments of DME Control Unit Plug Effects of Faults (Cross Reference List) 1 Power Supply. vrs “ 2 Engine Temperature Sensor 2 10 3 Throttle Potentiometer.... 4 il Temperature Sensor 5 Rpm signal... 6 ‘Speed signal <- Speedometer 7 Air flow sensor. 8 ‘Oxygen regulation... 14 9 ‘Oxygen sensor. 10 Ignition timing change... 18 " ‘Opening winding of idle stabilizer 16 12 Closing winding of idle Activation... “ sennnel 18 Triggering of AC relay. sent 17 4 KM00k S2NSOF 1 onnsnnnnnnnn 17 15 Knock sensor 2... 16 Control unit fauity 7 Hall signal. 18 VarioCam. 19 19 Idle CO potentiometer. a sn sonnel 20 Controt unit fatty... eneeeneenemecnemeen 1S) a Fuel pump relay (OME relay)... 2 Tank ventilation valve. 23 Check Engine warning lamp. 24-27 Injector valves 28 Fuel pressure 29 Intake system leaks... 30 Ground and plug connections... 31 Ignition system. 32 Alternator, regulator. 33 Leads K and L... CO and idle speed test Coding the contro! unit Check Engine lamp.. DME-Diagnosis/Troubleshooting D 2q28-1 Printed In Germany ~ I, 199124/28 DME-Diagnosis 968 Precautions Increased demands of modem engines on the ignition systems and a desire for freedom from main- tenance have led to the introduction of electronic ignition systems in standard production some time ago. Normally the ignition power of electronic systems (of almost all makes) is greater than that of conventional systems and further power increases can be expected in the future. This places electronic ignition systems in a power range where touching live parts or terminals may be hazard- ‘us (this applies both to primary and to secondary circuits). |i this context, we must point out that all relevant national safety regulations and legislation must always be observed when working on or testing ignition systems. The ignition (Le. ignition or power supply) must always be switched off when working on the ignition system. Such work includes: ‘© Connecting engine testers, e.g, timing light, dwell angle/speed tester, oscilloscope etc. ‘© Replacing ignition system components, e.g. spark plugs, ignition coil, distributor, ignition leads etc. The above hazardous voltage will be present in the entire system should it be necessary to switch on the ignition for ignition tests or engine adjustments. Consequently, sources of hazardous voltages are not limited to the individual components of the igni- tion system (such as distributor, ignition coil, control unit, ignition tackle etc.) but are also present on wiring hamesses, plug connections and testers. D 24/28 -2 ‘DME-Diagnosis/Troubleshooting Printed in Germany ~ I, 1991oe DME-Diagnosis 24/28 Important Vehicle Information + Always turn off the ignition or disconnect the battery for resistance tests. (If this is not done, the tester may be destroyed). + Always disconnect the rpm sensor plug for compression tests. (If this is not done, hazardous high voltages and insulation damage to the ignition coil, high-voltage distributor and ignition leads may result). + The specified ignition coil (refer to Order No.) must not be replaced by a different coll + Never connect a suppression capacitor to ignition coil teminals 1 and 15. + Never connect ignition coil terminal 1 to ground for burglar alarm. (Ignition coil and control unit may be destroyed). + Never connect the positive battery terminal or a test lamp to ignition coil terminal 1. (The control unit will be destroyed) + Never disconnect the ignition lead from ignition coil terminal 4 to high-voltage di 4 while the engine is running. tor terminal + Voltage flashover from ignition coil terminal 4 to coil terminals 1 and 15 must not occur. (Control unit may be destroyed). + To avoid destruction of the control unit, the secondary circuit of the ignition system must be sup- pressed with at least 4 kQ, the original distributor rotor with 1 KO suppression resistance having to be installed. + Disconnect DME control unit only after turning off the ignition. + Flashover or disruptive discharge in the area of the high-voltage distributor cap (poor insulation) may destroy the control unit. + Never disconnect the battery when the engine is running. + Battery polarity reversal could lead to destruction of the ignition coil and the DME control unit. + External engine starting with more than 16 V or with a boost battery charger is not permitted. + When pulling off the connectors, e.g. for air mass sensor, throttle valve switch, injection valves etc., make sure the inside gasket is not lost. + Always follow the accident prevention regulations when working on the fuel system. DME-Dlagnosis/Troubleshooting D 2428-3 Printed in Germany — Vill, 199324/28 DME-Diagnosis 968 Equipment Required for DME Testing: ~ _ Diagnostics tester 9288 with connecting leads - 1 oscilloscope approved by Porsche - 1 digital display multimeter with an inter- nal resistance of at least 50 k2 - 1 Bosch L-Jetronic test lead, Bosch No. 1684 463 093 (check lead for correct polarity at plugs) ~ 2 control unit plug test leads (shop-made) with 2 tab connectors no. 17.457.2 fitted to avoid damage to the plug terminals in the control unit plug during testing. - 2 adapter test leads, consisting of: 4 plug ‘connectors N 017.483.1 with 2 leads ‘approx. 150 mm long, soledered, - 1 three-pin test lead (e.g. VAG 1501). ~ 2 control unit plug test leads (shop-made) with 4 tab connectors N 17.457.2, ‘The test leads must always be used for the tests! All sender and ignition timing signals of Porsche vehicles can be checked with the engine testers recommended by Porsche. Since instructions for connection of testers on ‘a car will differ depending on the equipment manufacturer, these instructions must always be followed to ensure correct tester connec- tion. ‘The following signals can be checked with the oscilloscope: - Engine speed = Vehicle speed = ti (injection time) = Idle stabilizer = Hall signal = Tank venting signal = VarioCam Note for USA: ta fault that affects exhaust gas composition is detected by the Check Engine lamp and is read out, repair is possible with standard workshop tools D 24/28-4 DME-Diagnosis/Troubleshooting Printed in Germany ~ Il, 199468 DME-Diagnosis 24/28 Diagnosable DME Control Unit A self-diagnosis feature with fault memory is incorporated into the DME control unit to permit certain faults to be detected and stored. The DME control unit has a permanent positive connection to prevent deletion of detected and stored faults when the igintion is switched off. Detected faults remain stored in the fault memory for at least 50 engine starts. Caution: If the DME control unit plug or the battery is disconnected, the fault memory will be cleared ‘Tester Connections: ‘The diagnostics socket is located on the right-hand side of the passenger footwell Note ‘The fault path and fault code displayed on the System Tester 9288 will be complemented by the televant test point in the troubleshooting plan. ‘The Eprom module Version 4.0 may be used to select the following menus that may in turn be used to select additional submenus. These are displayed by the System Tester in text form. Selectable menus: © Fault memory © Drive links © Input signals ‘© Knock registration © Actual values © Drive link active This DME diagnosis/troubleshooting plan is based on the contents of the fault memory. Paths not covered by self-diagnosis are diagnosed by conventional means (test points 28 - 33, refer to fault list opposite). DME-Diagnosis/Troubleshooting D 24/28 -5 Printed In Germany ~ Il, 199124/28 DME-Diagnosis 62 Troubleshooting requires that the person performing the tests © is familiar with the location of components, function and technical relationships of the systems being tested © is able to read and evaluate Porsche wiring diagrams ‘© knows the functions of circuits and relays. © is capable of using testers such as oscilloscope, voltmeter, ohmmeter and ammeter, as well as of evaluating the test results. The fault text displayed indicates the fault path, Le. the fault may be present anywhere, from the control unit, across all connectors up to the component itself. Before reading the fault memory, do not try to locate faults by disconnecting plugs etc., since this may be detected and stored as a fault in the fault memory. Note for System Tester 9268, If the tester display shows ... not present, this could mean © Fault did not exis at time of testing © In case of a loose contact, an additional + symbol is displayed. Example: ... not present + Remedy: Visual inspection of path ‘¢ Conditions under which the fault is tested do not correspond to the conditions under which the fault occurred, Remedy: Conform with conditions displayed on the tester, Ifthe Signal unplausible message is displayed on the tester, this could mean ‘The signal of the monitored component is not within the tolerance range. Explanations for the counter shown on the tester display When the fault is detected for the first time, the counter is always set to 50. Ifa lower number is displayed, determine the difference between 50 and the value shown. This value represents the number determined from the combination of starting process, meeting the test condi- tions and non-presence of the fault. When the number 0 Is reached, the fault path is deleted in the control unit Should the fault status change from not present to present at a number below 50, the counter is reset to 50. I a number above 50 is displayed, the difference indicates the number of loose contacts that have occurred. Even at a value above £0, the counter counts down to zero when the above com- bination of conditions is met D 24/28 -6 DME-Diagnosis/Troubleshooting Printed in Germany ~ Il, 1991DME-Diagnosis 24/28 Pin assignment of DME control unit plug Note Slots marked black are not used. 1 Ignition coil Ground, ignition output stage (MP IX) Ground (Fuel pump relay) Idle speed positioner, opening winding not used ‘Speed signal at rev counter ‘Air mass sensor signal 8 Hall sender signal 9 Speed signal from speedometer 10 Ground, electronics (MP VIII) 11. Knock sensor 4 12 Positive terminal, Hall sender / throttle 13 Diagnostics L-wire 14 Ground, i jection valves (MP IX) 15 notused 16 Injection valve cylinder 3 17 18 19 20 24 22 23 24 25 26 27 28 29 30 31 32 Injection valve oylinder 1 Terminal30 Ground, electronics not used Check Engine warning lamp Idle speed positioner, closing winding Variocam Ground of remaining output stages (MP IX) Hotwire burotf Ground, air mass sensor Terminal 15 Oxygen sensorfidle CO potentiometer Knock sensor 2 Ground NTC/shield knock sensor Knock yes/no Control of AC relay DME-Dlagnosis/Troubleshooting Printed in Germany ~ Wi, 1991 D 24/28 -766t “al — Auemieg uf perung Sunooysejqnoiy/sisoubelq-aWa 8-822 a £1318) 2) 8) Fl ZF) Z| BI] ZI Z| Enoine in pertect running condition = z ? B)z) 2) 3) 2/3) 3] &| 8 | 8 | g | Sater charged iS gl3 elo] z/ 38) 2)° |) F | S| F] =) 2 | stanermotor cranks the engine g §| 2 a £/2/8 $|a|a|s e 13} 3 g|8 5 A gls 3 8\ 2 e ale g|8 cs Terms in bold letters Display Fault Memory / Fault Path | 1 | su ita lv | 24518 x x x x ipply voltage 24> 18 x fx |x x |x |x | x | 2 | Engine temperature sensor 2 14 |a | 45330 x x |x 3 | Throttle potentiometer 16 |v x x 4 | Olltemperature sensor 17 |a | 47330 x |x x |x x | x | 5 | Rpmsignar 18 |= | 49348 6 | Speed signal <- Speedometer 19 |= 9324 x fx [tx [x |x |x |x 7 | Airflow sensor 21 |va x fx |x x 8 | Oxygen regulation 23 x |x |x x 9 | Oxygen sensor 24 lv 10 | Ignition timing change 26 x x |x 11 | Opening winding of Idle stabilizer a7 |v x x |x 12 | Closing winding of idle stabilizer ze |v 13 | Activation of AC relay 20 |va x |x x 14| Knock sensor 1 34 x |x x 15 | Knock sensor 2 32 16 | Controt unit faulty 33 sisouBela-3WG 82/ve~ —— | x x 15 | Knock sensor 2 32 | x | x || 16 | Controt unit tautty 33 x x | 17 | Han signat 34 [= | x x 18 | VarloCam 35 |v 19 | Idle CO potentiometer 36 x x | 20| Control unit fauty a x | 21 | Fuel pump relay (OME-relay) 42 |v x |x x 22 | Tank ventilation relay 43 [Ve | | 23.| Check Engine warning lamp 45 Lx | x |x | x 24 | Injection vaive cylinder 1 51 |va x |x x |x |x 25 | Injection vaive cylinder 2 52 |va x |x x |x [x 26 | Injection valve cylinder 3 53 |va x |x x |x |x | 27 | Injection valve cylinder 4 54 |va x |x x |x |x x | 28 | Fuet pressure x |x x |x |x x | 29 | Intake system leaks x x |x x | 30] Ground and plug connections x |x x |x |x x | 31 | Ignition system = x x 32 | Alternator + Regulator v x | 33 | Leads K +L v V = Votmeter = Ohmmeter = Oscilloscope24/28 DME-Diagnosis 33 34 35 36 37 38 39 40 4 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Tank venting valve Injection valve cylinder 2 Injection valve cylinder 4 DME relay 85 DME relay 87 not used not used ‘AC switch input Coolant temperature switch (115°C) Position switch (selector lever) not used Ground, version coding Engine temperature sensor 2 not used Oil temperature sensor ‘Speed signal / reference mark ‘Speed signal / reference mark not used Ignition angle cut-in (Tiptronic) ‘Throttle position to transmission control unit Signal from throttle potentiometer Version coding Diagnosis for lead K ‘DME-Diagnosis/Troubleshooting Printed ln Germany ~ Mt, 1991,968 Fault, Fault Code Test Point 1a Power supply for DME control unit (V) DME-Diagnosis 24/ 28 Possible Causes, Ellmination, Remarks a) Permanent positive (B+) If there Is no B+ the fault memory Is cleared Test procedure: Connect a voltmeter to terminal 24 (-) and terminal 18 (+) of the con- trol unit plug with the help of test leads. Display: Battery voltage No display: Check current flow and ground paths in accordance with wiring diagram. Test point 1b Power supply of DME control unit (V) too highitoo low Fault code 1_11 'b) Power supply via terminal 15 Check regulator voltage with the engine running. Specified value approx. 13.8 V Connect a voltmeter to terminal 24 (-) and terminal 27 (+) of the control unit plug with the help of test leads. Turn on ignition Display: Battery voltage No display: Check current flow according to wiring diagram DME-Diagnosis/Troubleshooting Printed in Germany ~ il, 1991 1D 24/28 -924/28 Fault, Fault Code Test point 2 Engine temp. sensor (NTC Wa) Fault code 1_14 DME-Diagnosis 968 Possible Causes, Ellmination, Remarks Using System Tester 9288, the engine temperature can be read off directly in menu item ,Actual values". no is not plausible display: Connect ohmmeter to terminal 45 and terminal 30 of the discon- nected DME control unit plug with the help of test leads. Display at: OC = 44-68k2 15-30 = 14-3.6kQ 40C = —1-13k2 80°C = 250-3909 100 = 160-2100 If the above values are not obtained, check directly at engine temperature sensor. Note: Temperature sensor 2 informs the control unit of the engine temperature. It provides additional fuel in the cold starting and warm- up stages of engine operation, Open circuit (2): ‘The DME control unit of the 968 adjusts to a value pre-set in the control unit that approximately corresponds to that of the engine at operating temperature. Enrichment by the faulty temperature sensor 2 when the engine is warm does not occur (emergency running pro- gram). This resus in starting problems when the engine is cold (no cold start enrichment). Shot circuit to ground: When engine is cold: No engine pickup, too lean, engine stops. No effect it engine is at operating temperature. Replacement value is applicable to both types of fault! D 24/28 - 10 -Dlagnosis/Troubleshooting Printed in Germany ~ i, 1991968 DME-Diagnosis 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test point 3 Throttle Using System Tester 9288, the throttle angle may be read directly in potentiometer the Actual values menu item. Fault code 1.16 It no plausible display is obtained, check power supply Connect test lead VW 1501 between throttle potentiometer and dis- connected plug. Connect voltmeter between iead No. 1 and No. 2. Ignition on = display: approx. 5 V (Power supply of throttle poten- tiometer) No display: Check according to wiring diagram Connect voitmeter to lead No. 1 and No. 3. Display approx. 0.5 Vott. Operate throttle. Voltage should now increase to approx. 4.7 Volt. Test point 4 Oil temperature sensor Using System Tester 9288, the oil temperature may be read directly (in cylinder head) in the Actual values menu item. As an alternative, connect an Fault code 1.17 ohmmeter between terminal 47 and terminal 30 of the disconnected 2 DME contro! unit plug. play at: 60'S = 3.8K 85°C = 1.5k0 100°C = 930 0 It the above values are not reached, check directly at oil temperature sensor. Note: The engine temperature sensor informs the control unit of the actual oil temperature. Changes of the oil temperature cause the VarioCam shift points to be relocated. Test point 5 Rpm signal Run test using an oscilloscope. Connect and adjust shop oscillo- Fault code 1_18 scope according to manufacturer's instructions. Connect oscilloscope test lead with terminal 49 and terminal 48 of the disconnected DME control unit plug. DME-Diagnosis/Troubleshooting D 24/28 - 11 Printed in Germany ~ Il, 199124/28 Fault, Fault Code Test point 6 DME-Diagnosis 968 Possible Causes, Elimination, Remarks Start engine. Sinewave fluctuations of 3 V min, must now be dis- played. An intermittently higher amplitude indicates the reference Ti 1 ~ Rpm signal 2 — Reference mark signal Ifthe voltage signal is too low (< 3V), the gap between sensor and ring gear may be adjusted incorrectly Sensor gap: between ring gear and sensor: 0.8 +0.2 mm. Using System Tester 9288, the reference mark signal may be read directly in the Input signals menu item. Speed signall Using System Tester 9288, the speed signal may be read directly in Speedometer the Actual values menu item. As an alternative, check with an oscillo- scope. Fault code 118 To do so, connect oscilloscope to terminal 9 and terminal 24 of the control unit plug. Turn left front wheel manually The following signal must now be displayed: D 24/28 12 DME-Diagnosis/Troubleshooting Printed in Germany ~ Il, 199168 DME-Diagnosis 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test point 7 Ai flow Voltage supply (V) Seay a Disconnect plug at air flow sensor, connect voltmeter to plug ter- minals 2 and § using test leads. CA oS Gp 5432 1 Ignition on: Display: Voltage approx. 10 Volt up to 13.8 Volt No display: check in accordance with wiring diagram Reconnect plug. Checking the hot-wire signal with System Tester 9288, The air flow sensor signal may be tested directly in the Actual values menu item using System Tester 9288. To check the signal, remove upper air cleaner section and start engine. Display: approx. 2.6 +0.5 Volt Blow against hot wire. This must cause the System Tester display to change. DME-Diagnosis/Troubleshooting D 24/28 - 13 Printed in Germany ~ Il, 199124/28 DME-Diagnosis 968 Fault, Fault Code Possible Causes, Elimination, Remarks Test point 8 ‘Oxygen regulation stop Fault code 1_23 Checking the hot wire signal (V) Connect plug to air flow sensor. Pull off DME plug. Connect DME plug terminal 36 to ground (e.g. door stop). Connect Voltmeter to DME plug terminal 7 and 26. Display: ~ 1.4 V Blow against air flow sensor and observe voltmeter. A voltage change must occur (~ 1.6 - 5 V). ig the hot-wire burn-off circuit (visual check) Operate engine with air flow sensor installed and connected. When an engine temperature > 60° C is reached, increase engine speed to above 2,000 rpm and stop engine (ignition of) After a waiting time of approx. 4 seconds, the hot wire must glow for approx. 1 second (bum-off ‘The oxygen regulator cannot operate within its control range if extreme problems of mixture preparation occur, e.g. due to an exces- sively lean setting because of unmetered air, or due to an exces- sively rich setting because of a fauity injector valve. The oxygen reg- ulator then moves up to the stop position, Oxygen Check intake system for leaks regulation _(Test point 29) stop too rich: Oxygen Check fuel pressure (Test point 28) regulation Check injector valves for leaks stop too lean: D 24/28 - 14 DME-Diagnosis/Troubleshooting : Printed in Germany ~ it, 1891DME-Diagnosis 24/28 Test point 10 Ignition timing change Fault code 1_26 968 YL Fault, Fault Code Possible Causes, Elimination, Remarks Test point 9 Oxygen sensor (Vv) Checking the sensor signal (Sensor signal) Using the System Tester 9288, the oxygen sensor signal may be eum coca thas) read directly under the Actual values menu Item. Diagnosis can only be carried out if an engine temperature of 70 deg. C has been reached for more than 1 minute. not: Disconnect oxygen sensor plug. Connect digital voltmeter with test connector (sensor voltage signal) and ground at the sensor end. Sart engine and allow to warm up so that the oxygen sensor reaches its operating temperature. When the mixture is enriched, e.g. acceleration, a change in the voltage signal must be displayed. 7 Voltmeter display: approx. 150 mV - 900 mV (ace. to mixture composition) If the regulator sets in with a certain delay, the oxygen sensor heater must be checked. To do so, connect voltmeter at control unit end with sensor plug disconnected and engine running. System voltage must be present. Test connection: 1 = Sensor voltage 2 = Sensor heating 3. = Sensor heating Note: If the control unit detects an oxygen sensor voltage signal of more than 1.4 V or less than 0.1 V, the control unit switches to operation ‘without oxygen sensor. (Short to ground or open circuit) If regulation does not work and the sensor voltage is O.K., check the coding of the control unit before replacing it. Using the System Tester 9288, the ignition timing change signal may bbe modified directly in the Input signals menu item. On Tiptronic vehicles, ignition is retarded when a gear change is made. When the Ignition timing change fault message occurs, check wiring continuity between DME plug and Tiptronic connector. DME control unit plug: Pin 51, Tiptronic control unit plug: Pin 32 Caution, observe connection between plugs. This fault causes the Tiptronic to operate in emergency mode. For the test to be valid, a test drive is required since the signal is only displayed for a very short time. = DME-Diagnosis/Troubleshooting D 24/28 - 15 Printed in Germany ~ Ul, 199124/28 Fault, Fault Code Test points 11 and 12 Idle stabilizer (V) Fault code 1_27 128 DME-Diagnosis 968 Possible Causes, Elimination, Remarks The idle stabilizer is designed as a twin-winding actuator with one ‘opening winding and one closing winding. Using the System Tester 9288, actuation of the idle stabilizer may be read directly in the Drive links menu item. | no higher pulse Is present, check the following: Voltage supply Connect voltmeter with disconnected plug of idle stabilizer terminal 2 and engine ground. Ignition on. Display: Battery voltage \_ No display. Check power supply in accordance with wiring diagram, Checking the contro! signal Using the System Tester 9288, the idle stabilizer signal may be read directly in the Actual values menu item. Operational check: Switch on loads in idle mode. % display must change, idle speed remains constant. If not: Connect 3-pin adapter lead VW 1501 between idle stabilizer and plug port. Connect oscilloscope to the adapter lead terminal 2 and terminal 1 as well as terminal 2 and terminal 3, respectively Make sure the wiring connectors are not shorted to vehicle ground (to avoid short circuits). With the engine running, the following display must appear: JU If no audible pulse is detected even though voltage is present and a signal is applied, replace the idle stabilizer. D 24/28 - 16 DME-Diagnosis/Troubleshooting Printed in Germany ~ Il, 1991Fault, Fault Code Test point 13 Activation of AC relay Fault code 1_29 Test point 14 Knock sensor 1 Fault code 1_1 24/28 Possible Causes, Elimination, Remarks Using the System Tester 9288, activation of the AC relay may be checked directly in the Drive links menu item. fo sound is audible, check the following: 4) AC switch signal: DME plug disconnected, minal 40 and terminal 24, ‘AC switch on: Display approx. 12 Volt lf not: Check in accordance with wiring diagram If the air conditioning system is inoperative, the fault may be due to the 115° C coolant temperature switch. To check the switch, connect ohmmeter with terminal 41 of the disconnected control unit plug and ground. Ignition on. Display: IF not, check in accordance with wiring diagram ition on, connect voltmeter between ter- 2) Voltage at A/C relay: Connect DME plug. Remove A/C relay (G19) from Central Electrical ‘System. Connect voltmeter with relay base terminal 2 and terminal 7. Operate A/C switch with engine running. Display: Battery voltage after approx. 5 seconds No display: Check wiring between A/C relay and DME control unit. Mounting of knock sensor (observe torque and type of screw) ~~ Check wiring hamess and plug connection in accordance with wiring diagram — Reconnecting the plugs helps to eliminate contact resistances: — Check if coolant or other fluids have ingressed in the knock sen- sor area — Replace knock sensor If the knock sensor is faulty, ignition timing is retarded by 6° on the ‘crankshaft at a certain engine load. ~ DME-Diagnosis/Troubleshooting D 24/28 - 17 Printed in Germany =24/28 DME-Diagnosis 968 Fault, Fault Code Possible Causes, Elimination, Remarks Test point 15 Knock sensor Il Fault code 1_32 = Mounting of knock sensor (observe torque and type of screw) Test point 16 Control unit faulty (Knock computer) Fault code 1_33, Test point 17 Hall signal Fault code 1_34 = Check wiring hamess and plug connections in accordance with wiring diagrams = Reconnecting the sensors helps to eliminate contact resistances = Check if coolant or other fluids have ingressed in the knock sen- sor area = Replace knock sensor If the knock sensor is faulty, ignition timing is retarded by 6° on the crankshaft Ignition timing is retarded by 6° on the crankshaft for all cylinders from a certain engine load if this fault occurs. Replace control unit. To check the Hall signal, disconnect plug at the cylinder head be- hind the camshaft sprocket and insert 3-pin adapter lead (VW 1501). Connect oscilloscope to terminals 1 and 2 of the adapter lead, start engine. f the Hall system is O.K,, the following signal must be displayed: D 24/28 - 18 DME-Diagnosis/Troubleshooting Printed in Germany ~ il, 1991Fault, Fault Code DME-Diagnosis 24/28 Possible Causes, Elimination, Remarks Test point 18 VarioCam Fault code 1_35 Test point 19 Idle CO potentio- meter Fault code 1_36 Test point 20 Control unit faulty Fault code 1_41 Ifthe DME control unit detects a missing Hall signal, ignition timing is retarded by approx. 6 in all rpm ranges. Using the System Tester 9288, VarloCam may be checked directly in the Drive links menu item or the Drive link active test point A switching noise must be audible in case of the Drive links point. For the Drive link active menu item, the entire system checked with the engine running. With this test, there is a risk of the engine stalling due to valve overlap. This causes communication to the System Tester 9288 to be interrupted. To be able to continue the diagnosis, switch the ignition off and back on again. Then press the *>"key on the System Tester. If VarioCam is not triggered, disconnect plug at the solenoid. Switch ignition on. Connect voltmeter to plug (refer to drawing) and ground (engine), Display: Battery voltage No display: Check wiring according to wiring diagram (On vehicles without catalytic converter that show fault code 36, start by testing the control unit coding (Actual values menu item with ‘System Tester 9288). If the coding is O.K., check power supply for CO potentiometer and potentiometer signal in accordance with the wiring diagram, Using the System Tester 9288, the version coding may be read directly in the Actual values menu item. If this fault is detected by the control unit, maximum engine speed is limited to 6,000 rpm 6 minutes after starting the engine. This is done to protect the engine. DME-Diagnosis/Troubleshooting 1D 24/28- 19 Printed in Germany ~ Wl, 199124/28 DME-Diagnosis 968 Fault, Fault Code Possible Causes, Elimination, Remarks Test point 21 Fuel pump relay (DME relay) (V) Fault code 1_42 Start engine - the fuel pump must operate during engine starting. H not: ‘Switch of ignition, Disconnect control unit plug. Use a test lead to ‘connect terminal 36 and terminal 24 of the control unit plug. Using an additional test lead, connect terminal 3 of DME plug to ground: (€.g. door stop). The pump must run. It not: Check in accordance with wiring diagram Test point 22 Tank ventilation valve (V) Fault code 1_43. When the engine operates at operating temperature, the tank ventila- tion valve (at the brake booster) is opened for a longer or shorter pe- riod as a function of the load. The opening period is determined by a ‘ground pulse from the control unit. a) Activation test To activate the tank ventilation valve directly, System 9288 may be used, selecting the Drive links menuitem. i there is no audible Pulse from the tank venting valve, check voltage supply at the termi- nal — refer to drawing — of the tank ventilation valve plug and body ‘ground according to the wiring diagram. Ignition on. Display: Battery vottage b) Control signal test Connect DME test lead (Bosch No. 1 684 463 093) between tank ventilation valve and plug connection. Connect and adjust engine tester according to manufacturers instructions. D 24/28 - 20 DME-Diagnosis/Troubleshooting Printed in Germany ~ Wl, 1991Fault, Fault Code Test point 23 Check Engine warning lamp Fault code 1_45 24/28 Possible Causes, Elimination, Remarks ‘The tank ventilation valve is not activated permanently. Testing must be performed within 7 minutes after starting the engine at operating temperature. Then interrupt activation of ventilation valve for approx. 75 seconds, continue afterwards. Start engine and accelerate. With the engine at operating tempera- ture, the following display must be visible on the tester: The signal becomes wider as the air throughput increases. ther no signal, check path in accordance with wiring diagram A ground signal is fed from the control unit ~ terminal 21 to the Check Engine lamp", causing this lamp to come on when an emis- sion control component fails If the ,Check Engine" warning lamp fails, this fault is stored in the fault memory. ‘Check by supplying ground to disconnected DME control unit plug terminal 21 and switching on ignition. The Check Engine lamp must now come on. To replace a faulty display lamp, always use the specified lamp. Reading errors using the Check Engine warning lamp is covered on page 024/28 - 31, ~ DME-Diagnosis/Troubleshooting D 2a/28- 21 Printed in Germany ~ Wl, 199124/28 DME-Diagnosis 968 Fault, Fault Code Test point 24 - 27 Injector valves (v/2) Fault code 1_61 154 Possible Causes, Elimination, Remarks Using the System Tester 9288, the injector valves may be checked directly in the Drive links menu item or the Drive link active menu item Selective injection allows each injector valve to be actuated individually. in case of the Drive links test point, a rather weak switching noise of the injector valves is audible. In case of the Drive link active menu item, each individual injector valve may be isolated with the engine running, Power supply Disconnect valve plug, connect voltmeter to the injector valve plug terminal — refer to drawing — and ground (engine). Ignition on. Display: Battery voltage If no battery voltage is displayed, check according to wiring diagram. Checking coil resistance of injector valves Disconnect valve plug. Check coil resistance at injector valve ter- minal contacts with an ohmmeter. Test value: approx. 16 2 Injection output stage Adjust oscilloscope according to manufacturer's instructions. Con- ect a Bosch test lead (1 684 463 093) between injector valve and plug. Connect oscilloscope according to manufacturer's instructions with the test lead. Caution: Make sure the tester leads are not grounded in any way. D 24/28 - 22 ‘DME-Diagnosis/Troubleshooting Printed In Germany ~ Ml, 1991,Fault, Fault Code DME-Diagnosis/Troubleshooting Printed in Germany ~ i DME-Diagnosis 24/28 Possible Causes, Elimination, Remarks Start engine. If the injection output stage operates correctly or if the tester connections are correct, respectively, the following signal must bbe displayed: i signal D 24/28 - 2324/28 Fault, Fault Code Test point 28 Fuel pressure DME-Diagnosis 968 Possible Causes, Elimination, Remarks The loft-hand fuel collection pipe has a test connection at cyl. no. 3 Unscrew the cap nut of the test connection. Caution: The inserted ball seat could fall out! Connect pressure gauge P 378 or VW 1918 to the test connection. Start engine. Test pressure 3.3 +0.2 bar (Idle speed) In case of hot starting problems: Check with engine stopped and {uel pump running. For the test, remove fuel pump relay and jumper terminal 87b and terminal 30. Test pressure 3.8 +0.2 bar — Switch off fuel pump. Read off pressure on pressure gauge (nominal 3.8 +0.2 bar) — Max. permissible pressure drop with warm en 0.5 bar in 30 minutes. — Ifthe pressure drops below the specified value, proceed as described below: D 24/28- 24 iagnosis/Troubleshooting Printed in Germany ~ tl, 1991,968 DME-Diagnosis Fault, Fault Code Possible Caus Elimination, Remarks 24/28 Build up pressure again by switching on the fuel pump briefly. Remove return pipe from pressure regulator (fuel pump must not be ‘switched on). No fuel escaping from the pressure regulator connection ‘connection Fuel escaping from the pressure regulator L Reconnect return hose Replace pressure regulator Build up pressure again Disconnect rubber pressure hose (tank to pump) infront of the fuel pump Pressure drop | {Pressure drop not okay okay Faultin fuel] [ Replace fuel injectors pump hoiding leakage) valve Repeat leak test End Y DME-Diagnosis/Troubleshooting Printed in Germany ~ I, 1991, D 24/28 - 2524/28 DME-Diagnosis 968 Test point 29 Intake System Leaks Check all connections downstream of the air flow sensor for leaks. Remove upper air cleaner section. Attach Special Tool 9264/4 to the air mass sensor and build up a postive pressure of approx. 0.5 bar in the intake sys- tem. Leaks will cause the pressure in the in- take system to drop quickly. Note: Fault flashing code 1_23 (oxygen regulator at stop) appears in cars with oxygen regulation and very large leaks in the intake system (eq. intake pipe gasket). Test point 30 Ground connection/plug connections (V) Ground lead (2x) from wiring harness to engine block. Battery ground lead at clutch bell housing {engine ground) and body (body ground, next to battery). Fuel pump ground between rear lock crosswall and spare wheel well. ‘Are ground connections tight and free from corrosion? If not, undo, clean and r connections as specified. jhten ground, Note: Never start the engine as long as the ground lead between body and engine is disconnected! This will destroy the control unit immedi- ately! D 24/28 - 26 DME-Diagnosis/Troubleshooting Printed in Germany Il, 199168 DME-Diagnosis 24/28 Plug connections ‘© One 2-pin plug for each of the 4 injection ‘Are all plugs connected correctly, not loose valves and not corroded? The pins and sleeves of the le fited with plugs must not be bent! ‘The 968s fited wth a standard control unit The control unit is coded accordingly depend- The 55-pin plug on the DME control unit lp onthe vette model (behind the floor plate in the passenger footw) The type of coding may be retrieved under the Version coding heading in the Actual values © A 14-pin plug in the engine compartment menu. next to the brake booster : Power to the DME control unit is supplied @A3>pin plug for reference mark/engine ‘across ignition lock terminal 15 and terminal 30. speed sensor and a 3-pin plug for the oxygen sensor behind intake pipe for cylinder no. 4 (remove cover at fuel ring pipe first) ‘© A3-pin plug at throttle potentiometer ‘© A 2-pin plug at tank ventilation solenoid valve (at the brake booster) © AG>pin plug at the air mass sensor © A 2-pin plug at NTC II (The temperature sensor is screwed into the engine block above the left-hand balance shaft near cylinder no. 1) ‘© A3-pin Hall sender plug (behind the cam- shaft drive gear) © A2-pin plug for knock sensor | (between intake pipe for cylinder no. 1 and 2) © A2-pin plug for knock sensor Il (between intake pipe for cylinder 3 and 4) © A3:pin plug for the idle stabilizer DME-Diagnosis/Troubleshooting D 24/28 - 27 Printed in Germany - Il, 199124/28 Test point 31 Ignition system a) Secondary ignition display Adjust secondary ignition display at oscillo- scope. Connect test leads according to manufacturer's instructions. Note: Ita fault is displayed for all cylinders, the fault is located in the primary or secondary circuit from the ignition coil to the distributor rotor. If a fault is displayed for one cylinder only, the fault is located after the distributor rotor. Primary resistor: Terminal 1+15 = 04-069 Secondary resistor: Terminal 1+4 = 5 -7.2kQ b) Spark plug connector (2) Suppression resistor: 8 KO Visual inspection for damage, traces of buming ete. ©) Distributor Distributor rotor, distributor cap: ‘Suppression resistor: 1 k@ each Visual inspection for damage, dirt, faulty mount- ing postion. DME-Diagnosis 968 4d) Ignition timing test Ignition timing is tested with the engine at ‘operating temperature: Using System Tester 9288, ignition timing and engine speed can be read directly in the Actual values” menu item. Test values: 968 (with manual transmission) At 840 = 40 rpm ...10° + 3° 968 (with Tiptronic) ‘At 880 + 40 rpm... 10° D 24/28 - 28 DME-Diagnosis/Troubleshooting Printed in Germany - Il, 1991968 DME-Diagnosis Test point 32 Alternator, regulator Engine misfire may be caused by voltage peaks of the alternator. Take drive belt off the alternator, start engine. Check alternator and regulator after having remedied the faults. Test point 33 Leads K and L ‘The diagnosis connection between the DME Control unit and testers is established by ‘means of the two leads K and L. If no diag- nosis is possible, the following points must be checked: 1. Continuity test (refer to wiring diagram) Leads L: Pin 7 (19-pin diagnostic socket) — Pin 13 (OME plug) Leads K: Pin 8 (19-pin diagnostic socket) = Pin 85 (DME plug) 2. Ground short test (refer to wiring diagram) Leads L: The voltage at pin 7 (19-pin diagnos- tic socket) must be > 8 V when the ignition Ison. Lead K: The voltage at pin 8 (19-pin diagnos- tle socket) must be > 8 V when the ignition ison Assignments: 7 - Lead L 8-Lead K 10 - Ground 13 - Terminal 15 Possible fault cause at < 8 Volt: = Short to ground or open circuit in wiring or connectors = A defective control unit connected to the above leads. (May be any diagnosable control unit, need not necessarily be the DME control unit). Checking: Disconnect plugs at diagnosable Control units one after the other until the vott- age is > 8 V. Replace responsible control unit. ~ Tester faulty. — No power supply at the diagnostic plug. - No ground supply at diagnostic plug. DME-Diagnosis/Troubleshooting Printed in Germany ~ Il, 1991, D 24/28 - 2924/28 Notes on idling speed and idling CO testing: a) Idling speed Idle speed check value for engines at operat- Ing temperature: 840 + 40 rpm with manual transmission 880 + 40 rpm with Tiptronic bb) Idle speed CO of cars without catalytic converter The CO level is adjusted at the idle poten- tiometer in the engine compartment. The following requirements must be observed: — Engine at operating temperature = Engine in good mechanical condition, ignition o.k = All loads switched off = CO tester at operating temperature, calibrated and adjusted correctly Adjusting value: 0.5 - 1.5 % CO ©) Idle speed CO of cars with catalytic converter (On these vehicles, adaptation of idle speed CO level takes piace along with adaptation of the idle speed. As a result, only the actual con- dition can be checked on those vehicles. The following requirements must be observed when performing the checks: ~ Engine at operating temperature = Engine in good mechanical condition, ignition o.k = All loads disconnected DME-Diagnosis 968 — Exhaust tester at operating temperature, calibrated and adjusted correctly - Oxygen sensor plug connected Test value: 0.4 - 1.2 % CO After disconnecting the control unit plug or the battery, the engine must run at idle for at least 10 minutes before these values can be rechecked. Coding the control unit The DME control unit is coded using a jumper connection deviating from the control unit wiring loom. If the jumper connection is free, the control unit operates in controlled mode, ie. with oxygen sensor regulation. If a 1 k@ resistor is attached to the jumper, the control unit operates in uncontrolled mode, ie. without ‘oxygen sensor regulation. ‘The coding may also be read directly in the “Actual values" menu item using System Tester 9288. D 24/28 - 30 jnosis/Troubleshooting Printed in Germany ~ I, 1991968 DME-Diagnosis 24/28 Check-Engine Lamp (Malfunction Indicator Light MLL.) USA vehicles are fitted with with a warning lamp that lights up if a component relevant to exhaust gas ‘composition fails. ‘As a function check of the warning lamp, the lamp lights up when the ignition is switched on and ‘goes out when the engine is running after it has been started without depressing the accelerator. A flashing code of the warning lamp indicates the defective fault path. To trigger the flashing code, fully depress the accelerator pedal for 3 seconds with the engine off and the ignition on until the Check-Engine lamp flashes. Then ease off the throttle. If no fault is stored, i.e. no warning came from the warning lamp, a flashing code appears e 15 no fault. ° 1 5 + = Lampon O= Lampott It the warning lamp did indicate a warning, i.e. there is a fault, a flashing code appears, e.9. 1124 LL Fault code Constant fault (2 with loose contact) DME. “PULL ‘Oxygensensor The flashing code is listed in the Diagnosing/Troubleshooting plan on page D 24/28-8, ‘The fault can also be read directly using System Tester 9288. After the repair the fault memory must bbe erased using the SystemTester. If the fault memory Is read via the Check-Engine lamp, repairs may be performed using conven- tional shop equipment. DME-Diagnosis/Troubleshooting D 24/28 - 31 Printed in Germany ~ Ml, 1991968 Table of contents volume tl ‘The Repair Manual 968, Vol. lI, ,Transmission*, covers manual and Tiptronic transmissions. The description of Tiptronic transmission repairs is found after the section covering the manual transmission. General Technicaldata............. eee eee cess 80-01 Clutch, operation Identification of clutch pressure plates... eee eee Removing and installing clutch. ‘Adjusting the clutch pedal . . Manual Transmission, Operation, Housing Removing and installing transmission... . 2... ‘Adjusting gearshift... . . . Removing and instaling gear set Removing and instaling rive shaft seal ransm. has not been dismantled Removing and installing Sth 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... .. . eee Recalculating adjusting shim ,S4*. Dismantling and assembling end shield : Dismantling and assembling transmission housing . Manual Transmission, Gears, Shafts Dismantling and assembling drive shatt Dismantling and assembling drive pinion Differential / Transaxle System Removing and installing differential... 2... 2... eee eines 30>) Dismantling and assembling differential . 99-5 ‘Adjusting drive set. . . . 39-11 Table of contents 1 Printed in Germany ~ Xi, 1994Ye 62 General 30 Technical data 6-speed manual transmission G 44 Model Code Equipment Installed in: Model year letter G 4ajoo 6-speed 968 worldwide "92 Technical data 30-01 Printed in Germany - V, 1982General 30 Printed in Germany ~ Vv, 1982 968 Ye Technical data General data Manual transmission G 44 — Transmission ratios Ze:Zi=1 1st gear 2nd gear "38:19 = 2.000 3rd gear TES 4th gear 30; 7 L Sth gear 31:94 = 0912 ath gear 28:96 = 0.778 Reverse erry Final drive Hypoid bevel-gear drive with 12 mm offset Transmission ratio. 94:9 = 9.778 Final drive Filing capacity approx. 2.75 liter hypoid oll SAE 75 W £0 or API classification GLS (or MIL-L 2105 8) Technical data 30-03968 Technical Data General Tightening torques for manual transmission G 44 30 housing (Verbus-Ripp bott) Location Thread Tightening torque Nm (ftlb.) Selector shaft cover to trans- Ms 25 (18) mission housing Lock bolts to transmission M24x15 70 (52) housing and end shield Reverse light switch to cover 12x15 20(15) End shield to transmission Ms 25 (18) housing Drive shaft four-point bearing Ma7x1 150(111) End cover to end shield Me 25 (18) Retainer plate to end shield M8 (with collar) 25 (18) Deflection lever for reverse M14x15 35 (26) gear to end shield il filer and oil drain plug M22x15 35 (26) Threaded flange for guide M6 10 (7) (with Loctite 271) plate to transmission housing Side transmission cover Me 25 (18) - to transmission housing Halfshaft flange to differential M10 44 (32) Crown wheel to differential M12x 1.25 200 (148) Technical Data Printed in Germany ~ Vil, 1993, 30-05es Cute, Operation 30 Removing and Installing Clutch Removal 1. Disconnect battery ground cable. 2, Remove full set of power unit undertray panels. 3, Disconnect oxygen sensor connector and pull cable downwards. 4, Remove exhaust mainfold complete with catalytic converter. 5. Undo starter mounting bolts, remove heat shield and move starter to the side. 6. Unbolt clutch slave cylinder and hang to ‘one side, the line remaining connected. Attach note in intetior of vehicle: “Do not operate clutch pedal. 7. Remove cover of clutch housing. 8, Pull out release lever shaft using an M8 bolt after having undone the lock bolt Removing and Installing Clutch Printed in Germany - i, 199130 9. Release socket head bolt of clamping sleeve and push back clamping sleeve com- plete with central shaft | 10, Remove hexagon head bolts (M 6) for {guide tube and push guide tube towards thrust plate. 111. Mark installation position of thrust plate and flywheel for reassembly. 12, Release mult-tooth bolts of clutch thrust plate evenly and take out thrust plate together with guide tube and clutch drive plate. Clutch, Operation 968 Installation Grease all sliding surfaces for clutch release as well as central shaft teeth with Olista Longtime 3 EP. 1. Before fiting the complete clutch assembly (rive plate, thrust plate and guide tube), align release bearing and guide tube with regard to each other. Note hole pattern of thrust plate to flywheel. Note Insert release fork into clutch housing before installing the clutch assembly (installation of {ork is not possible afterwards). 2. Put clutch assembly in place and screw in mutti-tooth bolts of thrust plate manually. 3. Push central shaft | in forward direction, centering the drive plate at the same time. Removing and Installing Clutch Printed in Germany — I, 1991968 Clutch, Operation 30 Note ‘A groove is machined in central shaft ! to allow a screwdriver to be used to push the shaft forward. 4, Determine center position of clamping sleeve relative to central shatt II and tighten socket head bolt to 80 Nm (69 ftlb). Engage release fork. Relocate release lever Until needie sleeve and bore in the clutch housing line up. Push in release lever shaft to stop, making sure itis positioned correct- ly (milled surface pointing towards the mounting bolt). If required, mover release lever to and fro to faciltate alignment. Do Not use force to achieve correct alignment. 5. Tighten mounting screws of thrust plate =e evenly, Tightening torque 28 Nm (17 fb) 6. Tighten guide tube. Check for correct seat- ing. Tightening torque 10 Nm (7 tb) Removing and Installing Clutch 30-3 Printed in Germany - 1, 1991968 Clutch, Controls 30 Identification of clutch pressure plates To avoid confusion, the pressure plates are co- lor-marked for positive identification, 600 Color marking: 968 Green 911 Carrera 2/4 Blue 911 Carrera (993) No mark 911 Turbo 3.6 Red Identification of clutch pressure plates Printed in Germany ~ Xi, 1994 30-44968 Clutch, Controls 30 Adjusting the clutch pedal Note ‘The following items are essential requirements for smooth clutch operation and must therefore be ‘observed whenever the pedal is adjusted: ~ Correct bleeding of clutch hydraulics. — Tightness of hydraulic system. ~ Correct setting of pushrod and boost spring. ~ Pedal position according to standard setting. Checking and adjustment procedures 1. Adjusting pedal position/pushrod (dimension A = LHD: 147 mm / RHD: 109.5 mm). If repairs on the master cylinder have been carried out, the pushrod must be readjusted. Move the ‘sound insulation in this area out of the way. The correct pedal pos. is obtained automatically after the pushrod has been set to dimension A (measured between body and rod center). This dimen- sion is set by turning the hexagon head pushrod and by locking with the hex nut. Ht required, correct the cruise control switch position on vehicles equipped with cruise control. Adjusting the boost spring (dimension B = 65 mm) / or 68* mm). The boost spring can be set to dimension B = 65 mm + 1 or 68* mm + 1 mm only after the pedal Position has been checked and adjusted. Measure the dimension between the outer edge of the washer and the cutter support (refer to diagram). If the parts have been dismantled or when ordering spare parts, dimension B is 76 mm + or 78" mm 1 mm. In this case, the boost spring is secured with a cotter pin (2 mm dia). * New boost spring fitted as of April, 1993 (grey color) eal ‘Adjusting the clutch pedal 30-5 Printed in Germany — XI, 199430 Clutch, Controls 968 3. Clutch free play. ‘The free play cannot be adjusted. The clutch master cylinder is provided with an internal stop. if the boost spring and the pushrod are adjusted correctly, the clutch pedal is always forced against this stop. Pull the pedal back to check if this stop (= end position) is reached. Due to the fact that any frée play is automatically taken up hydraulically, the free play of the clutch cannot be checked at the clutch pedal. 30-6 ‘Adjusting the clutch pedal Printed in Germany — x1, 1994968 Manual Transmission, Operation, Housing 34 Removing and installing transmission, Model G 44 Removal 1. Undo drive shafts at transmission end and suspend horizontally on vehicle, 2, Disconnect connector for reverse light switch, 3 Push shift rod bellows to the rear and unscrew clamping screw. Disconnect, shift rod from intermediate lever. 4, Unscrew pan head screws of clamping sleeve actoss inspection holes and push clamping sleeve towards transmission. Supplier's address: Snap-on Tools GmbH Rudolph Diesel Strasse 6 D-7104 Obersulm-Willsbach Phone 07134/3054 or any other Snap-on distributor worldwide. 5. Locate transmission complete with central tube in installation position, placing a suitable wooden block between the Crosstube and the central tube. 6. Place a general-purpose transmission jack below the transmission and secure with a retaining strap. 7. Remove fastening bolts for transmission mounting, Note To fit the pan head screw into the central tube housing, use an extension with swivel joint (16° angle). Order No. SxW 10 8. Remove transmission/central tube fastening bolts. 9. Pull transmission to the rear and lower care- {fully towards bottom. Removing and installing transmission, Model G 44 Printed in Ger any -V, 199234 Manual Transmission, Operation, Housing 968 Installation 1. Fit transmission with general-purpose transmission jack. 2. Engage transmission and fit flange bolts. Tighten all fastening bolts to the specified torque. 8, Retain transmission in installation position and fit transmission mount. 4, Fit connectors for reverse light switch, shift rod and drive shafts. Tightening torques: Transmission to central tube M12 85.Nm (63 fib) M10 42.Nm (31 fib) Shift rod Ms 21\Nm(15 fib) Mounting bracket totransmission M8 — 23.Nm (17 ftlb) Drive shafts, M8 — 42.Nm (31 fib) Order of assembly of the clamping sleeve: Start by fiting one bolt each on left and right-hand side and tightening to 10 =5 Nm (7 +4 fib). Fit opposite bolts and tighten to ‘80 Nm (59 ftlb). Re-tighten the bolts fitted initially to 80 Nm (59 ftlb) 34-2 Removing and installing transmission, Model G 44 Printed in Germany - V, 1992968 Manual Transmission, Operation, Housing 34 Adjusting gearshift 1. Set manual shift lever (No. 3) to idle post tion. The transverse selector shaft is now in the Grd and 4th gear shift plane. With the gearshift mechanism adjusted correctly, the shift lever (No. 3) Is not in- clined in transverse direction. Adjusting shift lever position: Undo lock nuts (No. 1) and turn centerpiece of the joint rod (No. 2) until no transverse in- clination remains anymore at the shift lever (No. 3). 2, To adjust shift lever, move the shit lever ‘support mount (arrow) to the front or rear until the inclination is 85°. The shift lever must remain in neutral position during this adjustment operation, Adjusting gearshift Printed in Germany ~ Vi, 1992 34+ 2aManual Transmission, Operation, Housing 34 u Removing and installing gear set Tools No. | Designation ‘Special tool Order number | Explanation | = 1| Drift 9286 (000.721 925.60 2| Assembly sleeve 9285 000.721.925.50 | 3| Drift 9532 000.721.958.20 4) Hook west = WW Special Toot - Removing and installing gear set Printed in Germany - V, 1982 34-334 Manual Transmission, Operation, Housing 968 Removing and installing gear set 34-4 Removing and installing gear set S Printed in Germany ~V, 198234 968 Manual Transmission, Operation, Housing Note: No. | Designation Qty. | Removal Installation 1. | Shift catch (black) 1 Do not confuse with shift catch (No. 2) Tightening torque 70 Nm (62 ftlb) 2 | Shift catch (light) 3 Do not confuse with | shift catch (No. 1) | Tightening torque | 70 Nm (62 fb) 3 | Bot Me x22 3 Insert with Loctite 573 | and tighten to 25 Nm a) 4 | Cover 1 | 5 | Sealing ring 1 | Replace 6 | Reverse tight switch 1 | Tighten to 20 Nm | (05 fu) 7 | Selector shaft with shift 1 cylinder 8 | Adapter sleeves 2 | Use Special Tool 9532 to drive out 9 | BonMsxs6 12 Tighten to 25 Nm (18 ftlb) 10 | Full gear set 1 11 | Shaft seal 1 | May be replaced without | Replace, fit only after dismantiing the transmis- | gear set has been in- sion (refer to page stalled as it may other- 94-7) ‘wise be damaged. Pack space between sealing lip and dust lip with multi-purpose grease 12 | Transmission housing Removing and installing gear set Printed in Germany -V, 1992 34-534 Manual Transmission, Operation, Housing 968 Removal and installation notes Removal Note ‘When working on the gear set, it is not neces- ‘sary to remove the differential WW 540 into assembly stand and drain transmission oil, Installation Note To avoid damaging the seal, install drive shaft seal only after the gear set has been installed. 1. Coat end shield/transmission housing sealing surface with sealant (Loctite 573) and place full gear set carefully into trans- mission housing 2. Drive adapter sleeves into position and tighten mounting screws to 25 Nm (18 ftlb) 3. Fit seal for drive shatt (refer to page 34 - 7). Removing and installing gear set Printed in Germany ~262 Manual Transmission, Operation, Housing 34 Removing and installing drive shaft seal if transm. has not been dismantled Removal 1. Remove transmission. 2. Lever out seal carefully, using hook VW 681. Note Make sure the sealing surfaces for the seal are not damaged. Installation 1. Push assembly sleeve 9255 onto drive shaft splines. 2, Pack seal space between dust lip and sealing lip with multi purpose grease. 3. Push seal into place using Special Tool 9256 unti itis seated at the stop. Removing and installing gear set 34-7 Printed in Germany ~V, 1982968 Manual Transmission, Operation, Housing 34 Removing and installing 5th and 6th gear Tools reise No. | Designation ‘Special Tool Order number | Explanation 1 Thrust piece 9535 000.721.953.50 Thrust piece 9536 000.721.953.60 3| Pressing device 3276 I- WW Special Too! Removing and installing Sth and 6th gear 34-9 Printed in Germany — Vil, 1993,34 Manual Transmission, Operation, Housing 968 Removing and installing 5th and 6th gear 94-10 Removing and installing 5th and 6th gear Printed in Germany ~ V, 1992Manual Transmission, Operation, Housing 34 968 Note: No. | Designation Removal Installation 1 | Cover Use a large screwdriver to| Replace lever out. The oil catcher | is damaged in the process 2 | Oil catcher Lever out at bore using a | Replace. Observe sorewdriver installation position 3 | Bot Lock drive shaft, removing | Tighten to 150 Nm shift cylinder and engag- | (111 ftib) ing two gears 4 | Four-point bearing Pull out using thrust Heat to approx. 100°C Soenero "1 12 13 14 inner race Bolt M 8 x 60° End cap Gasket Adapter sleeve Lock ring Fixed gear, 5th gear Four-point bearing inner race Needle-roller bearing 5th gear loose gearwhee! with spring | | Synchronizing ring | Piece 9535 and intemal puller 30...37 mm (e.g. Kukko 21/5) Engage 2 gears and pull off using two-way puller Pull off across Sth gear loose gearwheel (No. 13), Using thrust piece 9596 and two-way puller Mark for reinstallation Mark for reinstallation and drive into place Tighten to 25 Nm (18 ttib) Replace Heat to approx. 120°C and drive in to stop, observing correct instal- lation position. Installation position: Flange towards gear- wheel for 6th gear Heat to approx. 100°C and drive in to stop il with transmission oil, Fit with the same gear- wheel as before Check for wear. Fit with same gearwheel| as before. Removing and installing Sth and 6th gear Printed in Germany - Xi, 199434 Manual Transmission, Operation, Housing 968 Note: No. | Designation Removal Installation 15. | Spiral pin Press out only with Press in only with Special Tool 3276 Special Tool 3276 16 | Selector sleeve Mark for reinstallation Marks on synchronizer along with synchronzier | hub and selector sleeve hub, Pull off shift rod must match along with shift fork and dog 17_| Shift fork 18 | Driver | Replace only complete with shift rod for Sth and 6th gear 19 | Bearing inner race Pul off across 6th gear | Heat to approx. 100°C. loose gearwheel (No. 22) | and drive in until itis using thrust piece 9536 | seated at the stop | and two-way puller 20. | Synchronizer hub Pull off along with bearing | Heat to approx. 100°C inner race (No. 19) and press in to stop, ob-| serving correct po: 21 | Synchronizing ring Mark for reinstallation Check for wear, fit with | the same gearwheel as before 22. | 6th gear loose gearwheel with spring 23. | Needle-roller bearing Mark for reinstallation ii with transmission ol. j Fit with the same gearwheel as before 24 | Thrust washer Cutout points towards snap ring 25 | End shield j * Note If the height of the lug (approx. 35 mm) at the end cap is insufficient, a washer must be inserted at both of the lowermost bolts (No. 8) 34-12 Removing and installing 6th and éth gear Printed in Germany ~ V, 1992968 Manual Transmission, Operation, Housing 34 Removal and assembly notes Removal 1, Remove end cap, piercing center of rubber 8, Pull out four-point bearing inner race with with a large screwdriver. Push in screw- thrust piece 9535, internal puller 30...37 mm. driver laterally between cap and oil catcher (€.9. Kukko 21/5) and support. and twist screwdriver to lever off the cap. Make sure the intemal puller engages into the circumferential groove in the inner race. 2. To undo the bolt (No. 3), the drive shaft must be locked. To do so, remove the shift 4, Pull off four-point bearing inner race using cylinder and engage two gears. thrust piece 9536 and two-way puller. W994 5. Push out spiral pin for driver, using Special Tool 3276. Removing and installing 5th and 6th gear 34-13 Printed In Germany - Xi, 190434 Manual Transmission, Operation, Housing 968 Note Installation The spiral pin must not be driven out as this, 41. Check synchronizing ring for wear, pressing will damage the mountings of the shift rod. the synchronizing ring into the sliding sleeve ‘and measuring gap ,a” in three places (A, B and ©) using a feeler gauge. ‘Add the measured values and divide by 3. The result must not be less than 0.5 mm. A = Spiral pin 6. Pull off bearing inner race and synchronizer ease hub with thrust piece 9596 and two-way puller. Heat synchronizer hub to approx. 100°C and press in to stop, observing correct position, Installation position: The protruding front area (atrow 1) points towards the ‘gearwheel for Sth gear and the oll groove (arrow 3) must line up with the oil bore (arrow 2) Note ‘The 6th gear fixed gearwheel can only be replaced ifthe end shield has been removed (refer to page 34 - 21) 94-14 Removing and installing Sth and 6th gear Printed in Germany ~ V, 1992968 Manual Transmission, Operation, Housing 34 3, Install sliding sleeve for Sth and 6th gear 6. Install oll catcher in correct position. complete with shift fork and driver, observ- Installation position: Large oil bore must Ing correct position. Installation position: line up with the groove in the cover. Marks on synchromesh hub and sliding sleeve must line up. GALS Ns ( 9 — A = Large oll bore B = Groove in cover ‘A= Roll pin Removing and installing Sth and 6th gear 34-15 Printed in Germany - V, 1992968 Manual Transmis 34 n, Operation, Housing Determining snap rings for tapered roller bearing and 6th gear gearwheel ‘Tapered roller bearing Press on tapered roller bearing unti itis ‘seated against the stop. Determine dimension between tapered roller bearing inner race and installed snap ring (push up), using a depth gauge, and deter- mine ring thickness according to table. Measuring range (mm) Snap ring Thickness (mm) cena Ho 6th gear gearwheel Press on 6th gear gearwheel until against the stop. seated Determine the thickest snap ring that can bare- ly be inserted and install snap ring. End play must not be more than 0.05 mm. ‘The following snap rings are available as spare parts: Thickness in mm 211-214 - 2.17 - 2.20 - 2.23 - 2.26 - 2.29 Determining snap rings for tapered roller bearing and 6th gear gearwheel Printed in Germany - V, 1992 34-17968 Manual Transmission, Operation, Housing Removing and installing drive pinion and drive shaft 34 Removing and installing Printed In Germany ~ V, 1992 pinion and drive shaft34 Manual Transmission, Operation, Housing 968 Removing and installing drive pinion and drive shaft 34-20 Removing and installing drive pinion and drive shaft Printed in Germany -V, 199234 968 Manual Transmission, Operation, Housing Note: No. | Designation Removal | Installation 1. | Shift catch (ight) Do not confuse with catch No. 1 on page 34 - Tighten to | 70 Nm (62 fb) 2 | Snap ring | 3. | Driver (1st and 2nd gear) | 4 | Shift rod (6th and 6th gear) Replace only as a unit with driver for Sth and th gears (also refer to page 34 - 12) 5 | Reverse driver Cutout must engage into reverse gear return lever Snap ring Cylinder roller bearing Pull off manually inner-race 8 | Drive shaft Take out along with shitt rod (No. 9) 9. | Shift rod (ard and ath Replace only as a unit gear) with shift lever with driver for 3rd and 4th gear 10. | Snap ring Note thickness for IF required, redetermine reinstallation thickness (refer to page 34-17) 11 | @th gear fixed gearwhee! Replacement is only Heat to approx. 120°C possible if end shield and press on to stop has been removed. using a shop press Press off using a suitable | Installation postion: shop press Flange must face tapered roller bearing 12. | Drive pinion 13. | Shift rod (1st and 2nd Replace only complete gear) with pin-locked shift fork 14 | End shiela Removing and installing drive pinion and drive shaft Printed in Germany ~ V, 199234 Manual Transmission, Operation, Housing Removal and installation notes Removal Note If repairs are limited to the drive pinion and drive shatt, it is not required to remove reverse gear. Installation 1. Determine snap rings for tapered roller bearings and 6th gear gearwheel (refer to page 34 - 17). 2. Install drive pinion with shift fork and shift rod for 1st/3nd gear without driver into end shield. 3, Heat 6th gear gearwheel to approx. 120°C and press on. Installation position: Flange must face tapered roller bearing 4. Fit snap ring, 5. Insert dive shaft complete with shit fork and 3rd/ath gear shift rod obliquely into the end shield. Observe correct installation Position of shift fork 6. Install inner race of cylinder roller bearing and fit snap ring. 7. Install driver for reverse, allowing the cutout to engage into the return lever, and slide Sthyeth gear shift rod across the driver. 8, Push t1st/2nd gear driver onto the shift rod and fit snap ring. 34-22 Removing and installing drive pinion and drive shaft Printed in Germany - V, 1992968 ‘Manual Transmission, Operation, Housing 34 Dismantling and assembling end cover Tools LI Co) No. | Designation Special tool [Order number | ‘Explanation 1] Thrust piece vw 432 - WW Special Too! 2] Drift P2375 000.721.975.00 3] Thrust piece 9535 000.721.953.50 4 Thrust piece WW 295 A - ‘WW Special Too! 5| Thrust piece 30-205 - ‘WW Special Too! Dismantling and assembling end cover 34-23 Printed in Germany ~ Vi, 1998Manual Transmission, Operation, Housing 34 Dismantling and assembling end cover Dismantling and assembling end cover 34-24 Printed in Germany ~ V, 1992968 Manual Transmission, Operation, Housing 34 Note: No. | Designation Qty. | Removal Installation 1. | Battle plate 1 | Lever out (e.g. using arm | Replace, lock in three of puller 9884) places 2 | Snap ring 1. | Note thickness for reinstal-| When replacing bearing lation and end cover, recalcu- late thickness. Make sure itis seated cor- rectly in the correct posi tion. 3. | Four-point bearing outer 1 | Take out, remove upset- race ting marks if required 4 | Cylindrical roler bearing 1 | Press out (e.g. with Using Tool 30-205, outer race ww 432) press in to stop, insert- ing Special Tool 9535 at collar/stop to support cylindrical roller bearing, 5 | Snap ring 1 Check for correct seat- ing 6 | Cylindrical roller bearing 1 | Pull out using intemal pul- | Removal damages the outer race ler 23.5...30 mm bearing, i.e. the bearing (e.g. Kukko 21/4) must always be re- placed. Use VW 295A to drive in to correct po- sition (a = 98.6 mm) 7 | Magnet with bushing 1 | Remains in end cover Drive in (e.g. using P 375) 8 | End cover 1 Dismantling and assembling end cover Printed in Germany - 1, 196434 Manual Transmission, Operation, Housing 968 Assembly notes 1. Using Too! 30-205, drive in cylindrical roller bearing outer race for drive pinion unti itis seated against the stop. Be sure to use Special Tool 9535 as a sup- port for the collaristop of the cylindrical rol- ler bearing. 2. Determining snap ring for four-point bearing: - Press in outer race of four-point bearing Until itis seated against the stop. + Determine the thickest snap ring that can just about be inserted. + End play must not be more than 0.08 mm. ‘3. When replacing the bearing races, upset the edge of the baffle plate. Insert baffle plate and use a drift (ball dia. = 5 mm) to apply new upsetting marks {arrow 2) at a distance of "a" = 5 mm to the initial upsetting marks (arrow 1). “bY = 2mm. “ch= 3mm 4. Upset baffle plate when replacing the end cover. = Reinstall baffle plate. ~ First upsetting mark (large arrow) must be at a distance of "d= 10 mm to the connecting line of the shaft center. Dismantling and assembling end cover Printed In Germany - XU, 1994968 Manual Transmission, Operation, Housing 34 = Also apply second and third upsetting marks at a distance of "a = 70 mm mm). Dismantling and assembling end cover 34-27 Printed in Germany - V, 1982968 Manual Trans! Recalculating adjusting shim ,S4" n, Operation, Housing 34 This adjustment is required if end shield, needle-roller bearing inner race for 1st gear loose gear- ‘wheel, synchronizer hub for 1st and 2nd gear, needle-roller bearing inner race for 2nd gear loose gearwheel, gearwheel for 3rd gear, spacer sleeve and gearwheel for 4th gear have been replaced. This adjustment allows the preload of the tapered roller bearings for the drive pinion to be reset. 1- End shield 2- Shim ,S4" 3 - Needle roller bearing inner race for gearwheel of 1st gear 4 Synchronizer hub for tst and 2nd gear 5 - Needle roller bearing inner race for gearwheel of 2nd gear 6 - Gearwheel for 3rd gear 7 - Spacer sleeve 8 - Gearwheel for 4th gear 9 Drive pinion Dim. Dim. Dim. Dim. Dim, Dim. Dim, Dim, Housing depth of the end shield »b" = Length of inner race/needle roller bearing for 1st gear loose gearwheel Length of hub of synchronizer hub for 1st and 2nd gear »d* =Length of inner race/needie roller bearing for 2nd gear loose gearwheel Length of 3rd gear gearwhee! af = Length of spacer sleeve Length of 4th gear gearwhee! »84" =Thickness of adjusting shim $4 Recalculating adjusting shim ,S4" Printed in Germany -V, 1992 34-2934 Manual Transmission, Operation, Housing 968 A- Replacing the end shield = Measure housing depth “a” of old and new ‘end shield and determine difference Example: Old end shield Housing depth 118.40 mm New end shield Housing depth “a 118.65 mm. Difference = 0.25 mm If the new end shield is deeper - fit thicker St If the old end shield is deeper - fit thinner Example: Old shim 0.95 mm Difference + 0.25 mm New adjusting shim "S4* 1.20 mm ‘The following shims are available as spare parts: Thickness in mm. 0.45 - 0.50 - 0.55 - 0.60 - 0.65 - 0.70 - 0.75 - 0.80 - 0.85 - 1.25 B - Replacing needle roller bearing for ‘ist gear Calculate length "b* of the inner race of the old and new needle roller bearings and deter- mine thickness Example: Old inner race: New inner race’ * = 33.40 mm Difference = 0.05 mm If the new inner race is longer - fit correspond- ingly thinner shim ,S4~ Ifthe old inner race is longer - ft correspond- Ingly thicker shim ,S4" C - Replacement of parts 4 to 8 - pages 34-29 Determine difference of dimensions between old and new parts in the same manner for dimensions "c" to “g” - pages 34 - 29 and determine required adjusting shim "S4’. D - Replacing only drive set refer to page 39 - 17. 34-30 Recalculating adjusting shim ,S4" Printed in Germany - V, 1992968 Manual Transmission, Operation, Housing Dismantling and assembling end shield 34 Tools No. | Designation Special tool [Order number | Explanation 1) Drift 9223 000.721.922.30 2| Thrust piece 9533 000.721.953.30 3| Thrust piece P 254b 000.721.254.20, 4| Thrust piece P254a 000.721.254.10 5| Threaded stud P 254 000.721.254.00 Dismantling and assembling end shield Printed in Germany - V, 1992 34-3134 Manual Transmission, Operation, Housing 968 Dismantling and assembling end shield 34-32 Dismantling and assembling end shield Printed In Germany - V, 1992968 Manual Transmission, Operation, Housing 34 Note: ~ No. | Designation Qty. | Removal Installation 1. | Shit rod (6th and 6th gear) | 1. | Refer to page 34 - 22 2 | Driver for reverse 1 | Refer to page 34 - 22 3 | Ball sloeve 1. | Pull out using internal Replace, drive in flush puller 145.185 (e.g using Special Tool 9223 Kukko 21/2) and counter- support 4 | Spring clamp 1 5 | Bolt with collar 1 Always replace with new (micro-sealed) bolt, tighten to 25 Nm (18 fb) 6 | Retainer plate 1 Observe installation pos. 7 | Axle 1 | Pull out 8 | Thrust spring 1 Observe installation pos. 9 | Synchronizing ring 1 Check for wear. Ob- serve installation pos. 10. | Return gear 1 11. | Deflection lever 1 12_| Tapered roller bearing 1. | Press out with Spectal Press in with P 254A outer race Tool 9533 and P 254. Place with larger diameter onto the outer race 13 X | Note thickness for reinstal-| If required, determine lation new thickness (refer to page 34 - 29) 14 | Cylindrical roller bearing 1 | Press out with P 254 B Press in with P 254 B outer race and P 254. Place with and P 254, observing larger diameter onto the | correct position. Installa- outer race tion pos.: a” = 9mm 15 | Needle sleeve 3. | Drive out (eg. using 9223) | Replace, press in with Special Too! 9228. In- | stall. pos.: ,a" = 2.5 mm. | 16 | Bolt for deftection lever 1 Tighten to 35 Nm (26 fb) | [47 | Cylindrical pin 1 18 | End shield 1 Replacement note: Redetermine thickness of shim $4" (refer to page 94 - 29) Dismantling and assembling end shield 34-33 Printed in Germany ~V, 199234 Manual Transmission, Operation, Housing 968 Assembly notes 1. Check synchronizing ring, pressing the ring ‘onto the taper of the gearwheel and measur- ing gap .a" using a feeler gauge. Gap “a* Installation dimension (new) Wear limit = 0.2 mm 0.75.23 mm Fit return gear with synchronizing ring, Fit return lever A and return gear “B", making sure the deflection lever engages into the driver of the return gear. = Install synchronizing ring, observing correct position. Installation position: Chamfer (arrow 1) faces drive shaft. = _ Install thrust spring into correct position. Installation position: Hook single-hook end into cutout in the synchronizing ring (arrow 2) and double-hook end into aper- ture at end shield (arrow 3). Push in axle correct position. ensuring itis seated in Place retainer plate .A” into position, Installation position: The radii of the bores for the lock pins of the synchronizing ring face the end shield Place spring clamp ,B" into position. Always replace screw ,D" (micro-sealed screw) and tighten to 25 Nm (18 ftlb). 34-34 Dismantling and assembling end shield Printed in Germany ~ V, 1992968 Manual Transmission, Operation, Housing 34 Dismantling and assembling end shield Printed in Germany - V, 199262 Manual Transmission, Operation, Housing 34 Dismantling and assembling transmission housing Tools No. | Designation —~—~*|-Specialtool_ | Order number | Expanation 1) Punch 7 wri 7 WW Special Tool 2| Threaded sleeve w77ins = WW Special Too! 3| Thrust piece 9247/4 | 000.721.924.70 4| Thrust piece 9247/83 000.721.924.70 5| Thrust piece 9534 000.721.953.40 6| Orit P set 00.721.981.00 | 7 | Thrust piece vw asa = WW Special Toot 8| Thrust piece 2050 = | VW Special Too! 9| Threaded stud P 254 000.721.254.00 | 10] Pushout lever west 7 W Special Toot 11] Dri 9223 000.721.922.30 Dismantling and assembling transmission housing Printed in Germany -V, 199234 Manual Transmission, Operation, Housing 968 Dismantling and assembling transmission housing 34-38 Dismantling and assembling transmission housing Printed in Germany ~ V, 198234 968 Manual Transmission, Operation, Housing ] Note: No. | Designation Qty. | Removal | Installation 1 | Plug 2 Tighten to 35 Nm (26 fib) 2 | Reverse light switch 1 Tighten to 20 Nm (15 ftib) 3 | Pan head screw 3 Tighten to 25 Nm (18 fb) 4 | Cover 1 Sealing ring jo. Replace 6 | Pan head screw 10 Tighten to 25 Nm | (18 fi) 7 | Transmission side cover 1 ‘When replacing cover, adjust ring gear 8 | Sealing ring 1 Replace 9 | Shaft seal 2 Pack space between } sealing lip and dust lip with multi-purpose grease. Use Special Tool 9534 to drive in to stop 10 | Snap ring 1 11 | Shroud 1 | 12 | Snap ring 1 13 | Form magneto 1 | 14 | Threaded flange 1 | Before screwing in, | coat with Loctite 271. Tightening torque 10 Nm (7 ftib) 15 | Shatt seal 1 | May also be replaced if | Do not ft until gear set | transmission has not been | has been installed (refer | dismantled to page 34 - 7). Pack | space between dust lip | and sealing lip with multipurpose grease 16 | Needle roller bearing 1. | Pull out with internal puller | Press in to stop (e.g. | 30-37 mm (e.g. Kukko | with P 381). The letter- | 21/8), VW 771/15 and WW | _ ing on the bearing must mA face the thrust piece Dismantling and assembling transmission housing Printed in Germany ~ V, 1992 34-3934 Manual Transmission, Operation, Housing Note: No. | Designation Qty. | Removal Installation 17 | Snap ring 1 18 | Ball sleeve 1 | Pull out with internal puller | Replace, use Special 14.20 mm (e.g. Kukko Tool 9223 to drive in to 21/2), WW 771/18 and stop mm | Shaft seal 1. | Pull out with VW 681. Pack space between May also be replaced if | dust lip and sealing | transmission has not lip with multipurpose | been dismantled (grease. Drive in to stop | | using Special Tool 9223 20 | Cover plate 1. | Press retaining lug down, | Engage retaining lug | inserting a small into breather tube screwdriver through the breather tube, and pull out | 21 | Ball sleeve 2 | Pull out with internal puller | Replace, drive in with | | 14.20 mm (e.g. Kukko. Special Tool 9223 | | 21/2), vw 71/1 and | wis 22 | Snap ring 1 | Lever out with two Check for correct screwdrivers seating | 23 | Needle roller bearing 1 | Pull out with internal puller | Press into correct pos. | 30..97 mm (@.g. Kukko (e.g. with VW 454). || 21/8), Ww771/1 and | Make sure the lettering vw 77115 on the bearing faces the thrust piece a" = 105 mm 24 | Tapered roller bearing 1. | Pull out with internal puller | Press in to stop outer race 71.100 mm (e.g. Kukko | (e.g. with Special Too! | 21/9) and countersuppot | 9247/4), supporting | cover at the aperture | | for the joint flange. When replacing, read- | Just ring gear. 25 | Tapered roller bearing 1 | Pull out with internal puller | Press in to stop (e.g outer race 50...70 mm (e.g. Kukko 21/8) and countersupport with Special Too! 2050) ‘The large diameter must face the outer race. When replacing, read- Just ring gear. Dismantling and assembling transmission housing Printed in Germany ~ V, 1992