| 42 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
9 4 4 |
| 3. |
The axial play of rear axle bearings can be adjusted to 0 ... 0.05 mm by thickness of circlip. The following circlips are available.
2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
|
| 4. |
Install thinnest circlip (2.00 mm) and drive against bearing outer race with Special Tool VW 415 a.
Measure gap between circlip and groove upper edge at several points.
|
| 5. |
Install circlip with correct thickness and make sure it fits correctly.
Example:
| Initially installed circlip |
2.00 mm |
| 0.10 mm |
feeler gauge blade fits
in gap |
| 0.15 mm |
feeler gauge blade does
not fit |
|
+ 0.10mm |
| Required circlip thickness |
2.10 mm
======= |
|
|
 |
| 6. |
Lubricate ball bearing with multipurpose grease.
Drive in seal with Special Tool VW 433 (with trailing arm on wood support) or with VW 415 a, 402, 412 and 441 until against stop.
Pack space between sealing lips with a multipurpose grease.
|
N o t e
Approx. 80 grams of grease in wheel bearing housing and in wheel bearings.
7. Press in rear wheel shaft (do not forget spacer).
|
| 42 - 6 |
Disassembling and Assembling Trailing Arm |
Printed in Germany |
| 9 4 4 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
42 |
| 8. |
Install spacer tube. Drive in roller bearing with a
suitable piece of pipe. If bearing has edging on only
one side of cage, this side has to face out.
|
| 9. |
Pull in roller bearing inner race with Special Tool
VW 454, outer spacer and castle nut.
|
| Printed in Germany |
| Disassembling and Assembling Trailing Arm |
|
42 - 7 |
|
| 42 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
9 4 4 |
|
| 9 4 4 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
42 |
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2
3
4
5
6
7 |
Pressing out mandrel
Circlip pliers
Pressing tool
Pipe
Extractor
Pressing out/in tool
Pressing tool
|
P 297 a
VW 432
VW 415 a
VW 459/1
VW 459/2
VW 412
|
Standard tool
e.g. Kukko 15-17 Gr. 2
|
| Printed in Germany - V, 1985 |
Disassembling and Assembling
Aluminum Trailing Arm |
|
42 - 9 |
|
| 42 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
9 4 4 |
| 42-10 |
Disassembling and Assembling Aluminum Trailing Arm |
Printed in Germany |
|
| 9 4 4 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
42 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10 |
Self-locking
nut
Washer
Socket-head
bolt
Backer
Drive shaft
(axle shaft
with rear-wheel
shaft)
Wheel hub
Trailing arm
Circlip
Inclined
ballbearing
Silentbloc
rubber mount
|
1
1
6
3
1
1
1
8
1
2 |
Because of
lack of space
(exhaust
assembly).
begin by dis-
connecting
shock absorber
from trailing
arm on left-
hand side
Drive out
with P297a
Heat trailing
arm to 120° -
150°C. press
out with
pressure
piece VW 432
First pry out
inner rubber
mount
|
Replace.
tightening
torque: 500 Nm
(368 ftlb)
Tightening
torque: 42 Nm
(31 ftlb)
Check for
damage, apply
a thin coat of
Optimoly HT to
splines
Press in wheel
hub by placing
wheel hub on a
suitable support
and applying
pressure to
inner race of
inclined ball-
bearing with
drift VW 415 a
Replace if
damage is
suspected
Replace if
necessary
Heat trailing
arm to 120° -
150°C, insert
new bearing and
press home with
VW 432.
Replace, press
in
|
Page 42 - 12
Reworking is
impermissible
Page 42 - 14
|
| Printed in Germany - XIII, 1987 |
Disassembling and Assembling
Aluminum Trailing Arm |
|
42-11 |
|
| 42 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
9 4 4 |
DISASSEMBLING AND ASSEMBLING ALUMINUM TRAILING ARM
R e m o v i n g / D i s a s s e m b l i n g
| 1. |
Take off rear wheel. Unscrew self-locking nut on drive shaft. |
| 2. |
Disconnect parking brake cable on parking brake lever.
|
| 3. |
Unscrew vibration damper on trailing arm. Lift trailing arm slightly with a suitable jack to avoid tension on the mounting bolt.
|
| 4. |
Unscrew axle shaft bolts on transmission and move out the complete drive shaft (axle shaft + wheel shaft). |
|
|
N o t e
Push up the transmission end of the shaft in direction of the intermediate shift lever on the transmission when moving out the left drive shaft, due to the lack of space (exhaust assembly).
| 5. |
Remove brake hose on trailing arm, by removing the spring lock and unscrewing the brake pipe.
Plug brake hose or hold down brake pedal slightly with a pedal prop.
Take wires for brake pad wear indicator out of holder. |
|
| 42 - 12 |
Disassembling and Assembling Aluminum Trailing Arm |
Printed in Germany |
|
| 9 4 4 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
42 |
| 6. |
Take plug for brake pad wear indicator
out of holder and disconnect. |
| 7. |
Unscrew brake caliper and remove brake
disc.
|
| 8. |
Drive out rear wheel hub with Special
Tool P 297 a. |
|
|
| 9. |
Remove parking brake shoes and spreader arm. Pull parking brake cable out of trailing arm.
|
| 10. |
Remove trailing arm after unscrewing on spring strut and rear axle cross tube. |
N o t e
Mark position of trailing arm to spring strut for installation later (toe, camber).
| 11. |
Take off brake guard and remove circlip for angular ball bearing. |
|
| Printed in Germany - V, 1985 |
Disassembling and Assembling
Aluminum Trailing Arm |
|
42-13 |
|
| 42 |
Rear Wheel Suspension, Axle Shaft |
9 4 4 |
| 12. |
Heat trailing arm to 120 ... 150° C. Press
out angular ball bearing with Special Tool
VW 432 and a suitable base. |
| 13. |
If applicable, remove rubber mounts.
Drive out inside rubber mount slightly
with a flat chisel applied alternately
and finally pry out with two tire irons.
Drive out inside rubber mount with a
suitable pressure piece. |
|
|
| 14. |
If applicable, press bearing inner race off
of wheel hub with an extractor and
Special Tool P 297 a. |
A s s e m b l i n g / I n s t a l l i n g
| 1. |
Set up and align trailing arm under a
press on VW 459 and suitable bases for
installation of the wheel bearing.
Remove trailing arm again and heat to
120 ... 150° C. Insert angular ball bear-
ing and press in slightly on the aligned
bases. |
|
| 42-14 |
Disassembling and Assembling Aluminum Trailing Arm |
Printed in Germany |
|
| 9 4 4 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
42 |
| 2. |
If applicable, press in new inside and
outside rubber mounts against stop. |
|
|
| 3. |
Press in wheel hub after installation of
the circlip. |
| 4. |
Install trailing arm. Tighten bolts and
nuts to correct tightening torque (see
page 42 - 02/03). Mount spreader arm
and parking brake shoes (see pages
46 - 11 to 46 - 15). |
N o t e
Insert drive shaft before mounting the
vibration damper on the trailing arm on
the left side.
| 5. |
Adjust parking brake. Bleed brakes.
Check wheel alignment. |
|
| Printed in Germany - V, 1985 |
Disassembling and Assembling
Aluminum Trailing Arm |
|
42-15 |
|
| 42 |
R e a r W h e e l S u s p e n s i o n , A x l e S h a f t |
9 4 4 |
|
| 944 |
Rear Wheel Suspension, Axle shaft |
42 |
Koni - Shock absorbers - References for 944 / 924 S
The contraction stage of Koni shock absorbers may be adjusted. Spare shock absorbers are pread-
justed.
Notes for 944 models fitted with steel trailing arms
In the course of Model Year 1982, the adjusting values of the shock absorbers (pressure and contrac-
tion stage) were modified.
Adapting the original version to the modified setting by adjusting the shocks is not possible. The
original version of the shock absorbers is no longer available. In case of repairs, vehicles fitted with
the original absorber type should be fitted with the modified shock absorbers. Combining original
and modified versions is only permissible if identical shock absorber pairs are used on each axle.
Part no. /
Identification |
Adjusting values* |
Application/ Installation |
477 513 031 J**
painted yellow
Mounting boss
dia. 12 mm |
adjusted approx. 1 turn,
starting from basic setting |
944 with optional shock absorbers
(M 474) and steel arms.
Orig. version (no longer available /
note above instructions) |
944 333 031 00**
painted yellow, with
blue adhesive tape
Mounting boss
dia. 12 mm |
basic setting adjusted
by approx. 1/2 turn |
944 with optional shock absorbers
(M 474) and steel arms.
Modified version.
Introduced during Model Year
1982 |
951 333 032 01 **
painted yellow
Mounting boss
dia. 14 mm |
basic setting adjusted
by up to approx. 1/2 turn
in some cases, adjusted by
1 turn (red dot) |
944 / 924 S with optional
shock absorbers (M 474) and
aluminum arm |
944 333 032 01 ***
painted yellow
with green tape
Mounting boss
dia. 14 mm |
adjusted approx. 1 turn
from basic setting |
924 S with sport running gear
M 030 (aluminum arms) |
951 333 032 04**
painted yellow,
Mounting boss
dia. 14 mm |
adjusted approx. 1 1/4 turn
from basic setting |
944 with sport running gear M 030
and aluminum arms |
| * |
The adjusting values are approximative. Precision adjustment is carried out in the factory
using shock absorber test equipment. |
| ** |
Part no. engraved near mounting boss of shock absorber |
| *** |
Identical to 951 333 032 01, but with modified setting. |
Koni - Shock absorbers - References for 944 / 924 S
Printed in Germany - XXIV, 1991
|
42 - 17 |
|
| 42 |
Rear Wheel Suspension, Axle shaft |
944 |
Koni - Shock absorbers - References for 944 S / 944 S2
The contraction stage of Koni shock absorbers may be adjusted. Spare shock absorbers are pread-
justed.
Part no. /
Identification |
Adjusting values* |
Application/ Installation |
951 333 032 01 **
painted yellow,
Mounting boss
dia. 14 mm |
basic setting adjusted by
up to 1/2 turn
in some cases adjusted by
1 turn (red dot) |
944 S with optional shock absorbers (M 474) |
951 333 032 08**
painted yellow, with 2 blue
color dots offset by
180 deg.
Mounting boss
dia. 14 mm |
basic setting |
944 S2 MY '89 with optional
shock absorbers (M 474) |
951 333 032 04** painted
yellow, with 2 white
dots offset by 180 deg.
Mounting boss
dia. 14 mm |
adjusted by approx. 1 1/4
turn from basic setting |
944 S / 944 S2 with
sport running gear M 030 |
To adjust the contraction stage, refer to page 42 - 19
| * |
The adjusting values are approximative. Precision adjustment is carried out in the factory using
shock absorber test equipment.
|
| ** |
Part no. engraved near the mounting boss of the shock absorber. |
| 42 - 18 |
Koni - Shock absorbers - References for 944 S / 944 S2
Printed in Germany - XXIV, 1991 |
|
| 944 |
Rear Wheel Suspension, Axle shaft |
42 |
Adjusting the Koni shock absorbers
Operations for adjusting the contraction
stage
| 1. |
For shock absorbers on cars fitted with
aluminum rear-axle trailing arms, remove the
rubber auxiliary spring (bump stop) from the
protective tube before adjusting the shock
absorber. Bores are provided for this effect
below the mounting boss of the shock ab-
sorber. Engage a length of wire into the
bores and push the auxiliary rubber spring
down and out of the protective tube and
take it off the shock absorber. |
Caution:
Take care not to damage the piston rod.
| 2. |
Push protective tube and piston rod assemb-
ly all the way down. Rotate protective tube
(but do not apply a force) until the adjust-
ment device engages. Mark engagement
position on the protective and shock tube
using a piece of chalk. |
|
|
3. Rotate the protective tube/piston rod:
To the left B
(counterclockwise) |
Protective tube/piston
rod points
up (installation
position)
|
softer contraction stage
|
To the right A
(clockwise) |
Protective tube/piston
rod points up
(installation position)
|
| softer contraction stage |
|
|
Adjusting the Koni shock absorbers
Printed in Germany - XXIV, 1991
|
42 - 19 |
|
| 42 |
Rear Wheel Suspension, Axle shaft |
944 |
| 4. |
After adjusting the shock absorber, pull
protective tube/piston rod up again to
disengage the adjustment device.
If required, (on cars fitted with aluminum
rear-axle trailing arms) refit the auxiliary
rubber spring. |
| 42 - 20 |
Adjusting the Koni shock absorbers
Printed in Germany - XXIV, 1991 |
|
| 944 |
Wheels, Tires, Alignment |
44 |
Wheels and tires
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 affects 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 sidewall
(cord breakage)!
Tire pressure of cold tires (summer and winter tires)
up to end of MY '89
| |
924 S / 944 |
944 S* / 944 S2 |
front
rear |
2.0 bar excess pressure
2.5 bar excess pressure |
2.5 bar excess pressure
2.5 bar excess pressure |
as of MY '90
| |
944 S2 MY '90 |
944 S2 as of MY '91 |
front
rear |
2.5 bar excess pressure
2.5 bar excess pressure
(optional:
3.0 bar excess pressure) |
2.5 bar excess pressure
2.5 bar excess pressure |
Collapsible spare tire
| front and rear |
2.5 bar excess pressure
2.2 bar excess pressure |
for 8 PR 89 P tires
for 4 PR 83 P tires |
| * |
Due to changes in standards and legislation, "V" and "ZR" tires for the 944 S require tire pressure
that deviate from the values indicated in the Owner's Manual.
Always use the new tire pressures indicated above. Relevant adhesive labels are available from all
official Porsche dealers. |
Wheels and tires
Printed in Germany - XXIV, 1991
|
44 - 01 |
|
| 44 |
Wheels, Tires, Alignment |
944 |
Tire and wheel survey / tire specification character
For a tire and wheel survey for summer and winter tires, refer to the relevant Technical Information
(TI), Group 4.
When replacing summer tires, check for the correct tire specification character. The specifica-
tion character N 1 or N 0, respectively, helps to distinguish summer tires approved by Porsche from
other versions of identical tire type and the same tire size. The tires approved by Porsche are also
identified in the corresponding TI.
Important Notes
From My '87 (with the exception of the 924 S model), the rim offset of the wheels has been
modified. Wheels designated for cars as of MY '87 must not be mounted on older vehicles.
In the same manner, wheels for cars made before MY '87 must not be fitted to vehicles produced
from MY '87.
On vehicles equipped with brake pad wear indicators, counterweights to a max. weight of 40 g may
be fitted on the inside of 15-inch light-alloy disc wheels (due to space limitations at the front axle).
If required, use 2 weights.
| 44 - 02 |
Wheels and tires
Printed in Germany - XXIV, 1991 |
|
| 944 |
Wheels, Tires, Alignment |
44 |
Sample measuring chart up to end of MY '89
Sample measuring chart up to end of MY '89
Printed in Germany - XXIV, 1991
|
44 - 03 |
|
| 424 |
W h e e l s , T i r e s , A l i g n m e n t |
9 4 4 |
|
| 944 |
Wheels, Tires, Alignment |
44 |
Sample test card 1990 models onward
Sample test card 1990 models onward
Printed in Germany - XXI, 1989
|
44 - 1 |
|
| 44 |
Wheels, Tires, Alignment |
944 |
Wheel Alignment Values - 924 S / 944 / 944 S / 944 S 2
The following values apply at curb weight according to DIN 70020 (car with full fuel tank, spare wheel
and tools).
Values for USA and Canada are given in brackets.
Wheel Alignment Values
|
Specified Value and Tolerance |
Max. Difference
Left to Right |
| Until end of '89 Mod. |
Since '90 Mod. * |
Front Axle
Toe - unpressed
Toe difference angle
at 20° lock
Camber
Caster
|
+ 10' ± 5'
- 40' to
- 1° 50'
- 20' ± 15'
2°30' + 30'
- 15'
|
+ 10' ± 5'
- 40' to
- 1° 50'
0° ± 10'
2°30' + 30'
- 15'
|
Can only be affected
by replacing steering
arms
10' until end of '89
models
20' since '90 models
30'
|
Rear Axle
Toe per wheel
Camber |
0° ± 5'
- 25' ± 30'
(- 1° ± 20')
|
+ 10' ± 10'
- 45' ± 20'
(- 1° ± 20')
|
10'
30'
30'
|
| * |
The changed wheel alignment values also apply to the 944 Turbo. Please note in the 944 Turbo
manual. They will be corrected in the next supplement. |
| 44 - 2 |
Wheel Alignment Values - 924 S / 944 / 944 S / 944 S 2
Printed in Germany - XXI, 1989 |
|
| 944 |
Wheels, Tires, Alignment |
44 |
Ride Level Height and Spring Strut Values
Front Axle
944 / 944 S M 030 / M 637
(spring struts adjustable in height)
944 S 2 M 030
(spring struts adjustable in height) |
Ride level height*
bolt lower edge
of rear arm mount
below wheel center
146 ± 10 mm
130 ± 10 mm |
Rear Axle
924 S / 944 / 944 S
until end of 1988 models
Standard (steel + alu. arms)
Torsion bar dia. 23.5 mm
M 030 / M 637 until end of
1986 models
Torsion bar dia. 24.5 mm
M 030 / M 637 87/88 models
Torsion bar dia. 25.5 mm
|
Spring strut adjustment
(angle of spring strut)**
23°
(24°30' USA. Canada)
20°
18°
|
Ride level height*
strut mt. center (torsion bar
center) below who ctr. (value)
- 3.5 ± 10 mm
- 18.5 ± 10 mm
- 18.5 ± 10 mm
|
Since 1989 models
944 standard with
torsion bar dia. 23.5 mm
944 S 2 standard with
torsion bar dia. 24 mm
944 / 944 S 2 M 030 / M 031
torsion bar dia. 25.5 mm
|
23°
(24°30' USA. Canada)
Conv.23°
Coupe 22°
18°
|
- 3.5 ± 10 mm
- 10.5 ± 10 mm
- 18.5 ± 10 mm
|
| * |
Max. left to right difference in ride level height: 10 mm.
Height of bumper is decisive for USNCanada cars. Distance from measuring surface (road/level
floor) to upper edge of bumper must be 522 ± 20 mm on the rear axle. On the front axle this dis-
tance must be 526 ± 20 mm or 533 ± 20 mm for the 944 S2.
|
| ** |
Max. left to right difference: 0,5°. 1° changes in spring strut inclination changes the ride level
height by approx. 5 mm.
|
Wheel Alignment Values - 924 S / 944 / 944 S / 944 S 2
Printed in Germany - XXI, 1989
|
44 - 2a |
|
| 44 |
Wheels, Tires, Axle Alignment |
9 4 4 |
CHECKING WHEEL ALIGNMENT
Check wheel alignment with an optical or electronic tester. Testing
procedures are described in the instructions supplied with the pertinent
tester. The following requirements must be fulfilled before commencing with
the wheel alignment test.
| - |
Car at curbweight to DIN 70020, i.e. ready-to-drive car with full fuel
tank, spare wheel and tools.
|
| - |
Correct joint and wheel bearing play.
|
| - |
Specified tire inflation pressure and uniform tire treads. |
If both the front and rear wheel alignment of a car are concerned, first
check and correct the rear wheel alignment. Have steering wheel and steering
gear in middle position when adjusting toe-in.
FRONT AXLE
Adjusting Camber
Camber is adjusted by turning the
eccentric bolt (arrow).
|
|
Adjusting Caster
| Version I = |
Cars with steel
control arms
|
| Version II = |
Cars with aluminium
control arms
|
| Version I = |
(Steel Control Arms) |
Caster is adjusted by moving the
rear control arm mount laterally.
|
| 44 - 2b |
Checking Wheel Alignment |
Printed in Germany - XXI, 1989 |
|
| 944 |
Wheels, Tires, Alignment |
44 |
Version II (aluminum control arms)
Undo self-locking hexagon nut A on caster ex-
center B. Turn the caster excenter B to set the
specified value. Depending on the position of
the excenter, use a 19 mm open-end wrench
(range C) or a 32 mm wrench (range D).
(Hexagon nut tightening torque
A = 85 Nm (63 ftlb))
Adjusting the toe
Preliminary operations: Center steering box in
the center position using Special Tool 9116.
If the steering wheel is offset, try to achieve
an optimum value when relocating the wheel.
Remove Special Tool 9116 afterwards.
|
|
Block steering wheel in center position using
a steering wheel locking tool and adjust toe
at the tie rods.
Toe difference angle
The toe difference angle is not adjustable (and
may be modified only by exchanging the steer-
ing levers).
Rear axle
Height check/height adjustment *
Measuring points: Center of torsion bar and
wheel center, both measured from road con-
tact surface.
Adjusting value: refer to page 44 - 2a.
If required, correct rear vehicle height at the
two-part spring brace by loosening mounting
bolt A and adjusting with eccentric bolt B.
| * |
On vehicles with ride height adjustment
feature, also check and adjust the front
axle height. For adjusting values, refer
to page 44 - 2a.
|
|
Notes on vehicle measurement
Printed in Germany - XXIV, 1991
|
44 - 3 |
|
| 44 |
W h e e l s , T i r e s , A x l e A l i g n m e n t |
9 4 4 |
A d j u s t i n g C a m b e r
Loosen bolted connection between spring
strut and trailing arm. Also loosen stabilizer
suspension in cars with a stabilizer.
Adjust to specified value by turning the
camber eccentric.
Without Stabilizer
With Stabilizer
|
|
A d j u s t i n g T o e
Adjust toe by moving trailing arm in slots
of spring strut. Use Special Tool 9171 for
this step.
|
| 44-4 |
Checking Wheel Alignment |
Printed in Germany |
|
| 9 4 4 |
Wheels, Tires, Axle Alignment |
44 |
INSTALLING AND REMOVING ALUMINUM WHEELS ON VEHICLE
G e n e r a l I n f o r m a t i o n
Aluminum wheel nuts must be loosened and tightened only with special tool
P 300.
The aluminum wheel nuts can shear by reason of:
| - |
use of unsuitable tools (the wheel nuts are held only by about 2/3
of total depth) |
| - |
excessive tightening torque |
| - |
excessively jerky loosening (impact wrench) |
| - |
lack of or unsuitable lubricant |
If this were to happen, the calott would shear off of the wheel nut's
hexagon exactly at the point of transition, thus impairing removal of the
rim.
I n s t a l l i n g & R e m o v i n g
| 1. |
Always use a Special Tool P 300 in
perfect condition. Other socket
wrenches, wrench sockets, or wheel
bolt wrenches must not be used.
Impact tools must never be used,
regardless of circumstances. |
| 2. |
Lubricate threads and calott with
Optimoly TA.
|
| 3. |
Always tighten nuts to specified
torque of 130 Nm (96 ftlb) |
|
|
R e m o v a l w i t h
S h e a r e d - o f f
N u t (s)
The rim can be taken off
the wheel hub without da-
mage using the tools listed
below. However, damage to
the wheel bolt(s) cannot be
avoided.
| I. |
Compass saw, 17.5 mm
diameter. This tool can be
used after grinding dow
and smoothing inside diameter
(welding seam must be ground
down). |
| II. |
Shaft for mounting compass
saw. |
| III. |
Commercially-available
hand drill |
|
| Printed in Germany - VII, 1986 |
Installing and Removing Aluminum
Wheels on Vehicle |
|
44-5 |
|
| 44 |
W h e e l s , T i r e s , A x l e A l i g n m e n t |
9 4 4 |
D e l i v e r y a n d S u p p l y S o u r c e s
Sauer-Werkzeug GmbH & Co. KG
Humboldstr. 53
2000 Hamburg 76
Order No.
303 017 - Compass saw 17.5
303 161 - Adapter, size 1
or on commercial market
| Manufacturer: |
The Cooper Group
Deutschland GmbH
7122 Besigheim |
Order No.
261 110 00 - Compass saw 17.5 - H 111
264 020 00 - Adapter M 402 H
| 1. |
Grind off calotte with the mentioned tools.
Work with a speed of approx. 450 rpm to guaran-
tee good chip removal. Also bleed tool.
The calotte will jump off of the wheel bolt after
complete removal of threads from the sheared
off wheel nut. |
N o t e
The wheel rim might be ground slightly during this
step, but this is not important.
| 2. |
Replace pertinent wheel bolt(s) on removed wheel
hub.
Use a proper size drift for removal and installation.
Front wheel hub must be heated to 120 - 150° C
for this step. |
| 44-6 |
Removing and Installing Aluminum Wheels on Car |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
GENERAL
As of model year '87, the Porsche 944,944 S and 944 turbo are available
with an anti-lock braking system (ABS) as an optional extra (M593).
The anti-lock braking system represents an important contribution to the
enhancement of active safety in the car.
It prevents the wheels locking in an emergency stop until shortly before
the car comes to a halt, thus assuring full steerability and directional
stability. In addition, the system optimizes the braking distance
corresponding to the varing degree of grip between wheel and road surface.
Nevertheless, it is still up to the driver to adapt his style of driving to
road and weather conditions and to the changing traffic situation.
The decisive advantage of ABS is in the stability and manoeuvrability which
it affords to the car in moments of danger - when the brakes are fully
applied even when the car is cornering.
In design and method of operation, the ABS is basically identical with that
fitted to the 928 S.
The 944 ABS is described in the Customer Services Information Sheet, '87
Models WKD 493 210.
Note:
The ABS control unit is matched to the approved tire dimensions. The use of
unapproved tires can lead to different wheel speeds which the control unit
interprets as different road speeds at the car's axles.
If the difference in rolling radius exceeds a certain amount, the control
unit deactivates the ABS and the ABS pilot lamp lights up.
ABS hydraulic unit changed from model year 1988 (blocking diode, for ABS
pilot lamp shifted from the hydraulic unit into valve relay.
| Printed in Germany - XVI, 1987 |
|
45 - 01 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
ABS - DIAGRAMMATIC VIEW
The three-channel ABS manufactured by Bosch has a separate speed sensor for
each wheel. A front/rear braking circuit split is used (black/white split),
in other words, one braking circuit acts on the front axle (push-rod
circuit) with the second acting on the rear axle (floating circuit).
1 - Tandem brake master cylinder
2 - Hydraulic unit
3 - Speed sensor (cross-pole), front*
4 - ABS control unit
5 - ABS pilot lamp
6 - Stoplights
7 - Speed sensor (flat-pole), rear*
| * |
Each wheel-speed sensor is accompanied by an impulse ring with 45 teeth.
The front-axle impulse rings are pressed onto the front-wheel hubs, the
rear-axle units are milled onto the wheel shafts. |
| 45 - 02 |
ABS - Diagrammatic View |
Printed in Germany |
|
| 944 |
Anti-lock Braking System |
45 |
Positions of ABS components
The control unit is mounted on the wheel arch
in the passenger-side footwell. |
|
|
The ABS relay is on central electric board.
944 = relay G20
968 = relay G22
|
|
|
The hydraulic unit is installed beneath the
right-hand front fender.
|
|
|
The solenoid-valve and pump-motor relays
are mounted on the hydraulic unit.
1 - Solenoid-valve relay
2 - Pump-motor relay
3 - Braking-force regulator
|
|
|
Positions of ABS components
Printed in Germany - XXVI, 1993
|
45 - 03 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
A
B
C
0
E
F
G
H
I
MP VI |
- ABS Control unit
- Hydraulic control unit
- ABS relay (G 20 on CEB)
- Central Electric Board
- To starter terminal 30
- ABS plug connector (RHD only)
- ABS wiring harness
- Combination lead 4 x
- Four-pin plug (near CEB)
- Ground pin - control unit
- Ground lead - hydraulic unit
|
|
|
a
b
C1
C2
C3
d
e
g1
g2
g3
g4
h
k |
- Pump motor
- Pump relay
- Solenoid valve, front left
- Solenoid valve, front right
- Solenoid valve, rear
- Valve relay
- Diode
- Speed sensor, front left
- Speed sensor, front right
- Speed sensor, rear left
- Speed sensor, rear right
- Stop light
- ABS lamp in combination
instrument
|
|
| 45 - 04 |
Circuit Diagram, Electrics |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
IMPORTANT NOTES ON TROUBLESHOOTING AND ON THE ABS TEST PROGRAM
A test program with ABS tester must be carried out after certain repairs to
the ASS (see Function testing, page 45 - 06). ABS Test Plan, Sheet No.
WKD 493 710 is required for this test and for troubleshooting.
| Printed in Germany - XIII,1987 |
Important Notes on Trouble-
shooting and ABS Test Program |
|
45 - 05 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
IMPORTANT NOTES FOR WORKING ON CARS WITH ABS
Note the following when working on cars with ABS:
Welding
Disconnect the plug from the
electronic control unit before
using electric welding equipment.
Painting
The maximum short-term load which
can be placed on the control unit
during painting is 95°C; the
maximum long-term load (approx. 2
hours) is 85°C.
Charging battery
When using a fast charger,
disconnect the battery from the
electrical system.
Installing battery
When the battery is reinstalled
after removal, retighten both cable
clamps correctly.
Assisted starting
Do not use a fast charger to start
the engine.
|
|
Multi-pin plug of electronic
control unit
Never disconnect or reconnect the
multi-pin plug of the electronic
control unit while the ignition is
switched on.
Function testing
After any work on the braking
system which did not effect parts
directly involved in the ABS, a
simple function check is all that
is required. In other words, the
pilot lamp in the instrument
cluster must go out when the engine
is started, if the ABS is intact.
Work of this nature includes
replacing brake pads, brake hoses,
brake discs, brake unit, tandem
master cylinder, brake cables and
parts of the parking brake lines
not connected to the hydraulic
unit.
If work is carried out on the
hydraulic unit* (the electronic
control unit*) the wheel-speed
sensors or the lines or if units
are replaced, for example when
accident damage is repaired, a
function test must be carried out
with the ABS tester. |
| * |
- |
It is impermissible to repair or disassemble hydraulic unit or
electronic control unit.
|
| |
- |
The electronic control unit has a self-diagnosis testing facility. For
this reason, it is neither possible nor necessary to check the control
unit unless the check is carried out as part of a ABS test required
for other reasons and only when this test is carried out with the
Bosch K 7 - ETT 016.00/VAG 1516 testing equipment. |
| 45 - 06 |
Important Notes for Working on
Cars with ABS |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
REMOVING AND INSTALLING HYDRAULIC
UNIT
Removing
| 1. |
With ignition switched off,
disconnect ground lead from
battery.
|
| 2. |
Remove right-hand front wheel.
Mark respective positions of
wheel and wheel hub for
reassembly. Remove wheel-arch
inner panel.
|
| 3. |
Disconnect braking-force
regulator (installed in 944 S and
944 turbo only) and all brake
lines (Nos. 1 - 6) from hydraulic
unit. |
Note:
If necessary, unclip the brake
lines from the holders in the wheel
arch. Insert stoppers immediately
to plug brake lines and connections
(risk of dirt penetrating the
system). If no stoppers are
available for the brake lines,
drain the reservoir beforehand and
cover the lines.
|
|
| 1 - |
From brake master cylinder,
front-axle braking circuit
(code V in some cases) |
| 2 - |
From brake master cylinder,
rear-axle braking circuit
(code H in some cases) |
| 3 - |
Rear brake line (code h) |
| 4 - |
Braking-force regulator (only
944 S and 944 turbo) |
| 5 - |
Front left brake line (code 1) |
| 6 - |
Front right brake line (code r) |
|
| Printed in Germany - XIII, 1987 |
Removing and Installing
Hydraulic Unit |
|
45 - 1 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
| 4. |
Disconnect ground and remove
mounting bolts from
hydraulic-unit holder. |
5. Remove cover from hydraulic unit.
|
|
| 6. |
Move hydraulic unit and holder
out slightly to gain access to
strain relief for 12-pole plug
(No. 3). Disconnect strain relief
and remove plug. |
Note:
The two relays for pump motor No. 2
and for the solenoid valve No. 1
can be replaced (page 45 - 6/
45 - 7).
| 7. |
Unclip ABS wire harness from
hydraulic-unit holder and remove
hydraulic unit with holder. |
|
| 45 - 2 |
Removing and Installing Hydraulic Unit |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
Installing
Note
| 1. |
Installation is ther
the above sequence.
ABS hydraulic unit modified as
from Mod. 88. Blocking diode for
ABS pilot light from the relay
socket integrated into the valve
relay (arrow). |
Identifying feature: Recessed
cover with the marking ABS
|
|
| 1. |
Installation is the reverse of
the above sequence.
|
| 2. |
It is essential to bear the
following in mind:
| - |
connect brake lines to
correct hydraulic-unit ports
(see page 45 - 1)
|
| - |
check that brake lines are
correctly routed |
|
| 3. |
Bleed braking system and check
for leaks. Same procedure as
for cars without ABS.
|
| 4. |
Install wheel-arch inner
panel and front wheel.
Conduct function test with
ABS tester. |
|
| Printed in Germany - XVI, 1987 |
Removing and Installing
Hydraulic Unit |
|
45 - 3 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
REMOVING AND INSTALLING ELECTRONIC CONTROL UNIT
Removing
Note:
The electronic control unit is in
the passenger-side footwell.
It is imperative to switch off the
ignition before disconnecting the
multi-pin plug from the control
unit or removing the control unit.
| 1. |
Disengage retaining spring
(spring lock) and disconnect plug
from electronic control unit. |
|
|
| 2. |
Unscrew retaining nuts and remove
electronic control unit from
holder. |
Installing
Note:
When replacing, take care to ensure
that the correct control unit is
used.
The control unit may be confused
with that for the 928 models, model
year '86 and earlier (for
90-tooth impulse rings).
Externally, the only difference
between the control units is the
Bosch or Porsche number.
|
| 45 - 4 |
Removing and Installing
Electronic Control Unit |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
| 1. |
Attach electronic control unit to
holder.
|
| 2. |
Re-connect multi-pin plug to
electronic control unit so that
it is securely seated.
The retaining spring must be
heard to lock into position. |
| Printed in Germany - XIII, 1987 |
Removing and Installing
Electronic Control Unit |
|
45 - 5 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
REMOVING AND INSTALLING RELAYS
General
| - |
The anti-lock braking system is equipped with three relays.
|
| - |
The ABS relay (arrowed) is mounted on the central electrics unit (relay G
20) it supplies voltage to the ABS control unit, the pump-motor relay and
the solenoid-valve relay (circuit diagram page 45 - 04).
|
| - |
The solenoid-valve relay and the pump-motor relay are situated beneath
the cover of the hydraulic unit.
The hydraulic unit is mounted in the rear of the right-hand front wheel
arch. |
Removing and Installing ABS relay
Remove cover from central electrics
unit.
Remove or connect ABS relay
(electronic relay with overvoltage
protection) with ignition switched
off.
|
|
|
| 45 - 6 |
Removing and Installing Relays |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
Removing and installing solenoid-
valve and pump-motor relays
| 1. |
Remove right-hand front wheel.
Remove wheel-arch inner panel. |
2. Remove hydraulic-unit cover.
|
|
| 3. |
With ignition switched off,
withdraw solenoid-valve relay No.
1 (5-pole/as from Mod. 88,
6-pole, see Page 45-3) or pump-
motor relay No.2 (4-pole). |
| 4. |
Installation is the reverse of
the above sequence. |
|
| Printed in Germany - XVI, 1987 |
| Removing and Installing Relays |
|
45 - 7 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
REMOVING AND INSTALLING WHEELSPEED SENSORS, FRONT AND REAR AXLES
Front axle
Removing
| - |
With the ignition switched off,
open and disconnect ABS cable
connector on spring strut
(No. 2).
|
| - |
Unscrew mounting bolt (hex
socket-head bolt) of wheelspeed
sensor No.1 and remove wheelspeed
sensor from steering knuckle. |
|
|
Installing
Note:
| - |
do not remove wheelspeed sensor
from its protective packing until
just before it is to be installed
(loss of permanent magnetism)
|
| - |
before installing, check that
there are no metallic particles
(chips) on the magnetic edge of
the wheelspeed sensor
|
| 1. |
Apply Molykote Longterm 2 to
wheelspeed sensor and hole in
steering knuckle. Replace O-ring
of wheelspeed sensor. |
|
| 45 - 8 |
Removing and Installing Wheelspeed Sensors |
Printed in Germany |
|
| 9 4 4 |
Anti-lock Braking System |
45 |
| 2. |
Without using force, insert
wheelspeed sensor in steering
knuckle and tighten hex
socket-head bolt to secure.
Tightening torque: 10 Nm (7 ftlb) |
Note:
The distance between wheelspeed
sensor and impulse ring is a
design feature and cannot be
adjusted.
| 3. |
Reconnect cable plug and place in
holder on spring strut.
If necessary, remove wheel.
|
| 4. |
Check operation with ABS
tester. |
|
|
Rear axle
Removing
| 1. |
With ignition switched off, open
and disconnect ABS cable
connector on control arm.
Withdraw clip for
wheelspeed-sensor cable from
holder.
Unscrew wheelspeed-sensor
retaining bolt. |
| 2. |
Remove wheel speedsensor from
trailing arm. |
|
| Printed in Germany - XIII,1987 |
Removing and Installing
Wheelspeed Sensors |
|
45 - 9 |
|
| 45 |
Anti-lock Braking System |
9 4 4 |
Installing
Note:
| - |
do not remove wheelspeed sensor
from its protective packing until
just before it is to be installed
(loss of permanent magnetism)
|
| - |
before installing, check that
there are no metallic particles
(chips) on the magnetic edge of
the wheelspeed sensor
|
| 1. |
Apply Molykote Longterm 2 to
wheelspeed sensor and hole in
trailing arm. Replace O-ring of
wheelspeed sensor. |
| 2. |
Without using force, insert
wheelspeed sensor in wheel
carrier and tighten hex
socket-head bolt to secure.
Tightening torque: 10 Nm (7 ftlb) |
Note:
The clearance between wheelspeed
sensor and impulse ring is a design
feature and cannot be adjusted.
|
|
| 3. |
Reconnect cable plug and insert
in holder. Insert cable clip in
holder on trailing arm. |
4. Check operation with ABS tester.
|
| 45 - 10 |
Removing and Installing Wheelspeed Sensors |
Printed in Germany |
|
| 944 |
Brakes, Mechanical |
46 |
Technical data 924 S / 944 / 944 S / 944 S2
| Designation |
Remarks, Dimensions |
Wear limit |
| 924 S/944/944 S |
944 S2 |
924 S/944/944 S |
944 S2 |
Service brake
(foot brake) |
Hydraulic two-circuit brake system with
front-axle/rear-axle brake circuit assignment
(black/white), brake booster, ventilated
brake disks with floating-frame caliper or fixed caliper
on front and rear axles.
The push-rod brake circuit is assigned to the front wheels.
Each fixed caliper has 4 pistons |
Brake boosters
(light-weight construction)
Booster factor
Brake master cylinder**
(aluminium)
up to end of Model 86
as well as 924 S (Ø in mm)
Model 87 onward
apart from 924 S (Ø in mm)
Brake-power controller in the
rear-axle brake circuit
Switching pressure 1 reduction
factor
Active brake disk Ø
front
rear |
Ø 9 inch
3.1 or 3.4*
23.81/19.05
23.81/20.64
33 bar / 046***
(944 S only)
282.5 mm
289 mm
224.6 mm
242 mm |
Ø 9 inch
3.4
-
23.81/20.64
18 bar/046
298 mm (304 mm)
299 mm
245 mm (250,8 mm)
246 mm |
|
|
| * |
Special running gear with brake system as on 944 Turbo from MY '89
|
| ** |
Model 87 onward, apart from 924 S, boost factor 3.4
|
| *** |
vehicles with ABS (special option for Mod. 87 onward / standard on part of production vehicles
as of model year '90) with two central valves.
|
| **** |
924 S and 944 without brake-power regulator |
Technical data 924 S / 944 / 944 S / 944 S2
Printed in Germany - XXIV, 1991
|
46 - 01 |
|
| 46 |
Brakes, Mechanical |
944 |
| Designation |
Remarks, Dimensions |
Wear limit |
924 S/944/
944 S |
944 S2 |
924 S/944/944 S |
944 S2 |
Piston 0/ in front
brake caliper mm
rear mm
Brake-pad thickness, front
rear
Brake-pad surface per
front wheel
Brake-pad surface per
rear wheel
Total brake-pad surface
| Thickness of new brake |
disk,
front
rear |
min. brake-disk thickness**
| after machining |
front
rear |
Max. thickness tolerance of brake
disk
Max. lateral run-out of brake disk
Max. lateral run-out, installed
Lateral runout of wheel hub max.
Max. raw depth after machining
|
54
36
13 mm
13 mm
92 cm2
63 cm2
310 cm2
20.5 mm
20 mm
19.1 mm
19.2 mm
0.02 mm
0.05 mm
0.1 mm
0.05 mm
0.006 mm
|
2 x 36 + 2 x 40
(2 x 36 + 2 x 44)*
2 x 28 + 2 x 30
13 mm
13 mm
86 cm2 (126 cm2)*
86 cm2
344 cm2(424 cm2)*
28 mm
24 mm
26.6 mm(30,6 mm)*
22.6 mm
0.02 mm
0.05 mm
0.1 mm
0.5 mm
0.006 mm
|
2 mm
2 mm
18.5 mm
18.6 mm
|
2 mm
2 mm
26 mm (30 mm)
22 mm
|
| * |
Special running gear with brake system as on 944 Turbo from model year '89
|
| ** |
The brake disk must only be machined symmetrically, i.e. the same
on both sides. |
| 46 - 02 |
Technical data 924 S / 944 / 944 S / 944 S2
Printed in Germany - XXIV, 1991 |
|
| 944 |
Brakes, Mechanical |
46 |
| Designation |
Remarks, Dimensions |
Wear limit |
| 924 S/944/944 S |
944 S2 |
924 S/944/944 S |
944 S2 |
Brake-pedal play with
brakes bled and
engine stationary
|
approx. 10 mm |
approx. 10 mm |
|
|
Parking brake
(handbrake)
|
mechanical, acting on both rear wheels
drum brake |
Parking-brake drum 0/
Width of brake shoes
Brake-pad surface per wheel
Brake-pad thickness |
180 mm
25 mm
85 cm2
4.5 mm |
180 mm
25 mm
85 cm2
4.5 mm |
181 mm
2mm |
181 mm
2mm |
Technical data 924 S / 944 / 944 S / 944 S2
Printed in Germany - XIX, 1989
|
46 - 03 |
|
| 46 |
Brakes/Mechanical Parts |
9 4 4 |
TORQUE SPECIFICATIONS FOR MECHANICAL BRAKE PARTS
| Location |
Description |
Threads |
Material |
Tightening
Torque
Nm (ft lb) |
Socket-head bolt
to clamping nut
Caliper
to steering knuckle
Brake disc to wheel
hub
Guard to steering
knuckle
Wheel huh to rear-
wreel shaft with
steel trailing arms
with aluminum
trailing arms
Brake-pipe holder
to brake backplate
or trailing arm
Wire holder to
trailing arm
Guard to brake
backplate or
trailing arm
Brake disc to wheel
hub
Floating caliper to
brake backplate or
trailing arm
Brake backplate to
trailing arm
Parking-brake lever
to bod |
Socket-head
bolt
Hex bolt
Hex nut
countersunk
screw
Hex bolt
Castle nut
Locknut
Hex bolt
Hex bolt
Hex bolt
Countersunk
bolt
Hex bolt
Hex bolt
Hex bolt |
M 7
M 12x1.5
M 8
M 6
M 7
M 24x1.5
M 22x1.5
M 6
M 6
M 6
M 6
M 12x1.5
M 10
M 8
|
10.9
8.8
8
8.8
8.8
8
8.8
8.8
8.8
8.8
8.8
10.9
8.8
|
13 + 3
(9.5 + 2.2)
85 (63)
23 (17)
10 (7)
10 (7)
380 + 70
(280 + 52)
500 (368)
10 (7)
10 (7)
10 (7)
5 (3.6)
85 (63)
58 (43)
21 (15.5)
|
| 46 - 04 |
Torque Specifications |
XIX, 1989 - Printed in Germany |
|
| 9 4 4 |
Brakes/Mechanical Parts |
46 |
| Location |
Description |
Threads |
Material |
Tightening
Torque
Nm (ft lb) |
Brake cable to yoke
Parking brake
cable to
turnbuckle
Brake booster to
connector
Connector to
firewall
Swivel on brake
push rod
|
Hex bolt
Nut
Hex nut
Hex nut
Hex nut
|
M 6
M 6
M 8
M 8
M 10
|
8.8
8
8
8
8
|
8.5 (6.2)
8.5 (6.2)
21 (15.5)
21 (15.5)
35 (26)
|
| Printed in Germany - XIX, 1989 |
|
46 - 05 |
|
| 46 |
Brakes/Mechanical |
9 4 4 |
NOTES ON BRAKING SYSTEM, '87 MODELS ONWARD
Brake Discs
As of model year '87 and with the exception of the 924 S, the pot size
(distance X) of the brake discs has been changed because of the installation
of ABS (optional extra M 593).
Front brake disc Rear brake disc
Asbestos-free brake pads worldwide as from model 89 and as from
model 88 for Sweden, Norway, Denmark (FA = Textar T 400 / RA = Textar T 426).
May be retrofitted to the front and rear axles of all 924 S/ 944 / S44 S
vericles. A combination of asbestos-free / asbestos is not permitted.
- Refer to page 46 - 07 for 944 S 2 brake pads.
| 46 - 06 |
Notes on Braking System
'87 Models Onward |
XIX, 1989 - Printed in Germany |
|
| 944 |
Brakes, Mechanical |
46 |
Notes on four-piston fixed brake calipers
A four-piston fixed caliper brake has been in-
stalled in the 944 S 2.
944 S 2 vehicles built during model year 1989
have varying construction statuses.
This involves the following components:
| - |
Front brake disks
Changed over to brake disks with semi-
ribs (arrow).
|
| - |
Front cover panel
Cutouts enlarged to cool brakes.
|
| - |
Four-piston fixed caliper, front and rear
Piston seal modified from wiper-ring ver-
sion to cap version.
|
| - |
Brake pads front and rear
Type of brake pad changed |
|
|
The following applies to repairs or as-
sembly work:
Front brake disk
When replacing brake discs, ensure that the
same type are used right and left.
Front cover plate
The cut-outs for brake cooling must be the
same size left and right. If panels with large
cut-outs are installed, never use plates with
smaller cut-outs.
Four-piston fixed caliper
The same type of fixed caliper must be used
on each axle.
Brake pads
Only use the same type of brake pads on
front and rear axles. Never mix brake pads
with asbestos/without asbestos or asbestos-
free brake pads of various types.
When replacing brake pads, use Pagid S
537 - 537 (asbestos-free) on the 944 S 2.
Not aplicable to M 030 (large brake ca-
lipers, as for turbo from MY '89).
Use asbestos-free Textar T 400 brake pads
on all 944 turbo vehicles and on the 944 S2
with special running gear M 030.
|
Notes on four-piston fixed brake calipers
Printed in Germany - XXIV, 1991
|
46 - 07 |
|
| 46 |
B r a k e s / M e c h a n i c a l P a r t s |
9 4 4 |
www.9ss1.dk/porsche944
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l P a r t s |
46 |
CHECKING THICKNESS OF BRAKE PADS
C a r s W i t h o u t B r a k e P a d
W e a r I n d i c a t o r
Replace brake pads when worn to thickness
of 2 mm.
C a r s W i t h B r a k e P a d W e a r
I n d i c a t o r
( S i n c e 1 9 8 4 M o d e l s )
Replace brake pads when brake pad indicator
lamp comes on, however at latest when worn
to thickness of 2 mm.
If brake pad wear is reported by the indicator
lamp, the warning contact (sensor with wire
and plug) must also be replaced. It will not be
necessary to replace the warning contact, if
brake pads are replaced when worn to a
thickness of 2.5 mm.
Replace warning contacts with ground wire
cores. If only the plastic part of the warning
contact is ground, replacement will not be
necessary.
| 1. |
Remove wheels to check brake pad
thickness. |
|
|
2. Inspect brake pads visually for wear.
Wear limit is reached, when pad has a
remaining thickness of 2 mm.
|
| Printed in Germany - Ill, 1983 |
|
46 - 1 |
|
| 46 |
B r a k e s / M e c h a n i c a l P a r t s |
9 4 4 |
REMOVING AND INSTALLING BRAKE PADS
R e m o v i n g
N o t e:
If brake pads can be re-used, mark them when
removing. Pads must not be moved from out-
side to inside and vice versa or from right to
left wheel. This would cause uneven braking
effect.
1. Remove spring-type locks for retaining pins.
2. Remove retaining pins.
|
|
| 3. |
Cars with brake pad wear indicator:
Pull warning contact out of pad plate. |
N o t e :
Replace warning contacts with ground off or
ground wire cores. Warning contacts can be
re-used when there are only traces of grinding
on the plastic part of the warning contact.
| 4. |
Pull out inner brake pad with a suitable
tool, e. g. Hazet 1966-2 impact puller. |
|
| 46 - 2 |
Removing and Installing Brake Pads |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l P a r t s |
46 |
| 5. |
Pull out outer brake pad. This requires
pressing out floating caliper frame until
brake pad protrudes out of pin on floating
caliper frame. |
Installing
| 1. |
Replace brake pads, which show deep
cracks, have become loose from back
plates or are covered with oil. Also in this
case replace all four pads of one axle.
|
| 2. |
Press back piston to initial position with
special tool. |
|
|
N o t e :
To prevent brake fluid tank from overflowing,
draw off small amount of brake fluid before
pressing back piston.
Use syringe reserved exclusively for brake
fluids.
Brake fluids are poisonous and must not be
siphoned off through a hose.
| 3. |
Clean brake pad bearing and sliding
surfaces in brake calipers with alcohol or
a cylindrical brush. Never use solutions
containing mineral oils or sharp edged
metallic tools.
|
| 4. |
Check 20° piston position and adjust with
piston turning pliers, if necessary. |
Front Axle
|
| Printed in Germany - III, 1983 |
| Removing and Installing Brake Pads |
|
46 - 3 |
|
| 46 |
B r a k e s / M e c h a n i c a l P a r t s |
9 4 4 |
Rear Axle
| 5. |
Install outer brake pad and press floating
caliper frame in direction of brake disc so
that pin engages in groove of pad back-
plate. |
N o t e :
Apply a thin coat of grease on bearing and
sliding surfaces to prevent seizure of brake
pads in brake calipers through corrosion.
Use Optimoly HT (copper pastel or
Plastilube (Schillings, P. O. Box 1703,
7080 Aalen).
|
|
| 6. |
Install inner brake pad.
|
| 7. |
Install retaining pin and cross spring.
Cars with brake pad wear indicator:
Press warning contact into inner pad back-
plate.
|
| 8. |
Install spring-type lock.
|
| 9. |
Depress brake pedal of stationary car
firmly several times to move brake pads
to their normal operating position. No
check level of brake fluid in tank, adding
more if necessary. |
B r e a k i n g I n B r a k e P a d s
New brake pads must be broken in during
the first 200 km. Only then will they reach
maximum friction and wear values. During
this time full stops from top speeds should
be limited to emergency situations.
|
| 46 - 4 |
Removing and Installing Brake Pads |
Printed in Germany |
|
| 944 |
Brakes, Mechanical |
46 |
Brake pads for four-piston fixed caliper brakes, removing and installing
The procedure for changing brake pads on
the 944 S 2 is the same as for other Porsche
models with four-piston fixed calipers.
Refer to the Workshop Manual for the 944
turbo for this procedure. In addition to this, ob-
serve the following:
| |
Use the correct type of brake pad.
Notes on Page 46 - 07.
Replace damper plates each time
brake pads are changed. Remove the
damper plates before pressing the piston
back into the initial position.
On the 944 S 2. the damper plates are
only installed on four- piston fixed calipers
with cap seal (both front and rear axles).
Also please refer to suppressor and vibra-
tion damper survey in Technical Informa-
tion Group 4, No. 1/90.
The damper plates have an adhesive strip
and protective foil. The protective foil
must be removed before installation.
The brake-pad carrier plates (reverse
side of brake pads) must not be lubri-
cated.
|
Brake pads for four-piston fixed caliper brakes, removing and installing
Printed in Germany - XXIV, 1991
|
46 - 4a |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l P a r t s |
44 |
|
| 9 4 4 |
Brakes/Mechanical Parts |
46 |
ADJUSTING BRAKE PUSHROD
Note:
The brake pushrod need only be
adjusted when:
| - |
the brake booster has been
replaced - swivel has been
removed from brake pushrod |
| - |
pushrod or swivel have been
turned. |
The brake pedal does not have a
stop. Its initial position is
reached when the braking unit
(brake booster + brake master
cylinder) are in the released
position. Since the brake pedal is
unsupported in its initial position
when the brake pushrod is correctly
adjusted, the fixed clearances in
the brake unit are assured.
Consequently, with the engine off
and brakes bled, approx. 10 mm of
pushrod play can be felt when the
brake-pedal pad is depressed by
hand.
Adjusting
| 1. |
Adjust length of brake pushrod by
turning swivel. The length from
brake booster-to-connector
(adapter) contact face to center
of swivel lockpin should be 186 +
1 mm or 207 + 1 mm (see page
47 - 11).
|
| 2. |
Tighten locknut.
|
| 3. |
Check stoplight switch setting. |
|
|
CHECKING STOPLIGHT SWITCH SETTING
The stoplight switch is a
mechanically operated switch
mounted on a bracket above the
brake-pedal pad. In the initial
position (neutral position) of the
brake-pedal lever, the distance
between stoplight and lever must be
5 mm. If necessary, turn mounting
nuts to change position of
stoplight switch until specified
gap of 5 mm is reached. Turn
mounting nuts in opposite
directions to lock.
|
| Printed in Germany - XIII,1987 |
Adjusting Brake Pushrod
Checking Stoplight Switch
Adjustment |
|
46 - 5 |
|
| 46 |
Brakes/Mechanical Parts |
9 4 4 |
CHECKING AND ADJUSTING PARKING
BRAKE
If no more than average force is
enough to raise the lever by more
than 2 notches without noticeable
braking effect. the parking brake
requires adjustment.
| 1. |
Jack up car and remove rear
wheels
|
| 2. |
Release parking brake and push
disc brake pads on rear wheels
back until brake disc can be
turned with ease.
|
| 3. |
Slacken adjusting nut on
turnbuckle until cable is slack.
|
| 4. |
Insert a screwdriver through the
hole in the brake disc and-turn
adjusting device until the wheel
is locked. Turn locking device in
opposite direction until wheel
can be turned freely. Follow this
by turning the adjusting device
back until the wheel can be
turned freely. and then turn back
(undo) by another 2 notches. |
|
|
| 5. |
Pull up parking-brake lever 2
notches and turn adjusting nut
until wheels can just be turned
by hand (with the lever in 4th
notch, the wheels must be locked). |
| 6. |
Release parking brake lever and
check that both wheels turn freely.
|
| 7. |
Lock adjusting nut. |
|
| 46 - 6 |
Adjusting Parking Brake |
XIX, 1989 - Printed in Germany |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l P a r t s |
46 |
MODIFIED SUSPENSION OF PARKING BRAKE CABLES
Since October 7, 1983 parking brake cables are suspended from the rear axle cross tube,
instead of the spring struts, so there is guarantee for free movement of parking brake cables
even during wheel bump travel.
Cars with the old suspension system can be converted to the new suspension. This is
accomplished by removing the straps on the spring struts and replacing them with retaining
straps on the left and right sides of the rear axle cross tube outside of the stabilizer mounts.
The retaining strap already installed on the left side of the rear axle cross tube (inside of
stabilizer mount) is not changed.
| Parts Required: |
2 x 477 711 979
2 x N 013 510 1
2 x N 013 530 3 |
Retaining strap
Rivet base
Rivet head |
Old Suspension |
|
New Suspension (since Oct. 7, 1983) |
| Printed in Germany - V, 1985 |
| Modified Suspension of Parking Brake Cables |
|
46 - 6 a |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l P a r t s |
44 |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l |
46 |
| Printed in Germany |
| Disassembling and Assembling Front Wheel Brake |
|
46 - 7 |
|
| 46 |
B r a k e s / M e c h a n i c a l |
9 4 4 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
|
Bolt
M 12 x 1.5 x 40
Spring
Caliper
Grease cap
Clamping nut with
bolt
Thrust washer
Wheel bearing, outer
Front wheel hub
Nut
Washer
Bolt
Brake disc
Bolt
M 7 x 10
Washer
Guard
|
2
2
1
1
1
1
1
1
5
5
5
1
3
3
1 |
Suspend from
suitable point with
a piece of wire.
Only detach brake
hose for repairs
Pry off with two
tire irons
|
Replace, if
necessary
Do not mix up
left and right
calipers if both
were removed.
Bleeder valves
must face up
Adjust wheel bearing
play. Bolt torque:
13 Nm (9 ft lb)
Check, replacing
if necessary
Replace, if
necessary
Check for wear
and damage. Mark
for installation
Replace, if
necessary
|
|
| 46 - 8 |
Disassembling and Assembling Front Wheel Brake |
Printed in Germany |
|
| 944 |
Brakes, Mechanical |
46 |
Disassembling and assembling notes
Disassembling
| 1. |
Remove brake caliper and suspend in a
suitable place (do not undo brake hose or
brake line).
|
| 2. |
Remove brake disc. Proceed according to
model specified (refer to below instructions). |
Brake disc of 944 up to end of MY '86
and all 924 S
| - |
Remove wheel hub with brake disc. |
| - |
Mark installation position of brake disc
relative to wheel hub. Remove fastening
screws. Take off wheel hub. |
|
|
Brake disc as of MY '87 for 944, 944 S
and 944 S 2
| - |
Brake disc may be dismantled without
removing the wheel hub. (Deviation from
explosion drawing and references on
page 46 - 7 / 46 - 8)
|
| - |
Take off brake disc after having removed
the countersunk screws. If the brake disc
has seized and cannot be freed even by
applying light blows with a rubber ham-
mer, screw two hexagon bolts evenly into
both 8 mm threads of the brake disc and
press off the disc. |
|
Disassembling and assembling front wheel brake
Printed in Germany - XXIV, 1991
|
46 - 9 |
|
| 46 |
Brakes, Mechanical |
944 |
Assembling
| 1. |
Check all parts for proper serviceable condi-
tion and replace if necessary.
|
| 2. |
Clean centering surface of the brake disc
on wheel hub and apply a very thin coat
of Optimoly TA.
|
| 3. |
Install brake disc.
If the wheel hub has been removed, insert
tapered roller bearing coated with multi-
purpose grease (Quantity for wheel bearing
and wheel hub approx. 60 g) and adjust
wheel bearing clearance (page 40 - 1).
|
| 4. |
Refit brake caliper. Tighten mounting
bolts to 85 Nm (63 ft lb). |
| 46 - 10 |
Disassembling and assembling front wheel brake
Printed in Germany - XXIV, 1991 |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l |
46 |
| * |
Parts only exist for steel trailing arms. |
| ** |
Parts differ for steel and aluininum trailing arms |
| Printed in Germany - V, 1985 |
| Disassembling and Assembling Rear Wheel Brake |
|
46 - 11 |
|
| 46 |
B r a k e s / M e c h a n i c a l |
9 4 4 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4*
5
6**
7
8
9
10
11
12
13**
14
15
16
17
|
Bolt
M 12 x 1.5 x 35
Washer
Floating frame
caliper
Spacer
Ctsk. screw
Brake disc
Spring
Support sleeve
Adjusting nut
Adjusting screw
Return spring
Brake shoe
Return spring
Thrust bar
Pivot pin
Circlip
Shaft
|
2
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1 |
Set back brake.
First unscrew nut
(no. 23), if wheel
hub has to be
removed,
|
Torque: 85 Nm
Replace if neces-
sary
Bleeder valve
faces up
Check for wear
and damage
Check for cor-
rect seating on
brake back-
plate or trailing
arm
Replace if neces-
sary; wear limit
2 mm
Grease lightly
Grease lightly
|
|
| 46 - 12 |
Disassembling and Assembling Rear Wheel Brake |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / M e c h a n i c a l |
46 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
18
19
20
21**
22*
23**
24**
25*
26*
27*
28*
29*
|
Operating lever
Bolt
- steel arms
- aluminum arms
Washer
- steel arms
- aluminum arms
Guard
Cotter pin
Castle nut for
steel trailing arms
Lock nut for alumi-
num trailing arms
Wheel hub
Bolt
Washer
Brake backplate
Spacer
Seal
|
1
4
3
4
3
1
1
1
1
4
4
1
1
1 |
|
Torque: 10 Nm
Replace, if
necessary
Replace
Torque:
380 + 70 Nm
for castle nut
(tighten to
380 Nm and
turn further
to next cotter
pin hole);
500 Nm for
lock nut
Apply thin coat
of Optimoly HT
on splines
Torque: 58 Nm
Position correctly
Replace
|
Do not un-
screw castle
or lock nut
to remove
parking brake
cable and
parking brake
shoes
|
| * |
Parts only exist for steel trailing arms. |
| ** |
Parts differ for steel and aluminum trailing arms. |
| Printed in Germany - V, 1985 |
| Disassembling and Assembling Rear Wheel Brake |
|
46 - 13 |
|
| 46 |
B r a k e s / M e c h a n i c a l |
9 4 4 |
DISASSEMBLING AND ASSEMBLING REAR WHEEL BRAKE
D i s a s s e m b l i n g
| 1. |
Remove spacer. If wheel hub has to be removed
(not necessary for replacement of parking brake
shoes), unscrew castle nut after removing cotter
pin. Car must be resting on its wheels to
unscrew castle nut.
|
| 2. |
Turn automatic slack control in "loosen" direction
with a screwdriver applied through hole in brake
disc. Detach floating frame caliper. Take off
brake disc after removing countersunk bolt.
|
| 3. |
Remove springs, automatic slack control and
upper return spring. Remove parking brake shoes. |
Assembling
| 1. |
Give automatic slack control, shaft on spreader
lever and sliding surfaces of parking brake shoes
a light coat of grease.
|
| 2. |
Assemble spreader lever. |
|
|
| 3. |
Mount long lower return spring on parking brake
shoes, move in parking brake shoes and insert in
spreader lever.
|
| 4. |
Connect upper return spring. Pull parking
brake shoes apart and insert automatic slack
control. |
| 5. |
Center parking brake shoes. Mount sprinqs. |
|
| 46 - 14 |
Disassembling and Assembling Rear Wheel Brake |
Printed in Germany |
|
| 944 |
Brakes, Mechanical |
46 |
Note
Make sure that hooks of springs engage cor-
rectly in land of brake backplate or trailing
arm.
| 6. |
Recheck installation of parking brake shoes,
automatic slack control, return springs,
springs and spreader lever, correcting if
necessary. |
| 7. |
Mount brake disc and brake caliper. Note
torque specifications.
Adjust and bleed brakes. |
Disassembling and assembling rear wheel brake
Printed in Germany - XXV, 1992
|
46 - 15 |
|
| 46 |
Brakes, Mechanical |
944 |
Checking brake disc lateral run out
| 1. |
Measuring requirements: No tilt play pres-
ent at wheel. If required, adjust wheel bear-
ing clearance of front wheels.
|
| 2. |
Fit adapter plate (Special Tool 9510/1) to
wheel hub. Tightening torque of wheel nuts
(mounting nuts): 130 Nm. |
| 3. |
Engage dial gauge holder, e.g. Ate Part
No. 03.9314-5500.3/01, into brake caliper,
determine center position and fit by turning
the wing screw. |
Notes
If required, fit dial gauge holder with Ate con-
version kit, Part No. 03.9314-5510.3/01
(longer wing screw and bracket for dial gauge
if required).
Four-piston fixed callper brake: Make sure
the spreader spring locating lug at the mount-
ing plate of the fixed caliper is not damaged
when the dial gauge holder is fitted in place.
Floating-caliper brake:
To fit the dial gauge holder, the brake pads
must be removed.
|
|
| 4. |
Fit dial gauge with a slight preload. Place
measuring pointer on maximum diameter of
braking surface. |
| 5. |
Rotate brake disc and read off runout on
dial gauge.
Max. permissible runout of fitted brake disc
max. 0.1 mm. |
Note
The floating frame of the floating-caliper brake
may touch the brake disc after the brake pads
have been removed. When rotating the disc,
push back the floating frame if required.
| Runout of removed |
|
| brake disc |
: max. 0.05 mm |
| Runout of wheel hub |
: max. 0.05 mm. |
| 6. |
If the brake disc runout exceeds 0.1 mm,
remove the brake disc and check runout of
the wheel hub. Mark position of disc with re-
gard to wheel hub. |
|
| 46 - 16 |
Checking brake disc lateral runout
Printed in Germany - XXV, 1992 |
|
| 944 |
Brakes, Mechanical |
46 |
| 7. |
Check wheel hub runout as follows:
Measure once outside (arrow) and once in-
side wheel stud area of hube face.
Lift off dial gauge carefully in cutout area of
wheel hub.
To fit the dial gauge, use either a magnetic
universal dial gauge holder, e.g. as supplied
by SNAP-ON (Order No. PMF 137), or a
dial gauge holder (VW 387). |
Notes
Make sure the brake hoses and brake lines
are not damaged when the brake caliper is
removed and installed.
The above SNAP-ON order no. PMF 137 is
valid for a complete dial gauge kit since the in-
dividual dial gauge holder is not available sep-
arately.
The dial gauge kit may also be used to check
the brake disc lateral runout.
|
|
| 8. |
Excessive wheel hub runout:
Replace wheel hub.
Wheel hub runout o.k.:
Cleaning level and centering surfaces of
brake disc and wheel hub. Then coat center-
ing surface of wheel hub with a thin coat of
Optimoly TA.
Fit brake disc to wheel hub in another posi-
tion, offset radially with regard to wheel nub.
Repeat measurements with fitted adapter.
plate - Special Tool 9510/1.
If the lateral runout is still in excess of
0.1 mm, the brake disc must be replaced. |
Note
If the brake disc runout has been reduced by
offsetting the brake disc with regard to the
wheel hub, one 6 mm countersunk screw
may be omitted if two 6 mm countersunk
screws had been fitted.
|
Checking brake disc lateral runout
Printed in Germany - XXV, 1992
|
46 - 17 |
|
| 46 |
Brakes, Mechanical |
944 |
Checking brake disc thickness
Measure brake disc thickness in approx. 8
places within the braking surface using a
micrometer.
| 46 - 18 |
Checking brake disc thickness
Printed in Germany - XXV, 1992 |
|
| 944 |
Brakes, Mechanical |
47 |
Tightening torque for hydraulic brake system
| Location |
Threads |
Tightening Torque Nm (ftlb) |
Brake-pressure line to
master cylinder, brake
hose, distributor and
brake caliper
Brake-power regulator to
master cylinder or
hydraulic unit
Brake hose to brake
caliper
Bleeder screw to floating
caliper
Bleeder screw to fixed
caliper
Master cylinder to brake
booster
Brake booster to adapter
Adapter to firewall
Fastening bracket on
brake carrier or trailing
arm
Stop screw in master
cylinder
|
M 10 x 1
M 10 x 1
M 10 x 1
M 7
M 10
M 8
M 8
M 8
M 6
M 6
|
12(9)
14(10.5)
14(10.5)
4(3)
8(6) - 12(9)
21(15.5)
21(15.5)
21(15.5)
10(7.5)
7(5) - 10(7.5)
|
Tightening torque for hydraulic brake system
Printed in Germany - XIX, 1989
|
47 - 01 |
|
| 47 |
Brakes/Hydraulics, Regulators, Booster |
9 4 4 |
NOTES ON BRAKING-FORCE BOOSTER
A braking-force booster is installed for the rear-axle braking circuit of the
944 S and 944 turbo.
The changeover pressure differs.
| 944 S |
33/5 |
| 944 S 2/ 944 turbo: |
18/5 |
| 924 S and 944 are not fitted with braking-force regulators |
Location
| Cars with ABS |
: screwed in to port h of hydraulic unit. |
| Cars without ABS |
: screwed in to the brake master cylinder (intermediate
piston circuit). |
Identification
Changeover pressure and reduction factor stamped on regulator.
33 or 18 = changeover pressure in bar 5 = reduction factor 0.46
(check correct correlation).
Notes on assembly
It is essential to ensure that correlation is correct. Under no circumstances
may braking-force regulators with a different reduction factor (e.g. 3 = 0.3)
be installed. When slackening and tightening the brake line, always counter by
holding the hexagon of the braking-force regulator. In contrast, never turn
the hexagon when removing or installing the regulator. The two flats at the
connecting thread are provided for this purpose.
| 47 - 02 |
Notes on Braking Force Regulator |
XIX, 1989 - Printed in Germany |
|
| 944 |
Brakes, Mechanical |
47 |
Notes on the four-piston fixed caliper
Assembly notes
Never separate the two halves of each
brake caliper from one another.
Disregard any information stating other-
wise, and alter any existing written documen-
tation to this effect.
It is possible to replace piston seals. wiper
rings and spring plates while fixed caliper is
assembled.
Always use brake-cylinder paste Unisilicon TK
44 N 2 when assembling brake pistons.
This also applies when repairing other brake
calipers. Unisilicon paste is available as a
spare part (Part No. 000.043.117.00).
x = never undo or tighten screws
|
|
In order to check that the brake caliper is in
the correct installation position, while brake
pads are installed, an arrow above the
Porsche trademark indicates the direction of
rotation for the brake disk.
Modification to the four-piston fixed calipers
During Model year 1989. the type of piston
seal was modified from a wiper ring to a pro-
tective cap.
When replacing components, make sure
that the same type of fixed caliper is used
on each axle. Never mix different types on
one axle
|
Notes on the four-piston fixed caliper
Printed in Germany - XIX, 1989
|
47 - 03 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| Printed in Germany - III, 1983 |
| Disassembling and Assembling Brake Caliper |
|
47 - 1 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12 |
Spring lock
Retaining pin
Cross spring
Brake pad
Mounting frame
Spring guide
(front wheel brake
caliper)
Brake cylinder
Floating frame
Spring guide
(rear wheel brake
caliper)
Clamping ring
Cap
Piston
|
1
2
1
2
1
1
1
1
1
1
1
1 |
Knock ouf of
floating frame
with a plastic
hammer. Place
wood liner in
floating frame
Press out of
cylinder with
compressed air.
Use wood liner.
Caution!
|
Replace, if
necessary
Replace, if
necessary
Replace, if
necessary
Check, replacing if
necessary.
Wear limit: 2 mm.
It is recommended
to install pads
after installation
of brake caliper
Make sure slides fit
correctly on rear
calipers
Don't mix up left
and right spring
guides
Make sure of
perfect fit
Replace
Use brake cylinder
paste. Adjust
piston with 20°
gauge
|
Greater angle
on upper spring
guide outlet
|
| 47 - 2 |
Disassembling and Assembling Brake Caliper |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
13
14
15
16 |
Seal
Dust cap
Bleeder screw
Slide (only on rear
wheel brake
calipers)
|
1
1
1
2 |
Remove with a
plastic rod
|
Replace; install
with brake cylinder
paste
Replace, if
necessary
|
|
| Printed in Germany |
| Disassembling and Assembling Brake Caliper |
|
47 - 3 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
DISASSEMBLING AND ASSEMBLING BRAKE CALIPER
D i s a s s e m b l i n g
| 1. |
Press floating frame off of mounting frame. |
| 2. |
Run mounting frame out of floating frame after
removal of spring guide (only on front wheel brake
calipers). |
| 3. |
Drive brake cylinder off of floating frame with a
plastic hammer applied alternately on sides. Use a
wood liner in floating frame to avoid damage. |
|
|
| 4. |
Press piston out of cylinder with compressed
air. |
Note
Support piston firmly on a wood liner.
CAUTION!
|
| 47 - 4 |
Disassembling and Assembling Brake Caliper |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
5. Remove seal with a plastic rod.
A s s e m b l i n g
| 1. |
Coat cylinder bore, piston and seal with a very
thin brake cylinder paste.
Press piston into cylinder in approximately
correct position (200 chamfer). |
|
|
| 2. |
Drive brake cylinder with spring guide on to
floating frame with a soft mandrel applied
alternately. |
| 3. |
Insert mounting frame. Be careful not to damage
the slides (slides only on rear wheel brake
calipers). |
| 4. |
Adjust piston 20° position with a piston turning
pliers accurately (see page 46 - 3). |
|
| Printed in Germany |
| Disassembling and Assembling Brake Caliper |
|
47 - 5 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
|
| 9 4 4 |
Brakes/Hydraulics, Regulators, Booster |
47 |
| Printed in Germany - XIII, 1987 |
Removing and Installing
Brake Booster |
|
47 - 7 |
|
| 47 |
Brakes/Hydraulics, Regulators, Booster |
9 4 4 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15 |
Brake-fluid
reservoir
Hex nut
Washer
Tandem brake
master cylinder
Seal
Lockpin
Hex nut
Spring washer
Seal
Hex nut
Washer
Adapter
Brake booster
Seal
Swivel
|
1
2
2
1
1
1
3
3
1
4
4
1
1
1
1 |
|
Apply thin coat
of brake-
cylinder paste
to plug No. 20
Replace if
necessary,
tightening
torque: 21 Nm
(15.5 ft lb)
Replace
Install right
way round
Tightening
torque: 21 Nm
(15.5 ft lb)
Replace if
necessary
Replace if
necessary
Tightening
torque: 21 Nm
(15.5 ft lb)
Note install-
ation position
Replace if
necessary
Adjust, see
page 47 - 11
|
Self-locking
(Teves design)
Only used when
No. 2 is not
self-locking
Page 47 - 11
Use square-
section or
O-ring
Page 47 - 11
|
| 47 - 8 |
Removing and Installing
Brake Booster |
XIII, 1987 - Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
16
17
18
19
20 |
Nut
Dust cover
Check valve
Rubber seal
Plug
|
1
1
1
1
2 |
|
Torque:
35 Nm (25 ft lb)
Replace if necessary
Check function by
blowing air into valve.
From engine end =
no flow (valve must
be tight). From brake
booster end = flow.
Replace; install with
brake cylinder paste
|
|
| Printed in Germany - I, 1982 |
| Removing and Installing Brake Booster |
|
47 - 9 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
REMOVING AND INSTALLING BRAKE BOOSTER
R e m o v i n g
| 1. |
Place rags underneath tandem brake master
cylinder and on left wheel house. Pull brake fluid
tank out of tandem brake master cylinder and
catch escaping brake fluid (do not reuse).
Place tank with connected clutch hose on wheel
house. |
| 2. |
Disconnect brake lines on brake master cylinder
(front axle push rod brake circuit). Unscrew
mounting nuts and take out brake master
cylinder. |
|
|
| 3. |
Disconnect vacuum hose on check valve of
brake booster. Pull out oil dipstick.
|
| 4. |
Pry off fuel line holding clip on mounting bolt
uniformly in area of adapter II (danger of
damaging). |
| 5. |
Remove lockpin for push rod on brake pedal.
|
| 6. |
Unscrew three mounting nuts of brake booster/
adapter assembly. Mounting nuts are accessible
after pulling down insulation sheet in footwell
(disconnect throttle cable on accelerator pedal
for this purpose).
|
| 7. |
Take out brake booster from above at engine
compartment end. |
|
| 47 - 10 |
Removing and Installing Brake Booster |
Printed in Germany |
|
| 9 4 4 |
Brakes/Hydraulics, Regulators, Booster |
47 |
Installing
Notes for replacement
| - |
With the exception of the 944
turbo and cars with ABS, brake
units (tandem brake master
cylinder and brake booster) from
two manufacturers were used in
production (Teves and Girling).
When replacement parts are
installed, tandem brake-master
cylinders and brake boosters from
either manufacturer can be
installed together in the car,
with the exception of the models
listed above.
|
| - |
In cars with ABS (M 593, '87
models onward), it is essential
to install brake master cylinders
with central valves
|
| - |
With the exception of the 924 S,
brake master cylinders installed
in '87 models onward have
different Ø and stroke.
Check correct correlation.
|
| 1. |
Screw swivel onto brake pushrod
and adjust. Tighten locknut.
| a = 186 + 1 mm - |
untii end of
model year '86
and 924 S
|
| a = 206 + 1 mm - |
'87 models
onward, except
924 S |
|
|
|
| 2. |
Assemble brake booster with
Adapter in correct position.
|
| 3. |
Install brake booster in car.
When inserting brake booster in
car, guide swivel of pushrod onto
brake pedal at same time and connect.
|
| 4. |
Check stoplight switch setting
and correct if necessary (46 - 5).
Install clips for fuel lines.
|
| 5. |
Install brake master cylinder.
Use new seal between brake master
cylinder and brake booster
and new plugs for the brake-fluid
reservoir. Use only
brake-cylinder paste or brake
fluid when pressing reservoir on
to plugs.
|
| 6. |
Bleed braking system and clutch.
Check for leaks and check
operation. |
|
| Printed in Germany - XIX,1989 |
Removing and Installing
Brake Booster |
|
47 - 11 |
|
| 47 |
Brakes/Hydraulics, Regulators, Booster |
9 4 4 |
REPAIRING BRAKE MASTER CYLINDER*
General
Stepped aluminum brake master cylinders from two manufacturers (Teves and
Girling) are used in production.
The secondary boot seal on the pushrod piston differs depending on the make of
the cylinder. Always use a correct repair kit when repairing a brake master
cylinder.
Teves Cylinder
One double-action secondary
boot (No. 9). brake-fluid
sealing to inside, vacuum
sealing to outside |
|
Girling Cylinder
2 secondary boots |
Types of brake master cylinder
Differences and
distinguishing features |
Teves |
Girling |
Manufacturer's code on
cylinder body
Stop screw for
intermediate piston
Cylinder body
Secondary boot seal on
pushrod piston
|
Ate
Screw at top
No leak bore
1 boot (guide
sleeve visible)
|
G
Screw on the right-hand
side
With leak bore
2 boots (stop washer
visible)
|
| * |
This description does not include brake master cylinders with central valves
(vehicles with ABS) and the standard brake master cylinder for 944, 944S and
944 turbo, '87 models onward. These brake master cylinders cannot and may
not be repaired.
|
| 47 - 12 |
Repairing Brake Master Cylinder |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
A - TEVES VERSION
B - GIRLING VERSION
| Printed in Germany - I, 1982 |
| Repairing Brake Master Cylinder |
|
47 - 13 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8 |
Brake fluid reservoir
Seal
Plug
Stop screw
Aluminum seal
Circlip
Primary piston
assy. consisting of:
Primary piston
Filler disc
Primary cup
Support ring
Spring
Stop sleeve
Travel limiting
screw
Secondary piston
assy. consisting
of:
Secondary cups
Secondary piston
Filler disc
Primary cup
Support ring
|
1
1
2
1
1
1
1
1 |
Clutch hose remains
connected
Apply pressure on
primary piston
|
Install with brake
cylinder paste
Replace
Replace; install with
brake cylinder paste
Replace
Replace, make sure of
proper fit
Coat piston skirt
with silicone grease
(see page 47 - 18)
|
Square or O-ring
(both are inter-
changeable) |
| 47 - 14 |
Repairing Brake Master Cylinder |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
9
10
11
12
10
11
12 |
Cylinder housing
Guide sleeve
Secondary cup
Stop washer
Stop washer
Secondary cup
Plastic washer
|
1
1
1
1
2
2
1 |
|
Position correctly,
inside chamfer faces
out
Sealing lip faces
cylinder bore; fill
groove with silicone
grease (see page
47 - 18)
Sealing lip faces
cylinder bore; fill
groove with silicone
grease (see page
47 - 18)
Position correctly,
lugs face out
|
Use proper
repair kit
depending on
make
O n l y
T e v e s
O n l y
T e v e s
O n l y
T e v e s
O n l y
G i r l i n g
O n l y
G i r l i n g
O n l y
G i r l i n g
|
| Printed in Germany - I, 1982 |
| Repairing Brake Master Cylinder |
|
47 - 15 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
REPAIRING BRAKE MASTER CYLINDER
D i s a s s e m b l i n g
| 1. |
Clean outside of removed brake master cylinder
(see page 47 - 10) with alcohol and dry with
compressed air.
|
| 2. |
Clamp cylinder housing in a vise (fitted with soft
jaws). Remove plugs for brake fluid reservoir
and stop screw for secondary piston.
|
| 3. |
Slide primary piston into cylinder housing
slightly with a rounded-off drift and remove
circlip.
Pull primary piston out of housing. |
| 4. |
Tap cylinder housing on a soft base (wood) until
the secondary piston slides out of housing. |
|
|
C l e a n i n g a n d C h e c k i n g P a r t s
| 1. |
Clean cylinder housing with alcohol and dry
with compressed air.
|
| 2. |
Check cylinder housing and threads for damage.
cylinder bore for scoring and corrosion. |
N o t e :
Never reuse a cylinder housing with damage in bore.
In this case a new tandem brake master cylinder
must be used.
Machining (polishing) the cylinder bore is not
approved.
| 3. |
If surface finish of cylinder bore is okay. check
whether all connecting. compensating and
inlet/outlet ports are open. |
A s s e m b l i n g
| 1. |
Give cylinder bore a light coat of brake cylinder
paste. Clamp cylinder housing in a vise (fitted
with soft jaws) with cylinder opening facing
down at an angle. |
|
| 47 - 16 |
Repairing Brake Master Cylinder |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| 2. |
Remove both plugs in assembly and packing
sleeve, and separate sleeve with intermediate
piston on entire sleeve. |
|
3. |
Slide sleeve for secondary set so far on sleeve
with push rod piston that both sleeve ends are
flush and skirt of push rod piston with inside
parts of secondary set is cleared. Then remove
plastic bag of silicone grease (insofar as not
supplied loose). seal, aluminum seal, circlip,
stop washer(s), secondary cup(s) and guide
sleeve or plastic washer. |
| 4. |
Run intermediate piston sleeve with outside
chamfer leading into large cylinder bore against
stop and hold tight. Push parts inside of this
sleeve into cylinder bore with a rounded-off
drift until intermediate piston rests on bottom
of cylinder. Hold inside parts tight with a mandrel.
Pull back assembly sleeve slightly. Screw in stop
screw with a new aluminum seal and tighten to
7 - 10 Nm torque. Release piston slowly until
it rests on stop screw. Remove drift and assembly
sleeve. |
|
|
| 5. |
Turn cylinder around in vise so that cylinder
opening faces up.
Insert the previously adjusted secondary set
sleeve and push rod piston sleeve as well as the
contained push rod piston into cylinder bore for
secondary set against seat with small sleeve dia-
meter leading and press push rod piston comple-
tely into cylinder bore with a rounded-off drift.
Remove assembly sleeves. |
| 6. |
Press push rod piston into cylinder bore slightly
and insert an assembly needle (made locally)
through afterrunning bore of push rod piston
brake circuit into annular space behind both
piston shoulders of push rod piston. Release push
rod piston slowly.
(See page 47 - 18 for sketch of locally made
assembly needle.) |
N o t e
For Teves version the assembly needle must be be-
hind the stop shoulder of the push rod piston (see
picture for point 8).
|
| Printed in Germany - I, 1982 |
| Repairing Brake Master Cylinder |
|
47 - 17 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
| 7. |
Apply a thin coat of silicone grease supplied in
repair kit on skirt of push rod piston and fill
grooves of secondary cup(s) with it. |
N o t e:
If there are two secondary cups (Girling
version), fill outer cup with most of the
silicone grease to prevent it from running dry.
| 8. |
Slide secondary set sleeve (c) and push rod piston sleeve (b) together in such a manner, that end of push rod piston sleeve is aligned with inside shoulder on small diameter end of secondary set sleeve.
Place stop washer in housing and install secondary cup on piston skirt.
Cup lips face cylinder bore. |
|
|
Hold cup with two fingers and slide assembly
sleeve with the adjusted step over the cup and
then into cylinder bore completely. First slide
intermediate piston sleeve (a) against seat on
secondary cup with inside chamfer over skirt
of push rod piston and press cup down, while
pulling back secondary set sleeve (c) and push
rod piston sleeve (b) by the same distance as
the cup height. Then remove assembly sleeves.
9 a.
|
T e v e s Ve r s i o n
Insert guide sleeve in correct position (inside
chamfer facing out). Install circlip.
|
|
9 b. |
G i r l i n g V e r s i o n
Slide plastic washer into cylinder bore with pin facing out. Install second secondary cup a described in point 8. Insert stop washer and circlip. |
|
| 47 - 18 |
Repairing Brake Master Cylinder |
III, 1983 - Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
| 10. |
Press primary piston into cylinder bore slightly
and remove assembly rod.
Recheck circlip for correct installation.
|
| 11. |
Install brake master cylinder in car. Use a new
seal between brake master cylinder and brake
booster as well as new plugs for brake fluid
reservoir.
Only use brake cylinder paste or brake fluid to
press plugs into brake fluid reservoir.
|
| 12. |
Bleed brakes and clutch. Check for leaks,
function and effect. |
| Printed in Germany - I, 1982 |
| Repairing Brake Master Cylinder |
|
47 - 19 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
BLEEDING BRAKING SYSTEM/CHANGING BRAKE FLUID
General
To assure speedy professional work, we recommend the use of electric refilling
and bleeding equipment. The work described below was carried out using Alfred
Teves Gmbh equipment. Refer to the Operating Instructions for a precise
description of the equipment.
Brake Fluid
Brake fluid is hygroscopic, in other words, it absorbs moisture from the air,
which lowers its boiling point.
| Example: |
At 2% water content, the boiling point of the brake fluid sinks by
approx. 60°C (minimum requirement for brake fluid to SAE J 1703 or
DOT 3 or DOT 4 min. 190°C, 230°C respectively). |
Brake fluid which is dirty or contains water may lead to failure of the
hydraulic braking system. Never reuse old brake fluid.
Brake fluid must be renewed at least every 2 years. Use DOT 3 or DOT 4
(SAE J 1703) brake fluid.
Capacity: 1 liter total (1000 cc), approx. 250 cc per wheel.
| 47 - 20 |
Notes on Bleeding Braking System
and Changing Brake Fluid |
Printed in Germany |
|
| 9 4 4 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
47 |
Bleeding brakes/changing brake
fluid
| 1. |
Top up level of fluid in
reservoir to brim. Remove filter
screen (restrictor).
|
| 2. |
Connect bleed nozzle to reservoir
and push rapid-action coupling of
filler hose on to nipple of bleed
nozzle. |
| 3. |
Switch pump on. Set selector
lever to "filling and bleeding"
position. |
|
|
| 4. |
Open each bleed valve in turn
until the brake fluid which
issues is clean and free of air
bubbles.
|
| 5. |
To make quite sure that the brake
fluid pumped from the system is
clean and free of air bubbles and
to determine the amount of brake
fluid used, catch the fluid in a
transparent container.
|
| 6. |
When bleeding the system, depress
the brake pedal several times
with bleed valves open to expell
all air bubbles from the brake
master cylinder.
|
Note:
There is no difference in the
procedure for bleeding the braking
system of cars fitted with ABS.
|
| Printed in Germany - XIII, 1987 |
Notes on Bleeding Braking System
and Changing Brake Fluid |
|
47 - 21 |
|
| 47 |
B r a k e s / H y d r a u l i c s , R e g u l a t o r s , B o o s t e r |
9 4 4 |
| 7. |
Once the system has been bled or
the brake-fluid changed, it is
advisable to carry out a
low-pressure leaktightness test.
Needless to say, the precondition
is that bleed nozzle, filler hose
and overflow hose (bleed hose)
are also completely leaktight.
All system bleed valves must be
closed. With the selector lever
still at the "fill and bleed"
position, check the overpressure
reading on the working-pressure
gage.
|
| 8. |
Now move selector lever to
position for leaktightness test.
For approx. 5 minutes, the
reading of the working-pressure
gage must remain unchanged.
If pressure drops within this
period there is a leak in the
braking system or clutch. |
|
|
| 9. |
Push dust caps onto bleed valves.
Use an extractor to bring the
level of fluid in the reservoir
down to the max. mark. Insert
filter screen and screw on
reservoir cap. |
|
| 47 - 22 |
Notes on Bleeding Braking System
and Changing Brake Fluid |
Printed in Germany |
|
Technical Data 924 S / 944 / 944 S / 944 S2
Steering
Steering wheel
Steering wheel ratio
at middle
Turning circle diameter
Track circle diameter
Steering wheel turns
from lock to lock
|
Standard:
Optional:
|
Rack-and-pinion steering, with hydraulic power
assistance as optional extra-power steering
(introduced in the course of model year '83)
380 mm dia.
360 mm dia.
| 22.39 : 1 |
(power steering
LHD 18.85 : 1
RHD 18.96 : 1) |
10.75 m
10.1 m
| 3.84 - 4.02 |
(power steering
LHD 3.24
RHD 3.26) |
|
Technical data 924 S / 944 / 944 S / 944 S2
Printed in Germany - XXVI, 1993
|
48 - 1 |
|
TORQUE SPECIFICATIONS FOR STEERING
| Location |
Description |
Threads |
Material |
Tightening
Torque
Nm (ft lb) |
Axle shaft to
steering gear and
steering column
Steering gear to
cross member
Cover for pinion
bearing
Cover for thrust-
piece mount
Locknut for
adjusting screw
Tie rod to
steering knuckle
Tie rod to rack (not
for power steering)
Tie-rod joint to
tie rod (not for
power steering)
Steering wheel to
steering colum
Steering colum
switch to outer tube
Outer tube to body
Mount to body
|
Self-locking
hex nut
Hex bolt
Hex bolt
Hex bolt
Hex nut
Castle nut
Locknut
Locking
nut
Hex nut
Hex nut
Socket-head
bolt
Hex bolt
Socket-head
bolt/hex bolt
Hex bolt
|
VM 8
M 8
M 6
M 6
M 10x1
M 12x1.5
M 12x1.5
M 22x1.5
M 14x1.5
M 16x1.5
M 8
M 5
M 8
M 6
|
12
8.8
8.8
8.8
22 H
8
C15Pb
17 H
17 H-2
8.8
8.8
8.8
|
30 + 5
(22 + 3.6)
23 (17)
7 (5.1)
7 (5.1)
25 (18)
30 + 20
(22 + 14)
50 (37)
50 (37)
30 (22)
45 (33)
15 (11)
4 (2.9)
23 (17)
7 (5.1)
|
| 48 - 02 |
Torque Specifications |
Printed in Germany |
|
| Location |
Description |
Threads |
Material |
Tightening
Torque
Nm (kpm) |
Power Steering*
Tie rod to rack
Tie rod joint to
tie rod
Feed and return
lines on steering
gear
Feed line on power
pump
Ring hose nipple
for intake hose
on power pump
|
Tie rod
Nut
Hollow union bolt
Hollow union bolt
Hollow union bolt
|
M 14 x 1.5
M 14 x 1.5
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
|
17 H
6.8
6.8
6.8
|
70 (7.0)
70 (7.0)
20 (2.0)
30 (3.0)
45 (4.5)
|
* Values not listed here are the same as for cars without power steering.
| Printed in Germany - V, 1985 |
|
48 - 03 |
|
Removing and installing manual steering gear
Tools
| No. |
Description |
Special Tool |
Order number |
Explanation |
1
2
3
- |
Torque wrench Stahlwille
730 R/20 or Hazet
6292-1 CT
Wrench socket
Tie-rod puller
Centering bolt
|
9116 |
000.721.911.60 |
commercially
available (refer to
workshop manual)
commercially
available, e.g.
Hazet or Stahlwille
(24 mm across flats)
commercially
available, e.g.
Nexus 168 - 1
|
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991
|
48 - 05 |
|
| 48 - 06 |
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991 |
|
| No. |
Description |
Qty. |
Note: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9 |
Self-locking hexagon
nut
Hexagon head bolt
Split pin
Castle nut or
lock ring
Hexagon head bolt
Washer
Clamp
Steering tie rod assy.
Lock nut
|
1
1
2
2
4
4
2
2
2 |
only present if castle
nut is fitted
if the steering or the tie-
rod(s) are to be replaced,
start by slackening the
castle nut(s), item 9.
undo only if the steering
or the tie rod(s) have to
be replaced.
|
replace, tighten to
30 Nm (22 ftlb)
when fitting steering
shaft, avoid putting the
shaft under strain
replace
Tighten castle nut to
30 Nm (22 ftlb), turn
to next split pin hole it
required (max. torque
50 Nm (37 ftlb)).
Tighten lock nut to
50 Nm. (37 ftlb)
tighten to 23 Nm (17 ftlb)
Fit with Contifix or
Capella - Oil B Waxfree
(supplied by Texaco).
Note instructions for
Capella assembly oil
on page 48 - 010.
when replacing, note
references on page
48 - 011 (3 versions).
Adjust with the steering
rack blocked
(page 48 - 011).
tighten to 50 Nm
(37 ftlb) with the steer-
ing rack adjusted cor-
rectly.
Check adjustment again
after having tightened
the adjustment.
|
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991
|
48 - 07 |
|
| No. |
Description |
Qty. |
Note: |
Removal |
Installalion |
10
11
12
13
14
15
16
17
18
|
Steering stop ring
Bellows, left-hand
Clamp
Bellows, right-hand
Rack-and-pinion
steering gear
Rubber insert,
right-hand (1 x)
left-hand (1 x)
Plug
Ball joint
Hexagon nut
|
2
1
1
1
1
2
1
2
2 |
center in centered posi-
tion relative to steering
gear, remove plug |
install in correct position.
Caution:
Never omit the stop ring
when fitting the steering
tie-rod to the steering
gear since this may
cause the tie-rod to
retract fully into the
steering gear housing
(risk of damage to the
steering)
check, replace if required
replace, only fitted to
RH side
check, replace if required
Never fit steering tie-
rod(s) without stop
ring, item 10.
Coat fully extended
tie-rod ends with VW
steering gear grease
AOF 063 000 04.
check, replace if required
replace if required
check, make sure cor-
rect version is fitted
when parts are replaced
(refer to spare parts
catalog)
|
| 48 - 08 |
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991 |
|
Removal and installation notes
Removal
| 1. |
Take off front wheels and driveline undertray.
|
| 2. |
Remove stabilizer by unbolting the stabilizer
supports at the control arms and the stabi-
lizer mounts at the side members.
|
| 3. |
Remove universal joint bolt from steering
gear. |
|
|
| 4. |
Loosen four steering gear fastening screws
far enough (do not unbolt completely) to
allow the articulated shaft to be removed
from the steering pinion.
If the steering gear and/or the tie-rod has to
be replaced, start by unbolting the tie-rod(s)
at the steering rack (do not remove yet).
Extend the steering rack as little as possible
out of the steering gear housing on the side
to be dismantled.
|
| 5. |
Press off tie rods (ball joints) using a com-
mercially available puller. |
| 6. |
Now screw the four fastening screws all the
way out and move the steering gear to the
front. |
|
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991
|
48 - 09 |
|
Installation
| 1. |
If the steering gear is being replaced, install
the rubber inserts and mounting clamps in
the correct position and coat with Capela-
Oil B Waxfree (supplied by Texaco)*.
Extend steering rack ends completely
and coat with VW steering gear grease
AOF 063 000 04.
|
| 2. |
Push articulated shaft in correct position
(steering wheel and steering gear in center
position) onto steering gear with the steer-
ing fastening screws screwed on only lightly
(to facilitate assembly).
|
| 3. |
Tighten steering gear. Tightening torque
23 Nm (17 ftlb). Tighten fastening screw of
articulated shaft with 30 Nm (22 ftlb).
|
| 4. |
If the tie-rods have been removed, assemble
them to the steering rack. Make sure the
relevant features are kept in mind.
Refer to page 48 - 011.
|
| 5. |
If required, readjust toe. |
|
|
Adjusting the steering
Adjustment operations are described on
page 48 - 18.
This is applicable to the manual steering
gear only.
The power steering gear is not adjustable.
|
* Capella assembly oil is no longer marketed. It is now replaced by Omnis 32.
| 48 - 010 |
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991 |
|
Tie-rods - Versions / Assembly
Versions
| A = |
Original version. For replacement purposes, version B may be fitted in pairs.
|
| B = |
Modified, rubber-damped version. Used on 944 up to end of MY '86 and on 924 S
irrespective of model year. Dimension X  343 mm
|
| C = |
Rubber-damped version for 944 MY '87. Slightly longer than version B.
Dimension X 374 mm. |
Assembly to steering gear
| - |
Center steering gear in center position using Special Tool 9116 (arrow).
|
| - |
Bolt on tie-rods uniformly complete with steering stop ring.
Distance a - steering gear housing to rubber stop = 64 - 1 mm.
|
| - |
Tighten lock nut with 50 Nm (37 ftlb). Refer to notes on page 44 - 012. |
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991
|
48 - 011 |
|
Important notes
During tightening, the stop surface at the steering stop ring shifts by approx. 1 mm.
I.e. adjusting distance a must be checked and readjusted, if required, after the lock nut has been
tightened.
The steering stop ring must not be omitted under any circumstances when the steering box or the
steering tie-rod is refitted. Otherwise the tie-rod may retract fully into the steering gear housing, caus-
ing the steering rack guide sleeve to be damaged.
Before refitting the protective sleeves (bellows), extend the steering tie-rods fully and coat the tie-rod
ends with VW steering gear grease AOF 063 000 04.
| 48 - 012 |
Removing and installing manual steering gear
Printed in Germany - XXIV, 1991 |
|
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2
3
|
Torque wrench
Stahlwille 730 R/20 or
Hazet 6292·1 CT
Wrench socket
Tie rod puller
|
9183 |
|
| Printed in Germany - I, 1982 |
| Removing and Installing Power Steering Gear |
|
48 - 1 |
|
A - SUCTION HOSE
B - PRESSURE LINE
C - RETURN LINE
| 48 - 2 |
Removing and Installing Power Steering Gear |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12
13 |
Hollow union bolt
Seal
Self-locking nut
Bolt
Cotter pin
Castle nut
Hollow union bolt
Seal
Steering tie rod
assy.
Dust cover
Bolt
Washer
Rack-and-pinion
power steering
gear
|
|
only present if
castle nut is
fitted
Only loosen if
steering or steering
tie rod(s) have to
be replaced
|
Torque:
30 Nm (22 ft lb)
Replace
Replace; torque:
30 Nm (22 ft lb)
Replace
Torque:
30 Nm (22 ft lb)
If necessary turn
further to next cotter
pin hole
(max. torque:
50 Nm - 36 ft lb)
Torque:
20 Nm (14 ft lb)
Replace
Use torque wrench
with 9183.
Torque:
85 Nm (61 ft lb)
Lock (peen) after
tightening
Check, replacing if
necessary
Torque:
23 Nm (17 ft lb)
Coat ends of
completely run out
pinion with VW
steering gear grease
AOF 063 000 04
|
Tighten lock nut
to 50 Nm
|
| Printed in Germany - XXIV, 1991 |
| Removing and Installing Power Steering Gear |
|
48 - 3 |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
14
15
15a
16
17 |
Clamp
Rubber insert,
right
Rubber insert,
left
Ball joint
Nut
|
2
1
1
2
2 |
|
Install with Contifix
or Capella-Oil 8 Wax-
free (Texaco) *
Check, replacing if
necessary
Check, replacing if
necessary
Check, replacing if
necessary
|
|
| * |
Capella assembly oil is no longer marketed. It is now replace by Omnis 32. |
| 48 - 4 |
Removing and Installing Power Steering Gear |
Printed in Germany |
|
REMOVING AND INSTALLING POWER STEERING GEAR
R e m o v i n g
| 1. |
Take off front wheels and splash shield.
|
| 2. |
Remove stabilizer by disconnecting stabilizer
mounts on control arms and stabilizer suspension on side members.
|
| 3. |
Disconnect ground wire on front axle cross
member. |
|
|
| 4. |
Loosen (do not remove) tie rod(s) on steering
rack with 9183 used in conjunction with a
suitable torque wrench. Only unscrew when
steering and/ or tie rod(s) have to be replaced.
The rack should then only be run out of steering
gear case as far as necessary on the
disconnecting side. |
| 5. |
Disconnect pressure line on power steering pump.
Catch hydraulic fluid running out of pump or
tank and power steering gear (never reuse). To
make sure that approximately all of the fluid
runs out of steering, position pressure line
(connection) lower than the steering and turn
the steering wheel from stop to stop several times. |
|
| Printed in Germany - I, 1982 |
| Removing and Installing Power Steering Gear |
|
48 - 5 |
|
| 6. |
Remove bolt on universal joint. Loosen (do not
unscrew completely) four mounting bolts of
steering gear until shaft can be removed from
steering pinion.
Unscrew pressure line clamp on steering gear to
have access to the left lower mounting bolt. |
| 7. |
Press out tie rods (ball joints) with a standard puller. |
|
|
| 8. |
Unscrew return line on steering gear. |
| 9. |
Now unscrew the four mounting bolts completely and take out steering gear forward. |
I n s t a l l i n g
| 1. |
If a new steering gear is being installed, mount
rubber inserts and clamps in correct position
with Cappela-Oil B Waxfree (Texaco) before
installing steering gear in car. Screw on pressure
line; tightening torque for hollow union bolt:
20 Nm (14 ft lb).
Coat ends of completely extended rack with VW
steering gear grease AOF 086000. |
|
| 48 - 6 |
Removing and Installing Power Steering Gear |
Printed in Germany |
|
| 2. |
Slide shaft on steering gear in correct position
(steering wheel and steering gear in center position).
The steering gear mounting bolts should only be
screwed in lightly for this job to facilitate installa-
tion.
|
| 3. |
Mount steering gear. Tightening torque:
23 Nm (17 ft lb). Tighten mounting bolt of
shaft to 30 Nm (22 ft lb).
|
| 4. |
Mount tie rods (if removed - see point 4) on
rack with a torque of 85 Nm (61 ft lb). Bend
down collar on opening of rack to lock. Make sure
that this does not damage surface of rack (leakage). |
|
|
| 5. |
After installing all parts, fill system with
hydraulic fluid, bleed steering system, check
for leaks and test function (see page 48 - 11).
|
| 6. |
Adjust toe, if necessary. |
|
| Printed in Germany - I, 1982 |
| Removing and Installing Power Steering Gear |
|
48 - 7 |
|
REMOVING AND INSTALLING POWER STEERING PUMP
R e m o v i n g
| 1. |
Remove splash shield.
|
| 2. |
Disconnect pressure line on power steering pump.
Catch escaping hydraulic fluid. but do not reuse. |
| 3. |
Remove intake hose after loosening clamp. |
|
|
| 4. |
Unscrew connecting rod on power steering pump and nut (arrow).
Turn connecting rod down. |
| 5. |
Remove mounting nut I and mounting bolt II.
Take off drive belt. |
|
| 48 - 8 |
Removing and Installing
Power Steering Pump
|
Printed in Germany |
|
| 6. |
Swivel power steering pump upward
on its bracket and remove spacer
from below. |
| 7. |
Take power steering pump out of bracket. |
I n s t a l l i n g
| 1. |
If the power steering pump pulley
has been removed, use Loctite
270 to secure the 3 mounting
bolts.
|
| 2. |
Install power steering pump in
car. Check and adjust drive-belt
tension (see page 13 - 2 a).
|
| 3. |
Make sure delivery line and
intake hose are correctly routed
(to prevent rubbing) when the
power steering pump is installed. |
|
|
| 4. |
Fill system with hydraulic fluid,
bleed steering system, check for
leaks and test function. |
|
| Printed in Germany - XIII, 1987 |
Removing and Installing
Power Steering Pump |
|
48 - 9 |
|
Checking and servicing the rack-and-pinion power steering
General
Power steering damage occurs due to lack of
oil in the hydraulic circuit. Even minor leaks
may cause the fluid to escape due to the high
oil pressure inside the hydraulic circuit and
may result in damage to the power-steering
pump.
Grunt sounds noticeable when turning the
steering wheel or foaming in the supply tank
indicate a lack of oil and/or air ingress.
Before topping up the supply tank, however,
eliminate any leaks in the inlet side and/or
replace any defective parts of the pressure
side.
Important note
Do not attempt to repair or dismantle rack-
and-pinion steering gear and power steer-
ing pump. Both steering gear and power
steering pump are available on an exchange
basis in various countries.
In countries that do not operate an exchange
part scheme, the steering gear as well as the
power steering pump may in certain cases be
reconditioned by an authorized ZF dealership.
|
|
Checking the power steering pump drive
belt tension
Refer to page 13 - 2a for the drive belt
tension.
Checking the steering system for leaks
(visual check)
With the engine running at idle, turn the steer-
ing wheel to lock and keep in that position.
This allows maximum line pressure to build up.
With the steering wheel in this position, check
all line connections for tightness, retighten if
necessary.
Run this check for max. 10 sec. If the check
requires more time, allow for a short break
every 10 seconds.
Checking the power steering fluid level
Screw off supply tank cover.
The supply tank is fitted to the right-hand
wheel house wall inside the engine compart-
ment.
|
Checking and servicing the rack-and-pinion power steering
Printed in Germany - XXIV, 1991
|
48 - 11 |
|
| 2. |
Run engine at idle. Wipe off dipstick, screw
cover back on and remove again. The fluid
level must be between both marks. If re-
quired, top up with ATF-DEXRON II D. |
Bleeding the steering system
| 1. |
To bleed the complete system after new
steering components or lines have been
fitted or after excessive hydraulic fluid los-
ses have been remedied, start engine
several times and turn off immediately as
soon as it has started. This process
causes the fluid level in the supply tank
to drop rapidly. Make sure to top up
continuously using ATF Dexron 11 D.
The supply tank must never run empty. |
Note
To facilitate refitting, establish the fluid level
using a measuring tape while topping up con-
stantly. Fluid level: approx. 40 mm from top
edge of supply tank.
|
|
| 2. |
As soon as the fluid level no longer drops
when the engine is started for a short mo-
ment, start the engine again and let it run
at idle speed.
|
| 3. |
Turn steering wheel rapidly from lock to lock
several times to allow air to escape from the
cylinders. When reaching the end position
of the piston, do not pull harder on the steer-
ing than is required for turning the steering
(to avoid unnecessary pressure buildup).
|
| 4. |
Check fluid level while performing this opera-
tion. If it continues to drop, top up until the
fluid remains at a constant level and no
more air bubbles rise in the supply tank
when the steering wheel is turned. |
Note
When stopping the engine, the fluid level
in the supply tank must not rise by more
than 10 mm.
If the fluid level with the engine stationary
and running, respectively, deviates by more
than 10 mm, trapped air remains in the
hydraulic fluid.
| 5. |
With the engine running at idle, establish
correct fluid level (between min. and max.
marks) without turning the steering wheel. |
|
| 48 - 12 |
Checking and servicing the rack-and-pinion power steering
Printed in Germany - XXIV, 1991 |
|
TOOLS
N o t e :
All parts (items 1 - 6) can be used for 944 and 928 models.
The pressure gage is mounted between power pump and pressure line (928: between pressure line and
steering gear).
If old pressure gage (no. 3, see below) is used, make sure high pressure hoses (no. 2 and no. 5) are
connected on pressure gage in correct position (sides mixed in comparison to 928).
Any connection of high pressure hoses is possible on pressure gage no. 3 a.
TOOL TABLE / PAGE 48 -14
* Depending on pressure gage version, M 18 x 1.5 or M 16 x 1.5 threads (see Tool Table).
| Printed in Germany - I, 1982 |
Checking Hydraulic Operation of Steering
(Pressure Test) |
|
48 - 13 |
|
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2
3
3a
4
5
6 |
Adapter
High pressure hose
up to 200 bar,
1.5 meters long
(2900 psi, 5 ft long)
Pressure gage
0 - 250 bar
(0 - 3600 psi)
Pressure gage
0 - 160 bar
(0 - 2300 psi)
Adapter
High pressure hose
200 bar, 2 meters long
(2900 psi,
6.5 ft long)
Connector
|
V. A. G. 1402
or US 1074 B
|
Made locally for pressure gage
(item no. 3); see sketch on page 48 - 13
Made locally for pressure gage
(item no. 3 a) with deviation from
sketch; threads not M 18 x 1.5
(for gage no. 3)
b u t M 1 6 x 1 . 5
Standard.
M 18 x 1.5 and sealing head on one end,
M 18 x 1.5 and flat seal on other end
for pressure gage no. 3.
M 16 x 1.5 and sealing head on one end,
M 16 x 1.5 and flat seal on other end
for pressure gage no. 3 a
Old version; no longer available
Standard,
M 18 x 1.5 to M 16 x 1.5
(not required for pressure gage 3 a)
Standard,
M 16 x 1.5 and sealing head on both ends
Standard,
M 16 x 1.5 and sealing head on one end
and M 14 x 1.5 with flat seal on other end
|
| 48 - 14 |
Checking Hydraulic Operation of Steering (Pressure Test) |
Printed in Germany |
|
CHECKING HYDRAULIC OPERATION OF STEERING
(PRESSURE TEST)
G e n e r a l I n f o r m a t i o n
Tester (pressure gage) is installed between power
pump and pressure line. If using old pressure gage,
install in correct position. Connections and lever
positions are marked for better understanding of
the following instructions.
O l d V e r s i o n
V. A. G. 1402 or US 1074 B
I
II
III
IV
V |
- Shut-off valve open
- Shut-off valve closed
- Restrictor
- From power pump
- To pressure line |
|
|
I n s t a l l i n g P r e s s u r e G a g e
| 1. |
Remove splash shield.
|
| 2. |
Detach pressure line on power pump. Catch
hydraulic fluid (but do not reuse). |
| 3. |
Screw high pressure hose no. 5 with connector
on power pump (use 14 x 18 seal). |
|
| Printed in Germany - I, 1982 |
| Checking Hydraulic Operation of Steering (Pressure Test) |
|
48 - 15 |
|
| 4. |
Mount 1.5 meter long high pressure hose
no. 2 on pressure pipe with help of hollow
bolt and adapter no. 1 (seals 2 x 14 x 18
and 1 x 18 x 22 or 1 x 16 x 20 are
required). |
| 5. |
Install pressure gage between high pres-
sure hoses and place on stand (e.g. tool-
box) in front of car in view of tester.
Make sure hose section of pressure line
is not bent off. Test hose must also have
safe distance to drive belts or pulleys. |
N o t e
Use adapter no. 4 and install high pressure
hose no. 5 on connection IV of pressure
gage in case of the old pressure gage version.
|
|
| 6. |
Open shutoff valve on pressure gage
(lever position I), fill supply tank and
bleed steering system (see page
48-11). |
C h e c k i n g D e l i v e r y P r e s s u r e
o f P o w e r P u m p
| 1. |
Close shutoff valve (lever position II)
with engine running at idle speed and
read pressure. Specification: 100 to
120 bar. Open shutoff valve again
immediately. |
N o t e
Shutoff valve should not be closed longer
than 5 seconds because of wear. Lever posi-
tion II right or II left must be selected for
pressure gage version 3a depending on how
high pressure hoses are connected on the
pressure gage. (No display with wrong lever
position II.)
| 2. |
Replace power pump, if specified value
is not reached or exceeded. |
C h e c k i n g S y s t e m P r e s s u r e
| 1. |
Let engine run at idle speed. Shutoff
valve must be open (lever position I).
|
| 2. |
Turn steering wheel against left and
right locks and read hydraulic pressure
from pressure gage each time. Specifica-
tion: 100 to 120 bar. It is not sufficient
that only the steering stop is effective,
but instead the returning force of the
rotary piston valve must also be over-
come. Force on steering wheel: approx.
100 N (10 kp).
|
| 3. |
If the specified value is not reached on
the left or/and right sides (excessive
leak oil flow), replace complete steering
gear. |
|
| 48 - 16 |
Checking Hydraulic Operation of Steering System
(Pressure Tests) |
V, 1985 - Printed in Germany |
|
REMOVING AND INSTALLING STEERING
WHEEL *
Removing
| 1. |
Pull impact pad off of steering
wheel with wheels in straight
ahead position. Begin at bottom
(only 4 spoke steering wheels)
and outside to avoid damage.
Pull off horn wires. |
| 2. |
Mark position of steering wheel
to steering shaft for
installation later.
|
| 3. |
Unscrew nut and take off steering
wheel with washer. |
|
|
Installing
| 1. |
Mount steering wheel with road
wheels in straight ahead position
or that marks are aligned in such
a manner, that steering wheel
spokes are horizontal
|
| 2. |
Install nut with washer and
torque to 45 Nm (4.5 kpm).
|
| 3. |
Mount horn wires on impact pad
and press impact pad onto
retaining pins.
|
| 4. |
Check function of horn and self-
cancelling action of turn signal
switch. |
|
| * |
Not applicable to airbag steering wheel (see Page 68-8 for marking
on airbag unit on the steering wheel). See Page 68-9 for removing
and installing airbag steering wheel.
|
| Printed in Germany - XVI, 1987 |
Removing and Installing
Steering Wheel |
|
48 - 17 |
|
Removing and Installing the steering shaft with protective tube
as from Model 85/2
Removing and installing the steering shaft with protective tube as from Model 85/2
Printed in Germany - XVII, 1988
|
48 - 19 |
|
Removing and installing the steering shaft with protective tube
as from Model 85/2
 83-48
| 48 - 20 |
Removing and installing the steering shaft with protective tube as from Model 85/2
Printed in Germany - XVII, 1988 |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 |
Cap
Hexagon nut
Spring washer
Steering wheel
Steering column switch
Breakaway screws
Steering-lock housing
Breakaway screw
Hexagon head screw
Washer
Shims
Hexagon head screw
Washer
Support ring
Rubber bearing
Lock nut
Hexagon head screw
|
1
1
1
1
1
2
1
1
1
2
x
2
2
1
1
2
2 |
Drill out
Chisel out
|
Tightening torque
45 Nm
Replace if necessary
Center the steering in
the middle position with
Special Tool 9116. lubri-
cate the hub with
MoIykote A and push on
with the spokes horizon-
tal
Tightening torque
23 Nm
Use the same number
as removed
Tightening torque
7 Nm
Apply a film of Contifix
Replace, Tightening
torque 30 + 5 Nm
|
Removing and installing the steering shaft with protective tube as from Model 85/2
Printed in Germany - XVII, 1988
|
48 - 21 |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
18
19
20
21
22
23
24
25
26 |
Protective tube
Steering cross-link
Circlip
Shim
Steering shaft
Needle bearing
Screw
Ignition-starter switch
Lock cylinder
|
1
1
1
1
1
1
2
1
1 |
See Page 94 - 5
|
Check the ball bearing,
replace the steering rod
tube if necessary
Install without stresses
Install without stresses
|
| 48 - 22 |
Removing and installing the steering shaft with protective tube as from Model 85/2
Printed in Germany - XVII, 1988 |
|
Notes on assembly
Removing
| 1. |
Disconnect the battery.
|
| 2. |
Remove the steering wheel (see Page 48 -
17, see Page 68 - 9 for the airbag steering
wheel). Loosen the cover panel on the left-
hand side of the switchboard. |
| 3. |
Loosen the cover panel from the steering
column switch and remove the cover for the
fastening screws in the switch panel.
|
|
|
| 4. |
Undo the fastening screws for the switch
panel and remove. Separate the plug con-
nection. |
| 5. |
Remove the knobs from the control switch.
Loosen the control switch panel carefully
with a spatula. |
|
Removing and Installing the steering shaft with protective tube as from Model 85/2
Printed In Germany - XVII, 1988
|
48 - 23 |
|
| 6. |
Undo the fastening screws for the control
switch and the steering lock cover. |
7. Remove the steering column switch.
|
|
| 8. |
Separate the plug connection for the ignition-
starter switch. Drill out the breakaway
screws in the steering column housing and
remove the housing. |
Note:
Make sure that the shims between the casing
tube and chassis do not get lost.
| 9. |
Chisel out the breakaway screw in the
protective tube and undo the hexagon head
screw. |
|
| 48 - 24 |
Removing and Installing the steering shaft with protective tube as from Model 85/2
Printed In Germany - XVII, 1988 |
|
| 10. |
Undo the hexagon head screws for the
support bearing. |
Note
944 turbo: the exhaust shield plate must be un-
done before removing the upper screw con-
nection for the steering cross-link.
| 11. |
Disconnect the cross-link from the steering
shaft. |
|
|
| 12. |
Disconnect the cross-link from the steering
gear. |
| 13. |
Pull out the steering shaft with protective
tube towards the interior of the vehicle.
|
| 14. |
Remove the circlip and shim from the steer-
ing shaft and pull the shaft out of the
protective tube. |
Installing
Note:
The assembly sequence must always be ob-
served to ensure stress-free installation of the
cross-link and steering shaft.
| 1. |
Apply a film of Contifix to the support ring
rubber bearing and slide both together onto
casing tube.
|
| 2. |
Install cross-link and protective tube with
steering shaft. all fastening screws remain
loose. |
|
Removing and Installing the steering shaft with protective tube as from Model 85/2
Printed In Germany - XVII, 1988
|
48 - 25 |
|
| 3. |
Tighten the fastening screw between cross-
link and steering shaft (upper), and then
tighten the fastening screw from the cross-
link to the steering gear (lower).
|
| 4. |
Use the same number of shims to adjust the
protective tube as were removed. (The steer-
ing shaft should be in the middle of the
upper edge of the dashboard cutout and the
support console).
|
| 5. |
Tighten the fastening screws for the protec-
tive tube. Adjust the support bearing and
tighten the fastening screws.
|
| 6. |
Adjust the steering-lock housing, the spigot
for the steering-wheel lock must engage
easily. Tighten the breakaway screws but do
not break off.
|
| 7. |
Adjust the steering column switch and
mount the steering wheel briefly. There
should be 2 - 4 mm play between the steer-
ing column switch and the steering wheel.
|
| 8. |
Once a functional and visual inspection has
been carried out on all relevant com-
ponents, break off the breakaway screws.
|
| 9. |
Install panels and covers.
|
| 10. |
Center the steering in the middle position
with Special Tool 9116 and mount the
steering wheel (lubricating the hub with
Molykote A), with the spokes horizontal. |
| 48 - 26 |
Removing and Installing the steering shaft with protective tube as from Model 85/2
Printed In Germany - XVII, 1988 |
|
Safety notes
Observe the following safety notes when performing body repairs:
| * |
Removal of components may change the gravity center of the vehicle.
The vehicle may therefore have to be tied down by additional measures on the lifting platform.
|
| * |
If welding or other spark-generating operations are performed in the vicinity of the battery,
the battery must be removed as a rule.
|
| * |
Rooms designated for body repairs may not be used to stock other vehicles without protection
(risk of fire damage due to sparks, battery, paint and body glass damage).
|
| * |
Be extremely careful when grinding or welding in the vicinity of the fuel tank and other parts of
the fuel system. If necessary, remove any components affected.
|
| * |
Do not weld, braze or solder any parts of the filled air conditioning system. This also applies to
welding, brazing or soldering operations on the vehicle that may result in the risk of components
of the air conditioning system warming up.
|
| * |
When drying the vehicle following a respray, do not expose the vehicle to temperatures of
max. 80°C for more than 2 hours. |
To protect electronic control units against excessive voltage when using electric welding equipment,
observe the following safety measures:
| * |
Disconnect clamp from negative battery terminal and cover negative battery terminal.
|
| * |
Connect ground clamp of the electric welding equipment directly and as closely as possible to
the component to be welded. Make sure no electrically insulated parts are located between the
ground clamp and the welding location.
|
| * |
Do not touch electronic control units and electric lines with the ground clamp or with the welding
electrode. |
Safety notes
Printed in Germany - XXIV, 1991
|
50 - 01 |
|
Treatment of electronic control units following accident repairs
Following an accident, electronic control units have to be replaced only if at least one of the
following conditions is met:
* The housing is visibly deformed or damaged.
* The support area and/or console is deformed (no outside damage evident on the unit).
* The connector is damaged or corroded due to moisture.
* Operation check and/or self-diagnosis of the units reveals the following fault:
"Control unit faulty".
If electronic components, e.g. the ABS control unit, have to be removed to allow repair operations
to be performed and if they are to be reused afterwards, they must be checked for proper operation
according to specifications after they have been refitted.
| 50 - 02 |
Safety notes
Printed in Germany - XXIV, 1991 |
|
ECONOMICAL BODY REPAIRS ON CELETTE ALIGNMENT BENCH
The attachment set ENS 224.300 was developed for drawing and straightening jobs on the body. This
attachment set consists of the basic equipment for Type 924, with which all of the important body take-up
points can be checked.
The new rear axle attachments are included in ENS 224.309 for cars beginning with 1978 model with the
modified rear axle.
For cars with modified control arm take-ups on the front axle, beginning with 1979 model, the pertinent
elements are part of attachment set ENS 224.308.
The side members in the front end of Type 944 cars have been changed in the area of the front control
arm take-ups. Attachment set ENS 224.307 is required to check these points and the rear control arm
take-ups.
The basic set ENS 224.300, attachment set ENS 224.307 and attachment set ENS 224.309 are required
for drawing and straightening jobs on Type 944.
The spring strut drifts and auxiliary platform take-ups must be adjusted to zero. The max. permissible
axial tolerance is ± 3 mm, whereby the difference between left and right may be max. 4 mm.
The height tolerance for all take-up points is 4 mm. The body should bolt on the attachment set at all
take-up points.
Celette Alignment Bench with Basic Set
| Printed in Germany |
| Body Repair Jobs on Celette Alignment Bench |
|
50 - 03 |
|
CELETTE ALIGNMENT BENCH -
UNIVERSAL ANCHORAGE
Remove the ribbed clamping shoes on the bearing
blocks (arrows) to mount a Type 944 body on the
Celette alignment bench with universal anchorage.
| 50 - 04 |
Celette Universal Anchorage |
I, 1982 - Printed in Germany |
|
Repair checking dimensions - Cabrio
Additions and differences of cabriolet to coupe bodywork dimensions
Remarks
Dimensions are measured direct and are therefore angled!
All dimensions are measured to center of hole!
Important!
For the axial dimensions the left/right deviation must not exceed the prescribed tolerance!
Repair checking dimensions - Cabrio
Printed in Germany - XXII, 1990
|
50 - 05b |
|
Repair checking dimensions - Cabrio
| Line |
Line designation |
mm |
A
B
C
D
E
F
G
H
I
K
L
M
N
O
P
Q |
Windshield frame corner left to corner right
Front bolting points of folding top bearings
Rear bolting points of side elements
Windscreen wiper mounting hole - corner of windshield frame
Windshield frame corner diagonally to front
bolting point of folding top bearing
Front bolting point of folding top mounting diagonally
to rear bolting point of side element
Front bolting point of folding top bearing to
mounting hole of closing cylinder, center rear
Front bolting point of folding top bearing to rear
bolting point of side element
Windshield frame corner horizontally to spot
welding flange of door sill (measured without cover strip)
Windshield frame corner to front bolting point
of folding top bearing
Top of B-pillar to folding top bearing
Top of B-pillar, parallel, to spot welding flange
of door sill
From Plan 0 to fastening point of tunnel strut
Fastening points of tunnel strut inside
Fastening points of tunnel strut outside
From Plan 0 to center of spring strut mounting
|
1245 ± 3
1442 ± 3
1328 ± 3
985 ± 2
1502 ± 3
1763 ± 3
1555 ± 3
1094 ± 3
790 ± 2
685 ± 2
26 ± 1
470 ± 2
790 ± 2
418 ± 2
638 ± 2
27 ± 1
|
All dimensions measured to center of hole!
| 50 - 05c |
Repair checking dimensions - Cabrio
Printed in Germany - XXII, 1990 |
|
Repair checking dimensions - Cabrio
Repair checking dimensions - Cabrio
Printed in Germany - XXII, 1990
|
50 - 05d |
|
DIMENSIONS FOR FLOOR PLATE/FRONT END
| Distance |
Description |
mm |
| A |
Side member take-up hole, front |
710 ± 3 |
| B |
Side member take-up hole, center |
758 ± 1 |
| C |
Side member take-up hole - control arm take-up |
330.4 ± 3 |
| D |
Side member take-up hole - rear cross member bolt |
599 ± 3 |
| E |
Rear cross member bolt - front cross member bolt |
120 ± 0 |
| F |
Side member take-up hole - stabilizer bolt |
831 ± 3 |
| G |
Outer control arm take-up - side member take-up hole |
1080 ± 5 |
| H |
Side member take-up hole - side member front edge |
1340 ± 5
(1360) |
| I |
Side member take-up hole - front side member take-up hole |
1127 ± 5
(1145) |
I m p o r t a n t !
The deviation between left and right must not exceed the specified tolerances for axial and diagonal
distances.
All distances are measured from or to center of hole and bolt as well as horizontally. Distances in brackets
are determined directly with a measuring tape.
| Printed in Germany |
|
50 - 07 |
|
| 50 - 08 |
Dimensions for Floor |
Printed in Germany |
|
| 9 4 4 |
B o d y - F r o n t S e c t i o n |
50 |
SIDE MEMBERS
In comparison to 1981 model 924 cars the front side members of the floor assembly have been
changed.
Take-up points for cross member and stabilizer are incorporated in the side members.
| Printed in Germany |
|
50 - 1 |
|
| 50 |
B o d y - F r o n t S e c t i o n |
9 4 4 |
LOCK CARRIER GAUGE 9117/1
The former gauge 9117 can only be used on Type 924 cars up to and including 1979 models. Beginning
with this date there were changes in the area of the inner pivot point installation.
The new gauge 9117/1 can be used for all 924 and 924 Turbo cars as well as 944 models from beginning of
production.
It is required for accurate welding of the lock carrier. It can also be used to check installation of concealed
headlight mounts.
| 50 - 2 |
Gauge 9117/1 for Lock Carrier |
Printed in Germany |
|
| 9 4 4 |
B o d y - F r o n t S e c t i o n |
50 |
FRONT AXLE TAKE-UP ATTACHMENT SET ENS 224 307
The attachment set for mounting the body after removal of engine and transmission consists of 2 parts
on each side, both of which are mounted on the cross member and control arm take-ups.
For economical front axle take-up, without removal of front mounted equipment, the control arm bolts
are loosened and the control arm pressed down. The attachment is inserted between the control arm and
body, and then bolted.
| Printed in Germany |
| Front Axle Take-up Attachment Set ENS 224 307 |
|
50 - 3 |
|
| 50 |
B o d y - F r o n t S e c t i o n |
9 4 4 |
ADAPTER 9175/1 FOR ENGINE CROSS MEMBER
AND STABILIZER TAKE-UP
Adapter 9175/1. which can only be used in con-
junction with front end gage 9175 (arrows). has
been designed for Type 944 cars.
After removal of engine/transmission the mounting
points in the side members can be checked for
correct positioning and dimensioning (arrows).
| 50 - 4 |
Adapter 9175/1 for Engine Cross Member and Stabilizer |
I, 1982 - Printed in Germany |
|
| 9 4 4 |
B o d y - F r o n t S e c t i o n |
50 |
REMOVING AND INSTALLING FRONT END PANEL
R e m o v i n g
| 1. |
Raise engine hood and run out concealed
headlights.
|
| 2. |
Cover bumpers and remove cover strips
to avoid damaging the paint finish. |
| 3. |
Unscrew mounting nuts and remove
bolts. |
|
|
|
| Printed in Germany - V, 1985 |
| Removing and Installing Front End Panel |
|
50 - 5 |
|
| 50 |
B o d y - F r o n t S e c t i o n |
9 4 4 |
4. Take end panel off of car forward.
I n s t a l l i n g
| 1. |
Move in end panel from front. Insert
mounting screws. Align end panel and
fenders to be in same plane. Tighten
nuts and screws. |
|
|
| 2. |
Lower engine hood and adjust front
panel that gap between panel and hood
runs at equal distance. Raise engine
hood and tighten screws. |
|
| 50 - 6 |
Removing and Installing Front End Panel |
Printed in Germany |
|
Replacing rear end-panel - Cabrio
The following end-panel is required as a spare part for the bodywork repair:
Replacing rear end-panel - Cabrio
Printed in Germany - XXII, 1990
|
53 - 1 |
|
| 53 |
Bodywork rear |
944 Cabriolet |
Replacing rear end-panel - Cabrio
Removing end-panel from body
| 53 - 2 |
Replacing rear end-panel - Cabrio
Printed in Germany - XXII, 1990 |
|
| 944 Cabriolet |
Bodywork rear |
53 |
Replacing rear end-panel - Cabrio
Removing end-panel from body
Straightening work on the body in this area must be completed before the end-panel is re-
placed!
No.
|
Task |
Instructions |
| 1. |
Separate spot welding joins
of rear end-panel to end
element and to spare wheel
recess pane |
Separate spot welding joins of end-panel to end element
and spare wheel recess panel using welding spot cutter.
|
| 2. |
Separate welding join of
end-panel to end element
Cut out end-panel along side
panels |
Cut through inert gas welding seams between end-panel
and end element using a bodywork saw.
Cut through end-panel to one side of end-panel/side
panel welding joins using a bodywork saw and remove.
|
| 3. |
Separate spot welding and
other welding joins of end-
panel to side panels |
Separate spot welding joins of end-panel to side panels
using a welding spot cutter.
Cut through welding joins of end-panel to side panels
using a bodywork saw. |
Replacing rear end-panel - Cabrio
Printed in Germany - XXII, 1990
|
53 - 3 |
|
| 53 |
Bodywork rear |
944 Cabriolet |
Replacing rear end-panel - Cabrio
Fitting end-panel into bodywork
| 53 - 4 |
Replacing rear end-panel - Cabrio
Printed in Germany - XXII, 1990 |
|
| 944 Cabriolet |
Bodywork rear |
53 |
Replacing rear end-panel - Cabrio
Fitting end-panel into bodywork
No.
|
Task |
Instructions |
| |
Clean welding surfaces |
Clean paint etc. from welding surfaces of body using a
hot-air blower or rotary brush. Remove the factory-ap-
plied primer on the welding surface of the replacement
part (end-panel) using a rotary brush.
|
| |
Prepare plug welding surfaces |
Drill holes in the end-panel at the join points to the end
element and the spare wheel recess panel for plug weld-
ing. Drill holes in the spot welding flange in the side
panels for plug welding to the end-panel.
|
| 1 |
Fit end-panel into bodywork
and tack weld
Assemble tail lights and
bumper to check body
contours |
Fit end-panel into bodywork, align it, fasten with clamp-
ing tools and tack weld using inert gas.
The body contours with the tack-welded end-panel must
fit in with the contours of the tail lights and bumper. Re-
move tail lights and bumper again atter checking.
|
| 2 |
Plug weld end-panel to end
element and spare wheel
recess panel |
Align end-panel with end element and spare wheel
recess panel and plug weld using inert gas.
|
| 3 |
Weld end-panel to end
element and side panels
using inert gas |
Align end-panel with end element and butt weld along
the whole seam using inert gas. Weld end-panel at hori-
zontal joins with side panels along the whole seam
using inert gas.
|
| 4 |
Plug weld side panels to
end-panel |
Align side panels with end-panel in the areas of the spot
welding flanges and plug weld them using inert gas.
|
| 5 |
Spot weld end-panel to spare
wheel recess panel
Grind down welding surfaces
|
Spot weld end-panel to spare wheel recess panel in the
areas of the tail lights and number plate. |
Replacing rear end-panel - Cabrio
Printed in Germany - XXII, 1990
|
53 - 5 |
|
| 53 |
Bodywork rear |
944 Cabriolet |
|
| 944 Cabriolet |
Bodywork rear |
53 |
Replacing rear side panel - Cabrio
The following side panel is required as a spare part for the bodywork repair:
Replacing rear side panel - Cabrio
Printed in Germany - XXII, 1990
|
53 - 7 |
|
| 53 |
Bodywork rear |
944 Cabriolet |
Replacing rear side panel - Cabrio
Removing side panel from bodywork and fitting it
| 53 - 8 |
Replacing rear side panel - Cabrio
Printed in Germany - XXII, 1990 |
|
| 944 Cabriolet |
Bodywork rear |
53 |
Replacing rear side panel - Cabrio
Removing side panel from bodywork and fitting it
Remove all applicates and covering parts on the side panel, inside and outside.
Straightening work on the bodywork in this area must be completed before the side panel is re-
placed!
No.
|
Task |
Instructions |
| |
Separate welding joins of side
panel to end element and
inner side panel |
Cut through inert gas welding seams between side
panel and end-panel and inert gas welding seam be-
tween side panel and inner side panel using a bodywork
saw.
|
| 1 |
Separate spot welding joins
of side panel to end-panel,
inner side panel, wheel arch
and door sill connection
element
|
Separate spot welding joins of side panel to end ele-
ment, inner side panel, wheel arch and door sill connec-
tion element using a welding spot cutter.
Remove side panel. |
| |
Clean welding surfaces |
Clean underseal, paint etc. from welding surfaces on
bodywork using a hot-air blower or rotary brush.
Remove the factory-applied primer on the welding sur-
faces of the replacement part (side panel) using a rotary
brush.
|
| 2 |
Fit side panel into bodywork
and tack weld |
Fit side panel into bodywork, align it, fasten with clamp-
ing tools and tack weld using inert gas.
|
| |
Assemble door, tail light and
bumper to check body
contours |
The body contours with the tack-welded side panel must
fit in with the contours of the tail light, bumper and door.
The gap between the door and the side panel must ex-
hibit a parallel shape.
Remove the door, tail light and bumper again after
checking. |
Replacing rear side panel - Cabrio
Printed in Germany - XXII, 1990
|
53 - 9 |
|
| 53 |
Bodywork rear |
944 Cabriolet |
No.
|
Task |
Instructions |
| 3 |
Weld side panel to inner side
panel with inert gas
Spot weld side panel to inner
side panel
Plug weld door sill connection
element to side panel
|
Align side panel with inner side panel and intermittently
weld along the whole seam (overlapped) using inert gas.
Align side panel with inner side panel (area of B-pillar)
and spot weld.
Align door sill connection element with side panel and
plug weld using inert gas. |
| 4 |
Spot weld side panel to inner
side panel, wheel arch and
door sill connection element
|
Align side panel with inner side panel, wheel arch and
door sill connection element and spot weld. |
| 5 |
Weld side panel to end
element using inert gas
Spot weld side panel to end
element and wheel arch
Plug weld side panel to end
element |
Align side panel with rear end element and butt weld
along the whole seam using inert gas.
Align side panel with rear end element (area to one side
of tail light) and spot weld.
Align side panel with wheel arch (area of bumper) and
spot weld.
Align side panel with rear end element (area of tail light)
and plug weld using inert gas.
|
| |
Grind down welding surfaces. |
|
| 53 - 10 |
Replacing rear side panel - Cabrio
Printed in Germany - XXII, 1990 |
|
Reworking inner rear side panel (striker area)
Required reworking operations on inner rear side panel when replacing the outer rear side
panel (for vehicles up to MY '91)
The stamping area for the striker was
enlarged on the outer rear side panels
as of MY '91. |
|
|
Before fitting a new outer rear side panel
into a vehicle up to MY '91, the inner rear
side panel has to be modified in the striker
stamping area. |
|
|
When fitting a new outer rear side panel, it
is also recommended to fit a new striker and
a new striker pin. |
|
 |
Reworking inner rear side panel (striker area)
Printed in Germany - XXV, 1992
|
53 - 11 |
|
| 9 4 4 |
B o d y - T a i l g a t e |
55 |
ADJUSTING ELECTRIC TAILGATE UNLOCKING CABLE
N o t e :
The crank on the drive motor has to be
moved to top dead center for adjustment
of the cable. Procedures:
| 1. |
Disconnect plug for unlocking motor.
|
| 2. |
Make up two leads, each with a flat male
plug and a flat female plug. |
| 3. |
Connect one of the leads between brown
wires of the disconnected plug sections. |
|
|
| 4. |
Connect second lead on blue wire of plug
section for the motor.
|
| 5. |
Contact positive pin (red wire) of plug
section for wire harness with other end of
lead briefly, until crank on motor has
reached top dead center. |
| 6. |
Adjust cable on adjusting threads that
locking bars of both locks are completely
open. |
|
| Printed in Germany - III, 1983 |
| Adjusting Electric Tailgate Unlocking Cable |
|
55 - 1 |
|
| 55 |
B o d y - T a i l g a t e |
9 4 4 |
| 7. |
Remove leads and connect plug sections.
|
| 8. |
Locks should not be operated in neutral
position of unlocking motor. |
| 55 - 2 |
Adjusting Electric Tailgate Unlocking Cable |
Printed in Germany |
|
Removing and installing the tailgate
lock microswitch
| 1. |
Loosen the carpet lining of the luggage
compartment at the rear wall.
|
| 2. |
Undo the fastening nuts. |
3. Disconnect the upper linkage.
4. Separate the plug connection.
5. Undo the threaded bolts.
|
|
6. Remove the tail gate lock with microswitch
7. Remove the clips.
Note
If necessary, you can operate the release
Mechanism by pulling on Bowden cable
until the tail gate is released mechanically.
|
Removing and installing the tailgate lock microswitch
Printed in Germany - XXVI, 1988
|
55 - 2a |
|
| 9 4 4 |
B o d y H o o d , T a i l g a t e |
55 |
REMOVING AND INSTALLING ENGINE HOOD
R e m o v i n g
| 1. |
Raise engine hood and support front
end.
|
| 2. |
Unclip retainers on bolts. |
| 3. |
Press down gas pressure props slightly
and pull out bolts with help of a pliers. |
|
|
| 4. |
Tilt gas pressure props to one side and
unclip in ball heads. |
|
| Printed in Germany - V, 1985 |
| Removing and Installing Engine Hood |
|
55 - 3 |
|
| 55 |
B o d y H o o d , T a i l g a t e |
9 4 4 |
| 5. |
Pull off hose on windshield washing
fluid tank and take hose out of holders. |
| 6. |
Disconnect electric plugs for windshield
spray jet heating and engine compart-
ment light, and take wires out of
holders. |
|
|
| 7. |
Unscrew hood mounting bolts and lift
hood off of car (with a second person). |
I n s t a l l i n g
| 1. |
Lift (with second person) hood on to
car, install and tighten mounting bolts
finger tight. Lower hood and align to
have equal clearance between fenders
and front panel. Raise hood and
tighten mounting bolts. |
|
| 55 - 4 |
Removing and Installing Engine Hood |
Printed in Germany |
|
| 9 4 4 |
B o d y H o o d , T a i l g a t e |
55 |
| 2. |
Support front end of engine hood. Clip
gas pressure props in the ball heads.
Compress gas pressure props slightly (do
not press up hood to avoid damaging the
windshield) and guide into gas pressure
prop take-ups. |
| 3. |
Compress gas pressure props to align
them with the take-up bores and insert
the bolts. Clip retainers in grooves of
bolts.
|
| 4. |
Secure hose for windshield washer in
holders and on washing fluid tank.
Connect electric plugs and secure wires
in holders. |
| Printed in Germany - V, 1985 |
| Removing and Installing Engine Hood |
|
55 - 5 |
|
| 55 |
B o d y H o o d , T a i l g a t e |
9 4 4 |
|
REPLACING FRONT HOOD CABLE
R e m o v a l .
If the hood does not open when the
hood release handle is pulled,
proceed as follows:
| 1. |
Raise vehicle on lifting platform,
unscrew engine splashguard. |
| 2. |
Using a suitable tool, open the
lower part of the hood lock from
below. |
|
|
| 3. |
Unscrew clamping screw on lower
part of hood lock. |
| 4. |
Pull away carpet in area of
hood release handle. |
|
| Printed in Germany - VII, 1986 |
|
55 - 7 |
|
| 5. |
Remove and support release handle.
Drive out rollpin and pull out hood
cable. |
I n s t a l l a t i o n
Installation is accomplished in reverse
order.
| 55 - 8 |
Replacing Hood Cable |
Printed in Germany |
|
REMOVING AND INSTALLING INSIDE DOOR HANDLE
R e m o v i n g
| 1. |
Move inside door handle to open position
and unclip retainer with a suitable tool. |
| 2. |
Pull out inside door handle. |
|
|
I n s t a l l i n g
| 1. |
Open internal mechanism with a suitable
tool, slide inside door handle into guide
and clip in retainer. |
|
| Printed in Germany - V, 1985 |
| Removing and Installing Inside Door Handle |
|
57 - 1 |
|
REMOVING AND INSTALLING DOOR PANELING
R e m o v a l
| 1. |
Remove hoods, unscrew fastening
screws for door paneling, loud-
speaker aperture, storage tray,
and the switch aperture. Dis-
connect electrical plugs. |
| 2. |
Unscrew armrest fastening screws,
and lift door panel up and away
from the door. |
|
|
I n s t a l l a t i o n
Installation is in reverse
order.
|
| Printed in Germany - VII, 1986 |
| Removing and Installing Door Paneling |
|
57 - 3 |
|
REMOVING AND INSTALLING WINDOW GUIDERAIL
R e m o v a l
N o t e
Before removal, the door panel,
film, and door window must be
removed.
Pull window guide out of window
guiderail. Unscrew the upper and
lower fastening screws and pull
window guiderail out from below.
|
|
I n s t a l l a t i o n
Installation takes place in
reverse order.
|
| 57 - 4 |
Removing and Installing Window Guiderail |
Printed in Germany |
|
REMOVING AND INSTALLING OUTSIDE DOOR HANDLE
R e m o v a l
N o t e
Before removal, the door paneling,
door film, door window, and window
guiderail must be removed.
| 1. |
Unscrew rachet fillister-head
screw on door frame. |
|
|
| 2. |
Push outside door handle forward
and detach from outer door panel.
Unclip connecting and actuating
rods on lock. Unscrew cable-
bracket screw and carefully un-
clip microswitch with suitable
tool. |
I n s t a l l a t i o n
Installation takes place in
reverse order.
|
| Printed in Germany - VII, 1986 |
Removing and Installing
Outside Door Handles |
|
57 - 5 |
|
REMOVING AND INSTALLING DOOR LOCK AND INNER ACTUATOR
R e m o v a l
N o t e:
Before removing the inner parts,
the door paneling, door film,
door window, and window guiderail
must be removed.
| 1. |
Unclip connecting and actuating
rods on door interior lock |
|
|
| 2. |
Unscrew lock-fastening screws
and remove inner and outer lock
parts from the door. |
I n s t a l l a t i o n
Installation takes place in reverse
order.
|
| 57 - 6 |
Removing and Installing Door Lock
and Interior Actuator |
Printed in Germany |
|
CENTRAL LOCKING SYSTEM
| Printed in Germany - VII, 1986 |
|
57 - 7 |
|
| 57 - 8 |
Central Locking System |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
10
11
12
13
|
Hex
screw
Washer
Sheet-metal
screw
Mounting
plate
Actuating
element
Retaining clip
Pin
Connecting rod
Rivet
Holder
Hex screw
Cable holder
Microswitch
|
2
2
2
1
1
1
1
1
1
1
1
1
1 |
|
Note setting
Clip on securely |
| Printed in Germany - VII, 1986 |
|
57 - 9 |
|
R e m o v i n g a n d I n -
s t a l l i n g C e n t r a l
L o c k i n g S y s t e m
B u t t o n
| 1. |
Pull out storage tray and ash-
tray. |
| 2. |
Unscrew fastening screw on cover
frame of middle console. |
|
|
| 3. |
Take central locking button
out of its catch and separate
plug connection |
|
| 57 - 10 |
Removing and Installing Central
Locking System Button |
Printed in Germany |
|
Removing and installing
central-locking control unit
The control unit is mounted beneath
the instrument panel and is
attached to the steering column by
a metal holder.
| 1. |
Detach control unit and unbolt
holder. |
2. Disconnect plug.
|
|
Removing and installing actuator
Removing
| 1. |
Remove door trim panel.
|
| 2. |
Remove mounting bolts from
holder. |
| 3. |
Remove linkage from ball joint
(door inside lock). |
|
| Printed in Germany - XIII, 1987 |
Removing and Installing
Central Locking Control Unit |
|
57 - 11 |
|
| 4. |
Disconnect plug, remove
connecting rod and unbolt holder. |
Installing
| 1. |
Screw holder on to actuator and
tighten until it is just possible
to move actuator.
|
| 2. |
Connect two halves of plug and
attach to holder.
|
| 3. |
Connect connecting rod to
actuator and push on to door
inside lock.
|
| 4. |
Bolt holder with actuator into
position inside door and tighten
so that holder can still be
moved. |
|
|
| 5. |
Push holder forward in slots in
door and tighten bolts. |
| 6. |
Hold the linkage of the locking
button to keep door lock in open
position. Push actuator forward
in slots of holder and tighten
bolts. |
|
| 57 - 12 |
Removing and Installing Actuator |
XIII, 1987 - Printed in Germany |
|
| 7. |
Slacken mounting bolts of holder
slightly and move actuator toward
rear in slots to obtain reserve
travel. Tighten mounting bolts. |
8.Check operation.
Note:
When sanding and painting, take
care to cover the lock well to
prevent malfunctions due to dust
penetrating the lock mechanism.
|
|
Removing and installing microswitch
in door lock cylinder
| 1. |
Remove door trim panel.
|
| 2. |
Remove plug from holder and
disconnect. |
| 3. |
Unbolt door outside handle and
remove. Detach cable holder
(strain relief). |
| 4. |
With a screwdriver, carefully
press off microswitch. |
|
| Printed in Germany - XIII, 1987 |
Removing and Installing
Microswitch in Door Lock
Cylinder |
|
57 - 13 |
|
CENTRAL LOCKING SYSTEM FUNCTION TABLE
| |
Mechanical
Function |
Ignition
off |
Ignition
on |
Left
Doors |
Key |
I - unlock |
C - unlock
C - lock |
C - unlock
C - lock |
Door-lock-
ing Knob |
I - lock
I - unlock
(each only with
door shut) |
C - unlock |
C - unlock |
Right
Doors |
Key |
I - unlock |
C - unlock
C - lock |
C - unlock
C - lock |
Door-lock-
ing Knob |
I - unlock
I - lock |
C - unlock |
C - unlock |
Central locking
button with
display |
no
function |
C - lock
no function |
C - unlock
C - lock
each with
Display |
I = Individual Door
C = Central function
| 57 - 14 |
Central Locking System
Function Table |
Printed in Germany |
|
CENTRAL LOCKING SYSTEM TROUBLESHOOTING
N o t e
The testing of the central locking
system and the localizing of a defect
can be carried out on the 12-pin
plug of the control unit without
extensive disassembly and assembly.
Make up 2 short auxiliary cables
with 2.5 mm round pins (from
defective lead cable or
commercially-available plug) for
connecting the measurement and test
equipment.
Use circuit diagram 944, 944 turbo
sheet 10, page 97 - 91.
| 1. |
Pull control unit from steering
column and disconnect plug. |
|
|
| 2. |
T e s t i n g C o n t r o l
U n i t P o w e r
S u p p l y |
Connect positive (30, fuse 8) to
term.6 and negative (-) to
term.5. With "ignition on" positive
(15,fuse 17) must be connected to
term.8.
| 3. |
T e s t i n g t h e C o n t r o l
E l e m e n t s |
The control elements are actuated
together. Connect plug term.6 (+)
and term. 3 with the auxiliary
lead.
Both doors "opened", bring opened
driver's doors into locked position
by the outside lock.
Plug auxiliary lead to term.5 (-)
and touch to term.4.
The control elements should
lock.
|
| Printed in Germany - VII, 1986 |
Central Locking System
Troubleshooting |
|
57 - 15 |
|
Reverse connections at terminals 3
and 4, in other words, briefly
connect plus to ter.4 and minus to
ter.3. The actuators must unlock.
| 3.1 |
Checking operation of
microswitches in the actuators
Set both doors to the open
position. Connect a continuity
tester across terminals 10 and
5. Lock and unlock the door
locking button of each door in
turn. In the locked position,
the tester must show
continuity.
Lock both doors. Connect
continuity tester across
terminals 2 and 5. Unlock and
lock doors at locking buttons.
In each case, the tester must
show continuity in the unlocked
position. |
| 4. |
Checking operation of
microswitches in lock cylinders
Connect continuity tester
across terminals 5 and 7.
Use key to turn lock cylinder
of each door toward "open". In
each case, the tester must show
continuity. |
|
|
Remove lead from ter.7 and connect
to ter.9. Turn lock cylinders
toward "closed". In each case, the
tester must show continuity.
| 5. |
Checking operation of push button
switch in central console
Connect continuity tester across
ter.12 and ter.5 (ground). When
the pushbutton switch is
actuated, the tester must show
continuity.
Use a length of wire to connect
ter.11 and ter.6 (+) the
indicator lamp in the pushbutton
switch must light up. Switch on
position lights. The key symbol
in the switch must be
illuminated. |
|
| 57 - 16 |
Central Locking System
Troubleshooting |
XIII, 1987 - Printed in Germany |
|
OPERATING INSTRUCTIONS FOR REMOVABLE SUN ROOF SINCE 1984 MODELS
The electrically operated and removable sun
roof can be opened in infinite steps up to
final position with a switch in the center
console after turning on the ignition.
Roof opened = tumbler switch pushed
back (a).
Roof closed = tumbler switch pushed
forward (b).
R e m o v i n g R o o f
The roof should be cleaned first to avoid
scratching the roof on deposits of dirt
while removing.
| 1. |
Turn off ignition and push back (a)
tumbler switch until drive elements
unlock the roof.
|
| 2. |
Release front fasteners. |
|
|
| 3. |
Lift and remove roof.
|
| 4. |
If applicable, place removed roof in
protective cover provided for storage
of roof. |
M o u n t i n g R o o f
| 1. |
Slide roof over wind deflector and front
guides from above at an angle. |
|
| Printed in Germany - V, 1985 |
| Working On Electric Sun Roof |
|
61 - 1 |
|
| 2. |
Lower roof toward rear.
|
| 3. |
Turn off ignition and push tumbler
switch forward (b) until drive elements
lock the roof.
|
| 4. |
Lock front fasteners. |
C l o s i n g R o o f M a n u a l l y
Should the electric sun roof operation fail,
the roof could also be closed manually. The
drive motor and wrench are located behind
the carpet on the left side section of the
luggage compartment.
| 1. |
Unclip and fold back carpet.
|
| 2. |
Unscrew winged screws on wrench and
take cap off of adjusting screw. |
| 3. |
Unscrew and remove adjusting screw (a)
with the wrench. |
|
|
| 4. |
Turn the now visible threaded sleeve
anticlockwise with the wrench until the
roof is closed. |
| 5. |
Screw in adjusting screw (a) again and
adjust the slip clutch (see page 61 - 18). |
|
| 61 - 2 |
Working On Electric Sun Roof |
Printed in Germany |
|
TROUBLESHOOTING SUN ROOF
| C o n d i t i o n |
C a u s e |
C o r r e c t i o n |
Roof motor runs, but roof
does not unlock or lift. |
Riser cable on drive
pinion defective.
Dog broken.
Drive pinion faulty. |
Replace assembly set.
Check and adjust clutch.
Replace dog.
Replace pinion on
motor. |
Roof does not run, no noise
when operating switch. |
Power supply for motor
and drive.
Microswitch faulty. |
Check power supply for
motor and drive.
Check microswitch. |
| Roof opens onesidedly. |
Gearbox faulty. |
Replace assembly set. |
Roof protrudes at rear in
locked state. |
Roof maladjusted. |
Adjust gates.
Adjust elements.
If necessary, correct
collar in roof opening. |
Roof protrudes at front in
locked state. |
Centering wedges too
high. |
Use washers underneath
centering wedges. |
| Roof leaks (water enters). |
Seal damaged.
Collar in roof opening
does not fit correctly. |
Replace seal.
Correct collar in roof
opening. |
| Rattling noise. |
a)
b)
c)
d) |
Gates loose.
Screws of assembly set
loose.
Roof fasteners and
centering wedges loose.
Wind deflector loose. |
|
Check gates, replacing if
necessary.
Tighten screws.
Tighten screws.
Tighten screws.
Tighten screws. |
Loud noise (knocking) in rear
roof beam and drive elements
do not move. |
Gearbox faulty. |
Replace assembly set. |
| Printed in Germany - V, 1985 |
| Working On Electric Sun Roof |
|
61 - 3 |
|
I m p o r t a n t I n f o r m a t i o n
| 1. |
Never open element guides and gearbox
on assembly set. |
|
|
| 2. |
Do not turn adjusting screw of slip
clutch, if not absolutely necessary. |
|
| 61 - 4 |
Working On Electric Sun Roof |
Printed in Germany |
|
REMOVING AND INSTALLING ELECTRIC SUN ROOF DRIVE AND ASSEMBLY SET
R e m o v i n g
| 1. |
Raise tailgate, remove trim panel clips
and place trim panel aside. |
| 2. |
Unscrew nuts on studs and disengage
electric drive in mounting points. |
|
|
| 3. |
Swing electric drive into inside of car
slightly.
Unscrew cover mounting screws and
remove cover. |
4. Disconnect plug on electric drive.
|
| Printed in Germany - V, 1985 |
|
61 - 5 |
|
| 5. |
Unciip drive cam and remove electric
drive with guide rail. |
6. Remove lifting sun roof.
7. Remove caps on heads of bolts.
| 8. |
Remove mounting bolts and washers,
and take off trim panel. |
|
|
9. Pull off edge guard partially (arrow).
10. Loosen roof liner on body partially.
| 11. |
Remove mounting screws of element
guides and transfer gearbox. |
| 12. |
Remove assembly set from car by
pulling long pipe out of C pillar. |
|
| 61 - 6 |
Jobs on Power Sun Roof |
Printed in Germany |
|
I n s t a l l i n g
| 1. |
Guide long pipe of assembly set into
assembly opening of body. Slide pipe
through the C pillar by turning the
entire part. Never use force, the pipe
must not be bent.
|
| 2. |
Secure element guides of assembly set
in holders on both sides lightly. |
| 3. |
Mount transfer gearbox in center of
roof beam.
Use new, non-microencased screws. |
|
|
| 4. |
Bolt rear end of element guides on
roof hoopsticks (without tension).
Adjust front mounting points of
element guides (see adjusting sun roof). |
| 5. |
The pipe with the raising cable must
protrude into the trunk parallel to the
side panel. The distance between the
end of the pipe and drive is 305 +
1.0 mm in pulled state and 40 + 1.0 mm
in pushed state. If these distances are
not reached, the assembly set has to be
replaced. Adjustment of the raising
cable is not possible. It must be possible
to move the raising cable back and
forth by hand. |
|
| Printed in Germany - V, 1985 |
|
61 - 7 |
|
| 6. |
Work drive with raising cable into guide
rail of electric drive, route along the rail
and clip on counterpiece in cam. |
|
|
| 7. |
The pipe must be placed in the pinion
housing precisely with the cams. |
8. Mount and bolt down cover.
| 9. |
Connect plugs. Place holder on end of
rail on studs of tailgate and screw on
nuts. |
|
| 61 - 8 |
Jobs on Power Sun Roof |
Printed in Germany |
|
| 10. |
Engage console of electric drive in rear
frame profile, screw on nuts and plug
console claws on edge guard. Tighten
all nuts. |
11. Adjust lifting sun roof.
| Printed in Germany - V, 1985 |
|
61 - 9 |
|
ADJUSTING LIFTING SUN ROOF
Following jobs must be completed before adjusting.
-
-
- |
Lifting sun roof removed.
Trim on rear roof frame removed.
Edge guard and roof liner on rear roof frame loosened on body partially
(see "Removing Electric Drive and Assembly Set" - points 6 through 10).
|
A d j u s t i n g
| 1. |
Place edge guard on collar, install roof,
arrest and adjust element guides in slots
that lifting roof lid and car roof are in
same plane.
Tighten mounting screws. |
| 2. |
Remove roof and pull off edge guard,
cement roof liner on body and slide on
edge guard. Screw trim panel on roof
frame and install caps on heads of screws. |
|
|
| 3. |
If staybolts of element guides are not
in neutral position + 3 mm (see sketch),
left trim panel must be removed in
luggage compartment and excessive
deviation eliminated by adjusting the
switch lever on the rail. |
| 4. |
Install trim panel again after finishing
adjustment. |
|
| 61 - 10 |
Jobs on Power Sun Roof |
Printed in Germany |
|
| 5. |
The gates bolted on the lifting roof lid
have slots, with which the lifting roof
lid and car roof panel can be adjusted to
be in the same plane. Check gate guides,
replacing if worn or damaged. |
| 6. |
Cable anchors located in the lifting
roof lid must be adjusted that the cable
of the lifting roof runs parallel to the
cable of the car roof. |
|
|
| 7. |
Should the lifting roof lid protrude at
the front, the centering wedges must be
unscrewed on the roof beam and
installed again with washers underneath. |
|
| Printed in Germany - V, 1985 |
|
61 - 11 |
|
REPLACING DRIVE DOG
R e m o v i n g
| 1. |
Remove electric drive, see "Removing
and Installing Electric Sun Roof Drive
and Assembly Set".
|
| 2. |
Spread clamping sleeve with a suitable
pliers and take off clamping sleeve and
drive dog. |
|
|
I n s t a l l i n g
| 1. |
Slide drive dog on to raising cable.
|
| 2. |
Clamp clamping sleeve to distance on
the raising cable and with the gap in
alignment with beads on the pipe. |
305 + 1.0 mm / 40 + 1.0 mm
3. Install electric drive.
|
| 61 - 12 |
Jobs on Power Sun Roof |
Printed in Germany |
|
REPLACING UNSCREWING - TYPE DRIVE DOG
R e m o v i n g
| 1. |
Remove electric drive, see "Removing
and Installing Electric Sun Roof Drive
and Assembly Set".
|
| 2. |
Unscrew mounting screw and lift off
drive dog.
|
I n s t a l l i n g
| 1. |
Adjust drive dog on raising cable and
install screw with washer on raising
cable. Drive dog must be aligned with
beads on pipe. |
|
|
2. Install electric drive.
|
| Printed in Germany - V, 1985 |
|
61 - 13 |
|
CHECKING CONTROLS OF POWER SUN ROOF DRIVE
| 1. |
Check fuse no. 8 (8 amps).
|
| 2. |
Take sun roof switch out of center
console with help of a spatula. Unfold
plug connection cover for switch. |
| 3. |
Perform following tests with a volt-
meter or test lamp.
|
| 3.1 |
Terminal 2 must have battery voltage
with the ignition turned on.
|
| 3.2 |
Terminal 3 must have battery voltage
with the ignition turned off and the
ignition key inserted (radio position).
|
| 3.3 |
Terminal 4 must have battery voltage
when the left front wheel is lifted
and rotated (speed above 5 km/h). |
|
|
Check lines or replace control unit for sun
roof/radio, if voltage values are not as
specified.
4. Check microswitch in roof opening.
N o t e
The microswitch will prevent running out
the lifting elements unintentionally after
removing the roof.
Check microswitch - see next page.
|
| 61 - 14 |
Jobs on Power Sun Roof |
Printed in Germany |
|
| 4.1 |
Microswitch must remain in closed
position with the roof installed up to
the maximum lifting position.
The switching point can be identified
by a loud "click".
|
| 4.2 |
The roof cannot be lifted when the
microswitch is open or a wire is
interrupted.
|
| 4.3 |
The operating lever on the micro-
switch must move easily. |
|
|
CHECKING POWER SUPPLY FOR SUN
ROOF MOTOR
| 1. |
Check fuse no. 9 (25 amps) in extra
fuse box.
|
| 2. |
If fuse is okay, loosen trim panel in
luggage compartment at rear left and
pull off relay on sun roof drive. |
| 3. |
Perform following tests with a voltmeter
or test lamp.
|
| 3.1 |
Both relay socket terminals 87 must have
battery voltage.
|
| 3.2 |
Terminals 86 and 87a must have ground
potential. |
|
| Printed in Germany - V, 1985 |
|
61 - 15 |
|
REMOVING AND INSTALLING SUN ROOF MICROSWITCH IN ROOF OPENING
R e m o v i n g
| 1. |
Unlock and remove lifting roof lid.
Disengage operating flap in lifting roof
mount with a body spatula. |
| 2. |
Unscrew lifting roof mount and press out
of wind deflector. |
|
|
| 3. |
Take microswitch out of lifting roof
mount and unsolder wires. |
I n s t a l l i n g
N o t e
Be careful not to pinch wires when
tightening screws.
The operating lever on the microswitch
must not clamp.
|
| 61 - 16 |
Jobs on Power Sun Roof |
Printed in Germany |
|
REMOVING AND INSTALLING SUN ROOF MICROSWITCH ON ELECTRIC
DRIVE
R e m o v i n g
| 1. |
Loosen trim panel in luggage compart-
ment at rear left.
|
| 2. |
Unscrew mounting bolt on micro-
switch holder. |
| 3. |
Pull out holder and unscrew micro-
switch. |
I n s t a l l i n g
Rear view of installed microswitch.
1 - Three wires connected
2 - Two wires connected
|
|
Wire connections on microswitch 1
3 = black/red
1 = green/red
2 = black
Wire connections on microswitch 2
3 - gray/green
1 - not connected
2 - gray/black
|
| Printed in Germany - V, 1985 |
|
61 - 17 |
|
ADJUSTING SLIP CLUTCH ON SUN ROOF MOTOR
N o t e
The slip clutch was adjusted in the factory
and only has to be readjusted, if the
adjusting screw had been removed for
manual operation of the roof.
The lock nut is cemented on the adjusting
screw at a distance of 2.5 mm from the
screw's head.
To guarantee perfect operation of the slip
clutch, the adjustment should be made by
measuring the power input of the sun roof
motor.
| 1. |
Remove fuse no. 9 in extra fuse box.
Connect ammeter on fuse carrier no. 9. |
|
|
| 2. |
Screw in adjusting screw on slip clutch
and tighten slightly. |
| 3. |
Turn on ignition and operate switch to
move lifting roof lid to final position
of drive.
Measure power input in final position
(clutch slips).
|
| 4. |
Tighten adjusting screw until power
input is 12 to 14 amperes.
|
| 5. |
Disconnect ammeter and install 25
ampere fuse again. |
|
| 61 - 18 |
Jobs on Power Sun Roof |
Printed in Germany |
|
Converting the lifting roof
Converting the lifting mechanism of the lifting roof to the new version (as of February, 1986)
Converting the lifting roof
Printed in Germany - XXIV, 1991
|
61 - 18a |
|
Converting the lifting mechanism
Converting the lifting mechanism of the lifting roof to the new version (as of February, 1986)
| No. |
Operation |
Instructions |
| |
Remove the lifting roof |
|
| |
Remove interior in the
rear roof rail area |
Remove roof lining, pull off rear edge protector and
loosen adjacent areas of roof lining. |
| |
Loosen side panel lining |
Open tailgate, loosen side panel lining clips and move
side panel lining aside. |
| |
Loosen mounting of electrical
drive |
Screw mounting nuts off the threaded studs and dis-
engage electrical drive from its mounting locations.
Move electrical drive aside and disconnect plug connec-
tors. |
| 1 |
Separate fitting
kit from electrical drive. |
Loosen fastening screws housing of electrical drive
and remove cover. Unclip yoke from switching cam and
remove yoke complete with lift cable from guide rail. |
| |
Separate yoke from lift
cable |
Loosen fastening screw and pull yoke off the lift cable. |
| 2 |
Loosen fitting kit in
roof area
Pull out fitting kit |
Loosen fastening screws for right-hand and left-hand
segment guide and for transfer box. |
| 3 |
Separate spotwelds of
support panels |
Separate spotwelds between support panels and roof
rail using a spotweld cutter. Separate MIG weld seams
between support panels (front side) and roof rail. |
| 4 |
Enlarge cutout
for drain hose |
Right-hand side only: Enlarge cutout for drain hose in
the body panel just enough to allow the short tube - in-
cluding the covering - of the mounting assembly to be
introduced into the cutout. |
| 5 |
Drill mounting hole
for tie-wrap |
Drill a 7.3 mm dia. hole for the tie-wrap in a position
offset 12 mm to the left (in forward direction). |
| 61 - 18b |
Converting the lifting mechanism
Printed in Germany - XXIV, 1991 |
|
| No. |
Operation |
Instructions |
| 6 |
Position adapter plates |
Positioning the left-hand adapter plate:
Center of vehicle to center of adapter plate 317.5 mm.
Positioning of right-hand adapter plate:
Center of vehicle to center of adapter plate 311.5 mm.
Drill blind rivet holes in roof rail. |
| |
Prime body sections affected |
Apply primer to body sections worked with grinding, drill-
ing or cutting equipment. |
| |
Rivet adapter plates in place
and fit tie-wraps |
Rivet adapter plates to roof rail. Fit tie-wraps. |
| 7 |
Block threaded plates for
fitting of transfer case |
Tighten threaded plates of old transfer case mounting to
prevent rattle (use short bolts). |
| 8 |
Insert and tighten fitting kit |
Insert assembly kit into body, tighten segment guides
and tighten up tie-wraps. |
| 9 |
Assemble and adjust
lift cable |
Fit connector and connecting tube to lift cable. Use con-
nector to install tube assembly kit and connecting tube.
Screw yoke to lift cable. Turn protruding section of lift
cable to adjust length to 284 mm (measured between
connecting tube and yoke).
Note: When adjusting, the arc segments must be
engaged to stop into the segment guides. |
| 10 |
Connect fitting kit
to electrical drive |
Insert yoke complete with lift cable into guiding sleeve of
the electrical drive and clip into actuating cam. Insert
connecting tube into housing, install and tighten cover. |
| |
Fit electrical drive
Install side panel lining |
Close connector for electrical drive. Engage electrical
drive into mounting points and tighten. |
| |
Install interior |
Glue roof liner to edge of body panel (roof aperture), put
edge protector back on and install roof lining. |
| |
Insert lifting roof
Check operation of lifting roof |
|
Converting the lifting mechanism
Printed in Germany - XXIV, 1991
|
61 - 18c |
|
Lifting sun roof as from February
1986
General
A new lifting sun roof lifting system has been
in use from February 1986 onwards. Opera-
tion of the new lifting sun roof has not
changed in comparison with the previous ver-
sion.
Closing lifting sun roof manually:
Should electric lifting sun roof operation fail,
the roof can also be closed manually. The
drive motor is located behind the carpet on
the left side section of the luggage compart-
ment.
| 1. |
Open the flap on the luggage compartment
cover. Remove securing screw of the round
rubber buffer, release clips on the carpet
and fold carpet back. |
|
|
2. Remove cover cap.
| 3. |
Plug the ignition plug wrench included in the
on-board tools onto the now visible
hexagon nut and tum in clockwise direction
until the lifting sun roof is closed. |
|
Lifting sun roof as from February 1986
Printed in Germany - XVI, 1987
|
61 - 19 |
|
Lifting sun roof - removing and in-
stalling electric sun roof drive and
assembly set
Removing
| 1. |
Open tailgate and flap on the luggage com-
partment cover. Unscrew securing screw of
round rubber buffer, remove trim panel clips
and place trim panel aside. |
|
|
| 2. |
Unscrew cover mounting screws and
remove cover from car. |
| 3. |
Unscrew hexagon nuts from studs and dis-
engage electric drive from mounting points. |
|
Lifting sun roof - removing and installing electric sun roof drive and assembly set
Printed in Germany - XVI, 1987
|
61 - 21 |
|
| 4. |
Swing electric drive into inside of car. Un-
screw mounting screw and hexagon nuts on
raising cable. Disconnect connector from
electric drive. |
| 5. |
At raising cable end, extract square shaft
from swing lever. |
|
|
| 6. |
Detach connecting tube with raising cable
from pinion housing and also detach electric
drive. |
| 7. |
On guide tube, press clamping sleeve in the
tube's longitudinal direction and extract con-
necting tube with clamping sleeve. |
|
| 61 - 22 |
Lifting sun roof - removing and installing electric sun roof drive and assembly set
Printed in Germany - XVI, 1987 |
|
| 8. |
Take out lifting sun roof and partly remove
roof trim panel, edge guard and roof section. |
|
|
| 9. |
Unscrew mounting screws and nuts of ele-
ment guides and remove cable tying straps. |
| 10. |
Remove assembly set from car by pulling
long pipe out of C pillar. |
|
Lifting sun roof - removing and installing electric sun roof drive and assembly set
Printed in Germany - XVI, 1987
|
61 - 23 |
|
Installing
| 1. |
Guide long pipe of assembly set into as-
sembly opening of body. Slide pipe through
the C pillar without using force.
|
| 2. |
Secure element guides with brackets in
holders on both sides lightly in the roof
beam. |
|
|
| 3. |
Slide element guides home into the brackets
and adjust parallel to each other in accord-
ance with the specified distances. Tighten
rear screws. Check dimensions in the ex-
tended and retracted positions of the ele-
ments and readjust if necessary. Tighten
front nuts. |
|
| 61 - 24 |
Lifting sun roof - removing and installing electric sun roof drive and assembly set
Printed in Germany - XVI, 1987 |
|
| 4. |
Plug connecting clip onto the raising cable
and install the clamping sleeve using special
tool "9261 ". Plug clamping sleeve home on
connecting and guide tube. |
| 5. |
Adjust raising cable with elements retracted
home and in accordance with the specified
dimensions. Turn clockwise for a longer dis-
tance and counterclockwise for a shorter dis-
tance. |
|
|
| 6. |
Carefully work the connecting tube with rais-
ing cable on the electric drive into the pinion
and pinion housing and secure with
hexagon nuts. Guide raising cables through
the trailing lever, insert into the square hole
in the swing lever and secure with the
screw. Join connector halves. |
| 7. |
Carry out further installation in reverse order
to removal. |
|
Lifting sun roof - removing and installing electric sun roof drive and assembly set
Printed in Germany - XVI, 1987
|
61 - 25 |
|
Adjusting lifting sun roof
| 1. |
Insert lifting sun roof and, if necessary, ad-
just on front and rear adjusting bolts until lift-
ing sun roof runs level with the roof. |
|
|
| 2. |
If necessary, adjust the adjusting screws of
the element guides so that the elements
travel into the gates with large-scale tension. |
|
Adjusting lifting sun roof
Printed in Germany - XVI, 1987
|
61 - 27 |
|
| 3. |
If the elements are not in zero position,
deviations must be equalized by adjusting
microswitches on the electric drive. |
| 4. |
The gates bolted on the lifting roof have
slots with which the lifting roof and car roof
panel can be adjusted to be in the same
plane. Check gate guides, replacing if worn
or damaged. |
|
|
| 5. |
To increase stability of shape, lifting sun roof
has been reinforced on the inside by ad-
hered aluminium profiles. The pull anchors
have been dropped. |
| 6. |
Should the lifting roof protrude at the front,
the centering wedges must be unscrewed
on the roof beam and installed again with
washers underneath. |
|
| 61 - 28 |
Adjusting lifting sun roof
Printed in Germany - XVI, 1987 |
|
Removing and installing raising
cables and elements
| 1. |
Remove electrical drives. See Lifting sun
roof - Removing and installing electric sun
roof drive and assembly set.
|
| 2. |
Using a drill, turn the raising cable on the
square shaft out of the assembly set. |
|
|
| 3. |
Pull element out of the element guide.
Grease new element and insert home. Use
special grease. |
| 4. |
Grease raising cable and insert in the as-
sembly set using a left-turning drill. Use spe-
cial grease. Make sure the elements lie on
the element guide. |
|
Removing and installing raising cables and elements
Printed in Germany - XVI, 1987
|
61 - 29 |
|
| 5. |
Adjust raising cable in accordance with dis-
tance data. |
| 61 - 30 |
Removing and installing raising cables and elements
Printed in Germany - XVI, 1987 |
|
Removing and Installing Gear in Ele-
ment Guide
Removing
| 1. |
Remove electric drive and installation kit -
see "Removing and Installing Electric Drive
and Installation Kit" under lifting roof.
|
| 2. |
Unscrew mounting screws of element plate |
|
|
| 3. |
Take off element plate and remove element
from the element housing. |
| 4. |
Press gear out of the element housing from
behind. |
|
Removing and Installing Gear in Element Guide
Printed in Germany - XXI, 1989
|
61 - 31 |
|
Installing
Remarks
Check the slip clutch of the electric drive
prior to installation of the gear - see "Slip
Clutch" on page 61 - 39.
| 1. |
Inspect gear, replacing if necessary.
Lubricate and insert gear in guide and rais-
ing cable in such a manner, that the element
bears on the element guide without tension
and without play. Use special grease. |
|
|
| 2. |
Make sure that plastic pipe bears in its
guide prior to installation of the element
plate. Bolt element plate on the element
housing. |
Remarks
Special grease: TL-VW 745 universal cold
grease, see Technical Information No. 2/86 X
(Table of Operating Fluids).
|
| 61 - 32 |
Removing and Installing Gear in Element Guide
Printed in Germany - XXI, 1989 |
|
Testing controls of lifting sun roof
drive
| 1. |
Check fuse number 8 (terminal 30). fuse
number 18 (terminal 15) and fuse number
36 (terminal R).
|
| 2. |
Remove lifting sun roof switch and hold
open cover on connector. |
| 3. |
Perform following tests with a voltmeter or a
test lamp:
|
| 3.1 |
Terminal 1 must have battery voltage with
the ignition turned on.
|
| 3.2 |
Terminal 2 must have battery voltage with
the ignition key in position R (radio posi-
tion). |
|
|
| 3.3 |
Terminal 5 must have battery voltage when
the speed is greater than or equal to 1.8
km/h and when the doors on cars with
central locking are locked. |
Check lines or replace control unit for lifting
sun roof if voltage values are not as specified.
4. Check microswitch in roof opening.
Note
The microswitch will prevent running out the
lifting elements unintentionally after removing
the roof.
| 4.1 |
Microswitch must remain in closed position
with the roof installed up to the maximum
lifting position.
|
| 4.2 |
The roof cannot be lifted when the micros-
witch is open or when a wire is interrupted.
|
| 4.3 |
The operating lever on the microswitch
must move easily. |
|
Testing controls of lifting sun roof drive
Printed in Germany - XVI, 1987
|
61 - 33 |
|
Checking power supply for lifting
sun roof motor
| 1. |
Check fuse number 1.
|
| 2. |
If fuse is okay, loosen trim panel in luggage
compartment at rear left and pull off relay. |
| 3. |
Perform following tests with a voltmeter:
|
| 3.1 |
Both relay socket terminals 87 must have
battery voltage.
|
| 3.2 |
Terminals 86 and 87 a must have ground
potential. |
| 61 - 34 |
Checking power supply for lifting sun roof motor
Printed in Germany - XVI, 1987 |
|
Removing and installing sun roof
microswitch in roof opening
Removing
| 1. |
Unlock and remove lifting sun roof.
|
| 2. |
Remove sun visors and roof frame trim.
|
| 3. |
Disengage operating flap in lifting roof
mount with a body spatula. |
|
|
| 4. |
Unscrew lifting roof mount and press out of
wind deflector. |
5. Release roof section and roof frame padding.
6. Disconnect the connector.
|
Removing and installing sun roof microswitch in roof opening
Printed in Germany - XVI, 1987
|
61 - 35 |
|
| 7. |
Carefully force microswitch out of lifting roof
mount using a screwdriver. |
Installing
Note
Be careful not to pinch wires when tightening
screws. The operating lever on the micros-
witch must not jam.
| 61 - 36 |
Removing and installing sun roof microswitch in roof opening
Printed in Germany - XVI, 1987 |
|
Adjusting lifting sun roof microswitch on electric drive
Microswitches I and II can only be adjusted together. In longitudinal direction leave a 7 mm
clearance between the outer edges of the microswitches and the recess, In transverse direction they
must be adjusted so that they switch reliably. but are not damaged mechanically by the lever. A
clearance of 2.5 mm must be observed in the case of microswitch II.
| Lever position: |
1 - released
2 - locked
3 - open |
Adjusting lifting sun roof microswitches on electric drive
Printed in Germany - XVI, 1987
|
61 - 37 |
|
Connections on the microswitches
Wire connections on microswitch I
1 - black/red
2 - green/red
4 - black
Wire connections on microswitch II
1 - grey/green
2 - not connected
4 - grey/black
Wire connections on microswitch III
1 - yellow
2 - yellow/black
4 - not connected
| 61 - 38 |
Connections on the microswitches
Printed in Germany - XVI, 1987 |
|
Slip Clutch
The slip clutch of the electric drive does not have to be loosened for manual operation of the lifting
roof, as compared with the former version.
Checking Slip Clutch:
Slip clutch is adjusted in the factory.
This adjustment can be checked by way of
the torque required to have the clutch slip as
described below.
| 1. |
Run out elements to the "lifting roof opened
about halfway" position to avoid damaging
the gears or raising cable (not necessary
when electric drive is disconnected on the
raising cable).
|
| 2. |
Turn hexagon nut - A - with a size 21 mm
wrench socket and torque wrench. The slip
clutch must slip at a torque of 6 ± 0.5 Nm. |
Remarks
The breaking loose torque could be consider-
ably greater, so that this test must be repeat-
ed six times in steps of 60 degrees.
|
|
Adjusting Slip Clutch:
The torque must be corrected if the slip clutch
test produces any deviation from the specified
torque of 6 ± 0.5 Nm.
| 1. |
Unscrew lock nut - C -.
|
| 2. |
Adjust the torque by turning hexagon nut
- B -.
Loosening the hexagon nut reduces the
torque.
Tightening the hexagon nut increases the
torque. |
Remarks
This adjustment should be carried out in very
small steps, since turning hexagon nut - B -
will cause considerable change in torque.
| 3. |
Install lock nut - C - with Loctite No. 270
and tighten with 15 ± 2 Nm torque. |
A = Hexagon nut for checking torque
B = Hexagon nut for adjusting torque
C = Lock nut
|
Slip Clutch
Printed in Germany - XXI, 1989
|
61 - 39 |
|
Removing and installing folding top
Removing and installing folding top
Printed in Germany - XXII, 1990
|
61 - 41 |
|
Removing and installing folding top
Removing folding top
| No. |
Task |
Instructions |
| 1 |
Release folding top |
Release front of folding top left and right using special
handles inside the vehicle and lift off and upwards. |
| |
Fold seat backrests
forwards |
Release both seat backrests and fold forwards. |
| 2 |
Remove rear side lining and
rear lining |
Pull off door gasket at B-pillar from spot welding flange
and detach adhesive fastening of rear side lining. Undo
screw fastening of rear side lining and take out lining.
Undo right and left screw fastenings of rear lining, unclip
8 press studs from hat shelf and remove rear lining. |
| 3 |
Undo fastening screws of
folding top retaining bracket
from rear inner side elements |
Undo two screw fastenings of rear inner side elements
on both left and right. |
| |
Detach luggage compartment
lining in area of hat shelf |
From luggage compartment side, detach adhesive
fastening of luggage compartment lining in area of hat
shelf |
| 4 |
Undo fastening nuts of
folding top retaining bracket in
area of luggage compartment |
From the luggage compartment side, undo 4 fastening
nuts of folding top retaining bracket. |
| 5 |
Undo screw fastenings of
folding top bearings |
Raise rear of folding top and undo screw fastenings of
both folding top bearing |
| 6 |
Undo plug-in fastenings of
articulated forks to support
struts 1 and screw fastenings
of support struts 2 to guide
levers |
Disengage securing plate from the connecting bolt of ar-
ticulated fork / support strut 1, press out connecting bolt
and detach support strut 1 from articulated fork. Un-
screw fastening bolt of support strut 2 from fastening
point on guide lever. |
| |
Lift folding top off vehicle |
|
| 61 - 42 |
Removing and installing folding top
Printed in Germany - XXII, 1990 |
|
Removing and installing folding top
Removing folding top
| No. |
Task |
Instructions |
| |
Place folding top on vehicle |
|
| |
Screw together support struts
2 to guide levers and plug-in
fastenings of articulated forks
to support struts 1 |
2 microencapsulated set screws M 8 x 20
2 securing plates
2 connecting bolts
Note
The microencapsulated set screws must be replaced by
new ones! |
| |
Restore screw fastenings of
folding top bearings |
4 fillister head screws with hexagonal socket heads
M 8 x 20 |
| |
Bolt on folding top retaining
brackets in area of luggage
compartment |
4 nuts M 6 |
| |
Bolt folding top retaining
brackets to rear inner side
elements |
4 sheet metal screws 4.2 x 16 |
| |
Fit rear lining |
8 Clips
2 sheet metal screws 3.5 x 16 |
| |
Fit rear side linings |
6 sheet metal screws 3.5 x 16
Dekalin adhesive |
| |
Fit door gasket onto spot
welding flange |
|
| |
Adjust folding top |
Adjust folding top in area of luggage compartment by
means of adjusting screws on folding top retaining
bracket so it is parallel to body contours |
| |
Bolt folding top retaining
bracket into place |
Bolt folding top retaining bracket into place in area of
luggage compartment |
| |
Glue luggage compartment
lining into place |
Dekalin adhesive |
Removing and installing folding top
Printed in Germany - XXII, 1990
|
61 - 43 |
|
REMOVING AND INSTALLING SPOILER AND BUMPER
| Printed in Germany |
| Removing and Installing Spoiler and Bumper |
|
63 - 1 |
|
REMOVING AND INSTALLING SPOILER AND BUMPER
| 63 - 2 |
Removing and Installing Spoiler and Bumper |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
|
Front spoiler
Mounting plate
Bracket
Snap nut
Bolt M 6 x 15
Washer A 6.4
Nut
Screw B 6.3 x 19
Nut M 6
Washer A 6.4
Bolt M 6 x 16
Cover
Side marker light
Gasket
Mounting part
Nut
Front fog ligh
|
1
2
1
3
6
6
6
3
1
1
1
1
2
2
1
4
2 |
Unscrew bolts on
fender mounting
plate and brace.
Disconnect side
marker lights and
front fog light plugs.
Unscrew bolts on front
spoiler bracket and
brace
|
Align with fenders.
Apply coat of non-
hardening body sealing
compound between
spoiler and fenders in
inside area of flange.
Position bracket
correctly
|
Polyurethane part.
Polyurethane part
|
| Printed in Germany |
| Removing and Installing Spoiler and Bumper |
|
63 - 3 |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
|
Bolt
Washer
Washer
Nut
Screw
Bumper
License plate holder
Nut
Screw M 6 x 15
Washer B 6.4
Nut M 6
Screw
Washer
Bolt M 10 x 60
Washer B 10
Washer A 10.5
Impact absorber
Washer 8.4
Washer B 8
Bolt M 8 x 25
Rubber guard strip
Washer
Nut
|
8
16
8
8
4
1
1
2
2
2
2
2
2
2
2
2
2
4
4
4
2
4
4 |
Disconnect turn sig-
nal plugs
|
Check for uniform
distance to body
Adjust to same height
as body edge
|
|
| 63 - 4 |
Removing and Installing Spoiler and Bumper |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
41
42
43
44
45
46
47
48
49
50
|
Spray jet
Nut
Turn signal
Threaded plate
Screw
Screw
Cover
Screw M 4 x 15
Washer
Nut
|
2
2
2
2
2
4
1
2
2
2 |
|
|
|
N o t e
If bumper does not have holes for installation of the cover, drill and countersink holes subsequently
according to specified dimensions.
N o t e
(holes only on right side)
Bumper top rightBumper bottom right
| Printed in Germany |
| Removing and Installing Spoiler and Bumper |
|
63 - 5 |
|
DISASSEMBLING AND ASSEMBLING REAL BUMPER
| 63 - 6 |
Disassembling and Assembling Rear Bumper |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note When: |
Special
Instructions |
Removing |
Installing |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
|
Bumper
Bolt M 12 x 65
Washer
Lockwasher
Impact absorber
Bolt M 8 x 20
Lockwasher
Bumper overrider
Overrider bracket
Washer
Nut M 6
Cover
Washer
Nut M 5
|
1
2
2
2
2
4
4
2
6
6
6
2
4
4 |
Replace if necessary
Replace if necessary
|
Check for uniform
distance to body
Adjust to same height
on left and right sides
Check for neat fit on
bumper and side panel
|
|
| Printed in Germany |
| Disassembling and Assembling Rear Bumper |
|
63 - 7 |
|
| 9 4 4 |
W i n d o w s, W i n d o w C o n t r o l s |
64 |
REMOVING AND INSTALLING WINDSHIELD
T o o l s
1 Cutting tool
2 Plastic wedge
3 Two double-suction cups
4 Manual cartridge gun
|
|
S t a n d a r d T o o l s
Carpet knife, combination pliers,
protective goggles and leather gloves.
A d h e s i v e S e a l i n g S e t
consisting of:
1
2
3
4
5
6
7 |
Adhesive sealing material in 300ml
cartridge
Injection nozzle
Cleaning solution 20 ml
Body primer 30 ml
Glass primer 30 ml
Primer application tool
Cutting wire 0.5 mm x 1.8 m |
|
| Printed in Germany - V, 1985 |
| Removing and Installing Windshield |
|
64 - 1 |
|
| 64 |
W i n d o w s, W i n d o w C o n t r o l s |
9 4 4 |
R e m o v i n g
| 1. |
Remove engine hood, windshield wipers,
sun visors, trim panel on front roof beam
and trim panels on A pillars.
|
| 2. |
Unplug windshield antenna. Unscrew
eccentric and lift off from above. Push
out upper spacer parts forward. Pull
cover strip out of holder. |
|
|
| 3. |
Bend open spacing frame in area of A
pillars and roof beam from the inside
with a suitable tool. |
| 4. |
Cut off half of cutting wire and
puncture through adhesive sealing
material with end of wire from the
inside with help of a pliers. |
|
| 64 - 2 |
Removing and Installing Windshield |
Printed in Germany |
|
| 9 4 4 |
W i n d o w s, W i n d o w C o n t r o l s |
64 |
5. Cover areas subject to damage.
| 6. |
Mount cutting tool on ends of wire.
Insert cutting tool into glued seal from
inside in order to avoid damaging the
window glass and antenna. Press down
wire with a plastic wedge and cut through
cemented seal. |
N o t e
D o n o t s a w , s i n c e t h i s w o u l d
c a u s e t h e w i r e t o h e a t u p a n d
b r e a k
|
|
| 7. |
Lift window glass at bottom slightly
and cut off spacing frame on left and
right sides. Take windshield glass out
of body opening. |
|
| Printed in Germany - V, 1985 |
| Removing and Installing Windshield |
|
64 - 3 |
|
| 64 |
W i n d o w s, W i n d o w C o n t r o l s |
9 4 4 |
| 8. |
Remove spacing frame and remaining
cemented seal from the windshield and
body opening edges with a carpet knife
only to the extent, that a surface
covering residual cement remains and
the windshield and lower body opening
edge do not have to be primed. |
|
|
I n s t a l l i n g
| 1. |
Install new spacing frame on body
opening edge, checking for good
seating. Coat tabs of sealing plugs
with cement prior to installation. |
|
| 64 - 4 |
Removing and Installing Windshield |
Printed in Germany |
|
| 9 4 4 |
W i n d o w s, W i n d o w C o n t r o l s |
64 |
| 2. |
Clean spacing frame with a lintless rag
and cleaning solution, and wipe off
afterwards. Apply coat of body primer
and allow it to air dry. |
| 3. |
Heat cartridge in a water bath having
a temperature of 40 to 60° C about
30 minutes prior to applying coat of
cement. Apply a tapered bead of
cement on the entire body opening
edge for the windshield. |
|
|
| 4. |
Mount spacers and insert eccentric.
Install doublesuction cups on wind-
shield on spacers and tilt into wind-
shield frame. Adjust the windshield
on the eccentrics to have a gap of
2 + 1 mm between the glass and body. |
|
| Printed in Germany - V, 1985 |
| Removing and Installing Windshield |
|
64 - 5 |
|
| 64 |
W i n d o w s, W i n d o w C o n t r o l s |
9 4 4 |
N o t e
The cement must have a drying temperature
of at least + 15° C, since lower temperatures
would impair the process considerably. High
moisture or sprinkling water on the cement
will accelerate drying. In spite of this, the
car must not be moved or operated before
3 hours drying time.
| 5. |
Press cover strip into holder.
|
| 6. |
Clean glass to remove residual cement.
Install A pillar trim panels, roof beam
trim panel, sun visors, windshield
wipers and engine hood.
|
| 7. |
When installing a new windshield, the
glass must be cleaned with a cleaning
solution and coated with glass primer
in the area of the filter print.
The coat of primer must not extend
beyond the filter print. |
N o t e
Sekuriflex windshields must not be
prime coated!
| 64 - 6 |
Removing and Installing Windshield |
Printed in Germany |
|
| 9 4 4 |
Windows, Window Controls |
64 |
REMOVING AND INSTALLING WINDSHIELD (SEKURIFLEX WINDSHIELD AND VEHICLES
EQUIPPED WITH AIRBAGS)
Tools
| No. |
Description |
Special Tool |
Remarks |
1
2
3 |
Double suction cup
Cartridge adhesive gun
Cutting tool |
V.A.G. 1344
V.A.G. 1344/1
V.A.G. 1561 |
VW Co. Ltd.
Customer Service
Equipment Sales |
4
5
6 |
U-shaped blade
Scraper
Cranked blade |
Commercially
available
Commercially
available
Commercially
available |
639 031 140 14*
639 031 130 22*
639 030 720 17*
| * |
Items 4-6 e.g. C.& E.
Fein GmbH & Co.
P.O.Box 172
7000 Stuttgart 1 |
|
| Printed in Germany - XI, 1986 |
Removing and Installing
Windshield |
|
64 - 7 |
|
| 64 |
Windows, Window Controls |
9 4 4 |
R e m o v i n g
| 1. |
Remove engine compartment hood,
windshield wipers, cover strip
for antenna cable, sun visors,
rear-view mirror, trim panel on
front roof beam and trim panels
on A pillars.
|
| 2. |
Unplug windshield antenna.
Unscrew eccentrics and lift off.
Remove spacers by pushing
forward. |
N o t e
When eccentric is lifted off, notch
must point toward mark on spacer.
|
|
| 3. |
Pull cover strip from holder. |
| 4. |
Cover exposed areas and open
side windows to avoid damage. |
N o t e
Do not reclose the side windows
until the cement curing time has
elapsed.
|
| 64 - 8 |
Removing and Installing Windshield |
Printed in Germany |
|
| 9 4 4 |
Windows, Window Controls |
64 |
| 5. |
Fit cranked blade in cutting
tool and set vibration regulator
to stage 3. Working from inside
the car, cut through bonding
bead between windshield and body
seam along the A pillars and the
front roof beam. |
| 6. |
Working from outside the car,
scrape all traces of cement off
edge of windshield. |
|
|
N o t e
Always sharpen blades on the
whetstone with cutting tool running
immediately before use.
| 7. |
Fit U-shaped blade in cutting
tool and set vibration regulator
to stage 6. Insert the blade
with the cutting edge parallel
to the cutting tool. Working
from outside, cut through the
rest of the cement film along
the scuttle. |
8. Lift glass out of frame.
|
| Printed in Germany - XI, 1986 |
Removing and Installing
Windshield |
|
64 - 9 |
|
| 64 |
Windows, Window Controls |
9 4 4 |
| 9. |
Use scraper to remove remaining
cement from body seam until only
a thin film is left on the
entire surface. |
I n s t a l l i n g
| 1. |
Clean body seam with cleaning
solution and wipe off with a
paper towel. |
N o t e
Ensure that no traces of cleaning
solution are left on the bonding
surface.
| 2. |
Apply primer to body seam. Do
not prime painted areas which
remain visible.
|
| 3. |
Apply activator to contact face
of Betaseal sealing strip of
Sekuriflex windshield. Wait for
at least 10 minutes before
proceeding to allow air to
escape. Do not prime the
Sekuriflex windshield
(Betaseal sealing strip). |
|
|
| 4. |
Apply a tapered bead of cement
right round body seam. |
|
| 64 - 10 |
Removing and Installing Windshield |
Printed in Germany |
|
| 9 4 4 |
Windows, Window Controls |
64 |
| 5. |
Install spacers and insert
eccentrics. Set windshield on
spacers and lower into frame.
Adjust eccentrics to position
windscreen so that at the top,
a gap of approx. 2 mm is left
between glass and body.
|
| 6. |
Press cover strip into holder.
|
| 7. |
Clean all traces of cement from
glass and connect windshield
antenna. Mount A-pillar panels,
roof-beam panel, sun visors,
windshield wipers, rear-view
mirror, antenna cable cover and
engine-compartment hood. |
N o t e
To assure adequate strength in the
adhesive bond, the following
boundary conditions must be
observed before the car leaves
the workshop:
Curing time
Temperature
Relative air
humidity |
min. 10 h
min. 15°C
min. 40% |
If temperatures or relative air
humidity are lower, more time must
be allowed for curing.
Do not move the car or start the
engine until the curing time has
elapsed.
|
|
Adhesive sealing set:
1
2
3
4
5
6 |
Adhesive sealing material
cartridge
Injection nozzle
Cleaning solution
Activator
Body primer
Swab |
|
| Printed in Germany - XI, 1986 |
Removing and Installing
Windshield |
|
64 - 11 |
|
| 64 |
Windows, Window Controls |
9 4 4 |
|
Removing and installing windshield - 2-pack adhesive
The following tools and materials are required for removal and installation of the windshield:
A
B
C |
Cutter
Twin-cup suction puller
Bonding gun |
VAG 1561
VAG 1344
VAG 1628 |
e.g. VW Werk AG
Service equipment supply |
D
E
F |
Cutting knife. U-shape
Flashing knife
Cutting knife, cranked |
639.031.140.14
639.031.130.22
639.030.720.17 |
e.g. C & E FEIN GmbH & Co.
P.O. Box 172
7000 Stuttgart 1 |
G
H
H1
H2
H3
H4
H5
H6
H7
H8 |
Mixing rod 9528
Adhesive set
- Cartridge component A
- Mixing cartridge comp. B
- Primer
- Activator
- Cleaning solution
- Injector nozzle
- Application nozzle
- Touch-in tool
|
000.721.952.80
000.043.038.01 |
Porsche Parts Department |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991
|
64 - 13 |
|
Removing and installing windshield - 2-pack adhesive
Removal of the windshield is identical to "Removing and installing the bonded windshield,
page 64 - 8 to 64 - 10".
| No. |
Operation |
Instructions |
| |
Remove interior in the
windshield area |
Remove sun visors, interior rearview mirror, front roof
rail lining and A-post lining. |
| |
Remove exterior parts in
the windshield area |
Remove front cover, windshield wipers, antenna cable
cover molding and spacers.
Disconnect windshield antenna connector and remove
windshield cover molding. |
| |
Spread protective cover
over instrument panel |
Cover instrument panel to avoid staining or damaging
the panel. |
| |
Open door windows |
Caution: The door windows must not be closed
before the adhesive har cured completely! |
| |
Cut out windshield in roof rail
and A-post area |
Insert cranked knife (F) into cutter (A). Set vibration
regulator to stage 3.
Cut bonding between windshield and body from inside
(passenger compartment) along A-posts and roof rail.
Cut off protruding adhesive from outside directly along
edge of windshield.
|
| |
Cut out windshield in
instrument panel area |
Insert U-shaped cutting knife (D) into cutter (A).
Insert cutting knife in such a manner that the cutting
edge is parallel to the cutter. Set vibration regulator to
stage 6. Cut through remaining bonding of the
windshield from outside along the instrument panel.
|
| 64 - 14 |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991 |
|
| No. |
Operation |
Instructions |
| |
Remove windshield |
|
| |
Apply adhesive to body |
Insert flashing knife (E) into cutter (A) and remove ad-
hesive only to the extent that the remaining adhesive
cover the whole area in a uniform manner. |
| |
Clean windshield aperture
of bodywork |
Clean windshield aperture of body thoroughly using
cleaning solution (H5).
Caution: Make sure no residue of the cleaning solu-
tion remain on the bodywork. |
| |
Apply primer to damaged
areas of bodywork |
Use primer (H3) to coat damaged areas in non-visible
section of windshield aperture. |
| |
Activate bonding section of
windshield |
Apply activator (H4) to bonding section of pre-coated
windshield.
Caution: Allow a flash-off time of at least 10 minutes! |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991
|
64 - 15 |
|
Removing and installing windshield- 2- pack adhesive
Preparing the adhesive cartridge for application of adhesive
 746 - 64
| 64 - 16 |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991 |
|
| No. |
Operation |
Instructions |
| |
Preparing the adhesive cartridge
for application of adhesive |
| 1 |
Open nozzle fitting of cartridge
containing component A |
Use a screwdriver to pierce the diaphragm in the nozzle
fitting of the cartridge containing component A (H1). |
| 2 |
Open flanged cover of cartridge
containing component A |
Use a screwdriver to pierce the flanged cover at the end
of the cartridge containing component A (H1). |
| 3 |
Screw injector nozzle to
cartridge containing
component A |
Screw injector nozzle (H6) to cartridge containing com-
ponent A (H1). |
| 4 |
Insert cartridge containing
component A into
bonding gun |
Insert cartridge containing component A (Hl) into bond-
ing gun (C).
Remove screw-on cap from mixing cartridge containing
component B (H2). |
| 5 |
Press component A into
mixing cartridge containing
component B |
Insert injector nozzle (H6) of cartridge containing com-
ponent A (H1) into mixing cartridge containing com-
ponent B (H2).
Use bonding gun (C) to press component A into mixing
cartridge (H2) containing component B. |
| 6 |
Close mixing cartridge |
Pull injector nozzle out of mixing cartridge and close
mixing cartridge with screw-on cap. |
| 7 |
Screw mixing rod into
mixing cartridge |
Screw mixing rod (G) manually into internal thread of
mixing disc in the mixing cartridge. Clamp other end of
mixing rod into a drill chuck.
Fit the drill into a suitable clamp. |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991
|
64 - 17 |
|
| No. |
Operation |
Instructions |
| 8 |
Mix component A and
component B |
Turn on drill (700 to 900 rpm) and rotate mixing
cartridge approx. 25 times from stop to stop.
Perform all 25 double strokes fairly rapidly. |
| 9 |
Engage mixing disc into
piston |
Pull back mixing cartridge until a rattling sensation is
felt.
Turn off drill and screw mixing rod out of mixing
cartridge.
The mixing disc will then engage into the piston of the
mixing cartridge. |
| 10 |
Insert mixing cartridge into
bonding gun |
Insert mixing cartridge with mixed 2-pack windshield ad-
hesive into bonding gun.
Screw application nozzle (H7) onto mixing cartridge. |
Caution: Open time is 15 minute!
Open time is the time available for application of the adhesive and for installing the windshield
into the body aperture.
|
| |
Apply adhesive to the
bodywork
|
Apply a trapezoidal continuous bead of 2-pack
adhesive to the body flange using the bonding gun. |
| |
Install spacers |
Push on spacers and insert eccentric adjusters. |
| |
Insert windshield into
body aperture |
Set up wind shield on spacers and tilt into windshield
aperture.
Use the eccentric adjusters to adjust the spacers in
such a manner that a 2 mm gap remains in the roofarea
between windshield and bodywork. |
| |
Clean visible areas |
Remove adhesive that has squeezed out immediately
and clean the visible areas affected using cleaning
solution (H5). |
| 64 - 18 |
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991 |
|
| No. |
Operation |
Instructions |
| |
Install exterior parts |
Press windshield cover molding into retainer. Insert
windshield antenna.
Install cover molding for antenna cable, windshield
wipers and front cover |
| |
Refit interior |
Refit A-post linings, roof rail linings, sun visors and inte-
rior rearview mirror. |
Caution
The bonding does not immediately reach its full strength. In order to ensure sufficient bonding
strength, the following conditions must be adhered to:
Curing time
Temperature
|
3 hours
min. 5° C |
Do not operate the vehicle before the curing time has elapsed!
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXIV, 1991
|
64 - 19 |
|
| 944 |
Glasses, Window Control |
64 |
Bonding the interior rearview mirror in place
The following materials are required for bonding of the complete interior rearview mirror:
A = Cleaning solution (000.043.157.00)*
B = Primer (000.043.158.00)*
C = Cover sheet (000.043.177.00)*
D = Activator (000.043.052.00)*
E = Adhesive (000.043.051.00)*
* Porsche part no.
Bonding the interior rearview mirror in place
Printed in Germany - XXIV, 1991
|
64 - 21 |
|
| 64 |
Glasses, Window Control |
944 |
Bonding the interior rearview mirror in place
Bonding the fully assembled interior mirror to the windshield
| 64 - 22 |
Bonding the interior rearview mirror in place
Printed in Germany - XXIV, 1991 |
|
| 944 |
Glasses, Window Control |
64 |
Bonding the interior rearview mirror in place
Bonding the fully assembled interior mirror to the windshield
| No. |
Operation |
Instructions |
| 1 |
Mark position of interior
rearview mirror
Remove adhesive residue
Roughen bonding plate of
rearview mirror
Clean bonding plate of
rearview mirror
Clean bonding area
of windshield |
Mark position of adhesive plate on outside of windshield.
| Cabriolet: |
Dimension A = 623 mm
Dimension B = 84 mm |
| Coupe: |
Dimension A = 623 mm
Dimension B = 142 mm |
Remove adhesive residue from windshield mechanically
using a scraper.
Remove adhesive residue from bonding plate of rear-
view mirror mechanically using a scraper.
Roughen bonding plate of rearview mirror mechanically
using sanding paper.
Clean bonding plate of rearview mirror using
cleaning solution (A).
Clean bonding area of windshield using cleaning
solution (A).
|
| 2 |
Mask off bonding area
of windshield |
Mask off bonding area of windshield using primer
template (cover sheet C).
The position mark of the interior rearview mirror must
be visible in the middle of the primer template.
|
| 3 |
Prime bonding area
of windshield |
Apply a thin coat of primer (8) to the masked bonding
area of the windshield.
Caution: Allow a flash-off time of 15 to 20 minutes!
|
| 4 |
Activate bonding area of
windshield |
Spray activator (D) onto bonding area
of the windshield.
Caution: Allow a flash-off time of 2 minutes!
|
Bonding the interior rearview mirror in place
Printed in Germany - XXIV, 1991
|
64 - 23 |
|
| 64 |
Glasses, Window Control |
944 |
| No. |
Operation |
Instructions |
| |
Remove primer template |
|
| 5 |
Apply adhesive to bonding
plate |
Apply a drop of adhesive (E) to the bonding plate of the
rearview mirror. |
| 6 |
Bond rearview mirror in place |
Press bonding plate of rearview mirror against primered
and activated windshield area. |
| |
|
Note: Press mirror in place for approx. 40 - 50 sec.!
Note:
Bonding strength
60 % after 1 hour
100 % after 24 hours
|
| 64 - 24 |
Bonding the interior rearview mirror in place
Printed in Germany - XXIV, 1991 |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t |
66 |
REMOVING PORSCHE EMBLEMS
Slide a suitable tool between the PORSCHE emblem
and liner and lift off from above.
I m p o r t a n t !
Be careful not to damage the paint!
| Printed in Germany |
|
66 - 1 |
|
| 66 |
E x t e r i o r E q u i p m e n t |
9 4 4 |
REPLACING STONE PROTECTION SHEETS
| 1. |
An industrial hot air blower or similar would be
suitable for the removal of stone protection
sheets. Heat entire adhesive surface and pull
off stone protection sheets.
|
| 2. |
Remove dirt from entire adhesive surfaces and
then clean with alcohol.
|
| 3. |
Moisten adhesive surfaces with a mixture of
50 % alcohol and water. so that the sheet will
not adhere too tight immediately.
|
| 4. |
Pull off paper backing on adhesive surface and
paste sheet according to specified dimensions. |
D i m e n s i o n s :
Distance A = approx. 3 mm
(parallel to wheel opening)
|
|
Distance B = approx. 3 mm
Distance C = approx. 3 mm
(parallel to wheel opening)
| 5. |
Paste sheets so that each pertinent lower edge
of sheet is applied on PVC guard.
|
| 6. |
Rub out moisture from center to the edges with
a plastic spatula or similar tool. Make sure that
no air bubbles remain trapped.
|
| 7. |
Pull off external paper backing and remove any
trapped air by puncturing with a pin. Then press
on sheet again. |
N o t e
Sheet and car temperature must not be below
+20°C(70°F).
|
| 66 - 2 |
Replacing Stone Protection Sheets |
Printed in Germany |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t |
66 |
REMOVING SIDE MOULDINGS
| 1. |
Remove rubber door weatherstrip at rear in area
of lock. Drill through plastic rivet with a 4 mm dia.
drill. |
| 2. |
Pull off side moulding carefully. If necessary, help
with a sharp knife. |
|
|
| 3. |
Remove remaining adhesive strips on body care-
fully with a special knife. Wrap tape around
edges of special knife to avoid paint damage.
(Special knife is available from paint store
outlets.) |
N o t e
As much of the adhesive strip should be removed
from the body as possible, without damaging the
paint.
|
| Printed in Germany |
|
66 - 3 |
|
| 66 |
E x t e r i o r E q u i p m e n t |
9 4 4 |
INSTALLING SIDE MOULDINGS
N o t e
The following points are important to assure good adhesion of the side mouldings.
| 1. |
Wash car. Clean body thoroughly in area of installation to remove dirt, grease, wax and other sealing
compounds; using alcohol or gasoline and acetone. Acetone may only be used once.
|
| 2. |
Do not install side mouldings outside in cold or moist weather. Car and ambient temperature should be
about +20°C (70°F). |
I n s t a l l i n g
| 1. |
First mark location of door strip according to the
specified dimensions. |
H e i g h t D i s t a n c e s :
Distance A = 230 mm
(rear door lower edge - strip lower edge)
|
|
Distance B = 220 mm
(front door lower edge - strip lower edge)
| 2. |
Prepare side mouldings for gluing.
The side moulding has adhesive strips on both
sides, which hold them in position until the
adhesive has become hard. If side moulding does
not haveadhesive strips, clean adhesive side and
glue adhesive strips. |
|
| 66 - 4 |
Installing Side Mouldings |
Printed in Germany |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t |
66 |
| 3. |
Coat adhesive groove of side moulding with
adhesive compound (Part No. AMV 176 00 05).
The adhesive bead coat should be 1 mm higher
than the side moulding contour. Strips must be
installed no later than 10 minutes after application
of adhesive coat. |
| 4. |
Pull off protective paper on adhesive surface. Do
not touch adhesive surface. First lightly place strip
directly on rear door edge and above marked
distances, check positioning and correct if
necessary, and then press on firmly with a rubber
roller. Remove rear rubber door weatherstrip in
area of lock. Drill a 4 mm dia. hole in strip and
door from behind and secure with a plastic rivet. |
|
|
| 5. |
Center front and rear adjacent strips with door
strip and install as described for door strip. |
C a u t i o n !
Cars with newly glued strips must not be run
through a car wash during the next 24 hours.
|
| Printed in Germany |
| Installing Side Mouldings |
|
66 - 5 |
|
| 66 |
E x t e r i o r E q u i p m e n t |
9 4 4 |
REMOVING AND INSTALLING ROOF ORNAMENTAL STRIP
R e m o v i n g
| 1. |
Press off roof strip to side in area of
holding clips carefully with a suitable
tool. |
| 2. |
Check holding clips and seal, replacing
if necessary. |
|
|
I n s t a l l i n g
| 1. |
Place roof strip on roof flush with rear
edge of roof and press into holding
clips. |
|
| 66 - 6 |
Removing and Installing Roof Ornamental Strip |
V, 1985 - Printed in Germany |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t / P a i n t |
66 |
BODY PAINT COLORS - 1982 MODEL
S t a n d a r d
|
S p e c i a l
|
mocca black
gabun grey
guards red
gambia red
mauritius blue
alpine white
havana brown
|
LM 9 V
LY 7 A
LM 3 A
LA 3 B
LY 5 A
L 90 E
LD 8 A
|
platinum metallic
light blue metallic
black metallic
Ihasa green metallic
surinam red metallic
meteor grey metallic
diamond silver metallic
|
LM 8 U
LM 5 Z
LM 9 Y
LA 6 V
LA 3 Y
LY 7 Z
L 97 A
|
BODY PAINT COLORS - 1983 MODEL
|
S t a n d a r d
|
S p e c i a l |
guards red
black
alpine white
copenhagen blue
pasadena yellow
|
LM 3 A
LO 41
L 90 E
LY 5 B
LY 1 L
|
platinum metallic
moss green metallic
light bronze metallic
saphire metallic
montego black metallic
sienna red metallic
gemini grey metallic
zermatt silver metallic
sable brown metallic
|
LM 8 U
LM 6 V
LM 1 V
LY 5 V
LY 9 V
LD 3 V
LZ 7 Z
LY 7 Y
LY 8 V
|
| Printed in Germany - I, 1982 |
|
66 - 7 |
|
| 66 |
E x t e r i o r E q u i p m e n t / P a i n t |
9 4 4 |
BODY PAINT COLORS - 1984 MODEL
S t a n d a r d:
|
S p e c i a l:
|
india red
black
alpine white
copenhagen blue
pasadena yellow
|
LM 3 A
LO 41
L 90 E
LY 5 B
LY 1 L
|
platinum metallic
Iight bronze metallic
saphire metallic
montego black metallic
ruby red metallic
gemini gray metallic
cermatt metallic
sobel metallic
|
LM 8 U
LM 1 V
LY 5 V
LY 9 V
LM 3 V
LZ 7 Z
LY 7 Y
LY 8 V
|
BODY PAINT COLORS - 1985 MODEL
|
S t a n d a r d:
|
S p e c i a l: |
india red
black
alpine white
copenhagen blue
pasadena beige
|
LM 3 A
L 041
L 90 E
LY 5 B
LM 1 N
|
saphire metallic
cermatt metallic
mahagoni brown metallic
crystall green metallic
granate red metallic
calahari beige metallic
slate gray metallic
graphite metallic
|
LY 5 V
LY 7 Y
LB 8 Z
LM 6 Y
LM 3 Y
LA 1 Y
LY 7 U
LB 7 V
|
| 66 - 8 |
Body paint colors |
V, 1985 - Printed in Germany |
|
| 9 4 4 |
Exterior Equipment/Paint |
66 |
BODY PAINT COLORS - 1986 MODEL
ONWARD
Standard:
|
Special:
|
india red
black
alpine white
copenhagen blue
Pastel beige
|
LM 3A
L 041
L 90E
LY 5B
LM 1N
|
Saphire metallic
Zermatt silver - metallic
Mahogany brown - metallic
Crystal green - metallic
Garnet red - metallic
Kalahari beige - metallic
Slate grey - metallic
Graphite - metallic
Pearl white - metallic
|
LY 5V
LY 7Y
LB 8Z
LM 6Y
LM 3Y
LA 1Y
LA 7U
LB 7V
LO A9
|
BODY PAINT COLORS - 1987 MODEL
ONWARD
|
Standard:
|
Special: |
Black
Alpine white
Lemon yellow
Azurite blue
Malven red
India red
|
L 041
L 90E
L MIA
L Y5D
L Y3E
L M3A
|
Zermatt silver - metallic
Slate grey - metallic
Satin black - metallic
Nautic - metallic
Flamingo - metallic
Marachino red - metallic
Almond beige - metallic
Nile green - metallic
Diamond blue - metallic
Nougat brown - metallic
|
L Y7Y
L Y7U
L Y9Y
L Y5Z
L Y4Z
L Y3V
L YIY
L Y6Y
L M5U
L M8V
|
| Printed in Germany - XIII, 1987 |
|
66 - 8a |
|
| 944 |
Exterior Equipment, Body Paint |
66 |
Body paint colors as from Model 1988
Standard:
|
Special:
|
Black
Alpine white
Azurite blue
India red
|
L 041
L 90E
L Y5D
L M3A
|
Zermatt silver metallic
Slate grey metallic
Satin black metallic
Nautic metallic
Maraschino red metallic
Nile green metallic
Almond beige metallic
Nougat brown metallic
|
L Y7Y
L Y7U
L Y9Y
L Y5Z
L Y3V
L Y6Y
L Y1Y
L M8V
|
Body paint colors as from Model 1989
|
Standard:
|
Special: |
Black
Alpine white
Azurite blue
India red
|
L 041
L 90E
L Y5D
L M3A
|
Zermatt silver metallic
Slate gray metallic
Satin black metallic
Glacier metallic
Bamboo metallic
Velvet red metallic
Dove blue metallic
linen metallic
|
L Y7Y
L Y7U
L Y9Y
L Y5U
L Y1Z
L M3U
L M5P
L M1U
|
| 66 - 8b |
Body paint colors
Printed in Germany - XVII, 1988 |
|
| 66 |
Exterior - Paintwork |
944 |
Body Paint Colors Beginning With
1990 Models
Standard Colors:
|
Special Colors:
|
Black
Alpine white
Azurite blue
India red
|
L 041
L 90E
L Y5D
L M3A
|
Crystal silver metallic
Titan metallic
Panthero metallic
Glacier metallic
Zyclam-red pearl effect
Velvet-red metallic
Dove-blue metallic
Linen metallic
|
L Y7T
L Y7P
L Y9Z
L Y5U
L Z3T
L M3U
L M5P
L M1U
|
Body Paint Colors Beginning With
1991 Models
|
Standard Colors:
|
Special Colors: |
Brilliant black
Alpine white
Azurite blue
Indian red
Star ruby
Maritime blue
|
L Y9B
L 90E
L Y5D
L M3A
L M3B
L M5A
|
Crystal silver metallic
Titan metallic
Panthero metallic
Glacier metallic
Zyclam-red pearl effect
Cobalt-blue metallic
|
L Y7T
L Y7P
L Y9Z
L Y5U
L Z3T
L M5N
|
Body paint colors
Printed in Germany - XXII, 1990
|
66 - 8c |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t, P a i n t |
66 |
REMOVING AND INSTALLING OUTSIDE MIRROR SINCE 1985 MODELS
N o t e
The mirror glass has a different mounting
method which is similar to a bayonet
fastener. The retaining ring on the mirror
glass can be turned with the help of a
screwdriver and unlocked or locked in
this manner.
Retaining ring unlocked
Retaining ring locked
|
|
| 1. |
Press in mirror glass at bottom. Turn
(unlock) retaining ring with a screw-
driver applied on the teeth through
bottom opening. The glass of left and
right mirrors is identical. |
| 2. |
Take off mirror glass and pull off
mirror heating plug. |
|
| Printed in Germany - V, 1985 |
Removing and Installing Outside
Mirror Since 1985 Models |
|
66 - 9 |
|
| 66 |
E x t e r i o r E q u i p m e n t, P a i n t |
9 4 4 |
| 4. |
Press round female plugs out ot plug
section with a pressing-out tool. |
|
|
| 5. |
Unscrew mounting screws on mirror
base and take off mirror housing. |
|
| 66 - 10 |
Removing and Installing Outside |
Printed in Germany |
|
| 9 4 4 |
E x t e r i o r E q u i p m e n t, P a i n t |
66 |
Plug Connections (Rear View)
Terminal 1 = white
Terminal 2 = white/brown - black
Terminal 3 = black
Terminal 4 = black/brown
Terminal 5 = brown
Terminal 6 = brown/yellow
|
|
N o t e
After installation of the mirror glass check,
whether the retaining ring has been locked
correctly.
This is done by pressing in the mirror glass
at top and checking the retaining ring
through the bottom gap.
|
| Printed in Germany - V, 1985 |
Removing and Installing Outside
Mirror Since 1985 Models |
|
66 - 11 |
|
| 66 |
Exterior Equipment (Paint) |
9 4 4 |
FASTENING T-BOLTS TO SPOT-WELD ROOF FLANGE
| 1. |
Clean fastening point on roof
flange down to bare metal. |
| 2. |
Mount contact pin, fitting piece,
and T-pin onto sheetmetal-working
device. |
|
|
| 3. |
Set sheetmetal-working device on-
to roof flange and weld T-pin on-
to flange. |
N o t e
For sheetmetal-working device,
fitting piece, and T-pins for welding
on the T-pins, see workshop manual.
|
| 66 - 12 |
Fastening T-Bolts onto Spot-
Weld Roof Flange |
VII, 1986 - Printed in Germany |
|
| 944 Cabriolet |
Exterior |
66 |
Removing and installing plastic end and side applicates
Removing and installing plastic end and side applicates
Printed in Germany - XXII, 1990
|
66 - 13 |
|
| 66 |
Exterior |
944 Cabriolet |
Removing and installing plastic end and side applicates
Note
Removing and installing the side applicates requires removal of folding top
(see "Removing and installing folding top", 61-41)
| No. |
Task |
Instructions |
| Removal: |
| |
Unclip luggage com-
partment lining |
|
| 1 |
Undo screw fastenings of end
applicate |
From the luggage compartment side, undo 4 fastening
nuts of end applicate. Remove end applicate. |
| 2 |
Undo fastening screws in
area of folding top cover |
Remove folding top gasket in area of side applicate from
spot welding flange. Undo 8 screw fastenings of side ap-
plicate in area of folding top cover. |
| 3 |
Undo fastening screws and
nuts of side applicate
Undo screw fastening of
shear-off device
|
Undo two fastening screws in transition area of side ap-
plicate to end applicate. From luggage compartment
side, undo 4 fastening nuts of side applicate. Undo
screw fastening of side applicate. Undo screw fastening
of shear-off device on tank filler neck cladding.
|
| |
Detach glued-on side appli-
cate from body
|
Starting from rear, detach glued-on side applicate from
body by pulling it cautiously away. |
| Installation: |
| |
Line side applicate with
butyl tape |
Seal screw fastenings with butyl tape.
Tack side applicate to body with butyl tape. |
| |
Screw side applicate to body |
4 nuts M 6
2 sheet metal screws 4.2 x 13
8 countersunk sheet metal screws 4.2 x 16 |
| |
Fit folding top gasket on |
Fit folding top gasket onto spot welding flange in area of
side applicate. |
| |
Bolt on end applicate
Clip in luggage compartment
lining |
4 nuts M 6 |
| 66 - 14 |
Removing and installing plastic end and side applicates
Printed in Germany - XXII, 1990 |
|
| 944 Cabriolet |
Exterior |
66 |
Removing and installing tank flap - Cabrio
Removing and installing tank flap - Cabrio
Printed in Germany - XXII, 1990
|
66 - 15 |
|
| 66 |
Exterior |
944 Cabriolet |
Removing and installing tank flap - Cabrio
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9 |
Sheet metal screw
4.2 x 14
Washer A 5
Bracket
Tank tang
Fillister head sheet metal
screw
4.2 x 19
Tank flap
Spacer disk
Stop
Sheet metal screw
|
2
2
1
1
2
1
0-2
2
2 |
|
Adjustment of the over-
all height of the tank flap
is by means of spacer
disks (rnax. 2 pcs.)
Fit onto sheet metal
screw
The angle of inclination
of the tank flap when
closed is altered by ad-
justing the sheet metal
screws
|
| 66 - 16 |
Removing and installing tank flap - Cabrio
Printed in Germany - XXII, 1990 |
|
| 944 |
Exterior Equipment |
66 |
Retrofitting new mirror generation for vehicles as of Model 85/2
Note
For vehicles fitted with driver's and
passenger's side mirrors only.
| 1. |
Remove door mirror. |
| 2. |
Assemble new door mirror. |
| 3. |
Cut mirror wire to required length. |
| 4. |
Fit new connectors and engage into
connector housing section acording to
below list:
| 1 - |
white |
| 2 - |
blue |
| 3 - |
black |
| 4 - |
red |
| 5 - |
brown |
| 6 - |
brown |
|
| 5. |
Fit mirror (route wire through stud into
mirror housing). |
| 6. |
Engage connector into connector housing
section. |
| 7. |
Assemble both connector housing sections
and tie connector housing into place. |
| 8. |
Fit mirror glass. |
Retrofitting new mirror generation for vehicles as of Model 85/2
Printed in Germany - XXV, 1992
|
66 - 17 |
|
| 66 |
Exterior Equipment |
944 |
www.9ss1.dk/porsche944
|
| 9 4 4 |
I n t e r i o r E q u i p m e n t |
68 |
REMOVING AND INSTALLING CENTER CONSOLE SINCE 1985/2 MODELS
| 1. |
Pull out tray holder and ashtray. |
| 2. |
Loosen mounting screws on cover
frame of center console. |
|
|
| 3. |
If car has a radio, it must be removed
with help of the supplied assembly
bar. |
| 4. |
Unscrew mounting screws of center
console and take off center console. |
|
| Printed in Germany - V, 1985 |
Removing and Installing Center
Console Since 1985/2 Models |
|
68 - 1 |
|
| 68 |
I n t e r i o r E q u i p m e n t |
9 4 4 |
REMOVING AND INSTALLING INSTRUMENT PANEL SINCE 1985/2 MODELS
R e m o v i n g
| 1. |
Remove instrument cluster and switch
plates - see Group 90.
|
| 2. |
Remove sun visors, trim panel on front
roof beam and trim panels on A pillars.
|
| 3. |
Unclip glove box light and disconnect
plugs.
|
| 4. |
Unscrew glove box mounting screws.
pull off vent hose and take out glove
box. |
| 5. |
Unscrew mounting screws on hinge
pillars. |
|
|
| 6. |
Unscrew mounting screws on A
pillars. |
|
| 68 - 2 |
Removing and Installing Instrument
Panel Since 1985/2 Models |
Printed in Germany |
|
| 9 4 4 |
I n t e r i o r E q u i p m e n t |
68 |
| 7. |
Unscrew mounting screws on
bracket. |
| 8. |
Pull air guides out of nozzles and
take off instrument panel. |
I n s t a l l i n g
Installation is in reverse sequence. Make
sure spring clamp engages in bracket.
|
|
|
| Printed in Germany - V, 1985 |
Removing and Installing Instrument
Panel Since 1985/2 Models |
|
68 - 3 |
|
| 68 |
Interior Equipment |
9 4 4 |
AIRBAG
1 - Front sensors
2 - Control unit with safety sensor
|
|
3 - Driver and front-passenger airbags
4 - Indicator lamp
|
The airbag system is triggered only in the event of a frontal collision
within the area identified by arrows.
| 68 - 4 |
Airbag |
X. 1986 - Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
SAFETY REGULATIONS FOR WORK ON CARS
WITH AIRBAG
The airbag units are pyrotechnic
devices assigned to hazard category
T 1. Handling, transport and
storage are subject to the laws
governing the handling of
explosives.
The legal stipulations below are
those in force in the Federal
Republic of Germany. In all other
countries, the applicable
regulations must be observed.
The trade inspection authority
(authority responsible) must be
given 14 days notice before work
with pyrotechnic devices commences.
D e s p a t c h
Airbag units may only be despatched
in the transport packaging
offically approved for the purpose.
The airbag units may not be trans-
ported with other hazardous goods.
Within the works facility, the
units must always be transported
in the case or in the goods com-
partment of a vehicle and the
aforementioned transport packaging
must be used. It is prohibited to
transport the units in the
passenger compartment.
|
|
S t o r a g e
Airbag units must be stored in
accordance with the 2nd ordinance
of the industrial explosives act.
This ordinance stipulates that
materials and devices may be stored
at certain locations without a
special storage approval. In the
case of pyrotechnic devices
assigned to category T 1, the
maximum is 20 kg (gross) in a
working area and a maximum of
200 kg (gross) in a storage area.
The airbag units must be stored
in a locked room.
When the airbag units are stored,
care must be taken to ensure that
the upholstered side faces upward
(if inadvertently triggered, the
airbag unit may be thrown upward
and could cause injury).
The airbag units may not be stored
with other hazardous goods (paints
etc.).
|
| Printed in Germany - X. 1986 |
|
68 - 5 |
|
| 68 |
Interior Equipment |
9 4 4 |
I n s t a l l a t i o n a n d
A d j u s t m e n t
Only trained personnel may inspect
and install the units.
Before commencing working on the
airbag system or adjacent parts
where there is a danger of live
parts being brought into the
vicinity of the airbag system, the
following safety precautions must
always be taken:
| 1. |
Switch off ignition.
|
| 2. |
Disconnect cable from minus pole
of battery and cover pole. |
Once the battery has been dis-
connected, installation work or
work with a hammer or similar tool
may only commence after a waiting
time of 20 minutes. This period is
required to interrupt the power
supply of the airbag system and
assure that the airbag is not
inadvertently triggered.
|
|
The airbag units must be installed
immediately after removal from the
store. Under no circumstances leave
the units unsupervised. If work is
interrupted, the airbag units must
be immediately locked away.
Do not bring airbag units into
contact with grease, oil,
detergents or the like.
Do not expose airbag units to
temperatures above 90°C, even for
short periods.
Never install airbag units, front
sensors or control units which have
been dropped from a height of more
than 0.5 m.
The steering wheel and the area
around the passenger-side airbag
must remain free of additional
panels, stickers or the like.
Under no circumstances may the
wiring or components of the airbag
system be modified in any way.
|
| 68 - 6 |
Safety Regulations |
XI, 1987 - Printed in Germany |
|
| 944 |
Interior Equipment |
68 |
Prior to commencement of straightening or
welding operations with an electric welder, al-
ways disconnect the battery.
If it is necessary to weld in the immediate
proximity of the forward sensors and the con-
trol unit, these must be removed beforehand.
Airbag components must not be repaired;
they must always be replaced.
Note
Wash your hands after touching airbag units
which have triggered.
|
|
Disposal of Airbag Units
See page 68 - 31.
|
Safety Instructions
Printed in Germany - XXIV, 1991
|
68 - 7 |
|
| 68 |
Interior Equipment |
9 4 4 |
REMOVING AND INSTALLING DRIVER
AIRBAG UNIT
| 1. |
Disconnect battery and cover
over pole/battery.
|
| 2. |
Loosen fastening screws (2 pieces)
with a screwdriver for socket-
head Torx T 30. |
3. Take apart plug connector.
|
|
N o t e
The airbag unit must always be put
down so that the upholstered side
is pointing upward.
The airbag unit must be stored
under lock and key if removed
for a lengthy period of time.
Follow safety instructions.
Tightening torque for fastening
screws: 10 Nm (7.5 ftlb)
|
| 68 - 8 |
Removing and Installing Driver Airbag Unit |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
REMOVING AND INSTALLING AIRBAG
STEERING WHEEL
R e m o v a l
| 1. |
Disconect battery and cover over
pole/battery.
|
| 2. |
Remove driver airbag unit (see
p. 68 - 8).
|
| 3. |
Loosen hexagon nut and take off
with spring washer. |
| 4. |
Mark position of steering wheel
to steering shaft for
re-installation |
|
|
I n s t a l l a t i o n
| 1. |
Put on steering wheel with wheels
in straight-ahead position or in
in accordance with marking such
that the upper steering-wheel
spokes are horizontal. |
N o t e
The steering wheel must be put on
such that the cable of the contact
unit is not jammed.
| 2. |
Mount hexagon nut with spring
washer and tighten to 45 Nm
(33.5 ftlb)
|
| 3. |
Install driver airbag unit (see
p. 68 - 8).
|
| 4. |
Check operation of horn. |
|
| Printed in Germany - X, 1986 |
Removing and Installing
Airbag Steering Wheel |
|
68 - 9 |
|
| 68 |
Interior Equipment |
9 4 4 |
REMOVING AND INSTALLING CONTACT UNIT
1. |
Remove airbag steering wheel
(see p. 68 - 9).
|
| 2. |
Loosen and remove trim. |
3. Remove right-hand switch panel
4. Take apart plug connectors.
5. Loosen fastening screws.
|
|
N o t e
Prior to installation of the contact
unit, place the front wheels in the
straight-ahead position and bring the
contact unit into the center position
(approx. 4 1/2 turns from left or
right end stop). The precise center
position is indicated by the two
arrows.
A new contact unit is locked in the
center position. The locking is not
removed until after the contact unit
has been installed.
|
| 68 - 10 |
Removing and Installing Contact Unit |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
REMOVING AND INSTALLING FRONT SENSORS
N o t e
The front sensors are positioned
on left and right in the driver
and front-passenger footwells at the
top on the wheelhouse wall.
The installation position is fixed
by the method of mounting.
| 1. |
Disconnect battery and cover over
pole/battery.
|
| 2. |
Take apart plug connector. |
|
|
| 3. |
Loosen rip nuts with special tool
P 9259. |
Special tool P 9259
N o t e
Use 1/4 inch inside hexagon for
tightening the rip nuts.
Use specified washers.
The mounting points on the body
must be bare down to the metal.
|
| Printed in Germany - X, 1986 |
Removing and Installin
Front Sensors |
|
68 - 11 |
|
| 68 |
Interior Equipment |
9 4 4 |
REMOVING AND INSTALLING FRONT-PASSENGER
AIRBAG UNIT
| 1. |
Disconnect battery and cover
over pole/battery.
|
| 2. |
Remove glovebox.
|
| 3. |
Remove air-guide hose.
|
| 4. |
Disconnect plug connectors from
the unit. |
| 5. |
Loosen fastening screws (hexagon
socket head 5 mm, 4 pieces).
|
| 6. |
Loosen fastening screw M 8. |
|
|
N o t e
The hexagon-socket-head cap screws
are micro-encapsulated. Use new
screws when installing.
The M 8 nut is self-locking.
Use new nut when installing.
The airbag unit must always be put
down such that the airbag is pointing
upward.
|
| 68 - 12 |
Removing and Installing
Front Passenger Airbag Unit |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
REMOVING AND INSTALLING CONTROL UNIT
| 1. |
Disconnect battery and cover over
pole/battery.
|
| 2. |
Remove glovebox.
|
| 3. |
Take apart plug conectors for left
front sensor, contact unit, right
front sensor, front passenger
airbag unit and 7-pin plug con-
nector to main wiring harness.
|
| 4. |
Remove fresh-air blower (access
to wiring harness).
|
| 5. |
Loosen cable binders along wiring
harness.
|
| 6. |
Loosen rip nuts with special tool
P 9259. |
 |
|
| 7. |
Remove control unit with water-
protection cap. |
N o t e
The ground cable is mounted on the
front left-hand mounting point. No
further ground cables may be
connected at this point.
The fastening points on the body
must be bare down to the metal.
Use 1/4 inch inside hexagon for
tightening the rip nuts. Use
specified washers.
|
| Printed in Germany - X, 1986 |
Removing and Installing
Control Unit |
|
68 - 13 |
|
| 68 |
Interior Equipment |
9 4 4 |
DIAGNOSIS
The airbag system is monitored
continuously by a diagnosis unit in
the control unit. Any fault which
may occur is indicated by the word
"airbag" in the instrument cluster.
When the ignition is switched on,
the airbag annunciator remains lit
for approximately 5 seconds before
going out. When the engine is
started the annunciator lights up
again for approx. 5 seconds. Any
further response of the annunciator
indicates a defect in the system.
The fault can be output via the
airbag annunciator when an
excitation signal is applied to the
diagnosis input line (application
of an earth signal). For this
purpose, an improvised tool must be
used to input a code.
Note:
The control unit needs a period of
2 minutes to detect all the faults
in the system. To assure that every
possible source of trouble is
tested in a diagnosis, the ignition
must remain switched on for at
least 2 minutes.
|
|
| 1 - |
Wire (commercially available)
approx. 0.5 m long
|
| 2 - |
Crocodile clip
|
| 3 - |
Pushbutton (e.g. limit switch
for tilting sunroof, use
closing function)
|
| 4 - |
Plug receptacle 171.971.998 B
|
| 5 - |
Round plug N 017.589.4
|
| 6 - |
Flat plug 6.3 x 0.8
111.971.959 |
Connect the round plug to pin 2 of
the plug receptacle.
| 1. |
Switch off ignition.
|
| 2. |
Connect improvised tool.
|
| 3. |
Press switch.
|
| 4. |
Switch ignition on.
|
| 5. |
Release switch 3 seconds after
ignition is switched on. |
|
| 68 - 14 |
Diagnosis |
XIII, 1987 - Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
The flashing code then runs off as
described below:
|
|
| 1. |
5-second lamp test.
|
| 2. |
Flashes 1 or more times, de-
pending on number of faults.
|
| 3. |
3 seconds - start for fault
code.
|
| 4. |
Flashes 1 to 4 times, depending
on group in fault table.
|
| 5. |
Flashes 1 to 4 times, depending
on line in fault table.
|
| 6. |
Flashes 1 to 4 times, depending
on column in fault table.
|
| 7. |
Flashes 1 or 2 times
1 = Short-time fault
2 = Long-time fault
|
| 8. |
3 seconds - start for fault
code of a further fault.
Light remains on - end of
interrogation. |
The flashing code interrogation
can be repeated as often as desired.
|
| Printed in Germany - X, 1986 |
|
68 - 15 |
|
| 68 |
Interior Equipment |
9 4 4 |
The flashing pulses must be noted
and the corresponding number must
be read from the following table;
e.g. flashing code 1 - 3 - 3 - 2
means the number 29 and signifies
a long-time fault.
1 - Group
3 - Line
3 - Column
2 - Long-time fault
Fault table for lamp codes
| |
Group 1 |
Group 2 |
Group 3 |
Group 4 |
Line |
| 01 |
11 |
21 |
31 |
02 |
12 |
22 |
32 |
03 |
13 |
23 |
33 |
04 |
14 |
24 |
34 |
1 |
| 05 |
|
25 |
|
06 |
|
26 |
|
07 |
17 |
27 |
|
08 |
18 |
28 |
|
2 |
| 09 |
19 |
29 |
|
0A |
1A |
2A |
|
0B |
1B |
2B |
|
0C |
1C |
2C |
|
3 |
| 0D |
1D |
2D |
|
0E |
1E |
2E |
|
|
1F |
2F |
|
|
20 |
30 |
|
4 |
| Colum |
1 |
2 |
3 |
4 |
1 |
2 |
3 |
4 |
1 |
2 |
3 |
4 |
1 |
2 |
3 |
4 |
|
The fault can be found in the
following fault code table with
the help of the number found in
the fault table for lamp codes;
e.g. for number 29: ignition
pill circuit 3 - break.
| 68 - 16 |
Diagnosis |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
Fault Code Table
| Hex-Code |
Fault Description |
|
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
0E
11
12 |
Front sensor left:
Front sensor left:
Front sensor right:
Front sensor right:
Front sensor left:
Front sensor right:
Front sensor lead
left:
Front sensor lead
right:
Front sensor lead
left:
Front sensor lead
right:
Front sensor lead
left:
Front sensor lead
right:
Front sensor lead
left
Front sensor lead
right:
Front sensor lead
left:
Front sensor lead
right:
|
closed 1 time
closed several times
closed 1 time
closed several times
closed permanently
closed permanently
leaks against positive
leaks against positive
leaks against ground
leaks against. ground
short circuit against
positive
short circuit against
positive
short circuit against
ground
short circuit against
ground
break
break
|
| Printed in Germany - X, 1986 |
|
68 - 17 |
|
| 68 |
Interior Equipment |
9 4 4 |
| Hex-Code |
Fault Description |
|
13
14
17
18
19
1A
1B
1C
1D
1E
1F
20
21
22
23
24
25
26 |
Front sensor lead left:
Front sensor lead right:
Ignition capacitor 1:
Ignition capacitor 2:
Transition resistance to
Ignition capacitor 1:
Transition resistance to
Ignition capacitor 2:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
|
excessive resistance
excessive resistance
insufficient capacitance
insufficient capacitance
excessive
excessive
leak against positive
leak against positive
leak against positive
short circuit against
positive
short circuit against
positive
short circuit against
positive
leak against ground
leak against ground
leak against ground
short circuit against
ground
short circuit against
ground
short circuit against
ground
|
| 68 - 18 |
Diagnosis |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
| Hex-Code |
Fault Description |
|
27
28
29
2A
2B
2C
2D
2E
2F
30
31
32
33
34 |
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pil1 circuit 3:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
Ignition pill circuit 1:
Ignition pill circuit 2:
Ignition pill circuit 3:
Failure warning lamp:
Failure warning lamp:
Control unit:
Firing order correct
Ignition current flowed
|
break
break
break
insufficient resistance
insufficient resistance
insufficient resistance
excessive resistance
excessive resistance
excessive resistance
short circuit
broken filament
internal fault
|
Ignition pill circuit 1: driver's airbag
Ignition pill circuits 2 and 3: passenger's airbag
| Printed in Germany - X, 1986 |
|
68 - 19 |
|
| 68 |
Interior Equipment |
9 4 4 |
The following jobs must be per-
formed when a fault occurs:
Faults 01 to 06
- Replace left or right front
sensor.
Faults 07 to 0E
| - |
Check front sensor with
ohmmeter
| 1. |
Ohmmeter to terminals 1 and 2
Reading: 10 kOhm/
|
| 2. |
Ohmmeter to terminals 2 and 3
Reading: 0 Ohm |
|
If the readings are obtained, erase
fault memory. If fault still present,
replace control unit.
If the readings are not obtained,
replace front sensor.
|
|
Fault 11 or 12
| - |
Check front sensor plug connec-
tion for correct tightness
of plug contacts and correct
tightness of plug connection.
|
| - |
Check front sensor with ohmmeter
(see faults 07 to 0E). |
If ohmmeter shows  Ohm for point 1
or 2, replace the front sensor. If
the readings are obtained, replace
control unit.
Fault 13 or 14
| - |
Check front sensor with ohmmeter
(see faults 07 to 0E).
If front sensor is OK, replace
control unit. |
|
| 68 - 20 |
Diagnosis |
XVII, 1988 - Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
Faults 17 to 1A
- Replace control unit.
Faults 1B, 1E, 21, 24
| - |
Try installing new contact unit.
Turn on ignition.
If fault still present. try
installing airbag unit.
If fault still present. replace
control unit. |
Erase fault memory. if applicable.
after re-assembling.
|
|
Faults 1C, 1D, 1F, 20, 22, 23, 25, 26
| - |
Try installing new airbag unit.
Turn on ignition.
If fault still present. replace
control unit.
Fault 27
|
| - |
Check tightness of plug connec-
tion to airbag unit.
|
| - |
Check tightness of plug connec-
tion to contact unit. |
If plug connections are tight. try
installing new contact unit.
Turn on ignition.
If fault still present. try
installing new airbag unit.
Turn on ignition.
If fault still present. replace
control unit.
|
| Printed in Germany - X, 1986 |
|
68 - 21 |
|
| 68 |
Interior Equipment |
9 4 4 |
Fault 28 or 29
| - |
Check tighness of plug con-
nection to airbag unit. |
If plug connection is OK, try
connecting new airbag unit. If
fault still present, replace
control unit.
Fault 2A
| - |
Try connecting new airbag unit.
If fault still present, replace
control unit. |
Fault 2B or 2C
| - |
Try connecting new airbag unit.
If fault still present, replace
control unit. |
Fault 2D
| - |
Replace contact unit.
|
| - |
Check plug contacts of plug
connections to airbag unit and
contact unit for corrosion. |
If contacts are in good condition,
try connecting new airbag unit. If
fault is still present, replace
control unit.
|
|
Fault 2E or 2F
| - |
Check plug contacts at plug con-
nections to airbag unit for
corrosion.
If contacts are in good con-
dition, try connecting new airbag
unit. If fault still present, re-
place control unit. |
Faults 30 and 31
Central warning lamp and belt symbol
still light up after failure of the
airbag sign.
| - |
Remove and check control lamp,
replacing if necessary.
|
| - |
Check wiring harness for damage,
replacing control unit if
necessary. |
Fault 32
Faults 33 and 34
Fault indications 33 and 34 are
displayed only after an accident
with airbag activation. In this
case, all. components must be
replaced.
|
| 68 - 22 |
Diagnosis |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
The fault memory has to be erased
after a disturbance in the airbag
system and its elimination.
E r a s i n g F a u l t
M e m o r y
| 1. |
Turn off ignition.
|
| 2. |
Apply locally made tool on
test plug.
|
| 3. |
Press switch button.
|
| 4. |
Turn on ignition. Switch remains
pressed 5 seconds, is then
released 5 seconds and pressed
again 5 seconds. |
N o t e :
The precision of a clock with
a seconds needle is sufficient.
| 5. |
Turn off ignition.
|
| 6. |
Check whether fault memory is
erased. Turn on ignition for
this purpose. Airbag sign light
must go out after 5 seconds. |
|
|
N o t e :
The exchange of a component must
be entered in the service booklet.
This is done by pasting the
documentation number label in a
provided field. Documentation numbers
are provided on replacement parts as
tear-off labels.
The following components must be
removed and replaced after an
accident with activation of the
airbag system.
-
-
-
- |
Control unit
Both front sensors
Contact unit
Both airbag units |
Removed parts must be sent to Porsche
or the respective importer. Airbag
units may only be shipped in officially
be approved packaging.
|
| Printed in Germany - X, 1986 |
|
68 - 23 |
|
| 68 |
Interior Equipment |
944 |
Checking airbag system operation
| 1. |
Functional check of airbag lettering.
Turn on ignition. The airbag lettering must
light up for approx. 5 seconds. If the letter-
ing remains dim, check bulb and/or supply
voltage.
|
| 2. |
Disconnect connector for contact unit
(below instrument panel).
|
| 3. |
Turn on ignition. |
The airbag lettering must now indicate a fault.
Read out fault memory and check if 27;
Ign. pill circuit 1 - open circuit; is indicated
(with new control unit: 49; refer to page
D 68 - 1).
Note
In addition to the airbag lettering, the central
warning lamp and the Fasten Seat belts sym-
bol (US models only) must light if a fault is
stored in the fault memory.
|
|
| 3a. |
Alternate fault simulation: Remove fuse for
power supply to the instrument cluster for
approx. 30 seconds with the ignition
switched on.
In this case, fault code 30 (with new con-
trol unit: 58) Warning light: short circuit to
battery + or ground; fault currently not
present, must be indicated. |
| 4. |
Reconnect connector and erase fault
memory.
|
| 5. |
Make sure no covers, decals or similar items
are fitted to the steering wheel and in the
passenger airbag area.
|
| 6. |
Visual inspection of components for
damages and modifications.
|
| 7. |
After checking the system, confirm the
check in the appropriate fields of the
warranty and maintenance booklet. |
|
| 68 - 24 |
Checking airbag system operation
Printed in Germany - XXIV, 1991 |
|
| 9 4 4 |
Interior Equipment |
68 |
REMOVING AND INSTALLING INERTIA-REEL LAP-AND-SHOULDER SAFETY BELTS FOR
REAR SEATS, USA CARS
A: Anchor point for inertia reel
B: Anchor point for upper attachment
C: Anchor point for lower attachment
| Printed in Germany - XV, 1987 |
Removing and Installing
Inertia-Reel Lap-and-Shoulder
Safety Belts for Rear Seats |
|
68 - 25 |
|
| 68 |
Interior Equipment |
9 4 4 |
| 68 - 26 |
Removing and Installing
Inertia-Reel Lap-and-Shoulder
Safety Belts for Rear Seats |
Printed in Germany |
|
| 9 4 4 |
Interior Equipment |
68 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
A
B
C |
Inertia-reel
lap-and-
shoulder
safety belt
Hex bolt
Spacer
Shoulder bolt
Cover
Tubular spacer
Washer
Hex bolt
Cover
Inertia reel
Upper
attachment
Lower
attachment
|
1
1
1
1
1
1
2
1
1
1
1
1 |
Remove sidewall
panel far enough to
give sccess |
Feed belt with lower and
upper attachments
through rose in sidewall
panel.
Tightening torque 40 Nm
(30 ftlb) (bolt without
collar)
Tightening torque
40 Nm (30 ftlb)
Tightening torque
40 Nm (30 ftlb)
Broad surface of cover
must face down.
|
| Printed in Germany - XV, 1987 |
Removing and Installing
Inertia-Reel Lap-and-Shoulder
Safety Belts for Rear Seats |
|
68 - 27 |
|
| 68 |
Interior Equipment |
9 4 4 |
|
| 944 |
Interior Equipment |
68 |
Inspecting Seat Belts
Checking Function
It must be possible to have the belt strap roll
off of the automatic reel via the reversing fit-
ting without hesitation when pulling the seat
belt uniformly and the tongue of the seat belt
must be heard engaging in the belt lock. The
automatic reel must lock when the seat belt
strap is pulled suddenly.
|
|
Checking Condition
A visual inspection of the seat belt must not
produce any damage or signs of wear on the
belt strap. The seat belt must be replaced, if
the belt strap is damaged in the form of cuts,
fringing, torn seams, rubbing spots or similar
conditions.
|
Additional Checking for Seat Belts with Overload Indicators (Tear Seams)-
Airbag Equipment
The tear seam on the belt strap above the holder must not be damaged in addition to the fact that
these seat belts must have perfect function and condition. The tear seam serves as an overload in-
dicator, which reports an overloaded condition and therefore the necessity to replace a seat belt.
1 = Anchorage point for holder
2 = Anchorage bolt
3 = Holder
4 = Plastic cap
5 = Indicator (tear seam)
6 = Belt strap
|
|
|
Inspecting Seat Belts
Printed in Germany - XXIV, 1991
|
68 - 29 |
|
| 68 |
Interior Equipment |
944 |
|
| 944 |
Interior Equipment |
68 |
Correct disposal of airbag units
Airbag units are pyrotechnic objects and
can represent an environmental hazard on
account of their character as explosion-risk bo-
dies and because of the materials they
contain.
For this reason, airbag units which have
not yet been ignited, or complete vehicles
containing such units must not be treated
as "normal" waste or disposed of on any
other final refuse dumps.
To avoid possible misues, the airbag units
must first be rendered harmless by electrical
ignition, making sure that all the relevant pre-
cautions are complied with.
In the case of airbag units incapable of ig-
niting or if ignition cannot be carried out in
safety, the airbag units must in all cases
be returned to Porsche or to the relevant
importer in their original spare part packs
and by the usual transport channels.
Note
Any specific local or national regulations or
legal verdicts which go beyond these instruc-
tions must be complied and given preference
over these instructions.
Correct disposal of airbag units
Printed in Germany - XXIV, 1991
|
68 - 31 |
|
| 68 |
Interior Equipment |
944 |
Safety measures
-
-
-
-
-
-
-
-
-
-
- |
Ignition and preparation should only be
carried out by properky qualified person-
nel under the supervision of a second, re-
sponsible person.
All other generally applicable accident pre-
vention regulations must be complied with.
Only ignite airbag units which are in origi-
nal condition and properly installed.
Ignite airbag units only in suitable open
spaces.
Use only the ignition equipment specifi-
cally intended for the purpose.
First remove all loose objects from the
airbag expansion area.
Anyone likely to be affected should be
warned about the noise in advance.
Use the whole length of the ignition dev-
ice's cable in order to maintain a safe dis-
tance from the airbag unit which is to be
ignited.
Do not connect the ignition device to the
power source until everything else is
ready.
Position yourself and anyone else
involved in front of the vehicle.
Ignite the airbag unir with the vehicle's
doors closed but the tailgate/trunk lid or
side windows open. |
|
|
-
-
- |
If ignition fails to occur, do not approach
the vehicle until approx. 3 minutes have
elapsed.
Allow airbag units to cool down after
ignition and observe them carefully.
Avoid skin contact with airbag units which
have been ignited. |
|
| 68 - 32 |
Correct disposal of airbag units
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
Tools
| No. |
Designation |
Special tool |
Order number |
Explanation |
1
2
|
Ignition device
Ignition cable |
9257*
9257/1* |
000.721.925.70
000.721.925.71 |
one-way part |
* Order according to requirements
Disposal of Airbag units
Printed in Germany - XXIV, 1991
|
68 - 33 |
|
| 68 |
Interior Equipment |
944 |
Connect ignition device
Diver's side
Directly to two-pin connector of contact unit
(below steering column).
Passenger's side
With ignition cable to both gas generators.
Place ignition device through door gap in
front of vehicle.
| 68 - 34 |
Disposal of Airbag units
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
Ignition
Connect ignition device to a car battery and
actuate toggle switch.
Note
Actuate ignition separately for driver's and
passenger's side.
After ignition on the passenger's side has
occurred, check if both gas generators have
ignited (smoldering marks visible on both
ignition cable connectors).
Disposal of Airbag units
Printed in Germany - XXIV, 1991
|
68 - 35 |
|
| 68 |
Interior Equipment |
944 |
Repairing horn buttons of airbag steering wheel
Removal
| 1. |
Remove airbag steering wheel
(refer to page 68-9).
|
| 2. |
Lever out horn button using a small
screwdriver. |
3. Take out contact spring.
Installation
Note
The silver contact in the middle of the contact
spring must point down.
|
|
4. Insert contact spring into the guides.
| 5. |
Engage horn button, starting with the upper
lug, and then press in all the way |
Note
Make sure all lugs have engaged properly.
When actuating the horn button it must spring
back freely into the normal position.
|
| 68 - 36 |
Repairing horn buttons of airbag steering wheel
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
Checking the function of the horn buttons.
| 6. |
Connect an ohmmeter to the connector and
to the steering wheel housing. |
Display: Ohm
Push one horn button after another.
Display: 0 - 5 Ohm
Repairing signal buttons of airbag steering wheel
Printed in Germany - XXIV, 1991
|
68 - 37 |
|
| 68 |
Interior Equipment |
944 |
|
| 944 |
Interior Equipment |
68 |
Diagnosis / Troubleshooting
For vehicles as of ... (refer to table below)
USA/Canada
- 944 S2 Cabriolet MY '90
- 944 S2 Coupe
VIN: 94 MN 410402
RoW
- 944 S2 MY '91
The airbag system is continuously monitored
by a diagnosis unit in the control unit. If a
fault occurs, it is indicated by a lettering in the
instrument cluster.
In the event of a fault, the central warning
lamp and the lettering come on. In cars for
the USA, the fasten seat belts symbol also
lights up.
The airbag lettering comes on for approx. 5
seconds when the ignition is switched on, and
then goes out. When the engine is started,
the lettering again comes on for approx.
5 seconds.
Should the warning lamp come on again later,
this indicates a fault in the airbag system. The
fault can be read out with System Tester
9288 and flashing code tester 9268.
Note:
The control unit needs approx. 70 seconds to
identify all faults in the system, and the igni-
tion must therefore be switched on for at least
this time.
|
|
After a fault in the airbag system has been
identified and rectified, the fault memory
must be erased.
If any components are exchanged, this must
be noted in the warranty and maintenance
booklet. The document number should be at-
tached in the free space provided. The docu-
ment number is shown on an adhesive label
which can be torn off the spare part.
Following an accident in which the airbag sys-
tem was activated, the following components
must be removed and renewed:
- control unit
- both front sensors
- contact unit
- both airbag units
If non-activated airbag units have to be re-
moved, they must be ignited electrically
before being disposed of (see Page 68 - 13).
|
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 1 |
|
| 68 |
Interior Equipment |
944 |
Reading out the fault memory
System Tester 9288: see Repair Manual Group 03, Self-diagnosis
Tester 9268: see Technical Service Information, Model '90.
Meaning of fault codes
1st figure:
2nd figure:
3rd figure:
4th figure: |
3 = Airbag system
1 = Fault still present
2 = Fault no longer present
3 = Failure time since first fault occurrence
= Fault code |
Before troubleshooting can be carried out correctly, the person concerned must
- be familiar with the component positions and the function and technical relationship of the
systems to be checked (model information)
- be able to read and evaluate Porsche circuit diagrams
- understand the function of the electrical circuits and relays
- be capable of operating and assessing the information supplied by the test gear.
Important:
If the tester display or the fault list indicates that a component is defective, the fault may not neces-
sarily be found in the component indicated but may be in the associated control unit or the connect-
ing circuits (electrical paths) between the component and the control unit. Before the fault memory
has been read out, no troubleshooting involving the pulling off of plugs or similar is to be carried out,
as this could also be stored as a fault in the memory.
| D 68 - 2 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
Note
The fault code can show two types of fault:
- Fault still present
- Fault no longer present
Faults are stored as no longer present if they occur briefly while the ignition is switched on, but are
no longer present when the ignition is switched off.
Faults still present are those which are permanent or remain present when the ignition is switched
off.
Do not assume that the fault in the readout is actually present or clearly identifiable during the check.
The cause of a fault being memorized may for example be undesirable interference with the airbag
system wiring while the ignition was switched on.
It is therefore important in the case of faults no longer present to determine the cause of the fault in
order to prevent it from recurring and to avoid renewing parts unnecessarily. Check the entire length
of the airbag system wiring for damage (wires no longer intact or trapped).
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 3 |
|
| 68 |
Interior Equipment |
944 |
Tools
Special tools 9516 and 9516/1 are used to check the ignition pill circuits.
If there is a fault in the ignition pill circuits, attach special tool 9516 in place of the airbag units, then
erase the fault memory. Switch the ignition off and on again.
The fault can then be localized by means of the diagnosis unit in the control unit.
If the warning light no longer indicates a fault, the airbag unit is defective and must be renewed.
If the warning light again indicates a fault, this is to be sought in the control unit or the wiring.
A fault in ignition pill circuit 1 may also be caused by the contact unit. Disconnect the wiring from the
contact unit and attach special tool 9516/1 in place of the contact unit. Erase the fault memory.
Switch the ignition off and then on again. If the warning light no longer indicates a fault, the contact
unit is defective; if the warning light again indicates a fault, this must be in the control unit or the wir-
ing.
Note
For safety reasons, never drive the vehicle with the special tools installed in place of the airbag units
| D 68 - 4 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
Fault code table
| Fault code |
Designation of fault |
11
12
13
14
15
16
17
18
19
20
21
22
25
26
27
28
29
30
33
34
35
36
37
38 |
Left front sensor: closed once
Left front sensor: closed several times
Right front sensor: closed once
Right front sensor: closed several times
Left front sensor: permanently closed*
Right front sensor: permanently closed
Left front sensor: contact resistance to UB
Right front sensor: contact resistance to UB
Left front sensor: contact resistance to earth/ground
Right front sensor: contact resistance to earth/ground
Left front sensor: short circuit to UB
Right front sensor: short circuit to UB
Left front sensor: resistance to earth/ground too high
Right front sensor: resistance to earth/ground too high
Left front sensor: break in feed wire**
Right front sensor: break in feed wire**
Left front sensor: line resistance too high
Right front sensor: line resistance too high
Ignition capacitor 1: capacitance too low
Ignition capacitor 2: capacitance too low
Ignition capacitor 1: contact resistance too high
Ignition capacitor 2: contact resistance too high
Ignition pill circuit 1: contact resistance to UB
Ignition pill circuit 2: contact resistance to UB
|
| * |
Fault code 60 respectively 105 is also shown with fault codes 15 and 16. Renew front sensor and
erase fault memory. Repeat the diagnosis. If fault code 60 respectively 105 appears again, renew
the control unit. |
| ** |
Fault code 25 or 26 also appears with fault code 27 or 28 respectively. |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 5 |
|
| 68 |
Interior Equipment |
944 |
| Fault code |
Designation of fault |
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
65
67 to 105 |
Ignition pill circuit 3: contact resistance to UB
Ignition pill circuit 1: short-circuit to UB
Ignition pill circuit 2: short-circuit to UB
Ignition pill circuit 3: short-circuit to UB
Ignition pill circuit 1: contact resistance to earth/ground
Ignition pill circuit 2: contact resistance to earth/ground
Ignition pill circuit 3: contact resistance to earth/ground
Ignition pill circuit 1 : short-circuit to earth/ground
Ignition pill circuit 2: short-circuit to earth/ground
Ignition pill circuit 3: short-circuit to earth/ground
Ignition pill circuit 1: break
Ignition pill circuit 2: break
Ignition pill circuit 3: break
Ignition pill circuit 1: resistance too low
Ignition pill circuit 2: resistance too low
Ignition pill circuit 3: resistance too low
Ignition pill circuit 1: resistance too high
Ignition pill circuit 2: resistance too high
Ignition pill circuit 3: resistance too high
Warning lamp: short-circuit to UB or earth/ground
Warning lamp: break
Diagnosis unit: defective
Correct ignition sequence (after crash)
Correct ignition current (after crash)
Ignition pill current transmitted (after crash)
Internal fault*
|
Ignition pill circuit 1: driver's airbag
Ignition pill circuit 2 and 3: passenger's airbag
| * |
When the airbag system is checked with the 9268 tester, fault code 60 is always indicated in the
event of an internal fault. |
| D 68 - 6 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Note
After any airbag system fault has been detected and rectified, the fault memory must be erased.
Test point 1
Left front sensor
closed once
Fault code 3_11
|
- Renew front sensor. |
Test point 2
Left front sensor
closed several times
Fault code 3_12
|
- Renew front sensor. |
Test point 3
Right front sensor
closed once
Fault code 3_13
|
- Renew front sensor. |
Test point 4
Right front sensor
closed several times
Fault code 3_14
|
- Renew front sensor. |
Test point 5
Left front sensor
closed permanently
Fault code 3_15
|
- Renew front sensor. |
Test point 6
Right front sensor
closed permanently
Fault code 3_16
|
- Renew front sensor. |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 7 |
|
| 68 |
Interior Equipment |
944 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 7
Left front sensor
Contact resistance
to UB
Fault code 3_17
|
| - |
Check front sensor at plug connection with ohmmeter. |
| |
1. |
Ohmmeter at terminal 1 and terminal 2
Display: 10 kOhm
|
| |
2. |
Ohmmeter at terminal 2 and terminal 3
Display: 0...0.5 Ohm
If measured values are within tolerance, renew
the control unit; if out of tolerance, renew the
front sensor.
|
|
Test point 8
Right front sensor
Contact resistance
to UB
Faultcode3_18
|
- See test point 7 |
Test point 9
Left front sensor
Contact resistance
against earth/ground
Fault code 3_19
|
- See test point 7 |
Test point 10
Right front sensor
Contact resistance
against earth/ground
Fault code 3_20
|
- See test point 7 |
Test point 11
Left front sensor
Short-circuit to UB
Fault code 3 _ 21
|
- See test point 7 |
| D 68 - 8 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 12
Right front sensor
Short-circuit to UB
Fault code 3_22
|
- See test point 7 |
Test point 13
Left front sensor
Earth/ground resistance
too high
Fault code 3_25
|
-
-
- |
Check front sensor: plug contacts and plug connection must en-
gage correctly.
Check front sensor with ohmmeter; see test point 7
Check mounting points; the metal must be bright for good
electrical contact.
|
|
Test point 14
Right front sensor
Earth/ground resistance
too high
Fault code 3_26
|
- See test point 13 |
Test point 15
Left front sensor
Break in feed line
Fault code 3_27
|
-
- |
Check front sensor plug connection: plug contacts and plug
connection must engage correctly.
Check front sensor mit ohmmeter (see test point 7). If no fault
is detected at front sensor, renew the control unit. |
|
Test point 16
Right front sensor
Break in feed line
Fault code 3_28
|
- See test point 15 |
Test point 17
Left front sensor
Line resistance too high
Fault code 3_29
|
| - |
Check front sensor with ohmmeter (see test point 7).
If no fault is detected at the front sensor, renew the
control unit. |
|
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 9 |
|
| 68 |
Interior Equipment |
944 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 18
Right front sensor
Line resistance too high
Fault code 3_30
|
- See test point 17 |
Test point 19
Ignition condenser 1
Capacnancetoo low
Fault code 3_33
|
- Renew the control unit. |
Test point 20
Ignition condenser 2
Capacnancetoo low
Fault code 3_34
|
- Renew the control unit. |
Test point 21
Ignition condenser 1
Contact resistance
too high
Fault code 3_35
|
- Renew the control unit. |
Test point 22
Ignition condenser 2
Contact resistance
too high
Fault code 3_36
|
- Renew the control unit. |
| D 68 - 10 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 23
Ignition pill circuit 1
Contact resistance
to UB
Fault code 3_37
|
1. Remove driver's airbag unit.
2. Attach special tool 9516 in place of the airbag unit.
3. Erase the fault memory.
4. Check whether fault is still present.
a) If fault is no longer present, renew the airbag unit.
| b) |
If fault is still present, separate connections
at contact unit and attach special tool 9516/1. |
5. Erase the fault memory.
6. Check whether fault is still present.
a) H the fault is no longer present, renew the contact unit.
b) If the fault is still present, renew the control unit.
|
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 11 |
|
| 68 |
Interior Equipment |
944 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
| |
Note
Ignition pill circuit 2 is the left of the two passenger-side airbag
circuits, ignition pill circuit 3 the right circuit.
|
Test point 24
Ignition pill circuit 2
Contact resistance
to UB
Fault code 3_38
|
1. Pull off plug at passenger-side airbag unit.
2. Attach special tool 9516.
3. Erase the fault memory.
4. Check whether fault is still prsent.
| a) |
If fault is no longer present, renew passenger-
side airbag. |
b) If fault is still present. renew the control unit.
|
Test point 25
Ignition pill circuit 3
Contact resistance
to UB
Fault code 3_39
|
- see test point 24 |
Test point 26
Ignition pill circuit 1
Short-circuit to UB
Fault code 3_40
|
- see test point 23 |
Test point 27
Ignition pill circuit 2
Short-circuit to UB
Fault code 3_41
|
- see test point 24 |
Test point 28
Ignition pill circuit 3
Short-circuit to UB
Fault code 3_42
|
- see test point 24 |
| D 68 - 12 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 29
Ignition pill circuit 1
Contact resistance to
earth/ground
Fault code 3_43
|
- see test point 23 |
Test point 30
Ignition pill circuit 2
Contact resistance to
earth/ground
Fault code 3_44
|
- see test point 24 |
Test point 31
Ignition pill circuit 3
Contact resistance to
earth/ground
Fault code 3_45
|
- see test point 24 |
Test point 32
Ignition pill circuit 1
Short-circuit
to earth/ground
Fault code 3_46
|
- see test point 23 |
Test point 33
Ignition pill circuit 2
Short-circuit
to earth/ground
Fault code 3_47
|
- see test point 24 |
Test point 34
Ignition pill circuit 3
Short-circuit
to earth/ground
Fault code 3_48
|
- see test point 24 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 13 |
|
| 68 |
Interior Equipment |
944 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 35
Ignition pill circuit 1
Break
Fault code 3_49
|
- Check that plug connection to airbag unit is correctly engaged.
- Check that plug connection to contact unit is correctly engaged.
If no fault is detected:
1. Remove driver's airbag unit.
2. Attach special tool 9516 in place of the airbag unit.
3. Erase the fault memory.
4. Check whether the fault is still present.
a) If the fault is no longer present, renew the airbag unit.
| b) |
If the fault is still present, separate the plug connection to the
contact unit and attach special tool 9516/1. |
5. Erase the fault memory.
|
| D 68 - 14 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
|
6. Check whether fault is still present.
a) If the fault is no longer present, renew the control unit.
b) If the fault is still present, renew the control unit.
|
Test point 36
Ignition pill circuit 2
Break
Fault code 3_50
|
| - |
Check that the plug connection to the airbag unit is correctly en-
gaged. |
If no fault is detected:
1. Pull off plug at passenger-side airbag unit.
2. Attach special tool 9516.
3. Erase the fault memory.
4. Check whether fault is still present.
| a) |
If the fault is no longer present, renew the passenger-
side airbag unit. |
b) If the fault is still present, renew the control unit.
|
Test point 37
Ignition pill circuit 3
Break
Fault code 3_51
|
- see test point 36 |
Test point 38
Ignition pill circuit 1
Resistance too low
Fault code 3_52
|
- see test point 23 |
Test point 39
Ignition pill circuit 2
Resistance too low
Fault code 3_53
|
- see test point 24 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 15 |
|
| 68 |
Interior Equipment |
944 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 40
Ignition pill circuit 3
Resistance too low
Fault code 3_54
|
- see test point 24 |
Test point 41
Ignition pill circuit 1
Resistance too high
Fault code 3_55
|
- see test point 23 |
Test point 42
Ignition pill circuit 2
Resistance too high
Fault code 3_56
|
- see test point 24 |
Test point 43
Ignition pill circuit 3
Resistance too high
Fault code 3_57
|
- see test point 24 |
Test point 44
Warning lamp: short-circuit
to UB or earth/ground Fault
code 3_58
|
- Check wiring for damage.
- Check instrument cluster.
|
Test point 45
Break in circuit at warning
lamp
Fault code 3_59
|
- Check power supply fuse tor lnstrument cluster
- Check warning lamp and renew if necessary.
- Check wiring for damage.
|
| D 68 - 16 |
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991 |
|
| 944 |
Interior Equipment |
68 |
| Fault, Fault Code |
Possible Causes, Elimination, Remarks |
Test point 46
Defective diagnosis unit
Fault code 3_60
|
- Renew the control unit |
Test point 47
Ignition sequence correct
(after crash)
Fault code 3_61
|
| - |
All airbag components must be renewed after the airbag has
been activated. |
|
Test point 48
Ignition current correct
(after crash)
Fault code 3_62
|
- see test point 47 |
Test point 49
Ignition pill current has
flowed (after crash)
Fault code 3_65
|
- see test point 47 |
Test point 50
Control unit defective
Fault code 3_67
|
- Renew the control unit |
Note on test point 50
With the 9288 System Tester, a fault code can be displayed in the range from 67 to 105.
On the 9268 Tester, code 60 is always displayed if the fault is in the range from 67 to 105.
Diagnosis / Troubleshooting
Printed in Germany - XXIV, 1991
|
D 68 - 17 |
|
| 68 |
Interior Equipment |
944 |
|
REMOVING AND INSTALLING FRONT SEATS
R e m o v i n g
| 1. |
Slide seat forward and unscrew rear
bolts. |
| 2. |
Slide seat back and unscrew fron
bolts. If car has power seats, disconnect
plug. Take seat out of car. |
|
|
I n s t a l l i n g
| 1. |
Check seat rails for wear and, if
necessary, replace before installation
of seat. Lubricate seat rails with grease.
|
| 2. |
Hun out seat rails on seat forward and
lock fully on both sides. |
| 3. |
Place seat on seat rail carriers. If car has
power seats, connect electric plug. Align
front end of seat with hole pattern.
Install and tighten front bolts slightly.
|
| 4. |
Slide seat forward and lock completely
(visual check). Screw in and slightly
tighten all 4 bolts.
|
| 5. |
Slide seat back and lock completely
(visual check). Tighten bolts.
|
| 6. |
Slide seat forward and lock completely
(visual check). Tighten bolts. |
|
| Printed in Germany - V, 1985 |
Removing and Installing
Front Seats |
|
72 - 1 |
|
N o t e
If locking behavior is not synchronous,
loosen front bolt on outside, slide seat
forward and lock completely (visual check).
Loosen rear bolts on outside and eliminate
residual tension by sliding seat accordingly.
Tighten bolts. Slide seat back and tighten
front outside bolt. Check whether seat rail
locking engages fully in all possible locking
positions.
| 72 - 2 |
Removing and Installing Front Seats |
Printed in Germany |
|
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2 |
Upholsterer's pliers
Pulling tool |
Improvised tool |
Commercially
available
e.g. Binder |
| Printed in Germany - I, 1987 |
|
72 - 3 |
|
REPLACING HEATING ELEMENT FOK SEAT
CUSHION HEATING
| 1. |
Move seat to highest position.
|
| 2. |
Remove seat (see Repair Manual,
page 72 - 1).
|
| 3. |
Disconnect plug of seat heating
(seat back and cushion). Use
ohmmeter to check conductance of
heating element. If element is
defective, resistance is
infinity. |
N o t e
The cushion and backrest heating
elements are connected in series:
do not apply more than 6 V to
either part (see also Quality
Information Group 7, 1/86 dated
18th April 1986).
| 4. |
Remove switch cover. Remove
attachment screws of backrest
hinge covers and remove covers
by pulling toward rear. |
|
|
| 5. |
Lay seat on backrest and use
side nippers to cut through
staples beneath seat cushion.
Straighten tabs on frame and
remove tensioning wire. Unhook
seat cover and pull up.
Disconnect cable connector and
retainer. |
| 6. |
Remove cushion complete with
upholstered cover from frame.
Push switch unit through hole
in cushion. |
|
| 72 - 4 |
Replacing Heating Element for Seat
Cushion Heating |
Printed in Germany |
|
| 7. |
Cut through remaining staples.
Break adhesive bond between
upholstered cover and cushion.
Remove cover. |
| 8. |
Cut through inside of cover
beside right-hand and left-hand
seams.
Caution: Do not damage outer
cover. |
|
|
N o t e
Do not cut past the cross seams. Do
not cut through the cross seams.
| 9. |
By twisting and pushing with the
improvised tool, carefully break
adhesive bond between outer
cover and padding material or
heating element.
Sever cable of defective heating
element. |
|
| Printed in Germany - XI, 1987 |
Replacing Heating Element for
Seat Cushion Heating |
|
72 - 5 |
|
Heating element for seat cushion.
N o t e
Install liner with grey felt
pointing toward outer cover.
| 10. |
With improvised tool, push
heating element between outer
and inner covers (or defective
heating element) into the
pocket. |
|
|
| 11. |
Cut off excess material (push-in
loops).
| Caution: |
Do not damage heating
wire |
|
| 12. |
Check conductance of heating
element.
|
| 13. |
Stitch or glue (latex) new
heating element to outer cove
on left and right. |
|
| 72 - 6 |
Replacing Heating Element for Seat
Cushion Heating |
Printed in Germany |
|
| 14. |
Lay cover on cushion and,
starting at the cross strip,
tack in place with 3 staples. |
| 15. |
Insert 5 staples in each length-
wise strip to hold cover at
sides. Use glue to fix cover at
backrest hinge. |
N o t e
To improve accessibility to the
tabs and for attaching the cover,
place the seat frame in the highest
position.
|
|
| 16. |
Place cover with seat cushion on
frame and push switch unit
through opening in cushion. |
| 17. |
Hook cover over tabs at front
and sides. Bend tabs slightly to
hold cover in this position.
|
| 18. |
Attach tensioning wire to seat
springs.
|
| 19. |
Insert two staples, one at the
rear left and one at the rear
right of the cover.
|
| 20. |
Hook rear of cover over tabs.
|
| 21. |
Press all tabs down fully. |
|
| Printed in Germany - XI, 1987 |
Replacing Heating Element for
Seat Cushion Heating |
|
72 - 7 |
|
22. Route cable and attach retainer.
| 23. |
Install switch cover and
backrest hinge cover.
|
| 24. |
Install seat (see Repair Manual,
page 72 - 1). |
| 72 - 8 |
Replacing Heating Element for Seat
Cushion Heating |
Printed in Germany |
|
REPLACING HEATING ELEMENT FOR
BACKREST HEATING
| 1. |
Move seat to highest position.
|
| 2. |
Remove seat (see Repair Manual,
page 72 - 1).
|
| 3. |
Disconnect plug of seat heating
(seat back and cushion). Use
ohmmeter to check conductance of
heating element. If element is
defective, resistance is
infinity. |
N o t e
The cushion and backrest heating
elements are connected in series:
do not apply more than 6 V to
either part (see also Quality
Information Group 7, 1/86 dated
18th April 1986).
| 4. |
Straighten tabs on seat frame
and unhook cover.
|
| 5. |
Pull up cover with backrest
padding and cut staples with
side nippers. |
|
|
| 6. |
Break adhesive bond between
cover and backrest padding.
Remove padding. |
| 7. |
Cut open inside of cover beside
right-hand and left-hand seams.
Caution: Do not damage outer
cover. |
|
| Printed in Germany - XI, 1987 |
Replacing Heating Element for
Backrest Heating |
|
72 - 9 |
|
N o t e
Do not cut the cover past the cross
seams. Do not cut through the cross
seams.
| 8. |
By twisting and pushing with the
improvised tool, carefully break
the adhesive bond between outer
cover and padding or heating
element. Cut off cable from
defective heating element. |
N o t e
Install the heating element with
the grey felt liner pointing toward
the outer cover.
|
|
| 9. |
With the aid of the improvised
tool, push heating element
between outer and inner covers
(or defective heating element)
into the pocket. |
| 10. |
Cut off excess material (push-in
loops).
| Caution: |
Do not damage heating
wire. |
|
| 11. |
Check heating element for
conductance. |
|
| 72 - 10 |
Replacing Heating Element for Backrest
Heating |
Printed in Germany |
|
| 12. |
Stitch or glue (latex) new
heating element to outer cover
on left and right. |
| 13. |
Glue cover and padding together
at top.
|
| 14. |
Attach cover at the sides an
bottom without creases and
insert staples. |
|
|
| 15. |
Attach padding to backres
springs with 4 staples. |
| 16. |
Route cable and attach.
|
| 17. |
Hook cover over tabs.
|
| 18. |
Press tabs down.
|
| 19. |
Install seat (see Repair Manual,
page 72 - 1. |
|
| Printed in Germany - XI, 1987 |
Replacing Heating Element
for Backrest Heating |
|
72 - 11 |
|
SEAT FRAME
| Printed in Germany - XV, 1987 |
| Electrically Adjustable Seat |
|
72 - 13 |
|
SEAT FRAME
| 72 - 14 |
Electrically Adjustable Seat |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
|
Cover
Tapping screw
Washer
Sheet-metal nut
Seat frame
Hex nut
Pin
Friction sleeve
Spring washer
Plastic washer
Hex nut
Guide spring
Seat rail,
left
Seat rail,
right
Transverse
strut
Up/down drive
gear, front
right and
rear left
Up/down drive
gear, front
left and
rear right
|
1
2
2
2
1
2
2
2
2
2
4
4
1
1
1
2
2 |
|
|
| Printed in Germany - XV, 1987 |
| Electrically Adjustable Seat |
|
72 - 15 |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
|
Slide
Washer
Hex bolt
Hex socket-
head bolt
Shaft, seat
adjustment,
left
Shaft, seat
adjustment,
right
Staple
Shaft, height
adjustment,
front left
Shaft, height
adjustment,
front right
Shaft, height
adjustment,
rear left
Shaft, height
adjustment,
rear right
Shaped spring
Shaped spring
Electric motor
Electric motor
Holder
Holder
|
4
4
8
4
1
1
3
1
1
1
1
3
3
2
1
1
1 |
|
|
| 72 - 16 |
Electrically Adjustable Seat |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
35
36
|
Hex bolt
Serrated washer |
6
6 |
|
|
| Printed in Germany - XV, 1987 |
| Electrically Adjustable Seat |
|
72 - 17 |
|
BACKREST
| 72 - 18 |
Electrically Adjustable Seat |
Printed in Germany |
|
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 |
Backrest frame
Lumbar support
Shaft, lumbar
support, height
adjustment
Circlip
Shaft, lumbar
support, shape
Circlip
Cross-recessed
bolt, M 5 x 8
Serrated washer
Electric motor
Cross-recessed
bolt, M5 x 16
Angle holder
Spacer
Hex bolt
Electric motor,
backrest
adjustment
Shaped spring
Guide
counterfunk screw 2
with hex socket
head
|
1
1
1
1
1
1
2
2
2
6
2
2
4
1
1
1
2 |
|
|
| Printed in Germany - XVII,1988 |
| Electrically Adjustable Seat |
|
72 - 19 |
|
Calibrating controllable seat heating
Model 89 onward
Control units
Note
The seat heating must be calibrated after the
control unit or heating elements have been re-
placed.
|
|
Control unit for seat heating without
seat-position control
|
A = Measuring points
B = Adjustment potentiometer
Calibrating controllable seat heating
Printed in Germany - XXV, 1992
|
72 - 21 |
|
Tools
| 1. |
Digital-voltmeter with an internal resistance
(Ri) >= 1 MOhm.
|
| 2. |
Two measuring probes with a maximum dia-
meter of 2 mm.
|
| 3. |
Thermometer (as recommended in the
Workshop Handbook).
|
| 4. |
2 mm wrench.
|
| 5. |
Two auxiliary cables to supply voltage to the
removed seat (terminals15 and 31). Use
adapter cable 9269 for seat-position
control. |
Calibration procedure
| 1. |
Store the seat to be calibrated in the
working area until it has assumed the
ambient temperature.
|
| 2. |
Provide power supply. |
Note
Do not switch on the seat heating. If switched
on unintentionally, the seat must cool down
until the heating elements have again adopted
the ambient temperature.
| 3. |
Measure the ambient temperature and refer
to the table for the relevant voltage value.
|
| 4. |
Connect the voltmeter to the control unit (A).
|
| 5. |
Set the voltage value on the calibration po-
tentiometer (8) so that it corresponds to the
appropriate value for the ambient temperatu-
re. |
|
|
Table
| Ambient temperature in °C |
Voltage in V |
0
2
4
6
8 |
1.50
1.55
1.60
1.65
1.70 |
10
12
14
16
18 |
1.75
1.80
1.85
1.90
1.95 |
20
22
24
26
28 |
2.00
2.05
2.10
2.15
2.20 |
30
32
34
36
38 |
2.25
2.30
2.35
2.40
2.45 |
40
42
44
46
48 |
2.50
2.55
2.60
2.65
2.70 |
Functional check
Switch on seat heating for approx. 10 sec.
with maximum heating power. After switching
off, measure the voltage at the control unit.
The value measured now must be considera-
bly higher.
|
| 72 - 22 |
Calibrating controllable seat heating
Printed in Germany - XIX, 1989 |
|
HEATING SYSTEM FROM 85/2 MODEL
Starting with the 85/2 model, all
944 vehicles received a new heating
system.
1 Defrost switch
2 Outside air blower switch
3 Defrost slide switch
4 Footwell slide switch
5 Temperature switch
6 Ventilation switch
The new heating system differs
from the old in that all control of
the flaps is accomplished via
electric control motors or by vacuum
pressure.
|
|
As a special option, there is an
automatic heating system with which
the interior temperature can be pre-
selected via a temperature-
preselection switch. The heating
system then independently controls
the interior temperature and
maintains it at the preselected
value, as long as the outside tem-
perature is lower than the
preselected interior temperature.
1 Defrost switch
2 Outside air blower switch
3 Defrost slide switch
4 Footwell slide switch
5 Temperature setting switch
6 Ventilation
For the removal, installation,
disassembly, and assembly of the
heating unit, see Repair Group 87.
Several assembly parts do not apply
to vehicles not having air condi-
tioning.
|
| Printed in Germany - VII, 1986 |
| Heating System from 85/2 Model |
|
80 - 1 |
|
| 9 4 4 |
V e n t i l a t i o n |
85 |
REMOVING AND INSTALLING FRESH AIR BLOWER SINCE 1985/2 MODELS
| 1. |
Remove fresh air well cover.
This is done by disconnecting and
pulling off windshield wiper arms.
Pull off rubber seal from above and
loosen cement of cover underneath
the windshield. |
When performed carefully, the cover can
be folded up to the windshield. It is then
not necessary to remove the wiper arms.
|
|
| 2. |
Unscrew fresh air blower mounting
screws. |
3. Disconnect plugs.
|
| Printed in Germany - V, 1985 |
Removing and Installing Fresh Air
Blower Since 1985/2 Models |
|
85 - 1 |
|
| 85 |
V e n t i l a t i o n |
9 4 4 |
| 4. |
Lift fresh air blower slightly. Pull off
inner vacuum line. |
| 5. |
Check sealing cord of fresh air blower,
replacing if necessary. |
| 85 - 2 |
Removing and Installing Fresh Air
Blower Since 1985/2 Models |
Printed in Germany |
|
Removing and installing the fresh air blower motor
1. Remove the fresh air blower.
2. Unlatch the plug connector in the holder.
3. Undo cable straps.
4. Pull off the vacuum hose.
|
|
| 5. |
Undo the fastening screws. |
| 6. |
Lay the blower housing on the upper part
and lift the lower part.
|
| 7. |
Take out the blower with fan wheels.
|
| 8. |
Undo the nut. |
Tightening torque: 300 Ncm
|
Removing and installing the fresh air blower motor
Printed in Germany - XVII, 1988
|
85 - 3 |
|
9. Take off the fan wheel.
10. Remove the disk.
11. Remove the second fan wheel
Note
When assembling, ensure that:
| 1. |
The air circulation flaps are seated correctly.
|
| 2. |
The engine ventilation hose is correctly
fitted between the upper and lower parts of
the housing. |
|
|
| 3. |
Carry out a functional check on the air
circulation flaps before installing in the
vehicle. |
|
| 85 - 4 |
Removing and installing the fresh air blower motor
Printed in Germany - XVII, 1988 |
|
| 9 4 4 |
Air-Conditioning System |
87 |
AIR-CONDITIONING SYSTEM FROM 85/2
Starting with the 85/2 model,
the air-conditioning system
was revised. The evaporator
is located together with the
heat exchanger in one housing.
Temperature control is automatic.
The flaps, which are actuated by
electric control motors, are
regulated via 3 temperature
sensors. The preselected
temperature is maintained over
the entire period of travel.
The electronics which process the
signals are located in the control
switch.
1 Ventilation switch
2 Defrost switch
3 Outside air blower switch
4 Defrost slide switch
5 Footwell slide switch
6 Temperature setting switch
7 A/C switch
|
|
When switch 1 is pressed, the
outside-air openings are closed
and conversion is made to air-
circulation.
When switch 2 is pressed, irrespec-
tive of the sliding switch position
(4 and 5), the footwell flap is
closed and the defrost flap opened.
At the same time, the heater is
turned all the way up, the outside
air blower switched to level 4, and
the A/C compressor switched on.
The outside air switch 3 has 5
positions. In position 0, the out-
side air blower starts upon ignition
at the lowest speed.
Slide switch 4
Left stop - defrost flap closed
right stop - defrost flap open
Slide switch 5
left stop - footwell flap closed
right stop - footwell flap open
Temperature setting switch 6
Left stop - maximum cooling
Right stop - maximum heating
When switch 7 is pressed, the A/C
compressor is switched on.
|
| Printed in Germany - VII, 1986 |
Air-Conditioning System
from 85/2 Model |
|
87 - 23 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
AIR-CONDITIONER TECHNICAL DATA
Refrigerant capacity
Refrigerator oil in compressor
Rupture seal on fluid reservoir
Compressor coupling power
consumption
|
|
950 g refrigerant R 12
80 cm3 ± 20 cm3 Densoil
The fusible element of the rupture
seal opens at approx. 30 bar over
pressure.
Approx. 40 watt
|
T i g h t e n i n g T o r q u e s
| Location |
Description |
Threads |
Tightening
Torque |
Compressor
Evaporator
Fluid reservoir
Condensor intake
Condensor outlet |
Hex bolt
Hex bolt
Union nut
Union nut
Union nut |
M8
M6
5/8" x 18 UNF
11/16" x 14 UNF
5/8" x 18 UNF |
28
6
17
44
17 |
| 87 - 24 |
Air-Conditioner Technical Data |
Printed in Germany |
|
| 944 |
Air-Conditioning System |
87 |
Location of components
1
2
3
4
4*
5 |
Fresh air blower
External sensor
Vacuum unit for fresh/circulation air flaps
Heating valve
Heater valve, as of MY '87
(16-valve engine)
Vacuum supply reservoir |
|
|
7 Relay for A/C compressors
8 Vacuum unit for heating valve
9 Plug connection for fresh air blower
10 Compressor
11 Fluid reservoir
12 Condenser
|
Location of components
Printed in Germany - XXVI, 1993
|
87 - 25 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
LOCATION OF COMPONENTS
1 Heater - A/C unit
2 Plug connection for solenoid valves
3 Plug connection for mixing chamber sensor
4 Mixing chamber sensors
5 Interior sensor
6 Connection plug
| 87 - 26 |
Location of Components |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
LOCATION OF COMPONENTS
1 Freeze protection
2 Defrost flap control motor
3 Control motor for temperature mix flap and baffle flap
4 Footwell flap control motor
5 Left footwell flap
| Printed in Germany - VII, 1986 |
|
87 - 27 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
LOCATION OF COMPONENTS
1 Expansion valve
2 Solenoid valve for fresh/circulation air flaps
3 Solenoid valve for heating valve
4 Vacuum supply line
5 Vacuum line for heating valve
6 Vacuum line for fresh circulation air flaps
7 Right footwell flap
| 87 - 28 |
Location of Components |
Printed in Germany |
|
Safety regulations for handling the refrigerant R12
The,refrigerant used R 12 is known as a safety
refrigerant In other words, this refrigerant is
non-combustible, non-explosive, non-toxic,
non-irritating, odorless and tasteless. Neverthe-
less, you should observe the following points:
| 1. |
All contact with liquid or gaseous refrigerant
must be avoided. Affected areas of the skin
must be treated like frostbite; wash off imme-
diately with cold water and then consult a
physician. Protective goggles must be worn
to protect the eyes. If refrigerant neverthe-
less enters the eyes, consult a physician im-
mediately. Rubber gloves must be worn to
protect the hands.
|
| 2. |
When performing repairs on the air-condi-
tioning system, all refrigerant must be ex-
tracted from the system and the refrigerant
cleaned. Refrigerant must not be allowed to
escape into the environment, because it at-
tacks the ozone layer of the earth.
|
| 3. |
Welding must not be performed on parts of
the closed air-conditioning system or in its
close proximity under any circumstances.
Irrespective of whether the system is filled
with refrigerant or not, a very high pressure
is produced by heating up which may lead
to damage to the system or even to an ex-
plosion. R12 is completely non-toxic at nor-
mal termperatures, but decomposes into hy-
drogen chloride and hydrogen fluoride after
contact with a flame or at high temperature.
These decomposition products contain,
among other things, chlorine and phosgene.
Since these products are injurious to health,
corresponding care must be taken. |
|
|
| 4. |
Refrigerant bottles must not be thrown and
must not be exposed to direct sun or other
sources of heat for long periods. The maxi-
mum permitted temperature of a filled re-
frigerant bottle must not exceed 45°C. |
|
Safety regulations for handling the refrigerant R12
Printed in Germany - XXII, 1990
|
87 - 29 |
|
Installation work with intervention in the refrigerant system
The content of the refrigerant system must be
properly disposed of before all work on the air-
conditioning system which necessitates open-
ing of the refrigerant system. The safety regula-
tions must be observed here.
Dird and moisture must be kept away from
the piping system of the air-conditioning sys-
tem. For this reason, extreme cleanliness
must be ensured during all work. No parts of
the system must be cleaned internally with hot
steam under any circumstances. Only nitro-
gen must be used for cleaning.
When a component is replaced, all openings
must be sealed with suitable stoppers.
Note
After the air-conditioning system has been re-
filled, the firsttime switching-on of the air-condi-
tioning compressor must be performed only
with the engine idling. After initial startup, the
compressor is fully operable under all operat-
ing conditions.
|
|
General work sequence
1. Extract refrigerant
2. Remove fault part.
3. Evacuate.
4. Check system for leaks.
5. Flush with refrigerant.
6. Perform extraction again.
7. Evacuate.
8. Fill.
Note
Pay attention to the sealing rings when discon-
necting the hose connections.
|
| 87 - 30 |
Installation work with intervention in the refrigerant system
Printed in Germany - XXII, 1990 |
|
| 9 4 4 |
Air-Conditioning System |
87 |
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2
3
4
5
6
7 |
Protective goggles
Rubber gloves
Fill hose
Filling aid
"chargefaster"
Angle piece for fil-
ling aid with re-
placement seal
Flask-connection
piece with re-
placement sealing
rings
Spring valve opener
with replacement
spring valves
|
-
-
-
-
-
-
- |
Commercially
available
Corrunercially
available
Commercially
available
2 pcs, length 1200 mm
1 pcs, length 500 mm
Thread 7/16 Inch UNF
Cornnercially
available
Cornnercially
available
Cornnercially
available
Cornnercially
available
|
| Printed in Germany - VII, 1986 |
|
87 - 31 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| No. |
Description |
Special Tool |
Remarks |
1
2
3
4 |
Leak-detector fluid
Electronic leak detector
Comb
Thermometer
|
-
-
-
- |
Commercially
available
Commercially
available
Commercially
available
Commercially
available
|
| 87 - 32 |
Tools |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
| No. |
Description |
Special Tool |
Remarks |
| 1 |
Evacuating and
filling unit
FSV - 102
Steel flask for
refrigerant R 12
|
-
- |
Commercially
available
Commercially
available
filling weight
14 kg |
N o t e
All tools and devices listed can be ob-
tained from refrigerant firms, and are
required for all air-conditioning repair
work necessitating work on the refrigerant
system.
| Printed in Germany - VII, 1986 |
|
87 - 33 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
USING THE FSV 102 SERVICE UNIT
This unit is for the testing, evacuation, flushing and filling of air-
conditioning systems. Essentially, the unit consists of a vacuum pump
filling cylinder with electric heating, measurement instruments, and valve
battery.
1 -
2 -
3 -
4 -
5 -
6 - |
Flask-connection valve
Filling valve (liquid)
Bleed nipple
High-pressure con-
nection nipple
Low-pressure connection
nipple
High-pressure cut-off
valve
|
|
7 -
8 -
9 -
10 -
11 -
12 - |
Low-presssure cut-off
valve
Pressure gauge (filling
cylinder
Filling valve (gaseous)
Pressure gauge (high-
pressue)
Pressure gauge (low
pressure)
Torrmeter
|
|
13 -
14 -
15 -
16 -
17 - |
Evacuating
valve
Torrmeter
meter cutoff
valve
Pump switch
Heating switch
Adjustment ring
for refrigerant
level
|
|
| 87 - 34 |
Use of the Service Unit - Description |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
SERVICE UNIT, ROBINAIR 95 302
| Printed in Germany - VII, 1986 |
|
87 - 35 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
INITIAL OPERATION
| 1. |
Plug in electric cable (220 V,
50 HZ). Switches 15 and 16
switched off, all valves closed.
|
| 2. |
Screw flask-connection piece
onto refrigerant flask.
Connect refrigerant flask and
flask connection valve 1 with
fill hose. Flask valve closed,
flask connection valve 1 opened.
|
| 3. |
Open the cap on bleed nipple
3 for a short period and close
it again, in order to remove
any excess pressure.
|
| 4. |
Open evacuating valve 3 and
torrmeter cutoff valve 14.
Switch on vacuum pump(switch 15).
At an ambient temperature under
+ 10° C, before switching on
unscrew quick-release connection
so that pump can warm up without
drawing vacuum. After 1 or 2
minutes, re-close quick-release
connection.
|
| 5. |
Evacuate until the maximum
final vacuum is reached (depend-
ing on prevailing air pressure).
Set torrmeter index indicator
this reading.
|
| 6. |
Open valves 2 and 9, and evacuate
further until the maximum
vacuum is once again reached. |
|
|
CHECKING SERVICE UNIT FOR LEAKAGE
| 1. |
Close evacuating valve 13. The
pressure on the torrmeter must not
rise; if it does, this indicates
leakage in the unit or at the
refrigerant-flask valve. If so,
rectify.
|
| 2. |
Switch off pump, close valves 2, 9,
and 14. |
|
| 87 - 36 |
Initial Operation -
Checking Service / Unit for Leakage |
XVII, 1988 - Printed in Germany |
|
Filling service unit
| 1. |
Place refrigerant flask at some height, prefer-
ably place upside down (make frame). Open
flask valve and allow fluid refrigerant to flow
into the filling flask. The fill quantity must not
exceed the maximum value (2200 g) on the
lowest scale.
|
| 2. |
If the flask pressure is not adequate to fill
the cylinder, the pressure building up can
be released by opening valves 9 and 6 or 9
and 7.
|
| 3. |
If the cylinder is full, close the flask valve
and valve 1. The unit is now ready for opera-
tion.
|
| 4. |
When refilling the cylinder, it is not neces-
sary to evacuate again, if refrigerant is al-
ready flowing through the fill hose when
screwing on to valve 1 (slightly open flask
valve beforehand). |
|
|
Connecting service unit to aircondi-
tioning system
| 1. |
Connect the two long fill hoses to connec-
tion nipples 4 and 5 of the service unit. All
service unit must be closed. |
Note
If the "Chargefaster" fillling aid is already con-
nected to connection nipple 5, connect the fill
hose to the filling aid.
| 2. |
Unscrew protective caps on valves.
|
| 3. |
Connect fill hose from connection nipple 4
to valve 1.
|
| 4. |
Connect fill hose from connection nipple 5
to valve 2. |
Important
As from model year '87, the arrangement of
the connection valves has been modified. The
high-pressure valve is located on the line from
the fluid reservoir to the evaporator in the area
of the left-hand spring strut; the low-pressure
valve is located directly at the compressor.
See Quality Information Bulletins 1/86 and 2/86
|
Filling service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990
|
87 - 37 |
|
Emptying the air conditioning
The refrigerant must be extracted using appro-
priate recycling equipment. See page 87 - 42c.
|
|
Evacuating air-conditioning system
| 1. |
Connect service unit.
|
| 2. |
Extract refrigerant.
|
| 3. |
Switch on vacuum pump.
|
| 4. |
Open low-pressure valve 7, high-pressure
valve 6, torrmeter cutoff valve 14, and
evacuating valve 13.
|
| 5. |
Leave vacuum pump switched on for at
least 15 minutes.
|
| 6. |
At a pressure of approx. 0.1 bar (absolute),
close evacuating valve 13 and torrmeter cut-
off valve. The latter is particulary important,
as the torrmeter would otherwise be de-
stroyed in subsequent flushing.
|
| 7. |
Switch off vacuum pump. |
Note
If the vacuum pressure is unattainable or can
be reached only after a very long time, or if
the pressure increases to above 0.2 bar (abso-
lute) approx. 10 minutes after turning off the
pump, the circulation system leaks and must
be sealed.
|
| 87 - 38 |
Emptying and evacuating air-conditioning system
Printed in Germany - XXII, 1990 |
|
Flushing air-conditioning system
| 1. |
Connect service unit.
|
| 2. |
Evacuate.
|
| 3. |
Open filling valve 2 and high-pressure valve
6. Allow enough fluid refrigerant to flow until
a pressure of approx. 2 bar (absolute) is indi-
cated. The liquid refrigerant vaporized in the
system and takes up any traces of water pre-
sent.
|
| 4. |
Extract refrigerant.
|
| 5. |
Evacuate. |
Filling air-conditioning system
| 1. |
All procedures described so far must have
been carried out, i.e., the system must be
evacuated, flushed. evacuated once more,
and must be sealed.
|
| 2. |
Close all valves on service unit. The filling
cylinder must contain sufficient refrigerant; if
not, refill.
|
| 3. |
To fill the system, there must be positive
pressure of approx. 7 barin the filling cyl-
inder. To reach this pressure, switch on the
filling cylinder heating. |
|
|
Note
A pressure rise of 1 bar takes approx.
10 minutes.
|
Flushing and filling air-conditioning system
Printed in Germany - XXII, 1990
|
87 - 39 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| 4. |
Depending on the value dis-
played on the pressure gauge
(e.g. 7 bar), set the filling
cylinder scale so that the
value indicated on the up er
edge of the scale comes to
rest over the viewing glass. |
It should be noted that this
scale is designed for use with
more than one refrigerant. The
refrigerant designations are
found on the lower edge of the
scale.
For automotive air-conditioning
systems, only the scales for
R 12 can be used.
|
|
| 5. |
Set the required refrigerant
quantity on the filling cylinder
with the sliding ring (difference
from previous refrigerant level).
|
| 6. |
Again check to see that all valves
- particularly the torrmeter cutoff
valve 14 - are closed.
|
| 7. |
Open the filling valve
2 and high pressure valve 6.
|
| 8. |
Observe the fluid display in the
viewing glass of the filling cy-
linder. When the level of liquid
has reached the setting ring,
close valve 2. Open filling valve
9 for a short period, in order to
force the quantity remaining in
fill hose into the air-conditioning
system. Close high-pressure valve
|
| 9. |
Switch off heating. Disconnect
fill hoses from compressor.
Screw protective cap on to valves. |
|
| 87 - 40 |
Filling Air-Conditioning System |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
REFILLING AIR-CONDITIONING SYSTEM
If gas bubbles are visible in the
fluid tank viewing glass when the
system is on, the system does not
contain sufficient refrigerant. The
system must not be drained in order
to refill.
| 1. |
Rectify any leakage.
|
| 2. |
Fasten "Chargefaster" filling
aid to connection nipple 5
(low pressure) with the help
of the angle piece. |
The filling aid can remain
permanently connected as a component
of the service unit.
| 3. |
Connect fill hose between filling
aid on service unit and valve
on vacuum line. Slightly
open valves 2 and 7 on the
service unit in order to evacuate
the fill hose through the refri-
gerant flowing cut. All other
valves on the service unit must
remain closed. |
|
|
| 4. |
Switch on air conditioner.
Engine speed approx. every
2000/1 min. Open filling
valve 2 and low-pressure valve
7.
|
| 5. |
Observe viewing glass in fluid
reservoir. When there is no long-
er any gas-bubble formation,
refill is complete. |
N o t e
While the compressor is running,
valves 6 and 7 must never be
opened simultaneously.
|
| Printed in Germany - VII, 1986 |
| Refilling Air-Conditioning System |
|
87 - 41 |
|
Installation work on the air-conditioning system
Service unit SECU
 330-87
| 87 - 42 |
Installation service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990 |
|
1 - Pressure gauge, low pressure
2 - Pressure, high pressure
3 - Torr meter
4 - Shut-off valve, low pressure (blue)
5 - Shut-off valve, high pressure (red)
6 - Shut-off valve, tormerer (black)
7 - Shut-off valve, vacuum pump (yellow)
8 - Connection piece, low pressure
9 - Connection piece, high pressure
10 - Shut-off valve, refrigerant inlet
11 - Shut-off valve, refrigerant outlet
| 12 - |
Connection piece, refrigerant inlet (from
refrigerant bottle)
|
| 13 - |
Connection piece, refrigerant outlet (to
refrigerant bottle) |
14 - Moisture indicator
15 - Drain valve, refrigerating oil
16 - Main switch
17 - Operating hours counter
18 - Pilot lamp, yellow
19 - Pilot lamp, red
20 - Pilot lamp, green
21 - Pressure gauge, filling cylinder
22 - Shut-off valve, filling cylinder
23 - Filling cylinder with weight scale
Installation service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990
|
87 - 42a |
|
Refrigerant extraction
1. Connect service unit to the system.
Note
Check at the liquid reservoir whether the sight
glass is still transparent. If the sight glass
shows signs of brown discoloration on the insi-
de, the refrigerant should be pr-filtered by me-
ans of a cleaning drier installed in-between in
the extraction hose. In this case, extract only
via the high-pressure side.
| 2. |
Open the shut-off valve, low pressure (4)
shut-off valve, high pressure (5) and shut-off
valve, refrigerant inlet (8).
|
| 3. |
Turn the main switch (16) fully to the right.
The green pilot lamp lights up. |
Note
Extraction takes place automatically. The unit
is switched off when all refrigerant has been
extracted from the circuit. The red pilot lamp
then lights up.
| 4. |
Close shut-off valves 4, 5 and 8.
|
| 5. |
Open the refrigerating oil drain cock (15)
and drain extracted refrigerating oil.
|
| 6. |
Determine the volume of the refrigerating oil. |
Note
The refrigerating oil is now sucked into the sy-
stem via the high-pressure side.
| 7. |
Fill system with new refrigerating oil (extrac-
ted volume + 10 cm3). |
|
|
Filling refrigerating oil
| 1. |
Unscrew the red hose on the service unit at
connection piece 9 and hold in the contai-
ner with new refrigerating oil.
|
| 2. |
Switch on vacuum pump.
|
| 3. |
Open shut-off valve for low pressure (4) and
vacuum pump (7). |
Note
The refrigerating oil is now sucked into the sy-
stem via the high pressure side.
| 4. |
After filling the refrigerating oil, close the
shut-off valves and switch off the vacuum
pump. |
|
| 87 - 42b |
Installation service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990 |
|
Evacuating the air-conditioning sys-
tem
| 1. |
Extract any pressure still present.
|
| 2. |
Switch on vacuum pump (turn main switch
to left).
|
| 3. |
Open shut-off valves for low pressure (4),
high pressure (5), torr meter (6) and
vacuum pump (7).
|
| 4. |
Leave vacuum pump switched on for at
least 15 minutes.
|
| 5. |
Close shut-off valves 6 and 7 at a pressure
of approx. 0.1 bar (absolute).
|
| 6. |
Switch off vacuum pump. |
Note
If the vacuum cannot be attained or can be
reached only after a very long time or if the
pressure increases over 0.2 bar (absolute) ap-
prox. 10 minutes after the pump is switched
off, there is a leak in the circuit and this must
be sealed.
|
|
Flushing the air-conditioning system
Note
Flushing the air-conditioning system serves
the purpose of drying the circuit.
| 1. |
Evacuate.
|
| 2. |
Open the shut-off valve for high pressure (5)
and the refrigerant outlet (11).
|
| 3. |
Allow refrigerant to flow in until a pressure of
approx. 2 bar (absolute) is indicated.
|
| 4 |
Close shut-off valves 5 and 11.
|
| 5. |
Extract refrigerant again.
|
| 6. |
Evacuate. |
|
Installation work on the air-conditioning system
Printed in Germany - XXII, 1990
|
87 - 42c |
|
Filling the air-conditioning system
Note
The air-conditioning system must be
evacuated and free of leaks. There must be
sufficient refrigerant in the filling cylinder. Top
up if necessary.
| 1. |
All valves on the service unit must be closed.
|
|
A pressure of approx. 7 bar is required to fill
the system. If the pressure is lower, the pres-
sure can be increased by cleaning the re-
frigerant (refer to
Page 87 - 25). If the pressure is higher than
10 bar (end of the weight scale), the pres-
sure in the filling cylinder can be lowered by
opening the shut-off valve 22. |
Note
The pressure increases by approx. 1.5 bar in
10 minutes.
| 3. |
In accordance with the value read off on the
pressure gauge 21, adjust the rotating scale
of the filling cylinder so that the value
specified at the top edge of the scale is posi-
tioned over the sight glass. |
Note
It must be noted that the rotating scale is de-
signed for the use of different refrigerants. The
refrigerant designations are specified at the
bottom scale edge.
Only the scales for R12 are applicable for auto-
mobile air-conditioning systems.
|
|
| 4. |
Set the required refrigerant quantity on the
filling cylinder with the rubber ring (differ-
ence to refrigerant level in filling cylinder).
|
| 5. |
Open the shut-off valves for high pressure
(5) and the refrigerant outlet (11)
|
| 6. |
Observe the fluid level indication in the sight
glass of the filling cylinder. When the filling
level has reached the setting ring, close shut-
off valves 11 and 5.
|
| 7. |
Check the refrigerating capacity (refer to
Page 87-60).
|
| 8. |
Disconnect filling hoses at compressor.
|
| 9. |
Screw protective caps onto the valves. |
|
| 87 - 42d |
Installation service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990 |
|
Topping up the air-conditioning
system
Note
If gas bubbles are visible in the sight glass of
the fluid reservoir when the air-conditioning
system is switched on, there is not sufficient
refrigerant in the system.
| 1. |
Extract refrigerant from air-conditioning sys-
tem.
|
| 2. |
Determine the volume of the refrigerating oil
extracted as well.
|
| 3. |
Fill system with new refrigerating oil.
|
| 4. |
Evacuate.
|
| 5. |
Check system for leaks.
|
| 6. |
Fill system with prescribed filling quantity. |
Filling service unit with refrigerant
| 1. |
Connect refrigerant bottle with the connec-
tion piece at the refrigerant inlet (12).
|
| 2. |
Open the valve on the refrigerant bottle and
shut-off valve 10.
|
| 3. |
Switch on the service unit with the main
switch (16). The green panel lamp lights up.
|
| 4. |
If there is sufficient refrigerant in the service
unit, close the bottle valve. The system
switches off automatically when the refriger-
ant is extracted up to the bottle valve.
|
| 5. |
Close the shut-off valve at the refrigerant
inlet (10). |
|
|
Emptying the service unit
Note
If the filling cylinder is full with refrigerant and
it is still necessary to extract further refriger-
ant, the clean refrigerant can be filled into a re-
frigerant bottle. Pay attention to the maximum
filling weight here. The refrigerant bottle
must not be overfilled.
| 1. |
Connect the refrigerant bottle with the con-
nection piece at the refrigerant outlet (13).
|
| 2. |
Increase the pressure in the filling cylinder
to approx. 8 bar by cleaning the refrigerant.
|
| 3. |
Open the bottle valve and the shut-off valve
at the refrigerant outlet (11).
|
| 4. |
After completing the emptying operation,
close the bottle valve and shut-off valve. |
Note
Do not completely empty the filling cylinder,
otherwise moisture may enter the service unit.
|
Installation service unit/connecting to air-cond. system
Printed in Germany - XXII, 1990
|
87 - 42e |
|
Cleaning the refrigerant
Note
If the extracted refrigerant is heavily contami-
nated, it must be pumped through the filter
systems several times.
The state of cleaning can be seen at the mois-
ture indicator (14).
| 1. |
Open the shut-off valve for the filling cylinder
(22).
|
| 2. |
Switch on the service unit. The green pilot
lamp lights up.
|
| 3. |
After cleaning the refrigerant (state visible at
the moisture indicator), close the shut-off
valve. |
Note
The unit switches off automatically when all re-
frigerant has been pumped into the filling cyl-
inder (red pilot lamp lights up). The pressure
then increases in the filling cylinder.
| 87 - 42f |
Installation work on the air-conditioning system
Printed in Germany - XXII, 1990 |
|
Disassembling and assembling heating - A/C unit
Disassembling and assembling heating - A/C unit
Printed in Germany - XXII, 1990
|
87 - 42g |
|
Disassembling and assembling heating - A/C unit
| 87 - 42h |
Disassembling and assembling heating - A/C unit
Printed in Germany - XXII, 1990 |
|
| 9 4 4 |
Air-Conditioning System |
87 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16 |
Left footwell
vent
Sheet-metal
screw
Cover
Control motor
Control motor
Linkage
Plastic
bearing
Plastic
bearing
Tab washer
Linkage
Retaining ring
Plastic ring
Shaft ring
Linkage
Plastic bearing
Linkage
|
1
17
1
2
1
1
4
4
1
1
2
2
2
1
2
1 |
|
|
| Printed in Germany - VII, 1986 |
Disassembling and Assembling
Heating - A/C Unit |
|
87 - 43 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
17
18
19
20
21
22 |
Angle
bracket
Angle
bracket
Screw
M 3 x 7 with
spring washer
De-icer
Rubber grommet
Screw
M 4 x 8 with
spring washer
and collar
|
1
1
4
1
1
4 |
Do not damage capil-
lary tube
Turn by 90°
|
Push in
up to
marking
|
| 87 - 44 |
Disassembling and Assembling
Heating - A/C Unit |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
| Printed in Germany - VII, 1986 |
Disassembling and Assembling
Heating - A/C Unit |
|
87 - 45 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37 |
Right footwell
vent
Solenoid valves
Vacuum
line
Vacuum
line
Vacuum
line
Vacuum
line
Branch piece
Bracket
Plug housing
Sheet-metal
screw, long
Cover
Bracket
Screw
M 4 x 10 with
spring washer
and collar
Bracket
Seal
|
1
2
1
1
1
2
1
1
1
6
1
1
1
1
1 |
|
|
| 87 - 46 |
Disassembling and Assembling
Heating - A/C Unit |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
38
39
40
41
42
43
44
45
46
47
48
49 |
Mounting
plate
Clip
Refrigerant tube
Refrigerant tube
Seal
Refrigerant
line
Seal
Clamp
Expansion valve
Fuse
Spring
Angle bracket
|
1
2
1
1
2
1
1
1
1
1
1
1 |
|
Replace
and moisten
with refri-
gerator oil
|
| Printed in Germany - VII, 1986 |
Disassembling and Assembling
Heating - A/C Unit |
|
87 - 47 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| 87 - 48 |
Disassembling and Assembling
Heating - A/C Unit |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65 |
Clamp
Clamp
Sheet-metal screw
Angle bracket
Sheet-metal screw
Vaporizer
Seal
Spacer
Water drain
hose
Lower part of
housing
Sheet-metal screw
Left footwell
flap
Right footwell
flap
Linkage
Heat exchanger
Clamp
|
13
1
5
1
2
1
1
1
1
1
2
1
1
1
1
1 |
Do not damage
discs
|
Do not
damage
discs
Replace and
moisten with
refrigerator
oil
|
| Printed in Germany |
Disassembling and Assembling
Heating - A/C Unit |
|
87 - 49 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
| No. |
Description |
Qty. |
Note when: |
Removal |
Installalion |
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80 |
Clamp
Sheet-metal
screw
Left upper
housing half
Right upper
housing half
Plate nut
Temperature-
mixing flap
Baffle flap
Defrost flap
Air ducting
Mixing-chamber
sensor
Rubber grommet
Foam sealing
Foam sealing
Foam sealing
Foam sealing
|
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1 |
|
Replace
Replace
Replace
Replace
|
| 87 - 50 |
Disassembling and Assembling
Heating - A/C Unit |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
POSITIONING OF FLAPS, AIR FLOW
A - Cold air
B - Warm air
F - Fresh air
U - Circulating air
1 - Fresh/circulating air flap
2 - Footwell flap
3 - Temperature-mixing flap
4 - Baffle flap
|
|
5 - Defrost flap
6 - Blower
7 - Vaporizer
8 - Heat exchanger
|
| Printed in Germany - VII, 1986 |
| Positioning of Flaps, Air Flow |
|
87 - 51 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
REMOVING AND INSTALLING HEATING - A/C UNIT
| 1. |
Drain air-conditioning system.
|
| 2. |
Drain refrigerant.
|
| 3. |
Remove fresh air blower (see
repair group 85).
|
| 4. |
Remove center console
(see repair group 68).
|
| 5. |
Remove instrument panel
(see repair group 68).
|
| 6. |
Unclip instrument-panel
wiring harness. |
| 7. |
Disconnect plug.
|
| 8. |
Disconnect plug at in-
terior-sensor blower.
|
| 9. |
Pull out air ducts.
|
| 10. |
Pull out drainage hose.
|
| 11. |
Unscrew A/C lines. |
|
|
| 12. |
Remove vacuum lines.
|
| 13. |
Unscrew refrigerant hoses.
|
| 14. |
Unscrew fastening nuts on
the outside (4 pcs.). |
| 15. |
Unscrew fastening nuts on the in-
side.
|
| 16. |
Unscrew bracket for instrument
panel.
|
| 17. |
Run out heating-A/C unit. |
N o t e
During installation, make sure that
water drainage pipe is reinserted.
|
| 87 - 52 |
Removing and Installing Heating -
A/C Unit |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
REMOVING AND INSTALLING COMPRESSOR
| 1. |
Drain air-conditioning system.
|
| 2. |
Loosen both lock nuts on clamp
clip. |
| 3. |
Loosen V-belt.
|
| 4. |
Loosen clamp clip fastening
and remove V-belt.
|
| 5. |
Disconnect plug. |
|
|
6.Loosen hose connections.
N o t e
The fastening screws are micro-
encapsulated. Use new screws dur-
ing installation.
In order to facilitate installation,
remove the generator ventilation
hose.
| 7. |
Unscrew compressor fastening
screws. |
A d j u s t i n g P o l y -
R i b B e l t
| 1. |
Prepare special tool 9201
for testing.
|
| 2. |
Turn tensioner until the set
value of 9.5 scale units is
reached. From this position,
turn tensioner another 2 turns
(increase tension, see also
p. 13-1). |
|
| Printed in Germany - VII, 1986 |
| Removing and Installing Compressor |
|
87 - 53 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
REMOVING AND INSTALLING CONDENSOR
| 1. |
Drain air-conditioning system.
|
| 2. |
Unscrew underbody protection.
|
| 3. |
Unscrew air duct.
|
| 4. |
Loosen hose connections. |
| 5. |
Unscrew fastening screws (2 pcs.).
|
| 6. |
Pull condensor out of rubber hold-
ers from below. |
|
|
REMOVING AND INSTALLING REFRIGERANT
TANK
| 1. |
Drain air-conditioning
system.
|
| 2. |
Loosen hose connections.
|
| 3. |
Loosen clamp.
|
| 4. |
Pull tank out from above. |
N o t e
During installation, make sure tha
the connection nipple marked "IN"
points forward.
The tank must be replaced in
case of system malfunction and after
every opening of the refrigerant
system.
|
| 87 - 54 |
Removing and Installing Condensor
Removing and Installing Refrigerant Tank |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
REMOVING AND INSTALLING INTERIOR
SENSOR BLOWER
1. Remove glove compartment.
| 2. |
Pull hose from interior
sensor. |
3. Loosen fastening nuts.
4. Disconnect plug.
N o t e
Make cable connection before in-
stallation.
|
|
REMOVING AND INSTALLING THE DE-ICER
1. Remove left footwell vent.
| 2. |
Loosen but do not entirely unscrew
fastening screws. |
| 3. |
Carefully pull capillary tube
out of vaporizer. |
N o t e
When installing, push capillary
tube into marking.
4. Pull off cable
|
| Printed in Germany - VII, 1986 |
Removing and Installing Interior
Sensor Blower
Removing and Installing De-icer |
|
87 - 55 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
REMOVING AND INSTALLING EXPANSION
VALVE
N o t e
The expansion valve can only be
removed and installed when the
heating - A/C unit is removed.
| 1. |
Pull off cold-insulating band
on expansion valve.
|
| 2. |
Press off bracket for capillary
tube. |
| 3. |
Unscrew union nuts and re-
move expansion valve. |
|
|
OIL DISTRIBUTION IN REFRIGERA-
TION CYCLE
Compressor
40% = approx. 30 cm3
Vaporizer
35% = approx. 30 cm3
Condensors
15% = approx. 10 cm3
Refrigerant tank/lines
10% = approx. 10 cm3
These proportions should be
maintained.
When a component is replaced, the
oil in the system must be added to
by the amount in the component re-
placed.
The proper quantity can be directly
filled into the new component.
If the compressor is replaced,
60 % =·approx. 50 cm3 oil must be re-
leased from the new compressor, since
this contains the oil for the entire
system.
|
| 87 - 56 |
Removing and Installing Expansion Valve
Oil Distribution in Refrigeration Cycle |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
REMOVING AND INSTALLING CONTROL
MOTOR FOR DEFROST FLAP
1. Unclip linkage.
2. Remove plug housing.
| 3. |
Unscrew the three fastening
screws. |
|
|
A d u s t i n g D e f r o s t
F l a p
| 1. |
Set control motor to final
"closed" position. To do this,
connect pin 4 with + and pin 5
with - of a 12 voltage source.
|
| 2. |
Close defrost flap and clip on
linkage. |
|
| Printed in Germany - VII, 1986 |
Removing and Installing Control
Motor for Defrost Flap |
|
87 - 57 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
REMOVING AND INSTALLING CONTROL
MOTOR FOR TEMPERATURE-MIXING FLAP
AND BAFFLE FLAP
| 1. |
Unclip temperature-mixing flap
linkage.
|
| 2. |
In order to disconnect the
linkage of the baffle flap, remove
retaining ring, plastic washer,
and shaft ring. |
3. Unscrew fastening screw.
|
|
A d u s t i n g t h e
T e m p e r a t u r e - M i x t u r e
F l a p a n d B a f f l e F l a p
| 1. |
Set the control motors to the final
"cool" position. To do this, con-
nect pin 4 with + and pin 5 with -
of a voltage source of 12 v.
|
| 2. |
Press temperature-mixing flap
lever upward until the flap is at
the stop. Clip on the linkage in
this position.
|
| 3. |
Loosen nut M 5 on baffle flap
linkage.
|
| 4. |
Press together the two linkage
halves and tighten nut M5. |
|
| 87 - 58 |
Removing and Installing Control Motor
for Temperature-Mixture Flap |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
REMOVING AND INSTALLING CONTROL
MOTOR FOR FOOTWELL FLAPS
1. Remove plug housing.
2. Unscrew cover.
3. Unclip linkage.
4. Unscrew fastening screws.
|
|
A d j u s t i n g t h e F o o t -
w e l l F l a p s
| 1. |
Set control motor to final
"closed" position. To do this
connect pin 4 with + and pin 5
with - of a 12 voltage source.
|
| 2. |
Close footwell flaps and con-
nect linkage. |
|
| Printed in Germany - VII, 1986 |
Removing and Installing
Control Motor for Footwell Flaps |
|
87 - 59 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
AIR-CONDITIONING SYSTEM TROUBLE-
SHOOTING
G e n e r a l R e q u i r e -
m e n t s
Heating is off. Polyrib belt
correctly tensioned.
At an engine speed of 2000 l/min,
an ambient temperature of approx.
20° C, and with the compressor
running, the following pressures
must be attained:
Low pressure: approx. 0.5 - 2.0 bar
High pressure: approx. 10 - 20 bar
Temperature at center nozzle:
approx. 2 - 4° C.
C o m p l e t e C o o l i n g
F a i l u r e
| 1. |
When bursting seal on refri-
gerant tank has been destroyed. |
The system was overheated. Check
direction of rotation of cooler
and condensor blowers. If the
blowers do not run, check fuses,
relays.
| 2. |
Connect service unit and read
off pressure values.
Low pressure: too low
High pressure: too low |
|
|
No refrigerant in system. Look for
leakage. Fill air-conditioning
system.
| 3. |
Turn on air-conditioner and read
off pressures.
Low pressure: too high
High pressure: too low |
Compressor is defective.
Low pressure: too low
High pressure: too high
Expansion valve is defective.
I n s u f f c i e n t
C o o l i n g
| 1. |
Low pressure: normal
High pressure: high |
System is too full. Drain and
refill system.
| 2. |
Low pressure: too low
High pressure: too low |
Insufficient refrigerant in
system. Look for leakage. Refill
system.
| 3. |
Low pressure: too high
High pressure: normal |
Expansion valve is defective.
|
| 87 - 60 |
Air-Conditioning System Troubleshooting |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
I n a d e q u a t e C o o l i n g
A f t e r S h o r t P e r i o d
o f O p e r a t i o n
Cooling is OK at first, but then
decreases in effectiveness during
operation.
Vaporizer is iced up. De-icing
switch does not turn off compres-
sor. Check capillary tube for
damage and correct seating.
or
Expansion valve iced up.
Warm expansion valve. The
cooling effect of the air-condi-
tioner should start back up.
Cause: Moisture in refrigerant.
Replace refrigerant tank.
Refill system.
|
|
H e a t e r h e a t s c o n -
t i n u o u s l y a n d
c a n n o l o n g e r b e
r e g u l a t e d
Interruption in sensor series. Check
outside sensor, interior sensor, and
mixing chamber sensor.
Remove control switch and pull plug A.
Outer sensor: Connect ohmmeter
with term. 9 and ground
| Reading: |
at 0°C - 34 kohm + 10%
at 10°C - 20 kohm + 10%
at 25°C - 10 kohm + 10% |
| Interior sensor: |
Connect ohmmeter
with term. 2 and ground |
Reading: As for outside sensor
| Mixing chamber sensor: |
Connect
with term. 1
and ground |
Reading: As for outside sensor
|
| Printed in Germany - VII, 1986 |
Air-Conditioning System
Troubleshooting |
|
87 - 61 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
H e a t i n g n o t
C o n t r o l l a b l e
| 1. |
The heating regulates in the
direction of maximum cooling and
heats only starting from a
temperature-switch position of
approx. 27. |
There is a short circuit in the
sensor series.
To check the 3 temperature sensors,
see "heater heats continuously and
can no longer be regulated".
| 2. |
Defrost flap not controllable.
Pull plug on control motor,
switch on ignition and set de-
frost slide switch to "closed".
position. |
Voltmeter at term. 1 and term. 2
Reading: approx. 6 V
Voltmeter at term. 2 and term. 3
Reading: approx. 0.1 V
Defrost slide switch in "open"
position.
Reading: approx. 6 V
Voltmeter at term. 2 and term. 4
Reading: approx. 0.1 V
Defrost slide switch in "closed".
position
Reading: approx. 10 V
|
|
Voltmeter at term. 2 and term. 5
Reading: approx. 0.1 V
Defrost slide switch in "open"
position
Reading: approx. 10 V
| 3. |
Temperature mixing flap and
baffle flap not controllable. |
Pull plug on control motor,
switch on ignition and set tempera-
ture pre-selector to maximum
cooling.
Voltmeter at term. l and term. 2
Reading: approx. 6 volts
Voltmeter at term. 1 and term. 3
Reading: approx. 2.5 volts
Voltmeter at term. 1 and term. 4
Reading: approx. 10 volt
Set temperature pre-selector to
maximum heating
Reading: approx. 0.1 volts
Voltmeter at term. 1 and term. 5
Reading: approx. 10 volts
Set temperature pre-selector to
maximum cooling.
Reading: approx. 0.1 volts.
|
| 87 - 62 |
Air-Conditioning System Troubleshooting |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
4. Footwell flaps not adjustable.
Pull plug on control motor,
switch on ignition, and set foot-
well slide switch to "closed"
position.
Voltmeter at term. 1 and term. 2
Reading: approx. 6 V
Voltmeter at term. 2 and term. 3
Reading: approx. 0.1 V
Footwell slide switch in "open"
position
Reading: approx. 6 V
Voltmeter at term. 2 and term. 4
Reading: approx. 0.1 V
Footwell slide switch in "closed"
position
Reading: approx. 10 V
Voltmeter at term. 2 and term. 5
Reading: approx. 0.1 V
Footwell slide switch in "open"
position.
Reading: approx. 10 V
|
|
S l u g g i s h I n t e r i o r
T e m p e r a t u r e R e g u l a -
t i o n
The system overheats and
reacts only very sluggishly.
Interior sensor not functioning.
Pull plug on interior sensor
blower and switch on ignition.
Voltmeter at term. 1 and term. 3
Reading: battery voltage
If no voltage present, check
fuse No. 17.
M a g n e t i c C o u p l i n g
s w i t c h i n g
| 1. |
Check voltage at compressor plug.
Voltage present
 Replace magnet coil.
no voltage present
Check low-pressure switch.
|
| 2. |
Check voltage at low-pressure
switch.
Voltage only at one pin
Check system fill quantity.
System correctly filled
Replace low-pressure switch. |
|
| Printed in Germany - VII, 1986 |
| Air-Conditioning System Troubleshooting |
|
87 - 63 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
No voltage present
Check A/C relay.
| 3. |
Check A/C relay.
There must be voltage at term. 3.
No voltage present
Check de-icer.
There must be no ground potential
at term. 2.
Ground present
| |
Check water-tempera-
ture switch. |
|
| 4. |
Check voltage at de-icer.
Voltage at only one pin
Replace de-icer.
No voltage
Replace control switch. |
|
|
C h e c k i n g V a c u u m
S y s t e m
| 1. |
Pull off vacuum hose on vacuum
reservoir.
|
| 2. |
Switch on vacuum hand pump.
|
| 3. |
Switch on ignition.
|
| 4. |
Press air-circulation button and
set temperature pre-selector
switch to maximum cooling.
|
| 5. |
Generate vacuum. The fresh/circula-
tion air flaps should close, as well
as the heating valve. |
| 6. |
If the fresh/circulation air flaps
and the heating valve do not close,
although the vacuum system has no
leakage, check voltage at solenoid
valves |
|
| 87 - 64 |
Air-Conditioning System Troubleshooting |
Printed in Germany |
|
TOOLS
| No. |
Description |
Special Tool |
Remarks |
1
2
3
4
5
6
7
|
Holding wrench
Coupling plate puller
Key puller
Friction washer puller
Axial face seal puller
Key inserter
Thrust member
|
95047-10040
95047-10060
95042-10160
95042-10150
95042-10130
95042-10190
95042-10250
|
Suppliers: see Workshop Manual |
Rem. and installing magnetic coupling, shaft sealing ring
Printed in Germany - XXIV, 1991
|
87 - 65 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
INSTALLING AND REMOVING MAGNETIC
COUPLING
| 1. |
For loosening or tightening
the fastening nut, use holding
wrench to counter-hold.
Tightening torque: 16 Nm/12 ftlb |
| 2. |
Remove coupling plate with
puller. |
3. Remove shims.
|
|
| 4. |
Remove retaining ring and
belt pulley. |
| 5. |
Remove retaining ring and
magnet coil. |
N o t e
Coil resistance is
3.8 ± 0.2 ohm.
|
| 87 - 66 |
Removing and Installing Magnetic Coupling |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
I n s t a l l a t i o n
The air gap between the coupling
plate and belt pulley is 0.4 - 0.7 mm.
If required, adjust air gap with shims.
|
|
Install the two retaining rings so
that the diagonal points upwards.
|
| Printed in Germany - VII, 1986 |
| Installing Magnetic Coupling |
|
87 - 67 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
REMOVING SHAFT SEALING
N o t e
Briefly loosen vent plugs on line
connections, so that any remain-
ing gas can escape.
| 1. |
Remove coupling plate.
|
| 2. |
Remove dust seal with blunt ob-
ject.
|
| 3. |
Remove key with key puller.
|
| 4. |
Remove shaft seal retaining ring.
|
| 5. |
Pull out friction washer using
puller. |
|
|
| 6. |
Remove axial face seal with puller.
Introduce puller. Push down the
axial face seal spring with the
puller and simultaneously turn
to the riqht, until the seal
catches. |
|
| 87 - 68 |
Removing Shaft Sealing |
Printed in Germany |
|
| 9 4 4 |
Air-Conditioning System |
87 |
INSTALLING SHAFT SEALING
N o t e
Prior to installaltilon coat axial
face seal and friction washer with
refrigerator oil.
Do not damage the sealing faces of
the shaft sealing.
| 1. |
Install axial face seal with
pulling tool.
|
| 2. |
Install friction washer with pul-
ling tool. |
| 3. |
Using thrust member and nut,
push friction washer to where
the groove for the retaining
ring is fully visible. |
|
|
| 4. |
Insert retaining ring and remove
thrust member. |
| 5. |
Insert key, apply key inserter,
and drive in the key. |
6. Insert dust sealing.
7. Install coupling plate.
Tightening torque: 16 Nm/12 ftlb
|
| Printed in Germany - VII, 1986 |
|
87 - 69 |
|
| 87 |
Air-Conditioning System |
9 4 4 |
www.9ss1.dk/porsche944
|
|
