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The number af knocks is displayed in per mill. Page Troubleshooting Troubleshooting Diagnosis using the tester can refer only to the error path, but not to a defective component. Note: Before troubleshooting, the entire error memory must be read out. Page 32 Error code This error code indicates an error in the area of the idle contact.
Page 33 Error code This error code draws attention to an error in the area of the full load contact. Possible errors: Ground fault Switch stuck Testing the full load contact Connect an ohmmeter between terminal 53 and terminal 24 on the DME plug.
The engine temperature sensor NTC 2 in- forms the control unit about the current engine Page 36 Error code When this error code appears, the Lambda control has detected too rich ar too lean a mixture. Possible causes for too lean a mixture: Lambda probe ground fault Intiltrated air on the intake side Intiltrated air on the exhaust side of the Lambda probe Injection valve does not open Ignition cut-out Page 37 Measure the voltage between pin 1 and engine ground.
The voltage is within the range of approx. Check the cable harness to the DME control unit with reference to the circuit diagram. Page 38 Error code This error code draws attention to an error in the area of knock sensor 1. Page 39 Error code Error code draws attention to an error in the area of the knock control in the DME con- trol unit.
If this error code appears, the control unit must be replaced. Page 40 Testing the Hall generator's power supply Disconnect the Hall generator's connector. If this is not the case, check the wiring with reference to the circuit diagram. Page Table Of Contents Error code - List Error code A digit 2 e. This does not apply to error codes and Page 42 03 - 30 Blank page The error memory cannot be reset as follows until this error code appears: The yellow key must be pressed until the function symbol see display appears on the function display.
Page System Adaptation 1. General information 1. All systems which have a diagnosis interface as per ISO Standard can be tested with this tester. Page 47 - Accessory - Item 1 Charger with connecting cable, 1. There then follows the display of the number of errors which are stored if any.
Page 49 Key 1 selects the next actuator e. Page 50 Proceed with key 1 Prerequisite: Eng. If key 1 is pressed: Start engine! Following engine start there appears: System is being adapted Systemtester Page 52 10 - Blank page Page 54 Tolerances and wear limits Engine M Page 55 Tolerances and wear limits Engine M Page 56 Tolerances and wear limits Engine M The bell housing remains attached to the engine.
Removing 1. Align lifting platform pads beneath jacking points and raise car. Place protective covers on fenders. Unbolt and remove front wheels. Page 59 7. Disconnect breather hose for toothed helt cover at rear of lower section of air filter. Unbolt filter assembly as a unit and remove. Remove air-flow sensor. Slacken and remove ignition-distributor cap and rotor. Mark installation position of rotor. Remove oil filter and ATF reservoir.
Remove engine underguard. Open coolant drain plug and catch coolant in a suitable container. Disconnect alternator breather hose. Disconnect coolant hose at bottom right of radiator from engine and remove. Catch any coolant which may be left. Page 61 Detach Poly-rib belt tensioner from air-conditioning compressor and remove belt. Remove compresor from bracket and place to one side. Do not disconnect refrigerant hoses.
Unbolt stabilizer with bracket from body and from control arms and remove. Disengage left and right tie rods. Disconnect leads from starting motor and remove starting motor. Remove clutch actuating cylinder from bell housing. Leave line connected. Unbolt and remove holder for line from upper crankcase half. Disconnect exhaust from flange of exhaust manifold and disconnect exhaust extraction line. Page 63 Pull engine forward, push rubber sleeve out of firewall toward engine compartment and carefully pull wire harness out of passenger-side footwell.
Installing Note the following: 1. Carefully feed wire harness for DME control unit, 8-pin connector and multi-pin connector into passenger-side footwell. Refill system with coolant and bleed system. Fill reservoir with ATF and bleed steering system. Run engine until it reaches operating temperature, check engine-oil level and coolant level, top up if necessary. Kolbenschmidt Standard size Note It recommended that the stocks of the relevant tolerance group are checked befare machining the cylinders.
Page 68 This page are missing or blank in the book! Page 69 Assemble cover of centrifugal oil compartment in upper crankcase section. Notes on installation Model 89 onward, Engine type M If the cover is removed, however, the bolt area must be heated with a hot-air blower under all circumstances.
Page 70 15 - Blank page Printed in Germany Unknow page 15 - Page 73 Adjusting with dial gages 2. Align second gage with hydraulic tappet of cylinder 1 intake valve. The dial gage must be aligned perpendicular to the intake valve. Turn the engine in the direction of rotation until piston reaches its upper limit af travel. Set dial gage af cylinder 1 intake-valve hydraulic tappet to 0. Turn crankshaft past ignition TDC cylinder 1 while observing cylinder 1 intake-valve dial gage. Setting Inlet valve cylinder 1 Testing and adjusting value 0.
This TDC mark is applied after the camshaft timing has been set on the new engine. Align lifting-platform pads beneath jacking points and raise car. Disconnect ground lead from battery 4. Disconnect breather hose for toothed-belt cover from rear of lower section of air filter. Page 79 8. Disconnect vacuum hose, fuel-line-pressure damper and fuel-distribution pipe from intake manifold, disconnect plug from idle actuator, remove fuel rail with injection valves and place to one side.
Disconnect throttle-valve switch connector. Unbolt intake manifold from cylinder head and remove. Relieve tension of camshaft toothed belt by slackening nut A and bolt B, pressing toothed-belt tensioner against the pressure of the spring with Special Tool and removing toothed belt from camshaft sprocket. Hold both camshafts in the bearings with Special Tool Undo and remove front double bearing bridge and bearing cover. Note The rear double bearing bridge may remain on the cylinder head.
Page 82 Installing and tightening the cylinder head Model 87 onward Engine type M Place the cylinder head gasket in the cer- rect position. Mount cylinder head Tightening sequence: Opposite to undoing sequence. Turn engine in direction of rotation by ap- prox. Lay intake shaft and exhaust camshaft in the timing chain.
Place both camshafts in the timing chain that the cast lugs are alignedwith the marked links of the chain. Page 84 6. Apply Loctite to the sealing surfaces of the front and rear double bearing bridges. Use the assembly drift, Special Tool and pressure piece to drive the sealing ring into position at the drive end of the camshaft. Place sealing washers in bearings and install bearing bridge with Loctite Tightening torque 20 Nm 15 ftlb. Note: Chain-tensioner plunger is spring-loaded.
When removing, compress plunger and hold in this position with suitable retainer improvised tool. Page 88 This page are missing or blank in the book!
Description Assembly bridge Lever arm Magnetic removal head Assembly head Spacer Screws Note If the cylinder head is installed, the lever arm must be angled more accutely. Mount the assembly bridge on the cylinder head.
Secure the cylinderhead to the work bench with a screw clamp to prevent tilting. Page 94 Remachining cylinder-head maling face Checking cylinder head for distortion Use a feeler gage an a straight edge or a precision straight edge to check the maling face of the cylinder head for distortion. Permissible maling-face uneveness: 0. Lubricate valve stem and install shaft. Clean the valve guides thoroughly. Use a new valve to measure the tilt play.
Mount bar gate holder VW on the cylinder head. The dial gaugemust be aligned parallel to the valve disk. Page 98 15 - Blank page Page Replacing the valve guides 1. Clean and inspect the cylinder head.
It is inexpedient to replace the valve guides cylinder heads where remachining is no longer possible on the valve seats or sealing areas. Lay the cylinder head on the ejection base. Ream the valve guides with Special Tool Proceed as follows: The valve guides must always be reamed with "petroleum" lubricant Withdraw the reamer regularly to remove chips.
Then finish-ream the boreagain with a dry reamer. Page Checking the valve seat wear limit 1. The valve seats in the 4-valve cylinder heads can be remachined. At the same time, the wear limit dimension must not be exceeded as this would mean that the hydraulic valve tappets may no longer function correctly. Check that the valve seat sits securely in cylinder head. Check the contact pattern. If the valve does make contact over the emire surface of the valve seat.
Page Check the contact pattern af the valve seat surface. Tool own construetion Valve spring Sp No. Machine a recess of approx. Only install valve- spring seat for measurement.
Page 5. Using a depth gauge, measure from the top surface of the valve-spring seat, vertically downwards through the recess to the outer spring contact surface. Installation length Inlet valve Throughout its lifetime, the has been modified by private teams and by the factory itself for racing, rallying and other forms of automotive competition.
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Porsche workshop manual download
Also See for Workshop manual - pages Driver manual - 67 pages Manual - pages. Table Of Contents. Quick Links. See also: Driver Manual , Workshop Manual. Table of Contents. Workshop Manuel.
Previous Page. Next Page. Porsche Workshop Manual pages. Volume 6 heating ventilation air condition electrics 76 pages. Track: Front Rear Ground clearance at per. Page 10 Max. Page 12 Technical data - Type 52 - Model 89 Values for adjustment and wear are to be found in the respective repair groups Notes: USA values are given in brackets Drive unit Internal engine designation Bore Stroke Displacement actual Displacement rounded down Compression ratio Max.
That is to say, the control unit is capable of detecting, storing and displaying system errors. The con- trol unit capable of diagnosis is identified by an altered part number. Page 15 Connection in the S In the S, the diagnosis socket is attached to a separate cable harness located above DME control unit. Ignition off After connecting the tester, the following dis- play must appear.
Display: If this is not the case, check the tester ter Page 17 Starting error diagnosis Condition: Engine off Ignition on Display: Press the green key until the clear symbol appears on the function display.
Display: The diagnosis sequence for the DME control unit then takes place. Page 18 Press the green key until the clear symbol ap- pears on the function display. The following display must then appear. Display: This now terminates diagnosis of the DME control unit. Page Function Check Actuator and input signal function checking An actuator and input signal function check can be carried out independently of an error diagnosis. This function check tests individual components or electrical signals with respect to their functioning or signal paths.
Functions ara triggered from the diagnosis tester. Page 20 Press the green key until the ctear symbol pears on the function display. This activates the first testing step and the injection valves are activated. Display: The injection valves must all operate audibly or tangibly. Note: If later attempts are made to start the engine, starting difficulties may occur because a slight residual amount of fuet is injected during this Page 21 As from the "idle contact" testing step, specific controls must additionally be operated on the car for the purpose of function checking.
Idle contact display: Slightly press the accelerator. The LED must go off after approx. Page 22 Initiale the air-conditioning control terminal testing step. Display: Switch on the air-conditioning system.
The LED must go off and the display will appear after approx. Display: If this is not the case, an error has occurred the area of the air-conditioning system's wiring. Page 23 Press the green key until the clear symbol appears. Display: End of the actuator and input signal function checks. Page 24 03 - 12 Blank page Page 26 03 - 14 Blank page Page 27 System adaption System adaption can be carried out with the tester. That is to say.
Note: For system adaption, it is necessary for the engine to be at operating temperature. Page 28 03 - 16 Blank Page Page Knock Detection Knock detection Before knock detection is carried out, error diagnosis must first of all be performed to guarantee that no electrical error has occurred in the area of the knock control and the knock sensors.
Knock detection should not be carried out if the customer has complained about poor out- put or too high a consumption, for instance. Page 30 The tester is now active. If knocking occurs, this will be indicated by the tester, e. Display: Counting is now complete.
The number af knocks is displayed in per mill. Page Troubleshooting Troubleshooting Diagnosis using the tester can refer only to the error path, but not to a defective component. Note: Before troubleshooting, the entire error memory must be read out. Page 32 Error code This error code indicates an error in the area of the idle contact. Page 33 Error code This error code draws attention to an error in the area of the full load contact.
Possible errors: Ground fault Switch stuck Testing the full load contact Connect an ohmmeter between terminal 53 and terminal 24 on the DME plug. The engine temperature sensor NTC 2 in- forms the control unit about the current engine Page 36 Error code When this error code appears, the Lambda control has detected too rich ar too lean a mixture. Possible causes for too lean a mixture: Lambda probe ground fault Intiltrated air on the intake side Intiltrated air on the exhaust side of the Lambda probe Injection valve does not open Ignition cut-out Page 37 Measure the voltage between pin 1 and engine ground.
The voltage is within the range of approx. Check the cable harness to the DME control unit with reference to the circuit diagram. Page 38 Error code This error code draws attention to an error in the area of knock sensor 1. Page 39 Error code Error code draws attention to an error in the area of the knock control in the DME con- trol unit.
If this error code appears, the control unit must be replaced. Page 40 Testing the Hall generator's power supply Disconnect the Hall generator's connector. If this is not the case, check the wiring with reference to the circuit diagram. Page Table Of Contents Error code - List Error code A digit 2 e. This does not apply to error codes and Page 42 03 - 30 Blank page The error memory cannot be reset as follows until this error code appears: The yellow key must be pressed until the function symbol see display appears on the function display.
Page System Adaptation 1. General information 1. All systems which have a diagnosis interface as per ISO Standard can be tested with this tester. Page 47 - Accessory - Item 1 Charger with connecting cable, 1. There then follows the display of the number of errors which are stored if any. Page 49 Key 1 selects the next actuator e.
Page 50 Proceed with key 1 Prerequisite: Eng. If key 1 is pressed: Start engine! Following engine start there appears: System is being adapted Systemtester Page 52 10 - Blank page Page 54 Tolerances and wear limits Engine M Page 55 Tolerances and wear limits Engine M Page 56 Tolerances and wear limits Engine M The bell housing remains attached to the engine.
Removing 1. Align lifting platform pads beneath jacking points and raise car. Place protective covers on fenders. Unbolt and remove front wheels. Page 59 7. Disconnect breather hose for toothed helt cover at rear of lower section of air filter.
Unbolt filter assembly as a unit and remove. Remove air-flow sensor. Slacken and remove ignition-distributor cap and rotor.
Mark installation position of rotor. Remove oil filter and ATF reservoir. Remove engine underguard. Open coolant drain plug and catch coolant in a suitable container.
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