Workshop Manual

Workshop Manual
Workshop
Manual
l
e
DR. ING. h. c. F. PORSCHE
Aktiengesellschaft
The Workshop Manual is only for the internal use of the Porsche Dealer Organization.
@ 1977
Dr. Ing. h.c. F. Porsche Akiengesellschaft
Sales, D-7140 Ludwigsburg
All rights reserved
- Printed in Germany
WKD 481 621
Print No. W 42X08-126-l
XX 1988
List of Repair Groups
General
Technical Data
Page 0.1
Group
Repair Groups
Maintenance,
Selfdiaanosis
03
Engine
Engine, Crankcase
Engine, Crankshaft, Pistons
Engine, Cylinder Head and Valve Drive
Engine, Lubrication
Engine, Cooling
Fuel Supply
Air Flow Controlled Fuel Injection
Exhaust System/Emission Controls
Starter, Power Supply, Cruise Control
Ignition System
10
13
15
17
19
20
24
26
27
28
Transmission
Clutch, Controls
Torque Converter
Manual Transmission, Controls, Case
Manual Transmission, Gears, Shafts
Automatic Transmission, Controls, Case
Automatic Transmission, Gears, Valve Body
Differential, Transaxle System
30
32
34
35
37
38
39
Chassis
Front Wheel Suspension
Rear Wheel Suspension, Axle Shaft
Wheels, Tires, Alignment
Antiblock System
Brakes, Mechanical
Brakes, Hydraulics
Steering
40
42
44
45
46
47
46
Body
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
Doors
Hardtop
Bumpers
Glasses, Window Control
Exterior Equipment
Interior Equipment
Seats
Seat Covers
50
51
53
55
57
61
63
64
66
68
72
74
Heating,
Ventilation,
Air Condition
Heater
Ventilation
Air Conditioner
80
85
87
Electrics
Instruments, Fuel Gauge, Alarm System
Radio
Windshield Wipers and Washer
Exterior Lights, Lamps, Switches
Interior Lights
Wiring
90
91
92
94
96
97
Printed in Germany
- Xx, 1987
928
Table of contents
Volume
VI
Page
Instruments,
Fuel Gauge, Alarm System
Diagnosis / trobleshooting
alarm system
D90 - 1
Wiring
Ground points on car
Correction to circuit diagrams, models 87 and 88, sheet 7
Additional electrical equipment
Repairing wiring harness no. 121
Current flow diagram, symbols and explanation
Current flow diagram
97-01
97-03
97-05
97-07
97-1
97-3
l
1
Table of contents
Printed
in Germany
- XXXI. 1993
929
l
Instruments,
Diagnosis /troubleshooting
Fuel Gauge, Alarm System
alarm system
The alarm control unit is diagnosable. It can
be read out only with System Tester 9288.
The menu includes the following
groups:
0
-
Fault memory
-
Drive links
-
Input signals
-
Country codes
90
Tools required for troubleshooting:
Special Tool 9540
functional
- Results
System check
Note
For some of the faults, two types of causes
must be distinguished:
The fault displayed is an actual fault that
has to be remedied.
The fault displayed is a fault condition
that has been caused deliberately, e.g. by
leaving the open glove compartment open.
Troubleshooting
requires that the person
performing the tests
l
-
is familiar with the location of components, function and technical ‘relation.
ship of the systems being tested
(refer to Model Information)
-
is able to read and evaluate Porsche
wiring diagrams
-
knows the functions
-
is capable of using testers and of evaluating the test results.
Diagnosis
Prlmod
The Special Tool is required because connector II is fitted with miniature terminals.
To avoid damaging the terminals, always use
the Special Tool for the tests.
When checking for continuity, attach connector to wiring harness only.
When checking signals and voltages, attach
connector to wiring harness and control unit.
of circuits and relays
I troubleshooting
In Germany
Note
- XXIX,1992
alarm system
DSO-1
90
Pin assignments
Instruments,
of alarm control unit connector
I-
Connector I
Terminal:
1 - Term. 30
2 -Term. 31 (Ground)
3 - Term. 30
4 - Anti-drive off feature
56 -Term. 15
7 - Interior light
8 - Turn signal left
9 - Turn signal right
lo-Horn
11 - Motor ,,Closed” Actuator door lock
12 - Motor ,,Open” Actuator door lock
13 14 - LED front passenger’s door
15 - LED driver’s door
S - Fuse
D90-2
928
Fuel Gauge, Alarm System
I
26
14
Jj,
Connector II
Terminal:
1 - Activate I closed
2 - Deactivate /open
3 - Rear lid contact
4 - Tailgate lock
5 - Hood contacf
6 - Speed0 signal Term. A
7 - Input 1
8 - Input 2
9 - Radio 2
10 - Central locking system position switch
,,Open”
11 - Central locking system button
12 - Central locking system position switch
,,Closed”
13 - Radio 1
14 - Diagnosis .,L”
15 - Diagnosis ,,K”
16 - Glove compartment contact
17-Input3
18 -Term. 15
20 -Central locking system button light
21 - Door contacts
23 -Term. 61
24 - External electronics
Diagnosis I troubleshooting
Printed
alarm system
in Germany
- XxX1.1993
928
0
Instruments,
Fuel Gauge, Alarm System
90
Fault memory
Overvlew
of posslble
displays
I
Control
defective
Glove
camp.
open during
activation
unit
Input
2
to ground
during
activation
l
Central
lock
button
closed
during
activation
Voltage
failure
1 during
alarm
output
I
I
Position
drives
unplausible
of
Input
1
to ground
during
activation
the
I
I
Door(s)
open during
activation
I
I
Position
switch
on drive
CJpWl
during
activation
Luggage
colnp.
open during
activation
Diagnosis
Printed
I troubleshooflng
in Germany
- XXIX,1992
alarm system
D90-3
90
Tailgate
switch
closed
during
D90-4
Instruments,
Fuel Gauge, Alarm System
928
lock
activation
Diagnosis
I troubleshootlng
Primed
alarm system
In Germany
- XXIX,1992
a
929
Instruments,
Fault, Fault Code
Possible
90
Fuel Gauge, Alarm System
Causes,
Elimination.
Remarks
Note
After a fault in the alarm system has occurred and after it has been remedied, the fault memory
must be erased.
Test Point 1
Control unit defective
-
Replace control unit.
-
Check battery.
-
Check fuse at control unit.
-
Check wiring according
-
Refer to Test Point 2
Test Point 2
Voltage failure Term. 30
with active alarm system
to wiring diagram
Test Point 3
Voltage failure
during
alarm output
Test Point 4
Position of the drives
unplausible
This fault is also stored if, for example, the driver’s door is open
when the key is used to actuate the central locking system from the
passenger’s door.
-
Disconnect plug II from control unit. Attach Special Tool 9540
at wiring harness.
With the doors unlocked, ground must be present at pin 10.
At the same time, no ground must be present at pin 12.
With the doors locked, ground must be present at pin 12.
At the same time, no ground must be present at pin 10.
-
If required, check wiring according
to wiring diagram.
The T6 (driver’s door) and T 22 (passenger’s door) connectors
are located inside the doors, i.e. the door trim must be removed
if the connectors are to be checked.
Test Point 5
Check LH and RH door contact switches for shorts to ground.
Doors(s) open
during activation
Diagnosis
Printed
I troubleshooting
in Germmy
- XXIX, 1992
-
Check wire from alarm contrd unit plug II terminal 21 to the door
contacts for short to ground, using Special Tool 9540.
-
Check wire from rear cover unlocking
ground across connector T 19.
alarm system
actuator for short to
DSO-5
90
FauIt, Fault Code
instruments,
Possible
928
Fuel Gauge, Alarm System
Causes,
Elimination,
Remarks
-
Check wire from relay base of central relay terminal D for short
to ground.
-
Check wire to window winder/sunroof
terminal 5, for short to ground.
-
Check engine hood contact switch for short to ground.
control unit plug I,
Test Point 6
Engine compartment
open during activation
Check wire from alarm control unit plug II, terminal 5, to engine
hood contact switch for short to ground using Special Tool 9540.
Note
The wire is routed across connector
T 33.
Check socket side of wire from connector T 33 terminal 5 to
engine compartment light for short to ground.
-
Check pin side of wire from connector T 33 terminal 5 to cooling
air control plug II, terminal 6, for short to ground.
Test Point 7
Luggage camp.
open during activation
Check tailgate contact switch for short to ground.
-
Check wire from alarm control unit plug II, terminal 3, to contact
switch for short to ground, using Special Tool 9540.
The wire is routed across connectors
T 19 and T 9
Test Point 6
Glove camp.
openm during activation
-
Check glove compartment
for short to ground.
switch and glove compartment
light
-
Check wire from alarm control unit plug II, terminal 16, to contact
switch for short to ground, using Special Tool 9540.
0
Note
The wire is routed across connector
D90-6
Diagnosis
T 1
/ troubleshooting
Printed
alarm system
in Germany
- XXIX, 1992
a
928
Instruments,
Fault. Fault Code
Possible
90
Fuel Gauge, Alarm System
Causes.
Ellmlnatlon.
Remarks
Test Point 9
Input 2 to ground
during activation
Note
The fault display may appear ti auxiliaty
tor) have been fitted.
systems (e.g. interior moni-
-
Check auxiliary system of input 2.
-
Check wire from alarm control unit plug II, terminal 8. to auxiliary
system for shorl to ground, using Special Tool 9540.
Test Point 10
Central lock button
closed during activation
Check central locking system button.
Check wire from alarm control unit plug II, terminal
for short to ground, using Special Tool 9540.
11, to button
Test Point 11
Input 1 to ground
during activation
Check auxiliary
system of input 1.
Check wire from alarm control unit plug II, terminal 7, to auxiliary
system for short to ground using Special Tool 9540.
Test Point 12
Input 3 to ground
during activation
to positive
Check auxiliary system of input 3.
Check wire from alarm control unit plug II, terminal 17, to auxiliary system for short to ground using Special Tool 9540 check
for short to positive.
Test Point 13
Position switch on drive
closed during activation
-
Check triggering of actuators.
Ground must be present at connectors
and 12, in the quiescent state.
T6 and T22, terminals
11
Note
Conectors T6 (driver’s door) and T 22 (passenger’s door) are
located inside the doors; i.e. the door trim must be removed
when the connectors are to be checked.
Positive voltage must be present at terminal 11 when the
actuator is triggered in the “open” direction.
Positive voltage must be present at terminal 12 when the
actuator is triggered in the ,,closed” direction.
Note
The actuators are only triggered for several milliseconds.
Dlagnosls
Printed
I troubleshootlng
in Germany
- XXXI, 1993
alarm system
D90-7
90
Fault, fault code
Instruments,
Possible
Fuel Gauge, Alarm System
causes.
remedies.
928
notes
-
Check wires from alarm control unit plug I, terminals
to the acutators for continuity.
11 and 12,
-
Check position switch at actuator (refer to Test Point 4).
-
Refer to Test Point 13,
-
On radios that do not have this contact, radio 1 input is wired
to ground.
Check wire from alarm control unit plug II, terminal 13, for
continuity to ground.
-
Check insulating
-
Check wire from alarm control unit plug II, terminal 9, to radio
plug, terminal 6. for short to ground.
-
Check alarm contact at radio or bracket, respectively.
-
Check tailgate release lock switch.
-
Check wiring from alarm control unit connector II, terminal 4. to
tailgate release lock switch for short to ground.
Test Point 14
Position switch on drive
open during activation
Test Point 15
Radii (closed loop)
interrupted during activation
Test Point 16
Radio contact to ground
during activation
strip on radio.
Test point 17
Tailgate lock switch closed
during activation
Note
The wire is routed across connector
D90-8
Diagnosis
T42,
I troubleshooting
Printed
alarm system
in Germany
-XXX&
1993
a
Instruments, Fuel
928
90
Gauge, Alarm System
Drive links
This function allows the following
to be triggered:
components
-
Function display in lock buttons
-
Lock
-
Alarm horn
-
Turn signals
-
Interior light
-
Button light in central locking system
bunon
-
External output
Alarm horn on: Alarm horn is triggered
continuously (continuous sound).
Function
display
1 = on
3 = off
Return
:
Turn signals on: All turn signals are triggered
continuously (continously lit).
N
If the function display is turned on, the doors
are locked and the LEDs light up permanently. The ,,on” display flashes on the tester.
If the function display is turned off again, the
LEDs are turned off as well. The doors are
unlocked again when the user returns to the
menu.
1
1,:T;;ydN
I
Lock closed: Doors are locked.
Lock open: Doors are unlocked.
The interior light must be in the door contact
position.
Button
light
1 = on
3 = off
Return:
N
Button light on: The light in the central lock
system button is triggered.
External
1 = on
3 = off
Return:
output
N
The external output is used to trigger other
control units, e.g. ultrasonic monitoring of the
interior.
l
Dlagnosls
PrInted
I troubleshootlng
in Germeny
- XXIX.1992
alarm system
D90-9
90
Instruments,
Possible fault displays
No activation
Door(s)
open
i
926
Fuel Gauge, Alarm System
Note
Fault summary is displayed if several drive
links (actuators) are triggered simultaneously,
e.g. if turn signals are on while the function
display is checked.
!
Return:
-
Check wiring to alarm control unit plug I,
terminals 8, 9, 10, 11, 12, and plug II,
terminal 20, for short to positive.
-
Check wiring to alarm control unit plug II,
terminal 24 (if connected) and terminal 7,
for short to ground.
N
-
Close doors
-
Check door contact wires to alarm control
unit plug II terminal 21 for short to ground.
5.
NO activation
Engine
running!
-
No activation
Fault
summary
!
Position
switch
?
Return:
Turn off engine, only switch on ignition.
NO response
Signal
unplausible
N
-
Refer to item 4.
-
Also check position switch
(refer to page D 90- 5).
!
6.
i
-
Return
N
Activation
correct.
Position
Return:
Replace control unk.
No activation
Fault
sumnary!
-
switch?
N
Check position switch
(refer to page D 90 - 5).
No response
Signal
unplausible
Position
switch
D90-10
!
?
-
Check position switch
(refer to page D 90 - 5)
-
Replace control unit,
Diagnosls
I troubleshooting
Printed
alarm system
in Germany
- XXIX,1992
a
Instruments,
928
-
Check following
-
1. GP VII: Battery to body
-
2. GP VIII. Body to engine
-
3. GP V: Body to alarm control unit
90
Fuel Gauge, Alarm System
-
Input 3 (auxiliary
-
Speed0 signal
-
Term. 15
-
Term. 61
system)
ground points:
Door(s)
Input
signals
This function allows the following
to be checked:
-
input signals
- open
Return:
i------
N
Open is displayed if at least one
Closed is displayed it both doors
If required, check wiring to alarm
for open circuit or short to ground
to wiring diagram.
door is open.
are closed.
control unit
according
Door contacts
2.
-
0
Engine compartment
switch
Luggage compartment
Position switches at drive motors
-
Central locking system button
-
Glove compartment
-
Radio closed loop
-
Alarm contact radio bracket
-
Tailgate lock button
-
Microswitch
button
-
Microswttch
-
Input 1 (auxiliary
system)
-
Input 2 (auxiliary
system)
Printed
in Germany
for deactivation
- XXIX,1992
- open
Return:
N
Open is displayed if engine hood is open.
Closed is displayed if engine hood is closed.
If required, check wiring to alarm control unit
for open circuit or short to ground according
to wiring diagram.
3.
Luggage
for activation of alarm
I troubleshootlng
compartment
switch
-
Dlagnosls
Engine
of alarm
alarm system
- open
Return
ccmpartment
N
Open is displayed if tailgate is open. Closed
is displayed lf tailgate is closed. If required,
check wiring to alarm control unit for open
circuit or short to ground according to wiring
diagram.
D90-11
90
Instruments,
928
Fuel Gauge, Alarm System
6.
Glove
Position
switch
open : - closed
closed:
- open Return
- open
Return:
N
This display appears if both lock buttons are
in the .,open” position.
compartment
N
Open is displayed il glove compartment is
open. Closed is displayed if glove compartment is closed.
48.
7.
Position
switch
open : - closed
closed:
- closed
Return:
Radio
(closed
- closed
Return:
N
This display appears if one lock button is
in the ,,open“ and one lock button is in the
,,closed” position.
loop)
N
The closed loop must be closed. On radios
that do not have this contact terminal, terminal 13, plug II, is wired to ground.
-
If the closed loop is open, check wiring
from alarm control unit, terminal 13, to
ground point V or to radio for open circuit.
8.
This display appears if both lock buttons are
in the ,,closed” position. If required, check
position switch (refer to page D 90 - 5)
5.
Central
locking
system
button
open Return:
If Radio contact closed is displayed:
N
Open is displayed if the central locking
system button has not been pressed down.
Closed display appears if the central locking
system button is pressed down.
D 90 - 12
-
Check insulating strip on radio.
-
Check wiring from alamr control unit plug
II, terminal 9, to alarm contact at radio
bracket or to alarm contact at CD player
for short to ground.
Dlagnosls
I twbleshootlng
Printed
alarm system
in Germany
- XXIX,1992
a
928
l
Instruments,
9.
Tailgate
Use the spare key to turn the locks of the
driver and passenger doors in the ,,opening”
direction. The display must switch from open
to closed.
lock
- open
Return:
90
Fuel Gauge, Alarm System
N
If closed is displayed in the off position, check
wiring from lock cylinders to alarm control unit
plug II, terminal 2, according to wiring
diagram for short to ground.
The spare key is needed for the checks act.
to items 9 to 11 since the ignition must be
engaged during the check.
Open is displayed if tailgate lock has not
been actuated. Closed is displayed if tailgate
lock is actuated.
If display remains in the open position after
the lock cylinders have been actuated, check
wiring for continuity according to wiring
diagram.
10.
12.
Input
Activate
button
- open
Return
- open Return :
:
N
Use the spare key to turn the locks of the
driver and passenger doors in the ,,closing”
direction. The display must switch from open
to closed.
-
If closed is displayed in the off position,
check wiring from lock cylinders to alarm
control unit plug II, terminal 1, for proper
grounding according to wiring diagram,
-
1
N
In the standard configuration, this input is not
used. Auxiliary systems may be connected to
this input.
Open is displayed if input is not used.
If required, check auxiliary systems according
to manufacturer’s instructions.
13.
If display remains in the open position
after the lock cylinders have been actuated, check wiring for continuity according to wiring diagram,
Refer to item 12.
11.
Deactivate
button
- open Return:
0
Dfagnosls / troubleshootlng
Printed in Germany - XXIX,1992
N
alarm system
D90-13
90
Instruments,
Note
14.
If present is displayed although the engine is
not running, this may be due to a summary
fault (refer to item 4, Drive links functional
group). In this case, start by remedying this
E7-l
fault.
If display is not present although the engine
is running, check wire from alarm control unit
plug II, terminal 23, to generator according to
wiring diagram.
Refer to item 12.
15.
Speedo
928
Fuel Gauge, Alarm System
signal
present
Return:
N
Display is not present if vehicle is stationary.
Display is present if vehicle is moving.
If required, check wiring from alarm control
unit plug II, terminal 6, to speedometer accordirg to wiring diagram.
present
Return:
N
I
If display is not present, check wire from
alarm control unit plug II, terminal 18, to central electrical system according to wiring diagram,
17.
Term.
present
Return:
D90-14
61
N
Dlagnosls
I troubleshootlng
Printed
alarm system
in Germany
- XxX1.1993
a
928
0
Instruments,
Fuel Gauge, Alarm System
Country codes
CH
The System Tester 9288 may be used to
encode three preset alarm versions
C number: 10.
90
USA
1. ROW (Rest of world)
2. CH (Switzerland)
3. USA
C numbers: 02, 04, 06. 08, 15. 18. 23, 24, 26,
31, 32, 36.
Alarm output
ROW
-
Alarm horn max. 30 sec. interval
-
Turn signals max. 5 min
-
Interior light flashes in an asynchronous
manner wlh turn signals (if in door contact position).
CH
-
The Country code menu displays the coded
version in the top leff corner, e.g. ROW;
the center displays Porsche or Workshop, depending on where the system has been
coded. The asterisk on the right is displayed
for versions that include the interior lights in
the alarm emission.
Alarm horn max. 30 sec. continuous.
USA
-
Alarm horn max. 4 mins. interval.
-
Turn signals max. 8 min.
-
Interior light flashes in an asynchronous
manner with turn signals (if in door contact position).
Alarm system
encodlng
When replacing the control unit, activate one
of the preset country codes according to the
national C number.
ROW
C numbers: 00, 05, 07, 09, 11, 12, 13, 14,
16, 17, 19, 20, 21, 22, 27, 28, 99.
a
Diagnosis
Printed
! troubleshooting
in Germny
- XXX1,1993
alarm system
D90-15
90
Result
Instruments,
memory
The result memory registers triggering of an
alarm, the contact that triggered the alarm as
well as the type of activation. A maximum of
10 results may be stored. If another result is
stored, the oldest result stored is deleted.
The result with the highest number is the
most up-to-date result.
Alarms may be triggered by contacts at the
following components:
-
Doors
-
Engine compartment
-
Luggage compartment
-
Glove compartment
-
Radio
920
Fuel Gauge, Alarm System
-
normal, i.e. locking the doors with the
key, thus activating the central locking
system
-
locking three tlmes, i.e. locking one of
the door locks rapidly for three consecutive times
-
System check
The type of activation may be invoked with
button 1 on the below display:
Alarm:
activated
by
xxxxxxxxxxxxxx
- x -
Note
Erase the result memory whenever
system has been checked.
Additional
alarm triggering
the alarm
options:
-
Term. 15 on after system has been
activated
-
Signal to input 1
-
Signal to input 2
-
Signal to input 3
-
Position switch
-
Open circuit of closed loop
(radio).
Up to three alarms may be triggered across
input 2.
The following
distinguished:
DSO-16
types of activation
are to be
Diagnosis/troubleshooting
Printed
alarm system
in Germany
- XXIX,1992
929
Instruments,
Fuel Gauge, Alarm System
90
System check
The System check menu item may be used
to check all components triggering an alarm
(except Term. 15). In this case, the alarm
horn is only triggered twiie for a short interval.
The following display appears after the
System check menu item has been called:
The individual alarm-triggering components
that may trigger an alarm (except Term. 15)
can now be checked. E.g. if a door is opened,
an alarm
is triggered. At the same time, triggering of
the alarm is stored in the resutt memory.
After the check has been completed and the
> key has been pressed, the following display
appears:
Note:
Erase
result
memory
!
Return:
N
The result memory must be erased since the
check has been stored in the memory.
a
Dlagnosls
Printed
/ troubleshootlng
in Germany
- XxX&l 993
alarm system
DSO-17
928
97
Wiring
GROUND
POINTS ON CAR
1. Battery negative pole to body in trunk at rear left.
4. Ground point on front left cross member.
! ’ ‘-.\
/*
2. 4..)
s’
_
.,_
\;.
,.
z
,
4.
i.d
\ %
r'
,
I
-W:?
(,’
w-cfli,
u
I Iv= c/d
‘, :i
‘i-.c,
^I“i
:
>’
w k-yp
I &.‘A
w#e-+
&.i
.c.
-
.IeT~O-
2. Ground points above central electric board.
?a
‘,
i
_.
'/ '
pm
_ ..-+*1\ “-1
5. Ground point on front right cross member.
_.-- -f-Y
!.
~~
r 7 1.
-p>yq -k -. “- 7
,-< ‘/ ~ /
3. Engine ground to body on right side member
P @?, ‘*. ’ :
-,-<.
4llimFyyfi
d
J
/
,~ ,,.a (,*:!
-.;y,<;I”~
/,” *.3.z.z
-f
6. Ground point underneath
to steering column.
instrument
panel next
hlll!nl=
.__’
‘- .>+
6
‘1
Printed in Germany
- VI, 1982
Ground Points on Car
97.01
97
928
Wiring
7. Ground point in trunk at rear right underneath
trim panel.
side
Side trim panel has to be removed to make thir ground
point accessible.
97-02
Ground Points on Car
Printed in Germany
929
Wiring
97
Correction to circuit diagrams,
Models 87 and 88, Sheet 7
The cable colors on connectors
3, 6 and 7 on the control unit to adjust the
seating position are not correct. The correct
assignments are:
Pin 1: brown
Pin 2: blue
Pin 3: red
l
The cable color at connector 11, pin 2
is green I brown (GN/BR), and not grey /
brown (GIVBR) as given.
0
Corractlon
to circuit
Printed in Germany
diagrams, Models 87 and 88, Sheet 7
- Xx, 1988
97 - 03
928
Wiring
Additional
97
electrical equipment
Note
Additional,electricaI
equipment is only to be
connected to the points described below.
Terminal 30. no fuse protection:
Screw connections
line
to central electrics supply
Terminal X. no fuse protection:
Leading to fuse 33
Terminal 15, no fuse protection:
Leading to fuse 43
Terminal 31:
Ground point V (above central electrics)
Provision
for fuses
Note
Additional electrical equipment must be protected against overloads if the above connec.
tion facilities are used.
1. Fuse 32:
The fuse must be wired to (for example)
plug R inside the central electrics.
2. Separate fuses
Additional
electrical
Printed in Germany
equipment
- XXV, 1990
97 - 05
928
97
Wiring
Repairing
wiring
harness
no. 121
Note
As of Model Year ‘93, the combination wirings
for ABS. BVA (brake pad wear indicator) and
RDK (tire pressure monitoring system) are incorporated into the wiring harness. If the
wiring is damaged, the integral wirings can be
cut off and may be replaced by repair wires.
Carry out the following functional check after
the repair:
ABS: Check with ABS tester.
BVA: The warning lamp must go off when
the engine is running and if the pads are o.k.
A - Left-hand combination wire
B - Right-hand combination wire
4. Remove PVC insulating tape.
RDK: The warning lamp must go off within
the specified air pressure range.
5. Remove shrink-fit caps from joints.
6. Cut off connector.
Joints
7. Remove combination
Rear: Inside the spare wheel well
Left-hand front: Inside the wheel housing
Right-hand front: Behind the Central Electrical
System
6. Install repair wires from wheel carriers
towards soare wheel well.
wires
Note
Use correct repair wires. The right-hand and
left-hand repair wires are of different lengths.
Rear
1. Disconnect
9. Strip wires on a length of IO mm
battery
2. Remove spare wheel.
3. Cut open the insulating tube of wiring
harness No. 121 from the rubber grommets
to the outgoing wire and remove the tube.
0
Repairing
Printed
wiring
in Germany
harness
-XXX,,
1993
no. 121
97 - 07
97
Wiring
10. Conect wires according to table using
crimp connectors and standard crimping
tool (A).
928
Combination
wire
Wiring harn. na 121
-
Color
Length
Color
rear left
C
r-l
brlge
brlrl
bribl
br/ws
br
bdgn
brisw
60 mm
90 mm
120mm
150mm
180mm
210 mm
240 mm
brlge
brlrt
WSISVP
ws*
br
SW
ws
a
rear right
brlge
brlrt
brlbl
brlws
br
brlgn
brlsw
60 mm
90 mm
120 mm
150 mm
180 mm
210 mm
240 mm
brlge
br/rt
ge/sw*
w’
br
SW
w
* screened wires
br
- brown
SW -black
ge -yellow
rt
-red
bl
blue
ws -white
cm - green
97 - 08
Repairing
wiring
Printed
harness
in Germany
no. 121
- XXX,, 1993
a
97
Wiring
928
11. Solder tips after crimping the connectors
(B).
12. Fit shrink-fit caps and shrink them into
place using a hot air gun (C).
13. Wrap up entire connection joint area using
commercially available PVC tape.
Left-hand
front
1. Disconnect
battery.
1316-97
2. Unbolt left-hand front wheel.
a
Wiring ham. no. 121
3. Remove left-hand front wheel housing liner.
Color
Length
left-hand
4. Cut off combination wire 300 mm from outgoing wire and remove wire.
5. Remove insulating tube along a length of
240 so that only 60 mm remain until the
outgoing wire.
6. Cut wiring to correct length according
table.
to
7. Install repair wire.
I
Color
br/ge
br/rt
brlbl
brlws
br
brlgn
brlsw
60mm
90 mm
120 mm
150mm
180mm
210mm
240 mm
front
brlge
br/rt
ltkw*
rt*
br
SW
rt
+ screened wires
6. Route repair wire in connection area
parallel to wiring harness No. 121.
9. Strip wirings over a length of 10 mm
10. Connect wires according to table using
crimp connectors and standard crimping
tool (A).
br
- brown
SW
black
-yellow
ge
rl
-red
bl
- blue
ws -white
gn -green
11. Solder tips after crimping the connectors
(B).
12. Fit shrink-fit caps and shrink them into
place using a hot air gun (C).
0
Repairing
Printed
wiring
in Germany
harness
- XXXI, 1933
no. 121
97 - 09
97
I
928
Wiring
l
11. Strip wires along a length of 10 mm.
12. Connect wiring according to table, using
crimp connectors and standard crimping
tool (A),
13. Wrap up entire connection joint area using
commercially available PVC tape.
Right-hand
l
front
1. Disconnect
battery.
Combination
Wiring harn. no.121
wire
2. Remove right-hand front wheel.
Color
3. Remove right-hand front wheel housing
liner.
right-hand
4. Cut off combination wire at the wheel housing grommet and remove combination wire.
brlge
brlrl
gn/sw*
5. Undo Central Electrical System and move
out of the way towards the rear.
cm*
br
SW
6. Pull wire (above Central Electrical System)
inwards.
v
front
* screened wires
7. Cut open insulating tube up to the connecting points.
8. Remove shrink-fit caps from connecting
points.
9. Cut off connector
br
- brown
SW -black
ge -yellow
rt
-red
bl
blue
ws -white
gn -green
10. Install repair wire, starting from the wheel
housing end.
97 - 010
Repairing
wiring
Printed
harness
in Germany-
no. 121
XXX,, 1993
a
i
97
13. Solder tipsaftercrimping
the connectors
(B),
14. Fit shrink caps and shrink them into place
using a hot air gun.
15. Wrap up entire connection joint area using
commercially available PVC tape.
Note
Route excess wire length above Central
Electrical System.
Repairing
Printed
wiring
in Germany
harness
- XXXI, 1993
no. 121
97-011
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