Porsche 928 1977 Workshop Manual
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l l l l
Workshop Manual
DR. ING. h. c. F. POR S C H E Aktiengesellschaft
The Workshop Manual is only for the internal use of the Porsche Dealer Organization
@ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft
Sales, D-7140 Ludwigsburg
All rights reserved Printed in Germany XX 1988
WKD 481 621
Print No. W 42606-126-l
l
List of Repair Groups
General
Repair Groups
Technical Data
Engine
Transmission
Chassis
Heating,
Ventilation,
Air Condition
Electrics
Maintenance, Selfdiagnosis
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
Clutch, Controls
Torque Converter
Manual Transmission, Controls, Case
Manual Transmission, Gears, Shafts
Automatic Transmission, Controls, Case
Automatic Transmission, Gears, Valve Body
Differential, Transaxle Svstem
Front Wheel Suspension
Rear Wheel Suspension, Axle Shaft
Wheels, Tires, Alignment
Antiblock System
Brakes, Mechanical
Brakes, Hydraulics
Steering
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
Doors
Hardtop
Bumpers
Glasses, Window Control
Exterior Equipment
Interior Equipment
Seats
Seat Covers
Heater
Ventilation
Air Conditioner
Instruments, Fuel Gauge, Alarm System
Radio
Windshield Wipers and Washer
Exterior Lights, Lamps, Switches
Interior Lights
Wiring
Printed in Germany - XX, 1987
80
85
87
90
91
92
94
96
97
63
64
66
68
72
74
50
51
53
55
57
61
30
32
34
35
37
38
39
40
42
44
45
46
47
48
Page 0.1
Group
03
19
20
24
26
27
28
10
13
15
17
0
928 Table of contents
Body - General
Special tools and shop materials for body repairs
Repair dimensions
Safety notes
Body-Front Section
Replacing pad of front wheelhouse ............................
Replacing front end partially ................................
Modifications on body front end ..............................
Body-Center Section
Replacing rocker panel
Body-Rear Section
Replacing rear apron and quarter panel
Replacing quarter panel end section
Body repairs to foam-filled cavities
Lids
Removing and installing engine hood cable
Replacing latch on rear lid lock (upper section)
Removing and installing electric rear lid unlocking device
Doors
Removing and installing door
Removing and installing door window and regulator
Removing and installing door lock
Checking door central locking system
Replacing door lock cylinder
Modification to rotary knob lock
Modification on unfinished shell
Troubleshooting central locking system -from 1980 models
Changes on doors and door lock cylinders
Sun roof
Removing and installing power sun roof
Removing and installing drive motor and gearbox for sun roof
Removing and installing wind deflector for sun roof
Removing and installing gates, guide, cables and guide rails
Modifications on sun roof
...........
...........
...........
...........
...........
...........
...........
...........
Table of contents
Printed in Germany - XXXI, 1993
Volume V
55-l
55-3
55-5
57-1
57-3
57-6
57-7
57-15
57-17
57-19
57-21
57-25
60-l
60-4
60-5
60-6
60-8
51-l
53-l
53-5
53-7
Page
.50-01
50-03
50-05
50-l
50-5
50-9
1
Volume V Table of contents
Bumpers
Removing and installing bumper
Removing and installing nose panel, ‘87 models onward
Disassembling and assembling bumpers
Removing and installing bumper
Glases, Window Control
Removing and installing power window operating switch
Installing adhesive plate for inside rear view mirror
Bonding the interior rearview mirror in place
Removing and installing windshield
Removing and installing the bonded windshield
Removing and installing the bonded rear side window
Removing and installing windshield - 2-pack adhesive
Removing and installing bonded rear side window - 2-pack adhesive
Exterior Equipment
Paint colors from 1978 models .................
Paint colors from 1980 models .................
Body paint colors from 1982 models ..............
Body paint colors from 1984 models ..............
Body paint colors from 1985 models ... ..........
Body paint colors, ‘86 models onward .............
Body paint colors ‘87 models onward ..............
Body paint colors . 1989 models onward ............
Body paint colors - 1990 models onward ...
Body paint colors - 1991 models onward ............
Body paint colors - 1992 models onward
Removing and installing side guard strips ...........
Service installing side guard strips ........ ....
Removing and installing front spoiler ..............
Removing and installing rear spoiler ..............
Removing and installing outside mirror .. ........
Service installing outside mirror on passenger’s door .....
Removing and installing sill covers .......... ....
Removing and installing rear spoiler ............
Removing and installing front air dam ..............
Fitting the CLUB SPORT emblem ................
Retrofitting new mirror generation for vehicles as of MY ‘87
2
Page
63-2
63-4a
63-5
63-6
64-1
64-2
64.2a
64-3
64-7
64-15
64-21
64-31
66-9
66-13
66-15
66-20
66-25
66-27
66-29
66-31
66-01
66-02
66-03
66-04
66-05
66-06
66-07
66-08
66-09
66.010
66-011
66-1
66-3
66-5
928
Table of contents
Printed in Germany - XXXI, 1993 a
a
928 Table of contents Volume V
Interior Equipment
Removing and installing rear side trim panel
Safety regulations for handling airbag vehicles
Removing and installing the airbag steering wheel
Removing and installing airbag components
Checking the airbag system to ensure that long-term functioning is guaranteed
Checking the safety belts
Correct disposal of airbag units
Diagnosis/Troubleshooting Airbag
Removing and installing power seat
Removing seat backrest motor
Disassembling seat controls
Disassembling left seat track and removing fore I aft seat control motor
Disassembling right seat track and removing seat height control motor
Seat and mirror position control system
Seat and mirror position control system, method of operation
Seat control unit, plug assignment
Checking seat and mirror position control system
Plug assignment, mirror control unit
Checking mirror control unit
Checking control panel
Electrically adjustable seat
Calibrating controllable seat heating
Checking seat heating
Instruments, Fuel Gauge, Alarm System
Precautions when working on oars with electronic control units .........
Location of relays and electronic controls in car .................
Removing and installing instrument cluster ...................
Disassembling and assembling instrument cluster ................
Removing and installing clock ..........................
Troubleshooting car radio .............................
Measuring antenna resistance ..........................
Removing trim plate for radio opening ......................
Instrument cluster as from 1979 models .....................
Location of fuses and relays in car 1980 model ................
Removing and installing radio (digital radio Bamberg QTS) ...........
Checking fuel consumption indicator .......................
Troubleshooting central warning system .....................
Troubleshooting central warning system I Function test on central warning unit
Table of contents
Printed in Germany - XXX,, 1993
72-l
72-3
72-4
72-5
72-6
72-7
72-9
72-11
72-13
72-17
72-19
72-22
72-23
72-31
72-33
68-1
68-3
68-5
68-6
68-11
68-13
68-15
D68 1
90-01
90-l
90-7
90-8
90-10
90-l 1
90-17
90-18 go-19
90-20
90-25
90-27
90-29
90-31
3
Volume V Table of contents
Central warning unit connection plan black plug
Central warning unti connection plan yellow plug
Single component function test
Alarm system 928
Service installing Blaupunki SQR 22 radio
Upshift indicator
Checking burglar alarm
Check auxiliary control unit burglar alarm
Backlit instrument cluster, removing and installing
Advancing the odometer reading of the backlight instrument cluster
Radio, Telephone, Bordcomputer
Facilities for subsequent telephone installation
Retrofitting CD player from model 89 onward
Windshield Wipers and Washer
Adjusting headlight cleaner jets
Service installing rear window wiper
Removing and installing windshield wipers beginning with 1983 models
Exterior Lights, Lamps, Switches
Bulb chart
Aiming headlights
Adjusting fog lights
Removing and installing steering column switch
Removing and installing switch in instrument cover
Removing and installing sealed beam headlight units
Headlight beam regulator, checking
Headlight beam regulator, removing and installing
Main headlamps, adjusting - USA (‘80 models onward)
Interior Lights
Bulb chart
Control panel variations R.o.W.
Control panel variations USA
92-1
92-2
92-6
94-1
94-2
94-3
94-4
94-5
94-6
94-8
94-10
94-14
96-1
96-2
96-3
90-32
90-33
90-34
90-41
90-49
90-53
90-55
90-56
90-57
90-59
91-1
91-11
928
4 Table of contents
Printed in Germany - XXXI, lW3
General Information 928
SPECIAL TOOLS AND SHOP MATERIALS FOR BODY REPAIRS
-
/
1 /
Template for windshield opening - 9158 i
Template for rear window opening - 9159
Template for rear side parts to PU trim - 9112
~ronr end gauge - 9174 a
Primed in Germany - II. 1918 Special To& and Shop Materials for
Body Repairs
50
General lnformarion
Tester for vacu”m sysrem - 9160
928
Spot welder
Inert gas welder for steel and galvanized metal
Inert gas welder for aluminum parts
Gas welder
Cutting-off grinder. swing grinder
Disc grinder - angled grinder
Pneumatic gun with attachments, chisel etc.
Shouldering pliers
Beam compass - water scale
Hydraulic 10 ton straightener with accersories
PwNnatic guns, equipment and materials for longterm undercoating for cavity sealing for sealing jobs
50 - 02 Special Tools and Shop Materials for
Body Repairs
Printed in Germany
928
Cellera1
Set of Attachements ENS 243.300 for Celette Alignment/Assembly Stand
50
Note
Both M 10 x.80 collared bolts included in attach- ment set ENS 243.300 are used to bolt the side member mounts to the body as shown in the figure.
BY bolting the body at these points first. deviations in distance to the other frame/floor check points can be determined and the front side members can be located accurately.
There are also two thin spacers for measurement of the upper shock absorber mounting point, in- stead of the thick spacers for models prior to 1919.
Printed in Germany - I, 1978
Special Tools and Shop Materials for Body Repairs
50 - 02 a
D
928
A-A
0
L--
1
I’rmted in Germany
C;C”eI:3, 50
Front view
Rear view
Clheckpoirits
Checkpoint: stabilizer bar
Pedal take-up
Checkpoint: rear axle cross member
Checkpoint: fear axle shock absorber
HA i Checkpoint: fear axle
TS = Checkpoint: dour lhingc pivot axis
LK = Ctxckpoint: steering rack
VF = Chrckpointz spring strut
VA = Checkpoint: front axle
PD = Checkpoint: impact absorber
All checkpoints are in reference to body tlangr surfaces.
REPAIR DIMENSIONS 928
Repair Dimensions ,~,iS ii::
General
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, l .
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 resuft 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. 50X 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. l .
Do not touch electronic control units and electric lines with the ground clamp or with the welding electrode. l
Safety notes
Prinlad in Germany - XXVII, 1991
50-05
50
General
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.
926
50 - 06 Safety notes
Printed in Germany - XXVII, 1991
Front End
50
REPLACING PART OF FRONT WHEEL HOUSE
Includes
Front bumper. front side member, lock cross member. lower CIOSS member, impact absorber mount, engine hood.
Removing
Radiator with lines. headlight with motor and linkage. engine assembly as far as required. Disconnect battery. Bumper panel with carrier and impact tubes (absorbers). radiator grill, covers beneath fender. vacuum reservoir. control unit (tempostat), both front fenders, lock lower section, hood release cable. data plate.
Note
The main headlights do not have to be removed to take off the front fenders.
Measuring Car
Move car on to a platform and measure front end of car with a water level and compass (see repair con- trol dimensions).
Remarks
A front end gauge and set of Celette straightening bench attachments are being prepared.
Cutting Out Damaged Parts
1. Cut off lock cross member and lower cross member (pneumatic chisel).
2. Cut through wheel house wall as far as requi- red with a cutting wheel and outside of side member as far as required with a cutting wheel.
Note
Cut surfaces should be offset to each other. a
Printed in Germany
Replacing Part of Front Wheel House 50 - 1
50
Front End
3. Pull or grind off scrap metal. Straighten and grind down mating surfaces.
4. Fit wheel hnilpe wail, cllt mating surface with an overlap and install. Check lateral position with a water lcvci applied at ope- ning for headlight shaft. Spot weld wbecl house and arc weld vertical seam on out- side.
4. Straighten inside of side member.
Check installed position with a water Ieael.
!I28
5. Install and spot weld impact absorber mount.
Also tack weld with arc welder.
Note
Figure shows this check on car with slight front end damage.
Installing
1. Fit outside of side member and cut it off to overlap by about 10 mm.
6. Install entire iowfr cnxs member. ctlc< I against front axle :ind weld.
--.. ./ -
2. Grind down spot welding flange and coat with spot welding paint.
3. Spot weld side member shells and inert gas weld mating surface.
50 -2 Replacing Part of Front Wheel House
Primed in Germany
928 Front End
50
7. Install lock member. spot and inert gas weld it to wheel house, impact absorber mount and side mcmhers.
10. Install headlight shafts and mounts.
Make sure that longer section of plastic plates face forward when installed (see anow) ! install siop bracket for headlights.
X. Install lid lock lower section. Secure it with pop rivets or 5 mm dia. screws.
9. Install and weld retractable ibeadlight mota console perpendicular and parallel to center- line of car.
1
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Printed in Germany
Replacing Part of Front \\ibcel House 50 - 3
50
Front End
11. Install headlight motor. route wiring and fasten with straps on lock member and wheel house. connect plugs.
928
16. Prime coat and seal (undercoat and sea- ling materials) all welded and spot welded seams as we11 as fIang.5.
12. Install liners and stop pads on lock member. adjust lock cable. Install and adjust lid.
17. Install covers above and behind lower fen- der.
18. Prepare car for painting.
13. Fit fender roughly. Position metal nuts on wheel house and hinge pillar. and install
Terostat tape. Bolt fender supports.
14. Install and bolt fender. making sure that there is uniform clearance to lid and doors.
15. Align headlight with fender. tighten mount and outa shaft.
50 - 4 Replacing Part of Front Wheel Howe Printed in Germany
928 Body / Front End
50
REPLACING FRONT END PARTlALLY
General Information
The besr method of repairing a damaged front end, of which the side memben are bent or distorted in area of front axle or engine mounts. would nor be replacing up to the deformation border, but complete replacement of side mem- bers and wheel houses at original connection points of floor or firewall.
These repairs can be besr performed with help from rhe Celette straighrening bench and pertinent attachmenr ser ENS 243. 300 or front end gauge 9114.
There instructions apply I” both one-side and two-side repairs.
Cutting Out Damaged Parts
1. Cut off end plare ar body floor plare.
P e.-. . --
2. 01 off wheel house wall and side member along firewall wirh a cutting wheel or pneumatic chisel.
Removing
Engine, rransmission and front axle, radiator, headlighrs with motor and holden. fenders, c”vers and radiator grill. bumper with brackets and impact absorben.
Includes:
Front bumper. front side member, complete wheel house with reinforcement for spring strut, lock cross member and lower cross member.
3. Cut off cross member and front lock carrier on damaged side, as long as only one side is being replaced.
4. Pull off scrap metal from wheel house and side member.
0
Printed inGermany - 11, 1978 Replacing Front End Partially 50 - 5
50 nody / Front End
Repairing
1. Place body on Celerte straightening bench and bolt down or use fronr end gauge 9174 fez repairs.
-/iEqyyW#
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. .I -. I
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4. install wheel house. line up a~ fire wall and side member and rack weld.
2. Position complete side member and bolt to all atrachment take-up poinrs.
5. Spar or inerr gas weld wheel house along side member flange and firewall.
3. Inen gas weld side member ro floor plate and weld floor member on inside and ON- side all the way rhrough.
6. Position lower cross member and lock cross member with help from arrachmenrs or front end gauge, rack weld and weld.
50 - 6 Replacing Front End Parrially
Printed in Germany
928
Body / Front End
50
7. lnslall spring sI*uI console reinforcemenr, hold with attachment and inerr gas weld 10 side member and wheel house.
9 Weld control arm console on inside of wheel house.
-
10. Position end plate wirh rake-up shell on floor plate. clamp and rack weld.
8. Line up top of console with wheel house and spring strut console. cut and weld.
II. Poairion console for stabilizer on side member
(295 mm from fronr cross member bolt. rear edge vertical) and weld IO side member.
--TV .-- --.
Printed in Germany - II. 1918 Replacing Front End Partially 50 - 1
50
Body / Front End
12. Weld console for concealed headlight motor
13. Apply prime coat paint and undercoaring or sealing marerial 10 all welded seams and joinrs. Spray Tectyl sealanr into cavities.
14. Position and mount fenders. headlights and engine hood.
15. Prepare car for painting.
50 - 8 Replacing Front End Partially Printed in Germany
928
0
MODIFICATIONS ON BODY FRONT END
From Chassis No. 928 910 0025 (on 5 cars initially).
928 910 0703 (standard production),
928 920 0514 (standard production) and 928 920 9534 (standard production) the rear threaded inserts of different version are welded in members 1, Part No. 928 501 015 02/
928 501 016 03. to facilitate installation of the engine carrier. Part No. 928 375 011 03.
Body / Front End
50
.--iM1ot-
Compare new threaded inserts (Fig. A) with the old version (Fig. B):
1. The 2 mm longer bearing surface protruding from the side member and tapered downward
2. lnside diameter of threaded insert at bottom changed fronl 12.2 mm to 10.2 mm.
I I
Figure B
3. M 10 x 85 mm bolts required for centering on
Celette straightening bench and front end gauge.
4. Take-up pins of straightening attachment for
Celette bench and front end gauge 9114 must
‘be shortened by 2 mm for measuring procedures.
Cars with old threaded inserts will then require use of 2 mm thick washers.
Figure A
5. New engine carrier. Part No. 928 473 011 03, can be installed on all cars. while former engine carrier can only be used in cars with old threaded inserts.
6. Cross member, Parr No. 928 501 091 02, is no longer used from the above mentioned chassis numbers, so that the welded nuts have been omitted in rear of member 1 for new cars.
Printed in Germany - IV. 1980
Modifications on Body Front End 50 - 9
50
Body Front End
7. When repairing the body from end make sure side members are replaced by a side member version corresponding to the opposite side.
The former member I,
Part No. 9‘28 501 015 02 left UI
928 501 016 03 right, valid up to rhe mentioned chassis numbers, will be replaced by members with Parr No.
928 501 915 00 and Y28 501 916 00 afler depletion of stocks. These members have welded nms at the ream for the omitted cross member, Parr No. 928 501 091 02, so that they can be used in all cars.
In only one member of new version is installed in an old car together with an old engine carrier. the rapered section of rhe threaded insert musr be shortened (ground off) by 2 mm
928
50 - 10 Modifications on Body From End Printed in Germany
928 Body Center Section
51
REPLACING DOOR ENTRANCE RAIL
Removing
1. Jack up car or place on a platform. Make sure that body is not subjected to torsional forcer.
Check: doors must open and close easily.
6. Cut off spot welding flange on top and bottom of entrance rail from side member. Remove entrance rail. If necessary. straighten or re- place land and side member.
2. Remove doors. unscrew hinges and door re- tainers, disconnect wire plugs. vacuum hoses and connecting pipe on side panel in footwell.
1. Shoulder front mating surface on rail panel with a shoulder pliers. make cuts in edges to be able to have the proper shape.
8. Grind off and pull of scrap metal on side mem- ber. Coat flanges with spot welding paint.
3. Remove entrance rail strip. door weatherstrip, seats. carpet, seat belts, trim and electric wires to an extent required.
Cutting and Straightening
4. Heat mating surface of entrance rail to fender
(outer side panel) with a welding torch and melt off the tin.
Installing
1. Fit and cut new rail panel.
5. Grind through welded seam at fender with a cutting wheel. Cut off front end of rail actor- ding to the extent ofdamage..
Printed in Germany
Replacing Door Entrance Rail 51 - 1
51
Body Center Section 928
2. Push in rear end of rail on fender (figure doer not show fender). Clamp and tack weld rail.
5. Grind down welded seams. tin. solder and finish.
ST
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3. Install doors and check alignment with rail. p ,,
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6. Check door alignment. Apply ndercoating and cavity sealaots.
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4. Inert gas weld front and rear mating surfaces.
Spot weld flanges on side member.
0
51 -2 Replacing Door Entrance Rail
Prepare car for painting.
Printed in Germany
928 Rear Body Section
REPLACING TAIL PANEL AND FENDER (OUTER SIDE PANEL)
53
Removing
Place car on platform. Take off rear wheels.
Disconnect battery wires. Unscrew coven in wheel house.
Remove bumper panel. member and impact tu- bes (absorbers).
Remove weathe:stri?s on lid and door frame, side panel trim. side window, emergency seat. seat belt, luggage compartment cover. front seat and carpets.
Remove fuel tank flap. fuel and expansion tanks. filter and fuel pump, wires. hoses and holding straps. Detach insulation sheet on inside of side panel to an extent as required.
4. Straighten rear cross member, side member and luggage compartment floor plate.
Cutting
1. Cut out damaged fender at spot welding flan- ges with a pneumatic chisel and at sectional surfaces with a cutting wheel. First heat and melt tin off of rail mating surface with a wel- ding torch.
5. Straighten and grind down spot welding flange.
Assembling
1. Spot weld tail panel and outer panel. align and cut to size.
2. Cut off tail panel. pull off all scrap metal and weld damaged spots.
3. Heat undercoating with a welding torch, and scrape or brush off undercoat.
Printed in Germany
Replacing Tail Panel and Fender 53 - 1
53
Rear Body Section
928
2. Coat flanges with spot welding paint. Bolt tail panel to impact tube mounts, clamp on cross member and straighten with a water level.
Check installed position of lock to trunk lid.
4. Weld both sides of reinforcement bracket on inside of roof frame.
5. Coat spot welding flanges with a welding paint.
3. Depending on accessibility, spot weld if at all possible or, if not. inert gas weld the ma- ting surfaces.
6. Fit fender and align with door and trunk lid.
Check ride window opening igauges are being prepared). Align upper front mating surface with an overlap. Shoulder one su- face with a shoulder pliers and make cuts in edges.
Note
Make the cut in a manner, that as little align- ment as possible will be required.
53 -2 Replacing Tail Panel and Fender Printed in Germany
Rear Body Section
7. Clamp fender in position, check installed posi- tion wiih doors. lid, window opening and bum- per panel, and t-ck weld.
9; Straighten welded seams and flanges.
53
\ . . . _,_ I., / .
7
10. Paste pieces of foam iubber underneath fender on outside of tail panel and in top of door frame to provide a seal.
3. Spot weld fender flange nil around and weld mating surfaces.
Primed in Germany
Replacing Tail Panel and Fender 53- 3
53
Rear Body Section i\.\
15. Seal spot welded flange in wheel house carefully and renew missing undercoat.
928
1G. Prepare car for painting.
Special Tool 9172 (template for rear side panels to PU trim) can be used to accurately locate the upper end points and outer bearing surfaces of rear side panels to the PU trim. starting from the threaded surfaces of the impact tubes and absorbers.
. . Solder welded seams on rail. door frame. li d frame and fender end section , and prepare them for painting.
12. Inctall lid and door locks. Check lid and door alignment. and correct if necessary.
13. Check fit of side window.
14. Fit bumper and panel. correct contour if necessary.
53 - 4 Replacing Tail Panel and Fender I, 1978 - Printed in Germany l
928 Rear Body Section
REPLACING FENDER END SECTION (OUTER SIDE PANEL)
53
Removing
Place car on a platform and take off wheels.
Disconnect battery wires.
Unscrew rear cover in wheel house and remove antenna.
Remove bumper panel. member and impact tu- her (absorbers).
Remove side panel trim. side window, luggage compartment cover and insulation material to an extent as required.
Straightening and Assembling
1. Straighten tail panel and inner frame. and re- place outer tail panel if necessary. Check in- stalled position of impact tube mounts.
Cutting
1. Cut off fender end section with a cutting wheel. pneumatic chisel etc. (determine cutting line to agree with extent of damage).
2. Straighten and grind spot welding flanges.
2. Pull or grind off scrap metal. Clean mating surfaces and flanges to remove undercoating and paint. and grind smooth.
3. Fit and cut fender. Cut mating surface at wheel opening flush. Coat spot welding flanges with spot welding paint.
3. Weld damaged spots.
4. Tack weld fender with an oxyacetylene welder, align installed position with window opening
(gauge or glass pane) and lower edge of lid.
5. Spot weld flanges and weld seams.
Printed in Germany
Replacing Fender End Section 53 - 5
53
Rear Body Section
6. Straighten and tin welded seams.
928
Note
Special To31 9112 (template for rear side panels to PU trim) can be used to accurately locate the upper end points and outer bearing surfaces of fear side panels to the PU trim. starting from the threaded surfaces of the impact tubes and ab- sorbers. l
1. Renew undercoat and prepare car for pain- ting.
53 - 6 Replacing Fender End Section
1. 1918 - Printed in Germany
a
929 Body-Rear Section
53
Body repairs to foam-filled cavities
Instructions for part-section repairs to body sections with foam-filled cavities lo reduce running
Body construction work for production cars includes a number of carefully matched measures to re- duce running noise. One of these measures is the injection of foam into certain body cavities in the following areas
- Upper B post
- Complete cross-member
- Lower C post
- Inner rear side panel
- Center left and right reinforcement using a special PUR (polyurethane) moulding foam.
When carrying out body repairs in these areas, particularly when part-sections only are replaced, the damaged sheet metal parts must be detached by mechanical methods (for instance by sawing, drilling and the use of suitable chisels), so that high temperatures are avoided. Before new parts are welded on or in, the synthetic foam must be removed, again by mechanical means such as pull- ing off followed by brushing with a wire brush, in the areas where welding is to take place.
Note that no new foam is applied in these areas. l
Body repairs to foam-filled cavities
Printed in Germany - XN 1990
53 - 7
Lids 55 928 l
REMOVING AND INSTALLING ENGINE HOOD CABLE
1. Remove left from wheel.
Unscrew cover in wheel housing.
2. Unscrew air inlet grill
3. Loosen screw on bottom of hood lock.
4. Unscrew clamp on lock cross member and pull hood cable out of lock. m--e- ~~~_ del
.I
5. Derach hood cable in wheel housing.
Printed inGermany - III, 1919 Removing and Installing Engine Hood Cable 55- 1
55 Lids
6. Pull off carper in footwell above hood cable grip. Use a screwdriver to lift cover at pivor point of grip and press up cover on lefr side.
028
8. Pull out hood cable rhrough grommer into foorwell. a
I. Remove cable grip and lay aside. Drive out spiral pin and pull hood cable with protecrive sleeve forward out of rhe housing.
55 - 2 Removing and Installing Engine Hood Cable Printed in Germany
l
9 28
REPLACING LATCH ON REAR LID LOCK I’PPER SECTION
Lids
55
General
If the edge of rhe plastic larch in lock upper section is worn and this is impairing the lock’s function, the larch of an installed lock upper section can be replaced. parts required:
Larch Part No. 028 512 161 02
Rivet pin Parr No. 928 512 165 02
2. Remove plasiic latch. making sure 1ba1 rhe spring behind is nor lox.
/_f”7-
.’
,y . $5.
Removing and Insralling
1. Drive rivet pin out of housing from the riveted side with a 3 to 4 mm dia. punch. Counter- hold the opposite side!
3. Install new latch wirh spring. pushing in ihe spring with a small screwdriver unril the larch bore aligns wirh rhe housing.
4. Press in rivet pin and lock by punching. Rivet pin most nor have lateral play.
If rhe lock cylinder has to be replaced. pull out pins on the side to be able to remove the cover.
If ir is difficult [o drive out the rivet pin, drill out river with a 5 to 6 mm dia. drill bit.
Printed inGermany - 111, 1979 Replacing Latch on Rear Lid Lock Upper Secrion 55 - 3
928
REMOVING AND INSTALLING REAR LID UNLOCKING DEVICE
Lids 55
Removing
1. Loosen and remove tool plate. Remove mounting bolts of motor bracket.
Installing
Installation is in reverse sequence.
2. Unclip operating rod on drive motor.
Check lid lock upper and lower sections.
Close lid, loosen bolts on bracket, pull motor down until unlocking cam rests on latch of lid lock upper section (slight resistance, do not press further in unlocking direction) and tighten bracket mounting bolts.
3. Disconnect plug on drive motor
Printed in Germany - VIII, 1984
Note:
Adjustments are made from passenger comoartment.
Removing and Installing
Electric Rear Lid Unlocking Device
55 5
a
Doors a
REMOVING AND INSTALLING DOOR
1. Pull off knob. unscrew knob liner and remove together with bearing shell.
5. Remove door vent nozzle and unscrew bolt located behind latter. Detach cover on connecting tube.
-*s*- -
P’ .
2. Unscrew grip shell on inside grip. Remove door trim panel from clips.
57
3. Remove side nozzle. Remove outside mirror switch. Note wire colors and pull off plugs.
Take off door trim panel from clips at bottom and remove with armrest.
Disconnect loudspeaker connections from door panel, pull off covering at narrowest opening point and saw through land, so that wire harness and vacuum hoses can be pulled through. Re- move door panel. l
4. Unscrew door trim panel screws, fold out armrest and unscrew Screws covered with caps (see arrows).
Printed inGermany _ 1, 1973
Removing and Installing Door 51-I
57
DOOIS
8. Pull off inside window sealing rail. Unclip window frame trim at top carefully and remove.
928
9. pull off door sealing sheet.
10. Detach door retainer and hinges. and take off door.
Note
If there is door retainer noise. spray door retainer and retaining rod with a sliding metal lubricant. e.g. Metal-lit from Bielefeld.
51- 2 Removing and Installing Door Printed in Germany
928 Doors
57
REMOVING AND INSTALLING DOOR WINDOW AND REGULATOR
Removing
1. Adjust door window (door trim panel removed). that slides on guide tube are accessible.
4. Urncrew window regulator from inside door panel farrows), pull off electric wire plugs from motor and remove window regulator through large opening in inside door panel.
2. Now unscrew slides and detach window lifting tube at top.
3. PuIl off inside window recess seal. then tilt and remove door window glass.
Installing
1. Place door window glass in door.
2. Install guides (position inward)
1.. ._ .,r,i,~.~,.;.....,;;:.,~; .,-:.. _ ..-. ,.-j
Note
Unscrew or detach guides (arrow) in upper door recess to improve accessibility (see figure to right).
Printed inGermany _ I, 1978
Removing and Installing Door Window and Regulator
51 - 3
57
Doors
3. Guide in window regulator. connect it to lifting rail and bolt to inside door panel (arrows). connect power supply plug.
928
Stop wedges must be installed only with counter- sunk metal screws.
4. Install window recess seals. window guides and ornamental frame. 5. Set guide tube with mounted slides in center position and bolt to lifting rail.
Note
Use a plastic hammer to install ornamental frame on edge of window opening. Coat rubber parts with petroleum. to facilitate pressing them into ornamental frame grooves. In the past a liner was mounted in the front curve with pop rivets. in the outer holes of which the ornamental strip comer was installed. The new comers are mounted with clips.
Note
Make sure that wire harness is routed to outside mirror, glass.
Lubricate so that it will not come in contact with window lifting a multi-purpose grease. rails and guide tube with
6. Run up window until it is completely in window frame. adjusting guide tube mountings if
“eCXSS=ry.
Printed in Germany
51 - 4 Removing and Installing Door Window and Regulator
928
7. Louien both slides to relieve pressure on kzindow glass and then tighten.
8. Lower window and mcasu~e distance to guide rail (5 to fi mm) and adjust lower slide, that windok glass runs in center of window frame.
If necessary. loosen slides and tighten again after removing stress from window glass.
D~oo IS
57 a
Printed inGermany 1. lY7E Removing and Installing Door Window and Regulator
57 5
57
Doors
REMOVING AND INSTALLING DOOR LOCK
1. Remove grommet plug from door frame and unscrew socket head screw. Remove lock cylinder and detach connector from door lock.
3. Detach connecting rod from outside door handle to lock. Unscrew and pull out outside door handle.
92H
4. Fill off connecting hoses to control valve
(driver’s door) and vacuum control (passenger’s door). and unscrew control parts.
2. Unscrew and remoye door lock cover.
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5. Unscrew self-locking screws on lock outside section. Unscrew inside door control and rcnlove with inside lock parts.
Note
This lock cover was not used on the first cars manufactured.
The figure shows front passenger’s door with a guide rail.
51 6 Removing and installing Door Lock
Note
Hoses are connected on control valve in driver’s door in red. blue and green as seen locking for- ward. In the passenger’s door the red jhosc is connected on the vacuum switching part front inside and the green hose outside. so that locking will be simultaneous.
Printed in Germany
928
CHECKING DOOR CENTRAL LOCKING SYSTEM
Doors
The centrd locking system of the doors employs YBCUU~. A vacuum of at least 400 mbar is required to guarantee operation.
For testing, this vacuum can be provided by running engine for about 2 minutes or with a vacuum
Pomp.
The necessary vacuum can be produced with just several pump actions by using Special Tool 9160 in a vacuum line, which is not connected with a vacuum tank. Pump would have to be operated about 50 times h,hen a vacuum tank is involved.
57 a pun,P 5 scale shows about 36 an = 450 hmn3 on baromerric column. which is equal To ahout 600 mbar
VXC,,,I”.
If system is in good condition. the vacuum built up by cnginc will be sufficient for unlocking and locking even 2 day? later.
If central locking system fails, first chrrk control lines of driver’s door for leaks.
If vacuum drops obviously while testing ;\illl a varuu1~1 por!1~ and without operating Lhr central lnrkino~l rvrti.,,, ,,7F :4 1PdI
If unlocking and locking are not possihlc in sPitc of sufficient vacuum. the cause could be a mechanical defert, incorrect assembly or pinched hoses. impairing the control function.
When functioning correctly, Ihc catch buttons of both doors must go up and down when un- locking and locking Ihe driver3 door with a key.
Doors can only be locked when doors or strikers are closed. a
Printed inGermany - 11:. 1979
Checking Door Central Locking System 51. 7
57
Doors
Layout of Central Locking System
928
-.-.-.-. .-.-.
1 = Control valve in driver’s door
2 - Vacuum switch in passenger’s door
0 - Vacuum tan!i in instrument panel
4 = Check valve
5 = connector
G = Plug
I = Vacuum line to brake booster
51 8 Checking Door Central Locking System Primed in Germany
928
Doors
57
Note in order to be able to seal hose connection of vacuum pump with control lines. one each coupling must ee installed in the lines.
When checking green line of driver’s door with a vacuum pump. lock must lock. Red line = unlock.
No varwm will build up in other lock position.
From Chassis No. 928 810 0554
928 83095'21
928 820 0054 a special vacuum tank and check valve are installed underneath the instrument panel for the central locking system, therefore having a separate vacuum circuit from that of the heater and fresh air controls.
~The ftist-cars were iiilrri--with~robbt~-ilojer:~he free through flow even in tight points. intioductibil bf hard-piastlc tubes has guaranteed
Varuum tank underneath instrument panel Test connrction in engine compartment
Printed inGermany - I. ,978 Checking Doar Central Locking System 51 - 9
57
Doors 928
As seen looking forward in car. vacuum lines on control valve of driver’s door are red. blue and green. On vacuum switch in passenger’s door green is connected at rear and red front inside.
Foam rubber strips must be used underneath plastic lines routed to the doors on the door inside panel.
Lines are held with clamps, while downward leading lines are mounted with clips.
With this arrangement red lines are used to lock system and green for unlocking.
When checl(ing blue line leading to driver s tlwx with a vacuum pump. there must be no drop in pressure without operation of locks. \Vhcn locking and unlocking. pressure gaugv could show up to approx. 20 mbar loss in each cast.
When testing the red or green line with a vacuum pump alternately. the locks of the doors must lock OI unlock respectively.
Important
This test requires that the doors or strikers be closed!
51- 10 Checking Door Central Locking System Printed in Germany
Doors
928 a
TROUBLESHOOTING CENTRAL LOCKING SYSTEM
Unlock driver’s door with key
Passenger’s door is not unlocked
/ I
Car was not used for longer lha” 2 days (per- missible vacuum loss).
57
Start engine briefly and the” check lock action.
If system is in good condilion. it should be possible to operate lock about 10 times. t
Vacuum Loss:
1. Troubleshooting Supply Line
Disconnect blue control line in footwcll o” lrlt side. Connect YBCUU”~ pump to blue hose leading tn vacuum tank. Run engine briefly or build up 400 to 500 mhar with pump and obseivc pxirure gauge. Gauge must remain ronstand without lock opwalion.
-.-k!g!g.-.-
LI l-----
If pieirure drops. check valve. vac”“m tank
OI hoses have leaks,
Printed in Germany 1. 1978 t~hecking Door < entral Locking System 5:- 11
57
Doors
2. l’roubleshonting I.eft Door
Connect va~uurn pump on blue hose leading to door lock and produce vacuum. Clpcrate door lock with Ikey and observe vacuum. Leaks could br in hoses or control valve.
-.-.-.
Remove door trim panel and replace damaged parts,
!1 28
Connect green and red lines in vacuun~ pump alt~rnatsly.
I
-
A Line has bcrn pinched. if lock doer not fun~iion a!ld there is no drop in vacuum.
.
If there is a loss in ~acuurn control valve has a leak or there is a mechani- cal defect in lock mechanism.
5;
Checking Door Central Locking System
Defect could be found at ruhbcr hosei in dool area or connecting tube to iootwrll.
Printed in Germany
923
3. Troubleshooting - Right Door
Connect vacuum pump at connecting point in footwell on left side. alternately. to red and green lines leading to right door. Vacuum built up in red lint slv.xld lock and in green line unlock lock.
I
_ i I
Doors
57
IS pressure drops without operating of lock. canncct vacuum pump at connecting points on right ride of footwell. II locking system functions. the SOUICC of defect is located inbctwwn.
Vacuum available. but no locking action
< nntrol linii arc pincht:d a vacuum Switch ii not p:~,sitiunrd ruiirctly.
Remove donr trim panel. replai:e control lines if necessary or adjust porition of vacuum iwitc:h in hurizonlal slots in inside door panel.
Printed in Germany - 1. 10% Checking r)o~r Central Imcking Syslem 5? I:?
57
Doors
4. Troubleshooting - Lock Mechanism
Possible Defects on Both Doors:
1. Defective lock cylinder.
2. Broken drive dog on lock cylinder.
3. Detached connecting or locking rod.
4. Lock mechanism too tight or clamped.
Driver’s door
923
Parsenjicr’s door
51-14
Checking Door Central Locking System
Printed in Germany l
928
Doors
57
REPLACING DOOR LOCK CYLINDERS
Removing and InsraIling
As from Chassis No. 928 810 2412
928 820 0884
928 920 9511 new door lock cylinders with a black escurcheon are insralled in all models. The old lock cylinders with a chromeplated escurcheon are replaced by new lock cylinders. Part NO. 928 531 901 02 with even codes or Parr No. 928 531 903 02 with un- even codes.
1. Pull off grommet from door frame and unscrew sacker head screw.
2. Loosen meral screw (arrow) and pull out lock cylinder far Enough. char operaring rod can he detached
If new lock cylinders are insralled in cars prior to the above mentioned chassis numbers. old operating rod must also be exchanged against a new one having Parr No. 928 531 111 03.
A ‘,
A - Old Version 8 - New Version
Printed in Germany- 11, 1978
3. Detach operating rod from inner lock. Arrach new operaring rod on inner lock s ball pin and lock cylinder.
Replacing Door Lock Cylinder 5; - 15
57
Doors
4. Press lock cover plate forward with a ICFW- driver. so rhar lock cylinder can he guided in all the way.
--;T.------- rc
/b&&q p,
3. lnsrall mounting screws for lock cylinder and lock cover. and press in grommet. never use grease containing copper powder or orher elecrrically conducrive marerials near rhe door lock cylinder con~acl swirch of cars with an alarm sysrem.
The alarm sysrem could sound off on its own through the effects of moisrure and elecrrically conducrive grease.
!I 2 8
- a
51 - 16 Replacing Door Lock Cylinder
I”, I!180 - Printed in Germany a
Doors
57
928 a
MODIFICATION ON ROTARY KNOB LOCK a
As from Chassis No. 928 810 1853
928 820 0661
928 820 9552 a modified rorary knob bearing is installed in all models.
This modification covers:
1. Rorary knob bearing
Driver’s door Parr No. 928 537 095 02
Passenger’s door Part No. 928 537 096 02
2. Bearing shell Part No. 928 537 585 02
3. Rorary knob
4. cap
Part No. 928 537 581 03
Part No. 911 537 703 00
Installing
1. lnserr rotary knob bearing. Attach safety rod on rorary knob bearing and inner lock, and mount rotary knob bearing.
The former rorary knob bearing parts are unvalid and will be replaced by the new parts.
When installing in doors of cars prior to the above mentioned chassis numbers, the door trim must be removed and the plastic sheet pulled off partially.
Open up opening in door inner panel for rorary knob bearing (arrow) IO approx. 26 mm dia.
Driver’s door a
Passenger’ s door
2. Paste on plastic sheer and install door trim.
On driver’s door fasten control valve with vacuum lines on rorary knob bearing at exacr center with hose rape. hinted inGermany - II, 1978 Modification on Rotary Knob Lock 57 - 17
57
Doors
3. Turn up bearing shell IO position on door trim.
928 a
4. Push on rotary knob and mount with washer and self-locking nur.
5. Press on cap.
57 - 18 Modification on Rotary Knob Lock Printed in Germany
928 a
MODIFICATION ON IINFINISHED DOOR SHELL
The opening for the door safety light mw be made in spare doors at the door pillar as shown in [he case of former version door shells for cars from 1980 models.
Dimensions in mm.
Doors
57 a
Printed inGermany - 1”s 1980 Modificarion on Unfinished Door Shell 57 - 19
a
928
TROUBLESHOOTING
Doors
CENTRAL LOCKING SYSTEM - From 1980 Models
57
Checking Power Supply
Note
The central locking system only works with the ignition turned off. If the ignition is turned on, the window lifting relay will interrupt the power supply to the controls.
Finding Defective Side
Both controls are connecred with each other elec- trically and could influence each other when de- fective.
To prevent this, disconnect the multiple pin plug of the wire harness in the passenger’s door to the tight hand side of the central electric board.
Check fuse no. 21 and both line fuses (0.4 A fine wire fuses) of left and right controls.
They are located in loose fuse holders behind rhe cenrral electric board. a
Check function of electric locking sysrem on driver’s side to find the defective side.
If fuses tared 0.25 A at others have been installed, replace them with 0.4 A fuses.
Note
The central locking system can only function properly when the lock mechanism moves easi:y. does not seize and the lock cylinders are okay. a
Printed inGermany - IV. 1980 Troubleshooting Central Locking System
- From 1980 Models
57 - 21
57
DOOIS
Removing Controls and Checking Funcrion after Removal n 2 8
1. Remove door trim panel.
If still disconnected, connect multiple pin plug of wire harness for passenger’s door.
Note
If a test lamp is used ro check the plugs. it could happen that the conrrol will be switched on
(power flow via test lamp).
2. Pull off plugs on control and check plug con- nections. 5. Remove lock cover. a
6. ,
4
1 = green/black
2 = yellow
3 = brown
4 = red/white
3. There should be battery voltage between lines of red/white term. 4 and brown term. 3 (igni- tion turned off).
6. Remove control.
4. With the opposite side in unlocked position. the following voltage conditions should be prevailling at rerm. 1 and 2:
Wire. yellow term. 2 - with voltage.
Wire, green/black term. 1 - without volrage.
V&age should be opposite when in locked position.
If voltage is not as described. replace control for opposite side a check wire harness.
51 - 22 Troubleshooting Central Locking sysrem
- From 1980 Models
Printed in Germany a
a
928
DOOIS a
I. Disconnect rransmitting linkage ar winder.
Installing and Adjusting Control
57
Note
Mount conrrol wirh the original M 6 x 8 bobs.
Longer bolts would impair clearance of winder.
1. Install control.
Winder must wm easily from stop to stop. Re- place the conrrol when movement is hard.
2. Pull up inner door recess seal above rhe con- trol, so rhar position of winder ro transmirring linkage can be observed from above after installation of conrrol.
8. Connect plugs on removed comrol (ignition turned off).
Turn winder clockwise from 1 to 2 by hand.
Conrrol should switch on in position 2 and continue rurning to 3.
Turn winder further by hand about 45’ (3 to
4). The control should rum further lo initial point 1.
Replace control, if function is nor correct.
3. New controls are supplied in locked poririon; the winder faces righr in installed position. a
Printed in Germany - IV. 1980 Troubleshooting Central Locking System
- From 1980 Models
51 - 23
57
Doors
4. To adjust, move lock mechanism of opened door IO “closed” position and push in locking button.
6. Unlock door and open the door lock by operaring the inside or outside handle.
I. Check function of locks on borh doors prior
IO final assembly.
Locking buttons must be pushed in by ar least 3 mm before the controls run.
._.?
5. Hold winder of conrrol in position 1 against
XOP.
Ball socket on linkage must be aligned wirh ball head of winder.
/
.-d Note
Doors can only be locked when both doors are closed. If one door is open when locking the doors, the locking system will return to open
Elate.
928 d Pi N?.Aq
/ I :-, ,” ‘, , w
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If ball socket and ball head are not aligned, cotrect position of control in mounring bores
0~ file slots, if necessary.
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1
51 - 24 Troubleshooring Central Locking System
- From 1980 Models
Printed in Germany
a
928
Doors
CHANGES ON DOORS AND DOOR LOCK CYLINDERS
The mounting points have been changed on doors and door lock cylinders.
Old Version Door Lock Cylinder -
A26mm
New Version Door Lock Cylinder -
829mm
Old Version Doors
57
New Version Doors
A
0
;
1
I
Since the old version doors still have the old mounting point, old or new door lock cylinders may be installed by filing the door mounting point.
A 6.4 mm dia. washer, a 6 mm dia. lock washer and a M 6 x 8 mm fillister head screw are required to mount the door lock cvlinder.
Printed in Germany - VI, 1982 Changes on Doors and Door Lock Cylinders 57-25
57
Doors 928
Doors with the new mounting point and new door lock cylinder require a spacer, 6.4 mm dia. washer, and a M 6 x 18 mm fillister head screw.
File mounting point if necessary. installation of the door lock cylinder requires use of a 6.4 mm dia washer, 6 mm dia. lock washer and a M 6 x 8 mm fillister head screw.
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The following procedures are required to install an old door lock cylinder in doors with the new mounting point.
Fit in door lock cylinder. Check distance between mounting point and door lock cylinder. Change mounting point with the locally made tool in such a manner, that door lock cylinder and mounting point are in same level.
57.26 Changes on Doors and Door Lock Cylinders Printed in Germany
928
REMOVING AND INSTALLING
(WITHOUT REMOVING GATES)
POWER SUN ROOF
Removing
I. Open sun roof lid to rear end position.
Unsrew sun roof liner mounting screws.
Sun Roof
2. Pull out sun roof liner toward front.
4. Close sun roof lid but for gap of approx
10 mm. Lift front end of sun roof lid slightly. push back sun roof lid out of guides and lift off toward front.
3. Detach front guide and gates by loosening screws on sun roof.
Printed in Germany X, 1964 Removing and Installing
Power Sun Roof
60. 1
60
Sun Roof
Installing
1. Check attachments before installing the sun roof lid (lid seals, gates and guides).
Replace parts, if necessary.
928
Note
Proceed as follows, if sun roof lid had been disconnected on the gate mounting screws or the gates had been replaced.
Installation is in reverse sequence.
2. Adjust sun roof liner that trim runs over roof frame without friction. j -y$,.‘~, .,‘
1. Correct the distance between gates, if necessary between brackets and gates, with washers.
,
60 - 2 Removing and Installing
Power Sun Roof
Printed in Germany
a
928
Sun Roof
60
I -3
.I $.L’:
./
‘d .‘..A
2. After closing the sun roof lid, the rear end of the lid must be in same plane as the roof panel. Height can be corrected with the rear gate screws.
3. The lid’s front edge can be adjusted to the roof plane with the recessed adjusting screws, whereby the mounting screws must be loosened first.
Printed in Germany _ X, 1964
Removing and Installing
Power Sun Roof
60 - 3
60
Sun Roof
REMOVING AND INSTALLING DRIVE MOTOR AND GEARBOX FOR SUN ROOF
Removing
1. Pull down rear end of cover slightly, disconnect spring wire and take off cover toward rear.
3. Check rubber/metal if necessary. mounts, replacing
928 a
2. Disconnect wire plugs. Unscrew mounting nuts and screw. Take off motor and gearbox.
Installing
Check motor, gearbox and clutch for damage before installing, replacing if necessary. Installation is in reverse seouence.
60-4 Removing and Installing
Drive Motor and Gearbox for Sun Roof
Printed in Germany
928 Sun Roof
60
REMOVING AND INSTALLING WIND DEFLECTOR
Removing
1. Open sun roof lid and unscrew deflector opener mounting screws.
FOR SUN ROOF
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2. Unclip locks on pins. a m,-
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!
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Installing
1. Inspect all parts (rubber pads, opener, pins, washers and locks), replacing parts when necessary, before installing the wind deflector.
3. Press pins out of hinges and take wind deflector with opener out of car.
Prjnted in Germany X, 1984
2. Installation is in reverse sequence.
Removing and Installing
Wind Deflector for Sun Roof
60 .5
60
Sun Roof
REMOVING AND INSTALLING GATES, GUIDE, CABLES AND GUIDE RAILS
Note
Sun roof gearbox is removed.
Removing
1. Take gates off of guide rails toward inside.
3. Lift front end of guide rails and push out guide toward front.
928 a
!
/ 9.4 a
2. Push back front guide, unscrew mounting screws of front cover plate and guide rails, and lift off cover plate.
4. Pull out cables toward front (only possible after removal of gearbox)
60 - 6 Removing and Installing
Gates, Guide. Cables and
Guide Rails
Printed in Germany
926
5. Pull guide rails out of spring clamps a?d rsmove toward front.
Sun Roof
60
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$
I?stalIi?q
Iwpect all parts fw damage before iwtalling, replacing parts if necessary. c,,/. a
1
. N q
1
I’
Lubricate all parts thoroughly with a special grease, e.g. Golda LS 2049
(application range from - 20’ / 4’ F +
90°C/194’ F).
Installation is in reverse sequence.
Printed in Germany . X, 1964 Removing and Installing
Gates, Guide, Cables and
Guide Rails
60 - 7
60
Sun Roof
MO’)IFICATIONS ON SUN ROOF
Different modifications have been made on the sun roof since 1978 models to improve the function.
1. The rear cross guide with the connecting rods attached to the gates and stop plates bolted on the sun roof and shim plates have bee? omitted and replaced by a water drain plate, which is bolted direct to the sun roof lid at rear.
2. The velvet strip Jvplied on the sun roof lid all around was replaced by a new part, which has an additionally flaked lip to prevent wind noise and improve sealing.
3. The front bolt holes in the front guide rails and lid hinge have been moved forward by 12 mm. In addition, in the middle of the new guide rail there is a third spring tongue resting against the sun roof head liner.
928 l
New Version
4. The height of the sun roof frame has been increased to improve clearance for lowering and returning.
Old Version
60-8 Modifications on Sun Roof Printed tn Germany a
63
RLl”,peiS
REhlOVlNG ANC 1~‘!,7-ALLlr\i~~ riL1hlFCKS
!I 2 8 a z s oo)i.b f~-i- i&i& -
,
‘I 1 t
.vi
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ILmi ;
- j
. - ~.,
4 i
0
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Printed in Germany a
63 - 2 Removing and Installing Rumper
- a
928 Bumpers
V”.
1
2
3
4
5
End cover cover frame
Metal screw
Holding strip. upper
6
7
8
3
0
1
4
5
2
3 ij
8
Description
Panel
Holding strip. side
Cover rail
Metal sc,ew
Self-locking nut
Washer
Headlight
Gasket
Plastic nut
Screw
Washer
Lockwasher
SCEW
1 I
0
2
1 1
SCIWJ
Lockwasher cage ll”t spray jet
Radiator grill
Qty .
RtXlOVing
Note When
Installing
1 Detach at fender First fit panel on body. and top and bottom machine/grind off bea- cross member, then ring surfaces. Rivet pull forward a little holding strips. Paint and disconnect hose with PUR paint and at spray jet install weatherstrip
2
2
4
2
2
1
Replace, if neces- Mouot on panel with sary. Drill out ri-
Y&S pop rivets
Replace, say. vets if neces-
Drill oat ri-
Mount on panel with pop rivets
Replace, if neces- sary
6
3
3
3
2
2
2
2
2
1
5
30
30
2 Open hose clip, de- Aim at center of head- lath hose light with 9135
Replace, if neces- Inrert plugs in moun- say ting holes on bottom cross member
Special
Instructions
63 a
Primed in Germany
Removing and Installing Bumper 63 - 3
63
Bumpers
NO.
22
23
24
14a
25
29
30
31
2s
26
27
Description
Rubber plug
Carrier impact tube
Impact
Cyl.
Washer
Bolt head
Washer
Washer absorber
Turn signal bolt
Eccentric disc
32
33
High beam headlight
Fog headlight
Oty.
Remwing
Nol: When
IMaIling
2
2
4
4
4
2
2
2
2
3
1
2
2
Straighten only slight damage, otherwise replace
Replace damaged parts
Replace damaged parts hit on carrier lo fit body
Bolt on carrier to fit body
Carrier can be off- set depending on in- stalled pnsiliw
Remove carrier, then Mount CIII carrier be- disassemble fore installation. *d- just on finished car.
Fasten wires with clips
Special
Instructions
63 - 4 Rrmoving and histalling Bumpa
Printed in Germany
-+
928 Bumpers
REMOVING AND INSTALLING NOSE PANEL, '87 MODELS ONWARD
Removing l.Remove wheels and front air dam.
2.Remove wheel-arch inner panel mounting bolts and remove wheel-arch inner panels from car.
3.Remove wheel-well bolts, disconnect outside-temperature sensor on left-hand side of car and remove wheel-well covers. cover mounting air hose for
63
4.Unplug electrical connections. a
Printed in Germany-XIX,1987 Removing and Installing
Nose Panel, '87 Models Onward
63-4a
63 Bumpers
5.Remove bolts holding panel to front fenders.
6.Remove cover-strip mounting bolts holding strip to front end section and remove panel from car.
928 a t
\._;,-‘<.!t+ .- -: i;, (qyr
‘p
B
:. ,..
*;I I”: j-y t
-_I kj Jh
Installing l.Before installation, check all mounting points and seals and replace seals if necessary.
2.When mounting the panel, check to ensure that the gaps between the lid and the fenders are equal and straight. Adjust at the mounting bolts of the cover strip. a a
. .
63 - 4 b Removing and Installing
'87 Models Onward
Nose Panel,
Printed in Germany a
Bumpers 63
DISASSEMBLING AND ASSEMBLING BUMPERS
The high heanl and fog headlights as well as the turn signals are removed or installed with the carrier.
\\iires are fastened to the carrier with hose clips for protection.
The carrier and/or panel do not have to be removed to replace single parts.
Auxiliary headlights can he replaced after unscrewing the radiator grill and cover frame.
Single turn signal lamps and fog headlights can be replaced from underneath the fender.
Mark wires to prevent mixups!
Until introduction of new PU irim, a weatherstrip is pasted along the entire mating surface to the body and fastened with clips. It is used to compensate for or cover up small irregularities in the body con- tour.
Pdirting
The panels are coated with a special polyurethane (PUR) paint. which is extremely elastic and scratch- proof.
New paint jobs “I the painting of large areas require the use of this paint. whereby the entire part must be ground clean and sprayed.
Scratches and small damage areas can be touched up with normal body paints.
When placed in an oven for drying (max. 60” C) the panels should be placed on aluminum carriers “I special stands to prevent permanent distortion. a
Printed in Germany
Disassembling and Assembling Rumperr 63 - 5
63
Bumpers
REMOVING AND INSTALLING BUMPERS
63 - 6 Removing and Installing Dumper
3'
0 i. y4 ~
‘\,.
)I
Lo
I’_ %R z
P
: \, F
A $ \
Ill top
,Y
\ '>
*-s-r/
“\
'i I ;“, "5
I /
Fi
-+-,
L..
\: b’ :sq>’ i
\’ ’
“.i sge:
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=
1”
, ~~&.. .,:: J /‘. 1: ~ .i;--.,‘-’ i
(1 (or- P In j
Printed in Germany a
a
9 2 8 Bompers
;\3.
1
5
6
3 u
1
2
3
PEltId
3
4
Holdi-g strip. uPPer i Iolding strip. center
4
423 ii
Description
End cover
Holding strip, lower
Self-locking nut
Washa
Reinforcement rail
Cover rail
Countersunk screw
Allen head screw
Cap
Tail light
License plate light
Cover frame
Metal screw
Carrier c!ty .
Removing
Note When
Installing
1
2
2
2
2
Detach Panel u” Aligr panel with fender. inside of fender and grind as required. coat top center with PIER paint. rivet holding strips. install weatherstrip
Pull out, now carrier mount- ing bolts are accessible
Replace, if da- maged
Replace, if da- maged
Replace, if da- maged
Mount on panel with pop rivets
Mount on panel with pop rivets
Mount on panel with pop rivets
1:
17
1
4
1
2
2
9
2
1
5
9 Replaced by posi- tions 9 i 10
Replaced by posi- tions 9 + 10
Unscrew, pull out lamp. pull off wires
Straighten only slight darnage, otherwise re-
JJIX?
Mount to bottom of panel with pop rivets
Special
Instruction*
63 a
Printed in Germany
Rcrnoving and Installing numper 63 - 7
63
Bumpers
NO.
1:
18
19
2.0
21
22
23
238
‘4
!5
26
17
Description
Threaded plate
Cyl. head bolt
Washer
Eccentric disc
Support
Metal screw
Impact tube
Impact absorber
Bolt
Lockwasher
Washer
Tail fog light
38
!Y
IO
11
Washer
Lockwasher
Nut
Rubber pad (USA)
12 Self-locking nut
QQ.
Removing
Note !>‘hen lnrtalling
2
2
Luck in guide
Accessible after removal of end cove1
2
2 Carrier will be nff- set depending on in- stalled position
2
2
2 Replace damaged pits
2 Replace damaged
PZU,S
8
1
4
8
Pull off COY~I frame
Bolt support lo carrier
Align installed posi- tion with carrier
Align installed posi- tion with carrier
3
1
1
2 Detach from carrier Cut out holder open- ing in new panel, mea- sure hole and install
4
Cut out opening in new panel with a knife.
Install light on carrier and adjust
Special
Inslructiuns
92n
63 - 8
Removing and Installing Bumper Primed in Germany
928
REMOVING AND INSTALLING BUMPER
1. The panel is bolted to fender with five bolts on the right side and four bolts on the left side.
First remove plastic cover on left rear wheel house.
Rumpers
63
.I
2. Until introduction of new PU panels. a weather- strip has to be pasted on the mating surfaces to the fear side panels and fastened with clips.
In this manner small irregularities in the body contour can be equallized or covered up.
F”
‘5 -ec, ~ ::; ; (
!’ ‘,
, .“*’ e,P
1 . .
I ..~Ly.;;;, ~.t.-- )
I z “b
3. Tail lights can be removed with the panel. if rubber grommets are pulled out of tail panel and the then accessible plugs are disconnec- teb.
4. Tears or impressions in PU parts can be pasted and filled in with engineering adhesives from
3 M. Art. No. 8101 or 3535 B/A. a
Printed inGermany - 1, 1978
Removing and Installing Bunlper 63 -9
,,”
928
The mounting of rubber pads on the rear bumper has been changed for USA cars since the 1919 models.
Painting
Cut ou[ rhe bumper rrim in area of the rubber pads prior to installing.
The PU panels are coated wirh a special polyure- thane (PUR) paint, which is extremely elastic and scratchproof.
Openings around the bolt and holder must be generous enough that the trim cannot be stressed or damaged when installing the rubber pads.
New paint jobs or the painting of large damaged areas require this paint. whereby the entire part must be ground clean and sprayed.
Only scratches 01 insignificant paint damage can be rouched up with normal body paint.
Panels insralled free of tension. no waves or distortion visible, do nor have IO be removed when car is placed in ;n oven for drying (max. object temperarure 80 C).
1
When drying panels in an oven (max. 60’ C). make sure that outer surfaces are nor loaded
(e.g. place on sryroper packing material or aluminum carriers). This will prevenr permanent distortion.
It is recommended to make rhe openings with a piercing saw.
Dimensions in mm.
63 - 10 Removing and Installing Bumper
IV. 1980 - Printed in Germany
928 Windows 64
REtiOVING AND INSTALLING POWER WINDOW OPERATING SWITCH
1. Unscrew side trim from center console
(2 screws). pull off clip and press down trim.
3. Loosen rear of center console, press up and press out switch.
2. Disconnect coupling on wire harness. hinted in Germany Removing and Installing Power Window Operating Switch 64 - 1
64 Windows
INSTALLING ADHESIVE PLATE FOR INSIDE REAR VIEW MIRROR
An inside rear view mirror which has fallen off can be pasted again, if the adhesive plate
(Part No. 477 845 043) and glass are not damaged.
Also applicable for the Sekuriflexwind- shield.
Installing Mirror Base
1. Mark installed position on outside of glass. Dimensions: 110 mm from roof edge to mirror base ca. 630 mm from A pillar to center of glass.
2. Remove all remainders of adhesive from windshield and adhesive plate and clean with fresh gasolin 80/l 10.
3. Spray a thin coat of Activator 312 NF on adhesive surface of windshield and allow to dry about 2 minutes.
4. Inject one drop of Loctite 312 on to adhesive plate and press on firmly. Turn adhesive plate, until some Loctite squeezes out on edges.
5. Position adhesive plate correctly, holding groove vertical, and press on for about 30 to 46 seconds.
6. Install inside mirror carefully after waiting about 1 hour.
Materials Required
Loctite 312, Part No. 000.043.051.00
Activator Loctite NF
Part No. 000.043.052.00
Note
After 1 hour approx. 60% and after 24 hours 100% of the adhesive strength has been reached.
928
64-2 Installing Adhesive Plate for Inside Rear View Mirror
XX, 1988 - Printed in Germany m
Giasses, Window Control
Bonding the interior rearview mirror in place
The following materials are required for bonding of the complete lnterlor rearview mirror:
64 l A=
B = c =
D =
E q
* Porsche part no
0 CT
C
B
Cleanlng solution (000.043.157.00)’
Primer (000.043.158.00)*
Cover sheet (000.043.177.00)’
Activator (000.043.052.00)’
Adhesive (000.043.051.00)*
752-a
Bonding the lnterlor rearview mirror In place
Printed in Germany - XXVII, 1941
64-2a
64
Glasses, Window Control
Bonding the interior rearview mirror in place
Bonding the fully assembled Interior mirror to the wlndshleld
928 a
64 - 2b Bonding the interior rearview mlrror in place
Printed in Germany - XXVII, 1991
a
928 Glasses, Wlndow Control
64
Bonding the interior rearview mirror in place
Bondlng the fully assembled interior mirror to the windshield
No.
1
2
3
Operation
Mark position of interior reafview mirror
Remove adhesive residue
Roughen bonding plate of rearview mirror
Clean bonding plate of rearview mirror
Clean bonding area of windshield
Mask off bonding area of windshield
Prime bonding area of windshield instructions
Mark position of adhesive plate on outside of windshield.
Dimension A = 630 mm
Dimension B = 110 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).
Mask oft bonding area of windshield using plate (cover sheet C). primer tem-
The position mark of the interior rearview mirror must be visible in the middle of the primer template.
Apply a thin coat of primer (B) to the masked bonding area of the windshield.
Caution: Allow a flash-off time of 15 to 20 minutes! a
Bonding the interior rearview mirror In place
Printed in Germany - XXVII, 1991
64-2~
64
Glasses, Window Control 928
5
6
No.
4
Operation
Activate bonding area of windshield lnstructlons
Spray activator (D) onto bonding area of the windshield.
Caution: Allow a flash-off time of 2 minutes!
Remove primer template
Apply adhesive to bonding plate
Bond rearview mirror in place
Apply a drop of adhesive (E) to the bonding plate of the rearview mirror.
Press bonding plate of rearview mirror against primered and activated windshield area.
Note: Press mirror In place for approx. 40 - 50 sec.!
0
Bondlng strength
60 % after 1 hour
100 % afler 24 hours
64 - 2d Bondlng the Interior rearview mirror in place
Printed in Germany - XXVII, 1991
*
928 Windows
64
REMOVING AND INSTALLING WINDSHIELD
Removing
I. Lift off cap on windshield wiper and loosen
SCEWS. Set up wiper arm and move it back and forth. until the wiper arm can be remo- ved _
4. Open engine hood. unscrew and remove apron panel.
2. Knock side ornamental strips off of retaining rail with a wood wedge.
9
‘I
$&f&T&
,!&&
@?.:-:
,<Jf
5. Unscrew sun visor mounts. Remove inside mirror by pressing up. Remove metal screw
(see arrow) from A pillar. Pull down head- liner on left and right sides far enough that the front clips can be disconnected.
3. Pull out upper ornamental strip.
Printed in Germany
Removing and Installing Windshield S4 - 3
64 Windows
6. First press side pads up and in, and then pull them out.
928
Note
T? prevent the weatherstrip from sticking to- gether again, press out the window glass care- fully at the same time or place a small block underneath.
Broken windows can be pressed out and the weatherstrip cot through with a knife.
Cover inside of car to protect sensitive areas against glass splitters.
I. Press the steel wire from Repair Kit 47: 898
Ull through windshield weatherstrip at an l>ppez e~,~~ an;: rer-rrra it *irMe. “f Syeciai
Tool VW 1351 (similar to a screwdriver). Now pull the wire toward the inside and hold it on the weatherstrip with the special 1001. Use the grip to pull the wire in up to this point. Re- peat this procedure around entire windshield.
8. Remove remainders of adhesive from win- dow and flange.
Note
Remainders of adhesive are best removed from wildoh’ and flange by dabbing with a little sea- lant material.
Installing
1. Place windshield in body. position and mark.
Place spacer blocks on bottom window flange.
2. Clean edge of glass and flange with acetone.
3
64 - 4 Removing and Instailing Windshield
Printed in Germany
YZS
Windows 64
3. Apply a coal of primer to adhesive surfaces on window and flange.
5. [mtall window glass with suction cups. Press on tight enough all around. that sealing cord fits well everywhere. Distance between flange and upper edge of glass should bc 10. 5 mm.
. . .’
!, ’
,~?.*a* ./-
(.
‘. a
Do cm1 apply a second coat of priming solution after air-drying: this would impair adhesion. i
6. install ornamental strips.
‘i. Install side pads, headliner and ‘un visors.
8. Install inside mirror.
J. Place cord seal in window opening and cnnnect ends with a diagonal cut.
9. Install apron panel and windshield wipers. a
Printed in Germany - I. 1978
Relmoving and Installing Windshield 64 - 5
929 Glasses, Window Control
64
Removing and installing the bonded windshield
The following tools and materials are required for removal and installation of the bonded windshield:
:.,~ f!j
~~,
F3
VAG 1561 Cutting device
Double suction cup
Glue gun
Scrapping knife
VAG 1344/l
6.39.03.113.02.2
E
F
Fl
F2
F3
F4
F5
F6
Cutting knife U-shape
Adhesive set
-Adhesive sealing camp.
- Working node
- Cleaning solution
Body primer
- Glass primer
- Swab
I
6.39.03.127.01.4
000.043.036.01
I
VW Werk AG
VAG 1344CS equipment sales e.g. C 8 E FEIN GmbH & Co.
Postfach 172
7000 Stuttgari 1
Porsche Parts Service
Removing and installing the bonded windshield
Printed in Germany - XXIV.1969
64 - 7
64
Glasses, Window Control
Removing and installing the bonded windshield
64 - 0
Removing and installing the bonded windshield
Printed in Germany - XXIV.lQEQ l
a
928 Glasses, Window Control
64
Removing and installing the bonded windshield
No. Work step Instructions
14
15
16
10
11
12
6
7
8
9
13
Remove the wipers
1 Move sleeves
2
3
4
5
Unscrew the hexagon nuts, lift off washers and wipers.
Remove the water collection strips
Separate transitlon from cover strips at top to water col- lection strip on right and left by moving the sleeves.
Drive the right and left water collection strips out of the holding rails by means of a wocden wedge.
Remove the top cover strip
- Top cover strip
Sealing tapes
- Adhesive tape
Remove the top cover strip from the plug-in clips using a plastic or wooden wedge. Remove the adhesive tape and sealing tapes.
Remove the cowl panels
- Hexagon sheet metal screws
Washers
- Sealing washers
- Sheet metal screws
- Washers
- Cowl panel
- Sea/
Open lid. Unscrew hexagon sheet metal screws. Re- move washers. Unscrew one sheet metal screw in each case at the right and left ends of the cowl panel, remove washers and remove cowl panel with seal.
Remove spacerblocks Remove the spacer blocks at the bottom between the bodywork and windshidd.
Unscrew the sun visor bearing
- Slotted oval trim-head tapping screws
- Sun visor bearing
Unscrew the slotted oval trim-head tapping screws and remove the sun visor bearing with sun visor.
Lii off the inside mirror Lii off the inside mirror upwards from the fixing plate parallel to the windshield.
Removing and installing the bonded windshleld
Printed in Germany - ,WN,lg8g
64-9
64
17
18
19
No. Work step
Remove the A - column panels
- Sheet metal screw
- A - column panel
Attach a cover to the
Instrument panel
Open the door windows
Glasses. Window Control
Unscrew the sheet metal screw on the A-column. Un- hook the front clips by pulling down the headlining on the right and left. Press the A-cdumn panels Inwards at the top and then pull out.
Cover the instrument panel to avoid soiling or damage.
20 Atrach adhesive tape to the bodywork
21 Cut out the windshield
928
Lower the door window panes.
Important: The door windows must be closed again only after completion of the hardening time.
Mask the bodywork in the visible area of the window cut- out with adhesive tape to protect the paint work.
Equip the cutting device (A) with a cranked knife (E).
Sharpen the cutting knife with a whetting stone with the machine running. Insert the cutting knife between the bodywork and windshield and set the oscillation control- ler to step 4. Cut through the adhesive bonding between the windshield and bodywork all-round.
22
23
Remove the windshield
Remove the adhesive sealing compound on the bodywork
Clean the window cut-out in the bodywork
Equip the cutting device (a) with a scraping knife (D) and remove theadhesive sealing compound on the body work so far that there is still a full covering of remaining adhesive.
Clean the window cut-out in the bodywork thoroughly with cleaning solution (F3).
Important: No cleaning solution residue must remain on the bodywork.
64- 10 Removing and installing the bonded windshield
Printed in Germany - MIV,lQSQ
928 Glasses, Window Control
64
No.
24
25
Work step
Prime damaged locations on the bodywork
Remove the adhesive tape on the bodywork
Clean the windshield
Apply a prime coat to the windshield
Apply adhesive sealing compound to the windshield
Instructions
Prime damage to the top coat in the invisible area of the window cut-out with body primer (F4).
Clean the area of the windshield to be glued thoroughly with deaning solution (F3).
Apply glass primer (F5) all-round to the area of the wind- shield to be glued.
Important: The glass primer requires a drying time of at least 15 minutes. No adhesive sealing compound must be applied before expiry of this time.
Using the glue gun, apply adhesive sealing compound
(Fl) all-round on the surface of the windshield to be glued in the form of a tapered bead (C).
Important: The windshield must be installed in the ve- hicle within a maximum of 10 minutes after adhesive ap- plication.
Position the double suction cups on the outer side of the windshield
Insert the spacer blocks
26 Insert the windshield in the bodywork
Insert the spacer blocks for positioning the windshield at the bottom in the bodywork (cowl).
Place the prepared windshield in the window cut-out of the bodywork, align and press on with the double suc- tion cups (6). The windshield must rest on the spacer blocks at the bottom.
Removing and installing the bonded windshield
Printed in Germany - XXIV,1989
64- 11
64
No. Work step
Clean the vision areas
Glasses. Window Control
Instructions
Excess adhesive sealing compound must be removed immediately and the affected vision areas cleaned with cleaning solution (F3).
926
Remove the cover on the instrument panel
Install the A-column panels
Fit the inside mirror
Fit the sun visors
Fit the cowl panel
Fit the top cover strip
Install the water collection strip
Fit the wipers lnser the A-column panels, clip in the headlining again by pressing up and insert sheet metal screws.
Push the inside mirror onto the fixing plate parallel to the windshield.
Secure the sun visor bearings with sun visors on the right and left with three slotted oval trim-head tapping screws in each case.
Insart the cowl panel with seal and screw in the hex- agon sheet metal screws with the corresponding wash- ers. Secure the right and left ends of the cowl panel with one sheet metal screw and washer in each case.
Attach the adhesive tape and sealing tapes. Secure the top cover strip to the plug-in clips with fitted sleeves.
Push the right and left water collection strips onto the holding rails, Produce a transition from the top cover strip to the right and left water collection strips by moving the sleeves.
Slip on the wipers, put on washers and screw tight with hexagon nuts. a
64- 12 Removing and installing the bonded windshield
Printed in Germany - XXIV.1989 a
928 Glasses. Window Control
Important:
In order to guarantee sufficient strength of the adhesive bond, the following parameter conditions must observed:
Hardening time 10 h
Temperature min. 15°C
Relative humidity min. 40%
The hardening time is extended at lower temperatures and with a lower relative humidity.
The vehicle must not be put into operation before expity of the hardening time!
64
Removing and installing the bonded windshield
Printed in Germany - XXIV,1989
64- 13
929 Glasses. Window Control
Removing and installing the bonded rear side window
The following tools and materials are required for removal and installation of the bonded rear side windows:
64
F
G H
Cutting device
Double suction cups
Glue gun
Scraping knife
Culved cutting knife
Adhesive sealing camp.
Body primer
Cleaning solution
VAG 1561
VAG 1344
VAG 134411
6.39.03.113.02.2
6.39.03.103.01.7
999.915.400.40
999.915.467.40
999.915.476.40
VW Werk AG
CS equipment sales e.g. C & E FEIN GmbH & Co.
Postfach 172
7000 Stuttgart 1
Porsche Parts Service
Removing and installing the bonded rear side window
Printed in Germany - XXIV,1989
64- 15
64
Glasses, Window Control
Removing and installing the bonded rear side window
64-16 Removing snd installing the bonded rear side window
Printed in Germany - XXIV,1989
926 Glasses, Window Control
Removing and installing the bonded rear side window
64
1
2
3
4
5
No.
6
7
6
Work step Instructions
Pull off the decorative frame
- Comer piece, top
Carefully release the decorative frame from the rubber seal in the area of the top corner piece using a wooden
- Decorative frame part, top
- Corner piece, bottom or plastic spatula. Insert fabric cloths between the deco- ratfve frame and rubber seal and pull out the decorative
- Decorative frame part, bottom frame by pulling the fabric cloth along the rubber seal.
Cut througmhe rubber seal Equip the cutting device (A) with the curved knife (E).
Sharpen the cutting knife with a whetting stone when the machlne is running. Insert the cutting knife in the rub- ber seal, set the oscillation controller to step 6 and cut through the rubber seal all-round between the rear side window and body work.
Remove the rear side window
Pull the rubber seal restdue off the bodywork
Mach adhesive tape to the bodywork
Remove the adhesive sealing compound on the bodywork
Clean the window cut-out in the bodywork
Mask the bodywork in the visible area of the window cut- out with adhesive tape to protect the paint work.
Equip the cutting device (A) with the scraping knife (C) and remove the adhesive sealing compound on the bodywork so far so that there is still full coverage with adhesive resfdue.
Thoroughly clean the window cut-out in the bodywork with cleaning solution (H). important: No deaning solution residue must remain on the bodywork.
Removing and installing
Printed in Germany - XXN,1989 the bonded rear skle window
&I- 17
64
Glasses. Window Control 929
No.
9
10
11
Work step
Prime damaged locations on the bodywork
Remove adhesive sealing compound on the rear side window
Clean the rear side window
Clean the rubber seal
A,op/y adhesive sealing compound in the window channel of the rubber seal instructions
Prime damage to the top coat in the non-visible area of the window cut-out with body primer (G).
Carefully remove the adhesive sealing compound on the rear side window with a fted knife. A full covering of adhesive residue may remain.
Thoroughly rub off the rear skie window wlh cleaning soiution (H). important:: No cleaning solution residue must remain on the window.
Clean the window channel of the rubber seal with cleaning sdution (H).
Important: No cleaning solution residue must remain in the window channel. insert a cartridge of adhesive sealing compound (P) in the glue gun (C) and glue the window channel of the rubber seal ail-round.
Important: The rear slde window must be installed in the vehicle within a maximum of 4 hours after adhesive application.
Place the rubber seal on the rear side window
Complete the rubber seal with the decorative frame
Press the top decorative frame part (2) into the rubber seal.
AssemMe the bottom decorative frame part (4) wfth the top corner piece (1) and bottom corner piece (3). press into the rubber seal, connect with the top decorative frame part (2) and press the assembled decorative frame completely into the rubber seal.
64- 16 Removing and installing the bonded rear side window
Printed in Germany - XXIV,1999
929 Glasses, Window Control
64
No.
12
13
Work step Instructions
P/ace the assembly cord In the rubber seal
Place the assembly cord for pulling in the rear side win- dow In the rubber seal.
The cord ends must cross approximately in the center of the Ccdumn area.
Remove the adhesive tape from the bodywork apply adhesive sealing compound to the bodywork
Apply adhesive sealing compound (F) all-round in the area of the window cut-out on the bodywork with the glue gun (C).
Fit the rear side window in the bodywork
Clean the vision areas
Place the assembled and prepared rear side window in the window cut-out of the bodywork, align and press on
From the passenger compartment, pull the rubber seal onto the bodywork bead by pulling out the assembly cord.
Excess adhesive sealing compound must be removed immediately and the affected vision areas must be cleaned with cleaning solution (H). l
Removing and installing the bonded rear side window
Printed in Germany - XXIV.1989
64- 19
0
92s Glasses
Removing and installing windshield - 2-pack adhesive
The following tools and materials are required for removal and installation of the windshield:
64
Cutter
Twin-cup suction puller
Bonding gun
Flashing knife
Cutting knife, U-type
Mixing rod 9528
G
Adhesive set
Gl
Cartridge component A
G2
- Cartridge component B
G3 - Mixing cartridge
G4 - Primer
G5 - Cleaning solution
G6 - injector nonle
G7 Application nozz/e
G8 - Filling non/e
G9 - Touch-in tool
--
VAG 1561
VAG 1344
VAG 134411
639.031 .130.22
639.031.270.14
000.721.952.80
000.043.038.01
VW Werk AG
Service equipment supply e.g. C & E FEIN GmbH & Co.
P.O. Box 172 ; D-7000 Stuttgart 1
Porsche Parts Service
Removing and installing windshield - apack adhesive
Printed In Germany - XXVII,1 391
64 - 21
64
Glasses
Removing and installing windshield - 2-pack adhesive
928
84 - 22 Removing and installing windshield - 2-pack adhesive
Printed in Germany - XWll,1991 a
64
Removing and installing windshield - 2-pack adhesive
Glasses / Window Control
64-22 Removing and installing windshield - Z-pack adhesive
Printed in Germany - XXVII, 1941
929 Glasses
64
Removing and Installing windshleld - 2-pack adhesive
Removing windshield:
6
7
8
9
10 l ::
13
14
15
3
4
5
No.
1
2
Operation
Remove windshield wipers
Relocate sleeves
Instructions
Undo hexagon nuts, lift off washers and wipers,
Remove drip moldings
ShiMt sleeves to separate junction between upper cover molding and RH and LH drip molding.
Using a wooden wedge, separate RH and LH drip mol- dingsfrom the retaining rails.
Remove upper cover molding upper cover molding
- sealing strips
- adhesive tape
Using a plastic or wooden wedge, separate upper cover molding from the locating clamps. Remove adhesive tape and sealing tapes.
Remove cowl panel
- Hex head sheetmetal screws
- Washers
- Sealing washers
- Sheetmetal screws
- Washers
- Cowl panel
- Seal
Open cover. Remove hexagon head sheetmetal screws.
Remove washers. Remove one sheetmetal screw each on right and M-hand side of cowl Panel, remove washers and take out cowl panel complete with weatherstrip.
Remove spacer blocks Remove spacer blocks between body and lower wlndshieid side.
Unscrew sun visor support
- Raised countersunk sheetmetal screws
- Sun visor support
Remove raised countersunk sheetmetal screws and sun visor support complete with sun vlsor.
Removing and installing windshield - apack adhesive
PrInted In Germany - Mo111,1991
84 - 23
Glasses
17
19
19
No.
16
20
21
22
Operation Instructions
Lii off interior rearview mirror Lift rearview mirror off the subplate, following a line parallel to the windshield.
Remove A-pillar linings
- Sheetmetal screw
A-post lining
Unscrew sheetmetal screw from A-pillar. Unclip front clips by pulling down right and left-hand sides of headlin ing. Press top of A-pillar linings to the inside and pull out.
Spread cover over instrument panel
Cover instrument panel to avoid staining or damaging the panel.
Open door windows Lower door windows.
Attention: The door windows must not be closed before the curing time has elapsed.
Attach body adhesive tape to the
Cut out windshield
Cover body in visible area of windshield aperture with adhesive tape to protect the paintwork.
Insert cranked knife (E) into cutter (A). With equipment running, sharpen cutter with grindstone. Place cutting knife between body and windshield and set vibration regulator to stage 4. Cut bonding between windshield and body in a continuous line.
Lift out windshield
23 Remove from body adhesive sealant lnserl flashing kntie (0) into cutter (A) and remove adhesive sealant from body only to the extent that the remaining adhesive covers the whole area in a unfform manner.
64-24 Removing and installing windshield - 2-pack adhesive hinled in Germany - XXVll,1991 a
928
No. Operation
Clean windshleld aperture of body
Glasses
Instructions
Clean wlndshield aperture of body thoroughly using cleaning solution (G5).
Attention: Make sure no cleaning solution residues remain on the body.
Use primer (G4) to coat damaged areas in non-visible section of windshield aperture.
64
Apply prlmer to damaged areas of body
Remove adhesive tape from bcdy
Clean windshield
24 Apply prlmer to windshield
Clean bonding area of windshield thoroughly using cleaning solution (G5).
Apply primer (G4) to the bonding area of the wlndshield in a continuous bead.
Attention: Drying time of the primer is at least 15 minutes. No windshield adhesive must be applied until this time has elapsed.
Removing and installing windshield - 2-pack adhesive
Printed In Germany - XXVll,l~l
84 - 25
64
Preparlng the adhesive cartridge for appllcatlon of adhesive
Glasses/Window Control 928
No.
25
26
27
28
29
30
31
32
Operation Instructions
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 (Hl).
Open flanged cover of cartridge containingcomponent A
Use the screwdriver handle to pierce the flanged cover at the end of the cartridge containing component A (Hl),
Screw filling nozzle onto cart- ridge containing component A
Screw filling nozzle (H9) onto cartridge containing component A (Hl).
Place cartridge containing component A into bonding gun
Place cartridge containing component A (Hl) into bond- ing gun (C).
Remove screw-on cap from mixing cartridge (H3).
Press component A into mixing cartridge
Insert filling nozzle (H9) of cartridge containing com- ponent A (Hl) into mixing cartridge.
Press component A into mixing cartridge (H3) using the bonding gun.
Open screw-on fitting of cart- ridge containing component B
Use a knife to cut off the tip of the nozzle fitting of the cartridge containing component B (H2).
Screw injector nozzle onto cartridge cont. component B
Screw injector nozzle (H7) onto cartridge containing component B (H2).
Place cartridge containing component B into bonding gun
Place cartridge containing component B (H2) into bonding gun (C). l
64 - 26 Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXVII, 1991
a
928 Glasses/Window Contml
64
No.
33
34
35
36
37
38
Operation
Press component B into mixing cartridge containing component A
Close mixing cartridge
Screw mixing rod into mixing cartridge
Mix component A and component B
Engage mixing disc into piston
Place mixing cartridge into bonding gun
Instructions
Introduce injector nozzle (H7) of cartridge containing component B (H2) into mixing cartridge (H3).
Use the bonding gun (C) to press component B (H2) into mixing cartridge (H3) containing component A.
Pull injector nozzle (H7) out of mixing cartridge (H3) and close mixing cartridge with screw-on cap.
Screw mixing rod (G) manually into internal thread of mixing disc in the mixing cartridge (H3). Clamp other end of mixing rod into a drill chuck.
Fit the drill into a suitable clamping device.
Switch on drill (900 to 1200 mm) and rotate mixing car- tridge 25 times from stop to stop.
Perform all 25 double strokes fairly rapidly.
Pull back mixing cartridge until a rattling sensation is feit.
Switch off drill and screw mixing rod out of mixing car- tridge.
The mixing disc will then engage into the piston of the mixing cartridge.
Insert mixing cartridge with mixed 2-pack windshield adhesive into bonding gun.
Screw application nozzle (H8) onto mixing cartridge.
Caution: Open time is 15 minutes!
Open time Is the time available for application of the adhesive and for installing the wlnd- shield Into the aperture in the body.
Removing and Installing wlndshleld - 2-pack adhesive
Printed in Germany - XXVII, 1991
64-27
64
Glasses 920
Installing the windshield:
No.
39
Operation
Apply windshield adhesive to the windshield
Instructions
Using the bonding gun (C), apply a trapezoidal con- tinuous bead of windshield adhesive to the bonding area of the windshield.
Position twin-cup suction pullers on outside of windshield
Insert spacer blocks
40 Insert windshield into body aperture
Clean visible areas
Insert spacer blocks for positioning of bottom of windshield into body (cowl panel).
Place prepared windshield into aperture in body, align and press into place using the twin-cup suction pullers
(B). Make sure the bottom of the windshield rests on the spacer blocks.
Remove adhesive that has squeezed out immediately and clean the affected visible areas using cleaning solution (G5).
Remove cover from the instrument panel
Install A-pillar linings
Install A-pillar linings, clip headlining into place by press- ing up and fit sheetmetal screws.
@
Fff interior rearview mirror
Fit sun visors
Push interior rearview mirror onto subplate, following a line parallel to the windshield.
Using three raised countersunk sheetmetal screws per side, install sun visor support with RH and LH sun visors.
64-28 Removing and installing windshield - 2-pack adhesive
Printed In Germany- XWll,1991 l
928
No. Operation
Fit cowl panel
Fit upper cover molding
Fit drip molding
Fit windshield
Glasses
64
Instructions
Put cowl panel complete with weatherstripping into place and screw in hex sheetmetal screws with washers. Tighten right-hand and leh-hand sides of cowl panel with one sheetmetal screw and washer each.
Attach adhesive strips and sealing strips. Install upper cover molding complete with sleeves to the locating clamps.
Push RH and LH drip moldings onto the retaining rails. Push sleeves into place to ensure smooth transl- tion of upper cover molding to RH and LH drip moldings.
Position windshield wipers, put washers into place and tighten using hexagon nuts. a
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 3 hours
Temperature min. 5°C
Do not operate the vehicle before the curing time has elapsed!
Removing and installing windshield - 2-pack adhesive
Prlnid In Germany - XXVII,1991
84 - 29
a
928 Glasses
Removing and installing bonded rear side window - 2-pack adhesive
The following tools and materials are required for removal and installation of the bonded rear side window:
64
Cutter
Twin-cup suction puller
Bonding gun
Flashing knife
Cutting knife, cranked
Mixing cartridge 9528
G
Gl
Adhesive set
- Cartridge component A
G2 - Cartridge component 6
G3 - Mixing cartridge
G4
G5
G6
- Primer
- Cleaning solution
Injector nozzle
G7
GE
G9
- Application nozzle
- FiNing no&e
- Touch-in tool
VAG 1561
VAG 1344
VAG 134411
639.031.130.22
639.031.030.17
000.721.952.80
000.043.038.01
VW Werk AG
Service equipment supply e.g. C & E FEIN GmbH & Co.
P.O. Box 172 ; D-7000 Stuttgart 1
Porsche Parts Service
Removing and installing bonded rear side window - 2-pack adhesive
Prlnled In Germany - XXVII,1 991
64- 31
64
Glasses
Removing and installing bonded rear side window - 2-pack adhesive
928
64 - 32 Removing and installing bonded rear side window - 2-pack adhesive
Printed in Germany - DXll,1491
64
Removing and installing bonded rear side window - 2-pack adhesive
Glasses 926
64 - 32 Removing and installing bonded rear quarter window - 2-pack adhesive
Printed in Germany - XXYII,I991
a
92s Glasses
64
Removing and installing bonded rear side window - 2-pack adhesive
Removing the rear side window:
1
2
3
4
5
No. Operation
Pull away trim molding
- upper corner section
- upper trim section lower comer section lower trim sect/on
Cut through rubber sea/
Instructions
Using a wooden or plastic spatula, carefully lift trim molding out of the window rubber, starting in the corner section area. Place a rag between trim molding and rub- ber seal and pull out molding by pulling the rag along the rubber seal.
Insert cranked knife (E) into cutter (A). Using a grincl- stone, sharpen the cutting knife with the equipment run- ning. Engage cutting knife into rubber seal, set vibration regulator to stage 6 and cut rubber seal in a continuous line between rear side window and body.
6 Lift out rear side window
Lf remains of rubber seai off the body
7 Attach adhesive to body tape Cover body In visible area of window aperture with adhesive tape to protect the paintwork.
6 Remove from body adhesive sea/ant Insert flashing knife (D) into cutter (A) and remove adhesive only to the extent that the remaining adhesive covers the whole area in a uniform manner.
Removing and installing bonded rear side window - 2-pack adhesive
Printed in Germany - XXVII,1 991
64-33
64
No. Operation
Clean window aperture in body
Apply primer to damaged areas of body
Remove adhesive sealant from rear side window
Clean rear side window
Clean rubber seal
Glasses
Instructions
Clean window aperture of body thoroughly using clean- ing solution (65).
Attention: Make sure no cleaning solution residues remain on the bodywork.
Use primer (G4) to coat damaged paintwork areas In non-visible section of window aperture.
Using a fixed knife, remove adhesive residue carefully from rear side window. A thin coating of adhesive cover- ing the bonding surface in a uniform manner may remain.
Clean rear side window thoroughly using cleaning solution (G5).
Attention: Make sure no cleaning solution residue remains on the wlndow.
Clean window channel of rubber strip using cleaning solution (G5).
Attention: Make sure no cleaning solution residue remains in the window channel.
64-34 Removing and installing bonded rear side window - 2-pack adhesive
Germany l
- xxVll,1991
928 Glasses /Window Control
Preparing the adheslve cartridge for application of adhesive
64
No.
9
10
13
14
15
16
17
Operation lnstructlons
Open nozzle fitting of cartridge Use a screwdriver to pierce the diaphragm in the nozzle containing component A fitting of the cartridge containing component A (Hl).
Open flanged cover of cartridge Use the screwdriver handle to pierce the flanged cover containingcomponent A at the end of the cartridge containing component A (Hl)
Screw filling nozzle onto cart- Screw filling nozzle (H9) onto cartridge containing ridge containing component A component A (Hl).
Place cartridge containing Place cartridge containing component A (Hi) into bond- component A into bonding gun ing gun (C).
Remove screw-on cap from mixing cartridge (H3).
Press component A into mixing cartridge
Insert filling nozzle (H9) of cartridge containing com- ponent A (HI) into mixing cartridge.
Press component A into mixing cartridge (H3) using the bonding gun.
Open screw-on fitting of cart- Use a knife to cut off the tip of the nozzle fitting of the ridge containing component B cartridge containing component B (H2).
Screw injector nozzle onto cartridge cont. component B
Screw injector nozzle (H7) onto cartridge containing component B (H2).
Place cartridge containing Place cartridge containing component B (H2) into component 0 into bonding gun bonding gun (C).
Press component B into mixing cartridge containing component A
Introduce injector nozzle (H7) of cartridge containing component B (H2) into mixing cartridge (H3).
Use the bonding gun (C) to press component B (H2) into mixing cartridge (H3) containing component A.
Removing and installing windshield - 2-pack adhesive
Printed in Germany - XXVII, 1991
64 - 35
64
Glasses / Window Control
No.
18
19
20
21
22
Operation
Close mixing cartridge
Screw mixing rod into mixing cartridge
Mix component A and component 6
Engage mixing disc piston into
Place mixing cartridge into bonding gun
Instructions
Pull injector nozzle (H7) out of mixing cartridge (H3) and close mixing cartridge with screw-on cap.
Screw mixing rod (G) manually into internal thread of mixing disc in the mixing cartridge (H3). Clamp other end of mixing rod into a drill chuck.
F) the drill into a suitable clamping device.
Switch on drill (900 to 1200 rpm) and rotate mixing car- tridge 25 times from stop to stop.
Perform all 25 double strokes fairly rapidly.
Pull back mixing cartridge until a rattling sensation is felt.
Switch off drill and screw mixing rod out of mixing car- tridge.
The mixing disc will then engage into the piston of the mixing cartridge.
Insert mixing cartridge with mixed 2.pack windshield adhesive into bonding gun.
Screw application nozzle (H8) onto mixing cartridge.
Caution: Open time is 15 minutes!
Open time is the time available for application of the adhesive and for installing the wlnd- shield into the aperture in the body.
920
64 - 36 Removing and Installing windshield - 2-pack adhesive
Printed in Germany - XXVII, 1991
a
926 Glasses
64
Installing the rear quarter wlndow:
No.
23
24
25
Operatlon
Apply window adhesive to the window channel of the rubber seal
Place rubber seal onto rear side window
Assemble trim molding to rubber seal
26 Place assembly cord into rubber sea/
Instructions
Place cartridge with window adhesive into bonding gun
(C) and apply a continuous bead of adhesive to the win- dow channel of the rubber seal.
Press upper trim sectlon (2) into rubber seal.
Assemble lower trim section (4) to upper corner section
(1) and lower corner section (3) press into rubber seal, assemble to upper trim section (2) and press fully assembled trim molding fully into rubber seal.
Place assembly cord for fitting of the rear side window into the rubber seal.
The ends of the cord must cross each other near the middle of the C-pillar area.
27
Remove adhesive tape from body
Apply window adhesive to the body
FL rear side window to body
Using the bondlng gun (C), apply a continuous bead of window adhesive to the window aperture area to the body.
Place assembled and prepared rear side window into the window aperture, align and press into place.
Working from passenger compartment side, slowly pull out the assembly cord to align the rubber seal to the body flange.
Removing and installing bonded rear side window - 2-pack adhesive
Printed in Germany - XWll,1991
64-37
No. Operation
Clean visible areas
Glasses 929
Instructions
Remove adhesive that has squeezed out immediately and clean the visible areas affected using cleaning solu- tion (G5).
64 - 38 Removing and installing bonded rear side window - apack adhesive a xxvll,1991
928
Standard: india red talbot yellow continental orange fern green olive green albert blue cockney brown mecca black cashmire beige black grand prix white
Exterior Equipment/Paint
408
451
502
700
908
027
106
107
273
274
387
PAINT COLORS - 1978
Special: oak green metallic silver green metallic lint green metallic minerva blue metallic petrol blue metallic brown copper metallic silver metallic
265
266
275
304
376
443
936
66
Standard: india red talbot yellow olive green arrow blue cockney brown mecca black cashmire beige lilac black grand prix white
027
106
274
305
408
451
502
601
700
908
PAINT COLORS - 1979
Special: oak green metallic lint green metallic light blue metallic minerva blue metallic petrol blue metallic brown copper metallic opal metallic tobacco metallic black metallic silver metallic
265
275
30T
304
376
443
463
464
708
936
Printed in Germany -VI. 1982 Paint Colors from 1978 Models 66 01
66
Exterior Equipment/Paint
Standard: india red talbot yellow olive green arrow blue cockney brown mecca black cashmire beige lilac black grand prix white
027
106
274
305
408
451
502
601
700
908
PAINT COLORS - 1980
Special: oak green metallic lint green metallic light blue metallic minerva blue metallic petrol blue metallic brown copper metallic opal metallic tabacco metallic black metallic silver metallic
265
275
30 T
304
376
443
463
464
708
936
Standard: india red arrow blue mrxxa black black chiffon white bamboo beige burnus brown mint green grand prix white
027
305
451
700
182
523
524
20 A
908
PAINT COLORS - 1981
Special: light blue metallic minerva blue metallic black metallic tin metallic platinum metallic pacific blue metallic palisander metallic moss green metallic wine red metallic
30 T
304
708
956
655
31 G
474
20 c
895
66-02 Paint Colors from 1980 Models Printed in Germany a
928 Exterior Equipment/Body
RANGE OF BODY PAINT COLORS AS FROM 1982 MODELS
Standard Colors: guards red royal blue mocha brown black chiffon white bamboo beige caramel brown mint green grand prix white
027
305
451
700 is2
523
524
20A
908
Special met. light blue met. minerva blue met. black met. pewter
Colors: met. platinum met. pacific blue met. rosewood met. “lOIS green met. wine red met. meteor grey met. light bronze
Paint
30T
304
708
956
655
31G
474
2oc
895
961
966
66
RANGE OF BODY PAINT COLORS AS FROM 1983 MODELS
Standard Colors: guards red black grand prix white glacier blue
027
700
908
322
Special Colors: met. pewter met. platinum met. “Km green met. slate blue met. quartz gray met. kiln red met. ruby red met. light bronze
956
655
2oc
661
662 ail at0
966
Printed in Germany VIII, 1984 Range of Body Paint Colors es from 1982 Models 66-03
66
Exterior Equipment/Body Paint
RANGE OF BODY PAINT COLORS AS FROM 1984 MODELS
Standard india red black grand prix white glacier blue chiffon white
Colors:
027
700
908
322
182
Special Colors: met. pewter met. platinum met. moss green met. slate blue met. quartz gray met. kiln red met. ruby red met. light bronze
928
661
662
811
810
956
655
2oc a
66-04 Range of Body Paint Colors as from 1984 Models Printed in Germany a
928 Exterior Eq uipment/Body Paint
66
Standard guards red black grand prix white l pastel beige marble gray
Colors:
RANGE OF BODY PAINT COLORS AS
FROM 1985 MODELS
027
700
908
536
673
Special Colors: met. nutmeg brown met. garnet red met. iridescent blue met. saphire blue met. crystal green met. white gold met. silver met. moss green met. meteor gray
33x
33N
539
936
2oc
961
492
822
33P
Printed in Germany X, 1984
Body Paint Colors
- 1985 Models
66 . 05
66 Exterior Equipment/Body Paint
RANGE OF BODY PAINT COLORS, 1986 MODELS ONWARD
Standard pastel beige marble gray india red grand prix white black dark blue
Colors:
536
673
027
908
700
347
Special Colors: nutmeg brown - metallic garnet red - metallic iris blue - metallic prussian blue - metallic cristal green - metallic white gold - metallic silver - metallic moss green - metallic meteor - metallic
492
822
33P
33x
33N
539
936
2oc
961
928
66 - 06 Range of Body Paint Colors,
86 Models Onward
XIII, 1986 - Printed in Germany l
l
928 Exterior Equipment
Body paint colors model 1987 onward
Standard:
Grand prix white
Black
Dark blue
Cherry red
Lemon yeilow
Ceramic beige
Turquoise
Guards red
908
700
347
80F low
499
21M
8OK
Special:
Silver - metallic lagoon green - metallic
Rock green - metallic
Nougat brown - metallic
Diamond blue - metallic
Espresso brown metallic
Marine blue metallic
Venice blue metallic
Cassis red metallic
Body paint colors model 1988 onward
Standard:
Grand prix white
Black
Dark blue
Cherry red
Lemon yellow
Ceramic beige
Turquoise
Guards red
908
700
347
8OF low
499
21M
8OK
Special:
Silver metallic
Lagoon green - metallic
Rock green - metallic
Nougat brown - metallic
Diamond blue - metallic
Espresso brown metallic
Marine blue metallic
Venice blue - metallic
Cassis red _ metallic
35Y
699
40B
697
40D
35v
(36P) 35U
980
35Y
699
408
697
40D
35v
36P
8oD
66
Body paint colors hinted in Germany - XXIV, 1989
66 - 07
66
Exterior Equipment
Body paint colors model 1989 onward
Standard:
Grand prix white
Black
Dark blue
Guards red
Linen
Apricot-beige
Murano green
908
700
347
8OK
6OM
548
22c
Special:
Silver - metallic
Diamond-blue metallic
Dove-blue metallic
Stone-grey metallic
Slate metallic
Valvet-red metallic
Linen metallic
Pine-green metallic
Cognac-brown metallic
Salmon-silver metallic
81L
550
22E
4OL
81K
980
697
378
693
22D
929
66-08 Body paint colors
Printed in Germany - XXIV, 1989
926 Exterior equipment
Body paint colors model 1990 onward
Standard:
Grand prix white
Black
Dark blue
India red
Linen
Apricot-beige
Murano green
908
700
347
80K
60 M
548
22 c
Special:
Silver metallic
Diamond-blue metallic
Dove-blue metallic
Pepple-grey metallic
Slate metallic
Velvet-red metallic
Linen metallic
Pine-green metallic
Cognac-brown metallic
Salmon-silver metallic
693
22D
81L
550
22E
4OL
61K
980
697
378
66
Body paint colors model 1990 onward
Printed in Germany - XXV, 1990
66 - 09
66
Exterior equipment
Body Paint Colors Beginning With 1991 Models
Standard Colors: Special Colors:
Grand Prix white
Black
Maritime blue
Indian red
Signal green
Mint green
Rubystone red
908
700
388
80K
22s
22R
82N
Polar silver metallic
Polar silver metallic
Horizon blue metallic
Cobalt blue metallic
Oakgreen metallic
Slate gray metallic
Slate grey metallic
Coral red metallic
Black pearl effect
Midnight blue metallic
Midnight blue pearl effect
Amethyst pearl effect
92 E
92 M’
37 x
37 u
22 L
22 D
23 F
82 H
738
37 w
39 c
38 A
Amethyst pearl effect
Amazon green pearl effect
83 K
37 2
Amazon green pearl effect 39 A
* = Water-base paints
Waler base paints are applied exclusively by the manufacturer during production spraying. For repair of watwer-base paints, conventional respray paints matching the color of the original paint are used.
I.e. the only prerequisite for resprays is that the correct respray paint is used (refer to Paint Manual, page L3 - 25). Color differences due to paint application do no occur.
928 l
66 - 010 Body Paint Colors Beginnlng With 1991 Models
Printed in Germany - XXVII, 1991 a
928 Exterior equipment
Body Paint Colors Beginning With 1992 Models
Standard Colors:
Grand Prix white
Black
Maritime blue
Indian red
Signal green
Mint green
Rubystone red
908
700
388
80K
22s
22R
82N
Special Colors:
Polar silver metallic
Polar silver metallic
Horizon blue metallic
Cobail blue metallic
Oakgreen metallic
Slate gray metallic
Slate grey metallic
Coral red metallic
Black pearl effect
Midnight blue metallic
Amethyst pearl effect
Amethyst pearl effect
Amazon green pearl effect
92 E
92 M
37 x
37 u
22 L
22 D
23 F a2 H
738
37 VP
38 A a3 K
39 A
66
* = Water-base paints
Body Paint Colors Beginning With 1992 Models
Printed in Germany - XXVII, 1991
66-011
928 Exterior Equipment - Painting
REMOVING AND INSTALLING SIDE GUARD STRIPS
66
Removing
1. Pull off rubber door wearherstrip at rear in area of lock and loosen nun of moulding strip. All other mountings are by pins in sockets and ad- hesive strips.
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3. Used side guard snips can be used again. if the old adhesive strips are pulled off and new double- sided adhesive foam rubber strips are installed
(3 M. Art. No. 4262. IO mm wide). The primed adhesive surface of the strip must not be washed!
4. Replace damaged sockers and make sure rhar tongues engage behind the metal edge.
2. Loosen strips at one end, pull out pins and then detach strips by pulling at a sharp angle. Do not bend off toward the outside, since this would deform the steel insert in rhe strip and the srrip could no longer be used. Press out pins on orher end of srrip carefully.
Installing
1. Clean body in working area thoroughly. with alcohol and clean cellulose. Ambient and ob- ject remperature must be at least + 20’ C.
2. Press sockers into the 10 mm dia. holes.
3. Position side guard strips for the differenr sections and heat the strips to about 60’ C to improve the adhesive force.
Printed in Germany- III. 1979 Removing and Installing Side Guard Strips 66 - 1
66
Exterior Equipment - Painting
4. Peel off paper backing from adhesive surface and do not touch the adhesive surface.
5. First install the door’s side guard strip. Guide the strip into rhe sacker or hole with help from another person. without Ierring the adhesive surface make contacr, so that the strip can be aligned. Press on strip firmly with a rubber roller or soft cloth (pressure about 70 - 80 N/
1 - 8 kp). Install a washer and nur on rhe
Threaded pin and press in rhe rubber door weatherstrip.
6. Align from and rear mating strips with door’s strip and press on as for door’ s strip.
66 - 2 Removing and Installing Side Guard Srrip
Printed in Germany
m
66
928
SERVICE INSTALLING
Exrerior Equipment - Painting
SIDE GI’ARD STRIPS
When service installing these strips. first draw rhe door’s strip on the door according IO specified dimen- sions and then align and drill holes for the fender’ I strips.
Drill 10 mm dia. holes for the sockets and one
6.5 mm dia. door hole at rear.
In longitudinal direction drill holes that rear door hole is at center of seal recess and all strips begin about 3 fo 4 mm behind [he door OI fender edge.
Height disrances:
Distance A = 200 mm
(ourer edge of door shoulder to center of strip)
Distance C = about 18 mm
(fender opening to center of strip)
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Press in sockets and make sure that tonguer engage behind metal edge. r/
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Distance B = 48 mm
(lower edge of grip plate to cemer of strip)
Printed in Germany - III. 1919 Service Insralling Side Guard Srrips 66 - 3
928 Exterior Equipment / Body Paint
66
8
!I
Bolt M 6 x 25 screw 5.5 x 16
Printed in Germany - IV, I!IBO
4
3
Warch locarion I” air inler grill
Warch rhreads in radiator grill, use studs if necessary
Removing and lnstallmg From Spoiler !rZR s 66 - 5
66
Exrerior Equipmenr / Rody Palnr
FRONT SPOlLER 1128 S REMOVING AND INSTALLING
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Removing
1. Unscrew and remove wheel well cover and holder (arrow).
,.
2. Unscrew mourning brackets in air ducts from fender supporrs and pull our the air ducrr. a
Also pull oil a,r gu,de hose from airernaior on lefl side.
3. Unscrew front spoiler at fender. plarric part and air inlet grill. Remove front spoiler.
4. Pull oui air inlet grill downward.
Disconnect outride remperarure sensor plug
(air conditioner).
66 - 6 Removing and lnrralling From Spoiler !I28 s
Printed in Germany
928 lnsralling
Exterior Equipment
1. Push air inlet grill inro openings from below.
In case of new trim mark openings according
IO dimensions (58 mm up to opening) and make up template for air inlet grill.
/ Body Pain,
66
3. lnserr air ducts and press L” from top and bol- tom guide rabs an air inlet grill and front spoiler.
Mount bracket on fender supporr with meral screw.
- a
Cur out openings with a piercing saw or metal shears and, if necessary, smooth edges with a wood grater or file.
2. Install front spoiler. making sure of clean fit an fender conrour and radiaror grill. Secure studs with self-locking nuts. Mourn from spoiler to left and righr of air inlet grill with brackets.
4. Install wheel well cover and secure with washers and 5.5 x 16 mm meral screws.
Place and secuxe spacer behind fender rim
On left side also mounr air guide hose on wheel well coveI. a
Primed inGermany - IV, 1980 Removing and lnsrallinp Front Spoiler ,128 s 66 - 1
66
Exterior Equipment / Body Paint
Secure plug on outside temperature sensor wirh a hose clamp and connect with the wire harness.
Prime coat entire new fender supports and apply a coal of undercoating. Install with self- lowing meta, ““10.
928
Route air guide hose undernearh the air duct between the side member and cowl panel bracker, and connect on the alternaror.
66 - 8 Removing and Installing From Spoiler ‘128 S
Printed in Germany a
l
928
REMOVING AND INSTALLING
Exterior Equipment
REAR SPOILER 928 S
/ Body Paint
66
Removing Rear Spoiler on Lid
1. Remove lid lock and rear window wiper.
2. Pull spreader rivers out of lid trim panel.
4. Pull down side trim panel secrionr. disconnecr- ing wires at same rime.
3. Press bottom of trim panel off of lid frame along window.
5. Unscrew all accessible Phillips screw (12) on inside of lid and two M 4 nuts on UI)D~~ part of spoiler (arrows).
0
Printed inGermany - IV- 1980 Removing and Installing Rear Spoiler 928 S 66 - 9
66
Exterior Equipment / Body Painr
Installing
928
3. Install rear spoiler. Mounr with 4. 2 x 32 mm metal screws and washers. Watch for neat fit on lid. Use IWO M 4 nun and above mentioned washers at upper part.
1. Check metal nuts inserted in the rear spoiler. replacing missing or damaged metal nun.
4. Install side lid trim secrions. Press defogger wires underneath retaining tabs on outside.
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2. Check that spacers on lid are posirioned car- rectly to bores in lid. Seal and secure loose spacers wirh Terostar 33 (Teroson) silicone adhesive.
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Make sure all retaining tabs engage correctly in rhe metal clips.
Align trim panels with lid frame and secwe with new spreader rivets. a
66 - 10 Removing and Insralling Rear Spoiler 928 S
Printed in Germany a
928 Exterior Equipment / Body Paint
5. Insert, align and secure lower trim panel with
6 spreader rivets.
Removing Side Rear Spoiler
66
1. Lift spoiler with a narrow purry knife about
5 cm behind the spoiler’s front edge enough that rhe Phillips screw undernearh is access- ible and can be unscrewed.
2. Provide access to second metal screw (arrow) about 25 cm behind spoiler’s front edge and
Iemwe screw.
3. Unscrew bracket on inner frame. Remove spoiler. l
Installing
6. Insrall lid lock. Seal off ourside of lock cylindel against upper escutcheon with a permanently elastic sealanr.
Install and secure rear window wiper parallel to side window strip.
1. Insert side fear spoiler and install covered
4.2 x 9. 5 mm metal screws.
Check clearance between meral screw and ornamental strip at front holding block, cutting out the ornamental strip in the broken line area if necessary.
Printed inGermany - IV, 1960 Removing and Insralling Rear Spoiler 928 S 66 - I1
66
Exterior Equipmenr / Body Paint
2. Mount seal on inner frame. Mount bracket on inner frame with M 6 x 16 oval head screw and on spoiler with M 6 x 10 hex. head screw wirh washer.
4. Check side spoiler for uniform fir to lid- mounted spoiler and correct adjusrment. if necessary.
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3. Check fit of spoiler on rear side section and window frame. If necessary, correct by apply- ing light knocks against mounting surfaces with a piece of wood. Tighten bolts.
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66 - 12 Removing and Installing Rear Spoiler !I28 S Printed in Germany a
a
926
REMOVING AND INSTALLING OUTSIDE MIRROR
1. Pry off clips on mirror glass with a putty knife on backplate and disconnect contact plugs on glass carefully.
Exterior Equipment
66 a
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2. Unscrew 3 screws through holes in backplate, take off foam rubber part and pull off wire plugs.
4. Unscrew fillister head screw on mirror base IO that mirror can be removed with the liner.
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5. Install in reverse order
3. Note wire positions in receptacle by colors.
Press in locks on each wire plug separately with an extraction tool and pull out wires.
6. If wire harness in door has to be removed, take off inside door trim panel and take harness out of holders. l
Printed in Germany - VI, 1982 Removing and Installing Outside Mirror 66-13
66
Exterior Equipment
928
8. When installing, make sure wire harness is secured with the provided holders and cannot contact the door window glass.
7. Disconnect plug underneath instrument panel, press out wires on outside door mirror with an extraction tool and pull out wire harness. j i i 1’” &/, n- i
66-14 Removing and Installing Outside Mirror
Printed in Germany a
a
928 Exterior Equipment
SERVICE INSTALLING OUTSIDE MIRROR ON PASSENGER’S DOOR
1. Remove inside trim panels on doors. Pull off door plastic sheets partially. Remove outside mirror and wire harness on driver’s door.
2. Paint mirror set to match body color of car.
3. Insert guide tube with spring and centering plates and torque to 15 + 3 Nm I130 + 2h.lbl with a multiple socket wrench.
66
5. Push threaded insert into door reinforcement and hold with a rollpin.
4. Mark location of hole on door outside panel according to specified dimensions, punch mark and drill 16 mm and 22 mm dia. holes with a standard compass saw. Cut out and file opening with suitable tools.
Caution!
Do not damage ment. door reinforce-
6. If necessary. align door reinforcement on door outside panel. Fit in mirror base, correcting drilled holes if necessary. Make sure of proper fit.
7. Install new wire harnesser from inside of door to outside and pull into mirrors. Mount mirrors and liners on doors with fillirter head screw.. which are torqued to 5.6 Nm 14 ftlb). a
Printed in Germany VI. 1982 Service Installing Outside Mirror on Passenger’s Door 66-15
66
Body Equipment
-
Right multiple pin plug (passenger’s side)
Rear view:
928 a
6. Wire harnesses must be secured in holders provided in a manner to prevent contact with the door window.
16
14
11
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46
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Terminal 66 = blue
Terminal 7 = white
Terminal 8 = black
Terminal 9 = gray/green
Terminal 16 = brown
9. Insert wires harnesses through guides and press into plug connections according to sketches.
66.16 Service Installing Outside Mirror on Passenger’s Door Printed in Germany
l
928
Left Multiple Pin Plug (Driver’s Side)
Rear view:
Exterior Equipment
Mirror multiple pin plug (passenger’s side)
Rear view:
66
6
5
1
2
3 a
Terminal 6 = blue
Terminal 7 = white
Terminal 8 = black
Terminal 9 = gray/green
Terminal 10 = white/red
Terminal 16 = brown
10. Press wires in mirrors into round male plugs according to sketches.
Terminal 1 = blue
Terminal 2 = black
Terminal 3 = gray/green
Terminal 4 = brown
Terminal 5 = brown
Terminal 6 = white
Printed in Germany VI, 1982 Service Installing Outride Mirror on Passenger’s Door 66-17
66
Exterior Equipment
Mirror multiple pin plug (driver’s door1
Rear view:
6
5
1
2
3
11. Compress wire plugs and secure with self- adhesive tape.
928
12. Mount cover with mirror glass carrier, connect and insert mirror glass.
Terminal 1 = black
Terminal 2 = yellow
Terminal 3 = gray/green
Terminal 4 = brown
Terminal 5 = brown
Terminal 6 = white
66-18 Service Installing Outside Mirror on Passenger’s Door
Printed in Germany a
928
13. Lift off knob on outside mirror switch and unscrew threaded sleeve with Special Tool 9209
Exterior Equipment
66
14. Remove outside mirror switch and disconnect plug. Cut out hole for switch. Insert switch in clips and connect with wire harness.
15. Paste plastic sheets on doors. Connect electric wires between door trim panels and wire harnesses with each other and install door trim panels,
Printed inGermany. VI. 1982 Service Installing Outside Mirror on Passenger’s Door 66.19
66 Exterior Equipment/Body Paint
REMOVING AND INSTALLING SILL COVERS
Removing l.Use a hot-air blower to heat sill cover on door to approx. 7O"C, carefully detach with a suitable tool and pull off.
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2.Remove sill strip mounting screws from front fender, use a hot-air blower to heat sill strip to approx. 7O"C, carefully detach, unclip and remove.
3.Remove screw holding cover strip in place.
928
66 - 20 Removing and Installing
Covers
Sill XIII, 1986 - Printed in Germany a
928
4.Unclip trim strip and remove upper securing screws of sill cover.
Exterior Equipment 66
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6.Remove sill cover securing nuts and remove cover from car.
5.Remove lower securing screws from sill cover; where cover is held by adhesive, use hot-air blower to heat cover to approx. 7O"C, carefully detach and pull off. b *%--
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Printed in Germany - XIII, 1986 Removing and Installing
Covers
Sill 66 - 21
66 Exterior Equipment
7.Lay sill cover on a level sur- face. To avoid damaging finish, place soft material beneath strip. Heat adhesive tape with hot-air blower to approx. 70°C and rub tape off.
928
9.Use a hot.air blower to heat ad- hesive tape on sill cover to approx. 70°C and rub off.
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Installing l.Check all sill cover securing points, renew if necessary.
8.Use hot-air blower to heat adhesive strips on fender sill cover to approx. 70°C and rub off.
66 - 22 Removing and Installing Sill Covers Printed in Germany a
-
928 Exterior Equipment 66
2.Clean sill covers with methylated spirits and a closed-cell cloth and apply new adhesive tape.
Note:
Never use tape older than 1 year, see date of manufacture. a
4.Carefully clean body with methylated spirits and closed- cell cloth in the area around the sill cover.
5.Peel protective backing from ad- hesive strips. Do not touch the adhesive surfaces.
6.Installation of the sill covers is the reverse of the removal procedure. Check that the height of the door-sill cover at front and rear corresponds to that of the other sill covers. jF
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3.Install cover strip. Check that gap between door and strip is uniform throughout its length.
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Printed in Germany - XIII, 1986 Removing and Installing
Covers
Sill 66 - 23
66 Exterior Equipment
7.Complete installation by pressing the sill covers firmly along the adhesive strip with a rubber roller.
928
8.The ambient and vehicle temper- atures must be at least 20°C.
9.After reapplication of adhesive sill strips, do not wash the car or apply preserving agents for at least 24 hours.
66 - 24 Removing and Installing Sill Covers Printed in Germany
928 Exterior Equipment 66
REMOVING AND INSTALLING REAR
SPOILER
Removing 3.Check hinges, renew if necessary.
Installing l.Open tailgate, remove spoiler securing screws and lift spoiler off tailgate. l.Using new screws, attach hinges i . a J. to spoiler.
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2.To protect paintwork, cover tail- gate with adhesive tape.
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2.Place spoiler on a soft surface, unscrew securing screws from hinges and remove hinges from spoiler.
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3.Inspect adhesive membrane which protects paintwork, renew if necessary, remove all traces of adhesive with methylated spirits and a closed-cell cloth.
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Printed in Germany - XIII, 1986 Removing and Installing
Spoiler
Rear 66 - 25
66 Exterior Equipment 928
4.When the new adhesive membrane is applied, the holes in the membrane must align exactly with the holes in the tailgate.
.
6.To adjust, disengage spoiler, slacken screws and adjust on both sides until spoiler holders engage simultaneously without spoiler touching tailgate.
5.Set spoiler on tailgate and secure with new micro-encap- sulated screws and washers.
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66 - 26 Removing and Installing Rear Spoiler Printed in Germany a
928 Exterior Equipment
REMOVING AND INSTALLING FRONT Ala
DAM
Removing l.Remove securing screws.
2.Pull front air dam horizontally off mounting clamps.
66
3.Press air dam down and remove the inner securing screws.
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Printed in Germany - XIII, 1986 Removing and Installing
Front Air Dam
66 - 27
66 Exterior Equipment
Installing l.Prior to installation of the front air dam, inspect all securing points and renew as necessary.
928
3.When pressing the front air dam into the securing clamps, check that the lower edge of the air dam engages the foremost holder on the transverse member.
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2.Installation is the reverse of the removal procedure.
66 - 28 Removing and Installing Front Air Dam Printed in Germany l
929 Exterior Equipment
66
Fitting the CLUB SPORT emblem
Note
The temperature of the vehicle and that of the foil must be at least 20°C when fitting the emblem
1. Remove any dirt from the area involved and clean with methlated spirit.
2. Dampen the area on the fender with a 50 % alcohol - water solution to ensure that the foil does not stick immediately when positioning.
3. Pull the beige protective paper from the foil and lay the foil on the edge of the fender.
Using a plastic spatula or similar, smooth out the moisture from the center outwards.
Make sure that no air bubbles remain trapped. z
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5. Pull the outer protective paper from the foil. Jr * r-” . ..w
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Fitting the CLUB SPORT emblem
Printed in Germany - XX, 1999
66-29
66
Exterior Equipment
6. Puncture any remaining air bubbles with a needle and press down the foil.
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928
88 - 30 Fitting the CLUB SPORT emblem
Printed in Germany-XX, 1989 a
928 Exterior Equipment
66
Retrofitting new mirror generation for vehicles as of MY ‘87
Note
Only for vehicles fitted with door mirrors on driver’s and passenger’s side.
1. Remove door mirror.
2. Assemble new door mirror.
3. Cut wire at mirror to required length (con- nectar is engaged into the reinforcement plate). a 4 Install new connectors and engage into con- nectar housing half according to below list.
1 -white
2 - blue
3 - black
4 red
5 brown
6 - brown
Vehicles with seat memory require an addition- al 4-pin connector (connector sockets).
1 - grey
2 green
3 - pink
4 yellow
On vehicles without seat memory, the wires not required are tied out of the way.
5. Fit mirror (route wire through stud into mir- ror housing).
6. Engage connector into connector housing half.
7. Assemble both connector housing halves and lock connector housing (6-pin) in the reinforcement plate (the 4-pin connector housing is tied out of the way).
6. Fit mirror glass. l
Retrofitting new mirror generation for vehicles as of MY ‘87
Printed in Germany - XXXI, 1993
66 - 31
928
REMOVING AND INSTALLING REAR SIDE TRIM PANEL
Interior Equipment
1. Disconnect and remove luggage compartment cover. tool plate, floor mat, spare wheel cover, edge guard on B pillars, parking brake cable cowr, emergency seat cushions and backrests.
2. Remove seat belt on side member and seat well at outside (arrows).
68
3. Remove escutcheon for seat belt and grab handle
(arrows).
5. Install in reverse order.
6. Make sure trim panel engages in proper holders in area of wheei house.
4. Remove screws (arrowsl and pry off trim panel at top with a suitable tool lcliprl and pull forward slightly. Pull off radio speaker wires, slide seat belt through opening and remove trim panel.
Printed in Germany VII. 1983 Removing and Installing Rear Side Trim Panel 68.1
a
926 Interior Equipment
68
Safety regulations for handling airbag vehicles
The airbag units are pyrotechnical objects of danger class T 1. Handling, transport and storage are subject to the Law on Explosives.
The listed legal regulations apply to the Fad- eral RepuMic of Germany. The respectively ap- plicable regulations must be observed in all other countries.
The start of work with pyrotechnical objects must be reported to the trade board (re- sponsible authority) 14 days previously,
Shipment
Shipment of airbag units must occur only in the transport packaging officially approved for this purpose. The airbag units must not be transported with other dangerous goods.
On company premises, transport must always occur in the trunk or cargo space of a vehicle using the above-mentioned transport packag- ing. Transport in the passenger compartment is prohibited. storage
Airbag units must be stored in accordance with the 2nd ordinance of the Law on Explo- sives. In accordance wfth this ordinance, small quantities of substances and objects can be stored in certain locations without special storage approval. In the case of pyrotechnical objects of the class T 1, these quantities are max. 20 kg (gross) in a working room and max. 200 kg (gross) in a storage room. The air bag units must be stored locked away.
When storing the airbag units, it must be en- sured that the padded side faces upward (risk of injury as the result of the airbag unit being catapulted up In the event of accidental igni- tion).
The airbag units must not be stored with other dangerous goods (paints etc.). a
Safety regulations for hsndling airbag vehicles
Printed in Germany - WV, 1989
69-3
68
Interior Equipment
926
Installation and adjustment work
Inspection and installation work must be per- formed only by competent personnel.
The following safety measures must always be taken before starting work on the airbag sys- tem as well as for work on neighboring parts where there is a risk of live parts coming close to the airbag system:
1. Switch off ignition.
2. Disconnect and cover negative terminal of the battery.
Note
Disconnect ground cable directly at the battery negative terminal on vehicles fitted with a tele- phone. If the ground terminal is disconnected in the luggage compartment, ground contact may be established across the telephone, thus destroying the telephone.
After disconnecting the battery, installation work or work on the vehicle with a hammer or similar tools must be started only afler a wait- ing period of 20 minutes. This is necessary to interrupt the power supply to the airbag sys- tem and to ensure that the system is not ig nited unintentionally.
Installation of the airbag units must take place immediately afterremoval from the storage lo- cation. They must not be left unattended under any circumstances. In the event of interruption- s in work, the airbag units must be locked away again immediately.
Airbag units must not come into contact with grease, oil, cleaning agents or similar.
Airbag units must not be exposed to tempera- tures over 90°C even on a short-term basis.
Airbag units, front sensors and control units which have been dropped from a height of more than 0.5 m must no longer be installed.
No additional panels, stickers or similar must be attached to the steering wheel and in the area of the passenger airbag.
NO changes must be made to the cabling and components of the airbag system.
The battery must always be disconnected be- fore the start of adjustment and welding work with an electrical welding unit.
If welding is necessary in the direct proximity of the front sensors and the control unit, these must be removed previously.
Cables from electrical auxiliary equipments must not be laid close to the airbag cable bundle.
Airbag components must not be repaired.
They must always be replaced.
Note
Wash your hands after touching tripped airbag units.
Disposal of airbag units
Non-ignited airbag units represent a danger, also to the environment. Non-ignited airbag units must not be scrapped. They should be neutralized by triggering them electrically (refer to page 68 - 15).
If the airbag units cannot be ignited, return them to Porsche or to the importer of your country, respectively, using the original trans- pod container of the spare pad and returning it via the same transport route.
66 - 4 Safety regulations for handling airbag vehicles
Printed In Germany - XXXIV, 1994
928 Interior Equipment
Disposal of airbag units
Airbag units that have not been ignited con- stitute a safety and environmental hazard.
Never scrap airbag units that have not been ignited. Deactivate the units by igniting them electrically (refer to page 68 - 15).
If the airbag units cannot be ignited, return them to Porsche or to the respective importer using the original packaging material and the same mode of transport.
68 l
Safety specifications for handling airbag vehicles
Printed in Germany - XXXIV, 1994
68-4a
a
928 Interior Equipment
68
Removing and installing the airbag steering wheel
Removal
1. Disconnect the battery and cover the termi- nal or battery.
2. Remove the driver airbag unit (refer to Page
68 4).
3. Undo the hexagon nut and remove with the spring washer.
Note
The steering wheel must be fitted so that the cable of the contact unit is not trapped.
4. Mark the position of the steering wheel with respect to the steering shaft for re-installa- tion.
Installation
1. Mount the steering wheel with the wheels in straight-ahead position or in accordance with the mark made during dismantling so that the upper steering wheel spokes are horizontal.
2. Fit the hexagon nut with spring washer and tighten with 45 Nm.
3. Install the driver airbag unit
4. Check horn functioning
Removing and installing the airbag steering wheel
Printed in Germany - XXIV, 1989
68 - 5
68
Interior Equipment
Removing and installing airbag components
Removing and installing the drive airbag unit
1. Disconnect the battery and cover the termi. nal or battery.
Note
The airbag unit must always be put down so that the padded side is facing upwards.
2. Undo the fixing screws (2 each) with a screwdriver for internal Tot-x T 30.
Note
The screws must be renewed after undoing.
Only use screws wlth a collar.
928
3. Disconnect the plug-in connection.
L
In the case of removal for a long period of time, the airbag unit must be kept locked away. Observe the safety regulations.
Tightening torque for fixing screws: 10 Nm
66-6 Removing and installing airbag components
Printed in Germany - XXIV. 1989
928 Interior Equipment
68
Removing and installing the contact unit
1. Remove the airbag steering wheel (refer to
P. 65 3).
5. Remove the contact units
2. Undo and remove the paneling.
Note
Before installing the contact unit, adjust the front wheels to straight-ahead position and ad- just the contact unit to center position (ap- prox. 4 l/2 turns from the left or right limit).
The exact center position is indicated by the two arrows. i
3. Disconnect the plug-in connections
I I
280.68
A new contact unit is locked in center posi- tion. The locking facility is removed only after installation of the contact unit.
4. Undo the fixing screws.
Removing and installing airbag components
Printed in Germany - XXV, 1989
68 - 7
68
Interior Equipment
Removing and installing the front sensors
Note
The front sensors are located on the left and right in the driver and passenger footwells on the top of the wheel house wall.
Front sensor, right
1. Disconnect the battery and cover the termi- nal or battery.
2. Remove the control unit cover.
The installation position is defined by the mounting:
Front sensor, len
1, Disconnect the battery and cover the termi- nal or battery
3. Disconnect the plug-in connections at the
LH and EZK control units, ignition circuit monitoring relay and at the coding connec- tor.
2. Remove the tire pressure warning system
(RdK), mirror and ABS control units.
4. Undo the fixing screws of the control unit holding plate and remove the holding plate with control units.
3. Disconnect the plug-in connection. The plug- in connection is located on the reinforce- ment of the front car strut.
4. Undo the tear-off nut with special tool 9259.
928
Special tool 9259 281.88
5. Undo the hexagon nut with the socket insert.
5. Remove the cover on the right next to the glove compartment.
6. Disconnect the plug-in connection. The plug- in connection is located nex to the lamp monitoring device.
7. Undo the tear-off nut with special tool 9259.
8. Undo the hexagon nut with the socket insert
68-8 Removing and installing airbag components
Printed in Germany - XXIV, 1989 a
a
- a
928 Interior EauiDment
68
Note
To tighten the tear-off nuts, use hexagon socket l/4 inch.
The fixing point on the bodywork must be metallically bright. The tear-off nuts are fitted without washers, while the hexagon nuts are fitted with washers.
Removing and installing the control unit
Note
The control unit is located on the tunnel below the center console.
1. Disconnect the battery and cover the termi- nal or battery.
2. Remove the side paneling of the center con- sole on the left and right.
3. Remove the kick protection
4. Disconnect the plug-in connections at the left front sensor, contact unit, right front sen- sor, right front sensor, passenger airbag unit and the 2-fold and 6-fold plug-in connec- tions to the main cable bundle.
Note
The 6-fold plug-in connection is secured by a red clip which is destroyed by dismantling.
The plug-in connection must be secured with a green clip during assembly.
5. Undo the cable ties along the cable bundle
6. Undo the cover on the fixing screws.
7. Undo the tear-off screws with special tool
9259.
8. Undo the hexagon screws with a socket in- sert.
Note
Install the tear-off screws diagonally.
The fixing points on the bodywork must be metallically bright.
Use a hexagon socket l/4 inch to tighten the tear-off screws. The tear-off screws are in- stalled without washers, while the hexagon screws are installed with washers.
2-fold and 6.fold plug-in connections under the fighr side paneling l
Removing and installing airbag components
Printed in Germany - XXIV. 1989
68 - 9
68
Interior Equipment
Removing and installing the pas- senger alrbag unit
1. Disconnect the battery and cover the termi- nal or battery.
2. Remove the instrument panel.
3. Disconnect the plug-in connections at the unit.
4. Undo the fixing screws.
The airbag unit must always be put down so that the airbag is facing up.
928
Note
The fixing screws are micro-encapsulated
Use new screws for installation.
Tightening torque: 10 Nm s8- 10
Removing and installing airbag components
Printed in Germany - XXIV, 1999 a
a
928 Interior Equipment
Checking operational readiness of airbag system
1. Check correct operation of the airbag warn- ing light. Switch on the ignition. The airbag warning light must come of for approx. 5 seconds. If it does not come on, check the bulb and the power supply.
2. With the igntiion switched on, pull out the fuse for the power supply to the instrument cluster for about 30 seconds. The airbag warning light should now indicate a fault.
Obtain a readout of the fault and check whether fault code 58 (warning light: short circuit to Us or ground, no fault present) is shown.
In addition to the airbag warning light, the cen- tral warning light and the seat belt symbol
(for U.S. vehicles only) should also come on if a fault has been stored in the fault memory.
3 Erase the fault memory
4 Check that no trim, adhesive labels or simi- lar items have been applied to the steering wheel or in the passenger’s airbag area.
5 System checking must be confirmed by stamping the appropriate spaces in the War- ranty and Maintenance Booklet.
68
Checking operational readiness of alrbag system
Printed in Germany - XXVII. 1991
68-11
68
Interior Equipment
Checking the readiness for operation of the airbag system
As of software level B 01
1. Functional check of the airbag warning light Switch on ignition. The airbag warning lamp must light up for approx.
5 seconds*. If the warning lamp does not light up, the bulb or the power supply should be checked.
2. Functional check of the fault memory.
Pull off fuse for instrument cluster power supply for approx. 30 seconds with the ignition switched on. The airbag warning must now display a fault. Read out fault and check if fault code 30 (Airbag warning light, signal unplausible, fault not present) is dis- played.
Note
Along with the airbag warning lamp, the central warning lamp must light up as well if a fault has been stored in the fault memory.
3. Erase fault memory.
4. Check to make sure that no trim, decals or other items are attached in the passenger airbag area.
5. Visually check components for damage or modifications.
6. The system check should be confirmed in the stamp fields provided for this purpose in the Warranty and Maintenance booklet.
* Reduced to approx. 2.5 seconds as of production date June 12, 1992.
66-12
928
Checking the readiness for operation of the airbag system
Printed in Germany - XXXI, 1993 a
928 Interior Equipment
68
Checking the safety belts
Functional test
It must be possible to unroll the belt without jerks from the automatic retractor by uniformly pulling it over the guide fitting. The plug-in tongue of the safety belt must engage audibly in the belt lock. The automatic retractor must lock when the belt is tugged abruptly.
Inspection of condition
The visual inspection must not reveal any dam- age or wear on the belt. If the belt shows signs of damage in the form cuts, fraying, seam tears, worn places etc., the safety belt must be replaced.
Additional inspection for safety belts with overload indicator (color marking -
Airbag equipment
In addition to the functional test and inspection of the condition of the safety belts, the color marking made above the holder fitting on the belt in the form of a white bar must not be visible outside the belt protector. This color marking acts as an overload indicator whose emergence from the belt pro- tector indicates overloading and the necessity to replace the safety belt.
0
1 = Mounting point for holder fitting
2 = Fixing screw
3 = Holder fitting
4 = Belt protector
5 = Indicator (cdor mark)
6 = Belt
Checking the safety belts
Printed in Germany - XXIV, 1989
68- 13
928 Interior Equipment
Correct disposal of airbag units
Airbag units are pyrotechnic objects and can represent an environmental hazard on ac- count 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 contain- ing such units must not be treated as “nor- mal” 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 re- turned 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.
68
Correct disposal of alrbag units
Printed in Germany - XXVII, 1991
68-15
68
Inferior Equipment
Safety measures
Ignition and preparation should only be carried out by propetky 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 air- bag 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 in- irolved 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 igni- tion and observe them carefully.
- Avoid skin contact with airbag units which have been ignited.
928 a
68-16 Correct disposal of alrbag units
Printed in Germany - XXVII, 1991
928 a
Tools
InteriorEquIpment
68
No. l 1
2
Designation
Ignition device
Ignition cable
-
Order number
000.721.925.7C
000.721.925.71
Explanation
Non-reusable part
Correct disposal of airbag units
Printed in Germany - XXVII, 1991
68- 17
68
Connecting the ignition device
Drlver’s side
InteriorEquIpment
-
/,*
0” tic2
$
II
\
Direct to 2-pin plug of contact unit (below steering column).
Passenger’sside
928
With ignition cable to both gas generators.
Run the ignition device out through the door gap to a point in front of the vehicle.
68 - 16 Correct disposal of airbag units
Printed in Germany - XXVII, 1991 l
928
Ignition
Interior Equlpment
68
Connect the ignition device to a car battery and operate the switch.
The driver’s side and passenger’s side airbag units must be ignited separately.
After igniting the passenger’s side airbag unit, check that both gas generators have ignited
(can be identified by both ignition cable plugs having melted).
Correct disposal of airbag units
Printed in Germany - XXVII, 1991
66- 19
928 Interior Equlpment
68
Diagnosis 1 Troubleshooting
The airbag system is continuously monitored by a diagnosis unit in the control unit. If a fault occurs, it is indicated by a warning lamp in the instrument cluster.
In the event of a fault, the central warning lamp and this warning lamp come on. In cars for the USA, the fasten seat belts symbol also lights up.
The airbag warning lamp comes on for ap- prox. 5 seconds when the ignition is switched on, and then goes out. When the engine is started, the warning lamp 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 15)
Dlagnosls I Troubleshooting
Printed in Germany - XXVII, 1991
D68-1
68 lnterlor Equipment
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
1 st figure:
2nd figure:
3 = Airbag system
1 = Fault still present
2 = Fault no longer present
3 = Failure time since first fault occurrence
3rd figure:
4th figure:
Before troubleshooting
= Fault code 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,
928
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.
D68-2 Diagnosis I Troubleshooting
Printed in Germany - XXVII, 1991
928 lnterlor Equipment
68
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 wlh 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). a
Diagnosis I Troubleshooting
Printed in Germany - XXVII, 1991
D68-3
928
Tools
Special tools 9516 and 951611 are used to check the ignition pill circuits
If there is a fautf 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/l 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.
D66-4 Diagnosis / Troubleshooting
Printed in Germany - XXVII, 1991 a
928 Interior EaulDment a
34
35
36
37
38
29
30
33
25
26
27
28
20
21
22
15
16
17
18
19
Fault code table
Fault code
11
12
13
14
Designation of fault
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 Ua
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 Ua
Right front sensor: short circuit to Ue
Left front sensor: resistance to earth/ground too high
Right front sensor: resistance to earthfground 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 Ua
* Fault code 60 is also shown with fault codes 15 and 16. Renew front sensor and erase fault memory. Repeat the diagnosis. If fault code 60 appears again, renew the control unit.
** Fault code 25 or 26 also appears with fault code 27 or 26 respectively.
Diagnosis I Troubleshooting
Printed in Germany - XXVII, 1991
D68-5
68
Interior Equipment 928
Fault code
39
40
41
48
49
50
51
52
45
46
47
42
43
44
1 Designation of fault
Ignition pill circuit 3: contact resistance to Ue
Ignition pill circuit 1: shoe-circuit to UB
Ignition pill circuit 2: short-circuit to Ua
Ignition pill circuit 3: short-circuit to UB
Ignition pill circuit 1: contact resistance to earth/ground
Ignition pill circuif 2: contact resistance to earth/ground
Ignition pill circuit 3: contact resistance to earth/ground
Ignition pill circuit 1: short-circuit to eafih/ground
Ignition pill circuit 2: shoe-circuit to ealthlground
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
53
54
55
56
57
58
59
60
Ignition pill circuit 2: resistance too high
Ignition pill circuit 3: resistance too high
Warning lamp: short-circuit to Ue or earth/ground
Warning lamp: break
Diagnosis unit: defective
61
62
Correct ignition sequence (after crash)
Correct ignition current (after crash)
65 Ignition pill current transmitted (after crash)
67 bis 105 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.
D66-6 Diagnosis I Troubleshooting
Printed in Germany -XXVII, 1991
l
928 Interior Equipment
Fault, Fault Code Possible Causes, Elimination, Remarks
Note
After any airbag system fauil 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
Test
point
4
Right front sensor closed several times
Fault code 3 _ 14
Test
point 5
Lefl front sensor closed permanently
Fault code 3 _ 15
- Renew front sensor.
- Renew front sensor
- Renew front sensor.
Test
point
6
Right front sensor closed permanently
Fault code 3 _ 16
- Renew front sensor,
68 a
Dlagnosis I Troubleshooting
Printed in Gsrmany - XW11.1991
D68-7
68
Fault, Fault Code
Test point 7
Letl front sensor
Contact resistance to Ue
Fault code 3 _ 17 lnterlor Equipment
Possible Causes, Elimination, Remarks
- Check front sensor at plug connection with ohmmeter
1. Ohmmeter at terminal 1 and terminal 2
Display: 10 kn
2. Ohmmeter at terminal 2 and terminal 3
Display: 0...0.5 R
If measured values are within tolerance, renew the control unit; if out of tolerance, renew the front sensor.
- See test Doint 7
928
Test point 8
Right front sensor
Contact resistance to UE
Fault code 3 _ 18
Test point 9
Left front sensor
Contact resistance against earth/ground
Fault code 3 _ 19
Test point 10
Right front sensor
Contact resistance against earth/ground
Fault code 3 _ 20
Test point 11
Left front sensor
Shod-circuit to UE
Fault code 3 _ 21
-
-
See test point 7
See test point 7
- See test point 7
D68-8 Diagnosis / Troubleshooting
Printed in Germany - XXVl1,1991 a
928 Interior Equipment
68
Fault, Fault Code
Test point 12
Right front sensor
Short-circuit to LIE
Fault code 3 _ 22
Test point 13
Left front sensor
Earth/ground resistance too high
Fault code 3 25
Possible Causes. Elimination, Remarks
- See test point 7
- 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
Test point 15
Left front sensor
Break in feed line
Fault code 3 _ 27
- see test point 13
- 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
Test point 17
Left front sensor
Line resistance too high
Fault code 3 _ 29
- see test point 15
- Check front sensor mit ohmmeter (see test point 7).
If no fault is detected at the front sensor, renew the control unit.
Dlagnosls I Troubleshooting
Printed in Germany - XXVII,1991
D68-9
68
Fault, Fault Code
Test point 18
Right front sensor
Line resistance too high
Fault code 3 _ 30
Test point 19
Ignition condenser 1
Capacitance too low
Fault code 3 _ 33
Test point 20
Ignition condenser 2
Capacitance too low
Fault code 3 ~ 34
Test point 21
Ignition condenser 1
Contact resistance too high
Fault code 3 _ 35
Test point 22
Ignition condenser 2
Contact resistance too high
Fault code 3 _ 36 lnterlor Equipment
Possible Causes, Elimination, Remarks
- See test point 17
- Renew the control unit.
- Renew the control unit.
- Renew the control unit.
- Renew the control unt.
928
D 68 - 10 Diagnosis / Troubleshootlng
Printed in Germany - XXVII.1991
928
Fault, Fault Code
Test point 23
Ignition pill circuit 1
Contact resistance to us
Fault code 3 _ 37
Interior EaulDment
Possible Causes, Elimlnatlon, Remarks
1. Remove driver’s airbag unit.
2. Attach special tool 9516 in place of the airbag unft.
68
3. Erase the fault memory
4. Check whether fault is still present a) If fauft is no longer present, renew the airbag unit b) If fault is still present, separate connections at contact unit and attach special tool 9516/i.
Dlagnosis I Troubleshooting
Printed in Germany - XXVII,199I
5. Erase the fault memory
6. Check whether fault is still present a) If the fault is no longer present, renew the contact unit b) If the fault is still present, renew the control unit,
D68-11
68
Fault, Fault Code
Test point 24
Ignition pill circuit 2
Contact resistance to UB
Fault code 3 _ 38
Interior Equlpment
Possible Causes, Elimination, Remarks
Ignition pill circuit 2 is the left of the two passenger-side airbag circuits, ignition pill circuit 3 the right circuit.
928
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 fault is no longer present, renew passenger. side airbag. b) If fault is still present, renew the control unit.
- see test point 24
Test
point
25
Ignition pill circuit 3
Contact resistance to us
Fault code 3 _ 39
Test
point
26
Ignition pill circuit 1
Short-circuit to Ua
Fault code 3 _ 40
Test point 27
Ignition pill circuit 2
Short-circuit to Us
Fault code 3 _ 41
Test point 28
Ignition pill circuit 3
Short-circuit to Ue
Fault code 3 _ 42
,- see test point 23
- see test point 24
- see test point 24
D 68- 12 Diagnosis I Troubleshootlng
Printed in Germany - XXVII,I991 l
928
Fault, Fault Code
Test point 29
Ignition pill circuit 1
Contact resistance to earth/ground
Fault code 3 _ 43
Test point 30
Ignition pill circuit 2
Contact resistance to earth/ground
Fault code 3 _ 44
Test point 31
ignition pill circuit 3
Contact resistance to earth/ground
Fault code 3 _ 45
Test point 32
Ignition pill circuit 1
Short-circuit to earth/ground
Fault code 3 _ 46
Test point 33
Ignition pill circuit 2
Short-circuit to earth/ground
Fault code 3 _ 47
Test point 34
Ignition pill circuit 3
Shot+circuit to earth/ground
Fault code 3 _ 46
Interior Equlpment
Possible Causes, Ellmlnatlon, Remarks
- see test point 23
- see test point 24
- see test point 24
- see test point 23
- see test point 24
- see test point 24
Diagnosis I Troubleshootlng
Printed in Germany - XXVII,1991
68
D88-13
68
Fault, Fault Code
Test point 35
Ignition pill circuit 1
Break
Fault code 3 _ 49 lnterlor Equlpment
Possible Causes, Elimination, Remarks
- 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.
\
I
928
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/i.
D68-14
5. Erase the fault memory
Diagnosis / Troubleshooting
Printed in Germany - XXVII,1991
928
Fault, Fault Code
Test
point
36
Ignition pill circuit 2
Break
Fault code 3 _ 50
Interior Equipment
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 faun is still present, renew the control unit.
68
- 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.
- see test point 36
Test
point
37
Ignition pill circuit 3
Break
Fault code 3 _ 51
Test point 36
Ignition pill circuit 1
Resistance too low
Fault code 3 _ 52
Test point 39
Ignition pill circuit 2
Resistance too low
Fault code 3 _ 53
- see test point 23
- see test point 24 l
Diagnosis / Troubleshooting
Printed in Germany - XXV11.1491
D68-15
68
Interior Equipment
Fault, Fault Code
Test point 40
Ignition pill circuif 3
Resistance too low
Fault code 3 _ 54
Test point 41
Ignition pill circuit 1
Resistance too high
Fault code 3 ~ 55
Test point 42
Ignition pill circuit 2
Resistance too high
Fault code 3 _ 56
Possible
-
-
-
Causes, Elimination, see test point 24 see test point 23 see test point 24
Remarks
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
Test point 45
Break in circuit at warning lamp
Fault code 3 _ 59
- Check wiring for damage.
- Check instrument cluster.
- Check power supply fuse for instrument cluster
- Check warning lamp and renew if necessary.
- Check wiring for damage,
D 68 - 16 Diagnosis I Troubleshootlng
Printed in Germany - XXV11.1991
InterlOr EClUlDnWnt
Fault, Fault Code
Test point 46
Defective diagnosis unit
Fault code 3 _ 60
Test point 47
Ignition sequence correct
(after crash)
Fault code 3-61
Test point 46
Ignition current correct
(after crash)
Fault code 3 _ 62
Test point 49
Ignition pill current has flowed (after crash)
Fault code 3 _ 65
Test point 50
Control unit defective
Fault code 3 _ 67
Possible Causes, Elimination, Remarks
- Renew the control unit
- All airbag components must be renewed after the airbag has been activated.
- see test point 47
- see test point 47
- Renew the control unit
68 a
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.
Dlagnosls / Troubleshooting
Printed in Germany - XXVll,1991
D68-17
928 Interior Equipment
Diagnosis 1 Troubleshooting Airbag
As of software level B 01
As of software level B 01, the waiting time for service operations is reduced from 20 minutes to 5 minutes (also refer to page 68 4).
As of manufacturing date June 12, 1992, the switch-on time of the airbag warning light is reduced from approx. 5 seconds to approx.
2.5 seconds.
68 l
Diagnosis/Troubleshooting Airbag
Printed in Germany -XXX& 1993
D 66 - 19
68
Tools
Interior Equlpment 928
Special Tool 9516 Special Tool 9516/I
Special Tools 9516 and 95160 are used to check the ignition pill circuits.
If there is a fauft in the ignition pill circuits, attach Special Tool 9516 in place of the aitbag units, then erase the fault memory. Switch the ignition off and on again.
The fault can then be identified by means of the diagnosis unit in the airbag control unit.
If the warning light no longer indicates a fault, the airbag unit is defective and must be replaced.
If the warning light again indicates a fault, the control unit or the wiring are at fault.
A fault in ignition pill circuit 1 may also be caused by the contact unit. Disconnect the wiring harness from the contact unit and attach Special Tool 9516/l in place of the contact unit. Erase the fault me- mory. 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, the control unit or the wiring are at fault.
Note
For safety reasons, never drive the vehicle with the special tools Installed in place of the alrbag unlts.
D 68 - 20 Diagnosis / Troubleshooting Alrbag
Printed in Germany - XXXI, 1993
928 Interior Equlpment
68 a I-
Special Tool 9541
Special Tool 9541 is used to check the wiring of the airbag system. It is attached in place of the control unit. For safety reasons, the wiring to the ignition pills cannot be checked with this tool.
Dlagnosls /Troubleshooting
Printed in Germany - XXXI. 19!33
Alrbag D68-21
68 lnterlor Eauloment
11
12
21
22
23
30
31
40to 47
50to54
60 to 62
70
1. Fault memory
Fault code table
Fault code
10
Deslgnatlon of fault
Ignition circuits - closed once
-closed several times
-permanently closed
- contact resistance to UB
- contact resistance to ground
- coupled l/3 or 2/3
Len front sensor
Right front sensor
- resistance too high
- resistance too high
Ignition pill circuit 1 - resistance too high /too low
Ignition pill circuit 2 - resistance too high /too low
Ignition pill circuif 3 - resistance too high / too low
Warning light airbag -Signal implausible
- Control unit defective
Crash entry
- Control unit defective
- Control unit defective
- Control unit defective
-only if airbag has been triggered
928
D68-22 Dlagnosls/Troubleshootlng Alrbag
Printed in Germany - XxX1,1993 l
Interior Eauloment
Fault, Fault Code Possible Causes, Elimlnatlon, Remarks
Note
After an airbag system fault has been detected and rectified, the fault memory must be erased.
Test point 1
lgnltlon clrcults closed once
Fault code 10
- Replace both front impact sensors
Check wiring harness for squeezed sections or chafing and replace if required.
Test point 2
Ignition circuits closed several times
Fault code 10
- Refer to test point 1.
Test point 3
lgnltlon clrcults closed permanently
Fault code 10
Test point 4
lgnltlonclrcults
Contact resistance to LIB
Fault code 10
- Refer to test point 1
- Check wiring harness to front impact sensors and ignition pills for squeezed sections and chafing. Replace if required.
- Using Special Tool 9541, check wiring to front impact sensors for short to positive terminal, replace if required.
- Check front impact sensors for short to positive terminal
- If no fault can be detected at the front impact sensors and at the wiring, the control unit must be replaced.
Test point 5
lgnltion clrcults
Contact resistance to ground
Fault code 10
- Check wiring harness to front impact sensors and ignition pills for squeezed sections and chafing. Replace if required.
- Using Special Tool 9541, check wiring harness to front impact sensors for short to ground.
- Check front impact sensors for short to ground.
- If no fault can be detected at the front impact sensors and at the wiring harness, replace the control unit.
Diagnosis /Troubleshooting Al&bag
Printed in Germany - XXXI. 1993
D68-23
68
Fault, Fault Code
Test point
6
lgnltlon clrcults
Coupled i/3 or 2/3
Fault code 10
Test point 7
Left front sensor
Resistance too high
Fault code 11 lnterlor Equipment
Possible Causes, Elimlnatlon, Remarks
- Check wiring harness and ignlion pills for squeezed sections and chafing. Replace if required
- If no fault can be detected, replace control unit.
928
- Using an ohmmeter, check front impact sensor at connector
1. Ohmmeter to terminals 1 and 2
Display: 10 kD
2. Ohmmeter to terminals 2 and 3
Display: 0...0.5 a
- Check control unit wiring to front impact sensor connector with
Special Tool 9541 and ohmmeter
Display: 0...0.5 n
- If no fautt is detected at the front impact sensor and at the wiring, replace control unt.
Test point 8
Right front
sensor
Resistance too high
Fault code 12
- refer to test point 7.
D68-24 Dlagnosls ITroubleshootIng Alrbag
Printed in German-XXXI, 1993 a
928
Fault, Fault Code
Test point 9
Ignition pill clrcult 1
Resistance loo high / too low
Fault code 21
InterlOr Eauloment
Possible Causes, Elimination, Remarks
I. Remove driver airbag - unit.
2. Attach Special Tool 9516 in place of airbag unit.
68
3. Erase fault memory.
4. Check if fault is still present. a) Replace airbag unit if the fault is no longer present. b) If the fault is still present, disconnect the contact unit wiring and attach Special Tool 9516/l.
5. Erase fault memory.
6. Check if fault is still present a) Replace contact unit if the fault is no longer displayed b) If the fault is still present, check wiring harness for squeezed sections and chafing. Replace if required.
Dlagno+ls I Troubleshootlng Alrbag
Printed in Germany - XXXI, 1993
D 68 - 25
68
Fault, Fault Code
Test point 10
Ignition pill clrcult 2
Resistance too high/too low
Fault code 22
Test point 11
Ignition pill circuit 3
Resistance too high/too low
Faultcode
Test point 12
Airbag warning light
Signal implausible
Fault code 30
Test point 13
Control unlt defecttve
Fault code
Interior Equlpment
Possible Causes, Ellmlnatlon, Remarks c) lf no fault is detected in the wiring harness, replace the control unit.
928
Note
Ignition pill circuit 2 at the passenger side airbag is the leftmost of the two circuils.
1. Disconnect plug at passenger side airbag unit.
2. Attach Special Tool 9516.
3. Erase the fault memory.
4. Check if fauil is still present. a) If the faut is no longer present, replace passenger skle airbag unit. b) lf the fault is still present, check wiring harness for squeezed sections and chafing. Replace it required. c) If no fault is detected in the wiring harness, replace the control unti.
Ignition pill circuit 3 at the passenger-side airbag is the rightmost of the two circuits.
- refer to test point 10.
- Check warning lamp, replace if required.
- Check wire from control unit lo instrument cluster or to diagnosis socket, respectively, for short to positive terminal.
- Check instrument cluster
- Replace antrol unit.
Note
This fault message may display several fault codes: 31, 40 to 47,50 lo 54 and 60 to 62.
D 88 - 26 Diagnosis I Troubleshooting Alrbag
Printed in Genany - XXXI. 1393
Fault, Fault Code
Test point
14:
Unknown fautl code fault code xxx
Possible Causes, Elimination, Remarks
- Check secondary ignition circuit.
- Erase fautl memory.
0
Dlagnosls /Troubleshooting Alrbag
Printed in Germany-XXXI. 1993
D68-27
68
Interior Equipment
Fault, Fault Code
2. Failure time
Possible Causes, Ellmlnatlon, Remarks
The Failure Time menu Pem displays the time elapsed since the first fautt was stored in the fault memory.
The maximum time that can be displayed is
99 hours and 59 minutes. If this time is ex- ceeded, the “>” sign is displayed ahead of the hours.
3.
Results
The Results menu item displays the crash data.
928
D88-28 Dlagnosls I Troubleshooting Alrbag
Printed in
Germany
-
XXXI. 1993
99x seats
72
REMOVING AN,, INSI’ALLINC ELECTRIC SEAT
Removing
1. Fold back lroni rarpcr and remove war carper.
3. Lifr sea and disconnect wire plugs. rbcn remove seat and rake threaded plarcs out of seat carrier conraIer.
4. lhscrew lefr and right sear frame rrim
2. Move back seat all the way and unscrew from socket head screws. rhen move seat forward and unscrew rear screws. vN!E,-,---
._ 1.
Installing
When installing rhe scat is normally bolted at rhe front holes of the seat rail carriers. but if more legroom is wanted, rhe holes 25 rmrn furrher back can be used.
-7 iC. w vll!@myCf .-I 1:
/
* ry-
If rhe electric seat system fails, the release lever
(arrow) can be pulled ou[ and rhc seat adjusted back or forward manually.
1
Printed inGermany - II. l9S8
Normal seats can be installed in place of electric sears.
Removing and Installing Electric Seat 72 - 1
72 seats
If damaged switches or wire harnesses are causing rhe trouble and have to be replaced, unscrew the enrire escutcheon plate. Afrer- wards the switches can be disconnected from rhe wires and removed.
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1
I
I
928
a a
12
-
2 Removing and Installing Electric Seat Printed in Germany a
928
REMOVING SEAT BACKREST MOTOR sears
72
1. Open zipper. Bend open metal tabs ar bortom of backrest and disconnect backrest cover.
4. Unscrew gear wheels or remove circlip and rake off gear wheels. i
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2. Disconnecr side cheek and srrip on backrest springs.
5. unscrew rnOIO, screws a
3. Detach pasted padding, unscrew cover and remove.
6. Detach front seal cover and pull up far enough. rhar motor is accessible from front and can be removed. a
Printed inGermany - II, 1~8 Removing Sea1 Backresr Motor 12
- 3
72 seats
DISASSEMBLING SEAT CONTROLS
928
1. Operate release lever, push sear forward or back against final stop and unscrew hexagon head screws (arrows).
3. Remove entire sear control and unscrew cover.
2. Detach and disconnect wire plugs
72- 4 Disassembling Sear Conrrols
Printed in Germany a
928
DlSASSEMBLlNG
CONTROL MOTOR
LEFT CONTROL HALF AND REMOVING AXIAL SEAT seats 72
1. Undo threaded connecrion at front of joint.
2. Turn up height con1101 on transmission tube
Q i$ ,*“”
143;
I? j K&
(1 :@
1 - Countersunk screw M 6
2 - Collar nut
3 - Washer
4 - Self-locking screw M 6
In this position the M 6 countersunk screw holding the sear carrier console could be replaced, if damaged.
3. Loosen motor carrier console and unscrew motor (3 self-locking screws).
Printed inGermany - II, 1978 Disassembling Left Control Half and and Removing Axial Sear Control Motor
12- 5
72 sears
DISASSEMBLING
CONTROL MOTOR
RIGHT CONTROL HALF AND REMOVING SEAT HEIGHT
1. Disconnect moror carrier console from conrrol half.
92x a
1 - Sacker head screw
2 - Washer
3 - Sleeve
4 - Self-locking screw M G x 12 mm
1
If rhe countersunk screw holding rhe seat on rhe sear carrier console have to be replaced, dis- connea rhe threaded connection ar fronr of joint (see page 72 - 5).
,?i
9
-'I .I ..
_ dd.---
2. Unscrew socket head screw (arrows) on ~OIOI carrier console. loosen straps and pull out nlomr.
12-6 Disassembling Right Conrrol Half and
Removing Seat Height Control Moror
Primed in Germany
928
SEAT AND MIRROR POSITION CONTROL
SYSTEM, '87 MODELS ONWARD
The seat and mirror position control system comprises the following components:
Control panel with 3 illuminated position keys (1) and one memory key (2) with integral pilot lamp.
Switch 2
- horizontal:
- vertical: rear backrest adjustment seat height adjustment,
Switch 3
- horizontal: lumbar support shape
- vertical: lumbar support/height
6 adjusting motors
72 a
3 seat switches for manual adjustment.
Switch 1
- horizontal: adjustment
- vertical: front fore and aft seat height adjustment, a
Printed in Germany - XVI,1987 l- Height, rear
2- Fore-and-aft adjustment
3- Height, front
4- Lumbar support, height
5- Backrest adjustment
6- Lumbar support, size
Seat and Mirror Position
Control System
72 - 7
72 Seats
6 potentiometers position to detect seat
C4l&m” r ~-I
-rJ*~
4 motors for mirror adjustment with
4 potentiometers to detect position of mirrors (2 for driver's-side and
2 for passenger-side mirrors).
928
The potentiometers are mounted directly on the adjusting motors.
2 are visible in the illustration.
1 mirror adjustor switch (1) and 1 mirror selector switch (2) for manual adjustment of the mirrors
Control unit for seat adjustment
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72 - 8 Seat and Mirror Position Control System Printed in Germany a
928 Seats 72
2 relay wire units harness. integrated in the
Photo shows relay unit removed with cover open.
Arrows positions indicate installation
METHOD OF OPERATION
Manual adjustment
The manual adjustment facility has been retained. This function always takes priority over automatic adjustment and is always possible regardless of vehicle status.
Storing a position
To store a position in the memory, press the memory key and the key for the desired position. The memory key must be pressed before the position key. Both keys must be held down simultaneously for at least 0.2 seconds.
Positions can be stored in the memory regardless of vehicle status.
Calling up a position
To assume a stored position automatically, hold the key for the desired position down. If the key is released, the adjustment is interrupted immediately.
The position of the mirror is not changed until approx. 0.5 seconds after the position key has been depressed. When the key is released, mirror adjustment is also interrupted unless the seat has reached its final position. Once the seat position is reached, the mirrors automatically move to the position stored in the memory.
A position can be called up regardless of vehicle status.
Printed in Germany - XVI,1987 Seat and Mirror Position Control
System, Method of Operation
72 - 9
72 Seats
Pilot lamp in the control panel.
Three position keys illuminated aid orientation and a red pilot lamp with the following functions are housed in the control panel: to
If a position key is depressed requesting an adjustment, the pilot lamp lights up until the adjustment has been completed. If the adjustment is interrupted, the pilot lamp will not go out if the ignition is on, or will continue to burn for 60 seconds after the interruption off. if the ignition is
If the position key for a position to which the seat is already set is pressed, the red pilot lamp lights up for approx. 0.5 seconds. If the position is adjusted manually, the pilot lamp goes out.
928 a
72 - 10 Method of Operation Printed in Germany
a
928 Seats
Plug asslgnment, control unit for seat adjustment
72
Plug assignment, control unit for seat adjustment
Printed In Germany-XXI, 1993
72- 11
72
Seats
Plug Terminal designation
8
10
11
12
13
14
+ - Potentiometer,
PLH - Potentiometer, is
MT
1r1 I
30’
- Potentiometer,
- Ter. 58 lumbar support, height t lum. sup. height pick-off lumbar support, height -
- Memory key
- Ter. 30 for mirror memory control unit
- Position key
%m-- . JI TUT mirror memory ( unit
SHVZ - Seat switch, height, r downward
SHVl - Seat swit'~ cn,
' " front upward
1 - Ter. 31 f or seat switch 1
SLAl - Seat switcn, tore-and-aft adjustment, toward rear
SLA2 =--' fore-and-aft toward front
- Relay unit 2
- Relay unit 2 adjustment,
- Relay unit 2
- Relay unit 2
L
SHH2
- Relay unit 2 rear downward
SHHl - Seat switr'
L-2-LL rear upward
- Ter. 31 for sea 2
SLEl a . backrest backrest, toward toward rear front
A - Relay unit 1
F
D
- Relay unit 1
- Relay unit 1
- Relay unit 1
-!-
E - Relay unit 1
SLH2 - Seat switch, lum. sup. height downward
SLHl - Seat switch, lum. sup. height upward
L - Ter. 31 for switch 3
SLWl - Seat switch, lumbar support shape retract
SLW2 - Seat switch, lumbar support shape
15 i I i i i
PIlot lamp lsition key 3
^ operating switch lsition key 2 xition key 1
/
1 4
1
2
3
I 1
I 2
:
;
: i
5
;
2
3
4
; c
4
5
: i
:
:
4
928 a a
Printed in Germany a
72 - 12 Seat Control Unit, Plug Assignment
928 Seats
CHECKING SEAT AND MIRROR POSITION
CONTROL SYSTEM
Checking seat control unit
Note:
Use the adapter cable (special tool 9269) to check the seat control unit.
Precondition battery for testing: charged
5.Detach control unit, open flap and attach by means of cable clios.
;!.*
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:
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72
Note:
Ter. 30 and Ter. 31 can be picked off at the 2-pole plug for a number of test steps.
1 - Ter. 31
2 - Ter. 30 l.Remove seat.
2.Lay seat on a trolley and position trolley beside car.
3.Connect adapter cable to seat.
4.Write seat position into memory with position key 1.
6.Disconnect plug 1. Connect voltmeter to terminal 1 (plus) and Ter. 3 (minus) in plug receptacle.
Reading: battery voltage
Connect voltmeter to Ter. 2
(plus) and Ter. 3, switch on ignition.
Reading: battery voltage
If there is no reading, check fuse
No. 21* (Ter. 30) and No. J**
(Ter. 15) and minus cable.
Reconnect plug.
* As from model 88, fuse
No.20
** As from model 88, fuse No.8 a
Printed in Germany - XX,1988
72 - 13 Checking Seat and Mirror
Position Control System
72
7. Open receptacle of plug 2. Leave plug connected.
Seats 928
If these values are not reached, replace poten- tiometers.
IO. Check plugs 4 through 8 in exactly the same way as described in Step 8.
11. Open plug receptacle of plug 9.
Leave plug connected.
Connect voltmeter to minus of adapter cable and pin 1. Switch on ignition and seat heating.
Reading: battery vottage
Switch off seat heating.
Reading: 0 Vott
If there is no reading, check switch for seat heating. Switch off ignition.
Checking the seat heatlng as of MY ‘89 refer to page 72 - 33
8. Disconnect plug 3. Connect voltmeter to pin
1 (plus) and pin 3 (minus) of control unk.
Press poskion key 1.
Reading: appmx. 5 volts
Note
Voltage is applied for only 30 - 60 seconds after the position key is pressed.
9. Connect ohmmeter to plug Ter. 1 and Ter. 3.
Reading: 2.2 - 3.2 kohm
Connect ohmmeter to Ter. 2 and Ter. 3
Reading: 0 - 3 kohm, depending upon pcsi- tion of the seat.
Connect voltmeter to pin 3 (plus) and pin 5
(minus).
Press position key 1.
Reading: battery voltage
Note
Voltage is applied for only approx. 30 - 60 seconds after the position key is pressed.
Close plug receptacle and disconnect plug.
Connect voltmeter to plug, Ter. 1 and minus.
Switch on parking light,
Reading: battery voltage
12. Connect ohmmeter to Ter. 2 and minus.
Press memcry key.
Reading: 0 - 2 ohm a a
72 - 14 Checking seat and mlrror posltlon control
Printed in Germany - XXXI. 1993
0
928 Seats l
Connect ohmmeter to Ter. 4 and minus, press position key 1.
Reading: 0 - 1 ohm
Press position key 2.
Reading: approx. 240 ohm
Press position key 3.
Reading: approx. 820 ohm.
If these values are not reached, check control panel and wiring.
13.Disconnect plug 10.
Connect voltmeter to plus and pin 3 of control unit.
Reading: battery voltage
14.Connect ohmmeter to plug and Ter. 3. Press switch
Reading: 0 - 0.3 ohm
Ter. 1
1 down.
Connect ohmmeter to Ter.
Ter. 3, push switch 1 up.
Reading: 0 - 0.3 ohm
2 and
Connect ohmmeter to Ter. 3 and
Ter. 4, press switch 1 toward rear.
Reading: 0 - 0.3 ohm
Connect ohmmeter to Ter. 3 and
Ter. 5, push switch 1 forward.
Reading: 0 - 0.3 ohm
16.Disconnect plug 14.
Test switch 3 in exactly the same way as described in steps
13 and 14.
17.Disconnect plug 11.
Connect voltmeter to plus of adapter plug. Push switch 3 up.
Pins 1 and 3 of the control unit must register minus.
Push switch 3 down.
Pins 2 and 3 must register minus.
Push switch 2 forward.
Pins 2 and 4 must register minus.
Push switch 2 toward rear.
Pins 1 and 4 must register minus.
Push switch 2 up.
Pins 1 and 5 must register minus.
Push switch 2 down.
Pins 2 and 5 must register minus.
If the values are not reached, replace switch.
15.Disconnect plug 12.
Test switch 2 in exactly the same way as described in steps
13 and 14.
18.Disconnect plug 13. Connect voltmeter to plus of adapter plug. Push switch 3 forward.
Pins 1 and 3 of control unit must register minus.
Push switch 3 toward rear.
Pins 2 and 3 must register minus.
72
Printed in Germany - XX,1988 Checking Seat and Mirror
Position Control System
72 - 15
72 Seats
Push switch 1 forward.
Pins 2 and 4 must register minus.
Push switch 1 toward rear.
Pins 1 and 4 must register minus.
Push switch 1 up.
Pins 1 and 5 must register minus.
Push switch 1 down.
Pins 2 and 5 must register minus.
19.0pen plug receptacle of plug 15.
Leave plug connected.
Connect voltmeter to plus and pin
3.
Reading: battery voltage
20.Switch on lights
Connect the voltmeter to negative and pin 2.
Reading: approx. I,8 V
2l.Connect the voltmeter to negative and pin 4
Reading: approx. 1,8 V
22.Connect the voltmeter to negative and pin 5.
Reading: approx. I,8 V
If the values stated are not reached, the control unit is defective.
928
Connect voltmeter to minus and pin
1. Press position key 2 or 3 briefly.
Reading: battery voltage
72 - 16 Checking Seat and Mirror
Position Control System
XIX/A, 1988 - Printed in Germany a
928 a
PLUG ASSIGNMENT, CONTROL UNIT FOR MIRROR ADJUSTMENT
Seats
72
PRI PLIPM1LPM2tPM1RPM2RMl~
Plug
2 t-1
Terminal designation
3 i:
5
PT
-
I
't/right
- Polarity, motor l/2
- Passenger-side mirror, left/right
- Passenger-side mirror, up/down
- Driver's mirror, up/down
- Position keys not occupied
30’ - Ter. 30 from seat memory control unit
MT - Memory key
31' - Ter. 31 from seat memory control unit
1 Pin
1
2 i
5
1
2 i
5
Printed in Germany - XVI,1987
Plug Assignment,
Mirror Control Unit
72 - 17
72 Seats
Plug
3
Terminal designation ometer right - ometer right + ometer left - ometer left +
_ - rvcr-Ilb.ometer, motor 1 left
NIL
, motor
M12R - M l/2, right
PMTR - P otentiometer, motor
2 left
1 right otor 2, right otor l/2, left otor 2, left motor 2 right left - driver's-side mirror right - passenger-side motor 1 - vertical travel mirror motor 2 - horizontal travel
::
12
13
14
Y
8
9
:
4"
5
928 l
72 - 18 Plug Assignment,
Mirror Control Unit
Printed in Germany a
928 Seats
72
Checking mirror control unit
Note:
The mirror control unit is mounted on the sidewall in the driver's-side footwell beside the
ABS control unit. l.Remove oddments tray.
2.Detach mirror control unit,
3.Disconnect plug 1.
4.Set mirror selector switch to driver's-side mirror.
5.Connect voltmeter to Ter.
(plus) and Ter. 2 (minus).
1
Push mirror adjuster switch to left.
Reading: battery voltage
Connect voltmeter to Ter.
(minus) and Ter. 2 (plus).
1
Push mirror adjuster switch to right.
Reading: battery voltage
6.Connect voltmeter to Ter. 5
(plus) and Ter. 2 (minus).
Push mirror adjuster switch up.
Reading: battery voltage
Connect voltmeter to Ter. 5
(minus) and Ter. 2 (plus).
Push mirror adjuster switch down.
Reading: battery voltage
7.Set mirror selector switch to passenger-side mirror.
8.Connect voltmeter to Ter. 3 (plus and Ter. 2 (minus).
Push mirror adjuster switch to left.
Reading: battery voltage
Connect voltmeter to Ter. 3
(minus) and Ter. 2 (plus).
Press mirror adjuster switch to right.
Reading: battery voltage
9.Connect voltmeter to Ter. 4
(plus) and Ter. 2 (minus).
Push mirror adjuster switch up.
Reading: battery voltage.
Connect voltmeter to Ter. 4
(minus) and Ter. 2 (plus).
Push mirror adjuster switch down.
Reading: battery voltage
Printed in Germany - XVI,1987 Checking Mirror Control Unit 72 - 19
72 Seats 928 lO.Disconnect plug 2.
Connect ohmmeter to minus and
Ter. 1, press position key 1.
Reading: 0 - 2 ohm
Press position key 2.
Reading: approx. 240 ohm
Press position key 3.
Reading: approx. 820 ohm ll.Connect
Ter. 4. ohmmeter to minus and
Press memory key.
Reading: 0 - 2 ohm
If the values are not reached, check control panel separately. lZ.Connect voltmeter to Ter. 3
(plus) and Ter. 5 (minus).
Press position key 1.
Reading: battery voltage
Note:
Voltage is applied for only approx.
30 seconds after the position keys are pressed.
13.0pen plug receptacle of plug 3.
Leave plug connected.
14.Connect voltmeter to Ter. 1
(minus) and Ter. 2 (plus).
Press position
Reading:
Note: approx. key 1
4.7 V
Voltage is applied for only approx.
30 seconds after the position keys are pressed.
15.Connect voltmeter to Ter. 3
(minus) and Ter. 4 (plus).
Press position key 1.
Reading: approx. 4.7 V
72 - 20 Checking Mirror Control Unit
16.Connect voltmeter to Ter. 4
(plus) and Ter. 5 (minus).
Press position key 1.
Reading: approx. 0.3 - 4.5 V
17.Connect voltmeter to Ter. 4
(plus) and Ter. 7 (minus).
Press position key 1.
Reading: 0.3 - 4.5 V
Printed in Germany
928 Seats 72
18.Connect voltmeter to Ter. 2
(plus) and Ter. 9 (minus).
Press position key 1.
Reading: 0.3 - 4.5 V
19.Connect voltmeter to Ter. 2
(plus) and Ter. 11 (minus).
Press position key 1.
Reading: 0.3 - 4.5 V
20.Set mirror selector switch to driver's-side mirror.
Zl.Connect voltmeter to Ter. 6
(plus) and Ter. 13 (minus).
Push mirror adjuster switch up.
Reading: battery voltage
22.Connect voltmeter to Ter. 6
(minus) and Ter. 13 (plus).
Push mirror adjuster switch down.
Reading: battery voltage
23.Connect voltmeter to Ter. 13
(minus) and Ter. 14 (plus). Push mirror selector switch to left.
Reading: battery voltage
25.Set mirror selector switch to passenger-side mirror.
26.Connect voltmeter to Ter. 8
(minus) and Ter. 10 (plus).
Push mirror adjuster switch up.
Reading: battery voltage
27.Connect voltmeter to Ter. 8
(plus) and Ter. 10 (minus).
Push mirror adjuster switch down.
Reading: battery voltage
28.Connect voltmeter to Ter. 8
(minus) and Ter. 12 (plus).
Push mirror adjuster switch to left.
Reading: battery voltage
29.Connect voltmeter to Ter. 8
(plus) and Ter. 12 (minus).
Push mirror adjuster switch to right.
Reading: battery voltage
If the values stated are not reached, the mirror control unit is defective.
24.Connect voltmeter to Ter. 13
(plus) and Ter. 14 (minus).
Push mirror adjuster switch to right.
Reading: battery voltage
Printed in Germany - XVI,1987 Checking Mirror Control Unit 72 - 21
72 Seats
CHECKING CONTROL PANEL l.Remove control panel.
Z.Disconnect plug.
Note
The test is conducted with the connector housing withdrawn.
3.Connect voltmeter to Ter. 1
(plus) and Ter. 4 (minus)
Reading: battery voltage
If there is no reading, check wiring to seat control unit, if necessary replace seat control unit.
4.Connect ohmmeter to Ter. 1 and
Ter. 4.
Reading: ohm
Press key 1.
Reading: approx. 0 ohm
Press key 2.
Reading: approx. 240 ohm
Press key 3.
Reading: approx. 820 ohm
5.Connect ohmmeter to Ter. 2 and
Ter. 4.
Reading: ohm
Press memory key.
Reading: approx. 0 ohm
72 - 22 Checking Control Panel XX,1988 - Printed in Germany
928
0 a
928 l
SEAT FRAME
Seats 72 l
Printed in Germany-XIX,1987 Electrically Adjustable Seat 72 - 23
72 Seats
SEAT FRAME
29 14 32
’ ? 5 i
A~,
,f m
72 - 24 Electrically Adjustable Seat Printed in Germany
0
928 a l r
8
9
10
11
12
13
3
4
5
No.
-
1
2
14 l5
16
17
Description
Cover
Self-tapping screw
Washer
Sheet-metal nut
Seat frame
Hex nut
Pin
Sliding sleeve
Spring washer
Plastic washer
Hex nut
Guide spring
Seat rail, left
Seat rail, right
Transverse stru
Lifter, front right and rear left
Lifter, front left and rear right
1
2
2
2
2
2
2
2
4
4
1
1
2
-
-
KY*
T
Removing
1
2
1
2
-
Seats
Note When:
Installing
72
0
Printed in Germany-XIX,1987 Electrically Adjustable Seat 72 - 25
928 72 Seats
No. Description KY.
29
30
31
32
33
34
18
19
20
21
22
23
24
25
26
27
28
Slide
Washer
Hex bolt
Socket-head bolt
Shaft, seat ad- justment, left
Shaft, seat ad- justment, 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
1
1
1
3
3
2
1
1
1
3
1
4
4 a
4
1
72 - 26 Electrically Adjustable Seat
Note When:
Installing
Printed in Germany a
928
No. Description
35
36
Hex bol
Serrated washer
F temoving
6
6 1
Note When:
Installing
Seats 72
0
Printed in Germany-XIX,1987 Electrically Adjustable Seat 72 - 27
72
Seats
BACKREST
15 . 14
928
72 - 28
Electrically Adjustable Seat Printed in Germany
928 a a
No.
-
1
2
3
8
9
10
11
12 l ::
15
16
17
6
7
4
5
Description
Rackrest frame
Lumbar support
Shaft, lumbat support, height adjustment
Circlip
Shaft, lumbar support, curvature
Circlip
Cross recessed screw M 5 x 8
Serrated washer
Electric motor
Cross recessed screw M 5 x 16
Angle
Spacer
Hex bolt
Electric motor, backrest adjustment
Shaped spring
Guide countersunk screw with inside hexagon head
-
NY.
-
1
1
1
?emoving a
Printed in Germany-XXII,1989
Seats
Note Whe
Installing
72
Electrically Adjustable Seat 72 - 29
928
Calibrating controllable seat heating
From Model 89 onwards
Control units
Note
The seat heating must be calibrated after the control unit or heating elements have been re- placed.
Seats
Control unit for seat heating without seat-position control
72
Control unit for seat heating with seat-position control
A - measuring point (V)
B Calibration potentiometer l
Calibrating controllable seat heating
Printed in Germany - XXII, 1989
72- 31
72 seats
926
Tools
1. Digital voltmeter with an internal resistance
(Ri) 21 Ma.
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 auxillaty cables to supply voltage to the removed seat (terminals 15 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 (B) so that it corresponds to the appropriate value for the ambient temperatu re.
0
2
4
6
8
10
12
14
16
18
Table
Ambient temperature in “C Voltage in V
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
30
32
34
36
38
20
22
24
26
28
2.00
2.05
2.10
2.15
2.20
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
Function check
Switch on seat heating for approx. 10 seconds with maximum heating power. After switching off, measure the voltage at the control unit. The value measured now must be considerably higher.
72 - 32 Calibrating controllable seat heating
Printed in Germany - XXI. 1989 a
928
Checking seat heating
As of Model Year ‘89
1. Remove switch cover (4 screws).
2. Disengage seat heating switch and pull out switch (take care not to damage the wire).
3. Switch on ignition,
4. Connect voltmeter to term. 1 (positive) and term. 2 (negative).
Seats
72
7. Push tip switch into “of? position and keep it in this position.
Display: approx. 0 V
8. Turn knurled wheel of potentiometer all the way up.
Display: approx. 3 V
9. Turn knurled wheel of potentiometer all the way down. The voltage must then drop to approx. 2 V.
10. Remove seat and connect to Special Tool
9269.
11. Switch on seat heating and set to maxi- mum heating output.
12. Measure voltage at 2-pin connector marked with digit 3.
I---
,343-n
Display: approx. 5 V
Note
If no voltage is displayed, check power supply according to wiring diagram.
5. Connect voltmeter to term. 2 (negative) and term. 3 (positive).
Display, depending on potentiometer setting: approx. 2 - 3 V
6. Push tip switch into “on” position and keep it in this position.
Display: approx. 5 V
When the seat heating is switched on, the voltage oscillates between 0 V and approx.
12 V (clocked voltage).
,344 72
72 - 33
Checking seat heating
Printed in Germany - XXXI, 1993
72
Checking resistance of heater elements
Note
Use a digital ohmmeter for the measurements.
1. Disconnect connector marked with digit 3.
2. Zero out ohmmeter.
3. Connect ohmmeter on pin side.
Display at 20’ C ambient temperature:
1.5to1.8R
Seats 928
72 - 34 Checking seat heating
Printed in Germany - XXXI, 1993
928 Controls, Instruments, Radio l
PRECAUTIONS WHEN WORKING ON CARS
WITH ELECTRONIC CONTROL UNITS
When working on cars with electronic control units, note the following:
Welding
If electric welding equipment is used, the plugs of electronic control units must be disconnected.
Painting
When painting cars, note that the max. long-term (approx. 2 hours) load for is 8O'C. electronic control units
Charging battery
Disconnect battery from car electrics when charging.
Emergency start
Never use a fast charger to start the engine.
Plug-in connector
Only connect and disconnect plug-in connector of electronic units with ignition control switched off.
90
Printed in Germany - XIII, 1986 Precautions when Working on Cars 90 - 01 with Electronic Control Units
928
Gauger. Instruments. Radio
90
LOCATION OF RELAYS AND ELECTRONIC CONTROLS IN CAR
Central Fuse / Relay Plate
The central fuse/relay plate is accessible after removal of a covex in footwell of front passenger’s side.
Relay for electric seat’s forward movement is located underneath the seat on the adjuring frame.
0 /y?f!y.Ig.pF-d-
! .9,;,’ :
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&,f:<:
Printed inGermany - IV. 1980
Location of Relays and Electronic Controls in Car 90 - 1
90
Gauges, Instruments, Radio 928
Fuses are numbered consecutively from lefty 10 right and are desigoated S 1 through S 34 on the current now diagram.
S 1 - Fog headlight
S 2 - Auxiliary headlight
S 3 - License plate light, engine compartment light
S 4 - Switch light (fog headlights, tail fog light, hazard light switch, fear window wiper, rear window defogger). light for cigar lighter s 5- Cigar lighter, instrument light
S 6 - Windshield wipers. cleaniog solution
PUMP s 7- Rear window wiper
S 8 - Sliding roof
S 9 - Backup light, mirror control
S 10 - Stop lights. tempostat cruise control, bulb control unit
S 11 - Instruments and indicator lamps in in- strument cluster. left
S 12 - Instruments and indicator lamps in in- strument cluster. right
S 13 Rot occupied s 14 - Seat adjustment
S 15 - Two -tone horns. antenna, rear window wiper return
S 16 - Condenser blower for air conditioning
S 17 - Fresh air blower, magnetic coupling on compressor (air conditioning)
S 18 - Rear window defogger, outside mirror defogging
S 19 - Retractable headlight motor
S 20 - Headlight cleaner pump
S 21 - Window controls
S 22 - Fuel pumps, warm-up regulator, throttle bypass valve
S 23 - Clock, glove box lamp, inside lights, make-up mirror light
S 24 - Higb beam headlight, left; high bean, indicator lamp
S 25 - High beam headlight, right
S 26 - Low beam headlight, left s27 - Low beam headlight. right
S 28 - Marker lights, left
S 29 - Mark= lights, right
S 30 - Front turn signals. left
S 31 - Rear turn signal. left
S 32 - Front turn signals. right
S 33 - Rear turn signal, right
S 34 - Tail fog light
90 -2 Location of Relays and Electronic, Controls io Car
Printed in Germany
928 Instruments. Gauges. Radio
90 a t
I /II
1 p,+y Gy 1x1-.’ ; XII; iv,: $G+--- “:
I,
I’,
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I2
Relays - identified with Rot’1 ‘n numrrais I tllrough XXII on cwl:al iuse /relay plare
I” v
I - II - Rear window defogger
111 - Headlight motor
- Fleadlighr tnain power supply
- Turn signal flasher
VI - Power window
VII - Headlight washer pump
VIII - Not used
IX - Time relay (seat belts)
X
XI
- Horn
- A/C compressor (speed limiter)
XII - Fog lights
XIII - Headlight beam power supply
XIV xv
- Headlight high/low beam
- Bridged for manual trans. (starter cut-out relay for automatic trans.)
XVI
XVII
- Safety relay (headlights)
Fuel pump
XVIII - Radiator fan
XIX - Intermittent wiper xx
XXI
XXII
1
- Intensive cleaner pump
- A/C and heater blower
- Defrost fan
- Stop/tail light monitoring unit
Printed in Germany - II. 1979 Location of Relays and Electronic Controls in Car 90 - 3
90
Instruments. Gauges, Radio
Relay Plate Plug Receptacles
J
K
L
M
N
Y
E
F c
D
G
H
A
R
- white
- blue
- red
- natural
- black
- white
- blue
_ red natural
- black
- white blue red -
(single u,ire)
0
+ hl
N
0
P
- blue
- red
- natural
- black
- wbitc
(single wire) x
Z
R w s
T
” v
- red
- natural
- black
- white j
1
1
Rear harness
Not used
90 - 4 Location of Relays and Electronic Conbvls in Car
Printed in Germany
928
92s
Central It’arning Systi:m
The central warning rystcm is mounted under- nc.ltll the fnotr~st in tlk driver’s foot~~cll.
Instruments, 90
One of tlk 25-pin. black rwcptacics on the cm- tral warning system is marked with a yellow label.
This label is to identify the respective receptacle terminal numbers (either yellow OI black) when using the current flow wiring diagram. a
Printed in Germany Location 01 Relays and Electronic Controls in Car go- 5
928 Gauges, Instruments. Radio
90
REMOVING AND INSTALLING INSTRUMENT CLUSTER
1. Disconnect battery ground lead.
2. Remove steering wheel.
3. Remove steering column switch.
4. Remove instrument cover mounting screws.
1. Lift instrument cover carefully and tilt it to the rear. Unscrew mounting bolt and remove instrument cluster.
5. Remove rear window wiper and defogger switch.
6. Disconnect both 12-pin plugs at instrument cluster. a
Printed in Germany
Removing and Installing Instrument Cluster so - 7
90
GaUgeS. Instruments. Radio
*
It-a-
0
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928 m
90 - 8 Disassembling and Assembling Instrument Cluster
Printed in Germany
l
Descriptim
2
I’hillips screw iIong:b
Phillips screw (short)
Housing
4 I
Connecting plug
Tcmperature/for1 ga,,ge
8 I
Voltage:oil pressure
!P”Ee
Phillips screw
Speedometer
Alla1 bead screw
Washer l‘achometer
Metal screlz’
Solenoid
Mb with holder
Bulb with holder
Plug guide
Conductor foil
Instrument carrier
1
2
3
4
1
3
1
4
11
2
1
2
1
1
?
I
4
4
4
5
I
QlY.
Gauges. Ii~rtrurr~ei~fs, Radio
Note When Special
90 l
Printed in Germany
Disassembling and Assembling
Instrument Cluster
90 -9
90
GElUgeS, Instruments. Radio
9 2 H
REMOVING AND INSTALLING CLOCK
1. Disconnect battery ground lead.
2. Llnscrew side trim (left or right) from center console (2 screws), pull off clip and press down trim. j-&&i -*
“xx -
.
,/--- J
2 ; 1, r .,-.
4- l+k,
_..
%i
. ..- ~_.---
1
0
3. Remove seat belt indicator lamp and hazard light switch.
4. Disconnect wires at clock.
5. Unscrew both clock mounting screws with a short Phillips screwdriver.
90 - 10 Removing and Installing Clock
Printed in Germany
9‘28 Gauges. Instruments. Radio
90
Tf!OLIBLESHOOTING CAR RADIO
Test Requirements:
Charged battery. ignition key turned to radio position. antenna rwl out.
1. Are stations received only on some of the four ware ranges (MW, Liz’, SK, LISW)? no
I Yes c
Replace radio ““it.
I
2. Are any stations at all received?
I
110
(
3. Check operating voltage at radio.
Is there 12 volts at radio housing?
I
See point 6.
Replace fues 01 eliminate interruption in wire
Printed in Germany
Troubleshooting Car Radio 90 - 11
90
Gauger, Instruments. Radio
4. Turn loudness control on radio lo full volume.
Is there loud noise in loudspeakers in all wave
,SWgCS,
1
Check loudspeaker connection and loudspeakers.
(Connect test loudspeaker.)
Is there loud noise now?
Yes
5. Check anlenna.
I ,i
Replace radio unit.
I
“0 a. Measure resistance with ohmmeter between antenna base and battery minus pole.
Is resistance ca. 0)
Yes j no b. Measure resistance with ohmmeter between antenna tip and hattery minus pole.
Is resistance more than 1 M-ohm) c hlake perfect ground connection between antenna base and fender (remove undercoating). ye’ I t c. Connect separate antenna cable between antenna and radio outside of car.
Czn stations be received now?
Replace antenna.
Replace radio unit. yes t
Replace antenna cable.
I
928
Printed in Germany 90 - 12 Troubleshooting Car Radio
928 GtlUgeS, Instruments. Radio
90
6. Is station reception clear and wdistorted>
L-
Check loudspeaker connection and loudspeakers.
(Connect test loudspeaker.)
Is reception now goodj a
Replace radio unit. 7. Is radio sensitive?
(Are remote stations received together with strong local stations>)
Note: Set sensitivity switch at position 1, see operating instructions.
I
I ?
8. Can the stations be set exactly in all wave
Check antenna.
(rce point 5)
Is radio now sensitive?
Replace radio unit.
Ino
Yes
+
9. 1s there interference when engine is not run- ning?
Exceptions: high tension. lightening, street- car cables. street lamps (for USW reception eleminated by AS”). no
Replace radio unit.
Replace radio unit.
Primed in Germany
Troubleshooting Car Radio 90 - 13
Gauges. Instruments. 90 Radio
I
“0
10.~1~ there interference when engine is running!
IL_ yes
I
11. Connect new radio for testing. Is there still interference?
Radio is good. ye5 IL+ t
12. Check car shielding and, if necessary, re- place shielding parts.
Replace radio unit.
928 a
90 - 14 Troubleshooting Car Radio
Printed in Germany a
a
Gauges. Instruments, Radio
90
Typical Interference Koisc
1. Inlerference from Ignition
Crackling noise depending on speed.
Run engine to speed of approx. 5000 rpm, +UID off ignition and check whether interference noise stops.
6. Interference from Static Charge
(in MW, I.W and SW ranges)
Clicking and crackling noise at high road speeds and on dry road surfaces.
In!erference noise stops when depressing the brake pedal.
2. Interference from Generator
Whistling noise depending on speed.
Remove geueralor belt and run engine briefly.
Whistling noise must not be heard.
3. Interference from Regulator
Clicking and crackling noise in certain speed ranges.
SwitWl on heavy-duty equipment (rear window defogger. headlights), which must change interference noise.
4, Interference from Tachometer
Clicking and crackling noise depending on speed.
Pull off plug receptacle G on central fuse/relay plate, which must cause interference noise to disappear.
5. Interference from Auxiliary Equipment
(windshield wipers, blower etc.!
Howling and crackling noise.
Interference noise stops when equipment concerned is turned off. a
Printed in Germany
Troubleshooting Car Radio 90 - 15
90
Gauges, Instruments. Radio 928
Possible Interference Routes
Interference can basically make its way into a car radio via three different routes.
3. Interference via Loudspeaker Wires
Correction:
Route loudspeaker wires outside of radiation range of interfering lines and not parallel to to wire harnesses.
1. Interference via Antenna
Turning the loudness control will also change the loudness of interference noise.
Correction: a. Eliminate interference at its source by in- stalling interference shields. b. Walk around car with a test antenna (or por- table radio) and find the place on car radia- ting maximum interference. Eliminate in- terference at this point by installing ground straps (e.g. between engine hood and hody) or tightening screws to have good connec- tions between body parts. a I a
2. Interference via Power Supply Line
Turning the loudness control will not change the loudness of interference noise.
Correction:
Install an interference suppressor in supply line.
90 - 16
Troubleshooting Car Radio
Prillted in Germany
97.8
MEASURING RESISTANCE ON ANTENNA
Gauges, Insrrumenrs, Radio
90 k
I
A-
>-.
.,
\
( ><, q ’ ’
Through-flow = 0 to 3.5 ohms
BaSepOint ground Lo engine block = 0 ohms hinted inGermany - IV, 1980
Insularion = at least 1 m-ohm
Measuring Resistance on Antenna
90 - 17
90
Gauger, Insrrumenrs, Radio
REMOVING MASK FOR RADIO OPENING
1. Push OUT cenier nozzle with a putty knife. 4. Remove mask.
928 a
/
,
.-.
- -.
._
2. Pull off cover frame, starring ar cop. a
3. Disconnect and remove keyboard.
90 - 18 Removing Mark for Radio Opening
Printed in Germany a
928 Gauges, Instruments,
INSTRUMENT CLUSTER AS FROM 1979 MODELS
Radio
90
,.
Iv
~‘~~p5$ ‘iy
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FR 1- $/Jwj’:;”
- = l2 R ’
To operate the indicator lamps incorporated in the instrument cluster as from 1979 models, it was necessary to increase the number of wire connections. The three wire connection strips on the back of the instrument are designated Ft. M and L on the current flow diagrams.
INSTRUMENT CLUSTER AS FROM 1982 MODELS
Because of economy control (ECI the number of wire connections on the connection strips has been increased to 14 and plug connections are different.
Printed in Germany VI. 1982 Instrument Cluster as from 1979 Models 90.19
90
Instruments. Gauges, Radio
LOCATION OF FUSES AND RELAYS IN CAR - 1980 MODEL
928
Fuses are numbered in order from left to right and appear on current flow diagrams as S 1 through S 34.
S 1 - Front fog lights
S 2 - Not used
S 3 - License plate lights, engine compart- ment light
S 4 - Switch lights (front fog lights, tail fog light, hazard lights, rear window wiper, rear window defogger). light for ciga- rette lighter
S 5 - Cigarette lighter
S 6 - Windshield wipers. pump for cleaning solution
S 1 - Not used
S a - Sunroof
S 9 - Backup lights, mirror control. rear window wiper. automatic air condi - tioner
S 10 - Stop lights, cruise control
S 11 - Instrument lights, light switch light, reset button light, selector lever light, clock light
S 12 - Instruments and indicator lamps in in- strument cluster
S 13 - Not used s 14 - Power seats
S 15 - Two-tone horns. power antenna, rear window wiper letun action
S 16 - Condenser fan for A/C
S 11 - Fresh air blower, A/C
S 18 - Rear window defogger, outside mirror heating
S 19 - Retractable headlight motor
S 20 - Pump for headlight washer
S 21 - Window controls, central locking system
S 22 - Fuel pump. control pressure regulator, auxiliary air regulator
S 23 Clock, glove box light, inside lights. vanity mirror light
S 24 - High beam left. high beam indicator
S 25 - High beam right
S 26 - Low beam left s 27 - Low beam right
S 7.8 - Side marker lights left
S 29 - Side marker lights right
S 30 - Turn signals front left
S 31 - Turn signals rear left
S 32 - Turn signals front right
S 33 - Turn signals rear right
S 34 - Not used
Note
There are two 0.4 A fuses in inline fuse holders behind the central fuse/relay board for the cm- tral locking system.
90 - 20 Location of Fuses and Relays in Car - 1980 Model I”, 1980 - Printed in Germany
928 Instruments, Gauges, Radio
90
0
“II
VIII
IX x
X1
XII
XIII
I + II
III
IV
1,
- Rear window defogger
- Not connected
- Not connected
- Hazard light/flasher
- Window control
- Headlight cleaner pump
- Not connected
- Not connected
- Horn
- Not connected
- Front fog light
- Wiper intermittent action
- Widge (start relay for automatic transmission)
XV - Rridgewtra cleaning pump)
- AFC fuel injection XVI
XVII - Fuel ,,ump
- A/C condenser fan XVIII
XIX + XX- Headlight combination
XXI
XXII
- Fresh air blower
- Defroster
Printed in Germany - IV, 1980 Location of Fuses and Relays in Car-1980 Model 90 - 21
92R
Time action relay for seat belt warning system is locared in center consoIe in from of radio.
Gauges. Insrrumenrs. Radio
90
Rear window wiper relay is located on left side behind rhe rool plate at rear.
Printed inGermany - IV. 1980 Location of Fuses and Relays in Car from 1980 Models
90 - 23
928 Instruments, Gauges, Radio l
REMOVING AND INSTALLING RADIO (DIGITAL RADIO EAMEERG QTSl
90
1. Press out center vent with a putty knife
2. Pull off cover beginning at top
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3. Unscrew and remove push button plate.
4. Unscrew tray underneath glove box and trim on side of center console.
5. Push assembly bar into openings of radio mask until it engages.
Pull radio out of center console.
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A a hinted in Germany VI, 1982 Removing and Installing Radio
(Digital Radio Earnberg QTS)
90.25
98
Instruments. Gauges, Radio
6. Pull off plugs on radio.
928
1 -Speaker connection, right
2 - Speaker connection, left
3 - Fuse holder (2.5 A fuse)
4 - Ground connection
5 - Plus connection wired via fuse and ignition lock
6 - Plus connection term. 30
(digital clock and station memory)
7 -Automatic antenna corm.
8 - Fuse 3.15 A (remove cap)
9 - Remote control connection
7. Unscrew radio mounting on left side
Unscrew radio mounting on right side and remove radio from left side.
90.26 Removing and Installing Radio
(Digital Radio Bamberg QTS)
Printed in Germany
928
CHECKING FUEL CONSUMPTION INDICATOR
Instruments,
AFC
1. Check connecting wires and plug connections between AFC control unit and instrument cluster for good contact and breaks.
2. The sensor signal (duration of injection) can be checked with an oscilloscope on the central electric plug L, term. 5, or on the instrument cluster (center multiple.pin plug, term. 11). The square wave signal changes frequency when the engine speed changes.
3. If the instrument cluster receives the sensor signal, check the printed circuit and. if necessary, replace the instrument.
4. If there is excessive deviation in the upper range between displayed and actual consumption, check the speedometer signals on left multiple-pin plug term. 2 by turning the driven wheels.
5. If the fuel consumption indicator does not return to zero after switching off the ignition, check whether center multiple-pin plug term. 14 of instrument cluster has + 12 volts (check fuse no. 23).
Gauges. Radio
90
Printed in Germany VI, 1982 Checking Fuel Consumption Indicator 90.27
928 lnstrUments,
TROUBLESHOOTING CENTRAL WARNING SYSTEM
Gauges, Radio
90
Function:
The central warning system monitors the following functions in the car.
1978 Models
1 - Oil pressure
2 - Oil level
3 - Brake circuit failure
4 - Brake fluid level
5 -Parking brake
6 - Coolant level
7 - Coolant temperature
8 - Fuel reserve
9 -Washer fluid level
10 -Brake pad wear
11 - Stop lights
12 -Tail lights
Indicator Panel for 1978 Models
Any deviation from specified condition or a defect will be displayed by the central warning lamp flashing or coming on, depending on priority, the acknowledge- ment button and the pertinent indicator lamp,
Beginning with 1979 models the acknowledgement button comes on together with the central warning lamp.
Printed in Germany - VI, 1982 Troubleshooting Central Warning System 90-29
90
Instruments, Gauges, Radio
Beginning with 1979 models
928
The central warning unit contains a “bulb check” function to check the light bulbs. All indicator lamps, the central warning lamp and the acknow- ledgement button lamp must come on after turning on the ignition.
Voltage is supplied to the central warning unit via term. 50 while starting the engine and cancels the
“bulb check” function. All indicator lamps go out except for the stop light indicator (goes out when operating brake pedal first time) and parking brake indicator (when parking brake is applied).
Monitoring the tail lights and stop lights is accomplished with a bulb check control unit, which together with the central warning unit will activate the pertinent indicator lamp when a bulb is defective or a wire has a break.
Acknowledgement beginning with button
1979 models a
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90.30 Troubleshooting Central Warning Unit Printed in Germany
928
Types of Defects
The following defects could occur in the central warning system.
1. Check lamp(r) do not come on when checking light bulbs.
Instruments. Gauges, Radio
2. Indicator lamp on continuously, instead of flashing (for functions 1 - 4).
3. Indicator lamp not on, even though monitored function is not okay.
4. Indicator lamp on, even though monitored func- tion is okay.
CWL = Central Warning Lamp
AEL = Acknowledgement Button Lamp
IL = Indicator Lamp (or Sign Light)
90
FUNCTION TEST ON CENTRAL WARNING UNIT
This test is applied to find a defect in the central warning unit itself.
Use a piece of wire to make connection between the connected multiple-pin plugs of the central warning unit and the pertinent polarity of the point being tested.
Refer to the central warning unit connection plan for designations and polarity.
Printed in Germany - VI. 1982 Troubleshooting Central Warning System
Function Test on Central Warning Unit
90.31
928
90
Instruments, Gauges, Radio
CENTRAL WARNING UNIT CONNECTION PLAN
BLACK PLUG t
II Oil presssure IL cwL,ABL, II with engine running lf1adlerl cwL.ABL,ll lflarherl
Oil press. sensor II Ll
Brake fluid switch
(delayed)
II Oil level IL r t
CONNECTIONS ON:
POLARITY
1
Ignition 1151
Alternator CD+)
Brake Fluid IL
Oil l*Yd rwitch
Brake circuit witch
Batter” voltage 1301
Brake cirwit IL wdL.ABL,IL Brake pad front
WL,ABL.IL Brake pad rear
Brake pad IL
:WL.ABL.It Parking brake
3ance,s CWL
,nd ABL
Acknowledgsmsnt bUttOn
Parking brake COnfact c
Ii
:WL.ABL,ll flarherl c :WL.ABL,ll
I1 c :WL.ABL. II
Ground,rteering eanrole starter (501 while startine
Central warning lamp and acknowledgement button c WL. ABL
Printed In Germany a
90-32
Central Warning Unit Connection Plan
Black Plug
928
CENTRAL WARNING UNIT CONNECTION PLAN
YELLOW PLUG
Instruments, Gauger, Radio
90
:WL.ABL,I
:WL.ABL.I
Bulb check control stop lights
Bulb check Control
Tail lighff
DISPLAY r -
CONNECTIONS ON:
POLARITY r cl cl
II q
25
12
13 c
24
23
11 c
22
10 i stop light IL
Tail light IL
II “asher fluid level IL
WL,ABL,ll
Iala”4 tiL.ABL.II
.“el res?rw sen*or
:aola”t temp. *enEm
NL.ABL. II lelayedl
:001ant lWd se”Scw
:wL, ABL, I
L
3
7
18
6 cl
5
7 I-) 17
Washer ‘hid level 6811601
7 1-j 16
Fuel re6orve IL
7 t-1 15
3
7
2 cl t-1
Coolant temp. IL
Coolant level IL
NL.ABL. II
Mayed
Printed in Germany VI, 1982
Central Warning Unit Connection Plan
Yellow Plug
90 33
90
Instruments, Gauges, Radio
Single Component Function Test
Observe the following points when checking the wiring.
- Plugs must be connected correctly.
- Plug contacts must not be deformed or pushed back.
- Wires must be checked for breaks or shorts
- Ground connections must not be loose or corroded.
Turn ignition on and operate starter briefly. All indicator lamps should go out with exception of stop light and battery charge indicator lamps.
Operate brake pedal to cancel the stop light indicator lame.
928
To be able to test the single components on a stopped engine, voltage must be supplied from term. 50 to the central warning unit without having the engine start.
This is accomplished by pulling off term. 4 ignition wire on the distributor and connecting it on ground
(engine cross member mounting bolt).
1. Parking Brake:
Pull up parking brake lever or connect parking brake contact with ground.
90.34 Single Component Function Test
CWL, ABL and parking brake IL should come on. Lamps must go out when releasing the parking brake or disconnecting ground.
Printed in Germany
928
Switch Function:
Parking brake released = contact open
Parking brake applied = contact made
Instruments. Gauges, Radio
90
CWL, AEL and coolant temperature IL should come on. Press acknowledgement button. CWL and ABL should go out, while IL remains on.
2. Coolant Temperature:
Pull off flat female plug on sensor term. W
(narrow female plug) and connect with ground.
IL should go out when disconnecting ground
Switch Function:
Temperature too high = contact made
Temperature normal = contact open
3. Oil Level:
Remove cap on multiple-pin plug in engine compartment at front right side (do not disconnect plug).
-
Connect term. 6 with ground.
Rimed in Germany - VI, 1982 Single Component Function Test 90-35
90
Instruments, Gauges, Radio
This test could also take place direct on the sensor
Pull off plug on sensor and connect with ground.
Test on Oil Pressure Switch
1
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2
928
Switch Function:
Oil level too low = contact made
Oil level normal = contact open
Switch
No oil pressure = contact made
Oil pressure
Function:
= contact open
4.Oil Pressure:
Connect term. 2 of multiple-pin plug in engine compartment with ground.
5.Brake Pad Wear:
Disconnect one plug of pad wear control (e. g, in engine compartment at front left next to brake master cylinder).
CWL. ABL and oil pressure IL should start to flash after about 2 seconds. Press acknowledgement button, lamps should continue flashing. Disconnect ground on term. 2, lamps should go out.
CWL, ABL and brake pad IL should come on.
Press acknowledgement button. CWL and ABL should go out, while IL remains on.
90.36 Single Component Function Test Printed in Germany
928 Instruments, Gauges, Radio
90
Function:
The wire connection will be broken and pad wear reported when the warning contact in one of the brake pads has been ground off.
The display can be cancelled by turning the ignition
Off.
The procedures described at the beginning of the function test will then be necessary for the following tests.
7.Washing Fluid Level:
Open cover for central electric board in passenger’s footwell.
Connect plug 0, term. 6 (green/blue) on ground with a piece of wire.
CWL, ABL and washing fluid IL should come on after approx. 20 seconds.
Press acknowledgement button. CWL and ABL should go out and IL must remain on.
Indicator lamp goes out when turning ignition off.
6. Coolant Level:
Pull off and bridge plugs on float switch.
Switch Function:
Level too low = contact made
Level normal = contact open
Testing on Float Switch
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L a
CWL. ABL and coolant level IL must come on after approx. 20 seconds.
Press acknowledgement button. CWL and ABL should go out and IL must remain on.
Disconnect bridged plugs, IL should remain on.
Switch Function:
Coolant level too low = contact made
Coolant level normal = contact open
Indicator lamp goes out when turning ignition off. The float switch is located in the right wheel house behind the rear cover.
Printed in Germany - VI. 1982 Single Component Function Test. ~~ 90 -37
90
Instruments, Gauges. Radio
8. Fuel Tank Reserve:
Remove cover in trunk on right side. Pull off plug on transmitter and bridge term. W and T with a piece of wire.
928
I
CWL. ABL and brake circuit IL must flash. Press acknowledgement button. All lamps should continue to flash. Disconnect bridge and connect plug on stop light switch. Lamps should continue to flash.
CWL, ABL and tank reserve IL should come on after approx. 10 seconds.
Press acknowledgement button. CWL and ABL should go out. while IL must remain on.
Indicator lamp will go out when turning ignition off.
Note
Brake circuit failure indicators can only be cancelled by disconnecting battery briefly.
Switch Function:
Reserve fuel level = contact made
Greater fuel level = contact open
Switch Function:
No brake pressure = Term. 81 and 81 a made
Term. 81 and 82 a open
Brake pressure = Term. 81 and 81 a open
Term. 81 and 82 a made
9. Brake Circuit Failure:
Pull off plug on one stop light switch below brake master cylinder and bridge opposite female plugs
(term. 81 and 82 a) with a piece of wire.
10. Brake Fluid Level:
Press down and hold float switch above brake fluid tank at least 20 seconds or bridge plug.
Printed in Germany 90-38 Single Component Function Test
928 Instruments, Gauges. Radio
90
12. Stop Lights:
Remove stop light bulb from one tail light assembly. Operate brake pedal.
CWL, ABL and stop light IL should come on.
Press acknowledgement button. CWL and ABL should go out. IL must remain on. Install light bulb again. IL should go out only after operating the brake pedal again.
CWL, ABL and brake fluid IL should start to flash after approx. 20 seconds.
Press acknowledgement button. Lamps should continue flashing.
Lamps will go out after switching ignition off,
Note
Light bulbs of same wattage must be installed on both sides. If not, the indicator will be activated even when both bulbs are functioning. Should the tail light or stop light indicator lamps come on in spite of perfect condition tail light assemblies. the defect could be in the central warning unit or bulb check control.
Switch Function:
Fluid level too low = contact made
Fluid level normal = contact open
11. Tail Lights:
Turn parking lights on. Remove tail light bulb from one tail light assembly.
CWL, ABL and tail light IL should comeon after approx. 4 seconds.
Press acknowledgement button.
CWL and ABL should go out. IL must remain on.
Tail light IL should go out after installation of light bulb.
When the bulb check control is defective, both tail lights and/or both stop lights could be malfunction- ing.
An adapter, Part No. 928.641.610.00, could be installed in place of the bulb check control as an emergency solution. The adapter will bridge the concerned connections.
Printed in Germany . VI, 1982 Single Component Function Test 90-39
90
Instruments. Gauges, Radio
In this case no warning lamps would be activated for failure of a stop or tail light.
Note
The central warning system is only available as optional extra (MI equipment in Type 928 cars beginning with
1980 model.
An adapter is installed standard in the same housing instead of the central warning system.
The monitored functions are limited to:
1 - Oil pressure
2 - Brake circuit failure
3 - Brake fluid level
4 -Brake pad wear
5 -Parking brake
6 - Coolant temperature
7 - Fuel tank reserve
There is not a red acknowledgement button in the center console then.
928
90.40 Single Component Function Test Printed in Germany
928
ALARM SYSTEM 928 instruments, Gauges, Radio
90
Description:
The alarm system is switched on and off when locking and unlocking the doors with the S key
(long key).
Beginning with 1981 models the alarm system is also switched off by unlocking the tailgate and switched on by locking the tailgate by way of an additional locking movement with the S key.
Using the auxiliary key will mean only mechanical locking and unlocking of both doors and the tailgate
The alarm is set off by opening the doors, tailgate or engine hood.
After activation of the alarm system a separate alarm horn will sound off intermittently for about
30 seconds (uninterrupted sound for Swiss version) and can be reactivated by repeating the described actions.
The engine can also not be started.
2. Disconnect two-pin plug underneath glove box on right side and remove glove box.
3. Pull off heating hose on right side.
4. Press alarm control unit off of brace at the retainer clamp with a screwdriver.
5. Pull off both plugs on alarm control unit.
Removing
Control and Installing
Unit
Alarm
Removing
Horn and Installing Alarm
1. Unscrew tray underneath the glove box.
1. Remove blower (see page 87 - 16 of this repair nWllIall.
2. Unscrew right engine hood hinge and remove grill. hinted inGermany - VI, 1982
Alarm System 928 90-41
90
Instruments, Gauges, Radio
3. Detach connecting rod
928
3. Unscrew alarm horn (M 10 hexagon nut,
17 mm wrench) and pull off wires.
4. Disconnect plug and remwe lock cylinder. a
Removing
Cylinder and installing Lock
1. Remove door panel.
2. Unscrew mounting bolt.
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Removing
Lock Upper and Installing
Section
Tailgate
1. Remove trim panel on bottom of tailgate by pulling out spreader rivets and pressing trim panel forward out of retaining clips.
Disconnect trunk light.
Printed in Germany a
90.42 Alarm System 928
928 Instruments, Gauges, Radio
Note
Secure wires with adhesive tape in area of rear window wiper drive when installing.
90
2. Disconnect trim panel on left ride and remove plug of alarm switch.
Secure plug connection with adhesive tape to prevent unintentional disconnection.
3. Unscrew and remove lock upper section.
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Alarm System 928 90.43 Printed in Germany - VI, 1982
90
Instruments, Gauges. Radio
Troubleshooting Alarm
Check contact switch on lock cylinder.
System:
1. Disconnect plug of lock cylinder contact switch being checked outside of door or tailgate.
- Plug for driver’s door underneath instrument panel on left side.
Disconnect door sill molding and side trim panel and press off carefully. Do not bend trim panel.
928 a
- Plug for passenger’s door underneath instrument panel on right side.
2. Connect ohmmeter on plug of wire leading to door.
- Plug for tailgate behind side panel trim on right side.
90.44 Alarm System 928 Printed in Germany a
928
- Activating alarm system = connection of meter on brown and brown/red wires.
- Deactivating alarm system = connection on brown and brown/green wires.
Instruments. Gauges, Radio
90
3. Lock or unlock pertinent lock cylinder with the S key.
Meter should not display resistance when switching the contact switch.
l-in
Note
Contact switch can only be replaced together with the lock cylinder.
3. Leave test lamp connected on term. 30 and make other connection on term. E.
Checking Wires and Connections
1. Remove alarm control unit.
Pull off both plugs on alarm control unit. a
2. Connect test lamp (max. 3 W) on term. 30 and Hn of two-pin plug.
When lamp comes on, there is battery voltage and wire to alarm horn and term. 31 on disconnected eight pin plug is okay.
Activate the alarm system with S key on both doors and the tailgate.
Lamp must come on briefly.
4. Connect test lamp on term. 30 and A.
Deactivate alarm system on both doors and tailgate.
Lamp should come on briefly.
Alarm System 928 90.45 hinted in Germany - VI, 1982
90
Instruments. Gauges, Radio
5. Connect test lamp on term. 30 and T.
Open and close both doors and tailgate separately. Lamp should come on while opening.
6. Connect test lamp on term. 30 and MK.
Open engine hood - lamp should come on.
8. Connect test lamp on term. 30 and K 1.
Lamp should come on.
Checking
Unit
Function of Control
928
Note
The switching point of the engine hood contact switch must be checked to prevent unintentional activation of the alarm system when car is shaken while alarm system is set.
Open engine hood slowly. Lamp should go out immediately before engagement in lock. Adjust switch if necesrary.
The use of a test lamp instead of the alarm horn is recommended Inoiselessl.
1. Connect eight-pin plug on alarm control unit
Two-pin plug remains disconnected.
2. Connect term. 30 (red wire) on control unit with a piece of wire. Connect test lamp on term.
Hn of control unit and red/white wire of two- pin plug.
7. Connect test lamp on term. 30 and 61 (connect on both term. 61 separately).
- Lamp comes on and goes out when turning ignition on (connection via central electric board Z 6).
- Lamp comes on and goes out after starting engine at high speed (connection via central electric board Z 1).
3. Lock door with S key (set alarm system) and unlock door with the auxiliary key. Lamp should flash, i.e. alarm should be activated.
Deactivate system - lamp goes out. Make test on both doors and tailgate.
4. Activate alarm on driver’s door and do not deactivate. Lamp flashes about 30 seconds.
Open engine hood. Alarm should be activated again.
90.46 Alarm System 928 Printed in Germany
928
5. Start engine when system has been activated.
Engine should not start.
8. Disconnect test lamp and connect two-pin plug on control unit. Check function of alarm horn by activating alarm again.
If functions are not fulfilled. replace alarm control unit.
Instruments, Gauges, Radio
90
Note
A defect in the control unit could cause failure of the ignition or fuel pump under certain circumstances, even when the alarm system is not activated.
If a new control unit were not immediately available in this case, the following measure will provide help.
Pull off plug Z on central electric board and bridge terminals 1 and 6 on central electric plug.
This will stop function of the alarm system.
Printed in Germany VI, 1982 Alarm System 928 90.47
928 Instruments, Gauges, Radio
90
SERVICE INSTALLING BLAUPUNKT RADIO SQR 22
(COLOGNE, ATLANTA OR MONTEREY)
Applicable for cars up to and including 1982 models.
Parts of 1983 model required for installation:
- Mask, upper
- Mask, lower
- Digital clock
4. File back radio opening at bottom to edge
(approx. 2 mm),catching burrs with a rag.
,
Additional Part Requirements:
- Two M 5 x 10 hexagon bolts with nuts and washers
(for installation of solenoid valve plate)
I
F’
1
- Six M 3.5 x 16 Allan screws
-w-
I
1. Remove shelf and trim on sides of center
CO”S&.
2. Remove center vent and cover frame.
3. Remove control switches, display panel and clock.
I
t
5. Mark location of opening for new digital clock and cut out opening with a suitable saw.
Deburr edges. a
Printed in Germany VII. 1983 Service Installing Blaupunkt SQR 22 Radio 90.49
90
Instruments. Gauges, Radio
6. Control switch and display panel must be brought to same height as radio opening by using suitable material on bearing surfaces (e.g. plastic or modelling wood). y--y-
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928
1
9. Make a radius on lower edge of display panel with a fine file.
7. Solenoid valve plate has to be moved down because of greater installed depth of new radio.
Make up two sheet metal holders for this purpose.
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10. Saw slots in front radio holder and push holder forward as far as possible when tightening screws.
8. Unscrew solenoid valve plate and screw it on tight underneath the flap box with sheet metal holders.
90 50 Service Installing Blaupunkt SQR 22 Radio Printed in Germanv
928 Instruments, Gauges, Radio
90
11. Move relay for seat belt fasten sign forward by approx. 40 mm.
Drill new hole with an angled drill,
14. Connect antenna, speaker, ground and feed wires on radio. Slide radio into opening until tabs on sides engage in holding frame.
15. Install upper mask frame and reinstall all removed parts.
12. Insert lower mask frame with digital clock and connect digital clock.
13. Install holding frame for radio in opening and secure by bending tabs provided on holding frame.
16. Ashtray can be brought to correct height by using suitable washers on ashtray mounting points.
Printed in Germany VII, 1963
Service Installing Blaupunkt SQR 22 Radio 90-51
a
928 Instruments,Gauges,Radio
UPSHIFT INDICATOR (0 n I y U S A in Cars with Manual Transmission)
90
Description on Troubleshooting and Information
The upshift indicator is an illuminated arrow integrated in the tachometer.
The Signals are: - engine speed, engine temperature,
- road speed and
- injection time.
If the upshift indicator malfunctions, first check the following points.
1. Engine must be operating correctly and engine speed displayed on the tachometer.
2. Coolant ( engine ) temperature must be displayed correctly on the instrument,
3. Speedometer must display the road speed correctly.
The upshift indicator will light up when it is practical and economical to shift up into the next higher gear. It works in gears 1 through
4 and remains illuminated until the next higher gear is engaged or the operating condition causing illumination of the indicator is changed (e.g. coasting, full throttle, etc.).
The indicator lamp is designed to be very bright for clear visibility in daylight driving and less bright for night driving when main lights are switched on.
If these points can be confirmed, the instrument cluster will be receiving signals
0” engine speed
- engine temperature and
- road speed
The electronic tachometer control is integrated lame. in the and cannot be replaced separate- ly, as also the indicator
The injection time (ti) signal will be in the
L-Jetronic control unit while the engine is running, but there could be a break or loose connection in the wiring between the control unit and instrument cluster.
Signals already available in the car are used to activate the indicator. Consequently there are no additional transmitters or sensors.
Printed in Germany VIII, 1984 Upshift Indicator 90 53
90
Instruments,Gauges,Radio
The ti signal can be checked with help of an oscilloscope on central electric plugs L 5 and
X 1 (plugs remain connected).
Ti signals have a rectangular pulse shape. The instrument cluster must be removed to check the ti signal wire for breaks.
This wire break test is made from instrument cluster term. 11 M to L-Jetronic control unit term. 11.
If signals are okay up to the instrument cluster, it will be necessary to check pertinent conducting paths on the printed circuit of the instrument cluster for breaks and good contact of connections.
If necessary, the tachometer must be re- placed.
928
90 54 Upshift Indicator Printed in Germany a
928 Instruments, Fuel Gauge, Alarm System
90 a
Checking burglar alarm
Note
The alarm control unit is located behind the glove compartment.
The following signals must be present at the alarm control unit terminals:
Input signals
1. Terminal 31: Ground
2. Terminal 30: Battery voltage
3. Terminal 15: Battery voltage with ignition switched on
4. Terminal 61: Battery voltage with engine run- ning
5. Terminal T: Ground with doors open or rear hood open.
6. Terminal MK: Ground with engine hood open or radio removed.
7. Terminal A : Ground with key in lock cylinder (doors or rear hood) turned in
“open” direction.
8. Terminal E ; Ground when lock cylinder turned towards “closed”.
Output signals
1. Terminal 87~ Battery voltage with ignition switched on.
2. Terminal Hn: Battery voltage with burglar alarm primed and triggered (permanently in
Swiss vehicles).
Note
There is a relay in the central console of USA vehicles which operates fog lamps and brake lamps as an visual warning in addition to the alarm horn.
90 - 55
Checking burglar alarm
Printed in Gsrmany - MII, 1989
90
Instruments, Fuel Gauge, Alarm System
Check auxiliary control unit - burglar alarm
Note Output signals
The auxiliary control unit is accommodated in the central console.
The output signals may only be checked with the relay fitted. r(
1. Terminal 2: Ground ff a) ground at terminal 6
/
1 b) burglar alarm primed after closing the rear hood approx. 25 seconds after the internal lighting has gone out (short pulse of approx.
0.5 seconds only).
1
2. Terminal 6: Ground if ground at terminal 9.
Input signals
Remove the relay and check the input signals at the base.
1. Terminal 1: Ground with rear hood open or for as long as the internal lighting is switched on by means of the time-lag relay.
2. Terminal 3: Ground
3. Terminal 4: Battery voltage (terminal 30)
4. Terminal 6: Ground with the key in the lock cylinder (doors or rear hood) turned towards “closed (only for as long as the lock cylinder is held in this position).
5. Terminal 9: Ground when the lock cylinder is turned towards “open”.
928 a
90 - 56 Check auxiliary control unit - burglar alarm
Printed in Germany - XXII. 1989 a
928 Instruments, Fuel Gauge, Alarm System
Backlit instrument cluster, removing and Installing
From Model 89 onwards
1. Disconnect battery.
2. Remove steering wheel
3. Remove cover under the instrument cowling
(2 screws).
4. Undo fastening screws (2) for instrument cowling.
5. Remove steering-column switch.
6. Remove ignition-lock cover.
(Procedure is described on page 94 - 4)
7. Disconnect plugs (4) from instrument cluster, turn both locking levers outwards for this.
Note
The plugs are coded and cannot be confused
8. Liff instrument cowling carefully and tip to the rear.
9. Pull instrument cluster from bracket
90 a
Backlit instrument cluster, removing and installing
Printed in Germany - XXII, 1989
90 - 57
926 Instruments, Fuel Gauge, Alarm System
90
Advancing the odometer reading of the backlight instrument cluster
Note
Advancing the odometer reading is performed within the the scope of the instrument cluster diagno- sis under menu item “Specific functions” and is required to adjust the odometer reading after replacement of the instrument cluster. This function is only available as of software level K 26.
1. Select Specific Functions (SF)
(refer to Service Information: Diagnosing the instrument cluster).
2. Select “Preset tot. Counter
3. Pulling the operating lever selects input mode
Note
The input mode is only accessed at a mileage below 256 kms or 256 miles, respectively.
Upon start of the input mode, the following display appears
4. Use the operating lever to enter the rightmost position
- up:
- down:
+ 1
-1
- press:
- pull: entered position moves 1 position to the left entered position moves 1 position to the right
(only required for fault correction).
Advancing the odometer reading of the backlight instrument cluster
Printed in Germany - XXVII, 1991
90 - 59
90
Example: input 3840 km
/WE
Instruments, Fuel Gauge, Alarm System
Operating lever is moved up three times pzzq
K 26 INPUT MODE
Press operating lever
928
Operating lever is moved down twice
1000038
Press operating lever
INPUT MODE
Operating lever is moved up four times
K 26
c I
INPUT MODE
Advancing the odometer reading of the backlight instrument cluster
Prinlcd in Germany - XXVII, ,991
0 90 - 60 l I
928
Press operating lever
/mm
Instruments, Fuel Gauge, Alarm System
90
To store the new value, the trip mileage reset button must be pressed without interruption for more than 14 seconds.
If the button is released prematurely, the function is aborted without the new odometer reading being stored
After 14 seconds have elapsed, the following display appears:
If storing is not possible (e.g. due to low battery voltage), the following fault message is displayed:
In this case, aborl the function and repeat advancing the odometer reading after having corrected the fault (charge battery). To access the selection mode of the instrument cluster again, the operat ing lever must be moved up again. a
Note
If a value above 256 kms is entered, repeated access to the enter tmode is denied and the odometer cannot be advanced again.
After terminal 30 has been disconnected, the total mileage indicated may deviate by +I- 8 kms.
Advancing the odometer reading of the backlight instrument cluster
Prinled in Germany - XXVII. 1991
90 - 61
929 Radio, Telephone, Bordcomputer
Facilities for subsequent telephone installation
M 195 Cellular telephone system
M 495 C-Net telephone system
As from Model 88, all 928 vehicles may be fitted with facilities for subsequent telephone installation.
This preliminary equipment embraces all cable harnesses required, the brackets for the radio and operating unit as well as the telephone an- tenna.
91
Facilities for subsequent telephone installation
Printed in Germany - XX, 1999
91 - 1
91
Radio, Telephone, Bordcomputer
Laying the cable harnesses in the vehicle
929
0
A Antenna separation filter
B Transceiver unit
C Operating unit
0 Battery
E Central electric system
91 - 2
1 Terminal 31
2 Terminal 30
3 Terminal 15
4 Antenna cable
Facilities for subsequent telephone installation
Printed in Germany-XX, 1998 a
928 Radio, Telephone, Bordcomputer
91
Installing the transceiver unit
The transceiver unit is installed under a cover panel on the right- hand side of the trunk.
The baseplate can be fitted with longitudinal slots to compensate for any irregularities.
1.2 Fastening points for the Cellular baseplate
I
1.1 Fastening points for the C-Net baseplate
Note
The riveted blind nuts are all situated in molded beads. When drilling, bear in mind that the fuel tank is directly below.
F = Direction of travel a
Facilities for subsequent telephone lnstsllation
Printed in Germany -XX, 1988
91-3
91
Radio, Telephone, Bordcomputer
2.1 Installation of the C-Net baseplate 3.1 Bracket for the C-Net transceiver unit
926 a a
2 2 Installation of the Cellular baseplate
3.2 Bracket for the Cellular transceiver unit
91 - 4 Facilities for subsequent telephone installation
Printed in Germany-XX, 1999 a
928
Radio, Telephone, Bordcomputer
4.1 Installation of the C-Net transceiver unit with accommodation of the excess length of the cable harness. i
:- r ;-..-.- c-
( v
,
,_, i j : ‘\ .I
/--.
---
‘1 ‘\‘, !> \,.”
; ;.,?$p ;: ) cs -,-” .,-\ /. 4
4.2 Installation of the Cellular transceiver unit c
91 a
Fecillties for subsequent telephone installation
Printed in Germany - XX, 1968
91 - 5
Radio, Telephone, Bordcomputer
91
Installation of the antenna
The telephone antenna Is mounted on the roof.
Installation of the antenna separation filter
The antenna separation filter is only installed for C-Net telephone systems.
The separation filter is mounted on the right- hand side of the transceiver unit. L
‘\j----J
?,.l hi-
B
A
Dimension A: Without sun roof
- 105 mm from the rear edge
Dimension B: With sun roof
- 40 mm from the rear edge
928 a
91 -6 Facilities for subsequent telephone installation
Printed in Germany -XX, 1980 a
928
Installing power supply lines
1. Ground wire
Radio, Telephone
91
The positive terminal 30 line is run from the positive pole of the battery to the fuse in the spare wheel well.
The ground wire is run along the rear wiring harness to the ground point.
2. Positive supply, terminal 30
From the fuse. the line continues along the trunk floor to the transmitter-receiver stage,
, -+--x- l , *: “. ,
>i ”
3. Positive supply. terminal 15
The positive terminal 15 line is run from fuse
No. 9 to plug N 1.1. From 1990 models on it runs from fuse 43 to plug N 2.4 (already wired).
Telephone pre-preparation
Printed in Germany - Xxv. 1990
91
Radio, Telephone
928
From plug N 1 .l (N 2.4 from 1990 models on) along the tunnel between the rear seats and to the transmitter-receiver stage in the trunk.
This line is run from the transmitter-receiver stage parallel to the terminal 15 power supply line as far as the control stage.
4. Line from transmitter-receiver stage to con- trol stage.
91 - 8
Telephone pre-preparation
Printed in Germany - Xxv, 1990
928
5. Antenna cable
Radio, Telephone, Bordcomputer
91
The antenna cable is fastened in the area of the roof support with 3 clips. It is laid from the antenna along the roof support to the B column on the right, down to the door seal and along the rear harness to the antenna separation filter.
*
Facilities for subsequent telephone installation
Printed in Germany - XX, 1988
91 - 9
l
Retrofitting CD player from Model 89 onwards
Vehicles with radio equipment or sound packet
Loudspeakers, amplifier and cables are in- stalled into these vehicles.
1. Install retaining frame for radio
2. Connect CD player.
Note
The connector assignment is specified on the
CD player.
3. Slide in CD player and latch.
Retrofitting CD player from Model 89 onwards
Printed in Germany - XXII, 1989
91-
11
928 Windshield Wipers and Washer
92
ADJUSTING HEADLIGHT CLEANER ,ETS
Special Tool 9135 l i
.
Insert tool into spray jet and turn jet insert so that long arm of tool points to center of lens. c a
Printed in Germany
Adjusting Headlight Cleaner Jets 92 - 1
c?YyT
W1I,dsiiicld
_ ,_ _I_____-_---_-_
\, i :<.I. !.~,!. .,; i i’Wi,)i rs Wld wa:i,er
..-_-~.-~;__
1 \.’ ‘,,, i
__-
928
I, Renlovc lrill> fri,r.i cc-r ll~i nt i>r N,I,IS , ~~~‘I:III!: c,tt spreader iiveli ,arlcl ;r~lci~i,lv ‘ri11l iivu,;l~~i
,,,I/ 01 hn!dinp Cl!,X. ecy--‘y-y rj _
:.. r,:; ,,,’ 11<11~,
‘r
4. h:nrk l’i <WC! IlClC <lui;;de (distance 47 :“rr;, an‘, isi,il <liill ‘I 0 prcven1 da;!iaj:e. rile s,,r:ace be-
~ni* dilllrd should he cwtrcd wiih rape.
.---
5. C$rn up bnlh !hoies wilh a lholeraw Make
SW? liut holes don’ f lhaw runou~. Remove bars.
_~~- -
-
.I
.-“Ts-
.c .+ +, i*
2. Mark hole for wiper mount on inside of panel seam with a scribe and suitable template. e. g. a cardboard strip. whose width equals the hole’s inside diameter.
6. Touch up edges of holes with IUSI protecrion paint and body paint. Insert rubber seal for wiper mount with a sealing compound and hoI1 wiper mount on rear lid,
‘12 - 2
Service lnrrallinfi Rear Window Wiper
,“, 1g8o _ Primed in Germany l
Windshield iVipers and Washer
92
4 ,=
@/ jc>+m
I 2 k/;,
1 i-‘;,l
! zzz?Lp:~~;
:~&fj+--~
&v
J ,. ;/
4
7
4
1
0
3
4
NO.
5
6
7
8
0
9
1
Dcrrriptinn oty.
Removing
Nolr \\‘hen
Instal I ins
Wiper mount. upper
,mit M 6 x 15
Lockwasher
Rubber hushing
Rllhber hilshin~
\i’iper arnl
Lockwasher
1
1
1
1
I
I l
’ 1
1
I
Nut M 6
WiaShCI
Nut M R
’ 1
1
1
Install with hody sealing compound
Spcri;ll Initr~~c.lin~s
Printed in Germany - IV. l?i;ii Scrvire Inrialling Rear Window Wiper !I” - n
92
Windshield Wiper3 and Washer ‘9 2 8
7. Remove access plate.
Detach carpet on lock cross member. Cut OL,I small holes in carpet for mounting bores of mnfor console. Glue carpet dclwn again.
1U. Connect two-pin plug and ground on wiper motor and boli motor console at the provided points. Adjust motor console in the slots un- til output shaft of console is aligned with shaft of cwer bearing.
-+ .- a
R. Remove foam rubber part behind the access plate. Install (glue) new foanl whber part with opening.
11. Turn lever on upper wiper mount clockwise against the stop. [ioli wiper arm so that dis- tance to left frame of rear lid is appron. 2 to 3 cm.
Torque for nut M R = 12 Nm 18 ft lb) and for M (i= 10 Nm (7 ft lb).
9. Connect relay with four-pin plug and insert in hole below the lock cross member.
92 -4 Service installing Rear Window Wiper Printed in Germany
928 Windshield Wipers and Washer
92
12. Remove right side trim panel from center con- s”,=.
Remove switch plate in center console. Un- screw right rear center console mounting scow and lift center console enough that two-pin plug for switch can be pushed through forward.
14. Close rear lid and wet down rear window.
Turn on ignition and operate rear window wiper. Rear window wiper should wipe four times and then return automatically to OFF position.
Check wiped area, correcting if necessary by changing wiper arm on shaft.
,
,
;. : l,\..
:// C’
Y1;--;’
;a ,,..’
. . . . . .
_-
I r ‘, ,,,
“X 6,
,, >:
-4
“.., /
\
_ _r!
0
,’
. .
.-%. ‘.
.‘&?A6
,
_ --
] -:$q
.;*S$+&~*
~.
_ ::a. - (.
1 .+ :;:>,
1
15. Mount trim panel on center console and rear lid. Replace access plate by a new enc.
13. Connect two-pin plug of switch with standard
PI%.
Printed in Germany - Iv, 1980 Service Installing Rear Window Wiper 92 - 5
92
Windshield Wipers and Washer
REMOVING
BEGINNING
AND INSTALLING
WITH 1983 MODELS
WINDSHIELD WIPERS
928 h,o
.-
-CL-G
‘Cl4
16-
17-e
22 5 6 2l20?9 18
I I I I ‘“y--15
92-6 Removing and Installing Windshield Wipers
Beginning with 1983 Models
Vll. 1983 Printed in Germany a
928
-
NO Description
4
5
1
2
SCWW
M6x18
Washer
3 Grommet
Nut
Lock nut
10
11
8
9
6
7
Crank
SCF?W
M6x12
Lock washer
Wiper motor
Cap
Nut
I7
18
I4
I5
I6
19
20
21
22
I2
13
Wiper arm, driver’s side
Wiper arm, passenger’s side
Cap, right
Cap, left
Nut
Washer
Rubber bushing
Rubber bushing
Crank drive
Connecting rod, left
Connecting rod, right
Windshield Wipers and Washer
1
2
2
2
1
1
1
1
2
1
2
2
3
1
1
1
1
1
1
-
SfV
Removing
1
Note When:
Installing
Torque:
25 Nm (18ftlbl
1
3 Torque:
11 Nm (8 ftlb)
Torque:
14 Nm I10 ftlb)
Special
Instructions
92
Printed in Germany VII, 1983 Removing and Installing Windshield Wipers
Beginning with 1983 Models
92 7
92
Windshield Wipers and Washer
REMOVING AND INSTALLING
WITH 1983 MODELS
WINDSHIELD WIPERS BEGINNING
1. Pull off seal for fresh air chamber and pull cover o”t forward.
3. Remove connection in fresh air chamber.
Disconnect plug and disengage plug socket for easier installation on wall.
928 a a
2. Remove wiper arms and wiper arm bases. Hexagon nut of left base can be removed with a flat, straight closed wrench.
4. Remove wiper assembly to the right, while swinging up wiper motor at same time.
T-
/ ,i..‘* a
92.8 Removing and Installing Windshield Wipers Beginning with 1983 Models
Printed in Germany a
a
928
5. Check installed position of wiper arms.
Windshield Wipers and Washer
92
Printed in Germany - VI I, 1983 Removing and Installing Windshield Wipers
Beginning with 1983 Models
92.9
y ,J 5 ixtvrior I.igl!ts, 1,amps, 5rri~ili~~c
94
III, Iii < ,,A ii’,
Fog light i-i 3
.,.
Main headlight
Scaled beam (7 inchj
Turn signals. irunt + rear
Stop light
Backup light
IParking l&lit, front
Side marker lights, lmnt + rear
7’ail ligllt. ~*a
ILictnrc plate light c
32 cp
5w
6 cp
5 1%’ i\j;i tts
55 \\ co/50 1%’
YC
SAT
R 19-5
-
,iasr
PK 22 i
10%
BA 15 s
89
SV8.5-8 a
Printed in Germany ,iUlh t~‘l,a,t :i-1 - 1
94
Exterior Lights, Lamps. Switciles
AIMING llEAULlCl,TS
Requirement:
Tire pressure correct. fuel tank full. driver’s seat occupied by a person or weight of appron. IO lkg
(155 lb).
4. Aim headlights with optical aiming equipment.
Note
--.
If equipped with lbeadlight beam adjuster, turn adjuster lknob so tbat wllite dot on lknob faces iorward (audible click). j,,_>?y---~
Adjusting screw A = vertical adjustment adjusting screw B = lateral adjustment
5. Reinstall trim ring and headlight cover.
928
1. Turn zn ignition.
“. Turn on headlights ,inu, lbeam?~. C.icln lenrcS..
~cmove 3 Phillips screws (arrows) and lahe ofi r;,dli:i~t mver and trin ring
- c,* _ 2
--
Aiming lIcodli~:i~ts j-l_ - ,.~_ ,. _..,
1, J 5:::
_~_ __.~ _
1’11111c“ /‘I rN;:,“y
94 EutCriur Ligllts. Lamp;. Switches ilEMO\‘ING AN” INSTI\LLlNG STEERING < OLUMN S\i,TC 1,
1. Disconnect battery ground lead.
2. Rrmovc steering wheel.
:3. Llnscrew cover underneatli steering column rwitcti.
5. Loascn inrmxnenl cmw mwmin,~ SCT~I~Y.
, ’
. . fz -4’2~prr
9s’
A ++
.I
2‘ %
-,g*., m”;k%;
.,\,.‘ ““1
I
‘3
;
-. ._ 1
-‘*<“”
;I +.j
I
%
+ up, 1
5
6. ILift instruulcnt cover. Pull off plugs and remove steering colun~n \witch.
*-
-~ -8 i. Ln.xcn rt~r-rmg column switch mulmting ECT~W.~
94 - .L IRemoving and Installing Steering C’olumn Switrh
Printed in Germany
Exterior Lights. Lamps. Switches
94
REMOVING AND INSTALLING SWITCH IN INSTRUMENT COVER
1. Pull off switch knob.
2. Compress both retaining springs.
3. Pull out switch and detach plugs.
Printed in Germany
Removing and Installing Switch in Instrument Cover
94 - 5
94
Exterior ILights, Lamps and Switches
RE.2lOVINti AND INSTALLING SEALED REAM HEADLIGHT “NlTS
928
1. Turn on qnition.
2. Turn light switch to position 2 ihcadlightc raised).
3. Turn ignition off.
4. Remove 3 Phillips screws @riowsl and take 1)11 headlight cover and trim ring.
5 iltiwve :4 small Phillips screws (arrows, frorrl rralcd heam wruring ring and remove ring.
1
6. Unplug connector. replace sealed beam unit and plug in connector.
I. Reinstall sealed beam securing ring.
8. Check lights.
9. Reinstall trim ring and headlight cover. q‘l - c Removing and Installing Sealed Ream lleadlight Units 1. 1978 - Printed inGermany
928 Exterior Lights, Lamps and Switches
94 a
AIMING MAIN HEADLIGHTS
(since 1980 Models)
- USA
Headlights must be aimed with an optical headlight aimer.
Requirements:
Tire pressure correct, fuel tank full, driver’s seat occupied by a person or weight of approx. 70 kg ( 155 Ibs.).
Adjusting screws
Screw “a” - vertical adjustment
Screw “b” - lateral adjustment
Printed in Germany
Aiming Main Headlights - USA (since 1980 Models) 94 - 7
928 Interior Lights
--
BULB CllART
1
Engine compartment ligtit
Inside light
ILuggage compartment light
Zlovr box light
Vanity mirror light battery charge indicator
,mtrurrient cluster light ishtray light
Heater/ventilation light switch
All other bulbs
(instrument light, indicator lamps etc. j
I
10 w
I
3 w
5 w
3 w
K hl
L
IVY 10 - 3
(VA)
Base
BA 15 s
SV 8.5 - 8
Rt!IllXkS
1
8” 7 - e sv 8.5 - 8 w 2.1x9.5 i
2 w BA I s I
1.2 w WT 5 - 1.2
( “)
1%’ 2x4.6 d
Prirlred in Germany IV, lii.ao
Bulb Chart !I‘:- I
96
Interior Lights
CONTROL PANEL VARIATIONS - 1980 Models
928
+ +
+
With manual tral warning air conditioner lighr
With automatic central warning air conditioner light and cen- and
96 - 2 Control Panel Variations Iv. 1980 - Printed in Germany
e
928
CONTROL PANEL VARIATIONS - early 1980 Models
Interior Lights
96 l
+ +
+
Note
Control panels will be replaced by different versions during course of model year 1980 (see page 96 - 2).
Standard
(manual warning air conditioner light
With automatic central warning and air conditioner light central and
Printed in Germany - IV, 1980 Control Panel Variations early 1980 Models 96 - 3

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