928 S4,928 GT Models 90,91

928 GTS

.Technical Speci , f icat 4s

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INTRODUCTION

We are publishing this booklet with information on

Technical Specifications

to provide the Porsche mechanic with dimensions and adjustment values necessary to perform expert repair.

We assume that the mechanic is familiar with the service operations outlined in the workshop manual.

When using this booklet, also refer to the Service Information Bulletins since the data and specifications are subject to change without prior notice.

Technical Specifications

928 S4,928 GT Models 90,91

928 GTS Models 92,93

1st edition Status as per 811992

4 Contents ,

Page

General

Important conversion factors and new dimensioning units ............. 7

Survey of type designations ........................... 8

Engine number codes as of Model 90 ...................... 10

Engine type codes ..............................................................

11

Chassis number codes 12

Transmission number codes as of Model 90 ................... 14

Transmission type codes ............................. 14

Transmission number codes as of Model 92 ................... 15

Transmission type codes ............................. 15

Engine and clutch

Engine data 928 S41928 GT 16

Engine data 928 GTS ...................................................................................

17 .. Technical datatype 928 S4. 18

Torque specifications - engine ..................................................

20

Tolerances and wear limits - engine 24

Crankshaft - normal and reconditioning dimensions ............... 28

Tightening sequence- crankcase - upper and lower parts 29

Checking pistons and cylinder bores 30 ... .. ... ..........................

Survey of pistons (dimensions, weights and compression) 32 ...........

Piston and cylinder marking ................ : .......... 33

Checking valve seat angles, valve dimensions and valve guides ...... ., . 34

Reworking valve seats and checking installation of valve springs. , . , . , . , 35

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Page

Machining the cylinder head mating face ..................... 36 Installing the cylinder head ............................ 37 Camshaft survey. ................................. 38 Checking camshaft adjustment .......................... 39 Adjusting camshaft belts, belt dimensions and adjustment values ................................. 40 Coolant mixing table and cleaning engine oil circuit. ....................................... 41 Test values - engine ................................ 42 Torque specifications - clutch ........................... 44 Clutch - general .................................. 45

Transmission

Torque specifications - manual transmission, shift actuation and central tube .......................... 46 5-speed manual transmission G 28, general data ................ 48 Torque specifications - automatic transmission .................. 50 4-speed automatic transmission A 28, general data ............... 53 Pressure specifications in bar overpressure as of Model 90 ........... 54 Shift points in knVh ................................ 55

6 Page

Front axle, steering, rear axle

Torque specifications-front axle . . . . Torque specifications - steering . . . . Torque specifications - rear axle . . . . Technical data - front axle, steering and rear axle . . . . . . . . . . . . . . Wheel alignment adjustment values . .

Brakes, wheels, tires

. . . . . . . . . ., ., . . . . . . 56.

. * . . , . . . . . , * ..,. I . . 58

.,., . . . . . . . . . . . . . . . 59

., . . . . . . . * . . . ...*. , 61

., . . . . ., . . . . . ,,.,,* 62

Torque specifications - mech. brake system ................... 63

Torque specifications - hydr. brake system ................... 64

Technical data - brake system .......................... 65

Wheels and tires ................................. 71

Air conditioning

Technical data - air conditioning ,’ . . . . . . . . . i . . , , . . , , . , . , . , 74 Torque specifications - air conditioning . . . . . . . . . . . . . . .,.... 75

General technical data

Dimensions . . . , . . . . . . . . . , . , . . . . . . . . . . . . ...* . . 76

Performance data , . , . , . , . . . . . . . . ..,.,, , ., .,....a 77

Weights . . , . , . . . , . . . . . . . , . . . , . . *., ., ., .,.. *. 78

Filling capacities . , . . . . . . . . . . . . . . . . . . . . ., . . . I . . . 79

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Important conversion factors and new dimensioning units

Former units

Pressure Technical atmosphere output Horsepower Force Kilopond Torque Kilopondmeter

Conversion factors

at (kp/cm2) in bar kp in N HP in kW kpm in Nm m/s in km/h at /nmmHg- kmk in mph (miles) OF (Fahren- heit) in°C I in U.S. gal I in Imp. gal

at (kp/cm2) Bar (bar) HP Kilowatt (kW) kp Newton (N) kpm Newtonmeter (Nm)

x 0.981 x 9.81 x 0.736 x 9.81 x3.6 x 735.56 x 0.621

(‘F-32) x 0.555 x 0.264 x 0.22

Present units

To convert tightening torques from kpm into Nm, the conversion factor 10 can be used. This is sufficient for workshop applications.

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8 Survey of type designations

Model Vehicle Engine Dis- Output Stroke/ Com- year type designation type placeDIN-kW bore pression desig- A = Automatic desig- ment (HP) (mm) ratio nation nation act. at rpm

(cm E

1990 928S4 Europe,RoW A M28142 4957 235(320) 78.91100 lO.O:l

928GTEurope,RoW M28147 4957 243(330) 78.91100 lO.O:l 928S4 USA,Canada A M28/42 4957 235(320) 78.9/100 lO.O:l 928GTUSA,Canada M28/47 4957 78.91100 lO.O:l 243(330)

1991 928S4Europe,RoW A M28/42 4957 235(320) 78.91100 lO.O:l 928GTEurope,RoW M28/47 4957 243(330) 78.91100 lO.O:l

928 S4 USA,Canada A M28142 4957 235(320) 78.91100 lO.O:l

928GTUSA,Canada M28147 ,4957 243(330) 78.91100 lO.O:l

Fuel-induc- Engine tion system numbers

Pu= Premium unleaded S+u q Super plus unleaded

Trans- Chassis mis- numbers sion type

LH-JetrotjcPu 81LOOOOl-50000 A28116 WPOZZZ 92ZLS8 4000145000 LH-JetronicPu 85L50001-60000 G28/55 WPOZZZ 92 ZLS8 4000145000 LH-JetronicPu 8l'LOOOOl-50000 A28/16 WPOJB2 920LS8 60001-65000 LH-JetronicPu 85L50001-60000 G28/55 WPOJB2 92OLS8 60001-65000

LH-JetronicPu 81MOOOOl-50000A28/16 WPOZZZ 92 ZMS8 CQOOl-05000 LH-JetronicPu 85M50001-6OOOOG28/55 WPOZZZ 92 ZMS8 00001-05000

.LH-JetronicPu 81MPOOOl-5OOOOA28/16 WPOAA2 92OMS8 10001-65000 LH-JetronicPu 85M50001-6OOOOG28155 WPOAA2 92OMS8 10001-65000

1992 928GTS Europe,RoW M28/49 5397 257(350) 85.9/100 10.4:1 928 GTS Europe, ROW A M28150 5397 257(350) 85.9/100 10.4:1

LH-JetronicStu 85NOOOOl-20000 G28/57 WPOZZZ 92 ZNS8 00001-05000 LH-JetronicStu 81N50001-60000 A28118 WPOZZZ 92 ZNS8 00001-05000

1993 928GTS USA,Canada M28149 5397 257(350) 85.91100 10.4:1 LH-JetronicStu 85NOOOOl-20000 G28157 WPOAA2 92OPS8 15001-17000

928 GTS USA,Canada A M28/50 5397 257(350) 85.91100 10.4:l LH-JetronicStu 81N50001-60000 A28118 WPOAA2 92OPS8 15001-17000

328GTS Europe,RoW M28149 5397 257(350) 85.91100 10.4:1 928 GTS Europe, ROW A M28150 5397 257(350) 85.91100 10.4:l 928GTS USA,Canada M28149 5397 257(350) 85.9/l@ 10.4:1 928 GTS USA,Canada A M28/50 5397 257(350) 85.9/100.10.4:1

LH-JetronicStu 85POOOOl-20000 G28157 WPOZZZ 92 ZPS8 00001-05000 LH-JetronicStu 81P50001-60000 A28/18 WPOZZZ 92ZPS8 00001-05000 LH-JetronicStu 85POOOOl-20000 G28/57 WPOAA2 92OPS8 20001-25000 LH-JetronicStu 81P50001-60000 A28118 WPO@2 920PS8 20001-25000

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IO Engine number codes as of Model 90

Explanation of digits:

1 2 3,

Type of engine Engine type Model year Serial number

45678

T jT1 8 = 8-cyl. engine. . 1 = Automatic L =1990

transmission M = 1991 5 = Manual N = 1992

transmission P = 1993

00001...99999 00001...99999

‘The first serial number figure is 501 in each case Example: 85M00604 Engine for 928 GT. 104th engine in model year 1991

Engine type codes

Pro- Model Type Diiplaca- Engine FUel lnatallad in A = Aute duction year desig ment output induction matic Year nation act. to DIN

(cm’) #w/HP)

1989/90 1990 M 28.47 4957 243(330) LH-Jetronic 928 GT worklwide M 28.42 4957 235(320) LH-Jetronic 928 54 worldwide A

1990191 1991 M 28.47 4957 243(330) LH-Jetronic 928 GT worldwide M 28.42 4957 235(320) LH-Jetronic 928 9 worklwiie A

1991192 1992 M 28.49 5397 257(350) LH-Jetronic 928 GTS worldwide M 28.50 5397 257(350) LH-Jetronic 928 GTS worldwideA

199Y93 1993 M 28.49 5397 257(350) LH-Jetronic 928 GTS worldwide M 28.50 5397 257(350) LH-Jetronic 928 GTS worldwideA

12 Chassis number codes (Model 90)

. wPom92z Ls640001-5000

6 0001-5000

II

Europe/Rest of world

USAlCeneda

Serial number

Code for body and engine

3rd digit of type

Manufacturing location

Model year (L= 1990, M = 1991, N = 1992, P= 1993)

Test digit or fill-in sign

1 St and 2nd digits of type

VDS code USA

World manufacturing code

‘i Notes:

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14 Transmission number codes as of Model 90

Transmission T

Index for bariants Model year -I--

Serial number

type within the unit no. 0 = without differential 1 = normal differential L= 1990 2 = ZF limited slip differential M = 1991

(M 220) 3 = controlled limited

slip differential

PW

Caution: The transmission nos. 1...109 of each type are reserved for testing and 301 JO0 for special transmissions. The first serial no. is 501.

Example: G 2855 3 L 00546 Transmission G 28/55 fitted in model year 1990 as the 46th standard transmission (with controlled limited slip differential PSD).

Transmission type codes

Transmis- No. of Installed in Installed as of sion type speeds Vehic. type Transm. no.

Remarks d

Mod. 90 G 28.55 A28.16

5 928 GT G 2855 3 L 00001 Manual transm. with PSD 4 928 S4 A 2816 3 L 00001 Autom. transm. with PSD

Mod. 91 G 28.55 5 928 GT G 2855 3 M 00001 Manual transm. with PSD

+ A28.16 4 928 S4 A2816 3 M 00001 Autom. transm. with PSD

t i ! ! 1 1 ;

1 i 1 1 1

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Transmission number codes as of Model 92

G 2857

T ,t Transmission

type

Index for kriants within the unit no. 0 = without differential 1 = normal differential 2 = ZF limited slip differential (M 220) ’ 3 = controlled limited slip differential (PSD)

002046

T Serial number

Caution: The transmission nos. 1...2000 of each type are reserved for testing. The first serial number is 2001.

Example: G 2857 3 002046

Transmission G 28/57 manufactured as of model year 1992 as the 46th standard transmission (with controlled limited slip differential PSD).

Transmission type codes

Transmis- No. of sion type speeds

Mod. 92 G 28.57 5 A28.18 4

Installed in Installed as of Vehic. type Transm. no.

928 GTS G 2857 3 000001 928 GTS A 2818 3 000001

Remarks

Manual transm. with PSD Autom. transm. with PSD

Mod. 93 G 28.57 A28.18

5 928 GTS G 2857 3 000001 Manual transm. with PSD 4 928 GTS A 2818.3 000001 Autom. transm. with PSD

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Engine data 928 S41928 GT

Enginetype M28.42 M28.47

Model year 1990,lQQl 1990,lQQt

No. of cylinders Bore Stroke Displacement (act.) Compression ratio Max. engine power, 80/i 2691EEC (Net Power, SAE J 1349) At engine speed Max. torque, _ 80112691EEC (Net Torque, SAE J 1349) At engine speed Max. specific power, DIN 70020 (SAE J 1349) Fuel octane rating Engine speed limitation by fuel cut-off Idle speed Engine weight (dry)

Note: USA values in brackets.

mm/in. mm/in. cm3/in.3

8 100 (3.94) 78.9 (3.11) 4957 (302.5) lO.O:l

8 100 (3.94) 78.9 (3.11) 4957 (302.5) lO.O:l

kW/HP 2351320 2431330 kW/HP 235 (316) 243 (326)

r Pm 6000 6200

Nmlkpm Nmllbft

rpm

430143.9 430143.9 430 (316.9) 430 (316.9) 3000 4100

kW/I(HP/I) kW/I(HP/I) RON

47.4164.6 47.4 (63.7) 95 Pu

49.0166.6 49.0 (65.8) 95 Pu

rpm

rpm kg

6600 6800 675 k 25 775+25 264 264

Engine data GTS

Enginetype

Model year

M28.49150

1992,19Q3

No. of cylinders Bore Stroke Displacement (act.) Compression ratio Max. engine power, 80112691EEC (Net Power, SAE J 1349) At engine speed Max. torque, 8011269IEEC (Net Torque, SAE J 1349) at engine speed Max. specific power, DIN 70020 (SAE J 1349) Fuel octane rating Engine speed limitation by fuel cut-off Idle speed Engine weight (dry)

mm/in. mm/in. cm3/in .3

8 100 (3.94) 85.9 (3.38) 5397 (329.3) 10.4:1

kW/HP 2571350 kW/HP 257 (345)

r Pm 5700

Nmlkpm 500/51 NrnIlbft 500 (369)

Pm 4250

kW/l(HP/l) kW/l(HP/l) RON

46.3163 46.3 (68.4) 98stu

rpm rpm kg

6600 675 f 25 ?SS

18 Technical data type 928 S4 engine type M 28.42 Technical data type 928 S4 engine type M 28.42

Engine design Design Crankcase

Crankshaft Connecting rods Pistons

Camshaft

Camshaft drive Cylinder head Valve arrangement Valve timing

Valve play Timing (1 mm stroke, zero play)

Intake opens Intake closes Exhaust opens Exhaust closes

Engine cooling Engine lubrication

Oil filter Oil pressure at 4000 rpm

Oil pressure indicators Oil consumption 111000 km Exhaust system

Exhaust emission control system

8-cyl. 4-stroke spark-ignition V-engine 2-piece light-alloy crankcase, without cy- linder liners Forged, 5 plain bearings Steel, sinter-forged Light-alloy, cast, contact surface iron-coated Cast, without bearing shells, running in camshaft housing Toothed belt and internal chain Light alloy 2 intake, 2 exhaust, suspended in V 2 overhead camshafts per bank of cylin- ders and hydraulic bucket tappets Self-adjusting (hydraulic) 11 degr. after TDC 36 degr. after BDC 17 degr. before BDC 2 degr. before TDC Closed coolant system Forced oil circulation with crescent pump In full flow Appr. 5 bar overpressure, at 80...100 OC oil temperature Indicator lamp and pressure gauge up to 1.5 Twin-pipe system throughout 3-way catalytic converters, P-pipe sys- tem in center muffler and rear muffler 3-way catalytic converters and second- ary air injection

Heater

Fuel system Fuel delivery Fuel grade RON Fuel consumption figures at constant QO km/h I1100 km at constant 120 km/h l/l 00 km EC urban cycle l/l 00 km Electrical system Interference suppression Battery voltage V Battery capacitance Ah Alternator/output A/W Ignition Ignition sequence Ignition timing Spark plugs Electrode gap mm Power transmission

Clutch

Pressure plate

Warm water heater with heat exchanger and fan LH-Jetronic 2 electric pumps 95 Manual trans. 9.7

12.0 21.9

Autom. 10.0 11.8 16.6

ECE-R 10 and 72/245/EEC 12 72 115/1610 Contactless, via EZK l-3-7-2-6-5-4-8 Via EZK Bosch WR 7 DC 0.7 + 0.1 Front-mounted engine, bolted together by a connecting tube to form a rigid drive unit - transaxle. Front engine, clutch, torsionally elastic drive shaft to transmission mounted in connecting tube, rear transmission inter- locked with axle drive, twin drive shafts to rear wheels Single-disk dry clutch with diaphragm spring, extended version, located at engine end GMFZ 250

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20 Torque specifications - engine

Location Thread

Main bearing bolts

Main bearing bolts

Oil pump bolts

Connecting rod bolts Verbusrip nut

928 GT (5.4 I) Engine type M 28.49150 Connecting rod bolts (Forged connecting rod) Verbusrip nut

Cylinder head bolts (hex. head bolts)

Camshaft bearing saddles to cylinder head

Socket head bolts for chain tensioner

M12x1.5

Ml0

M8

M 10x 1.25

M 10x 1.25

M6 M8

M6

Tightening torque Nm (ftib)

1st stage 30 (22) 2nd stage 55 (41) 3rd stage 75 t 5 (55 t 4)

1st stage 20 (15) 2nd stage 50 t 5 (37 t 4)

1st stage 15 (11) 2nd stage 20 (15)

75 (55)

25 (18) t 90’ turn

1st stage 20 (15) 2nd stage 90’ turn 3rd stage 90’ turn

10 (7) 20 (15)

10 (7)

Torque specifications - engine

Location Thread

Banjo,bolt I M8xl chain tensioner

Check valve I MlOxl chain tensioner

Camshaft bolts , M 10x 1.5

Cylinder head cover M6

Spark plugs M 14x 1.25

Flywheel bolts M 1’0 x 1.25

Pulley bolts

Oil drain plug

Screw plug of thermostat housing

Oil pressure sender

Screw plug of pressure relief valve

M 18x 1.5

M20x 1.5

M48x 1.5

M 18x 1.5

M 18x 1.5

Screw-in flange of bypass valve

Drain plug of cylinder block

Drain plug of radiator

Screw-in flange on radiator on engine

M24x 1.5

M 12x 1.5

Ml0

&? a 5 j’y(b I $ k :,

Tig hening torques Nm (ftib)

10 (7)

15 (11)

65 (48)

10 (7) 25-30 (18)

1st stage 40 (29) 2nd stage 90 (66)

295 (218)

50 (37)

80 (59)

35 (26)

40 (29)

70 (52)

35 (26)

1.5 (1)

70 (52) 70 (52)

22 Torque specifications - engine

Location Thread

Oil hose on screw-in M26x1.5 flange to top section of crankcase

To radiator M26x1.5

Temperature switch to radi- ator

Coolant circuit governor M 8 housing to engine

Remote thermometer sensor - water temperature

Check valve

Air line

Oxygen sensor M 18x1.5

Screw plug for exhaust M8xl sample pick-up to catalytic converter

Temperature sensor NTC II to governor housing

Attachment of knock sensor M 8

Attachment of knock sensor M 8 as of engine no. M 28.42 81 M 51771 M 28.47 85 M 01112 928 GTS (5.4 I) Engine type M 28.49150

Tightening torque Nm (ftib)

70 (52)

70 (52)

40 (29)

1st stage 10 (7) 2nd stage 20 t 2 (15 + 1)

25-30 (18-22)

55 (41)

30 (22)

55 (41)

15 (11)

12 (9)

20 (15) without washer

20 (15) original screw (micro-encapsulated) without washer

Torque specifications - engine 23 ‘-

Location

Attachment of intake distributor

Attachment of hall sender . Attachment of CO sample line to exhaust manifold

Cap nut to fuel fuel distribution pipe

Union nuts to fuel distributor pipe

All other bolts and nuts

M6 M8 Ml0

Thread

M8

M6

Tightening torque Nm (ftib)

15 (11)

8 (6)

25 (18)

M 12x 1.5 12 (9)

M 16x 1.5 30 (22)

8 t 2(6+1) 20 t 2(15+1) 40 t 5(29+4)

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24 Tolerances and wear limits - engine

’ Cooling system

Coolant thermostat

Cap for cooling system Pressure relief valve Vacuum valve

Oil circuit

Oil consumption

Oil pressure

at 80% oil temperature

Oil dipstick Oil capacity

Difference

Oil pump play:

Valve timing

Bore for camshaft

Camshaft

Engine type M 28.42147149150 When installed Wear (new) limit

Opening temperature 81...85”C

opens at overpr. closes at underpr.

Ill 000 km

min.-max.

Axial play

Radial play

Inner diameter

Diameter

0.9...1.15 bar 0.07...0.12 bar

up to approx. 1.5

at 3000 rpm

approx. 5 bar overpressure

7.5 I

1.51

0.080...0.120

0.060...0.088

t 0.021 28 -0

Tolerances and wear limits - engine

, Camshaft Axial play

Bore for bucket tappet Inner diameter

Bucket tapper Diameter

Camshaft Runout

Cylinder head with valves

Mounting face

Valve seat Intake Exhausf Intake Exhaust

Outer correction angle

Inner correction angle

Valve guides: A Intake and exhaust

Valve stem: Intake Exhaust

.

Distortion

Width Width Beating angle Beating angle

Inner diameter

Diameter Diameter

Engine type M 28.42147149150 Wheq installed Wear (new) limit

0.08...0.18

0.02

max. 0.03

1.5 1.8 45 degr. 45 degr.

60 degr.

7 t 0.015

6.97 - 0.012 6.94- 0.012

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26 Tolerances and wear limits - engine

Valve guide/valve stem -‘play

Intake Exhaust Compression

Pistons with connecting rods Cylinder/piston Play

Piston rings Vert. Play

Engine type Engine type M 28.$Z/47/4Q/50 M 28.42147149150 When installed Wear When installed Wear

(new) limit bw limit

8 bar and over

0.80 0.80 6.5 bar

0.008...0.032 approx. 0.080

Mahle KS. Groove 1 0.05... 0.04...

0.082 0.072 Groove 2 0.04... 0.02...

0.072 0.072 _ Groove 3 0.036... 0.036

0.136 0.136

Piston rings Gap width Groove 1 = 0.20...0.40 Groove 2 = 0.20...0.40 Groove 3 = 0.40...0.90

Con rod bush Diameter 24 ; ;$;;

Piston pin ,Diameter 24-0.004

Con rod bush/piston pin Radial- play 0.018...0.032

27 Tolerances and wear limits i engine

. Crankshaft and cylinder block

Crankshaft Runout measured at 2nd; 3rd or 4th bearing, bearings 1 and 5 on prisms

0.04 max. 0.06

Con rod bearing journal Diameter 51.971...51.990

Con rod bearing/crankshaft Radial play 0.027...0.069 Axial play 0.08...0.24

Crankshaft bearing journal Diameter 69.971...69.990

Crankshaft bearing/ crankshaft

Crankshaft bearing crankshaft

Cylinder bore

All dimensions in mm i

Radial play 0.028...0.070 0.16

Axial play 0.06...0.192 0.40

out-of-round 0.010 0.020

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28 Crankshaft - normal and reconditioning dimensions Tightening seq. - crankcase - upper and lower parts Size

Normal -0.25 -0.50

Crankcase Crankshaft CNnkShaft Thrust bearing 3 Bore dim. bearing joumal con rod journal width

dl journal dii. d2 journal dia.

Normal 69.971...69.990 51.971...51.990 max.30.08 75.000...75.019 69.721...69.740 51.721...51.740 Reconditioning size Oversize 69.471...69.490 51.471...51.490 30.200...30.239 75.250...75.269

Only regrind contact surface of radial sealing rings as far as necessary Otherwise, if required, repolish to peak-to-valley height of 0.8...2. After grinding, oil bores rounded to R 0,5. Sharp edges rounded with radius of 0.2...0.5.

Color coding of reconditioning sizes 1 st reconditioning size blue dot 2nd reconditioning size green dot

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Tightening sequence: ;

Tightening torque Numbers 1 . ..lO in 3 stages: 1st stage 30 Nm Thread M 12 x 1.5

(22 ftlb) 2nd stage 55 Nm (41 ftfb)

. 3rd stage 75 t 5 Nm (55 t 4 ftlb)

Numbers11 . ..22 in 2 stages: 1st stage 20 Nm (15 ftlb) Thread M 10 i 2nd stage 50 t 5 Nm (37 t 4 ftlb)

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30 Checking pistons and cylinder bores

Checking pistons Measure at approx. 62 mm from piston crown, offset 90 degr. from piston pin axis

Checking cylinder bores Measure at approx. 62 mm from upper edge of cylinder bore, transverse to cy- linder block Note: To perform measurement fit lower section of crankcase and tighten to prescribed torque.

Engine type M 28.41142147

Repair stage Piston dia. (mm) Kolben-

Cylinder bore Tolerance group (mm) identification

Stand. dimens. 99.980 100.000 0 99.990 &Oo.007 100.010 &0.005 1 100.000 100.020 2

1 st oversize 100.480 100.500 1 0 100.490 +0.007 100.510 I!?XIO5 1 1 100.500 100.520 1 2

Checking pistons and cylinder bores

Checking pistons Measure at approx. 50 mm from piston crown, offset 90 degr. from piston pin axis.

Engine type M 28.49150

Repair stage Piston dia. (mm) Kolben- schmidt

Checking cylinder bores Measure at approx. 50 mm from upper edge of cylinder bore, transverse to cy- linder block Note: To perform measurement fit,lower section of crankcase and tighten to prescribed torque.

Cylinder bore (mm)

Tolerance group identification

Stand. dimens. 99.980 100.000 0 99.990 I8I.007 100.010 fo.005 1 100.000 100.020 2

1 st oversize 100.480 100.500 1 0 100.490 ?0.007 100.510 3l.005 1 1 100.500 100.520 1 2

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Before machining cylinders it is advisable to check the stocks of the appropriate tolerance group and if necessary to hone the cylinder to the piston size available at that time. Delivery bottlenecks of specific tolerance groups are possible.

Before machining cylinders it is advisable to check the stocks of the appropriate tolerance group and if necessary to hone the cyfinder to the piston size available at that time.

1 Delivery bottlenecks of specific tolerance groups are possible.

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32 Survey of pistons (dimensions, weights and compression)

Engine M 28.42/47

worldwide Compression 1 O.O:l Nominal dia. 100.0 mm

Piston weight = 765 g Perm. tolerance = + 4 g

Engine htl28.49150 . .

worldwide Compression 1 O-4:1 Nominal dia. 100.0 mm

Piston weight = 720 g Perm. tolerance = + 4 g

Piston weight tolerances

Pistons and piston pins are paired in accordance with weight selection. Pistons are weighed with their pertinentparts (piston pins, piston rings, snap rings).

Piston pins must always remain assigned to the corresponding piston and must not be interchanged even within one engine set. Observe allocation during disas- sembly and assembly of engine, and mark if necessary.

If piston pins have been interchanged by mistake, reallocation must be carried out by checking the total weights.

Piston and cylinder marking 33

Identification of pistons on piston crown

Identification for cylinders on cylinder block

a - Cylinder designation (assignment) b - Tolerance group

Installation position of pistons With valve pockets of equal size on both sides, the installation position is marked by an arrow pointing towards the belt pulley.

Cylinder designation

Ignition sequence 1-37-2-6-54-8 Only pistons and cylinders of the same tolerance groups may be paired together. Various tolerance groups may ’ be used within one and the same en- gine.

Checking valve seat angles, valve dimensions and valve guides

Reworking valve seats and checking installation

Valve seat angles

of valve springs

Reworking valve seats

Intake seat width 1.5mm Exhaust seat width 1.8 mm

Valve dimensions

Checking valve guides Note:

The valve guide is measured at a valve stroke of 10 mm (distance between valve head and valve seat), Wear limit (play) for intake and exhaust guides = 0.80 mm.

Exhaust 33.00mm 6.94mm

113.70mm 45O ’

Checking installation length of valve springs with a depth gauge

The depth gauge is used to measure vertically down through the gap from the sur- face of the valve spring plate to the surface of the outer spring pad.

Installation length Intake 35.5 t 0.5 mm Exhaust 34.5 t 0.5 mm

The valve seats can be reworked until the wear limit sizes below are reached: Intake valve 44.4 mm Exhaust valve 43.4 mm.

Measurement is performed with the valve to be subsequently installed, from the end of the valve stem to the valve spring pad in the cylinder head. The valve must be held firmly on the valve seat.

36

. . :

- _ -.._ -_ _- -- --- ~---_-_ ~-.ys-v--3=.f-i~~~-~-

;:

Machining the cylinder head mating face

Permissible unevenness of mating face: 0.05 mm Permissible unevenness after machining: 0.03 mm Peak-to-valley height = 0.015 mm

Cylinder head reconditioning size and marking

Size new 147fO.l mm Gasket 1.1 mm Marking none

Size reconditioned Gasket Marking

146.8...146.6 mm 1.4mm N

Size new A = 147 f 0.1 mm Size worn A = 146.6 mm

Marking ,,N“

Apply to dead head beneath gasket surface of cylinder head cover on exhaust side, between cylinders 2 and 3/6 and 7.

Height of letter stamp ,,N” 6 mm

Installing the cylinder head

Cylinder head attached with hex. head bolts

Note The cylinder head can also be fiied with the engine installed. If both cylinder heads are to be removed and installed, it is advisable to remove the engine first.

Tightening sequence:

1

Slackening sequence: reverse order

Tightening specifications for cylinder head

1st stage 2nd stage 3rd stage

Note

20 Nm (15) 90’ turn 9OOturn

When fifing the hex. head bolts and washers, no lubricant must be used. Only the threads of the hex. head bolts must be lightly coated with engine oil.

37

38 Camshaft survey

Engine type

Right camshaft Cylinder bank 1...4 Intake shaft Exhaust shaft

Identification on rear end surface

Left camshaft Cylinder bank 5...8 Intake shaft Exhaust shaft

Identification on rear end surface

Valve timing 1 mm stroke, zero play

Intake opens Intake closes Exhaust opens Exhaust closes

Worldwide Worldwide Worldwide as of Model 90 as of Model 90 as of Model 92

928 S4 928 GT 928 GTS Engine type 928 S4 928 GT 928 GTS M 28.42 M 28.47 M. 28.49150 M 28.42 M 28.47 M. 28.49150

928.105.271 .OO 928.105.271 .Ol 928.105.271.03 928.105.273.00 928.105.273.01 928.105.273.03

271 .OO 271.01 271.03 4 273.00 273.01 273.03

928.105.272.00 928.105.272.01 928.105.272.03 928.105.274.00 928.105.274.01 928.105.274.03

272.00 272.01 272.03 274.00 274.01 274.03

11’ CA after TDC 3’ CA after TDC 13” CA after TDC 36” CA after BDC 42’ CA after BDC 61’ CA after BDC 17” CA before BDC 30” CA before BDC28” CA bef. BDC 2’ CA before TDC 5’ CA before TDC12” CA bef. TDC

Checking camshaft adjustment

Worldwide Worldwide Worldwide As of Model 90 As of Model 90 As of Model 92

Cylinder bank 1...4 Test/adjustment value 1.8fO.l mm 2.8fO.l mm 1.83 + 0.1 mm

Cylinder bank 5...8 Test/adjustment value 2.0 + 0.1 mm 3.1 +O.l mm 2.08 & 0.1 mm

All test/adjustment values measured at 20” CA after overlap TDC.

,

39

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i:

41 40 Adjusting camshaft belts

Engine type M 28.42147149150 Adjustment value: 5.0 t 0.3 scale units

i.

V-belt dimensions

Engine type M 28.42/47/49/50 !

V-belt for alternator (Polyrib) mm K6 858 LW M28.47149

V-belt for alternator (Polyrib) mm K6 872 LW M28.42150 V-belt for servo pump mm 12.5 x. 1000 LA V-belt for AC compressor mm 12.5 x 1125 LA M28.42/47

V-belt for NC compressor mm 12.5 x 1080 LA M28.49150 V-belt for aux. air pump mm 12.5 x 925 FO molded teeth

Checking V-belts Check tension by pressing the middle of the belt with one’s thumb. Belt should give by approx. 10 mm.

Adjusting tension of poly-rib belt for alternator

Adjustment value

New belt: 9.2 scale units Used belt: 8.4 t 0.8 scale units

Coolant mixing table (average values)

Frost protection Antifreeze to -25:C :g*g 4::

50;

Water Antifreeze Water

60% 6.4 I 55%

;*;I %

50% . 8:0 I

Cleaning the Complete Engine Oil System Following Engine Failure (Bearing Failure)

Note This cleaning sequence merely indicates where chips may be found. The actual amount of work involved must be determined separately for each individual case. The following parts should be replaced:

- Hydraulic valve tappets

- Chain tensioner

- Oil filter The following parts should be disman- tled, checked and thoroughly cleaned: - Oil pump - Thermostat housing - Bypass valve - Pressure relief valve - Oil restraining valve in cylinder head

The following parts must be thoroughly cleaned or flushed sev- eral times: Note All oil bores can be flushed thoroughly with conventional benzine. - Oil pan - Oil inlet pipe - Crankcase - Crankshaft - Cylinder heads - Oil lines - Oil filler neck - Oil cooler in radiator

Change oil filter and engine oil after approx. 500 km. Note Following an engine failure the com- plete intake system must be checked for foreign bodies and oil and cleaned be- fore assembly.

. .

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: ‘_

I- /1

‘., ..;

42 Test values for vehicle type 928 S4 - 928 GT - 928 GTS Engine type M 28.42/47/49/50

Test Electric fuel pump delivery quantity

Fuel pressure (engine stopped) Fuel pump relay bridged check value at idle speed Leak test Min. pressure after 20 min

Adjusting idle speed

Idle speed rpm

928 GT version Engine type M 28.4; Idle speed rpm co values %

HC values ppm

Test values min. 1250 crn3/30s

3.8 f 0.2 bar

approx. 3.3 bar

3.0 bar

Without catalytic converter

675 I& 25

775 f 25 0.5...1.5**

I 300

Catalytic converter vehicles

375 3125

775 f 25 1.4...1.2*

5 300’

Special notes

With catalytic converter vehicles an idle speed and CO adjustment is no longer possible

Measured upstream of catalytic converter, lambda sensor plug not disconnected

**On vehicles without catalytic converter, only a CO adjustment is possible. i

44 Torque specifications - clutch

Location Thread

Guide tube to clutch housing

Clutch slave cylinder

Clamp/central shaft I and II

Clutch housing/ central tube

Engine/clutch housing

Clutch housing/ cover

Clutch/ flywheel

Tightening torque Nm (ftlb)

M6xl 10 (7)

M 8x 1.25 23 (17)

M 10x 1.5 80 (59)

M 10x 1.5 45 (33)

M 12x 1.5 85 (63) L

M 8x 1.25 23 (17)

M 8x 1.25 23 (17)

45 Clutch

Engine type M 28.47149 t

Design Single-disk dry clutch with diaphragm spring, extended design, mounted on engine side. Hy- draulic operation. . i

Pressure plate GMFZ250 - I

Contact pressure M 28.47 9900...11100 N M 28.4912200...13500 N

Clutch plate dia. 250

Slave cylinder dia. 22.2 mm piston

* The clutch play cannot be checked at the clutch pedal due to the automatic hydraulic adjustment.

However, perfect functioning of the clutch must be guaranteed by a play of 0.5 mm between the push rod and the master cylinder piston.

This play cannot be measured, but must be determined by sense of feel at the clutch pedal. It will be approx. 3 mm at the pedal plate.

46 Torque specifications - manual transmission, shift actuation and central tube

Location Thread

Central tube/transmission

Securing nut/ drive pinion

Bearing cover/ transmission case

Plug/locks

Upper cover/ transmission case

Reverse gear lock plate/ upper cover

Ring gear bolt Side cover/ transmission case

Rear cover/ transmission case

Oil filling and drain plug

Clamping sleeve/ drive shaft

Reversing lamp switch

Joint flange/trans- mission output

Bearing body/inner- shift rod

M 10x 1.5

M32x1.5

M 8x 1.25

M 12x 1.5

M6xl

M6xl

M 12x1.25 M 8x 1.25

M 8x 1.25

M 24 x 1.5

M 10x 1.5

M 18x 1.5

MlOx1.5.

M8x1.25

Tightening torque Nm (ftlb)

58 (43)

300 (221)

30 (22)

20 (15)

10 (7) 16 (12)

10 (7)

165 (122) 22 (16)

22 (16)

22 (16)

80 (59)

22 (16)

43 (32)

15 (11)

Torque specifications - manual transmission, shift actuation and central tube

t Location

Transmission mount/ transmission case

# Central tube/ clutch housing

Shift rod/bearing body (Shift rod coupling)

Angled joint/ guide tube

Bracket mount for guide tube to body/ central tube

Cap and hex. head nut to threaded bolt for preselection fields

Thread Tightening torque Nm (ftlb)

M 12x 1.5 85 (63)

M 10x 1.5 43 (32)

M8x1.25 25 (18)

BM 10 25 (18)

M6xl 10 (7)

M14xl 50 (37)

47

,-

48

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f.

j

49 5-speed manual transmission G 28.55

General data

Design

Ratios*

1 st gear

2nd gear

3rd gear

4th gear

5th gear

Reverse

Final drive

Final drive ratio

Tracsmission oil

Filling capacity

Manual transmission Type G 28.55

Direct transmission with intermediate gear 1

Ti J-2 it iht it x iht T2:Tl 3222

17 1 44 1 2.5882 Il.4545 13.7645 1

22 38 1.7272 1.4545 2.5122

26 32 1.2307 1.4545 1.7900

29 27 0,931o 1,4545 1,354l

Direct 1 .OOOO Direct 1.0000

22 (30) 2.2727 1.4545 3.3056 (30) 50

Bevel gear differential without hypoid offset

11:30 i = 2.7272

Multigrade transmission oil SAE 75 W 90 API classification GL 5 (or MIL-L 2105 B)

Approx. 4.5 liters

TI = No. of teeth on first gear wheel in power flow of respective gear

T2 = No. of teeth on second gear wheel in power flow of respective gear

it = Gear ratio

il,,t = Intermediate gear ratio

5-speed manual transmission G 28.57

TI = No. of teeth on first gear wheel in power flow of respective gear

TZ = No. of teeth on second gear wheel in power flow of respective gear

it = Gear ratio

ilnt = Intermediate gear ratio

50 Torque specifications - automatic transmission

Location

Primary pump to front cover

Screw plug (torque converter)

Front cover to transmission case

Support flange to transmission case

Screw plug (counter-bearing brake band B 1)

Detent plate to range selection shaft

Leaf spring to transmission case

Starter interlock and reversing light switch to transmission case

Range selector lever to shaft

Secondary pump to transmission case

Nut for shaft of governor axial mounting

Thread

M8

MlOxl

M8

M6

M27x1.5

M6

M6

M6

M6

M6

M6

-.

Tightening torque Nm (ftlb)

20 (15)

14(10)

13 (10)

11 (8) .

70 (52) .

8 (6)

8 (6)

8 (6)

8 (6)

8 03

6 (4)

Torque specifications .- automatic ttinsmission

Location

Lower cover with reinforcement panel

Lower cover compl. to transmission case

Screw plug (modul- ating, governor, working pressure measurement point)

Bolt (vacuum box bracket)

Kick-down solenoid valve .

Facing plate to slide valve case

Facing plate to mounting housing

Mounting housing to slide valve case

Slide valve case to transmission

ATF filter to lower cover

Thread

M5

M6

M8xl

M6

M 14x 1.5

M4

M4

M5

M6

M5

Tightening torque Nm (ftlb)

4 (3)

8 (6)

13 (10)

8 (6)

20 (15)

3.3 (2.4)

3.3 (2.4)

0.15

8 (6)

4 (3)

I’ +. .i 51 ‘-:

:

f

52 53 Torque specifications - automatic transmission 40speed automatic transmission A 28.16118

Location Thread

Screw plug (ATF pan)

ATF pan to transmission case

Front torque con- verter case to trans- mission case

Driver plate to torque converter

Rear transmission case to transmission case

Bearing assembly to rear transmission case

Final drive to transmission case

Collar nut (drive pinion)

ATF filler pipe to ATF pan

ATF reservoir to ATF pan

Tightening torque Nm (ftlb)

MlOxl 14 (10)

M8 8 (6)

M8 23 (17)

M8 46 (34)

Ml0 42 (31)

M8 33 (24)

M 10 46 (34) M 10 46 (34)

M26x1.5

M 24

380 (280) A 28.16 450 (332) A 28.18

78 (58)

M6 6 (4)

/ I

/ /

j I

I

I !

!

General data A 28.16118

Design fully-automatic 4-speed planetary transmission

Ratios 1st gear 2nd gear 3rd gear 4th gear Reverse gear

3.87 2.25 1.44 1 .oo 5.59

Final drive Bevel gear differential without hypoid offset

Final drive ratio 13 : 33 i = 2.538

Stall speed A28.16 1750...2150 rpm

Capacity (final drive)

Capacity Automatic part with torque converter

A.28;18 2150-400 rpm

A 28.16 approx. 3.0 I A 28.18 approx. 1.9 I Hypoid transmission oil API classification GL5 (MIL - L 2105 B) SAE 90

Automatic part with torque converter approx. 7.3 I ATF - Dexron II D

54 Pressure spec. in bar overpressure as of Model 90 Shift points in km/h

Test pressure

Modulating pressure*

Working pressure

Governor pressure

Transmission type A28.16 A 26.18

4.2 + 0.05 4.4 f 0.05

16.0f 1 15.8 F 1

approx 0.2 0.45 at 20 km/h approx. 1 .l 1.40 at 50 km/h approx. 2.J 2.15 at lOO’km/h approx. 2.7 3.10 at 150 km/h

Measuring conditions

ATF temperature approx 8O’C, se- lector lever in position D, driving speed approx. 140 km/h, vacuum line on modulating pressure box disconnected

ATF temperature approx. 80X, selector lever in position D, en- gine running at 1400 rpm, hand- brake engaged and service brake operated. Do not test for longer than 5 seconds, vaccuum line on modulating pressure box discon- nected

Selector lever in position D, vehicle moving in part- load range, vacuum line on modula- ting pressure box disconnected -

*Note

If local conditions do not permit testing at approx. 140 km/h, the test can also be performed at 50 km/h.

I

I

1 I

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/

I

1

I

Transmission type Transmission type A 28.16 A 28.18

Accelerator pedal position km/h km/h km/h km/h

Selector lever position A v A v

Full throttle %I” 1-2-1 41...50 3O.a.23 41...50 30...24

Full throffle “D” 2-3-2 102...117 49...43 102...117 49...43

Full throttle “D” 3-4-3 169...188 144...128 169...188 144...128

Full throttle “2” l-2 53.m.58 - 53.a.58 -

Note: All speeds are approximate values

Symbols: A Upshift V I Downshift

-,

55

.i

,’

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,’

:

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.;: I

56 Torque specifications

Location

Upper control arm to body

Lower control arm to body at rear

Lower control arm to body at front

Protective bar to side member

McPherson strut to body

McPherson strut and stabilizer sus- pension to lower control arm

Stabilizer clip to side member

Stabilizer suspen- sion to stabilizer

Upper and lower control arms to steering knuckle

Protective panel to steering knuckle

Wiring retainer to steering knuckle

Brake caliper to steering knuckle

- front axle

Thread

M 14x 1.5

M 12x 1.5

M 12x 1.5

M 10

Ml0

M 12x 1.5

M 10

M 12x 1.5

M 12x 1.5

M7 /

15 (11) 1

M7 15 (11)

M 12x 1.5 85 (63) ! I

57

Torque specifications - front axle

Tightening torque Nm (ftlb)

Location

i

140 (103) Brake disk to wheel hub

120 (88)

85 (63)

46 (34) -

46 (34)

85 (63)

46 (34)

i Fillister head screw to clamping nut

Wheel to wheel hub

Track rod to steering arm

Rubber bearing on piston rod of McPherson strut

Ball joint (joint carrier) to lower control arm

Supporting ring on pivoting axle (upper control arm)

85 (63) I ,

65 (48) I !

Thread

M6

M7

M 14x 1.5

M 12x 1.5

M 12x 1.5

M 12x 1.5

M 12x 1.5

Tightening torque Nm (ftlb)

10 (7)

15 (11)

130 (96)

65 (48)

60 (44) ’

120 (88)

65 (63)

. .

58 Torque specifications - steering

Location

Steering gear to engine carrier

Track rod to steering arm

Universal joint to steering gear

Track rod to ball joint

Steering tie rod to steering rack

Universal joints to steering and universal shafts

Pressure and return lines to steering gear

Steering wheel to steering shaft

Stabilizer clip to side member

V-belt pulley to servo pump

Steering guard to body

Ring hose nipple for suction hose to servo pump

Thread

Ml0

M 12x1.5

M8

M 14x 1.5

M 16x 1.5

M8

M 14x 1.5

M 18x1.5

Ml0

M 14x 1.5

M 6 with 4 mm hex. sock- et bolt M 6 with 5 mm hex. socket bolt

M 18x 1.5

Tightening torque Nm (Mb)

46 (34)

65 (48)

28 (21)

45 (33)

150 (111)

28 (21)

30 (22) I

50 (37)

46 (34) I

50 (37) I !

9.7 (7.1) I I I

12 (9)

60 (44)

59 Torque specifications - rear axle

Location

Cross member to body

Light-alloy cast part (mounting) for lower control arm (as of Mod. 86) to body

Lower control arm to cross member (camber eccentric)

Lower control arm to body (toe eccentric)

Brake caliper to wheel carrier

Wheel carrier to lower control arm

Upper control arm to cross member, upper control arm to wheel carrier

Universal/rear wheel shaft to wheel hub

Universal shaft to transmission and drive shaft

Wheel to wheel hub McPherson strut to body

Stabilizer bearing to body

Thread

Ml0

Ml0

M 14x 1.5

M 12x 1.5

M 12x 1.5

M 14x 1.5

Ml0

M22x 1.5

Ml0

M 14x 1.5 Ml0

Ml0

ightening torque Nm (ftlb)

46 (34)

46 (34)

200 (147)

120 (88)

85 (63)

140 (103)

46 (34)

460 (339)

81 (60)

130 (96) 46 (34)

46 (34)

60 Torque specifications - rear axle

Location

Stabilizer suspension to lower control arm

Stabilizer suspension to stabilizer

Bearing pivot to lower control arm

Rubber bearing on piston rod (McPherson strut)

Transmission bearing to rear axle cross member

Speed sensor to wheel carrier

Retaining bracket to wheel carrier.

Retaining bracket to cross member

Guard plate to wheel carrier

Thread

Ml0

Ml0

M 12x1.5

M 12x1.5

M 12x 1.5

M6

M6

M6

M8 M6

Tightening torque Nm (ftlb)

46 (34)

46 (34)

85 (63)

58 (43)

85 (63)

10 (7)

10 (7)

6 (4)

23 (17) 10 (7)

Technical data - front axle, steering and rear axle

Front axle

Wheel suspension Independent suspension, double control arm with coil spring and shock absorber located inboard

Springs

Shock absorbers

Stabilizer

Steering .

Steering wheel dia.

Steering wheel ratio (mean value)

Rear axle

Wheel suspension

Springs

Shock absorbers

Stabilizer

1 coil spring per wheel

Double-acting shock absorbers

dia. 28 x 4 mm (tubular stabilizer)

Rack and pinion steering with track rods, hydraulicaly assisted - power steering

380 mm

17.75:l

Independent suspension with lower diagonal control arm and upper transverse control arm, coil spring and shock absorber located inboard

1 coil spring per wheel

Double-acting hydraulic shock absorbers

dia. 22.5 x 3.5 mm (tubular stabilizer)

62 Wheel alignment adjustment values*

The following values apply to curb weight in accordance with DIN 76020 (car with full fuel tank, spare wheel and tool kit).

Adjustment values and tolerance

Front axle Height adjustment: From wheel contact area to 190 - 20 mm** measurement surface on rear control arm bearing

Toe - unpressed

Toe difference angle,at 20’ lock :

t 15’+5’

-1 “t20’

Camber

Caster

-3OYzlO’

Mod. 90 3”30’+30’*** as of Mod. 91 4’+1’***

Rear axle Height adjustment: From wheel contact area to measurement surface on cross member

173+10mm**

Toe per wheel

Camber

+10’&5

-4o’&lO’

Max. difference left to riaht

10mm

may be affected only replacement by of steering arms

10’

20’ 20’

10mm

* Adjustment values for wheel alignment are only valid for actual vehicle height (see Rep. Manual page 44-l).

** The height adjustment values apply to new vehicles. Used vehicles may be up to 10 mm lower, i.e., the tolerance towards ,,tbo low“ may deviate by 10 mm. However, this must then be the case for both axles.

** The caster value of 4”tl’ can be set retroactively on Model ‘90 vehicles.

Torque specifications - mech. brake system

Ldcation

Fillister head screw to clamping nut

Brake cafiper to steering knuckle

Brake caliper to wheel carrier

Brake disk to wheel hub

Guard plate to steering knuckle

Handbrake locking segment to bearing bracket

Universal shaftI rear wheel shaft to wheel hub

Wheel to wheel hub

Locking segment to handbrake lever

Guard plate to wheel carrier

Speed sensor to wheel carrier and steering knuckle

Thread

M7 15 (11)

M 12x 1.5 85 (63)

M 12x 1.5 85 (63)

M6 10 (7)

M7 15 (11)

M8 25 (18)

M22x1.5 460 (339)

M 14x 1.5

M8

M8 - M6

M6

Tightening torque Nm (ftlb)

130 (96)

23 (17)

23 (17) 10 (7)

10 (7)

! : -_i

63 ”

r’ ?,’ >L i:

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I ;- L . .

f

64 Torque specifications - hydi. brake system

Location

Brake booster to bulkhead

Brake line to brake master cylinder, brake hoses, brake power regulator, T-distributor and hydraulic unit. Connecting line to 4-piston fixed caliper,

Brake hose to 4-piston fixed caliper

Rear brake hose to 4-piston fixed caliper

Lock nut to push rod (brake booster)

Bleed screw to 4-piston fixed caliper

Brake master cylinder to vacuum booster

Screw-in regulator to. hydraulic unit .

Hydraulic unit bracket to wheel well

Hydraulic unit to hydraulic unit bracket -

T-distributor to bracket

Thread Tightening torque Nm (ftlb)

M8 23 (17)

MlOxl 12 (9)

MlOxl 16.5 (122)

MlOxl 14 (10)

Ml0 35 (26)

Ml0 8-12 (6-9)

M8 23 (17)

MlOxl 14 (10)

M8

M6

M6

23 (17)

10 (7)

10 (7)

;. 65 /

Technical data - brake system, Mod. 90191

Designation

Brake booster dia. iv

Brake master cylinder dia.

\ front rear

Brake power regulator (screw-in regulator) Changeover pressure Reduction factor .

Brake disk dia. front rear

Effective brake disk dia.

front rear

Piston dia. in brake caliper

front

Dimensions/remarks Wear limit

10 inches 4.5 (inner boost factor)

as of Model 87 with shorter free play (shorter free pedal travel)

Tandem type with 2 central valves 23.81 mm 20.64 mm

18bar 0.46

304 mm 299 mm

250.8 mm 246 mm

per fixed caliper 2x44t2x36mm per fixed caliper 2x30t2x28mm

:.

66 Technical data - brake system, Mod. 90191 Technical data - brake system, Mod. 90191

Designation

Brake lining area per front wheel

Brake lining area per rear wheel

Total lining area

Lining thickness front rear

Brake disk thickness new front rear

Brake disks - min. thick- ness* after reworking front

rear

Max. thickness tolerance of brake disk

Max. lateral runout of brake disk

Max. lateral runout of brake disk in installed condition

Max. peak-@valley height after reworking

Dimensionskemarlts Wear limit

126 cm2

86 cm2

424 cm2

approx. 13 mm approx. 13 mm

32 mm 24 mm

2mm 2mm

30.6 mm- 30 mm 22.6 mm 22mm’

0.02 mm

0.05 mm

0.1 mm

0.006 mm

Designation

Play at brake pedal with brakes bled and engine off (foot brake lever without I stop)

\ Parking brake / (Handbrake)

Handbrake drum dia.

Brake shoe width

Brake lining area per wheel

Brake lining thickness

Dimensions/remarks Wear limit

approx. 10 mm due to preset clearances in brake booster

Drum brake, acting mechanically on both rear wheels

180 mm 181 mm

25 mm

85 cm2

4.5 mm 2mm

* The brake disk must only be reworked symmetrically, i.e. evenly from both sides.

:.

::

67

;8 69 Technical data - brake system as of Mod. 92 Technical data - brake system as of Mod. 92

Designation

Service brake (foot brake)

Brake booster dia. inches Boost factor

Brake master cylinder dia. front dia. rear

Brake-power regulator Changeover pressure Reduction factor

Brake disk dia. ’ front rear

Effective brake disk dia. front rear

Piston dia. in brake caliper front rear

Brake lining area front rear

Remarks, dimensions Wear limit 928 GTS 928 GTS

Hydraulic dual-circuit brake system with front axle/rear axle circuit split. Vacuum brake booster, internally ventilated brake disks with &piston fixed calipers front and rear. The push rod brake circuit is allocated to the front wheels. ABS is standard.

10 4.5

23.81 mm 20.64 mm

18 bar 0.46

322 mm 299 mm

259.6 mm 246 mm

2x44t2x36mm 2x30+,2x28mm

302 cm2 172 cm2

Designation

Total brake lining area

Lining thickness front rear

Brake disk thickness new front rear

Min. brake disk thickness*

after reworking front rear

Max. thickness tolerance of brake disk

Max. lateral runout of brake disk

Max. lateral runout of wheel hub

Max. lateral runout of brake disk in installed condition

Max. peak-to-valley height of brake disk after re- working

Rtiarks, dimensions Wear limit 928GTS , 928 GTS

474 cm2

approx. 12 mm approx. 12 mm

32 mm 24 mm

2mm 2mm

30.6 mm 22.6 mm

0.02 mm

0.05 mm

0.05 mm

0.1 mm

0.006 mm

30.0 mm 22.0 mm

70 Technical data - brake system as of Mod. 92

Designation Remarks, dimensions Wear limit 928 GTS 928 GTS

Push rod play (measured at brake pedal plate)

Parking brake (handbrake)

Handbrake drum dia.

Brake shoe widtf-r

Brake lining thickness

approx. 10 mm”

Drum brake, acting mechaically on both rear wheels

180 mm 181 mm

25 mm

4.5 mm 2mm

* The brake disk must only be reworked symmetrically, i.e. evenly from both sides.

** Normally determined by preset clearances in the brake booster if the footbrake lever remains unsupported.

Wheels and tires / 71

Tire conditiinltire pressure Tires represent safety elements which can only meet the requirements made of them if inflation pressure is correct and if tread depth is sufficient.

The inflation pressures quoted here are minimum pressures. Lower pressures must on no account be used, since they not only diminish handling quality but may also lead to serious tire damage.

Valve caps protect the valve from dust and dirt, and therefore also from leaks. Always tighten caps properly and replace missing caps.

For safety reasons, a check of the tire pressure should also be accompanied by a check to ensure that tread depth is sufficient, that no foreign bodies are embedded in the tire, and that there are no cuts, tears or bumps on the tire’s sidewall (break- age of webbing).

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72 Tire pressure (summer and winter tires) with tires cold (approx. 2O’C) Survey of tires and wheels/tire specification codes

15 and 164nch tires

front rear

Summer tires* Winter tires

2.5 bar overpressure 2.5 bar overpressure 3.0 bar overpressure** 3.0 bar overpressure

174nch tires

front rear

Summer tires Winter tires

2.5 bar overpressure 2.5 bar overpressure 2.5 bar overpressure 3.0 bar overpressure

Collapsible spare tire front and rear only permitted at front

2.5 bar overpressure wit8 PR 89 P/92 P tires 2.2 bar overpressure with 4 PR 83 P tires

* For “V” and “ZR” tires, amended standards and regulations require tire pressures which deviate from those given in the Driver’s Manual. The new tire inflation pressures quoted above must now be used. Corresponding information stickers are available from every Official Porsche Center.

** In the USA only 2.5 bar (36 psi) is in some cases permissible. This depends on the tires, since earlier tires had lettering on the sidewall which limited the permissible operating pressure of the tire (max. press.) in N. America to 36 psi (2.5 bar). Lettering for 3.0 bar tire pressure = max. press. 44 psi . or 300 Kpa.

The survey of tires and wheels for summer and winter is contained in the Techni- cal Information bulletins (TI), Group 4.

When replacing summer tires the tire specification number must be ob served. The specification codes NO, Nl , and N2 distinguish summer tires spe- cially approved by Porsche from other versions of the same tire type and tire size. The approved tires are also contained in the relevant TI.

NO, Nl and N2 tires, even of the same make, must not be used simultaneously on one and the same vehicle.

Checking Rims

The measuring points for vertical and lateral runout on the inner and outer rim beads are shown in the drawing.

Max, permissible vertical and lateral runout of light-alloy rims = 1 .O mm.

Note

Straightening twisted rims is not permissible.

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74 Technical data - air conditioning

Refrigerant volume with addit. air conditioner

Refrigerant oil in AIC compressor

Safety valve on fluid reservoir

950 g refrigerant R 12 1150 g refrigerant R 12

280 f 20 cm3 Densoil 6

The safety valve opens at a pressure of 40 + 5 bar.

As of model 93 refrigerant R 134 a

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Torque specifications - air conditioning

Location

Compressor intake line

Compressor pressure line

Condenser

Condenser fluid reservoir

Evaporator fluid tank

’ Pressure line expansion valve

Intake line expansion valve

Evaporator expansion valve

lesignation

Jnion nut

Union nut

Union nut

Union nut

Union nut

Retaining screw 5/8” x 18 UNF

Retaining screw 7/8”xl8NS

Retaining screw

Thread

718” x 14UNF

3Mx16UNF

3Wx16UNF

314” x 16 UNF

5Kx18UNF

3Wx18NS

rightening oque 33 Nm (24)

!4 Nm (18)

34 Nm (18)

24 Nm (18)

17 Nm (13)

: 17 Nm (13)

33 N”! (24)

24 Nm (18)

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Weights

Type Model year

Curt, weight to DIN

Perm. total weight

Penn. axle load front’

Penn. axle load rear*

Penn. trailer load unbraked”

Penn. trailer load braked**

Perm. roof load with Porsche rcoi transport system

Perm. drawbar load

Penn. towing weight

I

928 SW928 GT 90191

Europe USA low

rg 1580 kgllbs 159013505

cg 1920 kgllbs 190014189

tg 920 kgllbs 92012028

cg 1100 kgllbs 110012425

tg 750

1(g 1600

kg 35 kgllbs 35i 7i kg 75 kg/lbs 751 16:

kg 75

tg 3520

* The perm. total weight must not however be exceeded. ” Up to 16 % incline

928 GTS 92193

Europa USA ROW

kg 1620

kg 1960

kg 940

kg 1100

kg 750

kg 1600

kg 35 kg 75

kg 75

kg 3560

kg/lbs 163013593

kg/h 1925KJ44

kg/lbs 94012072

kg/lbs 110012425

kg/lbs 35l 77 kgnbs 75 1165

Filling capacities

Engine oil specification

Engine oil volume

Cooling system inc. heating

Power steering

Fuel tank

Brake fluid tank

Windshield washer system with headlamp cleaning system

Intensive cleaning system

Manual transmission with differential

Automatic transmission with torque converter

Final drive

Approved: API SE/SF with combination API SE/CC - SE/CD - SF/CC - SF/CD multigrade oils see works approval, Technical Information bulletins for engine oils

Apprbx. 7.5 I, plus 0.5 I when filter changed (measurement with oil dipstick is decisive crite- rion). Difference between “Min.” and “Max.” marks on dipstick = approx. 1.5 I.

Approx. 16 I coolant, factory filling gives frost pro- tection to -30% (Scandinavian countries to - 40°C). Only use antifreeze and corrosion inhibitors which are suitable for light-alloy engines and radiators.

Approx. 0.7 I hydraulic fluid, only ATF Dexron II

Approx. 86 I, inc. 12 I reserve

Approx. 0.2 I brake fluid in accordance with SAE J 1703 or DOT4

Approx. 7.5 I water

Approx. 0.6 I “Porsche Special Silicone Remover’

Multigrade transmisson oil SAE 75 W 90, API classification GL 5 (or MILL 2105 B) Volume approx. 4.5 I, 928 GTS approx. 4.8 I

Volume approx. 9.3 I Oil-change volume with torque converter approx. 7.3 I ATF Dexron Ii

Volume approx. 3.0 I, 928 GTS approx. 1.9 I API classification GL 5 (MIL-L 2105 B) SAE 90

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