Porsche 968 (1992-1995) - Workshop Manual - Wiring Schematics - Parts Manual

PORSCHE 968 WORKSHOP  MANUAL 1992-1995

- English Workshop Manual, Wiring Schematics and Spare Parts Catalogue to vehicles Porsche 968.


INDEX:

WORKSHOP MANUAL 1992-1995 (801 pages)

968 WORKSHOP MANUAL
Structure of the Workshop Manual

VOL I - ENGINE
General
Technical data
Maintenance, Self Diagnosis general
Maintenance
Operating instructions for system tester 9288
Engine, Crankcase, Engine Mounts
Tolerances and wear limits
Tightening torques for engine
Removing and installing engine (Manual transmission)
Removing and installing engine (Tiptronic transmission)
Engine, Crankshaft, Pistons
Adjusting guide rail for balance shaft toothed belt
Checking adjustment of balance shafts
Fitting toothed belt for balance shaft
Adjusting Special Tool 9201
Checking and adjusting balance shaft toothed belt tension
Crankcase markings
Locking the flywheel for assembly work
Engine support
Crankcase - Tools
Machining cylinder bores in upper crankcase section
Crankcase - Installation length or protrusion length of studs
Dismantling and assembling crankcase, crankshaft
Aligning the upper and lower parts of the crankcase
Crankshaft - Standard and Repair dimensions
Dimantling and assembling pistons, connecting rod
Checking piston and cylinder bore
Dismantling and assembling balance shaft drive
Removing and installing double-mass flywheel and grooved ball bearing
Engine, Cylinder Head, Valve Drive
Replacing the camshaft toothed belt (with hydraulic belt tensioner)
Adjusting and checking the camshaft setting
Applying TDC mark to camshaft sprocket
Camshaft adjustment gauge (shop made)
Fitting the camshafts
Fitting the camshaft seal
Camshaft references
Machining the cylinder head mating surface
Removing and installing the cylinder head
Valve dimensions
Dismantling and assembling camshaft drive
Engine, Lubrication
Removing and installing lubrication system components
Dismantling and assembling oil pressure release valve
Removing and installing oil restraining valve
Checking oil pressure
Cleaning the entire oil system
Engine, Cooling
Mixing table
Checking cooling and heating system for tightness
Fuel Supply
Fuel vacuum line routing
Fuel System - Electronic Ignition
Test values
Checking idle and CO level of vehicles without catalytic converter
Checking idle and CO level of vehicles with catalytic converter
Removing and installing DME injection system components
Removing and installing injection valves
Ignition System
Replacing spark plugs
DME control units as of Model Year ' 92
Removing and installing knock sensors
DME-Diagnosis / Troubleshooting
VOL II - MANUAL TRANSMISSION
General
Technical data
Clutch, operation
Removing and installing clutch
Identification of clutch pressure plates
Adjusting the clutch pedal
Manual Transmission, Operation, Housing
Removing and installing transmission
Adjusting gearshift
Removing and installing gear set
Removing and installing drive shaft seal if transmission has not been dismantled
Removing and installing 5th and 6th gear
Determining snap rings for tapered roller bearing and 6th gear gearwheel
Removing and installing drive pinion and drive shaft
Dismantling and assembling end cover
Recalculating adjusting shim ,,S4''
Dismantling and assembling end shield
Dismantling and assembling transmission housing
Manual Transmission, Gears, Shafts
Dismantling and assembling drive shaft
Dismantling and assembling drive pinion
Differential / Transaxle System
Removing and installing differential
Dismantling and assembling differential
Adjusting drive set
VOL II - TIPTRONIC TRANSMISSION
General
Technical data
Diagnosis
Diagnosis Tiptronic / Troubleshooting
Troubleshooting mechanical / hydraulic section
Clutch, Automatic Torque Converter
Removing and installing the torque converter
Removing and installing the rotary shaft seal for the torque converter
Automatic Transmission, Operation, Housing
Removing and installing the transmission
Keylock and Shiftlock Check Points / Adjustment operations
Shiftlock - Emergency operation
Removing and installing multi-function switch to transmission
Adjusting bowden cable for selector device
Automatic Transmission, Gears, Controls
Checking the ATF level
Changing the ATF level
Flushing ATF radiator and piping system
Removing and installing inductive engine speed pickup
Removing and installing hydraulic control unit
Removing and installing transmission wiring harness
Removing and installing solenoid
Removing and installing piston for brake band C '
Removing and installing spacer
Removing and installing spacer seals
Checking end play
Removing and installing ATF pump
Dismantling and assembling ATF pump

Differential / Transaxle System
Changing the transmission oil in rear-axle drive
Removing and installing spur gear drive
Replacing gasket between housing and housing flange of spur gear drive
Removing and installing output shaft
Removing and installing differential
VOL III - CHASSIS, BODY
Front Wheel Suspension
Torque specifications- Front axle
Technical Data 968 / 968 CS
Adjusting the front wheel bearings
Dismantling and assembling suspension
Rear Wheel Suspension, Drive Shaft
Torques specifications - rear axle
Technical data 968 / 968 CS
Disassembling and assembling suspension
Wheels, Tires, Alignment
Wheels and tires
Fitting 16" and 17" cup design wheels to the vehicle
Wheel mounting as of MY '94
Wheels and tires of the 968 CS
Sample measuring chart
Adjustment values for wheel alignment
Suspension alignment
Tire fitting
Brakes, Mechanical
Technical data
Torque specifications - mechanical brake system
Checking thickness of brake pads
Removing and installing brake pads
Adjusting the brake pushrod
Checking stop light switch adjustment
Checking and adjusting the parking brake
Checking brake disc lateral runout
Checking brake disc thickness
Brakes - Hydraulics, Regulator, Booster

Torques specifications - hydraulic brake system
Changing the brake fluid / bleeding the brakes
Steering
Torque specifications - steering
Technical data 968 / 968 CS
Removing and installing ignition steering lock
Replacing ignition switch
Replacing lock barrel of ignition steering lock
Body - General
Safety notes
Checking dimensions for body repairs
Checking dimensions for body repairs - Cabriolet
Special Tools and Metalworking Repair Tools
Body - Front
Replacing part of front end
Bodywork - Center
Replacing part of door sill with side member and floor pan
Replacing complete roof
Body - Rear
Replacing part of rear end
Lids
Dismantling and assembling front cover
Doors
Removing and fitting door outer handle
Dismantling and assembling door outer handle
Convertible Top
Removing and installing convertible top
Bumpers
Removing and fitting spoiler and bumpers
Removing and fitting rear spoiler and bumper
Glasses, Window Controls
Bonding the interior rearview mirror in place
Removing and installing windshield - 2-pack adhesive
Removing and installing rear side window - 2-pack adhesive
Exterior Equipment
Body paint colors beginning with 1992 models
Removing and installing plastic end and side applicates - Cabriolet
Removing and installing tank flap - Cabriolet
Removing and installing door mirror
Removing and fitting side member panel
Removing and installing badge on cover
Removing and installing wheel housing liner
Interior Equipment / Airbag
Inspecting seat belts
Safety Precautions for Working on Cars with Airbag
Replacing cover for passenger airbag
Removing and installing Airbag Steering wheel
Removing and installing Airbag components
Checking Airbag System Operation
Correct disposal of airbag units
Repairing horn buttons of airbag steering wheel
Diagnosis / Troubleshooting Airbag
Seats
Checking seat heating
Calibrating controllable seat heating
VOL IV - HEATING, VENTILATION, AIR CONDITION, ELECTRICS
Air Conditioning
Technical data of air conditioning system as of MY ' 93
Pressure and temperature specifications
Radio, Telephone, On-board Computer
Removing and installing antenna
Exterior Lights, Lamps, Switches, outside
Adjusting the pop-up headlight mechanical system
Checking headlight beam adjuster
Instruments, Fuel Gauge, Alarm System
Diagnosis / troubleshooting alarm system
VOL V - WIRING SCHEMATICS
Wiring
Passenger compartment wiring harness for 968 CS
Repairing the Tiptronic wiring harness
Routing the sensor wire at the Tiptronic transmission
Wiring diagram Model ' 92
Wiring diagram Model ' 93
Wiring diagram Model ' 94
Wiring diagram Model ' 95


PORSCHE 968 - HISTORY
968 history
Option codes
968 specifications
Founders
Production numbers
Chassis numbers



PARTS CATALOG 1992-1995 (346 pages)

MAIN GROUP 0: ACCESSORIES AND OTHERS
001: tools, stickers
002: inst set, snow chains, roof rack system
004: paint touch-up applicator
005: securing liquid, sealing compound
MAIN GROUP 1: ENGINE
101: replacement engine, crankcase, protective plate
102: crankshaft, pistons
103: cylinder head, camshaft, valve
104: engine lubrication
105: water cooling
106: air cleaner
107: lh-jetronic
109: engine suspension
198: repair kits
MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM
201: fuel system, tank, etc.
202: exhaust system, catalytic converter
298: repair kits
MAIN GROUP 3: TRANSMISSION
301: central tube, clutch
302: replacment transmission, transmission case
303: gear sets, shafts
304: shifts rods, forks
305: differential
306: transmission suspension
310: central tube, tiptronic
320: replacement transmission, tiptronic
330: converter, tiptronic
340: oil sump, oil attrainer, tiptronic
360: atf-cooler, atf-pipes, tiptronic
370: transmission suspension, tiptronic
398: repair kits, manual transmission, TIPTRONIC
MAIN GROUP 4: FRONT AXLE, STEERING
401: track control arm, cross member, air deflector
402: springs, shock absorber, stabilizer
403: steering, airbag
MAIN GROUP 5: REAR AXLE
501 rear axle, dirve shaft
502: vibration damper, stabilizer
598: repair kits
MAIN GROUP 6: WHEELS, BRAKES
601: wheels
602: disk brake, front
603: disk brake, rear, hand brake
604: brake master cylinder, brakeservo, reservoir, lines
605: hydraulic unit, antiblock system
698: repair kits
MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL SYSTEM
701: gear shift lever, hand brake lever
702: pedal system
MAIN GROUP 8: BODY
801: body, frame, fender
802: bumper, front embellisher, linings
803: covers, spoiler
804: doors
805: glasses
806: concealing headlamps
807: sound absorber, linings
808: seats
809: dashboard, rear-view-mirror
810: molding
811: lifting roof, folding top, sealing
812: seat belt
813: ventilation, heater, air conditioner
898: repair kits
MAIN GROUP 9: ELECTRICAL EQUIPMENT
901: electr. equipment engine, control unit, alternator, distributor
902: starter, battery, harnesses
903: switches, clock, temperture gauge, central electr. equipment, relay, horn
904: windshield wiper system
905: headlamp, turning signal, interior lights
906: instruments, sensor
907: tempomat
909: anti-theft device
910: electrical fan
911: radio, telephone, loudspeaker, antenna
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