Porsche 928 Service Manual / Repair Manual

Workshop Manual srs DR. ING. h. c. F. PORSCHE Aktiengesellschaft

928 Engine / Crankcase 10 a TOLERANCES. AND WEAR LlMITS Cooling System Coolanr thermostat Radiaror Cap High pressure valve LOW pressure valve Oil Circuit Oil consumprion Oil pressure at 80’ C oil temperarue and at 5000 rpm Oil dipstick Upper mark Lower mark Oil pump Clearance Valve Timing Camshaft bore Inside dia. Camshaft Bucket rappet bore Bucket tappet Camshaft Opening temperarure Opening pressure Opening pressure ltr/lOOO km Oil volume Oil volume Axial play Radial play Diamerer Axial play Inside dia. Diameter Runour Cylinder Head and Valves Bearing surface Valve sear: Intake Exhausr Make Exhaust Ourer correcrion angle Inner correction angle Valve guides: Intake and exhaust Valve stem: lnrake Exhaurt Disrorrion ,Widrh Width seat angle seat angle lnside dia. Diameter Diameter When Installed (new) 81 - &so c 0.9 - 1.15 bar 0. 07 - 0.12 bar 5 bar 1. 5 1tr 6. 0 111 0.080 - 0.120 0.060 0.088 60. 5 + 0.03 -0 60.5 - ‘. O3 - 0.045 0.10 - 0.18 38 + 0.010 + 0. 038 38 - 0.018 - 0.034 0.02 1.1 2. 0 450 4s” 300 600 9 + 0.015 8.97 0.012 8.95 - 0.012 Wear Limit ca. 1. 5 max. 0.08 Printed inGerma”y - II. 1916 Tolerances and Wear Limits 10 - 01

10 Engine / Crankcase 928 Valve guide/valve srem lnrake Exhaust Compression Clearance When lnsralled mew Wear Limit l 0.80 0.80 8 bar and more 6. 5 bar Pistons and Connecting Rods Cylinder/piston Clearance 0.024 - 0.048 ca. 0.080 Pisron rings Pirron rings Side clearance Groove 2 0.04 - Groove 3 0.013 - End clearance Groove 1 = 0.20 to 0.40 Groove 2 = 0.20 co 0.40 Groo”e 3 = 0.40 to 1.40 Conrod bushing Diameter Pisron pin Diameter Conrod bushing/piston pin Radial play Crankshafr and Engine Block Crankshafr Runour 0.04 - 0.06 max. 0.08 /measured on 2nd. 3rd or 4th bearings. 1st and 5th bearings iunnmg in vees) Conrod bearing journal Conrod bearing/crankshaft Crankshafr bearing journal Crankshaft bearing/crankshaft Crankshaft bearing/crankshaft Cylinder bore Diamerer 51.971 - 51.990 Radial play 0.034 - 0.092 Axial play 0.100 - 0.400 Diameter 69.971 - 69.990 Radial play 0.020 - 0.098 Axial play 0.110 0.312 our-of-rrue 0.010 0.020 24 + 0.018 + 0.028 24 - 0.004 0.018 - 0.032 l 10 - 02 Tolerances and Wear Limirs xx, 1988 - Printed in Germany

928 Engine/Crankcase 10 DESIGNATION OF CYLINDERS l Printed in Germany - VII, 1983 Technical Data lo-02a

928 Engine/Crankcase 10 l ENGINE TORQUE SPECIFICATIONS Location Main bearing Crankcase with “X” next to case number and all crankcases with closed main bearing bushing, bearing 1 Main bearing Crankcase with “X” next to case number and all crankcases with closed main bearing bushing, bearing 1 Oil pump Conrad nut with smooth bearing surface Conrod nut with ribbed bearing surface Cylinder head Tightening Specifications 3 steps: 1st step 2nd step 3rd step 2 step5: 1st step 2nd step 2 steps: 1st step 2nd step A) Pre-loading cylinder head gasket 1st Step 2nd step 3rd step 6) Gasket left in preloaded condition 30 minutes C) Final tightening: Nuts unscrewed one after the other by l/4 turn and then tightened, See note onpage15.7 New tightening instructions for changed cylinder head gasket: Part No. 928.104.361.02 Cyl. 1 - 4 Part No. 928.104.362.02 Cyl. 5 - 8 Part No. 928.104.371.09 Cyl. 1 - 4 Torque Nm Iftlb) 20 (141 40 (29) 60 + 5 (43 + 3.6) 75 + 5 (54 + 3.6) 20 (14) 40 + 5 (29 + 3.61 50 + 5 136 + 3.61 15 111) 20 (14) 58 + 5 (42 + 3.61 75 (541 20 (14) 50 (361 85 161) 85 (611 Threads M 12 x 1.5 M 10 M8 M 10 x 1.25 M 10 x 1.25 M 12x 1.5 Printed in Germany XII, 1986 Engine Torque Specifications 10-03

10 Engine, Crankcase 928 Location Location I Cs$;;;der head ! Tightening Procedures I New tightening proced- ure for cylinder head sasket: CT-NO. 928.104.372.09 Cyl. 5 - 8 from following engine numbers onward: 80 C 0260 M 28/09 I 80 C 5269 M 28;lO 82 C 0713 M 28/11 82 C 5782 M 28/12 81 C 1037 M 28/15 81 C 6398 M 28/16 80 C 8051 M 28/17 80 C 9155 M 28/18 1st step 20 (14.6) 2nd step 50 (36.5) 3rd step 90 (65.7) torquing by angle of rotation: 1st step 2nd step 3rd step 4th Step Only in conjunction with new stud bolt 20 90"of rotation 90"of rotation 90"of rotation Recognizable by: I Color:ochre (gal- vanized, yellow pas- sivated) Thread: longer and with cylinder head gasket 928.104.361.02/362.02 928.104.371.09/372.09 Torque Nm (ftlb) Thread a 10 - 04 Torque Settings for Engine XII, 1986 - Printed in Germany

Engine/Crankcase 10 a i xcation Camshaft housing :o cylinder head Tightening Specifications Torque Nm (kpm) 20 (2.01 Threads Ma ‘lug on camshaft housing 3amshaft Spark plugs 40 (4.0) M 18x 1.5 45 (4.51 M 10 (8.8) 65 (6.51 M 10 (10.9) 25 to 30 (2.5 to 3.0) Flywheel PlJlk?y Oil drain plug Thermostat housing plug Oil pressure sensor Pressure relief valve plug Bypass valve adapter Water drain plug in engine block 90 (9.01 M 10x 1.25 295 (29.5) M18x1.5 60 (6.0) M22x1.5 50 (5.0) MZOx1.5 80 (8.0) M48x1.5 35 (3.5) M 18x 1.5 40 (4.0) M 18x 1.5 70 (7.0) M 24 x 1.5 35 (3.51 MlZx1.5 Radiator water drain plug Adapter to radiator to engine Oil bore to adapter on crankcase upper section 1,5(0,2) M 10 70 (7.01 70 17.0) 70 (7.0) M26x1.5 Oil hose to adapter on radiator Temperature switch on radiator 70 (7.0) M26x1.5 40 (4.0) l Printed in Germany - XX. 1988 Engine Torque Specifications 10~05

10 Engine/Crankcase 928 Location Coolant thermostat housing to engine Tightening Specifications Two steps: 1st step 2nd step Torque Nm (kpml 10 (1.0) 20 + 2 (2.0 + 0.2) Threads M8 Coolant temperature transmitter 25 - 30 (2.5 - 3.0) Air Injection: Adapter on cylinder head Check valve Oxygen sensor air line Exhaust gas test nut on catalytic converter Exhaust gas test plug on catalytic converter Temperature sensor II to thermostat housing Temperature valve to connector CO test line to exhaust manifold 40 (4.01 55 (5.51 30 13.01 55 (5.5) M 16x 1.5 30 (3.0) M 14x 1.5 15 (1.5) M8xl 12 (1.2) max. 15 (1.5) MlOxl 25 12.5) All other bolts and nuts: M6 6 + 2 (0.6 + 0.21 M8 20 + 2 12.0 + 0.2) M 10 40 + 5 (4.0 + 0.51 10.06 EngineTorque Specifications Printed in Germany

928 Engine, Crankcase 10 Engine tightening torques (32~valve engine) Location /- Thread I Main bearing bolts Main bearing bolts Oil pump bolts Connecting rod bolts Verbusrip nut 928 GTS (5.4 I) Engine Type M 28.49150 Connecting rod bolts (forged con-rods) Verbusrip nut Cylinder head studs Cylinder head hexagon head bolts Camshaft bearing saddles to cylinder head Hex socket head bolts for chain tensioner Banjo bolt / chain tensioner Check valve / chain tensioner Camshaft bolt union Cylinder head cover Spark plugs Flywheel bolts M 12 x 1.5 M 10 M8 M 10 x 1.25 M 10 x 1.25 M6 M8 M6 M8X1 MlOxl M 10 x 1.5 M6 M 14 x 1.25 M 10 x 1.25 Tightening torque Nm (ftlb) 1st stage 30 (22) 2nd stage 55 (41) 3rd stage 75 +5 (55 c4) 1st stage 20 (15) 2nd stage 50 + 5 (37 + 4) 1st stage 15 (11) 2nd stage 20 (15) 75 (55) 25 + 90” tightening angle a Engine tightening torques (32~valve engine) Printed in Germany - XXVII, 1991 1st stage 2nd stage 3rd stage 4th stage 1st stage 2nd stage 3rd stage 10 (7) 20 (15) 10 (7) 10 (7) 15 (11) 65 (48) 10 (7) 25 to 30 (18 to 22) 1st stage 2nd stage 20 (15) 90” torque angle 90” torque angle 90” torque angle 20 (15) 90” torque angle 90” torque angle 40 (30) 90 (66) 10 - 07

Engine, Crankcase 928 Location Pulley bolts Oil drain plug Thermostat housing plug Oil pressure sender Pressure release valve plug Short-circuit valve screw-in flange Cylinder block drain plug Radiator drain plug Screw-in flange to radiator to engine Oil hose to screw-in flange at upper crankcase section at coolant radiator Temperature switch to coolant radiator Regulator housing for coolant circuit to engine Temp. sender unit coolant temperature Check valve Air line Oxygen sensor Exhaust gas takeoff plug to catalytic converter Temp. sensor NTC II to regulator housing -1 M 20 x 1.5 M 48 x 1.5 M 18 x 1.5 M 18 x 1.5 M 24 x 1.5 M 12 x 1.5 M 10 M 26 x 1.5 M 26 x 1.5 M8 M 18x 1.5 M8x1 Tightening torque Nm (ftlb) 295 (218) 50 (37) 80 (59) 35 (26) 40 (30) 70 (52) 35 (26) 1.5 (1) 70 (52) 70 (52) 70 (52) 70 (52) 40 (30) 1st stage 10 (7) 2nd stage 20 + 2(15 + 1) 25 30 (18 22) 55 (41) 30 (22) 55 (41) 15 (11) 12 (9) lo-08 Engine tightening torques (32~valve engine) a Printed in Germany - XXVII, 1991

Porsche 928 Service Manual / Repair Manual

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