Porsche 928 Electrics. Table of Contents

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PAGE 1 Table of Contents ALL PAGE NUMBERS ARE HYPERLINKED [SECTIONS BEYOND SECTION 8 ARE IN THE MAIN 928-ELECTRICS DOCUMENT ONLY] WIRING DIAGRAM PRIMER 1 2 WIRING OVERVIEW... 1 2.1 Standardized Wire Jacket Colors.

1 PAGE 1 Table of Contents ALL PAGE NUMBERS ARE HYPERLINKED [SECTIONS BEYOND SECTION 8 ARE IN THE MAIN 928-ELECTRICS DOCUMENT ONLY] WIRING DIAGRAM PRIMER 1 2 WIRING OVERVIEW Standardized Wire Jacket Colors Porsche Circuit Numbering Wiring Sizes/Thickness Wire Insulation & Looms WIRING DIAGRAMS STRUCTURE Wiring Diagram & Other Content General Wiring Diagram (WD) Grid Wire Identification Wire Connection Conventions Connecting Points (CP#) In Vehicle Location Notation Ground Points (GP x) Inter-Sheet Connection Tags Wire Grouping Conventions Wiring Looms (WL # or KS #) Grouping for Plug & Socket Terminals Plug Connectors WIRING DIAGRAM (WD) SYMBOLS MODULES Module Identification & Location CENTRAL ELECTRIC (CE) PANEL Central Electric (CE) Overview Central Electric (CE) Physical Implementation Central Electric (CE) General Connectivity CE Connectivity to Other Sheets Central Electric (CE) Internal Connectivity TOTAL CONNECTIVITY EXAMPLES Example: Tracing from CE to another WD Sheet Example: Tracing From WD Sheet to CE...29 SCHEMATIC COMPONENTS 44 8 SWITCHES Basic Operation, Symbol & Terminals INCANDESCENT BULBS CENTRAL ELECTRIC (CE) COMPONENTS... 53

2 PAGE Relays Special Function Relay Modules Fuses CE Plug Connectors...59 BASIC ELECTRIC THEORY BASICS: VOLTS, AMPS, OHMS & WATTS Terminology & Symbols Used In This Section Current (A) Voltage (V) Power (W) Resistance (Ω) & Ohms Law...63 BASIC DEBUG TECHNIQUES INTRODUCTION TO DEBUG THE CHALLENGE Step 0 Characterize the Failure Step 1 Suspect Yourself Step 2 Check Fuses Step 3 Basic Relay Checks Step 4 Check Grounds Step 4 Check Other Connections Step 5 Enlist the Support of Others Debug Tools Measuring Amps, Volts & Ohms Use of a Digital (or Analog) Multi-Meter Current Measurement Voltage Measurement Resistance Measurement Power Measurements...72 MORE ADVANCED THEORY (OPTIONAL) CHARGE, ENERGY, CAPACITANCE & INDUCTANCE Charge (C) Energy (J) Capacitance (F) Inductance (H) COMPONENT OPERATING DETAILS Resistors Thermistors & Thermal Switches Pressure Switches Inductors (Coils) Capacitors Diodes Light Emitting Diode (LED) Transistors Hall Effect Sensors...79

3 PAGE 3 15 MORE ADVANCED WIRING CONSIDERATIONS Wire Insulation Material Wiring Resistance Effects Basic Wiring Resistance Example Temperature Effects on Wiring ADVANCED BULB THEORY Light Output - Luminous Efficiency & Efficacy...86 MAJOR SYSTEM OPERATION OVERVIEW GENERATION, CHARGING & STARTING SYSTEMS Battery Battery Failure Mechanisms Battery Testing Battery Maintenance Battery Charging Alternator Alternator Failure Modes Starter Starter Failure Modes Parasitic Current Drain Debugging Excess Parasitic Current Drain POWER CONTROL & DISTRIBUTION SYSTEM Ignition Switch Failure Mode: X-Bus (X) & X-Bus Relay Cigar Lighter/Power Outlet Supply-Bus & Supply Relay ENGINE CONTROL & RELATED SYSTEMS Engine Control Systems Theory of Operation LH Jetronic Fuel Injection Theory of Operation EZK Spark Control The Ignition Circuit Monitoring Relay Common No-Start Diagnostics for the Porsche Checking the Mass Airflow Sensor (MAF) Engine/AC Cooling Fan System Overview Fan Controller Unit Fan Final Drive Stage Air Flap Control System ( 87-90) EXTERIOR LIGHTING & CONTROLS Main Light Switch Headlights Configuration for Motor Drive & Headlight Switching Headlight Failure Mechanisms: Headlight Remote Aim Adjustment...122

4 PAGE Front Fog Lights & Driving Lights Daytime Running Lights Turn Signals Hazard Switch Marker Lights Front Marker Lights Rear Marker Lights Brake (Stop) Lights Center Brake Light Other External Lighting Reversing Lights License Plate Lights Rear Fog Lights Door Open Safety Lights Parking Light Mode Bulb Monitoring System Failure Modes Bulb Monitoring INTERIOR LIGHTING & CONTROLS Location & Operation Door Open Safety Lights Interior Light Fixture Removal Failure Modes, Diagnosis & Repair Additional Interior Lighting Additional Interior Lighting Failure Modes Dashboard & Instrument Lighting Dashboard Illumination Failure Modes DASHBOARD & DIAGNOSTICS Analog Dashboard (Pre-1989) Digital Dashboard ( ) Fluid Level, Temperature and Pressure Sensors Brake Pad Monitoring System Additional dashboard features Vehicle Diagnostic Connector VEHICLE/DRIVING SAFETY SYSTEMS Airbag System Airbag Steering Wheel Removal High Physical Impacts to the Vehicle Windshield Wipers/Washers Front Windshield Wipers Front Windshield Washers with Heated Nozzles Intensive Washer system (< 92) Headlight Washer System Rear Windshield Washers (non-standard) Rear Windshield Wiper ABS System PSD System RDK Tire Pressure Monitoring System...144

5 PAGE RDK Failure Modes: Disabling the RDK system Catalytic Converter Temperature Monitoring VEHICLE SECURITY SYSTEMS Electric Central Door Locks Terminology: Central Locking Failure Modes Alarm System Alarm System Overview Alarm System Operation: Test the Alarm Alert! Terminating the armed/alert mode Locking the vehicle without alarm arming Ignition Disable Defeating the Ignition Disable Defeating the Lights & Horn Failure Modes: Intermittent False Alarms Unseen/Unknown Failures HVAC & REAR AC SYSTEM Front HVAC System Operation & Configuration General Operation Configuration: HVAC Head Unit Automatic Temperature Control Setting Re-Circulate ( ) Mode Automatic Windshield Defogger Over-ride Mode ( ) Relay On/Off Control & Fan Speed Control Fan Speed Control Night Illumination (incl. AC On/Off Switch) Diode Protection (on outputs) Rear (Supplemental) AC System (M570) HVAC Failure Modes: Complete System Failure Blower Fan Failure Blower Fan Insufficient Airflow/ Excessive Noise AC Not Cold AC Not Cold Enough Noises in Dash Erratic Temperature Control Rear AC Failure Modes CONVENIENCE & ENTERTAINMENT SYSTEMS Cruise Control System Electric Door Mirrors (Controls/Memory) All Mirrors (S4+) Mirror Controls (manual only) Mirror Controls with Memory (M537/M538 1 )...174

6 PAGE Electric Window & Sunroof Controls Early Window Relay System (Pre-1990) Failure modes (Pre-1990) Later Window Controller System ( ) Failure modes ( ) Power Seats Comfort Seat Non-Memory Sports Seat (M383, M387) Comfort Seat with Memory (M537, M538) Electric Rear Hatch Opener Mechanical Failure Mechanisms Electric Hatch Operation Electrical Failure Mechanisms Failure Due To Interior Light Problems Other Considerations Adding a Second Hatch Switch Audio: Radio & Booster Amplifier (etc) Factory Radio/head Unit options Factory Amplifier ( Booster ) Factory Installed Speakers Factory CD-Changer Factory Installed Phone Systems Noise Suppression for Audio ELECTRIC PROJECTS - 20 IDEAS PROJECT IDEAS OVERVIEW & COMPLEXITY RATINGS Upgrading to Higher Output Bulbs ( ) H4 Headlight Upgrade ( ) HID Headlight Upgrade ( ) Electric Headlight Aim Adjusters ( ) Radar Detector ( ) Remote External Sensors Radio & CD Changer Installation ( ) Navigation System ( ) Audio System ipod Interface ( ) Phone Hands Free System ( ) Keyless Entry System ( ) Aftermarket Alarm Systems ( ) Auto Dimming Rear View Mirror ( ) Permanently Installed Trickle Charger ( ) Rear Power Outlet / Rear Charger Port ( ) Battery Disconnect Switch ( ) Digital Intermittent Front Wipers ( ) Rear Wiper Improvements ( ) Illuminated Door Sill Logo Strips ( ) Integrated Garage Door Opener ( ) LED/Pulsing Central Brake Light ( ) Development Concept (Guidelines/Strategy)...208

7 PAGE 7 PROJECT TECHNIQUES - OVERVIEW PROJECT TECHNIQUES Removing the CE Panel Steps to remove the panel Preventative Cleaning & Repair Removal of Individual Fuse Blocks & Individual CE Sockets Fuse & CE Socket Terminals Relay Sockets & Carrier Removal from CE Relay Terminal Types Terminal Removal from Relay Sockets Adding Additional Fuse & Relays for Projects Adding Fuses/Relays direct to the CE panel Adding a Secondary Fuse/Relay Distribution Panel Adding Individual Fuses/Relays in Multiple Locations Locations for Adding Modules to a Simple Individual Power Tap Options on CE Panel Adding to Central Electric (CE) Plug Connectors Adding Connections to CE Socket R Adding/Modifying Connections to Existing CE Plugs CE Plug Pin Terminal Removal / Replacement Adding Connections via Unused Fuse Sockets Adding Relay Connections to CE Adding Fuse/Relay Connections Outside of CE Adding New Wiring Looms Routing Wires Up to the Headliner Routing Wires across the Vehicle Routing Wires to the Rear Routing Wires through the Firewall Routing Wires to the Front Fenders PHASED DEVELOPMENT PROCESS Development Phase 1 Prototyping Development Phase 2 Operation & Ergonomics Development Phase 3 Finished Implementation HELPFUL DOCUMENTATION PROCEDURES Documentation in Phase Documentation in Phase Documentation - Details Further Documentation Installation Location Examples Example Space Usage (for many of the Project Ideas) GENERAL MAINTENANCE & REFURBISHING Cleaning Grounds Cleaning Power Connections Cleaning Connections on the Instrument Pod Reworking Damaged Plug Connector Tails Replacing Bulbs in the Instrument Pod...241

8 PAGE LED Illumination for the Instrument Pod BASIC TOOLS REQUIRED FOR ELECTRICAL WORK In Vehicle Emergency Kit Supplies Needed for Electrical work Some Suggested Equipment & Parts Vendors APPENDIX A PROJECTS PROJECT DETAILS Upgrading to Higher Output Bulbs ( ) Sourcing & Cost H4 Headlight Upgrade ( ) Sourcing & Cost Conclusion Bi-Xenon HID Headlights, by Ed Scherer ( ) Introduction Sourcing & Cost What s In the Box Installation Additional Items Used During Installation Installing the Kit Modifying the Bulb Assembly Wiring Harnesses Headlight Anatomy, Top Side Headlight Anatomy, Bottom Side Sub-procedures Installing Right Side Ballast, Igniter, and Bulb Installing Left Side Ballast, Igniter and Bulb Aiming the Headlights Aiming Procedure Performance Final Thoughts Electric Headlight Aim Adjusters ( ) Sourcing & Cost Motor Connector Fabrication Motor Installation Theory of Operation Aiming Conclusion Radar Detector ( ) Goals Mounting Location Mounting Hardware Customizing Valentine1 Remote Units Sourcing & Cost Alternative Installation Options: Conclusion Audio System Installation ( ) Radio Sourcing & Cost...307

9 PAGE Power Retention Bus Navigation System ( ) Sourcing & Costs Audio System ipod Interface ( ) Audio Only Audio & Control/Display Phone Hands Free System ( ) Bluetooth Wireless - Wave of the Future Example Bluetooth System Audio Interfacing Phone Specific or Generic Plug In Types Antennas Auto-Dimming Rear View Mirror ( ) Conclusion Permanently Installed Trickle Charger ( ) Conclusion Rear Power Outlet / Rear Charger Port ( ) Installation Sourcing & Cost Conclusion Battery Disconnect Switch ( ) Warning Installation Considerations Fabrication Example Sourcing Alternatives Conclusion Digital Intermittent Front Wipers ( ) So what s the Problem? Looking for a Digital Option Installation Sourcing Conclusion Rear Wiper Improvements ( ) Original Configuration and Ergonomics Updated Configuration & Operation My New Rear Wiper Operation Safety Considerations Connection Locations on CE (GTS specific locations) Relay Modification Details Alternate Implementations Maintaining the Console Switch Location Conclusion Keyless Entry System ( ) Functional Options Installation Example Hatch Motor Modifications Additional Feature Alternate Implementation...338

10 PAGE Conclusion Aftermarket Alarm Systems ( ) Adding Alarm Features: Illuminated Door Sill Logo Strips ( ) Sourcing & Costs Installation Conclusion Integrated Garage Door Opener ( ) Evaluate your Remote s Operation Extended Transmission with One Press! Conclusion LED/Pulsing Central Brake Light ( ) Sourcing & Cost Installation Conclusion APPENDIX B REFERENCE DOCS ELECTRICAL DATA BURIED IN THE FWM WIRING DIAGRAM (WD) CONNECTOR LOCATOR WIRE COLOR VS FUNCTION RELAY LOCATIONS & TYPES FUSES CE LOOM IDENTIFICATION SPECIFIC FUNCTION TERMINAL IDS BULB REFERENCE Notes: Bulb/Lighting incl. USA vs. ROW INSTRUMENT POD BULBS LED s for Instruments/Switches TERMINAL SIZING CODES MODULE IDENTIFIER APPENDIX C QUICK REFERENCE CARD 372 APPENDIX D DOCUMENTATION DOCUMENTATION EXAMPLES: APPENDIX E - DOCUMENT NAVIGATION NAVIGATION APPENDIX F DOCUMENT FORMAT 381 APPENDIX G - REVIEWER UPDATE NOTES 383

Porsche 928 Electrics Figure Locator ALL PAGE NUMBERS ARE HYPERLINKED (FIGURES NUMBERED >35 ARE ONLY AVAILABLE IN THE MAIN 928-ELECTRICS DOCUMENT)

Porsche 928 Electrics Figure Locator ALL PAGE NUMBERS ARE HYPERLINKED (FIGURES NUMBERED >35 ARE ONLY AVAILABLE IN THE MAIN 928-ELECTRICS DOCUMENT) PAGE 1 Figure Locator ALL PAGE NUMBERS ARE HYPERLINKED (FIGURES NUMBERED >35 ARE ONLY AVAILABLE IN THE MAIN 928-ELECTRICS DOCUMENT) Figure 1 Wiring Diagram (WD) Grid:... 5 Figure 2 Wire Color & Size Conventions:...