Porsche 944 Instruction manual

Workshop Manuel
Volume IA - Engine, 16 valves
DR. ING. h. c. F. PORSCHE Aktiengesellschaft
As webpage by http://www.9ss1.dk/porsche944

944 Table of contents volume I-A
General
Technical data
Maintenance, Self-diagnosis
Fault diagnosis, DEE control unit
Connecting into the vehicle - 944S
Starting fault diagnosis
Functional test - actuator and input signal
List of test codes
System adaptation
Knock detection
Troubleshooting
List of fault codes
Clearing fault memory
Operating conditions for start of diagnosis
Operating instructions for System Tester 9288
Engine, Crankcase
Tightening torques for engine (16-valve)
Tolerances and wear limits
Engine, removing and installing
Engine, Crankshaft drive, Pistons
Notes on assembly for pistons, from Model 87 onward
Checking pistons and cylinder bore
Pistons from Model 89 onward
Installing cover for oil-centrifuge partition
Engine, Cylinder head, Valve drive
Camshaft salling, checking and adjusting
Camshaft salling, checking and adjusting for Model 89 onward
Applying the TOC mark on the camshaft sprocket
Camshafts and cylinder head, removing and installing
Cylinder head, installing and tightening
Camshafts, installing
Camshaft seal, installing
Camshaft specifications
Chain tensioner, removing and installing
Cylinder head, disassembling and assembling
Valve springs, removing and installing with Sauer tool
Page
0.9
03 - 1
03 - 3
03 - 5
03 - 7
03 - 13
03 - 15
03 - 17
03 - 19
03 - 29
03 - 31
03 - 32
03 - 33
10 - 0101
10 - 0102
10 - 101
13 - 101
13 - 102
13 - 103
13 - 105
15 - 101
15 - 104 a
15 - 104 b
15 - 105
15 - 110
15 - 111
15 - 112 a
15 - 112 b
15 - 113
15 - 115
15 - 118
Table of contents
Printed in Germany - XXIV, 1991
1

volume I-A Table of contents 944
Machining mating face, cylinder head
Vaive springs, removing and installing, removing valve stem seal
Valve stem seal, installing
Checking valve guides
Replacing valve guides
Checking valve seat wear limit
Valve seats, checking and machining
Checking and adjusting installation length of valve springs
Engine - Lubrication
Replacing engine oil and oil filter
Pressure-reduclng valve, removing and installing
Engine - Coating
Checking cooling and heating system for leaks
Fuel supply
Replacing fuel filter, checking injection lines for leaks and tightness
Checking delivery rate of fuel pump
Line routing, fuelsystem, M 44.40
Fuel preparation - L-Jetronic/regulation
Replacing air filter cartridge, checking intake-air guide hoses
Testing and adjusting specifications
Checking fuel pressure
Checking idle speed and CO - with catalytic convertor
Checking idle speed and CO - without catalytic convertor
Replacing air filter cartridge for Model 89 onward
Exhaust system
Exhaust system - check tightness of flanges
Ignition system
Equipment table
DEE control unit coding - 944 S, Model 87 onward
Replacing spark plugs
Equipment table, Model 89 onward
DEE control unit coding - 944 S 2, Model 89 onward
DME-Diagnosing / Troubleshooting
Page
15 - 120
15 - 121
15 - 122
15 - 123
15 - 125
15 - 130
15 - 131
15 - 133
17 - 101
17 - 102
19 - 101
20 - 101
20 - 102
20 - 103
24 - 101
24 - 102
24 - 103
24 - 105
24 - 106
24 - 107
26 - 101
28 - 101
28 - 103
28 - 104
28 - 105
28 - 107
D-24/28-1
2 Table of contents
Printed in Germany - XXIV, 1991

944 General
TYPE 944 S (16-VALVE ENGINES) - '87 MODELS ONWARD
Printed in Germany - XIII, 1987 Technical Data 0.9

General 944
TECHNICAL DATA
(Adjustment specifications and wear data are stated in the appropriate Repair Groups)
Note: US values are stated in parentheses
DRIVE UNIT
Internal engine designation
Number of cylinders
Bore
Stroke
Displacement (actual)
Compression ratio
Max. engine output to
80/1269/EC
Net power, SAE J 1349
at engine speed
Max. torque to
80/1269/EC
at engine speed
Net torque, SAE J 1349
Max. spec. power output
Net power, SAE J 1349
Fuel octane rating
Max. perm. engine speed
Engine weight (dry)
ENGINE DESIGN
Type
mm/in.
mm/in.
cc/in.
3
kW/PS
kW/HP
rpm
Nm/kpm
rpm
Nm/lbft
kW l/HP l
kW l/HPI
RON/MON
rpm
kg/lbs
M 44/40
4
100/3.94
78.9/3.11
2479/151
10.9 : 1
140/190 - 135/184 Australia
140/188
6000
230/23.5 - 225/22.9 Australia
4300
230/170
56.5/76.6-54.5/74.2 Australia
56.5/75.8
95/85 - 92/82 unleaded Australia
(95/85 premium unleaded)
6840
175/386
4-cylinder, 4-stroke in-line spark ignition
engine with two balance shafts
0.10 Technical Data Printed in Germany

944 General
Crankcase
Crankshaft
Crankshaft bearings
Connecting rods
Connecting rod-bearings
Pistons
Balance shafts
Balance-shaft bearings
Cylinders
Cylinder head
Valve guide
Valve arrangement
Valve timing
Camshaft
Camshaft drive
Balance-shaft drive
Valve clearance
Two-part light alloy crankcase
Forged, 5 bearings
Plain
Cast, opt. sinter-forged
Plain
Light alloy, cast
Forged
Plain bearings with bearing shells
Light alloy
Light alloy
Press-fit, special brass
2 intake, 2 exhaust
overhead V
Two overhead camshafts, hydraulic
bucket tappets
Without bearing shells, carried in
cylinder head
Toothed belt and internal chain
Toothed belt
Self-adjusting (hydraulic)
Timing Intake opens
Intake closes
Exhaust opens
Exhaust closes
4°after TDC
40°after BDC
36°before BDC
4°before TDC
Printed in Germany - XIII, 1987 Technical Data 0.11

General 944
ENGINE COOLING
ENGINE LUBRICATION
Lubrication
Oil pressure
Oil-pressure indicator
Max. oil temperature
Oil consumption
EXHAUST SYSTEM
EMISSION CONTROL
HEATING
n = 5000 rpm
l/1000 km
Sealed cooling system, electric fan
with thermoswitch, antifreeze effective
to - 25°C
Forced-feed lubrication with
sickle-type pump, oil filter and
oil-water heat exchanger in main oil
flow and secondary water flow
integrated in crankcase
Approx. 4 bar, at operating
temperature
Pilot lamp and pressure gage
140°C
Up to 1.5
Standard
2 double-wall manifolds, branch pipe to
primary muffler, 1st and 2nd
secondary mufflers
Option: M298 or M299 and USA and
Australia as standard, catalytic
converter instead af primary muffler
Standard: engine-internal
Option: M298 or M299
and Australia
heated oxygen sensor with 3-way
catalytic converter
Hot-water heating with heat exchanger
and blower
0.12 Technical Data Printed in Germany

944 General
FUEL SYSTEM
Injection
Fuel delivery
Fuel octane rating
Fuel consumption
to 80/1268/EC or
ECE R 15/04
Constant 90 km/h
Constant 120 km/h
EC exhaust urban
cycle
ELECTRICAL SYSTEM
Suppression
Battery voltage
Battery capacity
Alternator (output)
Ignition
Firing sequence
Ignition timing
RON/MON
l/100 km
l/100 km
l/100 km
V
Ah
A/W
DME
Digital Motor Electronics
1 electric fuel pump
Standard:
95/85 - European standard
premium unleaded
possible
Opt./M298:
95/85 unleaded
- European standard premium -
Australia: 91/82 unleaded
Standard:
6.7
8.3
12.5
ECE-R 10 and 72/245/EC
12
50 - optional 63,
sports package 36
115/1610
- sports package: 90/1260
By DME
1-3-4-2
By DME
Printed in Germany - XIII, 1987 Technical Data 0.13

General 944
BODY DESIGNS
Integral all-steel body with front air dam and rear
spoiler
- as coupe, opt.: removable hardtop panel, also
available with fog lamps set in PU front air dam as
optional extra.
DIMENSIONS (at DIN curb weight)
Length
Length with opt.
extra US bumpers
Width
Height
Wheel base (in
design pos.)
Track:
Front
Rear
Ground clearance
(at per. total
weight)
Bed clearance
(at per. total
weight)
Overhang angles:
Front
Rear
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
4230/165.354
4290/168.90
1735/68.31
1275/50.20
2400/94.49
1477/58.2
1477/58.2
1477/58.2
1451/57.1
1451/57.1
1451/57.1
1442
120/4.72
53/2.09
14°
15°
(4290/168.90)
Rim size
7 J x 15
7 J x 16
8 J x 16
7 J x 15
7 J x 16
8 J x 16
9 J x 16
0.14 Technical Data Printed in Germany

944 General
WEIGHTS - to DIN 700 20 -
Curb weight
Front
Rear
Total
Per. axle load
Front
Rear
Per. total
weight
Per. trailer
load
Braked trailer
Unbraked
trailer
Max. car/
trailer weight
Max. drawbar
load
Per. roof load
With genuine
Porsche roof
transport
system
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
Standard
640/1411
(650/1433)
640/1411
(650/1433)
1280/2822
730/1609
900/1984
1600/3527
1200/2646
1200
500/1102
500
2760/6085
2760
50/110
50
35/77
75/165
Sports package
630/1389
610/1345
(630/1389)
1240/2734
(1260/2778)
730/1609
(720/1587)
900/1984
1600/3527
(1550/3417)
up to 16% gradient
for Italy
up to 16% gradient
for Italy
for Italy
for Italy
up to 100 km/h
Australia,
standard
640/1411
640/1411
1280/2822
730/1609
920/2028
1620/3571
Printed in Germany - XIII, 1987 Technical Data 0.15

General 944
CAPACITIES
Engine (measurement with dipstick
as per Driver's Manual is definitive)
Engine oil
Engine coolant
Transmission with differential
Fuel tank
Brake-fluid reservoir
Windshield and headlight washing
fluid reservoir
Proprietary HD oils to APl
classification
SE or SF, see Driver's Manual
Approx. 6.0 l
Approx. 8.5 l
Approx. 2.0 l hypoid oil, SAE 80
to MIL-L 2105, APl classification
GL 4
Approx. 80 l, including approx.
8 l reserve
Approx. 0.2 l
Approx. 0.6 l
PERFORMANCE
Maximum speed
Acceleration from
0-100 km/h*
(0-60 mph)*
(1/4 mile
from standing
start)*
Kilometer from standing start*
CLIMBING PERFORMANCE
In % (slip limit)
km/h/mph
s
s
s
s
1st gear
2nd gear
3rd gear
4th gear
5th gear
228/142
7,9
(7.7)
(15.4)
27.8
62%
35.6%
21.5%
13.3%
9.4%
*DIN curb weight and half of payload
0.16 Technical Data Printed in Germany

944 General
Technical data - Type 944 52 - Model 89
(Values for adjustment and wear are to be found in the respective repair groups)
Notes: USA values are given in brackets
Drive unit
Internal engine designation
Bore
Stroke
Displacement (actual)
mm (in.)
mm (in.)
cm
3
(in.
3
)
Manual transmission M 44.41 (3.0 I)
104 (4.09)
88 (3.46)
2990 (182.5)
Displacement (rounded down) cm
3
2969
Compression ratio
Max. engine power
88/195/EEC
Net power, SAE J 1349
at engine speed
Max. torque
88/195 / EEC
(Net torque, SAE J 1349)
at engine speed
Max. output per litre
DIN 70020
(SAE J 1349)
Speed governed by
fuel cut-off
Engine weight (dry)
kW (HP)
kW (HP)
rpm
Nm (kpm)
Nm / lbft
rpm
KW/I (HP/I)
KW/I (HP/I)
rpm
kg
10.9: 1
155 (211)
155 (208)
5800
280 (28.5)
280 (207)
4100
51.8 (70.6)
51.8 (69.6)
6480 +- 20
175
Technical data
Printed in Germany - XIX, 1989
0.17

944 Maintenance, Self-diagnosis
03
DME control unit error diagnosis
DME control unit error diagnosis 944 S
as from 88 model
As from model year 88, the DME control unit
944 S is capable of a self-diagnosis. That is to
say, the control unit is capable of detecting,
storing and displaying system errors. The con-
trol unit capable of diagnosis is identified by
an altered part number. A specially developed
diagnostic tester (special tool No. 9268) is
then used to read out the error memory and
to test specific components and control sig-
nals af the fuel and ignition system.
87/793
Important: Before diagnosis, the battery or
the connector of the DME control unit must
not be disconnected as otherwise the error
memory will be erased.
DME control unit error diagnosis
Printed in Germany - XVI, 1987
03 - 1

03 Maintenance, Self-diagnosis 944
Display
LED off Test sequence terminated / igniti
Flashing LED Error code / test code
LED on Ignition on
03 - 2 DME control unit error diagnosis
Printed in Germany - XVI, 1987

944 Maintenance, Self-diagnosis
03
Connection in the 944 S
In the 944 S, the diagnosis socket is
attached
to a separate cable harness located above
the
DME control unit.
87/1012
Ignition off
After connecting the tester, the following dis-
play must appear.
Display:
If this is not the case, check the tester ter-
minals or check the power supply of the
diag-
nosis socket in the car by referring to the cir-
cuit diagram.
Diagnosis socket in the car
Pin 1 = terminal 15
Pin 2 = terminal 31
Pin 5 = terminal 30
Pin 9 = Hall generator
87/908
Connection in the 944 S
Printed in Germany - XVI, 1987
03 - 3

03 Maintenance, Self-diagnosis 944
Tester cable
Diagnosis
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
plug
unused
unused
unused
unused
unused
Round plug
Pin 4
Pin 1
Pin 7
Pin 6
Pin 2
Pin 5
Pin 3
34
Switch on the ignition
Display:
The ignition must not be switched off
during the entire error diagnosis
procedure.
03 - 4 Connection in the 944 S
Printed in Germany - XVI, 1987

944 Maintenance, Self-diagnosis
03
Starting error diagnosis
Condition:
Engine off
Ignition on
Display:
Press the green key until the clear symbol
appears on the function display.
Display:
Clear symbol
The diagnosis sequence for the DME control
unit then takes place.
If an error is displayed - take the note of the
error (e.g. 1211).
Display:
The error is displayed until the green key is
again pressed on the tester. The next
error code is then displayed. if applicable.
This must be repeated until 1000 appears on
the display.
If no error has occurred. the following display
appears.
Display:
Starting error diagnosis
Printed in Germany - XVI, 1987
03 - 5

03 Maintenance, Self-diagnosis 944
Press the green key until the clear symbol ap-
pears on the function display. The following
display must then appear.
Display:
This now terminates diagnosis of the DME
control unit.
If one or several errors (up to 5) has/have
been displayed, the error memory must be
reset; see chapter (Resetting the error
memory).
03 - 6 Starting error diagnosis
Printed in Germany - XVI, 1987

944 Maintenance, Self-diagnosis
03
Actuator and input signal function
checking
An actuator and input signal function check
can be carried out independently of an error
diagnosis. This function check tests
individual
components or electrical signals with
respect
to their functioning or signal paths.
Functions
ara triggered from the diagnosis tester.
During
functional checking of components, these
must audibly or tangibly operate and can
thus
be detected as being electrically in proper
working order or defective.
An error display via the tester is not possible
in
this mode, but faulty input signals or their
wiring connection ara detected by the tester.
Starting actuator and input signal
function check
Ignition off
Press the yellow key until the function symbol
(see display) appears on the function display.
Display:
Prass the green key until the clear symbol
ap-
pears on the function display.
Display:
Switch on the ignition within 8 seconds.
Actuator and input signal function checking
Printed in Germany - XVI, 1987
03 - 7

03 Maintenance, Self-diagnosis 944
Press the green key until the ctear symbol
ap-
pears on the function display. This activates
the first testing step and the injection valves
are activated.
Display:
The injection valves must all operate audibly
or tangibly.
Note:
If later attempts are made to start the engine,
starting difficulties may occur because a
slight
residual amount of fuet is injected during this
testing step.
The testing steps remain in operation until the
green key is again pressed on the tester and
the clear symbol appears.
The next testing step is initiated by again
pressing the green key.
Refer to the test code list for the sequence
of
testing steps.
03 - 8 Actuator and input signal function checking
Printed in Germany - XVI, 1987