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  9. Porsche 944 Turbo 1988 Instruction manual

Porsche 944 Turbo 1988 Instruction manual

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Workshop Manual
DR.
lNG.
h.
c.
F.
PORSCHE
Aktiengesellschaft
~ORKSHOP
~lANUAL
944
turbo
This
Workshop
Manual
describes
all
of the important operations
whose
proper
completion
requires
special
instructions.
This
manual
is
essential
for
shop foremen
and
mechanics, as the information contained
is
essential
for
the maintenance
of
vehicles in
safe
operating
condition.
The
basic
rules
of
safety
in vehicle
repair
naturally
also
apply throughout.
Only
maintenance procedures
differing
from
those
for
the vehicle type
944
are described in the
Workshop
Manual
944
turbo. All
other
information can
be
found
in the
Workshop
Manuals
944
and
924.
The
information in
this
manual
is
organized in
repair
groups according to
work
position
numbering.
The
two-digit
numbers
of
the
repair
groups
correspond to the
first
digits
of
the
work
position
numbers.
A
repair
group
table
and
an
index
of
key
words
assist
in
locating
information.
Exploded views are
numbered
in order of disassembly,
and
where
necessary
are
supplemented
by
instructions
on
assembly or
installation
and
the use of
special
tools.
Descriptions of design
and
function can
be
found in
the
service
training
course
reference
material.
The
contents
of
this
Workshop
Manual
will
from
time to time
be
supplemented
with Technical
and
Quality Information
Bulletins.
These information
Bulletins
are
compiled in
the
Technical
Handbook.
Printed
in
Germany
GENERAL
ENGINE
TRANSMISSION
CHASSIS
BODY
HEATING,
VENTILATION,
AIR
CONDITIONING
ELECTRICAL
COMPONENTS
Technical Data, general
Page
0.1
REPAIR
GROUPS
Engine I Crankcase
Engine I Crankcase, Pistons
Engine I Cylinder
Head,
Valve
Drive
Engine I Lubrication
Engine I Cooling
Fuel
Supply
Turbocharger
L-Jetronic
Fuel
Injection
Exhaust
System
Starter,
Power
Supply, Cruise Control
Ignition
System
Clutch I Operation
Manual
Transmission I Operation,
Housing
Manual
Transmission I Gears, Shafts
Differential
I Transaxle System
Front
Wheel
Suspension
Rear
Wheel
Suspension, Axle, Shaft
Wheels,
Tires,
Alignment
Anti-Blocking
System
Brakes I Mechanics
Brakes I Hydraulics
Steering
10
13
15
17
19
20
21
24
26
27
28
30
34
35
39
40
42
44
45
46
47
48
Body
-Front Section
50
Body
-Center Section
51
Body
-
Rear
Section
53
Engine
Hood,
Trunk
Lid
55
Doors
57
Hardtop
61
Bumpers
63
Windows,
Window
Controls
64
Exterior
Equipment
66
Interior
Equipment
68
Seats
72
Seat Upholstery
74
Heating
80
Ventilation
85
Air Conditioner
87
Instruments, Consumption
Gauge,
Alarm
System
90
Radio
91
Washer
and
Wiper
System
92
Exterior
Lights,
Lamps,
Switches
94
Interior
Lights
96
Wiring
97
944turbo Table of contents
General
Technical Data
Cylinder designations . . . . .
....
944 turbo-special model "S"
(M
758)
Lifting vehicle . . . . . . . .
Motor, Kurbelgehause
Tolerances and wear limits . . . .
..
Engine tightening torques . . . . .
Modified tightening torques for engine
Removing and installing engine
Engine I Crankshaft, Pistons
Power steering pump belt tightness -checking and adjustment . . . . . . . . .
Alternator and ale generator Poly-rib belt tightness -checking and adjustment
Balance shafts -tool for checking and adjusting toothed belt tightness
Balance shafts -checking and adjusting toothed belt tightness
Piston and cylinder bore -checking . . . . . . . .
Balance shaft drive disassembly and assembly . .
Installing bearing bridges of compensating shafts
Refacing the flywheel . . . . . . . . . . . . . .
Engine I Cylinder Head, Valve Drive
Camshafts -checking and adjusting toothed belt tightness
Valve spring installation
length-
checking and adjustment
Shaft seal on camshaft bearing cover -installation
Engine I Lubrication
Page
0.2
0.7
0.8a
0.9
10-
01
10-05
10-
010
10
- 1
13
- 1
13-2
13-
3
13-4
13-8
13-
9
13 -
14
13-
17
15 - 1
15-4
15-
5
Engine oil and oil filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1
Engine I Cooling
Cooling and heating system -checking for leaks I mixing table for coolant . . . . . . .
19
- 1
Fuel Supply
Fuel filter -replacing I Fuel and injection lines -checking
Fuel pump delivery rate -checking
Fuel lines and fuel system . . . . . . . . . . . . . . . . .
Table of contents
Printed
in
Germany-
IV, 1991
20-
1
20-2
20-3
1
Table
of
contents
Turbocharger
Charge pressure measuring tool . . . . . . . . . .
Turbocharger system -disassembly and assembly
Turbocharger -removal and installation . . . . . .
Exhaust turbocharger end and radial play -measuring
Charging pressure -measuring . . . . . . . . . . . . .
Turbocharger coolant pump -removal and installation
Parts of the turbo charger cooling system -removal and installation
Charging air cooler -removal and installation
L-Jetronic Fuel Injection
intake air guide and crankcase vent hoses -checking
Testing and adjusting values
Fuel pressure -checking . . . . . . . . . . . . . . . .
Idle speed adjustment . . . . . . . . . . . . . . . . .
Idle speed adjustment (USA and cat. conv. vehicles)
944turbo
Page
.
21
- 1
.
21
-2
.
21
-6
.
21
-9
.
21
-
10
.
21
-
11
.
21
-12a
.21-13
.
24-
1
.
24-2
.
24-3
.
24-5
.
24-9
CO level -correcting on air flow sensor (USA and catalytic converter vehicles) .
24-
13
.
24-
14
Idle actuator -removal and installation
Exhaust System
Exhaust system flanges -checking for tightness . . . . . . . . .
.............
26-
1
Starter, Power Supply, Cruise Control
Battery -checking . . . . . . . . . .
Generator-
removal and installation
Ignition System
Equipment survey chart
Accident hazards with electronic ignition systems
Important vehicle instructions . . . .
......
.
Component installation position . . . . . . . .
..
DME and K!CP control
unit-
removal and installation
Temperature sensor (NTC
II)-
removal and installation
Knock sensor -removal and installation . . . . . . . .
Spark plugs -replacement . . . . . . . . . . . . . . . .
DME and K!CP troubleshooting- testing equipment and tools
2
.
27-
1
.
27-3
.
28-
1
.
28-4
.
28-6
.
28-7
.
28-8
.
28-9
.
28-
10
.
28-
11
.
28-
12
Table
of
contents
Printed
in
Germany
-IV,
1991
944turbo
General Data -Clutch, Transmission
5 - speed manual transmission 016 RIS for 944 turbo . . . . . . . .
5 - speed manual transmission 083 D for 944 S (as from model 87)
5 - speed manual transmission 016R for 944 turbo S
Technical data (Type 016 RIS)
......
.
Tightening torques for manual transmission . . . . .
Technical data, clutch
................
.
Tightening torques for clutch, central tube, transmission mountings
and transmission linkage
Clutch Operation
Clutch play, checking .
Clutch driven plate, checking wear
Clutch, removing and installing
...
Manual Transmission I Operation, Housing
Oil level, checking . . . . . . . . . .
Cooler coil, removing and installing . . .
Gearbox, removing and installing . . . .
Gearbox, disassembling and assembling
Reartransmission cover, disassembling and assembling
End plate, disassembling and assembling
......
.
Transmission housing, disassemblig and assembling
Oil pump, disassembling and assembling . . .
Manual Transmission/Gears, Shafts
Input shaft, disassembling and assembling .
Output shaft, disassembling and assembling
Differential I Transaxle System
Differential -removal and installation . .
Differential -disassembly and assembly
Differential bevel gears -adjustment . .
Limited slip differential- disassembly and assembly (lock ratio: 40%)
Drive pinion and ring gear -adjustment . . . . . . . . . . . . . . . .
Table
of
contents
Printed
in
Germany -IV,
1991
Table
of
contents
Page
30-01
30-02
30-03
30-04
30-05
30-07
30-08
30-
1
30-2
30-3
34-
1
34-3
34-5
34-
11
34-23
34-27
34-35
34-45
35-
1
35-7
39-
1
39-5
39-
11
39-
12a
39-
13
3
Table
of
contents
Front
Wheel
Suspension
Technical Data
Tightening torque for front axle
Front axle modifications for 944 turbo special model "S"
Front wheel bearings -adjustment
Checking caps
of
ball joints on control arms and tie rods
Height -adjustable strut. disassembly and assembly
Tolerance groups of coil spring
Koni vibration damper
....
Koni vibration shock absorber with outside rebound travel adjustment
Rear Wheel Suspension, Axle Shaft
Technical Data .
Tightening torque for rear axle
Koni vibration damper I Koni damper -adjusting
Wheels, Tires,
Alignment
Wheels and tires
Sample measuring chart up to end of MY '89
Sample measuring chart as of MY '90
Adjustment values for wheel alignment
Vehiclemeasurement
Brakes I Mechanical Parts
Technical Data .
Tightening Torques
Brake pads -checking
Brake pads -removing and installing
Stop light switch adjustment -checking
Parking brake -adjustment
Front wheel brake as from model 87, disassembly and assembly
Rear wheel brake, disassembly and assembly
Checking lateral runout of brake disk
Checking brake-disk thickness
Brakes I Hydraulics, Regulator,
Booster
Tightening torque . . . . .
Brake system information
4
944turbo
Page
.
40-
01
.
40-02
.
40-04
.
40-
1
.
40-2
.
40-3
.
40-6
.
40-8
.
40-9
.42 -
01
.
42-
02
.
42-
1
.
44-
01
.
44-03
.
44-
1
.
44-2
.
44-4
.
46-
01
.
46-05
.
46-
1
.
46-2
.
46-5
.
46-6
.
46-7
.
46-9
.
46-
10
.
46-
11
.
47-
01
.
47-02
Table
of
contents
Printed
in
Germany -IV, 1991
944
turbo
Table
of
contents
Steering
Technical Data
..............................
.
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and installation work on the rack and pinion power steering
Hood
Page
48-01
48-02
48-
1
Front hood cable -replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 - 1
Bumpers
Lower trim panel -removal and installation
Spoiler and
bumper-
removal and installation
....
Spoiler and bumper -removal and installation (USA)
Exterior Equipment
Rocker panel covers -removing and installing
Rear apron spoiler -removing and installing
Finishes available, 1986 models onward
Turbo emblem -applying . . . . .
Washer and Wiper System
63-
1
63-3
63-9
66-
1
66-2
66-3
66-4
Headlight cleaner spray jets -aiming
.........................
92-
1
Exterior Lights, Lamps, Switches
Headlights -aiming . . . . . . . . . . . .
Fog lights -aiming . . . . . . . . . . . .
Concealed headlight linkage -lubricating
Table
of
contents
Printed
in
Germany-
IV,
1991
94-
1
94-2
94-3
5
944
turbo Genera1
Printed in
Germany
0.1
General
944
turbo
TECHNICAL
DATA
N o t
e:
Values
for
USA
in brackets
P o w e r P 1 a n t
Company
engine code
No.
of
cylinders
Bore
Stroke
Actual displacement
Compression
ratio
Max.
power
to
80/1269/EC
Net
power,
SAE
J
1349
At
engine speed
Max.
torque to
80/1269/EC
Net
power,
SAE
J
1349
At
engine speed
Max.
liter
output
Net
power,
SAE
J
1349
Fuel
octane grade
Max.
engine speed
Engine weight (dry)
E n g i n e De s i g n
Type
Crankcase
Crankshaft
Crankshaft bearings
0.2
Technical Data
M44/51
mm/in.
mm/in.
cm
3
/in.
3
4
100/3.94
78.9/3.11
2479/151
8.0
: 1
kW/HP
kW/HP
rpm
Nm/kpm
162/220
162/217
5800
330/33.6
Nm/ft. 1bs. 330/243.4
3500
rpm
kW
1/HP
1
kW
1/HP
1
RON/MON
65.3/88.7
65.3/87.5
96/86(96/86
lead-free)
rpm
kg/lbs
6500
182/401
Water-cooled,
axial,
four-cylinder,
four-stroke,
in-
line
internal
combustion engine
with
toothed-belt-driven
overhead
camshaft
and
two
balance
shafts
Light
alloy,
two-piece
Forged, with
five
bearings
Slide
bearings
Printed
in
Germany