Porsche 944 Turbo 1988 Instruction manual

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

944 turbo General
Connecting rods
Sinter-forged
Connected rod bearings Slide bearings
Piston pin bearings
Press-fit brass bushings
Pistons Forged
light alloy
Balance shafts Forged
Balance
shaft bearing Slide bearings with bearing shells
Cylinders Light alloy
Cylinder head Light alloy
Valve guides Press-fit special brass
Valve arrangement 1
intake, 1 exhaust, overhead, in-line
Valve timing By overhead camshaft and hydraulic cam followers
Camshaft Shell hardcast
Camshaft bearings Camshaft runs in camshaft housing without bearing
she 11 s
Camshaft drive Toothed belt with tensioning roller
Balance shaft drive Toothed belt with tensioning roller
Valve clearance Automatic hydraulic adjustment
Timing at 1 mm lift
and zero valve
clearance
Boost
E n g i n e
Cool ng
Printed in Germany
Intake opens 1° after TDC
Intake closes 49° after BDC
Exhaust opens 43° before BDC
Exhaust closes 3° before TDC
1 ETC, charging air cooling, electronic
pressure control, wastegate
Closed water cooling system,
two electric fans
with thermoswitch,
freeze protection to -25°C
Technical Data
0.3

General
944 turbo
E n g n e L u b r c a t i o n
System
Oil cooling
Oil filter
Oil pressure at 5000 rpm
Oil pressure display
Pressure
circulation with sickle-type pump
Oil cooler in air flow, thermostatically
controlled
Screwed on
Approx. 4 bar positive pressure at operating
temperature
Warning lamp at above 5 bar
Oil consumption,ltr./1000 km Up to 1.5
E x h a u s t S y s t e m Standard: Double-pipe
up to primary muffler,
primary
and final mufflers
E m s s i o n
C o n t r o 1
He a t n g
F u e S y s t e m
Fuel preparation
Fuel supply
(M298 and USA: as standard, cat. conv.
instead of primary
muffler, cat. conv. in
bypass
line)
(M298 and USA: 3-way cat. conv., controlled
air-fuel mixture)
Warm water heater with heat exchange and
blower
DME (Digital Motor Electronics)
1 electric delivery pump
Octane requirement RON/MON 96/86, 95/85 unleaded (96/86 unleaded)
E 1 e c t r i c a 1 S y s t e m
Interference suppression ECE-R 10 and 72/245/EWG or VDE 0879
Battery voltage V
Battery capacity Ah
Battery capacity Ah
(M-eq.)
Alternator output A/W
Ignition
Firing sequence
0.4 Technical
Data
12
50 ( 63)
63
115/1610
via
DME
1 - 3 - 4 - 2
Printed in Germany

944 turbo
Genera 1
Ignition timing control and
knock control
B o d y De s i g n
Electronically controlled map
2-door integral steel body, with
front and rear spoilers, as coupe with
optional
removal hardtop roof, with
integral foglights in polyurethane
front air dam
D i m e n s o n s (at DIN curb weight)
Length
Width
Height
mm/in.
mm/in.
mm/in.
4230/166.535 (4290/168.90)
1735/68.31
1275/50.20
Wheelbase (design
position) mm/in. 2400/94.49
Front
track
mm/in.
Rear
track mm/in.
Ground clearance (at max.
tot. weight) mm/in.
Bed clearance (at mm/in.
max. tot. weight)
Overhang angle, front
rear
We i g h t
Curb weight
(per
DIN 70020)
kg/lbs
Curb weight axle load kg/lbs
front
rear kg/lbs
Max. total weight kg/lbs
Max.
front axle load kg/lbs
Max. rear axle load kg/lbs
Max. roof load, incl.roof
baggage carrier kg/lbs
Max. trailer load,
without brakes*
Printed in
Germany
kg/lbs
- 7 J x
16 rim-1477/58.2
- 8 J x
16 rim-1451/57.1
120/4.72
53/2.09
1280/2822 (1315/2899)
640/1411 (660/1455)
640/1411 (655/1444)
1600/3527
730/1609
920/2028
35/77 or 75/165 with
original
Porsche roof transport system
500/1103
Technical Data 0.5

General
Max. trailer load
with brakes*
Max. car+trailer weight
Max. drawbar load
*Gradients
up to 16%
kg/lbs
kg/lbs
kg/lbs
F i 1 1 C a p a c i t i e s
Engine oil (measurement with dipstick
per owner's manual is definitive)
Engine oil volume
Engine coolant
Transmission with differential
Fuel tank
Brake fluid reservoir
Washing fluid reservoir and headlight
cleaning system
P e r f o r m a n c e
Top speed
Acceleration
from 0-100 km/h*
(0-60 mph)*
(1/4 mile)*
Kilometer from standing start*
H i 1 1 c 1 i m b i n g
In% (slip limit)
*DIN curb weight + 1/2 of payload
0.6
Technical Data
1200/2646
2800/6173
50/110
944 turbo
84 for Italy up to
100 km/h
Brand name heavy-duty
oil per API classifi-
cation SE or SF; see
Owner's
Manual
Approx. 6.5 ltr. with
filter
Approx 7.8 ltr.
Approx. 2.0 ltr. hypoid
gear lub.
SAE 80 per
mL-L 2105,
API
classification GL4
Approx. 80 ltr., incl.
approx. 8 ltr. reserve
Approx. 0.2
ltr.
Approx. 6.0 ltr.
km/h/mph 245/152
sec. 6.3
sec. (6.1)
sec. (14.4)
sec. 26.0
Manual
transmission
1st
gear 61.5%
2nd gear
49.0%
3rd gear 29.5%
4th gear 19.5%
5th gear
13.5%
Printed in Germany

944 turbo Genera1
DESIGNATION OF CYLINDERS
Printed in Germany
Technical Data
0.7

•
944 turbo General
944 turbo -special model "S" (M 758)
In model year 1988, there will be a limited number of exclusively equipped, tuned versions of the 944
turbo available, with a modified sports chassis suitable for the high driving performance.
The most significant modifications
or distinguishing features (exact description in information
brochure
WKD 495010)
87/955
1. Engine: 250 HP/184
kW, catalyst version for FRG , others in accordance with respective
national regulations.
2. Clutch: Clutch plate with
two -stage torsional spring damper, fr iction
lining bonded as well as riveted
to the support plate.
944 turbo -special model "S" (M 758)
Printed in Germany- 111,1988
0.8a

General
3. Transmission:
4. Chassis:
5. Paintwork:
6. Interior:
0.8b
944 turbo
Transmission ratio as standard but some parts adapted to the higher performance.
Only outwardly recognizable by the additional identification code
AOR.
-Milled forged wheels (larger cutouts)
front 7 J x 16
ET 65 mm with 225/ 50 VA 16
rear 9 J x 16
ET 60 mm with 245/ 45 VA 16
-Brake system: front-axle brakes similar to 928 S4 with asbestos-free brake pads.
-Wheel suspension: at front and rear axle bearings with harder rubber compounds
(shore hardness)
-Springs/shock absorbers: Harder spring rates (also with height adjustment at the front)
Koni twin tube pressurized shock absorbers (adjustable rebound).
Special color silver-rose metallic
multicolor burgundy
0.12
944 turbo -special model "S" (M 758)
Printed in Germany -Ill,1988

944turbo
7 EQuipment (incomplete listing). Listed equipment valid for all countries.
Special model ''S" turbo equipment M-
No . in the turbo series
Sportschassis
ABS
Limited-slip differential 40 % locking
ratio
(com
pi3,red with the series model special
option M 220 has reinforced plates and
pressure ring; differential bolts
molybdenum-coated and ground)
Comfort seat lett
Comfort seat right
8 Technical data·
Engine type M 44.52
Turbo special model ''S"
Performance 250 HP/184kW
at 6000 rpm
Torque
350 Nm
at 4000 rpm
Compression ratio 8.0:1
Fuel 95
RON
Unleaded
Leaded•
Curb
weight
1 350 kg
.Accelera
tion :
0 - 100 krnlh
(0- 62 mph) 5.7 s
0- 60 mph
5.5 s
Vmax 260 km/h
162 mph
• For vehicl es without catal'ytlc converter only
944 turbo • special model "S'' (M 758)
Printed in Germany -IV,1991
M030
M593
(M 220)
M43 7
M438
Enginetype M 44.51
turbo (series)
220
HP /1 62 kW
at 5800 rpm
330
Nm
at 3500 rpm
8.0:1
95 RON
Unleaded
Leaded*
1 350
kg
6.3 s
6. 1 s
245 km/h
152mph
General
O. Bc

944 turbo
LIFTING THE VEHICLE
l. Wi th Lifting
P 1 a t f o r m
L ift vehicle only at illus -
trated jacking points.
When driving vehicle onto lift-
ing platform, make sure of
sufficient space between pl at-
form and vehicle.
F r o n t
On inside side member
R e a r
On si de reinforcement
Printed in
Germany
General
Lifting the Vehicle 0.9

Genera1
2. W
i t h S h o p T r o 1 1 e y J a c k
Apply jack only underneath
jacking points
on sides of
vehicle. Never jack on
engine oil pan or transmission,
as this can cause serious
damage.
I m p o r t a n t
Avoid damage by inserting block
of wood between vehicle and jack.
0.10
Lifting the Vehicle
944 turbo
Printed in Germany