Porsche 944 Instruction manual

Workshop Manual
DR. lNG. h. c. F. PORSCHE Aktiengesellschaft

944 Table of contents volume
1-A
Page
General
Technicaldata ........................... 0.9
Maintenance, Self-diagnosis
Fault diagnosis, DEE control unit
Connecting into the vehicle -944 S .
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 setting, checking and adjusting . . . . . . . . . . . .
Camshaft setting, checking and adjusting for Model 89 onward
Applying the TDC mark on the camshaft sprocket . . .
Camshafts and cylinder head, removing and installing .
Cylinder head, installing and tightening
Camshafts,installing
Camshaftseal, installing . . . . . . . .
Camshaftspecifications . . . . . . . . .
Chain tensioner, removing and installing
Cylinder head, disassembling and assembling
Valve springs, removing and installing with Sauertool
Table of contents
Printed in Germany- XXIV, 1991
03-
03- 3
03- 5
03- 7
03- 13
03- 15
03- 17
0:1 -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
15-112a
15-112b
15-113
15-115
15-118
1

volume 1-A Table of contents.
Machining mating face, cylinder head
\/aive spr!ngs, removing and installing, removing vaive stem seal
Valve stem seal, installing
Check:ng valve guides
.....
Replacing valve guides . . . . .
Checking vahte·seat wear limit
Valve seats, checking and machining
Checking and adjusting installation length of valve springs
Engine -Lubrication
Replacing engine oil and o:! f:ter
Pressure-reducing valve, removing
a.-.·.l :r.sto.:1ing
Engine -Cooling
Page
.
15- 120
.15-121
. 15- 122
.
15- 123
.
15- 125
.
15- 130
.15-131
. 15- 133
.17-101
. 17- 102
944
Cw~.::king cooling and heating system for leaks ....................... 19- 101
Fuel supply
Replacing fuel filter, checking injection lines for leaks and tightness
Checking delivery rate
of fuel pump
Line routing, fuel system, 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
.20-101
. 20- 102
.
20- 103
.24-101
.24-102
. 24- 103
.
24- 105
.
24- 106
.
24- 107
Exhaust
system- check tightness of flanges ......................... 26- 101
Ignition system
Equipment table ..
DEE control unit coding- 944 S, Model87 onward
Replacing spark plugs
............... .
Equipment table,
Model89 onward ........ .
DEE control unit coding -944 S
2, Model 89 onward
DME-Diagnosing I Troubleshooting
......... .
2
. 28- 101
. 28- 103
.
28- 104
.
28- 105
.
28- 107
. D-24/28-1
Table of contents
Printed in Germany- XXIV, 1991

944
General
TYPE 944 S (16-VALVE ENGINES) -1 87 MODELS ONWARD
~'i·. "
. ~ .
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
0.10 Technical Data
mm/in.
rrun/in.
cc/in.
3
kW/PS
kW/HP
rpm
Nm/kpm
rpm
Nm/1bft
kW 1/HP 1
kW 1/HPI
RON/MON
rpm
kg/lbs
M44/40
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
Printed in Germany

944
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
Timing
Two-part light alloy crankcase
Forged, 5 bearings
Plain
Cast, opt.
sinter-forged
Plain
Light
alloy, cast
Forged
Genera1
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)
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
ENGINE COOLING
ENGINE LUBRICATION
Lubrication
Oil pressure
Oil-pressure indicator
Max. oil temperature
Oil consumption
EXHAUST SYSTEM
EMISSION CONTROL
HEATING
944
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
n =
5000 rpm Approx. 4 bar, at operating
temperature
l/1000
km
Pilot lamp and pressure gage
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 of 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
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
1/100 km
1/100 km
1/100 km
v
Ah
A/W
Printed in Germany -XIII,1987
General
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
Technical Data
0.13

Genera1
BODY DESIGNS
Integral all-steel body with front air dam and rear
spoi 1 er
944
-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.
0.14 Technical
Data
4230/165.354 (4290/168.90)
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
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
Printed in Germany

944
General
WEIGHTS -to DIN 700 20 -
Curb weight Standard Sports package
Australia,
standard
Front kg/lbs 640/1411 630/1389 640/1411
(650/1433)
Rear kg/lbs 640/1411 610/1345 640/1411
(650/1433) (630/1389)
Total kg/lbs 1280/2822 1240/2734 1280/2822
(1260/2778)
Per. axle load
Front kg/lbs 730/1609 730/1609 730/1609
(720/1587)
Rear kg/lbs 900/1984 900/1984 920/2028
Per.
tota 1
weight kg/lbs 1600/3527 1600/3527 1620/3571
(1550/3417)
Per.
trailer
load
Braked trailer
kg/lbs 1200/2646 up to 16% gradient
kg/lbs 1200
for Italy
Unbraked
kg/lbs 500/1102
up to 16% gradient
trailer
kg/ 1 bs
500
for Italy
Max. car/
trailer weight kg/lbs 2760/6085
kg/lbs
2760
for Italy
Max. drawbar
load kg/lbs 50/110
kg/1 bs
50
for Italy
up to 100 km/h
Per. roof load
kg/1 bs 35/77
With genuine
Porsche roof
kg/1 bs
75/165
transport
system
Printed in Germany- XIII,1987 Technical
Data
0.15

Genera 1
CAPACITIES
Engine (measurement with dipstick
as per Driver's Manual is definitive)
Engine oil
Engine coolant
Transmission with differential
Fue 1 tank
Brake-fluid
reservoir
Windshield and headlight washing
fluid reservoir
PERFORMANCE
Proprietary HD oils to API
classification
SE or SF, see Driver's Manual
Approx. 6.0 1
Approx. 8.5 1
944
Approx. 2.0 1 hypoid oil, SAE 80
to MIL-L 2105, API classification
GL 4
Approx. 80 1, including approx.
8 1
reserve
Approx. 0.2 1
Approx. 6.0 1
Maximum speed
km/h/mph 228/142
Acceleration
from 0-100 km/h* s 7.9
(0-60
mph)* s (7. 7)
(1/4 mile
from standing
start)* s (15.4)
Kilometer
from standing start* s 27.8
CLIMBING PERFORMANCE
In % (slip limit)
1st gear
2nd gear
3rd gear
4th gear
5th gear
*DIN curb weight and half of payload
0.16 Technical
Data
62%
35.6%
21.5%
13.3%
9.4%
Printed in Germany

944 General
Technical data - Type 944 S2 - 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)
Displacement (rounded down)
Compression ratio
Max. engine power
88I195IEEC
Net power, SAE J 1349
at engine speed
Max. torque
881195 I 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)
Technical Data
Printed in Germany - XIX, 1989
mm (in.)
mm (in.)
kW (HP)
kW (HP)
rpm
Nm (kpm)
Nm I lbft
rpm
'r<YVII (HPII)
'r<YYII (HPII)
rpm
kg
Manual transmission M
44.41 (3.0 I)
104 (4.09)
88
(3.46)
2990 (182.5)
2969
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
0.17

944 Maintenance,
Self~iagnosis
DME control unit error diagnosis
OME 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 of the fuel and ignition system.
87!793
Important: Before diagnosis, the battery or
the connector of the OME 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
03- 1

03
Display
0
LED
0
•
03-2
Control unit
identification
1 = LH I DME
2 = EZK
Maintenance, Self-diagnosis
Diagnosis mode
1 = Continuous error
2 = Occasionally occurring
error
3 = Actuator I input signal
testing
4 = System adaption
5 =
No error
Error code
test
code
Function
display
944
LED off Test sequence terminated I igniti
Flashing LED
LED on
Error code I test code
Ignition on
DME control unit error diagnosis
Printed in Germany -XVI, 1987

944 Maintenance, Self-diagnosis
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.
Connection in the 944 S
Printed in
Germany- XVI, 1987
Diagnosis socket in the car
Pin 1 = terminal 15
Pin 2 = terminal 31
Pin 5 = terminal 30
Pin 9 = Hall generator
03
87/908
03-3

03
Tester cable
Diagnosis plug
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6 unused
Pin ( unused
Pin 8 unusea
Pin 9 unused
Pin 10 unused
Pin 11
Pin 12
03- 4
Maintenance, Self-diagnosis
944
Round plug
Pin 4
Pin 1
Pin 7
Pin 6
Pin 2
Pin 5
Pin 3
34
Switch on the ignition
Display:
,.,,..,,.,,.,
•U
1.1 I.J I.J 48
The ignition must not be switched off
during the entire error diagnosis procedure.
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 ap-
pears on the function display.
Display:
•
Clear symbol
The diagnosis sequence for the
DME control
unit then takes place.
Starting error diagnosis
Printed in
Germany- XVI, 1987
If an error is displayed -take the note of the
error(e.g.1211).
Display:
()
12
'
I
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:
()
03-5

03
Maintenance, SeH~iagnosis
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
944
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
are 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 are detected by the tester.
Actuator and input signal function checking
Printed
in Germany- XVI, 1987
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:
0
re
UUI.JI-1
Press the green key until the clear symbol ap-
pears on the function display.
Display:
Switch on the ignition within 8 seconds.
03-7

03
Maintenance, Self-diagnosis
944
Press the green key until the clear symbol ap-
pears on the function display. This activates
the first testing step and the injection valves
are activated.
Display:
C)
I
I
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 fuel 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.
03-8
The next testing step is initiated by again press-
ing the green key.
Refer to the test code list for the sequence of
testing steps.
Actuator and input signal function checking
Printed in
Germany- XVI, 1987