Porsche 944 Instruction manual

Workshop Manual
0 R. IN G. h. c. F. P OR SCHE Aktiengeaellschaft

SUPPLEMENT TO REPAIR MANUAL 944
(V)
Instruction Sheet on Extending 944 Repair Manual in
Four Volumes
Survey of Repair Manual Volumes :
Volume = Engine
Volume II = Transmission
Volume
Ill = Running Gear, Heater, Air Conditioner, Body
Volume
IV
= Electrical System
Please insert sheets in various volumes of the repair manual as specified below:
/: . . ..
1. File pages 40-01 to 48- 17, 50-01 to 66-8 and 87- 1 to 87- 22 from old
Volume I in new Volume
Ill (Runn!ng Gear, Heater, Air Conditioner, Body).
2. File pages 90- 1 to 97-69 from old Volume I in new Volume IV (Electrical
System).
., ' '

WORKSHOP MANUAL 944
This Workshop Manual describes all
of the important operations for which special instructions are
required
to assure proper completion. This manual is essential for shop foremen and mechanics, who need
this information to keep the vehicles in safe operating condition. The basic safety rules, of course, also
apply
to repairs on vehicles without exception.
Only those repair jobs deviating
from those of vehicle type 924 are described in the 944 Workshop Manual.
Refer
to the 924 Workshop Manual for all other information.
The information is grouped according to repair numbers which are identical to the first two digits of the
warranty
job codes.
The repair group index, list
of contents and the register table are quick guides to find information in the
manual.
The layout drawings in this manual are numbered in the order of disassembling and, if necessary, also have
information
on assembly or installation and application of special tools.
Descriptions
of design and function can be found in the service training course reference material.
This Workshop Manual will be kept up to date with Technical Information Bulletins, which will be made
part of the manual from time to time. We recommend that these bulletins be filed in the standard type
folder provided for this purpose.
Printed in Germany

Ust of Repair Groups 944
General Technical Data Page 0.1
Repair Groups
Group
Maintenance, Self-diagnosis 03
Engine
Engine, Crankcase 10
Engine, Crankshaft, Pistons
13
Engine, Cylinder Head and Valve Drive 15
Engine,
lubrication
17
~
Engine, Cooling 19
Fuel Supply 20
Air
Aow Controlled Fuel Injection 24
Exhaust System/Emission Controls 26
Starter, Power Supply, Cruise Control 27
Ignition System 28
DME Diagnosis
Transmission Clutch, Controls 30
Torque Converter 32
Manual Transmission, Controls, Case
34
Manual Transmission, Gears, Shafts 35
Automatic Transmission, Controls, Case
37
Automatic Transmission, Gears, Valve Body
3e
Differential, Transaxle System 39
Chassis Front Wheel Suspension 40
Rear Wheel Suspension, Axle Shaft 42
Wheels, Tires, Alignment
44
Antiblock System
45
Brakes, Mechanical 46
Brakes, Hydraulics, Regulator, Booster 47
Steering
48
Body Body-Front Section 50
Body-Center Section
51
Body-Rear Section 53
Lids 55
Doors
57
Hardtop
61
Bumpers 63
Glasses, Window Control 64
Exterior Equipment 66
Interior Equipment 68
Seats 72
Seat Covers 74
Airbag Diagnosis
Heating, Heater 80
Ventilation, Ventilation 85
Air Condition Air Conditioner 87
Electrics
Instruments, Fuel Gauge, Alarm System 90
Radio, Telephone
91
Windshield Wipers and Washer 92
Exterior Lights, Lamps, Switches 94
Interior Lights
96
Wiring 97
Printed in Germany- XXI, 1989

944 Table of contents .volume I
Page
General
Technical data
................ 0.2
Engine, Crankcase
Tolerances and wear limits .
Tightening torques for engine . . . . . . . . . . . . .
Engine, removing and installing (manual transmission)
Hydraulic engine mounts, removing and installing . .
Checking hydraulic engine mounts
...
Installing new hydraulic engine mounts
Engine, Crankcase, Pistons
Checking and adjusting tension of Poly-rib belt for
.
10- 01
. 10- 03
. 10 - 1
.
10- 7
.10-10
. .10-11
alternator and compressor . . . . . . . . . . . . . . 13 - 1
Checking adjustment of compensating shaft . . . . . 13 - 2
Checking and adjusting tension of the power pump belt .
13 -2a
Calibrating Special Tool 9201 . . .
_. . . . . . . . . . . . . . . 13 -2b
Checking and adjusting toothed belt
tension- compensating shafts . 13 - 3
Checking and adjusting toothed belt
tension- compensating shafts (idler pulley with slot) 13 -6
Installing toothed belt- compensating shaft . . . . . . . . . . . . . . . . . . 13 - 11
Application -assembly stand VW 540 and engine holders 9127 and 9197 . . 13 - 13
Identification of engine number on crankcase . . . . . . .
Identification code, crankcase engine number ...... .
Crankcase and crankshaft, disassembling and assembling
Installing cover for the centrifugal compartment . . . . . .
Checking crankshaft bearing play
............ .
.13-14
. 13- 14b
.13-15
. 13- 20 b
. . 13 - 21
Identification code -upper and lower crankcase sections and compensating shaft cover 13 - 22
Sealing crankcase -upper and lower sections . 13 - 23
Installing upper and lower crankcase sections .
Aligning upper and lower crankcase sections .
Installing crankshaft seal (flywheel side)
....
Flywheel and grooved ball bearing, removing and installing .
Refacing the flywheel . . . . . . . . . . . . . .
Replacing setscrew (reference mark sensor)
..
Setting crankshaft to TDC, cylinder 1 ..... .
Crankshaft dimensions -standard and machined
Checking pistons and cylinder bore . . . . . . .
Pistons, disassembling and assembling con rods
Installing pistons with con rods . .
Pistons, from Model 89 onwards . . . . . . . . . .
Installing pistons with con rods . . . . . . . . . . . . .
Holding the flywheel for assembly work (with engine installed)
Table of contents
Printed in Germany- XXVI, 1993
. 13- 24
.
13- 24 a
. 13- 25
. 13- 26
. 13 -26a
.
13- 27
.
13- 28
. 13- 29
. 13- 31
. 13- 32
.
13- 34 a
.
13- 34 b
.
13- 35
.
13- 37
1

volume I
Table of contents
Compensating shaft drive, disassembling and assembling ..
Installing bearing bridges for compensating shafts ..... .
Compensating shaft drive, disassembling and assembling
..
Compensating shaft drive sprockets, installing (Model 84 onwards)
Machining cylinder bores
..................... .
Engine, Cylinder head, Valve drive
Camshaft belt tension, checking and adjusting
Installing camshaft belt and adjusting timing
Cylinder head, removing and installing . . .
Tightening specifications for cylinder head .
Valve drive, disassembling and assembling
Machining mating face, cylinder head
....
Replacing valve guides . . . . . . . . . . .
Valve drive, disassembling and assembling
Machining valve seats, checking valve guides
Valve drive, disassembling and assembling (camshaft housing) .
Camshaft drive, disassembling and assembling
.....
Camshaft specifications . . . . . . . . . . . . . . . . .
Adjusting camshaft belt with mechanical belt tensioner
Engine -Lubrication
Replacing engine oil and oil filter
Parts of the lubrication system, removing
and installing
Oil pump, disassembling and assembling
........ .
Sleeve for oil-pressure relief valve, removing and installing
Tightening specifications for oil-pump fastening screws .
Checking oil pressure . . . . . . . . . . . . . . . . . . .
Oil check valve
in cylinder head, removing and installing
Cleaning the engine oil system . . . . . . . . . .
Cleaning the main oil channel
in the crankcase .
Pressure-reducing valve, removing and installing .
Engine -Cooling
Replacing coolant and bleeding cooling system
Checking thermostat, checking system for leaks
Parts
of the cooling system, removing and installing
Parts
of the cooling system, removing and installing, Mod. 87 onwards
Radiator, removing and installing . . . . . . . . . . . . . . . . . . . .
Temperature switch, removing and installing- checking temperature switch
Cleaning cooling system after oil and water have been mixed . . . . . . . .
944
Page
13- 39
13- 44 f
13- 44 h
13- 50
13- 53
15 - 1
15- 5
15- 7
15-10a
15 - 11
15-16a
15-16b
15- 17
15- 19
15- 20
15- 25
15- 28
15- 29
17 - 1
17- 3
17- 10
17- 12
17- 13
17- 14
17- 16
17- 17
17- 18
17- 19
19 -
19 -3
19 -4
19 -
6a
19 -7
19- 9
19 -
11
2
Table of contents
Printed in Germany -XXVI, 1993

944 Table of contents volume 1
Page
Temperature switch, removing and installing- checking temperature switch
....... 19- 9
Cleaning cooling system after oil and water have been mixed . . . . . . . . . . . . . . 19 -
11
Fuel supply
Replacing fuel filter, checking injection lines for leaks and tightness . . . . . . . . . . . 20 - 1
Checking delivery rate offuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 2
Fuel pump, removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 3
Fuel tank, removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 4
Line routing, fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 7
Active-carbon tankfor pollution-free fuel-tank bleeding (layout) . . . . . . . . . . . . . . 20 - 8
Fuel expansion tank, removing and installing . . . . . 20 - 9
Checking fuel expansion tank . . . . . . . . . . . 20 - 10
Fuel-level sensor, removing and installing
.. 20- 11
L-Jetronic fuel injection
Replacing air-filtercartridge . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 1
Testing and adjusting specifications . . . . . . . . . . . . . . . . . . . . . . 24-3
Testing and adjusting specifications for Model85/2 onward and 924 S. . . . 24- 4
Checking fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 5
Adjusting idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 7
Adjusting idle speed -USA vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 9
Correcting
CO setting at air-flow sensor -USA vehicles . . . . . . . . . . . . . . . . . 24 -12
Injection valves, removing and installing . . . . . . . . .
Checking intake system
for leaks- troubleshooting ....... .
Adjusting idle speed for Model 85/2 onward and 924 S . . . . . .
Adjusting idle speed -USA and vehicles with catalytic convertor
from Model 85/2 onward and 924 S . . . . . . . . . . . . . .
. .
24- 13
. . 24- 15
.. 24- 17
.. 24-20
Testing and adjusting specifications, Model89 onward . . . . . . . . 24- 25
Adjusting idle speed and CO
for Model 89 onward . . . . . . . . . . 24 -26
Equipment table for Model 89 onward . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 -27
Exhaust system
Checking exhaust flanges for tightness . . . . . . . . . . . . . . . .
Replacing exhaust pipe
or primary muffler/catalytic convertor .
Starter, Power supply, Tempostat
.. 26- 1
. .
26-2
Automatic cruise control (Tempostat} . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 1
Tempostat control unit, removing and installing ...................... 27- 5
Tempostat operating switch (steering-column switch}, removing and installing ...... 27- 6
Actuator, removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 7
Tempostat bowden cable, removing and installing
..................... 27- 8
Table of contents
Printed in Germany- XXV, 1992 3

volume I Table of contents
Tempostat bowden cable, removing and installing ................... .
Clutch switch, removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting -Tempostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking multiple-pin connector of TerJ1)0stat control unit . . . . . . . . . . . . . .
Checking multiple-pin connectorof Tempostat actuator . . . . . . . . .
Automatic cruise control (Tempostat) from Model85/2 onward
.....
Tempostat control unit, removing and installing steering-column switch
from Model 85/2 onward . . . . . . . . . . . . . . . . . . . . . .
Actuator, removing and installing, from Model85/2 onward ...
Clutch switch, removing and installing, from Model85/2 onward.
Troubleshooting -Tempostat -from Model 85/2 onward . . . . .
Connector assignment, Tempostat control unit
......... .
Checking the multiple-pin connectors of the Tempostat control unit
from Model 85/2 onward . . . . . .
Alternator, removing and installing
Ignition system
Equipment table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accident hazards in electronic ignition systems . . . . . . . . . . . . . . . . . .
Ignition-distributor cap, removing and installing . . . . . . . . . . . . . . . . . .
Replacing spark plugs .................................. .
DEE ................................... .
Speed and reference-mark sensors, removing and installing . . . . .
Troubleshooting -DEE . . . . . . . . . . . . . . . . . . . . . . . .
Functional test -Lambda probe . . . . . . . . . . . . . . . . . . . .
Test -DEE control unit, test -Lambda probe . . . . . . . . . . . . .
DEE control unit, removing and installing, from Model85/2 onward .
DEE control unit
coding- 924 S from Model86 onward .......... .
DEE control unit
coding- 944, from Model85/2 onward .......... .
DEE control unit coding -944, 2.7 I . . . . . . . . . . . . . . . . . . . . . . . . . .
DEE control unit
coding- 944 turbo, from Mod. 85 onward ............ .
DEE control unit
coding- 924 S, from Model88 onward .............. .
DEE control unit coding- 944, from Model88 onward ............... .
Equipment table engine type M 44.09 to 12 . . . . . . . . . . . . . . . . . . . . . . .
Page
27-8
27-9
27- 10
27- 11
27- 12
27- 13
27- 17
27- 19
27-20
27-21
27-22
27-23
27-25
944
28- 1
28-3
28-5
28-7
28-9
28- 14
28- 16
28-37
28-38
28-39
28-41
28-42
28-42 a
28-43
28-45
28-46
28-47
4 Table
of contents
Printed in Germany- XXV, 1992

944
General
Printed in Germany 0.1

General
944
TECHNICAL DATA
(adjusting values and wear limits appear in pertinent repair groups)
Note: USA values in brackets.
E n g i n e M
44101 manuals - M 44103 automatics
Number
of cylinders
Bore
Stroke
Displacement (actual)
Displacement (fiscal)
Compression ratio
Max. engine power
to 8011269IEC
Net power, SAE J 1349
At engine speed
Max. torque to 8011269IEC
Net torque, SAE J 1349
At engine speed
Max. specific power output
Net power to SAE J 1349
Fuel grade
Engine
speed limit
Engine weight (dry)
Engine Design
Type
Crankcase
Crankshaft
Crankshaft bearings
0.2 Technical Data
mmlin.
mmlin.
cm31in.3
cm3
kWIHP
kWIHP
rpm
Nmlkpm
Nmlft.lbs.
rpm
kW I I HP I
kW I I HP I
rpm
kgllbs.
( M
44102 manuals - M 44104 automatics)
M 44105 manuals - M
44106 automatics
( M
44107 manuals - M 44108 automatics)
4
10013.94
78.913.11
24791151.26
2449
10.6: 1 (9.5: 1)
1201163 (1101150)
1161156 (1051143)
5800 (5500)
205120.9 (192119.6)
1991151.3 (1861137)
3000
48166 (44.4160.5)
48163 (42.4157.
7)
96 RON
(
91 RON -unleaded fuel only)
6500
1661366
Water-cooled, axial, 4 cylinder, 4 stroke,
in-line, internal combustion engine
with
toothed belt driven overhead camshaft
and
two compensating shafts
Two-piece, light alloy
Forged
steel
Five
V, 1985 Printed in Germany

944
Connecting rods
Conrad bearings
Piston
pin bearings
Pistons
Piston pins
Piston rings
Cylinders
Cylinder head
Valve
seat inserts (shrink-fit)
Valve guides
Valve arrangement
Exhaust valves
Valve springs
Valve
timing
Camshaft
Camshaft bearings
Camshaft drive
Valve clearance
Timing with 1 mm lift
and zero valve clearance
Engine Cooling
Engine Lubrication
System
Oil pressure at 5,000 rpm
Oil pressure display
Max.
oil temperature
Oil consumption
Printed in Germany -V, 1985
ltr./1000 km
General
Forged steel/cast since February, 1984
Plain
Press-fit brass bushings
Cast light
alloy
Floating installation, secured with circlips
2 compression rings and 1
oil scraper ring
Light alloy
Light alloy
Intake: FCr 330
Exhaust: CoMo 75
Press-fit special brass
1 intake, 1 exhaust, overhead, in-line
With armored seat
2 coil springs per valve
By overhead camshaft and
hydraulic cam
followers
Shell hard cast
Camshaft runs in camshaft
case without
bearing shells
Toothed belt with tensioning roller
Automatic hydraulic adjustment
Intake opens
1° after TDC
Intake closes 49° after BDC
Exhaust opens
43° before BDC
Exhaust closes
3° before TDC
Closed cooling system, electric fan with
thermo switch, antifreeze for - 25° C
Pressure
circulation with sickle-type pump,
oil filter and oil/water heat exchanger in
oil full flow and water bypass integrated in
crankcase
Approx. 4 bar at operating temperature
Indicator lamp and pressure gage
140° c
Up to 1.5
Technical Data 0.3

General
Exhaust System
Heating
Fuel System
Fuel supply
Fuel grade
Fuel consumption
to
80/1268/EC in
Also official specifications
for France and Great Britain
-
ECE A 70-
Electrical System
Interference suppression
Battery voltage
Battery capacity
Battery capacity (M-eq.)
Alternator output
Ignition
Spark plug connectors
Firing order
Ignition timing
control
Body Type
0.4 Technical Data
RON/MON
ltr./100 km
v
Ah
Ah
A/W
Manifold, single pipe up to primary
muffler, primary and final mufflers
(manifold, single pipe up
to 3-way
catalytic converter, final
muffler)
944
Warm water heater
with heat exchanger
and blower
DME (Digital
Motor Electronics)
1 electric delivery
pump
96/86 (91 /82 unleaded)
at 90 km/h
at 120 km/h
city cycle
Manuals
6.4
8.0
11.5
Automatics
6.5
8.1
11.3
ECE- R 10 and 72/245/EC or VDE 0879
12
50 (63)
63
90/1260, 115/1610 since 1985/2 models
Via DME
Without booster gap
1-3-4-2
Via DME
Coupe
with integral steel body, 2 doors,
bolted
front fenders, rear window and
spoiler tailgate, concealed headlights;
removable hardtop
roof as optional
extra equipment
Printed in Germany

944
Dimensions (at DIN curb weight)
Length
Length
with US bumpers
as optional equipment
Width
Height
Wheelbase (designed)
Front track
Rear track
Ground clearance
(at max. weight)
Bed clearance
Front overhang angle
(limited
by spoiler)
Rear overhang angle
(I imited by exhaust)
Weights (to DIN 70020)
Curb weight
Curb weight axle force
Front
Rear
Max. total weight
Max.
front axle load
Max. rear axle load
Payload
Max.
roof load, incl.
roof carrier
Max. trailer load
without brakes*
with brakes*
Max. car/trailer weight
Max. drawbar load
* Gradients up
to 16%
Printed in Germany - V, 1985
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
mm/in.
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
kg/lbs
General
4200/165.354 (4290/168.898)
4290/168.898
1735/68.307
1275/50.197
2400/94.488
7Jx15/7Jx16 1477/58.150
6J X 15/6J X 16 1452/57.165
5 1/2J X 15 1440/56.693
7J X 15/7J X 16
6J X 15/6J X 16
5 1/2J X 15
125/4.921
1451 /57.126
1426/56.142
1414/55.669
120/4.72 since 1985/2 models
53/2.087
1180/2601 (1260/2779)
since 1985/2 modeis:
1210/2668 (1260/2779)
580/1279 (620/1367)
600/1323 (640/1411)
since 1985/2 models:
630/1389 (640/1411)
1500/3307 (1550/3418)
since 1985/2 models:
1530/3373 (1550/3417)
720/1588
880/1940, 900/1984 since 1985/2
models
320/706 (290/639)
35/77 or 75/165
with roof
transporting system
500/1103
1200/2646
2700/5952 since 1985/2 models:
2730/6019 (2750/6063)
50/110
Technical
Data
0.5

General
Filling Capacities
Engine oil (volume depends on
measurement with oil dipstick -
see Owner's Manual)
Engine oil volume
Engine coolant volume
Transmission with differential
volume
Fuel tank volume
Brake fluid volume
Washing fluid volume for
windshield and headlights
Performance
Top speed
Acceleration from
0 to 100 km/h*
(0 to 60 mph)*
(1/4 mile)*
Kilometer from
standing start*
Hill Climbing
In% (slip limit)
* DIN curb weight+ 1/2 of payload
0.6 Technical Data
km/h I mph
sec
sec
sec
sec
1st gear
2nd gear
3rd gear
4th gear
5th gear
944
brand name HD oil to API Cl.
SE or SF -see Owner's Manual
approx. 6.0 ltr.
approx. 7.8 ltr.
approx. 2.0 ltr. of hypoid gear
lube SAE 80 to Ml L-L 2105,
API Classification GL 4
approx. 66 ltr., of which 9 ltr.
in reserve since 1985/2 models:
approx. 80 ltr., of which 8 ltr.
in reserve
approx. 0.2 ltr.
approx. 6.0 ltr.
220/137 (210/130)
Manuals Automatics
8.4 (9.3) 9.6
(8.3) (9.8)
(16.2) (17.2)
28.8(30.1) 30.5(31.4)
Manuals Automatics
63 55 (38.5)
36 (34)
25 (19)
23 (21)
15(11)
15 (14)
10 (8)
Printed in Germany

944
Technical Data
Type 944 -Model
88
(Adjusting values and wear limits appear in pertinent repair groups)
Note: USA values in brackets.
Engine
Engine type M 44/09 (manuals)
M 44/10 (automatics)
Bore mm/in. 100 (3.94)
Stroke mm/in. 78,9 (3.11)
Displacement (actual)
cm
3/in3. 2479 (151)
Displacement (fiscal)
cm
3 2449
Compression ratio
10.2: 1
Max. engine power
to 80/1269/EC 't<YV/PS 118 (160)
Net Power, SAE J 1349)
't<YV/HP 118 (158)
at engine speed 1/min 5900
max. torque
to 80/1269/EC
Nm/kpm
210 (21.4)
(Net Torque, SAE J 1349)
Nm/lb ft
210 (155)
at engine speed 1/min 4500
max. liter output
DIN 70020
't<YY/1 (PS/1)
47.6 (64.5)
(SAE J 1349)
t<YV/1 (HP/1)
47.6 (63.7)
Speed governed
by
fuel shutoff at 1/min 6640
Engine weight (dry) kg (lbs) 169 (373)
Technical Data
Printed in Germany- XVII, 1988
General
0.6a

944
General
DESIGNATION OF CYLINDERS
Printed in Germany Technical Data 0.7

944
TOLERANCES AND WEAR LIMITS
Cooling System
Thermostat
Radiator cap
High pressure valve
Low pressure valve
Oil Circuit
Oil consumption
Oil pressure at 80 °C (176
°F)
Opening temperature
Opening pressure
Opening pressure
ltr ./1000 km
(600 mi./US qt)
oil temperature and at 5000 rpm Pressure
Oil dipstick
Upper mark
Lower mark
V a I v e
Timing
Camshaft bore
Camshaft
Camshaft
Cam follower bore in camshaft
housing
Cam follower
Camshaft
Printed in Germany -I, 1982
Capacity
Capacity
Inside dia.
Diameter
End play
Inside dia.
Diameter
Runout
Engine/Crankcase
New Part
81 -85 °C
(178
-185 °F)
+0.15
1_ 0_
10 bar
+ 2.1
(14,5 _ 1_
5 psi)
0.1 bar
(1.5 psi)
approx. 4 bar
(58 psi)
5.5
ltr. (5.8 US qt)
4.2 ltr. (4.4 us qt)
60.5 ~~·
03
-0.04
60•5 + 0.055
0.10-0.18
38 +0.027
+0.007
38
-0.018
-0.034
0.02
Wear Limit
approx. 1.5
Tolerances and
Wear Limits
10
10-01

10
Engine/Crankcase
944
TOLERANCES AND WEAR LIMITS
New Part Wear Limit
Cylinder
Head and Valves
Mating surface Distortion max.
0.08
Valve seat:
Intake Width 1.7
Exhaust Width 2.0
Intake Seat angle 45°
Exhaust Seat angle
45°
Outer correction angle 30°
Inner correction angle 60°
Valve guides:
Intake and
exhaust Inside dia. 9 +
0.015
Valve stem:
Intake Diameter
8.97-0.012
Exhaust Diameter 8.95-0.012
Valve guide/valve stem Clearance
Intake 0.8
Exhaust 0.8
Compression Pressure
10 bar (145 psi)
or more
10-02
Tolerances and Wear Limits Printed
in Germany

944
TOLERANCES AND WEAR LIMITS
Pistons and Connecting Rods
Cylinder/piston
Piston rings
Piston rings
Connecting rod bushing
Piston pin
Connecting rod bushing/
piston pin
Crankshaft
and
Crankshaft
Engine
Connecting rod bearing journal
Connecting rod bearing/
crankshaft
Crankshaft bearing journal
Crankshaft bearing/crankshaft
Cylinder bore
Bore
for balance shaft
bearing shells in crankcase
and balance shaft cover
Bore
for bushing in bearing
housing
Balance shaft
Printed in Germany -I, 1982
Clearance
Side clearance
End gap
Diameter
Diameter
Radial play
B I o c k
Runout
Diameter
Radial play
End play
Diameter
Radial play
End play
Out-of-round
Diameter
Diameter
Diameter
Engine/Crankcase
10
New Part
Wear Limit
0.008 -0.032 approx.
0.080
Mahle
KS
Groove 1 0.05 -0.05
0.082 0.082
Groove 2 0.04 -0.05 -
0.072 0.082
Groove 3
0.023-
0.023-
0.137
Groove 1 =
0.20- 0.45
Groove 2 = 0.20 -0.45
Groove 3 =
0.38- 1.40
24 + 0.018
+ 0.028
24-0.004
0.137
0.018-0.032
0.04-0.06
51.971 -51.990
0.034 -0.092
0.100 -0.400
69.971
-69.990
0.020 -0.098
0.110-0.312
0.010
35.000-35.019
34.000- 34.019
30.975 -30.991
max.
0.08
0.40
0.020
Tolerances and Wear Limits
10- 02a

944 Engine, Crankcase
Tightening torques for engine
Location
Crankshaft/
Crankcase
Bolts -upper and lower
crankcase sections (studs)
Rotary body on
compensating shaft
MODEL
82-85
Cover for compensating
shaft housing
to upper
crankcase section
Hexagon head screw
Stud
MODEL
85 ONWARD
Compensating shafts with
separate bearing bridges:
Bearing bridges (nuts) of
compensating shafts
to
upper crankcase section
Cover for
compensating-shaft
housing to upper
crankcase section
Hexagon head screw
MODEL
87 ONWARD
Hexagon head screw
(bearing bridge) for
compensating-shaft
housing to upper
crankcase section
Bearing housing left and
right to upper crankcase
section
Tightening
torques for engine
Printed in Germany - XIX, 1989
Thread
M
12 X 1.5
M 10
M8
M6
M6
M6
M8
M8
M8
M6
M 8 X 55
M 8 X 58
M8
10
Tightening torque Nm (ftlb)
30(22) 1st stage
60° torque angle 2nd stage
20(15) 1st stage
50(37) 2nd stage
20(15)
10(7.5)
10(7.5) secured with Loctite
270
8(6)
15(11) 1st stage
20(15) 2nd stage
15(11) 1st stage
30(22) 2nd stage
15(11) 1st stage
33(24) 2nd stage
10(7.5)
15(11) 1st stage
20(15) 2nd stage
15(11) 1st stage
33(24) 2nd stage
20(15)
10- 03