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