Workshop Manuel Volume IA - Engine, 16 valves DR. ING. h. c. F. PORSCHE Aktiengesellschaft As webpage by http://www.9ss1.dk/porsche944
944 General WEIGHTS - to DIN 700 20 - Curb weight Front Rear Total Per. axle load Front Rear Per. total weight Per. trailer load Br
15 Engine/Cylinder Head, Valve Drive 944 Drawing Plunger to press out the valve guide 15 - 126 Replacing valve guides Printed in Germany - XV
944 Engine/Cylinder Head, Valve Drive 15 Drawing Plunger to press out the valve guide Plunger to press in the valve guide
15 Engine, Cylinder Head, Valve Drive 944 Replacing the valve guides 1. Clean and inspect the cylinder head. It is inexpedient to replace the val
944 Engine, Cylinder Head, Valve Drive 15 7. Ream the valve guides with Special Tool 3120 Proceed as follows: The valve guides must always be
15 Engine, Cylinder Head, Valve Drive 944 Checking the valve seat wear limit 1. The valve seats in the 4-valve cylinder heads can be remachined.
944 Engine, Cylinder Head, Valve Drive 15 Checking and remachining valve seats Visuel inspection 1. Check that the valve seat sits securely in t
15 Engine, Cylinder Head, Valve Drive 944 11864 4. Valve seat turning tool, e.g. Hunger VDSNL 1/45 I.K. 85/151 5. After milling, grind in
944 Engine, Cylinder Head and Valve Drive 15 Checking and adjusting installation length of valve springs Valve springs, Model 87 onward Engine t
15 Engine, Cylinder Head and Valve Drive 944 5. Using a depth gauge, measure from the top surface of the valve-spring seat, vertically downwards
944 Engine/Lubrication 17 CHANGING ENGINE OIL AND ENGINE OIL FILTER (16-VALVE ENGINES) Preconditioned: Engine at operating temperature. 1. Unsc
General 944 CAPACITIES Engine (measurement with dipstick as per Driver's Manual is definitive) Engine oil Engine coolant Transmission wi
17 Engine, Lubrication 944 Removing and installing the pressure reducing valve Engine type M44.40 80/17 1 - 2 - 3 - 4 - Se screw Pressure r
944 Engine/Cooling 19 MIXING TABLE FOR COOLANT (Average values) Antifreeze effective to Antifreeze Agent Water Antifreeze Agent Water - 25°
20 944 20 - 100 Blank Page
944 Fuel Supply 20 REPLACING FUEL FILTER (16-VALVE ENGINES) 1. Disconnect fuel lines, always counter when slackening threaded connectors. Catch
20 Fuel Supply 944 CHECKING DELIVERY RATE OF FUEL PUMP Precondition: Fuel filter and power supply OK. 1. Unbolt fuel return hose from pressur
944 Fuel Supply 20 FUEL SYSTEM LINE ROUTING (16-VALVE ENGINES) '87 MODELS ONWARD ENGINE TYPE M 44.40 1 Fuel pump 2 Fuel filter 3 Fu
24 944 24 - 100 Blank Page
944 L-Jetronic Fuel Injection 24 REPLACING AIR FILTER ELEMENT (16-VALVE ENGINES) 1. Use a screwdriver to remove mounting screws and remove up
24 Air Flow Controlled Fuelinjection 944 Testing and adjusting specifications Model 87 onward Engine type M 44.40/41 (3.0 I) Test Specifikation
944 L-Jetronic Fuel Injection 24 CHECKING FUEL PRESSURE TOOLS No. Description Special Tool Remarks Pressure gage
944 General Technical data - Type 944 52 - Model 89 (Values for adjustment and wear are to be found in the respective repair groups) Notes: USA
24 L-Jetronic Fuel Injection 944 CHECKING FUEL PRESSURE 1. Slacken and remove capped nut on test connection of fuel distribution line. Note:
944 Air Flow Controlled Fuel Injection 24 Checking idle speed and CO- with catalytic converter Model 87 onward Engine type M 44.40/41 (3.0 l) No
24 Air Flow Controlled Fuel Injection 944 Checking idle speed and CO without catalytic converter Model 87 onward Engine type M 44.40/41 (3.0 l)
944 Air Flow Controlled Fuel Injection 24 Replacing air filter insert Model 89 onward Engine type M 44.41 (3.0 l) 1. Replace front end plate. R
26 944 26 - 100 Blank Page
944 Exhaust System 26 CHECKING TIGHTNESS OF EXHAUST SYSTEM FLANGES (16-VALVE ENGINES) 1. Check tightness of exhaust flanges and check entire ex
28 944 28 - 100 Blank Page
944 Ignition System 28 EQUIPMENT TABlE Ignition Coil Type/Model Version Remarks 944 S 944 602 115 00 Bosch No. 0 221 118 322 Without series
28 Ignition System 944 DME control unit Type/Model Version Remarks 944 S Mod. '87 944.618.124.00 944.618.124.01 M 44.40 Spare part 944
944 Egnition System 28 DME CONTROL UNIT CODING, 944 S, '87 MODELS ONWARD 1 - 944.612.525.01 2 - 928.607.421.00 3 - 928.607
944 Maintenance, Self-diagnosis 03 DME control unit error diagnosis DME control unit error diagnosis 944 S as from 88 model As from model year
28 Ignition System 944 REPLACING SPARK PLUGS, 944 S 1. Pull off spark plug caps. 2. Unscrew spark plugs with commercially available wrench.
944 Ignition System 28 Equipment tabte 89 models onward Engine type M 44.41 (3.0 l) Ignition Coll Type/Model Version Remarks 944 S 2 944 602
28 Ignition System 944 DME Control unit Type/Model Version Remarks 944 S 2 Mod. ´89/90 944 S 2 Mod. ´91 944.618.124.02 944.618.124.05 H
944 Ignition System, Diagnosis 28 Coding - DEE control unit 944 S 2, Model 89 onwards 86/746 B 86/733 1 - 928.607.421.00 2 - 928.
DME-Diagnosis / Troubleshooting Dr. Ing. h.c. F. Porsche Aktiengesellschaft
944 S/944 S2 Fuel System - Electronic Control 24/28 Test Point Description Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24/28 Fuel System - Electronic Control 944 S/944 S2 Precautions Greater demands of modern engines on the ignition systems and a desire for freed
944 S/944 S2 Fuel System - Electronic Control 24/28 Important Vehicle Information Always turn off the ignition or disconnect the battery for res
24/28 Fuel System - Electronic Control 944 S/944 S2 Equipnient Required for DME Tests: - Diagnostics tester 9288 (9268) with connecting leads -
944 S/944 S2 Fuel System - Electronic Control 24/28 Diagnosable DME Control Unit Self-diagnosis with a fault memory, with which it is possible t
03 Maintenance, Self-diagnosis 944 Display LED off Test sequence terminated / igniti Flashing LED Error code
24/28 Fuel System - Electronic Control 944 S/944 S2 This DME 944 S Diagnosing/Troubleshooting Plan is based on the contents of the fault memory.
944 S/944 S2 Fuel System - Electronic Control 24/28 This page are missing or blank in the book ! D
24/28 Fuel System - Electronic Control 944 S/944 S2 This page are missing or blank in the book ! D
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 1a Power supply for DME
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 2: Idle speed contact ( )
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 3 Full load contact ( ) G
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 4 Engine tamp. sensor (NT
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 5a: Air flow sensor (V/ )
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Turn off ignition and reconnect p
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Connect two-pin DME test lead (Bo
944 Maintenance, Self-diagnosis 03 Connection in the 944 S In the 944 S, the diagnosis socket is attached to a separate cable harness located ab
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 8: Oxygen sensor (V) (sen
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks If no display: Disconnect plug on
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 12: Control unit (knock c
944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 15: DME relay (fuel pump)
24/28 Fuel System - Electronic Control 944 S/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Tank venting valve is not activat
944 S/944 S2 Fuel System - Electronic Control 24/28 Test Point 18: Fuel Pressure Fuel collection pipe has a test connection at left front. Unscre
24/28 Fuel System - Electronic Control 944 S/944 S2 Test Point 19: Intake System leaks Check all connections after the air flow sensor for leaks.
944 S/944 S2 Fuel System - Electronic Control 24/28 Plug Connections Are all plugs connected correctly, not loose and not corroded? Disconnect pl
24/28 Fuel System - Electronic Control 944 S/944 S2 Test Point 21: Speed/Reference Mark Sender This test can only be performed with an oscillo- s
944 S/944 S2 Fuel System - Electronic Control 24/28 No display: Disconnect plug of speed sender on plug plate in the engine compartment. Connect
03 Maintenance, Self-diagnosis 944 Tester cable Diagnosis Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 p
24/28 Fuel System - Electronic Control 944 S/944 S2 d) Ignition timing test Ignition timing is checked with the engine at operating temperature.
944 S/944 S2 Fuel System - Electronic Control 24/28 f) Ignition final stage control signal test Connect DME control unit plug. Connect oscillosc
24/28 Fuel System - Electronic Control 944 S/944 S2 Test Point 23: Fuel Injectors - Injection Timing (V/ ) Element activation menu: If a pulse i
944 S/944 S2 Fuel System - Electronic Control 24/28 Test Point 24: Alternator, Regulator Misfiring of the engine could be caused by the peak volt
24/28 Fuel System - Electronic Control 944 S/944 S2 Adjusting value: 0.5 - 1.5 % CO at 840 +- 40 rpm and ignition timing of 10° +- 3° before TDC.
944 S/944 S2 Fuel System - Electronic Control 24/28 Coding of Control Unit - 944 S Pertinent curve families are integrated in the DME control un
24/28 Fuel System - Electronic Control 944 S/944 S2 Coding af Control Unit - 944 S 2 Country Curve Family Switch 2 Pins Version Switch 3 Pins A
944 S/944 S2 Fuel System - Electronic Control 24/28 Check-Engine Lamp (Malfunction Indicator Light M.I.L) As from model year '91, Califomi
944 Maintenance, Self-diagnosis 03 Starting error diagnosis Condition: Engine off Ignition on Display: Press the green key until the clear s
03 Maintenance, Self-diagnosis 944 Press the green key until the clear symbol ap- pears on the function display. The following display must then
944 Maintenance, Self-diagnosis 03 Actuator and input signal function checking An actuator and input signal function check can be carried out ind
944 Table of contents volume I-A General Technical data Maintenance, Self-diagnosis Fault diagnosis, DEE control unit Connecting into the veh
03 Maintenance, Self-diagnosis 944 Press the green key until the ctear symbol ap- pears on the function display. This activates the first testing
944 Maintenance, Self-diagnosis 03 As from the "idle contact" testing step, specific controls must additionally be operated on the car f
03 Maintenance, Self-diagnosis 944 Initiale the air-conditioning control terminal 41 testing step. Display: Switch on the air-conditioning sys
944 Maintenance, Self-diagnosis 03 Press the green key until the clear symbol appears. Display: End of the actuator and input signal function
03 944 03 - 12 Blank page
944 Maintenance, Self-diagnosis 03 Test code list Test code Components 1311 1321 1322 1332 1333 1334 1335 Injection valv
03 944 03 - 14 Blank page
944 Maintenance, Self-diagnosis 03 System adaption System adaption can be carried out with the tester. That is to say. the electronic idle contro
03 944 03 - 16 Blank Page
944 Maintenance, Self-diagnosis 03 Knock detection Before knock detection is carried out, error diagnosis must first of all be performed to guara
volume I-A Table of contents 944 Machining mating face, cylinder head Vaive springs, removing and installing, removing valve stem seal Valve st
03 Maintenance, Self-diagnosis 944 The tester is now active. If knocking occurs, this will be indicated by the tester, e.g.: Display: After th
944 Maintenance, Self-diagnosis 03 Troubleshooting Diagnosis using the tester can refer only to the error path, but not to a defective component.
03 Maintenance, Self-diagnosis 944 Error code 1112 This error code indicates an error in the area of the idle contact. Possible error: Ground f
944 Maintenance, Self-diagnosis 03 Error code 1113 This error code draws attention to an error in the area of the full load contact. Possible er
03 Maintenance, Self-diagnosis 944 Display 0°C = 15 - 30°C = 80°C = 100°C = 4400 - 1400 - 250 - 160 - 6800 3600 390 21 If the values are
944 Maintenance, Self-diagnosis 03 Testing the power supply of the air-flow sensor: Ignition on On the extracted plug of the air-flow sensor, a
03 Maintenance, Self-diagnosis 944 Error code 1123 When this error code appears, the Lambda control has detected too rich ar too lean a mixture.
944 Maintenance, Self-diagnosis 03 Measure the voltage between pin 1 and engine ground. 35 The voltage is within the r
03 Maintenance, Self-diagnosis 944 Error code 1131 This error code draws attention to an error in the area of knock sensor 1. 87/911 Er
944 Maintenance, Self-diagnosis 03 Error code 1133 Error code 1133 draws attention to an error in the area of the knock control in the DME con- t
944 General TYPE 944 S (16-VALVE ENGINES) - '87 MODELS ONWARD Printed in Germany - XIII, 1987 Technical Data 0.9
03 Maintenance, Self-diagnosis 944 Testing the Hall generator's power supply Disconnect the Hall generator's connector. Ignition on
944 Maintenance, Self-diagnosis 03 Error code - List Error code 1500 1000 1111 1112 1113 1114 1121 1123 11
03 944 03 - 30 Blank page
944 Maintenance, Self-diagnosis 03 Resetting the error memory Once the DME control unit error diagnosis has been completed. this is completed by
03 Self-diagnosis 944 Operating conditions for start of diagnosis Systems Ignition on Engine standing still Engine running 944 S / 944 S
944 Self-diagnosis 03 Operating instructions for System Tester 9288 Operating instructions for System Tester 9288 Printed in German
03 Self-diagnosis 944 1. General information 1.1 Application The Systemtester 9288 (BOSCH KTS 301) is a microprocessor-con- trolled self-diagnosis
944 Self-diagnosis 03 1.3 Battery charger run off mains voltage (Figure 3) - Accessory - Item 1 Charger with connecting cable, 1.5 m long Item 2
03 Self-diagnosis 944 After pressing the key > , a selection menu is displayed: Menu 1 = Fault memory 2 = Drive links 3 = Input signals >
944 Self-diagnosis 03 Key 1 selects the next actuator (e. g. idle actuator). Following instruction: Repair fault accord- ing to repair instructions
General 944 TECHNICAL DATA (Adjustment specifications and wear data are stated in the appropriate Repair Groups) Note: US values are stated in
03 Self-diagnosis 944 Proceed with key 1 Prerequisite: Eng. at oper. temp. with all consumers and ignition off. Proceed with key > System adap
944 Self-diagnosis 03 The knock counter registers 10,000 ignitions before the display with the actual number of combustion "knocks" appea
10 944 10 - 0100 Blank page
944 Engine, Crankcase 10 Tightening torques for engine (16-valve) Location Thread Tightening torque Nm (ftlb) Crankshaft/ crankcase Upper and
10 Engine, Crankcase 944 Tolerances and wear limits Engine M 44.40/41 Cooling system Coolant thermostat Cooling system cap Pressure valve V
944 Engine, Crankcase 10 Tolerances and wear limits Engine M 44.40/41 Cylinder head with valves Mating surface Valve seat width Exhaust Seati
10 Engine, Crankcase 944 Tolerances and wear limits Engine M 44.40/41 Con rod bush Piston pin Con rod bush/piston pin Crankshaft and cyl
944 Engine/Crankcase 10 REMOVING AND INSTALlING ENGINE (16-VALVE ENGINES) TOOLS No. Description Special Tool Remarks Engine
10 Engine/Crankcase 944 REMOVING AND INSTALLING ENGINE (MANUAL TRANSMISSION) Remove by lowering engine from car. The bell housing remains attach
944 Engine/Crankcase 10 7. Disconnect breather hose for toothed helt cover at rear of lower section of air filter. Unbolt filter assembly as a un
944 General Crankcase Crankshaft Crankshaft bearings Connecting rods Connecting rod-bearings Pistons Balance shafts Balance-shaft bearings
10 Engine/Crankcase 944 12. Remove engine underguard. 13. Open coolant drain plug and catch coolant in a suitable container. Disconnect altern
944 Engine/Crankcase 10 19. Detach Poly-rib belt tensioner from air-conditioning compressor and remove belt. Remove compresor from bracket and pl
10 Engine/Crankcase 944 25. Disconnect leads from starting motor and remove starting motor. 26. Remove clutch actuating cylinder from bell housin
944 Engine/Crankcase 10 34. Pull engine forward, push rubber sleeve out of firewall toward engine compartment and carefully pull wire
10 Engine/Crankcase 944 7. Refill system with coolant and bleed system. 8. Fill reservoir with ATF and bleed steering system. 9. Run engine
944 Engine/Crankshaft, Pistons 13 PISTONS. '87 MODELS ONWARD (16-VALVE ENGINES) Engine M 44.40 worldwide Compression: 10.9 :
13 Engine/Crankcase, Pistons 944 Checking pistons and cylinder bores Motortype M 44.40 Repair Stage Piston Ø (mm) Fa. Kolbenschmidt Cylinder b
944 Engine/Crankshaft, Pistons 13 Pistons from Model 89 onwards Engine M 44. 41 (3.0 I) worldwide Compression ratio: 10.9 : 1 Nominal Ø 104.00
13 944 This page are missing or blank in the book ! 13 - 104 Blank
944 Engine/Crankshaft, Pistons 13 Assemble cover of centrifugal oil compartment in upper crankcase section. Notes on installation Model 89 onwar
General 944 ENGINE COOLING ENGINE LUBRICATION Lubrication Oil pressure Oil-pressure indicator Max. oil temperature Oil consumption E
15 944 15 - 100 Blank page
944 Engine/Cylinder 15 This page are missing or blank in the book ! Printed in Germany Unknow pag
15 Engine/Cylinder 944 This page are missing or blank in the book ! 15 - 102 Unknow page Printed
944 Engine/Cylinder Head, Valves 15 Adjusting with dial gages 2. Align dial gage with improvised extension (205 mm long) on piston crown {cylin
15 Engine/Cylinder Head, Valves 944 6. Turn the engine in the direction of rotation until piston reaches its upper limit af travel. 7. Set dia
944 Engine/Cylinder Head and Valve Drive 15 Checking or adjusting camshaft setting for Model 89 onward Engine type M 44.41 (3.0 l) Note The
15 Engine/Cylinder Head, Valve Drive 944 Applying the TDC mark on the camshaft sprocket Engine type M 44.40 / 41 (3.0 l) Note Camshaft sproc
944 Engine/Cylinder Head, Valves 15 TOOLS - REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD, DEGREES-OF-TURN METHOD OF TORQUING (16-VALVE ENG
15 Engine/Cylinder Head, Valves 944 REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD Removing: 1. Align lifting-platform pads beneath jackin
944 Engine/Cylinder Head, Valves 15 8. Disconnect vacuum hose, fuel-line-pressure damper and fuel-distribution pipe from intake manifold, discon
944 General FUEL SYSTEM Injection Fuel delivery Fuel octane rating Fuel consumption to 80/1268/EC or ECE R 15/04 Constant 90 km/h Const
15 Engine/Cylinder Head, Valves 944 15. Relieve tension of camshaft toothed belt by slackening nut A and bolt B, pressing toothed-belt tensioner
944 Engine/Cylinder Head and Valve Drive 15 20. Remove bearing cover from cylinders 1 + 3. Hold both camshafts in the bearings with Special Tool
15 Engine/Cylinder Head and Valve Drive 944 Installing and tightening the cylinder head Model 87 onward Engine type M 44.40 Note The cylinder
944 Engine/Cylinder Head, Valve Drive 15 Installing camshafts 1. Turn engine in direction of rotation by ap- prox. 45° before ignition TDC (cyli
15 Engine/Cylinder Head, Valve Drive 944 11639 6. Apply Loctite 574 to the sealing surfaces of the front and rear double bearing bridges. 7.
944 Engine/Cylinder Head, Valve Drive 15 Installing Camshaft Seal 1. Place sealing washers in bearings and install bearing bridge with Loctite
15 Engine/Cylinder Head and Valve Drive 944 Camshaft specifications Worldwide, Model 87 onward Worldwide, Model 89 onward Engine type Cams
944 Engine/Cylinder Head, Valves 15 REMOVING AND INSTALLING CHAIN TENSIONER Removing Remove hollow screws from cylinder head and chain tensioner
15 944 This page are missing or blank in the book ! 15 - 114 Blank page
944 Engine/Cylinder Head, Valves 15 TOOLS - CYLINDER HEAD (16-VALVE ENGINES) No. Description Special Tool Remarks 1 2 3 Puller
General 944 BODY DESIGNS Integral all-steel body with front air dam and rear spoiler - as coupe, opt.: removable hardtop panel, also
15 Engine/Cylinder Head, Valves 944 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD (16-VALVE ENGINES) 15 - 116 Disassembling and Assem
944 Engine/Cylinder Head, Valves 15 Note When: No. Description Qty. Removing Installing 1 2 3 4 5 6 7 8 9
15 Engine/Cylinder Head, Valve Drive 944 Cylinder Head (16 Valves) Removing and installing valve springs Tools 87/927 No. Description Special
944 Engine/Cylinder Head, Valve Drive 15 Notes on assembly Remove and install the valve springs with the special tool supplied by Sauer 1. Moun
15 Engine/Cylinder Head, Valves 944 Remachining cylinder-head maling face Checking cylinder head for distortion Use a feeler gage an a straight
944 Engine/Cylinder Head, Valves 15 NOTES ON ASSEMBLY REMOVING AND INSTALLING VALVE SPRINGS Cylinder head removed Remove and install valve spr
15 Engine/Cylinder Head, Valves 944 INSTALLING VALVE STEM SEAL Note: Always remember to place an 1 mm thick washer on the cylinder-head face bef
944 Engine/Cylinder Head, Valve Drive 15 Checking the valve guides 1. Clean the valve guides thoroughly. 2. Use a new valve to measure the tilt
15 944 15 - 124 Blank page
944 Engine/Cylinder Head, Valve Drive 15 Replacing valve guides Tools 87/918 No. Description Special tool Remarks 1 2 3 4 Ejection
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