porsche 944
WORKSHOP MANUAL
PORSCHE 944 WORKSHOP MANUAL (1982-1991) - English Workshop Manual, Wiring Diagram and Spare Parts Catalogue to vehicles Porsche 944 (1982-1991). CONTENTS: WORKSHOP MANUAL (2041 pages) 01-ENGINE REPAIR GROUPS Engine Table of Contents General Technical Data Engine Crankcase Tolerances & Wear Limits Tightening Torques Engine Removing/Installing (man) Hydraulic Engine Mounts Engine, Crankcase,Pistons Balance Shaft Adjustment Belt Tension Adjustment Procedures Toothed Belt Tension Compensating Shaft Toothed Belt- Roller with Slot Belt Tension Tool Calibration Polyrib Belt Adjustment Power Steering Belt Adjustment Installing Toothed Belt Comp Shaft Identification of Engine Number Sealing Crankcase Upper/Lower Sections Identification Codes U/L Crankcase Sections Crankshaft assembly/dissassembly Checking Crankshaft Bearing Clearance Installing U/L Crankcase Sections Installing Crankshaft Oil Seal Flywheel Removing and Installing Replacing Stud Reference Mark Sensor Setting Crankshaft to TDC Cyl 1 Resurfacing the Flywheel Checking Piston & Cylinder Bores Pistons Dissassembly/Conn Rods Installing Pistons With Connecting Rods Pistons Model '89 Forward Dissassembly/Assembly Compensating Shaft Drive Dissambly/assembly Balance Shaft Drive Installing Bearing Bridges of Compensating Shafts Installing Drive Gears of Balance Shafts Machining Cylinder Bores Engine Support Engine Cylinder Head, Valve Drive Camshaft Belt Tension Check/Adjust Install Camshaft Belt & Adjust Timing Cylinder Head Removing and Installing Tightening Specifications Valve Drive Assembly/Dissasembly Machining mating Face Cylinder Head Replacing Valve Guides Dissasembly/Assembly Valve Drive (camshaft housing) Camshaft Drive Assembly/Dissassembly Adjusting Camshaft Belt with Belt Tensioner Engine Lubrication Replacing Engine Oil & Filter Parts of Lubrication System Remove/Install Dissembly/Assembly of Oil Pump Sleeve for Oil Pressurre Relief Valve Tightening Specifications for Oil Pump Fastening Screws Checking Oil Pressure Oil Check Valve Removing/Installation Cleaning Engine Oil System Cleaning Main Oil Duct Removing & Installing Pressure Reducing Valve Engine Cooling Checking Thermostat Parts of Cooling System removing & Installing Radiator Installation/Removal Temerature Switch Removal/Installation Cleaning Cooling System after Oil Contamination Replacing Coolant & Bleeding System Fuel Supply Replacing Fuel Filter Checking Injection Lines Checking Fuel Pump Delivery Rate Fuel Pump Removal/Installation Fuel Tank Removal/Installation Fuel system Line Routing Active Carbon Tank (layout) Fuel Expansion Tank Removal/Installation Checking Fuel Expansion Tank Fuel Level Sensor Removal/Installation Fuel Level Sender Removal/Installation L-Jetronic Fuel Injection Repacing Air Filter Cartidge Checking Airguide & Crankcase Vent Hoses Testing & Adjusting Specifications Checking Fuel Pressure Idle Adjustment Correcting CO Setting on Airflow Sensor Fuel Injectors Removal/Installation Air Flow Sensor Removal/Installation Adjusting Idle Speed (late) Testing & Adjusting Specifications Adjusting Idle Speed & CO Equipment table '89 Onward Exhaust System Checking Exhaust Flanges for Tightness Repacing Exhaust Pipe/Catalytic covnverter/muffler Starter, Power Supply, Cruise Control Cruise Control -- Tempostat Tempostat Removal/Installation Tempostat Operating Switch Removal/Installation Actuator Removal/Installation Tempostat Bowden Cable Removal/Installation Clutch Switch Removal/Installation Troubleshooting Cruise Control Checking mult-pin connector Control Unit Tempostat (late) Tempostat (late) Removal/Installation Actuator (late) Removal/Installation Clutch Switch (late) Removal/Installation Troubleshooting Cruise Control (late) Connector Assignment Tempostat Checking Multi-Pin Plugs (late) Alternator Removal/Installation Ignition System Equipment Table Accident Hazards Distributor Cap Removal/Installation Spark Plugs Removal/Installation DEE Speed /Reference Mark Sensors Removal/Installation Troubleshooting DEE Testing Lambda Sensor DEE Removal/Installation DME Control Unit Codings Equipment Table 01A-ENGINE 16 VALVE ENGINE 16 VALVE Table of Contents General Technical Data Maintenance/Self Diagnosis DME Control Unit Connection into Vehicle 944 S Starting Fault Diagnosis Actuator Input Signal Functional Test List of Test Codes System Adaptation Knock Detection Troubleshooting List of Fault Codes Clearing Fault Memory Operating Conditions fo Start of Diagnosis Operating Instructions For System Tester Engine Crankcase Tightening Torques Tolerance & Wear Limits Engine Removal/Installion Engine, Crankshaft, Drive, Pistons Pistons '87 onward Checking Pistons & Cylinder Bores 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 '89 Onward Applying TDC Mark on Camshaft Sprocket Camshaft/Cylinder Head Removal/Installation Cylinder Head Installation/Tightening Installing Camshafts Camshaft Seal Installation Camshaft Specifications Chain Tensioner Removal/Installation Cylinder Head Assembly/Disassembly Cylinder Head Valve Springs Removal/Installation Remachining Cylinder Head Mating Face Valve Springs Removal/Installation Valve Stem Seal Removing Valve Stem Seal Installation Valve Guides Checking Valve Guides Replacing Valve Seats Checking/Machining Valve Springs Checking & Adjusting Length Engine Lubrication Changing Engine Oil & Filter Pressure Reducing Valve Removal/Installation Engine Cooling Mixing Table for Coolant Fuel Supply Replacing Fuel Filter Fuel & Injection Lines Checking Checking Fuel Delivery Rate Line Routing Fuel System L-Jetronic Air Filter Cartridge Replacement Intake Air Guide Hoses Checking Testing & Adjusting Specifications Checking Fuel Pressure Idle Speed & CO Checking w/Catalytic Converter Idle Speed & CO Checking wo/Catalytic Converter Air Filter Insert Replaceing post 88 Exhaust System Exhaust Flanges Checking Ignition System Equipment Table DME Control Unit Coding Spark Plugs Replacement Equipment Table post '88 DME Control Unit Coding post '88 DME Diagnosis/Troubleshooting Test Points Precautions Vehicle Information Equipment Required DME Control Unit Diagnosis Test Point 1A Power Supply Test Point 2 Idle Speed Contact Test Point 3 Full Load Contact Test Point 4 Engine Temp Sensor Test Point 5A /B Air Flow Sensor Test Point 6 Idle Speed Control Test Point 7 Oxygen Regulation Test Point 8 Oxygen Sensor Test Point 9 Air Temp Sensor Test Point 10/11 Knock Sensor Test Point 12 Control Unit Test Point 13 Hall Signal Test Point 14 Control Unit Faulty Test Point 15 DME Relay Test Point 16 Tank Venting Valve Test Point 17 Check Enginine Warning Lamp Test Point 18 Fuel Pressure Test Point 19 Intake System Leaks Test Point 20 Ground Connections Test Point 21 Speed Reference Mark Sensor Test Point 22 Ignition Test Point 23 Fuel Injectors Test Point 24 Alternator Regulator Test Point 25 Leads K & L Coding of Control Unit Check Engine Lamp 02-TRANSMISSION TRANSMISSION Table of Contents General Technical Data (Type 16J/K) Technical Data (Type 16J/K late) Techical Data (Type 16J/K & 083D) Technical Data (Type083F) Tightening Torques (Type 16J/K) Technical Data Clutch Clutch, Control Checking Clutch Drive Plate Checking Clutch Play Checking Release Travel Bleeding Clutch Clutch Removal/Installation Clutch Control Disassembly/Assembly Clutch Drive Disk Checking Pressure Plate Checking Overhauling Slave Cylinder Automatic Clutch - Torque Converter Converter (type 087M/N) Checking Converter (type 087M/N) Draining Converter (type 087M/N) Installing Manual Transmission, Control Housing Gearbox (Type 16J/K) Removing/Installing Gearbox (Type 16J/K) Removing/Installing (late) Adjusting Shift Changing Oil/Checking Level Transferbox (Type 16J/K) Removing/Installing Transfer box (Type 16J/K) Dissassembly/Assembly Rear Cover (Type 16J/K) Dissassembly/Assembly End Plate (Type 16J/K) Disassembly/Assembly Transmission Case (Type 16J/K) Disassembly/Assembly Manual Transmission Gears, shafts Input Shaft (Type 16J/K) Dissassembly/Assembly Output Shaft (Type 16J/K) Dissassembly/Assembly Pinion Shaft (Type 16J/K) Dissassembly/Assembly Synchronizer Ring Checking Automatic Transmission Transmission Identification Technical Data Position of Shift Elements Planetary Gears With Shift Parts Torque Specifications Selector Lever Removing/Installation Throttle & Control Pressure Cable Removal/Installation Throttle & Pressure Control Cable - Adjusting Functional Test Troubleshooting Table Transmission Removal/Installation Automatic Transmission Gears, Regulation Replacing ATF Fluid Flushing ATF Cooler & Line System Planetary Gear to Final Drive Disconnecting/Connecting Turbine Shaft Seal Removing & Installing Axial Play Planetary Gear/Final Drive Adjusting Planetary Gear Assembly/Dissassembly Ring Gear Assembly/Dissasembly Overrunning Clutch Assembly/Dissassembly Freewheel with Plastic Cage Assembly/Dissassembly Forward Clutch Assembly/Dissassembly Direct & Reverse Clutch Assembly/Dissassembly Oil Pump Assembly/Dissassembly Valve Body Assembly/Dissassembly Transfer and Intermediate Plates Assembly/Dissassembly Valve Body Assembly/Dissassembly 2nd Gear Brake Assembly/Dissassembly Governer Assembly/Dissassembly Parking Lock Assembly/Dissassembly Differential Differential Removal/Installation Differential Assembly/Dissassembly Pinion & Ring Gear Adjustment Checking Final Drive Oil Level Central Tube Torque Specifications Checking Oil Level in Final Drive Final Drive Assembly/Dissassembly Differential Assembly/Dissassembly Limited Slip Differential Assembly/Dissassembly Adjusting Drive Set Removing & Installing Central Tube Central Tube Assembly/Dissassembly Central Tube Checking Adjusting Dampers 03-CHASSIS CHASSIS, BODY Table of Contents Front Wheel Suspension Technical Data Tightening Torques Aluminium Control Arms modifications Notes on Front Axle (late) Running Gear Tuning Adjusting Front Wheel Bearings Ball Joint Caps Checking Wheel Bearings Assembly/Disassembly Koni Shock Absorbers Replacing Koni Shock Absorbers Adjusting Coil Springs Rear Wheel Suspension Axle Shafts Technical Data Tightening Torques Running Gear Tuning of 944 S2 Trailing Arms Assembly/Disassembly Aluminium Trailing Arms Assembly/Disassembly Koni Shock Absorbers 944S/944S2 Koni Shock Absorbers Adjusting Wheel, Tires, Alignment Wheels & Tires Sample Measuring Chart to '89 Sample Measuring Chart post '89 Wheel Alignment Values 924S/944/944S/944S2 Wheel Alignment checking Aluminum Wheels Removal/Installation Anti-Lock Braking System General ABS Layout Position of ABS Components Circuit Diagram Troubleshooting & Test Program Notes Working on Cars with ABS Notes Hydraulic Unit Removal/Installation Electronic Control Unit Removal/Installation Relays Removal/Installation Speed Sensors Removal/Installation Brakes Mechanical Technical Data Torque Specifications Brake Booster Notes (late) 4 piston Caliper Notes Brake Pads checking Brake Pads Removal/Installation Brake Pad 4-Piston Caliper Removal/Installation Brake Pushrod Adjustment Parking Brake Checking/Adjustment Front Wheel Brake Assembly/Disassembly Rear Wheel Brakes Assembly/Disassembly Brake Disc Lateral Runout Check Brake Thickness Check Brakes, Hydraulic System, Regulators, Boosters Tightening Torques Brake Booster Notes 4 piston Fixed Caliper Notes Brake Caliper Assembly/Disassembly Brake Booster Removal/Installation Brake Master Cylinder Bleeding & Replacing Brake System Fluid Steering Technical Data Torque Specifications Manual Steering Gear Removal/Installation Power Steering Gear Removal/Installation Power Steering Pump Removal/Installation Rack & Pinion Checking & Servicing Power Steering Checking Hydraulic Operation Steering Wheel Removal/Installation Steering Shaft With Protective Tube Removal/Installation (late) Body - General Safety Notes Celette Alignmnet Bench Repair Control Dimensions Floor Assembly Dimensions Body Front Section Side Members Lock Carrier Guage Front Axle Take Up Attachment Adapter for Cross Member & Stabilizer Pick Up Front End Panel Removal/Installation Bodywork Rear Rear End Panel Removal/Installation (cabrio) Rear Side Panel Removal/Installation(cabrio) Reworking Inner Side Panel Engine Hood, Tailgate Tailgate Electric Unlocking Cable Tailgate Lock Microswitch Removal/Installation Engine Hood Removal/Installation Engine Hood Cable Removal/Installation Doors Inside Door Handle Removal/Installation Door Panel Removal/Installation Window Guide Rail Removal/Installation Outside Door Handle Removal/Installation Door Lock/Inner Actuator Removal/Installation Central Locking System Central Locking System Button Removal/Installation Central Locking Control Unit Removal/Installation Door Lock Cylinder Microswitch Removal/Installation Central Locking System Function Table Central Locking System Troubleshooting Hardtop Working on Power Sunroof Troubleshooting Sunroof Sunroof Early (pre '86) Lifting Roof Conversion Electric Sunroof Drive/Assembly Removal/Installation Lifting Sunroof Adjustment Replacing Drive Dog Power Sunroof Control Checking Sunroof Microswitch in Roof opening Removal/Installation Slip Clutch on Roof Motor Adjusting Sunroofs Post '85 Lifting Sunroof Removal/Installation Lifting Sunroof Adjustment Elevation Cable & Segments Removal/Installation Gear in Element Guide Removal/Installation Testing Control in Lifting Sunroof Power Supply for Lifting Sunroof Microswitch in Sunroof Removal/Installation Microswitch in Electric Drive Adjusting Microswitch Connections Slip Clutch Folding Top Removal/Installation Bumpers Spoiler & Bumper Removal/Installation Rear Bumper Assembly/Disassembly Windshield Windshield Removal/Installation Windshield (Securiflex) Removal/Installation 2 Pack Adhesive Interior Rear View Mirror Bonding Exterior Equipment Porsche Emblem Removal/Installation Stone Guard Foil Removal/Installation Side Mouldings Removal/Installation Roof Ornamantal Strip Removal/Installation Paint Colors Outside Mirror Removal/Installation (late) Fastening T-Bolt to Roof Flange Plastic End & Side Applications Removal/Installation Tank Flap (cabrio) Removal/Installation Retrofitting New Mirror for Models as of 85/2 Interior Equipment Center Console Removal/Installation (late) Instrument Panel Removal/Installation Airbag Safety Regulations Drivers Airbag Removal/Installation Steering Wheel Airbag Removal/Installation Contact Unit Removal/Installation Front Sensor Removal/Installation Front Passenger Airbag Removal/Installation Control Unit Removal/Installation Diagnosis Checking Airbag System Operation Safety Belts Removal/Installation Safety Belts Inspection Airbag Unit Disposal Horn Buttons on Airbag Unit Repair Diagnosis/Troubleshooting Seats Front Seats Removal/Installation Seat Heating Removal/Installation Backrest Heating Element Removal/Installation Seat Frame Backrest Controllable Seat Heating Calibration Heating Heating (late) Fresh Air Blower Removal/Installation Air Conditioning System Air Conditioner Model '85 Onward Air Conditioner Technical Data Location of Components Safety Regulations for Handling R-12 Assembly work Involving Cooling System Using Service Equipment Service Unit Initial Operation Filling Service Unit Connecting to Air Conditioner Evacuating Air Conditioner Flushing Air Conditioner Re-Filling Air Conditioner Heating -A/C Unit Assembly/Disassembly Positioning of Flaps Airflow Heating -A/C Unit Removal/Installation Compressor Removal/Installation Condensor Removal/Installation Interior Sensor Blower Removal/Installation Expansion Valve Removal/Installation Defrost Flap Motor Removal/Installation Temperature Mixture Motor Removal/Installation Footwell Flaps Motor Troubleshooting Magnetic Coupling, Shaft Seal Removal/Installation 04-ELECTRICAL ELECTRICAL PART I Table of Contents Instruments, Consumption Indicators, Burgler Alarm Upshift Indicator/Economy Control Troubleshooting Fuel Indicator Troubleshooting Upshift Indicator Relay Arrangement post '83 Fuses on Central electric System post '83 Fuses in Aux Fuse box post '83 Instrument Cluster (late) Instrument Cluster Removal/Installation Speedometer Transmitter Removal/Installation Instruments Checking Burgler Alarm Checking Aux Control Unit Burgler Alarm Checking Radio, Telephone, On Board Computer Radio Removal/Installation Telephone Removal/Installation CD Player Retrofit post '88 WINDSHIELD WIPERS & WASHER Windshield Wipers Removal/Installation Windshield Washer Pump Removal/Installation EXTERIOR LIGHTS Lubricating Concealed Headlight Linkage Switch Covers Removal/Installation Lock Cylinders Removal/Installation Head Light Beam Adjustment CENTRAL ELECTRIC Central Electric Removal/Installation Central Electric Assignment Cable Harness Modification Supplemntal Electrical Equipment CURRENT FLOW WIRING DIAGRAMS '83 USA Part I Power Supply, Starter,DME, Fuel Pump Part 2 Light Switch Headlight,Fog, Light,Parking Light Part 3 Brake Light, Flasher, Turn Signal, Horn, Interior Part 4 Rear Defogger, Ignition, Starter, Seat Belts, Cluster Part 5 Instrument Center Console, Wind Shield Wiper Part 6 Air Blower, Cooling Fan Additional Diagram Air Conditioner 84' USA Part I Power Supply, Starter,DME, Fuel Pump Part 2 Light Switch Headlight,Fog, Light,Parking Light Part 3 Brake Light, Flasher, Turn Signal, Horn, Interior Part 4 Rear Defogger, Ignition, Starter, Seat Belts, Cluster Part 5 Instrument Center Console, Wind Shield Wiper Part 6 Air Blower, Cooling Fan Additional Diagrams Air Conditioner Electric Window Lifting Roof Tempostat '85/2 USA 944,944 Turbo (special vehicle #s) Page 1 Lighting Row Page 2 Lighting USA Page 3 Instrument Cluster & Sensor Page 4 Instrument Clusters/Sensors Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof Page 7 Engine Compartment Page 8 Central Electronics Box 85/2 USA 944,944 Turbo Page 1 Lighting Row Page 2 Lighting USA Page 3 Instrument Clusters/Sensors Page 4 Instrument Clusters/Sensors Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof Page 7 Engine Compartment Page 8 Central Electronics Box 86 USA 944,944 Turbo Page 1 Lighting Row Page 2 Lighting USA Page 3 Instrument Cluster & Sensor Page 4 Instrument Clusters/Sensors Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof Page 7 Tempostat 944 Page 8 Tempostat 944 Turbo Page 9 Central Electric System Page 10 Central Locking System Page 11 Fog Light, Fog Tail Light Page 12 Radio 87 USA 944,944S, 944 Turbo Page 1 Lighting Row Page 2 Lighting USA Page 3 Instrument Cluster & Sensor Page 4 Instrument Clusters/Sensors Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof Page 7 Tempostat 944 Page 8 Tempstat 944 Turbo Page 9 Tempstat 4 - Valves Page 10 Central electrical System Page 11 Central Locking System Page 12 Fog Light, Fog Tail Light Page 13 Radio Page 14 ABS, Airbag '86 USA 924 S Page 1 Lighting Page 2 Instrument Cluster, Sensors, Tilting Roof Page 3 Heating, Ventilation, Windshield Wiper Page 4 AC, Window Lifters, Alarm System Page 5 AC RHD Page 6 Tempstat Page 7 Tempostat '87 USA 924 S Page 1 Lighting Page 2 Lighting Row Page 3 Instrument Cluster & Sensors Page 4 Heating, Ventilation, Wiper, Washer, Mirrors Page 5 AC, Window Lifters, Alarm Page 6 AC RHD Page 7 Tempostat Page 8 Central electrical System Page 9 Radio 05-ELECTRICAL ELECTRICAL PART 2 Table of Contents 'Wiring Diagrams '88 944,944 Turbo, 944S Page 1 Lights Row/OPT. Equip Page 2 Lights USA Page 3 Instrument Cluster & Sender ROW Page 4 Instrument Cluster, Sender, Opt. Equip (USA) Page 5 Heating, Air Conditioning, Ventilation Page 6 Two-Tone Horns, Mirrors, Alarm Page 7 Engne Compartment, Cruise Control -944 Page 8 Engne Compartment, Cruise Control -944 Turbo Page 9 Engne Compartment, Cruise Control - 4 Valve Engine Page 10 Central Electric Page 11 Central Locks Page 12 Fog Light, Rear Fog Light Page 13 Radio Page 14 ABS, Airbag Page 15 Constr Components, Plug Connection, Ground Points'89 944,944 Turbo, 944S Page 1 Lights Row/OPT. Equip Page 2 Lights USA Page 3 Lights RHD Page 4 Instrument Cluster & Sender ROW Page 5 Instrument Cluster, Sender, Opt. Equip (USA) Page 6 Heating, Air Conditioning, Ventilation, Wipers Page 7 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof Page 8 Engne Compartment, Cruise Control -944 Page 9 Engne Compartment, Cruise Control -944 Turbo Page10 Engne Compartment, Cruise Control - 4 Valve Engine Page 11 Central Electric Page 12 Central Locks, Alarm System Page 13 Fog Light, Rear Fog Light Page 14 Radio Page 15 ABS, Airbag Page 16 Differing Cable Layout for LHD Page 17 Differing Cable Layout for RHD Page 18 Construction Components Page 19 Plug Connections, and Ground Points '90 Turbo, 944S2 Page 1 Lights Row/OPT. Equip SA/Japan Page 2 Lights USA Page 3 Instrument Cluster & Sender ROW /Japan Page 4 Instrument Cluster & Sender ROW USA Page 5 Heating, Air Conditioning, Ventilation, Wipers Page 6 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof Page 7 Engne Compartment, Cruise Control -944 Turbo Page 8 Engne Compartment, Cruise Control -4 Valve Page 9 Central Electric Page 10 Central Locks, Alarm System Page 11 Fog Light, Rear Fog Light Page 12 Radio Page 13 ABS, Airbag Page 14 944 Cabrio wiring Page 15 Construction Components Page 16 Plug Connections & Ground Points '91, 944S2 Page 1 Lights Row/OPT. Equip SA/Japan Page 2 Lights USA Page 3 Instrument Cluster & Sender ROW /Japan Page 4 Instrument Cluster & Sender ROW USA Page 5 Heating, Air Conditioning, Ventilation, Wipers Page 6 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof Page 7 Engne Compartment, Cruise Control -4 Valve Page 8 Central Electric Page 9 Central Locks, Alarm System Page 10 Fog Light, Rear Fog Light Page 11 Radio, Telephone Page 12 ABS, Airbag Page 13 944 Cabrio wiring Page 14 Construction Components Page 15 Plug Connections & Ground Points '88 924S Page 1 Lights USA Page 2 Lights Row Page 3 Instrument Cluster & Sender, Roof Page 4 Outside Mirror, Coolant Fan Motor, Heater Page 5 A/C, Power Window,Alarm Page 6 A/C RHD Page 7 Engne Compartment, Cruise Control Page 8 Central Electric Page 9 Radio 06-TURBO GENERAL Repair Groups Table of Contents Technical Data TABLE OF CONTENTS ENGINE Crankcase Crankshaft/Pistons Cylinder Head/Valve Drive Lubrication Cooling Fuel Supply Turbocharger Fuel Injection EXHAUST CHECKING BATTERY ALTERNATOR REMOVAL/INSTALLATION IGNITION SYSTEM Accident Hazards Equipment Survey Component Installation Positions DME Knock/Charging Pressure Removal/Installation Air Flow Sensor Removal/Installation Knock Sensor Removal/Installation Timing Valve Removal/Installation DME Knock/Charging Pressure Troubleshooting Plug Connections Trouble Shooting Chart Ground & Plug Connections Test Points Ground & Plug Voltage Supply RPM Sensor Reference Mark Sensor Ignition System Air Flow Sensor Fuel Pressure Idle Actuator Throttle Switch Temperature Sensor Injection Valves Knock/Charging Pressure Control Intake Pressure System Ignition Signal from DME Oxygen Sensor TRANSMISSION Clutch Technical Data Tightening Torques Checking Clutch Play Adjusting Clutch Spring Clutch Drive Plate Wear Clutch Removal/Installation Checking Oil Levels (Replacing Oil) Cooling Coil Removal/Installation Gear Box Removal/Installation Gear Box Assembly/Disassembly Rear Housing Cover Assembly/Disassembly End Plate Assembly/Disassembly Operation, Housing Transmission Housing Assembly/Disassembly Oil Pump Assembly/Disassembly Gears & Shafts Input Shaft Assembly/Disassembly Pinion Shaft Assembly/Disassembly Checking Sychromesh Rings DIFFERENTIAL / TRANSAXLE SYSTEM Differential Removal/Installation Differential Assembly/Disassembly Adjusting Differential Gears Limited Slip Differential Assembly/Disassembly Drive Pinion & Ring Gear Adjustment FRONT WHEEL SUSPENSION Front Axle Shaft Technical Data Tightening Torques Adjusting Front Wheel Bearings Checking Caps on Joints of Control Arms/Tie Rods Height Adjustable Strut Assembly/Disassembnly Coil Springs Shock Absorbers Rear Axles Technical Data Tightening Torques Rebound Travel Procedures Wheels & Tires General Vehicle Measurements Wheel Alignment Front Axle Rear Axle FRONT AXLE MODIFICATIONS BRAKES Mechanical Technical Data Brake Pads Checking Brake Pad Removal/Installation Tightening Torques Adjusting Brake Pad Push Brake Light Switch Adjustment Parking Brake Check/Adjustment Front Brakes Assembly/Disassembly (late) Rear Wheel Brakes Assembly/Disassembly Hydraulics Tightening Torques Braking System 4 Piston Calipers Modifications Brake Power Controller STEERING Tightening Torques Rack & Pinion Power Steering Check/Service Bleeding Steering System FRONT HOOD Replacing Hood Cable BUMPERS Lower Trim Panel Removal/Installation Spoiler & Bumper Removal/Installation EXTERIOR EQUIPMENT Rocker Panel Covers Removal/Installation Rear Apron Spoiler Finishes Available Applying Turbo Emblem WIPER WASHER SYSTEM Aiming Headlight Cleaner Spray Jets EXT. LIGHTS, LAMPS, SWITCHES Aiming Headlights Aiming Fog Lights Lubricating Headlight Linkage PARTS CATALOG 1982-1991 (1151 pages) 1985 MAIN GROUP 0: ACCESSORIES AND OTHERS 001: tools, stickers 002: inst set, snow chains, roof rack system 003: radio, loudspeaker, antenna 004: lacquers 005: securing liquids, sealing compounds MAIN GROUP 1: ENGINE 101: replacement engine, crankcase 102: crankshaft, piston 103: cylinder head, camshaft, valve 104: engine lubrication 105: water cooling 106: air filter system 107: l-jetronic 109: engine suspension 198: repair kits MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM 201: fuel system, carbon container, etc. 202: exhaust system, muffler, catalytic converter 298: repair kits MAIN GROUP 3: TRANSMISSION 301: clutch, central tube 302: replacement transmission 303: gear sets, shafts 304: shift rods, forks 305: differential 306: transmission suspension 307: central tube, automatic transmission 308: replacement transmission, automatic transmission 309: transmission case, automatic transmission 310: transmission parts, automatic transmission 311: differential, automatic transmission 312: transmission suspension, automatic transmission 398: repair kits MAIN GROUP 4: FRONT AXEL, STEERING 401: track control arm 402: springs, shock absorber, vibration damper 403: steering 404: sport type running gear MAIN GROUP 5: REAR AXLE 501: rear axle 502: vibration damper, stabilizer MAIN GROUP 6: WHEELS, BRAKES 601: wheels 602: disk brake, front 603: disk brake, rear 604: brake master cylinder, brakeservo, reservoir 698: repair kits MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER 701: shift mecansim, hand brake 702: pedal system MAIN GROUP 8: BODY 801: body, frame 802: bumper 803: cover 804: doors 805: glasses 806: concealing headlamps 807: sound absorber, carpet 808: seats 809: dashboard, rear-view-mirror, center console 810: trim frame 811: lifting roof 812: seat belt 813: heating, ventilation, air conditioner 898: repair kits MAIN GROUP 9: ELECTRICAL EQUIPMENT 901: electr. equipment engine, control unit 902: alternator, starter, battery, harnesses 903: switch, fuse box, relay, horn 904: windshield wiper system 905: concealing headlamps, turn signal 906: instruments 907: tempomat 909: anti-theft device 910: electric fan 998: repair kits MSP-PAGES V-PAGES 1988 MAIN GROUP 0: ACCESSORIES AND OTHERS 001: stickers 002: inst set, snow chains, trailer compling, roof rack system 004: lacquers 005: securing liquid, sealing coumpound MAIN GROUP 1: ENGINE 101: replacement engine, protective plate, crankcase 102: crankshaft, connecting rod, piston 103: cylinder head, valve, camshaft 104: engine lubrication 105: water-cooling 106: air filter system 107: l-jetronic, charger air cooler 109: engine suspension 198: repair kits MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM 201: fuel system, carbon container 202: exhaust system, muffler, catalytic converter 298: repair kits MAIN GROUP 3: TRANSMISSION 301: clutch, central tube 302: replacment transmission, transmission case 303: gears, shafts 304: transmission control, shift rods 305: differential 306: transmission suspension 307: central tube, automatic transmission 308: replacement transmission, automatic transmission 309: transmission case, automatic transmission 310: transmission control, automatic transmission 311: differential, automatic transmission 312: transmission suspension, automatic transmission 398: repair kits MAIN GROUP 4: FRONT AXLE, STEERING 401: track control, cross member 402: springs, shock absorber, stabilizer 403: steering, tie rod MAIN GROUP 5: REAR AXLE 501: rear axle 502: vibration damper, stabilizer 598: repair kits MAIN GROUP 6: WHEELS, BRAKES 601: wheels 602: disk brake, front 603: disk brake, rear, hand brake 604: master brake cylinder, brakeservo, reservoir 605: brake lines, antiblock system 698: repair kits MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER 701: shift control, hand brake lever 702: pedal system 798: repair kit MAIN GROUP 8: BODY 801: body, frame, interior and exterior panelling 802: bumper, front spoiler 803: cover 804: doors 805: glasses 806: concealing headlamps, turn signal 807: sound absorber, carpet 808: seats 809: dashboard lining, center console, rear-view-mirror 810: molding, insignias 811: lifting roof 812: seat belt 813: heating, ventilation, air conditioner 898: repair kits MAIN GROUP 9: ELECTRICAL EQUIPMENT 901: electr. equipment engine, distributer 902: alternator, starter, battery, harnesses 903: switch, fuse box, relay, horn 904: windshield wiper system 905: headlamp, turn signal, fog light 906: instruments 907: tempomat 909: anti-theft device 910: electric fan 911: radio, antenna, loudspeaker, soundsystem 998: installation set, repair kits MSP-PAGES V-PAGES 1991 MAIN GROUP 0: ACCESSORIES AND OTHERS 001: inst set, jack, stickers 002: inst set, snow chains etc. 004: paint touch-up applicator 005: securing liquid, sealing compound, preservative agent MAIN GROUP 1: ENGINE 101: short engine, crankcase 102: crankshaft, pistons 103: cylinder head, camshaft, valves etc. 104: engine lubrication 105: water pump 106: air filter system 107: l-jetronic 109: engine suspension 198: repair kits MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM 201: fuel tank, system etc. 202: exhaust system 298: repair kits MAIN GROUP 3: TRANSMISSION 301: central tube, clutch 302: replacement transmission, transmission case etc. 303: gears and shafts 304: transmission control 305: differentials 306: transmission suspension 307: central tube AT 308: replacement transmission etc. AT 309: transmission case etc. AT 310: transmission control etc. AT 311: differential AT 312: transmission suspension AT 398: repair kits MAIN GROUP 4: FRONT AXLE, STEERING 401: track control arm, cross member etc. 402: springs, shock absorber 403: steering MAIN GROUP 5: REAR AXLE 501: rear axle carrier, guiding arm etc. 502: vibration damper, stabilizer 598: repair kits MAIN GROUP 6: WHEELS, BRAKES 601: disk wheel 602: disk brake front axle 603: disk brake rear axle, hand brake 604: brake master cylinder, brakeservo reservoir etc. 605: brake lines antiblock system, hydraulic unit 698: repair kits MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER 701: control, hand brake lever 702: pedal system MAIN GROUP 8: BODY 801: body-in-white, panels, fender etc. 802: bumper, front spoiler etc. 803: cover, rear flap, spoiler 804: doors 805: glasses 806: concealing headlamps 807: sound absorber, linings 808: seats 809: dashboard, mirrors, center console etc. 810: molding, insignias 811: lifting roof, folding top 812: seat belt 813: heating and ventilation 898: repair kits MAIN GROUP 9: ELECTRICAL EQUIPMENT 901: electrical equipment engine 902: battery, harnesses, connectors etc. 903: switch, central electrical equipment, horn etc. 904: wiper, washer system 905: headlamp, lights 906: instruments 907: tempomat 909: anti-theft device 910: electric fan 911: radio, soundsystem 998: installation set, repair kits MSP-PAGES V-PAGES
Porsche 944 (1982-1991) - Workshop Manual - Wiring Diagrams - Parts Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
e-mail