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Porsche 944 Automobile User Manual

1. Fault not existing at time of testing loose contact Remedy visual inspection of path connection Conditions with which the fault is tested ara not the same as the conditions with which the fault had occurred Remedy conform with conditions displayed in the tester Signal Not Plausible Signal of the monitored component does not fit in the tolerance range of the value calculated in the control unit D 24 28 6 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 This page are missing or blank in the book DME Diagnosing Troubleshooting D 24 28 7 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 This page are missing or blank in the book D 24 28 8 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Fault Fault Code Possible Causes Elimination Remarks Test Point 1a a Perm pos B Fault memory is cancelled if there is Power no B supply for DME Testing control unit V Connect a voltmeter on terminal 24 and terminal 18 of the control unit plug with help of test leads Display battery voltage No display check current flow and ground paths according to the wiring diagram Test Point 1b b Power supply via DME relay Power supply for Connect a voltmeter on terminal 24 and terminal 37 of th
2. Menu 1 Fault memory 2 Drive links 3 Input signals lt Menu 1 System adaptation In the example press key 1 There then follows the display of the number of errors which are stored if any Number of faults 2 Proceed with key gt Additional info to every display with key 1 continue Proceed with key gt Error output 1 Engine temperature sensor 2 Short to ground not present If key 1 is pressed instead of the gt key the corresponding error code display appears the last two digits of the flashing code Fault code 14 Proceed with key gt Further errors are displayed if they exist 2 Idle contact Short to ground present If key 1 is pressed instead of key gt the corresponding error code display appears the last two digits of the flashing code Fault code 12 03 36 After the last displayed error the following instruction appears Repair fault accord ing to repair instructions Continue Proceed with key gt Fault repaired 1 yes 3 no Return to display No of errors with key 3 Proceed with key 1 Fault memory 1 Erase 3 Do not erase If key 3 is pressed Return to menu error memory The error memory is not erased Proceed with key 1 Fault memory has been cleared Return The test scope Read out error memory is terminated at this point 3 2 Actuator diagnosis If an actuator
3. Never disconnect the ignition lead between ignition coil terminal 4 and high tension distributor terminal 4 during operation Avoid voltage flashover from ignition coil terminal 4 to ignition coil terminals 1 and 15 control unit could be destroyed To avoid destruction of the control unit the secondary circuit of the ignition system must be suppressed with at least 4 k ohms whereby the original distributor rotor with 1 k ohm suppression resistance must be installed Disconnect DME control unit and ignition final stage plugs only atter turning off the ignition Flashover or disruptive discharge in the area of the high tension distributor cap poor insulation could destroy the control unit Never disconnect the battery while the engine is running e Mixing up battery pole connections could lead to destruction of the ignition final stage ignition coil and DME control unit Outside starting of the engine with more than 16 volts or a boost battery charger is forbidden Always conform with accident prevention regulations when working on fuel systems DME Diagnosing Troubleshooting D 24 28 3 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 Equipnient Required for DME Tests All sender and ignition timing signals of Porsche models can be checked with the Diagnostics tester 9288 9268 with engine reglers recommended by Porsche connecting leads Instructions for con
4. Workshop Manuel Volume IA Engine 16 valves DR ING h c F PORSCHE Aktiengesellschaft As webpage by http www 9ss1 dk porsche944 944 Table of contents General Technical data Maintenance Self diagnosis Fault diagnosis DEE control unit Connecting into the vehicle 944S Starting fault diagnosis Functional test actuator and input signal List of test codes System adaptation Knock detection Troubleshooting List of fault codes Clearing fault memory Operating conditions for start of diagnosis Operating instructions for System Tester 9288 Engine Crankcase Tightening torques for engine 16 valve Tolerances and wear limits Engine removing and installing Engine Crankshaft drive Pistons Notes on assembly for pistons from Model 87 onward Checking pistons and cylinder bore Pistons from Model 89 onward Installing cover for oil centrifuge partition Engine Cylinder head Valve drive Camshaft salling checking and adjusting Camshaft salling checking and adjusting for Model 89 onward Applying the TOC mark on the camshaft sprocket Camshafts and cylinder head removing and installing Cylinder head installing and tightening Camshafts installing Camshaft seal installing Camshaft specifications Chain tensioner removing and installing Cylinder head disassembling and assembling Valve springs removing and installing with Sauer tool Table of contents Printed in Germany XXIV 1991 volume
5. itself off Battery charger accessory Fitted accumulator with NiCd batteries The Systemtester 9288 must be switched off during the initial battery charging process Charging time gt 8 hours Connection to vehicle battery by means of vehicle specific adapter lead see 1 4 Discharged upon delivery Following charge Operating time 4 8 hours without scale illumination 1 2 hours with scale illumination Connection through ISO interface Charging voltage supply For test operation and for charging the NiCd batteries 4 Connection for Input and output devices Connection facility for Printer e g Epson IBM Hewlett Packard HP The Systemtester 92BB transmits data with the following configurations 8 data bits 1 start bit 1 stop bit No parity for printer matching Connection for vehicle Reading out the data Input for flashing code support specific adapter lead Plus in programme module see also Figure 2 C MOS Do not touch plug Operating system LCD drive Keyboard Interface communication Computations and data conversions 03 34 Plug in module remove rubber protector insert modul e fully Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 944 1 3 Battery charger run off mains voltage Figure 3 Accessory Item 1 Charger with connecting cable 1 5 m long Item 2 8 pin AMP plug 1 4 Vehicle specific adapter cable Porsche No 000 721 928
6. 1 Has the tester been operated incorrectly 2 Is the battery sufficiently charged 3 Is the adapter cable OK Please note when checking the adapter cable that a highly sensi tive electronic matching circuit is installed in the vicinity of the 19 pore plug No Description Description Function Remarks LCD indicator Dot matrix 5 x 8 If the Systemtester 9288 is switched on 4 lines each with 20 characters without the program module following Foreign languages possible the self test the tester switches off auto Illumination matically and informs the user that the program module is not fitted 2 Keyboard Keys 1 2 3 Selection key Keys lt gt Previous peget next page Switchingon Press any key Key H Help menu e g Switching off 180 s after last Illumination automatic depression of a key or Screens stored if no data stream flows Control unit overview across the seriel Setting up printer interface Switching off unit Key N Return to the next higher The last fjeld in the top right hand corner is program level following filled completely this means that this is a termination of a test stored figure and not an actual sequence or during atest real life figure sequence return to the last display Key Storing indication Key Playing back stored reading 3 Power supply If the voltage is not sufficient Charge battery appears on the display If this is not done the unit switches
7. 133 15 5 Using a depth gauge measure from the top surface of the valve spring seat vertically downwards through the recess to the outer spring contact surface 86 930 Installation length 38 0 0 5 mm 37 0 0 5 mm Inlet valve Exhaust valve 6 The installation length can be adjusted using shims 7 The valves must not be mixed up again after measurement 15 134 Engine Cylinder Head and Valve Drive 944 Valve spring Model 89 onward Engine type M 44 41 3 0 I Note A new type of valve spring has been installed in engine type M 44 41 3 0 I from Model 89 onward The installation length remains unchanged Installation lengths 38 0 0 5 mm 37 0 0 5 mm Inlet valve Exhaust valve Carry out working procedure Checking and adjusting installation length of valve springs as described on Page 15 133 Checking and adjusting installation length of valve springs Printed in Germany XIX 1989 944 Engine Lubrication 1 l CHANGING ENGINE OIL AND ENGINE OIL FILTER 16 VALVE ENGINES Preconditioned Engine at operating temperature 1 Unscrew and remove oil filler cap 2 Unscrew oil drain plug from oil pan and drain engine oil 4 Clean drain plug and never forget to replace seal Tightening torque 50 Nm 37 ftlb 5 Lightly oil gasket of oil filter screw in by ww 3ss1 dk p hand until gasket makes contact and turn 5 through one further turn to tighten To ensure that f
8. DIMENSIONS at DIN curb weight Length Length with opt extra US bumpers Width Height Wheel base in design pos Track Front Rear Ground clearance at per total weight Bed clearance at per total weight Overhang angles Front Rear 0 14 mm in mm in mm in mm in mm in mm in mm in mm in mm in Technical Data 4230 165 354 4290 168 90 4290 168 90 1735 68 31 1275 50 20 2400 94 49 Rim size 1477 58 2 7Jx15 1477 58 2 7Jx 16 1477 58 2 8Jx 16 1451 57 1 79x15 1451 57 1 7Jx16 1451 57 1 8Jx16 1442 9Jx16 120 4 72 53 2 09 14 15 Printed in Germany 944 WEIGHTS Curb weight Front Rear Total Per axle load Front Rear Per total weight Per trailer load Braked trailer Unbraked trailer Max car trailer weight Max drawbar load Per roof load With genuine Porsche roof transport system kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs to DIN 700 20 Standard 640 1411 650 1433 640 1411 650 1433 1280 2822 730 1609 900 1984 1600 3527 1200 2646 1200 500 1102 500 2 60 6085 2 60 50 110 50 35 77 75 165 Printed in Germany XIII 1987 General Sports package Australia standard 630 1389 640 141 1 610 1345 640 141 1 630 1389 1240 2734 1280 2822 1260 2778
9. Oxygen sensor USA Califomia Bridge against Japan battery voltage Oxygen sensor 928 607 421 00 ECE Bridge against grd 928 607 422 00 Sweden Resistance 6 8 ki against grd 944 612 522 00 Australia Bridge against ground Oxygen sensor 944 612 515 00 DME Diagnosing Troubleshooting D 24 28 31 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 Coding af Control Unit 944 S 2 Country Curve Family Switch Version Switch 2 Pins 3 Pins All with cat conv Califomia Japan Bridge against battery 928 607 421 00 All without cat conv Bridge against grd 928 607 422 000 As from model year 91 the code for California and Japan is being deleted identical worldwide D 24 28 32 DME Diagnosing Troubleshooting Printed In Germany XXIl 1990 944 5 944 S2 Fuel System Electronic Control 24 28 Check Engine Lamp Malfunction Indicator Light M I L As from model year 91 Califomian legislation prescribes a waming lamp which lights up if a part relevant to the exhaust gas fails As a function check of the warning lamp it lights up when the ignition is switched on and goes out once the engine is running when this is started without depressing the accelerator The waming lamp has a flashing code to indicate a defective fault path To trigger off the flashing code fully depress the accelerator pedal with the engine off and the ignition on for 3 seconds until the
10. Wire discontinuity During this test the plug af the DME control unit must be plugged in Troubleshooting Printed in Germany XVI 1987 944 Maintenance Self diagnosis 03 Testing the power supply of the air flow A voltage rise must be observed during this sensor time Ignition on Display On the extracted plug of the air flow sensor a approx 0 2 V ca 4 6 V voltage of 5 V 0 5 V must be measurable between terminal 3 positive and terminal 4 No abrupt voltage changes must be negative if necessary check by reference observed to the circuit diagram during opening or closing Abrupt voltage changes i e the air flow sensor is defective eee 33 Testing the air flow sensor From the extracted plug of the air flow sensor link plug terminal 3 to air flow sensor plug ter minal 3 and plug terminal 4 to air flow sensor plug terminal 4 using an auxiliary cable Measure the voltage between terminal 2 of the air flow sensor and ground Display approx 250 260 mV Detach the top of the air filter Using a non metallic tool slowly force the airflow sensor valve to full load position Troubleshooting 03 23 Printed in Germany XVI 1987 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 Possible causes for too lean a mixture Lambda probe ground fault Intiltrated air on the intake side
11. behind the camshaft drive gear 2 pin plug for knock sensor between in take pipes for cylinder no 1 and 2 2 pin plug for knock sensor II between in take pipes for cylinder no 3 and 4 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 Fuel System Electronic Control 24 28 2 pin plugon idle speed control between intake pipes for cylinder no 2 and 3 944 S2 between cylinder no 1 and 2 Plug for fuel injector ballast resistors in engine compartment at rear right next to the plug for the brake pad wear indicator 2 pin plugs on each of the four fuel injectors Because 944 S cars are supplied worldwide since 1987 models with only one standard control unit and said control unit is coded accordingly depending an country equipment this coding must be checked in case of complaint A 2 pin or 3 pin plug leads out at the DME wire harness near the plug receptacle in order to be able to call the different curve families Power is supplied to the DME control unit of a 944 S via terminal 30 battery in addition to via ignition lock terminal 15 D 24 28 23 24 28 Fuel System Electronic Control 944 5 944 52 Test Point 21 Speed Reference Mark Sender This test can only be performed with an oscillo scope Connect and adjust a workshop oscillo scope according to the supplied operating instructions for this purpose Connect the positive tester lead via a test lead
12. enrichment from a faulty NTC II when the engine is warm emergency running program This results in starting problems when the engine is cold no cold start enrichment Short 0 2 No engine pickup too lean and stopping of engine in cold state No effects in operating temperature state Replacement value is applicable to both types of fault DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Fault Fault Code Possible Causes Elimination Remarks Test The ratio between Up potentiometer voltage and Uv power supply voltage can Point 5a be read in the actual value menu with a 9288 System Tester Air flow sensor When opening the air flow sensor plate the ratio must be about 0 0 to 1 If not V Fault a Power supply voltage Code 121 Connect a voltmeter on terminal 3 and terminal 4 of the disconnected air flow sensor plug with help of test leads Turn on ignition Display 5 0 3 volts Test b Voltage drop on air flow sensor plate potentiometer V Point in 5b rn f 4 1 I q i I I Take off air cleaner connecting hose Connect pin 3 of the disconnected air flow sensor plug with air flow sensor plug terminal 3 and pin 4 with air flow sensor plug terminal 4 with help of test leads Connect a voltmeter on air flow sensor terminal 2 and terminal 4 turn on ignition Display approx 250 260 m V It must
13. lt Menu 1 Fault memory 2 Knock registration Proceed with key 2 Condition Engine at operating temperature Proceed with key gt lt Start knock registration before test drive Proceed with key gt lt A normal test drive is a pre requisite Proceed with key gt lt Stop the test drive only if the display with the no of knocks comes on Proeeed with key gt Knock registration 1 Start Return Pressing key 1 activates the engine knock counter Knoek registration in progress Please wait Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 944 The knock counter registers 10 000 ignitions before the display with the actual number of combustion knocks appears Number Knocks XXX Combustion XXXXX Continue gt Proceed with key gt Knock registration completed Return If knock registration is impossible due to lack of engine speed signal the following display appears No knock regist ration possible RPM signal Return Following completion of the knock registration test return to the menu with key N 3 6 Help menu The Help menu can be selected from every display by pressing key H Return to the initial display with key N Help menu 1 Illumination 2 Display stored 3 Ctrl unit chart Proceed for instance with key 1 Key 1 The scale illumination is switched on and the tester r
14. on control unit plug terminal 47 and negative tester lead via a test lead on control unit plug terminal 48 Crank engine with the starter motor Sinusoidal oscillation of at least 3 volts speed pulse and an applied higher amplitude reference mark must be displayed on the screen If the voltage signal is too small lt 3 V the 1 Speed signal distance between the sender and gear ring 2 Reference mark signal could be adjusted incorrectly Sender distance Between gear ring and sender 0 8 0 3 mm D 24 28 24 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 944 52 No display Disconnect plug of speed sender on plug plate in the engine compartment Connect tester leads on middle and outside pins of the plug on the sender end of the plug with help of test leads terminals 1 and 2 pin end Start the engine Sinusoidal oscillation must be displayed on the screen Speed sender plug Remarks The display must remain unchanged after Supplying ground to connection 3 If not check power flow spacing and condition of the sender DME Diagnosing Troubleshooting Printed In Germany XXI 1989 Fuel System Electronic Control 24 28 Test Point 22 Ignition a Secondary ignition display Adjust secondary ignition display an the oscilloscope Connect tester leads according to the supplied operating instructions Note lf a fault is displayed for all cylinders it is in th
15. read out the error memory once again _ Ete 03 31 03 Self diagnosis 944 Operating conditions for start of diagnosis Ignition on Systems Engine standing still Engine running 944 S 944 52 DME yes to n lt 2000 rpm Airbag yes yes Alarm system yes yes 03 32 Operating conditions for start of diagnosis Printed in Germany XXIV 1991 944 Self diagnosis 03 Operating instructions for System Tester 9288 Operating instructions for System Tester 9288 03 33 Printed in Germany XXIV 1991 03 1 General information 1 1 Application The Systemtester 9288 BOSCH KTS 301 is a microprocessor con trolled self diagnosis tester All systems which have a diagnosis interface as per ISO Standard can be tested with this tester The following tests are possible Reading out the fault memory Testing of the actuators Testing the circuit inputs System adaptation Engine knock detection Sensor and status checks tire pressure monitoring RDK 1 2 meer Fig 1 Self diagnosis 944 The Systemtester 9288 is a high quality pjece of electronic equip ment In order to prevent damage to the equipment as a result of improper use please read the information in the operating instructions carefully and comply with it In addition the instructions specifications of the vehicle manufac turer are also to be observed If the tester should fail check the following points before sending it in for repair
16. 24 101 Checking intake Air Guide Hoses 24 Air Flow Controlled Fuelinjection 944 Testing and adjusting specifications Model 87 onward Engine type M 44 40 41 3 0 Test Specifikation Remarks Electric fuel pump rate 850 cm 30 s Min delivery Fuel pressure engine stationary DEE relay 3 8 0 2 bar jumpered Checking value at idle approx 3 3 0 2 bar Leak test min pressure after 20 Min 2 0 bar Idle speed without catalytic with converter catalytic Idle speed rom 840 40 converte can only now be 840 40 checked Idle adjust ment no longer applies CO values 0 5 1 5 0 4 1 2 Measured upstream at catalytic converter and ppm lt 300 Lambda HC value lt 300 probe connector not separated CO adjustment no longer applies Note Carry out working procedure checking delivery rate of fuel pump and checking fuel pressure as described an Pages 20 102 and 24 103 respectively Tightening torque for cap nut 12 Nm 24 102 Testing and adjusting specifications Printed in Germany XIX 1989 944 L Jetronic Fuel Injection 24 CHECKING FUEL PRESSURE TOOLS LE No Description Special Tool Remarks Pressure gage with hose P 378 or VW 1318 from pressure tester Printed in Germany XIII 1987 Checking Fuel Pressure 24 103 24 L Jetronic Fuel Injection CHECKING FUEL PRESSURE 1 Slacken and remove capped nut on test connection of fuel distribution line Note Be caref
17. 28 101 DEE control unit coding 944 S Model 87 onward 28 103 Replacing spark plugs 28 104 Equipment table Model 89 onward 28 105 DEE control unit coding 944 S 2 Model 89 onward 28 107 DME Diagnosing Troubleshooting D 24 28 1 2 Table of contents Printed in Germany XXIV 1991 944 General TYPE 944 S 16 VALVE ENGINES 87 MODELS ONWARD Printed in Germany XIII 1987 Technical Data 0 9 General TECHNICAL DATA 944 Adjustment specifications and wear data are stated in the appropriate Repair Groups Note US values are stated in parentheses DRIVE UNIT Internal engine designation Number of cylinders Bore mm in stroke mm in Displacement actual cc in Compression ratio Max engine output to KW PS 80 1269 EC Net power SAE J 1349 KW HP at engine speed rom Max torque to Nm kpm 80 1269 EC at engine speed rom Net torque SAE J 1349 Nm lbft Max spec power output KW HP Net power SAE J 1349 kW I HPI Fuel octane rating RON MON Max perm engine speed rom Engine weight dry kg lbs ENGINE DESIGN Type 0 10 Technical Data M 44 40 4 100 3 94 78 9 3 11 2479 151 10 9 1 140 190 135 184 Australia 140 188 6000 230 23 5 225 22 9 Australia 4300 230 170 96 5 76 6 54 5 74 2 Australia 06 5 75 8 95 85 92 82 unleaded Australia 95 85 premium unleaded 6840 175 386 4 cylinder 4 stroke in line spark ignition engine with two balance shafts Printed in
18. 4 Disconnect DME control unit plug Turn on ignition If battery voltage is new supplied intermittently to terminal 1 of the control unit with help of a test lead e g control unit plug term 18 a high tension peak must be displayed on the oscilloscope each time ignition triggering E lll mi E a Components responsible for high tension for example ignition coil ignition leads spark plug connectors etc Power flow in lead between control unit plug and ignition final stage term 5 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 f Ignition final stage control signal test Very important Connect DME control unit plug Coat the baseplate with a heat conducting paste prior to installation of the ignition final Connect oscilloscope s positive tester lead stage Keep heat conducting paste off of on terminal 5 and negative tester lead on painted parts terminal 2 of the disconnected final stage plug Heat conducting paste Bosch No 5 942 860 003 ah gd gp ce gk oh C ae as Operate starter motor Oscilloscope should display the control 1 Final stage signal of the DME control unit 2 Baseplate DME Diagnosing Troubleshooting D 24 28 27 Printed In Germany XXI 1989 24 28 Test Point 23 Fuel Injectors Injection Timing V Element activation menu If a pulse is not heard check a Power supply Pu
19. 44 40 Piston rings M 44 41 Piston rings M 44 40 Piston rings M 44 41 Tolerances and wear limits Printed in Germany XXIV 1991 Engine Crankcase Distortion Intake Inner dia Dia Dia Rocking clearance Clearance Height clearance Groove 1 Groove 2 Groove 3 Height clearance Groove 1 Groove 2 Groove 3 Ring gap clearance Groove 1 Groove 2 Groove 3 Ring gap clearance Groove 1 Groove 2 Groove 3 For installing new 1 5 1 8 45 30 60 0 015 6 97 0 012 6 94 0 012 8 bar and above 0 008 0 032 0 040 0 075 0 020 0 055 0 020 0 055 0 040 0 075 0 030 0 065 0 020 0 055 0 20 0 40 0 20 0 45 0 30 0 60 0 20 0 50 0 20 0 55 0 30 0 90 10 Wear limit max 0 05 0 8 6 5 bar approx 0 080 10 0103 10 Tolerances and wear limits Engine M 44 40 41 Con rod bush Piston pin Con rod bush piston pin Crankshaft and cylinder block Crankshaft measure at bearing 2 3 or 4 Bearing 1 and 5 on prisms Con rod journal Con rod crankshaft Crankshaft beanng journal Crankshafts crankshaft Crankshaft bearing crankshaft Cylinder bore Bore for balance shaft bearing shells at crankcase or balance shaft cover Bore for bushing in bearing housing Balance shaft 10 0104 Engine Crankcase Dia Dia Radial clearance Runout Dia Radial clearance Axial clearance Dia Radial clearance Axial clearance Out o
20. 730 1609 730 1609 720 1587 900 1984 920 2028 1600 3527 1620 3571 1550 3417 up to 16 gradient for Italy up to 16 gradient for Italy for Italy for Italy up to 100 km h Technical Data 0 15 General CAPACITIES Engine measurement with dipstick as per Driver s Manual is definitive Engine oil Engine coolant Transmission with differential Fuel tank Brake fluid reservoir Windshield and headlight washing fluid reservoir PERFORMANCE Maximum speed km h mph Acceleration from 0 100 km h S 0 60 mph S 1 4 mile from standing start S Kilometer from standing start S CLIMBING PERFORMANCE In slip limit 1st gear 2nd gear 3rd gear 4th gear 5th gear DIN curb weight and half of payload _ eee 0 16 Technical Data 944 Proprietary HD oils to API classification SE or SF see Driver s Manual Approx 6 0 Approx 8 5 Approx 2 0 hypoid oil SAE 80 to MIL L 2105 API classification GL 4 Approx 80 I including approx 8 reserve Approx 0 2 Approx 0 6 228 142 7 9 7 7 15 4 21 8 62 35 6 21 5 13 3 9 4 Printed in Germany 944 Technical data Type 944 52 Model 89 General Values for adjustment and wear are to be found in the respective repair groups Notes USA values are given in brackets Drive unit Internal engine designation Bore Stroke Displacement actual Displacement rounded down Compression ratio Max engine power 88 195 EEC Ne
21. BDC 36 CS before BDC 4 CS before TDC Worldwide Model 89 onward 944S 2 M 44 41 3 0 944 105 277 07 944 105 275 09 2717 07 279 09 3 CS atter TDC 47 CS atter BDC 39 CS before BDC 7 CS before TDC Camshafts specifikations Printed in Germany XIX 1989 944 REMOVING AND INSTALLING CHAIN TENSIONER Removing Remove hollow screws from cylinder head and chain tensioner and remove complete with oil line and seals Note Chain tensioner plunger is spring loaded When removing compress plunger and hold in this position with suitable retainer improvised tool Installing 1 Chain tensioner can be installed without removal of retaining clamp 2 The retaining clamp for the chain tensioner plunger must be removed once the chain tensioner is installed Printed in Germany XIII 1987 Engine Cylinder Head Valves 1 5 3 When installing the oil delivery line install a sealing ring at both ends of the two hollow bolts The check valve is in the chain tensioner housing Tightening torque of hollow bolts 10 Nm 7 ftlb Ken Removing and Installing 15 113 Chain Tensioner 15 944 This page are missing or blank in the book 15 114 Blank page 944 Engine Cylinder Head Valves 1 5 TOOLS CYLINDER HEAD 16 VALVE ENGINES No Description Special Tool Remarks 1 Puller for valve stem 9237 seals 2 Press in tool for valve 9225 1 stem seals 3 Valve spring assembly tool 9242
22. Checking the valve guides 15 123 Printed in Germany XVII 1988 15 944 15 124 Blank page 944 Engine Cylinder Head Valve Drive Replacing valve guides Tools 15 No Description Special tool 1 Ejection base 2 Plunger 3 Plunger 4 Reamer 3120 Replacing valve guides Printed in Germany XVII 1988 87 918 Remarks See drawing See drawing See drawing VW special tool 15 125 15 Engine Cylinder Head Valve Drive 944 Drawing Plunger to press out the valve guide Material Wood ene y 15 126 Replacing valve guides Printed in Germany XVII 1988 944 Engine Cylinder Head Valve Drive 1 s Drawing Plunger to press out the valve guide Plunger to press in the valve guide Material St 37 a g 25 oO in fr A x N m in lt st oO O i cw 35 Replacing valve guides 15 127 Printed in Germany XVII 1988 15 Replacing the valve guides 1 Clean and inspect the cylinder head It is inexpedient to replace the valve guides in cylinder heads where remachining is no longer possible on the valve seats or sealing areas 2 Lay the cylinder head on the ejection base 3 Press out the valve guides from the camshaft side to the combustionchamber side with a press 87 921 4 Measure the bores in cylinder with an internat measuring caliper 15 128 Engine Cylinder Head Valve Drive 944 87 919 5 Machine the
23. I A Page 0 9 10 0101 10 0102 10 101 13 101 13 102 13 103 13 105 15 101 15 104 a 15 104 b 15 105 15 110 15 111 15 112a 15 112b 15 113 15 115 15 118 volume I A Table of contents 944 Page Machining mating face cylinder head 15 120 Vaive springs removing and installing removing valve stem seal 15 121 Valve stem seal installing 15 122 Checking valve guides 15 123 Replacing valve guides 15 125 Checking valve seat wear limit 15 130 Valve seats checking and machining 15 131 Checking and adjusting installation length of valve springs 15 133 Engine Lubrication Replacing engine oil and oil filter 17 101 Pressure reducling valve removing and installing 17 102 Engine Coating Checking cooling and heating system for leaks 19 101 Fuel supply Replacing fuel filter checking injection lines for leaks and tightness 20 101 Checking delivery rate of fuel pump 20 102 Line routing fuelsystem M 44 40 20 103 Fuel preparation L Jetronic regulation Replacing air filter cartridge checking intake air guide hoses 24 101 Testing and adjusting specifications 24 102 Checking fuel pressure 24 103 Checking idle speed and CO with catalytic convertor 24 105 Checking idle speed and CO without catalytic convertor 24 106 Replacing air filter cartridge for Model 89 onward 24 107 Exhaust system Exhaust system check tightness of flanges 26 101 Ignition system Equipment table
24. Knock Sensor II Control Unit Faulty Hall Signal Control Unit Faulty DME Relays Tank Venting Valve Check Engine Waming Lamp Fuel Pressure Intake System Leaks Ground and Plug Connections Speed Reference Mark Sender Ignition and Final Stage Fuel Injectors Injection Control Unit Alternator Regulator Leads K and L CO and Idle Speed Test Coding of Control Unit Check Engine Lamp DME Diagnosing Troubleshooting Printed In Germany XXI 1989 24 28 D 24 28 1 24 28 Fuel System Electronic Control 944 S 944 52 Precautions Greater demands of modern engines on the ignition systems and a desire for freedom from maintenance had led to the introduction of electronic ignition systems in standard production some time ago already Normally the ignition power of electronic systems almost all makes will be greater than that of conventional systems and evan greater power can be expected in the future This places electronic ignition systems in a power range where touching current carrying parts or terminats could be dangerous to lite both primary and secondary circuits In conjunction with this matter we must point out that there must always be conformance with safety regulations and legislation of a pertinent country when working on or testing ignition systems The ignition ignition or source of power must always be switched off when working on the ignition system Sample Jobs Connecting engine testers for exampl
25. Knock sensor 1 Knock sensor 2 Knock control in the control unit Hall generator signal DME control unit A digit 2 e g 1211 may appear in the second error code digit position to indicate sporadic errors i e an occasionally occurring error This does not apply to error codes 1000 and 1500 Error code List Printed in Germany XVI 1987 _ r a m T 03 29 03 944 03 30 Blank page 944 Maintenance Self diagnosis Resetting the error memory Once the DME control unit error diagnosis has been completed this is completed by error code 1000 The error memory cannot be reset as follows until this error code appears The yellow key must be pressed until the function symbol see display appears on the function display Display Function symbol The green key must be pressed until the clear symbol appears on the function display Display Resetting the error memory Printed in Germany XVI 1987 03 The error memory is reset if the LED goes off and the function display changes to 0000 Display Note A test drive must be carried out after resetting the error memory At the same time pay attention to the following 1 The engine must be at operating tempera ture i e at least 80 C 2 The duration ot the test drive minimum 6 minutes 3 At the end ot the test drive run the engine for at least 60 seconds without opening the throttle valve After the test drive
26. Or US 1020 US 1020 1 Printed in Germany XIII 1987 Tools Cylinder Head 15 115 1 Engine Cylinder Head Valves 944 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD 16 VALVE ENGINES 15 116 Disassembling and Assembling Cylinder Head Printed in Germany 944 No 10 Description Hydraulic valve tappet Conical valve keeper Spring plate Valve spring set Valve spring support Washer Valve stem seal Intake valve Exhaust valve Valve guide Qty 16 Printed in Germany XIII 1987 Engine Cylinder Head Valves 1 5 Note When Removing Installing Withdraw with a magnet Oil do not mix up Check correct seating Redetermine if necessary Note number Always replace drive in with press in tool Special Tool 9225 1 oil sealing lip use drift Oil valve stem Oil valve stem Disassembling and Assembling 15 117 Cylinder Head 1 Engine Cylinder Head Valve Drive 944 Cylinder Head 16 Valves Removing and installing valve springs Tools 87 927 No Description Special tool Remarks 1 Assembly bridge Supplier Sauer Hamburg 2 Lever arm Supplier Sauer Hamburg 3 Magnetic removal head Supplier Sauer Hamburg 4 Assembly head Supplier Sauer Hamburg 5 Spacer Supplier Sauer Hamburg 6 Screws Commercially available M 8x 40 Note If the cylinder head is installed the lever arm must be angled more accutely 15 118 Removing and installing valve springs Printed
27. SP valve guide Part No 944 104 327 51 outer diameter 11 26 mm accordingly The pressing must amount to 0 06 0 8 mm for intake and exhaust valve guides Example Bore in the cylinder head measures 11 020 mm Machine the outside diameter of the SP valve guide accordingly to 11 080 or 11 10 MM Note A 1 mm thick washer must always be placed on cylinder head face before installing the valve guide 6 Heat the cylinder head up to 170 C 338 F Apply a film of tallow tothe valve guides Position with a light knock align and from the camshaftside press into the cylinder head as far as the stop with aplunger Attention The temperature of 170 338 F must only be maintainedfor a maximum of 90 minutes Replacing the valve guides Printed in Germany XVII 1988 944 Engine Cylinder Head Valve Drive 7 Ream the valve guides with Special Tool 3120 Proceed as follows The valve guides must always be reamed with petroleum lubricant Withdraw the reamer regularly to remove chips Then finish ream the boreagain with a dry reamer 87 920 8 The valve seat rings must be remachined alter replacing the valve guides It is not enough to grind in the valves with grinding paste E ra m T Replacing the valve guides Printed in Germany XVII 1988 15 15 129 1 Engine Cylinder Head Valve Drive 944 Checking the valve seat wear limit 1 The valve seats in the 4 valve cylinder heads can
28. be possible to move the air flow sensor plate easily and without hesitation Observe the voltmeter s display at the same time Voltage jump of voltage drop should not be observed while the air flow sensor plate is opening or closing Display with air flow sensor prate in full load position approx 4 60 volts DME Diagnosing Troubleshooting D 24 28 13 Printed In Germany XXIV 1991 24 28 Fuel System Electronic Control 944 S 944 S2 Fault Fault Code Possible Causes Elimination Remarks Test Point 6 Idle speed control V Fault Code 1_22 only S2 D 24 28 14 Turn off ignition and reconnect plug if the voltage values have been reached Remarks Control unit produces replacement values in case of air flow sensor failure emergency running program Injection signal tifrom nominal air of the idle speed volumetric efficiency control for idle or a constant injection signal tifor partial load and full load ranges Element Activation Menu If pulse cannot be heard check Power supply Connect a voltmeter on terminal 2 and ground of the disconnected idle speed control plug Turn on ignition Display battery voltage No display Check power supply according to the wiring diagram Control signal test The pulse duty factor in can be read direct in the actual value menu with a 9288 System Tester Function test Switch on electric power consumers with engine running at idle speed The pulse duty factor mu
29. clutch bell housing engine ground and on body body ground next to battery Ignition final stage ground on side member at left front Fuel pump ground on rear lock cross wall behind the spare wheel Are ground connections tight and without corrosion Loosen clean and retighten ground connections as specified Caution Never start the engine as long as the ground lead between the body and engine is disconnected This would destroy the control unit immediately DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 944 52 Plug Connections Are all plugs connected correctly not loose and not corroded Disconnect plugs and check whether pins and terminals of plugs are bent or corroded 55 pin plug an DME control unit behind floor plate in the front passenger s footwell 14 pin plug in engine compartment next to the brake booster 3 pin plug for reference mark speed sender and 3 pin plug for oxygen sensor behind the intake pipe for cylinder no 4 first remove cover an the fuel ring pipe 3 pin plug an throttle valve switch 2 pin plug on electromagnetic valve for tank venting an brake boaster 4 pin plug an air flow sensor 2 pin plug an NTC Il temperature sensor is screwed in the engine block above the left compensating shaft near cylinder no 1 pin plug on ignition final stage in the engine compartment at front left 3 pin Hall sender plug
30. components or electrical signals with respect to their functioning or signal paths Functions ara triggered from the diagnosis tester During functional checking of components these must audibly or tangibly operate and can thus be detected as being electrically in proper working order or defective An error display via the tester is not possible in this mode but faulty input signals or their wiring connection ara detected by the tester Actuator and input signal function checking Printed in Germany XVI 1987 03 Starting actuator and input signal function check Ignition off Press the yellow key until the function symbol see display appears on the function display Display Prass the green key until the clear symbol ap pears on the function display Display Switch on the ignition within 8 seconds 03 7 03 Maintenance Self diagnosis 944 Press the green key until the ctear symbol ap pears on the function display This activates the first testing step and the injection valves are activated Display The injection valves must all operate audibly or tangibly Note If later attempts are made to start the engine starting difficulties may occur because a slight residual amount of fuet is injected during this testing step The testing steps remain in operation until the green key is again pressed on the tester and the clear symbol appears 03 8 The next testing step is
31. for characteristic map switch 3 928 607 422 00 2 Plug for variant switch 4 944 612 522 00 Country Characteristic map switch Varient switch ter 39 ter 54 USA rest of world with catalytic converters California 928 607 421 00 Japan EC without catalytic 928 607 422 00 converters Sweden 944 612 522 00 Australia 944 612 525 01 I en Printed in Germany XVII 1988 DME Control Unit Coding 28 103 944 S 87 Models Onward 28 Ignition System 944 REPLACING SPARK PLUGS 944 S 1 Pull off spark plug caps 2 Unscrew spark plugs with commercially available wrench A spark plug wrench is supplied as part of the car s toolkit 3 www 9ssi dk porsche944 a u Tightening torque 25 30 Nm 18 22 ftlb E ra m T 28 104 Replacing Spark Plugs Printed in Germany 944 Ignition System Equipment tabte 89 models onward Engine type M 44 41 3 0 Ignition Coll Type Model Version 944 S 2 944 602 115 00 Bosch No 0 221 118 322 Distributor Cap Type Model Version 944 S 2 928 602 211 01 Bosch No 1 235 522 395 Spark plugs Type Model Version 944 S 2 Bosch WR 5 DC Ignition trigger box Type Model Version 944 S 2 Bosch No 0 227 100 124 Equipment table 89 models onward Printed in Germany XXV 1992 928 602 706 01 28 Remarks without series resistors Remarks Only high tension distribution Remarks Spark gap 0 7 0 1 mm Remarks 28 105 28 DME Con
32. in Germany XVI 1987 944 Maintenance Self diagnosis 03 Troubleshooting Diagnosis using the tester can refer only to the error path but not to a defective component Note Before troubleshooting the entire error memory must be read out Troubleshooting Printed in Germany XVI 1987 Error code 1111 The supply voltage is too low lt 10 V or too high gt 16 V Possible causes for too low a supply voltage Battery exhausted Poor contact on the grounding strap Poor contact on the control unit A defective regulator may be the cause of too high a supply voltage E ra m T 03 19 03 Error code 1112 This error code indicates an error in the area of the idle contact Possible error Ground fault Switch stuck Testing the idle contact Extract the plug from the DME control unit 32 03 20 Maintenance Self diagnosis 944 Connect a ohmmeter between terminal 52 and terminal 24 on the DME plug Display Throttle valve closed R lt 10 2 Throttle valve open R 4 Switchover must already occur if the throttle valve is only slightly open approx 1 If the values ara not reached during this testing step measurement must be repeated directly on the throttle valve switch ee Troubleshooting Printed in Germany XVI 1987 944 Maintenance Self diagnosis Error code 1113 This error code draws attention to an error in the area of the full load contact Possi
33. initiated by again pressing the green key Refer to the test code list for the sequence of testing steps Actuator and input signal function checking Printed in Germany XVI 1987 944 Maintenance Self diagnosis As from the idle contact testing step specific controls must additionally be operated on the car for the purpose of function checking Idle contact display Slightly press the accelerator The LED must go off after approx 20 mm and the display will appear After approx 3 s Display If this is not the case an error has occurred In the area of the idle contact see Idle contact troubleshooting lf the display 0000 does not appear it is pos sible to switch at all times to the next testing step Press the green key until the clear symbol appears Actuator and input signal function checking Printed in Germany XVI 1987 03 Initiate the full load contact testing step Display Slowly press the accelerator until the full throttle position is reached The LED must go off and the display will appear after approx 3 s Display If this is not the case an error has occurred in the area of the full load contact see Full load contact troubleshooting 03 9 03 Initiale the air conditioning control terminal 41 testing step Display Maintenance Self diagnosis 944 Initiate the air conditioning control terminal 40 testing step Display Switch on the a
34. is selecled this is triggered by the ECU so that it can be checked for correct functioning The various actuators components are gone through one after the other and are selected with the gt key Operate the Systemtester 9288 as described under 3 1 until the following menu display appears Menu 1 Fault memory 2 Drive links 3 Input signals After pressing key 2 the display for the first actuator appears Injector to activate 1 Start Continue If key gt is pressed the next actuator is selected Pressing key 1 results in the following instruction Can injectors be heard felt 1 yes 3 no Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 944 Self diagnosis Key 1 selects the next actuator e g idle actuator Following instruction Repair fault accord ing to repair instructions Continue After pressing key gt the following display appears Injector to activate 1 Start Continue Proceed with key 1 Can injectors be heard felt 1 yes Send Proceed with key 1 to the next actuator Idle stabilizer to activate 1 Start Continue Proceed with key 1 Can idle stabilizer be heard felt 1 yes 3 no By pressing key 1 the next actuator is selected After pressing key 3 the next instruction appears Repair fault accord ing to repair instructions Continue Proceed with key gt Idle stabil
35. the throttle valve switch with help of test leads Display Throttle valve closed wf Throttle valve opened about 2 3rd af full gap lt 10 Remarks If the full load contact fails the control unit produces a load threshhold via the air flow sensor Value below this load threshold same as switch broken or above load threshold same as switch made DME Diagnosing Troubleshooting D 24 28 11 Printed In Germany XXI 1989 24 28 Fault Fault Code Test Point 4 Engine tamp sensor NTC II 42 Fault Code 1 14 D 24 28 12 Fuel System Electronic Control 944 S 944 S2 Possible Causes Elimination Remarks Engine temperature can be read direct from the actual value menu with a 9288 System Tester No Plausible Display Connect ohmmeter on terminal 45 and terminal 24 of the disconnected DME control unit plug with help af test leads Display at 0 C 4 4 6 8kil 15 30 C 1 4 3 6ki l 40 C 1 0 1 3Kll 80 C 250 390 100 C 160 2104 Test direct on the engine temperature sensor if the values are not reached Note Temperature sensor Il sends information about the engine temperature to the control unit It is used to provide a rich fuer air mix ture after a cold start or during warm up Break 1 DME control unit of the 944 S selects a resistance value which is stored in the control unit s memory and is approximately equal to that of an engine at operating temperature There is no
36. 108 Removing and Installing Camshafts and Cylinder Head 944 16 Remove distributor rotor Insert 3 temporary retaining bolts M 5 x 20 to hold camshaft sprocket to avoid upsetting basic camshaft setting when camshaft central bolt is slackened EN Yp LEISG MMAM 17 Slacken central bolt while countering Remove camshaft sprocket 18 Remove rear bracket 19 Unbolt and remove chain tensioner Note Chain tensioner plunger is spring loaded When removing compress plunger and after removal hold in this position with a piece of wire or a retaining clamp Printed in Germany 944 Engine Cylinder Head and Valve Drive 20 Remove bearing cover from cylinders 1 3 Hold both camshafts in the bearings with Special Tool 9226 Undo and remove front double bearing bridge and bearing cover 87 422 Note The rear double bearing bridge may remain on the cylinder head 21 Undo Special Tool evenly remove both camshafts with chain and lay together on one side 22 Undo cylinder head Undo in sequence from outside to inside 23 Remove cylinder head Checking or adjusting camshaft sitting f Model 89 onward Printed in Germany XIX 1989 15 Note If oil has been mixed with water the cylinder head must be subjected to a thorough visual inspection hairline fractures At the same time check the coating system for leaks Use test unit VW 1274 above the expansion tank for the teak test max 1 b
37. 7 b er ges 1 dk porsch e944 en EEE Tap u 20 102 Checking Delivery Rate of Fuel Pump _ ra m T Printed in Germany 944 Fuel Supply 20 FUEL SYSTEM LINE ROUTING 16 VALVE ENGINES 87 MODELS ONWARD ENGINE TYPE M 44 40 Fuel pump A Air flow sensor Fuel filter B Throttle valve housing b to fuel tank Fuel collector tube C Intake tube Pressure damper D Idle actuator Pressure regulator E Intake jet pump O AOUN ANZ r i _ __ a a ne en Sean Lo a from fuel tank c from activated charcoal canister d to brake unit F Electric tank breather valve Printed in Germany XIII 1987 Fuel System Line Routing 20 103 16 Valve Engines 24 944 24 100 Blank Page 944 REPLACING AIR FILTER ELEMENT 16 VALVE ENGINES 1 Use a screwdriver to remove mounting screws and remove upper part of air filter hee ni 3 Remove filter element and clean inside of lower half of air filter housing with a lint free cloth 4 Insert filter element place housing cover in position and tighten mounting screws Check that upper part of air filter is correctly seated Ete Printed in Germany XIII 1987 L Jetronic Fuel Injection 24 CHECKING INTAKE AIR GUIDE AND CRANKCASE BREATHER HOSES FOR LEAKS AND LOOSE CONNECTIONS 1 Check all hoses of intake system for loose connections 2 Retighten hose clamps vaew 9ssi dk porsche944 Replacing Air Filter Element
38. 81 1 5 Connecting lead Figure 4 Self fabrication for printer programme load station or similar unit For interface trunk assignment see manual of corresponding unit Printer cable for standard D 25 BOSCH No 1 684 465 193 Printer cable for EPSON BOSCH No 1 684 465 194 2 Connection The following points must be observed No gear must be engaged on the vehicle Automatic transmission in position N P Danger of Accident ALL work on the vehicle must only be carried outwith the ignition switched off After having connected the vehicle specific adapter cable the in structions listed under 3 ara displayed on the Systemtester 9288 2 1 Charging with the battery charger Fig 3 Connecting the Systemtester 9288 to the battery charger Fig 1 pos 5 2 2 Diagnosis Connecting the Systemtester 9288 to the diagnosis plug in the vehicle by means of the vehicle specific adapter cable Switch on the tester and proceed according to the instruetions displayed 3 Testing Scope of module Guidance through the menu communication with the ECU reading out the error memory and selection of the Help menus actuator diagnosis circuit inputs and system adaptation engine knock detec tion sensor and event check for the tire pressure monitor RDK 3 1 Reading out the error memory Connect the Systemtester 9288 see 2 Switch on the Systemtester possible with every key Display PORSCHE Eprom modul Mod i
39. 988 1 Engine Cylinder Head Valve Drive 944 Valve dimensions 11864 res 4 Valve seat turning tool e g Hunger tantar VDSNL 1 45 I K Valve dimensions 944 S As from Model 87 Engine type M 44 40 Dimension Intake Exhaust a 3 7 mm 33 mm Zi b 6 97 mm 6 94 mm 5 After milling grind in the valve seats c 114 7 mm 113 7 mm lightly with grinding paste Check the contact 7 45 45 pattern af the valve seat surface eg 15 132 Checking and remachining valve seats Printed in Germany XVII 1988 944 Engine Cylinder Head and Valve Drive Checking and adjusting installation length of valve springs Valve springs Model 87 onward Engine type M 44 40 Note When selecting the valve spring seat own construetion always ensure that the valve spring seat is 2 0 0 2 mm thick 1 03 Tool own construetion Valve spring Sp No 944 105 467 03 Auxiliary spring Sp No 928 107 171 01 1 Machine a recess of approx 10 mm width into valve spring seat Only install valve spring seat for measurement Checking and adjusting installation length of valve springs Printed in Germany XIX 1989 15 2 Shorten the auxiliary spring to approx 50 mm to ease assembly ca 50 t 3 Install valve and hold in valve seat Insert washer valve spring seat auxiliary spring and valve spring seat with machined recess 86 927 4 Use Special Tool 9242 to fit the conical valve keepers 15
40. Germany 944 Crankcase Crankshaft Crankshaft bearings Connecting rods Connecting rod bearings Pistons Balance shafts Balance shaft bearings Cylinders Cylinder head Valve guide Valve arrangement Valve timing Camshaft Camshaft drive Balance shaft drive Valve clearance Timing Printed in Germany XIII 1987 General Two part light alloy crankcase Forged 5 bearings Plain Cast opt sinter forged Plain Light alloy cast Forged Plain bearings with bearing shells Light alloy Light alloy Press fit special brass 2 intake 2 exhaust overhead V Two overhead camshafts hydraulic bucket tappets Without bearing shells carried in cylinder head Toothed belt and internal chain Toothed belt Self adjusting hydraulic Intake opens Intake closes Exhaust opens Exhaust closes 4 after TDC 40 after BDC 36 before BDC 4 before TDC Technical Data 0 11 General ENGINE COOLING ENGINE LUBRICATION Lubrication Oil pressure n 5000 rpm Oil pressure indicator Max oil temperature Oil consumption 1000 km EXHAUST SYSTEM EMISSION CONTROL HEATING 0 12 Technical Data 944 Sealed cooling system electric fan with thermoswitch antifreeze effective to 25 C Forced feed lubrication with sickle type pump oil filter and oil water heat exchanger in main oil flow and secondary water flow integrated in crankcase Approx 4 bar at operating temperature Pilot lam
41. Idle speed CO of cars with catalytic converter In addition to adaptation of the idle speed there is also adaptation of the idle speed CO level in these cars so that it is only necessary to check the actual state in such cars Requirements Engine at operating temperature Engine and ignition in perfect running condition All electric consumers switched off CO tester at operating temperature calibrated and adjusted correctly Oxygen sensor plug connected Test value 0 4 1 2 CO at 840 40 rom and ignition timing of 10 3 before TOC Afterwards the engine must be run at least 10 minutes after disconnection of the control unit plug or disconnection of the battery before it will be possible to recheck these values In addition the system must be adapted 944 944 52 D 24 28 30 DME Diagnosing Troubleshooting Printed In Germany XXII 1990 944 5 944 S2 Fuel System Electronic Control 24 28 Coding of Control Unit 944 S Pertinent curve families are integrated in the DME control unit in order to be able to comply with the legislation of different countries They can be read direct in the actual value menu with a 9288 System Tester One each 2 pin and 3 pin plug which are bridged differently depending on the country version lead out of the DME wire harness to call these curve families Country Curve Family Switch Version Switch 2 Pins 3 Pins USA Federal States FAG M 298
42. Intiltrated air on the exhaust side of the Lambda probe Injection valve does not open Ignition cut out Fuel pressure too low Possible causes for too rich a mixture No partial vaccum on the pressure regulator Injection valve does not close Return to the fuet tank clogged _ Ete 03 24 Error code 1124 This error code draws attention to an error in the area of the Lambda probe Possible errors Ground fault Short to positive Wire discontinuity Testing the Lambda probe signal F aww 9ss1 dk porsche9440 Figure 87 906 Disconnect the Lambda probe plug Note The voltage af the Lambda probe must only be measured using a digital voltmeter or only using a comparable measuring instru ment with an internal resistanee Ri of no less than 10 Mf Troubleshooting Printed in Germany XVI 1987 944 Maintenance Self diagnosis 03 Measure the voltage between pin 1 and engine ground 3 2 35 The voltage is within the range of approx 150 mV 900 mV depending on the mixture composition Check the cable harness to the DME control unit with reference to the circuit diagram eee Troubleshooting Printed in Germany XVI 1987 Error code 1125 This error code indicates an error in the area of the intake air temperature sensor NTC 1 in the air flow sensor Possible errors Ground fault Short to positive Wire discontinuity NTC 1 defective Testing the intake air temperature se
43. Malfunction Indicator Lamp flashes Then remove foot from accelerator If no fault is recorded i e no warning came from the indicator light there appears the flashing code a O no fault Lampon o Lamp off If the waming light did indicate a warning i e there is a fault there appears a flashing code e g 1124 ES Fault code LC Constant fault 2 with loose contact DME LH control unit 1124 O Oxygen sensor The flashing code is listed in the Diagnosing Troubleshooting plan on page D 24 28 7 The fault can also be read direct using System Tester 9288 After a repair the fault memory must be erased using the System Tester DME Diagnosing Troubleshooting D 24 28 33 Printed In Germany XXII 1990
44. a precision straight edge to check the maling face of the cylinder head for distortion Permissible maling face uneveness 0 05 mm Cylinder heads with distorted maling faces can be remachined and reused Permissible rough atter finishing 0 03 mm Remachining cylinder head Do not remove mor material from the cylinder head maling face than is necessary to achieve a smooth surface Max machining depth 146 6 mm Note on machining maling face Peak to valley 0 015 mm lf the new dimension tolerance is exceeded during machining a cylinder head gasket with a thickness of 1 4 mm must be fitted Size new 147 0 1 mm Size worn 146 6 mm oles mo Fian Pal il i d gr te Pr en s J AL E eg w Pha y 1 n Th er F Le EN 1126 15 15 120 Cylinder head refacing dimension and identification New dimension 147 0 1 mm Gasket 1 1 mm Identification none Refacing dimension 146 8 to 146 6 mm Gasket 1 4 mm Identification N Identification N To be embossed on exhaust side between cylinders no 2 and 3 on the casting lug below the sealing face of the cylinder head cover Punch character height N 6 mm Remachining cylinder heat mating face Printed in Germany XXV 1992 944 Engine Cylinder Head Valves 1 NOTES ON ASSEMBLY REMOVING AND INSTALLING VALVE REMOVING VALVE STEM SEAL SPRINGS Cylinder head removed Remove and install valve springs Rem
45. ar The camshaft cover must be removed for visual inspection 15 109 1 9 Engine Cylinder Head and Valve Drive 944 Installing and tightening the cylinder head Model 87 onward Engine type M 44 40 Note The cylinder head may be mounted with the engine installed 1 Place the cylinder head gasket in the cer rect position 2 Mount cylinder head Tightening sequence Be ir ui en a www 9ss1 dk 87 420 Opposite to undoing sequence Tightening specifications for cylinder head Model 87 onward Engine type M 44 40 st stage 20 Nm 2nd stage 90 torque angle 3rd stage 90 torque angle 15 110 Model 89 onward Engine type M 44 41 3 0 I Note The cylinder head has been reinforced by 20 mm in the area of the bearing surfaces for the cylinder head nuts This has altered the tightening sequence Tightening specifications Model 89 onward Engine type M 44 41 3 0 st stage 20 Nm 2nd stage 60 torque angle 3rd stage 90 torque angle Note Never use lubricant when fitting cylinder head nuts and washers Apply a light film of engine oil to the stud thread only Installing and tightening the cylinder head Printed in Germany XXV 1992 944 Engine Cylinder Head Valve Drive Installing camshafts 1 Turn engine in direction of rotation by ap prox 45 before ignition TDC cylinder 1 2 Lay intake shaft and exhaust camshaft in the timing chain 3 Place both camshafts in t
46. be remachined At the same time the wear limit dimension must not be exceeded as this would mean that the hydraulic valve tappets may no longer function correctly Wear dimension Intake valve Exhaust valve As from Model 87 44 4 mm 2 This is measured with the valve to be installed from the end of the valve shaft to the contact area afthe valve spring support in the cylinder head 11841 3 The valve must be held firmly on the valve seat for measurement ee 15 130 Checking the valve seat wear limit Printed in Germany XVII 1988 944 Engine Cylinder Head Valve Drive 1 s Checking and remachining valve seats 3 Valve seat milling cutter e g Visuel inspection Neway 234 45 Neway 213 60 1 Check that the valve seat sits securely in the cylinder head 2 Check the contact pattern If the valve does make contact over the emire surface of the valve seat remill the seat slighdy Remachining 1 Valve seats can be remachined for example with the Neway valve milleror the Hunger valve seat tuming tool ees 2 Remachine the valve seats with a 45 seat milling cutter Then machine the seat to the prescribed width with a 60 correction millingcutter A 30 correction milling cutter is not required Intake seat width 1 5mm Exhaust seat width 1 8 mm F E www 9ss1 dkiporsche944 Bi Si 11865 1 05 Checking and remachining valve seats 15 131 Printed in Germany XVII 1
47. ble errors Ground fault Switch stuck Testing the full load contact Connect an ohmmeter between terminal 53 and terminal 24 on the DME plug Display Throttle valve closed R Q Throttle valve in full load position R lt 10 The switching point must be briefly before full load If the values are not reached in this testing step measurement must be repeated directly on the throttle valve switch Eee Troubleshooting Printed in Germany XVI 1987 03 Error code 1114 This error code draws attention to an error in the area of the engine temperature sensor NTC 2 87 912 Possible errors Ground fault Short to positive Wire discontinuity NTC 2 defective Testing the engine temperature sensor Connect an ohmmeter between terminal 45 and terminal 24 on the DME plug 03 21 03 Maintenance Self diagnosis 944 Display 0 C 4400 l 6800 2 15 30 C 1400 l 3600 2 80 C 250 390 2 100 C 160 f2 210 If the values are not reached in this testing step measurement must be carried out directly on the engine temperature sensor The engine temperature sensor NTC 2 in forms the control unit about the current engine temperature It results in mixture enrichment during cold starts or hot running eee 03 22 Error code 1121 This error code draws attention to an error in the area of the air flow sensor 87 907 Possible errors Ground fault Short to positive
48. connect line www 9ss1 dk porsched44 Printed in Germany XIII 1987 Removing and Installing Engine steering detach hydraulic motor mount from engine supports and lower front axle cross member complete with steering and servo pump from car i www 9ss1 dk ar Bu a 10 105 10 Engine Crankcase 25 Disconnect leads from starting motor and remove starting motor 26 Remove clutch actuating cylinder from bell housing Leave line connected Unbolt and remove holder for line from upper crankcase half 2 Disconnect exhaust from flange of exhaust manifold and disconnect exhaust extraction line Remove oxygen sensor cable from bodywork 28 Disconnect flange downstream of catalytic converter and suspension and remove system 29 Remove upper transaxle bell housing mounting bolts 30 Disconnect coolant hoses for heating above exhaust manifold and from cylinder head 10 106 Removing and Installing Engine 944 31 Attach VW Special Tool 3033 suspension beam to transport bracket of engine as follows Pulley end Position 2 Flywheel end Position 12 In position 2 the threaded rod is beneath the suspension beam In position 12 the threaded rod is above the beam 32 Tighten workshop crane e g Bilstein K750 H slightly to take part af engine weight and remove support beam 10 222A Note Threaded rod af support beam 10 222A remains in front suspension eye 33 Remo
49. described below Build up pressure again by switching on the fuel pump briefly Remove return pipe on the pressure regulator fuel pump must not be switched on No fuel escaping from the pressure Fuel escaping from the pressure regulator regulator connection conneclion Reconnect return hose Replace pressure regulator Build up pressure again Disconnect rubber pressure hose tank to pump in front of the fuel Pump Pressure drop Fressure drop not okay okay Fault in fuel Replace fuel injectors pump holding leakage valve Check tuel injectors Heplace leaking fuel injectors End Repeat leak test DME Diagnosing Troubleshooting D 24 28 21 Printed In Germany XXI 1989 24 28 Test Point 19 Intake System leaks Check all connections after the air flow sensor for leaks Remove upper air cleaner section Apply Special Tool 9264 4 on the air flow sensor and produce approx 0 5 bar pressure in the intake system Leaks will cause the pressure in the system to drop quickly 944 S shut the safety pressure valve for crankcase breathing Remarks Flashing Fault Code 1_23 oxygen regulation on stop is displayed in cars with oxygen regulation and very large leakage in the intake system for example intake pipe gasket D 24 28 22 Fuel System Electronic Control 944 S 944 S2 Test Point 20 Ground Connections V Ground read 2 x from wire harness to engine block battery ground lead on
50. e timing light dwell angle speed tester oscilloscope etc Replacing ignition components for example Spark plugs ignition coil distributor ignition leads etc The above mentioned dangerous voltage will be present in the entire system should it be necessary to switch on the ignition for ignition tests or engine adjustments Consequently there is not onty danger on the various components of an ignition system such as for example distributor ignition coil control units ignition tackle but also on wire harnesses plug connections and testers D 24 28 2 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Important Vehicle Information Always turn off the ignition or disconnect the battery for resistance tests if not the tester could be destroyed Always disconnect the speed sender plug for compression tests if not there could be dangerous high tension and damaged insulation on the ignition coil high tension distributor and ignition leads Never replace a specified ignition coil see order number with a different ignition coil Never connect a suppression capacitor on ignition coil terminals 1 and 15 Never connect ignition coil terminal 1 on ground for the burglar alarm ignition coil and control unit could be destroyed Never connect battery or a test lamp on ignition coil terminal 1 control unit could be destroyed
51. e Self diagnosis 944 Display LED Bu Control unit Error code identification test code 1 LH DME 2 EZK Diagnosis mode Function displa 1 Continous error pray 2 Occasionally occurring error 3 Actualor unput signal testing 4 System adaption 2 No error LED off Test sequence terminated igniti OD Flashing LED Error code test code LED on Ignition on 03 2 DME control unit error diagnosis Printed in Germany XVI 1987 944 Maintenance Self diagnosis Connection in the 944 S Inthe 944 S the diagnosis socket is attached to a separate cable harness located above the DME control unit 87 1012 Ignition off After connecting the tester the following dis play must appear Display If this is not the case check the tester ter minals or check the power supply of the diag nosis socket in the car by referring to the cir cuit diagram Connection in the 944 S Printed in Germany XVI 1987 Diagnosis socket in the car Pin 1 terminal 15 Pin 2 terminal 31 Pin 5 terminal 30 Pin 9 Hall generator 03 87 908 03 3 03 Tester cable Diagnosis plug Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 03 4 Maintenance Self diagnosis 944 Switch on the ignition Round plug Display Pin 4 Pin 1 Pin 7 Pin 6 Pin The ignition must not be switched off during the entire error diagnosis p
52. e control unit plug DME with help of test leads Turn on ignition control unit V Display battery voltage too high too low No display check current flow path according to the wiring diagram Fault Code 111 Remarks Cars with burglar alarm check power supply from ignition lock via burglar alarm control unit to terminal 86 af the DME relay according to the wiring diagram Cars without burglar alarm check pin bridges on plug provided for installation of a burglar alarm control unit DME Diagnosing Troubleshooting D 24 28 9 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 Fault Fault Code Possible Causes Elimination Remarks Test Point 2 Idle speed Check via circuit input test with 9288 System Tester or 9268 Tester contact Ground short Select test step and operate accelerator pedal Fault Code 1_12 9288 Display Idle speed contact made Idle speed contact broken 9268 Display 1332 idle speed contact made 0000 idle speed contact broken No Display Pull off plug on DME control unit Connect ohmmeter between terminal 52 and terminal 24 with help of test leads Display Throttle valve closed lt 10 Throttle valve opened to gap of gt 1 l If the value of the idle speed contact is not reached in this test the test should be repeated direct on the throttle valve switch as described below Pull off plug on throttle valve switch Connect ohmmeter be
53. e engine cannot be started or the idle speed drops change tester connections on the Bosch lead and check tester adjustment DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 944 52 Test Point 24 Alternator Regulator Misfiring of the engine could be caused by the peak voltage of the alternator Take drive belt off of the alternator Start the engine Check alternator and regulator if the disturbances have been eliminated Test Point 25 Leads KandL Connections for diagnosing between the DME control unit and fasters are made with both leads K and L Check the following points when diagnosing is not possible 1 Power flow test see wiring diagram Lead L Pin 7 19 pin diagnostics socket Pin 13 DME plug Lead K Pin 8 19 pin diagnostics socket Pin 55 DME plug 2 Ground short test see wiring diagram Lead L Voltage on Pin 7 19 pin diagnostics socket must be gt 8 V with the ignition turned on Lead K Voltage on pin 8 19 pin diagnostics socket must be gt 8 V with the ignition turned on Possible Causes of Fault Ground short or break in wiring or plug connections Faulty control unit which is connected on these leads could be any diagnosable control unit does not always have to be the DME control unit DME Diagnosing Troubleshooting Printed In Germany XXI 1989 Fuel System Electronic Control 24 28 Checking Pull off plugs on diagnosable control uni
54. e primary or secondary circuit from the ignition coil to the distributor rotor If a fault is displayed for one cylinder this fault is located after the distributor rotor Primary resistor Term 1 15 0 4 0 6 secondary C resistor Term 1 4 5 7 2 k b Spark plug connectors Suppression resistor 3 k Visual inspection for damage or traces of burning c Distributor Distributor rotor distributor cap suppression resistor each 1 k 2 Visual inspection for damage dirt or wrong location D 24 28 25 24 28 d Ignition timing test Ignition timing is checked with the engine at operating temperature Ignition timing and engine speed can be read direct in the actual value menu with a 9288 System Tester Test value 944 S 944 S2 At 840 40 rpm 10 3 If there is no signal check Power supply to ignition final stage and ignition coil Ground connection for ignition final stage ground point on left front side member Plug connections on ignition final stage ignition coil and high tension distributor D 24 28 26 Fuel System Electronic Control 944 S 944 52 e Activation of high tension end if ignition sparks are not triggered Ignition triggering signal can be simulated for fast troubleshooting of the ignition end This requires connecting the oscilloscope term 4 tester lead on the ignition lead betw ignition cail and high tension distributor term
55. emtester 9288 as per 3 1 until the following menu display appears Menu 1 Fault memory 2 Drive links 3 Input signals Proceed with key gt lt Menu 1 System adaptation 03 37 03 Proceed with key 1 Prerequisite Eng at oper temp with all consumers and ignition off Proceed with key gt System adaptation 1 Start Return If key N is pressed return to menu If key 1 is pressed Start engine Following engine start there appears System is being adapted Please wait Atter approx 30 secs there appears System adaptation completed Return If it is impossible to carry out system adaptation idle contact not closed or delective the following display appears No system adapta tion possible Idle contact Return Atter cornpletion of the system adaptation return to the menu with key N 3 5 Engine knock registration The engine knock registration function can only be triggered through the EZK or DME control unit To this end operate the Systemtester 9288 as described in 3 1 until the following display appears Installed systems 1 LH 2 EZK 3 RDK 03 38 Self diagnosis 944 The particular system can be selected by means of key 1 2 or 3 For instance with key 2 the following display appears EZK System E01EZK Ser No 92861812415 RB No 0227400154 Proceed with key gt The following menu display appears
56. error code draws attention to an error in the area of the Hall generator 87 904 Possible errors Ground fault Short to positive Wire discontinuity Testing the Hall generator signal Using a suitable auxiliary ble connect an os cilloscope to the diagnosis plug pin 9 square wave signal and pin 2 ground If the Hall gen erator signal is O K the following picture must appear on the oscilloscope s screen 03 27 03 Maintenance Self diagnosis 944 approx 3 eee Testing the Hall generator s power supply Disconnect the Hall generator s connector Ignition on 36 A voltage of 12 Volt 1 V must be measurable between pin 1 positive and pin 3 negative If this is not the case check the wiring with reference to the circuit diagram _ r a m T 03 28 Error code 1141 Error code 1141 draws attention to an error in the area of the DME control unit If this error code appears the DME control unit must be replaced _ ra m T Troubleshooting Printed in Germany XVI 1987 944 Error code List Error code 1500 1000 1111 1112 1113 1114 1121 1123 1124 1125 1131 1132 1133 1134 1141 Maintenance Self diagnosis 03 Error path No error Output end Supply voltage too low high Idle contact Full load contact NTC 2 Air flow sensor Lambda control detects a too rich too lean mixture Lambda probe signal not correct NTC 1
57. eturns to the previous display Or with key 2 Self diagnosis 03 lt Help menu 1 Printer setting 2 Switch of equip 3 Baud Rate Proceed for instance with key 1 Printer setting 1 IBM 2 HP Quiet Jet 3 EPSON The selection of the printer results in the tester being set up for the printer type in question 3 7 Store measurement displays Key Using key all displays can be stored manually The following displays are stored automatically ECU Identity Installed systems All existing errors When the memory limit is reached the following instruction is displayed Data display mem full Return 3 8 Show stored measurement displays Key Using the keys lt or gt the stored displays for the selected system can be shown The stored displays can be called up by means of the key The system selection LH EZK RDK takes place with the keys 1 2o0r3 4 Service and wear parts BOSCH Fig BOSCH Part No Designation Comment 1 3 1 687 335 002 NC battery 4 1 1 684 483 152 Plug 4 2 1 684 485 170 Socket 9 pole 4 3 1 680 552 005 Data display stored 1 684 465 193 1 Print 2 Clear 1 684 465 194 Screwed cap Printer cable Standard D25 Printer cable Proceed with key 1 Stored displays ara printed out If printer connected Proceed with key 2 Stored displays are erased With the Help menu for instance Help menu 1 Illumination 2 Di
58. ew Illustration shows engine type M 44 40 J L 5 i j E N al Ho i 86 512 CO setting 0 5 1 5 Turn to the right richer mixture Turn to the left leaner mixture Checking idle speed 1 Connect separate soeedometer according to manufacturer s specifications Idle speed 840 40 rom Checking idle speed and CO with catalytic converte Printed in Germany XIX 1989 944 Air Flow Controlled Fuel Injection Replacing air filter insert Model 89 onward Engine type M 44 41 3 0 1 Replace front end plate Refer to 944 Workshop Manual Page 50 5 2 Undo retaining clips and remove housing cover with filter insert 3 Clean inside of filter housing with lint free cloth 4 Install new filter insert Observe installation position Arrow or TOP OBEN marking points towards the engine a 172 24 Checking idle speed and CO with catalytic converte Printed in Germany XIX 1989 24 24 107 26 944 26 100 Blank Page 944 Exhaust System 2 6 CHECKING TIGHTNESS OF EXHAUST SYSTEM FLANGES 16 VALVE ENGINES 1 Check tightness of exhaust flanges and check entire exhaust system for leaks 2 Check tightness of hex nuts on exhaust manifold cylinder head flange 3 Check tightness of all flange connectians in exhaust system together with oxygen sensor and exhaust extractian tube 4 Check tightness af bolts in primary muffler catalytic converter secondary muff
59. f round Dia Dia Dia 944 For installing Wear new limit 24 0 018 0 028 24 0 004 0 018 0 032 0 046 max 0 06 91 971 51 990 0 027 0 069 0 080 0 240 69 971 69 990 0 028 0 070 0 16 0 060 0 192 0 40 0 010 0 020 34 000 34 019 34 000 34 019 30 975 30 991 Tolerances and wear limits Printed in Germany XXIV 1991 944 Engine Crankcase 1 0 REMOVING AND INSTALIING ENGINE 16 VALVE ENGINES TOOLS ee fae y a Pee a T mn ee JE Wwww 9ss1 d porsche944 No Description Special Tool Remarks Engine suspension In conjunction beam 3033 with workshop VW Special Tool crane e g Bilstein K750 H Note If necessary use a commercially available carabiner load bearing capacity 650 kg to connect engine suspension beam to workshop crane Printed in Germany XIII 1987 Removing and Installing Engine 10 101 1 0 Engine Crankcase 944 REMOVING AND INSTALLING ENGINE MANUAL TRANSMISSION Remove by lowering engine from car The bell housing remains attached to the engine Removing 1 Align lifting platform pads beneath jacking points and raise Car 2 Place protective covers on fenders 3 Unbolt and remove front wheels 4 Disconnect battery bodywork ground lead Disconnect battery i positive lead Disconnect wire an ne harness and push both cables with E rubber grommets through splash wall Open cable clips 6 Slacken hose clamp for fuel return line and d
60. g Engine speed Oxygen sensor voltage Power supply Version code Air flow sensor signal Idle drive pulse duty factor Load signal DME Diagnosing Troubleshooting D 24 28 5 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 This DME 944 S Diagnosing Troubleshooting Plan is based on the contents of the fault memory Paths not included in self diagnosis can be diagnosed with conventional equipment Test Points 17 25 see Fault List Troubleshooting requires that the person performing the tests is familiar with the location of components the function and technical interconnections of the systems being tested model information can read and evaluate Porsche wiring diagrams knows the functions of circuits and relays and is capable of using testers such as the oscilloscpe voltmeter onmmeter and ammeter as well as evaluating the test results Important A fault text in the display Fault List and Flashing Code does not always indicate a fault in the pertinent component but could also concern the corresponding control unit or connecting leads paths between the component and control unit Troubleshooting on a running engine in the form of disconnection of plugs etc must not be carried out prior to reading the fault memory since such action could be stored as faults in the fault memory 9288 System Tester Information Displayed in Tester Fault does not exist this could mean
61. g a three square file as described on page 15 102 Fig 1 15 104b Applying the TDC mark on the camshaft sprocket Printed in Germany XXIV 1991 944 Engine Cylinder Head Valves 1 s TOOLS REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD DEGREES OF TURN METHOD OF TORQUING 16 VALVE ENGINES 4 No Description Special Tool Remarks 1 Assembly bridges for 9248 In conjunction with installing camshafts clamping bolt from Special Tool 9226 2 Pressure piece for 9234 sealing ring 3 Assembly drift for 9233 sealing ring 4 Angle reader Commercially available e g Stahlwille No 715 20 Printed in Germany XIII 1987 Tools Removing and Installing 15 105 Camshafts and Cylinder Head 1 Engine Cylinder Head Valves REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD Removing 1 Align lifting platform pads beneath jacking points and raise car 6 Remove throttle valve actuating able complete with reversing 2 Place protective covers on roller and holder Remove oil fenders dipstick Slacken hose clamps at intake manifold brake booster 3 Disconnect ground lead from and breather hose and remove battery 4 Disconnect breather hose for toothed belt cover from rear of p er lower section of air filter Detach EP Uy by 7 Remove cover of fuel distribution pipe Slacken hose clamp for fuel 5 Remove air flow sensor and return line and disconnect hose disconnect support M 8 bolt Disconnect fuel feed w
62. he timing chain SO that the cast lugs are alignedwith the marked links of the chain Oil the bearing jounals and place in the bearings carefully together with the timing chain Note The distance between the marking on the intake camshaft and the markingon the exhaust camshaft amounts to 7 outer chain links the distance betweenthe cast lugs measures approx 113 mm geet Eer is a AM www 9ss1 dk porsche844 11838 Installing camshafts Printed in Germany XVII 1988 19 4 Fasten the camshafts to the cylinder head with assembly bridges SpecialTool 9248 together with the clamping bolt of Special Tool 9226 www 9ss1 dk 87 422 5 Install the bearing bridges and bearing cover af the camshaft The bearingbridges and cover are production matched to the cylinder head and must alwaysbe installed as a set Note the identification code and pairing number Tightening torque for bearing bridges and cover 20 Nm 11804 15 111 1 s Engine Cylinder Head Valve Drive 944 Note The timing chain must always be replaced if the valves have beendamaged by the piston as a result of a broken toothed belt A thorough visual inspection must be made of the sprockets and chain tensioner E r a m T 11639 6 Apply Loctite 574 to the sealing surfaces of the front and rear double bearing bridges 7 Use the assembly drift Special Tool 9233 and pressure piece 9234 to drive the sealing ring into po
63. hile from intake manifold countering RER siyi Be a Www Ssst entire filter assembly and remove a te 4 We T om Be z a en 944 k 15 106 Removing and Installing Printed in Germany Camshafts and Cylinder Head 944 Engine Cylinder Head Valves 1 5 8 Disconnect vacuum hose 12 Pull off spark plug caps and fuel line pressure damper remove distributor cap Slacken and fuel distribution pipe hose clamp at ATF reservoir from intake manifold disconnect plug from idle 13 Unbolt and remove upper and actuator remove fuel rail with lower toothed belt covers injection valves and place to one front camshaft sprocket bracket side and cylinder head cover ae 14 Turn engine in direction of ee rotation until cylinder 1 ignition TDC is reached www 9ss1 dk 9 Disconnect throttle valve switch connector Unbolt intake manifold from cylinder head and remove 10 Remove engine underguard Open coolant drain plug and catch coolant in suitable container 11 Detach exhaust at exhaust manifold flange Printed in Germany XIII 1987 Removing and Installing 15 107 Camshafts and Cylinder Head 1 Engine Cylinder Head Valves 15 Relieve tension of camshaft toothed belt by slackening nut A and bolt B pressing toothed belt tensioner against the pressure of the spring with Special Tool 9200 and removing toothed belt from camshaft sprocket Fs Lt a Wi gi mki 15
64. ilable In some cases certain tolerance groups may be in short supply Pistons from Model 89 onwards Printed in Germany XXV 1992 13 103 13 944 This page are missing or blank in the book 13 104 Blank 944 Engine Crankshaft Pistons Assemble cover of centrifugal oil compartment in upper crankcase section Notes on installation Model 89 onward Engine type M 44 41 3 0 Note Under normal conditions it is not necessary to remove the cover when overhauling an engine If the cover is removed however the bolt area must be heated with a hot air blower under all circumstances Apply Loctite 270 to hexagon head screws Observe coding on the cover 13 Assemble cover of centrifugal oil compartment Printed in Germany XIX 1989 88 342 13 105 15 944 15 100 Blank page 944 Engine Cylinder This page are missing or blank in the book Printed in Germany Unknow page 15 15 101 1 s Engine Cylinder 944 This page are missing or blank in the book 15 102 Unknow page Printed in Germany 944 Engine Cylinder Head Valves 1 5 Adjusting with dial gages 2 Align dial gage with improvised p lat extension 205 mm long on piston crown cylinder 1 3 mm pretension Align second gage with hydraulic tappet of cylinder 1 intake valve The dial gage must be aligned perpendicular to the intake valve 3 mm pretension 4 Slacken camshaft central bolt note that it is essen
65. ilter is correctly seated recheck with oil filter wrench Tightening torque for guidance 20 Nm 14 ftlb 3 Remove oil filter with oil filter wrench Special Tool 9204 Catch remaining oil 6 Pour in engine oil run ergine to operating temperature and check for leaks 7 Check oil level with engine switched off Ete Printed in Germany XIII 1987 Changing Engine Oil 17 101 and Engine Oil Filter 1 l Engine Lubrication 944 Removing and installing the pressure reducing valve Engine type M44 40 2 3 4 80 17 1 Se screw Pressure reducing valve 2 O ring 3 O ring 4 1 Remove the cylinder head cover and undo the set screw by 2 rums 2 Ease the pressure reducing valve out of the seat with a screwdriverand take out upwards 3 Replace the O rings and apply a light film of oil before installation 4 Tighten the set screw carefully until you can feel the stop then tum back by 45 The screw must not be loose Microencapsulated renew if necessary _ Ge 17 102 Removing and installing the pressure reducing valve Printed in Germany XVII 1988 944 Engine Cooling MIXING TABLE FOR COOLANT Average values Antifreeze Antifreeze Agent Water Antifreeze Agent effective to 25 C 40 60 3 1 30 C 45 55 3 5 35 C 50 50 3 9 CHECKING HEATING AND COOLING SYSTEM FOR LEAKS 16 VALVE ENGINES 1 Visual inspection for leaks 2 Check routing of cooling and heating hoses look for
66. in Germany XVII 1988 944 Engine Cylinder Head Valve Drive 1 s Notes on assembly Remove and install the valve springs with the special tool supplied by Sauer 1 Mount the assembly bridge on the cylinder head Secure the cylinderhead to the work bench with a screw clamp to prevent tilting 2 Fasten the magnetic removal head to the Make lever arm Press the valve springstogether in the cylinder head and loosen the conical valve keeper from the valve shaft with a small screwdriver 87 926 5 Place washer valve spring support valve springs and spring plate in the cylinder head and prags together with the assembly head A small up and down movement of the lever arm allows the conical valve keepers to lock into place This movement also positions the conicalvalve keepers automatically in the correct location 87 926 3 All valve spring components can be pulled out with the magnetic removal head 4 Fasten the assembly head to the lever arm Prags the tensioningarms toget her and place the conical valve keepers in the asssembly head 87 925 6 When the conical valve keepers are locked in the tensioning arms of the assembly head point outwards E r a m T Removing and installing valve springs 15 119 Printed in Germany XVII 1988 1 Engine Cylinder Head Valves 944 Remachining cylinder head maling face Checking cylinder head for distortion Use a feeler gage an a straight edge or
67. int 12 Ignition timing is retarded 6 in case of this fault Control unit Replace control unit knock computer Fault Code 1 33 Test Point 13 Disconnect plug on cylinder head behind the camshaft drive gear and connect a Hall signal three pin adapter lead VW 1501 inbetween to check the Hall signal Connect Fault Code oscilloscope positive and negative test leads on terminals 1 and 2 of the adapter 1_34 lead Start the engine This signal should be displayed when the Hall system is okay a 1 turn Ignition timing will be retarded approximately 6 in all speed ranges if the DME control unit recognizes that the Hall signal is missing Protective circuit test Turn off ignition Disconnect Hall plug Start the engine Idle speed ignition timing will adjust itself to approximately 4 before TDC 944 S There must be a certain load signal from the air flow sensor in case of 944 S2 cars Test Point 14 Replace control unit Control unit faulty Fault Code 1 41 D 24 28 18 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Fault Fault Code Possible Causes Elimination Remarks Test Point 15 Start the engine fuel pump must run during engine starting DME relay It not fuel pump V Turn off ignition Disconnect control unit plug Connect terminal 3 and terminal 24 on the control unit plug with help of a test lead Turn on ign
68. ion can be carried out with the tester That is to say the electronic idle control in the DME control unit is adapted to the actual air throughput and to the current condition of the engine Note For system adaption it is necessary forthe The engine must now idle for at least 30 engine to be at operating temperature seconds Ignition off System adaption is then completed Press the yellow key the number af times Ignition off required for the function symbol to appear on the function display E ra m T Display Press the green key until the clear symbol appears on the function display Start the engine within 8 seconds Allow the engine to idle until the system adaption code appears System adaption 03 15 Printed in Germany XVI 1987 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 guarantee that no electrical error has Occurred in the area of the knock control and the knock sensors Knock detection should not be carried out if the customer has complained about poor out put or too high a consumption for instance Condition The engine most be at operating temperature during the test Testing most be carried out during a test drive or on the roller test stand Knock detection Printed in Germany XVI 1987 Knock detection Engine at operating temperature While the e
69. ir conditioning system The LED must go off and the display will appear after approx 3 s Display Switch off the air conditioning system The LED must go off and the display will appear after approx 3 s Display If this is not the case an error has occurred in the area of the air conditioning system s wiring Inthe event of an error check with reference to the circuit diagram Do not switch off the air conditioning system 03 10 If this is not the case an error has occurred In the area of the air conditioning system s wiring In the even of an error check with reference to the circuit diagram Actuator and input signal function checking Printed in Germany XVI 1987 944 Maintenance Self diagnosis Press the green key until the clear symbol appears Display End of the actuator and input signal function checks _ ete Actuator and input signal function checking Printed in Germany XVI 1987 03 03 11 03 944 03 12 Blank page 944 Maintenance Self diagnosis 03 Test code list Test code Components 1311 Injection valves 1321 Rotary idle controller 1322 solenoid valve tank bleeding 1332 Idle contact 1333 Full load contact 1334 Air conditioning AC switch 1335 Air conditioning compressor coupling tee Test code list 03 13 Printed in Germany XVI 1987 03 944 03 14 Blank page 944 Maintenance Self diagnosis 03 System adaption Display System adapt
70. isconnect hose Disconnect fuel feed while countering Detach cable from tempostat serve motor Disconnect series resistor injection nozzle connector 5 Unbolt panel in passenger side footwell and remove Unbolt carrier plate for DME control unit and disconnect control unit plug Disconnect 8 pin connector I i 1 3 i E 9ssi1 dk 10 102 Removing and Installing Engine Printed in Germany 944 7 Disconnect breather hose for toothed helt cover at rear of lower section of air filter Unbolt filter assembly as a unit and remove 9 Slacken and remove ignition distributor cap and rotor Mark installation position of rotor Remove oil filter and ATF reservoir Printed in Germany XIII 1987 Engine Crankcase 1 0 10 Remove throttle valve actuating cable complete with reversing roller and holder Disconnect oxygen sensor plug connector Slacken hose clamps at intake manifold and brake booster and disconnect hoses wwin9ss1 dk persches4 58 Ge a A fn rn Be Ei Ti 1 11 Remove cable clips from bulkhead Disconnect two pin and multi pin connectors Disconnect vacuum hose from tank breather valve u ww 9ss1 dk Pa a Removing and Installing Engine 10 103 1 0 Engine Crankcase 944 12 Remove engine underguard www 9ss1 dk porsche944 13 Open coolant drain plug and 17 Disconnect radiator at brackets catch coolant in a suitable and remove radiator by lowering c
71. ition the pump must run It not Check current flow and ground paths of DME relay and fuel pump according to the wiring diagram Test Point 16 Electric valve for brake booster will be opened more or less long depending on Tank the engine load when an engine having operating temperature is running The venting opened time is determined by a ground pulse from the control unit valve V Fault a Activation test Code 1 43 Activate the tank venting valve in the element activation menu of the tester It a not 944 pulse is not heard check power supply to terminal 1 of the electromagnetic valve S plug according to the wiring diagram b Control signal test Install DME test read Bosch No 1 684 463 093 between the electromagnetic valve and plug connection Connect and adjust engine tester according to the supplied operating instructions DME Diagnosing Troubleshooting D 24 28 19 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 Fault Fault Code Possible Causes Elimination Remarks Tank venting valve is not activated permanently Test must be performed within 7 minutes after starting an engine having operating temperature interrupt tank venting valve activation approx 75 seconds afterward and then continue Start engine and accelerate This must be displayed in the tester for an engine at operating temperature Signal will be wider as the air flow rate increases Check path accordi
72. izer to activate 1 Start Continue After pressing key 1 the following display appears Can idle stabilizer be heard felt 1 yes 3 no By pressing key 1 the next actuator is selected The actuators are selected one after the other and triggered until the following display appears Drive link test completed Return Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 03 By pressing the key N the operator is returned to the menu 3 3 Circuit inputs In addition lo the actuators the Systemtester 9288 can also check circuit inputs To this end operate the Systemtester 9288 in accordance with 3 1 until this menu display appears Menu 1 Fault memory 2 Drive links 3 Input signals Press key 3 Idle contact 1 Start Continue By pressing key gt the next circuit input is selected The next display appears when key 1 is pressed Activate accl pedal Idle contact closed Continue Operate the accelerator pedal the following display appears Activate accl pedal Idle contact open Continue The next circuit input is selected by pressing key gt Repeat until this display appears Input signals testing compleled Return Press key N for return to menu 3 4 System adaptation When the function System adaplation is triggered the ECU re gisters the basic air requirement of the engine To this end operate the Syst
73. k regulating system faults is integrated in the DME control unit of 944 S cars beginning with 1988 models The DME control unit has a permanent positive connection to prevent cancellation of detected and stored faults by turning off the ignition Detected faults remain stored in the memory for at least 50 engine starts exception idle speed switch interruption faults Important lf the DME control unit plug or battery is disconnected the fault memory and system adaptation will be cancelled Tester Connections A 12 pin plug which leads out of the DME wire harness in the passenger s footwell to the right above the DME control unit is provided for diagnosing in cars since 1988 models 9268 Flashing Code Testers can be connected on this plug A 19 pin plug replaces the 12 pin plug beginning with 1990 L models Either a 9288 System Tester or the Flashing Code Tester via adapter leads 9268 2 can be connected on this plug Operation of the testers is explained in the instructions supplied with the testers Note A pertinent test point is supplemented by a corresponding fault flashing code of Tester 9268 Example Test Point 2 idle speed contact 1 12 Second digit display 1 fault exists 2 fault does not exist The following actual engine data can be read direct in the actual value menu with a 9288 system Tester beginning with the version 2 0 tester module status Intake air temperature Engine temperature Ignition timin
74. ler flange Check exhaust system hangers Tightening torques of nuts and bolts M8 20 2Nm 14 1 4 ftlb M10 40 5Nm 30 3 6 ftlb Printed in Germany XIII 1987 Checking Tightness of Exhaust 26 101 System Flanges 28 944 28 100 Blank Page 944 EQUIPMENT TABIE Ignition Coil Type Model 944 S Distributor Cap Type Model 944 S Spark plugs Type Model 944 S Ignition trigger box Type Model 944 S Version 944 602 115 00 Bosch No 0 221 118 322 Version 928 602 211 01 Bosch No 1 235 522 395 Version Bosch WR 7 DC Version 928 602 706 01 Bosch No 0 227 100 124 Printed in Germany XIII 1987 Ignition System 28 Remarks Without series resistors Remarks Only high tension distribution Remarks Spark gap 0 7 0 1 mm Remarks Equipment Table 28 101 28 Ignition System 944 DME control unit Type Model Version Remarks 944 S Mod 87 944 618 124 000 M 44 40 944 618 124 01 Spare part 944 S Mod 88 944 618 124 01 M 44 40 Hall probe for knock sensors Type Model Version Remarks 944 S 944 606 170 01 Knock sensor Type Model Version Remarks 944 S 944 606 145 00 Tightening torque 20 Nm 14 ftlb use specified mounting bolt without washer 28 102 Printed in Germany XXV 1992 944 Egnition System 28 DME CONTROL UNIT CODING 944 S 87 MODELS ONWARD PresyIsiod yp ssE MAMM 1 944 612 525 01 2 928 607 421 00 1 Plug
75. ll off injector plug Connect voltmeter on injector plug terminal 2 and ground with help of test leads Turn on ignition Display battery voltage lf there is no dispiay 2 Disconnect 5 pin plug of fuel injector ballast resistors Connect voltmeter between terminal 3 terminal sleeve end and ground Turn on ignition If battery voltage is displayed Turn off ignition and pull off all plugs on fuel injectors Check power flow and resistance between the S pin plug of ballast resistors and terminal 2 of each fuel injector plug with an ohmmeter Resistance of each ballast resistor 6 9 1 Check current path according to the wiring diagram if battery voltage is not displayed D 24 28 28 Fuel System Electronic Control 944 S 944 52 b Coil resistanee test of fuel injectors Pull off injector plugs Check coil resistance on the contacts of the fuel injectors with an ohmmeter Test value 2 3 N c Injection final stage Adjust oscilloscope according to the supplied operating instructions Connect Bosch test lead 1 684 463 093 between fuel injector and plug Connect tester leads on Bosch lead according to the supplied operating instructions Caution Tester leads must not have any contact with ground Start the engine These displays must appear in the oscilloscope if the injection final stage is working perfectly and test connections are correct Starter speed Remarks lf th
76. lowly until dial gage shows that piston has reached the upper limit of travel With the crankshaft in sre this position the camshafts are at ignition TDC for cylinder 4 15 104 Checking an Adjusting Printed in Germany Camshaft Settings 944 Engine Cylinder Head and Valve Drive 1 s Checking or adjusting camshaft setting for Model 89 onward Engine type M 44 41 3 0 I Note The timing has changed with installation of new camshafts for engine type M 44 41 3 0 I for Model 89 onward Setting Inlet valve cylinder 1 Testing and adjusting value 0 75 0 1 mm The camshaft is adjusted according to the same procedure as described on Page 15 102 Checking or adjusting camshaft setting f Model 89 onward 15 104a Printed in Germany XIX 1989 1 s Engine Cylinder Head Valve Drive 944 Applying the TDC mark on the camshaft sprocket Engine type M 44 40 41 3 0 I Note Camshaft sprockets available from the spare parts department do not have a TDC mark This TDC mark is applied after the camshaft timing has been set on the new engine 1 Position the new camshaft sprocket over the old sprocket and transfer the TDC mark to the new sprocket using a color pencil 2 Fit new camshaft sprocket and adjust camshaft timing as described in the Repair Manual page 15 102 to 104 3 After operation 12 page 15 104 has been carried out engrave the TDC mark in its final position on the new camshaft sprocket usin
77. nection of testers on a car will be different depending on the 1 oscilloscope approved by Porsche make so that it will always be necessary to conform with the instructions supplied 1 digital display multimeter with an internal with a pertinent tester resistance of at least 10 M ohms Sender Signals Which Can Be Checked 1 Bosch L Jetronic test lead Bosch No With An Oscilloscope 1684 463 093 check read for correct polarity in plugs Speed sender signal 2 control unit plug test leads local Injection ti signals manufacture fitted with 2 flat male plugs N 17 457 2 in order to avoid damage on Idle speed control activation signal plug pins in the control unit plug while testing Hall sender signal 2 adapter test leads consisting of 4 plug Ignition trigger signal to ignition final stage connectors N 017 483 1 soldered with 2 approx 150 mm lang leads Tank venting activation signal 1 three pin test lead e g VW VAG 1501 as well as 2 control unit plug test leads local Reed switch signal speedometer manufacture fitted with 4 flat male plugs N 17 457 2 ABS wheel sensor signals Test leads must always be used for testing D 24 28 4 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Diagnosable DME Control Unit Self diagnosis with a fault memory with which it is possible to detect and store certain injection ignition and knoc
78. ng to the wiring diagram if there is no signal Replace control unit if necessary Test Point 17 A ground signal from control unit plug terminal 22 goes to and switches on the Check Check Engine Lamp if a component influencing emission control fails Engine ee lf the Check Engine warning lamp fails this fault is stored in the fault lamp memory Fault Code 1 45 Check by supplying ground to control unit plug terminal 22 and turning on the California as ignition of 1991 models Always replace a faulty display lamp with a specified lamp D 24 28 20 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Test Point 18 Fuel Pressure Hot starting problems Fuel collection pipe has a test Check with the engine stopped and fuel pump connection at left front Unscrew running without vacuum on the pressure regulator cap nut of the test connection this requires removing the DME relay and bridging terminals 87b and 30 Important Inserted ball seal could fall out Test pressure 3 8 0 2 bar Connect P 378 pressure tester on Stop fuel pump Read pressure on the pres the test connection Start the sure tester specitication 3 8 0 2 bar engine Vacuum on pressure regulator at idle speed Max permissible pressure drop on warm engine 0 5 bar in 30 minutes Test pressure 3 3 0 2 bar It the pressure drops below the specitied value proceed as
79. ngine is running simultaneously press the yellow and the green key until the knock detection function symbol appears on the function display Display The tester is new in knock detection mode Note Normal driving is a prerequisite for the test drive roller test stand Start the test drive roller test stand Press the green key until the clear symbol appears on the function display Display 03 17 03 Maintenance Self diagnosis 944 The tester is now active If knocking occurs To restart knack detection the green key this will be indicated by the tester e g must be pressed until the clear symbol again appears Display A knock display of gt 2 5 25 draws attention to an error Error possibilities After the expiry of 10000 ignitions the function Defective cup tappets display will change to r Conical rod damage Crank mechanism damage Display To terminale knock detection mode the green and yellow keys must be pressed simultaneously until the display appears Display Counting is now complete The number af knocks is displayed in per mill In this example 25 knocks have occurred Knock detection must be carried out until the function display switches over from the clear BE symbol to the knock detection symbol This is always the case once 10000 ignitions have occurred All occurring knocks are added up and displayed as the end result 03 18 Knock detection Printed
80. nsor Connect an ohmmeter between terminal 44 and terminal 26 on the DME plug Display 0 C 4400 1l 6800 15 30 C 1400 l 3600 2 40 C 1000 2 1300 2 lf the values are not reached during this testing step measurement must be carried out directly on the intake air tempertaure sensor Connect an ohmmeter between pin 1 and pin 4 on the air flow sensor Display as above _ eee 03 25 03 Error code 1131 This error code draws attention to an error in the area of knock sensor 1 nn n 87 911 E r a m T 03 26 Maintenance Self diagnosis 944 Error code 1132 This error code draws attention to an error in the area of knock sensor 2 Sn A en T ET a w 9ss1 dk porscheg44 y a a F 87 910 Error testing of the knock sensors is an active error test i e error testing is carried out during driving lf an error has occurred first check the wiring for a ground fault a short to positive and for continuity with reference to the circuit diagram before replacing the knock sensor _ Ete Troubleshooting Printed in Germany XVI 1987 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 trol unit If this error code appears the DME control unit must be replaced E ra m T Troubleshooting Printed in Germany XVI 1987 Error code 1134 This
81. ntro XX XX XX If a specific instruction does not appear in a display it is always possible to proceed by pressing the button gt Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 Self diagnosis 03 Due to the fact that the Systemtester 9288 can store error displays see Chapter 3 7 the following display will appear if errors have been stored in the image memory Stored displays erased 1 yes 3 no Key 3 Display Print out displays continue H Help menu see 3 6 or key 1 Display Vehicle types 1 944S 2 911 Carrera 4 3 928S 4 Selection of the vehicle type with key 1 2 or 3 After the vehicle type has been selected the following instruction appears Connect adapter cable to veh plug Ignition ON After completion The following then appears Wait for Data Break off test After a short pause the Systemtester 9288 reperts all the sys tems that are installed in the particular vehicle If a system is pre ceded by this means that at least 1 error is stored in that particular system Examples Installed systems The particular system can be selected by means ef key 1 2 or 3 After selection for instance with key 1 the following display appears LH System L01 LH JET 92861812313 0280002507 Ser No RB No 03 35 03 Self diagnosis 944 After pressing the key gt a selection menu is displayed
82. ode 1_ 25 D 24 28 16 Fuel System Electronic Control 944 S 944 S2 Possible Causes Elimination Remarks Sensor signal test Sensor voltage can be read direct in the actual value menu with a 9288 System Tester If not Disconnect oxygen sensor plug Connect a digital display voltmeter on the sensor end test connection sensor voltage signal and ground Start and run engine warm so that the oxygen sensor reaches its operating temperature A change in the voltage signal must be displayed when the mixture is richer e g by accelerating Display on voltmeter approx 150 mV 900 mV depending on composition of mixture Remarks lf the control unit recognizes an oxygen sensor voltage signal of more than 1 V or less than 0 1 V the control unit will switch over to operation without oxygen sensor short or break If regulation does not work and the sensor voltage signal is okay check the coding of the control unit before replacing the control unit Intake air temperature can be read direct in the actual value menu with a 9288 System Tester If not or when a non plausible value is displayed Connect an ohmmeter on terminal 44 and terminal 26 of the disconnected DME control unit plug Display at OC 4 4 6 8 ki 15 30 C 1 4 3 6 ki 40 C 1 1 3 ki DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Fault Fault Code Possible Cause
83. oint 3 6 ftlb Control arm to cross member 65 Nm 48 ftlb Cross member to body 85 Nm 53 ftlb 10 107 1 0 Engine Crankcase 7 Refill system with coolant and bleed system Er zz www 9ss1 dk He 8 Fillreservoir with ATF and bleed steering system 9 Run engine until it reaches operating temperature check engine oil level and coolant level top up if necessary _ eee 10 108 Removing and Installing Engine 944 Printed in Germany 944 PISTONS 87 MODELS ONWARD Engine Crankshaft Pistons 1 3 16 VALVE ENGINES Engine M 44 40 worldwide Compression 10 9 1 Nominal dia 100 00 mm An arrow pointing toward the belt pulley indicates the installation position _ ra m T Printed in Germany XIII 1987 1 Plain compression ring chrome plated 2 Oil scraper ring 3 Three part oil wiper ring Notes on Assembly Pistons 13 101 87 Models Onward 1 3 Engine Crankcase Pistons 944 Checking pistons and cylinder bores Motortype M 44 40 Repair Stage Piston Cylinder bore dia tolerance group mm mm code Fa Kolbenschmidt Standard size 99 980 100 000 0 99 990 0 007 100 010 0 005 1 100 000 100 020 2 Oversize 1 100 480 100 500 0 100 490 0 007 100 510 0 005 1 100 500 100 520 2 Checking pistons Checking cylinder bores Measure approx 61 mm from piston crown Measure approx 61 mm from upper edge of 90 offset from piston pin axis cylinde
84. ontainer Disconnect alternator from car breather hose 18 Attach support beam 10 222 A to 14 Disconnect coolant hose at front transport bracket of bottom right of radiator from engine and hold engine in engine and remove Catch any installation position Check coolant which may be left that beam is correctly attached 15 Disconnect electric leads from fan motors detach fan motor bracket from radiator and remove by lowering from car 16 Slacken coolant hose and breather hose from top left of radiator and remove Disconnect electrical connection from temperature switch to radiator Disconnect coolant hose from expansion tank and remove 10 104 Removing and Installing Engine Printed in Germany 944 19 Detach Poly rib belt tensioner from air conditioning compressor and remove belt Remove compresor from bracket and place to one side Do not disconnect refrigerant hoses 20 Unbolt stabilizer with bracket from body and from control arms and remove Disengage left and right tie rods 22 23 10 Engine Crankcase Disconnect servo pump from bracket moving spacer sleeve forward to remove Leave servo pump hanging from steering Disconnect left and right control arms from front axle traverse and rear bearings and pull forward to remove Do not slacken bolts in bearing bracket mit r T 24 Unbolt universal joint from 21 Slacken hose clamps between ATF cooler and steering and dis
85. orque angle 20 15 60 torque angle 90 torque angle 20 15 10 7 5 10 7 5 10 7 5 10 7 5 1 st stage 2nd stage 3nd stage 1 st stage 2nd stage 3nd stage 10 01 0101 10 Tolerances and wear limits Engine M 44 40 41 Cooling system Coolant thermostat Cooling system cap Pressure valve Vacuum valve Oil circuit Oil consumption Oil pressure at 80 C oil temperature at 5 000 rpm Oil capacity Difference of quantity between dipstick marks Valve timing Camshaft bore Camshaft Camshaft Bucket tappet bore Bucket tappets Camshaft 10 0102 Engine Crankcase Opening temperature opens at excess pressure opens at vacuum 1 600 miles excess pressure 6 from MY 88 Inner dia Dia Axial clearance Inner dia dia Runout 944 For installing Wear new limit 81 85 C 13 2120 0 1 bar approx 1 5 approx 4 bar 6 5 approx 1 5 28 0 021 0 28 0 04 0 055 0 08 0 18 35 0 025 0 041 35 0 025 0 041 0 02 Tolerances and wear limits Printed in Germany XXIV 1991 944 Tolerances and wear limits Engine M 44 40 41 Cylinder head with valves Mating surface Valve seat width Exhaust Seating angle Outer correction angle Inner correction angle Valve guides Valve stem Intake Exhaust Valve guide valve stem Intake Exhaust Compression Pistons with connecting rods Cylinders pistons Piston rings M
86. ove valve stem seal with Special with US 1020 US 1020 1 Tool 9237 REMOVING AND INSTALLING VALVE SPRINGS _ eEte Cylinder head installed Remove and install valve springs with Special Tool 9242 Printed in Germany XIII 1987 Removing and Installing 15 121 Valve Springs Remove Valve Stem Seal 1 Engine Cylinder Head Valves 944 INSTALLING VALVE STEM SEAL Note Always remember to place an 1 mm 1 Lubricate valve stem and install thick washer on the cylinder head shaft Place an 1 mm thick washer face before installing the valve on cylinder head face Push drift stem seal over valve stem Lubricate sealing lip of valve stem seal and position on drift Using Special Tool 9225 1 carefully and gently push seal as far as it will go onto valve guide 2 The valve stem seal is correctly seated when Special Tool 9225 1 and washer make contact Note The assembly drifts are available as spare parts _ Ete 15 122 Installing Valve Stem Seal Printed in Germany 944 Engine Cylinder Head Valve Drive 1 s Checking the valve guides 1 Clean the valve guides thoroughly 2 Use a new valve to measure the tilt play 3 Mount bar gate holder VW 387 on the cylinder head The dial gaugemust be aligned parallel to the valve disk 4 The tilt play is measured with 10 mm valve stroke distance betweenthe valve disk and valve seat Wear limit for intake and exhaust guides 0 80 mm 15 2 ang N
87. p and pressure gage 140 C Up to 1 5 Standard 2 double wall manifolds branch pipe to primary muffler 1st and 2nd secondary mufflers Option M298 or M299 and USA and Australia as standard catalytic converter instead af primary muffler Standard engine internal Option M298 or M299 and Australia heated oxygen sensor with 3 way catalytic converter Hot water heating with heat exchanger and blower Printed in Germany 944 FUEL SYSTEM Injection Fuel delivery Fuel octane rating RON MON Fuel consumption to 80 1268 EC or ECE R 15 04 100 km 100 km Constant 90 km h Constant 120 km h EC exhaust urban cycle 100 km ELECTRICAL SYSTEM Suppression Battery voltage V Battery capacity Ah A W Alternator output Ignition Firing sequence Ignition timing Printed in Germany XIII 1987 General DME Digital Motor Electronics 1 electric fuel pump Standard 95 85 European standard premium unleaded possible Opt M298 95 85 unleaded European standard premium Australia 91 82 unleaded Standard 6 7 8 3 12 5 ECE R 10 and 72 245 EC 12 50 optional 63 sports package 36 115 1610 sports package 90 1260 By DME 1 3 4 2 By DME Technical Data 0 13 General BODY DESIGNS 944 Integral all steel body with front air dam and rear spoiler aS Coupe opt removable hardtop panel also available with fog lamps set in PU front air dam as optional extra
88. r bore transverse to engine block Mount lower crankcase section and tighten bolts to specified torque for measuring Note lt recommended that the stocks of the relevant tolerance group are checked befare machining the cylinders If necessary hone to the piston size available In some cases certain tolerance groups may be in short supply 13 102 Checking pistons and cylinder bores Printed in Germany XXV 1992 944 Engine Crankshaft Pistons 1 3 Pistons from Model 89 onwards 171 13 Checking pistons and cylinder bore Engine type M 44 41 3 0 Repair size Piston mm MAHLE Standard 103 980 103 990 0 007 104 000 Oversize 1 104 480 104 490 0 007 104 500 Checking pistons Measure approx 52 mm from crown of pis ton 90 offset to axis of piston bolt Note Engine M 44 41 3 0 I worldwide Compression ratio 10 9 1 Nominal 104 00 mm The installation position is indicated by the enlarged intake valve pockets Cylinder bore Tolerance groups mm Code 104 000 0 104 010 0 005 1 104 020 2 1 04 500 0 104 510 0 005 1 104 520 2 Checking cylinder bore Measure approx 52 mm from top edge of cylinder bore across cylinder block For measurement mount lower crankcase section and tighten with prescribed tightening torque It is recommended that the stocks of the relevant tolerance group are checked before machining the cylinders If necessary hone to the piston size ava
89. rocedure _ tere Pin 5 Pin 3 34 Connection in the 944 S Printed in Germany XVI 1987 944 Maintenance Self diagnosis Starting error diagnosis Condition Engine off Ignition on Display Press the green key until the clear symbol appears on the function display Display Clear symbol The diagnosis sequence for the DME control unit then takes place Starting error diagnosis Printed in Germany XVI 1987 03 lf an error is displayed take the note of the error e g 1211 Display The error is displayed until the green key is again pressed on the tester The next error code is then displayed if applicable This must be repeated until 1000 appears on the display lf no error has occurred the following display appears Display 03 5 03 Maintenance Self diagnosis 944 Press the green key until the clear symbol ap pears on the function display The following display must then appear Display This now terminates diagnosis of the DME control unit If one or several errors up to 5 has have been displayed the error memory must be reset see chapter Resetting the error memory ee 03 6 Starting error diagnosis Printed in Germany XVI 1987 944 Maintenance Self diagnosis Actuator and input signal function checking An actuator and input signal function check can be carried out independently of an error diagnosis This function check tests individual
90. s Elimination Remarks If no display Disconnect plug on air flow sensor Connect an ohmmeter on air flow sensor terminals 1 and 4 with help of test leads Display same as above Note In case of a break there will be a replacement value equal to an intake air temperature of 20 C emergency running program nn oe Saas m Test Point 10 Knock sensor Knock sensor l Knock signal not plausible Check Installation of knock sensor check tightening torque and type of screw Fault Code Wire harness and plug connections according to wiring diagram 1 31 Reconnecting sensors eliminates contact resistance Whether coolant or other liquids are in area of the knock sensor Replace knock sensor Ignition timing retarded by 6 on crankshaft in case of a faulty Knock sensor Test Point 11 Knock sensor Knock sensor Il Knock signal not plausible Check ll Installation of knock sensor check tightening torque and type of screw Fault Code Wire harness and plug connections according to wiring diagram 1 32 Reconnecting sensors eliminates contact resistance Whether coolant or other liquids are in area of the knock sensor Replace knock sensor Ignition timing retarded by 6 on crankshaft in case of a faulty knock sensor DME Diagnosing Troubleshooting D 24 28 17 Printed In Germany XXI 1989 24 28 Fuel System Electronic Control 944 S 944 52 Fault Fault Code Possible Causes Elimination Remarks Test Po
91. signs of porosity swelling cracks and rubbing Replace damaged hoses 3 Retighten hose clamps Ete Printed in Germany XIII 1987 Checking Cooling and Heating system for Leaks 19 Water 4 7 4 3 3 9 19 101 20 944 20 100 Blank Page 944 Fuel Supply 20 REPLACING FUEL FILTER 16 VALVE CHECKING FUEL AND INJECTION LINES ENGINES FOR LEAKS AND LOOSE CONNECTIONS 1 Disconnect fuel lines always counter 1 Visual inspection for leaks when slackening threaded connectors Catch fuel exiting from lines in a suitable container 2 Retighten union nuts and hose clamp 2 Slacken retaining clamp and remove fuel filter ie ds Po Er 5 Fay i if WI mx 3 D ra m T s 3 Install new filter Direction of flow is as indicated by the arrow De Printed in Germany XIII 1987 Replacing Fuel Filter Checking 20 101 Injection Lines for Leaks and Loose Connections 20 Fuel Supply 944 CHECKING DELIVERY RATE OF FUEL PUMP Precondition Allow fuel to flow into graduated cylinder for 30 seconds Minimum delivery rate is 850 Fuel filter and power supply OK cc 30s if necessary replace fuel pump 1 Unbolt fuel return hose from pressure regulator Connect a length of commercially available fuel hose and place one end in a graduated cylinder capacity apprax 1500 cc 2 Disconnect DME relay from central electrics and using a length of wire jumper terminals 30 and 8
92. sition at the drive end of the camshaft Lubricate the sealing lip before assembly 11794 15 112 Installing camshafts Printed in Germany XVII 1988 944 Engine Cylinder Head Valve Drive 1 s Installing Camshaft Seal 1 Place sealing washers in bearings and Engine installed install bearing bridge with Loctite 574 Tightening torque 20 Nm 15 ftlb Note If the sealing cover af an engine leaks with the engine installed the procedure for installing the cover is as follows 1 Place camshafts and sealing washers in bearing 2 Apply Loctite 574 to bearing bridge and install Place a 0 20 mm feeler gauge between bearing bridge and cylinder head and tighten botts slightly by hand 87 465 2 After torquing the bearing bridge install sealing cover with the aid af Special Tool 9234 ra ui rl 928 01 o 3 Apply a light film af oil to sealing cover d m a u o press an by hand Tighten bearing bridge 4 to 20 Nm 15 ftlb x 86 925 Installing Camshafts Seal 15 112a Printed in Germany XVII 1988 15 Camshaft specifications Engine type Camshafts Inlet shaft Exhaust shaft Identification code On the rear face Timing 1 mm stroke zero play Inlet opens Inlet closes Exhaust opens Exhaust closes 15 112b Engine Cylinder Head and Valve Drive 944 Worldwide Model 87 onward 944 S M 44 40 944 105 277 04 944 105 275 04 277 04 275 04 4 CS atter TDC 40 CS atter
93. splay stored 3 Cril unit chart If the key gt is pressed a further section of the Help menu is displayed Operating instructions for System Tester 9288 Printed in Germany XXIV 1991 EPSON 4 1 Service parts Porsche Designation Systemtester 9288 Adapter cable Battery charger Module D Module GB USA Module F Module I Module E Porsche Part No 000 721 928 80 000 721 928 81 000 721 928 82 000 721 928 84 000 721 928 85 000 721 928 86 000 721 928 87 000 721 928 88 Special tool No 9288 9288 1 9288 2 9288 4 9288 5 9288 6 9288 7 9288 8 03 39 10 944 10 0100 Blank page 944 Engine Crankcase Tightening torques for engine 16 valve Location Crankshaft crankcase Upper and lower crankcase sections studs Knock sensor Cylinder head Cylinder head to upper crankcase section Engine type M 44 40 Engine type M 44 41 3 0 Camshaft bearing to cylinder head Allen screws for chain tensioner Banjo bolt Chain tensioner Cover for cylinder head Fastening Hall sensor Thread M 12x 1 5 M 10 M 8 M 6 M 8 M 12 M 8 M 6 M8x1 M6 M6 Tightening torques for engine 16 valve Printed in Germany XIX 1989 Tightening torque Nm ftlb 30 22 60 torque angle 1 st stage 2nd stage 1 st stage 2nd stage 20 15 original screw without washer refer to Page 15 110 20 15 90 torque angle 90 t
94. st change and the idle soeed must remain constant If not DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 5 944 S2 Fuel System Electronic Control 24 28 Fault Fault Code Possible Causes Elimination Remarks Connect two pin DME test lead Bosch No 1 684 463 093 between the speed control and plug Connect and adjust engine tester to supplied operating instructions Make sure that electric lead connections do not have contact with vehicle ground danger of short Displayed with the engine running Frequency approx 100 Hz Replace the idle speed control it the pulse cannot be heard in spite of correct power supply and received signal Test Point 7 Oxygen regulation cannot work in its regulating range in case at disturbances in Oxygen air fuel mixture for example too lean because of excessive air or too rich regulation because of a sticking fuel injector It then moves against the stop on stop Fault Code Test 1 Check CO level with the engine running and CO 1 23 tester connected between 0 4 and 1 2 too lean Check intake system for leaks Test Point 19 too rich Check system pressure Test Point 18 Check fuel injectors for leaks Test Point 18 DME Diagnosing Troubleshooting D 24 28 15 Printed In Germany XXI 1989 24 28 Fault Fault Code Test Point 8 Oxygen sensor V sensor signal Fault Code 1_24 Test Point 9 Air temperature sensor NTC I 2 Fault C
95. t power SAE J 1349 at engine speed Max torque 88 195 EEC Net torque SAE J 1349 at engine speed Max output per litre DIN 70020 SAE J 1349 Speed governed by fuel cut off Engine weight dry Technical data Printed in Germany XIX 1989 mm in mm in cm in cm kW HP kW HP rom Nm kpm Nm Ibft rom KW I HP I KW I HP I rom kg Manual transmission M 44 41 3 0 104 4 09 88 3 46 2990 182 5 2969 10 9 1 155 211 155 208 5800 280 28 5 280 207 4100 51 8 70 6 51 8 69 6 6480 20 175 0 17 944 Maintenance Self diagnosis DME control unit error diagnosis DME control unit error diagnosis 944 S as from 88 model As from model year 88 the DME control unit 944 S is capable of a self diagnosis That is to say the control unit is capable of detecting storing and displaying system errors The con trol unit capable of diagnosis is identified by an altered part number A specially developed diagnostic tester special tool No 9268 is then used to read out the error memory and to test specific components and control sig nals af the fuel and ignition system CY Ne J se 87 793 Important Before diagnosis the battery or the connector of the DME control unit must not be disconnected as otherwise the error memory will be erased DME control unit error diagnosis Printed in Germany XVI 1987 03 03 1 03 Maintenanc
96. tial to counter Slacken temporary retaining bolts Turn engine in direction opposite to direction of rotation until camshaft sprocket reaches stop inside feather key groove 3 Remove distributor rotor and lock camshaft sprocket with 3 2 Mii M 5 x 15 to prevent camshaft sprocket or camshaft turning when camshaft central bolt is slackened www 9ss dk porsche944 _ G 5 Tighten temporary retaining bolts 6 Nm 4 4 ftlb and central bolt approx 40 Nm 30 ftlb Printed in Germany XIII 1987 Checking an Adjusting 15 103 Camshaft Settings 1 Engine Cylinder Head Valves 944 6 Turn the engine in the direction of rotation until piston reaches its upper limit af travel 7 Set dial gage af cylinder 1 intake valve hydraulic tappet to 0 8 Turn crankshaft past ignition TDC cylinder 1 while observing cylinder 1 intake valve dial gage Turn engine until gage shows 1 4 0 1 mm lift Note 11 Tighten temporary retaining a bolts and central bolt Do not turn engine in direction Tightening torque of central opposite to direction of rotation bolt 65 70 Nm 48 52 ftlb 9 Slacken central bolt and 12 Recheck by turning crankshaft temporary retaining bolts while through another 2 turns and doing so ensure that the reading checking setting of 1 4 0 1 mm an the dial gage is not changed 13 Remove temporary retaining bolts and install distributor rotor 10 Now turn crankshaft s
97. to operating temperature 70 90 C oil temperature Use the oil temperature tester Special Tools 9122 and 9122 2 J 4 _ i j www 9ss1 dk porsche944 85 114 3 Do not separate the connection for the Lambda probe Connect CO tester and separate soeedometer according to the manufacturer s specifications CO reference value 0 4 1 2 Idle speed 840 40 rom 24 105 24 Checking idle speed and CO without catalytic converter Model 87 onward Engine type M 44 40 41 3 0 I Note It is no longer possible to adjust the idle speed The throttle valve connector adjustment therefore no longer applies Idie CO adjustment Adjustment preconditions Engine in perfect mechanical conditions Consumers must be switched off during adjustment work Carry out adjustment as quickly as possible to ensure that the intake paths do not heat up thus falsifying the CO value Ambient temperature 15 35 C 1 Warm engine up to operating temperature 70 90 C oii temperature Use oil tempe rature tester Special Tools 9122 and 9122 2 2 Check CO value If the CO value is not within the prescribed tolerances correct the setting at the air flow sensor Remove the sealing plug in the access bore to the CO adjusting screw 24 106 Air Flow Controlled Fuel Injection 944 Engine type M 44 40 Standard screwdriver for 3 mm Allen screw Engine type M 44 41 3 0 Standard angled screwdriver for 5 mm Allen scr
98. trol unit Type Model 944 S 2 Mod 89 90 944 S 2 Mod 91 Ignition System Version 944 618 124 02 944 618 124 05 Hall probe for knock sensors Type Model 944 52 Knock sensor Type Model 944 52 28 106 Version 944 606 170 01 Version 944 606 145 00 944 Remarks Remarks Remarks Tightening torque 20 Nm 14 ftlb use specified mounting bolt without washer Equipment table 89 models onward Printed in Germany XXV 1992 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 1 not used 2 928 607 422 00 2 connector for variant switch Country Variant switch USA rest of world with catalytic convertor California Japan 928 607 421 00 Rest of world without catalytic converter 928 607 422 00 Coding DEE control unit 944 S 2 Model 89 onwards 28 107 Printed in Germany XIX 1989 DME Diagnosis Troubleshooting Dr Ing h c F Porsche Aktiengesellschaft 944 944 52 Test Point oo DO POD Fuel System Electronic Control Description Precautions Important Vehicle Information Testing Requirements Effects of Faults Cross Reference List DME Control Unit Plug Connections Power Supply Idie Speed Contact Full Load Contact Engine Temperature Sensor Air Flow Sensor Idle Speed Control Activation Oxygen Regulation Stop Oxygen Sensor Intake Air Temperature Sensor Knock Sensor
99. ts one after the other until there is gt 8 V Replace fault eausing control unit Tester faulty Power supply lacking on diagnostics socket Ground supply lacking on diagnostics socket Information for idle speed and idle speed CO test a Idle speed 944 S engines have adaptive idle speed volumetric efficiency regulation since 1987 models This means that the idle speed of all versions does not have to be adjusted The system of cars with adaptive idle speed volumetric efficiency regulation should be adapted each time the DME control unit had been disconnected on permanent positive or after each inspection Idle speed control value for engine at operating temperature 840 40 rpm b Idle speed CO of cars without catalytic converter CO level is still adjusted on the CO adjusting screw in the air flow sensor Requirements Engine at operating temperature Engine and ignition in perfect running condition All electric consumers switched off CO tester at operating temperature calibrated and adjusted correctly D 24 28 29 24 28 Fuel System Electronic Control Adjusting value 0 5 1 5 CO at 840 40 rom and ignition timing of 10 3 before TDC Adapt the system after adjusting the CO level An adapter plug 911 612 422 8 must be con nected on the oxygen sensor connecting lead of cars without a catalytic converter in order to avoid diffusion see wiring diagram c
100. tween terminals 1 and 2 of the throttle valve switch with help of test leads Display Throttle valve closed lt 10 Throttle valve opened to gap of 1 fl Idle speed Testing same as described for ground short contact 41 fault stored in memory as of 1991 models Break Fault Code 1_15 Check for correct adjustment correcting if necessary Cause for example could be an incorrectly adjusted throttle valve switch or accelerator cable D 24 28 10 DME Diagnosing Troubleshooting Printed In Germany XXI 1989 944 S 944 52 Fault Fault Code Test Point 3 Full load contact Ground short Fault Code 1_13 Fuel System Electronic Control 24 28 Possible Causes Elimination Remarks Check via circuit input test with a 9288 System Tester or 9268 Tester Select test step and operate accelerator pedal 9288 Display Full load contact broken Full load contact made 9268 Display 1333 tull load contact broken 0000 full load contact made No Display Connect ohmmeter on terminal 53 and terminal 24 of the disconnected DME control unit plug with help of test leads Display Throttle valve closed w Throttle valve opened about 2 3rd of full gap lt 10 1 If the value of the full load contact is not reached in this test the test should be repeated direct on the throttle valve switch as described below Pull off plug on throttle valve switch Connect ohmmeter between terminal 3 and terminal 2 of
101. ul that sealing ball does not fall out when capped nut is removed 2 Connect pressure gage with hose from pressure tester P 378 or VW 1318 to test connection 3 Disconnect DME relay from central electrics and jumper terminals 30 and 87 b with a length of electric wire Fuel pump must now run 24 104 Checking Fuel Pressure 944 ae NE gest dk porsche 44 Sse EEE ee u u T A Control value Engine stopped 3 8 0 2 bar DME relay jumpered Engine idling approx 3 3 bar 5 Tightening torque of capped nut 22 Nm 16 ftlb _ Ete Printed in Germany 944 Air Flow Controlled Fuel Injection Checking idle speed and CO with catalytic converter Model 87 onward Engine type M 44 40 41 3 0 Note lt is no longer possible to adjust idle speed or CO on vehicles with catalytic converters The Lambda probe remains connected while chekking idle soeed and CO Checking preconditions Engine in perfect mechanical condition Con sumers must be switched off during checks Carry out checks as quickly as possible to ensure that the intake paths do not heat up thus falsifying the CO value Ambient temperature 15 35 C 1 Fit standard exhaust adapter to the test connector of the catalytic converter Engine type M 44 40 86 463 Checking idle speed and CO with catalytic converter Printed in Germany XIX 1989 24 Engine type M 44 41 3 0 I 173 24 2 Warm engine up
102. ve lower transaxle bell housing mounting bolts Printed in Germany 944 34 Pull engine forward push rubber sleeve out of firewall toward engine compartment and carefully pull wire harness out of passenger side footwell 35 Separate engine from central tube central shaft and lower from car Installing Note the following 1 Carefully feed wire harness for DME control unit 8 pin connector and multi pin connector into passenger side footwell 2 Begin by screwing transaxle bell housing mounting bolts into place but do not tighten Note Do not tighten mounting bolts fully until hydraulic motor bearing has been attached to the front axle cross member Tightening torque of mounting bolts 42 Nm 31 ftlb 3 Install control arms pressing sleeve in rubber metal bearing down slightly to facilitate installation Printed in Germany XIII 1987 Removing and Installing Engine Engine Crankcase www 9ss1 dk porsche944 igs BT 4 Place a 4mm thick steel washer in each of the threaded connections between the right hand engine support viewed in the forward direction of travel and the hydraulic motor bearing 5 Check that the radiator is correctly seated on the rubber mounts 6 Tighten nuts and bolts to the specified torques Tightening torques Stablizer to 25 Nm 18 ftlb aluminium control arm Track rod to 50 Nm 37 ftlb steering knuckle locknut Steering 30 5 Nm 22 universal j

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