Porsche 944 Instruction manual

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 volume I-A

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

Page

0.9

03 - 1

03 - 3

03 - 5

03 - 7

03 - 13

03 - 15

03 - 17

03 - 19

03 - 29

03 - 31

03 - 32

03 - 33

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 - 112 a

15 - 112 b

15 - 113

15 - 115

15 - 118

Table of contents

Printed in Germany - XXIV, 1991

volume I-A Table of contents 944

Machining mating face, cylinder head

Vaive springs, removing and installing, removing valve stem seal

Valve stem seal, installing

Checking valve guides

Replacing valve guides

Checking valve seat wear limit

Valve seats, checking and machining

Checking and adjusting installation length of valve springs

Engine - Lubrication

Replacing engine oil and oil filter

Pressure-reduclng valve, removing and installing

Engine - Coating

Checking cooling and heating system for leaks

Fuel supply

Replacing fuel filter, checking injection lines for leaks and tightness

Checking delivery rate of fuel pump

Line routing, fuelsystem, M 44.40

Fuel preparation - L-Jetronic/regulation

Replacing air filter cartridge, checking intake-air guide hoses

Testing and adjusting specifications

Checking fuel pressure

Checking idle speed and CO - with catalytic convertor

Checking idle speed and CO - without catalytic convertor

Replacing air filter cartridge for Model 89 onward

Exhaust system

Exhaust system - check tightness of flanges

Ignition system

Equipment table

DEE control unit coding - 944 S, Model 87 onward

Replacing spark plugs

Equipment table, Model 89 onward

DEE control unit coding - 944 S 2, Model 89 onward

DME-Diagnosing / Troubleshooting

Page

15 - 120

15 - 121

15 - 122

15 - 123

15 - 125

15 - 130

15 - 131

15 - 133

17 - 101

17 - 102

19 - 101

20 - 101

20 - 102

20 - 103

24 - 101

24 - 102

24 - 103

24 - 105

24 - 106

24 - 107

26 - 101

28 - 101

28 - 103

28 - 104

28 - 105

28 - 107

D-24/28-1

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 944

TECHNICAL DATA

(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

Stroke

Displacement (actual)

Compression ratio

Max. engine output to

80/1269/EC

Net power, SAE J 1349

at engine speed

Max. torque to

80/1269/EC

at engine speed

Net torque, SAE J 1349

Max. spec. power output

Net power, SAE J 1349

Fuel octane rating

Max. perm. engine speed

Engine weight (dry)

ENGINE DESIGN

Type

mm/in.

cc/in.

kW/PS

kW/HP

rpm

Nm/kpm

rpm

Nm/lbft

kW l/HP l

kW l/HPI

RON/MON

rpm

kg/lbs

M 44/40

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

56.5/76.6-54.5/74.2 Australia

56.5/75.8

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

0.10 Technical Data Printed in Germany

944 General

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

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

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)

Timing Intake opens

Intake closes

Exhaust opens

Exhaust closes

4°after TDC

40°after BDC

36°before BDC

4°before TDC

Printed in Germany - XIII, 1987 Technical Data 0.11

General 944

ENGINE COOLING

ENGINE LUBRICATION

Lubrication

Oil pressure

Oil-pressure indicator

Max. oil temperature

Oil consumption

EXHAUST SYSTEM

EMISSION CONTROL

HEATING

n = 5000 rpm

l/1000 km

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 lamp 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

0.12 Technical Data Printed in Germany

944 General

FUEL SYSTEM

Injection

Fuel delivery

Fuel octane rating

Fuel consumption

to 80/1268/EC or

ECE R 15/04

Constant 90 km/h

Constant 120 km/h

EC exhaust urban

cycle

ELECTRICAL SYSTEM

Suppression

Battery voltage

Battery capacity

Alternator (output)

Ignition

Firing sequence

Ignition timing

RON/MON

l/100 km

A/W

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

50 - optional 63,

sports package 36

115/1610

- sports package: 90/1260

By DME

1-3-4-2

By DME

Printed in Germany - XIII, 1987 Technical Data 0.13

General 944

BODY DESIGNS

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.

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

mm/in.

4230/165.354

4290/168.90

1735/68.31

1275/50.20

2400/94.49

1477/58.2

1451/57.1

1442

120/4.72

53/2.09

14°

15°

(4290/168.90)

Rim size

7 J x 15

7 J x 16

8 J x 16

7 J x 15

7 J x 16

8 J x 16

9 J x 16

0.14 Technical Data Printed in Germany

944 General

WEIGHTS - to DIN 700 20 -

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

Standard

640/1411

(650/1433)

640/1411

(650/1433)

1280/2822

730/1609

900/1984

1600/3527

1200/2646

1200

500/1102

500

2760/6085

2760

50/110

35/77

75/165

Sports package

630/1389

610/1345

(630/1389)

1240/2734

(1260/2778)

730/1609

(720/1587)

900/1984

1600/3527

(1550/3417)

up to 16% gradient

for Italy

up to 16% gradient

for Italy

up to 100 km/h

Australia,

standard

640/1411

1280/2822

730/1609

920/2028

1620/3571

Printed in Germany - XIII, 1987 Technical Data 0.15

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