Porsche 944 1982 to 1991 - Service Manual - Wiring Diagram - Parts Catalogue

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PORSCHE 944 WORKSHOP MANUAL (1982-1991)

- English Service Manual, Wiring Diagram and Spare Parts Catalogue to vehicles Porsche 944 1982 to 1991.

CONTENTS:

WORKSHOP MANUAL   (2041 pages)

01-ENGINE
REPAIR GROUPS
Engine
Table of Contents
General
Technical Data
Engine Crankcase
Tolerances & Wear Limits
Tightening Torques
Engine Removing/Installing (man)
Hydraulic Engine Mounts
Engine, Crankcase,Pistons
Balance Shaft Adjustment
Belt Tension Adjustment Procedures
Toothed Belt Tension Compensating Shaft
Toothed Belt- Roller with Slot
Belt Tension Tool Calibration
Polyrib Belt Adjustment
Power Steering Belt Adjustment
Installing Toothed Belt Comp Shaft
Identification of Engine Number
Sealing Crankcase Upper/Lower Sections
Identification Codes U/L Crankcase Sections
Crankshaft assembly/dissassembly
Checking Crankshaft Bearing Clearance
Installing U/L Crankcase Sections
Installing Crankshaft Oil Seal
Flywheel Removing and Installing
Replacing Stud Reference Mark Sensor
Setting Crankshaft to TDC Cyl 1
Resurfacing the Flywheel
Checking Piston & Cylinder Bores
Pistons Dissassembly/Conn Rods
Installing Pistons With Connecting Rods
Pistons Model '89 Forward
Dissassembly/Assembly Compensating Shaft Drive
Dissambly/assembly Balance Shaft Drive
Installing Bearing Bridges of Compensating Shafts
Installing Drive Gears of Balance Shafts
Machining Cylinder Bores
Engine Support
Engine Cylinder Head, Valve Drive
Camshaft Belt Tension Check/Adjust
Install Camshaft Belt & Adjust Timing
Cylinder Head Removing and Installing
Tightening Specifications
Valve Drive Assembly/Dissasembly
Machining mating Face Cylinder Head
Replacing Valve Guides
Dissasembly/Assembly Valve Drive (camshaft housing)
Camshaft Drive Assembly/Dissassembly
Adjusting Camshaft Belt with Belt Tensioner
Engine Lubrication
Replacing Engine Oil & Filter
Parts of Lubrication System Remove/Install
Dissembly/Assembly of Oil Pump
Sleeve for Oil Pressurre Relief Valve
Tightening Specifications for Oil Pump Fastening Screws
Checking Oil Pressure
Oil Check Valve Removing/Installation
Cleaning Engine Oil System
Cleaning Main Oil Duct
Removing & Installing Pressure Reducing Valve
Engine Cooling
Checking Thermostat
Parts of Cooling System removing & Installing
Radiator Installation/Removal
Temerature Switch Removal/Installation
Cleaning Cooling System after Oil Contamination
Replacing Coolant & Bleeding System
Fuel Supply
Replacing Fuel Filter
Checking Injection Lines
Checking Fuel Pump Delivery Rate
Fuel Pump Removal/Installation
Fuel Tank Removal/Installation
Fuel system Line Routing
Active Carbon Tank (layout)
Fuel Expansion Tank Removal/Installation
Checking Fuel Expansion Tank
Fuel Level Sensor Removal/Installation
Fuel Level Sender Removal/Installation
L-Jetronic Fuel Injection
Repacing Air Filter Cartidge
Checking Airguide & Crankcase Vent Hoses
Testing & Adjusting Specifications
Checking Fuel Pressure
Idle Adjustment
Correcting CO Setting on Airflow Sensor
Fuel Injectors Removal/Installation
Air Flow Sensor Removal/Installation
Adjusting Idle Speed (late)
Testing & Adjusting Specifications
Adjusting Idle Speed & CO
Equipment table '89 Onward
Exhaust System
Checking Exhaust Flanges for Tightness
Repacing Exhaust Pipe/Catalytic covnverter/muffler
Starter, Power Supply, Cruise Control
Cruise Control -- Tempostat
Tempostat Removal/Installation
Tempostat Operating Switch Removal/Installation
Actuator Removal/Installation
Tempostat Bowden Cable Removal/Installation
Clutch Switch Removal/Installation
Troubleshooting Cruise Control
Checking mult-pin connector Control Unit
Tempostat (late)
Tempostat (late) Removal/Installation
Actuator (late) Removal/Installation
Clutch Switch (late) Removal/Installation
Troubleshooting Cruise Control (late)
Connector Assignment Tempostat
Checking Multi-Pin Plugs (late)
Alternator Removal/Installation
Ignition System
Equipment Table
Accident Hazards
Distributor Cap Removal/Installation
Spark Plugs Removal/Installation
DEE
Speed /Reference Mark Sensors Removal/Installation
Troubleshooting DEE
Testing Lambda Sensor
DEE Removal/Installation
DME Control Unit Codings
Equipment Table
01A-ENGINE 16 VALVE
ENGINE 16 VALVE
Table of Contents
General
Technical Data
Maintenance/Self Diagnosis
DME Control Unit
Connection into Vehicle 944 S
Starting Fault Diagnosis
Actuator Input Signal Functional Test
List of Test Codes
System Adaptation
Knock Detection
Troubleshooting
List of Fault Codes
Clearing Fault Memory
Operating Conditions fo Start of Diagnosis
Operating Instructions For System Tester
Engine Crankcase
Tightening Torques
Tolerance & Wear Limits
Engine Removal/Installion
Engine, Crankshaft, Drive, Pistons
Pistons '87 onward
Checking Pistons & Cylinder Bores
Pistons from Model '89 Onward
Installing Cover for Oil Centrifuge Partition
Engine Cylinder Head, Valve Drive
Camshaft Setting Checking, and Adjusting
Camshaft Setting Checking, and Adjusting '89 Onward
Applying TDC Mark on Camshaft Sprocket
Camshaft/Cylinder Head Removal/Installation
Cylinder Head Installation/Tightening
Installing Camshafts
Camshaft Seal Installation
Camshaft Specifications
Chain Tensioner Removal/Installation
Cylinder Head Assembly/Disassembly
Cylinder Head Valve Springs Removal/Installation
Remachining Cylinder Head Mating Face
Valve Springs Removal/Installation
Valve Stem Seal Removing
Valve Stem Seal Installation
Valve Guides Checking
Valve Guides Replacing
Valve Seats Checking/Machining
Valve Springs Checking & Adjusting Length
Engine Lubrication
Changing Engine Oil & Filter
Pressure Reducing Valve Removal/Installation
Engine Cooling
Mixing Table for Coolant
Fuel Supply
Replacing Fuel Filter
Fuel & Injection Lines Checking
Checking Fuel Delivery Rate
Line Routing Fuel System
L-Jetronic
Air Filter Cartridge Replacement
Intake Air Guide Hoses Checking
Testing & Adjusting Specifications
Checking Fuel Pressure
Idle Speed & CO Checking w/Catalytic Converter
Idle Speed & CO Checking wo/Catalytic Converter
Air Filter Insert Replaceing post 88
Exhaust System
Exhaust Flanges Checking
Ignition System
Equipment Table
DME Control Unit Coding
Spark Plugs Replacement
Equipment Table post '88
DME Control Unit Coding post '88
DME Diagnosis/Troubleshooting
Test Points
Precautions
Vehicle Information
Equipment Required
DME Control Unit Diagnosis
Test Point 1A Power Supply
Test Point 2 Idle Speed Contact
Test Point 3 Full Load Contact
Test Point 4 Engine Temp Sensor
Test Point 5A /B Air Flow Sensor
Test Point 6 Idle Speed Control
Test Point 7 Oxygen Regulation
Test Point 8 Oxygen Sensor
Test Point 9 Air Temp Sensor
Test Point 10/11 Knock Sensor
Test Point 12 Control Unit
Test Point 13 Hall Signal
Test Point 14 Control Unit Faulty
Test Point 15 DME Relay
Test Point 16 Tank Venting Valve
Test Point 17 Check Enginine Warning Lamp
Test Point 18 Fuel Pressure
Test Point 19 Intake System Leaks
Test Point 20 Ground Connections
Test Point 21 Speed Reference Mark Sensor
Test Point 22 Ignition
Test Point 23 Fuel Injectors
Test Point 24 Alternator Regulator
Test Point 25 Leads K & L
Coding of Control Unit
Check Engine Lamp
02-TRANSMISSION
TRANSMISSION
Table of Contents
General
Technical Data (Type 16J/K)
Technical Data (Type 16J/K late)
Techical Data (Type 16J/K & 083D)
Technical Data (Type083F)
Tightening Torques (Type 16J/K)
Technical Data Clutch
Clutch, Control
Checking Clutch Drive Plate
Checking Clutch Play
Checking Release Travel
Bleeding Clutch
Clutch Removal/Installation
Clutch Control Disassembly/Assembly
Clutch Drive Disk Checking
Pressure Plate Checking
Overhauling Slave Cylinder
Automatic Clutch - Torque Converter
Converter (type 087M/N) Checking
Converter (type 087M/N) Draining
Converter (type 087M/N) Installing
Manual Transmission, Control Housing
Gearbox (Type 16J/K) Removing/Installing
Gearbox (Type 16J/K) Removing/Installing (late)
Adjusting Shift
Changing Oil/Checking Level
Transferbox (Type 16J/K) Removing/Installing
Transfer box (Type 16J/K) Dissassembly/Assembly
Rear Cover (Type 16J/K) Dissassembly/Assembly
End Plate (Type 16J/K) Disassembly/Assembly
Transmission Case (Type 16J/K) Disassembly/Assembly
Manual Transmission Gears, shafts
Input Shaft (Type 16J/K) Dissassembly/Assembly
Output Shaft (Type 16J/K) Dissassembly/Assembly
Pinion Shaft (Type 16J/K) Dissassembly/Assembly
Synchronizer Ring Checking
Automatic Transmission
Transmission Identification
Technical Data
Position of Shift Elements
Planetary Gears With Shift Parts
Torque Specifications
Selector Lever Removing/Installation
Throttle & Control Pressure Cable Removal/Installation
Throttle & Pressure Control Cable - Adjusting
Functional Test
Troubleshooting Table
Transmission Removal/Installation
Automatic Transmission Gears, Regulation
Replacing ATF Fluid
Flushing ATF Cooler & Line System
Planetary Gear to Final Drive Disconnecting/Connecting
Turbine Shaft Seal Removing & Installing
Axial Play Planetary Gear/Final Drive Adjusting
Planetary Gear Assembly/Dissassembly
Ring Gear Assembly/Dissasembly
Overrunning Clutch Assembly/Dissassembly
Freewheel with Plastic Cage Assembly/Dissassembly
Forward Clutch Assembly/Dissassembly
Direct & Reverse Clutch Assembly/Dissassembly
Oil Pump Assembly/Dissassembly
Valve Body Assembly/Dissassembly
Transfer and Intermediate Plates Assembly/Dissassembly
Valve Body Assembly/Dissassembly
2nd Gear Brake Assembly/Dissassembly
Governer Assembly/Dissassembly
Parking Lock Assembly/Dissassembly
Differential
Differential Removal/Installation
Differential Assembly/Dissassembly
Pinion & Ring Gear Adjustment
Checking Final Drive Oil Level
Central Tube Torque Specifications
Checking Oil Level in Final Drive
Final Drive Assembly/Dissassembly
Differential Assembly/Dissassembly
Limited Slip Differential Assembly/Dissassembly
Adjusting Drive Set
Removing & Installing Central Tube
Central Tube Assembly/Dissassembly
Central Tube Checking
Adjusting Dampers
03-CHASSIS
CHASSIS, BODY
Table of Contents
Front Wheel Suspension
Technical Data
Tightening Torques
Aluminium Control Arms modifications
Notes on Front Axle (late)
Running Gear Tuning
Adjusting Front Wheel Bearings
Ball Joint Caps Checking
Wheel Bearings Assembly/Disassembly
Koni Shock Absorbers Replacing
Koni Shock Absorbers Adjusting
Coil Springs
Rear Wheel Suspension Axle Shafts
Technical Data
Tightening Torques
Running Gear Tuning of 944 S2
Trailing Arms Assembly/Disassembly
Aluminium Trailing Arms Assembly/Disassembly
Koni Shock Absorbers 944S/944S2
Koni Shock Absorbers Adjusting
Wheel, Tires, Alignment
Wheels & Tires
Sample Measuring Chart to '89
Sample Measuring Chart post '89
Wheel Alignment Values 924S/944/944S/944S2
Wheel Alignment checking
Aluminum Wheels Removal/Installation
Anti-Lock Braking System
General
ABS Layout
Position of ABS Components
Circuit Diagram
Troubleshooting & Test Program Notes
Working on Cars with ABS Notes
Hydraulic Unit Removal/Installation
Electronic Control Unit Removal/Installation
Relays Removal/Installation
Speed Sensors Removal/Installation
Brakes Mechanical
Technical Data
Torque Specifications
Brake Booster Notes (late)
4 piston Caliper Notes
Brake Pads checking
Brake Pads Removal/Installation
Brake Pad 4-Piston Caliper Removal/Installation
Brake Pushrod Adjustment
Parking Brake Checking/Adjustment
Front Wheel Brake Assembly/Disassembly
Rear Wheel Brakes Assembly/Disassembly
Brake Disc Lateral Runout Check
Brake Thickness Check
Brakes, Hydraulic System, Regulators, Boosters
Tightening Torques
Brake Booster Notes
4 piston Fixed Caliper Notes
Brake Caliper Assembly/Disassembly
Brake Booster Removal/Installation
Brake Master Cylinder
Bleeding & Replacing Brake System Fluid
Steering
Technical Data
Torque Specifications
Manual Steering Gear Removal/Installation
Power Steering Gear Removal/Installation
Power Steering Pump Removal/Installation
Rack & Pinion Checking & Servicing
Power Steering Checking Hydraulic Operation
Steering Wheel Removal/Installation
Steering Shaft With Protective Tube Removal/Installation (late)
Body - General
Safety Notes
Celette Alignmnet Bench
Repair Control Dimensions
Floor Assembly Dimensions
Body Front Section
Side Members
Lock Carrier Guage
Front Axle Take Up Attachment
Adapter for Cross Member & Stabilizer Pick Up
Front End Panel Removal/Installation
Bodywork Rear
Rear End Panel Removal/Installation (cabrio)
Rear Side Panel Removal/Installation(cabrio)
Reworking Inner Side Panel
Engine Hood, Tailgate
Tailgate Electric Unlocking Cable
Tailgate Lock Microswitch Removal/Installation
Engine Hood Removal/Installation
Engine Hood Cable Removal/Installation
Doors
Inside Door Handle Removal/Installation
Door Panel Removal/Installation
Window Guide Rail Removal/Installation
Outside Door Handle Removal/Installation
Door Lock/Inner Actuator Removal/Installation
Central Locking System
Central Locking System Button Removal/Installation
Central Locking Control Unit Removal/Installation
Door Lock Cylinder Microswitch Removal/Installation
Central Locking System Function Table
Central Locking System Troubleshooting
Hardtop
Working on Power Sunroof
Troubleshooting Sunroof
Sunroof Early (pre '86)
Lifting Roof Conversion
Electric Sunroof Drive/Assembly Removal/Installation
Lifting Sunroof Adjustment
Replacing Drive Dog
Power Sunroof Control Checking
Sunroof Microswitch in Roof opening Removal/Installation
Slip Clutch on Roof Motor Adjusting
Sunroofs Post '85
Lifting Sunroof Removal/Installation
Lifting Sunroof Adjustment
Elevation Cable & Segments Removal/Installation
Gear in Element Guide Removal/Installation
Testing Control in Lifting Sunroof
Power Supply for Lifting Sunroof
Microswitch in Sunroof Removal/Installation
Microswitch in Electric Drive Adjusting
Microswitch Connections
Slip Clutch
Folding Top Removal/Installation
Bumpers
Spoiler & Bumper Removal/Installation
Rear Bumper Assembly/Disassembly
Windshield
Windshield Removal/Installation
Windshield (Securiflex) Removal/Installation
2 Pack Adhesive
Interior Rear View Mirror Bonding
Exterior Equipment
Porsche Emblem Removal/Installation
Stone Guard Foil Removal/Installation
Side Mouldings Removal/Installation
Roof Ornamantal Strip Removal/Installation
Paint Colors
Outside Mirror Removal/Installation (late)
Fastening T-Bolt to Roof Flange
Plastic End & Side Applications Removal/Installation
Tank Flap (cabrio) Removal/Installation
Retrofitting New Mirror for Models as of 85/2
Interior Equipment
Center Console Removal/Installation (late)
Instrument Panel Removal/Installation
Airbag
Safety Regulations
Drivers Airbag Removal/Installation
Steering Wheel Airbag Removal/Installation
Contact Unit Removal/Installation
Front Sensor Removal/Installation
Front Passenger Airbag Removal/Installation
Control Unit Removal/Installation
Diagnosis
Checking Airbag System Operation
Safety Belts Removal/Installation
Safety Belts Inspection
Airbag Unit Disposal
Horn Buttons on Airbag Unit Repair
Diagnosis/Troubleshooting
Seats
Front Seats Removal/Installation
Seat Heating Removal/Installation
Backrest Heating Element Removal/Installation
Seat Frame
Backrest
Controllable Seat Heating Calibration
Heating
Heating (late)
Fresh Air Blower Removal/Installation
Air Conditioning System
Air Conditioner Model '85 Onward
Air Conditioner Technical Data
Location of Components
Safety Regulations for Handling R-12
Assembly work Involving Cooling System
Using Service Equipment
Service Unit
Initial Operation
Filling Service Unit
Connecting to Air Conditioner
Evacuating Air Conditioner
Flushing Air Conditioner
Re-Filling Air Conditioner
Heating -A/C Unit Assembly/Disassembly
Positioning of Flaps Airflow
Heating -A/C Unit Removal/Installation
Compressor Removal/Installation
Condensor Removal/Installation
Interior Sensor Blower Removal/Installation
Expansion Valve Removal/Installation
Defrost Flap Motor Removal/Installation
Temperature Mixture Motor Removal/Installation
Footwell Flaps Motor
Troubleshooting
Magnetic Coupling, Shaft Seal Removal/Installation
04-ELECTRICAL
ELECTRICAL PART I
Table of Contents
Instruments, Consumption Indicators, Burgler Alarm
Upshift Indicator/Economy Control
Troubleshooting Fuel Indicator
Troubleshooting Upshift Indicator
Relay Arrangement post '83
Fuses on Central electric System post '83
Fuses in Aux Fuse box post '83
Instrument Cluster (late)
Instrument Cluster Removal/Installation
Speedometer Transmitter Removal/Installation
Instruments Checking
Burgler Alarm Checking
Aux Control Unit Burgler Alarm Checking
Radio, Telephone, On Board Computer
Radio Removal/Installation
Telephone Removal/Installation
CD Player Retrofit post '88

AND MORE.....