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Workshop Manuel
Volume IA - Engine, 16 valves
DR. ING. h. c. F. PORSCHE Aktiengesellschaft
As webpage by http://www.9ss1.dk/porsche944
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944 Table of contents volume I-A Page General 0.9 Technical data Maintenance, Self-diagnosis Fault diagnosis, DEE control unit 03 - 1 Connecting into the vehicle - 944S 03 - 3 Starting fault diagnosis 03 - 5 Functional test - actuator and input signal 03 - 7 List of test codes 03 - 13 System adaptation 03 - 15 Knock detection 03 - 17 Troubleshooting 03 - 19 List of fault codes 03 - 29 Clearing fault memory 03 - 31 Operating conditions for start
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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 filte
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944 General TYPE 944 S (16-VALVE ENGINES) - '87 MODELS ONWARD Printed in Germany - XIII, 1987 Technical Data 0.9
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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 M 44/40 Number of cylinders 4 Bore mm/in. 100/3.94 Stroke mm/in. 78.9/3.11 3 Displacement (actual) cc/in. 2479/151 Compression ratio 10.9 : 1 Max. engine output to kW/PS 140/190 - 135/184 Australia 80/1269/EC Net power, SAE J 1349 kW/HP 140/188
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944 General Crankcase Two-part light alloy crankcase Crankshaft Forged, 5 bearings Crankshaft bearings Plain Connecting rods Cast, opt. sinter-forged Connecting rod-bearings Plain Pistons Light alloy, cast Balance shafts Forged Balance-shaft bearings Plain bearings with bearing shells Cylinders Light alloy Cylinder head Light alloy Valve guide Press-fit, special brass Valve arrangement 2 intake, 2 exhaust overhead V Valve timing Two overhe
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General 944 ENGINE COOLING Sealed cooling system, electric fan with thermoswitch, antifreeze effective to - 25°C ENGINE LUBRICATION Lubrication 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 Oil pressure n = 5000 rpm Approx. 4 bar, at operating temperature Oil-pressure indicator Pilot lamp and pressure gage Max. oil temperature 140°C
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944 General FUEL SYSTEM Injection DME Digital Motor Electronics Fuel delivery 1 electric fuel pump Standard: 95/85 - European standard Fuel octane rating RON/MON premium unleaded possible Opt./M298: 95/85 unleaded - European standard premium - Australia: 91/82 unleaded Fuel consumption Standard: to 80/1268/EC or ECE R 15/04 Constant 90 km/h l/100 km 6.7 Constant 120 km/h l/100 km 8.3 EC exhaust urban cycle l/100 km 1
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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 mm/in. 4230/165.354 (4290/168.90) Length with opt. mm/in. 4290/168.90 extra US bumpers Width mm/in. 1735/68.31 Height mm/in. 1275/50.20 Wheel base (in mm/in. 2400/94.49 design pos.)
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944 General WEIGHTS - to DIN 700 20 - Curb weight Standard Sports package Australia, standard Front kg/lbs 640/1411 630/1389 640/1411 (650/1433) Rear kg/lbs 640/1411 610/1345 640/1411 (650/1433) (630/1389) Total kg/lbs 1280/2822 1240/2734 1280/2822 (1260/2778) Per. axle load Front kg/lbs 730/1609 730/1609 730/1609 (720/1587) Rear kg/lbs 900/1984 900/1984 920/2028 Per. total kg/lbs 1600/3527 1600/3527 1620/3571
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General 944 CAPACITIES Engine (measurement with dipstick Proprietary HD oils to APl as per Driver's Manual is definitive) classification SE or SF, see Driver's Manual Engine oil Approx. 6.0 l Engine coolant Approx. 8.5 l Transmission with differential Approx. 2.0 l hypoid oil, SAE 80 to MIL-L 2105, APl classification GL 4 Fuel tank Approx. 80 l, including approx. 8 l reserve Brake-fluid reservoir Approx. 0.2 l Windshield and headlight washing Approx.
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944 General Technical data - Type 944 52 - Model 89 (Values for adjustment and wear are to be found in the respective repair groups) Notes: USA values are given in brackets Drive unit Internal engine designation Manual transmission M 44.41 (3.0 I) Bore mm (in.) 104 (4.09) Stroke mm (in.) 88 (3.46) 3 3 Displacement (actual) cm (in. ) 2990 (182.5) 3 Displacement (rounded down) cm 2969 Compression ratio 10.9: 1 Max. engine power 88/195/EEC kW (HP) 155
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03 944 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
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03 Maintenance, Self-diagnosis 944 Display LED off Test sequence terminated / igniti Flashing LED Error code / test code LED on Ignition on 03 - 2 DME control unit error diagnosis Printed in Germany - XVI, 1987
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03 944 Maintenance, Self-diagnosis Diagnosis socket in the car Connection in the 944 S Pin 1 = terminal 15 In the 944 S, the diagnosis socket is Pin 2 = terminal 31 attached to a separate cable harness located above Pin 5 = terminal 30 the DME control unit. Pin 9 = Hall generator 87/1012 87/908 Ignition off After connecting the tester, the following dis- play must appear. Display: If this is not the case, check the tester ter-
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03 Maintenance, Self-diagnosis 944 Switch on the ignition Tester cable Display: Diagnosis plug Round plug Pin 1 Pin 4 Pin 2 Pin 1 Pin 3 Pin 7 Pin 4 Pin 6 The ignition must not be switched off Pin 5 Pin 2 during the entire error diagnosis procedure. Pin 6 unused Pin 7 unused Pin 8 unused Pin 9 unused Pin 10 unused Pin 11 Pin 5 Pin 12 Pin 3 34 03 - 4 Connection i
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03 944 Maintenance, Self-diagnosis If an error is displayed - take the note of the Starting error diagnosis error (e.g. 1211). Display: Condition: Engine off Ignition on 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 Press the green key until the clear symbol the display. appears on the function display.
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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). 03 - 6 Starting error diagnosis Printed in Germany - XVI, 1987
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03 944 Maintenance, Self-diagnosis Actuator and input signal function Starting actuator and input signal checking function check An actuator and input signal function check Ignition off can be carried out independently of an error diagnosis. This function check tests Press the yellow key until the function symbol individual (see display) appears on the function display. components or electrical signals with respect Display: to their functioning or signal paths. Func
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03 Maintenance, Self-diagnosis 944 Press the green key until the ctear symbol The next testing step is initiated by again pressing the green key. ap- pears on the function display. This activates the first testing step and the injection valves Refer to the test code list for the sequence are activated. of testing steps. Display: The injection valves must all operate audibly or tangibly. Note: If later attempts are made to start the engine, starting diffi
