Porsche 944 (1982-1991) - Workshop Manual - Wiring Schematics - Parts Manual

PORSCHE 944 WORKSHOP MANUAL (1982-1991)

- English Workshop Manual, Wiring Schematics and Spare Parts Catalogue to vehicles Porsche 944 (1982-1991).

INDEX:

WORKSHOP MANUAL   (2041 pages)

01-ENGINE
REPAIR GROUPS
Engine
Table of Contents
General
Technical Data
Engine Crankcase
Tolerances & Wear Limits
Tightening Torques
Engine Removing/Installing (man)
Hydraulic Engine Mounts
Engine, Crankcase,Pistons
Balance Shaft Adjustment
Belt Tension Adjustment Procedures
Toothed Belt Tension Compensating Shaft
Toothed Belt- Roller with Slot
Belt Tension Tool Calibration
Polyrib Belt Adjustment
Power Steering Belt Adjustment
Installing Toothed Belt Comp Shaft
Identification of Engine Number
Sealing Crankcase Upper/Lower Sections
Identification Codes U/L Crankcase Sections
Crankshaft assembly/dissassembly
Checking Crankshaft Bearing Clearance
Installing U/L Crankcase Sections
Installing Crankshaft Oil Seal
Flywheel Removing and Installing
Replacing Stud Reference Mark Sensor
Setting Crankshaft to TDC Cyl 1
Resurfacing the Flywheel
Checking Piston & Cylinder Bores
Pistons Dissassembly/Conn Rods
Installing Pistons With Connecting Rods
Pistons Model '89 Forward
Dissassembly/Assembly Compensating Shaft Drive
Dissambly/assembly Balance Shaft Drive
Installing Bearing Bridges of Compensating Shafts
Installing Drive Gears of Balance Shafts
Machining Cylinder Bores
Engine Support
Engine Cylinder Head, Valve Drive
Camshaft Belt Tension Check/Adjust
Install Camshaft Belt & Adjust Timing
Cylinder Head Removing and Installing
Tightening Specifications
Valve Drive Assembly/Dissasembly
Machining mating Face Cylinder Head
Replacing Valve Guides
Dissasembly/Assembly Valve Drive (camshaft housing)
Camshaft Drive Assembly/Dissassembly
Adjusting Camshaft Belt with Belt Tensioner
Engine Lubrication
Replacing Engine Oil & Filter
Parts of Lubrication System Remove/Install
Dissembly/Assembly of Oil Pump
Sleeve for Oil Pressurre Relief Valve
Tightening Specifications for Oil Pump Fastening Screws
Checking Oil Pressure
Oil Check Valve Removing/Installation
Cleaning Engine Oil System
Cleaning Main Oil Duct
Removing & Installing Pressure Reducing Valve
Engine Cooling
Checking Thermostat
Parts of Cooling System removing & Installing
Radiator Installation/Removal
Temerature Switch Removal/Installation
Cleaning Cooling System after Oil Contamination
Replacing Coolant & Bleeding System
Fuel Supply
Replacing Fuel Filter
Checking Injection Lines
Checking Fuel Pump Delivery Rate
Fuel Pump Removal/Installation
Fuel Tank Removal/Installation
Fuel system Line Routing
Active Carbon Tank (layout)
Fuel Expansion Tank Removal/Installation
Checking Fuel Expansion Tank
Fuel Level Sensor Removal/Installation
Fuel Level Sender Removal/Installation
L-Jetronic Fuel Injection
Repacing Air Filter Cartidge
Checking Airguide & Crankcase Vent Hoses
Testing & Adjusting Specifications
Checking Fuel Pressure
Idle Adjustment
Correcting CO Setting on Airflow Sensor
Fuel Injectors Removal/Installation
Air Flow Sensor Removal/Installation
Adjusting Idle Speed (late)
Testing & Adjusting Specifications
Adjusting Idle Speed & CO
Equipment table '89 Onward
Exhaust System
Checking Exhaust Flanges for Tightness
Repacing Exhaust Pipe/Catalytic covnverter/muffler
Starter, Power Supply, Cruise Control
Cruise Control -- Tempostat
Tempostat Removal/Installation
Tempostat Operating Switch Removal/Installation
Actuator Removal/Installation
Tempostat Bowden Cable Removal/Installation
Clutch Switch Removal/Installation
Troubleshooting Cruise Control
Checking mult-pin connector Control Unit
Tempostat (late)
Tempostat (late) Removal/Installation
Actuator (late) Removal/Installation
Clutch Switch (late) Removal/Installation
Troubleshooting Cruise Control (late)
Connector Assignment Tempostat
Checking Multi-Pin Plugs (late)
Alternator Removal/Installation
Ignition System
Equipment Table
Accident Hazards
Distributor Cap Removal/Installation
Spark Plugs Removal/Installation
DEE
Speed /Reference Mark Sensors Removal/Installation
Troubleshooting DEE
Testing Lambda Sensor
DEE Removal/Installation
DME Control Unit Codings
Equipment Table
01A-ENGINE 16 VALVE
ENGINE 16 VALVE
Table of Contents
General
Technical Data
Maintenance/Self Diagnosis
DME Control Unit
Connection into Vehicle 944 S
Starting Fault Diagnosis
Actuator Input Signal Functional Test
List of Test Codes
System Adaptation
Knock Detection
Troubleshooting
List of Fault Codes
Clearing Fault Memory
Operating Conditions fo Start of Diagnosis
Operating Instructions For System Tester
Engine Crankcase
Tightening Torques
Tolerance & Wear Limits
Engine Removal/Installion
Engine, Crankshaft, Drive, Pistons
Pistons '87 onward
Checking Pistons & Cylinder Bores
Pistons from Model '89 Onward
Installing Cover for Oil Centrifuge Partition
Engine Cylinder Head, Valve Drive
Camshaft Setting Checking, and Adjusting
Camshaft Setting Checking, and Adjusting '89 Onward
Applying TDC Mark on Camshaft Sprocket
Camshaft/Cylinder Head Removal/Installation
Cylinder Head Installation/Tightening
Installing Camshafts
Camshaft Seal Installation
Camshaft Specifications
Chain Tensioner Removal/Installation
Cylinder Head Assembly/Disassembly
Cylinder Head Valve Springs Removal/Installation
Remachining Cylinder Head Mating Face
Valve Springs Removal/Installation
Valve Stem Seal Removing
Valve Stem Seal Installation
Valve Guides Checking
Valve Guides Replacing
Valve Seats Checking/Machining
Valve Springs Checking & Adjusting Length
Engine Lubrication
Changing Engine Oil & Filter
Pressure Reducing Valve Removal/Installation
Engine Cooling
Mixing Table for Coolant
Fuel Supply
Replacing Fuel Filter
Fuel & Injection Lines Checking
Checking Fuel Delivery Rate
Line Routing Fuel System
L-Jetronic
Air Filter Cartridge Replacement
Intake Air Guide Hoses Checking
Testing & Adjusting Specifications
Checking Fuel Pressure
Idle Speed & CO Checking w/Catalytic Converter
Idle Speed & CO Checking wo/Catalytic Converter
Air Filter Insert Replaceing post 88
Exhaust System
Exhaust Flanges Checking
Ignition System
Equipment Table
DME Control Unit Coding
Spark Plugs Replacement
Equipment Table post '88
DME Control Unit Coding post '88
DME Diagnosis/Troubleshooting
Test Points
Precautions
Vehicle Information
Equipment Required
DME Control Unit Diagnosis
Test Point 1A Power Supply
Test Point 2 Idle Speed Contact
Test Point 3 Full Load Contact
Test Point 4 Engine Temp Sensor
Test Point 5A /B Air Flow Sensor
Test Point 6 Idle Speed Control
Test Point 7 Oxygen Regulation
Test Point 8 Oxygen Sensor
Test Point 9 Air Temp Sensor
Test Point 10/11 Knock Sensor
Test Point 12 Control Unit
Test Point 13 Hall Signal
Test Point 14 Control Unit Faulty
Test Point 15 DME Relay
Test Point 16 Tank Venting Valve
Test Point 17 Check Enginine Warning Lamp
Test Point 18 Fuel Pressure
Test Point 19 Intake System Leaks
Test Point 20 Ground Connections
Test Point 21 Speed Reference Mark Sensor
Test Point 22 Ignition
Test Point 23 Fuel Injectors
Test Point 24 Alternator Regulator
Test Point 25 Leads K & L
Coding of Control Unit
Check Engine Lamp
02-TRANSMISSION
TRANSMISSION
Table of Contents
General
Technical Data (Type 16J/K)
Technical Data (Type 16J/K late)
Techical Data (Type 16J/K & 083D)
Technical Data (Type083F)
Tightening Torques (Type 16J/K)
Technical Data Clutch
Clutch, Control
Checking Clutch Drive Plate
Checking Clutch Play
Checking Release Travel
Bleeding Clutch
Clutch Removal/Installation
Clutch Control Disassembly/Assembly
Clutch Drive Disk Checking
Pressure Plate Checking
Overhauling Slave Cylinder
Automatic Clutch - Torque Converter
Converter (type 087M/N) Checking
Converter (type 087M/N) Draining
Converter (type 087M/N) Installing
Manual Transmission, Control Housing
Gearbox (Type 16J/K) Removing/Installing
Gearbox (Type 16J/K) Removing/Installing (late)
Adjusting Shift
Changing Oil/Checking Level
Transferbox (Type 16J/K) Removing/Installing
Transfer box (Type 16J/K) Dissassembly/Assembly
Rear Cover (Type 16J/K) Dissassembly/Assembly
End Plate (Type 16J/K) Disassembly/Assembly
Transmission Case (Type 16J/K) Disassembly/Assembly
Manual Transmission Gears, shafts
Input Shaft (Type 16J/K) Dissassembly/Assembly
Output Shaft (Type 16J/K) Dissassembly/Assembly
Pinion Shaft (Type 16J/K) Dissassembly/Assembly
Synchronizer Ring Checking
Automatic Transmission
Transmission Identification
Technical Data
Position of Shift Elements
Planetary Gears With Shift Parts
Torque Specifications
Selector Lever Removing/Installation
Throttle & Control Pressure Cable Removal/Installation
Throttle & Pressure Control Cable - Adjusting
Functional Test
Troubleshooting Table
Transmission Removal/Installation
Automatic Transmission Gears, Regulation
Replacing ATF Fluid
Flushing ATF Cooler & Line System
Planetary Gear to Final Drive Disconnecting/Connecting
Turbine Shaft Seal Removing & Installing
Axial Play Planetary Gear/Final Drive Adjusting
Planetary Gear Assembly/Dissassembly
Ring Gear Assembly/Dissasembly
Overrunning Clutch Assembly/Dissassembly
Freewheel with Plastic Cage Assembly/Dissassembly
Forward Clutch Assembly/Dissassembly
Direct & Reverse Clutch Assembly/Dissassembly
Oil Pump Assembly/Dissassembly
Valve Body Assembly/Dissassembly
Transfer and Intermediate Plates Assembly/Dissassembly
Valve Body Assembly/Dissassembly
2nd Gear Brake Assembly/Dissassembly
Governer Assembly/Dissassembly
Parking Lock Assembly/Dissassembly
Differential
Differential Removal/Installation
Differential Assembly/Dissassembly
Pinion & Ring Gear Adjustment
Checking Final Drive Oil Level
Central Tube Torque Specifications
Checking Oil Level in Final Drive
Final Drive Assembly/Dissassembly
Differential Assembly/Dissassembly
Limited Slip Differential Assembly/Dissassembly
Adjusting Drive Set
Removing & Installing Central Tube
Central Tube Assembly/Dissassembly
Central Tube Checking
Adjusting Dampers
03-CHASSIS
CHASSIS, BODY
Table of Contents
Front Wheel Suspension
Technical Data
Tightening Torques
Aluminium Control Arms modifications
Notes on Front Axle (late)
Running Gear Tuning
Adjusting Front Wheel Bearings
Ball Joint Caps Checking
Wheel Bearings Assembly/Disassembly
Koni Shock Absorbers Replacing
Koni Shock Absorbers Adjusting
Coil Springs
Rear Wheel Suspension Axle Shafts
Technical Data
Tightening Torques
Running Gear Tuning of 944 S2
Trailing Arms Assembly/Disassembly
Aluminium Trailing Arms Assembly/Disassembly
Koni Shock Absorbers 944S/944S2
Koni Shock Absorbers Adjusting
Wheel, Tires, Alignment
Wheels & Tires
Sample Measuring Chart to '89
Sample Measuring Chart post '89
Wheel Alignment Values 924S/944/944S/944S2
Wheel Alignment checking
Aluminum Wheels Removal/Installation
Anti-Lock Braking System
General
ABS Layout
Position of ABS Components
Circuit Diagram
Troubleshooting & Test Program Notes
Working on Cars with ABS Notes
Hydraulic Unit Removal/Installation
Electronic Control Unit Removal/Installation
Relays Removal/Installation
Speed Sensors Removal/Installation
Brakes Mechanical
Technical Data
Torque Specifications
Brake Booster Notes (late)
4 piston Caliper Notes
Brake Pads checking
Brake Pads Removal/Installation
Brake Pad 4-Piston Caliper Removal/Installation
Brake Pushrod Adjustment
Parking Brake Checking/Adjustment
Front Wheel Brake Assembly/Disassembly
Rear Wheel Brakes Assembly/Disassembly
Brake Disc Lateral Runout Check
Brake Thickness Check
Brakes, Hydraulic System, Regulators, Boosters
Tightening Torques
Brake Booster Notes
4 piston Fixed Caliper Notes
Brake Caliper Assembly/Disassembly
Brake Booster Removal/Installation
Brake Master Cylinder
Bleeding & Replacing Brake System Fluid
Steering
Technical Data
Torque Specifications
Manual Steering Gear Removal/Installation
Power Steering Gear Removal/Installation
Power Steering Pump Removal/Installation
Rack & Pinion Checking & Servicing
Power Steering Checking Hydraulic Operation
Steering Wheel Removal/Installation
Steering Shaft With Protective Tube Removal/Installation (late)
Body - General
Safety Notes
Celette Alignmnet Bench
Repair Control Dimensions
Floor Assembly Dimensions
Body Front Section
Side Members
Lock Carrier Guage
Front Axle Take Up Attachment
Adapter for Cross Member & Stabilizer Pick Up
Front End Panel Removal/Installation
Bodywork Rear
Rear End Panel Removal/Installation (cabrio)
Rear Side Panel Removal/Installation(cabrio)
Reworking Inner Side Panel
Engine Hood, Tailgate
Tailgate Electric Unlocking Cable
Tailgate Lock Microswitch Removal/Installation
Engine Hood Removal/Installation
Engine Hood Cable Removal/Installation
Doors
Inside Door Handle Removal/Installation
Door Panel Removal/Installation
Window Guide Rail Removal/Installation
Outside Door Handle Removal/Installation
Door Lock/Inner Actuator Removal/Installation
Central Locking System
Central Locking System Button Removal/Installation
Central Locking Control Unit Removal/Installation
Door Lock Cylinder Microswitch Removal/Installation
Central Locking System Function Table
Central Locking System Troubleshooting
Hardtop
Working on Power Sunroof
Troubleshooting Sunroof
Sunroof Early (pre '86)
Lifting Roof Conversion
Electric Sunroof Drive/Assembly Removal/Installation
Lifting Sunroof Adjustment
Replacing Drive Dog
Power Sunroof Control Checking
Sunroof Microswitch in Roof opening Removal/Installation
Slip Clutch on Roof Motor Adjusting
Sunroofs Post '85
Lifting Sunroof Removal/Installation
Lifting Sunroof Adjustment
Elevation Cable & Segments Removal/Installation
Gear in Element Guide Removal/Installation
Testing Control in Lifting Sunroof
Power Supply for Lifting Sunroof
Microswitch in Sunroof Removal/Installation
Microswitch in Electric Drive Adjusting
Microswitch Connections
Slip Clutch
Folding Top Removal/Installation
Bumpers
Spoiler & Bumper Removal/Installation
Rear Bumper Assembly/Disassembly
Windshield
Windshield Removal/Installation
Windshield (Securiflex) Removal/Installation
2 Pack Adhesive
Interior Rear View Mirror Bonding
Exterior Equipment
Porsche Emblem Removal/Installation
Stone Guard Foil Removal/Installation
Side Mouldings Removal/Installation
Roof Ornamantal Strip Removal/Installation
Paint Colors
Outside Mirror Removal/Installation (late)
Fastening T-Bolt to Roof Flange
Plastic End & Side Applications Removal/Installation
Tank Flap (cabrio) Removal/Installation
Retrofitting New Mirror for Models as of 85/2
Interior Equipment
Center Console Removal/Installation (late)
Instrument Panel Removal/Installation
Airbag
Safety Regulations
Drivers Airbag Removal/Installation
Steering Wheel Airbag Removal/Installation
Contact Unit Removal/Installation
Front Sensor Removal/Installation
Front Passenger Airbag Removal/Installation
Control Unit Removal/Installation
Diagnosis
Checking Airbag System Operation
Safety Belts Removal/Installation
Safety Belts Inspection
Airbag Unit Disposal
Horn Buttons on Airbag Unit Repair
Diagnosis/Troubleshooting
Seats
Front Seats Removal/Installation
Seat Heating Removal/Installation
Backrest Heating Element Removal/Installation
Seat Frame
Backrest
Controllable Seat Heating Calibration
Heating
Heating (late)
Fresh Air Blower Removal/Installation
Air Conditioning System
Air Conditioner Model '85 Onward
Air Conditioner Technical Data
Location of Components
Safety Regulations for Handling R-12
Assembly work Involving Cooling System
Using Service Equipment
Service Unit
Initial Operation
Filling Service Unit
Connecting to Air Conditioner
Evacuating Air Conditioner
Flushing Air Conditioner
Re-Filling Air Conditioner
Heating -A/C Unit Assembly/Disassembly
Positioning of Flaps Airflow
Heating -A/C Unit Removal/Installation
Compressor Removal/Installation
Condensor Removal/Installation
Interior Sensor Blower Removal/Installation
Expansion Valve Removal/Installation
Defrost Flap Motor Removal/Installation
Temperature Mixture Motor Removal/Installation
Footwell Flaps Motor
Troubleshooting
Magnetic Coupling, Shaft Seal Removal/Installation
04-ELECTRICAL
ELECTRICAL PART I
Table of Contents
Instruments, Consumption Indicators, Burgler Alarm
Upshift Indicator/Economy Control
Troubleshooting Fuel Indicator
Troubleshooting Upshift Indicator
Relay Arrangement post '83
Fuses on Central electric System post '83
Fuses in Aux Fuse box post '83
Instrument Cluster (late)
Instrument Cluster Removal/Installation
Speedometer Transmitter Removal/Installation
Instruments Checking
Burgler Alarm Checking
Aux Control Unit Burgler Alarm Checking
Radio, Telephone, On Board Computer
Radio Removal/Installation
Telephone Removal/Installation
CD Player Retrofit post '88
WINDSHIELD WIPERS & WASHER
Windshield Wipers Removal/Installation
Windshield Washer Pump Removal/Installation
EXTERIOR LIGHTS
Lubricating Concealed Headlight Linkage
Switch Covers Removal/Installation
Lock Cylinders Removal/Installation
Head Light Beam Adjustment
CENTRAL ELECTRIC
Central Electric Removal/Installation
Central Electric Assignment
Cable Harness Modification
Supplemntal Electrical Equipment
CURRENT FLOW WIRING SCHEMATICS
'83 USA
Part I Power Supply, Starter,DME, Fuel Pump
Part 2 Light Switch Headlight,Fog, Light,Parking Light
Part 3 Brake Light, Flasher, Turn Signal, Horn, Interior
Part 4 Rear Defogger, Ignition, Starter, Seat Belts, Cluster
Part 5 Instrument Center Console, Wind Shield Wiper
Part 6 Air Blower, Cooling Fan
Additional Diagram Air Conditioner
84' USA
Part I Power Supply, Starter,DME, Fuel Pump
Part 2 Light Switch Headlight,Fog, Light,Parking Light
Part 3 Brake Light, Flasher, Turn Signal, Horn, Interior
Part 4 Rear Defogger, Ignition, Starter, Seat Belts, Cluster
Part 5 Instrument Center Console, Wind Shield Wiper
Part 6 Air Blower, Cooling Fan
Additional Diagrams
Air Conditioner
Electric Window
Lifting Roof
Tempostat
'85/2 USA 944,944 Turbo (special vehicle #s)
Page 1 Lighting Row
Page 2 Lighting USA
Page 3 Instrument Cluster & Sensor
Page 4 Instrument Clusters/Sensors
Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer
Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof
Page 7 Engine Compartment
Page 8 Central Electronics Box
85/2 USA 944,944 Turbo
Page 1 Lighting Row
Page 2 Lighting USA
Page 3 Instrument Clusters/Sensors
Page 4 Instrument Clusters/Sensors
Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer
Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof
Page 7 Engine Compartment
Page 8 Central Electronics Box
86 USA 944,944 Turbo
Page 1 Lighting Row
Page 2 Lighting USA
Page 3 Instrument Cluster & Sensor
Page 4 Instrument Clusters/Sensors
Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer
Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof
Page 7 Tempostat 944
Page 8 Tempostat 944 Turbo
Page 9 Central Electric System
Page 10 Central Locking System
Page 11 Fog Light, Fog Tail Light
Page 12 Radio
87 USA 944,944S, 944 Turbo
Page 1 Lighting Row
Page 2 Lighting USA
Page 3 Instrument Cluster & Sensor
Page 4 Instrument Clusters/Sensors
Page 5 Heating, Ventilation, A/C, Seats, Wipers/Washer
Page 6 Horns, Mirror, Power Windows, Alarm System, Tilting Roof
Page 7 Tempostat 944
Page 8 Tempstat 944 Turbo
Page 9 Tempstat 4 - Valves
Page 10 Central electrical System
Page 11 Central Locking System
Page 12 Fog Light, Fog Tail Light
Page 13 Radio
Page 14 ABS, Airbag
'86 USA 924 S
Page 1 Lighting
Page 2 Instrument Cluster, Sensors, Tilting Roof
Page 3 Heating, Ventilation, Windshield Wiper
Page 4 AC, Window Lifters, Alarm System
Page 5 AC RHD
Page 6 Tempstat
Page 7 Tempostat
'87 USA 924 S
Page 1 Lighting
Page 2 Lighting Row
Page 3 Instrument Cluster & Sensors
Page 4 Heating, Ventilation, Wiper, Washer, Mirrors
Page 5 AC, Window Lifters, Alarm
Page 6 AC RHD
Page 7 Tempostat
Page 8 Central electrical System
Page 9 Radio
05-ELECTRICAL
ELECTRICAL PART 2
Table of Contents
'Wiring Schematics
'88 944,944 Turbo, 944S
Page 1 Lights Row/OPT. Equip
Page 2 Lights USA
Page 3 Instrument Cluster & Sender ROW
Page 4 Instrument Cluster, Sender, Opt. Equip (USA)
Page 5 Heating, Air Conditioning, Ventilation
Page 6 Two-Tone Horns, Mirrors, Alarm
Page 7 Engne Compartment, Cruise Control -944
Page 8 Engne Compartment, Cruise Control -944 Turbo
Page 9 Engne Compartment, Cruise Control - 4 Valve Engine
Page 10 Central Electric
Page 11 Central Locks
Page 12 Fog Light, Rear Fog Light
Page 13 Radio
Page 14 ABS, Airbag
Page 15 Constr Components, Plug Connection, Ground Points'89 944,944 Turbo, 944S
Page 1 Lights Row/OPT. Equip
Page 2 Lights USA
Page 3 Lights RHD
Page 4 Instrument Cluster & Sender ROW
Page 5 Instrument Cluster, Sender, Opt. Equip (USA)
Page 6 Heating, Air Conditioning, Ventilation, Wipers
Page 7 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof
Page 8 Engne Compartment, Cruise Control -944
Page 9 Engne Compartment, Cruise Control -944 Turbo
Page10 Engne Compartment, Cruise Control - 4 Valve Engine
Page 11 Central Electric
Page 12 Central Locks, Alarm System
Page 13 Fog Light, Rear Fog Light
Page 14 Radio
Page 15 ABS, Airbag
Page 16 Differing Cable Layout for LHD
Page 17 Differing Cable Layout for RHD
Page 18 Construction Components
Page 19 Plug Connections, and Ground Points '90 Turbo, 944S2
Page 1 Lights Row/OPT. Equip SA/Japan
Page 2 Lights USA
Page 3 Instrument Cluster & Sender ROW /Japan
Page 4 Instrument Cluster & Sender ROW USA
Page 5 Heating, Air Conditioning, Ventilation, Wipers
Page 6 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof
Page 7 Engne Compartment, Cruise Control -944 Turbo
Page 8 Engne Compartment, Cruise Control -4 Valve
Page 9 Central Electric
Page 10 Central Locks, Alarm System
Page 11 Fog Light, Rear Fog Light
Page 12 Radio
Page 13 ABS, Airbag
Page 14 944 Cabrio wiring
Page 15 Construction Components
Page 16 Plug Connections & Ground Points '91, 944S2
Page 1 Lights Row/OPT. Equip SA/Japan
Page 2 Lights USA
Page 3 Instrument Cluster & Sender ROW /Japan
Page 4 Instrument Cluster & Sender ROW USA
Page 5 Heating, Air Conditioning, Ventilation, Wipers
Page 6 Two-Tone Horns, Mirrors, Alarm, Tailgate Unlocking, Roof
Page 7 Engne Compartment, Cruise Control -4 Valve
Page 8 Central Electric
Page 9 Central Locks, Alarm System
Page 10 Fog Light, Rear Fog Light
Page 11 Radio, Telephone
Page 12 ABS, Airbag
Page 13 944 Cabrio wiring
Page 14 Construction Components
Page 15 Plug Connections & Ground Points '88 924S
Page 1 Lights USA
Page 2 Lights Row
Page 3 Instrument Cluster & Sender, Roof
Page 4 Outside Mirror, Coolant Fan Motor, Heater
Page 5 A/C, Power Window,Alarm
Page 6 A/C RHD
Page 7 Engne Compartment, Cruise Control
Page 8 Central Electric
Page 9 Radio
06-TURBO
GENERAL
Repair Groups
Table of Contents
Technical Data
TABLE OF CONTENTS
ENGINE
Crankcase
Crankshaft/Pistons
Cylinder Head/Valve Drive
Lubrication
Cooling
Fuel Supply
Turbocharger
Fuel Injection
EXHAUST
CHECKING BATTERY
ALTERNATOR REMOVAL/INSTALLATION
IGNITION SYSTEM
Accident Hazards
Equipment Survey
Component Installation Positions
DME Knock/Charging Pressure Removal/Installation
Air Flow Sensor Removal/Installation
Knock Sensor Removal/Installation
Timing Valve Removal/Installation
DME Knock/Charging Pressure Troubleshooting
Plug Connections
Trouble Shooting Chart
Ground & Plug Connections
Test Points
Ground & Plug
Voltage Supply
RPM Sensor
Reference Mark Sensor
Ignition System
Air Flow Sensor
Fuel Pressure
Idle Actuator
Throttle Switch
Temperature Sensor
Injection Valves
Knock/Charging Pressure Control
Intake Pressure System
Ignition Signal from DME
Oxygen Sensor
TRANSMISSION
Clutch
Technical Data
Tightening Torques
Checking Clutch Play
Adjusting Clutch Spring
Clutch Drive Plate Wear
Clutch Removal/Installation
Checking Oil Levels (Replacing Oil)
Cooling Coil Removal/Installation
Gear Box Removal/Installation
Gear Box Assembly/Disassembly
Rear Housing Cover Assembly/Disassembly
End Plate Assembly/Disassembly
Operation, Housing
Transmission Housing Assembly/Disassembly
Oil Pump Assembly/Disassembly
Gears & Shafts
Input Shaft Assembly/Disassembly
Pinion Shaft Assembly/Disassembly
Checking Sychromesh Rings
DIFFERENTIAL / TRANSAXLE SYSTEM
Differential Removal/Installation
Differential Assembly/Disassembly
Adjusting Differential Gears
Limited Slip Differential Assembly/Disassembly
Drive Pinion & Ring Gear Adjustment
FRONT WHEEL SUSPENSION
Front Axle Shaft
Technical Data
Tightening Torques
Adjusting Front Wheel Bearings
Checking Caps on Joints of Control Arms/Tie Rods
Height Adjustable Strut Assembly/Disassembnly
Coil Springs
Shock Absorbers
Rear Axles
Technical Data
Tightening Torques
Rebound Travel Procedures
Wheels & Tires
General
Vehicle Measurements
Wheel Alignment
Front Axle
Rear Axle
FRONT AXLE MODIFICATIONS
BRAKES
Mechanical
Technical Data
Brake Pads Checking
Brake Pad Removal/Installation
Tightening Torques
Adjusting Brake Pad Push
Brake Light Switch Adjustment
Parking Brake Check/Adjustment
Front Brakes Assembly/Disassembly (late)
Rear Wheel Brakes Assembly/Disassembly
Hydraulics
Tightening Torques
Braking System
4 Piston Calipers Modifications
Brake Power Controller
STEERING
Tightening Torques
Rack & Pinion Power Steering Check/Service
Bleeding Steering System
FRONT HOOD
Replacing Hood Cable
BUMPERS
Lower Trim Panel Removal/Installation
Spoiler & Bumper Removal/Installation
EXTERIOR EQUIPMENT
Rocker Panel Covers Removal/Installation
Rear Apron Spoiler
Finishes Available
Applying Turbo Emblem
WIPER WASHER SYSTEM
Aiming Headlight Cleaner Spray Jets
EXT. LIGHTS, LAMPS, SWITCHES
Aiming Headlights
Aiming Fog Lights
Lubricating Headlight Linkage



PARTS CATALOG  1982-1991  (1151 pages)

1985
MAIN GROUP 0: ACCESSORIES AND OTHERS
001: tools, stickers
002: inst set, snow chains, roof rack system
003: radio, loudspeaker, antenna
004: lacquers
005: securing liquids, sealing compounds
MAIN GROUP 1: ENGINE
101: replacement engine, crankcase
102: crankshaft, piston
103: cylinder head, camshaft, valve
104: engine lubrication
105: water cooling
106: air filter system
107: l-jetronic
109: engine suspension
198: repair kits
MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM
201: fuel system, carbon container, etc.
202: exhaust system, muffler, catalytic converter
298: repair kits
MAIN GROUP 3: TRANSMISSION
301: clutch, central tube
302: replacement transmission
303: gear sets, shafts
304: shift rods, forks
305: differential
306: transmission suspension
307: central tube, automatic transmission
308: replacement transmission, automatic transmission
309: transmission case, automatic transmission
310: transmission parts, automatic transmission
311: differential, automatic transmission
312: transmission suspension, automatic transmission
398: repair kits
MAIN GROUP 4: FRONT AXEL, STEERING
401: track control arm
402: springs, shock absorber, vibration damper
403: steering
404: sport type running gear
MAIN GROUP 5: REAR AXLE
501: rear axle
502: vibration damper, stabilizer
MAIN GROUP 6: WHEELS, BRAKES
601: wheels
602: disk brake, front
603: disk brake, rear
604: brake master cylinder, brakeservo, reservoir
698: repair kits
MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER
701: shift mecansim, hand brake
702: pedal system
MAIN GROUP 8: BODY
801: body, frame
802: bumper
803: cover
804: doors
805: glasses
806: concealing headlamps
807: sound absorber, carpet
808: seats
809: dashboard, rear-view-mirror, center console
810: trim frame
811: lifting roof
812: seat belt
813: heating, ventilation, air conditioner
898: repair kits
MAIN GROUP 9: ELECTRICAL EQUIPMENT
901: electr. equipment engine, control unit
902: alternator, starter, battery, harnesses
903: switch, fuse box, relay, horn
904: windshield wiper system
905: concealing headlamps, turn signal
906: instruments
907: tempomat
909: anti-theft device
910: electric fan
998: repair kits
MSP-PAGES
V-PAGES
1988
MAIN GROUP 0: ACCESSORIES AND OTHERS
001: stickers
002: inst set, snow chains, trailer compling, roof rack system
004: lacquers
005: securing liquid, sealing coumpound
MAIN GROUP 1: ENGINE
101: replacement engine, protective plate, crankcase
102: crankshaft, connecting rod, piston
103: cylinder head, valve, camshaft
104: engine lubrication
105: water-cooling
106: air filter system
107: l-jetronic, charger air cooler
109: engine suspension
198: repair kits
MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM
201: fuel system, carbon container
202: exhaust system, muffler, catalytic converter
298: repair kits
MAIN GROUP 3: TRANSMISSION
301: clutch, central tube
302: replacment transmission, transmission case
303: gears, shafts
304: transmission control, shift rods
305: differential
306: transmission suspension
307: central tube, automatic transmission
308: replacement transmission, automatic transmission
309: transmission case, automatic transmission
310: transmission control, automatic transmission
311: differential, automatic transmission
312: transmission suspension, automatic transmission
398: repair kits
MAIN GROUP 4: FRONT AXLE, STEERING
401: track control, cross member
402: springs, shock absorber, stabilizer
403: steering, tie rod
MAIN GROUP 5: REAR AXLE

501: rear axle
502: vibration damper, stabilizer
598: repair kits
MAIN GROUP 6: WHEELS, BRAKES
601: wheels
602: disk brake, front
603: disk brake, rear, hand brake
604: master brake cylinder, brakeservo, reservoir
605: brake lines, antiblock system
698: repair kits
MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER
701: shift control, hand brake lever
702: pedal system
798: repair kit
MAIN GROUP 8: BODY
801: body, frame, interior and exterior panelling
802: bumper, front spoiler
803: cover
804: doors
805: glasses
806: concealing headlamps, turn signal
807: sound absorber, carpet
808: seats
809: dashboard lining, center console, rear-view-mirror
810: molding, insignias
811: lifting roof
812: seat belt
813: heating, ventilation, air conditioner
898: repair kits
MAIN GROUP 9: ELECTRICAL EQUIPMENT
901: electr. equipment engine, distributer
902: alternator, starter, battery, harnesses
903: switch, fuse box, relay, horn
904: windshield wiper system
905: headlamp, turn signal, fog light
906: instruments
907: tempomat
909: anti-theft device
910: electric fan
911: radio, antenna, loudspeaker, soundsystem
998: installation set, repair kits
MSP-PAGES
V-PAGES
1991
MAIN GROUP 0: ACCESSORIES AND OTHERS
001: inst set, jack, stickers
002: inst set, snow chains etc.
004: paint touch-up applicator
005: securing liquid, sealing compound, preservative agent
MAIN GROUP 1: ENGINE
101: short engine, crankcase
102: crankshaft, pistons
103: cylinder head, camshaft, valves etc.
104: engine lubrication
105: water pump
106: air filter system
107: l-jetronic
109: engine suspension
198: repair kits
MAIN GROUP 2: FUEL SYSTEM, EXHAUST SYSTEM
201: fuel tank, system etc.
202: exhaust system
298: repair kits
MAIN GROUP 3: TRANSMISSION
301: central tube, clutch
302: replacement transmission, transmission case etc.
303: gears and shafts
304: transmission control
305: differentials
306: transmission suspension
307: central tube AT
308: replacement transmission etc. AT
309: transmission case etc. AT
310: transmission control etc. AT
311: differential AT
312: transmission suspension AT
398: repair kits
MAIN GROUP 4: FRONT AXLE, STEERING
401: track control arm, cross member etc.
402: springs, shock absorber
403: steering
MAIN GROUP 5: REAR AXLE
501: rear axle carrier, guiding arm etc.
502: vibration damper, stabilizer
598: repair kits
MAIN GROUP 6: WHEELS, BRAKES
601: disk wheel
602: disk brake front axle
603: disk brake rear axle, hand brake
604: brake master cylinder, brakeservo reservoir etc.
605: brake lines antiblock system, hydraulic unit
698: repair kits
MAIN GROUP 7: HAND LEVER SYSTEM, PEDAL CLUSTER
701: control, hand brake lever
702: pedal system
MAIN GROUP 8: BODY
801: body-in-white, panels, fender etc.
802: bumper, front spoiler etc.
803: cover, rear flap, spoiler
804: doors
805: glasses
806: concealing headlamps
807: sound absorber, linings
808: seats
809: dashboard, mirrors, center console etc.
810: molding, insignias
811: lifting roof, folding top
812: seat belt
813: heating and ventilation
898: repair kits
MAIN GROUP 9: ELECTRICAL EQUIPMENT
901: electrical equipment engine
902: battery, harnesses, connectors etc.
903: switch, central electrical equipment, horn etc.
904: wiper, washer system
905: headlamp, lights
906: instruments
907: tempomat
909: anti-theft device
910: electric fan
911: radio, soundsystem
998: installation set, repair kits
MSP-PAGES
V-PAGES

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