Porsche 944 1981-1991 Complete Service & Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: 944 Generation Production Years Covered: 1981-1991 Codes Internal Model Code: 944 👋 Introduction Market Position Vehicle Segment: Front-engine, rear-wheel-drive sports coupe, positioned as...

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Taper: Car

Distributeur:

UGS: 196297

Mots clés: 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 914 944 Car Cars Porsche

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Porsche

Model:

Generation

Production Years Covered:

1981-1991

Codes

Internal Model Code:

👋 Introduction

Market Position

Vehicle Segment:

Front-engine, rear-wheel-drive sports coupe, positioned as an entry-level Porsche offering a blend of performance and practicality.

Competitive Analysis

Competitors:

Competed with vehicles such as the Chevrolet Camaro/Pontiac Firebird, Ford Mustang, Datsun/Nissan 300ZX, Toyota Supra, and BMW 3-Series (E30).

Key Features

Transaxle Design:

Unique transaxle design (transmission and differential combined at the rear) for optimal weight distribution and handling.

Engine Layout:

Inline-four cylinder engine mounted longitudinally in front of the driver, featuring a balance shaft for smoother operation.

Handling Characteristics:

Renowned for its balanced chassis, responsive steering, and predictable handling, characteristic of Porsche engineering.

Design Evolution:

Evolved from the Porsche 924, featuring a distinctive 'flat nose' design and improved aerodynamics.

📋 Manual Details

Coverage Areas

Comprehensive Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Bodywork, Interior, HVAC, Diagnostics

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Complete Service & Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed breakdown of 2.5L M44.xx inline-4 engine, including cylinder head, block, pistons, crankshaft, camshafts, timing belt, valve train, seals, and gaskets. Covers both naturally aspirated and turbo variants.

Fuel System:

Bosch L-Jetronic and Motronic fuel injection systems, fuel pumps, injectors, fuel pressure regulators, fuel lines, fuel tank, and emissions control components.

Cooling System:

Radiator, water pump, thermostat, hoses, coolant reservoir, fan operation, and coolant specifications.

Exhaust System:

Exhaust manifold, catalytic converter (where applicable), muffler, exhaust pipes, and mounting hardware. Covers emissions control.

Ignition System:

Distributor, ignition coils, spark plugs, ignition timing adjustment, and related sensors.

Transmission Manual:

Detailed procedures for the 5-speed manual transaxle, including clutch replacement, gearbox overhaul, shifting mechanism, and lubricant specifications.

Transmission Automatic:

Information on the optional automatic transaxle, including shifting behavior, adjustments, and fluid specifications.

Drivetrain:

Rear-wheel drive transaxle, driveshafts, CV joints, and differential maintenance and repair.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, springs, shocks, and wheel bearings. Includes alignment specifications.

Steering System:

Power steering rack and pinion, steering column, universal joints, and fluid requirements.

Brake System:

Front and rear disc brakes, brake calipers, master cylinder, brake lines, parking brake, ABS system (where applicable), and brake fluid specifications.

Electrical System Lighting:

Headlights, taillights, interior lighting, fog lights, and bulb specifications.

Suspension Rear

Rear Suspension:

Trailing arms, multi-link setup, springs, shocks, sway bar, and wheel bearings. Includes alignment specifications.

Electrical System Accessories

Accessories:

Wipers, horn, power windows, mirrors, seat adjustment, central locking, and radio installation/removal.

Electrical System Charging

Charging System:

Alternator, voltage regulator, battery specifications, and charging system testing.

Electrical System Starting

Starting System:

Starter motor, starter solenoid, and ignition switch operation.

Bodywork Exterior

Exterior Panels:

Body panel removal and installation (fenders, doors, hood, trunk lid), trim, bumpers, and glass replacement.

Bodywork Interior

Interior Trim:

Dashboard removal, door panel removal, seat upholstery, carpet, and headliner.

Hvac System

HVAC Components:

Air conditioning system (refrigerant types, compressor, condenser, evaporator), heater core, blower motor, and climate control panel operation.

Diagnostics Troubleshooting

Fault Finding:

Diagnostic trouble codes (DTCs) for Motronic systems, systematic troubleshooting guides for common issues, wiring diagrams, and testing procedures for sensors and actuators.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, timing belt replacement, coolant flush, brake fluid flush, air filter replacement.

Engine Rebuild:

Complete engine overhaul procedures, including torque specifications, piston ring gap, bearing clearance, and cylinder honing.

Transmission Overhaul:

Step-by-step instructions for the disassembly, inspection, and reassembly of the transaxle.

Brake System Repair:

Brake pad replacement, caliper overhaul, rotor replacement, brake bleeding, and ABS diagnostics.

Suspension Component Replacement:

Replacement of struts, shocks, control arms, ball joints, bushings, and wheel bearings.

Electrical Component Testing:

Testing of alternators, starters, sensors, relays, and fuses using multimeters and diagnostic tools.

Clutch Replacement:

Detailed instructions for removing and replacing the clutch assembly.

Timing Belt Replacement:

Critical procedures for aligning timing marks and replacing the timing belt to prevent catastrophic engine damage.

Fuel Injector Testing:

Procedures for testing fuel injector resistance and flow rates.

Air Conditioning Service:

Basic A/C service procedures, refrigerant charging, and leak detection.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures for engine management, ABS, and other electronic systems. Includes specific testing parameters and troubleshooting charts.

Rebuild Procedures:

Comprehensive instructions for complete engine and transmission rebuilds, including disassembly, cleaning, inspection, part replacement, and reassembly.

Wiring Diagrams:

Detailed electrical schematics for all major systems, including component identification and wire colors.

Torque Specifications:

Extensive list of torque specifications for all critical fasteners, essential for proper assembly and preventing damage.

Technical Bulletins:

May include references or summaries of Technical Service Bulletins (TSBs) relevant to the covered period.

📊 Manual Specifications

File Format

Format:

Print Quality

Resolution:

High-resolution scans suitable for digital viewing and printing.

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper:

Not Applicable (Digital PDF)

Searchability

Text Search:

Searchable PDF text for quick information retrieval.

Navigability

Bookmarks Links:

Likely includes bookmarks and internal links for easy navigation through sections and chapters.

⚙️ Engine Specifications

Primary Engine

Engine Code Family:

Engine Type:

Inline-4 Cylinder, DOHC

Displacement Na:

2.5 Liters (2479 cc)

Displacement Turbo:

2.5 Liters (2479 cc)

Performance

Horsepower Na Early:

143 hp @ 5500 rpm

Torque Na Early:

147 lb-ft @ 3000 rpm

Horsepower Turbo Early:

160 hp @ 5000 rpm (with less boost, often referred to as 'non-intercooled')

Torque Turbo Early:

188 lb-ft @ 3000 rpm

Horsepower Turbo Late:

187 hp @ 5500 rpm (Intercooled Turbo S/SE)

Torque Turbo Late:

209 lb-ft @ 3000 rpm (Intercooled Turbo S/SE)

Horsepower 2.7L:

168 hp @ 5500 rpm (for early 2.7L models)

Torque 2.7L:

170 lb-ft @ 4500 rpm (for early 2.7L models)

Fuel System

Injection System Na:

Bosch L-Jetronic

Injection System Turbo:

Bosch Motronic (later models integrated fuel and ignition)

Recommended Fuel:

Unleaded gasoline, 91 octane (RON+MON)/95 AKI or higher

Engine Internals

Balance Shafts:

Yes, crucial for smoothing the inline-4 operation.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transaxle

Optional

Transmission Type:

3-speed Automatic Transaxle (early models), 4-speed Automatic Transaxle (later models, e.g., Tiptronic on some later variants but rare on standard 944)

Features

Transaxle Layout:

Rear-mounted transaxle (gearbox and differential integrated) for 50/50 weight distribution.

Fluid Specifications

Manual Transmission Fluid:

GL-4 or GL-5 SAE 75W-90 gear oil

Automatic Transmission Fluid:

Dexron III or equivalent

📐 Dimensions

Exterior

Length:

Approx. 4200 mm (165.3 in)

Width:

Approx. 1735 mm (68.3 in)

Height:

Approx. 1275 mm (50.2 in)

Wheelbase:

Approx. 2400 mm (94.5 in)

Weights

Curb Weight Na:

Approx. 1250-1350 kg (2750-2980 lbs)

Curb Weight Turbo:

Approx. 1350-1450 kg (2980-3200 lbs)

Cargo

Trunk Volume:

Usable rear cargo area behind seats, plus front trunk space. Specific volume varies by year and configuration.

Wheel Specs

Wheel Bolt Pattern:

5x130 mm

Tire Sizes Front:

Typically 205/55VR16 or 225/50VR16

Tire Sizes Rear:

Typically 225/50VR16 or 245/45VR16

🛡️ Safety Features

Ratings

Crash Test Performance:

While official NHTSA/Euro NCAP ratings for this era are limited, the 944 featured a robust chassis design. The rigid body structure, integrated roll bar in the roof (on some models), and substantial A-pillars contributed to occupant protection.

Active Features

Anti-lock Braking System (ABS) became available and standard on later models.

Passive Features

Seatbelts:

Three-point seat belts, often with inertia reels.

Fuel Tank Placement:

Fuel tank was located behind the rear axle for improved safety.

Crumple Zones:

Designed with front and rear crumple zones to absorb impact energy.

💡 Technology Features

Infotainment

Audio System:

Factory premium sound systems were available, often with cassette players. Aftermarket head units are common upgrades.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Climate Control:

Manual or automatic climate control systems depending on the model and year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 12 months, whichever comes first.

Timing Belt Replacement Interval:

Every 30,000-50,000 miles (48,000-80,000 km) or 4-5 years, due to its critical nature.

Spark Plug Replacement:

Every 15,000-30,000 miles (24,000-48,000 km), depending on plug type.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Engine Oil Capacity:

Approx. 5.5 Liters (5.8 US Quarts) with filter change, using SAE 15W-50 or 20W-50 synthetic oil, depending on climate.

Coolant Capacity:

Approx. 8.5 Liters (9.0 US Quarts), using a 50/50 mix of P-OAT coolant (e.g., G12/G13 equivalent or Porsche approved) and distilled water.

Known Issues

Timing Belt Failure:

Critical failure point; belt degradation or incorrect tension can lead to severe engine damage (bent valves).

Rear Main Seal Leaks:

Common for the rear crankshaft seal to leak due to age and heat cycling.

Balance Shaft Belt:

The separate balance shaft belt can also degrade and cause issues if not replaced with the main timing belt.

Fuel Injector Clogging:

Can lead to rough running, misfires, and performance degradation.

Electrical Gremlins:

Corroded connections, failing relays, and aging wiring can cause intermittent issues in various systems.

Window Regulator Failure:

Common for power window mechanisms to wear out.

Idler Pulley Bearing Failure:

Failure of the idler pulley for the timing belt can be catastrophic.

📚 Vehicle History

Brand Heritage

Porsche Philosophy:

Built upon Porsche's reputation for performance, engineering, and superior handling, albeit with a more accessible price point than the 911.

Model Evolution

924 To 944 Transition:

The 944 was an evolution of the front-engined, water-cooled Porsche 924, significantly re-engineered with a larger and more powerful engine, wider fenders, revised suspension, and improved styling.

Turbo Introduction:

The 944 Turbo (951) was introduced in 1985, offering a substantial increase in power and performance with intercooled turbocharging.

2.5 To 2.7 Engine:

A 2.7-liter engine was offered briefly in some markets in 1986, bridging the gap before later updates.

S2 And Turbo S Models:

Later years saw the introduction of the 944 S2 (naturally aspirated 3.0L) and the more powerful 944 Turbo S (211 hp).

Production

Manufacturing Location:

Neckarsulm, Germany (Audi AG plant, under contract to Porsche)

Production Volume:

Over 160,000 units produced across all variants, making it a successful model for Porsche.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Porsche 944 was a perennial contender and often named to Car and Driver's '10Best' list during its production run for its exceptional handling and performance.

Ratings

Automotive Journalism Reviews:

Consistently praised by automotive journalists for its sophisticated chassis, powerful engine (especially the Turbo models), and driver-focused cockpit.

Certifications

Performance Benchmarks:

Often cited for its acceleration times and track-capable performance relative to its contemporaries.