Porsche 944 turbo Workshop Manual

Workshop Manual

DR. lNG. h.

c.

F. PORSCHE Aktiengesellschaft

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~ORKSHOP ~lANUAL 944 turbo

This Workshop Manual describes all of the important operations whose proper completion requires special instructions. This manual is essential for shop foremen and mechanics, as the information contained is essential for the maintenance of vehicles in safe operating condition. The basic rules of safety in vehicle repair naturally also apply throughout.

Only maintenance procedures differing from those for the vehicle type 944 are described in the Workshop Manual 944 turbo. All other information can be found in the Workshop Manuals 944 and 924.

The information in this manual is organized in repair groups according to work position numbering. The two-digit numbers of the repair groups correspond to the first digits of the work position numbers.

A repair group table and an index of key words assist in locating information.

Exploded views are numbered in order of disassembly, and where necessary are supplemented by instructions on assembly or installation and the use of special tools.

Descriptions of design and function can be found in the service training course reference material.

The contents of this Workshop Manual will from time to time be supplemented with Technical and Quality Information Bulletins. These information

Bulletins are compiled in the Technical Handbook.

Printed in Germany



GENERAL

ENGINE

Technical Data, general Page 0.1

REPAIR GROUPS

Engine I Crankcase

Engine I Crankcase, Pistons

Engine I Cylinder Head, Valve Drive

Engine I Lubrication

Engine I Cooling

Fuel Supply

Turbocharger

L-Jetronic Fuel Injection

Exhaust System

Starter, Power Supply, Cruise Control

Ignition System

10

13

15

17

19

20

21

24

26

27

28

TRANSMISSION

CHASSIS

Clutch I Operation

Manual Transmission I Operation, Housing

Manual Transmission I Gears, Shafts

Differential I Transaxle System

Front Wheel Suspension

Rear Wheel Suspension, Axle, Shaft

Wheels, Tires, Alignment

Anti-Blocking System

Brakes I Mechanics

Brakes I Hydraulics

Steering

BODY

Body - Front Section

Body - Center Section

Body - Rear Section

Engine Hood, Trunk Lid

Doors

Hardtop

Bumpers

Windows, Window Controls

Exterior Equipment

Interior Equipment

Seats

Seat Upholstery

HEATING,

VENTILATION,

AIR CONDITIONING

ELECTRICAL

COMPONENTS

Heating

Ventilation

Air Conditioner

80

85

87

Instruments, Consumption Gauge, Alarm System 90

Radio

Washer and Wiper System

Exterior Lights, Lamps, Switches

Interior Lights

Wiring 97

91

92

94

96

57

61

63

64

66

50

51

53

55

68

72

74

40

42

44

45

46

47

48

30

34

35

39



944turbo Table of contents

Page

General

Technical Data

Cylinder designations . . . . . . . . .

944 turbo-special model "S" (M 758)

Lifting vehicle . . . . . . . .

0.2

0.7

0.8a

0.9

Motor, Kurbelgehause

Tolerances and wear limits . . . . ..

Engine tightening torques . . . . .

Modified tightening torques for engine

Removing and installing engine

Engine I Crankshaft, Pistons

Power steering pump belt tightness - checking and adjustment . . . . . . . . .

Alternator and ale generator Poly-rib belt tightness - checking and adjustment

Balance shafts - tool for checking and adjusting toothed belt tightness

Balance shafts - checking and adjusting toothed belt tightness

Piston and cylinder bore - checking . . . . . . . .

Balance shaft drive disassembly and assembly . .

Installing bearing bridges of compensating shafts

Refacing the flywheel . . . . . . . . . . . . . .

Engine I Cylinder Head, Valve Drive

Camshafts - checking and adjusting toothed belt tightness

Valve spring installation length- checking and adjustment

Shaft seal on camshaft bearing cover - installation

10- 01

10-05

10- 010

10 1

13 - 1

13-2

13- 3

13-4

13-8

13- 9

13 - 14

13- 17

15 - 1

15-4

15- 5

Engine I Lubrication

Engine oil and oil filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1

Engine I Cooling

Cooling and heating system - checking for leaks I mixing table for coolant . . . . . . . 19 - 1

Fuel Supply

Fuel filter - replacing I Fuel and injection lines - checking

Fuel pump delivery rate - checking

Fuel lines and fuel system . . . . . . . . . . . . . . . . .

20- 1

20-2

20-3

Table of contents

Printed in Germany- IV, 1991



1

Table of contents 944turbo

Page

Turbocharger

Charge pressure measuring tool . . . . . . . . . .

Turbocharger system - disassembly and assembly

Turbocharger - removal and installation . . . . . .

Exhaust turbocharger end and radial play - measuring

Charging pressure - measuring . . . . . . . . . . . . .

Turbocharger coolant pump - removal and installation

Parts of the turbo charger cooling system - removal and installation

Charging air cooler - removal and installation

. 21 - 1

. 21 -2

. 21 -6

. 21 -9

. 21 - 10

. 21 - 11

. 21 - 12a

.21-13

L-Jetronic Fuel Injection intake air guide and crankcase vent hoses - checking

Testing and adjusting values

Fuel pressure - checking . . . . . . . . . . . . . . . .

Idle speed adjustment . . . . . . . . . . . . . . . . .

Idle speed adjustment (USA and cat. conv. vehicles)

CO level -correcting on air flow sensor (USA and catalytic converter vehicles)

Idle actuator - removal and installation

. 24- 1

. 24-2

. 24-3

. 24-5

. 24-9

. 24- 13

. 24- 14

Exhaust System

Exhaust system flanges - checking for tightness . . . . . . . . . . . . . . . . . . . . . .

Starter, Power Supply, Cruise Control

Battery - checking . . . . . . . . . .

Generator- removal and installation

Ignition System

Equipment survey chart

Accident hazards with electronic ignition systems

Important vehicle instructions . . . . . . . . . . .

Component installation position . . . . . . . . ..

DME and K!CP control unit- removal and installation

Temperature sensor (NTC II)- removal and installation

Knock sensor - removal and installation . . . . . . . .

Spark plugs - replacement . . . . . . . . . . . . . . . .

DME and K!CP troubleshooting- testing equipment and tools

. 27- 1

. 27-3

. 28- 1

. 28-4

. 28-6

. 28-7

. 28-8

. 28-9

. 2810

. 28- 11

. 28- 12

2



Table of contents

Printed in Germany -IV, 1991

944turbo

General Data - Clutch, Transmission

5 - speed manual transmission 016 RIS for 944 turbo . . . . . . . .

5 - speed manual transmission 083 D for 944 S (as from model 87)

5 - speed manual transmission 0 16R for 944 turbo S

Technical data (Type 016 RIS) . . . . . . .

Tightening torques for manual transmission . . . . .

Technical data, clutch . . . . . . . . . . . . . . . . .

Tightening torques for clutch, central tube, transmission mountings and transmission linkage

Clutch Operation

Clutch play, checking .

Clutch driven plate, checking wear

Clutch, removing and installing . . .


Oil level, checking . . . . . . . . . .

Cooler coil, removing and installing . . .

Gearbox, removing and installing . . . .

Gearbox, disassembling and assembling

Rear transmission cover, disassembling and assembling

End plate, disassembling and assembling . . . . . . .

Transmission housing, disassemblig and assembling

Oil pump, disassembling and assembling . . .

Manual Transmission/Gears, Shafts

Input shaft, disassembling and assembling .

Output shaft, disassembling and assembling

Differential I Transaxle System

Differential - removal and installation . .

Differential - disassembly and assembly

Differential bevel gears - adjustment . .

Limited slip differential- disassembly and assembly (lock ratio: 40%)

Drive pinion and ring gear - adjustment . . . . . . . . . . . . . . . .

Table of contents

30- 1

30-2

30-3

34- 1

34-3

34-5

34- 11

34-23

34-27

34-35

34-45

Page

30-01

30-02

30-03

30-04

30-05

30-07

30-08

35- 1

35-7

39- 1

39-5

39- 11

39- 12a

39- 13

Table of contents

Printed in Germany - IV, 1991



3

Table of contents

Front Wheel Suspension

Technical Data

Tightening torque for front axle

Front axle modifications for 944 turbo special model "S"

Front wheel bearings - adjustment

Checking caps of ball joints on control arms and tie rods

Height - adjustable strut. disassembly and assembly

Tolerance groups of coil spring

Koni vibration damper . . . .

Koni vibration shock absorber with outside rebound travel adjustment

Rear Wheel Suspension, Axle Shaft

Technical Data .

Tightening torque for rear axle

Koni vibration damper I Koni damper - adjusting

Wheels, Tires, Alignment

Wheels and tires

Sample measuring chart up to end of MY '89

Sample measuring chart as of MY '90

Adjustment values for wheel alignment

Vehicle measurement

Brakes I Mechanical Parts

Technical Data .

Tightening Torques

Brake pads - checking

Brake pads - removing and installing

Stop light switch adjustment - checking

Parking brake - adjustment

Front wheel brake as from model 87, disassembly and assembly

Rear wheel brake, disassembly and assembly

Checking lateral runout of brake disk

Checking brake-disk thickness

Brakes I Hydraulics, Regulator, Booster

Tightening torque . . . . .

Brake system information

4



Table of contents

Printed in Germany - IV, 1991

944turbo

. 44- 01

. 44-03

. 44- 1

. 44-2

. 44-4

. 46- 01

. 46-05

. 461

. 46-2

. 46-5

. 46-6

. 46-7

. 46-9

. 46- 10

. 4611

. 47- 01

. 47-02

Page

. 40- 01

. 40-02

. 40-04

. 401

. 40-2

. 40-3

. 40-6

. 40-8

. 40-9

. 42 - 01

. 42- 02

. 421

944 turbo Table of contents

Page

Steering

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and installation work on the rack and pinion power steering

48-01

48-02

481

Hood

Front hood cable - replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 - 1

Bumpers

Lower trim panel - removal and installation

Spoiler and bumper- removal and installation . . . .

Spoiler and bumper - removal and installation (USA)

63- 1

63-3

63-9

Exterior Equipment

Rocker panel covers - removing and installing

Rear apron spoiler - removing and installing

Finishes available, 1986 models onward

Turbo emblem - applying . . . . .

66- 1

66-2

66-3

66-4

Washer and Wiper System

Headlight cleaner spray jets - aiming

Exterior Lights, Lamps, Switches

Headlights - aiming . . . . . . . . . . . .

Fog lights - aiming . . . . . . . . . . . .

Concealed headlight linkage - lubricating

. . . . . . . . . . . . . . . . . . . . . . . . . 921

941

94-2

94-3

Table of contents




5

944 turbo Genera 1

Printed in Germany



0.1

General

TECHNICAL DATA

N o t e: Values for USA in brackets

P o w e r P 1 a n t

Company engine code

No. of cylinders

Bore

Stroke

Actual displacement mm/in. mm/in. cm 3 /in.

3

Compression ratio

Max. power to

80/1269/EC

Net power, SAE J 1349

At engine speed

Max. torque to

80/1269/EC

Net power, SAE J 1349 kW/HP kW/HP rpm

Nm/kpm

Nm/ft. rpm

1 bs.

At engine speed

Max. liter output

Net power, SAE J 1349

Fuel octane grade kW 1/HP 1 kW 1/HP 1

RON/MON

Max. engine speed

Engine weight (dry)

E n g i n e

Type

D

e s i g n rpm kg/lbs

Crankcase

Crankshaft

Crankshaft bearings

944 turbo

M 44/51

4

100/3.94

78.9/3.11

2479/151

8.0 : 1

162/220

162/217

5800

330/33.6

330/243.4

3500

65.3/88.7

65.3/87.5

96/86(96/86 lead-free)

6500

182/401

Water-cooled, axial, four-cylinder, four-stroke, inline internal combustion engine with toothed-belt-driven overhead camshaft and two balance shafts

Light alloy, two-piece

Forged, with five bearings

Slide bearings

0.2 Technical Data



Printed in Germany

944 turbo General

Connecting rods Sinter-forged

Connected rod bearings Slide bearings

Piston pin bearings

Pistons

Press-fit brass bushings

Forged light alloy

Balance shafts Forged

Balance shaft bearing Slide bearings with bearing shells

Cylinders

Cylinder head

Light alloy

Light alloy

Valve guides

Valve arrangement

Valve timing

Camshaft

Camshaft bearings

Camshaft drive

Balance shaft drive

Valve clearance

Timing at 1 mm lift and zero valve clearance

Boost

E

n g i n e

Cool ng

Press-fit special brass

1 intake, 1 exhaust, overhead, in-line

By overhead camshaft and hydraulic cam followers

Shell hardcast

Camshaft runs in camshaft housing without bearing she 11 s

Toothed belt with tensioning roller

Toothed belt with tensioning roller

Automatic hydraulic adjustment

Intake opens 1° after TDC

Intake closes 49° after BDC

Exhaust opens 43° before BDC

Exhaust closes 3° before TDC

1 ETC, charging air cooling, electronic pressure control, wastegate

Closed water cooling system, two electric fans with thermoswitch, freeze protection to -25°C

Printed in Germany



Technical Data 0.3

General 944 turbo

E n g n e

System

Oil cooling

L u b r c a t i o n

Pressure circulation with sickle-type pump

Oil cooler in air flow, thermostatically controlled

Screwed on Oil filter

Oil pressure at 5000 rpm Approx. 4 bar positive pressure at operating temperature

Oil pressure display Warning lamp at above 5 bar

Oil consumption,ltr./1000 km Up to 1.5

E x h a u s t S y s t e m Standard: Double-pipe up to primary muffler, primary and final mufflers

(M298 and USA: as standard, cat. conv. instead of primary muffler, cat. conv. in bypass line)

E

m s s i o n

C o n t r o 1

H

e a t n g

(M298 and USA: 3-way cat. conv., controlled air-fuel mixture)

Warm water heater with heat exchange and blower

F u e S y s t e m

Fuel preparation

Fuel supply

DME (Digital Motor Electronics)

1 electric delivery pump

Octane requirement RON/MON 96/86, 95/85 unleaded (96/86 unleaded)

E 1 e c t r i c a 1 S y s t e m

Interference suppression

Battery voltage V

Battery capacity Ah

Battery capacity Ah

(M-eq.)

ECE-R 10 and 72/245/EWG or VDE 0879

12

50 ( 63)

63

Alternator output A/W

Ignition

Firing sequence

115/1610 via DME

1 - 3 - 4 - 2

0.4 Technical Data



Printed in Germany

944 turbo Genera 1

Ignition timing control and knock control

B o d y

D

e s i g n

Electronically controlled map

2-door integral steel body, with front and rear spoilers, as coupe with optional removal hardtop roof, with integral foglights in polyurethane front air dam

D i m e n s o n s (at DIN curb weight)

Length mm/in. 4230/166.535 (4290/168.90)

Width

Height mm/in. mm/in.

1735/68.31

1275/50.20

Wheelbase (design position) mm/in. 2400/94.49

Front track mm/in. - 7 J x 16 rim-1477/58.2

- 8 J x 16 rim-1451/57.1 Rear track mm/in.

Ground clearance (at max. tot. weight) mm/in. 120/4.72

53/2.09 Bed clearance (at mm/in. max. tot. weight)

Overhang angle, front rear

W e i g h t

Curb weight

(per DIN 70020) kg/lbs 1280/2822 (1315/2899)

Curb weight axle load kg/lbs front rear kg/lbs

Max. total weight kg/lbs

Max. front axle load kg/lbs

Max. rear axle load kg/lbs

Max. roof load, incl.roof baggage carrier kg/lbs

640/1411 (660/1455)

640/1411 (655/1444)

1600/3527

730/1609

920/2028

35/77 or 75/165 with original

Porsche roof transport system

Max. trailer load, without brakes* kg/lbs 500/1103

Technical Data Printed in Germany



0.5

General 944 turbo

Max. trailer load with brakes*

Max. car+trailer weight

Max. drawbar load kg/lbs kg/lbs kg/lbs

1200/2646

2800/6173

50/110

84 for Italy up to

100 km/h

*Gradients up to 16%

F i 1 1 C a p a c i t i e s

Engine oil (measurement with dipstick per owner's manual is definitive)

Engine oil volume

Engine coolant

Transmission with differential

Fuel tank

Brand name heavy-duty oil per API classification SE or SF; see

Owner's Manual

Approx. 6.5 ltr. with filter

Approx 7. 8 ltr.

Approx. 2.0 ltr. hypoid gear lub. SAE 80 per mL-L 2105, API classification GL4

Approx. 80 ltr., incl. approx. 8 ltr. reserve

Approx. 0.2 ltr.

Approx. 6.0 ltr.

Brake fluid reservoir

Washing fluid reservoir and headlight cleaning system

P e r f o r m a n c e

Top speed

Acceleration from 0-100 km/h*

(0-60 mph)*

(1/4 mile)*

Kilometer from standing start*

H i 1 1 c

1 i m b i n g

In% (slip limit) km/h/mph 245/152 sec. sec. sec. sec.

6. 3

(6.1)

(14.4)

26.0

Manual transmission

1st gear 61.5%

2nd gear 49.0%

3rd gear 29.5%

4th gear 19.5%

5th gear 13.5%

*DIN curb weight + 1/2 of payload

0.6 Technical Data



Printed in Germany

944 turbo

DESIGNATION OF CYLINDERS

Genera 1

Printed in Germany



Technical Data 0.7

•

944 turbo General

944 turbo - special model "S" (M 758)

In model year 1988 , there will be a limited number of exclusively equipped , t uned v ersions of the 944 turbo available , with a modified sports chassis suitable for the high driving performance

87/955

The most significant modifications or distinguishing features (exact description in information brochure WKD 495010)

1 . Engine : 250 HP/184 kW, catalyst version for FRG , others in accordance with respective national regulations .

2 . Clutch : Clutch plate wi t h two stage torsional spring damper , fr i ction lining bonded as well as ri v eted to the support plate .

0.8a 944 turbo - special model "S" (M 758)

Printed in Germany- 111,1988



General 944 turbo

3 . Transmission :

4 . Chassis :

Transmission ratio as standard but some parts adapted to the higher performance.

Only outwardly recognizable by the additional identification code AOR.

Milled forged wheels (larger cutouts) front 7 J x 16 ET 65 mm with 225 / 50 VA 16 rear 9 J x 16 ET 60 mm with 245 / 45 VA 16

Brake system : front-axle brakes similar to 928 S4 with asbestos-free brake pads .

5 . Paintwork :

6 . Interior :

Wheel suspension: at front and rear axle bearings with harder rubber compounds

(shore hardness)

- Springs / shock absorbers: Harder spring rates (also with height adjustment at the front)

Koni twin tube pressurized shock absorbers (adjustable rebound).

Special color silver rose metallic multicolor burgundy

0.8b



0.12

944 t urbo - special model "S" (M 758)

Printed in Germany Ill, 1988

944turbo Gener al

7 EQuipment (incom plete list in g) . Listed equipment valid for all countries .

Special model ''S" turbo equipment M No . in the turbo series

S ports

ABS chassis

Limited -s lip different ia l 40 % locking ratio

(com pi3,red with the series model specia l option M 220 has r einforced plates and pressure ring ; differential bolts molybdenum-coated and ground)

M030

M593

( M 220)

Comfort seat lett

Comfort seat right

M43 7

M438

8 Technical data ·

Performance

Torque

Compression r atio

Fuel

Engine type M 44 .

52

Turbo special model ''S"

250 HP / 184 kW a t 6000 rpm

350 Nm at 4 000 rpm

8 .

0 : 1

95 RON

Unleaded

L eaded•

Curb weight 1 350 kg

.Acce

l era tion :

0 100 krnlh (062 mph)

0- 60 mph

5 .

7 s

5.5 s

Vmax 260 km/h

162 mph

• For veh icl es w ithout catal'ytlc converter only

6.3 s

6.

1 s

245 km/h

152 mph

Eng i ne type M 44.51 turbo (series)

220 HP / 1 62 kW at 5800 rpm

330 Nm at 3500 rpm

8.0:1

95 RON

Unleaded

Lead ed*

1 350 kg

944 turbo • special model " S ' ' (M 758)

Printed i n Germany IV,1991



O .

Bc

944 turbo

LIFTING THE VEHICLE l.

W i th L i f t i n g

P 1

a

t f o r m

L ift vehicle only at illus trated jacking points .

When driving vehicle onto lifting platform, make sure of sufficient space between p l atform and vehicle.

F r o n t

On inside side member

R e a r

On s i de reinforcement

General

Printed in Germany



Lifting the Vehicle 0.9

Genera 1

2 . W i t h S h o p T r o 1 1 e y J a c k

Apply jack only underneath jacking points on sides of vehicle. Never jack on engine oil pan or transmission, as this can cause serious damage.

I m p o r t a n t

Avoid damage by inserting block of wood between vehicle and jack.

944 turbo

0.10 Lifting the Vehicle



Printed in Germany

944 turbo Engine, Crankcase 10

TOLERANCES AMD WEAR LIMITS

On Installation (new)

C o o 1 i n g S y s t e m

Coolant thermostat Opening temperature

Opens at overpressure Radiator cap

Over pressure valve

Low pressure valve Opens at negative pre s sure

1.5 + 0.15 bar

- 0.10

0.1 bar

Wear Limit

0 i S y s t e m

Oil consumption

Oil pressure at 80 ° C oil temperature and 5000 rpm ltr.

/ 1000 km

Po s itive pressure

Dipstick

Upper mark

Lower mark

Contents

Contents

V a 1 v e T i m i n g

Camshaft bore Inside dia.

Camshaft Di a meter

Camshaft

Cam follower bore in camshaft hou s ing

Cam follower s

A x

In ial play s ide dia.

Diameter

Camshaft Runout approx. 4 bar

6.5 ltr.

5,3 ltr.

60 .

5 + 0.03

- 0

60.5 - 0 .

0 4

- 0.05

5

0.10 - 0.1

8

38 + 0.027

+ 0.

007

38 - 0 .

018

- 0 .

034

0.0

2 up to 1.5

Printed in G e rm a ny



Toler a nc es and W ar Limits 10 0 1

10 Engine, Crankcase 944 turbo

TOLERANCES AND WEAR LIMITS

On Installation (new)

C y l i n d e r H e a d a n d V a 1 v e s

Bearing surface

Valve

seat:

Intake

Exhaust

Intake

Exhaust

Outer correction angle

Inner

correction

angle

Valve guides:

Intake and Exhaust

Valve

stem

:

Intake

Exhaust

Valve guide I Valve

stem

Intake '

Exhaust

Compression

Distortion

Width

Width

Seat angle

Seat angle

Inside dia.

Diameter

Diameter

Clearance

1.7

2.5

45 °

45 °

30°

60 °

9 + 0.015

8.97 0.012

8.95 0.012

10 bar positive pressure and above

Wear Limit

Max.

0.08

0.8

0.8

6.5 bar

P i s t o n s· a n d C o n n e c t i n g R o d s

KS - Pistons

Cylinder/Piston Clearance 0.008 · ;- 0.032

Piston rings

Piston rings

Approx.

0.080

(limit for wear and deformation)

Side clearance Groove 1

= 0.04 - 0.072

Groove 2

= 0.03 - 0.062

Groove 3 = 0.02 - 0.055

End gap Groove 1 = 0.20 - 0.40

Groove 2 = 0.20 0.40

Groove 3 = 0.30 - 0.60

0.80

0.80

1.20

10 - 02 Tolerances and Wear Limits



Printed in Germany


Connecting

rod

bushing

Piston pin

Connecting r od bushing/ piston pin

Diameter

Diameter

On Insta

11-

ation (new)

24 + 0.018

+ 0.028

24 0.004

Radial play 0.018 0.032

C r a n

k

s h a f t a n d E n g i n

e B 1

o c

k

Wear Limit

..

. a

Crankshaft

Connecting

Connecting

crankshaft rod rod

bearing bearing

journal

I

Runout

Diameter

0.04 - 0.06

51.971 - 51.990

Radial play 0.034 - 0 .

092

End play

Crankshaft bearing journal Diameter

Crankshaft bearing/crankshaft Radial play 0.020 - 0.098

Crankshaft bearing/

0 . 100 - 0 .400

69.97169.990

crankshaft

Cylinder bore

Bore for balance shaft bearing shells in

crankcase

End play out-up-round

Diameter and balance shaft cover

Bore for bushing in bearing Diameter housjng

0.110 - 0.312

0.010

35.000-35.019

34.000 - 34.019

Balance

shaft

Diameter 30.975 - 30 .991

Max. 0.08

0.40

0.020

Printed in

Germany



Tolerances and

Wear Limi ts 10 - 03


TIGHTENING TORQUE FOR ENGINE

Location

Crankcase upper and lower sections

(studs)

Rotation element to balance shaft

Tightening

Instructions

Torque

Nm (ftlb)

3 steps: 1st step 20 (14)

2nd step 40 {29)

3rd step 75 (54)

2 steps: 1st step

2nd step

Bolt lightly oiled

20 (14)

50 (36)

8 (6)

20 (14)

10 (7) sealed with Loctite

270

10

Thread

M 12

X

1.5

M 10

M 6

M 8

M 6

Balance shaft housing cover to crankcase upper section

Hex bo1t

Balance shaft bearing bridges

(nuts) on cra nkcase upper section

Left and right side< of bearing housing to crankcase upper section

Connecting rod

Verbus rip nut

2 steps: 1st step . 15 (11)

2nd step 20 (14)

2 steps: 1st step

2nd step

15 (11)

30 + 3 (22 + 2)

;

20

75

(14)

+ 5 (54 + 3 .

6)

M

M

~1

6

8

M 8

M

8

10xl.25

-

20 (14) M 8 Water drain plug in crankcase upper section

Fastening oil pan to crank cas e

M 6

Oil pan to

Oil lighter oil pan dra i n plug

3 steps: 1st step hand-tighten

2nd step 4 (3)

3rd step 9.5 (7)

5.6 (4) sealed with Loctite

270

50 (36)

M 5

~1 20

X

1.5

Printed in Germany



Tightening Torque 10 05


Location

Left and right engine supports to crankcase

Flywheel to crankshaft

Halder for sensors to crankcase

Sprocket to crankshaft

Sensor to holder

Pulley to sprocket

Cyli n der head to crankcase upper section

Intake pipe to cylinder head

Hollow-core bolt for negativ e pressure connection

Neck for coolant pipe

Tightening

Instructions

Torque

Nm (ftlb}

48 (35}

90 (65}

20 (14)

210 (145)

8 (6)

8 (6)

Tightening cylinder he a d gasket:

1st step

2nd step

3rd step

Threads of st uds must be

1 ig htly oiled

-

2 0 (14)

50 (36)

90 (65)

;

20 (14)

10 (7)

20 (14)

Thread

M 10

M 10x1.25

M 8

M 16xl.5

M 6

M 6

M 8

M 8xl

M 8

Prin ted in Germany 10 - 06 T ig h te ning Torque



944 turbo Engine, Crankcase

Location

Heated feed connection to cylinder head

Camshaft housing to cylinder head

Aluminium plug bolts in camshaft housing

Camshaft bearing to camshaft housing

Knock sensor

:

Camshaft sprocket to camshaft polygon socket-head bolt

Console to camshaft bearing

Connector to drive dog

Cover and transport guard to camshaft housing

Distributor arm to connector

Tightening

Instructions

Use original bolt without washer

'

Torque

Nm (ftlb)

20 (14)

20 (14)

40 (29)

8 (

8 (

6)

9 (6.6)

65 - 70

(47-51)

6}

5 (3.6)

8 ( 6}

4 (3)

10

Thread

M 8

M 8

Ml8xl.5

M 6

M 8

M 10

M 6

M 5

M 6

M 4

Printed in Germany



Tightening Torque 10 - 07


~ ·

Location

Sprocket to balance shaft

Tensioning roller to bearing housing

Guiding roller to bearing housing, right

Water pump to crankcase

Guid i ng roller to water pump housing

Oil pump to crankcase

Tensioning roller to oil pump housing

Dri ve belt cover

Spark plugs

Alternator console to crankcase

Cap nut on catalytic converter

Temperature sensor

Oil pressure sensor

Diaphragm damper anc pressure regulator to fuel collection pipe

Cap nut on fuel collection pipe

Tightening

Instructions

Torque

Nm (ftlb)

45 {33)

45 (33)

45 (33) (sealed with Loctite 270)

8

45 (33)

45 ( 33)

8 ( 6) t

25 30

(18-22)

45 (33)

30 (22)

15

(6)

(11)

35 ( 2 5)

30 (22)

22 (16)

Thread

M 10

M 10

M 10

8 {6) {sealed with Loctite 270) M 6

45 {33) M 10

M 6

~1 10

M 10

M 6

M14x1.25

~1 10

M 14xl. 5

M 12xl. 5

~1 18xl. 5

M 16xl.5 r~ 12xl. 5

·

10 - 08 Tightening Torque



Printed in Germany


Location

Housing liner in oil pump housing

Cooler housing/ thermostat housing to crankcase housing

Threaded plug on oil/water cooler housing

Coolant bleeder bolt

Pressure relief valve, oil filter

Oil trap to crankcase

Hollow-core bolt/ oil line to balance shaft cover

Hollow-core bolt/ oil return line to oil pan

Hollow-core bo1t/ coolant line to exhaust turbocharger

Connection stud to exhaust turbocharger

Coupling nut/coolant lead to exhaust turbocharger

All other bolts and nuts:

M 6

M 8 t~ 10

Tightening

Instructions

Joint surface sealed with

Loctite 574

8 + 2 (6 + 1.4) .

20 + 2 (14 + 1.4)

40 + 5 (29 + 3.6)

Torque

Nm (ft1b)

8 (6)

20 (14)

35 (25}

12 + 3

(9 + 2)

45 (33)

20 (14)

20 {14)

25 + 3

(18 + 2)

75 + 5

(55 + 3.6)

35 + 5

(25 + 3.6)

35 + 5

(25 + 3.6)

35 + 5

(25 + 3.6)

Thread

M 6

M 16x1.5 f'.1 16x1.5

M 22x1.5

M 8 mBx1.5

~1 8

X

1 fv1

20xl.5

M 8

M 14

M 26xl. 5

Printed in Germany



Tightening Torque 10 - 09

10

Engine, Crankcase


Location Thread

Crankshaft/ crankcase

Bolts of crankcase top and bottom sections (studs)

M 12 X 1,5

M 10

M8

M6

M6

, ,

Oil pan to crankcase

Oil pan insert to oil pan

Knock sensor as of MY 88

Cylinder" head

Cylinder head to crankcase top section

Engine type M 44 .

51/52

Fuel system

Cap nut at fuel collection pipe

M5

MB

M 12

M 12 X 1,5

944turbo

Tightening torque Nm (ftlb)

30 (22)

60° torque angle

20 (15)

50 (37)

20 (15)

10 (7)

Stage 1

Stage 2

Stage 1

Stage 2 hand-tight

4 (3)

10 (7)

Stage 1

Stage 2

Stage 3

6 (4) , use Loctite 270 to secure

20 (15) , genuine bolt without washer

20 (15) Stage 1 goo torque angle Stage 2 goo torque angle Stage3

12 (9)

10 010




Printed In Germany -IV , 1991

944 turbo

REMOVING AND INSTALLING ENGINE

TOOLS

Engine I Crankcase 10

No. Description

Engine suspension fixture

Special Tool

3033

Remarks

Used together with a shop hoist, e.g.

Bilstein

K750

H.

N

o t e:

If necessary, connect engine suspension fixture and shop hoist with standard spring-loaded hooks (load capacity: 650 kg).

Printed in Germany



Removing and Installing Engine 10 1

10 Engine I Crankcase 944 turbo

REMOVING AND INSTALLING ENGINE (MANUAL TRANSMISSION)

Engine is removed from below.

Clutch housing remains on engine.

R e m o v a 1

1. Set up lifting platform and lift car on jacking points.

•

2. Place protective covers on fenders.

3 . loosen and remove front wheels.

4. Disconnect ground lead on battery/body. Disconnect battery plus cable, separate cable harness, and push both cables with the rubber grommet through the fire wall . Open wire straps .

5. Unscrew and remove cover in footwell of passenger side. Unscrew carrier for DME and knock control unit and remove both multiple -pi n plugs. Disconnect vacuum hose on knock control unit. Disconnect four-pin plug .

6. Loosen fuel return hose clamp and pull off hose. Unscrew fuel feed hose, while counterholding. Disconnect cable on cruise control motor.

10 2 Removing and Installing Engine



7. Unscrew and remove air cleaner upper section.

Printed in Germany

944 turbo Engine I Crankcase 10

8. Remove both charging -air guide pipes.

10. Unscrew and remove distributor cover. Remove oil fi lte r and ATF supply reservoir.

11. Disconnect throttle operating cable. Disconnect oxygen sensor plug connection a n d loos en wire strap s. Unscrew coolant expansion tank cap.

9. Remove air clean~r lower section toget her w ith air flow sensor.

12. Remove front and lower trim panel and engine splashgua rd.

Printed in Germany





13. Unscre w coolant drain plug and catch escaping coolant. Disco nnect alternator venting hose.

14. Loosen and remove coolant hose on radiator at bottom right and on engine. Catch escaping coolant. Disconnect oil coo1er from body, allowing it to hang on the hoses.

17. Unscrew and remove coolant hose and vent hose on rad ia tor at top left. Remove electric connection from temperature switch on radiator.

15. Pu ll off electric wires on fan motors. Unscrew fan motor brackets on radiator and remove from below.

16. Loosen coolant hoses on coolant pipe (cross member) and remove cross member.

18. Loosen and remove coolant hose from expansion tank to turbocharger. Disconnect tank discharging valve suction hose on intake air cowl. Remove coolant pump with its bracket from body.




Printed in Germany


19. Detach radiator holder and remove radiator from above. Unscrew radiator mount and remove from body.

21. Loosen poly-rib drive belt tensioner on a/c compressor and remove belt. Unscrew compressor on console and allow it to hang down to the side (refrigerant hoses remain connected).

~0. Suspend engine from front transporting bracket with

Special Tool 10-222 A, and hold in installed position. 22. Unscrew and remove stabilizer with holders on body and control arms. Disconnect left and right tie rods.

23. Loosen hose clamps between ATF cooler and steering, and disconnect hose.

Printed in G e rmany



Removing and Installing Engine 10 - 5


24. Unscre w power pump from con so le and let it hang down on st eer i n g.

27. Unsc rew def lection plate o n star ter and clutch housing and remove toward rear.

25. Unscrew left and right co ntrol arms on front axle cross member and rear mou nt, and pull out f r om front. (Console bolts must not be loosened).

26. Unscrew un i ver sa l jo int from steeri ng gear and upper hydraulic engine mounts from engine supports . Remove front axle c ross member with steer ing gear and power pump from below.

28 . Disconn e ct electrica l connec tions on starter and unscre w starter . Loo sen ho se c lamps on clutc h housing.

29. Unscrew clutch slave c ylinder on clutch hou sing (li n e remains connecte d ) .

30 . Re n~ve exhaust assembly together with ca talyt ic converter .

Unscrew bo l ts on flange between turbocharger and exha u s t pipe, as well ' as flange on bypass va .

lve.

I




Pr int e d in Germany


..

31. Unscre w flange after catalytic and suspension , and remove assembly.

36. Connect Special Tool 3033 in transporting bracket of engine as described below.

32. Unscrew hose clamp, exhaust flange, and bypass valve holder.

Remove bypass valve . Unscrew bracket on transaxle at bottom and push back.

33. Unscrew upper transaxle housing mounting bolts.

I clutch

Pulley:

Flywheel:

Pos. 3

Pos. 11

In Position 3 the threaded rod is

"below" the suspension unit. In

Position 11 the threaded rod is

"above" the suspension fixture.

34 . Disconnect coolant hoses for heater above exhaust manifold and on cylinder head.

Loosen wire strap on firewall.

Disconnect two-pin and multiplepin plugs. Pull off vacuum hose on tank discharging valve ar.d brake booster. Remove diagnosis plug from holder downward.

37. SJ~ghtly tighten suspension f ~ xture on engine using a shop hoist, e.g. K 750 H, and remove

Special Tool 10 - 222A.

38. Remove lower transaxlelclutch housing mounting bolts.

39. Pull engine forward, press rubber sleeve out of separating wall towards engine compartment, and remove wire harness carefully.

Printed in Germany



Removing and Installing Engine 10 - 7


40. Separate engine from central tube or central shaft, and lower engine.

I n s t a 1 1 a t o n

The following should be observed :

1. Carefully guide wire harness for

DME and knock control unit, multiple-pin plug, and vacuum hose into footwell on passenger side.

2. Screw in transaxle I clutch housing mounting bolts first, but do not tigh te n.

4. Make sure radiator fits properly in rubber mou nts .

N o t e

Tighten mounting bolts to final torque only after installation of hydraulic engin e mounts on front axle cross member.

Tightening torque of mounting bolts: 42 Nm (3 0 ftlb).

3 . Install control arms. For ea s ier installation, press down s lightly on sleeves in rubber lm irdle mounts.

5. Tighte~ bolts and nuts to sp~cified tightening to rq ue.

6. Fill and bleed cool in g syste m .

10 8 Removing and Installing Engin e



Pr inted in Germany

944 turbo

7. Fill sup ply reservoir with ATF and bleed steering system .

8. Run engine to operating temperature.

Check engine oil and c o olant level, correcti ng if necessa ry .

Engine I Crankcase 10

Printed in Germany




944 turbo Engine I Crankshaft, Pistons

13

CHECKING AND ADJUSTING POWER STEERING PUMP DRIVE BELT TIGHTNESS

C

h e c k i n g

Check tightness by applying thumb pressure on belt midway between two pulleys. Deflection: approx. 5 mm.

3. Loosen connecting rod bolts slight l y.

Loosen connect in g rod nuts and turn connecting rod until correct belt tightness is obtained.

A d j u s t i n g

1.

Remove engine splashguard .

2. Loosen upper mounting bolt or nut slightly.

4. After finishing adjustments, retighten mounting bolts and/or n4ts.

Printed in Germany



Checking and Adjusting Power

Steering Pump Drive Belt Tightne ss

13 - 1

13 Engine I Crankshaft, Pistons 944 turbo

CHEC KING AND ADJUSTING TIGHTNESS OF POLY-RIB DRIVE BELT FOR ALTERNATOR

AND A/C COMPRESSOR

C h e c k i n g a n d a d j u s t i n g

1 . Remove engine splashguard .

N o t e

2 . Loos en connecting rod hex bolts sl igrtly. Loosen connecting rod nuts and turn back connect ing rod one turn (reduces tightness).

Sli d es m u st be in perfect contact with drive belt . The special tool must not be turned or move d on drive belt during checking.

3. Prepare Special To ol 9201 for checki ng operation. Pu ll out lockp in in special tool and push out test pin opposite lockpin co mpletely. Line u p drag needle with gage needle .

4. Slide special tool onto belt.

Press in gaging pin (arrow) slowly until lockpin is felt to engage, and read value indicated on dial gage. Adjusting value: 9.5 scale units . From this position, turn t he connectingr rod one more complete turn (increase tension) .

13 - 2


Checking and Adjusting Tightness 111,1988Printed in Germany of Poly-Rib Drive Belt for

Alternator and A/C Compressor manuals search engine

..

944 turbo

TOOLS

Engine I Crankshaft, Pistons 13

' )

L

3

No.

1

Descrip tio n

Drive belt tight ness tester

/\cj ust i ng gag e

Adjust ing wrench

Special Tool

9201

9207

9244

Remarks

Printed in Germany



Tools for Checking and Adjusting Tightness of Toothed Belt f or Balance Shafts

13 3


CHECKING AND ADJUSTING TIGHTNESS OF TOOTHED DRIVE BELT FOR

BALANCE SHAFTS

N o t e

Toothed drive belt tightness must only be checked and adjusted on a cold engine (room temperature).

1. Unscrew and remove engine splash-

9Uard, air cleaner upper section, and air cleaner lower section together with air flow sensor .

2. Remove poly-rib drive belt or power steering pump drive be1t .

N o t e

Before unscrewing locknuts, always loosen connecting rod hex bolts s lightly . a. Lvosen guide roller enough so tha t guide roller no l cnger tensions toothed drive belt .

3. Disconnect vent hose at top and remove toothed drive belt cover.

13 - 4 Checking and Adjusting Tightness of Toothed

Downloaded from

Belt for Balance Shafts www.Manualslib.com


Prin te d in Germany

944 turbo Engine I Crankshaft, Pistons 13

5a . Turn crankshaft clockwise until

TDC mark on camshaft sprocket is aligned with mark cast in console for distributor cap.

6. Check basic position of balance shaft sprockets. Marks on sprockets must be aligned with marks of rear toothed drive belt cover. b. TDC mark on flywheel and cast boss on clutch housing must also be aligned.

7. Prepare Special Tool 9201 for testing operation. Pull out lockpin on special tool and push out test pin opposite lockpin completely. L ine up drag needle with gage need~e.

B. Slide special tool onto belt.

Pus~ in gage pin (arrow) s lowl y unti1 lockpin is felt to engage, and ' read value indicated on dial gage .

N o t e

In order to rule out incorrect displays, make sure to line up drag needle with gage needle after engagemEnt of lockpin (turn counterclockwise).

Pri 11ted in Germany



Checking and Adjusting Tightn ess of Toothed 13 5

Belt for Balance Shafts

13 Engine I Crankshaft, Pistons

A d j u s t i n g V a 1 u e:

(new and used belts)

2.7 + 0.3 scale units

Correct toothed drive belt tightness if necessary.

944 turbo

10. Adjust guide roller after adjusting tightness of toothed belt. Set distance between guide roller and toothed belt in area of lower balance shaft to 0.5 mm using Special Tool 9207 or a 0.5 mm feeler gage blade, pre-tensioning upper belt strap with 0 to 1 mm at same time.

Secure guide roller in this position. If the adjusting distance is insufficient, turn guide roller 180° and repeat adjusting procedure. Tighten hex nut to torque of 45 Nm (33 ftlb), making sure to counterhold.

A d j u s t i n g

9. When tightening, turn tensioning roller clockwise. Turn tensioning roller counter-clockwise to loosen belt. Tighten nut to torque of

45 Nm (33 ftlb), making sure to counterhold.

11. Install and adjust poly-rib belt , or power pump drive belt.

13 6 Checking and Adjusting Tightness of Toothed

Downloaded from

Belt for Balance Shafts www.Manualslib.com


Printed in Germany

944 turb o

N o t e

Sl ides m u st have full contact on t h e dr ive belt.

The special tool must not be turned or moved on belt wh i l e c he c king.

Engine I Crankshaft, P isto n s 13

Id ler pull ey

Printed in Germany



Checking and Adjusting Tightness of Toothed 13 - 7

Belt for Bal anc e Shafts

944turbo

13

Engin e I crank s ha ft, pistons

Check i ng pistons and cylinder bores

EDEDCDEB

Repair Stage Piston 0

(mm)

Fa . Kolb e nschmidt

Cy l inder bore dia . to l erance gro u p

(mm) code

S tandard s i ze 99 , 980

99 , 9 9 0

1 00 , 000

± 0 ,0 07 100 , 010 ± 0 , 005

100 ,00 0 100 , 020

O v e r s ize 1 100 , 480 100 , 500

100,490 ± 0,007 1 00,510 ± 0,005

100 , 500 1 00,520

0

1

2

0

1 z

C h ecking p ist on s

M eas ure approx . 62 mm f r om piston crown , g o · offset from p i ston pin axis .

C h ec k i ng c ylind e r bor es

Measure approx. 65 mm from uppe r edge of cylinder bo r e , tra n sverse to engine block.

Mount lowe r cra nk case section and tighten bo l ts to specified t orque for measuring .

N ote

It recommended that the s to c ks of the relevant tolerance group are checked before machi n ing the c ylind e r s . If necessary , hone t o the piston s i ze ava i lab l e .

In so me c ases , certa i n tol e r a nc e groups may be in short supply .

13 8



Check i ng p i ston s and c y lind e r bores

Printed in Germany - IV , 1991

944 turbo Engine

I

Crankshaft, Pistons

13

DISASSEMBLING AND ASSEMBLING PISTONS AND CONNECTING RODS

30 31

32

33 35 40 42 39 41

36 31 38 l

5 29 26 22 21 25 24 t

,

34

1 2 3 4 6 7 11 13 8 9 10 12 20 15 14 19 18 17 16 23

Printed in Germany



Disassembling and Assembling Pistons and Connecting Rods

13 9

·

13 Engine I Crankshaft, Pistons 944 turoo

No. Description

1 Hex bolt, t4 10

X

35

Qty. Removing

1

2

4

5

6

Washer

3 Call ar for upper balance shaft

Drive gear for balance shaft

Woodruff key

Upper balance shaft seal ring

30 X 47

7 Spacer

8 Hex bolt

M 8 X 35

1

1

1

1

1

1

3

Note When:

Installing

Coat threads with

Loctite 574, torque:

45 Nm (33 ftlb), counterhold with

Special Tool 9200.

Position correctly.

Position correctly, locating tab inserts into unmarked groove of drive gear. t1ark

11 11 0 is visible in large opening in collar.

Check ease of movement on seat of balance shaft, machining if necessary. Lightly coat seat with

Optimoly HT.

Replace, oillubricate sealing lip, mark (arrow) faces in direction of turn of balance shaft.

'

13 - 10 Disassembling and Assembling Balance

Shaft Drive



Printed in Germany


No. Description

9 Washer A 8.4

10 Upper bearing housing

11 Polyester seal

12 0-Ring

Qty. Removing

3

1

1

1

Note When:

Installing

Replace, making sure of correct fi{.

Replace, lightly coat with oil, make sure it is not twisted.

13 Sleeve

14 Hex bolt

M8x55

15 Washer A 8.4

16 Hex bolt

M6x50

17 : Washer A 6.4

18 Hex bolt

M6x42

19 Washer A 6.4

20 Upper balance shaft housing

4

8

1

4

2

1

4

2 l

Apply Loctite

574 to sealing surface with vel our roller.

Note tightening instructions.

-

21 End ring

22 Round seal

1

1 Replace

Printed in Germany



Disassembling and Assembling Balance

Shaft Drive

13 - 11

13 Engine 1 Crankshaft, Pistons 944 turbo

No. Description

23 Seal ring

Qty. Removing

1

24 Hex nut

M 8

2

25 Washer 2

26 Bearing bridge 1 for balance shaft

27 Upper balance shaft

28 Bearing shell

1

1

29 Bearing shell

30 Hex . bolt

M10x35

1

1

Note When:

Installing

Replace, insert in bearing bridge takeup bore with grease.

Tightening torque

30 + 3 Nm (22 + 2 ftlb)

31

33

Washer

32 Collar for lower balance shaft

Drive gear for balance shaft

1

1

1

.

l

Check for correct fit.

Check for correct fit .

Lightly coat threads with

Loctite 574, torque :

45 Nm (33 ftlb), counterhold using holding wrench 9200.

Position correctly.

Position correctly, with locating tab protruding into groove "0" of drive gear; mark "0" is visible in square opening of collar.

Check ease of movement on se at of balance shaft, machining if necessary. .Apply thin coat of Optimoly

HT to seat.

13 - 1 2 Disassembling and Assembling Balanc e

Shaft Drive



Prin ted in Germany


No. Description

34 Woodruff key

35 Balance shaft seal ring

30 X 48

Qty. Removing

1

1

Note When:

Installing

Replace, oillubricate sealing

1 i p. Observe marking (arrow).

Rotational direction counter-clockwise.

36 Spacer sleeve

37 Hex bolt

M 8 X 60

38 Washer

39 Lower bearing housing

40 Polyester seal

41 0-Ring

3

3

1

1

1

Replace, making sure of correct seating.

Replace, lightly lubricate with oil, make sure ring is not in a twisted position.

42 Sleeve 1

Printed in Germany



Disassembling and Assembling Balance

Shaft Drive

13 - 13


INSTALLATION INSTRUCTIONS

Crankcase upper and lower sections as well as bearing bridges of balance shafts are machined together and must always be installed together . Check identification codes.

In addition, the bearing bridges are stamped with 1 and 2.

I n s t a 1 1 i n g B e a r i n g

B r i d g e s o f B a 1 a n c e

S h a f t s

~

In ins talled position it must be possible to read the identification co des of both bearing bridges from the front (as seen looking forward in vehicle).

1 = Right side

Picture shows left balance shaft .

2

=

Left side

13 - 14 Installing Beari n g Bridges of Compensating

Shafts



Printed in Germany

9 44t ur bo Engine I

Note

The bearing bridge for the left balance shaft has on oil feed bore for the exhaust turbocharger . Before installing the balance shaft, it is vital to ascertain that the seal ring is in position in the take-up bore of the bearing bridge

(use grease) . crankshaft , pistons

13

Assembly note

Whenever performing repairs on the engine, make su re the seal is replaced .

Installing bearing bridges of compensating shafts

Printed in Germany IV, 1991



13 15

13 Engine I Crankshaft , Pistons

ASSEMBLY INSTRUCTIONS

TIGHTENING PROCEDURES AND TORQUES FOR CRANKCASE UPPER SECTION ON

BALANCE SHAFT HOUSING

944 turbo

N o t e

The crankcase upper section and ba la n ce shaft hou sing must be aligned with one another as described below.

!.Hand-tighten all hexagonal-head bolt s .

2.Mount bearing housing with a lightly oiled 0-ring, but without tightening mounting bolts.

3 .

Tightening torque forM 6 bolts= 10 Nm (7 ftlb) .

Tightening torque for

MB

bolts in 2 steps:

1st step

2nd step

= 15 Nm (11 ftlb)

= 20 Nm (14 ftlb)

See illustration for order of tightening.



<::h,-4'"+

Printed in Germa n y

944twbo Engine, Cylinder Head, Pistons

Refaclng the flywheel

If severe score or burning marks are evident on the flywheel, the clutch disc mating surface In the flywheel may be refaced on a lathe .

Remove as little material as possible .

Wear limit for flywheel thickness: 25 .

2 mm .

13

1

727/13

1 Wear limit 25,2 mm

2 Remove as little material as possible

3 Max. runout 0 .

05 mm

Note for refacing the mating surface:

Surface roughness + unevenness = 0.008 mm

Refacing the flywheel

Printed In Germany N, 1991



13- 17

944 turbo

TOOLS

Engine I Cylinder Hea d, Valve Drive 15

No.

1

2

Description

Belt tightness tester

Adjusting wr ench

Special Tool

9201

9244

Remarks

Printed in Germany



Checking and Adjusting Tightness of Camshaft Drive Belt

15 - 1

15 Engine I Cylinder Head, Valve Drive 944 turbo

CHECKING AND ADJUSTING TIGHTNESS

OF CAMSHAFT DRIVE BELT

N o t e

Tightness of the toothed drive belt may only be checked and adjusted on a col d engine (room temperature).

C h e c k i n g

1. Turn crankshaft slowly clock wi se until TDC mark on camshaft sproc ket lines up with mark cast in console for distributor cap.

3. Turn engine co unterc lockwise on cranks haft approx. 10 cranks haft degrees, which equals approx . 1 .

5 teeth toward mark on cams haft sproc ket.

N o t e

4. Prepare Special Tool 9201 for check

1 ing operation. Pull out lockpin on Special Tool and push test pin opposite lockpin completely out . Line up drag needle with gage needle.

Wh ile turning, check toothed drive belt for wear and dam age.

2. The TDC mark on fly wh eel a nd the cast boss on the clutc h housing must likewise be alig ned.

5. Slide special tool onto belt.

Slo wly push in gaging pin (arro w ) until lockpin is felt to engage, and read value indicated on dial gage.

15 - 2 Checking and Adjusting Tightness of Camshaft Drive Belt



Printed in Ge rman y

944 turbo Engine I Cylinder Head, Valve Drive 15

N o t e A d j u s t i n g:

To avoid incorrect rea dings, always line up drag needle and gaging needle only after engagement of the lockpin

(t urn counter-clockwise).

6. To tighten, turn tensioning roller counter -clockw ise.

To loosen, turn tensioning roller clockwise . Move tensioning roller accordingly wi th Special Tool 9244

( adjusting wrench).

A d j u s t i n g V a 1 u e s:

New belt:

Used belt:

4 .

0 + 0.3 scale units

2.7

+

0.3 scale units

Correct toothed drive belt tightness i f necessary .

N o t e

Slides must have full contact with drive belt. Do not turn or move special tool on belt during testing.

7 . Tighten mounting nut to torque of

45 Nm (33 ftlb), making sure to counter hold.

8. Cran k engine two turns cloc kwise and align TOC mark on camshaft sprock et with mark cast in co nsole for distributor cap.

Crarik engine counter-clockwise from this position about 10 crankshaft degrees.

9. Recheck , and if necessary correct tig htness of toothed drive belt.

Printed in Germany



Checking and Adjust ing Tightness of Camshaft Drive Belt

15 - 3

15 Engine I Cylinder Head, Valve Drive

CHECKING AND ADJUSTING INSTALLED LENGTH OF VALVE

SPRINGS

1 . Install Special Tool 9138/1 w ith the s h ims , spring retaine r, and two collets belonging to the valve in question.

2. Read distance on Sp ec ial Tool

9138/1 and if necessary co rrect by installing or remov ing shims .

Shims are a v aila ble in thicknesse s of 0.5 and 1.0 mm.

Intake valve

Exhaust valve

41.0

40.0

+

+

0. 5

0 .5 mm mm

944 turbo

N o t e

The oute r valve spr i ng ha s a length when at rest of approx . 58 mm

( appr ox . 52 mm s u ction motor) .

Identifying mar k: 2 light purple / green lines on the spring w ire .

15 - 4

Checking and Adjusting Installed

Length of Valve Springs



Printed i n Germany

944 turbo Engine I Cylinder Head, Valve Drive 15

INSTALLING SHAFT SEAL ON

CAMSHAFT BEARING COVER

N o t e

The shaft seal (32 x 47 x 7) and spacing sleeve for the camshaft are no longer identical with the seal and spacer for the upper balance shaft (they were previously).

Marking (arrow) points in direction of turning of camshaft .

Lubricate sealing l ip with oil and install together w ith spacer, and drive end with Special Tool 9202

(pressure pad).

Printed in Germany



Installing S haft Seal on Camshaft

Bearing Cover

15 5

944 turbo

REPLACING ENGINE OIL AND FILTER

Requirement:

Engine at operating temperature.

1. Unscrew and remove oil filler cap.

-

2. Remove engi ne splashguard. Remove drain plug from oil pan and drain engine oil.

Engine I Lubrication 17

3. Unscrew oil filter with Special

Tool 9204 (oil filter wrench).

Catch remaining oil.

4. Clean drain plug, making sure to replace seal. Tightening torque:

50 Nm (36 ftlb).

5. Give gasket on oil filter a light coat of oil . Screw filter on by hand until gasket makes contact, and then tighten by one additional tu~n. Finally recheck tightness of filter with oil filter wren ch.

Recommended tightening torque:

20 Nm (14 ftlb).

6. Add engine oil , run engine to operating temperature, and check for leaks.

7 . Check oil level on stoppe d engine.

Printed in Germany



Replacing Engine Oil and Filter 17 - 1

944 turbo Engine I Cooling 19

COOLANT MIXING TABLE

(A v e r a g e V a 1 u e s)

Freeze

Protection

Anti-Freeze

- 25°

- 30°

- 35° c (-13CF) 40 % c (-22°F) 45 % c (-31°F) 50 %

CHECKING COOLING AND HEATING

SYSTEM FOR LEAKS

1. Inspect visually for leaks.

2. Check cooling and heating hoses for correct routing, porosity, swelling, tears, and rubbing damage. Replace damaged hoses.

3. Tighten hose clamps.

Water Anti-Freeze

60 %

55 %

50 %

3.1 1 tr

3.5 ltr

3. 9 1 tr

Water

4. 7 ltr

4.3 ltr

3.9 ltr

Printed in Germany



Checking Cooling and Heating

System for Leaks

19 - 1

944 turbo Fuel Supply

REPLACING FUEL FILTER CHECKI NG FUEL AND I N JECTION LI N ES

FOR LEAK S AND TIGH TNESS

1. Detach fuel lines, making sure to co unterhold . Ca tch escaping 1. Inspect visual ly for leaks. fuel.

2. Loosen clam p and remove fuel filter .

2 . Ti ghten coupling nut s and hose c lamps .

20

3 . Install new fi lter, c hecking d i rection of flo w of arrow.

= direction

Pr inted in Germany



Replacing Fuel Filter,

Checking Fuel and Inje ction L ine s

20 - 1

20 Fuel Supply 944 turbo

CHECKING

FUEL PUMP DELIVERY RATE

Requirements:

Fuel filter and electric power supply okay.

1. Unscrew fuel return hose on pressure regulator and hold end of hose in a measuring glass

(volume: approx . 1500 cm 3 ).

Let fue l run

30 seconds . at least 850

Replace fuel i n to measuring glass

Delivery rate should be cm3f30 seconds. pump if necessary.

2. Pull off DME relay on central electr ic board and bridge terminals 30 and 87 b with a piece of wire.

20 2 Checking Fuel Pump Delivery Rate



Pri n ted i n G e rmany

944 turbo

FUEL SYSTEM LINE ROUTING

Fuel Supply 20

I

I

I

I

I

I

I

I

I

L------,

I

I

I

I

I

I

I

I

\

\.._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

I

I

I

A

7

1 -

2 -

Fuel pump

Fuel filter

3 - Pressure damper

4 - Pressure regulator

5- Injection line

6 - Fuel injector

7 - Fuel return

A - Charging air cooler

8 Air flow sensor

;

H - Air circulation valve

I - Temperature valve

(open above 58°C/

136.4°F)

C - Throttle housing

0 - Intake pipe

E - To charging pressure control valve

F - To brake booster

G - Idle actuator

J Shutoff valve

K - Control valve

L - To control unit

(charging pressure control)

M - Timing valve for charging pressure

Printed in Germany



Fuel System I Line Routing 20 3

944 turbo

TOOL

Measuring charging pressure

Turbocharger 21

No. Description

1 Pressure gage with adapter

Special Tool

9103/2

Remarks

Use pressure hose from Speci a 1 Tool

9103

Printed in Germany



Charging Pressure Measuring Tool 21 1

•

21 Turbocharger

TURBOCHARGER SYSTEM DISASSEMBLY AND ASSEMBLY

3 5 4 8

9

20

26

25

12

944 turbo

30

29

10

22 11

23

.------------38

. - - - - - - . , 36

,.-- 35

· - r - 37

T--':: --?--.:.,---- 44

21 2 Turbocharger System Disassemb ly and Ass emb ly



Printed in Germany

944 turbo Turbocharger 21

No. Description

1 Hose clamp

2 Hose

3 Hex bolt

M8 X 10

4 Washer

5 Hollow-core bolt

6 Seal ring

7 Water hose

8 Hex bolt

M8 X 20

9

10

Washer

Oil line

11 0 - Ring

2

1

2

1

1

2

1

1

Qty.

1

Removing

1

1

Note When :

Installing

Replace

Always replace. t·1ake sure of correct seating groove. in

12 Cooling water pipe

13 Seal ring

14 Pan head bolt

M8 X 25

15 Washer

16 Pan head bolt

M8 X 125

17 Washer

18 Pan head bolt

M8 X 35

1

1

1

1

1

1

1

Always replace

Printed in Germany



Turbocharger System Disassembly and Assembly

21 - 3

21

Turbocharger

944

turbo

No. Description

19 Washer

20

-

Turbocharger

21 0-Ring

Qty. Removing

1

1

1

Note When:

Installing

Always replace.

Make sure

of correct seating in

groove.

Che ck and if necessary replace .

22 Locknut

30

31

32

23 Exhaust pipe

24

25

26

Filler seal ring

Threaded

·

connection

Seal ring

27 Temperature

switch

28 . Seal ring

29 Hollow-core bolt

33

34

35

36

37

Seal

ring

Hose

clamp

Ventilation

1

ine

Threaded connection

Seal

ring

Hex bolt

M6 X 20

Washer

Oi 1

return

line

2

1

1

1

1

1.

1

2

2

1

1

1

1

4

1

1

.

-

I

Always

Replace

Replace

Replace

Replace

replace

21 4

Turbocharger System

Di sasse mbly and As

se

mbly



Printed in

Germany

944 turbo Turbocharger

21

No. Description

38

0-Ring

Qty. Removing

1

Note when:

Installing

Always replace.

Make sure of correct seating in groove.

39

Hex bolt

MlO

X

45

40

41

Washer

Hex bolt

M10

x 55

42 Pan head bolt

M 10

X

55

43

44

Washer

Engine support

1

3

2

1

1

1

Printed in Germany



Turbocharger System Di sassem bly

and

Assembly

21 5

21 Turbocharger 944 turbo

REMOVING AND INSTALLING TURBOCHARGER

1. Disconnect ground lead on battery.

2. Unscre w section air and cleaner upper remove together with air intake and filter cartridge.

5. Pull o ff spark plug co nne ctors .

Unscrew distri butor cap. Detach fue l co llectio n pipe w it h fuel in j ectors and ignition leads on intake air di stributor and cams haf t h o u sing.

3. Remove both charging air guide pipes.

4. Disconnect fuel feed and ret ur n l i ne s , and set aside. Detach vacuum hoses from press ur e regu lator and pre ss ure damper .

Disconnect cable on cruise c ontrol motor .

6. Carefully remove fuel col lection pipe w ith fuel injecto r s and ig nition le ad s fro m in t a ke air dist r i butor, and se t aside .

7 . Di sc onnect thr ottle operating cab le . Loosen and remove vacuum ho s es from intake air d ist ributo r.

·'

21 6 Removing and Instal ling Turbocharger



Pr inte d in Germany


8. Remove intake air distributor with throttle housing, and cover intake ports leading to intake valves.

13. Unscrew exhaust flange on turbine housing, coolant lines, and oil pressure line on turbocharger.

9. Remove engine splashguard.

10. Drain and catch coolant. Pull off alternator ventilation hose.

Remove coolant pump with bracket from body .

11 . Loosen with and guide remove tube oil cipstick and main brake cylinder heat dissipater.

14. Loosen and pull off intake air cowl between air flow sensor and turbocharger (compressor housing) as well as pressure hose to charging air cooler.

15. Remove shield for universal joint on engine support. Loosen turbocharger attachment on motor support from below.

12. Unscrew flange between turbocharger and exhaust assembly with the M 8 bolt on engine block.

Printed in Germany



Removing and Installing Turbocharger 21 - 7

21 Tu rb ocharger

I n s t a 1 1 i n g

1. Always use new seals (filling seal rings).

2. Make sure round sea l ring fits correctly on left engine support.

3. Insert seals for exhaust flanges and secure them from falling out

(e.g. with grease) .

4. Check and if necessary replace locknuts for exhaust flanges.

5. Tigh ten the M 8 bolt of the exhaust flange on engine block only after installation of all bolts for exhaust flanges and turbocharger.

6. All bolts in the turbocharger I exhaust flange area shoul d be coated with Optimoly HT.

944 turbo

21 - 8

Removing an d Installing Turbocharger



Printed in Germany

944 turbo

MEASURING END PLAY ON EXHAUST TURBOCHARGER

1. Mount dial gage with bracket.

Special Tool VW 387 can be used as a dial gage bracket.

2. Bring dial gage measuring stud into contact with turbine wheel shaft end. Press rotor shaft against dial gage and note gage reading. Push rotor shaft in the opposite direction and note reading. The difference between the readings obtained is the end play.

Max. play 0 .

16 mm.

Turbocharger 21

MEASURING EXHAUST TURBOCHARGER

RADIAL PLAY

Radial play is measured only on the turbine side.

Set dia l gage measu ring stud against hub face. Press turbine wheel to one side and record reading. Press turbine wheel in opposite direction and again record reading. The difference between the readings obtained is the radial play.

Max. play 0 .4

2 mm.

Printed in Germany



Measuring Exhaust Turb ocharger and Radial Play

21 9

21

Turboc har ger 9 44 tur bo


General

Special tool9103/2 (pressure gage) shows charging pressure in bar above atmospheric pressure.

By contrast, the charging pressure indicator in the vehicle tachometer shows charging pressure in bar absolute pressure .

Air pressure at sea level

Boost pressure 944 turbo M 44 .

51/52 bar , absolu te value

1

1 , 75 ± 10% bar , excess pressure

0

0 , 75 ± 10%

:.~

Maximum boost pressure of 1.75 bar (absolute value) is reached a t approx . 3,000 rpm. At higher engine speeds (engine t ype M 44.51) the boost pr essure drops again and reache s a boo s t pressure of

1 .

52 ± 0.03 bar (abso lute value) at 5,800 rpm . With engine type M 44.52

, the boost pressure remains constant at 5,800 rpm ( 1.

75 bar absolute value) and drops only after this value has been passed.

Note

Measure charging pressure only under dry roadway conditions.

1 . Connect pressure hose with adapter piece to pressure damper vacuum connection.

2. Locate pressure gage on passenger s id e of passenge r compa rtm ent, with hose running from engine compartment.

Note

Make certai n that the hose is not pinched at hood body c ross ing.

3. A ccelera te to approx . 3000 rpm in 2nd gear, and using simul tan eous braking against the motor m .

ai ntain rpm . H ave a second person read o!f c h arging pressure.

Charging presure 1.6

1 .

7 bar (abso lute ).

Not e

Carry out measuring as qu ick ly as possible (a pprox . 3-5 sec.), to avoid ove rh eating brakes.

21 • 10






REMOVING AND INSTALLING TURBOCHARGER COOLANT PUMP

R e m o v a 1

1 . Remove intake snorkel from air filter upper section.

3 . Loosen hose clamps on air intake cowl, remove hose connections from cowl and remove cowl .

2 . Remove vacuum connection on bypass air valve. Loosen and remove hose clamps on charging air guide pipe, throttle housing, and bypass air valve.

4. Pinch off coolant hoses to turbocharger and pump with hose clips.

Print e d in German y



Removing and In s talling Turbocharger

C oolant Pump

21 - 11

21 Turbocharger

5. Disconnect electric plug connection and loosen pump along with bracket.

.l

6. Loosen hose clamp on turbocharger coolant water pipe and pull the hose forward along with the pump.

7. Loosen lower hose clamp on pump, pull off hose, and remove pump .

I n s t a 1 1 a t o n

1. Make sure of correct seating of hoses and hose clamps.

2. Fill and bleed cooling system.

944 turbo

N o t e c h e c k i n g F u n c t

0 f T u r b o c h a r g e r c

0 0

1 a n t p u m p o n

1. Turn on ignition and start engine.

2. Turn off motor. The pump must be switched on for 25 seconds after turning off engine. At this time coolant can be observed flowing back into the expansion tank .

21 12


Removing and Installing Turbocharger

Coolant Pump manuals search engine

Printed in Germany

944 turbo Turbo charger

Turbo charger cooling system components, removing and installing

21

No. Description

1 Hexagon head screw

M6x20

2 Washer A 6.4

3 Housing

4 0-ring seal 28 x 2 .

5

5 Thermostat for turbo charger cooling system

Oty . Removing

2

2

6 Water pump

Note :

Installation

Replace

Observe the mounting position, long cylindrical part into the plastic housing

Turbo charger cooling system components , removing and installing

Printed in Germany- Ill, 1988



2112 a


REt40VAL AND INSTALLATION OF CHARGING

AIR COOLER

R e m o v a 1 I n s t a 1 1 a t i o n

1. Remove front end panel. See

Workshop Manual, 944, page

50-5.

2. Loosen air duct on cooler and body and lift out.

Make sure of correct seating of rubber connection between cooler and charging air duct, as well as of hose clamps.

3 . Loosen hose clamps for charging air duct and unscrew hex bolts on cooler.

4. Remove cooler with rubber connection towards the front.

Printed in Germany



Removal and Installation of

Charging Air Cooler

21 13

944 turbo L-Jetronic Fuel Injectio n 24

REPLACING AIR FILTER CARTRIDGE

2. Loosen clamps and unscrew bolts with screwdriver. Remove air cleaner upper section.

CHECKING INTAKE AIR GUIDE AND CRANK-

CASE END HOSES FOR LEAKS AND TIGHT FIT

1. Unscrew air intake on air cleaner upper section. 1. Check all hose s of intake system for correct fit.

2 . Tighten hose clamps.

3. Remove air filter cartri d ge and clea n inside of air cleaner lower section with a cloth that w ill not leave l int.

4. Install air filter cartridge.

Mount housing cover and tighten mounting bolts. Engage clamps.

Make sure dust cover fits corr ectly between air cleaner intake and wheelwell side panel.

Downloaded from

Printed in Germany Repl. Air Filter Cartridge, Checking Intake Air 241 www.Manualslib.com


Vent Hoses for Leaks and Fit

24 L -Jetr o nic Fuel Injection 944 turbo

TESTING AND ADJUSTING VALUES

T es t step Tes ting and Adjusting Value Remarks

Elect ri c fuel pump delivery rate

Fuel pressure

(engine stopped) , fuel pump bridged

At

2.3 least

.

....

850 cc/30s

.. 2.7 bar

Test value at idle sppe d

:.1 leak t est , m1n1 mum press ure afte r 20 min .

Approx. 2 bar

1 bar

Idle adjustment

Idle speed in rpm co

1 eve 1 in %

HC values in ppm

840

-

+ 40

1.0 1.5 *0.6 + 0.2

~3 00 * ~ 300

* Measured upstream o f catalytic converter with oxygen sensor plug disconnected

*USA and catalytic converter models

2 4 2 Testing and Adjusting Values



11,1987-Printed in Germany

944 turbo

L

-Jetronic Fuel Injection

CHECKING FUEL PRESSURE

TOOLS

24

No. Description

Pre ssure meter with ho se from pressure tester

Special Tool p 378

Rer.1arks or VW 1318

Printed in Germany



Checking Fuel Pressure 24 - 3

24 L-Jetronic Fuel Injection

CHECKING FUEL PRESSURE

1. D i sengage and fold up cover.

Unscrew and remove cap nut on test connection of fuel dist r ibution line.

N o

t

e

Make sure sealing ball does not fall out when removing cap nut.

2 . Connect pressure meter with hose from Special Tool P 378 or VW

1318 on test connection.

944 turbo

4. Test Values:

Engine stopped 2 .

3 to 2.7 bar

(DME relay bridged)

Engine running at idle speed approx. 2 bar

5. Tightening torque for cap nut:

22 Nm (16 ftlb).

3. Pull of DME relay on ce ntral electric board and bri d ge terminals 30 and 87 b with a piece of wire . Fuel pump should now run.

Printed in Germany 24 - 4 Checking Fuel Pressure



944 turbo L Jetronic Fuel Injection

IDLE ADJUSTMENTS

T o o 1 s

24

No . Description

1 Oil temperature tester with sensor

2 Articulated screw driver

3 Lead

Special Too l

9122 + 9122/2

9230 l

-

Remarks

Made loca lly, or use test relay

9246.

Printed in Germany



I dl e Adjustments 24 5

24

L Jetronic Fuel Injection 944 turbo

IDLE ADJUSTMENTS

Note:

Requirements for adjustments:

Engine in perfect mechanica l condition. All electric equipment s witched off for duration of adjustment. Adjustments must be made as quickly as possible to avoid excess ive heat in intake ports which would lead to incorrect CO levels. Ambient temperature: 15 to 35°C/59 to 95°F .

~

1.Run engine to operating temper ature {oil temperature 70 to 90°C/

158 to 194°F) . Use Special Tools

9122 and 9122/2 (oil temperature tester with sensor) to measure the oil temperature .

CO adjustment rang e : 1.0 to 1.5%.

Clockwise turn = richer mixt ure

Counter clockwise turn = leaner mixture

3.Connect separate tachometer per manufactu rer' s instructions.

Idle adjustment value:

840 ::. 40 rpm.

4.Check and, if necessary, adjust engine idle speed. This requires stopping the operation of the id le speed charging control . a.Jumper

, round female plugs B and C on di?gnosis socket with a wire lead: This stops operation of the idle charging control.

2 .

Check CO level . If CO level is not within specified range , correct setting on air flow se nsor, us ing

Special Tool 9230 (articulate d sc rewdriver).

2 4 6 Idle Adjustments



11,1987-Printed in Germany

944 turbo L-Jetronic Fuel I n jection 24

S.Turn control scre w (bypass) on t h rottle housing until specified s peed of 8 4 0 + 4 0 rpm is reac hed. b.Instead of a wir e lead , Special

Tool 9246 (test re lay ) ca n also b e used. The idle charging co ntr o l i s out of operation when the green test lamp lights up.

6.Restore ope rati on of idle c harging co ntr ol after finishing adjust ments by r emoving wi r e l ead or test relay from diagnosis s ocket.

?

.R

ec he ck setti ng s.

8.Close access boring to CO adjustment sc rew w it h plug ET-No. 944

606 935 0 1 { blue ) . c.Check and , if necessary, adj ust engi ne i dl e sp eed with VAG tester

1367 ( for example).

Printe d in Germany -1 !,1987



Idle Ad j ustmen ts 24 7

944 turbo L-Jetronic Fuel Injection

IDLE ADJUSTMENTS - USA and catalytic converter models

T o o 1 s

24

2

2

3

No.

1

Description

Oil temperature tester with sensor

Exhaust tester

Wire lead

Specia l Tool

9122 i

+ 9122/2

' us 4492

4 Articulated screwdriver

9230

Remarks

Made locally, or use test relay 9246

Printed in Germany



Idle Adjustments - USA and

Catalytic Converter Mode ls

24 - 9

24 L-Jetronic Fuel Injection 944 turbo

IDLE ADJUSTMENTS - USA and catalytic converte r models

Anmerkung: PLEASE TRANSLATE THIS

R e q u i r e m e n t s f o r

Ad j u s t me n t s:

~

Engine in perfect mechanical condition. All electrical equipment switche d off for duration of adjustment. Adju stme nts mu st be made as quickly as poss ible to avoid excessive heat in intake port s and thereby ske wed CO levels. Ambient t emperatu re: 15 to 35 °C I 59 to 95 ° F.

1. Push exhaust take-up hose or CO tester US 4492 onto CO co llecting pipe. 3 . Disconnect oxygen sensor plug and co nne ct CO tester per manufacturer 1 s instructions.

2. Run engine to operating temperature (oil temperature 70 to

90°C 1 158 to 194°F) oil temperature.

. Use Special

Tool 9122 and 912212 to monitor 4. Check CO l evel . If CO level is not within s pecif ied range, correct setting on air flow sensor. Use Special Tool 9230

(ar ticulat ed sc rewdriv er) .

24 - 10 I dle Adjustment s - USA and

Catalytic Co nverter Models



Printed in Germany

944 turbo L-Jetronic Fuel Injection 24

CO adjustment level: 0.6 + 0.2

%

Clockwise turn =

Counter-clockwise turn richer mixture

= leaner mixture

Note

If it is necessary to correct the CO level at the air flow sensor , the plug in the access bore to the idle speed CO setting screw has to be removed, which requires removing the air flo w sensor.

S.Connect oxygen sensor plug and close CO sampling tube in eng i ne compartment after finishing adjustme n ts.

6.Connect a separte tachometer per instructions supplied with unit.

Idle speed adjustment level: 840 +

40 rpm. -

?

.

Check and, if necessary, adjust engine idle speed . This requires stopping the operation of the idle speed charging control. a.Jumper round female plugs B and C on diagnosis socket with wire lead. This stops operation of t h e idle charging control . b .

Instead of a wire lead, Special

Tool 9246 (test relay) can also be used. Idle charging control has be~n put out of operation green test lamp lights up. when the

Printed in Germany-11 , 1987



Idle Adjustments USA and

Catalytic Converter Models

24 11

24 L-Jetronic Fuel Injection c.Check and , if necessary , adjust idle speed (for example w ith VAG tester 1367).

8.Turn control scre w (bypass) on throttle housing until s pecified speed of 840 ~ 40 rpm is reached.

944 turbo

9.Restore operation of id l e charging co ntr ol a fter compl eting adjustme nt s by removing w ire lead or test relay from diagnosis socket.

10.Rec

heck sett ings.

2 4 12 Idle Adjustments US A and Catalytic

Converter odels



Printed in Germany

944 turbo L-Jetronic Fuel I njection

CORRECTING CO LEVEL ON AIR FLOW SENSOR IN USA AND CATALYTIC CONVERTER

MODELS

N o t e

If the CO level is not as specified, the plug in the access bore to the idle speed CO setting screw must be removed, requiring the removal of the air flow sensor.

Clock wi se = Richer mixture

Counter-clockwise

=

Leaner Mixture

R e m o v a 1

1. Remove air flow senso r.

2. Drill a 2 mm dia. hole in plug down to stop (steel insert).

3. Pull out plug using size 2 screw extractor.

3. After completing adjust ments, close access bore to CO sett ing screw wit h new plug. Press in plug flush.

N o t e

Never reuse a drilled plug!

24

I n s t a 1 1 a t i o n

1 . Install air flow sens or.

2. Adjust CO level and e ng ine idle speed . Turn CO setti ng screw using Speci al Tool 9230

(articu lated scre wdriver ).

Printed in Germany



Correcting CO Level on Air Flow Sensor in USA a nd Cata lyt ic Converter Models

24 13

24 L-Jetronic Fuel Injection 944 turbo

REMOVING AND INSTALLING IDLE ACTUATOR

R e m o v a 1

1. Disconnect battery ground lead.

2. Disconnect cable on cruise control motor. Pull off vacuum hoses on pressure regulator and pressure damper.

4. Carefully remove fuel distribution pipe with fuel injectors and ignition leads from intake air distributor and set aside.

5. Disconnect throttle operating cable. Loosen and remove vacuum hoses from intake air distributor.

3. Remove spark plug connectors.

Unscrew distributor cap. Unscrew fuel distribution pipe with fuel injectors and ignition leads on intake air distributor and camshaft housing.

6. Remove intake air distributor with throttle housing, and cover intake ports leading to intake valves.

24 14 Removing and Installing Idle Actuator



Printed in Germany

944 turbo L Jetro nic Fuel Injection

7. Disconnect electric plug connection on idle actuato r.

Unscrew Allen head bolt M 8 on crankcase and take out idle actuator with bracket. Loosen hose connection from c harging air guide pipe and remove.

24


1. When in stalli ng idle ac tuator, take note of flow thr oug h (a rrow) d ir ection. Arrow points to intake air distributor.

2 . Take care to position vacuum hoses and hose clamps correctly . Always replace seals for intake air dist r ibutor and hollow-core bolt.

Tig hten ing torque of hollow-core bolt is 10 Nm (7 ftlb).

Printed in Germany



Removing and Insta l ling Idle Actuator 24 - 15

944 turbo

CHECKING TIGHTNE SS OF EXHAUST SYSTEM FLANGES

1. Check tightne ss of exhaust flanges as well as checking co mplete ex haust system for leaks .

2. Ch eck tightness of hex nuts on exhaust manifold I cyli nder head flange.

3. Check tight ne ss of all flange con n ections from exhaust system/ turbocharger a nd bypass valve.

Exhaust System 26

4. Check tightnes s of bolts on primary muffler (catalytic con verter ) I final muffler flange . Check exhaust system suspension points.

Tighte ning torque for bolts and nuts:

M 8 20 + 2 Nm {14 + 1 .

4 ftlb)

MlO 40 + 5 Nm (29 + 3.6 ftlb)

Printed in Germany



Checking Tig htness of E xhaust System

Flanges

26 - 1

944 turbo Starter, Po w er Supply, Cruise Control 27

CHECKING BATTERY C h e c k i n g A c i d L e v e

N o t e 1 . Unscrew all caps and check acid level in each cell.

Due to the danger of short circuits, it is important to always disconnect the battery when working on the electrical system. However, the battery must never be disconnected while the engine is running.

1 . Open engine hood battery cover. and remove

2. If acid level is below the mark, pour in distilled w ater only.

Never raise acid level above this mark.

An insufficient acid level will shorten the battery•s service life.

2. Loosen and remove ground lead.

Printed in Germany



C he c k ing B at t ery 27 1

27 Starter, Power Supply, Cruise Control

C h ~ c k i n g A c i d D e n s i t y

The acid will normally indicate the charge condition of the battery.

Measure acid density with an areometer.

The following values must be reached:

Charge Condition

Fully charged

Half charged

Discharged

Normal Climates kg/ltr Be

1.28

1.20

1.12

32

24

16

Tropical

Climates kg/ltr

1.23

1.16

1.08

Be

27

20

11

944 turbo

·._.·'

·.

C h a r g i n g B a t t e r y

C h e ~ k i n g B a t t e r y

V o 1 t a g e

Measure voltage of battery under load with a suitable tester.

N o t e

Never smoke or use open flame in rooms where batteries are charged.

The voltage mu s t not drop below a minimum of 9.6 V with a load current of approx. 110 A.

1. Disconnect battery from car•s electrical system for charging.

If the voltage is lower at this load (approx. 8 to 10 seconds), the battery has either been discharged or is defective.

2. Unscrew all caps prior to charging.

3. Connect positive pole of battery with positive pole of charger, and negative pole of battery with negative pole of charger.

,

Print e d in Germany

27 - 2 Checking Battery



944 turbo Starter , Power supply , Cruise control

27

Alternator , removing and installing

1 . Disconnect the battery.

2. Disconnect top part of the air filter and remove with air induction funnel and filter in sert.

3 . Remove the left-hand charge-ai r guide tube .

5 . Remove the lower part of the front spoiler and sump guard.

85(158

4. Remov e the lower part o f the air f i lter wit h air flow sensor .

85/11

6. Open the coola nt drain p lu g and drain off coo l ant.

7. Pull off the venti l a t ion hose for the alternator .

8 . Release the tension on th e poly-rib belt and remove .


Printed in Germany- Ill , 1988



85(1 3

54/13

27 3

27

9 . Undo lower fastening screw .

Starter , Power supply , Cruise contro l

12. Undo h ose clip.

944 turbo

10 . Disconnect the radiator hoses from the coo l ant p ip e (c r oss-st r ut) and remove cross-s trut.

11 . Detach th e . in let air box bet w een airf low sensor and t u rbo charger (compressor housing) and put on one side.

Note

Seal the co mpressor ho u sing with a suitab l e p lug .

88/12

13. Undo the upp e r fastening screw.

88/46

88/13

274




Printed in Germany Ill , 1988

944 turb o Starter , Power supp l y , C r uise control

14 . Using a screwdriver, press the a lternator out o f the conso l e .

16 . Undo connectors.

27

-

88/14

1 5. Put the alternator on o n e s i de and remove the air b ox.

Installat i on

Poly rib belt tension adjustment , see Page 13 2 .

Fill w ith coola n t and bleed , see Workshop m anual 944 , Page 1 9 -2 .

88/18

88/15

Alternator , removing and installing

Printed In Germany Ill , 1988



27 5

944 turbo Ignition System 28

EQUIPMENT SURVEY

I g n i t i o n C o i

Type I Model

944 turbo

Version

944 602 115 00

Bosch No.

0 221 118 322

D i s t r i b u t o r (Cap)

Type I Model

944 turbo

Version

944 602 251 00

Bosch No.

1 235 522 325

S p a r k P 1 u g s

Type I Model

944 turbo

Remarks

Without ballast resistors

Remarks

Only high voltage distribution

Version

999 170 158 90

Bosch WR 7 DC

Champion RN-9YC

Remarks

Electrode gap:

0.7 + 0.1 mm

Printed in Germany



Equipment S urv e y 28 - 1

28 Ignition System

OME - C o n t r o

Type I Model

944 turbo

U n i t

Version

951 618 121 02

Bosch No.

0 261 200 075

951 618 121 08

944 turbo

Remarks installed as from

11.8.87

K n o c k I C h a r g i n g P r e s s u r e C o n t r o 1 U n i t

Type I Model Remarks

944 turbo

Version

951 618 113 02

Bosch No.

0 261 201 013

K n o c k S e n s o r

Type I Model

944 turbo until mod. 87

944 turbo as from mod. 88

Version

951 606 141 00

Bosch No.

0 261 231 001

944 606 145 00

Bosch No.

0 261 231 006

'

Remarks

Tightening torque: 9 Nm as from mod.88

Use specified mounting bolt

{without washer).

28 - 2 Equipment Survey



III,198 8 Printed in Germany


T i m i n g V a 1 v e

Type I Model

944 turbo

Version

951. 606 .117. 00

S p a r k P 1 u g T e r m n a 1

Type I Model

944 turbo

Version

928.609.105.03

Beru No.

0.300.322.101

R e v o 1 u t i o n S e n s o r

Type J Model

944 turbo

Version

944. 606 .115. 00

R e f e r e n c e M a r k S e n s o r

Type I Model

944 turbo

Version

J

944. 606', 115.00

Remarks

Remarks

Without auxiliary spark gap

Remarks

Remarks

Printed in Germany



Equipment Survey 28 - 3

28 Ignition System 944 turbo

ACCIDENT HAZARDS WITH ELECTRONIC IGNITION SYSTEMS

The increased requirements placed by modern engines on ignition systems and the desire for freedom from maintenance led some time ago to the introduction of electronic ignition systems as standard equipment. As a rule, the ignition power of electronic systems is higher than that of conventional systems, and further increases in power are in store.

Electronic ignition systems hereby have reached a level of power high enough to be fatal if live parts or terminals are touched (both primary and secondary sides).

In this connection we refer the reader to VDE regulations, in particular

VDE 0104/7.67, or the applicable regulations in each country, concerning

" working with and testing ignition systems.

Always switch off the ignition (disconnect ignition or power supply) before working on ignition systems. This includes work such as:

Connecting engine test equipment (stroboscope lamps, dwell angle/rpm testers, ignition oscilloscopes, etc.).

-Replacing ignition system components (spark plugs, ignition coil, distributor, ignition leads, etc.).

If i t is necessary to turn on the ignition for ignition tests or engine adjustments, there will be dangerous voltage throughout the entire system.

Consequently, accident hazard exists not only on the various equipment parts of the ignition system (for example, distributor, ignition coil, control unit, ignition tackle), but also on wire harnesses (e.g. tachometer connection, diagnosis plug), plug connections, and test equipment.

28 - 4 Accident Hazards with Electronic Ignition Systems Printed in Germany




5

©

4

0

3_5.: · .. : :...·.:.·.:

~:...

· .:.·.:

·.: :.::...·..;

·..:.1~ ....

----------------1

0

0 0 3

1

2

= Battery

= Ignition lock

3

=

DME Control unit

4 =

Ignition coil

5 = Distributor

6

=

Spark plug

Printed in Germany Accident Hazards with Electronic Ignition Systems 28 - 5




IMPORTANT INFORMATION

In order to prevent damage to the DME and knock/charging pressure system, the following safety rules should be observed:

8. The specified ignition coil must not be replaced by another ignition coil.

9. Suppressor condensers must not be connected to terminals 1 and

15 on the ignition coil.

1. Do not start engine without battery being firmly connected.

2. Incorrect polarity in supply voltage, for instance as a result of reversed battery connection, can cause the destruction of the control units.

10. Terminal 1 of the ignition coil must not be connected to ground for anti-theft purposes

{"ignition on" would destroy ignition coil).

3. Do not disconnect battery while engine is running.

11. A battery + current must not be connected to ignition coil terminal 1. The same applies to test lamps.

4. Do not use a quick charger for starting the engine.

Starting assistance should only be given with a second 12 V battery.

12. The ignition lead from ignition coil terminal 4 to high-voltage distributor terminal 4 must not be removed during operation.

\

5. Before quick charging, disconnect battery from vehicle's electrical system.

6 . Make sure ign i tion is switched off or battery disconnected before carrying out resistance measurements.

7. When testing compression, pull out control unit plug or firmly connect ignition coil terminal 4 to a ground with auxiliary cable, to preclude hazardous high voltage and damage to insulation on ignition coil, high voltage distributor, and ignition tackle.

The auxiliary cable must be shielded with a shielding sleeve of at least 2 kOhm.

2 8 - 6 Important Information



Printed in Germany

944 turbo

COMPONENT INSTALLATION POSITIONS

Ignition System 28

..

1 - Altitude correction box (in footwell of passenger compartme nt, passenger side)

2 - Knock/charge pressure control unit

(in footwell of passenger compartment, passenger side)

3 DME control unit (in footwell of passenger compartment, passenger side)

4 OT sensor connection

5 Timing valve

6 Id l e actuator distributor)

(under intake air

7 - Knock sensor

8 - Fuel pressure test connection

9 Ignition coil

10

11 D~lE relay

12 Plug connection for reference sensor , rpm sensor , and oxygen sensor

13 - Test socket for knock/ charging pressure control

14 - Throttle switch/ potentiometer

15 -

Distributor cap

Temperature sensor

NTC II

16 Air flow sensor

Printed in Germany



Component Installation Positions 28 - 7


REMOVING AND INSTALLING DME AND KNOCK/CHARGING PRESSURE CONTROL UNITS

1. Fold back mat in passenger side footwell. Unscrew and remove footwell cover.

3. Pull out control unit plug and unscrew control unit.

2. Unscre w control unit bracket and fold forward.

28 8 Removing and Installing DME and Knock/

Charging Pressure Control Units



Printed in Germany


..

RE M W

SENSOR

RE MO VING AND INSTALLING TEMPERATURE

SE N SOR ( NTC I I)

1. Unscrew air filter upper section and pull out along with filter cartri dge .

1. Remove air air flow filter sensor. housing with

2 . Loosen an d remove intake air co wl on air flow se n sor .

Unsc rew air filter housing lower sectio n and rem o v e plug connection on air flow sensor .

2. Detach plug connection on temperature sensor and unscr ew tem perature sensor .

3. Take out air filter housing lower section and unscr e w air flow sensor .

Tightening torque 15 Nm (11 ftlb) .

Printed in Germany



Removing and Installing Air Flow

Sensor and Temperature Sensor (NTC II)

28 9


REMOVING AND INSTALLING KNOCK

SENSOR

N o t e

Use new original bolt (microencapsulated) without washer.

1. Loosen cruise control cable and hose on air intake distributor plug connector for cylinder 3.

Tightening torque: 9 Nm,as from and set to one side. Detach spark mod. 88 20 Nm.

Use care when working on knock sensor.

For instance, the knock sensor should not be allowed to fall onto a hard floor from a great height, as otherwise the piezoelectric crystal could be damaged.

2 . Unscrew knock sensor and pull upwards. Disconnect plug connector.

28 - 10 Removing and Installing Knock Sensor III,l988 Printed in Germany




REMOVING AND INSTALLING TIMING VALVE REPLACING SPARK PLUGS

1. Remove intake air distributor.

2. Disconnect plug connector on timing valve. Loosen hose connections and unscre w fastening bolt on timing valve.

1. Pull off spark plug connector.

2. Unscrew spark plug with a standard wrench. A spark plug wrench is part of the tool kit supplied with the vehicle.

3 . Lightly coat spark plug threads with graphite grease or a similar pr oduct, e.g. Molykote White HTP paste .

Tighte~ing torque : 25 - 30 Nm (18 -

22 ftl , b) .

Printed in Gennany



Removing and Installing Timing Valve,

Replacing Spark Plugs

28 11


TROUBLESHOOTING DME AND KNOCK/

CHARGING PRESSURE CONTROL

TEST EQUIPMENT AND TOOLS

Engine tester with oscilloscope , e.g. 1010/1090, Bosch MOT 300/400

- Multiple teste r (internal resistance at least 20 kOhm/V)

Pressure pump (VAG 1274)

Vacuum hand pump (9160)

Adapter lead (Bosch 11 L-Jetronic 11

No. 1684 463 093)

Pressure gage (VAG 1318)

-Two auxiliary electric leads

(locally made) for tests on multiple pin plug of control units and on plug connections with the same contacts.

1 Highly flexib le line

2 - Alligator clips (as commonly used)

3- Flat male pl ug 2.8 ( N 17.457.2)

- 2 Adapters auxiliary leads

( l ocally made)

1- Highly flexible line , 10-20 em long

2 Insulating tubing

3Flat contact N 17.182.2

28 - 12 Troubleshooting OME and Knock/Charging



, Test Equipment and Tools

Printed in Germany


PLUG CONNECTIONS

Throttle switch (view of disconnected plug connector)

Air flow sensor (view of disconnected plug connector)

1 2 3 4 5 6 1 2 3 4

Reference mark/rpm sensors (view of disconnected plug connector) Test socket

3 2 1

Idle

actuator (view

of dis-

connected plug connector).

Oxygen sensor

1

3 4 5

Printed in

Germany



3 2

Plug Connections 28 13


DME control unit

~~~~~~~~~~~~~~~wm

1------- .. ---------

~

18 17 16 15 14 13 12 11 10 9 8 1 6 5 4 3 2 1 _ _ _ _ , -

14 - ti-signals, injection valves

3 + 4

15 ti-signals, injection valves

1 + 2

16 - Ground

17 Ground

18 Voltage supply relay G5 87

19 Ground

20 Ground routing relay G5-85b

Q

1 Ignition impulse at ignition co i1 termi na 1 1

2 Throttle switch idle contact terminal 6

3 Full-load signal from K/CP control

4 - Sta(ting signal (ignition lock 50)

5 -

6 -

Ground and shielding, reference mark sensor

Air flow sensor - 4 (NTC I)

7 Air flow sensor 2

(air flap potentiometer}

8 RPM sensor

9 Air flow sensor - 3

21 4-pole separation point terminal 2 tachometer 1 K/CP terminal 9

22 Air flow sensor - 1 (NTC I)

23 Shielding (rpm sensor/oxygen sensor)

24 Oxygen sensor (USA/lead-free engines)

25 Reference mark sensor

26 -

27 -

28 -

29 -

30 -

Reference mark sensor

RPM sensor

Ground

A/C compressor (+)

Altitude compensation box

{USA/l~ad-free engines) map re-switching plug

10 -Map change (on for Switz.,

Swed., Austria, New Zeal.,

Cal., Japan}

11 4-pole separation point terminal 1 (consumption indicator)

12 Test socket (A)

(USA lead-free engines)

13 NTC II

31 -

32 Input TO* final stage of K/CP von control

33 Idle actuator - 3

34 -

35 -

Trigger signal for K/CP control

Idle actuator 5

Supply voltage relay G5 87

Printed in Germany 28 - 14 Plug Connections



944 turbo Ignition System 28

KICP control unit

25 24 23 22 21 20 19 18 17 16 15 14

J~::~-----t:::::J-[::J---1 c- - - - c::::J c:::J -

1

c:::::2 -

-J

2 - Timing valve (output)

3 LED

5 - Vacuum pipe pressure signal

(pressure indicator output)

6 - U (Battery)

9- Ignition signal , (input)

10 - Ignition signal shield

11 - Knock sensor

12 - Ground, knock sensor shield

13 Knock sensor

14 - Vehicle ground .

16 Ignition signal (output)

18 -Test socket I full-load signal (output)

20 - Vehicle ground (electronic ground connection)

21 - Angle sensor -

22 - Angle sensor -

23 - Angle sensor ground, angle sensor line shielding

24 - tr-signal I input

Thrott l e

Position

Plug connector in engine compartment

(14 pole)

1 3 5 7 9 11 13

©

0

"!

• • 0 0 0 0 0

" · _j

2 4 6 8 10 12 14

1 Ignition coil terminal 1

2 - DME relay terminal 87

3 - DME relay terminal 87

4 DME relay terminal 87 a

5 D~1E re 1 ay termi na 1 85 b

7 - Ignition lock terminal 50

13 - AIC compressor +

Plug Connections 20 - 15 Printed in Germany




TROUBLESHOOTING CHART

Oxygen sensor function

'"

Temperature sensor (NTC II)

Throttle switch

16

X

10

X X X

X

Ignition signal

Altitude compensation box

15

14

X

X

Vacuum-pressure system sealing 13 x x x x x x

Knock/charging pressure control 12 x x x x x x

(Blink code)

Injection valves 11 x x x x x x

X X

9 X X X X X X

Idle actuator

Fuel pressure

Air flow sensor

Ignition system


RP~1 sensor

Supply vo1tage control unit fuel pump

I

Ground and plug connections

8 X X X X

7 X X X X X X

6 X X X X X X

5 X X X X X X

4

3

2

1 X

X X X X

X X X X

X X

X X X X

'

TEST CONDITIONS:

Engine in good mechanical condition

Battery charged

11

X

11

= check with suitable test equipment

1. Engine will not or is hard to start

2. Poor idling

3. Poor pick-up

4. Misfiring

5. Excessive fuel consumption

6. Insufficient power see Test Chart

28 16 Troubleshooting Chart





N o t e

The test points should be run through in the sequence give n, especially when the cause o f trouble is poor running or no running of the engine.

TEST POINT 1

Ground and Plug Connectio n s

Check ground connections on eng in e flange and clutch ho u s i ng , and ground cable from body to e n g i ne, for firm seating, good contact , and cleanliness.

Check plug connection for OME and K/CP control unit behind passenger side footwe 11 cover.

Check 14-pole plu g c o nnection i n engine compartment over power brake unit.

N

o t e

Check plug connection for reference

Never start engine with disconnected and rpm sensors and oxygen sensor. engine bo d y ground cable! This would immediately destroy t h e control unit.

Printed in Germany



Test Point 1

Ground and Plug Connections

28 17

28 Ignition System

Plug connection for throttle s witch I potentiometer

944 turbo

Plug connection for timing valve

Piug conne ction for air flo w sensor Knock sensor (between cyls. 2 and 3)

NTC II in engine block (at cyl. 1) Plug connection for idle actuator

28 18 Test Point 1

Ground and Plug Connections



Printed in Germ a ny

944 turbo Ignition System 28

TEST POINT 2

1. Voltage supply for DME and K/CP control unit.

N o t e

Ignition must be switched off before disengaging control unit plugs!

1.1. Pull out plug connections on both control units .

1.2

. Switch on ignition and measure voltage at DME plug between terminals 35 and 5 and again between terminals 18 and 5.

1.3. Measure voltage on K/CP plug between terminals 6 and 14.

25 24 23 22 21 20 19 18 17 16 15 14

~c:J-----t::l-c:::::::l---~

~~ ~ ~ ~~~~~ ~~~~n~W$

J ~ ---~-----------.. ,

18 17 16 15 14 13 12 1 1 10 9 8 7 6 5 4 3 2 1 _ __,.

-

Indication

=

Battery voltage

If there is no indication, d i sconnect 14-pole plug connection in engine compartment and measure voltage between termin a l 3 (pin bushing side) and ground.

I n dic a tion = B a ttery volta g e

1 3 5 7 9 11 13

•

.

• • •

©

0 !

• • 0 0 0 0 0 r · _j

2 4 6 8 10 12 14

Indi c ation

=

Batte r y voltage

If there is no indication, check

DME relay in centr a l electric system.

Prin te d in G erma ny



Test P oi n t 2

V o l t ag e S u pp l y

28 19


2. Voltage supply, fuel pump

2.1 Start engine. During the starting procedure the fuel pump must engage.

The action of the fuel pump can be heard and felt at the fuel tank next to the pump; if necessary connect pressure gage for fuel pressure.

0

2.2 If the pump does not operate, remove DME relay in cent ral electric system and bridge terminals 30 and 87 bon the relay socket.

TEST POINT 3

RPM Sensor

N o t e

The function of the rpm and reference mark sensors can only be tested with an oscilloscope.

1. Set oscilloscope per manufacturer's instructions.

2. Connect DME control unit plug terminals 8 and 27 with the tester .

3. Start engine . A sine wave with an amplitude greater than ?.5 V should become visible on the scr(::en. t

U > 2 , 5V

The fuel pump should run . If not, check fuel pump and leads to fuel pump .

If the voltage s ignal is too small , the sensor interval (0.8 + 0 .3 mm) must be checked. See \t!orkshop r:anual

944, Page 28 14.

28 - 20 Test Point 3

RP~1 Sensor



Printed in Germany


If no sensor signal is visible, despite proper connection and setting of the oscilloscope, check rpm sensor for power flow and insulation.

4. Detach plug connection in engine compartment and carry out test with oscilloscope once again.

Coil r esistance terminals 1 and 2

Control value: 0.6 to 1.6 Kohms

Insulation resistance terminals 2 and

3

Control value: greater than 1 Mohms

If necessary, replace sensor .

TES T POINT 4


1 . Carry out testing as for rpm senscr. Connection to control unit plug: term. 25 positive connection ter m . 26 negative connection

2. Start engine. A singl e sine wave should become visible on the screen. It is important that the wave starts with a positive slope and shows more than 2 V on the screen scale at a sta rter speed of at least 200 rpm.

If the voltage signal is too small, the sensor interval to the reference mark (0 .8 + 0.3 mm) must be checked.

See Workshop ~ · 1anua 1 944, Page 28 -

1ll.

J , • •

If there is no sensor signal, proceed as in Test Point 3 (rpm sensor). The same control values apply.

Printed in Germany



Test Point 4 28 21


TEST POINT 5

I g n i t i o n S y s t e m

1 . Set secondary image on oscilloscope. Connect testing cables per manufacturer • s instructions .

N o t e

If a defect is displayed for all cylinders, H will be in t h e primary or s econdary circuit fro m the ig niti on coil to the distributor motor. I f a defect is displayed for only one cylinder, it w i ll lie after the distributor rotor.

2 . Check spark plug connectors and leads for damage and spots.

Shielding resistance: 1 burned

Kohm

Ignition timing at 840! 40

3° BTDC rpm 50+

Control value at ?500 rpm = 35 ° +

BTDC

3 (.)

3 . Check distributor cap and rotor for damage , burnt spots , and dirt.

Shielded resistance: 1 Kohm.

The TDC s~nsor system can be used for testirig (wi th a suit a ble tester ) .

4. Check ignition coil .

Primary resistance terminals 1

15 = 0 .4 0.6 ohm

Secondary resistance terminals 1

4 = 5 7 .

2 Kohm

5. Ignition timing check

An adjustment of ignition timing is not necessary. Engine should be at operating ten 1 perature.

Printed in Germany 28 22 Test Point 5

Ignition System




TEST POINT 6

A i r F 1 o w S e n s o r

N o t e

3. Check supply voltage of air flow sensor. Connect a voltmeter to terminals 9 and 5 (ground) on the reverse of the control unit with suitable measuring tips.

The sealing of the plug connector on the air flow sensor has been improved.

For this reason it is no longer possible to take a measurement while the plug is connec:ed . Testing must therefore be carried out on the co ntrol unit plug in a n opened and con~ected condition.

Control value: 5 + 0.5 V

4. Dismount air filter and connect voltmeter with terminals 7 and 5

(grounc) on control unit plug.

Check voltage drop on air flow sensor.

1. Loosen and fold down control unit bracket in passenger side footwell.

Pull out and remove plug connector on DME control unit.

Control value approx. 250 260 mV

5 . Push air flap to full load throush air intake openin£.

2. Remove upper section of plL!g connector, cutting cable band and loosening fastening screw. Pull plug upp~r section away lengthwise .

Control value full load approx.

4.6 v

6 . Check temperature sensor (NTC I intake air temperature). Connect terminals 22 and 6 on the pulled control unit p1ug with an ohmmeter (on the pulled plug of air flow sensor terminals 1 and

4).

Control value at 15 to 30°C (59 to

86 ° F): 1.43.6 Kohms

At 40VC (104cF): 1 1.3 Kohms

N o t e

Brea~ on temper at ure sensor causes richer mixture .

Short circuit on temperature sensor causes leaner mixture .

7 . Carefully assemble upper section of plug connector and re connect.

Printed in Germany



Test Point 6

Air Flow Sensor

28 - 23


TEST POINT 7

FUEL PRESSURE

1. Disengage cover ing cap and fold upward, and unscrew cap nut on test connection of fuel distribution line.

N o t e

When removing cap nut be care ful that sealing ball does not fall out.

•

2. Connect pressure gage to test connection with hose from pressure tester P 378 or VW 1318 .

4 . Test value s:

Engine off 2.3 to 2.7 bar (DME relay bridged)

Engine idling approx . 2 bar

Tightening torque of cap nut 22 Nm (16 ftl b).

5 . Slo wly pin ch off return line with hose clamp. If pressure remains un der 4 bar, check fuel filter, if necessary replace fuel pump.

3. Remove DME relay from central electric system and bridge terminals 30 and 87 b w ith auxiliary cable . Fuel pump should now operate.


Fuel Pressure



Printed in Germany


TEST POINT 8

Idle Actuator

1. Remove plug connection on idle actuator.

3. During stable idling, screw in throttle air circulation bol t.

After a short deviation, the idl e speed should re-adjust itself to approx. 840 rpm.

4. In order to check the activation of the idle actuator by the control unit, connect a new or correctly-functioning idle actuator to the plug connector, and switch on ignition. The idle actuator should vibrate due to frequency activation. Start engine and increase idle speed by screwing out air circulation screw. The idle actuator should turn in the direction of closing.

After lowering idle speed , the idle actuator should turn in the direction of opening.

Switch on ignition and connect voltmeter to the middle contact of the plug connector and to ground.

Indication: Battery voltage

2. Re-connect plug connector on idle actuat or and connect revolution speed tester. Idle engine (840 +

40 rpm).

Printed in Germany



Test Point 8

Idle Actuator

28 25

28 Ignition System 944 turb o

.

, _ . /

TEST PO I NT 9

1. T h r o t t 1 e S w i t c h

(Idle Contact)

2.2 Switch off ig n i t ion and pull plu g c onnector on K / CP cont r ol un i t .

Connec t ohmmeter ( pr e f er abl y pointer-type instrumen t ) with terminals 2 2 and 23.

1 .

1 On c old DME control unit plug connect terminal 2 and ground

· with ohmmeter.

Indication:

Throttle closed

Throttle open =

=

0 - 10

~ ohm ohm

(after approx. 1° of opening)

Move throttle slowly t o full load position. The in st rument m ust swing continuously to th e f i nal value without br e aks.

1.2 If there is no indication, carr y o ut testing directly on throttle switch, terminals 4 and 6.

Indication:

Idle position 320 6 70 o hm

Full load pos i tion 2.7 4 .7 K oh m

~ 1.3 If the switch is oka y , check power flow to DME control unit plug ter m inal 2.

2. T h r o t t 1 e

P o t e n t i o m e t e r

2.1

3 . C h e c k i n g T h

r

V a 1 v e C u tc f f o t t 1 e

3 .

1 Pull off plug on th r o tt le switch and br i dge te r min a l s 4 and 6 with auxiliary wire.

Remove plug ccnnector on throttle swit c h. Connect voltmeter with terminals 1 and 2 on plug and swit c h o n ignition.

3 .

2 Start engine and inc r ea s e s p e e d to approx. 1600 rp m . The mot or should begin to surg e .

Indi c ation approx. 5 V

- - . /


Throttle Switch



Printed in Germany


4. C h e c k

L i n g F u 1 1 o a d I m p u 1 s e

N o t e

Since the full load impulse is generated by the K/CP control unit at a throttle position of 65 ° , this test can only be carried out when the engine is running. In order to avoid overrevving the engine, remove

2 injection valve plugs.

4.1 Connect terminals Band Con testing socket with voltmeter.

4.3 If no indication follows, check connection between terminal B on test socket and terminal 18 on

K/CP control unit plug.

4 .

4 If the connection is okay, replace K/CP control unit.

Indication : approx. 5 V

4.2 Open throttle valve fully for a short per i od (do not overrev eng i ne).

Indication : voltage goes back to 0 V.

Printed in Germany



Test Point 9

Throttle Switch

28 - 27


TEST POINT 10 N o t e

T e m p e r a t u r e S e n s o r Break on temperature sensor causes

(NTC II) richer mixture.

1. Pull out DME control unit plug and connect ohmmeter with terminal 13 and ground.

Sensor control values: at 0 ° C/32°F

15-30°C/59 -86 °F

40°C/104°F

80°C/176°F

100°C/212°F

=

=

=

=

=

4.4 6.8

1.4 3 .6

1 1.3

250 390

160 210

Kohm

Kohm

Kohm ohm ohm

If the control values are not reached, carry out measurement directly on temperature sensor.

S hort causes

2. circuit leaner on temperature mixture.

Allow warmed-up

Pull off plug temperature sensor. The engine s h ould cut off due to overenrichme nt.

Re-insert plug. engine to idle. connector on sensor


Temperature Sensor



Printed in Germany

944 turbo

TEST POINT 11

I n j e c t i o n V a 1 v e s

1. If engine can be run, disconnect plugs on injector s separately.

If injectors are intact, engine speed will drop each time.

2. If engine cannot be run , measure voltage on plug connections of in j ectors.


3. Measure coil resistance on f l at male plugs of injection valves .

Ignition System 28

Cont ro l value:3,5-5,5 ohms

Print ed in Germany



Test Point 11

Injection Valves

28 29

2 8 Ignition System 944 turbo

TEST POINT 12

KNOCK/CHARGING PRESSURE CONTROL

The knock/charging pressure system includes a self-monitoring system, which ca n output a recognized defect with the help of a test adapter.

The output is in the form of a blink code, similar to morse code.

If a defect has been found, the engine will operate on a safety system

(basic charging pressure up to approx. 0.3 bar overpressure and 6 ° later ignition), which means significantly reduced performance.

N o t e

~

A defect stored in memory is erased when ignition is switched off. For this reason , the defect must be read out directly after a test drive without switching off ignition.

1

= LED red (bl ink code)

2 = LED green (lights up when terminals B and C are bridged)

3

= Switch for bridging terminals B and C

28 30 Test Point 12

Knock/Charging Pressure Control



Printed in Germany


Blink code

1 - 2

2 - 1

2 - 2

Problem

Supplied voltage smaller 10.2 V

Possible Defect

Battery, alternator, control unit, wiring

Testing

Voltage drop at plus and ground terminals; Battery discharged;

Alternator or control unit defective.

Knock sensor monitoring

Knock sensor monitoring

Knock sensor supplies excessively large signal or K/CP control unit is defective.

Knock sensor supplies excessively small or no signal, or K/CP control unit is defective.

Testing

1. Check plug connection on knock sensor for correct seating and inspect spring contacts.

2. Remove plug connector on K/CP control unit. Connect ohmmeter to terminals 11 and 13.

Control value: 270 330 Kohm

If 0 ohms or.oare indicated, check wiring connections

(including ground contact). Exact inner resistance of the knock sensor does not rule out a defect in the sensor.

If necessary, replace knock : sensor.

3. Check fastening of knock sensor. Be sure to observe tightening torque, and use fastening bolt without washer.

Ti~htening torque: 9 Nm, as from mod. 88, 20 Nm

Printed in GermanyIII,1988



Test Point 12


28 - 31


Blink code

2 3

3 1

Problem

Knock control unit defective

Charging pressure too low or no charging pressure

Possible

Exchange

C harging valve

Defect knock control unit pressure regulator stuck in open position.

Testing

The exhaust system should be cold for testing the charging pressure control valve.

1 . Lift vehicle, start engine, and let idle.

2 . C h eck bypass pipe for warming.

If the bypass pipe heats up , the ~ harging pressure con trol valve is defective, i .

e. is stuck ' in the open position.

Remove bypass pipe, and check and if necessar y repla ce charging pressure control valve.

28 32 Test Point 12




Printed in Germany


Blink code

3 1

Problem Possible Defect

Charging pressure too low: 0.3 bar

(positive pressure) basic chargi ng pressure available

N o t e

Localis i ng defect

The "charging pressure too low" problem is only stored in memory when the difference in pressure from normal pressure is 0.45 bar; this problem can thus exist without setting off a blink code defect indication.

Testing

1 . Pinch off actuating line to charging pressure control valve with hose clamp .

Downloaded from

Printed in Germany www.Manualslib.com

2 . Test-drive vehic le and measure charging pressure with pressu r e gage P9103/2. If charging pressure is availab l e and climbs above 0.7 bar (positive pressure) following systems can be considered to be in good order :

Charging pressure control valve

Exhaust turbocharger

- Air intake system

- Air circulation valve

3 . The cause of the problem must then be located in the timing va lve area. manuals search engine

Test Point 12


28 - 33

2 8 Ignition System 944 turbo

- Checking timing valve

The function of the timing valve and of actuation can be acoustically checked .

4. Check blue/red lead from timing valve to K/CP control unit terminal 2.

If all functions are

K/CP control unit. okay, replace

1 . Start engine and give a quick spurt of gas at the throttle.

When the air flap in the air flow sensor swings more than

60 % , the actuation of the timing valve begins. A light clicki ng should be audible from the timing valve, or should be able to be felt with a metal rod.

2. If no function of the timing valve can be heard, measure voltage supply to valve.

Remove plug connector at timing valve and connect red/ green lead and ground on volt meter.

N o t e

Actuation of not of a occu defe the r with ct timing valve simultaneous

5. Check exhaust line from solenoid valve connection 11 R 11 to intake air cowl for ease of flow. does presence code on test adapter.


3. Apply battery voltage and ground to timing valve.

The valve must audibly s witch.

Timing valve inner resista n ce

18 - 45 ohms.

R w

C Connect~on to pressure pipe

R Return ' to intake s ide

W Control lead to charging pressure control valve

28 34 Test Point 12

Knock/Charging Pressure Contro l



Printed in Germany

944 turbo Ignition Sys tem 28

6. Visually inspect connection at intake air co w l for rubber residue (reduction of c ross section).

Exhaust system obstructed

(ca talyti c converter mode l s)

1 . Connect p r essure gage P9103/2 at e xhaust collect ion pipe i n engine compa rtment.

If no charging pres s ure is obtai ned despite c utting off t he co ntr o l l in e to the c harging pressu re contro l valve, other causes must be i nv estig ate d .

Check exhaust system for leaks .

2 . Test-drive vehicle. Test values:

At full load wi t h engi n e sp eed o f

3500 rpm and approx. 0 .

7 bar chargi ng pressure, exhaust pressure should be 0 .

8 + 0 .

1 bar.

Check sealing of s u ctio n and c h arging pressure syst em (see Test

Pointp) .

Check ' throttle for complete opening.

Printed in Germany



Test Po i nt 12

Knock/Charging P r essure Control

28 35


Check turbocharger

1. Remove intake air cowl and check compressor impeller of turbocharger for damage.

- Check bypass-air valve for function.

1 . Remove bypass-air valve and apply approx. 0.5 bar negative pressure with vacuum hand pump.

2. Check turbocharger shaft by hand for ease of motion and excessive play.

3. The turbine (exhaust side) can be checked only after dismantling t u rbocharger.

The bypass-air valve should open with the applied negative pressure remaining present.

2. Install bypass-air valve, start engine , and allow to idle.

Connect vacuum hand pump to connection line of air circulation valve.

The suction system negative pressure must be present at the connection.

This means that when engine is in operation with charging pressure, the bypass air valve is acted upon by the charging pressure and remains closed.

Printed in Germany 28 36 Test Point 12




944 turbo

Blink code

3 - 2

Ignition System 28


Excessive c harging pressure

Testing

Charging pressure is not being control actuated valve

C heck actuation l ine to charging pressure control valve for flow-through and damage.

Charging pressure co ntrol valve sticks in closed position or the membrane leaks.

Testing

The exhaust system should be cold during testing of the charging pressure control valve.

1. Lift vehicle. Disconnect actuating line to charging pressure control valve and connect pressure pump (VAG 1274 ).

Printed in Germany



Test Point 12


28 - 37

•


2. Start engine and allow to idle. After a short time the exhaust pipe to the charging pressure control valve should heat up while the bypass pipe remains cold

(charging pressure control valve closed) .

3. Apply approx. 0.6 bar pressure (max. 1.0 bar) to charging pressu re control valve w ith the hand pum p.

The bypass p ipe shoul d then likewise heat up

(charging pressur e control valve open).

When the applied pressure is s uddenly removed, the valve should close with an audible 11 Click 11

,

If functioning is not as described, replace charging p r essure control valve.





Printed in Germany

944 turbo

Blink code

Ignition System 28


Actuation line to timing valve is broken or throttle at connection "C" of timing valve is blocked.

Testing

1. Remove timing valve and check throttle at connection "C".

R w

2 . C h eck l ea d from pres s ure pipe to timing valve for f l owthrough or interruption .

Pri n ted in Germany



Test Point 1 2

Knock/C h a r gi n g Pressure Co n trol

28 39

~1:1 Ignition System

Blink code

3 3

4 - 1

4 - 2

944 turbo

Problem Possible De fect

Timing valve has continuous current

Testing

1. Remove plug connector at t i ming valve and switch on ignition.

2. Connect both co ntacts of p lug connector with test lamp.

If the test lamp lights up, the lead to the

K/CP control unit (red/blue term . 2 ) must be checked for ground connection or the K/CP control unit i s defective.

Pressure sensor in

K/CP control unit defective

Replace control unit

N o t e

Flashing code 3 3 may be c aused by a detective throttle valve potentiom e ter. Th erefo re, fir st check the throttle valve potentiom eter in accordance with Item 9 before re p la c ing the control unit.

Throttle po t entiometer

Plug c o nn ec t o r ha s fa l le n off; s up ply lin e t o po ten t i ometer has g ro und

·' contact; poten ti o meter is defectiv e .

N o t e

I f defe ct s ignal 3 3 i s pre se n t at the same time, the pre ss ure sen s o r is in good co ndition.

Throttle p ote ntiomet e r

Check l ea d s to potenti omet er for s h or t circ uit s .

Po tenti ometer defect iv e.

28 40 Test P o in t 1 2

Knock/Charging Pr ess ur e Control



III,l9 88 Print e d in Germa n y


TEST POINT 13

I n t a k e

S y stem

P r e s s u r e

S e a 1 i n g

1. Check all connection points after air flow sensor for tight fit and sealing.

2. Using the locally made tool

( see ~orkshop Manual 944 , page

24 -1 5), build up 0.5 bar pressure in intake system and chec k sealing.

TEST POINT 14

A 1 t i t u d e

B

0 X

C o r r e c t i o n

(Test below 1000 m/3300 ft above sea level )

The altitude correction box is located above the K/CP control unit.

1. Let engine idle. Remove oxygen sensor plug connector and measure

CO before catalytic converter.

2 . Remove plug connection of altitude correction box and bridge plug connections with a suitable wire.

The CO test value s h ould change approx. 1 % towards leanness .

3. Connect plug connection on altitude correction box with ohmmeter.

Contra 1 va 1 ue: oo ohms (s witch open)

Above approx. 1000 m/3300 ft above sea level, the switch in the altitude correction box is closed.

Control value: 0 ohms

Downloaded from

Printed in Germany Test Point 13

Intake Pres. Syst .

S ealing www.Manualslib.com


Test Point 14

Altitude Correction Box

28 41


TEST POINT 15

I f

C g n r o m D~tE t o K/ CP o n i t t i r o o n

1 U

S n i i g t n a

1. Pull off plug connector on K/CP control unit. Connect oscilloscope at plug terminal 9 and ground.

2. Start engine.

A square wave signal should become visible on the screen .

N o t e

The engine can be operated without the K/CP control unit in an emergency or for troubleshooting purposes.

In order to do this, the ignition signal must be bridged at the K/CP control unit plug terminals 9 and

16 with an auxiliary wire.

The engine wil l then run with reduced power .

----.~1

'---1

If no signal is present, replace DME control unit.


Ignition signal from DME to K/CP control unit



Printed in Germany


TEST POINT 16

0 x y g e n S e n s o r

F u n c t i o n

(Short test)

- Engine at operat i ng temperature

Idle speed correctly set.

1. Connect exhaust tester at collectio n nozzle in engine compartment .

The CO value shou ld rise.

4. Re-connect plug connection on oxygen sensor. The CO value s hould set itself to the control value o f 0.6 ± 0.2%.

If there is no change in the CO level, there is a defect in the oxygen sensor or in the DME control unit.

DME C o n t r o

(0

F u n c t i o n)

U n i t x y g e n C o n t r o l

1. The same test requirements apply as for the oxygen sensor function test. 2. Detach plug connection of oxygen sensor and note CO value .

3. Pull off negative pressure line from fuel pressure regulator and close with suitable stopper.

2 . Temporarily connect terminal 1 on the oxygen sensor plug connector

{plug half to control unit) to ground with an auxiliary lead.

The CO level should rise.

If there is no change in the CO level check connection to DME control unit

(terminal 24 green), and if necessary rep l ace control unit.

Printed in Germany



Test Point 16

Oxygen Sensor

28 - 43

28 Ignition System

T e s t i n g 0 x y g e n

S e n s o r (S e n s o r

V o 1 t a g e)

1. The same test requirements apply as for the oxygen sensor function test.

2. Disconnect oxygen sensor plug connector.

3. Connect voltmeter at terminal 1

(plug half to sensor).

·The voltage should be in the area of

0 • 1 V to 1. 0 V •

(Sensor voltage depends on oxygen content in exhaust).

944 turbo

28 44 Test Point 16

Oxygen Sensor



Printed in Germany

944 t urbo General data

5speed manual transmission 016 R / S for 944 turbo

30

793

Codes and date of mfg of transmiss i on

Examp le : 5P 15 10

I I I

Code letter Day M onth

5

I

Year of ma nufa cture ( 1 985)

Type

016

016 s s

Code letter

SP

Equipment i nstalled in : Model year

016 R

UY

9U with o i l cooler 944 turb o until mod . '86 * as from M od. '87 ** as from mod. '85 ** 016 R SA with oil coo l e r a nd lim. slip diffe r en tial without oil coole r

.

$ 44 turb o

944 turbo without oil cooler but with lim. slip d iffe r en tial

944 turbo as from mod . '87 * as from mod. '87 **

* = s tandard ** =o ption

Apart from the o il pump with serpe nt ine cooling pipe, transmission type 016 S is identical to tr ansmis sion type 016 R with regard to construction and repair .

Technical data (Type 016 R / S)

Printed in Germany Ill , 1988



30 01

30 General Data Clutch, Transmission

5-SPEEO MANUAL TRANSMISSION 083 0 FOR 944 S (87 MODELS ONWARD)

944 turbo

Type

083 0

083 0

Code

AGP

AGR

Installed in vehicles for: rest of the world rest of the world (with limited-slip diff.)

As regards design and repair work , there are onlj a small number of differences between the 083 0 transmission a nd the 016 R turbo transmission.

The most important differences are:

no transmission-oil pump can be supplied

final drive ratio increased 9 : 35 transmission case machined for ring gear

design dimension 11 R0 11 58.15 mm (turbo transmission 59.65 mm)

III,1988-Printed in Germany 30 02 Technical Data

(Type 083 D)



9 44 turbo General data

5-speed manua l transmission 016 R for 944 turbo S

30

Codes and date of mfg of transmission

Exam pl e: AOR 1 5 02 8

I I I I

Code l etter Day M onth Yea r of manufacture (1988)

Type Equipment I n s talled In :

016R

Code lett e r

AOR with oil coole r and lim. s l ip d ifferen t ia l

944 turboS

944 turbo

Model y e ar as from mod . ' 88 mod . ' 89/'90 /' 91

A pa rt f r o m a f ew deviations, t ransmission 016 R , code AOR, is identical to the turbo transmission

016 R , code SR . with regard to construction and repa i r .

The most si g nificant devia t ions are:

tr ansmission oil cooling as standard

limit e d s l ip d i ff e r e n tia l as sta n da rd ( w it h r einfo r ce d inner pla t es and molybdenum coated differential

s h a ft s)

ge a rwheels for firs t a n d secon d gear on the drive shaft a r e blasted for i ncreased stre n gth

Technical data (Type 016 R )

P r inted i n German yI V, 1 99 1



3 0. 0 3

30

General data

Ratios

1st gear

2nd gear

3rd gear

4th gear

5th gear

Reverse gear

Final drive

Final drive ratio

Power train

Capacity

General data

5-speed manual transmission

016 R/016 S/083 D

944 turbo

10:35

17:35

25:35

29:30

35:29 j

= 3,500 i = 2,059 i = 1,400 i = 1,034 i = 0,829

12: 42 i = 3,500

Hypoid pinion set with 12 mm displacement

8:27 i = 3,375 (944 turbo)

8:27 i = 3,375 (944 turbo S)

9:35 i

=

3,889 (944 S)

Front-mounted engine and rear-mounted transmission bolted together via a torque tube to form a rigid drive unit. Front-mounted engine, clutch torsionally elastic shaft (25 mm dia.) to transmission running on 4 bear ings in torque tube, rear-mounted transmis s ion interlocked with final drive (transaxle), dual-joint drive s hafts to rear wheels. approx. 2,0 I hypoid transmission oil SAE 75 W 90 to

API Class GL S or MIL-L 21 OS B, or SAE 80 to API

Class GL 4 or MIL-L 21 OS (refer to page 34-1)

30-04



Technical data (Type 016 R)


944 turbo General Data Clutch, Transmission 30

TIGHTENING TORQUES FOR MANUAL TRANSMISSION

Location Description Thread

Oi1 filler plug to Plug transmission housing

M 24

Oil drain plug to transmission housing

Plug

Cover to end plate Pan head bolt

M 24

Selecter shaft cover to transmission housing

Ball bearing on input shaft

I

Hex bolt

End plate to transHex bolt mission housing

Bolt

M 6

I

M 8

I

~1 17

M 8

5th gear to drive pinion

Hex bolt M 10

Shift lock to end plate and transmission housing

Shift travel stop to end plate

Operating lever to end plate

Threaded sleeve

Stop screw

Phi 11 ips head bolt

M 18

M 14

M 10

Reverse gear shaft Hex bolt bolt to end plate with collar

~1 8

Materia 1

-

-

-

8.8

8.

8

10.9

8.8

8.8

8.8

8.8

8.8

Torque

Am (ftlb)

24 (17.7)

24 (17.7)

8 ( 6 )

2 4 (17.7)

150 (110)

24 ( 17. 7)

7 0 (51)

30 (22)

3 0 (22)

35 (25)

24 {17. 7)

Printed in Germany



Tightening torques

(Type 016 R)

30 05

30 General Data

.. ocation Description Thread Materia 1

Shaft flange to differentia 1

Side transmission cover to transmission housing

Ring gear to differential housing

Backup light

• switch to transmission housing

Speedometer sock et to transmission housing

Cooling coil to cover and oil pump

Oil pump cover to side transmission cover

Cooling coil bracket to transmi s sion housing

Cooling coil shackle to bracket

Drive s haft to flange

Bolt

Hex bolt

Hex bolt

Switch

Speedometer socket

Pan head/ hex bolt

Hex bolt

Locknut

Pan head bolt

Allen head bolt

I

M

M

M

8

8

~1 18

M 18

M 8

M 6

M

M

M

10

8

6

8

8.8

10.9

12.9

-

-

10.9

8.8

8.8

8

8.8

12.9

Torque

Nm (ftlb)

24 {17. 7)

24 ( 17.7)

90 ( 65)

42 (30)

42 ( 30)

2 4 (17.7)

8 (6)

24 (17.7)

8 ( 6)

42 ( 30)

944 turbo

Printed in Germany

30 06 Tightening torques

(Type 016 R)



944 turbo General Data , Clutch, Tran smiss ion 30

General Data

Desi gn

Pressure plate

Clutch

Single plate, dr y clutc h with diaphragm springs, cold version, located o n engine end, h ydra u lic operatio n

GMFZ 240

Contact pressure 8700 9500 N

(large d ynes)

TO 240 (ste el spring torsion dam per ) C lu tc h disc

The clutc h dis c has a t w o-step ste el spring torsion damper

944 turbo

1st step: T hree lig h t com press ion springs 0

944 t u rbo S

1st step : Six lig h t compression springs

2nd step: Four heavy s ets of springs

E

2 nd step : Four h eavy sets of springs

Printed in Ge rm any 111 , 1988



Techni cal Data 30 07

944 turbo

30 General Data

TIGHTENING TORQUE FOR CLUTCH, C ENTRAL TUBE, TRAN SM ISSION SUSP ENSION,

AND SH IFT

Locati on De scr iption Thread Material Torque in Nm

(ftlb)

CLU T C H

Guide clutch s leeve h o on using

Hex bolt M 7 8.8 15

(1 '5)

C lut c h and gea r ring installation

Socket bolt head M 8 8 25

(2,5)

F l y\'1hee 1 to cranks h aft

Socket b olt head M 10x1.25 10.9 90

(9,0)

C lut to ch housing engine*

H ex bolt M 12 8.8 75*

(7,5)

Starter housing t o clutch Hex bolt M 12 65

(6,5)

Protective to c panel lutch housing

Hex bolt M 10 8.8 42

(4,2)

Release with c lever lut c s h hou haft s ing

He

He x x bolt nut

M

M

6x35

6

8.8

8

9.5

(0,95)

7.5

(0,75)

Reference mark, rpm, and DC sensor bracket to c lutch housing

Pan

H ex head bolt

I

Refere nce mark, rp m, and DC sensor to bracket

Pan

He x he a d bolt

I

S lav e cy linder to c lut c h housing

H ex b o lt

Master cylinder to firewall

He x nut

Clutch tube to cl ut c h hose and to master and sla v e cyli nders

Coupling bolt

* Grease he x bolt with Optimoly TA.

M

M

M

M

8

6

8x2

8

M 1 2

8

8.8

8.8

8

20

(2,0)

8

(0,8}

21

(2,1)

21

(2,1}

16

{1 ,6)

111,19 88 Printed in Germany

30 08

Tightening T orq u e



944 turbo General Data - Clutch, Transmission

Location Description Thread Material

Central shaft to Pan head transmission input bolt shaft (split ring)

M 10x46 12.9

Central tube flange Hex bolt to clutch housing

Central tube housing to trans-

~ission housing

M 10x35 8.8

Pan head I M 12 x 75 10.9

Hex bolt

M 10 x 60 8.8

Torque

Nm

/kpm (ftlb)

80

/8.0 (60)

42

/4.2 {30)

85

/8.5 (62)

42

/4.2 (30)

TRANSMISSION SUSPENSION

Transmission mount to body

Hex bolt

Hex bolt Transmission bearings to trans-

""ission mount

Bracket to trans-

~ission and trans-

""ission bearings

Hex bolt

SHIFT

Joint rod to transBall-end

~ission housing bolt

Hex nut Joint rod to intermediate shift lever

Shift rod Bolt

Shift lever plate Hex bolt to central tube

Intermediate shift

1 ever to shift shaft

Bolt

M 10

M 8

~1 8

M 8

M 8

M 8

~1 8x12

M 8

8.8

8.8

8

46

/4.6 (34)

23

/2.3 (17)

23

/2.3 (17)

9 S Mn28K

8.8

9 S Mn28K

8.8

14

/1.4 {10)

21

/2.1 (15)

21

/2.1 (15)

21

/2.1 (15)

22.5

/2.25 (16.6)

30

Technical Data 30 - 09 Print e d in Germany



944 turbo Clutch Operation 30

CHECKING CLUTCH PLAY

Due to the automatic hydraulic clutch adjustment, clutch play can not be checked at the clutch pedal.

However, for perfect clutch operation there must be a play of

0.5 mm between pressure rod and master cylinder piston.

This play cannot be measured and must be determined at clutch pedal by feel. It is about pedal plate.

If necessary, correct play by adjusting piston rod.

3 mm at the

ADJUSTING CLUTCH SPRING

In order to reduce the amount of foot force required to operate the pedal, there is a spring which reduces pedal force. This spring has to be pre-tensioned to the correct level for this purpose.

Distance A is measured in engaged state (clutch pedal at final stop) between the outer edge of the plate and the knife-edge bearing.

- Distance A for green-coded spring

(no longer available as spare part ) = 60 mm (75 mm*)

- Distance A for blue-coded spring

(harder spring rate/used as from

Feb. 1986) = 55 mm (68 mm*)

If necessary, correct by turning hexagon nut.

* Value in brackets stands for distance A in assembled condition.

Servo spring I guide rod pre-assembled with assembling wire

(split pin 0

3 mm).

Printed in Germany-III,l988



C h ecking Clutch Play

Adjusting C lut c h S pring

30 - 1

30 Clutch Operation 944 turbo

.

I

CHECKING CLUTCH DRIVE PLATE WEAR

Clutch drive plate installed

C h e c k i n g

Remove cap.

Clutch drive plate removed.

C h e c k:

Measure the distance between the surface of the lining and the head of the rivet with a depth gauge or slide caliper

(dimension X).

N o t e:

Only measure on the beaded side of the rivet head.

1

2 r~easure distance "A" with suitable too 1 •

1 lining

Wear limit 0.2 mm

2 clutch lining

New part distance

Wear 1 imit

18

34 mm mm

30 2

Checking Clutch Drive Plate Wear



111 ,1988Printed in Germany

944 turbo

REMOVING AND INSTALLI NG CLUTCH

Cars with two-part exhaust cross pipe

Clutch Operation 30

Modified /c urrent version

Note:

The following work must also be carr ied o ut on earlier cars with single -part exhaust c ross pipe: l.Re

move and install intake-air manifold

2.R

emove and instal l guard for brake master cylinder.

Original version

3.Remov

e and install single -part exhaust cross-pipe.

Printed in Ge rm a ny-1 1,1987



Removing and Installing Clutch 30 3

30

Clutch Ope r ation 944 tur b o

Removing and installing clutch

Note

W he n performing operation s on the transaxle s ystem that require rotation or shift i ng of the t ransaxle tube , always wear leather gloves to a void any risk of injury .

Removing

1 . Align ho i se beneath car an raise car on c hecking points.

2 . Pl a ce covers over fenders.

3 . Disconnect ground lead from battery .

4 . Disconnect ground cable from clutch housing (1 ). After removing hex bolts , remove ref erence-marK transmitter (2) and speed trans mitter ( 3) for DME from holder . Detach cable bundle to starter at upper attachment point ( 4 ) .

Note

Access to attachment point 4 (starter cable) is best once the central tube has been disconnected from clutch housing. See item 15.

6. Detach both shields from starter and clutch housing and withdraw to rear.

7 . Disconnect electrical connections to starter and remove starter, remove hose clamp on clutch housing. Remove clutch actuating cylinder without disconnecting line .

8. Remove exhaust system as a unit. Unbolt flange connection between tu r bo-cha r ger and exhaust pipe and flange to bypass valve. Remove securing bolts from suspension points, remove exhaust system and shield at primary muffler.

1 0. Remove transmission.

See 944 Repair Manual , Volume II

Transmission, page 34 4.

11 . Remove transverse strut between body and rear-axle carrier.

5 . Remove engine ground

30.4



R e m o ving and In s talling clut c h

Printed in GermanyIV, 1991

944 turbo

12.Slacken hose clamp on fuel filter and transmission carrier and remove.

C lu tch O p erat i on 30

13.Unbolt bypass valve w ith hol der from c e ntral tube and sl i d ing flange and remove.

14 .

Re m o v e cent r al t u be/cl ut ch hous ing mou n ti n g bo l ts (4 ).

Slac ke n both suspensio n clam p s o f exhaust system , but do n ot remove.

15 .

Unbolt shift lever w i t h b e ar i n g bracket from central tub e .

18.

Wi t h dr aw r el ease lever s haft w i th

8 mm b olt a fter remo vi ng retaini n g bolt.

16.Se

parate ce n tra l t ube and clutch hou sing, pu s h ing se l ec tor rod to rear at the same time .

17 .

Tu rn c e nt r al t ube clock wise th rough 90° and p ull to rear .

Note pos i ti o n of c atch hooks .

N o te :

Do not d amage in sulatio n for shift linkag e .

1 9.

U nb ol t and re c m o lut v e. c h hou si n g fr o m eng i n e

2 0.Un

i formly uns c rew b o lts of cl utch pressure plate and r e move pressure plate with driven plate.

Printe d i n Ge r ma n y 11 , 1987



R e moving and Insta l ling Cl ut c h 3 0 5

30 Clutch Operation 944 turbo

INSTALLING Note: l .Check flywheel, starter ring gear, grooved ballbearing in crankshaft, seal/crankshaft , release bearing, guide sleeve, release lever, pressure plate and clutch plate for wear or damage.

Replace the grounding point (hex bolt) on the clutch housing of earlier cars with a M8x15 mm stud bolt. Use adhesive, e.g. Loctite 270 to bond stud bolt.

2.Coat guide sleeve with multi purpose MoS grease and apply a thin coat or MoS multi-purpose grease to

spline~

of central shaft and the grooved ballbearing/flywheel area. Lubricate release lever (fork , ball socket and needle sleeves) with white solid lubricating paste AOS 126 0006.

4.Install clutch housing and release lever together on engine/release bearing. The bonded bolt in the flywheel for the reference mark transmitter must point down (to avoid damage).

Tighten clutch hou sing bolts.

Note:

3.Install clutch. The friction surfaces must be clean and free of grease. Use central shaft 1 of a

928 (or a shortened central shaft from a damaged central tube) to center the clutch plate. Tighten bolts uniformly in diagonally opposite sequence. Tightening torque 25 Nm (18 ftlb). Counter by holding hex bolt of front pulley.

Apply Optimoly TA to threads of clutch housing bolts.

5 .Move sle as release lever eve

(milled and bore are aligned. far as it

S in lide lever shaft right face toward will until needle clutch in way go. housing release round securing

bolt)

If necessary, move release lever back and forth.

Never use force.

30 - 6 Removing and Installing Clutch



Printed in Germany

944 turbo Clutch Operation 30

6.With release-lever shaft correctly positioned, screw in mounting bolt and lock with hex nut .

5.Test drive car (on road or roller dynamometer). Check exhaust system for leaks.

7.The sequence for installing central tube, transmission , exhaust system etc. is the reverse of the removal sequence.

When installing, always note the following:

6.Allow exhaust system to cool down and retighten all accessib le nuts and bolts of the system to the specified torque. It is particularly important to retighten the flange between bypass line and exhaust cross pipe.

!.Always use new seal rings (packing rings).

2.0nce all the exhaust-system bolts have been inserted, tighten the flange connection between turbocharger and exhaust system first .

3.Align bypass valve between clutch housing and body.

4.Tighten the M6 bolts connecting bypass line/exhaust cross pipe uniformly to the specified torque

(10 Nm, 7 ftlb).

Printed in Germany-11,1987



Removing and Installing Clutch 30 - 7

9 44 tu rbo Manual T ra n s mission I Operation , Housing

34

Checking o il levels I replacing transmission oil (type 016 R/S )

Capacity : Approx . 2.0 I hypoid transmission o il

S AE 7 5 W 90 to API Cla s s GL 5 or

MIL L 21 05 8 or SAE 80 to API Class GL 4 or

MIL L 2105 ( r efe r t o page 3 4 1 )

1 . Clean outside of filler and drain plugs, and then unscrew •

Note

The fluid level inside the transmission housings used in production is approx. 6 to 8 mm below the fille r neck when 2 lite r s of transmis sion oil ha ve been f illed in.

•

1 - Drain plug

2 Filler plug

2. With car parked on level surface and transmission at operating t emperatu re , drain oil from transmission .

3 . Clean filler and drain plugs, and insta l l. Tight ening torque: 24 Nm ( 18 ftlb) .

4. With car parked on level surface , for oil into tra n smission.

E

E co

<D

.

1

Checking oil levels I replacing t ransmis sion oil (type 016 R / S)

Printed in Ger man y IV , 1991



944 turbo Manual Transmission I Operating, Housing 34

REMOVING AND INSTALLING COOLING COIL

1 2 17

14 4 3 5 15 11 12 11 16 13 9

Printed in Germany



Remov i ng and Installing Cooling Coil

(Type 016 R)

3 4 - 3

34 Manual Transmission I Operating, Housing 944 turbo

No. Description

2

3

1 Pan head bolt

Holding panel

Hex bolt

4

5

6

7

Sleeve

Shackle

Holding panel

Locknut

Qty. Removing

1

1

1

1

1

1

1

1

1

10

11

15

16

17

12

13

14

8

9

Washer

Pan head bolt

Sleeve

Pan head bolt

Shackle

Bracket

Cooling coil

Hose section

Hose section

0-ring

18 0-ring

1

2

1

1

1

1

2

1

1

19 Clip 2

Note When:

Installing

Tightening torque

24 Nm (17.7 ftlb)

Tightening torque

24 Nm (17.7 ftlb)

Tightening torque

24 Nm (17.7 ftlb)

Tightening torque

8 Nm (6 ftlb)

Replace, coat with transmission oil


34 - 4 Removing and Installing Cooling Coil

(Type 016 R)



Printed in Germany

944 turbo

TOOLS

Manual Transmission I Operation, Housing 34

No. Descr ip tion

1 Assembly stand

2 Assem b ly sleeve

3 Puller hook

4 Shift grip

Special Tool vw

540

9178 vw

681

9155

Remarks

Printed in Germany



Removing an d Installing Gearbox

(Type 016 R)

34 5

944 tu rb o 34 Manual Transmission 1 Operation, Housing

REMOVING AND INSTALLING GEARBOX

16 17

.

'

,.

""-

13 6 7 3 2 4

I

.1.

} I

\ 1 l ~

5

I

2 1 12 11 10 9 1 8

/

<~

/

/ r

1 8

II

..

.

1 5 14 13 20 1 9 18 1 7 16

Printed in Germany 34 - 6 Removing and Installing Gearbox

(Type 016 R)



944 turbo Manual Transmission I Operation, Housing 34

.

.

.

No. Description

1 Sealing ring

2 Threaded sleeve

3 Gasket

4 Spring

5 Sleeve

6 Speedometer socket

7 Speedometer gear

8 Hex bolt

9 Spring washer

10 Cover

11 Gasket

12 Selector shaft

(complete)

13 Dowel sleeve

14 Hex bolt

1

1

1

1

Qty.

1

Removing

Note When :

Installing

Remove with vw 681 Install only after installing gear set.

Oil sealing lip.

Drive 1.5 mm into housing with Special

Tool 9178 and suitable pipe section.

1 Tightening torque

30 Nm (22 ftlb)

Replace

1

Tightening torque

42 Nm (31 ftlb)

Oil pilot

3 Tightening torque

8 Nm (6 ftlb)

3

1

1

1

Install in correct position, manufac -

1 turer s symbol outward

Replace

2

12 Tightening to rq ue

24 Nm (17 .7 ftlb)

Printed in Germany



Removing and Insta l ling Gearbox

(Type 016 R)

34 - 7

34 Manual Transmission 1 Operation, Housing 944 turbo

No. Description

15 End plate

16

17

18

19

Allen head bolt

Flange shaft

Hex bolt with washer

Cover

20

21

Differential

Transmission housing

Qty. Removing

1

2

2

9

1

1 Remove gearbox before removing

Note When:

Installing

Coat sealing surface with Curi 1 KIH

Tightening torque

24 Nm (17.7 ftlb}

Coat shaft with oil

Tightening torque

24 Nm {17.7 ftlb)

Evenly coat sealing surface with Loctite

573 or 574.

Light oil coat on tapered roller bearing and pinion teeth

1 If transmission case is to be replaced and

11 deviation r 11 is not on ring gear, check location of drive pinion before removing gearbox (actual distance).

34 - 8 Removing and Installing Gearbox

(Type 016 R)



Printed in Germany


INSTRUCTIONS FOR REMOVING AND

INSTALLING

R e m o v a 1

N o t e

The differential need not be removed for work on the gearbox.

2. Remove cooling coil.

3. Remove threaded sleeve and locking parts for reverse gear lock.

4. Take out selector shaft hex bolts and remove complete selector shaft (do not disassemble).

A

If the transmission housing or taper roller bearing for the drive pinion are to be replaced and deviation "r 11 is not given on ring gear, note location of drive pinion before removing gearbox

(actual distance).

5. Knock back dowel sleeves on end plate.

1 . Clamp transmi ssion in assembly stand with Special

Tool VW 540 and drain oil.

6. Unscrew hex bolts on end plate and pull out end plate with gear set.


N o t E

Install input shaft seal ring only after installation of gear set

(danger of damage).

1. Coat end plates/transmission housing sealing surface with

Curil KIH.

Printed in Germany



Removing and Installing Gearbox

(Type 016 R)

34 9

34 Manual Transmission I Operation, Housing

2 . Knock in dowel sleeves and tighten mounting bolts to a torque of 24 Nm (17.7 ftlb).

3. Drive input shaft seal 1.5 mm into housing with Special Tool

9178 and suitable pipe section .

944 turbo

4. Run a check by shifting throgh all gears with Special Tool

9155.

34 10 Removing and Installing Gearbox

(Type 016 R)



Printed in Germany

944 turbo Manual Transmission 1 Operation, Housing 34

DISASSEMBLING AND ASSEMBLING GEARBOX

1 2 3 6

, l.l

(:~

9 10 11 13 15 1216 17 37 30 l f tl l ~ , ) v

,·

.

31

32 33 35 34 26 27 2928

Printed in Germany



Disassembling and Assem b ling Gearbox

(Type 016 R)

34 - 11

34 Manual Transmission I Operation, Housing 944 turbo

•

No. Description

1

2

3

4

5

End cover deckel

Bolt

(micro-encapsulated)

Saucer spring

Pan head bolt

8

X

45

Washer

Note When:

Qty . Removing

1 Insert large screwdriver into center of rubber and pry out

Installing

Replace

1 Use only once; tightening torque 150 Nm

(110 ftlb)

1

7

5

Tightening torque

24 Nm (17.7 ftlb)

Two bolts without washers for crash protection

6 Ba 11 bearing/ inner race

7 Cover

1

8 Gasket

9 Ba 11 bearing/

Inner ra c e

10 Clutch body for 5th gear

1

11 Synchromesh ring

1

12 Adapter sleeve

13 Circlip

1

1

14 5th gear wheel 1 with sliding sleeve and synchronizer

1 Knock off with plastic hammer

1

1 Pull off with two-arm puller l

Replace

Heat to about 120°C/

248 ° F and knock on

Check for wear

Slide on sliding sleeve with short collar facing gear

34 - 12 Disassembling and Assembling Gearbox

(Type 016 R)



Printed in Germany


No. Description

15 5th gear selector fork

Qty. Removing

1

16 Needle bearing

17 Thrust washer

18 Stop bolt

1

1

1

Note When:

Installing

Available only with selector rod for 5th gear

Install with gear

1 ube

19 Gasket

(Paper)

20 Locking bolt

1

1

21 Seal ring 1

22 Hex bolt

(microencapsulated)

23 Washer

24 Gear

25 Shim

26 Dowel sleeve

27 Dowel sleeve

28 Selector rod for 3rd and

4th gear

1

1

1

1

• I Pull off w1th twoarm puller

Note thickness for reinstallation

1

1

1 Do not lose small locking piece

Tightening torque

30 Nm (22 ftl b). Do not confuse with bolt position 20

0.2 mm thick, replace, do not confuse with seal ring position 21

Tightening torque

30 Nm (22 ftlb), do not confuse with stop bolt position 18

Replace, do not confuse with gasket position 19

Use only once, tightening torque 70 Nm

(51 ftlb)

Heat to about 120°C/

248°F and install

If necessary, determine new thickness




Disassembling and Assembling Gearbox

(Type 016 R)

34 - 13


No . Description

29 Small locking piece

Qty. Removing

1

.

.

1 30 Bolt for operating lever

31 Reversing lever

32 Input shaft

1

1

Note When:

Installing

Insert in selector rod with a little grease

Adjust operating lever and tighten to torque of 35 Nm

(25 ftlb)

Adjust before installing shaft

·

Remove roller bearing inner race from input

·

shaft before installing

33 Selector fork for 3rd and 4th gear

34 Selector rod with selector fork for 1st and 2nd gear

35 Drive pinion

36 Dowel sleeve

37 End plate

1

1

1

2

1 Determine new shim thickness S4 when replacing

I

Downloaded from

34 - 14 Disassembling and Assembling Gearbox

(Type 016 R) www.Manualslib.com


Printed in Germany


•

INSTRUCTIONS FOR DISASSEMBLY AND ASSEMBLY

D i s a s s e m b 1 y

1. Remove end cover by punctu ring center of rubber with a la rge screwdriver and prying off cover.

2. Clamp input shaft in a vice and unscrew input s haft bolt.

Fit vice with soft jaws .

4. Knock off end plate cover with plasti c hammer and remove 1st inner race/ball bearing (A).

3. Clamp gearbox in vice on end plate and unscrew cover fastening bolts.

Printed in Germany




(Ty pe 016 R)

3 4 - 15


5 . Pull off clut c h and 2nd inner race / ball bearing with thrust p i ece VW 431.

944 turbo

A- two-arm puller (as commonly used), for example Kukko 20/10

6 . Remove 5th gear sync hromesh ring.

7. Knock out 5th gear selector for dowel sleeve. Counterhold with hammer, so that selector rod bore in end plate is not widened .

8. Remove c ir cl ip for synchronizer.

9. Remove 5th gear wheel a l ong with sliding s leev e and synchronizer, needle bearing and 5th gear selector fork .

Note that selector rod remains in end plate.

34 16 Disassembling and Assembling Gearbox

{Ty pe 016 R)



Pri nted in Germany

944 turbo

10. Remove thrust washer.


13. Pull off 5th gear wheel w ith thrust piece VW 431.

34

11. Unscre w stop and locking bolts for selector rods.

12. Cla m p 4th gear/drive pinion in a vice and unscrew drive pinion hex bolt . Make sure vice is fitted with soft jaws!

A - Two-arm puller (as commonly used), for example Kukko

20/10, if necessary grind down claws slightly or pry away gear slightly with two tire irons.

14. Remove shim for 5th gear wheel .

15. Clamp end plate in vice with shafts forward.

Printed in Germany Disassembling and Assembling Gearbox

(Type 016 R)



34 - 17

34 Manual Transmissio n I Operation, H ous ing

16. Knock out dowel sleeve for dog on 1st and 2nd gear selec tor rod. Counterhold with hammer.

Turn dog to face upwards.

17. Drive out do w el sleeve f or 3rd and 4th gear selector for k.

Counterhold w ith hammer.

944 turbo

18. Pull out selector rod for 3rd and 4th gears (sele ctor fo rk remains in s l iding sleeve) .

Do not lose small locking piec e !

19 . Unsc rew bolt for o p erati ng lever.

20. Pull drive p 1n 1 o n and input s h aft forward sl i g htly. Remove input shaft together with 3rd a nd 4th gear se lector fork.

21. Disco nnect spr in g clamp fo r r eve rs e gear on pinio n shaft end and turn to one si de.

22. Pull drive pin ion fo rward far e nou gh so that selector rod and selector fork fo r 1st and

2nd gears c an be removed.

23 . Swing out drive pinion.

3 4 - 18 Disassembling and Assembling Gearbox

( T ype 016 R)



Printed in Germany

0

944 turbo

A s s e m b 1 y

1. Complete end plate

(see Page 34 - 27)

2. Check positioning of locking pieces.


4. Install and adjust operating lever (see Page 34 - 32)

5. Engage reverse gear and disconnect spring clamp on one side, and then swing in drive pinion.

A Locking pieces

3. Insert springs and sleeves for gear arrest (1st through

4th gears).

6. Insert 1st and 2nd gear selector fork and selector rod, and push drive pinion in fully.

7. Engage spring clamp and disengage reverse gear.

8. Slide in 3rd and 4th gear selector fork so as to be positioned correctly with opening in land on selector rod for 5th and reverse gears.

Printed in Germany




(Type 016 R)

34 19


9. Insert input shaft, insert

3rd and 4th gear selector fork in sliding sleeve and push in input shaft completely.

13. Lock dog for 1st and 2nd gear selector rod onto rod with a pin . Counterhold with hammer.

N

o

t

e

Pull cylindrical roller bearing inner race off of input shaft to make installation easier.

10. Put selector rods in neutral position and make sure lock pieces are positioned correctly (see Page 34 19 ).

11. Sli de in 3rd and 4th gear selector rod with small lock piece ( insert with grease).

12. Lock 3rd and 4th gear selector f ork on selector rod with a pin, counterholding with a hammer.

14. Screw in stop and locking bolts for selector rods with seals and tighten to a torque of 30 Nm

(22 ftlb).

15. Clamp 4th gear/drive p1n1on in a vice. Make sure to use soft jaws!

16. Determine shim for 5th gear wheel.

Measure distance "a 11 w ith a depth gage and find thickness and part number of shim from the following table.

34 20 Disassembling and Assembling Gearbox

( Type 016 R)



Printed in Germany


D i s t an ce 11 a

( mm )

11

8.35 ..

. 8.6

4

8.

65 .

.. 8.9

4

8.9

5 ... 9.

2 4

9 .2

5 .

.

. 9 .

54

9 .

5 5 ... 9.

8 4

Shim

Thi c kPart Number ne ss

( mm )

1 .

1 0 1 6 311 391

1.

4 016 311 391 A

1 .

7 016 311 391 8

2 .

0 016 3 11 391

2 .

3 0 16 311 391 c

D

18. Tighten hex bolt for drive pinion to a torque of 70 Nm

( 51 ftlb) .

19. Clamp input shaft in a vice so that shafts are vertical.

20. Lightly grease cyl i ndrica l rollers of input shaft bearing and press outward.

21. Center input shaft in bearing and slide on inner race of cylindrical roller bearing.

22. Insert circlip for cylindrical roller bearing inner race and put on thrust washer .

17. Heat 5th gear / drive p1n1on to about 120 ° C/248°F and mount gear with collar facing drive p i nion. If necessary, drive on against stop with a suitable mandrel.

A- Circlip

8 Thrust washer

Printed i n Germany




( Type 016 R)

34 21

34 Manual Transmission I Operation , Housing

23. Mount 5th gear wh eel w ith synchronizer and sliding sleeve, needle bearing, and selector fork. Lock selector fork onto selector rod with pin , counterholdi ng w ith hammer.

944 turbo

26. Heat c lut ch to about 120°C/

248°F a nd moun t, if necessary driving on unt il reaching the stop wit h a suitable pipe section.

24. Insert ci r clip for s yn c hron ize r .

25 . Insert 5th gear synchromesh ring.

27. Heat s e co nd ball be ar in g in ner ring to about 120°C/248 °F and install.

28 . Install dowel sleeves, position g a sket , and mount end p l ate cover .

2 9. Hea~ first ball bearing inner race to abo ut 120 °C/2 4 8° F and in ~tall .

30. Tighten bolt for input s haft to a torque of 150 Nm (110 ftlb).

3 1. Tighten cover / end plate bo l ts to a torque of 24 Nm (17.7 ftlb) .

32. Pres s in new end cove r.

34 22 Disassem bl ing an d Assembl i ng Gearbox

( Type 016 R)



Printed in Germany

944 turbo Manual Transmission I Operation, Housing 34

DISASSEMBLING AND ASSEMBLING REAR HOUSING COVER

(

6 7 3 5 2 4 1

Printed in Germany Disassembling and Assembling Rear

Housing Cover (Type 016 R)



34 23


-·

No . Description

1 Pressure plate

2 Circlip

3 Ba 11 bearing

4 Cylindrical pin

5 Magnet

6 0-ring

7 Cover

1

1

1

Note When:

Qty. Removing

1 Knock out with a suitable mandrel

Installing

Caulk at three points

1

1 Press out with inner race

Heat cover to approx.

120°C/248°F. Insert bearing and press in with VW 30 205.

Replace,

1 ube oi 1 coat with

1

DISASSEMBLY AND ASSEMBLY INSTRUCTIONS

0 i s a s s e m b 1 y

1. Knock out pressure plate with suitable mandrel and remove circlip.

2. Press out ball bearing, inserting inner race of ball bearing for this purpose.

34 24 Disassembling and Assembling Rear

Housing Cover (Type 016 R)



Printed in Germany

944 turbo Manual Transmission 1 Operation , Housing 34

A s s e m b 1 y

1. Heat cover to approx. 120°C/

248°F, insert bearing, and press in with VW 30-205.

2. Insert circlip into groove.

Press in pressur e plate and caulk three points to lock.

Printed in Germany



Disassembling and Assembling Rear

Housing Cover (Type 0 16 R)

34 25

944 turbo

TOOLS


1

3

2

No. Description

1 Pressing tool

2 Pin

3 Pressing tool

Special Tool vw 472

; p 254 p 254 b

~

Remarks

Printed in Germany



Disassembling and Assembling End Plate

(Type 016 R)

34 27


DISASS EMBLING AND ASSEMBLING END PLATE

1 1 12

~ 6

2

3

4

5

6

29

--

23

944 turbo

7 8 9 10 17 28 27 16 1 26 2 2 21 1 9 20

34 28 Disassembling and Assembling End Pl ate

(Type 016 R)



Printe d in Germany


No. Description

1 Shift rod for

5th and r everse gears

2 Threaded sleeve

Qty.

1

Removing

1

3 Seal ring

4 Spring

5 Bushin g

6 Locking piece

..

7 Stop screw

8 Gasket

{ Paper )

9 Sleeve

10 Spring

11 Locking bolt

12 Seal ring

1

1

1

2

1

1

1

1

1

1

Note When:

Installing

Available only as complete spare part

Tightening torque

3 0 Nrn (22 ftlb)

Replace

Tightening torque

30 Nm (?.2 ftlb)

Do not confuse with bolt position 11

Replace, do not confuse with seal ring position 12.

Tightening torque

30 Nm (22 ftlb)

Do not c onfuse with screw position 7.

Replace if n ecessary.

Do not conf use with gasket position 8.

13 S leeve

14 Spr in g

15 Pan head bolt

1

1

1 Adjust operating lever and tighten bolt to torque of

35 N m (26 f tlb) .

Adjust 16 Operating

1 ever

17 Sleeve

18 Spring

1

1

1

Printed in Germany



Disassembling and Assembling End Plate

(Type 016 R)

34 29


No . Description

19 Spring c lamp

20 Hex bolt with collar

21 Holding plate

Qty. Removing

1

1

Note W

Installing

1

Tightening torque

24 Nm (17.7 ftlb)

??????? of holes for locking pins towards end plate

22 Reverse gear shaft

23 Spring

24* Synchromesh ring

25 Reverse gear

26 Cylinder roller bearing outer race

28 Shim S4

29 End plate

1

1

1

1

1 Press out with P 254 and P 254 b

27 Tapered roller 1 Press out with bearing outer race suitable mandrel crosswise

X

1

Note thickness reinstalling fo · r

Locate single -angled end in recess of synchromesh ring.

Turn double-angled end to the left and locate in opening in end plate.

Check for wear.

Press into correct position with P 254 and P 254 b.

Pre ss in with vw

472

Determine new thickne ss if necessary

If replaced, determine new thickness for shim S4

*In stall synchromesh ring in correct position . The flattened side must point to gear set (see Page 34- 32).

34 -

Downloaded from

30 Disassembling and Assembling End Plate



Printed in Germany


DISASSEMBLY AND ASSEMBLY

INSTRUCTIONS


1. Press out cylindrical rolle r bearing outer race with

P 254 and P 254 b.

A s s e m b 1 y

1. Press in cylindrical roller bearing outer race to correct position with P 254 and P 254 b. Pressing depth

a

= 8 .

5 to 9.0 mm.

2. Press out tapered roller bear ing outer race with suita b le mandrel cross wise.

2. Press i n tapered rol le r bearing outer race w ith VW 472.

Printed in Germany



Disassembling a nd Assembling End Plate

(Type 016 R)

34 31


3. Check synchromesh ring.

Press synchromesh ring on cone of gear and measure clearance "a" with a feeler gage blade.

Clearance New

"a" Installed

Distance

Reverse 0.75 to gear 2.3 mm

Wear

Limit

0.2 mm

944 turbo

6. Adjust operating lever:

Insert reverse gear arrest.

4. Install shifting gear for reverse gear along with synchronizer. The flattened side of the synchromesh ring must point to gear set .

A - Reverse gear arrest

Insert selector rod for 5th and reverse gears as well as operating lever in correct position.

Press operating lever in direction of arrow until it rests on selector rod and in dog of shift gear.

5. Lightly grease locking piece and insert in correct position.


manuals search engine Printed in Germany


Screw in adjusting bolt until it stops on threaded sleeve.

Install 5th gear ar rest.

Engage reverse gear several times and check reversing mechanism for ease o f movement at all points.

N o t e

Operating lever has been adjusted correctly wh e n it is centered exactly above bushing for reverse gear arrest.

Press operating lever agai nst bolt ana loosen bolt until the beginning o f threading audibly meshes i n threaded sleeve.

( loosen at least l/4th turn).

Screw in bolt and tighter. to torque of 35 Nm (25 ftlb).

Printed in Germany



Disassembling and As semb ling End Plate

(Type 016 R)

34 33


0 e t e r m i n i n g N e w

T h i c k n e s s o f S h i

"S 4 11 m

This procedure will be necessary when replacing the end plate . It provides preloading for the drive pinion tapered roller bearings.

Example:

Old shim

+Difference

New shim S4

Replacement Part

No.

016 311 393

016 311 393 A

016 311 393 B

016 311 393 c

016 311 393 D

016 311 393 E

016 311 393 F

016 311 393 G

016 311 393 H

016 311 393 J

016 311 393 K

016 311 393 L

Measure housing depth "a" of old and new end plates, and determine difference.

Example:

Old end plate housing depth "a" =

New end plate housing depth "a"

=

Difference

119.10 mm

119.35 mm

0.25 mm

If new end plate is deeper, install thicker shim S4.

If old end bracket is deeper, install thinner shim S4.

944 turbo

0.95 mm

0.25 mm

1.20 mm

Thickness

(mm)

0.24

0.27

0.30

0.33

0.36

0.39

0.42

0.45

0 .

69

0 .

93

1.17

1.41

34 34 Disassembling and Assembling End Plate

(Type 016 R)



Printed in Germany

944 turbo

TOOLS


3 4

3

4

1

2

No. Description

Slide hammer

Puller

Handrel

Pin

8

9

5 ~4andrel

6 Thrust piece

7 Thrust pad

Threaded sleeve

10

Ma ndrel

Thrust pad

11

12

Internal puller

46 56 mm

Internal puller

30 37

0101

13 Counter support

Special Tool vw

771 vw

681 vw

295 p 254

30-505

9247/1-4 vw

30 205 vw

771/15 vw

2062 vw

511

i

-

ill

12

Remarks

As commonly used

As commonly used

As commonly used

Printed in Germany Disassembling and Assembling Transmission

Housing (Type 016 R)



34 35

34 Manual Transmission I Operation , Housing 944 turbo

DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING

6 4 5 3 20 19 21 22 11 12 8 7 9 10 16 27 23 15

28 18 14 29 1 17 2 26 25

34 - 36 Disassembling and Assembling Transmission




Printed in Germany


No ., Description

1 Drain plug

,.., t.

Filling bolt

3 Cover

4 Clamping sleeve

5 ~1agnet

6 Seal ring

1

1

1

Qty. Removing

1

..

1

1

Note When:

Installing

Tightening torque

24 Nm (17 .

7 ftlb)

Tightening torque

24 Nm (17.7 ftlb)

When replacing, adjust gear ring.

Clean

Drive in to stop with vw

2062. Pack space between sealing lips with mul ti-p urpose grease.

Tighte n ing torque

30 Nm (22 ftlb )

Replace

7 Threaded sleeve

8 G .o.sket

9 ,

10

11

1

I)

J.L

"':) l..J

14

Spring

Bushing

Backup light s witch

Cap

Speedometer socket

Speedometer pinior.

1

1

1

1

1

1 Pull o ff

1

I

Tightening torque

'42 N 30 ftlb)

Tightening torque

42 Nrn (30 ftlb)

Oil guide pin

Printed in Germany



Disassembling and Assembling Transmission


34 37


No. Description

15

16

17

18

19 Tapered roller be aring outer race

20 Shim S2

21

Deflector

Seal ring

Seal ring

Seal ring

Taper e d roller bearing outer race

Note When:

Qty. Removing

1

1

Press down retainer with small screwdriver applied through vent pipe and pull out deflector.

Pull out with VW 681

Installing

Engage retainer in vent pipe.

Replace, packing space between sealing

1 ips with multipurpose grease.

1

1

1

Drive in to stop with

VW 2062. Pack space between sealing lips with multi-purpose grease.

Insert only after insta11ing gear set.

Oil sealing lip.

Drive into housing to a depth of 1.5 mm with Special Tool

9178 and suitable pipe section.

Press in with VW 30-

205 and VW 30-505.

X

1

Pull out with i nterna 1 pu11er

Note thickness for reinstallation

Pull out with i nterna 1 puller

Determine ness

Drive and if nece

VW in new thickssary with

295.

VW

.

511

Downloaded from

34 38

Di s assembling and A ssemb ling Tran sm i s sio n

H ousing (Type 016 R) www.Manualslib.com


Printed in Germany


2 7

28

29

No.

' J "

'-'-

23

24

25

2 6

Description

Shim S1

Needle bearing

Needle bearing

Tapered roller bearing outer race

S him S 3

Qty. Removing v

1\

Note thickness for re-installat ion

Note When:

Installing

Determine new thickness i f necessary

1 Pull out with internal puller and VW 771

Drive in with Special

Tool 9247/1 and P 254

1 Pull out with i nterna 1 puller and V\~ 771

Drive in with Special

Tool 9247/2 and P 254

1 Heat housing and press in with Special

Tool 9247/3 and P 254

X

When replacing~ measure installed position (actual distance) of drive pinion prior to removal. Drive out with Special Tool

9247/4 and VW 771.

Not e thi c kn ess fo r r e ·i n s t a ll a ti on

Det n er ess mine new i f ne ce s s t hickary.

Dow e l s l Ee v e

Do w e l s 1

E !

E: Ve

H o u s in g

2

1

.l

~Jh e n repl ac ing , me as ure in s t al led po s ition (actual c istan c e) o f drive pin i on befor e ~{ s ass embl y .

P rinted i n Germa n y Disa sse mb l ing a n d A ssem bl i n g Tr a n s m i ss i o n

H o u s i n g {Ty p e 01 6 R)



3 4 - 39


DISASSEMBLY AND ASSEMBLY INSTRUCTIO N S


1. Remove seal for flange shaft w ith pu 11 er VW 681.

3. Remove rear needle bearing for input shaft with an internal claw puller, for example Kukko

21/5, slide hammer VW 771, and threaded sleeve VW 771/15.

2 . Remove front needle bearing for input shaft with an internal puller, for example Kukko 21/5 ,

Special Tool VW 771, and threaded sleeve VW 7 71/15 .

4. Knock out tapered ro1ler bearing outer race for drive pinion wit h Special Tool 9247/4 and slide hammer W 771.

AInternal puller

N o t e

Since the tapered roller bearing outer race has a tight press-fit in the housing, it is a good idea to heat the housing for disassembly as well.


manuals search engine Transmission Printed in Germany


5. Pull out outer race for small tapered roller bearing. Use a 46 to 56 mm internal puller with countersupport for this step.

A s s e m b 1 y

N o t e

Since the tapered roller bearing outer race for the drive pinion bearing must be installed with a very tight press fit, it is essential to carefully heat the transmission housing before installation. In order to be able to install the outer race without difficulty , housing temperature should be at least 150°C/302°F.

Temperatures up to 180°C/356°F will not damage the housing.

Heating with hot water or with a washing machine is not sufficient.

6. Pull out outer race for large tapered roller bearing. Use a 46 to 56 mm internal puller with countersupport for this step.

. i

Printed in Germany Disassembling a nd Assembling Transmission




34 - 41


1 . Install tapered roller bearing outer race for drive pinion in the heated housing. Always work with a press to avoid canting .

Use Special Tool 9 2 47 / 3 and pin P 254. Hold preloading under the press for about 2 more minutes unt i l heat transfer has taken place.

2 . Knock in rear needl e bearing for input shaft using Special Tool

9247/1.

3 . Knock in front needle bearing for input shaft up to stop , using Special Tool 9247/2.

34 - 42 Disassembling a nd Assembling Transmission

Housing (Ty pe 016 R)



Printed in Germany

944 turbo Manual Transmission I Operation~ Housing 34

4. Press in outer race for large tapered roller bearing using VW

511 and VW 295 .

6. Dri ve in seal ring for flange shaft up to stop with mandrel vw

2062 .

•

5. Press in outer race for small tapered roller bearing (inside transmission cover). Heating the cover is recommen ded. Use thrust pad VW 30-205 and mandrel 30-505.

N o t e

It is recommended to install the sea ls for the flange shafts only after i nstallation of the differential~ in order to avoid damage .

7. Drive end seal ring for selector shaft up to stop with a suitable mandrel.

Printed in Germany Disassembling and Assembling Transmis s ion




34 - 43


8. Insert speedometer pinion.

Prior to assembly, give guide pin a good coat of transmission oil.

944 turbo

1 - Speedometer socket

2 - Speedometer pinion

A - Prior to assembly, lubricate this area well with transmission oil.

Downloaded from

34

-

44 Disassembling and Assembling Transmission

Housing (Type 016 R) www.Manualslib.com


Printed in Germany

944 turbo Manual Transmission I Operation, Hou si ng 34

DISASSE MBLING AND ASSEMB LIN G OIL PUMP

18 3 6 13 4 5

17

1 2 15 7 8 14 19 16 11 1 0

Pri nte d in Germany



Disassem b ling a nd Assembl ing Oil P ump 34 45

(Ty pe 0 1 6 R)

Manual Transmission I Operation, Housing 944 turbo

No.

1

2

5

6

Washer

3 Cover

4 Ball

Spring

Gasket

7 Holding clip

8 Screen

9 Impeller

10 Circlip

11 Drive gear

12 Woodruff key

13 Impeller

14 ' Bushing

15

16

17

Description

Hex bolt

Bushing

Bushing

Bushing

18 0-ring

19 Side transmission cover

Qty.

4

4

1

1

1

1

1

1

1

1

1

1

1

1 Pull out with suitable internal puller

1 Pull out with suitable internal puller

1

1

1

1

Removing

Pull out with suitable internal puller

Pull out with suitable internal puller

Note When:

Installing

Tighten crosswise to torque of 8 Nm

(6 ftlb), and check pump for freedom of movement.

Replace, re-determine thickness

Drive into correct position with able mandrel

Drive into suitcorrect position with suitable mandrel

Drive into correct position with suitable mandrel

Drive into correct position with suitab 1 e mandre 1


34 - 46

Disassembling and Assembling Oil Pump

(Type 016 R}



Printed in Germany




1. Note installation position of bushings for re-installation.

2. Set end play of pump to 0.05 +

0.1 mm with suitable paper gasket. Gaskets in thicknesses of 0.15 and 0.20 mm are available.

2. Pull out bushings with suitable internal puller.

Assembly

1. Drive bushing into side transmission cover in correct position until stop with suitable mandrel (see sketch).

3. Tighten hex bolts for pump cover to a torque of 8 Nm (6 ftlb), and check pump for ease of motion.

NG300

Printed in G er many



Dis as s e mbling a nd As se mblin g Oi l Pump

{Type 016 R)

34 - 47

944 turbo

TOOLS

Manual Transmission I Gears and Shafts 35

4

~., -

'-

.

1

No . Description

1 Circlip pliers

2 Feeler blade gage

3 Pressing plate

4 Pipe section

5 Separator

Special Tool

'

VW 161 a vw

401 vw

519

Remarks

As commonly used

'For example,

Kukko 15-17 Gr. 1

Printed in Germany



Disassembling and Assembling Input Shaft 35 1

(Type 016 R)

944 turbo 35 Manual Transmission I Gear s and Shafts

DISASSEMBLING AND ASSEMBLING IN P UT SHAFT l

,--

- - - -

-

-

-----,

i

I

I

12

11-'-: ,.,...-~11

~ --,.-'~:..___

10

.

.

-.;

0

.

.

~ 5

~6

..... \ 7

I ~ ~ -~ a

! o-4

~

L. _ ___

_ j

--3

.-

35 2

Downloaded from

Disassembling and Assembling Input Shaft

(Type 0 16 R) www.Manualslib.com


9

...

•

,.

'

c

if •

•

d

...

,, b

~ a

C -,

C

Pr in ted in Germany

944 turbo Manual Transmission I Gears and Shafts 35

·

...

...

No. Description

1 Circlip

2 Fourth gear

3 Needle bearing

4 Synchromesh ring

5 Circlip

Qty. Removing

1

1

1

1

6 c

Synchronizer with sliding sleeve for 3rd and 4th gears a Sliding sleeve b Synchronizer

Spring

1

1

2

1 Press off with 3rd gear wheel d locking piece

7

8

Synchromesh ring for

3rd gear

3rd gear

3. Gang

1

3

1

1

.

.

9 Needle bearing

10 Circlip ring

1

1

11 Inner race 1

..

I

Note When:

Installing

End

0.4 oil play nm

Check for

0.1 to

Oil with transmission wear

Re-determine thickness

Position correctly, measure end play

Position

Check for correctly. wear

Measure end play between 2nd and 3rd gear wheels. Control value

Oil oi 1 shaft

0.1 with

Install to 0.39 mm transmission

Install only a fter installation of input only after installation of input shaft

12 Input shaft 1

Printed in Germany



Disassembling and Assembling Input Shaft

(Type 016 R)

35 3

35 Manual Transmission I Gears and Shafts 944 turbo


D i s a s s e m b 1 y A s s e m b 1 y

1. Press off sliding sleeve/ synchronizer with 3rd gear wheel.

1. Assemble sliding sleeve and sync h ronizer for 3rd and 4th gears . It is not necessary to pair in a certain position.

However, the wide collar of the hub must face the 4th gear wheel.

2. Mount springs with 120° offset.

Angled end of spring must engage in hollo w lockpiece.

35 - 4 Disassem b ling a nd A ssembling Inpu t S h aft

{Type 0 1 6 R }



Printed in Germany


3. Press on sliding sleeve and synchronizer in correct position using VW 519. Turn synchromesh ring so that grooves align with locking pieces.

4. Measure end play of synchronizer with a feeler gage blade and adjust by selecting the correct circlip. End play should be between 0 and 0.05 mm. The lo wer value is preferable.

"'

N

o t e

The wide collar of hub must face

4th gear wheel.

The follo wing circlips are available:

Replacement

Part No.

088 311 317

088 311 317 B

088 ' 311 317 c

'

Thickness

(mm)

1.50

1.56

1.62

Printed in Germany



Disassembling and Assembling Input S haft

(Type 016 R)

35 5

35 Manual Transmission 1 Gears and Shafts

5 . Measure play between 2nd and

3rd gears. Nominal value:

0.1 to 0.39 mm. If this tolerance cannot be reached, recheck adjustment of synchronizer.

944 turbo

C h e c k i n g S y n c h r o m e s h R i n g s

1. Clean synchromesh rings an d gears.

2. Press dry synchromesh rings on tapers of gears and measure clearance " a " with a feeler gage blade.

6. Measure end play on 4th gea r.

Nominal value: 0.1 to 0 .

44 mm.

If this tolerance can not be reached, recheck adjustme nt of synchronizer.

Clearance

.. a ..

New

Distance

3r d a nd 1.0 to

4th gea r 1.7 mm

5th gear 1.0 to

1.9 mm

Wear Limit

0 .

5 mm

0 .

5 mm

35 6 Disassembling a nd Assembling Input Shaft

( T ype 016 R)




•

944 turbo

TOOLS

Manual Transmission 1 Gears and Shafts 35

6

No. Description

1 Support ra i 1

2 Pipe section

3 Pressing plate

4 Feeler blade gage

5 Separator

6 Pressing tool

Special Tool' vw

457 vw

519 vw

401 vw

454

Remarks

As commonly used

For example Kukko

15 17 Gr. 1

Printed in Germany



Disassembling and Assembling Pinion Shaft

(Type 016 R)

35 7




No. Description

1 Tapered roller bearing

2 1st gear wheel

3 Needle bearing

4 Synchromesh ring for 1st gear

5 Circlip

6 Synchronizer with sliding sleeve for 1st and 2nd gears

6a Sliding sleeve

6b Synchronizer

6c Spring

6d Locking piece

7 Synchromesh ring for 2nd gear

1

1

2

3

1

Qty. Removing

1 Press off with vw 457

1

Note When:

Installing

Replace if necessary.

Always replace both bearings at same time.

Check end play.

1 Lubricate with gear oil

1

1

Identification: 1 tooth missing every

3. Friction surfaces coated with molybdenum.

Spiral groove. Check for wear.


1

!

Position correctly

Friction surface coated with molybdenum spiral groove

"

8

9

2nd gear wheel

Needle bearing

10 Circlip

1

1

1

Lubricate with gear oil


Printed in Germany



Disassembling and Assembling Pinion Shafts

(Type 016 R)

35 - 9

35 Manual Transmission I Gears and Shafts 944 turbo

No. Description

11 3rd gear wheel

12 Circlip

13 Circlip

14 4th gear wheel

Qty. Removing

1

1

1

1

15 Tapered ro 1l er 1 Press off bearing with separator

16 Pinion shaft 1

Note When:

Installing

Check for wear.

Insta 11 warm and press on. Large collar faces 2nd gear wheel. Adjust end play.

Thickness always

2.4

nm

Re-determine thick.. ness

Check for wear.

Insta 11 warm and press on. Large collar faces 3rd gear wheel. Adjust end play.

Replace if necessary.

Always replace both bearings at same time.

Check for wear.

Paired with ring gear

(pinion set). When replacing pinion set, adjust pinion shaft and ring gear.

35 -

Downloaded from

10 Disassembling and Assembling Pinion Shafts

(Type 016 R} www.Manualslib.com


Printed in Genmany



N o t e

When replacing tapered roller bearings, determine installed position of pinion shaft (actual l ocation) before removing gearbox.

2. Press off sliding sleeve and synchronizer with 2nd gear.

Use support rails VW 457.


1. Press off inner race of tapered roller bearing with 1st gear.

Use support rails VW 457.

3. Press off 3rd gear wheel.

Printed in Germany




(Type 016 R)

35 11

35 Manual Transmission I Gears and Shafts

4. Press off 4th gear with a separator, for example Kukko

15-17 Gr. 1.

944 turbo

A s s e m b 1 y

1. Heat inner race for tapered roller bearing to approx. 120°C/

248°F and press it on.

5. Press off inner race for tapered roller bearing w ith a separator, for example Kukko

15-17 Gr. 1.

2. Heat gear wheel for 4th gear to approx. 120 ° C / 248°F and press on. The collar must face the

3rd gear wheel.

35 12 Disassembling and Assembling Pinion Shafts

(Type 016 R)



Printed in Germany

944 turbo Manual Transmission I Gears and S haft s 35

3. Adjust end play on 4th gear wheel (gear must have cooled off and be pressed against stop).

Measure and install the thick est possible circlip. The end play must not exceed max.

0.03 mm.

N o t e

Perform this adjusting proce dure very carefully, as otherwise the service life of the tapere d roller beari ngs will be impaired.

The following circlips are available:

Replacement

Part No.

016 311 363 AA

016 311 363 AB

016 311 363 AC

016 311 363 AD

016 311 363 AE

016 311 363 AF

016 311 363 AG

016 311 363 AH

016 311 363 AJ

Thickness

(mm)

2.24

2.26

2.28

2.30

2 .3

2

2 .

34

2.36

2 .

38

2.

4 0

4. Press on 3rd gear wheel with col lar facing 2nd gear wheel, afte r installing circlip

(a rrow ) 016 311 363 AJ, 2.4 mm thick.

N

o t e

Clean gear and shaft, removing all oil and grease , with a clean gasolin e. Heat gear on a hotplate to approx. 120° C/248°F .

Printed in Germany



Disassem bl ing and Assemb l ing Pinion Shafts

(Type 016 R)

35 13


5. Measure end play on 3rd gear wheel w i th a feeler gage blade and adjust by using the appropriate circlip. Play should be between 0 and 0.04 mm, with the lower value being preferable.

944 turbo

N

o t e

Coat molybdenum-coated synchromesh rings with an approved transmission oil.


Replacement

Part No.

Thickness

(mm)

016 311 287

016 311 287 A

016 311 287 B

1.65

1. 70

1. 75

6. Assemble sliding sleeve and synchronizer for 1st and 2nd gears. It is not necessary to pair in a certain position .

Insert lock pieces and install springs with a 120° offset .

Angled end of spring must engage in hollow lock piece .

7. Press on sliding sleeve and synchronizer. Turn synchromesh ring so that grooves are aligned w it h lock pieces.

35 14 Disassembling and Assembling Pinion S h afts

(Type 016 R)



Printed in Germany


8 . Adjust end play on synchronizer. Measure end play with a feeler gage blade and adjust by selecting the appropriate circlip. Play should be between 0 and 0.04 mm, with the lower value being preferable.

-

9 . Heat inner race for tapered roller bearing to approx. 120°C/

248°F and press on with VW 454.


Replacement

Part No.

Thickness

(mm)

016 311 327

016 311 327 A

016 311 327 B

1.50

1.55

1.60

10 . Measure play on 1st gear wheel.

Play should lie between 0.10 and 0.40 mm. If necessary, check adjustment of synchronizer. Parts must be pressed on up to stop! i

Printed in Germany




(Type 016 R)

35 - 15


C h e c k i n g S y n c h r om e s h R i n g s

1. Clean synchromesh rings and gears.

2. Press dried synchromesh rings onto tapers of gears and measure clearance feeler gage blade.

11 a 11 with a

"' Clearance nan

New Distance Wear

Limit

1st a nd

2nd gears

1.0 to

1. 7 nm

0 .

5 mm

944 turbo

35 16 Disassembling and Assembling Pinion Shafts

(Type 016 R)



Printed in Germany

944 turbo Differe

nt

ia l

I

Transaxle System

REMOVING AND INSTALLING DIFFERENTIAL

39

21 12 11 10 9 1 8 16 17 1

/

<~

/

/

14 13 19 18 17 16

Printed in Germany



Removing a

nd

Installing Differential

(Type 016 R)

39 1

39 Differential I Transaxle System 944 turbo

No. Description

1 Seal ring

2

3

4

Threaded sleeve 1

Gasket

Spring

Qty. Removing

1 Pull out with vw

681

1

1

Note When:

Installing

Install only after installing gear set.

Oil sealing lip.

Drive 1.5 mm into housing with Special

Tool 9178 and suitable pipe section.

Tightening torque

30 Nm (22 ftlb)

Replace

5

6

7

8

Bushing

Speedometer socket

Speedometer pinion

Hex .

bolt

1

1

1

3

Tightening torque

42 Nm (30 ftlb)

Oil guide pin

Tightening torque

8 Nm (6 ftlb)

9

10

Lock washer

Cover

3

1

11

12

13

14

Gasket

Selector shaft

(complete)

Dowe1 sleeve

Hex bolt

1

1

2

12

'

Position correct1y

(manufacturer 1 s mark outwards)

Replace

Tightening torque

24 Nm (17.7 ftlb)

39 2

Downloaded from

Removing and Installing Differential



Printed in Germany

..

944 turbo Differential I Transaxle System 39

.

No.

15

Description

End plate

16 Allen head bolt

17 Flange shaft

18

19

Hex bo 1t with washer

Cover

20

21

Differential

'

Transmission housing

Qty

1

2

2

9

1

1

1

. Removing

.

.

Remove gearbo x before removing differential

If the transmission housing requires replacement and deviation

"r" is not given on ring gear, c heck po sit ion of pinion sh aft prior to removing gearbox

(actual distance).

Note When:

Insta 11 ing

Coat sealing surface with Curil KIH

Tightening torque

24 Nm (17 .

7 ftlb)

Lubricate shaft

Tightening torque

24 Nm (17.7 ftlb)

·

Evenly coat sealing surface w it h Loctite

573 or 574

Light coat of oil for tapered ro l ler bearings and conical gear teeth

Printed in Germany




(Type 016 R)

39 - 3


ASSEMBLY AND DISASSEMBLY INSTRUCTIONS


N o t e

Before removing the differential, the gearbox must be removed.

1. Remove cooling coil.

2. Unscrew mounting bolt for flange shaft and take off flange shaft , counterholding with a mandrel.

A s s e m b 1 y

1. Tighten mounting bolts for side transmission cover to a torque of 24 Nm (17.7 ftlb).

2. Tighten mounting bolts for flange shaft to a torque of 24 Nm (17.7 ftlb)

2. Unscrew final drive cover mounting bolts and pry off cover with two tire irons.

39 4

Downloaded from




Printed in Germany

94~ turbo

TO OL S

Differential I Transaxle System 39

3

No.

Description

1 Two arm extractor

.... i.

3

Pressing tool

Pipe section

Special Tool vw vw

40-105

40-21

Remarks

As commonly used for example

Kukko 44/2

Printed in Germany Disassembling and Assembling Differential

(Type 016 R)



39 5

944 turbo 39 Differential I Transaxle System

DISASSEMBLING AND ASSEMBLING DIFFERENTIAL

3 - - - - -

4 , - - -

6

14 12 13 11

15 -----! s -tl

2 - - - -

10 9 12 11 13 8 9 10

39 6 Disassembling and Assemblin g Differential

(Type 016 R)



Printed in Germany

~'

J


No. Description

1 Drive gear

2 " Inner race for large tapered roller bearing

3

4

Inner race for small tapered roller bearing

Drive gear

5 Hex bolt

6 ' Ring gear

] ,

8

Dowel sleeve

Pin

Qty. Removing

10

1

1

1

Note When:

Ins talling

1

.

.

1 Remove with suitable two-arm puller and

Special Tool vw 40-105

1 Remove with suitable two-arm puller and

Special Tool g vw

40-105

1

Heat to appro x . 100°C

/ 212 ° F and press on with Special Tool VW

40-21.

Heat to approx. 100°C

/2 12°F and press on with Special Tool VW

40-21. ·

Insta 11 so that position of recess corresponds to position of recess in housing

Loosen, then tighten crosswise to torque of 90 Nm (65 ftlb)

Heat to approx. 120°C

/ 248 ° F

Knock in flush

Knock in carefully, to avoid damage to thrust washers. Lock with dowel sleeve.

;

9 Small differential gear

10 Thrust washer

11 Large differential gear

12 Nut

2

2

2

2

Check for wear

Adjust

Downloaded from

Printed in Germany www.Manualslib.com

Disassembling and Assembling Differential

(Type 016 R) manuals search engine

39 - 7

39

Differential

I

Transaxle System

No. Description

13 Shim

14

15

Locking pin

Housing

Qty. Removing

2

1

1

944 turbo

Note When:

Installing

Determine new thickness

When replacing adjust ring gear

39 - 8

Downloaded from

Disassembling and As

s

embling Differential

(Type 016 R)

www.Manualslib.com


Printed in Germany

944 turbo Differential I Tra n saxle System 39



1. Clamp differential in a vice and unscrew ring gear bolts. Fit vice with soft jaws.

3. Pull off inner races for large and small tapered roller bear ings. Use a suitable t w o arm extractor and pressing tool v w

40 105.

2. Take ring gear off of h ousi n g.

.

'

Printed in Germany Disassem blin g a nd Ass embl i n g Differe nt ial

(Type 016 R)



39 - 9

39 Differential I Transaxle System

Assembly

N o t e

During assembly, lubricate the following parts with transmission oil: running surfaces of the housing as well as large and small differential gears, and thrust washers.

1. Heat inner races for small and large tapered roller bearings to approx. 100°C/2l2°F, position, and press on with pipe sections VW 40-21.

944 turbo

3. Heat ring gear to approx.

120°C/248°F and install.

Align bolt hole s with each other using centering pins.

2. Install differential gears.

Install large d ifferen tial gears with correct shims .

Install small differential gears with 180° offset

(hold thrust washers in place with a small amount of grease) and swing in. Align thrust washers with shaft bore, knock in shaft carefully, and lock with a dowel sleeve.

A - Centering pins

39 10 Disassembling and Assembling Differential

(Type 016 R)



Printed in Germany


ADJUS T ING DIFFERENTIAL GEARS

1. Install l arge differential gears with thinnest shims

(0.5 mrn).

4. Adjust play to maximum of 0.10 mm by inserting a shim of the correct thickness.

N o t e

2. Install small differential gears with thrust washers and press in shaft.

N o t e

Adjustment is also correct when no play can be felt but the differential gears still turn easily and without catching.

From this point on be careful not to mix up differential gears and thrust washers.

3. Press small differential gears outwards and check play of large differential gears by hand (arrows).

The following shims are available:

Replacement

Part No.

Thickness

(mm)

011 519 215

088 409 249

088 409 249 A

088 409 249 B

0.5

0.6

0.7

0.8

Printed in Germany Disassembling and Assembling Differential

(Type 016 R)



39 - 11

944 turbo Differential, Transaxle system

Umlted-slip differential, dlsmanUing and assembling (locking ratio 40 %)

Tools

39

"'

,.

130

10,5

--

-

-$ ·

-

·

-I

75

105

.I

-I t

No. Description

Connector

Special tool Remarks

Own construction .

The knuckle flange connector can be manufactured from 6 x 18 bar steel .

Llmlted~slip differential, dismantling and assembling (locking ratio 40 %)

Printed in Germany -Ill, 1988



39- 12 a

39

Differential, Transaxle system 944turbo

Limited-slip differential, dismantling and assembling (locking ratio 40 %)

13 4 5 6

I .

r·-·-·-·-·-·--·-·-·--·~

i

11 12 11

. l

....

8 7 6 5 4 3 2 1

39- 12 b Limited-slip differential, dismantling and assembling (locking ratio 40 %)

Printed In Germany- Ill, 1988



944 turbo Differential, Transaxle system

39

.

.,.

No. Description

1 Cheese head screw

2 Driving wheel

3 Housing cover

4 Friction washer

5 Diaphragm spring

6 Outer plate

7 Inner plate* (molybdenumcoated)

8 Thrust ring*

9 Shaft bevel gear

10 Threaded disk

11 Bevel pinion

12 Differential shaft*

13 Differential housing

Qty. Removing

8

1

Note:

Installing

Apply a film of Loctite

262 and tighten with 38

Nm

Install in the correct posi· tion

1

2

2 Observe installation posi· tion

2

2

Insert in the correct position

Insert in the correct position

4

2

1

2

2

2 Press out of the shaft bevel gear

Press in in the correct position

*Note

The limited-slip differential for the 944 turbo S has reinforced 2.5 mm thick inner plates (944 turbo only 2.0 mm thick). The two thrust rings are each remachined by 0.5 m.m in order to provide the same plate package thickness (dimension B).

Apart from this, the 944 turboS differential shafts are molybdenum-coated .

Limited-slip differential, dismantling and assembling (locking ratio 40 %)

Printed in Germany Ill, 1988



39- 12 c

39

Differential , T r ansaxle system 944 turbo li mited-slip differential , dismantling and assembling (40 % locking ratio )

Dis mant li ng

1 . Undo the Allen screw on the housing cover, remove dr i ving wheel (only for transmissions with an oil pump) and cover . d) P l ates: Check in n er and outer plates for wear. Neithe r t h e ou t er plates' guide l ugs nor the gear teeth of the inner plates may be worn down.

2 . Before assembly, lubricate all slide faces of p l ates, thrust rings and differential shafts with Hypoid t r ansmission oil SAE 80.

3. Insert t h e th r us t washers so that the re t ain ing lug latches into the hole i n the ho u s i ng or cover. To make assemb l y easier, use a lit tle grease to stick the washers in place.

4 . Insta ll other components as shown in the exploded illustration.

87-1032

2. Remove all i n ner parts , observing the instal lation position of the diaphragm springs.

A s sembling

1. Check all components for wear or damage and replace if necessary. a) Differe n tial h o u sing: check the guide grooves for th e outer plates and thrust rings for wear . b) Thrust rings: The guide lugs and thrus t surfaces must n ot be too worn down or scratched . It m ust also be easy to move them in the differe n tial housing. c) Sha ft b e v e l gea rs: T h e thrust surfaces for the thrust washers must not be worn down and i t must be easy to move the inner plates on the teeth of the bevel gears.

39 12 d Lim i ted slip differential , dismantling and assembling (40 % locking ratio)

Printed in Germany Ill, 1988



944 turbo Differen ti al , T r ansa x le system

39

5 . Under normal conditions, install the diaphragm springs with the raised section pointing outwards towards the knuckle flange .

Re-specifying the thickness of the plate package:

The thick n ess of the plate package must be re specified w hen new components are used .

1. Measu r e housing depth dimension " a " with a depth gauge . Example : a = 77.50 mm

••

A = Diaphragm spring

43 39

Note

If the r e is noise , the manufacturer turns the diap hr agm sp ri ng on the housing side. These limited-slip differentials are identified by a yellow dot on the differential housing .

85 105

A = Diaphragm spring

B = Yellow dot

42 · 39 limited-slip d i fferential , dismantling and assembling (40 % locking ratio )




39 1 2 e

39

D i fferential , Transaxle system

2 . Measure the thickness of the plate packag e dimension "b" (w ith 2.0 mm thick inner and outer plates, but with out diaphragm sp r ings). To do this, clamp the plate package in the vise slightly , and measure dimens i on " b " with a ca liper gauge . Ex amp le: b =

73.20 mm.

944 turb o

3. Measure di m ension " e " ( mus t b e 4 .2 mm) . e = ab

Exam ple a= 77.50 mm b

=

73 .

30 rnm e

= 4 .

20 mm

10923

45-39 e2

+ e2

= e

=

4.2 mm

Not e

Ins tal l thicker or thinner outer plates i f dimension "e " is too grea t o r too sma l l.

"e" less than 4 .2 mm insta ll thinner p l ates

"e" greater t h an 4 .2 mm i ns t all thicker pl ates

Outer p l ates are avai l ab l e in thicknesses of 1 .

9 mm, 2 .

0 mm and 2.

1 mm.

39- 12 f Limited slip d i fferential, dismantling and assembling (40 % locking ratio )




944 t urbo Differential , Transaxle system

4. After assembly , measure the breakaway torque w ith one shaft bev el gear blocked and one driven . To do this , cl amp a flange with two scre ws in the v i se and put th e differential o nt o th is . M ou nt a second flange with o wn co n s tru ction co nnector , and c r ank the differential w i th a torque wrenc h . A torque of 1 0 ... 35 Nm must be ach i eved .

39

A = Connector (o w n c onstruction) e5 . 1os

Note

I f it is not possible to achieve the p r esc r ibed t o rque with the th ic kest outer plate , all plate s are w o rn and must be r eplaced.

Limited slip differential, dismantling and assembling (40 % locking ratio)




39- 12 g

Differential I Transaxle System 39 944 turbo

TOOL

1

14

12

15

9

,

~

........

--8

Printed in Germany



Ad j usting Drive Pinion and Ring Gear 39 13

(Ty pe 016 R)


No. Description

1 Universal gage

2 Universal dial gage holder

3

4

Centering disk

Centering disk

5 Master gage

6 Gage plate

7 Sleeve

8 Dial gage extension

9.3 mm

9 Gage plunger

10 Dial gage

11

_.

Adju.stabl e lever gage

12 , Dial gage extension

Special Tool vw

385/1 vw 387 vw

385/2 vw 385/3 vw

385/30 vw

385/17 vw 521/8 vw 385/15 vw 385/14 vw 388

13 Dial gage

14

15

Adjusting device

Torque meter vw 521/4

!

Remarks

944 turbo

As commonly used, range 3 mm

As commonly used, length approx.

30

I11T1

As c0111Tlonly used, range 5

1m1

As commonly used,

0 to 600 Ncm

{0 to 4,4 ftlb)

·

39 - 14

Downloaded from

Adjusting Drive Pinion and Ring Gear

{Type 016 R) www.Manualslib.com


Printed in Germany


ADJUSTING PINION AND RING GEAR

N o t e

Careful adjustment of the drive p1n1on and ring gear is essential for the long service life and quiet running of the final drive. For this reason, drive pinions and ring gears are paired during production and checked on special testing machines for good surface appearance and low noise levels in both directions of rotation. The position of quietest running is determined by moving the drive pinion in an axial direction, while keeping the ring gear far enough out of the play-free gearing to keep backlash within the specified tolerance.

The deviation 11 r 11 in relation to master gage 11 R0 11 is measured and inscribed on the outside periphery of the ring gear pelonging to a pinion/ring gear set supplied as a spare part. Each gear set (drive pinion and ring gear) must only be replaced together.

Printed in Germany




{Type 016 R)

39 - 15

39

Differentlai/TransaxleSystem

Adjustment and identification of pinion/ring gear sets

944turbo

~

Y=f=r

I I I

1 2 3 rm'

1 2 3

Service Sets

1 . Code "K" 827 indicates a pinion/ring gear set with Klingelnberg teeth and a ratio of 8:27.

The number always has 3 digits.

2 . Pair code 312 of pinion/ring gear set. Number always has 3 digits.

3. Devia~ion "r'' in reference to master gage of special testing machines used in production.

Deviation "r" is always given in 1/100 mm and always has 2 digits. For example, "25" means "r"

=

0.25 mm. Other letters or digits concern manufacturing and material batches.

Ro Length of master gage used in special testing machine.

"Ro" = 59,65 mm (type 016 RIS and 083 F transmission)

"Ro" =58, 15 mm (type 083 D transmission)

,.___Po

Sets supplied with vehicles

Note

In series production, the location of the drive pinion ist determined as distance "Po" (center of ring gear to back of pinion head). Deviation

"r" on the ring gear and the pair code are omitted. Because deviation "r'' is not given, an as-is measurement must be taken prior to removal of the drive pinion when replacing parts which will have direct influence on the installed position of the drive pinion.

X- This data not required in production.

E - Actual , distance between ring gear shaft and face of pinion at point of quietest running for this particular set.

Vo - Hypoid displacement = 12 mm

39 ·16



Adjust. and ldent. of pln./rlng gear sets (type 016 RIS}


944 turbo Dlfferentlai/TransaxleSystem

Recommended Sequence for adjusting pinion/ring gear sets

39

S1 = Shim for ring gear

S2 ,., Shim for ring gear

When it is necessary to adjust the pinion ring g~ar, ist is in the interests of efficiency to adhere to the following sequence of procedures :

1. Determine total shim thickness "Stot" (S1 plus S2) for the specified pre loading of tapered roller bearing/differential.

2. Determine total shim thickness "Stot" (S3 plus S4) for specified preloading of tapered roller bearing/drive pinion.

3. Divide total shim thickness "Stot" in S3 and

S4 in such a way that the distance from the center of the ring gear to the pinion face corresponds to the installed distance "E" determined during production.

S3 =Shim for pinion

S4 = Shim for pinion

4. Divide total shim thickness "Stot" in 81 and

S2 in such a manner that the specified amount of backlash is present between ring gear and pinion.

The goal of these adjustment is to reattain position of quietest running as was determin~d in the special testing machine during production .

The greatest possible care and cleanliness during all assembly and measuring operatons are absolute requirements for good results.

Adjust. and ident. of pin./ring gear sets (type 016 R/S)

Printed in Germany -IV, 1991



39- 17


A d j u s t m e n t 0 v e r v i e w

The pinion and ring gear have to be adjusted only when work on the final drive requires the replacement of pa r t s having direct influence on the adjustment of the final drive. Refer to the following table to avoid unnecessary adjustment work!

Ring Gear

(51 + S2)

Pinion,

Deviation

11r11

Pinion s him

115411

X

Distance

X Transmission ho usi ng

End plate

Differential housing

Tapered roller bearing for pinion

Tapered roller bearing ' for d i f f e rent i a .

l

Pinion /ri ng gear set

Final drive cover

X

X

X

X

X

X

X

·

39 - 18 Adjusting Drive Pinion and Ring Gear

(Type 016 R)



Printed in Germany

944 turbo Differential I Transaxle System

::S!:t

D

e t e r m i n i n g

D r i v e P i n i o n

I n s t a 1 1 e d P o s i t i o n o f

(A s i s D i s t a n c e)

This operation is only necessary when deviation 11 r 11 is not given on the r i ng gear and parts have to be replaced which have direct influence on the drive pinion position. This would include both tapered roller bearings for drive pinion and transmission housing.

Removing Differential

.

..

Complete universal gage as shown in tool list, insert in transmission housing, and measure distance from

11 Ro 11 (max. deflection / point of reversal). Measured value will equal deviation 11 r 11

•

Note this value.

After replacing parts, adjust drive pinion as described. Use deviation

11 r 11 determined for finding shim thickness S3.





(Typ e 016 R)

39 - 19

944 turbo 39 Differential I Transaxle System

A d j u s t i n g D r i v e

P i n i o n

Re-adjustment of the pinion/ring gear set according to the following instructions will only be necessary when replacing this set. If other parts which likewise influence the drive pinion are being replaced, adjust using the previously determined installed position (as-is distance).

~

D e t e r m i n i n g T o t a 1

S h i m T h i

Stot (S3 plug S4) c k n e s s

(Preloading of tapered roller bearing/pinion shaft adjustment)

1. Install tapered roller bearing outer race without shims into transmission housing or end plate.

2. Install completely assembled drive pinion. Mount end plate and tighten bolts to a torque of

24 Nm (17.7 ftlb).

4. Mount gages. Set dial gage (3 mm range) to 0 with 1

30 mm. mm preloading.

Dial gage extension length approx.

3. Turn drive pinion about 20 full revolutions by hand so that both tapered roller bearings are preloaded, while lifting and lowering drive pinion.

5. Move drive p1n1on up and down.

Read play on dial gage and note this value. Do not turn drive pinion during this s-fep to avoid false readings.

Example: 1.30 mm.

6. Remove end plate again.

-

.

_ _ _

_,·

39 20 Adjusting Drive Pinion and Ring Gear

(Type 016 R)



Printed in Germany

944turbo DlfferentlalfTransaxleSystem

Determining total shim thickness "s tot " (S3 plus S4)

Stot Measuring value

+ loading

Loading 0,30 mm (constant value)

Measured value

Stot

1,30 mm

(example)

1 , 60 mm

3. Complete universal gage as shown.

39

Determining Deviation "e"

1 . Install shim of determined total thickness (in th i s example, 1 .

60 mm) behind tapered roller bearing outer race in den plate (S4 side). Reinstall end plate, bolt, and turn drive pinion about 20 revolutions in each direction .

2 . Adjust set ring o f gage VW 385/1 to distance

"a" .

4. Use dial gage extension VW 385/15 , with length of 9.3 mm.

5. Set universal master gage to dimension

Ro = 59.65 mm (type 016 R/S and 083 F transmission)

Ro = 58.15 mm (type 083 D transmission) and place on universal gage. Set dial gage

(3 mm range) to 0 with 1 mm preloading.

6. Set adjustable set ring back against stop.

7. Place gage plate VW 385/17 (with magnet) on pinion head.

8. Take off master gage and insert universal gage in housing (installed position). Centering disk VW 385/2 toward final drive cover.

A = approx. 50 mm

Adjust. and ldent . of pin./ring gear sets (type 016 R/S)




39. 21


9. Mount final drive cover carefully (do not knock, danger of gage plate slipping). Fasten with 4 bo 1 ts .

10. Pull 2nd centering disk out using the adjustable set ring fa r enough so that the universal gage can barely be turned by hand.

944 turbo

11 . Turn universal gage until dial gage tip runs on gage plate on pinion head and displays maximum deflection

(point of reversal). The measured value is dimension

"e".

For example: 0 .

46 mm .

D e t e r m i n i n g T h i c kn e s s o f S h i m "S3"

I

S3 = e + r

I e = Determined value (max. dial gage deflection) r = Deviation (given on ring gear in

1/100 mm or determined by measuring actual di stance)

Example:

Dial gage reading "e"

Deviation "r•• given on ring gear

S him thickness "$3 11

0.46 mm

+ 0 .

18 mm

0.64 mm

39 -

Downloaded from

22 Adjusting Drive Pinion and Ring Gear



Printed in Germany

944turbo

Available Shims S3 :

Thickness (mm)

0,20

0,25

0,30

0,35

0,40

0,65

0,90

1,15

Note

Due to the tolerances of the shims, it is possible to measure any thickness for "S3".

Measure shim thickness at many different points with a micrometer. In addition, check shims for burrs and damage.

Install only shims in perfect condition!

DlfferentlalfTransaxleSystem

39

Dicke der Elnstellschelben "S4" bestlmmen ls4

=

Stot • "S3"

Example:

Total shim thickness

Shim thickness S3

Shim thickness S4

1,60mm

0,64mm

0,96mm

Adjust . and ldent. of pln./rlng gear sets (type 016 R/S)




39.23

39

Dlfferentlai/TransaxleSystem

Available shims S4 :

Thick n ess (mm)

0 , 24

0 , 27

0 , 30

0 , 33

0 , 36

0 , 39

0,42

0,45

0,69

0,93

1,17

1 ,41

Measure thickness of shims at several points with a micrometer . In addition, check shims for burrs and damage.

Install only shims in perfect condition.

C hecking Dimension " E "

1 . Install drive pinion with measured shims S3 and S4. Bolt end plate and rotate drive pinion in both directions about 20 full revolutions by hand, so that both tapered roller bearings will be preloaded by the rotation and can settle .

2. Apply universal gage and check distance.

3. If shims have been selected correctly, the dial gage (read counterclockwise) should display the value of deviation "r'' inscribed on the ring gear to a tolerance of

± 0,04 mm.

944 turbo

Checking p re loadlng of tape red roller bearing s on drive pinion

Screw in hex bolt in drive pinion . Apply torque meter and read friction torque .

For new bearings it should be 200 to 400 Ncm

( 1 .5 to 3.0 ftlb) and 30 to 60 Ncm (0 .

22 to

0.44 ftlb) for used bearings .

Note

Lubricate bearings with hypoid gear oil.

A -Standa rd torqu e meter, 0 to 600 Ncm (0 to

0.44 ftlb).

39-24



Adjust. and ldent. of pln./rlng gear sets (type 016 R / S)



A d j u s t n g R n g

G e a r

N o t e

The ring gear must be adjusted if

Transmission housing,

Final drive cover,

Tapered roller bearings for differential~

Pinion/ring gear set are replaced (see also "Necessary

Adjustments 11

) .

0 e t e r m i n i n g T o t a 1

S h i m T h i c k n e s s 11 S tot 11

(Sl plus S2)

(For determining preloading of tapered roller bearings on differential)

1. Remove drive pinion.

5. Place differential in housing.

Installation position: ring gear leading into housing.

6. Mount cover and tighten bolts crosswise to a torque of 24 Nm

(17.7 ftlb).

7. Clamp transmission in assembly stand with cover facing up .

2. Remove seals for shaft flanges.

3. Remove outer rings of tapered roller bearings for differential .

Remove shims.

4. Drive in tapered ro ller bearing outer races without shims against stop.

A - Dial gage extension approx.

30 mm

8. Place end gage plate VW 385/17 o~ collar of differential.

Printed in Germany




(Type 016 R)

39 - 25


9. Mount universal dial gage holder

VW 387 with dial gage and extension on housing and set dial gage to 0 with 1 mm preloading .

10 . Move differential up and down , read and note play on dial gage

(e.g. 1. 42 mm) .

11. Install shims with total shim thickness 11 Stot'' determined this example 1 .

92 mm) behind tapered roller bearing outer

Cin race end cover (S2 side).

Lubricate both tapered roller bearings with hypoid oil.

12. Remount cover.

13 . Guide adjusting device VW 521/4 together with sleeve

VW

521/8 into neck of differential, and clamp.

A -

Dial gage extension approx .

30 mm

N o t e

Do not turn differential while measuring play, as this w i l l falsify results.

11 Stot 11

= Measured value + loading

Mea sured value (example) 1.42 mm

Loading (constant value) +0 .

50 mm

Stot 1.92 mm

A Standard torque meter, 0 to 600

Ncm (0 to 4,4 ftlb)

B

-

Sleeve

VW

521/8

C

-

Adjusting device 521/4

14. Place 0 to 600 Ncm (0 to 4,4 ftlb) torque meter on adjusting device and turn slowly and evenly. The friction torque of new tapered roller bearings should be at least 250 Ncm

(1,8 ftlb).

It is not necessary to measure friction torque of used tapered roller bearings.

39 -

Downloaded from

26 Adjusting Drive Pinion and Ring Gear



Printed in Germany


••

N o t e

When adjusting the pinion/ri ng gear set, adjust and check drive pinion at same time.

3 . Carefully turn differential co unt erclock wi se with adjusting device VW 521/4 until ring gear rests on drive pinion.

A d j u s t i n g B a c k-

1 a s h

Prerequisite: drive p1n1on adjusted and installed with S3 and

S4.

Turn differential several times to preload and settle tape r ed roller bearings .

4.

At this point, set dial gage to 0 with 2 mm preloading.

5 . Turn differential clockwise until ring gear comes to rest against the opposite flank of the next drive pinion tooth. Read off and note backlash.

1. Place adjustable lever VW 388 on adjusting device VW 521/4. Lever length via large hexagon surface is 79 mm to upper edge of ball.

7 . Add up the four measured values and calculate me an backlash.

2. Apply universa l dial gage holder with dial gage and exte nsion so that there is a right angl e between the dial gage axis and the lever.

6. Repeat measurement procedu re three times, turning ring gear 90° further each time.

D e t e r m i n

B a c k 1 a s h n g M e a n

Example:

1st measurement

2nd measurement

3rd measurement

4th mea .

surement

Sum

0.84 mm

0 .

85 mm

0 .84 mm

0.83 mm

3 .36 mm

Mean backlash = 3.36 4 = 0 .

84 mm a = approx. 79 mm

Printed in Germany




(Ty pe 016 R)

39 27


N o t e

If measured values deviate from each other by more than 0.06, the installation of the ring gear or the pinion/ring gear set is not correct. Check installation, replacing pinion/ring gear set if necessary.

D e t e r m i n i n g S h i m

T h i c k n e s s S2 (opposite ring gear)

S2

=

Stot

+Lift (axial displacement of ring gear from play-free gear mesh to attain backlash)

- Measured mean backlash

Stot

=

Total shim thickness

, Balance Sl + S2

Lift= 0.15 mm (constant value)

Example:

Stot

+Lift

-

S2 t · ~ean backlash

1. 92

1'001

0.15 mm

0.84 mm

1.23 mm


Replacement

Part No.

Thickness

(rnm)

113 517 2 01 A

113 517 202 A

113 517 203 A

113 517 204 A

113 517 205 A

113

113

113

113

113

113

517 206 A

517 207 A

517 208 A

517 209 A

517 210 A

517 211 A

0.15

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1.20

It is possible to measure exact shim thicknesses due to differing tolerances.

D e t e r m i n i n g S h i m

T h i

Side) c k n e s s S1 (Ring Gear lsl = Stot s21

Example:

Stot

S2

S1

1. 92 lllll

-1.23

ITITl

-

-

------

39 28

Downloaded from

Adjusting Drive Pinion a nd Ring Gear

(Type 016 R) · www.Manualslib.com


Printed in Germany

944 turbo Differential


Replacement

Part No.

018 409 381

018 409 383

018 409 385

018 409 387

018 409 389

018 409 391

018 409 393

Thickness

(mm)

0.15

0.20

0.25

0.50

0.80

1.00

1.50

It is possible to measure exact shim thicknesses due to the differing tolerances.

Measure thickness of shims at several different points with a micrometer. In addition~ check shims for burrs and damage.

Install only shims in perfect condition!

Install shims S1 and S2 as determined.

Check Measurement

Measure backlash on periphery four times. It should be:

0.12 to 0.22 mm

N o t e

The individual measurement results must not deviate from each other by more than 0.05 mm.

I Transaxle System 39

Printed in Germany




(Type 016 R)

39 - 29

944 turbo Front Wheel Suspension

40

Technical Data

Front axle

Suspension

Springs

Shock absorbers

Stabilizers up to end MY '88

MY'89 as of MY '90 up to end of MY '86

MY '87/88 as of MY 89

Independent wheel suspension with ·light-alloy control arms and spring struts

(McPherson type)

Inboard scrub radius up to end of MY 86, outboard scrub radius as of MY '87 one coil spring per wheel, mounted coaxially to damper strut double-acting hydraulic damper struts of twin-tube gas shock type

Manufacturer, identification standard optional

Fichtel und Sachs black

Koni yellow and/or yellow/heightadjustable for sports-type running gear M030* of

MY '87/88

Koni yellow/height-adjustable

Fichtel und Sachs black with white nameplate and red

-lettering (part no.) on nameplate

Koni yellow/ height-adjustable

Solid stabilizer 0 22.5 mm or

Tubular stabilizer 0 24 x 3. 7 mm

(introduced during MY '87)

Tubular stabilizer 0 25.5 x 4 mm or

Tubular stabilizer 0 26.8 x 4 mm for sports-type running gear M030*

Tubular stabilizer 0 26.8 x · 4 mm

*

standard equipment for 944 turbo special model "S" (M758)

Technical Data




40-01

40 Front Wheel Suspension 944 turbo

TIGHTENING TORQUES FOR FRONT AXLE

L ocat ion Description Thread

Control arm to cross member

Control arm to body

..

Control arm mounting to contro l arm

(caster eccentric)

Contra 1 ar m to s teering k nu ck l e

Cross member to body

Guard p l ate for hydr . mo u nting to cross member

Tie roc! to steeri ng knuck le

Stab ilize r mounting body

Sta bil izer c l amp to mount in g

Stabilizer mounti ng to contro l arm

Cast l e nut

L ock nut

H ex bolt

Locknut

Selflocking h ex nut

Selflocking

Hex nut

Hex bolt

Selflo ck i ng

He x nut

Selfl ock ing

He x nut

H ex bolt

H ex b olt

M1 2x l. 5

M 10

M12x1 .

5

M 1 0

M 12

~1 6

Ml 2x1.5

M1 2x 1 ,5

M 8 r ~ 8

.

.

M 10

-

I

Material

8

Torque in

Nm

(ftlb)

65

(48)

8 .

8

8

1 2

8 .8

8 .

8

8.8

8

8

46

(34)

8 5

(62)

50

(37)

85

(62)

10

(7)

30 + 20

(22 + 14)

50

23

(17)

(1 7)

~5

( 18)

I

I

I

I l

I

40 02 Tightening Tor qu es



Printed in GermanyIV, 1991

944 turbo Front Wheel Suspension 40


Spring strut mount to shock strut

Pan head bolt to clamping nut

Self-locking hex nut

Allen bolt

Guard plate to steering knuckle

Hex bolt

... Fixed caliper to Hex bolt steering knuckle Pan head

Spring strut to steering knuckle

Spring strut to body

Spoiler to spring strut

Brake disk to wheel hub

Self-locking hex nut

Hex nut

Hex bolt

Hex nut

Countersunk head bolt

Light alloy wheel to brake disk

Light alloy wheel nut

M14x1.5

M 7

M 7

M12x1.5

M12x1.5

M 8

M 6

M 8

M 6

M14x1.5

Material Torque in

Nm

{ ftl b)

8 77

{56. 7)

10.9 13

{9+2.2)

8.8

8.8

10

8

10

{7)

85

(62)

100

{ 73. 7)

25

(18)

10

(7)

8

8.8

23

(17)

10

(7)

AlZnMgCu 130

1. 5 F 53 (96)

Printed in Germany- 111,19 88



Ti g htening T o rques 40 - 03

40

Front wheel suspension

The front axle modifications for 944 turbo special model

"s••

(M 758)

1-----,...----

944 turbo

7-----+

40-04 The front axle modifications for 944 turbo special model "5" (M 758)




944turbo Front wheel suspension

The front axle modifications for 944 turbo special model "S" (M 758)·

40

...

No./Designation

1 Strut bearing

2 Vibration shock absorbers

3 Coil spring

4 Adjustable spring seats

5 Steering knuckle

The most major modifications*

Harder rubber compound

Rebound travel adjustable from the outside

(harder rebound than sports shock absorber

M 474 even at the basic setting)

With harder spring rate

Vehicle height adjustable, thus enabling compensation for differences in wheel load, left to right

Fastening points for brake caliper

Notes

Green identification

Adjusting rebound travel Page 40-9 I

40-10

Page 40-6 I 40-7

See repair group

44 for height adjustment

Four-piston fixed caliper similar to

928 S 4 (difference: brake line connector)

6 Wheel hub

7 Brake disk

2.85 mm longer (to accommodate the 928 S 4 brake disk)

32 mm thick

(series 28 mm) up to end of MY 88

From 928 S 4

* standard for 944 turbo model year '89 partially standard for 944 turbo model year '90

The front axle modifications for 944 turbo special model "S" (M 758)

Print e d in. G e rm a nyJV, 1991



40-05

944 turbo Fro n t Wh eel Suspension

ADJUSTING FRONT WHEEL BEARINGS

Wheel bearing play is adjusted correctly as long as pressure plate can be moved by finger pressure applied to a screwdriver (never by turning or with leverage).

1. Remove wheel. Pry off hubcap with two tire irons.

2. Unscrew pan head bolt of clamping nut . Tighten clamping nut slightly, turning hub at same time.

3. Unscrew clamping nut until pressure plate can barely be moved by finger pressure applied to a screwdriver.

Do not support screwdriver on hub when testing this.

5. Rec h eck adjustment by moving pressure plate, correcting if necessary.

40

4. Tighten panhead bolt of clamping nut to a torque of 1 3 + 3 Nm , without turning clamping nut.

Printed in Germany- III,1988 Adjusting Front Wheel Bearing Play



40 - 1

40 F r ont Wh eel Suspe n sio n 944 turbo

CHECKING CAPS ON JOINTS OF CONTROL ARMS AND TIE RODS

The rubber caps on the joints of t h e front axle can be damaged from exter n al influences, for example fly in g sto n es or repair work. If a rubber cap is damaged so that it leaks, the control arm or t h e applicable joint of a tie rod must be replaced, since t h e entry of dirt or moisture will destroy the joint. For this reason, the following points are included in the service schedule:

Cbeck tightness of all connections on steering gear, tie rods, and control arms , as well as checking protective caps and joints for function and leakag e.

We recommend that a visual check for leakage be carried out on joint caps every time work is performed on t he front axle.

C h e c k n g

C a p s o n

C o n t r o l

R u b b e r

J o i n t s

A r m s

0 f

1. Lift car on lifting platform .

Disengage steering lock.

2. Turn front wheels against lock.

4. After turning front whee ls against stop on other side , inspect other half of rubber caps .

Thers is a small surface in the area of the brake guards where visual inspection is not possible.

Inspect this area by feel.

3. Visually inspec t left and right visible surfaces after cleaning.

Rub ber caps should be pressed with fingers so as to be able to recognize hidden cracks.

402 Checking Caps on Joints of Control Arms 111,1988- Printed in Germany an d Tie Rods



944 turbo Fr on t wheel suspe n si on

40

Height-ad j us t able strut , dismantling and assemb li ng

D i smant li ng

1 . Tension the coil spring with a spring tensioning device , e.g. from Klann (see workshop manual). Remove the dust cap f rom the piston rod and undo the lock nut.

N ote

Make sure tha t the height-adjustment thread is not damaged .

Chec k vib r a tion shock absorbers

It is only possible to check v ibration shock absorbers correctly with a test machine. A visual and/or functional test will , however. show whether shock absorbers are completely defect , or still capable of performance .

Expand and contract v i bration shock absor bers manually in the installed position. It must be possible to move the shock absorber across its entire stroke without jerking. The stages of pull and push absorption must be clearly felt up to the stop . Because of the gas pressure , it becomes more difficult to move the piston rod as it travels further into the shock absorber. If shock absorbers have been installed for a long time, pump a few times in installed position if necessary .

Replace heav i ly leaking vibration shock absorbers .

If the gas pressure has dropped ins i de the shock absorber (shock absorber does not automatically r eturn to the stop of the pull stage) , but there is no evidence of o i ly vapor

(oil mist), the shock absorber may still be used as long as it ful f ills all other r equirements. Shock absorbers which show ev i dence

; o f both facto r s - oily vapor (oil mist) and lack of gas pressure must be replaced .

88/55

2. Remove all components from the piston rod.

Height-adjustable strut , dismantling and assembling




4 0-3

40

F r ont wheel suspens i on 944 turbo

As s em b ling

Notes

Observe the tolerance groups when rep l acing coil spr ings , i.e. always install spr ings w i th identical co lor codings (page 40 7) .

S t rut bearings for sport chassis

M 030* as from model 87 (refer to s pare parts catalog) have a harder rubber co mpound .

I d enti fied by a gre en strip on the underside A , a l so occasionally on the upper side.

Lu bricate the threaded ring, adjustable sp r i ng

, sea t 8 and cou nternut w ith Optimoly TA

1 . Mount the larger spring diameter to the upper sp r i ng seat.

2. If parts a r e re pl aced which influence the height adj u stment (coil spring/threaded ring/lower sp r ing seat) , adjust the s pring sea t to the same position as before o r carry out a basic adjustment.

When new s prings are u s ed , fo llow up by making height co rrection s or fine adjustments

(afte r the strut is installed) (Page 44 7}.

Basic se tting dimension 232 ± 1 mm (bottom edge o f the s pring seat to the middle of the lo w er fastening screw)

40 ·4

87/992

* fitt ed as stan da rd in 944 Turb o Speci a l model " S " ( M7 58)

4 0 4



Height-adju s table strut , disman t ling and assembling

Printed in G e rmany Ill , 1988

944tu~:bo Front wheel suspension

40

Note to 2.

Strut Installation :

There Is a hole on the outer side of the strut bearing and a bolt on the wheel well to ensure the correct installation position.

The following must be ~bserved when adjusting height :

One-sided height adjustment produces an alteration in wheel load at the same time. ~ wheel load is altered for one wheel this alters the wheel loads on the other wheels .

For this reason, the two adjustable front-axle spring seats must be adjusted from the basic setting to the same extent to ensure that the difference in wheel load between right and left does not assume unacceptable proportions .

(The exception being a combination of springs, one in use for a long time and one new one) . lf · wheel load scales are used, the difference in wheel load Oess than

20 kg at front and rear axles wherever possible) is adjusted by altering the height of the vehicle within the height tolerance . Priority is given to the lowest possible difference in wheel load between right and left.

Make sure that the rebound settings for left and right vibration shock absorbers are not adjusted differently (Page 40 - 9 I 40-1 O).

3 . Check wheel settings and correct if necessary.

Height-adjustable strut, dismantling and assembling

Printed In Germany -Ill, 1988



40.5

40

Front Wheel Suspension

.

Tolerance groups of coli springs

944 turbo

General Information

The coli spring versions differ from each other by their length and spring stiffness (spring rate) .

They are identified by yellow, grey or white/yellow color marks, respectively .

Spring rate 21.8 N/mm (constant wire0 = 12.0 mm) : spring A (ldent . yellow)

Spring rate 28.0 N/mm (non-constant wire 0

=

11 .

7 12 .

2 mm) : spring B (ldent . white/yellow)

Spring rate 28 .

0 N/mm (constant wire 0 = 11 .

6 mm) : spring (ldent. grey)

•

In addition, each spring version (yellow, grey and white/yellow Identification) Is also classified Into two or three tolerance groups, respectively (tolerance of spring rate) .

A

A

=

944 Turbo with standard and with sport-type shocks up to end of MY '88

B

B

=

944 Turbo with sport-type running gear

M 030* as of MY '87 and standard for MY '89

- =

944 ' Turbo with standard shocks as of MY ' 90

87-4181

Assembly notes

For repairs, always fit springs with identical color marks . Since the vehicle is subject to settling of the suspension with increasing mileage, this may result In uneven vehicle height if only one spring

/s replaced. We therefore recommend the springs to be exchanged in pairs. In certain cases, springs are only available in pairs. Replacing springs in pairs Is not required In the case of vehicles with height adjustment facility (spring type B).

* standard equipment for 944 turbo special model "S" (M 758) .

40-6



Tolerance groups of coli springs

Printed In Germany IV, 1991

944 turbo Front Wheel Suspension

Overview

Coli spring, part no. 951 343 531 01 (Type A)

Application: 944 turbo with standard and sport-type shock absorbers up to end of MY '88

Group

1

2

3

Length , removed approx. 396 mm approx . 396 mm approx. 396 mm

Spring force F at length L1 = 251 mm

3034 3118 N

3118-3202 N

3202 3286 N

Color dot

1 yellow

2 yellow

3 yellow

Order

Index

101

102

103

40

•

Coli spring, part no . 944 343 531 01 (Type B) .

Application : 944 turbo with sport-type running gear M 030* as of MY ' 87 and standard for MY ' 89

Group

1

Length, removed approx. 329 mm approx . 329 mm

Spring force F at

Length L 1 = 220 mm

Color dot

3050 3150 N

Order

Index

1 white 1 yellow 101

3150 3250 N 2 white 1 yellow 102

Coli spring , part no. 951 343 531 03 (Type ).

Application: 944 turbo with standard shock absorbers as of MY '90

Group Length, removed Spring force F at

Length L1 = 241 mm

Color dot Order

Index**

1 approx . 356 mm 3082-3168 N 1 grey

2 approx . 356 mm 3168-3253 N 2 grey

3 approx. 356 mm 3253-3330 N 3 grey

* standard equipment for 944 turbo special model "S" (M 758)

**

Springs are only avaDable In pairs. Selection of a specific tolerance group Is not possible.

Tolerance groups of coli springs

Printed In Germanyr.l

, 1 991



40-7

•

40

Front wheel suspension 944turbo

Koni vibration shock absorbers without rebound travel adjustment from outside

T here are no shock absorber inserts for the Koni shock-absorber strut of the 944 turbo, because it cannot be taken apart .

The rebound travel can be adjusted for Koni shock-absorber struts . Replacement shock absorber struts are adjusted .

Shock absorber strut

Systernlldentificat i on

Setting * Application/installation

Twin tube , gas shock absorber painted yellow

Basic setting adjusted approx . 1 / 2 turn

944 turbo up to end of MY 88

Spare parts : refer to the spare parts catalog for the appropriate part numbers .

Modifications as from Model 87

Brake hose retainer position and retainer for combination connector and earthing bolt . The damping power has not altered .

* These specifications are approximate values . Precise adjustments are made in the factury with a shock absorber testing machine .

40 .

8 Konl vibration shock absorbers without rebound travel adjustment from outside




944turbo Front wheel suspension

40

•

Koni vibration shock absorber with outside rebound travel adjustment

The Koni shock absorbers, adjustable from outside (with adjustable front-axle height), are used in the sports chassis M 030* as from Model87. As is the case for shock absorber struts not adjustable from outside , there are no replacement shock absorber inserts

Shock absorber strut

Systemtldentification

Twin tubes, pressurized

Painted yellow

Adjustable height

SP No .

embossed

(above the height-adjustment thread on the shockabsorber tube)

Settings

Adjusted approx. 3/4 turn from the basic setting

(right-hand stop/softest rebound)

Application/installation

944 turbo special model "S" (M 758) and 944 turbo with sports chassis

M 030 as from Model 87 standard for MY 89

Adjusting rebound travel

1. Remove the dust cap from the piston rod. 2 . Plug the adjusting wheel onto the setting screw.

871993

871958

* fitted as standard in 944 Turbo-special model "S" (M 758) and for MY 89

Konl vibration shock absorber wtth outside rebound travel adjustment




40-9

40

Front wheel suspension

3 . The damping power can be adapted to specific driving conditions by turning the setting screw steplessly with the adjusting wheel.

When doing this, always start at the zero position (right-hand stop/softest rebound).

Always adjust the shock absorbers axle-byaxle with the same number of turns.

Harder rebound

Turn to the left (counter-clockwise)

Softer rebound

Turn to the right ( clockwise )

Note

When setting, always use the original adjusting wheel and not pliers .

4. Remove the adjusting wheel and replace the dust cap. (Always remove the adjusting wheel after each setting to avoid damaging the hood) .

944 turbo

40- 10 Konl vibration shock absorber with outside rebound travel adjustment




944turbo Front Wheel Suspension

42

•

Technical Data

Rear axle

Suspension

Suspension

Torsion bar

Shock absorbers

Stabilizers

Adjustment of spring braces

(Inclination of spring brace) up to end of MY '88 as of MY '89 up to end of MY '88

MY'89 as of MY '90

Independent suspension on light-alloy semi-traDing arms one round transverse torsion bar per wheel

0 23.5 mm (0 25.5 mm for M 030* of

MY ' 87/88)

025 .

5 mm double-acting hydraulic shock absorbers of twin-tube gas shock design

Manufacturer/Identification standard

Flchtel und Sachs optional

Konl grey-green or stripe on dot lower mounting eye yellow or yellow with 2 white color dots offset by 180° for sportstype running gear

M 030* of

MY '87/88

Konl yellow with 2 white colordots offset by 180°

Flchtel und Sachs grey with blue

Stripes on lower mounting lug

Konl yellow with

2 white color dots offset by 180°

18mm

16 mm as of MY '89 (Introduced during

MY '89) page 44-3

* standard equipment for 944 turbo special model

·s"

(M 758)

Technical Data

Printed In Germanyr.t, 1991



42-01

42 Rear Wheel Suspension, Axle Shaft 944 turbo

Bearing · flange to cross tube

Bearing flange to body

Thrust bearing to bearing flange

•

Thrust bearing to body

Mount to body

Mount to strut

'

Trailing arm to rear axle strut

Trailing arm to rear axle st rut

Trai ling arm to cross tube

Shock absorber to body

Shock absorber to trailing arm

Adjusting lever to sp ring s trut

TIGHTENING TORQUES FOR REAR AXLE

Location Description

Hex bolt

Locknut

Locknut

He x bolt

Hex bolt

Locknut

Locknut, camber eccentric

Locknut

Locknut

Hex nut

He x bolt

Locknut, ecce ntric and he x bolt

Thread

M

M

M

Ml

10

Ml2xl.5

10

M 10

M 10

8

2xl.5

Ml 2xl.5

M1 2x 1.5

M1 2xl.5

I

M14xl.5

Ml6xl. 5

10

8

8

8.8

10

8.8

8.8

8

8.8

8

8

10

Materia 1 Torque in

Nm

(ftlb)

46

(34)

70

(51)

46

(34)

46

(34)

46

{34)

23

(17)

90

(66)

103

(76)

61

(45)

61

(45}

12~

( 90. 7)

245

{1 80. 7)

42 - 02 Tightening Torque s



III,198 8 - Printed in Germany

42

Rear wheel sutpenslon, axle shaft 944turbo

•

Setting procedure for rebound travel

1 . Remove the additional rubber spring (bump stop) from the protective tube . There are holes below the mounting ring for this. Push a wire through the hole and slid~ the additional rubber spring downwards out of the protective tube , then remove it from the shock absorber .

Note :

Do not damage the piston rod when doing this.

2. Tum the protective tube/piston rod to achieve the required damping power :

To the left B

(counter-clock wise)

Protective tube/piston rod pointing upwards (Installed position)

Softer rebound

To the right A

(counter .clock

wise)

Protective tube/piston rod pointing up wards (installed position)

Harder rebound

8 7/962

1 . Press the protective tube with the piston rod right down to the bottom. Turn the protec tive tube (without using force) until the ad justment device latches in . Mark the latching position on the protective and shock absor ber tubes with chalk .

. 8 7 1984

42-2

Konl vibration shock absorbers I adjusting Konl shock absorbers

Printed In Germany - Ill, 1988



•

944 turbo Rear wheel suspension , axle shaft

3. Afte r adjusting , pull the protective tube / pis ton rod upward s again to disengage the ad j ustment dev i ce . Repl a ce additional rubber s pr i ng

42

Koni vibration shock absorbers I adjusting Koni shock absorbers

Printed in Germany- Ill , 1988



42 3

•

944 turbo Wheels, Tires, Alignment

44

Wheels and tires

Tire condition 1 tire pressure

Tires are safety relevant Items that are only capable of meeting the requirements apllcable if they are run at the correct tire pressure and with sufficient tread depth .

The tire pressures IndiCated are minimum pressures . The tires must never be run at lower pressures since this Influences roadholdlng In a negative manner and may lead to severe tire damage .

Valve caps protect the valve aga i nst dust and dirt and therefore help prevent leaks . Always screw on caps tightly and replace missing caps .

For safety reasons, do not limit tire checks to checking the tire pressure but also check for sufficient tread depth, Ingress of foreign matter, pinholes , cuts, tears and bulges In the sidewalls (cord break) I

Tire pressure for cold tires (summer and winter tires)

Up to end of MY '89 front rear

2.5 bar excess pressure

2 .

5 bar excess pressure

As of MY '90 front rear

Folding spare tire front and rear

2 .

5 bar excess pressure

3 .

0 bar excess pressure ·

I

2.5 bar excess pressure

2.2 bar excess pressure for tires 8 PR 89 P for tires 4 PR 83 P

Wheels and tires

Printed In Germany IV , 1991



44-01

44

Wheels, Tlrea, Alignment

Tire and wheel survey I tire speclflc8tlon ldenttftcatlon mark

T he t i re and wheel survey for summer and winter tires Is to be found In the corresponding Technical

Information (11) Group 4 .

When replacing summer tires, check for the correct tire spectflcstlon number. The specification character N 1 or N 0, respectively , helps to distinguish summer tires approved by Porsche from other versions Of Identical tire type and the same tire size. The tires approved by Porsche are also Identified In the corresponding Tl.

•

Important note

From MY '87, the rim offset of the wheels has been changed. Wheels designated for cars as of MY ' 87 must not be mounted on older vehicles. At the same time, wheels for cars made before

MY '87 must not be fitted to vehicles produced from MY '87 .

For 15-lnch light-alloy disc wheels , fit counterweights to a max. weight of 40 g on the Inside

(space limitations) . If required (if out-of-balance Is more severe), use 2 weights .

15-lnch disc wheels are only admissible for winter tires on vehicles up to end of MY ' 86.

44-02



Wheels and tires

Printed In Germanyr.l

, 1991

•

944 turbo Wheels, Tires , Alignme nt

Sample measuring chart up to end of MY ' 89

Name :

V eh ic le l dent. No.

:

Dat e:

V ehi c le :

All P o r s che type s 92 4 / 9 4 4 until end of m o d e l y e a r 8 9

L l ce ns " pl a t e No : m iles/~ m : m easu r ed by :

A lm s and t ire s

( damage an d treads )

- - -

- - camber

1

MEASURING CHART

D i ff er e n ce a n g l e a t 200 tu rn i n g ra d l ue

2 1 0 toe-o u t

V eh ic l e : E mp ~ a c co r d to I N 70020 ng

(wit h lu ll fu el tan~, spare wh ee l and t oo l s) 2 0 l.!

.t.l.u.!.J.

IJ.Ili.J

.

,I t oe I n

' " ' l 'f l 'l'j'n'l'nTrrl t oe-ou t

20" right t u m -i n meas u r e d l ett

0 I 2

!JI

.I.

,I toe-In

L !.

I .I.u.l.

l .

!

, l ' l 'l'l'l 'fl Tl'l' l cValues for

0 I

20" l e tt tu rni n m e asure d right

7

USA vehicles

2 1 0

+ l.u.l

, u.l.

1,t!

,~

1'1'fl'i'j'l'l'j'l'l'l o 2

~ ~

II

:;:

Q

-;::

2 toe · in (not pressedl

:;:

.go

3

·

~

~

• u c

~

~

~

G .. u

•

z c a ster

2

:

~

•

.:

~

~

'tJ

~

3

;; u

..

•

~

E

2 l ~ caster camber

Rear-wheel a djus _ ment toe-In

0

+~ -

44

Re f e r to inst r uctions in

Repair M anual f or height adj u stm e nts

WK042 1220

Sample measuring chart up to end of MY ' 89

Printed i n Ge rm an y N , 1991



Printed in Ge r many

44 03

•

M4turbo Wheela, Tlree, Alignment

Sample measuring chart as of MY '90

Name :

Vehicle ldent . No .:

Date :

Veh ic le : All Porsche types 944 90 models onward

Llcens• plate No : miles/l<m : measured by :

MEASURING CHART

Rims and tires

(damage and treads)

...

II

"'

~

:!

..

•

~

~

D

E

•

•

l

3

•

Difference angle at 200 turning radiua

2 1

LuJ.1

!I.!.!J.!ll.!.,

0

I toe-In

&1'1'1'1'1'j'l'll'l'l'j" 11 l 1 0 toe-out

Litl,,l, d,uJ.u,, ' t o . - l n '

'

1'1'1'1 lo.-out

20" right tum ·l n measured left

0 2

2 1 0

+

l.u.!JJJut~

1TI'I'rf''ri'lil -

0

20" l eft turn · in measured right

7

7 0 1 toe-in {not pressed)

Vehicle : Em~

-~htacco ng t o IN 70020

(with lull fuel tank , spare whee l and tools ) e>- Values for

USA vehicles

J z

44 camber cuter cuter

Rear-wheel adj~ment toe-ln

1

0

+~camber

WKD426220

Sample meaawtng chart •• of MY '90

Prlnt.d In Germany- rl, 1991



Refer to instructions in

Repair Manual adjustments for height

Pr i nted In Germany

44- 1

44

Wheels, Tires, Alignment 944 turbo


T he following values are valid for the vehicle curb we i ght to DIN 70020 (vehicle tank full , with spare wheel and tools) .

Ad j ustment values for U .

S . and Canadian models are given In brackets .

0

Wheel alignment values

Adjustment value and tolerance up to end of MY ' 89 as of MY '90

Front axle

Toe - unpressed + 10 ' ± 5 ' + 10 ' ± 5 '

Toe difference angle at

20 ° steering lock

- 40' to

-

1° 50 '

40 ' to

1 ° 50'

Camber 20 ' ± 15 ' 0° ± 10'

Caster

Rear axle

Toe (each wheel)

Camber

2"30' + 30'

- 15'

0 ° ± 5 '

- 25' ± 30 '

( 1 ° ± 20 ' )

2°30 ' + 30 '

15'

+ 10' ± 10'

- 45' ± 20'

(- 1 ° ± 20') max . difference left to right correct i on only poss i ble by replacing the steering arms

10' to end of MY '89

20 ' as of MY '90

30 '

10 '

30'

30 '

44-2




Printed i n Germany 'N , 1991

944turbo Wheels, Tires , Alignment

44

•

Adjustment values for height and spring brace adjustment

Front axle

Sport-type running gear M 030***

(height-adjustable spring struts)

Height adjustment*

Bolt bottom edge measured from rear steering arm under wheel center (p . 44-7)

130 ± 10 mm

Rear axle Spring brace adjustment

(Inclination of spring brace)** height adjustment* center of brace bearing (center of torsion bar) below wheel center (-value) up to end of MY ' 88

Standard and M 474

(M 474 = Shock absorber with sports tuning)

Torsion bar 0 23 .

5 mm (2f>030 ' USA. Canada)

3 .

5 ± 10 mm

Sport-type ruMing gear M 030*** 18"

Torsion .

bar 0 25.5 mm

-18 .

5 ± 10 mm as of MY '89

Standard and sport-type running gear M 030***

Torsion bar 0 25.5 mm

-18.5 ± 10 mm

* max. height difference left to right 10 mm .

For U .

S. and Canadian vehicles the bumper height Is decisive. The distance from the measuring surface (road /level surface) to the top edge of the bumper must be

522 ± 20 mm at the rear axle . The distance at the front axle must be 533 ± 20 mm.

** max. difference right to left 0.5". Changing the Inclination of the spring brace by 1° Is equivalent to approx. 5 mm change of vehicle height.

*** Standard equipment of 944 turbo special model "S" (M758)


Printed in Germany IV , 1991



44 3

44

Wheels, tires, axle alignment 944turbo

Vehicle measurements

General

Carry out vehicle measurements with an optical or electronic wheel-alignment analyzer . Refer to the wheel alignment analyzer ' s operating instructions for measurement procedures. The following precon ditions must be fulfilled before measuring:

Curb weight of the vehicle in accordance with DIN 70020, i.e. vehicle ready for driving with full fuel tank and spare wheel .

Adequate play on joint and wheel bearing

Correct tire Inflation pressure, approximately uniform tread depth

0

If the vehicle is to be measured front and rear, first check the rear-axle wheel alignment and adjust if necessary. Set steering wheel and steering gear to the middle position at toe .

Before adjusting front and rear wheel alignment , it is advisable (or necessary *) to check the height adjustment of the rear axle and / or the front axle, for vehicles with adjustable front struts , at DIN curb weight.

If wheel-load scales are available it is possible to reduce the difference in wheel load between right and left to a minimum thanks to the height-adjustment facility . The difference in wheel load Is adjusted by altering the height of the vehicle within the height tolerances. Priority is given to a minimum difference in wheel load between right and left .

* Following work which causes an alteration In height or if the height Is obviously Incorrect .

44-4



Vehicle measurements

Printed In Germany - Ill, 1988

M4turbo WhMis, tires, axle alignment

Important notes for vehicle measur· lng procedures

Obs.w the following when rne~surlng vehicles :

Height adJustment/Wheel-load aneratlon

Altering the height on one side automatically causes a change In wheel load . An alteration of load on one wheel also affects the loads on the other wheels .

If the Initial compression of a spring Is Increased on one side Olftlng the vehicle) the wheel load becomes greater .

If the Initial compression of a spring Is reduced on one side Oowerlng the vehicle) this reduces the wheel load.

An alteration In wheel load Is always felt diagonally on the other side of the axle. That means If the load on one wheel is reduced or

Increased, the same effect Is felt at the diagonally opposite wheel.

Example

The Initial spring compression Is Increased rear left C .

The wheel load Is then :

- greater at rear left C and front right B

less at rear right 0 and front left A

44

Th& difference In wheel load between left and right for front and rear axles should be kept to a minimum (less than 20 kg if possible) .

44-5 VehlcleiMIIS...-.menta

Printed In Germany Ill, 1188



44

Wheels, tires, axle alignment 944 turbo

Checking the height I adjusting the height

Drive the vehicle on to the test platform and check the height adjustment of the rear axle or (in the case of adjustment facilities at the front) at rear and front axles and correct if necessary .

Rear axle

Measuring points are at the middle of the torsion bar and at the middle of the wheel, both measured from the wheel contact area.

Setting: Page 44- 3

If necessary, correct the rear vehicle height by means of eccentric screw B on the two-part

_. shock absorber, undoing fastening screw A beforehand.

Front axle

(For vehicles with adjustable struts)

1 . Setting I (basic setting)

= 232 ± 1 mm (from the bottom edge of the spring seat).

To adjust , undo the counternuts and turn the spring seat accordingly

Always observe the following notes (Page

44-7) when setting.

44-6



88/93

Vehicle measurement


M4turbo Wheels, tires, ole alignment

44

•

Notes on setting I (basic setting)

A basic setting (specified Initial spring compression) Is usually adequate . The nominal vehicle height Is then within tolerance .

Starting at the basic setting, a height correction may be necessary and/or It Is possible to make fine adjustments .

Fine ad!ustment:

It is possible to keep differences in wheel loads to a minimum (below 20 kg) with the help d wheel-load scales .

The vehicle height can be exactly adjusted within the tolerances (priority is given to a minimum difference in wheel load between right and left at front and rear axles)

Height correction:

To compensate for differences when Installing only one new spring.

' 2 . Height correction or fine adjustment

(Only If necessary or desirable) . Measuring point Is the bottom edge of the suspension link bearing bolt = 130 ± 10 mm* below the middle of the wheel . Max. tolerance between right and left 10 mm :

If necessary tum the spring seat accordingly .

Refer to the above-mentioned notes for this .

Example*

(Measuring the height at one wheel)

Measure to the middle of the wheel a= 300 mm

Specified height

E = 130 ±10 mm

Value (from wheel contact surface to measuring point)

= 170 ± 10 mm

• Bumper height Is decisive for USA cars. Distance from measuring platform (road/level surface) to upper edge of front covering (upper edge of bumper) must be 533 ± 20 mm.

44-7 Vehicle me~~surement

Printed In Germany -Ill, 1988



44

Wheels, tires, axle alignment

Wheel alignment

Front axle

Adjusting the camber

The camber i s adjusted by turning the eccentric screw (arrow) . Remove the brake-cooling air guide for this if necessary .

Note

For the 944 turbo special modei"S" (M 758), avoid damaging the brake line (bending).

Adjusting the caster

Remove sump guard

944 turbo

44-8



Vehicle measurement


..

144turbo Wheels, tires, axle alignment

44

Undo self-locking hexagon nuts A on caster eccentric B. Adjust to the specified value by turning caster eccentric B. Depending on the position of the eccentric, use a 19 mm openend wrench In area C or a 32 mm open-end wrench In area D. (Tightening torque for hexagon nuts = A 85 Nm) .

Adjusting the toe

Preparation: Center steering gear In middle position with special tool 9116. If the steering wheel Is offset, try to get the best value when converting.

Remove special tool 9116 afterwards .

Vehicle measurement

Printed In Germany Ill, 1988



44-9

44

Wheels, tires, axle alignment 944 turbo aamp the steering wheel In the middle position and adjust the toe at the tie rods.

Rear axle

Adjusting the camber

Loosen stabilizer suspension and the screw connection between shock absorber and control arm . Adjust to the specified value by turn-

Ing the camber eccentric.

Toe difference angle

The toe difference angle cannot be adjusted

(it can only be influenced by replacing the steering arms) .

Adjusting the toe

Adjust the toe by moving the control arms In the slots on the spring strut. Use special tool

9171 for this .

44-10



Vehicle measurement

Printed In Germany -Ill, 1988

944 turbo

Technical Data

Brakes, Mechanical

46

Designation Remarks, dimensions up to end of 88

Wear limit as of MY 89 up to end of MY 88 as of MY 89

Operating brakes

(foot brake)

Brake booster

Qlght weight built)

Boost coefficient

Brake master cylinder***

(aluminum design)

0inmm

Hydraulic dual circuit brake system with front/rear axle circuit division

(black/white} , brake booster, vented brake discs with fixed caliper on front and rear axle .

The pushrod brake circuit Is allocated to the front wheels .

4 pistons per each fiXed caliper . ABS optional as of MY ' 87 (M593} , as of MY '88 Included In standard specification of some models.

0 91nch 0 9 inch

3 .

4 3 .

1 or 3 .

4** up to end of MY '86

23.81/19.05

MY '87/88

23.81/20.64

23.81/20.64

Brake power regulator In rear axle circuit switchover pressure/ reduction coefficient

Brake discs 0 front rear

Effective brake disc dla . front rear

18 bar I 046

298 mm (304 mm)*

299mm

18 bar/046

304mm

299 · mm

'

245 mm (250,8 mm)* 250,8 mm

246 mm 246 mm

* 944 turbo special model ~s" (M 758}

** as of MY '87, boost coefficient 3.4

*** for vehicles with ABS (optional equipment as of MY ' 87 I standard as of MY '89) with two central valves

Technical Data

Printed In Germany- IV, 1991



46-01

46

Brakes, Mechanical 944 turbo

Des i gnat i on Remarks , dimensions up to end of MY 88 as of MY 89

P i ston dia. I n brake caliper front, mm rear, mm

2x36 + 2x38

MY 87/88

2x36

(2 X 36

+ 2x40

+ 2 X 44)*

2

X

28 + 2

X

30

2x36

2x28

+ 2x44

+ 2x30

Brake pad thickness front rear

Brake pad area

(each front wheel

Brake pad area

(each rear wheel)

Total brake pad area

13mm

13mm

86 cm

86cm

2

2

(126 cm

2

Tolerance of thickness of brake disc max .

Lateral runout of brake disc max.

Lateral runout of fitted brake disc max .

Lateral runout of wheel hub max .

0 .

02 mm

0.05 mm

0 .

1 mm

0 .

05 mm

)*

13mm

13mm

126 cm

86cm

2

2

344 cm

2

(424 cm

2

)* 424 cm

2

Brake pad thickness , new front rear

Min. brake disc thickness** after refacing front rear

28 mm (32 mm)*

24mm

32mm

24mm

26 .

6 mm (30 .

6 mm)* 30 .

6 mm

22 .

6 mm 22 .

6 mm

0.02 mm

0,05 mm

0 .

1 mm

I

0.05 mm

Wear limit as of up to end of MY 88 MY89

2mm

2mm

2mm

2mm

26 mm (30 mm)* 30mm

22mm 22mm

Surface roughness of brake disc after machining max. 0.006 mm 0.006 mm

* 944 turbo special model "S " (M 758)

** The brake disc may only be machined symmetrically, I.e. in a uniform manner on both sides

46-02



Technical Data

Printed In Germany - IV, 1991

944 turbo Brakes, Mechanical Parts 46

•

CHECKING THICKNESS OF BRAKE PADS

N

o t e

All brake pads on one axle must be replaced when the brake pad wear indicator lamp comes on, and no later than when remaining pad thickness is 2 mm. If brake pad wear is reported by the indicator lamp, the warning contact (sensor including wire and plug) must also be replaced. Warning contact replacement is not necessary if brake pads are replaced no later than with a thickness of 2.5 mm.

Warning contacts whose electric lead core is ground (worn) must be replaced. Replacement is not necessary when only the plastic part of the warning contact is worn.

1. Remove wheels to check thickness of brake pads.

2. Visually inspect brake pads for wear.

Wear limit is reached when pad has a remaining thickness of 2 mm.

Printed in Germany



Checking Thickness of Brake Pads 46 1

46

Brakes, Mechanical 944 turbo

Removing and installing brake pads

Removing

Note

If the brake pads are to be reused, mark them for refitting prior to removal . Changing the pads from the outside to the inside and viceversa as well as from the right-hand to the lefthand wheel Is not permissible and may result

I n uneven braking efficiency.

1 . Compress expander spring in the middle and disengage from its support .

At the same time, or before compressing the expander spring, press spring towards the brake disc In the retainer area (to unload the spring). This helps to avoid damage to the retainer .

2 . Pull up warning contact lead at the brake caliper and pull warning contact out of the brake pad plate .

Note

Replace warning contact If the core of the lead Is ground through or down to the bare core. The warning contact may be reused If grinding marks are limited to the plastic section of the warning contact.

3 . Pull out brake pads using a pad removal tool . For brake calipers fitted with suppressors or vibration dampers with an adhesive coating, respectively , make sure the follow-

Ing points are observed :

Push out brake pads along with suppressors or vibration dampers , respectively . If this Is not possible (depending on the degree of wear of th~ brake pads), separate suppressors I vlb~tlon dampers from the brake back-

Ing plate · using a spatula before removing the pads. In both cases, push brake pads as tar

.

back as possible using the piston retraction tool . If required, draw off some brake fluid from the reservoir first.

Warning : Engage the spatula exactly between the brake pad and the suppressor I vibration damper to avoid damaging the brake piston seals .

46-2



Removing and Installing brake pads

Printed In Germany -IV, 1991

944turbo Brakes, Mechanical

46

Designation Remarks, dimensions up to end of MY 88 as of MY 89 approx. 10 mm approx. 1 0 mm

Wear limit up to end of MY 88 MY'89

Play at brake pedal with brakes bled and e ngine standing still

Parking brake

(hand brake)

Parking brake drum dia .

Drum brake, with mechanical action on both rear wheels

180 mm

Brake shoe w i dth 25mm

Brake lining area (each wheel 85cm

2

Brake lining thickness 4 .

5mm

180mm

25mm

85cm

4 .

2

5mm

181 mm

2mm as of

181 mm

2mm

Technical Data




46-03

944 turbo Brakes, Mechanical

.

Notes

From MY '89 and, in some cases , from

MY '88, fixed calipers used In conjunction with asbestos-free brake pads must be fitted with vibration absorbers or suppressors .

For allocation to the various types of brake calipers, refer to the Technical Informations

Gr . 4 as well as the spare parts catalog .

For the double-sided special adhesive tape, use Scotch - 3M tape

(No. 9485, width 38 mm).

46

•

Since the suppressors have an adhesive coat-

Ing , they must be replaced whenever the brake pads are removed or replaced .

VIbration dampers (suppressor plates with Integral absorber weights) must also be coated with an adhesive backing . AJways replace the vibration dampers that feature a backing coat whenever the brake pads are removed or replaced.

For fixed calipers with scraper ring piston seals, a version without coating is currently

(May, 1991) used . The version without coating should be fitted with special double-sided adhesive tape (arrow).

Vibration dampers are only used for the front axle with large fixed calipers (for radial fitting, refer to page 46 7).

Do not combine asbestos-free and asbestostype brake pads on one and the same vehicle.

For types of brake calipers and notes on spare part replacement, refer to page 47- 04.


Printed In Germany IV , 1991



46-3

46

Brakes, Mechanical 944turbo

Installation

1. If required , push piston back i nto original position using a retraction tool.

2 . Clean brake pad seat and guiding area of brake pads i n brake caliper using white spirits and a cylinder brush or special brush to ensure smooth sliding action of the pads in the pad tunnel. Make sure the brake piston seals (dust seals) are not damaged .

3 . Check brake calipers for correct mounting position . Small pistons must face the entry side of the brake disc . This is also indicated by the arrow above the PORSCHE logo that indicates the sense of rotation of the brake disc .

Note

In addition , the larger pistons of the front calipers of vehicles made up to the end of

MY ' 86 feature a small recess that points towards the entry side of the brake disc

(towards the smaller pistons) . The edges of the recess of the piston must be parallel to the guiding area of the brake pad.

4 . If vibration dampers or suppressors, respec tively , are used, insert them Into brake pistons .

Replace suppressors as a rule, replace vibra tion dampers or line wtth double-sided adhesive tape (refer to notes on pages 46 3) .

Remove protective backing from suppressors or vibration dampers before Installation.

Make sure they are allocated to the correct version (Technical Information Gr. 4 and spare parts catalog) .

46.4



Removing and Installing brake pads

Printed In Germany -IV , 1991

944 turbo Brakes, Mechanical

46

5. Insert brake pads. Check for correct pad quality.

Note

Brake backing plates (rear of brake pads) must not be greased when used in conjunction with vibration dampers or suppressors.

To avoid corrosion of the brake pads Inside the brake caliper, however , coat the seating and guiding surfaces (arrow A) with a thin coat of lubricant, e .

g. using Optimoly HT (Cu paste) or Plas tilube (supplied by Messrs. Schillings,

Postfach 1703, 7080 Aalen).

6 . Coat engaging lugs of the expander spring with Optimoly T A or Plastllube. If required, fit new expander spring in such a manner that the flat side points towards the brake disc. If

It Is installed incorrectly, correct seating of the brake pads cannot be ensured , causing the raised section in the middle of the cross to rub on the brake disc. Compress center section of expander spring and engage spring . Check for correct engagement of the expander spring (arrow). Do not force expander spring when fitting in place

(risk of breaking the retainer).

Brake disc

~ t

3

A

1 Piston

2 Noise s uppres so r

3 Brake pad

(

Outside

+

~ p;;;=

'

) with o ut lub r icant or grease


Printed In Germany- N , 1991



46-48

46

Brakes, Mechanical

7 . Push warning contact In correct position

Into pad plate and connect warning contact lead to the brake caliper .

Note

In case of unfavorable tolerances, the ex pander spring may have to be disengaged again. e .

Depress brake pedal several times firmly to allow the brake pads to settle In the operat -

Ing position . Check brake fluid reservoir level and refill if necessary.

Running In the brake pads

New brake pads require a running-In period of approx . 200 km. Optimum friction and wear coefficients are only reached after this period .

During the initial running-in period, do not brake fully from high speeds except In case of emergency .

944 turbo

46- 4b



Removing and Installing brake pads


944 turbo Brakes, Mechanical Parts 46

TIGHTENING TORQUES FOR MECHANICAL BRAKE PARTS

Location Description Thread Material

Pan head bolt to clamping nut

Fixed caliper to steering knuckle

Brake disk to front wheel hub

Guard plate to steering knuckle

Air guide plate to spring strut

Wheel hub to rear wheel shaft

Brake line holder to trailing arm

Cable holder to trailing arm

Guard plate to trailing arm

Brake disk to rear wheel hub

Fixed caliper to trailing ann

Parking brake lever to body

Brake cab 1 e to . pivot end

Allen head M 7 bolt

Hex bolt

10.9

M 12

X

1.5 8.8

Hex nut

Hex bolt

M 8

M 7

8

8.8

Hex bolt M 6

Locknut M 22

Hex screw M 6

X

1.5 8

8.8

8.8 Hex screw M 6

Hex screw M 6 8.8

Countersunk M 6 screw

Hex bolt

I

8.8

M 12

X

1.5 8.8

8.8 Hex bolt M 8

Hex screw M 6 8.8

Torque in

Nm

(ftlb)

13+3

(9+2.2)

85

( 62. 7)

10

(7)

10

{7)

5

(3.6}

85

( 62. 7)

21

{15. 5}

8.5

{6.3)

23

(17)

10

(7)

10

(7)

500

(370)

10

(7)

Printed in Germany- III,1988



Tightening Torques 46.05

944 turbo 46 Brakes, Mechanical Parts

Location Description

Parking brake cable Nut to clamping lock

Brake power assist to connector

Hex nut

Hex nut Connector to fi rewa 11

Pivot end on brake push rod

Hex nut

Thread

M 6

M 8

M 8

-

M 10

8

8

8

8

Material Torque in

Nm

(ftlb)

8.5

(6.3)

21

(15.5)

21

(15. 5)

35

(25)

46.06 Tightening Torques



III,1988- Printed in Germany

944 turbo Brakes, Mechanical Parts 46

ADJUSTING BRAKE PUSH ROD CHECKING BRAKE LIGHT SWITCH

ADJUSTMENT

N o t e

The brake push requires adjustment only when :

- the brake power a s sist unit i s replaced,

- the pivot end of the brake push rod has been removed, or

- the push rod or pivot end has been turned.

The brake pedal does not have a stop.

Its initial position is reached when the brake unit (power assist and brake master cylinder) are in released pos i tion. Since with a correctly adjusted brake push rod the brake pedal is without support in the initial position , t he set air clearances in the brake power assist unit are guaranteed. Consequently, with the engine stopped and the brakes bled, appro x . 10 mm of push rod play will be noticed on the brake pedal plate when operated manually .

The brake light switch is a mechanically operated switch, which is installed on a console above the brake pedal plate. The distance between brake light switch and brake pedal should be 5 mm with brake pedal in initial (neutral) posit i on. If necessary, change position of brake light switch by turning mounting nuts until a distance of 5 mm is reached.

Turn mounting nuts against each other

(lock).

.

~

I

A d j u s t i n g

1. Adjust length of brake push rod by turning pivet end.

Length from contact surface of brake power assist on connector

(mounting piece) to the bearing pin center of pivet end should be 186 + 1 mm until end of mod. 86 and/or ~06 + 1 mm as from mod. 87

2. Tighten locknut.

3. Check brake light switch adjustment.

Printed in Germany- III, 1988 Adjusting Brake Push Rod,

Checking Brake Light Switch Adjustment

46 5



46

Brakes, Mechanical Parts 944 turbo

Checking and adjusting parking brake

The parking brake must be adjusted if the parking brake lever can be pulled up by more than two teeth by applying average force , without showing any braking effect .

1 . Jack up car and remove rear wheels.

2 . Release parking brake and press back disk brake pads on rear wheels until brake disk can be turned easiliy .

3 . If necessary, loosen adjusting nut on clamp far enough so that cable is under no tension .

4 . Using a screwdriver inserted through the hole in the brake disk , turn adjusting device so that the wheel can no longer be turned .

Now turn back adjusting device until wheel can be turned freely, then turn back

(loosen) by two catches.

5 . Pull up parking brake lever two teeth and turn adjusting nut until wheels can only with difficulty be rotated by hand (at 4th tooth the wheels must be firmly stopped}.

6. Release parking brake lever and check whether both wheel turn freely .

7 . Lock adjusting nut.

46-6



Adjusting parking brake


944 turbo Brakes, Mechanical

46

Dismantling and assembling front brakes, as of MY '87

General Information

Starting with Model Year '87 , mounting of the brake disc on the 944/944 Sand 944 turbo has been modified . Mounting on the 924 S remains the same.

Type/Model Year

944//944 turbo up to end of MY '86 and all

924 S models

944/944 S/944 turbo as of MY '87 and all 944 S2 models

Dismantling

1. Remove brake caliper and suspend In a suitable place (do not disconnect brake hose or brake pipe but extend at spring strut).

Mounting with hexagon head screw

Mounting/Notes

Mounted on wheel hub with five M8 bolts. To remove the brake disc, the wheel hub has to be removed.

Mounted on wheel hub with two M6 countersunk screws.

The brake disc may be removed without removing the wheel hub.

Mounting with cylinder bolts

88181

Dismantling and assembling front brakes, as of MY '87




46-7

46

Brakes, Mechanical

2 . Remove brake discs after having removed the cylinder bolt(s) . If a brake disc that is stuck cannot be freed even when light blows with a plast i c hammer are applied , screw two hexagon head bolts evenly into both 8 mm threads of the brake disc and press disc off .

Assembly

1 . Check all parts for good condition and replace if necessary.

2 . Clean centering surface for the brake disc on the wheel hub and coat very lightly with

Optimoly T A.

3 . Install brake disc and brake caliper . Tighten bolts of the brake caliper with 85 Nm.

944 turbo

Parts replacement note

For the 944 turbo, four brake disc versions fo r the front axle are available

(up to end of MY ' 86)

II Model Year 87 and 88 I as of MY 87 I modified cup heigh t

Ill MY ' 881 modified In vent duct area.

(Retrofitting only in pairs- for MY '87 vehicles is possible)

IV as of MY '89 and

944 turbo special model " S" I right- and l eft-hand discs are different (note difference when assembling)

Difference : shape of I nvolute and spare part no . (marked on brake disc)

Spare part left-hand side -

3rd group no . uneven

Spare part right-hand side -

3rd group no. even

Example:

Part No. Brake disc LH:

I

928 .

351 .

(M;i.04

Part No. Brake disc RH :

928 .

351.~ .

04

46-8



Dismantling and assembling front brakes, as of MY '87


944turbo Brake, mechanical parts

46

Rear wheel brake, dismantling and assembling

Refer to the 944 repair manual for dismantling and assembly procedures for the rear wheel brakes.

Differences between the 944 turbo and 944:

- Four-piston fixed caliper with larger brake pads

Thicker brake disk with larger diameter .

Rear wheel brake, dismantling and assembling




46-9

944 turbo Brakes I Hydraulics, Regulators, Power Assist 47

HYDRAU L IC BRAKE PARTS TIGHTENING TORQUES


Pipe coupling M10 X 1 nut

Material

5.8

Torque in

Nm /k pm

(ftlb)

12/1.2

(8.8)

Brake pressure pipe to brake master cylinder, brake hose, branch and caliper

Brake power regulator to brake master cylinder

..

Brake hose to fixed caliper

Bleeder bolt to fi x ed caliper

Brake master cylinder to brake power assist

Brake power assist to adapter

Adapter to firewall

Guard plate for brake unit to bod y

Bracket to rear trailing arm

Stop bolt in brake master cylinder

Brake hose M10 X 1

Bleeder bolt M10

Hex nut r18 8

Hex nut

Hex nut

Hex bolt

Hex nut

Hex screw

Hex screw

MlO X 1 r~8

M8

M6

M6

~16

'

M6

8

8

8.8

14 / 1.4

(10)

14/1.4

(10)

8-12/0.8-

1.2(6-8 .

8)

21 /2 .1

(15.5)

21/2.1

(15. 5}

21/2.1

(15.5)

10 /1.

0

(7)

5 / 0.5

(3.6)

10/1.0

(7)

7-10

/ 0.7-1.0

(5 7)




Tightening Torques 47 01

47 Brakes I Hydraulics, Regulators, Power Assist 944 turbo

BRAKING SYSTEM

B r a k e U n i t

The removal procedure for the brake power assist (brake booster) can be found in the 944 Workshop Manual.

In addition, the following procedures and information must be observed. a. Remove brake guardplate as follows:

detach fuel collection pipe complete with injection valves from intake air distributor

(intake pipe). Note that fuel collection pipe remains in vehicle. remove intake air distributor. remove bracket for turbocharger coolant pump and run out brake guard plate after loosening fastening bolts. If necessary, replace guard plate. b. When loosening and pulling on the brake line, counterhold on hexagon of braking power regulator. However, when assembling or disassembling regulator do not on hexagon.

The two surfaces next to the screw-in thread are provided for this purpose.

I Fuel collecting pipe

II Intake air distributor (intake pipe)

III Bracket for turbocharger coolant pump

IV Brake guard plate

47 - 02 Braking System


manuals search engine c. During repair, due to their differing pedal travel, only main brake cylinders and brake power assists from the ATE company may be installed. This applies only to the 944 turbo.

Printed in Germany

944turbo Brakes, Hydraulics, Regulator, Booster

Brake system notes

Four-piston fixed caliper

Do not separate the caliper sections from each other.

Piston seals, dirt scraper rings and spring plates may be replaced with the fixed caliper remaining assembled .

To remove the spring plates, heat the mounting bolts to approx. 150°C using a hot air gun since the bolts have been inserted with locking compound . Use new bolts for reassembly . Coat bolt threads lightly with

Loctite 270. When assembling the brake pistons, always use Unisilikon TK 44 N 2 brake cylinder paste .

Unlsilikon paste is available from the spare parts department (Part No . 000 .

043.117

.

00).

47

To allow for checking of the correct mounting position of the brake calipers with the brake pads in place, the fixed calipers are marked with an arrow above the Porsche logo to Indicate the sense of rotation of the brake disc.

X = Never loosen or tighten those bohs

For modifications on the front-axle fixed calipers and notes on parts replacement, refer to page 47-04.

11 582

47-03 Brake system notes

Printed In Germany IV, 1991



47

Brakes, Hydraulics, Regulator, Booster 944 turbo

Modifications on the four-piston fixed calipers

Modification 1

As of MY ' 87* , the piston diameters in the front-axle fixed calipers were Increased from

36/38 mm to 36/40 mm .

The rear-axle fixed calipers remain unchanged

(0 30/28 mm) .

Note

The recessed surface (milled surface) on the large pistons of the front fixed calipers is no longer present as of MY '87*.

Parts replacement

The front axle brake calipers with a piston diameter of 40/36 mm may be retrofmed into earlier vehicles but only in pairs.

Comb i nation of 0 36/38 mm on one side and

0 36/40 mm on the other side is not permitted .

Modification Ill

In the course of Model Year 1989, the brake piston seals of the front and rear axles were modified . The seal was cha r.

ged from a scraper ring to a dust cap type.

Modified design

Modification II

As of MY ' 89 and for the 944 turbo special model "S " (M 758), the piston diameter at the front axle was increased to 44/36 mm .

The modified brake caliper is now mounted radially by means of cylinder bolt was axial, i.e. lateral mounting with hexagonhead bolts

(p. 46 7) .

1

·'

Dust boot

2 Suppressor

3 Rubber seal (rectangular ring)

4 Piston

5 Brake caliper housing

4 7-o4

*In some cases (USA spec .

) fixed calipers with 0 38/36 mm pistons continued to be fitted during

Model Year 1987.

47-04



Brake system notes

P ri nted in Germany IV, 1991

944 turbo Brakes, Hydraulics, Regulator, Booster

47

Fonner version

The scraper ring provided a sliding seal at the piston surface.

Parts replacement

Brake pads up to end of MY '88

944 turbo

Front axle: Jurfd 238, asbestos-type

Rear axle: Jurid 238, asbestos-type or

Front axle : Textar T400, asbestos-free

Rear axle: Textar T400, asbestos-free

Combination of asbestos-free and asbestostype brake pads is not permitted

Make sure only brake calipers of identical design are fitted to one and the same axle.

944 turbo special model "S"

Front axle: Textar T400 with or without sinter plug asbestos-free

Rear axle: Textar T400 without sinter plug, asbestos-free

Brake pads as of MY '89

Front axle: Textar T 400 asbestos-free

Rear axle: Textar T 400 asbestos-free

Brake system notes

Prlnted In Germany -IV, 1991



47-05

47

Brakes, Hydraulics, Regulator, Booster

Brake power controller

A brake power controller Is provided for the rear brake circuit.

On vehicles without ABS, the brake power controller Is screwed Into the Intermediate piston circuit of the brake master cylinder.

On vehicles with ABS, the brake power controller Is screwed Into port h of the hydraulics unit .

For notes on removing and Installing, refer to page 47-02 . r

944turbo

Swltchover pressure of the brake power controller Is 18 bar. Reduction coefficient

0.46 = designator 5 (Designator 3 refers to reduction coefficient 0.3). Only fitting of the

5/18 brake power controller is permissible.

47-06



Brake system notes

Printed in Germany rv,

1991

944turb0

Technical data

Steering

Steering wheel

•

Steering wheel ratio in center

Turning circle diameter

Track circle diameter

Steering wheel turns from stop to stop

Standard :

Optional

Steering

Rack and pinion steering , with hydraulic power assist

380 mm 0 4 spoke

360 mm 0 4 spoke

360 mm 0 4 - spoke with raised hub

Left-hand steering 18,85 : 1.

Right-hand steering 18,96 : 1

10,75m

10,1 m

Left-hand steering 3,24

Right hand steering 3,26

48

Technical data




48-01

48 Steering 944 turbo

TIGHTENING TORQUE FOR STEERING

Locatio n Description Thread

Axle s haft to steerSelfing gear and steerlocking ing shaft He x nut

He x bolt Steering gear to cross member

Cover for pinion bearing

Cover for thrust pie ce bearing

Steering wheel to steering column

Steering column s wit ch to o ut er tube

Outer tube to body

Hex

He

He

He x x x screw bolt nut bolt

Mount to body

He x bolt

He x sc rew

Tie rod Tie rod to rack

Tie rod joint to tie rod

Tie rod to steering knuckle

Hex bolt

Castle nut

Lock nut

VM

M

M

M

8

6

6

8

M16x1.5

M 5

M 8

M 6

M14xl. 5

M14 x 1.

5 I

Ml-2 x l. 5

M12x1,5

Material

12

Torque in

Nm

(ftlb)

30+5

(22+3.6)

8.8

8.8

23

(17)

7

( 5)

8.8 7

(5)

17 H 2 45

(33)

4

(3)

8.8

8.8

17 H

8

23

(17)

7

(5)

70

(51)

70

(51)

30+20

(22+14)

50

48 - 02 Tightening Torques



111,1988- Printed in Germany

•

944 turbo Steering 48

Location

Feed and return

1 i nes on steering gear

Feed line on power steering pump

Ring hose nipple for intake hose on power s teering pump

Description Thread Material

Hollow-core bolt

Hollow-core bolt

Hollow-core bolt

M 12 X 1. 5 6.8

M 14 X 1.5 6.8

M 16 X 1.5 6.8

Torque in

Nm

(ftlb)

20

(14)

30

(22)

45

(33)

Printed in Germany111,198 8



Tightening Torque s 48 03

944turbo Steering

48

•

Checking and servicing the rack-and pinion power steering

General

Power steering damage occurs due to lack of oil in the hydraulic circuit. Even minor leaks may cause the fluid to escape due to the high oil pressure inside the hydraulic circuit and may result in damage to the power-steering pump .

Grunt sounds noticeable when turning the steering wheel or foaming in the supply tank indicate a lack of oil and/or air ingress . Before topp i ng up the supply tank, however , eliminate any leaks in the inlet side and/or replace any defective parts of the pressure side .

Important note

Do not attempt to repair or dismantle rackand-pinion steering gear and power-steer-

Ing pump. Both steering gear and power steering pump are available on an exchange basis in various countries .

In countries that do not operate an exchange part scheme, the steering gear as well as the power steering pump may in certain cases be reconditioned by an authorized ZF dealership .

Checking the power steering pump drive belt tension

Adjustment of the drive belt is described on page 131.

Checking the steering system for leaks

(visual inspection)

With the engine running at idle, turn the steer ing wheel to lock and keep in that pos i tion .

This allows maximum l i ne pressure to build up.

When the steering wheel in this position , check all line connections for tightness, retighten if necessary.

Run this check for max. 1 0 sec. If the check requires more time, allow for a short break every 10 seconds.

Checking the power steering fluid level

Screw off supply tank cover.

The supply tank is fitted to the right hand wheel house wall inside the engine compart ment.





48- 1

48

Steering 944turbo

2. Run e n gine a t id l e. W i pe off dipstick , screw c o ve r back on and remove again . The fluid lev e l must be betwee n both marks . If requ i red , top up with ATF DEXRON II D .

Bleeding the steering system

1 . To bleed the complete system after new steering components or lines have been fitted or after excessive hydraulic fluid loses have been remedied, stan engine several times and turn off Immediately as soon as It has staned. This process causes the fluid level In the supply tank to drop rapidly. Make sure to top up contlnously using ATF Dexron II D. The supply tank must never run empty .

Note

To facilitate refitting, establish the fluid level using a measuring tape while topping up cons tantly . Fluid level: approx . 40 mm from top e dge ofsupply tank .

2 . As soon as the fluid level no longe r drops when the engine is started for a short mo ment , start the engine again and let i t run at i dle speed.

3 . Turn steering wheel rapidly from lock to lock several times to allow air to escape from the cylinders . When reach i ng the end position of the piston, do not pull harder on the steering than is required for turning the steering

(to avoid unnecessary pressure buidlup) .

4 . Check fluid level while performing this operation . If it continues to drop, top up until the fluid remains at a constant level and no more air bubbles rise in the supply tank when the steering whee l is turned .

Note

When stopp i ng the engine, the fluid level in the supply tank must not rise by more than

10mm.

If the fluid level with the engine stationary and running, respectively , deviates by more than

10 mm, trapped air remains in the hydraulic fluid.

5 . With the engine running at idle, establish cor rect f l u i d level (between min . and max . marks) without turning the steering wheel.




P ri nted in Germany- IV , 1 99 1

944 turbo

5. The oil level in the supply reservoir must not rise by more than 10 mm after turning off the engine.

N o t e

If the difference in oil level between a stopped engine and running engine exceeds 10 mm, too much air is trapped in the hydraulic fluid.

6. After wiping off dipstick, screw cap on supply tank and remove again (engine must be idling).

If necessary, add a specified hydraulic fluid (see point 2

'Checking Power Steering

Hydraulic Fluid Level').

Steering 48

Printed in Germany



Bleeding Steering System 48 3

944turbo Front hood

Replacing front hood cable

Removal:

1 . Raise concealed headlights . Cover bumpers to avoid damaging the paint fin i sh. Remove cover strips .

..

2. Undo fastening nuts and remove bolts.

851 186

55

851190

851 195

851 18 7

55- 1 Replacing front hood cable




..

55

3 . Pull the cover plate slightly forwards and undo the fastening screws with a fine Phillips screwdriver , then remove the cover plate from the vehicle .

Front hood 944 turbo

88158

5 . Remove the complete air filter system and undo the clamping screw on the hood lock .

4 . Open the hood lock with a suitable tool and raise the hood .

·'

88/117A

55-2



Replacing front hood cable

Printed in Germany Ill, 1988

944 turbo Front hood

55

6 . Pull away the carpet in the area of the hood release handle .

2. Insert the cover plate from the front. Start turning the fastening screws. Adjust cover plate level with the fender . Tighten nut s and bolts .

...

86/115

7 . Remove and support the release handle .

Drive out the roll pin and pull out the hood cable.

85/199

3 . Close the hood and adjust the cover plate in such a way that the gap between it and the hood is the same all r o und. Open the hood and tighten the bolts .

86/ 1 16

Installing

1 . Install the new hood cable in reverse order .

Replacing front hood cable




85 / 1 93

55-3

944 turbo

REMOVING AND INSTALLING LOWER TRIM PANEL

R e m o v a 1

1 . Unscrew sheet-metal screws between engine splashguard and lower trim panel .

,

Bumpers 63

2. Remove plugs, unscrew nuts and bolts and detach lower trim panel from vehicle.


Before installation, inspect all fasteners and if necessary replace. Installation is in the reverse order of the above steps.

Print e d in Germ a ny



Removing and Installing

Lower Trim Panel

63 - 1

..

944 turbo

REMOVING AND INSTALLING SPOILER AND BUMPER

Bumpers 63

Printed in Germany




Spoiler and Bumper

63 3

63 Bumpers

REMOVING AND INSTALLING SPOILER AND BUMPER

12

19 17 25 29 27

28

24 32 33 31

34

944 turbo

33 34 23

22

.---11

1)------' 10

~ --9

43

44 42 13 41 40 17 8 7 20 48 45 16

~T

5 6 20 1 4 2

Printed in Germany 63 - 4

Downloaded from

Rem o ving and Installing

Spoiler and Bumper www.Manualslib.com


944 turbo Bumpers 63

•

No. Description

39 Plastic nut

40 Licence plate holder

41 Backing

42 Nut

43 Washer

44 Sheet-metal screw

45 Turn signal light

46 Backing

47 Nut

48 Light

49 Backing

50 Nut

51 Towline eye

Qty. Removing

2

1

2

4

4

2

6

6

1

2

2

2

2

Note When:

Installing

Printed in Germany




Spoiler and Bumper

63 - 7

•

944 turbo

REMOVING AND INSTALLING USA SPOILER AND BUMPER

Bumpers

63

Printed in Germany



Removing and Installing USA

Spoiler and Bumper

63 - 9

63 Bumpers

REMOVING AND

INSTALLING USA SPOILER AND BUMPER

944 turbo

18

12

19 17 29 27

30 28

24 32 33 31 35 39

34

33 34 21 23

22

13

43

44 42

54

40 17

20 r

45 1

ItT

5 6 20 1 4 2 52

Printed in Germany 63 - 10

Downloaded from


Spoiler and Bumper www.Manualslib.com



No. Description

1 Front spoiler

Qty. Removing

1

Note When:

Loosen screw connections to fenders, air ducts, and wheel wells.

Installing

Fit onto fender

2 Mounting strip

3 Washer 86.4

4 Hex bolt

5 Washer 86.4

6 Hex head sheet-metal screw

7 Washer 86.4

8 Sheet-metal screw

9

10

11

12

Cutter

Spring washer

83.7

Sheet-meta 1 screw

83.9 Y. 19

Spring

Cable clamp 13

14 Nozzle

15 Washer

16 Nut

17 Hose clamp

18 Hose

2

2

2

1

4

6

2

2

2

6

6

1

1

2

2

4

1

!

Printed in Germa ny




Spoiler and Bumper

63 5

63 Bumpers

No.

26

27

Description

19 Valve

20 · Sheet-meta 1 nut

21

22

23

Air duct

Washer B5.3

24

25

Qty. Removing

1

..

9

2

6

Hex-head sheet 6 metal bolt

B2 4.8 X 13

Bumper 1

Cover

Impact tube

1

I')

L

Washer 4

28 Bolt

M 8 X 25

4

29

30

31

Washer 8.4

Pan head bolt

M 8 X 70

Air duct

2

2

1

32

33

34

35

36

37

38

Sheet-metal nut

4.8 X 19

Spacer

Hex bolt ~16

Air duct

Sheet-metal nut

4.2 X 13

Washer A4.3

Sheet-metal screw

B 4.2 X 13

2

4

4

1

I')

L

2

2

Note When:

Installing

I

944 turbo

Downloaded from

Removing and Installing www.Manualslib.com


Printed in Germany


Note When :

No. Description

1 Front spoiler

Qty. Removing

1 Loosen screw connection to fenders, air ducts, and wheel wells

2

Installing

Fit onto fenders

2

5

Mounting strip

3 Washer 86.4

4 Hex bolt ~16

Washer 86.4

6 Hex head sheet-metal screw

7 Washer 86.4

8

9

Sheet-metal screw

Cover

10

11

Spring washer

83.7

Sheet-metal screw

83.9 X 19

12 Spring

13 Cable clamp

14 Nozzle

15 Washer

16 Nut

17 Hose clamp

18 Hose

2

?

1

..

1

1

4

6

2

2

2

6

6

2

2

4

1

I

Printed in Germany




Spoiler and Bumper

63 - 11

63 Bumpers 944 turbo

Downloaded from

No. Description

19 Valve

20 Sheet-metal nut

21 Air duct

Qty. Removing

1

9

22 Washer 85.3

23 Hex head sheet6 metal screw

BZ 4.8 x 13

2

6

24 Bumper

25 Cover

1

1

26 Impact absorber 2

27

28

Washer

Bolt M8 x 25

4

4

29 Washer 8.4

30 Pan head bolt

M8 X 70

31 Air duct

2

2

1

32 Sheet-metal nut

4 .

8 X 19

33 Spacer

34 Hex bolt 6

35 Air duct

36 Sheet-metal nut

4.2

X

13

2

4

4

1

2

2 37 Washer A 4.3


B 4.2

X

13

2

Note When:

Installing

I

63 - 12 Removing and Installing USA www.Manualslib.com


Printed in Germany

.

.

-"


No. Description

39 Plastic nut

40 Licence plate holder

41 Backing

42 Nut

43 Washer


45 Turn signal light

46 Backing

47 Nut

48 ' Light

49 Backing

50 Nut

51 Side marker light

52 Mount

53 Knurled nut


Qty. Removing

2

1

2

4

4

4

2

4

4

2

4

2

2

6

6

2

Note When:

Installing

I

Printed in Germany




Spoiler and Bumper

63 - 13

944 turbo Exterior Equipment 66

REMOVING AND INSTALLING ROCKER PANEL COVERS

R e m o v a 1

1 . Bore open tubular rivets, if bolted unscrew mounting bolts of front rocker panel covers and remove rocker panel covers from vehicle.

2 . Unscrew plastic mounting nuts for rear rocker panel covers, remove washers and detach rocker panel covers from vehicle .


Prior to installation check all fastening parts. Replace where necessary. Installation is the rever s e of the removal procedure.

Pr i nted i n G e rm a ny



R e m v i ng and In s talling Ro c ker Panel Covers 66 1

66 Exterior Equipment 944 turbo

REMOVING AND INSTALLING REAR APRON SPOILER

R e m o v a l

1 . Unscrew lower mounting belts for rear apron spoiler.

2. Open trunk lid, and lift trunk floor cover out of vehicle.

Unscrew mounting nuts on rear side pieces and remove rear apron spoiler from vehicle.

I n s t a 1 l a t o n

Prior to installation, check all fastening parts and replace where nece$sary. Installation is the reverse of the removal steps above. '

66 - 2

Downloaded from


Rear Apron Spoiler www.Manualslib.com


Printed in Germany

944 turbo Exterior Equipment

FINISHES AVAILABLE, 86 MODELS ONWARD

Standard:

Indian red

Black

Alpine white

Copenhagen blue

Pastel beige

LM 3 A

L 041

L 90 E

LY 5 B

LM 1 N

Special:

Sapphire metallic LY 5 V

Zermatt silver metallic LY 7 Y

Mahagony brown metallic LB 8 Z

Crystal green metallic LM 6 Y

Garnet red metallic LM 3 Y

Kalahari beige metallic LA 1 Y

Stone grey metallic LY 7 U

LB 7 V Graphite metallic

Pearl luster white metallic LO A 9

66

FINISHES AVAILABLE, 87 MODELS ONWARD

Standard:

Black

Alpine white

Lemon yellow

Azurite blue

Malven red lndid red

L 041

L 90E

L MIA

L Y5D

L Y3E

L M3A

Special:

Zermatt silver metallic L Y7Y

Stone grey metallic

Satin black metallic

I aut i c met a 11 i c

L Y7U

L ygy

L Y5Z

Flamingo metallic L Y4Z

Maraschino red metallic L Y3V

Almond beige metallic

Nile green metallic

Diamond blue metallic

Nougat brown metallic

L YIY

L Y6Y

L M5U

L M8V

Printed in Germany-11,1987



Finishes Available, 86 Models

Onward

66 3

66 Exterior Equipment

APPLYING TURBO EMBLEM l.Remove all traces of soiling from the surface and clean with white spirit.

2.Wet surface with a 50 % alcoholwater mixture to prevent the film adhering immediately.

3.Remove beige protective paper from the film and position film parallel with edge of fender.

944 turbo

5.Remove outer protective paper, pierce any remaining air bubbles with a needle and press film down again.

4.Use a plastic spatula or the like to squeeze moisture from beneath the film. Work from the middle towards the edges and ensure that no air bubbles are trapped beneath the film.

Note:

The film and car temperatures must not be less than +20°C.

66 - 4 Applying Turbo Emblem



Printed in Germany

944 turbo Wiper and Washer System 92

AIMING HEADLIGHT CLEANER SPRAY JETS

Special aiming tool No. 3019 A 3. Activate cleaning and check spray effectiveness.

1. Run headlights out.

2. Insert aiming tool in spray jet.

With the help of the aiming tool, turn spray jet so that the telescopic extension of the tool points to the middle of the lens.

Printed in Germany



Aiming Headlight Cleaner Spray Jets 92 - 1

944 turbo Exterior Lights, Lamps, Switches 94

AIMING HEADLIGHTS

R e q u i rem e n t s:

Proper tir~ inflation pressure, full fuel tank, person or a weight of about

70 kg (155 lbs) in driver 1 s seat .

USA Version

1. Turn on low beams (USA version: high beams) and clean lens.

2. Correct a1m1ng with an optical headlight aimer.

Rest of World Version

A

=

Lateral control

B = Vertical control

Printed in Germany



Aiming Headlights 94 - 1

94 Exterior Lights, Lamps, Switches

AIMING FOG LIGHTS

R e q u i r e m e n t s:

Proper tire inflation pressure, full fuel tank, person or a weight of about

70 kg (155 lbs) in driver's seat.

1. Unscrew and remove transparent covers.

USA Version

944 turbo

2. Correct aim with an optical headlight aimer.

94 - 2 Aiming Fog Lights



Printed in Germany

944 turbo

LUBRICATING CONCEALED HEADLIGHT

LINKAGE

Lubricate linkage of concealed headlights with a standard multi-purpose grease at each inspection or after every engine cleaning.

Exterior Lights, Lamps, Switches 94

Printed in Germany



Lubricating Concealed Headlight Linkage 94 - 3

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