Porsche M 44/01 Workshop Manual
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Porsche M 44/01 Workshop Manual

Porsche M 44/01 Workshop Manual

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Workshop Manuel
Volume I - Engine, 8 valves
DR. ING. h. c. F. PORSCHE Aktiengesellschaft

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Summary of Contents for Porsche M 44/01

  • Page 1 Workshop Manuel Volume I - Engine, 8 valves DR. ING. h. c. F. PORSCHE Aktiengesellschaft...
  • Page 2 WORKSHOP MANUAL 944 This Workshop Manual descr ibes all of the important operations for which special instructions are required to assure proper completion. This manual is essential for shop foremen and mechanics, who need this information to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply to repairs on vehicles without exception.

  • Page 3: General

    List of Repair Groups 944 General Technical Data Page 0.1 Repair Groups Group Maintenance, Self-diagnosis Engine Engine, Crankcase Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Air Flow Controlled Fuel Injection Exhaust System/Emission Controls Starter, Power Supply, Cruise Control Ignition System DME Diagnosis...
  • Page 4 9 4 4 Blank Page...

  • Page 5: Table Of Contents

    Table of contents volume I Page General Technical data Engine, Crankcase Tolerances and wear limits 10 - 01 Tightening torques for engine 10 - 03 Engine, removing and installing (manual transmission) 10 - 1 Hydraulic engine mounts, removing and installing 10 - 7 Checking hydraulic engine mounts 10 - 10...
  • Page 6 volume I Table of contents Page Compensating shaft drive, disassembling and assembling 13 - 39 Installing bearing bridges for compensating shafts 13 - 44 f Compensating shaft drive, disassembling and assembling 13 - 44 h Compensating shaft drive sprockets, installing (Model 84 onwards) 13 - 50 Machining cylinder bores 13 - 53...
  • Page 7 Table of contents volume I Page Temperature switch, removing and installing - checking temperature switch 19 - 9 Cleaning cooling system after oil and water have been mixed 19 - 11 Fuel supply Replacing fuel filter, checking injection lines for leaks and tightness 20 - 1 Checking delivery rate of fuel pump 20 - 2...
  • Page 8 volume I Table of contents Page Tempostat bowden cable, removing and installing 27 - 8 Clutch switch, removing and installing 27 - 9 Troubleshooting-Tempostat 27 - 10 Checking multiple-pin connector of Tempostat control unit 27 - 11 Checking multiple-pin connector of Tempostat actuator 27 - 12 Automatic cruise control (Tempostat) from Model 85/2 onward 27 - 13...
  • Page 9 G e n e r a l Printed in Germany...
  • Page 10 (adjusting values and wear limits appear in pertinent repair groups) Note: USA values in brackets. E n g i n e M 44/01 manuals - M 44/03 automatics (M 44/02 manuals - M 44/04 automatics) M 44/05 manuals - M 44/06 automatics...
  • Page 11 G e n e r a l Connecting rods Forged steel/cast since February, 1984 Conrod bearings Plain Piston pin bearings Press-fit brass bushings Pistons Cast fight alloy Piston pins Floating installation, secured with circlips Piston rings 2 compression rings and 1 oil scraper ring Cylinders Light alloy Cylinder head...
  • Page 12 G e n e r a l E x h a u s t S y s t e m Manifold, single pipe up to primary muffler, primary and final mufflers (manifold, single pipe up to 3-way catalytic converter, final muffler) H e a t i n g Warm water heater with heat exchanger and blower...
  • Page 13 G e n e r a l D i m e n s i o n s (at DIN curb weight) Length mm/in. 4200/165.354 (4290/168.898) Length with US bumpers as optional equipment mm/in. 4290/168.898 Width mm/in. 1735/68.307 Height mm/in. 1275/50.197 Wheelbase (designed) mm/in.
  • Page 14 G e n e r a l F i l l i n g C a p a c i t i e s Engine oil (volume depends on brand name HD oil to API CI. measurement with oil dipstick - SE or SF - see Owner's Manual see Owner's Manual) Engine oil volume...
  • Page 15 General Technical Data Type 944 - Model 88 (Adjusting values and wear limits appear in pertinent repair groups) Note: USA values in brackets. Engine Engine type M 44/09 (manuals) M 44/10 (automatics) Bore mm/in. 100 (3.94) Stroke mm/in. 78,9 (3.11) Displacement (actual) cm3/in3.
  • Page 16 G e n e r a l 9 4 4 DESIGNATION OF CYLINDERS Technical Data Printed in Germany...
  • Page 17 9 4 4 E n g i n e / C r a n k c a s e TOLERANCES AND WEAR LlMITS New Part Wear Limit C o o l i n g S y s t e m Thermostat Opening temperature 81 - 85 °...
  • Page 18 E n g i n e / C r a n k c a s e 9 4 4 TOLERANCES AND WEAR LlMITS New Part Wear limit C y l i n d e r H e a d a n d V a l v e s Mating surface Distortion max.
  • Page 19 9 4 4 E n g i n e / C r a n k c a s e TOLERANCES AND WEAR LlMITS New Part Wear Limit P i s t o n s a n d C o n n e c t i n g R o d s Cylinder/piston Clearance 0.008 - 0.032...
  • Page 20 9 4 4 10 - 02b Blank Page...

  • Page 21: Engine, Crankcase

    Engine, Crankcase Tightening torques for engine Location Thread Tightening torque Nm (ftlb) Crankshaft/ Crankcase Bolts - upper and lower M 12 x 1.5 30(22) 1st stage crankcase sections (studs) 60° torque angle 2nd stage M 10 20(15) 1st stage 50(37) 2nd stage 20(15) 10(7.5)
  • Page 22 Location Thread Tightening torque Nm (ftlb) Con rod bolt Verbusrip M 10 x 1.25 75(55) + 5(4) Con rod bolt with smooth M 10 x 1.25 57(42) + 5(4) contact surface Water drain plug in upper 20(15) crankcase section Oil pan to crankcase hand tight 1st stage 4(3)
  • Page 23 Engine/Crankcase Location Thread Tightening torque Nm (ftlb) Tensioning pulley to belt M 10 45(33) Tensioner Fastening - belt cover 8(6) Console for generator to M 10 45(33) Crankcase Remote thermometer M 10 x 1 35(26) Sensor Temperature sensor M 12 x 1.5 15(11) (NTC II) Oil pressure sensor...
  • Page 24 Engine/Crankcase Location Thread Tightening torque Nm (ftlb) Camshaft pulley to camshaft Allen screw Screw with internall M 10 45(33) serrations M 10 65(48) - 70(52) Console to camshaft 8(6) bearing Connector to driver 5(4) secured with Loctite 221 Distributor rotor to 4(3) selt-locking connector Transport strap to...
  • Page 25 9 4 4 E n g i n e / C r a n k c a s e TOOLS Description Special Tool Remarks Chain sling US 1105 Printed in Germany Removing and Installing Engine 10 - 1...
  • Page 26 E n g i n e / C r a n k c a s e 9 4 4 REMOVING AND INSTALLlNG ENGINE ( M a n u a l T r a n s m i s s i o n ) E n g i n e r e m o v e d f r o m u n d e r n e a t 7.
  • Page 27 9 4 4 E n g i n e / C r a n k c a s e 14. Unscrew fuel return line. 10. Disconnect air cleaner with air flow sensor on body and on coolant hose, and lay aside. 15.
  • Page 28 E n g i n e / C r a n k c a s e 9 4 4 22. Unscrew stabilizer on body and control arms, and remove. 23. Unscrew shield for right engine mount on front axle cross member. 24.
  • Page 29 9 4 4 E n g i n e / C r a n k c a s e 28. Remove coolant hose on bottom of radiator. 41. Attach Special Tool US 1105 on engine (shorter end towards rear of engine). 29.
  • Page 30 E n g i n e / C r a n k c a s e 9 4 4 I n s t a l l i n g Note the following for installation. 1. First insert transaxle/clutch housing mounting bolts, but do not tighten.
  • Page 31 9 4 4 E n g i n e / C r a n k c a s e REMOVING AND INSTALLlNG HYDRAULIC ENGINE MOUNTS R e m o v i n g 5. Unscrew shield for right engine mount on front axle cross member.
  • Page 32 E n g i n e / C r a n k c a s e 9 4 4 8. Unscrew universal joint on steering gear, hydraulic engine mount on engine brackets and front axle cross member on side members. N o t e Mark installed position of universal joint to steering gear.
  • Page 33 9 4 4 E n g i n e / C r a n k c a s e 5. Tighten self-Iocking mounting nuts in the order given below. Hydraulic engine mount to front axle cross member. Hydraulic engine mount to engine brackets. Universal joint to steering gear.
  • Page 34 Engine/Crankcase CHECKING HYDRAULIC ENGINE BELTS G e n e r a l I n f o r m a t i o n Hydraulic engine mounts cannot be tested 100% with conventional workshop equipment. However, the test procedures listed below can be used to determine whether hydraulic engine mounts are defective or seriously impaired in effectiveness.

  • Page 35: Installing New Hydraulic Engine Mounts

    Engine, Crankshaft, Pistons Installing new hydraulic engine mounts Vehicle type 924 S - 944 - 944 S - 944 S2 - 944 turbo Note The old hydraulic engine mount that was fitted 1. The new hydraulic engine mount may be ret- using 4 mm spacers has been discontinued rofitted to all vehicles as of Model Year '82.
  • Page 36 13 - 00 Blank Page...
  • Page 37 Engine / Crankshaft, Pistons Polyrib drive belt for alternator or a/c compressor 5-rib poly-rib belt Adjusting 1. Loosen hexagon head bolts of connecting Checking rod slightly 1. Prepare Special Tool 9202 for checking. Pull 2. Loosen rock nuts of connecting rod and turn out lockpin on special tool and slide out tes- connecting rod accordingly until the correct ting pin opposite the lockpin completely.

  • Page 38: Engine, Crankcase, Pistons

    E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 CHECKING ADJUSTMENT OF BALANCE SHAFTS 1. Remove splash shield. 2. Turn crankshaft clockwise until TDC mark on camshaft sprocket is aligned with cast mark in mount for ignition cap.
  • Page 39 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s CHECKING AND ADJUSTING TIGHTNESS OF POWER STEERING PUMP DRIVE BELT C h e c k i n g 3.

  • Page 40: Calibrating Special Tool 9201 13 - 2B

    E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 CALlBRATING SPECIAL TOOL 9201 TOOL CALlBRATING Tools Required: Small screwdriver 1.6 x 40 x 0.4 mm Gage 9201/2 1.
  • Page 41 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s Consequently the measurement with a gage should be repeated with different sliding shoe positions. Find the position, where the scale value is closest to the 4.0 adjusting value.
  • Page 42 9 4 4 13 - 2 d Blank Page...
  • Page 43 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s CHECKING AND ADJUSTING TIGHTNESS OF DRIVE BELT FOR BALANCE SHAFTS (ROLLER WITH SLOT) N o t e : Only check and adjust drive belt tightness on a cold engine (ambient temperature approx.
  • Page 44 E n g i n e, C r a n k c a s e, P i s t o n s 9 4 4 6. Check basic position of balance shaft sprockets. Marks on sprockets should be aligned with marks of rear drive belt cover.
  • Page 45 Engine/Crankshaft, Pistons 11. Install Poly-Rib belt and adjust; see page 13 - 1 Note: Slides must make full-surface contact with belt. While measuring, do not allow the Special Tool to turn or move on the belt. Printed in Germany - XIII, 1987 13 - 5 Checking and Adjusting Tension of Drive Belt for Balance Shafts...
  • Page 46 Engine/Crankshaft, Pistons TOOLS Description Special Tool Remarks Tester for belt 9201 tension Gage 9207 Wrench 9244 13 - 6 Tools - Checking and Adjusting XIII, 1987 - Printed in Germany Tension of Drive Belt for Balance Shafts...

  • Page 47: Cover

    Engine/Crankshaft, Pistons CHECKING AND ADJUSTING TENSION OF DRIVE BELT FOR BALANCE SHAFTS (ROLLER WITH SLOT) Note: Do not check or adjust drive-belt tension unless engine is cold (at room temperature). 4. Slacken pulley so that it no 1. Remove air-cleaner assembly, longer tensions drive belt.
  • Page 48 Engine/Crankshaft, Pistons Illustration shows 16-VALVE ENGINE 5b. TDC mark on flywheel must also be 7. Prepare Special Tool 9201 for aligned. testing. Pull lockpin from Special Tool and push gage pin opposite lockpin out as far as it will go. Align telltale and measuring needles.
  • Page 49 Engine/Crankshaft, Pistons Specified value: 10. After adjusting drive-belt tension, adjust idler pulley. (new or used belt) Using Special Tool 9207 or 2.7 +- 0.3 scale gradations feeler gage (0.5 mm) set pulley so that there is a clearance of If necessary, correct belt tension. 0.5 mm between belt and pulley at the lower balance shaft when 0 to 1 mm pretension is applied...
  • Page 50 Engine/Crankshaft, Pistons Note: Slides must make full-surface with contact belt. While measuring, do not allow the Special Tool to turn or move on the belt. 13 - 10 Checking and Adjusting Tension XIII, 1987 - Printed in Germany of Drive Belt for Balance Shafts...
  • Page 51 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s TOOLS Description Special Tool Remarks Assembly sleeve 9203 Pressure pad for crankshaft 9126 seal on flywheel end Feeler gauge standard tool Dial gauge holder...
  • Page 52 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 TOOLS Description Special Tool Remarks Thrust pad 9210 To install bearing sleeve for balance shaft bearing housing 13 - 12 Crankscase Tools...
  • Page 53 Engine, Crankshaft, Pistons Engine Assembly Support Tools Designation SpecialTool Order number Explanation Engine support 9127 000.721.912.70 Engine support adapter 9197 000.721.919.70 Engine Assembly Support 13 - 13 Printed in Germany - XXVI, 1993...
  • Page 54 Engine, Crankshaft, Pistons Identification of engine number on crankcase The engine number is stamped into the left- As of Model Year 1988, the engine number hand rear crankcase section (relative to is located on the right-hand rear side of the direction of travel).
  • Page 55 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s Note When: Special Description Qty. Instructions Removing Installing Bolt Torque: 90 Nm (65 ft lb) Flywheel Stud M 6 x 16 see page 13 - 24...
  • Page 56 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 Note When: Special Description Qty. Instructions Removing Installing Crankcase lower Clean sealing see page 13.21 section surface and remove grease in area of...
  • Page 57 E n g i n e / C r a n k c a s e, P i s t o n s DISASSEMBLlNG AND ASSEMBLlNG CRANKCASE AND CRANKSHAFT SINCE 1985/2 MODELS M a i n B e a r i n g N o . 1 M a i n B e a r i n g s N o .
  • Page 58 Engine, Crankshaft, Pistons Notes on assembly Mount the cover of the centrifugal oil compartment in the upper part of the crankcase. Model 89, 2.7 l M 44/11/12 Note It is not usually necessary to remove the cover when overhauling an engine. Should this be necessary, however, always heat the screw area with a hot-air blower.
  • Page 59 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s CHECKING CRANKSHAFT BEARING CLEARANCE The "Plastigage" method is a simple way of checking bearing clearance. Plastigage is available in three different sizes for measuring ranges from 0.025 to 0.23 mm.
  • Page 60 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 CODES OF CRANKCASE UPPER AND LOWER SECTIONS AS WELL AS BALANCE SHAFT COVER 1. Crankcase upper and lower sections as well as the balance shaft cover are machined together and must always be installed together.

  • Page 61: Sealing Crankcase - Upper And Lower Sections 13 - 24 A

    9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s SEALING UPPER AND LOWER CRANKCASE SECTIONS N o t e Only Loctite 574 (orange) should be used as a sealant. Loctite 574 will dry only in conjunetion with metal and exelusion of air.

  • Page 62: Installing Upper And Lower Crankcase Sections

    E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 INSTALLlNG UPPER AND LOWER CRANKCASE SECTIONS 1. Coat lower crankcase section with Loctite 574 areas of oil intake and sealing surface in areas flywheel 2.
  • Page 63 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s INSTALLlNG CRANKSHAFT OIL SEAL (FLYWHEEL END) 1. Lubricate sealing lip with oil and slide oil seal over Special Tool 9203 on to crankshaft.
  • Page 64 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 REMOVING AND INSTALLlNG FLYWHEEL R e m o v i n g Mount Special Tool 9130 on flywheel with two hex. head bolts and loosen socket head bolts.
  • Page 65 Engine, Crankshaft, Pistons Notes on assembly Aligning the upper and lower parts of the crankcase. Note When assembling, make sure that there is no offset between the crankcase halves on the facing surface (on the oil pump side). 1. Using a plastic hammer, align the slightly tightened lower part of the crankcase (tightening torque 10 - 20 Nm) with the upper part of the crankcase.
  • Page 66 Engine, Crankshaft, Pistons Flywheel, removing and installing Removing Fasten bracket Special Tool 9130 to the flywheel with two hexagon head screws and undo the screws with internal serrations Installing Tighten the screws with internal serrations in 2 stages. 1st stage 40 Nm 2nd stage 90 Nm...

  • Page 67: Refacing The Flywheel

    Engine, Crankshaft, Pistons Refacing the flywheel If severe score or burning marks are evident on the flywheel, the clutch disc mating surtace on the flywheel maybe refaced on a lathe. Remove as little material as possible. Wear limit for flywheel thickness 11.8 mm. 728/13 1 Wear limit 11.8 mm 2 Remove as little material as possible...
  • Page 68 9 4 4 13 - 26b Blank Page...
  • Page 69 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s REPLACING STUD (REFERENCE MARK SENSOR) 1. Heat stud locally to about 200 ° C (400 ° F) to unseal loctite 270.

  • Page 70: Setting Crankshaft To Tdc, Cylinder

    E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 SETTING CRANKSHAFT TO TDC IN CYLINDER NO. 1 C r a n k s h a f t P o s i t i o n C r a n k s h a f t P o s i t i o n (E n g i n e I n s t a l l e d) (E n g i n e R e m o v e d)
  • Page 71 Engine / Crankshaft, Pistons Checking pistons and cylinder bores Motortype M 44.01...10 (2,5 l) Repair Stage Piston Ø Piston Ø Cylinder bore dia. tolerance group (mm) (mm) (mm) code Fa. Mahle Fa. Kolbenschmidt Standard size 99,980 99,980 100,000 99,990 +- 0,005 99,990 +- 0,007 100,010+- 0,005 100,000...
  • Page 72 Engine, Crankshaft, Pistons Pistons, disassembling and assembling con rods 13 - 32 Pistons, disassembling and assembling con rods 13 - 28 USA Printed in Germany - XIX, 1989...
  • Page 73 Engine / Crankcase, Pistons Note when: Description Qty. Removing Installing Connecting rod nut Replace, tighten to specified torque. Lubricate threads and bearing surface Connecting rod cap Pay attention to pair numbers Lower bearing Always renew worn shell half bearing shells Circlip Pry out Position correctly...
  • Page 74 Engine / Crankcase, Pistons Note when: Description Qty. Removing Installing Upper conrod Always renew worn bearing shell half bearing shells Connecting rod with conrod bolts Upper crankcase Check cylinder bores section after mounting lower crankcase section and tightening bolts to specified torque PISTON SURVEY Europe and Rest of World...
  • Page 75 E n g i n e / C r a n k c a s e, P i s t o n s INSTALLING PISTON AND CONNECTING ROD C o n n e c t i n g R o d The material of connecting rods was changed since February, 1984.

  • Page 76: Checking Pistons And Cylinder Bore 13 - 34 A

    Engine / Crankshaft, Pistons Pistons from Model 89 onward Engine M 44. 11/12 (2,7 l) worldwide Compression ratio: 10.9 : 1 Nominal Ø 104.00 mm The installation position is indicated by an arrow pointing towards the pulley. Checking pistons and cylinder bore Engine type M 44.11/12 (2,7 l) Repair size Piston Ø...
  • Page 77 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Bolt Coat threads with M 10 x 35 Loctite 574 Torque: 45 Nm.
  • Page 78 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 Note when: Special Description Qty. Instruction Removing Installing Spacer Gasket Replace and position correctly O-ring Replace and give light coat...
  • Page 79 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Upper compensating shaft End ring Seal Replace Bearing shell Position...
  • Page 80 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 Note when: Special Description Qty. Instruction Removing Installing Lower bearing Housing Shaft seal Replace and 30 x 48 lubricate sealing lip with oil...
  • Page 81 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s TIGHTENING PROCEDURES FOR CRANKCASE UPPER SECTION ON BALANCE SHAFT HOUSING N o t e Crankcase upper section and balance shaft housing must be aligned with each other as described below.
  • Page 82 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 TIGHTENING SPECIFICATIONS: Bolts 8 Nm (6 ft Ib) Nuts on studs 2 steps: 1st step 15 Nm(11 ft lb) 2nd step 30 Nm (22 ft lb)
  • Page 83 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s INSTALLlNG DRIVE GEARS OF BALANCE SHAFTS N o t e Drive shafts are identical parts. I n s t a l l i n g D r i v e G e a r o f U p p e r M o u n t i n g D r i v e G e a r B a l a n c e S h a f t...
  • Page 84 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 DISASSEMBLlNG AND ASSEMBLlNG BALANCE SHAFT DRIVE 13 - 42 Disassembling and Assembling Balance Shaft Drive Printed in Germany...
  • Page 85 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s DISASSEMBLlNG AND ASSEMBLlNG COMPENSATING SHAFT DRIVE SINCE 1985/2 MODELS C o m p e n s a t i n g S h a f t s w i t h S e p a r a t e B e a r i n g B r i d g e s - V, 1985 13 - 44a Disassembling and Assembling...
  • Page 86 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Bolt Coat threads M 10 x 35 with Loctite 574, torque: 45 Nm, hold with Special...
  • Page 87 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Washer A 8.4 Upper bearing housing Polyester seal Replace, check for correct fit.
  • Page 88 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Seal Replace, install in bearing bridge take-up bore with grease. Nut M 8 Torque: 30+ 3 Nm...
  • Page 89 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Woodruff key Shaft real Replace, lubri- 30 x 48 cate sealing lip with oil.
  • Page 90 E n g i n e / C r a n k c a s e, P i s t o n s INSTALLlNG BEARING BRIDGES OF COMPENSATING SHAFTS 1985/2 MODELS Crankcase upper and lower sections as well In addition, the bearing bridges are stamped as bearing bridges of compensating shafts with 1 and 2.
  • Page 91 Engine / Crankshaft, Pistons Note The bearing bridge for the left balance shaft has on oil feed bore for the exhaust turbo- charger. Before installing the balance shaft, it is vital to ascertain that the seal ring is in posi- tion in the take-up bore of the bearing bridge (use grease).
  • Page 92 Engine/Crankshaft, Pistons NOTES ON ASSEMBLY '85 MODELS ONWARD ENGINE TYPE M 44.05/06/07/08 TORQUING PROCEDURE, CRANKCASE UPPER HALF - COMPENSATING-SHAFT COVER Note: When aligning crankcase upper halt and compensating-shaft cover, proceed as follows: 1. Tighten all hex bolts by hand 2. Install bearing housing with O-ring lightly oiled but without mounting bolts.
  • Page 93 Engine/Crankshaft, Pistons NOTES ON ASSEMBLY '87 MODELS ONWARD ENGINE TYPE M 44.40/05/06/07/08 TORQUING PROCEDURE, UPPER CRANKCASE HALF/COMPENSATING SHAFT COVER BOLTS (with integrated bearing bridge) Note: It is imperative to align upper half of crankcase and compensating-shaft cover as follows: 1. Tighten all hex bolts by hand. 2.
  • Page 94 9 4 4 13 - 46 Blank Page...
  • Page 95 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s Note when: Special Description Qty. Instruction Removing Installing Nut M 10 Washer A 10.5 Roller or roller Check with slot...
  • Page 96 Engine / Crankshaft, Pistons Note when: Description Qty. Removing Installing Washer Position correctly Collar Position correctly Balance shaft Check movement on drive gear seat of balance shaft Woodruff key Balance shaft Check movement on drive gear seat of balance shaft Woodruff key Torque: 8 Nm Bolt...
  • Page 97 9 4 4 Engine / Crankshaft, Pistons Note when: Description Qty. Removing Installing Gear for camshaft Belt collar faces drive compensating shaft drive gear Woodruff key Thrust washer Seal Replace ASSEMBLY NOTES ON SECURING THE PULLEY The pulley (A) without recess must only be installed for old crankshafts without extended journal for accom- modation of the serve pump drive.
  • Page 98 E n g i n e / C r a n k c a s e, P i s t o n s 9 4 4 INSTALLING DRIVE GEARS OF BALANCE SHAFTS ( S i n c e 1 9 8 4 M o d e l s ) N o t e : Groove code "U"...
  • Page 99 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s 4. Tighten bolt while holding with Special 2. Push drive gear without a groove code on Tool 9200.
  • Page 100 9 4 4 13 - 52 Blank Page...
  • Page 101 9 4 4 E n g i n e / C r a n k c a s e, P i s t o n s MACHINING CYLINDER BORES IN UPPER CRANKCASE SECTION The upper crankcase section is an aluminum alloy product and contains minute particles of pure silicium.
  • Page 102 E n g i n e / C r a n k c a s e, P i s t o n s PROCEDURES It is absolutely Tightening Procedures Torque in Nm Threads necessary to bolt the upper and lower M 12 x 1.5 3 steps: step 1...
  • Page 103 E n g i n e / C r a n k c a s e, P i s t o n s H o n i n g P r o c e d u r e s Perform all honing and lapping jobs w i t h o u t the upper dressing guide shoe. The protrusion of the bronze bar on main guide shoe no.
  • Page 104 E n g i n e / C r a n k c a s e, P i s t o n s Machining Cylinder Bores with SUNNEN 10/CV 616 Machine. 1. Roughing 2. Dressing 3. Polishing 4. Lapping to Dia to Dia.
  • Page 105 E n g i n e / C r a n k c a s e, P i s t o n s A chamfer of 0.5 mm x 30° has to be machined on the upper cylinder wall of machined cylinder bores after finishing the honing procedures.
  • Page 106 9 4 4 15 - 0 Blank Page...
  • Page 107 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s TOOLS Description Special Tool Remarks Belt tightness tester 9201 Adjusting gauge for roller 9207 with slot Printed in Germany...
  • Page 108 15 - 2 Blank Page...
  • Page 109 E n g i n e / C y l i n d e r H e a d, V a l v e s CHECKING AND ADJUSTING TIGHTNESS OF CAMSHAFT DRIVE BELT N o t e The tightness of the drive belt must only be checked and adjusted on a cold engine (room temperature).
  • Page 110 E n g i n e / C y l i n d e r H e a d, V a l v e s A d j u s t i n g V a l u e : 6.
  • Page 111 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s INSTALLlNG CAMSHAFT DRIVE BELT AND ADJUSTING TIMING 1. Turn engine crankshaft to TDC for cylinder no. 3.
  • Page 112 9 4 4 15 - 6 Blank Page...
  • Page 113 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s REMOVING AND INSTALLlNG CYLINDER HEAD R e m o v i n g The cylinder head can be taken off without removing the engine.
  • Page 114 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 10. Relax belt tension and pull camshaft belt off 14. Unscrew aluminum plugs, coolant line and of camshaft sprocket.
  • Page 115 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s 16. Unscrew bolt of intake brace. 17. Remove intake distributor by dismantling 19.
  • Page 116 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 I n s t a l l i n g A. Preloading Cylinder Head Gasket 1.
  • Page 117 Engine, Cylinder Head, Valve Drive Installation instructions Tightening torque specifications for cylinder head as from Model 82 Engine type M44. 01... 10 Applicable in conjunction with 12 mm high nut and new washer 1st stage 20 Nm 2nd stage 90° torque angle 3rd stage 90°...
  • Page 118 9 4 4 15 - 10b Blank Page...
  • Page 119 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s TOOLS Description Special Tool Remarks Wrench socket 9133 Spark plug wrench Standard Valve spring compressor US 1020 with US 1020/1 or...
  • Page 120 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 DISASSEMBLING AND ASSEMBLING VALVE DRIVE 15 - 12 Disassembling and Assembling Valve Drive Printed in Germany...
  • Page 121 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s Note when: Special Description Qty. Instruction Removing Installing Gasket Replace Gasket Replace Spark plug Torque: 25 - 30 Nm (18 -22...
  • Page 122 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 Note when: Special Description Qty. Instruction Removing Installing Washer Rounded surface faces up Cylinder head Cylinder head Always replace...
  • Page 123 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s Note when: Special Description Qty. Instruction Removing Installing Dowel pin Plug Seal Printed in Germany Disassembling and Assembling Valve Drive 15 - 15...
  • Page 124 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 DISASSEMBLlNG AND ASSEMBLlNG VALVE TRAIN I n s t a l l i n g C y l i n d e r H e a d N o t e The cylinder head can be removed from an engine in...
  • Page 125 Engine / Cylinder Head, Valve Drive Grinding Cylinder Head Maling Surface Checking Cylinder Head for Distortion Note Check mating surface of cylinder head for dis- When refacing the sealing surface on the com- tortion with a feeler gauge blade and straight- bustion chamber side, always check the seal- edge.
  • Page 126 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 REPLACING VALVE GUIDES TOOLS Description Special Tool Remarks Pressing out base 9220 Driver 9224 Pressure pad...
  • Page 127 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s REPLACING VALVE GUIDES 1. Clean and inspect cylinder head. Cylinder heads, the valve seats or sealing surfaces of which can no longer be machined, are not suitable for replacement of valve guides.
  • Page 128 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 N o t e : 6. Grind off a service valve guide, Part No. If appropriate workshop equipment 928 104 328 52 (13.27 mm outside dia- is available, cool valve guides in liquid air and...
  • Page 129 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s 10. Valve seat inserts must also be machined after replacing valve guides. Grinding in valves with grinding paste would not be sufficient.
  • Page 130 9 4 4 15 - 16 f Blank Page...
  • Page 131 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s R e m o v i n g a n d I n s t a l l i n g C h e c k i n g I n s t a l i e d L e n g t h V a l v e S p r i n g s o f V a l v e S p r i n g s...
  • Page 132 Engine, Cylinder Head, Valve Drive Valve sizes Engine type M 44.01 - 10 Dimension Intake Exhaust 45.00 mm 40.00 mm 8.97 mm 8.95 mm 1. Slide the plastic assembly sleeve, e.g. from 111.50 mm 111.90 mm the spare parts valve stem seal kit for Type 45°...
  • Page 133 Engine / Cylinder Head, Valve Drive Machining Valve Seats Note Before refacing the valve seats, check dimen- The amount ot metal removed should be sion "A" to avoid carrying out work that may limited to .an absolute minimum, to prevent be unnecessary since the wear limit has premature wear of part.
  • Page 134 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 DISASSEMBLlNG AND ASSEMBLlNG VALVE DRIVE (CAMSHAFT HOUSING) 15 - 20 Disassembling and Assembling Valve Drive (Camshaft Housing) Printed in Germany...
  • Page 135 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s Note when: Special Description Qty. Instructions Removing Installing Distributor cap Bolt Lock with M 4 x 6 Loctite 221 Distributor rotor...
  • Page 136 E n g i n e / C y l i n d e r H e a d, V a l v e s 9 4 4 Note when: Special Description Qty. Instructions Removing Installing Woodruff key 4 x 4 Bolt M 6 x 35 Washer...
  • Page 137 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s Note when: Special Description Qty. Instructions Removing Installing Plug M 18 x 1.5 Seal A 18 x 22 Bolt with non-...
  • Page 138 Engine / Cylinder Head, Valves INSTALLING SHAFT SEAL ON CAMSHAFT FITTING DISTRIBUTOR ROTOR BEARING COVER Note Note Distributor rotor, connector and hex Shaft seal is an identical part with socket bolt are adhered to each shaft seal for upper balance shaft. other.
  • Page 139 9 4 4 E n g i n e / C y l i n d e r H e a d, V a l v e s DISASSEMBLlNG AND ASSEMBLlNG CAMSHAFT DRIVE Printed in Germany Disassembling and Assembling Camshaft Drive 15 - 25...
  • Page 140 E n g i n e / C y l i n d e r H e a d, V a l v e s Note when: Special Description Qty. Instructions Removing Installing Hexagon head bolt M 10 x 35 Washer A 10.5 Roller Check...
  • Page 141 Engine / Cylinder Head, Valve Drive Disassembling and assembling camshaft drive Installing camshaft housing Note 1. It is essential that cylinder no. 1 be at TDC and the camshaft sprocket aligned with mark to install a complete camshaft hous- ing, since otherwise valves could be dam- aged.
  • Page 142 Engine, Cylinder Head, Valve Drive Camshaft- Worldwide Installation Engine type 944 As from Model 82 M 44. 01 - 0.4 M 44. 05 - 10 M 44. 11/12 (2.7 l) Camshaft 944.105.155.05 944.105.155.09 944.105.155.10 Identification code between exhaust and intake cams on cylinder 2 155.05 155.09...
  • Page 143 Engine / Cylinder Head, Valve Drive Adjusting camshaft belt with mechanical belt tensioner Model 87 onward Engine type 44.40/41/05-12 Note The belt must only be checked and adjusted 2. The TDC marking on the flywheel must also when the engine is Cold (room temperature). be in line.
  • Page 144 Engine, Cylinder Head, Valve Drive Note 4. Check mobility af the tensioning roller lever with thumb pressure an the toothed side of Idle-pulley width af the belt tensioner the drive belt between camshaft pulley and deflection roller (water pump). 16-VALVE 2-VALVE 5.
  • Page 145 9 4 4 E n g i n e / L u b r i c a t i o n REPLACING ENGINE OIL AND ENGINE FILTER Requirements: Engine at operating temperature. 1. Unscrew oil drain plug on oil pan and drain 3.
  • Page 146 9 4 4 17 - 2 Blank Page...
  • Page 147 9 4 4 E n g i n e / L u b r i c a t i o n TOOLS Description Special Tool Remarks Pressure pad 10 - 203 Only use outer part Oil filter wrench 9204 Printed in Germany Tools 17 - 3...
  • Page 148 E n g i n e / L u b r i c a t i o n 9 4 4 17 - 4 Removing and Installing Lubricating System Components I, 1982 - Printed in Germany...
  • Page 149 9 4 4 E n g i n e / L u b r i c a t i o n Note when: Special Description Qty. InstructionS Removing Installing Oil dipstick Guide tube Install with Loctite 638 Plug Torque: 50 Nm M 20 x 1.5 (36 ft lb) Seal...
  • Page 150 E n g i n e / L u b r i c a t i o n 9 4 4 Note when: Special Description Qty. Instructions Removing Installing Oil intake pipe Seal Always replace Bolt M 8 x 50 Oil drain pipe O-ring Camshaft drive gear...
  • Page 151 9 4 4 E n g i n e / L u b r i c a t i o n Note when: Special Description Qty. Instructions Removing Installing Seal Replace Plug for pressure Torque: 45 Nm relief valve M 20 x 1.5 Seal Replace Spring...
  • Page 152 E n g i n e / L u b r i c a t i o n 9 4 4 Note when: Special Description Qty. Instructions Removing Installing Rubber ring Replace and paste on crankcase upper section with Loctite 638 Seal Replace and lubricate lightly...
  • Page 153 9 4 4 E n g i n e / L u b r i c a t i o n REMOVING AND INSTALLlNG PARTS OF LUBRICATING SYSTEM Remove housing insert. Apply toothed sleeve on sealing lip and seal simultaneously and drive in with Special Tool 10 - 203 (only outer part).
  • Page 154 E n g i n e / L u b r i c a t i o n 9 4 4 DISASSEMBLlNG AND ASSEMBLlNG OIL PUMP 17 - 10 Disassembling and Assembling Oil Pump Printed in Germany...
  • Page 155 9 4 4 E n g i n e / L u b r i c a t i o n Note when: Special Description Qty. Instructions Removing Installing Shaft seal Replace, lubricate lip 38 x 55 x 7 with oil, install seal together with toothed sleeve and drive in with tool 10-203 (only outer...
  • Page 156 E n g i n e / L u b r i c a t i o n 9 4 4 REMOVING AND INSTALLlNG BUSHING FOR OIL PRESSURE RELIEF VALVE R e m o v i n g Remove damaged bushing by unscrewing with grip 2.
  • Page 157 9 4 4 E n g i n e / L u b r i c a t i o n TIGHTENING PROCEDURES FOR OIL PAN MOUNTING BOLTS 1st step: install bolts 2nd step: 4 Nm (3 ft lb) 3rd step: 8 Nm (6 ft lb) T i g h t e n i n g s e q u e n c e: clockwise from inside to outside.
  • Page 158 E n g i n e / L u b r i c a t i o n TOOLS Description Special Tool Remarks Oil pressure tester VW 1342 17 - 14 Tools - Checking Oil Pressure V, 1985 - Printed in Germany...
  • Page 159 E n g i n e / L u b r i c a t i o n CHECKING OIL PRESSURE 1. Remove oil pressure transmitter and screw oil pressure tester VW 1342 together with M 10 x 1 adapter, Part No. 999.105.013.02, and M 10 x 1/M 18 x 1.5 adapter, Part No.
  • Page 160 Engine / Lubrication REMOVING AND INSTALLING OIL CHECK Cut thread using M 10 threaded blind VALVE IN CYLINDER HEAD hole drill. Turn out valve using an M 10 bolt and a spacer sleeve. Note When overhauling engines, only the oil check valves from the 944 turbo engine, Part No.
  • Page 161 Engine, Lubrication Cleaning the entire engine oil system after an engine fallure (bearing failure) Note The following parts must be cleaned tho- roughly and/or rinsedthrough repeatedly: This cleaning sequence is only intended to give pointers as to whereyou may find chips. Note: The actual amount of work involved will depend oneach individual case of engine...
  • Page 162 Engine, Lubrication Cleaning the main oil duct in the crankcase Note Both sealing caps must be removed from the 2. Drive into a place with a plunger, crankcase for this procedure. e.g. VW 295. Removing Note 1. Drill a hole in the sealing cap The sealing cap must lie approx.
  • Page 163 Engine, Lubrication Removing and instaIling the pressure reducing valve Engine type M 44. 11/12 (2.7 l) 81/17 1 - Fillister head screw 2 - Gasket 3 - Pressure reducing valve 4 - O-ring 1. Remove the camshaft housing, undo and remove the fillister head screw.
  • Page 164 9 4 4 19 - 00 Blank Page...
  • Page 165 9 4 4 E n g i n e / C o o l i n g REPLACING COOLANT AND BLEEDING COOLING SYSTEM 1. Drain coolant (only from cold engine). Set 2. Install drain plugs. heater Tightening torque: control lever to "warm" position and unscrew Radiator 5 Nm (43 in.
  • Page 166 E n g i n e / C o o l i n g 9 4 4 REPLACING COOLANT AND BLEEDING COOLING SYSTEM (With New Bleeder Adapter) 1. Drain coolant (only when engine is cold). 2. Screw in drain plugs. Set heater lever at "warm"...
  • Page 167 9 4 4 E n g i n e / C o o l i n g CHECKING THERMOSTAT CHECKING COOLlNG AND HEATING SYSTEM FOR LEAKS Place thermostat in a water bath. 1. Inspect visuillly for leaks. Begins to = approx. 83° +- 2°C (181° +- open 3.5°...
  • Page 168 E n g i n e / C o o l i n g 9 4 4 REMOVING AND INSTALLlNG PARTS OF COOLING SYSTEM 19 - 4 Removing and Installing Parts of Cooling System V, 1985 - Printed in Germany...
  • Page 169 E n g i n e / C o o l i n g Note when: Special Description Qty. Instructions Removing Installing Hexagon head bolt M 8 x 25 Washer Housing for oil/ water cooler see P. 19-6 Profile gasket with Always replace vulcanized seals Oil/water cooler...
  • Page 170 E n g i n e / C o o l i n g Note when: Special Description Qty. Instructions Removing Installing Soeket head screw M 6 x 70 Washer Soeket head screw M 6 x 35 Washer Bracket Hexagon out M 6 Washer Water pump, assembly...
  • Page 171 Engine/Cooling REMOVING AND INSTALLING PARTS OF COOLING SYSTEM, 187 MODELS ONWARD Printed in Germany - XIII, 1987 19 - 6 a Removing and Installing Parts of Cooling System, '87 Models Onward...
  • Page 172 Engine/Cooling Note when: Description Qty. Removing Installing Oil pressure- relief valve Sealing ring Replace Round-section Replace sealing ring Hex bolt M8 x 25 Washer Housing for oil-water heat exchanger Special- Replace section gasket Oil-water heat Place in housing exchanger before assembly Shim (alum- inum, 0.5 mm) Plastic washer...
  • Page 173 Engine, Cooling Notes on assembly A modified oil/water heat exchanger housing has been installed as from Model 87. Part No.: 944 107 149 06. The lower part of the hous- ing's heat-exchanger mounting has been mod- ified. Always use the new housingwhen over- hauling engines in earlier models.
  • Page 174 19 - 6 d Blank Page...
  • Page 175 9 4 4 E n g i n e / C o o l i n g REMOVING AND INSTALLING RADIATOR R e m o v i n g 1. Unscrew cap on expansion tank. If engine is hot, first turn cap to first catch and let pressure escape.
  • Page 176 E n g i n e / C o o l i n g 9 4 4 9. Loosen two straps on coolant feed hose and two clamps. 10. Disconnect vent hose, tilting radiator back slightly for this purpose. 11. Remove radiator from below. I n s t a l l i n g 1.
  • Page 177 Engine/Cooling REMOVING AND INSTALLING TEMPERATURE SWITCH Removing 1. Remove air cleaner complete with air flow sensor. 2. Remove splash guard. 3. Remove fan housing. 4. Drain approx. 2 liters of coolant. Installing 5. Unscrew temperature switch Torques: (wrench size across flats: - with plastic thread: 20 Nm 30 mm).
  • Page 178 Engine/Cooling 2. Connect testing buller on flat male plugs of switch. Place switch in warm water bath. Buzzer must sound off at temperature of about 92° C and stop buzzing when temperature drops to approx. 87°C. 19 - 10 Removing and Installing Temperature XVI, 1987 - Printed in Germany Switch, Checking Temperature Switch...
  • Page 179 Engine, Cooling Cleaning the cooling system after 7. Fill the cooling system with new cold cleaning agent and fresh, warm water and water has been contaminated with clean again. Rinsing Cleaning Then rinse out with clear, warm water. Repeat 1. Drain the coolant (drain plugs on cooler and the rinsing procedure until there is no evidence crankcase).
  • Page 180 9 4 4 20 - 00 Blank Page...
  • Page 181 9 4 4 F u e l S u p p l y REPLACING FUEL FILTER CHECKING FUEL AND INJECTION LINES FOR LEAKS AND TIGHTNESS 1. Pinch fuel teed line shut with a standard hose 1. Inspect visually for leaks. clamp.
  • Page 182 F u e l S u p p l y 9 4 4 CHECKING FUEL PUMP DELIVERY RATE Requirements: 4. Bridge terminals 30 and 87 b with a piece of wire. Fuel pump should new run. Fuel filter and power supply in perfect condition. 1.
  • Page 183 F u e l S u p p l y REMOVING AND INSTALLlNG FUEL PUMP N o t e Conform with local safety regulations for working on fuel systems. R e m o v i n g 1. Disconnect battery ground lead. 2.
  • Page 184 F u e l S u p p l y REMOVING AND INSTALLING FUEL TANK R e m o v i n g 1. Disconnect battery ground lead. 2. Draw out fuel. 6. Unscrew fuel pipe from pump on fuel filter, while counterholding with a second wrench.
  • Page 185 9 4 4 F u e l S u p p l y 10. Remove trunk floor cover. Take off cover for fuel level transmitter. Pull off fuel return hose and electric plug on level transmitter. 11. Remove right rear side window. Loosen and take off side trim panel carefully.
  • Page 186 Fuel Supply 2. Insert both inner sealing hoses (with bead) into connecting hose. Coat inner sealing hoses with assembly oil, e.g. Capella WE32 or Omnis 32. If necessary. Contifix tire mounting paste can also be used. 3. Slide preassembled connecting hose onto tank neck or filler neck, paying attention to correct seating of inner sealing hoses...
  • Page 187 F u e l S u p p l y FUEL SYSTEM LINE ROUTING - 1985/2 MODELS 1 - Fuel pump A - Air flow sensor 2 - Fuel filter B - Throttle housing 3 - Pressure damper C - Ejection pump 4 - Pressure regulator D - Intake pipe 5 - Injection line...
  • Page 188 F u e l S u p p l y ACTIVE CARBON TANK FOR POLLUTANT-FREE FUEL TANK VENTING (LAYOUT) 1 - Fuel tank 7 - Temperature valve 2 - Expansion tank 8 - Shutoff valve 3 - Vent line 9 - Vacuum line 4 - Safety valve 10 - Throttle valve 5 - Active carbon tank...
  • Page 189 F u e l S u p p l y REMOVING AND INSTALLING FUEL EXPANSION TANK (Since July, 1983) N o t e I n s t a l l i n g Conform with local safety regulations for 1. Check for perfect seating of hoses and working on fuel systems.
  • Page 190 F u e l S u p p l y CHECKING FUEL EXPANSION TANK 1. Check fuel expansion tank after removal. 2. Plug venting connection. 3. Connect manual vacuum pump 9160 on drawing-off connection. 4. The pressure gage reading should not drop with sufficient vacuum (approx.
  • Page 191 Fuel Supply REMOVING AND INSTALLING FUEL LEVEL SENDER TOOLS Description Special Tool Remarks Pin wrench 9190 Printed in Germany - XIII, 1987 20 - 11 Removing and Installing Fuel Level Sender...
  • Page 192 Fuel Supply REMOVING AND INSTALLING FUEL LEVEL SENDER Note: Installing Observe safety precautions for 1. Always use a new seal. Coat working on the fuel system. Do not thread and contact face of union remove sender when tank is full. nut with Optimoly TA.
  • Page 193 9 4 4 A F C F u e l S y s t e m REPLACING AIR FILTER CARTRIDGE CHECKING INTAKE AIR GUIDE AND CRANK CASE VENT HOSES FOR LEAKS AND TIGHT 1. Check all hoses of intake system for correct fit. 1.
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  • Page 195 E l e c t r o n i c F u e l I n j e c t i o n TESTING AND ADJUSTING SPECIFICATIONS Test Specification Remarks Electric fuel pump Delivery rate at least 850 cc/30 sec. Fuel pressure (engine stopped) Fuel pump bridged...
  • Page 196 L - J e t r o n i c F u e l I n j e c t i o n TESTING AND ADJUSTING SPECIFICATIONS MODELS FROM 85/2 AND 924 S Test Specification Remarks Electric fuel pump Delivery rate min.
  • Page 197 L - J e t r o n i c F u e l I n j e c t i o n CHECKING FUEL PRESSURE TOOLS Description Special Tool Remarks Pressure gage with hose P 378 or VW 1318 from pressure tester - V, 1985 Checking Fuel Pressure...
  • Page 198 L - J e t r o n i c F u e l I n j e c t i o n 9 4 4 CHECKING FUEL PRESSURE 1. Unlock and fold up cover. Unscrew and 4. Bridge terminals 30 and 87b with a remove capped out on test connection pjece of wire.
  • Page 199 9 4 4 E l e c t r o n i c F u e l I n j e c t i o n MAKING IDLE ADJUSTMENTS - USA TOOLS Description Special Tool Remarks Oil temperature tester 9122 Testing sensor 9122/1 Exhaust gas test line...
  • Page 200 E l e c t r o n i c F u e l I n j e c t i o n 9 4 4 ADJUSTING IDLE SPEED/CO - USA N o t e 3. Connect oil temperature tester 9122. Adjust test A d j u s t i n g R e q u i r e m e n t s: sensor to length of oil dipstick.
  • Page 201 9 4 4 E l e c t r o n i c F u e l I n j e c t i o n 6. Pull off rubber cap on plug for oxygen sensor and detach plug. 7. Check CO level. If CO level is not the specified value, correct the setting on the air flow sensor.
  • Page 202 E l e c t r o n i c F u e l I n j e c t i o n 9 4 4 CORRECTING CO SETTING ON AIR FLOW SENSOR - USA N o t e If CO level is not as specified, remove plug from 3.
  • Page 203 9 4 4 E l e c t r o n i c F u e l I n j e c t i o n REMOVING AND INSTALLING FUEL INJECTORS Note when: Special Description Qty. Instructions Removing Installing Fuel distribution tube Retaining clamp Check for correct fit...
  • Page 204 F u e l S y s t e m 9 4 4 INSTALLING FUEL INJECTORS 1. Coat bottom seal with a silicone grease, e. g. Bosch Ft 2 v 2 and press fuel injectors into bores of intake manifold separately. 2.
  • Page 205 Fuel System - L-Jetronic / Control Removing and Installing Air Flow Sensor Removing 1. Loosen hose clamp on intake air cowl, dis- connect plug on air flow sensor, unscrew phillips head screws on upper air cleaner section and take out air filter cartridge. 7885 2.
  • Page 206 9 4 4 24 - 12b Blank Page...
  • Page 207 9 4 4 E l e c t r o n i c F u e l I n j e c t i o n REMOVING AND INSTALLING FUEL INJECTORS Note when: Special Description Qty. Instructions Removing Installing Fuel distribution tube Retaining clamp Check for correct fit...
  • Page 208 L-Jetronic, Fuel System InstaIling Fuel injectors Installing Instructions 1. Apply a thin coat of oil to lower seal and press fuel injectors into bores of intake manifold separately. 2. Then push fuel distributor pipe on fuel injec- tars and mount retaining clamps. 24 - 14 Installing Fuel Injectors Printed in Germany - XXV, 1992...
  • Page 209 L-Jetronic Fuel Injection ADJUSTING IDLE SPEED MODELS FROM 85/2 AND 924 S T o o l s Description Specia1 Tool Remarks Oil temperature 9122 + 9122/2 tester with sensor Locally made lead Printed in Germany - VII, 1986 24 - 17 Adjusting Idle Speed, Models from 85/2 and 924S...
  • Page 210 L - J e t r o n i c F u e l I n j e c t i o n ADJUSTING IDLE SPEED A d j u s t i n g R e q u i r e m e n t s Engine in perfect running condition.
  • Page 211 L - J e t r o n i c F u e l I n j e c t i o n b.) Check and adjust engine idle speed with VAG tester 1367. 5. Turn control screw (bypass) on throttle housing until specified speed of 840 +- 20 rpm is reached.
  • Page 212 L-Jetronic Fuel Injection ADJUSTING IDLE SPEED - USA - AND CATALYTIC CONVERTER CARS, MODELS FROM 85/2 AND 924 S T o o l s Description Special Tool Remarks Oil temperature 9122 + 9122/2 tester with sensor Exhaust sensor US 4492 Locally made lead 24 - 20 Adjusting Idle Speed-USA and...
  • Page 213 L - J e t r o n i c F u e l I n j e c t i o n ADJUSTING IDLE SPEED - USA and Catalytic Converter Cars Note: A d j u s t i n g R e q u i r e m e n t s Engine in perfect running condition.
  • Page 214 L - J e t r o n i c F u e l I n j e c t i o n CO level specification: 0.6 +- 0.2 % by vol. Turned clockwise = richer mixture. Turned anticlockwise = leaner mixture. N o t e If the CO level has to be corrected on the air flow sensor, remove the air flow sensor...
  • Page 215 L - J e t r o n i c F u e l I n j e c t i o n 9. Restore operation of idle speed filling control by removing locally made lead on diagnosis plug atter finishing adjustments.
  • Page 216 24 - 24 Blank Page...
  • Page 217 Air Flow Controlled Fuel Injection Testing and adjusting specifications Engine type M 44.11/12 (2.7 l) Test Specification Remarks Electric fuel pump Delivery rate at least 850 cm3 /30 s Fuel pressure (engine stationary) DME relay bypassed 3.8 +- 0.2 bar Control value at idle approx.
  • Page 218 Air Flow Controlled Fuel Injection Adjusting Idle speed and CO As from Model 89 Enginetype M 44. 11/12 (2.7 l) Note Carry out the working procedure ADJUSTING IDLE SPEED/CO as described on Pages 24-17 to 24-23. Vehicles without catalytic converter Idle speed = 840 +- 40 rpm = 0.5 - 1.5% (measured in the final exhaust pipe)
  • Page 219 Air Flow Controlled Fuel Injection Equipment table As from model 89 Engine type M 44 11/12 (2.7 l) Electric Fuel filter Fuel Fuel fuel pump pressure damper pressure regulator 944.608.102.06 928.110.253.00 944.110.201.04 944.110.198.06 Bosch No. Purolator No. Bosch No. Bosch No. 0580.464.042 506.883.901.5 0280.161.036...
  • Page 220 9 4 4 26 - 0 Blank Page...
  • Page 221 9 4 4 E x h a u s t S y s t e m CHECKING TIGHTNESS OF EXHAUST SYSTEM FLANGES 1. Check tightness of hexagon nuts on exhaust mani- fold/cylinder head. 2. Check tightness of hexagon nuts on exhaust mani- fold/primary muffler flange.
  • Page 222 E x h a u s t S y s t e m 9 4 4 REPLACING EXHAUST PIPE OR PRIMARY MUFFLER/ CATALYTIC CONVERTER Note when: Special Description Qty. Instructions Removing Installing Exhaust pipe Sleeve Primary muffler 26 - 2 Replacing Exhaust Pipe or Primary Muffler / III, 1983 - Printed in Germany...
  • Page 223 9 4 4 E x h a u s t S y s t e m REPLACING EXHAUST PIPE OR PRIMARY MUFFLER / CATALYTIC CONVERTER 1. Remove complete primary muffler or catalytic converter. Mark cutting point and saw off exhaust pipe (cutting plane perpendicular to pipe axis, dimensions in mm).
  • Page 224 9 4 4 27 - 0 Blank Page...
  • Page 225 9 4 4 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l AUTOMATIC CRUISE CONTROL (TEMPOSTAT) - III, 1983 Automatic Cruise Control (Tempostat) 27 - 1...
  • Page 226 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 9 4 4 AUTOMATIC CRUISE CONTROL (TEMPOSTAT) 27 - 2 Automatic Cruise Control (Tempostat) Printed in Germany...
  • Page 227 9 4 4 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l Note when: Special Description Qty.
  • Page 228 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 9 4 4 Note when: Special Description Qty.
  • Page 229 9 4 4 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l REMOVING AND INSTALLING CONTROL UNIT FOR CRUISE CONTROL 1.
  • Page 230 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 9 4 4 REMOVING AND INSTALLlNG CRUISE CONTROL SWITCH (STEERING COLUMN SWITCH) 1.
  • Page 231 9 4 4 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 6. Cruise control switch and turn signal 3.
  • Page 232 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 9 4 4 REMOVING AND INSTALLlNG CRUISE CONTROL CABLE 1.
  • Page 233 9 4 4 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l A d j u s t i n g 2.
  • Page 234 S t a r t e r , P o w e r S u p p l y , C r u i s e C o n t r o l 9 4 4 TROUBLESHOOTING CRUISE CONTROL First check the following points if automatic If a defect is not found while checking these cruise control malfunctions.
  • Page 235 Starter, Power Supply, Cruise Control TESTING MULTIPLE-PIN PLUG FOR CONTROL UNIT FOR CRUISE CONTROL WITH AN OHMMETER 1. With ignition off, pull 4. Connect tester to term. 12 and multiple-pin plug on control term. 4. unit. Reading = 0 volt Operate "ON/ACCELERATE"...
  • Page 236 Starter, Power Supply, Cruise Control 8. Connect tester to term.12 and 4. Connect tester to term. 2 and term. term.11 (Hall pulse generator) 4 (potentiometer +). transmitter. Reading = 2 to 4 kohm Turn left front wheel slowly by hand. Voltage must rise and drop from less than 1 V to greater 5.
  • Page 237 Starter, Power Supply, Tempostat AUTOMATIC CRUISE CONTROL (TEMPOSTAT) FROM 85/2 MODEL Printed in Germany - VII, 1986 27 - 13 Automatic Cruise Control (Tempostat)
  • Page 238 Starter, Power Supply, Tempostat AUTOMATIC CRUISE CONTROL (TEMPOSTAT) FROM 85/2 MODEL 27 - 14 Automatic Cruise Control Printed in Germany (Tempostat)
  • Page 239 Starter, Power Supply, Tempostat Description Qty. Note When: Removing Installing Hex - bolt M 6 x 25 Washer. Spacers Rubber grommet nut M 6 Bowden cable Plug holder Plug bolt M 6 x 10 Drive holder Drive holder Drive Nut M 6 Front end cable plug Instrument...
  • Page 240 Starter, Power Supply, Tempostat Description Qty. Note When: Removing Installing Lock washer Washer Roller Bushing Reverse- transfer lever Extension spring Bushing Accelerator lever Accelerator pedal Clutch switch Plug Rubber stop 27 - 16 Automatic Cruise Control Printed in Germany (Tempostat)
  • Page 241 Starter, Power Supply, Tempostat REMOVING AND INSTALLING REMOVING AND INSTALLING STEERING CONTROL UNIT FOR CRUISE CONTROL COLUMN SWITCH N o t e 1. Disconnect battery. The control unit is located on the left in the driver's side footwell 2. Pull off cover by hand. underneath the instrument panel.
  • Page 242 Starter, Power Supply, Tempostat 4. Remove buttons on heater control 6. Loosen but do not unsrew steering switch. Using a putty knife, care- column switch fastening screw. fully push down switch cover. Pull out steering column switch and disconnect plugs. Pull out four-pin plug of control switch from underneath the instrument panel and disconnect.
  • Page 243 Starter, Power Supply, Tempostat REMOVING AND INSTALLING DRIVE. 5. Unscrew mount on body and remove holder from drive. 1. Switch off ignition. 2. Open holder for multiple-pin plug and disconnect plug. 3. Press off cable retaining clip. 4. Unscrew lock nut on cable adjusting screw completely and disconnect cable.
  • Page 244 Starter, Power Supply, Tempostat REMOVING AND INSTALLING CLUTCH 3. Unsrew lock nut and remove SWITCH switch. N o t e A d u s t i n g Instead of the switch, cars with Adjust clutch switch so that the automatic transmission have a bridge.
  • Page 245 Starter, Power Supply, Tempostat CRUISE CONTROL TROUBLESHOOTING If no defect is found while checking these points, troubleshooting must be continued on the control unit In case of automatic cruise control multiple-pin plug. malfunctions, check the following points first: 1. Check cable for damage and correct adjustment.
  • Page 246 Starter, Power Supply, Tempostat PLUG ASSIGNMENT, CONTROL UNIT FOR Plug 1 CRUISE CONTROL 1. Speedometer signal 2. Brake lights 3. "Switch off" 4. Term. 15 5. Switch "Resume" 6. Switch "On/Accelerate" 7. Clutch switch 8. Term. 31 Plug 2 1. Clutch 2.
  • Page 247 Starter, Power Supply, Tempostat CHECKING MULTIPLE-PIN PLUGS 6. Connect tester to term.6 and term.8 OF CONTROL UNIT FOR CRUISE CONTROL Reading: 0 volt Operate switch to "0n/Accelerate" Reading: battery voltage" N o t e Check Plug 1 with a voltmeter and Plug 2 with an ohmmeter.
  • Page 248 Starter, Power Supply, Tempostat 9. Connect ohmmeter term. 1 and term. 2 on plug 2. Reading every 30 - 40 ohm 10. Connect tester to term. 4 and term. 7. Reading: 2 - 4 kohm 11. Connect testers term. 4 and term. 8 Reading: every 2 - 4 kohm 12.
  • Page 249 Starter, Power Supply, Cruise Control Removing and installing the alternator on vehicles with air-conditioning system Removing Installing Check the tension of the alternator's Poly-rib 1. Disconnect the battery from ground. belt and adjustaccording to Page 13 - 1. Tightening torque for the fastening screws 2.
  • Page 250 9 4 4 28 - 0 Blank Page...
  • Page 251 9 4 4 I g n i t i o n S y s t e m EQUIPMENT SURVEY I g n i t i o n C a i l Type/Model Version Remarks 944 602 115 00 Without ballast resistors Bosch No.
  • Page 252 I g n i t i o n S y s t e m 9 4 4 D M E C o n t r o l U n i t Type/Model Version Remarks 944 618 111 01 Bosch No. 0 261 200 015 S p a r k P l u g C a p s Type/Model...
  • Page 253 9 4 4 I g n i t i o n S y s t e m DANGERS ON ELECTRONIC IGNITION SYSTEMS The Type 944 is equipped with a digital engine electronic system (DME). In comparison to conventional systems the ignition power of DME is so high, that contact with current carrying parts while engine is running could be fatal.
  • Page 254 9 4 4 28 - 4 Blank Page...
  • Page 255 9 4 4 I g n i t i o n S y s t e m REMOVING AND INSTALLlNG DISTRIBUTOR CAP N o t e To facilitate installation work we recommend chan- ging a standard screwdriver into a locally made tool.
  • Page 256 9 4 4 28 - 6 Blank Page...
  • Page 257 9 4 4 I g n i t i o n S y s t e m REPLACING SPARK PLUGS 1. Pull off spark plug caps. 2. Unscrew spark plugs with a conventional wrench (e.g. Hazet No. 767-1). A spark plug wrench is pro- vided in the car's tools.
  • Page 258 I g n i t i o n S y s t e m 9 4 4 D M E ( D I G I T A L E N G I N E E L E C T R O N I C S ) 28 - 10 Printed in Germany...
  • Page 259 9 4 4 I g n i t i o n S y s t e m Description Qty. Note When: Special Instructions Removing Installing Multiple pin plug for Have plug engage DME control-unit firmly Screw B 4.8 x 18 Washer A 5.3 Altitude correction DME control-unit...
  • Page 260 I g n i t i o n S y s t e m 9 4 4 Description Qty. Note When: Special Instructions Removing Installing Ground wire on clutch bell housing Bolt M 6 x 12 Washer A 6.4 Eleetronic ground on engine block Distributor cap Bolt M 4 x 6...
  • Page 261 9 4 4 I g n i t i o n S y s t e m Description Qty. Note When: Special Instructions Removing Installing Bolt M 4 x 10 Washer A 4 Throttle switch Switching point < 1° throttle angle Temperature sensor Torque: 12 -15 Nm (9-11...
  • Page 262 I g n i t i o n S y s t e m 9 4 4 REMOVING AND INSTALLlNG SPEED AND REFERENCE MARK SENSORS R e m o v i n g I n s t a l l i n g 1.
  • Page 263 9 4 4 I g n i t i o n S y s t e m A d j u s t i n g w i t h E n g i n e R e m o v e d 1.
  • Page 264 I g n i t i o n S y s t e m 9 4 4 TROUBLESHOOTING DME T e s t e r s a n d T o o l s N o t e : Conform with the following safety measures to - Engine tester with oscilloscope, e.
  • Page 265 9 4 4 I g n i t i o n S y s t e m INSTALLATION OF DME COMPONENTS 1. Pressure regulator 2. Fuel distributor 3. Diaphragm damper 4. Ground terminals for DME 5. Speed and reference mark transmitters 6.
  • Page 266 I g n i t i o n S y s t e m 9 4 4 R e l a y f o r F u e l P u m p a n d P o w e r S u p p l y - D M E 28 - 18 Troubleshooting DME Printed in Germany...
  • Page 267 9 4 4 I g n i t i o n S y s t e m DME PLUG CONNECTIONS T o p V i e w o f 3 5 P i n P l u g T o p V i e w o f P l u g D i s c o n n e c t e d o n D M E D i s c o n n e c t e d o n T h r o t t l e C o n t r o l U n i t...
  • Page 268 I g n i t i o n S y s t e m 9 4 4 T o p V i e w o f 9 P i n R o u n d P l u g R e c e p t a c l e ( A b o v e B r a k e B o o s t e r ) N o t e : The fuel pump can be run by connecting battery on...
  • Page 269 9 4 4 I g n i t i o n S y s t e m Printed in Germany - I, 1982 Troubleshooting DME 28 - 21...
  • Page 270 I g n i t i o n S y s t e m 9 4 4 N o t e : 3. Check plug connections Iisted below carefully for tight fit, bent plug sleeves and corrosion. The test points should be performed in the given sequence, especially when the customer complaint concerns an engine which cannot be started or is hard to start.
  • Page 271 9 4 4 I g n i t i o n S y s t e m 3.3 Plug connection for air flow sensor. 3.6 Plug connection tor fuel injectors. 3.4 Plug connection for throttle switch. 3.7 Plug connection above brake booster. 3.8 Relay socket of fuel pump relay.
  • Page 272 I g n i t i o n S y s t e m 9 4 4 TEST POINT 2 P o w e r S u p p l y f o r D M E C o n t r o l 2.
  • Page 273 9 4 4 I g n i t i o n S y s t e m SUN 1010 SUN 1080 BOSCH MOT 002.01 Cylinder selector switch Range selector switch set set to 2 to 2 to "special" pos. Engine cylinder switch set Special wire connected on test to 4-stroke to 4-stroke...
  • Page 274 I g n i t i o n S y s t e m 9 4 4 TEST POINT 4 R e f e r e n c e M a r k T r a n s m i t t e r Adjust oscilloscope as described in point 3.
  • Page 275 9 4 4 I g n i t i o n S y s t e m TEST POINT 5 I g n i t i o n S y s t e m 1. Adjust secondary image on oscilloscope: term.
  • Page 276 I g n i t i o n S y s t e m 9 4 4 TEST POINT 6 A i r F l o w S e n s o r 4. Check temperature sensor I (intake air tempera- ture).
  • Page 277 9 4 4 I g n i t i o n S y s t e m TEST POINT 7 F u e l P r e s s u r e 1. Open flap on distribution tube. 3. Start engine and measure fuel pressure at idle Unscrew capped nut on test connection.
  • Page 278 I g n i t i o n S y s t e m 9 4 4 Replace pressure regulator if pressure rises above TEST POINT 8 4 bar (58 psi). F u e l I n j e c t o r s a n d I n j e c t i o n T i m i n g If pressure remains below 4 bar (58 psi), check fuel filter or replace fuel pump.
  • Page 279 9 4 4 I g n i t i o n S y s t e m 2. C h e c k i n g I n j e c t i o n T i m i n g Adjust oscilloscope as described in test point 3.
  • Page 280 I g n i t i o n S y s t e m 9 4 4 Start engine. The following oscillographs will be displayed on the oscilloscope when injection timing is correct. STARTER SPEED ti = Injection time IDLE SPEED ACCELERATION DECELERATION (coasting)
  • Page 281 9 4 4 I g n i t i o n S y s t e m TEST POINT 9 TEST POINT 10 T e m p e r a t u r e S e n s o r I I T h r o t t l e S w i t c h ( E n g i n e T e m p e r a t u r e ) 1.
  • Page 282 I g n i t i o n S y s t e m 9 4 4 C h e c k F u l l T h r o t t l e E n r i c h m e n t 3.
  • Page 283 9 4 4 I g n i t i o n S y s t e m TEST POINT 11 C o l d S t a r t E n r i c h m e n t Connect and adjust oscilloscope as described in test point 8 (injection timing).
  • Page 284 I g n i t i o n S y s t e m 9 4 4 TEST POINT 12 TEST POINT 14 L e a k s i n I n t a k e S y s t e m CO and idle speed adjustments (see Repair 1.
  • Page 285 Ignition System TESTING LAMBOA SENSOR OPERATION (Short test) 3. Pull off negative pressure line from fuel pressure regulator and Prerequisites: close with suitable plug. - Engine at operating temperature - Idle speed correctly set 1. Connect exhaust tester at bleed nozzle in engine compartment.
  • Page 286 Ignition System TESTING DEE CONTROL UNIT TESTING LAMBDA SENSOR (Lamba Control Function) (Sensor Voltage) 1. Same prerequisites as for l. Prerequisites as for "Testing "Testing Lambda Sensor Operation". Lambda Sensor Operation". 2. Disconnect lambda sensor plug. Briefly connect term. 1 on the 2.
  • Page 287 Ignition System REMOVING AND INSTALLING DEE CONTROL UNIT IN MODELS AS OF 85/2 1. Fold back mat in passenger's 3. Unlock and pull out side footwell. Unscrew and remove control unit plug footwell cover. 2. Unscrew control unit bracket and DEE control unit. Printed in Germany - VII, 1985 28 - 39 Removing and Installing...
  • Page 288 28 - 40 Blank Page...
  • Page 289 Ignition System DME CONTROL UNIT CODING, 924 S '86 MODELS ONWARD 1 - Plug for characteristic-map switch 1 - 944.612.525.01 2 - Plug for variant switch 2 - 944.612.421.00 Country DME Control Unit Impedance Coding plug Adapter 944.612.525.01 944.612.421.00 Rest of world 944.618.121.04 Sweden, 944.618.121.04...
  • Page 290 Ignition System DME CONTROL UNIT CODING, 944 '85/2 MODELS ONWARD 1 - Plug for characteristic-map switch 1 - 944.612.525.01 2 - Plug for variant switch 2 - 944.612.421.00 Country DME Control Unit Impedance Coding plug Adapter 944.612.421.00 944.612.525.01 Rest of world 944.618.121.03 Sweden, 944.618.121.03...
  • Page 291 Ignition System DME control unit coding 944 2.7 l 1 - Connector for the performance 1 - 944.612.525.01 characteristic switch 2 - 944.612.421.00 2 - connector for the variant switch Country Resistance adapter Coding connector 944.612.421.00 944.612.525.01 California. Japan with catalytic converter R.o.w.
  • Page 292 28 - 42b Blank Page...
  • Page 293 Ignition System DME CONTROL UNIT CODING, 944 TURBO, '85 MODELS ONWARD 1 - Plug for characteristic-map switch 1 - 944.612.525.01 2 - Plug for variant switch 2 - 944.612.421.00 Country DME Control Unit Impedance Coding plug Adapter 944.612.421.00 944.612.525.01 Rest of world 944.618.121.02 Sweden, 944.618.121.02...
  • Page 294 28 - 44 Blank Page...
  • Page 295 Ignition System CODING OF DEE CONTROL UNITS, 924 S, '88 MODELS ONWARD 1 - Plug for characteristic-map switch 1 - 944.612.525.01 2 - Plug for variant switch 2 - 944.612.421.00 Country DEE Control Unit Impedance Adapter Coding plug 944.612.421.00 944.612.525.01 944.618.121.05 RoW with cat.
  • Page 296 Ignition System CODING OF DEE CONTROL UNITS, 944, '88 MODELS ONWARD 1 - Plug for characteristic-map switch 1 - 944.612.525.01 2 - Plug for variant switch 2 - 944.612.421.00 Country DME Control Unit Impedance Adapter Coding plug 944.612.421.00 944.612.525.01 944.618.121.05 RoW with cat.
  • Page 297 Ignition System Equipment Table Engine type M 44.09/10 Type/Model Version Remarks 924 S Mod. '88 944.618.121.05 DME control unit Engine type M 44.11/12 Type/Model Version Remarks 944 Mod. '89 944.618.121.06 DME control unit Equlpment Table 28 - 47 Printed in Germany - XXV, 1992...

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