Workshop Manual cS ea DR. ING. h. c. F. PORSCHE Aktiengesellschaft948 Table of contents volume LA Page General Technicaldata . og Maintenance, Self-diagnosis Fault diagnosis, DEE control unit 03-1 Connecting into the vehicle - 944 S . 8- 3 ‘Starting fault diagnosis 03- 5 Functional test - actuator and input signal 03-7 List of test codes 03-13, ‘System adaptation 03-15 ‘Knock detection 3-17 Troubleshooting 03-19 List of faut codes 03-29 Clearing fault memory 03-31 Operating conditions for start of diagnosis 03-32 Operating instructions for System Tester 9288 03 - 33 Engine, Crankcase Tightening torques for engine (16-valve) 10-0101 Tolerances and wear limits 10-0102 Engine, removing and installing 40-101 Engine, Crankshaft drive, Pistons Notes on assembly for pistons, from Model 87 onward 13-101 Checking pistons and cylinder bore 13-102 Pistons from Model 89 onward 13-103 Installing cover for oil-centrifuge partition 13-105 Engine, Cylinder head, Valve drive Camshatt setting, checking and adjusting 15-101 Camshatt setting, checking and adjusting for Model 89 onward. 15-104a Applying the TDC mark on the camshaft sprocket 15-104b ‘Camshafts and cylinder head, removing and installing 15-105 Cylinder head, installing and tightening 15-110 Camshafts, installing 15-111 Camshaft seal, installing 15-1124 Camshaft specifications 18-112b ‘Chain tensioner, removing and instaling 15-113 Cylinder head, disassembling and assembling 5-115 Valve springs, removing and installing with Sauer tool 5-118 Table of contents Printed in Germany ~ YOUV, 1991volume |-A Table of contents. 944 Page Machining mating face, cylinder head . 15-120 Vaive springs, removing and installing, removing vaive stem seal 18-121 Valve stem seal, installing 15-122 Checking vaive guides 15-123 Replacing valve guides 15-125 Checking vaive-seat wear limit . 15-130 Valve seats, checking and machining 115-131 ‘Checking and adjusting installation length of valve springs 15-133 Engine - Lubrication Replacing engine oil and oi! fiter 17-101 Pressure-reducing valve, removing ar! stating 17-102 Engine - Cooling Gnecking cooling and heating system for leaks 19-101 Fuel supply Replacing tue! fiter, checking injection lines for leaks and tightness 20-101 Checking delivery rate of fuel pump. 20-102 Line routing, fuel system, M 44.40 20-103 Fuel preparation - L-Jetronic/regulation Replacing air fiter cartridge, checking intake-air guide hoses 24-101 Testing and adjusting specifications 24-102 Checking fuel pressure : 24-103 Checking idle speed and CO - with catalytic convertor (24-105 Checking idle speed and CO - without catalytic convertor 24-106 Replacing air filter cartridge for Model 89 onward 24-107 Exhaust system Exhaust system - check tightness of flanges 26-101 Ignition system Equipment table 28-101 DEE control unit coding - 944 S, Model 87 onward 28-103 Replacing spark plugs 28-104 Equipment table, Model 89 onward 28-105 DEE control unit coding - 944 S 2, Model 89 onward 28-107 DME-Diagnosing / Troubleshooting D.2428-1 2 Table of contents Printed in Germany ~ XXIV, 1991944 General TYPE 944 S (16-VALVE ENGINES) - ‘87 MODELS ONWARD Printed in Germany - XIII,1987 Technical Data 0.9General 944 TECHNICAL DATA (Adjustment specifications and wear data are stated in the appropriate Repair Groups) Note: US values are stated in parentheses DRIVE UNIT Internal engine designation Number of cylinders Bore Stroke Displacement (actual) Compression ratio Max. engine output to 80/1269/EC Net power, SAE J 1349 at engine speed Max. torque to 80/1269/EC at engine speed Net torque, SAE J 1349 Max. spec. power output Net power, SAE J 1349 Fuel octane rating Max. perm. engine speed Engine weight (dry) ENGINE DESIGN Type mm/in. mmn/in. cc/in.? kw/PS KW/HP rpm Nm/kpm rpm Nm/1bFt kW 1/HP 1 kW 1/HPT RON/MON rpm kg/1bs M 44/40 4 100/3.94 78.9/3.11 2479/151 10.9: 1 140/190 - 135/184 Australia 140/188 6000 230/23.5 - 225/22.9 Australia 4300 230/170 56.5/76.6-54.5/74.2 Australia 56.5/75.8 95/85 ~ 92/82 unleaded Australia (95/85 premium unleaded) 6840 175/386 4-cylinder, 4-stroke in-line spark ignition engine with two balance shafts 0.10 Technical Data Printed in Germany944 Crankcase Two-part light alloy crankcase Crankshaft Forged, 5 bearings Crankshaft bearings Plain Connecting rods Cast, opt. sinter-forged Connecting rod-bearings Plain Pistons Light alloy, cast Balance shafts Forged Balance-shaft bearings Plain bearings with bearing shells Cylinders Light alloy Cylinder head Light alloy Valve guide Press-fit, special brass Valve arrangement 2 intake, 2 exhaust overhead V Valve timing Two overhead camshafts, hydraulic bucket tappets Camshaft Without bearing shells, carried in cylinder head Camshaft drive Toothed belt and internal chain Balance-shaft drive Toothed belt Valve clearance Self-adjusting (hydraulic) Timing Intake opens 4° after TOC Intake closes 40° after BOC Exhaust opens 36° before BDC Exhaust closes 4° before TOC Printed in Germany - XIII,1987 Technical Data 0.11General 944 ENGINE COOLING ENGINE LUBRICATION Lubrication Oi] pressure n = 5000 rpm Oil-pressure indicator Max. oi1 temperature 011 consumption 1/1000 km EXHAUST SYSTEM EMISSION CONTROL HEATING Sealed cooling system, electric fan with thermoswitch, antifreeze effective to - 25°C Forced-feed lubrication with sickle-type pump, oi] filter and oil-water heat exchanger in main oi] flow and secondary water flow integrated in crankcase Approx. 4 bar, at operating temperature Pilot lamp and pressure gage 140°C Up to 1.5 Standard 2 double-wall manifolds, branch pipe to primary muffler, 1st and 2nd secondary mufflers Option: M298 or M299 and USA and Australia as standard, catalytic converter instead of primary muffler Standard: engine-internal Option: M298 or M299 and Australia heated oxygen sensor with 3-way catalytic converter Hot-water heating with heat exchanger and blower 0.12 Technical Data Printed in Germany944 General FUEL SYSTEM Injection Fuel delivery Fuel octane rating Fuel consumption to 80/1268/EC or ECE R 15/04 Constant 90 km/h Constant 120 km/h EC exhaust urban cycle ELECTRICAL SYSTEM Suppression Battery voltage Battery capacity Alternator (output) Ignition Firing sequence Ignition timing RON/MON 1/100. km 1/100. km 1/100 km Ah AW OME Digital Motor Electronics 1 electric fuel pump Standard: 95/85 - European standard premium unleaded possible Opt. /M298: 95/85 unleaded - European standard premium - Australia: 91/82 unleaded Standard: 6.7 8.3 12.5 ECE-R 10 and 72/245/EC 12 50 - optional 63, sports package 36 115/1610 = sports package: 90/1260 By OME 1-3-4-2 By DME Printed in Germany - XIII,1987 Technical Data 0.13General 944 BODY DESIGNS Integral all-steel body with front air dam and rear spoiler = as coupé, opt.: removable hardtop panel, also available with fog lamps set in PU front air dam as optional extra. DIMENSIONS (at DIN curb weight) Length mm/in, 4230/165.354 (4290/168.90) Length with opt. m/in. 4290/168.90 extra US bumpers Width mn/in. 1735/68.31 Height mn/in. 1275/50.20 Wheel base (in design pos.) mm/in, 2400/94.49 Track: Rim size Front mm/in. 1477/58.2 Tox 15 1477/58.2 70x 16 1477/58.2 Bd x 16 Rear m/in. 1451/57.1 Tox 15 1451/57.1 73x16 1451/57.1 Bd x 16 1442 9dx 16 Ground clearance mm/in. 120/4.72 (at per. total weight) Bed clearance mn/in. 53/2.09 (at per. total weight) Overhang angles: Front 14° Rear 15° 0.14 Technical Data Printed in Germany944 General WEIGHTS = to DIN 700 20 - Curb weight Standard Sports package Australia, standard Front. kg/1bs 6640/1411 630/1389 6640/1411 (650/143) Rear kg/1bs 640/1411 1610/1345 640/1411 (650/1433) —_(630/1389) Total kg/Ibs 1280/2822 1240/2734 1280/2822 (1260/2778) Per. axle load Front kg/Ibs 730/1609 730/1609 730/1609 (720/1587) Rear kg/Ibs 900/1984 1900/1984 920/2028 Per. total weight. kg/ Ibs. 1600/3527 1600/3527 1620/3571 (1550/3417) Per. trailer Toad Braked trailer kg/Ibs 1200/2646 up to 16% gradient kg/Tbs 1200 for Italy Unbraked kg/Ibs 500/1102 up to 16% gradient trailer kg/1bs 500 for Italy Max. car/ trailer weight kg/Ibs 2760/6085 kg/Ibs 2760 for Italy Max. drawbar Toad kg/ lbs 50/110 kg/Ibs 50 for Italy up to 100 km/h Per. roof load kg/Ibs 35/77 With genuine Porsche roof —_kg/Tbs 75/165 transport system Printed in Germany - XI11,1987 Technical Data 0.15General 944 CAPACITIES Engine (measurement with dipstick as per Driver's Manual is definitive) Engine oi! Engine coolant Transmission with differential Fuel tank Brake-fluid reservoir Windshield and headlight washing fluid reservoir PERFORMANCE Maximum speed km/h/mph Acceleration from 0-100 km/h* s (0-60 mph)* (1/4 mile from standing start)* s Kilometer from standing start* s CLIMBING PERFORMANCE In & (slip limit) Ast gear 2nd gear 3rd gear 4th gear 5th gear *DIN curb weight and half of payload Proprietary HD oils to API classification SE or SF, see Driver's Manual Approx. 6.0 1 Approx. 8.5 1 Approx. 2.0 1 hypoid oi1, SAE 80 to MIL-L 2105, API classification a4 Approx. 80 1, including approx. 8 1 reserve Approx. 0.21 Approx. 6.01 228/142 7.9 (7.7) (15.4) 27.8 62% 35.6% 21.5% 13.3% 9.4% 0.16 Technical Data Printed in Germany944 General Technical data - Type 944 S2 - Model 89 (Values for adjustment and wear are to be found in the respective repair groups) Notes: USA values are given in brackets Drive unit Internal engine designation Manual transmission M 44.41 (3.0 I) Bore mm (in) 104 (4.09) Stroke mm (in) 88 (3.46) Displacement (actual) om*(in§) 2990 (182.5) Displacement (rounded down) em? 2969 Compression ratio 10.91 Max. engine power 88/195/EEC kw (HP) 185 (211) Net power, SAE J 1349 KW (HP) 188 (208) at engine speed rpm. 5800 Max. torque 88/195 / EEC Nm (kpm) 280 (28.5) (Net torque, SAE J 1349) Nm / bt 280 (207) at engine speed rpm 4100 Max. output per litre DIN 70020 Kwa (HP) 51.8 (70.6) (GAE J 1349) KWAI (HPI) 51.8 (69.6) Speed governed by fuel cut-off tpm 6480 +20 Engine weight (dry) kg 175 Technical Data 0.17 Printod in Germany ~ X%,1989944 Maintenance, Self-diagnosis 03 DME control unit error diagnosis DME control unit error diagnosis 944 S as from 88 model ‘As from model year 88, the DME control unit {944 S is capable of a self-diagnosis. That is to say, the control unit is capable of detecting, storing and displaying system errors. The con- trol unit capable of diagnosis is identified by an altered part number. A specially developed diagnostic tester (special too! No. 9268) is then used to read out the error memory and to test specific components and control sig- nls of the fuel and ignition system. Important: Before diagnosis, the battery or the connector of the OME control unit must not be disconnected as otherwise the error memory will be erased. DME control unit error diagnosis Printed in Germany ~ XVI, 1987 03-403 Maintenance, Se-dagnosis Pa Display Control unit Error code identification test code 1 = LH/ DME 2 = EZK Diagnosis mode Function display 1 = Continuous error 2 = Occasionally occurring error 3 = Actuator / input signal testing 4/= System adaption 5 = Noerror LED off Test sequence terminated / igniti od Flashing LED Error code / test code @ LED on Ignition on 03-2 DME control unit error diagnosis Printed in Germany - XVI, 198703 944 Maintenance, Self-diagnosi Connection in the 944 S Diagnosis socket in the car In the 944 S, the diagnosis socket is attached Pin 1 = terminal 15 toa separate cable harness located above the DME control unt. Pin 2 = terminal 31 Pin 5 = terminal 30 Ping = Hall generator \ ail a a Ignition off After connecting the tester, the following dis- play must appear. Display: If this is not the case, check the tester ter- rminals or check the power supply of the diag- nosis socket in the car by referring to the cir- cuit diagram. Connection in the 944 S 03-3 Printed in Germany - XVI, 198703 Maintenance, Self-diagnosis 944 Tester cable ‘Switch on the ignition Diagnosis plug Round plug Display: Pin 1 Pina Pin 2 ————iPint rms et e3333. Pins Pina ‘The ignition must not be switched off Pin7 unused Ping unused Pin 10 unused Pin 14 Pins Pin 12 ——-_ Pina 03-4 Connection in the 944 S Printed in Germany - XVI, 1987a4 Maintenance, Self-diagnosis 03 Starting error diagnosis Condition: Engine off Ignition on Display: Press the green key until the clear symbol ap- pears on the function display. AAAN ® BWUUUO Clear symbol ‘The diagnosis sequence for the DME control unit then takes place. an error is displayed — take the note of the error (e.g. 1211) Display: The error is displayed until the green key is again pressed on the tester. The next error code is then displayed, if applicable. ‘This must be repeated until 1000 appears on the display. If no error has occurred, the following display appears, Display: ‘Starting error diagnosis Printed in Germany ~ XVI, 198703 Maintenance, Setf-diagnosis 944 Press the green key until the clear symbol ap- pears on the function display. The following display must then appear. Display: This now terminates diagnosis of the DME control unit. It one or several errors (up to 5) has/have been displayed, the error memory must be reset; see chapter (Resetting the error memory). 03-6 Starting error diagnosis Printed in Germany — XVI, 1987944 Maintenance, Selt-diagnosis 03 Actuator and input signal function checking ‘An actuator and input signal function check can be carried out independently of an error diagnosis. This function check tests individual components or electrical signals with respect to their functioning or signal paths. Functions are triggered from the diagnosis tester. During functional checking of components, these must audibly or tangibly operate and can thus be detected as being electrically in proper working order or defective. ‘An error display via the tester is not possible in this mode, but faulty input signals or their Wiring connection are detected by the tester. Starting actuator and input signal function check Ignition off Press the yellow key until the function symbol (see display) appears on the function display. Display: Press the green key until the clear symbol ap: pears on the function display. Display: ANAM O YUULO ‘Switch on the ignition within 8 seconds. Actuator and input signal function checking Printed in Germany ~ XVI, 198703 Maintenance, Sel-dlagnosis ous Press the green key until the clear symbol ap- pears on the function display. This activates the first testing step and the injection valves. are activated, Display: ‘The injection valves must all operate audibly or tangibly. Note: If later attempts are made to start the engine, starting difficulties may occur because a slight residual amount of fuel is injected during this, testing step. ‘The testing steps remain in operation until the green key is again pressed on the tester and the clear symbol appears. The next testing step is inated by again press- ing the green key. Refer to the test code list for the sequence of testing steps. 03-8 ‘Actuator and input signal function checking Printed in Germany ~ XVI, 198790a Maintenance, Self-diagnosis 03 ‘As from the "idle contact” testing step, specific ‘controls must additionally be operated on the cat for the purpose of function checking. Idle contact display: Slightly press the accelerator. The LED must 0 off after approx. 20 mm and the display will appear after approx. 3 s. Display: {if this is not the case, an error has occurred in the area of the idle contact (see Idle contact, troubleshooting). Ifthe display 0000 does not appear, itis pos- sible to switch at all times to the next testing step. Press the green key until the clear sym- bol appears. Initiate the full load contact testing step. Display: Slowly press the accelerator until the full throt- tle position is reached. The LED must go off and the display will appear after approx. 3 s. Display: If this is not the case, an error has occurred in the area of the full load contact (see Full load contact troubleshooting) ‘Actuator and input signal function checking Printed in Germany ~ XVI, 1987 03-903 Maintenance, Self-diagnosis 944 Initiate the air-conditioning control terminal 41 testing step. Display: Initiate the air-conditioning control terminal 40, testing step. Display: >» 1334. » 1335-_| Switch on the air-conditioning system. The LED must go off and the display will ap- pear after approx. 3 s. Display: ‘Switch off the air conditioning system. ‘The LED must go off and the display will ap- pear after approx. 3 s. Display: CAMO ~ UU. If this is not the case, an error has occurred in the area of the air-conditioning system's wiring. In the event of an error, check with reference to the circuit diagram. Do not switch off the air-conditioning system. If this is not the case, an error has ocourred in the area of the air-conditioning system's wiring. In the event of an error, check with reference to the circuit diagram. 03-10 ‘Actuator and input signal function checking Printed in Germany ~ XVI, 1987944 Maintenance, Selt-diagnosis 03 Press the green key until the clear symbol ap- pears. Display: End of the actuator and input signal function checks. ‘Actuator and input signal function checking 03-11 Printed in Germany ~ XVI, 1987944 Maintenance, Self-diagnosis 03 Test code list Test code Components 1311 Injection valves 1921 Rotary idle controller 1922 Solenoid valve - tank bleeding 1932 Idle contact 1333 Full load contact 1334 Ai-conditioning/AC switch 1335 Air-conditioning/compressor coupling Test code list 03-13 Printed in Germany ~ XVI, 1987944 Maintenance, Self-diagnosis 03 System adaption ‘System adaption can be carried out with the tester. That is to say, the electronic idle control in the DME control unit is adapted to the ac- tual air throughput and to the current condition of the engine. Note: For system adaption, itis necessary for the en- gine to be at operating temperature. Ignition off Press the yellow key the number of times re- quired for the function symbol to appear on the function display. Display: Press the green key until the clear symbol ap- pears on the function display. Start the engine within 8 seconds. Allow the engine to idle until the system adaption code appears. Display: The engine must now idle for at least 30, seconds. ‘System adaption is then completed. Ignition off System adaption Printed in Germany ~ XVI, 1987 03-15944 Maintenance, Self-diagnosis 03 Knock detection Before knock detection is carried out, error Giagnosis must first of all be performed to ‘guarantee that no electrical error has occurred in the area of the knock control and the knock sensors. Knock detection should not be carried out if the customer has complained about poor out- Put or too high a consumption, for instance. Condition: The engine must be at operating temperature during the test. Testing must be carried out during a test drive or on the roller test stand. Knock detection Engine at operating temperature While the engine is running, simultaneously press the yellow and the green key until the knock detection function symbol appears on the function display. Display: ‘The tester is now in knock detection mode. Note: Normal driving is a prerequisite for the test Grive (roller test stand). Start the test drive (roller test stand). Press the green key until the clear symbol ap- pears on the function display. Display: Knock detection Printed in Germany - XVI, 1987 03-1703 The tester is now active. If knocking occurs, this will be indicated by the tester, e.g. Display: © 8E098e After the expiry of 10000 ignitions, the function display will change to Display: Counting is now complete, ‘The number of knocks is displayed in per mil In this example, 25 knocks have occurred. Knock detection must be carried out until the function display switches over from the clear symbol to the knock detection symbol. This is. always the case once 10000 igntions have oc- curred. All occurring knocks are added up and displayed as the end resut. Maintenance, Selt-diagnosis 944 To restart knock detection, the green key must be pressed until the clear symbol again ap- pears. A knock display of > 2.5 (25) draws attention to an error. Error possibilities: Defective cup tappets Conical rod damage Crank mechanism damage To terminate knock detection mode, the green and yellow keys must be pressed simul- taneously unti the display appears. Display: ro wy TM VUIvYy 03-18 Knock detection Printed in Germany ~ XVI, 1987944 Maintenance, Self-diagnosis 03 Troubleshooting Diagnosis using the tester can refer only to the error path, but not to a defective com- ponent, Note: Before troubleshooting, the entire error memory must be read out. Error code 1111 ‘The supply voltage is too low < 10 Vortoo high > 16 V. Possible causes for too low a supply voltage: Battery exhausted Poor contact on the grounding strap Poor contact on the control unit A defective regulator may be the cause of too high a supply voltage. Troubleshooting Printed in Germany ~ XVI, 1987 03-1903 Maintenance, Seltaiagnosis as Error code 1112 This error code indicates an error in the area of the idle contact Possible error: Ground fault ‘Switch stuck Testing the idle contact Extract the plug from the DME control unit. Connect an ohmmeter between terminal 52 and terminal 24 on the DME plug. Display: Throttle valve closed: R < 100 Throttle valve open: R = =f ‘Switchover must already occur if the throttle valve is only slightly open (approx. 1°) If the values are not reached during this testing step, measurement must be repeated directly on the throttle valve switch. 03 - 20 ‘Troubleshooting Printed in Germany ~ XVI, 1987944 Maintenance, Selt-diagnosis 03 Error code 1113 ‘This error code draws attention to an error in the area of the full load contact. Possible errors: Ground fault ‘Switch stuck Testing the full load contact Connect an ohmmeter between terminal 53 and terminal 24 on the DME plug. Display: Throttle valve closed: R= of ‘Throttle valve in full load position: R < 10.0 ‘The switching point must be briefly before full load. If the values are not reached in this testing step, measurement must be repeated directly on the throttle valve switch. Error code 1114 This error code draws attention to an error in the area of the engine temperature sensor (NTC 2), Possible errors Ground fault ‘Short to positive Wire discontinuity NTC 2 defective Testing the engine temperature sensor. Connect an ohmmeter between terminal 45 and terminal 24 on the DME plug. Troubleshooting Printed in Germany ~ XVI, 1987 03-2103 Maintenance, Sltdlagnosi aaa Display: 0°C = 4400.9 - 6800 0 15-30°C = 14009- 3600.0 BC = 2500- 3900 wor = 160n- 210 I the values are not reached in this testing step, measurement must be carried out direct- ly on the engine temperature sensor. The engine temperature sensor (NTC 2) forms the control unit about the current engine temperature. It results in mixture enrichment during cold starts or hot running. Error code 1121 This error code draws attention to an error in the area of the air-low sensor. Possible errors: Ground fault ‘Short to positive Wire discontinuity During this test, the plug of the DME con- trol unit must be plugged in. 03 - 22 Troubleshooting Printed in Germany XVI, 1987944 Maintenance, Selt-diagnosis 03 Testing the power supply of the air-flow sensor: Ignition on (On the extracted plug of the airflow sensor, a voltage of 5 V 0,5 V must be measurable be- tween terminal 3 (positive) and terminal 4 (negative) (i necessary, check by reference to the circuit diagram) 123465 Testing the air-flow sensor From the extracted plug of the airflow sensor, link plug terminal 3 to air-flow sensor plug ter- minal 3 and plug terminal 4 to airflow sensor plug terminal 4 using an auxiliary cable. Measure the voltage between terminal 2 of the airflow sensor and ground. Display: approx. 250 - 260 mV Detach the top of the air fiter. Using a non-metallic tool, slowly force the air- flow sensor valve to full load position. ‘voltage rise must be observed during this time. Display: approx. 0.2 V- ca. 46V No abrupt voltage changes must be observed during opening or closing. (Abrupt voltage changes, ie. the air-low sensor is defective). Troubleshooting Printed in Germany - XVI, 198703 Maintenance, Self-diagnosis 944 Error code 1123 When this error code appears, the Lambda control has detected too rich or too lean a mix- ture. Possible causes for too lean a mixture: Lambda probe ground fault Infitrated air on the intake side Infitated air on the exhaust side of the Lambda probe Injection valve does not open Ignition cut-out Fuel pressure too low Possible causes for too rich a mixtu No partial vaccum on the pressure regulator Injection valve does not close Return to the fuel tank clogged. Error code 1124 This error code draws attention to an error in the area of the Lambda probe. Possible errors: Ground fault Short to positive Wire discontinuity Testing the Lambda probe signal. Disconnect the Lambda probe plug. Note: ‘The voltage of the Lambda probe must only be measured using a digital voltmeter, or ‘only using a comparable measuring instru- ment with an internal resistance (Ri) of no less than 10 MQ. 03 - 24 Troubleshooting Printed in Germany - XVI, 1987944 Maintenance, Selt-diagnosis 03 Measure the voltage between pin 1 and engine ground, ‘The voltage is within the range of approx. 150 mV - 900 mV depending on the mixture com- position, Check the cable harness to the DME control unit with reference to the circuit diagram. Error code 1125 This error code indicates an error in the area of the intake air temperature sensor (NTC 1) in the air-low sensor. Possible errors: Ground fault Short to positive Wire discontinuity NTC 1 defective Testing the intake air temperature sensor. Connect an ohmmeter between terminal 44 ‘and terminal 26 on the DME plug. Display: OC = 4400.0 - 68009 15-30°C = 1400.9 - 3600.0 40 = 10000- 13000 Ifthe values are not reached during this testing step, measurement must be carried out direct- ly on the intake air tempertaure sensor. Connect an ohmmeter between pin 1 and pin 4.0n the alr-flow sensor. Display: as above Troubleshooting Printed in Germany - XVI, 1987 03 - 2503 Maintenance, Selt-diagnosis 944 Error code 1131 Error code 1132 This error code draws attention to an error in This error code draws attention to an error in the area of knock sensor 1 the area of knock sensor 2. Error testing of the knock sensors is an active ‘error test, Le. error testing is carried out during driving, if an error has occurred, first check the wiring for a ground fault, a short to positive and for ‘continuity with reference to the circuit diagram before replacing the knock sensor. 03 - 26 Troubleshooting Printed in Germany ~ XVI, 1987944 Maintenance, Sett-diagnosis 03 Error code 1133 Error code 1133 draws attention to an error in the area of the knock control in the DME con- trol unit. If this error code appears, the DME control unit must be replaced Error code 1134 This error code draws attention to an error in the area of the Hall generator. Possible errors: Ground fault ‘Short to positive Wire discontinuity Testing the Hall generator signal Using a suitable auniliary cable, connect an os- cilloscope to the diagnosis plug, pin 9 (square- wave signal) and pin 2 (ground). If the Hall gen- erator signal is O.K., the following picture must appear on the osciloscope's screen. Troubleshooting Printed in Germany - XVI, 198703 Maintenance, Selidagnosis sas Error code 1141 Error code 1141 draws attention to an error in the area of the DME control unit. If this error code appears, the DME control unit must be replaced. Testing the Hall generator’s power supply Disconnect the Hall generator’s connector. Ignition on 3} Avoltage of 12 Volt = 1 V must be measurable between pin 1 (positive) and pin 3 (negative). If this is not the case, check the wiring with reference to the circuit diagram, 03 - 28 Troubleshooting Printed in Germany - XVI, 198703 944 Maintenance, Selt-diagnosi Error code - List Error code Error path 1500 No error 1000 Output end ant ‘Supply voltage too low/high 1112 Idle contact 1113 Full load contact 114 Ntc2 124 jow sensor 1123 Lambda control detects a too rich / too lean mixture 1124 Lambda probe signal not correct, 1125 Ntc1 1131 Knock sensor 1 1132 Knock sensor 2 1133 Knock control in the control unit 1194 Hall generator signal 141 DME control unit ‘A digit 2 (e.g. 1211) may appear in the second error code digit position to indicate "sporadic errors", ie. an occasionally occurring error. This does not apply to error codes 1000 and 1500. Error code - List 03 - 29 Printed in Germany ~ XVI, 1987944 Maintenance, Self-diagnosis Resetting the error memory ‘Once the DME control unit error diagnosis has been completed, this is completed by error code 1000. The error memory cannot be reset as follows until this error code appears: The yellow key must be pressed until the func- tion symbol (see display) appears on the func- tion display, Display: Function symbol ‘The green key must be pressed until the clear symbol appears on the function display. Display: AAAN I UUUUO 03 The error memory is reset if the LED goes off and the function display changes to 0000. Display: Note: A test drive must be carried out after resetting the error memory. ‘At the same time, pay attention to the following: 1. The engine must be at operating tempera- ture, ie, at least 80°C 2. The duration of the test drive (minimum 6 minutes) 3. At the end of the test drive, run the engine for at least 60 seconds without opening the throttle valve After the test drive, read out the error memory ‘once again, Resetting the error memory Printed in Germany ~ XVI, 1987 03-3103 Selt-diagnosis 944 Operating conditions for start of diagnosis Systems Ignition on } Engine standing still | Engine running 1944S / 94482 | DME yes ton < 2000 rpm Airbag yes yes Alarm system yes yes 03-32 (Operating conditions for start of diagnosis Printed in Germany ~ XXIV, 1991ou Settaiagnosis 03 Operating instructions for System Tester 9288 Operating instructions for System Tester 9288 03-33 Printed tn Germany ~ XXIV, 1991,03 Selt-diagnosis 944 1. General information 14 Application The Systemteste 9288 (SOSCH KTS 301 i¢9 miroprocessor-con- trolled seclagnosie tester ‘Allsystoms which havea clagnsis interface speriSO Standardcan be tested with this tester. The following ects are possible (© Reading out he fault memory 1 Testing ofthe actuators 1 Testing the eet inputs ‘Sytem adaptation 1 Enginesnock detection '© Sensor and status checks, tre-pessure monitoring (FOX) 12 Construction Fg. 1) ‘The Systemtester 9288 is» high-quality piece of electronic equip- ‘ment inorder to prevent damage to the equipment es result i= reper use, pease ead the informstion nthe operating instructions arty and comply wath i In aio, the instructions epectcatins ofthe vehicle manutac- tore are ais tobe observed tthe tester shoulda check the folowing points before sendingitin foe tei: 1. Has the tester been operated incorecty? 2. isthe battery suicienty charged? 3. Is the acaptr cable OK? (Peace note when checking the adeptereablethats hight ansi- {ive slecirone matching cut isinetaledinthevityof the 1S- pale pes) No. | Desripton Function Remarks 1 | Leo indeator Det mate 5 8 ‘ines each with 20 chersctre Foreign languages posse I the Systemtester 9288 i etched on without the program module, following the selt-sest the tortor switches off auto- imatcally and informs the use thatthe Program module not fed 2 | Keyboars Keys 1.2.3. = Selection key fre Thin frome” Gepeaton of tay oF cern = NBT | Mattie net anand sari rogram level olowing fermination ofa tert, sequence or, during 2 test sequence, tun tothe Tas display Key = Storing indication Key & = Playing beck stored veaing file completly, this mess that thi is 2 Stored figure and not an actus reatie fgure. ‘a | Power supe ited sccumulator with NiCd betes. ‘The Systemtester 9288 must be stoned off during the intl battery charging process (Charging te > 8 hours Discharged upon delivery. Following charge: (Operating time: 458 hours without scale lamination 12 houts with Seale ilominaton Ihe vtage i nt sutient, “Charge batery” appears ‘on the dspay tis is Connection to vehicle battery by means of vehici-specfie adapter leas [see 16) Connection through 1$0-intertace (Charging voltage supply ot done, the unit stones ita of Battery charger faczessory) For tet operation and fr charging the Nica batterie, “4 | conection for Input and output devees Connection feity for Printer 2.3 Epson, 18M, Hewlett Packard (HP) The Systemtester $288 transmits data with the following configurations: 2B data bits /1 stan bt /1 stop bit No party for printer matching 5 | conection for veicle specific adapter lead Reading out the date Input for Mashing-code support, 6 | Pugin programme module (see aso Figure 2) A\ coos Do not toveh vg! (Operating system LC rive Keyboard Intedae communization Computations and data conversions Pug in module remove rubber protector, Insort module ful Operating instructions for System Tester 9288 Printed in Germany ~ XXIV, 1991os Sett-diagnosis 03 12 bouncer nett sine vooe Fre onthe a a ne Sener £28 canon rr ty Se tee No leg sor apse or Sennett tans sone ton Ore vith oman ea 18 ang fen2 Baap Sod de cen 14 voice spec dpe ate ine | poner 00072192881 Lire | Kev 15 conating ee oe oe trot pene od stn rt — For interface-trenk assignment, see manual of corresponding unit. Gisplays: " Per nse ey ac 25 omer Bese Setter ss Pn nse PSO Bese ae et 08 We Hopman era Dit 2. Connection ee ‘The following points must be observed: 5 = aa oa 4 Vo qurmer trend Asenaeorriaisn mio Bie secon = ALLwork on the vehicle must only be carried out with the ignition ‘Selection of the vehicle type with key 1, 2 oF 3. one Aermovtce preston ler bering etn Arming come eile nga he ime os Sst nar boyd eer sn comes eae eae else 2 caning win nary care 3 pie Se Comecing te Sema 929 he sey ee 3 Kirton: > mt Theo en om omerng he Sroeriet02881 hess ln be | warie icle by means of the vehicle-specific adapter cable, | Date Scho eon pce! cargo mete siete ow Set sera shor pee Seer 288 pte 3. Testing ey Taste tata ovr onda Soest ae rote ore Guidoace through the mens, communication with the ECU, reading Exemptes fut the enter memory and selection of the "Hep" menus, actuator agnosis, ccuitinputs and system acaptation,engine-knockdetec+ | tested systems tion sensor and event chek forthe tie-pressure monitor (ADK). 131 Reading-out the error memory Connect the Systemtester 9288 (see 2) ‘Switch on the Systemtester, ‘The particular sytem canbe selected by means of key, 20r3. Apossibie with every ke!) ‘After selection lor instance with Key the folowing spay ap- Disa: pears: PORSCHE wu prom model eng Sytem: Lot LET Mod. inti. xe Ser. No: 92661612913 | B.No: 0280002507 | a speci instruction does not appear in espa itis aways pos- ble to proceed by presing the button >. Operating instructions for System Tester 9288 03-35 Printed in Germany ~ XXIV, 198103 ‘Alter pressing the key > 2 slection menu i ployed: ‘Mens 1 = Fault memory 2 = Drive lnke 3 = Input signals = Men 1 = Sytem adaptation Inthe example press ey Tete then folows the display ofthe ‘umber of errs which are sored (f any Number of toute ate Proceed with key > ‘Acsitona info to very display with key! Proceed with key = nor output 1: Engine temperature sensor 2 ‘Short to ground ot present tke pressed instead ofthe > key, the corresponding eror code display appears (he last two digits ofthe Faehing code) Fouteode: = 14 — Proceed with key > Forther errs sre csplayed (they exis): 2: te comet Short to ground | [__ present | key is pressedinstesdot key > the corresponding eror-code splay appears the last eights ofthe Mashing code). Fault code: 12 — Selt-diagnosis 944 Alter the net played error, the folowing inetuction appears Reps out accor. ing to repair | instetions Continse: > Proceed with key > aut repaied ? te yee | 32n0 Feturn to splay “No, of errors” with key 3. Proeged with key 1 Fou memory 1s ease 35 Do not ease ‘they 3s pressed = Return t9 menu “tro memory” “The error memory snot erased Proceed with key has been cleaved Return N ‘The test scope “Read-out error memory" i terminated at thi 22 Actuator diagnosis. \Wanactuatoris selected this istiggeredbytheECUsothatitean be checked for correct functioning. ‘The various actuators components are gone through one after ‘me other and are selected withthe > bey Operate the Systemteste: 9268 os desribed under 21 unt the following men display appear: Menu 1 1 = Fat memery 2 = Drive links 3 Input signais > After pressing key 2 the esply forthe fst actuator appears: Injector vaste Continue: Whey > is pressed, the next actuator is selected, Pressing hey 1 results in the folowing instruction Can injectors be heard ft? Taye | 3200 03 - 36 ‘Operating instructions for System Tester 9288 Printed in Germany ~ XXIV, 1981Self-diagnosis 03 Key 1 selects the nest actuator (e.g ie actuator. Flowing in- Repair fault accord ing to repair Continue 5 Alter peesing key >, the following display appears: Injector v= start Continue: 5 Proceed with key 1 Con rectors be hae elt? Proceed with key tothe next actustr 1a tects | Pr Sor i Conti | oo } Proceed with key Can ie stabitzer beneard / felt, 32m By pressing key thenext actustorie selected. After resting key 2 the nest ineirtion appesrs Repair ful accord ing to repaie Cetin > Proceed with key = ae aber to activate Yaseen Conte: 5 After pressing kay 1 the following spiny appears: Can ide taizer beheard/ felt? neta ato By pressing key, the nex actuator is selected, The actuators are salecle one ater he other an triggered unt the following i ay appears: eve ink ast completed Return: N By pressing the key N, the operator is retuned tothe menu 233 Creu inputs In aditon to the actustors, the Systemtester 9288 can aso check reuitnputs. To this end, operate the Systermester 9288, in accordance with 23 un this menu Seplay appears Mens 1 = Fault memory 2= Dive ike 3 Input gnats ross key 3 ale contact Y= Sut Continue: > 2y pressing key > the nest circuit input is selected. “The ext spay appears when key 1s presse. ‘Aetiate al pedal (ale contact = cored — Continue eI (Operate the accelerator peda, the following sepay appear: Activate acl. pedal Ine contact Continue > “The nex circuitinputis selected by pressing key >. Repeat uti th depleysppears Input signals texting completes Return " Press key N for return to mens 34 System adaptation \When the funtion System adaptation is twiggered the ECU re Sisters the base ar requirement ofthe engine. To ths end, operate the Systemtester 9288 as per 3.1 uti the following menu display appears: ens 1 = Fautt memory 2 = Drive lnke 3 Input signals > Proceed with key > = Mens 1 1 = System adaptation Operating instructions for System Tester 9288, Printed in Germany ~ XXIV, 199103 Self-diagnosis 944 Proceed with ey “he paniuarestem canbe sleced by means okey, 20r3 Forhatnce with key 2 te folowng Spay appr a = winatonmes | sytem: EO1EZK 2 ignton ot Ser hos 82061612815 RB. No: 0227400154 Proceed wth ay > ey Proceed with key > ——— ‘System adoption ‘The folowing mena delay appear t= see = Menu — a 2 Tock renattion It hey Nis pressed ‘Tetum to men omavanvena It key 1 is pressed: ve consion | Engine a operating stant engine Erin 2 Proceed with hey = Flowing engine stat there appers —————— = Stet knock System isbeing | | teisatonbetore adapted tetaiie Please wait Proceed with key = ‘Alter approx. 30 sees there appears: ae System adaptation | eels completes Return N Iti impossible to ary out system adaptation le contact nt closed, oF detective), the flowing cspiay appears: No system adaptation | <_ Stop the test, drive ony ifthe Sfepiay wth the no of knocks comes on. (ae coral? fet s proceed wth ay > ok egaton Aer compe fh yt adattin turf the mens eck is wen fem: ON 215 Engine knock reitation Pretiog ey acta he eginetnck conte: The engine knock regain funn can ony be tigre tego Econ! ont. Kock agian Toh nd operate the Sytrtater 92089 esrb in 31 inproress tal honing Silay appa hse vat insted atone freee ai tex 32 * pox 03 - 38 ing instructions for System Tester 9288 Printed in Germany - XXIV, 1991g Self-diagnosis 03 “Te knock counter registers 10,000 ignitions before the display withthe actual numberof combustion “knocks” spears. [meee] Kock x Combustion: maxx Contin 5 Proceed with key > Kock registration — | completed etn | 1 knock registration imposible (due to lack of engine-speed Signal the folowing espay appears: ——4 [no noc eit faton possible. RPM egal? Return N Flowing completion f the knock esstratin test, atu the menu with key 36 Help menu ‘The “Hep” menu can bo selected fom every display by pressing ey Retr to the inital display with ey N 2 Dispay stored 3=ctuntemn > Proceed fo instance with key Key The seaeiluminationis switched on andthe testerretursto the previous dispay Help menu 1 = Printer setting 2 Switch off eauip, | 3+ ama Rote Proceed for instance with key 1 Printer eating | | 1 exe | HP Quit Jet 34 EPSON “The selection of the printer eau in the tester being setup for the painter tpe in gestion. 37 Store measurement displays (Key ) Using key} al eepays can be stored manual The folowing isplays are stored automaticaly = ECUAdentty = estate systems = all existing errs ‘when the memery limi is reached, the following instruction i epleyed Data espley mem. ‘at Return 28 Show stored measurement dieplays (Key 1 Using the keys < or > the stored clsplys forthe selected eye ‘The stored ciplays canbe cad up by means of the G hey. ‘The system election (M-E2K-ROK) takes place with heey, Zork, 4, Service and wear parts (80SCH) or iy 2 ve] eer asso02 | xc omy vs dap sd Ga) iteease 90 | Se | te 1 = Pit | 4/3 | 1680552005 | Screwedcap | Hoe eee | sort | | Sorcet an 1 aon aes tos | frat Posed htt (er Sec pe utter oma ocd wy Sd canoe wn 44 Serve parts Posh erwin | Ponce Pov Ho. | Spe oa With the “Help” menu, for instance ‘sr 1 esi Help menu ‘Adapter cable | 000.721:928.81 | 9288/1 | 1 omnton sree | Soosatazses | saesra | srbanes | facie” | Gooatseet | soere Sleauesn = Meade Gavusw | Goaalszses | sze/s sa Moaacte "| Soot saeee | sae/e Tesy=epmvodalierwetontibe"idy’ maniacs. | Mande | ono7atez088 | S201 ole Meadel® | Gooatazeee | sare Operating instructions for System Tester 9268 03-39 Printed in Germany ~ XXIV, 1991Engine, Crankcase 10 Tightening torques for engine (16-valve) Location Thread | Tightening torque Nm ({tib) Crankshatty | crankcase Upper and lower M12x15 30(22) 1st stage crankcase sections 60° torque angle 2nd stage (studs) M10 | 2018) Ist stage | 50(37) 2nd stage Ms 20(18) Mo 10(7.5) Knock sensor | ome | 20(15) original screw | without washer Cylinder head | Cylinder head to upper | refer to Page 15 - 110 crankcase section 20(15) 1st stage Engine type M 44.40 ae | a0 torque angle 2nd stage | 90 *torque angle rd stage Engine type M 44.41 | oma 20(15) Ist stage Go) 60° torque angle 2nd stage | 90" torque angle 3rd stage Camshaft bearing to MB | 20005) finder head | Allen screws for chain Me 107.5) tensioner Banjo bot / Mext | 1075) Chain tensioner | Cover for cylinder head M6 | 1007.5) | Fastening / | Me 1017.5) Hall sensor Tightening torques for engine (16-valve) Printed in Germany ~ XX, 1989 10 - 010110 Engine, Crankcase 944 Tolerances and wear limits Engine M 44.40/41 Forinstalling Wear (new) limit Cooling system Coolant thermostat Opening temperature 81-85°C Cooling system cap Pressurevalve opens at excess pressure 13.15 Vacuumvalve opens at vacuum 0.1 bar Oilcircuit il consumption 600 miles approx. 1.5 Oil pressure at 80° C oil temperature: at 5,000 rpm. excess pressure approx. 4 bar Oil capacity 6 |, from MY 88 65! Difference of quantity between dipstick marks approx. 1.51 Valve timing Camshaft bore Inner dia. 28 + 0.021 -0 Camshaft Dia 28-0.04 ~ 0,055 Camshaft ‘Axial clearance 0.08..0.18 Bucket tappet bore Inner dia. 35 - 0.025 - 0.041 Bucket tappets dia. 35- 0.025 -0.041 Camshatt Runout 0.02 10 - 0102 Tolerances and wear limits Printed in Germany ~ XXIV, 1991944 Engine, Crankcase 10 Tolerances and wear limits Engine M 44.40/41 Forinstalling Wear (new) limit Cylinder head with valves Mating surface Distortion max. 0.05 Valve seat width Intake: 15 Exhaust 18 Seating angle 45° Outer correction angle 30° Inner correction angle 60" Valve guides: Inner dia. 7 + 0.015 Valve stem: Intake Dia 697 -0.012 Exhaust Dia 6.94-0.012 Valve guide/valve stem Rocking clearance Intake 08 Exhaust 08 Compression Bbarand 6 Sbar above Pistons with connecting rods Cylinders/pistons Clearance 0.008-0.032 approx. 0.080 Piston rings M 44/40 Height clearance Groove 1 0.040...0.075 Groove 2 0.020...0.055 Groove 3 0.020...0.055 Piston rings M 44/41 Height clearance Groove t 0.040...0.075 Groove 2 0.030...0.085 Groove 3 0.020..0.055 Piston rings M 44/40 Ring gap clearance Groove 1 0.20...0.40 Groove 0.20..0.45 Groove3 _0.30...0.60 Piston rings M 44/41, Ring gap clearance Groove 1 0.20...0.50 Groove2 0.20..0.55 Groove 3 0:30...0.90 Tolerances and wear limits 10 - 0103 Printed in Germany ~ X00, 199110 Engine, Crankcase 944 Tolerances and wear limits Engine M 44.40/41 Forinstalling Wear (new) limit Con rod bush Dia, 24 + 0.018 + 0.028 Piston pin Dia 24-0.004 Con rod bush/piston pin Radialclearance 0.018-0.032 Crankshatt and cylinder block Crankshaft Runout 0.046 max. 0.06 measure at bearing 2, 3 or 4 Bearing 1 and 5 on prisms Con rod journal Dia, 51.971-51.990 Con rod/erankshatt Radialclearance 0.027-0.069 Axialclearance 0.080...0.240 Crankshaft bearing journal Dia 69.971-69.990 Crankshatts/ crankshaft Radial clearance 0.028-0.070 0.16 Crankshatt bearing/ crankshaft Axialclearance 0.060..0.192 0,40 Cylinder bore Out-ot-round 0.010 0,020 Bore for balance shaft bearing shells at crankcase or balance shaft cover Dia. 34.000...34.019 Bore for bushing in bearing housing Dia, 34.000...34.019, Balance shaft Dia, 30.975...30.991 10-0104 Tolerances and wear limits Printed in Germany — X00, 1991944 Engine/Crankcase 10 REMOVING AND INSTALLING ENGINE (16-VALVE ENGINES) TOOLS No. Description Special Toot Remarks, Engine suspension In conjunction beam 3033 with workshop, (WW Special Tool) crane, e.g Bilstein K750 H. Note: If necessary, use a commercially available carabiner (load-bearing capacity 650 kg) to connect engine suspension beam to workshop crane. Printed in Germany - XIII,1987 Removing and Installing Engine 10 - 10110 Engine/Crankcase 944 REMOVING AND INSTALLING ENGINE (MANUAL TRANSMISSION) Remove by lowering engine from car. The bell housing remains attached to the engine. Removing L.Align lifting platform pads beneath jacking points and raise car. 2.Place protective covers on fenders. 3.Unbolt and remove front wheels. 4,Disconnect battery/bodywork ground lead. Disconnect battery positive lead. Disconnect wire harness and push both cables with rubber grommets through splash 6.Slacken hose clamp for fuel wall. Open cable clips. return line and disconnect hose. Disconnect fuel feed while countering. Detach cable from 5.Unbolt panel in passenger-side tempostat servo motor. Disconnect footwell and remove. Unbolt series resistor/injection nozzle carrier plate for DME control connector. unit and disconnect control-unit plug. Disconnect 8-pin connector. 10 - 102 Removing and Installing Engine Printed in Germany944 Engine/Crankcase 10 7.Disconnect breather hose for toothed belt cover at rear of lower section of air filter. Unbolt filter assembly as a unit and remove. 9.Slacken and remove ignition-distributor cap and rotor. (Mark installation position of rotor). Remove oi] filter and ATF reservoir. 10.Remove throttle valve actuating cable complete with reversing roller and holder. Disconnect oxygen sensor plug connector. Slacken hose clamps at intake manifold and brake booster and disconnect hoses. 11.Remove cable clips from bulkhead. Disconnect two-pin and multi-pin connectors. Disconnect vacuum hose from tank breather valve. Printed in Germany - XIII,1987 Removing and Installing Engine 10 - 10310 Engine/Crankcase 944 12.Remove engine underguard. a i La ae ia BS 13.0pen coolant drain plug and catch coolant in a suitable container. Disconnect alternator breather hose. 14.Disconnect coolant hose at bottom right of radiator from engine and remove. Catch any coolant which may be left. 15.Disconnect electric leads from fan motors, detach fan-motor bracket from radiator and remove by Towering from car. 16.Slacken coolant hose and breather hose from top left of radiator and remove. Disconnect electrical connection from temperature switch to radiator. Disconnect coolant hose from expansion tank and remove. 17.Disconnect radiator at brackets and remove radiator by lowering from car. 18.Attach support beam 10-222 A to front transport bracket of engine and hold engine in installation position. Check that beam is correctly attached. 10 - 104 Removing and Installing Engine Printed in Germany944 Engine/Crankcase 10 19.Detach Poly-rib belt tensioner from air-conditioning compressor and remove belt. Remove compresor from bracket and place to one side. (Do not disconnect refrigerant hoses). 20.Unbolt stabilizer with bracket from body and from control arms and remove. Disengage left and right tie rods. 21.Slacken hose clamps between ATF cooler and steering and disconnect line. 22.Disconnect servo pump from bracket, moving spacer sleeve forward to remove. Leave servo pump hanging from steering. 23.Disconnect left and right control arms from front-axle traverse and rear bearings and pull forward to remove. (Do not slacken bolts in bearing bracket). 24.Unbolt universal joint from steering, detach hydraulic motor mount from engine supports and lower front-axle cross menber complete with steering and servo pump from car. Printed in Germany - XIII,1987 Removing and Installing Engine 10 - 10510 Engine/Crankcase 944 25.Disconnect leads from starting 31.Attach VW Special Tool 3033 motor and remove starting motor. suspension beam to transport bracket of engine as follows: 26.Remove clutch actuating cylinder Pulley end: Position 2 from bell housing. (Leave line Flywheel end: Position 12 connected). Unbolt and remove holder for line from upper In position 2, the threaded rod is crankcase half. "beneath" the suspension beam. In position 12, the threaded rod is the beam. 27.Disconnect exhaust from flange of exhaust manifold and disconnect exhaust extraction line. Remove oxygen-sensor cable from bodywork. 32.Tighten workshop crane e.g. Bilstein K750 H slightly to take 28.Disconnect flange downstream of part of engine weight and remove catalytic converter and Support beam 10 - 222A. Suspension and remove system. Note: 29.Remove upper transaxle/bell housing mounting bolts. Threaded rod of support beam 10 - 222A remains in front suspension eye. 30.Disconnect coolant hoses for heating above exhaust manifold and from cylinder head. 33.Remove lower transaxle/bell housing mounting bolts. 10 - 106 Removing and Installing Engine Printed in Germany944 Engine/Crankcase 10 34.Pull engine forward, push rubber sleeve out of firewall toward engine compartment and carefully pull wire harness out of passenger-side footwell. 35.Separate engine from central tube/central shaft and lower from car. Installing Note the following: 1.Carefully feed wire harness for DME control unit, 8-pin connector and multi-pin connector into passenger-side footwell. 2.Begin by screwing transaxle/bell housing mounting bolts into place, but do not tighten. Not Do not tighten mounting bolts fully until hydraulic motor bearing has been attached to the front-axle cross member. Tightening torque of mounting bolts: 42 Nm (31 ft1b). 3.Install control arms, pressing sleeve in rubber-metal bearing down slightly to facilitate installation. 4.Place a 4mm thick steel washer in each of the threaded connections between the right-hand engine support (viewed in the forward direction of travel) and the hydraulic motor bearing. 5.Check that the radiator is correctly seated on the rubber mounts. 6.Tighten nuts and bolts to the specified torques. Tightening torques: Stablizer to 25 Nm (18 ftlb) aluminium control arm Track rod to 50 Nm (37 ftIb) steering knuckle (locknut) 30 + 5 Nm (22 + Steering - (ean universal joint Control arm to cross member 65 Nm (48 ft1b) Cross member to body 85 Nm (53 ft1b) Printed in Germany - XIII,1987 Removing and Installing Engine 10 - 10710 Engine/Crankcase 944 7.Refill system with coolant and bleed system. 8.Fi11 reservoir with ATF and bleed steering system. 9.Run engine until it reaches operating temperature, check engine-o11 level and coolant level, top up if necessary. 10 - 108 Removing and Installing Engine Printed in Germany944 Engine/Crankshaft, Pistons 13 PISTONS, '87 MODELS ONWARD (16-VALVE ENGINES) Engine M 44.40 worldwide 1 - Plain compression ring, Compression: 10.9 : 1 chrome-plated Nominal dia. 100.00 mm 2 - Oi) scraper ring 3 - Three-part oj] wiper ring An arrow pointing toward the belt pulley indicates the installation position. Printed in Germany - XI1I,1987 Notes on Assembly, Pistons, 13 - 101 "87 Models Onward13 Engine / crankshaft, pistons 944 Checking pistons and cylinder bores Motortype M 44.40 Repair Stage Piston @ Cylinder bore dia. tolerance group (mm) (mm) code Fa, Kolbenschmidt Standard size 99.980 100.000 0 99.990 +0.007 100.010+0.005 1 100.000 100.020 2 Oversize 1 100.480 100.500 ro 100.490 +0,007 100.510+0.005 1 1 100.500 100.520 12 Checking pistons Checking cylinder bores Measure approx. 61 mm from piston crown, Measure approx. 61 mm from upper edge of 90° offset from piston pin axis. cylinder bore, transverse to engine block. Mount lower crankcase section and tighten bolts to specified torque for measuring. Note It recommended that the stocks of the relevant tolerance group are checked before machining the cy- linders. t necessary, hone to the piston size available. In some cases, certain tolerance groups may be in short supply. 13-102 Checking pistons and cylinder bores, Printed in Germany ~ XXV, 1982944 Engine, Crankshatt, Pistons 13 Pistons from Model 89 onwards Checking pistons and cylinder bore Engine type M 44.41 (3.0 1) Engine M 44. 41 (3.0 1) worldwide Compression ratio: 10.9 :1 Nominal © 104.00 mm The installation position is indicated by the en- larged intake-valve pockets. Repair size Piston @ Cylinder bore Tolerance groups (mm) (mm) Code MAHLE Standard 103.980 104.000 ° 103.990 + 0.007 104.010 + 0.005 1 104.000 104.020 2 Oversize 1 104.480, 104.500 10 104.480 + 0.007 104.510 + 0.005 "4 104.500 104.520 12 Checking pistons ‘Checking cylinder bore Measure approx. 52 mm from crown of pi ton, 90° offset to axis of piston bott Note Measure approx. 52 mm from top edge of cylinder bore, across cylinder block. For measurement, mount lower crankcase ‘section and tighten with prescribed tightening torque. It is recommended that the stocks of the relevant tolerance group are checked before machining the cylinders. If necessary, hone to the piston size available. In some cases, certain tolerance groups may be in short supply. Pistons from Model 89 onwards Printed in Germany ~ XXV, 1992 13-103944 Engine, Crankshaft, Pistons 13 Assemble cover of centrifugal oil compartment in upper crankcase section. Notes on installation Model 89 onward, Engine type M 44.41 (3.01) Note Under normal conditions, it is not necessary to remove the cover when overhauling an engine. If the cover is removed, however, the bolt area must be heated with a hot-air blower under all circumstances. Apply Loctite 270 to hexagon head screws. Observe coding on the cover. Assemble cover of centrifugal oil compartment Printed in Germany ~ XX, 1989 13 - 105,944 Engine/Cylinder Head, Valves 15 Adjusting with dial gages 2.Align dial gage with improvised extension (205 mm long) on piston crown (cylinder 1). 3 mm pretension. Align second gage with hydraulic tappet of cylinder 1 intake valve. The dial gage must be aligned perpendicular to the intake valve. 3 mm pretension. 4.Slacken camshaft central bolt - note that it is essential to counter. Slacken temporary retaining bolts. Turn engine in direction opposite to direction : of rotation until camshaft oy sprocket reaches stop inside feather-key groove. bs 1 3.Remove distributor rotor and lock camshaft sprocket with 3 bolts M5 x 15, to prevent camshaft sprocket or camshaft turning when camshaft central bolt is slackened. 5. Tighten temporary retaining bolts (6 Nm, 4.4 ft1b) and central bolt (approx. 40 Nm, 30 ftTb). Printed in Germany - XIII,1987 Checking and Adjusting 15 - 103 Camshaft Settings15 Engine/Cylinder Head, Valves 944 6.Turn the engine in the direction of rotation until piston reaches its upper limit of travel. 7.Set dial gage of cylinder 1 intake-valve hydraulic tappet to 0. 8.Turn crankshaft past ignition TOC (cylinder 1) while observing cylinder 1 intake-valve dial gage. Turn engine until gage shows 1.4 + 0.1 mm lift. Note: Do not turn engine in direction opposite to direction of rotation. 9.Slacken central bolt and tenporary retaining bolts; while doing so, ensure that the reading of 1.4 +'0.1 mm on the dial gage is not Changed. 10.Now turn crankshaft slowly until dial gage shows that piston has reached the upper limit of travel. With the crankshaft in this position, the camshafts are at ignition TOC for cylinder 4. 11, Tighten temporary retaining bolts and central bolt. Tightening torque of central bolt: 65 - 70 Nm (48 - 52 ftlb). 12.Recheck by turning crankshaft through another 2 turns and checking setting. 13.Remove temporary retaining bolts and install distributor rotor. 15 - 104 Checking and Adjusting Camshaft Settings Printed in Germany944 Engine, Cylinder Head and Valve Drive 15 Checking or adjusting camshatt setting for Model 89 onward Engine type M 44.41 (3.01) Note ‘The timing has changed with installation of new camshafts for engine type M 44.41 (3.0 1) for Model 89 onward. Setting Inlet valve cylinder 1 Testing and adjusting value 0.75 + 0.1 mm The camshaft is adjusted according to the same procedure as described on Page 48 - 102. Checking or adjusting camshaft setting f. Model 89 onward Printed in Germany ~ XX, 1989 15- 104a15 Engi , Cylinder Head, Valve Drive Applying the TDC mark on the camshaft sprocket Engine type M 44.40 / 41 (3.0 I) Note Camshaft sprockets available from the spare parts department do not have a TDC mark This TOC mark is applied after the camshaft timing has been set on the new engine 1. Position the new camshaft sprocket over the old sprocket and transfer the TOC mark to the new sprocket using a color pencil. 2. Fit new camshaft sprocket and adjust camshatt timing as described in the Repair Manual, page 15-102 to 104 3. After operation 12, page 15-104, has been carried out, engrave the TDC mark in its final position on the new camshaft sprocket using a three-square-file as described on page 15-102, Fig. 1 944 15 104b Applying the TDC mark on the camshaft sprocket Printed in Germany ~ XXIV, 1991944 Engine/Cylinder Head, Valves 15 TOOLS - REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD, DEGREES-OF-TURN METHOD OF TORQUING (16-VALVE ENGINES) No. | Description Special Tool Remarks, 1 | Assembly bridges for 9248 In conjunction with | installing camshafts clamping bolt from | Special Tool 9226 2 | Pressure piece for 9234 | sealing ring 3. | Assembly drift for 9233, | sealing ring 4 | Angle reader | Commercially available | e.g.Stahlwille No. 715/20 Printed in Germany ~ XIII,1987 Tools - Removing and Installing 15 - 105 Camshafts and Cylinder Head15 Engine/Cylinder Head, Valves 944 REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD Removing L.Align lifting-platform pads beneath jacking points and raise 6.Remove throttle-valve actuating car. cable complete with reversing roller and holder. Remove oi] dipstick. Slacken hose clamps at 2.Place protective covers on intake manifold, brake booster fenders. and breather hose and remove. 3.Disconnect ground lead from battery. 4.Disconnect breather hose for toothed-belt cover from rear of lower section of air filter. Detach entire filter assembly and remove. 7.Remove cover of fuel-distribution pipe. Slacken hose clamp for fuel return line and disconnect hose. 5.Remove air-flow sensor and Disconnect fuel feed while disconnect support (M 8 bolt) countering. from intake manifold. 15 - 106 Removing and Installing Printed in Germany Camshafts and Cylinder Head944 Engine/Cylinder Head, Valves 15 8.Disconnect vacuum hose, 12.Pull off spark-plug caps and fuel-line-pressure damper remove distributor cap. Slacken and fuel-distribution pipe hose clamp at ATF reservoir. from intake manifold, disconnect plug from’ idle actuator, remove fuel rail with 13.Unbolt and remove upper and injection valves and place to one lower toothed-belt covers, side. front camshaft sprocket bracket and cylinder-head cover. 14.Turn engine in direction of rotation until cylinder 1 ignition TDC is reached. 9.Disconnect throttle-valve switch connector. Unbolt intake manifold from cylinder head and remove. 10.Remove engine underguard. Open coolant drain plug and catch coolant in suitable container. 11,Detach exhaust at exhaust-manifold flange. Printed in Germany - XIII,1987 Removing and Installing 15 - 107 Camshafts and Cylinder HeadEngine/Cylinder Head, Valves 15 944 15.Relieve tension of camshaft toothed belt by slackening nut A and bolt B, pressing toothed-belt tensioner against the pressure of the spring with Special Tool 9200 and removing toothed belt from camshaft sprocket. 16.Remove distributor rotor. Insert 3 temporary retaining bolts M5 x 20 to hold camshaft sprocket to avoid upsetting basic camshaft setting when camshaft central bolt is slackened. 17.Slacken central bolt while countering. Remove camshaft sprocket. 18.Remove rear bracket. 19.Unbolt and remove chain tensioner. Note: Chain-tensioner plunger is spring loaded. When removing, compress plunger and after removal hold in this position with a piece of wire or a retaining clamp. 15 - 108 Removing and Installing Camshafts and Cylinder Head Printed in Germanyas Engine, Cylinder Head and Valve Drive 15 20. Remove bearing cover from cylinders Note ie If oil has been mixed with water, the cylinder head must be subjected to a thorough visual inspection (hairline fractures). At the same time, check the cooling system for leaks. Use test unit VW 1274 above the expansion tank for the leak test (max. 1 bar). The camshaft Cover must be removed for visual inspection. Hold both camshafts in the bearings with Special Tool 9226. Undo and remove front double bearing bridge and bearing cover. Note ‘The rear double bearing bridge may remain on the cylinder head. 21. Undo Special Tool evenly, remove both camshafts with chain and lay together on one side. 22. Undo cylinder head. Undo in sequence: from outside to inside. 23. Remove cylinder head. Checking or adjusting camshaft setting f. Model 89 onward 15-109 Printed in Germany ~ Xx, 1989,15 Engine, Cylinder Head and Valve Drive 944 Installing and tightening the c} ‘Model 87 onward Engine type M 44.40 Note ‘The cylinder head may be mounted with the engine installed. 1. Place the cylinder head gasket in the cor- rect position. 2. Mount cylinder head Tightening sequence: Opposite to undoing sequence. Tightening specifications for cylinder head Model 87 onward Engine type M 44.40 der head Model 89 onward Engine type M 44.41 (3.0 1) Note The cylinder head has been reinforced by 20 mm in the area of the bearing surfaces for the cylinder head nuts. This has altered the tighte- ning sequence. Tightening specifications Model 89 onward Engine type M 44.41 (3.0 1) 1st stage 20.Nm 2nd stage 60" torque angle 3rd stage 90" torque angle Note Never use lubricant when fiting cylinder head nuts and washers. Apply a light film of engine oil to the stud thread only. ist stage 20Nm 2nd stage 90" torque angle 3rd stage 90" torque angle 15-110 htening the cylinder head Printed in Germany ~ XXV, 1992one Engine, Cylinder Head, Valve Drive 15 Installing camshatts 4, Fasten the camshafts to the cylinder head with assembly bridges SpecialTool 9248 1. Turn engine in direction of rotation by together with the clamping bolt of Special approx. 45° before ignition TDG (cylinder 1). Tool 8226. 2. Lay intake shaft and exhaust camshaft in the timing chain 3. Place both camshafts in the timing chain so that the cast lugs are alignedwith the ‘marked links of the chain. Oil the bearing jounals and place in the bearings carefully together with the timing chain Note ‘The distance between the marking on the intake camshaft and the markingon the exhaust camshaft amounts to 7 outer chain links; the distance betweenthe cast lugs mea. orvas sures approx. 113 mm. 5. Install the bearing bridges and bearing cover of the camshaft. The bearingbridges and cover are production-matched to the cylinder head and must alwaysbe installed ‘as a set. Note the identification code and pairing number. Tightening torque for bearing bridges and cover 20 Nm Installing camshafts 15-111 Printed in Germany — XV, 1988,15 Engine, Cylinder Head, Valve Drive 944 Note ‘The timing chain must always be replaced i the valves have beendamaged by the piston as a result of a broken toothed belt. A tho- rough visual inspection must be made of the sprockets and chain tensioner. 6. Apply Loctite 574 to the sealing surfaces of the front and rear double bearing bridges. 7. Use the assembly drift, Special Tool 9233 and pressure piece 9234 to drive the sealing ring into position at the drive end of the camshaft. Lubricate the sealing lip before assembly. 15-112 Installing camshafts Printed in Germany ~ XVI, 1988ose Engine, Cylinder Head, Valve Drive 15 Installing Camshaft Seal 1. Place sealing washers in bearings and install bearing bridge with Loctite 574. Tightening torque 20 Nm (15 fib). Note: It the sealing cover of an engine leaks with the engine installed, the procedure for installing the cover is as follows: 1. Place camshafts and sealing washers in bearing 2. Apply Loctite 574 to bearing bridge and install, Place a 0.20 mm feeler gauge between bearing bridge and cylinder head and tighten bolts slightly by hand, 2. Alter torquing the bearing bridge, install sealing cover with the aid of Special Tool 9234 3. Apply a light flm of oil to sealing cover and press on by hand. Tighten bearing bridge to 20 Nm (15 fib). Installing Camshaft Seal 15-1128 Printed in Germany ~ Xvi, 198815 Engine, Cylinder Head and Valve Drive Camshatt specifications Worldwide, Model 87 onward Worldwide, Model 89 onward Engine type | 9sas 94452 | M4440 M4441 (3.0) Camshafts Inlet shaft | 944.105.277.04 1944.105.277.07 Exhaust shaft 1944.105.275.04 1944.105.275.09 Identiication code | 27708 2rro7 (On the rear | 275.04 275.09 face Timing | 1mm stroke, zero play | Inlet opens | a C8 after TOC cs after TOC Inlet closes 40°CS after BDC 47 cS after BDC Exhaust opens 36° CS before BDC 39°CS before BDC Exhaust closes | 4 CS. before TOC | rcs before ToC 15 - 112b ‘Camshaft specifications Printed in Germany ~ XIX, 1989944 Engine/Cylinder Head, Valves 15 REMOVING AND INSTALLING CHAIN TENSIONER Removing Remove hollow screws from cylinder head and chain tensioner and remove complete with oil line and seals. Note: Chain-tensioner plunger is spring-loaded. When removing, compress plunger and hold in this position with suitable retainer (improvised tool). Installing 1.Chain tensioner can be installed without removal of retaining clamp. 2.The retaining clamp for the chain-tensioner plunger must be removed once the chain tensioner is installed. 3.When installing the oi] delivery line, install a sealing ring at both’ends of the two hollow bolts. The check valve is in the chain tensioner housing. Tightening torque of hollow bolts: 10 Nm (7 ftIb) Printed in Germany ~ XI11,1987 Removing and Installing 15 - 113 Chain Tensioner944 Engine/Cylinder Head, Valves 15 TOOLS - CYLINDER HEAD (16-VALVE ENGINES) 3 No. | Description Special Tool Remarks 1 | Puller for valve stem 9237 seals 2 | Press-in tool for valve 9225/1 stem seals 3 | Valve spring assembly tool] 9242 Or Us 1020 + US 1020/1 Printed in Germany - XIII,1987 Tools - Cylinder Head 15 - 11515 Engine/Cylinder Head, Valves 944 DISASSENBLING AND ASSEMBLING CYLINDER HEAD (16-VALVE ENGINES) 15 - 116 Disassembling and Assembling Cylinder Head Printed in Germany944 Engine/Cylinder Head, Valves 15 Note When: No. | Description | Qty. | Removing Installing 1 | Hydraulic 16 | Mithdraw with a magnet, | Of1 valve tappet do not mix up 2 | Conical valve | 32 Check correct keeper seating 3 | Spring plate | 16 4 | Valve spring | 16 set 5 | Valve spring | 16 support 6 | Washer X | Note number Redetermine if necessary 7 | Valve stem seal] 16 Always replace, drive in with press-in tool, Special Tool 9225/1, of] sealing Vip, use drift 8 | Intake valve e Oil valve stem 9 | Exhaust valve | 8 Oi} velve stem 10 | Valve guide 16 Printed in Germany - XIII,1987 Disassembling and Assembling 15 - 117 Cylinder Head15 Engine, Cylinder Head, Valve Drive Cylinder Head (16 Valves) Removing and installing valve springs Tools No. _| Description | _ Special toot | Remarks 1 | Assembly bridge ‘Supplier: Sauer Hamburg 2 | Lever arm ‘Supplier: Sauer Hamburg 3 | Magnetic removal head ‘Supplier: Sauer Hamburg 4 | Assembly head ‘Supplier: Sauer Hamburg 5 | Spacer ‘Supplier: Sauer Hamburg 6 | Screws commercially available M 8 x 40 Note If the cylinder head is installed, the lever arm must be angled more accutely. 15-118 ‘Removing and installing valve springs Printed in Germany ~ XV, 1988ona Engine, Cylinder Head, Valve Drive 15 Notes on assembly Remove and install the valve springs with the special tool supplied bySauer 1, Mount the assembly bridge on the cylinder head. Secure the cylinderhead to the work bench with a screw clamp to prevent tilting, 2 Fasten the magnetic removal head to the lever arm. Press the valve springstogether in the cylinder head and loosen the conical valve keeper from the valve shaft with a ‘small screwariver, ome 5 Place washer, valve spring suppor, valve springs and spring plate in the cylinder head and press together with the assembly head. ‘A-small up and down movement of the lever arm allows the conical valvekeepers to lock into place. This movement also positions the conicalvalve keepers automatically in the correct location. 3. All valve spring components can be pulled out with the magnetic removal head. 4, Fasten the assembly head to the lever arm. Press the tensioningarms together and place the conical valve keepers in the asssembly head, 6 When the conical valve keepers are locked in, the tensioning arms of the assembly head point outwards. Removing and installing valve springs 15-119 Printed in Germany ~ XV, 196815 Engine / Cylinder Head, Valves 944 Remachining cylinder-head mating face Checking cylinder head for distortion Use a feeler gage an a straight edge or a pre- cision straight edge to check the mating face of the cylinder head for distortion Permissible mating-tace uneveness: 0.05 mm Cylinder heads with distorted mating faces can be remachined and reused. Permissible rough after finishing: 0.03 mm. Remachining cylinder head Do not remove mor material from the cylinder- head mating face than is necessary to achieve a smooth surface. Max. machining depth 146.6 mm. Note on machining mating face: Peak-to-valley = 0.015 mm It the new-dimension tolerance is exceeded during machining, a cylinder head gasket with a thickness of 1.4 mm must be fitted. = 14740. 1mm = 146.6 mm. Size new Size worn 5S ; J Cylinder head refacing dimension and Identification New dimension £1474 0.1mm Gasket 1.1 mm Identification :none Refacing dimension _—: 146.8 to 146.6 mm Gasket 214mm, Identification N Identification * To be embossed on exhaust side, between cy- linders no. 2 and 3, on the casting lug below the sealing face of the cylinder head cover. Punch character helght “N" = 6 mm 15-120 Remachining cylinder-head mating face Printed in Germany ~ XXV, 1982944 Engine/Cylinder Head, Valves 15 NOTES ON ASSEMBLY REMOVING AND INSTALLING VALVE REMOVING VALVE STEN SEAL SPRINGS Cylinder head removed Remove and install valve springs Remove valve stem seal with Special with US 1020 + US 1020/1. Tool 9237. REMOVING AND INSTALLING VALVE SPRINGS Cylinder head installed Remove and install valve springs with Special Tool 9242. Printed in Germany - XIII,1987 Removing and Installing 15 - 121 Valve Springs Removing Valve Stem Seal15 Engine/Cylinder Head, Valves 944 INSTALLING VALVE STEM SEAL Note: Always remember to place an 1 mm thick washer on the cylinder-head face before installing the valve stem seal. \ | | l.Lubricate valve stem and install shaft. Place an 1 mm thick washer on cylinder-head face. Push drift over valve stem. Lubricate sealing lip of valve stem seal and position on drift. Using Special Too! 9225/1, carefully and gently push seal as far as it will go onto valve guide. 2.The valve stem seal is correctly seated when Special Tool 9225/1 and washer make contact. Not The assembly drifts are available as spare parts. 15 - 122 Installing Valve Stem Seal Printed in Germanyos Engine, Cylinder Head, Valve Drive 15 Checking the valve guides 1. Clean the valve guides thoroughly. 2. Use a new valve to measure the tit play. ‘3. Mount bar gate holder VW 387 on the cylinder head. The dial gaugemust be aligned parallel to the valve disk. 4. The tit play is measured with 10 mm valve stroke (distance betweenthe valve disk and valve seat). Wear limit for intake and exhaust guides = 0.80 mm. Checking the vaive guides Printed in Germany ~ XV, 1968 15-123944 Engine, Cylinder Head, Valve Drive 15 Replacing valve guides Tools No. | Description |__ Special too! Remarks 1 | Ejection base ‘See drawing 2 | Plunger See drawing 3° | Plunger See drawing 4 | Reamer 3120 W special too! Replacing vaive guides 15-125 Printed in Germany ~ XVI, 19881 5 Engine, Cylinder Head, Valve Drive 944 Drawing Plunger to press out the valve guide do =| 26 _ fA c Material: Wood t " J = - 5 5071 gz | \ t + 4 A « | y 3 g 2 g y | . C } + 4. CD I TF z | Sh ¢ NX i YD 15-126 Replacing valve guides Printed in Germany ~ XVI, 1988948 Engine, Cylinder Head, Valve Drive 15 Drawing Plunger to press out the valve guide Plunger to press in the valve guide Material: St 37 Replacing valve guides 15-127 Printed in Germany ~ XVI, 196815 Engine, Cylinder Head, Valve Drive ou Replacing the valve guides 1. Clean and inspect the cylinder head. It is inexpedient to replace the valve guides in cylinder heads where remachining is no longer possible on the valve seats or sealing areas. 2. Lay the cylinder head on the ejection base. 3. Press out the valve guides from the camshaft side to the combustionchamber side with a press. 4. Measure the bores in cylinder with an internal measuring caliper. 5, Machine the SP valve guide Part No. 944 104 927 51 (outer diameter 11.26 mm) accordingly. The pressing must amount to 0.06 - 0.8 mm for intake and exhaust valve guides Example Bore in the cylinder head measures 11.020 mm. Machine the outside diameter of the SP valve guide accordingly to 11.080 or 11.10 mm, Note ‘A1 mm thick washer must always be placed on cylinder-head face before installing the valve guide. 6. Heat the cylinder head up to 170 °C (338°F), Apply a film of tallow tothe valve guides, position with a light knock, align and, from the camshaftside, press into the cylinder head as far as the stop with a plunger. Attention The temperature of 170 °C (338 °F) must only be maintainedttor a maximum of 90 minutes. 15-128 Replacing the valve guides Printed in Germany ~ XV, 1988944 Engine, Cylinder Head, Valve Drive 15 7. Ream the valve guides with Special Tool 3120. Proceed as follows: ‘The valve guides must always be reamed with “petroleum lubricant. Withdraw the reamer regularly to remove chips. Then finish-ream the boreagain with a dry reamer. 8. The valve seat rings must be remachined after replacing the valve guides.tt is not ‘enough to grind in the valves with grinding paste Replacing the valve guides 15-129 Printed in Germany ~ XVI, 1988,15 Engine, Cylinder Head, Valve Drive 944 Checking the vaive seat wear limit 1. The valve seats in the 4-valve cylinder heads can be remachined. At the same time, the wear limit dimension must not be exceeded as this would mean that the hydraulic valve tappets may no longer function correctly. 2. This is measured with the valve to be installed, from the end of the valve shaft to the contact area of the valve spring support in the cylinder head. 3, The valve must be held firmly on the valve seat for measurement. 15-130 ‘Checking the valve seat wear limit Printed in Germany ~ Vi, 1988,oe Engine, Cylinder Head, Valve Drive 15 Checking and remachining valve 3. Valve seat milling cutter, e.g. seats Neway 234 45° Visual inspection Neway 213 60° 1. Check that the valve seat sits securely in the cylinder head, 2. Check the contact patter. If the valve does make contact over the entire surface of the valve seat, remill the seat slightly. Remachining 1. Valve seats can be remachined, for ‘example, with the Neway valve mileror the Hunger valve seat turing tool. 2. Remachine the valve seats with a 45° seat milling cutter. Then machine the seat to the prescribed width with a 60° correction millingcutter. A 30° correction miling cutter is not required. Intake seat width 1.5 mm Exhaust seat width 1.8 mm x #/ eos [ox {ihe Checking and remachining valve seats 15-131 Printed in Germany ~ Xvi, 1968,15 Engine, Cylinder Head, Valve Drive 944 4. Valve seat turing tool, e.g. Hunger VDSNL 1/48 LK, 5. After milling, grind in the valve seats lightly with grinding paste.Check the contact Pattern of the valve seat surface. Valve dimensions Valve dimensions 944 S ‘As from Model 87 Engine type M 44.40 6.97 mm 1147 mm | 113.7 mm roe 15 - 132 ‘Checking and remachining valve seats Printed in Germany ~ XVI, 1988944 Engine, Cylinder Head and Valve Drive 15 Checking and adjusting installation length of vaive springs Valve springs, Model 87 onward Engine type M 44.40 Note When selecting the valve-spring seat (own construction) always ensure that the valve- spring seat is 2.0 + 0.2 mm thick Tool (own construction) Valve spring Sp No. 944.105.467.03 Auxiliary spring Sp No. 928.107.171.01 1. Machine a recess of approx. 10 mm width into valve-spring seat. Only instal valve- spring seat for measurement. 2. Shorten the auxiliary spring to approx. 50 mm to ease assembly. ca.50. t 3. Install valve and hold in valve seat. Insert washer, valve-spring seat, auxiliary spring and valve-spring seat with machined recess. 4. Use Special Tool 9242 to fit the conical valve keepers. Checking and adjusting installation length of valve springs Printed in Germany ~ XX, 1989 15-13315 Engine, Cylinder Head and Valve Drive 944 55. Using a depth gauge, measure from the top surface of the valve-spring seat, vertically downwards through the recess to the outer spring contact surface. Installation length Inlet valve Exhaust valve 38.0 + 0.5 mm 37.0 + 0.5 mm 6. The installation length can be adjusted using shims. 7. The valves must not be mixed up again after measurement. Valve spring, Model 89 onward Engine type M 44.41 (3.0 1) Note ‘A-new type of valve spring has been installed in engine type M 44.41 (3.0 I) from Model 89 onward. The installation length remains unchanged. Installation lengths Inlet valve Exhaust valve 38.0 + 0.5mm 37.0 + 0.5mm Carry out working procedure Checking and adjusting installation length of valve springs as described on Page 15 - 133. 15-134 ‘Checking and adjusting installation length of valve springs Printed in Germany ~ XX, 1989944 Engine/Lubrication 17 CHANGING ENGINE OIL AND ENGINE OIL FILTER (16-VALVE ENGINES) Preconditioned: Engine at operating temperature. 1.Unscrew and remove oi] filler cap. 2.Unscrew oi1 drain plug from of] pan and drain engine oi]. 3.Remove of] filter with oi1-filter wrench, Special Tol 9208, Catch remaining oi1. 4.Clean drain plug and never forget to replace seal. Tightening torque: 50 Nm (37 ftlb). 5.Lightly oi] gasket of oil filter, screw in by hand until gasket makes contact, and turn through one further turn to tighten. To ensure that filter is correctly seated, recheck with oil-filter wrench. Tightening torque (for guidance): 20 Nm (14 ftib). 6.Pour in engine oil, run engine to operating temperature and check for leaks. 7.Check 011 level with engine switched off. Printed in Germany ~ XII1,1987 Changing Engine Oi] and Engine Oi] Filter 17 - 10117 Engine, Lubrication oss Removing and installing the pressure reducing valve Engine type M44.40 1- Set screw 2 - Pressure reducing valve 3- O-ring 4+ Oxring 1, Remove the cylinder head cover and undo the set screw by 2 turns 2. Ease the pressure reducing valve out of the seat with a screwdriverand take out upwards. 3. Replace the O-rings and apply a light film of oil before installation. 4, Tighten the set screw carefully until you can feel the stop, then turn back by 45°, The screw must not be loose. (Microencapsulated, renew if necessary) 17 - 102 Removing and installing the pressure reducing valve Printed in Germany ~ XV, 1988944 Engine/Cool ing MIXING TABLE FOR COOLANT {Average values) Antifreeze Antifreeze agent Water Antifreeze Agent effective to 19 Water - 25°C 40% 60% ~ 30°C 45% 55u - 35°C 50% 50% CHECKING HEATING AND COOLING SYSTEM FOR LEAKS (16-VALVE ENGINES) 1.Visual inspection for leaks. 2.Check routing of cooling and heating hoses, look for signs of porosity, swelling, cracks and rubbing. Replace damaged hoses. 3.Retighten hose clamps. ere Printed in Germany - XIII,1987 Checking Cooling and Heating System for Leaks 19 - 101944 Fuel Supply 20 REPLACING FUEL FILTER (16-VALVE ENGINES) 1.Disconnect fuel lines, always counter when slackening threaded connectors. Catch fuel exiting from lines in a suitable container. 2.Slacken retaining clamp and remove fuel filter. CHECKING FUEL AND INJECTION LINES FOR LEAKS AND LOOSE CONNECTIONS 1.Visual inspection for leaks. 2.Retighten union nuts and hose clamp. 3.Install new filter. Direction of flow is as indicated by the arrow. Printed in Germany - XII1,1987 Replacing Fuel Filter, Checking 20 - 101 Injection Lines for Leaks and Loose ConnectionsFuel Suppl 944 20 ply CHECKING DELIVERY RATE OF FUEL PUMP Preconditior Allow fuel to flow into graduated cylinder for 30 seconds. Minimum Fuel filter and power supply OK. delivery rate is 850 cc/30s, if necessary replace fuel pump. 1.Unbolt fuel return hose from pressure regulator. Connect a Vength of commercially available fuel hose and place one end in a graduated cylinder (capacity approx. 1500 cc). 2.Disconnect OME relay from central electrics and, using 2 length of wire, jumper terminals 30 and 87 b. 20 - 102 Checking Delivery Rate of Fuel Pump Printed in Germany944 Fuel Supply 20 FUEL SYSTEM LINE ROUTING (16-VALVE ENGINES) "87 MODELS ONWARD ENGINE TYPE M 44.40 o-—nigf] = fom eee |] 1 Fuel pump A Air flow sensor a from fuel tank 2 Fuel filter B Throttle valve housing b to fuel tank 3 Fuel collector tube C Intake tube c from activated charcoal 4 Pressure damper D Idle actuator canister 5 Pressure regulator £ Intake jet pump d to brake unit F Electric tank breather valve Printed in Germany - XI11,1987 Fuel System Line Routing 20 - 103 (16-Valve Engines)944 L-Jetronic Fuel Injection 24 REPLACING AIR FILTER ELEMENT CHECKING INTAKE AIR GUIDE AND (16-VALVE ENGINES) CRANKCASE BREATHER HOSES FOR LEAKS AND LOOSE CONNECTIONS: 1.Use a screwdriver to remove 1.Check all hoses of intake system mounting screws and remove upper for loose connections. part of air filter. 2.Retighten hose clamps. 3.Remove filter element and clean inside of Tower half of air-filter housing with a lint-free cloth 4.Insert filter element, place housing cover in position and tighten mounting screws. Check that upper part of air filter is correctly seated. Printed in Germany - XIII,1987 Replacing Air Filter Element, 24 - 101 Checking intake Air Guide Hoses24 Air Flow Controled Fuel Inection os Testing and adjusting specifications Model 87 onward Engine type M 44.40/41 (3.0 1) Test Specitication Remarks Electric fuel pump Min, delivery rate 850 cm¥/30 5 Fuel pressure {engine stationary) DEE relay jumpered 3.8 + 02 bar Checking value at idle approx. 3.3 +0.2 bar Leak test ] min. pressure after | 20 Min, 2.0 bar Idle speed without catalytic with | converter catalytic converter **Idle speed ‘pm 840 + 40** 840 = 40" can only now be checked. Idle adjust- ‘ment no longer applies, CO values % 05.15 04.4.2 * Measured upstream of catalytic converter and | Lambda HC value ppm 300 s300* | probe connector not | separated CO adjustment no | longer applies. Note Carry out working procedure checking delivery rate of fuel pump and checking fuel pressure as described on Pages 20 - 102 and 24 - 103 respectively. Tightening torque for cap nut 12 Nm. 24- 102 Testing and adjusting specifications Printed in Germany ~ XX, 1989944 L-Jetronic Fuel Injection 24 CHECKING FUEL PRESSURE TOOLS No.| Description | Special Tool Remarks T | Pressure gage with hose P 378 or WW 1318 from pressure tester Printed in Germany - XIII,1987 Checking Fuel Pressure 24 - 103DQ = wetronic Fuel Injection 944 CHECKING FUEL PRESSURE 1,Slacken and remove capped nut on test connection of fuel distribution line. Note: Be careful that sealing ball does not fall out when capped nut is removed. 2.Connect pressure gage with hose from pressure tester P 378 or VW 1318 to test connection. 4.Control value: Engine stopped 3.8 + 0.2 bar (DME relay jumpered) Engine idling, approx. 3.3 bar 5. Tightening torque of capped nut: 22/Nm (16 ft1b) 3.Disconnect DME relay from central electrics and jumper terminals 30 and 87 b with a length of electric wire. Fuel pump must now run. 24 - 104 Checking Fuel Pressure Printed in Germany944 Air Flow Controlled Fuel Injection Checking idle speed and CO - with catalytic converter Model 87 onward Engine type M 44.40/41 (3.0 1) Note Itis no longer possible to adjust idle speed or CO on vehicles with catalytic converters. The Lambda probe remains connected while chek- king idle speed and CO. Checking preconditions Engine in perfect mechanical condition. Con. sumers must be switched off during checks. Carry out checks as quickly as possible to ensure that the intake paths do not heat up thus falsifying the CO value. Ambient tempera ture 15 - 95°C, 1. Fit standard exhaust adapter to the test connector of the catalytic converter. Engine type M 44.40 24 Engine type M 44.41 (3.0 1) 2. Warm engine up to operating temperature. (70 - 90° C oil temperature. Use the oil-tem- perature tester, Special Tools 9122 and 9122/2. 3. Do not separate the connection for the Lambda probe. Connect CO tester and sepa- rate speedometer according to the manufac- turer's specifications. CO reference value 0.4...1.2% Idle speed 840 +40 rpm Checking idle speed and CO- with catalytic converter Printed in Germany ~ XX 1989 24 - 10524 Air Flow Controlled Fuel Injection 944 Checking idle speed and CO without catalytic converter Model 87 onward Engine type M 44.40/41 (3.0 1) Note It is no longer possible to adjust the idle speed. The throttle valve connector adjust- ‘ment therefore no longer applies. Idle/CO adjustment Adjustment preconditions Engine in perfect mechanical conditions. Con- sumers must be switched off during adjust- ment work. Carry out adjustment as quickly as possible to ensure that the intake paths do not heat up thus falsifying the CO value ‘Ambient temperature 15 - 35* C. 1. Warm engine up to operating temperature. (70 - 90°C oil temperature). Use oil tempera- ture tester, Special Tools 9122 and 9122/2. 2, Check CO value. If the CO value is not within the prescribed tolerances, correct the setting at the airflow sensor. Remove the sealing plug in the access bore to the CO adjusting screw. Engine type M 44.40 Standard screwdriver for 3 mm Allen screw. Engine type M 44.41 (3.0 1) Standard angled screwdriver for 5 mm Allen screw. Ilustration shows engine type M 44.40 CO setting: 0.5..1.5 % Tum to the right - richer mocure Tum to the left - leaner mixture Checking idle speed. 1. Connect separate speedometer according to manufacturer's specifications. Idle speed 840 + 40 rpm 24-106 Checking idle speed and CO- with catalytic converter Printed in Germany ~ XX, 1988944 Air Flow Controlled Fuel Injection Replacing air filter insert Model 89 onward Engine type M 44.41 (3.0 1) 1. Replace front end plate. Refer to 944 Works- hop Manual Page 50 - . 2. Undo retaining clips and remove housing cover with fter insert 3. Clean inside of fitter housing with lint-free loth. 4, Install new filter insert. Observe installation position. Arrow or TOP-OBEN marking points towards the engine. 24 Checking idle speed and CO- with catalytic convertor Printed in Germany ~ XX, 1989 24-107944 Exhaust System 26 CHECKING TIGHTNESS OF EXHAUST SYSTEM FLANGES (16-VALVE ENGINES) 1.Check tightness of exhaust flanges and check entire exhaust system for leaks. 2.Check tightness of hex nuts on exhaust manifold/cylinder head flange. 3.Check tightness of ali flange connections in exhaust system, together with oxygen sensor and exhaust extraction tube. 4.Check tightness of bolts in primary muffler (catalytic converter)/secondary muffler flange. Check exhaust-system hangers. Tightening torques of nuts and bolts: M8 20+ 2 Nm (14 + 1.4 ftIb) M10 40 + 5 Nm (30 + 3.6 ftlb) Printed in Germany - XI11,1987 Checking Tightness of Exhaust 26 - 101 System Flanges94a Ignition System 28 EQUIPMENT TABLE Ignition Coil Type/Mode1 Version Remarks 34a S 944 602 115 00 Without series Bosch No. resistors 0 221 118 322 Distributor (Cap) Type/Model Version Remarks ES 328 602 11 OF ‘Only _high=tens ton | Bosch No. distribution 1 235 622 395 Spark plugs Type/Model Version Remarks was Bosch wR TDC Spark gap 0.7 + 0.1 mm | | | Ignition trigger box Type/Model Version Remarks 34a S ] 928 602 706 OT Bosch No. 0 227 100 124 Printed in Germany - XII1,1987 Equipment Table 28 - 10128 Igniton System 944 DME contro! unit ‘Type/Model Version Remarks 944 S Mod. '87 944.618.124.00 M 44.40 944.618.124.01 ‘Spare part 944 S Mod. '88 944.618.124.01 M 44.40 Hall probe for knock sensors ‘Type/Model Version Remarks 44S 1944,606.170.01 Knock sensor Type/Model Version Remarks 9448 1944,606.145.00 Tightening torque = 20 Nm (14 fib), use specified mounting bott (without washer) 28 - 102 Printed in Germany ~ XXV, 1992944 Ignition System 28 OME CONTROL UNIT CODING, 944 S, ‘87 MODELS ONWARD 944.612.525.01 1 = Plug for characteristic-map 928.607.421.00 switch 928.607.422.00 2 - Plug for variant switch 944.612.522.00 ] [Country Characteristic-map switch, Varient switch, ter. 39 | ter. 54 | | | i \USA, rest of iworld with > - catalytic converters California, - | 928.607.421.00 Japan | EC, without catalytic i - 928.607.422.00 converters i | [Sweden - 944.612.522.00 i australia 944.612.525.01 . Printed in Germany-XVII ,1988 DME Control Unit Coding, 28 - 103 944 S '87 Models Onward28 _Isnition systen REPLACING SPARK PLUGS, 944 S 1.Pull off spark plug caps. 2.Unscrew spark plugs with commercially available wrench. A spark-plug wrench is supplied as part of the car's toolkit. Tightening torque: 25 - 30 Nm (18 - 22 ftib). 944 28 - 104 Replacing Spark Plugs Printed in Germany944 Igniton System 28 Equipment table 89 models onward Engine type M 44.41 (3.0 1) Ignition Coit ‘Type/Model Version Remarks 94482 944 602 115 00 without series resistors Bosch No. 0.221 118 322 Distributor (Cap) ‘Type/Model Version Remarks 944.82 928 602 211 01 (Only high-tension distribution Bosch No, 1 235 522 395 Spark plugs Type/Model Version Remarks 944 S2 Bosch WR 5 DC ‘Spark gap 0,7 +0,1 mm Ignition trigger box Type/Model Version Remarks e442 928 602 706 01 Bosch No. 0.227 100 124 Equipment table 89 models onward Printed in Germany — XXV, 1982 28-10528 Ignton System oa DME Control unit Type/Model Version Remarks 944 S 2 Mod. "89/90 944.618.124.02 944 S 2 Mod. ‘91 944.618.124.05 Hall probe for knock sensors Type/Model Version Remarks, o4as2 944 606. 170 01 Knock sensor Type/Model Version Remarks 94482 1944.606.145.00 Tightening torque = 20 Nm (14 ftlb), use specified mounting bott (without washer) 28-106 Equipment table 89 models onward inted in Germany — X0CV, 1982ou Ignition System, Diagnosis 28 Coding - DEE control unit 944 S 2, Model 89 onwards 1 928,607.421.00 1 = not used 2 - 928.607.422.00 2 - connector for variant switch Country Variant switch USA, rest of word with — catalytic convertor California, Japan 928.607.421.00 Rest of world without catalytic convertor 1928.607.422.00 Coding - DEE control unit 944 S 2, Model 89 onwards 28-107 Printed in Germany ~ XIX, 1989DME-Diagnosis / Troubleshooting Dr. Ing. h.c. F. Porsche AktiengesellschaftFuel System - Electronic Control 24/28 944 S/oaa S2 Test Point Description Page Precautions . 2 Important Vehicle Information 3 Testing Requirements 4 Effects of Faults (Cross Reference Lis). 7 DME Control Unit Plug Connections. 8 1 Power Supply... 9 2 Idle Speed Contact. 10 3 Full Load Contact. 44 4 Engine Temperature Sensor... 12 5 Air Flow Sensor. 13 6 Idle Speed Control Activation.. 14 7 ‘Oxygen Regulation Stop 18 8 Oxygen SeNSOF enn 16 9 Intake Air Temperature Sensor... 16 10 Knock Sensor |... 17 1" Knock Sensor I 17 12 Control Unit Faulty. 18 13 Hall Signal ne 18 14 Control Unit Fauity 18 18 DME Relays. 19 16 Tank Venting Vaive.... 19 7 ‘Check Engine Warning Lamp... 20 18 Fuel Pressure. . nn 21 19 Intake System Leaks 22 20 Ground and Plug Connections. 22 a ‘Speed/Reference Mark Sender... 24 2 Ignition and Final Stage : 25 23 Fuel Injectors ~ Injection Control Unit. 28 24 ‘Alternator / Regulator 23 25 Leads K and L. 29 CO and Idle Speed Test. 30 Coding of Control Unit... 31 Check-Engine-Lamp.. 83 DME - Diagnosing/Troubleshooting D 2a28-4 Printed In Germany ~ Xx, 198924/28 Fuel System - Electronic Control 94a S/oaa S2 Precautions Greater demands of modern engines on the ignition systems and a desire for freedom from mai tenance had led to the introduction of electronic ignition systems in standard production some time ago already. Normally the ignition power of electronic systems (almost all makes) will be greater than that of conventional systems and even greater power can be expected in the future. This places elec- tronic ignition systems in a power range, where touching current carrying parts or terminals could be dangerous to life (both primary and secondary circuits). In conjunction with this matter we must point out that there must always be conformance with safety regulations and legislation of a pertinent country when working on or testing ignition systems. The ig- nition (ignition or source of power) must always be switched off when working on the ignition system. ‘Sample Jobs: ‘¢ Connecting engine testers, for example: timing light, dwell angle/speed tester, oscilloscope, etc. ‘© Replacing ignition components, for example: spark plugs, ignition coil, distributor, ignition leads, ete. The above mentioned dangerous voltage will be present in the entire system should it be necessary to switch on the ignition for ignition tests or engine adjustments. Consequently there is not only danger on the various components of an ignition system (such as, for example, distributor, ignition coil, control units, ignition tackle), but also on wire harnesses, plug con- nections and testers. D 24/28 -2 DME - Diagnosing/Troubleshooting Printed in Germany ~ XX), 1989a4 sions S2 Fuel System ~ Electronic Control 24/28 important Vehicle Information ‘Always tur off the ignition or disconnect the battery for resistance tests (if not, the tester could be destroyed) ‘¢ Always disconnect the speed sender plug for compression tests (if not, there could be dangerous high tension and damaged insulation on the ignition coll, high tension distributor and ignition leads). @ Never replace a specified ignition coll (see order number) with a different ignition coil ‘Never connect a suppression capacitor on ignition coil terminals 1 and 15. ‘® Never connect ignition coil terminal 1 on ground for the burglar alarm (ignition coll and control unit could be destroyed. ‘® Never connect battery + or a test lamp on ignition coil terminal 1 (control unit could be de- stroyed) ‘¢ Never disconnect the ignition lead between ignition coil terminal 4 and high tension distributor ter- minal 4 during operation. ‘© Avoid voltage flashover from ignition coll terminal 4 to ignition coil terminals 1 and 15 (control unit could be destroyed) '® To avoid destruction of the control unit, the secondary circuit of the ignition system must be suppressed with at least 4 k-ohms, whereby the original distributor rotor with 1 k-ohm suppression resistance must be installed. ‘@ Disconnect DME control unit and ignition final stage plugs only after turning off the ignition. ‘® Flashover or disruptive discharge in the area of the high tension distributor cap (poor insulation) could destroy the control unit. © Never disconnect the battery while the engine is running. ‘© Mixing up battery pole connections could lead to destruction of the ignition final stage, ignition coil and DME contro! unit ‘© Outside starting of the engine with more than 16 volts or a boost battery charger is forbidden, Always conform with accident prevention regulations when working on fuel systems. DME — Diagnosing/Troubleshooting D 24/28 - 3 Printed in Germany ~ 1, 198824/28 Fuel System - Electronic Control 944 S/94a $2 Equiprient Required for DME Tests: = Diagnostics tester 9288 (9268) with con- necting leads = 1 oscilloscope approved by Porsche = 1 digital display multimeter with an intern- al resistance of at least 10 M-ohms - 1 Bosch L-vetronic test lead, Bosch No. 1684 463 093 (check lead for correct polarity in plugs) 2 control unit plug test leads (local manu- facture) fitted with 2 flat male plugs, N 17.457.2, in order to avoid damage on plug pins in the control unit plug while test- ing - 2 adapter test leads. consisting of 4 plug connectors, N 017.483.1, soldered with 2 approx. 150 mm long leads ~ 1 three-pin test lead (e.g. VW VAG 1501) = 2 control unit plug test leads (local manu- facture) fitted with 4 flat male plugs, N 17.4572 - Test leads must always be used for test- ing! = Allssender and ignition timing signals of Porsche models can be checked with the engine testers recommended by Porsche. Instructions for connection of testers on a car will be different depending on the make, so that it will always be necessary to conform with the instructions supplied with a pertinent tester. int atm chs - Speed sender signal ~ _ Injection (ti) signals ~ epee ttn ~ Hall sender signal = ABS wheel sensor signals D 24/28 -4 DME ~ Diagnosing/Troubleshooting Printed in Germany ~ 1, 1969944 S/944 S2 Fuel System - Electronic Control 24/28 Diagnosable DME Control Unit Self-diagnosis with a fault memory, with which it is possible to detect and store certain injection. igni: tion and knock regulating system faults, is integrated in the DME control unit of 944 S cars beginning with 1988 models. ‘The DME control unit has a permanent positive connection to prevent cancellation of detected and stored faults by turning off the ignition. Detected faults remain stored in the memory for at least 50 en- gine starts (exception: idle speed switch interruption faults). Important! If the DME control unit plug or battery is disconnected, the fault memory and system adaptation will be cancelled. Tester Connections: ‘A 12-pin plug, which leads out of the DME wire harness in the passenger's footwell to the right above the DME control unit, is provided for diagnosing in cars since 1988 models. 9268 Flashing Code Testers can be connected on this plug. ‘A 19:pin plug replaces the 12-pin plug beginning with 1990 (L) models. Either a 9288 System Tester or the Flashing Code Tester (via adapter leads 9268/2) can be connected on this plug. Operation of the testers is explained in the instructions supplied with the testers. Note: A pertinent test point is supplemented by a corresponding fault flashing code of Tester 9268. Example: Test Point 2 = idle speed contact (1-12) Second digit display: "1" fault exists "2" fault does not exist The following actual engine data can be read direct in the “actual value” menu with a 9288 System Tester beginning with the version 2.0 tester module status. Intake air temperature Engine temperature Ignition timing Engine speed Oxygen sensor voltage Power supply Version code Air flow sensor signal ldle drive pulse duty factor Load signal DME - Diagnosing/Troubleshooting D 24/28 - 5 Printed in Germany ~ XXI, 196924/28 Fuel System - Electronic Control 944 s/oas 82 This DME 944 S Diagnosing/Troubleshooting Plan is based on the contents of the fault memory. Paths not included in self-diagnosis can be diagnosed with conventional equipment (Test Points 17 ~ 25, see Fault List). Troubleshooting requires that the person performing the tests ¢ is familiar with the location of components, the function and technical interconnections of the sys- tems being tested (model information), © can read and evaluate Porsche wiring diagrams, ‘© knows the functions of circuits and relays, and capable of using testers, such as the oscilloscpe, voltmeter, ohmmeter and ammeter, as well as evaluating the test results. Important! AA fault text in the display (Fault List and Flashing Code) does not always indicate a fault in the perti- nent component, but could also concern the corresponding control unit or connecting leads (paths) between the component and control unit. Troubleshooting on a running engine in the form of disconnection of plugs, etc. must not be carried ut prior to reading the fault memory, since such action could be stored as faults in the fault memory. 9288 System Tester Information Displayed in Tester Fault does not exist, this could mean: © Fault not existing at time of testing (loose contact) Remedy: visual inspection of path (connection). ‘© Conditions, with which the fault is tested, are not the same as the conditions, with which the fault had occurred, Remedy: conform with conditions displayed in the tester. Plausibi Signal of the monitored component does not fit in the tolerance range of the value calculated in the control unit. D 24/28-6 DME - Diagnosing/Troubleshooting Printed in Germany ~ 00, 1989944 S/oaa $2 Fault, Fault Code Test Point 1a Power supply for DME control unit (V) Test Point 1b Power supply for DME contro! unit (V) too high / too low Fault Code 1_11 Fuel System ~ Electronic Control 24/28 Possible Causes, Elimination, Remarks a) Perm. pos. (B+) Fault memory is cancelled, if there is no B +. Testing: Connect a voltmeter on terminal 24 (-) and terminal 18 (+) of the Control unit plug with help of test leads. Display: battery voltage No display: check current flow and ground paths according to the wiring diagram. b) Power supply via DME relay Connect a voltmeter on terminal 24 (-) and terminal 37 (+) of the control unit plug with help of test leads. Turn on ignition. Display: battery voltage No display: check current flow path according to the wiring diagram. Remarks: Cars with burglar alarm: check power supply from ignition lock via burglar alarm control unit to terminal 86 of the DME relay according to the wiring diagram. Cars without burglar alarm: check pin bridges on plug (provided for installation of a burglar alarm control unit) DME Diagnosing/Troubleshooting D 24/28 - 9 Printed in Germany ~ XX), 198024/28 Fault, Fault Code Test Point 2: Idle speed contact (2) Ground short Fault Code 1_12 Idle speed contact (2) Break Fuel System - Electronic Control 944 S/oaa S2 Possible Causes, Elimination, Remarks Check via circuit input test with 9288 System Tester or 9268 Tester. Select test step and operate accelerator pedal 9288 Display: Idle speed contact made Idle speed contact broken 9268 Display: 1332 (idle speed contact made) (0000 (idle speed contact broken) No Display: Pull off plug on DME control unit. Connect ohmmeter between terminal 52 and terminal 24 with help of test leads. Display: Throttle valve closed <102 Throttle valve opened to gap of >1° = @2 If the value of the idle speed contact is not reached in this test, the test should be repeated direct on the throttle valve switch as describ- ed below. Pull off plug on throttle valve switch. Connect ohmmeter between ter- rminals 1 and 2 of the throttle valve switch with help of test leads. Display: Throttle valve closed <109 Throttle valve opened to gap of > 1° = = Testing same as described for ground short (fault stored in memory as of 1991 models). Fault Code 1_15 Check for correct adjustment, correcting if necessary. Cause, for example, could be an incorrectly adjusted throttle valve switch or accelerator cable. D 24/28 - 10 DME Diagnosing/Troubleshooting Printed in Germany ~ 0, 1988944 $/944 S2 Fault, Fault Code Fuel System - Electronic Control 24/28 Possible Causes, Elimination, Remarks Test Point 3 Full load contact (2) Ground short Fault Code 1_13 Check via circuit input test with a 9288 System Tester or 9268 Tester. Select test step and operate accelerator pedal. 9288 Display: Full load contact broken Full load contact made 9268 Display: 1333 (full load contact broken) (0000 (full load contact made) No Display: Connect ohmmeter on terminal 53 and terminal 24 of the disconnect- ed DME control unit plug with help of test leads. Display: Throttle valve closed 2a Throttle valve opened about 2/8rd of full gap <102 If the value of the full load contact is not reached in this test, the test should be repeated direct on the throttle valve switch as described below. Pull off plug on throttle valve switch. Connect ohmmeter between ter- minal 3 and terminal 2 of the throttle valve switch with help of test leads. Display: Throttle valve closed 22 Throttle valve opened about 23rd of full gap <109 Remarks: If the full load contact fails, the control unit produces a load thresh- hold via the air flow sensor. Value below this load threshold same as switch broken or above load threshold same as switch made, DME Diagnosing/Troubleshooting D 2428-11 Printed in Germany ~ XX), 198924/28 Fault, Fault Code Test Point 4 Engine temp. sensor (NTC 1/9) Fault Code 1_14 Fuel System ~ Electronic Control 944 $/944 S2 Possible Causes, Elimination, Remarks Engine temperature can be read direct from the “actual value” menu with a 9288 System Tester. No Plausible Display: Connect ohmmeter on terminal 45 and terminal 24 of the disconnect- ‘ed DME control unit plug with help of test leads. Display at: OC = 44-68kQ 18 - 30°C 1.4-36kQ 40°C 1.0 - 1.3 kQ gOS = 250-3902 100° = 160-2102 Test direct on the engine temperature sensor, if the values are not reached. Note: Temperature sensor II sends information about the engine temperature to the control unit. It is used to provide a rich fuel/air mixture after a cold start or during warm-up, Break (@ 9) DME control unit of the 944 selects a resistance value, which is stored in the control unit's memory and is approximately equal to that of an engine at operating temperature. There is no enrichment from a faulty NTC Il when the engine is warm (emergency running program). This results in starting problems when the engine is cold (no cold start enrichment) Short (0 2): No engine pickup, too lean and stopping of engine in cold state. No effects in operating temperature state Replacement value is applicable to both types of fault! D 2a/2e - 12 DME Diagnosing/Troubleshooting Printed in Germany ~ XXI, 1969944 S/944 S2 Fault, Fault Code Test Point 5a: Air flow sensor (V/Q) Fault Code 1_21 Test Point 5b: Fuel System - Electronic Control 24/28 Possible Causes, Elimination, Remarks ‘The ratio between Up (potentiometer voltage) and Uv (power supply voltage) can be read in the “actual value” menu with a 9288 System Tester. When opening the air flow sensor plate the ratio must be about 0.0 to 1. Ht not: a) Power supply voltage Connect a voltmeter on terminal 3 and terminal 4 of the discon- nected air flow sensor plug with help of test leads. Turn on ignition. Display: 5 + 0.3 volts ) Voltage drop on air flow sensor plate potentiometer (V) =S—= Take off air cleaner connecting hose. Connect pin 3 of the discon- nected air flow sensor plug with air flow sensor plug terminal 3 and pin 4 with air flow sensor plug terminal 4 with help of test leads. Connect a voltmeter on air flow sensor terminal 2 and terminal 4 (tur on ignition). Display: approx. 250 - 260 mV It must be possible to move the air flow sensor plate easily and without hesitation. Observe the voltmeters display at the same time Voltage jump or voltage drop should not be observed while the air flow sensor plate is opening or closing Display with air flow sensor plate in full load position: approx. 4.60 volts. DME Diagnosing/Troubleshooting D 24/28 - 13, Printed in Germany — X00, 199124/28 Fault, Fault Code Test Point 6: Idle speed contro! (V) Fault Code 1_22 only $2 Fuel System ~ Electronic Control 944 S/94a S2 Possible Causes, Elimination, Remarks ‘Turn off ignition and reconnect plug if the voltage values have been reached. Remarks: Control unit produces replacement values in case of air low sensor failure (emergency running program). Injection signal from nominal ar ofthe idle speed volumetric efic- ency control for idle or a constant injection signal t; for partial load and ful load ranges. Element Activation Menu I pulse cannot be heard, check: Power supply Connect a voltmeter on terminal 2 and ground of the disconnected idle speed con trol plug Turn on ignition Display: battery voltage No display: Check power supply according to the wiring diagram. Control signal test ‘The pulse duty factor in % can be read direct in the “actual value" menu with a 9288 System Tester. Function test: Switch on electric power consumers with engine run- ning at idle speed. The pulse duty factor must change and the idle speed must remain constant I not D 24/28 - 14 DME Diagnosing/Troubleshooting Printed in Germany ~ 00, 1988944 S/944 S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Connect two-pin DME test lead (Bosch No. 1 684 463 093) between the speed control and plug. Connect and adjust engine tester to supplied operating instructions. Make sure that electric lead connections do not have contact with ve- hicle ground (danger of short). Displayed with the engine running: Frequency: approx. 100 Hz Replace the idle speed control if the pulse cannot be heard in spite of correct power supply and received signal. Test Point 7 Oxygen regulation (Oxygen regulation cannot work in its regulating range in case of dis- on stop turbances in airftuel mixture; for example: too lean because of exces- Fax caenies sive air or too rich because of a sticking fuel injector. It then moves . against the stop. Test 1 Check CO level with the engine running and CO tester connected (between 0.4 and 1.2 %) 100 lean: Check intake system for leaks (lest Point 19). to9 rich: Check system pressure (Test Point 18) ‘Check fuel injectors for leaks (Test Point 18). DME Diagnosing/Troubleshooting D 24/28 - 15 Printed in Germany ~ XX), 198924/28 Fault, Fault Code Fuel System - Electronic Control 944 S/oaa $2 Possible Causes, Eli ation, Remarks Test Point 8: Oxygen sensor (V) (sensor signal) Fault Code 1_24 Test Point 9 ‘Air temperature sensor NTC 1 (Q) Fault Code 1_25 Sensor signal test ‘Sensor voltage can be read direct in the “actual value" menu with a 9288 System Tester. Ht not Disconnect oxygen sensor plug. Connect a di tion (sensor voltage signal) and ground. ceawamyennstaengnen \ © J ee the voltage signal must be displayed when the mix- Display on voltmeter: approx. 150 mV - 900 mV (depending on composition of mixture) Remarks: | the control unit recognizes an oxygen sensor voltage signal of more than 1 V or less than 0.1 V, the control unit will switch over to ‘operation without oxygen sensor (short or break). If regulation does not work and the sensor voltage signal is okay, ‘check the coding of the control unit before replacing the control unit. Intake air temperature can be read dire with a 9288 System Tester. the “actual value” menu If not or when a non-plausible value is displayed: Connect an ohmmeter on terminal 44 and terminal 26 of the discon- nected DME control unit plug. D 24/28 - 16 ‘DME Diagnosing/Troubleshooting Printed in Germany ~ 0, 1988944 $/944 S2 Fault, Fault Code Test Point 10 Knock sensor | Fault Code 1_31 Test Point 11 Knock sensor i! Fault Code 1_32 Fuel System - Electronic Control 24/28 Possible Causes, Elimination, Remarks If no display: Disconnect plug on air flow sensor. Connect an ohm- ‘meter on air flow sensor terminals 1 and 4 with help of test leads. Display: same as above. Note: In case of a break, there will be a replacement value equal to an intake air temperature of 20° C (emergency running program). Knock sensor I: Knock signal not plausible. Check: — Installation of knock sensor (check tightening torque and type of screw). Wire harness and plug connections according to wiring diagram. Reconnecting sensors eliminates contact resistance. = Whether coolant or other liquids are in area of the knock sensor. Replace knock sensor. Ignition timing retarded by 6° on crankshaft in case of a faulty knock sensor, Knock sensor Il: Knock signal not plausible. Check: ~ Installation of knock sensor (check tightening torque and type of screw), - Wire harness and plug connections according to wiring diagram. Reconnecting sensors eliminates contact resistance. Whether coolant or other liquids are in area of the knock sensor. Replace knock sensor. Ignition timing retarded by 6° on crankshaft in case of a faulty knock sensor. DME Diagnosing/Troubleshooting D 24/28 - 17 Printed in Germany ~ 200, 198924/28 Fuel System ~ Electronic Controt 944 $/944 S2 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 12 Control unit (knock computer) Fault Code 1_33 Test Point 13: Hall signal Fault Code 1_34 Test Point 14: Controt unit faulty Fault Code 1_41 Ignition timing is retarded 6° in case of this fault, Replace control unit. Disconnect plug on cylinder head behind the camshaft drive gear and connect a three-pin adapter lead (VW 1501) inbetween to check the Hall signal. Connect oscilloscope positive and negative test leads on terminals 1 and 2 of the adapter lead. Start the engine. This signal should be displayed when the Hall system is okay: —=— ttun = —- Ignition timing will be retarded approximately 6° in all speed ranges, it the DME control unit recognizes that the Hall signal is missing Protective circuit test: Turn off ignition. Disconnect Hall plug. Start the engine. idle speed ig- nition timing will adjust itself to approximately 4° before TDC (944 S), There must be a certain load signal from the air flow sensor in case of 944 S2 cars. Replace control unit D 24/28 - 18 DME Diagnosing/Troubleshooting Printed in Germany ~ 0, 1969944 S/oaa S2 Fuel System - Electronic Control 24/28 Fault, Fault Code Possible Causes, Elimination, Remarks Test Point 15 DME relay (fuel pump) (V) Test Point 16: ‘Tank venting valve (V) Fault Code 1_43 (not 944 S) Start the engine — fuel pump must run during engine starting. It not ‘Tum off ignition. Disconnect control unit plug. Connect terminal 3 and terminal 24 on the control unit plug with help of a test lead. ‘Tum on ignition ~ the pump must run! H not: Check current flow and ground paths of DME relay and fuel pump according to the wiring diagram. Electric valve (for brake booster) will be opened more or less long de- pending on the engine load when an engine having operating temper- ature is running. The opened time is determined by a ground pulse from the control unit. a) Activation test ‘Activate the tank venting valve in the “element activation’ menu of the tester. fa pulse is not heard, check power supply to terminal 1 of the electromagnetic valve plug according to the wiring diagram b) Control signal test Install DME test lead (Bosch No. 1 684 463 093) between the electro- magnetic valve and plug connection. Connect and adjust engine tester according to the supplied operating instructions. DME Diagnosing/Troubleshooting D 24/28 - 19 Printed in Germany ~ XX, 198924/28 Fault, Fault Code Test Point 17 Check Engine warning lamp Fault Code 1_45, (California as of 1991 models) Fuel System - Electronic Control! 944 $/944 S2 Possible Causes, Elimination, Remarks Tank venting valve is not activated permanently. ‘Test must be performed within 7 minutes after starting an engine having operating temperature (interrupt tank venting valve activation approx. 75 seconds afterward and then continue), Start engine and accelerate. This must be displayed in the tester for ‘an engine at operating temperature: ‘Signal wil be wider as the air flow rate increases! Check path according to the wiring diagram if there is no signal Replace control unit if necessary. ‘A ground signal from control unit plug terminal 22 goes to and switches on the "Check Engine Lamp’, it a component influencing emission control fails. If the "Check Engine" warning lamp fails, this fault is stored in the fault memory. Check by supplying ground to control unit plug terminal 22 and turn- ing on the ignition. Always replace a faulty display lamp with a specified lamp. D 24/28 - 20 DME Diagnosing/Troubleshooting Printed in Germany ~ XXI, 1989944 $/944 S2 Fuel System ~ Electronic Control 24/28 Test Point 18: Fuel Pressure Fuel collection pipe has a test connection at left front. Unscrew cap nut of the test connec- tion, Important! Inserted ball seal could fall out! Connect P 378 pressure tester on the test con- nection. Start the engine. Vacuum on pressure regulator at idle speed: Test pressure: 3.3 + 0.2 bar Hot starting problems: Check with the engine stopped and fuel pump running, without vacuum on the pressure regu- lator (this requires removing the DME relay and bridging terminals 87 and 30): Test pressure: 3.8 + 0.2 bar = Stop fuel pump. Read pressure on the pres- sure tester (specification: 3.8 + 0.2 bar). = Max. permissible pressure drop on warm engine: 0.5 bar in 30 minutes. = If the pressure drops below the specified value, proceed as described below. Build up pressure again by switching on the fuel pump briefly. Remove retum pipe on the pressure regulator (uel pump must not be switched on). | No tuel escaping trom the pressure regulator connection ‘connection Fuel escaping from the pressure regulator I Reconnect return hose Replace pressure regulator ee [Bui up pressure again [ Disconnect nubber pressure hose (tank to pump) infront ofthe fuel pump T Pressure drop | [Pressure drop ot okay ‘okay I Fault intuel | [ Replace uel injectors ‘pump holding (eakage) valve I ] ‘Check tuel injectors. Replace leaking fue! Injectors. Repeat leak test End DME - Diagnosing/Troubleshooting Printed in Germany ~ XX, 1986 D 24/28 - 2124/28 Fuel System - Electronic Control 944 S/9aa S2 Test Point 19: Intake System Leaks Check all connections atter the air flow sensor for leaks. Remove upper air cleaner section. ‘Apply Special Tool 8264/4 on the air flow sen- sor and produce approx. 0.5 bar pressure in the intake system. Leaks will cause the pres- sure in the system to drop quickly. (044 S: shut the safety pressure valve for crank- case breathing) Remarks: Flashing Fault Code 1_28 (oxygen regulation (on stop) is displayed in cars with oxygen regu- lation and very large leakage in the intake sys- tem (for example: intake pipe gasket). Test Point 20: Ground Connections ™) ‘© Ground lead (2 x) from wire harness to en- gine block. ‘© Battery ground lead on clutch bell housing (engine ground) and on body (body ‘ground next to battery) © Ignition final stage ground on side member at left front, ‘© Fuel pump ground on rear lock cross wall behind the spare wheel. © Are ground connections tight and without corrosion? Loosen, clean and retighten ground connections as specified. Caution! Never start the engine as long as the ground lead between the body and engine is disconnected! This would destroy the contro! unit immedi- ately!. D 24/28 - 22 DME ~ Diagnosing/Troubleshooting Printed in Germany ~ XX, 1989944 S/9aa S2 Fuel System ~ Electronic Control 24/28 Plug Connections ‘Are all plugs connected correctly, not loose and not corded? Disconnect plugs and check whether pins and terminals of plugs are bent or corroded. ‘© 55-pin plug on DME control unit (behind floor plate in the front passenger's foot- well), @ 14-pin plug in engine compartment next to the brake booster. ¢ 3:pin plug for reference mark/speed sender and 3-pin plug for oxygen sensor behind the intake pipe for cylinder no. 4 (first remove cover on the fuel ring-pipe). ‘© 3:pin plug on throttle valve switch, © 2:pin plug on electromagnetic valve for tank venting (on brake booster) © 4:pin plug on air flow sensor. ‘© 2:pin plug on NTC It temperature sensor is sorewed in the engine block above the left compensating shatt near eyinder no. » ‘© 7-pin plug on ignition final stage in the en- gine compartment at front left. © S-pin Hall sender plug (behind the cam- shaft drive gear). © 2>pin plug for knock sensor | (between in- take pipes for cylinder no. 1 and 2). ‘© 2>pin plug for knock sensor Il (between in- take pipes for cylinder no. 3 and 4). © pin plug on idle speed control (between intake pipes for cylinder no. 2 and 3) ‘944 $2: between cylinder no. 1 and 2. ‘© Plug for fuel injector ballast resistors (in en- gine compartment at rear right next to the plug for the brake pad wear indicator) ¢ 2:pin plugs on each of the four fuel injec- tors. Because 944 S cars are supplied worldwide since 1987 models with only one standard con- trol unit and said control unit is coded accord- ingly depending on country equipment, this coding must be checked in case of complaint. A 2-pin or 3-pin plug leads out of the DME wire harness near the plug receptacle, in order to be able to call the different curve families. Power is supplied to the DME control unt of a 944 S via terminal 30 (battery +) in addition to Via ignition lock terminal 15. DME ~ Diagnosing/Troubleshooting Printed ia Germany ~ %, 1989 D 24/28 - 2324/28 Fuel System ~ Electronic Control 944 S/944 S2 Test Point 21: Speed/Reference Mark Sender This test can only be performed with an oscillo- scope. Connect and adjust a workshop oscillo- ‘scope according to the supplied operating in- structions for this purpose. Connect the positive tester lead via a test lead ‘on control unit plug terminal 47 and negative tester lead via a test lead on control unit plug terminal 48. Crank engine with the starter motor. Sinusoidal oscillation of at least 3 volts (speed pulse) and ‘an applied higher amplitude (reference mark) must be displayed on the screen. A If the voltage signal is too small (< 3 V), the 1 ~ Speed signal distance between the sender and gear ring 2- Reference mark signal could be adjusted incorrectly Sender distance: Between gear ting and sender: 0.8 + 0.3 mm. D 24/28 - 24 DME - Diagnosing/Troubleshooting Printed in Germany ~ 4, 1988944 $/944 S2 Fuel System - Electronic Control 24/28 No display: Disconnect plug of speed sender on plug plate in the engine compartment. Connect tester leads on middle and outside pins of the plug ‘on the sender end of the plug with help of test leads (terminals 1 and 2, pin end). Start the en- gine. Sinusoidal oscillation must be displayed con the screen, Speed sender plug Remarks: ‘The display must remain unchanged after sup- plying ground to connection 3. It not, check power flow, spacing and condi- tion of the sender. Test Point 22: Ignition 8) Secondary ignition display ‘Adjust secondary ignition display on the oscillo- scope. Connect tester leads according to the supplied operating instructions. Note: Ifa faut is displayed for all cylinders, iis in the primary or secondary circuit from the igni- tion coil to the distributor rotor. I a fault is dis- played for one cylinder, this fault is located after the distributor rotor. Term. +15 Term.1+4 Primary resistor: ‘Secondary resistor: 04.062 5-72 kQ ) Spark plug connectors (2) ‘Suppression resistor: 3 k@ Visual inspection for damage or traces of burn- ing. ©) Distributor Distributor rotor, distributor cap: suppression resistor = each 1 kQ. Visual inspection for damage, dirt or wrong location. DME - Diagnosing/Troubleshooting Printed in Germany ~ 21, 1989 D 24/28 - 2524/28 4d) Ignition timing test Ignition timing is checked with the engine at operating temperature. Ignition timing and engine speed can be read direct in the "actual value" menu with a 9288 ‘System Tester. Test value: (94S + 944 S2) At 840 + 40 rpm 10° + 3° Fuel System ~ Electronic Control 94a $/9aa S2 e) Activation of high tension end i ignition sparks are not triggered) Ignition triggering signal can be simulated for fast troubleshooting of the ignition end. This re- quires connecting the oscilloscope term. 4 tester lead on the ignition lead betw. ignition coil and high tension distributor (term. 4). Disconnect DME control unit plug. Turn on igni It battery voltage is now supplied intermittently to terminal 1 of the control unit with help of a test lead (e.g. control unit plug term. 18), a high tension peak must be displayed on the oscilloscope each time (ignition triggering). If there is no signal, check: ~ Power supply to ignition final stage and ignition coil ~ Ground connection for ignition final stage (ground point on let front side member). ~ Plug connections on ignition final stage, ig- nition coil and high tension distributor Components responsible for high tension (for example: ignition coil, ignition leads, spark plug connectors, etc.) ~ Power flow in lead between control unit plug and ignition final stage term. 5. D 2a/2e - 26 DME ~ Diagnosing/Troubleshooting Printed in Germany — ¥, 198944 sions s2 Fuel System - Eletronie Control 24/28 4) Ignition final stage control signal test Connect DME control unit plug. Connect oscilloscope’s positive tester lead on terminal § and negative tester lead on terminal 2 of the disconnected final stage plug. Very important: Coat the baseplate with a heat conducting paste prior to installation of the ignition final stage. Keep heat conducting paste off of painted parts. Heat conducting paste: Bosch No. 5 942 860 003. Operate starter motor. Oscilloscope should display the control signal ‘of the DME control unit, 1 ~ Final stage 2 Baseplate DME - Diagnosing/Troubleshooting Printed in Germany ~ XX, 1989 D 24/28 - 2724/28 Fuel System - Electronic Control 944 S/9aa S2 Test Point 23: Fuel Injectors - Injec- tion Timing (V/2) Element activation menu: Ifa pulse is not heard, check a) Power supply Pull off injector plug. Connect voltmeter on in- jector plug terminal 2 and ground with help of test leads. Turn on ignition. Display: battery voltage It there is no display: 2 Disconnect §-pin plug of fue! injector ballast re- sistors. Connect voltmeter between terminal 3 (terminal sleeve end) and ground. Tum on ignition, If battery voltage is displayed, turn off ignition and pull off all plugs on fue! injectors. Check power flow and resistance between the 5-pin plug of ballast resistors and terminal 2 of each fue! injector plug with an chmmeter. Resistance of each ballast resistor 2 1 Check current path according to the wiring dia- gram if battery voltage is not displayed. b) Coil resistance test of fuel injectors Pull off injector plugs. Check coil resistance on the contacts of the fue! injectors with an ohmmeter. Test value: 2-3 2 ¢) Injection final stage Adjust oscilloscope according to the supplied operating instructions. Connect Bosch test lead (1 684 463 093) between fuel injector and plug. Connect tester leads on Bosch lead ac- cording to the supplied operating instructions. Caution: Tester leads must not have any contact with ground. Start the engine. These displays must appear in the oscilloscope if the injection final stage is working perfectly and test connections are cor- rect, Starter speed Remarks: If the engine cannot be started or the idle speed drops, change tester connections on the Bosch lead and check tester adjustment. D 24/28 - 28 DME ~ Diagnosing/Troubleshooting Printed in Germany ~ 00, 1989944 S/9aa S2 Fuel System ~ Electronic Control 24/28 Test Point 24: Alternator, Regulator Misfiring of the engine could be caused by the Peak voltage of the alternator. Take drive belt off of the alternator. Start the engine. Check alternator and regulator if the disturb- ances have been eliminated. Test Point 25: Leads K and L Connections for diagnosing between the DME control unit and testers are made with both leads K and L. Check the following points when diagnosing is not possible. 1. Power flow test (see wiring diagram) Lead L: Pin 7 (19:pin diagnostics socket) - Pin 13 (OME plug) Lead K: Pin 8 (19-pin diagnostics socket) ~ Pin 55 (OME plug) 2. Ground short test (see wiring diagram) Lead L: Voltage on Pin 7 (19-pin diagnostics socket) must be > 8 V with the ignition turned on, Lead K: Voltage on pin 8 (19-pin diagnostics. socket) must be > 8 V with the ignition tured on. Possible Causes of Fault: = Ground short or break in wiring of plug con nections. ~ Faulty control unit, which is connected on these leads (could be any diagnosable con- trol unit; does not always have to be the DME control unit), Checking: Pull off plugs on diagnosable con- ‘rol units one after the other until there is > 8 V. Replace fault-causing control unit. = Tester faulty. - Power supply lacking on diagnostics socket = Ground supply lac socket. ‘on diagnostics Information for idle speed and idle speed CO test: a) Idle speed ‘944 S engines have adaptive idle speed volumetric efficiency regulation since 1987 ‘models. This means that the idle speed of all versions does not have to be adjusted. The system of cars with adaptive idle speed volumetric efficiency regulation should be adapted each time the DME control unit had been disconnected on permanent positive or after each inspection. Idle speed control value for engine at operat- ing temperature: 840 = 40 rpm. b) Idle speed CO of cars without catalytic converter CO level is stil adjusted on the CO adjusting ‘screw in the air flow sensor. Requirements: - Engine at operating temperature. = Engine and ignition in perfect running condi- tion. = All electric consumers switched off ~ CO tester at operating temperature, cali- brated and adjusted correctiy DME - Diagnosing/Troubleshooting Printed in Germany ~ 1, 1989 D 24/28 - 2924/28 Fuel System — Electronic Control 944 $/944 S2 Adjustirig value: 0.5 - 1.5 % CO at 840 = 40 rpm and ignition timing of 10° + 3° before TDC. ‘Adapt the system after adjusting the CO level ‘An adapter plug (911.612.422.8) must be con- nected on the oxygen sensor connecting lead of cars without a catalytic converte, in order to avoid diffusion (see wiring diagram). ¢) Idle speed CO of cars with catalytic converter In addition to adaptation of the idle speed there is also adaptation of the idle speed CO level in these cars, so that itis only necessary to check the actual state in such cars. Requirements: = Engine at operating temperature. = Engine and ignition in perfect running condi- tion, = All electric consumers switched off = CO tester at operating temperature, cali- brated and adjusted correctly = Oxygen sensor plug connected. Test value: 0.4~ 1.2 % CO at 840 40 rpm and ignition timing of 10° + 3° before TOC. Afterwards the engine must be run at least 10 minutes after disconnection of the con- trol unit plug or disconnection of the battery, before it will be possible to recheck these values. In addition, the system must be adapted. D 24/28 - 30 DME ~ Diagnosing/Troubleshooting Printed in Germany ~ XX944 §/944 S2 Fuel System — Electronic Control 24/28 Coding of Control Unit - 944 S Pertinent curve families are integrated in the DME control uni, in order to be able to comply with the legislation of different countries. They can be read tem Tester. a ' : ‘One each 2-pin and 3-pin plug, which are bridged differently deper ‘out of the DME wire harness to call these curve families. fect in the “actual value” menu with a 9288 Sys- jing on the country version, lead Country Curve Family Switch Version Switch 2 Pins 3 Pins USA Federal States FRG M 298 - - ‘Oxygen sensor USA California Bridge against Japan battery voltage ‘Oxygen sensor : 928.607.421.00 ECE - Bridge against gra. 928.607.422.00 ‘Sweden - Resistance 68 k® against grd. 1944.612.522.00 Australia Bridge against ground - ‘Oxygen sensor 944.612,515.00 DME ~ Diagnosing/Troubleshooting D 2428-31 Printed in Germany ~ XX), 198924/28 Fuel System — Electronic Control 944 S/944 S2 Coding of Control Unit - 944 S 2 Country Curve Family Switch Version Switch 2 Pins 3 Pins Al with cat. conv. - California, Japan Bridge against battery + 1928,607.421.00, Ail without cat. conv. - Bridge against grd. 1928.607,422.000 AAs from model year ’91, the code for California and Japan is being deleted (identical worldwide). D 2a/2e - 32 DME - Diagnosing/Troubleshooting Printed in Germany ~ Xt, 1990eas se Fuel system, electronic control 24/28 Check-Engine Lamp (Malfunction Indicator Light M.1.L.) ‘As from model year '91, Californian legislation prescribes a waming lamp which lights up if a part rele- vant to the exhaust gas fails. ‘As a function check of the warning lamp, it lights up when the ignition is switched on and goes out ‘once the engine is running when this is started without depressing the accelerator. The waming lamp has a flashing code to indicate a defective fault path. To trigger off the flashing code, fully depress the accelerator pedal with the engine off and the igni- tion on for 3 seconds until the Malfunction Indicator Lamp flashes. Then remove foot from accelerator. If no fault is recorded, i.e. no warning came from the indicator light, there appears the flashing code e 1500 no fault. ° @ = Lampon O = Lampoff If the warning light did indicate a warning, ie. there is a fault, there appears a flashing code, e.g 1124 | | Fault code | L___ Constant fault (2 with loose contact) DME/LH control unit e | | | | 1124 Oxygen sensor ‘The flashing code is listed in the Diagnosing/Troubleshooting plan on page D 24/28-7. ‘The fault can also be read direct using System Tester 9288. After a repair the fault memory must be erased using the System Tester. DME-Diagnosing/Troubleshooting D 24/28 - 33 Printed in Germany ~ Xi, 1980