1982–1991 Porsche 944 Workshop Manual (P/N WKD 481 821)

• Coverage: Covers the 1982-1991 Porsche 944-series platform, with model-specific material for the 944, 944 Turbo, 944 S, 944 S2, and 944 S2 Cabriolet. The engine section in this PDF is the 16-valve 944 S/944 S2 supplement for M 44.40 and M 44.41; it is not the separate 8-valve or Turbo internal-engine overhaul volume.
• Engine and DME repair: Documents 16-valve engine removal and installation, piston and cylinder-bore inspection, camshaft timing, cylinder-head and camshaft service, valve-guide and valve-seat work, chain-tensioner service, fuel-pressure testing, and DME fault diagnosis with Tester 9268 and System Tester 9288.
• Transmission and driveline: Details clutch and hydraulic-control work, 016 J/K manual transmission teardown, 087 M/N automatic transmission testing and internal repair, differential setup, 40% limited-slip differential service, and central-tube/damper inspection.
• Chassis, body, and HVAC: Includes front and rear suspension repair, wheel alignment, ABS test procedures, four-piston brake-caliper service, power-steering pressure checks and bleeding, Celette body-alignment data, Cabriolet body and folding-roof work, airbag diagnosis, and R12 air-conditioning service.
• Electrical diagnosis and wiring: Provides model-year current-flow diagrams from Model 83 through Model 91, covering regional lighting, engine-compartment and cruise-control circuits, central electrics, locks and alarm, ABS and airbag, HVAC, connector locations, ground points, and M-number equipment.
• Document size: The 1,423-page PDF is organized as 150 engine/DME pages, 270 transmission pages, 165 chassis pages, 218 body pages, 61 HVAC pages, 45 electrical pages, and 514 wiring pages. The factory pages were printed in Germany and incorporate revisions dated through 1992.

16-Valve Engine and DME Coverage

The engine material is centered on the M 44.40 used in the 944 S and the M 44.41 3.0-liter engine used in the 944 S2. Factory procedures cover engine removal, piston and bore tolerance-group checks, camshaft setting, cylinder-head removal and installation, camshaft and seal installation, chain-tensioner removal, cylinder-head disassembly, valve-spring work, guide replacement, seat machining, and valve-spring installed-height adjustment.

Reference tables provide tightening sequences, wear limits, clearances, machining limits, lubrication data, fuel-system test specifications, ignition equipment assignments, and market-specific DME coding. Variant notes distinguish Model 87 and Model 89-onward builds, catalytic and non-catalytic versions, regional coding, standard and sport-package configurations, and later 944 S2 equipment.

The diagnostic sections cover fault-memory readout, actuator diagnosis, circuit-input testing, system adaptation, knock registration, and stored-value displays. Their test-point plans address throttle contacts, temperature and air-flow sensors, oxygen and knock sensors, Hall and speed/reference signals, DME relay operation, ignition output, injectors, and the check-engine lamp.

Transmission, Chassis, and Body Repair Depth

Manual-transmission coverage includes gearbox removal, shift adjustment, transfer-box and housing work, input- and output-shaft disassembly, and ring-and-pinion setup. The automatic-transmission chapters add selector and control-pressure cable adjustment, functional testing, troubleshooting tables, planetary gear and clutch-pack repair, oil-pump and valve-body service, and final-drive adjustment.

The chassis sections address aluminum control and trailing arms, wheel bearings, Koni shock absorbers, alignment, ABS components and circuit diagnosis, mechanical and hydraulic brakes, brake-fluid bleeding, and manual or power steering.

Body chapters move into collision-repair dimensions and Celette bench fixtures, front and rear panel replacement, central locking, power sunroof and folding-top work, bonded glass, airbag diagnosis, seat heating, and Cabriolet-specific repairs. HVAC material covers leak testing, evacuation, flushing, filling, flap controls, compressor and condenser removal, expansion-valve service, and troubleshooting.

Diagrams, Tools, and Repair Cautions

Representative illustrations include the M 44.40 fuel-system line-routing diagram, the 16-valve cylinder-head exploded view, ABS layout and circuit diagrams, DME connector/test-point views, model-year current-flow sheets, and plug-connection and ground-point maps. Selected 924 S wiring sections are also included.

The tool plates identify the 3033 engine suspension beam, 9248/9226 camshaft bridge and clamp, 9242 valve-spring tool, 9237/9225/1 valve-stem-seal tools, P 378 fuel-pressure gauge, and System Tester 9288.

The engine section notes that replacement camshaft sprockets may not carry a TDC mark; an incorrectly indexed timing setup can put the 16-valve valvetrain at risk. The DME diagnosis material also warns that operating the engine with the engine-to-body ground disconnected can destroy the control unit.

Fuel, brake, air-conditioning, airbag, lifting, and electrical procedures should be carried out with the factory safety precautions and specified test equipment.

Important Scope Note

This set supports broad 944-series drivetrain, chassis, body, HVAC, electrical, and wiring repair, plus internal 16-valve engine work on the 944 S and 944 S2. A separate factory engine volume is still required for a full internal overhaul of the base 8-valve 944 or 944 Turbo engine.