Porsche 944, S, S2 & Turbo Workshop Manual Set, 1982–1991

The volumes combine shared workshop procedures with model-specific supplements and wiring information. Engine, transmission and market notes identify which material applies to each configuration.

Engine coverage: The engine material is the 16-valve 944 S / S2 supplement. The separate internal-engine volumes for the base 8-valve 944 and 944 Turbo are not included.

PDF Search, Bookmarks and Wiring Detail

Finding pages and reading circuits: PDF text search is unavailable. Embedded bookmarks provide access to the main systems, but several wiring entries open contents pages rather than the corresponding diagrams. Small pin numbers and wire codes require zooming, and wide wiring sheets are divided across adjacent pages.

One printable English PDF contains 1,423 pages, including three volume title pages, 14 contents pages and four repair-group lists. The factory pages were printed in Germany and include revisions through 1993.

Engine, Drivetrain and Vehicle-System Work

This selection of workshop content is not a complete contents list; other subjects include controllable seat-heating calibration and headlight beam-control checks.

• 16-valve engine and DME: Engine removal, piston and cylinder-bore inspection, cylinder-head service, camshaft timing, fuel-pressure testing and electronic fault diagnosis.

• Transmission and driveline: Clutch hydraulics, manual and automatic transmission repair, differential adjustment, limited-slip differential service, and central-tube inspection.

• Suspension and steering: Control-arm and trailing-arm repair, wheel bearings, Koni damper adjustment, alignment, power-steering pressure testing and bleeding.

• Brakes and ABS: Brake hydraulics, master-cylinder repair, bleeding, ABS component replacement, circuit information and four-piston caliper service notes.

• Body and restraints: Celette alignment data, panel replacement, central locking, power sunroof diagnosis, Cabriolet folding-top work, bonded glass and airbag troubleshooting.

• Heating and air conditioning: R12 system testing, evacuation, flushing and filling, heater/A/C unit repair, flap controls and refrigerant-component replacement.

• Electrical equipment and wiring: Instrument and alarm diagnosis, model-specific current-flow diagrams, regional circuits, connector tables, ground-point maps and equipment-code references.

This set suits technicians familiar with Porsche system operation, wiring diagrams and electrical test equipment; its DME troubleshooting assumes those skills.

16-Valve Engine and DME Detail

Cylinder-head and timing work: Step-by-step procedures cover camshaft and seal installation, chain-tensioner removal, cylinder-head disassembly, valve-guide replacement, valve-seat machining and valve-spring installed-height adjustment. Piston and bore tables distinguish tolerance groups, while reference tables provide tightening sequences, clearances and machining limits.

Illustrations include the cylinder-head exploded view and M 44.40 fuel-system line routing. Routine engine material also addresses oil and filter changes, cooling-system leak checks, fuel-filter replacement, pump delivery and intake-hose inspection.

Diagnostic testing: Tester 9268 and System Tester 9288 procedures cover fault-memory readout, actuator and input-signal checks, adaptation, knock registration and stored readings. Equipment tables and market-specific DME coding distinguish catalytic and non-catalytic versions and Model 87 versus Model 89-onward configurations.

Connector and test-point views support checks of throttle contacts, temperature and air-flow sensors, oxygen and knock sensors, Hall and speed/reference signals, the DME relay, ignition output, injectors and the check-engine lamp. The diagnostic plan explains why a component-related fault message can also indicate a control-unit or wiring problem, helping distinguish the test path before parts are selected.

Tools and repair cautions: Tool plates identify engine support beam 3033, camshaft bridges 9248 with clamp 9226, valve-spring tool 9242, valve-stem-seal tools 9237 and 9225/1, and fuel-pressure gauge P 378.

Replacement camshaft sprockets may lack a TDC mark, and the camshaft installation notes warn of piston-to-valve damage. The ground-connection test also warns that starting the engine with the engine-to-body ground disconnected can destroy the DME control unit.

Transmission Procedures and Their Limits

Detailed manual-transmission procedures address 016 J/K gear-carrier and housing work, input- and pinion-shaft disassembly, synchronizer inspection, shift adjustment, and ring-and-pinion setup. The 083 D and 083 F entries provide identification, specifications and design comparisons; they are not complete S/S2 gearbox teardown chapters.

The 087 M/N automatic material extends to selector and control-pressure cable adjustment, functional and pressure tests, troubleshooting charts, planetary gears, clutch packs, the oil pump, valve body and final drive. Separate procedures cover the 40% limited-slip differential and central-tube bearings and dampers.

Chassis, Brakes and ABS Requirements

Suspension chapters distinguish steel and aluminum arms, spring tolerance groups, Koni configurations and model-specific ride-height settings. Steering coverage includes manual and power-steering gear removal, hydraulic checks and system bleeding.

Brake material includes disc inspection, caliper and master-cylinder work, and hydraulic service. Four-piston caliper notes distinguish seal and pad configurations; the complete S2 brake-pad replacement procedure is referred to the separate 944 Turbo workshop manual.

ABS layout and circuit diagrams accompany component replacement instructions. Factory ABS troubleshooting and specified post-repair tests require the separate ABS Test Plan WKD 493 710.

Body, Cabriolet and HVAC Work

Body information includes Celette bench fixtures, collision-repair dimensions, front-panel replacement and Cabriolet rear-panel repairs. Central-locking and sunroof tests cover actuators, microswitches and drive controls; folding-top, bonded-glass, airbag and seat-heating material adds model-specific repair detail.

HVAC chapters cover leak testing and refrigerant servicing, heater/A/C unit disassembly, flap positioning, and compressor, condenser and expansion-valve removal. Troubleshooting addresses temperature regulation, airflow and electrical controls.

Wiring Selection and Circuit References

Current-flow diagrams span Model 83 through Model 91, with lighting, engine-compartment and cruise-control circuits, central electrics, locks, alarm, HVAC, ABS and airbag sheets. Plug-connection tables, ground-point maps and M-number lists distinguish regional and optional equipment.

The Model 85/2 diagrams and harness-modification notes have specific VIN limits. A separate factory note applies the Model 90 Turbo/S2 diagrams to the Model 91 Turbo Cabriolet.

Fuel-system, brake, airbag, refrigerant, lifting and electrical work require the factory safety precautions and the equipment specified for the procedure.

Fuel-Pressure and Cylinder-Head Specification Preview

For M 44.40 / M 44.41, the fuel-system test table specifies 3.8 ± 0.2 bar with the engine stationary and the DME relay jumpered. Its leak test requires at least 2.0 bar residual pressure after 20 minutes.

The 16-valve cylinder-head section permits 0.05 mm mating-face unevenness and distinguishes the dimensional limits for new and refaced heads.