Shop Manual

Camshaft Assembly Installation

A coat of grease on the outside of the outside of the lifters will help hold the lifters in the cam housing during installation.

Camshaft Assembly Oil Seal Replacement

Refer to the Timing and Balance Shaft Belt Drawings for details:

Camshaft Assembly Removal

If you happen to have the original tool kit that comes with the car, there is a long Allen head tool with a rubber socket for holding the bolt for removal (v…

Camshaft Chain and Tensioner Replacement (16V Engines)

In addition to the concern that 8V 944s have with regard to timing belt maintenance, 16V 944 owners must also be concerned with the maintenance of the timing…

Cooling Fan Operation and Troubleshooting

Introduction(#intro)

Cooling System Troubleshooting

Normally Aspirated 944 Cooling System

The normally aspirated 944 cooling system operates bypassing the radiator until the coolant temperature reaches 83 °C when the thermostat opens. After the th…

Radiator Removal and Installation

Before you remove the radiator hoses, note the position of the hose clamps on the hoses. When you reinstall the hoses try to install the clamps in the same o…

Thermofan Switch Replacement

Due to differences in manufacturing tolerances, you may find a 1-1/8" deep socket that will fit. However, due to the tight space, it's almost impossible to r…

Thermostat - General Information, Testing, and Replacement

If your car is experiencing overheating or overcooling problems, they may be due to a faulty thermostat. Overcooling problems are causes by a thermostat that…

Turbocharged 944 Cooling System

The 944 Turbo cooling system operates bypassing the radiator until the coolant temperature reaches 83 °C when the thermostat opens. After the thermostat open…

Water Pump Information and Replacement

There are two different styles of water pumps used on the 924S and 944 (including Turbos). The new style coolant pump has a guard rail for the timing belt an…

Cylinder Head and Head Gasket Installation

If not specified apply the following fastener torque specs.

Cylinder Head and Head Gasket Removal (8V Cars)

I've never tried it personally but, Tim Richards suggests removing the cylinder head with the exhaust manifolds still attached. According to Tim, it saves a …

944 Engine Installation

As the engine removal procedure is written assuming the engine is removed from below, the installation procedure detailed here is based on the same assumptio…

944 Engine Removal

NOTE: Many of the cars that have been around for a while have had the back belly pan removed and left off for easier access to the oil drain plug.

Balance Shaft Oil Seal Replacement

The following procedure will provide instructions for replacing the balance shaft seals on a 944. It will also provide instructions for resealing the balance…

Balance Shaft Sprocket Installation and Alignment Check

If your 944 is experiencing vibration problems, the cause could be a balance shaft misalignment. This can occur if the balance shaft belt slips a tooth, the …

Camshaft / Balance Shaft Belt Information

Timing belts have long been the source of many heated discussions and much heartache for 944 owners. Every new or potential 944 owner should read Jim Pasha's…

Crank Scraper Install

A common performance upgrade to 944 and 951 model Porsches is the installation of a Crank Scraper. It is a cheap way, especially when included during other p…

Engine Starting and Running Troubleshooter

Troubleshooting starting and running problems can sometimes be quite difficult. This is especially true if you aren't aware if all the possible causes of a p…

Flywheel Lock Installation

Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1

If you do not have a deep 15/16" or 24 mm socket, a shallow socket with a short extension (1-2") will work.

Motor Mounts - Replacing

First, I'd like to thank Ben Davis for providing the pictures for this procedure.

Timing Belt and Balance Shaft Belt Installation

Refer to the Timing and Balance Shaft Belt Drawings for details:

Timing Belt and Balance Shaft Belt Removal

Refer to the Timing and Balance Shaft Belt Drawings for details:

Timing Belt and Balance Shaft Belt Tensioning

Refer to the Timing Belt Arrangement drawings below for details.

Turbocharger Replacement

Replacing the turbocharger on a 951 is not extremely difficult. However, it is very tedious because there are a lot of components that must be removed to get…

Exhaust System Removal and Installation

It may be necessary to remove the coolant return pipe completely to get the exhaust headers out. This will require partially draining the coolant system.

Wastegate - Fabricating and Installing Shims

During the installation of the 2.8L engine into my car, I decided that at some point I might wish to shim my factory wastegate. To prepare for that, I remove…

Wastegate - Removal and Installation

For those of you who've removed the wastegate from a 944 Turbo, I'm sure you'll agree that there is no easy way to get the wastegate out of the car. There ar…

Wastegate Testing

If you're reading this, you're probably considering testing the wastegate because you're experiencing a low charging system pressure. In other words, you wil…

Front Crankshaft Oil Seal Replacement

New Style Oil Cooler Seals

This document contains information from Porsche Technical Bulletin 8813 dated June 10, 1988.

Oil Cooler General Information and Seal Replacement

The first indication of failing oil cooler seals are normally a "milkshake" looking mixture in the coolant tank. This can also be indicated by a failing head…

Oil Cooler Pressure Test

The following contains factory instructions for pressure testing the oil cooler element used on normally aspirated 944s. If you have experienced a mixing of …

Oil Pan Gasket Replacement

Without question replacing the oil pan gasket on a 944 is one of those jobs that ranks high on my "I don't want to do that job again" scale. On the surface, …

Oil Pressure General Information and Troubleshooting Tips

The 944's oil pressure should run 4-5 bar at idle when the engine is cold. It will gradually decrease to 2-3 bar at idle as the engine oil warms to normal op…

Oil Pressure Relief Valve General Information

Early 944s produced from 1983 to 1986 used a three piece piston and spring oil pressure relief valve. Early 1987 924S used the spring and piston relief valve…

Oil Pressure Sending Unit Replacement

On normally aspirated cars the power steering pump may not have to be removed to access the oil pressure sending unit. On turbocharged cars and normally aspi…

Oil Pump Removal and Installation

Removing and installing the oil pump is best done with the oil pan removed. However, it can be done by loosening the bolts on the oil pan and dropping the pa…

Air Filter Housing and Air Flow Sensor - Removal and Installation

This procedure is used to remove the air filter housing and air flow sensor on 944s and 944 Turbos. Thanks to Tom Harrison for taking the time to provide fee…

DME Control Unit Chip Installation (Including KLR Chip for Turbos)

Before removing the old chip (Turbocharged cars) make sure you have identified the correct chip for installation. On 1988 model and newer cars this is simpli…

DME Control Unit Removal and Installation

DME Relay Information and Testing

The DME relay which is used on 1985.5 and newer 944s is essentially the same as the fuel pump relay used on early 944s. The fuel pump relay on the early cars…

Fuel Injector and Fuel Rail Removal and Installation

Stuff catch rags underneath the fuel pressure damper and fuel pressure regulator to catch fuel when disconnecting the fuel supply and return lines.

Fuel Injector Information

In this document, I've tried to provide as much information as possible about the Bosch injectors used in 944 and 968 applications. Unfortunately, the inform…

Fuel Pressure - Checking

Refer to FUEL-20(/manual/fuel-ignition/adapter-for-non-metric-thread-fuel-pressure-gauges) for instructions on how to make an adapter for fuel pressure gauge…

Fuel Pressure Regulator - General Information and Replacement

For years, 944 owners and even experienced Porsche mechanics, have on a regular basis replaced perfectly good DMEs, fuel pumps, and various other components …

Fuel Pump Delivery Rate Checking

Be sure to have rags ready to catch excess fuel when disconnecting fuel lines / caps. The fuel in the fuel rail may be under high pressure and may spray if t…

Fuel Pump Information and Replacement

The Bosch fuel pumps used in Porsches are generally extremely reliable and not prone to failure. If you have a fuel pump that needs to be replaced, there is …

Fuel Pump Suction Strainer - Removing, Cleaning, and Replacing

If you have a problem which involves a low fuel system pressure or inadequate fuel pump capacity it may be due to a clogged fuel filter or fuel tank strainer…

Fuel Rail Adapter - Making an Adapter for Non-Metric Thread Fuel Pressure Gauges

If you live in the United States and you want to check the fuel pressure on your 944 you have two choices. The first choice is to buy a fuel pressure gauge w…

Fuel System Leakdown Failure

Fuel System leakdown failures can be caused by a leaking fuel injector(s), a bad fuel pressure regulator (FPR), or a leaking fuel pump check valve. When this…

Idle Control Motor Replacement

If the rubber mounts are broken, the controller and the bracket will come out as one. Remove the bottom section of the broken rubber mounting bolts from the …

Idle Speed Adjustment

Idle speed adjustment is not normally required on 944s. However, the idle speed adjusting screw will sometimes back out causing idle speed to become out of a…

Intake Manifold Removal and Installation

On normally aspirated cars, there are hoses underneath the intake manifold which can not be disconnected from the intake until it is lifted.

Oxygen Sensor General Information, Testing, and Replacement

For 944s which are equipped with oxygen sensors (not all are), the O2 sensor measures the oxygen content in the exhaust and provides an output feedback signa…

Throttle Position Switch - Information, Troubleshooting, Replacement, and Adjustment

A faulty throttle position switch (TPS) can result in a number of poor running problems. Because they can result in such a large number of problems, faulty s…

Distributor Cap and Rotor Replacement

Removing and installing the distributor cap on a 944 can be extremely frustrating. Why? Probably because it seems like such a simple job and often isn't. Onc…

Ignition System Troubleshooting

If you've come to this procedure, you probably suspect that you have a no spark condition. If so, you should have already verified that you actually have a n…

Speed and Reference Sensors - Checking, Replacement, and Adjustment

The 944 Engine Managment system uses two crankshaft sensors. One (Reference Sensor) determines the #1 piston (front of the engine) position relative to Top D…

Air Bag System Testing

The information in this procedure comes from the Porsche factory airbag system diagnostics procedure. Personally, I have not had the opportunity to use this …

Air Bag Warning Light Reset

I'm not sure who actually came up with this procedure originally. However, to my knowledge it first appeared in the 944 FAQ which is now maintained by Kevin …

Air Flow Meter (AFM) Operation and Testing

The following article provides a summary of the operation of the 944 Air Flow Meter (AFM), also commonly referred to as the Air Flow Sensor. Also, covered is…

Alarm System - Bypassing

Sometimes engine starting and running problems can be caused by a faulty alarm module (if the car is equipped with an alarm system). Since testing the alarm …

Alternator Replacement

Replacing the alternator in a 944 is not extremely difficult. However, it is somewhat time consuming since a large number of parts have to be removed to actu…

Checking Starter Operation

I personally don't recommend testing the starter while it is in the vehicle. Realize that the engine will turn during starter testing and you should not appl…

Cruise Control - General Information and Repair

Cruise control problems are fairly common in 944s. The most frequent problems include failing to engage, failing to maintain speed, and picking up a set amou…

Early 944 Fuse List

Electric Window Troubleshooting

When things go wrong with your electric windows, it can sometimes be frustrating to figure out the cause of the problem. This troubleshooting procedure is in…

Excessive Battery Discharge Rate

All 924s, 944s, and 968s use a BCI Group 41 size battery. That means that the dimensions of the battery are 11- 3/16" L x 6 - 7/8" W x 6 - 7/8" H. For a full…

Fuel Level Indication Problems / Repairs

Fuel level indication problems are generally caused by a problem with the gauge or the sending unit. Our discussion here will focus on isolating the cause of…

Gauges - Removing Early 944 Gauges

One of the hardest part of removing the gauges on an early 944 is disconnecting the speedometer cable from the back of the speedometer. To do this, the gauge…

Gauges - Removing Late 944 (1985.5 and newer) Gauge Cluster

Headlight Motor Removal, Cleaning, and Installation

If you are having problems with your headlights cycling up and down when you operate them, the problem is most likely a dirty electrical contact wheel inside…

Ignition Switch and Wiring Test

Bad ignition switches are becoming a more common cause of starting problems on 944s. So, take a look at your ignition switch and if it's cracked, it's likely…

Ignition Switch Replacement

The following ignition switch replacement procedure was authored by Dean Smith. I'd like to thank Dean for taking the time to write such a complete, detailed…

Late 944 Fuse List

Odometer Repair

<http://www.klaindustries.net>

Rear Hatch Defroster Troubleshooting and Repair

The rear hatch defroster grid is basically a big resistor. So, when the defroster is operating properly, with a voltmeter you will be able to measure +12 VDC…

Sensors and Gauges - Information, Troubleshooting, and Testing

Coolant Temperature Gauge Testing(#coolant)

Starter Removal and Installation

Stereo - Head Unit and Speaker Replacement Guide

Replacing the stereo head unit in a 944 is fairly straight forward. Any standard DIN head unit will fit. However, there are some minor issues which must be c…

Stereo - Rear Speaker Replacement

Rear stereo replacement in a 944 or 968 is a bit of a pain. However, it's just takes a little time and patience. Many folks will tell you that the rear quart…

Sunroof Component Testing

Testing and/or Replacing the Micro-Switch Between the Sun visors(#microswitch)

944 Turbo Bumper Cover Removal

Battery Tray Repairs

A leaking battery tray can be catastrophic. Particularly if you own a 944 which has it's DME located in the passenger's footwell. When the battery tray leaks…

Cargo Cover Repair

When the cargo cover fails to retract, there are normally two causes. The coil spring for the cover retracting mechanism is broken or the spring has come out…

Clock and Temperature Control Unit Removal and Replacement

This is a procedure which I've had requests for many times in the past. I've simply put off writing this procedure for some time. If you need to replace your…

Door Handle - Removal, Installation, and Adjustment

There are many different procedures floating around describing how to replace the door handles on a 944 and every one of them will work. Some procedures will…

Door Panel Removal and Installation

Early 944 Dash Replacement

Replacing the dash in a 944 is not overly difficult. However, it is very tedious and a lot of patience is required. It's going to take a lot of time but, don…

Headlight Motor Circuit Operation and Repair

The following procedure, written by Dave Simms, is based on the headlight motor circuits in 1983 and 1984 model 944s. Dave has also included information on h…

Hood Crest - Removal and Installation

When you remove the nose panel, you will find that the crest is held in place by two posts. The posts will be held by one of two different types of retaining…

Hood Insultation - Removal

As the hood insulation on 944 ages it will flake off and make a mess all over the engine compartment which is extremely difficult to clean up. The solution t…

Hood Strut Replacement

Hood strut replacement on a 944 is fairly straight forward. However, I've offered a few tips here which may save you some trouble during the installation. It…

Late Model 944 Dash Replacement

Replacing the dash in a late model 944 is not overly difficult. However, it is very tedious and a lot of patience is required. It's going to take a lot of ti…

Mirror Removal and Installation - Exterior

If you remove both mirrors or are installing new mirrors on the car and you have the mirrors disassembled, make sure you get the correct glass in the correct…

Nose Panel - Removal and Installation

On 924s and 944s between the headlights that holds the Porsche crest is sometimes referred to as the nose panel and sometimes as the header panel. Regardless…

Painting a 944

This is not necessarily intended for someone to paint their own car. It's more intended to inform 944 owners as to what exactly it takes to PROPERLY paint a …

Rear Hatch - Squeaking

A noisy rear hatch (squeaking or rattling) can be caused by several different things.

Rear Hatch Strut Replacement

The most important part of replacing the rear hatch struts is making sure you have the correct parts. If you get the wrong struts in the wrong location, your…

Steering Wheel Removal and Installation

Stone Guard Removal and Installation

New stone guards are available from Porsche or many of the aftermarket parts houses offer stone guard kits. You can also purchase 3M Urethane Stone guard mat…

Sunroof Gear Replacement

The first step in replacing the plastic gears in the late model 944 sunroof is to determine whether one or both of the gears are stripped. If only one of the…

Sunroof Operation, Troubleshooting, and Repair

On pre-1985.5 cars, the sunroof is operated by turning the ignition switch to the "ON" position. The sunroof console switch is then pushed back ("A" directio…

944 HVAC Operation and Malfunctions

This procedure will concentrate primarily on the operation and malfunctions of the late model 944 HVAC system (1985.5 and newer). That's primarily because th…

Air Conditioning Troubleshooting and Repair

Since I'm constantly receiving questions on 944 air conditioning systems, I figured it's time to come up with come helpful troubleshooting tips. Working on t…

Heater Core Removal and Replacement

First, I'd like to apologize for sitting on this procedure for so long. I was searching through some of my files the other day and realized only then that I …

Clutch Master Cylinder Replacement

This procedure details replacement of the clutch master cylinder on 944s and 968s. Terry Jenner did a great job with this procedure. He wrote the procedure, …

Clutch Replacement

Replacing the clutch on a 944 can be one of the most intimidating jobs a home mechanic can undertake. Although there is nothing about a clutch replacement th…

Clutch Slave Cylinder Replacement

Replacing the clutch slave cylinder on a 944 is a fairly simple procedure. The difficult part of the job is bleeding the slave cylinder. This procedure will …

Torque Tube Removal, Rebuilding, and Installation

It may be necessary to remove the starter and slave cylinder in order to access all the bolts / fasteners for the torque tube and torque tube carrier.

Transaxle - Checking, Repairing, and Replacing the Shift Lever and Shift Linkage

Sloppy or difficult shifting on a manual transaxle is normally the result of shift linkage adjustment or worn shift linkage components. The follow procedure …

Transaxle Removal and Installation

Brakes - Inspecting / Replacing Brake Rotors

Cars equipped with option M758.

Brakes - Master Cylinder Replacement

Porsche uses master cylinders and brake boosters on 944s which were manufactured by two companies (Teves and Girling). You may actually have a master cylinde…

Brakes - Parking Brake Adjustment

Power Steering Pump Replacement

I'd like to express my appreciation to Erik Ohrnberger who authored this

Power Steering Rack Rebuild

The following steering rack rebuild procedure was written by Karl "Doc" Wilen. I'd like to thank Doc for taking the time to write this procedure and take pic…

Steering Rack Replacement

The following repair procedure is provided through the courtesy of Raymond Hartle. Ray wrote the following procedure while replacing the power steering rack …

944 Control Arms - General Information, Rebuilding, and Aftermarket Replacements

944 Control Arms - General Information, Rebuilding, and Aftermarket Replacements

Control Arm Replacement

Since the 1985 ½ model year, 944s have used aluminum control arms which use ball joints that can not be replaced, as least not by the home mechanic. Early 94…

CV Joints - General Information, Removal, Installation, and Maintenance

Many thanks to Ben Davis for taking the time document this procedure with pictures.

Front Sway Bar Removal and Installation

Front Wheel Bearings - Checking, Adjustment, Repacking, and Replacement

Rear Sway Bar Removal and Installation

Rear Wheel Bearing Replacement - Aluminum Trailing Arm

Changing the wheel bearing on an aluminum trailing arm is somewhat different than a steel trailing arm. First, the aluminum trailing arm uses a single sealed…

Rear Wheel Bearing Replacement - Steel Trailing Arms

I'd like to thank Ben Davis for providing the pictures for this procedure. Ben took the time to take pictures as he was performing this procedure. The additi…

Shock Replacement

It really is surprising just how much difference replacing a bad set of shocks can make in the ride and comfort of any car. So, just how can you tell if your…

Strut Removal and Replacement

Extreme caution must be used when using double spring compressors where the springs are not held rigidly in place. This is the type of compressors you'll nor…

Suspension Information and Upgrades

The intent of this article is to provide a discussion regarding suspension dynamics in general and information regarding potential upgrades to the 944 suspen…

Torsion Bars - Removing, Replacing, and Indexing

Replacing the torsion bar on a 944 is not all that difficult. However, reindexing the torsion after completion is a pain and can be very time consuming. Ther…