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Porsche 944 Turbo 1987-1991 All Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: 944 Turbo Model Designation: 944 S2 Turbo / Turbo S Chassis Code: 951 Generation Generation Code: G29 (Facelift) Codes Engine Code Prefix: M44.50 (Turbo), M44.52 (Turbo S) 👋 Introduction Market Position Market Segment: Performance Sports Coupe Competitive Analysis Competitors Era: Chevrolet Corvette (C4), Nissan 300ZX (Z31), Toyota Supra (MkIII), BMW M3 (E30), Ferrari 308/328 GTB Key Features Vehicle Philosophy: Transaxle layout, balanced weight distribution, turbocharged performance, advanced engineering for its era. Manual Value Proposition Diy Benefit: Enables independent maintenance and repair, saving significant costs compared to dealership service. Knowledge Transfer: Provides in-depth understanding of complex Porsche engineering, empowering owners with technical insight. Accessibility: Digital format allows for quick access and on-the-go reference, ideal for roadside diagnostics or workshop use. 📋 Manual Details Coverage Areas Covered Years: 1987, 1988, 1989, 1990, 1991 Page Count Estimated Page Count: Extensive (typically 1000+ pages for complete factory manuals, this download compilation is comprehensive) Manual Type Type: Comprehensive Service and Repair Manual (Downloadable) Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Fuel Injection (Bosch Motronic M3.1), Ignition, Engine Control Unit (ECU) Engine Mechanical: Disassembly, Reassembly, Component Specifications, Cylinder Head, Block, Crankshaft, Pistons, Connecting Rods, Valves Turbocharging: Turbocharger, Intercooler, Wastegate, Boost Control Transmission: Manual (G50/00), Clutch, Gearbox Overhaul, Differential Braking System: Hydraulic System, ABS (Anti-lock Braking System), Disc Brakes, Calipers, Master Cylinder Suspension And Steering: Front and Rear Suspension, Shock Absorbers, Springs, Bushings, Power Steering System Electrical System: Wiring Diagrams, Battery, Alternator, Starter, Lighting, Fuses, Relays, Instrumentation Body And Chassis: Body Panels, Doors, Hood, Trunk, Interior Trim, Chassis Components Cooling System: Radiator, Fan, Hoses, Thermostat, Coolant Fuel System: Fuel Tank, Fuel Pump, Fuel Lines, Fuel Filter, Injectors Emission Control: Catalytic Converter, EGR System (if applicable), Emission Components Restraint System: Seat Belts, Airbags (if equipped, though unlikely for early 944 Turbos) Chassis Body: Frame and body structure, doors, windows, locks, bumpers, exterior trim, interior trim, seats. Axle And Driveshaft: Rear axle assembly, CV joints, driveshaft, U-joints. Procedures Included Maintenance: Routine Checks, Oil Changes, Filter Replacements, Fluid Checks, Belt Tensioning Troubleshooting: Diagnostic Flowcharts, Symptom-Based Problem Solving, Common Faults and Fixes Repair: Step-by-Step Repair Instructions for all major systems Rebuilds: Engine, Transmission, Turbocharger Rebuild Procedures Diagnostics: Diagnostic Trouble Codes (DTCs), Sensor Testing, Actuator Testing Adjustment: Valve Clearance Adjustment, Idle Speed Control, Turbo Boost Control Lubrication: Periodic lubrication points and specifications for chassis components. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and transmission rebuilds, including electrical diagnostics and wiring schematics. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: Digital Download (Quality dependent on source scan, generally good for clarity) Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Software Requirements Reader Requirements: Adobe PDF Reader Compression Requirements: WinZip or equivalent for compressed files Operating Systems Compatibility: All versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4, DOHC, 16 Valves Displacement: 2.5 Liters (2479 cc) Bore X Stroke: 104.0 mm x 73.0 mm Compression Ratio: 8.5:1 (Turbo), 9.0:1 (Turbo S) Horsepower Hp: 217 hp @ 5500 rpm (Turbo), 247 hp @ 5500 rpm (Turbo S) Torque Lb Ft: 245 lb-ft @ 3500 rpm (Turbo), 258 lb-ft @ 4000 rpm (Turbo S) Performance 0 60 Mph Seconds: Approx. 6.0 - 6.5 seconds Top Speed Mph: Approx. 150-155 mph Fuel System Injection System: Bosch Motronic M3.1 Electronic Fuel Injection Fuel Type: Premium Unleaded Gasoline (91+ Octane) Turbocharging Turbocharger Model: Garrett AiResearch T03/04B Boost Pressure: 1.1 bar (16 psi) with manual boost control (Turbo S typically had adjustable boost) 🔧 Transmission Standard Type: 5-Speed Manual (G50/00 transaxle) Features Layout: Transaxle (Engine and transmission in rear-biased configuration) Clutch Type: Hydraulically Actuated Single Dry Plate Clutch 📐 Dimensions Exterior Length: 4215 mm (165.9 in) Width: 1735 mm (68.3 in) Height: 1275 mm (50.2 in) Wheelbase: 2450 mm (96.5 in) Weights Curb Weight: Approx. 1360 kg (2998 lbs) Gross Weight Rating: Approx. 1800 kg (3968 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: Not extensively rated by modern standards, but known for robust build quality and good occupant protection for its era. Focus on chassis integrity. Active Features ABS: Standard (Bosch ABS III) Passive Features Airbags: Driver Airbag (Standard on later models, optional/absent on very early '87 cars). Seat Belts: 3-Point Inertial Reel Seat Belts Rollover Protection: Reinforced A-pillars and Targa roof structure provide significant rollover protection. 💡 Technology Features Infotainment Audio System: Factory AM/FM Cassette player with optional CD changer. Typically 8-speaker premium sound system. Driver Assistance Cruise Control: Standard Connectivity Bluetooth: Not available (aftermarket solutions exist). 🔧 Maintenance Service Intervals Oil Change: Every 5,000 - 7,500 miles or annually. Use high-quality synthetic oil. Timing Belt Replacement: Every 45,000 miles or 4-5 years (critical maintenance item due to interference engine design). Spark Plugs: Inspect at 15,000 miles, replace as needed...
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Porsche 944 Turbo 1987-1991 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
944 Turbo
Model Designation:
944 S2 Turbo / Turbo S
Chassis Code:
951
Generation
Generation Code:
G29 (Facelift)
Codes
Engine Code Prefix:
M44.50 (Turbo), M44.52 (Turbo S)
👋 Introduction
Market Position
Market Segment:
Performance Sports Coupe
Competitive Analysis
Competitors Era:
Chevrolet Corvette (C4), Nissan 300ZX (Z31), Toyota Supra (MkIII), BMW M3 (E30), Ferrari 308/328 GTB
Key Features
Vehicle Philosophy:
Transaxle layout, balanced weight distribution, turbocharged performance, advanced engineering for its era.
Manual Value Proposition
Diy Benefit:
Enables independent maintenance and repair, saving significant costs compared to dealership service.
Knowledge Transfer:
Provides in-depth understanding of complex Porsche engineering, empowering owners with technical insight.
Accessibility:
Digital format allows for quick access and on-the-go reference, ideal for roadside diagnostics or workshop use.
📋 Manual Details
Coverage Areas
Covered Years:
1987, 1988, 1989, 1990, 1991
Page Count
Estimated Page Count:
Extensive (typically 1000+ pages for complete factory manuals, this download compilation is comprehensive)
Manual Type
Type:
Comprehensive Service and Repair Manual (Downloadable)
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Fuel Injection (Bosch Motronic M3.1), Ignition, Engine Control Unit (ECU)
Engine Mechanical:
Disassembly, Reassembly, Component Specifications, Cylinder Head, Block, Crankshaft, Pistons, Connecting Rods, Valves
Turbocharging:
Turbocharger, Intercooler, Wastegate, Boost Control
Transmission:
Manual (G50/00), Clutch, Gearbox Overhaul, Differential
Braking System:
Hydraulic System, ABS (Anti-lock Braking System), Disc Brakes, Calipers, Master Cylinder
Suspension And Steering:
Front and Rear Suspension, Shock Absorbers, Springs, Bushings, Power Steering System
Electrical System:
Wiring Diagrams, Battery, Alternator, Starter, Lighting, Fuses, Relays, Instrumentation
Body And Chassis:
Body Panels, Doors, Hood, Trunk, Interior Trim, Chassis Components
Cooling System:
Radiator, Fan, Hoses, Thermostat, Coolant
Fuel System:
Fuel Tank, Fuel Pump, Fuel Lines, Fuel Filter, Injectors
Emission Control:
Catalytic Converter, EGR System (if applicable), Emission Components
Restraint System:
Seat Belts, Airbags (if equipped, though unlikely for early 944 Turbos)
Chassis Body:
Frame and body structure, doors, windows, locks, bumpers, exterior trim, interior trim, seats.
Axle And Driveshaft:
Rear axle assembly, CV joints, driveshaft, U-joints.
Procedures Included
Maintenance:
Routine Checks, Oil Changes, Filter Replacements, Fluid Checks, Belt Tensioning
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Problem Solving, Common Faults and Fixes
Repair:
Step-by-Step Repair Instructions for all major systems
Rebuilds:
Engine, Transmission, Turbocharger Rebuild Procedures
Diagnostics:
Diagnostic Trouble Codes (DTCs), Sensor Testing, Actuator Testing
Adjustment:
Valve Clearance Adjustment, Idle Speed Control, Turbo Boost Control
Lubrication:
Periodic lubrication points and specifications for chassis components.
Technical Depth
Depth:
Comprehensive from basic maintenance to advanced engine and transmission rebuilds, including electrical diagnostics and wiring schematics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
Digital Download (Quality dependent on source scan, generally good for clarity)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Software Requirements
Reader Requirements:
Adobe PDF Reader
Compression Requirements:
WinZip or equivalent for compressed files
Operating Systems
Compatibility:
All versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4, DOHC, 16 Valves
Displacement:
2.5 Liters (2479 cc)
Bore X Stroke:
104.0 mm x 73.0 mm
Compression Ratio:
8.5:1 (Turbo), 9.0:1 (Turbo S)
Horsepower Hp:
217 hp @ 5500 rpm (Turbo), 247 hp @ 5500 rpm (Turbo S)
Torque Lb Ft:
245 lb-ft @ 3500 rpm (Turbo), 258 lb-ft @ 4000 rpm (Turbo S)
Performance
0 60 Mph Seconds:
Approx. 6.0 - 6.5 seconds
Top Speed Mph:
Approx. 150-155 mph
Fuel System
Injection System:
Bosch Motronic M3.1 Electronic Fuel Injection
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Turbocharging
Turbocharger Model:
Garrett AiResearch T03/04B
Boost Pressure:
1.1 bar (16 psi) with manual boost control (Turbo S typically had adjustable boost)
🔧 Transmission
Standard
Type:
5-Speed Manual (G50/00 transaxle)
Features
Layout:
Transaxle (Engine and transmission in rear-biased configuration)
Clutch Type:
Hydraulically Actuated Single Dry Plate Clutch
📐 Dimensions
Exterior
Length:
4215 mm (165.9 in)
Width:
1735 mm (68.3 in)
Height:
1275 mm (50.2 in)
Wheelbase:
2450 mm (96.5 in)
Weights
Curb Weight:
Approx. 1360 kg (2998 lbs)
Gross Weight Rating:
Approx. 1800 kg (3968 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not extensively rated by modern standards, but known for robust build quality and good occupant protection for its era. Focus on chassis integrity.
Active Features
ABS:
Standard (Bosch ABS III)
Passive Features
Airbags:
Driver Airbag (Standard on later models, optional/absent on very early '87 cars).
Seat Belts:
3-Point Inertial Reel Seat Belts
Rollover Protection:
Reinforced A-pillars and Targa roof structure provide significant rollover protection.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Cassette player with optional CD changer. Typically 8-speaker premium sound system.
Driver Assistance
Cruise Control:
Standard
Connectivity
Bluetooth:
Not available (aftermarket solutions exist).
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 miles or annually. Use high-quality synthetic oil.
Timing Belt Replacement:
Every 45,000 miles or 4-5 years (critical maintenance item due to interference engine design).
Spark Plugs:
Inspect at 15,000 miles, replace as needed (typically Bosch Super Plus or equivalent).
Fluid Specifications
Engine Oil:
SAE 5W-40 Synthetic (API SG/SH or ACEA A2/A3 recommended). Capacity: 5.5 Liters (5.8 US Quarts) with filter.
Coolant:
Porsche Approved Antifreeze (G 002 000) or equivalent - 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 (check specific year requirements), flush and refill every 2 years.
Transmission Fluid:
GL-4 Hypoid Gear Oil (75W-90 or 75W-80). Capacity: Approx. 2.3 Liters (2.4 US Quarts).
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Known Issues
Common Problems:
Cracked dashboard, coolant leaks (especially from the 'eighth cylinder' or pipe connections), turbocharger oil leaks, worn shifter bushings, power steering hose leaks, electrical gremlins, timing belt failure (if not replaced).
Maintenance Focus:
Proactive replacement of aging rubber components (hoses, belts, bushings) is crucial for reliability. Regular inspection of turbo system components is recommended.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Porsche is renowned for its engineering prowess, motorsport heritage, and iconic sports car designs, with a focus on performance and driver engagement.
Model Evolution
944 Lineage:
The 944 Turbo (951) was an evolution of the 924 and naturally aspirated 944, featuring a powerful turbocharged engine and upgraded chassis and braking systems to handle the increased performance. The Turbo S variant offered further enhancements.
Production
Production Years:
1985-1991 (Turbo/Turbo S)
Manufacturing Location:
Neckarsulm, Germany
🏆 Awards & Recognition
Recognitions
Historic Acclaim:
Consistently praised for its handling, performance balance, and sophisticated engineering. Considered a modern classic and a true driver's car.
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