Porsche 944 Turbo 1987-1991 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Porsche Model: 944 Turbo Model Code: 944S2 Turbo (M44.52) Generation Generation Designation: Second Generation (G2) Facelift Year: 1989 👋 Introduction Market Position Vehicle Segment: Front-engine, rear-wheel-drive, four-cylinder sports coupe. Brand Positioning: Premium performance and luxury sports car manufacturer. Competitive Analysis Key Competitors: Chevrolet Corvette, Nissan 300ZX, Toyota Supra, BMW 3 Series Coupe. Key Features Performance Focus: Tuned for a balance of performance, handling, and everyday usability, with turbocharging providing significant power gains. Handling Characteristics: Renowned for excellent weight distribution, balanced chassis, and precise steering, often praised for its 'modern' feel compared to earlier Porsches. 📋 Manual Details Coverage Areas Covered Years: 1987, 1988, 1989, 1990, 1991 Covered Models: Porsche 944 Turbo Page Count Estimated Page Count: Extensive (typical factory service manuals are 1000+ pages) Manual Type Manual Classification: Factory Service Repair Manual Additional Manual Types: Troubleshooting Guide, Shop Repair Manual, Maintenance Schedule, Workshop Manual, Wiring Diagram Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, component inspection, machining, torque specifications, timing procedures, lubrication systems, cooling systems. Engine Management: Fuel injection system (Bosch DME), ignition system, emission control systems, sensor diagnostics, ECU operation. Transmission: Manual transmission (G50/10 transaxle from 1987 onwards, before that the earlier transaxle), clutch system, differential, driveshafts, maintenance, repair, and overhaul. Drivetrain: Transaxle, driveshafts, CV joints, wheel bearings, lubrication. Suspension: Front and rear suspension components, struts, shock absorbers, control arms, bushings, anti-roll bars, alignment procedures, specifications. Steering: Power steering system, steering rack, pump, hoses, tie rods, steering column, alignment. Brakes: Hydraulic system, ABS system (if equipped), brake discs, calipers, pads, lines, master cylinder, bleeding procedures, specifications. Electrical System: Wiring diagrams, fuse box layouts, relay functions, battery, alternator, starter, lighting systems, instrument cluster, body control modules. Body And Chassis: Body panels, doors, windows, locks, interior trim, exterior trim, structural components, collision repair information, rust prevention. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling. Fuel System: Fuel pump, fuel filter, fuel lines, injectors, fuel tank, fuel pressure testing. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection and replacement. Diagnostics And Troubleshooting: Systematic troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs) for DME system, symptom-based diagnostics. Component Repair And Replacement: Step-by-step instructions for removing, repairing, and reinstalling virtually all mechanical and electrical components. Overhaul Procedures: Detailed instructions for complete engine and transmission overhauls. Wiring Diagram Interpretation: Comprehensive electrical schematics with component identification and circuit tracing guides. Technical Depth Depth Of Information: Comprehensive, covering all aspects from basic maintenance to advanced diagnostics and complete overhauls. Detail Level: Factory-level detail with torque specifications, clearances, and assembly sequences. 📊 Manual Specifications File Format Digital Format: PDF Digital Requirements: Adobe PDF Reader File Compression: Likely requires WinZip or similar for initial download if compressed. Print Quality Digital Printability: Printable pages for offline use. Binding Type Binding Physical: N/A (Digital Format) Paper Type Paper Physical: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4, Turbocharged Engine Code: M44.52 Displacement: 2.5 Liters (2479 cc) Bore X Stroke: 104.0 mm x 70.8 mm Compression Ratio: 8.5:1 Valve Train: Dual Overhead Camshafts (DOHC), 2 valves per cylinder Performance Horsepower: 220 hp @ 5800 rpm (DIN) Torque: 250 lb-ft (340 Nm) @ 3500 rpm (DIN) Redline: 6500 rpm Fuel System Fuel Delivery: Bosch Motronic DME (Digital Motor Electronics) fuel injection with electronic ignition control Fuel Type: Premium Unleaded Gasoline (91 RON / 87 AKI recommended) Turbocharging Turbocharger Model: Garrett AiResearch T3 Boost Pressure: 0.7 bar (10.15 psi) nominal 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transaxle Transaxle Code: G50/10 (from 1987 onwards) Optional Optional Transmission: None for 944 Turbo models. Features Clutch Type: Hydraulically actuated single-plate dry clutch Differential Type: Limited Slip Differential (LSD) standard 📐 Dimensions Exterior Length: 4205 mm (165.5 in) Width: 1735 mm (68.3 in) Height: 1280 mm (50.4 in) Wheelbase: 2400 mm (94.5 in) Front Track: 1470 mm (57.9 in) Rear Track: 1444 mm (56.9 in) Weights Curb Weight: Approx. 1370 kg (3020 lbs) Gross Vehicle Weight Rating: Approx. 1770 kg (3902 lbs) Cargo Trunk Volume: Front trunk: 7.2 cu ft; Rear hatch area: 12.4 cu ft (expandable) 🛡️ Safety Features Ratings Crash Test Ratings: NHTSA and IIHS ratings not readily available for this era and specific model. Porsche vehicles of this period were known for robust safety structures. Active Features ABS: Anti-lock Braking System (ABS) standard Passive Features Airbags: Driver's side airbag standard from 1987 onwards. Seatbelts: 3-point inertia-reel seatbelts Chassis Design: Reinforced safety cage, crumple zones. 💡 Technology Features Infotainment Audio System: Factory fitted premium sound system (e.g., Blaupunkt) with cassette player; aftermarket head unit options are common. Instrument Cluster: Analog gauges including tachometer, speedometer, oil pressure, oil temperature, voltmeter, and boost gauge. Driver Assistance Cruise Control: Standard ABS: Standard Connectivity Connectivity Features:...
Fuel injection system (Bosch DME), ignition system, emission control systems, sensor diagnostics, ECU operation.
Transmission:
Manual transmission (G50/10 transaxle from 1987 onwards, before that the earlier transaxle), clutch system, differential, driveshafts, maintenance, repair, and overhaul.
Porsche approved coolant (ethylene glycol based) with corrosion inhibitors, mixed 50/50 with distilled water.
Known Issues
Common Wear Items:
Timing belt tensioner, fuel pump, fuel pressure regulator, suspension bushings, clutch assembly, camshaft seals, rear main seal, CV joints.
Turbo Specific Issues:
Oil leaks from turbocharger lines, potential for turbocharger wear, DME relay failure.
Electrical Quirks:
Aging wiring harnesses can lead to intermittent issues; DME relay is a known failure point.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Porsche, founded in 1931, is synonymous with performance, motorsport, and precision engineering.
Model Evolution
944 Introduction:
The 944 was introduced in 1982 as a successor to the 924, aiming for a more refined and performance-oriented package.
Turbo Introduction:
The 944 Turbo (or 944 S2 Turbo) was launched in 1985 and received updates throughout its production, culminating in the later models covered by this manual.
Facelift Details:
The 1989 facelift brought significant revisions including updated bodywork (with a more integrated bumper design), revised interior, and the new G50 transaxle from the 911 Carrera for later Turbo models.
Production
Production Years:
1985-1991
Manufacturing Location:
Neckarsulm, Germany
🏆 Awards & Recognition
Recognitions
Automotive Press Acclaim:
The 944 series, including the Turbo, was generally well-received by the automotive press for its handling, performance, and build quality.
Club And Enthusiast Status:
Highly regarded by Porsche enthusiasts for its unique blend of turbocharged power and classic 944 chassis dynamics.
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