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1989-1991 Porsche 944 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: 944 Model Years Covered: 1989, 1990, 1991 Codes Chassis Codes: 944S2, 944Turbo (951) 👋 Introduction Market Position Vehicle Segment: Front-engine, rear-wheel-drive sports car / grand tourer Competitors: Chevrolet Camaro, Pontiac Firebird, Ford Mustang, Nissan 300ZX, Toyota Supra, BMW 3 Series Coupe Key Features Chassis Design: Transaxle layout for balanced weight distribution Engine Layout: Inline-four cylinder, front-mounted Aerodynamics: Sleek, aerodynamic styling typical of Porsche design Handling: Renowned for excellent handling characteristics and driver engagement 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital Download (PDF) Page Count Estimated Page Count: 1500+ 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block assembly, piston and connecting rod assemblies, crankshaft, camshafts, timing belt, oil pump, lubrication system Engine Management Electronics: Engine control unit (ECU) diagnosis, sensors (MAP, TPS, O2, Coolant Temp), actuators (injectors, idle control valve), ignition system, fuel injection system (Bosch Motronic) Fuel System: Fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator, fuel tank Cooling System: Radiator, coolant hoses, water pump, thermostat, expansion tank, cooling fan operation Exhaust System: Exhaust manifolds, catalytic converter (if applicable), mufflers, oxygen sensors Transmission Manual: Clutch system, gearbox overhaul, gear shift linkage, transmission fluid specifications Transmission Automatic: Automatic transmission (optional) diagnosis, fluid, seals, torque converter, electronic control unit Drivetrain: Driveshafts, CV joints, differential, rear transaxle assembly Suspension Front: MacPherson struts, control arms, bushings, anti-roll bar, wheel bearings Suspension Rear: Trailing arms, shock absorbers, springs, bushings, suspension geometry Steering System: Power steering pump, steering rack, tie rods, steering column, alignment specifications Brake System: Front and rear brake calipers, rotors, pads, brake lines, master cylinder, ABS system (Anti-lock Braking System) diagnosis and components Electrical System: Wiring diagrams, battery, alternator, starter motor, fuses, relays, lighting system, gauges, interior electronics Body And Chassis: Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, sound deadening Climate Control: HVAC system, A/C compressor, blower motor, heater core, refrigerant system, climate control panel Wheels And Tires: Tire sizes, wheel specifications, torque specifications, tire pressure recommendations Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and changes, belt inspections and replacements, spark plug replacement, brake fluid flush Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common fault identification and repair Repair Procedures: Step-by-step repair instructions for all major mechanical and electrical components Disassembly And Assembly: Detailed instructions for removing and reinstalling major components and sub-assemblies Special Tools: Identification and usage of specific Porsche tools required for certain repairs Torque Specifications: Precise torque values for all fasteners and critical components Alignment Specifications: Front and rear wheel alignment angles Technical Depth Diagnostic Information: In-depth diagnostic procedures, fault codes (OBD-I related for era), electrical schematics Rebuild Instructions: Comprehensive instructions for engine and transmission rebuilds Electrical Schematics Detail: Detailed, component-level wiring diagrams for all vehicle systems 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution scans for clarity of diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-4 (944S2), Turbocharged Inline-4 (944 Turbo/S2 Turbo) Displacement 944S2: 3.0 Liters (2990 cc) Horsepower 944S2: 208 hp @ 5800 rpm Torque 944S2: 207 lb-ft @ 4000 rpm Displacement 944Turbo: 2.5 Liters (2479 cc) Horsepower 944Turbo: 220 hp @ 6000 rpm (standard Turbo), 250 hp @ 6000 rpm (944 Turbo S) Torque 944Turbo: 245 lb-ft @ 3500 rpm (standard Turbo), 258 lb-ft @ 3500 rpm (944 Turbo S) Fuel System Fuel Injection: Bosch Motronic (DME or M) engine management with sequential fuel injection Fuel Type: Premium Unleaded Gasoline 🔧 Transmission Standard Transmission Type: 5-speed Manual Transaxle Optional Transmission Type Optional: 3-speed Automatic Transaxle (less common on later models) Features Transaxle Design: Rear-mounted transaxle for optimal weight distribution Clutch Type: Hydraulically actuated single dry plate clutch 📐 Dimensions Exterior Wheelbase: 2499 mm (98.4 inches) Length: 4250 mm (167.3 inches) Width: 1700 mm (66.9 inches) Height: 1275 mm (50.2 inches) Weights Curb Weight 944S2: Approx. 1360 kg (2998 lbs) Curb Weight 944Turbo: Approx. 1370 kg (3020 lbs) 🛡️ Safety Features Passive Features Airbags: Driver-side airbag (standard on later models/years), Passenger airbag (optional or standard on late 944S2) Seatbelts: 3-point inertia-reel seatbelts Body Construction: Integral safety cage, crumple zones Active Features ABS: Anti-lock Braking System (ABS) standard on 944S2 and Turbo models Braking System: Four-wheel disc brakes (often larger on Turbo/S2 models), ventilated front discs 💡 Technology Features Infotainment Audio System: Factory fitted or aftermarket radio/cassette player, often with amplifier integration (e.g., Blaupunkt, Porsche Sound System) Gauges: Comprehensive analog gauge cluster including tachometer, speedometer, oil pressure, oil temperature, voltmeter, fuel level Driver Assistance ABS: Anti-lock Braking System Cruise Control: Optional on some models Connectivity Connectivity Features: None (pre-digital era) 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles...
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1989-1991 Porsche 944 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
944
Model Years Covered:
1989, 1990, 1991
Codes
Chassis Codes:
944S2, 944Turbo (951)
👋 Introduction
Market Position
Vehicle Segment:
Front-engine, rear-wheel-drive sports car / grand tourer
Competitors:
Chevrolet Camaro, Pontiac Firebird, Ford Mustang, Nissan 300ZX, Toyota Supra, BMW 3 Series Coupe
Key Features
Chassis Design:
Transaxle layout for balanced weight distribution
Engine Layout:
Inline-four cylinder, front-mounted
Aerodynamics:
Sleek, aerodynamic styling typical of Porsche design
Handling:
Renowned for excellent handling characteristics and driver engagement
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital Download (PDF)
Page Count
Estimated Page Count:
1500+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, block assembly, piston and connecting rod assemblies, crankshaft, camshafts, timing belt, oil pump, lubrication system
Engine Management Electronics:
Engine control unit (ECU) diagnosis, sensors (MAP, TPS, O2, Coolant Temp), actuators (injectors, idle control valve), ignition system, fuel injection system (Bosch Motronic)
Fuel System:
Fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator, fuel tank
Cooling System:
Radiator, coolant hoses, water pump, thermostat, expansion tank, cooling fan operation
Exhaust System:
Exhaust manifolds, catalytic converter (if applicable), mufflers, oxygen sensors
Transmission Manual:
Clutch system, gearbox overhaul, gear shift linkage, transmission fluid specifications
Transmission Automatic:
Automatic transmission (optional) diagnosis, fluid, seals, torque converter, electronic control unit
Drivetrain:
Driveshafts, CV joints, differential, rear transaxle assembly
Suspension Front:
MacPherson struts, control arms, bushings, anti-roll bar, wheel bearings
Suspension Rear:
Trailing arms, shock absorbers, springs, bushings, suspension geometry
Steering System:
Power steering pump, steering rack, tie rods, steering column, alignment specifications
Brake System:
Front and rear brake calipers, rotors, pads, brake lines, master cylinder, ABS system (Anti-lock Braking System) diagnosis and components
Electrical System:
Wiring diagrams, battery, alternator, starter motor, fuses, relays, lighting system, gauges, interior electronics
Body And Chassis:
Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, sound deadening
Climate Control:
HVAC system, A/C compressor, blower motor, heater core, refrigerant system, climate control panel
Wheels And Tires:
Tire sizes, wheel specifications, torque specifications, tire pressure recommendations
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and changes, belt inspections and replacements, spark plug replacement, brake fluid flush
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common fault identification and repair
Repair Procedures:
Step-by-step repair instructions for all major mechanical and electrical components
Disassembly And Assembly:
Detailed instructions for removing and reinstalling major components and sub-assemblies
Special Tools:
Identification and usage of specific Porsche tools required for certain repairs
Torque Specifications:
Precise torque values for all fasteners and critical components
Alignment Specifications:
Front and rear wheel alignment angles
Technical Depth
Diagnostic Information:
In-depth diagnostic procedures, fault codes (OBD-I related for era), electrical schematics
Rebuild Instructions:
Comprehensive instructions for engine and transmission rebuilds
Electrical Schematics Detail:
Detailed, component-level wiring diagrams for all vehicle systems
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution scans for clarity of diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-4 (944S2), Turbocharged Inline-4 (944 Turbo/S2 Turbo)
Displacement 944S2:
3.0 Liters (2990 cc)
Horsepower 944S2:
208 hp @ 5800 rpm
Torque 944S2:
207 lb-ft @ 4000 rpm
Displacement 944Turbo:
2.5 Liters (2479 cc)
Horsepower 944Turbo:
220 hp @ 6000 rpm (standard Turbo), 250 hp @ 6000 rpm (944 Turbo S)
Torque 944Turbo:
245 lb-ft @ 3500 rpm (standard Turbo), 258 lb-ft @ 3500 rpm (944 Turbo S)
Fuel System
Fuel Injection:
Bosch Motronic (DME or M) engine management with sequential fuel injection
Fuel Type:
Premium Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transaxle
Optional
Transmission Type Optional:
3-speed Automatic Transaxle (less common on later models)
Features
Transaxle Design:
Rear-mounted transaxle for optimal weight distribution
Clutch Type:
Hydraulically actuated single dry plate clutch
📐 Dimensions
Exterior
Wheelbase:
2499 mm (98.4 inches)
Length:
4250 mm (167.3 inches)
Width:
1700 mm (66.9 inches)
Height:
1275 mm (50.2 inches)
Weights
Curb Weight 944S2:
Approx. 1360 kg (2998 lbs)
Curb Weight 944Turbo:
Approx. 1370 kg (3020 lbs)
🛡️ Safety Features
Passive Features
Airbags:
Driver-side airbag (standard on later models/years), Passenger airbag (optional or standard on late 944S2)
Seatbelts:
3-point inertia-reel seatbelts
Body Construction:
Integral safety cage, crumple zones
Active Features
ABS:
Anti-lock Braking System (ABS) standard on 944S2 and Turbo models
Braking System:
Four-wheel disc brakes (often larger on Turbo/S2 models), ventilated front discs
💡 Technology Features
Infotainment
Audio System:
Factory fitted or aftermarket radio/cassette player, often with amplifier integration (e.g., Blaupunkt, Porsche Sound System)
Gauges:
Comprehensive analog gauge cluster including tachometer, speedometer, oil pressure, oil temperature, voltmeter, fuel level
Driver Assistance
ABS:
Anti-lock Braking System
Cruise Control:
Optional on some models
Connectivity
Connectivity Features:
None (pre-digital era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles or 12 months (recommend synthetic oil)
Timing Belt Replacement:
Every 30,000 miles or 3 years (critical component, failure causes severe engine damage)
Spark Plug Replacement:
Every 30,000 miles
Fluid Specifications
Engine Oil Type:
API SG/SH, ACEA A2 or A3 rated synthetic oil, viscosity 5W-40 or 10W-40 depending on climate (e.g., Mobil 1 5W-40)
Coolant Type:
Porsche approved coolant (Glysantin G05 or similar) at 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid
Transmission Fluid Manual:
GL-4 SAE 75W-90 gear oil (e.g., Swepco 201, Mobil 1 75W-90)
Transmission Fluid Automatic:
Dexron III or equivalent ATF
Power Steering Fluid:
ATF (Dexron II/III compatible)
Known Issues
Common Issues:
Timing belt failure (critical maintenance), worn suspension bushings, fuel injector leaks, power steering pump leaks, electrical gremlins (especially window regulators, alarm system), cracked dashboard, coolant leaks from hoses or water pump, ABS sensor failures
Maintenance Alert:
Regularly check and replace the timing belt; consider a tensioner upgrade. Address suspension wear to maintain handling.
📚 Vehicle History
Brand Heritage
Manufacturer:
Porsche AG
Model Evolution
Predecessor:
Porsche 924
944 Introduction:
1981
944 Facelift:
Significant facelift in 1985 (often referred to as the '2nd generation' 944) with revised front/rear styling, interior, and suspension upgrades.
944 Variants:
Introduced 944 Turbo (951) in 1985, 944 S in 1987 (16-valve engine), 944 S2 in 1989 (2.5L replaced by 3.0L, shared with Turbo S engine block).
Production
Production Years:
1981-1991
Production Location:
Neckarsulm, Germany (Audi AG plant)
🏆 Awards & Recognition
Recognitions
Automotive Press Accolades:
Consistently praised by automotive journalists for its handling, performance, and build quality, often considered one of the best handling cars of its era.
Model Reputation:
Established the Porsche 944 as a credible and capable sports car, bridging the gap between the 924 and the 911.
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