radiator PORSCHE 944 1987 1.G Owners Manual

INDEX
A
ABS Acceleration diagram Accelerator pedal Air Bag System Air - cleaner
- conditioner
- filter
Alternator warning light Antifreeze Antilock, Brake system Anti-theft alarm Ashtray Automatic- garage door
- speed control
- transmission
- transmission fluid B
Battery
Boost pressure gauge
Brake - booster
- fluid
- fluid warning light
- pads
- parking
- pedal
- system
- warning light
Break-in hints
Bulb replacing
Buzzer 28,39
118-129
55
20, 21, 38, 3980, 8144-4680,81 39
74,75,11028, 39
11
42, 98
25
29
53-55
78,110,128
90-9234
27
39,79,11039
27,37,47,79,80 26
26, 27
26,27,11537
47
93-98
10,18,24,30
C/D
CASIS
Capacities
Car care instructions
Casis
Catalytic Converter
Cautions
Central locking
Central warning light
Cigarette lighter
Cleaning
Clock
Clutch pedal
Collapsible spare tire
Control warning light system
Coolant Temperature Gauge
Cooling system
Corrosion prevention
Dashboard
Defogging/defrosting
Dimensions
Doors
Driving hints
E/F
Electrical system
Emergency- flasher
- starting
Emission Control System
Engine - cooling
- exhaust
- hood
- number
- oil checking & changing
- oil
-speed, max 35
110
61-66
35
50,10267
13
37
41
61-66 40
27
85
36-39 36
74-77
65-66
24
44-46 114
12,138-9, 48, 49
89-92
41
92
100-103 74-77
48
586
69-72
69,110,111,128
34,47,52,106-
108
Fan control switch knob
Fan, radiator
Filling capacities
Fog lights
Fuel - economy
- evaporation control
- gauge
- recommendation
- tank
Fuses and relays
G/H
Gas Station Information
Gasohol
Gasoline
Gear ratio diagram
Gearshift lever
Glove compartment
Hatchback
Headlights
Headlight- dimmer
- flasher
- switch
- washing system
Heater/ventilation controls
Hood - front
- rear
Horn
I/J
Ignition/steering lock
Instrument illumination
Instruments
Interior ligh 44
36, 74 110
30, 96, 97
49
103 37
50, 51
50,110
89,126
126-129 51
50,51
122-125 52-55
42
56
30,95,99 30
30
30
31,32,81,11044-4658
56,57
21,24
24
30
33-40
43, 98
4

Jack
- supports
K/L
Keys
Kickdown
Lane changer
Leather
License plate light
Light switch
Lights - ashtray
- fog
- interior
- license plate
- parking
- turn signal
Locks - doors, wheels
Loudspeakers
Lubricants
Luggage compartment
M/O
Manual transmission
- oil
Mirrors
Oil- change
- consumption
- filter changing
- pressure gauge
- pressure warning light
Octane rating
Oxygen Sensor
P/R
Paint code number 68
87, 88, 129
10-11,86 55
30
65
98
30
98
30, 96, 97
43, 9898
30, 37, 93, 94
30,93,94
10-13, 86 89
110,111 57
52,122-125 77,11022,43
71,72
47, 69
71, 72 38
38
50, 51,106-108 101,102
7
Parking- brake
- lights
Performance
Power assisted steering
Power train
Power windows
Prop-up roof
Radiator fan
Rear - hood
- view mirrors
- window defogger
- wiper
Recirculation Switch
Refrigerant
Relays
Rims
Roof racks
Roof, removable S
Safe driving hints
Safetybelts
Safety belt warning light
Safety compliance sticker
Seat heating System
Seats
Sekuriflex windshield
Shift indicator
Shift points
Side marker lights
Ski racks
Snow- chains
- tires
Spare tire, collapsible
Spark plugs
Specifications, engine
26, 3730,37,93,94116731091259, 6036, 7456,572241424446,11089,12664,112,11357,11459, 60
8-9
17-21,6518,3771514-1631, 63, 643552-559457,11483, 84,112,113
83,84, 111,113
85106-108106-109
Speedometer
Starting procedures
Sun visors
T/U
Tachometer
Technical data
Tirepressure
Tires
Tool kit
Trip odometer
Transmission oil
Trunk
Turn signal lights
Undercoating
Unleaded fuel
V/W
Vehicle identification
Ventilation
Voltmeter
Warning/indicator lights
Washer reservoir
Washing
Water temperature gauge
Weatherstrips
Weights
Wheel alignment
Wheel nuts, lockable
Wheels
Wheel changing
Windows
Windshield- washer reservoir
- wiper/washer lever 3324, 2543
34, 35105-12582,112,113,12947,82-87,112,113683377, 78,11056,5730, 37, 93, 9465, 66,10050, 51,106-108,110
6-744-463835-4081,11061-6636641141158647,64,82-87,11285-8812,63,6481,11031
5

Ignition/Starter Switch with Steering Lock
The steering is equipped with an anti-theft
ignition lock.
Switch positions
0
The steering is blocked by the steering lock: all circuits wired through the ignition
are switched off.
The ignition key can only be withdrawn in the
"0" position. The parking lights can be
operated in this position by pushing the turn
signal indicator lever up and down (also see
"Parking lights").
1 Position for radio. Steering unlocked. If it is difficult to turn the key, gently move the
steering wheel until the key turns freely.
Note: all circuits which are disconnected in
position "3" can be switched on.
To conserve battery power, switch off other
electrical consumers while playing radio in
position "1".
2
Ignition on. All electric circuits are
operational. With the engine stationary, the
central warning light and all individual
warning lights located in both combination
instruments will light up for a bulb check.
3
The starter is operated by turning the
ignition key to the right. As soon as the
engine starts, release the key. It will spring
back to position "2". With the engine
running, the central and individual warning
lights should go out (see "Central warning
light").
To conserve battery power, the electric
circuits for headlights, rear window de-
fogger/defroster, temperature control and
wiper/washer system are temporarily interrupted during the starting process.
The starter should not be operated for more
than 10 to 15 seconds at a time. If the engine
does not start the first time or stalls at any
time, the ignition key must be returned to the
"0" position. The non-repeat lock in the switch
prevents the
starter from being operated when the engine is running and guards against
starter damage.
To remove the key and to lock the steering
wheel
, turn the key back to position "0" and
pull out. Turn the steering wheel until it locks.

WARNING
Never remove key from ignition lock or
turn key off while vehicle is moving. The
steering wheel will lock, causing loss of
control.
Instrument panel lights
Warning lights for alternator, oil pressure, and
brake system will light up for a bulb check
when the ignition is turned on. They should go out after the engine is started. The brake
warning light will go out after the parking
brake has been fully released. See
"Warning lights" for more details.
Buzzer
If you leave the key in the ignition/steering
lock, the buzzer will sound when the driver's
door is opened. This is a reminder to remove
the key.
For further details see "Starting Procedures"
on the following page.

24

Starting Procedures

WARNING
Fasten safety belts before driving.
Never start or let the engine run in an enclosed, unventilated area. Exhaust
fumes from the engine contain carbon
monoxide, which is a colorless and
odorless gas. Carbon monoxide can be
fatal if inhaled.

Never leave engine idling unattended. An unattended vehicle with a running engine
is potentially hazardous.
Do not park or operate the vehicle in areas where the hot exhaust system may
come in contact with dry grass, brush,
fuel spill or other flammable material.
Never leave engine idling. When starting engine, be ready to drive immediately.
Maintain moderate speed until engine is
warm.

Automatic Transmission - Start with selec-
tor lever in Park.
Manual Transmission - Start with gearshift
lever in Neutral.
Temperature sensors on the engine auto- matically provide the correct fuel/air mixture
required for starting.
Therefore, do not depress the accelerator
pedal while starting a cold or a warm engine.
When starting at very low outside
temperatures , fully depress the clutch pedal,
so that the starter only has to crank the
engine.
As soon as the engine starts, release the ignition key.
If the engine fails to start after 10 to 15
seconds of cranking, wait about 10
seconds before engaging starter again.
Do not let engine idle to warm it up. After
starting, drive vehicle at moderate speeds and with gradual accelerations. Avoid high rpm
and full throttle operation until the engine has
reached normal operating temperature.
Stopping engine
Turn key back to position 0.
Do not stop engine immediately after hard
or extended driving. Keep engine running
at increased idle for about two minutes to
prevent excessive heat buildup before
turning off engine.
WARNING
Before you check anything in the engine compartment, let the engine cool down.
Hot components can burn skin on
contact.

The radiator fan switches on automatically when the coolant reaches a
certain temperature and continues to run
(even with ignition off) until the coolant
temperature drops. Therefore, never
touch the fan blades as they will rotate
spontaneously when the thermoswitch
turns the fan on.

If you have an automatic garage door...
The transistorized ignition system in your
Porsche may interfere with your electronically
operated garage door. To check this: drive
your Porsche close to the garage door and
run the engine at different speeds.
If the garage door opens or closes without
your operating the garage door unit in your
car, contact the dealer who installed the
automatic garage door to have the frequency
and/or coding of the garage door signal
modified.
25

Left Instrument Cluster
The left instrument cluster includes the
coolant temperature and fuel gauges as well
as warning lights for coolant temperature, fuel
reserve, brake-
lining wear, safety belt, parking light and parking brake. The two arrows at the
top are turn signal indicators for vehicles with
trailer coupling.
Coolant temperature

Indicator
Needle in lower field - engine is cold
Avoid high speeds and high engine rpm. During cold engine operation, engine
response and power levels will vary from that
of a warm engine. Due caution and notice of
these engine characteristics will ensure safe
operation of the vehicle.
Needle in center field - normal

Under normal driving conditions, needle
should remain in center field. The needle may
reach the upper field, especially at high
engine loads, but should return to "normal"
when engine load is reduced.

Needle in upper field - warning
If needle enters the upper field the engine is
overheating the warning light comes on.
Reduce speed and engine rpm. The needle
should return to the center field and the
indicator light goes out.
If the needle does not return to the center
field, and the indicator light does not go out,
the radiator fan may not be working to
provide sufficient engine cooling. Pull off the
road and turn off the engine. The fan should
still be running for a while. Failure to do so
may result in severe damage to the engine.
WARNING
Before you check anything in the engine compartment, let the engine cool down.
Hot components can burn skin on
contact. The radiator fan switches on automatically when the coolant reaches a
certain temperature and continues to run
(even with ignition off), until the coolant
temperature drops. Therefore, never

touch the fan blades as they will rotate spontaneously when the termoswitch
turns the fan on.
Be careful if you have to remove the cap from a hot coolant fluid reservoir. Protect
your hands, arms and face against
scalding. Use a thick rag and open the
cap carefully one turn to allow excess
pressure to escape before removing the
cap.

If the fan is not working, the fuse for the fan
may be burned out, or the relay may be
defective. See "Fuses and Relays".
After the engine has cooled down, check the coolant level (see "Cooling System"). If the
coolant level is low, top it up with water.
Check for possible leaks.
If the coolant level is normal, proceed to the
nearest workshop. Avoid idle speed and stop-
and-go driving. But with an inoperative fan,
the coolant will heat up again. When the
needle enters the upper field, stop again and
let the engine cool down before you continue
driving.
Coolant system malfunctions should be
remedied by the nearest Porsche dealer, as
severe engine damage may occur.

36


Fuel Gauge and FuelReserve Indicator
When the ignition is turned on, the amount of
fuel in the tank is indicated by the fuel gauge
in the right part of the dial.
If the needle enters the area in the bottom and the fuel reserve indicator lights up, there is
only a reserve of about. 2.1 U.S. gal/8 liters
left in the tank. Time to refuel at the next gas
station.
Brake Pad
Warning Light
The brake pad warning light comes on when the ignition is turned on and goes out after the engine has started.
If the light stays on when the engine is
running or comes on while driving, the brake
pads are worn, excessively.
Do not continue to operate the vehicle but
have your Porsche dealer check and
replace the brake pads.

Safety Belt
Warning Light
When the ignition is turned on the light will
come on for about 6 seconds to remind driver
and passenger to buckle up. See "Safety
Belts" for more details.


Parking Brake Light
The parking brake light will light up when the
ignition is turned on and the parking brake is
set.
The light goes out when the parking brake is fully released.
Parking Light
The parking light indicator at the bottom in the
left instrument cluster lights up when the
parking lights are switched on.

Turn Signal
Indicator Light
The turn signal indicator light, which is located below the central warning light, will flash at the same frequency as the turn signals. If a turn
signal fails, the control light flashes at about
twice the normal frequency. Have your dealer
check and repair it for you.
High Beam Indicator
Light

The high-beam indicator light, which is located at the top between the tachometer and the
right instrument cluster, will light up when you
switch on the high beams or when you flash
signal. The indicator goes out when you
switch to low beam.

Central Warning Light
The central warning light comes on after
turning on the ignition. This light monitors all
functions displayed by the instruments. If one
of these functions fails, the central warning
light and the pertinent indicator light come on
until the malfunction has been corrected. The
vehicle should immediately be taken to the
nearest authorized workshop.

37

Exercise Extreme Caution when Working under the
Engine Hood


The engine compartment of any motor vehicle is a potentially hazardous area. If you are not
fully familiar with proper repair procedures, do
not attempt the adjustments described on the
following pages. This caution applies to the
entire vehicle.
Only work on your vehicle outdoors or in a well ventilated area. Ensure that there are no open flames in the
area of your vehicles at any time when
gasoline fumes might be present. Be
especially cautious of such devices such as
hot water heaters which ignite a flame
intermittently.
Before working on any part in the engine
compartment, turn the engine off and let it
cool down sufficiently. Hot engine
compartment components can burn skin on
contact.
Even after the engine has stopped the
radiator fan may continue running until the
temperature of the coolant has dropped to a
certain level. Therefore, never touch the fan
blades as they will rotate spontaneously
when the thermostat turns the fan on, even with ignition off. Be alert and cautious around engine at all
times while the engine is running.
If work has to be done with the engine
running, always set the parking brake, and
make sure the shift lever is in either Neutral
or Park.
Exercise extreme caution to prevent
neckties, jewelry or long hair from getting
caught in the fan blades, the drive belts, or
any other moving engine parts.
Your Porsche is equipped with a
transistorized ignition system with
breakerless distributor. When the ignition is
on, high voltage is present in all wires
connected with the ignition system; therefore
exercise extreme caution when working on
any part of the engine while the ignition is on
or the engine is running.
Always support your car with safety stands if it is necessary to work underneath the car.
The jack supplied with the car is not
adequate for this purpose.
When working underneath the car without
safety stands but with the wheels on the
ground, make sure the car is on level ground, that the wheels are blocked, and that the
engine cannot be started. REMOVE THE
IGNITION KEY.
Do not smoke or allow an open flame around the battery or gasoline. Keep a fire extinguisher in close reach.
Incomplete or improper servicing may cause
problems in the operation of the car. If in
doubt about any servicing, have it done by
your authorized Porsche dealer or any other
properly equipped and qualified workshop.
Improper maintenance during the warranty
period may affect your warranty coverage.
67





Tool Kit and Car Jack
The tool kit and jack are stored in the luggage
compartment under the floor mat.
The car jack must be screwed open a little
before it can be removed from the holder.
The tool kit contains tools needed for minor
emergency roadside repairs, adjustments and
wheel changing.
Regulations in some countries require
additional tools. Details should be obtained
prior to leaving for a foreign country.
WARNING

Use the jack only for changing a tire. Never jack up other vehicles or other loads with it. Follow all warnings and instructions found in this manual for changing a tire. The jack must never be used as a support to work underneath the vehicle. If the jack is accidently dislodged, you or bystanders could be seriously injured. When working
under the vehicle, always use safety
stands specifically designed for this
purpose.



68

Power Assisted Steering
The hydraulic assistance system allows
effortless steering under all driving conditions.
Slight hissing or squeaking sounds during
sharp turns (turning steering wheel from lock
to lock) are normal and do not indicate a
defective steering mechanism.
If the engine is not running, po
wer assisted steering is no longer effective. You can
continue to steer the car but more effort
will be required to turn the steering wheel.

Checking the fluid level
The hydraulic fluid level should be checked at
regular intervals. The fluid reservoir is
mounted on the right wheel housing in the
engine compartment.
1.
Unscrew cap from reservoir and wipe
dipstick with a lint free cloth.
2.
Let engine run at idle speed. Reinstall cap
and unscrew again. The fluid level should
be between the upper and lower mark on
the dipstick.
If necessary, top up with ATF-Dextron®.
3. Reinstall cap and handtighten securely.
73

Cooling System
Only use additives recommended for
aluminium engines and radiators. Your
Porsche dealer will be able to advise you.
For year round driving, phosphate-free
antifreeze is added at the factory for
temperatures down to:
-31° F / -35° C
Because of its anti-corrosion properties,
antifreeze should also remain in the cooling
system for summer operation. Cooling system capacity and specified antifreeze and water
ratios are listed under "Filling capacities".
Use any quality phosphate-free anti-freeze
containing ethylene glycol, available at your
Porsche dealer. Anti-freeze other than
specified by Porsche for aluminium engi-
nes and radiators may cause corrosion of
the cooling system, leading to engine
overheating and damage.

Only
for topping up coolant, a small amount of anti-freeze containing ethylene glycol and
phosphates may be used if recommended
anti-freeze is not available.
The anti-corrosion properties and the
antifreeze consistency will diminish gradually.
We recommend renewing the coolant mixture
at least every 2 years.
WARNING
The radiator fan is electrically driven. It is
switched on automatically by a thermostat
when the coolant reaches 198°F / 92°C.
Even when the engine is turned off, the fan will continue running, until the coolant
temperature has dropped to 189°F / 87°C
and until the engine itself has cooled down sufficiently.
Checking coolant level in expansion tank
A correctly functioning cooling system requires only minor care. The coolant level
should be checked from time to time, and
always before going on a longer trip.
The
expansion tank with filler cap opening is
located in the engine compartment (see
illustration). Since the expansion tank is
transparent, the coolant level can be checked
visually without removing the filler cap.

74

When the engine is cold, the coolant level
should reach the minimum mark on the
expansion tank. When the engine is warm, the coolant level will be above the minimum mark. Since the closed cooling system loses almost
no coolant, topping up is normally not
required. An obvious loss of coolant indicates
leakage. In this case contact your dealer.
WARNING

Do not open the filler cap when the engine is hot because of the danger of
scalding. Allow the engine to cool down.
Protect your hands, arms and face.

Using a thick rag, open the cap carefully and only enough to allow excess
pressure to escape before removing the
cap.
To avoid damage to the engine, only add
cold antifreeze and cold water
to the cooling system when the engine is also cold. A warm engine should only be topped up if the coolant level has dropped appreciably below
the minimum mark. Too much added coolant
will escape through the pressure cap when coolant warms up.
If more than about 1.06 U.S qt or 1 liter must
be added, the cooling system should be bled.

Winter operation At the beginning of the winter season, have the coolant checked for anti-freeze
concentration.
The ratio between water and anti-freeze
necessary to prevent freezing depends on the
anticipated outside temperatures. The ratios
can be taken from the mixing chart listed
under "Filling Capacities" or from the container of the antifreeze manufacturer.
Increasing the anti-freeze in the coolant
further than shown on the container is not
only uneconomical, it is also detrimental to engine cooling.
75





944 Draining the coolant
Engine must be cold
1. Move temperature control lever to "warm".
2.
Remove filler cap from expansion tank.
3. Unscrew drain plug on radiator and on engine block (curved arrows). Allow coolant to drain completely.
Bleeding cooling system and topping up
coolant
1. Reinstall radiator drain plug. Do not overtighten plug (required torque is 43 in.
lb/5 Nm).
2.
When reinstalling engine block drain-plug,
use a new gasket. Do not overtighten plug
(required torque is 14 ft lb/20 Nm).
3.
Move temperature control lever to "warm".
4. Unscrew the vent plug (single white arrow)
and remove.
5. Remove the expansion tank filler cap and
slowly pour coolant into the tank. Stop
pouring as soon as fluid runs out of vent
plug opening.
6.
The expansion tank should only be about
half full so as to prevent any overflow once
the engine is warm.
7.
Screw in the vent plug loosely.
8. Start the engine. Let engine run at increased idle until it has reached operating temperature (the radiator fan will turn on
and off).
76

Engine Design Specifications
Design
Operating cycle
Lubrication
Cylinder block
Cylinder head
Valve operation
Camshaft drive
Crankshaft
Fuel injection 4-cylinder, in-line engine, front mount with two ba
lance-shafts
4-stroke
Pressure oil circulation from oil sump,
full flow filter
Light metal
Light metal
Overhead camshaft
(944 S: 2 overhead camshafts)
Spur belt drive
Forged, 5 main bearings
AFC (Air Flow Control) Power Train
Manual transmission
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
Axle ratio Gear ratio 944
3.600:1
2.125:1
1.458:1
1.071:1
0.730:1
3.500:1
3.889:1 Gear ratio 944 S
3.500:1
2.059:1
1.400:1
1.034:1
0.829:1
3.500:1
3.889:1 Gear ratio 944 Turbo
3.500:1
2.059:1
1.400:1
1.034:1
0.829:1
3.500:1
3.375:1
Clutch
Power transmission Single plate dry disc, hydraulically operated
Double constant velocity joints and drive shaft
Automatic transmission 944
Gear ratio 1st gear
2nd gear
3rd gear
Reverse gear
Axle ratio
Clutch 2.714:1
1.500:1
1.000:1
2.429:1
3.455:1
Hydrodynamic torque converter
109

Filling Capacities
Engine oil With filter change approx. 6.34 (Turbo: approx. 6.87) U.S. qts. or 6 (Turbo: approx. 6.5) liters.
Check oil level with dipstick a few minutes after e ngine has stopped. The difference between
the max. and min. marks on the dipstick is approx. 1 U.S. qt. or 1 liter.
Only use brand name oil which has been tested and a pproved by Porsche.
Your authorized Porsche dealer will be glad to advi se you.
Porsche does not recommend the use of oil additives . See also "Engine Oils".
Cooling system with heating
Approx. 8,2 U.S. qts. or 7,8 liters. Factory filled to -31°F (-35°C). Only use phosphate-free
anti-freeze containing ethylene glycol recommended for aluminum engines and radiators.
Manual transmission
Approx. 0.53 U.S. gal. or 2.0 liters. Use hypoid oi l SAE 80 labeled "For Service API/GL4 or
Mil-L 2105".
Automatic transmission with
torque converter Approx. 1.72 U.S. gal. or 6.5 liters ATF Dexron®. At oil c hanges 3 U.S. qts. or 2.8 liters are
required.
Differential of automatic transmission
Approx. 1 U.S. qts. or 1 liter hypoid oil SAE 90 ac cording to API classification GL 5 or
Mil-L 2105 B.
Power steering
Approx. 0.63 U.S. qts. or 0.6 liter ATF Dexron®
Fuel tank Approx. 21.1 U.S. gals, or 80 liters including a re serve of 2.1 U.S. gals, or 8 liters.
Unleaded fuel only! Minimum octane rating 944 91 RO N (87 CLC or AKI ((R+M)/2) rating on fuel
pumps in U.S.A.), 944 S / 944 Turbo 95 RON (90 CLC or AKI ((R+M)/2) rating on fuel pumps in U.S.A.)
Brake fluid Approx. 0.42 U.S. pint or 0.2 liter. Only use brake fluid conforming to specifications
SAE J 1703, DOT 3 or DOT 4.
Windshield and headlight washer system
Approx. 1.59 U.S. gals, or 6.0 liters.
Refrigerant for air conditioning Approx. 33.5 oz or 950 g. Refrigerant R 12 (CCI2F2)
Cooling system mixing chart
(Approximate values)
Anti-freeze-Water
Consult your authorized dealer about
the approved anti-freeze mixtures. Temp, down to
-13° F (-25°C) -23° F (-30° C) -31° F (-35° C)
Anti-freeze
40%
45%
50% Water
60% 55% 50%
Anti-freeze

3.1 liters / 3.3 U.S. qts.3.5 liters / 3.7 U.S. qts.3.9 liters / 4.1 U.S. qts.
Water
4.7 liters / 5.0 U.S. qts.
4.3 liters / 4.5 U.S. qts. 3.9 liters / 4.1 U.S. qts.
110