Porsche 944 SOHC Repair Manual 1983-1989

The Porsche 944 SOHC Repair Manual 1983-1989 by Haynes covers all models, including Turbo. Note: this manual does not include information specific to 944S models.
Book Excerpt: 1983-1989 Porsche 944 SOHC Repair Manual GENERAL ENGINE OVERHAUL PROCEDURES

ENGINE BLOCK - CLEANING

1. Using a gasket scraper, remove all traces of gasket material from the engine block. Be very careful not to nick or gouge the gasket sealing surfaces.
2. Remove the main bearing inserts from the upper and lower sections of the engine block. Tag the bearings, indicating which cylinder they were removed from and whether they were in the upper or lower section, and then set them aside.
3. If the engine is extremely dirty it should be taken to an automotive machine shop to be steam cleaned.
4. After the block is returned, clean all oil holes and oil galleries one more time. Brushes specifically designed for this purpose are available at most auto parts stores. Flush the passages with warm water until the water runs clear, dry the block thoroughly and wipe all machined surfaces with a light corrosion preventative oil. If you have access to compressed air, use it to speed the drying process and to blow out all the holes and galleries.
5. If the block is not extremely dirty or sludged up, you can do an adequate cleaning job with warm soapy water and a stiff brush. Take plenty of time and do a thorough job. Regardless of the cleaning method used, be sure to clean all oil holes and galleries very thoroughly, dry the block completely and coat all machined surfaces with light oil.
6. The threaded holes in the block must be clean to ensure accurate torque readings during reassembly. Run the proper size tap into each of the holes to remove any corrosion, thread sealant or sludge and to restore any damaged threads. If possible, use compressed air to clear the holes of debris produced by this operation.
7. If the engine is not going to be reassembled right away, cover it with a large plastic trash bag to keep it clean.

AUTOMATIC TRANSMISSION

AUTOMATIC TRANSMISSION - REMOVAL AND INSTALLATION
(Refer to illustrations 7.8, 7.10, 7.11, 7.14 and 7.22) REMOVAL

1. Disconnect the negative cable at the battery. Place the cable out of the way so that is cannot accidently come into contact with the terminal, which would again allow current flow.
2. Raise the vehicle and support it securely on jackstands.
3. Remove the exhaust system.
4. Detach the driveaxles from the transmission and suspend them out of the way horizontally on pieces of wire so the CV joint boots are not damaged.
5. Disconnect and plug the fluid cooler tubes at the transmission.
6. On later models, disconnect the speedometer cable from the transmission.
7. Disconnect selector lever and transmission lever cables. The cable has a locking ball at its head to retain the cable.
8. Remove the inspection hole cover form the bellhousing for access to the torque converter (see illustration). Mark the torque converter-to-driveplate relationship so they can be reinstalled in the same position. Remove the three torque converter mounting bolts in turn, using a wrench on the front pulley to turn the engine.
9. Support the transmission with a jack.
10. Raise the transmission slightly and remove the retaining bolts from the mounts and bellhousing (see illustration).
11. The torque converter must remain with the transmission during removal. Retainers can be made from short pieces (approximately 4 inches long) of strap metal with holes drilled in the ends so they can be bolted to the transmission (see illustration). Alternately, an assistant can hold the torque converter in position during removal.
12. Carefully move the transmission to the rear and lower it from the vehicle.
13. Lower the transmission onto a clean working surface and remove the torque converter.

Subject: 1983, 1984, 1985, 1986, 1987, 1988, 1989 Porsche 944 SOHC service, maintenance, repair. ISBN-10: 1850106576 | ISBN-13: 9781850106579 | Haynes 80035