Safety notes
ECONOMICAL BODY REPAIRS ON CELETTE ALIGNMENT BENCH The attachment set ENS 224.300 was developed for drawing and straightening jobs on the body. This attachment set consists of the basic equipment for Type 924, with which all of the important body take-up points can be checked. The new rear axle attachments are included in ENS 224.309 for cars beginning with 1978 model with the modified rear axle. For cars with modified control arm take-ups on the front axle, beginning with 1979 model, the...
Important notes 1
During tightening, the stop surface at the steering stop ring shifts by approx. 1 mm. I.e. adjusting distance a must be checked and readjusted, if required, after the lock nut has been The steering stop ring must not be omitted under any circumstances when the steering box or the steering tie-rod is refitted. Otherwise the tie-rod may retract fully into the steering gear housing, causing the steering rack guide sleeve to be damaged. Before refitting the protective sleeves bellows , extend the...
Safety Instructions
REMOVING AND INSTALLING DRIVER AIRBAG UNIT 1. Disconnect battery and cover over pole battery. The airbag unit must always be put down so that the upholstered side is pointing upward. 2. Loosen fastening screws 2 pieces with a screwdriver for socket-head Torx T 30. The airbag unit must be stored 3. Take apart plug connector. under lock and key if removed for a lengthy period of time. Follow safety instructions. Tightening torque for fastening screws 10 Nm 7.5 ftlb REMOVING AND INSTALLING AIRBAG...
Removing and installing windshield 2pack adhesive
The following tools and materials are required for removal and installation of the windshield
Notes for 944 models fitted with steel trailing arms
In the course of Model Year 1982, the adjusting values of the shock absorbers pressure and contraction stage were modified. Adapting the original version to the modified setting by adjusting the shocks is not possible. The original version of the shock absorbers is no longer available. In case of repairs, vehicles fitted with the original absorber type should be fitted with the modified shock absorbers. Combining original and modified versions is only permissible if identical shock absorber...
Running gear tuning rubbermetal mounts of 944 S2
Starting with Model Year 1991, a standardized version of the rubber-metal mounts of the running gear was used. Based on the former versions of hard as used on the 944 Turbo and 944 S2 with M 030, and the soft version fitted as standard equipment to the 944 S2, an ideal state of tuning was determined. This concerns both the front and the rear axle. Please refer to page 42 - 04 for an overview of the old and new versions as used from MY '91 . When performing repair operations, make sure this...
Filling airconditioning system
1 .All procedures described so far must have been carried out, i.e., the system must be evacuated, flushed, evacuated once more, and must be sealed. 2. Close all valves on service unit. The filling cylinder must contain sufficient refrigerant if not, refill. 3. To fill the system, there must be positive pressure of approx. 7 barin the filling cylinder. To reach this pressure, switch on the filling cylinder heating. 4.Depending on the value displayed on the pressure gauge e.g. 7 bar , set the...
Technical Data 924 S 944 944 S I 944 S2
Axle shaft to steering gear and steering column Tie rod to rack not for power steering Tie-rod joint to tie rod not for power steering Steering column switch to outer tube Feed and return lines on steering gear Ring hose nipple for intake hose on power pump Values not listed here are the same as for cars without power steering.
Installing Note
The assembly sequence must always be observed to ensure stress-free installation of the cross-link and steering shaft. 1. Apply a film of Contifix to the support ring rubber bearing and slide both together onto casing tube. 2. Install cross-link and protective tube with steering shaft, all fastening screws remain loose. 3. Tighten the fastening screw between crosslink and steering shaft upper , and then tighten the fastening screw from the cross link to the steering gear lower . 4. Use the same...
BodyGeneral
Safety notes Maintenance work using the Celette straightening bench 50- 03 Celette universal Repair control Dimensions for floor Side members Gauge for lock carrier 9117 1 . 50 - 2 Right-angle set for front-axle pick-up ENS 224307 50 - 3 Adapter for engine cross-member and stabilizer pick-up 9175 1 . . . 50 - 4. Front end panel, removing and - 5 .
Body paint colors as from Model 1988
Body paint colors as from Model 1989
X
IMPORTANT NOTES ON TROUBLESHOOTING AND ON THE ABS TEST PROGRAM A test program with ABS tester must be carried out after certain repairs to the ABS see Function testing, page 45 - 06 . ABS Test Plan, Sheet No. WKD 493 710 is required for this test and for troubleshooting.
Info Gkc
Suspend from Do not mix up suitable point with left and right a piece of wire. calipers if both Only detach brake were removed, hose for repairs Bleeder valves must face up Adjust wheel bearing play. Bolt torque 13 Nm 9 ft lb Check for wear and damage. Mark for installation 1. Remove brake caliper and suspend in a suitable place do not undo brake hose or brake line . 2. Remove brake disc. Proceed according to model specified refer to below instructions . Brake disc of 944 up to end of MY '86 -...
Removing and installing manual steering gear Tools
Torque wrench Stahlwille 730 R 20 or Hazet 6292-1 CT commercially available refer to workshop manual commercially available, e.g. Hazet or Stahlwille 24 mm across flats commercially available, e.g. Nexus 168-1 when fitting steering shaft, avoid putting the shaft under strain only present if castle nut is fitted 30 Nm 22 ftlb , turn to next split pin hole if required max. torque 50 Nm 37 ftlb . Tighten lock nut to 50 Nm. 37 ftlb if the steering or the tie-rod s are to be replaced, start by...
Running gear tuning rubbermetal mounts of 944 S2 1
Starting with Model Year 1991, a standardized version of the rubber-metal mounts of the running gear was used. Based on the former hard versions as used on the 944 Turbo and 944 S2 mit M 030, and the soft version fitted as standard equipment to the 944 S2, an ideal state of tuning was determined. This concerns both the front and the rear axle. When performing repair operations, make sure this modification is taken into account. Front axle and rear axle Running gear tuning rubber-metal mounts of...
On vehicles with ride height adjustment
feature, also check and adjust the front axle height. For adjusting values, refer to page 44 - 2a. Loosen bolted connection between spring strut and trailing arm. Also loosen stabilizer suspension in cars with a stabilizer. Adjust to specified value by turning the camber eccentric. Adjust toe by moving trailing arm in slots of spring strut. Use Special Tool 9171 for this step. INSTALLING AND REMOVING ALUMINUM WHEELS ON VEHICLE General Information Aluminum wheel nuts must be loosened and...
Info Rxx
Removing and installing the tailgate lock microswitch 1. Loosen the carpet lining of the luggage compartment at the rear wall. 3 Disconnect the upper linkage. 4. Separate the plug connection. 6. Remove the tailgate lock with microswitch. If necessary, you can operate the release mechanism by pulling on the Bowden cable until the tailgate is released mechanically. REMOVING AND INSTALLING ENGINE HOOD Removing 1. Raise engine hood and support front end. 3. Press down gas pressure props slightly...
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4. Unscrew axle shaft bolts on transmission and move out the complete drive shaft axle shaft wheel shaft . 6. Take plug for brake pad wear indicator out of holder and disconnect. 7. Unscrew brake caliper and remove brake disc. 8. Drive out rear wheel hub with Special Tool P 297 a. 9. Remove parking brake shoes and spreader arm. Pull parking brake cable out of trailing arm. 10. Remove trailing arm after unscrewing on spring strut and rear axle cross tube. Mark position of trailing arm to spring...
Removal
1. Take off front wheels and driveline undertray. 2. Remove stabilizer by unbolting the stabilizer supports at the control arms and the stabilizer mounts at the side members. 3. Remove universal joint bolt from steering gear. 4. Loosen four steering gear fastening screws far enough do not unbolt completely to allow the articulated shaft to be removed from the steering pinion. If the steering gear and or the tie-rod has to be replaced, start by unbolting the tie-rod s at the steering rack do not...
Checking brake disc lateral runout
1. Measuring requirements No tilt play present at wheel. If required, adjust wheel bearing clearance of front wheels. 2. Fit adapter plate Special Tool 9510 1 to wheel hub. Tightening torque of wheel nuts mounting nuts 130 Nm. 3. Engage dial gauge holder, e.g. Ate Part No. 03.9314-5500.3 01, into brake caliper, determine center position and fit by turning the wing screw. If required, fit dial gauge holder with Ate conversion kit, Part No. 03.9314-5510.3 01 longer wing screw and bracket for dial...