Clark's Garage Shop Manual

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Welcome to Clark's Garage Shop Manual. The procedures here are group alphabetically as much as possible. If you don't find what you're looking for, try the 'Search' button on the main menu or drop me an email. I may be working on what you're looking for.

If you would like to submit an article or procedure for the web site, or have an idea for a new procedure, please email me.

Clark's Garage © 1998

A B C D E F G H I J M N O P R S T V W

Air Bag

Air Bag System Testing

Air Bag Warning Light Reset

Air Conditioning

Air Conditioning System Operation and Troubleshooting

Air Filter

Filter Housing Removal and Installation

Air Flow Sensor

Removal and Installation

Air Flow Sensor Operation and Testing

Alarm System

Alarm System Bypassing

Alternator

B

Balance Shafts

Balance Shaft Oil Seal Replacement

Belt - General Information

Belt Installation

Belt Tensioning

Sprocket Installation and Alignment Check

Battery

Battery Tray Leaks / Repair

Excessive Battery Discharge Rate

Bolts

Allen Head and Cheesehead Bolt Removal

Brakes

Checking the Brake System

Checking Brake Pad Thickenss and Brake Pad Replacement

Fluid Replacement and Bleeding

Master Cylinder Replacement

Parking Brake Adjustment

Rotors - Inspecting and Replacing

Bumper

Bumper Cover Removal (951)

C

Camera Bar

Constructing a Camera Bar

Camshaft Assembly Installation

Camshaft Assembly Oil Seal Replacement

Camshaft Assembly Removal

Camshaft (Timing) Belt General Information

Camshaft (Timing) Belt Installation

Camshaft (Timing) Belt Removal

Camshaft (Timing) Belt and Balance Shaft Belt Tensioning

Camshaft Chain Tensioner Replacement (16V)

Cargo Cover

Cargo Cover Repair

Chips (Computer)

Installation see DME Control Unit - Chip Installation (Including KLR chip for Turbos)

Clock

Removal and Replacement

Clutch

Clutch Disc Wear Check

Clutch Master Cylinder Replacement

Slave Cylinder Replacement and Bleeding

Color Codes

944 Interior Color Codes

944 Paint Codes

Control Arms

944 Control Arms - General Information, Rebuilding, and Aftermarket Replacements

Removal and Installation

Cooling System

Flow Diagram and Description - Normally Aspirated 944

Flow Diagram and Description - Turbocharged 944

Cooling System Draining, Filling, and Venting

Fan Operation and Troubleshooting

Troubleshooting Cooling System Problems

Crankshaft

Front Oil Seal Replacement

Rear Oil Seal Replacement

Crank Scraper Installation

Cruise Control

General Information and Repair

CV Joints

CV Joint Boot Inspection

General Information, Removal, Installation, and Maintenance

Cylinder Head

Cylinder Head and Head Gasket Installation

Cylinder Head and Head Gasket Removal

Cylinder Head Tightening Sequence and Torque Specifications

D

Dash

Early 944 Dash Replacement (Pre-1985.5)

Late 944 Dash Replacement (1985.5 and Newer)

Defroster

Troubleshooting Rear Hatch Defroster

Distributor

Distributor Cap and Rotor Replacement

DME Control Unit

Chip Installation (Including KLR chip for Turbos)

Control Unit Removal and Installation

DME Wiring Diagram - 944 Turbo

DME Wiring Diagram - Normally Aspirated 944

DME Relay

Technical Information and Testing

Door Handles

Removal, Installation, and Adjustment

Door Panels

Removal and Installation

E

Electrical

Engine

951 Engine Performance Modifications

Engine Oil and Filter Replacement

Starting and Running Troubleshooter

Exhaust

Exhaust System Removal and Installation

F

Flywheel

Flywheel Lock Installation

Fuel and Vacuum Line Routing

Fuel and Vacuum Line Diagram (1985.5 and Newer N/A 944s)

Fuel and Vacuum Line Diagram (16V Normally-Aspirated 944s)

Fuel and Vacuum Line Diagram (944 Turbo)

Fuel Filter

Fuel Injector

Fuel Injector Information

Fuel Injector and Fuel Rail Removal and Installation

Fuel Level

Level Indication Problems / Repairs

Fuel Pressure

Fuel Rail Adapter - Making an Adapter for Non-Metric Thread Fuel Pressure Gauges

Fuel Pressure Regulator

General Information and Replacement

Fuel Pump

Delivery Rate - Checking

Fuel Pump Replacement

Fuel Pump Suction Strainer - Removing, Cleaning, and Replacing

Fuses

Early 944 Fuse List (pre-1985.5)

Late Early 944 Fuse List (1985.5 and newer)

Fuel System

Fuel System Leakdown Testing

TOP

G

Gauges

Early 944 Gauge Removal

Late 944 (1985.5 and newer) Gauge Removal

Information and Troubleshooting (See Sensors and Gauges)

H

Hatch

Head Gasket

See Cylinder Head

Headlights

Headlight Motor Circuit Operation and Repair

Headlight Motor Removal, Cleaning, and Installation

Headlight Operating Mechanism Linkage Lubrication

Heater

Heater Core Removal and Replacement

Heater Malfunctions

Hood Crest

Removal and Installation

Hood Insulation

Hood Struts

Information and Replacement

HVAC

Check Valve Information

I

Idle

Idle Speed Adjustment

Idle Control Motor (Idle Stabilizer) Replacement

Ignition

Ignition Switch and Wiring Test

Ignition Switch Replacement

Ignition System Troubleshooting

Instrument Panel

Instrument Panel Lights

Instrument Cluster Removal (see Gauges)

Intake Manifold

Removal and Installation

J

Jacking

Jacking a 944 / Placing a 944 on Jack Stands

M

Maintenance

Peroidic Maintenance Schedule

Mirror

Removal and Installation

Motor Mounts

N

Nose Panel

Removal and Installation

O

Odometer

Repairing Odometer

Oil

Engine Oil and Filter Change

Oil Flow Diagram - 924S, 944, 944 Turbo

Oil Cooler

General Information and Seal Replacement

Oil Cooler Pressure Testing - Normally Aspirated Cars

New Style Oil Cooler O-Rings

Oil Pan

Gasket Replacement

Oil Pressure

General Information and Troubleshooting

Oil Pressure Relief Valve General Information

Oil Pressure Sending Unit Replacement

Oil Pump

Removal and Installation

O₂ Sensor

Oxygen Sensor General Information, Testing, and Replacement

P

Paint

Parts

924 - 1976 to 1979

924 - 1980 to 1985

924S - 1986 to 1988

944 - 1982 to 1985

944 - 1985 to 1988

944 - 1989 to 1991

Performance

Performance Products and Services Vendors

Crank Scraper Installation

Power Steering Pump

Power Steering Rack

R

Radiator

Removal and Installation

Repairing a Squeaking or Rattling Rear Hatch

Rear Hatch Strut Replacement

S

Sensors and Gauges

Information, Troubleshooting, and Testing

Shocks (Rear)

Spark Plugs

Changing Spark Plugs / Checking the Condition of Spark Plugs

Speed and Reference Sensors

Checking, Replacement, and Adjustment

Speedometer

Speedometer, Gear Ratio, and Tire Size Calculator

Speedometer, Gear Ratio, and Tire Size Manual Calculations

Starter

Checking Starter Operation

Removal and Installation

Stereo

Head Unit and Speaker Replacement Guide

Rear Speaker Replacement

Steering Wheel

Steering Wheel Removal and Installation

Stone Guards

Removal and Installation

Struts (Front)

Removal and Installation

Sunroof

Operation, Troubleshooting, and Repair

Sunroof Component Testing

Plastic Gear Replacement

Suspension

Suspension Upgrades

Sway Bars

Front Sway Bar Removal and Installation

Rear Sway Bar Removal and Installation

T

Temperature Control Unit

Removal and Replacement

Thermofan Switch

Thermostat

General Information, Testing, and Replacement

Throttle Position Switch

Information, Troubleshooting, Replacement, and Adjustment

Timing Belt

Top Dead Center (TDC)

Locating and Setting Engine to TDC

Torque Tube

Removal, Rebuilding, and Installation

Torsion Bar

Removing, Replacing, and Reindexing

Towing

General Information and Towing Eye

Transaxle

Changing Manual Transaxle Fluid

Checking, Repairing, and Replacing the Shift Lever and Shift Linkage

Transaxle Removal and Installation

Troubleshooting

TS-01, Engine (includes Oil Pressure problems)

TS-02, Cooling System

TS-03, Fuel System

TS-05, Manual Transmission

TS-06, Automatic Transmission

TS-08, Suspension and Steering

TS-09, Electrical (including Instruments)

TS-10, Heating, Ventilation, and Air Conditioning (HVAC)

Turbocharger

Replacement (Including Tips on K27 Turbocharger Installation)

K26 Turbocharger Identification

Turn Signals

Common Problems and Repairs

V

Vacuum Line Routing

See "Fuel and Vacuum Line Routing"

W

Wastegate

Fabricating and Installing Shims

Removal and Installation

Water Pump

Information and Replacement

Wheels

Wheel Bearings

Front Wheel Bearings - Checking, Adjustment, Repacking, and Replacement

Rear Wheel Bearing Replacement - Steel Trailing Arms

Rear Wheel Bearing Replacement - Aluminum Trailing Arms

Windows (Electrical)

Troubleshooting and Switch Repair

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