Cylinder Head and Head Gasket Installation – 2.5L NA

Overview

This procedure guides you through installing a new cylinder head and head gasket on your Porsche 944 variants with an 8-valve engine. It’s essential for restoring engine performance after issues like gasket failure or head damage, ensuring a proper seal between the cylinder head and engine block. This guide covers the 83-85.5 and 86-88 variants, with specific differences noted where applicable.

Pink and blue text represent links to additional resources and partner websites.

Tools Required

• Jack stands or ramps (ft. Double Locks)
• 6mm Allen head socket (Hex)
• Metric socket set (Various Options)
• Metric wrench set (Combo / Rachet)
• Torque wrench (Click / Electric)

Parts Required

• Full Kit – PartWorks.de
• Head gasket (944 104 374 14) – Combined for 83-85.5 and 86-88
• Cam housing gasket (944 105 199 03) – Combined for 83-85.5 and 86-88
• Intake manifold gaskets (4 required) (944 110 163 05) – Combined for 83-85.5 and 86-88
• Exhaust manifold gaskets (4 required):
  • (83-85.5) (928 111 193 12)
  • (86-88) (944 111 196 00)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Cylinder Head Tightening Sequence and Torque Specifications
• Intake Manifold Removal and Installation
• Camshaft Assembly Installation
• Fuel Injector and Fuel Rail Removal and Installation
• Camshaft and Balance Shaft Belt Installation
• Camshaft and Balance Shaft Belt Tension – Checking and Adjusting
• Air Filter Housing and Air Flow Sensor – Installation
• Distributor Cap and Rotor Replacement
• Coolant System Draining, Filling, and Venting

Step-by-Step Procedure

Step 1: Prepare the Engine Block

1. Clean the mating surfaces of the cylinder head and engine block. Remove all old gasket material and deposits using a scraper carefully—aluminum scratches easily.
2. For minor scratches, smooth them out with emery cloth or steel wool. If there are deep gouges, machining may be needed, which could require removing the engine and head studs.

Step 2: Install the Head Gasket

3. Place the new head gasket (944 104 374 14) onto the engine block, aligning it properly with the cylinder bores and coolant passages.

Step 3: Install the Cylinder Head

4. Lift the cylinder head and carefully lower it onto the block, aligning it with the head gasket and studs. (Tip: You can leave the exhaust manifolds attached to save time, as suggested by Tim Richards via Clarks Garage.)
5. Install the two M8 Allen head bolts (6mm head) at the front of the cylinder head. Tighten them to 20 Nm (15 ft-lbs) using a torque wrench.

Step 4: Secure the Cylinder Head

6. Lightly coat the head stud threads with engine oil—do not use any other lubricant.
7. Install all head stud nuts by hand until finger-tight.
8. Torque the nuts in three stages using a torque wrench. Follow this link to ensure this step – Cylinder Head Tightening Sequence and Torque Specifications – is followed accurately for your specific model (83-85.5 or 86-88).

Step 5: Connect Coolant Hoses

9. Attach the coolant hose at the rear of the cylinder head that connects to the heater control valve.
10. Connect the coolant outlet hose at the front of the cylinder head.

Step 6: Install the Exhaust Manifold

11. Position the exhaust manifold in the car, aligning it with the cylinder head.
12. Install the exhaust manifold studs and nuts:
    (83-85.5) Use gaskets (928 111 193 12).
    (86-88) Use gaskets (944 111 196 00).
13. Tighten the exhaust manifold nuts to 20 Nm (15 ft-lbs).

Step 7: Install Remaining Components

14. Follow this link to ensure this step – Intake Manifold Removal and Installation – is followed accurately to install the intake manifold with gaskets (944 110 163 05).
15. Follow this link to ensure this step – Camshaft Assembly Installation – is followed accurately to install the camshaft assembly with gasket (944 105 199 03).
16. Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – is followed accurately to install the fuel rail and injectors.
17. Follow this link to ensure this step – Camshaft and Balance Shaft Belt Installation – and this link – Camshaft and Balance Shaft Belt Tension – Checking and Adjusting – are followed accurately to install and tension the camshaft belt.
18. Install the front timing covers.
19. Follow this link to ensure this step – Air Filter Housing and Air Flow Sensor – Installation – is followed accurately to install the air filter housing and air flow sensor.
20. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – is followed accurately to install the rotor and distributor cap.

Step 8: Final Connections and Coolant

21. Route the coil wire to the distributor and connect the plug wires from the distributor to the spark plugs.
22. Follow this link to ensure this step – Coolant System Draining, Filling, and Venting – is followed accurately to fill and vent the coolant system.
23. Reconnect the battery leads.

Post Procedure Checklist

• Start the engine and let it reach normal operating temperature.
• Check for coolant leaks around the head gasket and hoses.
• Inspect the exhaust manifold for leaks.
• After running, re-torque the exhaust manifold nuts to 20 Nm (15 ft-lbs) if needed.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube