Engine Installation

Overview

This guide walks you through installing the 16v engine in your Porsche 944 S2. It’s a big job, but crucial for getting your car back on the road after an engine removal or rebuild. We’ll assume you’re dropping the engine in from below, with the steering rack and cross-member already out of the way. With the right tools and a bit of patience, you’ll have that engine snugly in place.

Pink and blue text represents links to additional resources, tools, parts, and partner websites.

Tools Required

• Jack stands
• Floor jack
• Hose clamps or locking pliers (locking pliers might damage hoses)
• Metric socket set (including 13mm, 17mm, and 19mm sockets)
• Metric wrench set (including 10mm (3/8 inch), 13mm, and 17mm wrenches)
• Phillips and flathead screwdrivers
• Engine hoist
• Diagonal cutters
• Clothes hangers, bailing wire, or bungee cords (various sizes)
• Clutch alignment tool (for manual transmission)

Parts Required

• Upper motor mount bolts (8mm, length varies per motor mount replacement)
• Lower motor mount bolts (10mm)
• Cross-member mounting bolts (12mm)
• Torque tube to clutch housing bolts (4x M10 x 35mm, 944 116 080 03)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Motor Mount Replacement
• DME Control Unit Installation
• Air Filter Housing and Air Flow Sensor – Removal
• Distributor Cap and Rotor Replacement
• Radiator Removal
• Coolant System Draining, Filling, and Venting

Step-by-Step Procedure

1. Prepare the Engine and Car

1. For manual transmission cars, if you removed the clutch disc or pressure plate, make sure they’re aligned using a clutch alignment tool before proceeding. You can get one from Baum Tools or a universal one from an auto parts store.
2. Check that the motor mount brackets are securely bolted to the engine block.
3. Raise the car on jack stands high enough to slide the engine underneath—about 3 feet (0.9 meters) should do it.
4. Position the engine under the car, centered in the engine bay.

2. Lift and Position the Engine

5. Hook up an engine hoist to the lifting points—one at the back of the cam housing, one near the alternator.
6. Hoist the engine up, tilting it forward to clear the front of the drive shaft. Once the drive shaft lines up with the clutch housing, slide the engine back. Rock it gently if needed, but it should slide onto the drive shaft easily if the clutch is aligned.

3. Secure the Engine

7. Bolt the torque tube flange to the clutch housing using four M10 x 35mm bolts (944 116 080 03). Tighten them to 42 Nm (30 ft-lbs) with a 17mm wrench.
8. Before moving on, replace them if needed using the Motor Mount Replacement procedure.
9. Fit the motor mounts into the cross-member. Install the lower 10mm motor mount bolts but don’t tighten them fully yet.

4. Install the Cross-Member

10. Use a floor jack to lift the cross-member into place under the engine. Make sure the motor mounts align with the brackets on the engine block.
11. Slide the steering shaft universal joint onto the steering rack spline before the cross-member is fully up. Match the orientation marks you made during removal, then secure it with the locking bolt.
12. Install the upper 8mm motor mount bolts (length depends on your mounts—see Motor Mount Replacement). Tighten them to 23 Nm (17 ft-lbs) with a 13mm socket. Then tighten the lower 10mm bolts to 32 Nm (24 ft-lbs) with a 17mm socket.
13. Secure the cross-member with 12mm mounting bolts and torque them to 85 Nm (63 ft-lbs) using a 19mm socket.
14. Lower and remove the engine hoist and floor jack.

5. Reconnect Suspension and Accessories

15. Reattach the suspension control arms and stabilizer bar. Torque the control arm to cross-member lock nut (12mm) to 48 Nm (35 ft-lbs) and the rear control arm bracket bolts (10mm) to 34 Nm (25 ft-lbs).
16. Connect the steering knuckle to the control arm ball joint and torque the lock nut (10mm) to 37 Nm (27 ft-lbs).
17. Bolt the air conditioning compressor back into place.
18. Install the front stabilizer bar. Torque the stabilizer to control arm lock nut (10mm) to 18 Nm (13 ft-lbs) and the bracket-to-body bolts (8mm) to 17 Nm (13 ft-lbs).
19. If removed, reinstall the alternator.
20. Attach the motor mount heat shield.
21. Install the slave cylinder for the clutch.

6. Hook Up Systems

22. Reinstall the exhaust system (S2-specific, non-turbo).
23. Connect the fuel supply and return lines.
24. Attach the charcoal venting hose and AC fast idle hose.
25. Reconnect all vacuum and coolant hoses, including the heater control valve hose and coolant return line from the heater core.
26. Install the power steering pump and reconnect its hoses.
27. Mount the starter and reconnect its electrical leads.
28. Route the engine wiring harness through the firewall to the DME control unit.
29. Reconnect all engine grounds—clean them thoroughly first. Look for one near the top of the clutch housing (driver’s side), one on the block nearby, and one on the firewall (engine or battery compartment).
30. Hook up the brake booster vacuum hose.
31. Connect the throttle cable (and cruise control cable/servomotor connector if equipped).

7. Final Installations

32. Install the radiator—follow this link to ensure this step—Radiator Installation—is followed accurately.
33. Install the rotor and distributor cap—follow this link to ensure this step—Distributor Cap and Rotor Replacement—is followed accurately.
34. Install the air flow sensor and air filter housing—follow this link to ensure this step—Air Filter Housing and Air Flow Sensor – Installation—is followed accurately.
35. Secure the engine wiring harness to the firewall with cable ties.
36. Inside the car, connect the wiring harness to the DME control unit—follow this link to ensure this step—DME Control Unit Installation—is followed accurately.

8. Fill and Test

37. Fill and vent the coolant system—follow this link to ensure this step—Coolant System Draining, Filling, and Venting—is followed accurately.
38. Fill the power steering reservoir.
39. Check the engine oil level and top off if needed.
40. Connect the battery leads.
41. Reinstall the fuel pump fuse if you removed it.
42. Start the engine and let it warm up. Check for leaks in the engine bay and underneath. Turn the steering wheel side to side and top off the power steering fluid if necessary.
43. Shut off the engine, install the skid pan and front wheels, then lower the car off the jack stands.

Post Procedure Checklist

• Check for leaks under the car and in the engine bay.
• Ensure the steering moves smoothly and the power steering fluid level is correct.
• Verify the engine runs smoothly with no odd noises.
• Confirm all electrical connections (grounds, DME, etc.) are secure.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• Youtube