Engine Removal

Overview

This guide walks you through removing the 16v engine from your Porsche 944 S2. It’s a big job, but essential if you’re planning a rebuild, major repairs, or an engine swap. The engine comes out from underneath the car, so you’ll need enough clearance and the right tools to get it done safely and smoothly.

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 may damage hoses)
• Metric socket set
• Metric wrench set
• Phillips and flat-tip screwdriver set
• Engine hoist
• Diagonal cutters
• Several clothes hangers, bailing wire, or bungee cords (various sizes)
• 10mm (3/8 inch) wrench (for general bolts)
• 13mm wrench (for motor mount nuts)
• Punch and hammer (for steering shaft alignment)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• DME Control Unit Removal
• 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

Step 1: Depressurize the Fuel System

1. Locate and remove the fuel pump fuse from the fuse box.
2. Try starting the car—it might crank briefly but should stall as the fuel pressure drops.

Step 2: Disconnect the Battery

3. Unhook the battery ground cable first, then the positive cable.
4. Push the positive cable through the firewall hole into the engine bay (removing the battery makes this easier).

Step 3: Disconnect Cruise Control (If Equipped)

5. Find the cruise control servo near the passenger-side strut tower and unplug its electrical connector.

Step 4: Remove the DME Control Unit

6. Follow this link to ensure this step—DME Control Unit Removal—is followed accurately.
7. Cut or release any tie wraps holding the battery cable near the firewall to free it from the DME wiring bundle.
8. Pull the DME plug through the firewall into the engine bay, disconnecting any other wired connectors in the bundle as needed.

Step 5: Remove Air Intake Components

9. Follow this link to ensure this step—Air Filter Housing and Air Flow Sensor Removal—is followed accurately.

Step 6: Remove Distributor Components

10. Follow this link to ensure this step—Distributor Cap and Rotor Replacement—is followed accurately.

Step 7: Lift the Car

11. Loosen the front wheel lug nuts by one or two turns.
12. Raise the car onto jack stands, starting with a lower height for topside work. You’ll need at least 21 inches (53 cm) of clearance later to remove the engine from below.
13. Take off the front wheels.

Step 8: Remove Underbody Panels

14. From underneath, remove all skid plates or belly pans shielding the engine bottom. Some older cars may already be missing the rear pan for oil drain access.

Step 9: Remove the Radiator

15. Follow this link to ensure this step—Radiator Removal—is followed accurately.

Step 10: Disconnect Firewall Wiring and Cables

16. Unplug all wiring harness connectors at the firewall and cut any remaining cable ties.
17. Detach the throttle cable (and cruise control cable, if equipped).
18. Disconnect the brake booster vacuum hose.
19. Unbolt the engine ground cables from the firewall.

Step 11: Remove Starter and Power Steering Pump

20. In the engine bay, unplug the starter wiring connector and remove the starter.
21. Disconnect the power steering pump hoses and remove the pump.

Step 12: Handle Clutch and Coolant Hoses

22. Remove the bolts holding the clutch slave cylinder bracket.
23. Label all hoses for reinstallation, then remove the coolant hose from the heater valve.
24. Disconnect the coolant return hose at the rear of the cylinder head.
25. If not already done, remove the coolant feed hoses from the expansion tank.

Step 13: Remove Vacuum and Fuel Lines

26. Disconnect the vacuum lines to the vent valve and thermo valve at the engine’s rear.
27. Remove the A/C fast idle hose and charcoal venting hose.
28. Unhook the fuel supply and return lines—use hose clamps or have rags ready for minor leaks.

Step 14: Prepare the Engine Hoist

29. Attach the engine hoist to the lifting rings on the 3.0L engine.

Step 15: Remove Exhaust and Oxygen Sensor

30. Disconnect the oxygen sensor wire at the firewall and remove the sensor from the exhaust.
31. Remove the exhaust system from the car.

Step 16: Reposition the Slave Cylinder

32. Unbolt the clutch slave cylinder and move it aside, keeping the fluid lines attached.

Step 17: Remove Motor Mount Shield and Alternator

33. Take off the right-side motor mount shield.
34. Remove the alternator (optional, but recommended for easier removal).

Step 18: Disconnect Front Suspension Components

35. Unbolt the front stabilizer bar drop links and control arm bolts, then remove the stabilizer.
36. Unbolt the A/C compressor (leave lines attached) and hang it from the front strut spring with wire or a bungee cord.
37. Remove the bolts connecting the torque tube to the clutch housing.
38. Disconnect the steering tie rod ends.

Step 19: Disconnect Steering Gear

39. Mark the splined input shaft on the steering rack and the universal joint with a punch or bright nail polish for alignment later.
40. Separate the steering gear shaft using a punch and hammer, avoiding damage to the splines.

Step 20: Remove Suspension and Cross Member

41. Unbolt the suspension control arms from the chassis.
42. Disconnect the suspension ball joints on the control arms.
43. Remove the motor mount nuts and bolts using a 13mm wrench.
44. Support the cross member with a floor jack and a piece of wood.
45. With the engine hoist supporting the engine, remove the cross member bolts.
46. Lower the cross member (with steering rack and stabilizer bar attached) from the car.

Step 21: Lower the Engine

47. Lower the engine with the hoist, moving it forward to free the drive shaft splines.
48. Set the engine onto carpet or cardboard to slide it out from under the car easily.
49. Disconnect the hoist, slide the engine out, then reattach the hoist to move it to your workspace.

Post Procedure Checklist

• Check all disconnected hoses and wiring for damage before reinstallation.
• Ensure the engine is stable and secure on your work surface.
• Inspect the engine bay for any forgotten tools or loose parts.

Sources

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