Oil Pan Gasket Replacement

Overview

This procedure replaces the oil pan gasket on your Porsche 944 S / S2 with its 16v engine. It’s a critical maintenance task to stop oil leaks and keep your engine running smoothly. The job involves lowering the front suspension cross-member and supporting the engine from above, making it a bit involved but manageable with the right tools and patience. Expect it to take 8-10 hours if you’re mechanically inclined.

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Tools Required

• Metric wrench set (e.g., 10mm (3/8 inch), 13mm, 19mm)
• Metric socket set (e.g., 10mm (3/8 inch), 13mm, 19mm)
• Silastic 730 RTV (000 043 019 00) or Permatex Ultra Grey sealant
• Floor jack
• Jack stands
• Engine hoist or factory engine support (VW 10-220 or VW 10-220A) or homemade equivalent
• Tie rod separator (gear puller type recommended)
• Catch rags
• Catch pan
• Torque wrench

Parts Required

• Oil pan gasket (944 101 205 02)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Exhaust System Removal and Installation

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Disconnect the positive battery lead to ensure safety while working.
2. Raise the vehicle and secure it on jack stands at a comfortable working height.
3. Place a catch pan under the oil pan and remove the drain plug to drain the engine oil completely.

Step 2: Disconnect Front Suspension Components

4. Remove the bolts securing the front stabilizer bar to the chassis (drop link bolts) and control arms using a 13mm wrench. Take the stabilizer bar out of the vehicle.
5. Use a gear puller-type tie rod separator to disconnect the steering tie rod ends from the steering knuckles without damaging the boots.
6. Mark the splined input shaft on the steering rack and the universal joint on the steering shaft with nail polish or a punch for proper alignment during reassembly.
7. Disconnect the steering gear shaft from the steering rack using a punch and hammer, being careful not to damage the splines.
8. Remove the bolts attaching the suspension control arms to the chassis with a 10mm (3/8 inch) wrench.
9. Disconnect the ball joints linking the steering knuckles to the control arms.

Step 3: Support the Engine and Lower the Cross-Member

10. Remove the bolts at the top of the motor mounts that connect them to the motor mount brackets using a 13mm wrench.
11. Position a floor jack with a piece of wood under the cross-member to support it securely.
12. Use an engine hoist or factory engine support tool (VW 10-220 or VW 10-220A) to hold the engine from above.
13. Remove the four cross-member-to-body bolts (M12) with a 19mm socket, leaving the steering rack and stabilizer bar attached. Lower the entire assembly, including the control arms, to clear space for the oil pan.

Step 4: Remove and Replace the Oil Pan Gasket

14. Remove the 22 oil pan retaining bolts using a 10mm (3/8 inch) wrench. You may need a small pry tool to gently loosen the oil pan from the crankcase.
15. Lift the oil pan off the vehicle and set it aside.
16. Inspect the crankcase interior for damage, check the oil pickup tube for cracks, ensure it’s secure, and clean any debris from the screen.
17. Clean the oil pan thoroughly, removing any debris, and check for signs of engine damage like metal filings.
18. Remove the old gasket from the oil pan. Install the new oil pan gasket (944 101 205 02). Apply Silastic 730 RTV (000 043 019 00) or Permatex Ultra Grey sealant to the gasket corners. Optionally, use a small amount of 3M Trim Adhesive on the outer edge to hold the gasket in place during installation—avoid overapplying.

Step 5: Reinstall the Oil Pan

19. Position the oil pan onto the crankcase and loosely install the 22 bolts with a 10mm (3/8 inch) wrench.
20. Tighten the bolts in this sequence using a torque wrench: First to 4 Nm (3 ft-lbs), then to 8 Nm (6 ft-lbs). Do not overtighten.

Step 6: Reassemble the Cross-Member and Suspension

21. Raise the cross-member back into place with the floor jack, aligning the motor mounts with their brackets and the steering linkage with the steering rack splines (using your alignment marks). Install the four cross-member bolts (M12) and torque to 85 Nm (63 ft-lbs) with a 19mm socket. Install the motor mount bolts (M8) and torque to 23 Nm (17 ft-lbs) with a 13mm socket.
22. Secure the steering linkage to the steering rack splined shaft and tighten the bolt.
23. Install the control arm-to-chassis bolts (M10) and torque to 46 Nm (34 ft-lbs) with a 10mm (3/8 inch) wrench.
24. Attach the control arm ball joints to the steering knuckles and torque the lock nuts (M10) to 50 Nm (37 ft-lbs).
25. Reinstall the front stabilizer bar. Torque the stabilizer linkage-to-body bolts (M8) to 23 Nm (17 ft-lbs). For aluminum control arms (standard on the S2), torque the stabilizer-to-control arm locknuts to 25 Nm (18 ft-lbs).

Step 7: Finalize the Job

26. Follow this link to ensure this step – Exhaust System Removal and Installation – of the process is followed accurately for any exhaust components disturbed during the procedure.
27. Install the oil drain plug and fill the engine with the correct amount of oil (refer to your owner’s manual for capacity).
28. Reconnect the positive battery lead.
29. Lower the vehicle off the jack stands.

Post Procedure Checklist

• Check for oil leaks around the oil pan after running the engine for a few minutes.
• Verify the steering aligns properly by driving a short distance, such as 0.5 miles (0.8 km).
• Ensure all bolts are torqued to spec and no tools are left under the car.

Sources

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