Cylinder Head and Head Gasket Removal – 2.5L NA

Overview

This procedure guides you through removing the cylinder head and head gasket on all Porsche 944  variants with an 8-valve engine. It’s essential for tasks like replacing a blown head gasket, inspecting the cylinders, or rebuilding the engine. Doing this right ensures your engine stays reliable and leak-free.

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Tools Required

• Jack stands or ramps
• 6mm Allen head socket or 6mm (1/4 inch) hex key
• Metric socket set
• Metric wrench set (including 12mm and 13mm wrenches)
• Flywheel lock (P9206) (optional but recommended)
• Pry bar
• Flat tip screwdriver

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1
• Fuel Injector and Fuel Rail Removal and Installation
• Camshaft Assembly Removal
• Intake Manifold Removal and Installation
• Coolant System Draining, Filling, and Venting

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Raise the car and secure it on jack stands or ramps to access the engine safely.

Step 2: Set Engine to TDC

2. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – of the process is followed accurately. This aligns the engine for safe cylinder head removal.

Step 3: Remove Fuel Components

3. Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – of the process is followed accurately. This clears the top of the engine.

Step 4: Remove Intake Manifold

4. Follow this link to ensure this step – Intake Manifold Removal and Installation – of the process is followed accurately. This exposes the cylinder head.

Step 5: Remove Camshaft Assembly

5. Follow this link to ensure this step – Camshaft Assembly Removal – of the process is followed accurately. This gives you clear access to the head bolts.

Step 6: Drain Cooling System

6. Follow this link to ensure this step – Coolant System Draining, Filling, and Venting – of the process is followed accurately. Drain the coolant to avoid spills when removing the head.

Step 7: Remove Exhaust Manifolds (Combined)

7. Disconnect the exhaust header where it connects to the rest of the exhaust system.
8. Remove the manifold mounting studs at the exhaust ports on the cylinder head. Use one of these methods:
   • Loosen the retaining nut slightly, add a second nut as a jam nut, tighten the outer nut against the inner one, then turn the inner nut counterclockwise with a 13mm wrench to remove the stud.
   • Remove the retaining nut fully and use a stud extractor that won’t damage the threads to back the stud out.
9. (Optional) For easier removal, use M8 copper nuts with 12mm flats as jam nuts. Install a 13mm factory nut inside, then the copper nut outside, and use a 13mm socket over the copper nut to turn the inner nut.
10. If the manifolds won’t clear the studs due to tight clearance (often with older engine mounts), remove the bottom nut from the engine mount on the exhaust side and jack up that side of the engine slightly until they clear.
11. Remove the exhaust manifolds from the car.

Step 8: Disconnect Coolant Hoses (Combined)

12. Disconnect the coolant hose at the front of the cylinder head.
13. Disconnect the hose at the back of the cylinder head that goes to the heater control valve.

Step 9: Remove Cylinder Head Bolts (Combined)

14. Using a 6mm Allen head socket or 6mm (1/4 inch) hex key, remove the two Allen head bolts at the front of the cylinder head.
15. Loosen the cylinder head retaining nuts in a crosswise pattern, working from the outside toward the center.

Step 10: Remove Cylinder Head (Combined)

16. Lift the cylinder head off the engine. Use the tabs at the front and rear as leverage points.
17. If the head is stuck, gently insert a pry bar under the tabs and pry it loose.

Post Procedure Checklist

• Inspect the cylinder head and block mating surfaces for damage or warping.
• Check that all coolant hoses are disconnected and not leaking.
• Ensure no tools or debris are left in the engine compartment.

Sources

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