Engine Removal – 2.5L NA

Overview

This guide outlines the procedure to remove the engine from all Porsche 944 8-valve engine configurations, covering both pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) variants. Engine removal is necessary for major repairs, such as rebuilding the engine or replacing critical components like the clutch or timing belt. This process involves disconnecting electrical, fuel, and cooling systems, and lowering the engine from underneath the vehicle. Follow each step carefully to ensure safety and avoid damage to components.

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

Tools Required

• Jack stands
• Floor jack
• Hose clamps or locking pliers
• Metric socket set
• Metric wrench set
• Phillips and flathead screwdriver set
• Engine hoist
• Diagonal cutters
• Clothes hangers, bailing wire, or bungee cords (various sizes)

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 in the driver’s footwell.
2. Attempt to start the vehicle. It may briefly start but should stall as the fuel system depressurizes. Repeat until the engine no longer starts.

Step 2: Disconnect the Battery

3. Disconnect the battery ground cable (negative) first, followed by the positive cable.
4. Push the positive cable through the firewall hole into the engine compartment. Removing the battery may make this easier.

Step 3: Disconnect Cruise Control (If Equipped)

5. If the vehicle has cruise control, disconnect the electrical connector at the cruise control servo unit near the passenger-side strut tower.

Step 4: Disconnect the DME Control Unit

6. Follow this link to ensure this step – DME Control Unit Removal – is completed accurately.
7. Cut or release any tie wraps securing the battery cable at the firewall to clear the DME wire bundle.
8. Pull the DME control unit plug through the firewall opening into the engine compartment. Disconnect any additional connectors in the DME wire 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 completed accurately.

Step 6: Remove Distributor Components

10. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – is completed accurately.

Step 7: Prepare the Vehicle for Lifting

11. Loosen the lug nuts on the front wheels by one or two turns using a 19mm (3/4 inch) lug wrench.
12. Raise the vehicle onto jack stands, ensuring at least 21 inches (53 cm) of clearance under the car for engine removal. Start with a lower height for topside work, then raise higher later.
13. Remove the front wheels.

Step 8: Remove Underbody Panels

14. From underneath, remove all skid plates or belly pans protecting the engine using a 13mm (1/2 inch) socket. For vehicles with the turbo aerodynamics package (Pre-85.5), also remove the skid pan under the nose panel.

Step 9: Remove the Radiator

15. Follow this link to ensure this step – Radiator Removal – is completed accurately.

– Clean debris from the radiator coils while it’s out. Consider having it inspected by a radiator shop.

– Optional: Replace radiator hoses (944 106 241 02) or install a lower-temperature thermofan switch (944 606 481 00).

Step 10: Disconnect Firewall Wiring and Cables

16. Unplug all wiring harness connectors at the firewall and cut any remaining cable ties.
17. Disconnect the throttle cable. If equipped with cruise control, disconnect the cruise control cable.
18. Disconnect the brake booster vacuum hose using a flathead screwdriver.
19. Disconnect the engine ground cables at the firewall using a 13mm (1/2 inch) wrench.

Step 11: Remove Starter and Power Steering Pump

20. In the engine compartment, disconnect the starter wiring connector.
21. Remove the starter using a 17mm (11/16 inch) socket. Set it aside.
22. Disconnect the hoses from the power steering pump and remove the pump using a 13mm (1/2 inch) socket.

Step 12: Remove Clutch Slave Cylinder

23. Remove the clutch slave cylinder bracket bolts using a 13mm (1/2 inch) socket and move the cylinder aside, keeping fluid lines attached.

Step 13: Disconnect Cooling and Vacuum Hoses

24. Mark all hoses for reassembly using a permanent marker.
25. Remove the coolant hose from the heater valve using a flathead screwdriver.
26. Remove the coolant return heater hose at the rear of the cylinder head.
27. If not already done, remove the coolant feed hoses on the expansion tank.
28. Disconnect the vacuum lines to the vent valve and thermo valve at the back of the engine.
29. Remove the A/C fast idle hose and charcoal venting hose.

Step 14: Disconnect Fuel Lines

30. Disconnect the fuel supply and return lines using a 17mm (11/16 inch) wrench. Use hose clamps or locking pliers to prevent leakage, or have rags ready to catch residual fuel.

Step 15: Prepare Engine for Hoisting

31. Attach an engine hoist to the lifting rings on the engine, ensuring secure connections.
32. If equipped with an oxygen sensor (Pre-85.5), disconnect the O2 sensor wire at the firewall and remove the sensor from the exhaust using a 22mm (7/8 inch) wrench.

Step 16: Remove Exhaust System

33. Remove the exhaust system by unbolting it from the exhaust manifold and hangers using a 13mm (1/2 inch) socket.

Step 17: Remove Motor Mount Shield and Alternator

34. Remove the right-side motor mount shield using a 13mm (1/2 inch) socket.
35. Optional: Remove the alternator using a 15mm (9/16 inch) socket to reduce weight, though it can remain attached.

Step 18: Disconnect Front Suspension Components

36. Remove the front stabilizer bar drop link bolts and control arm bolts using a 17mm (11/16 inch) socket, then remove the stabilizer bar.
37. Unbolt the A/C compressor using a 13mm (1/2 inch) socket and hang it from the front strut spring with bailing wire, keeping lines intact.
38. Remove the bolts attaching the torque tube to the clutch housing using a 19mm (3/4 inch) socket.
39. Disconnect the steering tie rod ends using a 17mm (11/16 inch) wrench.
40. Mark the splined input shaft on the steering rack and the universal joint on the steering shaft for reassembly using a punch or bright nail polish.
41. Disconnect the steering gear shaft using a punch and hammer, avoiding damage to the splines.
42. Remove the bolts attaching the suspension control arm to the chassis using a 19mm (3/4 inch) socket.
43. Disconnect the suspension ball joints on the control arm using a 17mm (11/16 inch) wrench.

Step 19: Remove Motor Mounts and Cross Member

44. Remove the motor mount nuts and bolts using a 17mm (11/16 inch) socket.
45. Support the cross member with a floor jack and a piece of wood.
46. With the engine supported by the hoist, remove the cross member bolts using a 19mm (3/4 inch) socket.
47. Lower the cross member with the steering rack and stabilizer bar attached.

Step 20: Lower the Engine

48. Lower the engine using the hoist, moving it forward to disengage the drive shaft splines. Place the engine on a piece of cardboard or carpet to slide it out easily.
49. Disconnect the hoist and slide the engine out from under the vehicle.
50. Reattach the hoist and move the engine to a workbench or storage area.

Post Procedure Checklist

• Verify all tools and debris are removed from the engine bay.
• Check that all disconnected hoses and wiring are labeled for reassembly.
• Inspect the engine bay for any damaged components or leaks.
• Ensure the radiator and other removed components are stored safely for reinstallation.

Sources

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