Cylinder Head and Head Gasket Installation

Tools

• Jack stands or ramps
• 6 mm Allen head socket
• Metric socket set
• Metric wrench set
• Torque wrench

Other Procedures Needed

• CYL-03: Cylinder Head Tightening Sequence and Torque Specifications
• FUEL-09: Intake Manifold Removal and Installation
• CAM-02: Camshaft Assembly Installation
• FUEL-02: Fuel Injector and Fuel Rail Removal and Installation
• ENG-06: Camshaft and Balance Shaft Belt Installation
• ENG-10: Camshaft and Balance Shaft Belt Tension — Checking and Adjusting
• AF-01: Air Filter Housing and Air Flow Sensor — Removal and Installation
• IGN-01: Distributor Cap and Rotor Replacement
• COOL-02: Coolant System Draining, Filling, and Venting

Parts

Head Gaskets

Model/Year	Part Number
924 (1977–1982)	931 104 337 06
924S (1987–1988), 944 (1983–1988), 944S (1987–1988)	944 104 374 14
924 Turbo (1980–1982)	944 104 337 03
944 Turbo (1986–1988)	951 104 374 02

Cam Housing Gaskets

Model/Year	Part Number
924 (1977–1982)	060 198 025
924S (1987–1988), 944 (1983–1988), 944 Turbo (1986–1988)	944 105 199 03
924 Turbo (1980–1982)	060 198 025 A
944S (1987–1988)	928 104 447 09

Intake Manifold Gaskets

Model/Year	Quantity	Part Number
924 (1977–1982)	1	047 133 227
924S (1987–1988), 944 (1983–1988), 944 Turbo (1986–1988)	4	944 110 163 05
924 Turbo (1980–1982)	4	931 110 147 00
944S (1987–1988)	1	944 110 305 02

Exhaust Manifold Gaskets

Model/Year	Quantity	Part Number
924 (1977–1982)	4	048 129 589 A
924S (1987–1988), 944 (1985.5–1988), 944 Turbo (1986–1988)	4	944 111 196 00
944 (1983–1985.5)	4	928 111 193 12
924 Turbo (1980–1982)	4	931 111 191 00
944S (1987–1988)	4	944 111 205 00

Default Fastener Torques

Unless a specific torque value is given, apply the following defaults:

Fastener Size	Torque
6 mm	8 Nm (6 ft-lbs)
8 mm	20 Nm (15 ft-lbs)
10 mm	40 Nm (29 ft-lbs)

Procedure

1. Ensure that the mating surfaces on the cylinder head and block are clean. Remove all old gasket material and deposits. Use scrapers carefully to avoid gouging the aluminum surfaces — minor scratches can be removed with emery cloth or steel wool; deep gouges require machining.
2. Place the new head gasket on the block.

Note: The cylinder head can be installed with the exhaust manifolds still attached, which can save significant disassembly and reassembly time. This depends on available clearance, which is influenced by engine mount condition.

3. Install the cylinder head onto the block.
4. Install the two M8 Allen head bolts (6 mm head) at the front of the cylinder head and torque to 20 Nm (15 ft-lbs).
5. Coat the head stud threads with a light film of engine oil. Do not use any other lubricant.
6. Install all head stud nuts finger tight, then torque in three steps to the appropriate specification for your engine. Refer to CYL-03 for the correct torque values and tightening pattern.
7. Connect the coolant hose at the back of the cylinder head going to the heater control valve.
8. Connect the coolant outlet hose at the front of the cylinder head.
9. Position the exhaust manifold in the car.
10. Install the exhaust manifold studs and retaining nuts. Torque the exhaust manifold nuts to 20 Nm (15 ft-lbs).
11. Using FUEL-09, install the intake manifold.
12. Using CAM-02, install the camshaft assembly.
13. Using FUEL-02, install the fuel rail and injectors.
14. Using ENG-06 and ENG-10, install and tension the camshaft belt.
15. Install the front timing covers.
16. Using AF-01, install the air filter housing and air flow sensor.
17. Using IGN-01, install the rotor and distributor cap.
18. Route the coil wire to the distributor and plug wires from the distributor to the spark plugs.
19. Using COOL-02, fill and vent the coolant system.
20. Reconnect the battery negative lead.

Note: After the engine has been run to normal operating temperature, check and re-torque the exhaust manifold retaining nuts as necessary.