12 Steps to Remove an Air-Cooled Porsche Engine for Repairs
Does it really only take 12 steps to remove an air-cooled Porsche engine for repairs?
I wouldn’t have believed it, but Air Brigade recently “shadowed’ Air Brigade Charter member Charlie Hickey as he tackled his winter service project to fix an oil cooler leak in his 1972 Porsche 911T Targa.
In a previous service Charlie had replaced the gaskets, but the leak persisted so Charlie knew the engine had to come out again so the oil cooler could be sent to a radiator shop for internal repairs to the unit.
Charlie recruited Air Brigade members for assistance including TD King, Don Therien and Joe Esposito. Also on hand were PCA members Bob Disney and Mark Cigal. Air Brigade Commander Jim Moore thought it would be the perfect opportunity to record the process of engine removal.
Please be aware that every step was not photographed because there are many wires and cables requiring disconnection. Only the major mechanical steps were recorded.
Charlie is an advanced “shade tree” mechanic and has his garage set up with a two-post lift and a full complement of tools that makes the job easier. This was not the first time this numbers matching 2.4-liter flat-six engine had been removed, and will probably not be the last time.
The process started with an overview of what the team was tackling on top and underneath the engine bay. Contrary to new Porsches, you’ll note that the engine is readily accessible which facilitates the engine removal with only 12 steps.
Step One – Start the process by draining the oil. Since this car requires 10 quarts, allow time for everything to drain completely.
Step Two - Disconnect the shift linkage in the tunnel as opposed to at the shifter so that you can re-hook-up at installation without having to adjust the linkage.
Step Three – Set the proper placement of the jack points to lift the car so you can start disconnecting all hoses and wire connectors. On many early Porsches this lift points are crushed from owners using floor jacks without a lift puck.
Step Four – Disconnect the Universal joints
Step Five – Disconnect clutch cable, throttle linkage, speedometer and ground cable.
Step Six – Disconnect half shafts using a hex wrench extension.
Step Seven – Disconnection of oil lines requires special large Porsche wrenches that Charlie has owned for years.
Step Eight – Lower lift and check that all wires and cables are disconnected in the engine bay. In this case Charlie is disconnecting the electronic ignition.
Step Nine – Slide lift table under engine. A floor jack is positioned under the transmission while the lift table is positioned under the engine. Two by four’s are used on the lift table to provide a cushion for the heat exchangers to rest on.