Camshaft Assembly Installation

Overview

This guide outlines the procedure for installing the camshaft assembly on all Porsche 944 variants with a 8-valve engine, covering both pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) variants. The camshaft assembly is critical for controlling the engine’s valve timing, ensuring optimal performance. Proper installation prevents misalignment, oil leaks, and engine damage. This guide is tailored for DIY enthusiasts with mechanical experience, focusing on clarity and precision.

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

Tools Required

• 8mm (5/16 inch) Allen head socket or 8mm (5/16 inch) hex key
• 6mm (1/4 inch) Allen head socket with 152mm (6 inch) socket extension OR long 6mm (1/4 inch) Allen head socket (preferred)
• 10mm (3/8 inch) socket
• Flat tip screwdriver
• Flywheel lock tool 9206 (optional)
• 27mm (1-1/16 inch) thin head open-end wrench (Pre-85.5 with eccentric roller tensioners)
• 19mm (3/4 inch) socket (Pre-85.5 with eccentric roller tensioners)
• 12mm (1/2 inch) socket (85.5 Onwards with spring tensioners)

Parts Required

• Cam housing gasket 944 105 167 00

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Fuel Injector and Fuel Rail Removal and Installation
• Distributor Cap and Rotor Replacement
• Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1
• Camshaft Belt Installation
• Camshaft Belt Tension – Checking and Adjusting

Step-by-Step Procedure

Step 1: Prepare the Cylinder Head

1. Remove all old gasket material from the mating surfaces of the cylinder head and camshaft housing. Use a scraper carefully to avoid gouging or scratching the surfaces.
2. Smooth minor scratches on the mating surfaces using emery cloth or fine-grit sandpaper.

Step 2: Verify Cam Sprocket and Distributor Housing

3. Ensure the rear distributor housing and cam sprocket are-installed.
4. Align the mark on the cam sprocket with the mark on the rear distributor housing to set the engine to Top Dead Center (TDC). Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – is followed accurately.

Step 3: Prepare Lifters

5. If reusing old lifters, install each lifter in its original location from removal.

If installing new lifters:
Soak new lifters in engine oil for several hours before installation.
Compress the lifters between your fingers, then soak them in oil again to minimize self-adjustment time after engine startup.
Apply a thin coat of grease to the outer surface of each lifter to hold them in place in the cam housing during installation.

Step 4: Install the Cam Housing Gasket

6. Place a new cam housing gasket 944 105 167 00 onto the cylinder head mating surface. Ensure the gasket is oriented correctly, with “OPEN” or “TOP” facing up to avoid blocking the oil supply passage to the cam housing.

Step 5: Install the Cam Housing

7. Verify the engine is set to TDC. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – is followed accurately.
8. Place the cam housing onto the cylinder head, ensuring it engages the alignment pins. The housing may not sit flush due to cam lobes pressing against valves, which is normal.
9. Apply a small amount of grease to the heads of the M8 cam housing bolts or the tip of the 8mm (5/16 inch) Allen head socket to hold the bolts during installation.
10. Install the coolant return pipe while installing the cam housing bolts.
11. Tighten the cam housing bolts evenly to pull the housing down onto the alignment pins. No specific tightening sequence is required, but ensure even pressure.

Note: The cam may shift slightly from the TDC alignment mark during tightening, which is expected.

12. Once the housing is fully seated, torque the cam housing bolts to 20 Nm (14 ft-lbs) using a torque wrench.

Step 6: Install and Tension the Camshaft Belt

13. Install and tension the camshaft belt. Follow these links to ensure this step – Camshaft Belt Installation and Camshaft Belt Tension – Checking and Adjusting – is followed accurately.

For Pre-85.5 models:
Use a 27mm (1-1/16 inch) thin head open-end wrench and a 19mm (3/4 inch) socket for eccentric roller tensioners.

For 85.5 Onwards models:
Use a 12mm (1/2 inch) socket for spring tensioners.

Step 7: Install Front Timing Covers

14. Install the front timing covers over the camshaft belt.

Step 8: Install Fuel Rail and Injectors

15. Install the fuel rail and injectors. Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – is followed accurately.

Step 9: Install Distributor Cap and Rotor

16. Install the distributor cap and rotor. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – is followed accurately.

Step 10: Reconnect Cruise Control (If Equipped)

17. If your vehicle has cruise control, reconnect the cruise control cable to the cruise control servo.

Step 11: Reconnect Battery

18. Connect the battery leads to the battery terminals.

Post Procedure Checklist

• Verify the camshaft belt is properly tensioned and aligned.
• Check for oil leaks around the cam housing gasket.
• Ensure the engine rotates smoothly by hand (using a wrench on the crankshaft pulley) to confirm no valve interference.
• Start the engine and listen for abnormal noises from the camshaft area.
• Confirm the engine idles smoothly and there are no fault codes (if applicable).

Sources

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