Camshaft Assembly Installation

Overview

This procedure outlines the steps to install the camshaft assembly on the Porsche 944 S2 with a 3.0L 16V engine. The camshaft assembly is critical for controlling the engine’s valve timing, ensuring optimal performance. Proper installation ensures the camshaft housing is securely mounted, correctly aligned, and sealed to prevent oil leaks and maintain engine efficiency.

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Tools Required

• 8mm (5/16 inch) Allen head socket or 8mm hex key
• 6mm (1/4 inch) Allen head socket with 152mm (6 inch) socket extension OR long 6mm Allen head socket (preferred)
• 10mm (3/8 inch) socket
• Flat tip screwdriver
• Flywheel lock tool (Porsche tool 9206) (optional)
• 12mm (1/2 inch) socket (for spring tensioners)

Parts Required

• Camshaft housing gasket, 944 105 135 02

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 and Camshaft Housing

1. 1. Remove all old gasket material from the mating surfaces of the cylinder head and camshaft housing. Use a plastic scraper to avoid scratching the surfaces.

Note: Minor scratches can be smoothed with fine-grit sandpaper or emery cloth.

1. Verify that the rear distributor housing and camshaft sprocket are installed.
2. Align the camshaft sprocket mark 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 2: Prepare the Lifters

4. 4. If reusing old lifters, ensure each lifter is reinstalled in its original position.

For new lifters:

• Soak new lifters in engine oil for several hours before installation.

• Compress the lifters between your fingers and soak them again to reduce self-adjustment time after engine startup.

Note: Apply a thin coat of grease to the outer surface of the lifters to help them stay in place during camshaft housing installation.

Step 3: Install the Camshaft Housing Gasket

5. Place a new camshaft housing gasket (944 105 135 02) 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.
6. Confirm the engine is aligned to TDC. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – is followed accurately.

Step 4: Mount the Camshaft Housing

7. 7. Position the camshaft housing onto the cylinder head, ensuring it engages the alignment pins. The housing may not sit flush due to cam lobes pressing on valves, which is normal.

Note: As bolts are tightened, the camshaft may shift slightly from the TDC mark, which is expected.

7. Install the M8 camshaft housing bolts using an 8mm (5/16 inch) Allen head socket. Apply a small amount of grease to the bolt heads or socket to hold the bolts during installation.
8. Install the coolant return pipe alongside the camshaft housing bolts.
9. Tighten the bolts evenly to pull the housing down onto the alignment pins. Once fully seated, torque the bolts to 20 Nm (15 ft-lbs).

Step 5: Complete the Installation

11. Install and tension the camshaft belt. Follow these links to ensure these steps – Camshaft Belt Installation and Camshaft Belt Tension – Checking and Adjusting – are followed accurately.
12. Install the front timing covers using a 10mm (3/8 inch) socket for the bolts.
13. Install the fuel rail and injectors Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – is followed accurately.
14. Install the distributor cap and rotor. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – is followed accurately.
15. If equipped, reconnect the cruise control cable to the cruise control servo.
16. Reconnect the battery leads.

Post Procedure Checklist

• Verify the camshaft housing bolts are torqued to 20 Nm (15 ft-lbs).
• Check that the camshaft belt is properly tensioned.
• Inspect for oil leaks around the camshaft housing gasket after starting the engine.
• Confirm the engine runs smoothly and there are no unusual noises from the camshaft area.

Sources

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