Camshaft Assembly Removal

Overview

This guide details the removal of the camshaft assembly from a Porsche 944 S2 with a 3.0L 16-valve (16v) engine. The camshaft assembly includes both intake and exhaust camshafts, lifters, and the cam housing, critical for the engine’s double overhead cam (DOHC) system. Removing this assembly is necessary for tasks like camshaft replacement, lifter maintenance, or cylinder head access. Proper execution preserves engine timing and prevents damage to the 16v components.

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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
• 10mm (3/8 inch) socket
• Flat tip screwdriver
• 27mm (1-1/16 inch) thin head open-end wrench
• 19mm (3/4 inch) socket
• Flywheel lock tool 9206 (optional)

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

Step-by-Step Procedure

Step 1: Prepare the Engine

1. Disconnect the negative battery lead to ensure safety during the procedure.
2. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – is followed accurately to set the engine to TDC for cylinder number 1. This aligns the 16v engine’s dual camshafts correctly.

Step 2: Remove Fuel and Ignition Components

3. Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – is followed accurately to remove the fuel rail and injectors from the 16v engine.
4. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – is followed accurately to remove the distributor cap and rotor.

Step 3: Remove Timing and Distributor Covers

5. Using a 10mm (3/8 inch) socket and ratchet, remove the front timing and balance shaft belt covers by unscrewing the M6 bolts. This exposes the 16v engine’s timing belt system.
6. Using a 10mm (3/8 inch) socket and ratchet, remove the front distributor housing cover by unscrewing the three M6 bolts.

Step 4: Release Timing Belt Tension

7. Loosen the camshaft tensioning roller lock nut using a 27mm (1-1/16 inch) thin head open-end wrench. The 944 S2’s 16v engine uses an eccentric roller tensioner.
8. Turn the camshaft tensioning roller nut beneath the lock nut clockwise using a 19mm (3/4 inch) socket to release tension on the timing belt. This adjusts the eccentric roller to slacken the belt.
9. Slide the timing belt off the camshaft sprockets (intake and exhaust). Note: The belt does not need to be fully removed unless other work requires it.

Step 5: Remove Rear Timing Cover and Sensor Plug

10. Remove the two M6 bolts attaching the rear timing cover to the rear distributor housing using a 10mm (3/8 inch) socket.
11. Disconnect the sensor plug retaining strap on the engine lifting bracket at the back of the cam housing by removing the M6 bolt with a 10mm (3/8 inch) wrench.

Step 6: Remove Cam Housing Plugs and Bolts

12. Using an 8mm (5/16 inch) hex key or Allen head socket, remove the plugs from the top of the cam housing to access the retaining bolts.
13. Using a 6mm (1/4 inch) Allen head socket with a 152mm (6 inch) extension or a long 6mm (1/4 inch) Allen head socket, remove the 15 M8 cam housing retaining bolts. Tighten to 20 Nm (15 ft-lbs) upon reinstallation. Note: Tape the socket to the extension to prevent it from falling into the cam housing.

Note:

• Two of the cam housing bolts also secure the bracket for the heater core return line’s hard pipe section. If only removing the cam housing, move the return line out of the way without disconnecting it. If removing the cylinder head, follow the head removal procedure to disconnect the return line after draining the coolant system.

Step 7: Remove the Camshaft Assembly

14. Lift the cam housing upward slightly and tilt it toward the right side of the car to keep the lifters (16 per cam housing for the 16v engine) in their respective openings. This preserves the lifters for reuse.

Note:

• If lifters must be removed, store them in a way that allows identification for correct reinstallation orientation to maintain proper valve operation.

Post Procedure Checklist

• Verify that all tools and debris are removed from the engine bay.
• Ensure the timing belt is properly stored and not damaged if it was not fully removed.
• Check that all 16 lifters are either retained in the cam housing or stored correctly for reinstallation.
• Inspect the cam housing, camshafts, and surrounding areas for any loose bolts or components.

Sources

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