Camshaft Assembly Removal

Overview

This procedure outlines the steps to remove the camshaft assembly from all Porsche 944 variants with an 8-valve engine. The camshaft assembly, located in the cam housing, is critical for controlling valve timing. Removing it is necessary for tasks like inspecting or replacing lifters, camshaft, or other cylinder head components. This guide covers the 1983–1985.5 (Pre-85.5) and 1986–1988 (85.5 Onwards) variants, with specific steps for each where applicable.

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

Tools Required

• 8 mm (5/16 inch) Allen head socket or 8 mm hex key
• 6 mm (1/4 inch) Allen head socket with 150 mm (6 inch) socket extension or long 6 mm Allen head socket
• 10 mm (3/8 inch) socket
• Flat tip screwdriver
• Flywheel lock tool (Porsche tool 9206, optional)
• 27 mm (1-1/16 inch) thin head open end wrench (Pre-85.5)
• 19 mm (3/4 inch) socket (Pre-85.5)
• 12 mm (1/2 inch) socket (85.5 Onwards)
• Pry bar or balance shaft pin spanner (Porsche tool, 85.5 Onwards)

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: Disconnect the Battery

1. Locate the battery in the engine compartment (front, driver’s side).
2. Use a 10 mm (3/8 inch) wrench to loosen and remove the negative (-) battery cable.
3. Secure the cable away from the battery terminal to prevent accidental contact.

Step 2: Set Engine to Top Dead Center (TDC)

4. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – of the process is followed accurately.
5. Verify the engine is at TDC for cylinder 1 by checking the alignment marks on the crankshaft and camshaft sprockets.

Step 3: Remove Fuel Rail and Injectors

6. Follow this link to ensure this step – Fuel Injector and Fuel Rail Removal and Installation – of the process is followed accurately.
7. Place a rag under the fuel rail to catch any residual fuel.

Step 4: Remove Distributor Cap and Rotor

8. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – of the process is followed accurately.
9. Secure the distributor cap and rotor aside to avoid damage.

Step 5: Disconnect Cruise Control Cable (If Equipped)

10. Locate the cruise control cable connected to the cruise control servo (near the throttle body).
11. Disconnect the cable by loosening the retaining clip or bolt using a 10 mm (3/8 inch) wrench.
12. Move the cable out of the way and secure it to prevent interference.

Step 6: Remove Timing and Balance Shaft Belt Covers

13. Use a 10 mm (3/8 inch) socket to remove the M6 bolts securing the front timing and balance shaft belt covers.
14. Carefully lift off the covers and set them aside.

Step 7: Remove Distributor Housing Cover

15. Use a 10 mm (3/8 inch) socket to remove the three M6 bolts securing the front distributor housing cover.
16. Remove the cover and set it aside.

Step 8: Release Timing Belt Tension

17. Release tension on the timing belt based on your model year:

For 85.5 Onwards models:
Locate the spring tensioner, which has a triangular front plate.
Use a 12 mm (1/2 inch) socket to loosen (but do not remove) the locknut and bolt on the side of the triangle near the tensioning spring.
Push down on the tensioner lever arm to compress the spring, using a pry bar or a balance shaft pin spanner (Porsche tool) for easier operation. The spanner’s pins fit into two holes on the tensioner.
While the spring is compressed, tighten the locknut and bolt to secure the tensioner in place.

For Pre-85.5 models:
Locate the camshaft tensioning roller (eccentric roller type).
Use a 19 mm (3/4 inch) socket to loosen the tensioning roller locknut.
Use a 27 mm (1-1/16 inch) thin head open end wrench to turn the tensioning roller nut clockwise, releasing tension on the timing belt.

Step 9: Remove Timing Belt from Camshaft Sprocket

18. With tension released, carefully slide the timing belt off the camshaft sprocket.
19. Note: The timing belt does not need to be fully removed unless other procedures require it.

Step 10: Remove Rear Timing Cover Bolts

20. Use a 10 mm (3/8 inch) socket to remove the two M6 bolts securing the rear timing cover to the rear distributor housing.
21. Set the bolts aside in a labeled container for reassembly.

Step 11: Disconnect Sensor Plug Retaining Strap (If Equipped)

22. Locate the sensor plug retaining strap on the engine lifting bracket at the back of the cam housing.
23. Use a 10 mm (3/8 inch) wrench to remove the M6 bolt securing the strap.
24. Move the strap and sensor plug out of the way.

Step 12: Remove Cam Housing Plugs

25. Use an 8 mm (5/16 inch) Allen head socket or hex key to remove the plugs from the top of the cam housing.
26. Store the plugs in a clean, labeled container.

Step 13: Remove Cam Housing Bolts

27. Use a 6 mm (1/4 inch) Allen head socket with a 150 mm (6 inch) extension or a long 6 mm Allen head socket to remove the 15 M8 bolts securing the cam housing.

– Note: Two of these 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 cylinder head removal procedure to disconnect the return line after draining the coolant.

Step 14: Remove Cam Housing

28. Lift the cam housing upward slightly to disengage it from the cylinder head.
29. Tilt the cam housing toward the right side of the car (passenger side in LHD models) to keep the lifters in their respective openings in the bottom of the cam housing.

– Note: Keeping lifters in place is critical if reusing them. If lifters must be removed, store them in a labeled container to maintain their correct orientation for reinstallation.

Post Procedure Checklist

• Verify all tools and loose parts are accounted for and removed from the engine compartment.
• Ensure the timing belt is securely positioned off the camshaft sprocket but not damaged.
• Check that lifters are either still in place in the cam housing or properly stored and labeled if removed.
• Inspect the cam housing and camshaft for any signs of wear or damage before proceeding with further repairs.

Sources

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