Camshaft (Timing) Belt Removal – 2.5L NA

Overview

This procedure outlines the steps to remove the camshaft (timing) belt on a Porsche 944 with an 8-valve engine. Removing the timing belt is necessary for maintenance tasks such as replacing the belt, water pump, or oil seals. Proper execution ensures the engine components remain undamaged. This guide covers the 1983–1985.5 (pre-85.5) and 1985.5–1988 (85.5 onwards) models, noting differences where applicable.

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Tools Required

• Jack stands
• Floor jack
• Metric socket set (including 10mm (3/8 inch), 13mm (1/2 inch), 24mm (15/16 inch))
• Metric wrench set (including 10mm (3/8 inch), 13mm (1/2 inch))
• Porsche Timing Belt Tension tool (P9201)
• Flywheel Lock (P9206) (optional, for crankshaft gear removal)
• Gear puller (optional, for crankshaft gear removal)

Parts Required

• Timing belt (if replacing), 944 105 157 02
• Camshaft tensioning roller (if replacing), 944 105 241 02 (Pre-85.5) or 944 105 321 00 (85.5 Onwards)
• Water pump idler roller (if replacing), 944 105 027 02

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1
• Distributor Cap and Rotor Replacement
• Air Filter Housing and Air Flow Sensor – Removal

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Disconnect the negative battery lead, followed by the positive lead, to ensure safety during the procedure.
2. Raise the vehicle using a floor jack and secure it with jack stands.
3. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – of the process is followed accurately to position the number 1 piston at TDC.

Step 2: Access the Timing Belt

4. Remove the alternator and power steering pump belts to access the front engine components.
5. Follow this link to ensure this step – Air Filter Housing and Air Flow Sensor – Removal– of the process is followed accurately to remove the air cleaner housing and air flow sensor assembly.
6. Follow this link to ensure this step – Distributor Cap and Rotor Replacement – of the process is followed accurately to remove the distributor cap and the aluminum cover behind it, exposing the camshaft sprocket.
7. Remove the front engine cover (two pieces) using a 10mm (3/8 inch) socket to access the timing belt. The cover is secured with 10mm head bolts.

Step 3: Release Timing Belt Tension

8. If the timing belt is to be reused, mark the belt with the direction of rotation before removing it.

For Pre-85.5 models:
Loosen the camshaft tensioning roller lock nut using a 13mm (1/2 inch) wrench. Hold the flats on the tensioner roller with a 13mm (1/2 inch) open-end wrench to provide counter-torque while loosening to prevent stress on the tensioner roller stud.
Turn the camshaft tensioning roller nut clockwise to release the tension on the timing belt.

For 85.5 Onwards models:
Locate the spring tensioner’s front plate (triangular shape). Loosen, but do not remove, the locknut and bolt on the side of the triangle near the tensioning spring using a 13mm (1/2 inch) wrench.
Push down on the tensioner lever arm to release tension on the timing belt. While the spring is compressed, tighten the locking bolt and nut to hold the tensioner in place.

Step 4: Remove the Timing Belt

9. Carefully remove the timing belt, 944 105 157 02, from the crankshaft gear, camshaft sprocket, water pump pulley, and tensioning roller. Avoid twisting the belt if it is to be reused. If the belt cannot be easily removed, you may need to remove the crankshaft gear (see Step 5).

Step 5: Optional Component Removal (if needed)

10. If inspecting or replacing the camshaft tensioning roller, 944 105 241 02 (Pre-85.5) or 944 105 321 00 (85.5 Onwards), remove the lock nut using a 13mm (1/2 inch) wrench and slide the roller off the shaft.
11. If inspecting or replacing the water pump idler roller, 944 105 027 02, remove the retaining bolt using a 13mm (1/2 inch) socket and slide the roller off.
12. If removing the crankshaft gear, 944 102 277 04, for water pump or oil seal maintenance, follow this link to ensure this step – Flywheel Lock Installation – of the process is followed accurately to install the flywheel lock. Then, remove the crankshaft pulley bolt using a 24mm (15/16 inch) deep socket and use a gear puller to slide the gear off. Alternatively, gently use a pry bar, applying minimal pressure to avoid damaging the plastic rear timing cover.
13. If replacing the water pump or front crankshaft oil seal, remove the back timing cover by removing the 10mm (3/8 inch) bolts holding it in place.

Post Procedure Checklist

• Verify that the camshaft sprocket and crankshaft remain aligned at TDC for cylinder number 1.
• Ensure all tools and debris are removed from the engine bay.
• Inspect the timing belt for wear or damage if it is to be reused.
• Check the camshaft sprocket, 944 105 053 00, and crankshaft gear, 944 102 277 04, for signs of wear or damage.
• Verify that all removed components (e.g., tensioning roller, idler roller) are in good condition or replaced as needed.

Sources

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