Work Procedure Porsche 944S - Camshaft Drive Belt Replacement

NOTE: The engine must be cold to perform this operation.

1. Open front hood and install fender covers.

2. Disconnect minus cable on battery.

3. Remove complete air filter housing.

4. Remove air hose from top cam belt housing.

5. Remove cable holder from top cam belt housing.

6. Remove top camshaft drive belt housing (7 bolts - M6 x 12).

7. Remove high tension wire on distributor cap, coming from coil.

8. Remove top metal drive belt cover together with the installed distributor cap and move to the rear.

9. Lift car and remove lower engine protection cover.

10. Loosen adjusting rod for servo pump and remove belt.

11. Loosen adjusting rod for alternator and A/C compressor and remove Polyrib belt.

12. Remove bottom drive belt cover. (4 bolts - M6 x 12).

NOTE: Do not loosen or remove pulley pack on crankshaft!

13. Turn engine to TDC of No. 1 cylinder; firing position.

14. Loosen nut on balance shaft tensioning wheel approximately 1 turn, to loosen belt turn counter clockwise.

15. Remove bolt M10 x 35 and washers from lower balance shaft, use special tool 9200 to counterhold.

16. Mark belt for reinstallation, must run in the same direction as before! (Do not twist belt!)

17. Remove balance shaft belt.

18. Lower car.

19. Loosen camshaft drive belt, by loosening the M8 bolt and nut on the belt tensioner, using special tool 9200.

20. Slide off belt from camshaft gear.



21. Remove idle roller on oil pump (1 bolt M10 x 30), see photo #1a.



22. Remove both M6 nuts on belt guide rail and pull off guide rail.

23. Remove three M8 nuts on tensioner and remove complete unit. (see photo #1b)

NOTE: For easier removal of the belt, bring tensioner into the center adjusting area of tensioner.
24. Remove camshaft drive belt.

25. Inspect gears, if dirty, clean with a brass wire brush.

26. Lift car.

NOTE: It is absolutely necessary to lift the car, since the installation of the belt can only be done from the bottom.



27. Install the new drive belt, part #944.105.323.00, without forcing, by slipping the belt over the pulley pack, start at the bottom right (in driving direction) push over balance shaft drive gear. See photo #2, if necessary push rear cam cover back for more clearance.

NOTE: Do not use sharp tools!
28. Check crankshaft TDC mark on flywheel-bell housing and if necessary bring to TDC by turning the crankshaft slightly to the right or left.

NOTE: To avoid piston/valve contact, do not rotate crankshaft more than 20 degrees either side of TDC.

29. Lower car.

30. Reinstall belt tensioner, torque the three M8 nuts to 20 N-m (14 ft.lbs.).

31. Move tensioner into the fully off position, using special tool 9200.
32. Slip new cam belt onto camshaft drive gear, do not move the camshaft!

NOTE: On cars of Model Year 1987 up to engine No. 42H02372 it is possible that the tensioner adjusting area is not enough to slip the belt onto the camshaft drive gear. In these cases, remove the tensioner bolt M8 x 45 to loosen the tensioner more.
33. Loosen nut and bolt to tension the camshaft drive belt. Then tighten bolt and nut.
34. Reinstall idler roller onto the oil pump. Torque bolt to 45 N-m (33 ft.lbs.).

35. Reinstall belt rail, using 2 new M6 nuts part #999.084.092.02, torque to 8 N-m (6 ft.lbs.).

36. Lift car.

37. Rotate engine two crankshaft revolutions and bring engine back to TDC - No. 1.
38. Lower car.

39. Check TDC position on crank and camshaft, the mark on the camshaft gear must be back in line with the housing mark.

NOTE: The position of the camshaft gear to the camshaft itself need not be checked.

40. Readjust cam belt, by loosening the bolt and nut on the tensioner. Then torque bolt and nut to 20 N-m (14 ft.lbs.)

41. Mark the timing notch on the camshaft gear with white paint for better identification at the 2500 mile adjustment procedure.

42. Lift car.

43. Reinstall balance shaft drive belt, assure correct position of the balance shaft.

NOTE: The old belt must be installed to run in the same direction as before the removal.

44. Loosen idler pulley and turn into relaxed position.

45. Adjust balance shaft belt tension with special tool 9201 to the value of 2.7 + 0.3 on the tool scale. Use special tool 9207 to move tensioning wheel clockwise to tension belt. Then torque M10 nut on the tensioning wheel to 45 N-m (33 ft.lbs.).

46. Adjust idler pulley with special tool 9207 and 1 mm belt pre-load, torque to 45 N-m (33 ft.lbs.).

47. Reinstall lower balance shaft drive gear bolt and washers, torque to 45 N-m (33 ft.lbs.).

48. Reinstall lower cam belt cover.

49. Reinstall polyrib belt for alternator and A/C compressor, tension belt.

NOTE: The tension of the belt has changed from previous information. Adjust belt to 9.5 on the special tool 9201, plus 1 complete turn on the adjusting rod (not 2 turns!).

50. Reinstall servo pump belt and tension belt (approx. 5 mm belt deflection).

51. Reinstall lower engine protection cover.

52. Lower car.

53. Reinstall top metal camshaft cover with the distributor cap.

54. Reinstall drive belt cover and cable harness clamp for the hall sensor.

55. Reinstall air hose on cam housing.

56. Reinstall high tension wire on distributor cap.

57. Reinstall air filter.

58. Reconnect battery and reset time clock.
59. Mark top cam housing with center punch for identification purpose, that a new type belt was installed.
60. Start engine, check operation.

61. Remove fender covers, close hood.

NOTE: The new type camshaft drive belt, Part #944.105.323.00, is to checked and adjusted at 2500 miles, 30,000 miles and by 45,000 miles the belt has to be replaced. After replacement of the belt, the cycle repeats itself.

The check and adjust operation at 15,000 miles is eliminated and should not be performed.