Camshaft (Timing) Belt and Balance Shaft Belt Removal

Tools

• Jack stands
• Floor jack
• Metric socket set
• Metric wrench set
• Porsche Timing Belt Tension tool (P9201)
• Flywheel Lock (P9206)
• Balance Shaft Pin Spanner (P9200) or equivalent (if removing balance shaft sprockets)
• Gear puller (if removing the crankshaft gear)

Other Procedures Needed

• ENG-03: Flywheel Lock Installation
• ENG-13: Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1
• AF-01: Air Filter Housing and Air Flow Sensor — Removal and Installation
• IGN-01: Distributor Cap and Rotor Replacement

Refer to the appropriate timing belt arrangement diagram for your model:

• 1982–1986 944 with eccentric roller tensioners
• 1987–on 944 with spring tensioners
• 1992–1995 968 with hydraulic tensioners

Procedure

1. Disconnect the battery negative lead.
2. Position the number 1 piston to TDC (ENG-13).
3. Disconnect the battery positive lead.

Note: It is possible to remove the timing belt without removing the balance shaft belt gear on the crankshaft. However, it is extremely difficult to install the new belt with the balance shaft gear in place. To avoid risking belt damage, it is preferable to install the flywheel lock and remove the balance shaft gear. If you choose not to, delete steps involving flywheel lock installation, crankshaft pulley bolt removal, and removal of the power steering and balance shaft gears.

4. Using ENG-03, install the flywheel lock.
5. Remove the alternator and power steering pump belts.
6. On turbo models, remove the turbocharger outlet line to the intercooler (large diameter aluminum tube to which the air filter assembly is clamped).
7. Using AF-01, remove the air cleaner housing and air flow sensor assembly as a unit.
8. Remove the front engine cover to access the timing and balance shaft belts. (The cover is two pieces and is attached by 10 mm head bolts.)
9. Remove the crankshaft pulley bolt using a 24 mm or 15/16" deep socket. Remove the power steering pulley. Remove the alternator/AC pulley and balance belt gear as a unit from the crankshaft.
10. Loosen the balance shaft belt tensioner sprocket lock nut, then turn the tensioner nut counterclockwise to release the tension on the balance shaft belt.
11. Loosen the balance belt idler roller lock nut, then rotate the idler to provide clearance for removal of the balance shaft belt.
12. Remove the balance shaft belt and mark the direction of rotation on the belt if it is to be reused.
13. If the balance shaft belt idler and balance shaft tensioning roller are to be inspected or removed for other maintenance (water pump or oil seals), remove the locknuts and slide the rollers off the shafts.
14. If the balance shaft sprockets need to be removed (water pump or oil seals), lock the sprocket in place using the Balance Shaft Pin Spanner to hold the sprocket while loosening the retaining nut.
15. After the retaining bolts have been removed, slide the balance shaft sprockets straight off the shaft. A small pry bar may be needed to start removal.
16. Using IGN-01, remove the distributor cap and the aluminum cover behind the distributor cap. This will reveal the main camshaft sprocket.
17. If the timing belt is to be reused, mark the belt for direction of rotation before removing it.
18. On cars without spring tensioners (pre-1987): a. Loosen the camshaft tensioning roller lock nut and turn the camshaft tensioning roller nut clockwise to release belt tension. Hold the flats on the tensioner roller with an open-end wrench while loosening the locknut to provide counter-torque. Failure to provide counter-torque while loosening (or tightening) the locknut causes stress on the tensioner roller stud which can lead to long-term failure. b. Remove the timing belt, being careful not to twist the belt if it is to be reused. It may be necessary to remove the balance belt gear on the crankshaft to allow removal of the timing belt. c. If the camshaft tensioning roller is to be inspected or removed for other maintenance, remove the lock nut and slide the camshaft tensioning roller off the shaft.
19. On cars with spring tensioners (1987 and newer): a. The front plate of the spring tensioner resembles a triangle. Loosen, but do not remove, the locknut and bolt on the side of the triangle near the tensioning spring. b. Remove the tension on the belt by pushing down on the tensioner lever arm (this can also be done using the factory balance shaft spanner). With the spring still compressed, tighten the locking bolt and nut. c. Remove the timing belt, being careful not to twist the belt if it is to be reused. d. If water pump or oil seal maintenance is being performed, remove the entire spring tensioner assembly as a unit. The three bolts on the face plate are not used to remove the unit — there are three bolts at the back of the tensioner near the block which must be removed.

Note: On spring tensioner cars, it is very difficult to remove and install the timing belt with the spring tensioner assembly in place. It is preferable to remove the spring tensioner assembly during belt removal and reinstall it while routing the timing belt during installation.

20. If the camshaft belt idler is to be inspected or removed for other maintenance, remove the retaining bolt and the camshaft belt idler.
21. If the crankshaft gear needs to be removed, a gear puller is the easiest method. If a pry bar is used instead, apply pressure gently so as not to damage the rear timing belt cover (it is made of plastic).
22. Remove the rear timing cover by removing the 10 mm bolts holding it in place. The rear timing cover must be removed when replacing the water pump, front crankshaft oil seal, or balance shaft oil seals.