Camshaft (Timing) Belt and Balance Shaft Belt Installation

Tools

• Jack stands
• Floor jack
• Metric socket set
• Metric wrench set
• Porsche Timing Belt Tension tool (P9201)
• Balance Shaft Pin Spanner (P9200) or equivalent (if balance shaft sprockets have been removed)

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
• ENG-08: Balance Shaft Sprocket Installation and Alignment Check
• ENG-10: Camshaft and Balance Shaft Belt Tension — Checking and Adjusting

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

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

Camshaft Belt Installation

1. Install the rear timing cover if removed.
2. Install the water pump idler roller if removed. Tighten the idler roller retaining bolt to 45 Nm (33 ft-lbs).
3. Install the crankshaft gear if removed, ensuring that the lip on the timing gear is oriented toward the front of the car.
4. Install the camshaft sprocket if removed.
5. Install the cam belt tensioning roller if removed.

Note: On cars with spring tensioners, it is preferable to install the spring tensioner while routing the timing belt rather than before. Removing the spring tensioner assembly makes routing the belt significantly easier.

6. If the flywheel lock was not used, verify crankshaft at TDC on cylinder #1 (ENG-13).
7. Align the mark on the camshaft sprocket with the mark on the rear distributor housing.
8. Install the timing belt as follows: a. Place the belt on the crankshaft gear. b. Route the belt around the camshaft sprocket. Ensure that there is no slack in the belt between the cam sprocket and crankshaft gear. Make sure that neither the crankshaft nor the cam sprocket moves from TDC during belt installation. c. Finish by routing the belt around the water pump pulley and tensioning roller.
9. Tension the camshaft belt using ENG-10.

Balance Belt Installation

1. If removed, install the balance belt sprockets using ENG-08.
2. Using ENG-13, set the crankshaft to TDC for cylinder #1.
3. Install the balance belt gear on the crankshaft if removed.
4. If the crankshaft bolt was removed, perform the following: a. Using ENG-03, install the flywheel lock. b. Ensure the crankshaft timing gear, balance shaft belt gear, and alternator/AC compressor pulley are installed. c. Install the crankshaft bolt and torque to 210 Nm (155 ft-lbs). d. If equipped, install the power steering pulley. Tension the pulley mounting bolts to 13 Nm (9.5 ft-lbs). e. Remove the flywheel lock.
5. Align the upper balance shaft so that the notch on the edge of the sprocket aligns with the notch in the rear timing cover. It is located at approximately the 1 o'clock position.
6. Align the lower balance shaft so that the notch on the edge of the sprocket aligns with the raised tab which is molded into the rear timing cover. It is located at approximately the 7 o'clock position.
7. Install the balance belt as follows: a. Route the balance belt from the upper balance sprocket around the crankshaft gear. Ensure there is no slack in the belt from the upper sprocket to the crankshaft gear. b. Continue routing the belt around the lower balance sprocket, again ensuring there is no slack from the crankshaft sprocket to the lower balance sprocket. c. Route the belt around the tensioning roller and back to the upper balance sprocket. d. Pre-tension the balance shaft belt enough to remove any slackness and tighten the tensioning roller locknut.

Note: Turn the tensioning roller clockwise to tighten, counterclockwise to loosen.

8. Install the balance shaft sprocket covers and retaining bolts. Tighten the retaining bolts to 45 Nm (33 ft-lbs) while holding the sprocket with Special Tool P9200.
9. Rotate the crankshaft two complete turns and set at TDC for cylinder #1.
10. Verify that the camshaft, balance shaft, and flywheel marks are aligned for TDC.

Note: It is not unusual for the balance shaft marks to be slightly out of alignment. Most often if they do not align, the lower shaft will be aligned with its mark and the upper shaft will be off by approximately one-half tooth. If the shafts are out of alignment by a full tooth or more, they should be realigned.

11. Tension the balance shaft belt using ENG-10.
12. Install the front timing belt covers.
13. Install alternator and power steering belts and re-tension.
14. Install the air filter assembly (AF-01).
15. Reconnect the battery.