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 10 Picture Essay: S2 Cam Chain Tensioner Ramp Job (Read 6579 times)
IXIVIV
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Picture Essay: S2 Cam Chain Tensioner Ramp Job
Aug 2nd, 2011 at 4:08am
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Please note that I am hosting these images from Australia and Ian is therefore not being hit with the bandwidth/data for these images - they are around 70kb each so if you want to avoid downloading them all please don't bother with this thread.

Here is the all important "Danger Will Robinson! Danger!" thread:
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The parts are available very cheap here at 944Online!


Now I present a reasonably detailed photo essay of the S2 cam chain tensioner ramp replacement job.

I am not a mechanic and have only followed all the advice and instructions from here and the other famous 944 authoritative sites on the web.

Any mistakes or omissions are entirely my own - and I'm sure some may be found.  I do not pretend that this is authoritative but merely adds to the wealth of information out there about this job and these wonderful motor cars.


The images are in sequence and I have tried to show the steps all the way through.

Certainly I think that for some people who haven't done it before it is helpful to see what is "inside" and what the various bits look like.

You will also see the simple set of tools I used and some of the steps I took to make sure that nothing got mixed up, out of order or misplaced.

The job is indeed one any reasonably mechanically minded person can do and, as has been mentioned here countless times, is absolutely essential on all motors with this cam chain tensioner system...

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...Old ramps are orange.  These are about 65,000km old and the whole assembly was replaced last time according to my receipts.  I wanted to manually ensure that the ramps were not getting brittle.
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Keep stuff out of the motor!

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j-tube - both ends...

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Compress the tensioner assembly and lock the top ramp down.

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and remove
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New ones
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J-Tube
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new gasket set
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All done.
Took me nearly two hours because I went very slowly and photographed everything as I went, checked and rechecked the tensions of everything etc.
This can easily be done in an hour by anyone who has the tools and know how.

Thanks to Ian and 944Online who I purchased the ramp kit and the gasket set from, shipped internationally in a matter of days!  Thanks for the community resource and great service team!
Hopefully these pics will make a small difference to someone out there who would otherwise not want to do this simple and absolutely essential job!
  

Will: 1990, 944 S2, 3.0l, Manual, Azurite Blue [L Y5D], Coupe,&&Australia
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jws
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #1 - Aug 3rd, 2011 at 10:50am
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Nice post and I am sure this will be helpful for someone down the road.  It took me a little less then 1 hour to do mine.  No one should have any reservations about doing this because it's a pretty easy job.

Smiley Wink Cheesy Grin Angry Sad Shocked 8) ??? Roll Eyes Tongue Embarrassed Lips Sealed Undecided Kiss Cry
  
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1933beer
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #2 - Aug 3rd, 2011 at 3:50pm
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great post, wish I had had all these pics when I did mine in 09. your old pads looks better than mine. just to add not to over tighten the the allens it was easy and I stripped out the threads. I was able to put a longer bolt in and not do more major work.
  

1990 944 S2 convertible
1985 Celica GTS convertible
1997 BMW Z3 convertible
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #3 - Aug 4th, 2011 at 9:19pm
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Quote:
I was able to put a longer bolt in and not do more major work.


No such luck in my garage.
Oh my gosh, that was a nightmare...
Lips Sealed Lips Sealed Lips Sealed Lips Sealed Lips Sealed
  

-Jacob&&&&1987 Porsche 944 Super Variant, zermatt gray&&&&"Buying a car because it's reliable is like marrying someone because they are punctual." -Jeremy Clarkson &&&&
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IAN - 944ONLINE
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #4 - Aug 10th, 2011 at 9:43am
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THANK YOU !!

I'll post this in the tech section as well

ian
  

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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #5 - Dec 14th, 2011 at 8:26am
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This is a fanastic how-to-post!  Thank you very much, as I intend to take on this project as one of my first tasks with the "new" car.

Could I ask you which tools are necessary (size of sockets, etc.) and what torques are correct for the valve cover studs, as well as all fasteners associated with the cam tensioner and pads?

Thank you for anything you can pass along!

Note:  A more careful review of the cars records shows the pads were replaced 2.5 years and 30K miles ago, so I'm thinking this comes off the "immediate need" list.

That said, how often is it recommended the pads be replaced? 

Thank you!
« Last Edit: Dec 14th, 2011 at 8:25pm by »  
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IAN - 944ONLINE
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #6 - Dec 27th, 2011 at 3:54pm
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wow
very nice  !!
thanks for the post and I'll add it in the TECH section

  

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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #7 - Dec 28th, 2011 at 5:43pm
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Good post. Finally someone paying attention to 16 ventliters. Grin
  

I love my Porsche. Even if it does leak oil and break regularly.
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NeinKampf
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #8 - Jan 25th, 2012 at 12:24pm
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Great photo essay. Thx for posting. Am just about to do this on my 90 S2 @ 60k miles. Couple of questions, because I have never pulled this valve cover before. Any of you on this thread feel free to answer:

a) Locktite - did you/should you use it on every valve cover bolt, and the bolts on the j-tube and tensioner assembly? What's the recommended/preferred brand?

b) Valve cover gasket - Assuming you used a standard rubber gasket kit from, say, 944 online, do you coat them w/ a sealing protectant of any kind or use additional silicone in the corners, etc., (if so what do you recommend?) Or can you just lay the gasket(s) in place and tighten down the cover to spec, using the correct order procedure?

c) valve cover bolt thrust washers...do these need to be replaced during this procedure? My kit did not come with them.

d) Is the valve cover cast aluminum? If so, that powder coat looks like a ceramic type of material. Clearly it can be re-powder coated, since 944Online sells a version.  But, does anybody know what Porsche called that light tan color? I would like to have it reconditioned to look the original.

Thx!
  

An age is called dark not because the light fails to shine, but because people refuse to see it.
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #9 - Jan 25th, 2012 at 12:38pm
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NeinKampf wrote on Jan 25th, 2012 at 12:24pm:
Great photo essay. Thx for posting. Am just about to do this on my 90 S2 @ 60k miles. Couple of questions, because I have never pulled this valve cover before. Any of you on this thread feel free to answer:

a) Locktite - did you/should you use it on every valve cover bolt, and the bolts on the j-tube and tensioner assembly? What's the recommended/preferred brand?

b) Valve cover gasket - Assuming you used a standard rubber gasket kit from, say, 944 online, do you coat them w/ a sealing protectant of any kind or use additional silicone in the corners, etc., (if so what do you recommend?) Or can you just lay the gasket(s) in place and tighten down the cover to spec, using the correct order procedure?

c) valve cover bolt thrust washers...do these need to be replaced during this procedure? My kit did not come with them.

d) Is the valve cover cast aluminum? If so, that powder coat looks like a ceramic type of material. Clearly it can be re-powder coated, since 944Online sells a version.  But, does anybody know what Porsche called that light tan color? I would like to have it reconditioned to look the original.

Thx!


a) No I didn't and you should have to. I did use it on the two bolts holding down the tensioner tower. I used Loc-tite brand.
b) Get a new one that Ian sells. Most auto parts stores sell just the valve cover gasket, the kit IAN sells has the plug hole and bolt gaskets. No other sealants are needed.
c) the bolt gaskets should be replaced.
d) Yes it's aluminum. The ones that 944 online sells I believe are new and yes Porsche did change the color on them.
  

1990 944 S2 cab - 5.7l *Update* LE2 Heads, 11.0:1, Cstm Intake, .565 223 230 cam 418rwhp 423rwtq. &&Light travels faster than sound. That is why some people appear smart, until you hear them speak.
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1933beer
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #10 - Jan 25th, 2012 at 1:54pm
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nein Kampf translate to " no struggle" ?

My first thought that was Mein Kampf . I was thinking what a handel. Does the guy know who wrote that certain  booK with that title?

most people, my self included just repaint it the color they like. I coldn't find the original so I just sand blasted and used silver high temp paint. the color works well with the intake manifold.

please ensure you don't over tighten the  tensioner assembly. you will strip it ( ask me how I know) and no I didn't crank it down to do it.I think the tourch is 6lbs. that is why you should use the locktite.
  

1990 944 S2 convertible
1985 Celica GTS convertible
1997 BMW Z3 convertible
Council Bluffs, IA near Omaha, NE
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NeinKampf
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #11 - Jan 26th, 2012 at 10:53am
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Dawgz & Beer,
Thx for the feedback. I'll do a post on how it goes, and any learnings that aren't already common knowledge.

ps. right on the "no struggle". Nein a play off of 9. And yes, I did read the original in 8th grade, much to my teachers' chagrin.
  

An age is called dark not because the light fails to shine, but because people refuse to see it.
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #12 - Jan 29th, 2012 at 3:56pm
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OK, Update. Job proceeding smoothly. Got new pads replaced and tensioner remounted. Slipping the j-tube back in place, and, you guessed it, lost a washer down oil galley, just behind the large bolt underneath the exhaust cam chain sprocket...didn't even know that hole was there.   Roll Eyes

So, what now? Washer must be brass, since magnets don't work on it. Do I have to pull the oil pan?
  

An age is called dark not because the light fails to shine, but because people refuse to see it.
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #13 - Jan 30th, 2012 at 10:14am
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NeinKampf wrote on Jan 29th, 2012 at 3:56pm:
OK, Update. Job proceeding smoothly. Got new pads replaced and tensioner remounted. Slipping the j-tube back in place, and, you guessed it, lost a washer down oil galley, just behind the large bolt underneath the exhaust cam chain sprocket...didn't even know that hole was there.   Roll Eyes


Sorry about the washer, and unfortunately I can't offer any advice on what to do either.   I did want to say I love the picture of Barrel Monster! I live in his "home town"...   Smiley
  
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Re: Picture Essay: S2 Cam Chain Tensioner Ramp Job
Reply #14 - Jan 30th, 2012 at 11:49am
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hopefully if it made it to the oil pan I would drain the oil and hope that it comes out. If not you can and probably should pull the pan, however, that being said your oil pickup has a screen on it so the motor should not suck the washer back though again.
  

1990 944 S2 cab - 5.7l *Update* LE2 Heads, 11.0:1, Cstm Intake, .565 223 230 cam 418rwhp 423rwtq. &&Light travels faster than sound. That is why some people appear smart, until you hear them speak.
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