Jo1 jgj

camshaft A - Bearing' saddle for exhaust camshaft

7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ftlb.).

8. Unscrew tensioning screw (special tool 9632) from the tensioning element

Porsche 968 Variocam

9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.

Porsche Variocam Sprocket
500_96

10. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6x 15 (10.9).

Tighten hexagon-head bolts by hand only.

11. Unscrew chain tensioner (fitted on the crankcase half of cylinder bank 4 - 6) and fasten auxiliary chain tensioner (special tool 9599).

12. Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight.

The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.

46337

13. Fit auxiliary chain tensioner on cylinder head 1 - 3 and adjust pre-tension force (refer to step 12).

Engine 497 Camshaft Assembly
449-97

14. Fit cylinder-head cover. Remove holding-down device 9611.

Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to: Sealing cover for camshaft housing (cylinder-head cover), Service No. 15 91 51.

Camshaft Cylinder Bead
430.1 „96

Carefully place the cyiinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centring pins into the corners of the cylinder head as centring aids.

Immediately remove silicone material emerging in the area of the camshaft closure cap.

Pulled Head Stud Porsche
497-%

16. Fasten blocking device (special tool 9612) on the cylinder head.

503.96

15. For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595).

Special tool fitting sequence:

A - Fastening screw with star knob on the cylinder-head lug.

Pull back B and C when tightening.

B - Centring piece in groove of the exhaust camshaft

Pull sword bolt (C) back when tightening.

C - Sword bolt

17. Allocate camshafts; to do this, turn the pre-tensioned centre piece accordingly until the sword bolt can be fixed in the bearing bore.

Chrysler Grand Voyager Central Lock Unit

97-220

18. Fasten sprocket wheel. Tightening torque: 14 Nm (10.5 ftlb.).

19. Remove blocking device. Note

The auxiliary chain tensioners must remain fitted on cylinder bank 4 - 6 for the subsequent assembly work.

20. Fit oil extraction pump Note

The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position or direction of rotation must be correct.

Installation position of oil extraction pump at cylinder head i - 3 (flywheel side): The arrow for the direction of rotation or the marking "1 - 3" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws. Tightening torque: 10 Nm (7.5 ftlb.}.

Porsche 997 Variocam

21. Fit camshaft closure cap dry.

22. Fit closure cap on tensioning element (VarioCam).

Tightening torque 10 Nm (7.5 ftlb.).

Removing valve tappets of cylinder bank 4 -S

1. Remove fixing pin. Turn crankshaft clockwise until the bore 1 OT (top dead centre) in the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

997 Crankshaft Locking Pin Position

2. Check camshaft adjustment at cylinder bank 4 - 6:

The groove in the camshaft must face inward toward the crankcase.

Porsche Tool 9632

3. Turn engine by 90° on assembly support until cylinder bank 4 - 6 faces upwards.

4. Unscrew chain tensioner of cylinder bank 4 - 6.

Porsche Tool 9632
67237

5. Remove closure cap from tensioning element (VarioCam). Hexagon-head bolts M6 x 20 (2 ea.).

6. Remove cylinder-head cover. Loosen hexagon-head bolts from the outside to the inside.

7. Fit holding-down device for camshafts, special tool 9611, Use auxiliary screws M6 x 45,

Porsche Variocam Sprocket

97-21S

9. Relieve camshaft tensioning element with tensioning screw, special tool 9632.

Note

Screw tensioning screw in only until the chain is slightly relieved.

10. Unscrew three fastening screws (M6 x 95) for tensioning element.

11. Affix auxiliary chain tensioner (screw in by approx. 3 turns). Undo four hexagon-head bolts (M6 x 15) on the chain sprocket. Remove auxiliary chain tensioner again.

12. Remove drive plate. Connect sprocket wheel and chain with a tie wrap (installation position). With a second tie wrap, suspend the sprocket wheei and chain to the side under slight tension.

986 Chain Tool

13. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.

14. Remove holding-down device (special tool 9611) from the camshafts.

97-21S

8. Detach and remove oil extraction pump at cylinder head 4 - 6 (pulley side).

668_97

15. Carefully lift the complete unit, camshafts with chain and tensioning element, out of the cylinder head. The chain must not jump over. The groove or tab of the camshaft position sensor cover must face downward. If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to: Completing camshafts, Service No. 15 05 33.

16. Lift out valve tappets with a magnet.

17. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside and remove the guide.

Installing valve tappets

1. Check guide for damage.

Refer to: Checking guide for valve tappets, Service No. 15 59 02.

Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque 10 Nm (7.5 ftlb.)

3. Lightly oil the valve tappet and fit it in the guide.

4. Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face downward.

Chain Tightening Devices

5. Fit special tool 9611, holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 fab.).

Porsche Tool 9632

6. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Grease bearing surface, fit bearing saddles in correct position and tighten evenly. Tightening torque 10 Nm (7.5 ftib.)

A2959

E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft

7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ftlb.)

8. Unscrew tensioning screw, special tool 9632, from the tensioning element.

9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.

10. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6 x 15 (10.9). Tighten hexagon-head bolts by hand oniy.

11. Fit auxiliary chain tensioner, special tool 9599, on cylinder head 4 - 6.

Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight. The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.

12. Check whether the auxiliary chain tensioners of cylinder bank 1 - 3 and the auxiliary chain tensioner are fitted on the crankcase half.

Tool 9599 Auxiliary Chain Tensioners

13. Remove holding-down device 9611.

97-218

14. Prepare cylinder-head cover for installation: Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to: Sealing cover for camshaft housing (cylinder-head cover), Service No. 15 91 51.

43C_1_96

Carefully place the cylinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centring pins into the corners of the cylinder head as centring aids.

Immediately remove silicone material emerging in the area of the camshaft closure cap.

15, Fasten blocking device (special tool 9612) on the cylinder head.

Porsche 964 Damaged Cylinder Studs
503.96

Special tool ¡Fitting sequence:

A - Fastening screw with star knob on the cylinder-head lug. Pull back E and C when tightening.

B - Centring piece in groove of the exhaust camshaft. Pull sword bolt (C) back when tightening.

C - Sword bolt

16. Allocate camshafts; to do this, turn the pre-tensioned centre piece accordingly until the sword bolt can be fixed in the bearing bore.

Installation position of oil extraction pump at cylinder bead 4 - S (pulley side): The arrow for the direction of rotation or the marking "4 - 6" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws. Tightening torque 10 Nm (7.5 ftlb.)

Porsche Variocam Sprocket

97-220

668.97

97-220

17. Fasten sprocket wheel. Tightening torque 14 Nm (10.5 ftlb.)

18. Remove blocking device.

19. Fit camshaft closure caps (3 ea.) dry.

20. Fit closure cap on tensioning element (VarioCam).

Tightening torque 10 Nm (7.5 ftlb.)

21. Fit oil supply pump. Note

The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position or direction of rotation must be correct.

22. Unscrew auxiliary chain tensioner, put new sealing ring on the original chain tensioner and install.

Tightening torque SO Nm (59 ftlb.) Allocation of chain tensioners

Porsche Variocam Sprocket

50237

A - Chain tensioner, cylinder bank 4 - 6

identification "Without"

B - Chain tensioner on the crankcase

Identification "1 ring"

C - Chain tensioner, cylinder bank 1 - 3 Identification "2 rings"

installation position of the chain tensioners

(engine in installed position)

Chain tensioner on cylinder bank 1 - 3 509.57

15 ©5 33 Completing camshafts

PreassembEing camshafts

The inlet camshaft, exhaust camshaft, tensioning element (VarioCam) and chain must be pre-assembled before installation in the cylinder head.

Camshaft allocation

Camshafts of cylinder bank 1 - 3

Identification on the camshaft

Inlet camshaft: 221.04/2.5 IN 13

Exhaust camshaft: 222.04/2.5 EX 13

Allocating tensioning elements identification for cylinder bank 1 - 3:

B - So/enoid valve surface colour identification on the camshaft t>/ack

Inlet camshaft: 216.04/2.5 IN 46

Exhaust camshaft: 218.04/2.5 EX 46 Identification for cylinder bank 4 - 6:

1 r

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1

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116.04,''

20 8.04/

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516.97

A = Cyf. bank 4 - 6 B = Solenoid valve surface colour grey

465.97

Move camshafts, chain and tensioning element of cylinder bank 1 - 3 to basic position or installation position.

1. Place the iniet camshaft and exhaust camshaft on a soft surface. The lug of the camshaft position sensor cover or the groove on the iniet camshaft and the dotting marks must face upward.

648.97

2. Place chain on the drive sprockets of the camshafts. The coloured outer lugs of the chain must face the dotting marks.

Porsche Tool 9632

3. Fit tensioning element.

3.1 Press slide rails together and push upward.

Porsche Tool 9632

648.97

3.2 Lift inlet camshaft and insert tensioning element from the front.

Porsche Tool 9632

491_97

635.97

3.2 Lift inlet camshaft and insert tensioning element from the front.

491_97

3.3 Fit chain; when doing so, observe clearance between the gear wheels and the lower slide rail.

635.97

4. Complete unit is preassembled and ready for installation. Do not remove the tension screw, special tool 9632, until the bearing saddles and the chain tensioner have been fastened on the cylinder head. If the allocation is correct, the groove or lug of the camshaft position sensor housing iaces upward.

Porsche Tool 9632

Move camshafts, chair and tensioning element of cylinder bank 4 - 6 to basic position or installation position.

1. The lug of the camshaft position sensor cover or the groove on the inlet camshaft must face upward. The dotting marks must face upward.

Mote

The rotor cover for the camshaft position sensor is no longer installed in vehicles without M660 (OBDil) or M661 (stricter emissions concept).

2. Put on and fit chain as described for cylinder bank 1 - 3.

Porsche Tool 9632
650_97

3. Complete unit is assembled and ready for installation. Do not remove the tension screw, special tool 9632, until the bearing saddles and the chain tensioner have been fastened on the cylinder head. If the allocation is correct, the groove or lug of the camshaft position sensor housing faces downward.

Camshaft Position Sensor Housing

9S6152I

15 31 51 Sealing cover for camshaft housing (cylinder-head caver)

Sealing the cylinder-head cover sealing surface

Use only the sealant Drei Bond silicone, type 1209, to seal the sealing surface on the cylinder-head cover,

Note

After the sealant has been applied, the cylinder head must be joined with the cylinder-head cover within 5 minutes.

Application of silicone bead

At the processing nozzle, cut off the first metering step. Apply a uniform bead approximately 1.5 mm wide to the cleaned sealing surface of the cylinder-head cover.

430_1_96

Applying the sealant on the sealing surface of the cylinder-head cover

Sealing Bead Area
451-96

Apply bead of sealant in the bearing saddle area.

Sealing screw union at the oil pressure duct

If the hexagon-head bolt (arrow) was loosened, the micro-encapsulated hexagon-head bolt must always be replaced. Part number 900.378.163.09 (M6 x 16).

Micro Encapsulated Bolt

671_97

Fastening cover for camshaft ¡housing [cylinder head cover}

Tightening torque: 13 Nm (10.0 ftlb.) Tightening sequence:

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15 5® 02 Checking guide for valve tappets

Before installing the valve tappet guide in the cylinder head, check it for damage or existing defects. The valve tappet guide must be replaced if it displays irregularities deviating from the limit-sample picture.

Limit sample picture

The irregularities shown in the limit sample picture are normal and are not regarded as damage influencing the function of the part or requiring replacement of the part

C = Irregular contact patterns in the running surfaces of the valve tappet guide

D - Grooves in the oil pockets

Permissible irregularities:

B = Fractures at the edges of the running surface of the valve tappet guide

15 4® IS Removoctg and Er.staiEing oi! protection tube - engine snstaäEedl

Tools

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A

Q

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631_97

Item Designation

A Spark-plug wrench

B Internal puller 23.5 - 30 mm 0

C Hand pressure piece, for fitting the oil protection tubes

D Pressure piece, for fitting the oil protection tubes

Special tool commercially available commercially available

9604

9605/1

Explanation

Refer to Workshop Equipment Manual, Chapter 2.4, Nos. 14 + 15

Refer to Workshop Equipment Manual, Chapter 2.4, No. 108

Kesnovliiig EBid installing oil protection ttmlbe - ercgirce DrcsîaUBedl

632.97

15 46 19 Removing and installing oiE protection tube - engine installed

98S1551 Printed in Germany - 16, 1997

Removal

Note

For removal ("Removing oil protection tube"}, the cylinder-head cover must be heated in the area of the oil protection tube. Two different methods can be used for this:

First method: Heat cylinder-head cover in the area of the oil protection tube using an industrial hot-air gun.

Second method: Warm engine up to operating temperature.

The second method is preferrable if no further assembly work has to be performed, e.g. sealing cylinder-head cover, replacing tensioning element [VarioCamJ or replacing the flat-base tappets, etc.

No. Procedure

1 Removing ignition coil

2 Removing spark plugs

Instructions

Lift the vehicle. Pull off plug. Unscrew hexagon socket head screws (wrench size 5) and pull off ignition coil with ignition-coil plug.

Unscrew spark plugs using commercially available socket wrench insert; refer to Workshop Equipment Manual, Chapter 2.4, Nos. 14 and 15.

Note

Only the Snap-on spark-plug wrench, order No. S 9706, and the Snap-on extension, order No. FXW 4, are approved for this work.

3 + 4 Fitting internal puller in the Push internal puller as far as it will go into the oil oil protection tube protection tube. Turn hexagon nut on the threaded rod clockwise until the spreader arms are in position. For improved representation, drawing No. 4 shows the removed oil protection tube with the internal puller spread.

Installation

No. Procedure

5 Pulling off oil protection tube

Instructions

Fit washer (approx. 40 mm 0) and hexagon nut (M10) on the threaded rod. Press oil protection tube outward using two mounting levers, always using a suitable wooden support.

6 Fitting oil protection tube

Fit new sealing rings and coat with tyre mounting paste. Using the pressure piece (special tool 9605/1) and hand pressure piece (special tool 9604), manually press in the oil protection tube as far as it will go.

Fitting spark plug Fit spark plug with the prescribed spark-plug wrench.

Fitting ignition coil Tightening torque 10 Nm (7.5 ftlb.)

15 46 19 Removing and installing oil protection tube - engine installed 93S15S1 Printed in Germany - 16, 1997

15 46 19 Removing aord installing oi!

Removal

Remove the cylinder-head cover, heat upper area with a hot-air gun and press the oil protection tube out.

Installation

1. Coat sealing rings with tyre mounting paste. Push tube onto pressure piece, special tool 9605. Place hand pressure piece, special tool 9604, onto the pressure piece.

protection tube - engine removed]

2. Manually press the oil protection tube as far as it will go into the fitted cylinder-head cover.

Picture Porsche 986 Engine

15 5£ 2© Removing and installing va [ye tappets - engine instated Tools

Porsche 986 Timing Tensioner Tool

Item

Designation

Special tool

Explanation

A

Fixing pin for pulley

9595

1 set = 2 ea. (use short fixing pin)

B

Auxiliary chain tensioner for valve timing adjustment

9599

1 set - 3 ea.

C

Locking device for camshafts in timing position

9612

D

Ring wrench (32 mm}

E

Holding-down device for camshafts

9634

F

Holding-down device for camshafts

9611

1 set = 4 ea.

6.4 Undo the compressor fastening screw between the intake pipes of cylinders 4 and 5.

6.7 Lift the air-conditioning compressor with the connected lines out of the engine compartment and place on a wooden surface on the centre tunnel or console.

6.5 Undo the 8+ connection (box) on the engine and put it aside.

6.6 Suck out fluid from power steering reservoir until level is below the joint. Open bayonet lock and remove the reservoir. Close opening.

7. Remove the rear wheels.

8. Remove right and left diagonal braces.

9. Remove rear support sheet.

2S-96

10. Detach and remove exhaust manifold of cylinder head 4 - 6.

715_97

707_97

14. Drain engine oil.

Surgical Treatment Rectal Prolapse

717_97

497-96

10. Detach and remove exhaust manifold of cylinder head 4 - 6.

715_97

11. Unclip oxygen-sensor plug from the brackets of the rear-axle support.

12. Detach cable between engine and rear-axle support at the rear-axle support.

717_97

13. Detach rear-axle support and remove to the side.

707_97

14. Drain engine oil.

Removing valve tappeis of cylinder bank 1 - 3

1. Move camshafts of cylinder bank 1 - 3 to basic position or removal position. Turn crankshaft clockwise until the bore 1 OT (top dead centre} in the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

497-96

View from the flywheel side 52537

4. Unscrew chain tensioner of cylinder bank 1 - 3.

Pulley Side View Drawing
Drawing shows closure cap of cylinder 60237 bank 4 - 6 (pulley side)

3. Check basic camshaft adjustment of cylinder bank 1 -3 .

The groove in the camshaft must face outward toward the cylinder-head cover.

Note

The basic camshaft adjustment can be checked only after removal of the camshaft closure caps.

2. Remove camshaft closure caps above the cylinder-head oii pumps. The closure cap of cylinder bank 1 - 3 is located on the flywheel side and the closure cap of cylinder bank 4 - 6 is located on the pulley side. Drive awl into centre of the closure cap and lever off the cap.

View from the flywheel side 52537

If the position of the camshafts is incorrect, remove fixing pin at the pulley and rotate the crankshaft 360° clockwise. Then position or fix the fixing pin in the bore (1 OT) and in the fixing bore in the crankcase again.

4. Unscrew chain tensioner of cylinder bank 1 - 3.

/nsta/lafion position of chain tensioner 509.97 on cylinder bank 1 - 3

5, Detach arid remove oil extraction pump at cylinder head 1 - 3 - on the flywheel side.

5, Detach arid remove oil extraction pump at cylinder head 1 - 3 - on the flywheel side.

Chinese New Year Money Envelope Template

713.97

713.97

6. Separate plug connection of the tensioning element (VarioCam).

7. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).

8. Remove ignition coils, spark plugs and oil protection tubes.

Note

As the available space is limited, the oil protection tubes must be removed before the cylinder-head cover can be removed, "Removing and installing oil protection tube": refer to Group 1, Service No. 15 46 19.

9. Remove the camshaft closure caps from the passenger compartment side. Drive awl into centre of the closure cap and lever off the cap.

10. Fit special tool, holding-down device 9624, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 30.

Porsche Tool 9632

11. Remove cylinder-head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach cylinder-head cover by tapping lightly with a plastic hammer.

12. Additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.

13. Relieve camshaft tensioning element with special tool, tensioning screw 9632. Screw tensioning screw in only until the chain is slightly relieved.

Porsche Tool 9632
723-97

16. Remove drive plate. Remove sprocket wheel and chain and connect with a tie wrap (installation position).

Porsche Tool 9632

724.97

Porsche Tool 9632

65B_97

724.97

14. Unscrew three fastening screws (M6 x 95) for tensioning element.

15. Affix auxiliary chain tensioner (screw in by approx. 3 turns). Undo four hexagon-head bolts (M6 x 15) on the chain sprocket. Remove auxiliary chain tensioner again.

65B_97

17. Detach bearing saddles and lever out of the guide sleeves.

Preliminaiy work for vafve tapraei removal

1. Disconnect battery.

2. Set up and secure convertible top compartment lid.

3. Remove top engine-compartment cover,

4. Remove left-hand seat.

5. Remove rear wall lining and rear wall cover Put on floor protection cover.

986 Engine Cover Removal

6. In vehicles with air conditioning, the following additional operations must be performed:

6.1 Remove drive belt. Mark the running direction of the belt with a coloured pen. Relieve the belt tension. To do this, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the drive pulleys.

Hydraulic Tappet Screw Plug
275-96

6.2 Remove pulley of the hydraulic pump.

6.3 Undo the front compressor fastening screws (2 ea.) and disconnect the electrical plug connection.

Hydraulic Tappet Screw Plug

18. Remove special tools, holding-down devices 9611 and 9624, and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder head. The chain must not jump over during this operation; reallocate if necessary.

246_97

19. Lift out valve tappets with a magnet.

20. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside and remove the guide.

installing valve tappets of cylinder bank 1-3

1. Check guide for damage.

Refer to: Checking guide for valve tappets, Service No. 15 59 02.

2. Fit guide. Tighten pan-head screws {M6 x 35) from the inside to the outside.

Tightening torque: 10 Nm (7.5 ftib.)

3. Lightly oil the valve tappets and fit in the guide.

4. Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face outward In installed position.

If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to: Completing camshafts, Service No. 15 05 33.

659 97

246_97
Porsche 986 Torque Chart

246_97

5. Fasten special tool, holding-down device 9511, with auxiliary screws M6 x 45.

659 97

6. Fit special tool, holding-down device 9624, on the cylinder head using a hexagon-head bolt M8 x 30.

Porsche Tool 9632
633.97

7. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ftlb.)

E39S9

19473

A3959 i

E = Bearing saddle for inlet camshaft 4oi_u6 A = Bearing saddle for exhaust camshaft

8. Fit tensioning element (VarioCam), Tighten 3 M6 x 95 pan-head screws.

Tightening torque: 10 Nm (7.5 ftlb.).

9. Unscrew tensioning screw, special tool 9632, from the tensioning element.

10. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.

11. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolt M6 x 15 (10.9).

Tighten hexagon-head bolt by hand only.

12. Unscrew chain tensioner (fitted on the crank-case half of cylinder bank 4 - 6) and fasten auxiliary chain tensioner (special tool 9599}. Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight.

The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.

14. Fit cylinder-head cover. Remove holding-down device 9611. Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to: Sealing cover for camshaft housing (cylinder-head cover), Service No. 15 91 51.

13. Fit auxiliary chain tensioner on cylinder head 1 - 3 and adjust pre-tension force (refer to step 12).

430_1_96

Carefully place the cylinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centring pins into the corners of the cylinder head as centring aids. Tightening torque: 13 Nm (10.0 ftlb.)

B - Centring piece in groove of the exhaust camshaft Pull back sword bolt (C) when tightening.

C - Sword bolt

Arte Romero Brito Para Colorir

16, Fasten blocking device (special tool 9612) on the cylinder head.

503.96

Special-tool fitting sequence:

A - Fastening screw with star knob on the cylinder-head lug. Pull back centring piece (B) and sword bolt (C) when tightening.

B - Centring piece in groove of the exhaust camshaft Pull back sword bolt (C) when tightening.

C - Sword bolt

Immediately remove silicone material emerging in the area of the camshaft closure cap.

15. For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595).

16, Fasten blocking device (special tool 9612) on the cylinder head.

2005 Hpop Cover Gasket

713_97

503.96

713_97

17. Allocate camshafts; to do this, turn the pre-tensioned centre piece accordingly until the sword bolt can be fixed in the bearing bore.

Lawn Mower Drawing

18. Fasten sprocket wheel. Tightening torque: 14 Nm (10.5 ftlb.)

19. Remove blocking device. Note

The auxiliary chain tensioners must remain fitted on cylinder bank 4 - 5 for the subsequent assembly work.

20. Fit oil extraction pump. Note

The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position or direction of rotation must be correct.

Installation position of oil extraction pump at cylinder head 1 - 3 (flywheel side}: The arrow for the direction of rotation or the marking "1 - 3" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws.

Tightening torque: 10 Nm (7.5 ftlb.).

Visual Example Phonation

21. Fit camshaft closure cap dry.

22. Fit closure cap on tensioning element (VarioCam).

Tightening torque: 10 IMm (7.5 ftlb.).

Removing valve tappeis of cylinder bank 4 -S

1. Remove fixing pin. Turn crankshaft 360° clockwise until the bore 1 OT (top dead centre) in the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

497-96

2. Check camshaft adjustment at cylinder bank 4 - 6:

The groove in the camshaft must face inward toward the crankcase,

Open And Closed Books Clip Art
3. Unscrew chain tensioner of cylinder bank 4 - 6.

4. Detach and remove oil extraction pump at cylinder head 4 - 6 (pulley side).

5. Separate plug connection of the tensioning element (VarioCam).

6. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).

7. Remove ignition coils, spark plugs and oil protection tubes.

Note

As the available space is limited, the oil protection tubes must be removed before the cylinder-head cover can be removed. "Removing and installing oil protection tube": refer to Group 1, Service No, 15 45 19.

8. Remove the camshaft closure caps from the underside of the vehicle. Drive awl into centre of the closure cap and lever off the cap.

9. Fit special tool, holding-down device 9624, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 30.

Letter Pic
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10. Remove cylinder-head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach cylinder-head cover by tapping lightly with a plastic hammer,

11. Additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.

12. Relieve camshaft tensioning element with tensioning screw, special tool 9632, Screw tensioning screw in only until the chain is slightly relieved.

13. Unscrew three fastening screws (M6 x 95) for tensioning element.

14. Affix auxiliary chain tensioner (screw in by approx. 3 turns). Undo four hexagon-head bolts (M6 x 15} on the chain sprocket. Remove auxiliary chain tensioner again.

Porsche Tool 9632

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15. Remove drive plate. Remove sprocket wheel and chain and connect with a tie wrap for the subsequent installation position.

Porsche Tool 9632

18. Lift out valve tappets with a magnet.

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18. Lift out valve tappets with a magnet.

19. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside and remove the guide.

15. Remove drive plate. Remove sprocket wheel and chain and connect with a tie wrap for the subsequent installation position.

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16. Detach bearing saddles and lever out of the guide sleeves.

17. Remove special tools, holding-down devices 9611 and 9624, and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder heads. The chain musi not jump over during this operation; reallocate if necessary.

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Installing waive tappets of cylinder bank 4 - 6

1. Check guide for damage.

Refer to: Checking guide for valve tappets, Service No. 15 59 02.

2. Fit guide. Tighten pan-head screws {M6 x 35} from the inside to the outside.

Tightening torque: 10 Nm (7.5 ftlb.)

3. Lightly oil the valve tappets and fit in the guide.

4. Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face outward in installed position.

If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to: Completing camshafts, Service No. 15 05 33.

5. Fasten special tool, holding-down device 9611, with auxiliary screws M6 x 45.

6. Fit special tool, holding-down device 9624, on the cylinder head using a hexagon-head bolt M8 x 30.

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7. Check dowel sleeves (4 ea.} of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ftlb.)

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