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Removing Camshafts, Cylinder Bank 4 - 6

  1. Remove air conditioning compressor. Refer to REMOVING AND INSTALLING THE COMPRESSOR .
  2. Remove the holder for the servo line.
  3. Remove 3 ignition coils. Pull off the cable plug on the ignition coils. Unscrew the two M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess.
    NOTE:
    • If the camshaft adjustment valve is to be removed, the O-ring and the oil strainer must be replaced.
    • The cover with integral seal for the camshaft adjustment valve must also be replaced.
  4. Pull off the cable plug on the camshaft adjustment valve. Remove the holder and the cover for the valve on the cylinder head cover. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the camshaft adjustment valve from the sheetmetal bracket and remove the holders. Pull off the valve cover.
  5. Remove the oil extraction pump and the brown closure cap (45 mm). Unscrew the 4 M6 x 20 hexagon-head bolts on the oil extraction pump and remove the pump carefully (do not damage the fitting bore). Push a small screwdriver into the Centre of the closure cap and lever off the cover.
    Fig 1: Identifying Oil Extraction Pump Identification Mark
    G03092377Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Remove 2 green closure caps. Press a small screwdriver into the Centre of the piercing point of the closure cap and lever off the cover.
  7. Turn the engine clockwise at the belt pulley of the crankshaft to the overlapping TDC of cylinder 4. Fix with special tool (fixing pins) 9595/1. At this point, the smaller circular cutout on the cut grooves of the inlet and exhaust camshafts on cylinder 1 must point towards the cylinder head cover. See Fig 2.(check with adjustment gauge 9686). If this is not the case, turn the engine through another 360° as described above.
    Fig 2: Fixing Crankshaft Belt Pulley With Special Tool 9595/1
    G03092378Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 3: Positioning Camshafts In Overlapping TDC Of Cylinders 1 or 4
    G03092379Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Before disassembling the cylinder head cover, it is essential to unscrew the central screw on the camshaft adjustment device.
  8. Unscrew the central screw on the camshaft adjustment device. Position the retaining tool 9685 on the hexagon of the adapter and place the contact block of the tool on the fitting bore of the cylinder head cover for the oil extraction pump; if necessary, position the contact block by undoing and tightening the hexagon-head bolt. If the special tool can not be positioned in this way, the engine must be turned further in the direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the cylinder head cover. Unscrew the central screw.
    Fig 4: Identifying Central Screw On Camshaft Adjustment Device
    G03092380Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Unscrew the 4 M6 x 16 hexagon-head bolts on the chain sprocket of the exhaust camshaft. Do not remove the chain sprocket.
    CAUTION: When levering off the cylinder head cover, the cast lugs may break.
  10. Remove the cylinder head cover. See REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003 .
  11. Turn the engine at the assembly support so that cylinder bank 4 - 6 stands vertically upwards.
  12. Remove the chain tensioner, side 4-6. See Fig 5. Hexagon socket a/f 14. Requirement: servo-tank, air conditioning compressor and holder for the servo line are removed.
    Fig 5: Locating Chain Tensioner, Side 4-6 Hexagon Socket
    G03092381Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. Unscrew the guide rail screw of cylinder bank 4 - 6 (belt pulley side), hexagon socket a/f 6.
  14. Remove the chain sprocket of the exhaust camshaft 4 - 6. Lift control chain off the chain sprocket and remove the chain sprocket. Lay the control chain on the mounting tab for the chain sprocket.
  15. Remove the 4 camshaft bearings and the guide rail. Unscrew 8 pan-head screws (hexagon socket a/f 5): 6 M6 x 35, 2 M6 x 40.
  16. Remove camshafts. Remove the exhaust camshaft 4 - 6, lift the control chain off the camshaft adjuster of the inlet camshaft 4 - 6 and remove the camshaft. Lay the control chain in the chain housing in the cylinder head.
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