Installing Camshafts - Cylinder Bank 1 - 3

In order to remove the play from the control chain drive, turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to 60° before TDC (identification U6 on the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.

Fig 1: Identifying U6 On Belt Pulley
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Turn the engine at the assembly support until the cylinder bank 1 - 3 stands vertically upwards.
Oil the bearing surfaces of the camshafts with new engine oil.
Insert inlet camshaft 1-3. If necessary, pre-assemble the inlet camshaft. See DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT - AS OF MY 2003 . Pull the control chain out of the chain housing of the cylinder head, e.g. with a welding wire, and position on the toothed ring of the camshaft adjuster, at the same time inserting the camshaft at overlapping TDC of cylinder 1 -arrow- (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head). See Fig 2.

Fig 2: Locating Camshaft Lobes Of Cylinder 1 Point Diagonally Downwards Towards The Outside Of The Cylinder Head
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Make sure that the bearing sleeve of the inlet camshaft is positioned correctly.
The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points vertically upwards (the rib of the cylinder head should also be at the Centre in relation to the bearing sleeve). In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite off-centre blind hole bore. Any other bores are through-holes for guiding the oil.

Fig 3: Locating Centrally Bored Blind Hole Points
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Insert exhaust camshaft 1-3. Lay the control chain on the flange for the chain sprocket, then insert the camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head).

Fig 4: Locating Camshaft Lobes Of Cylinder 1 Pointing Diagonally Downwards Towards The Outside Of The Cylinder Head
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Install the chain sprocket of the exhaust camshaft. Insert the chain sprocket in the control chain, then position on the camshaft flange. The 4 threaded bores in the camshaft flange must be fully visible on the left at the slot curves of the chain sprocket, so that the 4 M6 x 12 hexagon-head bolts can still be positioned to fasten the chain sprocket.

Fig 5: Locating Holes On Chain Sprocket
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 6: Identifying Chain Sprocket Hexagon-Head Bolts
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly. Observe the identification. See Figure.
  
  Fig 7: Locating Camshaft Identification Marks
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
- Designation of inlet camshaft bearing: thrust bearing: E and pairing number on cylinder head/cylinder head cover, bearing cover of the bearing sleeve: only pairing number.
- Designation of exhaust camshaft bearing: thrust bearing on chain sprocket: 1A and pairing number on cylinder head/cylinder head cover, 2nd thrust bearing: 2A and pairing number on cylinder head/cylinder head cover.
Insert 3 thrust bearings and 1 bearing cover for the bearing sleeve of the camshafts with the guide rail for the control chain. 8 bearing screws, hexagon socket: Position 6 M6 x 35 and 2 M6 x 40 for camshaft bearing and guiderail and tighten slightly. See Fig 8 and Fig 9.

Fig 8: Locating Bearing Cover Screws

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 9: Locating 6 M6 x 35 and 2 M6 x 40 For Camshaft Bearing

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Align camshafts. On both camshafts, the smaller circular cutout must lie at the top (arrows). If necessary, shift the camshafts slightly.

Fig 10: Locating Smaller Circular Cutout
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fix the camshafts with special tool (adjustment gauge) 9686 and fasten the gauge with 1 M8 auxiliary screw (e.g. M8 x 16 hexagon-head bolt) (flat tool surface should face upwards). Only tighten the screw slightly.

Fig 11: Installing Special Tool (9686)
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Screw the bearing cover screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment gauge alternately by another approx. 90° until the specified tightening torque of 10 Nm (7.5 ft.lb) is reached.
Tightening torque 10 Nm (7.5 ft.lb)
Fit the chain tensioner, side 1-3 (hexagon socket a/f 32). Replace sealing ring. Position the chain tensioner with new sealing ring and tighten to the specified torque.

Fig 12: Locating Chain Tensioner, Side 1-3
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ft.lb.)
NOTE:
- Move the engine at the belt pulley of the crankshaft to the TDC marking without fail.
Turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to the TDC marking (the TDC bore in the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.

Fig 13: Installing Special Tool (Fixing Pins) 9595/1 Into Belt Pulley
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tighten the 4 M6 x 12 hexagon-head bolts for the chain sprocket of the exhaust camshaft crosswise to the specified torque.
Tightening torque 14 Nm (10.5 ft.lb.)

Fig 14: Identifying Hexagon-Head Bolts For Chain Sprocket
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Replace central screw for camshaft adjustment device.
Tighten the central screw of the camshaft adjusting device. Position the special tool (retaining tool) 9685 on the adapter of the central screw and place the loose contact block at the fitting bore of the oil extraction pump. Tighten the hexagon-head bolt on the contact block.

Fig 15: Tightening Central Screw Of The Camshaft Adjusting Device
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tighten the new central screw in two stages.
1st stage: pre-tightening torque 50 Nm (37 ft.lb)

Fig 16: Tightening New Central Screw
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Before the final tightening of the central screw, remove the special tool (adjustment gauge) 9686 without fail.
Remove special tool (adjustment gauge) 9686. Unscrew the M8 auxiliary screw and pull off the gauge.
2nd stage: final tightening of central screw with torque angle wrench 110° turn.
NOTE:
- Replace the seals for the spark plug recesses.
Replace the 3 seals for the spark-plug recesses.

Fig 17: Locating Seals For The Spark-Plug Recesses
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Only if the camshaft adjustment valve was removed:
- Replace oil strainer -arrow-. See Fig 18.
  
  Fig 18: Replacing Oil Strainer
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
- Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore).
Install cylinder head cover. See REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003 .
NOTE:
- Replace O-ring in the oil extraction pumps.
- Do not tilt oil extraction pump when inserting it. Otherwise, the fitting bore on the cylinder head/cylinder head cover could be damaged.
- Pay attention to the installation position!
Fit oil extraction pump with new O-ring. Insert oil extraction pump carefully in the fitting bore on the cylinder head (installation position: Identification -1 - 3- faces crankcase). Position 4 M6 x 20 hexagon-head bolts on cylinder head and cylinder head cover and tighten to the specified torque.

Fig 19: Identifying Oil Extraction Pump Identification Mark
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 13 Nm (9.5 ft.lb)
NOTE:
- Replace all plastic closure caps on the cylinder head/cylinder head cover.
Place a new, brown, dry closure cap (45 mm) on the large bore for the exhaust camshaft and tap it in gently with a plastic hammer.
Insert 2 new, green, dry closure caps into the small bores on the cylinder head and tap them in gently with a plastic hammer.
NOTE:
- Replace cover with integral seal for camshaft adjustment valve.
Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to valve.
Tightening torque 10 Nm (7.5 ft.lb)
Install ignition coils. Insert 3 ignition coils into the spark-plug recesses, position 2 M6 x 25 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to ignition coils.
Tightening torque 10 Nm (7.5 ft.lb)
Connect cable plug to oil pressure sensor.