Installing Cylinder Head Cover - Cylinder Banks 1-3 And 4-6

NOTE:

The sealing surfaces of the cylinder heads and the cylinder head covers must be cleaned before the new sealant is applied. Avoid damage!

Clean sealing surfaces. Remove any sealant residue from the sealing surfaces on the cylinder head and the cylinder head cover thoroughly. Then rub down with a clean cloth soaked in a decreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head.
NOTE:
- Replace the seals for the spark-plug recesses.
Insert the 3 seals for the spark-plug recesses.

Fig 1: Locating Spark Plug Seals
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Only if the camshaft adjustment valve was removed:
- Replace oil strainer -arrow-. See Fig 2.
  
  Fig 2: 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).
Only the following sealants may be used to seal the cylinder head cover (these are available from the Porsche Parts Service):
- "Drei Bond" silicone - type 1209
- Loctite 5900
Fix cylinder head cover. Apply a thin bead of sealant on the cylinder head cover. See Fig 3. The bead should not be higher than 1.5 mm.

Fig 3: Applying Thin Bead Of Sealant On Cylinder Head Cover
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- If the O-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder head cover and then position the 4 M6 x 20 hexagon-head bolts.
- Identification on the oil extraction pump in Fig 4 cylinder side 1-3 faces the crankcase.
Fig 4: Identifying Mark On Oil Extraction Pump
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit 20 M6 x 30 hexagon-head bolts on the cylinder head cover and 2 or 4, M6 x 20 hexagon-head bolts for the oil extraction pump. See Fig 5
Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque.

Fig 5: Cylinder Head Cover Tightening Torque Sequence
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 13 Nm (9.5 ft.lb)
Tighten 2 or 4 M6 x 20 hexagon-head bolts of the oil extraction pump to the specified torque.
Tightening torque 13 Nm (9.5 ft.lb)
NOTE:
- Replace all plastic closure caps on the cylinder head/cylinder head cover joint.
For each cylinder head, place a new, brown, dry closure cap (45 mm) on the bore for the exhaust camshaft and tap it in gently with a plastic hammer.
Insert 2 new, green, dry closure caps for each cylinder head into the small bores and tap them in gently with a plastic hammer.
NOTE:
- Replace cover with integral seal for the 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)
Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Unscrew 2 M6 x 25 pan-head screws for each ignition coil hexagon socket a/f 5) on the cylinder head cover and tighten to the specified torque. Connect cable plug to ignition coils.
Tightening torque 10 Nm (7.5 ft.lb.)
Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.

TIGHTENING TORQUES - CYLINDER HEAD COVER, AS OF MY 2003

Location	Thread	Tightening torque Nm (ft.lb)
Hexagon-head bolt for cylinder head cover	M6 x 30 (10.9)	13 (9.5)
Hexagon-head bolt for oil extraction pump	M6 x 20 (10.9)	13 (9.5)
Pan-head screws for hydraulic valve holder and cover (hexagon socket a/f 5)	M6 x 20	10 (7.5)
Pan-head screws for ignition coils (hexagon socket a/f 5)	M6 x 25	10 (7.5)