Installing Camshaft Controller

→ Do not turn the engine without camshaft controllers.

→ Counter the camshafts at the hexagon when tightening the camshaft controllers.

Information 

• Pay attention to marking and allocation of camshaft controllers to camshafts! 
• Do not interchange camshaft controllers! 
• Always replace all fastening screws for the sprockets. 

1. Install camshaft controllers. Guide the timing chain around the components at the same time.
   1. 1.1. Check the position of the camshafts.

      Camshaft bar T10068A  must fit into the grooves on the intake and outlet camshafts

      Cylinder 1 must be set to compression TDC. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES 

      Fig 1: Identifying Camshaft Bar

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 1.2. Secure drive gear wheel for high-pressure pump using adjusting tool T10363 -3-  . Make sure that the marking -1-  on the drive cam for the high-pressure pump is pointing straight up. Fit adjusting tool with a fastening screw and tighten hand-tight -2-  .
      Fig 2: Securing Drive Gear Wheel For DFI High-Pressure Pump

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 1.3. From now on, read and follow the details and instructions for setting the timing → 150516 SETTING THE TIMING ON V6 DFI ENGINES  and → 150502 CHECKING THE TIMING ON V6 DFI ENGINES .

      Information 

      Tips for fitting the camshaft controllers: 

      • The two camshaft controllers (identified by "24E" on the intake side and "32A" on the outlet side) can be screwed onto the camshaft mounting in one position only because of a dowel pin. 
      • Turn the sensor wheel 1 on the removed intake camshaft controller as far as it will go to the right. Hold the controller at this position. It must be possible to fit the controller easily on the intake camshaft with the camshaft roller chain set "tightly" and then tighten it hand-tight. 
      • The outlet camshaft controller is locked in >> idle state <<. As a result, the sensor wheel will not turn when you set the timing. If the locking mechanism is not engaged (locked) in "idle state", the controller must be turned in both directions by hand until it locks. If this is not possible, replace the camshaft controller. 
      • There must be exactly 16 rollers between the markings on the camshaft controllers "24E" and "32A" and the markings must be flush with the FSI marking. →  150502 CHECKING THE TIMING ON V6 DFI ENGINES  
   4. 1.4. Turn sensor wheel -1-  on the intake camshaft controller as far as it will go to the right. Then position intake camshaft controller on the camshaft and fix in place with the fastening screw. The fastening screw must always be replaced.
      Fig 3: Rotating Sensor Wheel On Intake Camshaft Controller

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 4: Overview Of Timing Chains

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   5. 1.4.1. Counter the camshaft at the hexagon with an open-ended wrench.

      Tighten fastening screw -22-  with a torque wrench → Tightening torque: 60 Nm (44 ft lbs.)  and then tighten further to → Torque angle: 90°  .

      Fig 5: Tightening Camshaft Hexagon Fastening Screw

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   6. 1.5. Place outlet camshaft controller on the camshaft. Place timing chain over the sprocket on the outlet camshaft controller -4-  . Fix the outlet camshaft controller in place with the fastening screw -22-  . The fastening screw must always be replaced  .
   7. 1.5.1. Counter the camshaft at the hexagon -arrows- with an open-ended wrench (a/f 27).

      Tighten the fastening screw with a torque wrench → Tightening torque: 60 Nm (44 ft lbs.)  and then tighten further to → Torque angle: 90°.

2. Tension the timing chain.
   1. 2.1. Fit tensioning rail -8-  for the chain tensioner on the timing chain.
   2. 2.2. Fit guide rail -23-  on the timing chain and fit the screw -21-. → Tightening torque: 23 Nm (17 ft lbs.). 
   3. 2.3. Sealing ring -10-  on the chain tensioner -9- must always be replaced  .
   4. 2.3.1. Then tighten the chain tensioner with a torque wrench. → Tightening torque: 40 Nm (30 ft lbs.). 
   5. 2.4. Camshaft bar T10068A  must now be removed.
   6. 2.5. Adjusting tool T10363  must be removed from the drive gear wheel for the high-pressure pump.
3. After you have fitted the timing chain, turn the crankshaft twice and check the timing. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES . Adjust the timing if necessary. → 150516 SETTING THE TIMING ON V6 DFI ENGINES