Installing Camshafts, Setting Timing - Cylinder Bank 1-3

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NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

CAUTION: Timing chains positioned incorrectly

Too much wear on sprockets and timing chains
Engine damage

→ Perform a visual inspection to check the position of the timing chains on the tensioning and guide rails.

Information

Before final tightening (torque angle) of the central screws, the special tool staking tool 9772 must be removed.

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

Torx screws: (E..) for external Torx, (T..) for internal Torx.
Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

Continue to turn the crankshaft clockwise (running direction of engine) to 60° before TDC at the vibration damper.
1. 1.1. This position is marked U 3/6 on the surface.
2. 1.2. Fix using a long Locating Pin 9595/1 -1- .
  
  Fig 1: Identifying Marked Position And Locating Pin 9595/1
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Turn the engine on the assembly support until cylinder bank 1-3 is at the top.
Fit lower part of bearing saddle -1- .
1. 3.1. Check position of oil bores and position and fit the component on the dowel sleeves.
  
  Fig 2: Identifying Lower Part Of Bearing Saddle 1-3
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of OptimolOptipit grease (Part No. 000.043.204.17) on the bearings.
1. 4.1. Check that all bucket tappets are installed correctly.
Fit the outlet camshaft and sprocket.

Fig 3: Identifying Outlet Camshaft And Sprocket (Cylinder Bank 1-3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 5.1. Check that the friction plate is fitted in the sprocket.
  
  Fig 4: Identifying Friction Plate In Sprocket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Screw in the central screw but make sure that the sprocket can still turn slightly.
3. 5.3. Lift the timing chain and position the camshaft and sprocket at the overlapping position of cylinder 1. The cams must be facing downwards at an angle with respect to the cylinder head wall and the camshaft must lie loosely in the bearing positions.
4. 5.4. Another feature is the data matrix code marking on the reconditioned surface next to the dihedron -inset- . These markings must be facing the observer at overlapping position.
  
  Fig 5: Identifying Marking On Camshafts 1-3 At Overlap
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the intake camshaft.
1. 6.1. Check that the friction plate is fitted on the shaft.
  
  Fig 6: Identifying Position Of Friction Plate On Intake Camshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 6.2. Lift the timing chain and engage and secure the camshaft controller. Guide the intake camshaft into the controller and set it to the overlapping position of cylinder 4. The cams must be facing downwards at an angle with respect to the spark-plug recess and the camshaft must lie loosely in the bearing positions.
  
  Fig 7: Identifying Intake Camshaft With Camshaft Controller
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 6.3. The square marking on the camshaft must be facing the observer.
4. 6.4. Screw in the internal Torx central screw (T55, M12 x 1.5 x 110) loosely by hand so that the controller can still turn.
Check cam position of cylinder 1 before fitting the bearing saddle and bearing covers. The cams must be facing the cylinder head wall and must point downwards at an angle.
1. 7.1. Check the position of the outlet sprocket again (position of driver for high-pressure pump).
Use a torch to check that the timing chains are on the tensioning and guide rails between the guide pins -arrow- .

Fig 8: Locating Guide Pins On Tensioning And Guide Rails
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of OptimolOptipit grease (Part No. 000.043.204.17) on the bearings.
Fit bearing saddle and bearing covers.
1. 10.1. Fit bearing saddle and bearing covers and observe markings.
2. 10.2. Fit four external Torx screws (E10, M6 x 55) on the bearing saddle.
3. 10.3. Fit two external Torx screws (E10, M6 x 37) on each of the bearing covers.
4. 10.4. Fit and tighten screws according to the specified tightening sequence.
  → Initial tightening torque for bearing covers and bearing saddle: 5 Nm (3.5 ft. lb.)
  
  → Re-tightening bearing covers and bearing saddle: 5 Nm (3.5 ft. lb.)
  
  → Final tightening torque angle for bearing covers and bearing saddle: 50 °
  
  Fig 9: Tightening Sequence For Mounting Camshafts 1-3
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
1. 11.1. There must be perceptible clearance because otherwise the shafts will have to be fitted again.
Screw in and tighten chain tensioner with a new seal.
→ Tightening torque for chain tensioner: 80 Nm (59 ft. lb.)

Set the timing, cylinder bank 1-3: Essentially, the timing for cylinder bank 1-3 is set in the same way as for cylinder bank 4-6.
Check cam position for cylinder 1 and markings again.

Fig 10: Identifying Cam Position For Cylinder 1 At Overlap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 11: Identifying Marking On Camshafts 1-3 At Overlap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The adjusting device is positioned on the reconditioned dihedron of the camshafts -arrows- .

Fig 12: Locating Position Of Dihedron Of Camshafts 1-3
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 14.1. Check the position of the intake and outlet side.
  1. A - A = Outlet
  2. E - E = Intake
  1. Staking tool
  2. Staking guide
    
    Fig 13: Locating Fitting Position Of Staking Tool For Cylinder Bank 1-3
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit special tool Staking Tool 9772 on the cylinder head and camshafts.
1. 15.1. Secure on the cylinder head with four screws (M6 x 25) and tighten screws hand-tight.
  
  Fig 14: Identifying Staking Tool Screws For Cylinder Bank 1-3
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten adjusting screw on the staking tool by turning it clockwise.
→ Tightening torque for adjusting screw: 10 Nm (7.5 ft. lb.)

Fig 15: Tightening Adjusting Screw On Staking Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Turn the crankshaft clockwise (running direction of engine) to the TDC marking at the vibration damper.
1. 17.1. This position is marked TCD 1/4 on the vibration damper.
2. 17.2. Fix using a long Locating Pin 9595/1 .
  
  Fig 16: Fixing Vibration Damper Using Locating Pin 9595/1
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten central screws for sprocket and camshaft controller to the prescribed initial tightening torque.

Fig 17: Identifying Central Screws On Camshaft Timing Gears
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 18.1. Tighten central screw on sprocket -1- initially, countering with a holding wrench 9775 .
  → Initial tightening torque for central screw on outlet sprocket: 30 Nm (22 ft. lb.)
2. 18.2. Tighten central screw on camshaft controller -2- initially, countering with a long open-ended wrench (a/f 32) at the driver -3- .
  → Initial tightening torque for central screw on camshaft controller: 35 Nm (26 ft. lb.)
Remove special tool staking tool 9772 .
1. 19.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the tool.
2. 19.2. Unscrew fastening screws on the cylinder head and remove the tool.
Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.
1. 20.1. Tighten central screw on sprocket and counter with a Holding Wrench 9775 -1- while doing this.
  → Final tightening torque angle for central screw on outlet sprocket: 65 °
  
  Fig 18: Tightening Central Screws On Sprocket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 20.2. Tighten central screw on camshaft controller, countering with a long open-ended wrench (a/f 32) -1- .
  → Final tightening torque angle for central screw on camshaft controller: 125 °
  
  Fig 19: Tightening Central Screw On Camshaft Controller
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Then check the position of the camshafts on both sides again (pay attention to overlapping position).
1. 21.1. It must be possible to screw in the adjusting screw by hand at the Staking Tool 9772 .
2. 21.2. Remove the tool and complete the engine.