Adjusting timing, side 1 - 3

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

Fig 1: Aligning Camshaft Smaller Circular Cutouts At The Top (Cylinder Bank 1-3)
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Fix the camshafts with special tool adjustment gauge 9686 and fasten the gauge with one M8 auxiliary screw (e.g. M8 x 16 hexagon-head bolt) (flat tool surface should face upwards). Only tighten the screw slightly.

Fig 2: Fixing Camshafts With Special Tool
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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 ftlb.) is reached.
Tightening torque: 10 Nm (7.5 ftlb.)
Fit the chain tensioner, side 1-3 (hexagon socket a/f 32s). Replace sealing ring. Position the chain tensioner with new sealing ring and tighten with a torque wrench.

Fig 3: Fitting Chain Tensioner, Cylinder Bank 1-3
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Tightening torque: 80 Nm (59 ftlb.)
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 as of mod. 98 9595/1. Use short fixing pin.

Fig 4: Turning Engine At Belt Pulley Of Crankshaft Clockwise To TDC Marking
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Tighten the four M6 x 12 hexagon-head bolts for the chain sprocket of the exhaust camshaft crosswise with a torque wrench.

Fig 5: Locating Four M6 X 12 Hexagon-Head Bolts For The Chain Sprocket Of The Exhaust Camshaft
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Tightening torque: 14 Nm (10.5 ftlb.)
Tighten the central screw of the camshaft adjusting device. Position 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 6: Tightening Hexagon-Head Bolt On Contact Block
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Tighten the central screw in two stages.
First stage: pre-tightening torque: 50 Nm (37 ftlb.).

Fig 7: Tightening Central Screw
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NOTE:
- Before the final tightening of the central screw, remove special tool adjustment gauge 9686 without fail.
Remove special tool adjustment gauge 9686. Unscrew the M8 auxiliary screw and pull off the gauge.
Second stage: final tightening of central screw: 110° torque angle with torque angle wrench.
Replace the three seals for the spark-plug recesses.

Fig 8: Replacing Seals For Spark-Plug Recesses
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Install the cylinder head cover. See REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED (AS OF MY 02)
Fit both holders (A and B) and two new covers for the magnetic hydraulic valves for Vario-Cam Plus. Push two new covers (identical parts) over the valves and position and tighten two holders with two M6 x 20 hexagon socket head bolts each.

Fig 9: Identifying Holders
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1. A: Holder for camshaft adjustment valve
2. B: Holder for valve lift adjustment valve
Cover for magnetic hydraulic valves in installation position with integrated seal

Fig 10: Identifying Covers For Magnetic Hydraulic Valves
Courtesy of PORSCHE OF NORTH AMERICA, INC.
- 1 : Camshaft adjustment valve (control chain side)
- 2 : Valve lift adjustment valve
Tightening torque: 10 Nm (7.5 ftlb.)
Install ignition coils. Insert three ignition coils in the spark-plug recesses, position and then tighten two M6 x 25 hexagon socket head bolts.
Tightening torque: 10 Nm (7.5 ftlb.)
Install holder for the main muffler. Insert holder from the clutch side, position two M8 x 30 hexagon-head bolts at the top and two M8 x 25 hexagon-head bolts at the bottom and tighten. Connect the electrical plug of ignition coil cylinder 2 and the two electrical plugs of the magnetic hydraulic valves, then fasten the cable in the sheetmetal brackets.
Tightening torque: 23 Nm (17 ftlb.)
Install the shield. Insert the shield, position and tighten the two M6 x 16 hexagon-head bolts.
Tightening torque: 10 Nm (7.5 ftlb.)
Turn the engine at the assembly support by approx. 90° until the engine is horizontal (intake system at the top).