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Installing camshafts - cylinder bank 4 - 6: Notes

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  1. 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). Refer to Fig 1. Fix with the special tool fixing pins as of mod. 98 9595/1. Use short fixing pin.
    Fig 1: Turning Engine At Belt Pulley Of Crankshaft Clockwise To 60° Before TDC
    G03100255Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Turn the engine at the assembly support until cylinder bank 4-6 stands vertically upwards.
    CAUTION: Flat-base tappets have been run in the fitting bores and must be inserted again in their original position (allocation). For oiling, only use new engine oil.
  3. Install flat-base tappets, side 4-6. Coat the tappets with new engine oil and insert them according to the relevant allocation for each cylinder (as removed). Make sure that the dowel pins of the inlet stroke tappets are flush with the bores in the housing -arrow-. 
    Fig 2: Checking That Dowel Pins Of Inlet Stroke Tappets Are Flush With Bores In Housing
    G03100256Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Oil the bearing surfaces of the camshafts with new engine oil.
  5. Insert inlet camshaft 4-6. If necessary, pre-assemble the inlet camshaft. Refer to DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT . Pull the control chain out of the chain housing of the cylinder head 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 4 (the cams of cylinder 4 point towards the bulkhead of the flat-base tappet housing, -arrows-  ).
    Fig 3: Ensuring That Cams Of Cylinder 4 Point Towards Bulkhead Of Flat-Base Tappet Housing
    G03100257Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Make sure that the bearing sleeve of the inlet camshaft is positioned correctly.
  6. 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 center 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 4: Identifying Bearing Sleeve Of Inlet Camshaft
    G03100258Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Insert exhaust camshaft 4-6. Lay the control chain on the flange for the chain sprocket, then insert the camshaft at overlapping TDC of cylinder 4 (the cams of cylinder 4 point towards the cams of the inlet camshaft -arrows-  ).
    Fig 5: Identifying Cam Lobes Of Cylinder 4 Pointing Towards Cams Of Inlet Camshaft
    G03100259Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Install the chain sprocket of the exhaust camshaft. Insert the chain sprocket in the control chain, then position on the camshaft flange. The four threaded bores in the camshaft flange must be approximately half covered to the right by the slots of the chain sprocket in the engine direction of rotation.
    Fig 6: Identifying Threaded Bores In The Camshaft Flange
    G03100260Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly. Observe the identification (Fig 7 shows inlet camshaft bearings).
    • 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.
    Fig 7: Inlet Camshaft Bearing Identification
    G03100261Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Insert three thrust bearings and one bearing cover for the bearing sleeve of the camshafts with the guide rail for the control chain. Eight hexagon socket bearing screws: position six M6 x 35 (Item 1) and two M6 x 40 (Item 2) screws for the camshaft bearings and the guide rail and tighten slightly.
    Fig 8: Inserting Three Thrust Bearings And One Bearing Cover
    G03100262Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Position of the bearing screws: Item 1 = M6 x 35, Item 2 = M6 x 40 

    Fig 9: Identifying Position Of Bearing Screws
    G03100263Courtesy of PORSCHE OF NORTH AMERICA, INC.
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