Installing cylinder head cover - cylinder bank 1 - 3

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Porsche 911, 2004 Porsche 911, 2003 Porsche 911, 2002 Porsche 911, and 2001 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

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 degreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head.
Replace the 3 seals for the spark-plug recesses.
Only the following sealants may be used to seal the cylinder head cover:
- Drei Bond Silikon - type 1209 (beige)
- Loctite 5900 (black)
Fit a new "PHI" 45 mm cap into the bore of the exhaust camshaft dry.
NOTE: Make sure that no sealant residue can enter the oil bores!
Apply a thin bead of sealant on the cylinder head cover -as shown in Fig 1. The bead should not be higher than 1.5 mm.

Fig 1: Applying Thin Bead Of Sealant On Cylinder Head Cover
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit 20 M6 x 30 hexagon-head bolts on the cylinder head cover and 2 M6 x 20 hexagon-head bolts for the oil extraction pump.
Refasten the cap of the stabilizer mount. Tighten the two M8 hexagon-head bolts (-1- ) for this purpose.

Fig 2: Tightening Two Stabilizer Mount M8 Hexagon-Head Bolts
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque: 23 Nm (17 ftlb.)
Insert 2 new green closure caps into the small bores on the cylinder head dry.
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 hexagon-head bolts M6 x 20.
Tighten the 20 hexagon-head bolts in the specified tightening sequence with a torque wrench.

Fig 3: Cylinder Head Cover Bolt Tightening Sequence
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 13 Nm (10.0 ftlb.)
Tighten 2 or 4 M6 x 20 hexagon-head bolts of the oil extraction pump with a torque wrench.
Tightening torque 13 Nm (10.0 ftlb.)
NOTE:
- Recheck to make sure that the closure caps are seated properly.
Fit 2 magnetic hydraulic valves (camshaft and valve lift adjustment), paying attention to the installation position. Carefully insert the magnetic hydraulic valve for camshaft adjustment into the bore of the cylinder head. When doing this, make sure that the cutout on the valve and the dowel pin of the cylinder head fit together. When fitting the valve for valve lift adjustment, make sure that the plug position is correct.
Fit 2 holders and 2 covers for the magnetic hydraulic valves: Screw in 4 M6 x 20 pan-head screws (hexagon socket a/f 5), insert the connection cable for the hydraulic valves into the sheetmetal bracket and fit the sheetmetal holder. Screw 2 covers for the hydraulic valves into place.
Tightening torque 10 Nm (7.5 ftlb.)
Fit 3 ignition coils: Tighten 6 M6 x 25 pan-head screws (hexagon socket a/f 5).
Tightening torque 10 Nm (7.5 ftlb.)
Fit holder for rear muffler (-2- ). Fit cable plugs of the ignition coils and of the magnetic hydraulic valves. Screw in and tighten 4 hexagon-head bolts: top 2 M8 x 30, bottom 2 M8 x 25.
Fig 4 shows engine side 1 - 3

Fig 4: Fitting Holder For Rear Muffler
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque: 23 Nm (17 ftlb.)
NOTE:
- Fastening nuts, hexagon-head bolts and seals for the exhaust manifold must be replaced.
Fit the exhaust manifold. To do this, put three new M8 fastening nuts and a new metal seal on the catalytic converter flange. Then fasten the exhaust manifold on the cylinder head with six new M8 x 28 hexagon-head bolts and a new seal.
Tighten 9 M8 screw connections with the prescribed torque.
Tightening torque: 23 Nm (17 ftlb.)
Raise the engine again and then tighten the two collar nuts (a/f 18) on the rear engine mounts. Check hoses and cables for damage
Tightening torque 85 Nm (63 ftlb.)
Fit shield: Tighten 2 M6 x 16 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
Refit rear muffler Refer to REMOVING AND INSTALLING REAR MUFFLERS .
Fill in engine oil and check the engine oil level (top up if necessary). Refer to ENGINE OIL AND OIL FILTER CHANGE ENGINE OIL AND OIL FILTER CHANGE AS OF MY 02 .
Connect the battery. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .