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Home >> Porsche >> 2016 >> 911 Turbo, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 4 (Engine - 911 CARRERA (996)) >> Removing camshafts - engine removed (as of MY 02) >> Removing camshafts, cylinder bank 4 - 6

Removing camshafts, cylinder bank 4 - 6

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.
  1. Pull the 2 cable plugs off the oil temperature switch.
  2. Remove the shield: unscrew 2 hexagon-head bolts M6x16. Pull out the shield to the clutch side.
  3. Remove holder for the main muffler: pull off the electrical plug of ignition coil cyl. 5 and the 2 electrical plugs of the magnetic hydraulic valves. Unscrew 4 hexagon-head bolts: top 2 M8x30, bottom 2 M8x25, then pull out the holder towards the belt pulley side.
  4. Remove 3 ignition coils: unscrew 6 hexagon socket head bolts M6x25 and pull the ignition coils out from the spark-plug recess.
  5. Remove the oil extraction pump and the brown closure cap "PHI" 45 mm (belt pulley side). Unscrew the 4 hexagon-head bolts M6x20 on the oil extraction pump and remove the pump carefully (do not damage the fitting bore). Push a small screwdriver into the center of the closure cap and lever off the cover.
    Fig 1: Removing Oil Extraction Pump (Cylinder Bank 4-6)
    G03100249Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Remove the 2 green closure caps (clutch side). Press a small screwdriver into the center of the piercing point of the closure cap and lever off the cover.
  7. Turn the engine clockwise at the belt pulley of the crankshaft to the overlapping TDC of cylinder 4. Fix with the short fixing pin as of mod. 98 9595/1. At this point, the smaller circular cutouts on the cut grooves of the inlet and exhaust camshafts on cylinder 1 must point towards the cylinder head cover (check with adjustment gauge 9686). If this is not the case, turn the engine through another 360° as described above.
    Fig 2: Turning Engine Clockwise At Belt Pulley Of Crankshaft To Overlapping TDC Of Cylinder 4
    G03100250Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Position of the camshafts in overlapping TDC of cylinders 1 or 4 

    Fig 3: Identifying Position Of Camshafts In Overlapping TDC Of Cylinders 1 Or 4
    G03100251Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE: Before disassembling the cylinder head cover, it is essential to unscrew the central screw on the camshaft adjustment device.
  8. Unscrew the central screw on the camshaft adjustment device. Position the retaining tool 9685 on the hexagon of the adapter and place the contact block of the tool on the fitting bore of the cylinder head cover for the oil extraction pump; if necessary, position the contact block by undoing and tightening the hexagon-head bolt. If the special tool can not be positioned in this way, the engine must be turned further in the direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the cylinder head cover. Unscrew the central screw.
    Fig 4: Positioning Retaining Tool 9685 On Hexagon Of Adapter
    G03100252Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Unscrew the 4 hexagon-head bolts M6x16 on the chain sprocket of the exhaust camshaft. Do not remove the chain sprocket.
  10. Remove 2 holders and 2 covers for the magnetic hydraulic valves: unscrew 4 hexagon socket head bolts M6x20, disconnect the connection cable for the hydraulic valves from the sheetmetal bracket and remove the holders. Pull off 2 covers for the hydraulic valves.
  11. Remove 2 magnetic hydraulic valves (camshaft and valve lift adjustment). Pull both valves carefully out of the bores. This removal is necessary, because otherwise the exhaust manifold would have to be removed before removing the cylinder head cover.

    Pay attention to cleanliness without fail! 

  12. Remove the ground strap from the cylinder head. Unscrew 1 hexagon-head bolt M8x20.
    CAUTION: When levering off the cylinder head cover, the cast lugs may break.
  13. Remove the cylinder head cover. See REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED (AS OF MY 02) .
  14. Turn the engine at the assembly support so that the cylinder bank 4-6 stands vertically upwards.
  15. Remove the chain tensioner, side 4-6. Hexagon socket a/f 14. Prerequisite: servo-tank, air-conditioning compressor and holder for the air-conditioning compressor are removed.
    Fig 5: Removing Chain Tensioner, Cylinder Bank 4-6
    G03100253Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Unscrew the guide rail screw of cylinder bank 4-6 (belt pulley side). Hexagon socket a/f 6.
  17. Remove the chain sprocket of the exhaust camshaft 4-6. Lift control chain off the chain sprocket and remove the chain sprocket. Lay the control chain on the mounting tab for the chain sprocket.
  18. Remove the 4 camshaft bearings and the guide rail. Unscrew the 8 hexagon socket head bolts, 6 M6x35, 2 M6x40.
  19. Remove the camshafts. Remove the exhaust camshaft 4-6, lift the control chain off the camshaft adjuster of the inlet camshaft 4-6 and remove the camshaft. Lay the control chain in the chain housing in the cylinder head.
  20. Remove the flat-based tappets. Pull the flat-based tappets upwards out of the camshaft housing. To avoid confusing the individual flat-based tappets, lay them on a prepared sheet of paper (see Fig 6) and cover, because of the risk of soiling.

    Fig 6  shows cylinder side 1-3 

    Fig 6: Laying Out Tappets On Prepared Sheet Of Paper
    G03100254Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Do not confuse the flat-base tappets. The flat-base tappets have been run in the fitting bores in the housing. Therefore they must not be interchanged or soiled.
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