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Removing valve tappets of the cylinder bank 1 - 3 - Engine installed

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  1. Move camshafts of cylinder bank 1-3 to basic position. Turn crankshaft clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595 or 9595/1.
    Fig 1: Aligning Belt Pulley Bore 1 OT With Fixing Bore On The Crankcase
    G03100012Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 2: Positioning Crankshaft With Short Fixing Pin
    G03100013Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Pull off closure caps of cylinder head 1 - 3 - flywheel side. Turn shop-made extractor into center of piercing point of closure cap and pull off the cap.
    Fig 3: Identifying Shop-Made Extractor
    G03100014Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 4: Pulling Off Closure Cap Of Cylinder Head 1-3, Flywheel Side
    G03100015Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Check basic camshaft adjustment of cylinder bank 1 - 3. Ensure that the groove in the camshaft faces outward toward the cylinder head cover.

    View from the flywheel side 

    Fig 5: Identifying Groove In Camshaft - Cylinder Bank 1-3
    G03100016Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. If the position of the camshafts is incorrect or the groove in the inlet camshaft does not face outward, remove fixing pin of belt pulley and turn crankshaft a further 360° clockwise. Then position or fix the fixing pin in the bore (1 OT) and the fixing bore in the crankcase again.
  5. Check the position of the groove again.
  6. Remove ignition coils and spark plugs.
  7. Pull off oil protection tubes. Refer to REMOVING AND INSTALLING OIL PROTECTION TUBES - ENGINE INSTALLED .
  8. Pull off closure caps (2 ea.) of cylinder head 1 - 3 - pulley side.
    Fig 6: Pulling Off Closure Caps Of Cylinder Head 1-3 (Pulley Side)
    G03100017Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Diagram shows lower closure cap

  9. Fit special tool, holding-down device 9634, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 3.
    NOTE:
    • In order to prevent damage to the camshafts or saddle bearings, it is essential to fit the holding-down device before detaching the cylinder head cover.
    Fig 7: Fitting Special Tool 9634 On Cylinder Head
    G03100018Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Separate plug connection of the tensioning element (VarioCam).
  11. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).
  12. Undo the fastening screws of the oil extraction pump.
  13. Remove cylinder head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach the cylinder head cover by knocking it gently with a plastic hammer, and press off carefully.
    Fig 8: Removing Cylinder Head Cover
    G03100019Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Remove oil extraction pump.
    Fig 9: Removing Oil Extraction Pump
    G03100020Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. To relieve the camshafts from strain, additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.
    Fig 10: Fastening Holding-Down Device Of Special Tool
    G03100021Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Relieve camshaft tensioning element (VarioCam) with special tool, tensioning screw 9632. Screw in tensioning screw only so far as to slightly relieve the chain.
    Fig 11: Relieving Camshaft Tensioning Element With Special Tool
    G03100022Courtesy of PORSCHE OF NORTH AMERICA, INC.
  17. Unscrew and remove three fastening screws (M6 x 95) for tensioning element.
  18. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.

    Rear axle cross member removed for clearer illustration 

    Fig 12: Identifying Four Hexagon-Head Bolts On Chain Sprocket
    G03100023Courtesy of PORSCHE OF NORTH AMERICA, INC.
  19. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.
  20. Relieve chain of tension. Unscrew chain tensioner of cylinder bank 1 - 3. ("2 rings" identification on chain tensioner and crankcase).
    Fig 13: Identifying Chain Tensioner Of Cylinder Bank 1 - 3
    G03100024Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Take off drive plate of oil extraction pump. Remove sprocket wheel and chain and connect with a tie wrap (installation position).
  22. Detach bearing saddles and lever out of the guide sleeves by hand. Do not use a tool.
  23. Remove special tools (holding-down devices 9611 and 9634) and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder head. The chain must not jump over during this operation; reallocate if necessary. The groove or tab of the camshaft position sensor cover must face upward.
    Fig 14: Identifying Groove Or Tab Of The Camshaft Position Sensor
    G03100025Courtesy of PORSCHE OF NORTH AMERICA, INC.
  24. Pull out valve tappets by hand.
    NOTE:
    • Do not use a magnet.
  25. Detach guide for valve tappet. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide.
    Fig 15: Identifying Pan-Head Screws
    G03100026Courtesy of PORSCHE OF NORTH AMERICA, INC.
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