Removing Camshafts

NOTIFICATION 

Dirt and contamination 

• Risk of damage to units or components 
  • → Protect components from dirt and contamination.
  • → Clean or replace dirty components.

Information 

The hexagon sleeves will be deformed during the loosening process and must be replaced!

Component overview of cylinder head/camshafts/bearing covers (view of cylinders 3-4): 

Fig 1: Camshafts/Cylinder Head Components Location (Cylinders 3-4)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Camshafts/cylinder head (cylinders 3-4)

1. Intake camshaft
2. Outlet camshaft
3. Dowel sleeve, upper 7 x 11
4. Bearing cover
5. Screw, M6 x 38 - observe tightening sequence!
6. Screw, M6 x 38 (cylinder head 1-2) or M6 x 70 (cylinder head 3-4)
7. Camshaft bearing saddle
8. Dowel sleeve, 6 x 25
9. Lower part of bearing saddle (only for cylinder head 3-4)
10. Lower dowel sleeve (observe different size compared to item 3)

Individual parts of camshafts: 

Fig 2: Camshafts Components Location

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Camshafts/camshaft controllers

1. Friction plate - always replace
2. Hexagon sleeve - always replace
3. Central screw (M12 x 110) for camshaft controller
4. Sealing ring
5. Actuator for camshaft control on intake side
6. Actuator for camshaft control on outlet side
7. Aluminium screw, M6 x 14 - always replace

Information 

• The camshafts may only be removed at the position 260° after TDC. 
• Only at this position can you be sure that the valves are not touching against the pistons and cannot be damaged when the engine turns. 

1. Turn the crankshaft clockwise (direction of rotation of engine)  to position 260° after TDC.
   1. 1.1 Secure > 9888 - locking tool-1-  to the crankshaft with three screws -2-  .
   2. 1.2 Turn the crankshaft using > 9773 - turning device  until the bores are aligned.
   3. 1.3 Fix using a long > 9595/1 - locating pin-3-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Position 260° after TDC

2. Turn the engine at the assembly support so that the cylinder bank to be fitted is at the top.
3. Check cam position. Data matrix code -1 and 2- on both camshafts is facing you! 
   1. 3.1 Turn the crankshaft a further 360° clockwise if necessary.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Data matrix code on the camshafts

   1. Data matrix code on intake camshaft
   2. Data matrix code on outlet camshaft
4. Overview of central screws for camshaft actuator.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Installation overview of central screws for camshaft controllers

   1. Actuator for intake camshaft
   2. Actuator for outlet camshaft
   3. Central screws (central valves)
5. Loosen central screws.

   The help of another person is required! 

   Tools:

   • -item 1-  : > 9863/3 - Open-ended wrench, a/f 39  for countering
   • -item 2-  : > 9863 - Socket wrench for camshaft 
   • -item 3-  : > V.A.G 1332 - Torque wrench, 40-200 Nm (30-148 ftlb.) 
   1. 5.1 Counter at the hexagon sleeves with the open-ended wrench.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Central screw for camshaft control

6. Remove chain tensioner - cylinder bank 1-2: 
   1. 6.1 Unscrew chain tensioner -1-  in the oil pan area.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Chain tensioner on cylinder bank 1-2

7. Remove chain tensioner - cylinder bank 3-4: 
   1. 7.1 Loosen oil separator.

      > 105519 REMOVING AND INSTALLING OIL SEPARATOR .

   2. 7.2 Unscrew screws and lift up oil separator -1-  .
   3. 7.3 Loosen chain tensioner using 3/8-inch flexible-head socket-wrench insert, a/f 15 mm -2-  .
   4. 7.4 Guide out chain tensioner -3-  (-Arrow-  ).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Chain tensioner on cylinder bank 3-4

8. Set the chain tensioner -1-  down on a clean surface and replace O-ring (loss preventer for sealing ring) -2-  and sealing ring -3-  .
   1. 8.1 First fit the sealing ring and then the O-ring! 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Sealing ring and O-ring on chain tensioner

9. Remove bearing saddle.
   1. 9.1 Unscrew screws -1-  .
   2. 9.2 Guide out bearing saddle -2-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing bearing saddle (cylinder bank 1-2 shown)

10. Remove camshaft actuators and fit timing chain into the chain housing in the cylinder head.
    1. 10.1 Unscrew central screws with hexagon sleeves on the actuators.
    2. 10.2 Lift the timing chain and remove camshaft actuators one by one.

       Replace friction plates! 

    3. 10.3 For storage purposes, fit the actuators back on the camshafts. Tighten central screws only slightly.
    4. 10.4 Replace hexagon sleeves! 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Friction plate in camshaft actuator

    1. Camshaft actuator (back)
    2. Friction plate
11. Remove camshafts.
    1. 11.1 Loosen and unscrew screws for the bearing covers -1 to 8-  from the outside in.
    2. 11.2 Remove bearing covers and camshafts.
    Fig 3: Camshaft Bearing Cover/Bearing Saddle Bolts Tightening Sequence

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tightening sequence for camshaft bearing cover/bearing saddle (view of cylinder head 1-2)

    Information 

    • Do not clean the camshaft controller in a parts washer. 
    • Only the outside can be cleaned using a clean, lint-free cloth. 
12. Clean components.
13. If the hydraulic tappets are removed, set them down on a clean surface and mark the installation position on the surface accordingly.
    1. 13.1 During re-installation, the tappets must be coated fully with Renolin (from Fuchs) or new engine oil and must be inserted again according to installation position before removal! 
    2. 13.2 Also coat new hydraulic tappets with Renolin or new engine oil!