Component Markings And Distinguishing Features

Information

The camshaft markings are on a surface next to the dihedron.
The part number and data matrix code are important (They help when fitting the camshafts}.

Markings: Data matrix code on dihedron.

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Data matrix code on the camshafts

1	Data matrix code on intake camshaft (at overlapping position)
2	Data matrix code on outlet camshaft (at overlapping position)

Part numbers or camshafts:

Intake tide:

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Intake camshafts

1	Intake camshaft on bank 1-3, marking: 9A2.105.504.01
2	Intake camshaft on bank 4-6, marking: 9A2.105.514.01

Outlet side:

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Outlet camshafts

1	Outlet camshaft on bank 1-3, marking: 9A2.105.524.01
2	Outlet camshaft on bank 4-6, marking: 9A2.105.534.01

Camshaft mount:

Bearing saddle: Matching number for cylinder head, upper and lower part on the front (chain box side)
Bearing cover: Matching number for cylinder head and allocation to intake and outlet side of cylinder (e.g. A1 for outlet cylinder 1)

Camshaft controllers:

The camshaft controllers for intake and outlet camshafts are different.

The central screws are identical.

Fig 1: Camshaft Controllers Components Location

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Installation overview of central screws for camshaft controllers

1	Intake camshaft controller (aluminium surface)
2	Outlet camshaft controller (black)
3	Central screws (central valves)

Installing camshafts and setting timing - cylinders 4-6

NOTE: Dirt and contamination

Risk of damage to units or components
→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Before final tightening (torque angle) of the central screws, the > 9772/1 - staking tool must be removed.
Replace the hexagon sleeves for the central screws.

Secure the crankshaft.
Turn crankshaft at the vibration damper clockwise (direction of rotation of engine) to TDC position of cylinder 1/4.

The position is marked by A and OT 1.

Use a long > 9595/1 - locating pin-1- to fix the vibration damper in place.

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TDC position of vibration damper
Turn the engine at the assembly support so that the cylinder bank to be worked on is at the top.
Insert lower part of bearing saddle -1- .
Check matching number for upper part and position of oil bores.

Position lower part of bearing saddle -1- at the dowel sleeves and insert it.

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Lower part of bearing saddle - cylinder bank 4-6
Oil the bearing locations of the camshafts with new engine oil. When rebuilding the engine, coat the bearing locations with Optimol Optipit grease (Part No. 000.043.204.17).
Check that all hydraulic tappets are installed correctly.
Insert camshafts -1 and 2- .
Insert camshafts -1 and 2- into the cylinder head in such a way that the cams -Arrows- are pointing inwards at an angle, towards the spark plug bore and the camshafts -1 and 2- are not tensioned.

Check whether the data matrix code markings on the dihedron are facing you.

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Cam position of cylinder 4 at overlapping TDC

1 Intake camshaft

2 Outlet camshaft

Secure camshafts -1 and 2- .

> 9772/1 - Staking tools-3- must be fitted on the dihedron -Arrows- of the camshafts. Also make sure that the adjusting screws -5- are sticking out far enough and are not touching the camshafts.

Fit cheese head bolts -4- by hand.

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Fitting position of staking tools

1	Intake c mshrft
2	Outlet camshaft
3	Staking tools 9772/1
4	Cheese head bolts
5	Adjusting screws

Install bearing saddle and bearing covers.
Do not install the centre bearing covers until you have set the timing.

Fit bearing saddle and bearing covers. Observe markings while doing this.

Fit bearing saddle screws -13 to 16- .

Fit and tighten screws for bearing covers -3 to 6- and -9 to 12- .

Fig 2: Camshaft Bearing Cover Screws Tightening Sequence
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Tightening sequence for camshaft bearing cover
Fit and tighten screws in ascending sequence. (Except -1 and 2- and -7 and 8- )
Tool: > 9768 - Electronic torque wrench, 2 - 100 Nm (1.5 - 74 ftlb.)

Screws, M6 x 38:

> Initial tightening 5 Nm (3.5 ftlb.)

> Torque angle 50 Grad

Scews, M6 x 70 (bearing saddle):

> Initial tightening 5 Nm (3.5 ftlb.)

> Torque angle 90 Grad

Fig 3: Camshaft Bearing Cover Screws Tightening Sequence
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Tightening sequence for camshaft bearing cover
Check that the new friction plates -2- are inserted into the camshaft controllers -3- .

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Friction plate in camshait controller

Install camshaft controllers -1- and 2- .

Fit camshaft controllers -1 and 2- with new friction plates on camshafts.

Install the timing chain.

Tighten central screws -3- with new drivers slightly by hand.

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Installation overview of central screws for camshaft controllers

1	Camshaft controller, intake
2	Camshaft controller, outlet
3	Central screws (central valves)

CAUTION: Timing chains positioned incorrectly

Too much wear on sprockets and timing chains
Engine damage
→ Perform a visual inspection to check the position of the timing chains on the tensioning and guide rails.

Use a torch to check that the timing chains -1- are on the tensioning and guide rails between the guide pins -Arrows- .

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Position of timing chain in tensioning and guide rails

Information
- The chain tensioner from the 1st generation 1991 engine is used for setting the timing on the 992 engine.
- This has a higher spring force and allows more accurate adjustment.
Screw in and tighten chain tensioner with old seal.
Use chain tensioner 9A1.105.157.02 (1st generation 991 engine) for setting the timing.

> Tightening torque 80 (59 ftlb. ) Nm

Set the timing, cylinder bank 4-6:
> 9772/1 - Staking tool must be tightened hand-tight with the cheese head bolts.
Tighten adjusting screws -1- of the staking tools slowly on both sides.
Do not exceed the specified tightening specification (tool will become tilted)!

> Tightening torque 2 Nm (1.5 ftlb.)

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Adjusting screws on staking tools
Pre-tighten central screws.
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.)
Pre-tighten central screws and use > 9863/3 - open-ended wrench, a/f 39 to counter at the hexagon driver -arrow- .

> Initial tightening 30 (22 ftlb) Nm

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Central screw for camshaft controller (view of intake side)
Check axial bearing play at the camshafts (by gently pulling and pressing on the camshaft controllers).
If there s not a clearly perceptible amount of play, the shafts will have to be re-fitted.
> 9772/1 - Staking tool must now be removed.
Loosen adjusting screws.

Unscrew cheese head bolts on the bearing cover supports and remove tools.
Install centre bearing covers at the camshafts.
Fit centre bearing covers.

Fit and tighten screws uniformly.

> Initial tightening 5 Nm (3.5 ftlb.)

> Torque angle 50 Grad
Tighten central screws to their final tightening torque.
Tools:
- -item 1- : > 9863/3 - Open-ended wrench, a/f 39 for countering
- -item 2- : > 9863 - Socket wrench for camshaft
- -item 3- : > 9768 - Electronic torque wrench, 2 - 100 Nm (1.5 - 74 ftlb.)
Tighten central sire'vs and set threshold torque on the electronic torque wrench to 30 Nm (22 ftlb.).

> Final tightening torque angle 40 Grad +/- 5 Grad

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Tightening camshaft controllers - bank 4-6
Unscrew replacement chain tensioner and screw in and tighten original chain tensioner with a new seal.
> Tightening torque 80 Nm (59 ftlb.)