Installing Camshaft Actuator

NOTIFICATION 

Timing not set correctly 

• Risk of engine damage 
• Rough running engine 
• Loss of engine power 
  • Do not use force when fitting the staking tool.
  • Make sure that the gap is equal on both sides.
  • When inserting the staking tools, do not use force to turn the camshafts against any resistance.
  • The engine must be exactly at top dead center.
  • The opposite cylinder must be at ignition TDC.

NOTIFICATION 

Dirt and contamination 

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

Information 

Camshaft actuator must not be disassembled! 

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Friction plate in camshaft actuator

• The camshaft actuator must never be disassembled. 
• To replace the friction plate -1- , lever it out carefully using a small slotted screwdriver -2-  .

1. Fit new friction plates between the camshaft actuators and camshaft stub.
2. Install the timing chain.
   1. 2.1  Fit timing chain on the camshaft actuators.
3. Install camshaft actuator (cylinder bank 1).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Markings on camshaft actuator (cylinder bank 1)

   1. 3.1  Fit camshaft actuator with timing chain fitted and markings -1 and 2-  aligned with the corresponding markings on the camshaft housing -Arrows-  on the camshafts.

      Check that the friction plates are fitted and seated correctly.

4. Install camshaft actuator (cylinder bank 2).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Markings on camshaft actuator (cylinder bank 2)

   1. 4.1  Fit camshaft actuator with timing chain fitted and markings -1 and 2-  aligned with the corresponding markings on the camshaft housing -Lines-  on the camshafts.

      Check that the friction plates are fitted and seated correctly.

5. Replace O-rings -1-  on the central valves -2-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   O-ring on central valve

   1. 5.1  Lever out old O-ring using a plastic wedge and dispose of it.
   2. 5.2  Coat groove on central valve and new O-ring with oil.
   3. 5.3  Carefully slide O-ring over the thread and shoulder -3-  of the central valve and press it on using a plastic wedge.
   4. 5.4  Do not use sharp-edged tools, such as a screwdriver. Never mask the thread with tape.
6. > T03006 - Locking pin-3-  can now be removed from the chain tensioner -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Fixing device for chain tensioner

   Information 

   You will need a second mechanic to help you with this step.

7. Tighten camshaft actuator -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tightening camshaft actuator

   1. 7.1  A second mechanic must use > V.A.G 1331A - torque wrench, 6-50 Nm (4.5-37 ftlb.)-5-  with > VAS 261 001 - ring spanner insert, a/f 41-4-  and > T90001 - counterhold tool-3-  to pre-tension the outlet camshaft actuator -1-  to 30 Nm (22 ftlb.)  by turning it anti-clockwise and hold it securely.
   2. 7.2  Tighten camshaft actuators -1 and 2-  in the following sequence. (Camshaft actuator is still pre-tensioned) 
      1. 7.2.1  Tighten intake camshaft actuator -2-  .

         > Initial tightening 30 Nm (22 ftlb.) 

      2. 7.2.2  Tighten outlet camshaft actuator -1-  .

         > Initial tightening 30 Nm (22 ftlb.) 

8. Remove staking tools and turn the engine through two turns.
9. Check the timing again.

   > Setting timing for camshafts (V6 Turbo) 

10. If the timing is OK:

    Remove staking tools and tighten camshaft actuators.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Final tightening of camshaft actuator

    1. 10.1  > T90001 - Counterhold tool-3-  and > T90002 - counterhold tool-4-  must be fitted on the outlet camshaft actuator.
    2. 10.2  > T90002 - Counterhold tool-4-  must be supported on the intake camshaft actuator.

       Turn the crankshaft slightly to do this if necessary. (Only turn clockwise) 

    3. 10.3  Tighten outlet camshaft actuator -1-  .

       > Final tightening + 35° 

    4. 10.4  > T90001 - Counterhold tool-3-  and > T90002 - counterhold tool-4-  must be fitted on the intake camshaft actuator.
    5. 10.5  > T90002 - Counterhold tool-4-  must be supported on the outlet camshaft actuator -1-  .

       Turn the crankshaft slightly to do this if necessary. (Only turn clockwise) 

    6. 10.6  Tighten intake camshaft actuator -2-  .

       > Final tightening + 35° 

    7. 10.7  > T90001 - Counterhold tool-3-  and > T90002 - counterhold tool-4-  must now be removed.
11. Fit screw plug for crankshaft -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Screw plug for crankshaft

    1. 11.1  Replace O-ring on screw plug for crankshaft.
    2. 11.2  Position holder for vacuum reservoir -3-  .
    3. 11.3  Screw in and tighten screw plug for crankshaft -1-  in bore -2-  .

       > Tightening torque 25 Nm (18.4 ftlb.) 

12. Loosen engine from assembly support.

    > 100113 SECURING ENGINE ON ASSEMBLY SUPPORT (V6 TURBO)

13. Install vacuum reservoir -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Vacuum reservoir

    1. 13.1  Position vacuum reservoir -1-  .
    2. 13.2  Screw on and tighten nuts -3-  .

       > Tightening torque 9 Nm (6.5 ftlb.) 

    3. 13.3  Fit and tighten screws -2-  .

       > Tightening torque 9 Nm (6.5 ftlb.) 

14. Install left engine carrier -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Left engine carrier

    1. 14.1  Position left engine carrier -1-  .
    2. 14.2  Fit and tighten screws -2-  .

       > Tightening torque 55 Nm (40.6 ftlb.) 

15. Install stoppers on camshafts -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Stoppers on camshafts

    1. 15.1  Insert stoppers on camshafts -1-  .
    2. 15.2  Replace screws for stoppers on camshafts -2-  .
    3. 15.3  Screw in and tighten screws for stoppers on camshafts -2-  .

       > Tightening torque 9 Nm (6.5 ftlb.) 

    4. 15.4  Fit and lock quick connector -3-  for the vacuum line -4-  .