Installing Camshaft Actuators - Setting The Timing

Information 

No TDC markings on cylinder head cover - setting the timing using a template

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Template for setting the timing

• Some cylinder head covers have no TDC markings 
• The template can be found under Workservice information 1505 - Template for camshaft adjustment - EA 825 4.0 V8 Biturbo in the PCSS (Porsche Central Service System) 
• Print the template, check printout based on the control dimension, cut out the template and screw it onto the cylinder head cover 

1. Check whether the crankshaft, the camshafts and the chain tensioners are fixed.

   Information 

   Camshaft actuator must not be disassembled! 

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   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-  .
2. Fit new friction plates between the camshaft actuators and camshaft stub.
3. Allocate actuators to the camshafts. The actuator with the black surface -Arrow-  is for the outlet side.

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   Distinguishing features of actuators

   1	Camshaft actuator inlet
   2	Camshaft actuator outlet
   3	TDC markings

4. Position the actuators on the camshafts and fit timing chain. Make sure that the markings on the actuators -1-  match the cylinder head covers -2-  .

   If there are no markings -2- on the cylinder head cover, print the template and position it. 

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   TDC markings on cylinder head cover

5. Replace O-rings -1-  on the central valves -2-  .
   1. 5.1 Lever out old O-ring -1-  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.

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   O-ring on central valve

6. Remove latch on the chain tensioner -3-  .

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   Securing chain tensioner

7. Screw in central valves.
8. Pre-tension the timing chain and pre-tighten central valves.

   Observe specified tightening sequence! 

   • 1st outlet, cylinder bank 2
   • 2nd intake, cylinder bank 2
   • 3rd intake, cylinder bank 1
   • 4th outlet, cylinder bank 1
   1. 8.1 Use > VAS 261 005 - hook wrench-1-  to pre-tension the actuators anti-clockwise and use > T90000 - socket E24-2-  and a torque wrench -3-  to pre-tighten the central valves.

   > Initial tightening 27 Nm (20 ftlb.) 

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   Pre-tensioning control chain

9. Remove all staking tools.
   1. 9.1 > T40331 - Camshaft clamp  and adapter can now be removed.
   2. 9.2 Unscrew > T40069 - locking pin  .
   3. 9.3 Screw in stoppers with new sealing rings and tighten them.
10. Secure central valves.
    1. 10.1 > T90001 - Counterhold tool-1-  and > T90002 - counterhold tool-2-  must be fitted on the actuators. To do this, turn the engine clockwise until the tool engages.
    2. 10.2 Tighten central valves using > T90000 - socket E24-3-  .

       > Final tightening + 30 Nm (22 ftlb.) 

       > Final tightening + 35° 

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       Secure central valves