Back To Article

ENGINE
15 ­ Engine ­ Cylinder Head, Valve Control ­ 911 Carrera (991)

WM 150519 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES

SETTING TIMING) (GT3 & GT3 RS)
TOOLS

Designation Type Number Description Â

locating pin Special tool 9595/1 Â

turning device Special tool 9773 Â

socket wrench for Special tool 9863 Â

camshaft

retainer Special tool 9863/2 Â

open­ended wrench Special tool 9863/3 Â

a/f 39

chain tensioner Special tool 9875 Â

Mounting saddles Special tool 9876 Â

3404 of 5326
Retainers Special tool 9877 Â

Staking tool Special tool 9879 Â

1. Remove high­pressure pump on the relevant side.

→ REMOVING HIGH­PRESSURE PUMP

2. Remove tappets for the high­pressure pump ­1­ using a magnet.

Fig. 1: Identifying High­Pressure Pump Tappets

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Remove cylinder head cover.

→ Removing Cylinder Head Cover

3405 of 5326
4. Remove solenoid hydraulic valves for camshaft control.

→ Removing Solenoid Hydraulic Valve For Camshaft Controllers

REMOVING CAMSHAFTS

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

The camshafts can only be removed in the overlapping position at the top dead center of pistons 1 or 4.
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.
The camshaft controller must not be cleaned in a parts washer.
Only the outside can be cleaned using a clean, lint­free cloth.

Individual parts of camshafts:

1. Central valve for camshaft controller

2. Hexagon sleeve ­ always replace
3. Friction plate ­ always replace

Fig. 2: Identifying Camshafts Parts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Turn the engine at the assembly support so that the cylinder bank to be worked on is at the top.
2. Secure camshafts.
2.1. Mounting saddles 9876 ­1­ must be screwed onto the camshafts and tightened uniformly.

Check installation position and markings!

3406 of 5326
→ Tightening torque: 10 Nm (7.5 ft.lb.)

2.2. Retainers 9877 ­2­ must be pulled out ­arrows­ .

Fig. 3: Pulling Mounting Saddles On Camshafts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The crankshaft must not be turned when the retainers are fitted.
3. Use special tool turning device 9773 ­1­ to turn the crankshaft clockwise as far as the TDC marking on
cylinder 1/4 at the pulley.
3.1. Fix the pulley above the staking bore using a locating pin 9595/1 ­2­ .

3407 of 5326
Fig. 4: Identifying TDC Position Marking On Cylinder 1/4 On Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Check cam position on cylinder 1 or 4.

4.1. Check the position of the data matrix code ­1­ on both camshafts. These must be facing the
observer at overlapping position.

3408 of 5326
Fig. 5: Identifying Part Number And Data Matrix Code Marking On Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Cam positions on intake ­1­ and outlet camshaft ­2­

Overlapping position of cylinder bank 1­3: Cams on cylinder 1 are facing outward at an
angle.
Overlapping position of cylinder bank 4­6: Cams on cylinder 4 are facing inward at an angle
with respect to the spark­plug recess.

Cylinder 1:

3409 of 5326
Fig. 6: Locating Cam Position On Cylinder 1 (Overlap)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cylinder 4:

3410 of 5326
Fig. 7: Locating Cam Position On Cylinder 4 (Overlap)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

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

5. Loosen central valves for camshaft control using socket wrench for camshaft 9863 ­1­ . Counter at the
hexagon sleeves using open­ended wrench a/f 39 9863/3 ­2­ .

3411 of 5326
Fig. 8: Loosening Camshaft Control Central Valves
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Remove chain tensioner.

→ Removing Chain Tensioner

7. Remove actuators for camshafts ­2­ .

7.1. Unscrew central valves for camshaft control.
7.2. Guide out actuators.

3412 of 5326
Fig. 9: Removing Camshafts Actuators
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Remove camshafts.
8.1. Mounting saddles 9876 must be loosened uniformly and removed.
8.2. Lift camshafts out of the cylinder head. Lay the timing chain ­2­ in the chain housing in the
cylinder head.

3413 of 5326
Fig. 10: Removing Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING CAMSHAFTS
Component Markings And Distinguishing Features

Information

The part number and data matrix code must be facing the observer when inserting the camshafts.

Markings:

1. Data matrix code

2. Part number
3. Camshaft

3414 of 5326
Fig. 11: Identifying Part Number And Data Matrix Code Marking On Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Part numbers on camshafts:

Intake side:

The intake camshafts have an additional cam for driving the high­pressure pumps.

1. Intake camshaft, cylinder bank 4­6, part number 9A1.105.276.92

2. Intake camshaft, cylinder bank 1­3, part number 9A1.105.275.92
3. Markings on the camshaft
4. Cam for driving high­pressure pumps
5. Conical dihedron for setting valve timing

3415 of 5326
Fig. 12: Locating Intake Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Outlet side:

1. Outlet camshaft, cylinder bank 4­6, part number 9A1.105.278.92

2. Outlet camshaft, cylinder bank 1­3, part number 9A1.105.277.92
3. Markings on the camshaft
4. Conical dihedron for setting valve timing

3416 of 5326
Fig. 13: Identifying Outlet Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Difference between camshaft actuators:

The actuator for the intake camshaft is different to the actuator for the outlet camshaft. The outlet side
has a higher collar ­arrow­.

1. Camshaft actuator ­ intake side, Part number 946.105.051.75

2. Camshaft actuator ­ outlet side, Part number 9A1.105.054.90

3417 of 5326
Fig. 14: Locating Camshaft Actuators
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Installing Camshafts And Setting Timing

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

The procedure for installing and adjusting the camshafts is described on one cylinder bank as an example.

1. Continue to turn the crankshaft clockwise (running direction of engine) to 60° before TDC at the
pulley.
1.1. This position is marked U 3/6 on the surface.
1.2. Secure the pulley using a long locating pin 9595/1 ­1­ .

3418 of 5326
Fig. 15: Identifying U 3/6 Marking On Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Turn the engine at the assembly support so that the cylinder bank you want to work on is at the top.
3. Only for cylinders 4­6: Insert lower part of bearing saddle ­1­ .
3.1. Check position of oil bores and position and fit the component over the dowel sleeves.

3419 of 5326
Fig. 16: Identifying Lower Part Of Bearing Saddle 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light
coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
5. Check that all hydraulic tappets and valve levers are installed correctly.

Information

The part number and data matrix code must be facing the observer when inserting the camshafts.
6. Insert both camshafts in overlapping position.
7. Mounting saddles 9876 ­1­ must be fitted on the camshafts. Then fit screws uniformly and tighten hand­
tight.

Check installation position and markings!

→ Tightening torque: 10 Nm (7.5 ft lb.)

3420 of 5326
Fig. 17: Installing Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Check that the new friction plate ­2­ is fitted in the actuators ­3­ .

3421 of 5326
Fig. 18: Identifying Friction Plate In Camshaft Actuator
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Install camshaft actuators ­2­ .

9.1. Lift up the timing chain ­1­ .
9.2. Guide the actuators past the timing chain and fit them on the camshaft.
9.3. Position timing chain on the actuators.
9.4. Screw in central valves for camshaft control using new hexagon sleeves and tighten slightly so
that the actuators can still turn.

3422 of 5326
Fig. 19: Installing Actuators
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Check cam position for cylinder 4 again. The cams must be facing downwards at an angle with respect to
the spark­plug recess ­arrows­

3423 of 5326
Fig. 20: Locating Cam Position On Cylinder 4 (Overlap)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.1. Another feature is the data matrix code marking ­1­ on the camshaft ­3­ . These markings
must be facing the observer at overlapping position.
1. Data matrix code
2. Part number
3. Camshaft

3424 of 5326
Fig. 21: Identifying Part Number And Data Matrix Code Marking On Camshaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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.

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

3425 of 5326
Fig. 22: Locating Timing Chain In Tensioning And Guide Rails
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Screw in special tool chain tensioner 9875 .

Set the timing:

13. Staking tool 9879 ­1­ must be adapted for the respective cylinder bank. Always check markings
"A" and "B"!

The feet with the short screws ­2­ are for cylinder bank 1­3

The feet with the long screws ­3­ are for cylinder bank 4­6

1. Staking tool 9879

2. Foot with short screw for cylinder bank 1­3
3. Foot with long screw for cylinder bank 4­6
4. "A" marking
5. "B" marking

3426 of 5326
Fig. 23: Identifying Staking Tool 9879
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Staking tool 9879

2. Screw points
3. Adjusting screw
4. Screw, M8 ­ pointing towards flywheel

Fig. 24: Identifying Staking Tool 9879 Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

14. Secure the camshafts using staking tool 9879 ­1­ .

14.1. Before positioning the staking tool, make sure that the adjusting screw is unscrewed.
14.2. Position the staking tool on the dihedron of the camshafts.
14.3. Align camshafts using an open­ended wrench (a/f 32).
14.4. Screw in screws ­2­ and tighten hand­tight.
3427 of 5326
Fig. 25: Identifying Staking Tool Screws (Cylinder Bank 4­6)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15. Screw in adjusting screw ­arrow­ on the staking tool ­1­ and tighten using a torque wrench ­2­ .

→ Tightening torque: 8 Nm (6 ftlb.)

3428 of 5326
Fig. 26: Adjusting Screw On Staking Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The crankshaft must not be turned when the retainers are fitted.
16. Use special tool turning device 9773 ­1­ to turn the crankshaft clockwise as far as the TDC marking on
cylinder 1/4 at the pulley.
16.1. Secure the pulley above the staking bore using a locating pin 9595/1 ­2­ .

3429 of 5326
Fig. 27: Identifying TDC Position Marking On Cylinder 1/4 On Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The special tool staking tool 9879 must be removed before tightening the central valves to their final
tightening torque.

17. Secure central valves for camshaft control ­1­ .

17.1. Secure new hexagon sleeves ­2­ using retainer 9863/2 ­3­ . Secure the retainer to the
cylinder head using an M6 screw ­4­ .
17.2. Pre­tighten central valves for camshaft position using socket wrench for camshaft 9863 ­5­ .
17.3. Staking tool 9879 must now be removed.
17.3.1. Loosen the adjusting screw.
17.3.2. Unscrew fastening screw on the cylinder head and remove the tool.
17.4. Tighten central valves for camshaft control using socket wrench for camshaft 9863 ­5­ .

3430 of 5326
Fig. 28: Securing Camshaft Control Central Valves
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

18. Unscrew special tool chain tensioner 9875 .

19. Screw in and tighten chain tensioner with a new sealing ring.

→ Installing Chain Tensioner.

SUBSEQUENT WORK

1. Install solenoid hydraulic valves for camshaft control.

→ Installing Solenoid Hydraulic Valve For Camshaft Controllers

2. Install cylinder head cover.

→ Installing Cylinder Head Cover

3. Coat tappets for high­pressure pump ­1­ with oil and fit them at the correct installation position.

3431 of 5326
Fig. 29: Identifying High­Pressure Pump Tappets
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Install high­pressure pump on the relevant side.

→ INSTALLING HIGH­PRESSURE PUMP

WM 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES

SETTING TIMING) (EXCEPT CARRERA "EDITION", CARRERA
CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

locating pin Special tool 9595/1 Â

Electronic torque
wrench, 2 ­ 100 Special tool 9768 Â
Nm/1.5 ­ 74 ftlb.

3432 of 5326
staking tool Special tool 9772 Â

turning device Special tool 9773 Â

holding wrench Special tool 9775 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

M22 x 1.5;
Tightening
Chain tensioner replace sealing 80 Nm (59 ftlb.) Â Â
torque
ring
Camshaft External Torx,
Initial tightening 5 Nm (3.5 ftlb.) Â Â
bearing cover M6 x 37
External Torx
screw, M6 x 37 ­
Camshaft
set threshold Torque angle 50°  Â
bearing cover
torque of 5 Nm
(3.5 ftlb.)
Internal Torx
Camshaft
screw, M12 x 1.5
controller to Initial tightening 5 Nm (3.5 ftlb.) Â Â
x 110 ­ replace
camshaft
friction washer
Internal Torx
screw, M12 x 1.5
Camshaft x 110 ­ replace
controller to friction washer ­ Torque angle 90°  Â
camshaft set threshold
torque of 30 Nm
(22 ftlb.)
Internal Torx
Sprocket to screw, M12 x 1.5 Tightening
5 Nm (3.5 ftlb.) Â Â
camshaft x 60 ­ replace torque
friction washer
Internal Torx
screw, M12 x 1.5
x 60 ­ replace
friction washer ­
Sprocket to
set threshold Torque angle 65°  Â
camshaft

3433 of 5326
torque of 30 Nm
(22 ftlb.)

PRELIMINARY WORK

1. Remove engine. → REMOVING ENGINE

2. Remove engine carrier. → REMOVING ENGINE CARRIER
3. Remove turbocharger. → REMOVING TURBOCHARGER
4. Remove spark plugs. → REMOVING SPARK PLUGS
5. Remove cylinder head cover. → Removing Cylinder Head Cover
6. Remove high­pressure pump. → REMOVING HIGH­PRESSURE PUMP
7. Remove vacuum pump. → REMOVING VACUUM PUMP
8. Remove cover ­1­ on positive crankcase ventilation line.
8.1. Cylinder bank 1­3: Unscrew external Torx screws ­4­ and replace O­ring ­3­ and molded seal
­2­ .

Fig. 30: Removing Positive Crankcase Ventilation Cover 1­3

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8.2. Cylinder bank 4­6: Unscrew external Torx screws ­3­ and replace O­ring ­2­ .

3434 of 5326
Fig. 31: Removing Positive Crankcase Ventilation Cover 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

REMOVING CAMSHAFTS

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Component overview of cylinder head/camshafts (view of bank 1­3):

3435 of 5326
Fig. 32: Overview Of Cylinder Head/Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Camshaft mounting saddle

2. External Torx screw, M6 x 37
3. Dowel sleeves for cylinder head ­ replace if damaged
4. Bearing saddle (upper part)
5. Bearing saddle (lower part)
6. External Torx screw, M6 x 55

Individual parts of camshafts:

Fig. 33: Identifying Camshafts Parts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Central screw for camshaft controller, M12 x 110 (replace screw)

2. Central screw for sprocket, M12 x 60 (replace screw)

3436 of 5326
3. Driver for camshaft controller
4. Friction plate (replace)
5. Intake camshaft
6. Outlet camshaft

Information

The camshafts can only be removed in the overlapping position at the top dead center of pistons 1 or 4.
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 engine at the assembly support so that the cylinder bank to be worked on is at the top.
2. Use special tool turning device 9773 ­1­ to turn the crankshaft clockwise at the vibration damper as
far as the TDC marking on cylinder 1/4 .
2.1. Fix the vibration damper in place above the staking bore using a locating pin 9595/1 ­2­ .

Fig. 34: Identifying TDC Marking On Cylinder 1/4 On Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Check cam position on cylinders 1 and 4.

3.1. Check the position of the data matrix code on both camshafts. These must be facing the
observer at overlapping position.
3.2. Overlap of cylinder 1: The cams must be facing downwards at an angle to the cylinder head
wall ­arrows­ .
1. Intake camshaft 1­3
2. Outlet camshaft 1­3

3437 of 5326
Fig. 35: Locating Cam Position For Cylinder 1 On Overlap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3.3. Overlap of cylinder 4 (viewed from above): The cams are facing each other and are at a
slight angle with respect to the spark­plug recess ­arrows­ .

3438 of 5326
Fig. 36: Locating Cam Position Of Cylinder 4 On Overlap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove central screws on camshaft timing gears.

4.1. Loosen internal Torx central screw on the outlet sprocket. To do this, counter with special tool
holding wrench 9775 ­1­ .

3439 of 5326
Fig. 37: Loosening Outlet Sprocket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Loosen internal Torx central screw on the camshaft controller. To do this, counter with a long
open­ended wrench (a/f 32) ­1­ .

3440 of 5326
Fig. 38: Loosening Camshaft Controller
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove chain tensioner.

5.1. Cylinder bank 1­3: The chain tensioner is on the exhaust side.
5.2. Cylinder bank 4­6: Chain tensioner is on top of cylinder head.
5.3. Replace sealing ring.
6. Loosen camshafts.
6.1. Loosen and unscrew external Torx screws on the bearing saddle ­2­ .
6.2. Loosen and unscrew external Torx screws for the mounting saddles ­1­ from the outside to the
inside.
6.3. Remove bearing saddle and mounting saddles.

3441 of 5326
Fig. 39: Identifying Camshaft Mount
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Lift camshafts out of the cylinder head. Lay the timing chain into the chain housing in the cylinder head.
7.1. Unscrew central screw on the camshaft controller ­1­ .
7.2. Lift up the camshaft controller with the intake camshaft and pull the camshaft ­2­ to the
flywheel side using one hand. Lift up the timing chain and remove the camshaft controller.

Be particularly careful with the friction plate!

3442 of 5326
Fig. 40: Identifying Intake Camshaft With Camshaft Controller
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7.3. Place the camshaft controller on the intake camshaft again for storage. Tighten screw only
slightly.
7.4. Remove outlet camshafts ­1­ complete with the sprocket ­2­ .

3443 of 5326
Fig. 41: Identifying Outlet Camshaft With Sprocket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Replace the friction plates of the sprocket and camshaft controller.

Information

The camshaft controller must not be cleaned in a parts washer.

Only the outside can be cleaned using a clean, lint­free cloth.
9. Clean components.
9.1. Do not clean the camshaft controller in a parts washer!

INSTALLING CAMSHAFTS AND SETTING TIMING

Component Markings And Distinguishing Features

Information

The camshaft markings are on a surface next to the dihedron.

The part number and data matrix code (helps when inserting the camshafts) are important.

Identification markings:

1. Data matrix code

2. Part No.
3. Conical dihedron for setting the timing

3444 of 5326
Fig. 42: Identifying Part Number And Data Matrix Code Marking On Camshaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Part numbers on camshafts:

Intake side:

1. 3.8­litre engine ­ MA 1.03: Intake camshaft (short) on cylinder bank 4­6, marking: 9A1.105.276.01
2. 3.8­litre engine ­ MA 1.03: Intake camshaft on cylinder bank 1­3, marking: 9A1.105.275.01
3. 3.4­litre engine ­ MA 1.04: Intake camshaft (short) on cylinder bank 4­6, marking: 9A1.105.284.01
4. 3.4­litre engine ­ MA 1.04: Intake camshaft on cylinder bank 1­3, marking: 9A1.105.283.01

3445 of 5326
Fig. 43: Identifying Intake Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Outlet side:

1. 3.8­litre engine ­ MA 1.03: Outlet camshaft (short) on cylinder bank 4­6, marking: 9A1.105.278.01
2. 3.8­litre engine ­ MA 1.03: Outlet camshaft on cylinder bank 1­3, marking: 9A1.105.277.01
3. 3.4­litre engine ­ MA 1.04: Outlet camshaft (short) on cylinder bank 4­6, marking: 9A1.105.286.01
4. 3.4­litre engine ­ MA 1.04: Outlet camshaft on cylinder bank 1­3, marking: 9A1.105.285.01

3446 of 5326
Fig. 44: Identifying Outlet Camshafts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Distinguishing features of outlet sprockets:

1­3 ­ Sprocket for outlet camshaft on cylinder 1­3, driver for high­pressure pump: Recess 13.5 mm and 11.6
mm deep.

4­6 ­ Sprocket for outlet camshaft on cylinder 4­6, driver for vacuum pump, both recesses 11.6 mm deep.

3447 of 5326
Fig. 45: Identifying Outlet Sprockets
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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)

Installing Camshafts, Setting Timing ­ Cylinder Bank 4­6

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Turn the crankshaft clockwise (direction of rotation of engine) to 60° before TDC at the vibration
damper.
1.1. This position is marked U 3/6 on the surface.
1.2. Fix using a long locating pin 9595/1 ­1­ .

3448 of 5326
Fig. 46: Identifying U 3/6 Marking On Vibration Damper
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Turn the engine at the assembly support so that the cylinder bank to be fitted is at the top.
3. Insert lower part of bearing saddle ­1­ . Check matching number!
3.1. Check position of oil bores and position and fit the component over the dowel sleeves.

3449 of 5326
Fig. 47: Identifying Lower Part Of Bearing Saddle 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light
coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
4.1. Check that all hydraulic tappets are installed correctly.
5. Check that the new friction plate ­1­ is fitted in the outlet sprocket.

3450 of 5326
Fig. 48: Identifying Friction Plate In Outlet Sprocket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Fit outlet camshaft ­1­ and sprocket ­2­ .

6.1. Tighten the central screw only slightly so that the sprocket can still turn.
6.2. Lift the timing chain and position the camshaft and sprocket at the overlapping position of
cylinder 4. The cams must then be facing downwards at an angle with respect to the spark­plug
recess and the camshaft must lie loosely in the bearing positions.

Fig. 49: Identifying Outlet Camshaft And Sprocket (Cylinder Bank 1­3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Check that the new friction plate ­2­ is fitted in the camshaft controller ­3­ .

3451 of 5326
Fig. 50: Identifying Friction Plate In Camshaft Controller
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Insert intake camshaft ­2­ .

8.1. Lift the timing chain and engage and secure the camshaft controller ­1­ . Guide the intake
camshaft into the controller and set it to the overlapping position of cylinder 4. The cams must then
be facing downwards at an angle with respect to the spark­plug recess and the camshaft must lie
loosely in the bearing positions.
8.2. Screw in the central screw loosely by hand so that the controller can still turn.

3452 of 5326
Fig. 51: Identifying Intake Camshaft With Camshaft Controller (Cylinder Bank 1­3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Check cam position for cylinder 4 again. The cams must be facing downwards at an angle with respect to
the spark­plug recess ­arrows­ .

3453 of 5326
Fig. 52: Locating Cam Position On Cylinder 4 (Overlap)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9.1. Another feature is the data matrix code marking ­1­ on the reconditioned surface next to the
dihedron ­3­ . These markings must be facing the observer at overlapping position.

3454 of 5326
Fig. 53: Identifying Part Number And Data Matrix Code Marking On Camshaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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.

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

3455 of 5326
Fig. 54: Locating Timing Chain In Tensioning And Guide Rails
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light
coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
12. Fit bearing saddle and bearing covers.
12.1. Fit bearing saddle and bearing covers and observe markings!
12.2. Fit four external Torx screws (M6 x 55) on the bearing saddle.
12.3. Fit two external Torx screws (M6 x 37) on each of the bearing covers.
12.4. Fit and tighten screws according to the tightening sequence ­1 to 16­ .

Tool recommendation: Electronic torque wrench, 2 ­ 100 Nm/1.5 ­ 74 ftlb. 9768

12.4.1. Initial tightening 5 Nm (3.5 ftlb.)

12.4.2.
12.4.3. Final tightening Torque angle 50°

3456 of 5326
Fig. 55: Camshaft Bearing Cover Screws Tightening Sequence
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
13.1. There must be perceptible clearance because otherwise the shafts will have to be re­
fitted!
14. Screw in and tighten chain tensioner with a new seal.

Tightening torque 80 Nm (59 ftlb.)

Set the timing, cylinder bank 4­6:

15. Position the staking tool 9772 on the reconditioned dihedron of the camshafts.
15.1. Check the position of the intake and outlet side.
1. A ­ A = Outlet
2. E ­ E = Intake
3. 1 ­ Adjustment device
4. 2 ­ Staking guide

Fig. 56: Fitting Camshafts Cylinder Bank 4­6 (Flywheel Side)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Fit staking tool ­1­ on the cylinder head and camshafts.
16.1. Secure on the cylinder head with four screws ­2­ (use M6 x 25 screws from the cylinder head
cover). Tighten screws only slightly.

Fig. 57: Identifying Staking Tool Screws For Cylinder Bank 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Tighten adjusting screw ­arrow­ on the staking tool ­1­ using a torque wrench ­2­ .

→ Tightening torque: 10 Nm (7.5 ftlb.)

3457 of 5326
Fig. 58: Adjusting Screw On Staking Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

18. Turn the crankshaft clockwise (direction of rotation of engine) to the TDC marking at the vibration
damper.
18.1. This position is marked TCD 1/4 on the surface.
18.2. Fix using a long locating pin 9595/1 ­2­ .

Fig. 59: Identifying TDC Marking On Cylinder 1/4 On Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

19. Pre­tighten central screws for the sprocket and camshaft controller.
19.1. Tighten central screw on sprocket initially and counter with a holding wrench 9775 while
doing this.

Tightening torque 5 Nm (3.5 ftlb.)

19.2. Tighten central screw on camshaft controller initially, countering with a long open­ended
wrench (a/f 32) at the driver.

Initial tightening 5 Nm (3.5 ftlb.)

Information

Before final tightening (torque angle) of the central screws, the special tool staking tool 9772 must
be removed.

20. Staking tool 9772 must now be removed.

20.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the
tool.
20.2. Unscrew fastening screw on the cylinder head and remove the tool.
21. Tighten central screws on the sprocket and camshaft controller to the specified final torque using a torque
angle wrench ­2­ .
21.1. Tighten central screw on sprocket and counter with a holding wrench 9775 ­1­ while doing
this.

Torque angle 65°

Fig. 60: Loosening Outlet Sprocket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

21.2. Tighten central screw on camshaft controller, countering with a long open­ended wrench (a/f
32) ­1­ .

Torque angle 90°

Fig. 61: Loosening Camshaft Controller

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Installing Camshafts, Setting Timing ­ Cylinder Bank 1­3

NOTE: Dirt and contamination

Risk of damage to units or components

3458 of 5326
→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

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.

Information

Before final tightening (torque angle) of the central screws, the special tool staking tool 9772 must be
removed.

1. Continue to turn the crankshaft clockwise (direction of rotation of engine) to 60° before TDC at the
vibration damper.
1.1. This position is marked U 3/6 on the surface.
1.2. Fix using a long locating pin 9595/1 ­1­ .

Fig. 62: Identifying U 3/6 Marking On Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Turn the engine on the assembly support until cylinder bank 1­3 is at the top.
3. Insert lower part of bearing saddle ­1­ . Check matching number!
3.1. Check position of oil bores and position and fit the component over the dowel sleeves.

Fig. 63: Identifying Lower Part Of Bearing Saddle On Cylinder Bank 1­3
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light
coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
4.1. Check that all hydraulic tappets are installed correctly.
5. Check that the new friction plate is fitted in the sprocket.
6. Fit outlet camshaft and sprocket.
6.1. Tighten the central screw only slightly so that the sprocket can still turn.
6.2. Lift the timing chain and position the camshaft and sprocket at the overlapping position of
cylinder 1. The cams must then be facing outwards at an angle with respect to the cylinder head
wall and the camshaft must lie loosely in the bearing positions.
6.3. Another feature is the data matrix code marking on the reconditioned surface next to the
dihedron. These markings must be facing the observer at overlapping position.

Information

The outlet sprocket must be positioned correctly in order to build up the pressure of the high­pressure
pump correctly when starting the engine.

7. After fitting the outlet camshaft, the sprocket must be aligned with the driver for the high­pressure pump.
7.1. Cylinder head positioned vertically: The sprocket must be positioned towards the top left
using the deeper recess on the driver (13.5 mm) ­1­ at approx. 15 degrees with respect to the
sealing face of the cylinder head.

Fig. 64: Identifying Driver High­Pressure

3459 of Pump
5326 Position (15°)
Fig. 64: Identifying Driver High­Pressure Pump Position (15°)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Check that the new friction plate is fitted in the camshaft controller.
9. Insert intake camshaft.
9.1. Lift the timing chain and engage and secure the camshaft controller. Guide the intake camshaft
into the controller and set it to the overlapping position of cylinder 1. The cams must then be facing
outwards at an angle with respect to the cylinder head wall and the camshaft must lie loosely in the
bearing positions.
9.2. The data matrix code marking on the camshaft must be facing the observer.
9.3. Tighten the central screw only slightly by hand so that the camshaft controller can still turn.
10. Check cam position of cylinder 1 before fitting the bearing saddle and bearing covers. The cams must be
facing outwards at an angle with respect to the cylinder head wall ­arrows­ .
10.1. Check the position of the outlet sprocket again (position of driver for high­pressure pump).

Fig. 65: Locating Cam Position For Cylinder 1 (Overlap)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Fig. 66: Locating Timing Chain In Tensioning And Guide Rails

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light
coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
13. Fit bearing saddle and bearing covers.
13.1. Fit bearing saddle and bearing covers and check markings!
13.2. Fit four external Torx screws (M6 x 55) on the bearing saddle.
13.3. Fit two external Torx screws (M6 x 37) on each of the bearing covers.
13.4. Fit and tighten screws for the bearing covers and bearing saddle according to the specified
tightening sequence (as for cylinder bank 4­6).

Tool recommendation: Electronic torque wrench, 2 ­ 100 Nm/1.5 ­ 74 ftlb. 9768

13.4.1. Initial tightening: 5 Nm (3.5 ftlb.)

13.4.2. Subsequent tightening: 5 Nm (3.5 ftlb.)
13.4.3. Final tightening torque angle: 50 degrees
14. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
14.1. There must be perceptible clearance because otherwise the shafts will have to be re­
fitted!
15. Screw in and tighten chain tensioner with a new seal.

Tightening torque 80 Nm (59 ftlb.)

Set the timing, cylinder bank 1­3: The timing for cylinder bank 1­3 is set in the same way as for
cylinder bank 4­6.

16. The adjusting device is positioned on the reconditioned dihedron of the camshafts.
16.1. Check the position of the intake and outlet side.
17. Staking tool 9772 must be fitted on the cylinder head and camshafts.

3460 of 5326
17.1. Secure on the cylinder head with four screws (M6 x 25 screws from cylinder head). Tighten
screws slightly with your hand.
18. Tighten adjusting screw on the staking tool.

=> Tightening torque for adjusting screw: 10 Nm (7.5 ftlb.)

19. Turn the crankshaft clockwise (direction of rotation of engine) to the TDC marking of cylinders 1 and
4 at the vibration damper.
19.1. This position is marked TDC 1/4 on the vibration damper.
19.2. Fix using a long locating pin 9595/1 .
20. Check position of the outlet sprocket.
20.1. The sprocket must now be positioned towards the top left with the deeper recess on the driver
(13.5 mm) ­1­ at approx. 45 degrees with respect to the sealing face of the cylinder head.
20.2. If this is not the case, the outlet camshaft must be re­aligned with the sprocket.

Fig. 67: Locating End Position Of Driver High­Pressure Pump (45°)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

21. Pre­tighten central screws for the sprocket and camshaft controller.
21.1. Tighten central screw on sprocket initially and counter with holding wrench 9775 while
doing this.

Tightening torque 5 Nm (3.5 ftlb.)

21.2. Tighten central screw on camshaft controller initially, countering with a long open­ended
wrench (a/f 32) at the driver.

Initial tightening 5 Nm (3.5 ftlb.)

22. Staking tool 9772 must now be removed.

22.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the
tool.
22.2. Unscrew fastening screw on the cylinder head and remove the tool.
23. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a
torque angle wrench.
23.1. Tighten central screw on sprocket and counter with a holding wrench 9775 while doing this.

Torque angle 65°

23.2. Tighten central screw on camshaft controller, countering with a long open­ended wrench (a/f
32).

Torque angle 90°

24. Then check the position of the camshafts on both sides again (pay attention to overlapping position).
24.1. It must be possible to screw in the adjusting screw by hand at the staking tool 9772 .
24.2. Remove the tool and complete the engine.

SUBSEQUENT WORK

1. Fit cover for crankcase ventilation line.

2. Install high­pressure pump. → INSTALLING HIGH­PRESSURE PUMP
3. Install vacuum pump. → INSTALLING VACUUM PUMP
4. Install cylinder head cover. → Installing Cylinder Head Cover
3461 of 5326
5. Install spark plugs. → INSTALLING SPARK PLUGS
6. Install turbocharger. → INSTALLING TURBOCHARGER
7. Install engine carrier. → INSTALLING ENGINE CARRIER
8. Install engine. → INSTALLING ENGINE

WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

locating pin Special tool 9595/1 Â
turning device Special tool 9773 Â

PRELIMINARY WORK
Preliminary Work For Chain Tensioner For Cylinder Bank 4­6

1. Remove air cleaner housing.

→ REMOVING AIR CLEANER HOUSING .

2. Remove heat shield on the engine carrier.

→ REMOVING HEAT SHIELD .

Preliminary Work For Chain Tensioner For Cylinder Bank 1­3

1. Drain engine oil.

→ DRAINING ENGINE OIL .

2. Remove heat shield on the engine carrier.

→ REMOVING HEAT SHIELD .

REMOVING CHAIN TENSIONER

Removing Chain Tensioner For Cylinder Bank 4­6

1. Position pulley in order to secure it.

1.1. Turn the pulley clockwise using special tool turning device 9773 ­2­ until one staking bore is
flush with the bore in the crankcase.
1.2. Stake the pulley using the short locating pin 9595/1 ­1­ .

Fig. 68: Tightening Pulley

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Release and disconnect cable plug ­1­ for coolant temperature sensor ­2­ .

Fig. 69: Identifying Coolant Temperature Sensor Cable Plug

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Loosen and unscrew chain tensioner ­1­ .

3462 of 5326
Fig. 70: Identifying Chain Tensioner
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Replace O­ring ­2­ and sealing ring ­3­ for chain tensioner ­1­ .

Fig. 71: Identifying Chain Tensioner, O­Ring And Sealing Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Removing Chain Tensioner For Cylinder Bank 1­3

1. Position pulley from below in the same way as for cylinder bank 4­6.
1.1. Turn the pulley clockwise using special tool turning device 9773 until one staking bore is
flush with the bore in the crankcase.
1.2. Stake the pulley using the short locating pin 9595/1 .
2. Loosen and unscrew chain tensioner ­1­ .

Collect any remaining oil that emerges.

Fig. 72: Identifying Chain Tensioner

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Replace O­ring and sealing ring.

INSTALLING CHAIN TENSIONER

Installing Chain Tensioner For Cylinder Bank 4­6

1. Screw in and tighten chain tensioner ­1­ with new seals.

Fig. 73: Identifying Chain Tensioner

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Connect cable plug ­1­ for coolant temperature sensor ­2­ .

2.1. Check that the cable plug is seated securely.

Fig. 74: Identifying Coolant Temperature Sensor Cable Plug

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Remove locating pin and tool from the pulley.

Installing Chain Tensioner For Cylinder Bank 1­3

1. Screw in and tighten chain tensioner ­1­ with new seals from below.

Tightening torque: 80 Nm (59 ft.lb.)

Fig. 75: Identifying Chain Tensioner

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Remove locating pin and tool from the pulley.

SUBSEQUENT WORK
Subsequent Work For Chain Tensioner For Cylinder Bank 4­6

3463 of 5326
1. Install air cleaner housing.

→ INSTALLING AIR CLEANER HOUSING .

2. Install lower part of lid lock.

→ INSTALLING LOWER PART OF LID LOCK .

3. Install engine­compartment blower.

→ INSTALLING ENGINE­COMPARTMENT BLOWER .

Subsequent Work For Chain Tensioner For Cylinder Bank 1­3

1. Fill in engine oil.

→ FILLING ENGINE OIL .

2. Check engine­oil level.

→ CHECKING OIL LEVEL .

WM 153719 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE

FOR CAMSHAFT CONTROLLERS (EXCEPT CARRERA "EDITION",
CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", TURBO S
CABRIO, CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

relay puller Special tool 9235 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Hydraulic valve
for camshaft Tightening
M5 x 12 8 Nm (6 ftlb.) Â Â
control to torque
cylinder head
Holder securing
high­pressure
External Torx Tightening 13 Nm (9.5
line and low­ Â Â
screw, M6 x 16 torque ftlb.)
pressure line to
cylinder head

PRELIMINARY WORK

1. Remove rear spoiler. → REMOVING REAR SPOILER

REMOVING SOLENOID HYDRAULIC VALVE FOR CAMSHAFT CONTROLLERS

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

3464 of 5326
→ Clean or replace dirty components.

Cylinder 1­3

1. Disconnect fuel lines ­1­ by unscrewing the screw ­arrow­ .

Not for Turbo vehicles!

Fig. 76: Locating Fuel Lines On Cylinder Head

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Proceed as follows for cylinder 1­3 and cylinder 4­6

2. Remove the valve.

2.1. Pull off cable plug ­1­ by pressing the spring clamps on the connector. Note installation
position.
2.2. Unscrew two external Torx screws (E8, M5 x 12) ­2­ .
2.3. Pull off the valve.
2.4. If the valve is tight, use special tool relay puller 9235 to pull it off. Then protect the valve
body with fabric tape.
2.5. Replace O­ring.

Fig. 77: Identifying Camshaft Control Solenoid Hydraulic Valve

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING SOLENOID HYDRAULIC VALVE FOR CAMSHAFT CONTROLLERS

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Cylinder 1­3 and cylinder 4­6

1. Fit valve with new O­ring.

1.1. Insert valve and check installation position and correct cable plug position.
1.2. Fit and tighten two external Torx screws (E8, M5 x 12) ­2­ . Tightening torque 8 Nm (6 ftlb.)
1.3. Connect cable plug ­1­ .

Fig. 78: Identifying Camshaft Control Solenoid Hydraulic Valve

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Proceed as follows for cylinder 1­3

2. Secure the fuel lines ­1­ by tightening the screw ­1­ . Tightening torque 13 Nm (9.5 ftlb.)

Not for Turbo vehicles!

Fig. 79: Locating Fuel Lines On Cylinder Head

Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3465 of 5326
SUBSEQUENT WORK

1. Install rear spoiler. → INSTALLING REAR SPOILER

WM 155519 REMOVING AND INSTALLING HYDRAULIC VALVE FOR VALVE

LIFT SWITCHOVER (EXCEPT CARRERA "EDITION", CARRERA
CABRIOLET "EDITION", CARRERA 4 "EDITION", TURBO CABRIO,
TURBO S CABRIO, CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

cover for dust
protection when Special tool NR.165 Â
fitting the engine

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Hydraulic valve
Tightening
for valve lift M5 x 12 8 Nm (6 ftlb.) Â Â
torque
adjustment

PRELIMINARY WORK

Remove heat shield at the top. → REMOVING HEAT SHIELD ­ UPPER PART

REMOVING HYDRAULIC VALVE FOR VALVE LIFT SWITCHOVER

CAUTION: Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

1. Remove hydraulic valve for valve lift switchover.

1.1. Pull off cable plug ­1­ by pressing the spring clamp ­arrow­ .
1.2. Unscrew screws ­2­ and remove hydraulic valve.

Fig. 80: Locating Valve Lift Adjustment Valve And Cylinder 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Replace O­ring ­2­ and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).

Fig. 81: Locating Valve Lift Switchover Hydraulic Valve

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING HYDRAULIC VALVE FOR VALVE LIFT SWITCHOVER

CAUTION: Ingress of dirt

3466 of 5326
Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

1. Fit hydraulic valve for valve lift switchover.

1.1. Fit hydraulic valve with new O­ring at the correct position in the cylinder head.
1.2. Fit and tighten two screws ­2­ . Tightening torque 8 Nm (6 ftlb.)
1.3. Connect cable plug ­1­ .

Fig. 82: Locating Valve Lift Adjustment Valve And Cylinder 4­6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Install heat shield at the top. → INSTALLING HEAT SHIELD

WM 157019 REMOVING AND INSTALLING CYLINDER HEAD (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", TURBO CABRIO, TURBO S CABRIO, CARRERA 4 CABRIOLET
"EDITION", GT3, GT3 RS)
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Cylinder head to External Torx, Tightening 13 Nm (9.5
 Â
crankcase M6 x 25 torque ftlb.)
Cylinder head to External Torx, Tightening 13 Nm (9.5
 Â
crankcase M6 x 80 torque ftlb.)
Internal Torx
screw, M12 x 1.5
Cylinder head to
x 140 (6x) ­ 10 Nm (7.5
crankcase: Step Initial tightening  Â
External Torx ftlb.)
1
screw, M12 x 1.5
x 140 (2x)
Cylinder head to
Tightening 50 Nm (37
crankcase: Step   Â
torque ftlb.)
2
Cylinder head to
Loosen all
crankcase: Step  0 Nm (0 ftlb.)  Â
screws
3
Cylinder head to
crankcase: Step  Initial tightening 4 Nm (3 ftlb.)  Â
4
Cylinder head to
Subsequent
crankcase: Step  12 Nm (9 ftlb.)  Â
tightening
5
Screws 1­4 as
Cylinder head to per tightening
crankcase: Step sequence ­ set Torque angle 65°  Â
3467 of 5326
6 threshold torque
of 15 Nm (11
ftlb.)
Screws 5­8 as
per tightening
Cylinder head to
sequence ­ set
crankcase: Step Torque angle 60°  Â
threshold torque
7
of 15 Nm (11
ftlb.)
Cylinder head to Screws 1­4 as
Final tightening
crankcase: Step per tightening 65°  Â
torque angle
8 sequence
Cylinder head to Screws 5­8 as
Final tightening
crankcase: Step per tightening 60°  Â
torque angle
9 sequence

PRELIMINARY WORK

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Remove engine.

→ REMOVING ENGINE .

2. Remove transmission.

→ REMOVING TRANSMISSION .

→ REMOVING PORSCHE DOPPELKUPPLUNG (PDK) .

3. Carry out the following work on the engine assembly support.

→ MOUNTING ENGINE ON ASSEMBLY SUPPORT .

4. Completely remove intake­air distributor.

→ REMOVING INTAKE­AIR DISTRIBUTOR 1­3 .

5. Remove camshafts.

→ Removing Camshafts.

REMOVING CYLINDER HEAD

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

3468 of 5326
Component overview of screws on cylinder head:

Fig. 83: Overview Of Screws On Cylinder Head

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. External Torx screw, M6 x 25 (bank 1­3: six screws, bank 4­6: five screws)
2. External Torx screw, M6 x 80
3. Internal Torx screw, M12 x 1.5 x 140
4. External Torx screw, M12 x 1.5 x 140

Information

Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their
installation position in the cylinder head.
Components have been run in fitted bores and must not be confused.
Do not use magnets for removal or installation. This can cause the components to malfunction.

1. Remove hydraulic tappets.

1.1. Pull bucket tappets ­1­ and switching tappets ­2­ out of the fitting bores in the cylinder head.
Do not use magnets.

Fig. 84: Identifying Hydraulic Tappets

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.2. Lay components on a clean, labelled surface.

Fig. 85: Example Of Laying Aside Hydraulic Tappets

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.3. If you see signs of wear, replace the relevant hydraulic tappet and check the fitting bore on the
cylinder head.

Remove cylinder head 1­3:

2. Remove two bearing pins on the cylinder head.

2.1. Top bearing pin ­1­ for the guide rail.
2.2. Bottom bearing pin ­2­ for the tensioning rail.
2.3. Replace O­rings.

Fig. 86: Identifying Bearing Pins On Cylinder Bank 1­3

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Remove cylinder head 1­3.

3.1. Unscrew three M6 external Torx screws on the outside of the cylinder head.
3.2. Unscrew four M6 external Torx screws ­1 and 2­ on the inside of the cylinder head.
3.3. Loosen external Torx screws ­3­ and internal Torx screws ­4­ (M12 x 140) from the outside in
and unscrew them.

Fig. 87: Identifying Screws On Cylinder Head 1­3

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3469 of 5326
Remove cylinder head 4­6:

4. Pull off oil supply valve ­1­ for vacuum pump and remove bearing pin ­2­ for guide rail in the cylinder
head.
4.1. Replace O­rings.

Fig. 88: Identifying Bearing Pins On Cylinder Bank 4­6

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Bearing pins on cylinder bank 4­6

5. Remove cylinder head 4­6.

5.1. Unscrew two external Torx screws on the outside of the cylinder head.
5.2. Unscrew four external Torx screws ­1 and 2­ on the inside of the cylinder head.
5.3. Loosen external Torx screws ­3­ and internal Torx screws ­4­ (M12 x 140) from the outside in
and unscrew them.

Fig. 89: Identifying Screws On Inside Of Cylinder Head 4­6

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Lift off the relevant cylinder head. It is quite heavy ­ so be careful .

6.1. Check the fitting bores of the hydraulic tappets for signs of wear. If you see signs of wear, the
cylinder head and any worn cam followers must be replaced.
6.2. Check the sealing face for signs of distortion and wear before re­installation and carry out
appropriate repairs if necessary.
7. Remove and dispose of cylinder­head gasket. Check dowel sleeves for signs of damage and replace if
necessary.

INSTALLING CYLINDER HEAD

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their
installation position in the cylinder head.
Components have been run in fitted bores and must not be confused.
Do not use magnets for removal or installation. This can cause the components to malfunction.

1. Fit new cylinder­head gasket. Check that the dowel sleeves are installed correctly.
2. Carefully place cylinder head in position.

Information

The tightening sequence must be strictly observed.

3. Secure cylinder head.
3.1. Fit cylinder­head screws (M12 x 140) and tighten according to specifications.
3470 of 5326
Initial tightening 10 Nm (7.5 ftlb.)

Tightening torque 50 Nm (37 ftlb.)

Loosen screws: Loosen all screws 0 Nm (0 ftlb.)

Initial tightening 4 Nm (3 ftlb.)

Subsequent tightening 12 Nm (9 ftlb.)

Screws 1­4: Threshold torque: 15 Nm (11 ft.lb.), Torque angle 65°

Screws 5­8: Threshold torque: 15 Nm (11 ft.lb.), Torque angle 60°

Screws 1­4: Final tightening torque angle 65°

Screws 5­8: Final tightening torque angle 60°

3.2. Screw in external M6 Torx screws on the inside of the cylinder head and tighten according to
specifications.

Screw position ­9­ : Tightening torque 13 Nm (9.5 ftlb.)

Screw position ­10­ : Tightening torque 13 Nm (9.5 ftlb.)

3.3. Screw in external M6 Torx screws ­11­ on the outside of the cylinder head and tighten
according to specifications.

Tightening torque 13 Nm (9.5 ftlb.)

Fig. 90: Cylinder Head Screws Tightening Sequence (Side 1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Coat hydraulic tappets with new engine oil and insert in original installation position.

SUBSEQUENT WORK

1. Install camshafts.

→ Installing Camshafts And Setting Timing.

2. Install cylinder head cover.

→ Installing Cylinder Head Cover.

3. Install intake­air distributor.

→INSTALLING INTAKE­AIR DISTRIBUTOR .

4. Remove engine from assembly support. → 1001IN TOOLS FOR REMOVING UNITS AND
WORKING ON THE ENGINE ASSEMBLY SUPPORT
5. Mount transmission. → MOUNTING TRANSMISSION →
6. Install engine.

→ INSTALLING ENGINE .

WM 157037 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD

(EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION",
3471 of 5326
CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3
RS)
TOOLS

Designation Type Number Description Â

puller VW tool 3364 Â
assembly driver Special tool 9606/1 Â
cover for dust
protection when Special tool NR.165 Â
fitting the engine
Valve key fitting Commercially
Nr.54 Pos.1 Â
and removal tool available tool
Commercially
Assembly tool set Nr.54 Pos.1C Â
available tool

PRELIMINARY WORK

1. Remove engine.

→ REMOVING ENGINE .

2. Remove transmission.

→ REMOVING TRANSMISSION .

3. Remove cylinder head.

→ Removing Cylinder Head.

DISASSEMBLING CYLINDER HEAD

CAUTION: Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.
→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

Recommended tools: Valve key fitting and removal tool Nr.54 Pos.1

Fig. 91: Identifying Cylinder Head Tools

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Pressure fork with lever

2. Engaging lock
3. Assembly cartridge
4. Valve key insertion device
5. Assembly tool set Nr.54 Pos.1C
6. Valve locating screws (from Sauer tool set No. 54­1)

Component overview of cylinder head

3472 of 5326
Fig. 92: Overview Of Cylinder Head
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Cylinder head
2. Intake valve
3. Valve­stem seal
4. Lower valve­spring plate (intake)
5. Valve spring set, conical (intake)
6. Upper valve­spring plate (intake)
7. Valve keys
8. Outlet valve
9. Lower valve­spring plate (outlet)
10. Valve spring set, cylindrical (outlet)
11. Upper valve­spring plate (outlet)

Information

Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original
installation location.

1. Screw three valve locating screws ­arrows­ into the spark plug threads.
1.1. Alternatively, rubber or plastic wedges can be used.

Fig. 93: Locating Valve Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Attach the screw clamps for fixing the cylinder head only on the unions, never on the sealing face.

2. Fix cylinder head at the side ­arrows­ to the workbench with screw clamps.
2.1. Clamp a piece of wood in between to protect the unions.

Fig. 94: Installing Cylinder Head Clamps

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Attach tools to the cylinder head.

3.1. Screw engaging lock ­1­ into the appropriate threaded bore.
3.2. Insert guide bush ­2­ and push it down as far as it will go.
3.3. Fit assembly cartridge ­3­ into the guide bush.
3.4. Engage pressure fork with lever ­4­ at a suitable position on the engaging lock and support it
on the assembly cartridge.

Fig. 95: Engaging Pressure Fork With Lever

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

The flexible rotating head of the assembly cartridge must be positioned almost on the assembly
cartridge.
If this is not the case, the valve key mounting will not be positioned over the valve stem and it will
not be possible to fit the valve keys.
4. Remove valve keys.
3473 of 5326
4.1. Press the valve springs together by pressing the pressure forks ­arrow­ .
4.2. The valve keys are attached and secured by turning the flexible rotary head of the assembly
cartridge ­arrow­ .

Fig. 96: Removing Valve Springs

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Valve springs and valve­spring plates are different for intake and outlet valves.
The valve springs for the intake valves are conical, while the valve springs for the outlet valves are
cylindrical. Check installation position!
5. Remove valve springs and upper valve­spring plate using a bar magnet.
5.1. Do not confuse valve springs during installation!
1. Valve spring set, conical (intake)
2. Valve spring set, cylindrical (outlet)

Fig. 97: Identifying Intake/Outlet Valve Springs

Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Removing Valve­Stem Seal

Information

1. Pull off the valve­stem seal using the puller 3364 .

Fig. 98: Pulling Valve­Stem Seal

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Check valve springs, valves, valve guides and valve seats for damage.
3. Thoroughly clean cylinder head and all parts before assembly.
Installing Valve­Stem Seals

Information

Replace valve­stem seal.

1. Insert lower valve­spring plate.

1.1. Oil the valve stem lightly and position assembly sleeve (shim set for valve­stem seals).
1.2. Slide new valve­stem seal over the sleeve by hand.

Fig. 99: Identifying Valve­Stem Seal

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Use assembly driver 9606/1 to press the valve­stem seal as far as it will go onto the valve stem ­arrow­ .
2.1. Remove tool and assembly sleeve.

Fig. 100: Pressing Valve­Stem Seal

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

ASSEMBLING CYLINDER HEAD

3474 of 5326
Information

Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their
original installation location.
Valve springs and valve­spring plates are different for intake and outlet valves.
The valve springs for the intake valves are conical, while the valve springs for the outlet valves are
cylindrical. Check installation position!
The flexible rotating head of the assembly cartridge must be positioned almost on the assembly cartridge.
If this is not the case, the valve key mounting will not be positioned over the valve stem and the valve keys
will not be moved to the correct position.

1. Insert corresponding valve springs and upper valve­spring plate.

2. Insert guide bush ­2­ and push it down as far as it will go.
2.1. Insert assembly cartridge ­3­ with secured valve keys into the guide bush.
3. Engage pressure fork with lever ­4­ at a suitable position on the engaging lock ­1­ and support it on the
assembly cartridge ­3­ .

Fig. 101: Engaging Pressure Fork With Lever

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Press the valve springs together using the pressure fork.

4.1. The valve keys are released by pulling on the assembly cartridge ­arrow­ and are positioned
on the valve stem.

Fig. 102: Pulling Valve Springs

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove pressure folk with lever and assembly cartridge and check that the valve keys are seated
securely.
5.1. Repeat the process if necessary.

SUBSEQUENT WORK

1. Install cylinder head.

→ Installing Cylinder Head.

2. Mount transmission.

→ MOUNTING TRANSMISSION .

→ MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

3. Install engine.

→ INSTALLING ENGINE .

WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER

(EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION",
TURBO, TURBO S, CARRERA 4 "EDITION", TURBO CABRIO, TURBO S
CABRIO, CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TECHNICAL VALUES

3475 of 5326
Location Description Type Basic value Tolerance 1 Tolerance 2
Vent cover for
cylinder 1­3 to External Torx
Tightening 13 Nm (9.5
cylinder screw, M6 x 25 Â Â
torque ftlb.)
head/cylinder (3x)
head cover
Internal Torx
screw, M6 x 25 ­
Cylinder head
the first four Tightening 13 Nm (9.5
cover to cylinder  Â
screws must torque ftlb.)
head
always be re­
tightened.
Ground strap to Internal Torx
Tightening 10 Nm (7.5
cylinder head screw, M6 x 12 Â Â
torque ftlb.)
cover (4x)
Holder for rear External Torx
Tightening 23 Nm (17
silencer to screw, M8 x 20 Â Â
torque ftlb.)
cylinder head (4x)

PRELIMINARY WORK

1. Drain engine oil. →DRAINING ENGINE OIL .

2. Remove exhaust manifold on the relevant side. → REMOVING EXHAUST MANIFOLD
3. Remove rear silencer. → REMOVING REAR SILENCER
4. Lower the engine. → LOWERING AND SECURING THE ENGINE
5. Remove ignition coils. → REMOVING IGNITION COILS

REMOVING CYLINDER HEAD COVER

Removing Cylinder Head Cover 1­3

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Disconnect electric lines.

1.1. Disconnect ground straps ­1­ by unscrewing the screws.
1.2. Release electric plug connection ­2­ at the solenoid hydraulic valve for valve lift adjustment ­
a­ and pull it off ­A­ .
1.3. Release electric plug connection ­3­ at the hall sender ­b­ and pull it off ­B­ .

Fig. 103: Disconnecting Ground Straps And Plug Connections On Cylinder Head
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Disconnect electric line ­1­ for oxygen sensor upstream of catalytic converter by unclipping the line ­
arrows­ .

Fig. 104: Locating Oxygen Sensor Upstream Electric Line Of Catalytic Converter, Cylinder 1­3
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3476 of 5326
3. Disconnect electric line for oxygen sensor downstream of catalytic converter ­1­ .
3.1. Unclip line ­1­ at the clip ­2­ for the rear silencer holder ­3­ .
3.2. Unclip line ­1­ at the clip ­4­ .

Fig. 105: Identifying Oxygen Sensor Downstream Electric Line Of Catalytic Converter,
Cylinder 1­3
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove holder ­1­ for rear silencer.

4.1. Unscrew screws ­2­ and remove the holder ­1­ .

Fig. 106: Identifying Rear Silencer Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Release positive crankcase ventilation pipe ­1­ on the cylinder head cover ­2­ (­3­ ) and disconnect it.

Fig. 107: Identifying Positive Crankcase Ventilation Hose On Cylinder Head Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Remove positive crankcase ventilation cover ­1­ .

6.1. Unscrew screws ­4­ and pull off the cover.
6.2. Replace O­ring ­3­ .
6.3. Check molded seal ­2­ and replace it if damaged.

Fig. 108: Removing Positive Crankcase Ventilation Cover 1­3

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Remove cylinder head cover.

7.1. Loosen screws ­20... 1­ from the outside in and unscrew them.
7.2. Remove molded seal and remove cylinder head cover by pulling it downwards.

Fig. 109: Cylinder Head Cover Screws Loosening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Carefully clean the molded seal using a clean, lint­free cloth.

9. Clean sealing faces on the cylinder head and cover. To do this, soak a clean, lint­free cloth in acetone or
solvent naphtha and wipe off the surfaces.
9.1. Allow components to dry off sufficiently.

Removing Cylinder Head Cover 4­6

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Disconnect electric lines.

1.1. Disconnect ground straps ­1­ by unscrewing the screws.
3477 of 5326
1.2. Release electric plug connection ­2­ at the solenoid hydraulic valves for valve lift adjustment ­
a­ and pull it off ­A­ .
1.3. Release electric plug connection ­3­ at the hall sender ­b­ and pull it off ­B­ .

Fig. 110: Disconnecting Ground Straps And Plug Connections On Cylinder Head
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Disconnect electric line for oxygen sensor upstream of catalytic converter ­1­ by unclipping the line at the
clips ­arrows­ .

Fig. 111: Locating Oxygen Sensor Upstream Electric Line Of Catalytic Converter Clips
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Disconnect electric line for oxygen sensor downstream of catalytic converter ­1­ by unclipping the line at
clip ­2­ and ­3­ .

Fig. 112: Identifying Oxygen Sensor Downstream Electric Line Of Catalytic Converter, Cylinder 4­
6
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove holder ­1­ for rear silencer.

4.1. Unscrew screws ­2­ and remove the holder ­1­ .

Fig. 113: Identifying Rear Silencer Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove cylinder head cover.

5.1. Loosen screws ­20... 1­ from the outside in and unscrew them.
5.2. Remove molded seal and remove cylinder head cover by pulling it downwards.

Fig. 114: Cylinder Head Cover Screws Loosening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Carefully clean the molded seal using a clean, lint­free cloth.

7. Clean sealing faces on the cylinder head and cover. To do this, soak a clean, lint­free cloth in acetone or
solvent naphtha and wipe off the surfaces.
7.1. Allow components to dry off sufficiently.

INSTALLING CYLINDER HEAD COVER

Installing Cylinder Head Cover 1­3

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Fit seal ­1­ into the cylinder head cover.

3478 of 5326
Fig. 115: Identifying Seal On Cylinder Head Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Fit and tighten screws according to the specified tightening sequence. Tightening torque 13 Nm (9.5
ftlb.)

Fig. 116: Cylinder Head Cover Screws Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Install positive crankcase ventilation cover ­1­ .

3.1. Fit molded seal ­2­ .
3.2. Fit O­ring ­3­ .
3.3. Fit cover and tighten screws ­4­ . Tightening torque 13 Nm (9.5 ftlb.)

Fig. 117: Installing Positive Crankcase Ventilation Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect positive crankcase ventilation pipe ­1­ to the cylinder head cover ­2­ .

Fig. 118: Identifying Positive Crankcase Ventilation Hose On Cylinder Head Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Install holder ­1­ for rear silencer.

5.1. Fit holder ­1­ and tighten screws ­2­ . Tightening torque 23 Nm (17 ftlb.)

Fig. 119: Identifying Rear Silencer Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Secure electric line for oxygen sensor upstream of catalytic converter ­1­ at the clips ­arrows­ .

Fig. 120: Locating Oxygen Sensor Upstream Electric Line Of Catalytic Converter Clips
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Secure electric line for oxygen sensor downstream of catalytic converter ­1­ at the clips ­2 and 4­ .

Fig. 121: Identifying Oxygen Sensor Downstream Electric Line Of Catalytic Converter
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Connect electric lines.

8.1. Secure ground straps by tightening the screws.

Tightening torque 10 Nm (7.5 ftlb.)

8.2. Connect electric plug connections to solenoid hydraulic valve for valve lift adjustment and hall
sender.

Installing Cylinder Head Cover 4­6

NOTE: Dirt and contamination

Risk of damage to units or components

3479 of 5326
→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Fit seal ­1­ in cylinder head cover.

Fig. 122: Identifying Seal On Cylinder Head Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Fit and tighten screws according to the specified tightening sequence. Tightening torque 13 Nm (9.5
ftlb.)

Fig. 123: Cylinder Head Cover Screws Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Install holder ­1­ for rear silencer.

3.1. Fit holder ­1­ and tighten screws ­2­ . Tightening torque 23 Nm (17 ftlb.)

Fig. 124: Identifying Rear Silencer Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Secure electric line for oxygen sensor upstream of catalytic converter ­1­ by clipping in the line at the
clips ­arrows­ .

Fig. 125: Locating Oxygen Sensor Upstream Electric Line Of Catalytic Converter Clips
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Secure electric line for oxygen sensor downstream of catalytic converter ­1­ by clipping in the line at clip
­2­ and ­3­ .

Fig. 126: Identifying Oxygen Sensor Downstream Electric Line Of Catalytic Converter
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Connect electric lines.

6.1. Secure ground straps by tightening the screws.

Tightening torque 10 Nm (7.5 ftlb.)

6.2. Connect electric plug connections to solenoid hydraulic valve for valve lift adjustment and hall
sender.

SUBSEQUENT WORK

1. Install ignition coils. → INSTALLING IGNITION COILS

2. Secure engine in installation position. → INSTALLATION
3. Install rear silencer. → INSTALLING REAR SILENCER
4. Install exhaust manifold. → INSTALLING EXHAUST MANIFOLD
5. Fill in engine oil. → FILLING ENGINE OIL .

Copyright 2016 Mitchell Repair Information Company, LLC. All Rights Reserved.

Article GUID: A00704562

3480 of 5326