Timing Components: Service and Repair

Setting timing





1. Fit auxiliary chain tensioner for both cylinder banks. Secure each chain tensioner plate with two M6 pan-head screws and tighten to 10 Nm (7.5 ft. lbs.). Pretension the hexagon-head bolts until the ring groove on the piston just disappears from view.
2. Turn the engine clockwise at the belt pulley of the crankshaft twice through 360° to check that the auxiliary chain tensioners are correctly tensioned. If necessary, correct the setting of the piston (see step 1).





3. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 - 3 using the universal dial gauge holder. Extend the probe of the dial gauge until it is certain that measurement on the piston crown is possible.
Setting cylinder bank 1 - 3:
4. To set the timing, the respective cylinder side must be positioned to overlapping TDC. For this purpose, turn the engine at the belt pulley of the crankshaft (in operating direction) until the maximum defection (reversing point) is attained on the dial gauge. The second mark on the belt pulley must line up with the joint face of the crankcase halves. Re-check if cams of cylinder 1 are pointing towards each other -see Figure 5.1 - Installing camshafts-.





5. Fit adjustment devices. Use two M6 screws to fasten the base plate of both staking tools at the end of the cylinder bank (clutch side) on the sealing surface for the valve cover. Tighten screws by hand only -arrows-.
6. Insert holding keys. Insert the holding keys 9661/2 and 9661/3 into the frame according to their identification and secure each of them with two fit bolts (assigned to the special tool) to prevent them from dropping.





Adjustment device for cylinder bank 1 - 3

Note;
- The camshaft adjusting element must be positioned at the left-hand stop! Use special tool holding wrench 9653!
- When turning the camshafts make sure that the intermediate ribs on the cylinder head are not compressed by the open-ended wrench (sealing surface towards cylinder head cover)!





7. Turn camshaft adjusting element of the inlet camshaft to its left stop. To do this, use the special tool holding wrench 9653 to reduce the oil pressure in the adjusting element by turning it to the left and right until the mechanical stop can be felt. Turn the adjusting element anti-clockwise to the left stop.





8. Set camshafts on cylinder side 1 - 3 (cams of both camshafts point towards each other on cylinder 1). To do this, use a suitable open-ended wrench (a/f 30) on the hexagon lug to turn the camshafts until the holding key of the staking tool enters the slot of the camshaft. Fix holding keys using the fit bolts belonging to the special tool. Re-check the left stop of the camshaft adjusting element.

Note;
- The holding keys 9661/3 must only remain fitted while fixing the camshafts for initial tightening of sprockets and camshaft adjusting elements to 30 Nm (22 ft. lbs.). Ensure they are removed for final tightening. To facilitate subsequent checks, mount the base plates for banks 1 - 3 and 4 -6.

9. Fasten sprockets. Check whether the adjusting element of the inlet camshaft is still at the left stop. Now tighten the fastening screws for the adjusting element and the sprocket with initial tightening torque of 30 Nm (22 ft. lbs.). When doing so, counter the sprockets using the appropriate special tools holding wrench 9653 or holding wrench 9653/1. Subsequently remove the holding keys 9661/2 and 9661/3 and tighten the screw for the exhaust camshaft with a 90° torque angle and the screw for the inlet camshaft with a 130° torque angle. Counter at the sprocket or adjusting element with the appropriate special tool.





Holding wrench 9653 for the camshaft adjusting element
10. Turn the engine on the belt pulley of the crankshaft by 360° clockwise so that the second cylinder side can be set. (Observe maximum defection of dial gauge indicator or TDC position!). The second mark on the belt pulley must line up with the joint face of the crankcase halves.
11. Set cylinder bank 4 - 6 in the same way as bank 1 - 3 (cams of both camshafts on cylinder 4 pointing away from each other) -see Figure 5.2 - Installing camshafts-.





Adjustment device for cylinders 4 - 6
12. Fasten sprocket and adjusting element 4 -6 in the same way as bank 1 - 3.
13. Check the timing. In each case turn the engine on the belt pulley of the crankshaft clockwise by a further 360° and insert the holding keys for each cylinder bank in turn so that the banks can be checked.
14. Remove the adjustment devices and the dial gauge if timing is set correctly, otherwise repeat the setting.
15. Remove the auxiliary chain tensioner. To do this, relieve the auxiliary chain tensioners and loosen the two pan-head screws of each.
16. Reinstall chain tensioner. Insert the chain tensioner into the chain housing in accordance with its identification, then fit the chain tensioner cover with a new seal. Tighten the M6 fastening screws to 10 Nm (7.5 ft. lbs.).
17. Clean sealing surface for the camshaft housing cover. Remove any sealant residue from the sealing surfaces with a new brass wire brush and then degrease with acetone.

Note;
- To seal the camshaft housing cover, use only the approved sealant from the Porsche Parts Catalog!





18. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm -Figure- (drying time of sealant approximately 5 min). Also coat the bores marked by -arrows- with sealant. Next put on the camshaft housing cover and tighten the 17 fastening screws from the inside outwards to the specified torque.
- 14 screws M6 x 35, cylinder bank 1 - 3
- 13 screws M6 x 35, cylinder bank 4 - 6
- On cylinder bank 4 - 6 one screw M6 x 45 for oil line holder
- One screw M6 x 75 per cylinder bank -arrow upper right in figure-
- Two screws M6 x 25 between the spark plugs for cylinders 1 and 2 and between 4 and 5 respectively
Tightening torque M6 (8.8) 10 Nm (7.5 ft. lbs.)
19. Install solenoid hydraulic valve for valve lift adjustment. Tighten at hexagon to the specified torque.
Tightening torque 25 Nm (19 ft. lbs.).
20. Fit the closure cap and the oil extraction pump with new O-rings. Fastening screws: 3 M6 x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque.
Tightening torque M6 (8.8) 10 Nm (7.5 ft. lbs.)
21. Fit four new closure caps (green) for camshaft housing cover in dry state.
22. Fit spark plugs.
Tightening torque: - new spark plugs 30 Nm (22 ft. lbs.); used spark plugs 25 Nm (19 ft. lbs.)
23. Install ignition coils and connect cable plugs.
Tightening torque for pan-head screws M6 x 25: 10 Nm (7.5 ft. lbs.)
24. Install unit carrier.
Tightening torque 65 Nm (48 ft. lbs.).
25. Install coolant guide housing and engine carrier.
Tightening torque 30 Nm (22 ft. lbs.)
26. Install generator.
Tightening torque for M10 screws, 46 Nm (34 ft. lbs.); M8 nut, 15 Nm (11 ft. lbs.)

Note;
- Replace fastening screws M8 x 28 (10.9) and metal seals for the exhaust manifold!

27. Install exhaust manifold using new seals. Tighten the new screws from the inside outwards to the specified torque. Lightly oil thread and screw head bearing surface.
Tightening torque: Initial tightening 25 Nm (19 ft. lbs.); final tightening 33 Nm (24 ft. lbs.)
28. Install oil container.
29. Fit holder for rear muffler. Tighten four M8 screws (short screws at top, long screws below) to the specified torque.
Tightening torque: 23 Nm (17 ft. lbs.)
30. Install exhaust system and catalytic converters.
31. Install engine.
32. Fill in engine oil.