Cover For Camshaft Housing
Removing and installing cover for camshaft housing
Preliminary Work
Caution
Risk of damage due to particles 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 engine.
2. Remove transmission.
3. Secure engine support to the engine/transmission flange with screw sleeves.
4. Secure engine to the assembly support with an engine lift. Get another person to help you do this.
5. Remove rear silencers.
Intake air pipe on cylinder side 1-3:
6. Remove intake air pipe leading to the turbocharger. Screw off one M6 collar nut -1- and two Torx screws (M6 x 20) -Arrows- and pull off the pipe.
6.1. Unclip vacuum line on intake air pipe, pull it off the turbocharger and remove the intake air pipe.
Intake air line flange, side 1-3
Continue with Step 9.
Cylinder side 4-6:
7. Remove intake air pipe leading to the turbocharger. Unscrew two Torx screws (M6 x 20) -Arrows- and pull off the pipe.
Intake air line flange, side 4-6
7.1. Unclip vacuum line on intake air pipe, pull it off the turbocharger and remove the intake air pipe.
8. Remove oil tank.
Continue with Step 9.
9. Remove connecting lines (coolant and engine oil) on the turbocharger.
10. Remove electric servo motor for turbocharger.
10.1. Disconnect cable plug.
10.2. Unscrew three cheese head bolts (M6 x 25) and remove electric servo motor.
11. Remove heat shield. Unscrew two M6 Torx screws and remove heat shield.
12. Disconnect cable plugs for the ignition coils, solenoid hydraulic valve (valve lift adjustment) and hall sender.
13. Loosen fuel line on pressure regulator for fuel collection pipe on cylinder side 4-6. Always counter at the pressure regulator when doing this.
Fuel connection to pressure regulator
14. Loosen fuel collection pipe.
14.1. Unclip cable duct on fuel collection pipe.
14.2. Unscrew two M6 Torx screws and remove fuel collection pipe with fuel injectors from the intake distributor.
15. Remove turbocharger holder.
16. Remove ignition coils. Unscrew two Torx screws (M6 x 25) on each and pull off coils.
17. Remove oil line on oil suction pump. Counter at the oil suction pump connection piece while doing this.
Removing cover for camshaft housing
Caution
Risk of damage due to particles 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.
Caution
Lever off camshaft housing cover.
Cast lugs can break off.
- Carefully lift off the cover.
1. Remove small lids (green) between camshaft housing cover and cylinder head.
1.1. To do so, puncture the lids in the middle and lever out using a small slotted screwdriver.
2. Loosen oil suction pump or tandem pump.
2.1. Tandem pump, side 1-3: unscrew three Torx screws (M6 x 35), remove cable holder on exhaust temperature sensor and take off pump.
2.2. Suction pump, side 4-6: unscrew three Torx screws (M6 x 35) and take off pump.
3. Loosen camshaft actuator lid. Remove three Torx screws (M6 x 20) and one cable holder for oxygen sensors.
4. Pull off oil suction pump/tandem pump and lids.
Oil suction pump, camshaft cover
5. Remove camshaft housing cover.
Camshaft housing cover
5.1. Unscrew 17 M6 Torx screws -1- from the outside in.
Camshaft housing cover
5.2. Side 1-3: 14 M6 x 35 screws, two M6 x 25 screws (solenoid hydraulic valve support) and one M6 x 75 screw.
5.3. Side 4-6: two M6 x 40 screws (oil tank support), 12 M6 x 35 screws, two M6 x 25 screws (solenoid hydraulic valve support) and one M6 x 75 screw.
6. Remove solenoid hydraulic valve for valve lift adjustment with support.
7. Lift off camshaft housing cover.
7.1. Carefully lift up the cover using a large screwdriver if necessary.
Lifting off camshaft housing cover
8. Carefully clean all sealing faces.
Installing cover for camshaft housing
Caution
Risk of damage due to particles 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.
Information
Only use Drei Bond, type 2210 sealant.
1. Carefully apply a uniform bead of sealant approximately 1 mm wide to the camshaft housing cover.
Applying sealant to camshaft housing cover
2. Fit camshaft housing cover.
2.1. Fit cover and secure with four M6 x 35 screws (tighten screws slightly).
Information
Use Kluber grease (Syntheso glep, Part No. 000.043.204.68, available from the Porsche Parts Service) for all lubrication points.
2.2. Insert solenoid hydraulic valve with a new O-ring on the cylinder head and fit support using two Torx screws (M6 x 25).
2.3. Fit the remaining Torx screws evenly.
2.3.1. Side 1-3: ten M6 x 35 screws and one M6 x 75 screw.
2.3.2. Side 4-6: two M6 x 40 screws (oil tank support), eight M6 x 35 screws and one M6 x 75 screw.
2.4. Tighten all screws -1- in diagonally opposite sequence from the inside out. - Tightening torque: 10 Nm (7.5 ftlb.)
Camshaft housing cover
3. Install camshaft actuator lid with a new O-ring. Fit three Torx screws (M6 x 20) and one cable holder for oxygen sensors. - Tightening torque: 10 Nm (7.5 ftlb.)
4. Install oil suction pump or tandem pump with new O-rings. Coat O-rings with Kluber grease.
4.1. Tandem pump, side 1-3: fit pump with three Torx screws (M6 x 35) and cable holder for exhaust temperature sensor and tighten screws. - Tightening torque: 10 Nm (7.5 ftlb.)
4.2. Oil suction pump, side 4-6: fit pump with three Torx screws (M6 x 35) and tighten screws. - Tightening torque: 10 Nm (7.5 ftlb.)
5. Fit two new lids (do not grease them).
5.1. Carefully tap lids onto the camshaft housing using a plastic hammer.
Subsequent Work
Caution
Risk of damage due to particles 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. Fit oil lines on oil suction pump. Counter at the oil suction pump connection piece while doing this. - tightening torque: 40 Nm (30 ftlb.)
2. Install ignition coils. Insert two Torx screws (M6 x 25) for each coil and tighten screws. - tightening torque: 10 Nm (7.5 ftlb.)
3. Connect cable plugs for the ignition coils, solenoid hydraulic valve (valve lift adjustment) and hall sender.
4. Install heat shield. Insert and tighten two Torx screws (M6 x 12). - tightening torque: 10 Nm (7.5 ftlb.)
5. Fit electric servo motor for turbocharger.
5.1. Insert and tighten three cheese head bolts (M6 x 25). - tightening torque: 10 Nm (7.5 ftlb.)
5.2. Connect cable plugs on side 1-3.
6. Install oil tank on cylinder side 4-6.
7. Fit turbocharger holder on camshaft housing. - tightening torque: 23 Nm (17 ftlb.)
8. Install fuel collection pipe. Replace O-rings on the fuel injectors.
8.1. Grease O-rings on fuel injectors lightly.
8.2. Fit fuel collection pipe with fuel injectors on the intake distributor.
8.3. Fit and tighten two Torx screws (M6 x 12). - tightening torque: 10 Nm (7.5 ftlb.)
8.4. Clip in cable duct on fuel collection pipe.
9. Fit fuel line on pressure regulator for fuel collection pipe on cylinder side 4-6. Always counter at the pressure regulator while doing this. - tightening torque: 30 Nm (22 ftlb.)
Fuel connection to pressure regulator
Information
Use Kluber grease (Syntheso glep, Part No. 000.043.204.68, available from the Porsche Parts Service) for all lubrication points.
10. Fit connecting lines (coolant and engine oil) on turbocharger with new O-rings and grease O-rings. - tightening torque: 10 Nm (7.5 ftlb.)
11. Secure turbocharger to holder with one M8 x 16 Torx screw. - tightening torque: 23 Nm (17 ftlb.)
Intake air pipe on cylinder side 1-3:
12. Fit intake air pipe for turbocharger 1-3. Replace and grease O-ring.
12.1. Position intake air pipe and connect it to the turbocharger with a new O-ring.
12.2. Fit two Torx screws (M6 x 20) -arrow- and one M6 collar nut -1- and tighten them.
Intake air pipe flange on side 1-3
12.3. Clip in vacuum line on intake air pipe and connect it to the turbocharger.
Continue with Step 14.
Intake air pipe on cylinder side 4-6:
13. Fit intake air pipe for turbocharger 4-6. Replace and grease O-ring.
13.1. Position intake air pipe and connect it to the turbocharger with a new O-ring.
13.2. Fit and tighten two Torx screws (M6 x 20) -arrows-.
Intake air line flange on side 4-6
13.3. Clip in vacuum line on intake air pipe and connect it to the turbocharger.
13.4. Connect cable plugs for electronic adjusters -2-.
14. Fit rear silencers.
15. Loosen engine on the assembly support with an engine lift and remove lifting platform. Get another person to help you do this.
16. Screw off screw sleeves for the engine support on the engine/transmission flange and remove support.
17. Refit transmission.
18. Install engine.