Engine: Adjustments Porsche Boxster 986 рестайлинг

ALLOCATION OF CAMSHAFT ADJUSTMENT DEVICE ON INLET CAMSHAFTS

Camshaft adjustment device on inlet camshaft, cylinder bank 1 - 3

Note. Side 1 - 3: the arrow should be attached in anti-clockwise position

1. Designation, side 1 - 3

Scheme 109

1. Part number, cylinder bank, manufacturer information, direction of rotation of engine (arrow), production date.

Camshaft adjustment device on inlet camshaft, cylinder bank 4 - 6

Note. Side 4 - 6: the arrow should be attached in clockwise position

1. Designation, side 4 - 6

Scheme 110

1. Part number, cylinder bank, manufacturer information, direction of rotation of engine (arrow), production date.

Scheme 111

Scheme 112

Scheme 113

1. Chain tensioner on crankcase (oil filter area). Identification: 1 ring
2. Chain tensioner on cylinder head, cylinder bank 1-3. Identification: 2 rings
3. Chain tensioner on cylinder head, cylinder bank 4 - 6. No identification. Fastened with hexagon socket.

Tightening torque for chain tensioners: 80 Nm (59 ft.lb.)

Engine type M 96/23 and M 96/24

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

1. Pull off the cable plug on the oil pressure sensor.
2. Remove 3 ignition coils. Pull off the cable plug on the ignition coils. Unscrew the 2 M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess. NOTE: If the camshaft adjustment valve is to be removed, the O-ring and the oil strainer must be replaced. The cover with integral seal for the camshaft adjustment valve must also be replaced.
3. Pull off the cable plug on the camshaft adjustment valve. Remove the holder and the cover for the valve on the cylinder head cover. Unscrew two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the camshaft adjustment valve from the sheetmetal bracket and remove the holders. Pull off the valve cover.
4. Remove the oil abstraction pump and the brown closure cap (45 mm). Unscrew the 4 M6 x 20 hexagon-head bolts on the oil extraction pump and remove the pump carefully (do not damage the fitting bore). Press a screwdriver into the Centre of the piercing point of the closure cap and lever off the cover.
5. Remove 2 green closure caps. Press a small screwdriver into the Centre of the piercing point of the closure cap and lever off the cover.
6. Turn the engine clockwise at the belt pulley of the crankshaft to the overlapping TDC of cylinder 1. Fix with special tool (fixing pins) 9595/1. At this point, the smaller circular cutout on the cut grooves of the inlet and exhaust camshafts on cylinder 1 must point towards the cylinder head cover. (Scheme 122)(check with adjustment gauge 9686). If this is not the case, turn the engine through another 360° as described above. NOTE: Before disassembling the cylinder head cover, it is essential to unscrew the central screw on the camshaft adjustment device.
7. Unscrew the central screw on the camshaft adjustment device. Position the retaining tool 9685 on the hexagon of the adapter and place the contact block as a counter on the fitting bore of the cylinder head cover; if necessary, position the contact block by undoing and tightening the M8 hexagon-head bolt. If the special tool can not be positioned on the hexagon of the adapter in this way, the engine must be turned further in the direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the central screw of the cylinder head cover, ready for unscrewing. Unscrew the central screw.
8. Unscrew the 4 M6x16 hexagon-head bolts on the chain sprocket of the exhaust camshaft. Do not remove the chain sprocket. CAUTION: When levering off the cylinder head cover, the cast lugs may break.
9. Remove the cylinder head cover. See «REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003»(ref-199829-S01390738082005102100000).
10. Turn the engine at the assembly support so that cylinder bank 1 - 3 stands vertically upwards.
11. Remove the chain tensioner side 1-3 -arrow- (hexagon a/f 30). (Scheme 124)
12. Remove the chain sprocket of the exhaust camshaft 1 - 3. Lift control chain off the chain sprocket and remove the chain sprocket. Lay the control chain on the mounting tab for the chain sprocket.
13. Remove the 4 camshaft thrust bearings and the guide rail. Unscrew 8 pan-head screws (hexagon socket a/f 5): 6 M6 x 35, 2 M6 x 40. Lift the thrust bearing and the guide rail carefully off the bearing surfaces or the control chain.
14. Remove camshafts. Remove the exhaust camshaft 1 - 3, lift the control chain off the camshaft adjuster of the inlet camshaft 1 - 3 and remove the camshaft. Lay the control chain in the chain housing in the cylinder head.

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

1. Remove air conditioning compressor. Refer to «REMOVING AND INSTALLING THE COMPRESSOR»(ref-199820-S35833963642005102000000).
2. Remove the holder for the servo line.
3. Remove 3 ignition coils. Pull off the cable plug on the ignition coils. Unscrew the two M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess. NOTE: If the camshaft adjustment valve is to be removed, the O-ring and the oil strainer must be replaced. The cover with integral seal for the camshaft adjustment valve must also be replaced.
4. Pull off the cable plug on the camshaft adjustment valve. Remove the holder and the cover for the valve on the cylinder head cover. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the camshaft adjustment valve from the sheetmetal bracket and remove the holders. Pull off the valve cover.
5. Remove the oil extraction pump and the brown closure cap (45 mm). Unscrew the 4 M6 x 20 hexagon-head bolts on the oil extraction pump and remove the pump carefully (do not damage the fitting bore). Push a small screwdriver into the Centre of the closure cap and lever off the cover.
6. Remove 2 green closure caps. Press a small screwdriver into the Centre of the piercing point of the closure cap and lever off the cover.
7. Turn the engine clockwise at the belt pulley of the crankshaft to the overlapping TDC of cylinder 4. Fix with special tool (fixing pins) 9595/1. At this point, the smaller circular cutout on the cut grooves of the inlet and exhaust camshafts on cylinder 1 must point towards the cylinder head cover. (Scheme 126)(check with adjustment gauge 9686). If this is not the case, turn the engine through another 360° as described above. NOTE: Before disassembling the cylinder head cover, it is essential to unscrew the central screw on the camshaft adjustment device.
8. Unscrew the central screw on the camshaft adjustment device. Position the retaining tool 9685 on the hexagon of the adapter and place the contact block of the tool on the fitting bore of the cylinder head cover for the oil extraction pump; if necessary, position the contact block by undoing and tightening the hexagon-head bolt. If the special tool can not be positioned in this way, the engine must be turned further in the direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the cylinder head cover. Unscrew the central screw.
9. Unscrew the 4 M6 x 16 hexagon-head bolts on the chain sprocket of the exhaust camshaft. Do not remove the chain sprocket. CAUTION: When levering off the cylinder head cover, the cast lugs may break.
10. Remove the cylinder head cover. See «REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003»(ref-199829-S01390738082005102100000).
11. Turn the engine at the assembly support so that cylinder bank 4 - 6 stands vertically upwards.
12. Remove the chain tensioner, side 4-6. (Scheme 129) Hexagon socket a/f 14. Requirement: servo-tank, air conditioning compressor and holder for the servo line are removed.
13. Unscrew the guide rail screw of cylinder bank 4 - 6 (belt pulley side), hexagon socket a/f 6.
14. Remove the chain sprocket of the exhaust camshaft 4 - 6. Lift control chain off the chain sprocket and remove the chain sprocket. Lay the control chain on the mounting tab for the chain sprocket.
15. Remove the 4 camshaft bearings and the guide rail. Unscrew 8 pan-head screws (hexagon socket a/f 5): 6 M6 x 35, 2 M6 x 40.
16. Remove camshafts. Remove the exhaust camshaft 4 - 6, lift the control chain off the camshaft adjuster of the inlet camshaft 4 - 6 and remove the camshaft. Lay the control chain in the chain housing in the cylinder head.

Engine type M 96/23 and M 96/24

1. Engine completed except for the cylinder heads
2. Flat-base tappet housing and flat-base tappet installed

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. In order to remove the play from the control chain drive, turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to 60° before TDC (identification U6 on the belt pulley is flush with the fixing bore in the crankcase). (Scheme 130) Fix with special tool (fixing pins) 9595/1, use short fixing pin.
2. Turn the engine at the assembly support until cylinder bank 4 - 6 stands vertically upwards.
3. Oil the bearing surfaces of the camshafts with new engine oil.
4. Insert inlet camshaft 4 - 6. If necessary, pre-assemble the inlet camshaft. See «DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT - AS OF MY 2003»(ref-199829-S24434722842005102100000). Pull the control chain out of the chain housing of the cylinder head, for example, with a welding wire, and position on the toothed ring of the camshaft adjuster, at the same time inserting the camshaft at overlapping TDC of cylinder 4 -arrows- (the cams of cylinder 4 point towards the bulkhead of the flat-base tappet housing). (Scheme 131) NOTE: Make sure that the bearing sleeve of the inlet camshaft is positioned correctly.
5. The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points vertically upwards -arrow- (the rib of the cylinder head should also be at the Centre in relation to the bearing sleeve). (Scheme 132) In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite off-centre blind hole bore. Any other bores are through-holes for guiding the oil.
6. Insert exhaust camshaft 4 - 6. Lay the control chain on the flange for the chain sprocket, then insert the camshaft at overlapping TDC of cylinder 4 -arrows- (the cams of cylinder 4 point towards the cams of the inlet camshaft). (Scheme 133)
7. Install the chain sprocket of the exhaust camshaft. Insert the chain sprocket in the control chain, then position on the camshaft flange. The 4 threaded bores in the camshaft flange must be approximately half covered to the right by the slots of the chain sprocket in the engine direction of rotation -arrows-. (Scheme 134) NOTE: Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly. Observe the identification -arrows-. (Scheme 135) Designation of inlet camshaft bearing: thrust bearing: E and pairing number on cylinder head/cylinder head cover, bearing cover of the bearing sleeve: only pairing number. (Scheme 135) Designation of exhaust camshaft bearing: thrust bearing on chain sprocket: 1A and pairing number on cylinder head/cylinder head cover, 2nd thrust bearing: 2A and pairing number on cylinder head/cylinder head cover. (Scheme 135)
8. Insert 3 thrust bearings and 1 bearing cover for the bearing sleeve of the camshafts with the guide rail for the control chain. (Scheme 136) 8 bearing screws, hexagon socket: Position 6 M6 x 35 and 2 M6 x 40 for camshaft bearing and guiderail and tighten slightly. (Scheme 137)

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

1. Align camshafts. On both camshafts, the smaller circular cutout -arrows- must lie at the top. (Scheme 138)
2. Fix the camshafts with special tool (adjustment gauge) 9686 and fasten the gauge with 1 M8 auxiliary screw (e.g. M8 x 16 hexagon-head bolt) (flat tool surface should face upwards). Only tighten the screw slightly.
3. Screw the bearing cover screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment gauge alternately by another approx. 90° until the specified tightening torque of 10 Nm (7.5 ft.lb.) is reached. Tightening torque 10 Nm (7.5 ft.lb)
4. Insert the guide rail screw with a new O-ring and tighten (M6 hexagon socket a/f 5). Tightening torque 10 Nm (7.5 ft.lb)
5. Fit the chain tensioner, side 4-6 (hexagon socket a/f 14) -arrow-. (Scheme 140) Replace sealing ring. Position the chain tensioner with new sealing ring and tighten to the specified torque. Tightening torque 80 Nm (59 ft.lb) NOTE: Move the engine at the belt pulley of the crankshaft to the TDC marking without fail.
6. Turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to the TDC marking (the TDC bore in the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.
7. Position the 4 M6 x 12 hexagon-head bolts for the chain sprocket of the exhaust camshaft and tighten crosswise to the specified torque. Tightening torque 14 Nm (10.5 ft.lb.) NOTE: Replace central screw for camshaft adjustment device.
8. Tighten the central screw of the camshaft adjusting device. Position the special tool (retaining tool) 9685 on the adapter of the central screw and place the loose contact block at the fitting bore of the oil extraction pump. Tighten the hexagon-head bolt on the contact block.
9. Tighten the new central screw in two stages. 1st stage: pre-tightening torque 50 Nm (37 ft.lb.) NOTE: Before the final tightening of the central screw, remove the special tool (adjustment gauge) 9686 without fail.
10. Remove special tool adjustment gauge 9686. Unscrew the M8 auxiliary screw and pull off the gauge. 2nd stage: final tightening of central screw with torque angle wrench 110° turn. NOTE: Replace the seals for the spark plug recesses.
11. Insert 3 seals for the spark-plug recesses -arrow-. (Scheme 145) NOTE: Only if the camshaft adjustment valve was removed: Replace oil strainer -arrow-. (Scheme 146) Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore).
12. Install cylinder head cover. See «REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003»(ref-199829-S01390738082005102100000). NOTE: Replace O-ring in the oil extraction pumps. Do not tilt oil extraction pump when inserting it. Otherwise, the fitting bore on the cylinder head/cylinder head cover could be damaged. Pay attention to the installation position!
13. Fit oil extraction pump with new O-ring. Insert oil extraction pump carefully in the fitting bore on the cylinder head (installation position: Identification 4-6- faces crankcase). Position 4 M6 x 20 hexagon-head bolts on cylinder head and cylinder head cover and tighten to the specified torque. Tightening torque 13 Nm (9.5 ft.lb.) NOTE: Replace all plastic closure caps on the cylinder head/cylinder head cover.
14. Place a new, brown, dry closure cap (45 mm) on the large bore for the exhaust camshaft and tap it in gently with a plastic hammer.
15. Insert 2 new, green, dry closure caps into the small bores on the cylinder head and tap them in gently with a plastic hammer. NOTE: Replace cover with integral seal for camshaft adjustment valve.
16. Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to valve. Tightening torque 10 Nm (7.5 ft.lb)
17. Install ignition coils. Insert 3 ignition coils into the spark-plug recesses, position 2 M6 x 25 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to ignition coils. Tightening torque 10 Nm (7.5 ft.lb)
18. Fit the holder for the servo line.
19. Install air conditioning compressor. Refer to «REMOVING AND INSTALLING THE COMPRESSOR»(ref-199820-S35833963642005102000000).

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

1. In order to remove the play from the control chain drive, turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to 60° before TDC (identification U6 on the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.
2. Turn the engine at the assembly support until the cylinder bank 1 - 3 stands vertically upwards.
3. Oil the bearing surfaces of the camshafts with new engine oil.
4. Insert inlet camshaft 1-3. If necessary, pre-assemble the inlet camshaft. See «DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT - AS OF MY 2003»(ref-199829-S24434722842005102100000). Pull the control chain out of the chain housing of the cylinder head, e.g. with a welding wire, and position on the toothed ring of the camshaft adjuster, at the same time inserting the camshaft at overlapping TDC of cylinder 1 -arrow- (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head). (Scheme 149) NOTE: Make sure that the bearing sleeve of the inlet camshaft is positioned correctly.
5. The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points vertically upwards (the rib of the cylinder head should also be at the Centre in relation to the bearing sleeve). In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite off-centre blind hole bore. Any other bores are through-holes for guiding the oil.
6. Insert exhaust camshaft 1-3. Lay the control chain on the flange for the chain sprocket, then insert the camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head).
7. Install the chain sprocket of the exhaust camshaft. Insert the chain sprocket in the control chain, then position on the camshaft flange. The 4 threaded bores in the camshaft flange must be fully visible on the left at the slot curves of the chain sprocket, so that the 4 M6 x 12 hexagon-head bolts can still be positioned to fasten the chain sprocket. NOTE: Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly. Observe the identification. (Scheme 135) Designation of inlet camshaft bearing: thrust bearing: E and pairing number on cylinder head/cylinder head cover, bearing cover of the bearing sleeve: only pairing number. Designation of exhaust camshaft bearing: thrust bearing on chain sprocket: 1A and pairing number on cylinder head/cylinder head cover, 2nd thrust bearing: 2A and pairing number on cylinder head/cylinder head cover.
8. Insert 3 thrust bearings and 1 bearing cover for the bearing sleeve of the camshafts with the guide rail for the control chain. 8 bearing screws, hexagon socket: Position 6 M6 x 35 and 2 M6 x 40 for camshaft bearing and guiderail and tighten slightly. (Scheme 155)and (Scheme 156).

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

1. Align camshafts. On both camshafts, the smaller circular cutout must lie at the top (arrows). If necessary, shift the camshafts slightly.
2. Fix the camshafts with special tool (adjustment gauge) 9686 and fasten the gauge with 1 M8 auxiliary screw (e.g. M8 x 16 hexagon-head bolt) (flat tool surface should face upwards). Only tighten the screw slightly.
3. Screw the bearing cover screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment gauge alternately by another approx. 90° until the specified tightening torque of 10 Nm (7.5 ft.lb) is reached. Tightening torque 10 Nm (7.5 ft.lb)
4. Fit the chain tensioner, side 1-3 (hexagon socket a/f 32). Replace sealing ring. Position the chain tensioner with new sealing ring and tighten to the specified torque. Tightening torque 80 Nm (59 ft.lb.) NOTE: Move the engine at the belt pulley of the crankshaft to the TDC marking without fail.
5. Turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to the TDC marking (the TDC bore in the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.
6. Tighten the 4 M6 x 12 hexagon-head bolts for the chain sprocket of the exhaust camshaft crosswise to the specified torque. Tightening torque 14 Nm (10.5 ft.lb.) NOTE: Replace central screw for camshaft adjustment device.
7. Tighten the central screw of the camshaft adjusting device. Position the special tool (retaining tool) 9685 on the adapter of the central screw and place the loose contact block at the fitting bore of the oil extraction pump. Tighten the hexagon-head bolt on the contact block.
8. Tighten the new central screw in two stages. 1st stage: pre-tightening torque 50 Nm (37 ft.lb) NOTE: Before the final tightening of the central screw, remove the special tool (adjustment gauge) 9686 without fail.
9. Remove special tool (adjustment gauge) 9686. Unscrew the M8 auxiliary screw and pull off the gauge. 2nd stage: final tightening of central screw with torque angle wrench 110° turn. NOTE: Replace the seals for the spark plug recesses.
10. Replace the 3 seals for the spark-plug recesses. NOTE: Only if the camshaft adjustment valve was removed: Replace oil strainer -arrow-. see scheme 631 Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore).
11. Install cylinder head cover. See «REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003»(ref-199829-S01390738082005102100000). NOTE: Replace O-ring in the oil extraction pumps. Do not tilt oil extraction pump when inserting it. Otherwise, the fitting bore on the cylinder head/cylinder head cover could be damaged. Pay attention to the installation position!
12. Fit oil extraction pump with new O-ring. Insert oil extraction pump carefully in the fitting bore on the cylinder head (installation position: Identification -1 - 3- faces crankcase). Position 4 M6 x 20 hexagon-head bolts on cylinder head and cylinder head cover and tighten to the specified torque. Tightening torque 13 Nm (9.5 ft.lb) NOTE: Replace all plastic closure caps on the cylinder head/cylinder head cover.
13. Place a new, brown, dry closure cap (45 mm) on the large bore for the exhaust camshaft and tap it in gently with a plastic hammer.
14. Insert 2 new, green, dry closure caps into the small bores on the cylinder head and tap them in gently with a plastic hammer. NOTE: Replace cover with integral seal for camshaft adjustment valve.
15. Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to valve. Tightening torque 10 Nm (7.5 ft.lb)
16. Install ignition coils. Insert 3 ignition coils into the spark-plug recesses, position 2 M6 x 25 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to ignition coils. Tightening torque 10 Nm (7.5 ft.lb)
17. Connect cable plug to oil pressure sensor.