Removing and Installing Cylinder Head Cover - Engine Removed
Removing And Installing Cylinder Head Cover - Engine Removed
Engine type M 96/23 and M 96/24
CAUTION: When working on the engine, absolute cleanliness is essential. An engine cover should be used on the engine assembly support. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores.
Removing Cylinder Head Cover - Cylinder Banks 1 - 3 and 4 - 6
- Preliminary work: drain engine oil.
Cylinder Bank 1 - 3
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 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 0-ring and the oil strainer must be replaced.
- The cover with integral seal for the camshaft adjustment valve must 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 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.
CAUTION: When fevering off the cylinder bead cover, the cast lugs may break.
4. Remove cylinder head cover. Unscrew 20 M6 x 30 hexagon-head bolts from the cylinder head cover and the 2 M6 x 20 hexagon-head bolts, which are screwed to the cylinder head cover, from the oil extraction pump. To release the cylinder head cover, raise the cover carefully at the two protruding cast edges with a slotted screwdriver. Remove cylinder head cover.
Levering off the cylinder head cover, Figure shows side 1-3
NOTE: Once you have levered off the cylinder head cover, check the 0-ring on the oil extraction pump for damage (particularly in the disconnection point area). If the 0-ring needs to be replaced, also unscrew the 2 lower M6 x 20 hexagon-head bolts and remove the pump.
5. Remove the brown closure cap (dia. 45 mm) and 2 green closure caps.
Cylinder Bank 4 - 6
1. 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 0-ring and the oil strainer must be replaced.
- The cover with integral seal for the camshaft adjustment valve must be replaced.
2. 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.
3. Remove cylinder head cover. Repeat step 4 as with cylinder bank 1-3.
NOTE: Once you have levered off the cylinder head cover, check the 0-ring on the oil extraction pump for damage (particularly in the disconnection point area). If the 0-ring needs to be replaced, also unscrew the 2 lower M6 x 20 hexagon-head bolts and remove the pump.
4. Remove the brown closure cap (dia. 45 mm) and 2 green closure caps.
Installing Cylinder Head Cover - Cylinder Banks 1 - 3 and 4 - 6
NOTE: The sealing surfaces of the cylinder heads and the cylinder head covers must be cleaned before the new sealant is applied. Avoid damage.
1. Clean sealing surfaces. Remove any sealant residue from the sealing surfaces on the cylinder head and the cylinder head cover thoroughly. Then rub down with a clean cloth soaked in a degreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head.
NOTE: Replace the seals for the spark-plug recesses.
2. Insert the 3 seals for the spark-plug recesses.
NOTE:
- Only if the camshaft adjustment valve was removed:
- Replace oil strainer -arrow-.
- Insert camshaft adjustment valve with a new 0-ring again (installation position: ensure that dowel pin is in the cylinder head bore).
Only the following sealants may be used to seal the cylinder head cover (these are available from the Porsche Parts Service):
- "Drei Bond" silicone - type 1209
- Loctite 5900
3. Fix cylinder head cover. Apply a thin bead of sealant on the cylinder head cover -as shown in the Figure-. The bead should not be higher than 1.5 mm.
NOTE:
- If the 0-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder bead cover and then position the 4 M6 x 20 hexagon-head bolts.
- Identification on the oil extraction pump -in the Figure cylinder side 1 - 3- faces the crankcase.
4. Fit 20 M6 x 30 hexagon-head bolts on the cylinder head cover and 2 (or 4, see Note) M6 x 20 hexagon-head bolts for the oil extraction pump.
5. Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque.
Tightening torque 13 Nm (9.5 ftlb.)
6. Tighten 2 or 4 M6 x 20 hexagon-head bolts of the oil extraction pump to the specified torque.
Tightening torque 13 Nm (9.5 ftlb.)
NOTE: Replace all plastic closure caps on the cylinder head/cylinder head cover joint.
7. For each cylinder head, place a new, brown, dry closure cap (dia. 45 mm) on the bore for the exhaust camshaft and tap it in gently with a plastic hammer.
8. Insert 2 new, green, dry closure caps for each cylinder head into the small bores and tap them in gently with a plastic hammer.
NOTE: Replace cover with integral seal for the camshaft adjustment valve.
9. 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 ftlb.)
10. Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Unscrew 2 M6 x 25 pan-head screws for each ignition coil hexagon socket a/f 5) on the cylinder head cover and tighten to the specified torque. Connect cable plug to ignition coils.
Tightening torque 10 Nm (7.5 ftlb.)
11. Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.
Tightening Torques
