Removing and Installing Cylinder Head Covers - Engine Installed
Removing And Installing Cylinder Head Covers - Engine Installed
Engine type M 96/23 and M 96/24
CAUTION:
- When working on the engine, absolute cleanliness is essential. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores.
- The engine may no longer be turned at the crankshaft after the cylinder bead cover has been removed.
Removing Cylinder Head Cover - Cylinder Banks 1 - 3 And 4 - 6 - USA Vehicles
1. Disconnect the battery.
2. Remove respective rear wheel. To do this, use the socket wrench insert No. P 300 to avoid damaging the wheel.
3. Remove the rear underbody panel. Undo the torx screws, plastic nuts and the centre M6 hexagon nut.
4. Drain engine oil. After a dripping time of about 20 minutes, refit oil drain plug (hexagon socket a/f 8) with a new sealing ring.
Tightening torque 50 Nm (37 ftlb.)
5. Remove side plastic strut by undoing the M6 hexagon nut -arrow-.
6. Pull cable plug off oxygen sensor towards the front -arrow- expose the oxygen sensor cable.
7. Pull cable plug on cylinder head cover off oxygen sensor -1- and remove cable plug holder from cylinder head cover by undoing the M6 hexagon-head bolt -2-.
8. Unscrew exhaust manifold with catalytic converter. Remove flange with 2 M8 hexagon nuts and 1 M8 hexagon-head bolt as well as 6 exhaust manifold screws. Remove and replace metal seals.
9. Remove side plastic cover by undoing 2 M6 hexagon-head bolts -arrows- (cylinder bank 1 - 3).
10. Pull cable plugs off the ignition coils, oil pressure sensor (cylinder bank 1 - 3) and magnetic hydraulic valve.
11. Cylinder bank 4 - 6: Remove the holder for the servo line by undoing the M6 hexagon-head bolt -arrow-.
12. Remove 3 ignition coils. Unscrew 6 M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess.
13. Remove holder and cover for magnetic hydraulic valve. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the hydraulic valve from the sheetmetal bracket and remove the holders. Remove cover with hydraulic valve.
CAUTION: When levering off the cylinder head cover, the cast lugs may break.
Figure shows upper cast lug
Levering off the cylinder head cover, Figure shows cylinder bank 4 - 6 RoW
14. Remove the cylinder head cover. To do this, unscrew 20 M6 x 30 hexagon-head bolts from the cylinder head cover. Unscrew the four M6 x 20 hexagon-head bolts on the sides of the oil extraction pump. To release the cylinder head cover, raise the cover carefully at the two protruding cast edges with a slotted screwdriver. If necessary, loosen the cover by carefully tapping it with a plastic hammer. Collect the dripping engine oil.
NOTE: After removing the oil extraction pump, check the 0-ring for damage and replace if necessary.
15. Remove oil extraction pump.
16. Disconnect the holder for the coolant lines and carefully push the coolant lines aside. Remove cylinder head cover (cylinder bank 1 - 3).
17. Remove the brown closure cap (dia. 45 mm) and 2 green closure caps.
NOTE: To work on cylinder bank 4 - 6, follow the steps described for cylinder bank 1 - 3.
Installing Cylinder Head Cover - Cylinder Banks 1 - 3 And 4 - 6 - USA Vehicles
NOTE: The sealing surfaces of the cylinder heads as well as the cylinder head covers must be cleaned carefully 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.
- Pull the oil strainer -arrow- out using pointed-nose pliers and replace.
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
NOTE: When applying the sealant, always make sure that the oil ducts in the cylinder head are not blocked.
3. Carefully apply a thin bead of sealant on the cylinder head cover -see Figure-. The bead should not be higher than 1.5 mm.
4. Push the coolant lines aside and fix cylinder head cover. Fasten coolant lines.
5. Position 20 M6 x 30 hexagon-head bolts on the cylinder head cover.
6. Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque.
Tightening torque 13 Nm (9.5 ftlb.)
NOTE:
- If the 0-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder head 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.
- The screws for the oil extraction pump are micro-encapsulated and are therefore to be replaced.
7. Carefully remove excess sealant before installing the oil extraction pump. Insert oil extraction pump in the fitting bore.
8. Position 4 M6 x 20 hexagon-head bolts (micro-encapsulated) on the oil extraction pump and tighten 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.
9. For each cylinder head, place a new, brown, dry closure cap (dia. 45 mm) on the bore for the exhaust camshaft and press in until they are flush.
10. Insert 2 new, green, dry closure caps for each cylinder head into the small bores and press in until they are flush.
11. Insert camshaft adjustment valve with a new 0-ring again (installation position: ensure that dowel pin is in the cylinder head bore.).
NOTE: Replace cover with integral seal for the camshaft adjustment valve.
12. 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. Push cable plug onto camshaft adjustment valve.
Tightening torque 10 Nm (7.5 ftlb.)
13. Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Position 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.)
14. Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.
15. Cylinder bank 1 - 3: Fit side plastic cover by screwing two M6 hexagon-head bolts -arrows- into place.
Tightening torque 10 Nm (7.5 ftlb.)
16. Cylinder bank 4 - 6: Attach the holder for the servo line by tightening the M6 hexagon-head bolt -arrow-.
Tightening torque 10 Nm (7.5 ftlb.)
NOTE:
- Always replace the metal seals on the exhaust manifold and flange.
- The M8 x 28 exhaust manifold screws are to be replaced.
- Replace the screws and nuts on the flange if necessary.
17. Install exhaust manifold with catalytic converter. To do this, screw the exhaust manifold into place on the catalytic converter using 2 M8 hexagon nuts and one M8 hexagon-head bolt and on the cylinder head using 6 new M8 x 28 hexagon-head bolts. Replace metal seals.
Tightening torque 23 Nm (17 ftlb.)
18. Attach oxygen sensor cable plug holder to cylinder head cover by tightening the M6 hexagon-head bolt. Lay oxygen sensor cable and clip in to sheetmetal bracket. Connect both oxygen sensor cable plugs in front of and behind the catalytic converter.
Side oxygen sensor cable plug in front of catalytic converter
Tightening torque screw for holder 10 Nm (7.5 ftlb.)
Side oxygen sensor cable plug behind catalytic converter
19. Attach side plastic strut by tightening the M6 hexagon nut -arrow-.
Tightening torque 10 Nm (7.5 ftlb.)
20. Fit the rear underbody panel. Position the torx screws, plastic nuts and the centre M6 hexagon nut and tighten.
21. Mount respective rear wheel. To do this, use the socket wrench insert No. P 300 to avoid damaging the wheel.
Tightening torque 130 Nm (96 ftlb.).
22. Fill engine oil according to specifications.
23. Connect the battery.
Removing And Installing Cylinder Head Covers - Engine Installed - RoW Vehicles
The process of removing and installing cylinder head covers for RoW vehicles is similar to that for USA vehicles with the following exception:
- The exhaust manifolds need not be removed.
Tightening Torques
