Installing Unit Carrier (Coolant Distributor Housing)

Information

Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).

Replace two seals -3- and two O-rings -8- on the unit carrier. Replace one seal -4- for the coolant connection piece.

Fig 1: Identifying Unit Carrier Seals
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Replace molded seal on the connecting tube -3- .

Fig 2: Identifying Thermostat Housing And Connecting Tube
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Install unit carrier (coolant distributor housing).
1. 3.1. Insert unit carrier -6- into the thermostat housing -7- .
2. 3.2. Screw in and tighten three external Torx screws (E12, M8 x 50) -4 and 5- on the unit carrier.
  → Tightening torque: 33 Nm (24 ft. lb.)
3. 3.3. Connect and engage the cable plug on the coolant temperature sensor.
4. 3.4. Install coolant connection piece.
  1. 3.4.1. Fit the coolant connection piece -3- and tighten Torx screws (M8 x 70) -1- .
    → Tightening torque: 33 Nm (24 ft. lb.)
  2. 3.4.2. Fit and secure a spring band clamp on the coolant hose.
  3. 3.4.3. Fit coolant hose on the coolant connection piece and secure with a spring clamp on the Henn coupling. Make sure that the Henn coupling locks with an audible click.
    
    Fig 3: Identifying Coolant Distributor Housing Unit Carrier
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 1 - External Torx screws, M8 x 70
    2. 3 - Coolant connection piece
    3. 4 - External Torx screw, M8 x 50
    4. 5 - External Torx screw, M8 x 50
    5. 6 - Unit carrier
    6. 7 - Thermostat housing
Fig 4: Fitting Coolant Connection Piece
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Install bracket for the coolant pump.
1. 4.1. Replace O-rings.
  Grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
2. 4.2. Fit bracket for coolant pump -1- .
  1. 4.2.1. Turn the bracket for the coolant pump slightly and guide into position from the right.
  2. 4.2.2. Carefully press the bracket for the coolant pump into the mounting.
3. 4.3. Secure bracket for coolant pump -1- .
  1. 4.3.1. Screw in and tighten external Torx screws -3, 4, 5 and 6- first.
  2. 4.3.2. Tighten one external Torx screw (E10, M6 x 20).
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  3. 4.3.3. Tighten one external Torx screw (E12, M8 x 25).
    → Tightening torque: 33 Nm (24 ft. lb.) .
  4. 4.3.4. Tighten two external Torx screws (E12, M8 x 50).
    To tighten the external Torx screw, the tensioner must be turned and locked.
    
    → Tightening torque: 33 Nm (24 ft. lb.) .
    1. 1 - Bracket for coolant pump
    2. 3 - External Torx screw, M8 x 50
    3. 4 - External Torx screw, M8 x 50
    4. 5 - External Torx screw, M6 x 20
    5. 6 - External Torx screw, M8 x 25
      
      Fig 5: Identifying Coolant Pump Bracket
      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install thermostat housing lid -1- .
1. 5.1. Secure the thermostat housing lid.
  1. 5.1.1. Fit and tighten one external Torx screw (E10, M6 x 50) at the bottom of the thermostat housing.
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  2. 5.1.2. Fit the thermostat housing lid and screw in and tighten three external Torx screws (E10, M6 x 50) -3- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  3. 5.1.3. Tighten one external Torx screw (E10, M6 x 40) -2- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
2. 5.2. Secure intake coolant pipe -5- .
  1. 5.2.1. Replace O-rings.
    Grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
  2. 5.2.2. Press the intake coolant pipe into the thermostat housing.
  3. 5.2.3. Fit and tighten two external Torx screws (E10, M6 x 12) -4- on the intake coolant pipe.
    → Tightening torque: 13 Nm (9.5 ft. lb.)
3. 5.3. Connect the coolant hose to the thermostat housing lid and secure with a spring band clamp.
Fig 6: Identifying Intake Tube And Thermostat Housing
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Install water connection piece -3- .
1. 6.1. Fit water connection piece.
2. 6.2. Fit and tighten six external Torx screws (E10, M6 x 25) -1- on the bracket for the coolant pump -5- and crankcase.
  → Tightening torque: 13 Nm (9.5 ft. lb.)
3. 6.3. Secure the vacuum line at the water connection piece.
  Fit and tighten one external Torx screw (E10, M6 x 12) -2- .
  
  → Tightening torque: 13 Nm (9.5 ft. lb.)
Fig 7: Installing Water Connection Piece
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Install vibration damper -1- .
→ 137519 REMOVING AND INSTALLING VIBRATION DAMPER - TURBO - section on "Installing"

Fig 8: Installing Vibration Damper
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Information

The threaded bolt on the bracket for the engine carrier must be bonded using Loctite 243 and can only be subjected to pressure after a hardening time of three hours.
Install engine carrier bracket.
1. 8.1. Fit the drive belt on the vibration damper.
2. 8.2. Fit the engine carrier bracket -3- .
3. 8.3. Apply Loctite to the threaded bolt (stud) M10 x 120.
4. 8.4. Screw in and tighten threaded bolt (stud) M10 x 120.
  Screw two M10 nuts -1- onto the M10 x 120 threaded bolt -2- to lock it and tighten the threaded bolt.
  
  → Tightening torque: 5 Nm (3.5 ft. lb.)
Fig 9: Identifying Vibration Damper Threaded Bolt (Stud)
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