Assembling Engine

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx  .
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Fit crankcase half 4-6 on the engine assembly support.
   1. 1.1. Use mounting parts 9590  to secure to the engine adapter 9771  .

      → 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .

   Information 

   • The bearing shells must be allocated according to specifications  .
   • Observe difference between partial-groove bearings and smooth bearings  .
   • Coat bearing shells with new engine oil  .

   Information 

   Always replace gaskets and O-rings.

   • Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68)  .
2. Fit new bearing shells on the crankcase halves. The following markings ensure correct allocation.
   1. 2.1. Crankcase half 4-6  : Markings on crankshaft. The upper series of letters -1-  is for the crankcase. Allocation starts at the supporting mount (-SL-  ) on the belt side and is read from left to right. The supporting mount does not have a number, while the main bearings are numbered -HL 1-7-  (number 7 is at the flywheel side).
      • G  - Bearing shell, Yellow
      • R  - Bearing shell, Red
      • B  - Bearing shell, Blue
      • SL  - Supporting mount
      • HL  - Main bearing
      • PL  - Connecting rod bearing
        Fig 1: Identifying Marking For Bearing Shell Allocation On Crankshaft

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   2. 2.2. Crankcase 1-3:  Markings on crankcase half. The series of letters -1-  is read from left to right. Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
      • G  - Bearing shell, Yellow
      • R  - Bearing shell, Red
      • B  - Bearing shell, Blue
        Fig 2: Identifying Marking On Crankcase Half 1-3

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   3. 2.3. There are also different types of bearing shells.
      1. Partial-groove bearing shell
      2. Smooth bearing shell
         Fig 3: Identifying Bearing Shells Fitted On Crankcase

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   4. 2.4. Fit and grease new O-ring on the crankcase sealing face.
3. Insert two thrust washers -1-  on the main bearing. The oil grooves must be facing outwards → Thrust washer on crankshaft. 
   Fig 4: Identifying Thrust Washer On Crankshaft

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   Fig 5: Identifying Position Of Grooves On Thrust Washer

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   Information 

   • Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged  .
   • The tensioning rails on cylinder bank 1-3 and 4-6 are identical  .
   • The guide rails on cylinder bank 1-3 and 4-6 are identical  .
   • The slots in the cylinder head must be positioned during installation  .
4. Install tensioning rail for oil-pump drive chain in crankcase 4-6.
   1. Rail
   2. Tensioning spring
      Fig 6: Identifying Tensioning Rail For Oil-Pump Timing Chain

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   1. 4.1. Fit tensioning rail -1-  using a short bearing pin.

      → Tightening torque: 10 Nm (7.5 ftlb.) 

      Fig 7: Identifying Tensioning Rail For Oil-Pump Drive In Crankcase

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      Position of bearing pin -4-  on tensioning rail for oil-pump drive chain.

      Fig 8: Identifying Bearing Pins On Cylinder Bank 4-6

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5. Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2-  .

   → Tightening torque: 10 Nm (7.5 ftlb.) 

   1. 5.1. Place spring -2-  on tensioning rail -1-  for oil-pump drive chain into the cut-out in the guide rail -3-  .
      Fig 9: Identifying Position Of Tensioning Spring In Guide Rail

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6. Insert crankshaft with timing chains -2 + 3-  .
   1. 6.1. Engage oil pump gear -1-  in the drive chain.
      Fig 10: Inserting Crankshaft Into Crankcase Half 4-6

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7. Fix crankshaft in place using special tool holding bridge 9779 -1-  .
   1. 7.1. Fit and tighten two fastening screws hand-tight.
      Fig 11: Identifying Crankshaft Holding Bridge (9779)

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8. Install pistons on cylinder bank 4-6 and connecting rods 1-3.

   → 131020 REMOVING AND INSTALLING PISTONS AND HANDLING TOOLS .

9. Fit 14 through-bolt screws (E14, M10 x 195) -1-  with new sealing washers -3-  .
   1. 9.1. Fit protective sleeve 9786 -2-  over the screw thread. Slide sealing washer onto the screw. Remove protective sleeve.
      Fig 12: Identifying Through-Bolt Screw, Sealing Washer And Protective Sleeve

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      Information 

      • The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant  .
      • Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only. 
      • Join the crankcase halves within max. 5 minutes of applying the bead of sealant  .
10. Apply sealing compound to crankcase half 4-6. Observe processing instructions.
    1. 10.1. Use Dobotech sealing compound (Part No. 000.043.207.31).
    2. 10.2. Carefully apply a continuous bead of sealant -arrow 1-  with a diameter of 1 mm. Follow sealant contour as shown in illustration.
    3. 10.3. Remove residual silicone in the crankshaft flange area following installation-arrow 2-  .
       Fig 13: Identifying Sealant Applying Area On Crankcase Half 4-6

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11. Fit rubber sleeves on connecting rods 1-3 (assembly aid 9795  ) and position vertically.
    1. 11.1. The restraining straps P221  can be used if necessary. Since only two connecting rods can be fixed in place in this case, the third connecting rod must be held when positioning the crankcase half.
12. Check guide rail -1-  for the oil-pump drive chain on crankcase half 1-3.
    Fig 14: Identifying Guide Rail For Oil-Pump Drive Chain

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    1. 12.1. Replace guide rail -1-  in the event of visible or obvious damage. This can be unclipped and clipped in again -arrows-  .
       Fig 15: Installing Guide Rail For Oil-Pump Drive Chain

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       Information 

       • Get another person to help you join crankcase halves 1-3.
13. With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
14. Fit 14 through-bolt screws and tighten according to the specified tightening torque and sequence.
    1. 14.1. → Initial tightening: 5 Nm (3.5 ftlb.) 
    2. 14.2. → Initial tightening: 12 Nm (9 ftlb.) 
    3. 14.3. → Tightening torque: 15 Nm (11 ftlb.) 
    4. 14.4. → Torque angle: 75° (56 ftlb.) 
    5. 14.5. → Final tightening - torque angle: 75° (56 ftlb.) 
       Fig 16: Identifying Through-Bolt Screws On Crankcase

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       1-14  - External Torx screw M10 x 1.5 x 195 with sealing washer

15. Fit 19 external Torx screws (E10 and E12) for the outer cross bolt connection and tighten according to the specified tightening sequence.
    1. 15.1. Three M8 x 35 screws, position -15, 16, 17-  . → Initial tightening: 5 Nm (3.5 ftlb.) 

       → Torque angle: 70° 

    2. 15.2. One M8 x 120 screw, position -33-  .

       → Tightening torque: 33 Nm (24 ftlb.) 

    3. 15.3. 15 screws - one M6 x 40 -18-  , 14 M6 x 25 -19-32-  .

       → Tightening torque: 13 Nm (9.5 ftlb.) 

       Fig 17: Identifying Outer Cross Bolt Connection Tightening Sequence

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16. Fit and tighten two mounting parts 9590  for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.

    → 131020 REMOVING AND INSTALLING PISTONS AND HANDLING TOOLS .

18. Turn the crankshaft clockwise a number of times at the vibration damper using turning device 9773  in order to check for smooth operation and correct function.
    1. 18.1. Then, turn the crankshaft so that none of the pistons are at TDC position.
19. Fit crankshaft sealing rings at the flywheel and drive side.

    → Installing Crankshaft Sealing Ring - Flywheel Side .

    → Installing Crankshaft Sealing Ring - Belt Side .

20. Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3-  .
    Fig 18: Identifying Bearing Pins On Cylinder Bank 4-6

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    1. 20.1. Fit tensioning rail for cylinder bank 1-3.
    2. 20.2. Secure guide rail for cylinder bank 1-3 in the crankcase with a long bearing pin -1-  .
       Fig 19: Identifying Bearing Pins On Cylinder Bank 1-3

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    3. 20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
21. Pull timing chains out of the chain slot.
22. Fit the oil guide (oil plate) -1-  using six external Torx screws M6 x 20 -2-  .

    → Tightening torque: 13 Nm (9.5 ftlb.) 

    Fig 20: Identifying Oil Guide (Oil Plate) On Crankcase

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23. Install oil pump.

    → Installation .

24. Install coolant pipe -1-  for the coolant pump.
    1. 24.1. Fit and tighten two external Torx screws (E10, M6 x 12) -2-  .

       → Tightening torque: 13 Nm (9.5 ftlb.) 

       Fig 21: Identifying Coolant Pipe And Screws

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25. Install the oil pan.

    → Installing oil pan .

26. Insert 12 displacement bodies -1-  on cylinder bank 1-3.
    Fig 22: Locating Piston Marking And Displacement Bodies On Cylinder Bank 1-3

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    Information 

    • Always guide timing chains with your hand when turning the crankshaft. 
27. Fit cylinder head 1-3 and 4-6.

    → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

28. Fit oil supply valve for vacuum pump -1-  and new O-ring -2-  on cylinder head 4-6. Engage timing chain at the valve.
    Fig 23: Identifying Oil Supply Valve For Vacuum Pump And New O-Ring

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29. Hold the tensioning rail for cylinders 1-3 -1-  using a pair of flat-nosed pliers -3-  and use a socket-wrench insert -4-  to screw in the bearing pin -2-  .
    Fig 24: Holding Tensioning Rail

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    1. 29.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
    2. 29.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
30. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
    1. Tensioning spring for tensioning rail
    2. Guide rail
       Fig 25: Identifying Tensioning Rail For Oil-Pump Drive Chain And Guide Rail

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
31. Install solenoid hydraulic valves for camshaft control with new O-rings.
    1. 31.1. Tighten two external Torx screws (E8) M5 x 12 on each valve.

       → Tightening torque: 8 Nm (6 ftlb.) 

32. Install camshafts.

    → Installing camshaft - engine removed .

33. Install cylinder head cover.

    → Installing cylinder head cover .

34. Fit cover for positive crankcase ventilation.
    1. 34.1. Fit cover for cylinder bank 1-3 -1-  with new gaskets -2 + 3-  and secure with three external Torx screws M6 x 20 -4-  .
       Fig 26: Identifying Cover On Positive Crankcase Ventilation 1-3

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    2. 34.2. Fit cover for cylinder bank 4-6 -1-  with a new O-ring -2-  and secure with two external Torx screws M6 x 20 -3-  .
       Fig 27: Identifying Cover On Positive Crankcase Ventilation 4-6

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35. Fit spark plugs.

    → Installing Spark Plugs .

36. Install bar ignition modules.

    → Installing Ignition Coils .