Assembling Engine
WARNING: This page is about a different variant/trim than selected.
NOTE:
NOTIFICATION
Ingress of dirt
→ Ensure absolute cleanliness when working on the engine.
→ Lay removed engine parts on a clean surface and cover them.
→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.
Ingress of dirt
- Danger of material damage due to blocked oil bores/oil ducts
→ Ensure absolute cleanliness when working on the engine.
→ Lay removed engine parts on a clean surface and cover them.
→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.
CAUTION:
Heavy components
→ Wear personal protective gear.
→ Get someone to help if necessary.
- Risk of squashing
→ Wear personal protective gear.
→ Get someone to help if necessary.
CAUTION:
Leaks due to insufficiently or differently tempered components!
→ All components must be at least 17°C.
→ Components must not be too hot (distortion).
→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.
- If cold or differently tempered components are sealed to each other by applying a sealant, adhesion problems or leaks can result because of condensed water forming or components becoming distorted.
→ All components must be at least 17°C.
→ Components must not be too hot (distortion).
→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.
CAUTION:
Emerging residual fluid can soil the engine!
→ Place a drip tray under the engine at the assembly support.
→ Have a sufficient number of cleaning cloths ready.
→ Close off engine openings using stoppers.
- Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
→ Place a drip tray under the engine at the assembly support.
→ Have a sufficient number of cleaning cloths ready.
→ Close off engine openings using stoppers.
Information
The tightening specifications for the basic engine are stored centrally.
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or
> WM, 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS FOR ENGINE
Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
Information
Colour marking on bearing shell
- The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour marking must match the corresponding letter on the flywheel flange of the crankshaft . -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct colour classification of the bearing shell.
Information
Connecting rod code and direction of travel a
Connecting rod code "A"
- The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
- When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
- The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
- The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
- When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
- Naturally aspirated engines and turbo engines have different pistons.
- The code on the connecting-rod big end and connecting rod cap must be on the same side and at the exhaust side
. -A- NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
Information
- Connecting rod bolts must always be replaced.
- Place crankshaft bearing shells into the lower part of the crankcase.
- 1.1 Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-
. Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The engraved letters are the abbreviations for the colour code of the bearing shells (G for yellow, B for blue, R for red, N for green). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells must all have a yellow marking in this case.
Crankshaft
1 Crankshaft (stroke: 83 mm) 2 Straight pin, 6 x 20 3 Spring wedge 4 Thrust washer 5 Main bearing shell, upper 6 Main bearing shell, lower 7 Shaft seal 8 View of crankshaft flange 9 Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGGGBBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A - 1.2 Place crankshaft bearing shells with lubricating groove and bore -2-
into the upper part of the crankcase -1-
. Smooth crankshaft bearing shells -3-
belong in the lower part of the crankcase. Insert the thrust washers into the centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
Inserting bearing shells
Inserting bearing shells
Thrust washer
- 1.3 Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.
- 1.1 Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-
. Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The engraved letters are the abbreviations for the colour code of the bearing shells (G for yellow, B for blue, R for red, N for green). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells must all have a yellow marking in this case.
- If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
- 2.1 Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.
- 2.2 Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.
- 2.3 Fit knock sensors correctly.
Knock sensors
1 Knock sensor 2 Screw, M8 x 35 - 2.4 Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2-
Seals between crankcase and thermostat housing
- Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals on left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.
Coolant guide
1 Coolant pipe 2 M6 screw 3 Sealing ring 4 Screw plug, M16 x 1.5 5 M6 screw 6 Coolant guide tube (collection pipe) 7 Metal seal 8 Stopper - Fit oil spray jets -6-
.
Upper part of crankcase
Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown. > Spray direction > Spray direction from side
Spray direction
Spray direction from side
- Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.
- Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see > 131037 DISASSEMBLING AND ASSEMBLING PISTONS
Piston, connecting rod
1 Piston-ring set 2 Pistons 3 Circlip/piston-pin circlip 4 Piston pins 5 Connecting rods 6 Connecting rod bolt; replace as it must be tightened in the plastic area 7 Connecting-rod bearing shells - Check that all the seals are installed in the oil plate (oil return). > Oil return (oil plate) Oil guide (oil plate)
Oil return (oil plate)
- If you have not already done so, drive dowel sleeves for the metal seals in the chain housing cover using a copper or plastic hammer.
- Insert new metal seals on the chain housing cover and press onto the dowel sleeves.
- Oil pump is pre-fitted with the oil pressure control valve.
- Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
- If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
- Move starter into installation position and screw down.
- Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
- First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1-
). Then position the drive pinion of the oil pump chain -2-
with respect to the crankcase.
Timing chain pinion on crankshaft stub
Timing chain pinion with two diamond washers
- Fit crankshaft holding bridge > 9677/1 - holding bridge in the centre of the crankshaft.
Crankshaft secured
- Turn upper part of crankcase and oil cylinder liners.
- Pre-tension pistons using an assembly funnel > 9784/1 - funnel and press pistons into the cylinder. For details, see > 131020 Removing and installing pistons
- Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 04/10) to the lower part of the crankcase as shown. Insert sealing ring -3-
into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.
Applying sealant
1 Wipe off residual sealant after fitting A Direction of travel - Tighten M11 and M10 bearing screws to the prescribed torques. > Tightening sequence for thrust-bearing screws
Tightening sequence for thrust-bearing screws
1 to 20 Tightening sequence for M11 and M10 screws => Observe different torques! A Direction of travel Lower part of crankcase
1 Lower part of crankcase 2 Straight pin, 6 x 18 3 O-ring 4 Sealant application - Doboseal 224N (999.915.573.43, status 04/10) 5 Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. 6 Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. 7 Aluminium screw , M8 x 70; (cross bolt connection); always use new aluminium screws 8 Screw, M8 x 35 9 Screw, M8 x 50 10 Dowel sleeve A Direction of travel - Fit cross bolt connection.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)
- Fit M8 screws on the side -8 and 9- . Remove emerging sealant.
- Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.
- Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.
Oil guide (oil plate)
- Fit the oil pump > Oil pump on naturally aspirated engine
.
Oil pump on naturally aspirated engine
- Position the oil pump sprocket with drive chain with respect to the crankshaft chain pinion > Oil pump chain
. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.
Oil pump chain
Countering oil pump pinion
- Fit cover plate for oil pump drive (drive pinion cover) using three screws.
- Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.
- Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. -8-
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Camshafts (cylinder bank 1 to 4 shown)
1 Camshaft (outlet) 2 Camshaft (intake) 3 Hydraulic valve for variable valve lift control 4 Screw, M5 x 12 5 Switching tappet (oil with engine oil) 6 Bucket tappet (oil with engine oil) 7 Stopper 8 Mounting saddle 1 to 4 9 Stopper 10 Bearing locations (oil with engine oil) A Direction of travel - Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.
Cylinder head (1 to 4 shown)
1 Cylinder head 1 to 4 2 Cylinder-head gasket 1 to 4 3 M8 screw 4 Cap 5 Stopper 6 Stopper 7 Restrictor for valve lift adjustment 8 Cylinder-head screws => For tightening specifications, see Tightening sequence for cylinder head 9 Spark plug Tightening sequence for cylinder head
- Fit front M8 screw of cylinder head 1 to 4. -3-
- Coat camshaft bearings with normal multipurpose grease or engine oil.
- Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
- Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2-
Staking bore 45 degrees before TDC
Information
- A data matrix code is shown on the staking dihedron of the camshafts.
- This is a square black/white dotted marking used for identification purposes during the production process.
- This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts exert the least amount of pressure on the valves when the data matrix code is facing upwards during installation.
- Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position housings correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft housings evenly and gradually, and tighten slowly to the specified tightening torque. The camshafts must not be preloaded or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be confused because of the bearing locations and length.
Camshaft identification on V8 naturally aspirated engine
A Cylinders 1 to 4 B Cylinders 5 to 8 1 Outlet camshaft identification (green) 2 Intake camshaft identification (white) 3 Intake camshaft identification (white) 4 Outlet camshaft identification (green) Camshaft bearing cover identification
All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads
1 Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1) 2 Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2) 3 Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3) 4 Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4) 5 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1) 6 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2) 7 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3) 8 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4) arrow Direction of travel Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Camshaft mount, cylinders 5 to 8
1 Dowel sleeves 2 Bearing cover (intake) 3 Screw, M6 x 70 4 Bearing cover 5 Screw, M6 x 35 6 Bearing cover (outlet) 7 Bearing surfaces (oil with engine oil) A Direction of travel - Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4-
Camshaft adjustment
1 Screw, M12 Tighten fully after setting timing. 2 Camshaft controller with integrated hexagon for countering 3 Camshaft control hydraulic valve 4 Screw, M5 x 12 - Fit threaded peg for tensioning and guide rails if necessary. -1 and 2-
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Timing chain and chain guide
1 Threaded peg 2 Threaded peg 3 Guide rail 4 Tensioning rail 5 Chain tensioner with sealing ring 6 Pin (for locking the oil-pump tensioning rail) A Direction of travel - Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).
- Fit U-shaped deflection rail -4-
.
Timing chain and sprockets
1 Double-chain camshaft drive 2 Camshaft sprocket 3 Screw, M12 Tighten fully after setting timing. 4 Deflector rail 5 Screw, M8 x 35 6 Camshaft-to-camshaft guide pad A Direction of travel - Fit tensioning rail and let it hang.
- Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
- Loosely fit camshaft controller and sprockets using screws.
- Position timing chain and guide correctly over guide and tensioning rails.
- Fit chain housing cover. Secure sheetmetal holder for the tank vent valve to the upper screw on the chain housing cover at the 1st cylinder.
> 153319 REMOVING AND INSTALLING CHAIN HOUSING COVER
Chain tensioner is still removed.
- Replace and fit joint flange (sealing ring) between the vibration damper and chain housing cover.
>WM, 137419 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT PULLEY .
- Turn the engine around. Oil pump is upright.
- Lay sealing ring in the lower part of the crankcase.
- Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.
Applying sealant to oil guide housing
1 Sealant application (geometry, 1-mm bead of sealant) 2 Sealant application - Doboseal 224N (999.915.573.43, status 04/10) A Direction of travel - Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the chain housing cover (using a dial gauge, etc.). For details, see > 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
- Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4-
. Don't forget the screws between the oil guide housing and chain housing cover (five screws behind front vibration balancer, bores are currently overhead). -7-
Oil guide housing with accessories
1 Screw, M6 x 20 2 Joint flange 3 Sealing ring 4 Oil guide housing to lower part of crankcase - aluminium screw 5 Oil level sensor 6 Oil level sensor to oil guide housing (steel screw) 7 Timing-case cover to oil guide housing - aluminium screw - Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings. > Oil lines on naturally aspirated engine
> Oil lines, intake pipe on naturally aspirated engine
Oil lines on naturally aspirated engine
Oil lines, intake pipe on naturally aspirated engine
- Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -2 and 3-
.
Oil guide housing with accessories
1 Screw, M6 x 20 2 Joint flange 3 Sealing ring 4 Oil guide housing to lower part of crankcase - aluminium screw 5 Oil level sensor 6 Oil level sensor to oil guide housing (steel screw) 7 Timing-case cover to oil guide housing - aluminium screw - Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-
- Fit oil pan with reusable seal and tighten evenly and in diagonally opposite sequence.
Oil pan
- Turn the engine around.
- Position vibration balancer with screw tightened by hand.
- Set the timing. Follow procedure exactly.
WARNING: Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
→ The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings. - Tighten vibration balancer -3 and 4-
to the specified torque (use a brace > 9679/1 - brace). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For details, see > WM, 137619 REMOVING AND INSTALLING VIBRATION DAMPER (CRANKSHAFT PULLEY)
Supporting engine (illustration shows V8 engine supported on assembly support)
Pulleys
1 Water pump pulley 2 Screw, M8 x 16 3 Vibration damper 4 Screw, M18 x 1.5 x 72; use new screw 5 Power-steering pump pulley 6 Screw, M8 x 16 7 Tandem pump pulley - Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP
- Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.
>WM, 477619 REMOVING AND INSTALLING V8/TURBO/GTS VACUUM PUMP .
Vacuum pump
1 Vacuum pump 2 Screw, M6 x 25 3 O-ring 4 O-ring - Fit spark plugs if necessary.
- Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see > 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
- Fit both eyelets.
- Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
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Thermostat housing and coolant regulator
1 Thermostat housing 2 Screw, M6 x 25 3 Screw, M6 x 25; screwed to fuel high-pressure distribution pipe => see relevant article 4 Seal for thermostat housing; replace 5 Thermostat insert; including electric heating element - Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see > 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
- Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!
Coolant guide
1 Heater coolant pipe 2 M6 screw 3 Sealing ring 4 Screw plug, M16 x 1.5 5 M6 screw 6 Coolant guide tube (collection pipe) 7 Metal seal 8 Stopper - Fit water pump. Fit pulley for water pump. For details, see > 195019 REMOVING AND INSTALLING COOLANT PUMP
- Fit oil pressure sensor with adapter. Replace sealing rings.
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Oil pressure sensor and oil pressure measuring point
1 Oil pressure sensor adapter 2 O-ring 3 Oil-pressure sender with temperature sensor 4 Screw, M6 x 40 5 Stopper 6 Sealing ring A Direction of travel - Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-
.
Left bracket for auxiliary units and engine mounting
- Fit bearing console on the right. -1-
Right bracket for auxiliary units and engine mounting
- Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position.
- Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
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Coolant supply on naturally aspirated engine
1 M6 screw; securing coolant line to collection pipe 2 Coolant pipe 3 Connection piece screw 4 Connection piece on generator 5 Coolant supply hose for oil/coolant heat exchanger 6 Coolant supply hose to generator - Fit the generator and crash support. For details, see > 272219 REMOVING AND INSTALLING GENERATOR
Generator
1 Generator 2 Screw, M8 x 95 3 Screw, M8 x 35 4 Bores for screws, M8 x 95 A View - Fit deflection rollers and belt tensioner and press on cover.
Belt drive
1 Deflection roller 2 Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever 3 M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console 4 Deflection roller 5 Dual poly-V-belt - Fit crankshaft sealing ring on flywheel side. See > 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (on transmission side)
- Fit coolant hosing and secure clamps.
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Coolant supply on naturally aspirated engine
1 M6 screw; securing coolant line to collection pipe 2 Coolant pipe 3 Connection piece screw 4 Connection piece on generator 5 Coolant supply hose for oil/coolant heat exchanger 6 Coolant supply hose to generator Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Coolant return on naturally aspirated engine
1 Connection piece on generator 2 Connection piece screw 3 Screw, M6 x 20 4 Coolant return line 5 Coolant return hose assembly 6 Holder 7 M6 screw Aluminium screw ; always use new aluminium screws 8 Clip - Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
Ventilation
1 Vent line 2 Screw, M6 x 16 - Roughly position engine wire harness. Fit cable duct onto coolant collection pipe and route both harnesses for the cylinder banks. At the chain housing cover, route them down to the generator. Wire up air-conditioning compressor, insert injectors and wire up bar ignition modules. Screw down ground points. For details, see > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE
- Fit high-pressure line and low-pressure line > High-pressure pump on naturally aspirated engine
. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
High-pressure pump on naturally aspirated engine
- Fit high-pressure fuel distribution pipe. For details, see > 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION PIPE
- Check the DFI high-pressure system for leaks.
>WM, 243001 CHECKING FUEL DISTRIBUTOR PIPE (HIGH-PRESSURE SYSTEM) FOR LEAKS
- Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
Exhaust manifold on naturally aspirated engine (cylinders 1 to 4 shown)
- Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. -3-
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Ventilation on naturally aspirated engines
1 Engine ventilation line 2 Oil mist separator line to intake-air distributor 3 Tank ventilation 4 Aluminium holder 5 Aluminium screw (holder); see Chain housing cover - Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see > 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
- Fit oil mist separator. For details, see > WM, 105519 REMOVING AND INSTALLING OIL SEPARATOR
- Fit power-steering pump. For details, see installation description
- Fit air-conditioning compressor.
- Fit pulley for power-steering pump or tandem pump.
Pulleys
1 Water pump pulley 2 Screw, M8 x 16 3 Vibration damper 4 Screw, M18; use a new screw 5 Power-steering pump pulley 6 Screw, M8 x 16 7 Tandem pump pulley - Fit drive belt and then tighten it (manipulate belt tensioner using a socket or ring wrench).
- Fit heat protection panels on generator and on exhaust manifold.
Heat protection panels on V8 naturally aspirated engine
- Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.
NOTE:
NOTIFICATION
Ingress of dirt
→ Ensure absolute cleanliness when working on the engine.
→ Lay removed engine parts on a clean surface and cover them.
→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.
Ingress of dirt
- Danger of material damage due to blocked oil bores/oil ducts
→ Ensure absolute cleanliness when working on the engine.
→ Lay removed engine parts on a clean surface and cover them.
→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.
CAUTION:
Heavy components
→ Wear personal protective gear.
→ Get someone to help if necessary.
- Risk of squashing
→ Wear personal protective gear.
→ Get someone to help if necessary.
CAUTION:
Leaks due to insufficiently or differently tempered components!
→ All components must be at least 17°C.
→ Components must not be too hot (distortion).
→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.
- If cold or differently tempered components are sealed to each other by applying a sealant, adhesion problems or leaks can result because of condensed water forming or components becoming distorted.
→ All components must be at least 17°C.
→ Components must not be too hot (distortion).
→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.
CAUTION:
Emerging residual fluid can soil the engine!
→ Place a drip tray under the engine at the assembly support.
→ Have a sufficient number of cleaning cloths ready.
→ Close off engine openings using stoppers.
- Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
→ Place a drip tray under the engine at the assembly support.
→ Have a sufficient number of cleaning cloths ready.
→ Close off engine openings using stoppers.
Information
The tightening specifications for the basic engine are stored centrally.
/
or
> WM, 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS FOR ENGINE
Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
Information
Colour marking on bearing shell
- The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour marking must match the corresponding letter on the flywheel flange of the crankshaft . -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct colour classification of the bearing shell.
Information
Connecting rod code and direction of travel a
Connecting rod code "A"
- The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
- When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
- The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
- The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
- When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
- Naturally aspirated engines and turbo engines have different pistons.
- The code on the connecting-rod big end and connecting rod cap must be on the same side and at the exhaust side
. -A- NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
Information
- Connecting rod bolts must always be replaced.
- Place crankshaft bearing shells into the lower part of the crankcase.
- 1.1 Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-
. Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The letters are the abbreviations for the colour code of the bearing shells (G for yellow, B for blue, R for red, N for green). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells must all have a yellow marking in this case.
Crankshaft
1 Crankshaft (stroke: 83 mm) 2 Straight pin, 6 x 20 3 Spring wedge 4 Thrust washer 5 Main bearing shell, upper 6 Main bearing shell, lower 7 Shaft seal 8 View of crankshaft flange 9 Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGGGBBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A - 1.2 Place crankshaft bearing shells with lubricating groove and bore -2-
into the upper part of the crankcase -1-
. Smooth crankshaft bearing shells -3-
belong in the lower part of the crankcase. Insert the thrust washers into the centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
Inserting bearing shells
Inserting bearing shells
Thrust washer
- 1.3 Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.
- 1.1 Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-
. Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The letters are the abbreviations for the colour code of the bearing shells (G for yellow, B for blue, R for red, N for green). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells must all have a yellow marking in this case.
- If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
- 2.1 Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.
- 2.2 Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.
- 2.3 Fit knock sensors correctly.
Knock sensors
1 Knock sensor 2 Screw, M8 x 35 - 2.4 Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2-
Seals between crankcase and thermostat housing
- Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals at the left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.
Coolant guide
1 Coolant pipe 2 M6 screw 3 Sealing ring 4 Screw plug, M16 x 1.5 5 M6 screw 6 Coolant guide tube (collection pipe) 7 Metal seal 8 Stopper - Fit oil spray jets -6-
.
Upper part of crankcase
Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown. > Spray direction > Spray direction from side
Spray direction
Spray direction from side
- Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.
- Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see > 131037 DISASSEMBLING AND ASSEMBLING PISTONS
Piston, connecting rod
1 Piston-ring set 2 Pistons 3 Circlip/piston-pin circlip 4 Piston pins 5 Connecting rods 6 Connecting rod bolt; replace as it must be tightened in the plastic area 7 Connecting-rod bearing shells - Check that all the seals are installed in the oil plate (oil return). > Oil return (oil plate)
Oil return (oil plate)
- If you have not already done so, drive dowel sleeves for the metal seals in the chain housing cover using a copper or plastic hammer.
- Insert new metal seals on the chain housing cover and press onto the dowel sleeves.
- Oil pump is pre-fitted with the oil pressure control valve.
- Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
- If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
- Move starter into installation position and screw down.
- Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
- First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1-
). Then position the drive pinion of the oil pump chain -2-
with respect to the crankcase.
Timing chain pinion on crankshaft stub
Timing chain pinion with two diamond washers
- Fit crankshaft holding bridge > 9677/1 - holding bridge in the centre of the crankshaft.
Crankshaft secured
- Turn upper part of crankcase and oil cylinder liners.
- Pre-tension pistons using an assembly funnel > 9784/1 - funnel and press pistons into the cylinder. For details, see > 131020 Removing and installing pistons
- Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/09) to the lower part of the crankcase as shown. Insert sealing ring -3-
into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.
Applying sealant
1 Wipe off sealant residues after fitting A Direction of travel - Screw down M11 and M10 bearing screws to the prescribed torques. -5 and 6-
.
Tightening sequence for thrust-bearing screws
1 to 20 Tightening sequence for M11 and M10 screws => Observe different torques! A Direction of travel Lower part of crankcase
1 Lower part of crankcase 2 Straight pin, 6 x 18 3 O-ring 4 Sealant application - Doboseal 224N (999.915.573.43, status 04/10) 5 Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. 6 Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. 7 Aluminium screw , M8 x 70; (cross bolt connection); always use new aluminium screws 8 Screw, M8 x 35 9 Screw, M8 x 50 10 Dowel sleeve A Direction of travel - Fit cross bolt connection.
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Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)
- Fit M8 screws on the side -9 and 8- . Remove emerging sealant.
- Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.
- Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.
Oil guide (oil plate)
- Grease sealing ring between the oil plate transfer pipe and oil pump sparingly with Kluber Syntheso GLEP 1 and fit oil pump. Secure the oil pump.
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Oil pump on turbo engine M48/51 with oil extraction stage
1 Oil pump with extraction stage 2 Screw, M8 x 22; replace 3 Oil pump sprocket 4 Cap screw, M36 5 Solenoid valve 6 O-ring (grease before fitting) 7 Dowel sleeve 8 Screw, M6 x 45 9 Sprocket cover 10 Screw, M6 x 16 11 Drive chain 12 Connection for intake manifold joining socket A Direction of travel - Position oil pump sprocket with drive chain with respect to crankshaft chain pinion > Oil pump chain
. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.
Oil pump chain
Countering oil pump pinion
- Fit cover plate for oil pump drive (drive pinion cover) using three screws.
- Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.
- Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. -8-
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Camshafts (cylinder bank 1 to 4 shown)
1 Camshaft (outlet) 2 Camshaft (intake) 3 Hydraulic valve for variable valve lift control 4 Screw, M5 x 12 5 Switching tappet (oil with engine oil) 6 Bucket tappet (oil with engine oil) 7 Stopper 8 Mounting saddle 1 to 4 9 Stopper 10 Bearing locations (oil with engine oil) A Direction of travel - Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.
Cylinder head (1 to 4 shown)
1 Cylinder head 1 to 4 2 Cylinder head gasket 1 to 4 3 M8 screw 4 Cap 5 Stopper 6 Stopper 7 Restrictor for valve lift adjustment 8 Cylinder-head screws => For tightening specifications, see Tightening sequence for cylinder head 9 Spark plug Tightening sequence for cylinder head
- Fit front M8 screw of cylinder head 1 to 4. -3-
- Coat camshaft bearings with normal multipurpose grease or engine oil.
- Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
- Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2-
Staking bore 45 degrees before TDC
Information
- A data matrix code is shown on the staking dihedron of the camshafts.
- This is a square black/white dotted marking used for identification purposes during the production process.
- This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts exert the least amount of pressure on the valves when the data matrix code is facing upwards during installation.
- Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position housings correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft housings evenly and gradually, and slowly approach the tightening torque. The camshafts must not be preloaded or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be confused because of the bearing locations and length.
Camshaft identification on V8 turbo engine
A Cylinders 1 to 4 B Cylinders 5 to 8 1 Outlet camshaft identification (green) 2 Intake camshaft identification (blue) 3 Intake camshaft identification (blue) 4 Outlet camshaft identification (green) Camshaft bearing cover identification
All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads
1 Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1) 2 Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2) 3 Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3) 4 Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4) 5 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1) 6 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2) 7 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3) 8 Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4) arrow Direction of travel Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Camshaft mount, cylinders 5 to 8
1 Dowel sleeves 2 Bearing cover (intake) 3 Screw, M6 x 70 4 Bearing cover 5 Screw, M6 x 35 6 Bearing cover (outlet) 7 Bearing surfaces (oil with engine oil) A Direction of travel - Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4-
Camshaft adjustment
1 Screw, M12 Tighten fully after setting timing. 2 Camshaft controller with integrated hexagon for countering 3 Camshaft control hydraulic valve 4 Screw, M5 x 12 - Fit threaded peg for tensioning and guide rails if necessary. -1 and 2-
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Timing chain and chain guide
1 Threaded peg 2 Threaded peg 3 Guide rail 4 Tensioning rail 5 Chain tensioner with sealing ring 6 Pin (for locking the oil-pump tensioning rail) A Direction of travel - Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).
- Fit U-shaped deflection rail -4-
.
Timing chain and sprockets
1 Double-chain camshaft drive 2 Camshaft sprocket 3 Screw, M12 Tighten fully after setting timing. 4 Deflector rail 5 Screw, M8 x 35 6 Camshaft-to-camshaft guide pad A Direction of travel - Fit tensioning rail and let it hang.
- Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
- Loosely fit camshaft controller and sprockets using screws.
- Position timing chain and guide correctly over guide and tensioning rails.
- Fit chain housing cover. Secure sheetmetal holder for tank vent valve to the upper screw on the chain housing cover at the 1st cylinder.
> 153319 REMOVING AND INSTALLING CHAIN HOUSING COVER
Chain tensioner is still removed.
- Replace and fit joint flange (sealing ring) between the vibration damper and chain housing cover.
> WM, 137419 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT PULLEY
- Turn the engine around. Oil pump is upright.
- Lay sealing ring in the lower part of the crankcase.
- Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.
Applying sealant to oil guide housing
1 Sealant application (geometry, 1-mm bead of sealant) 2 Doboseal 224N (999.915.573.43, status 04/10) A Direction of travel - Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the chain housing cover (using a dial gauge, etc.). For details, see > 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
- Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4-
. Don't forget the screws between the oil guide housing and chain housing cover (five screws behind front vibration balancer, bores are currently overhead). -7-
Oil guide housing with accessories
1 Screw, M6 x 20 2 Joint flange 3 Sealing ring 4 Oil guide housing to lower part of crankcase - aluminium screw ; always use new aluminium screws 5 Oil level sensor 6 Oil level sensor to oil guide housing (steel screw) 7 Chain housing cover to oil guide housing - aluminium screw ; always use new aluminium screws - Equip intake manifold oil strainer with sealing ring and then fit it. Tighten all oil pipes.
Oil lines on turbo engine
1 Oil extraction line for turbocharger, cylinders 1 to 4 2 Oil extraction line for turbocharger, cylinders 5 to 8 3 Intake pipe on oil pump 4 O-ring 5 Oil pressure pipe 6 O-ring 7 O-ring, 22 x 3 8 Oil regulating line 9 O-ring 10 O-ring 11 Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing; oil regulating line to oil pump and oil guide housing; turbocharger extraction line to oil pump 12 Screw, M6 x 20 A For arrangement of oil lines, see other illustrations B Direction of travel Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Oil lines, intake pipe on turbo engine
1 Mount for oil extraction line for turbocharger, cylinders 1 to 4 2 Mount for oil extraction line for turbocharger, cylinders 5 to 8 3 Mount for oil separator vent line, cylinders 5 to 8 4 Mount for oil pump intake manifold 6 Mounting point for oil pressure pipe 9 Mount for oil regulating line A Direction of travel - Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -2 and 3- .
- Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-
- Fit lower oil pan and tighten evenly crosswise (the inserted seal can be reused provided it does not leak and is not damaged). Insert and fit oil drain plug with new sealing ring.
Oil pan
1 Oil pan with reusable seal inserted 2 Sealing ring 3 Oil drain plug, M18 4 Screw, M6 x 20 A Direction of travel - Turn the engine around.
- Position vibration balancer with screw tightened by hand.
- Set the timing. Follow procedure exactly.
WARNING: Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
→ The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings. - Tighten vibration balancer -3 and 4-
to the specified torque (use a brace > 9679/1 - brace). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For details, see > WM, 137619 REMOVING AND INSTALLING VIBRATION DAMPER (CRANKSHAFT PULLEY)
Supporting engine (illustration shows V8 engine supported on assembly support)
Pulleys
1 Water pump pulley 2 Screw, M8 x 16 3 Vibration damper 4 Screw, M18 x 1.5 x 72; use new screw 5 Power-steering pump pulley 6 Screw, M8 x 16 7 Tandem pump pulley - Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP
- Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.
> WM, 477619 REMOVING AND INSTALLING V8/TURBO/GTS VACUUM PUMP
Vacuum pump
1 Vacuum pump 2 Screw, M6 x 25 3 O-ring 4 O-ring - Fit spark plugs if necessary.
- Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see > 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
- Fit both eyelets.
- Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
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Thermostat housing and coolant regulator
1 Thermostat housing 2 Screw, M6 x 25 3 Screw, M6 x 25; screwed to fuel high-pressure distribution pipe => see relevant article 4 Seal for thermostat housing; replace 5 Thermostat insert; including electric heating element - Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see > 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
- Lay boost-pressure control and circulating air lines at the engine and clip in.
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Boost pressure and wastegate
1 Pressure line, boost pressure line 2 Hose clamp 3 Cycle valve 4 Combination holder 5 Holder to chain housing cover 6 Control line 7 Control line 8 Hose holder Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Boost pressure and wastegate 2
1 Pressure line 2 Vacuum line 3 Hose clamp 4 Screw, M6 x 12 5 Holder 6 Rubber element 7 Electric change-over valve 8 Control line A View A - Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!
Coolant guide
1 Heater coolant pipe 2 M6 screw 3 Sealing ring 4 Screw plug, M16 x 1.5 5 M6 screw 6 Coolant guide tube (collection pipe) 7 Metal seal 8 Stopper - Fit water pump. Fit pulley for water pump. For details, see > 195019 REMOVING AND INSTALLING COOLANT PUMP
- Fit oil pressure sensor with adapter. Replace sealing rings.
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Oil pressure sensor and oil pressure measuring point
1 Oil pressure sensor adapter 2 O-ring 3 Oil-pressure sender with temperature sensor 4 Screw, M6 x 40 5 Stopper 6 Sealing ring A Direction of travel - Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC). Fit auxiliary unit bracket for right engine mount.
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Left bracket for auxiliary units and engine mounting
1 Bracket for auxiliary units/engine mounting 2 Screw, M10 x 45 3 Hydraulic mount, left 4 Engine carrier 5 Screw, M10 x 65 6 Dowel sleeve 7 Nut, M12 x 1.5 Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Right bracket for auxiliary units and engine mounting
1 Engine carrier, cylinders 1 to 4 2 Screw, M10 x 45 3 Hydraulic mount, right 4 Engine carrier 5 Screw, M10 x 65 6 Nut, M12 x 1.5 7 Bores for screws, M10 x 45 A Installation view of engine carrier on crankcase - Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
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Coolant supply on turbo engine
1 M6 screw; securing coolant line to collection pipe 2 Coolant pipe 3 Connection piece screw 4 Connection piece on generator 5 Coolant supply hose for oil/coolant heat exchanger 6 Coolant supply hose to generator - Fit the generator and crash support. For details, see > 272219 REMOVING AND INSTALLING GENERATOR
Generator
1 Generator 2 Screw, M8 x 95 3 Screw, M8 x 35 4 Bores for screws, M8 x 95 A View - Fit deflection rollers and belt tensioner and press on cover.
Belt drive
1 Deflection roller 2 Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever 3 M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console 4 Deflection roller 5 Dual poly-V-belt - Fit crankshaft sealing ring on flywheel side. See > 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (on transmission side)
- Fit coolant hosing and secure clamps.
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Coolant return on turbo engine
1 Connection piece on generator 2 Connection piece screw 3 Screw, M6 x 20 4 Coolant return line 5 Coolant return hose assembly 6 Holder 7 M6 screw Aluminium screw ; always use new aluminium screws 8 Clip Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Coolant supply on turbo engine
1 M6 screw; securing coolant line to collection pipe 2 Coolant pipe 3 Connection piece screw 4 Connection piece on generator 5 Coolant supply hose for oil/coolant heat exchanger 6 Coolant supply hose to generator - Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
Ventilation
1 Vent line 2 Screw, M6 x 16 - If you have not already done so, secure sheetmetal holder of tank vent valve to the second upper screw of the chain housing cover at the 1st cylinder.
- Fit PCV lines.
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Positive crankcase ventilation (PCV) on turbo engine
1 Ventilation pipe with sealing ring (holder to chain housing cover) 2 Screw, M6 x 12 A Installation view of ventilation pipe - Roughly position engine wire harness. Fit cable duct onto coolant collection pipe and route both harnesses for the cylinder banks. At the chain housing cover, route them down to the generator. Wire up air-conditioning compressor, insert injectors and wire up bar ignition modules. Screw down ground points. For details, see > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
- Fit high-pressure line between the high-pressure pump and fuel distribution pipe item 2. To do this, fit union nut in cylinder head item 4. Clip in cable duct at the union nut.
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High-pressure pump, turbo engine
1 High-pressure pump 2 High-pressure line; (3 turns: tighten, loosen, tighten) 3 Low-pressure line; (3 turns: tighten, loosen, tighten) 4 Screw socket, M8 5 Screw socket, M6 6 Protective plate 7 Screw, M6 x 20 8 Screw, M6 x 25 A Required line distance (5 to 8 mm) between high-pressure line and low-pressure line Temperature sensor; not shown on low-pressure line - Fit high-pressure fuel distribution pipe. For details, see > 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION PIPE
- Check the DFI high-pressure system for leaks.
> WM, 243001 CHECKING FUEL DISTRIBUTOR PIPE (HIGH-PRESSURE SYSTEM) FOR LEAKS
- Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
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Tightening sequence for exhaust manifold on turbo engine, cylinders 1 to 4
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Exhaust manifold on turbo engine, cylinders 1 to 4
1 Exhaust manifold 2 Exhaust manifold seal 3 Turbocharger seal 4 Screw, M8 x 75 5 Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence A Marking on seal visible from outside Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Exhaust manifold on turbo engine, cylinders 5 to 8
1 Exhaust manifold 2 Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence 3 Screw, M8 x 75 4 Turbocharger seal 5 Exhaust manifold seal A Marking on seal visible from outside - Pre-fit the coolant and oil circuit lines, which are hard to reach when fitted, on the turbocharger.
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Turbocharger, cylinders 1 to 4 - cooling
1 Coolant return line for turbocharger, cylinders 1 to 4 2 Coolant supply line for turbocharger, cylinders 1 to 4 3 Coolant supply hose for turbocharger, cylinders 1 to 4 4 Screw, M6 x 16 5 Clamp 6 Hexagon nut, M6 7 Banjo bolt, M12 x 1.25; coolant supply line to turbocharger; coolant return line to turbocharger 8 Connection for coolant supply hose for turbocharger, cylinders 1 to 4 9 Connection for coolant return hose for turbocharger, cylinders 1 to 4 A Direction of travel Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Turbocharger, cylinders 5 to 8 - cooling
1 Coolant supply line for turbocharger, cylinders 5 to 8 2 Hexagon nut, M6 3 Clamp 4 Coolant return line for turbocharger, cylinders 5 to 8 5 Banjo bolt, M12 x 1.25; coolant supply line to turbocharger; coolant return line to turbocharger 6 Connection for collection pipe 7 Connection for coolant supply hose for turbocharger, cylinders 5 to 8 8 Turbocharger, cylinders 5 to 8 A Direction of travel Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Oil circuit for turbocharger, cylinders 1 to 4
1 Turbocharger vent line for cylinders 1 to 4; vent line to oil extraction line for turbocharger; holding clamp for vent line to collection pipe, M6 screw; holding clamp for vent line to collection pipe, M6 nut 2 Oil feed line for turbocharger, cylinders 1 to 4; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head 3 Connection piece 4 Sealing ring 5 Oil extraction line 6 Screw, M6 x 12 7 Screw, M6 x 16 8 Turbocharger seal, cylinders 1 to 4 Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Oil circuit for turbocharger, cylinders 5 to 8
1 Oil supply line for turbocharger, cylinders 5 to 8 2 M6 nut 3 Holding clamp 4 Vent line for turbocharger, cylinders 5 to 8 5 Holding clamp 6 Screw, M6 x 12; holder for turbocharger oil feed line to lower part of crankcase; holding clamp for oil feed line to holder 7 Screw, M6 x 16 8 Oil extraction line 9 Turbocharger seal, cylinders 5 to 8 10 Sealing ring 11 Connection piece 12 Clamp 13 Holder for oil supply line - Fit the turbocharger. Fit seals correctly. Observe tightening sequence. It is best to fit the turbocharger to the engine with the lines connected and fitted and then screw it on.
- Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. > Ventilation on turbo engines
Ventilation on turbo engines
1 Engine ventilation line 2 Check valve for full-throttle ventilation with lines secured 3 Tank ventilation 4 Aluminium holder 5 Aluminium screw (holder); see Chain housing cover 6 Belt tensioner 7 Holder 8 Fastening screw; see Belt drive - Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see > 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
- Fit oil mist separator. For details, see > WM, 105519 REMOVING AND INSTALLING OIL SEPARATOR
- Fit power-steering pump. For details, see installation description
- Fit air conditioning compressor.
- Fit pulley for power-steering pump or tandem pump.
Pulleys
1 Water pump pulley 2 Screw, M8 x 16 3 Vibration damper 4 Screw, M18; use a new screw 5 Power-steering pump pulley 6 Screw, M8 x 16 7 Tandem pump pulley - Fit drive belt and then tighten it (manipulate belt tensioner using a socket or ring wrench).
- Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.