Installing Engine

→ Enlist assistance of second and, if necessary, third person

Information 

• The engine/transmission unit is essentially installed in reverse order to removal. 
• First complete the fluid systems opened during removal. 

Information 

• The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 

Information 

Listen for a clearly audible locking sound when fitting all rapid-action coupling connections and cable plugs. Pull to check that connections are secure.

Information 

• Check to see if spacers are fitted on cylinder head side 4-6 (relates to all all-wheel drive vehicles). 
• These must be converted when replacing the engine. 
• Replace damaged spacers. 

1. Only for all-wheel drive vehicles: Check that the spacer -1- is fitted on cylinder head side 4-6. 
   1. 1.1. Secure the spacer on a new engine using two screws -2-  .

      → Tightening torque: 13 Nm (9.5 ft. lb.) 

      Fig 1: Installing All-Wheel Drive Vehicle Spacer

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Raise the engine as far as required using the elevating platform until the secondary-air line for cylinder bank 1-3 can be fitted.
3. Fit secondary-air line for cylinder bank 1-3 with a new seal on cylinder head 1-3.
   1. 3.1. Fit two external Torx screws (E10, M6 x 16).
      Fig 2: Identifying Secondary-Air Line (Cylinder Head 1-3)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • Get a second person to check the engine/transmission clearance when lifting it. 
   • Pay particular attention to the clearance between the rear-axle cross member and supporting dome. 
4. Raise engine/transmission unit into installation position and secure the unit mounts.
   1. 4.1. Install transmission bracket.
      1. 4.1.1. Fit four M10 hexagon nuts and two hexagon-head bolts (M10 x 55) -arrows-  on the transmission bracket and tighten them.

         → Tightening torque: 65 Nm (48 ft. lb.) 

         Fig 3: Locating Transmission Bracket Threaded Joint

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 4.2. Fit two M10 collar nuts on the transmission support. → Tightening torque: 65 Nm (48 ft. lb.) 
   3. 4.3. Tighten two M12 collar nuts -1-  on the engine mount. → Tightening torque: 85 Nm (63 ft. lb.) 
      Fig 4: Identifying Engine Carrier And Engine Mount (Cylinder Bank 4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Lift the vehicle and move elevating platform out of the work area.

   Information 

   • Check O-rings on the plug-in couplings and replace them if necessary. 
   • Clean plug connection and coolant hoses before assembly. 
   • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
   • Remove stoppers before fitting the coolant lines and hoses. 
6. Remove stoppers from the coolant lines before fitting.
7. Fit coolant hoses for heating and disc valve.
   1. 7.1. Connect the hoses -1-  and close the spring band clamps -2-  .
      Fig 5: Identifying Heating Circuit Coolant Hoses

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 7.2. Fit cable plug -1-  and coolant hose -2-  on the disc valve.
      Fig 6: Identifying Disc Valve Cable Plug And Coolant Hose

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Fit drive shafts.

   → WM 422119 REMOVING AND INSTALLING REAR DRIVE SHAFT .

   → Tightening torque: 90 Nm (67 ft. lb.) 

9. Install cardan shaft.

   → 390219 REMOVING AND INSTALLING CARDAN SHAFT .

   Fig 7: Locating Cardan Shaft Bolts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Vehicles With Manual Transmission: 
    1. 10.1. Fit clutch line.
       Fig 8: Connecting Clutch Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 10.2. Fit electric lines to the B+ box -1-  and connect cable plug -2-  for reversing light.

       → Tightening torque: 23 Nm (17 ft. lb.) 

       Fig 9: Identifying B+ Box And Reversing Light Switch (Manual Transmission)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 10.3. Fit shift cables -1-  and secure in place in the supports -2-  .
       Fig 10: Locating Shift Cables (Manual Transmission)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Vehicles with Porsche Doppelkupplung (PDK): 
    1. 11.1. Fit cable plug (bayonet lock). The connectors and housing must be locked together so that the relevant connector can be plugged in.
    2. 11.2. Check locking position of the connector -2-  in the connector housing -1-  . The small lug -3-  must be touching the connector housing so that the position is aligned with the arrow marking on the housing.
       Fig 11: PDK Connector Locking Position

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       If the connector is not locked, turn it clockwise -arrow-  as far as it will go -1-  .

       Fig 12: Locking PDK Connector

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 11.3. Fit connector (arrows -1-  must be aligned).
       Fig 13: Identifying PDK Connector Markings

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 11.4. Close bayonet locks by turning them clockwise. Then clip in cable guide on the transmission -2-  .
       Fig 14: Identifying PDK Cable Plug And Cable Guide

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 11.5. Fit locking cable.
    6. 11.6. Fit electric lines on the B+ box. Tighten hexagon nut. →

       Tightening torque: 23 Nm (17 ft. lb.) 

    7. 11.7. Plug in cable plug for reversing light.

    All Vehicles: 

    Information 

    Check for cuts on the entire diameter of the inner rubber edge on the pressure hose leading to the turbocharger. Replace if damaged.

12. Fit intake air hoses -2-  on the turbochargers.
    1. 12.1. Tighten screw-type clamps -1-  .

       → Tightening torque: 3 Nm (2 ft. lb.) 

       Fig 15: Identifying Turbocharger Intake Hose

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Secure engine ground strap -1-  to the body.

    → Tightening torque: 23 Nm (17 ft. lb.) 

    Fig 16: Identifying Engine Ground Strap

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Install chassis components:
    1. 14.1. Rear cross member: hexagon-head bolts and M12 collar nuts.

       → Tightening torque: 110 Nm (81.5 ft. lb.) 

    2. 14.2. Diagonal braces to rear cross member: M12 hexagon-head bolt.

       → Tightening torque: 110 Nm (81.5 ft. lb.) 

    3. 14.3. Diagonal brace to rear-axle carrier: M10 collar nut.

       → Tightening torque: 23 Nm (17 ft. lb.) 

    4. 14.4. Diagonal brace to body: M10 hexagon-head bolt.

       → Tightening torque: 65 Nm (48 ft. lb.) 

    5. 14.5. Transverse strut to body: M10 hexagon-head bolt.

       → Tightening torque: 65 Nm (48 ft. lb.) 

15. Install rear anti-roll bar.

    → 429019 REMOVING AND INSTALLING REAR ANTI-ROLL BAR .

    1. 15.1. Engage anti-roll bar on the connecting links and then secure on the rear axle carrier using two hexagon-head bolts on each -1-  .

       → Tightening torque: 23 Nm (17 ft. lb.) 

    2. 15.2. Fit new M10 collar nuts -2-  on the connecting link joint. Counter with a Torx socket-wrench insert when tightening.
       Fig 17: Identifying Rear Anti-Roll Bar Mount

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       Fig 18: Fitting Anti-Roll Bar To Connecting Link

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       → Initial tightening torque: 50 Nm (37 ft. lb.) 

    3. 15.3. Loosen collar nuts by 90 degrees and then tighten them again.

       → Final tightening torque: 65 Nm (48 ft. lb.) 

16. Fit tailpipe covers.

    → Tightening torque: 30 Nm (22 ft. lb.) 

17. Lower the vehicle.
18. Fit secondary-air line in engine compartment on cylinder head 1-3.

    For tools, see section on removal! 

    1. 18.1. Secure the line on cylinder head 1-3 with an external Torx screw (E10, M6 x 16) -2-  .

       → Tightening torque: 13 Nm (9.5 ft. lb.) 

       Fig 19: Securing Secondary-Air Line Holder Using Tool

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Install center intake-air distributor.

    → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - TURBO .

    1. 19.1. Grease O-rings with a light coating of Kluber Syntheso Glep.
20. Connect fuel line connections at the left in the engine compartment.
    1. 20.1. Connect fuel tank ventilation line -1-  .
    2. 20.2. Connect fuel pressure line (low pressure) -2-  and clip it into the holder -3-  .
    3. 20.3. Pull to check that the lines are secure.
       Fig 20: Identifying Engine Compartment Fuel Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
21. Fit coolant hoses on the left in the engine compartment.
    1. 21.1. Lightly grease the inside of the hoses.
    2. 21.2. Slide on the hoses and close the spring band clamps.
       1. Coolant ventilation
       2. Filler line to coolant regulator housing
       3. Engine supply line from radiator
          Fig 21: Identifying Engine Compartment Coolant Hoses

          Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Fit engine wire harness.
    1. Blue ring
    2. Grey ring
    3. Black ring
       Fig 22: Locating Engine Wire Harness Connection

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 22.1. Turn the bayonet lock clockwise as far as it will go to close it.
    2. 22.2. Secure the wire harness on the holder with a new tie-wrap -arrow-  .
       Fig 23: Locating Tie-Wrap (Engine Wire Harness)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
23. Fit air-conditioning compressor -1-  .

    → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

    1. 23.1. Screw in rear screws -2-  with holder.
    2. 23.2. Screw in front screws -4-  .
    3. 23.3. Tighten fastening screws to the specified torque.

       → Tightening torque: 23 Nm (17 ft. lb.) 

    4. 23.4. Connect cable plug -3-  for control line.
       Fig 24: Identifying Air-Conditioning Compressor Fasteners

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Check O-rings on the plug-in couplings and replace them if necessary. 
    • Clean plug connection and coolant hoses before assembly. 
    • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
    • Remove stoppers before fitting the coolant lines and hoses. 
24. Fit coolant hose -2-  on the right in the engine compartment.
    1. 24.1. Lightly grease the O-ring.
    2. 24.2. Check the position of the safety clip and connect the coolant hose.
       Fig 25: Identifying Coolant Hose And Power-Steering Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Fit power-steering lines -1-  .

    → 4X00IN PLUG-IN COUPLINGS FOR HYDRAULIC LINES - AS OF MODEL YEAR 2009 .

    1. 25.1. Connect the pressure line.
    2. 25.2. Fit the return hose on the line using the spring band clamp.
26. Fit the drive belt. Pay attention to rolling direction of previously used belts.

    → 137819 REMOVING AND INSTALLING DRIVE BELT - TURBO .

    Fig 26: Fitting Drive Belt

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 26.1. Check that the drive belt is positioned correctly on the pulleys.
27. Connect plug connections for oxygen sensors and exhaust temperature sensors in the engine compartment.
    1. 27.1. Plug in connectors for exhaust temperature sensors in the connector housing (at the left in engine compartment).
    2. 27.2. Route line for exhaust temperature sensor at the left together with the oxygen sensor cable.
    3. 27.3. Connect plug connections for oxygen sensors and secure them in the connector housings.

    Position	Connector	Cable	Oxygen sensor
    1	Grey	Black	Behind catalytic converter
    2	Black	Blue	Ahead of catalytic converter