Disassembling Engine

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165  on the engine assembly support.

1. Place a pan under the engine to collect emerging fluids.
2. Drain engine oil. Also loosen the oil filter at the bracket so that the remaining oil can drain more easily → 170155 CHANGING ENGINE OIL AND OIL FILTER .
3. Remove rear silencer → 263319 REMOVING AND INSTALLING REAR SILENCER .
   1. 3.1. Screw off four M8 lock nuts on the turbochargers.
   2. 3.2. Open the holding clamps on the engine carrier and get another person to help you to remove the silencer.
4. Remove intake air pipes.
   1. 4.1. Unclip vacuum lines for the ambient air valves on the turbocharger.
   2. 4.2. Unscrew two Torx screws (M6) -arrows-  on the turbochargers. Disengage intake pipes from the holders and remove them.
      Fig 1: Locating Intake Air Pipe Connector (Side 4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Remove oil and coolant supply lines on the turbocharger.
6. Remove turbocharger on side 1-3. Loosen threaded connection on holder for turbocharger 1-3 and take off turbocharger.
7. Remove turbocharger on side 4-6. Loosen threaded connection on holder for turbocharger 4-6 and take off turbocharger.
8. Remove secondary-air pump.
   1. 8.1. Unclip vent line for the oil tank.
   2. 8.2. Unscrew two M6 Torx screws and disconnect cable plug.
9. Remove engine carrier by unscrewing four Torx screws (M10 x 70) and remove bracket.
10. Remove the oil extraction lines for the oil tank at the turbocharger.
    1. 10.1. Unscrew two M6 x 12 Torx screws and pull off lines.
11. Remove oil return line for engine extraction pump.
    1. 11.1. Unscrew M16 banjo bolt and remove (replace) two aluminum sealing rings.
12. Remove oil tank.
    1. 12.1. Unscrew three M8 x 30 Torx screws.
    2. 12.2. Loosen five clamps for the breather hoses and pull off the hoses.
    3. 12.3. Loosen the union nut (a/f 32) on the oil line and put it aside. Disconnect cable plug for oil-level sender.
    4. 12.4. Unscrew two Torx screws (M6 x 16) on the feed line from the engine and remove (replace) O-ring.
13. Remove heat shields for ignition coils. Loosen and unscrew two Torx screws (M6 x 12) on each and remove heat shields.
14. Loosen ground cable on cover for camshaft housing 1-3 and 4-6. Unscrew one Torx screw (M6 x 35) on each.
15. Disconnect all plug connections for the engine wire harness in order to remove the intake manifold → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
    1. 15.1. Slide engine compartment temperature sensor out of the rubber sleeve.
    2. 15.2. Unclip cable duct on intake distributor 4-6 (three clip points).
16. Disengage vent line for oil/water heat exchanger.
17. Remove intake manifold.
    Fig 2: Identifying Intake Distributor

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 17.1. Unscrew six hexagon socket head bolts (M6 x 25) on each, together with the captive washer -1-  . Tool recommendation: Long socket head insert with ball joint.
       Fig 3: Identifying Intake Distributor Screw Connection

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 17.2. Loosen the throttle body holder at the oil-filter console by unscrewing one M6 hexagon nut.
    3. 17.3. Loosen fuel line on pressure regulator for fuel collection pipe on side 4-6. Screw on M14 union nut (a/f 19) -1-  and counter at the pressure regulator at the same time with an open-ended wrench (a/f 22).
       Fig 4: Identifying Fuel Connection And Pressure Regulator

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 17.4. Loosen the line for the turbocharger switch-over valve at the distributor pipe by opening the screw-type clamp and pulling off the line.
    5. 17.5. Pull off vacuum line on the connection to the tandem pump. Remove switch-over valve and lines.
    6. 17.6. Lift up the intake manifold and disconnect the secondary air line at the shut-off valve, side 4-6.
    7. 17.7. Completely remove the intake manifold.
18. Remove combination valves for secondary air for cylinders 1-3 and 4-6.
    1. 18.1. Disconnect secondary air line on combination valve for side 1-3 -2-  and 4-6. Remove all lines.
    2. 18.2. Unscrew three hexagon socket head bolts (M6 x 20) on each, together with the captive washer -1-  . Remove valves and dispose of O-rings.
       Fig 5: Identifying Secondary Air Combination Valve

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Remove vent lines -1-  on the oil/water heat exchangers. Open two screw-type clamps and pull off the hoses.
    Fig 6: Identifying Oil/Water Heat Exchangers Vent Lines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
20. Loosen hydraulic line for the clutch at the power-steering supply tank by pressing the plastic sleeve towards the tank using the disassembly tool Nr.21  and pull out the line.
    Fig 7: Removing Hydraulic Line

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
21. Unclip vent line for turbocharger 1-3 and remove line.
22. Remove coolant run-on pump.
    1. 22.1. Pull off cable plugs -1 and 2-  .
       Fig 8: Identifying Coolant Run-On Pump Cable Plugs

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 22.2. Open the clamp -1-  and remove lines for the turbochargers.
       Fig 9: Identifying Run-On Pump Coolant Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 22.3. Unscrew M6 x 12 fastening screw -2-  , open the screw-type clamp -1-  and pull off the coolant hose. Remove run-on pump -3-  .
       Fig 10: Identifying Run-On Pump

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
23. Remove generator → 272219 REMOVING AND INSTALLING GENERATOR .
24. Remove the oil return line from the engine to the oil/water heat exchanger.
    1. 24.1. Unscrew two M6 x 16 Torx screws -1-  on the heat exchanger and remove the metal seal.
       Fig 11: Identifying Oil Return Line And Engine To Oil/Water Heat Exchanger

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 24.2. Loosen the union nut (a/f 32) on the lower side of the crankcase and remove the line -2-  .
25. Unscrew two M6 x 55 Torx screws for the heater pipe holder -1-  and B+ line.
    Fig 12: Identifying Plastic Holder, Heater Pipes Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 25.1. Slide the plastic holder to the left to remove it -arrow-  .
       Fig 13: Sliding Heater Pipes Holder

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
26. Unclip power-steering lines for the power-assisted clutch and loosen and remove lines at the tank.
27. Loosen fuel lines -1-  at the fuel cooler - make sure to counter with an open-ended wrench (a/f 17/15 -2-  ) while doing this.
    Fig 14: Loosening Fuel Lines At Fuel Cooler

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Remove air conditioning compressor → WM 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .
    1. 28.1. Disconnect plug connection for air conditioning compressor -1-  .
       Fig 15: Identifying Air Conditioning Compressor Cable Plug

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Disconnect other cable plug connections.
    1. 29.1. Knock sensors.
    2. 29.2. Combination connector -1-  for oil pressure and oil temperature.
       Fig 16: Identifying Oil Pressure/Oil Temperature Combination Connector

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 29.3. Terminal 50 from generator.
30. Release cable duct -2-  . Unscrew two Torx screws (M6 x 16) -1-  (on cylinder side 1-3 with fuel line attachment).
    Fig 17: Identifying Cable Duct Attachment

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
31. Remove wire harness with temperature sensor for turbocharger. Unclip lines for exhaust temperature sensors at two places.
32. Take off fuel line on side 1-3.
33. Remove the two holders for the turbochargers.
    1. 33.1. Side 1-3: unscrew two Torx screws -1-  (M8 x 20 and M8 x 35) and remove holder -2-  and ground cable.
       Fig 18: Identifying Turbocharger Holder (Side 1-3)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 33.2. Side 4-6: unscrew two Torx screws -1-  (M8 x 20 and M8 x 35) and remove holder -2-  .
       Fig 19: Identifying Turbocharger Holder (Side 4-6)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
34. Remove oil return line for the oil tank by loosening one union nut (a/f 27) on oil suction pump 1-3 and 4-6.
35. Remove oil supply lines for the turbochargers.
    1. 35.1. Side 1-3: unscrew one M6 x 10 Torx socket screw (stainless steel) -2-  and dispose of O-ring.
       Fig 20: Identifying Turbocharger Oil Supply Line (1-3)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 35.2. Side 4-6: unscrew one M6 x 10 Torx socket screw (stainless steel) -1-  and dispose of O-ring.
       Fig 21: Identifying Turbocharger Oil Supply Line (4-6)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Remove coolant lines on cylinder side 1-3.
    1. 36.1. Open one screw-type clamp on the heater pipe return line -2-  and two screw-type clamps on the supply line for the water pump and thermostat -1-  .
       Fig 22: Identifying Coolant Lines Screw-Type Clamps

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 36.2. Loosen screw-type clamps -1-  on the coolant lines at the heat exchanger bracket.
       Fig 23: Identifying Coolant Connection For Heater And Heat Exchanger Bracket

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
37. Remove coolant pipes -2-  . Replace sealing sleeves -3-  when joining the pipes again.
    Fig 24: Identifying Coolant Pipes

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 37.1. Left coolant pipe: open the screw-type clamp and unscrew two Torx screws (M6 x 20). Remove coolant pipe.
       Fig 25: Identifying Left Coolant Pipe Coolant Hose

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 37.2. Right coolant pipe: unscrew two Torx screws (M6 x 20) and remove coolant pipe.
38. Unscrew fastening screw (M6 x 16) for B+ line at transport eyelet and remove line.
39. Remove the two oil/water heat exchangers. A holder -2-  is also secured to the small heat exchanger.
    1. 39.1. Unscrew four Torx screws (M6 x 16) -1-  on the small heat exchanger.
       Fig 26: Identifying Small Oil/Water Heat Exchanger

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 39.2. Unscrew four Torx screws (M6 x 16) -1-  on the large heat exchanger.
       Fig 27: Identifying Large Oil/Water Heat Exchanger

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 39.3. Replace O-rings during installation: four O-rings on the large heat exchanger -1-  and three O-rings on the small heat exchanger -2-  .
       Fig 28: Identifying Oil/Water Heat Exchanger

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
40. Remove heat exchanger bracket.
    1. 40.1. Unscrew four coated Torx socket screws (M6 x 20) -1-  .
       Fig 29: Identifying Heat Exchanger Bracket Threaded Joint

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
41. Loosen holder for oil-filter console by removing two Torx screws (M6 x 16) -1-  .
    Fig 30: Identifying Oil-Filter Console Holder

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
42. Take off the heat exchanger bracket. Dispose of O-rings.
    1. 42.1. Slide the handle of a wooden hammer under the bracket and carefully lever the bracket off.
    2. 42.2. Place a clean absorbent cloth underneath to catch residual fluid.
43. Remove secondary unit carrier. Unscrew four Torx screws (M10 x 60) -1-  . Remove unit carrier and power-steering pump.
    Fig 31: Removing Secondary Unit Carrier

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
44. Take off coolant guide housing together with water pump and oil suction pump. Collect emerging coolant.
45. Remove exhaust manifold. Unscrew nine M8 x 28 screws -1-  on each. Remove exhaust manifold -2-  with metal seal.
    Fig 32: Identifying Exhaust Manifold Threaded Joint

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
46. Remove six ignition coils. Unscrew two Torx socket screws (M6 x 25) on each and take off the coils.
47. Remove six spark plugs. Always make sure to use spark plug socket wrench Nr.14  and extension Nr.15  to avoid damaging the ceramic body.
48. Remove oil suction pump/tandem pump.
    1. 48.1. Tandem pump, side 1-3: unscrew three Torx screws (M6 x 35), remove cable holder on exhaust temperature sensor and take off pump.
    2. 48.2. Suction pump, side 4-6: unscrew three Torx screws (M6 x 35) and take off pump.
49. Remove camshaft actuator lid. Remove three Torx screws (M6 x 20) and one cable holder for oxygen sensors.
50. Remove solenoid hydraulic valves for camshaft adjustment. Unscrew two x 20 Torx screws (micro-self-locking) on each and pull out valves.
51. Remove pulse sender and holder.
    1. 51.1. Unscrew two Torx screws (one M6 x 35, one M6 x 25) and remove pulse sender and cable.
       Fig 33: Locating Pulse Sender Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 51.2. Unscrew M6 fastening screw -1-  on the cylinder head and remove holder -2-  .
       Fig 34: Identifying Pulse Sender Plug Connection Holder

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Do not remove the screw securing the chain in place (sealed screw).

52. Remove cover for camshaft housing → 159119 REMOVING AND INSTALLING COVER FOR CAMSHAFT HOUSING .
    1. 52.1. Do not remove sealed screw securing the timing chain -1-  in place.
       Fig 35: Identifying Timing Chain

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 52.2. Unscrew 17 Torx screws -1-  from the inside out (16 M6 x 35 screws and one M6 x 75 screw).
       Fig 36: Identifying Camshaft Housing Cover

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 52.3. Remove all holders.
    4. 52.4. Carefully lever off the housing cover using a large screwdriver if necessary.
       Fig 37: Lifting Off Camshaft Housing Cover

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
53. Remove camshafts → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .
    NOTE: Interchanged or dirty bucket tappets

    • Scoring on cylinder head

    → Since the bucket tappets have been run in the fitting bores, do not interchange them.

    → Absolute cleanliness is essential.

    NOTE: Interchanged or dirty bucket tappets

    • Scoring on cylinder head

    → Since the bucket tappets have been run in the fitting bores, do not interchange them.

    → Absolute cleanliness is essential.

54. Remove bucket tappets and switchable tappets. Check parts for signs of wear and replace if necessary.
    1. 54.1. Lay components down in such a way that they can be inserted again at their original position during reinstallation. Designate a clean surface, for example, for this purpose.
55. Remove camshaft housing. → 150319 REMOVING AND INSTALLING CAMSHAFT HOUSING .
    1. 55.1. Loosen 18 M8 x 50 Torx screws according to specifications and unscrew them. Remove housing and take out metal seal.
56. Be careful with the aluminum sleeve -1-  on the timing chain box.
    Fig 38: Identifying Chain Box Aluminum Sleeve

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
57. Remove cylinder head.
    1. 57.1. Remove 12 internal serration collar nuts (M12) using a socket wrench 9295  .
    2. 57.2. Carefully lift off the cylinder head and remove the cylinder head gasket.
58. Replace guide and tensioning rails.
    1. 58.1. Guide rail: unscrew two bearing pins of different lengths. Top = 69 mm (chain box) -2-  , bottom = 74.5 mm (crankcase) -1-  and dispose of sealing ring.
       Fig 39: Identifying Guide Rail Bearing Pins

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 58.2. Lift the rail out of the chain box.
    3. 58.3. Tensioning rail: unscrew one threaded bolt with a length of 74.5 mm (crankcase) and dispose of sealing ring.
    4. 58.4. Lift the rail out of the chain box.
       Fig 40: Identifying Guide And Tensioning Rails Pins

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       • 1 - Pin = 69 mm
       • 2 - Pin = 74.5 mm
59. Remove chain box.
    1. 59.1. Remove five M8 screws: two M8 x 35 screws with washer (on the dowel sleeves), two M8 x 30 screws with washer, one M8 x 25 Torx screw.
    2. 59.2. Dispose of metal seal.
60. Remove coolant connection piece on cylinder housing. Unscrew two Torx screws (M6 x 20), take off connection piece and dispose of O-ring.
61. Carefully clean all components and sealing surfaces.

Remove cylinder side 4-6 in the same way as cylinder side 1-3.