Preliminary Work
- Risk of damage to units or components
→ Protect components from dirt and contamination.
→ Clean or replace dirty components.
- Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.
→ Use suction to remove ignitable vapors.
→ Attach warning sign in a clearly visible position.
Information
- All engine repairs must be carried out using only the specified tools.
- Only these tools have been tested and approved.
Information
- Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness).
- → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E..) for external Torx, (T..) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
- Remove the engine.
- Remove the transmission.
→ WM 343527 REMOVING AND MOUNTING TRANSMISSION .
→ 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .
- Remove the flywheel.
→ 136019 REMOVING AND INSTALLING FLYWHEEL - PDK TRANSMISSION - TURBO .
→ 136019 REMOVING AND INSTALLING DUAL-MASS FLYWHEEL - TURBO .
- Mount the engine on the engine assembly support.
→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .
- Remove rear silencer.
→ 263319 REMOVING AND INSTALLING REAR SILENCER - TURBO .
Get another person to help you carry out the work!
- 5.1. Unclip oxygen sensor cable -arrows-
.
- Oxygen sensor upstream of catalytic converter
- Oxygen sensor downstream of catalytic converter
- 5.2. Remove the four M8 hexagon nuts (a/f 13) on the turbocharger flange and replace the nuts.
- 5.3. Unscrew one external Torx screw (E10, M6 x 12) on the turbocharger heat shield.
- 5.4. Remove rear silencer.
- 5.1. Unclip oxygen sensor cable -arrows-
.
- Remove engine carrier -1-
.
→ 103019 REMOVING AND INSTALLING ENGINE CARRIER - TURBO .
- 6.1. Unclip exhaust temperature sensor line.
- 6.2. Remove engine carrier with intermediate flange and holder for rear silencer.
- Remove intake air lines -1-
.
- 7.1. Cylinder bank 1-3:
- 7.1.1. Remove hose connections on the ambient air valve -2 and 3- and unclip the hose -arrow- .
- 7.1.2. Unscrew two external Torx screws (E10, M6 x 30) on the turbocharger and remove the cover and the intake air line.
- 7.2. Cylinder bank 4-6:
- 7.2.1. Disconnect positive crankcase ventilation line -4- , remove hose connections on the ambient air valve -2 and 3- and unclip the hose -left arrow- .
- 7.2.2. Unscrew two external Torx screws (E10, M6 x 20) on the turbocharger and remove the intake air line.
- 7.1. Cylinder bank 1-3:
- Remove secondary-air pump -1-
.
→ 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP - TURBO .
- 8.1. Pull off hose -2- and disconnect cable plug.
- 8.2. Unscrew two M6 external Torx screws (E10) and remove the pump.
- Loosen three external Torx screws (E12, M8 x 12) -2- on the hydraulic pump pulley -1- (do not unscrew fully).
- Remove the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT - TURBO .
- 10.1. Unscrew screws for hydraulic pump pulley and remove the pulley.
- Remove the generator.
→ 272219 REMOVING AND INSTALLING GENERATOR .
- 11.1. Unplug electric plug connection -1- and lift off the rubber cover -2- with a screwdriver -arrow- .
- 11.2. Loosen the B+ line by unscrewing one M8 hexagon nut (a/f 13) -1- .
- Completely remove the intake-air distributor -1-
.
→ 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - TURBO .
- 12.1. Remove connections on the center part.
- 12.2. Unscrew one external Torx screw (E10, M6 x 16) used to secure the cable duct.
- 12.3. Unscrew two external Torx screws (E10, M6 x 12) at the oil filler tube.
- 12.4. Disconnect cable plug at the intake manifold pressure sensor and engine compartment temperature sensor.
- 12.5. Unscrew six external Torx screws (E10, M6 x 35) on each intake-air distributor and remove the intake-air distributor by lifting up cylinder bank 4-6 first -arrow- .
- Remove oil return lines and exhaust temperature sensor.
→ 217819 REMOVING AND INSTALLING OIL RETURN LINE FOR TURBOCHARGER .
→ 216420 REMOVING AND INSTALLING EXHAUST TEMPERATURE SENSORS .
- 13.1. Remove oil return line -1- and exhaust temperature sensor -4- on turbocharger 1-3.
- 13.2. Remove exhaust temperature sensor -1- on turbocharger 4-6.
- 13.3. Remove oil return line.
- 13.4. Expose line -1- for exhaust temperature sensor 4-6 -arrows- .
- 13.5. Remove oil return lines -1- at the oil pan.
- Loosen fastening points securing coolant and oil lines to the turbocharger.
- 14.1. Coolant lines -1- and oil line -3- on cylinder bank 1-3: Open spring band clamps -2- and unscrew two M6 external Torx screws (E10) -4 and 5- .
- 14.2. Remove oil pressure line from the cylinder head. Unscrew one external Torx screw (E10, M6 x 12).
- 14.3. Coolant lines and oil line on cylinder bank 4-6:
Unscrew three M6 external Torx screws (E10) -1 to 3-
.
- Holder for oil line
- Holder for coolant lines
- Oil pressure line connection on cylinder head
- 14.4. Loosen the oil pressure line -1- at the holder by unscrewing the external Torx screw (E10, M6 x 12) -2- .
- 14.5. Replace O-rings on oil pressure lines.
- Remove turbocharger with wire assembly.
- Remove heat shields -2- . Unscrew two external Torx screws (E10, M6 x 12) -3- .
- Remove exhaust manifold.
- Drain engine oil.
→ 170155 CHANGING ENGINE OIL AND OIL FILTER - TURBO .
- 18.1. Unscrew drain plug and collect emerging oil.
- 18.2. Then screw in drain plug with a new sealing ring and tighten to the specified torque.
→ Tightening torque: 50 Nm (37 ft. lb.)
- Remove oil filler neck -1-
.
→ 171519 REMOVING AND INSTALLING OIL FILLER NECK - TURBO .
- 19.1. Unscrew two external Torx screws (E10, M6 x 20) -2- and pull the connection piece out of the crankcase.
- 19.2. Close off opening with adhesive tape or a stopper.
- 19.3. Replace O-ring.
- Unplug cable plugs in the cylinder head cover area, disconnect ground straps for ignition coils and unclip cable duct.
- 20.1. Cylinder bank 1-3:
- Internal Torx screws (T40) securing ground connection for bar ignition modules
- Connectors for bar ignition modules
- Hall sender
- Solenoid hydraulic valve for valve lift adjustment
- Cable duct
- 20.2. Cylinder bank 4-6:
- Internal Torx screws (T40) securing ground connection for bar ignition modules
- Connectors for bar ignition modules
- Hall sender
- Solenoid hydraulic valve for valve lift adjustment
- Cable duct
- 20.1. Cylinder bank 1-3:
- Remove holder for turbocharger, pull off bar ignition modules and disconnect coolant pipe.
- 21.1. Unscrew two external Torx screws (E12, M8 x 35) -2- and remove the holder -1- .
- 21.2. Pull off bar ignition modules -3- .
- Disconnect B+ line -1- and control line for solenoid switch (terminal 50) -2- at the starter.
- Remove positive crankcase ventilation line -1-
(air-conditioning compressor remains in the vehicle when you remove the engine).
- 23.1. Open rapid-action couplings by pressing the locking ring -3- and unclip line from the holder -arrow- .
- 23.2. Replace O-rings on the connection point to the bracket for the oil/water heat exchanger.
- Remove hydraulic pump -1- together with the pressure line -2- and return line -3- .
- Remove housing cover for coolant regulator -1-
and coolant intake tube -5-
(from the coolant reservoir).
- 25.1. Unscrew one external Torx screw (E10) M6 x 40 -2- , three M6 x 50 screws -3- and take off the cover and thermostat.
- 25.2. Unscrew two external Torx screws (E10, M6 x 12) -4- and pull off the intake tube. Replace O-rings.
- Disconnect vent line -1-
, unclip B+ line -2-
and remove the oil separator -3-
.
- 26.1. Unscrew two external Torx screws (E10, M6 x 25) -4- and pull off the oil separator. Replace O-rings.
- Remove secondary-air lines.
- Remove electric control valve -1-
and vacuum lines -3-
on the flywheel side.
- 28.1. Release cable plug on control valve -2- and pull it off.
- Expose oil-level sender cable -1-
and vacuum line -2-
.
- 29.1. Expose vacuum line and cable and loosen vacuum line holder -3- .
- 29.2. Release and pull off cable plug -4- for oil-level sender at the oil pan.
- Unplug several cable plugs at the engine, unclip all cable holders and unscrew two external Torx screws (E12, M8 x 16) on the cable duct.
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
- Solenoid hydraulic valve for camshaft control (top of cylinder head)
- Fuel pressure sensor on fuel collection pipe, cylinder bank 4-6
- Oil pressure and temperature sensor on bracket for oil/water heat exchanger
- Fuel injectors
- Knock sensors
- Flow control valve on high-pressure pump
- Coolant temperature sensor on unit carrier
- Pressure-regulating valve
- Coolant run-on pump
- 30.1. Remove engine wire harness.
- Remove coolant pipe with coolant hose and connection piece (Henn coupling).
- 31.1. To do this, unscrew three external Torx screws (E12, M8 x 70) -2- on the unit carrier at the right.
- 31.2. Unscrew two external Torx screws (E10, M6 x 12) -2- and remove the coolant pipe and connection piece -1- .
- Remove coolant distributor -1-
and coolant hoses.
- 32.1. Open two spring band clamps and pull off coolant hoses. Unscrew two external Torx screws (E10, M6 x 25).
- 32.2. Pull the coolant distributor -1- up out of the coolant pipes -2- .
- 32.3. Open two spring band clamps -1- and pull the coolant hoses -2- off the oil/water heat exchanger.
- 32.4. Replace O-rings -1- and grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
- Remove transport eyebolt.
- 33.1. Unscrew two external Torx screws (E10, M6 x 25).
- Remove coolant run-on pump -1-
.
- 34.1. Cable plug -2- for coolant run-on pump (already disconnected).
- 34.2. Open spring band clamps -3 and 4- and pull off hoses.
- 34.3. Remove run-on pump.
- Remove fuel connection line -1-
to the fuel collection pipes.
- 35.1. Loosen two external Torx screws (E10, M6 x 12) at the clamps.
- 35.2. Unscrew two external Torx screws (E10) on the fuel line holders. One screw on the center holder M6 x 16 -3- and one screw on the right holder M6 x 60 (screw point for bracket for oil/water heat exchanger) -2- .
- 35.3. Screw off three union nuts (a/f 17) -4- and remove the line. Soak up emerging fuel with a cloth.
- Remove oil/water heat exchanger -1-
.
- 36.1. Unscrew six internal Torx screws (T30, M6 x 20) -2- and remove heat exchanger.
- 36.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
- 36.3. Replace O-rings.
Information
- The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side.
- The bracket's aluminum supports can break off in the crankcase.
- Remove bracket for oil/water heat exchanger -1-
.
- 37.1. Unscrew six external Torx screws (E10): four M6 x 45 screws -2- and two M6 x 60 screws -3- . Pull the bracket up and out.
- 37.2. Close off oil ducts with stoppers.
- 37.3. Replace two O-rings at the top -4- and four O-rings on the underside.
- Remove fuel collection pipes.
- 38.1. Unscrew four external Torx screws (E10, M6 x 30) -1- and pull the fuel collection pipes -2- out of the cylinder heads.
- 38.2. Close off fitted bores in the cylinder head with stoppers.
- Remove knock sensors (mark installation position using a water-resistant marker).
→ 287219 REMOVING AND INSTALLING KNOCK SENSOR - TURBO .
- 39.1. Unscrew one external Torx screw (E12, M8 x 35) on each sensor and remove sensors.
- Remove fuel lines for the high and low-pressure side and remove cover.
- 40.1. Unscrew three external Torx screws (E10, M6 x 12) on the heat shield and remove the heat shield.
- 40.2. Unscrew three external Torx screws (E10) on the cover -1- : two M6 x 25 screws -2- and one M6 x 40 screw -3- .
- 40.3. Loosen and screw off hexagon union nuts on the high-pressure pump. Low-pressure line -5- : a/f 17, high-pressure line -4- : a/f 14.
- 40.4. Unscrew one external Torx screw (E10) M6 x 16 and one M6 x 12 screw at the retaining points and remove the lines.
- Remove high-pressure pump -6-
.
→ 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP - TURBO .
- 41.1. Unscrew two external Torx screws (E10, M6 x 25) -7- and pull out the pump.
- 41.2. Replace O-ring.
- Remove vacuum line -1-
for brake booster.
→ 477755 REPLACING VACUUM LINE FOR BRAKE BOOSTER (SECTION AT ENGINE) .
- 42.1. Unscrew external Torx screws (E10, M6 x 12) -2- and pull out line at the vacuum pump.
- Remove vacuum pump -3-
.
→ 477619 REMOVING AND INSTALLING VACUUM PUMP .
- 43.1. Remove vacuum line. Unscrew one M6 external Torx screw (E10) and pull off the line.
- 43.2. Unscrew three M6 external Torx screws (E10) -4- and remove the pump.
- 43.3. Replace O-ring.
- Remove lower coolant guide -1-
.
- 44.1. Unscrew six external Torx screws (E10, M6 x 25) -2- .
- 44.2. Check molded seals and replace if necessary.
- Use turning device 9773 -1-
to turn the engine clockwise at the vibration damper until the TDC 1/4
marking on the vibration damper is aligned with the bore in the crankcase.
- 45.1. Secure the engine using one of the locating pins 9595/1 -2- on the vibration damper.
- Remove vibration damper.
→ 137519 REMOVING AND INSTALLING VIBRATION DAMPER - TURBO .
- 46.1. Loosen and unscrew six external Torx screws (E12, M8 x 25 x 1) and remove the vibration damper.
- 46.2. Check dowel sleeve and crankshaft flange for damage.
- Loosen bracket for coolant pump -1-
.
- 47.1. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Lock the tensioner at the crankcase bore using an M8 screw (e.g. M8 x 50) -2- .
- 47.2. Unscrew four external Torx screws: one M8 x 70 (E12) -3- , one M8 x 50 (E12) -4- , one M6 x 20 (E10) -5- and one M8 x 25 (E12) -6- .
- 47.3. Unscrew M10 threaded bolt (engine carrier mounting) -7- (two M10 lock nuts).
- Remove coolant connection pipe -1-
to the thermostat housing.
- 48.1. Unscrew one external Torx screw (E10, M6 x 12) -2- on the retaining bracket for the crankcase.
- 48.2. Pull out pipe -1- on the thermostat housing.
- Remove thermostat housing -2-
.
- 49.1. Unscrew three external Torx screws (E10) M6 x 25 -4- and one M6 x 50 -3- .
- 49.2. Turn bracket for coolant pump slightly to the right.
- 49.3. Pull the thermostat housing -1- down at the unit carrier (double O-ring seal) and lift it off at the connecting tube -2- to the coolant pump at the same time.
- 49.4. Pull off bracket for coolant pump -1- . Replace O-rings -2 + 3- . Check seal for damage and replace it if necessary.
- 49.5. Replace molded seal on the connecting tube -3- .
- Remove unit carrier (coolant distributor housing).
The screws for the engine connection piece -2- and the additional attachment for the coolant pump bracket -3 (left) and 5- have already been removed.
→ 195919 REMOVING AND INSTALLING UNIT CARRIER (COOLANT DISTRIBUTOR HOUSING) - TURBO .
- 50.1. Unscrew one external Torx screw M8 x 50 -3 (right)- and one M8 x 35 -4- . Remove carrier, check dowel sleeve for damage and replace if necessary.
- 50.2. Replace molded seals.
- Remove cover for positive crankcase ventilation at the cylinder head.
- 51.1. Cover on cylinder bank 1-3 -1- : Unscrew three external Torx screws (M6 x 20) -4- and replace O-ring -3- and molded seal -2- .
- 51.2. Cover on cylinder bank 4-6 -1- : Unscrew two external Torx screws (M6 x 20) -3- and replace O-ring -2- .
- Remove solenoid hydraulic valves for camshaft control.
- 52.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.
- 52.2. Replace O-rings.
- Remove hall senders on the cylinder head cover.
→ 283919 REMOVING AND INSTALLING HALL SENDER .
- 53.1. Unscrew one external Torx screw (T40, M6 x 16) on each and pull off the hall senders.
- 53.2. Replace O-ring.
- Remove solenoid hydraulic valves for valve lift adjustment.
→ 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT .
- 54.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.