Subsequent Work

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).

Information

Always replace gaskets and O-rings.

Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).

Install upper coolant distributor housing (unit carrier) -1- .
→ 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING .

Fig 1: Identifying Unit Carrier (Installed)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Fit coolant connection piece using three external Torx screws (E12, M8 x 70) -2- .
2. 1.2. Fit unit carrier using two external Torx screws (E12): one M8 x 50 screw -3 (right)- and one M6 x 35 screw -4- .
3. 1.3. Secure coolant pipe for the unit carrier -1- to the cylinder head using two external Torx screws (E10, M6 x 12) -2- .
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 2: Identifying Coolant Pipe With Hose And Connection Piece
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit bracket for coolant pump -1- with new O-rings -2 + 3- .

Fig 3: Identifying Coolant Pipes O-Rings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 2.1. Fit one M10 threaded bolt (engine carrier mounting) -7- (using two M10 lock nuts).
  → Tightening torque: 5 Nm (3.5 ft. lb.)
2. 2.2. Fit the bracket using 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- .
  
  Fig 4: Identifying Coolant Pump Bracket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install housing for coolant regulator.
→ 195519 REMOVING AND INSTALLING HOUSING FOR COOLANT REGULATOR .
1. 3.1. Fit housing on the unit carrier and secure to the connecting tube for the coolant pump using three external Torx screws (E10, M6 x 25).
2. 3.2. Fit one external Torx screw (E10) M6 x 50.
3. 3.3. Tighten screws in sequence.→ Tightening torque: 13 Nm (9.5 ft. lb.)
  → Tightening torque: 13 Nm (9.5 ft. lb.)
Tighten fastening screws on coolant pump bracket and unit carrier.
1. 4.1. → Tightening torque: 33 Nm (24 ft. lb.)
2. 4.2. → Tightening torque: 23 Nm (17 ft. lb.) Coolant pump bracket
  → Tightening torque: 13 Nm (9.5 ft. lb.)
3. 4.3. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Remove screw from the crankcase bore and allow the belt tensioner to slide back to normal position.
Fit vibration damper. Secure with a locating pin (8 mm) for countering purposes.
→ WM 137519 REMOVING AND INSTALLING VIBRATION DAMPER .
1. 5.1. Fit and tighten six external Torx screws (E12) M8 x 1 x 25 (fine thread).
  → Tightening torque: 60 Nm (44 ft. lb.)
Fit lower parts of heat shield using external Torx screws (E10) M6 x 12.
→ Tightening torque: 10 Nm (7.5 ft. lb.)
Turn the engine so that the oil pan is at the top.
Install coolant pipe -1- for the coolant regulator housing and secure with one external Torx screw (E10, M6 x 12) -2- .
→ Tightening torque: 13 Nm (9.5 ft. lb.)

Fig 5: Identifying Coolant Connection Pipe And Thermostat Housing
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit holder for rear silencer using four external Torx screws (E12, M8 x 20).
→ Tightening torque: 23 Nm (17 ft. lb.)
Fit exhaust manifold with new seals. Fit and tighten nine external Torx screws (E12, M8 x 21) from the inside out.
→ 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD WITH CATALYTIC CONVERTER .

→ Tightening torque: 23 Nm (17 ft. lb.)
Turn the engine 180° at the assembly support.
Install coolant distributor. Coat new O-rings -1- with Kluber Gel.
1. 12.1. Fit coolant distributor into coolant pipes.
  
  Fig 6: Identifying Coolant Distributor O-Rings
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Fit coolant distributor -1- using two external Torx screws (E10, M6 x 25) -2- and tighten screws.
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 7: Identifying Coolant Distributor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fuel collection pipes -2- and injectors.
→ 243019 REMOVING AND INSTALLING FUEL COLLECTION PIPE WITH FUEL INJECTORS .

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

Fig 8: Identifying Fuel Collection Pipe Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install the starter.
→ 276019 REMOVING AND INSTALLING STARTER .
Install bracket for oil/water heat exchanger -1- with new O-rings.
Fit and tighten seven external Torx screws (E10): five M6 x 45 screws -2- and two M6 x 60 screws -3- .

→ Tightening torque: 13 Nm (9.5 ft. lb.)
1. 15.1. Pull out stoppers and fit and grease new O-rings -4- .
  
  Fig 9: Identifying Oil/Water Heat Exchanger Bracket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil/water heat exchanger -1- .
→ 174019 REMOVING AND INSTALLING OIL/WATER HEAT EXCHANGER .

Fit and tighten six internal Torx screws (T30) M6 x 20 -2- .

→ Contact force: 13 Nm (9.5 ft. lb.)

Fig 10: Identifying Oil/Water Heat Exchanger Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil separator -1- with new O-rings.
1. 17.1. Grease O-rings, fit oil separator and secure with two external Torx screws (E10, M6 x 25) -2- .
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 11: Identifying Oil Separator Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install high-pressure pump.
→ 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP .
Fit fuel lines -2 + 4- to high-pressure pump.
1. 19.1. Grease thread with OKS 1700 lubricant (Part No. 000.043.207.36) and tighten union nuts.
2. 19.2. Fit line bracket using M6 external Torx screws -3 + 5- .
3. 19.3. First tighten the union nuts, then the screws on the line bracket.
  → Tightening torque: 20 Nm (15 ft. lb.)
  
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 12: Identifying High/Low-Pressure Connection Fuel Lines
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install coolant regulator with housing cover -1- and intake tube -5- .
1. 20.1. External Torx screws (E10) on housing cover: Tighten three M6 x 50 screws -3- and one M6 x 40 screw -2- .
2. 20.2. Grease new O-rings on the intake tube and fit tube into the coolant regulator housing. Tighten external Torx screws M6 x 12 -4- .
3. 20.3. → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 13: Identifying Intake Tube And Coolant Regulator Housing
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install vacuum pump for brake booster.
→ 477619 REMOVING AND INSTALLING VACUUM PUMP .
Install vacuum line.
→ 477755 REPLACING VACUUM LINE FOR BRAKE BOOSTER (SECTION AT ENGINE) .
Install hydraulic pump with reservoir.
→ 489819 REMOVING AND INSTALLING HYDRAULIC PUMP .
Install air conditioning compressor.
→ 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .
Install B+ wire harness (engine).
→ 974519 REMOVING AND INSTALLING WIRE HARNESS FOR BATTERY WIRING .
Fit engine wire harness.
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
1. 26.1. Secure cable duct to cylinder head 1-3 and 4-6 using one external Torx screw (E12, M8 x 16) on each.
  → Tightening torque: 23 Nm (17 ft. lb.)
Fit fuel connection line (high-pressure side) to fuel collection pipe.
→ 243019 REMOVING AND INSTALLING FUEL COLLECTION PIPE WITH FUEL INJECTORS .
1. 27.1. Grease thread with OKS 1700 lubricant and tighten threaded connections -1 to 5- according to tightening sequence.
  → Tightening torque: 20 Nm (15 ft. lb.)
  
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 14: Fuel Connection Line Tightening Sequence
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit coolant hoses -2- to oil/water heat exchangers.
1. 28.1. Coat hoses with Kluber Gel and fit them. Close two spring band clamps -1- .
  
  Fig 15: Identifying Heat Exchanger Coolant Hoses
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install the generator.
→ 272219 REMOVING AND INSTALLING GENERATOR .
Install oil filler neck -1- .
1. 30.1. Grease new O-ring and fit oil filler neck on crankcase.
2. 30.2. Tighten two external Torx screws (E10, M6 x 20) -2- .
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 16: Identifying Oil Filler Neck
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install positive crankcase ventilation line -1- .
1. 31.1. Grease two new O-rings and fit line to bracket for oil/water heat exchanger. Tighten external Torx screw (E10, M6 x 20) -2- .
2. 31.2. Clip in line at two places and fit rapid-action couplings on cylinders 1-3, cylinders 4-6 and on the oil filler neck -3- .
  
  Fig 17: Locating Positive Crankcase Ventilation Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and crankcase vent line.
Install intake-air distributor.
→ 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .
1. 33.1. Fit complete intake-air distributor and position it on the cylinder heads.
2. 33.2. Fit six external Torx screws (E10, M6 x 35) on each and tighten according to the specified tightening sequence.
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 18: Intake-Air Distributor Torx Screws Tightening Sequence (3.8-Litre Engine)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit tank vent valve on holder and attach rapid-action coupling to resonance tube.
1. 34.1. Plug in cable plugs on intake-air distributor for cylinder bank 1-3. Tighten one external Torx screw (E10, M6 x 12) -2- used to secure the cable duct.
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  1. Cable plug on engine compartment temperature sensor
  2. Cable duct mounting on cylinder bank 1-3
  3. Cable plug on control valve for tank ventilation
    
    Fig 19: Identifying Intake-Air Distributor Cable Plugs (1-3)
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Only for 3.8-litre engine: Plug in cable plug -1- and attach vacuum line -2- on control valve for tuning flap.

Fig 20: Identifying Tuning Flap Control Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit oil filler neck to holder. To do this, tighten three external Torx screws (E10, M6 x 12) -2- .
→ Tightening torque: 13 Nm (9.5 ft. lb.)

Fig 21: Identifying Oil-Fill Pipe Holder And Positive Crankcase Ventilation Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 36.1. Unclip positive crankcase ventilation line -3- at the oil-fill pipe.
Connect positive crankcase ventilation line on the resonance tube -1- and clip it in at the intake-air distributor -arrows- .

Fig 22: Locating Positive Crankcase Ventilation Line (Cylinder Bank 4-6)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 37.1. Tighten one external Torx screw (E10, M6 x 12) -2- used to secure the cable duct to intake-air distributor 4-6.
Fit hydraulic pump pulley using three external Torx screws (E12, M8 x 12).
Install the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT .
Tighten external Torx screws on hydraulic pump pulley.
→ Tightening torque: 23 Nm (17 ft. lb.)
Fit engine carrier -1- and holder for front silencer -5- .
→ 103019 REMOVING AND INSTALLING ENGINE CARRIER .

Fig 23: Identifying Engine Carrier And Holder (Front Silencer)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit rear silencer.
→ 263319 REMOVING AND INSTALLING REAR SILENCER .
Fit front silencer.
→ 262519 REMOVING AND INSTALLING FRONT SILENCER .
Remove the engine from the engine assembly support.
→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .
Fit flywheel with new screws.
→ 136019 REMOVING AND INSTALLING FLYWHEEL - PDK TRANSMISSION .

→ 136019 REMOVING AND INSTALLING DUAL-MASS FLYWHEEL .
Mount the transmission.
→ WM 343527 REMOVING AND MOUNTING TRANSMISSION .

→ 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .
Install the engine.
→ 100119 REMOVING AND INSTALLING ENGINE .