Subsequent Work

→ 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). 

Information 

• The tightening torques for the engine are listed in the following documents and must be used in accordance with these specifications. 

Repair group 1: → 1X00IN TECHNICAL VALUES .

Repair group 2: → 2X00IN TECHNICAL VALUES .

1. Install upper coolant distributor housing (unit carrier).

   → Installing Distributor Housing .

   1. Distributor housing
   2. Screws M8 x 70 for coolant connection piece and housing
   3. Screws, M8 x 50
   4. Screw, M8 x 35
   Fig 1: Identifying Unit Carrier Screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Slide bracket for coolant pump -1-  with new O-rings -2 and 3-  onto coolant pipe -4-  and connection piece.
   Fig 2: Identifying Coolant Pipes O-Rings

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Screw on coolant pump bracket -1-  .
   1. 3.1. Bond threaded bolt -6-  with Loctite 243.

      Allow a curing time of 24 hours! 

      → Tightening torque: 5 Nm (3.5 ftlb.) 

   2. 3.2. Fit and tighten external Torx screws.
      Fig 3: Identifying Coolant Pump Bracket

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Install high-pressure pump.

   → Installing High-Pressure Pump .

5. Fit fuel lines -2 and 4-  on high-pressure pump -1-  .

   → Installing Fuel Line (Low-Pressure Side) .

   → Installing Fuel Line .

   1. 5.1. Coat thread with OKS 1701 lubricant (Part No. 000.043.207.36).

      Allow a drying time of 60 minutes for the lubricant! 

      Fig 4: Identifying High/Low-Pressure Connection Fuel Lines

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6. Install coolant pipe -1-  for the coolant regulator housing and secure with external Torx screw -2-  .
   Fig 5: Identifying Coolant Regulator Housing Coolant Pipe

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7. Install coolant regulator housing -1-  .

   → Installation Coolant Regulator Housing .

   Fig 6: Identifying Coolant Regulator Housing

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8. Fit belt tensioner.

   → Installing Belt Tensioner .

9. Fit vibration damper.

   → Installing Vibration Damper .

10. Fit heat shields.
11. Turn the engine at the assembly support so that the oil pan is at the top.
12. Fit holder for rear silencer.
13. Install exhaust manifold with new seals.

    → Installing Exhaust Manifold .

14. Turn the engine 180° at the assembly support.
15. Install coolant distributor. Coat new O-rings -1-  with Kluber Gel.
    1. 15.1. Fit coolant distributor into coolant pipes.
       Fig 7: Identifying Coolant Distributor O-Rings

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 15.2. Fit coolant distributor -1-  using external Torx screws -2-  and tighten screws.
       Fig 8: Identifying Coolant Distributor Screws

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16. Fit fuel collection pipes and injectors.

    → Installing Fuel Collection Pipe .

17. Install the starter.

    → Installing Starter .

18. Install bracket for oil-water heat exchanger -1-  .

    → Installing Bracket For Oil-Water Heat Exchanger .

    1. 18.1. Pull out stoppers and fit and grease new O-rings -4-  .
       Fig 9: Identifying Oil-Water Heat Exchanger Bracket

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19. Install oil-water heat exchanger -1-  .

    → Installing Oil/Water Heat Exchanger .

    Fig 10: Identifying Oil-Water Heat Exchanger

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20. Install oil separator with new O-rings.

    → Installing Oil Separator  .

21. Install vacuum pump for brake booster.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

22. Fit vacuum line (vacuum pump).
23. Vehicles with Porsche Dynamic Chassis Control (PDCC):  Install hydraulic pump and lines.

    → Installing Pump (PDCC) .

24. Vehicles without Porsche Dynamic Chassis Control (PDCC):  Install console with deflection roller -1-  .
    1. 24.1. Fit and tighten external Torx screws -2 and 3-  .
       Fig 11: Identifying Deflection Roller Console Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Install air-conditioning compressor.

    → Installing Air-Conditioning Compressor .

26. Install B+ wire harness (engine).

    → Installing Wire Harness For Battery Wiring .

27. Fit engine wire harness.

    → Installing Wire Harness For Engine .

28. Fit fuel connection line to fuel collection pipe.

    → Installing Fuel Connection Line .

29. Fit coolant hoses -2-  to oil-water heat exchanger.
    1. 29.1. Coat hoses with Kluber Gel and fit them. Close spring band clamps -1-  .
       Fig 12: Identifying Heat Exchanger Coolant Hoses

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
30. Install the generator.

    → Installing Generator .

31. Install oil filler neck -1-  .
    1. 31.1. Grease new O-ring and fit oil filler neck on crankcase.
    2. 31.2. Tighten external Torx screws -2-  .
       Fig 13: Identifying Oil Filler Neck

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
32. Install positive crankcase ventilation line -1-  .
    1. 32.1. Grease new O-rings and fit line to bracket for oil-water heat exchanger. Tighten external Torx screw -2-  .
    2. 32.2. Clip in line at two places and fit quick connectors on cylinders 1-3, cylinders 4-6 and on the oil filler neck -3-  .
       Fig 14: Identifying Positive Crankcase Ventilation Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
33. Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and positive crankcase ventilation line.
34. Install intake-air distributor.

    → Installing Intake-Air Distributor .

    1. 34.1. Grease new molded seals.
    2. 34.2. Fit complete intake-air distributor and position it on the cylinder heads.
    3. 34.3. Fit external Torx screws and tighten according to the specified tightening sequence.
       Fig 15: Intake-Air Distributor Screws Tightening Sequence

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
35. Fit tank vent valve and engine compartment temperature sensor.
    1. 35.1. Plug in cable plugs -1 and 3-  on intake-air distributor for cylinder bank 1-3. Tighten external Torx screw -2-  used to secure the cable duct.
       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 16: Identifying Intake-Air Distributor Cable Plugs (1-3)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. 3.8-litre engine only:  Fit vacuum line on vacuum unit for tuning flap.
37. Fit oil filler neck on holder for intake-air distributor. Tighten external Torx screws -2-  .
    Fig 17: Identifying Oil Filler Tube And Positive Crankcase Ventilation Line Holder

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
38. Connect positive crankcase ventilation line -1-  to the resonance tube and clip it in at the intake-air distributor -arrows-  .
    1. 38.1. Tighten external Torx screw -2-  used to secure the cable duct to intake-air distributor 4-6.
       Fig 18: Locating Positive Crankcase Ventilation Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
39. For vehicles with PDCC:  Fit hydraulic pump pulley using screws.
40. Install the drive belt.

    → Installing Drive Belt .

41. Tighten external Torx screws on hydraulic pump pulley.
42. Fit engine carrier and holder for front silencer.

    → Installing Engine Carrier  .

43. Fit rear silencer.

    → Installing Rear Silencer .

44. Fit front silencer.

    → Installing Front Silencer .

45. Remove the engine from the engine assembly support.

    → 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .

46. Fit flywheel with new screws.

    → Installing Flywheel .

    → Installing Flywheel .

47. Mount transmission.

    → Mounting Transmission .

    → Mounting Porsche Doppelkupplung (PDK) .

48. Install engine.

    → Installing Engine  .