Structure of the basic engine

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NOTE: All O-rings and seals (shaft seals) and micro-encapsulated screws or fastening nuts must be replaced.

NOTE: Replace M9 x 1.25 con-rod bolts and piston pin circlips.

Pre-fit pistons and connecting rods 1-3 for the installation Refer to REMOVING AND INSTALLING PISTONS .
NOTE: The intermediate shaft cover is only fitted once the bearing housing has been installed in the crankcase and the crankcase is completely fastened.
Assemble bearing housing Refer to DISASSEMBLING AND ASSEMBLING BEARING HOUSING WITH CRANKSHAFT .
Fix crankcase half 1-3 to the engine support with 2 mounting elements 9590.
CAUTION:
As of model year 2003, new dowel sleeves will be used to center the housing bearing in crankcase half 1-3.
- The fitted bores in both components are different compared with the engines up to model year 2002 (bore depth and version).
Distinction:

Dowel pin up to and including model year 2002 and dowel sleeve as of model year 2003

Fig 1: Identifying Dowel Pin Dimension
Courtesy of PORSCHE OF NORTH AMERICA, INC.
- Dimension A (pin up to and including MY 2002): approx. 22 mm
- Dimension B (sleeve as of MY 2003): approx. 26.5 mm
To center the bearing housing, insert 2 dowel pins or dowel sleeves into the fitted bores of crankcase half 1-3.
Fitted bore (belt pulley side) as of MY 2003

Fig 2: Identifying Fitted Bore (Belt Pulley Side) As Of MY 2003
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Carefully insert housing bearing into crankcase half 1-3. Ensure that the positioning is correct (dowel pins or dowel sleeves).

Fig 3: Inserting Housing Bearing Into Crankcase Half 1-3
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fix bearing housing to crankcase 1-3 using 2 cylinder-head screws and spacer sleeves 9613. Turn crankcase half by 180° on the assembly support.
Fit belt pulley with hexagon-head bolt.
NOTE:
- As of model year 2002 (3.6 l), two new tools are used for fitting the pistons. Usage is in accordance with the details provided in the description for the 3.4 l engine.
- Centring piece 9602/5 for fitting piston pins on crankcase side 4-6 for 3.6 l engine
  
  Fig 4: Identifying Centring Piece 9602/5
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
- Assembly aid 9598/2 for positioning pistons for 3.6 l engine
  
  Fig 5: Identifying Assembly Aid 9598/2
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Replace con-rod bolts.
Coat connecting rod bearing shells, pistons and cylinder bores 1-3 with new engine oil, fit pistons with connecting rods 1-3. Refer to REMOVING AND INSTALLING PISTONS .

Screw connections for connecting rod bearing cover when fitting pistons side 1-3

Fig 6: Identifying Connecting Rod Bearing Bolts

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Insert new rubber rings for coolant ducts.
Only the following sealants may be used to seal the engine (these are available from Porsche Parts Service):
- "Drei Bond" silicone - type 1209
- Loctite 5900
Apply a bead of sealant to crankcase half 4-6. Refer to Fig 7. Observe a maximum drying time of 5 minutes.
View of crankcase half 4-6: Sealant application and tightening sequence of crankcase cross bolt connection

Fig 7: Crankcase Cross Bolt Connection Tightening Sequence
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- With the help of a second person, carefully place crankcase half 4-6 in position on crankcase half 1-3.
With the help of a second person, place crankcase half 4-6 in position on crankcase half 1-3 and at the same time guide the timing chain through the chain space. Knock gently on crankcase half 4-6 using a plastic hammer.
Fit special tool (centering mandrel) 9645 for the intermediate shaft. Position centering mandrel on the mounting point of the oil pump and turn the star knob clockwise until it is braced in the crankcase. Refer to REMOVING AND INSTALLING PISTONS .
Fit 24 M6 x 35 hexagon-head bolts (2 micro-encapsulated) on the crankcase and tighten to the specified torque in accordance with the given tightening sequence. Refer to Fig 7. View of crankcase half 4 - 6-. The micro-encapsulated screws are used in positions 8 and 9.
Tightening torque 13 Nm (9.5 ftlb.)
Install crankshaft sealing ring (belt pulley side) Refer to REMOVING AND INSTALLING CRANKSHAFT SEALING RING .
NOTE:
- As of model year 2003, two new tools are stipulated for installing the crankshaft sealing ring on the flywheel side.
- Measuring mandrel 9699/1 for checking the correct crankshaft position to the crankcase
  
  Fig 8: Identifying Measuring Mandrel 9699/1
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
- Assembly fixture 9699 for installing shaft seal in correct position
  
  Fig 9: Identifying Fixture 9699
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
- The sealing lip and the outer race of the shaft seal must be coated with fresh engine oil before installation.
Fit shaft seal on the flywheel side. Check the position of the crankshaft using measuring mandrel 9699/1. Coat the sealing ring inside and out with fresh engine oil and pre-position it on the crankshaft flange. Position assembly fixture 9699 on the crankshaft flange with the M8 hexagon socket head bolt and at the same time position the dowel pin in the crankshaft flange in the fitted bore of the fixture. Turn clockwise on the hexagon (a/f 19) as far as it will go. Refer to REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE .
NOTE:
- Replace M6 x 20 micro-encapsulated hexagon-head bolts and M8 hexagon nuts for the intermediate shaft cover.
Fit intermediate shaft cover. Lightly grease sealing ring and take-up bore, carefully position cover on the bore and insert uniformly with the new screws, tighten screws. Then position the new hexagon nut on the threaded pin. Tighten the nuts using special tool (socket wrench) 9110 and, at the same time, have a second person counter with a 7 x 1.1 slotted screwdriver on the slotted threaded pin. Refer to Fig 10.

Fig 10: Inserting Screwdriver Into Slotted Threaded Pin
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Tightening torque for hexagon-head bolts 10 Nm (7.5 ftlb.)

Tightening torque for hexagon nut 12 (+) 1 Nm (9 (+) 0.5 ftlb.)
Unscrew 2 cylinder-head screws and spacer sleeves 9613 from crankcase 1-3.
NOTE:
- Tighten additional screws to the specified torque on crankcase side 1-3 only after the cylinder head has been installed.
Position 2 additional M9 x 94 screws for the bearing housing on crankcase side 1-3. Refer to Fig 11. Fit 1 screw with a new O-ring.

Fig 11: Identifying Screws For Bearing Housing On Crankcase Side 1-3
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit 1 M9 x 150 additional screw with a new O-ring for the new bearing housing, position it on crankcase side 4-6. Refer to Fig 12. Tighten to the specified torque.

Fig 12: Fitting 1 M9 X 150 Additional Screw With New O-Ring
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 22 Nm (16 ftlb.)
Fit the belt pulley with socket wrench insert 9594 and retaining device 9593.

Fig 13: Fitting Belt Pulley Bolt With Socket Wrench
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 50 Nm (37 ftlb.) (+) 90° torque angle
NOTE:
- Use the following new tools for fitting pistons side 4-6 (see also information on fitting pistons side 1-3):
- Centring piece 9602/5 for fitting piston pins side 4-6
- Assembly aid 9598/2 for positioning the pistons
Install pistons 4-6. Refer to REMOVING AND INSTALLING PISTONS .
Fit M27 aluminum screw plug (hexagon socket a/f 12) for piston pin bore with a new sealing ring.
Tightening torque 80 Nm (59 ftlb.)
Install guide and tensioning rails. Fit 2 M6 threaded pins (hexagon socket a/f 5) with new O-rings, insert the guide and tensioning rails with the pins in the chain spaces. Tighten threaded pins to the specified torque. Fix timing chain with chain sprockets, for example, with the old O-rings from the oil extraction pumps.
Position of threaded pins and fixing timing chain

Fig 14: Identifying Position Of Threaded Pins
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Tightening torque 10 Nm (7.5 ftlb.)
Remove centering mandrel for intermediate shaft.
NOTE:
- Replace O-rings for the oil pump and sealing rings for coolant guide housing.
Fit oil pump with coolant guide housing. Coat oil pump flange with aluminum grease. Lightly coat hexagon driver for oil pump with high pressure grease and insert it in intermediate shaft. Position coolant guide housing, together with oil pump and new sealing rings, on crankcase. Position 10 hexagon-head bolts: 8 M6 x 20 and 2 M6 x 70, and tighten to the specified torque.
Tightening torque 10 Nm (7.5 ftlb.)
Fit all coolant closure caps with new sealing rings.
Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ftlb.)
Install temperature sensor for coolant (M14 a/f 22).
Tightening torque 25 +/- 5 Nm (19 +/- 3.5 ftlb.)
Fit thermostat housing and water pump with new gaskets.
Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ftlb.)
Turn crankcase by 180° on the assembly support. Fit air/oil separator (swirl pots), oil suction pipe and oil pan cover. Use new O-rings and, for the oil suction pipe, 2 new M6 x 20 micro-encapsulated hexagon-head bolts. Apply sealant to oil pan cover; after a maximum drying time of 5 minutes fit this cover to the crankcase using 13 M6 x 20 hexagon-head bolts.

Fig 15: Identifying Air/Oil Separator & Oil Suction Pipe
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ftlb.)
Fit new oil filter with new O-ring.
Tightening torque 25 Nm (19 ftlb.)