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Disassembling and assembling engine: Disassembly

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NOTE: Before the engine is fastened to the engine holder or assembly stand, detach and remove the thrust plate and flywheel.
  1. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.
    Fig 1: Fastening Toothed Segment On Crankcase Half With Hexagon-Head Bolt M12 X 50
    G03099312Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Detach thrust plate.
    NOTE: In order to avoid deformation of the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.
  3. Remove thrust plate and drive plate.
  4. Detach flywheel (Torx T55).
  5. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.
    Fig 2: Fastening Engine Holder To Crankcase Half Of Cylinder Bank 1 - 3
    G03099313Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Undo the oil drain plug on the oil pan and drain off the engine oil. Use a hexagon socket wrench insert for 8 mm hexagon socket head bolts.
    Fig 3: Removing Oil Drain Plug
    G03099314Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Remove engine carrier.
  8. Remove drive belt. Mark the running direction with a colored pen. Relieve the belt tension. To do this, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the drive pulleys.
    Fig 4: Turning Drive Belt Tensioning Roller Clockwise
    G03099315Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Remove generator from bracket. To do this, undo upper right-hand fastening screw on generator (1) by approx. 3 turns. A gentle tap on the fastening screw loosens the front fastening bushing in the generator arm. Unscrew fastening screw (1) and fastening screw (2).
    Fig 5: Identifying Generator Fastening Screws
    G03099316Courtesy of PORSCHE OF NORTH AMERICA, INC.
    1. Turn generator clockwise and remove from bracket.
      Fig 6: Turning Generator Clockwise And Removing It From Bracket (1 Of 2)
      G03099317Courtesy of PORSCHE OF NORTH AMERICA, INC.
      Fig 7: Turning Generator Clockwise And Removing It From Bracket (2 Of 2)
      G03099318Courtesy of PORSCHE OF NORTH AMERICA, INC.
    2. Disconnect electrical plug connection.
      Fig 8: Disconnecting Generator Electrical Plug Connection
      G03099319Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Remove supply tank of the power steering system. To do this, remove the fluid in the upper supply tank until below the joint.
    Fig 9: Removing Fluid In Upper Supply Tank Until Below Joint
    G03099320Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Turn bayonet lock in the direction indicated by the arrow and pull off the supply tank.

    Bayonet lock open 

    Fig 10: Turning Bayonet Lock In Direction Indicated By Arrow
    G03099321Courtesy of PORSCHE OF NORTH AMERICA, INC.
  12. Remove fluid in lower supply tank.
  13. Undo oil separator on the crankshaft.
    Fig 11: Removing Oil Separator On Crankshaft
    G03099322Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Undo the intake distributor on the intake pipe supports and remove the complete intake system with oil separator. Remove engine wiring harness with oil vent line.
    Fig 12: Removing Intake Distributor On Intake Pipe Supports
    G03099323Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. Pull out oil dipstick and undo guide for dipstick.
  16. Undo two hexagon-head bolts (a/f 10 mm) on the oil filler neck. Pull oil filler neck out of the crankcase.
  17. Undo intake pipe supports from the cylinder heads and remove completely with the fuel ring pipe.
    Fig 13: Removing Intake Pipe Supports From The Cylinder Heads
    G03099324Courtesy of PORSCHE OF NORTH AMERICA, INC.
  18. Remove starter (width across flats 16 mm).
  19. Loosen belt pulley on the hydraulic pump.
  20. Detaching steering return line. In order to detach the line from the supply tank, push the red unlocking ring forward (arrows) and simultaneously pull out the line. Use two plastic spatulas to press the unlocking ring.
    Fig 14: Detaching Steering Return Line
    G03099325Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Detaching steering return line from the supply tank with tool. The line can also be detached using a commercially available tool. The removal tool from Messrs. Snap-On, for example, is recommendable. Insert tool between line and the red unlocking ring and unlock. Pull line to the rear and simultaneously press the tool against the red ring. Carefully protect the line against dirt and scratches with a cap.
    Fig 15: Removing Steering Return Line From Supply Tank
    G03099326Courtesy of PORSCHE OF NORTH AMERICA, INC.
  22. Detach hydraulic pump and steering supply line. Undo steering supply line (wrench size 17); simultaneously counter at the body (wrench size 27). Undo three hexagon-head bolts (M8 x 12) and remove hydraulic pump to the rear.
    Fig 16: Removing Hydraulic Pump Hexagon-Head Bolts
    G03099327Courtesy of PORSCHE OF NORTH AMERICA, INC.
  23. Remove oil-water heat exchanger. Remove vent line. Undo four hexagon socket head bolts (a/f 5 mm).
  24. Remove vacuum tank.
  25. Remove knock sensors.
  26. Remove holders for rear muffler.
    Fig 17: Removing Holders For Rear Muffler
    G03099328Courtesy of PORSCHE OF NORTH AMERICA, INC.
  27. Remove shields from cylinder heads.
  28. Remove ignition coils.
  29. Remove exhaust manifold.
  30. Turn crankshaft clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595/1.
    Fig 18: Turning Crankshaft Clockwise Until Bore 1 OT In Belt Pulley Is Aligned With Fixing Bore On Crankcase
    G03099329Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 19: Setting Crankshaft Position With Fixing Pin (Short) Of Special Tool 9595/1
    G03099330Courtesy of PORSCHE OF NORTH AMERICA, INC.
  31. Check basic camshaft position of cylinder bank 1 -3. Remove closure cap. The closure cap of cylinder bank 1 - 3 is located on the flywheel side. Ensure that the groove in the camshaft faces outward toward the cylinder head cover.
    Fig 20: Checking Basic Camshaft Position Of Cylinder Bank 1-3
    G03099331Courtesy of PORSCHE OF NORTH AMERICA, INC.
  32. If the position of the camshafts is incorrect, remove fixing pin at the pulley and rotate the crankshaft 360° clockwise.
  33. Relieve camshaft drive chains. Unscrew chain tensioner of cylinder bank 1-3. ("2 rings" identification on hexagon of chain tensioner and on cylinder head, a/f 32 mm).
    Fig 21: Unscrewing Chain Tensioner Of Cylinder Bank 1-3
    G03099332Courtesy of PORSCHE OF NORTH AMERICA, INC.
  34. Pull off camshaft closure caps at pulley side of cylinder head 1 - 3.
  35. Prepare special tool, holding-down device 9643, for installation: Unscrew hexagon socket head bolts and replace with M8 x 25 hexagon-head bolts. Adjust insertion depth. Insertion depth for inlet camshaft 15 mm, insertion depth for outlet camshaft 17 mm.
    Fig 22: Preparing Special Tool, Holding-Down Device 9643, For Installation
    G03099333Courtesy of PORSCHE OF NORTH AMERICA, INC.
  36. Fit special tool, holding-down device 9643, on the cylinder head and fasten with a hexagon-head bolt M8 x 30.
    NOTE:
    • In order to prevent damage, it is essential to fit the holding-down device before detaching the cylinder head cover.
    Fig 23: Fitting Special Tool On Cylinder Head
    G03099334Courtesy of PORSCHE OF NORTH AMERICA, INC.
  37. Detach and remove oil extraction pump at cylinder head 1 - 3- on the flywheel side.
  38. Unscrew hexagon-head bolts M6 x 20 (2 ea.). Remove closure cap from tensioning element (VarioCam).
  39. Remove cylinder head cover. Loosen hexagon-head bolts from the outside to the inside. Detach the cylinder head cover by knocking it gently with a plastic hammer, and press off carefully.
  40. Fasten special tool 9611, holding-down device for camshafts, with auxiliary screws M6 x 45.
    Fig 24: Fastening Holding-Down Device For Camshafts
    G03099335Courtesy of PORSCHE OF NORTH AMERICA, INC.
  41. Relieve camshaft tensioning element with special tool, tensioning screw 9632.
    Fig 25: Relieving Camshaft Tensioning Element
    G03099336Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE: Screw in tensioning screw only so far as to slightly relieve the chain.
  42. Unscrew three fastening screws (M6 x 95) on tensioning element.
  43. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.
    Fig 26: Identifying Four Hexagon-Head Bolts (M6 X 15) On Chain Sprocket
    G03099337Courtesy of PORSCHE OF NORTH AMERICA, INC.
  44. Remove drive plate and sprocket wheel.
    Fig 27: Removing Camshaft Drive Plate And Sprocket Wheel
    G03099338Courtesy of PORSCHE OF NORTH AMERICA, INC.
  45. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.
  46. Remove holding-down device (special tools 9611 and 9643).
  47. Carefully lift the complete unit, camshafts with chain and tensioning element out of the cylinder head. The chain must not jump over. Perform reallocation during refitting if necessary.
    Fig 28: Lifting Complete Unit, Camshafts With Chain And Tensioning Element Out Of Cylinder Head
    G03099339Courtesy of PORSCHE OF NORTH AMERICA, INC.
  48. Remove valve tappets.
  49. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide for the valve tappets.
    Fig 29: Identifying Pan-Head Screws
    G03099340Courtesy of PORSCHE OF NORTH AMERICA, INC.
  50. Undo oil baffle (hexagon-head bolt M6 x 16).
    NOTE: The oil baffle is fitted only on cylinder head 1-3.
    Fig 30: Identifying Oil Baffle Hexagon-Head Bolt M6 X 16
    G03099341Courtesy of PORSCHE OF NORTH AMERICA, INC.
  51. Unscrew four pan-head screws M6 x 35 (with captive washers) in the area of the chain box.
    Fig 31: Identifying Four Pan-Head Screws M6 X 35 In Area Of Chain Box
    G03099342Courtesy of PORSCHE OF NORTH AMERICA, INC.
  52. Undo the upper fastening screw for guide rails. Use a 6 mm Allen key.
  53. Loosen cylinder head screws from outside to inside and remove the cylinder head. Remove and dispose of cylinder head gasket.
    Fig 32: Cylinder Head Screw Loosening Sequence
    G03099343Courtesy of PORSCHE OF NORTH AMERICA, INC.
  54. Remove cylinder head from cylinder bank 4 - 6. Advance crankshaft 360° clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
    Fig 33: Aligning Belt Pulley With Fixing Bore On Crankcase
    G03099344Courtesy of PORSCHE OF NORTH AMERICA, INC.
  55. Check camshaft adjustment at cylinder bank 4 - 6: The groove in the camshaft must face inward toward the crankcase.
    Fig 34: Checking Camshaft Adjustment At Cylinder Bank 4-6
    G03099345Courtesy of PORSCHE OF NORTH AMERICA, INC.
  56. Unscrew chain tensioner of cylinder bank 4 - 6. Identification "Ohne" (without)
    Fig 35: Identifying Chain Tensioner Of Cylinder Bank 4-6
    G03099346Courtesy of PORSCHE OF NORTH AMERICA, INC.
  57. Carry out further disassembly steps on cylinder head 4 -6, as described for cylinder head 1 -3.
  58. Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool 9594 (socket wrench insert), and hold with special tool 9593 (retaining device) at the same time.
    Fig 36: Loosening Belt Pulley Hexagon-Head Bolt
    G03099347Courtesy of PORSCHE OF NORTH AMERICA, INC.
  59. Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6). "1 Ring" identification
    Fig 37: Identifying Primary Chain Tensioner (Cylinder Bank 4-6)
    G03099348Courtesy of PORSCHE OF NORTH AMERICA, INC.
  60. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the lock nut with the special tool 9110 (socket wrench insert) and hold with a screwdriver 7.0 x 1.1 at the slotted threaded pin at the same time.
    Fig 38: Removing Intermediate Shaft Flange Lock Nut With Special Tool 9110 And Hold With A Screwdriver
    G03099349Courtesy of PORSCHE OF NORTH AMERICA, INC.
  61. Remove coolant guide housing with oil pump. Pull hexagon oil pump driver out of intermediate-shaft flange.
    Fig 39: Removing Coolant Guide Housing With Oil Pump
    G03099350Courtesy of PORSCHE OF NORTH AMERICA, INC.
  62. Detach guide rail and tensioning rail of cylinder bank 1-3 (flywheel side).
    Fig 40: Identifying Guide Rail And Tensioning Rail Of Cylinder Bank 1-3
    G03099351Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 41: Identifying Guide Rail And Tensioning Rail Of Cylinder Bank 1-3 (View From Flywheel Side)
    G03099352Courtesy of PORSCHE OF NORTH AMERICA, INC.
  63. Detach slide rails and tensioning rails of cylinder bank 4 - 6 (flywheel side).

    View from the belt pulley side 

    Fig 42: Identifying Slide Rails And Tensioning Rails Of Cylinder Bank 4-6
    G03099353Courtesy of PORSCHE OF NORTH AMERICA, INC.

    View from the belt pulley side 

    Fig 43: Identifying Slide Rails And Tensioning Rails Of Cylinder Bank 4-6 (View From Belt Pulley Side)
    G03099354Courtesy of PORSCHE OF NORTH AMERICA, INC.
  64. Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer and lever the oil pan off at the leverage bar using a plastic-coated mounting lever.
    Fig 44: Levering Off Oil Pan
    G03099355Courtesy of PORSCHE OF NORTH AMERICA, INC.
  65. Remove air/oil separator and oil suction pipe.
    Fig 45: Removing Air/Oil Separator And Oil Suction Pipe
    G03099356Courtesy of PORSCHE OF NORTH AMERICA, INC.
  66. Turn crankcase by 180°. Undo fastening screws between crankcase half of cylinder bank 1-3 and bearing housing.
    Fig 46: Identifying Fastening Screws Between Crankcase Half Of Cylinder Bank 1-3 And Bearing Housing
    G03099357Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 47: Removing Fastening Screws Between Crankcase Half Of Cylinder Bank 1-3 And Bearing Housing
    G03099358Courtesy of PORSCHE OF NORTH AMERICA, INC.
  67. Undo fastening screw between crankcase half of cylinder bank 4-6 and bearing housing.
    Fig 48: Identifying Fastening Screw Between Crankcase Half Of Cylinder Bank 4-6 And Bearing Housing
    G03099359Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 49: Removing Screw Between Crankcase Half Of Cylinder Bank 4-6 And Bearing Housing
    G03099360Courtesy of PORSCHE OF NORTH AMERICA, INC.
  68. Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 24 ea.) joining the crankcase halves.
    WARNING: Danger of damage to pistons if crankcase half is tilted!
    • Do not tilt crankshaft half
    • Lift the crankcase half up and off
    • Two people required to remove crankcase half
    Fig 50: Separating Crankcase Half
    G03099361Courtesy of PORSCHE OF NORTH AMERICA, INC.
  69. For the following disassembly procedure, the crankcase half and bearing housing unit must be held by at least two screwed connections for safety reasons. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below. Tightening torque approx. 20 Nm (15 ftlb.). Use Torx screwdriver insert T50 or T55.
    Fig 51: Identifying Special Tool 9613
    G03099362Courtesy of PORSCHE OF NORTH AMERICA, INC.
  70. Identify pistons of cylinder 4-6. Lever off front piston pin circlip. Push out piston pin. Allocate the same corresponding pistons to the piston pins again after disassembly.
    Fig 52: Pushing Out Piston Pin
    G03099363Courtesy of PORSCHE OF NORTH AMERICA, INC.
  71. Remove pistons with connecting rods on cylinder bank 1-3. Mark pistons. Unscrew connecting-rod bolts. Remove twelve-edged socket wrench insert a/f 14 mm and connecting-rod bearing cap.
    Fig 53: Locating Connecting Rod Bolts On Cylinder Bank 1-3
    G03099364Courtesy of PORSCHE OF NORTH AMERICA, INC.
  72. Push connecting rod with piston downwards out of the cylinder using a shop-made plastic mandrel.
    Fig 54: Pushing Connecting Rod With Piston Downwards Out Of Cylinder
    G03099365Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Join connecting rod and connecting-rod bearing cap again immediately after removal. The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.
  73. Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 25 hexagon-head bolts.
    Fig 55: Fastening Assembly Fixture (Special Tool 9607) On Bearing Housing With Hexagon-Head Bolts
    G03099366Courtesy of PORSCHE OF NORTH AMERICA, INC.
  74. Remove plastic spacer sleeves, special tool 9613 again.
    Fig 56: Removing Special Tool 9613
    G03099367Courtesy of PORSCHE OF NORTH AMERICA, INC.
  75. Fasten suspension eye, attach spring hook, and lift bearing housing out of the crankcase half using a workshop crane or engine lifter. Do not damage sealing surfaces when lifting out.
    NOTE:
    • The bearing housing and assembly fixture, special tool 9607, remain screwed together when disassembling the bearing housing and intermediate shaft.
    Fig 57: Lifting Bearing Housing Out Of Crankcase Half
    G03099368Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 58: Removing Crankcase Half Cylinder Bank 1-3 From Engine Holder
    G03099369Courtesy of PORSCHE OF NORTH AMERICA, INC.
  76. Disassemble bearing housing on intermediate shaft. See DISASSEMBLING AND ASSEMBLING BEARING HOUSING WITH CRANKSHAFT .
  77. Remove crankcase half cylinder bank 1 - 3 from the engine holder.
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