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Installing engine

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NOTE:
  • The engine-transmission unit is installed in the reverse order. The following points must be given special attention.
  • Have a second person observe the engine-transmission clearance when inserting!
  1. Lift engine-transmission unit approximately to halfway of the car jack. Also guide the oil filler neck and different hose lines in the left engine compartment when inserting!
    NOTE:
    • The ground cable on the holder of the plug connection of the impulse sender must also be screwed on!
  2. Fit plate holder for the plug connection of the pulse sender and the plastic cable retainer. Position 1 M6x12 hexagon-head bolt and tighten with tightening torque. Screw in cable retainer and clip in cable.
    Fig 1: Fit Plate Holder For Plug Connection Of Pulse Sender And Plastic Cable Retainer
    G03099590Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque: 10 Nm (7.5 ftlb.) 

  3. Connect servo lines. Push plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.
    Fig 2: Pushing Plug Into Plug-In Coupling In A Straight Line
    G03099591Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • The plug connection is designed so that there is an axial play of approx. 1 mm in the coupling.
  4. Check proper engagement of the plug coupling with special tool Test tool 9623, see TOOLS, REMOVING AND INSTALLING ENGINE AS FROM MY 02 . Insert special tool into the groove (-arrow-  ) and check that the plug is seated correctly in the coupling by applying slight pressure. The plug must not slide out.
    Fig 3: Checking Proper Engagement Of Plug Coupling
    G03099592Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Have a second person observe the engine-transmission clearance when inserting!
    • Also guide the oil filler neck and different hose lines in the left engine compartment when inserting!
  5. Move the engine-transmission unit into the installation position and tighten the engine or transmission mount screw connection with tightening torque.

    Tightening torque of engine mount to engine carrier: 85 Nm (63 ftlb.) 

    Tightening torque of transmission bracket on body: 65 Nm (48 ftlb.) 

    NOTE:
    • Allocation of the round connector:
    • Lower plug - grey inner ring
    • Upper plug - black inner ring
  6. Fit engine wiring harness. Turn bayonet lock in clockwise direction (approx. 90°), until the marking of the round connector and the housing correspond.
    Fig 4: Turning Bayonet Lock In Clockwise Direction
    G03099593Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Fit air-conditioning compressor: before installing the compressor check whether the aluminum spacer sleeve (-arrow-  ) is inserted. Grease and fit sleeve. Also insert ground cable before installation.
    Fig 5: Fitting Air-Conditioning Compressor Aluminum Spacer Sleeve
    G03099594Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Place 3 M8 hexagon-head bolts onto the air conditioning compressor (2 short screws at rear -1-  ), 1 long screw at front -2-  ) and tighten to tightening torque.
    Fig 6: Placing M8 Hexagon-Head Bolts Onto Air Conditioning Compressor
    G03099595Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque: 23 Nm (17 ftlb.) 

  9. Fitting drive belt: Observe sequence when fitting the belt and direction of motion if the belt has been used.
    Fig 7: Drive (Serpentine) Belt Fitting Sequence
    G03099596Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Insert servo container. Remove plug, insert container into the flange, turn bayonet lock clockwise (-arrow-  ) until the markings of the flange and the container are aligned.
    Fig 8: Turning Bayonet Lock Clockwise Until Markings Of Flange And Container Are Aligned
    G03099597Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Top up Pentosin. Check fluid levels, see Refer to TEST AND ASSEMBLY WORK ON POWER-ASSISTED STEERING . Observe warning notes on use of Pentosin!
  12. Top up coolant and bleed cooling system, see Refer to DRAINING AND FILLING IN COOLANT (INCLUDES: BLEEDING) .
  13. Fit hall sender on cylinder head bank 4 -6. Replace micro-encapsulated M6 hexagon socket head bolt.

    Tightening torque: 10 Nm (7.5 ftlb.) 

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