Installing Engine

→ Enlist assistance of second and, if necessary, third person

1. Carefully guide in the engine/transmission unit using the Master Gear unit elevating platform WE 1206  .
2. For all-wheel drive vehicles:  Install cardan shaft.

   → 390219 REMOVING AND INSTALLING CARDAN SHAFT .

3. Fit holder -1-  for coolant pipes -arrow-  .
   Fig 1: Locating Coolant Pipes Holder

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4. Raise engine/transmission unit into installation position and secure the unit mounts.
   1. 4.1. Fit and tighten six M10 x 40 screws -2-  on the brace plate -1-  . Tightening torque 30 Nm (22 ftlb.) +90 Grad 
   2. 4.2. Fit and tighten two M10 x 50 screws on the transmission bracket. Tightening torque 65 Nm (48 ftlb.) 
   3. 4.3. Fit and tighten two M10 collar nuts on the transmission support. Tightening torque 65 Nm (48 ftlb.) 
      Fig 2: Identifying Brace Plate And Transmission Bracket

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5. Secure the engine carrier -1-  to the engine mount with two collar nuts -2-  .
   Fig 3: Identifying Engine Carrier Collar Nuts

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6. Loosen tension straps and move Master Gear unit elevating platform WE 1206  out of the work area.
7. Work on the Porsche Doppelkupplung (PDK): 
   1. 7.1. Connect cable plug at the bottom -1-  and fit cable guide -2-  on the transmission -arrow-  .
      Fig 4: Locating Bottom PDK Cable Plug And Cable Guide

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8. Clip in end piece -1-  of the locking cable -arrow-  and connect cable plug -2-  .

   → 371319 REMOVING AND INSTALLING LOCKING CABLE .

   1. 8.1. Clip in locking cable on the support.
      Fig 5: Locating PDK Cable Plug

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9. Connect cable plugs for control valve -1-  and temperature sensor -2-  .
   Fig 6: Locating Control Valve And Temperature Sensor Cable Plugs

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10. Fit B+ line -3-  on the transmission.
    1. 10.1. Insert line shoe and fit and tighten M8 hexagon nut -2-  . Close the lid -1-  . Tightening torque 23 Nm (17 ftlb.) 
       Fig 7: Identifying B+ Line

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11. Secure ground cable -1-  for engine to the body using an M8 hexagon nut -2-  . Tightening torque 23 Nm (17 ftlb.) 
    Fig 8: Identifying Engine Ground Strap

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12. Connect vacuum lines -1 + 2-  .
    Fig 9: Locating Brake Booster And Engine/Transmission Supply Vacuum Lines

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    Information 

    • Always observe specifications relating to chassis components. 

    Secure chassis components according to the instructions in the specified document. 

    → 4X00IN TIGHTENING TORQUES FOR REAR AXLE .

13. Install rear-axle cross member -1-  .

    → 420619 REMOVE AND INSTALL REAR AXLE CROSS MEMBER .

    1. 13.1. Mounting with two hexagon-head bolts (M12 x 95) at the left -2-  .
       Fig 10: Identifying Left Cross Member Threaded Joint

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    2. 13.2. Mounting with two hexagon-head bolts (M12 x 95) at the right -2-  .
       Fig 11: Identifying Right Cross Member Threaded Joint

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14. Fit wishbone -1-  on the wheel carrier using a nut -2-  and bolt -3-  .
    Fig 12: Identifying Wheel Carrier Cross Member Brace

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15. Install diagonal braces.

    → Installing Rear-Axle Cross Member .

    1. Diagonal braces
    2. Hexagon-head bolt, M12 x 40
    3. Hexagon-head bolt, M12 x 30
    4. Cheese head bolt, M10 x 45
    Fig 13: Identifying Engine Diagonal Braces

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16. Fit anti-roll bar on the PDCC actuator or connecting link.

    → Installing Rear Anti-Roll Bar .

17. Vehicles with Porsche Dynamic Chassis Control (PDCC): 
    1. 17.1. Fit lines on the underbody and secure at the retaining points.

       → 4303IN COMPONENT ARRANGEMENT .

       → 4X00IN TIGHTENING TORQUES FOR PORSCHE DYNAMIC CHASSIS CONTROL (PDCC) .

18. Connect cable plug for headlight levelling system at the left and right.
19. Fit air-conditioning lines -1-  with new O-rings.

    → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

    1. 19.1. Counter with special tool assembly tool 9822  .
    2. 19.2. Tighten the screws. Tightening torque 22 Nm (16 ftlb.) 
       Fig 14: Identifying Air-Conditioning Lines

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    Information 

    • Check O-rings on the plug-in couplings and replace them if necessary. 
    • Clean plug connection and coolant hoses before assembly. 
    • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
    • Remove stoppers before fitting the coolant lines and hoses. 
20. Fit coolant hoses in the engine compartment.
    1. 20.1. Lightly grease the O-rings.
    2. 20.2. Check that the coolant hoses are fitted securely.
21. Connect plug-in coupling -1-  for the fuel low-pressure line in the engine compartment.
    1. 21.1. Check that the line is fitted securely.
       Fig 15: Locating Fuel Low-Pressure Line Connection

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22. Connect vent lines for coolant -1 + 2-  and fuel -3-  .
    Fig 16: Identifying Coolant And Tank Vent Lines

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