Preliminary Work

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

• All engine repairs must be carried out using only the specified tools  .
• Only these tools have been tested and approved  .

1. Remove engine.

   → 100119 REMOVING AND INSTALLING ENGINE .

2. Remove transmission.

   → 343527 REMOVING AND MOUNTING TRANSMISSION .

   → 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

3. Support the engine on the engine assembly support.

   → 1001IN TOOLS FOR REMOVING/INSTALLING UNITS AND WORKING ON ASSEMBLY SUPPORT .

4. Drain engine oil.
   1. 4.1. Unscrew oil drain plug and collect engine oil.
   2. 4.2. Screw in and tighten screw with new seal.
5. Remove engine carrier -2-  with bracket.

   → 103219 REMOVING AND INSTALLING ENGINE CARRIER .

   1. 5.1. Unscrew and remove lower fastening screws -3-  (only one visible).
   2. 5.2. Unscrew upper left fastening screw -1-  and remove spacer -4-  .
   3. 5.3. Remove engine carrier.
   4. 5.4. Unscrew and remove spacer bolt -5-  .
      Fig 1: Identifying Engine Carrier, Spacer Bolt, Screws

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Remove intake-air distributor completely.

   → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .

7. Overview of components on belt side (removal steps described below).
   Fig 2: Overview Of Belt Side Components

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Oil separator
   2. Vacuum pump
   3. Low-pressure fuel line
   4. Fuel tank vent line
   5. Coolant connection piece
   6. Vibration damper
   7. Coolant pump with bracket
   8. Coolant regulator housing
   9. Belt tensioner
   10. Coolant distributor housing (unit carrier)
   11. Generator
   12. Air-conditioning lines
   13. Console with deflection roller
   14. Air-conditioning compressor
8. Remove drive belt.

   → WM 137855 REPLACING DRIVE BELT .

9. Release oxygen sensor cables -1 and 2-  .
   Fig 3: Identifying Oxygen Sensor Cables

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness)  .
   • → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
10. Disconnect various connectors on the engine wire harness.

    → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

    1. 10.1. Pull off the following cable plugs:
       • Camshaft adjustment (2x)
       • Valve lift adjustment (2x) -3- 
       • Hall sender (2x) -4- 
       • Coolant temperature sensor
       • Knock sensors (2x)
       • Generator
       • Air-conditioning compressor
       • Oil pressure regulating valve
       • Ignition coils (6x) -1- 
       • Sensor for oil pressure and oil temperature
       • Oil level sensor
         Fig 4: Identifying Cable Plugs And Cable Routing On Cylinder Head Cover

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 10.2. Unscrew and remove two M6 internal Torx screws -2-  on the ground cables for the ignition coils for each cylinder bank.
    3. 10.3. Unscrew and remove one external Torx screw -1-  on each cable duct for cylinder bank 1-3 and 4-6.
       Fig 5: Identifying Cable Duct Attachment Screw

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 10.4. Unclip cable duct on cylinder bank 1-3 and 4-6 towards the belt side.
11. Remove ignition coils.

    → 282020 REMOVING AND INSTALLING IGNITION COILS .

12. Remove spark plugs.

    → 287020 REMOVING AND INSTALLING SPARK PLUGS .

13. Remove crankcase vent line -1-  .
    1. 13.1. Press locking ring on cylinder head cover 1-3 -5-  and pull off the line.
    2. 13.2. Press locking ring and pull off line at the oil filler neck -3-  .
    3. 13.3. Press locking ring on vent cover on cylinder head 4-6 -2-  and pull off the line.
    4. 13.4. Unscrew and remove one external Torx screw (M6 x 20) -4-  on the oil cooler bracket and pull off the line. Replace O-rings.
       Fig 6: Identifying Positive Crankcase Ventilation Line Components

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       1. Positive crankcase ventilation line
       2. Connection on cylinder head 1-3
       3. Connection on oil filler neck
       4. Connection on oil cooler bracket
       5. Connection on cylinder head 4-6
14. Remove oil separator -1-  .
    1. 14.1. Unscrew and remove external Torx screws (M6 x 25) -2-  and pull off the oil separator.
    2. 14.2. Replace O-rings on the oil separator.
       Fig 7: Identifying Oil Separator With External Torx Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Remove generator.

    → 272219 REMOVING AND INSTALLING GENERATOR .

16. Disconnect B+ wiring harness.
    1. 16.1. Loosen B+ line at the junction point -1-  and pull protection cap -2-  off the starter.
    2. 16.2. Unscrew terminal 50 hexagon nut on the solenoid switch for the starter.
    3. 16.3. Unscrew hexagon nut on the B+ line for the starter.
    4. 16.4. Remove wiring harness.
       Fig 8: Identifying B+ Line Junction Point And Starter Protection Cap

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Remove air-conditioning compressor.

    → 873419 REMOVING AND INSTALLING AIR CONDITIONING COMPRESSOR .

18. Remove control valve for thermal management.
    1. 18.1. Open the hose clamp -2-  and pull off the hose -3-  .

       Collect emerging coolant in a container  .

    2. 18.2. Pull off vacuum hose -1-  (-arrow-  ).
    3. 18.3. Unscrew and remove two fastening screws -4-  and pull control valve -5-  down out of the coolant connection piece.

       Replace O-ring  .

       Fig 9: Pulling Vacuum Hose

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Remove coolant connection piece -3-  .
    1. 19.1. Unscrew lower fastening screw -4-  .
    2. 19.2. Unscrew and remove fastening screws at the top -1-  , move holder -2-  with connected lines aside and remove coolant connection piece.

       Check molded seal and replace it if damaged  .

       Fig 10: Identifying Coolant Connection Piece, Fastening Screw

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
20. Remove deflection roller.
    1. 20.1. Unscrew three fastening screws -1-  and remove deflection roller and holder -2-  .
       Fig 11: Identifying Deflection Roller With Fastening Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
21. Use Turning Device 9773 -1-  to turn the engine clockwise at the vibration damper until the TDC 1/4  marking on the vibration damper is aligned with the bore in the crankcase.
    1. 21.1. Secure the engine using one of the Locating Pins 9595/1 -2-  on the vibration damper.
       Fig 12: Installing Engine Using Locating Pins 9595/1 2 On Vibration Damper

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Remove vibration damper.

    → 137519 REMOVING AND INSTALLING VIBRATION DAMPER .

23. Remove coolant pipe for the thermal management bypass valve.
    1. 23.1. Open the clamp -2-  and pull off coolant hose -1-  .
    2. 23.2. Unscrew and remove fastening screw -5-  on the coolant regulator housing.
    3. 23.3. Unscrew fastening screw -3-  and pull coolant pipe -4-  off the coolant regulator housing.
    4. 23.4. Replace O-rings on the coolant pipe.
       Fig 13: Identifying Lower Coolant Pipe, Coolant Hose, Fastening Screw, O-Ring

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Remove coolant pump holder.
    1. 24.1. Unscrew external Torx screws -2-  on the coolant pump holder -3-  .
       Fig 14: Identifying Coolant Pump Fastening Screws (Bottom)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Pull coolant hose off the coolant regulator housing and remove the housing.
    1. 25.1. Open the clamp -2-  and pull off coolant hose -1-  .
    2. 25.2. Unscrew and remove fastening screw -3-  on the coolant regulator housing.
       Fig 15: Identifying Coolant Hose, Clamp And Fastening Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
26. Remove coolant regulator housing.

    → WM 195519 REMOVING AND INSTALLING COOLANT REGULATOR HOUSING .

    1. 26.1. Unscrew three external Torx screws -1-  on the connecting tube -2-  for the coolant regulator housing.
       Fig 16: Identifying Coolant Pipe Fastening Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 26.2. Pull coolant regulator housing -1-  forward off the rear coolant pipe -3-  .
    3. 26.3. Replace O-rings -4-  , check molded seal -2-  and replace if damaged.
    Fig 17: Pulling Coolant Regulator Housing

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
27. Remove coolant guide -1-  at the bottom.
    1. 27.1. Unscrew six external Torx screws -2-  and remove coolant guide.
    2. 27.2. Check molded seals and replace if necessary.
       Fig 18: Identifying Lower Coolant Guide And External Torx Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Remove exhaust manifold.

    → 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD WITH CATALYTIC CONVERTER .

29. Remove coolant pipes -2-  at the coolant distributor -1-  .
    1. 29.1. Unscrew two external Torx screws at the distributor.
       Fig 19: Identifying Coolant Pipes And Distributor

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 29.2. Pull distributor up and off.
       Fig 20: Identifying Coolant Collection Unit Connecting Pipes O-Rings

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 29.3. Replace O-rings -1-  .
30. Remove coolant collection unit and coolant hoses (on the oil-water heat exchanger) -2-  .
    1. 30.1. Open spring band clamps -1-  and pull off hoses.
       Fig 21: Identifying Coolant Hoses Spring Band Clamps

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 30.2. Unscrew external Torx screws -2-  and pull coolant collection unit -1-  up and off.
       Fig 22: Identifying Coolant Collection Unit With External Torx Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
31. Remove bracket -1-  for coolant pump.
    1. 31.1. Unscrew external Torx screws - M8 -2, 3 and 5-  and M6 -4-  .
       Fig 23: Identifying Coolant Pump Bracket And External Torx Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 31.2. Replace O-rings -2 and 3-  on the coolant pipe -4-  and coolant connection piece.
       Fig 24: Identifying Coolant Pipes O-Rings

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
32. Remove distributor housing (unit carrier) -1-  .
    1. 32.1. Unscrew two external Torx screws - one M8 x 35 and one M8 x 50 - at the unit carrier -2-  .
       Fig 25: Identifying Coolant Distributor Housing Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
33. Remove fuel connection line.

    → 249019 REMOVING AND INSTALLING FUEL CONNECTION LINE .

34. Remove oil filler neck.

    → 171519 REMOVING AND INSTALLING OIL FILLER NECK .

35. Remove oil-water heat exchanger.

    → 174019 REMOVING AND INSTALLING OIL-WATER HEAT EXCHANGER .

36. Remove starter.

    → 276019 REMOVING AND INSTALLING STARTER .

    Information 

    • The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side  .
    • The bracket's aluminum supports can break off in the crankcase  .
37. Remove bracket for oil-water heat exchanger.

    → 176719 REMOVING AND INSTALLING BRACKET FOR OIL COOLER .

38. Remove fuel collection pipes with fuel injectors.

    → 243019 REMOVING AND INSTALLING FUEL COLLECTION PIPE WITH FUEL INJECTORS .

39. Remove high-pressure pump.

    → 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP .

40. Disconnect vacuum line for brake booster at the oil pan.
41. Remove vacuum pump on cylinder head 4-6.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

42. Remove cover -1-  on positive crankcase ventilation line.
    1. 42.1. Cylinder bank 1-3: Unscrew external Torx screws -4-  and replace O-ring -3-  and molded seal -2-  .
       Fig 26: Identifying Positive Crankcase Ventilation Cover, Screws, O-Ring And Molded Seal

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 42.2. Cylinder bank 4-6: Unscrew external Torx screws -3-  and replace O-ring -2-  .
       Fig 27: Identifying Positive Crankcase Ventilation Cover, Screws, O-Ring And Molded Seal

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
43. Remove hydraulic valves for camshaft control.

    → 153719 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR CAMSHAFT CONTROL .

44. Remove hydraulic valves for valve lift switchover.

    → WM 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT .