Assembling Engine

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Always replace gaskets and O-rings.

• Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68)  .

Information 

• The tightening torques for the engine are listed in the following documents and must be used in accordance with these specifications  .

Technical Values And Tightening Torques: 

Repair Group 1: → WM 1X00IN TECHNICAL VALUES (ALL MODELS) .

Repair Group 2: → WM 2X00IN TECHNICAL VALUES (ALL MODELS) .

Overview Of Bearing Shell Allocation: 

1. Main bearing shells - red, yellow, blue
2. Partial-groove bearing shells - red, yellow, blue
3. Thrust washers
4. Supporting mount shells - red, yellow, blue

1. Fit crankcase half 4-6 on the engine assembly support.
   1. 1.1. Use Mounting Parts 9590  to secure to the Engine Adapter 9771  .

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

      Information 

      • The bearing shells must be allocated according to specifications  .
      • Observe difference between partial-groove bearings and smooth bearings  .
      • Coat bearing shells with new engine oil  .
2. Fit new bearing shells on crankcase half 4-6. The following markings ensure correct allocation.
   1. 2.1. Crankcase half 4-6:  Markings are on the crankshaft. The upper series of letters -1-  is for the crankcase. Allocation starts at the supporting mount -SL-  on the belt side and is read from left to right. The supporting mount does not have a number, while the main bearings are numbered -HL: 1 to 7-  (number 7 is at the flywheel side).
      1. Series of letters at the top, supporting mount shells and main bearing shells
      2. Series of letters on connecting-rod bearing shells
      1. SL  - Supporting mount
      2. HL  - Main bearing
      3. PL  - Connecting-rod bearing
      4. R  - Bearing shell, Red
      5. G  - Bearing shell, Yellow
      6. B  - Bearing shell, Blue
      Fig 2: Identifying Bearing Shell Allocation Mark On Crankshaft

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit new bearing shells on crankcase half 1-3.
   1. 3.1. Crankcase 1-3:  Markings -1-  on crankcase half. The series of letters is read from left to right. Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
      1. G  - Bearing shell, Yellow
      2. R  - Bearing shell, Red
      3. B  - Bearing shell, Blue
      Fig 3: Identifying Marking On Crankcase

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 3.2. There are also different types of bearing shells (see bearing shell allocationFig 1).
      1. Partial-groove bearing shell (cylinders 2, 4 and 6)
      2. Smooth bearing shell
      Fig 4: Identifying Bearing Shells Position On Crankcase

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 3.3. Fit and grease new O-ring on the crankcase sealing surface.
4. Insert two thrust washers -1-  on main bearing 4. Oil grooves must always be facing outwards.
   Fig 5: Locating Thrust Washer Grooves

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged  .
   • The tensioning rails on cylinder bank 1-3 and 4-6 are identical  .
   • The guide rails on cylinder bank 1-3 and 4-6 are identical  .
   • The slots in the cylinder head must be positioned during installation  .
5. Install tensioning rail for oil-pump drive chain in crankcase 4-6.
   1. Rail
   2. Tensioning Spring
   Fig 6: Identifying Tensioning Spring And Rail For Oil-Pump Timing Chain

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 5.1. Fit tensioning rail -1-  for oil pump chain using a short bearing pin.
      Fig 7: Identifying Tensioning Rail For Oil-Pump Drive

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2-  .
   1. Oil pump supply valve on vacuum pump
   2. Bearing pin for guide rail
   3. Bearing pins for tensioning rail
   4. Bearing pin for tensioning rail for oil-pump drive chain
   Fig 8: Identifying Cylinder Bank Bearing Pins

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 6.1. Place spring -2-  on tensioning rail -1-  for oil-pump drive chain into the cut-out in the guide rail -3-  .
      Fig 9: Identifying Spring On Tensioning Rail For Oil-Pump Drive Chain

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Insert crankshaft with timing chains -2 and 3-  .
   1. 7.1. Engage oil pump gear -1-  in the drive chain.
      Fig 10: Identifying Oil Pump Gear, Crankshaft, Timing Chains

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Fix crankshaft in place using special tool Holding Bridge 9779 -1-  .
   1. 8.1. Fit and tighten fastening screws -2-  hand-tight.
      Fig 11: Identifying Holding Bridge 9779 For Crankshaft

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Install pistons on cylinder bank 4-6 and connecting rods 1-3.

   → 131020 REMOVING AND INSTALLING PISTONS .

10. Replace through bolts.

    The sealing washers can be replaced and the screws can be re-used! To do this, proceed as follows: 

    1. 10.1. Fit through bolts -1-  with new sealing washers.
    2. 10.2. Protective Sleeve 9786 -2-  must be pulled over the screw thread. Guide sealing washer -3-  over the protective sleeve for the screw head and remove protective sleeve.
       1. Through bolt
       2. Protective sleeve 9786
       3. Sealing washer (not yet available as a spare part)
       Fig 12: Identifying Through Bolt, Sealing Washer And Protective Sleeve

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Information 

       • The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant  .
       • Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only  .
       • Join the crankcase halves within max. 5 minutes of applying the bead of sealant  .
11. Apply sealant to crankcase half 4-6. Observe processing instructions.
    1. 11.1. Use Dobotech sealant (Part No. 000.043.207.31).
    2. 11.2. Carefully apply a continuous bead of sealant -arrow 1-  with a diameter of 1 mm. Follow sealant contour as shown in illustration.
    3. 11.3. Remove residual silicone in the crankshaft flange area following installation -arrow 2-  .
       Fig 13: Applying Sealant On Crankcase Half 4-6

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Fit rubber sleeves on connecting rods 1-3 (Assembly Aid 9795  ) and position vertically.
    1. 12.1. The Restraining Straps P221  can be used if necessary. Only two connecting rods can be fixed in place in this case. The third connecting rod must be held when positioning the crankcase half.

       Information 

13. With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
14. Fit through bolts and tighten according to the specified tightening torque and sequence.

    → WM 1X00IN TECHNICAL VALUES (ALL MODELS) .

    Fig 14: Crankcase Through Bolts Tightening Sequence

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    1-14  - External Torx screw with sealing washer

15. Fit external Torx screws for the outer cross bolt connection and tighten according to the specified tightening sequence.

    → WM 1X00IN TECHNICAL VALUES (ALL MODELS) .

    Fig 15: Outer Cross Bolt Connection Screws Tightening Sequence

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
16. Screw in and tighten two Mounting Parts 9590  for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.

    → 131020 REMOVING AND INSTALLING PISTONS .

18. Turn the crankshaft clockwise a number of times at the vibration damper using Turning Device 9773  in order to check for smooth operation and correct function.
    1. 18.1. Then, turn the crankshaft so that none of the pistons are at top dead center (TDC).
19. Fit crankshaft sealing rings at the flywheel and drive side.

    → WM 137455 REPLACING CRANKSHAFT SEALING RING - BELT SIDE .

20. Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3-  .
    Fig 16: Identifying Cylinder Bank 4-6 Bearing Pins

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 20.1. Fit tensioning rail for cylinder bank 1-3.
    2. 20.2. Secure guide rail for cylinder bank 1-3 in the crankcase with long bearing pins -1-  .
       Fig 17: Identifying Cylinder Bank 1-3 Bearing Pins

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ft. lbs.)  .
21. Fit the oil guide (oil plate) -1-  using external Torx screws -2-  .
    Fig 18: Identifying Crankcase Oil Plate External Torx Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Install oil pump.

    → 172019 REMOVING AND INSTALLING OIL PUMP .

23. Install coolant pipe -1-  for the coolant pump.
    1. 23.1. Fit and tighten external Torx screws -2-  .
       Fig 19: Identifying Coolant Pipe Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Insert displacement bodies -1-  on cylinder bank 1-3.
    Fig 20: Identifying Displacement Bodies On Cylinder Bank

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Always guide timing chains with your hand when turning the crankshaft  .
25. Fit cylinder head 1-3 and 4-6.

    → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

26. Pull timing chain 1-3 out of the chain slot and fit oil supply valve -1-  for the vacuum pump on the cylinder head with a new O-ring -2-  . Engage timing chain at the valve.
    Fig 21: Identifying Oil Supply Valve With O-Ring

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
27. Hold tensioning rail -1-  for cylinders 1-3 using a pair of flat-nosed pliers -3-  and screw in bearing pin -4-  .
    Fig 22: Holding Tensioning Rail For Cylinders Using Pair Of Flat-Nosed Pliers

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 27.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
    2. 27.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ft. lbs.)  .
28. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
    1. Tensioning Spring For Tensioning Rail
    2. Guide Rail
    Fig 23: Identifying Tensioning Rail For Oil-Pump Drive Chain And Guide Rail

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Install oil pan.

    → 175019 REMOVING AND INSTALLING OIL PAN .

30. Install hydraulic valves for camshaft control with new O-rings.

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

31. Install camshafts.

    → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .

32. Install cylinder head cover.

    → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER .

33. Install vacuum pump for brake booster.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

34. Fit vacuum line (vacuum pump).
35. Fit cover for positive crankcase ventilation.
    1. 35.1. Fit cover for cylinder bank 1-3 -1-  with new gaskets -2 and 3-  and secure with external Torx screws -4-  .
       Fig 24: Identifying Cylinder Bank Cover, Gasket And Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 35.2. Fit cover for cylinder bank 4-6 -1-  with a new O-ring -2-  and secure with external Torx screws -3-  .
       Fig 25: Identifying Cylinder Bank Cover, Gasket And Screws

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Fit spark plugs.

    → 287020 REMOVING AND INSTALLING SPARK PLUGS .

37. Install ignition coils.

    → 282020 REMOVING AND INSTALLING IGNITION COILS .