Subsequent Work

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93) .

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 .

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

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

Install upper coolant distributor housing -1- (unit carrier).
→ 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING .
1. Distributor housing
2. M8 x 35 screws at the left and M8 x 50 screws at the right
Fig 1: Identifying Coolant Distributor Housing Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Slide bracket for coolant pump -1- with new O-rings -2 and 3- onto coolant pipe -4- and connection piece.

Fig 2: Identifying O-Rings, Coolant Pipes And Pump
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Screw on coolant pump bracket -1- .
1. 3.1. Fit and tighten external Torx screws M8 -2, 3 and 5- and M6 -4- .
  
  Fig 3: Identifying Coolant Pump Bracket Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit vibration damper.
→ 137519 REMOVING AND INSTALLING VIBRATION DAMPER .
Fit belt tensioner.
→ 137319 REMOVING AND INSTALLING BELT TENSIONER .
Install high-pressure pump.
→ 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP .
Fit fuel lines -2 and 4- on high-pressure pump -1- .
→ WM 203819 ENGINE FUEL LINE (LOW-PRESSURE LINE) .

→ WM 249019 HIGH-PRESSURE PUMP FUEL LINE - CONNECTING LINE (ALL MODELS) .
1. 7.1. Coat thread with OKS 1701 lubricant (Part No. 000.043.207.36).
  Allow a drying time of 60 minutes for the lubricant!
  
  Fig 4: Identifying Fuel Lines For High/Low-Pressure Connection
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install coolant pipe -1- for the coolant regulator housing and secure with external Torx screw -2- .

Fig 5: Identifying Coolant Pipe With Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install housing for coolant regulator.
→ WM 195519 REMOVING AND INSTALLING COOLANT REGULATOR HOUSING .
Turn the engine at the assembly support so that the oil pan is at the top.
Install exhaust manifold with new seals.
→ 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD WITH CATALYTIC CONVERTER .
Turn the engine 180° at the assembly support.
Install coolant distributor. Coat new O-rings -1- with Kluber Gel.
1. 13.1. Fit coolant distributor into coolant pipes.
  
  Fig 6: Identifying Connecting Pipes O-Rings For Coolant Distributor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 13.2. Fit coolant distributor -1- using external Torx screws -2- and tighten screws.
  
  Fig 7: Identifying Coolant Distributor With External Torx Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fuel collection pipes with fuel injectors.
→ 243019 REMOVING AND INSTALLING FUEL COLLECTION PIPE WITH FUEL INJECTORS .
Install the starter.
→ 276019 REMOVING AND INSTALLING STARTER .
Install bracket for oil-water heat exchanger.
→ 176719 REMOVING AND INSTALLING BRACKET FOR OIL COOLER .
1. 16.1. Pull out stoppers and fit and grease new O-rings.
  
  Fig 8: Identifying Console Threaded Joint And Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil-water heat exchanger.
→ 174019 REMOVING AND INSTALLING OIL-WATER HEAT EXCHANGER .

Fig 9: Identifying Oil-Water Heat Exchanger With Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil separator with new O-rings.
→ 105519 REMOVING AND INSTALLING OIL SEPARATOR .
Install console with deflection roller -1- .
→ WM 137719 REMOVING AND INSTALLING CONSOLE WITH DEFLECTION ROLLER .
1. 19.1. Fit and tighten external Torx screws -2 and 3- .
  
  Fig 10: Identifying Deflection Roller Console With Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install air-conditioning compressor.
→ 873419 REMOVING AND INSTALLING AIR CONDITIONING COMPRESSOR .
Install hydraulic valves for valve lift switchover.
→ WM 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT .
Install B+ wire harness (engine).
→ 974519 REMOVING AND INSTALLING WIRE HARNESS FOR BATTERY WIRING .
Install engine wire harness.
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
Route oxygen sensor cable and secure in the holders.
Fit fuel connection line to fuel collection pipe.
→ 249019 REMOVING AND INSTALLING FUEL CONNECTION LINE .
Fit coolant hoses -2- to oil-water heat exchanger.
1. 26.1. Coat hoses with Kluber Gel and fit them. Close spring band clamps -1- .
  
  Fig 11: Identifying Coolant Hoses And Spring Band Clamps
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install the generator.
→ 272219 REMOVING AND INSTALLING GENERATOR .
Install oil filler neck.
→ 171519 REMOVING AND INSTALLING OIL FILLER NECK .
1. 28.1. Grease new O-ring and fit oil filler neck on crankcase.
2. 28.2. Tighten external Torx screws.
Install positive crankcase ventilation line -1- .
→ 105219 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION LINE .
1. 29.1. Grease new O-rings and fit line to bracket for oil-water heat exchanger -4- . Tighten external Torx screw.
2. 29.2. Clip in line at two places and fit quick connectors on cylinders 1-3 -5- , cylinders 4-6 -2- and on the oil filler neck -3- .
  
  Fig 12: Identifying Positive Crankcase Ventilation Line, Cylinder Head, Oil Filler Neck, Oil Cooler Bracket
  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
Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and positive crankcase ventilation line.
Connect all possible plug connections for the engine wire harness before fitting the intake system.
Install intake-air distributor.
→ 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .
1. 32.1. Grease new molded seals.
2. 32.2. Fit complete intake-air distributor and position it on the cylinder heads.
3. 32.3. Fit external Torx screws and tighten uniformly according to the specified tightening sequence -1 - 12- .
  
  Fig 13: Intake-Air Distributor Screws Tightening Sequence
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit tank vent valve and engine compartment temperature sensor.
1. 33.1. Plug in cable plugs -1 and 3- on intake-air distributor 1-3. Screw in external Torx screw -2- used to secure the cable duct.
  1. Cable plug on engine compartment temperature sensor
  2. Cable duct mounting on cylinder bank 1-3
  3. Cable plug on control valve for tank ventilation
  Fig 14: Identifying Intake-Air Distributor Cable Plugs
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3.4 Liter Engine Only: Fit vacuum line on vacuum unit for tuning flap.
Fit oil filler neck on holder for intake-air distributor. Tighten external Torx screws.
Connect positive crankcase ventilation line to the resonance tube and oil separator and clip it in at the intake-air distributor.
1. 36.1. Tighten external Torx screw used to secure the cable duct to the intake-air distributor.
  
  Fig 15: Tightening Oil Filler Neck Screw Holder For Intake-Air Distributor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install drive belt.
→ WM 137855 REPLACING DRIVE BELT .
Fit engine carrier with bracket.
→ 103219 REMOVING AND INSTALLING ENGINE CARRIER .
Remove engine from the engine assembly support.
→ 1001IN TOOLS FOR REMOVING/INSTALLING UNITS AND WORKING ON ASSEMBLY SUPPORT .
Fit flywheel with new screws.
→ 136019 REMOVING AND INSTALLING FLYWHEEL - PDK TRANSMISSION .

→ 136019 REMOVING AND INSTALLING FLYWHEEL .
Mount transmission.
→ 343527 REMOVING AND MOUNTING TRANSMISSION .

→ 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .
Install engine.
→ 100119 REMOVING AND INSTALLING ENGINE .