Disassembling Engine Down To Crankcase

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

WARNING: Pentosin is hazardous to health

Danger of material damage and injury

→ Wear protective gloves and goggles.

→ If the fluid gets into your eyes or on your skin, rinse or wash immediately with water.

→ Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.

→ Use caps to protect the wiring against soiling and damage.

Information

The bearing housing remains screwed to the retaining device when the bearing housing and intermediate shaft are disassembled.

Engine support 9589 must be secured to the crankcase using special tool mounting elements 9590 . Refit engine with support on the engine assembly support.

Fig 1: Supporting Engine
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Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8) → WM 170155 CHANGING ENGINE OIL AND OIL FILTER - section on "Draining".

Fig 2: Removing Oil Drain Plug
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Remove engine carrier. Unscrew 4 M10 collar nuts and 1 M6 x 20 Torx screw.

Fig 3: Identifying Engine Carrier Screws
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Undo 3 M8 x 12 fastening screws on the belt pulley for the servo pump (do not remove).
Remove drive belt. Mark the running direction with a colored pen, turn the tensioning roller (a/f 24) clockwise, hold still and simultaneously remove the belt from the drive pulleys. Check the belt for damage, replace if necessary. → WM 137819 REMOVING AND INSTALLING DRIVE BELT - section on "Removing".

Fig 4: Removing Belt Tensioner
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Only for Tiptronic: remove guide for drive belt, to do this, unscrew two M6 x 20 Torx screws.
Unclip hose assembly on the intake distributor, cylinder side 1 - 3:

Fig 5: Identifying Vacuum Lines
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Unplug crankcase ventilation line on pre-separator, cylinder 4-6.

Fig 6: Identifying Engine (Side 4-6)
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Remove shields for ignition coils on the left and the right, unscrew 2 M6 x 16 fastening screws.

Fig 7: Identifying Ignition Coil Shield
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Disconnect electric plug connections (engine wire harness) on engine and unclip wire harness on the fuel collection pipes.

Fig 8: Identifying Engine (Side 1-3)
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- Three injection valve plugs per cylinder side -1-
- Three ignition coil plugs per cylinder side -2-
- Two plugs for camshaft adjustment hydraulic valves, two for valve lift adjustment hydraulic valves -3-
- Plug for engine coolant temperature sensor, two plugs for oil pressure sensor on cylinder head cover 4 - 6 -4-
- Two hall sender connectors
- Plugs for speed sender
- Plug for electric switch-over valve (intake distributor 1-3)
- Ground cable for front face of cylinder 4-6 (one M6 x 12 Torx screw)
- Plug for engine compartment temperature sensor (intake distributor 4-6)
Unclip fuel ring pipe on the engine eyelet and unscrew two M6 x 16 Torx screws, remove engine eyelet.
Detach holder for the throttle body on the servo pump. To do so, unscrew an M6 hexagon nut. Unplug cable plug for potentiometer and line for crankcase venting.
Undo holder for servo supply tank on intake distributor 4-6.
Only for 3.6L engine: Remove the relevant six M6 x 35 (micro-self-locking) fastening screws for the intake distributor on the intake pipe supports on the left and the right. Pull off one vacuum line and remove the intake distributor completely.

Fig 9: Locating Intake Distributor - 3.6L
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Only for 3.6L engine: Remove intake pipe support. Unscrew four M6 x 35 screws, unscrew one M6 x 12 screw for ground strap on cylinder bank 4 - 6. Take off intake pipe support, seal intake openings on cylinder head (e.g. with adhesive tape).

Fig 10: Locating Intake Pipe Support
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Only for 3.8L engine: Unscrew the four M6 x 35 Torx screws. Completely remove the intake distributor. Seal intake openings on cylinder head (e.g. with adhesive tape).

Fig 11: Identifying Intake Distributor Screw Connection
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Remove belt pulley from servo pump. Unscrew three fastening screws and remove belt pulley.
Remove generator. Undo the fastening screw on the deflection roller -1- and unscrew approx. three turns. Using an aluminum mandrel, tap lightly on the screw head to undo the pilot bushing in the generator swivel arm. Unscrew the screw and remove with the deflection roller. Unscrew the second screw -2- and carefully take out the generator.

Fig 12: Locating Generator Screw
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Lift the generator out of the bracket and disconnect the two electric connecting lines -arrows- .

Fig 13: Locating Generator Electric Connections
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Remove mount for the coolant vent line. Unscrew one M6 x 16 (micro-self-locking), remove mount, replace screw.
Unplug all vent lines for oil mist collector.

Fig 14: Locating Oil Mist Collector - Line Connections (3.8 L Engine)
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Unscrew the two M6 x 20 Torx screws on the 3.8 l oil mist collector mount and pull off collector. Replace two O-rings during installation. The screws tighten the secondary air line on cylinder head 4-6 at the same time.

Fig 15: Locating Oil Mist Collector Threaded Joint (3.8 L)
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The oil mist collector on a 3.6 l engine is removed in the same way as the 996 unit.

Fig 16: Identifying Oil Mist Collector - 3.6 L Engine
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Unscrew one fastening screw for the wire harness guide on the bracket for the secondary air pump -1- and unclip the guide -2- on the bracket -arrow- .

Fig 17: Locating Secondary Air Pump Wire Harness
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Remove the secondary air pump. Unplug cable plug, unscrew three M6 x 20 Torx screws on the bracket -1- and completely take out the pump with bracket and line. Use new seals when installing.

Fig 18: Identifying Secondary Air Pump With Bracket
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Release the wire harness on the holder before the heat exchanger. Then unscrew the plastic holder.

Fig 19: Removing Heat Exchanger Wire Harness
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Undo the wire harness on the center of engine (connections to starter) -arrow- and unclip on the heat exchanger -1- . Unplug cable plug for knock sensors -2- and oil-level sensor. Then completely remove the engine wire harness.

Fig 20: Removing Wire Harness
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Remove the oil filler neck. Unscrew 2 M6 x 16 Torx screws (micro-self-locking), pull out oil filler neck, check the O-ring and replace if necessary.

Fig 21: Locating Oil Filler Neck
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Remove oil/water heat exchanger. Unscrew the four inner M6 x 16 Torx screws, take off heat exchanger. Replace O-rings during installation.
Remove hydraulic pump with servo line and supply tank. Undo servo line (a/f 16) -1- , counter on large hexagon when doing this (a/f 27). Unscrew four Torx screws (3 M8 x 30 at the front -arrows- , one M8 x 12 at the back), take the servo pump with line and supply tank out of the bracket.

Fig 22: Locating Servo Pump Screws
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Remove bracket for servo pump. Unscrew 4 M8 x 35 Torx screws, remove bracket.

Fig 23: Identifying Servo Pump Bracket
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Remove one M8 x 60 screw for deflection roller -1- and six M6 x 20 Torx screws for closure cap -2- with bleeder lines for coolant system.

Fig 24: Identifying Coolant Deflection Roller And Closure Cap
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Only in manual transmissions: Remove the starter. Unscrew two M10 x 35 Torx screws -1- , take off starter -2- .

Fig 25: Identifying Starter Screws
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Remove oil-level sensor (a/f 19), remove knock sensor, to do this, mark the installation position with a paint marker, then unscrew one M8 x 35 Torx screw each and take off the sensors.
Remove canister for additional volumes of crankcase venting to the cylinder heads 1-3 and 4-6. Unscrew two M6 x 25 Torx screws each, take off canister. Use new O-rings when installing.
Remove the holder for the main muffler on the left and right. Unscrew two M8 x 30 Torx screws each on the intake side and two M8 x 25 each on the exhaust side and take off mount.

Fig 26: Locating NSD Mount
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Remove mount and sealing cap for hydraulic valves for camshaft adjustment -2- . Unscrew two M6 x 20 Torx screws each, take off mount and sealing cap.

Fig 27: Identifying Camshaft Adjustment Hydraulic Valves
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Remove three ignition coils per cylinder side -1- . Unscrew 12 M6 x 25 Torx screws, pull off ignition coils.
Remove six spark plugs. Use only approved tool spark plug socket wrench 14 from Snap-On (in case ceramic body breaks) → 287020 REMOVING AND INSTALLING SPARK PLUGS - section on "Removing".
Pull off hydraulic valves for camshaft and valve lift adjustment. To do this, the special tool relay puller 9235 can be used. Pull the oil strainer for the camshaft adjustment valve out of the valve bore -1- with a magnet, replace the oil strainer.

Fig 28: Removing Oil Strainer Hydraulic Valve
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Remove the exhaust manifold. Unscrew six M8 x 28 screws each, remove manifold and seal.
Remove coolant pipe for heating. Side 1-3: unscrew two M6 x 12 Torx screws, side 4-6: unscrew three M6 x 12 Torx screws, remove coolant pipe.
Remove oil pressure sensor on cylinder head cover 4 - 6 (a/f 19).
Remove the mount for the air conditioning compressor. Unscrew two M8 fastening screws, and remove bracket.
Remove hall sender. Unscrew 1 M6 x 16 pan-head screw (hexagon socket a/f 5, micro-self-locking) and pull off hall sender, replace screws.
Remove knock sensors. Mark installation position (plug connection) with a paint marker, unscrew one M8 x 35 Torx screw each, pull sensors out of crankcase.
Remove speed sender, unscrew one M6 x 16 pan-head screw (hexagon socket a/f 5, micro-self-locking), remove sender, replace screw.
Pull coolant hose assembly out of plastic holder on crankcase. Undo spring band clamps on water pump and thermostat and take off hoses. Remove mount, to do this, unscrew one M6 x 16 Torx screw (micro-self-locking), replace screw.

Fig 29: Identifying Coolant Hoses Mount
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Remove all plastic closure caps on the cylinder heads, and replace closure caps.
Turn engine on the belt pulley of the crankshaft clockwise to the overlapping TDC of cylinder bank 1 - 3. To check cylinder 1-3, insert the special tool adjusting gauge 9686 in the camshaft slots. If the gauge cannot be inserted, the engine must be turned an additional 360°.
Remove oil extraction pump cylinders 1-3. Unscrew four M6 x 20 Torx screws (micro-self-locking), carefully pull the oil extraction pumps out of the fitting bore. Replace screws.
Remove tandem pump on cylinder side 4-6. Unscrew four M6 x 30 fastening screws -1- , pull vacuum line -2- out of the connection fitting on the pump, take out the pump. Replace O-rings.

Fig 30: Identifying Tandem Pump Screws (Side 4-6)
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Information
- The central screws of the camshaft control elements must be undone before removing the cylinder head cover.
- This ensures that the camshafts are not under tension in the cylinder head and the valves are not touching against the pistons.
The central screws of the camshaft adjuster must be undone before removing the cylinder head covers. To do this, place special tool retaining tool 9685 on the large hexagon of the central screw and cylinder head cover and undo the screws.
Removing camshafts, cylinder bank 1-3:
Remove cylinder head cover 1-3 → WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - engine removed - section on "Removing".
Remove all chain tensioners and replace aluminum sealing rings during installation.
Remove upper M6 screw (hexagon socket a/f 5) for guide rail cylinder 4-6.
Remove camshaft side 1-3 → WM 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) - section on "Removing".
NOTE:
Interchanged or dirty bucket tappets
- Scoring on cylinder head
→ Since the bucket tappets have been run in the fitting bores, do not interchange them.

→ Absolute cleanliness is essential.
Remove the bucket tappets. Pull each of the components out of the bucket tappet housing using a strong magnet. To avoid confusing the individual bucket tappets, lay them on a labelled, clean surface (see Fig 31) and cover them.

Fig 31: Example Of Laying Aside Bucket Tappets
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Place engine on the belt pulley of the crankshaft clockwise to the overlapping TDC of cylinder bank 4-6. To do this, turn the engine a further 360° clockwise. To check cylinder 4-6, insert the special tool adjusting gauge 9686 in the camshaft slots.
Removing camshafts, cylinder bank 4-6:
Remove cylinder head cover 4-6 → WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - engine removed - section on "Removing".
Unscrew the top M6 guide rail screw (hexagon socket a/f 5) on cylinder 4-6.
Remove camshaft side 4-6 → WM 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) - section on "Removing".
Remove flat-base tappet housing. Unscrew 11 M6 x 35 Torx screws per housing, one 1/4-inch E10 socket is necessary for this. Take flat-base tappet housing out of the cylinder head. It is absolutely necessary to replace O-rings for spark-plug recesses when installing.
Unscrew the top M6 guide rail screw (hexagon socket a/f 5) on cylinder 1-3.
Unscrew four M6 x 30 Torx screws -Pos 1 - 4- per cylinder bank.

Fig 32: External Cylinder Head Screw Loosening Sequence
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Remove cylinder head. Undo and unscrew 12 M10 x 230 Torx screws from inside to outside on each cylinder head. Lift the cylinder header and seal off the crankcase.
Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the engraved markings -arrow points to flywheel side- visible. Before removing, number and mark the pistons in the installation position.

Fig 33: Locating Installation Position Of Pistons
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Unscrew M27 aluminum screw plug for the assembly bore (piston pin).
Remove coolant closure cap (with connection for coolant ventilation). Unscrew six M6 x 20 inner Torx screws, remove cover, and replace the seal.
Remove connection supports for coolant hose on the top of the coolant guide housing. Unscrew two M6 x 20 Torx screws and remove cover.
Remove coolant temperature sensor (a/f 22).
Remove coolant closure cap at the bottom of the coolant guide housing. Unscrew four M6 x 20 Torx screws and remove cover.
Remove coolant pump. Unscrew seven hexagon-head bolts (two M6 x 30 and five M6 x 25) and remove pump.
Remove thermostat housing. Unscrew four M6 x 20 Torx screws and remove housing, including thermostat.
Remove coolant guide housing and oil pump. Unscrew ten Torx screws, namely eight M6 x 20 and two M6 x 70, and carefully lift off housing with seal (press lightly with an assembly lever if necessary). Pull out the driver for the oil pump. Remove the drive belt guide in Tiptronic vehicles.

Fig 34: Locating Coolant Guide Housing Screw Connection
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Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning rails from the chain spaces.
Remove oil filter with special tool Release Key 9204 .
Unscrew 13 M6 x 20 Torx screws on the oil pan cover. Tap cover gently on the sides using a plastic hammer, then carefully lift it at the leverage bar -see Fig 35 using a plastic-coated mounting lever and remove the oil pan.

Fig 35: Lifting Oil Pan Cover
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Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20 Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove the oil suction pipe.

Fig 36: Identifying Oil Pan Components
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Remove bearing cover for intermediate shaft → WM 152119 REMOVING AND INSTALLING BEARING COVER FOR INTERMEDIATE SHAFT - M96/05 (CARR. COUPE, CARR. CABRIO, CARR. 4 COUPE, TARGA 4 & CARR. 4 CABRIO) - Section on Removing.
Undo M16 x 1.5 x 60 hexagon-head bolt for belt pulley or vibration damper with special tool Socket Wrench Insert 9594 , while countering with special tool Retaining Device 9593 → Screw on belt pulley - 3.6 l engine or Holding Wrench 9732 . Do not unscrew the screw.

Fig 37: Removing Belt Pulley - 3.6 L Engine
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