Assembling Engine

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NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

NOTE: Residual sealant

Oil bores blocked

→ Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.

Information

Always replace gaskets and O-rings.

Information

Always replace lock nuts.

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

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

Torx screws: (E..) for external Torx, (T..) for internal Torx.
Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

Install cylinder head.

1.1. Fit new metal seal (identical part). The "TOP" marking must be facing you.
1.2. Fit twelve M10 internal multiple-tooth nuts -1- using socket wrench 9295 (coat sealing surface with a small amount of oil). Cover intake openings (with adhesive tape or a clean cloth).
1.3. Tighten multiple-tooth nuts according to tightening specifications (see table below) and always tighten in diagonally opposite sequence from the inside out.

Fig 1: Identifying Cylinder Head Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Sequence	Designation	Value	Unit
Step 1	Initial tightening, all nuts	30 (22)	Nm (ft. lb.)
Step 2	Loosen all nuts
Step 3	Joining torque, all nuts	20 (15)	Nm (ft. lb.)
Step 4	Subsequent tightening, threshold torque	20 (15)	Nm (ft. lb.)
Step 5	Final tightening	120 ± 2	Degrees, torque angle

Information

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

Install coolant connection piece with new O-rings on the cylinder housing. Grease O-rings.
1. 2.1. Fit and tighten two external Torx screws (M6 x 20).
  → Tightening torque: 10 Nm (7.5 ft. lb.)
Fit tensioning and guide rails in the crankcase using one pin on each rail.→ Length: 74.5 mm

Fig 2: Checking Lower Pin Length
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Fit guide rail with a short pin and a new sealing ring.
2. 3.2. Fit guide rail with a long pin and a new sealing ring.
3. 3.3. Check that the rails run smoothly and then tighten both pins. → Tightening torque: 31 Nm (23 ft. lb.)
Align chain box with guide and tensioning rails.
Install timing chain box with a new seal.
1. 5.1. Screw in five M8 screws: two M8 x 35 screws with washer (on the dowel sleeves), two M8 x 30 screws with washer, one M8 x 25 external Torx screw.→ Tightening torque: 23 Nm (17 ft. lb.)
Pull timing chain out of the chain slot and secure guide rail to the chain box. Insert short pin at the top (length = 69 mm) -2- with a new sealing ring. → Tightening torque: 31 Nm (23 ft. lb.)

Fig 3: Removing Guide Rail Bearing Pin
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit new O-rings on aluminum sleeves, grease them (with Kluber grease) and insert into the chain box.
Insert a new molded seal into the chain box groove and coat with Kluber grease.
Install camshaft housing.
→ 150319 REMOVING AND INSTALLING CAMSHAFT HOUSING .
1. 9.1. Fit new metal seal and carefully position housing (be careful with the O-rings on the aluminum sleeve).
2. 9.2. Fit 18 screws (M8 x 50), screw in uniformly and tighten in diagonally opposite sequence in two steps from the inside out.
  → Initial tightening: 23 Nm (17 ft. lb.)
  
  → Final tightening: 28 Nm (21 ft. lb.)
Coat fitting bores for bucket tappets with new engine oil.
CAUTION:
Interchanged or dirty bucket tappets.
- Damage to engine components.
→ The components have been run in the fitting bores in the housing, therefore do not interchange them.

→ Absolute cleanliness is essential.
Fit bucket tappets and switchable tappets. Every component (that was already installed) must be refitted at its original position.
Coat camshaft bearing surfaces with new engine oil. When installing bearings for the first time, coat them with acid-free grease (Optimol Optipit, Part No. 000.043.204.17).
Install camshafts.
→ 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .
Install cover for camshaft housing.
→ 159119 REMOVING AND INSTALLING COVER FOR CAMSHAFT HOUSING - GT3 .
Fit spark plugs.
→ Tightening torque: 30 Nm (22 ft. lb.)
Install bar ignition modules. → Tightening torque: 10 Nm (7.5 ft. lb.)
Install solenoid hydraulic camshaft adjustment valves for the intake and outlet side.
Tap four new plastic lids onto the camshaft housing cover using a plastic hammer.
Fit covers on camshaft housing -1 and 3- using three external Torx screws (M6 x 20) -2- on each cover and fit holder for oxygen sensor cables on the top cover.
1. 19.1. The oil pipe is screwed to the bottom cover on side 4-6 with external Torx screws (M6 x 30).
2. 19.2. → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 4: Identifying Camshaft-Housing Cover (Cylinder Bank 4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install vacuum pump -2- .
→ 477619 REMOVING AND INSTALLING VACUUM PUMP .
1. 20.1. Secure oil pipe at the bottom using external Torx screws (M6 x 30).
2. 20.2. → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 5: Locating Camshaft-Housing Cover And Vacuum Pump
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install vacuum line for brake booster.
1. 21.1. Connect the line at the pump by screwing in the M6 external Torx screws -2 and 3- and fit the vacuum hose -1- .
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 6: Identifying Vacuum Line (Cylinder Bank 1-3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 21.2. Secure the holding clamp on the camshaft-housing cover -arrow- .
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 7: Locating Cable Plugs And Ignition Coils (Camshaft-Housing Cover)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 21.3. Fit and tighten M6 external Torx screw -2- on the engine flange.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 8: Identifying Engine/Transmission Flange Vacuum Line Mounting
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install bracket for oil/water heat exchanger.
→ 176719 REMOVING AND INSTALLING BRACKET FOR OIL COOLER .
1. 22.1. Fit four new O-rings on the connecting flanges. Coat O-rings with Kluber grease.
2. 22.2. Apply a uniform bead of sealant (Drei Bond 2210 sealant) to the sealing face -1- for the crankcase. Fit a new seal.
3. 22.3. Position the bracket and slide coolant hoses onto the connection pieces -2- .
4. 22.4. Fit and tighten four new M6 internal Torx screws (coated).
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 9: Identifying Oil Module Sealing Surfaces And Connection Piece
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit new oil filter. Coat O-ring with Kluber grease.
→ Tightening torque: 25 Nm (19 ft. lb.)
Fit oil/water heat exchanger. Coat new O-rings with Kluber grease.
1. 24.1. Fit oil/water heat exchanger with four new O-rings and secure with four M6 external Torx screws.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
Attach the vent line -1- to the oil/water heat exchanger and close the spring band clamp.

Fig 10: Identifying Oil/Water Heat Exchanger Vent Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Position coolant guide housing with oil pump.
1. 26.1. Grease new O-ring and insert driver for oil pump into the Torx splines.
2. 26.2. Fix housing in place on the crankcase with two screws (M10 x 60). These screws must be removed again before fitting the engine carrier.
Secure the coolant hoses to the coolant connection pieces with screw-type clamps.
Install secondary unit carrier.
1. 28.1. Coat coolant hose from the heat exchanger bracket (right side) with Kluber grease and fit to the carrier with a screw-type clamp.
2. 28.2. Insert four external Torx screws (M10 x 60) and tighten only slightly.
Tighten screw-type clamp on connection piece for heat exchanger bracket.
Install coolant pipes -2- .

Fig 11: Identifying Coolant Pipes
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 30.1. Replace O-rings on the (four) new sealing sleeves -3- and grease them.
2. 30.2. Insert sealing sleeve into secondary unit carrier.
3. 30.3. Loosely fit bottom heating tube with pulse sender holder.
4. 30.4. Position top heating tube with coolant pipe and coolant hose. Fix connection piece in place on the crankcase using two M6 external Torx screws. Clip pipe into pulse sender holder.
5. 30.5. Tighten screw-type clamps -1 and 2- on the coolant hoses.
  
  Fig 12: Identifying Coolant Lines Screw-Type Clamps
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 30.6. Fit coolant hoses on bottom heating tube and tighten screw-type clamps -1- .
  
  Fig 13: Identifying Heater And Heat Exchanger Bracket Coolant Connection
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 30.7. Fit right coolant connection piece on the secondary unit carrier. Screw in two external Torx screws only slightly on the crankcase.
Tighten four external Torx screws (M10 x 60) -1- on the secondary unit carrier.
→ Tightening torque: 65 Nm (48 ft. lb.)

Fig 14: Identifying Secondary Unit Carrier Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten M6 external Torx screws on the coolant pipes.
1. 32.1. → Tightening torque: 10 Nm (7.5 ft. lb.)
Tighten screw-type clamps on the heater pipelines.
Secure heater pipes.
1. 34.1. Slide on sliding parts for plastic holder for heater pipes.
  
  Fig 15: Sliding Heater Pipes Holder
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 34.2. Position B+ line and secure holder with two external Torx screws (M6 x 55).
  → Tightening torque: 10 Nm (7.5 ft. lb.)
Secure pulse sender holder to the cylinder head using one external Torx screw (M6 x 12).
→ Tightening torque: 10 Nm (7.5 ft. lb.)
Fit and secure engine wire harness.
1. 36.1. Connect electric connectors for knock sensors, coolant temperature sensor and oil pressure/temperature sensor.
Install the generator.
→ 272219 REMOVING AND INSTALLING GENERATOR .
Secure oil-filter console to holder and oil pipe with two M6 external Torx screws.
1. 38.1. M6 x 16 screw -1- on holder.
  
  Fig 16: Identifying Rear Holder Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  M6 x 12 screw -1- on oil pipe.
  
  Fig 17: Identifying Oil Pipe Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 38.2. → Tightening torque: 10 Nm (7.5 ft. lb.)
Install air-conditioning compressor.
→ 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .
Fit oil line at the crankcase.
1. 40.1. Fit and secure the bottom line using a union nut (a/f 32). Counter at the connection piece (a/f 32).
  → Tightening torque: 60 Nm (44 ft. lb.)
Fit oil return line -1- at suction pump on engine, cylinder bank 4-6.
1. 41.1. Secure union nut (a/f 36) at the oil suction pump connection piece -arrow- and counter at the connection piece.
  → Tightening torque: 60 Nm (44 ft. lb.)
2. 41.2. Secure the holding clamp -2- on the camshaft-housing cover.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 18: Locating Oil Return Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit all cable plugs for the engine wire harness.
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
Fit heat shields -1- for ignition coils using two external Torx screws (M6 x 12) -2- on each.
→ Tightening torque: 10 Nm (7.5 ft. lb.)

Fig 19: Identifying Ignition Coils Heat Shield (Side 4-6)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Place new O-rings on two combination valves for secondary air and fit the valves. Connecting flanges must be facing the flywheel side.
1. 44.1. Coat O-rings with Kluber grease.
2. 44.2. Fit two hexagon socket head bolts (M6 x 20) with a captive washer on each and tighten them.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
3. 44.3. Fit secondary air line by tightening the union nuts.
Fit intake pipe support with new seal and fuel line.
1. 45.1. Fit and tighten 24 external Torx screws (M6 x 20).
2. 45.2. Secure holding clamp for fuel line to the oil-filter console with an external Torx screw (M6 x 12).
3. 45.3. → Tightening torque: 10 Nm (7.5 ft. lb.)
Fit and position intake manifold in rubber support for intake pipe support.
→ 244620 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .
Tighten screw-type clamps for the intake manifold.
→ Tightening torque: 3 Nm (2 ft. lb.)
Connect cable plug for electronic accelerator.
Connect cable plug -1- for secondary-air pump and fit hose -3- on pump. Then close the spring band clamp -2- .

Fig 20: Identifying Secondary Air Line And Cable Plug
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil tank. Fit and tighten three M8 threaded connections.
→ 175219 REMOVING AND INSTALLING OIL TANK .

→ Tightening torque: 23 Nm (17 ft. lb.)
Fit oil lines at the oil tank.→ Tightening torque: 60 Nm (44 ft. lb.)
1. 51.1. Connect cable plug -1- for oil-level sender.
2. 51.2. Fit and tighten union nuts (a/f 32) -2- . Counter at the oil tank connection piece -3- when doing so.
  
  Fig 21: Identifying Oil Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 51.3. Fit hose assembly -1, 3, 4- at the oil tank and close spring band clamps.
  
  Fig 22: Identifying Oil Tank Connections (Rear)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT .
Unscrew screws (M10 x 60) used to secure the coolant guide module.
Fit engine carrier and holder for rear silencer.
→ 103019 REMOVING AND INSTALLING ENGINE CARRIER .
1. 54.1. Screw in and tighten four M10
  Torx screws uniformly. → Tightening torque: 65 Nm (48 ft. lb.)
Install front and rear silencers.
→ 262519 REMOVING AND INSTALLING FRONT SILENCER - GT3 .

→ 263319 REMOVING AND INSTALLING REAR SILENCER - GT3 .