Assembling Engine

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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)

Fit all threaded connections according to instructions in the document → 1X00IN TIGHTENING TORQUES FOR ENGINE MA170 AND MA170 S .

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 UNITS AND WORKING ON THE ENGINE 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.
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).
Fit new bearing shells on the crankcase halves. The following markings ensure correct allocation.
1. 2.1. Crankcase half 4-6: Markings on 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 1-7- (number 7 is at the flywheel side) .
  1. G - Bearing shell, Yellow
  2. R - Bearing shell, Red
  3. B - Bearing shell, Blue
    
    Fig 1: Identifying Bearing Shell Allocation Marking On Crankshaft
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Crankcase 1-3: Markings on crankcase half.
  The series of letters -1- 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 2: Identifying Crankcase Half Marking (1-3)
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 2.3. There are also different types of bearing shells.
  1. Partial-groove bearing shell for oil supply to main bearings 2, 4 and 6
  2. Smooth bearing shell
    
    Fig 3: Identifying Crankcase Bearing Shells
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 2.4. Fit and grease new O-ring on the crankcase sealing face.
Insert two thrust washers -1- on the main bearing. The oil grooves must be facing outwards →

Fig 4: Identifying Crankshaft Thrust Washer
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 5: Identifying Thrust Washer Oil Grooves Position
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.
Install tensioning rail for oil-pump drive chain in crankcase 4-6.
1. Rail
2. Tensioning spring
  
  Fig 6: Identifying Oil-Pump Timing Chain Tensioning Rail
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 4.1. Fit tensioning rail -1- using a short bearing pin.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 7: Identifying Oil-Pump Drive Tensioning Rail (Crankcase)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Position of bearing pin -4- on tensioning rail for oil-pump drive chain.
  
  Fig 8: Identifying Cylinder Bank Bearing Pins (4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2- .
→ Tightening torque: 10 Nm (7.5 ft. lb.)
1. 5.1. Place spring -2- on tensioning rail -1- for oil-pump drive chain into the cut-out in the guide rail -3- .
  
  Fig 9: Identifying Position Of Tensioning Spring In Guide Rail
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Insert crankshaft with timing chains -2 + 3- .
1. 6.1. Engage oil pump gear -1- in the drive chain.
  
  Fig 10: Inserting Crankshaft Into Crankcase Half (4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fix crankshaft in place using special tool holding bridge 9779 -1- .
1. 7.1. Fit and tighten two fastening screws hand-tight.
  
  Fig 11: Identifying Crankshaft Holding Bridge (9779)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install pistons on cylinder bank 4-6 and connecting rods 1-3.
→ 131020 REMOVING AND INSTALLING PISTONS - TURBO .
Fit 14 through-bolt screws (E14, M10 x 195) -1- with new sealing washers -3- .
1. 9.1. Fit protective sleeve 9786 -2- over the screw thread. Slide sealing washer onto the screw. Remove protective sleeve.
  
  Fig 12: Identifying Through-Bolt Screw, 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.
Apply sealing compound to crankcase half 4-6. Observe processing instructions.
1. 10.1. Use Dobotech sealing compound (Part No. 000.043.207.31)!
2. 10.2. Carefully apply a continuous bead of sealant -arrow 1- with a diameter of 1 mm. Follow sealant contour as shown in illustration.
3. 10.3. 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.
Fit rubber sleeves on connecting rods 1-3 (assembly aid 9795 ) -1- and position vertically.

Fig 14: Identifying Connecting Rods With Assembly Aid (9795 Rubber Sleeves)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 11.1. The restraining straps P221 -1- can be used if necessary. Since only two connecting rods can be fixed in place in this case, the third connecting rod -2- must be held when positioning the crankcase half.
  
  Fig 15: Identifying Connecting Rods With Restraining Strap (P221)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check guide rail -1- for the oil-pump drive chain on crankcase half 1-3.

Fig 16: Identifying Oil-Pump Drive Chain Guide Rail
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 12.1. Replace guide rail -1- in the event of visible or obvious damage. This can be unclipped and clipped in again -arrows- .
  
  Fig 17: Removing Oil-Pump Drive Chain Guide Rail
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
- Get another person to help you join crankcase halves 1-3.
With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
Fit 14 through-bolt screws and tighten according to the specified tightening torque and sequence.
1. 14.1. → Initial tightening: 5 Nm (3.5 ft. lb.)
2. 14.2. → Initial tightening: 12 Nm (9 ft. lb.)
3. 14.3. → Tightening torque: 15 Nm (11 ft. lb.)
4. 14.4. → Torque angle: 75°
5. 14.5. → Final tightening - torque angle: 75°
  
  Fig 18: Crankcase Through-Bolt Screws Tightening Sequence
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1-14 - External Torx screw M10 x 1.5 x 195 with sealing washer
Fit 19 external Torx screws (E10 and E12) for the outer cross bolt connection and tighten according to the specified tightening sequence.
1. 15.1. Three M8 x 35 screws, item -15, 16, 17- .→ Initial tightening: 5 Nm (3.5 ft. lb.)
  → Torque angle: 70°
2. 15.2. One M8 x 120 screw, item -33- .
  → Tightening torque: 33 Nm (24 ft. lb.)
3. 15.3. 15 screws - one M6 x 40 -18- , 14 M6 x 25 -19-32- .
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 19: Outer Cross Bolt Connection Tightening Sequence
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit and tighten two mounting parts 9590 for bolting crankcase half 1-3 to the engine support.
Install pistons for cylinder bank 1-3.
→ 131020 REMOVING AND INSTALLING PISTONS - TURBO .
Turn the crankshaft clockwise a number of times at the flange 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 TDC position.
Fit crankshaft sealing rings at the flywheel and drive side.
→ 135919 REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE - TURBO .

→ 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING - BELT SIDE .
Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3- .

Fig 20: Identifying Cylinder Bank Bearing Pins (4-6)
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 a long bearing pin -1- .
  
  Fig 21: Identifying Cylinder Bank Bearing Pins (1-3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ft. lb.) .
Fit the oil guide (oil plate) -1- using six external Torx screws M6 x 20 -2- .
→ Tightening torque: 13 Nm (9.5 ft. lb.)

Fig 22: Identifying Crankcase Oil Guide (Oil Plate)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install oil pump.
→ 172019 REMOVING AND INSTALLING OIL PUMP .
Install coolant pipe -1- for the coolant pump.
1. 23.1. Fit and tighten two external Torx screws (E10, M6 x 12) -2- .
  → Tightening torque: 13 Nm (9.5 ft. lb.)
  
  Fig 23: Identifying Coolant Pump And Pipe
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install upper part of oil pan.
→ 175019 REMOVING AND INSTALLING OIL PAN .
Install oil lines in the oil pan.
1. 25.1. Install supply line -5- by screwing in and tightening three external Torx screws (E10, M6 x 16) -2- .
2. 25.2. Fit return lines -1 and 3- for the turbocharger by screwing in and tightening two external Torx screws (E10) M6 x 16 -2- and one (E10) M6 x 12 on each -4- .
  
  Fig 24: Identifying Oil Lines
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install lower part of oil pan.
→ 175019 REMOVING AND INSTALLING OIL PAN .
Insert 12 displacement bodies -1- on cylinder bank 1-3.

Fig 25: Locating Piston Marking And Displacement Bodies (Cylinder Bank 1-3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information
- Always guide timing chains with your hand when turning the crankshaft.
Fit cylinder head 1-3 and 4-6.
→ 157019 REMOVING AND INSTALLING CYLINDER HEAD .
Pull timing chain 1-3 out of the chain slot and fit oil supply valve for vacuum pump -1- on the cylinder head with a new O-ring -2- . Engage timing chain at the valve.

Fig 26: Identifying Vacuum Pump Oil Supply Valve (Brake Booster)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Hold the tensioning rail for cylinders 1-3 -1- using a pair of flat-nosed pliers -3- and use a socket-wrench insert -4- to screw in the bearing pin -2- .

Fig 27: Holding Tensioning Rail
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 30.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
2. 30.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ft. lb.) .
Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
1. Tensioning rail with tensioning spring
2. Guide rail
  
  Fig 28: Identifying Oil-Pump Drive Chain And Guide Rail
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install solenoid hydraulic valves with new O-rings for camshaft control.
1. 32.1. Tighten two external Torx screws (E8) M5 x 12 on each valve.
  → Tightening torque: 8 Nm (6 ft. lb.)
Install camshafts.
→ 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .
Install cylinder head cover.
→ 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - TURBO .
Fit cover for positive crankcase ventilation. Replace seals.
1. 35.1. Fit cover for cylinder bank 1-3 -1- with new seals -2 + 3- and secure with three external Torx screws M6 x 20 -4- .
  
  Fig 29: Installing Positive Crankcase Ventilation Cover (1-3)
  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 two external Torx screws M6 x 20 -3- .
  
  Fig 30: Installing Positive Crankcase Ventilation Cover (4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit spark plugs.
→ 287020 REMOVING AND INSTALLING SPARK PLUGS - TURBO .
Install bar ignition modules.
→ 282019 REMOVING AND INSTALLING BAR IGNITION MODULE - TURBO .