Subsequent Work

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Position engine to the compression TDC of cylinder 1.
Arrow - Crankshaft/vibration balancer marking

Fig 1: Locating Pulley And Housing Cover TDC Marking
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Install cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI ENGINES

Fig 2: Identifying Cylinder Head Numbers
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1-6 - Pistons of cylinders 1 - 6

1-20 - Tightening sequence for cylinder-head screws → Initial tightening: 15 Nm (11 ft. lb.) → Tightening Torque: 30 Nm (22 ft. lb.) → Torque angle: 180°
1. 2.1. Thoroughly clean all sealing faces before assembly.
2. 2.2. Cylinder head gasket must always be replaced .
3. 2.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
  1. 2.3.1. Tighten cylinder-head screws to an initial Tightening Torque of 15 Nm (11 ft. lb.).
  2. 2.3.2. Tighten cylinder-head screws to 30 Nm (22 ft. lb.).
  3. 2.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ft. lb.).
  4. 2.3.4. And finally, tighten cylinder-head screws to a torque angle of 180°.
Fit timing chains. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY DRIVE MECHANISM)

Fig 3: Overview Of Timing Chains
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1. Timing Chain Housing
2. Oval-Head Screw On Timing Chain Housing → Tightening Torque: 8 Nm (6 ft. lb.)
3. Timing Chain
4. Outlet Camshaft Controller (Marking 32 A)
5. Sealing Ring
6. Oil Pump
7. Fastening Screw On Oil Pump → Tightening Torque: 8 Nm (6 ft. lb.)
8. Tensioning Rail
9. Chain Tensioner On Timing Chain → Tightening Torque: 40 Nm (30 ft. lb.)
10. Sealing Ring (A22 x 27), Always Replace
11. Bearing Pin On Guide Rail → Tightening Torque: 10 Nm (7.5 ft. lb.)
12. Sprocket
13. Drive Wheel For Timing Chain
14. Hexagon-Head Bolt → Initial Tightening: 60 Nm (44 ft. lb.) → Torque Angle: 90°
15. Chain Tensioner For Drive Chain
16. Drive Gear Wheel For Drive Chain
17. Drive Chain
18. Guide Rail For Drive Chain
19. Bolt For Guide Rail → Tightening Torque: 10 Nm (7.5 ft. lb.)
20. Fastening Screw On Guide Rail → Tightening Torque: 20 Nm (15 ft. lb.)
21. Hexagon-Head Bolt On Guide Rail → Tightening Torque: 23 Nm (17 ft. lb.)
22. Hexagon-Head Bolts On Camshaft Controllers → Initial Tightening: 60 Nm (44 ft. lb.) → Torque Angle: 90°
23. Guide Rail For Timing Chain
24. Drive Gear Wheel For High-Pressure Pump
25. Intake Camshaft Controller (Marking 24 E)
26. Valve For Outlet Camshaft Controller
27. Valve For Intake Camshaft Controller
28. Guide Rail
1. 3.1. Install chain tensioner. → 153619 REMOVING AND INSTALLING CHAIN TENSIONER
2. 3.2. Install camshaft controllers. → 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER ON V6 DFI ENGINES
Check the timing. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES
Fit upper and lower timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER ON V6 DFI ENGINES
1. 5.1. Fit lower timing-case cover.
  
  Fig 4: Identifying Cylinder Block And Vibration Balancer Joint Flange
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Cylinder Block
  2. Vibration Balancer Joint Flange
  3. Hexagon-Head Bolt On Vibration Balancer Joint Flange
  4. Straight Pin, M8 x 18
  5. Lower Timing-Case Cover
  6. Hexagon-Head Bolt On Lower Timing-Case Cover → Tightening Torque: 10 Nm (7.5 ft. lb.)
2. 5.2. Fit upper timing-case cover.
  
  Fig 5: Identifying Vacuum Pump Components
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Drive Shaft
  2. Upper Timing-Case Cover
  3. Oval-Head Screw → Tightening Torque: 8 Nm (6 ft. lb.)
  4. Oval-Head Screw On Vacuum Pump → Tightening Torque: 8 Nm (6 ft. lb.)
  5. Housing
  6. Seal
  7. Sealing Ring
Install oil pan. → 175019 REMOVING AND INSTALLING OIL PAN ON V6 DFI ENGINES

Fig 6: Oil Pan Bolt Tightening Sequence
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1-25 - Hexagon-head bolts on oil pan → Tightening Torque: 12 Nm (9 ft. lb.)
Install cylinder head cover. → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER ON V6 DFI ENGINES

Fig 7: Identifying Cylinder Head Cover And Valve Cover Seal
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Cylinder head cover
2. Cylinder head gasket
3. Fastening screw on cylinder head cover → Tightening Torque: 10 Nm (7.5 ft. lb.)
4. Cap
Install fuel distributor pipe and fuel injectors. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) ON DFI ENGINES

Fig 8: Identifying Fuel Distributor Pipe And Fuel Injectors
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Fuel Low-Pressure Line → Tightening Torque: 22 Nm (16 ft. lb.) → Tightening Torque: 35 Nm (26 ft. lb.)
2. Cheese Head Bolts On Fuel Distributor Pipe → Initial Tightening: 30 Nm (22 ft. lb.) → Torque Angle: 90°
3. Fuel Injectors
Install intake-air distributor. → 244619 REMOVING AND INSTALLING DFI INTAKE-AIR DISTRIBUTOR
Install guide tube for oil dipstick. Sealing ring must always be replaced . → 171719 REMOVING AND INSTALLING GUIDE TUBE FOR OIL DIPSTICK ON DFI ENGINES
Install bar ignition modules. → 282020 REMOVING AND INSTALLING DFI BAR IGNITION MODULES

Fig 9: Identifying Bar Ignition Modules And Clips
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1. Connectors For Bar Ignition Modules
2. Retaining Clips
3. Engine Wire Harness
Fit engine wire harness. → INSTALLING WIRE HARNESS FOR ENGINE
Remove engine from the mounting bracket.
Mount the transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
Install the engine.
Perform a test drive and check for leaks and correct function.
1. 16.1. Clean the engine and carry out a thorough check for leaks after the test drive.