Subsequent Work: Notes

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Information

If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must be uniformly at least → Temperature: 17°C .

Information

Detailed instructions for installing pistons must be observed at all times .
The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the same side .

Fig 1: Locating Connecting Rods Cast Lugs And Pistons
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Install pistons. → 131019 REMOVING AND INSTALLING PISTONS ON V6 DFI ENGINES
1. 1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool Funnel T10333 can be positioned flat on the cylinder block.
2. 1.2. Oil the piston well and insert it into the funnel.
3. 1.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle of the cylinder block and the arrows -3- on the pistons are facing the vibration damper.
4. 1.4. Position the piston funnel on the cylinder block and align it so that the high edge -arrow- is facing the middle of the cylinder block.
5. 1.5. Slide piston fully into the cylinder bore.
  1. 1.5.1. Turn the crankshaft back and forth if necessary.
6. 1.6. Insert dowel sleeves back into the bore holes -arrow- .
7. 1.7. Oil connecting-rod bearing shells -5- .
  Information
  - Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers .
  - The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C- . The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides .
    
    Fig 2: Identifying Connecting-Rod And Cap Alignment
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them .
8. 1.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
9. 1.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until they are seated correctly so that the Tightening Torque will be accurate.
10. 1.10. Tighten all connecting rod bearing screws -7- to the specified Tightening Torque.
11. 1.11. Turn the crankshaft several times to check that it turns smoothly.
12. 1.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
  
  Fig 3: Overview Of Piston And Connecting Rod
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Piston Rings (Move Gap By 120°)
  2. Piston
  3. Circlip
  4. Bearing Shells Must Always Be Replaced . Observe Relevant Classification.
  5. Con-Rod Bearings
  6. Connecting Rod Bearing Cap
  7. Connecting Rod Bolts → Initial Tightening: 30 Nm (22 ft. lb.) → Torque Angle: 90°
  8. Cylinder Block
  9. Piston Pin
  Arrow - Dowel pin
  
  Fig 4: Locating Cylinder Block Dowel Sleeve
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 5: Identifying Pistons Installation Position (V6 DFI Engine)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Valve Recesses On Cylinders 1, 3 And 5
  2. Valve Recesses On Cylinders 2, 4 And 6
  3. Arrow Pointing Towards Vibration Balancer
  Fig 6: Locating Cylinder Block Piston Funnel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Arrow - Setting of gap on drive plate for inductive pickup (speed sender)
  
  Fig 7: Locating Drive Plate Gap
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit joint flange for vibration balancer. → 137419 REMOVING AND INSTALLING SEALING RING FOR VIBRATION BALANCER ON DFI ENGINES
1. 2.1. Apply 2-mm thick bead of sealant -arrows- .
2. 2.2. Assembly Tool T10215 (guide sleeve) -1- must be fitted on the crank pin -3- to prevent damage to the vibration balancer joint flange.
3. 2.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.
4. 2.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
  
  Fig 8: Identifying Crankshaft Joint Flange And Cylinder Block
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Cylinder Block
  2. Vibration Balancer Joint Flange
  3. Hexagon-Head Bolt On Vibration Balancer Joint Flange → Tightening Torque: 10 Nm (7.5 ft. lb.)
  4. Straight Pin, M8 x 18
  5. Lower Timing-Case Cover
  6. Hexagon-Head Bolt On Lower Timing-Case Cover → Tightening Torque: 8 Nm (6 ft. lb.)
  Fig 9: Applying Sealant To Joint Flange
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Assembly Tool (Guide Sleeve)
  2. Vibration Balancer Joint Flange
  3. Crankshaft Flange
  Fig 10: Identifying Front Crankshaft Joint Flange
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit vibration balancer for crankshaft. → 137619 REMOVING AND INSTALLING VIBRATION BALANCER (CRANKSHAFT PULLEY) ON V6 DFI ENGINES
1. 3.1. Tighten hexagon-head bolt on crankshaft vibration balancer → Initial tightening: 100 Nm (74 ft. lb.) → Torque angle: 180° .
  
  Fig 11: Tightening Crankshaft Vibration Balancer Bolt
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Position engine to the compression TDC of cylinder 1.
Arrow - Crankshaft/vibration balancer marking

Fig 12: Locating Pulley And Housing Cover TDC Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
If the oil retaining valve was removed during removal, fit a New sealing ring on the oil retaining valve before inserting it into the crankcase -arrow- .
Arrow - Oil retaining valve

Fig 13: Identifying Oil Retaining Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI ENGINES
1. 6.1. Thoroughly clean all sealing faces before assembly.
2. 6.2. Cylinder head gasket Must Always Be Replaced .
3. 6.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
  1. 6.3.1. Tighten cylinder-head screws to an initial Tightening Torque of 15 Nm (11 ft. lb.).
  2. 6.3.2. Tighten cylinder-head screws to 30 Nm (22 ft. lb.).
  3. 6.3.3. Then tighten all cylinder-head screws a Second Time to 30 Nm (22 ft. lb.).
  4. 6.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
    
    Fig 14: Identifying Cylinder-Head Screw Tightening Sequence
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    
    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°
Fit timing chains. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY DRIVE MECHANISM)
1. 7.1. Install timing chain housing.
2. 7.2. Install chain tensioner. → 153619 REMOVING AND INSTALLING CHAIN TENSIONER
3. 7.3. Install camshaft controllers. → 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER ON V6 DFI ENGINES
  
  Fig 15: Overview Of Timing Chains
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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
  Fig 16: Identifying Timing Chain Housing Bolts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Cheese head bolt → Tightening Torque: 8 Nm (6 ft. lb.)
  2. Timing chain housing
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. 9.1. Fit lower timing-case cover.
2. 9.2. Fit upper timing-case cover.
  
  Fig 17: Identifying Cylinder Block And Crankshaft 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.)
  Fig 18: 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
  Information