Converting Reconditioned Engine

Information 

Tightening torques, tightening sequence and assembly overviews for the engine and transmission:

• Group 1: →  1X00IN TECHNICAL VALUES 
• Group 2: →  2X00IN TECHNICAL VALUES 
• Group 3: →  3X00IN TECHNICAL VALUES 

Information 

• All components listed must be removed from the old engine and installed on the new engine  .
• Replace seals and O-rings  .
• Replace aluminum screws and torque angle-tightened screws  .

1. Convert engine carrier. → 103019 REMOVING AND INSTALLING ENGINE CARRIER 
2. Convert pressure pipes -1-  .
   1. 2.1. Release retaining clip -2-  and pull it off the turbocharger -3-  .
   2. 2.2. Loosen clamp -4-  and pull change-over valve -5-  off the intake manifold -6-  .
   3. 2.3. Remove pressure pipe -1-  with change-over valve -5-  .
      Fig 1: Identifying Engine Pressure Pipes

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit new intake pipes on new engine.
   1. 3.1. Replace intake pipes -1-  after loosening the screw-type clamp -arrow-  securing intake pipe to turbocharger.
   2. 3.2. Release positive crankcase ventilation line -2-  and pull it off the intake pipe.
   3. 3.3. Release tank vent line -3-  and pull it off.
   4. 3.4. Loosen clamp -4-  and pull off line -5-  .
      Fig 2: Identifying Intake Pipe, Tank Vent Line And Clamp

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Convert coolant hoses.
   1. 4.1. Loosen clamps -arrows-  and pull off coolant hoses -1-  and -2-  .
   2. 4.2. Collect emerging coolant.
      Fig 3: Locating Coolant Regulator Housing Coolant Hoses

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Convert secondary air valves with lines.
   1. 5.1. Unscrew screws -1-  securing secondary air line to cylinder head.
   2. 5.2. Unscrew screws -2-  on holder -3-  securing secondary air valve to cylinder head.
   3. 5.3. Unscrew screw -4-  securing secondary air line -5-  to coolant distributor -6-  .
   4. 5.4. Loosen clamp -arrow-  using spring band clamp pliers WE 1648  and pull off secondary air hose -7-  .
      Fig 4: Identifying Engine Secondary Air Lines

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Convert secondary-air pump. → 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP
7. Convert drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
8. Convert drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
9. Convert hydraulic pump with PDCC lines. → 489819 REMOVING AND INSTALLING HYDRAULIC PUMP
10. Convert air-conditioning compressor. → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR
11. Convert the generator. → 272219 REMOVING AND INSTALLING GENERATOR