Assembling V8 4.8-Litre DFI Engine As Of October 2008

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

CAUTION: Heavy components

Risk of squashing

→ Wear personal protective gear.

→ Get someone to help if necessary.

CAUTION: Leaks due to components being at too low a temperature or at different temperatures!

If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.

→ Components must have reached at least 17°C throughout.

→ Components must not be too hot (distortion).

→ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.

CAUTION: Emerging residual fluid can soil the engine!

Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.

→ Place a drip tray under the engine at the assembly support.

→ Have a sufficient number of cleaning cloths ready.

→ Close off engine openings with plugs.

Information

Connecting rod bolts must always be replaced.

Information

All tightening torques, tightening sequences and assembly overviews are published in the corresponding document. → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS FOR V8 4.8-LITRE DFI NATURALLY ASPIRATED AND TURBO ENGINES
Many details are provided in the corresponding individual repair instructions.

Place crankshaft bearing shells into the lower part of the crankcase.
Information
- The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour marking must match the corresponding letter on the flywheel flange of the crankshaft. -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct colour classification of the bearing shell .
  
  Fig 1: Locating Color Marking On Bearing Shell
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9- . Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The letters are the abbreviations for the colour code of the bearing shells (G for yellow , B for blue , R for red , N for green ). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells should all have a yellow marking in this case.
  
  Fig 2: Exploded View Of Crankshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Crankshaft (stroke: 83 mm)
  2. Straight pin, 6 x 20
  3. Spring, 5 x 6.5
  4. Thrust washer
  5. Main bearing shell, upper
  6. Main bearing shell, lower
  7. Shaft seal
  8. View of crankshaft flange
  9. Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGGG-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A
2. 1.2. Place crankshaft bearing shells with lubricating groove and bore -2- into the upper part of the crankcase -1- . Smooth crankshaft bearing shells -3- belong in the lower part of the crankcase. Insert the thrust washers into the centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
  
  Fig 3: Identifying Bearing Shells And Lubricating Grooves
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 4: Inserting Bearing Shells
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 5: Identifying Thrust Washer
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.
If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
1. 2.1. Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.
2. 2.2. Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.
3. 2.3. Fit knock sensors correctly.
  
  Fig 6: Exploded View Of Knock Sensors
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Knock sensor
  2. Screw, M8 x 35 → Tightening torque: 23 Nm (17 ft lbs.)
4. 2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2-
  
  Fig 7: Identifying Seals Between Crankcase And Thermostat Housing
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check coolant guide housing (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals on left and right -10- , screw in screws securely on metal seals by hand. Move coolant guide housing at upper part of crankcase into installation position and fit it -9- .

Fig 8: Exploded View Of Coolant Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Coolant pipe
2. Coolant sensor → Tightening torque: 30 Nm (22 ft lbs.)
3. Screw, M6 x 16 → Tightening torque: 12 Nm (9 ft lbs.)
4. Screw, M6 x 12
5. Holding clamp
6. Sealing ring
7. Screw plug, M16 x 1.5 → Tightening torque: 30 Nm (22 ft lbs.)
8. Screw, M6 x 25 → Tightening torque: 12 Nm (9 ft lbs.)
9. Collection pipe
10. Distributor pipe seal
11. Cap
If you have not already done so, insert three screw plugs for the coolant guide housing with sealing ring and fit them (two in direction of transmission and one on the side close to cyl. 8).
Place dowel sleeves into upper part of crankcase if necessary and drive in using a copper or plastic hammer. When doing so, make sure that the dowel sleeves do not tilt. Fit two large dowel sleeves into the upper part of the crankcase on the flywheel side. Fit four large dowel sleeves into the upper part of the crankcase on the cylinder head side (two dowel sleeves for cylinder bank 1 to 4 and two dowel sleeves for cylinder bank 5 to 8). Fit two small dowel sleeves at the upper part of the crankcase on the thermostat housing side. Fit one small dowel sleeve at the lower part of the crankcase on the timing chain side (cyl. 5).

Fig 9: Exploded View Of Upper Part Of Crankcase
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Upper part of crankcase
2. Cap
3. Sealing ring
4. Screw plug on upper part of crankcase
5. Dowel sleeve
6. Oil spray jet
7. Screw, M6 x 16
Pre-fit spring wedge into the corresponding groove of the crankshaft using a plastic hammer. -3-
Information
- The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
- When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
- The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
- The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
- When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
- Naturally aspirated engines and turbo engines have different pistons.
  
  Fig 10: Identifying Connecting Rod Code And Direction Of Travel Arrow
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side . -A-
  NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
  
  Fig 11: Identifying Connecting Rod Code - A
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. To do this, perform the following steps.

Fig 12: Exploded View Of Piston, Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Piston-ring set
2. Pistons
3. Circlip/piston-pin circlip
4. Piston pins
5. Connecting rods
6. Connecting rod bolt; replace as it must be tightened in the plastic area
7. Connecting-rod bearing shells
  
  Fig 13: Locating Connecting-Rod Assembly, Bearing Shells
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. View A (identification area for connecting-rod number; fit connecting rod with identification area facing exhaust side; markings on rod and lid must be on the same side)
2. View B (fit bearing shells flush and press into position)
3. View C (fit bearing shells flush and press into position)
  
  Fig 14: Identifying Piston Classification
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Mahle control stamp
  2. Arrow marking in direction of travel
  3. Porsche short numeric code without main or middle number
  4. Cylinder bank identification
  5. Marking area for weight group
  6. Marking area for dimension group
  7. Barcode 128 (short numeric code (without main group) and weight group)
  8. Direction of travel arrow
  9. Mahle short numeric code
1. 7.1. Select the pistons based on cylinder bank and pre-fit a piston-pin circlip. One end of the piston-pin circlip is inserted into the ring groove of the piston pin eye -1- . Press the other end into the ring groove with your thumb. -finger- The opening of the piston-pin circlip is pointing to 6 or 11 o'clock.
  
  Fig 15: Inserting Piston-Pin Circlip Into Ring Groove
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Lever the piston-pin circlip into the ring groove using a small screwdriver while continuing to press it down. → see Fig 16
  
  Fig 16: Inserting Piston-Pin Circlip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. If the piston-pin circlip does not slide into the ring groove right away, press the other end of the piston-pin circlip into the ring groove -arrow- . Check that the circlip is seated correctly.
  
  Fig 17: Pressing Piston-Pin Circlip Into Ring Groove
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
  - When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
  - The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
  - The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
  - When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank .
  - Naturally aspirated engines and turbo engines have different pistons .
    
    Fig 18: Identifying Connecting Rod Code And Direction Of Travel Arrow
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side . -A-
    NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
    
    Fig 19: Identifying Connecting Rod Code - A
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 7.4. Turn piston and move connecting rod to the correct installation position. Insert connecting rod into piston.
  
  Fig 20: Identifying Piston On Retaining Device
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 7.5. Oil piston pin and all contact points.
6. 7.6. Fit piston pin using plunger 9500/8 and fit second piston-pin circlip. Check for smooth operation.
  
  Fig 21: Inserting Piston Pin Using Plunger
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 7.7. Place piston, with the connecting rod fitted, on a soft surface. Do not use the vice to secure the connecting rod.
8. 7.8. When fitting piston rings, the oil scraper ring is fitted first.
9. 7.9. Carefully insert inner spring into the lower groove by hand, keeping it away from the piston crown.
10. 7.10. Insert oil scraper ring over the inner spring into the groove by hand. "TOP" marking on piston rings must always be facing upwards to the piston crown. Spread piston rings just far enough for them to fit over the piston. Avoid straining the piston rings as this will result in permanent deformation of the piston ring.
11. 7.11. Select both compression rings based on the height of the corresponding piston ring groove and install with the "TOP" marking facing the piston crown.
12. 7.12. Clamp the piston ring gap using piston ring pliers or by hand and insert into the appropriate piston ring groove.
  
  Fig 22: Piston Ring Gap Using Piston Ring Pliers
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. 7.13. Twist piston ring gaps so that they are offset with respect to each other by 120°.
14. 7.14. Oil piston rings and set down the assembly-ready piston. Fit remaining pistons and connecting rods in the same way.
  Information
  - The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
  - When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
  - The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
  - The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code . -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
  - When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
  - Naturally aspirated engines and turbo engines have different pistons.
    
    Fig 23: Identifying Connecting Rod Code And Direction Of Travel Arrow
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side . -A-
    NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
    
    Fig 24: Identifying Connecting Rod Code - A
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. 7.15. Select connecting-rod bearing shells based on the marking on the crankshaft flywheel flange and insert into the connecting-rod big end and the connecting rod cap according to the twist lock. Fit connecting rod bearing cap onto the connecting-rod big end again hand-tight.
16. 7.16. Place all eight pistons with the connecting rods fitted on a clean surface, sorted by cylinder.
Grease the seal on the thermostat insert sparingly with Kluber Syntheso GLEP 1 and fit it into the thermostat housing by hand. Press thermostat insert in as far as it will go. For details, see → Installing Coolant Regulator
Check that all the seals are installed in the oil plate.

Fig 25: Exploded View Of Oil Guide (Oil Plate)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
If you have not already done so, drive eight dowel sleeves for the metal seals in the timing-case cover using a copper or plastic hammer. Insert metal seals and press on dowel sleeves.
Oil pump is pre-fitted with the oil pressure control valve.
Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
Move starter into installation position and screw down. → Tightening torque: 45 Nm (33 ft lbs.)+8 Nm (+6 ft lbs.)
Insert oil spray jets into upper part of crankcase and screw down → Tightening torque: 10 Nm (7.5 ft lbs.). To do this, grease the sealing ring sparingly with KluUber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown. →

Fig 26: Identifying Spray Direction
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 27: Identifying Spray Direction From Side
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1- ). Then position the drive pinion of the oil pump chain -2- with respect to the crankcase.

Fig 28: Installing Timing Chain Pinion On Crankshaft Stub
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 29: Identifying Timing Chain Pinion And Diamond Washers
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Fit crankshaft holding bridge holding bridge 9677/1 in the centre of the crankshaft.

Fig 30: Identifying Crankshaft Secured Tool
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Turn upper part of crankcase and oil cylinder liners.
Information
- The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
- When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
- The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
- The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
- When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank .
- Naturally aspirated engines and turbo engines have different pistons.
  
  Fig 31: Identifying Connecting Rod Code And Direction Of Travel Arrow
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side . -A-
  NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
  
  Fig 32: Identifying Connecting Rod Code - A
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tension piston using a commercially available piston ring restraining strap (e.g. Universal piston ring restraining strap Nr.55 ) or assembly funnel funnel 9784/1 and press piston into cylinder. When doing so, make sure that the direction of travel arrow on the piston crown is pointing in the direction of travel and the connecting rod code has been fitted facing the exhaust side. Push the pistons in until the connecting rod bearing is lying on the con-rod journal of the crankshaft. Once all the pistons with connecting rod have been pushed in, fit connecting rod cap evenly and synchronously with the correct bearing shell. Fit with new connecting rod bolt to the prescribed tightening torque. For details, see → WM 131020 REMOVING AND INSTALLING PISTONS ON 4.8-LITRE DFI ENGINES

Fig 33: Exploded View Of Piston And Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Oil piston-ring set with engine oil; TOP marking facing upwards; oil scraper ring down
2. Piston; different on naturally aspirated and turbo engines; combustion chamber recess facing centre of engine; left and right different; direction of travel arrow in direction of travel
3. Piston-pin circlip (positioned at 6 o'clock or 11 o'clock)
4. Piston pin; oil
5. Connecting rod
6. Connecting rod bolt; replace as it must be tightened in the plastic area; oil bolt → Tightening torque: 8 Nm (6 ft lbs.)+2 Nm (+1.5 ft lbs.) → Tightening torque: 20 Nm (15 ft lbs.) → Tightening torque: 40 Nm (30 ft lbs.) → Torque angle: 90°
7. Connecting rod bearing shells; oil with engine oil
  
  Fig 34: Identifying Tensioning Pistons
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 35: Locating Piston Assembly
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 36: Pressing In Pistons
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/08) to the lower part of the crankcase as shown. Insert sealing ring -3- into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.

Fig 37: Identifying Sealant Applying Area
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Wipe off sealant residues after fitting
1. Direction of travel
Tighten M11 and M10 bearing screws to the prescribed torques. -5 and 6-

Fig 38: Tightening Sequence For Thrust-Bearing Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1 bis 20 - Tightening sequence for M11 and M10 screws => Observe different torques!
1. Direction of travel
  
  Fig 39: Exploded View Of Lower Part Of Crankcase
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Lower part of crankcase
2. Straight pin, 6 x 18
3. O-ring
4. Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. → Initial tightening: 30 Nm (22 ft lbs.) → Torque angle: 90°
6. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. → Initial tightening: 22 Nm (16 ft lbs.) → Torque angle: 60°
7. Aluminium screw , M8 x 70; (cross bolt connection); always use new aluminium screws; observe tightening sequence as for steel screws → Initial tightening: 10 Nm (7.5 ft lbs.) and → Final tightening: 90°
8. Screw, M8 x 35 → Tightening torque: 23 Nm (17 ft lbs.)
9. Screw, M8 x 50 → Tightening torque: 23 Nm (17 ft lbs.)
10. Dowel sleeve
1. Direction of travel
Fit cross bolt connection.

Fig 40: Identifying Tightening Sequence For Securing Lower Part Of Crankcase To Upper Part Of Crankcase (Cross Bolt Connection)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit M8 screws on the side -8 and 9- . Remove emerging sealant.
Punch in or imprint the engine number if necessary (when replacing engine).
Move oil plate with all the seals into installation position and secure to the lower part of the crankcase. → Tightening torque: 10 Nm (7.5 ft lbs.)

Fig 41: Exploded View Of Oil Guide (Oil Plate)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grease sealing ring between the oil plate transfer pipe and oil pump sparingly with KluUber Syntheso GLEP 1 and fit oil pump. Secure the oil pump.

Fig 42: Exploded View Of Oil Pump On Naturally Aspirated Engine M48/01
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Oil pump
2. Screw, M8 x 22; replace; 1st turn → Initial tightening: 20 Nm (15 ft lbs.) ; final tightening (torque angle) → Torque angle: 90°
3. Oil pump sprocket
4. Cap screw, M36 x 1.5 x 12 → Tightening torque: 40 Nm (30 ft lbs.)
5. Solenoid valve
6. O-ring (grease before fitting)
7. Dowel sleeve
8. Screw, M6 x 45 → Tightening torque: 13 Nm (9.5 ft lbs.)
9. Sprocket cover
10. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
11. Drive chain
Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion . Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw. 1st turn → Initial tightening: 20 Nm (15 ft lbs.) ; final tightening (torque angle) → Torque angle: 90°

Fig 43: Fitting Oil Pump Sprocket With Oil Pump Chain
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 44: Countering Oil Pump Pinion
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Fit cover plate for oil pump drive using three screws. → Tightening torque: 10 Nm (7.5 ft lbs.)
Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.
Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. see Fig 45, item 8

Fig 45: Exploded View Of Camshafts, Cylinder Bank 1 To 4
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Camshaft (outlet)
2. Camshaft (intake)
3. Hydraulic valve for variable valve lift control
4. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ft lbs.)
5. Switching tappet (oil with engine oil)
6. Bucket tappet (oil with engine oil)
7. Stopper
8. Mounting saddle 1 to 4
9. Stopper
10. Bearing locations (oil with engine oil)
1. Direction of travel
Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.

Fig 46: Exploded View Of Cylinder Head 1 To 4
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Cylinder head 1 to 4
2. Cylinder head gasket 1 to 4
3. Screw, M8 → Tightening torque: 23 Nm (17 ft lbs.)
4. Cap
5. Stopper
6. Stopper
7. Restrictor for valve lift control → Tightening torque: 1.5 Nm (1.0 ft lbs.)
8. Cylinder-head screws => For tightening specifications, see Fig 47
9. Spark plug; when re-installed → Tightening torque: 25 Nm (19 ft lbs.)+3 Nm (+2 ft lbs.) ; if fitting new spark plugs → Tightening torque: 30 Nm (22 ft lbs.)+3 Nm (+2 ft lbs.)
  
  Fig 47: Identifying Tightening Sequence For Cylinder Head
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  1 bis 10 - 1st initial tightening → Tightening torque: 30 Nm (22 ft lbs.) ; 2nd initial tightening → Tightening torque: 50 Nm (37 ft lbs.) ; loosen by 2 turns → Torque angle: 720° ; 1st turn → Tightening torque: 30 Nm (22 ft lbs.) ; 2nd turn → Tightening torque: 30 Nm (22 ft lbs.) ; 3rd turn and final tightening (torque angle) → Torque angle: 110°
Fit front M8 screw of cylinder head 1 to 4. → Tightening torque: 23 Nm (17 ft lbs.)
Make sure that the intake openings have been protected using adhesive tape or something similar to prevent them from becoming dirty.
Insert front camshaft mounting saddles (lower parts) of cylinder heads. Item 8

Fig 48: Exploded View Of Camshafts, Cylinder Bank 1 To 4
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Camshaft (outlet)
2. Camshaft (intake)
3. Hydraulic valve for variable valve lift control
4. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ft lbs.)
5. Switching tappet (oil with engine oil)
6. Bucket tappet (oil with engine oil)
7. Stopper
8. Mounting saddle 1 to 4
9. Stopper
10. Bearing locations (oil with engine oil)
1. Direction of travel
Coat camshaft bearings with normal multipurpose grease or engine oil.
Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). Item 2

Fig 49: Staking Bore 45 Degrees Before TDC
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

A data matrix coding is shown on the staking dihedron of the camshafts. This is a square black/white dotted marking used for electronic identification purposes during the production process. This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts press against the valves the least when the data matrix coding is facing upwards during installation.
Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position housings correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft housings evenly and gradually, and slowly tighten to the specified tightening torque. The camshafts must not be strained or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be used interchangeably because of the bearing locations and length.

Fig 50: Identifying Camshaft Identification On V8 Naturally Aspirated Engine M48/01
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Cylinders 1 to 4
2. Cylinders 5 to 8
1. Outlet camshaft identification (green)
2. Intake camshaft identification (white)
3. Intake camshaft identification (white)
4. Outlet camshaft identification (green)
  
  Fig 51: Identifying Camshaft Housing Identification
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads
1. Matching number for cylinder head/intake camshaft housing, cylinder 1 (E1)
2. Matching number for cylinder head/intake camshaft housing, cylinder 2 (E2)
3. Matching number for cylinder head/intake camshaft housing, cylinder 3 (E3)
4. Matching number for cylinder head/intake camshaft housing, cylinder 4 (E4)
5. Matching number for cylinder head/outlet camshaft housing, cylinder 1 (A1)
6. Matching number for cylinder head/outlet camshaft housing, cylinder 2 (A2)
7. Matching number for cylinder head/outlet camshaft housing, cylinder 3 (A3)
8. Matching number for cylinder head/outlet camshaft housing, cylinder 4 (A4)
Pfeil - Direction of travel

Fig 52: Exploded View Of Camshaft Mount, Cylinders 5 To 8
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Dowel sleeves
2. Housing (intake)
3. Screw, M6 x 70 → Tightening torque: 13 Nm (9.5 ft lbs.)
4. Housing
5. Screw, M6 x 35 → Tightening torque: 13 Nm (9.5 ft lbs.)
6. Housing (outlet)
7. Bearing surfaces (oil with engine oil)
1. Direction of travel
Move both hydraulic valves for camshaft control into installation position and fit them. Item 5

Fig 53: Exploded View Of Camshaft Control
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Screw, M12 Tighten fully after setting timing.
2. Hexagon sleeve
3. Camshaft controller
4. Washer (reusable); replace if disassembled completely
5. Hydraulic valve for camshaft control
6. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ft lbs.)
1. Direction of travel
Insert oil vent line at the firewall side of cylinder 5 and screw it on. Grease sealing ring sparingly with KluUber Syntheso GLEP 1.

Fig 54: Exploded View Of Vent Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Vent line to cylinder head/crankcase/oil pump
2. O-ring
3. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Check valve
1. Direction of travel
Fit threaded peg for tensioning and guide rails. Items 1 and 2

Fig 55: Exploded View Of Timing Chain And Chain Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Threaded peg → Tightening torque: 35 Nm (26 ft lbs.)
2. Threaded peg → Tightening torque: 20 Nm (15 ft lbs.)
3. Guide rail
4. Tensioning rail
5. Chain tensioner with sealing ring
6. Pin (for locking the oil-pump tensioning rail)
1. Direction of travel
Fit guide rail with oil pump chain tensioning rail and pull locking pin (tensioning rail will be released).
Fit "U"-shaped deflection rail item 4.

Fig 56: Exploded View Of Timing Chain And Sprockets
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Double-chain camshaft drive
2. Camshaft sprocket
3. Screw, M12 Tighten fully after setting timing.
4. Deflection rail
5. Screw, M8 x 35 → Tightening torque: 32 Nm (24 ft lbs.)
6. Camshaft-to-camshaft guide pad
1. Direction of travel
Fit tensioning rail and let it hang.
Fit both small guide rail pieces between the camshaft controller and sprocket.
Loosely fit camshaft controller and sprockets using screws (do not forget new diamond washer under the camshaft controllers).
Position timing chain and guide correctly over guide and tensioning rails.
Fill Loctite 5900 (000.043.204.35 status 04/07) first into the opening of the seal for the timing-case cover. Apply sealant as shown in the illustrations. Install the timing-case cover within 5 minutes.

Fig 57: Exploded View Of Timing-Case Cover Seals
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Timing-case cover
2. Timing-case cover seal, outer right (fill openings with sealant, see 6)
3. Timing-case cover seal, inner
4. Timing-case cover seal, rib
5. Timing-case cover seal, outer left (fill openings with sealant, see 6)
6. Applying sealant to timing chain housing; Loctite 5900 (000.043.204.35 status 04/07)
1. Direction of travel
  
  Fig 58: Identifying Sealant Applying Area (Fill Openings In Metal Seal With Sealant)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Move timing-case cover with pre-fitted metal seals into installation position (carefully insert oil vent line, grease sealing ring with KluUber Syntheso GLEP 1 if necessary). When doing so, press the tensioning rail away from the sprocket at the timing chain using a screwdriver (second worker required). Position timing-case cover.
Fit the timing-case cover using four to six screws. Align timing-case cover with the edge of the lower part of the crankcase (realign using plastic hammer if necessary). Fit remaining screws. Check projection again with respect to the lower part of the crankcase and realign if necessary. The timing-case cover can be adjusted using a dial gauge, steel rule or by touch (projection of timing-case cover with respect to the lower part of the crankcase). It should not be possible to feel or measure any projection on either side of the timing-case cover.
Example: Adjusting timing-case cover using a dial gauge
Insert the dial gauge into the universal gauge holder and position it so that the dial gauge has a preload of about 1 mm.

Fig 59: Adjusting Preload
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Set dial gauge scale to 0. To do this, place the dial gauge holder on a completely flat surface (e.g. crankcase) and turn the dial gauge scale until the pointer is at 0.

Fig 60: Setting Dial Gauge Scale To Zero
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Measure offset. In order to do this, push with the holder starting from the lower part of the crankcase towards the timing-case cover (the foot of the dial gauge holder is not located on the same component as the dial gauge probe) and measure the offset. The timing-case cover must not be set back any more than 0.1 mm. A projection is not permissible.

Fig 61: Measuring Offset
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Align the timing-case covers by tapping lightly with a rubber hammer.

Fig 62: Aligning Chain Case Lid
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Then check the position of the timing-case cover again with the dial gauge.

Fig 63: Checking Position Of Timing-Case Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit timing-case cover according to specifications. When doing so, do not forget any of the sheetmetal holders under the screws.

Fig 64: Tightening Sequence For Timing-Case Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Aluminium screw , M6 x 30; timing-case cover to crankcase and cylinder head; always use new aluminium screws; → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
2. Aluminium screw , M6 x 55; inner timing-case cover to upper part of crankcase and cylinder head; always use new aluminium screws; → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90° ; outer timing-case cover to cylinder head → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
3. Aluminium screw , M8 x 55; timing-case cover (chain tensioner position) to upper part of crankcase and cylinder head; always use new aluminium screws; → Initial tightening: 10 Nm (7.5 ft lbs.) and → Final tightening: 90°
4. The timing-case cover must be level with the lower part of the crankcase (use a steel rule or dial gauge)
Fit new joint flange between the vibration damper and timing-case cover. Align joint flange, fit screws and pull plastic sleeve.

Fig 65: Identifying Seal With Plastic Sleeve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 66: Exploded View Of Chain Tensioner And Joint Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer
2. Aluminium screw M6 x 20; always use new aluminium screws; → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
3. Aluminium screw M6 x 55; always use new aluminium screws; → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
4. Sealing ring
5. Chain tensioner → Tightening torque: 60 Nm (44 ft lbs.)
Turn the engine around. Oil pump is upright.
Lay sealing ring in the lower part of the crankcase.
Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.

Fig 67: Applying Sealant To Oil Guide Housing
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Seal application (geometry, 1-mm bead of sealant)
2. Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
1. Direction of travel
Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the timing-case cover (using a dial gauge, etc.).
Screw down oil guide housing. Tighten all screws evenly crosswise. see item 6 Do not forget screws between the oil guide housing and timing-case cover (four screws behind front vibration balancer, bores are currently overhead).

Fig 68: Exploded View Of Oil Guide Housing With Accessories
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Guide tube
2. O-ring
3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Oil dipstick
5. O-ring
6. Timing-case cover to oil guide housing Aluminium screw ; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90° ; oil-level sensor to oil guide housing (steel screw) → Tightening torque: 12 Nm (9 ft lbs.) ; oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
7. Oil level sensor
8. O-ring
9. Joint flange
10. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.)
11. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Direction of travel
Equip intake manifold oil strainer with sealing ring and then fit it. Tighten all oil pipes. Replace sealing rings.

Fig 69: Exploded View Of Oil Lines On Naturally Aspirated Engine (M48/01)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Intake pipe on oil pump
2. O-ring
3. Oil pressure pipe
4. O-ring
5. O-ring
6. Oil regulating line
7. O-ring
8. O-ring
9. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.) ; oil control line to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.)
10. Screw, M6 x 20 → Tightening torque: 12 Nm (9 ft lbs.)
  
  Fig 70: Identifying Oil Lines, Intake Pipe On Naturally Aspirated Engine M48/01
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Mount for oil pump intake manifold
2. Mount for oil separator vent line, cylinders 5 to 8
3. Mount for oil pressure pipe
4. Mount for oil regulating line
Push joint flange of the oil pressure control valve through the side oil pan opening via the oil pressure control valve and secure using two screws. Item 10 Fit oil level sensor (turn carefully when inserting) item 7

Fig 71: Exploded View Of Oil Guide Housing With Accessories
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Guide tube
2. O-ring
3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Oil dipstick
5. O-ring
6. Timing-case cover to oil guide housing Aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90° ; oil-level sensor to oil guide housing (steel screw) → Tightening torque: 12 Nm (9 ft lbs.) ; oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
7. Oil level sensor
8. O-ring
9. Joint flange
10. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.)
11. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Direction of travel
Fit lower oil pan and tighten evenly crosswise (the inserted seal can be reused provided it does not leak and is not damaged). Insert and fit oil drain plug with new sealing ring.

Fig 72: Exploded View Of Oil Pan
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Oil pan with reusable seal inserted
2. Sealing ring
3. Oil drain plug, M18 x 1.5 → Tightening torque: 50 Nm (37 ft lbs.)
4. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Direction of travel
Turn the engine around.
Position vibration balancer with screw tightened by hand.
Set the timing. Follow procedure exactly. → WM 150516 SETTING CAMSHAFT TIMING ON 4.8-LITRE DFI ENGINES
Fit small side line brackets for the ATF lines.
WARNING:
Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
→ The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings.
Tighten vibration balancer to the specified torque (use counter-hold tool counter-hold tool 9679/1 ). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For exact tightening specification, see legend for figure Figure- item 4

Fig 73: Supporting Engine (Illustration Shows V8 4.5-Litre Engine Supported On Assembly Support)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 74: Exploded View Of Pulleys
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Water pump pulley
2. Screw, M8 x 16 → Tightening torque: 23 Nm (17 ft lbs.)
3. Vibration damper
4. Screw, M18 x 1.5 x 72; use new screw; → Tightening torque: 20 Nm (15 ft lbs.) → Tightening torque: 50 Nm (37 ft lbs.) → Tightening torque: 100 Nm (74 ft lbs.) → Torque angle: 180°
5. Power-steering pump pulley
6. Screw, M8 x 16 → Tightening torque: 23 Nm (17 ft lbs.)
7. Tandem pump pulley
Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see → Installing High-Pressure Pump
Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.

Fig 75: Exploded View Of Vacuum Pump
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Vacuum pump
2. Screw, M6 x 25 → Tightening torque: 10 Nm (7.5 ft lbs.)
3. O-ring
4. O-ring
Fit spark plugs if necessary. → Installing Spark Plugs
Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see → Installing Cylinder Head Cover (Valve Cover)
Fit both eyelets.
Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with KluUber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw.

Fig 76: Exploded View Of Thermostat Housing
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Thermostat housing
2. Screw, M6 x 25 → Tightening torque: 10 Nm (7.5 ft lbs.)
3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe => see relevant section
4. Seal for thermostat housing; replace
5. Thermostat
6. Intake socket
1. Direction of travel
Information
- 000 043 204 68 (Status 02/07) "KluUber Syntheso GLEP 1" is a neutral-reaction assembly grease for connection pieces and sealing rings in oily or water-carrying areas.
- Use "KluUber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
- "KluUberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.
Grease sealing rings at the intake socket between the water pump and thermostat housing with KluUberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing.
Grease both sealing rings on the coolant pipe sparingly with KluUber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!

Fig 77: Exploded View Of Coolant Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Coolant pipe with sealing ring
2. Coolant sensor → Tightening torque: 30 Nm (22 ft lbs.)
3. Screw, M6 x 16 → Tightening torque: 12 Nm (9 ft lbs.)
4. Screw, M6 x 12 (currently not installed)
5. Holding clamp (currently not installed)
6. Sealing ring
7. Screw plug, M16 x 1.5 → Tightening torque: 30 Nm (22 ft lbs.)
8. Screw, M6 x 25 → Tightening torque: 12 Nm (9 ft lbs.)
9. Collection pipe
10. Distributor pipe seal
11. Cap
1. Direction of travel
Fit water pump. → Installing Coolant Pump Fit pulley for water pump.
Fit oil pressure sensor with adapter. Replace sealing rings.

Fig 78: Exploded View Of Oil Pressure Sensor And Oil Pressure Measuring Point
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Oil pressure sensor adapter
2. O-ring
3. Oil-pressure sender with temperature sensor
4. Screw, M6 x 40 → Tightening torque: 10 Nm (7.5 ft lbs.)
5. Stopper → Tightening torque: 15 Nm (11 ft lbs.)
6. Sealing ring
1. Direction of travel
Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) at the left. Fit auxiliary unit bracket for right engine mounting.

Fig 79: Exploded View Of Left Bracket For Auxiliary Units And Engine Mounting
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Bracket for auxiliary units/engine mounting
2. Screw, M10 x 45 → Tightening torque: 65 Nm (48 ft lbs.)
3. Hydraulic mount, left
4. Engine carrier
5. Screw, M10 x 65 → Tightening torque: 60 Nm (44 ft lbs.)
6. Dowel sleeve
7. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ft lbs.)
  
  Fig 80: Exploded View Of Right Bracket For Auxiliary Units And Engine Mounting
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Engine carrier, cylinders 1 to 4
2. Screw, M10 x 45 → Tightening torque: 65 Nm (48 ft lbs.)
3. Hydraulic mount, right
4. Engine carrier
5. Screw, M10 x 65 → Tightening torque: 60 Nm (44 ft lbs.)
6. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ft lbs.)
7. Bores for screws, M10 x 45
1. Installation view of engine carrier on crankcase
Fit cable clips (sheet-metal clips to the unit brackets and valve covers.
Fit adapter plate for power-steering pump if necessary.

Fig 81: Exploded View Of Auxiliary Units
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Air conditioning compressor
2. Screw, M10 x 100
3. Screw, M8 x 10
4. Holder
5. Screw, M8 x 20; tandem pump to bracket for auxiliary units → Tightening torque: 23 Nm (17 ft lbs.) ; power-steering pump to bracket for auxiliary units → Tightening torque: 23 Nm (17 ft lbs.)
6. Tandem pump
7. Screw, M8 x 35; power-steering pump to adapter bracket → Tightening torque: 23 Nm (17 ft lbs.) ; tandem pump/adapter bracket to bracket for auxiliary units → Tightening torque: 23 Nm (17 ft lbs.)
8. Power-steering pump
9. Aluminium screw , M8; always use new aluminium screws → Initial tightening: 10 Nm (7.5 ft lbs.) and → Final tightening: 90°
10. Support bracket
11. Dowel sleeve
Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.

Fig 82: Exploded View Of Coolant Supply Line On Naturally Aspirated Engine M48/01
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
2. Coolant pipe
3. Coolant supply hose
4. Coolant hose
Align both engine mountings (hydraulic mounts) and fit them in the brackets for auxiliary units. When doing so, briefly hold the engine carrier to align it with the engine mounting.

Fig 83: Exploded View Of Left Bracket For Auxiliary Units And Engine Mounting
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Bracket for auxiliary units/engine mounting
2. Screw, M10 x 45 → Tightening torque: 65 Nm (48 ft lbs.)
3. Hydraulic mount, left
4. Engine carrier
5. Screw, M10 x 65 → Tightening torque: 60 Nm (44 ft lbs.)
6. Dowel sleeve
7. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ft lbs.)
  
  Fig 84: Exploded View Of Right Bracket For Auxiliary Units And Engine Mounting
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Engine carrier, cylinders 1 to 4
2. Screw, M10 x 45 → Tightening torque: 65 Nm (48 ft lbs.)
3. Hydraulic mount, right
4. Engine carrier
5. Screw, M10 x 65 → Tightening torque: 60 Nm (44 ft lbs.)
6. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ft lbs.)
7. Bores for screws, M10 x 45
1. Installation view of engine carrier on crankcase
Position generator.

Fig 85: Exploded View Of Generator
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Generator
2. Screw, M8 x 95 → Tightening torque: 23 Nm (17 ft lbs.)
3. Screw, M8 x 35 → Tightening torque: 23 Nm (17 ft lbs.)
4. Bores for screws, M8 x 95
1. View
Position generator's crash support.
Screw down generator's crash support and generator. → Installing The Generator
Fit deflection rollers and belt tensioner and press on cover.

Fig 86: Exploded View Of Belt Drive
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Deflection roller → Tightening torque: 32 Nm (24 ft lbs.)
2. Hydraulic belt tensioner; tensioner to lever → Tightening torque: 32 Nm (24 ft lbs.) ; tensioning roller to tensioning lever → Tightening torque: 32 Nm (24 ft lbs.)
3. Screw, M8 x 96; complete lever to timing-case cover and cylinder head → Tightening torque: 32 Nm (24 ft lbs.) ; belt tensioner and timing-case cover to bracket → Tightening torque: 32 Nm (24 ft lbs.)
4. Deflection roller → Tightening torque: 32 Nm (24 ft lbs.)
5. Dual poly-V-belt
If you have not already done so, secure sheetmetal holder of tank vent to the second upper screw of the timing-case cover at the 1st cylinder.
Fit crankshaft sealing ring on flywheel side. See → Installing Sealing Ring For Crankshaft (Transmission Side)
Fit coolant hosing and secure clamps.

Fig 87: Exploded View Of Coolant Return Line On Naturally Aspirated Engine M48/01
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Coolant pipe
2. Coolant hose
3. Holder
4. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
5. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.)
  
  Fig 88: Exploded View Of Coolant Supply Line On Naturally Aspirated Engine M48/01
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
2. Coolant pipe
3. Coolant supply hose
4. Coolant hose
Roughly position engine wire harness. Place cable duct onto coolant collection pipe and lay both harnesses for the cylinder banks. At the timing-case cover lay them downwards to the generator. Wire up air conditioning compressor, insert injectors, wire up bar ignition modules. Screw down ground points. For details, see → Installing Wire Harness For Engine
Fit high-pressure line between the high-pressure pump and fuel distribution pipe item 2. To do this, fit union nut in cylinder head item 4. Clip in cable duct at the union nut.

Fig 89: Exploded View Of High-Pressure Pump On Naturally Aspirated Engine M48/01, 3-Piston Pump
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. High-pressure pump
2. High-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ft lbs.)
3. Low-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ft lbs.)
4. Screw socket, M8 → Tightening torque: 23 Nm (17 ft lbs.)
5. Screw socket, M6 → Tightening torque: 10 Nm (7.5 ft lbs.)
6. Protective plate
7. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
8. Screw, M6 x 25 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Required line distance (5 to 8 mm) between high-pressure line and low-pressure line
  - Temperature sensor; not shown, to low-pressure line → Tightening torque: 20 Nm (15 ft lbs.)
Fit oil dipstick tube item 1 (first grease sealing rings sparingly with KluUber Syntheso GLEP 1). Screw down on timing-case cover at the top.

Fig 90: Exploded View Of Oil Guide Housing With Accessories
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Guide tube
2. O-ring
3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Oil dipstick
5. O-ring
6. Timing-case cover to oil guide housing Aluminium screw ; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90° ; oil-level sensor to oil guide housing (steel screw) → Tightening torque: 12 Nm (9 ft lbs.) ; oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
7. Oil level sensor
8. O-ring
9. Joint flange
10. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.)
11. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Direction of travel
Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with KluUber Syntheso GLEP 1). Detach injector plug and fit coolant vent line into the clips at the rear under the cable duct if necessary. Screw down coolant vent line with seals at both cylinder heads.

Fig 91: Exploded View Of Ventilation
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Vent line
2. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.)
1. Direction of travel
Fit DFI high-pressure fuel distribution pipe. For details see → Installing Fuel Distribution Pipe (Fuel Rail)
Check the DFI high-pressure system for leaks. → WM 243001 CHECKING FUEL DISTRIBUTION PIPE (FUEL RAIL) ON DFI ENGINES FOR LEAKS
Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.

Fig 92: Exploded View Of Exhaust Manifold On Naturally Aspirated Engine M48/01, Cylinders 1 To 4
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1. Exhaust manifold
2. Exhaust manifold seal
3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence → Tightening torque: 33 Nm (24 ft lbs.) (check nuts by clicking once)
4. Lambda sensor → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.)
1. Marking on seal visible from outside
Fig 93: Exploded View Of Exhaust Manifold On Naturally Aspirated Engine M48/01, Cylinders 5 To 8
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Exhaust manifold
2. Seal
3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence → Tightening torque: 33 Nm (24 ft lbs.) (check nuts by clicking once)
4. Lambda sensor → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.)
1. Marking on seal visible from outside
  
  Fig 94: Identifying Exhaust Manifold Tightening Sequence On Naturally Aspirated Engine M48/01, Cylinders 1 To 4
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Lay cable for lambda sensors and clip into position.

Fig 95: Exploded View Of Lambda Sensor On Naturally Aspirated Engine M48/01, Cylinders 1 To 4
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1. Lambda sensor on primary catalytic converter → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.)
2. Cable attachment
3. Holder
4. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
5. Cable attachment
1. View A
2. View B
  
  Fig 96: Exploded View Of Lambda Sensor On Naturally Aspirated Engine M48/01, Cylinders 5 To 8
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Lambda sensor on primary catalytic converter → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.)
2. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
3. Holder
4. Holder
5. Holder
6. Cable attachment
7. Cable attachment
1. View A
Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. Item 7

Fig 97: Oil Mist Separator For Positive Crankcase Ventilation (M48/01 Naturally Aspirated Engine)
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1. Engine ventilation → Tightening torque: 10 Nm (7.5 ft lbs.)
2. Engine ventilation line
3. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Lid with seal
5. Engine ventilation line
6. Line
7. Tank ventilation with holder → Initial tightening: 4 Nm (3 ft lbs.) and → Final tightening: 90°
Prepare and fit intake module. Ensure that the seals are seated correctly. Place intake module in installation position. Check that the switch-over valve is seated and connected properly. For details, see → Installing Intake-Air Distributor
Grease sealing rings for the two oil mist separators sparingly with KluUber Syntheso GLEP 1. Press oil mist separators onto the connection pieces on both valve covers. First fit the positive crankcase ventilation line between the timing-case cover and the oil mist separator at cylinder bank 5 to 8. Tighten screws and fit connecting tube between the oil mist separators. For details, see → Installing Oil Mist Separator
Fit power-steering pump. → Installing Hydraulic Pump (Cayenne Turbo/Cayenne S)
Fit air conditioning compressor. → Installing Air Conditioning Compressor
Fit pulley for power-steering pump or tandem pump.

Fig 98: Exploded View Of Pulleys
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1. Water pump pulley
2. Screw, M8 x 16
3. Vibration damper
4. Screw, M18 x 1.5 x 72; use new screw
5. Power-steering pump pulley
6. Screw, M8 x 16 → Tightening torque: 23 Nm (17 ft lbs.)
7. Tandem pump pulley
Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). → Installing Drive Belt
Fit heat protection panels on generator and on exhaust manifold. → Tightening torque: 10 Nm (7.5 ft lbs.)

Fig 99: Locating Heat Protection Panels On V8 Naturally Aspirated Engine
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Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.