Assembling Engine

Information 

Detailed information on 

• tightening torque,
• tightening sequence,
• component allocations, classifications,
• surface treatment,
• replacing parts,
• applying sealant

can be found in the following documents: 

• →1X00IN TECHNICAL VALUES
• →2X00IN TECHNICAL VALUES
• →3X00IN TECHNICAL VALUES TRANSMISSION

Information 

• Do not remove stoppers used to close off connections during disassembly until just before fitting the affected component. 

Information 

Replace worn bearing shells.

1. Assembly is performed in reverse order. Note particularly:
2. Clean components and replace damaged components.

   Information 

   Sealing faces must be free of oil and grease.

   1. 2.1 Clean sealing faces.
   2. 2.2 Clean the thread and re-cut if necessary.
3. Install knock sensor.

   → WM, 287219 REMOVING AND INSTALLING KNOCK SENSOR (V6 TURBO)

4. Install piston spray nozzles -2-  .
   1. 4.1 Position piston spray nozzles -2-  .
   2. 4.2 Fit screws for piston spray nozzles -1-  and tighten to →Initial tightening 10 Nm (7.5 ftlb.)  and →Final tightening + 45°  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Piston spray nozzles on cylinder block

5. Install crankshaft with new bearing shells into the cylinder block.

   →134819 REMOVING AND INSTALLING CRANKSHAFT (V6 TURBO)

6. Install new bearing shells in pistons and connecting rods.

   → Removing and installing piston (V6 Turbo)

7. Install balance shafts.

   → 138519 REMOVING AND INSTALLING BALANCE SHAFT (V6 TURBO)

8. Assemble cylinder heads.
   1. 8.1 Install new valve-stem seals.
9. Install both cylinder heads with new cylinder-head gaskets.
10. Install coolant switching valve -3-  .
    1. 10.1 Fit and position coolant switching valve -3-  on coolant pipe -4-  .
    2. 10.2 Tighten screws on coolant control valve -2-  to > Tightening torque 9 Nm (6.5 ftlb.)  .
    3. 10.3 Connect vacuum hose -1-  .

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    Coolant switching valve

11. Install coolant flanges on left and right cylinder bank.
    1. 11.1 Position coolant flanges.
    2. 11.2 Fit screws -1 to 3-  and tighten to > Tightening torque 9 Nm (6.6 ftlb.)  .

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    Coolant flanges

12. Replace crankshaft sealing rings on both sides of the engine.
13. Install oil windage tray -2-  .
    1. 13.1 Position oil windage tray -2-  on cylinder block.
    2. 13.2 Replace oil windage tray screws -1 and 3- 
    3. 13.3 Fit screws securing oil windage tray to cylinder block -1-  and tighten crosswise.

       Tighten M6 x 18 screws (3 ea.)  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90° 

       Tighten M6 x 30 screws (13 ea.)  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90°  .

    4. 13.4 Tighten screws securing chain housing cover to oil windage tray -3-  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90°  .

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    Oil windage tray

14. Install pipe for drive shaft -1-  .
    1. 14.1 Insert pipe for drive shaft -1-  from one side and push it into position using a suitable tool.
    2. 14.2 Fit O-ring -2-  on both sides of the engine.

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    Pipe for drive shaft

15. Install shaft cover -1-  on both sides of the engine.
    1. 15.1 Fit shaft cover -1-  .
    2. 15.2 Fit screws for shaft cover -2-  and tighten to > Tightening torque 9 Nm (6.5 ftlb.)  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Shaft cover

16. Install drive belt deflection roller for generator -1-  .
    1. 16.1 Position deflection roller -1-  .
    2. 16.2 Fit screw for deflection roller -3-  and tighten to > Tightening torque 25 Nm (19 ftlb.)  .
    3. 16.3 Push on dust boot -2-  .

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    Deflection roller for drive belt for generator

17. Install generator support -1-  .
    1. 17.1 Position generator support -1-  .
    2. 17.2 Fit screws -2-  and tighten to > Initial tightening 8 Nm (6 ftlb.)  and > Final tightening + 90°  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Generator support

18. Install air-conditioning compressor -5-  support.
    1. 18.1 Position air-conditioning compressor -5-  support.
    2. 18.2 Fit screws for air-conditioning compressor bracket -4-  and tighten to > Initial tightening 8 Nm (6 ftlb.)  and > Final tightening + 90°  .
    3. 18.3 Install tensioning roller -3-  .
       1. 18.3.1 Position tensioning roller -3-  .
       2. 18.3.2 Replace screw on tensioning roller -2-  for air-conditioning compressor drive belt.
       3. 18.3.3 Fit new  screw on tensioning roller -2-  and tighten to > Tightening torque 25 Nm (19 ftlb.)  .
       4. 18.3.4 Push on dust boot -1-  .

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    Air-conditioning compressor support (shown on V6 Monoturbo)

19. Connect all vacuum hoses in accordance with the markings.