Converting Reconditioned Engine

Information 

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

• Group 1:

  > WM, 1X00IN TECHNICAL VALUES - V6 BITURBO

• Group 2:

  > 2X00IN TECHNICAL VALUES

• Group 3:

  > WM 3X00IN TECHNICAL VALUES, TRANSMISSION (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0))

Information 

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

1. Convert engine carrier.

   > 103019 REMOVING AND INSTALLING ENGINE CARRIER 

2. Convert pressure pipes -1-  .
   1. Release retaining clip -2-  and pull it off the turbocharger -3-  .
   2. Loosen clamp -4-  and pull change-over valve -5-  off the intake manifold -6-  .
   3. Remove pressure pipe -1-  with change-over valve -5-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pressure pipes 

3. Fit new intake pipes on new engine.
   1. Replace intake pipes -1-  after loosening the screw-type clamp -arrow-  securing intake pipe to turbocharger.
   2. Release positive crankcase ventilation line -2-  and pull it off the intake pipe.
   3. Release tank vent line -3-  and pull it off.
   4. Loosen clamp -4-  and pull off line -5-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Intake pipe 

4. Convert coolant hoses.
   1. Loosen clamps -arrows-  and pull off coolant hoses -1-  and -2-  .
   2. Collect emerging coolant.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Coolant hoses on coolant regulator housing 

5. Convert secondary air valves with lines.
   1. Unscrew screws -1-  securing secondary air line to cylinder head.
   2. Unscrew screws -2-  on holder -3-  securing secondary air valve to cylinder head.
   3. Unscrew screw -4-  securing secondary air line -5-  to coolant distributor -6-  .
   4. Loosen clamp -arrow-  using > VAS 6891 - Spring Band Clamp Pliers and pull off secondary air hose -7-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Secondary air lines 

6. Convert secondary-air pump.

   > 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP

7. Convert drive plate.

   > WM, 136319 REMOVING AND INSTALLING DRIVE PLATE

8. Convert drive belt.

   > 137819 REMOVING AND INSTALLING DRIVE BELT

9. Convert hydraulic pump with PDCC lines.

   > WM 489819 REMOVING AND INSTALLING HYDRAULIC PUMP - 3.6 V6 (PDCC) (CAYENNE TIP, CAYENNE MAN)

10. Convert air-conditioning compressor

    > WM 873419 REMOVING AND INSTALLING ELECTRIC AIR-CONDITIONING COMPRESSOR (CAYENNE GTS, CAYENNE TURBO S, CAYENNE S E-HYBRID)

11. Convert the generator.

    > WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE S, CAYENNE TURBO)