Assembling Engine

→ 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.

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ 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.

→ 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 

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

• The bearing shells are available in various classes. The classes are indicated by the color marking on the outside. For every bearing (main and connecting rod bearings), the color 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 color classification of the bearing shell. 
  Fig 1: Locating Color Marking On Bearing Shell

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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 2: Identifying Connecting Rod Code And Direction Of Travel Arrow

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• 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 3: Identifying Connecting Rod Code "A"

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Information 

• Connecting rod bolts must always be replaced. 

Information 

Please observe the following for the V6 => 

• The repair concepts for the V6 are the same as for the V8. 
• The special features and component deviations are listed and shown in →  1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS  . 
• More significant deviations are shown in separate descriptions. 
• If no special features are specifically highlighted, the assembly and adjustment instructions for the V8 apply. 

Information 

• Particular care and attention must be paid to the combined V6 oil pump balance shaft module during disassembly and assembly work. This is completely different from the V8 oil pump concept. 
• The V6 oil pump balance shaft module with the balance weight is installed at a defined position with respect to the crankshaft. 
• The balance shaft in the V6 oil pump balance shaft module is fixed to the crankshaft. Non-observance of this requirement results in strong vibrations in the engine. 
• For details  , see → 172019 REMOVING AND INSTALLING OIL PUMP .

1. Place crankshaft bearing shells into the lower part of the crankcase.
   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 color 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.
      1. Crankshaft (stroke: 83 mm)
      2. Straight pin, 6 x 20
      3. Spring wedge
      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 
      Fig 4: Identifying Crankshaft
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   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 center with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
      Fig 5: Inserting Bearing Shells

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      Fig 6: Inserting Bearing Shells

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   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.
   Fig 7: Identifying Thrust Washer
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2. 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 8: Identifying Knock Sensors

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      1. Knock sensor
      2. Screw, M8 x 35
   4. 2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2- 
      Fig 9: Identifying Seals Between Crankcase And Thermostat Housing

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3. Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals at the left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.
   1. Coolant pipe
   2. M6 screw
   3. Sealing ring
   4. Screw plug, M16 x 1.5
   5. M6 screw
   6. Coolant guide tube (collection pipe)
   7. Metal seal
   8. Stopper
   Fig 10: Identifying Coolant Guide
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4. Fit oil spray jets -6-  .
   Fig 11: Identifying Upper Part Of Crankcase

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   Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber 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. → Spray direction  → Spray direction from side 

   Fig 12: Identifying Correct Direction For Pointing Oil Spray Jets

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   Fig 13: Identifying Correct Direction For Pointing Oil Spray Jets (Spray Direction From Side)

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5. Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.
6. Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see → 131037 DISASSEMBLING AND ASSEMBLING PISTONS
   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 14: Identifying Piston And Connecting Rod
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7. Check that all the seals are installed in the oil plate (oil return). → Oil return (oil plate), 4WD shown 
   1. Oil guide (oil plate)
   2. Oil return seal
   3. Screw, M6 x 20
   Fig 15: Identifying Oil Return (Oil Plate, 4WD)
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8. If you have not already done so, drive dowel sleeves for the metal seals in the timing-case cover using a copper or plastic hammer.
9. Insert new metal seals on the timing-case cover and press onto dowel sleeves.
10. Oil pump is pre-fitted with the oil pressure control valve.
11. 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.
12. 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.
13. Move starter into installation position and screw down. → 276019 REMOVING AND INSTALLING STARTER
14. Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
15. 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 16: Positioning Timing Chain Pinion On Crankshaft Stub

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    Fig 17: Identifying Timing Chain Pinion With Two Diamond Washers

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16. Fit crankshaft holding bridge holding bridge 9677/1  in the center of the crankshaft.
    Fig 18: Identifying Crankshaft

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17. Turn upper part of crankcase and oil cylinder liners.
18. Pre-tension pistons using an assembly funnel funnel 9784/1  and press pistons into the cylinder. For details, see → 131020 REMOVING AND INSTALLING PISTONS
19. Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/09) 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.
    1. Wipe off sealant residues after fitting
    1. Direction of travel
    Fig 19: Applying Sealant
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20. Tighten M11 and M10 bearing screws to the prescribed torques. -5 and 6-  . The bearing screws for the 4WD shaft are shorter. Do not use the wrong screws.

    1 to 20  - Tightening sequence for M11 and M10 screws => Observe different torques!

    1. Direction of travel
    Fig 20: Tightening Sequence For Thrust-Bearing Screws
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    Fig 21: Identifying Lower Part Of Crankcase (2WD)

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    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.
    6. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
    7. Aluminum screw  , M8 x 70; (cross bolt connection); always use new aluminum screws
    8. Screw, M8 x 35
    9. Screw, M8 x 50
    10. Dowel sleeve
    1. Direction of travel
    Fig 22: Identifying Lower Part Of Crankcase (V8 4WD)

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    1. Lower part of crankcase
    2. Straight pin, 6 x 18
    3. Dowel sleeve
    4. Seal
    5. Joint flange
    6. Screw, M6 x 20
    7. Screw, M8 x 35
    8. Screw, M8 x 50
    9. Sealing rings for joint flange/cross tube
    10. Cross tube for four-wheel drive cross shaft
    11. Aluminum screw  , M8 x 70; (cross bolt connection); always use new aluminum screws
    12. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
    13. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence.
    14. Sealing ring

    -  - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

21. Fit cross bolt connection.
    Fig 23: Tightening Sequence For Securing Lower Part Of Crankcase To Upper Part Of Crankcase (Cross Bolt Connection)

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22. Fit M8 screws on the side -8 and 9-  . Remove emerging sealant.
23. Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.
24. Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.
    Fig 24: Identifying Oil Guide (Oil Plate) And Oil Return Seal (2WD)

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    1. Oil guide (oil plate)
    2. Oil return seal
    3. Screw, M6 x 20
    Fig 25: Identifying Oil Guide (Oil Plate) And Oil Return Seal (4WD)

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    1. Oil guide (oil plate)
    2. Oil return seal
    3. Screw, M6 x 20
25. Fit the oil pump → Oil pump on naturally aspirated engine  . Fit suction tube for auxiliary sump → Suction tube for auxiliary sump  .
    Fig 26: Identifying Oil Pump On Naturally Aspirated Engine

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    1. Oil pump
    2. Screw, M8 x 22; replace
    3. Oil pump sprocket
    4. Cap screw, M36
    5. Solenoid valve
    6. Sealing rings (grease before fitting)
    7. Dowel sleeve
    8. Screw, M6 x 45
    9. Sprocket cover
    10. Screw, M6 x 16
    11. Drive chain
    Fig 27: Identifying Suction Tube For Auxiliary Sump

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    1. Suction tube for auxiliary sump
    2. Sealing ring
    3. M6 screw

    3 Magnifying glass  - View of click position

26. Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion → Oil pump chain  . Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.
    Fig 28: Installing Oil Pump Chain

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    Fig 29: Installing Countering Oil Pump Pinion

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27. Fit cover plate for oil pump drive (drive pinion cover) using three screws.
28. 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.
29. 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. -8- 
    Fig 30: Identifying Camshafts (Cylinder Bank 1 To 4)

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    1. Camshaft (outlet)
    2. Camshaft (intake)
    3. Hydraulic valve for variable valve lift control
    4. Screw, M5 x 12
    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
30. Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.
    Fig 31: Identifying Cylinder Head (1 To 4)

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    1. Cylinder head 1 to 4
    2. Cylinder head gasket 1 to 4
    3. M8 screw
    4. Cap
    5. Stopper
    6. Stopper
    7. Restrictor for valve lift adjustment
    8. Cylinder-head screws => For tightening specifications, see Fig 32
    9. Spark plug
    Fig 32: Tightening Sequence For Cylinder Head Screws

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31. Fit front M8 screw of cylinder head 1 to 4. -3- 
32. Coat camshaft bearings with normal multipurpose grease or engine oil.
33. 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.
34. 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). -2- 
    Fig 33: Staking Bore 45 Degrees Before TDC

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    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.

35. 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 bearing covers correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft bearing covers 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.
    1. Cylinders 1 to 4
    2. Cylinders 5 to 8
    Fig 34: Camshaft Identification On V8 Naturally Aspirated Engine
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    1. Outlet camshaft identification (green)
    2. Intake camshaft identification (white)
    3. Intake camshaft identification (white)
    4. Outlet camshaft identification (green)
    Fig 35: Camshaft Bearing Cover Identification

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    • 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 bearing cover, cylinder 1 (E1)
    2. Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2)
    3. Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3)
    4. Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4)
    5. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
    6. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2)
    7. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3)
    8. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4)

    Arrow  - Direction of travel

    Fig 36: Identifying Camshaft Mount, Cylinders 5 To 8

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    1. Dowel sleeves
    2. Bearing cover (intake)
    3. Screw, M6 x 70
    4. Bearing cover
    5. Screw, M6 x 35
    6. Bearing cover (outlet)
    7. Bearing surfaces (oil with engine oil)
    1. Direction of travel
36. Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4- 
    Fig 37: Identifying Camshaft Controller, Camshaft Control Hydraulic Valve And Screws

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    1. Screw, M12 Tighten fully after setting timing. 
    2. Camshaft controller with integrated hexagon for countering
    3. Camshaft control hydraulic valve
    4. Screw, M5 x 12
37. Fit threaded peg for tensioning and guide rails if necessary. -1 and 2- 
    Fig 38: Identifying Timing Chain And Chain Guide

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    1. Threaded peg
    2. Threaded peg
    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
38. Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).
39. Fit "U"-shaped deflection rail -4-  .
    Fig 39: Routing Of Timing Chain

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    1. Double-chain camshaft drive
    2. Camshaft sprocket
    3. Screw, M12 Tighten fully after setting timing. 
    4. Deflector rail
    5. Screw, M8 x 35
    6. Camshaft-to-camshaft guide pad
    1. Direction of travel
40. Fit tensioning rail and let it hang.
41. Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
42. Loosely fit camshaft controller and sprockets using screws.
43. Position timing chain and guide correctly over guide and tensioning rails.
44. Fit timing-case cover. Secure sheetmetal holder for tank vent to the upper screw on the timing-case cover at the 1st cylinder. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER ; chain tensioner is still removed.
45. Replace and fit joint flange (sealing ring) between the vibration damper and timing-case cover. → 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
46. Turn the engine around. Oil pump is upright.
47. Lay sealing ring in the lower part of the crankcase.
48. Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.
    Fig 40: Applying Sealant To Oil Guide Housing (2WD)

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    1. Sealant application (geometry, 1-mm bead of sealant)
    2. Sealant application - Doboseal 224N (999.915.573.43, status 09/09)
    1. Direction of travel
    Fig 41: Identifying Sealant Applying Areas Of Oil Guide Housing (4WD)

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    1. Sealant application (geometry, sealing bead = 1 mm); Doboseal 224N (999.915.573.43, status 09/09)
49. 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 dial gauge, etc.). For details, see → 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
50. Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4-  . Don't forget the screws between the oil guide housing and timing-case cover (five screws behind front vibration balancer, bores are currently overhead). -7- 
    Fig 42: Identifying Oil Guide Housing With Accessories (2WD)

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    1. Screw, M6 x 20
    2. Joint flange
    3. Sealing ring
    4. Oil guide housing to lower part of crankcase - aluminum screw  ; always use new aluminum screws
    5. Oil level sensor
    6. Oil level sensor to oil guide housing (steel screw)
    7. Timing-case cover to oil guide housing - aluminum screw  ; always use new aluminum screws
51. Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings.
    Fig 43: Identifying Oil Lines On Naturally Aspirated Engine

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    1. Oil pump intake manifold; screw M6 x 20
    2. Sealing ring
    3. Oil pressure pipe; screw M6 x 16
    4. Sealing ring
    5. Sealing ring; oil before fitting
    6. Oil regulating line; screw M6 x 16
    7. Sealing ring
    8. Sealing ring; oil before fitting
    9. Oil pipes to oil pump and oil guide housing
    10. Oil pipes to oil pump and oil guide housing
    Fig 44: Identifying Oil Lines On Naturally Aspirated Engine (View With Oil Pan Removed)

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    1. Mounting point for oil pressure pipe
    2. Mounting point for auxiliary sump intake manifold
    3. Mount for oil pump intake manifold
    4. Mount for oil regulating line
52. Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -1, 2 and 3-  .
53. Fit oil level sensor (turn carefully when inserting sensor). -5 and 6- 
54. Fit oil pan with a new seal and tighten evenly and in diagonally opposite sequence.
    Fig 45: Identifying Oil Pan

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    1. Oil pan
    2. Seal; replace following removal
    3. Seal; replace following removal
    4. Oil drain plug, M18; aluminum screw; reusable
    5. Screw, M6 x 20
55. Turn the engine around.
56. Position vibration balancer with screw tightened by hand.
57. Set the timing. Follow procedure exactly. → 150516 SETTING TIMING FOR CAMSHAFTS
    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.

58. Tighten vibration balancer -3 and 4-  to the specified torque (use a brace brace 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 details, see → 137619 REMOVING AND INSTALLING PULLEY (VIBRATION BALANCER)
    Fig 46: Supporting Engine (V8 Engine Supported On Assembly Support)

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    Fig 47: Identifying 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
    7. Tandem pump pulley
59. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see → 477619 REMOVING AND INSTALLING VACUUM PUMP
60. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.
    Fig 48: Identifying Vacuum Pump, O-Rings And Screws

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    1. Vacuum pump
    2. Screw, M6 x 25
    3. O-ring
    4. O-ring
61. Fit spark plugs if necessary.

    → 287020 REMOVING AND INSTALLING SPARK PLUGS

62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
63. Fit both eyelets.
64. 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 Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
    Fig 49: Identifying Thermostat Housing And Coolant Regulator

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Thermostat housing
    2. Screw, M6 x 25
    3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe => see relevant section
    4. Seal for thermostat housing; replace
    5. Thermostat insert; including electric heating element
65. Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see → 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
66. Grease both sealing rings on the coolant pipe sparingly with Kluber 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 50: Identifying Coolant Guide

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Heater coolant pipe
    2. M6 screw
    3. Sealing ring
    4. Screw plug, M16 x 1.5
    5. M6 screw
    6. Coolant guide tube (collection pipe)
    7. Metal seal
    8. Stopper
67. Fit the water pump. Fit pulley for water pump. For details, see → 195019 REMOVING AND INSTALLING COOLANT PUMP
68. Fit oil pressure sensor with adapter. Replace sealing rings.
    Fig 51: Identifying 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
    5. Stopper
    6. Sealing ring
    1. Direction of travel
69. On 4WD vehicles, install one cross shaft cover with the cross shaft pipe -1-  . Replace sealing rings in the covers.
    1. 69.1. Apply housing seal -2-  (Doboseal 224N (999.915.573.43 status 09/09)) to the seating points of the two cross shaft covers close to the edge of the housing.
    2. 69.2. Position cross shaft cover with cross shaft pipe -1-  .

       Make sure that the cross shaft pipe is protruding at a center position from the opposite opening on the oil guide housing.

       Fig 52: Identifying Cross Shaft Pipe With Cover

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       The -TOP-  marking must be facing upwards.

    3. 69.3. Screw in fastening screws -arrows-  .
70. Install the second cross shaft cover -1-  .
    1. 70.1. Position the cross shaft cover -1-  .

       Make sure that the cross shaft pipe is inserted into the center opening on the cover.

       The -TOP-  marking must be facing upwards.

    2. 70.2. Screw in fastening screws.
    Fig 53: Locating Cross Shaft Cover Screws
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
71. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-  . Fit bearing console -4-  .
    Fig 54: Identifying Left Bracket For Auxiliary Units And 2WD Engine Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Bracket for auxiliary units
    2. Screw, M10 x 45
    3. Dowel sleeve
    4. Engine carrier
    5. Hydraulic mount, left
    6. M12 nut
    Fig 55: Identifying Left Bracket For Auxiliary Units And 4WD Engine Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Bracket for auxiliary units
    2. Screw, M10 x 45
    3. Dowel sleeve
    4. Engine carrier/cross-shaft engine carrier
    5. Hydraulic mount, left
    6. M12 nut
72. Fit bearing console on the right on 2WD vehicles.
    Fig 56: Identifying Engine Mounting, Right

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Engine carrier
    2. Screw, M10 x 45
    3. Nut, M12 x 1.5
    4. Hydraulic mount, right
    5. Installation view of screw-on points for engine carrier on crankcase
73. Fit front-wheel drive (all-wheel drive) for 4WD vehicles. → 398819 REMOVING AND INSTALLING FOUR-WHEEL FINAL DRIVE
74. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position. → 103519 REMOVING AND INSTALLING ENGINE MOUNTING 
75. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
    Fig 57: Identifying Coolant Supply On Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
76. Fit the generator and crash support. For details, see → 272219 REMOVING AND INSTALLING GENERATOR
    Fig 58: Identifying Generator

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Generator
    2. Screw, M8 x 95
    3. Screw, M8 x 35
    4. Bores for screws, M8 x 95
    1. View
77. Fit deflection rollers and belt tensioner and press on cover.
    Fig 59: Routing Of Belt Drive

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Deflection roller
    2. Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever
    3. M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console
    4. Deflection roller
    5. Dual poly-V-belt
78. Fit crankshaft sealing ring on flywheel side. See → 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (TRANSMISSION SIDE)
79. Fit coolant hosing and secure clamps.
    Fig 60: Identifying Coolant Supply On Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
    Fig 61: Identifying Coolant Return On Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Connection piece on generator
    2. Connection piece screw
    3. Screw, M6 x 20
    4. Coolant return line
    5. Coolant return hose assembly
    6. Holder
    7. M6 screw Aluminum screw  ; always use new aluminum screws
    8. Clip
80. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
    1. Vent line
    2. Screw, M6 x 16
    Fig 62: Identifying Vent Line And Screws
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
81. 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
82. Fit high-pressure line and low-pressure line. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
    Fig 63: Identifying High-Pressure Pump, Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. High-pressure pump
    2. High-pressure line; (3 turns: tighten, loosen, tighten)
    3. M6 screw on low-pressure line
    4. Low-pressure line; (3 turns: tighten, loosen, tighten); counter at the hexagon at the high-pressure pump
    5. Screw socket, M8
    6. Screw socket, M6
    7. Protective plate
    8. Screw, M6 x 20

    Magnifying Glass  - Required line distance (5 to 8 mm) between components

83. Fit high-pressure fuel distribution pipe. For details, see → Installing Fuel Distributor Pipe
84. Check the DFI high-pressure system for leaks. → 243001 CHECKING FUEL COLLECTION PIPE FOR LEAKS
85. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
    Fig 64: Tightening Sequence For Exhaust Manifold On Naturally Aspirated Engine, Cylinders 1 To 4

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    1 to 12  - Applies to both sides, always start at the timing-case cover

    Fig 65: Identifying Exhaust Manifold Seal And Mount On Naturally Aspirated Engine, Cylinders 1 To 4

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 1  - Exhaust manifold
    2. 2  - Exhaust manifold seal
    3. 3  - Studs M8;
    4. 5  - M8 hexagon nut; replace; (check nuts by clicking once); observe tightening sequence
    1. M6 screw; heat shield to exhaust manifold
    Fig 66: Identifying Exhaust Manifold Seal And Mount On Naturally Aspirated Engine, Cylinders 5 To 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Exhaust manifold
    2. Seal
    3. M8 hexagon nut; replace; (check nuts by clicking once); observe tightening sequence
    4. M6 screw; securing heat shield to exhaust manifold;
86. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. -3- 
    Fig 67: Ventilation On Naturally Aspirated Engines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Engine ventilation line
    2. Oil mist separator line to intake-air distributor
    3. Tank ventilation
    4. Aluminum holder
    5. Aluminum screw (holder); see Timing-case cover
87. Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
88. Fit oil mist separator. For details, see → 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR .
89. Fit power-steering pump. For details, see installation description → Installing Hydraulic Pump
90. Fit air conditioning compressor. → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR
91. Fit pulley for power-steering pump or tandem pump.
    Fig 68: Identifying Pulleys

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Water pump pulley
    2. Screw, M8 x 16
    3. Vibration damper
    4. M18 screw; always use a new screw
    5. Power-steering pump pulley
    6. Screw, M8 x 16
    7. Tandem pump pulley
92. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). → Installing Drive Belt
93. Fit heat protection panels on generator and on exhaust manifold.
94. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.

→ 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.

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ 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.

→ 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 

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

• The bearing shells are available in various classes. The classes are indicated by the color marking on the outside. For every bearing (main and connecting rod bearings), the color 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 color classification of the bearing shell. 
  Fig 1: Locating Color Marking On Bearing Shell

  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. 
Fig 2: Connecting Rod Code And Direction Of Travel Arrow
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• 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. 
• 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 3: Identifying Connecting Rod Code "A"

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Information 

• Connecting rod bolts must always be replaced. 

1. Place crankshaft bearing shells into the lower part of the crankcase.
   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 color 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.
      1. Crankshaft (stroke: 83 mm)
      2. Straight pin, 6 x 20
      3. Spring wedge
      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 
      Fig 4: Identifying Crankshaft
      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   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 center with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
      Fig 5: Inserting Bearing Shells

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      Fig 6: Inserting Bearing Shells

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 7: Identifying Thrust Washer

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   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.
2. 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.
      Fig 8: Identifying Knock Sensors

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 2.3. Fit knock sensors correctly.
      1. Knock sensor
      2. Screw, M8 x 35
   4. 2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2- 
      Fig 9: Identifying Seals Between Crankcase And Thermostat Housing

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals at the left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.
   1. Coolant pipe
   2. M6 screw
   3. Sealing ring
   4. Screw plug, M16 x 1.5
   5. M6 screw
   6. Coolant guide tube (collection pipe)
   7. Metal seal
   8. Stopper
   Fig 10: Identifying Coolant Guide
   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit oil spray jets -6-  .
   Fig 11: Identifying Upper Part Of Crankcase

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 12: Identifying Correct Direction For Pointing Oil Spray Jets

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber 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. → Spray direction  → Spray direction from side 

   Fig 13: Identifying Correct Direction For Pointing Oil Spray Jets (Spray Direction From Side)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.
6. Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see → 131037 DISASSEMBLING AND ASSEMBLING PISTONS
   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 14: Exploded View Of Piston And Connecting Rod
   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Check that all the seals are installed in the oil plate (oil return). → Oil return (oil plate), 4WD shown 
   1. Oil guide (oil plate)
   2. Oil return seal
   3. Screw, M6 x 20
   Fig 15: Identifying Oil Guide (Oil Plate) And Oil Return Seal (4WD)
   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. If you have not already done so, drive dowel sleeves for the metal seals in the timing-case cover using a copper or plastic hammer.
9. Insert new metal seals on the timing-case cover and press onto dowel sleeves.
10. Oil pump is pre-fitted with the oil pressure control valve.
11. 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.
12. 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.
13. Move starter into installation position and screw down. → 276019 REMOVING AND INSTALLING STARTER
14. Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
15. 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 16: Positioning Timing Chain Pinion On Crankshaft Stub

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    Fig 17: Identifying Timing Chain Pinion With Two Diamond Washers

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16. Fit crankshaft holding bridge holding bridge 9677/1  in the center of the crankshaft.
    Fig 18: Identifying Crankshaft Holding Bridge

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Turn upper part of crankcase and oil cylinder liners.
18. Pre-tension pistons using an assembly funnel funnel 9784/1  and press pistons into the cylinder. For details, see → 131020 REMOVING AND INSTALLING PISTONS
19. Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/09) to the lower part of the crankcase as shown. Insert sealing ring -14-  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.
    1. Wipe off sealant residues after fitting
    1. Direction of travel
    Fig 19: Applying Sealant
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
20. Tighten M11 and M10 bearing screws to the prescribed torques -12 and 13-  . The bearing screws for the 4WD shaft are shorter. Do not use the wrong screws.

    1 to 20  - Tightening sequence for M11 and M10 screws => Observe different torques!

    A  - Direction of travel

    Fig 20: Tightening Sequence For Thrust-Bearing Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 21: Identifying Lower Part Of Crankcase (V8 4WD)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Lower part of crankcase
    2. Straight pin, 6 x 18
    3. Dowel sleeve
    4. Seal
    5. Joint flange
    6. Screw, M6 x 20
    7. Screw, M8 x 35
    8. Screw, M8 x 50
    9. Sealing rings for joint flange/cross tube
    10. Cross tube for four-wheel drive cross shaft
    11. Aluminum screw  , M8 x 70; (cross bolt connection); always use new aluminum screws
    12. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
    13. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence.
    14. Sealing ring

    -  - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

    Fig 22: Tightening Sequence For Securing Lower Part Of Crankcase To Upper Part Of Crankcase (Cross Bolt Connection)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
21. Fit cross bolt connection.
22. Fit M8 screws on the side -7 and 8-  .

    Remove emerging sealant.

23. Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.
24. Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.
    Fig 23: Identifying Oil Guide (Oil Plate) And Oil Return Seal (4WD)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Oil guide (oil plate)
    2. Oil return seal
    3. Screw, M6 x 20
25. Fit the oil pump → Oil pump, turbo engine  . Fit suction tube for auxiliary sump → Suction tube for auxiliary sump  .
    Fig 24: Identifying Oil Pump, Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Oil pump with extraction stage
    2. Screw, M8 x 22; replace
    3. Oil pump sprocket
    4. Cap screw, M36
    5. Solenoid valve
    6. Sealing rings (grease before fitting)
    7. Dowel sleeve
    8. Screw, M6 x 45
    9. Sprocket cover
    10. Screw, M6 x 16
    11. Drive chain
    Fig 25: Identifying Suction Tube For Auxiliary Sump

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Suction tube for auxiliary sump
    2. Sealing ring
    3. M6 screw

    3 Magnifying glass  - View of click position

26. Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion → Oil pump chain  . Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.
    Fig 26: Installing Oil Pump Chain

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    Fig 27: Countering Oil Pump Pinion

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27. Fit cover plate for oil pump drive (drive pinion cover) using three screws.
28. 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.
29. 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. -8- 
    Fig 28: Identifying Camshafts (Cylinder Bank 1 To 4)

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    1. Camshaft (outlet)
    2. Camshaft (intake)
    3. Hydraulic valve for variable valve lift control
    4. Screw, M5 x 12
    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
30. Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.
    Fig 29: Identifying 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. M8 screw
    4. Lid
    5. Stopper
    6. Stopper
    7. Restrictor for valve lift adjustment
    8. Cylinder-head screws => For tightening specifications, see Fig 30
    9. Spark plug
    Fig 30: Tightening Sequence For Cylinder Head Screws

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31. Fit front M8 screw of cylinder head 1 to 4. -3- 
32. Coat camshaft bearings with normal multipurpose grease or engine oil.
33. 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.
34. 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). -2- 
    Fig 31: 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.

35. 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 bearing covers correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft bearing covers 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.
    1. Cylinders 1 to 4
    2. Cylinders 5 to 8
    Fig 32: Camshaft Identification On V8 Turbo Engine
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Outlet camshaft identification (green)
    2. Intake camshaft identification (blue)
    3. Intake camshaft identification (blue)
    4. Outlet camshaft identification (green)
    • - All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads 
    Fig 33: Camshaft Bearing Cover Identification

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1)
    2. Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2)
    3. Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3)
    4. Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4)
    5. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
    6. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2)
    7. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3)
    8. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4)

    Arrow  - Direction of travel

    Fig 34: Identifying Camshaft Mount, Cylinders 5 To 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Dowel sleeves
    2. Bearing cover (intake)
    3. Screw, M6 x 70
    4. Bearing cover
    5. Screw, M6 x 35
    6. Bearing cover (outlet)
    7. Bearing surfaces (oil with engine oil)
    1. Direction of travel
36. Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4- 
    Fig 35: Identifying Camshaft Adjustment

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Screw, M12 Tighten fully after setting timing. 
    2. Camshaft controller with integrated hexagon for countering
    3. Camshaft control hydraulic valve
    4. Screw, M5 x 12
37. Fit threaded peg for tensioning and guide rails if necessary. -1 and 2- 
    Fig 36: Identifying Timing Chain And Chain Guide

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Threaded peg
    2. Threaded peg
    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
38. Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).
39. Fit "U"-shaped deflection rail -4-  .
    Fig 37: Identifying 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. Deflector rail
    5. Screw, M8 x 35
    6. Camshaft-to-camshaft guide pad
    1. Direction of travel
40. Fit tensioning rail and let it hang.
41. Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
42. Loosely fit camshaft controller and sprockets using screws.
43. Position timing chain and guide correctly over guide and tensioning rails.
44. Fit timing-case cover. Secure sheetmetal holder for tank vent to the upper screw on the timing-case cover at the 1st cylinder.

    → 153319 REMOVING AND INSTALLING TIMING-CASE COVER ; chain tensioner is still removed.

45. Replace and fit joint flange (sealing ring) between the vibration damper and timing-case cover. → 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
46. Turn the engine around. Oil pump is upright.
47. Lay sealing ring in the lower part of the crankcase.
48. Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.
    1. Sealant application (geometry, sealing bead = 1 mm); Doboseal 224N (999.915.573.43, status 09/09)
       Fig 38: Applying Sealant To Oil Guide Housing (4WD)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
49. 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 dial gauge, etc.). For details, see → 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
50. Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4-  . Don't forget the screws between the oil guide housing and timing-case cover (five screws behind front vibration balancer, bores are currently overhead). -7- 
    Fig 39: Identifying Oil Guide Housing With Accessories

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Screw, M6 x 20
    2. Joint flange
    3. Sealing ring
    4. Oil guide housing to lower part of crankcase - aluminum screw  ; always use new aluminum screws
    5. Oil level sensor
    6. Oil level sensor to oil guide housing (steel screw)
    7. Timing-case cover to oil guide housing - aluminum screw  ; always use new aluminum screws
51. Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings.
    Fig 40: Identifying Oil Lines On Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Suction pipe between the oil pump and turbocharger (fitted in oil guide housing)
    2. Suction pipe between the oil pump and turbocharger (fitted in oil guide housing)
    3. Intake pipe on oil pump
    4. Sealing ring
    5. Oil pressure pipe
    6. Sealing ring
    7. Sealing ring; oil before fitting
    8. Oil regulating line
    9. Sealing ring
    10. Sealing ring; oil before fitting
    11. Oil pipes to oil pump and oil guide housing
    12. Oil pipes to oil pump and oil guide housing
    Fig 41: Identifying Oil Lines On Turbo Engine (View With Oil Pan Removed)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Mounting point for oil pressure pipe
    2. Mounting point for oil extraction line for turbocharger, cylinders 5 to 8
    3. Mounting point for oil extraction line for turbocharger, cylinders 1 to 4
    4. Mounting point for auxiliary sump intake manifold
    5. Mount for oil pump intake manifold
    6. Mounting point for oil regulating line
52. Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -1, 2 and 3-  .
53. Fit oil level sensor (turn carefully when inserting sensor). -5 and 6- 
54. Fit oil pan with a new seal and tighten evenly and in diagonally opposite sequence.
    Fig 42: Identifying Oil Pan

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Oil pan
    2. Seal; replace following removal
    3. Seal; replace following removal
    4. Oil drain plug, M18; aluminum screw; reusable
    5. Screw, M6 x 20
55. Turn the engine around.
56. Position vibration balancer with screw tightened by hand.
57. Set the timing. Follow procedure exactly. → 150516 SETTING TIMING FOR CAMSHAFTS
    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.

    Fig 43: Supporting Engine (V8 Engine Supported On Assembly Support)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
58. Tighten vibration balancer -3 and 4-  to the specified torque (use a brace brace 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 details, see → 137619 REMOVING AND INSTALLING PULLEY (VIBRATION BALANCER)
    Fig 44: Identifying Pulleys

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
    7. Tandem pump pulley
59. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see → 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP
60. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it. → 477619 REMOVING AND INSTALLING VACUUM PUMP
    Fig 45: Identifying Vacuum Pump, O-Rings And Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Vacuum pump
    2. Screw, M6 x 25
    3. O-ring
    4. O-ring
61. Fit spark plugs if necessary. → 287020 REMOVING AND INSTALLING SPARK PLUGS
62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
63. Fit both eyelets.
64. 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 Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
    Fig 46: Identifying Thermostat Housing And Coolant Regulator

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Thermostat housing
    2. Screw, M6 x 25
    3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe => see relevant section
    4. Seal for thermostat housing; replace
    5. Thermostat insert; including electric heating element
65. Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see → 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
66. Route boost-pressure control and wastegate lines and fit holder.
    Fig 47: Identifying Boost Pressure And Wastegate 2

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Pressure line
    2. Vacuum line
    3. Hose clamp
    4. Screw, M6 x 12
    5. Holder
    6. Rubber element
    7. Electric change-over valve
    8. Control line
    1. View A; pressure line/intake-air distributor connection
    Fig 48: Identifying Boost Pressure And Wastegate 1

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Pressure line, boost pressure line
    2. Hose clamp
    3. Cycle valve
    4. Holder on timing-case cover
    5. Combination holder
    6. Wastegate control line, cylinders 5 to 8
    7. Wastegate control line, cylinders 1 to 4
    8. Hose holder
    9. Screw on timing-case cover; see Timing-case cover
67. Grease both sealing rings on the coolant pipe sparingly with Kluber 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 49: Identifying Coolant Guide

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Heater coolant pipe
    2. M6 screw
    3. Sealing ring
    4. Screw plug, M16 x 1.5
    5. M6 screw
    6. Coolant guide tube (collection pipe)
    7. Metal seal
    8. Stopper
68. Fit the water pump. Fit pulley for water pump. For details, see → 195019 REMOVING AND INSTALLING COOLANT PUMP
69. Fit oil pressure sensor with adapter. Replace sealing rings.
    Fig 50: Identifying 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
    5. Stopper
    6. Sealing ring
    1. Direction of travel
70. On 4WD vehicles, install one cross shaft cover with the cross shaft pipe -1-  .

    Replace sealing rings in the covers.

    1. 70.1. Apply housing seal -2-  (Doboseal 224N (999.915.573.43 status 09/09)) to the seating points of the two cross shaft covers close to the edge of the housing.
    2. 70.2. Position cross shaft cover with cross shaft pipe -1-  .

       Make sure that the cross shaft pipe is protruding at a center position from the opposite opening on the oil guide housing. The -TOP-  marking must be facing upwards.

       Fig 51: Identifying Cross Shaft Pipe With Cover

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 70.3. Screw in fastening screws -arrows-  .
71. Install the second cross shaft cover -1-  .
    1. 71.1. Position the cross shaft cover -1-  .

       Make sure that the cross shaft pipe is inserted into the center opening on the cover.

       The -TOP-  marking must be facing upwards.

    2. 71.2. Screw in fastening screws.
    Fig 52: Locating Cross Shaft Cover Screws
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
72. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-  .
    Fig 53: Identifying Left Bracket For Auxiliary Units And 4WD Turbo Engine Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Bracket for auxiliary units
    2. Screw, M10 x 45
    3. Dowel sleeve
    4. Engine carrier/cross-shaft engine carrier
    5. Hydraulic mount, left
    6. M12 nut
    7. Heat protection panel
    8. Screw, M6 x 12
73. Fit front-wheel drive (all-wheel drive) for 4WD vehicles. → 398819 REMOVING AND INSTALLING FOUR-WHEEL FINAL DRIVE
74. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position. → 103519 REMOVING AND INSTALLING ENGINE MOUNTING 
75. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
    Fig 54: Identifying Coolant Supply On Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
76. Fit the generator and crash support. For details, see → 272219 REMOVING AND INSTALLING GENERATOR
    Fig 55: Identifying Generator

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Generator
    2. Screw, M8 x 95
    3. Screw, M8 x 35
    4. Bores for screws, M8 x 95
    1. View
77. Fit deflection rollers and belt tensioner and press on cover.
    Fig 56: Routing Of Belt Drive

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Deflection roller
    2. Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever
    3. M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console
    4. Deflection roller
    5. Dual poly-V-belt
78. Fit crankshaft sealing ring on flywheel side. See → 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (TRANSMISSION SIDE)
79. Fit coolant hosing and secure clamps.
    Fig 57: Coolant Return Connection On Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Connection piece on generator
    2. Connection piece screw
    3. Screw, M6 x 20
    4. Coolant return line
    5. Coolant return hose assembly
    6. Holder
    7. M6 screw Aluminum screw  ; always use new aluminum screws
    8. Clip
    Fig 58: Identifying Coolant Supply Connection On Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
80. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
    Fig 59: Identifying Vent Line And Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Vent line
    2. Screw, M6 x 16
81. 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 → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE
82. Fit high-pressure line and low-pressure line. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
    Fig 60: Identifying High-Pressure Pump, Turbo Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. High-pressure pump
    2. High-pressure line; (3 turns: tighten, loosen, tighten)
    3. M6 screw on low-pressure line
    4. Low-pressure line; (3 turns: tighten, loosen, tighten); counter at the hexagon at the high-pressure pump
    5. Screw socket, M8
    6. Screw socket, M6
    7. Protective plate
    8. Screw, M6 x 20

    Magnifying glass  - Required line distance (5 to 8 mm) between components

83. Fit high-pressure fuel distribution pipe. For details, see → Installing Fuel Distributor Pipe
84. Check the DFI high-pressure system for leaks. → 243001 CHECKING FUEL COLLECTION PIPE FOR LEAKS
85. Fit the turbocharger. Fit seals correctly. Observe tightening sequence. It is best to fit the turbocharger to the engine with the lines connected and fitted and then screw it on.
    Fig 61: Identifying Turbocharger, Cylinders 1 To 4

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Turbocharger coolant return line
    2. Turbocharger coolant supply line
    3. Clamp
    4. Coolant supply hose for turbocharger
    5. Turbocharger; exhaust manifold/turbocharger module
    Fig 62: Identifying Turbocharger, Cylinder 5 To 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Turbocharger coolant return line
    2. Turbocharger coolant supply line
    3. Coolant supply line holder to oil guide housing
    Fig 63: Oil Circuit For Turbocharger, Cylinders 1 To 4

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for turbocharger and holding clamp for vent line to collection pipe
    2. Oil feed line for turbocharger, cylinders 1 to 4; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head not represented  - Connection piece for check valve to turbocharger
    3. Holder
    4. Seal
    5. Oil extraction line
    6. Screw, M6 x 12; oil extraction line for turbocharger to oil guide housing and oil feed line for turbocharger at the holder
    7. Screw, M6 x 16
    Fig 64: Oil Circuit For Turbocharger, Cylinders 5 To 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Oil feed line for turbocharger, cylinders 5 to 8; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head
    2. Vent line for turbocharger, cylinders 5 to 8; vent line to oil extraction line for turbocharger
    3. M6 screw; oil extraction line for turbocharger to oil guide housing and holding clamp
    4. Retaining clip
    5. Oil extraction line
    6. Screw, M6 x 16
    7. Seal
    Fig 65: Identifying Turbocharger Exhaust Manifold, Cylinders 1 To 4

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Turbocharger exhaust manifold, cylinders 1 to 4
    2. Seal; install so that marking on seal is legible
    3. Lower tab washer
    4. Upper tab washer
    5. Nut M8; turbocharger exhaust manifold to cylinder head; replace
    Fig 66: Identifying Turbocharger Exhaust Manifold, Cylinders 5 To 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Turbocharger exhaust manifold, cylinders 5 to 8
    2. Seal; install so that marking on seal is legible
    3. Nut M8; turbocharger exhaust manifold to cylinder head; replace
    4. Upper tab washer
    5. Lower tab washer

    1 to 12  - applies to both sides, always start at the timing-case cover

    Fig 67: Tightening Sequence For Turbocharger Exhaust Manifold

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
86. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. → Ventilation on turbo engines 
    Fig 68: Ventilation On Turbo Engines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Engine ventilation line
    2. Check valve for full-throttle ventilation with lines secured
    3. Tank ventilation
    4. Aluminum holder
    5. Aluminum screw (holder); see Timing-case cover
    6. Belt tensioner
    7. Holder
    8. Fastening screw; see Fig 56
87. Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
88. Fit oil mist separator. For details, see → 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR .
89. Fit power-steering pump. For details, see installation description → Installing Hydraulic Pump
90. Fit air conditioning compressor. → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR
91. Fit pulley for power-steering pump or tandem pump.
    Fig 69: Identifying Pulleys

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Water pump pulley
    2. Screw, M8 x 16
    3. Vibration damper
    4. M18 screw; always use a new screw
    5. Power-steering pump pulley
    6. Screw, M8 x 16
    7. Tandem pump pulley
92. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). → Installing Drive Belt
93. Fit heat protection panels on generator and on exhaust manifold.
94. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.