Assembling Engine: Notes

Information 

• Always replace seals and O-rings. 
• Coat all O-rings and sealing surfaces with a light coating of Vaseline to prevent damage to the O-rings. 
• Lubricate all bearing locations with a light coating of engine oil (unless a different procedure is specified). 

Information 

• Coat threaded connections and fuel line cones with Microgleit DF977S lubricant (Part No. 000.043.209.35). 
• Allow components to dry off for at least 15 minutes! 

1. Assemble crankshaft.

   > 134837 DISASSEMBLING AND ASSEMBLING CRANKSHAFT

2. Determine bearing shell allocation for crankcase half on cylinder bank 2.

   The bearing shell allocation for crankcase half on cylinder bank 2 is marked on the crankshaft. The upper series of letters -1-  is for the crankcase. Allocation starts at the supporting mount -SL-  on the belt side and is read from left to right. The supporting mount does not have a number, while the main bearings are numbered -HL: 1 to 7-  (main bearing HL 7 is at the flywheel side).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Marking for bearing shell allocation on the crankshaft

   1	Series of letters at the top, supporting mount shells and main bearing shells
   2	Series of letters on connecting-rod bearing shells
   SL	Supporting mount
   HL	Main bearing
   PL	Connecting-rod bearing
   R	Bearing shell, Red
   G	Bearing shell, Yellow
   B	Bearing shell, Blue

   Information 

   • The bearing shells must be allocated according to specifications. 
   • Observe difference between partial-groove bearings and smooth bearings. 
   • Grease bearing shells with Optimal Optipit lubricant (Part No. 000.043.305.56), or use new engine oil. 
   • The "thinner" bearing shells must always be inserted into the crankcase half for cylinders 4-6. 
   • Red bearing shell = thin; yellow bearing shell = medium; blue bearing shell = thick 
3. Install new  main bearing shells -1 and 2-  and new  supporting mount shell -3-  in crankcase half on cylinder bank 2.

   Check the position of the partial-groove bearing shells -1-  and the smooth bearing shells -2-  when doing this.

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   Bearing shells fitted on crankcase half on cylinder bank 2

   1	Partial-groove bearing shells
   2	Smooth bearing shells
   3	Supporting mount

4. Insert thrust washers -1-  on main bearing 4 -2-  . When doing so, make sure that the oil grooves -3-  are facing outwards.

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   Thrust washers

5. Determine bearing shell allocation for crankcase half on cylinder bank 1.

   The bearing shell allocation -1-  for crankcase half on cylinder bank 1 is marked on the crankcase half on cylinder bank 1. The series of letters is read from left to right. Allocation starts at the flywheel side and ends at the supporting mount on the belt side.

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   Marking on crankcase half on cylinder bank 1

   G	Bearing shell, Yellow
   R	Bearing shell, Red
   B	Bearing shell, Blue

   Information 

   • The bearing shells must be allocated according to specifications. 
   • Observe difference between partial-groove bearings and smooth bearings. 
   • Grease bearing shells with Optimal Optipit lubricant (Part No. 000.043.305.56), or use new engine oil. 
   • The "thinner" bearing shells must always be inserted into the crankcase half for cylinders 4-6. 
   • Red bearing shell = thin; yellow bearing shell = medium; blue bearing shell = thick 
6. Install new  main bearing shells -1 and 2-  and new supporting mount shell -3-  in crankcase half on cylinder bank 1.

   Check the position of the partial-groove bearing shells -1-  and the smooth bearing shells -2-  when doing this.

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   Bearing shells fitted on crankcase half on cylinder bank 1

   1	Partial-groove bearing shells
   2	Smooth bearing shells
   3	Supporting mount

7. Install tensioning rail for oil pump timing chain -1-  in crankcase half on cylinder bank 2.
   1. 7.1  Fit new  O-ring in bearing pin -2-  .
   2. 7.2  Position tensioning rail for oil pump timing chain -1-  .
   3. 7.3  Fit and tighten bearing pins -2-  .

      > Tightening torque 10 N.m (7.5 ft lb.) 

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   Tensioning rail for oil pump timing chain

8. Install guide rail for crankcase half on cylinder bank 2 -1-  .

   Fit new  O-ring in bearing pin -2-  .

   1. 8.1  Position guide rail for crankcase half on cylinder bank 2 -1-  .
   2. 8.2  Fit and tighten bearing pins -2-  .

      > Tightening torque 10 N.m (7.5 ft lb.) 

   3. 8.3  Position spring for tensioning rail for oil pump timing chain -3-  into the cut-out on the guide rail for crankcase half on cylinder bank 2 -1-  .

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   Guide rail for crankcase half on cylinder bank 2

9. Install crankshaft -1-  with timing chains -2-  and connecting rods for cylinders 1-3 -3-  .
   1. 9.1  Position crankshaft -1-  in crankcase half on cylinder bank 2.

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   Crankshaft

10. Fix crankshaft in place with > 9779 - holding bridge-1-  .
    1. 10.1  Fit screws -2-  by hand and tighten slightly.

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    Holding bridge 9779 for crankshaft

11. Install pistons with connecting rods for cylinders 4-6.

    > 131020 REMOVING AND INSTALLING PISTONS

    Information 

    • The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant. 
    • Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only. 
    • Join the crankcase halves within max. 5 minutes of applying the bead of sealant. 
12. Apply sealant on crankcase half on cylinder bank 2. Observe processing instructions.
    1. 12.1  Carefully apply a continuous bead of sealant -1-  with a diameter of 1 mm.
    2. 12.2  Remove residual sealant in the crankshaft flange area -2-  following installation.

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    Sealant on crankcase half on cylinder bank 2

13. > 9795 - Assembly aid  must be pushed onto connecting rods 1-3. Then, position connecting rods 1-3 vertically.
14. > 9779 - Holding bridge  must now be removed.
15. Install crankcase half on cylinder bank 1 -35-  .
    1. 15.1  Fit new  O-ring.
    2. 15.2  Check that dowel sleeves are fitted correctly.
    3. 15.3  Position crankcase half on cylinder bank 1 -35-  .
    4. 15.4  Fit new  screws and tighten in the sequence -1 to 14-  .

       > Initial tightening 5 N.m (3.7 ft lb.) 

       > Initial tightening 15 N.m (11.1 ft lb.) 

       > Initial tightening 50 N.m (36.9 ft lb.) 

       > Loosen 360° 

       > Initial tightening 5 N.m (3.7 ft lb.) 

       > Tightening torque 15 N.m (11.1 ft lb.) 

       > Torque angle 75° 

       > Final tightening 75° 

    5. 15.5  Fit new  screws and tighten in the sequence -15 to 16-  .

       > Initial tightening 3 N.m (2.2 ft lb.) 

       > Final tightening 70° 

    6. 15.6  Tighten screw -17-  .

       > Tightening torque 33 N.m (24.3 ft lb.) 

    7. 15.7  Position engine transport bracket -34-  .
    8. 15.8  Fit screws and tighten in the sequence -18 to 32-  .

       > Tightening torque 13 N.m (9.6 ft lb.) 

    9. 15.9  Fit and tighten screw -33-  .

       > Tightening torque 33 N.m (24.3 ft lb.) 

    Fig 1: Crankcase Half Screws Tightening Sequence

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    Screws for crankcase half on cylinder bank 1

16. Install pistons for cylinders 1-3.

    > 131020 REMOVING AND INSTALLING PISTONS

17. Install crankshaft sealing ring on flywheel side.

    > 135955 REPLACING CRANKSHAFT SEALING RING - FLYWHEEL SIDE

18. Install crankshaft sealing ring on belt side.

    > 137455 REPLACING CRANKSHAFT SEALING RING - BELT SIDE

19. Install oil windage tray -1-  .
    1. 19.1  Position oil windage tray -1-  .
    2. 19.2  Fit and tighten screws -2-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

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    Oil plate

20. Install oil pump.

    > 172019 REMOVING AND REINSTALLING OIL PUMP

21. Install displacement bodies for crankcase half on cylinder block 1 -1-  .

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    Displacement bodies for crankcase half on cylinder block 1

22. Install vibration damper.

    > 137519 REMOVING AND INSTALLING VIBRATION DAMPER

    Information 

    • Always guide timing chains with your hand when turning the crankshaft. 
23. Turn the crankshaft clockwise a number of times at the vibration damper using > 9773 - turning device  in order to check for smooth operation and correct function.
    1. 23.1  Then, turn the crankshaft so that none  of the pistons are at top dead center (TDC).
24. Assemble cylinder heads.

    > 157037 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD

25. Install cylinder heads.

    > 157019 REMOVING AND INSTALLING CYLINDER HEAD

26. Install tensioning rail -1-  and guide rail -2-  for timing chain on cylinder bank 2.
    1. 26.1  Fit new  O-ring in bearing pin -3 to 5-  .
    2. 26.2  Position tensioning rail -1-  using flat-nosed pliers.
    3. 26.3  Fit and tighten bearing pin for tensioning rail -3-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

    4. 26.4  Position guide rail -2-  .
    5. 26.5  Fit and tighten bearing pin for guide rail -4-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

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    Tensioning rail and guide rail for timing chain on cylinder bank 2

27. Install tensioning rail -1-  and guide rail -2-  for timing chain on cylinder bank 1.

    Fit new  O-ring in bearing pin -3 and 4-  .

    1. 27.1  Position tensioning rail -1-  using flat-nosed pliers.
    2. 27.2  Fit and tighten bearing pin for tensioning rail -3-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

    3. 27.3  Position guide rail -2-  using flat-nosed pliers.
    4. 27.4  Fit and tighten bearing pin for guide rail -4-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

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    Tensioning rail and guide rail for timing chain on cylinder bank 1

28. Install camshafts.

    > 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING)

29. Install cylinder head cover.

    > 158219 REMOVE AND INSTALL THE CYLINDER HEAD COVER

30. Install actuator for camshaft control.

    > 153919 REMOVING AND INSTALLING ACTUATOR FOR CAMSHAFT CONTROL

31. Fit spark plugs.

    > 287020 REMOVING AND INSTALLING SPARK PLUGS

32. Install ignition coils.

    > 282020 REMOVING AND INSTALLING IGNITION COILS

33. Install fuel collection pipe (with fuel injectors).

    > 243019 REMOVING AND INSTALLING FUEL COLLECTION PIPE (WITH FUEL INJECTORS)

34. Install hall sender.

    > 283919 REMOVING AND INSTALLING CAMSHAFT SENSOR

35. Install knock sensors.

    > 287219 REMOVING AND INSTALLING KNOCK SENSOR

36. Position starter -1-  and fit and tighten screws -2-  .

    > Tightening torque 45 N.m (33 ft lb.) 

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    Starter

37. Install oil line for cylinder bank 2 -1-  .
    1. 37.1  Fit new  O-rings.
    2. 37.2  Position oil line for cylinder bank 2 -1-  .
    3. 37.3  Fit and tighten screws -2-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

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    Oil line for cylinder bank 2

38. Install oil-filter housing -1-  .

    Insert new  sealing rings.

    1. 38.1  Position oil-filter housing -1-  .
    2. 38.2  Fit and tighten screws -2-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

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    Oil-filter housing

39. Install high-pressure pumps.

    > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP

40. Install fuel supply line (engine) -1-  .
    1. 40.1  Position fuel supply line (engine) -1-  .
    2. 40.2  Clip fuel supply line (engine) -1-  into holders -4-  .
    3. 40.3  Fit union nuts -3-  and screws on holder for fuel supply line (engine) -2-  , but do not tighten yet.
    4. 40.4  Tighten union nuts -3-  .

       > Initial tightening 8 N.m (5.9 ft lb.) 

       > Final tightening torque angle 50° 

    5. 40.5  Tighten screws on holder for fuel supply line (engine) -2-  .

       > Tightening torque 13 N.m (9.6 ft lb.) 

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    Fuel supply line (engine)

41. Install fuel high-pressure line on cylinder bank 1 -1-  .
    1. 41.1  Position fuel high-pressure line -1-  with pressure sensor -6-  .
    2. 41.2  Fit union nuts -4 and 5-  , but do not tighten yet.
    3. 41.3  Fit screw for fuel high-pressure line -3-  and screw for fuel high-pressure line holder -2-  , but do not tighten yet.
    4. 41.4  Tighten union nuts -4 and 5-  .

       > Initial tightening 8 N.m (5.9 ft lb.) 

       > Final tightening torque angle + 50° 

    5. 41.5  Tighten screw on fuel high-pressure line -3-  .

       > Tightening torque 13 N.m (9.6 ft lb.) 

    6. 41.6  Tighten screw on fuel high-pressure line holder -2-  .

       > Tightening torque 13 N.m (9.6 ft lb.) 

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    Fuel high-pressure line on cylinder bank 1

42. Install fuel high-pressure line on cylinder bank 2 -1-  .
    1. 42.1  Position fuel high-pressure line -1-  with pressure sensor -5-  .
    2. 42.2  Fit union nuts -3 and 4-  , but do not tighten yet.
    3. 42.3  Fit screw for fuel high-pressure line holder -2-  , but do not tighten yet.
    4. 42.4  Tighten union nuts -3 and 4-  .

       > Initial tightening 8 N.m (5.9 ft lb.) 

       > Final tightening torque angle + 50° 

    5. 42.5  Tighten screw on fuel high-pressure line holder -2-  .

       > Tightening torque 13 N.m (9.6 ft lb.) 

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    Fuel high-pressure line on cylinder bank 2

43. Position coolant vent line -1-  and clip it in -2-  .

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    Coolant vent line

44. Install tank vent line -1-  .
    1. 44.1  Position tank vent valve -1-  and clip it in -3-  .
    2. 44.2  Fit and tighten screw on holder -2-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

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    Tank vent line

45. Position vacuum line -1-  and fit and tighten screw -2-  .

    > Tightening torque 10 N.m (7.5 ft lb.) 

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    Vacuum line

46. Install oil filler neck -1-  .
    1. 46.1  Fit new  O-ring.
    2. 46.2  Position oil filler neck -1-  .
    3. 46.3  Fit and tighten screws -2-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

    4. 46.4  Fit and tighten screw on oil feed pipe holder -3-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

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    Oil filler neck

47. Install collection pipe for transmission cooling -1-  .
    1. 47.1  Fit new  O-rings and coat with Kluber Gel.
    2. 47.2  Position collection pipe for transmission cooling -1-  together with coolant hoses -4 to 6-  .
    3. 47.3  Fit and tighten screws on collection pipe for transmission cooling -9-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

    4. 47.4  Fit and tighten screw on holder -8-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

    5. 47.5  Clip coolant hose -4-  into holder -7-  .
    6. 47.6  Connect coolant hoses -4 and 5-  to oil/water heat exchanger -2-  .
    7. 47.7  Fasten spring band clamps -3-  using > VAS 6890 - spring band clamp pliers  .

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    Collection pipe for transmission cooling

48. Install coolant intake pipe -1-  and coolant return pipe -2-  .
    1. 48.1  Secure coolant intake pipe -1-  and coolant return pipe -2-  to collection pipe for transmission cooling -3-  .
    2. 48.2  Fit and tighten screws -4-  .

       > Tightening torque 10 N.m (7.5 ft lb.) 

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    Coolant intake pipe and coolant return pipe

49. Install wire harness for engine.

    > 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

50. Install heat shields (on catalytic converter/particle filter).

    > 261219 REMOVING AND INSTALLING HEAT SHIELD (ON CATALYTIC CONVERTER/PARTICLE FILTER)

51. Install exhaust manifold with catalytic converter.

    > 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD WITH CATALYTIC CONVERTER

52. Install oxygen sensors downstream of catalytic converter.

    > 247319 REMOVING AND INSTALLING OXYGEN SENSOR DOWNSTREAM OF CATALYTIC CONVERTER

53. Install oxygen sensors upstream of catalytic converter.

    > 246919 REMOVING AND INSTALLING OXYGEN SENSOR UPSTREAM OF CATALYTIC CONVERTER

54. Install coolant pump housing -1-  .

    Fit new  O-rings and coat with Kluber Gel.

    1. 54.1  Connect coolant pump housing -1-  to coolant pipe -4-  and cylinder head housing -5-  .
    2. 54.2  Fit and tighten screws -3-  .

       > Tightening torque 33 N.m (24 ft lb.) 

    3. 54.3  Push control line -2-  onto coolant pump housing -1-  .

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    Coolant pump

55. Install coolant guide -1-  .
    1. 55.1  Fit new  seals and coat with Kluber Gel.
    2. 55.2  Position coolant guide -1-  .
    3. 55.3  Fit and tighten screws -2 and 3-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

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    Lower coolant guide

56. Install coolant regulator housing.

    > 195519 REMOVING AND INSTALLING COOLANT REGULATOR HOUSING

57. Install coolant distributor housing.

    > 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING

58. Install directional-control valve for thermal management.

    > 196819 REMOVING AND INSTALLING DIRECTIONAL-CONTROL VALVE FOR THERMAL MANAGEMENT

59. Install belt tensioner.

    > 137319 REMOVING AND INSTALLING BELT TENSIONER

60. Install generator.

    > 272219 REMOVING AND INSTALLING GENERATOR

61. Install console with deflection roller.

    > 137719 REMOVING AND INSTALLING CONSOLE WITH DEFLECTION ROLLER

62. Install air-conditioning compressor.

    > 873419 REMOVING AND INSTALLING AIR CONDITIONING COMPRESSOR

63. Install the oil separator.

    > 105519 REMOVING AND INSTALLING OIL SEPARATOR 

64. Install positive crankcase ventilation line.

    > 105219 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION LINE 

65. Install the drive belt.

    > 137819 REMOVING AND INSTALLING DRIVE BELT

66. Fit and tighten spacer bolt on engine carrier (bracket) -1-  .

    > Tightening torque 60 N.m (44 ft lb.) 

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    Spacer bolt for engine carrier (bracket)

67. Install engine carrier (bracket).

    > 103019 REMOVING AND INSTALLING ENGINE CARRIER (BRACKET)