Disassembling Engine

NOTIFICATION 

Interchanged or dirty bucket tappets 

• Scoring on cylinder head 
• → Since the bucket tappets have been run in the fitting bores, do not interchange them.
• → Absolute cleanliness is essential.

Information 

• Have a collection pan and cloths ready before starting to work on the engine. 
• Close off open connections using suitable stoppers. 
• Residual fluid can leak out. 

Information 

For many components, it is only necessary to partially disassemble the engine. The extent of disassembly depends on the damage and scope of repairs to be carried out.

1. Mark vacuum hoses so that they cannot get mixed up.
2. Remove turbocharger.
   • 213019 Removing and installing turbocharger 
3. Remove high-pressure pump.
   • 246319 Removing and installing high-pressure pump (V6 Turbo) 
4. Remove upper chain housing cover.
   • 153319 Removing and installing upper chain housing cover (V6 Turbo) 
5. Remove ignition coils.
   • 282020 Removing and installing ignition coils (V6 Turbo) 
6. Remove spark plugs.
   • 287020 Removing and installing spark plugs (V6 Turbo) 
7. Remove oil separator.
   • 105519 Removing and installing oil separator (V6 Turbo) 
8. Remove oil filter housing.
   • 172919 Removing and installing oil filter housing (V6 Turbo) 
9. Remove oil cooler.
   • 174019 Removing and installing oil cooler (V6 Turbo) 
10. Remove fuel collection pipe.
    • 243019 Removing and installing fuel collection pipe 
11. Remove injector valves.
    • 244019 Removing and installing injector valve (V6 Turbo) 
12. Remove hydraulic valve for valve lift switchover.
    • 155519 Removing and installing hydraulic valve for valve lift switchover (V6 Turbo) 
13. Remove tank vent valve.
    • 202319 Removing and installing tank vent valve 
14. Remove drive belt.
    • 137819 Removing and installing drive belt (V6 Turbo) 
15. Remove air-conditioning compressor.
    • 873419 Removing and installing air-conditioning compressor 
16. Removing the generator.
    • 272219 Removing and installing generator (V6 Turbo) 
17. Remove air-conditioning compressor support -5-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Air-conditioning compressor support (shown on V6 Monoturbo)

    1. 17.1  Remove tensioning roller. -3- 
       1. 17.1.1  Carefully lever off the dust cap -1-  with a suitable tool.
       2. 17.1.2  Unscrewing screw on tensioning roller -2-  .
       3. 17.1.3  Remove tensioning roller -3-  .
    2. 17.2  Unscrew the screws of the air conditioning compressor support -4-  .
    3. 17.3  Remove air-conditioning compressor support. -5- 
18. Remove the generator -1-  support.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Generator support

    1. 18.1  Unscrew screws -2-  .
    2. 18.2  Remove generator support -1-  .
19. Remove deflection roller -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Deflection roller for drive belt for generator

    1. 19.1  Carefully lever off the dust cap -2-  with a suitable tool.
    2. 19.2  Unscrew screw on deflection roller -3-  .
    3. 19.3  Remove deflection roller -1-  .
20. Remove crankshaft vibration damper.
    • 137519 Removing and installing crankshaft vibration damper (V6 Turbo) 
21. Remove the drive plate.
    • 136319 Removing and installing drive plate 
22. Removing pressure-regulating valve.
    • 172619 Removing and installing pressure-regulating valve (V6 Turbo) 
23. Remove intake distributor.
    • 244619 Removing and installing the intake distributor (V6 Turbo) 
24. Remove oil pan.
    • 175019 Removing and installing oil pan (V6 Turbo) 
25. Remove oil guide housing.
    • 174619 Removing and installing oil guide housing (V6 Turbo) 
26. Remove oil pump.
    • 172019 Removing and installing oil pump (V6 Turbo) 
27. Remove lower chain housing cover.
    • 153319 Removing and installing lower chain housing cover (V6 Turbo) 
28. Remove crankcase cover.
    • 101419 Removing and installing crankcase cover (V6 Turbo) 
29. Remove coolant pump.
    • 195019 Removing and installing coolant pump (V6 Turbo) 
30. Remove coolant regulator.
    • 195819 Removing and installing coolant regulator (V6 Turbo) 
31. Remove the coolant switching valve -3-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant switching valve

    1. 31.1  Pull off vacuum hose -1-  .
    2. 31.2  Unscrew screws on coolant switching valve -2-  and pull coolant switching valve -3-  off the coolant pipe -4-  .
       1. 31.2.1  Replace screws.
32. Remove coolant flanges on left and right cylinder bank.
    Fig 1: Coolant Flanges Screws Loosening Sequence

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant flanges

    1. 32.1  Unscrew screws -1 to 3-  .
    2. 32.2  Remove coolant flanges.
33. Remove brake booster vacuum pump.
    • 477619 Removing and installing brake booster vacuum pump (V6 Turbo) 
34. Remove control chain.
    • 153519 Removing and installing control chain (V6 Turbo) 
35. Remove chain tensioner.
    • 153619 Removing and installing chain tensioner (V6 Turbo) 
36. Remove guide and tension rails.
    • 154719 Removing and installing guide and tension rail (V6 Turbo) 
37. Remove the cylinder head cover.
    • 158219 Removing and installing cylinder head cover (V6 Turbo) 
38. Remove camshafts.
    • 150520 Removing and installing camshafts 
39. Remove cylinder heads.
    • 157019 Removing and installing cylinder head (V6 Turbo) 
40. Disassembling cylinder heads.
41. 40.1  Remove valve lifter.
    • 155920 Removing and installing valve lifter 
42. 40.2  Remove valves.
    • 156120 Removing and installing valves (V6 Turbo) 
43. 40.3  Remove valve-stem seals.
    • 156356 Replacing valve-stem seals 
44. Remove balance shaft.
    • 138519 Removing and installing balance shaft 
45. Remove crankshaft.
    • 134819 Removing and installing crankshaft (V6 Turbo) 
46. Remove pistons and connecting rods.
    • 131020 Removing and installing piston (V6 Turbo) 
47. Remove oil spray jets.
    • 101320 Removing and installing oil spray jets 
48. Remove knock sensor.
    • Removing and installing knock sensor (V6 Turbo)