Converting Reconditioned Engine

Information 

• All components listed must be removed from the old engine and installed on the new engine. 
• Seals and O-rings must be replaced. 
• Aluminium screws and torque angle-tightened screws must be replaced. 
• All stoppers must be removed from the new engine. 

1. Convert coolant hoses -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Coolant hoses

   1. 1.1  Mark the positions of the coolant hoses -1-  .
   2. 1.2  Loosen spring band clamps -2-  using > VAS 6890 - spring band clamps pliers  .
   3. 1.3  Remove coolant hoses -1-  .
   4. 1.4  Refit coolant hoses on the reconditioned engine and check that the coolant hoses are positioned correctly -1-  .
2. Convert pressure hoses -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Pressure hoses

   1. 2.1  Mark the positions of the pressure hoses -1-  .
   2. 2.2  Loosen clamps on pressure hoses -2-  and pull off pressure hoses.
   3. 2.3  Refit pressure hoses -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 2.3.1  Make sure that the pressure hoses a re positioned correctly -2-  .
      2. 2.3.2  Tighten clamps on pressure hoses -2-  .
         • Tightening torque 5.5 Nm (4.1 ftlb.) 
3. Convert engine support -1-  at the left and right.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Right engine support

   1. 3.1  Unscrew screws on engine support -2-  .
   2. 3.2  Remove engine support -1-  .
   3. 3.3  Refit engine support -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 3.3.1  Tighten screws on engine support -2-  .
         • Tightening torque 50 Nm (37 ftlb.) 
4. Convert air-conditioning compressor bracket -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Air-conditioning compressor bracket

   1. 4.1  Unscrew screw on tensioning roller -2-  .
   2. 4.2  Remove tensioning roller -3-  .
   3. 4.3  Unscrew screws on air-conditioning compressor bracket -4-  .
      1. 4.3.1  Replace screws.
   4. 4.4  Remove air-conditioning compressor bracket -1-  .
   5. 4.5  Refit air-conditioning compressor bracket -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 4.5.1 Tighten new  screws for the air-conditioning compressor bracket -4-  .
         • Initial tightening 8 Nm (6 ftlb.)  > Final tightening + 90° 
      2. 4.5.2  Fit screw on tensioning roller -2-  , but do not tighten yet.
5. Convert generator bracket -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Generator bracket

   1. 5.1  Unscrew screws -2-  .
   2. 5.2  Remove generator bracket -1-  .
   3. 5.3  Refit generator bracket -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 5.3.1  Tighten screws -2-  .
         • Initial tightening 8 Nm (6 ftlb.)  > Final tightening + 90 (67 ftlb.) °