Assembling Engine

NOTIFICATION 

Dirt and contamination 

• Risk of damage to units or components 
  • → Protect components from dirt and contamination.
  • → Clean or replace dirty components.

Information 

• Get another person to help you fit crankcase halves 1-2. 

Information 

• Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged. 

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 

• Some of the illustrations show the 6-cylinder engine variant as an example. 
• But this does not affect the procedure or the steps to be carried out. 

Information 

• The tightening torques for the engine are listed in the following documents and must be used in accordance with these specifications. 

Technical values and tightening torques: 

Repair group 1:

> 1X00IN TECHNICAL VALUES - GROUP 1

.

Repair group 2:

> 2X00IN TECHNICAL VALUES - GROUP 2 .

Overview of bearing shell allocation: 

Allocation of crankshaft bearing shells

1. Main bearing shells - red, yellow, blue
2. Partial-groove bearing shells - red, yellow, blue
3. Thrust washers
4. Supporting mount shells - red, yellow, blue

1. Fit crankcase half 3-4 on the engine assembly support.
   1. 1.1 Use > 9590 - mounting parts  to secure to the > 9771 - engine adapter  .

      1001IN TOOLS FOR REMOVING/INSTALLING UNITS AND WORKING ON ASSEMBLY SUPPORT .

   Information 

   • The bearing shells must be allocated according to specifications. 
   • Observe difference between partial-groove bearings and smooth bearings. 
   • Grease bearing shells with Optimol 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 
2. If the allocation of the bearing shell pairs (main and support bearings) is based on the markings, the following general rule applies: 
   • The thinner bearing shell must always be inserted into crankcase half 3-4! 
3. Fit new bearing shells on crankcase half 3-4. The following markings ensure correct allocation.
   1. 3.1 Crankcase half 3-4  : Markings are on the crankshaft. The upper series of letters -1-  is for the crankcase. Allocation starts at the support bearing -SL-  on the belt side and is read from left to right. The support bearing does not have a number, while the main bearings are numbered -HL 1 bis 5-  (number 5 is at the flywheel side).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Marking for bearing shell allocation on the crankshaft

   1. Position of support and main bearing shells on crankshaft (support bearings not numbered!)
   2. Series of letters on support and main bearing shells
   3. Position of connecting-rod bearing shells
   4. Series of letters on connecting-rod bearing shells

   SL  Supporting mount

   HL  Main bearing

   PL  Connecting-rod bearing

   R  Red bearing shell ("thin")

   G  Yellow bearing shell ("medium")

   B  Blue bearing shell ("thick")

4. Fit new bearing shells on crankcase half 1-2.

   Always observe specification (Step 2)! 

   1. 4.1 Crankcase 1-2:  Markings -1-  on crankcase half. 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.
   2. 4.2 Fit and grease new O-ring on the crankcase sealing face.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Marking for bearing shell allocation on crankcase half 1-2

   1. Bearings fitted in bearing seat on crankcase half 1-2

   R  Red bearing shell ("thin")

   G  Yellow bearing shell ("medium")

   B  Blue bearing shell ("thick")

5. Insert two thrust washers -1-  on main bearing 2. Oil grooves must always be facing outwards.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Position of grooves on thrust washer

6. Install tensioning rail for oil-pump drive chain in crankcase 3-4.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tensioning rail for oil-pump timing chain

   1. Rail
   2. Tensioning spring
   1. 6.1 Fit tensioning rail -1-  for oil pump chain using a short bearing pin.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tensioning rail for oil-pump drive in crankcase

7. Fit guide rail for cylinder bank 3-4 and secure in the crankcase using a short bearing pin.
   1. 7.1 Place spring -2-  on tensioning rail -1-  for oil-pump drive chain into the cut-out in the guide rail -3-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Position of tensioning spring in guide rail

8. Insert crankshaft -1-  with timing chains -2-  .
   1. 8.1 Engage oil pump gear in the drive chain.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Crankshaft and timing chains in crankcase half 3-4

9. Fix crankshaft in place using special tool > 9779 - holding bridge-1-  .
   1. 9.1 Fit and tighten fastening screws -2-  hand-tight.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Holding bridge 9779 for crankshaft (shown on 6-cylinder engine)

10. Install pistons on cylinder bank 3-4 and connecting rods 1-2.

    > 131020 REMOVING AND INSTALLING PISTONS - portion on "Installing".

11. Have new through bolts with sealing washers ready.

    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 to crankcase half 3-4. Observe processing instructions.
    1. 12.1 Use sealant listed in Spare Parts Catalogue (Part No. 000.043.207.31).
    2. 12.2 Carefully apply a continuous bead of sealant -1 to 3-  with a diameter of 1 mm. Follow sealant contour as shown in illustration.
    3. 12.3 Remove residual silicone in the crankshaft flange area -4-  following installation.
    4. 12.4 Fit new sealing ring -5-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Applying sealant on crankcase half 3-4

13. Fit rubber sleeves on connecting rods 1-2 (> 9795 - assembly aid  ) and position vertically.
14. With the help of a second person, place crankcase half 1-2 on crankcase half 3-4.
15. Fit through bolts -1 to 10-  and tighten according to the specified tightening torque and sequence.

    > 1X00IN Technical values .

    Fig 2: Crankcase Bolts Tightening Sequence

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tightening sequence for crankcase

16. Fit external Torx screws -11 to 25-  for the outer cross bolt connection and tighten according to the specified tightening sequence.

    > 1X00IN Technical values - Group 1 .

17. Fit and tighten > 9590 - mounting parts  for bolting crankcase half 1-2 to the top of the engine support.
18. Install pistons for cylinder bank 1-2.

    > 131020 REMOVING AND INSTALLING PISTONS - portion on "Installing".

19. 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. 19.1 Then, turn the crankshaft so that none of the pistons are at top dead centre (TDC).
20. Fit crankshaft sealing rings at the flywheel and belt side.

    > 137455 REPLACING CRANKSHAFT SEALING RING - BELT SIDE .

    > 135955 REPLACING CRANKSHAFT SEALING RING - FLYWHEEL SIDE .

21. Fit tensioning rail for cylinder bank 3-4 using a long bearing pin -3-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bearing pins for bank 3-4 (shown on 6-cylinder engine)

    1. 21.1 Fit tensioning rail for cylinder bank 1-2.
    2. 21.2 Secure guide rail for cylinder bank 1-2 in the crankcase with long bearing pins -1-  .

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Bearing pins for bank 1-2 (shown on 6-cylinder engine)

    3. 21.3 Tighten bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
22. Install oil windage tray.
23. Install upper part of oil pan.

    > 175019 REMOVING AND INSTALLING OIL PAN (UPPER PART) - portion on "Installing".

24. Install oil pump.

    > 172019 REMOVING AND INSTALLING OIL PUMP - portion on "Installing".

25. Install coolant pipe for coolant pump.
    1. 25.1 Fit and tighten external Torx screws.
26. Insert displacement bodies on cylinder bank 1-2.

    Information 

    • Always guide timing chains with your hand when turning the crankshaft. 
27. Fit cylinder head 1--2 and 3-  -4.

    > 157019 REMOVING AND INSTALLING CYLINDER HEAD - portion on "Installing".

28. Hold tensioning rail -1-  for cylinders 1-2 using a pair of flat-nosed pliers -3-  and screw in bearing pin -4-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fitting tensioning rail and guide rail

    1. 28.1 Secure guide rail for cylinders 3-4 in the cylinder head with a short bearing pin.
    2. 28.2 Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
29. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tensioning rail for oil-pump drive chain and guide rail

    1. Tensioning spring for tensioning rail
    2. Guide rail
30. Install lower part of oil pan.

    > 175019 REMOVING AND INSTALLING OIL PAN (LOWER PART) - portion on "Installing".

31. Install camshafts.

    > 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .

32. Install cylinder head cover.

    > 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - portion on "Installing".

33. Install vacuum pump for brake booster.

    > 477619 REMOVING AND INSTALLING VACUUM PUMP - portion on "Installing".

34. Fit vacuum line (vacuum pump).
35. Fit cover for positive crankcase ventilation.
    1. 35.1 Fit cover for cylinder bank 1-3 -1-  with new gaskets -2 and 3-  and secure with external Torx screws -4-  .

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Positive crankcase ventilation cover 1-3

    2. 35.2 Fit cover for cylinder bank 4-6 -1-  with a new O-ring -2-  and secure with external Torx screws -3-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Positive crankcase ventilation cover 4-6

36. Fit spark plugs.

    > 287020 REMOVING AND INSTALLING SPARK PLUGS - portion on "Installing".

37. Install ignition coils.

    > 282020 REMOVING AND INSTALLING IGNITION COILS - portion on "Installing".