Subsequent Work
NOTIFICATION
Dirt and contamination
- Risk of damage to units or components
- → Protect components from dirt and contamination.
- → Clean or replace dirty components.
Information
- Coat O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).
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.
Repair group 1:
.
Repair group 2:
- Install upper coolant distributor housing -1-
(unit carrier).
> 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING - portion on "Installing".
Coolant distributor housing screws
- Distributor housing
- M8 x 35 screws at the left and M8 x 50 screws at the right
- Slide bracket for coolant pump -1-
with new O-rings -2 and 3-
onto coolant pipe -4-
and connection piece.
O-rings for coolant pipes on coolant pump
- Screw on coolant pump bracket -1-
.
- 3.1 Fit and tighten external Torx screws M8 -2, 3 and 5- and M6 -4- .
Bracket for coolant pump
- Fit vibration damper.
> 137519 REMOVING AND INSTALLING VIBRATION DAMPER (2.0 L) - portion on "Installing".
> 137519 REMOVING AND INSTALLING VIBRATION DAMPER (2.5 L) - portion on "Installing".
- Fit belt tensioner.
> 137319 REMOVING AND INSTALLING BELT TENSIONER - portion on "Installing".
- Install the high-pressure pump.
> 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP - portion on "Installing".
- Install fuel lines.
> 249019 REMOVING AND INSTALLING FUEL LINE - portion on "Installing"
.
> 203819 REMOVING AND INSTALLING SUPPLY LINE (ENGINE) - portion on "Installing".
- Install coolant pipe -1-
for the coolant regulator housing and secure with external Torx screw -2-
.
Coolant pipe for coolant regulator housing (shown on 991 engine)
- Install housing for coolant regulator.
> 195519 REMOVING AND INSTALLING COOLANT REGULATOR HOUSING - portion on "Installing".
- Turn the engine at the assembly support so that the oil pan is at the top.
- Install exhaust manifold with new seals.
> 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD - portion on "Installing".
- Turn the engine 180° at the assembly support.
- Install coolant distributor. Coat new O-rings -1-
with Kluber Gel.
- 13.1 Fit coolant distributor into coolant pipes.
O-rings for connecting pipes for coolant distributor
- 13.2 Fit coolant distributor -1- using external Torx screws -2- and tighten screws.
Coolant distributor
- 13.1 Fit coolant distributor into coolant pipes.
- Install fuel injector.
> 244019 REMOVING AND INSTALLING FUEL INJECTOR - portion on "Installing".
- Install fuel collection pipes.
> 243020 REMOVING AND INSTALLING FUEL COLLECTION PIPE - portion on "Installing".
- Install the starter.
> 276019 REMOVING AND INSTALLING STARTER - portion on "Installing".
- Install bracket for oil-water heat exchanger.
For tightening torques, see
> 1X00IN Technical values - Group 1 .
- 17.1 Pull out stoppers and fit and grease new O-rings.
Console threaded joint
- Install oil-water heat exchanger.
> 174019 REMOVING AND INSTALLING OIL/WATER HEAT EXCHANGER - portion on "Installing".
Threaded joint for oil-water heat exchanger
- Install oil separator with new O-rings.
> 105519 REMOVING AND INSTALLING OIL SEPARATOR - portion on "Installing".
- Install console with deflection roller -1-
.
> 137719 REMOVING AND INSTALLING DEFLECTION ROLLER - portion on "Installing".
- 20.1 Fit and tighten external Torx screws -2 and 3- .
Deflection roller console
- Install air-conditioning compressor.
> 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR - portion on "Installing".
- Install hydraulic valves for valve lift switchover.
> 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT - portion on "Installing".
- Install B+ wire harness (engine).
> 974519 REMOVING AND INSTALLING WIRE HARNESS FOR BATTERY WIRING - portion on "Installing".
- Install engine wire harness.
> 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE - portion on "Installing".
- Route oxygen sensor cable and secure in the holders.
- Fit coolant hoses -2-
to oil-water heat exchanger.
- 26.1 Coat hoses with Kluber Gel and fit them. Close spring band clamps -1- .
Coolant hoses at the heat exchanger (view of engine without PDCC)
- Install generator.
> 272219 REMOVING AND INSTALLING GENERATOR - portion on "Installing".
- Install oil filler neck.
> 171519 REMOVING AND INSTALLING OIL FILLER NECK - portion on "Installing".
- 28.1 Grease new O-ring and fit oil filler neck on crankcase.
- 28.2 Tighten external Torx screws.
- Install positive crankcase ventilation lines.
> 105219 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION LINE - portion on "Installing".
- 29.1 Grease O-rings.
- 29.2 Connect short -2- and long section -1- .
Installation positions of positive crankcase ventilation lines
- Positive crankcase ventilation line, long section
- Positive crankcase ventilation line, short section
- Oil separator
- Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and positive crankcase ventilation line.
- Connect all possible plug connections for the engine wire harness before fitting the intake system.
- Install intake-air distributor.
> 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - portion on "Installing".
- 32.1 Grease new moulded seals.
- 32.2 Fit complete intake-air distributor and position it on the cylinder heads.
- 32.3 Fit external Torx screws and tighten uniformly according to the specified tightening sequence -1 - 12- .
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tightening sequence for intake-air distributor (shown as an example)
- Install turbocharger with all lines.
> WM, 213019 - REMOVE AND INSTALL TURBOCHARGER - portion on "Installing".
> 213019 REMOVING AND INSTALLING TURBOCHARGER - portion on "Installing".
- Fit tank vent line and engine compartment temperature sensor.
> 202319 REMOVING AND INSTALLING TANK VENT VALVE - portion on "Installing".
- Fit oil filler neck on holder for intake-air distributor. Tighten external Torx screws.
- Connect positive crankcase ventilation line to the resonance tube and oil separator and clip it in at the intake-air distributor.
- 36.1 Tighten external Torx screw used to secure the cable duct to the intake-air distributor.
Positive crankcase ventilation line and tool use in engine compartment (rear)
- Install the drive belt.
> 137819 REMOVING AND INSTALLING DRIVE BELT - portion on "Installing".
- Install engine support.
- Install catalytic converter with cross tube.
> 267319 REMOVING AND INSTALLING CATALYTIC CONVERTER - portion on "Installing".
- Fit engine carrier (bracket).
> 103019 REMOVING AND INSTALLING ENGINE CARRIER (BRACKET) - portion on "Installing".
- Install charge-air cooler holder.
> 214219 REMOVING AND INSTALLING CHARGE-AIR COOLER HOLDER - portion on "Installing".
- Remove engine from the engine assembly support.
1001IN TOOLS FOR REMOVING/INSTALLING UNITS AND WORKING ON ASSEMBLY SUPPORT .
- Fit flywheel with new screws.
> WM, 136019 - REMOVING AND INSTALLING FLYWHEEL FOR DOUBLE CLUTCH TRANSMISSION - portion on "Installing".
> WM, 136019 - REMOVING AND INSTALLING FLYWHEEL - portion on "Installing"
- Mount transmission.
> WM, 373427 - REMOVING AND MOUNTING DOUBLE CLUTCH TRANSMISSION - portion on "Mounting".
> 343527 REMOVING AND MOUNTING TRANSMISSION - portion on "Mounting".
- Install the engine.
> WM, 100119 - REMOVING AND INSTALLING ENGINE - portion on "Installing".
- Install charge air cooler.
> 214319 Removing and installing charge-air cooler portion on "Installing".
- Fill in drained fluids and check fluid levels.
- Complete the vehicle.