Completing Reconditioned Engine

Information 

Tightening torques, tightening sequence and assembly overviews for the engine and transmission:

• Group 1: 

  > 1X00IN - TECHNICAL VALUES

• Group 2: 

  > 2X00IN - TECHNICAL VALUES

• Group 3: 

  > 3X00IN - TECHNICAL VALUES

Information 

• O-rings must always be replaced. 
• O-rings must be coated lightly with Kluber Syntheso Glep. 

1. Convert engine mount supports -1 and 2-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Engine supports

   1. 1.1  Unscrew screws -3-  and remove supports -1 and 2-  .
   2. 1.2  Position supports -1 and 2-  on new engine.
   3. 1.3  Screw in and tighten screws -3-  .

      Tightening torque 40 Nm (30 ftlb.) 

2. Convert engine wire harness.

   > 975219 - REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

3. Re-fit generator.

   > 272219 - REMOVING AND INSTALLING GENERATOR (R4)

4. Remove turbocharger on new engine.

   > 213019 - REMOVING AND INSTALLING TURBOCHARGER (R4)

5. Remove and convert the starter.

   > 276019 - REMOVING AND INSTALLING STARTER (R4)

6. Re-install turbocharger on the new engine.

   > 213019 - REMOVING AND INSTALLING TURBOCHARGER (R4)

   Information 

   • Replace O-rings on the cooling system. 
   • Clean plug connection and coolant hoses before assembly. 
   • Remove stoppers before fitting the coolant lines and hoses. 
7. Convert coolant line for heater -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Coolant line for heating

   1. 7.1  Loosen retaining clip -2-  and pull off coolant line for heater -1-  .
   2. 7.2  Push coolant line for heater -1-  onto new engine.
   3. 7.3  Press retaining clip -2-  down to lock it.

   Information 

   • Replace O-rings on the cooling system. 
   • Clean plug connection and coolant hoses before assembly. 
   • Remove stoppers before fitting the coolant lines and hoses. 
8. Convert coolant lines -1-  at the coolant pump.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Coolant lines on coolant pump

   1. 8.1  Lift retaining clips -2-  , loosen spring band clamp -3-  using VAS 6890 - spring band clamp pliers  and disconnect coolant lines
   2. 8.2  Push coolant lines -1-  onto new engine.
   3. 8.3  Press retaining clips -2-  down to lock them.
   4. 8.4  Fasten spring band clamp -3-  using VAS 6890 - spring band clamp pliers  .