Assembling Engine

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Marking on crankshaft with respect to bracing gear wheel

1. Install crankshaft.
   1. 1.1 Insert crankshaft bearing shells.
      1. 1.1.1 Check allocation of crankshaft bearing shells.
   2. 1.2 Insert crankshaft with the help of another person.
      1. 1.2.1 Insert thrust washers at the 4th crankshaft bearing.
   3. 1.3 Move bearing cover into installation position. Fit and tighten screws.

      > 134819 REMOVING AND INSTALLING CRANKSHAFT (V8 BITURBO)

   4. 1.4 Turn the crankshaft and check clearance.
   5. 1.5 Secure the crankshaft.
      1. 1.5.1 Turn crankshaft to TDC of cylinder 1.
      2. 1.5.2 Screw in > T40069 - locking pin  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Allocation of crankshaft bearing shells to bearing covers

2. Install pistons -1-  .
   1. 2.1 Check installation position of pistons! 
   2. 2.2 Insert piston -1-  into cylinder bore using > T90004 - funnel-2-  .

      > WM, 131020 REMOVING AND INSTALLING PISTONS (V8 BITURBO)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Piston with piston installation sleeve (similar to illustration)

3. Install intermediate shaft -1-  .
   1. 3.1 Coat bearing locations of the intermediate shaft -1-  with oil and guide it into the crankcase.
   2. 3.2 Coat axial bearing washer -4-  with oil and slide it onto the intermediate shaft -1-  .
   3. 3.3 Fit cover -6-  with seal -5-  .
      1. 3.3.1 Fit and tighten new screws -7-  .

      Information 

      Check that the bracing gear wheel is installed at the correct position:

      • Once the bracing gear wheel is secured, the intermediate shaft should only have a minimum amount of play (< 1 mm). 
      • If there is too much play, check the installation position of the bracing gear wheel. The splines of the intermediate shaft and bracing gear wheel must engage. 
      • If there is a marking on the crankshaft: Align the marking on the bracing gear wheel with the marking on the crankshaft. 
   4. 3.4 Fit bracing gear wheel.
      1. 3.4.1 Fit bracing gear wheel -10-  on intermediate shaft.
      2. 3.4.2 Tighten screw on bracing gear wheel -8-  .
   5. 3.5 Fit coolant pump drive gear wheel -2-  .
      1. 3.5.1 Fit coolant pump drive gear wheel -2-  on intermediate shaft -1-  and fit and tighten screw -3-  .
   6. 3.6 Pull off > T40362 - locking pin-9-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Intermediate shaft

4. Install guide and tensioning rails.

   > 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS (V8 BITURBO)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Guide and tensioning rails

5. Install lower chain housing cover.
   1. 5.1 Clean sealing faces thoroughly and apply sealant Loctite 5970-BM  .
   2. 5.2 Carefully fit the chain housing cover on the crankcase.
   3. 5.3 Fit and tighten screws -1 to 19-  uniformly in the specified tightening sequence.

      > 153319 REMOVING AND INSTALLING LOWER CHAIN HOUSING COVER (V8 BITURBO)

   4. 5.4 Install new sealing ring.

      > 135955 REPLACING CRANKSHAFT-FLYWHEEL SEALING RING

      Fig 1: Chain Housing Cover Screws Tightening Sequence

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Tightening sequence for chain housing cover

6. Install crankcase cover at the front.

   > WM, 101419 REMOVING AND INSTALLING FRONT CRANKCASE COVER (V8 BITURBO) 

   1. 6.1 Clean sealing faces thoroughly and apply sealant Loctite 5970-BM  .
   2. 6.2 Fit and tighten screws -10 to 1-  in the specified tightening sequence.
   3. 6.3 Install new sealing ring.

      > 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING

      Fig 2: Crankcase Cover Screws Tightening Sequence

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Crankcase cover

7. Installing cylinder heads

   > WM, 157019 REMOVING AND INSTALLING CYLINDER HEAD

   1. 7.1 Fit new cylinder head gasket.
   2. 7.2 Fit and tighten screws -2 and 3-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Cylinder head

8. Install camshafts.
   1. 8.1 Oil bearing locations of the camshafts.
   2. 8.2 Fit camshafts at the correct position without tension with the data matrix code facing upwards.
      1. 8.2.1 Check that the axial bearing washers are fitted correctly.
   3. 8.3 Move bearing cover into installation position and fit and tighten screws -1 to 20-  uniformly in the specified tightening sequence.

      > 150520 REMOVING AND INSTALLING CAMSHAFTS (V8 BITURBO)

      Fig 3: Camshaft Bearing Cover Screws Tightening Sequence

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Tightening sequence for camshaft bearing cover

      1 to 20

      Tightening sequence for bearing cover

9. Install cylinder head cover.
   1. 9.1 Clean sealing faces thoroughly and apply sealant Loctite 5970-BM  .
   2. 9.2 Fit cylinder head cover uniformly and align using > T40116 - locating pins  .
   3. 9.3 Fit and tighten screws -1 to 24-  uniformly in the specified tightening sequence.
      1. 9.3.1 Pull out > T40116 - locating pins  .

         > 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER

         Fig 4: Cylinder Head Cover Screws Tightening Sequence

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.

         Tightening sequence for cylinder head cover

         1 to 22

         Tightening sequence for cylinder head cover at the left and right

10. Install camshaft actuators.

    > 158420 REMOVING AND INSTALLING CAMSHAFT ACTUATORS (INCLUDES SETTING TIMING)

11. Install upper chain housing cover -1-  .

    > 153319 REMOVING AND INSTALLING UPPER CHAIN HOUSING COVER (V8 BITURBO)

    1. 11.1 Clean sealing faces thoroughly and apply sealant Loctite 5970-BM  .
    2. 11.2 Fit upper chain housing cover -1-  uniformly.
    3. 11.3 Fit and tighten screws -2-  uniformly.

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Upper chain housing cover