Assembling Engine

NOTIFICATION 

Interchanged or dirty bucket tappets 

• Scoring on cylinder head 
  • → Since the bucket tappets have been run in the fitting bores, do not interchange them.
  • → Absolute cleanliness is essential.

Information 

• Do not remove stoppers used to close off connections during disassembly until just before fitting the affected component. 

Information 

Replace worn bearing shells.

Information 

Sealing faces must be free of oil and grease.

1. Clean components and perform visual inspection. Replace damaged components.
   1. 1.1  Clean sealing faces.
   2. 1.2  Clean the thread and re-cut if necessary.
2. Replace both crankshaft sealing rings.

   > Replacing sealing ring for crankshaft pulley 

   > Replacing crankshaft-flywheel sealing ring 

3. Install crankshaft.

   > Removing and installing crankshaft (V8 biturbo) 

4. Assemble pistons.

   > Disassembling and assembling pistons 

5. Install piston and connecting rod.

   > Removing and installing pistons 

6. Install crankcase cover.

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

7. Install cylinder heads.

   > WM, 157019 REMOVING AND INSTALLING CYLINDER HEAD

8. Install camshafts.

   > WM, 150520 REMOVING AND INSTALLING CAMSHAFTS (V8 BITURBO)

9. Install cylinder head cover.

   > WM, 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER

10. Install chain tensioner.

    > Removing and installing chain tensioner 

11. Install guide and tensioning rails.

    > WM, 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS

12. Install camshaft actuators.

    > WM, 158419 REMOVING AND INSTALLING CAMSHAFT ACTUATOR (INCLUDES SETTING TIMING)

13. Install lower chain housing cover.

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

14. Install upper chain housing cover.

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

15. Install oil pump.

    > Removing and installing oil pump (V8 biturbo) 

16. Install oil guide housing.

    > Removing and installing oil guide housing (V8 biturbo) 

17. Install the oil pan.

    > Removing and installing oil pan (V8 biturbo) 

18. Install solenoid hydraulic valves for valve lift adjustment.

    > Removing and installing solenoid hydraulic valve for valve lift adjustment 

19. Install fuel injectors.

    > Removing and installing fuel injector 

20. Insert tappets for high-pressure pumps -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tappets for high-pressure pump (similar to illustration)

21. Install high-pressure pumps.

    > Removing and installing high-pressure pump (V8 biturbo) 

22. Remove both fuel lines (high-pressure pump to rail).

    > Removing and installing fuel line (V8 biturbo) 

23. Install upper heat insulation -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat insulation

24. Fit spark plugs.

    > Removing and installing spark plugs 

25. Install ignition coils.

    > Removing and installing ignition coils (V8 biturbo) 

26. Install knock sensors.

    > Removing and installing knock sensor (V8 biturbo) 

27. Install intake-air distributor.

    > Removing and installing intake-air distributor (V8 biturbo) 

28. Install vacuum line -2-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Vacuum system

    1. 28.1  Push vacuum line connection -2-  onto the brake booster vacuum pump -1-  in accordance with the markings.
    2. 28.2  Push vacuum line connection -2-  onto connections -3 to 7-  in accordance with the markings.
29. Install tank vent valve.

    > Removing and installing tank vent valve (V8 biturbo) 

30. Install wire harness for engine.

    > Refer to the appropriate service information.

31. Installing oil separator

    > Removing and installing oil separator (V8 biturbo) 

32. Install coolant lines -2 and 5-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant lines

    1. 32.1  Fit coolant lines -2 and 5-  .
    2. 32.2  Screw in and tighten screws for coolant lines -1-  .

       > Tightening torque 9 Nm (6.5 ftlb.) 

    3. 32.3  Screw in and tighten screws for coolant lines -3 and 4-  .

       > Tightening torque 9 Nm (6.5 ftlb.) 

33. Install drive plate.

    > Removing and installing drive plate 

34. Install coolant pump.

    > Removing and installing coolant pump (V8 biturbo) 

35. Install coolant regulator housing.

    > Removing and installing coolant regulator housing (V8 biturbo) 

36. Install air-conditioning compressor bracket -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Air-conditioning compressor bracket

    1. 36.1  Position air-conditioning compressor bracket -1-  .
    2. 36.2  Fit and tighten screws for air-conditioning compressor bracket -2-  .

       > Tightening torque 23 Nm (17 ftlb.) 

37. Install air-conditioning compressor.

    V8 biturbo: 

    > Removing and installing air conditioning compressor 

    V8 Hybrid: 

    > Removing and installing air conditioning compressor 

38. Install generator bracket

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Generator bracket

    1. 38.1  Position generator bracket -1-  .
    2. 38.2  Fit and tighten screws on generator bracket -2-  .

       > Tightening torque 23 Nm (17 ftlb.) 

39. Install generator.

    > Removing and installing generator (V8 biturbo) 

40. Install crankshaft vibration damper.

    > Removing and installing crankshaft vibration damper (V8 biturbo) 

41. Not for PHEV: 

    Install belt tensioner for air-conditioning compressor.

    > 137319 REMOVING AND INSTALLING BELT TENSIONER (AIR-CONDITIONING COMPRESSOR)

42. Not for PHEV: 

    Install belt tensioner for generator.

    > 137319 REMOVING AND INSTALLING BELT TENSIONER (GENERATOR)

43. Install both drive belts.

    > Removing and installing drive belt (V8 biturbo) 

44. Install oil-water heat exchanger.

    > Removing and installing oil/water heat exchanger (V8 biturbo) 

45. Install oil temperature sensor.

    > Removing and installing oil temperature sensor 

46. Install oil pressure switch.

    > Removing and installing oil pressure switch (V8 biturbo) 

47. Install piston spray nozzle control valve.

    > Removing and installing piston spray nozzle control valve (V8 biturbo) 

48. Install inner heat shields -1-  and front heat shield -2-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat protection in inner V

    1. 48.1  Install front heat shield -2-  .
       1. 48.1.1  Fit front heat shield -2-  .
       2. 48.1.2  Fit and tighten screw for front heat shield -5-  .

          > Tightening torque 9 Nm (6.5 ftlb.) 

    2. 48.2  Install inner heat shields -1-  .
       1. 48.2.1  Fit inner heat shields -1-  .
       2. 48.2.2  Fit and tighten screws for inner heat shields -3-  .

          > Tightening torque 9 Nm (6.5 ftlb.) 

       3. 48.2.3  Connect and lock electric plug connection -4-  .
49. Install oil filter housing.

    > Removing and installing oil filter housing (V8 biturbo) 

50. Install both exhaust manifolds.

    > Removing and installing exhaust manifold (V8 Turbo) 

51. Install turbocharger.

    > Removing and installing turbocharger (V8 biturbo)