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Assembling Engine

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Replace worn bearing shells.

  1. Assembly is performed in reverse order. Note particularly:
  2. Clean components and replace damaged components.

    Information 

    Sealing faces must be free of oil and grease.

    1. 2.1 Clean sealing faces.
    2. 2.2 Clean the thread and re-cut if necessary.
  3. Install knock sensor.

    → WM, 287219 REMOVING AND INSTALLING KNOCK SENSOR (V6 TURBO)

  4. Install piston spray nozzles -2-  .
    1. 4.1 Position piston spray nozzles -2-  .
    2. 4.2 Fit screws for piston spray nozzles -1-  and tighten to →Initial tightening 10 Nm (7.5 ftlb.)  and →Final tightening + 45°  .
    G15822001Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Piston spray nozzles on cylinder block

  5. Install crankshaft with new bearing shells into the cylinder block.

    →134819 REMOVING AND INSTALLING CRANKSHAFT (V6 TURBO)

  6. Install new bearing shells in pistons and connecting rods.

    → Removing and installing piston (V6 Turbo)

  7. Install balance shafts.

    → 138519 REMOVING AND INSTALLING BALANCE SHAFT (V6 TURBO)

  8. Assemble cylinder heads.
    1. 8.1 Install new valve-stem seals.
  9. Install both cylinder heads with new cylinder-head gaskets.
  10. Install coolant switching valve -3-  .
    1. 10.1 Fit and position coolant switching valve -3-  on coolant pipe -4-  .
    2. 10.2 Tighten screws on coolant control valve -2-  to > Tightening torque 9 Nm (6.5 ftlb.)  .
    3. 10.3 Connect vacuum hose -1-  .
    G15822002Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant switching valve

  11. Install coolant flanges on left and right cylinder bank.
    1. 11.1 Position coolant flanges.
    2. 11.2 Fit screws -1 to 3-  and tighten to > Tightening torque 9 Nm (6.6 ftlb.)  .
    G15822003Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant flanges

  12. Replace crankshaft sealing rings on both sides of the engine.
  13. Install oil windage tray -2-  .
    1. 13.1 Position oil windage tray -2-  on cylinder block.
    2. 13.2 Replace oil windage tray screws -1 and 3- 
    3. 13.3 Fit screws securing oil windage tray to cylinder block -1-  and tighten crosswise.

      Tighten M6 x 18 screws (3 ea.)  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90° 

      Tighten M6 x 30 screws (13 ea.)  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90°  .

    4. 13.4 Tighten screws securing chain housing cover to oil windage tray -3-  to > Initial tightening 3 Nm (2 ftlb.)  and > Final tightening + 90°  .
    G15822004Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Oil windage tray

  14. Install pipe for drive shaft -1-  .
    1. 14.1 Insert pipe for drive shaft -1-  from one side and push it into position using a suitable tool.
    2. 14.2 Fit O-ring -2-  on both sides of the engine.
    G15822005Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Pipe for drive shaft

  15. Install shaft cover -1-  on both sides of the engine.
    1. 15.1 Fit shaft cover -1-  .
    2. 15.2 Fit screws for shaft cover -2-  and tighten to > Tightening torque 9 Nm (6.5 ftlb.)  .
    G15822006Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Shaft cover

  16. Install drive belt deflection roller for generator -1-  .
    1. 16.1 Position deflection roller -1-  .
    2. 16.2 Fit screw for deflection roller -3-  and tighten to > Tightening torque 25 Nm (19 ftlb.)  .
    3. 16.3 Push on dust boot -2-  .
    G15822007Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Deflection roller for drive belt for generator

  17. Install generator support -1-  .
    1. 17.1 Position generator support -1-  .
    2. 17.2 Fit screws -2-  and tighten to > Initial tightening 8 Nm (6 ftlb.)  and > Final tightening + 90°  .
    G15822008Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Generator support

  18. Install air-conditioning compressor -5-  support.
    1. 18.1 Position air-conditioning compressor -5-  support.
    2. 18.2 Fit screws for air-conditioning compressor bracket -4-  and tighten to > Initial tightening 8 Nm (6 ftlb.)  and > Final tightening + 90°  .
    3. 18.3 Install tensioning roller -3-  .
      1. 18.3.1 Position tensioning roller -3-  .
      2. 18.3.2 Replace screw on tensioning roller -2-  for air-conditioning compressor drive belt.
      3. 18.3.3 Fit new  screw on tensioning roller -2-  and tighten to > Tightening torque 25 Nm (19 ftlb.)  .
      4. 18.3.4 Push on dust boot -1-  .
    G15822009Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Air-conditioning compressor support (shown on V6 Monoturbo)

  19. Connect all vacuum hoses in accordance with the markings.
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