Converting Reconditioned Engine

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Information

All components listed must be removed from the old engine and installed on the new engine.
Seals and O-rings must be replaced.
Aluminium screws and torque angle-tightened screws must be replaced.
All stoppers must be removed from the new engine.

Information

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

Group 1:
> 1X00IN TECHNICAL VALUES
Group 2:
> WM, 2X00IN TECHNICAL VALUES (V6 TURBO)
Group 3:
> 3X00IN TECHNICAL VALUES

Convert all-wheel final drive.
> 398819 REMOVING AND INSTALLING FOUR-WHEEL FINAL DRIVE
Convert coolant pipes -4- .
1. 2.1 Loosen and unscrew screws -1, 3 and 5- .
2. 2.2 Loosen hose clamp -2 and 6- and pull off coolant pipes.
3. 2.3 Remove coolant pipes -4- .
4. 2.4 Push on coolant pipes -4- on the joint. Secure coolant pipes -4- with hose clamp -2 and 6- .
5. 2.5 Secure coolant pipes -4- . Fit and tighten screws -1, 3 and 5- .
  Screws -1, 3 and 5- : >
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Converting coolant lines
Convert bracket for torque support -2- .
1. 3.1 Loosen and unscrew screws -1- .
2. 3.2 Remove the bracket -2- .
3. 3.3 Move bracket -2- into installation position and fit and tighten screws -1- .
  Screws -1- : >
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Converting bracket
Convert heat shield for high-pressure pump -1- .
> 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP
1. 4.1 Unscrew screws -2- and remove heat shield -1- .
2. 4.2 Fit heat shield -1- on high-pressure pump. Fit and tighten screws -2- .
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Converting heat shield for high-pressure pump
Convert coolant lines -1- and -2- on the cylinder head on bank 2.
1. 5.1 Unscrew screws -3- .
2. 5.2 Loosen clamps -4- and pull off coolant hoses -1- and -2- .
3. 5.3 Collect emerging coolant.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Coolant lines on ATF cooler
Convert coolant line -1- at the coolant pump.
1. 6.1 Loosen clamp -arrow- and pull off coolant line.
2. 6.2 Collect emerging coolant.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Coolant line for coolant pump
Convert vacuum lines -1 and 3- .
1. 7.1 Release and disconnect vacuum line -1- from vacuum pump -2- .
2. 7.2 Pull off vacuum line -3- .
3. 7.3 Connect and lock vacuum line -1- and vacuum line -3- .
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Converting vacuum lines
Convert oil dipstick.
Convert moulded hose on throttle valves.
Convert primary catalytic converter with holder.
> 267619 REMOVING AND INSTALLING PRIMARY CATALYTIC CONVERTER (V6 BITURBO)
Convert drive belt with belt tensioner and deflection roller.
> 137819 REMOVING AND INSTALLING DRIVE BELT (V8 BITURBO)
Convert generator with bracket.
> WM, 272219 REMOVING AND INSTALLING GENERATOR (V6 TURBO)
Convert air-conditioning compressor with bracket and lines.
> WM, 873419 REMOVING AND INSTALLING AIR CONDITIONING COMPRESSOR