Assembling
Tools
Tools for fitting pistons
Assembling engine
The engine is assembled in reverse order to the disassembly. Components that are not replaced must be cleaned.
Caution: When working on the engine, absolute cleanliness is essential! An engine cover should be used on the engine assembly support. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores.
Structure of the basic engine
Note;
- All O-rings and seals (shaft seals) and micro-encapsulated screws or fastening nuts must be replaced.
Note;
- Replace M9 x 1.25 con-rod bolts and piston pin circlips.
1. Pre-fit pistons and connecting rods 1 - 3 for the installation Refer to, Removing and installing pistons.
Note;
- The intermediate shaft cover is only fitted once the bearing housing has been installed in the crankcase and the crankcase is completely fastened.
2. Assemble bearing housing.
3. Fix crankcase half 1 - 3 to the engine support with 2 mounting elements 9590.
Caution: As of model year 2003, new dowel sleeves will be used to centre the housing bearing in crankcase half 1 - 3.
- The fitted bores in both components are different compared with the engines up to model year 2002 (bore depth and version).
Distinction:
Dowel pin up to and including model year 2002 and dowel sleeve as of model year 2003
- Dimension A (pin up to and including MY 2002): approximately 22 mm
- Dimension B (sleeve as of MY 2003): approximately 26.5 mm
4. To centre the bearing housing, insert 2 dowel pins or dowel sleeves into the fitted bores of crankcase half 1 - 3.
Fitted bore (belt pulley side) as of MY 2003 -arrow-
5. Carefully insert housing bearing into crankcase half 1 - 3. Ensure that the positioning is correct (dowel pins or dowel sleeves).
6. Fix bearing housing to crankcase 1 - 3 using 2 cylinder-head screws and spacer sleeves 9613. Turn crankcase half by 180° on the assembly support.
7. Fit belt pulley with hexagon-head bolt.
Note;
- As of model year 2002 (3.6 l), two new tools are used for fitting the pistons. Usage is in accordance with the details provided in the description for the 3.4 l engine.
- Centering piece 9602/5 for fitting piston pins on crankcase side 4 - 6 for 3.6 l engine
- Assembly aid 9598/2 for positioning pistons for 3.6 l engine
Note;
- Replace con-rod bolts.
8. Coat connecting rod bearing shells, pistons and cylinder bores 1 - 3 with new engine oil, fit pistons with connecting rods 1 - 3.
Screw connections for connecting rod bearing cover when fitting pistons side 1 - 3
9. Insert new rubber rings for coolant ducts.
Only the following sealants may be used to seal the engine (these are available from Porsche Parts Service):
- "Drei Bond" silicone - type 1209
- Loctite 5900
10. Apply a bead of sealant to crankcase half 4 - 6 -see Figure-. Observe a maximum drying time of 5 minutes.
View of crankcase half 4 - 6: Sealant application and tightening sequence of crankcase cross bolt connection
Note;
- With the help of a second person, carefully place crankcase half 4 - 6 in position on crankcase half 1 - 3.
11. With the help of a second person, place crankcase half 4 - 6 in position on crankcase half 1 - 3 and at the same time guide the timing chain through the chain space. Knock gently on crankcase half 4 - 6 using a plastic hammer.
12. Fit special tool (centering mandrel) 9645 for the intermediate shaft. Position centering mandrel on the mounting point of the oil pump and turn the star knob clockwise until it is braced in the crankcase.
13. Fit 24 M6 x 35 hexagon-head bolts (2 micro-encapsulated) on the crankcase and tighten to the specified torque in accordance with the given tightening sequence -see Figure above: View of crankcase half 4 - 6-. The micro-encapsulated screws are used in positions 8 and 9.
Tightening torque 13 Nm (9.5 ft. lbs.)
14. Install crankshaft sealing ring (belt pulley side).
Note;
- As of model year 2003, two new tools are stipulated for installing the crankshaft sealing ring on the flywheel side.
- Measuring mandrel 9699/1 for checking the correct crankshaft position to the crankcase
- Assembly fixture 9699 for installing shaft seal in correct position
- The sealing lip and the outer race of the shaft seal must be coated with fresh engine oil before installation.
15. Fit shaft seal on the flywheel side. Check the position of the crankshaft using measuring mandrel 9699/1. Coat the sealing ring inside and out with fresh engine oil and pre-position it on the crankshaft flange. Position assembly fixture 9699 on the crankshaft flange with the M8 hexagon socket head bolt and at the same time position the dowel pin in the crankshaft flange in the fitted bore of the fixture. Turn clockwise on the hexagon (a/f 19) as far as it will go.
Note;
- Replace M6 x 20 micro-encapsulated hexagon-head bolts and M8 hexagon nuts for the intermediate shaft cover.
16. Fit intermediate shaft cover. Lightly grease sealing ring and take-up bore, carefully position cover on the bore and insert uniformly with the new screws, tighten screws. Then position the new hexagon nut on the threaded pin. Tighten the nuts using special tool (socket wrench) 9110 and, at the same time, have a second person counter with a 7 x 1.1 slotted screwdriver on the slotted threaded pin -see Figure-.
Tightening torque for hexagon-head bolts 10 Nm (7.5 ft. lbs.)
Tightening torque for hexagon nut 12 + 1 Nm (9 + 0.5 ft. lbs.)
17. Unscrew 2 cylinder-head screws and spacer sleeves 9613 from crankcase 1 - 3.
Note;
- Tighten additional screws to the specified torque on crankcase side 1 - 3 only after the cylinder head has been installed.
18. Position 2 additional M9 x 94 screws for the bearing housing on crankcase side 1 - 3 -see Figure-. Fit 1 screw with a new O-ring.
19. Fit 1 M9 x 150 additional screw with a new O-ring for the new bearing housing, position it on crankcase side 4 - 6 -see Figure- and tighten to the specified torque.
Tightening torque 22 Nm (16 ft. lbs.)
20. Fit the belt pulley with socket wrench insert 9594 and retaining device 9593.
Tightening torque 50 Nm (37 ft. lbs.) + 90° torque angle
Note;
- Use the following new tools for fitting pistons side 4 - 6 (see also information on fitting pistons side 1 - 3):
- Centering piece 9602/5 for fitting piston pins side 4 - 6
- Assembly aid 9598/2 for positioning the pistons
21. Install pistons 4 - 6.
22. Fit M27 aluminum screw plug (hexagon socket a/f 12) for piston pin bore with a new sealing ring.
Tightening torque 80 Nm (59 ft. lbs.)
23. Install guide and tensioning rails. Fit 2 M6 threaded pins (hexagon socket a/f 5) with new O-rings, insert the guide and tensioning rails with the pins in the chain spaces. Tighten threaded pins to the specified torque. Fix timing chain with chain sprockets, e.g. with the old O-rings from the oil extraction pumps.
Position of threaded pins and fixing timing chain Tightening torque 10 Nm (7.5 ft. lbs.)
24. Remove centering mandrel for intermediate shaft.
Note;
- Replace O-rings for the oil pump and sealing rings for coolant guide housing.
25. Fit oil pump with coolant guide housing. Coat oil pump flange with aluminum grease. Lightly coat hexagon driver for oil pump with high pressure grease and insert it in intermediate shaft. Position coolant guide housing, together with oil pump and new sealing rings, on crankcase. Position 10 hexagon-head bolts: 8 M6 x 20 and 2 M6 x 70, and tighten to the specified torque.
Tightening torque 10 Nm (7.5 ft. lbs.)
26. Fit all coolant closure caps with new sealing rings.
Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ft. lbs.)
27. Install temperature sensor for coolant (M14 a/f 22).
Tightening torque 25 ± 5 Nm (19 ± 3.5 ft. lbs.)
28. Fit thermostat housing and water pump with new gaskets.
Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ft. lbs.)
29. Turn crankcase by 180° on the assembly support. Fit air/oil separator (swirl pots), oil suction pipe and oil pan cover. Use new O-rings and, for the oil suction pipe, 2 new M6 x 20 micro-encapsulated hexagon-head bolts. Apply sealant to oil pan cover; after a maximum drying time of 5 minutes fit this cover to the crankcase using 13 M6 x 20 hexagon-head bolts.
Tightening torque for M6 hexagon-head bolts 10 Nm (7.5 ft. lbs.)
30. Fit new oil filter with new O-ring.
Tightening torque 25 Nm (19 ft. lbs.)
Fitting cylinder head
Fitting cylinder head side 1 - 3
1. Turn crankcase by 90° on the assembly support (side 1 - 3 upwards).
Note;
- Cylinder head gaskets are identical parts, lay them down with the TOP identification facing upwards.
2. Fit cylinder head with new gasket. Position gasket, insert 12 M10 Torx screws in cylinder head and tighten in accordance with the tightening sequence -Items 1 - 12-.
Tightening specification for cylinder-head screws:
- Initial tightening in accordance with tightening sequence 30 Nm (22 ft. lbs.), undo all screws again
- Initial tightening in accordance with tightening sequence 20 Nm (15 ft. lbs.)
- Final tightening in accordance with tightening sequence 2 x 70° torque angle
3. Position and tighten 4 pan-head screws with M6 x 30 captive washers (hexagon socket 10.9, a/f 5) -Items 1 - 4- on the chain space. Use of a magnetic bit is recommended so that the screw to be fitted in the slot -Item 4- cannot fall into the crankcase.
Tightening torque 13 Nm (9.5 ft. lbs.)
4. Fit threaded pin for guide rail with a new O-ring on the cylinder head.
Tightening torque 10 Nm (7.5 ft. lbs.)
5. Tighten 2 additional M9 x 94 screws to the specified torque for the bearing housing on crankcase side 1 - 3 -see Figure-.
Tightening torque 22 Nm (16 ft. lbs.)
Note;
- The O-rings for the spark-plug recesses must be replaced.
6. Insert 3 new O-rings in the spark-plug recesses -arrows- , lightly coat with high pressure grease. Insert flat-base tappet housing with 11 M6 x 35 pan-head screws (hexagon socket a/f 5), tighten screws outwards from the inside.
O-rings for spark-plug recess
Tightening torque 10 Nm (7.5 ft. lbs.)
Note;
- Re-insert flat-base tappets in the fitted bores in which they were positioned before the disassembly. The flat-base tappets have been run in the fitting bores in the housing and therefore may not be switched.
7. Coat flat-base tappets with fresh engine oil and insert in the fitted bores in the flat-base tappet housing (operating plunger with dowel pin -arrow on the inlet side).
8. Install camshafts and adjust timing.
The installation of cylinder head side 4 - 6 is carried out in the same way as the assembly sequence of side 1 - 3 with the following exception:
- The threaded pin for guide rail 4 - 6 (belt pulley side) on the cylinder head is inserted only after the timing chain has been fitted on the camshaft wheels.
Engine accessories
Install engine accessories in the reverse sequence to that in which they were removed. Some additional instructions follow.
- Spark plugs:
Tightening torque for old spark plugs: 25 Nm (19 ft. lbs.)
Tightening torque for new spark plugs: 30 Nm (22 ft. lbs.)
- Hall sender: use 2 new M6 micro-encapsulated pan-head screws (hexagon socket a/f 5).
Tightening torque 10 ± 0.5 Nm (7.5 ± 0.5 ft. lbs.)
- Exhaust manifold: use new M8 x 28 hexagon-head bolts.
Tightening torque: 23 Nm (17 ft. lbs.)
- Holder for coolant ventilation: replace 1 M6 x 16 (micro-encapsulated).
Tightening torque 10 Nm (7.5 ft. lbs.)
- Speed sender: replace 1 M6 x 16 (micro-encapsulated).
Tightening torque 10 ± 0.5 Nm (7.5 ± 0.5 ft. lbs.)
- Intake pipe support: install with 4 M6 x 35 hexagon-head bolts and new sealing rings.
Tightening torque 10 Nm (7.5 ft. lbs.)
- Intake distributor: install with 6 new M6 x 35 micro-encapsulated hexagon-head bolts and new molded seals on intake pipe support.
Tightening torque 10 Nm (7.5 ft. lbs.)
- Generator: tighten M8 hexagon nut for B+ cable to the specified torque.
Tightening torque 15 Nm (11 ft. lbs.)