Component Changes For Engines Produced As of Model Year 2009
IMPORTANT component changes for V8 engines as of October 2008
Information
Component changes for engines produced as of model year 2009, calendar week 42/2008
Information
Component changes implemented as of the following engine numbers:
M4801 905541
M480IG 904965
M4851 901689
M4851S 900562
M4851T 901788
Information
At present, aluminium screws are used for the cylinder head cover, timing-case cover, lower part of crankcase and oil guide housing. Observe modified tightening specifications as instructed.
In addition, the new timing-case cover can only be retrofitted (on older engines) in conjunction with aluminium screws and the new chain tensioner.
The joint flange behind the vibration balancer is secured to the timing-case cover with aluminium screws.
In addition, the crankcase can only be retrofitted (in older engines) with a new starter and modified primary catalytic converter support.
New sealant in conjunction with aluminium screws for the crankcase and oil guide housing. Old sealant must not be used if sealant is likely to come into direct contact with aluminium screws!
The crankshaft mount now has four conventional bearings (one more colour classification). Install new crankshaft only with new modified bearing shells.
Lower part of crankcase (outer cross bolt connection) with aluminium screws and new sealant
Oil guide housing with aluminium screws and new sealant
Cylinder heads with new spark plugs. If a cylinder head is replaced on an older engine, the spark plugs on the opposite cylinder head must be changed (replaced).
Modified camshafts only in conjunction with modified screws for sprockets and camshaft controllers. Install new camshafts only with modified screws (external Torx) for the camshaft controller and sprocket (screw length!). The tightening torque remains the same.
Modified ignition rod modules with aluminium screws and engine wire harness.
Modified valve cover with aluminium screws and modified cap on solenoid valves for camshaft controllers. Eyelets still have steel screws.
Modified valve cover and cylinder head on cylinder bank 1 to 4 have an additional M8 thread bore and M8 screw (aluminium). If the cylinder head is replaced (on older engines), the valve cover must also be replaced. Modified valve cover must be installed on the old cylinder head using an M6 screw when retrofitting the valve cover on older engines.
Countersunk screws for securing auxiliary unit brackets and engine carrier to the crankcase. The tightening torque remains unchanged.
Crash support (support bracket) on generator with aluminium screws.
Always check component pairings!
Always check specific engine numbers!
Information on aluminium screws
Information
Aluminium screws and steel screws have different properties!
Most aluminium screws are identified on Porsche V-engines by an internal Torx screw with internal pin. Aluminium screws can be identified differently on transmissions, on the chassis and on engines from other manufacturers.
Another differentiating feature is that aluminium screws are lighter than steel screws of the same size (e.g. screws used in bar ignition modules).
The aluminium screws used at present have the additional marking RIBE (manufacturer) and AL9 (strength) on the screw head.
Screws with an internal pin can be loosened and tightened using commercially available bit inserts with a hole (safety bits).
Aluminium screw on V-engines
Aluminium screws must be used only once. Replace the screws whenever they have been loosened.
Aluminium screws must always be tightened in two steps (torque and torque angle) or require a special yield-point wrench Electronic torque wrench 9768. The specified tightening torques and torque angles must always be observed. The extent to which a screw is tightened can be limited using a yield-point wrench.
There is no need to tighten by clicking once as this may cause irreparable damage to the screw.
Sealants that can come into contact with aluminium screws in threaded bores must be approved for use with aluminium screws by Porsche - if this is not observed, there will be increased friction in the screw thread and the aluminium screw will break.
Aluminium screws must not be fitted using tightening parameters for steel screws - the aluminium screw will break.
Screw threads must be perfectly clean. Sealant residue or chips increase the friction coefficient - the aluminium screw will break. Blow out thread holes.
Aluminium screws
Overview of repair-relevant component changes as of model year 2009, calendar week 42/2008
Information
The eyelets must not be inadvertently secured using aluminium screws! - Aluminium screws would break and the suspended engine would fall down!
Lower part of crankcase
1 - Lower part of crankcase
2 - Straight pin, 6 x 18
3 - O-ring
4 - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5 - Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. - Initial tightening: 30 Nm (22 ftlb.) - Torque angle: 90 degrees
6 - Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. - Initial tightening: 22 Nm (16 ftlb.) - Torque angle: 60 degrees
7 - Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws; observe tightening sequence as for steel screws - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees
8 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
9 - Screw, M8 x 50 - Tightening torque: 23 Nm (17 ftlb.)
10 - Dowel sleeve
A - Direction of travel
Crankshaft
1 - Crankshaft
2 - Straight pin, 6 x 20
3 - Spring, 5 x 6.5
4 - Thrust washer (grooves facing out)
5 - Main bearing shell, upper
6 - Main bearing shell, lower
7 - Shaft sealing ring - Do not touch sealing ring lip! Clean crankshaft flange and oil lightly
8 - View of crankshaft flange
9 - Crankshaft bearing classification Y Yellow; B Blue, R Red; N Green - (example: YYYYY-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) - For numbering, see A
A - Direction of travel (main bearing 1 is the first in direction of travel against output)
Tightening sequence for timing-case cover
A - Aluminium screw, M6 x 30; timing-case cover to crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
B - Aluminium screw, M6 x 55; inner timing-case cover to upper part of crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees; outer timing case cover to cylinder head - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
C - Aluminium screw, M8 x 55; timing-case cover (chain tensioner position) to upper part of crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees
D - The timing-case cover must be level with the lower part of the crankcase (use steel rule or dial gauge)
Chain tensioner, sealing flange
1 - Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer
2 - Aluminium screw M6 x 20; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
3 - Aluminium screw M6 x 55; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - Sealing ring
5 - Chain tensioner - Tightening torque: 60 Nm (44 ftlb.)
Bar ignition modules and valve cover, cylinder bank 1 to 4
1 - Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2 - Bar ignition module
3 - Aluminium screw, M6 x 20; bar ignition module; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - Aluminium screw, M6 x 30; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
5 - Cap
6 - Aluminium screw, M8 x 35 (on torque support); always use new aluminium screws; - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees Steel screw on eyelet!
7 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
8 - sheet metal holder
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)
Bar ignition modules and valve cover, cylinder bank 5 to 8
1 - Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2 - Eyelet
3 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
4 - Aluminium screw, M6 x 30; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
5 - Bar ignition module
6 - Aluminium screw, M6 x 20; bar ignition module; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
7 - sheet metal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)
Valve cover seals, cylinders 1 to 4
1 - Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2 - Oil cap
3 - Aluminium screw, M6 x 20; hall sender (phase sensor); always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - Hall sender
5 - O-ring
6 - Valve cover seal
7 - Valve cover seal, inner
8 - Seal for hydraulic valve for camshaft control
Valve cover seals, cylinders 5 to 8
1 - Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2 - Hall sender
3 - Aluminium screw, M6 x 20; hall sender (phase sensor); always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - O-ring
5 - Valve cover seal
6 - Valve cover seal, inner
7 - Seal for hydraulic valve for camshaft control
Oil guide housing with accessories
1 - Guide tube
2 - O-ring
3 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Oil dipstick
5 - O-ring
6 - Timing-case cover to oil guide housing Aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.) oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
7 - Oil-level sensor
8 - O-ring
9 - Sealing flange
10 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)
11 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel
Applying sealant to oil guide housing
1 - Sealant application (geometry, 1-mm bead of sealant)
2 - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
A - Direction of travel
Auxiliary units
1 - Air conditioning compressor
2 - Screw, M10 x 100
3 - Screw, M8 x 10
4 - Holder
5 - Screw, M8 x 20; tandem pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.); power-steering pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
6 - Tandem pump
7 - Screw, M8 x 35; power-steering pump to adapter bracket - Tightening torque: 23 Nm (17 ftlb.); tandem pump/adapter bracket to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
8 - Power-steering pump
9 - Aluminium screw, M8; always use new aluminium screws - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees
10 - Support bracket
11 - Dowel sleeve