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ENGINE
10 ­ Engine ­ Crankcase, Suspension ­ 911 Carrera (991)

WM 100109 LOWERING THE ENGINE (EXCEPT CARRERA "EDITION",

CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3 RS)
TOOLS

Designation Type Number Description Â

hydraulic garage Workshop WE 1032 Â
jack H 2 SL equipment

transmission jack Workshop WE 1082 Â

V.A.G. 1383 A equipment

Master Gear unit Workshop WE 1206 Â

elevating platform equipment

Retainer plate Special tool 9769 Â

Support Special tool 9769/1 Â

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 Support Special tool 9769/2 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Engine carrier to Collar nut, M12 Tightening 85 Nm (63 Â Â
engine mounting torque ftlb.)

PRELIMINARY WORK

1. Remove air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

2. Remove cover for rear underbody if necessary.

→ 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

LOWERING AND SECURING THE ENGINE

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

Information

When lowering, the engine must not rest on the rear axle cross member.

For working in the engine compartment:

1. Support the engine at the oil pan using hydraulic garage jack H 2 SL WE 1032 and transmission jack
plate of transmission jack V.A.G. 1383 A WE 1082 .
1.1. Loosen two M12 collar nuts on the engine mount at the left and right only as much as required
so that the engine flange is not touching the rear­axle cross member.
1.2. Slowly lower the engine using the jack.

Additional work for removing/fitting resonance tube and intake­air distributor on GT3 vehicles in
order to lower the engine further:

2. Remove engine guard.

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 → 108019 REMOVING AND INSTALLING ENGINE GUARD.

3. Remove support plate.

→ 421419 REMOVING AND INSTALLING SUPPORT PLATE .

4. Remove cover for rear underbody.

→ 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

5. Remove rear axle carrier.

→ 420619 REMOVING AND INSTALLING REAR­AXLE CROSS MEMBER .

Fig. 1: Identifying Rear­Axle Cross Member

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Loosen the anti­roll bar at the rubber mountings ­4­ .

→ 429019 REMOVING AND INSTALLING REAR ANTI­ROLL BAR .

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 Fig. 2: Identifying Anti­Roll Bar Mount
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

For working under the vehicle:

7. Support the engine using the Master Gear unit elevating platform WE 1206 and the special tools
specified below.

Fig. 3: Supporting Engine Using Master Gear Unit Elevating Platform

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Master Gear unit elevating platform WE 1206

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 2. Support 9769/1 for Porsche Doppelkupplung (PDK) and 7­speed manual transmission (991)
3. Support 9769/2 for 6­speed manual transmission (2nd generation 997)
4. Retainer plate 9769 for engine
7.1. Mounting points on engine:

Fig. 4: Locating Engine Mounting Points (Carrera)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

It may only be supported over a large area at the oil pan.

Localized loading is not permitted.
8. Or: Support the engine at the oil pan using transmission jack V.A.G. 1383 A WE 1082 .
9. Once you have completed the required work, raise the engine to installation position and secure the
engine carrier ­1­ with two M12 collar nuts ­2­ .

Tightening torque 85 Nm (63 ftlb.)

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 Fig. 5: Identifying Engine Carrier Collar Nuts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. GT3 vehicles: Re­fit rear axle carrier, anti­roll bar, engine guard, support plate and underbody cover if
necessary.

→ 429019 REMOVING AND INSTALLING REAR ANTI­ROLL BAR (WITHOUT PDCC) .

→ 420619 REMOVING AND INSTALLING REAR­AXLE CROSS MEMBER .

SUBSEQUENT WORK

1. Install cover for rear underbody if it was removed.

→ 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

2. Install air cleaner housing.

→ Installing Air Cleaner Housing .

3. GT3 vehicles: Install lower part of lid lock.

→ 558719 REMOVING AND INSTALLING UPPER PART OF REAR LID LOCK .

WM 100119 REMOVING AND INSTALLING ENGINE (EXCEPT CARRERA

"EDITION", CARRERA CABRIOLET "EDITION", TURBO, TURBO S,
CARRERA 4 "EDITION", TURBO CABRIO, TURBO S CABRIO, CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

3167 of 5326 Â
 Designation Type Number Description Â
Master Gear unit Workshop WE 1206 Â
elevating platform equipment

Socket­wrench Special tool 300 Â

insert

strapping belt Special tool 9454 Â

Retainer plate Special tool 9769 Â

Support Special tool 9769/1 Â

Support Special tool 9769/2 Â

loosening tool Special tool 9780 Â

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 PIWIS Tester II Special tool 9818 Â

assembly tool Special tool 9822 Â

disassembly tool Commercially Nr.21 Â

available tool

socket­wrench Special tool P300 Â

insert

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Ground strap to Collar nut, M8 Tightening 23 Nm (17 Â Â
body torque ftlb.)
Brace plate to Hexagon­head Tightening 30 Nm (22 +90 Grad Â
rear body bolt, M10 x 40 ­ torque ftlb.)
initial tightening
and torque angle
Transmission Hexagon­head Tightening 65 Nm (48 Â Â
bracket to body bolt, M10 x 50 torque ftlb.)
Transmission Collar nut, M10 Tightening 65 Nm (48 Â Â
support to body torque ftlb.)
B+ line to Collar nut, M8 Tightening 23 Nm (17 Â Â
transmission torque ftlb.)
cable socket
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Fastening screws Internal Torx Tightening 22 Nm (16 Â Â
for air­ screw, M8 torque ftlb.)
conditioning line
connection point
in engine
compartment

PRELIMINARY WORK

CAUTION: Hot components

Risk of burns

→ Let hot components cool down.

→ Wear personal protective gear.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

WARNING: Vehicle can fall down

Risk of squashing or crushing

Risk of damage to the vehicle

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

1. Raise the vehicle at the prescribed jacking points.

→ 4X00IN LIFTING THE VEHICLE .

2. Read out the fault memory using PIWIS Tester II 9818 .

→ 033500 FAULT MEMORY FOR ON­BOARD DIAGNOSIS .

3. Loosen rear wheel bolts (do not remove).

Use special tool socket­wrench insert P300 .

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4. Fit protective covers.
5. Drain refrigerant from the air­conditioning system.

Observe specifications for working on the air­conditioning system!

→ 870317 DRAINING AND FILLING REFRIGERANT .

6. Open the engine compartment lid and extend the rear spoiler using the rocker switch in the passenger
compartment.
6.1. On Cabriolet vehicles, open convertible­top compartment lid!
7. Disconnect the battery ground terminal and cover battery terminals or battery.
8. Unclip the right cover ­1­ (­arrow­ ).
8.1. Disconnect plug connection for rear spoiler.

Fig. 6: Removing Engine Compartment Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Remove engine­compartment blower ­1­ .

→ 198119 REMOVING AND INSTALLING ENGINE­COMPARTMENT BLOWER .

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 Fig. 7: Removing Engine­Compartment Blower Bracket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Remove air guide ­1­ for air cleaner.

10.1. Unclip cable ­2­ for engine compartment lid.
10.2. Unclip air guide and remove it by pulling it up ­arrow­ .

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 Fig. 8: Pulling Air Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Open the coolant cap ­1­ on the service tray and unscrew M6 screw ­2­ for the left cover.

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 Fig. 9: Identifying Coolant Reservoir Cap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Pull off oil filler hose ­1­ on the left cover by opening the spring band clamp ­2­ .

Fig. 10: Identifying Oil Filler Hose

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13. Remove rear spoiler.

→ 665819 REMOVING AND INSTALLING REAR SPOILER .

14. Remove rear apron.

→ 635519 REMOVING AND INSTALLING REAR APRON .

15. Remove side retaining frame (heat protection) for the rear apron at the left and right.

→ 261519 REMOVING AND INSTALLING RETAINING FRAME WITH HEAT PROTECTION

.

16. Remove the complete air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

17. Open plug connections for oxygen sensors.

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17.1. Pull plug connection for oxygen sensor upstream of catalytic converter ­1­ out of the holder
­2­ and open it.

Fig. 11: Pulling Oxygen Sensor Plug Connection (Upstream)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17.2. Unclip plug connection for oxygen sensor downstream of catalytic converter ­1­ by lifting up
the locking tab ­2­ . Then open the plug connection.

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 Fig. 12: Pulling Oxygen Sensor Plug Connection (Downstream)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17.3. Expose oxygen sensor cable and place it between the engine and engine carrier.
18. Pull off vacuum line ­1­ for control valve for exhaust flap and disconnect oxygen sensor cable.
18.1. Open tie­wrap ­3­ on the oxygen sensor cable ­2­ .

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 Fig. 13: Pulling Vacuum Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

19. Open engine wire harness connections to the engine control unit and main wire harness.

→ 247019 REMOVING AND INSTALLING DME CONTROL UNIT .

19.1. Before removing the cable plugs on the engine control unit, pull the release tabs.
1. Small connector on engine control unit
2. Large connector on engine control unit
3. Cable plugs
4. 2 cable plugs on plug connection for vehicle wire harness

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 Fig. 14: Identifying Control Unit And Vehicle Engine Wire Harness Connection
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20. On Cabriolet vehicles: Remove support plate.

→ 421419 REMOVING AND INSTALLING SUPPORT PLATE .

21. Remove cover for center and rear underbody.

→ 519319 REMOVING AND INSTALLING COVER FOR CENTRE UNDERBODY .

→ 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

22. Drain coolant from the engine.

→ 193817 DRAINING AND FILLING COOLANT .

22.1. Fit the two screw plugs with new sealing rings after draining coolant.
23. Loosen drive shafts on the transmission.

→ 422119 REMOVING AND INSTALLING REAR DRIVE SHAFT .

23.1. Get another person to counter at the relevant wheel.

24. Remove rear wheels.

Use special tool Socket­wrench insert 300 .

REMOVING ENGINE

1. Open air­conditioning lines ­1­ .

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 1.1. Unscrew M8 fastening screws ­2­ on the high­pressure and low­pressure lines and counter
with assembly tool 9822 while doing this.
1.2. Replace O­rings.

Fig. 15: Identifying Air­Conditioning Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

2. Pull off right coolant hose.

2.1. Remove spring clamp ­1­ and pull off the coolant hose ­2­ .
2.2. Close off the opening with a clean cloth or stopper. Re­fit spring clamp.
2.3. Check O­ring and replace it if necessary.

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 Fig. 16: Identifying Coolant Hose And Spring Clamp
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

3. Before opening the fuel line, attach or mount a warning sign ­1­ in a clearly visible position on the
vehicle.

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 Fig. 17: Identifying Fuel System Warning Sign
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Open fuel low­pressure connection ­1­ at the left­hand side of the engine compartment.
4.1. Soak up emerging fuel with a cloth.
4.2. Press locking lugs on the plug­in coupling ­arrow­ and pull off the line.

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 Fig. 18: Locating Fuel Low­Pressure Line Connection
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Open vent line on the coolant reservoir ­1­ and tank vent line ­3­ .
5.1. Press locking lugs on the coolant vent line and pull off line to the engine.
5.2. Press locking lug on the tank vent line and pull off the line.

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 Fig. 19: Identifying Coolant And Tank Vent Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Open supply hose connections ­1­ for engine cooling and heating ­arrows­ .
6.1. Place cloths underneath.
6.2. Remove spring band clamp ­2­ and pull off the supply hose.
6.3. Open rapid­action coupling ­3­ for the heating hose by pressing the locking lugs.

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 Fig. 20: Locating Coolant Supply Hose
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Pull off left coolant hose ­1­ .

7.1. Remove spring clamp ­2­ and pull off the coolant hose.

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 Fig. 21: Identifying Coolant Hose
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7.2. Close off the opening with a clean cloth or stopper. Re­fit spring clamp.
7.3. Check O­ring and replace it if necessary.

WARNING: Danger of injury and material damage when using Pentosin.

Risk of skin irritation and damage to skin.
Damage to hoses and wiring.

→ Wear protective gloves and goggles.

→ In the event of contact (eyes or skin), wash immediately with water.

→ Collect emerging Pentosin.

→ Use caps to protect the wiring against soiling and damage.

→ Clean hoses and wiring immediately.

Raise the vehicle.

Only for vehicles with Porsche Dynamic Chassis Control (PDCC):

Remove holder ­1­ for PDCC lines at the right.

Unscrew two M6 fastening screws ­2­ .

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Fig. 22: Identifying PDCC Lines Holder
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Unclip PDCC lines ­1 and 2 ­ at the right ­arrows­ .

Remove fixing clip ­3­ .

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Fig. 23: Locating PDCC Lines Clip
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Disconnect and close off PDCC lines on the distributor.

Loosen union nuts ­1­ on the pressure lines.

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Fig. 24: Identifying Distributor PDCC Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Close off lines and secure them at the side with a tie­wrap.

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Fig. 25: Locating PDCC Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Disconnect plug­in couplings ­1 and 2­ for the steering hydraulic system on the valve block.
Collect Pentosin that leaks out in a suitable container.

Fig. 26: Identifying Valve Block PDCC Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Open the return line ­1­ using special tool ­2­ loosening tool 9780 .

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Fig. 27: Opening PDCC Return Line On Valve Block Using Tool (9780)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Open the pressure line ­1­ using an open­ended wrench (a/f 15). Press thrust ring towards the valve
block using an open­ended wrench and pull off the line.

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Fig. 28: Opening PDCC Pressure Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Close off PDCC lines and secure them with a tie­wrap.

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 Fig. 29: Locating PDCC Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

All vehicles:

8. Unplug cable plug for headlight levelling system ­1­ at the left and right.

Fig. 30: Identifying Headlight Levelling System Cable Plug

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Loosen ground cable ­1­ on the longitudinal member. Screw off M8 hexagon nut ­2­ and remove cable
eyelet from the threaded bolt.

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 Fig. 31: Identifying Engine Ground Strap
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Remove diagonal braces ­1­ .

10.1. Unscrew two hexagon­head bolts (M12 x 30) and washer at the front ­2­ .
10.2. Unscrew two hexagon­head bolts (M12 x 40) at the rear ­3­ .
10.3. Unscrew two internal serration screws (M10 x 45) ­4­ and remove braces.

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 Fig. 32: Identifying Engine Diagonal Braces
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Loosen cross member braces ­1­ on the wheel carrier.

11.1. Unscrew M12 collar nut ­2­ and counter at the screw ­3­ .

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 Fig. 33: Identifying Wheel Carrier Cross Member Brace
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Remove anti­roll bar on the connecting link or PDCC actuator.

12.1. Unscrew M10 collar nut and counter at the internal Torx screw while doing this.
13. Remove rear cross member ­1­ .

→ 420619 REMOVING AND INSTALLING REAR­AXLE CROSS MEMBER .

It is advisable to get a second person to help you to remove the cross member.

13.1. Slide a transmission support under the cross member.

13.2. Unscrew two hexagon­head bolts (M12 x 95) ­2­ at the right.

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Fig. 34: Identifying Right Cross Member Threaded Joint
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13.3. Unscrew two hexagon­head bolts (M12 x 95) ­2­ at the left.

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 Fig. 35: Identifying Left Cross Member Threaded Joint
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13.4. Lower the cross member and anti­roll bar with the transmission support and set them down.

Vehicles with Porsche Doppelkupplung (PDK):

14. Remove parking lock cable ­1­ and cable plug at the top ­2­ .
14.1. Press end piece of cable off the ball head of the parking lock lever using disassembly tool
Nr.21 (­arrow­ ).
14.2. Disconnect cable plug at the top by turning the bayonet lock anti­clockwise.

Fig. 36: Pressing Parking Lock Cable And PDK Cable Plug
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15. Unclip operating cable at the support.

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 Fig. 37: Removing Parking Lock Cable
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Disconnect cable plugs for disc valve control (only for PDK) ­1­ and temperature sensor ­2­ .
16.1. Unclip line ­arrows­ .

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 Fig. 38: Locating Control Valve And Temperature Sensor Cable Plugs
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Pull off cable plug for PDK at the bottom ­1­ and unclip cable guide ­2­ on the transmission ­arrow­ .
17.1. Open the bayonet lock by turning it anti­clockwise.

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 Fig. 39: Locating Bottom PDK Cable Plug And Cable Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

18. Disconnect B+ line at the connection point.

18.1. Open cover ­1­ , unscrew M8 hexagon nut ­2­ and remove line ­3­ .

Fig. 40: Identifying B+ Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

19. Pull off vacuum hose ­1­ and vacuum line for the brake booster ­2­ .
19.1. Press locking ring together and pull off the vacuum line ­arrow­ .

Fig. 41: Locating Brake Booster Vacuum Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20. Master Gear unit elevating platform WE 1206 must be ready for removing the engine.

→ TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY

SUPPORT.

20.1. Observe installation position.

Fig. 42: Identifying Master Gear Unit Elevating Platform (WE 1206)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Master Gear unit elevating platform WE 1206

2. Support 9769/1 for Porsche Doppelkupplung (PDK) and 7­speed manual transmission
3. Support 9769/2 for 6­speed manual transmission (2nd generation 997)
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 4. Retainer plate 9769 for engine
21. Move the elevating platform ­1­ under the vehicle. Position the supports ­2­ of the retainer plate 9769 on
the engine.

Fig. 43: Supporting Engine Using Unit Elevating Platform

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

21.1. The tilt angle ­3­ of the elevating platform plate can be changed to suit the installation
position of the engine/transmission unit.
21.2. Mounting points ­arrows­ for the retainer plate supports.

Fig. 44: Locating Engine Mounting Points

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

21.3. Support 9769/1 must be positioned under the transmission.

21.4. Support the engine/transmission unit slightly with the elevating platform.
22. For safety reasons, the engine must also be secured on the elevating platform by fastening a tension strap
(strapping belt 9454 ­item 1­ ) on the exhaust manifold ­arrows­ .

Fig. 45: Securing Engine On Elevating Platform

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

23. Loosen brace plate ­1­ and transmission bracket.

23.1. Unscrew six hexagon­head bolts (M10 x 40) ­2­ on the brace plate and remove plate and
brace.
23.2. Unscrew two hexagon­head bolts (M10 x 50) ­3­ on the transmission bracket.
23.3. Unscrew two M10 collar nuts ­4­ on the gear support.

Fig. 46: Identifying Brace Plate And Transmission Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

24. Pull off plastic holder ­1­ for the coolant pipes and coolant vent line ­arrow­ .

Fig. 47: Pulling Coolant Pipes Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

25. For all­wheel drive vehicles: Remove cardan shaft.

→ 390219 REMOVING AND INSTALLING CARDAN SHAFT .

26. Loosen and screw off two M12 collar nuts (a/f 18, long socket­wrench insert) ­2­ on the engine carrier ­1­
.

Fig. 48: Identifying Engine Carrier Collar Nuts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

CAUTION: Risk of material damage when lowering engine

Damaged components must be replaced.

→ Get one or two more people to help.

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 27. Slowly lower the engine/transmission unit with the elevating platform.

INSTALLING ENGINE

CAUTION: Risk of damage when inserting the engine/transmission unit into the vehicle

Material damage!

→ Enlist assistance of second and, if necessary, third person

1. Carefully guide in the engine/transmission unit using the Master Gear unit elevating platform WE
1206 .
2. For all­wheel drive vehicles: Install cardan shaft.

→ 390219 REMOVING AND INSTALLING CARDAN SHAFT .

3. Fit holder ­1­ for coolant pipes ­arrow­ .

Fig. 49: Locating Coolant Pipes Holder

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Raise engine/transmission unit into installation position and secure the unit mounts.
4.1. Fit and tighten six M10 x 40 screws ­2­ on the brace plate ­1­ . Tightening torque 30 Nm (22
ftlb.) +90 Grad
4.2. Fit and tighten two M10 x 50 screws on the transmission bracket. Tightening torque 65 Nm
(48 ftlb.)
4.3. Fit and tighten two M10 collar nuts on the transmission support. Tightening torque 65 Nm
(48 ftlb.)

Fig. 50: Identifying Brace Plate And Transmission Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Secure the engine carrier ­1­ to the engine mount with two collar nuts ­2­ .

Fig. 51: Identifying Engine Carrier Collar Nuts

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Loosen tension straps and move Master Gear unit elevating platform WE 1206 out of the work area.
7. Work on the Porsche Doppelkupplung (PDK):
7.1. Connect cable plug at the bottom ­1­ and fit cable guide ­2­ on the transmission ­arrow­ .

Fig. 52: Locating Bottom PDK Cable Plug And Cable Guide
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Clip in end piece ­1­ of the locking cable ­arrow­ and connect cable plug ­2­ .

→ 371319 REMOVING AND INSTALLING LOCKING CABLE .

8.1. Clip in locking cable on the support.

Fig. 53: Locating PDK Cable Plug

Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 9. Connect cable plugs for control valve ­1­ and temperature sensor ­2­ .

Fig. 54: Locating Control Valve And Temperature Sensor Cable Plugs
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Fit B+ line ­3­ on the transmission.

10.1. Insert line shoe and fit and tighten M8 hexagon nut ­2­ . Close the lid ­1­ . Tightening torque
23 Nm (17 ftlb.)

Fig. 55: Identifying B+ Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Secure ground cable ­1­ for engine to the body using an M8 hexagon nut ­2­ . Tightening torque 23 Nm
(17 ftlb.)

Fig. 56: Identifying Engine Ground Strap

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Connect vacuum lines ­1 + 2­ .

Fig. 57: Locating Brake Booster And Engine/Transmission Supply Vacuum Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Always observe specifications relating to chassis components.

Secure chassis components according to the instructions in the specified document.

→ 4X00IN TIGHTENING TORQUES FOR REAR AXLE .

13. Install rear­axle cross member ­1­ .

→ 420619 REMOVE AND INSTALL REAR AXLE CROSS MEMBER .

13.1. Mounting with two hexagon­head bolts (M12 x 95) at the left ­2­ .

Fig. 58: Identifying Left Cross Member Threaded Joint

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13.2. Mounting with two hexagon­head bolts (M12 x 95) at the right ­2­ .

Fig. 59: Identifying Right Cross Member Threaded Joint

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

14. Fit wishbone ­1­ on the wheel carrier using a nut ­2­ and bolt ­3­ .

Fig. 60: Identifying Wheel Carrier Cross Member Brace

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15. Install diagonal braces.

→ Installing Rear­Axle Cross Member .

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 1. Diagonal braces
2. Hexagon­head bolt, M12 x 40
3. Hexagon­head bolt, M12 x 30
4. Cheese head bolt, M10 x 45

Fig. 61: Identifying Engine Diagonal Braces

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Fit anti­roll bar on the PDCC actuator or connecting link.

→ Installing Rear Anti­Roll Bar .

17. Vehicles with Porsche Dynamic Chassis Control (PDCC):

17.1. Fit lines on the underbody and secure at the retaining points.

→ 4303IN COMPONENT ARRANGEMENT .

→ 4X00IN TIGHTENING TORQUES FOR PORSCHE DYNAMIC CHASSIS CONTROL

(PDCC) .

18. Connect cable plug for headlight levelling system at the left and right.
19. Fit air­conditioning lines ­1­ with new O­rings.

→ 873419 REMOVING AND INSTALLING AIR­CONDITIONING COMPRESSOR .

19.1. Counter with special tool assembly tool 9822 .

19.2. Tighten the screws. Tightening torque 22 Nm (16 ftlb.)

Fig. 62: Identifying Air­Conditioning Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Check O­rings on the plug­in couplings and replace them if necessary.

Clean plug connection and coolant hoses before assembly.
Coat O­rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93).
Remove stoppers before fitting the coolant lines and hoses.
20. Fit coolant hoses in the engine compartment.
20.1. Lightly grease the O­rings.
20.2. Check that the coolant hoses are fitted securely.
21. Connect plug­in coupling ­1­ for the fuel low­pressure line in the engine compartment.
21.1. Check that the line is fitted securely.

Fig. 63: Locating Fuel Low­Pressure Line Connection

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

22. Connect vent lines for coolant ­1 + 2­ and fuel ­3­ .

Fig. 64: Identifying Coolant And Tank Vent Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK
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Information

Check O­rings on the plug­in couplings and replace them if necessary.

Clean plug connection and coolant hoses before assembly.
Coat O­rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93).
Remove stoppers before fitting the coolant lines and hoses.

1. Fit rear wheels. Socket­wrench insert 300 should be used.

→ 440519 REMOVING AND INSTALLING WHEEL .

2. Secure the drive shafts on the transmission flange. Get another person to counter at the rear wheels.

→ Installing Drive Shaft .

3. Fit oxygen sensor plug connections at the left and right in the engine compartment, route the lines and
secure them at the retaining points.

→ Installing Oxygen Sensor Upstream Of Catalytic Converter .

→ Installing Oxygen Sensor Downstream Of Catalytic Converter .

4. Fill in coolant.

→ Filling Coolant 193817 Draining And Filling Coolant .

4.1. Check all connections on the cooling system that were opened during removal for leaks.
5. Install side retaining frame (heat protection) for the rear apron.

→ 261519 REMOVING AND INSTALLING RETAINING FRAME WITH HEAT PROTECTION

.

6. Install rear apron.

→ Installing Rear Apron .

7. Connect the battery.

→ WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

8. Only for vehicles with PDCC: Fill in Pentosin at the hydraulic reservoir, check the fluid level and top
up if necessary.

→ 430501 CHECKING FLUID LEVEL (PDCC) .

Information

Only for vehicles with PDCC: After installing a replacement engine, pressure must be applied to
the PDCC pump via the reservoir.
9. Only for vehicles with PDCC: Apply pressure to the pump via the reservoir.

→ 430307 BLEEDING THE PDCC SYSTEM .

10. Install air cleaner housing.

→ Installing air cleaner housing .

11. Install rear spoiler.

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 → Installing Rear Spoiler .

12. Fit engine­compartment blower.

→ Installing Engine­Compartment Blower .

13. Install air guide.

→ Installing Air Guide In Wheel Housing .

14. Fit all covers.

15. Check engine­oil level and top up with new engine oil if necessary.

→ 170101 CHECKING ENGINE­OIL LEVEL .

16. Bleed the cooling system according to specifications using PIWIS Tester II 9818 .

→ 190107 BLEEDING THE COOLING SYSTEM .

17. On Cabriolet vehicles: Install support plate.

→ 421419 REMOVING AND INSTALLING SUPPORT PLATE .

18. Install underbody cover.

→ Installing Cover For Centre Underbody .

→ 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

19. Remove protective covers.

WM 1001IN POSITION AND MARKING OF ENGINE NUMBER (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION")
TOOLS

Designation Type Number Description Â

Connect Commercially Nr.197 Â
compressed­air available tool
marking pen

INFORMATION
Position Of Engine Number

Overview on vehicle:

Fig. 65: Identifying Engine Number Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

The engine number is located on the crankcase towards the rear of the oil pan.

Fig. 66: Identifying Engine Number Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INFORMATION
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Engine Number Marking

Information

Do not use steel stamping numbers to mark the engine number on direct fuel injection engines.
Due to the material composition, the engine number must be engraved using the specified tool.

1. Connect compressed­air marking pen Nr.197 ­1­ to compressed air supply.

1.1. Turn the adjusting ring to ­arrows­ open or close the compressed air supply.
1.2. First test the tool on a piece of waste material.

Fig. 67: Turning Adjusting Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Use the marking pen to engrave the engine number into the crankcase.

Fig. 68: Identifying Engine Number

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.1. To provide a clear marking, use a 0.5 (5 mm) template!

Fig. 69: Identifying Template

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE

ENGINE ASSEMBLY SUPPORT (EXCEPT CARRERA "EDITION", CARRERA
CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION")
TOOLS

Designation Type Number Description Â

engine/transmission Workshop WE 1171 Â
repair stand WW­MG equipment
600/v
Master Gear unit Workshop WE 1206 Â
elevating platform equipment
mobile assembly Workshop WE 1323 Â
station equipment
strapping belts Special tool 9454 Â
mounting parts Special tool 9590 Â
Retainer plate Special tool 9769 Â
Support Special tool 9769/1 Â
engine adapter Special tool 9771 Â
Mounting set Special tool 9771/1 Â
Engine support Special tool 9771/2 Â

INFORMATION
Individual Components And Setup For Removing Units

­­­

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Master Gear Unit Elevating Platform WE 1206

Fig. 70: Identifying Master Gear Unit Elevating Platform

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Mounting tools:

Fig. 71: Identifying Engine/Transmission Mounting Tools

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

A. Retainer plate 9769 .

B. Support 9769/1 for manual transmission and Porsche Doppelkupplung (PDK)

Setup on elevating platform: Tighten screws hand­tight.

Fig. 72: Identifying Elevating Platform

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Unit elevating platform

2. Support for transmission
3. Retainer plate

Support for transmission: Position bolt on the support ­1­ in the take­up hole ­arrow­ .

Fig. 73: Supporting PDK Transmission

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Engine mounting points: For positioning the retainer plate supports ­arrows­ .

Fig. 74: Locating Engine Mounting Points

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Removing transmission from engine and mounting transmission on engine

1. Fit lifting strap(s) ­1­ as shown.

Fig. 75: Lifting Transmission Using Strap

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Loosen flange bolts in the sequence ­1 to 6­ .

→ 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

2.1. Secure in reverse order!

Fig. 76: Engine Flange Bolts Loosening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Transporting The Engine In The Workshop

Information

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 991 engines do not have the engine transport eyebolt . The spare part (9A1.101.213.00, 997­2) must be
fitted on the crankcase in order to transport the engine.
The transport eyebolt is fitted on 981 engines.
The engine transport eyebolt must only be used briefly for transporting the engine with the workshop
crane and for mounting the engine on the assembly support.
The transmission must always be removed beforehand to avoid fracturing the cast iron on the crankcase.
The engine must also be suspended on the engine carrier.

1. Adapter with carabiner for lifting equipment

2. Transport eyebolt (spare part number: 9A1.101.213.00)

Fig. 77: Lifting Engine Transport Eyebolt

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Engine lifting positions:

Fig. 78: Lifting Engine Carrier (Carrera)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Lifting strap
2. Lifting equipment for crane

Fig. 79: Lifting Engine

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Lifting equipment with carabiner hook

arrows ­ Suspending engine using transport eyebolt and lifting strap on the engine carrier

Transporting the engine with the workshop crane:

Fig. 80: Lifting Engine On Workshop Crane

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Transporting the engine using the Master Gear unit elevating platform WE 1206:

For safety reasons, strapping belts 9454 must be used to secure the engine on the elevating platform ­1­.

On the Carrera, secure the engine across the two exhaust manifolds.

On the Boxster/Cayman, secure the engine using the engine flange.

Fig. 81: Securing Engine Using Flange

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Mounting Engine On Assembly Support

Individual components of the engine/gear support:

Fig. 82: Identifying Supporting Engine And Transmission Components

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

A. Engine support 9771/2

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 B. Engine adapter 9771
C. Mounting set 9771/1

Engine support setup on engine/transmission repair stand WW­MG 600/v WE 1171 or mobile assembly
station WE 1323

Fig. 83: Supporting Engine Assembly

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Mobile assembly station

2. Engine support 9771/2
3. Mounting set 9771/1
4. Engine adapter

Information

The crankcase is very hard due to its material composition and as a result, there is a high risk that it will
break at the flange eyes if excessive pressure is applied.
Given this, the engine adapter 9771 must always be screwed on at the engine flange first.
If this is not possible, the tightening and loosening sequence must always be observed.

1. Secure engine adapter 9971 to the engine using six mounting parts 9590 . Tighten screws hand­tight
only.

Crankcase flange: Screw­on points for the engine adapter ­1 to 6­ .

Fig. 84: Engine Flange Bolts Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.1. Screw mounting set loosely to the engine adapter.

1.2. Screw engine support loosely to the mounting set, align the lever arms and then tighten screws
well.
2. Lift the engine with the workshop crane and secure it on the engine assembly support.

Engine on assembly support

Fig. 85: Locating Engine Support Mounting Points

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

NOTE: Engine housing overload.

Risk of engine damage if housing breaks.

→ Observe loosening and tightening sequence!

→ Loosening sequence: Loosen screws from the bottom up.

→ Tightening sequence: Tighten screws from top to bottom.

3. The tightening and loosening sequence must always be observed when fitting the engine on or removing
the engine from the engine support.
3.1. Tightening sequence: Always tighten screws ­1 and 2­ last.
3.2. Loosening sequence: Always loosen screws ­1 and 2­ first.

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WM 1001Z1 DISASSEMBLING ENGINE (EXCEPT CARRERA "EDITION",
CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

mounting parts Special tool 9590 Â
locating pin Special tool 9595/1 Â
turning device Special tool 9773 Â

PRELIMINARY WORK

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Grease O­rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).

Information

All engine repairs must be carried out using only the specified tools.
Only these tools have been tested and approved.

Information

Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire
harness).
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

1. Remove engine.

→ 100119 REMOVING AND INSTALLING ENGINE.

2. Remove transmission.

→ 343527 REMOVING AND MOUNTING TRANSMISSION

→ 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

3. Remove flywheel.

→ 136019 REMOVING AND INSTALLING FLYWHEEL ­ PORSCHE DOPPELKUPPLUNG

(PDK) .

→ 136019 REMOVING AND INSTALLING FLYWHEEL .

4. Mount the engine on the engine assembly support.

→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY
SUPPORT.
3211 of 5326
 5. Remove front silencer.

→ 262519 REMOVING AND INSTALLING FRONT SILENCER .

6. Remove rear silencer.

→ 263319 REMOVING AND INSTALLING REAR SILENCER .

7. Remove engine carrier ­1­ .

→ 103019 REMOVING AND INSTALLING ENGINE CARRIER.

Fig. 86: Identifying Engine Carrier Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Drain engine oil.

→ 170155 CHANGING ENGINE OIL AND OIL FILTER

9. Remove cover for drive belt ­1­ and generator ­2­ .

→ 138419 REMOVING AND INSTALLING COVER FOR DRIVE BELT .

9.1. Do not loosen the connecting screws between the two covers.

Fig. 87: Identifying Drive Belt Covers Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Vehicles with Porsche Dynamic Chassis Control (PDCC): Loosen three external Torx screws on the
pulley (do not unscrew fully).
11. Remove drive belt.

→ 137819 REMOVING AND INSTALLING DRIVE BELT .

11.1. Only for PDCC: Unscrew screws for pulley and remove pulley.
12. Remove the generator.

→ 272219 REMOVING AND INSTALLING GENERATOR .

Fig. 88: Loosening Generator Fastening Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13. Disconnect cable plugs for tank ventilation ­3­ and engine temperature sensor ­1­ on the intake­air
distributor on bank 1­3. Unscrew screw ­2­ for cable duct mounting.

Fig. 89: Identifying Intake­Air Distributor Cable Plugs (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

14. 3.8­litre engine only: Pull off vacuum line on vacuum unit for tuning flap.
15. Disconnect positive crankcase ventilation line ­1­ at the resonance tube and unclip it at the intake­air
distributor ­arrows­ .
15.1. Unscrew screw ­2­ for cable duct mounting on the intake­air distributor on bank 4­6.

3212 of 5326
 Fig. 90: Locating Positive Crankcase Ventilation Line On Cylinder Bank (4­6)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Loosen holder at the oil­fill pipe.

16.1. Unscrew two screws ­2­ .
16.2. Unclip positive crankcase ventilation line ­3­ at the oil­fill pipe and cylinder head 1­3.

Fig. 91: Identifying Oil Filler Tube And Positive Crankcase Ventilation Line Holder
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Unscrew three fastening screws for the engine wire harness cable duct at the cylinder head (1­3 and 4­6).
18. Completely remove intake­air distributor.

→ 244619 REMOVING AND INSTALLING INTAKE­AIR DISTRIBUTOR .

19. Remove positive crankcase ventilation line ­1­ .

19.1. Unclip connection at cylinder head 4­6 ­item 3 (right)­ and unscrew fastening screw ­2­ on
the oil module.
19.2. Disconnect line, unclip it from the holder and remove it.
19.3. Replace O­rings.

Fig. 92: Identifying Positive Crankcase Ventilation Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20. Remove oil filler neck ­1­ .

20.1. Unscrew two external Torx screws ­2­ and pull the connection piece out of the crankcase.
20.2. Close off opening with adhesive tape or a stopper.
20.3. Replace O­ring.

Fig. 93: Identifying Oil Filler Neck

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

21. Remove air­conditioning compressor.

→ 873419 REMOVING AND INSTALLING AIR­CONDITIONING COMPRESSOR .

22. Vehicles without Porsche Dynamic Chassis Control (PDCC): Remove console with deflection roller
­1­ .
22.1. Unscrew three fastening screws ­2 and 3­ and remove console.

Fig. 94: Identifying Deflection Roller Console Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

23. Vehicles with Porsche Dynamic Chassis Control (PDCC): Remove pump together with the pressure
line and return line.

→ 430619 REMOVING AND INSTALLING PUMP (PDCC) .

1. Hydraulic pump (PDCC)

2. Pressure line
3. Return line

3213 of 5326
 Fig. 95: Identifying Hydraulic Pump And Lines
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

24. Remove oil separator ­1­ .

24.1. Unclip B+ line at the oil separator.
24.2. Unscrew external Torx screws ­2­ and pull off the oil separator.
24.3. Replace O­rings.

Fig. 96: Identifying Oil Separator Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

25. Remove heat shields ­1­ for ignition coils.

25.1. Unscrew external Torx screws ­2­ and remove heat shields.

Fig. 97: Identifying Heat Shield Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

26. Unplug cable plugs at the cylinder head and disconnect ground straps for ignition coils.
1. Connectors for ignition coils
2. Screws for ground connection for ignition coils
3. Hall sender
4. Solenoid hydraulic valve for valve lift adjustment

Fig. 98: Identifying Cylinder Head Cover Cable Plugs

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

27. Disconnect B+ line and control line for solenoid switch (terminal 50) at the starter.
27.1. Screw off M8 ­1­ and M6 ­2­ collar nuts and remove lines.
27.2. Remove B+ wire harness.

Fig. 99: Removing Starter Cable Shoe Nut

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

28. Remove engine wire harness by disconnecting several cable plugs at the engine and unclipping the cable
holder.

→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

Solenoid hydraulic valve for camshaft control (top of cylinder head)

Pressure sensor at fuel collection pipe, bank 4­6
Oil pressure and temperature sensor on bracket for oil­water heat exchanger
Fuel injectors
Knock sensors
Flow control valve on high­pressure pump
Coolant temperature sensor at cylinder head 1­3
Pressure­regulating valve and oil­level sender on oil pan
28.1. Remove wire harness.
29. Remove holder for rear silencer ­1­ .
29.1. Unscrew external Torx screws ­2­ and remove holder.

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 Fig. 100: Identifying Rear Silencer Holder
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

30. Remove ignition coils.

30.1. Unscrew internal Torx screws and pull off ignition coils.
31. Remove hall sender.
31.1. Unscrew screw and pull off hall sender.
32. Remove spark plugs.

→ 287020 REMOVING AND INSTALLING SPARK PLUGS .

33. Remove fuel connection line ­1­ .

33.1. Loosen external Torx screws ­2 and 3­ at the clamps.
33.2. Unscrew union nuts ­4­ and remove line. Soak up emerging fuel with a cloth.

Fig. 101: Identifying Fuel Connection Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

34. Remove coolant collection unit and coolant hoses (on the oil­water heat exchanger) ­2­ .
34.1. Open spring band clamps ­1­ and pull off hoses.

Fig. 102: Identifying Oil­Water Heat Exchanger Coolant Hoses

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

34.2. Unscrew external Torx screws ­2­ and pull coolant collection unit ­1­ up and off.

Fig. 103: Identifying Coolant Collection Unit

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

34.3. Coolant collection unit ­1­ and connecting pipes ­2­ for the coolant pump and thermostat
housing.

Fig. 104: Identifying Coolant Collection Unit And Connecting Pipes

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

34.4. Replace O­rings ­1­ and grease new O­rings with Kluberplus Gel (Part No. 000.043.205.93).

Fig. 105: Identifying Connecting Pipes O­Rings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

35. Remove the starter.

→ 276019 REMOVING AND INSTALLING STARTER .

36. Remove fuel collection pipes ­2­ with fuel injectors.

36.1. Spray the fuel injector seats in the cylinder head with anti­rust agent.
36.2. Unscrew external Torx screws ­1­ .
36.3. Pull fuel collection pipe ­2­ with fuel injectors out of the cylinder heads.
36.4. Close off fitting bores in the cylinder head with stoppers.

3215 of 5326
 Fig. 106: Identifying Fuel Collection Pipe Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

37. Remove oil­water heat exchanger ­1­ .

37.1. Unscrew internal Torx screws ­2­ and remove heat exchanger.
37.2. Soak up any drops of fluid with a clean cloth and clean the sealing faces.
37.3. Replace O­rings.

Fig. 107: Identifying Oil­Water Heat Exchanger

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one
side.
The bracket's aluminum supports can break off in the crankcase.
38. Remove bracket ­1­ for oil­water heat exchanger.
38.1. Unscrew external Torx screws ­2 and 3­ . Pull the bracket up and out.
38.2. Close off oil ducts with stoppers.
38.3. Replace O­rings at the top ­4­ and on the underside.

Fig. 108: Identifying Oil­Water Heat Exchanger Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

39. Remove knock sensors (mark installation position using a water­resistant marker).
39.1. Unscrew external Torx screw and remove sensors.
40. Remove exhaust manifold with catalytic converter.

→ 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD .

41. Remove cover ­1­ on positive crankcase ventilation line.

41.1. Cylinder bank 1­3: Unscrew external Torx screws ­4­ and replace O­ring ­3­ and molded seal
­2­ .

Fig. 109: Identifying Positive Crankcase Ventilation Cover (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

41.2. Cylinder bank 4­6: Unscrew external Torx screws ­3­ and replace O­ring ­2­ .

Fig. 110: Identifying Positive Crankcase Ventilation Cover (4­6)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

42. Remove vacuum line ­1­ for the vacuum pump (cylinder bank 4­6).
42.1. Unscrew external Torx screws ­2­ and remove line.

Fig. 111: Identifying Brake Booster Vacuum Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

43. Remove vacuum pump.

→ 477619 REMOVING AND INSTALLING VACUUM PUMP .

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44. Remove support for high­pressure pump.
44.1. Unscrew external Torx screws on the heat shield and remove heat shield.
44.2. Unscrew external Torx screws ­1 and 2­ and remove support.

Fig. 112: Identifying High­Pressure Pump Support

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

45. Remove high­pressure pump ­1­ and fuel lines ­2 and 4­ .

45.1. Unscrew external Torx screws ­3 and 5­ at the mounting points.
45.2. Unscrew external Torx screws at the pump, pull out the pump and remove together with the
lines.
45.3. Replace O­ring.

Fig. 113: Identifying High­Pressure Pump And Fuel Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

46. Remove wastegate with coolant pipe.

46.1. Unscrew fastening screw ­2­ for the coolant pipe ­1­ .

Fig. 114: Identifying Lower Coolant Pipe

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

46.2. Unscrew fastening screws ­4­ for the wastegate ­3­ .

Fig. 115: Identifying Wastegate With Coolant Connection Piece

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

46.3. Pull off wastegate and pull coolant pipe out of the coolant regulator housing.
47. Remove coolant distributor housing (unit carrier) ­1­ with coolant connection piece.

→ 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING .

47.1. Check molded seals and replace if necessary.

1. Coolant distributor housing (unit carrier)
2. Screws, M8 x 70 ­ on coolant connection piece
3. Screws, M8 x 50
4. Screw, M8 x 35

Fig. 116: Identifying Coolant Distributor Housing

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

48. Remove belt tensioner.

→ 137319 REMOVING AND INSTALLING BELT TENSIONER .

49. Remove coolant regulator housing ­1­ .

Fig. 117: Identifying Coolant Regulator Housing

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

49.1. Unscrew external Torx screw ­3­ on the intake tube holder ­4­ .
3217 of 5326
 49.2. Unscrew external Torx screw ­2­ on the coolant pump holder ­1­ .

Fig. 118: Identifying Coolant Pump Holder Screw

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

49.3. Unscrew external Torx screws ­4­ on the coolant pump connection piece.

Fig. 119: Pulling Coolant Pipe Housing

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

49.4. Unscrew external Torx screws ­3­ on the housing, pull the housing off the coolant pipe ­1­
and replace O­rings.
49.5. Replace molded seal ­3­ on the connecting tube ­2­ .

Fig. 120: Identifying Coolant Regulator Housing And Connecting Tube

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

50. Remove coolant guide ­1­ at the bottom.

50.1. Unscrew external Torx screws ­2­ .
50.2. Check molded seals and replace if necessary.

Fig. 121: Identifying Lower Coolant Guide

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

51. Use turning device 9773 to turn the engine clockwise at the vibration damper until the TDC 1/4 marking
on the vibration damper is aligned with the bore in the crankcase.
51.1. Stake using a locating pin 9595/1 on the vibration damper.

Fig. 122: Turning Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

52. Remove vibration damper.

52.1. Loosen and unscrew external Torx screws and remove the vibration damper.
52.2. Check dowel sleeve and crankshaft flange for damage.
53. Remove bracket for the coolant pump ­1­ .
53.1. Unscrew external Torx screws ­2 to 5­ . Unscrew threaded bolt ­6­ .

Fig. 123: Identifying Coolant Pump Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

53.2. Replace O­rings ­2 and 3­ on the coolant pipe ­4­ and coolant connection piece.

Fig. 124: Identifying Coolant Pipes O­Rings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

54. Remove coolant connecting tube (for coolant regulator housing) ­1­ .
54.1. Unscrew external Torx screw ­2­ on the retaining bracket for the crankcase.

Fig. 125: Identifying Coolant Connecting Tube

Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3218 of 5326
 55. Remove hydraulic valves for camshaft control.

→ 153719 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR

CAMSHAFT CONTROLLERS .

56. Remove hydraulic valves for valve lift switchover.

→ 155519 REMOVING AND INSTALLING HYDRAULIC VALVE FOR VALVE LIFT

SWITCHOVER .

DISASSEMBLING ENGINE

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Guide the timing chains with your hand when turning the crankshaft so that they do not get stuck in the
crankcase.

1. Remove cylinder head cover.

→ 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER .

1.1. Unscrew one external Torx screw for the engine ground strap on cylinder bank 4­6 and remove
ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
2.1. Cam positions on intake ­1­ and outlet camshaft ­2­:
Overlapping position of cylinder bank 1­3: Cams on cylinder 1 are facing outward at an
angle.
Overlapping position of cylinder bank 4­6: Cams on cylinder 4 are facing inward at an angle
with respect to the spark­plug recess.

Cylinder 1:

Fig. 126: Locating Cam (Cylinder 1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cylinder 4:

Fig. 127: Locating Cam (Cylinder 4)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.2. If the camshafts are at overlapping position, rectangular markings ­1­ can be seen on the outlet
and intake camshaft (data matrix code).

Fig. 128: Identifying Camshaft Part Number And Data Matrix Code Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Remove camshafts.
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 → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .

Information

Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance
with their installation position in the cylinder head.
Components have been run in in fitted bores and must not be confused.
Do not use magnets for removal or installation. This can cause the components to malfunction.
4. Remove hydraulic tappets.
4.1. Pull bucket tappets ­1­ and switching tappets ­2­ out of the fitting bores in the cylinder head.
Do not use magnets.

Fig. 129: Identifying Hydraulic Tappets For Valve Control

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Lay components on a clean, labelled surface.

Fig. 130: Example Of Bucket Tappets

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove tensioning and guide rails.

5.1. Cylinders 1­3: Unscrew one bearing pin for the tensioning rail ­2­ and two bearing pins for
the guide rail ­1­ .

Fig. 131: Identifying Cylinder Bank Bearing Pins (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.2. Pull out the tensioning and guide rails ­1­ using flat­nosed pliers ­3­ .

Fig. 132: Pulling Guide Rail

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.3. Lay the timing chain in the chain slot.

5.4. Pull oil supply valve ­1­ on the vacuum pump out of the cylinder head using a pair of flat­
nosed pliers. Replace O­ring.

Fig. 133: Pulling Oil Supply Valve

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

View of oil supply valve ­1­ with O­ring ­2­ removed:

Fig. 134: Identifying Oil Supply Valve And O­Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.5. Cylinders 4­6: Unscrew two bearing pins ­2­ for the guide rail and one bearing pin for the
tensioning rail ­3­ .

Fig. 135: Identifying Cylinder Bank Bearing Pins (4­6)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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 5.6. The bearing pin for the tensioning rail on bank 4­6 ­1­ is longer than the five other bearing pins
­2­ for the timing chain rails.
1. Bearing pins for tensioning rail on cylinder bank 4­6
2. Bearing pins for both guide rails and tensioning rail on cylinder bank 1­3

Fig. 136: Identifying Bearing Pins

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.7. Replace O­rings ­3­ .

6. Remove cylinder head with cylinder­head gasket.

→ 157019 REMOVING AND INSTALLING CYLINDER HEAD .

7. Pull out displacement bodies ­1­ on cylinder bank 1­3 using flat­nosed pliers.

Fig. 137: Identifying Cylinder Bank Marking Pistons (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Turn the engine at the engine assembly support so that the oil pan is at the top.
9. Remove oil pan.

→ 175019 REMOVING AND INSTALLING OIL PAN

10. Remove coolant pipe ­1­ for the coolant pump.

10.1. Unscrew two external Torx screws ­2­ and remove the pipe.

Fig. 138: Identifying Coolant Pipe Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Remove oil pump and oil guide.

→ 172019 REMOVING AND INSTALLING OIL PUMP .

12. Turn the engine at the engine assembly support so that cylinder bank 1­3 is facing upwards.
13. Remove pistons for cylinders 1­3.

→ 131020 REMOVING AND INSTALLING PISTONS .

14. Remove crankcase half 1­3.

14.1. Unscrew 19 external Torx screws for the outer cross bolt connection. The threaded bolt must
be removed for the screw ­item 17­ .

Fig. 139: Identifying Outer Cross Bolt Connection Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15, 16 and 17 ­ External Torx screw, M8 x 35

External Torx screw, M6 x 40
19­32 ­ External Torx screw, M6 x 25
External Torx screw, M8 x 120
14.2. Loosen and unscrew through bolts (M10 x 195) in the opposite sequence to the tightening
sequence.

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 Fig. 140: Crankcase Screws Loosening Sequence
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1­14 ­ External Torx screw (M10 x 1.5 x 195) with sealing washer
14.3. Replace screws.

Once the sealing washers are approved as spare parts in the Spare Parts Catalogue, new
sealing washers can be fitted and the screws can be re­used!

15. Unscrew two mounting parts 9590 for bolting crankcase half 1­3 to the engine support.
16. Lift off crankcase 1­3.
16.1. To do this, put on heat­resistant gloves and heat the sealant at the joint slightly with a hot­air
gun.
16.2. Lift up crankcase half 1­3 at the positions shown ­arrows­ using a large slotted screwdriver.

Fig. 141: Locating Lever Positions On Crankcase

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16.3. Slide in two pieces of wood ­1­ above the oil­pump pressure channels and lift up the
crankcase half using a mounting lever ­items 2 and 3­ .

Fig. 142: Locating Crankcase Mounting Lever Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Remove pistons with connecting rods for cylinders 4­6.

→ 131020 REMOVING AND INSTALLING PISTONS .

17.1. Remove connecting rods 1­3 on the crankshaft.

18. Remove and dispose of crankshaft sealing rings.
19. Lift crankshaft with timing chains out of crankcase half 4­6.

Fig. 143: Identifying Crankshaft And Timing Chains

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

19.1. Remove bearing shells from the crankcase halves and dispose of them.
19.2. The deviation sample catalogue for the Cayenne can be used to assess the cylinder linings.
20. Clean the crankcase and sealing faces.

WM 1001Z2 ASSEMBLING ENGINE (EXCEPT CARRERA "EDITION",

CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

mounting parts Special tool 9590 Â
engine adapter Special tool 9771 Â
turning device Special tool 9773 Â
holding bridge Special tool 9779 Â
Protective sleeve Special tool 9786 Â
assembly aid Special tool 9795 Â
3222 of 5326
 restraining straps Special tool P221 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Threaded bolt Bond with Tightening 5 Nm (3.5 Â Â
for engine Loctite 243 torque ftlb.)
carrier

ASSEMBLING ENGINE

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Always replace gaskets and O­rings.

Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).

Information

The tightening torques for the engine are listed in the following documents and must be used in
accordance with these specifications.

Technical values and tightening torques:

Repair group 1: → 1X00IN TECHNICAL VALUES .

Repair group 2: → 2X00IN TECHNICAL VALUES .

Overview of bearing shell allocation:

Fig. 144: Identifying Crankshaft Shell

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Main bearing shells ­ red, yellow, blue

2. Partial­groove bearing shells ­ red, yellow, blue
3. Thrust washers
4. Supporting mount shells ­ red, yellow, blue

1. Fit crankcase half 4­6 on the engine assembly support.

1.1. Use mounting parts 9590 to secure to the engine adapter 9771 .

→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY
SUPPORT.

Information

The bearing shells must be allocated according to specifications.

Observe difference between partial­groove bearings and smooth bearings.
3223 of 5326
 Coat bearing shells with new engine oil.
2. Fit new bearing shells on crankcase half 4­6. The following markings ensure correct allocation.
2.1. Crankcase half 4­6: Markings are on the crankshaft. The upper series of letters ­1­ is for the
crankcase. Allocation starts at the supporting mount ­SL­ on the belt side and is read from left to
right. The supporting mount does not have a number, while the main bearings are numbered ­HL:
1 to 7­ (number 7 is at the flywheel side).
1. Series of letters at the top, supporting mount shells and main bearing shells
2. Series of letters on connecting­rod bearing shells
SL ­ Supporting mount
HL ­ Main bearing
PL ­ Connecting­rod bearing
R ­ Bearing shell, Red
G ­ Bearing shell, Yellow
B ­ Bearing shell, Blue

Fig. 145: Identifying Crankshaft Bearing Shell Mark

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Fit new bearing shells on crankcase half 1­3.

3.1. Crankcase 1­3: Markings ­1­ on crankcase half. The series of letters is read from left to right.
Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
G ­ Bearing shell, Yellow
R ­ Bearing shell, Red
B ­ Bearing shell, Blue

Fig. 146: Identifying Crankcase Marking

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3.2. There are also different types of bearing shells (see bearing shell allocationFig. 144).
1. Partial­groove bearing shell (cylinders 2, 4 and 6)
2. Smooth bearing shell

Fig. 147: Identifying Crankcase Bearing Shells

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3.3. Fit and grease new O­ring on the crankcase sealing face.
4. Insert two thrust washers ­1­ on main bearing 4. Oil grooves must always be facing outwards.

Fig. 148: Locating Thrust Washer Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Check guide and tensioning rails for visible and obvious signs of wear before installation and
replace if damaged.
The tensioning rails on cylinder bank 1­3 and 4­6 are identical.
The guide rails on cylinder bank 1­3 and 4­6 are identical.
The slots in the cylinder head must be positioned during installation.
5. Install tensioning rail for oil­pump drive chain in crankcase 4­6.
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 1. Rail
2. Tensioning spring

Fig. 149: Identifying Oil­Pump Timing Chain Tensioning Rail

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.1. Fit tensioning rail ­1­ for oil pump chain using a short bearing pin.

Fig. 150: Identifying Oil­Pump Drive Tensioning Rail

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Fit guide rail for cylinder bank 4­6 and secure in the crankcase with a short bearing pin ­2­ .
1. Oil pump supply valve on vacuum pump
2. Bearing pin for guide rail
3. Bearing pins for tensioning rail
4. Bearing pin for tensioning rail for oil­pump drive chain

Fig. 151: Identifying Cylinder Bank Bearing Pins (4­6)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.1. Place spring ­2­ on tensioning rail ­1­ for oil­pump drive chain into the cut­out in the guide rail
­3­ .

Fig. 152: Identifying Tensioning Spring Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Insert crankshaft with timing chains ­2 and 3­ .

7.1. Engage oil pump gear ­1­ in the drive chain.

Fig. 153: Identifying Crankshaft

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Fix crankshaft in place using special tool holding bridge 9779 ­1­ .
8.1. Fit and tighten fastening screws ­2­ hand­tight.

Fig. 154: Placing Crankshaft

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Install pistons on cylinder bank 4­6 and connecting rods 1­3.

→ 131020 REMOVING AND INSTALLING PISTONS AND HANDLING TOOLS .

10. Replace through bolts.

Once the sealing washers are approved as spare parts in the Spare Parts Catalogue, the sealing
washers can be replaced and the screws can be re­used! To do this, proceed as follows:

10.1. Fit through bolts ­1­ with new sealing washers.

10.2. Protective sleeve 9786 ­2­ must be pulled over the screw thread. Guide sealing washer ­3­
over the protective sleeve for the screw head and remove protective sleeve.
1. Through bolt

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 2. Protective sleeve 9786
3. Sealing washer (not yet available as a spare part)

Fig. 155: Identifying Sealing Washer And Protective Sleeve

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before
applying sealant.
Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the
required area only.
Join the crankcase halves within max. 5 minutes of applying the bead of sealant.
11. Apply sealant to crankcase half 4­6. Observe processing instructions.
11.1. Use Dobotech sealing compound (Part No. 000.043.207.31).
11.2. Carefully apply a continuous bead of sealant ­arrow 1­ with a diameter of 1 mm. Follow
sealant contour as shown in Fig. 156.
11.3. Remove residual silicone in the crankshaft flange area following installation ­arrow 2­ .

Fig. 156: Locating Crankcase Sealant Applying Area

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Fit rubber sleeves on connecting rods 1­3 (assembly aid 9795 ) and position vertically.
12.1. The restraining straps P221 can be used if necessary. Only two connecting rods can be fixed
in place in this case. The third connecting rod must be held when positioning the crankcase half.

Information

Get another person to help you join crankcase halves 1­3.

13. With the help of a second person, place crankcase half 1­3 on crankcase half 4­6.
14. Fit through bolts and tighten according to the specified tightening torque and sequence.

→ 1X00IN TECHNICAL VALUES

Fig. 157: Crankcase Bolts Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1­14 ­ External Torx screw with sealing washer

15. Fit external Torx screws for the outer cross bolt connection and tighten according to the specified
tightening sequence.

→ 1X00IN TECHNICAL VALUES

Fig. 158: Crankcase Bolts Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Screw in and tighten two mounting parts 9590 for bolting crankcase half 1­3 to the engine support.
17. Install pistons for cylinder bank 1­3.

→ 131020 REMOVING AND INSTALLING PISTONS .

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18. Turn the crankshaft clockwise a number of times at the vibration damper using turning device 9773 in
order to check for smooth operation and correct function.
18.1. Then, turn the crankshaft so that none of the pistons are at top dead center (TDC).
19. Fit crankshaft sealing rings at the flywheel and drive side.

→ 137455 REPLACING CRANKSHAFT SEALING RING (ON BELT SIDE) .

20. Fit tensioning rail for cylinder bank 4­6 using a long bearing pin ­3­ .

Fig. 159: Identifying Cylinder Bank Bearing Pins (4­6)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20.1. Fit tensioning rail for cylinder bank 1­3.

20.2. Secure guide rail for cylinder bank 1­3 in the crankcase with long bearing pins ­1­ .

Fig. 160: Identifying Cylinder Bank Bearing Pins (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ftlb.) .

21. Fit the oil guide (oil plate) ­1­ using external Torx screws ­2­ .

Fig. 161: Identifying Crankcase Oil Guide

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

22. Install oil pump.

→ 172019 REMOVING AND INSTALLING OIL PUMP .

23. Install coolant pipe ­1­ for the coolant pump.

23.1. Fit and tighten external Torx screws ­2­ .

Fig. 162: Identifying Coolant Pipe

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

24. Insert displacement bodies ­1­ on cylinder bank 1­3.

Fig. 163: Identifying Cylinder Bank Marking Pistons (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Always guide timing chains with your hand when turning the crankshaft.
25. Fit cylinder head 1­3 and 4­6.

→ 157019 REMOVING AND INSTALLING CYLINDER HEAD .

26. Pull timing chain 1­3 out of the chain slot and fit oil supply valve
­1­ for the vacuum pump on the cylinder head with a new O­ring
­2­ . Engage timing chain at the valve.

3227 of 5326
 Fig. 164: Identifying Oil Supply Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

27. Hold tensioning rail ­1­ for cylinders 1­3 using a pair of flat­nosed pliers ­3­ and screw in bearing pin ­4­
.

Fig. 165: Installing Tensioning Rail And Guide Rail

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

27.1. Secure guide rail for cylinders 4­6 in the cylinder head with a short bearing pin.
27.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.) .
28. Check installation position of tensioning rail for oil­pump drive chain and guide rail again.
1. Tensioning spring for tensioning rail
2. Guide rail

Fig. 166: Identifying Oil­Pump Drive Chain And Guide Rail Tensioning Rail
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

29. Install oil pan.

→ Installing Oil Pan

30. Install hydraulic valves for camshaft control with new O­rings.
30.1. Tighten external Torx screws.
31. Install camshafts.

→ Installing Camshafts And Setting Timing .

32. Install cylinder head cover.

→ Installing Cylinder Head Cover .

33. Fit cover for positive crankcase ventilation.

33.1. Fit cover for cylinder bank 1­3 ­1­ with new gaskets ­2 and 3­ and secure with external Torx
screws ­4­ .

Fig. 167: Identifying Positive Crankcase Ventilation Cover (1­3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

33.2. Fit cover for cylinder bank 4­6 ­1­ with a new O­ring ­2­ and secure with external Torx
screws ­3­ .

Fig. 168: Identifying Positive Crankcase Ventilation Cover (4­6)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

34. Fit spark plugs.

→ Installing Spark Plugs .

35. Install ignition coils.

→ 282020 REMOVING AND INSTALLING IGNITION COILS .

SUBSEQUENT WORK
3228 of 5326
NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Grease O­rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).

Information

Always replace gaskets and O­rings.

Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).

Information

The tightening torques for the engine are listed in the following documents and must be used in
accordance with these specifications.

Repair group 1: → 1X00IN TECHNICAL VALUES .

Repair group 2: → 2X00IN TECHNICAL VALUES .

1. Install upper coolant distributor housing (unit carrier).

→ Installing Distributor Housing .

1. Distributor housing
2. Screws M8 x 70 for coolant connection piece and housing
3. Screws, M8 x 50
4. Screw, M8 x 35

Fig. 169: Identifying Unit Carrier Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Slide bracket for coolant pump ­1­ with new O­rings ­2 and 3­ onto coolant pipe ­4­ and connection
piece.

Fig. 170: Identifying Coolant Pipes O­Rings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Screw on coolant pump bracket ­1­ .

3.1. Bond threaded bolt ­6­ with Loctite 243.

Allow a curing time of 24 hours!

→ Tightening torque: 5 Nm (3.5 ftlb.)

3.2. Fit and tighten external Torx screws.

3229 of 5326
 Fig. 171: Identifying Coolant Pump Bracket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Install high­pressure pump.

→ Installing High­Pressure Pump .

5. Fit fuel lines ­2 and 4­ on high­pressure pump ­1­ .

→ Installing Fuel Line (Low­Pressure Side) .

→ Installing Fuel Line .

5.1. Coat thread with OKS 1701 lubricant (Part No. 000.043.207.36).

Allow a drying time of 60 minutes for the lubricant!

Fig. 172: Identifying High/Low­Pressure Connection Fuel Lines

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Install coolant pipe ­1­ for the coolant regulator housing and secure with external Torx screw ­2­ .

Fig. 173: Identifying Coolant Regulator Housing Coolant Pipe

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Install coolant regulator housing ­1­ .

→ Installation Coolant Regulator Housing .

Fig. 174: Identifying Coolant Regulator Housing

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Fit belt tensioner.

→ Installing Belt Tensioner .

9. Fit vibration damper.

→ Installing Vibration Damper .

10. Fit heat shields.

11. Turn the engine at the assembly support so that the oil pan is at the top.
12. Fit holder for rear silencer.
13. Install exhaust manifold with new seals.

→ Installing Exhaust Manifold .

14. Turn the engine 180° at the assembly support.

15. Install coolant distributor. Coat new O­rings ­1­ with Kluber Gel.
15.1. Fit coolant distributor into coolant pipes.

Fig. 175: Identifying Coolant Distributor O­Rings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15.2. Fit coolant distributor ­1­ using external Torx screws ­2­ and tighten screws.
3230 of 5326
 Fig. 176: Identifying Coolant Distributor Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

16. Fit fuel collection pipes and injectors.

→ Installing Fuel Collection Pipe .

17. Install the starter.

→ Installing Starter .

18. Install bracket for oil­water heat exchanger ­1­ .

→ Installing Bracket For Oil­Water Heat Exchanger .

18.1. Pull out stoppers and fit and grease new O­rings ­4­ .

Fig. 177: Identifying Oil­Water Heat Exchanger Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

19. Install oil­water heat exchanger ­1­ .

→ Installing Oil/Water Heat Exchanger .

Fig. 178: Identifying Oil­Water Heat Exchanger

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

20. Install oil separator with new O­rings.

→ Installing Oil Separator .

21. Install vacuum pump for brake booster.

→ 477619 REMOVING AND INSTALLING VACUUM PUMP .

22. Fit vacuum line (vacuum pump).

23. Vehicles with Porsche Dynamic Chassis Control (PDCC): Install hydraulic pump and lines.

→ Installing Pump (PDCC) .

24. Vehicles without Porsche Dynamic Chassis Control (PDCC): Install console with deflection roller ­1­
.
24.1. Fit and tighten external Torx screws ­2 and 3­ .

Fig. 179: Identifying Deflection Roller Console Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

25. Install air­conditioning compressor.

→ Installing Air­Conditioning Compressor .

26. Install B+ wire harness (engine).

→ Installing Wire Harness For Battery Wiring .

27. Fit engine wire harness.

3231 of 5326
 → Installing Wire Harness For Engine .

28. Fit fuel connection line to fuel collection pipe.

→ Installing Fuel Connection Line .

29. Fit coolant hoses ­2­ to oil­water heat exchanger.

29.1. Coat hoses with Kluber Gel and fit them. Close spring band clamps ­1­ .

Fig. 180: Identifying Heat Exchanger Coolant Hoses

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

30. Install the generator.

→ Installing Generator .

31. Install oil filler neck ­1­ .

31.1. Grease new O­ring and fit oil filler neck on crankcase.
31.2. Tighten external Torx screws ­2­ .

Fig. 181: Identifying Oil Filler Neck

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

32. Install positive crankcase ventilation line ­1­ .

32.1. Grease new O­rings and fit line to bracket for oil­water heat exchanger. Tighten external Torx
screw ­2­ .
32.2. Clip in line at two places and fit quick connectors on cylinders 1­3, cylinders 4­6 and on the
oil filler neck ­3­ .

Fig. 182: Identifying Positive Crankcase Ventilation Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

33. Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and
positive crankcase ventilation line.
34. Install intake­air distributor.

→ Installing Intake­Air Distributor .

34.1. Grease new molded seals.

34.2. Fit complete intake­air distributor and position it on the cylinder heads.
34.3. Fit external Torx screws and tighten according to the specified tightening sequence.

Fig. 183: Intake­Air Distributor Screws Tightening Sequence

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

35. Fit tank vent valve and engine compartment temperature sensor.
35.1. Plug in cable plugs ­1 and 3­ on intake­air distributor for cylinder bank 1­3. Tighten external
Torx screw ­2­ used to secure the cable duct.
1. Cable plug on engine compartment temperature sensor
2. Cable duct mounting on cylinder bank 1­3
3. Cable plug on control valve for tank ventilation

3232 of 5326
 Fig. 184: Identifying Intake­Air Distributor Cable Plugs (1­3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

36. 3.8­litre engine only: Fit vacuum line on vacuum unit for tuning flap.
37. Fit oil filler neck on holder for intake­air distributor. Tighten external Torx screws ­2­ .

Fig. 185: Identifying Oil Filler Tube And Positive Crankcase Ventilation Line Holder
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

38. Connect positive crankcase ventilation line ­1­ to the resonance tube and clip it in at the intake­air
distributor ­arrows­ .
38.1. Tighten external Torx screw ­2­ used to secure the cable duct to intake­air distributor 4­6.

Fig. 186: Locating Positive Crankcase Ventilation Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

39. For vehicles with PDCC: Fit hydraulic pump pulley using screws.
40. Install the drive belt.

→ Installing Drive Belt .

41. Tighten external Torx screws on hydraulic pump pulley.

42. Fit engine carrier and holder for front silencer.

→ Installing Engine Carrier .

43. Fit rear silencer.

→ Installing Rear Silencer .

44. Fit front silencer.

→ Installing Front Silencer .

45. Remove the engine from the engine assembly support.

→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY
SUPPORT.

46. Fit flywheel with new screws.

→ Installing Flywheel .

→ Installing Flywheel .

47. Mount transmission.

→ Mounting Transmission .

→ Mounting Porsche Doppelkupplung (PDK) .

48. Install engine.

→ Installing Engine .

WM 101802 CHECKING PRESSURE LOSS OF CYLINDERS (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
3233 of 5326
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3 RS)
TOOLS

Designation Type Number Description Â

locating pin Special tool 9595/1 Â
turning device Special tool 9773 Â
Socket­wrench Special tool P300 Â
insert

INFORMATION
Information And Tools

The engine must be at operating temperature in order to carry out the pressure loss test.

Information

In the case of new engines that have not yet been fully run in (less than 5, 000 km), there may be higher
pressure losses than after the run­in period as cylinders, pistons and piston rings have not yet attained
their final dimensional stability.
Differences between the individual cylinders of up to two graduation lines = 4 % pressure loss are not
significant.

Assessing The Problem

A pressure loss test can be carried out in order to determine the extent of the problem more precisely following
a compression pressure test. The leak is located by listening for sounds of escaping air.

The following areas can be checked:

Intake manifolds (checking intake valves)

Exhaust manifolds and exhaust pipes (checking outlet valves)

Positive crankcase ventilation and oil filler neck (checking piston rings)

Coolant filler neck and spark plug bore of adjacent cylinder (checking cylinder head gasket)

Recommended tester (from Leitenberger Autotestgerate):

Fig. 187: Identifying Pressure Loss Testing Tool

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Pressure gauge, Leitenberger, Item No. DRV 05 (041113)

2. Pressure­regulating valve on pressure gauge
3. Dead­center position gauge, Leitenberger, Item No. OT 04 (041310_1)
4. Adapter, ZKS 01.1, plug thread M14 x 1.5 and M18 x 1.5

PRELIMINARY WORK

CAUTION: Hot components

Risk of burns

→ Wear personal protective gear.

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 1. Start the engine and let it heat up (warm to touch).

WARNING: Vehicle can fall down

Risk of squashing or crushing
Risk of damage to the vehicle

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

2. Raise the vehicle. → 4X00IN LIFTING THE VEHICLE

3. Remove rear wheels. → 440519 REMOVING AND INSTALLING WHEEL WITH CENTRAL
BOLT
4. Remove spark plugs. → 287020 REMOVING AND INSTALLING SPARK PLUGS
Preliminary Work

1. Start the engine and let it heat up (warm to touch).

WARNING: Vehicle can fall down

Risk of squashing or crushing
Risk of damage to the vehicle

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

2. Raise the vehicle.

→ 4X00IN LIFTING THE VEHICLE .

3. Remove rear wheels.

Socket­wrench insert P300 should be used.

→ 440519 REMOVING AND INSTALLING WHEEL .

CAUTION: Hot components

Risk of burns

→ Wear personal protective gear.

4. Remove front silencer.

→ 262519 REMOVING AND INSTALLING FRONT SILENCER .

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 5. Remove heat shield on the engine carrier.

→ 261419 REMOVING AND INSTALLING HEAT SHIELD ON ENGINE CARRIER .

6. Remove upper part of heat shield.

→ 261219 REMOVING AND INSTALLING HEAT SHIELD .

7. Remove ignition coil.

→ 282020 REMOVING AND INSTALLING IGNITION COILS .

8. Remove spark plugs.

→ 287020 REMOVING AND INSTALLING SPARK PLUGS .

CHECKING PRESSURE LOSS OF CYLINDERS

The Scope Of Work Described Here Was Carried Out Using The Recommended Tester

WARNING: Engine can turn without control (the crankshaft can turn because of the
pressure in the cylinder).

Danger of crushing (injury)

Tools can become jammed (material damage)

→ The piston must be exactly at top dead center (TDC) position (secure the crankshaft).

→ Do not touch any belt drive components when building up pressure.

→ Do not insert any tools on the crankshaft belt pulley.

1. Set the piston position (ignition TDC) and connect test tools.
1.1. Screw in adapter ­1­ for M14 spark plug thread and tighten hand­tight. Connect dead­center
position gauge ­2­ .

Fig. 188: Checking Piston Position Using Dead­Centre Position Gauge

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.2. Turn the crankshaft clockwise at the vibration damper as far as the TDC marking of cylinder 1
using turning device 9773 .
1.3. Determine the piston position (ignition TDC) of the cylinder to be checked using the dead­
center position gauge.
1.3.1. Piston position of the cylinder to be checked is correct:

Continue with Step 1.4 (Fix vibration damper in place).

1.3.2. Piston position of the cylinder to be checked is incorrect (overlap):

Continue to turn the crankshaft 360° clockwise at the vibration damper.

1.4. Fix vibration damper ­1­ in place with locating pin 9595/1 ­4­ .

Fig. 189: Disconnecting Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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 1.5. Remove the dead­centre position gauge.
2. Set the pressure gauge ­1­ .
2.1. Connect the compressed air hose ­2­ to the pressure gauge.
2.2. Connect the compressed air hose to the compressed air system.
2.3. Pull and turn the pressure­regulating valve ­3­ until the pointer on the pressure loss tester
shows 23 % ­arrow­ .
2.4. Lock the pressure­regulating valve. Disconnect compressed air hose.

Fig. 190: Installing Pressure Gauge

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Pressure of between 6 and 12 bar is required for carrying out the pressure loss test.
Start the test at cylinder 1 and continue according to firing order (1 ­ 6 ­ 2 ­ 4 ­ 3 ­ 5).
3. Connect the pressure gauge ­1­ to the adapter ­3­ .
3.1. Secure the pressure gauge with tie­wraps ­2­ and connect the test hose to the adapter ­arrow­ .
3.2. Connect the compressed air hose to the pressure gauge.

Fig. 191: Connecting Pressure Gauge To Adapter

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Check the pressure loss.

4.1. The pointer on the pressure gauge must move within the green area (0­25 %).

A loss in pressure of more than 25 % is no longer acceptable and the source of the problem
must be found!

4.2. Pressure loss within tolerance range:

4.2.1. Check the pressure loss on the next cylinder in the same way as for cylinder 1.

Firing order: 1 ­ 6 ­ 2 ­ 4 ­ 3 ­ 5

4.3. Pressure loss not within tolerance range:

4.3.1. Locate the leak by listening for sounds of escaping air.

The following areas can be checked:

Intake manifolds (checking intake valves)

Exhaust manifolds and exhaust pipes (checking outlet valves)

Positive crankcase ventilation and oil filler neck (checking piston rings)

Coolant filler neck and spark plug bore of adjacent cylinder (checking cylinder head gasket)

4.3.2. Then, continue checking the next cylinder in the same way as for cylinder 1.

Firing order: 1 ­ 6 ­ 2 ­ 4 ­ 3 ­ 5

5. Remove the turning device from the vibration damper.

SUBSEQUENT WORK

1. Install spark plugs. → Installing Spark Plugs

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 2. Fit rear wheels. → Installing Wheel With Central Bolt

SUBSEQUENT WORK

1. Fit spark plugs.

→ Installing Spark Plugs .

2. Install ignition coil.

→ Installing Ignition Coils .

3. Install upper part of heat shield.

→ Installing Heat Shield .

4. Install heat shield on the engine carrier.

→ 261419 REMOVING AND INSTALLING HEAT SHIELD ON ENGINE CARRIER .

5. Install front silencer.

→ Installing Front Silencer .

6. Mount rear wheels.

Socket­wrench insert P300 should be used.

→ Installing Wheel .

WM 103019 REMOVING AND INSTALLING ENGINE CARRIER (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3 RS)
TOOLS

Designation Type Number Description Â

transmission and Workshop WE 1223 Â
unit jack Junior equipment
Jack 2.0
GA passenger car Workshop WE 1224 Â
transmission plate equipment

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Engine carrier to M10 Tightening 60 Nm (44 Â Â
crankcase ­ torque ftlb.)
collar nut
Engine carrier to M10 x 92 Tightening 60 Nm (44 Â Â
crankcase ­ bolt torque ftlb.)
Heat shield to Hexagon­head Tightening 10 Nm (7.5 Â Â
engine carrier bolt, M6 x 16 torque ftlb.)
Engine carrier to M10 x 135 Tightening 60 Nm (44 Â Â
crankcase ­ bolt torque ftlb.)
Engine carrier to Collar nut, M12 Tightening 85 Nm (63 Â Â
engine mounting torque ftlb.)
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PRELIMINARY WORK

1. Remove front silencer. → 262519 REMOVING AND INSTALLING FRONT SILENCER

REMOVING ENGINE CARRIER

Component overview of engine carrier ­ Carrera:

Fig. 192: Overview Of Engine Carrier

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Engine carrier
2. Intermediate flange
3. Heat shield
4. Bracket for front silencer
5. Collar nuts, M10
6. Stud, M10 x 140
7. Stud, M10 x 80
8. Hexagon­head bolt, M10 x 92
9. Hexagon­head bolt, M6 x 16
10. Hexagon­head bolt, M10 x 135
11. Spacer sleeve
12. Engine mounting
13. Torx screw, M8 x 35, for active engine mountings: M8 x 65
14. Collar nut, M12

Engine carrier for some GT3 vehicles without heat shield:

Fig. 193: Overview Of Engine Carrier ­ GT3

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Engine carrier
2. Intermediate flange
3. Rear silencer (muffler) holder
4. Collar nuts, M10
5. Stud, M10 x 140
6. Stud, M10 x 80
7. Hexagon­head bolt, M10 x 92
8. Hexagon­head bolt, M10 x 135
9. Spacer sleeve
10. Active engine mount
11. External Torx screw, M8 x 65
12. Collar nut, M12

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

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Information

It may only be supported over a large area at the oil pan.

Localized loading is not permitted.

1. Support engine with transmission and unit jack Junior Jack 2.0 WE 1223 and GA passenger car
transmission plate WE 1224 at the oil pan.
1.1. When positioning, pay attention to the oil level sensor.
2. Loosen and unscrew two M12 collar nuts ­1­ on the engine mounting.

Fig. 194: Identifying Engine Carrier Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Remove heat shield.

Also for some GT3 vehicles!

3.1. Unscrew three hexagon­head bolts (M6 x 16) and remove heat shield.
4. 3.8­litre engine only: Unclip vacuum hose at three places on the engine carrier.
5. Remove engine carrier.
5.1. Remove hexagon­head bolt (M10 x 135) through the bore in the rear cross member. Be careful
with the sleeve in the engine compartment.
5.2. Loosen and unscrew two M10 collar nuts.

Information

When lowering, the engine must not rest on the rear axle cross member.
6. Carefully lower the engine.
6.1. Loosen and unscrew M10 x 92 hexagon­head bolt.
6.2. Guide engine carrier with front silencer bracket out of the threaded bolts and remove both
parts.
6.3. The intermediate flange can remain on the threaded bolts.
7. Clean engine carrier carefully with solvent naphtha and check for damage (e.g. cracks, deformation).
8. The engine carrier must be replaced if it is damaged.

INSTALLING ENGINE CARRIER

1. Insert engine carrier into threaded bolt and position using two M10 collar nuts.
1.1. Fit hexagon­head bolt (M10 x 92) and screw in as far as it will go.

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

2. Raise engine to its installation position using the transmission jack.

2.1. Tighten two M12 collar nuts ­1­ on the engine mounting at the left and right.

Fig. 195: Identifying Engine Carrier Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.2. Position spacer sleeve ­2­ for special screw ­1­ in the engine compartment.

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 2.3. Insert hexagon­head bolt (M10 x 135) through the bore in the rear­end carrier and tighten it.

Tightening torque 60 Nm (44 ftlb.)

Fig. 196: Identifying Engine Carrier And Spacer Sleeve Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Tighten two M10 collar nuts.

Tightening torque 60 Nm (44 ftlb.)

4. Screw in and tighten hexagon­head bolt (M10 x 92).

Tightening torque 60 Nm (44 ftlb.)

5. 3.8­litre engine only: Clip in vacuum hose on the engine carrier.

6. Install heat shield.

Also installed on some GT3 vehicles!

6.1. Position heat shield and fit and tighten hexagon­head bolts (M6 x 16).

Tightening torque 10 Nm (7.5 ftlb.)

7. Tighten M12 collar nuts on the left and right engine mountings.

Tightening torque 85 Nm (63 ftlb.)

SUBSEQUENT WORK

1. Install front silencer. → Installing Front Silencer

WM 103519 REMOVING AND INSTALLING ENGINE MOUNTING (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION")
TOOLS

Designation Type Number Description Â

floor jack H 2 SL Workshop WE 1032 Â
equipment
transmission jack Workshop WE 1082 Â
V.A.G 1383 A equipment

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Engine mount to External Torx Tightening 23 Nm (17 Â Â
body screw, M8 x 35 or torque ftlb.)
M8 x 65
Engine carrier to Collar nut, M12 Tightening 85 Nm (63 Â Â
engine mounting torque ftlb.)

PRELIMINARY WORK

1. Remove rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER

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 2. Remove air cleaner. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING

REMOVAL
Removing Engine Mounting

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

1. Support engine in installation position using floor jack H 2 SL WE 1032 and transmission jack plate of
transmission jack V.A.G 1383 A WE 1082 at the oil pan.
2. Loosen and unscrew M12 hexagon nut ­1­ on the engine mounting.

Fig. 197: Identifying Engine Carrier Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Unscrew two Torx screws (M8 x 35; M8 x 65 for active engine mountings) ­2­ on the engine mounting
­1­ .
4. For active engine mountings: Release and pull off cable plug ­3­ .

Fig. 198: Identifying Left Engine Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Guide engine mounting ­1­ up out of the engine carrier.

Fig. 199: Identifying Vehicle Engine Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Check engine mounting carefully for signs of damage (dents, cracks on metal body, threaded bolts) or
leaks (emerging hydraulic fluid).
6.1. Replace component if necessary.

INSTALLATION
Installing Engine Mounting

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

1. Fit engine mounting ­1­ on engine carrier and at the same time guide the threaded bolt ­2­ through the
bearing eyelet on the engine carrier.

Fig. 200: Identifying Vehicle Engine Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Screw in and tighten two hexagon­head bolts (M8 x 35; M8 x 65 for active engine mountings) ­2­ .

Tightening torque 23 Nm (17 ftlb.)

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 3. For active engine mountings: Plug in cable plug ­3­ .

Fig. 201: Identifying Left Engine Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Fit and tighten M12 hexagon nut ­1­ on the threaded bolt for the engine mounting.

Tightening torque 85 Nm (63 ftlb.)

Fig. 202: Identifying Engine Carrier Mounting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Lower jack together with transmission jack plate and push out of work area.

SUBSEQUENT WORK

1. Install air cleaner. → Installing Air Cleaner Housing

2. Install rear spoiler. → Installing Rear Spoiler

WM 105519 REMOVING AND INSTALLING OIL SEPARATOR (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Oil separator to External Torx, Tightening 10 Nm (7.5 Â Â
bracket M6 x 28 (2x) ­ torque ftlb.)
self­tapping
screws
Oil separator to Screw, M6 x 25 Tightening 13 Nm (9.5 Â Â
bracket torque ftlb.)

PRELIMINARY WORK

1. On Cabriolet vehicles: Open convertible­top compartment lid.

2. Remove air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

Information

When lowering, the engine must not rest on the rear axle cross member.

Information

It may only be supported over a large area at the oil pan.

Localized loading is not permitted.
3. Remove intake­air distributor, side 4­6.

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 → 244619 REMOVING AND INSTALLING INTAKE­AIR DISTRIBUTOR .

INFORMATION
Component Information

1. Oil separator
2. Bracket for oil/water heat exchanger
3. O­rings (replace and grease)
4. External Torx screws (M6 x 20)

Fig. 203: Overview Of Oil Separator

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING OIL SEPARATOR

1. Remove adhesive tape or stoppers from the bores.

2. Replace O­rings and grease with Kluber Syntheso Glep (Porsche part number 000.043.204.68).
3. Install oil separator.
3.1. Fit oil separator into the bracket for the oil/water heat exchanger.
3.2. Fit and tighten two screws. Tightening torque 10 Nm (7.5 ftlb.)
3.3. Fit engine vent line on the oil separator and check that it is seated securely.
4. Metric screws (M6 x 25) can also be used as an alternative to the standard self­tapping screws.

Tightening torque 13 Nm (9.5 ftlb.)

5. Clip in electric line for starter.

SUBSEQUENT WORK

Information

It may only be supported over a large area at the oil pan.

Localized loading is not permitted.

1. Install intake­air distributor pipe on cylinder bank 4­6.

→ Installing Intake­Air Distributor ­ Side 4­6 .

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

2. Slowly raise the engine using a jack.

→ 100109 LOWERING THE ENGINE.

3. Install air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

4. On Cabriolet vehicles: Close convertible­top compartment lid.

WM 108019 REMOVING AND INSTALLING ENGINE GUARD (GT3, GT3 RS)

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TOOLS

Designation Type Number Description Â

access ramps Special tool 9453 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Engine guard M6 Tightening 10 Nm (7.5 Â Â
torque ftlb.)

REMOVING ENGINE GUARD

WARNING: Vehicle can fall down

Risk of squashing or crushing

Risk of damage to the vehicle

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

1. Raise the vehicle.

Raise the vehicle at the prescribed jacking points.

→ 4X00IN LIFTING THE VEHICLE .

1.1. Depending on the lifting platform used, access ramps 9453 may be required.
2. Unscrew fastening screws ­2­ and remove engine guard ­1­ .

Fig. 204: Identifying Engine Guard

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING ENGINE GUARD

1. Fit engine guard and tighten fastening screws.

→ Tightening torque: 10 Nm (7.5 ftlb.)

2. Lower the vehicle.

Copyright 2016 Mitchell Repair Information Company, LLC. All Rights Reserved.

Article GUID: A00704554

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