Engine Mechanical (997) Porsche 911 GT3 997

M96/05 and M97/01 engines

* including double-mass flywheel

Engine design

* Timing in late position with 1 mm valve lift and zero clearance

Engine control

Tools

Designation Type Number Explanation 3/8" extension, 16° movable special tool NR.15 socket wrench insert special tool P 300 mounting peg special tool P 9163/2 retainer plate special tool P 9592 support plate special tool P 9592/1 support plate special tool P 9592/2 assembly aid special tool P 9622 test tool special tool P 9623

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Preparations for removing the engine

Note. Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.

> Raise the vehicle at the prescribed jacking points.

1. Place jacks under the vehicle at the prescribed jacking points. Refer to 40 Lifting the vehicle - as of MY 2005 (All Models) .

2. Use PIWIS tester to read out error memory --> 01 01 IN DIAGNOSTIC SYSTEM: READING OUT FAULT MEMORY AND ACTIVATING SYSTEMS - AS OF MY 2005 (ALL MODELS) .

3. Position protective supports on the body to avoid damage.

4. Disconnect battery and cover up battery or contacts. Refer to 27 06 IN Work instructions after disconnecting the battery - as of MY 2005 (All Models) .

5. Remove both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damage to the wheel rims --> 44 05 94 BALANCING/OPTIMIZING WHEELS - AS OF MY 2005 (ALL MODELS) .

6. Remove rear apron. --> BUMPERS .

7. Removing side retaining frames (heat shields), left and right --> 63 50 19 REMOVING AND INSTALLING REAR BUMPER - AS OF MY 2005 (ALL MODELS)

Scheme 103

8. Undo support holding rear spoiler to body -2-. Turn the support towards the brake disc. (Scheme 99)

9. Remove cover for rear and center underbody. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

Removing engine

> Do not work on the engine while it is hot.

1. Remove the air cleaner housing completely --> 24 25 19 REMOVING AND INSTALLING AIR CLEANER HOUSING - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

Scheme 104

2. Open reservoir cap on coolant expansion tank -1-, fold up bleeder valve -2-. (Scheme 100)

Scheme 105

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

3. Drain coolant --> 19 38 17 DRAINING AND FILLING IN COOLANT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

3.1. Open coolant drain plug and refit with new sealing ring --> Tightening torque: 10 (7.5 ftlb.) Nm

3.2. Open coolant feed line (Henn coupling) to engine at underbody and reconnect.

3.3. Heating supply and return lines (open spring band clamps in direction of radiator)

Scheme 106

4. Open line connections in engine compartment.

4.1. Loosen the vacuum lines for the brake booster -1-. For the tandem pump feed line, remove the plastic protection, push the holder forward and pull off the line. Immediately put plastic protection back in place. (Scheme 102)

4.2. Disconnect tank vent line -2-. In order to do this, press the lugs of the rapid-action coupling and pull off the line. (Scheme 102)

4.3. Disconnect bleeder hose from coolant expansion tank -3-. (Scheme 102)

Scheme 107

Note. The spring band clamp is vulcanized on the coolant supply hose of the coolant expansion tank to the engine! The vulcanization diminishes after the clamp has been opened and tightened several times. Therefore do not pull off as this could damage the hose.

5. Disconnect coolant pump feeder hose -1-. Open spring band clamp -2- and pull off the hose. (Scheme 103)

Scheme 108

6. Pull off hose from coolant pipe under coolant expansion tank -1-. In order to do this, lift the safety clip on the Henn coupling out of the lock -Arrow- using a screwdriver and pull out the hose. Plug the opening with a clean cloth. Put the safety clip back in place after removing the engine (Scheme 104)

Scheme 109

7. Pull off tandem pump feeder line -1- and right coolant pipe feeder hose -3-. Open and remove spring band clamp on vacuum line. After that, lift safety clip on Henn coupling out of the lock -2-, pull off coolant hose. Plug the opening with a clean cloth. Put the safety clip back in place after removing the engine (Scheme 105)

Scheme 110

8. In Tiptronic vehicles, pull the coolant hose to the flat-seat valve off the transmission. Clamp shut hose -Arrow-, open the spring band clamp and pull off the hose. Collect escaping coolant, close off hose and flat-seat valve with plugs. (Scheme 106)

Scheme 111

9. Before opening the fuel lines, put up or attach to vehicle a warning sign in a clearly visible position --> Warning sign. (Scheme 107)

Scheme 112

> Do not work on fuel system if engine is hot!

> Do not smoke, avoid fire and naked flames!

> Wear fuel-resistant protective gloves and goggles.

> Attach warning sign to vehicle in a clearly visible position.

10. Open fuel supply line. Press the lugs on the rapid-action coupling and pull off the line. Collect escaping fuel with a cloth.

Scheme 113

11. Unclip fuel line from holder on coolant expansion tank -Arrow-. (Scheme 109)

Scheme 114

> place between engine and engine strut

12. Unclip the oxygen sensor plug connections -1,2- from the holders on the right and left in the engine compartment. Push the red lugs upward with a small screwdriver and unplug the connector. The connectors are color-coded to prevent confusing them. (Scheme 110)

Scheme 115

13. Loosen drive belt. Mark the running direction of the belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24) clockwise -Arrow-, hold tightly and simultaneously take the drive belt off the deflection pulley. Carefully allow the tensioning roller to turn back into tensioning position. (Scheme 111)

Note. The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).

14. Remove air-conditioning compressor. Refer to 87 34 19 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

Scheme 116

15. Disconnect ground connector from intake distributor side 4-6 -Arrow-. (Scheme 112)

Scheme 117

16. Pull the engine compartment temperature sensor out of the intake distributor 4-6 together with the rubber sleeve -1- and unscrew the rear fastening screws -2- of the air-condition compressor. (Scheme 113)

Scheme 118

17. Unscrew the front fastening screw -Arrow- of the air-conditioning compressor. Due to the restricted accessibility, the use of a 3/8" extension, 16° movable NR.15 with a long Torx E10 socket wrench is recommended. To lift out the air-conditioning compressor, the screw must be pulled upwards and held in position. (Scheme 114)

18. Remove the holder for the servo lines, lift out the air-conditioning compressor with the connected lines and place on its side on a protective support. Secure additionally with a tie-wrap.

Scheme 119

19. Disconnect engine wiring harness (2 round connectors with bayonet locks) from the plug connections in the right of the engine compartment. In order to do this, open the bayonet locks by turning them anti-clockwise.

Scheme 120

20. Open tie-wrap -Arrow- on engine wiring harness cable guide and lay wiring harness on engine. (Scheme 116)

Scheme 121

> Wear protective gloves and goggles

> If the eyes or skin come into contact with the fluid, wash immediately with water!

> Collect escaping Pentosin

> Use caps to protect the wiring against soiling and damage!

> Immediately clean hoses and wiring thoroughly

21. Open power steering pressure pipe and return line. Loosen screws on pressure line (counter) -1-. Open spring band clamp on return line (hose). (Scheme 117)

Scheme 122

22. Pull off return hose and open pressure pipe. Collect escaping Pentosin in a small container and then close off the return line again.

Scheme 123

Note. If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid P 9622 is already contained in the parts set.

23. Loosen pressure pipe nipple -A- on the pipe. Tilt holder on one side -C, Arrow- and simultaneously pull to disengage. Detach nipple from the pipe and remove the old O-ring. Close off line. (Scheme 119)

Scheme 124

24. Place holder -C- into threaded part -A- and, if necessary, fasten using assembly aid P 9622. Screw threaded part with new O-ring into the screw coupling -B- and tighten. Always counter when tightening. --> Tightening torque: 30 (22 ftlb.) Nm (Scheme 120)

Scheme 125

25. Tie up oil filler neck with welding wire, string or tie-wrap.

Scheme 126

26. Release drive shafts from transmission (a second person should actuate the brake pedal to hold it). Slide suitable protection (e. g. an open plastic pipe, an old coolant hose with a diameter of about 30 mm) over the shaft in the area of the rear axle or place foam padding underneath it --> 42 21 19 REMOVING AND INSTALLING DRIVE SHAFT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

Scheme 127

27. In Tiptronic vehicles, an aluminum spacer ring is installed between the drive shaft and the transmission flange. These rings must be removed.

Scheme 128

28. Disconnect the ground strap on the underside between the engine and the body. Unscrew one M8 hexagon nut -Arrow-, remove ground strap from threaded pin. (Scheme 124)

Scheme 129

29. Remove the rear stabilizer. Unscrew two M8x40 hexagon-head bolts -1- on the left and right. Remove the M10 hexagon nuts on the connecting rod while holding the internal Torx -2- to counter. Remove stabilizer --> 42 91 19 REMOVING AND INSTALLING CONNECTING LINK (SUSPENSION/STABILIZER) - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4). (Scheme 125)

Scheme 130

30. Remove the front transverse strut, both the diagonal braces and the rear cross member.

30.1. Front transverse strut -A-: unscrew two M10x40 hexagon-head bolts. (Scheme 126)

30.2. Diagonal braces -B-: Unscrew two M12x30 hexagon-head bolts on the rear cross member, two M10x40 hexagon-head bolts at the front and two M10 hexagon nuts on the rubber mounts. (Scheme 126)

30.3. Rear cross member, lower fastening -C-: unscrew two M12 hexagon nuts while holding the M12x80 hexagon-head bolts to counter, pull both screws out of drillings. (Scheme 126)

Scheme 131

31. Rear cross member, top fastening: Loosen (do not remove) two M12 hexagon nuts (long slots on cross member), take off cross member downwards.

Scheme 132

32. Open B-Plus box on transmission -Arrow-, unscrew hexagon nut and disconnect the cables. (Scheme 128)

Scheme 133

33. Manual transmission: Unclip B-Plus line from shift console -1- and pull through in direction of travel. (Scheme 129)

Scheme 134

34. Tiptronic transmission: Detach selector cable. Lever out selector cable end piece -1- at the ball head of the selector lever -Arrow- using a screwdriver. (Scheme 130)

Scheme 135

35. Unclip Tiptronic transmission cable plug and then disconnect plug connection.

Scheme 136

36. Manual transmission: detach shift cables from the support bracket. Lever off the end pieces from the ball heads of the external shift mechanism. Press the retaining clips together and pull the cable sleeves out of the support bracket.

Scheme 137

37. Manual transmission: disconnect cable plug for reverse gear switch and unclip from cable guide.

Scheme 138

38. Remove the hall sender from cylinder bank 4-6. Unscrew one M6 hexagon socket head bolt (micro-encapsulated) -1- pull hall sender -2- out of the drilling and hang to one side. (Scheme 134)

39. Attach special tool retainer plate P 9592 to engine.

Scheme 139

40. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts. (Scheme 135)

40.1. Screw special tool mounting peg P 9163/2 to the support plate in the marked position -996- using four M8x25 hexagon bolts. (Scheme 135)

41. Tiptronic vehicles: Attach special tool support plate P 9592/2 to the support plate P 9592/1 using three fastening screws.

Scheme 140

42. Manual transmission: to support the manual transmission, attach scantling (approx. 6.5 cm) -2- to support plate P 9592/1 -1- using a wooden bolt. (Scheme 136)

Scheme 141

43. Attachment of scantling -Arrow- to support plate 9592/1 (Scheme 137)

Scheme 142

44. Engine retainer plate fully attached to engine.

1. 1 - support plate on retainer plate: position 9592
2. 2 - mounting plate 9163/2 on retainer plate: position 996
3. 3 - support plate 9592/2 for Tiptronic transmission
4. 4 - fastening for support plate 9592/2

Scheme 143

45. Fasten mounting plate for sports cars -2- to the Master Gear unit lifting platform (see figure) using four screws and nuts. To counter the tilt of the engine within the vehicle, the plate must be raised by 6 mm on one side in the opposite direction to the direction of travel. This can be achieved for example by using two sheet steel panels -1- or thick washers for the rear screws. (Scheme 139)

see Workshop Equipment Manual gr. 3.0.13 Unit lifting platform (+ sports cars mounting accessory)

Scheme 144

46. Remove the transmission support. Unscrew four M10 hexagon nuts and two M10x55 hexagon-head bolts and remove the transmission support.

47. Undo the screw connection of the transmission bracket. Loosen two M10 hexagon-collar nuts on the transmission bracket (do not unscrew completely!)

Scheme 145

48. Position unit lifting platform under the vehicle and position the take-up bore of the mounting peg -1- with a slight degree of pre-tension. (Scheme 141)

49. Unscrew two M10 hexagon-collar nuts from the transmission bracket.

50. Loosen two M12 hexagon-collar nuts on the engine carrier (wrench size 18) and unscrew.

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

51. Slowly lower the engine/transmission unit about halfway with the unit lifting platform.

Scheme 146

52. Remove wire retainer and sheetmetal bracket for the plug connection of the pulse sender. Unscrew one M6x12 hexagon-head bolt, unclip cable from the wire retainer and unscrew it. Put plug connection with cable to one side.

Scheme 147

53. Manual transmission: remove clutch slave cylinder. Refer to 30 30 19 Removing and installing clutch slave cylinder - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4). Unclip line -2-, unscrew two fastening screws -3- and remove cylinder. (Scheme 143)

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

Note. If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must be refitted under all circumstances to maintain the structural strength.

54. Completely lower the engine/transmission unit using the unit lifting platform.

Installing engine

Note. The engine/transmission unit is installed in the reverse order of its removal. The following work steps are specially repeated here to avoid faulty installation or damage.

Note. The ground cable on the holder of the plug connection of the impulse sender must always also be screwed on !

1. Attach safety clip of -arrow- Henn coupling for coolant hose to coolant expansion tank. (Scheme 144)

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

2. Lift engine/transmission unit about half the run-in of the engine using the unit lifting platform.

3. Fit sheetmetal holder for the plug connection of the pulse sender and the plastic wire retainer. Position and tighten one M6x12 hexagon-head bolt --> Tightening torque: 7.5 ftlb. . Screw in wire retainer and clip in cable.

4. Manual transmission: install clutch slave cylinder. Refer to 30 30 19 Removing and installing clutch slave cylinder - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) . Insert cylinder and push in. Position both screws by hand and tighten. Clip line into holder. --> Tightening torque: 17 ftlb.

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

5. Lift engine/transmission unit to installation position and tighten the collar nuts of the engine and transmission mounts. --> Tightening torque: 63 ftlb. --> Tightening torque: 48 ftlb.

6. Fit transmission support. --> Tightening torque: 48 ftlb.

7. Enlisting the assistance of a second person, completely detach the engine retainer plate.

8. Install the hall sender in cylinder bank 4-6. Insert hall sender and fasten using a new M6 hexagon socket head bolt (micro-encapsulated) -1-. --> Tightening torque: 7.5 ftlb. see scheme 51

9. Attach engine ground cable to body. --> Tightening torque: 17 ftlb.

10. Fasten drive shafts to transmission flange. In Tiptronic vehicles, insert the spacer rings. --> Tightening torque: 60 ftlb.

11. Attach B-Plus line to transmission. Connect lines to B-Plus box and fasten using collar nuts. --> Tightening torque: 17 ftlb.

12. Manual transmission: clip the B-Plus lines into the cable guide on the transmission bracket between the yellow markings -arrows-. see scheme 53

13. Connect and clip in cable plug of reversing switch (manual transmission)/connector for Tiptronic transmission.

14. Install chassis components

14.1. Rear cross member: M12 hexagon-collar nuts --> Tightening torque: 74 ftlb.

14.2. Diagonal braces on rear cross member: hexagon-head bolt --> Tightening torque: 74 ftlb.

14.3. Diagonal brace on rear-axle support: collar nut --> Tightening torque: 48 ftlb.

14.4. Diagonal brace to body: hexagon-head bolt --> Tightening torque: 48 ftlb.

Scheme 148

15. Front transverse strut, Tiptronic transmission: hexagon-head bolt --> Tightening torque: 48 ftlb.

Scheme 149

16. Transverse strut, manual transmission: hexagon-head bolt --> Tightening torque: 48 ftlb.

17. Installing rear stabilizer. Refer to 42 91 19 REMOVING AND INSTALLING CONNECTING LINK (SUSPENSION/STABILIZER) - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

17.1. Engage stabilizer in connecting rod and then fasten to rear-axle support using two hexagonal-head bolts respectively. --> Tightening torque: 17 ftlb.

Scheme 150

18. Position new M10 collar nuts on the connections to the connecting rod. Make sure to counter with a Torx socket wrench insert when tightening --> 42 91 19 REMOVING AND INSTALLING CONNECTING LINK (SUSPENSION/STABILIZER) - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4). --> Tightening torque initial tightening: 37 ftlb. see scheme 58

18.1. Loosen collar nuts and tighten them again. --> Tightening torque final tightening: 37 ftlb.

19. Install Tiptronic selector cable. Refer to 37 15 19 Removing and installing selector lever cable - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 151

20. Install shift cables for manual transmission. . Refer to 34 12 19 Removing and installing shift and selector cables - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 152

21. Connect servo pressure pipe. Push plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.

Scheme 153

Note. The servo line plug-in coupling is designed so that there is an axial play of approx. 1 mm in the coupling.

22. Inspect correct engagement of the plug coupling with special tool test tool P 9623 . Insert special tool into the groove and check that the plug is seated correctly in the coupling by applying slight pressure. The plug must not slide out.

23. Attach servo return hose to the line using the spring band clamp.

Note. Allocation of the engine wiring harness round connectors: Lower plug - grey inner ring Upper plug - black inner ring

24. Fit engine wiring harness. Turn bayonet lock in clockwise direction (approx. 90°), until the markings of the round connector and the housing correspond. Fix the wiring harness onto the holder with a new tie-wrap.

Scheme 154

25. Installing air-conditioning compressor: before installing the compressor check whether the aluminum spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also connect ground cable before installation. (Scheme 150)

Scheme 155

26. Fit air-conditioning compressor and fasten using three M8 Torx screws (two short ones at the rear, one long one at the front) -1-. --> Tightening torque: 17 ftlb. (Scheme 151)

Scheme 156

27. Fit drive belt. Pay attention to operating direction of used belts. Double-check that the position of the belt on the belt pulleys is correct.

Installing engine - subsequent work

1. Top up coolant and bleed cooling system. Refer to 19 38 17 DRAINING AND FILLING IN COOLANT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

2. Position rear spoiler support with M6 hexagon-head bolt on the body -2-, do not tighten until after fitting the rear spoiler. --> Tightening torque: 7.5 ftlb. (Scheme 153)

3. Install lateral retaining brackets (heat shields) of rear spoiler. Refer to 63 50 19 REMOVING AND INSTALLING REAR BUMPER - AS OF MY 2005 (ALL MODELS) .

4. Install rear spoiler. Refer to 63 55 19 REMOVING AND INSTALLING REAR SPOILER - AS OF MY 2005 (CARRERA 2, CABRIO 2, CARRERA 4, CABRIO 4) .

5. Fit rear wheels, to tighten the wheel bolts use special tool socket wrench insert P 300 . Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) . --> Tightening torque: 96 ftlb.

6. Connect the battery.

7. Warm up engine to operating temperature and recheck the coolant level. Inspect all cooling system connections that were opened during removal for leaks.

8. Check power steering fluid level (Pentosin) and top up if necessary --> 48 02 01 CHECKING THE FLUID LEVEL FOR THE POWER-ASSISTED STEERING - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

9. Check engine oil level and top up if necessary --> 17 01 01 CHECKING ENGINE OIL LEVEL - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

10. Remove protective covers.

Designation Type Number Explanation spark plug socket wrench commercially available tool 14 cover for dust protection when fitting the engine special tool NR.165 release key special tool P 9204 relay puller special tool P 9235 Engine support special tool P 9589 mounting elements special tool P 9590 retaining device special tool P 9593 socket wrench insert special tool P 9594 retaining tool special tool P 9685 adjusting gauge special tool P 9686 holding wrench special tool P 9732

Scheme 157

Scheme 158

Preliminary work for disassembling engine

1. Remove engine. Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Remove transmission. Refer to 37 35 27 Removing and refitting the automatic transmission - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S) or Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Tiptronic transmission

3. Remove converter housing. Refer to 32 43 19 Removing and installing converter housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

4. Remove drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Manual transmission

5. Remove clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

6. Remove double-mass flywheel. Refer to 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) . Refer to 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

7. Remove rear silencer and catalytic converters.

Component overview - engine

Note. The overview graphics are shown schematically and may be different to how the components actually look.

Intake system, belt drive

Scheme 159

1. 1 - Intake distributor
2. 2 - Belt drive
3. 3 - Belt guide and belt tensioner

Engine - lubrication

Scheme 160

1. 4 - Oil pumps, heat exchanger, coolant guide housing
2. 5 - Oil pan, oil separator

Cylinder head, crankcase

Scheme 161

1. 6 - Cylinder-head cover, camshafts, flat-base tappet housing, cylinder head
2. 7 - Cylinder head, flat-base tappets
3. 8 - Crankcase halves

Crank drive, pistons

Scheme 162

1. 9 - Pistons, connecting rods
2. 10 - Bearing housing with intermediate shaft
3. 11 - Bearing housing halves with crankshaft

Disassembling engine down to crankcase

> When working on the engine, absolute cleanliness is essential.

> Lay removed engine parts on a clean base and cover them without fail.

> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

> Wear protective gloves and goggles.

> If you come into contact with coolant, wash off immediately with plenty of warm water.

> Wear protective gloves and goggles.

> If the eyes or skin come into contact with the fluid, wash immediately with water.

> Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.

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

Note. The bearing housing remains screwed to the retaining device when the bearing housing and intermediate shaft are disassembled.

Scheme 163

1. Engine support P 9589 must be secured to the crankcase using special tool mounting elements P 9590 . Refit engine with support on the engine assembly support.

Scheme 164

2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8). Refer to 17 01 55 Engine oil and oil filter change - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 165

3. Remove engine carrier. Unscrew 4 M10 collar nuts and 1 M6 x 20 Torx screw.

4. Undo 3 M8 x 12 fastening screws on the belt pulley for the servo pump (do not remove).

5. Remove drive belt. Mark the running direction with a colored pen, turn the tensioning roller (a/f 24) clockwise, hold still and simultaneously remove the belt from the drive pulleys. Check the belt for damage, replace if necessary. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

6. Only for Tiptronic: remove guide for drive belt, to do this, unscrew two M6 x 20 Torx screws.

Scheme 166

7. Unclip hose assembly on the intake distributor, cylinder side 1 - 3

Scheme 167

8. Unplug crankcase ventilation line on pre-separator, cylinder 4-6.

Scheme 168

9. Remove shields for ignition coils on the left and the right, unscrew 2 M6 x 16 fastening screws.

Scheme 169

10. Disconnect electric plug connections (engine wire harness) on engine and unclip wire harness on the fuel collection pipes.

1. Three injection valve plugs per cylinder side -1- (Scheme 164)
2. Three ignition coil plugs per cylinder side -2- (Scheme 164)
3. Two plugs for camshaft adjustment hydraulic valves, two for valve lift adjustment hydraulic valves -3- (Scheme 164)
4. Plug for engine coolant temperature sensor, two plugs for oil pressure sensor on cylinder head cover 4 - 6 -4- (Scheme 164)
5. Two hall sender connectors
6. Plugs for speed sender
7. Plug for electric switch-over valve (intake distributor 1-3)
8. Ground cable for front face of cylinder 4-6 (one M6 x 12 Torx screw)
9. Plug for engine compartment temperature sensor (intake distributor 4-6)

11. Unclip fuel ring pipe on the engine eyelet and unscrew two M6 x 16 Torx screws, remove engine eyelet.

12. Detach holder for the throttle body on the servo pump. To do so, unscrew an M6 hexagon nut. Unplug cable plug for potentiometer and line for crankcase venting.

13. Undo holder for servo supply tank on intake distributor 4-6.

Scheme 170

14. Only for 3.6L engine: Remove the relevant six M6 x 35 (micro-self-locking) fastening screws for the intake distributor on the intake pipe supports on the left and the right. Pull off one vacuum line and remove the intake distributor completely.

Scheme 171

15. Only for 3.6L engine: Remove intake pipe support. Unscrew four M6 x 35 screws, unscrew one M6 x 12 screw for ground strap on cylinder bank 4 - 6. Take off intake pipe support, seal intake openings on cylinder head (e. g. with adhesive tape).

Scheme 172

16. Only for 3.8L engine: Unscrew the four M6 x 35 Torx screws. Completely remove the intake distributor. Seal intake openings on cylinder head (e. g. with adhesive tape).

17. Remove belt pulley from servo pump. Unscrew three fastening screws and remove belt pulley.

Scheme 173

18. Remove generator. Undo the fastening screw on the deflection roller -1- and unscrew approx. three turns. Using an aluminum mandrel, tap lightly on the screw head to undo the pilot bushing in the generator swivel arm. Unscrew the screw and remove with the deflection roller. Unscrew the second screw -2- and carefully take out the generator. (Scheme 167)

Scheme 174

19. Lift the generator out of the bracket and disconnect the two electric connecting lines -Arrows- .

20. Remove mount for the coolant vent line. Unscrew one M6 x 16 (micro-self-locking), remove mount, replace screw.

Scheme 175

21. Unplug all vent lines for oil mist collector.

Scheme 176

22. Unscrew the two M6 x 20 Torx screws on the 3.8 l oil mist collector mount and pull off collector. Replace two O-rings during installation. The screws tighten the secondary air line on cylinder head 4-6 at the same time.

Scheme 177

23. The oil mist collector on a 3.6 l engine is removed in the same way as the 996 unit.

Scheme 178

24. Unscrew one fastening screw for the wire harness guide on the bracket for the secondary air pump -1- and unclip the guide -2- on the bracket -Arrow-. (Scheme 172)

Scheme 179

25. Remove the secondary air pump. Unplug cable plug, unscrew three M6 x 20 Torx screws on the bracket -1- and completely take out the pump with bracket and line. Use new seals when installing. (Scheme 173)

Scheme 180

26. Release the wire harness on the holder before the heat exchanger. Then unscrew the plastic holder.

Scheme 181

27. Undo the wire harness on the center of engine (connections to starter) -Arrow- and unclip on the heat exchanger -1-. Unplug cable plug for knock sensors -2- and oil-level sensor. Then completely remove the engine wire harness. (Scheme 175)

Scheme 182

28. Remove the oil filler neck. Unscrew 2 M6 x 16 Torx screws (micro-self-locking), pull out oil filler neck, check the O-ring and replace if necessary.

29. Remove oil/water heat exchanger. Unscrew the four inner M6 x 16 Torx screws, take off heat exchanger. Replace O-rings during installation.

Scheme 183

30. Remove hydraulic pump with servo line and supply tank. Undo servo line (a/f 16) -1-, counter on large hexagon when doing this (a/f 27). Unscrew four Torx screws (3 M8 x 30 at the front -Arrows-, one M8 x 12 at the back), take the servo pump with line and supply tank out of the bracket. (Scheme 177)

Scheme 184

31. Remove bracket for servo pump. Unscrew 4 M8 x 35 Torx screws, remove bracket.

Scheme 185

32. Remove one M8 x 60 screw for deflection roller -1- and six M6 x 20 Torx screws for closure cap -2- with bleeder lines for coolant system. (Scheme 179)

Scheme 186

33. Only in manual transmissions: Remove the starter. Unscrew two M10 x 35 Torx screws -1-, take off starter -2-. (Scheme 180)

34. Remove oil-level sensor (a/f 19), remove knock sensor, to do this, mark the installation position with a paint marker, then unscrew one M8 x 35 Torx screw each and take off the sensors.

35. Remove canister for additional volumes of crankcase venting to the cylinder heads 1-3 and 4-6. Unscrew two M6 x 25 Torx screws each, take off canister. Use new O-rings when installing.

Scheme 187

36. Remove the holder for the main muffler on the left and right. Unscrew two M8 x 30 Torx screws each on the intake side and two M8 x 25 each on the exhaust side and take off mount.

Scheme 188

37. Remove mount and sealing cap for hydraulic valves for camshaft adjustment -2-. Unscrew two M6 x 20 Torx screws each, take off mount and sealing cap. (Scheme 182)

38. Remove three ignition coils per cylinder side -1-. Unscrew 12 M6 x 25 Torx screws, pull off ignition coils. (Scheme 182)

39. Remove six spark plugs. Use only approved tool spark plug socket wrench 14 from Snap-On (in case ceramic body breaks). Refer to 28 70 20 Removing and installing spark plugs - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 189

40. Pull off hydraulic valves for camshaft and valve lift adjustment. To do this, the special tool relay puller P 9235 can be used. Pull the oil strainer for the camshaft adjustment valve out of the valve bore -1- with a magnet, replace the oil strainer. (Scheme 183)

41. Remove the exhaust manifold. Unscrew six M8 x 28 screws each, remove manifold and seal.

42. Remove coolant pipe for heating. Side 1-3: unscrew two M6 x 12 Torx screws, side 4-6: unscrew three M6 x 12 Torx screws, remove coolant pipe.

43. Remove oil pressure sensor on cylinder head cover 4 - 6 (a/f 19).

44. Remove the mount for the air conditioning compressor. Unscrew two M8 fastening screws, and remove bracket.

45. Remove hall sender. Unscrew 1 M6 x 16 pan-head screw (hexagon socket a/f 5, micro-self-locking) and pull off hall sender, replace screws.

46. Remove knock sensors. Mark installation position (plug connection) with a paint marker, unscrew one M8 x 35 Torx screw each, pull sensors out of crankcase.

47. Remove speed sender, unscrew one M6 x 16 pan-head screw (hexagon socket a/f 5, micro-self-locking), remove sender, replace screw.

Scheme 190

48. Pull coolant hose assembly out of plastic holder on crankcase. Undo spring band clamps on water pump and thermostat and take off hoses. Remove mount, to do this, unscrew one M6 x 16 Torx screw (micro-self-locking), replace screw.

49. Remove all plastic closure caps on the cylinder heads, and replace closure caps.

50. Turn engine on the belt pulley of the crankshaft clockwise to the overlapping TDC of cylinder bank 1 - 3. To check cylinder 1-3, insert the special tool adjusting gauge P 9686 in the camshaft slots. If the gauge cannot be inserted, the engine must be turned an additional 360°.

51. Remove oil extraction pump cylinders 1-3. Unscrew four M6 x 20 Torx screws (micro-self-locking), carefully pull the oil extraction pumps out of the fitting bore. Replace screws.

Scheme 191

52. Remove tandem pump on cylinder side 4-6. Unscrew four M6 x 30 fastening screws -1-, pull vacuum line -2- out of the connection fitting on the pump, take out the pump. Replace O-rings. (Scheme 185)

Note. The central screws of the camshaft adjustment elements must be undone before removing the cylinder head cover.

53. The central screws of the camshaft adjuster must be undone before removing the cylinder head covers. To do this, place special tool retaining tool P 9685 on the large hexagon of the central screw and cylinder head cover and undo the screws.

Removing camshafts, cylinder bank 1-3

54. Remove cylinder head cover 1-3. Refer to 15 82 19 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

55. Remove all chain tensioners and replace aluminum sealing rings during installation.

56. Remove upper M6 screw (hexagon socket a/f 5) for guide rail cylinder 4-6.

57. Remove camshaft side 1-3. Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 4) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2S, Cabrio 2S) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) .

Scheme 192

> The components have been run in the fitting bores in the housing, therefore do not interchange them.

> Pay attention to cleanliness.

58. Remove the flat-based tappets. Pull the components out with a strong magnet out of the flat-base tappets housing. To avoid confusing the individual flat-based tappets, lay them on a labelled, clean surface (see example) and cover.

59. Place engine on the belt pulley of the crankshaft clockwise to the overlapping TDC of cylinder bank 4-6. To do this, turn the engine a further 360° clockwise. To check cylinder 4-6, insert the special tool adjusting gauge P 9686 in the camshaft slots.

Removing camshafts, cylinder bank 4-6

60. Remove cylinder head cover 4-6. Refer to 15 82 19 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

61. Unscrew the top M6 guide rail screw (hexagon socket a/f 5) on cylinder 4-6.

62. Remove camshaft side 4-6. Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 4) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2S, Cabrio 2S) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) .

63. Remove flat-base tappet housing. Unscrew 11 M6 x 35 Torx screws per housing, one 1/4-inch E10 socket is necessary for this. Take flat-base tappet housing out of the cylinder head. It is absolutely necessary to replace O-rings for spark-plug recesses when installing.

64. Unscrew the top M6 guide rail screw (hexagon socket a/f 5) on cylinder 1-3.

Scheme 193

65. Unscrew four M6 x 30 Torx screws -Pos 1 - 4- per cylinder bank. (Scheme 187)

66. Remove cylinder head. Undo and unscrew 12 M10 x 230 Torx screws from inside to outside on each cylinder head. Lift the cylinder header and seal off the crankcase.

Scheme 194

67. Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the engraved markings -Arrow facing flywheel side- visible. Before removing, number and mark the pistons in the installation position.

68. Unscrew M27 aluminum screw plug for the assembly bore (piston pin).

69. Remove coolant closure cap (with connection for coolant ventilation). Unscrew six M6 x 20 inner Torx screws, remove cover, and replace the seal.

70. Remove connection supports for coolant hose on the top of the coolant guide housing. Unscrew two M6 x 20 Torx screws and remove cover.

71. Remove coolant temperature sensor (a/f 22).

72. Remove coolant closure cap at the bottom of the coolant guide housing. Unscrew four M6 x 20 Torx screws and remove cover.

73. Remove coolant pump. Unscrew seven hexagon-head bolts (two M6 x 30 and five M6 x 25) and remove pump.

74. Remove thermostat housing. Unscrew four M6 x 20 Torx screws and remove housing, including thermostat.

Scheme 195

75. Remove coolant guide housing and oil pump. Unscrew ten Torx screws, namely eight M6 x 20 and two M6 x 70, and carefully lift off housing with seal (press lightly with an assembly lever if necessary). Pull out the driver for the oil pump. Remove the drive belt guide in Tiptronic vehicles.

76. Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning rails from the chain spaces.

77. Remove oil filter with special tool release key P 9204 .

Scheme 196

78. Unscrew 13 M6 x 20 Torx screws on the oil pan cover. Tap cover gently on the sides using a plastic hammer, then carefully lift it at the leverage bar -see Figure- using a plastic-coated mounting lever and remove the oil pan. (Scheme 190)

Scheme 197

79. Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20 Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove the oil suction pipe.

80. Remove bearing cover for intermediate shaft. Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M96/05 - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) . Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M97/01 - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

Scheme 198

81. Undo M16 x 1.5 x 60 hexagon-head bolt for belt pulley or vibration damper with special tool socket wrench insert P 9594, while countering with special tool retaining device P 9593 --> Screw on belt pulley - 3.6 l engine or holding wrench P 9732. Do not unscrew the screw. (Scheme 192)

Assembling engine - starting with the crankcase

> When working on the engine, absolute cleanliness is essential.

> Lay removed engine parts on a clean base and cover them without fail.

> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

Note. All O-rings and seals (shaft seals) and micro-encapsulated screws or lock nuts must be replaced.

The engine is assembled in reverse order to the disassembly. Components that are not replaced must be cleaned.

Markings on crankcase

Scheme 199

Engine number

Scheme 200

Cylinder arrangement

Note. Replace M6 microencapsulated screws and M8 hexagon collar nut for intermediate shaft bearing cap.

1. Fit bearing cover for intermediate shaft with new sealing ring. Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M96/05 - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) . Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M97/01 - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

2. Install guide rail for cylinder 4-6. Insert guide rail with slot into the crankcase. Fit screw with new O-ring, grease the O-ring with Optimol MP3. --> Tightening torque: 10 (7.5 ftlb.) Nm

3. Install tensioning rail for cylinder 4-6. Fit screw with new O-ring, grease the O-ring with Optimol MP3. --> Tightening torque: 10 (7.5 ftlb.) Nm

4. Remove auxiliary screw for gear carrier.

5. Fit air/oil separator (swirl pots) and suction pipe. Replace two micro-self-locking M6 x 20 Torx screws and O-rings for the suction tube. --> Tightening torque: 10 (7.5 ftlb.) Nm

6. Install oil pan. Apply a bead of sealant, Loctite 5900 , to the cleaned and greased oil pan and secure with 13 M6 x 20 Torx screws from the inside out. --> Tightening torque: 10 (7.5 ftlb.) Nm

7. Fit oil filter, grease new O-ring with Optimol MP3. --> Tightening torque: 25 (19 ftlb.) Nm

8. Fit thermostat with new seal. Tighten four M6 x 20 Torx screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

9. Fit tensioning rail for cylinder 1-3. Fit screw with new O-ring, grease the O-ring with Optimol MP3. --> Tightening torque: 10 (7.5 ftlb.) Nm

Note. Replace O-rings for the oil pump and sealing rings for coolant guide housing.

10. Install coolant pump. Position pump with the new seal (a single part in conjunction with the seal for the oil pump housing). Position and tighten seven M6 Torx screws (two M6 x 30 screws on the dowel sleeves, five M6 x 25 screws). --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 201

11. Remove centering mandrel for intermediate shaft. Position oil pump with new seal and two new O-rings. Grease the O-rings with Optimol MP3. Pull timing chain 4-6 outward so that the intermediate shaft is centered. Align driver for the oil pump and then push the housing together with the oil pump into the bearing seat. It is advisable to get a second person to assist to make the assembly easier.

12. Coat the thread of two M6 x 70 Torx screws with Loctite 574 and position on oil pump housing. Position the remaining eight M6 x 20 Torx screws, tighten all screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

13. Fit coolant connection piece with new seal and two M6 x 20 Torx socket screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

14. Fit coolant breather adapter with new seal and six M6 x 20 Torx socket screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

15. Fit pulse sender with new, micro-self-locking M6 cheese head bolt. --> Tightening torque: 10 (7.5 ftlb.) Nm

16. Fit belt pulley/vibration balancer. Refer to 13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) . Refer to 13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

Scheme 202

17. Fix timing chains with chain sprockets, e. g. with the old O-rings from the oil suction pumps.

18. Install temperature sensor for coolant (M14 a/f 22). --> Tightening torque: 25 (19 ftlb.) Nm +/-5 (3.5 ftlb.) Nm

Note. Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards.

19. Fit new cylinder-head gaskets, the TOP marking is legible from above.

20. Fit cylinder heads. Refer to 15 70 19 Removing and installing cylinder head - engine removed - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) . Observe tightening sequence and tightening specification of cylinder-head screws. --> Initial tightening: 30 (22 ftlb.) Nm , loosen all screws, --> 2nd initial tightening: 20 (15 ftlb.) Nm ; --> 2 x torque angle (final tightening): 70°

Scheme 203

21. Tighten external M6 (Torx) cylinder-head screws. --> Tightening torque: 13 (9.5 ftlb.) Nm

22. Install guide rail for cylinder 1-3. The slot is positioned in the crankcase, the sealing lip towards the outside. Fit screw with new O-ring, grease the O-ring with Optimol MP3. --> Tightening torque: 10 (7.5 ftlb.) Nm

The threaded pin for guide rail 4-6 (belt pulley side) on the cylinder head is inserted only after the timing chain has been fitted on the camshaft wheels.

Scheme 204

Note. The O-rings for the spark-plug recesses must be replaced.

23. Insert three new O-rings in the spark-plug recesses, lightly coat with high pressure grease. Fit flat-base tappet housing with 11 M6 x 35 Torx screws and tighten screws from the inside out. --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 205

Note. Re-insert flat-base tappets in the fitted bores in which they were positioned before the disassembly. The flat-base tappets have been run in the fitting bores in the housing and therefore may not be switched.

24. Coat flat-base tappets with new engine oil and insert in the fitted bores in the flat-base tappet housing (operating plunger with dowel pin on the inlet side).

25. Install camshafts and adjust controls as for engine type M96/03-3, 6l as of model year 2002. Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 4) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2S, Cabrio 2S) . Refer to 15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) .

Scheme 206

26. Fit cylinder head cover. Eight new, coated screws -1- must be used for the threaded joints on the camshaft bearing surfaces. For each one, tighten 20 M6 fastening screws according to the tightening sequence. Of each of the sets of 20 screws, only position two screws on the oil suction side (or tandem pump) and only perform the final tightening after fitting the pumps. Refer to 15 82 19 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4). --> Tightening torque: 13 (9.5 ftlb.) Nm (Scheme 201)

Sealant application on cylinder head cover

Scheme 207

Tightening sequence for cylinder head cover

Scheme 208

27. Install tandem pump and oil suction pump with new, micro-self-locking screws and new O-rings. Fit the line on the tandem pump with two new O-rings. Grease O-rings with Optimol MP3. --> Tightening torque: 10 (7.5 ftlb.) Nm

Install engine accessories in the reverse sequence to that in which they were removed. Some additional instructions follow.

Install six spark plugs: --> Tightening torque: 30 (22 ftlb.) Nm ; --> Tightening torque: 25 (19 ftlb.) Nm

Six ignition coils: tighten two M6 Torx socket screws for each of them. --> Tightening torque: 10 (7.5 ftlb.) Nm

Hall sender: use two new M6 micro-self-locking screws. --> Tightening torque: 10 (7.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm

Exhaust manifold: use new M8 x 28 hexagon-head bolts. --> Tightening torque: 23 (17 ftlb.) Nm

Support for coolant ventilation: replace one M6 x 16 (micro-self-locking) screw. --> Tightening torque: 10 (7.5 ftlb.) Nm

Fit oil separator with new O-rings. Screw in M6 x 20 fastening screws on support bracket (3.8 l engine) or crankcase (3.6 l engine). --> Tightening torque: 10 (7.5 ftlb.) Nm

Install secondary air pump three M6 x 20 Torx screws on the bracket --> Tightening torque: 10 (7.5 ftlb.) Nm

Intake pipe support in the 3.6 l: install with four M6 x 35 Torx screws and new seals. --> Tightening torque: 10 (7.5 ftlb.) Nm

Intake-air distributor in the 3.6 l: install with six M6 x 35 Torx screws and new moulded seals on intake pipe support. --> Tightening torque: 10 (7.5 ftlb.) Nm

Intake-air distributor in the 3.8 l: four M6 Torx screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

Install generator: tighten M8 hexagon nut for B+ cable to the specified torque. --> Tightening torque: 15 (11 ftlb.) Nm . Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Assembling engine, touching up

1. Fit flywheel. Refer to 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 (Carrera 2, Cabrio 2, Carrera 4, Cabrio 4) . Refer to 13 60 19 Removing and installing double-mass flywheel - as of MY 2005 (Carrera 2S, Cabrio 2S, Carrera 4) .

2. Fit clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

or

3. Fit converter housing. Refer to 32 43 19 Removing and installing converter housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

4. Fit drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

5. Mount transmission. Refer to 37 35 27 Removing and refitting the automatic transmission - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S) or Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

6. Install engine > 100119 Removing and installing engine - section on "Installing" .

Preliminary work

> Do not work on the engine while it is hot.

1. Remove air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Remove both catalytic converters. Refer to 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Removing engine carrier

Engine carrier components

Scheme 209

> Support engine at all times.

1. Support engine in installation position with a transmission jack.

2. Remove engine carrier. Unscrew four M10 collar nuts -1- and one M6 Torx screw -2-. (Scheme 204)

3. Unscrew M12 collar nuts on engine mounting (hydraulic mount).

4. Carefully lower engine and move engine carrier out of threaded bolts, remove carrier.

5. Carefully clean engine carrier using solvent naphtha and check for damage (e. g. cracks).

6. The engine carrier must be replaced if it is damaged.

Installing engine carrier

1. Insert engine carrier in threaded bolts. Screw on four M10 collar nuts and one M6 Torx screw.

2. Raise engine in installation position using transmission jack, screw in two M12 collar nuts on engine mounting.

3. Tighten the four M10 collar nuts and the M6 Torx screw. --> Tightening torque: 65 (48 ftlb.) Nm ; --> Tightening torque: 10 (7.5 ftlb.) Nm

4. Tighten M12 collar nuts on left and right engine mountings. --> Tightening torque: 85 (63 ftlb.) Nm .

Subsequent work

1. Install catalytic converters. Refer to 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Install air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Designation Type Number Explanation retainer plate special tool P 9592

Removing engine mounting

1. Remove air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Support engine in installation position with a jack. To do this, attach special tool retainer plate P 9592 to engine.

Scheme 210

3. Loosen and unscrew M12 collar nut on engine carrier -Arrow-. (Scheme 205)

Scheme 211

4. Unscrew two hexagon-head bolts (M8 x 40) on engine mounting.

Scheme 212

Scheme 213

5. Guide engine mounting -1- upwards out of the engine carrier. (Scheme 208)

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

Installing engine mounting

1. Insert engine mounting -1- into body and engine carrier by guiding the threaded bolt for the engine mounting -2- into the bushing-type eyelet on the engine carrier. (Scheme 209)

2. Screw in and tighten two M8 x 40 hexagon-head bolts. --> Tightening torque: 23 (17 ftlb.) Nm .

3. Place collar nut on the threaded bolt for the engine mounting and tighten it -Arrow-. --> Tightening torque: 85 (63 ftlb.) Nm see scheme 126

4. Lower workshop jack and move out of work area. Remove special tool retainer plate P 9592 .

5. Install air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Designation Type Number Explanation 3/8" extension, 16° movable special tool NR.15

Preliminary work for removing oil separator

1. Remove air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Removing oil separator

Note. Cover engine openings (e. g. intake openings, crankcase, oil lines, open reservoirs etc.) cover with a cloth to avoid dirt and foreign bodies falling in. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).

Note. The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit.

1. Detach air-conditioning compressor without disconnecting the air-conditioning lines --> 87 34 19 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4) .

2. Disconnect ground connector from intake distributor side 4-6 -arrow-. (Scheme 210)

3. Pull the engine compartment temperature sensor out of the intake distributor 4-6 together with the rubber sleeve -1- and unscrew the rear fastening screws -2- of the air-conditioning compressor. (Scheme 211)

4. Unscrew the front fastening screw -arrow- of the air-conditioning compressor. Due to the restricted accessibility, the use of a 3/8" extension, 16° movable NR.15 with a long Torx E10 socket wrench is recommended. To lift out the air-conditioning compressor, the screw must be pulled upwards and held in position. (Scheme 212)

5. Lift out the air-conditioning compressor with the leads connected and lay to one side on a protective support. Secure additionally with a tie-wrap.

Scheme 214

6. Remove distributor pipe. To do this, remove the fastening nut M6 of the throttle body from the rubber mount of the servo pump -2-. (Scheme 213)

7. Release cable plug on throttle body, and pull out and release cable -1-. (Scheme 213)

8. Release crankcase venting pipe connection from distributor pipe and remove -3-. (Scheme 213)

Scheme 215

9. Loosen the four screw-type hose clamps on the rubber sleeves to the side intake distributors and push the rubber sleeves onto the distributor pipe. Remove distributor pipe together with mounted throttle body. Remove distributor pipe from the engine compartment.

Scheme 216

10. Release tuning pipe. To do this, mark the installation position of the tuning pipe and loosen screw-type hose clamps -arrows-. see scheme 132

Scheme 217

11. Remove both side fastening screws -arrows-. see scheme 133

Scheme 218

12. Carefully turn the oil separator and pull it out of the bore. Check sealing rings and replace if necessary -arrow-. see scheme 134

Scheme 219

13. Remove connections to the oil separator. For this purpose, place a cloth underneath as coolant emerges from the bottom vent line. Press and remove the connections -arrows-. Remove oil separator from the engine compartment. see scheme 135

Installing oil separator

1. Check seals of oil separator and replace if necessary. Place oil separator in the installation position and make all connections -arrows-. see scheme 136

2. Lightly coat the sealing rings to the crankcase with Optimol MP3 -arrow-. Carefully turn the oil separator and press it into the bore of the crankcase. (Scheme 214)

3. Fit both side fastening screws -arrows-. (Scheme 215)

4. Fit air-conditioning compressor: before installing the compressor check whether the aluminum spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also guide through ground cable before installation. (Scheme 216)

5. Fit air-conditioning compressor and fasten using three M8 Torx screws (two short ones at the rear, one long one at the front). See details and tightening torques. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

6. Fit drive belt. Pay attention to operating direction of used belts. Double-check that the position of the belt on the belt pulleys is correct.

7. Fit engine compartment temperature sensor with the rubber sleeve in the intake distributor 4-6.

8. Connect ground connector to intake distributor side 4-6 -arrow-. (Scheme 218)

Subsequent work for installing oil separator

1. Install air cleaner housing. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Poses Online

See also:
• 40 Lifting the vehicle - as of MY 2005 (All Models)
• 01 01 IN DIAGNOSTIC SYSTEM: READING OUT FAULT MEMORY AND ACTIVATING SYSTEMS - AS OF MY 2005 (ALL MODELS)
• 27 06 IN Work instructions after disconnecting the battery - as of MY 2005 (All Models)
• 44 05 94 BALANCING/OPTIMIZING WHEELS - AS OF MY 2005 (ALL MODELS)
• BUMPERS
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• 24 25 19 REMOVING AND INSTALLING AIR CLEANER HOUSING - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 19 38 17 DRAINING AND FILLING IN COOLANT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 87 34 19 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 42 21 19 REMOVING AND INSTALLING DRIVE SHAFT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 30 30 19 Removing and installing clutch slave cylinder - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 37 15 19 Removing and installing selector lever cable - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 34 12 19 Removing and installing shift and selector cables - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 48 02 01 CHECKING THE FLUID LEVEL FOR THE POWER-ASSISTED STEERING - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 17 01 01 CHECKING ENGINE OIL LEVEL - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4, CABRIO 4)
• 32 43 19 Removing and installing converter housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 28 70 20 Removing and installing spark plugs - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 15 82 19 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• socket wrench insert P 300