Engine Assembly

All parts must be clean and ready for reassembly at this point. All machine work should be completed and all new replacement parts should be on hand. Use suitable engine assembling lubricant during assembly.

• If the engine failed mechanically, it is important to check the intake system for foreign objects.

• If the engine is disassembled because of bearing failure, a thorough flushing of the lubrication system must be carried out prior to reassembly. Refer to 130 Crankcase and Crankshaft and 170 Engine Lubrication.

Porsche Intermediate Shaft Failure

♦ Various head studs have been used on the Carrera 911 engines. Always check with an authorized Porsche parts department for the latest in parts information.

♦ If either the crankcase, the crankshaft drive gear or the intermediate shaft drive gear are replaced, special installation instructions apply. See 130 Crankshaft and Crankcase.

Cylinder numbering is shown in illustration. Cylinder position will be referred to during the assembly process.

The assembly procedure is divided into subsections, as follows:

♦ Crankshaft, assembling

♦ Crankcase, assembling

♦ Pistons and cylinders, installing

I Cylinder heads, installing

♦ Camshaft cases, camshafts and camshaft timing chains, installing

♦ Camshaft timing, adjusting

♦ Engine peripherals, installing

Porsche Crankshaft Nose Bearing

— Install spacer to crankshaft.

— Install distributor drive gear to crankshaft.

Common Rail System

1. Crankshaft nose bearing 4. Spacer

2. Circlip 5. Drive gear (with

3. Drive gear (for distributor) mark 0 or 1)

Install gear retaining circlip to crankshaft.

• Circlip used to hold gears in place on crankshaft comes in different thicknesses. See Table a.

• Select circlip to best obtain near zero clearance.

Table a. Crankshaft Gear Circlip Thickness

Porsche PIN

Thickness

Mark

901 102 148 00

2.4 mm

0

901 102 148 01

2.3 mm

1

901 102 148 02

2.2 mm

2

901 102 148 03

2.1 mm

3

— Install new connecting rod bolts in each connecting rod.

— Install connecting rod bearing shells in connecting rods.

Use protective gloves or shop rag when handling the hot gear.

1. Crankshaft nose bearing 4. Spacer

2. Circlip 5. Drive gear (with

3. Drive gear (for distributor) mark 0 or 1)

Install distributor drive gear with marks on face of gear facing pulley end of crankshaft.

Use protective gloves or shop rag when handling the hot gear.

— Install spacer to crankshaft.

— Install distributor drive gear to crankshaft.

^Crankshaft, assembling

Crankshaft reconditioning information is given in 130 Crank-case and Crankshaft.

Check crankshaft drive gear for wear prior to installation. If gear is worn or damaged, replacement gear must be matched to crankcase and to gear on intermediate shaft. See 130 Crankcase and Crankshaft for checking and replacing.

— Mount crankshaft to Porsche special tool P 209 or equivalent and clamp tool with crankshaft in shop vise.

Install drive gear to crankshaft.

• Install woodruff key to crankshaft

• With shoulder on gear facing in (arrow), slide drive gear fully onto crankshaft.

Connecting Rod Match Number

^ Install connecting rods on crankshaft in their original locations. Matching numbers on side of connecting rod and rod cap should all be facing same side of engine (i.e., all numbers face exhaust side of engine).

— Install new connecting rod nuts on all rod bolts.

Tightening Torque

• Connecting rod cap to connecting rod

Porsche 911 Oil Drain Plug Location

ICrankcase, assembling

— Mount right side crankcase half on engine stand.

— Install and tighten oil drain plug using new sealing ring.

Tightening Torque

^ Install intermediate shaft bearing shells in crankcase halves.

Due to the high loads the timing chains put on the intermediate shaft, it is recommended that the intermediate shaft bearings be replaced during engine overhaul.

350 Oil Pump Intermediate Shaft

^ Place oil pump sealing O-rings (arrows) in right crankcase half.

Porsche 911 Oil Pump Coupling

0018317

1. Oil pump sealing O-rings

2. Oil pump

3. Oil pump drive shaft

4. Intermediate shaft bearings

6. Timing chain

0018317

1. Oil pump sealing O-rings

2. Oil pump

3. Oil pump drive shaft

4. Intermediate shaft bearings

6. Timing chain

— Lubricate oil pump gears with engine assembling lubricant.

^ Place both timing chains on intermediate shaft sprockets.

Install oil pump drive shaft with oil pump to intermediate shaft.

' Check intermediate shaft gear for wear prior to installation. If the intermediate shaft gear is worn or damaged, the replacement gear must be matched to the crankcase and crankshaft drive gear. See 130 Crankcase and Crankshaft for checking and replacing.

• The intermediate shaft is hollow and should be cleaned out whenever the engine is being reconditioned and in case of engine bearing failure. See 130 Crankcase and Crankshaft.

Porsche Intermediate Shaft Failure

Lower complete intermediate shaft assembly into right crankcase half, guiding front timing chain (arrow) through opening in case.

Place new locking tabs (arrows) on oil pump mounting studs and install and torque nuts. Bend lock tabs up into place.

Tightening Torque

Porsche Intermediate Shaft Failure

0018727

^ Lubricate crankshaft main bearing shells with engine oil and install in crankcase halves.

— Install crankshaft nose bearing locating pin in crankcase half.

^ Without nose bearing outer sealing O-ring in place, lay crankshaft nose bearing in crankcase so that it locks into locating pin (A). Draw a line (B) on each side of bearing to use as a reference when installing crankshaft assembly.

— Remove nose bearing. Install nose bearing outer O-ring.

— Lubricate nose bearing and install on crankshaft.

^ Place crankshaft assembly into right crankcase half.

• Make sure right side connecting rods for cylinders 4,5, and 6 are pointing down.

• Check that nose bearing (A) is correctly seated in case.

• Slowly turn crankshaft back and forth to check for binding or interference.

• Porsche special tool P221 can be used to support the left side connecting rods during crankcase assembly.

' Porsche special tool P222 can be used to support the left timing chain during crankcase assembly.

Porrche Oil Pump 1989
0018314
Porsche 911 Firing Order Picture
0018323
Porsche 911 Oil Pump Seal

Place two sealing O-rings (A) in oil pump.

• Check to see that oil passage sealing O-ring previously placed in right crankcase half (B) remains undisturbed.

• Lubricate all with engine oil.

Different size seals are used. Be sure to install the correct parts.

— Using Loctite® 574 sealant, apply even thin coat on both crankcase mating surfaces.

— Place left case-half in position over right case-half. Tap case-halves together lightly with a rubber mallet.

Turn the crankshaft back and forth periodically to check for binding.

— Place sealing O-rings on two case studs in oil cooler housing.

^ When installing case washers, align bevel on washers (arrow) correctly. Bevels should face nut or bolt head.

Install capped case nuts (arrows) in oil cooler housing.

Tightening Torque

Sealing

0018344

Sealing

0018344

911 Porsche Case Sealant

0018343

Insert M10 Through

Check crankshaft for free movement by turning slowly back and forth.

Install washer and nut in timing chain cut-out on left side of engine.

Tightening Torque

Insert M10 bolts through case.

• Make sure beveled washers and sealing O-rings are installed correctly.

• Install case nuts and tighten.

Tightening Torque

— Install crankshaft seals on flywheel and pulley ends of engine. (special tools P 216 and 9126)

— Install crankshaft pulley, counterholding with Porsche special tool 9236 or equivalent when torquing bolt.

Tightening Torque

• Crankshaft pulley to crankshaft 80 Nm (59 ft-lb)

If the crankshaft pulley locating hole orpin is damaged, valve timing may be affected. Replace a pulley with elongated/damaged hole.

Install 22 M8 nuts and bolts around outer edge of crank-case.

Tightening Torque

• Crankcase perimeter fasteners (M8) ... 25 Nm (18 ft-lb)

Porsche Crankshaft Pulley

0018333

— Install oil pressure sending units.

Tightening Torques

• Oil warning light sending unit to crankcase 20 Nm (14 ft-lb)

• Oil gauge sending unit to crankcase 35 Nm (25 ft-lb)

Install oil temperature thermostat with new sealing O-ring (arrow).

Tightening Torque

• Oil temperature thermostat to crankcase 8 Nm (6 ft-lb)

— Install breather cap (A) with a new gasket.

Tightening Torque

— Install oil temperature sensor.

Tightening Torque

• Oil temperature sensor to crankcase ... 25 Nm (18 ft-lb)

Install chain guide rails inside crankcase chain housings.

• Note location of different guide rail in lower right slot.

Use screwdriver to push chain guide rail toward pulley end of engine (arrow) while tightening retaining bolts.

Tightening Torque

• Timing chain guide retaining bolt to crankcase 25 Nm (18 ft-lb)

Porsche 911 Cylinder Sleeves

Brown*

0018036 guide

999 5454 Press Tool

0018337

0018337

Carrera 996 Oil Pressure Relief Spring

^ Install oil pressure relief valve assemblies in crankcase. Coat relief valves with assembly lube before installing.

Tightening Torque

• Oil pressure relief valve plug to crankcase 60 Nm (44 ft-lb)

The main (vertical) pressure relief valve uses a sleeve (A) and longer spring (B). For further details, see 130 Crankcase and Crankshaft.

IPistons and cylinders, installing

Measurement and reconditioning of pistons and cylinders is covered in 131 Pistons and Cylinders.

Porsche 911 Cylinder Sleeves

0018302

• Be sure to keep each piston and cylinder set clearly marked and together.

• Be sure used pistons and cylinders are reinstalled in the exact same locations and positions.

Set crankshaft to Z1 TDC.

0018302

944 Turbo Engine Oem Piston Direction

^ Install piston 1 with flat of intake valve relief (arrow) up.

Porsche 911 Bracket Oil Thermostat

0018345

^ Oil wrist pin and install. If necessary, tap pin in gently using soft punch. Install retaining circlips.

• The wrist pin circlips installed on new pistons are for transportation purposes only. Replace these clips with ones provided separately with the pistons.

• Always be sure that both piston pin clips are in place before installing the cylinder.

— Rotate crankshaft and install pistons 2 and 3.

When turning crankshaft, manually guide pistons in and out of crankcase bores in order to avoid damaging the piston skirts or rings. Use shop towels around the pistons for protection.

0018345

Piston Ring Set Position

— Reset crankshaft to Z1 compression stroke.

^ Set piston ring gaps to clock positions 4,10 and 2 (arrows).

— Place a new cylinder base gasket on cylinder 1 and lubricate cylinder wall.

If cylinder heads have been machined, be sure to use 0.50 instead of 0.25 mm thick copper gaskets at cylinder bases. See 150 Cylinder Heads.

When installing cylinders, make sure the deeper cylinder cooling fins point down.

Using a ring compressor such as Porsche special tool US 1008 a or equivalent, slide cylinder over piston and into side of case.

1984 Porsche 944 Engine Piston Position

„0018346

^ Temporarily hold cylinder in position using Porsche special tools P140 (arrows).

As a substitute for the special tools, slide two sockets over the cylinder head studs for each cylinder and install two cylinder head nuts finger tight.

— Rotate crankshaft and install cylinders 2 and 3.

When rotating crankshaft, manually guide pistons in and out of crankcase bores in order to avoid damaging the piston skirts or rings. Use shop towels around the pistons for protection.

Porsche 911 Engine Stand

0018035

^ Install left side cylinder air shroud plates.

— Install right side pistons and cylinders (4, 5, 6).

— Install right side air guides.

Porsche 911 Engine Stand

^Cylinder heads, installing

Repairs to cylinder heads and valves are described in 150 Cylinder Heads.

— With engine on engine stand and pistons, cylinders and air guides installed, rotate engine on stand so that left side cylinders are up.

Cylinder head 3 has a threaded boss for the cylinder head temperature sensor.

Using screwdriver as guide, slide head washer over head studs.

Prior to cylinder head installation be sure to remove temporary cylinder hold down nuts.

— Lubricate cylinder head studs, nuts and washers lightly with Optimoly®HT (Porsche part number 901 104 382 02) or equivalent. Starting with cylinder head 3, install left side cylinder heads.

Porsche 911 Engine Stand

0018726

Install head nuts and hand tighten each one. Use cross pattern to torque cylinder head nuts.

Tightening Torques

• Cylinder head to crankcase

Rotate engine on stand so that right side cylinders are up.

Starting with cylinder 6, install right side cylinder heads and tighten to specifications as described above for cylinders 1 -3.

Rotate engine on stand. Working on left side bottom of crankcase, install oil pressure line.

ICamshaft cases, camshafts and camshaft timing chains, installing

Additional camshaft timing chain information can be found in 152 Camshaft Timing Chains.

CAUTION—

Install camshaft cases and camshafts on left or right side according to marks made during disassembly.

— Use Loctite®574 to coat machined sealing surfaces on camshaft cases.

— Place new sealing O-rings on oil return tubes.

— Holding oil return tubes in place, guide right camshaft case over its mounting studs.

Two piece oil return tube replacement is covered in 170 Engine Lubrication.

^ Install 18 retaining nuts (arrows) and tighten after making sure oil return tubes are correctly positioned.

Tightening Torque

• Camshaft case to cylinder head 25 Nm (18 ft-lb)

— Install right timing chain housing with new gasket.

Tightening Torque

• Timing chain housing to crankcase 25 Nm (18 ft-lb)

— Slide right camshaft into camshaft case.

911 Cam Box Loctite 574

JX11S338.

Porsche 911 Timing Chain Cover Rings

— Install camshaft end cover with new O-ring and gasket. Install end cover retaining bolts and tighten.

— Reinstall right camshaft thrust spacer, sprocket shims, woodruff key and sprocket flange.

— Install right camshaft sprocket to timing chain. Slide sprocket over sprocket flange.

— Install sprocket washer and mounting bolt finger tight.

^ Install right timing chain guide rail in housing, if previously removed.

— Install right timing chain tensioner and idler sprocket assembly using new O-ring. Tighten tensioner mounting nuts.

— Install left camshaft, camshaft case, timing chain guide rail, camshaft sprocket assembly and timing chain as described in previous steps.

Camshaft sprocket orientation

Front is:

Left of car C

Right

Left and right camshaft sprockets are identical. Dished side of sprocket must face pulley side of engine on left camshaft (cylinders 1 - 3) and flywheel side of engine on right camshaft (cylinders 4 - 6)

911 Camshaft Sprocket Shims

1. Sprocket mounting bolt

2. Lock washer

3. Sprocket lockpin

4. Camshaft sprocket

5. Sprocket flange

6. Camshaft retaining bolt

7. Sprocket spacer shims

8. Thrust spacer

9. Camshaft end cover 10.Sealing O-ring

11. Gasket

12. Camshaft

13.Woodruff key

Camshaft sprocket assembly

1. Sprocket mounting bolt

2. Lock washer

3. Sprocket lockpin

4. Camshaft sprocket

5. Sprocket flange

6. Camshaft retaining bolt

7. Sprocket spacer shims

8. Thrust spacer

9. Camshaft end cover 10.Sealing O-ring

11. Gasket

12. Camshaft

13.Woodruff key

Timing chain sprocket parallelism

Front of intermediate shaft

0018045

Front of intermediate shaft

0018045

A Factory distance from end of intermediate shaft to face of cylinder 1 -B Factory distance from end of intermediate shaft to face of cylinder 4 -

3 (left) timing chain sprocket = 98.07± 0.25 mm (3.86 ± 0.01 in.) 6 (right) timing chain sprocket = 43.27 ± 0.25 mm (1.70 ± 0.01 in.)

— Check parallelism of intermediate shaft and camshaft sprockets by measuring distance from front of intermediate shaft to front edge of gear wheels. Use quality straight edge when making measurement.

0018242

• Normally, if reinstalling camshafts and sprockets, 3 sprocket spacer shims will be necessary under the left sprocket and 4 shims under the right sprocket.

• If new camshafts or sprockets are being installed, camshaft sprocket spacing must be adjusted by adding or subtracting spacer shims so that each sprocket Is parallel with the corresponding intermediate shaft sprocket. See 152 Camshaft Timing Chains.

^ A preliminary setting of camshaft timing must be done as follows (refer to illustration on next page):

• Set front crankshaft pulley to Z1 (TDC).

• Remove camshaft sprocket bolts.

• Rotate left camshaft until "930" points up.

• Install camshaft sprocket lockpin.

• Reinstall left camshaft sprocket bolt finger tight.

• Repeat for right camshaft.

0018242

Valve overlap

4 before TDC :

Exaust -

50 after BDC

4 before TDC :

Exaust -

50 after BDC

Tdc Turbo Overlap
- Intake
Porsche 911 Cam Timing

^Camshaft timing, adjusting

Camshaft timing is adjusted using a dial gauge setup. The dial gauge is used to precisely set the position of each camshaft in relation to partially open ("overlapped") valves.

Camshaft timing specification in degrees of rotation are given below.

Camshaft Timing Specifications

• Intake valve opens 4° before TDC

• Intake valve closes 50° after BDC

• Exhaust valve opens 46° before BDC

• Exhaust valve closes At TDC

Rocker shaft and arm, installing

Set crankshaft to Z1 cylinder 1 compression stroke.

• Check to see that punch marks or "930" on camshaft ends point up.

Assemble rocker shaft.

Install cylinder 1 intake and exhaust rocker shafts with rocker arms:

• Install rocker shaft with 5 mm bolt facing cylinder 2.

• Tap rocker shaft into bore until shaft is flush with inner edge of support.

• Place rocker arm in position and tap rocker shaft in until shaft slides into far side support.

How Porsche 911 Rocker Arm Removal

0018305

2. Expansion sleeve 5. Expansion nut (8mm alien)

3. Rockershaft

0018305

2. Expansion sleeve 5. Expansion nut (8mm alien)

3. Rockershaft

Porsche 930 Side Rocker Assembly

0018728

^ Place 0.5 mm (0.02 in.) feeler gauge between far side support and rocker arm.

• Continue to tap shaft until feeler gauge engages slot in rocker shaft.

• Remove feeler gauge and tap shaft in approximately 1.5 mm (0.06 in) further until shaft is approximately flush with outside edge of camshaft case (thinner bearing support side of casting).

Tightening Torque

0018728

Porsche 911 Cylinder Sleeves

Adjust cylinder 1 intake and exhaust valve clearance.

Valve Clearance

Porsche 911 Cylinder Sleeves

0018242

Left (cylinders 1-3) camshaft timing

Set crankshaft to Z1 (TDC) cylinder 1 compression stroke.

• Check to see that punch marks or "930" on camshaft ends point up.

0018242

Porsche P207

^ Using Porsche special tool P 207, mount dial gauge on camshaft case stud next to cylinder 1 intake valve.

• Set dial gauge plunger against valve spring retainer on cylinder 1 intake valve.

• Zero dial gauge with approximately 10 mm (0.4 in.) preload.

— Starting at Z1 (TDC) mark on pulley, turn crankshaft slowly in clockwise direction approximately 1 full turn while observing dial gauge. Turn crankshaft far enough to reach valve overlap adjusting value.

Valve Overlap Adjustment

— Unscrew and remove left timing chain sprocket mounting bolt.

Pull out camshaft sprocket lockpin (arrow) using Porsche special tool P 212 or equivalent.

— Turn crankshaft (either clockwise or counterclockwise, as necessary) just until Z1 mark on pulley is aligned accurately with joint of crankcase.

— Reinstall lockpin in hole with best alignment. Install camshaft sprocket bolt finger tight.

— Turn crankshaft clockwise two full turns. Recheck timing adjustment. Value must be within tolerance range.

Valve Overlap Adjustment

— Torque camshaft sprocket bolt when settings are correct.

Use Porsche special tool 9191 or equivalent to counterhold camshaft sprocket when torquing bolt.

Tightening Torque

♦ Chain sprocket to camshaft 120 Nm (89 ft-lb)

Porsche 911 Rocker Arm Shaft

0013335

Timing Sprocket Tdc

Right (cylinders 4-6) camshaft timing

^ Set crankshaft to Z1 (TDC) cylinder 4 compression stroke.

• Check to see that punch marks or "930" on camshaft ends point down.

— Install cylinder 4 rocker shafts and arms as described earlier.

• Install 5 mm alien bolt with bolt head facing cylinder 5.

Tightening Torque

— Adjust cylinder 4 intake and exhaust valve clearance.

Valve Clearance

With crankshaft at cylinder 4 TDC compression stroke, use Porsche special tool P 207 to mount dial gauge on camshaft case stud next to cylinder 4 intake valve.

• Set dial gauge plunger against valve spring retainer on cylinder 4 intake valve.

• Zero dial gauge with approximately 10 mm (0.4 in.) preload.

— Starting at Z1 (TDC) mark on pulley, turn crankshaft slowly in clockwise direction approximately 1 full turn while observing dial gauge. Turn crankshaft far enough to reach valve overlap adjusting value.

Valve Overlap Adjustment

ooi8s98 ~ Unscrew and remove right timing chain sprocket mounting bolt.

^ Pull out camshaft sprocket lockpin using special tool P 212 (arrow).

— Turn crankshaft just until Z1 mark on pulley is aligned accurately with joint of crankcase.

— Reinstall lockpin in hole with best alignment. Install camshaft sprocket bolt finger tight.

— Turn crankshaft clockwise two full turns. Recheck timing adjustment. Value must be within tolerance range.

Valve Overlap Adjustment

• Tolerance range 1.1 -1.4 mm (0.043 - 0.055 in.)

— Torque camshaft sprocket bolt when settings are correct.

Cylinder Compression Tolerance

0018733

1989 4g64 Engine Valve Adjusters

Use Porsche special tool 9191 or equivalent to counterhold camshaft sprocket when torquing bolt.

Tightening Torque

• Chain sprocket to camshaft 120 Nm (89 ft-lb)

^ Set crankshaft to Z1 (TDC) cylinder 1 compression stroke. NOTE —

Check to see that punch marks or "930" on camshaft ends point up.

The following instructions apply when installing rocker shafts.

• Cylinder 2 and 5:5 mm alien bolt head can be installed either way.

• Cylinder 3: install 5 mm alien bolt with bolt head facing cylinder 2.

• Cylinder 6: install 5 mm alien bolt with bolt head facing cylinder 5.

— Turn crankshaft 120° in normal direction of rotation. Install cylinder 6 rocker shafts and arms as described earlier.

Tightening Torque

• Rocker shaft pinch bolt

18 Nm (16 ft-lb)

Adjust cylinder 6 valve clearance.

Valve Clearance

• Adjusting value

0.10 mm (0.004 in.)

^ Following firing order, turn crankshaft 120° in normal direction of rotation and install rocker arms for next cylinder and adjust valves.

— Repeat until all rocker arms are installed and valves adjusted.

— Install valve covers with new gaskets, sealing washers and lock nuts.

Tightening Torque

— Install timing chain housing covers with new gaskets, sealing washers and lock nuts.

Tightening Torque

• Chain housing cover to housing 8 Nm (71 in-lb)

— Install right and left camshaft and timing chain tensioner oil feed lines with new sealing washers.

lEngine peripherals, installing

With crankshaft at TDC, install distributor so that mark on distributor rotor aligns with mark on distributor housing (arrows).

• The marks line up approximately, not precisely.

♦ There is only one way to install the distributor housing.

• The marks line up approximately, not precisely.

♦ There is only one way to install the distributor housing.

Tightening Torque

• Distributor base clamp (M8)

18 Nm (14 ft-lb)

Install new spark plugs.

Tightening Torque

• Spark plug to cylinder head

25-30 Nm (18-22 ft-lb)

— Install engine mount carrier and cross member.

— Install A/C compressor mounting brackets.

Porsche 911 Sheet Metal

— Install all sheet metal shrouding around engine.

Tightening Torques

• Engine mount carrier to crankcase 40 Nm (30 ft-lb)

• Engine mount crossmember to carrier 40 Nm (30 ft-lb)

Install oil cooler from below. Install top and bottom (arrows) oil cooler mounting nuts.

CAUTION—

Always use new O-ring seals.

Tightening Torques

— Install all sheet metal shrouding around engine.

Porsche 911 Firing Order Picture

0018734

Porsche 911 Sheet Metal

0018717

^ Set complete fuel system, intake manifold, alternator and cooling shroud in place.

• Reattach alternator ground to top of crankcase under shroud.

• Install intake runner washers and nuts.

Tightening Torque

• Intake manifold to cylinder heads 25 Nm (18 ft-lb)

— Connect all spark plug wires and install all wire holders.

— Rotate engine on stand and install heat exchangers, catalytic converter and muffler. See 260 Exhaust System.

Tightening Torques

• Heat exchangers to cylinder heads 25 Nm (18 ft-lb)

— Remove engine from engine stand.

— Install flywheel, clutch assembly and transmission as described in 101 Engine Removal and Installation.

Tightening Torques

— Install engine. See 101 Engine Removal and Installation.

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