Part 2
Tightening torques, tightening sequences, assembly overviews for V8 4.8 l DFI naturally aspirated and turbo engine as of October 2008 (Continued)
Engine - Crankcase, suspension
Upper part of crankcase
1 - Upper part of crankcase
2 - Lid
3 - Sealing ring
4 - Screw plug on upper part of crankcase - Tightening torque: 75 Nm (56 ftlb.)
5 - Dowel sleeve
6 - Oil spray jet
7 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel
Lower part of crankcase
1 - Lower part of crankcase
2 - Straight pin, 6 x 18
3 - O-ring
4 - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5 - Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. - Initial tightening: 30 Nm (22 ftlb.) - Torque angle: 90°
6 - Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. - Initial tightening: 22 Nm (16 ftlb.) - Torque angle: 60°
7 - Aluminum screw, M8 x 70; (cross bolt connection); always use new aluminum screws; observe tightening sequence as for steel screws - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90°
8 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
9 - Screw, M8 x 50 - Tightening torque: 23 Nm (17 ftlb.)
10 - Dowel sleeve
A - Direction of travel
Sealant application
1 - Wipe off sealant residues after fitting
A - Direction of travel
Tightening sequence for thrust-bearing screws
1 through 20 - Tightening sequence for M11 and M10 screws - Observe different torques!
A - Direction of travel
Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)
Left bracket for auxiliary units and engine mounting
1 - Bracket for auxiliary units/engine mounting
2 - Screw, M10 x 45 - Tightening torque: 65 Nm (48 ftlb.)
3 - Hydraulic mount, left
4 - Engine carrier
5 - Screw, M10 x 65 - Tightening torque: 60 Nm (44 ftlb.)
6 - Dowel sleeve
7 - Nut, M12 x 1.5 - Tightening torque: 75 Nm (56 ftlb.)
Right bracket for auxiliary units and engine mounting
1 - Engine carrier, cylinders 1 to 4
2 - Screw, M10 x 45 - Tightening torque: 65 Nm (48 ftlb.)
3 - Hydraulic mount, right
4 - Engine carrier
5 - Screw, M10 x 65 - Tightening torque: 60 Nm (44 ftlb.)
6 - Nut, M12 x 1.5 - Tightening torque: 75 Nm (56 ftlb.)
7 - Bores for screws, M10 x 45
A - Installation view of engine carrier on crankcase
Vent line
1 - Vent line to cylinder head/crankcase/oil pump
2 - O-ring
3 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Check valve
A - Direction of travel
Oil mist separator for positive crankcase ventilation (M48/51 turbo engine)
1 - Engine ventilation - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Engine ventilation line
3 - Tank ventilation
4 - Holder - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°
Oil mist separator for positive crankcase ventilation (M48/01 naturally aspirated engine)
1 - Engine ventilation - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Engine ventilation line
3 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Lid with seal
5 - Engine ventilation line
6 - Line
7 - Tank ventilation with holder - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°
Positive crankcase ventilation, M48/51 Turbo
1 - Check valve
2 - Engine ventilation line
3 - Positive crankcase ventilation line to pressure pipe
4 - Holder (see Belt tensioner/belt drive)
5 - Line
Positive crankcase ventilation (PCV), M48/51 Turbo
1 - Ventilation pipe with sealing ring (holder to timing-case cover) - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°
2 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Installation view of ventilation pipe
Engine - Crankgear, pistons
Crankshaft
1 - Crankshaft
2 - Straight pin, 6 x 20
3 - Spring, 5 x 6.5
4 - Thrust washer (grooves facing out)
5 - Main bearing shell, upper
6 - Main bearing shell, lower
7 - Shaft sealing ring - Do not touch sealing ring lip! Clean crankshaft flange and oil lightly
8 - View of crankshaft flange
9 - Crankshaft bearing classification (four types) Y Yellow; B Blue, R Red; N Green - (example: YYYYYBBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) - For numbering, see A
A - Direction of travel (main bearing 1 is the first in direction of travel against output)
Belt drive
1 - Deflection roller - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
2 - Hydraulic belt tensioner; tensioner to lever - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.); tensioning roller to tensioning lever - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
3 - Screw, M8 x 96; complete lever to timing-case cover and cylinder head - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.); belt tensioner and timing-case cover to bracket - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
4 - Deflection roller - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
5 - Dual poly V-belt
Piston, connecting rod
1 - Piston-ring set; oil with engine oil; TOP marking facing upwards; oil scraper ring down
2 - Piston; different on naturally aspirated and turbo engines; combustion chamber recess facing center of engine; left and right different; direction of travel arrow in direction of travel
3 - Piston-pin circlip (positioned at 6 o'clock or 11 o'clock)
4 - Piston pin; oil
5 - Connecting rod
6 - Connecting rod bolt; replace as it must be tightened in the plastic area; oil bolt - Tightening torque: 8 Nm (6 ftlb.)+2 Nm (+1.5 ftlb.) - Tightening torque: 20 Nm (15 ftlb.) - Tightening torque: 40 Nm (30 ftlb.) - Torque angle: 90°
7 - Connecting rod bearing shells; oil with engine oil
Connecting-rod assembly, bearing shells
A - View A (identification area for connecting-rod number; fit connecting rod with identification area facing exhaust side; markings on rod and cap must be on the same side)
B - View B (fit bearing shells flush and press in by hand)
C - View C (fit bearing shells flush and press in by hand)
Piston classification
1 - Inspection stamp (supplier)
2 - Arrow marking in direction of travel
3 - Porsche short numeric code without main or middle number
4 - Cylinder bank identification
5 - Marking area for weight group
6 - Marking area for dimension group
7 - Barcode 128 (short numeric code (without main group) and weight group)
8 - Direction of travel arrow
9 - Short numeric code (supplier)
Radial shaft seal
1 - Radial shaft seal (use protection cap for radial shaft seal for fitting; only fit when crankcase is screwed on)
2 - Crankcase
3 - Crankshaft
4 - Radial shaft seal (sectional view)
A - Direction of travel
Pulleys
1 - Water pump pulley
2 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.)
3 - Vibration damper
4 - Screw, M18 x 1.5 x 72; use new screw; - Tightening torque: 20 Nm (15 ftlb.) - Tightening torque: 50 Nm (37 ftlb.) - Tightening torque: 100 Nm (74 ftlb.) - Torque angle: 180°
5 - Pulley on power-steering pump
6 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.)
7 - Tandem pump pulley